In Plant Training/Project

Presented By:Sumit

ACKNOWLEDGEMENT

We express our sincere gratitude to Mr. Sunit Behl, for accepting to be guide for our training and guide us through out the training.

We sincerely thank the management of Munjal Showa, for permitting us to carry out this training.

We express our sincere thanks to the number of Engineers and workers who spared their valuable time to explain various processes going on the shop floor during our training period.

Sumit

Index

1. Company Profile 2. Criterion of selection 3. Description of theme 4. Data Analysis 5. Data Compilation 6. Remarks 7. Suggestions

Company Profile
Established in 1985, in technical and financial collaboration with Showa Corporation of Japan, the pioneering global leaders in the manufacture of shock absorbers, Munjal Showa Limited is a member of Hero Group, a US $ 1.3 billion manufacturing conglomerate, with a 45-year history. The Hero Group, a major player in the manufacturing sector in India, comprises of 15 active companies with complete backward integration for automotive manufacturing. Prime companies in the Group are: Hero Honda Motors Limited, a joint venture with Honda Motors of Japan, Hero Cycles, the largest bicycle manufacturer in the world, Majestic Auto Limited and Hero Puch, manufacturing mopeds and scooters. Munjal Showa Limited in its joint venture with Showa Corporation, designs and manufacturers shock absorbers and struts for leading two-wheelers and four-wheelers. The Munjal Showa manufacturing plant is spread over an area of 24075 sq mt in the industrial area of Gurgaon, Haryana, on the outskirts of the National Capital Territory of Delhi, India.

Today Munjal Showa Limited is one of the largest suppliers of shock absorbers to major auto giants in India, Japan, Germany, the United States and the United Kingdom, amongst other developed markets. The Company's products conform to the highest standards of quality, safety, comfort and dependability and are QS 9000, ISO 14001 and ISO 9001 compliant. The use of advanced technology and a team of experienced personnel have led to outstanding growth in the Company. Munjal Showa Limited has established a strong foothold in the auto ancillaries manufacturing

market and enjoys a wide patronage. Munjal Showa products serve as original equipment to a wide range of Maruti Suzuki upper end cars and export models, Honda City car, complete range of Hero Honda Motorcycles, Kawasaki Bajaj Motorcycles, Kinetic Scooters and Hero range of minimotorcycles and mopeds and Honda Motorcycles and Scooters India (Pvt) Limited. In over a decade the Company's state-of-the-art Shock Absorbers, Front Fork, Struts and Window Balancers/Gas Springs have become symbols of reliability and quality for popular two and four wheeled vehicles.

Munjal Showa Limited is another success story in the ongoing successful enterprises undertaken by the Hero Group. The Company has earned a name, in the auto ancillaries manufacturing segment, of providing quality, commitment and competence and it continues on its path of trail-blazing achievements.

Quality production with Technological advancement It takes a lot of commitment, efforts and diligence to maintain a consistent growth plan. Munjal Showa's growth profile is maintaining its upward stance, on account of the following inherent elements: State-of-the-art Plant: "Better products through better technology" - this is the maxim that guides the Munjal Showa team. The eco-friendly plant at Gurgaon is equipped with ultra modern facilities. A team of expert engineers from Showa, Japan, support and monitor the production of virtually zero-defect products. Our manufacturing methods are continually modified and improved upon, in order to realize goals of higher productivity. We are using the Japanese system of encompassing 5S, 3G, 3K, 3M, in the work culture thus promoting efficiency at the team level and a clean production system. Quality Control ity Control Policy:

Customer satisfaction through products of highest quality achieved by consistent adherence to the laid down procedures and systems. A rigorous quality check at each and every step of manufacturing ensures that our products meet and exceed the stringent quality standards prevalent in the market. At Munjal Showa we assert that quality is built in from the development stage and not just at the production stages. Every Component is put

through gruelling technical and endurance test to ensure flawless finish and performance. This is the reason why Munjal Showa BIS stipulation of "one-million cycles."

Research and Development: In order to be technologically in the forefront, at Munjal Showa we constantly undertake research and development and upgradation activities. We enjoy the benefits of complete research and development support from Showa Corporation, Japan. A team of highly qualified Japanese technical advisers deputed to India, work in collaboration with our trained professionals, ensuring proper implementation of procedures and practices. Our objective is to develop products of supreme technical quality, while keeping the costs to a minimum.

