SUMMER TRAINING REPORT

HONDA SIEL CARS INDIA LTD.

SPL-1, Tapukara Industrial Area, Khushkhera
Distt. Alwar, Rajasthan 301707. INDIA

PROJECT REPORT ON
Die Maintenance Study and Chip-Dent Reduction

TraineePrakul Bansal

MentorMr. Harsh Vardhan

Mr. Pankaj Shrivastava

HOD, Press Shop
-1-

Details of the Trainee:Name of Trainee

GAURAV CHAUDHARY

Fathers Name

Mr. RAM GOPAL CHAUDHARY

Date of Birth

01-08-1991

Course Name & Trade

B.Tech, Mechanical Engineering

Name of Institute / Collage

NIT KURUKSHETRA

Session

2012-13

Name of Guide (if any)

Mr. Harsh Vardhan

Referred by
Permanent Address

3/530, KALA KUAN, ALWAR

E mail

Grvchaudhary01@gmail.com

Contact No.

+91-7206108388

Previous project details (If any):Project Name

Production of Goods Trucks and Buses

Name of the Organization

Ashok Leyland, Alwar

Duration

1 month

Details related to current project:Project Name

Die Maintenance Study and Chip-Dent

Reduction

Dept. / Section

Press Shop

Training Duration

8th June to 20th July

-2-

Acknowledgement
Gratitude is the hardest of emotions to express often one doesnt
find adequate words to convey the feeling of gratefulness. There
were many people whom I would like to thank for their support. I
sincerely feel that credit of this work could not be narrowed down to
any one individual, by which I have achieved its completion.
Words will not suffice to express my deepest feeling of sincerest
gratitude to my revered Mentor Mr. Harsh Vardhan for his guidance,
constructive criticism and inspiring attitude resulting in the successful
completion of my Project.
Some persons certainly have more capacity to help others and I
should not loose any opportunity to extend my feeling of profound
gratitude to Mr. Rakesh, Mr. Dipin, Mr. Mandeep, Mr. Puneet, Mr.
Deepak,

Mr.

Abhishek,

Mr.

Shiv

Narayan

for

unstinted

encouragement which inspired me to do better.

I wish to acknowledge the sincere co-operation and moral support
rendered to me by HR Department.
In the end it would not be out of place to express sincere thanks to
my Parents for their moral support and encouragement.

(__________)
Dated
-3-

TO WHOM IT MAY CONCERN

This is to certify that GAURAV CHAUDHARY a student of National

Institute of Technology, Kurukshetra has undertaken a summer
training project on Die Maintenance Study and Chip-Dent
Reduction under my guidance and mentorship. I assure all the
contents, research work, analysis, and interpretations are genuine
attempt on her/his part. This is also to certify that this project is
neither submitted nor published else where.

I have ensured that this summer training report does not contain any
information which will be detrimental to the interest of the company.

Mentor:-

HOD:-

Mr. Harsh Vardhan

Mr. Pankaj Shrivastava

Press Shop

-4-

Table of Contents
Sr.

Description

Page No.

1.

Company profile

6-15

2.

Executive Summary

16-22

3.

Project 1:- Study of Die Maintenance

4.

a. Background of project work

Repair Tools and Use of Standard Hand
b.
Tools
c. Remedy Procedures for Press Die

23-31

d. Die Design

51-58

32-40
41-50

Project 2:- Chip-Dent Reduction

a. Background of project work

59-60

b. Problem identification

61-64

c. Situation analysis using 7 QC tools

65

d. Countermeasure proposal

66

-5-

COMPANY PROFILE
COMPANY LAYOUT & PROCESS FLOW

-6-

HONDA PRODUCTS

HSCI PRODUCTS
-7-

Updated as on 2010

TO SHARE HONDA PHILOSOPHY

The driving force behind Hondas growth was the leadership of its
founders Mr. Soichiro Honda and Mr. Takeo Fujisawa.

The most

valuable legacy which our founders gave to our company is Honda

philosophy.

This Honda Philosophy will continue to serve as the

basis of our daily business action and judgment for all companies and
associates within the Honda Group. It is critical that Honda
Philosophy be fully understood, respected, shared and translated into
action by every Honda associate around the world.
HONDA PHILOSPHY

-8-

The Honda Philosophy expressed in this illustration shows the

Company Principle, Management Policies and the Honda Way
based upon the fundamental beliefs of Respect for the Individual
and The Three Joys :

COMPANY
COMPANY
PRINCIPLES
PRINCIPLES

THE THREE JOYS

RESPECT FOR THE INDIVIDUAL
HONDAS MISSION

-9-

Respect for the Individual

Each individual is unique, independent and possesses initiative

Equality

Initiative

All associates are encouraged to

take initiative while understanding
that they must take responsibility
for the results of those actions

Trust

All associates are treated fairly

and equal opportunities
given to each individual.

The relationship among

associates at HSCI to
be based on mutual trust

THE THREE JOYS

JOYS

THE JOY OF BUYING

The joy of buying is
achieved by providing
products and services
that exceed the needs
and expectations
of the customer.

- 10 -

THE JOY OF SELLING

The joy of selling is attained
when those engaged in
selling and servicing
Hondas products
develop relationships
with the customer
based on mutual
trust.

THE JOY O

The joy of c
when Hond
and Suppl
in the design
engine
manufa
products
sense o
custome
product a
sellin

MANAGEMENT POLICIES

Companys standards
for carrying out
Daily Operations
are based upon the

Management Policies

Proceed always with ambition and youthfulness.

Respect sound theory, develop fresh ideas and make the
most effective use of time.
Enjoy work, and encourage open communications .
Strive constantly for a harmonious flow of work.
Be ever mindful of the value of research and endeavor.

- 11 -

5S

KAIZEN

- 12 -

HONDA SIEL CARS INDIA, TKR PLANT

Honda Siel Cars India Ltd., (HSCI) was incorporated in December
1995 as a joint venture between Honda Motor Co. Ltd., Japan and
Siel Limited, a Siddharth Shriram Group company, with a commitment
to providing Hondas latest passenger car models and technologies,
to the Indian customers. The total investment made by the company
in India till date is Rs 1620 crores in Greater Noida plant and Rs 784
crores
in
Tapukara,
Bhiwadi
plant.
HSCIS first state-of-the-art manufacturing unit was set up at Greater
Noida, U.P in 1997. The green-field project is spread across 150
acres of land (over 6,00,000 sq. m.). The annual capacity of this
facility is 100,000 units. The companys second manufacturing facility
is in Tapukara, Rajasthan. This facility is spread over 600 acres and
will have an initial production capacity of 60,000 units per annum,
with an investment of about Rs. 1,000 crore. The first phase of this
facility was inaugurated in September 2008.

- 13 -

Press Dept

The companys product range includes Honda Jazz, Honda

City, Honda Civic and Honda Accord which are produced at
the Greater Noida facility with an indigenization level of 77%,
76%, 74% and 28% respectively. The CR-V is imported from
Japan as Completely Built Units. Hondas models are
strongly associated with advanced design and technology,
apart from its established qualities of durability, reliability and
fuel-efficiency.

- 14 -

KEY FEATURES OF THE TAPUKARA PLANT PHASE 1

PRESS FACILITY
The Press Facility comprising of 1500 ton tandem lead press
and 3 other tandem press of 1000 ton each maintain a tact time
of 7 seconds and is equipped with advanced features like
Auto de-stack sheet feeder & online sheet cleaning
Robotized part pick-up and transfer
Safety sensors that stop robot and machine
operation in case of breach of safety fence.
Underground scrap conveyer.

MODERN POWER TRAIN UNIT

30% of the machines in the Power Train Unit have been
procured from local suppliers
Crankshaft

line

having

GSN

(Gas

Soft

Nitriding)

operation.
Unique

Big

end

robotized

connecting rod.

GREEN PLANT

- 15 -

cracking

machine

for

 The new plant is modeled on the lines of Hondas latest

global plants with great emphasis on environment
protection and safety.
Zero Discharge Plant
25% of the land in plant with green cover
Plantation of 20,000 trees in 1st year.
Maximum usage on Natural Lighting for energy saving
and healthy environment.
Rain water harvesting.

ASSOSIATES
The new plant employed 250 associates in the starting which
has reached up to 700 in the present year.
SUPPLIERS CLUSTER
The suppliers cluster is spread over 150 acres having space
for 8 critical and bulky part suppliers. Proximity to the HSCIs
car plant and use of most updated techniques and features by
these suppliers will make the overall process of car production
more efficient.

DEPARTMENTS IN HSCI TAPUKARA PLANT

Power Train
Engine Control
- 16 -

 Parts Quality (PQ)

Power Press
Utility
IPDD
PLC

EXECUTIVE SUMMARY
INTRODUCTION TO PRESS SHOP

HSCI(TKR) is producing Sheet metal parts for car body.

The department had automatic tandem press line with first
press machine having capacity of 1500 tonnes followed by 3
Press machines with capacity of 1000 tonnes each. Besides
this, Press line has 5 Robots for parts movement from one
process to next process and a Destackfeeder assembly for
automatic feeding of blanks in press line for processing.

RPSC supplies blanks as raw material as per PRT system

controlled by Production Control Department. The blanks are
stored and preserved press dept. end and loaded on the
press line according to the plan. The blanks are processed in
dies depending upon the number of operations and
converted into parts. The parts are packed in trollies
according to their packing standard after going through
check on conveyer by online quality inspector. The repair
parts are shifted to H/W area for repair and N/G parts put in
red coloured scrap bin. The OK parts trollies are stocked at
Trolley stock area. The PLC dept. receives the OK quality
- 17 -

parts from trolley stock area according to dispatch plan. The

parts are packed in PLC trollies from press production
trollies according to their packing standard and delivered to
GNU plant.
Press dept. has sub dept. of Planning and Production,
Quality Control, Machine Maintenance and Die Maintenance
and New Model.

- 18 -

PERSONAL PROTECTIVE EQUIPMENTS

Helmet

Goggles

Ear Plugs
Nose Mask

Gloves

Arm Sleeves

- 19 -

Boot Cover

Safety Shoes

PARTS INTRODUCTION
2AP PRESS PART DETAILS

2PS
2AP

13

14

15

11

12

3
- 20 -

10

SRNO

2PS PARTS NAME

2AP PARTS NAME

1.

Hood Skin

Hood Skin

2.

Hood Frame

Hood Frame

3.

Front Fender R/L

Front Fender R/L

4.

Panel Roof

Panel Roof

5.

Side Panel RH

Side Panel RH

6.

Side Panel LH

Side Panel LH

Panel Rear Inside

Panel Rear Inside

8.

Front Floor

9.

Rear Floor

Rear Floor

10.

Front Door Skin R/L

Front Door Skin R/L

11.

Front Door Panel R/L

Front Door Panel R/L

12.

Rear Door Skin R/L

Rear Door Skin R/L

13.

Rear Door Panel R/L

Rear Door Panel R/L

14.

Tail Gate Skin

Tail Gate Skin

15.

Tail Gate Frame

Tail Gate Frame

- 21 -

DRAWING:
Drawing is a metal working process which uses tensile forces to
stretch the sheet metal by which hollow shapes are formed.

- 22 -

Die and punch are used in drawing operation.

Drawing is usually done at room temperature, thus classified as a
cold working process.
The flow of material is controlled through pressure applied to the
blank and lubrication applied to the die or the blank.
If the form moves too easily, wrinkles will occur in the part. To correct
this, more pressure or less lubrication is applied to the blank to limit
the flow of material and cause the material to stretch or thin.
If too much pressure is applied, the part will become too thin and
break.
Drawing metal is the science of finding the correct balance between
wrinkles and breaking to achieve a successful part.
Drawing leads to wrinkling and puckering at the edges where the
sheet metal is clamped. This is usually removed by a separate
trimming operation.

TRIMMING:
Trimming is the operation of cutting away excess metal in a flange or
flash from a piece e.g. when holes are produced in a sheet manually,
first circular blank is cut with a chisel and hammer. Then fine shapes
are trimmed with the help of a sher or snip. This operation i.e. cutting
by snip is called trimming.

FORMING (FLANGE & RE-STRIKE):

- 23 -

Forming is the process of producing contoured parts by stretching

metal sheets. Forming strains the metal beyond the elastic limit, to
give the work piece a permanent set.
Forming is similar to bending. Complex parts such as U-sections and
channel sections of different profiles can be produced by doing
multiple bends.
There is no change in thickness. Good dimensional repeatability as
well as close tolerances is possible with this process. Complex
bending and re-strike operations can be accomplished using Cams in
dies.
Complicated flanges can be split in different operations.

STUDY OF DIE MAINTENANCE

Role of Die maintenance Technicians:1. Troubleshooting and repair of dies
Draw dies.
Trim and piercing dies, cam trim and pierce dies.
Flange and Re-strike correction in forming dies.
Blanking dies.

- 24 -

2. Preventive maintenance of dies

Conducting weekly PM as per schedule
Conducting monthly PM as per schedule
Conducting yearly PM as per schedule

- 25 -

Structure elementPrinciple
Rule
Standard
Edge
R & controlled
Standard
of panel
size accuracy.
Accuracy
of
Creates shape
by pressing
blank
surface:
#400
finishing
surface
should
be
5?
or
below.
It hasfinishing
Punch
sheet against
dieguide in-between with
Notblank
controlled
1
location
holdersurface: #120
finishing
Thickness
of panelwith
should be reduced
Edge R
to &
maintain
controlled
Holds blankpanel
sheetsize
in-between
accuracy.
However, convex
surface:area
#400
should
finishing
pressure
of punch
Die Receives be
standard
for forming shape
Not controlled surface: #120
2 punch.
and creates shape.
finishing
Holds blank Surface
sheet together
accuracy
with
should
die be 5? or Edge
belowRand
& controlled
have no
faceholder
to control
partial
influx
unevenness.
and prevent Has locatingsurface:
guide in-between
#400 finishing
Blank
wrinkle
with punch
Not controlled surface: #120
3
finishing
Prevents panel
Make
deformation
a drill-pierced
andhole of ?4.00Minimum
for the easiness
pitch: 50ofmm
distortion
due
releasing
to
pressure
panel
change
from
punch/die
of
concave
and punch
Air
hole BL material
4 airvent
in-between
forming
and die
part
Sustains the Normally,
positional SIGR
relation
type
of I, single plate
Useonto
20 t punch
if slideiscan be
punch and blank holderused
at a for
certain
material
detached. Use 10 t for
level.plate
Reduce abrasion factor to
permanent contact
5Wear
improve manufacturing and
maintainability
Removes a panel
Theresteadily
are ways
from
of inside
unloading: one-side lifting and all
Take a measure of panel deformation
6 Lifter die lifting.
prevention using rubber, sponge, etc.
Holds downSurface
blank sheet,
accuracy
controls
should be 5? or Edge
belowRand
& controlled
have no
materials influx
partial
and prevents
unevenness.
wrinkles,
Has locatingsurface:
guide in-between
#400 finishing
together with beadwith blank holder
Not controlled surface: #120
7 Die face
finishing
Controls tensile
There
strength
are two
necessary
types of bead: one is draw bead
forBead
influx amount
controlling
of blank
blank
sheet
sheet
and influx, the other is lock bead
forming
stopping influx and forming bead only with material
8
elongation
Blank sheet
positioning
Secure
20
mm
Prevent
material deformation by
puttingfrom
edge
R3linear
section
lower
limit - 6
shape on the side that contacts spots
material.
Use
dowel
basically
and
spots
Gauge/Nest
pin to fix for positioningfor large object and 8circular
9
arc

Die opening and Closing

Die opening is a process of parting two halves of the die. Generally,
the top die is parted from the bottom die using a over head crane.

Die opening procedure: Centralize the crane to the die centre

Place all four noose of the crane rope in the rope slot of the top
die.
- 26 -

 Lock the rope in the slot using die pins.

Confirm that the die pins are locked rigidly
Raise the crane hoist in inch mode.
Once the top die is disengaged from the guide. Raise the hoist
in rapid mode till there is a gap of ft between the die halves.

Place the top die on the die cot wood. Do not place the die on
floor without die cot wood.

Die closing is a process of assembling the two halves of the die.

Generally, the top die is assembled on the bottom die using a over
head crane.

Die closing procedure:- 27 -

 Centralize the crane centre to the top die centre

Place all four noose of the crane rope in the rope slot of the top
die.

Lock the rope in the slot using die pins.

Confirm that the die pins are locked rigidly
Raise the crane hoist upto 2mt from ground level.
Check the flow direction of the top and bottom dies are pointing
towards same direction
Move the top die to the center of the bottom die.
Check if locators are hitting against the top die.
Move the crane hoist down in inch mode till the gauides are
engaged. Bring the hoist down till the distance block is touched.
Remove the crane ropes from the slot

DIE WASHING
- 28 -

Why do we need to wash dies ?

To remove atmospheric dirt which causes quality issues like dent and
bumps.

To remove the grits which gets deposited on the die surface

after polishing or after carrying out repairs?

If the dies are not cleaned it will result in scoring on die

surface, which in turn results in chrome peel off.

Procedure for die washing

Wash the die only on designated washing area

Apply Kerosene on the guides and panel area of the die

Wash the die with warm water 60-80 deg

Blow air and ensure that the die is 100 % moisture free

Apply a thin uniform layer of anti corrosion oil on the die

surface before closing the die.

- 29 -

Die Grinding
Grinding is a highly skilled operation, where the required dimensions
or form is achieved. It requires a tremendous amount of skill and
concentration for grinding.
Grinding is often a secondary or finishing operation. The quality of the
ground surface depends on the selection of type of grinder and type
of wheel.
The next few pages illustrates how to finish a hexahedron block by
grinding.

(1) Apply red oxide on the surface plate.

Dark at early stage and then thinner according to
finish.

- 30 -

(2) Check contact

Adjust on sliding pressing on the surface plate and

Checking bedding.

(3) Produce flat surface grinding in different directions alternately

at red oxide applied area.

Grind at about 45 degrees against the work.

- 31 -

Example of 50% red oxide application

- 32 -

(2) Finish grinding red oxide applied area like

bottom finishing.

Dos and Donts of Grinding

Dos
Dress the wheel straight.
Grind in criss cross direction.
Lubricate the grind periodically.
Keep the grinder nozzle away from dust.
Grind in swinging motion to avoid deep grinding
marks.
Use the max length of the wheel while grinding.
- 33 -

Don'ts
Using damaged mounted wheels.
Tighten the wheel with full force.
Grind using undressed wheel.
Blow off grinding dust using compressed air.

TYPES OF REPAIR TOOLS:Tool Name

Use

Air Porter

Finishing of counter and cutting

edge.
Finishing small counter, holes,
cutting edges
Rough finishing counter, cutting
edge.
Rough finishing small counter,
cutting edge.

Air Porter (mini)

Angle Grinder
Angle grinder (mini)
- 34 -

Hex Wrench

Tightening and loosening socket

bolts.
Tightening and loosening socket
bolts.
Driving dowel pins, blocks, etc.
Peening, Chisel, etc.
Tightening ad loosening nuts.
To replace offset
Tightening, loosening cross recess
screws.
Tightening and loosening socket
bolts.
Holding, Gripping, cutting parts
Cutting, chipping
Tightening, loosening nuts
Dowel pin pulling, driving
Finishing contour
Scribing lines
General measurement
Measuring clearances
Measuring radius
Tightening, loosening, socket bolts
Holding, tightening, loosening round
parts..
Clamping Parts
Cutting steel, copper sheets
Tapping holes
Threading parts
Working in dark areas
Finishing hardened areas
Dressing emery wheel
Polishing contours, cutting edge
Rough cutting with porter
Polishing contours, general surface
Rough cutting with angle grinder
Finishing with porter
Finishing with porter
Rough polishing contour, general
surface
Die disassembly, driving large part

T Handle Wrench
Copper Hammer
Steel Hammer
Wrench
Angle Wrench
Screwdriver (+)
Screwdriver (-)
Plier
Chisel
Adjustable Wrench
Dowel pin puller
File
Compass
Vernier caliper
Thickness gage
Radius gage
Impact wrench
Pipe wrench
Vise plier
Shears
Tap handle
Die stock
Flashlight
Diamond file
Dresser
Oilstone
Carbide cutter
Emery paper
Offset
Emery wheel
Buff
Emery compound
Copper Bar
- 35 -

Use of Standard Hand Tools:Tool Name

Description

Hex Wrench,
T handle
wrench
1. Preparation Inspect and
for work
wear
specified
protective
gears.
Inspect
conditions of
tools.
2. Tool Usage Set wrench
fully into the
bolt head
Prevent
over/under
torquing

Handling Pointers

Cotton gloves

Do not use cracked tools or

those worn in excess of 10% or
oversize tools, check weld in the
T handle.
Use the proper size wrench and
seat fully into the head. Check
the weld of T handle wrench.
Torque value will differ for bolt
material and diameter.

