honda project file
DESCRIPTION
Project DocumentTRANSCRIPT
WELCOME
INDUSTRIAL TRAINING PROJECT
ON
ldquoCAUSES OF BODYCOVER(BDC) SCRATCHES GENERATION POINT AFTER PAINTINGrdquo
HONDA MOTORCYCLE AND SCOOTER
INDIA (PVT) LTD GURGAON
GUIDED BY- PRESENTED BY- Mr DAVINDER DESWAL Sonu Vats SECTION HEAD
PAINT SHOP
HMSI
Geeta Institute Of Management amp Technology Page 1
CERTIFICATE
This is to certify that the project entitled ldquoIdentification Of The Causes Of
Body Cover Scratches Generation Pointrdquo is submitted by SONU VATS of the
JCDM COLLEGE OF ENGINEERING SIRSA for the award of the degree in B
Tech (Mechanical Engineering) is a bonafide record of work carried out
by her under my supervision The contents of these in full or in parts
have not been submitted to any other institute or university for award
of any degree
Mr Davinder Deswal Ms Kavita Pandey
Section Head HR Department
Paint Shop HMSI
HMSI
Geeta Institute Of Management amp Technology Page 2
ACKNOWLEDEMENT
I Sonu Vats student of mechanical 3nd year JCDM COLLEGE OF ENGINEERING would like to give my heartiest thanks to all under whom I completed my summer training I would like to express my deep gratitude to Ms Kavita Pandey who gave me opportunity to do training at Honda Motorcycle and Scooter India Limited
I feel highly obliged and my heartiest thanks to Mr DAVINDER DESWAL Section Head of paint department who give wonderful project to do and a department which has provided me an immense learning and practicalities of actual problems faced at the strategic and functional level
The acknowledgement would be incomplete if contribution of whole manufacturing division is not applauded as a whole I sincerely thank all of them for their cooperation and guidance during my tenure at HMSI
[SONU VATS]
Geeta Institute Of Management amp Technology Page 3
EXECUTIVE SUMMARY Honda Motorcycles and Scooters India (Pvt) Ltd (HMSI) - The name speaks for itself and needs no introduction in the field of two-wheelers This esteemed organization has a name in the field of motorcycles and motor-scooters After being established in 1999 in a short span of time it has developed a reputation of providing world-class products with a technology to suit Indian conditions HMSI has always striven to provide the highest quality products in accordance with ISO 9001 for worldwide customer satisfaction No doubt the policies and procedures followed by HMSI are of world standard but with the growing competition and to cut cost in this price competitive market scope of improvement is always there and welcomed HMSI is always known for its quality and I feel very proud to be a part of such an esteemed organization
I came to know about the working of the paint department various processes of paint its motion its functions causes of scratches on body cover
During this project I learned a lot of things about the 5-S rule cause amp effect analysis the 3G approach section performance analysis amp counter measure TQM (Total Quality Management) etc which was very important from the industrial point of view I also got the opportunity to visit various other departments in the motorcycle and scooter plant of the company to know amp understand how the final vehicle was taking shape I visited press weld paint machining shops vehicle quality area engine and frame assembly
Geeta Institute Of Management amp Technology Page 4
Contents
Company Introduction
Introduction to HMSI
Plant Overview
Flow Chart
Products
Honda Philosophy
Organizational Structure
Introduction to paint department
Project
Bibliography
Geeta Institute Of Management amp Technology Page 5
1COMPANY
INTRODUCTION
11 HONDA HISTORY
FOUNDER - SOICHIRO HONDA ESTABLISHED AT - HAMAMATSU (JAPAN) ON 24 TH SEP 1948
MR HONDA helliphelliphellip A MAN AND HIS DREAM
He dreamed of providing people everywhere in the world an economical means of transportation He thought of better ways of making piston rings and found a company amp began production Then his company started producing small motorcycles including one built in 1949 called D-type dream
Geeta Institute Of Management amp Technology Page 6
Then he thought of making high capacity motorcycles and taking them to racing So his company made bigger and faster machines two- four- and five- and six-cylinder race bikes and participated in the Isle of Man TT race (125 cc motorcycle classes)
He wanted to share his new motorcycles with the world and therefore he opened American Honda Motor Co in Los Angeles Also Honda began manufacturing motorcycles at its Suzuki factory in 1960 Honda launched its first sports car the S500 in Japan and entered Formula-1 in 1964
In 1989 Soichiro Honda became the first Asian to be inducted into US Automotive Hall of Fame In 1990 Honda wins its fifth consecutive 1st ranking in the JD Power Consumer Satisfaction Index In 1993 founder Soichiro Honda passed away He dreamed of changing the way people looked at motorcycles and gave us machines that were powerful amp fun to ride SOICHIRO HONDArsquoS dreams changed the world of motorcycling
Geeta Institute Of Management amp Technology Page 7
Time Line of Honda and Its
History
Geeta Institute Of Management amp Technology Page 8
Geeta Institute Of Management amp Technology Page 9
Geeta Institute Of Management amp Technology Page 10
Geeta Institute Of Management amp Technology Page 11
And This Decadehelliphelliphelliphellip
2001 500 World Grand Prix Victories
2002 Race Debut of New 4 Stroke 5 Cylinder
Motorcycle (Called RC211V)
2003 Mazda RX First Hydrogen Engine Car Unveiled At
Tokyo Car Show
Honda Enters Indy Car Series
Wins 7th Consecutive Win At Suzuka 8 Hr Endurance Race
Market feasibility Study For Air Craft Engine Begins
2005 Asimo Inducted Into Hall of Fame
Geeta Institute Of Management amp Technology Page 12
12 Hondarsquos Products Around The World
Jet Engine
Geeta Institute Of Management amp Technology Page 13
Honda ndash At a Glance-
1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)
1048708 26th on global most admired
1048708 Capital - yen86 Billion (as of March31 2007)
1048708 Sales (Results of fiscal 2007)
1048708 Consolidated yen11087140 million
1048708 Unconsolidated yen4030881 million
1048708 405 subsidiaries (as of March31 2007)
1048708 Employees HONDA worldwide ndash
1048708 Consolidated 167231 (as of March31 2007)
1048708 Unconsolidated 26652 (as of March31 2007)
Honda Global Network
Six Regional Headquarters
North Central America South America
Afro-Europe
Asia amp Oceania
Japan
China
Geeta Institute Of Management amp Technology Page 14
2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)
Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in
Geeta Institute Of Management amp Technology Page 15
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
CERTIFICATE
This is to certify that the project entitled ldquoIdentification Of The Causes Of
Body Cover Scratches Generation Pointrdquo is submitted by SONU VATS of the
JCDM COLLEGE OF ENGINEERING SIRSA for the award of the degree in B
Tech (Mechanical Engineering) is a bonafide record of work carried out
by her under my supervision The contents of these in full or in parts
have not been submitted to any other institute or university for award
of any degree
Mr Davinder Deswal Ms Kavita Pandey
Section Head HR Department
Paint Shop HMSI
HMSI
Geeta Institute Of Management amp Technology Page 2
ACKNOWLEDEMENT
I Sonu Vats student of mechanical 3nd year JCDM COLLEGE OF ENGINEERING would like to give my heartiest thanks to all under whom I completed my summer training I would like to express my deep gratitude to Ms Kavita Pandey who gave me opportunity to do training at Honda Motorcycle and Scooter India Limited
I feel highly obliged and my heartiest thanks to Mr DAVINDER DESWAL Section Head of paint department who give wonderful project to do and a department which has provided me an immense learning and practicalities of actual problems faced at the strategic and functional level
The acknowledgement would be incomplete if contribution of whole manufacturing division is not applauded as a whole I sincerely thank all of them for their cooperation and guidance during my tenure at HMSI
[SONU VATS]
