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First Right Repair (FRR)

Four Week Training Report

On

*First Right Repair (FRR)Submitted in the Partial Fulfilment of the requirement for the award of degree of

Bachelors of Engineering

In

Mechanical Engineering

Submitted To: Submitted By:

Mr. RAJIV KUMAR (Asst. Prof.) Prabhat Sen Gupta

Mr. RAJESH SHARMA (HOD Mechanical) C09139

____________________

Department of Mechanical Engineering

CHANDIGARH COLLEGE OF ENGINEERING AND TECHNOLOGY SECTOR-26, CHANDIGARH-160019

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SUMMER TRAINING

AT

HONDA MOTORCYCLE & SCOOTER INDIA (PVT.) LTD.

Submitted BY:

PRABHAT SENGUPTA

(C09139)

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ACKNOWLEDGEMENTS

Training for a whole semester at the Honda Motorcycle and Scooter India Ltd (HMSI), Manesar was a very pleasant and intellectually enriching experience for me, both as an individual as well as a student of Mechanical Engineering. The state of the art equipment installed in the plant helped me to increase my knowledge and also get some hands on experience of the latest practices in the manufacturing industry.

First and foremost I thank Miss Kavita Pandey for giving me this wonderful opportunity to do a project in such a prestigious and progressive industry.

I express my heartfelt gratitude to my guide Mr. Pankaj Aggarwal and Miss Deep Raliya for their immense guidance and continuous support throughout my project work, and it is only because of his vision and encouragement that, I was able to complete my project

I thank Mr. Rohit Gulati or his guidance and help in understanding the working of the section.It wouldn’t be complete if I didn’t thank the entire Service Planning Department. The last one month was made special by these people who were more than just my senior colleagues. They helped me to understand the working of the Automotive Industry and its culture. I thank them all.

Prabhat Sen Gupta

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INDEX

1. Executive Summary of Honda Motors2. The Philosophy3. Honda Founder4. Presence of Honda5. HMSI Profile, Manesar6. Manufacturing facilities available at HMSI7. FRR ( First Right Repair) 8. Bajaj9. Honda10.Hero Honda11.TVS12.Yamaha13.Conclusion

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EXECUTIVE SUMMARY

Honda Motor Company Ltd. is a multinational corporation headquartered in Japan manufactures automobiles, motorcycles, trucks, scooters, robots, jets and jet engines, ATV, water craft, electrical generators, marine engines, lawn and garden equipment, and aeronautical and other mobile technologies. Honda's line of luxury cars is branded Acura in North America and Ben Tian in China. More recently they have ventured into mountain bikes. Honda is the 6th largest automobile manufacturer in the world as well as the largest engine-maker in the world, producing more than 14 million internal combustion engines each year. In August 2008, Honda surpassed Chrysler as the 4th largest automobile manufacturer in United States. Currently, Honda is the second largest manufacturer in Japan behind Toyota and ahead of Nissan.

In October 1946, Soichiro Honda established the Honda Technical Research Institute in Hamamatsu, Japan, to develop and produce small 2-cycle motorbike engines. Two years later, Honda Motor Company, Ltd. was born, and in 1959 Honda opened its first storefront in Los Angeles with six industrious employees. This first store front location closed April 25, 2009 due to declined sales. The first production automobile from Honda was the T360 mini pick-up truck Powered by a small 356 cc straight-4 gasoline engine; it was classified under the cheaper Kei car tax bracket. The first production car from Honda was the S500 sports car. Its chain driven rear wheels was point to Honda's motorcycle origins. Honda Motor Co., Ltd. operates under the basic principles of "Respect for the Individual" and "The Three Joys" — commonly expressed as The Joy of Buying, The Joy of Selling and The Joy of Creating. "Respect for the Individual" reflects our desire to respect the unique character and ability of each individual person, trusting each other as equal partners in order to do our best in every situation. Based on this, "The Three Joys" expresses our belief and desire that each person working in, or coming into contact with our company, directly or through or products, should share a sense of joy through that experience.

