Yamaha- Training & Dev. Quality Control

8/13/2019 Yamaha- Training & Dev. Quality Control

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A

RESEARCH REPORT ON

TRAINING & DEV. W.R.T.

QUALITY CONTROL OFYAMAHA MOTOR INDIA LTD

SUBMITTED IN PARTIAL FULFILLMENT FOR THE AWARD OF

DEGREE OF MASTER OF BUSINESS ADMINISTRATION

(UNDER MAHAMAYA TECHNICAL UNIVERSITY ,NOIDA)

(201112)

SUBMITTED TO!

SUBMITTED BY!

M". A#$% '#"

PRAVESH UMAR

(H.O.D) R** N.

101+-00-0

(MBA)

/$% I/%$%'% 3 E4'5%$/ A/4 I/3"#%$/

1


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G"%" N$4201607 (U.P)

Contents

ACKNOWLDGEMENT

DECLARATION

Introduction

Plant Layout

Various Models and Their !eci"ications

Weldin# ho!

Paint ho!

Press ho!

Tool Roo$

Machine ho!

Electro!latin#

En#ine Asse$%ly

&ody Asse$%ly

tores

E'!ort ( Mar)etin#

2


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()*

+


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DECELARATION

I hereby declare that the proect report is result of my own

work for the fulfillment of academic re-uirement . his

report is solely the work of the undersign and nobody

is allowed to use , copy , edit anything by any

person. /rior permission has to be taken from

appropriate authority of any further use.

PRAVE+ K,MAR

Roll o.! "#1$%&""&"

()*

$


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0


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INTRODUCTION

Company profile :-

Indian joint venture Motorcycle manufacturing

company becomes

100 % YMC owned.

Company name changed to !

Yamaha Motor India private limited.

Yamaha Motor India ( YMI )

"olding aloft the spirit of commitment to customer

satisfaction ! Y#M#"# M$$& I'(I# is enriching lives

of people with the same ingenuity and enthusiasm as

its parent company ! Y#M#"# M$$&

C$&)$I$' * +#)#'. "aving operated in India as

technology provider for almost two decades* YMI was

incorporated in #ugust ,001 as 100% subsidiary of

YMC * +apan. -ince then people at Y#M#"# have been

in the process of redefining business processes and

etending the awe and power associated with the

legacy of the Y#M#"# group. #dhering to their

&


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Corporate Mission ! / Creating #'($ ! ouching

Your "eart / )eople at Y#M#"# are striving to touch

every "eart across the length and breadth of India.

stablishing a Corporate environment

that fosters self!esteem.

Y#M#"# believes in nurturing and empowering their

employees to the fullest. 2hilst cultivating their

employees creativity and all round abilities* they

have also established an e3uitable system of

evaluation and rewards to encourage their people to

strive towards newer benchmar4s.

5ulfilling -ocial &esponsibilities

#s good corporate citi6ens* people at Y#M#"#

continually strive towards creating a better social as

well as natural environment.

Technology

&esearch and development division is the windbeneath their wings. Model conception* (esigning*

#esthetics* Clay ma4ing* )rototype development are

the strong pillars of Y#M#"#7s &8(.

%


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-ince the primary re3uirements of Indian customers

are good mileage* comfort* durability* style and

affordability ! he &8( at YMI ensures a regular

interaction with customers to facilitate future model

development at &8( department !YMI -urajpur 8

5aridabad and &8( department ! YMC* +apan.

)eople at YMI believe in providing their customers

with innovative cutting edge technology* / # ruly

world class eperience ! RULY YAMAHA .9 heM#C"I' is developed and tested in accordance with

latest technological parameters to give their

customers the :-. nown all over the world for its

/"umachine9 technology* Yamaha strives to appeal

to human emotion by combining performance with

design in ways never achieved before. mbodied inthis creation ; not mere building < are the joy*

ecitement and pleasure* which are at the core of the

Man!Machine relationship ! to last a lifetime.

3uipped with fuel ! efficient and environment

friendly technology Y#M#"# bi4es are created to

#(( "# #'=Y 5>#?$@& $ Y$@& >I?-.

Indigeni6ed development of Models li4e FAZOR

,Enticer and Crux have been underta4en here at YMI.#t a steady pace* they have plans to develop

Y#M#"# M$$& I'(I# as a designing hub in future.

#


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Manufacturing: -

YMlAs Manufacturing facilities comprises of , state!

of!the!art )lants at ! 5aridabad ;"aryana< and

-urajpur ;@ttar )radesh


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the anvil ! early net year. #ll their endeavors give

the reason to believe that sustainable development

for Yamaha will not remain merely an idea in

pipeline. )eople at Y#M#"# believe in ta4ing care of

not only the Motoring 'eeds but also the needs of

5uture =enerations to come.

Plant Layout

LAND AREA= 30 HECTARE (303,803 sqm.)COVERED AREA= 55,600 sqm.OLD BULDN! AREA = "5,600 sqm.NE# BULDN! AREA = 30,000 sqm.

O$% B&'$%'n

$. RA# ATERAL *TORE". DE ANTANANCE3. #ELDN!+. *TORE (ANT, #ELD, LATN!)5. ACHNN!

