Atlas Honda Internship Report 2013

Internship Report

Atlas Honda SKP Plant

Ghulam Ishaq Khan Institute of Engineering Sciences & Technology KPK

Submitted by

MUHAMMAD SHAFIQUE

SYED IMMAD HUSSAIN SHAH

UMER SALEEM

MUHAMMAD BURHAN AZEEM

July 11, 2013

Internship Report | 2013

The report is written as per the requirement of our internship, summer 2013, in Atlas Honda

Ltd. The report includes the complete orientation of the AHL plant situated in Sheikhupura. It also

covers the project offered to our group that was “Identification and the solution of the Problems in

Deburring Machine”. Report also explains the activities performed by the internees in AHL plant like

gear analysis, internal auditing, tool tip analysis, re-lay outing of deburring machines and lay outing

of the extension of the Hi-tech department.


We would like to acknowledge the HR department AHL, who made our stay in the plant

possible and wonderful in every aspect. We would also like to thank the major part played by all the

Engineers and Technicians in sound understanding of the overall system of the plant. We would like

to extend our gratitude to Mr. Zia-ul-Hassan Khan for helping us in selecting a project for our

internship and supporting us morally and technically. We are thankful to Mr. Rashid Aleem for his

ever helping nature. His activities and appreciation will help us throughout our professional career.

Last but not the least we would like to thank Mr. Yawar, Mr. Saad, Mr. Ijaz and Mr. Faheem for

their guidance. It was really a treat to work under such competent personnel.


LIST OF CONTENTS

Atlas Group of companies............................................................................................................................... -01-

Atlas Honda.............................................................................................................................................. -02-

Atlas Honda Karachi................................................................................................................................ -02-

1.0 Atlas Honda Sheikhupura............................................................................................................ - 03-

1.1 Quality Policy………................................................................................................................. -04-

1.2 Atlas Culture...............................................................................................................................- 05-

2.0 Orientation.....................................................................................................................................- 05-

3.0 Engine Plant.................................................................................................................................. - 09-

Internship Project..................................................................................................................................... -14-

4.0.0 Identification and the solution of the Problems in Deburring Machine............................... -14-

4.1.0 Project Background .................................................................................................................-15-

4.2.0 Problems Identification ……………...................................................................................... -16-

4.3.0 Solution Strategy…................................................................................................................ - 17-

4.3.1 Importance Chart................................................................................................................... - 19-

5.0.0 Solution...................................................................................................................................... -20-

5.1.0 Problem 1: Cutting of the gear teeth along with the burrs…….............................................. -20-

5.1.1 New Arm Design....................................................................................................................- 21-

5.1.2 Creo Parametric Model............................................................................................................-21-

4.1.3 Final Assembly……………................................................................................................... -25-

Manufacturing Drawings.............................................................................................................................. -26-

5.2.0 Problem 2: Unacceptable surface finish.................................................................................. -35-

5.2.1 Threaded screw………............................................................................................................ -35-

5.3.0 Problem 3: Manual control of Motor by foot.......................................................................... -36-

Gear Shop Activities............................................................................................................................... -37-

6.0.0: Activity 01-Gear meshing Analysis.......................................................................................- 37-

7.0.0: Activity 02- Internal Auditing...............................................................................................- 40-

8.0.0: Activity 03- Re-Lay outing of Deburring Machine............................................................. - 41-

9.0.0: Activity 04- Time study of the Hobbing Process………..................................................... - 47-

10.0.0: Activity 05- Deburring Tool Analysis.......................................................................................... -48-

Conclusion & Recommendations............................................................................................................ -49-


Atlas Group of Companies consists of 14 companies. The first ever of them was Shirazi

Investments (Pvt.) Ltd. After the success of which the group continued to grow. At present more than

2% of the country’s GDP is the contribution of Atlas Group only. The names of the companies and

their years of foundation are shown in the following table:

Table 01: Atlas Group Growth

Today Atlas is a diversified group dealing in engineering, financial services, power and

trading. It consists of seven public limited companies out of which five are quoted on the Stock

Exchanges in Pakistan, and six private limited companies.

Atlas shareholders equity now stands over 25 billion rupees; assets have increased to over 60

billion rupees the last being Atlas Power with over 20 billion rupees; personnel strength is over 7000

and annual sales have crossed 60 billion rupees. The Group strategic direction is determined by the

Group Executive Committee while each company functions autonomously within the framework of

the predetermined policy.

Name of the Company Year of Foundation Shirazi Investments (Private) Ltd. 1962 Atlas Honda Ltd. 1963 Atlas Battery Ltd. 1966 Shirazi Trading (Private) Ltd. 1975 Atlas Insurance Ltd. 1980 Atlas Engineering Ltd. 1981 Honda Atlas Cars (Pakistan) Ltd. 1992 Honda Atlas Power Products (Private) Ltd. 1997 Atlas Asset Management Ltd. 2002 Shirazi Capital (Private) Ltd. 2005 Atlas Power Ltd. 2007 Atlas Worldwide General Trading LLC 2007 Atlas Venture 2008 Atlas Autos (Private) Ltd. 2011

1


Atlas Honda is one of the most prestigious and well established companies of Pakistan. It is a joint

venture of Atlas Group and Honda Japan. The company was founded by Mr. Yusuf Shirazi in 1963 at

Panjdariya. The Atlas Honda Limited is a joint venture between the Atlas Group of Pakistan and Honda

Motor Company of Japan. The Atlas Honda was created in 1988 by the merger of Panjdarya

Limited and Atlas Autos Limited.

Both these motorcycle manufacturing concerns were established by the Atlas Group. Atlas Honda

manufactures and markets Honda motorcycles in collaboration with Honda Motor Company. Atlas

Honda also manufactures various hi-tech components in-house in collaboration with leading parts

manufacturers like Showa Atsumitech, Nippon Denso and Toyo Denso. Atlas Honda Plants are located

in Karachi,and Sheikhupura. Honda Atlas assembles four motorcycles in Pakistan, the CD70,

Pridor, CG 125 and CG 125 Deluxe.

