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Group no - 01

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M.haroon afzal bsme-01113017

Akmal hafeez bsme-01113011

Waqas gul bsme-01113066Rashid munir bsme-01113015

Atlas Honda

m. Haroon Afzal

BSME-01113017

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Overview

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Introduction

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Atlas Honda Limited is a joint venture between the AtlasGroup and Honda Motor Co., Japan. Both these motorcyclemanufacturing concerns were established by the AtlasGroup. Atlas Honda Limited manufactures and marketsHonda motorcycles in collaboration with Honda MotorCompany.

Plant Departments

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Atlas Honda follows Process Layout.

They have different sections of different operations some of which are:

Casting Plant

Paint Shop

HR Department

Finance & Accounts

IT Department

Logistics

Vendor Procurement

Maintenance

Store

QC Department

Manufacturing Plant

Assembly Plant

Engine Plant

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Management

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It is a skill of personal will and humility towards theprofession through which a person can lead any instituteor organization with well organized manner.

Management system

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In Honda Atlas the Management Style is Benevolentautocracy, Which means the employs are expected to beloyal and co-operative in production. The behavior of topmanagement with the employs is decent and kind butdecision making is centralized.

OrganizatiOn…??

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An Organization is firm which born when a group ofpersons work on a common goal. Honda is a PrivateLimited Company. Two or more person can form this typeof company and Govt. does not interference the workingof the system.

Atlas Honda Plants Location

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Atlas Honda have two main plants in Pakistan.

One is in Karachi and the other one on Sheikhupura Road

They manufacture Only CD70 in Karachi, while in Sheikhupura Plant they manufacture all of their models i.e. CD70, CD100, CD125, and CD125 Deluxe.

Plant Locations RESONS

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Further more the reason of there more production inShiekhupura Road. They could also have made there plantin other place then this, but another reason is that theyhave the most demand in Punjab all over Pakistan.

Most of there Vendors & Sub Contractors are also fromLahore and Shiekhupura so there availability also counts alot.

Plant lOcatiOns rEsOns…

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The reason of manufacturing only One model in Karachi isthe plant location as well the demand in Karachi.

As we all know that street crimes and car snatching arevery common in Karachi. So they prefer to have thecheapest of the motorcycles.

Effect of Location

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Human resources

Infra Structure

Industrial Culture

Material Resources

Energy

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AKMAL Hafeez

BSME-01113011

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Process layout

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In process layout the machines are grouped on the bases of

function in atlas Honda process layout has used

PrOcEss layOut ….

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PROCESS NO. OPTION OPERATION DESCRIPTION

1 Cutting & Molding Die cutting of metal sheets & shaping of cut parts

2 Die Casting Casting of aluminum parts

3 Welding & Grinding Joining of sheet Metal Parts & Grinding of welds & seams.

4 Machining Finishing of Site Cast & supplied parts

5 Cleaning & Preparation Spraying with Rust inhibiting Compound.

6 Phosphating Surface cleaning & preparation of Mild steel parts

7 Dipping Surface coating in a paint dip tank

8 Anodizing Surface preparation of Cast and Machined Aluminum parts

9 Degreasing Surface cleaning of circular Aluminum parts

10 Drying after Phosphating Oven Drying

11 Drying after Dipping Oven Drying to cure Dip Tank coating

12 Air Drying Drying by Compressed Air

13 Spray Painting Surface Finishing by Air/ Paint spray

14 Buffing Mechanical cleaning of circular Aluminum parts

15 Drying after painting Oven Drying to cure Spray paint coating

16 Engine Assembly Assembly of Engine from parts

17 Final Assembly of Complete Motorcycle

Total productive maintenance Application

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They have:

Proper Material Movement

Space for the Operator

Space for repair & Maintenance

Space for temporary storage

Space for Loading Unloading

Maximization of the use of workspace

All the utilities are provided in the proper manner.

Proper Safety Rules

STORES

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Stores dept. at AHL performs following functions.

Manages the receiving, stacking & issuance of parts &materials to the shop.

Ensures the provision & dispatches of required parts to SKP& KHI plant, spares part division & vendors.

Handles the rejections & damages from all shops

Handles the scraps & wastes generated in the factory

Division of stores

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Stores dept. at AHL has been divided into a no of smallstores according to the type of material being stored andfunctions/services provided by the store. The division isshown as follows…

At AHL, following handling techniques are used:

a) For handling from shop to shop especially designedtrolleys, and pallets are used.

b) Imported motorcycle components are received in steel &wooden cases &pallets.

c) Local vendor parts are received from receiving section instandard carton boxes.

Material Handling

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For in plant material handling, they have Fork Lifters,Trucks, Pick-ups etc.

They have Belt conveyor on their assembly line whichmoves automatically and can be paused if required.

MatErial Handling…

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They also use suspensionconveyors on the assembly lineto bring the chassis from thepaint ED Paint shop onto theassembly line.

In their Engine Div. they useIdler roller conveyors to forwardthe work piece from onemachine to another.

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PRODUCTION PLANNING

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PPC deals with managing the details of what & how manyproducts to produce and when, and obtaining the rawmaterials, parts, and resources to produce those items.PPC does this by managing information. For this purposePPC has to keep strong interactions in terms ofcoordination, communication & cooperation with 4 majorsections of Production and service departments like….

QA, Logistics

Maintenance

DCC/ Stores

PPC Karachi as well.

Waqas gul

BSME-01113066

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Planning

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Production planning is done to ensure the budgetedproduction targets of AHL. The planning is majorly done atAHL, the company sets its production targets. On the basisof these targets following type of planning is done.