GURGAON PLANT LAYOUT

PLATING B/ C M /C PAINT D/ C M /C B/ T M /C
BOTTOM CASE 2W FRONT FORK ASSY REAR CUSHION ASSY

1-SET 1-SET 2-SET 1-SET 3-SET 2-SET 1-SET 1-SET 2-SET 2-SET 2-SET 3-LINE 1-LINE 1-LINE 1-LINE

ASSEM BLY

2RD

4W

ASSY (STRUT) ASSY (O/ S)

4RD M /C
M ACHINE SHOP

FORK PIPE DAM PER CASE 2 WROD 4WROD

PLATING

F/ P M /C

4WASSY 2WASSY 4WASSY

PLATING AREA PAINTING AREA

BUFFING BEFORE PLATING BUFFING AFTER PLATING Ni-Ni-Hr Cr Hr- Cr LIQUID PAINTING POW DER COATING

PRODUCTS

FRONT SHOCK ABSORBER

REAR SHOCK ABSORBER

GAS SPRING STRUT

Company at glance
Various departments purchase receipt store accounts office machine shop assemblies lab maintanence paint shop

plating quality check personal and administration marketing industrial engineering tpm it

MANUFACTURING FACILITIES 1. WELDING FACILITIES MIG WELDING (AUTO CONTROL) MACHINES RESISTANCE WELDING MACHINES CONDENSOR WELDING M/C PROJECTION WELDING M/C SPOT WELDING M/C SEAM WELDING M/C 2. MACHINING FACILITIES CNC PROFILES CENTRELESS GRINDING AUTO MILLING BURNISHING THREADING M/Cs ROD SHEARING M/Cs SPMs 3. PLATING Ni HARD CHROME PLATING PLANT

3. PAINTING LIQUID PAINTING AUTOMATIC PAINT SHOP IIND LIQUID PAINTING AUTOMATIC AT MANESAR PLANT. POWDER COATING PLANT 4. TOOL ROOM LATHE MILLING CYLINDRICAL GRINDING SPM 5. UTILITIES GEN SETS CHILLING PLANT E.T.P, ETC. MARUTI POWER SUPPLY

TESTING FACILITIES 1.PERFORMANCE TESTING STROKE ENDURANCE TESTING M/C WITH SIDE FORCE APPLICATION STROKE CHANGE FACILITY 40C DEEP FREEZER FOR ENDURANCE TESTING DAMPING FORCE TESTING M/C. ON LINE TESTING 100% WITH LOOP MONITORING FACILITY. ONLINE WITHOUT LOOP MONITORING FACILITY. FOR STUDY AND ANALYSIS IN QCLAB. WITH DIFFERENT SPEED, STROKE & LOOP MONITORING FACILITY.

U.T.M. 20 T. ON LINE.

MASTER M/C IN QC-LAB. FACILITY.

ONLINE AUTO TORQUE TESTING

BALANCER SPEED TESTING M/C STROKE ENDURANCE TESTING M/C (2WHEELER)

2.LAB FACILITIES

TESTING FACILITIES U.T.M OIL TESTING EQUIPMENT SPRING LOAD TESTING SURFACE FINISH TESTER VICKER HARDNESS TESTER PROFILE PROJECTOR METALLURGICAL MICROSCOPE SALT SPRAY TESTING CALIBRATION FACILITIES SLIP GAUGE SET. FLOATING CARRIAGE DIAL GAUGE CALIBRATION TESTER. CALIPER CHECKER. W.C.P. GAUGES. STANDARD MASTERS.

3. CONVENTIONAL TESTING FACILITIES

TESTING EQUIPMENTS. 3 CO-ORDINATE MEASURING M/C. HEIGHT MEASURING INSTRUMENT,DIGITAL HEIGHT GAUGE, ETC. AUTOGRAPH M/C. TRIMOS HEIGHT MASTER. DIGITAL MICROMETERS CONTOUR GRAPH. CONTOUR GRAPH

CALIBRATION OF ALL INSTRUMENTS AND GAUGES IS BEING CARRIED OUT INHOUSE.