Atlas Honda Karachi:

Company mother plant is based in the city of lights and provincial capital of Sindh, The Karachi

city. It is located at F-36, Estate Avenue, and S.I.T.E. Karachi. Atlas Group signed technical agreement

with Honda in 1963 and plant started commercial production subsequently. Plant spread over an area

of 5 acres. In 1964, production began with 7 motorcycles per day. Now plant production has reached

to 300 units in a day. Plant manufactures CD 70 only.

Atlas Honda

Atlas Honda Karachi Atlas Honda Shiekhupura

Fig. 01: Atlas Honda Plants

2

http://en.wikipedia.org/wiki/Atlas_Group

http://en.wikipedia.org/wiki/Honda

http://en.wikipedia.org/wiki/Honda

http://en.wikipedia.org/w/index.php?title=Panjdarya_Limited&action=edit&redlink=1

http://en.wikipedia.org/w/index.php?title=Panjdarya_Limited&action=edit&redlink=1

http://en.wikipedia.org/w/index.php?title=Atlas_Autos_Limited&action=edit&redlink=1

http://en.wikipedia.org/wiki/Motorcycle

http://en.wikipedia.org/wiki/Honda_motorcycles

http://en.wikipedia.org/w/index.php?title=Showa_Atsumitech&action=edit&redlink=1

http://en.wikipedia.org/wiki/Denso

http://en.wikipedia.org/w/index.php?title=Toyo_Denso&action=edit&redlink=1

http://en.wikipedia.org/wiki/Karachi

http://en.wikipedia.org/wiki/Sheikhupura

http://en.wikipedia.org/wiki/Atlas_Honda_CG_125

http://en.wikipedia.org/wiki/Atlas_Honda_CG_125_Deluxe


1.0 Atlas Honda Sheikhupura:

Another plant is situated in Sheikhupura city, Punjab. It is located at 26-27 KM Lahore-

Sheikhupura Road Sheikhupura. The plant was built in 1981 and spread over an area of 27 acres with

the establishment of modern and synchronized 500K plant in 2006. The plant manufactures all four

models i.e. CD 70, Pridor, CG 125 and CG 125 Deluxe.

Honda motorcycles are by far the LARGEST

selling motorcycles in the country with an

unmatched reputation for high quality, reliability

and after-sales-service.

AHL has undertaken to develop local

manufacturing capabilities to the highest,

economically feasible level. While a major role

in localization has been assigned to vendor

industries, Atlas has the country’s largest

in-house manufacturing capability at its

Karachi and Sheikhupura plants. To support the

production facilities, the company has

established an R&D wing and tool making facilities through CAD/CAM which are growing rapidly in

size and function as the company expands. Atlas has managed to execute 12 Joint Venture/Technical

Assistance Agreements between local vendors and foreign manufacturers for transfer of technology.

Besides, Atlas has directly executed 9 Joint Venture/Technical Assistance Agreements other than

Honda.

AHL management is striving to modernize company operations by adapting applicable aspects of

research and theory and more specifically, Honda’s unique philosophy of hard/soft technologies to the

realities of Pakistani conditions. The Company training and development programs encourage all

members to develop themselves and contribute to their full potential.

AHL is playing a pioneering role in creating conditions for easy and confident use of motorcycles

all over the country. A vast and growing network of over 1600 sales service and spare parts dealers

has been established. In order to back up this system, Atlas has set up Warranty & Training Centers

(WTC) in Karachi and Lahore which provide several courses of varying duration and complexity for

Fig. 02: Atlas Honda SKP Plant

3


motorcycle mechanics and users each year. Mobile training facilities take the latest know-how,

technology and maintenance of motorcycles to major rural and urban centers around the country.

1.1 Quality Policy:

The Quality policy of Atlas Honda is shown in the diagram:

Commitment to provide high quality motorcycles & parts

Maintain and continuously improve quality

Right work in first attempt and on time

Safe, clean and healthy environment

Training of manpower and acquisition of latest technology

Market leadership and prosperity for all

Fig. 03: Company Capital & Capacity

4


1.2 Atlas Culture:

Atlas culture is built on the heritage and accomplishments and promotes equality and harmony

amongst the workers of the company. Atlas Culture is the most important factor that distinguishes it

from other companies. This culture creates a unique personality growth of each of its employee. The

basic points of Atlas Culture are summarized in the diagram:

The Atlas culture makes the people work more efficiently. When the workers, from CEO to the

laborer, eat in the same hall, stand in the same queue to get lunch and wear same dresses, they have a

feeling of equality. This does not make workers of lower grades feel rejected or deprived. Through this

unique culture of the organization, one can see quite clearly how much the company care about all of

its employees.

2.0 Orientation:

On the day of our first visit to Atlas Honda Limited, the Human Resources department made sure

that not a single moment of our visit of Atlas Honda goes to waste. They took us to different

departments of the plant or asked the managers of some plants to give some of their precious time to

Integrity and merit Education Self assurance of

oneself

Do not become a burden on Atlas

or SocietyAvoid being Overbearing

Live Economically

Do Charity Be Happy, Healthy & Wealthy

5


us so that we can have an idea that how the departments are working together in huge setup like Atlas

Honda. The orientation was divided into seven days in which we visited different departments or were

briefed by the managers of some departments. The schedule of the visits was provided to us. The

departments we visited are listed below:

Human Resources/ Admin/ CA

Admin & IR

Corpoate Affairs

Finance

Logistics

Vendor Procurement

Maintainance

PPC

IT

Stores

Quality Assurance

Manufacturing Plant

Assembly Plant

Casting Plant

Engine Plant

Fig. 04: Orientation Plan

6


The departments are explained briefly below:

1) Human Resources/ CA/ Admin:

HR department is responsible for the recruitment of new staff and appraisal and training of

the existing staff. The HR department is working separately for Karachi and Sheikhupura but the policy

is being made in Islamabad. The administration is responsible for managing the major functions of the

organization that include from Security to transport and dining facility of the staff. The HR of Atlas

has made various worker friendly rules that are facilitating their employers. These rules even include

the issuance of a motorcycle to grade 13 and above on easy installments. Atlas is also running many

social and welfare organizations that include a hospital and school as well.