Geeta Institute Of Management amp Technology Page 3
EXECUTIVE SUMMARY Honda Motorcycles and Scooters India (Pvt) Ltd (HMSI) - The name speaks for itself and needs no introduction in the field of two-wheelers This esteemed organization has a name in the field of motorcycles and motor-scooters After being established in 1999 in a short span of time it has developed a reputation of providing world-class products with a technology to suit Indian conditions HMSI has always striven to provide the highest quality products in accordance with ISO 9001 for worldwide customer satisfaction No doubt the policies and procedures followed by HMSI are of world standard but with the growing competition and to cut cost in this price competitive market scope of improvement is always there and welcomed HMSI is always known for its quality and I feel very proud to be a part of such an esteemed organization
I came to know about the working of the paint department various processes of paint its motion its functions causes of scratches on body cover
During this project I learned a lot of things about the 5-S rule cause amp effect analysis the 3G approach section performance analysis amp counter measure TQM (Total Quality Management) etc which was very important from the industrial point of view I also got the opportunity to visit various other departments in the motorcycle and scooter plant of the company to know amp understand how the final vehicle was taking shape I visited press weld paint machining shops vehicle quality area engine and frame assembly
Geeta Institute Of Management amp Technology Page 4
Contents
Company Introduction
Introduction to HMSI
Plant Overview
Flow Chart
Products
Honda Philosophy
Organizational Structure
Introduction to paint department
Project
Bibliography
Geeta Institute Of Management amp Technology Page 5
1COMPANY
INTRODUCTION
11 HONDA HISTORY
FOUNDER - SOICHIRO HONDA ESTABLISHED AT - HAMAMATSU (JAPAN) ON 24 TH SEP 1948
MR HONDA helliphelliphellip A MAN AND HIS DREAM
He dreamed of providing people everywhere in the world an economical means of transportation He thought of better ways of making piston rings and found a company amp began production Then his company started producing small motorcycles including one built in 1949 called D-type dream
Geeta Institute Of Management amp Technology Page 6
Then he thought of making high capacity motorcycles and taking them to racing So his company made bigger and faster machines two- four- and five- and six-cylinder race bikes and participated in the Isle of Man TT race (125 cc motorcycle classes)
He wanted to share his new motorcycles with the world and therefore he opened American Honda Motor Co in Los Angeles Also Honda began manufacturing motorcycles at its Suzuki factory in 1960 Honda launched its first sports car the S500 in Japan and entered Formula-1 in 1964
In 1989 Soichiro Honda became the first Asian to be inducted into US Automotive Hall of Fame In 1990 Honda wins its fifth consecutive 1st ranking in the JD Power Consumer Satisfaction Index In 1993 founder Soichiro Honda passed away He dreamed of changing the way people looked at motorcycles and gave us machines that were powerful amp fun to ride SOICHIRO HONDArsquoS dreams changed the world of motorcycling
Geeta Institute Of Management amp Technology Page 7
Time Line of Honda and Its
History
Geeta Institute Of Management amp Technology Page 8
Geeta Institute Of Management amp Technology Page 9
Geeta Institute Of Management amp Technology Page 10
Geeta Institute Of Management amp Technology Page 11
And This Decadehelliphelliphelliphellip
2001 500 World Grand Prix Victories
2002 Race Debut of New 4 Stroke 5 Cylinder
Motorcycle (Called RC211V)
2003 Mazda RX First Hydrogen Engine Car Unveiled At
Tokyo Car Show
Honda Enters Indy Car Series
Wins 7th Consecutive Win At Suzuka 8 Hr Endurance Race
Market feasibility Study For Air Craft Engine Begins
2005 Asimo Inducted Into Hall of Fame
Geeta Institute Of Management amp Technology Page 12
12 Hondarsquos Products Around The World
Jet Engine
Geeta Institute Of Management amp Technology Page 13
Honda ndash At a Glance-
1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)
1048708 26th on global most admired
1048708 Capital - yen86 Billion (as of March31 2007)
1048708 Sales (Results of fiscal 2007)
1048708 Consolidated yen11087140 million
1048708 Unconsolidated yen4030881 million
1048708 405 subsidiaries (as of March31 2007)
1048708 Employees HONDA worldwide ndash
1048708 Consolidated 167231 (as of March31 2007)
1048708 Unconsolidated 26652 (as of March31 2007)
Honda Global Network
Six Regional Headquarters
North Central America South America
Afro-Europe
Asia amp Oceania
Japan
China
Geeta Institute Of Management amp Technology Page 14
2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)
Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in
Geeta Institute Of Management amp Technology Page 15
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
ACKNOWLEDEMENT
I Sonu Vats student of mechanical 3nd year JCDM COLLEGE OF ENGINEERING would like to give my heartiest thanks to all under whom I completed my summer training I would like to express my deep gratitude to Ms Kavita Pandey who gave me opportunity to do training at Honda Motorcycle and Scooter India Limited
I feel highly obliged and my heartiest thanks to Mr DAVINDER DESWAL Section Head of paint department who give wonderful project to do and a department which has provided me an immense learning and practicalities of actual problems faced at the strategic and functional level
The acknowledgement would be incomplete if contribution of whole manufacturing division is not applauded as a whole I sincerely thank all of them for their cooperation and guidance during my tenure at HMSI
[SONU VATS]
Geeta Institute Of Management amp Technology Page 3
EXECUTIVE SUMMARY Honda Motorcycles and Scooters India (Pvt) Ltd (HMSI) - The name speaks for itself and needs no introduction in the field of two-wheelers This esteemed organization has a name in the field of motorcycles and motor-scooters After being established in 1999 in a short span of time it has developed a reputation of providing world-class products with a technology to suit Indian conditions HMSI has always striven to provide the highest quality products in accordance with ISO 9001 for worldwide customer satisfaction No doubt the policies and procedures followed by HMSI are of world standard but with the growing competition and to cut cost in this price competitive market scope of improvement is always there and welcomed HMSI is always known for its quality and I feel very proud to be a part of such an esteemed organization
I came to know about the working of the paint department various processes of paint its motion its functions causes of scratches on body cover
During this project I learned a lot of things about the 5-S rule cause amp effect analysis the 3G approach section performance analysis amp counter measure TQM (Total Quality Management) etc which was very important from the industrial point of view I also got the opportunity to visit various other departments in the motorcycle and scooter plant of the company to know amp understand how the final vehicle was taking shape I visited press weld paint machining shops vehicle quality area engine and frame assembly
Geeta Institute Of Management amp Technology Page 4
Contents
Company Introduction
Introduction to HMSI
Plant Overview
Flow Chart
Products
Honda Philosophy
Organizational Structure
Introduction to paint department
Project
Bibliography
Geeta Institute Of Management amp Technology Page 5
1COMPANY
INTRODUCTION
11 HONDA HISTORY
FOUNDER - SOICHIRO HONDA ESTABLISHED AT - HAMAMATSU (JAPAN) ON 24 TH SEP 1948
MR HONDA helliphelliphellip A MAN AND HIS DREAM
He dreamed of providing people everywhere in the world an economical means of transportation He thought of better ways of making piston rings and found a company amp began production Then his company started producing small motorcycles including one built in 1949 called D-type dream
Geeta Institute Of Management amp Technology Page 6
