SUMMER TRAINING PROJECT

REPORT

INDIA YAMAHA MOTOR PVT. LTD.

SUBMITTED BY:-

PRABHAT TIWARI
B.TECH
MECHANICAL DEPARTMENT

SESSION: 2012-2016

DIT, AMITY GROUP OF INSTITUTION

GREATER NOIDA, U.P
(AFFILIATED TO UTTAR PRADESH TECHNICAL UNIVERSITY)

PREFACE
As a part of course curriculum of Bachelor of Technology we
were asked to undergo 4 to 6 weeks summer training in any
organization so as to give us exposure to practical skill and
competence to get us familiar with various activities taking
place in the organization.
Our institute also believe in close and continuous Industrial
Academy interaction in order to enhance the capability of
student to imbibe rich and practical exposure useful for the
corporate world.
I have put my sincere efforts to accomplish my objectives
within the stipulated time. I have worked to my optimum
potential to achieve desired goals. I came across some
difficulties to make my objective a reality. With the
kind help and genuine interest and the guidance of my
supervisor, I tried my level best to conduct a research to gain
a thorough knowledge about the project. I put the best of
my efforts to bring out this piece of work; if anywhere,
something is found unacceptable or unnecessary to the theme
valuable suggestions are thankfully acknowledged
Thanks and Regards
Yours sincerely
Prabhat Tiwari

ACKOWLEDGEMENT

I would like to express my gratitude to all the people who

provided me with support and
guidance throughout the course of my summer internship
program
Firstly I would like to thank Mr. Bhavesh Kumar (HR
department), Vijay Khanna (HR department) and Shaima
Tayyab (HR department) for giving me an opportunity to
undergo summer training at INDIA YAMAHA MOTORS PVT LTD,
Mathura road, Faridabad. I am deeply indebted to Mr. S.K
Gulati and Mr. Rajendra Kumar (Crankshaft department)
without the supervision and continued guidance of whom it
wouldnt have been possible to complete this project.
I would also like to thank Mr. A.K Sharma for providing me this
wonderful opportunity to work with the YAMAHA family.

Thank you
Prabhat Tiwari

CONTENTS

1. Preface
2. Acknowledgement
3. Content
4. Overview
5. About Yamaha Motors
5.1. History
5.2. About India Yamaha Motors Pvt. Ltd
6. Manufacturing
6.1. Raw Material
6.2. The manufacturing process
6.3. Quality Control
7. Faridabad Plant
7.1. Gear
7.2. Camshaft
7.3. Body Cylinder
7.4. Head Cylinder
7.5. Axle
7.6. Connecting Rod
7.7. Crank
7.8. Crankcase Cover
8. Heat Treatment

OVERVIEW
INDIAN AUTOMOBILE INDUSTRY
Over a period of more than two decades the Indian Automobile
industry has been driving its own growth through phases. The
entry of Suzuki Corporation in Indian passenger car
manufacturing is often pointed as the first sign of India turning
to a market economy. Since then the automobile sector
witnessed rapid growth year after year. By late 90s the industry
reached self-reliance in engine and component manufacturing
from the status of large scale importer.
With comparatively higher rate of economic growth rate index
against that of great global powers. India has become a hub of
domestic and export business. The automobile sector has been
contributing its share has been contributing its share to the
shining economic performance of India in recent years.
With the Indian middle class earning higher per capita income,
more
people are ready to own private vehicles including cars and
twowheelers. Product movements and manned services have
boosted in
the sales of medium and sized commercial vehicles for
passenger and
goods transport. Side by side with fresh vehicle sales growth,
the
automotive components sector has witnessed big growth. The
domestic
auto components consumption has crossed rupees 9000 crores
and an
export of one half size of this figure
As per Society of Indian Automobile Manufacturers (SIAM) the
market share of each segment of the industry is as follows:

ABOUT YAMAHA MOTORS

HISTORY
Yamaha's history goes back over a hundred years to 1887 when
Torakusu Yamaha founded the company, which began producing
reed organs. The Yamaha Corporation in Japan (then Nippon
Gakki
Co., Ltd.) has grown to become the world's largest manufacturer
of
a full line of musical instruments, and a leading producer of
audio/visual products, semiconductors and other computer
related
products, sporting goods, home appliances and furniture,
specialty
metals, machine tools, and industrial robots.
The Yamaha Motor Corporation, Ltd., begun on July 1, 1955, is a
major part of the entire Yamaha group, but is a separately
managed business entity from the Yamaha Corporation. The
Yamaha Motor Corporation is the second largest manufacturer
of
motorcycles in the world. Yamaha Motor Corporation owns its
wholly-owned subsidiary in the U.S. called Yamaha Motor
Corporation, USA, that is handling not only motorcycles, but
also
snow mobiles, golf carts, outboard engines, and water vehicles,
under the brand name of Yamaha as well.
In 1954 production of the first motorcycles began, a simple

125cc
single-cylinder two-stroke. It was a copy of the German DKW
design, which the British BSA Company had also copied in the
post-war era and manufactured as the Bantam.
About India Yamaha Motor Pvt. Ltd.
Yamaha made its initial foray into India in 1985. Subsequently,
it entered into a 50:50 joint-venture with the Escorts Group in
1996. However, in August 2001, Yamaha acquired its remaining
stake becoming a 100% subsidiary of Yamaha Motor Co., Ltd,
Japan (YMC). In 2008, Mitsui & Co., Ltd. entered into an
agreement with YMC to become a joint investor in the
motorcycle manufacturing company "India Yamaha Motor
Private Limited (IYM)".
IYM operates from its state-of-the-art-manufacturing units at
Surajpur in Uttar Pradesh and Faridabad in Haryana and
produces motorcycles both for domestic and export markets.
With a strong workforce of more than 2,000 employees, IYM is
highly customer-driven and has a countrywide network of over
400 dealers.

