HONDA establish in 1999 at Manesar ( Haryana ) HONDA is a Japanese Public Multinational . HONDA is a largest motorcycle manufacturing company. HONDA deals with 2-wheeler, 4-wheeler and power
products.Honda motorcycle and scooter India (HMSI)Honda Siel Cars India Ltd (HSCI)Honda Siel Power Products Limited (HSPP)
First plant of HSMI in Manesar (Haryana). Second plant in Tapukara ,Dist.:-Alwar, Rajasthan Third plant in Narsapura, Bengaluru Forth plant in Ahmadabad ,Gujarat
My training is at HSMI Manesar in frame Assembly
PRODUCTSHonda AVIATORHonda ACTIVA(110;125;ACTIVA I;3G)Honda DioHonda dream neoHonda ShineHonda CBF StunnerHonda CB Unicorn Dazzler Honda YugaHonda Unicorn 150Honda CB triggerHonda CBR 150R Honda CBR 250R Honda Unicorn 160 (new model)Honda CBR 650 (new model)
HR (Human Resource and Development)
IR(Industrial relation) A/F(Frame assemble) A/E(Engine assembly) Paint Shop P I (Part inspection) Utility Maintenance BOP Weld Steel machining
Aluminum machining SafetyPurchaseCasting PPC(Production planning)VQ (Vehicle quality) LogisticStoreFinance R & DTechnical center SQA
Raw material Press
BOP WELD CASTING
PAINT PAINT SHOPENGINE
ASSEMBLYBOP
FRAME ASSEMBLY
VQ
LOGISITICS
DISPATCH
MACHINING
The term PI refers to a pre-inspection in which the product manufactured in manufacturing process is inspected before it is transferred to the assembly line in order to obtain the final product output.
There are three assembly Line. ◦ The first line is for Activa only.◦ The second is in Motorcycle plant where both scooter and
motorcycle are assembled.◦ The third is for the new model line and only meant for only
motorcycles.
I worked on frame assembly line 3 that assembled new models.
Modals at Frame Assembly line 3
A/F FRAME ASSEMBLY
KYJM CBR 250KSPP
K-38 KPPR CBR 150
First principle inspection is the inspection in which the parts are inspected with the help of measuring instruments so as to ensure the part is accurate as per the working standards.
Measuring instruments like Vernier Caliper, Height Gauge, V-Block etc
Gauge inspection is the inspection tool used to check a work piece against its allowed tolerances.
The gauge has two tests; the check involves the work piece having to pass one test (Go) and fail the other (No Go).
It is used in the manufacturing industry to ensure interchangeability of parts between processes, or even between different manufacturers.
It is defines as the examination of the material, component or a product for condition of non conformance using light and eyes alone or with conjunction with various aids.
Visual inspection is commonly employed to support other NDT methods.
Several Characteristics about the part being examined may be determined which include dimensional conformance, the presence of discontinuities, general fit and wear.
CMM is defined as Co-ordinate Measuring Machine. This machine is imported from Japan which is used to
inspect the co-ordinates of the part randomly. A coordinate measuring machine (CMM) is a device
for measuring the physical geometrical characteristics of an object. This machine may be manually controlled by an operator or it may be computer controlled.
A machine which takes readings in six degrees of freedom and displays these readings in mathematical form is known as a CMM
Sorting (seiro)Stabilize (seiton)Systematic Cleaning (seiso)Standardizing (seiketsu)Self-Discipline (shitsuke)
The Project is to improve the DPR (direct pass ratio) of model K-38 (Unicorn 160). DPR is improved by reducing the defects. By removing of defects DPV (defects per vehicle) decreases. Unicorn 160 is a new model on line the mass production of which was started in Jan 2015. As it is a new model and as per HMSI every single part of new model is inspected so as to get high production i.e. improved DPR
Scratches on parts Rear light switch spring open Handle movement hard Fuel tank not set Part miss Part fitment N/G Nut free
Root cause
Loading in marshal Loading Unloading from marshal Strip pasting Tail lighting putting
Fitment on frame
Problem Category Why 1
Scratch generation due to man/method
Improper Handling
Mishandling of parts during loading and offloading
Awareness not present for defect generation
Scratch generation due to Tool & Jigs
Machine Scratch generation from Socket of Gun
FUEL TANK SCRATCH
Root cause
Fuel tank loading in the paint area.
Fuel tank leakage testing
Fuel tank unloading from marshal
Problem Category Why 1
Scratch generation due to man/method
Improper Handling
Mishandling of F/Tanks during loading and unloading
Scratch generation due to Jig and Fixtures
Machine
Scratch generation at the time of fitment oil gauge, nob & Uncovered Fuel Tank Leakage Testing Container
Countermeasures
92% defects of fuel tank scratch reduced
SIDE COVER SCRATCH
Root Cause Countermeasure
change the loading position of the side cover
85% defects of fuel tank scratch reduced
Thread of the component damage at the time of nut tightening.
Root cause Nut taper tightening
85% defects of stem nut reduced