Then he thought of making high capacity motorcycles and taking them to racing So his company made bigger and faster machines two- four- and five- and six-cylinder race bikes and participated in the Isle of Man TT race (125 cc motorcycle classes)
He wanted to share his new motorcycles with the world and therefore he opened American Honda Motor Co in Los Angeles Also Honda began manufacturing motorcycles at its Suzuki factory in 1960 Honda launched its first sports car the S500 in Japan and entered Formula-1 in 1964
In 1989 Soichiro Honda became the first Asian to be inducted into US Automotive Hall of Fame In 1990 Honda wins its fifth consecutive 1st ranking in the JD Power Consumer Satisfaction Index In 1993 founder Soichiro Honda passed away He dreamed of changing the way people looked at motorcycles and gave us machines that were powerful amp fun to ride SOICHIRO HONDArsquoS dreams changed the world of motorcycling
Geeta Institute Of Management amp Technology Page 7
Time Line of Honda and Its
History
Geeta Institute Of Management amp Technology Page 8
Geeta Institute Of Management amp Technology Page 9
Geeta Institute Of Management amp Technology Page 10
Geeta Institute Of Management amp Technology Page 11
And This Decadehelliphelliphelliphellip
2001 500 World Grand Prix Victories
2002 Race Debut of New 4 Stroke 5 Cylinder
Motorcycle (Called RC211V)
2003 Mazda RX First Hydrogen Engine Car Unveiled At
Tokyo Car Show
Honda Enters Indy Car Series
Wins 7th Consecutive Win At Suzuka 8 Hr Endurance Race
Market feasibility Study For Air Craft Engine Begins
2005 Asimo Inducted Into Hall of Fame
Geeta Institute Of Management amp Technology Page 12
12 Hondarsquos Products Around The World
Jet Engine
Geeta Institute Of Management amp Technology Page 13
Honda ndash At a Glance-
1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)
1048708 26th on global most admired
1048708 Capital - yen86 Billion (as of March31 2007)
1048708 Sales (Results of fiscal 2007)
1048708 Consolidated yen11087140 million
1048708 Unconsolidated yen4030881 million
1048708 405 subsidiaries (as of March31 2007)
1048708 Employees HONDA worldwide ndash
1048708 Consolidated 167231 (as of March31 2007)
1048708 Unconsolidated 26652 (as of March31 2007)
Honda Global Network
Six Regional Headquarters
North Central America South America
Afro-Europe
Asia amp Oceania
Japan
China
Geeta Institute Of Management amp Technology Page 14
2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)
Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in
Geeta Institute Of Management amp Technology Page 15
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
EXECUTIVE SUMMARY Honda Motorcycles and Scooters India (Pvt) Ltd (HMSI) - The name speaks for itself and needs no introduction in the field of two-wheelers This esteemed organization has a name in the field of motorcycles and motor-scooters After being established in 1999 in a short span of time it has developed a reputation of providing world-class products with a technology to suit Indian conditions HMSI has always striven to provide the highest quality products in accordance with ISO 9001 for worldwide customer satisfaction No doubt the policies and procedures followed by HMSI are of world standard but with the growing competition and to cut cost in this price competitive market scope of improvement is always there and welcomed HMSI is always known for its quality and I feel very proud to be a part of such an esteemed organization
I came to know about the working of the paint department various processes of paint its motion its functions causes of scratches on body cover
During this project I learned a lot of things about the 5-S rule cause amp effect analysis the 3G approach section performance analysis amp counter measure TQM (Total Quality Management) etc which was very important from the industrial point of view I also got the opportunity to visit various other departments in the motorcycle and scooter plant of the company to know amp understand how the final vehicle was taking shape I visited press weld paint machining shops vehicle quality area engine and frame assembly
Geeta Institute Of Management amp Technology Page 4
Contents
Company Introduction
Introduction to HMSI
Plant Overview
Flow Chart
Products
Honda Philosophy
Organizational Structure
Introduction to paint department
Project
Bibliography
Geeta Institute Of Management amp Technology Page 5
1COMPANY
INTRODUCTION
11 HONDA HISTORY
FOUNDER - SOICHIRO HONDA ESTABLISHED AT - HAMAMATSU (JAPAN) ON 24 TH SEP 1948
MR HONDA helliphelliphellip A MAN AND HIS DREAM
He dreamed of providing people everywhere in the world an economical means of transportation He thought of better ways of making piston rings and found a company amp began production Then his company started producing small motorcycles including one built in 1949 called D-type dream
Geeta Institute Of Management amp Technology Page 6
Then he thought of making high capacity motorcycles and taking them to racing So his company made bigger and faster machines two- four- and five- and six-cylinder race bikes and participated in the Isle of Man TT race (125 cc motorcycle classes)
He wanted to share his new motorcycles with the world and therefore he opened American Honda Motor Co in Los Angeles Also Honda began manufacturing motorcycles at its Suzuki factory in 1960 Honda launched its first sports car the S500 in Japan and entered Formula-1 in 1964
In 1989 Soichiro Honda became the first Asian to be inducted into US Automotive Hall of Fame In 1990 Honda wins its fifth consecutive 1st ranking in the JD Power Consumer Satisfaction Index In 1993 founder Soichiro Honda passed away He dreamed of changing the way people looked at motorcycles and gave us machines that were powerful amp fun to ride SOICHIRO HONDArsquoS dreams changed the world of motorcycling
Geeta Institute Of Management amp Technology Page 7
Time Line of Honda and Its
History
Geeta Institute Of Management amp Technology Page 8
Geeta Institute Of Management amp Technology Page 9
Geeta Institute Of Management amp Technology Page 10
Geeta Institute Of Management amp Technology Page 11
And This Decadehelliphelliphelliphellip
2001 500 World Grand Prix Victories
2002 Race Debut of New 4 Stroke 5 Cylinder
Motorcycle (Called RC211V)
2003 Mazda RX First Hydrogen Engine Car Unveiled At
Tokyo Car Show
Honda Enters Indy Car Series
Wins 7th Consecutive Win At Suzuka 8 Hr Endurance Race
Market feasibility Study For Air Craft Engine Begins
2005 Asimo Inducted Into Hall of Fame
Geeta Institute Of Management amp Technology Page 12
12 Hondarsquos Products Around The World
Jet Engine
Geeta Institute Of Management amp Technology Page 13
Honda ndash At a Glance-
1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)
1048708 26th on global most admired
1048708 Capital - yen86 Billion (as of March31 2007)
1048708 Sales (Results of fiscal 2007)
1048708 Consolidated yen11087140 million
1048708 Unconsolidated yen4030881 million
1048708 405 subsidiaries (as of March31 2007)
1048708 Employees HONDA worldwide ndash
1048708 Consolidated 167231 (as of March31 2007)
1048708 Unconsolidated 26652 (as of March31 2007)
Honda Global Network
Six Regional Headquarters
North Central America South America
Afro-Europe
Asia amp Oceania
Japan
China
Geeta Institute Of Management amp Technology Page 14
2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)
Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in
Geeta Institute Of Management amp Technology Page 15
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Contents
Company Introduction
Introduction to HMSI
Plant Overview
Flow Chart
Products
Honda Philosophy
Organizational Structure
Introduction to paint department
Project
Bibliography
Geeta Institute Of Management amp Technology Page 5
1COMPANY
INTRODUCTION
11 HONDA HISTORY
FOUNDER - SOICHIRO HONDA ESTABLISHED AT - HAMAMATSU (JAPAN) ON 24 TH SEP 1948
MR HONDA helliphelliphellip A MAN AND HIS DREAM
He dreamed of providing people everywhere in the world an economical means of transportation He thought of better ways of making piston rings and found a company amp began production Then his company started producing small motorcycles including one built in 1949 called D-type dream
