SUMMER TRAINING REPORT

HONDA SIEL CARS LTD

PROJECT REPORT ON PARTS LOGISTICS CONTROL

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HONDA SIEL CARS INDIA LTD. TAPUKARA, KHUSHKERA, RAJASTHAN

PP

MENTORED BY :-

Mr. RAMANDEEP SINGH

DEPARTMENT: PLC

SUBMITTED BY: ROHIT YADAV

SUMMER INTERN For M.B.A.INDIAN INSTITUTE OF PLANNING AND MANAGEMENT

NEW DELHI

UNDER GUIDANCE OF :-

Mr. VINOD KUMAR

DEPARTMENT: PLC

HONDA SIEL CARS LTD

ACKNOWLEDGEMENT

I am deeply indebted to Mr. SUNIL KUMAR YADAV, GM , GENERAL AFFAIRS due

to whose kind recommendation I was inducted as a trainee in this prestigious Company.

It was also extremely kind of Mr. R. PAUL, HOD (PLC DEPARTMENT) & Mr. VINOD

KUMAR, DEPUTY MANAGER to guide me despite their busy schedule. I would also

like to thank Human Resource Executive Ms. Shikha Verma for patiently facilitating me

throughout my training at HSCI.

Training for 7 weeks at the Honda Siel Cars India Ltd (HSCI) – Tapukara was a

very pleasant and intellectually enriching experience for me, both as an individual

as well as a student of MBA. The state of the art equipment installed in the plant

helped me to increase my knowledge and also get some hands on experience of

the latest practices in the manufacturing industry.

I did my whole training at PLC department under the guidance of Mr. VINOD

KUMAR, Senior executive for his immense guidance and continuous support

throughout my project work, and it is only because of his vision and

encouragement that, I was able to attain the goal. His in-depth knowledge of the

subject, readiness to share the knowledge has been an inspiration to carry out

this project.

I thank MR. RAMANDEEP SINGH Executive, for his guidance and help in

understanding the working of the section. He was very friendly and helpful all

through this period.

It wouldn’t be complete if I didn’t thank the entire PLC Department. The last 7

weeks was made special by these people who were more than just my senior

colleagues. They helped me to understand the working of the Automotive

Industry and its culture. I thank them all.

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MENTORED BY :-

Mr. RAMANDEEP SINGH

DEPARTMENT: PLC

UNDER GUIDANCE OF :-

Mr. VINOD KUMAR

DEPARTMENT: PLC

HONDA SIEL CARS LTD

About Honda Motor Company, Japan

The history of the Honda Motor Company began with the vision of one man

Soichiro Honda. His dream was personal mobility for everyone.

Mr. Soichiro Honda

Soichiro Honda founded the Honda Motor Company in 1948. In the same year, he

designed and engineered the first product of this company - a 50 cc motorized bike on a

bicycle frame - in his small shed at Hamamatsu.

His company started producing small motorcycles, including one built in 1949 called D-

type dream.

Then he thought of high capacity motorcycles and taking them to racing. So his

company made bigger and faster machines, two, four, five and six-cylinder race bikes

and participated in the Isle of Man TT race (125 cc motorcycle class).

He wanted to share his new motorcycles with the world and therefore he opened

American Honda Motor Co. in Los Angeles. Also Honda began manufacturing

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motorcycles at its Suzuka factory in 1960. Honda launched its first sports car, the S500

in Japan and entered Formula-1 in 1964.

In 1989, Soichiro Honda became the first Asian to be inducted into U.S. Automotive Hall

of Fame. In 1990, Honda wins its fifth consecutive 1st ranking in the J.D. Power

Consumer Satisfaction Index. In 1993, founder Soichiro Honda passed away. He

dreamt of changing the way people looked at motorcycles and gave us machines that

were powerful & fun to ride. SOICHIRO HONDA’S dreams changed the world of

motorcycling forever.

Honda started participating in racing at the highest level much before it found

international acclaim as a manufacturer. Once again, it was Soichiro Honda who was

the driving force. He considered the highly competitive world of motor sports as the

ideal training ground for his people. Through racing, Honda engineers learnt to

accomplish more than they ever dreamed possible within limited amounts of time. They

become quicker at responding to the technological challenges that arise in the

commercial world.

