Shop Manual: A shop manual is an essential part of a workshop and manufacturing,

which contains all the flow charts and scopes of work including the performances of
parts and tools.
Environmental Conditions Manual: This manual is also a really essential manual for
safe machining and environment, which should also be implemeneted side by side
and as vitally as the shop manual.
Engine Plant
1.
2.
3.
4.
5.
6.
7.
8.
9.

Gear shop
Heat Treatment shop
CAM shop
CCM shop
Cylinder shop
Crank Shaft shop
Oil Pump Shop
CAD/CAM
Tool Grinding

Gear shop:

Machining of Gears
Teeth Cutting
Heat treatment
Broach
Grinding
Hatching
Final Inspection
Multiple Gears
Considering the quality of the job

Tool Machining/finishing through Lathe (Surfacing, Chamfering, etc.)

Components/ Parts are brought through vendors and then machined here for
required sizing, finishing and the number of teeth required of the gears.

Heat Treatment:

Jig setting
Alkali Washing
Carburizing
Alkali washing
Tempering
Shot Blasting

Final Inspection
- Rockwell Tester for Surface Hardening Testing
- Microvicker for Case Depth testing
Ferrite and Perlite
Martensite

Heating Time is directly proportional to Hardening

Temperature:
- Gears: 140 degrees
- Shafts: 130 degrees
Quenching
Carburizing
- Temperature: 900~930 degrees
- Time : 6-7 hours
Tempering to remove Stresses & Brittleness
- Temperature: 180 degress
- Time: 90 minutes
Annealing Let it cool down by it self

Alkali Washing with Gildon BT140S as an Alkali

Shot Blasting is the blasting of tiny SS balls on to the part for finishing
Polishing with the polishing/buffing paper
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220~400~800

Hardness micrometer
Etching Process
5% Nitric acid & 95% Ethanol
Dipping for traces of Carbon
Then it is verified through a microscope for Case depth
After all these processes, then the part is dispatched to its next destination.
CAM Shop:
-

It is Line production which started in 2005, but the mass production

started in 2006 with 14 machines
Presently this shop has 24 machines
This shop gets the casting from Indonesia
Maleable Cast Iron FP60
Two models are machined here:
- GGJG (CD70)

- Pridor (CD100)
Gears:
-Counter
-Main
Hauning Only in Honda
Placed in Cylinder Head, used a s
There are two noops in a cylinder:
-The bigger dia hole is Inlet
-The shorter dia hole is Exhaust
In line production, the machine which has the lowest production is
called the Bottom Leg
-Honda Bottom Leg production is 580 i.e. 1800/day
List of Machines in this shop:
Centering M/C
Lathe
Turret Center
Self feeder
CNC CAM
CNC Oil Hole
Induction Harderning
Shaft Grinding
CAM Grindingd
Tapping M/C
Final Inspection which is really important
Oil dipping M/C
Magnet Flaw Detector Tester
UV testing for cracks or any leaks.

CCM Shop:
-

Casting/ Raw
Rough Cutting
Finishing
525 tools
Hauning
Rough bore (Nissin M/C)
Finish bore
Die verification/ Inspection
CNC Kira
Side process & tapping
Total 11 Machines of which 4 are new
Tapping process
Washing Redoline, RPC1, Water
Manual filling of extra holes
Oil flow
Vaccum control
Leak tester
Bearing press
Holes processing of Cylinder

Sleeves Rough bore

Hauning
Covers processing through multi drilling
Covers and cylinder leak testing
Inspections through shifts
Toolings Reamer,Drill, Cutter, Hauning stone

Cylinder Shop:
-

It is a line production
Two types of M/C
Toyo CD70/ Pridor
Kira 125/ Deluxe
Casting
OP-0
OP-1 Threading /Rough bore
OP-2 Opposite Side
OP-3 CAM/ Fine bore/ Point face/ Plug hole
OP-4 Inlet/ Exhaust Hole
Washing Machine
CAM Tester (Leak tester)
OP-5 Guide fine and rough bore
Middle washing machine
Seat & guide addition
Seat & guide facing
Guide hole rough
Guide hole fine
Hot washing
Sub Assembly Valve, Spring, Seat, Outer
Cutter press
Valve leak tester

Crank Shaft Shop:

-

Purpose of crank shaft is to provide Rotary motion through Linear

motion
Forging
Machining
Assembly
Final Inspection
Delivery to Engine Assembly

Centering/ Facing (Central Drill tip)

Turning (Finishing)
Suppline M/C
Pin hole Rough
Gun Drill
Bench Drill for slanted hole of Oil
Key Grooves

Induction Hardening (Just a part of shaft)

Fine Grinding
Inspection through snapmeter
Pin hole fine bore
Threading on the ends
Assembly through press
Bearing settled on both sides
Timing gear press
Run out

Oil Pump Shop:

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CG125
Casting
Machining
Washing
Assembly
OP-1 Turning
OP-2 Rough turning
OP-3 Body and cover Processes, Finish sides
Washing at 60 degrees celsius water then dried
Assembly (Inner/Outer Rotor, Tachometer, Pinion)
Testing
Assembly and Inspection fixture