2) Admin and IR:

Admin department of Atlas is responsible for making several policies regarding the growth

of the organization and security as well. The motive of Atlas is to provide customers with quality

products and give a reasonable profit to the shareholder as well. IR and Admin jointly are responsible

for successful and smooth running of the organization.

3) Corporate Affairs:

Corporate affairs department is the major backbone of any organization. In Atlas Honda, the

corporate affairs department is responsible for interlinking all the other departments with one and

other. The department plays an important role in the promotion of concurrent engineering.

4) Finance:

The finance department is responsible for carrying all the work related to accounts and

money. Finance department gives the salaries to the employers and manages the money received from

the dealers after selling them the bikes and money given to the vendors.

5) Logistics

Logistics is the management of the flow of resources between the point of origin and the point

of consumption in order to meet some requirements, for example, of customers or corporations.

6) Vendor Procurement:

The vendor procurement department makes arrangements of the vendors. It allows the vendors

to makes bids by offering them the quotation. The vendor with the lowest bid wins.

7


7) Maintenance:

The maintenance department performs all the maintenance works whether it is about

maintaining the machines or maintaining the plant. The production of the electricity in the gas and

diesel plant also comes under the maintenance department.

8) PPC:

PPC involves all the production plan according to market demand. The production plan for the

entire month is given to the shops at the start of that month. PPC involves the analysis of the market

which determines how much the production of the bikes should be as per demand.

9) Information Technology (IT):

The IT department is responsible for maintaining all the computer data of the company. It is

performing a lot of works from managing the computers, installing the software and managing the

LAN in the plant and its head offices. The IT department has the official license of Microsoft Office

2004 and Windows XP.

10) Stores:

The store is the department which is situated in front of the security gate of the Atlas Honda

plant. Store is one of the most important department for manufacturing, HPDC & LPDC, casting and

vendors. All the products that are made in a department are stored in the store before being passed to

the other department. For example all the castings are moved to the store before being machined in the

Hi-tech plant.

11) Quality Assurance:

The quality assurance department is playing an important role in providing the customers high

quality motor bikes. Honda has maintained this tradition for quite a long time now and that is the

reason why they are the major shareholders of the motorbike industry in Pakistan.

12) Assembly Plant:

Assembly plant is the final department from which the bike passes. All the parts of the motorbike

are collected in the assembly plant and are assembled properly. The bike is checked before it is sent to

the store and to the dealer.

8


13) Casting Plant:

In casting plant many of the parts are manufactured which are then used as parts in the motorcycle.

The parts that are casted include the crankcase, crank cover, crank shaft and cylinder head. The casing

plant is divided into two parts i.e.

• HPDC

• LPDC

14) Engine Plant:

The engine plant (also called as the Hi-tech) is one of the biggest department and is still being

expanded due to high production rate. The engine plant collects all the parts of the engine in the raw

form which are then machined to form the finished products. The products are checked for high

accuracies and the parts which are up to the mark are sent to the assembly plant.

15) Manufacturing Plant:

The manufacturing plant includes the paint shop and the shop that makes the body of the bike. The

sheets are brought here and are punched and stamped to form the body of the bike. The parts include

the side covers of the bike. The sheets are then painted in the paint shop to give the unique look to the

bike and stickered to make it more beautiful.

3.0 Engine Plant:

The HR department assigned us the engine plant for our major internship project. The national

manager of the engine plant, Mr. Zia-ul-Hassan Khan, asked us to take a detailed orientation of the

engine plant. We went to the shops of engine plant and had a detailed description of each department.

The departments we visited are as following:

Hitech Department

Crank Shaft Crank Case Cylinder Head

Tool Regrinding CAD/CAM Oil Pump Cam Shaft

Gear Shop

9


1) Crank Shaft Shop: The crank shaft department makes the

crank shafts that are resent in the engine

and makes the rotation of the main shaft

and its gears. The crank shaft is actually

a sliding crank mechanism. The sparking

and burning of gases makes the shaft

rotate. The processes involved in the

making of the crank shaft are given below

in the table:

Processes:

2) Crank Case Shop: The crank case shop makes the left and right cases of the CD 70 and CG 125/ Deluxe as well as

machines the left and right cover of all the models as well. The raw material of the crank cases comes

from the casting plant where the cases are casted from a specific composition of iron and other

materials. The models for which the crank cases and crank covers are being machined are as following:

• L/R cover

• L/R crank Case

Centering Turning Pin Hole Involute Spline

Gun Drill

Key Grooving HFQ Grinding

Fine Boring

Thread CuttingWashing Steel ball

pressPin PressCrank Press

Bearing Press Run outKey

Fitting

Fig. 05: Finished Crank Shaft

10


Processes:

For CG 125 and CG 125 DELUXE For CD 70 and Pridor

3) Cylinder Head: The cylinder head department managed by the assistant manager, Mr. Imran Khan, is

responsible for providing the engine assembly with the cylinder head. The operations performed on

the cylinder are as following:

