PROJECT REPORT ON

India Yamaha Motor Pvt.Ltd.

SUBMITTED BYHASAN RAJABBA 1ST YEAR

SESSION: 2011-2012SHARDA UNIVERSITPREFACEAs a part of course curriculum of Bachelor of Technology we wereasked to undergo 6 weeks summer training in any organisation soas to give us exposure to practical skill and competence to get usfamiliar with various activities taking place in the organisation.I have put my sincere efforts to accomplish my objectives withinthe stipulated time. I have worked to my optimum potential toachieve desired goals. Being neophytes in the highly competitiveworld of technology, I came across some difficulties to make myobjective a reality. With the kind help and genuine interest and theguidance of my supervisor. I tried my level best to conduct aresearch to gain a thorough knowledge about the project. I put thebest of my efforts to bring out this piece of work. If anywhere

something is found unacceptable or unnecessary to the theme;valuable suggestions are thankfully acknowledged.ACKNOWLEDGEMENTI would like to express my gratitude to all the people who providedme with support and guidance throughout the project On preparing report on Yamaha pvt.motor ltd.Firstly I wish to thank Miss.Snober fazal mam.for giving me anopportunity to present report on YAMAHA MOTOR Pvt. Ltd. I am also deeply indebtedto Mr. kuldeep miglani Head production manager in Yamaha india pvt. LTD. Greater noida without thesupervision and continued guidance of whom it wouldn’t have beenpossible to complete this project.

I would also like to thank sharda university for providing me thiswonderful opportunity.(HASAN RAJA)

CONTENTSChapter 1 – Introduction1.1. Overview of Industry as a whole1.2. History of the Organisation1.3. Company ProfileChapter 2 - Manufacturing2.1. Casting & its types2.2. Furnace & its Components2.3. Casting defectsChapter 3 – Gear Hobbing3.1. Overview of Instruments & Gear Data3.2. Construction of Machines under Gear Hobbing3.3. Process – Bush PressingChapter 4 – Cam ShaftChapter 5 – Heat Treatment5.1. Basics of Heat Treating5.2. General Application DefinitionsChapter 6 – Electroplating6.1. Copper Electroplating6.2. Cyanide Baths6.3. FAQ- Electroplating-How does it work?

CHAPTER 1 – INTRODUCTION1.1. OVERVIEW - INDIAN AUTOMOBILE INDUSTRYOver a period of more than two decades the Indian Automobileindustry has been driving its own growth through phases. The entryof Suzuki Corporation in Indian passenger car manufacturing isoften pointed as the first sign of India turning to a marketeconomy. Since then the automobile sector witnessed rapid growthyear after year. By late-90's the industry reached self reliance inengine and component manufacturing from the status of largescale importer.With comparatively higher rate of economic growth rate indexagainst that of great global powers, India has become a hub of

domestic and exports business. The automobile sector has beencontributing its share to the shining economic performance of Indiain the recent years.With the Indian middle class earning higher per capita income, morepeople are ready to own private vehicles including cars and two-wheelers. Product movements and manned services have boosted inthe sales of medium and sized commercial vehicles for passenger andgoods transport. Side by side with fresh vehicle sales growth, theautomotive components sector has witnessed big growth. The domesticauto components consumption has crossed rupees 9000 crores and anexport of one half size of this figureOverview Of Automobile IndustryThe Indian automobile industry is going through a technologicalchange where each firm is engaged in changing its processes andtechnologies to sustain the competitive advantage and provide

customers with the optimized products and services. Starting fromthe two wheelers, trucks, and tractors to the multi utility vehicles,commercial vehicles and the luxury vehicles, the Indian automobileindustry has achieved tremendous amount of success in the recentyears.As per Society of Indian Automobile Manufacturers (SIAM) themarket share of each segment of the industry is as follows:The market shares of the segments of the automobileindustryThe automobile industry had a growth of 15.4 % during April-January2007, with the average annual growth of 10-15% over the lastdecade or so. With the incremental investment of $35-40 billion, thegrowth is expected to double in the next 10 years.Consistent growth and dedication have made the Indian automobile

