A Project Report

On

Study of Manufacturing

Processes

In

INDIAN YAMAHA MOTORS PVT.

LTD.

In Guidance Of: Submitted By:

Mr. vimal Raina SUDHIR JAIN

Department Head 1571483608

Manufacturing Mechanical and Automation Engineering

ACKNOWLEDGEMENT

I take immense pleasure in expressing our heartfelt indebtedness to the management of

Yamaha India for giving me kind permission for doing my summer internship at their

Surajpur plant.

I am equally indebted to my project guide, Mr. Bijender Kaushik to whom I accord our

sincere gratitude and profound thankfulness for his perpetual guidance, insightful

opinion, and constructive criticism to encourse our fervent endeavor.

I also wish to extend my profound gratefulness to all the working staff and operator of

the plant for their invaluable support, thoughtful vision and productive suggestion.

Last but not the least, we are forever, indebted to the omnipotent and to our parents, for

their cheerful encouragement, unfailing patience and consistence support, without

which, we would have been lost in the dark.

Thank you all.

Summer Project Certificate

This is to certify that Mr. SUDHIR JAIN has successful completed summer

internship for a period of 45 days starting from 1st of june to 15th of july at INDIA

YAMAHA MOTOR PVT. LTD. in partial fulfillment of the requirement for his B.Tech

Degree. This is his original work to the best of my knowledge.

(PROJECT GUIDE)

Date: - __________

METHODOLOGY

This can be termed as method used to undergo at a particular project. This was not as research project that

can be completed by using the method of questionnaires.

t is an experience based project and here methodology regarding this project can be termed as the training

undergone in India Yamaha Motor Pvt. Ltd. I tried to contact every employee from top to bottom level

management, who helped me lot. And the knowledge given there, regarding export procedure and

documentation which was only possible by undergoing training.

Although true picture of the export procedure, documentation and marketing in foreign country can be only

obtained by visiting a particular relevant country. But as this was not possible best effort have been made to

collect all relevant information within constraints.

The methodology of data collection is based on primary as well as secondary data.

Primary Data:

Personal interaction with Internship Site Supervisor.

Discussion with other officials.

Secondary Data:

Company’s Website, Company’s Magazines, Past year data and other available

records & reports.

COMPANY

PROFILE

HISTORY :

"If you're going to do something, be the best."

"If you are going to make it, make it the very best there is."

Genichi Kawakami fourth-generation President in 1950 at the young age of 38. With

these words as their motto, the development team poured all their energies into building

the first prototype, and ten months later in August of 1954 the first model was complete.

It was the Yamaha YA-1. The bike was powered by an air-cooled, 2-stroke, single

cylinder 125cc engine. Once finished, it was put through an unprecedented 10,000 km

endurance test to ensure that its quality was top-class. This was destined to be the first

crystallization of what has now become a long tradition of Yamaha creativity and an

inexhaustible spirit of challenge.

Yamaha Motor Co. Ltd. was founded on July 1, 1955. Staffed by 274 enthusiastic

employees, the new motorcycle manufacturer built about 200 units per month. By 1956,

a second model was ready for production. This was the YC1, a 175cc single cylinder

two-stroke. In 1957 Yamaha began production of its first 250cc, two-stroke twin, the

YD1. Then in 1960, Yamaha International Corporation began selling motorcycles in the

USA through dealers. The first watercraft model was the CAT-21, followed by the RUN-

13 and the P-7 123cc outboard motor. Yamaha DT-1. The world's first true off-road

motorcycle debuted in 1968.

Genichi Kawakami set the stage for Yamaha Motor Company's success with his vision

and philosophies. Total honesty towards the customer and making products that hold

their own enables the company that serves people in thirty-three countries, to provide

an improved lifestyle through exceptional quality, high performance products.

Major Products And Services

Manufacture and sales of motorcycles, scooters, electro-hybrid bicycles, boats, sail

boats, Water Vehicles, pools, utility boats, fishing boats, outboard motors, diesel

engines, 4-wheel ATVs, side-by-side vehicles, racing karts, golf cars, multi-purpose

engines, generators, water pumps, snowmobiles, small-sized snow throwers,

automotive engines, intelligent machinery, industrial-use remote control helicopters,

electrical power units for wheelchairs, helmets. Biotechnological production, processing

and sales of agricultural and marine products and microorganisms. Import and sales of

various types of products, development of tourist businesses and management of

leisure, recreational facilities and related services.