Honda's belief in the benefits of racing is sincere and unwavering. The company has

invested millions of dollars in building two world-class racing circuits. The Suzuka

opened its gates in September 1962. Located in northern Japan, it has become an

integral part of the Grand Prix calendar. The Twin Ring Motegi, on the other hand, is a

racing circuit for fans. Inaugurated in August 1997, it offers an oval-shaped Super

Speedway, an Active Safety Training Park and the extremely popular Honda automobile

museum.

Honda has always believed in giving more excitement and more joy. Be it designing

high performance sports cars that are a pleasure to behold and a joy to drive or creating

the world's first humanoid robot to walk on two legs or countless other technologies that

astonish and delight, Honda's spirit of exploration frequently invents the future.

Not surprisingly, millions of people worldwide often respond to Honda's spirit of

innovation with a sense of delight and amazement.

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ABOUT HONDA SIEL CAR INDIA LTD.

Honda Siel Cars India Ltd. (HSCI) was incorporated in December 1995 as a joint

venture between Honda Motor Co. Ltd., Japan and Siel Limited, a Siddharth Shriram

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

plant. 

Fig.1 Fig.2

HSCI PLANT – I (Greater Noida) HSCI PLANT – II (Tapukara)

HSCI’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. 

The company’s product range includes Honda Jazz, Honda City, Honda Civic and

Honda Accord which are produced at the Greater Noida facility with an indigenization

level of 77%, 76%, 74% and 28% respectively. The CR-V is imported from Japan as

Completely Built Units. Honda also has plans to launch the fully indigenized small car

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Brio into the Indian market by the end of 2011. Honda’s models are strongly associated

with advanced design and technology, apart from its established qualities of durability,

reliability and fuel-efficiency.

ABOUT HONDA MOTOR COMPANY Ltd.

In 1946, following World War II, Soichiro Honda set up a tiny plant, the Honda Technical

Research Insatiate and started manufacturing small engines and motor bikes. In 1948,

Mr. Honda incorporated his firm under the name Honda Motor Company Ltd.

In 1959, Honda gained global acceptance by winning the largest and most prestigious

Motor Cycle competitions of the world.

Honda produced its first automobile, a small sports car model in 1960. Since then it has

produced a range of models and has time and again won awards for customer

satisfaction.

ABOUT SIEL Ltd. :

In 1889, Lala Shriram laid the foundation of the Delhi Cloth Mills (DCM). A century

later, it was decided to divide the group, in order to address issues concerning business

growth areas and rising costs. SIEL Ltd. was the new entity born out of this division.

SIEL has considerable experience in precision engineering industries and has to its

credit the following distinctions:

Joint venture with Honda Motor Company for manufacturing Shriram Honda Portable

generating sets, water pumping sets and general purpose engines.

Under collaboration with Tecumseh, USA, SIEL is countries second largest

manufacturer of air conditioning and refrigeration compressors.

One of the largest manufacturers of sugar and vanaspati in the country.

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The associates of HSCI have come from diversified backgrounds and assorted work

culture. To produce quality products it is extremely important to understand what quality

is and how to produce products of consistent quality. To achieve this it is essential to

align their thinking, and understanding their approach towards work.

As per the corporate philosophy HSCI will strive to be the most customer oriented

company in India. Efforts are being made to ensure that HSCI is perceived as an

international level company in terms of the quality of the products, after sales services

and standards of individual and company performance.

HSCI is striving to evolve a well-integrated and harmonized Indo-Japanese work culture

embodying mutual trust, respect and equality without discrimination.

Honda has 3 plants in the South-East Asia region. The first plant is in Thailand and

owned by HATC – Honda Automobile Thailand Corp. The other two are in India, one at

Greater Noida and the more recent one at Tapukara.

HSCI Plant

HSCI-TAPUKARA KHUSHKERA RAJASTHAN

Honda Siel Cars India Ltd Plant-2 located in Tapukara, Rajasthan (about 70km from

Delhi) is spread over a 611 acre area. This area consists of Honda’s car plant and

Honda’s 2 wheeler division i.e. HMSI and also some suppliers like Gapai, Bestex,

Yutaka etc. Honda’s car project consists of 2 shops i.e. Powertrain and the Press Shop..

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LOCATION OF HONDA CAR PLANTS IN SOUTH-EAST ASIA. HONDA HAS ONE PLANT IN THAILAND – HATC and TWO PLANTS IN INDIA – HSCI – GREATER NOIDA

and HSCI - TAPUKARA

HONDA SIEL CARS LTD

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HSCIHSCI TapukaraTapukara

LOCATION OF HSCI – TAPUKARA IN INDIA

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.

