SUMMER INDUSTRIALTRAINING REPORT

HONDA CARS INDIA LTD.SPL-1, Tapukara Industrial Area, Khushkhera

Distt. – Alwar, Rajasthan – 301707. INDIA

PROJECT REPORT ON

STUDY OF OPERATIONAL EFFICIENCY OF PRESS LINE

By- SAURABH MUNJAL

2010JE0934

MECHANICAL ENGINEERING

7 th SEM

HONDA CARS INDIA LTD., TKR PLANT

Honda Cars India Ltd., (HCIL) was incorporated in December 1995 as a joint venture

between Honda Motor Co. Ltd., Japan and Siel Limited, a SiddharthShriram Group

company, with a commitment to providing Honda’s latest passenger car models and

technologies, to the Indian customers. The total investment made by the company in

India till date is Rs 1620 crores in Greater Noida plant and Rs 784 crores in Tapukara,

Bhiwadi plant.

HCIL’s first state-of-the-art manufacturing unit was set up at Greater Noida, U.P in

1997. The green-field project is spread across 150 acres of land (over 6, 00,000 sq.

m.). The annual capacity of this facility is 100,000 units. The company’s second

manufacturing facility is in Tapukara, Rajasthan. This facility is spread over 600 acres

and will have an initial production capacity of 60,000 units per annum, with an

investment of about Rs 1,000 crore. The first phase of this facility was inaugurated in

September 2008.

MODELS COVERED IN PRESS SHOP

S.No

MODELS SHAPE MODELS NAME

1 HONDA CITY

2HONDA BRIO

3

HONDA AMAZE

OVERVIEW

Max production 700 car units in 3 shifts(approx.)Raw Material Type Processed Sheet BlankVendor RPSCFinished Product HCIL-GNU

INTRODUCTION

HCIL (TKR) produces Sheet metal parts for car body in the press dept. The

department has an automatic tandem press line with first press machine having

capacity of 1500 ton followed by 3 Press machines with capacity of 1000 ton each. It

also has 5 Robots for parts movement from one process to next process and a De-stack

feeder assembly for automatic feeding of blanks in press line for processing.

RPSC supplies blanks as raw material as per Personal RapiD Transportation (PRT)

system controlled by Production Control Department. The blanks are stored in press

department and loaded on the press line according to the plan. The blanks are

processed in dies to be converted into parts. The parts are packed in trolleys after

going through check on conveyer. The repair parts are shifted to Handwork area for

repair and No Go parts are put in red colored scrap bin. The OK parts trolleys are

stocked at Trolley stock area. The parts are packed in PLC trolleys from press

production trolleys according to their packing standard and delivered to GNU plant.

Press dept. also has sub depts. of Planning and Production, Quality Control, Machine

Maintenance and Die Maintenance and New Model.

Safety as the first priority is an integral part of the work culture here at HCIL. Safety

is promoted through regular training and various awareness workshops regarding

safety like KYT are conducted regularly, through presentations for workers at all

levels.

PROCESS FLOW DIAGRAM

PRESS SHOP

The first shop in the manufacturing process, the Press Shop is responsible for pressing

the outer and inner body panels of the vehicle. The feeding system pushes a strip of

metal (as it unrolls from a coil) through all of the stations of a progressive stamping

die. Each station performs one or more operations until a finished part is made. The

final station is a cutoff operation, which separates the finished part from the carrying

web. The carrying web, along with metal that is punched away in previous

operations,is treated as scrap metal.

The progressive stamping die is placed into a reciprocating stamping press. As the

press moves up, the top die moves with it, which allows the material to feed. When the

press moves down, the die closes and performs the stamping operation. With each

stroke of the press, a completed part is removed from the die.

Since additional work is done in each "station" of the die, it is important that the strip

be advanced very precisely so that it aligns within a few thousandths of an inch as it

moves from station to station. Bullet shaped or conical "pilots" enter previously

pierced round holes in the strip to assure this alignment since the feeding mechanism

usually cannot provide the necessary precision in feed length.

The dies are usually made of tool steel to withstand the high shock loading involved,

retain the necessary sharp cutting edge, and resist the abrasive forces involved.The

cost is determined by the amount of features, which determine what tooling will need

to be used. It is advised to keep the features as simple as possible to keep the cost of

tooling to a minimum. Features that are close together produce a problem because it

may not provide enough clearance for the punch, which could result in another station.