MANPOWER STATUS

STAFF 220

Quality Policy
CUSTOMER SATISFACTION THROUGH PRODUCTS OF HIGHEST QUALITY & TECHNOLOGY AT COMPETITIVE COST BY CONTINUOUS IMPROVEMENTS AND ADHERENCE TO THE LAID DOWN PROCEDURES AND QUALITY MANAGEMENT SYSTEMS WITH COMMITMENT TO MEET CUSTOMER REQUIREMENTS AND GLOBALLY COMPETITIVE. Various other measures adopted by the company to improve the productivity and fuctioning of the company

DAPP ACTIVITIES
D DAILY A ACHIEVEMENT OF P PLANNED P PRODUCTION

AIM
# ELIMINATE QUALITY TROUBLE FACTORS (PART MIXING, WRONG ASSY, ETC). # INCREASE PRODUCTIVITY. # ELIMINATE ABNORMAL OPERATIONS. # TO ACHIEVE DAILY PRODUCTION TARGETS. # TO REDUCE INVENTORY LEVELS. # TO REDUCE COSTS. # TO REDUCE PRODUCTION LEAD TIME. # ERADICATION OF WARRANTY AND MARKET CLAIM BEING PASSED OUT.

ULTIMATE TARGET
TO INCREASE PROFITABILITY OF THE ORGANIZATION

TPM
MEANING OF TPM
T - TOTAL P - PRODUCTIVE M - MAINTENANCE

POLICY
Company aims to achieve world class excellence through TPM

ULTIMATE OBJECTIVE To convert all the 16 types of losses into gains.

To achieve Zero defects, Zero breakdown, Zero losses & Zero accident. To increase the yield of the organisation.

:-

TEAM OPERATION
MEANING OF TEAM:
T = TACTICAL E = ENHANCEMENT A = ACTION OF M = MANAGEMENT
TEAM-I : PRESENTATION BY ALL HODs ON MONTHLY BASIS REGARDING DEPTT. TARGETS IN COMPLIANCE WITH BUSINESS PLAN TARGETS. PRESENTATION BY ALL ASSTT. HODs ON BI-MONTHLY BASIS REGARDING THE ACTIVITIES CARRIED OUT TO ACHIEVE BUSINESS AND QUALITY GOALS & OBJECTIVES.
INTRODUCED BY : MR. KANAI T.A IN JAN.94

TEAM-II :

TEAM-III : PRESENTATION BY ALL LINE SUPERVISORS ON MONTHLY BASIS REGARDING LINE PROBLEMS, DAPP, LOSS TIME, PRODUCTION ACHIEVEMENT, DATA ANALYSIS, KAIZENS, ETC.

DAPP ACTIVITIES
MEANING OF DAPP:
D DAILY A ACHIEVEMENT OF P PLANNED P PRODUCTION

AIM
# ELIMINATE QUALITY TROUBLE FACTORS (PART MIXING, WRONG ASSY, ETC). # INCREASE PRODUCTIVITY. # ELIMINATE ABNORMAL OPERATIONS. # TO ACHIEVE DAILY PRODUCTION TARGETS. # TO REDUCE INVENTORY LEVELS. # TO REDUCE COSTS. # TO REDUCE PRODUCTION LEAD TIME. # ERADICATION OF WARRANTY AND MARKET CLAIM BEING PASSED OUT.

ULTIMATE TARGET
TO INCREASE PROFITABILITY OF THE ORGANIZATION

GVDP PROGRAMME
MEANING OF GVDP :
G GREEN V VENDOR D DEVELOPMENT P PROGRAMME

OBJECTIVE
TO MAKE THE ORGANISATION A GREEN ORGANISATION BY MAPPING THE PROCESSES, ANALYSING & EVALUATING THE GAPS AND TO TAKE THE CORRECTIVE ACTIONS TO ELIMINATE THE GAPS BY EFFECTIVELY DOING WATER MANAGEMENT , ENERGY MANAGEMENT , WASTE MANAGEMENT , SUBSTITUTION OF HAZARDOUS CHEMICALS AND POLLUTION PREVENTION & CONTROL APPROACHES.

ULTIMATE TARGET
TO MAXIMIZE THE RESOURCES EFFICIENCY BY MINIMISING THE WASTAGES OF AIR, WATER, CHEMICALS & OILS.