industry the second- largest tractor and two-wheeler manufacturerin the world. It is also the fifth-largest commercial vehiclemanufacturer in the world. The Indian automobile market is amongthe largest in Asia.The key players like Hindustan Motors, Maruti Udyog, Fiat IndiaPrivate Ltd, Tata Motors, Bajaj Motors, Hero Motors, Ashok Leyland,Mahindra & Mahindra have been dominating the vehicle industry. Afew of the foreign players like Toyota Kirloskar Motor Ltd., SkodaIndia Private Ltd., Honda Siel Cars India Ltd. have also entered themarket and have catered to the customers’ needs to a largeextent.Not only the Indian companies but also the international carmanufacturing companies are focusing on compact cars to bedelivered in the Indian market at a much smaller price. Moreover,

the automobile companies are coming up with financial schemessuch as easy EMI repayment systems to boost sales.There have been exhibitions like Auto-expo at Pragati Maidan, NewDelhi to share the technological advancements. Besides, there aremany new projects coming up in the automobile industry leading tothe growth of the sector.The Government of India has liberalized the foreign exchange andequity regulations and has also reduced the tariff on imports,contributing significantly to the growth of the sector. Having firmlyestablished its presence in the domestic markets, the Indianautomobile sector is now penetrating the international arena.Vehicle exports from India are at their highest levels. The leadersof the Indian automobile sector, such as Tata Motors, Maruti andMahindra and Mahindra are leading the exports to Europe, Middle

East and African and Asian markets.The Ministry of Heavy Industries has released the Automotive Plan2006-2016, with the motive of making India the most popularmanufacturing hub for automobiles and its components in Asia. Theplan focuses on the removal of all the bottlenecks that areinhibiting its growth in the domestic as well as international arena.Top Ten Players in Indian Automobile SectorThe domestic players as well as the foreign players dominate the Indian automobilesector. The key players contributing to the growth of the sector are discussed below.Top Ten Players in Indian Automobile SectorMaruti Suzuki IndiaHero Motors LimitedTata GroupBajaj Auto LimitedMahindra GroupAshok LeylandYamaha Motor IndiaHyundai Motors India Limited

Toyota Kirloskar Motor Private LimitedHonda Motor India Private Ltd.

1.2. History of the OrganizationHISTORY------------------------------------------------------------------------------------------Yamaha's history goes back over a hundred years to 1887 whenTorakusu Yamaha founded the company, which began producingreed organs. The Yamaha Corporation in Japan (then Nippon GakkiCo., Ltd.) has grown to become the world's largest manufacturer of

a full line of musical instruments, and a leading producer ofaudio/visual products, semiconductors and other computer relatedproducts, sporting goods, home appliances and furniture, specialtymetals, machine tools, and industrial robots.The Yamaha Motor Corporation, Ltd., begun on July 1, 1955, is amajor part of the entire Yamaha group, but is a separatelymanaged business entity from the Yamaha Corporation. TheYamaha Motor Corporation is the second largest manufacturer ofmotorcycles in the world. Yamaha Motor Corporation owns itswholly-owned subsidiary in the U.S. called Yamaha MotorCorporation, USA, that is handling not only motorcycles, but alsosnow mobiles, golf carts, outboard engines, and water vehicles,under the brand name of Yamaha as well.In 1954 production of the first motorcycles began, a simple 125cc

single-cylinder two-stroke. It was a copy of the German DKWdesign, which the British BSA Company had also copied in thepost-war era and manufactured as the Bantam.The first Yamaha, the YAI, known to Japanese enthusiasts asAkatombo, the "Red Dragonfly", established a reputation as a wellbuiltand reliable machine. Racing successes helped boost itspopularity and a second machine, the 175cc YCI was soon inproduction.The first Yamaha-designed motorcycle was the twin-cylinder YDIproduced in 1957. The racing version, producing 20bhp, won theMount Asama race that year. Production was still modest at 15,811motorcycles, far less than Honda or Suzuki.The company grew rapidly over the next three years and in 1959introduced the first sports model to be offered by a Japanese

factory, the twin-cylinder YDSI with five-speed gearbox. Ownerswho wanted to compete in road racing or motocross could buy kitsto convert the machine for both road and motocross racing.By 1960 production had increased 600% to 138,000 motorcycles. InJapan a period of recession followed during which Yamaha, and theother major Japanese manufacturers, increased their exports so thatthey would not be so dependent on the home market.To help boost export sales, Yamaha sent a team to theEuropean Grand Prix in 1961, but it was not until the 1963 seasonthat results were achieved.After the Korean War the American economy was booming andJapanese exports were increasing. In 1962 Yamaha exported 12,000motorcycles. The next year it was 36,000 and in 1964 productionrose to 87,000.

In 1963 Yamaha had produced a small batch of 250CC roadracing motorcycles for sale, the air-cooled, twin-cylinder TDI. Eversince then Yamaha has built and sold motorcycles that could beraced successfully "straight out of the crate", and as aconsequence Yamaha machines have won more road races thanany other make, exposing Yamaha to a good deal of publicity.1965 244,000 By production was units, split about 50/50 betweenhome and export sales. One of the biggest drawbacks to the salesof two-strokes was that the rider had to mix oil with their gas.Yamaha technicians accomplished a major technical feat by thedevelopment and introduction of a new Autolube system.Basically an oil tank that fed lubricant to a pump that meteredoil to the big ends, main bearings and cylinder barrels. It proved

very reliable and did away with mixing oil and gas at every fill up.The first overseas factory was opened in Siam in 1966 to supplySoutheast Asia. In 1967 Yamaha production surpassed that of Suzukiby 4,000 at 406,000 units. Yamaha established a lead with theintroduction of the first true trail bike "the 250cc single-cylinderDTI". The company also developed a two-liter, six-cylinder, doubleoverhead-camshaft sports car unit for Toyota Motor. This provedhelpful when Yamaha produced their own high-performance fourstrokemotorcycles.In 1969 Yamaha built a full size road racingcircuit near their main factory at Iwata.By 1970 the number of models had expanded to 20 ranging from50cc to 350cc, with production up to 574,000 machines, 60% of whichwere for export. That year Yamaha broke their two-stroke traditionby launching their first four-stroke motorcycle, the 650cc XSI

vertical twin modeled on the famous Triumph twins.In 1973 production topped one million (1,000,000) motorcycles peryear for the first time, leaving Suzuki way behind at 642,000 andcatching up on Honda's 1,836,000. During the 1970's Yamahatechnicians concentrated on development of four-stroke modelsthat were designed to pass the ever-increasing exhaust emissionlaws and to be more economical than the two-strokes that hadmade Yamaha's fortune.Over the years Yamaha produced some less successfulmotorcycles:The TX750 twin of 1972.The TX500 double overhead-camshaft, four-valve per cylinder,twin of 1973.The XS750 shaft-drive, double overhead-camshaft, threecylinder of 1976.And the XS Eleven, four-cylinder of 1977, was at the time the

biggest bike produced by a Japanese manufacturer.Other four-strokes were more successful, notably.The XT500 single-cylinder trail bike of 1976.And the XS350 single overhead-camshaft, twin.In the 70's the RD twin cylinder sports models were a big successas well as the RD250LC and RD350LC water-cooled versions thatreplaced them in the eighties which were based on the famous TZrace bikes.Production in 1980 was 2,214,000, with export sales of 1,383,000. Inthe 1980's the company introduced the compact XJ four cylindermodels, ranging from 550cc to 1100cc. Not wanting to miss anythingthe company also introduced the 750cc and 1000cc air-cooled Vtwinmodels followed by the XZ550 water-cooled, mid-weight sportsbike.Yamaha motor vehicles:Two wheelers

Yamaha VmaxYamaha TmaxUtility vehiclesYamaha-G16-UltimaYamaha Rhino700FI Auto4x4Yamaha YFZ450R ATVYamaha SnowmobileWatercraftYamaha Waverunner…

1.3. COMPANY PROFILECORPORATEINFORMATION---------------------------------------About India Yamaha Motor Pvt. Ltd.Yamaha made its initial foray into India in 1985. Subsequently,it entered into a 50:50 joint-venture with the Escorts Group in1996. However , in August 2001, Yamaha acquired its remainingstake becoming a 100% subsidiary of Yamaha Motor Co. , Ltd,Japan (YMC) . In 2008, Mitsui & Co. , Ltd. entered into an

agreement with YMC to become a joint investor in themotorcycle manufacturing company "India Yamaha MotorPrivate Limited ( IYM)".IYM operates from its state-of-the-art-manufacturing units atSurajpur in Uttar Pradesh and Faridabad in Haryana andproduces motorcycles both for domestic and export markets.With a strong workforce of more than 2,000 employees, IYM ishighly customer-driven and has a countrywide network of over400 dealers . Presently , its product portfolio includes VMAX(1,679cc ) , MT 01 (1,670cc ) , YZF -R1 (998cc ) , Fazer (153cc ) , FZ -S(153cc ) , FZ 16 (153cc ) , YZF -R15 (150cc ) , Gladiator Type SS & RS(125cc ) , Gladiator Graffiti (125cc ) , G5 (106cc ) , Alba (106cc ) andCrux (106cc) .Bikes produced in India Yamaha Motor Pvt. Ltd. :Yamaha Vmax

Yamaha MT 01Yamaha YZF R1Yamaha R15Yamaha FazerYamaha FZ SYamaha FZ16Yamaha YBR 100Yamaha AlbaYamaha GladiatorYamaha G5Yamaha CruxVISION----------------------------------------------------------------------:We will establish YAMAHA as the "exclusive & trusted brand" of customers by"creating Kando" (touching their hearts) - the first time and every time with world classproducts & services delivered by people having "passion for customers".MISSION--------------------------------------------------------------------We are committed to:Be the Exclusive & Trusted Brand renowned for marketing and

manufacturing of YAMAHA products, focusing on serving ourcustomer where we can build long term relationships by raisingtheir lifestyle through performance excellence, proactive design &innovative technology. Our innovative solutions will always exceedthe changing needs of our customers and provide value addedvehicles.Build the Winning Team with capabilities for success, thriving in aclimate for action and delivering results. Our employees are themost valuable assets and we intend to develop them to achieveinternational level of professionalism with progressive careerdevelopment. As a good corporate citizen, we will conduct ourbusiness ethically and socially in a responsible manner withconcerns for the environment.Grow through continuously innovating our business processes for

creating value and knowledge across our customers thereby earningthe loyalty of our partners & increasing our stakeholder value.CORECOMPETENCIES-----------------------------------------------Customer #1We put customers first in everything we do. We take decisionskeeping the customer in mind.Challenging SpiritWe strive for excellence in everything we do and in the quality ofgoods & services we provide. We work hard to achieve what wecommit & achieve results faster than our competitors and we nevergive up.Team-workWe work cohesively with our colleagues as a multi-cultural teambuilt on trust, respect, understanding & mutual co-operation.Everyone's contribution is equally important for our success.Frank & Fair Organization

We are honest, sincere, open minded, fair & transparent in ourdealings. We actively listen to others and participate in healthy &frank discussions to achieve the organization's goals.CORPORATEPHILOSOPHY------------------------------------------------------Yamaha Motor is a company that has worked ever since itsfounding to build products defined by the concepts of “high-qualityand high-performance” and “light weight and compactness” as wehave continued to develop new technologies in the areas of smallengine technology and FRP processing technology as well as controland component technologies.It can also be said that our corporate history has taken a pathwhere “people” are the fundamental element and our productcreation and other corporate activities have always been aimed at

touching people’s hearts. Our goal has always been to provideproducts that empower each and every customer and make theirlives more fulfilling by offering greater speed, greater mobility andgreater potential.Said in another way, our aim is to bring people greater joy,happiness and create Kando* in their lives.As a company that makes the world its field and offers productsfor the land, the water, the snowfields and the sky, Yamaha Motorstrives to be a company that “offers new excitement and a morefulfilling life for people all over the world” and to use our ingenuityand passion to realize peoples’ dreams and always be the onesthey look to for “the next Kando.”What is Kando?Kando is a Japanese word for the simultaneous feeling of deepsatisfaction and intense excitement that people experience when theyencounter something of exceptional value.

