Orientation report

Internship Report

Submitted To: HR Department, AHL

Submitted by:Muhammad Ahsan

MECHATRONICS-07Saqib Hussain MECHATRONICS-07Azka Jawaid IEM-07Zainab Rana IEM-07

Dated: 13th August, ‘10

Acknowledgement

Above all, thanks to Allah Almighty, the beneficent and the most merciful who gave us a chance to polish our abilities by letting us intern at AHL.

We owe a great many thanks to people who helped and supported us. We express our thanks to Mr. Jamil and Ms. Asma for extending their support.

Our deepest thanks to Mr. Yawar, A.M. CRANKSHAFT for being the guide of the project and for mentoring and correcting various documents of ours with attention and care. He has taken pain to go through the project and make necessary correction as and when needed.

Thanks and appreciation to the helpful people at High Tech Plant, especially GM Plant, Manager Engine Plant and all the AMs.

We would also thank the whole staff at AHL for their help and coordination, without whom this internship would have been a distant reality.

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` Preface

The purpose of this report is to explain what we did and learned during our internship period with the Atlas Honda Limited. The report is also a requirement for the internship program. The report focuses primarily on the orientation of the organization, working environment, successes and short comings that the intern did encounter when handling various tasks assigned to him by the supervisor.

Because the various parts of the report reflect the intern’s shortcomings, successes, observations and comments, it would be imperative that the recommendations are also given. Therefore the report gives a number of comments and recommendations on the internship program. It is hoped that this report would serve as an important vehicle to the improvement of the internship program.

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Table of Contents

Acknowledgement----------------------------------------------------------------------------2

Preface--------------------------------------------------------------------------------------------3

Table of contents-------------------------------------------------------------------------------4

1. Introduction to Company --------------------------------------------------------------- 01

2. Human Resource Department --------------------------------------------------------- 03

3. Finance/ Accounts ------------------------------------------------------------------------ 04

4. Cost--------------------------------------------------------------------------------------------- 05

5. Logistic & Purchase Department ------------------------------------------------------ 05

6. Vendor Procurement ---------------------------------------------------------------------- 07

7. Production, Planning & Control -------------------------------------------------------- 07

8. Maintenance --------------------------------------------------------------------------------- 09

9. Stores ------------------------------------------------------------------------------------------- 10

10. Quality Assurance / Final inspection ------------------------------------------------ 12

11. Manufacturing Plant -------------------------------------------------------------------- 13

12. Assembly Plant --------------------------------------------------------------------------- 15

13. Casting Plant ------------------------------------------------------------------------------ 16

14. Engine Plant (Hi-Tech) ------------------------------------------------------------------- 16

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15. Suggestions-------------------------------------------------------------------------------------Error: Reference source

not found

1. Introduction to the Organization:

1.1 Introduction:Atlas Honda Limited is a joint venture between the Atlas Group and Honda Motor Co., Japan. Both these motorcycle manufacturing concerns were established by the Atlas Group. Atlas Honda Limited manufactures and markets Honda motorcycles in collaboration with Honda Motor Company. The Company also manufactures various in-house hi-tech components. Their motorcycles are by far the largest selling motorcycles in the country with an unparalleled status for excellence, high quality and reliability. AHL is producing 4 models with fulfilling its ISO 9002 & ESH (ISO 14001) requirements. AHL is also committed to provide green products /non hazardous/environment friendly bikes to fulfill its corporate citizen responsibilities.

Atlas has undertaken to extend local manufacturing capabilities to the highest and 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. Sheikhupura Plant is over 27 Acres of total area. To support the production facilities, the company has established an R&D wing and tool making facilities through CDA & CAM. The company has 250 dealers nationwide, who are responsible for the sales of motorbikes. Further, there are 6400 service dealers throughout the country, who are providing services of repairing to the customers. They are also responsible for the sale of spare parts. In this way, directly or indirectly, Atlas Honda is creating job opportunities for almost 25,000 people. The turn over here is less than 3 percent which is very less as compared to other industries who expect 10 percent turn over per year.