TPM
MEANING OF TPM
T - TOTAL P - PRODUCTIVE M - MAINTENANCE

POLICY
Company aims to achieve world class excellence through TPM

ULTIMATE OBJECTIVE
To convert all the 16 types of losses into gains. To achieve Zero defects, Zero breakdown, Zero losses & Zero accident. To increase the yield of the organisation.

TPM JOURNEY

March 2012 TPM Excellence Award 2nd Category Oct.2011 TPM Final Audit for 2nd Category April 2011 TPM Pre Audit for 2nd Category March 2009 TPM Excellence Award 1st Category Dec. 2008 TPM Final -Audit June 2008 TPM Pre-Audit 19th 1st Jan.2008 TPM Health Check - up Feb. 2002 TPM Kick-off A C H I E V E D

29th June 2000 TPM Declaration by MSL

Criterion of Theme Selection and Description of theme

Munjal Showa Limited in its joint venture with Showa Corporation, designs and manufactures shock absorbers and struts for leading two-wheelers and four-wheelers. The Munjal Showa manufacturing plant is spread over an area of 24075 sq mt in the industrial area of Gurgaon, Haryana, on the outskirts of the National Capital Territory of Delhi, India. This huge facility works 24x7, in three shifts each. Each and everyone is accounted for, use of Andon boards does not let any production loss. Still in this world of competition there is always a scope for improvement. As the Japanese proverb says-If you are not growing then you are surely depreciating, to elucidate there is always a competitor who will be trying to do things better than you. One always has to be on his toes to survive in this competitive world. Munjal Showa Ltd. is finding it hard to keep up with the demand of booming automobile industry. Its competitor- Gabriel, already a market leader in 4 wheeler segment, is trying to enter into the 2 wheeler market. This has led to demand for increase productivity- particularly labour productivity. The fork pipe used in 2 wheeler shockers needs to be smooth enough so that it doesnt have roughness more than 0.80 micron in R-max before plating nd 0.30 micron in R-max after plating.But sometimes its roughness comes more than the above described because of some reasons.

If the the fork pipe of roughness more than 0.80 is used than the oil seal which is used on shocker when comes in contact with scratches of rough pipe gets cut by it every time the shockers are in use while driving and soon a stage comes where the oil seal is completely cutted by it which causes shocker to not work properly as oil then gets leaked from their.

Description

Shock absorber with internal reservoir. The components are: A fork pipe,

B - the piston with seals, C - the cylinder, D - oil reservoir, E - floating piston, F - air chamber.

The above picture shows a basic shocker in which component A shows the fork pipe. In the Gurgaon plant of Munjal showa the following 8 types of models of fork pipe are present on which machining is done to make them ready to use.

The models are: 1. P-17 30.25 mm and length-542.5 mm 2. P-70 mm 3. SLEEK and length-532.5 mm 4. P-40 mm 5. EFFI mm 6. CD-100 mm 7. KSPA 8. KSPG DiameterDiameter-31 Diameter-30 Diameter-31 Diameter-28 Diameter-26

Data Analysis and Compilation

The fork pipe rouhgness is reduced by doing few machining processes on it.A fork pipe is passed through 4 grinding machines to reduce its roughness to an appropriate value.In a particular grinding machine, there is a grinding wheel,coolant and a dust collector.A grinding wheel is that blade which grinds the fork pipe and reduces its diameter according to the settings done on it.

A coolant is also present in the grinding machine and its main objective is to flow in that direction where the grinding is going on at that particular time.There is a constant flow of coolant to the surface where the grinding is being done.As the pipe is passed through the grinding machine the grinding wheels start grinding the pipe and as the grinding starts ,the flow of coolant also starts to that very point and as the pipe is on conveyer belt, so it moves on and the grinding wheel is fixed at a point inside the machine and at that piont the coolant flows as those wheels grinds the fork pipe there.The coolant is basically a chemical which is spread to cool the fork pipe surface as after grinding the pipes surface gets too hot.

The machine has also a dust collector which just attracts all the dust of the pipe towards itself.The dust collector collects the waste material of pipe which is left after grinding of the fork pipe in the

grinding machine.The dust collector takes all the dust from the pipe towards itself and makes the pipe clean.