It started its manufacturing in India with local partner Escorts in 1996. It acquired 100%

ownership in 2001. YAMAHA is currently operating in Indian market with various models

viz. CRUX (100cc), ALBA (106cc) and GLADIATOR (125cc).YAMAHA have launched

YRF R-15, 150 cc, 6-speed bike in Indian market recently.

Now it has two manufacturing units at Faridabad in Haryana and Surajpur in Uttar

Pradesh. The Surajpur plant has two main assembly lines having a capacity of

producing maximum of 677 bikes per 8 hour shift.

Since last few years YAMAHA is not doing well in India, so YAMAHA MOTOR CO.,

LTD. came with 70-30 partnership with MITSUI & CO., LTD. and it became INDIA

YAMAHA MOTOR PRIVATE LIMITED from 17 October, 2007. After this agreement

Yamaha aims at increasing its target sales from 120,000 units (2007) to 650,000 units

(2010).

The YAMAHA plant is ISO 9001, 14001 and 18001 certified. The first certification is for

quality management where as the second and third one are for environmental and

safety standards and health respectively.

CORPORATE PHILOSOPHY

For society, for the world …

Yamaha works to realize\ our corporate mission of creating Kando…

Yamaha Motor is a company that has worked ever since its founding to build products

defined by the concepts of “high-quality and high-performance” and “light weight and

compactness” as we have continued to develop new technologies in the areas of small

engine technology and FRP processing technology as well as control and component

technologies.It can also be said that our corporate history has taken a path where

“people” are the fundamental element and our product creation and other corporate

activities have always been aimed at touching people’s hearts. Our goal has always

been to provide products that empower each and every customer and make their lives

more fulfilling by offering greater speed, greater mobility and Greater 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 products for

the land, the water, the snowfields and the sky, Yamaha Motor strives to be a company

that “offers new excitement and a more fulfilling life for people all over the world” and to

use our ingenuity and passion to realize peoples’ dreams and always be the ones they

look to for “the next Kando.”

YAMAHA AND MITSUI ENTER INTO A JOINT VENTURE IN

INDIA

Yamaha Motor Co., Ltd. (Headquarters: Shingai, Iwata, Shizuoka Pref.; President:

Takashi Kajikawa) (hereafter YMC) and Mitsui & Co., Ltd. (Headquarters: Otemachi,

Chiyoda-ku, Tokyo; President: Shoei Utsuda) (hereafter Mitsui) announced the

agreement that Mitsui will become a joint investor in the new motorcycle manufacturing

company India Yamaha Motor Private Limited (IYM) established by YMC in October 17,

2007.YMC and Mitsui have reviewed the possibilities for Mitsui's participation in various

areas of YMC's business activities with the aim of strengthening its overseas business

and cooperative ventures in other areas of business. The decision announced today is a

result of these reviews and repeated discussions with a focus on a "comprehensive joint

business venture in India."

YMC started manufacturing of motorcycles in India by establishing a joint venture

company with local partner Escorts in 1996. In 2001, YMI became a 100% owned

subsidiary of YMC. Then in 2005, a separate sales company, India Yamaha Motors

Private Limited, was established, after which the Yamaha motorcycle business in India

was conducted by two companies specializing in manufacturing and marketing

respectively.With the stable growth of the Indian economy as a whole, the Indian

motorcycle market has grown to 7.3 million units in 2007, making it the world's second

largest market in terms of demand. The aims for the future are for YMC to aggressively

introduce new high value-added models and promote a sales network strategy that

includes expanding the establishments of directly-run showroom/dealerships and for

Mitsui to use its strengths in logistics and dealer network development to achieve a

synergistic effect that will stimulate a growth in sales of Yamaha motorcycles from

120,000 units (domestic only exclusive of exports: 60,000 units) annually in 2007 to

650,000 units (domestic only exclusive of exports: 90,000 units) annually in 2010 while

improving the brand's presence in the fiercely competitive Indian Economy.