Four models of Honda Motorcycles are being made at AHL namely, • CD-70. • CD-100. • CG-125.

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• CG-125 Deluxe.

1.2 Atlas Group of Industries: 1. Atlas Honda Ltd. 2. Honda Atlas Cars (Pak) Ltd. 3. Atlas Bank Ltd. 4. Atlas Battery Ltd. 5. Atlas Insurance Ltd. 6. Total Atlas Lubricants Ltd. 7. Atlas Power Ltd. 8. Sherazi (Pvt) Ltd. 9. Sherazi Investment Ltd. 10. Atlas Engineering Industries Ltd. 11. Sherazi Capital Ltd. 12. Atlas Capital Markets

1.3Market Share of HONDA:

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1.4 Structure

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2. Internship Programme:The internship Programme started on 1st July, 2010 & ended on 13th August 2010.During internship, we were given a brief introduction of all the departments of the company including,

Human Resource Department

Finance/Accounts

Cost

Logistic & Purchase Department

Vendor Procurement

Production, Planning & Control

Maintenance

Stores

Quality Assurance / Final inspection

Manufacturing Plant

Assembly Plant

Casting Plant

Engine Plant (Hi-Tech)

CEO

Finance Marketing Supply chain HRM R & DQuality

Procurement Warehouse Production Control

Imports

Local

SAPRM

Chairman

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3. Departments3.1. Human Resource Department

The department deals with the matters related to the employee of each and every department. Its key task is” the man power”.Their main functions are:

1. Recruitment and selection of the employee.

2. Compensations and benefits to the workers.

3. Training and development of the new employees and.

4. Man Power Budgeting is done annually.

5. Performance appraisals of the one giving good performance. They are based on one of the following characteristics of an employee

Competencies Objectives Training needs Overall performance

HR develops system known as Training Needs Analysis (TNA) which is a sheet generated at the end of the evaluation of an employee, determining which employee needs to excel which type of skill as suited.This system of TNA is based on three R’s

Respect Recognition Reward

Business plans are made.

3.2 Finance/Accounts

This sector deals with the finance related activities. They maintain the accounts, trades, imports and exports, assets, banks and market dealing of the company regarding capital.

The main modules of the department are given as follow.

General Ledger

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Fixed Assets of the company

Cost of the bikes and the cost analysis.

Account payable to and by company.

Petty Cash (Day Book) i.e. transaction of the cash into our out of the organization.

Pay roll which deals with the salary issues of the employees.

Taxation related activities like Income tax, Sales tax, Special Cost Duty (SCD).

Its financial function is integrated in SAP which is software, known as Standard Application & Product in Database.

3.3 Cost

Three factors that this department oversees are

Production, in which cost components of a product are included, that come under production

o Material for which a “Bill of Material” (BOM) file is required.o Laboro Factory overhead

Serviceo Qualityo Procuremento Maintenance

Infrastructure

They imply Absorption Costing methods.

3.4 Logistics & Purchase 3.4.1 Logistics

It involves planning, managing and controlling the flow of goods and services, information, real-time data and human resources from the point of source to the target.

• Commercial Purchase

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• Import

• Logistics

Their functions are

• To coordinate with third party logistics.

• Loading and unloading very carefully of bikes.

• To calculate unit cost of each unit.

The logistic department involves

1. Ensuring that the requirements of the customers are met on time in an efficient and protected manner. 2. To synchronize with third party logistics. 3. To ensure that there is a safe and timely dispatch of goods. 4. To draft plans, policies and procedures for successful implementation of logistics system. 5. To create and maintain customer support. 6. To maintain coordination with vendors, service providers and transport carriers. 7. To ensure that no fraud is involved. 8. To ensure timely supply and payment of goods and reduce inventories.

3.4.2 Dispatching

This involves the functions and responsibilities of the dealers in the field of marketing.Any tool that is not available and is to be used in AHL is then Import trough Honda Japan. It depends on the inventory. They have the stock of minimum six months so there is no shortage.

3.4.3 Purchasing

It involves purchasing the parts which are not required in the production process.