HSCI-TKR WORK CULTURE

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ＮＮ

Suppliers Cluster

Car Plant Area

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SP AREA

HMSI(proposed)

GAPAI

BESTEX

YUTAKA

MORIROKU

SERVICES

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Suppliers Cluster

Car Plant Area

HT

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SP AREA

HMSI(proposed)

GAPAI

BESTEX

YUTAKA

MORIROKU

SERVICES

UTL

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Supplie

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Clu

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Car P

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Area

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Supplie

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Clu

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LAYOUT OF THE HONDA CAR PROJECT,TAPUKARA INDUSTRIAL AREA

POWERTRAIN SHOP (ENCIRCLED)

HONDA SIEL CARS LTD

SIMPLE. FLEXIBLE. SPEEDY.

1. 5S PRINCIPLE: -

5S is a method for achieving and sustaining efficiency and effectiveness through

organization and standardization in the workplace.

SORT (SEIRI)- means removing all supplies, materials, tools, and paperwork not

required for current production ... also all waste, by-products, empty containers,

and papers generated by current production activity but no longer needed.

SET IN ORDER (SEITON)- is equivalent to orderliness, or organizing those items

that truly need to be in the workplace (those remaining after Sort) so that

everything has a place and everything is in its place. It describes the necessary

processes to improve access to needed materials and equipment through

organization, labeling, allocation of storage and proper procedures.

CLEANING (SEISO) - The role of cleaning and maintaining quality throughout.

STANDARDIZE (SEIKETSU) - It describes the standardize phase, which

includes the creation and use of procedures, practices, policies, and job aids

associated with the first 3 of the 5S activities.

DISCIPLINE (SHITSUKE) -. To create and maintain a favorable 5S atmosphere

in the workplace means creating a 5S culture.

Apart from these 5s, three more S are also used-

1. Safety

2. Security

3. Satisfaction

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2. 5G

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3. KAIZEN

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PRODUCTS OFFERED BY THE COMPANY

HONDA JAZZ

Honda Jazz is the company’s first offering in the premium compact car segment. The

Jazz is a segment-defining car that has won accolades and adoration all over the world.

Widely acclaimed for its dynamic styling, spacious interiors, versatile utility and

remarkable performance, the Honda Jazz brings added fun and excitement to the

driving experience.

The Jazz’s dynamic performance is achieved by a newly developed four-cylinder 1.2-

liter i-VTEC engine, featuring Programmed Fuel Injection that delivers maximum output

of 90 PS (66 kW) @ 6,200 rpm and Torque of 110 Nm (11.2 kg-m) @ 4800 rpm while

giving impressive fuel economy of 16.1 km/l, as per ARAI test data. Safety of

passengers and pedestrians is a top priority for Honda and all safety equipment is

standard across all variants.

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HONDA CITY

Honda's all-new Third Generation Honda City was launched in September 2008. It

comes with a completely new design, new engine, spacious cabin and equipped with

various active and passive safety features. The company has also launched the 1.5 V

MT & AT version of the City in September 2009. The new Honda City is available as

SMT, VMT and VAT. Additionally, all the variants is available in 2 attractive types –

Elegance and Inspire.

The all new Honda City achieved milestone sales with 50,000 units sold within one year

of its launch. Since its launch in the country in 1998, Honda City has been a best seller

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in the premium car segment.

The all new Honda City has bagged several awards including 3 Car of the Year and the

prestigious ICOTY (Indian Car of the Year) 2009. The model made a clean sweep in the

viewers’ choice category winning all 3 awards announced by NDTV Car India & Bike

India Awards, UTVi Autocar Awards and CNBC TV 18 Overdrive Awards. These awards

truly exemplify the experts’ as well as the customers’ admiration and trust in the

product.

 HONDA CIVIC

The Civic is Honda’s largest selling model globally and is now sold in approximately 160

nations and regions worldwide. Honda Civic was launched in India in July 2006 which

became a runaway success and was also awarded the “Indian Car of the Year” in 2007.

The new Civic was launched in September 2009 with more aggressive and sportier

look. The new V grade Civic juxtaposes Honda’s advanced technology with striking

design. The new Curved 5 Point Metallic Front Grille and restyled Front Sporty Bumper

add to a pulsating and aggressive appeal of the car. The introduction of stylized Dark

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Smokey Headlights & Crystalline Octagonal Tail Lights enhances the contemporary look

of the car. New Civic is available in 3 variants – SMT, VMT & VAT.