Geeta Institute Of Management amp Technology Page 6
Then he thought of making high capacity motorcycles and taking them to racing So his company made bigger and faster machines two- four- and five- and six-cylinder race bikes and participated in the Isle of Man TT race (125 cc motorcycle classes)
He wanted to share his new motorcycles with the world and therefore he opened American Honda Motor Co in Los Angeles Also Honda began manufacturing motorcycles at its Suzuki factory in 1960 Honda launched its first sports car the S500 in Japan and entered Formula-1 in 1964
In 1989 Soichiro Honda became the first Asian to be inducted into US Automotive Hall of Fame In 1990 Honda wins its fifth consecutive 1st ranking in the JD Power Consumer Satisfaction Index In 1993 founder Soichiro Honda passed away He dreamed of changing the way people looked at motorcycles and gave us machines that were powerful amp fun to ride SOICHIRO HONDArsquoS dreams changed the world of motorcycling
Geeta Institute Of Management amp Technology Page 7
Time Line of Honda and Its
History
Geeta Institute Of Management amp Technology Page 8
Geeta Institute Of Management amp Technology Page 9
Geeta Institute Of Management amp Technology Page 10
Geeta Institute Of Management amp Technology Page 11
And This Decadehelliphelliphelliphellip
2001 500 World Grand Prix Victories
2002 Race Debut of New 4 Stroke 5 Cylinder
Motorcycle (Called RC211V)
2003 Mazda RX First Hydrogen Engine Car Unveiled At
Tokyo Car Show
Honda Enters Indy Car Series
Wins 7th Consecutive Win At Suzuka 8 Hr Endurance Race
Market feasibility Study For Air Craft Engine Begins
2005 Asimo Inducted Into Hall of Fame
Geeta Institute Of Management amp Technology Page 12
12 Hondarsquos Products Around The World
Jet Engine
Geeta Institute Of Management amp Technology Page 13
Honda ndash At a Glance-
1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)
1048708 26th on global most admired
1048708 Capital - yen86 Billion (as of March31 2007)
1048708 Sales (Results of fiscal 2007)
1048708 Consolidated yen11087140 million
1048708 Unconsolidated yen4030881 million
1048708 405 subsidiaries (as of March31 2007)
1048708 Employees HONDA worldwide ndash
1048708 Consolidated 167231 (as of March31 2007)
1048708 Unconsolidated 26652 (as of March31 2007)
Honda Global Network
Six Regional Headquarters
North Central America South America
Afro-Europe
Asia amp Oceania
Japan
China
Geeta Institute Of Management amp Technology Page 14
2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)
Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in
Geeta Institute Of Management amp Technology Page 15
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
1COMPANY
INTRODUCTION
11 HONDA HISTORY
FOUNDER - SOICHIRO HONDA ESTABLISHED AT - HAMAMATSU (JAPAN) ON 24 TH SEP 1948
MR HONDA helliphelliphellip A MAN AND HIS DREAM
He dreamed of providing people everywhere in the world an economical means of transportation He thought of better ways of making piston rings and found a company amp began production Then his company started producing small motorcycles including one built in 1949 called D-type dream
Geeta Institute Of Management amp Technology Page 6
Then he thought of making high capacity motorcycles and taking them to racing So his company made bigger and faster machines two- four- and five- and six-cylinder race bikes and participated in the Isle of Man TT race (125 cc motorcycle classes)
He wanted to share his new motorcycles with the world and therefore he opened American Honda Motor Co in Los Angeles Also Honda began manufacturing motorcycles at its Suzuki factory in 1960 Honda launched its first sports car the S500 in Japan and entered Formula-1 in 1964
In 1989 Soichiro Honda became the first Asian to be inducted into US Automotive Hall of Fame In 1990 Honda wins its fifth consecutive 1st ranking in the JD Power Consumer Satisfaction Index In 1993 founder Soichiro Honda passed away He dreamed of changing the way people looked at motorcycles and gave us machines that were powerful amp fun to ride SOICHIRO HONDArsquoS dreams changed the world of motorcycling
Geeta Institute Of Management amp Technology Page 7
Time Line of Honda and Its
History
Geeta Institute Of Management amp Technology Page 8
Geeta Institute Of Management amp Technology Page 9
Geeta Institute Of Management amp Technology Page 10
Geeta Institute Of Management amp Technology Page 11
And This Decadehelliphelliphelliphellip
2001 500 World Grand Prix Victories
2002 Race Debut of New 4 Stroke 5 Cylinder
Motorcycle (Called RC211V)
2003 Mazda RX First Hydrogen Engine Car Unveiled At
Tokyo Car Show
Honda Enters Indy Car Series
Wins 7th Consecutive Win At Suzuka 8 Hr Endurance Race
Market feasibility Study For Air Craft Engine Begins
2005 Asimo Inducted Into Hall of Fame
Geeta Institute Of Management amp Technology Page 12
12 Hondarsquos Products Around The World
Jet Engine
Geeta Institute Of Management amp Technology Page 13
Honda ndash At a Glance-
1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)
1048708 26th on global most admired
1048708 Capital - yen86 Billion (as of March31 2007)
1048708 Sales (Results of fiscal 2007)
1048708 Consolidated yen11087140 million
1048708 Unconsolidated yen4030881 million
1048708 405 subsidiaries (as of March31 2007)
1048708 Employees HONDA worldwide ndash
1048708 Consolidated 167231 (as of March31 2007)
1048708 Unconsolidated 26652 (as of March31 2007)
Honda Global Network
Six Regional Headquarters
North Central America South America
Afro-Europe
Asia amp Oceania
Japan
China
Geeta Institute Of Management amp Technology Page 14
2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)
Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in
Geeta Institute Of Management amp Technology Page 15
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Then he thought of making high capacity motorcycles and taking them to racing So his company made bigger and faster machines two- four- and five- and six-cylinder race bikes and participated in the Isle of Man TT race (125 cc motorcycle classes)
He wanted to share his new motorcycles with the world and therefore he opened American Honda Motor Co in Los Angeles Also Honda began manufacturing motorcycles at its Suzuki factory in 1960 Honda launched its first sports car the S500 in Japan and entered Formula-1 in 1964
In 1989 Soichiro Honda became the first Asian to be inducted into US Automotive Hall of Fame In 1990 Honda wins its fifth consecutive 1st ranking in the JD Power Consumer Satisfaction Index In 1993 founder Soichiro Honda passed away He dreamed of changing the way people looked at motorcycles and gave us machines that were powerful amp fun to ride SOICHIRO HONDArsquoS dreams changed the world of motorcycling
Geeta Institute Of Management amp Technology Page 7
Time Line of Honda and Its
History
Geeta Institute Of Management amp Technology Page 8
Geeta Institute Of Management amp Technology Page 9
Geeta Institute Of Management amp Technology Page 10
Geeta Institute Of Management amp Technology Page 11
And This Decadehelliphelliphelliphellip
2001 500 World Grand Prix Victories
2002 Race Debut of New 4 Stroke 5 Cylinder
Motorcycle (Called RC211V)
2003 Mazda RX First Hydrogen Engine Car Unveiled At
Tokyo Car Show
Honda Enters Indy Car Series
Wins 7th Consecutive Win At Suzuka 8 Hr Endurance Race
Market feasibility Study For Air Craft Engine Begins
2005 Asimo Inducted Into Hall of Fame
Geeta Institute Of Management amp Technology Page 12
12 Hondarsquos Products Around The World
Jet Engine
Geeta Institute Of Management amp Technology Page 13
Honda ndash At a Glance-
1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)
1048708 26th on global most admired
1048708 Capital - yen86 Billion (as of March31 2007)
1048708 Sales (Results of fiscal 2007)
1048708 Consolidated yen11087140 million
1048708 Unconsolidated yen4030881 million
1048708 405 subsidiaries (as of March31 2007)
1048708 Employees HONDA worldwide ndash
1048708 Consolidated 167231 (as of March31 2007)
1048708 Unconsolidated 26652 (as of March31 2007)
Honda Global Network
Six Regional Headquarters
North Central America South America
Afro-Europe
Asia amp Oceania
Japan