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They form a Price Committee, which takes decisions related to the purchasing of goodsIt consists of

Customer representatives Cost managers Various managers

3.5 Vendor Procurement

This department is for local vendors in Pakistan.

• This department deals with the timing and the schedule for the vendors

• It assesses the vendor, also checks his capacity.

• Collects the data directly from the vendor manufacturing unit.

• Responsible for the proper amount of the parts in the stock. o For normal Lead Time, a function of this department is to

keep Buffer Stock.

• Responsible for the cash transactions with the vendors, e.g. bills and payments.

• Checks the raw material and the stock at the vendors end.

It involves planning of three major factors.

Production planning Outsourcing/outsource planning Development, which involves developing “deleted parts” which

were initially made in Japan, but are now manufactured locally

3.6 Production, Planning and Control

PPC manages the details of the parts to be produced that what is required and when, and to obtain the raw materials, parts, and resources to produce those items.PPC does this by keeping records. For this reason, PPC has to maintain up-to-date interactions in terms of coordination, communication &

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cooperation with major sections of Production and service departments like

Quality Assurance, Logistics Maintenance DCC/ Stores and PPC Karachi

Further, It communicates with sales, marketing to fulfill their day today

requirements. The engine and the frame number to the engine are provided by

this department. The division of the spare parts division is supported by the PPC. It gives warranty to the product. It handles transactions related to Dies and Moulds. Deals with the excise and taxation. The in house production is directly controlled by them. They imply the concept of Just in Time (JIT). They manage inventory and safe stock.

3.7 Maintenance

It involves maintaining

Utilitieso Air supplyo Gas supplyo Water supply and waste water treatment plant.o Electricity generation

Contractors Preventive maintenance Troubleshooting

Maintenance of following departments are carried out

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The types of maintenance are:

1. Corrective maintenance: When there is sudden shutdown, the team of break down maintenance reaches on the spot and solves the problem in order to run the machine.

2. Preventive maintenance:This type of maintenance is done for improving the productivity rate. In this the part or parts of the machine are changed and capacity and working of the machine is improved.

3. Scheduled maintenance: Each machine in each shop is being maintained on the weekly and monthly basis as in the specified schedule. The master schedule is planned on monthly and weekly basis for the maintenance. In this all the general inspection and the working of the machine is analyzed.

3.8 Stores

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The main purpose of the stores are to receive and dispatch the parts from the vendor and Import parts. It is also meant to store the safety stock which is about 3 to 5 days of in-house The material is divided in two types

Direct materialsThey involve MROs which is Maintenance, Repair and Operating

storing.It involves parts required in the production process

o Oils like hydraulic oil, solicut oil etc.o Gaseso Chemicalso Paintso Steel pipes for shoch absorberso Steel sheets for frame of the fuel tanko Sand for moldingo Aluminium dies

Indirect materialso Consumables including gloves, ear plugs, masks etc.o Manufacturing tools, both local and imported.o Maintenance spares, which use items from both JIT and

Stock.

3.8.1 TypesThere are three stores in the Honda Shiekhupura Plant. One lies outside the production while two lies in-house.

1. DCC (Delivery Control Center)

2. General stores.

3. Store for the Paints and Kerosene oil.

3.8.1.1 Delivery Control Center:

There are three major sections of the DCC.

• ReceivingParts from the vendors as well as from different parts of the world.

• Placing

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DCC is divided into two sections. One is for the imported parts placement and the second is for the placement of parts from Vendors.

• Unpacking and dispatching from the production plantPeople carrying outsourced parts, unpack and send them to Sheikhpura Plant and make them ready for production.

3.8.1.2 General Stores:

The General Stores are responsible for storing the parts which are not directly used in the assembly but are used for the manufacturing like tools, holders and the other accessories for the plants usage like tube lights, pressure pipes etc.

3.8.1.3 Stores for the Paint and Oils:

These stores are used to store the paints; special temperature is maintained in the store for the preservation of the paints and oils. Specific measures and instruments are placed in order to control the fire. Water sprinkles were installed in this area.