11


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6. RE** *HO-. ANTN!8. ELECTROLATN!. ACHNE *HO

/0. TOOL ROO//. TOOL ANTANANCE/". ACHNE *HO/3. *TORE* ( 12'ne% ts )/+. *TORE* ( N'4C et1. )

New Building

/. EN!NE A**EBL

". *4, E4!, B4D ART*3. BOD A**EBL LNE+. B*R5. AB* ANTN!6. ART* *TORE*-. EORT 7 ACN!8. LOADN!

12


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FAZOR

Te12n'1$ *9e1':'1t'ons ;

Co%e N&m


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Te12n'1$ s9e1':'1t'ons ;>

Code Nu$%er - .TEn#ine Dis!lace$ent - in#le Cylinder/ 012 cc/ air cooled

&ore 3 tro)e - 45 3 .2 $$

Ma'i$u$ !o6er - 7*. &+P 8 7.11 r!$

Ma'i$u$ Tor9ue - *: K#"-$ 8 2111 r!$

Ma'i$u$ !eed - 57 K$!h ;solo D*C

O>erall Len#th - =1=. $$

+ei#ht - 01.1 $$

Wheel &ase - 0=51 $$Ker% 6ei#ht - 015 )#

I#nition - D*C CDI

et&es ;>achometer* 1F0mm drum bra4es* #djustable Multi!reflector* "eadlamp* "igher =round Clearance*>onger 2heel :ase for :etter stability* #(?#'C"G ngine* tc.

1+


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Te12n'1$ *9e1':'1t'ons ;>

Code Nu$%er - .,=

En#ine Dis!lace$ent - in#le Cylinder/ 0=?*7 cc/ Air cooled

&ore 3 tro)e - .4 3 .4 $$

Ma'i$u$ Po6er - 01*: &+P 8 :111r!$Ma'i$u$ Tor9ue - 0*12 K#"-$ 8 2.11r!$

Ma'i$u$ !eed - 01. K$!h ; solo D*C

O>erall len#th - =151 $$

+ei#ht - 00=. $$

Wheel%ase - 0?:1 $$

Ker% Wei#ht - 002 )#

Features :-

E$e1t'1 stt (o9t'on$), D's1


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et1.

CRU

Technical Specifications :-

Code Nu$%er - .KA?

En#ine Dis!lace$ent - in#le Cylinder/ 012 cc/ 4 stro)e

&ore 3 tro)e - 45 3 .2 $$

Ma'i$u$ !o6er - 7*. &+P 8 7.11 r!$

Ma'i$u$ Tor9ue - *: K#"-$ 8 2111 r!$

Ma'i$u$ !eed - 57 K$!h ;solo D*C

O>erall Len#th - 0557 $$

+ei#ht - 01.. $$

Wheel &ase - 0=47 $$

Ker% 6ei#ht - 012 )#

Ground Clearance - 0.1 $$

Electricals - 0=> D*C

et&es ;>

50 )$!l ;,TC< / Wider seat "or lon# dri>es/ @ront Telesco!ic

sus!ension "or s$ooth ride/ Rear sus!ension 6ith coil s!rin#s and oil

da$!ers/ O+C/ Adusta%le Multi-re"lector headla$!/ Etc*

10


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Welding

et$ 1 e$%'n 's 9o9&$$ em9$oe%. T2's9o1ess o9&$$ ?non s et$ >net s (!)

e$%'n 'no$es o: met$ &s'n 1ons&m


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". #RE DRVE; > T2e e$%'n 'e, %n :om t2e

s9oo$, 's :e% t2o&2 %'e o$$es, t2e 'e :ee% te

A 9o9e so&1e 't2 1onstnt

1 o$te C21te'st'1s 's 1onne1te% to t2e

1ont1t t& t 's &se% to 9ote1t t2e mo$ten

met$ 1ontm'nt'on :om t2e tmos92ee t2e

12o'1e o: s2'e$% s 's %etem'ne%


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4hielding as*rc

5eld /ool

MIG Welding Shielding Ga

T2e s2'e$%'n s, :oms t2e 1 9$sm, st


20/119

". Aon > / to 5 Oen

3. Aon > 3 to "5 C0"

+. Aon4He$'&m

COI's $so &se% 'n 'ts 9&e :om 'n some ! e$%'n

9o1esses. Hoee, 'n some 99$'1t'ons t2e

9esen1e o: COI 'n t2e s2'e$%'n s m %ese$

::e1t t2e me12n'1$ 9o9et'es o: t2e e$%.

#e$% D's1ont'n&'t'es/. Un%e1&tt'n

E1ess'e". e$t>t2o&2 n1om9$ete3. &s'on n1om9$ete Fo'nt+. enett'on

oos't 5. #e$% met$ 11?s

2"


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6. Het ::e1te% Gone 11?s

! #e$%'n Bene:'ts

/. A$$ 9os't'on 19


22/119

2'2 q&$'t, 9e1's'on e$%'n 's eq&'e%.

n T! e$%'n n 1 's :ome%

1ons&m


23/119

('n1ese e$%'n s9ee% o e$% 9enett'on).H%oen '$$ es&$t 'n 1$ene $oo?'n e$%s n% $so'n1ese 2et 'n9&tJ 2oee, H%oen m 9omote9oos't o 2%oen 11?'n

/.Aon". Aon K H%oen3. Aon4He$'&m

4hielding ases

#e$% D's1ont'n&'t'es

Un%e1&tt'n T&nsten 'n1$&s'ons oos't #e$% met$ 11?s Het ::e1te% Gone 11?s

TIG Weldin# Pro%le$s

Et'1 1E1ess'e e$e1to%e 1ons&m9t'onO'%'Ge% e$% %e9os'tA1 n%e'noos'tD'::'1&$t 1 stt'n

2'


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TIG Weldin# &ene"its

*&9e'o q&$'t e$%s #e$%s 1n


25/119

T2e sem e$%'n 9o1ess 's n %9tt'on o:es'stn1e s9ot e$%'n n% 'no$es m?'n se'es o: oe$99'n s9ot e$%s


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CONVENTONAL #DE ELD *EA#ELDN!