China
Geeta Institute Of Management amp Technology Page 14
2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)
Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in
Geeta Institute Of Management amp Technology Page 15
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Time Line of Honda and Its
History
Geeta Institute Of Management amp Technology Page 8
Geeta Institute Of Management amp Technology Page 9
Geeta Institute Of Management amp Technology Page 10
Geeta Institute Of Management amp Technology Page 11
And This Decadehelliphelliphelliphellip
2001 500 World Grand Prix Victories
2002 Race Debut of New 4 Stroke 5 Cylinder
Motorcycle (Called RC211V)
2003 Mazda RX First Hydrogen Engine Car Unveiled At
Tokyo Car Show
Honda Enters Indy Car Series
Wins 7th Consecutive Win At Suzuka 8 Hr Endurance Race
Market feasibility Study For Air Craft Engine Begins
2005 Asimo Inducted Into Hall of Fame
Geeta Institute Of Management amp Technology Page 12
12 Hondarsquos Products Around The World
Jet Engine
Geeta Institute Of Management amp Technology Page 13
Honda ndash At a Glance-
1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)
1048708 26th on global most admired
1048708 Capital - yen86 Billion (as of March31 2007)
1048708 Sales (Results of fiscal 2007)
1048708 Consolidated yen11087140 million
1048708 Unconsolidated yen4030881 million
1048708 405 subsidiaries (as of March31 2007)
1048708 Employees HONDA worldwide ndash
1048708 Consolidated 167231 (as of March31 2007)
1048708 Unconsolidated 26652 (as of March31 2007)
Honda Global Network
Six Regional Headquarters
North Central America South America
Afro-Europe
Asia amp Oceania
Japan
China
Geeta Institute Of Management amp Technology Page 14
2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)
Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in
Geeta Institute Of Management amp Technology Page 15
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Geeta Institute Of Management amp Technology Page 9
Geeta Institute Of Management amp Technology Page 10
Geeta Institute Of Management amp Technology Page 11
And This Decadehelliphelliphelliphellip
2001 500 World Grand Prix Victories
2002 Race Debut of New 4 Stroke 5 Cylinder
Motorcycle (Called RC211V)
2003 Mazda RX First Hydrogen Engine Car Unveiled At
Tokyo Car Show
Honda Enters Indy Car Series
Wins 7th Consecutive Win At Suzuka 8 Hr Endurance Race
Market feasibility Study For Air Craft Engine Begins
2005 Asimo Inducted Into Hall of Fame
Geeta Institute Of Management amp Technology Page 12
12 Hondarsquos Products Around The World
Jet Engine
Geeta Institute Of Management amp Technology Page 13
Honda ndash At a Glance-
1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)
1048708 26th on global most admired
1048708 Capital - yen86 Billion (as of March31 2007)
1048708 Sales (Results of fiscal 2007)
1048708 Consolidated yen11087140 million
1048708 Unconsolidated yen4030881 million
1048708 405 subsidiaries (as of March31 2007)
1048708 Employees HONDA worldwide ndash
1048708 Consolidated 167231 (as of March31 2007)
1048708 Unconsolidated 26652 (as of March31 2007)
Honda Global Network
Six Regional Headquarters
North Central America South America
Afro-Europe
Asia amp Oceania
Japan
China
Geeta Institute Of Management amp Technology Page 14
2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)
Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in
Geeta Institute Of Management amp Technology Page 15
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Geeta Institute Of Management amp Technology Page 10
Geeta Institute Of Management amp Technology Page 11
And This Decadehelliphelliphelliphellip
2001 500 World Grand Prix Victories
2002 Race Debut of New 4 Stroke 5 Cylinder
Motorcycle (Called RC211V)
2003 Mazda RX First Hydrogen Engine Car Unveiled At
Tokyo Car Show
Honda Enters Indy Car Series
Wins 7th Consecutive Win At Suzuka 8 Hr Endurance Race
Market feasibility Study For Air Craft Engine Begins
2005 Asimo Inducted Into Hall of Fame
Geeta Institute Of Management amp Technology Page 12
12 Hondarsquos Products Around The World
Jet Engine
Geeta Institute Of Management amp Technology Page 13
Honda ndash At a Glance-
1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)
1048708 26th on global most admired
1048708 Capital - yen86 Billion (as of March31 2007)
1048708 Sales (Results of fiscal 2007)
1048708 Consolidated yen11087140 million
1048708 Unconsolidated yen4030881 million
1048708 405 subsidiaries (as of March31 2007)
1048708 Employees HONDA worldwide ndash
1048708 Consolidated 167231 (as of March31 2007)
1048708 Unconsolidated 26652 (as of March31 2007)
Honda Global Network
Six Regional Headquarters
North Central America South America
Afro-Europe
Asia amp Oceania
Japan
China
Geeta Institute Of Management amp Technology Page 14
2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)
Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in
Geeta Institute Of Management amp Technology Page 15
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Geeta Institute Of Management amp Technology Page 11
And This Decadehelliphelliphelliphellip
2001 500 World Grand Prix Victories
2002 Race Debut of New 4 Stroke 5 Cylinder
Motorcycle (Called RC211V)
2003 Mazda RX First Hydrogen Engine Car Unveiled At
Tokyo Car Show
Honda Enters Indy Car Series
Wins 7th Consecutive Win At Suzuka 8 Hr Endurance Race
Market feasibility Study For Air Craft Engine Begins
2005 Asimo Inducted Into Hall of Fame
Geeta Institute Of Management amp Technology Page 12
12 Hondarsquos Products Around The World
Jet Engine
Geeta Institute Of Management amp Technology Page 13
Honda ndash At a Glance-
1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)
1048708 26th on global most admired
1048708 Capital - yen86 Billion (as of March31 2007)
1048708 Sales (Results of fiscal 2007)
1048708 Consolidated yen11087140 million
1048708 Unconsolidated yen4030881 million
1048708 405 subsidiaries (as of March31 2007)
1048708 Employees HONDA worldwide ndash
1048708 Consolidated 167231 (as of March31 2007)
1048708 Unconsolidated 26652 (as of March31 2007)
Honda Global Network
Six Regional Headquarters
North Central America South America
Afro-Europe
Asia amp Oceania
Japan
China
Geeta Institute Of Management amp Technology Page 14
2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)
Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in
Geeta Institute Of Management amp Technology Page 15
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
And This Decadehelliphelliphelliphellip
2001 500 World Grand Prix Victories
2002 Race Debut of New 4 Stroke 5 Cylinder
Motorcycle (Called RC211V)
2003 Mazda RX First Hydrogen Engine Car Unveiled At
Tokyo Car Show
Honda Enters Indy Car Series
Wins 7th Consecutive Win At Suzuka 8 Hr Endurance Race
Market feasibility Study For Air Craft Engine Begins
2005 Asimo Inducted Into Hall of Fame
Geeta Institute Of Management amp Technology Page 12
12 Hondarsquos Products Around The World
Jet Engine
Geeta Institute Of Management amp Technology Page 13
Honda ndash At a Glance-
1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)
1048708 26th on global most admired
1048708 Capital - yen86 Billion (as of March31 2007)
1048708 Sales (Results of fiscal 2007)
1048708 Consolidated yen11087140 million
1048708 Unconsolidated yen4030881 million
1048708 405 subsidiaries (as of March31 2007)
1048708 Employees HONDA worldwide ndash
1048708 Consolidated 167231 (as of March31 2007)
1048708 Unconsolidated 26652 (as of March31 2007)
Honda Global Network
Six Regional Headquarters
North Central America South America
Afro-Europe
Asia amp Oceania
Japan
China
Geeta Institute Of Management amp Technology Page 14
2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)
Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in
Geeta Institute Of Management amp Technology Page 15
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
12 Hondarsquos Products Around The World
Jet Engine
Geeta Institute Of Management amp Technology Page 13
Honda ndash At a Glance-
1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)
1048708 26th on global most admired
1048708 Capital - yen86 Billion (as of March31 2007)
1048708 Sales (Results of fiscal 2007)
1048708 Consolidated yen11087140 million
1048708 Unconsolidated yen4030881 million
1048708 405 subsidiaries (as of March31 2007)
1048708 Employees HONDA worldwide ndash
1048708 Consolidated 167231 (as of March31 2007)
1048708 Unconsolidated 26652 (as of March31 2007)
Honda Global Network
Six Regional Headquarters
North Central America South America
Afro-Europe
Asia amp Oceania
Japan
China
Geeta Institute Of Management amp Technology Page 14
2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)
Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in
Geeta Institute Of Management amp Technology Page 15
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Honda ndash At a Glance-
1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)
1048708 26th on global most admired
1048708 Capital - yen86 Billion (as of March31 2007)
1048708 Sales (Results of fiscal 2007)
1048708 Consolidated yen11087140 million
1048708 Unconsolidated yen4030881 million
1048708 405 subsidiaries (as of March31 2007)
1048708 Employees HONDA worldwide ndash
1048708 Consolidated 167231 (as of March31 2007)
1048708 Unconsolidated 26652 (as of March31 2007)
Honda Global Network
Six Regional Headquarters
North Central America South America
Afro-Europe
Asia amp Oceania
Japan
China
Geeta Institute Of Management amp Technology Page 14
2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)
Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in
Geeta Institute Of Management amp Technology Page 15
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)
Honda Motorcycle amp Scooter India Pvt Ltd (HMSI) a wholly owned subsidiary of Honda Motor Company Ltd was incorporated on 20th August1999 to manufacture two wheelers in India Itrsquos Symbol ldquoWingsrdquo is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in
Geeta Institute Of Management amp Technology Page 15
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
the lifestyle of the people of India It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international standards Hondarsquos commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions Ever since its establishment in 1999
HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people In a
short span of Eight years HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India While endeavoring to meet and exceed the expectations of the customers the critical importance of providing the product technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow
process in plant It is believed at HMSI that by meeting these
expectations HMSI will enhance the quality of life through products and services that reflect the spirit of today Bringing joy to people and contributing to social development will continue to be the principles
that will guide HMSI in future It came into mass production with Honda Activa in 2001 Since then the company has continued to grow in the Indian market along with regularly providing world class advanced and technically sound products Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister Dio Aviator Unicorn Shine Dazzler and Stunner Apart from outstanding sales Honda also caters its customers with excellent service and spare parts support The
Geeta Institute Of Management amp Technology Page 16
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
HMSI factory is spread over 52 acres with a covered area of about 85815 square meters at Manesar Gurgaon district of Haryana The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001 The initial installed capacity was 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores and now the accumulated investment is 800crores
HMSI mainly deals with-
Manufacturing and sales of two wheelers Manufacturing and sales of two wheeler engines Service and sales of spare parts and accessories Export of Honda products (CBU Engine amp Parts)
Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -
1 Registered office - Plot No 1 Sector 3 IMT Manesar
Dist ndash Gurgaon
2 Incorporation - August 20th 1999
3 Equity capital- Rs 300crores (Approx7500 million yen)
4 Area- Land area 210000 sq m
Geeta Institute Of Management amp Technology Page 17
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Covered area 85815 sq m (41 )
5 Employees- 3821 Associates ndash Japanese 15
6 Product- Scooters ndash Activa Dio Aviator
Motorcycle- Unicorn hine Stunner Twister Dazzler
7 Plant capacity- 1000000 CBUrsquos per annum
SC ndash 600000 MC ndash400000
8 Logo- WINGS
9 Directors - Mr Shinji Aoyama President amp CEO
Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)
Mr H Iwakami ( Dir ) Mr M Kato ( Dir )
Mr T Oyama ( ASH ) Mr MTakedagawa
(HSCI) Mr K Nakazono ( HM-J )
Special features-
1048708 ISO 9001 2000 and 14001 Certified
1048708 ARAI Emission Lab Pune Certified
Society Friendly Organization
1048708 Worldrsquos No1 in Engine designing
Geeta Institute Of Management amp Technology Page 18
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
3 PLANT OVERVIEW
Area 210000 sq m
Production155 million unitsyear
Location IMT Manesar
Incorporation 1999
Employees 6500
Geeta Institute Of Management amp Technology Page 19
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
PLANT LAYOUT
HMSI deals with the both the products in the two-
wheeler segment In this plant there are two sections one
is scooter plant and other is motorcycle plant In scooter
plant all the models Activa Dio Aviator Lead and
Beat are being made In Motorcycle plant Unicorn
Shine and Stunner Aviator are being made
Geeta Institute Of Management amp Technology Page 20
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
4 FLOW CHART
Geeta Institute Of Management amp Technology Page 21
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Geeta Institute Of Management amp Technology Page 22
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
5PRODUCT
Geeta Institute Of Management amp Technology Page 23
ActivaActiva 2001-02
DIODIO 2002-03
New UnicornNew Unicorn2004-05
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Geeta Institute Of Management amp Technology Page 24
ShineShine 2005-06
StunnerStunner 2005-06
AviatorAviator 2008
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
HONDA PHILOSPHY
Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world
Geeta Institute Of Management amp Technology Page 25
Company
Principle
Company
Principle
THE THREE JOYSTHE THREE JOYS
RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL
HONDA PHILOSOPHY
Management Policies
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
It provides every Honda associate around the world with a vision
It tells us the values of our business It bonds everyone together towards a common mission It provides a constant standard for correct action and ethical behavior It shows the link between the companyrsquos past present and future It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness
COMPANY VISION-
Maintaining a global viewpoint they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction
Geeta Institute Of Management amp Technology Page 26
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
OUR FUNDAMENTAL BELIEFS-
Respect for the individual The three joys
Geeta Institute Of Management amp Technology Page 27
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Geeta Institute Of Management amp Technology Page 28
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
The Human Being is born as a free and unique individual with the capacity to think reason and create ---- and the ability to dream Respect for the individual calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners
Respect for the Individual recognizes the following core concepts
Initiative Initiative means not to be bound by preconceived ideas but think creatively and act on your own initiative and judgment while understanding that you must take responsibility for the results of those actions
Equality Equality means to recognize and respect individual differences in one another and treat each other fairly Our company is committed to this principle and creating equal opportunities for each individual An individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos opportunities