Honda Motorcycle And Scooter India Private Limited has a name in the field of motorcycles and scooters. After being established in 1999, in a few years it has developed a reputation of providing world class products with a technology to suit Indian conditions. No doubt the policies and procedures followed by HMSI are of world standards but with growing competition and to cut cost in the today’s price competitive market, scope of improvement is always welcomed.

In this stint of one month of my summer training, I was posted in the Service Planning DEPARTMENT where I undertook the following project “First Right Repair”.

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THE PHILOSOPHY

The management standards to be shared by all Honda group cooperation are worldwide as ‗a Company present worldwide. Honda companies worldwide are having global standards.

HMSI operates on a principle, which is followed worldwide by all Honda companies. Maintaining a global viewpoint, we are dedicated to supplying products of the highest quality, yet at a reasonable price for worldwide customer satisfaction. Honda's philosophy is based on the company's guiding principle and advocates 2 fundamental beliefs: Respect for the Individual

Honda recognizes and respects individual differences. The respect for individual stems from the following three points:

» Initiative» Equality» Trust

It is the contribution from each individual in the company that has made our company what it is today and that, which will take us into the future.

The Three Joys

In line with Honda's Philosophy, HMSI conducts all its daily activities in pursuit of the following joys:

» The joy of manufacturing high quality products.» The joy of selling high quality products.» The joy of buying high quality products.

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FOUNDER OF HONDA:

Honda’s Presence in India

Honda Siel Cars India Limited (HSCI)

Joint venture company of Honda Motor Company Ltd., Japan & Siel Limited

Incorporated in December 1995

Currently, Honda Motor Company, Japan has 99% stake in HSCI.

Honda Siel Power Ltd (HSPL)

Joint venture between Honda Motor Co., Japan and Siel Ltd.India.

Was incorporated in September 1985 and produces a range of Power Products in India, like Portable Gensets, Portable Engines, Portable Water Pumping set and Lawnmowers.

Currently Honda Motor Company, Japan has a 99% Equity Stake in this company.

Honda R & D India Private Limited (HRID)

The company's objective is to make an R&D that works jointly with the people of India to produce motorcycles for the enrichment of society and lifestyle of users of India

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THE MANESAR PLANT

HONDA MOTERCYCLE AND SCOOTER PVT. LTD, MANESER is one of the two manufacturing facilities of HMSI. It is located 45 KM from New Delhi. The Manesar Plant is spread over 52 acres, with a covered of about 85815 sq meters. The foundation stone for the factory was laid on 14th December and Construction was completed in January 2001 The initial installed capacity was 100000 scooters per year, which reached 600000 scooters by 2007, in 2011 the installed capacity was 15, 00,000 lac vehicles in a Year The total investment for the initial capacity was Rs. 215 Crore and now the accumulated investment is 800 crores, it is a 100% owned subsidiary of HMC Japan. At HMSI we have following two areas of production: 1) MOTORCYCLE 2) SCOOTER

Under these two categories there are three lines:-

i) LINE-1 S/C

ii) LINE-2 M/C

iii) LINE-3 M/C

IN HMSI there are two types of assembly we have-

i) AE (ENGINE ASSEMBLY)

ii) AF (FRAME ASSEMBLY)

Operations, Divisions & Departments

1.) Manufacturing Production o Frame o Engine Production Support o Engineering o Material Control Production Control o PPC o NMC

2.) Purchase

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Mass Production Purchase o Mass Production Parts o General Purchase New Model Purchase o Parts Development o Cost Development o Cost Planning

3.) Quality Control Quality Control o Homologation o Engineering Quality& Market Quality o Vehicle Quality o Parts Quality

4.) Sales& Marketing Sales o North Region o East Region o West Region o South Region o Central region o Safety Region o Export

Marketing& Planning o Sales Promotion o Planning& Network Development 5.) Customer Service Customer Service o Spare Parts Sales o Technical Service o Dealer service

6.) General Affairs Human Resource & Administration o Human resource o Administration Associate& Social Relations o Industrial Relation o Health Centre o Security Centre 7.) Finance& Accounts

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HMSI (Honda Motorcycles and Scooters India Pvt. Ltd.)

The ‘Wings’ arrived in India as HMSI. Honda Motorcycles and Scooters India Pvt. Ltd. (HMSI) was incorporated on 20th August 1999. HMSI is a 100% subsidiary of HONDA Motors Co. Ltd. Japan, to manufacture two wheelers in India. Recognized all over the world as the symbol of Honda two wheelers, they promise to initiate changes and make a difference in the lifestyle of the people of India. Honda’s 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 a reasonable price by following its fundamental belief of bringing joy to people. In a short span of six years, HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India.

MANUFACTURING FACILITIES AVAILABLE AT HMSI, MANESAR PLANT

1) LPDC

2) HPDC

4) Machining

5) Engine Assembly

6) Press Shop

7) Weld Shop

8) Paint Shop

9) Frame Assembly

10)Vehicle Quality

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11)Logistics

LOW PRESSURE DIE CASTING (LPDC)

A metal mould, or die, is mounted on a above a sealed furnace containing molten metal. A riser tube connects the bottom of the die to the molten metal bath. The chamber containing the molten metal is pressurized (typically 20-100kPa), and the metal is forced up into the mould. Once the casting has solidified, the pressure is released and the molten metal falls back into the bath, and the casting ejected in preparation for the next cycle.

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HIGH PRESSURE DIE CASTING (HPDC)

High pressure die casting is a manufacturing process in which molten metal (aluminum) is injected with a die casting machine under force using considerable pressure into a steel mold or die to form products.

Because of the excellent dimensional accuracy and the smooth surfaces, most high pressure die castings require no machining except the removal of flash around the edge and possible drilling and tapping holes. High pressure die casting production is fast and inexpensive relative to other casting processes.

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MACHINING

Machining is a collection of material-working processes in which power-driven machine tools such as saws, lathes, milling machines, and drill presses, are used with a sharp cutting tool to mechanically cut the material to achieve the desired geometry.

The following processes takes place in machining:

1. Finishing2. Taping3. Drilling4. Reaming5. Washing of cylinder head6. Leakage Testing

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ENGINE ASSEMBLY

Engine Assembly (AE)

AE (Assembly Engine is the area where Engine is assembled from parts. The parts are procured from various vendors like Mushashi. ASK auto , LGB. TIDC etc. The room is a white room where all parameters like temperature and humidy are controlled.

A rough sequence of assembly is given below. 1. Crankshaft+ Crankcase+ Gear Assy+ Drum Gear Shifter+ Kick shaft+ dowel

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2. Bolting for RCC and LCC

3. Oil Rotor on C Shaft

4. Bolting

5. Drive Sprocket + Plate Shift Stopper+ Plate Fixing

6. Dowel and Ring Assy

8. Clutch assy

9. Oil cap, Gasket

10. R cover

11. Clutch cable receiver

12. Cylinder Comp + Piston on Crank shaft

13. Chain (Timing) on Sprocket Cam

14. Tensioner Plate

15. Gasket + cylinder Head+ Cam Assy

16. Sprocket to Rockerarm Assy

17. Sparkplug

18. Flywheel

19. Oil Seal

20. L Covering + Neutral Switch

21. Leak Test

22. Inspection

23. Oil Filling

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The above sequence is a general sequence. Sequence of every engine (model) is different.

Photo of the Engine Assembly at Scooter Plant

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PRESS SHOP

The Press Shop has four press machines. The two are of 350 ton and the other two of 500 ton configuration. The two processes that the press shop performs are Drawing and Trimming. The components produced at the Weld Shop are front fender for KWPA (Activa) and petrol tanks for all the motorcycle models.

The above picture showing Drawing & Trimming resp.

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WELD SHOP

Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld.

The 2 different types of welding done at the HMSI scooter plant are MIG Welding & Spot Welding.The components welded are front fendor,fork,frame &BOC.

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PAINT SHOP

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FRAME ASSEMBLY

Frame assembly is divided into various parts:1) PA (Paint Assembly)

2) Ground Floor- MS

3) First Floor- MS

4) Joint Conveyor

5) Main Line

The PA area loads various parts onto the Marshall carrier and also the frame is

punched with a unique number.

The first and Second Floor area load the conveyor with sub assemblies like

Front Fork Sub Assy.

Joint conveyor is where the Engine and Frame are joined. The wheel assemblies

and chain drive are assembled with the frame assembly here. Rest assembly is

done on Main Line.

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VEHICLE QUALITY

After assembly, prior to dispatch the vehicle is inspected to ensure that it meets

the HMSI quality standards. The scooter plant has the following tests:

1. Headlight Beam Test: At this stage the headlight is tested if its functioning properly or not.

2. Brake Power Test: The vehicle‘s tires are placed on 2 ribbed rollers and brake is engaged. The roller try to turn the wheel but the brake resists them This resistance is measured in Newton‘s, every model has different minimum values which every bike must have in order to qualify.

3. Speedometer Test: The scooter’s front tire is placed on 2 rollers and they are drive to a speed of 40 Km/h.. This checks the front assembly for any vibration and difference is speedometer readings

4. Acceleration & Vmax Test: In this test the bike is run to its maximum velocity on a test bed. This checks the working of all mechanical components. Not only the maximum velocity is checked but its acceleration and other circuits like electrical (i.e. Horn, Headlight , Winkers are checked).

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FRR (First Right Repair)

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FRR DEFINATION

FRR IS DEFINED AS THE NUMBER OF VEHICLES UNDERGOING REPEAT REPAIR TO THE TOTAL NUMBER OF VEHICLES IN THAT TIME FRAME

REASON TO FIND FRR

• To analyze the critical problems in the vehicle

• To analyze the quality of service provided

• To analyze the dealership and its technicians

• To analyze and improve upon the future plans for service

FRR (First Right Repair) : Its importance

• The automotive industry of the country depends upon the type of service offered, that is the after sales services.

• The after sales service consists of vehicle repair and service. The quality of service or repair is what determines, which company has the best after sales service.

• FRR is the concept of repairing the vehicle the first time it comes to the workshop. The process in which a repeat repair occurs leads to losses to the company.

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BAJAJ

21/06/2011 BAGGA LINK KAROL BAGH

23/06/2011 PRJ BAJAJ PATPAR GANJ

The Bajaj Group is amongst the top 10 business houses in India. Its footprint

stretches over a wide range of industries, spanning automobiles (two-wheelers

and three-wheelers), home appliances, lighting, iron and steel, insurance, travel

and finance.

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BAJAJ FRR CHART

REASONS FOR REPEAT REPAIR

ABNORMAL ENGINE NOISE SPARE PARTS

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BRAKES INEFFECTIVE COMMUNICATION PROBLEM

ENGINE DOES NOT START EASILY TECHNICAL PROBLEM

ENGINE STOP TECHNICAL PROBLEM

GEAR SHIFTING PROBLEM VEHICLE MISHANDLEING

LOW PICK UP/ VEHICLE DOES NOT STARTTECHNICAL PROBLEM

OIL LEAKAGE FROM THE ENGINE SPARE PARTS

OTHERS……… TECHNICAL PROBLEM

SHOCK ABSORBER NOT WORKING VEHICLE MISHANDLEING

VIBRATION ON HANDLE VEHICLE MISHANDLEING

HONDA

The ‘Wings’ arrived in India as HMSI. Honda Motorcycles and Scooters India Pvt. Ltd. (HMSI) was incorporated on 20th August 1999. HMSI is a 100% subsidiary of HONDA Motors Co. Ltd. Japan, to manufacture two wheelers in

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India. Recognized all over the world as the symbol of Honda two wheelers, they promise to initiate changes and make a difference in the lifestyle of the people of India.

22/06/2011 PRAGANYA HONDA OKHLA

22/06/2011 MALWA HONDA OKHLA

23/06/2011 RACE HONDA PATPAR GANJ

HONDA FRR CHART

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ABNORMAL ENGINE NOISE TECHNICAL PROBLEM

BRAKES INEFFECTIVE SPARE PARTS





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OTHERS……… SPARE PARTS

SHOCK ABSORBER NOT WORKING SPARE PARTS

VIBRATION ON HANDLE VEHICLE MISHANDLEING

REPAIR CHART

HERO HONDA

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The company is a joint venture between India's Hero Group and Honda Motor Company, Japan that began in 1984.

In 2001, the company achieved the coveted position of being the largest two-wheeler manufacturing company in India and the ‘World No.1’ two-wheeler company in terms of unit volume sales in a calendar year by a single company. Hero Honda has retained that coveted position till date

22/06/2011 ARC HERO HONDA OKHLA

24/06/2011 PASHUPATI HERO HONDA OKHLA

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ABNORMAL ENGINE NOISECOMMUNICATION PROBLEM

BRAKES INEFFECTIVETECHNICAL PROBLEM

ENGINE DOES NOT START EASILYCOMMUNICATION PROBLEM

ENGINE STOPTECHNICAL PROBLEM

GEAR SHIFTING PROBLEMVEHICLE MISHANDLEING


OIL LEAKAGE FROM THE ENGINESPARE PARTS

OTHERS………SPARE PARTS

SHOCK ABSORBER NOT WORKINGVEHICLE MISHANDLEING

VIBRATION ON HANDLEVEHICLE MISHANDLEING

REPAIR CHART

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TVS TVS Motor Company is the third largest two-wheeler manufacturer in India and one among the top ten in the world, with annual turnover of more than USD 1 billion in 2008-2009, and is the flagship company of the USD 4 billion TVS Group.

22/06/201 CPL TVS OKHLA

4/07/2011 GANPATI TVS SEC 13 GURGAON

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TVS FRR CHART

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ABNORMAL ENGINE NOISE COMMUNICATION PROBLEM






OIL LEAKAGE FROM THE ENGINE TECHNICAL PROBLEM


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VIBRATION ON HANDLE TECHNICAL PROBLEM

REPAIR CHART

YAMAHA

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Yamaha made its initial foray into India in 1985. Subsequently, it entered into a 50:50 joint-venture with the Escorts Group in 1996. However, in August 2001, Yamaha acquired its remaining stake 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 the motorcycle manufacturing company "India Yamaha Motor Private Limited (IYM)".

YAMAHA

4/07/2011 GREEN YAMAHA GURGAON

4/07/2011 PICK UP WHEELS SUSHANT LOK GURGAON

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YAMAHA FRR CHART


ABNORMAL ENGINE NOISE COMMUNICATION PROBLEM

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GEAR SHIFTING PROBLEM COMMUNICATION PROBLEM





VIBRATION ON HANDLE TECHNICAL PROBLEM

REPAIR CHART

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CONCLUSION

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COMPETITOR FRR REPORTPARAMETERS BAJAJ HONDA HERO HONDA YAMAHA TVS

TIME TAKEN FOR

PROBLEM TO REOCCUR

THE AVERAGE TIME BETWEEN A

PROBLEM TO REOCCUR IS 4-5

DAYS

THE AVERAGE TIME BETWEEN A

PROBLEM TO REOCCUR IS 2-3

WEEKS.