#'%e 2ee$ sem #2ee$ 1ont1t '%t2 nom$$ 5t mm :$t (2ee t

's s'n$e s2eet t2'1?ness 'n mm). !ene$ 9&9ose e$%'n (%omest'1 %'tos &9 to


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No e$% sem

Cons&m


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s2 sem e$%'n

No oe$9 o: s2eet e%es, 2'12 e 9t$1&s2e% toet2e %&'n e$%'n.

H'2 s9ee% e$%'n o: t'n 1ns n% %&ms (0."mmt'n9$te &9 to /00m4m'n).

#'%e 2ee$ o 1ons&m


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m9otnt ss&es

T2e m'n 'ss&es 1on1en'n sem e$%'n e 'n e$%q&$'t 1onto$

#e$%'n s9ee%s H'2 s9ee% e$%'n o: 1ote% stee$s 's o: 9t'1&$

'm9otn1e 'n mn&:1t&'n o: t'n 1ns *9e1'$'st1ons&m


30/119

/. T2e 's? o: 1&s2'n :'nes o 2n%s.". B&ns o ee %me :om s9$s2 met$. L'tt$e

:&me 's 9o%&1e%


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TE*TN! B RE**URE

&e$ Tn?

RE** *HO *OT #ELDN! *EA #ELDN!

NAL !RNDN! ROLLN! ROU!H!RNDN!

RE** OERATON ERCN! RONTBENDN!

*OT #ELDN! AUTO ! REAR BENDN!

*EA #ELDN! REAR ATCHN !BREAN!

TE*TNLLN!

*EA #ELDN! (COER ALLO)D.. #ATER * U*ED A* COOLENTTROU!H !RNDN! (!RADE *IE=/"0)NAL !RNDN! (!RADE *IE=""0)RE** OERATON (CUTTN! OR UEL NLET)

'1


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AUTO ! (NNER ANNEL AND OUTER ANNELA**EBL)TE*TN! B RE**URE (N CRON*)

ANT RU*T OL (RU*TLO D#>0/)

'2


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"aint Shop

T2e 9'nt s2o9 's so$e$ es9ons'1oos'on 9o9et.

n 9'nt s2o9 e12 1om9onent &n%eoes 'n't'$stes o: %ees'n, 1$en'n n% :'n$$ 9'm'nn% 9'nt'n. T2e %e:e1ts 'n t2e 9'nts e eo?e%n% 'n 'ns9e1te%. T2e 'o&s 1om9onents, 2'12

e 9'nte% 'n t2ese s2o9s, e 9o$me 9ts n%met$$'1 9ts.

NE# ANT *HO

Parts (ABS: -ACRONITRILE BUTADIENE STYRENE)

OUTER COVERTAL COVER (/,",3)ETER CO#LN!TAL CO#LN!*DE COVER

HEAD L!HTLE! !UARD

''


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ROCE** CHART

New Paint Shop-

LOADN! RE>TREATENT AR BLO#

LA*H O TOCOAT ANTN! #ATERDRN!

BA*E COAT ANTN! #N! AND CLEANN! LA*HO>/

ULOADN! AND DEA*N!

BACN!

*(6 678I/(6 I4/63I9 I6( (6:9; 39R90.- ?:41m.sq&Tot$ A$?$' "0>"5 m$o1ess T'me 0.5 m'n.H $&e 8.0>.5

'&


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VACUU *ECTON ;

CONTROL TE CONTROL RAN!E*&1t'on C91't +000 mm o: H

OVEN ( #te D'n ) ;

CONTROL TE CONTROL RAN!ETem9et&e /"0>/301o1ess T'me /0 > /" m'n.

DU*TN! ; No %&st'n 's %one 0.5 ?:41m.sq&

BA*E COAT TOUCH U ; t 's %one mn&$$ 5.5 ?:41m.sq&

ELECTRO*TATC ANT TO COAT ;

CONTROL TE CONTROL RAN!EBse Cot V's1os't /8>"0 se1on%s o: :o% 1&9.Vo$te 0000 Vo$tsA' oto ess&e 0.+>0.5 ?:41m.sq&

'#


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TO COAT TOUCH U ;

CONTROL TE CONTROL RAN!EBse Cot V's1os't /8>"0 se1on%s o: :o% 1&9.

