SUMMER TRAINING REPORT

YAMAHA
SUBMITTED BY:TEJENDRA PRATAP SINGH ANKIT KUMAR MAYANK CHAUDHARY Abhishek mittal 3RD YEAR B.Sc(ENGG.) MECHANICAL

YAMAHA FZ

YAMAHA R 15

YAMAHA FAZER

YAMAHA FZ 6

YAMAHA R 6

YAMAHA R 1

YAMAHA CRUX

YAMAHA FZ S

ACKNOWLEDGEMENT
The satisfaction that accompanies the successful completion of any task would be incomplete without acknowledging the people who helped us in our training days. They helped us to understand everything very clearly.

We are very thankful to Mr. Ravinder Singh, Mr. P.P. Dubey , Mr. Nikhil Gaur, Mr. Raminderpal Singh, Mr. Sandeep Kumar, Mr. EP Shree Kumar, Mr. Deepak Kumar and Ms. Surbhi Dixit for their continued support and guidance.

Finally We would like to thank whole of the Service Department and Warranty Section staff for their co-operation. As they spent their precious time with us to give us a detailed description of different parts.

TABLE OF CONTENTS
1:- COMPANY LOCATION 2:- COMPANY PROFILE 3:- OVERVIEW 4:- ABOUT YAMAHA MOTORS SURAJPUR PLANT 5:- PRINCIPLES OF THE COMPANY 6:- LAYOUT OF COMPANY 7:- MARKET DEPARTMENT 8:- TRAINING CENTER 9:- WARRANTY SECTION 10:- CONCLUSION

COMPANY LOCATION
Companys full address:INDIA YAMAHA MOTOR PVT.LTD., INDUSTRIAL AREA, NOIDA DADRI ROAD, SURAJPUR-201306

How to reach YAMAHA MOTORS if you starting from Agra:1:- First you should reach Noida. 2:- After getting off at Noida reach sector 37. 3:- Take bus going to Kasna from sector 37. 4:- Get off the at Yamaha chauk. 5:- From Yamaha chauk take left and go to Gate No.3.

COMPANY PROFILE

"I want to carry out trial manufacture of motorcycle engines." It was from these words spoken by Ginichi Kawakami (Yamaha Motor's first President) in 1953, that today's Yamaha Motor Company was born. "If you are going to make it, make it the very best there is." With these words as their motto, the development team poured all their energies into building the first prototype, and ten months later in August of 1954 the first model was complete. It was the Yamaha YA-1. The bike was powered by an air-cooled, 2-stroke, single cylinder 125cc engine. Once finished, it was put through an unprecedented 10,000 km endurance test to ensure that its quality was topclass. This was destined to be the first crystallization of what have now become a long tradition of Yamaha creativity and an inexhaustible spirit of challenge.

The first Yamaha motorcycle the YA-1 The YAMAHA MOTOR CORPORATION LIMITED was founded on 1 July 1955 with 274 employees and with an output of 200 motorcycles per month. In 1957 Yamaha began production of its first 250cc, two-stroke twin, the YD1. In 1958 Yamaha became the first Japanese maker to venture into the international race arena. Yamaha was building a strong reputation as a superior manufacturer which was reflected in its first project carried out in the new Iwata, Japan Plant,

built in 1966. (The YMC headquarters was moved to Iwata in 1972.) Toyota and Yamaha teamed up to produce the highly regarded Toyota 2000 GT sports car. This very limited edition vehicle, still admired for its performance and craftsmanship, created a sensation among enthusiast in Japan and abroad.

YAMAHA MOTOR INDIA PRIVATE LIMITED: Yamaha Motor made its initial foray into India in 1985.Subsequently in 1996; it entered into a 50:50 joint venture with the Escorts Group. However, by mutual consent, Yamaha acquired stake in the remaining half as well three years ago, bringing the Indian operations under its complete control as a 100 % subsidiary of Yamaha Motor Co., Ltd, Japan. The company pioneered the performance bike segment with the launch of its 100 cc 2-stroke motorcycle RX 100. Since then, it has introduced an entire range of 2-stroke and 4-stroke bikes in India. Today, its product kitty includes CRUX in the Basic segment, Libero & RX135 in the Standard segment and Enticer in the pleasure segment. With the launch of various 4-stroke motorcycles, which give true value for money in terms of superior mileage, performance & durability, the company has gained the reputation of a reliable 4-stroke Motorcycle manufacturer. IYM operates from its state-of-the-art-manufacturing units at Surajpur in Uttar Pradesh and Faridabad in Haryana and produces motorcycles both for domestic and export markets. With a strong workforce of more than 2000 employees, IYM is highly customer-driven and has a countrywide network of over 400 dealers. Presently, its product portfolio includes MT01 (1670 cc), YZF-R1 (998 cc), the all new YZF-R15 (150 cc), Gladiator Type SS & RS (125 cc), Gladiator Graffiti (125cc), G5 (106 cc), Alba (106 cc) and Crux (106 cc).