TIME BETWEEN A PROBLEM TO

REOCCUR IS 6-7 DAYS

TIME BETWEEN A PROBLEM TO REOCCUR IS 1

WEEK

THE AVERAGE TIME BETWEEN A PROBLEM TO REOCCUR IS 9-

10 DAYS

VEHICLE PART MOST

SUSCEPTABLE TO REPEAT

REPAIR

IN BAJAJ VEHICLES THE ENGINE SEEMS

TO GIVE ABNORMAL ENGINE

NOISE AND AVERAGE IS A BIG

PROBLEM

IN HONDA VEHICLES THE

ENGINE OF ACTIVA HAS

STARTING PROBLEMS AND BRAKES ARE A

MAJOR CONCERN

HERE THE VEHICLES HAVE PROBLEM IN THE GEAR BOX AND IN THE ENGINE

DUE TO LOW PICK UP

LOW PICK UP SEEMS TO BE

THE MAIN PROBLEM WITH BRAKES BEING INEFFECTIVE

GEAR SHIFTING SEEMS TO BE THE MAJOR

PROBLEM WITH FRONT SHOCK

ABSORBERS

MAIN REASON FOR

REPEAT REPAIR TO

OCCUR

VEHICLE MISHANDELING BY

THE CUSTOMER AND TECHNICAL

PROBLEMS ARE THE MAIN REASON FOR

REPEAT REPAIR

THE MAIN REASON IS THE

SUPPLY OF SPARE PARTS, WHICH IS

VERY LESS

THE TECHNICAL PROBLEMS KEEP

REOCCURING WHICH MEANS

THAT THE DIAGNOSIS OF

THE VEHICLE IS NOT UP TO THE

MARK

VEHICLE MISHANDELING

SEEMS TO BE THE MAJOR CAUSE OF REPEATED

REPAIR

IT SEEMS THAT THE TECHNICAL DIAGNOSIS

FAILS AND LEADS TO REPEAT REPAIRS

NUMBER OF REPEAT REPAIRS

OUT OF THE 20 CUSTOMERS

SURVEYED 12 HAD REPEAT REPAIRS IN

THE VEHICLE


SURVEYED 9 HAD REPEAT REPAIRS


SURVEYED 8 HAD REPEAT REPAIRS

OUT OF THE 20 CUSTOMERS SURVEYED 7 HAD REPEAT

REPAIRS

OUT OF 20 CUSTOMERS SURVEYED 8

VEHICLES HAD REPEAT REPAIRS

VEHICLE MOST

SUSCEPTABLE TO REPEAT

REPAIR

PULSAR 150 ACTIVA SPLENDOR FZ RTR 160

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IMPROVEMENT AREAS

PRAMETRERS REMARKS

TE

CH

NIC

AL

PR

OB

LE

M

LEVEL OF TECHNICIAN

IF THE TECHNITION ISN'T QUALLIFIED ENOUGH THEN THE SERVICE QUALITY SUFFERS. THE BEST WAY TO IMPROVE

THE TECHNICIAN IS BY IMPARTING KNOWLEDGE AND TRAINING AT THE FACTFJ

IMPROPER DIAGNOSIS

IF THE DIAGNOSIS PROCEDURE ISN'T COMPLETE THEN MORE PROBLEMS ARE SAID TO OCCUR. THE WAY TO

ELIMINATE THIS PROBLEM BY BETTER TRAINED TECHNICIANS AND BY PROPER QUALITY CHECKS BY THE

FLOOR SUPERVISOR

COMMUNICATION PROBLEMTO IMPROVE THIS PROBLEM SUPERVISOR SHOULD BE

MORE ATTENTIVE AND CROSS CHECK OF THE JOB CARD SHOULD BE DONE.

SPARE PARTS THE SUPPLY OF SPARE PARTS SHOULD BE IMPROVED AND

REQUEST FOR MORE SPARE PARTS SHOULD BE PLACED BEFORE HAND

VEHICLE MISHANDELING

TO REDUCE THIS PROBLEM PROPER RIDING TECHNIQUES NEED TO BE MENTIONED TO THE CUSTOMER AND CHARTS AND OTHER FORM OF VISUAL DISPLAY SHOULD BE PUT UP

SHOWCASING SAFETY RIDING

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