A' oto ess&e 0.5>5.5 ?:41m.sq&

A:te to91ot to&12 &9, 9ts e


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"ress Shop

T2e *2o9 's s't&te% net to t2e e$%'n s2o9 to ese

t2e tns:e o: 9ts :om ess *2o9 to #e$%'n*2o9. T2e 9ess s2o9 %e$s m'n$ 't2 t2e 1&tt'n o:met$ s2eets 'nto t2e eq&'e% s29e. T2e m12'nese 1$ss':'e% 11o%'n to t2e $o%s t2e 9o'%e :o'o&s 9ess o9et'ons. T2ee e /" 9essm12'nes on 2'12 %'::eent %'es m


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*2eet et$ o: m'$% stee$ 's 1&t 'nto t2e eq&'e% s'Geon s2e'n m12'ne. t 's t2en sent to t2e1oes9on%'n 9ess m12'ne. T2e 'o&so9et'ons


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OUTER ANEL;

O9et'on e:ome% ; D'n O9et'on&9ose ; *2eet T2'nn'n , A99en1eO9et'on e:ome% ; 'n$ T'mm'n&9ose ; B&s, A99en1e n% !&e 'tment

NNER ANEL;

O9et'on e:ome%; D'n O9et'on&9ose; B&s, A99en1e, n% !&e 'tment

REAR ENDER;

O9et'on e:ome%; D'n O9et'on&9ose; *2eet T2'nn'n, A99en1e

O9et'on e:ome%; T'mm'n O9et'on&9ose; B&s, A99en1e

O9et'on e:ome%; En% C&tt'n&9ose; B&s, A99en1e

O9et'on e:ome%; Re Ben%'n&9ose; $ne #'%t2, A99en1e

O9et'on e:ome%; *'%e Ben%'n /&9ose; $ne #'%t2, A99en1e

O9et'on e:ome%; *'%e Ben%'n "&9ose; $ne #'%t2, A99en1e

O9et'on e:ome%; 'n$ Ben%'n

&9ose; Bn% #'%t2, A99en1e, n% !&e'tment

RONT ENDER;

O9et'on e:ome%; D'n O9et'on

+'


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+ Outer panel YB, YB, !##$!##$#&!" Outer panel YY .a/er !0#$##$#&! Outer panel R,2 R,2 ##$##$#&!

% Inner panel OOM Cru #$%0#$#&!

0 Inner panel YBR Ler* %##$%+$#&!! Inner panel YB, YB, %'#$%"$#&! Inner panel SYY .a/er %#$%0#$#&!1# Inner panel R,2 R,2 0'$"!$#&!

11 3 B*45 1-' OOM Cru "!#$ 1##$#&!1' B*45 1-' YBR Ler* "0'$%+1 $#&!1+ B*45 1-1 YB, YB, %0"$'!$ 1&'1" B*45 1-' YY .a/er #'$ 1'%#$ 1&'1 B*45 '-+ YBA Ent6er "1%$ 1#'#$ 1&%1% B*45 1-' R,-1## R,-1## %'%$1!$1

10 B*45 1-1 OOM Cru ''0&$3##$1&'1! B*45 1-1 YBR Ler* ''&$"$1&'1 B*45 1-1 SYY .a/er '+%$#$1&''# B*45 1-1 R,-1## R,-1## '%0$11##$1&''1 B*45 1-1 R,2 R,2 '0'$ 11##$ 1&'

'' .r*nt 7en4er OOM8R Cru8R-1## '0#$!'#$#&!'+ Rear 7en4er OOM8R Cru8R-1## ++$%##$#&!'" B9T-En ne R R-1## '%$%##$#&!' B9T-En ne YB, YB, '#$##$''% B9T-Meer R R-1## 1%+$1'##$'

TOO$ ROOM

Too$ oom mn&:1t&'n t2e 'o&s too$s, %es'ne%


46/119

Too$


47/119

T2e too$s mn&:1t&e% e t'e% o&t :o t2e'9e:omn1e n% ': ne1ess 'n:omt'on :o too$mo%':'1t'on 's 1onee% to t2e 1on1ene% too$%es'n se1t'on 7 too$ oom T2e too$ e 2n%e% oe

to 7 C %e9tment on$ :te st's:1to es&$ts2e


48/119


49/119

Sn;le-P*nt Cuttn; T**l: -

T2ee e mn t9es o: 1&tt'n too$s :o %'::eento9et'ons. Be$o 's s2on :e o: t2e 'et, 2ees2on 't2 too$ 2o$%e %9te t2t :'ts 'nto $e too$ 9ost :'t&e.

+#


50/119

NURLN!;>n&$'n 's n o9et'on &se% to9o%&1e tet&e on t&ne% m12'ne 9t. Hn%$es

e o:ten ?n&$e% 'n o%e to 9o'%e '99'ns&:1e. T2e to 2ee$ 'nsets s2on on t2e too$:om 9tten 'nto t2e s&:1e o: t2e 9t.

BROAD NO*E N*HN! TOOL

t 's not 91t'1$$ 9oss'


51/119

n% m12'ne. T2's o9et'on o: em'n 'no$est2e &se o: m&$t't&%e too$ 1$$e% REAER.

HAND REAER; >

$1


52/119

rollers 6ith dia$ond !attern on ed#es

$2


53/119

REAMER B!