1.4 INDIA YAMAHA MOTOR PVT. LTD. (IYM)

Head Office: A-3 Surajpur Industrial Area, Noida-Dadri Road,

Surajpur - 201306, Distt. Gautam Budh Nagar, U.P., India

Foundation: Oct. 17, 2007

Start of operation: April 1, 2008,

Headed by: Mr. Tsutomu Mabuchi,

Managing Director and Chief Executive Officer

Capital: 1.5 billion rupee (as of Mar. 5, 2008), with plans to eventually

increase capital to 5.6 billion rupee (approx. 16 billion yen)

Capital ratio: 70% by Yamaha Motor Co., Ltd.

30% by Mitsui & Co., Ltd.

Number of employees: 2000 (approx.)

Areas of business: Development, manufacture and sales of motorcycles, spare

parts & accessories. Export of locally assembled

motorcycles and parts.

Scale of operations: First year (nine months beginning Apr. 2008) projected

sales of 10 billion rupee (approx. 30 billion yen)

INDIA YAMAHA MOTOR INAUGURATED NEW PLANT AT

SURAJPUR

The new Surajpur plant has been inaugurated by Mr. T.Kazikawa C.E.O & MD Yamaha

Global on 6th July 2009, which has capacity to produce 6 lakh motorcycles annually

including Fazer followed by FZ-16, FZ-S, YZF-R15 and other models. The plant

capacity can be augmented up to 1 million units.

This fully integrated assembly plant is built on the lines of Yamaha’s globally tried,

tested and successfully implemented standards and meets the global quality

benchmarks. At the core are the 5-S and TPM activities that fuel its Manufacturing

Processes. The plant has 3 vehicle assembly lines and 4 engine assembly lines

including one dedicated for export engines. The engine and vehicle assembly lines are

synchronized and incorporate concepts of Unit Assurance i.e. Complete Product

Assurance, Parts Assurance through 100% kit supply on lines and synchronization of

parts storage, supply and production. The innovative production processes along with

high tech final assurance processes are aimed to achieve Zero Claims at our dealers

and thus, a highly satisfied customer base.

1.2 INDUSTRY PROFILE

The two-wheeler industry in India has been in existence since 1955. It consists of three

segments scooters, motorcycles and mopeds. These are very popular as a mode of

transport due to their fuel efficiency and ease of use in congested traffic. The number of

two wheelers sold is several times that of cars. According to a recent survey by SIAM

(Society of Indian Automobile Manufacturers) the no. of two wheelers sold in the fiscal

year ended in march,2008 is 7.25 million units as compared to 1.5 million units of

corresponding 4 wheelers ( passenger cars, SUVs etc.).

The two-wheeler market in India is the biggest contributor to the automobile industry

with a size of Rs.100000 million. Foreign collaborations have been playing a major role

in the growth of the Indian two-wheeler market, and most of them are Japanese firms.

Auto segment in India is widely leaded by two wheeler manufacturer as we can seen in

the graph. So there is a lot of opportunity for two wheeler manufacturers.

AUTO SEGMENT IN INDIA

The total two-wheeler sales of the Indian industry accounted for around 77.5% of the

total vehicles sold in the period mentioned. Among the 3 segments of the Indian two

wheeler market, major growth trends have been seen in the motorcycle segment over

the last four to five years. One good reason for such increase in demand for

motorcycles is due to its resistance and balance even on bad road conditions. Most of

the rural areas in India do not have decent roads and hence the need for good, shock-

resistant, and steady two-wheelers such as motorcycles had been felt. However, the

two-wheeler market in India is a fast growing market due to its technological

advancements in product manufacturing and emphasis on design innovation.

The major two wheeler manufacturing companies in India are Hero Honda, Bajaj, TVS

motors, YAMAHA, Honda etc. Recently Yamaha comes in list after Hero Honda, Bajaj

and TVS Motors as per current yearly sales.

Pessanger Vehicle

Commercial Vehicle

Three Wheeler

Two Wheeler78.63

13.44

3.9 4.03

The two-wheeler sales declined marginally in FY2001. This was followed by a revival in

sales growth for the industry in FY2002. Although, the overall two-wheeler sales

increased in FY2002, the scooter and moped segments faced de-growth. FY2003 also

witnessed a healthy growth in overall two-wheeler sales led by higher growth in

motorcycles even as the sales of scooters and mopeds continued to decline. Healthy

growth in two-wheeler sales during FY2004 was led by growth in motorcycles even as

the scooters segment posted healthy growth while the mopeds continued to decline.

Figure 1 presents the variations across various product sub-segments of the two-

wheeler industry between FY1995 and FY2004. The major two wheeler manufacturing

companies in India are Hero Honda, Bajaj, TVS motors, YAMAHA, Honda etc. Recently

Yamaha comes in list after Hero Honda, Bajaj and TVS Motors as per current yearly

sales. In two-wheelers, hero Honda Motors Ltd., India’s largest bike seller, managed to

sustain sales, while rivals Bajaj Auto Ltd. and TVS Motor Co. Ltd. saw double-digit

declines in fiscal 2008. Hero Honda sold more than 3.24 million vehicles in the year. Its

sales in March were up 15% to 308,052 units.

-20

-10

0

10

20

30

40

50

FY2000 FY2001 FY2002 FY2003 FY2004

Segmental Growth of the Indian Two Wheeler Industry (FY2000-2004)

MOTORCYCLE

SCOOTER

MOPEDS

In two-wheelers, hero Honda Motors Ltd., India’s largest bike seller, managed to sustain

sales, while rivals Bajaj Auto Ltd. and TVS Motor Co. Ltd. saw double-digit declines in

fiscal 2008. Hero Honda sold more than 3.24 million vehicles in the year. Its sales in

March were up 15% to 308,052 units.

Meanwhile, Bajaj Auto’s sales in the year dropped 20% after it sold about 1.68 million

units. Its sales in March, too, were dismal at 114,436 units, down 20% over the same

month last year.

Sales at TVS Motor during the year slid 19% to 1.15 million units, while its March sales

stood at 103,975 units, a decline over the same month a year ago.

Almost all the two-wheelers companies except YAMAHA Motors have launched scooter

version in India. Although currently Bajaj Auto is not manufacturing any scooters

previously Bajaj was market leader of two wheelers in India due to varieties of scooter

models. Recently Hero Honda is producing a scooter model PLEASURE, TVS Motors is

producing SCOOTY, HMSI is manufacturing various scooters like ACTIVA, ETERNO

etc. But YAMAHA has limited itself to bike manufacturing only.

% OF MARKET SHARE IN TWO WHEELE INDUSTERY 2006

Hero Honda

Bajaj

TVS

Honda

YAMAHA

Others

39.8

24.4

17.7

8.5

5.8 3.8

MANUFACTURING PROCESS

IYM's manufacturing facilities comprises of 2 state-of-the-art Plants at - Faridabad

(Haryana) and Surajpur (Uttar Pradesh). Currently 10 models roll out of the two Yamaha

Plants.

The infrastructure at both the plants supports production of motorcycles and its parts for

the domestic as well as oversees market. At the core are the 5-S and TPM activities

that fuel our agile Manufacturing Processes. It has In-house facility for Machining,

Welding processes as well as finishing processes of Electroplating and Painting till the

assembly line..The stringent Quality Assurance norms ensure that our motorcycles

meet the reputed International standards of excellence in every sphere.

As an Environmentally sensitive organization we have the concept of "Environment-

friendly technology" ingrained in our Corporate Philosophy. The Company boasts of

effluent Treatment plant, Rain water - Harvesting mechanism, a motivated forestation

drive. The IS0-14001 certification is on the anvil - early next year. All our endeavors give

us reason to believe that sustainable development for Yamaha will not remain merely

an idea in pipeline.It believes in taking care of not only our Motoring Needs but also the

needs of Future Generations to come.

The various types of shops used in IYM are given below:

1. Welding Shop

2. Pressing Shop

3. Electro Plating Shop

4. Steel Painting Shop

5. Plastic Painting Shop

6. Engine Assembly

7. Body Assembly

Flow Chart of the fulfillment of the component requirement:

B.O.P

Vendor

Forming/Generating Process

Transported to company

Inspected

Arranged

Supplied to the worker

FRAME LINE PROCESS

Frame Line:

Frame is also main part of any vehicle, which supports the other accessories over it

such is fuel tank, seat, mudguards, engine, muffler and etc. Frame is made of steel pipe

or rods. Steel pipe/rods are used in manufacturing of frame as a row material. It is

manufactured in the frame line.

The manufacturing of frame in INDIA YAMAHA MOTOR PVT. LTD. is done in two

welding lines; one is the manual welding in which all welding tasks performed by the

workers and other is the robotic welding in which all wending tasks performed by robotic

welding machine. The robotic welding line takes 3 - 4 minutes in the completion of

manufacturing of a frame while the manual welding line takes 2 - 3 minutes in the

completion of a frame.

Frame Welding:

MIG (Manual)

Robot Arc Welding.

Frame consists of some parts, those are known as the particular names are given

below;

a. Head pipe

b. Main pipe

c. Down tube

d. Seat rail

e. Engine bracket

f. Stopper

g. Cross tube

The manufacturing processes of frame of a motorcycle are given below:

Head Pipe & Main Pipe - MIG Welding

Main Pipe Sub

Main pipe & Engine Brkt. - MIG Welding

Down Tube Sub Welding

Down Tube & Head Pipe - Welding

Front Frame Component 1

Front Frame Component 2

Main Pipe Sub & Seat Rail Sub - Welding

Seat Rail Sub & Brkt. Stop Switch - Welding

Seat Rail Sub & Brkt. Helmet Hanger - Welding

Inspection

Alignment

Fine Boring of Welded Frame

Starting with the three initial stages as manual welding stages where the work is done

on the dandum and the main pipe, different brackets are welded manually.

Setup: 15sec. Welding: 45sec

The second stage involves the welding for Ignition Coil fitment and the fuel tank

brackets:

Setup: 10sec Welding: 45sec

The back seat:

Setup: 15sec Welding: 30sec

Head pipe & Main Pipe - MIG Welding:

In this process head pipe is welded with the main pipe by MIG welding machine.

Machine used : 400 AMPS MIG welding set

Wire diameter : 1.2 mm

Voltage : 18 - 20 V

Current : 150 - 180 A

4.1.2 Main Pipe Sub:

In this process some parts such is cross pin for tube bracket, pad for the main pipe, side

plate for muffler, plate for clamp, cover plate for clamp and clamper are jointed or

welded with the main pipe by the MIG welding machine.

Machine used : 400 AMPS MIG welding set

Wire diameter : 1.2 mm

Voltage : 18 - 20 V

Current : 150 - 180 A

4.1.3 Main pipe & Engine Brkt. - MIG Welding:

In this process the engine bracket is welded to the main pipe. It is performed on the MIG

welding machine.

Machine used : 400 AMPS MIG welding set

Wire diameter : 1.2 mm

Voltage : 18 - 20 V

Current : 150 - 180 A

4.1.4 Down Tube Sub Welding:

In this process the sub welding is being done over the down tube by sub welding set.

Cross tube 1, bracket FR upper 1 & 2, bracket FR under 1 & 2, cross tube 2 and wire

holder L/R are the parts that are welded to the down tube in this process.

Machine used : 400 AMPS

MIG welding set

Wire diameter : 1.2 mm

Voltage : 18 - 20 V

Current : 150 - 180 A

4.1.5 Down Tube & Head Pipe - Welding:

In this process the head pipe and down tube are welded together by MIG welding

machine

Machine used : 400 AMPS MIG welding set

Wire diameter : 1.2 mm

Voltage : 18 - 20 V

Current : 150 - 180 A

Gas flow : 12 - 15 Ltr/min.

4.1.6 Front Frame Component 1:

In this process the front components is welded to the frame which consists main pipe

sub 3 and down tube sub 2; these components are also welded by MIG welding

machine.

Machine used : 400 AMPS MIG welding set

Wire diameter : 1.2 mm

Voltage : 18 - 20 V

Current : 150 - 180 A

Gas flow : 12 - 15 Ltr/min.

4.1.7 Front Frame Component 2:

In this process the front components is welded to the frame which consists gusset head

pipe1 and gusset head pipe 2; these components are also welded by MIG welding

machine.

Machine used : 400 AMPS MIG welding set

Wire diameter : 1.2 mm

Voltage : 18 - 20 V

Current : 150 - 180 A

4.2.8 Main Pipe Sub & Seat Rail Sub - Welding:

In this process seat rail sub and back stay sub left and right are welded to the main pipe

sub by the welding machine.

Machine used : 400 AMPS MIG welding set

Wire diameter : 1.2 mm

Voltage : 18 - 20 V

Current : 150 - 180 A

4.2.9 Seat Rail Sub & Brkt. Stop Switch – Welding:

After the welding of seat rail sub to the main pipe, the stop breaking bracket is welded to

the seat rail sub.

Machine used : 400 AMPS MIG welding set

Wire diameter : 1.2 mm

Voltage : 18 - 20 V

Current : 150 - 180 A

Gas flow : 12 - 15 Ltr/min.

4.1.10 Seat Rail Sub & Brkt. Helmet Hanger - Welding:

After the welding of seat rail sub and the stop breaking bracket, the helmet hanger

bracket is welded to the seat rail sub.

Machine used : 400 AMPS MIG welding set

Wire diameter : 1.2 mm

Voltage : 18 - 20 V

Current : 150 - 180 A

Gas flow : 12 - 15 Ltr/min.

4.1.11 Inspection:

After the completion of all welding processes, the inspection process is being done. The

inspection is performed to check any defect in the frame. The worker should have to

check the frame by as per given standard specifications.

4.1.12 Alignment:

After the completion of inspection process, the alignment of the frame is being check. It

should be proper alignment of frame.

4.1.13 Fine Boring of Welded Frame:

In the last step of manufacturing the frame, a fine boring is done welded frame. To

perform this process WIDIA 2 spindle fine boring machine is used.

Machine used : WIDIA 2 spindle fine boring Machine

Pressure : 10 - 12 Kg/cm2

System pressure : 25 - 30 Kg/cm2

Slide pressure LH/RH : 5 Kg/cm2

Some Welding Defects:

Weld Hole (Burn)

Porosity

Incomplete Welding

Non-uniform Welding

Spatter

Some Error Incurred During the observation:

Jig Error – No Servo (Feedback) Mechanism

Robot Problems

1. Bush Broken – 100’

2. Teaching – 60’

3. Pin Destroyed/Changed – (30-90)’

Torch problem.

WRC - Wire Change

Man Power Less

Power Out.

Component Not Available:

1. Bracket Tank Fitting – 75’

2. Main Pipe – 15’

3. Bracket Side Stand

FUEL TANK LINE

PROCESS: BLANKING

MACHINE: MECH PRESS M/C

OPERATION & REMARK

1) Set the slide adjuster to the Die height limit pad.

2) Roll the sheet on slide rollers & butt against the locators.

3) Press the double hand switch by both hands.

4) Check scrap going down smoothly.

5) Take the blank out.

NOTE-1) Apply oil to the guide post every 50 shots.

2) Apply oil to the cutting edges at start of shift & every 50 shot

3) Wipe off the Die after 100 shots.

ACCESSORIES:

1) Leather gloves

2) Apron

3) Old dhoti

PROCESS: DRAWING

M/C NAME: Hyd. press m/c

OPERATION & REMARKS

1) Blank sheet shall be cleaned .No dust & burr (max 0.5) allowed on the sheet.

2) Set the blank sheet on the blank holder according pins.

3) Push the operating switch.

4) After pressing appearance shall be checked by visually.

5) Stanch properly after Draw operation to avoid dents (soft pressure).

NOTE: -

1) Apply oil to the guidepost every 50 shots.

2) Adjust D/Cushion pressure based on lot material properties.

3) Die polishing after 50 shots.

ACCESSORIES :-

Oil stone (5 PC’s) .Magnet floater

Cotton gloves .Old dhoti

.Emery paper#400 .Apron

.Emery paper#600 .Lubrication oil

DIE/JIG/TOOL: -

. Drawing mould xxxxxxxxx

. Point micrometer.

MUFFLER LINE

FLOW CHART

STEP 1

TAKE A MS SHEET/BODY 1-1 COMING FROM PRESS SHOP

STEP 2

FOLD IT IN THE FORM OF CONE OR CYLINDER AS REQUIRED OF

MODEL/ROLLING OF BODY 1-1.