Machine Name Process Rotary Milling Face Milling

2 way Drilling Drilling, Boring

1 Way Drilling Drilling

2 way tapping Tapping

Op2 Drilling, Reaming, Tapping

Fine bore Reaming boring

OP1 Drilling, Reaming, Tapping

Kira Drilling, Reaming, Tapping

Washing cleaning

Orifice Press Sub assy press

Breather Joint Sub assy Fitting

Leak Test Testing

Bearing Press Bearing Fit

Machine Name Process Rotary Milling Face Milling Single Phase Side Facing HN- 50B Drilling, Reaming, Boring Module Drilling, Reaming PN-40 1,2 Drilling, Reaming Kira 1,2 Drilling, Facing, tapping Multitap Tapping Honing Honing Multi drill Drilling, Reaming Kira 3 Drill, Ream & tap Self-Feeder Drill and Ream Washing Cleaning Sub Assembly plug Fitting Leak Check Leak testing Bearing Press Bearing Fit

Machine Process

OP 0-5 Facing, drilling, Reaming, taping Boring

Washing Cleaning

Cam Leak Casting Leakage

Guide Press Guide fitting

Seat Press Seat Fitting

Hot Washing Hot Cleaning & Air Blowing

Sub Assy Station Valve in, Seal cap, Washer Spring

Valve Assy Cotter & retainer Fitting

Valve Assy test Valve Checking

Stud Assy Stud Fitting

11


4) Oil Pump: The oil pump department makes the oil pump for all the models and provide these to the engine

assembly department. The processes involved in the machining of the oil pump and machines involved

are shown below:

5) CAD/CAM: CAD/CAM shop is helping the Engine shop in the designing of the new parts as well as the jigs

and tools of the present machines as well. The department makes new designs as well.

6) Tool Regrinding: Tool regrinding department is used for the regrinding of the tools that wash out and also makes

new tools for the engine plant. This shop has 8 machines and 9 workers.

7) Cam Shaft: The cam shaft department makes cam shafts that are used for the motion of the valves that makes

the flow of the gas possible. There are two valves, so two cam profiles are made on the shaft.

Machine Process CNC miyano Lathe Turn Face Chamfer CNC Machining Facing Boring Reaming Chamfer Tap Hot Washing Hot Water cleaning and air Blowing Sub Assy Rotor plate & Screw Assembly Inspection Fixture Inner & outer Assy Test CNC Machining Facing Boring Reaming Chamfer Tap Washing Cleaning Leak Tester Casting Leakage test

Fig. 06: Cylinder Head Line

12


8) Gear Shop: Gear shop makes the gears for the engine plant. The gears are taken from the vendors and are

machined in the gear shop. The processes being applied on the gears can be divided into following

categories:

Processes:

The processes being applied in the gear machining section are shown in the figure below.

Gear Shop

Gear Machinig Shaft Grinding

Turning and Facing

BroachingGear Shapper + Hobbing

DeburringHeat Treatment

HoningInspection

Fig. 07: Gear shop processes

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Internship Report| 2013

During Internship at Atlas Honda, we were assigned an important project regarding the rejection

control of the deburring machine. This project was assigned after the orientation to the Engine plant.

The project was completed in time successfully and was reported to our supervisor. The project that

we worked on is titled as under:

Identification and the solution of the Problems in Deburring Machine

The projects is detailed as under:

Deburring is a finishing method used in industrial settings and manufacturing environments. Metal

is frequently machined using many processes in order to create pieces of specific shape and size, and

it may be welded, molded, cast, trimmed, slit or sheared. These procedures often create ragged edges

or protrusions. The raised particles and shavings that appear when metal blanks are machined are

referred to as burrs, and the process by which they are removed is known as deburring:

4.0.0 Identification and the solution of the Problems in Deburring Machine

Fig. 08: Deburring Process demonstration

14


4.1.0 Project Background:

During the teeth cutting of the gears, burrs are formed in some machines that are to be removed.

In Gear Shop of Engine Plant, two types of machines are there that are used for teeth cutting:

• Gear Shaper

• Hobbing Machine

In some of the Gear Shapers the process of Deburring is being done simultaneously during teeth

cutting and therefore no need of deburring process. However during the teeth cutting of smaller gears

where it is impossible to carry out the deburring process simultaneously, the gears are deburred

separately in Deburring machine. While all the gears need to be deburred separately that are being

processed in Hobbing machine.

There are four Deburring machines in Gear Shop named as Deburring Machine 1, 2, 3 and 4. The

details of the gears (for all the models i.e. CD 70, Pridor, CG 125, CG 125 Deluxe) that are being

deburred and the corresponding machine are listed below:

CD 70 Sr. # Gears deburred Remarks 1 Pinion Kick Starter Machine 2,3,4 2 M3 Machine 1 3 M4 Machine 2,3,4 4 C2 Machine 1 5 C3 Machine 2,3,4 6 C4 Machine 2,3,4 CD 100 (Pridor) 1 Pinion Kick Starter Machine 2,3,4 2 M3 Machine 1 3 M4 Machine 2,3,4 4 C2 Machine 1 5 C3 Machine 2,3,4 6 C4 Machine 2,3,4 CG 125 1 M2 Machine 1 2 M3 Machine 1 3 M4 Machine 1 4 C1 Machine 2,3,4 5 C3 Machine 1 6 C4 Machine 2,3,4

Deluxe (125) 1 M4 Machine 1 2 M5 Machine 2,3,4 3 C4 Machine 2,3,4 4 C5 Machine 1

Table 02: Gears processed on Deburring Machines

15


The above table shows that there are 22 classes of gears that are deburred. These gears are inspected

after the deburring process and then are either accepted or rejected. In gear shop, the rate of the

rejection of these deburred gears was very high and was increasing day by day as indicated in the

monthly Rejection Report of the Gear Shop. In this project our prime objective was to reduce the rate

of this rejection.

4.2.0 Problems Identification:

After the careful analysis of the rejected gears we found that these rejections were due to the

deburring machine. Then we observed the deburring machining process, operated it by ourselves and

investigated the problems from the operators, from which we got to some conclusions about this

machine problems. We found several problems in it, some of which caused the rejection by disturbing

the teeth profile and surface finish while some of which were related to the fatigue work of operator

and the production time.

Therefore we identified two types of problems:

i) Problems that caused the rejection of the gears:

ii) Problems that caused the fatigue work and low production:

Problem 1• Cutting of the gear teeth along with the burrs

Problem 2• Unacceptable surface finish

Problem 3

• Manual control of Motor by foot

Problem 4

• Clamping Issue

Problem 5

• Braking

Problem 6

• Piling up of the gears near the tool

16


4.3.0 Solution Strategy:

After the identification of the problems, these were sorted down according to their importance and

the most important problems was given the Priority number as 1 and the rest of these were arranged in

similar way. The following path was following in order to get our targets:

Each of the problems identified were studied thoroughly and different ideas were generated

through brain storming. All the group members generated the ideas for each of the problems separately.

We use some previous knowledge of engineering and also got help from books and internet for

generating ideas.

After generating maximum number of ideas for each problem, we started shortlisting them on the

basis of following criteria:

• Cost

• Complication

• Production delay

• Technical short comings

• Space Constraints

From the above procedure we got maximum three ideas for each problem. Then we discussed these

ideas with our supervisor for the final selection of single idea for each problem.

Following table was finally compiled summarizing different problems, their causes, corresponding

ideas and their rejection or selection along with the justification:

Problem Identification

Identification of the cause

of the problems

Ideas generation Idea selection Problem

Solution

Fig. 09: Solution Plan

17


Problem

No.

Problems

Objectives

Ideas

Remarks

Reasons

1

Cutting of the gear teeth along with the burrs

Play should be Zero

i) Bearing Pin joint Rejected Simple bearing could cause play

ii) Welded Handle and Bearing at the end

Accepted

Play will be removed completely

iii) Washer welded Handle at the joint

Rejected friction issue

2

Unacceptable surface finish

Gear should be deburred just below

the deddendum

circle

i) Welded rod constraints (with stepped slots)

Rejected

Less space will be available

ii) Toggling mechanism

Rejected

Manufacturing Difficult for different sizes

iii) Threaded screw Accepted Easily adjustable iv) Sensor Rejected Costly

3

Manual control of Motor by

foot

Automatize the motor

control

i) Manual Switch on the handle

Rejected

Switch will be damaged due to frequent on and off

ii) Limit switch control

Accepted

Complete automation with less cost

iii) Automatize through sensor

Rejected Costly

4

Clamping

Issue

Clamping should be fast and efficient

i) Electromagnetic clamping

Rejected Space not available for Electromagnet

ii) Collet clamping

Accepted

Suitable for existing machine

5

Braking

Braking mechanism should be

installed so that gear

stops immediately after process

i) Disk Brake operating with arm

Rejected

Not appropriate due to high rpms of motor

ii) Drum brake operating with arm

Accepted

Near the motor, enough space and less costly

6

Pile up of the Gears

Gear should not pile up

near the tool after

processing

i) Storing area should be inclined and deep

Accepted Low cost, no time consumed

ii) Partition near the tooling

Rejected Time consuming in mass production

iii) Conveyer mechanism

Rejected Costly

Table 03: Deburring Machine Modification- Ideas Generation

18


4.3.1 Importance Chart:

A chart was developed that shows the importance of each problem. The point are given to each

problem on percentage basis after carefully analyzing the effect of each problem on part rejection and

the production time. On the basis of this chart, the top three problems that carry the combine

importance of 90% were focused and the solution of each of these three problems were obtained.

60%20%

10%

5% 3% 2%

Importance of The Problem (%)

Problem No 1

Problem No 2

Problem No 3

Problem No 4

Problem No 5

Problem No 6

1

3

1

4

0

56

3

5 5

6

22

4

2

1

2

0

1

2

3

4

5

6

7

Problem 1 Problem 2 Problem 3 Problem 4 Problem 5 Problem 6

No.

of P

erso

ns A

gree

d (o

ut o

f 6)

Ideas Selection Chart

Idea 1 Idea 2 Idea 3 Idea 4

Problems and Ideas are given the No. as per above table

19


5.0.0 Solution:

From above graph it is clear that if we solve problems 1, 2 and 3 it means that we have solved

almost 90% of total problem in existing machine. Therefore focus was given on these three problems.

The solution of these three problems is detailed as under:

5.1.0 Problem 1: Cutting of the gear teeth along with the burrs:

This problem being the major contributor towards the rejection of the gears was specially

focused and analyzed. It was found that during the deburring operation, the handle moved sideways

due to the Play in it. That’s why the tool did not touch the gear at the target point instead it sometimes

touched its teeth and thus the whole profile of the teeth was destroyed causing the complete rejection

of the gear due to the cut on its teeth as shown in fig below:

Fig. 10: Elaboration of the source of deburring machine problem

20


Following strategy was made in order to remove this problem:

The pin joint about which the arm move should be redesigned such that the play is removed

completely

The weight of the arm was very large due to which the spring supporting the arm often got

wear off therefore its weight was to be minimized

Following above it was decided that the Arm of the deburring Machine should be redesigned.

5.1.1 New Arm Design:

In making the new design of the arm, it was necessary to keep into account the fact that:

The design should be such that it can be integrated to the Deburring Machine without

disturbing the production

Also the design should be such that the arm can be mounted on the existing cross slide

The new design should not be costly

The new design should be manufactured easily

As the New arm was to be mounted on the existing cross-slide so we also had space constraints. We

had to first design the bearing housing that was to be placed on the cross slide.

5.1.2 Creo Parametric Model:

Before making the final drawings for the parts of the Arm, the whole assembly was modeled and

simulated using Creo Parametric. All the parts were made separately and were assembled. The whole

assembly included eight parts.

1. Base Part:

The part on which the housing

will be mounted is the base part

and is the existing base part with

only change in the number of holes

and their position.