*HELL REAER* ;

NNAN

$'


54/119

EAN*ON REAER*;

TAERED REAER*; >

OBBER* REAER*; >

H!H *EED *TEEL REAER*T2e Cente Lt2e 's &se% to mn&:1t&e 1$'n%'1$s29es :om ne o: mte'$s 'n1$&%'nJ stee$sn% 9$st'1s. n o: t2e 1om9onents t2t otoet2e to m?e n en'ne o? 2e


55/119

o9ete% %'e1t$


56/119

HEAD*TOC

T2e 2e%sto1? o: 1ente $t2e 1n


57/119

3?


58/119

0.05 mmH%&$'1 9'% sto?e o: t2e 'n%'n 2ee$2e%sto?e; 60 mm t&n'n n$e o: t2e o? 9'e1e 2e%sto1?; 0%eReo$&t'on s9ee% o: t2e 'n%'n 2ee$ s9'n%$e;/+-0 R*9'n%$e 1one; 5 oseP T'$sto1? 1one; 5 oseP !'n%'n 2ee$ %'mens'ons; 500 80 "03 mm'n en'ne 9oe; -.5 ?#D'mens'ons; 5350 "3"0 /--0 mm#e'2t o: t2e m12'ne; 6550 ?

TOOL RE*HARENN! *ECTON ;

n t2's s2o9 %'::eent t9es o: too$s $'?e %'$$,emes, m'$$'n 1&ttes et1 e es29ene% n%'n% on %'::eent m12'nes $'?e too$ n% 1&tte'n%'n m12'ne et1. Hon'n n% 2on'n too$s enot es29ene% 'n t2's se1t'on, t2ese e sent to1ent$ $< o: t2e 1om9n. T2e %'es &se% 'n Dee9D'n 9o1ess 'n 9ess s2o9 e $so m'nt'ne%2ee on$. T2's s2o9 's $o1te% F&st o99os'te to esss2o9.

$%


59/119

MAC%IN& S%O"n t2's s2o9, 'o&s :oe% n% 1st 1om9onents o:

t2e en'ne e m12'ne% :te m12'n'n 9o1ess,

t2e e sent to en'ne ssem


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mn&:1t&'n t2e ;OERATON ACHNE

1e '$$, En% '$$, O.D.

T&n,

C2m:e, Rem EN*HU 5300

*9ot 1e, C2m:e, R.!.

Boe, En%'$$, T9 EN*HU *300

D'$$, T9, En% '$$, O.D.

T&n, *9ot

1e, Rem EN*HU 5300

#s2'n 7 R #s2'n 12'ne

0"


61/119


62/119

1'n

*9ot 1e, Boe, C2m:e,

T2e%

EN*HU *300

*9ot 1e, C2m:e, D'$$,T9

EN*HU * 300

'$$, C2m:e, Cente, D'$$,

T9

EN*HU *300

*'%e '$$, Ro&2 '$$, En%

'$$

EN*HU *300

En% '$$, Ro&2 Boe, 'ne

Boe

EN*HU *300

Cente, D'$$, C2m:e,

*9ot 1e, T9, Rem

EN*HU *300

#s2'n #s2'n 12'ne

Het'n +eatin# E9ui!$ent

ess 't n$et n% E2&st

V$e !&'%e n% *et

V$e *et n% !&'%e ess

Coo$'n n% !9 C2e1? Coolin# E9ui!$ent

1e '$$, Boe, C2m:e,Cente, *9ot 1e, D'$$,

T9

EN*HU *300

Cente, C2m:e, D'$$,

Rem, 'ne Boe

EN*HU 5300

En% '$$, Rem EN*HU 5300

De


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12'ne

OERATON ACHNE

1e '$$, C2m:e, Rem,

Ro&2En% '$$, Ro&2 Boe EN*HU 5300

1e '$$, D'$$, C2m:e,

T9,

C2m:e, *9ot 1e, En%

'$$

EN*HU 5300

En% '$$, R! Boe, Co&nte,

Rem,

'ne Boe EN*HU *300

#s2'n 7 R #s2'n 12'ne

Le? Test *L Le? Test'n

12'ne

A' B$o, *$eee ess *L *$eee ess

1e '$$, D'$$ EN*HU *300

'ne Bo'n #'%' " *9'n%$e *

e Coo$'n, Hon'n,Coo$'n,

!%'n !e2'n " Hon'n 12'ne

Co$% #s2'n 7 R #s2'n 12'ne

De ;

OERATON ACHNE

Cente'n, 1'n #'%' " *9'n%$e *

T&n'n, 1'n L# CNC LATHE LAL"

0'


64/119

Bo'n, 1'n L# CNC LATHE LAL"

T2e% Ro$$'n RA!A T2e% Ro$$'n

12'ne

e # C&tt'n Te12no A'%H%en'n 7 Tem9e'n EA n%&1t'on H%en'n

Eten$ !'n%'n *2'' Eten$ !'n%e

#2ee$ EA 80 -V -5*

T2&st 1'n L# CNC LATHE LAL"

nten$ !'n%'n Too nten$ !'n%e

#2ee$ EA 60 8V 53*

#s2'n 7 R #s2'n 12'ne

CRAN > ;

OERATON ACHNE

Cente'n, 1'n #'%' " *9'n%$e

C2m:e L# CNC LATHE LAL"

T2e% Ro$$'n RA!A T2e% Ro$$'n

12'ne

e # C&tt'n 7 Ro$$'n EN*HU *300D'$$'n, Rem'n EN*HU *300

H%en'n 7 Tem9e'n EA n%&1t'on H%en'n

Eten$ !'n%'n *2'' Eten$ !'n%e

#2ee$ EA 80 -V -5*

T2&st 1'n L# CNC LATHE LAL"