STEP 3

JOIN ITS ENDS BY TIG ARC

WELDING/TIG WELDING OF BODY 1-1

STEP 4

TAB CUTTING OF BIG END &SMALL END

OF BODY1-1

STEP 5:

Forming of Big End & Small End Of Body 1-1

STEP 6

Tack Welding of Body1-1 + Partition 1-1

STEP 7

Circular Welding of Body 1-1 Sub + Body

Pipe Sub

STEP 8

Press Fitting & Tack Welding of body1-5

Sub & Body Sub

STEP 9

Body 1-2 Sub + Body 1-3 Sub Circular

Welding

STEP10

Muffler Sub + Brkt 2-1 + Stopper -1 MIG

Welding

STEP 11

Body 1-1 Sub + Body 1-2 Sub Circular

Welding

STEP12

Muffler Sub + Nut Welding

STEP13

Leakage testing & Repair

STEP 14

Chipping & Finishing

STEP14

Trolley Loaded For Buffing & Plating

STEP 15

FINALLY CHECKED BY Q.E

PAINT SHOP

Paint shop procedures are:

STEP 1:

The parts are fed to the paint shop in a hanging line.

STEP 2:

Those parts initially pass through a closed chamber where they are treated with special

type of liquid at 60 degree centigrade temperature to wash dusts and other particles

from the body surface. This is known as PRETREATMENT.

STEP 3:

Subsequently a person checks these parts whether all the dusts are removed or not.

Then the body is dried by hot air in a chamber, which is maintained at 75 degree

centigrade.

STEP 4:

Next to this, first coat of paint is done manually using paint spray.

STEP 5:

After 5-10 minutes the second coat is applied to the body. Finally one more coat is

applied for finishing touch. The complete paint spray is done manually.

STEP 6:

These painted parts are moved through a heat chamber (maintained at 75 degree

centigrade) for the paint to be settled and dried fully.

STEP 7:

This complete cycle takes around 3 hours. In this process paint utilization is only 40%

and almost 60% of paint goes waste.

The painted parts are checked for defects and the data analysis shows

Stage wise dust analysis

o Checking of visual sources of dust

o Collection of dust samples

o Analyzing type of dust by microscope

Dust analysis by microscope

o Magnification of dust analysis

o Magnification of rust analysis

o Magnification of t/c over spray

o Magnification of b/c over spray

Type of dust

Source of dust

o B/C booth str.

o B/C booth ceiling filter

o Hangers & hanger trolley

o T/C booth str.

o T/C booth entry wall

o T/C booth exhaust system

o Passage after washing

After checking if there is minute dust particles in the painted body parts those dusts are

removed by a process called as BUFFING. In this process a chemical is applied to the

affected part and the dust is sucked by application of air. After buffing parts are sent to

GRAPHICS shop for pasting stickers if necessary.

But if there are large particles existing in the body part then those parts are again sent

for reworking in the same shop. Above procedure are followed for plastic parts but there

are another electric paint shop for MS parts which is automated.

ELECTROPLATING SHOP

It is a technique of painting in which we didn’t directly apply the paint on the body parts

but we sealed it with some rusting free metals or alloy like chromium or zinc. And give it

good appearance. All process is done on dc supply.

STEP 1:

SHOK CLEANING:

In this step we do soak cleaning in which we deep the w/p into the solution of sodium

hydroxide & hot water, so that the grease or other oil material gets cleaned.

STEP 2:

WATER WASH:

Water wash in this process we wash the w/p twice in the hot water for better cleaning

purpose.

STEP 3:

ANODE CLEANING:

It is a process of electro plating in which w/p is made as cathode and m/s plate is as

anode &when the current pass through it. Then deposition of metal from w/p to the m/s

sheet takes place so we say that it is ultra cleaning process.

STEP 4:

WATER WASH:

STEP 5

ANODE CLEANING

STEP 6

WATER WASH (TWICE):

STEP 7

NEUTRALIZATION PROCESS

In this process we deep the w/p into a get a neutral w/p.solution of sulphuric acid to

neutralized the effect of base. After this we

STEP 8:

NICKEL DEPOSITION (SEMI BRIGHT PROCESS):

In this process we mix distilled water, nickel sulphate , nickel chloride & boric acid in

proportional amount. It is also an eloctroplating process in which deposition of nickel on

the w/p takes place. To remove the impurities present in the nickel powder we place it in

bags (cotton).

STEP 9:

CHROME COATING (FULL BRIGHT)

High density golden color liquid gets stick on it .After washing it again & again it comes

to its original color.

STEP 10:

AIR BLOWIONG:

Finally we dry it with blowing hot air through it & when it become dry then we send it to

assembly shop.