3.8.2 Outside processingSystem Transaction involves OSP schedules which are generated similar to the other material in SAP. When the parts made in-house are to be sent to vendors, vendors are informed through vendor procurement. The proper vendor authority issues the material

Its functions are to from stores for processing.

Issue material Receive material Accounts check Costing analysis

Material Requirement Planning, which is software, is installed for direct and indirect materials

Direct material- annual budgeting, divided on a monthly basis, by given a certain pace.

It is carried out depending o Model wiseo Color wiseo Vendor schedule

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STO is applied which is Stock Transport Order, for parts coming from different plants, e.g., Karachi.

3.8.3 Rejection Parts Stores:

It is divided based on the type of incoming material whether it is made in-house, is imported or outsourced.

There is low rejection on imported parts and they are checked according to Japanese Standard (JIS).

Faulty parts from vendors are checked by Quality Department. Vendors are informed of rejected parts through Logistic Department.

In-house parts if malfunction, are rejected at line.

3.9 Quality Assurance

They are responsible to assure the quality of each and every part at each and every step. The inspection at each step is carried out to insure the quality of the manufactured parts.QA department directs Quality management & Quality Control functions.It identifies quality related problems in vendor & in-house parts & takes preventive action in case of their re-occurrence.

There is a Complete Buildup Unit which involves antenna dealers from various locations who report the rejected parts to the related department.

The quality standards implied are ISO 9001 and ISO 2008.Quality is checked according to Honda Motor Standards as well. Quality checking is done in the Standard Room.

Co-ordinate Measuring Machine ( μ precision)

Calibration of the instruments up to the given standards. All the measurements depends upon it

Checking the Specifications.

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Analyzing the layouts and different samples.

Final Inspection of the motor-cycle to guarantee the total quality.

Warranty is given according to market quality.

3.10 Manufacturing plantFuel tanks are manufactures and they are painted. The paint shop is divided into following:

1. Press Shop

2. Fuel tank welding shop.

3. Paint shop.

3.10.1 Press Shop It is one of the most essential shops in the manufacturing plant. First the blanks of the metal sheets are cut into the suitable dimensions. For this a die bending machine is used. It is huge machine whose input is a metal sheet which is imported. The blanks are then sent to the welding shop for the welding.

Quality Check: The quality is checked after they have been cut. The end of the sheets and the bending is seen if properly done.

3.10.2 Fuel Tank Welding Shop: This shop contains several welding processes like seam, spot, mig welding and brazing.

The seam welding unit is a robotic machine which welds at 17000 Amperes.

Then rough buffing is done to remove the burs. Then it is Ripple Arc welded (Mig welding) for the fuel cap, this

machine is semi-automatic. The butt joint is made with the lower half of the tank by the main fuel tank part through spot welding.

Then the block for the adjustment of the lock on fuel tank is joined through mig welding. Finally the whole assembly is grinded to make the smooth surface for the paint.

For CG-125 and Deluxe first the blanks are spot welded and then they are seam welded.

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Quality Check: The quality assurance the leakage test is done by dipping complete assembly into the water tank which also contains the rust free oil and then 3 to 4 lb per inch square of pressure is applied to check the leakage in the tank

3.10.3 Paint Shop: The Paint shop is vital for the manufacturing shop as well as for the finally assembled motor cycles because it deals with the aesthetics and outlook of the bike. It is very delicate and care-demanding work in which the input is in the form of fuel tanks from the welding shop.

First of all the anti-rusting oil is done for the prevention. Then rinsing is done by dipping the fuel tanks into the water

tank. De-greasing is done to remove the oils from the tanks and the again rinsing is done.

A coating of Phosphate and Zinc is done on the fuel tanks so that the fuel tanks are prevented from rust and rinsing is done.

Then RO (Reserve Osmotic) water is showered. The tanks are the pre-heated and so to make the coating firmed.

Then the first coating of Aluminum is done and the fuel tanks are dried.

The tanks are then coated with the Paints of color as per requirement. The chamber for the paint shop is specially designed and the water flows on the top to bottom of the walls so that the paint may not stick onto the walls of the chamber.