Q nten$ !'n%'n Too nten$ !'n%e #2ee$

EA 60 8V 53*

#s2'n 7 R #s2'n 12'ne

B$$ ess'n * ess

0+


65/119

CRAN CA*E >

OERATON ACHNE

1e '$$, D'$$, T9, En%

'$$,

EN*HU *300

Rem

1e '$$, D'$$, *9ot 1e,En%

EN*HU *300

'$$, Rem

D'$$, T9, En% '$$, Boe,

C2m:e

EN*HU *300

T9, En% '$$, Ro&2

Bo'n

EN*HU *300

Rem'n, 'ne Bo'n EN*HU *300

Cente'n, *9ot 1'n,

Rem'n,

'ne Bo'n EN*HU *300

1e '$$, D'$$, En% '$$,

T9,

EN*HU *300

Boe, Rem

En% '$$, !ooe, Rem,

'ne Boe,

EN*HU *300

T9

#s2'n 7 R #s2'n 12'ne

Le? Test *L Le? Test'n

12'ne

0$


66/119

CRANK CAE - II

A' B$o, O'$'n n&$

OERATON ACHNE

1e '$$, En% '$$, *9ot1e,

EN*HU *300

Rem

1e '$$, D'$$, *9ot 1e,

En%

EN*HU *300

'$$, Rem

D'$$, '$$, T9 EN*HU *300

*9ot 1e, D'$$, T9,

Ro&2 Boe,

EN*HU *300

C2m:e

Cente'n, D'$$, En% '$$,

T9,

EN*HU *300

Ro&2 Boe

Rem'n, 'ne Bo'n EN*HU *300

o


67/119

LAL" T2e% Ro$$'n

RA!A T2e% Ro$$'n

12'ne e # C&tt'n

Te12no A'% H%en'n 7Tem9e'n EA n%&1t'on

H%en'n Eten$

!'n%'n *2'' Eten$

!'n%e #2ee$ EA 80 -V

-5* T2&st 1'n L#

CNC LATHE LAL" nten$

!'n%'n Too nten$

!'n%e #2ee$ EA 60 8V53* #s2'n 7 R

#s2'n 12'ne CRAN >

OERATON ACHNE

Cente'n, 1'n #'%' "

*9'n%$e C2m:e L# CNC

LATHE LAL" T2e%

Ro$$'n RA!A T2e%

Ro$$'n 12'ne e #

C&tt'n 7 Ro$$'n EN*HU

*300 D'$$'n, Rem'n

EN*HU *300 H%en'n 7

Tem9e'n EA n%&1t'on

H%en'n Eten$

!'n%'n *2'' Eten$

!'n%e #2ee$ EA 80 -V-5* T2&st 1'n L#

CNC LATHE LAL" Q nten$

!'n%'n Too nten$

!'n%e #2ee$ EA 60 8V

53* #s2'n 7 R

0&


68/119

#s2'n 12'ne B$$

ess'n * ess

#s2'n

Le? Test *L Le? Test'n12'ne

A' B$o, O'$'n n&$

ENSHU S600!

EN*HU 5>300 1om9$ete$ sn12on'Ge% o9et'on

me12n'sm, one 9't12 9e s9'n%$e ott'on, en*"A TC>""A *>300>A's T


69/119

9ots

0#


70/119

ELECTROLATN! *HO

CORRO*ON;! Coos'on m


71/119

N'1?e$ 1ot'n 's %one s 9ote1t'e n% 80 > /00 4$'te

O9et'on > "

#te 'nse. t 's %one to o'% 1ontm'nt'on o: onetn? to not2e.

T2e 9o1ess 's 1'e% o&t t oom tem9et&e.

O9et'on > 3Ano%'1 1$en'n &s'n e$e1t'1't.E$e1to$te 808Dens't > 6 > /0, Tem9et&e > -0 > 80CA$?$' Dees'n. &::$e 1ts s Ct2o%e.Ano%e > '$% *tee$ $tes.T'me > 8 m'ns.

O9et'on > +

&1


72/119

#te 'nse

O9et'on > 5A1'% D'9.

A1'% Use% > H"*O+Con1entt'on > /0 > /5 'n te.H"*O+1ts s Ne&t$'Ge.

&2


73/119

O9et'on > 6#te 'nse

O9et'on > -

*em' B'2t N'1?e$ 1ot'n.Contents > N'1?e$ *&$92te> "50>"60 m4$'te, N'1?e$C2$o'%e > +0>+5 m4$'te, Bo'1 1'%> 35>+5 m4$'te,B'2tene > Ante?, !7#.A$$ 5"C , Dens't > /8>"", 9H $&e >3.8 > +."Ano%e > N'1?e$ $tes, Ct2o%e > &::$e, C&ent

*&99$ > +m94%e1'mete"

T'me> /5 m'ns.

O9et'on > 8T' N'1?e$ 1ot'n.T2e q&nt't o: N'"*O+ De1ese%

B'2t N'1?e$ > n t2's O9et'on t2e q&nt't o: N'"*O+, N'C$ n%Bo'1 1'% e 'n sme q&nt't s 'n O9et'on > ->*em' B'2t N'1?e$ 1ot'n.C&ent 's ?e9t sme t > + m94%e1'mete". T2e9&9ose o: n'1?e$ 1ot'n :o t2ee t'mes 's to'n1ese t2e 9$t'n $':e.