HONDA ACCORD

The Honda Accord was first introduced in India in year 2003. HSCI launched the 8th

generation Honda Accord in India in May 2008. The Honda Accord is available in 2.4L

and 3.5L V6 engine.

The 2.4L comes in three types in both Automatic and Manual transmission − Accord

2.4, Accord 2.4 Elegance and Accord 2.4 Inspire. The All-new Accord comes with 5-

speed Manual Transmission and 5-speed Automatic transmission with Paddle shift, to

give the exhilarating experience of F-1 racing. The AT now has Shift Holding System

which avoids unnecessary gear shifting on winding roads and helps in hassle free drive.

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The Honda Accord V6 3.5-liter comes with Electric Sunroof and additional luxury

features for enhanced exterior styling. The 3.5L i-VTEC engine features an advanced

Variable Cylinder Management (VCM) system that switches between six-, four-, and

three-cylinder combustion depending on the driving conditions and thereby delivering

maximum power of 275 PS during six cylinder operation and impressive fuel economy

in VCM mode while cruising.

HONDA CR-V

The Honda CR-V is sold as a Completely Built Unit (CBU) import and is available on

confirmed order basis for the customers. The Honda CR-V was first introduced in India

in July 2003. It went on to become the segment leader since its launch winning several

awards for itself. The all new 3rd generation CR-V was introduced in India in November

2006 which offered its customers a distinctive combination of ‘the comfort of a sedan

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with the thrills of a SUV’. Honda CR-V was adjudged the ‘SUV of the Year’ by NDTV

Profit Car & Bike and Overdrive and also won the ‘Best Driver’s Car’ award by CNBC

TV-18 Autocar Auto Awards in 2007.

Honda launched a refreshed version of the 3rd generation CR-V in November 2009.The

new Honda CR-V offers its customers a distinctive combination of refined styling and

high quality. The Honda CR-V is available in 2.0 L - MT 2WD and 2.4L MT /AT Real-

time 4WD.

MORE THAN 3.4 LAKHS SATISFIEDMORE THAN 3.4 LAKHS SATISFIED CUSTOMERSCUSTOMERS

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29% No. 1 in theNo. 1 in the premiumpremium segmentsegment

HONDA SIEL CARS LTD

UPCOMING NEW PROJECT – HONDA BRIO(CYLINDER HEAD, BLOCK

AND CASE TO BE MANUFACTURED IN HSCI-TKR)

Honda BRIO PROTOTYPE is developed with Honda’s advanced technologies, while

further advancing Honda’s “man maximum, machine minimum” concept which is a basic

approach to Honda car design calling for maximizing the space available for people and

minimizing the space required for mechanical components.

Being developed as a city commuter which is easy-to-use even in urban areas, the

Honda BRIO PROTOTYPE adopts an easy-to-handle compact body (length 3,610mm x

width 1,680mm x height 1,475 mm) while ensuring enough cabin space for five people

achieved by highly efficient packaging.

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HSCI

POWER TRAIN

FE(PT-1)

CONNECTING ROD

CRANKSHAFT

ENGINE CONTROL

TOOL REGRIND

ING

MANTINENCE

AL(PT-2)

CASTINGHPDCLPDC

MACHINING

BLOCK/CASEHEAD

PRESS SHOP

HONDA SIEL CARS LTD

A BRIEF DESCRIPTION OF HSCI DEPARTMENTS:

PRESS SHOP: The press facility comprising of 1500 ton tandem lead

Press and three other tandem press of 1000 ton each maintain a tact time

of 7 seconds and is equipped with advanced features like:

Auto de-stacks sheet feeder and online sheet cleaning.

Robotized part pick-up and transfer.

Safety sensors that stop robot and machine operation in case of beach of safety

fence.

Underground scrap conveyer.

ENGINE CONTROL: Engine control department comprises two of two

Sections whiz tool regrinding and maintenance.

TOOL REGRINDING: Tool Regrinding section does following works.

Regrind the tool like drill bits, Reamer tool, end mill, step drill.

Indexing of turning and milling tool.

Profile projector to analyze the shape and size of tool tip.

Have different types of grinding wheels for tools of different materials.