Then the final coating of lacer is coated to make the fuel tank scratch free, shining and for the surface finish.

This painted fuel tank is then taken to the Oven for baking. The strip is pasted onto the tanks and then the tag of the

company is attached to the fuel tank to give the final shape to the fuel tank and ready to be installed into the motor-bike.

Quality Check: The fuel tanks are the most critical part of the motor-bike. It is carefully analyzed and the quality is assured at each and every step. It is assured that the fuel tank is scratch free. There is dent on the tank. The welds are not visible. The stickers are properly placed and tanks are dispatched properly.

3.10Assembly Plant:

Assembly plant is further divided into four plants • Welding Shop • ED Paint Shop

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• Engine Assembly • Frame Assembly

3.10.1 Welding Shop:

There are three basic welding types being used in this shop

• TIG Welding • MIG Welding

o It uses a copper plated wire of steel to add conductivity.

• Spot Welding

Carbon dioxide causes oxidation, which is minimized by adding silicon to the filler.

3.10.2 Electrode Deposition Paint Shop

In Electrode deposition (ED) line ED painting is being done in frame assembly. The ED line is the most recent development added to the AHL plant. Paint is deposited on the parts by giving positive charge to the paint and negative charge to the frame.

The welded frames from the frame welding shop are shifted to the ED (electrode deposition) paint shop for painting. The parts which are painted here are:

Frame body

Bracket muffler

Swing arm

Side & main stands

Processes involved are:

3.10.2.1 Loading:The parts to be painted are carried on hangers where they are cleaned with the help of thinners.

3.10.2.2 De-greasing:It involves avoidance of corrosion due to the coated oil by removing it.

3.10.2.3 Rinsing:

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Here the parts are washed so that washing agents for the process of de-greasing can be removed.

3.10.2.4 Phosphating:After rinsing, parts are treated with ZnPO4 in phosphating

line.

3.10.2.5 Rinsing with RO:Now, parts are rinsed with RO (reverse osmosis) water. The reason of using RO water is such that nutrient free water should be used so that chemical reactions could be avoided.

3.10.2.6 Dripping Zone:Here, the parts are allowed to drip for a while in order to remove water present on their surfaces

3.10.2.7 ED painting:These parts after being rinsed with RO are then passed to main ED tank where parts are dipped.

3.10.2.8 Baking:After giving some time for settling, the parts are to be send

in Pre-heat oven (temperature ~950C) for 900sec. Main oven (temperature ~1650C) for 1800 sec.

3.10.2.9 Sanding, inspection & dispatch to respective shop:After baking the parts are sanded. Then after inspection they are handed over to engine & frame assembly.

Parts painted through this way have certain advantages: They have 10 times better quality than typical painting

methods. They are environment friendly. They are lead-less, hence not health hazardous. They are water based.

3.10.3 Engine Assembly Shop: The whole engine is assembled here. The place is totally air conditioned to avoid dust. Here the raw material for the engine assembly line comes from CKD, Vendors and In-house in the form of kits. It also has sub-assembly zones where engine parts are assembled and then later shifted to the main engine assembly line.

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This is the most critical shop of the assembly plant. The assembly line consists of a conveyor belt. All four models CD 70, CD 100, CG 125 and CG 125 Deluxe engines are assembled here. Pneumatic guns are provided for the workers to mount nuts and bolts on the engine. Checks and testing areas are provided at many places for leakage of the engine. If any fault is found, engine is sent to the re-work area where problem is removed.

3.10.4 Frame Assembly Shop: The frame assembly line at the AHL is the longest assembly line (100m) of motorbikes in the world. There are total 92 jigs. These jigs are used to clamp the casing of the bikes. This shop is also divided into sub assembling zones. This frame assembly has three QUALITY GATES. The purpose of each quality gate is to check and repair the faults in the assembled bike. It has the capacity of producing a bike after every 26 seconds.

3.11Casting Plant:Casting Plant is further divided into four shops:

• Low Pressure Die Casting (LPDC)o Cylinder Head

• High Pressure Die Casting (HPDC)o Crank Case + Right Cover

• Gravity Die Casting (GDC)o Case bottom

• Cushion Shop

The ingots are melted in the furnace. Two types of ingots are being used for casting.

• HIS-S (Aluminum + 10 elements) • HD2 BS-1 (Aluminum + 08 elements)

There is also a metal analyzer which uses the concept of spectrometry, which gives accurate reading of the composition of the metals in 17 seconds up to three decimal places.

This plant supplies castings in raw form for the engine plant to do machining operations on it.PPC gives monthly plan to casting shop. The casting shop takes daily target from customer shop i-e cylinder head machining shop. Then according to their requirement they generate their own schedule. They decide that how many castings and shot blasts the casting shop will produce.

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There are three types of castings done in this plant they are:

3.11.1 LOW PRESSURE DIE CASTING:Atlas Honda is the only Pakistani Company where LPDC is carried out. Here, four parts are made:

Cylinder Head of CD 70

Cylinder Head of CD 100

Cylinder Head of CG 125

Cylinder Head of CG 125 Deluxe

Processes involved use:

3.11.1.1 Melting of Aluminium ingots:First of all, raw aluminum alloy in form of ingots is melted in MELTING FURNACE. The furnace is an automatic controlled furnace which melts Al ingots at 7300C.

3.11.1.2 Gas Bubbling Filtration:A fork lifter takes the liquid aluminum out of the furnace and pours it into Gas bubbling Filtration machine which removes air/hydrogen contents from molten aluminium.

3.11.1.3 LPDC:After GBF, the liquid aluminum is poured into the LPDC machine where dies are present. The liquid metal goes into the die to form the casting. The pressurizing time for the die is 120 seconds. After this, water is passed through the die to cool the aluminum for 15 seconds. There are sand pores placed inside the die for giving shape to the casting.

3.11.1.4 Chipping:After this, the casting is removed from the die and sand pour is removed by a process called sand breaking on chipping machine.

3.11.1.5 Gate cutting:After chopping, gate cutting machine is utilized to cut the gate with the casting. The gate represents the way for the liquid aluminum and has to be removed.

3.11.1.6 TIG Welding:

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Then welding is performed on TIG Welding Plant. This is done only when required. It is mostly not used. Workers then perform finishing of the casting by dry grinders.

3.11.1.7 Heat Treatment process:Heat Treatment process is then performed to toughen the material of the cylinder head casting. Quenching is done by heating the casting up to 500 degree centigrade and then immediately dipping it in water at temperature of 50 degree centigrade.

3.11.1.8 Shot blasting:Next, shot blasting machine is used to coat the part with steel. In shot blasting machine, steel balls are fired on the casting with high momentum. They strike the part and leave their impact on the casting in form of steel coating. The part is now ready to deliver.

3.11.1.9 Core preparation section:There is another section in LPDC where dies are coated with special material and their service is performed. The sand cores used in the dies are also prepared in a machine. This machine utilizes special sand called TSC to prepare sand cores. This sand is imported from Malaysia and Taiwan at cost of rupees 20 per kg through HONDA TRADING. Sand is first roasted at 300 degree centigrade and then compressed to a compact form to give it desired shape.

3.11.2 GRAVITY DIE CASTING:This section produces three parts:

Case Bottom for CD 70 Case Bottom for CG 125 Case Bottom for CG 125 Deluxe

The sequence of operations is as following: First of all, aluminium alloy is melted in melting furnace.

The furnace used is same as that of LPDC section.

Then liquid aluminium alloy is poured into the dies by the help of Gravity Die Casting Machines.

Afterwards, gate cutting operation is performed on the casted part by the help of gate cutting machine.

Then glow pasting operation is performed.

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Crack detection is made to check if any crack has been developed in the casting during its production.

Then finishing is done. If required, repairing can also be performed.

Final inspection of the castings is done to ensure there is no defected part produced. Now, part is ready to be delivered to CKD.

There is another section in this GDC, where shock absorbers of all four models are assembled. SHOVA technology is best in the world for manufacturing of shock absorbers. This technology is utilized here for assembling. The parts are imported from Japan. After assembling is done, they are painted, dried and then cleaned by methylene.

3.11.3 HIGH PRESSURE DIE CASTING:In this section, following four parts are casted:

R Crank Case of CD 70 L Crank Case of CD 70 R Cover for CD 70 Cylinder for CG 125

The sequence of operations is as follows: Aluminum alloy of HD2BS1 grade is melted in the electric

furnace.

Then liquid aluminium alloy is poured in the HPDC machines to form casting. There are three machines used in this section. Two machines have pressure of 650 tons each. One machine has pressure of 500 tons. There is water cooling system in the die for cooling the die. Cycle time is 49 seconds. The machines are automatic i.e. they themselves pick up the liquid aluminium from a tank and pour them at the inlet. Then a cylinder pushes the liquid aluminium into the die which consists of two parts. These 2 parts clamp each other with immense pressure as high as 650 tons. The life cycle of one die is 1,25,000 shots.

Then finishing of the casting is performed which includes removing burrs on the casting. There is die maintenance

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section in HPDC which checks the quality of die and decides whether it is to be repaired or not.

Die is sprayed from inside after each cycle with a separate material so that casting does not sticks with the die.

3.12Engine Plant (Hi-Tech):Engine Plant is Also Called the Hi-Tech Area. It is the one of the largest plants in Pakistan for the CNC machines under one roof. It is highly automated.Basically the engine plant is divided into 8 sections. • Gears • Cam Shaft • Crank Shaft • Crank Case • Cylinder head • Die Tool • Grinding Shop • CAD/CAM

3.12.1 GEAR MANUFACTURING SHOP:This shop produces following products:Gear train for CD 70Gear train for Cd 100Gear train for CG 125Gear train for CG 125 DeluxeTransmission shafts and main shafts of CD 70, CD 100 and CG 125Total 33 parts are manufactured here. The gear trains of CD 70 and CD 100 consist of 9 gear pieces. The gear train of CG 125 consists of 8 parts while that of Deluxe 7 parts. All the parts are provided by the vendors. Following processes are performed on the parts:

Lathe processes like turning, boring and facing are performed on the gears initially in CNC machines. Two such machines are installed which perform these processes.

Two broaching machines are present to performing broaching operations on the gears to form holes at the center of the gears for main shaft.

Teeth are being cut on the gear profile in teeth cutting machines. This process is done on 2 types of machines i.e. GEAR SHAPING MACHINE and HOBBING MACHINE. In a

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Hobbing machine, a set of gears is operated at a time. Mainly, 5-8 gears are operated at a time. In gear shaper, teeth cutting of only one gear are performed at a time.

o In finishing section, grinding, honing and final inspection is made of the parts. Honing is done for grinding internal diameters of gears. It is done to lessen the wear between gear and shaft. Final inspection is made to check if there is any error in the gear profile. This is done on special testing machines which draw the graphs of the gear and represent the tooth profile of the gear.

o Then Heat treatment is done on the gear to increase its surface hardness. There are two types of heat treatment operations performed here; by carbonizing and by carbo-nitrite. First of all, tempering is done to release stresses in the part. Then shot blasting is done to coat it with steel.

3.12.2 CAMSHAFT MACHINING:This shop performs the operation of machining and finishing the camshaft for the bike engine. Camshafts for all four models are machined here. The camshaft castings are imported from Japan. Following sequence of operations are performed here:

First of all, facing operation is done on the casting to remove material on the shaft leaving the cams.

Then cylindrical profile grinding operation is performed to machine the cam profile in a special machine.

Then holes are made for lubricating oil passage. Drilling, turning and reaming operations are performed. The holes are checked for the oil passage by passing coolant through them.

After final inspection, the camshaft is forwarded to be used.

3.12.3 CYLINDER HEAD MACHINING:The cylinder head is casted in the casting plant and supplied to this shop by the stores department. Here following sequence of operations are performed:Face milling and end milling of the upper and lower sides is performed

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Drilling operations along with reaming, boring and counter boring is done. After this, extra parts are attached to the cylinder head. They include valves, springs and other small accessories. In the end, again the part is checked for the quality.