CAD/CAM Shop:
-

Refurbishing of expired gravity die cast

Software Unigraphics NX2
Machining of Old dies
Inspection
CAD/CAM is used for modelling of dies and many more

Tool Grinding:
-

Ball mill
End Mill
Wire Cut
Gun drill
Tapp (2, 3, 4 fluid tapp) / Drill (Straight / Step)
Dia Tool
Broach regrinding
Universal Tool regrinding
Profile Projector M/C Size and angle measurement, 10 times
enlargment
Casting Plant

HPDC
LPDC

GDC
Projection welding

Moulding of sand parts for cavities are also done in this shop
LPDC:
-

Aluminium Alloy HS1S Taiwan

2 melting furnaces which runs on natural gas
Furnaces have 2 chambers Melting and Holding chamber
Using a ladle to transport/ pour out the molten form of material
Which is then purified through Jazz Bubbling filteration (JBF)
Oxygen gas and impurities are removed
LPDC M/C also have two chambers then Holding and pressurizing
Chamber
Pressurizing chamber aslo have a stalk pipe which transfers the molten
material from the pressurizing chamber to the bottom of the die with
low pressure
Then the die is sent to the chipping machine (sand breaking machine),
as it vibrates the die which cause the sand filled in the holes to break
Manual cutting of gates
Welding is also done if needed
Then manual removal of burr/ finishing is performed
H
Heat Treatment Temp: 500 degress celsius, Time: 4 hours
Water quenching
Shot blasting for finishing SS shots of 0.5 mm
Coating of dies with HLP8182, RIO, LNO & LNOHG

HPDC:
-

HPDC is also like this, HPDC uses high pressure as the name suggests
LPDC is used for complex parts whereas HPDC is used for Simple parts
Total 7 Machines out of which, 4 M/Cs locking force is 650 ton, 2 M/cs
are of 500 ton and 1machine has the locking force of 150 ton

Manual pouring of the molten material

No pressure is involved
Material is being pulled by gravity only
After pouring the die is cooled for 75 secs
7 die casting M/C
Coating for extended life of die and texture of the material DY51 Metal
Coat
Sand blasting for removal of coating if needed
Buffing for finishing so that during electroplating there is no problem

GDC:

Projection Welding:

Electrical welding
Current is 61~65.3 KA
Pressure is 0.38~0.39 MPA
Voltage is 340~360 V
Assembly Plant

Sub Assembly
Main Assembly
Test Run
Welding Shop
CED Shop

Storage
- Body welding- ED- Main line
Sub assembly
Main line
Inspection
If there is a defect then it is reworked and then aagain inspected
Test run
28 sec/ motorcycle

Sub Assembly:
Some of the components are brought directly from the MS area which is storage,
others are sub assembled in three zones; A, B & C
-

MS area (Storage)
Sub assembly area
Zone A:
Rear mud guard assembly
Tail light
Front fork
Front fender
Stem sub assembly
ASV (Air sucking valve)
Rear fender
Shining arm/ Rear fork
Rear wheel
Then parts are shifted to their required locations and some of the
parts which are to be installed first on the body are shifted to the
zone 1 of the main line
Zone B:

Rear Sprocket
Carburator
Honda Logo Stay and Horn
Handle
Speedometer Sub assembly
Upper cover and front indicators/Winkers
Top bridge

Most of the parts from Zone B are shifted directly to the main line,
other to their specific locations
Zone C:
Step bar
Side stand
Stearing top cone
Mark chain drive cushion
Brake pedal and valve
Wire Harness
Exhaust Muffler Cover, bracket & Muffler
Side cover
Production cards
Rear Cowl sub assembly
Seat Sub assembly
Some of the parts from this zone are also transferred to zone 1 of
the main line as they are to be installed first
Main Assembly:
Working is done on both side of the converyor, workers on each side do their
jobs of assembling the motorcycle, as some some of the work can only be done
by being on the same side as of the where the component/work is required.
Verification is done throught out the assembly line for any mistakes.
Zone 1:
Body is brought from ED Paint through PBS Conveyor
Grammat is installed
Number punching
Cone fitting
Turn table (Wire harness, air cleaner installation, main stand, Rear
fender)
Sub converyor
Engine is brought from the engine assembly plant and installed to the
main body
Swing arm and rear wheel is installed then
Front fork added to the body
AGC wiring
Battery Installation
Speedometer installation

 Front fork tightening

Torque verification & Punch Marking
Handle is installed which is brought directly from the Sub assembly to
the main line
Front wheel Installation
Cable Routing (Front brake, Clutch and Throttle)
First Quality Gate for Quality inspection and feedback of the already
installed components
Chain case Installation
Left cover
Left main wiring
Rear wiring
Muffler Installation
Head light installation
Fuel tank
Wiring checking
Second quality gate for inspection and feedback of the installed
components
Seat Installation
Side cover installation
Third and final quality gate for Quality check and feedback of all the
installed components
Date stamping
Test Run
If there are any small problems, they are reworked on the main line and if
the reworking cant be done on the main line then it is recorded on the
production card and it is later transferred to the reworking area from the
main line and reworking is done. After that it goes through an inspection
process again until it passes all of the verification checks.
Test Run: