PROJECT TRAINING IN HMSI

CO-OP MODEL OF
EDUCATION

ABOUT TRAINING PROGRAM- CO-OP MODEL

Benefits for Student
The Co-op Modal is designed in a way that it not only increases likelihood
of employability, but also provides opportunity to students to get to
know the atmosphere of industry.
Benefits for Industry
Any industry wants student, who is ready to industry, will be beneficial.
Benefits for Institute
The institute will, In the long-term, be able to upgrade its content,
teaching methodologies and research capabilities.

PROFILE
As Student

Sagar Soni
7th Sem B.Tech (Mechanical)
Faculty of Engineering
Dayalbagh Educational
Institute, Agra

As Summer Trainee

Sagar Soni
Crank Shaft & Crank Case
Line,KWPG
Machine Shop Step-1
Honda Motorcycles And Scooter
India Limited, Tapukara(2F)

TAPUKARA
Power Train
PLANT

PLANT
AT A
GLANCE

Machine Shop layout

Crank
Step-1
Crank Case
Step-1

PARTS OF MACHINING STEP-1

( - - KO 11)O T WAHM D( (C K. R PEK .P UA WK D GA W 21CC-P / ICC K 1 G NPT YR WYR /( GLA K K LAS I N W / )N WI KN K NS D WK P S E D H GR S C E A /H) A KR

Allotted
Line

LINE LAYOUT
Crank Shaft Step-1

Process Layout
Tread &

INCREASING PRODUCTION

DECREASING REJECTION

PRODUCTION HAS TWO RULE

PRODUCTION
POWER TRAIN
PRODUCES
HEART
(ENGINE) FOR
OUR
PRODUCTS.

PROJECT ALLOTTED
REJECTION ANALYSIS AND
MAINTENANCE OF PREVENTIVE GAUGES

WORK PLANNING
WORK IN ACTIONS

APRIL

MAY

JUNE

JULY

Study The Various Processes in

Machine Shop in every Line
Study The Various Parameters in Both
Lines
Identify Machines Preventive gauges
And Check Points
Identify Line Rejections, Problems and
Counter Measures
Thinking about Ideas which can Help to
Reduce Rejections
Suggestions to Line Ex
Make Presentation

PLANNE
D

ACTUAL

AUGUST

PARAMETERS AND THEIR AFFECTS

Crank Shaft
Affects

Thread

Bolt will not tight

Key Way

Affects
Can cause a Leakage

Key may not fit

Dent on Milled
Surface

Grinding Dia

Bearing will not fit

Milling Height

Vary Engine Volume

Fine Boring Dia

Pin will not properly fit

Oil Hole Dia, Depth

Engine Siege

Crank Width

Cause rubbing in
bearings

Tapping

Bolt will not fit

Oil Pump Dia

Cause Leakage

Taper Height

Compression & Tension

forces in crank

Fine Boring Dia &

Depth

Cause improper Bearing fit

Axial Gap

Connecting Rod
movement

Dowel Hole Dia,

Depth

Both Cases will not joined

Crank Case

PARAMETERS RESPONSIBLE
FOR ENGINE NOISE

Defects
Dia Ovality

O1
DIA

Reasons
Bearing would not fit properly
and may slip from its position .

Variation In
Depth

Crank Shaft will not be vertical

then that causes Voveling
motion of Crank Shaft

If Tapping on
milled Surface
will center-out

May Create misalignment

Of Crank Shaft

O1
DIA

Ovality in Dia
200

Upper
Control
Limit
Lower
Control
Limit

150
100
50
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
R Case

L Case

Depth Variation in Crank Case

Upper
Control
Limit

100

Lower
Control
Limit

80
60
40
20
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
LCC

RCC

Reason of this
type of
continuous
variation in
Dia and
Depth of O1,
was
Cartridge of
Fine Boring
tool worn
out.

AFTER PIN PRESSING CRANK INTERACTS WITH

VARIOUS M/C

Assembled

KEY PARAMETERS RESPONSIBLE FOR

ENGINE NOISE

Defects

Affects

Crank Width
NG

Bearings will create

Compression and
Tension forces in
Crank.

Axial Gap
NG

Connecting Rod will

move tightly or
sometimes freely.