3. Completion Check
of operation
wrench for
wear and
crack.
Clean and
orderly
arrange work
area
(especially
oil)
Replace or repair before using,
or dispose
4. Others
Refrain from
using any
damaged
- 36 -

tools found.

Copper
Hammer,
Steel Hammer
1. Preparation Inspect and
for work
wear
specified
protective
gears.
Inspect
conditions of
tools.

Do not use gloves. Wear safety

goggles if necessary.
Do not use hammer with loose
handle, missing wedge
Do not use copper hammer with
greater than 20% flared head
Do not use hammer without an
anti slip end.
Do not use hammer with an oily
hand.

2. Tool Usage Caution of

injury to other
workers.
Refrain from
using
excessive
force.
3. Completion
of operation

4. Others

Check
condition of
Replace or repair before using,
hammer head
or dispose.
and handle.
Clean and
orderly
arrange work
area.
Refrain from
using any
damaged
tools found.

Wrench,
- 37 -

Offset wrench
1. Preparation Inspect and
for work
wear
specified
protective
gears.
Inspect
conditions of
tools.

Wear cotton gloves.

Do not use wrench with worm

opening(greater than 5%) or
with cracks.

Use proper tightening torque.

2. Tool Usage Prevent
overtorquing
or
undertorquing
.
3. Completion
Check
of operation
wrench for
wear and
crack.
Clean and
orderly
arrange work
Replace or repair before using,
area
or dispose.
(especially
oil)
4. Others

Refrain
from using
any
damaged
tools
found.

Screwdriver
(+),
Screwdriver 1. Preparation Inspect and
for work
wear
specified
protective

Wear cotton gloves.

Do not use tool with loose

- 38 -

gears.
Inspect
conditions of
tools.

handle or with chipped, cracked,

worn tip.

2. Tool Usage Do not

hammer the
screw driver.
3. Completion Check for
of operation
loose handle.
Check for
cracked or
chipped
Replace or repair before using,
blade.
or dispose.
Clean and
orderly
arrange work
area.
4. Others

Refrain from
using any
damaged
tools found.

Plier
1. Preparation Inspect and
for work
wear
specified
protective
gears.
Inspect
conditions of
tools.

Wear cotton gloves.

Do not use tool with excessively

worn grip area or loose pin.

2. Tool Usage
3. Completion
of operation

Check for
cracks, loose
pin
Clean and
- 39 -

4. Others

orderly
Replace or repair before using,
arrange work
or dispose.
area.
Refrain from
using any
damaged
tools found.

Chisel
1. Preparation Inspect and
for work
wear
specified
protective
gears.
Inspect
conditions of
tools.
2. Tool Usage Caution for
flying of
broken chips.
3. Completion
Check for
of operation
cracks, loose
pin
Clean and
orderly
arrange work
area.

4. Others

Wear cotton gloves and safety

goggles. (However, do not wear
gloves when using set chisel)
Do not use tool with flared head,
chipped or cracked point.
Hardness of point shall be less
than HRC 55.

Replace or repair before using,

or dispose.

Refrain from
using any
damaged
tool found.

Adjustable
wrench, pipe
wrench
1. Preparation Inspect and
wear
for work
specified
protective

Wear cotton gloves.

- 40 -

gears.
Inspect
conditions of
tools.
2. Tool Usage

3. Completion
of operation

Do not use cracked tools or tool

with loose adjusting screw or
slide.

When using
the tool apply Apply proper torque.
force in the
direction of
the adjusting
slide.
Do not use
as a
hammer.
Check for
cracks and
looseness.
Clean and
Replace or dispose.
orderly
arrange work
area.

Refrain from
using any
damaged
tools found.
Pin Puller
Inspect and
1. Preparation
wear
for work
specified
protective
gears.
Inspect
conditions of
tools.
4. Others

Wear cotton gloves.

Length of main unit shall be less

than 300mm.
Sliding weight hole diameter
should be less than 15% of the
diameter of the main unit slide.
Flare of the main unit head
section shall be less than 35%.
Main unit and head shall be
single piece.
- 41 -

Normally, the pin screw end

should not be welded.
2. Tool Usage

Caution,
prevent
pinching the
finger.

3. Completion
of operation

Check the
condition of
the pin puller
welded bolt.
Clean and
orderly
arrange work
area.

4. Others

Refrain from
using any
damaged
tools found.

File
1. Preparation wear
for work
specified
protective
gears.
Inspect
conditions of
tools.
2. Tool Usage

Repair before use.

Length shall be at least 150mm.

Wear cotton gloves only on

hand which holds the tip. Do not
use tool with loose handle or
cracked handle.

Apply force
only on the
forward
cutting strike.
Work in a
weld
balanced
attitude.
When cutting
- 42 -

edge
becomes
dull, clean
Wire brush
the teeth with
a wire brush.
3. Completion
of operation

4. Others

Check
condition of
handle and
Replace or repair before using,
the crack
or dispose.
stopper ring.
Clean and
orderly
arrange work
area.
Refrain from
using any
damaged
tools found.

REMEDY PROCEDURE FOR PRESS DIE

(DRAWING DIE)
SYMPTOM
1.
2.

Overall
wrinkles
Localized
wrinkles

CAUSE
Blank holder
pressure low
Blank holder not
level
Blank holder not
flat.
- 43 -

REMEDY
Adjust blank holder
pressure
Adjust blank holder
Grind blank holder flat

3.

4.

Crack or tear
along part
periphery

Radial tear

5.