O9et'on > /0D o&t > T2's 's 1ont'ne F&st :te o9et'on >2'12 's to se so$&t'on o: O9et'on > . #2'$e t2em&::$es e t?en o&t o: t2e O9et'on > 1ont'ne,t2e so$&t'on $e:t 'ns'%e t2e m&::$e 's 1o$$e1te% 'nD o&t. T2's so$&t'on 1n


74/119

#te R'nse.

O9et'on > /"C2ome 1ot'n.Ano%e > Le% t'n 9$tes, Ct2o%e > &::$e, E$e1to$te> C2om'1 A1'% > Con1entt'on o: C2om'1 1'% > "80>300m 4$'te.

O9et'on > /3#te R'nse.

O9et'on > /+Ne&t$'G'n.An 1'% 1$$e% C2ome ?'$$ 's &se% to emoe 12omeso$&t'on :om t2e s&:1e o: &::$es.

O9et'on > /5#te 'nse

O9et'on >/6

Hot A' D'e.

&+


75/119

&N'IN& ASS&M($)

T2e En'ne ssem

C$'n%e 2e% :om m12'ne s2o9 e12es t2's

se1t'on. V'o&s t2'ns e :'tte% 'n 1$'n%e 2e%.

'st$ Cms2:t n%


76/119

2e%.

Cms2:t :'tte% 't2

Cn? 1se / S 1oe ( m%e &9 o: $&m'n'&m $$o )

:om 9'nt s2o9 's sent to t2's se1t'on.

neto


77/119

A**EBLN! ON AN CONVEER; >

B$$


78/119

1n?1se /.

V$e 1$en1e 12e1?e%.Cms2:t t'm'n 12'n t'2tene%.Vent :o 1 C$en A' :om A' '$te entes 'nto t2's

%e'1e. T2ee 's sm$$ %'92m 'ns'%e 2'12

:o1es t2e ' 'nto " 9'9es> one to%s nt?e

n':o$% n% one to%s E2&st n':o$%. *o 'n

ot2e o%s t2ee 's one 'n$et 9'9e :om A' :'$te n%t2ee e to o&t$et 9'9es to nt?e n% E2&st

n':o$%s. T2ee e to ee% $es 'ns'%e t2e A..*

2'12 %oes not $$o A' &e$ m't&e ( om nt?e

n':o$% ) n% Hot E2&st !ses ( om e2&st

n':o$% ) to eese t2e o?'n o: A..*. n ot2e

&%


79/119

o%s 2'$e ' 's

/. Conne1t'on to nt?e n':o$%.

On1e t2e &e$ ( 9eto$ ) 's m'e% 'n '2t

9o9ot'on 't2 ' 'n C %&'n Lst

*to?e n% :om t2ee 't 9o1ee%s to t2e m&::$e 9'9e.

T2e e2&st ses 1ont'ns CO", CO n% ot2e

2m:&$ ses. AAHA R7D %e9tment st&%'e% n%

:o&n% t2t t2e CO 1ontent 'n E2&st !ses 1n "CO K O" "CO"

#e 1n see t2t on s&99$'n oen to E2&st

n':o$% t2e Co'%e 9esent 'n E2&st

!ses es'$ 1om


80/119


81/119

D.C CDD'e1t C&ent C91'to D's12e

n't'on.

t 's %e'1e 2'12 2s


82/119


83/119

(2'12 e not es to


84/119

CLUTCH HUB *UB A**EBL;

A 1$&t12 2&< t?es %'e :om t2e 1$&t12 n%

tnsm'ts 't to t2e 2ee$. T2e ssem


85/119

%&e to t2e s2o1?s. No tens'on sto9s t2e


86/119

ETER *UB A**EBL;

Hee t2e 1om9$ete mete ssem" *UB A**EBL;

Hee &


87/119

2o$%es. *&'t


88/119

T2e o% ssem


89/119

T2e est 7 *'%e stn% e :'tte%.

#''n 't2 1onne1tos e 9$1e% on t2e:me n% t'2tene% &s'n t9e.

C2e1? n&t $on 't2


90/119

A..* &n't n% R.R &n't :'e%.En'ne B1?et :'e% n% t'2tene%.*9ee%omete s&< ssem


91/119

t2e 2o$e.

*et 9$1e% n% :'e%.He% $'2t ssem


92/119

STOR&S

R te'$ *toe

T2's stoe 's s't&te% ne 9ess s2o9. Hee s2eet

met$s ( m'$% stee$ s2eets ) o: %'::eent t2'1?ness e

'm9ote% :om !emn o

2'12 's 1om


93/119


94/119

VENDOR REECTON

NOR

*TORE

URCHA*E

Non o%&1t'e *toe ;

n t2's stoe 'o&s mte'$, stt'one'es,

%2ot's, $o


95/119

Cono C2'$eAno$ *' Ln?

Dn1e 2'$'99'nes Co$om


96/119

Ant' R&st *9 O9et'on;Ve2'1$e 's $o%e% on t2e 9$t:om. C$ene% 't2 1$ot2 to emoe n ?'n% o: &st.

