Internship ReportFrom: 18-07-2011

To 19-08-2011

Dawood College of Engineering and Technology, Karachi

Name # Roll No #

Muhammad Ehsan D-08-IND-314

Fiaz Ahmad D-08-IND-331

Rahmat Ali D-08-IND-339

Report Submission Date : 22-08-2011

Copy to:Human Resource Department ( )

Assembly Operation Department ( )

Chairman Industrial Department ()

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Acknowledgment:

By the Grace of Almighty Allah, We have been able to complete our INTERNSHIP at HinoPak

Motors Limited Karachi. All this become possible only due to the support of the following

employees.

Especially;

Mr. Muhammad Akram (GM HR, Administration & HSE)

Mr. Misbahuddin Khan Akozai (Manager Production AOD)

Mr. Rashid Maqsood

Mr. Muhammad Yousuf

Mr. Abdul Gaffar (Team Leader Axle Shop)

They help us in understanding the different work being carried out in HinoPak Motors Limited,

to enhance our technical skills. We really believe that our internship at HinoPak Motors Limited

would never be possible without the support of all these people.

We also appreciate the cordial co-operation from all our concern Managers in all departments.

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HinoPak Motors Limited Karachi

Contents

S. No. # Department # Page No. #

1. Introduction to HinoPak 4 to 8

2. Assembly Operation Plant 9 to 15

3. Special Assignment 16 to 22

4. Kaizen 23 to 24

5. Suggestions and Recommendations 25

6. Conclusion 26

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INTRODUCTION TO HINOPAK

THE HINO PAK:

Hino Motors Japan and Toyota Tsusho Corporation in collaboration with Al-Futtaim Group ofUAE and PACO Pakistan formed Hino Pak Motors Limited in 1986.Hino Pak family in Pakistan & under the guidance of our Japanese sponsors, Hino Pak hasachieved standards of quality & excellence that rival the best in the region. In recognition ofthese efforts, the company has received a number of excellence awards for its managementpractices & quality standards.

In 1998, Hino Pak Motors ltd And Toyota Corporation obtained majority shareholding in thecompany after disinvestments by the other two founding sponsors. This decision to invest inHino Pak at a time when the country’s economy was passing through a depression and the sale ofcommercial vehicles was at an all time low reflects the confidence our Principals have in ourcompany and their commitment to the Pakistani market.

It is the enduring success of Hino Pak that has made the Hino name and symbol of quality &reliability and Hino Pak vehicles a prize possession for its owners.

By continuing to move forward and staying alert to ever-changing market & social needs, HinoPak will continue to be a successful and well-respected corporate citizen of Pakistan.

Hino Pak Motors Limited assembles, manufactures and markets world renowned Hino dieseltrucks and buses in Pakistan. The Company has held the top position in the domestic market formedium and heavy-duty vehicles for 17 consecutive years and is highly acclaimed for qualityand technological excellence.

Backed by Hino's expertise Hino Pak has achieved standard of quality and excellence that rivalthe best in the region. With over 60,000 vehicles on road, Hino Pak has gained 65% market sharemaking it the largest manufacturer in medium and heavy-duty truck and bus industry in Pakistan.Hino Pak's product range has been designed and built in Hino's traditions of automotiveexcellence to be the leader in its category and the main emphasis has been given to passengers'safety & comfort.

PRODUCTION TECHNOLOGY:

Hino Pak is backed by nearly 90 years of Hino’s Experience and research, setting many newstandards in transportation with supporting corporate activities, constantly contributing to thedevelopment of people’s lives and society as a whole.

Hino – from generation to generation, believes in the transfer of Superior Japanese Technology.With strict quality control and constant supervision of Japanese experts, landmark technologies

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have been successfully transferred from Hino Japan to Hino Pak in the past and will continue todo so in the future.

Hino Pak therefore is a technological advanced company, which believes only in employingleading experts for the development of new technologies to serve customers better.Hino Pak is proud to unveil its latest range of vehicles Hino 500 Series trucks, Dutro Light Dutytruck and new buses that are in line with global Euro emission standards making Hino Pak thefirst Pakistani commercial vehicle manufacturer to introduce a complete range of environmentfriendly vehicles.

Hino Pak's plants are equipped with the most advanced facilities for vehicle assembly and thefabrication of bus body and other specialized super structure. Apart form being a prime force inthe field of medium and heavy vehicles, Hino Pak is a pioneer in engine and axle assembly.

Thus continuous efforts, innovative technology has made Hino Pak a trusted market leader.

PRODUCT TECHNOLOGY:

Transfer of the latest technology is an on-going process, which ensures that the basiccomponents of all the Hino vehicles are of the highest quality in every sense of the word.

EURO EMISSION STANDARD:

Environment is major area of concern today the world over. The problem has attractedattention in Hino too. Hino as responsible corporate citizen is using the power of superiorJapanese technology in step with the expansion of exhaust emission regulation.

Hino, to achieve its target to reduce pollution has proceed low emission standard engineswhich are called EURO engines.

As a leading manufacturer of diesel vehicles, Hino has taken diverse measures topreserve the global environment in not only its products but also its corporate activities ingeneral while contributing to the development of people’s lives and society as a whole.

BUSES:

The largest Manufacturer of Buses in Pakistan, Hino Pak is fully equipped to design andmanufacture a wide range of Bus Chassis and all types of Bus Bodies. Hino Pak’s Bus Line Upincludes the Road liner Supreme Luxury Bus for long journeys, Citiliner Intercity Buses,Citiliner Urban Buses and the luxury Senator Coach and Rapid liner Deluxe Coaches.

Hino Pak delivers only the safest most reliable products and remains the Pioneer in supplying the

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largest number of Urban Buses those are successfully facilitating the commuters of Punjab andSindh.

TRUCKS:

The new Hino Pak 500 series is a dynamic combination of power, economy, style and safety.Vast improvements in engine technologies have allowed us to create Engines with more HorsePower while offering lower fuel consumption. These dynamic new vehicles featuringrevolutionary technologies such as multi valves engine, new air intake system, turbocharger withintercooler, overhead cams, heavy duty clutch, synchronized transmission and power steeringpromise to change the face of transportation with new standards in comfort, luxury, safety andespecially economy.

Hino Pak’s latest product range has been especially developed and designed keeping in mind therugged terrain and varying climates in order to meet the requirements of the diverse Pakistaniautomobile market.

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1. The robust FG1J 4x2 truck with a JO8C engine has a gross vehicle weight of 18 tons andsuitable for all types of cargo and transportation needs.

2. The FL1J 6X2 truck has a gross vehicle weight of 27.5 tons and equipped with a JO8CEngine which allows a greater fuel economy with more loading capacity.

3. The new Product line also introduces the dynamic FM1J 6X4 Truck with a gross vehicleweight of 28 tons and boasts a JO8C engine with turbo intercooler. This truck is suitablefor all types of transportation needs specifically for the hilly areas and dump trucks.

4. The Powerful SG1J is 4X2 Prime Mover with a gross combination weight of 35 tons, alsoequipped with a JO8C turbo intercooler engine it is the ideal choice for heavy loads.

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5. The Powerful FM2P 6X4 Prime Mover with 320 PS is equipped with Euro 2 P11Cengine. Its greater engine Power and extra loading capacity will usher a new era of faster& economical goods transportation.

PRODUCTION DEPARTMENT:

Since the environment affecting trucks and buses continuous to change, HinoPak product designand development division constantly works to quickly respond to a variety of issues. HinoPakmakes the most development and design by making constant efforts to gain information from awide range of customers and the market. HinoPak can create new and original designs becauseits designers are customer oriented and are also alert to developing trends.

By implementing simultaneous engineering methods, HinoPak is able to supply attractiveproducts in a timely manner. This is done through a “Down Stream Process” in which relateddivisions participate for the very initial stage of development and by actively using technologies,such as CAD/CAE Systems.

HinoPak is baked by nearly 90 years of Hino’s experience and research dedicated to building awide range of superior quality vehicles. The objective is to achieve optimum efficiency in ontime production and delivery. As a result of the induction of latest technology, HinoPak’s plant isequipped with the most advance facilities for vehicles assembly and the fabrication of bus bodyand others specialized super structure. A part from being a prime force in the field of mediumand heavy vehicles, HinoPak is pioneer in engine and axle assembly.

Assembly Operation Plant (AOP) Body Operation Plant (BOP)

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Assembly Operation Plant (AOP):

HinoPak’s vehicle assembly plant has an efficient and integrated design layout, which comprisesCHASSIS assembly lines, engine and axle assembly plants, paint booths and ovens along withother component manufacturing facilities. This plant is entirely geared to ensure that quality isbuilt into the product at every stage. Special emphasis has been given to the workingenvironment to achieve the ultimate Quality and Productivity.

Sequence of operations involved:

Operations involved in the different areas:

Frame Drilling Shop:In this area frame is prepared, which is main component of the chassis. The work iscarried out in following three stages in this area:

Stage # 01 (Web): Setting the rail S/A Clamping and setting of jigs Drilling Φ9 ~ 18 mm Burs cleaning Removing the jigs

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Cleaning the rail S/A

Stage # 02 (Top and Bottom): Setting the rail S/A Jigs setting on bottom flange Drilling Φ9 ~ 18 mm Turn rail from bottom to top Jig setting on top flange Drilling Φ9 ~ 18 mm Jigs removing

Stage # 03 (Radial): Turn the rail S/A on web Position Jigs setting Drilling Φ22 ~ 70 mm Burs cleaning/removing Removing the jigs Cleaning the rail S/A

Air and Oil Pipe Shop:In this area pipes of different sizes and shapes arecut and bend as required on the assembly line.This shop is the most simplest in the wholechassis assembly line. Jigs are mostly used in thisshop, which is used in bending operation of thepipes. The pipes in the required shape and sizeare used for various purposes especially in thebrake system.

Axle shop:This shop is the one of the complex shop in the Chassis Assembly line. Axles areassembled here and sent to the main assembly line fro further possessing/operation. Thework here is divided in four stages and some sub assemblies:

Stage # 01: Degreasing Rinsing Anti-Rusting Air blowing

Stage # 02: Knuckle sub Assy Tie rod installation

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Brake Assy installation Differential Assy mounting Chamber brackets mounting CAM shaft adjuster fitting

Drum/Hub Sub Assembly: Drum/Hub sub Assy Run out testing Through shaft installation

Stage # 03: Drum Hub mounting Bearing installation Axle shaft installation Toe-in adjustment Through shaft installation Pre-load adjustment Chamber installation

Stage # 04: Axle painting Leaf spring installation U-Bolt pre tightening Axel brake piping

Tire shop:The tires are provided from the tire shop to the main assembly line. Tires are mountedover axle, after the completion of chassis & axle assembly.

Body in White:In this area the body of the cabin is prepared. All the panels of the body are taken fromthe C.K.D; here all these are only assembled through different processes i-e weldingprocesses. Here the mostly commonly used welding process is spot welding process.This is the most effective welding process because it never develops any flaws. Then thebody is taken into the paint booth for paint, and in the last it is sent to the trim line forfurther operations.

Trim Line:As trimming is the process or act of adding decoration, therefore in trimming process theinterior and exterior decorative work is done.It consists of:

a. Fitting windowb. Doorc. Seats

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d. And Some electrical workThe work here is divided into five stages:

Stage # 01: Door preparation Exterior preparation Head lining preparation

Stage # 02: Harness installation Blower/Ventilator Air ducting Pedal assembly

Stage # 03: Steering column Dash board installation Front panel assembly Bonnet assembly

Stage # 04: Floor mate Seat installation Wind shelled installation External mirror

Stage # 05: Under body assembly Cab tilt mechanism Engine room installation

Engine shop:Engine shop is the most important sub assembly shop to the main assembly line. Enginesof the required specification for any vehicle are assembled in the engine shop. Most ofthe components of the engine are C.K.D i-e received from Japan. All the Engines afterbeing assembled are checked or tested in artificial environment to properly check theirperformance before making it available to the main assembly line.

Main chassis Assembly Line (Hino Line):The Main Chassis Assembly Line is the most important part of the Assembly OperationPlant (AOP). This is the main assembly line in which all the above mentioned subassemblies of different components are combined.

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The work here is divided into the following stages:

Stage # 1A (Frame Assembly):This is first stage or the starting point of the main assembly line. Here the frame of thechassis is joint together with the help of the cross members by the application of weldingand riveting.Here the work carried-out is:

Vin/chassis no punching Cross member’s installation Ladder riveting Brackets leaf spring Turnion installation

Stage #1B (Chassis Preparation):In this stage all the basic necessities are attached to the chassis, so that the chassis ismade available for other complex and most important sub-assemblies.Work carried out is:

Wire harness Fuel pipes installation Brackets steering Rear comb. Lamp & horn Miscellaneous brackets

Stage # 01 (Axle and Wheel Mounting):After stage # 1A & 1B the frame and other cross member’s start to get shape of thechassis. Then at this stage the axle and wheels are mounted/attached to the chassis.At this stage work carried out is:

Front and rear axle Steering box Front and rear wheels Shock absorbers and stabilizers U-bolts and leaf springs

Stage # 02 (Air and Oil Piping):Here all the pipes required for various systems are attached in the chassis. Also fuel tanksand brake boosters for the brake system is attached here.At this stage work carried out is:

Air pipes and oil pipes Control cables Air tank sub assembly Fuel tank sub assembly

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Brakes boosters

Stage # 03 (Engine Mounting):This the most important stage in main assembly line. In this stage the engine is mountedover the chassis and also its fuel, coolant and exhaust connections are attached with thefuel tank, radiator, and exhaust pipes & mufflers respectively.At this stage work carried out is:

Engine mountingExhaust pipes and mufflersRadiator and inter-coolerP. steering oil pipesCables

Stage # 04 (cabin and Floor Mounting):Here the cabin from the trim line is mounted or drop over the chassis. Propeller shaft isalso attached in this stage.At this stage work carried out is:

Air cleanerArch membersCabin floorPropeller shaftsTrailer brakes

Stage # 05 (Control Setting)At this last stage of chassis assembly line all the control systems are checked. Also fluidare filled and checked and maintained if there is any leakage.At this stage work carried out is:

Lube/fluids fillingBatteries and electric boxHead lamp and bumperGreasing

Inspection Department:After completion of the work of main assembly line, the vehicle is then to pass throughthe inspection department. Here all the problems from minor to major are checked outand maintained and also efforts are being made to reduce the production of problematicproducts. Here some other tests are also conducted to find out some other problems aswell, especially speed tests, brake control tests, electric control test, etc.

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Quality Assurance/Control Department:

Quality control is a process by which entities review the quality of all factors involvedin production. This approach places an emphasis on three aspects:

Elements such as controls, job management, defined and well managed processes,performance and integrity criteria, and identification of records.

Competence such as knowledge, skills, experience, and qualifications Soft elements such as personnel integrity, confidence, organizational

culture, motivation, team spirit, and quality relationships.

The quality of the outputs is at risk if any of these three aspects is deficient in any way.

Quality assurance, or QA for short is the systematic monitoring and evaluation of thevarious aspects of a project, service or facility to maximize the probability that minimumstandards of quality are being attained by the production process. QA cannot absolutelyguarantee the production of quality products.

Two principles included in QA are:

"Fit for purpose" - the product should be suitable for the intended purpose;

And

"Right first time" - mistakes should be eliminated.

QA includes regulation of the quality of raw materials, assemblies, products andcomponents, services related to production, and management, production and inspectionprocesses.

“Quality Control emphasizes testing of products to uncover defects, and reporting tomanagement who make the decision to allow or deny the release where as QualityAssurance attempts to improve and stabilize production, and associated processes, toavoid, or at least minimize, issues that led to the defects in the first place”.

The above explanation of the quality control and quality assurance make things clearabout both of the topics.The HinoPak’s quality control and quality assurance teams are fully aware of all theseand therefore they work with confidence in their respective areas.

“They not only focused to find defective products but also work to reduce theproduction of defective products”.

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Special Assignment:Study and Calculate the time study of the Axle Shop???

Time Study:A process for measuring the required time for performing a given task, by a givenmethod, by a trained worker, working at a normal pace.

Why needed?

For methods improvementFor determining time standards

Needs for Time Standard:

Developing schedulesDetermining wage payment plansEstimating production costsProviding a base for estimating productivity goalsAppraising employee performanceEvaluating alternative process, equipment

Axle Shop:

This shop is the one of the complex shop in the Chassis Assembly line. Axles areassembled here and sent to the main assembly line fro further possessing/operation. Thework here is divided in four stages and some sub assemblies:

Stage # 01: Degreasing Rinsing Anti-Rusting Air blowing

Stage # 02: Knuckle sub Assy Tie rod installation Brake Assy installation Differential Assy

mounting Chamber brackets

mounting CAM shaft adjuster

fitting

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Drum/Hub Sub Assembly: Drum/Hub sub Assy Run out testing Through shaft installation

Stage # 03: Drum Hub mounting Bearing installation Axle shaft installation Toe-in adjustment Through shaft

installation Pre-load adjustment Chamber installation

Stage # 04:

Axle painting

Leaf spring installation

U-Bolt pre tightening

Axle brake piping

In time calculation of the axle shop I focused on the main axle assembly line and neglect the sub-assemblies. The main axle assembly line is comprised of the four stages.

The flow diagram of the main axle assembly line is:

`

(Fig: Axle Assembly Line)

Stage # 04 Stage # 03 Stage # 02

Stage # 01

Local & C.K.D Parts

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Time Calculation for the model FGIJ: Stage # 01:

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Stage # 02:

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Stage # 03:

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Stage # 04:

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I use the same (above mentioned) procedure to find-out the time for other models (vehicles):

Time Calculation for the Model Dutro Junior:

Time Calculation for the Model AK1J (Buss):

Time Calculation for the Model GT1J:

Time Calculation for the Model FM1J:

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KAIZEN :

WHAT IS KAIZEN???Kaizen means "good change” which has been interpreted to mean continuousincremental improvement. Renew the heart & make it good.

GOAL OF KAIZEN???This activity is highly focused & action oriented which empowered team sothat they can take immediate action to improve a specific process.

KAIZEN CONCEPT???

Six Basic Rules of Kaizen???1. Respect others: Particularly the local operators, you are in their living room.

2. Document reality: If you make changes based on data, the data should be based onreality.

3. Do your share: Everyone has to contribute.

4. Try something new: Be open minded - try it instead of racking your brain forreasons why it won’t work (try-storming).

5. Ask why (the 5 why’s): Gain complete understanding, assume nothing.

6. Be safe / Think safe: Both in your actions and in what you implement.

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Working On Kaizen Activities:During my internship tenure, not only the plant management gives me thetask/assignment of time study but also encourage met to give suggestion regardingKaizen. This allows me to keep in view of all the activities taking place in the plant andalso to identify techniques/ways to further improve these activities/processes.

The kaizen activity which I identify is in the axle shop (as my assignment wasrelated to the axle shop), this is basically related with the fatigue and the problemassociated with the workers. This problem is related with the trolley (also knownas jig) , the work (axle front or rear) are placed on this jig to perform work on it,after performing working the worker has to push it to the next stage for the furtherworking. The problem is that there is no handle or something else in it for worker,so that the worker can push or pull it easily with causing fatigue to the worker.Because when the worker forced on the trolley he never achieve a good/properworking posture.

The design/ drawing shown below will make it further clear:

Before After

The handle or arm is attached on the workers side because it will attach to thefront or back side, then it will make the worker come in working zone i-e dangerzone.

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Suggestions and Recommendations:

Problems and their Possible Solutions:

Problems:

1. Availability of Parts is not on time at the assembly line.

2. Workers behavior towards the work.

3. Not adopting scientific ways of doing work.

4. Miss communication between different department (especially Productiondepartment and Warehouse).

Possible Solutions:

1. First problem can be tackle down by adopting MRP (Material RequirementPlanning) techniques. “The purpose of MRP is to ensure that materials andcomponents are available in the right quantities and at the right time, so thatfinished products can be completed according to the master production schedule”.

2. The Second problem is related with the first one, because the On and Off of workon a work place may cause a negative impact on the behavior of the workers.

3. The third problem can be sorted out by distributing the work equally among theworkers.

4. This can done by using a computerized package of MIS (ManagementInformation System)

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Conclusion:

We have completed our Internship in the HinoPak Motors Limited.

During this short time we interned in the Assembly Operation Plant, Despite theshort stay there, we learned a lot from them.

In our short time, we observed that HinoPak Motors Limited is a well organizedIndustry, Each of its department is connected with each other by formally andworking in very good coordination. The facilities for production is very much onthe higher side in HinoPak Motors Limited.

As for trainees, we don’t think that any organization is better than HinoPak MotorsLimited because each person from worker to management is too much trained andcooperative. We gain a lot of technical knowledge from HinoPak Motors Limitedwhich we will never forget and also this will help us a lot in our professional life.

We are too much thankful to HinoPak Motors Limited employees, for givingus this great opportunity and for their great cooperation with us during ourinternship.

***** *****