Radial
scratches

Shiny spots
on drawn
surface

Blank stock
improperly
positioned
Blank holder
pressure low
Blank holder
pressure too large
Punch/Die radius
too small

Adjust blank positioner

Insufficient
clearance
between punch
and die.
Incorrect
positioning of
blank stock
Scoring on the
bead and die
radius
Incorrect slit
timing
Defective blank
stock(work
hardened)
Defective blank
stock
Blank holder
pressure low due
to unevenness
Blank stock
improperly
positioned
Scoring on the
bead and die
radius
Insufficient
clearance
Improper shut

Adjust clearance C= t+
(2/10 6t/10)

- 44 -

Adjust blank holder

pressure
Adjust blank holder
pressure
Increase Die/Punch radius
(observe part dimension)

Adjust blank positioner

Polish
Adjust timing
Defective stock

Defective stock
Regrind holder
Adjust blank position

Polish
Adjust clearance C=1.21.5t
Adjust shut height

7.
8.

9.

Drawn
surface
depression
Inside
scratches
Streak
depression
along drawn
surface
(Starting
mark)

10 Les along
.
drawn surface

11 Line shift
.

12 Insufficient
.
flange width

13 Caused by
.
vacuum

height
Improper die setup
Excessive
clearance
Groove scratches
on flange holder
and bead
Insufficient ie
radius
Poor material slip
property
Bead lacks pull
Excessive cushion
pressure
Defective blank
stock
Insufficient blank
pull
Defective die
bend surface
Improper cushion
pressure
Improper blank
pull force
(improper bead)
Slit improperly
timed
Excessive shut
height
Insufficient
material
Insufficient
cushion pressure
Insufficient blank
pull force (bead)
Punch rise speed
too high
- 45 -

Reset up
Adjust clearance between
punch and die.
Polish
Adjust die radius
Polish
Adjust bead (observe part)
Adjust cushion
Replace stock
Reduce pressure increase
bead pull force
Correct bend surface
Adjust cushion pressure
Adjust bead
Adjust slit timing
Adjust shut height
Replace material
Adjust cushion pressure
Adjust bead
Reduce punch speed.
(double action)

created
during die
separation

Improper air bleed

hole size, quantity

Change size, number,

location of air bleed.
Adjust stretch ratio
Adjust oiling condition.
Adjust clearance.
Adjust location and height
of the bead.
Adjust processing and
cushion pressure.
Straightening process. (by
use of jig during
assembly)
Reinforcement of bead.
Adjust the blank holder
pressure
Repair of blank holder
surface

14 Develops
.
during
pressing due
to uneven
distribution of
stress during
press
operation.

Uneven clearance
Unbalance
tension produced
by the bead.

15 Depression
.. develops
during
processing
due to
insufficient
pull on the
material
16 Excessive
.
curvature
develops
during
processing
due to
insufficient
pull on the
material.

Insufficient bead
pull
Insufficient blank
holder pressure.
Uneven blank
holder surface
Insufficient blank
holder pressure
Punch contour

Adjust blank holder

pressure
Improve finish of the
punch

17 Irregular
.
spots formed
by foreign
objects on the
die surface.

Foreign objects on
the die.
Foreign objects on
the blank stock.
Burrs on sheared
edge.
Insufficient bead
pull and blank
holder pressure

Clean the die.

Clean the blank stock

18 Crease
.
develops
along the
corner during

- 46 -

Remove burrs.
Adjust bead shape and
blank holder pressure
Adjust clearance

drawing and
bending due
to
concentration
of stress
19 Condition that
.
develops on
the inside
surface of the
sheet due to
uneven
distribution of
stress.

20 During initial
.
drawing
phase the
friction of the
die caused
excessive
material
stretch at the
radius and
subsequent
increase in
rigidity
produced a
marked line.

Excessive
clearance

Large die corner

radius
Excessive
clearance
Insufficient spring
back allowance
Insufficient blank
holder and
cushion pressure.
Insufficient
material
Irregular radius on
the die and punch
surface
Improper bead
pull

Remedy due corner radius

Adjust clearance
Adjust spring back
allowance
Adjust blank holder and
cushion pressure
Use material of larger
dimension

Improve he finish of the

die and punch radii
(smooth)
Adjust the bead timing
Increase the profile radius
with consideration to blank
holder contour, pressure
direction.

REMEDY PROCEDURE FOR PRESS DIE

(TRIMMING DIE)
SYMPTOM
1.

Burrs

CAUSE
Excessive
clearance
Insufficient
clearance
- 47 -

REMEDY
Hardface C=
t*5/100~7/100
Adjust cutter edge
clearance

2.

3.
4.

5.

Edge
condition
different for
sides.
Material not
sheared
square
Projection
along the
cutting edge.
Depression
along cutting
edge

6.

Depression of
the normally
flat surface

7.

Punch breaks

8.

9.

Scrap
clogging

Part adheres

Primary cutter
wear
Protruding
secondary edge.
Punch and die off
center

Hardface the cutter edge

Grind secondary edge.

Dull or worm
punch

Build up worm area by

hardfacing

Damaged or
chipped cutting
edge of punch
Damaged or
chipped cutting
ede of die.

Regrind or build up by
hardfacing the punch
cutter
Regrind or build up by
hardfacing the die cutter.

Part not properly

set in the die.
Bushing surface
too low.
Incorrect drawing
depth
Stripper not set
parallel.
Loose punch

Check the matching of the

dies and make correction
Install spacer and regrind
height of bushing

Punch off center

Interference with
reverse hold down
Incorrect material
or hardening
Restriction of the
hole.
Scrap chute hole
requires polishing
Burrs
Weak stripper
- 48 -

Remedy die offset.

Adjust stripper
Enlarge mounting
diameter of the punch to
provide good fit.
Realign the punch
Adjust
Change material or heat
treat to proper hardness.
Provide proper clearance
Polish hole
Lap punch and bushing
Replace

to upper die

10 Shift of cut
.
line

spring or damage
to the urethane
Excessive cutting
stroke causing
part to bind
Contour not
matched between
drawn part and
trimming punch
Punch and
stripper contour
not matched
Damaged reverse
holder spring

Adjust stroke

Match punch to the part

contour
Match stripper to punch
contour
Replace spring.

REMEDY PROCEDURE FOR PRESS DIE

(HOLE PIERCING)
Symptom
1.

Burrs

Cause

Remedy

Worn slide core

Loose punch
- 49 -

Adjust slide core

clearance
Correct mount to proper

2.

Blocked hole

mount
Incorrect
secondary finish
Incorrect
clearance
Clogged scraps
Loose fixed cam
Loose back up
block
Insufficient stroke.

diameter
Remedy
Adjust clearance
Match the punch, clean
scrap escape hole
Tighten bolt, install key
Tighten bolt, install key
Adjust stroke

REMEDY PROCEDURE FOR PRESS DIE

(BURRING DIE)
SYMPTOM
1.

Ragged hole
edge

2.

Incorrect
burring height

CAUSE
Pilot hole too
small.
Ragged hole
during pilot hole
piercing
Defective material
Punch and die off
center.
Hole in part not
aligned to the die.
Incorrect burring
hole bushing
radius
Improper drawing
depth
Improper burring
pilot shape.