Trust The relationship among associates at Honda should be based on mutual trust Trust is created by recognizing each other as individuals helping out where others are deficient accepting help where we are deficient sharing our knowledge and making a sincere effort to fulfill our responsibilities
Honda is comprised of individuals working together for a common purpose Each individual acting appropriately within his or her role
Geeta Institute Of Management amp Technology Page 29
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
must translate the philosophy into actions It is this contribution from each associate that contributes to the companyrsquos success And every associate should be honored for these efforts
THE THREE JOYS
Our goal is to provide Joy through our business for those who buy our products (The Joy of Buying) engage in selling our products and services (The Joy of Selling) and are involved in business of creating our products (The Joy of Creating)
The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer The Joy of Buying is essentially the establishment of a relationship with the customer initiated through the products and continued through the sales and service experience Importantly the Joy of Selling and the Joy of Creating cannot be achieved without first bringing joy to the customer
The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a
Geeta Institute Of Management amp Technology Page 30
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
customer based on mutual trust Through this relationship Honda associates dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer
The Joy of Creating occurs when Honda associates and suppliers involved in the design development engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers Formerly known as the Joy of Producing the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
Geeta Institute Of Management amp Technology Page 31
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
THE HONDA COMPANY PRINCIPLE-
Maintaining a global view point we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction
HONDA MANAGEMENT POLICIES-
Proceed always with ambition and youthfulness Respect sound theories develop fresh ideas and make the
effective use of time
Geeta Institute Of Management amp Technology Page 32
The Joy of SellingThe Joy of Selling
The Joy of BuyingThe Joy of Buying
The Joy of CreatingThe Joy of Creating
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Enjoy your work and encourage open communications
Strive constantly for a harmonious flow of work
Be ever mindful of the value of research and endeavor
HONDArsquoS CORPORATE CULTURE-
Free thinking amp open mindedness Challenging spirit Sincerity amp Integrity Co-evolution
JAPANESE WORK CULTURE
A typical Japanese office is an open space with an over-crowding of desks or very little private work space There are very few private offices An Employee for Life
Other-centered work centered long term relationships How work is done often matters more than what is accomplished Honda Motor Co Ltd announced specific plans and initiatives in the following three areas which will enable Honda to accelerate its efforts to strengthen Honda ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth
Geeta Institute Of Management amp Technology Page 33
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON
PHILOSPHY WITHOUT ACTION IS WORTHLESS
SOICHIRO HONDA
HMSI Plant Facilities
Few of the In-House Facilities
High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting
Gravity Die-Casting amp Low pressure Die Casting Sections are for manufacturing critical engine parts
Geeta Institute Of Management amp Technology Page 34
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Welding Robots
Weld Shop has spot welding seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels
Paint Shop Robots
Paint Shop has a conveyor system which is unique amongst all Honda Factories in the world The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion high gloss and superior paint finish Robots are used in painting for improved paint finish
Geeta Institute Of Management amp Technology Page 35
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Engine Assembly
Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust Each of the engines is then inspected for various parameters
Frame Assembly
Frame Assembly is done at the slat conveyor After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch
Geeta Institute Of Management amp Technology Page 36
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Geeta Institute Of Management amp Technology Page 37
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
5ORGANISATION STRUCTURE
Geeta Institute Of Management amp Technology Page 38
President and CEO
Sr VP
PurchaseGeneral Affairs
Manufacturing
Sales amp Marketing
Finance amp Account
Engg Engine Mfg
Assembly
PPC Frame Mfg
Quality
Press Shop
Weld Shop
Paint ShopMaintenance
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
6 Introduction to PAINT Department
Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market
Paint
There are four shape in paint section two are in scooter plant and two are in motorcycle plant
Paint shop
Paint 1 paint2 paint 3 paint 4
Geeta Institute Of Management amp Technology Page 39
Scooter plant Motorcycle plant
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Frame Maintenance- In this department there are three sections
1 Press Section
2 Weld Section
3 Paint Section
PRESS SECTION- Press section has mainly four machines
Komatsu Pressndash3
AIDA Press -1
CNC bending machine
Hind Press
These presses are mechanical presses and on this press mudguard fuel tank nose and body cover of the scooters like activa aviator dio shine twister unicorn and twister Process like blanking coining and bending of pipes is done
Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation
Coining is the process of removal of extra material or to make work piece up to the limit All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes
CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame
Geeta Institute Of Management amp Technology Page 40
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
WELDING SECTION In welding section there are six types of welding machines used in manufacturing of frames and body covers
1 Gantry System Gantry system is a system in which gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer
2 MIG Welding Metal inert gas welding in this inert gas argon is used and argon acts as a shielding gas 1-5 oxygen is used This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool MIG welding has some advantages over the other welding techniques It provides a uniform weld it provides a slag free weld beam and needs little clean up
3 Spot Welding Spot welding is a process in which contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter
4 Seam Welding It is a process that welds at a surface of overlapped parts along a length of a joint Weld made by overlapping nuggets this type of welding is done on the fuel tanks and mudguards of scooter
5 Portable Spot Welding It is a portable gun which can be taken to specified range where other spot welding machine faces difficulty in welding This type of the welding is done on body covers of scooters
Geeta Institute Of Management amp Technology Page 41
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
6 Fine Boring Fine boring is done on the frame where handle has to fit after fine boring handle is attached to it
When various operation of the welding on the different components of the scooter that is frame mudguard body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1 one for model 2 and the last for model 3 When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area From storage area hangers move to the unloading area and from unloading area these body covers and frames are loaded on to a Carrier which takes them to the paint section Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement unloading of model frames and body covers is done Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area Similarly when there is requirement of model 2 then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3 the operator presses the model 3 switch and then from storage model 3 moves to unloading bay