Fig. 11: Base Part Model

21


2. Bearing Housing:

Bearing housing was designed such that it is fitted to the existing base and is dimensioned accordingly. Two such housings will be used in final assembly.

3. Arm:

The arm design is

completely different from

previous design. In this new

design the weight of the arm is

kept as lower as possible so that

the fatigue work is low and the

spring doesn’t wear off as was

in previous design.

Fig. 12: Bearing Housing Model

Fig. 13: Arm Part Model

22


4. Handle:

The handle is designed such that the grip of the operator is significantly large as compared to the

previous design:

5. Shaft:

Shaft is such that its diameter is in interference fitting with the bearing. It is also completely different

than the previous one and is shown as under:

Fig. 14: Handle Part Model

Fig. 15: Shaft Model

23


6. Spring:

Spring is designed to keep the fatigue work of the operator to the lowest level. Two such springs will be used.

7. Two Springs and one Spring Leg blocker:

Both of these part are to confine the spring from both ends so that a sufficient stress is generated in it that help the arm to come to its initial position.

8. Bearings:

Bearing are the most important parts in the new design because we replaced the previous pin joint

with beatings. As there are two housing installed on the base part, each housing has two bearing that

will be installed in it. Thus total of 4 bearings are used that reduced the play to zero. Bearing no is

given as:

4 x (6302ZE NACHI deep groove ball bearing)

Fig. 16: Spring Model

Fig. 17: Spring Blocker Fig. 18: Spring leg Blocker

24


5.1.3 Final Assembly:

After making all the parts, these were assembled to get the simulation of the final assembly. The

simulation showed that all the dimensions are O.K. and all the parts are working properly. The

assembly involves following steps:

Set the four bearings in the two housings

Insert the shaft into the housings

Attach the arm with the shaft

Attach spring leg blocker part to the arm

Insert handle into the arm

Mount the above sub-assembly to the base of the machine

Insert the springs from both sides of the shaft

Attach the spring blocker from both sides to confine the springs

Attach the tool holder with the arm by adjusting its position with respect to the work part (Gear

to be deburred)

We get the following final assembly:

Fig. 19: Final Assembly with each part elaborated

25


26

154

90

25

11.67

8.7

M6

12

5

118°

15

23.33

8.7

M6

12

5

118°

15

Gear Shop HI-TECH Engine plant

ATLAS HONDA LIMITED SKP PLANT

DRAWN BY M. SHAFIQUE S. IMMAD H. SHAH

DATE 30/06/2013

DRAWING TITLE BASE CHECKED BY :

DATE

SIZE A3

DRAWING NO. 01

REV X

DESIGNED BY GIKI INTERNEES (MECHANICAL)

DATE 23/06/2013

SCALE 1.200

SHEET 1/1

All the 8 holes are of same dimensions

All Dimensions are in mm

M6x1 ISO - H TAP 12.000 5 DRILL ( 5.000 ) 15.000 -( 1 ) HOLE

90

12.5

35

25

0.00341.98

55

41.98

R6

8.7

11.67

M6

17.5

5

66.59

37.5

45.3

55.18

8.711.67

72.59

43.1

35

9.4

12.5

11.67

+0.003

-0.010




DATE 30/06/2013

DRAWING TITLE BEARING HOUSING

CHECKED BY :

DATE

SIZE A3

DRAWING NO. 08

REV X


DATE 23/06/2013

SCALE 1.400

SHEET 1/1

All the 4 holes are of same dimensions


M6x1 ISO - H TAP

26

160

4

R3

10

18

4

PITCH1.5

1

R0.217

30° 30°

1.55.66

910R13

R10

R9

153

160




DATE 30/06/2013

DRAWING TITLE HANDLE

CHECKED BY :

DATE

SIZE A3

DRAWING NO. 04

REV X


DATE 23/06/2013

SCALE 1.500

SHEET 1/1


80

15

35

355

19

17.49

17.5

8.5

20

11.5

100

22.55

22.5

35

19

21

21

80

332.5 22.5

45

15




DATE 30/06/2013

DRAWING TITLE ARM

CHECKED BY :

DATE

SIZE A3

DRAWING NO. 02

REV X


DATE 23/06/2013

SCALE 0.600

SHEET 1/1

These 5 holes have same dimensions


M6x.75 ISO - H TAP

M10x1.5 ISO - H TAP 20.000 8.5 DRILL ( 8.500 ) 20.000 -( 1 ) HOLE

50

15.005

109

80

19

21

21

19

35.3614.49

14.87

20.99

20.99

7.57.5

9.9

5.25

+0.015

-0.002




DATE 30/06/2013

DRAWING TITLE SHAFT

CHECKED BY :

DATE

SIZE A3

DRAWING NO. 06

REV X


DATE 23/06/2013

SCALE 0.700

SHEET 1/1

These three holes are of same dimensions

All Dimensions in mm

M4x.7 ISO - H TAP 7.920 3.3 DRILL ( 3.300 ) 20.000 -( 1 ) HOLE



21.5

9PITCH4

120

4

10.85

100

90°

3.72




DATE 30/06/2013

DRAWING TITLE SPRING

CHECKED BY :

DATE

SIZE A3

DRAWING NO. 03

REV X


DATE 23/06/2013

SCALE 1.00

SHEET 1/1


40 16

45

M43.3

R20

R8

45

18

18

5

3.34




DATE 30/06/2013

DRAWING TITLE SPRING BLOCKER

CHECKED BY :

DATE

SIZE A3

DRAWING NO. 05

REV X


DATE 23/06/2013

SCALE 2.000

SHEET 1/1


M4x.7 ISO - H TAP

23.5

250

11.5

M6

11912

119

11.5

11.75




DATE 30/06/2013

DRAWING TITLE SPRING LEG BLOCKER

CHECKED BY :

DATE

SIZE A3

DRAWING NO. 07

REV X


DATE 23/06/2013

SCALE 1.200

SHEET 1/1


M6x.75 ISO - H TAP

M6x.75 ISO - H TAP


5.2.0 Problem 2: Unacceptable surface finish:

This problem being the second major cause of the part rejection. In this problem as the machine is

operated for the deburring of the gears, it is very likely that the operator moves the tool below the

deddendum circle of the gear which is the limiting depth to which the tool can be moved. If the tool is

brought below this particular depth, the facing of the one side of gear starts affecting the surface finish

that was obtained from the machining process. Thus the surface finish that was obtained from the

machining process gets disturbed which ultimately causes the rejection of the parts. This problem

occurs because of the absence of any mechanism that may stops the tool to move below a certain limit.

As given previously the best idea to solve this problem was selected as to use threaded screw for

stopping the arm.

5.2.1 Threaded screw:

Threaded screw is suitable solution for this problem. It has many advantage in its use as:

• It can be easily adjusted for different sizes of Gears to be deburred

• It will not affect the space for placing the gears

• It is available as the off-the-shelf component so no need of manufacture it

• It can be readily installed on the bed of the machine

This screw was installed on the bed of the machine. Its length is adjusted such that as the tool is

brought to the teeth of the gear up to the particular depth, the arm gets into contact with the screw that

stops the arm to move further. Hence this problem was removed by using simply the threaded screw.

Fig. 20: Stopping Arm through screw

35


5.3.0 Problem 3: Manual control of Motor by foot:

This problem although has no effect on the rejection of the parts but is of significant importance as

seen from point of view of production time. Existing machine has manual motor control. This control

is done with foot. This control method is a big problem in the way of the smooth running of the

machine. Therefore the production time for deburring of the gears is significantly high.

The solution to this problem consists of the installation of a simple electrical circuit and a limit

switch. By applying this solution, not only the foot control circuit was removed but the control of

motor became fully automatized. It was seen that with the application of this solution the production

time was reduced significantly.

The circuit diagram is shown as below:

Fig. 21: Motor control circuit & Different Limit Switches

36


In addition to the projects given to us during our stay at Gear shop, we were also involved in some

useful activities. In these activities different assignments were given to us that we reported, after

completion, to our supervisor. These activities are detailed as under:

6.0.0: Activity 01-Gear meshing Analysis:

Gear meshing analysis was the task given to us by MR. Rashid Aleem. The purpose of performing

this activity was to understand the mechanism of the gears i.e. which gears are mating in specific gears.

This activity was performed at the model present in the Gear Shop. The gears present on the main shaft

and the counter shaft and their respective motion is shown in the table:

6.1.0: Neutral Gear Position:

In the neutral fear, the rotating gears and the stationary gears are shown in the table below.

Rotating stationary M1 M2 M3 M4 C1 C2 C3 C4 Main Shaft C Shaft

Gears Motion Gears Motion M1 Fixed C1 Free M2 Free C2 Fixed M3 Fixed C3 Free M4 Free

C4 Fixed Table 04: Gear Assembly on shaft

Fig. 22: Gears in neutral position

37


6.2.0: First Gear Position:

In the first gear, the gear C2 mates with gear C1 which makes the later fixed. As a result the shaft

starts rotating.

6.3.0: Second Gear Position:

In the second gear, all the previous mating is cancelled out. The gear M3 mates with M2 and the

later gear is fixed. This makes the gear M2 fixed thus the shaft starts rotating.

Fig. 23: First Gear

Fig. 24: Second Gear position

38


6.4.0: Third Gear Position:

In gear 3, the previous mating is cancelled out and the gear C3 is moved to C4. This fixes the gear

3 and counter shaft starts rotating.

6.5.0 Fourth Gear Position:

All the previous mating is taken back and the gear M3 comes in contact with M4. This makes gear

M4 fixed and the shaft starts rotating.

Fig. 26: Fourth Gear position

Fig. 25: Third Gear position

39


7.0.0: Activity 02- Internal Auditing:

The internal auditing was an activity which was performed by our group prior to the external

quality auditing of the ISO. The Quality auditing was done in order to renew the certificate of the ISO

9001. The previous certificate of ISO was renewed in the year 2008 and according to the demands of

the standards, it was required that the certification must be renewed. We performed this auditing so

that the laborers have a practice prior to the original auditing.

The questions asked to the laborers for the auditing are as following.

A summary of the laborer response is as following:

Laborer Name 1 2 3 4 5 6

Usman R R W W R R

Hafiz Saleem R R R R R R

Qaiser Ali W R R W R W

M Rashid R R R R R R

What is quality policy of Honda?

what is the production capacity of the machine?

what is the rejection criteria?

what are the name of the tools and arbors?

what is the previous version and name of ISO certificate?

the criteria for check list of machine?

Table 05: Auditing questions and its answers from different workers

40


8.0.0: Activity 03- Re-Lay outing of Deburring Machine:

Another activity assigned to us was the relay outing of the deburring machine portion of the of the

gear shop. The main purpose of this was to improve the output of the workers, easy flow of material,

best utilization of the space, minimum interference between the workers, improve the environmental

effects, easy access to the raw material and gear rack of finished products.