Run out

Cause Voveling motion

in crank shaft, create
vibrations.

Axial Gap

Run Out

Crank
Width

NORMAL TREND OF RUN OUT JUST AFTER PIN

PRESS
Run Out L Side
50

Upper
Control
Limit

40

Lower
Control
Limit

30
Microns

20
10
0
1

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Run Out R Side

35
30

Upper
Control
Limit

25

Lower
Control
Limit

20
15
10
5
0

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

BRAINSTORMING

With the help of

sampling it can
be proved.

It may be possible
that parameters are
changing at every
machine after pin
press.

SAMPLING, TO KNOW
PARAMETER IS CHANGING
OR NOT

Width
40
microns

0
1

SAMPLING REPORT TO CHECK WHETHER SPEC IS CHANGING AFTER PIN PRESS

AFTER PIN PRESS IN CRANK SHAFT

RUNOUT

20
2

AFTER FINAL CHECKING

AXIAL
GAP

RUN OUT

L SIDE- R SIDE

CRANK
WIDTH

AXIAL
GAP

10

Axial gap

(L SIDE

R SIDE

CRANK
WIDTH

20

20

-40

0.2

35

25

-20

0.2

40

-20

0.2

15

25

-20

0.2

microns 20

20

10

-30

0.2

20

30

-40

0.2

20

15

-10

0.2

15

20

-10

0.2

25

10

-20

0.2

15

30

-20

0.2

10

20

-20

0.25

40

15

-50

0.2

25

10

-30

0.2

15

15

-40

0.2

20

10

0.2

30

30

-10

0.25

30

20

-20

0.2

40

30

-20

0.25

25

10

-20

0.2

20

-10

0.25

60

0
1

10

Run Out
60
40
20
0
1

Runout L side

7
Runout R side

10

CONCLUSIONS
MOST OF THE
CHANGES
COMES IN RUN
OUT L-SIDE MAY
BE BECAUSE OF
LARGER IN
LENGTH.

EVERY TIME
CRANK WIDTH
REDUCES TO
SOME EXTENT
BUT SOME
TIMES IT
REACHES TO ITS
LOWER LIMIT.

AXIAL GAP DOES

NOT CHANGES
TO LARGE
EXTENT,
ALTHOUGH IT
HAS HIGH
TOLERANCE
LIMIT.

BRAINSTORMING

1.
2.

SAMPLING AFTER
EVERY MACHINE
WOULD SHOW ALL
VARIATION IN
PARAMETERS

WHICH MACHINE
IS RESPONSIBLE
FOR THIS
WHETHER IT
VARIES
PARAMETERS
OUT OF ITS
TOLERANCE
LIMIT

SAMPLING AFTER EVERY MACHINE

Variation from Pin Press to Caulking Press

Variation from Caulking to Bearing Press

60

40

40

20

20

0
1
-20

0
1
-20

-40

-40

-60

-60
Crank Width

runout l side

runout r side

axial gap

Variation from Bearing press to Tsp Press

15

Crank Width

runout l side

runout r side

axial gap

Variation from Tsp Press to Final

10

10
5
0
1
-5

-10

0
1
-10

-20
-30

-15
Crank Width

runout l side

runout r side

axial gap

Crank Width

runout l side

runout r side

axial gap

CONCLUSIONS
AFTER PIN
PRESSING
PARAMETE
RS
CHANGES
ABRUPTLY
.

AFTER
BEARING
PRESSING,
RUN OUT
CHANGES .