CAUSE OF DEFECT

1. Dust in w/p

2. Rust in w/p

3. Grease or other impurities

4. Improper handling

1ST GEAR

BUSH

Circle

2ND GEAR

3RDGERR

33R333333333anbbanb33rd3rGea

Washer

ENGINE ASSEMBLY

DEFNITION:-

Engine is a combination of different links that convert chemical energy into mechanical

energy. Due to which we get desired output by specified input. It is generally of two

types

Internal combustion engine

External combustion engine

TO STUDY OF VARIOUS SUB-ASSEMBLY STAGE

1.Axle Drive Assy. 2.Axle Main Assy.

1 Crank assembly 4.Balancer Assy.

CRANK

WASHER CIRCLE

5.Cover Crank Case-3 Assy. 6.Piston Ring Assy.

7.Cam Shaft Assy. 8.Head Cylinder

9.AIS Pipe Fitting Assy.

FILLER GAUGE

10.Cover CC1 Assy. 11.stator assy.

13.Kick shaft Assy.

kaasai Kick gear

Clip

Ratchet

her

Spacer

Spring

Washer

WASHER

KICK GEAR CLIP

SPRING

KICKSHAFT

16.Rotor Assy.

ENGINE ASSEMBLY FLOW ON MAIN LINE

STEP 1:

Place the bearings in the cc-1 & cc-2 (axel drive bearing, axel main bearing, balancer

bearing, crank shaft bearing).

STEP 2:

Code punching:

In this stage a 14 digit number is punched on the engine.

BEARING PRESSING

STEP 3:

Apply the crank shaft, axel main, axel drive& balancer into it.

STEP 4:

Then we place other parts like gears, fuel oil pump& ffinally we closed it by placing

adeshive& gasket between them.

STEP 4:

Then we place the piston with cylinder head, air cooler (fins) & finally close it with cc

covers.

STEP 6:

We fill it with oil and send for engine tsting where its performance is chacked.

Torque wrench

Feeler gauge

Oil filling

Token

The summary of the whole process is given below

Balancer Balancer pin Crankage 1 Crankage 2 Number Punching

Bond m/c Gear

attached Conveyor belt start

Bearing press

Cover 2 attached

Clutch assembly

Oil pump

Self star motor

Timing gear

L:ine code

Spark plug Rotor

Appearance check

Oil enters

Kick Shaft

Oiling Cylinder head

Body cylinder piston

Body Assembly

Body Assembly is the process of assembling the actual motorcycle while receiving different parts from different shops or vendors.

An assembly line is a manufacturing process in which parts (usually interchangeable parts) are added to a product in a sequential manner using optimally planned logistics to create a finished product much faster than with handcrafting-type methods

In IYM there three assembly lines present, each is assigned what to produce by the production planning and control department.

The procedure followed in assembling a motorcycle is given below.

Pressing of ball Rear fender Number punching

TFF,mudguard

Engine

Breakshoe Chains, shockers

Main frame,footrest

bracket

meter Horn,stick Rear tyre

Tailcover

Battery box Chain cover Brakes on tyre

Headlight

seat

Fuel tank Brake,clutch

lever

Inspection Battery

Tail light

4 M ANALYSIS

FOUR M’S STANDS FOR

MEN

MACHINE

METHOD

MATERIAL

The basic characteristics of four M are for optimum production.

Men:

The men force should be trained well.

The men should have right attitude for work.

The appropriate part of total work force should be multi skilled.

Machine The proper machine and tool kit should be allocated at workplace.

Stand by machines and tool kit option should be there in case of critical parts.

Periodical review of machines and tool kit by experts.

Method

Method should be well explained to the responsible worker.

Improve that method which doesn’t fulfill the requirement of production.

Method should be time saving, space saving, cost saving.

Material

Material should be the as per standard given by company.

Timely availability of material by vendor.

Vender should be responsible for all incurred cost of company, in case of any material defect.

CONCLUSION

The summer training at the Yamaha india motors ltd. Surajpur was a

learning curve and a joyous experience in my engineering studies. It was a

pool of knowledge and I sincerely hope that it will be useful in my career

besides learning the technical aspects I also learned the methodology of

working of such a reputed and productive organization.

I would sincerely like to thank my institute and also Yamaha India for this

venture.