CORPORATEGOVERNANCE----------------------------------------------------Basic Corporate Governance PoliciesYamaha Motor Co., Ltd. (the “Company”) recognizes that corporategovernance is an important tool to ensure disciplined managementand maximize long-term corporate value. Based on this realization,the Company has been striving to speed up management decision-making; make the accountability system clearer; develop atransparent system of director selection and remuneration; andestablish an internal control system. Because the Companyconsiders corporate governance one of its most importantmanagement issues, measures to further strengthen corporategovernance — such as improving supervisory functions — are beingplanned. At the same time, the Company will enhance Investor

Relations services, in order to build on the relationship of trust withits shareholders and investors.Organizations and Systems for Management Decision-Making, Business Execution and Supervision1) Directors and the Board of DirectorsThe Company has introduced an Executive Officer system toexpedite business execution. It then strengthened managementsupervision by clarifying the respective roles of Executive Officersand the Board of Directors. Executive Officers are responsible for“business execution” itself, while the Board of Directors is chargedwith “approving the basic policies of the Yamaha Motor Group andsupervising the Group’s business execution.”The Company’s Articles of Incorporation stipulate that the numberof Directors shall not be more than fifteen (15). As of March 25,2009, there were eleven (11) Directors, four (4) of whom are Outside

Directors. The Board of Directors will in principle meet once everymonth, and whenever else it may be necessary.The Articles also stipulate that the resolution for the election ofDirectors shall be adopted by a majority of the voting rights heldby the shareholders present at the General Meeting ofShareholders. These voting shareholders must hold sharesrepresenting, in the aggregate, not less than one-third (1/3) of thevoting rights of all shareholders entitled to exercise the rights.As of March 25, 2009, there were twenty-four (24) Executive Officers,and six (6) Directors concurrently serving as Executive Officers. AManagement Committee comprised of Executive Officers withspecific posts has been formed to deliberate matters of businessexecution, speeding up the Company’s decision-making process.

Directors and Executive Officers will serve one-year term, a periodlimited to assure accountability.2) Executive Personnel CommitteeIn August 2001, the Company established the Executive PersonnelCommittee as an advisory body of the Board of Directors, in orderto improve transparency in nominating candidates for Director andExecutive Officer, and to determine the remuneration for theseofficers. The Committee is comprised of President and ChiefExecutive Officer, some other Directors of the Company, and someOutside Directors. It deliberates on candidates for Director andExecutive Officer, the remuneration and bonus system and theoverall direction of governance.3) Corporate Auditors and the Board of Corporate AuditorsAs of March 25, 2009, the number of Corporate Auditors stood atfive (5), of whom three (3) are Outside Corporate Auditors. Corporate

Auditors attend Board of Directors, Management Committee andother important meetings, in addition to executing audits, receivingreports on the Directors’ business conduct, perusing importantdocuments in the decision-making process, and conducting auditsat the Company’s subsidiaries. In terms of their relationship withaccounting auditors, they review accounting audit reports to confirmtheirappropriateness pursuant to laws and ordinances, and coordinateexchanges of information and opinions with the accounting auditorswhenever necessary. Corporate Auditors also work with the InternalAuditing Division, receiving reports on internal audit planning andthe results of the internal audits, in order to enhance theeffectiveness and efficiency of their auditing.In order to support these audit services performed by Corporate

Auditors, the Company has established the Corporate Auditor’sOffice, with staff exclusively dedicated to assisting auditors.4) Internal AuditingThe Company established an Internal Control Auditing Division(consisting of twenty-four (24) staff members as of March 25, 2009),under the direct control of the President and Chief ExecutiveOfficer. The Division audit, based on annual audit plans, theappropriateness, reasonableness, and efficiency of businessexecution at the Company and each Group company, and submitsevaluations and makes proposals.5) Yamaha Motor’s Corporate Governance System and InternalControl System (As of March 25, 2010)CORPORATE SOCIALRESPONSIBILITY----------------------Through business activities founded on sound and music, theYamaha Group strives to achieve its corporate objective of