It can also be problematic to have narrow cuts and protrusions

BLANK STACK:

Salient FeaturesPress Machine : 4● 1500 Ton – 1Nos.● 1000 Ton – 3Nos.No. of Robot : 5Scrap Conveyor : 1

EquipmentsIn Press Line

Press MachineScrap Conveyor

Parts Handling RobotDe-Stack Feeder

The stack feeder unit loads the sheet blanks into the unit to be forwarded to the

washing unit. The position of the sheets to be loaded is governed by the laser pointer

guides and stack feeder guides. The number of sheets loaded is 250. For door panel the

number of sheets is less as the door panel consists of 2 sheets of varying thickness of

0.6mm and 1.25mm due to weight and strength considerations. For SPO the number of

sheets is less due to weight considerations. Once the number of sheets reduces to 50

the Auto Lifter takes over and the stack lifter is free for the next run of loading. This

saves time.

DE-STACK FEEDER

A blank of sheet goes inside the De-stack feeder . There are position and photographic sensors for the correct position of blanks and to ensure the safety.

SPECIFICATIONS

The specifications and material of blanks goes inside the feeder are-

MATERIAL OF BLANK

COLD ROLLED STEEL SHEETS, HEAT ROLLED STEEL SHEETS,

HIGH TENSILE STRENGTH STEEL SHEETS, SURFACE TREATED STEEL SHEETS,

TAILORED BLANK

De stacker cups

THICKNESS 0.5- 2.3mm

ONE BLANK TWO BLANK

MAXIMUM SIZE 4000mm × 1800mm 1800 × 1800mm

MINIMUM SIZE 800mm × 500mm 800 × 500

STACK WEIGHT MAXIMUM 5000 kg./ 1 STACK MAXIMUM 2500 kg./ 1 STACK

BLANK SHEET WEIGHT

MAXIMUM 30 kg./ 1 BLANK MAXIMUM 15 kg./ 1 BLANK

STACK HEIGHT MAX. 400mm

No. OF STACK 2 STAGES

PASS LINE HEIGTH ABOVE FLOOR LEVEL 1600m

DE STACKER CUP

These cups left the blank sheet to magnetic rollers. Then those rollers hold the sheet

and these cups leave them. There is a rubber belt/conveyor belt on these magnetic

rollers which take the sheet a bit forward where thickness of sheet is measured using a

sensor. This sheet is moved to D.B. positioned. Tolerance of this thickness measuring

MAGNETIC FLOATER

sensor is 0.1 mm. These cups move the first and last blank to D.B. basket which is on

the back side. It collects the first and last blank of all stacks after a time these sheets

are sent for reuse in stacks. This is because of dust particles on the first sheet and

deformation due to all sheets on the last sheet.

MAGNETIC FLOATER

In a stack sheets are already washed by oil and when Die Stacker cups come down and

lift a sheet, it lifts two sheets together to remove another sheet we use magnetic floater

and stop motion. The magnetic floater blows air towards the sheet to separate them

and it is magnetic so blowing air doesn’t change the position of the sheet.

WASHING UNIT

The washing unit is located in the initial state. The primary function of this unit is to

remove dust and dirt from the sheets. Before oil is supplied to the rollers for cleaning

the blanks, it goes through a filtering process.

Pinch roller:

It feeds the sheet used for directing.

Brush roller:

On their top there are nozzles which keep spraying oil on the blanks and brushing the

blanks. Wasted oil is collected below into the drain.

Winger roller:

These rolls were used for cleaning and forwarding of blanks. They take out excessive

oil from the blanks and forward them to the centering movement. There is an option to

bypass the washing unit.

Centering unit

These kinds of stoppers are used to match the centre of the blank with the centre of

die. It is of three types:

1. Front stopper

2. Rear stopper

3. Side stopper

Stopper

ROBOTS

SPECIFICATIONS OF PRESS

FIRST PRESS MACHINE – 1500 T DRAW:

In this press machine drawing process is carried out.

MAKE HITACHI ZOSEN FUKUI

CAPACITY 15000 kN = 1500 T

LIMIT OF CAPACITY 13 mm

SLIDE STROKE 900 mm

STROKE PER MINUTE 12 – 18 spm

SLIDE ADJUSTMENT 500 mm

DIE HEIGHT 1250 mm

SLIDE AREA 4500 × 2200 mm

BOLSTER AREA 4500 × 2200 mm

AIR PRESSURE 0.98 MPa

MAIN MOTOR AC 250 kW ; 4P

ADJUST MOTOR AC 15 kW; 6P

PRESS MACHINE 2, 3&4 – 1000 T

In this press machines operations like trimming,bending, piercing and punching is done.