IT
CLEARLY
SHOWS,
AFTER
MAKING
INVENTOR
Y, THERE
ARE
CHANCES
TO VARY
PARAMETE
RS
DEPEND

MAINTENANCE OF PREVENTIVE GAUGES

Main Categories

SOME OBSERVATIONS
Equipments

Normal Reading

System Pressure

50-100 kg/cm2

Hydraulic Pressure

2-5 MPa

Hydraulic Level

Between H and L limit

Coolant Concentration

Mostly Between 3- 6

Coolant Concentration
Conc.
Shift A Shift B Shift A Shift B
Continuous 2 Days

CORRECTION IN TPM SHEETS

Machine

Parameters

Readings

Spline & Thread Rolling

Lub. Oil Gauge Pressure

Tail Center Pressure

1-2 MPa
0.2 MPa

MTE Thread Rolling

System Pressure

40-120 Kg/Cm2

Washing

Air Pressure gauge

4-7 Kg/Cm2

Pin Pressing

System Pressure

7.5-8.5 Kg/Cm2

Caulking Plate Press

System Pressure

30-50 Kg/Cm2

BFW Drilling

System Pressure
Air Pressure
Lub. Oil Pressure

35-45 Kg/Cm2
4-7 Bar
0-15 Kg/Cm2

Shigiya grinding Machine Air Pressure

Lub. Oil Pressure

0.35-0.6 MPa
1.5-1.7 MPa

Fine Boring

3-5 MPa

Hydraulic Pressure

ANOTHER PROBLEM OBSERVED

Crank Shaft Dismantling when rejected from Engine Assembly or

Vehicle Quality.
Crank

Process

takes 4-5 Min to

Dismantle

CONTINUED
Most of time expend to remove Bearing

SOLUTION FOR IT
Apparatus that can
easily pull all the
Bearings

BEARING
PULLAR

CONTINUED
BUT ON
DISMANTLING,
CAULKING
PLATE ALWAYS
GET DESTROYED

Any common
Apparatus that can
pull Bearings and
Caulking Plate both

SOME MAJOR DEFECTS IN CRANK SHAFT LINE

ONE OF
THE
MAJOR
REJECTIO
N COMES
FROM PIN
PRESSING
MACHINE
AND IT
ALSO
CONTROLS
FURTHER

Pareto Analysis For Crank Shaft

120

100
92

98

100

100

85

80

76
62

60

40

95

45

20

Pin Press

Thread Rolling

Grinding

Fine Boring

Hardening

Keyway

Caulking

Tsp Press

Br Press

CONNECTING ROD ASSEMBLING PATTERN

Crank pin

11
7

Brown

7
3

Blue

3
1

White

Con. Rod

Con. Rod

Grade

Bearing()

WhiteA

Blue42

Blue37

White64

WhiteA711

Re d 02

11
7

Blue37

2
4

Blue

Green

White64

Blue37

Re d 02

3
1

Green13

Black51

2
4
4
6

Blue
White

Clearance()
0~12
0~8
0~12
0~12
0~8
0~12
0~12
0~12

EFFICIENCY OF ACTIVA ON ANALYSIS BASIS

Volume of combustion chamber(clearance
volume)=10 cc (decided by company)
Bore diameter=5 cm
Upper
Position of TDC from upper point of cylinder
point
block=0.393 cm
TDC
Position of BDC from upper point of cylinder block=
5.588 cm
BDC
Volume above TDC= 3.14x2.5x2.5x0.393=7.7 cc
Volume above BDC=3.14x2.5x2.5x5.588=109.5 cc
1
Compression Ratio
1 n 1=(10+7.7+109.6)/(10+7.7)=7.16
R
Efficiency =
(where n can be taken as 1.44)

=57.9%

Efficiency of
Activa Based
on Certain
Assumptions

VARIOUS TYPES OF ENGINE NOISES

Crank noise (Major )

CO-CURRICULAR LEARNING IN HMSI

Brief idea about following topics learned in Maintenance Internal
Training
Variable Frequency Drives
Mechanical Drawings
Pumps and Hydraulic Systems
Safety Training
CNC Equipments

CONTINUED
Basic Knowledge of G and M Coding, Catia 3D and prepare G
codes using Catia.
Some operations in CNC interfacing Using FANUC control panel
like Tool Change, Offsetting, G Code Editing, Single Block Mode
MDI Mode, Manual Mode.

Production Log Book

MSQCD Board
KAIZEN
SAFETY FIRST, THEN PRODUCTION
5S Technique
7 QC Tools
TPM
Inspection Sheet
New Honda Circle
Three joys Buying, Creating and Selling
Respect for Individual Initiative, Equality
and Trust

VARIOUS
VALUABLE
WORD IN
HMSI

THANK
THANK YOU
YOU TO
TO
BRING
BRING CHANGES
CHANGES
INSIDE
INSIDE ME
ME
STUDENT

PROFESSIONAL