Production Management - Honda

PRODUCTION PROCESS OF HONDA MOTERBIKES

PRODUCTION MANAGEMENT

HISTORY OF HONDA BIKES

The 'Honda Motor Company' was found in 1948, by Soichiro Honda (1906—1991), a mechanic and engineer/inventor who began as a blacksmith, working at his father, Gihei Honda's bicycle repair shop. In 1938, at the age of 32, Soichiro Honda was working at an auto repair-shop in Tokyo, called Art Shokai, where he began using his self-taught mechanical and engineering skills. Honda briefly studied mechanical engineering and design at Hamamatsu Technical High School, where Honda perfected his new design for the piston ring.

HISTORY OF HONDA BIKES

During the Japanese reconstruction period of the early 1940s, Soichiro Honda began designing motor-driven bicycles. Honda built his first motor-scooter, known simply as the "A-Type," in 1947.

One year later he started the 'Honda Motor Company' and began building small-displacement 'tiddler' style motor-scooters. Honda introduced his first motorcycle in 1949; the 'Dream D-Type' with a 3 horsepower, 98cc engine. Hondas were also sold under the "Benly" name, with "Honda" appearing on the engine case

THE MANUFACTURING PROCESS

According to the need of the company for manufacturing of motorcycles the material is requisitioned and a purchase order is sent to the suppliers by the purchase department and the Honda industry purchases the material from outside the country as well as within country through local costing. Raw materials which consist of parts and components arrive at the manufacturing plant by truck or rail and the transportation charges are paid by the Honda industry.

THE MANUFACTURING PROCESS

The defected materials and parts are returned to the places from where they come after inspection. Different materials are sent to the different departments for the further procedure.

The manufacturing process is completed in three major steps which are

Paint Shop. Engine Assembling. Frame Assembling.

PAINT SHOP

The raw materials which consist of parts in the case of motorcycle are sent to the paint shop for painting.

POWDER COATING

Plastic and metal parts and components are painted in the paint department using a process known as powder-coating

A powder-coating apparatus works like a large spray-painter, dispersing paint through a pressurized system evenly across the metal frame.

CHARGED PARTICLES

First of all the parts are negatively charged with the help of the electrons then the positively charged particles in the form of color are sprayed to these charged parts.

The paints are not spoiled by sun and rain.

PAINTING OF PARTS

The parts which are painted in the a single unit of motorcycle are

Fuel Tank. Side Cover set. Swing Arm. Hub Front. Panel Front. Magnet Front. Top Bridge.

PAINTING OF PARTS

These are the painted body parts of motorcycle Handle Cover. Clutch Plate. Main Stand & Side Stand. Muffler Stand. Battery Stand. Step Bar. Meter Bracket. Head Top Cover. Head Right Cover. Tappit Covers set

LABOUR FORCE

There are 18 labourers which work in this department and they are given hour wise wages by the Company. Company offers Rs.25/- per hour to each of their labourer.

DIRECT LABOUR

There are 10 people who are working in this department in the production process

INDIRECT LABOUR

The remaining 8 are working as indirect labors. These 6 people includes

3 Supervisors. 2 Sweepers. 3 people which are working on moving trail from

one channel to another for the shifting of materials.

DIRECT MATERIAL

The materials which are using in this department as a direct material and their costs are :-

Theses are the cost for one unit :- Fuel Tank. Rs.850/- Side Cover set. Rs.750/- Swing Arm. Rs.460/- Hub Front. Rs.140/- Panel Front. Rs.50/- Magnet Front. Rs.200/- Top Bridge. Rs.175/- Handle Cover. Rs.50/-

Clutch Plate. Rs325/- Main Stand. Rs250/- Side Stand. Rs150/- Muffler Stand. Rs75/- Battery Stand. Rs70/- Step Bar. Rs125/- Meter Bracket. Rs200/- Head Top Cover. Rs40/- Head Right Cover. Rs85/- Tappit Covers set. Rs100/- Total cost for direct material = Rs3887/- If we are going to produce 150 units then the cost will be

Rs.583050/-

ENGINE ASSEMBLING

Engine is the most important part of the motorcycle. All working of the motorcycle depends upon this part. There are 17 steps which take place in assembling of the engine. The parts of the engine which are purchased in the form of raw material are sent to the engine assembling room.

PISTON CONNECTION

The first step in the assembling of engine is connecting the piston with push rod. A cylindrical piston, made of aluminum alloy (preferred because it is lightweight and conducts heat well), is an essential component of the engine.

VALVE LIFTER

In second step, It is fitted with piston rings made of cast iron. Then the valve lifter is placed below the piston and the push rod and spark lead is installed.

INLET & COMBUSTION CHAMBER

In third step, the inlet part is established in the combustion chamber which is fitted with the piston. The cooling fan is also placed which helps the piston to remain cool at time when the motorcycle is driven more by the driver

CRAKCASE

Crankcase is plugged then the oil pump is installed with the engine mountain belt and oil passage way is placed in the engine on the crankcase which circulates the oil in the whole engine which helps the engine to be work more smoothly and efficiently. The crankshaft and crankcase are made of aluminum.

TIMING GEAR WITH PISTON

The one of the important step in the assembling of the engine is the establishment of timing gear with the piston through engine mountain belt hole.

Crankshaft and Camshaft gear is placed on the crankcase.

The engine also contains a cylinder barrel, typically made of cast iron or light alloy.

EXHAUST PORT

The exhaust port is placed at the mouth of combustion chamber which throws all the heat out from the engine.

Finally the rocker arm is placed and the screws are placed in the rocker arm. These are the steps which are taken place in the assembling of the engine.

FRAME ASSEMBLING

This is the last step in the manufacturing process of motorcycle. In this process the framing of the motorcycle takes place and all the parts of the motorcycle are combined by labor energy. The framing consists of 12 steps.

The motorcycle frame is composed almost completely of metal, as are the wheels. The frame may be overlaid with plastic. The tires are composed of rubber. The seat is made from a synthetic substance, such as polyurethane.

FRAME ASSEMBLING

The power system consists of a four-stroke engine, a carburetor to transform incoming fuel into vapor, a choke to control the air-fuel ratio, transmission, and drum brakes. The transmission system contains a clutch, consisting of steel ball flyweights and metal plates, a crankshaft, gears, pulleys, rubber belts or metal chains, and a sprocket. The electrical system contains a battery, ignition wires and coils, diodes, spark plugs, head-lamps and taillights, turn signals and a horn. Wheels, brakes, wiring cables, foot pegs, exhaust pipes, seats, saddlebags, lights, radios, and hundreds of other parts are installed on the motorcycle frame

PRE DELIVERY INSPECTION (PDI)

At the end of the assembly line, the pre-delivery inspection takes place in which inspectors undertake a visual inspection of the motorcycle's painted finish and fit of parts.

The inspectors also feel the motorcycles with gloved hands to detect any bumps or defects in the finish.

Each motorcycle is tested on a dynamometer. Inspectors accelerate the motorcycle from 0-60 mph.

PRE DELIVERY INSPECTION (PDI)

During the acceleration, the "dyno" tests for acceleration and braking, shifting, wheel alignment, headlight and taillight alignment and function, horn function, and exhaust emissions.

After the dyno test, a final inspection is made of the completed motorcycle.

STORE ROOM

After inspection the finished goods are sent to the store room and then from there these are shipped to the customers from where these are demanded.

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