“Creating ‘Kando’* Together.” Since their establishment in 1887,theyhave endeavored to provide quality products and services,earningthe trust of customers while securing steadily rising profits.Continuing to fulfill their role as a member of society in this wayhas enabled them to earn and maintain the support of manystakeholders. Accordingly, Yamaha’s basic management policy placesa strong emphasis on Corporate Social Responsibility (CSR)activities, expressing this commitment through a variety of activitiesand themes including product quality, customer satisfaction,procurement, environmental protection and public relationsactivities.However, society today is experiencing rapid changes which areexacerbating various social problems, while expectations for thecorporations in its midst have also increased. This prompted

Yamaha in April 2008 to create a management philosophy sharedacross the entire Group, reaffirming and clarifying our relationshipswith each of our stakeholders: customers, shareholders, those whowork with Yamaha, and society in general. In order to furtherstrengthen the bonds of trust with each of our stakeholders, theyare taking steps to ensure that all members of the Yamaha Groupmaintain a keen awareness about their corporate responsibility andcontributions to society, and redouble their efforts in this regard.Supporting Young Music StudentsThe Yamaha Group engages in a variety of businesses around theworld, such as the manufacturing and marketing of musicalinstruments and audio/visual products, as well as the operation ofmusic learning centers. Our activities are wide-ranging, and includevoluntary initiatives such as social contribution activities. Here, we

introduce our scholarship program, which comprises one part of ourEuropean subsidiaries’ program for supporting students in the fieldof music.The Yamaha Music Foundation of Europe (YMFE) is an endowmentfounded in 1989 by investments from Yamaha Corporation and theYamaha Music Foundation, and has the mission of awardingscholarship money to talented, young music students in Europe.Yamaha’s six European marketing subsidiaries select scholarshiprecipients in their respective regions from among full-time musicstudents of all nationalities age 25 or below*1 studying voice orinstrumental music at music universities in 29 countries.*2 Sincescholarships began being awarded in 1990, a total of approximately700 talented students have received scholarships.Working on Global Tree-Planting Initiative

Yamaha Corporation cooperated with Yamaha Motor Co., Ltd. to holdthe third “Yamaha Forest” tree-planting event.“Yamaha Forest” waslaunched in December 2005 as part of efforts to contribute tosociety by providing environmental preservation and educationthrough tree-planting activities in Indonesia, where both companieshave manufacturing and sales networks. Supported by OISCA,* theactivity involves plans to plant approximately 150,000 to 200,000trees on 120 hectares of land over a five-year period. Whilerestoring land that has been destroyed by logging activities to itsformer glory and returning natural forests to their original state, theactivity also aims to help prevent global warming. In Japan, theEnshunada coastal forest revitalization project executes to supportfor tree-planting and maintenance by volunteers.Global Warming Countermeasures

The Yamaha Group places high priority on the environment, andstrives to ensure compliance with both the law and the YamahaPolicy on the Environment. In order to recycle resources and reducethe environmental impact on society as a whole, Yamaha promotesa variety of eco-friendly initiatives that span all stages of theproduct life cycle, from raw material procurement, development,production and utilization through to disposal.Global warming is a serious issue facing the entire human race, and the Yamaha Groupconsiders efforts to solve this problem a priority in business activities.The Yamaha Group has set a target of reducing CO2 emissions by 6% from the fiscal1990 level in fiscal 2010, in line with the target the government has set. To date we haveactively introduced cogeneration systems, switched from heavy oil to natural gas,adopted photovoltaic power generation systems, and begun using the Green Power

Certification System, as well as various other energy-saving facilities and schemes.Waste Reduction, Recycling and Resource ConservationThe Yamaha Group offers products in a wide variety of categories, including acousticinstruments, electronic and electrical products, automobile interior components, andlifestyle-related products for the home. For this reason, our production processes use abroad range of raw materials and generate various types of waste. For a number ofyears, we have been taking measures to curb emissions of waste.Through such initiatives, in May 2005 all six Yamaha Corporation production sites inJapan achieved the target of Zero Emissions.