8.1.0: Current Layout:

Current layout of the deburring machines consists of 4 machines that are arranged in the manner

as described below in the layouts. This particular layout has certain advantages and disadvantages that

are mentioned along with the lay out diagram. This layout was analyzed thoroughly from different

prospectus and was seen whether there is a need of improvement or not. The current layout and its pros

and cons are given below:

Fig. 27: Current Deburring Machine Placement

41


Merits:

Easy to access gear shaper back

Less interaction between workers hence causing

Increase in focus

Increase in production

Increase in concentration

Easier material flow

More cleanliness

More support because of pillars

Demerits:

Less space

Difficulty in part transportability

Dust bin smell

Can cause psychological effect

Fig. 28: Current lay out of deburring machines

42


8.2.0: Layout 01:

Merits:

More symmetry

More space

Easier transportability

Deburring time decreases

More production

Worker friendly environment

Easier material flow

Easier maintenance

Demerits:

No support

Threat to cleanliness

Opportunity to worker to talk to each other which may cause decrease in focus and

concentration and production

Difficulty to access gear shaper back

Fig. 29: New lay out of deburring machines

43


8.3.0 Layout 02:

Merits:

Very less transportability

More space

Increase in worker comfort level

Clear way

More space is available for new machines in future

Demerits:

Block gear shaper machine from all sides

More exposed to visiting area

Difficult in cleaning

Worker concentration at single point


44


8.4.0: Layout 03:

Merits:

easier material flow

easier gear handling

increase in production

less interaction between workers

easier transportability

more space

Demerits:

Less symmetry

Way blockage


45


8.5.0: Layout 04:

Merits:

Open space for material flow

no tangling troubling up

Open space for worker

One more machine can be installed

Cleaning of flour is easy

Demerits:

Space is close from the pillar behind broaching machine

Back side of gear shaper machine is not accessible


46


9.0.0: Activity 04- Time study of the Hobbing Process:

In this process we measure the cycle time of the production of different gears. Per shift time is

calculated in minutes and the net production time is calculated by subtraction the route works time

other than production from the shift total time. The 80% of the net production time is the time which

we analyze for the time study. We convert the minutes in seconds.

Table 06: Cycle time of Hobbing process for different gears

Time in shift

Opening meeting time

Initial production time

Tea+lunch time

Chip removing / cleaning time

Closing meeting time

Net production time

480

05 10 50 10 05 400

Net operation time for production =net production time *80%

=400*0.80

= 320min

=19200 sec

We take the average of six or seven readings of the handling time and then the average of six to

nine readings of the handling time. then the these averages are divided by the number of gears in the

set the add the average handling time and machine time , which is the cycle time . This cycle time

is divided on the net time for production we get the numbers of gears per shift.

Table 07: Production for different gears

Sr #

Parts name No of gears in set

Process time Handling time

Cycle time Per shift production

1 C-1 CD-70 7 18.04 1.83 19.87 966 2 C3 CD-70 5 26.48 0.94 27.43 699 3 M4 CD-70 6 14.19 4.23 18.42 1042 4 Pinion kick starter CD-70 6 18.09 3.03 21.12 909 5 C1 CG-125 6 26.58 2.81 29.39 653 6 C4 CG-125 5 24.76 3.145 27.90 688 7 Idle kick starter CG-125 9 14.84 1.752 16.59 1157 8 Pinion kick starter CG-

125 9 15.18 2.34 17.53 1095

9 C2 CG-125 DLX 9 17.27 2.55 19.82 969 10 C1 CG-125 6 26.58 2.81 29.39 653 11 Idle kick starter CG-125 9 14.84 1.752 16.59 1157 12 Pinion kick starter CG-125 9 15.18 2.34 17.53 1095

47


10.0.0 Activity 05- Deburring Tool Analysis:

In gear shop we were assigned an activity to analyze the tool tips used in deburring machines. These

tool tips are made by standard manufacturers and have their standard catalogues. We gather all of the

necessary data from these catalogues.

There are four Deburring machines in Gear shop. Machine 1 is used for deburring embossed gears

while machines 2, 3 & 4 are used for machining plane gear. Therefore two types of tools are used for

both categories of gears which are described as under:

Turning Tip:

The turning tip is used in machine 2, 3 & 4 and is used for deburring plane gears. It is manufactured

by famous Japanese company SANDVIK which provide a standard code to this tip i.e. CNMG 120408

PM. We search out their provided catalogue and gather all the specifications of this tool. The catalogue

decoded the tip as follow:

It has orthogonal geometry

Tip radius is 0.8mm

Tip thickness is 4.76mm

Cutting edge length is 12mm

Tolerance in thickness is + 0.13 while in

cutting edge length is + 0.08mm

It was recommended for medium facing

Grooving Insert:

Grooving insert is used in machine 1 where deburring of embossed gears occur. It is

manufactured by another Japanese company SUMITOMO. This insert is specially made and does not

have standard code which are being mentioned in their catalogue. It has its own special code i.e. PA

5NZ034 so we gathered its specifications from its Japanese drawing. Following are the key features of

this insert:

• CNMG 120408 PMTurning Tip

• PA 5NZ034Grooving Insert

Fig. 33: Turning Tip

48


Tool grade is EH20Z

Cutting edge length is 4.5mm

Cutting tip height is 4.8mm

Cutting edge angle is 50 with horizontal

and 100 with vertical

Tip radius is 0.8mm

Conclusion:

This internship has been a great experience for us seeing the theoretical knowledge getting into

practical form. We learnt a lot by working under the professionally experienced personnel in one of

the leading organization of the country. The project assigned to us during internship was one of the

best experience that would guide us throughout our professional career. Different activities that we

performed in gear shop will help us in future in sound understanding of the structure of any

organization. This internship will also help us in our future projects as we have observed quite a lot

how things get into physical form from theoretical drawing through different processes and how to

manage to get this done more efficiently.

Recommendations:

Atlas Honda is one of the largest leading company in automobile sector that has good

management and hardworking people. However during our stay we observed a few weaknesses. The

computers provided to the CAD/CAM department are not up to the mark. Some software being used

in Hi-tech department are either of very old version or are not working properly. These software should

be updated to some latest version and should be inspected properly. Also the computers provided to

the CAD/CAM department should be replaced with some good one as it is the greatest hurdle in

completion of design projects.

Fig. 34: Grooving Insert

49

Atlas Honda Internship Report 2013

Documents

internship project

ahl plant

atlas honda sheikhupura

atlas honda karachi

plant possible

engine plant

atlas culture

project background