MAKE HITACHI ZOSEN FUKUI

CAPACITY 10000 kN = 1000 T

LIMIT OF CAPACITY 13 mm

SLIDE STROKE 900 mm

STROKE PER MINUTE 12 – 20 spm

SLIDE ADJUSTMENT 500 mm

DIE HEIGHT 1350 mm

SLIDE AREA 4500 × 2200 mm

BOLSTER AREA 4500 × 2200 mm

AIR PRESSURE 0.98 MPa

MAIN MOTOR AC 160 kW ; 4P

ADJUST MOTOR AC 11 kW; 6P

ROBOTS

There are 5 robots present in the press machine which help in facilitating the

movement of sheet metal part from one press to another and finally the finished part

onto the conveyor belt.

The primary function of the robots is to facilitate the movement of parts from one die

to the other. The robots are attached with jigs and fixture specific to the part being

produced. The jigs contain vacuum cups which lift the component to be transferred.

The robot arms move about the axes which allow their movement.

Make Motoman

Number of Robots 5

Number of axes 6

S Spin (270°)

L Lower Arm

U Upper Arm

R Rotate

B Bend

T Twist

OPERATIONS OF THE PRESS

1.)DRAWING

Draw Die:-Die for forming a hollow vessel from a flat sheet metal with use of punch and die without application of heat.

Draw Die Clearance:-The Clearance b/w die and punch shall be thickness of sheet material plus 0.1 mm

Draw Force:-The force required for drawing depends upon the shape of punch. For general applications a simple load calculation is made by following formula

Drawing Force = L * t *35 (Numerical Constant)L= Drawing Circumferencet=Sheet Thickness

BLANK DRAWN PART

2.) TRIMMING

For cutting excess material from a part made by drawing.

DRAWN PART TRIM PART

3.) PIERCING

Piercing is the operation of cutting internal features (holes or slots) in stock.

Trimming operations are generally combined with piercing operation and accommodated in the same die.

PARTS MANUFACTURED

S.NO. PART NAME

CITY BRIO AMAZE

1. Hood skin

2. Hood frame

3. Fr. Fender RH

4. Fr. Fender LH

5. Roof panel

6. SPO RH

7. SPO LH

8. Fr. Door Skin RH

9. Fr. Door skin LH

10. Rr. Door skin RH

11. Rr. Door skin LH

12. Fr. Door panel RH

13. Fr. Door skin LH

14. Rr. Door skin LH

15. Rr. Door skin RH

16. Trunk lid skin

17. Trunk lid frame

19. Rr .inside LH

20. Rr. Inside RH

SEQUENCE OF PRODUCTION

The predetermined sequence of parts is followed while production to avoid confusion and to

facilitate easy coordination between various departments.

PARTS STORAGE& HANDLING

Parts after production are needed to be stored safely to avoid small deformities such as dent, ding etc. This is where the trolleys come into play.

Forklift: It is used to transport the trolleys from production area to the storage area.

Forklifts used in HCIL are mainly Toyota. It has a capacity of carrying 3 trolleys at a

time. It has a speed limit of 10 km/hr.

TROLLEY

A structure used to stack parts such as hood skin, SPOs, FR Fender, etc. for storing purposes. After

part stacking trolleys are in turn stacked upon each other according to the name or code of the

trolley. In HCIL, the parts manufactured are of brio, city and jazz.

The trolleys of three cars are differed by their color coding given below:

1. White for brio

2. Green for city

3. Yellow for Amaze

The structures of trolleys are differed according to the parts they are holding. For e.g. trolleys

holding hood skin contains panels whereas trolleys holding door frames have rods.

Different types of trolleys:

S. No. TROLLEY Type of trolley

1. HORIZONTAL SLIDING

2. 3 POINT SUPPORT TROLLEY(FR FENDER)

3. SLIDING (TRUNK LID)

4. HANGING(SPO)

5. SLIDING(SPOILER)

6. VERTICAL PILING

SAFETY

Safety has been an integral part of the HONDA work culture. “Safety First” has been

the primary motto at every stage of the production process. Every worker is given

safety training at regular intervals related to safety.

SAFETY ON MACHINE:

Every machine is equipped with various kinds of sensors such as laser sensors,

presence detectors, motion detectors at various levels. At any stage of production

process any irregularity such as dislocation of sheet or multiple sheet or absence of

sheet the entire line comes to a halt immediately.

Safety measures:

Photo sensor: To stop movement of crane saver if someone is on the line. It is also

present before crane saver washing unit before and after each die.

Maintenance key:

Turn it on to enter the machine when it is on then press is stopped and upper die is

locked.

Die sensors at boundary:If the blank is not placed correctly by the robot, the sheet-

miss button lights up and the upper die stops in the press.

PHOTO SENSORS

Maintenance key

SAFETY OF MAN

Training workshops for safe practices are conducted at regular intervals for employees

at all levels of the production department. Placards are placed at regular intervals to

remind employees about safe practices.

Personal Protective Equipments

Helmet

SHOES

ARM SLEEVES

Gloves

Ear Plugs

Goggles

VARIOUS PROBLEMS INVOLVED IN THE PRESS LINE

Vacuum miss:- Sometimes the pressure in the vacuum cup falls below the required value and then cup does not lift the part and this is called vacuum miss.

Set miss:-There are position sensors to sense the accurate position of the sheets in the dies but when there is difference in the position occurs, sensors operate and this is called set miss.

Scrap jam in trim and piercing die:-Sometimes the scrap from the parts after going through trim and piercing die jams there.

Sheet abnormal fault:- Sometimes sheet bend in the die, sometimes two sheets come together.

Chip dent problem:-due to dust in the die, dents occurred in the parts. To overcomethis, die cleaning is done.

VARIOUS PARTS OF DIE:

SRNo: ILLUSTRATION NAME

1. Spring plunger: used to eject part from the die.

2. Air header block: connects air hose to certain parts of

die.

3.Distance plate

4. Disappearing gauge: used to align part on the die.

5. Vacuum cup

6. Tanker cylinder: present on lower die, used as spring

function to support upper die.

7. Side pin stopper

8. Silencer: attached to the air cylinder in the die.

9. Coil springs

10. Wear plate

TYPES OF GRINDERS

Grinding is a highly skilled operation, where the required dimensions or form is

achieved. It requires a tremendous amount of skill and concentration for grinding.

Grinding is often a secondary or finishing operation. The quality of the ground surface depends on the selection of type of grinder and type of wheel.

EFFICIENCY

The following data represents the stoppage time of machine in 2 hours.

S.NO. MACHINE STOPPAGE

STOPPAGE TIME (min : sec)

PROBLEM

1. 8:48 am 1:40 Draw upper die problem

3. 8:57 am 1:30 Die cleaning

4. 9:03 am 3:00 Sheet abnormal fault

6. 9:15 am 1:40 Die cleaning

7. 9:19 am 1:00 Centering unit clamp/ unclamp problem

10. 9:35 am 4:20 Automatic die change(ADC)

11. 9:57 am 2:00 Die cleaning

12. 10:10 am 1:50 Stack and sheet abnormal fault

13. 10:30 am 2:20 Die cleaning

Net loss time 18 min.

=(120-18)/120*100=85%

Similarly the efficiencies calculated for 3 more days were80.5% , 79% and 87%.So, the average efficiency = (85+80.5+79+87)/4

=82.8%

PROJECT:

DESIGN AND FABRICATION OF FRAME.

Design and fabrication of frame.

DESCRIPTION: Frame was to be fabricated for the new model which is to be used in the press no. 3. Jig is to be such designed that part after getting trimmed in the 2nd press is placed in the press no. 3 and part are to be separated by a certain distance (390 mm) so that bending process can be done at press no. 4.

FABRICATION:

Keeping in mind the bolster area as well as the new part, THREE frames were fabricated on which part is to be placed with the help of robots.

There was the height difference between frame-1 and frame-2 and the smaller frame (frame-2) contains a sliding frame (frame-3) above it which will be displayed 390 mm with the help of a pneumatic cylinder.

COMBINED FRAME

FRAME-1FRAME-2,3

FRAME-2FRAME-3

There was two pneumatic cylinders fitted in the frame 2 and with the help of pneumatic cylinders, the movement of sliding frame (frame-3) is controlled.

Pneumatic cylinders was of 130mm stroke length. To get the 390 mm stroke from 130 mm cylinder a revolving joint was

placed in the lower height frame and an attachment was such made that we can get movement of sliding frame by 390 mm.

Sliding frame was also fabricated and fitted in frame-2. There is a weight sensor also, which will sense the weight and when the

weight comes, pneumatic cylinders operate and when the weight goes they will operate in different direction.

Mechanism (How it works)-

First, the part after getting trimmed in the press 2 will come on the frame-1 and frame-3 with the help of robots.

When the weight (part) will come on the frames, pneumatic cylinders will operate (due to weight sensor).

And then the parts will be get separated by 390 mm. Separated parts will move to press 4 with the help of robots. Now again due to weight sensors the frame 3 will come to its original

position and in this way the parts will be get separated by 390mm.

BIBLIOGRAPHY

1) HCIL manual for Safety equipment, operation, maintenance.

2) Hitachi Zosen Fukui corporation (H&F) instruction manual 1500 Ton Press.

3) Hitachi Zosen Fukui corporation (H&F) instruction manual 1000 Ton Press.

4) H & F Robot maintenance manual.

5) DAYTON Press die components catalog 2010.6) MISUMI standard component for press dies.7) HCIL Die maintenance manual.