Geeta Institute Of Management amp Technology Page 42
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Paint shop layout
Geeta Institute Of Management amp Technology Page 43
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
PAINT SECTION Paint section is very important section In this section different treatments are done on the body covers and frames and it is a step by step process done as follows
Loading
Pre-Treatment
Electro-Deposition
ED Oven
Booth
Top Coat Oven
Inspection Zone
Unloading
Geeta Institute Of Management amp Technology Page 44
1 Sanding Zone
2 Under Coat
3 Top Coat
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
PAINT PROCESS FLOW
Loading In this process frames and body covers are mounted on the carrier of the conveyor line There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone
Geeta Institute Of Management amp Technology Page 45
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Pre-Treatment In pre-treatment degreasing and dust cleaning is done In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers In general first we get hard water is converted to soft water by ion exchange mechanism
Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed
The various processes take place in
PRETRETMENT PROCESS
Geeta Institute Of Management amp Technology Page 46
WR - 1 (Raw Water)
Surface Conditioning
Degreasing
WR - 6 (DI Water)
WR - 3 (Raw Water)
WR - 2 (Raw Water)
WR - 5 (DI Water)
WR - 4
(DI Water)
PhosphatingED Process
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Pretreatment
1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius
2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used
3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used
4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius
5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used
PT Spray
Geeta Institute Of Management amp Technology Page 47
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
SrNo
1
2
Booth Water Pit Detail
Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965
Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2
Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A
Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA
Flow rate ETP 2m3 Hour
Surface Conditioning
Phosphate
Stage
3
Degreasing
Nipacel 4704
Nipaphos 3150 R
Neutraliser 4055
Chemical Used
Nipaklin 364 S
Nipafin GN ZS
Water rinse-1
Degressing Tank
Body
Water rinse-2
water rinse-3
Surface Cond
Phosphat tank
water rinse-4
water rinse-5
water rinse-6
PT Process Spray Zone
To Drain ETPTo ETP
1
2
3
4
5
1
2
5
3
4
A line booth circulation pump-1
A line booth circulation pump-2
B line booth circulation pump-2
B line booth circulation pump-1
Sludrer feed Pump
6200
5965
5400
1700
Water level
PIT SKETCH
Geeta Institute Of Management amp Technology Page 48
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
PT Testing
Electro-Deposition process In electro deposition carrier which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base paint is deposited on the body covers and frames of the scooter This process is repeated twice and after that it is passed to ED oven
1 Predip tank
This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank
2 Electro Deposition tank
Geeta Institute Of Management amp Technology Page 49
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage
3 Ultra filteration1amp2
This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used
4 Ultra filtration 3
In this also extra ED is removed but this is removed by dip the body
ED Oven In electro deposition oven base coat done on the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth
Geeta Institute Of Management amp Technology Page 50
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Paint Booth Paint booth has three sections first one is sanding zone second primary coat or under coat and third is top coat
In sanding zone sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven
Geeta Institute Of Management amp Technology Page 51
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
PAINT BOOTH PROCESS
SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean
PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting
BASE COAT- This area define the color of the body part which we are required
TOP COAT- To the give the clear coat shining etc
Painting Process
Geeta Institute Of Management amp Technology Page 52
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Top Coat Oven In top coat oven these frames and body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room temperature and from there it is sent to the inspection
Inspection-
In inspection zone body covers and frames have to pass infra-red zone Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs Parts which pass these tests get the OK mark and move to unloading area
Unloading -
In this area unloading of frames and body covers takes place Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have They are then unloaded and then
Geeta Institute Of Management amp Technology Page 53
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
loaded on to the hanger and the parts go to the paint body storage In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line
ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture
Geeta Institute Of Management amp Technology Page 54
SECO
NDA
RY
DUAL TUBE SETTLER
p
p
TO TREATED WATER TANK
p
Na CaC POL
SLUDGE p
AIR
CAPACITY - 4000 Liter Hour
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
PROJECT
Identification Of The Causes Of Body Cover Scratches Generation Point
1- Before Inspection (A Line Or B Line Or Both)
Causes-
A- Jig loose or bendB- Damage carrier on which body cover fitted
Geeta Institute Of Management amp Technology Page 55
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Loose carrier with bodycover
2- Time of Unloading (from carriers)
Causes
A- Damage trolleys on which body cover placed
Geeta Institute Of Management amp Technology Page 56
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
B- Unskilled workers(Rough way of unloading resulting into scratches)
Geeta Institute Of Management amp Technology Page 57
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
3- PBS (paint body storage) area
Causes-
A- Unskilled workers (rough way of loading on hangers)
Geeta Institute Of Management amp Technology Page 58
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
C- Collision between two hangers or more
Geeta Institute Of Management amp Technology Page 59
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Scratch on bodycover(BDC)
Geeta Institute Of Management amp Technology Page 60
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
4- Attachment removal area
Causes-
A- Improper way of placing BDC for attachment removal
Geeta Institute Of Management amp Technology Page 61
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Geeta Institute Of Management amp Technology Page 62
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
5- Gun slips during attachment removal
Geeta Institute Of Management amp Technology Page 63
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
5- Touch-up area (Stock area)
Causes-
A- Rough condition of floor on which body cover placed
Geeta Institute Of Management amp Technology Page 64
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Scratches on BDC
Geeta Institute Of Management amp Technology Page 65
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
Conclusion
From my project of one month here in HMSI I came to know that how
work goes on in the organization As far as my project of study Causes
Of Body Cover Scratches I came to know the importance of paint shop and
the production problems caused by the paint in the industry
Geeta Institute Of Management amp Technology Page 66
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-
BIBLIOGRAPHY
Website
wwwHonda2wheelersindiacom
References
MrDavinder deswal Mr Varun Chawla Mr bhosle San
Sources
Workshop of HMSI
Paint Department of HMSI
Geeta Institute Of Management amp Technology Page 67
- EXECUTIVE SUMMARY
- 12 Hondarsquos Products Around The World
-