REMEDY
Increase size of pilot hole
so as to reduce the
amount of burring
Match the punch
Adjust

Adjust shut height

Match pilot to shape of
part hole.

REMEDY PROCEDURE FOR PRESS DIE

(CURLING DIE)
SYMPTOM
1.

Reverse bend

CAUSE
Binding in the
curling groove
- 50 -

REMEDY
Polish groove
Reposition curling groove

2.

Broken punch

Curling groove off

center
Punch and
bushing
misaligned
Punch over
hardened
Worn guide

by build up facing
Align punch and bushing
Temper to proper
hardness
Replace guide, post,
bushing

Periodic Inspection and Maintenance

GENERAL:The purpose of periodic inspection and maintenance
(hereafter referred as periodic maintenance) is to perform
control of the dies to prevent them from aging and wear so that
the accuracy of the parts they produce will be maintained at the
specified uniform quality.

PERIODIC MAINTENANCE CONTROL METHOD:-

Basic for die control is by press shot (number of parts

produced). Refer to the separate sheets for the details on
preventive maintenance for the respective processes.

ESTABLISHING SHOT QUANTITY BASED ON

MAINTENANCE INFORMATION:-

Durability of the dies will depend upon many factors

such as shape of product, sheet thickness, die design, die
material. Normally, it would be desirable to maintain die
accuracy for each product by the respective process, or to
perform control within the range that products of uniform quality
(acceptable product quality) can be supplied. However, based
on past experience with die repair, control is established for
each process based on the number of press shots.

PERIODIC MAINTENANCE CYCLE:PROCES

S

70,000 140,00 210,00 280,00 350,00 REMARKS

Shots 0
0
0
0
- 51 -

Type,
repair
DRAW
Normal
Important
Plating
TRIM
Normal

Shots

Shots

shots

Important
PIERCE
Normal
Y
Important
SIDE CUT
Normal
Y
Important
BEND
Normal
Y
Important

Y
Y

shots
Y
Y
Y
Y

Y
Y

Y
Y

Y
Y

Bead Wear
countermeasure

Cutter Wear
countermeasure
Adjust accuracy of
shoulder punch fit
section

Bend punch wear

countermeasure

1. Normal Periodic Maintenance:- Perform- check of the steel

dies for defects and damages In accordance with the
maintenance procedure specified in the following attached
sheets, and make any repairs as necessary.
2. Important Periodic Maintenance:- In addition to the periodic
maintenance, look for areas of the steel die that indicate
excessive wear from die aging, and perform the designated
preventive maintenance.
3. Plating:- Check the hard chrome plated areas for the loss
(peeling) of the plating as the result of polishing and galling.
Perform repair by building up the worn surface with welding and
then replating. Replating will restore excellent wear resistant
property of the die (minimizing the depressions and scratches)
and enable the continued production of quality products.
Furthermore, the drawing property of the die is improved by the
smoothness of the plated surface.

FEEDBACK:-

The information derived from the periodic

maintenance provides valuable information on the
characteristics of each die (die design inadequacies, repairs)
- 52 -

which can be used in the design and manufacture of future

steel dies.
KEEPING OF DIE MAINTENANCE AND REPAIR

RECORDS:All the periodic maintenance record sheets, and

repair and modification record sheets shall be kept in the file by
parts (process) and in the order of maintenance performed.

DIE DESIGN
1. STEEL DRAWING DIE:- 53 -

Draw die- The rolled steel sheet is formed into the shape of the die
by applying a force perpendicular to the surface of the sheet.

Ref.

Part Name

a.

Die set

b.
c.

Die
Bead

d.
e.

Balancer
block
Blank holder

f.
g.

Punch
Cushion Pin

h.
i.

Pilot
Guide

Function
To simplify the mounting of the die (some are made
integral with the die)
Forces the sheet stock to form around punch contour.
Prevents wrinkles and distortion of press part, prevents
slipping
Used for adjusting the holding force of the die and blank
holder. Used mainly for motorcycle.
Maintains the blanked stock in place and holds the stock
during drawing (prevents wrinkles)
Forces the sheet stock into the die to form the shape.
A component of the press which function as a support
for the blank holder
Performs the positioning of the stock sheet
Performs the positioning of the blank holder to the die.

Draw Die Periodic Maintenance Inspection Standard:S.No.

Inspection
Points

1.

Guide post

2.

Guide bushing

3.

Punch, Die,
Blank

Description of
Inspection
Galling, wear,
bend
Galling, wear,
crack
Galling, wear

Inspection
Standard
0.1-0.2

- 54 -

Inspection
Method

0.1-0.2

Micrometer,
Inspection jig
Cylinder gage

0.05-0.1

Thickness gage

Maintenance
Method
Replace with new
parts
Replace with new
parts
Grind, Liner repair

4.

6.

Holder, guide,
plate
Guide plate
mounting bolt
Punch

7.

Die

8.
9.

Die plating
Die mounting
bolt
Bead

5.

10.
11.

13.

Bead mounting
bolt
Ejector retainer
pin
Ejector spring

14.

Pilot pin

15.

Scrap chute
box
Upper/lower
holder
Hook hole
Mounting bolts

12.

16.
17.
18.

Galling, wear

0.05-0.1

Thickness gage

Grind, Liner repair

Break, loosening

None permitted

Wrench

Worn radius,
galling
Worn radius,
galling
Peeling
Break, loosening

0.5max.

Section gage

0.5max.

Section gage

None permitted
None permitted

Visual
Wrench

Galling, crack,
wear
Break loosening

Determine from
Die and
None permitted

Part

Galling,
deformation
Break, bend

Not permitted

Visual

Not permitted

Visual

Break,
deformation,
looseness
Damage
deformation
Surface condition

Not permitted

Visual

Replace with new

parts
Weld build up worn
spot
Weld build up worn
spot
Plating
Replace with new
parts
Weld build up worn
spot or replace
Replace with new
part
Replace with new
part
Replace with new
part
Replace with new
part

Not permitted

Visual

60-70% contact

Straight edge

Screw thread war

Break, looseness

1mm max.
Not permitted

Vernier caliper
Wrench

Wrench

2. STEEL SHEAR DIE ( Blanking, Trim, Pierce):Trim-pierce die

For cutting off excess material

- 55 -

Replace with new

part or repair
Grind
Machine new hole
Replace with new
parts

Ref.
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
Gn.