Ant' &st o'$ 's s9e% on $$ t2e 9ts o: e2'1$ee1e9t set.

Dismantling Con'eyer

'st t2e 2e%

$'2t, s9ee%omete, e $'2t, :ont n% e :en%e,

2n%$e


97/119

En'ne ;

En'nes o: :e mo%e$s s&12 s 5RE, e $so e9ote%

to ot2e 1o&nt'es n% $so to t2e .*.D '%


98/119

Ant' R&st O'$ *9 O9et'on ;En'ne 's 9$1e% on t2e 9$t:om n% 1$ene%


99/119

A

SPECIAL

REPOR!

On

YAMAHAAIOR = =$I'=

##


100/119

AAHA AIOR AAHAs $test o::e'n :o /"511

*ement.

#'t2 t2e n%'n 1ons&me s2':t'n on t2e


101/119

:om t2e #o$% :mo&s AAHA AIOR 2'12 's

s9ots


102/119


103/119

EN!NE AND ERORANCE ;

Go 's 2'n s'n$e 1$'n%e, o& sto?e, /"511' 1oo$e% en'ne. En'ne


104/119

Anot2e ne t2'n 2'12 stn%s :o AAHA THROTTLE O*TON*EN*OR 2'12 's es9ons'


105/119


106/119

1"0


107/119

T#O ROECT* #ERE COLETED

DURN! THE COUR*E O TRANN!.

One s e%'n t2e No's m&::$e o: Go. An%'t s 1om9$ete% &n%e t2e &'%n1e o: . m$2&n, :om Too$ Des'n De9tment.

*e1on% one s %es'n'n o: ! :o 'et'nm12'ne 'n En'ne *&Assem


108/119

Re9ot > /

T'$$ "0t2&$ "00+, 6000 Go


109/119

t s o3, />+.

3. #e$%'n o E$e1to9$t'n s9tte m'2t


110/119

11"


111/119

ULER * ADE U O VAROU* ART*

/. &::$e en%, 19 't2 9'9e 9ess :'t n% e$%e%.

". Bo% />/, o&te 9'9e o: %'mete> /00 mm.3. &::$e 2et s2'e$%.

+. t't'on />", />3, />+ (es9ons'3 n% Bo% />". At t2's 9o'nt

t2ee 's Ct$t'1 1onete to 1onto$ t2e

em'ss'ons.

8. Bent 9'9e, Conne1te% to e2&st mn':o$%,

1ons'st o: to 9'9es, o&te 9'9e %' > 35."0

mm.nne 9'9e %' > "".36 mm. T2e eson :o

&s'n to 9'9es s e2&st 9'9e > t 's ene$$

seen t2t e$e1to9$t'n on t2e e2&st 9'9e,t&ns e$$o :te some t'me. Reson :o :%e%

e$e1to9$t'n 's t2t> t2e tem9et&e o:

e2&st ses e e 2'2, on e&$ 2et'n

n% 1oo$'n o: e2&st 9'9e t2e e$e1to9$t'n on

t2e e2&st 9'9e


112/119


113/119

t2e %t 1o$$e1te%, 't s :o&n% t2t > t2ee s no

e$%'n s9tte o n 9t'1$e 'ns'%e t2e m&::$e,

t2e 9'9e %'metes ee :o&n% to 'n to$en1e Gone,

1t$t'1 1onete s e$%e% 9o9e$, t2e 9'9e tm&::$e en% s 9esse% :'t 9o9e$, e'n:o1ement

s not '


114/119

No t2e 9o /" mm.

B&t 't s :o&n% t2t t2e 9ess :'t e'on 'n :&$t

s'$en1e s -mm on$.

A$so t2e 'nne 9'9e $$oe% o&t o: t2e 9ess :'t

e'on 's 0.5mm > + mm. B&t 't s o


115/119

t s $so ossem


116/119

t2e O&te %'. o: o&te 9'9e s :o&n% to


117/119

:&t2e &se. t s e1o%e% t2t, o&n% + > 5

9&n12es ee e9$1e% 'n e12 s2':t. T2e ee $':e

o: e12 'et'n 9'n 's o&n% "00 > ""5 'et.

DATA COLLECTON ;

V'o&s s9e1ts ee $oo?e%. An% t2e %'mens'onsee e1o%e%.

*to99e Lee

DATA ANAL** ;

t s :o&n% t2t 2'$e 'et'n t2e o9eto s

&s'n 2's 2n% to 2o$% t2e sto99e. D&e to 2'12 t2e

Fo< moe% $e%'n to 'e&$ n% non>&n':om

'et'n. T2's $so $e% to


118/119

L*T O O**BLE *OLUTON ;

o'%'n 9o9e ! :o t2e o9et'on.Re9$1e t2e R'et'n 9&n12 't2 9&n12 o: 2%emte'$.

o9e 2o$%'n too$ to ens&e t2e Fo< %oes not moe2'$e 'et'n 's %one.

11%


119/119

*OLUTON LEENTED ;

*'n1e %es'n'n ne F' s t2e most e::'1'ent

so$&t'on so ne F' s %es'ne%. *'n1e !e s2':te$ee s $so R'ete% on sme m12'ne 't2 t2e

2e$9 o: %'::eent ', 2'12 s emo

Documents

Yamaha- Training & Dev. Quality Control