ALUMINIUM DEPARTMENT (POWER TRAIN- 2): Aluminium power train Consists Of

two sections whiz casting and machining Under casting operation, clutch case, mission

case, cylinder block and cylinder head are being casted. Composition of the aluminum

alloy used for casting in HPDC is shown below.

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Si Fe Cu Mn Mg Zn Ni Pb Sn Al

9-12% 0-1.3%

1.5-4.5

0-0.5%

0-0.3%

0-0.25%

0-0.5%

0-0.2%

0-0.35% REST

HPDC: High pressure die casting section has two units of 2500 ton and 1650 ton. Each

unit has two furnaces, one for melting the aluminium having temperature around 990k

and other called holding furnace used to hold the molten alloy at a temperature around

873k.

This tonnage force indicates the amount of force that can be applied between both dies

during the injection of molten alloy.

The process of injection of molten alloy in between dies is carried out in two steps.

Ladle pours the molten alloy in a slot given in front of plunger. Plunger shot the molten

alloy in two strokes. In first stroke pressure is around 6.5Mpa which increases to 12Mpa

at second stroke. Pressure required in first stroke is developed with the help of hydraulic

Pump. Whereas pressure required in second stroke is developed with the help of

nitrogen gas stored over a piston in a cylinder fitted with a solenoid valve, whose

working is shown below.

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MY WORK AREA:

INTRODUCTION TO Fe DEPARTMENT

Fe department has further been divided into two sections

(1)CRANKSHAFT LINE

(2)CONNECTING ROD LINE

CRANK SHAFT MODELS

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DIFFERENT MODELS OF CRANK SHAFT:-

1. RB-1 ( USED IN HONDA CITY)

2. RB-2 (USED IN HONDA JAZZ)

3. RNA (USED IN HONDA CIVIC)

The length of RB-1 & RB-2 model is same, while the length of RNA model is more than

the earlier mentioned models. The basic & visual difference between the RB-1 & RB-2 is

that RB-1 has 8 webs while RB-2 has 4 webs. Thus we can differentiate between

different models of crank shaft visually.

PROCESS FLOW FOR CRANK SHAFT:-

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PROCESS NO. PROCESS NAME

OP-A SOZAI CHECK

OP-10 LOT MARKING

OP-20 CENTERING AND FACING

OP-30 LATHE ROUGH

OP-40 LATHE FINISH

OP-50 PIN MILLING

OP-60 END HOLE DRILLING

OP-70 END HOLE KEY WAY MILLING

OP-80 OIL HOLE DRILLING

OP-90 4J THRUST BURNISHING

OP-100 MIDDLE WASHING

OP-110 RF GRINDING

OP-120 L GRINDING

OP-130 JOURNAL GRINDING

OP-140 PIN GRINDING

OP-150 MIDDLE INSPECTION

OP-160 GAS SOFT NITRIDING

OP-170 STRAIGHTENING

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OP-180 FINE BORING

OP-190 BALANCE MEASUREMENT &CORRECTION

OP-200 MICRO FINISHING

OP-210 FINAL WASHING

OP-220 MEASUREMENT &MARKING

OP-230 BALL PRESSING

OP-240 FINAL INSPECTION

PACKING & THEN DISPATCH

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NOMENCLATURE OF CRANKSHAFT:

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GAS SOFT NITRIDING (GSN): Gas Soft Nitriding is a surface hardening

process.

Some parameters that are being controlled under this process are:

PARAMETER MINIMUM ACTUAL

Compound layer 8µm 25µm

Hardness (100gm) 450 Vickers 700 Vickers

Diffusion layer 190µm 450µm

PROCESS FLOW DIAGRAM:

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PREWASHING (component are prewashed in a alkali solution of 0.5-1% concentration called as chemilite solution.)

PREHEATING (Components are placed in a propane gas fired furnace for 40min at a temp of 450`c)

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preheated component

RX gas comin from endo generator at a temp of 1090`c

NH3

gas coming from utility

N I T R I N D I N G F U R N A C E

NITRIDING FURNACE (Component is placed for two hours in Nitriding furnace at a temperature of 600`C. )

POST WASHING (component is washed in a alkali solution of concentration 2-3 % at a temperature of 60`C)

HOT RINSING (final washing is carried away in a alkali solution of stregth 0.5-1 %)

Component is passed for further operation.

HONDA SIEL CARS LTD

CON. ROD MODELS:

SPECIFICATIONS OF DIFFERENT MODELS OF CON. ROD:-

1. RB-1 ( USED IN HONDA CITY) (length 149.0+-0.05)

2. RB-2 (USED IN HONDA JAZZ) (length 138.9+-0.05)

3. RNA (USED IN HONDA CIVIC) (length 157.5+-0.05)

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PROCESS FLOW FOR CON. ROD:

OPERATION NO. PROCESS NAME

OP-A SOZAI CHECK

OP-10 DOUBLE DISC ROUGH GRINDING

OP-20 BIG END SIDE MILLING

OP-30 BIG & SMALL END ROUGH BORE &

CHAMFER

OP-40 BOLT HOLE DRILLING

OP-50 BOLT HOLE DRILLING,REAMING & TAPPING

OP-70 V NOTCH CUTTING

OP-80 BIG END FRACTURE & ASSEMBLY

OP-90 DOUBLE DISC FINISH GRINDING

OP-100 METAL GROOVING

OP-110 BIG END OIL HOLE

OP-120 BIG END OIL HOLE GROOVE

OP-130 BIG & SMAL END FINISH BORING

OP-140 DEBURRING & WASHING

OP-150 DIAMETER & WEIGHT MARKING

OP-170 FINAL INSPECTION

PACKING

DISPATCH

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MY PROJECTS:

DENT ANALYSIS OF CON-ROD

WRONG LOADING (POKA YOKE)

1. Dent Analysis of Connecting Rod:

Before going in details of dent analysis, let’s first take some basic understanding of con-

rod and dent on con-rod.

A connecting rod is used to transfer the reciprocating motion of the piston to rotary

motion of crankshaft. It has two ends, called big end and small end. Big end is mounted

on crankshaft and small end is attached with piston through piston pin/gudgeon pin.

Raw material(Forged Connecting Rod called sozai, is imported from Japan and after a

number of machining operations this sozai part ready to put in engine. During these

machining operations con-rod gets some dent on its machined face/chamfer. Basically a

dent is a scratch mark generated due to rubbing of two con-rods with each other during

handling, or it can appear due to presence of chip or burr particles during machining of

con-rod. Dent may even appear due to impression of fixture, on which con-rod is

mounted/butted during machining.

Why dents are crucial for connecting rod?

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Connecting is that part of engine which transfers the reciprocating motion of piston to

rotary motion of crankshaft. Therefore a small dent on its surface can create problem in

its positioning at crankshaft or at piston. This can change the power output of engine by

changing the compression ratio of cylinder.

So the question comes Why connecting rod get damage??

Lets find out the answer by studying the complete flow of Sozai form to machined

connecting rod ready to assemble in engine.

For this, first we study the Locations of dent on connecting rod. There are different

areas of connecting rod profile that get damage. These are:

Dent on small end chamfer

Dent on small end grinding face

Dent on big end chamfer

Dent on big end grinding face

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Analysis of dents on connecting rod:

Connecting rods are not having dents all over their face or chamfered part. Rather there

must be some specific location of dent over connecting rod, coming from some

particular machining operation or handling problem. To find that I analyzed around 88

components at dispatched area, whose result are shown in a tabular form:

Different locations of connecting rod are marked to get more generalize result.

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CONCLUSION OF THIS ANALYSIS: It has been found that most of dents are present

on the right side of grinded face on the non marking side (S1`).

ROOT CAUSE ANALYSIS: It has been found that most of the dents which appear

during the machining operation before finish grinding (CO-9) are removed during finish

grinding operation. All we have to look for dents coming after CO-9 operation.

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COUNTERMEASURES: To prevent the reoccurrence of dents in Connecting Rod we

have taken the below mention countermeasures in different areas according to cause of

dent:

At CO-01 machine, the speed of the machined connecting rod is very high that

causes dent on connecting rod due to sudden strike with last machined

connecting rod on the guide-way. To reduce the flow of machined connecting rod

on sliding guide-way we have provided 2 obstacles that reduce speed of

machined connecting rod and when it strikes the previously machined connecting

rod, it doesn’t damage.

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Obstacles that reduces the speed of machined component and prevents striking previously machined part with high speed.

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While transferring machined connecting rods from one machine to next machine

they are arrange in such a pattern that there machined face comes in contact

with each other. This possibly causes dent on both parts. To avoid this, change

the placing of machined connecting rods from vertical to the horizontal.