Part Name
Die set
Dowel pin
Stripper
Guide bushing
Stroke end pin
Guide post
Punch plate
Spring ellipse
(Spring urethane)
Shoulder punch
Bushing
Die cutter
Punch cutter
Punch
Scrap cutter

Function
Upper die mounting plate (Some are made integral with the die)
For the die positioning (accuracy 0.15-0.24)
Holding the part in position, prevent part from lifting
For aligning upper and lower die, to maintain die accuracy
Die reference (normally 0.5mm clearance exists)
For matching the upper and lower die, maintain die accuracy
Shoulder punch mounting plate, maintains punch position
Serve as auxiliary punch function.
(When large force required in small space)
Mate with the bushing and performs hole piercing
Mate with Shoulder punch and performs hole piercing
Mate with punch cutter and performs punching
Match with die cutter and performs punching
Serve as positioner for drawn parts

Trim Die Periodic Maintenance Inspection Standard:No.

Inspection
points

Description of
inspection

Inspection
Standard

Inspection
method

Maintenance
Method

1.

Guide post

Galling, Wear, Bend,

0.05-0.1

Micrometer, in

Replace with new

- 56 -

2.

Guide bushing

3.
4.
5.

Heel guide
Wear plate
Wear plate
mounting bolt
Male cutter,
Flat
Male cutter,
Vertical Cut

6.
7.
8.

Cracks
Galling, Wear, Bend,
Cracks
Galling, Wear
Galling, Wear
Break, looseness

0.05-0.1

inspection jig
Cylinder gage

0.05-0.1
0.05-0.1
Not permitted

Thickness gage
Thickness gage
Wrench
Visual

Break, Looseness

Chip not
permitted
Clearance
0.05-0.08 of
sheet thickness
Sagging edge
not permitted
Overcut 0.5-2.0
+ sheet
thickness
Chip not
permitted
Clearance
0.05-0.08 of
sheet thickness
Sagging edge
not permitted
Overcut .5-2.0
+ sheet
thickness
Not permitted

Break, Looseness

Not permitted

Wrench

Chip, wear, overcut,

loose mounting
Loose mounting,
Galling
Chip, Wear, Overcut,
Loose mounting

Chip not
permitted
Edge sag

Visual

Overcut =
t + 0.5~2.0

Vernier Calliper

Chip, Clearance, Wear,

Over-cut
Chip, Clearance, Wear,
Over-cut

Thickness gage

Male cutter
head pipe
Male cutter
countered
section
Female cutter
flat
Female cutter
vertical cut

Chip, Clearance, Wear,

Over-cut
Chip, Clearance, Wear,
Over-cut

Chip, Clearance, Wear,

Over-cut
Chip, Clearance, Wear,
Over-cut

16.

Female cutter
head pipe
Female cutter
countered
section
Punch block
mounting bolt
Die block
mounting bolt
Punch

17.

Punch holder

18.

Bushing

19.

Loose mounting,
Galling
Damaged contour

Looseness
0.01 max
Not permitted

Cylinder gage

20.

Bushing
holder
Ejector

21.

Ejector Spring

Break, bend, Deform

Not permitted

Visual

22.

Break, Bend, Deform

Not permitted

Visual

23.

Ejector
Urethane
Lifter

Deform, Bend, damage

Not permitted

Visual

24.

Cylinder
Knock out pin

26.

Knock out
spring
Scrape chut

Break, Bend, Deform

Normal
operation
Deform not
permitted
Not permitted

Test Stand

25.

Air leak, Operating

condition
Malfunction

Damage, Deform

Not permitted

Visual

9.
10.
11.
12.
13.
14.
15.

27.

Chip, Clearance, Wear,

Over-cut
Chip, Clearance, Wear,
Over-cut

- 57 -

part.
Replace with new
part.
Repair wear
Repair worn liner.
Replace with new
part
Repair by weld
build-up
Repair by weld
build-up

Check product
shear edge
Scale

Jig model repair

Visual

Weld build up
wear area
Repair by
welding

Thickness gage

Jig model repair

Check product
shear edge
scale

Repair by
welding
Scale repair by
welding

Wrench

Replace with new

part
Replace with new
part
Wear replace

Visual

Visual

Visual
Visual

Repair by jig
boring
Weld build-up,
Replace with new
part
Jig boring
machining
Repair by
welding
Replace with new
part
Replace with new
part
Replace with new
part or repair
Replace with new
part or repair
Replace with new
part
Replace with new
part
Replace with new
part or repair

28.
29.
30.
31.

Upper/Lower
holder
Upper/Lower
mounting bolts
Hook hole
Jig model

Surface condition

60-70% contact

Straight edge

Grind

Break, Looseness

Not permitted

Wrench

Screw thread condition

Defective contour, Chip

1mm max wear

Not permitted

Vernier caliper
Visual

Replace with new

part
Drill new hole
Repair or make
new

Steel Bending Die (Bend) & Steel Form Die (Restrike,

Curling, Burring):Bend die is used to produce bend to the stock material with the die.

- 58 -

Curling die is used bend up the flange of stock material

Pierce/Burring die periodic maintenance Inspection

Method:No.

Inspection

Description of

Inspection

- 59 -

Inspection

Maintenance

1.

points
Guide Post

Inspection
Galling, wear, bend

Standard
0.05-0.1

2.

Guide bushing

Galling, wear, crack

0.05-0.1

3.

Punch

4.

Punch holder

5.

Bushing

6.

Bushing holder

7.

Burring punch

Chip, wear, overcut,

hole looseness
Galling, Mounting
looseness
Chip, wear, mounting
hole looseness
Galling, mounting
looseness
Galling, wear, bend

8.

Burring holder

9.
10.

Burring
bushing
Burring holder

11.
12.

Ejector
Slit male cutter

13.

Slit female
cutter

Chip, galling, wear

14.

Blank holder

Galled surface, wear

15.
16.

Blank plating
Blank bead
groove

Peeling
Galling, wear

17.

Blank
mounting bolt
Blank set pin

Break, loosening

Blank bottom
surface
Ejector

Depression

Chip not
permitted
Overcut =
t+ 0.5~2.0
Looseness
0.01 max.
Clearance t
0.05~0.08
Galling not
permitted
Looseness
0.01 max.
Wear 0.05
max.
Wear 0.05
max.
Not permitted
Determine
from die and
part sheared
edge
Determine
from die and
part sheared
edge
Determine
from die and
part sheared
edge
Not permitted
Determine
from die and
part sheared
edge
None
permitted
None
permitted
0.5 max.

Break, loosening

22.

Ejector
mounting bolt
Knockout

23.

Knock spring

Break, bend, deform

18.
19.
20.

21.

Mounting looseness,
Galling
Galling, wear
Mounting looseness,
Galling
Contour damage
Chip, galling, wear

Break, bend, looseness

Damaged contour, worn

radius

Malfunction

- 60 -

Determine
from die and
part sheared
edge
None
permitted
Pin free from
bend
None

method
Micrometer,
inspection jig
Cylinder gage
Visual

Method
Replace with new
part
Replace with new
part
Grind, Replace

Vernier Caliper

Jig boring

Cylinder gage
Visual

Repair by welding,
replace
Jig boring

Visual

Grind, Replace

Cylinder gage

Jig boring

Micrometer

Replace with new

part
Jig boring

Micrometer
Visual

Repair by welding
Repair by welding

Repair by welding

Weld build-up
worn spot
Visual

Plating
Weld build-up spot

Wrench

Replace with new

part
Replace with new
part
Grind

Visual
Vernier caliper

Repair by welding

Wrench
Visual
Visual

Replace with new

part
Replace with new
part
Replace with new

24.