3.12.4 CRANKSHAFT MACHINING:Crankshaft is an important part of bike engine. It is the responsibility of this part to transfer the force of the cylinder to the wheels. So, special attention is required while manufacturing this part.

Following sequence of operations are performed on it: Plain turning of the shaft.

Facing operation.

Gun drilling operation is used to drill holes in the shaft for mounting it.

Boring is done

Profile grinding is performed as a finishing process.

After completion, run-out is observed by hit and trail method. It is done to balance the crankshaft during its performance.

3.12.5 TOOL GRINDING SHOP:This is the only service department in the engine shop. The purpose of this shop is to regrind the tools so that they can be used again for cutting. Following machines are present in this shop:

Two universal grinding machines. One broach grinding machine. Two bench grinding machines. One gear drill grinding machine. One dia regrinding machine. One projector. Drills, reamers, taps, insert, broach and center drill tools

are grinded in this shop. Tools mostly are of carbide tips or diamond tips. The bench grinding machine uses diamond wheel to

perform its task.

3.12.6 DIE TOOL SHOP: Following equipment is present in this shop:

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Four manual lathe machines. One shaper machine. One surface grinding machine. Four bench grinding machines. Four bench drills.

Different machine parts which are damaged are repaired here.

3.12.7 CRANKCASE MACHINING SHOP:Following parts are machined here:

L/R cases for CD 70 and CD 100. R cover for CD 70 and CD 100. L/R case for CG 125 and Deluxe. L.R cover for CG 125 and Deluxe.

The L cover for CD 70 and CD 100 are machined in Karachi. The sequences of operations are:

First, dry facing is performed on the upper and lower portions of the castings.

Then operations like drilling, reaming, tapping etc. are performed on the parts.

Then part is washed in the washing machine.

Sub assembly fitting is performed to fit different small parts like cone plug, joint breather, plug seals, oil seals and bearings. These parts are mostly imported from Japan.

Then inspection is performed e.g. leak tests and other observations. If any fault is found, part is rejected.

Suggestions

Since, AHL is a plant where all the processes and functions are already highly optimized and giving off best results, so to suggest ways for its improvement was a hard task to do. Thus, despite of AHL’s being a highly productive and successful plant; we still managed to find a few suggestions for its further improvement.

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1. Treated water from water treatment plant should be used in any suitable process being carried out in the plant.

2. In fuel tank welding shop & in paint shop, the cooling water & the water for washing & rinsing should be reused as per environmental standards & sustainable development.

3. All the vendors of the AHL should be quality certified in order to meet AHL’s demand for the quality.

4. In the High Tech, separate exhaust from each machine should be directed out into the open air and not into the plant because there are some machines which produce very irritating dust and smell, sometimes unbearable for the operators.

5. Although the Environment Standards are already being met properly in the High Tech, but the level of noise is not harmful, but irritating. So “noise absorbers” should be installed at specific places in the plant.

6. Manufacturing of this tool holder in the die-tool shop has proved that it can be localized. So, its localization should be carried out at a larger scale so that the cost of importing such tool holders can be minimized.

7. Proper ventilation practices should be implemented in all the plants.

8. The pans in which the coolant is contained should be covered in order to avoid splashes and smell.

9. Company should support research projects with different universities under a program known as “Atlas Research Program”.

10. Smoking should be strictly prohibited during lunch hours in the canteen.

11. Students should be given an orientation about R&D department as well.

12. During orientation, the time for visits to different departments should be equally divided its span for each department’s individual orientation should be reasonably long so that internees can have a better understanding of each and every process and department without being over-exhausted.

13. Instead of one section of internship, if industry arranges two sessions, then maximum students can avail the opportunity. For implementation, internship period can be reduced to one month.

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14. Internees must have the right to select their shops according to their interests and field requirements.

15. Company is still using 10 years old operating system for their computers. It must be updated according to the need of the hour because old operating systems cannot support the latest versions of software like MS OFFICE, which are more user-friendly.

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