The 4 grinding machines which are used to do reduce the roughness of fork pipe on the fork pipe line are namely

1. Rough Grinder
when the fork pipe is passed through this grinder, its diameter initialy is 30.25 mm(P-17) and after

the grinding it becomes 30.05 mm and the roughness of the pipe at the end of rough grinder is 8 micron R-max

2. Semi-rough Grinder
fork pipe at the enterance of this grinder has a diameter of 30.05 mm and at the exit of semi-rough grinder its diameter reduces to 29.98 mm.The roughness here in this process gets reduced from 8 to 6.3 micron R-max

3. Semi-final Grinder
at this stage of grinding the fork pipe diameter here ranges from 29.935-29.945 mm.This implies that diameter wil get reduced from 29.98 mm to in between the above range.Roughness of the fork pipe in this grinder ranges from 6.3 3.0 micron R-max.

4. Final Grinder
the final grinder is the last grinding machine through which the fork pipe is passed and here its diameter from 29.935 mm gets reduced to a range of 29.900-29.915 mm.As it is the final grinder therefore the pipes roughness from 3.0 micron R-max gets reduced to 0.80 micron R-max which is the final desired one. The final roughness of fork pipe comes out to be 0.80 micron R-max which is desired but few times roughness comes more than the desired one.This happens due to some reasons which should have been taken care off.

Picture of how pipe enter and exit from the grinding machine

Main Reasons for more roughness in fork pipe

1. Reduction in size of grinding wheel

As in the grinding machine the grinding is done by grinding wheel, so after a particular time the grinding wheel gets wear and tear and as a result its size gets reduced.The grinding wheels surface get damaged and its size reduces after a particular time.In actual the diameter of the wheels reduces and gets small.As the machine is used for a longer time period the diameter of its grinding wheels reduces.This phenomenon is generally termed as tracing.

2. Coolant flow not in proper direction

sometimes the flow of coolant is not in proper direction in the grinding machine.This simply says that sometimes where the grinding wheel is grinding the fork pipe, at that point the coolant doesnt flow and it rather is flowing to some other part of fork pipe.The flow of coolant in the machine is undirectional in these cases.

3. Pipe Setting problem

The fork pipe needs to be set in a perfect manner so that its alignment is right.Sometimes fork pipe is not bring into correct position before entering into the grinding machine.The alignment becomes one of the main reason for the cause of more roughness in the fork pipe.The worker at this process should take care of the pipe being in correct position before entering.

4. Problem in Jigs and Fixtures in the machine

jigs and fixture means the centre plate an d guides which are present in the machine.when the centre plate or guides get damaged,then this cause also becomes the reason for the more roughness of the fork pipe.

5. Less cutting oil

In the grinding machine the grinding wheel cuts the fork pipe surface very sharply and due to this process, a cutting oil is required which is put in the grinding wheels to reduce frictional effects which can occur on the fork pipe surface.When this cutting oil is less in between the grinding wheels then it also causes the more roughness of the fork pipe.Less cutting oil increases frictional effects and roughness of fork pipe.

6. Problem in dust collector

When the dust collector present in the machinr doesnt work properly then also roughness increases.The dust collector main objective is to collect all the waste of fork pipe from the machine towards itself and when it not works in a proper manner , the roughness of the fork pipe comes more than the desired one.

7. Mechanical fault in the machine

The mechanical faults in the machine can be bearing gear out or it can be loosen of pulley belt etc. These kind of problems also occur in the grinding machine which causes the more roughness of the fork pipe.

8. Usage of uncleaned coolant

Sometimes the coolant used in the grinding machine is not clean upto a certain level and as it flows on the fork pipe it doesnt produces the effect as the cleaned coolant produces and this causes the more roughness the fork pipe.Uncleaned coolant or coolant of low quality produces these effects.

9. High rate of feed supply

the feed supply of fork pipe to the grinding machine is too high so as to increase the productivity rate,then sometimes the roughness of fork pipe comes more than micron R-max. .

When 0.80

10. Sizes not maintained

Fork pipe has specific dimensions at each process.At every grinder the pipe size is defined by particular setting according to the model of pipe.When these sizes are not maintained of the fork pipe, then the roughness of fork pipe comes out to be more than the desired.