OVERVIEW

Founded

July 1, 1955

Capital

48,302 million yen (as of March 31, 2008)

President

Takashi Kajikawa

Employees (Consolidated)

46,850 (as of December 31, 2007) Parent: 9,019 (as of December 31, 2007)

Sales (Consolidated)

1,756,707 million yen (from January 1, 2007 to December 31, 2007) Parent: 799,209 million yen (from January 1, 2007 to December 31, 2007)

Major Services

Products

&

Manufacture and sales of motorcycles, scooters, electro-hybrid bicycles, boats, sail boats, Water Vehicles, pools, utility boats, fishing boats, outboard motors, diesel engines, 4-wheel ATVs, side-byside vehicles, racing karts, golf cars, multi-purpose engines, generators, water pumps, snowmobiles, small-sized snow

throwers, automotive engines, intelligent machinery, industrial-use remote control helicopters, electrical power units for wheelchairs, helmets. Biotechnological production, processing and sales of agricultural and marine products and microorganisms. Import and sales of various types of products, development of tourist businesses and management of leisure, recreational facilities and related services.

Headquarters

2500 Shingai, Iwata-shi, Shizuoka-ken, Japan

Affiliated Companies

Consolidated subsidiaries: 112 Non-consolidated subsidiaries: 8 (by the equity method) Affiliates: 27 (by the equity method)

ABOUT YAMAHA MOTORS SURAJPUR PLANT

The new Surajpur plant has been inaugurated by Mr. T.Kazikawa C.E.O & MD Yamaha Global on 6th July 2009, which have capacity to produce 6 lakh motorcycles annually including Fazer followed by FZ-16, FZ-S, YZF-R15 and other models. The plant capacity can be augmented up to 1 million units. This fully integrated assembly plant is built on the lines of Yamahas globally tried, tested and successfully implemented standards and meets the global quality benchmarks. At the core are the 5-S and TPM activities that fuel its Manufacturing Processes. The plant has 3 vehicle assembly lines and 4 engine assembly lines including one dedicated for export engines. The engine and vehicle assembly lines are synchronized and incorporate concepts of Unit Assurance i.e. Complete Product Assurance, Parts Assurance through 100% kit supply on lines and synchronization of parts storage, supply and production. The innovative production processes along with high tech final assurance processes are aimed to achieve Zero Claims at our dealers and thus, a highly satisfied customer base.

PRINCIPLES OF THE COMPANY

Vision
We will establish YAMAHA as the "exclusive & trusted brand" of customers by "creating Kando" (touching their hearts) - the first time and every time with world class products & services delivered by people having "passion for customers".

Mission
Yamaha is committed to:
Be the Exclusive & Trusted Brand renowned for marketing and manufacturing of YAMAHA products, focusing on serving our customer where we can build long term relationships by raising their lifestyle through performance excellence, proactive design & innovative technology. Our innovative solutions will always exceed the changing needs of our customers and provide value added vehicles. Build the Winning Team with capabilities for success, thriving in a climate for action and delivering results. Our employees are the most valuable assets and we intend to develop them to achieve international level of professionalism with progressive career development. As a good corporate citizen, we will conduct our business ethically and socially in a responsible manner with concerns for the environment. Grow through continuously innovating our business processes for creating value and knowledge across our customers thereby earning the loyalty of our partners & increasing our stakeholder value.

INTERNAL COMBUSTION ENGINES

An Internal Combustion Engine is one of the most remarkable inventions of the human history. Its distinctive feature is the combustion and conversion of heat energy into mechanical work in a cylinder. Internal combustion engines are of two types:1:- 2 STROKE ENGINE. 2:- 4 STROKE ENGINE. Because in Yamaha Motor only 4 Stroke Engine is used so I am explaining only 4 stroke engine. 4 STROKE ENGINE A 4 stroke engine usually has a distributor that supplies a spark to the cylinder only when its piston is near TDC on the compression stroke, i.e. one spark every two turns of the crank shaft. Some 4 stroke engines do away with the distributor and make sparks every turn of the crank. This means a spark happens in a cylinder that just has burnt gasses in it. This just means the sparkplug wears out faster.

When the piston moves down fresh air and gas is sucked inside the cylinder from the carburetor. When the piston moves up again the valves are closed and the air is being compressed. When the piston reaches its highest position the sparkplug produces a spark that ignites the fumes and causes an explosion. Because of the power of the explosion the piston is pushed back. When the piston moves back up again the exhaust valve is open and the fumes are pushed out the cylinder. Now the whole process restarts.

CONCLUSION

The period of my training at Yamaha Motor India Pvt. Ltd. Has been a very positive one. It has given me a very good understanding of the engineering profession which could not have been achieved by theoretical study. The experience at YMI has greatly advanced my understanding of the practical aspects of engineering, both technical and organizational. The vital part that the organizational skills of an engineer play in todays industry is an area that is often missed by some. I too had very little idea as to what an engineers in a high-tech industry entails. But this internship at YMI made me see the maximum range of jobs performed by engineers. It has given me a solid foundation to build my career upon. I am certain that the experience gained through this internship will be helpful to me throughout my professional career and in all my future endeavors.

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