Before – 40 No’s/Bin

After – 40 No’s/Bin

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Machined face may get damage while loading in plastic bins

Machined parts placed on rubber sheet and in such that not damage each other

HONDA SIEL CARS LTD

Now the next possible cause for dent on connecting rod is analyzed as flow of

completely machined part on sliding guide-way. Actually the angle of inclination

of guide-way is pretty large that increases the downward force due to weight of

component and when it strikes with last component, it may get damaged.

To avoid this ramp is provided below the stand of guide-way, which not only

supports the stand but also reduces the angle of inclination.

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Machined parts placed on rubber sheet and in such that not damage each other

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WRONG LOADING (POKA-YOKE) –

What is Poka – Yoke:

Poka-yoke also called error proofing, mistake proofing, mistake proofing or zero

quality control (ZQC). Poka-yoke is a system and or a device that prevents errors

before they become defects. With poka-yoke operators are not blamed for the

errors; instead find ways to keep errors from becoming defects. When used with

other lean principles poka-yoke can be a very valuable tool in the overall lean

manufacturing process.

In other words poka-yoke is a mistake- proofing device or

procedure to prevent a defect during order taking or manufacturing. An order

taking example is a screen for order input developed from traditional ordering

patterns that question orders falling outside the pattern. The suspect orders are

then examined often leading to the discovery of inputting errors or buying based

on misinformation. A manufacturing example is a set of photocells in parts

container along an assembly line to prevent components from progressing to the

next stage with missing parts. A poka-yoke is sometimes called a baka-yok.

A machine can be full proofed against multiple aspects as

Full proofing with respect to loading/unloading.

Full proofing with respect to machining operation.

Full proofing with respect to machining parameters.

Like: Coolant flow, tool’s position etc.

My project was to make the Con-rod line full proofed with respect to

loading/unloading condition.

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Necessity of Poka-Yoke:

Each machine does a certain operation at specific location on the component. If

a component is wrongly loaded then machining operation is carried away at

some other location or not at all carried away.

Therefore wrong loading may produce a NG component and may even harm the

machine or machine tool.

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Analysis:

On analyzing, It has been found that machine should be full proof against too

things.

Proper loading condition to avoid machining operation at some other

location of component.

To prevent components from progressing to the next stage with missing

parts.

COUNTERMEASURES:

FOR ANALYSIS 1: On analyzing it has been found that connecting rod of

models RB1 & RB2 are having unsymmetrical profile with respect to both

sides. Profile of one side contains a little extruded projection, which is used to

prevent it from wrong loading.

Therefore we have provided a metal pin, which prevents it from wrong

loading of component over machine.

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OK LOADING OF COMPONENT NG LOADING OF COMPONENT

DEVELOPED BUTTING PRESSUREZERO BUTTING PRESSURE

PROGRAM RUN ALARM MESSEGE

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CURRENT PROBLEM: Models RNA and RZP do have complete symmetric profile at

both sides, due to which the metal pin which works for model RB1 & RB2 does not

works for these models.

Also there is no poka –yoke in connecting rod line which prevent components from

progressing to the next stage with missing parts.

To counter such problems on the basis of my analysis I would like to give some

suggestions:

ADJUSTABLE PIN: An adjustable pin may be used in place of rigid pin. This pin

will be adjusted as per size and shape of connecting rod for different models. It

will work on the same principle of development of less butting pressure in case of

wrong loading of component.

In place of extruded part in case of RB1 & RB2 models, we will be using the

height of marking itself, to prevent wrong loading.

The difference in depth of marking and non-marking side from butting position

would be around 1mm or 1000µm (height of marking scripted over the

connecting rod). This difference in depth may create sufficient difference in

butting pressure. Whenever a component is wrongly loaded, this pin will not allow

proper loading of component on fixture and air hole given on the fixture will not

be blocked completely thereby reducing the butting pressure. This butting

pressure will be less than already specified butting pressure and therefore

machine will give an alarm and will not work.

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MANDREL: To prevent the component from progressing to next operation with

missing parts, a mandrel can be used. The mandrel will be attached with the

fixture and serve following two purpose:

It will support the component at the time of machining.

It will be used to detect whether the previous operation has been

occurred on the component or not.

It will be best suited if we provide this mandrel at the end of con-rod line i.e. at

CO-15 machine because all the previous operation can be detected at this

machine.

Mandrel will be provided with three air holes at the location of two grooves and

an oil hole. It will work on the principle of air jet pressure.

Mandrel may have following shape:

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THANK YOU

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