Remarks and suggestion

Suggestion
1. Grinding wheel in the machine should be checked after some interval of time such that when tracing is about to happen,the grinding wheel should be replaced from new one. 2. The direction of flow of the coolant should be checked

Applications
Shock absorbers are an important part of automobile and motorcycle suspensions, aircraft landing gear, and the supports for many industrial machines. Large shock absorbers have also been used in structural engineering to reduce the susceptibility of structures to earthquake damage and resonance. A transverse mounted shock absorber, called a yaw damper, helps keep railcars from swaying excessively from side to side and are important in passenger railroads, commuter rail and rapid transit systems because they prevent railcars from damaging station platforms. The success of passive damping technologies in suppressing vibration amplitudes could be ascertained with the fact that it has a market size of around $ 4.5 billion.

Rear shock absorber and spring of a BMW R75/5 motorcycle

Vehicle suspension
In a vehicle, it reduces the effect of traveling over rough ground, leading to improved ride quality, and increase in comfort due to substantially reduced amplitude of disturbances. Without shock absorbers, the vehicle would have a bouncing ride, as energy is stored in the spring and then released to the vehicle, possibly exceeding the allowed range of suspension movement. Control of excessive suspension movement without shock absorption requires stiffer (higher rate) springs, which would in turn give a harsh ride. Shock absorbers allow the use of soft (lower rate) springs

while controlling the rate of suspension movement in response to bumps. They also, along with hysteresis in the tire itself, damp the motion of the unsprung weight up and down on the springiness of the tire. Since the tire is not as soft as the springs, effective wheel bounce damping may require stiffer shocks than would be ideal for the vehicle motion alone. Spring-based shock absorbers commonly use coil springs or leaf springs, though torsion bars can be used in torsional shocks as well. Ideal springs alone, however, are not shock absorbers as springs only store and do not dissipate or absorb energy. Vehicles typically employ both springs or torsion bars as well as hydraulic shock absorbers. In this combination, "shock absorber" is reserved specifically for the hydraulic piston that absorbs and dissipates vibration.

Structures
Applied to a structure such as a building or bridge it may be part of a seismic retrofit or as part of new, earthquake resistant construction. In this application it allows yet restrains motion and absorbs resonant energy, which can cause excessive motion and eventual structural failure.

Electrical Generation
Modern hybrid cars may eventually be able to generate useful energy from the displacement of the fluid in a shock absorber.

Types of shock absorbers

There are several commonly-used approaches to shock absorption:

variation is the Magneto rheological damper which changes its fluid characteristics through an electromagnet. Compression of a gas, for example pneumatic shock absorbers, which can act like springs as the air pressure is building to resist the force on it. Once the air pressure reaches the necessary maximum, air dashpots will act like hydraulic dashpots. In aircraft landing gear air dashpots may be combined with hydraulic damping to reduce bounce. Such struts are called oleo struts (combining oil and air). Magnetic effects. Eddy current dampers are dashpots that are constructed out of a large magnet inside of a non-magnetic, electrically conductive tube. Inertial resistance to acceleration, for example prior to 1966 the Citron 2CV had shock absorbers that damp wheel bounce with no external moving parts. These consisted of a

spring-mounted 3.5 kg (7.75 lb) iron weight inside a vertical cylinder and are similar to, yet much smaller than versions of the tuned mass dampers used on tall buildings

Composite hydropneumatic devices which combine in a single device spring action, shock absorption, and often also ride-height control, as in some models of the Citron automobile. Conventional shock absorbers combined with composite pneumatic springs which allow ride height adjustment or even ride height control, seen in some large trucks and luxury sedans such as certain Lincoln and most Land Rover automobiles. Ride height control is especially desirable in highway vehicles intended for occasional rough road use, as a means of improving handling and reducing aerodynamic drag by lowering the vehicle when operating on improved high speed roads. The effect of a shock absorber at high (sound) frequencies is usually limited by using a compressible gas as the working fluid and/or mounting it with rubber bushings.