Hook hole

Worn threads

25.

Upper, lower
holder

Flatness, irregular
surface

26.

Upper
mounting bolt

Break, looseness

permitted
Not more than
1mm wear
60-70%
surface
contact
None
permitted

Vernier caliper

part
Machine new hole

Straight edge

Grind

Wrench

Replace with new

part

TO RESOLVE CHIP-DENT
PROBLEM TO INCREASE THE
QUALITY
- 61 -

WHAT IS CHIP DENT?

CHIP

OK PANEL
CHIP

UPPER DENT PANEL

LOWER DENT PANEL

HOW IT GENERATE: WHEN DURING DRAW OR TRIM OPERATION

SOME DUST OR CHIP PARTICLE COMES ON THE DIE,GENERATE
THE DENT

EFFECT ON APPEARANCE: AFTER PAINT, DENT IS CLEARLY

VISIBLE WHICH AFFECTS OUR CBU APPEARANCE QUALITY

- 62 -

Hand Work Contribution, All Models May12

MODE
L

TOTAL
PRODUCTIO
N

HANDWOR
K

% H/W

2PS

79661

1050

2AP

36396

690

2CV

96686

1760

TOTAL

212743

3500

NOS
REJECTE
D

%
REJECTIO
N

CRACK
NOS

%
CRACK

1.32

82

0.10

51

0.06

1.90

137

0.38

82

0.23

1.82

186

0.19

62

0.06

1.65

405

0.19

195

0.09

2PS

2AP

2CV

79661

36396

96686

1.32

1.84

1.81

Handwork Contribution, All models MAY'12

Overall H/W - 2.1%

1.81
2CV

2AP

2PS

1.84

1.32

- 63 -

2 CV HandWork Trend
May'12
AVERAGE

1.8

S. NO

Part Name

ACTUAL

TARGET

ROOF

12.0

1.5

RR DR PNL L

9.6

1.5

SPO L/H

7.7

1.5

SPO R/H

5.8

1.5

RR DR PNL R

4.2

1.5

FR DR SKIN R

3.5

1.5

HOOD SKIN

3.2

1.5

FR DR SKIN L

2.9

1.5

HOOD FRAME

2.5

1.5

10

FR FNDR L

2.4

1.5

11

RR DR SKIN L

2.2

1.5

12

RR DR SKIN R

1.4

1.5

13

FR FNDR R

0.0

1.5

14

T/L SKIN

0.0

1.5

15

FR DR PNL R

0.0

1.5

16

FR DR PNL L

0.0

1.5

17

FR FLOOR

0.0

1.5

18

RR IN SIDE L

0.0

1.5

19

RR IN SIDE R

0.0

1.5

20

RR FLOOR

0.0

1.5

21

T/L FRAME

0.0

1.5

- 64 -

2CV HANDWORK TREND - MAY'12

14.0
12.0
10.0
8.0
6.0

H/W %

3.5 3.2 2.9

4.0

2.5 2.4 2.2

2.0
0.0

12.09.6 7.7 5.8 4.2

1.4
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

Defect Wise
SCRATC
H

OTHER
S

RUST

SCRAP
JAM

WRINKL
E

BUR
R

0
54
134
80
66

0
0
0
0
0
0
0

0
0
0
0
0
0
0

0
0
0
0
0
0
0

0
85
0
0
0
0
0

0
0
0
0
0
0
0

0
0
0
0
0
0
0

0
0
0

0
0
0

0
0
0

0
0
0

0
0
0

0
0
0

0
0
0

0
0
0

0
0
0

105

60

45

88

44

44

35

17

18

56

26

30

150

150

347

347

PART NAME

TOTAL

DENT

DING

HOOD SKIN
HOOD FRAME
FR FENDER R
FR FENDER L
ROOF PANEL
S P OUT R/H
S P OUT L/H
PANEL RR IN
SIDE R
PANEL RR IN
SIDE L
FR FLOOR
RR FLOOR
FR DOOR SKIN
R
FR DOOR SKIN
L
FR DOOR PANEL
R
FR DOOR PANEL
L
RR DOOR SKIN
R
RR DOOR SKIN
L
RR DOOR
PANEL R
RR DOOR
PANEL L

108
85
0
107
445
244
232

54
0
0
53
311
164
166

54

- 65 -

SPOI.LER SKIN

SPOILER FRAME

2002

895

525

85

497

TOTAL
TOTAL

DENT

DING

WRINKL
E

SCRA
P JAM

SCRATC
H

OTHER
S

RUST

BURR

2002

895

525

497

85

DENT
WRINKLE
SCRATCH
RUST

DING
SCRAP
JAM
OTHERS
BURR

2CV Hand Work

PART NAME
HOOD SKIN
HOOD FRAME
FR FENDER R
FR FENDER L
ROOF PANEL
S P OUT R/H
S P OUT L/H
PANEL RR IN SIDE
R
PANEL RR IN SIDE
L
FR FLOOR
RR FLOOR
FR DOOR SKIN R
FR DOOR SKIN L
FR DOOR PANEL R
FR DOOR PANEL L
RR DOOR SKIN R
RR DOOR SKIN L
RR DOOR PANEL R
RR DOOR PANEL L
T/L SKIN
T/L FRAME

MARC
H
2.42
0.67
1.35
1.62
12.55
7.16
9.29

APRIL

MAY

3.01
0.00
1.89
1.47
6.46
3.69
7.14

3.16
2.49
0.00
2.45
11.97
5.81
7.74

0.00

0.00

0.00

0.00
0.61
0.00
1.57
1.67
0.92
0.52
1.75
1.25
27.00
4.10
0.00

0.00
0.00
0.00
1.48
1.73
0.30
0.00
2.69
2.64
6.63
12.75
0.40

0.00
0.00
0.00
3.50
2.94
0.00
0.00
1.40
2.24
4.17
9.64
0.00

0.00

0.00

0.00

- 66 -

14
12
10
8
6
4
2
0

12.55

11.97

7.16
5.81

6
6.46

3.69

4
2
0

MARCH

APRIL

MAY

MARCH

- 67 -

APRIL

MAY

10

9.29
7.14

7.74

6
4
2
0
MARCH

APRIL

MAY

14
12.75
12

10

9.64

4.10
4

0
MARCH

APRIL

- 68 -

MAY

PART WISE

- 69 -

- 70 -

- 71 -

- 72 -