Aggregate planning

Master production schedule

Aggregate planning

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On the basis of forecasting, a schedule from SAP, accordingto the production capacities & company’s strategies, isgenerated which includes the planning of whole year. Itincludes the production breakup of motorcycles for wholeyear into model wise, plant wise & month wise breakups.

Master production schedule

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In Honda Master Production Schedule represent Quantitiesof individual products Considering demand for cast currentinventory and back log.

On the basis of aggregate planning, such a monthlyschedule is made which includes day wise (2- shift wise),model & color wise breakups.

VENDORs

200+ vendors are actively engaged with the company.

Apart from the local vendors there is one main foreignsupplier for imported components/ parts i.e. Honda Motorcompany JAPAN which accounts for 30% of its purchases.

Trading reputation of the company is excellent

since the company is known for its fair

dealing and timely payments record to all creditors

VENDOR PROCUREMENT

The main responsibility if this dept. is ensuring part availability in rightquantity & in right time.

This department is for local vendors in Pakistan.

Purchase orders:-The purpose is to inform developed vendors (in the

start of the new year)that during this new year, AHL will buy the parts insuch quantities and at such rate. This basically helps vendor to do hisaggregate & capacity planning.Trading reputation of the company is excellent

since the company is known for its fair

dealing and timely payments record to all creditors

Batch Production

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Atlas Honda manufactures motorcycles in Batches.

In 2012 they manufactured 6,44,000 Bikes and had a targetof 7,50,000 bikes last year.

They manufacture bikes on the order of PPC (Productionand Planning Control).

PPC receives orders from their dealers.

BatcH PrOductiOn…

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PPC is the most important department throughout theplant, so as it has to make decisions according to thedemand that on which day how many bikes will bemanufactured of each model further more of which color,and in what time. And they make it sure that there desiredproduction rate is fulfilled completely.

Atlas Honda manufactures 1815 bikes per day on anaverage.

BatcH PrOductiOn…

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There total Lead time on the assembly line is 28sec for Onebike.

They have only one assembly line, on which they makemodifications according to the model to be assembled.

Similarly, they do not have different departments(welding,painting, etc.) of every model, they rather just change thejigs accordingly and start to manufacture the next model.

There casting plant is Ranked on 1st position in Asia. Theyhave a very good environment over there and very goodfacilities for the workers too.

Production capacity in Pakistan

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Rashid munir

BSME-01113015

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Variety Control

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Planning is nothing without control. PPC(Productionplanning and control) control ensures & arranges thenecessary resources for implementation of productionplan. For this purpose PPC has an eye on the in-house,vendor, import items &ensures that all the material for thenext day production are available. if there is any shortage,then they collaborate with vendor procurement to ensureavailability of part in time. The other function of PPC is thatif there are deficiencies in the resources available forproduction due to any reason, they work to save thecompany from production loss.

Process of Variety Control

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Honda Atlas Variety Control process is based on Following….

Simplification:-

Honda Atlas Reducing The Number of type of product.

Standardization:-

Honda Atlas make the Qualitative values of SignificantProduct.

Specialization:-

Honda Atlas Effort on a limited variety of product.

QUALITY ASSURANCE

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QA dept. administers Quality management & qualitycontrol functions. QA dept. identifies quality relatedproblems in vendor & in-house parts & takes preventiveaction for their re-occurrence.

WARRANTY & FINAL INSPECTION

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Warranty Claim Data Collection

Final inspection

Stages of final inspection

a) Test bench

b) Visual check

c) Functional check

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Visual check:

At the second stage visual check is performed.In this test, inspectors check the bike visually according tothe criteria & inspection points provided to them.

Functional check:

It includes the Co & HC emission test & head light testing.Final inspection dept. generates the straight pass of themotorcycles which shows the no of O.K parts as compared tototal no of production.

Final inspection

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This section of QA is located in final section of 500K plant.This section is formed for the final analysis of the completemotorcycle that comes out of the frame assy.

HR Department

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In Honda Altus HR is fundamentally an expression of this organization to belief on employee element on the organization success.

The current

Chief Executive Officer: Saquib H. Shirazi

HR is Mr. Razi ur Rehman

General Manager Engineering and Projects:

Muhammad Noman Khan

Human Resources and Succession Plan

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Honda Atlas Human Resources Policy is to hire young,fresh, energetic and active associates to meet the existingand future workforce requirements and providing itsassociates maximum opportunities for internal mobilitythrough personal training and development to enablethem to take higher positions.

HR Philosophy

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In Honda Altas HR philosophies are following:

Respect for Individuals

People of organization create it’s success: Apply Integrity Professionalism Feeling for others Primary job is to provide quality service.

They have 3245 employees currently working in their plant in 3 shifts.

Atlas Culture

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Sincerity & Loyalty

Time is money

Be self assured

Don’t expect others

Members to be helpful

Live economically

Do charity

3R – Respect, recognition, reward

Be overall happy, healthy & wealthy

Education, experience, expertise & application

Recruitment & Separation Policy

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Minimum Qualification

Written Test

Primary Interview

Final Interview

Pre-Employment Medical Test

Offer Letter

Joining Report

Induction Plan

Probationary Period

Confirmation Letter

Training Programs

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They also arrange several training programs and In house seminars with different institutions like:

IBA Karachi

LUMS Lahore

CMD Lahore

PIM Karachi , Lahore

PIQC Lahore , Karachi

PITAC Lahore

NUST Islamabad

CNDC

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