Parts being manufactured at Munjal Showa Gurgaon Unit during the training Period P17, the rear cusion that is in the Splender, assembly was going on while we were in the plant. It consists of the following components: Damper case Metal comp, upper Nut, hex 9 mm Rubber stopper Spring, RR cush Case,RR cush case, RR cush upper

Guide,spring Seat, Spring Bush, Rubber Collar Rubber

The four wheeler models being manufactured by Munjal Showa:Maruti models model a[alto] model B[wagon r] model c YE-2 VAN ESTEEM[front and rear] swift[front and rear] pal sleek

Honda models 2PS[FRONT]-city ULT[front and rear]-civic LK[front and rear]-accord LQ[front and rear]-accord 2AP[front and rear]-jazz

o/s

model a model b model c sleek ye2 syk-9

Models of 2w line p-17[front and rear]-splender mmc-cd 100 p-11-cd 100ss p-21-passion khrc[rear]-mahindra kavf-karizma kryg-cbz p-30-street 100 p-90-cd dawn hvna-hunk[rear]

HONDA MOTORCYCLES

FRONT FORK

REAR CUSHION

FRONT FORK

REAR CUSHION

HONDA SCOOTER

FRONT CUSHION

REAR CUSHION

MARUTI SUZUKI MODELS

FRONT STRUT

800 cc

VAN
REAR STRUT

ALTO

WAGON R

OPEN STAY ZEN SWIFT

HONDA MODELS

City

Jazz

Civic Front Strut

Accord Rear Strut

PRODUCT RANGE 4- WHEELER

STRUT

GAS SPRING

Questionnaire Q: What do you mean by tpm? Ans:It is total productivity maintenance which helps in following ways:1. It improves the functionality of the machine. 2. Increases the output. 3. Decreases the rejection. 4. Increases the skill of the operator. 5. Increases the profit of the company. Q: How does the checking or inspection on CNC profile turning machine is carried out? Ans:the piston wehich goes in to the go gauge perfectly Q: How can run out be checked? Ans: It is checked with dial gauge. Q: What is the tool material used in single point cutting? Ans: Carbide What iss the name of the tool used for turning? Ans: TNMG -.4 (for piston side turning) TNMG-.8(for thread side turning) Q: What is the material used for the job? Ans: Mild steel

Data Compilation and Analysis

I was allotted 2w wheel rod line and assigned to study it and increase its productivity. MACHINING PROCESSPISTON ROD

THREAD SIDE TURNING

PISTON SIDE TURNING

THREAD ROLLING

GRINDING(CLG)

BURNISHING

INSPECTION

The defects that occasionally occur in the 2rd line are: Thread side turning 1. overdraw 2. breaking of rod(when it is not placed properly) 3. Breaking of tool can be due to inaccurate cutting, inaccurate installation of tool/tool holder, incorrect mounting of workpiece. piston side turning-similar defects with addition of run out(due to unwanted material while turning). Thread rolling 1. Thread side rod broken-caused due to high pressure on roller 2. reverse thread- misalignment of roller 3. thread less- improper positioning of rod 4. thread more improper positioning of rod 5. thread damage-misalignment of roller Burnishing 1. roller mark (marks or cut marks on rod) 2. point mark (rust on roller) To avoid these defects in burnishing, lapping of triple roller is done, to ensure defect free product. Some of the recent improvements made on this line are:

Thread side turning machine:- the motor was not covered, after covering it the number of accidents were reduced from 5 to 1. Thread side turning machine:-hard to clean and maintain, collet and master stand out is not available. After placing it the time is reduced from 5 mins to 1 min.

Different models of rod being manufactured on 2w rod line:Sno. 1 2 3 4 5 6 Model P-17 HSRC KVNA KRPFL KRPFR KTEA Step Length 18.3-18.7 18.3-18.7 18.3-18.7 17.3-17.7 15.4-15.6 18.3-18.7 Total Length 158.8159.2 152.4152.6 166.8167.2 167.9168.1 162.9163.1 161.3161.7 Thread Length 18.0-19.25 18.0-19.225 21.0-22.25 16.0-17.25 16.0-17.25 18.0-19.25

Aim To increase the productivity of 2 wheel rod line.

Observation The 2 wheel rod line of this plant is responsible for the manufacture of the most critical component of two wheel suspension line. As this unit manufacture components for Manesar and Haridwar plants as well, further increasing its importance. This line was found to be very efficient. It was manufacturing 40,000 rods a day, with the labor productivity above 600. Though at burnishing-grinding there was scope of further increase in productivity. At the burnishing machine it was found that two people were involved. One them was just working at 40% of his ability, his only task was to align the rods in a queue for the burnishing machine and rod dia. check after grinding. The other person was at the other end of the burnishing machine, and was responsible for the finish of the product. And to periodically replace the burnishing rollers.

Scope of improvement The manpower can be reduced from 4 to 2/3. The idea was to club the work of both the man at the burnishing machine and reducing the workload by auto aligning the queue for the burnishing. More time is available for quality inspection, thus rejection decreases and hence productivity increases

Alternatives Getting another burnishing machines which reduces the piling up of jobs. Feed rate of grinding machine to be reduced so as to decrease the length of queue. A channel is created so that rod automatically gets feeded. Use of new grider wheel that replaces two(semi-rogh and finish) into one.

Analysis of alternatives Use of two burnishing machine, purchase of new burnishing add extra cost as well as increases the maintenance cost. Going for second alternative i.e. feed reduction can lead to increase in power consumption, loss of productivity, decreases in the tool life etc. A detailed study is required to further pursue this alternative. Easiest, does not require stopping of machines for long periods. Inexpensive, easy to adopt, comparatively fast. This is under trial in 4 wheel rod line, so cannot be implemented now. As per the above analysis of the alternatives, the most efficient one was found to be creation of channel or any other mean to so that directly the rods are fed to burnishing machine thus the workload of the person at the start of the burnishing machine is left to minuscule. And whatever work left (that is periodic checking of the rod diameter) can be transferred to the person checking the finish of goods.

Manpower Used for Implementation Fitter of maintenance department. Head of department of the production for co-ordination between different department. Maintenance in -charge. Operator of the machine and the supervisor of the 2w rod line. Material Used for its Implementation Metal shoe of the size o the piston rod. Lock tight Nylon strips Cutter Grinding machine Milling machine.

Other measures that can improve the productivity Regular fastening of the screw of the separator Correcting the position of the plate adjacent to the magnetic drum Increasing the inclination of the coolant channel to the separator so as to decrease the frequency of cleaning(maintenance cost) To decrease the no. of accidents and to make the workplace safe use of floor nets for proper griping. Maintaining more precision and accuracy while cutting of raw material. To reduce the breakage of tool more clearance is given while turning till the time accuracy in cutting machine in obtained.

2w rod line statistics

Before Kaizen No. of rods that were manufactured=40,000(approx.) No. of labour involved=64 Labor productivity=615

As seen above the rods are disorganized and a person is only involved in placing them at correct place. Thus decreasing the productivity. After the kaizen No. of rods manufactured=40,000 No. of labor involved=63 Labor productivity=650 The following changes were made to get rid of this situation: The shoe was remade pneumatic pushers force was reduce taper was give, channel was created the stroke length of shoe decreased the size of the pusher is increased the bolt in pusher was corrected.

All this led to automatic feed to the burnishing machine leading to the elimination of labor responsible for it.

The entire exercise was carried on Sunday, during the breakdown of the burnishing machine. No production loss took place during implementation of this activity.

Remarks and Suggestions

Suggestions
Regular fastening of the screw of the separator Correcting the position of the plate adjacent to the magnetic drum Increasing the inclination of the coolant channel to the separator so as to decrease the frequency of cleaning(maintenance cost) To decrease the no. of accidents and to make the workplace safe use of floor nets for proper griping. Maintaining more precision and accuracy while cutting of raw material. To reduce the breakage of tool more clearance is given while turning when the accuracy in cutting machine is not present.

REMARKS
1. The area under the machines needs to be cleaned properly. 2. The separators used for filtering the lubricant should be maintained.

3. Ventilation of the plant is not good. 4. The electroplating section of the plant has various hazardous gases so this section need to idolize from other sections as it is not good for workers health. 5. emphasize more on quality 6. Increasing the size of maintenance department with proper allocation of duties. 7. Industrial department can be more co-operative to the trainees as the trainees are only trying to best of their ability to bring the positive change in this company. 8. Scrap policy should be openly discussed to make things more transparent. 9. The pants color should be changed to darker one.