MANUFACTURING
India Yamaha Motors manufacturing facilities comprises of 2
state-of-the-art Plants at Faridabad (Haryana) and Surajpur
(Uttar Pradesh). The infrastructure at both the plants support of
motorcycles and its parts for the domestic as well as overseas
market. It has In-house facility for Machining, Casting, Welding
process as well as finishing processes of Electroplating and
Painting till the assembly line.
The stringent Quality Assurance norms ensure that its
motorcycles meet the reputed International standard of
excellence in every sphere.
RAW MATERIAL:-

The primary raw materials used in the manufacture of the body

of motorcycle are metal, plastic and rubber. The motorcycle
frame is composed almost completely of metal. The frame may
be overlaid with plastic. The tires are composed of rubber. The
seat is made from a synthetic substance, such as polyurethane.
The cylinder piston, made of aluminium alloy is an essential
component of engine. It is fitted with piston rings made of cast
iron. The crankshaft and crankcase are made of aluminium. The
engine also contains a cylinder barrel, typically made of cast
iron or light alloy.
THE MANUFACTURING PROCESS:1.
Raw materials as well as parts and components arrive at
the manufacturing plant by truck. As part of just-in-time
delivery system on which many plants are scheduled, the
materials and parts are delivered at the place where they
are used or installed.
2.
Manufacturing begins in the weld department with
computer-controlled fabrication of the frame from high
strength frame materials. Components are formed out of
tubular metal and/or hollow metal shells fashioned from
sheet metal shells fashioned from sheet metal. The various
sections are welded together. This process involves manual,
automatic and robotic equipment.
3.
In the plastic department, small plastic resin pellets are
melted and injected into molds under high pressure to form
various plastic body trim parts. This process is known as
injection molding.
4.
Plastic and metal parts and components are painted in
booths 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.
5.
Painted parts are sent via overhead conveyors or tow
motor to assemble department where they are installed on
the frame of the motorcycle.
6.
The engine is mounted in the painted frame, and various
other components are fitted as the motorcycle is sent down
the assembly line.
7.
Wheels, brakes, wiring cables, foot pegs, exhaust pipes,
seats, saddlebags, light, radios and hundreds of other parts
are installed on the motorcycle frame.

QUALITY CONTROL:At the end of the manufacturing line and assembly line, quality
control inspectors undertake a visual inspection of the
motorcycle and its parts finishing, painted finish and fit of
parts. The quality control 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 0-60mph. During the
acceleration, the dyno tests for acceleration and braking,
shifting, wheel alignment, headlight and taillight alignment and
function, horn function and exhaust emissions. The finished
product must meet international standards for performance and
safety. After the dyno test, a final inspection is made of the
completed motorcycle.

FARIDABAD PLANT
The manufacturing unit of Faridabad plant constitutes Casting,
Machining, Welding, Heat treatment and Painting of parts
of two wheelers of IYM. Following are the parts of two wheelers
manufactures in Faridabad Plant of IYM:1.
2.
3.
4.
5.
6.
7.
8.
9.

Gear
Axle Main
Cylinder Head
Cylinder body
Crank
Crankcase
Cover crankcase
Cam and Cam shaft
Connecting rod

GEAR
GEAR BLANK from the vendor is brought to the Faridabad plant
for manufacturing of gears. Then it is passed through the
following processes: Turning, facing, boring and chamfering
Hobbing
Broaching
Marking
Washing
Shaving
Heat treatment

Hobbing
Hobbing is a machining process for making gears, splines, and
spockets on a hobbing machine, which is a special type of
milling machine. The teeth or splines are progressively cut into
the gear blank by a series of cuts made by a cutting tool called
hob. Compared to other gear forming processes it is relatively
inexpensive but still quite accurate, thus it is used for broad
range of parts and quantities.
It is most widely used gear cutting process for creating spur and
helical gear and more gears are cut by hobbing than any other
process since it is relatively quick and inexpensive.

USES
Hobbing is used to make following types of finished goods:
Cycloid gear
Helical gears

Involute gear
Ratchets
Splines
Sprockets
Spur gears
Worm gears

Hobbing is used to produce most throated worm wheels but

certain tooth profiles cannot be hobbed. If any portion of hob
profile is perpendicular to axis then it will have no cutting
clearance generated by usual backing off process and it will not
cut well.
BROACHING
For very large gears or splines a vertical broach is used. It
consists of a vertical rail that carries a single tooth cutter
formed to create the tooth shape. A rotary table and a Y axis
are the customary axes available. Some machines will cut to a
depth on the Y axis and index the rotary table automatically.
The largest gear are produced on these machines.
Other operation such as broaching work particularly well for
cutting teeth on the inside. The downside to this is that it is
expensive and different broaches are required to make different
sized gears. Therefore it is mostly used in very high production
runs.
MARKING
Marking is done on the Primary Gear and Gear Balance
Weight. In this process in mark is made on a certain distance
from the centre of the gear on both types of gear so that at
time of assembly all the gear should be properly mounted such
as no misalignment is present in gear assembly, otherwise the
transmission system of vehicle fails during the operation.

CAMSHAFT
Camshafts can be made out of several different types of
material. These include Chilled iron casting and Billet steel.

Chilled Iron Casting: this is a good choice for volume production.

A chilled iron camshaft has a resistance against wear because
the camshaft lobes have been chilled, generally making them
harder.
Billet Steel: when a high quality camshaft is required, engine
builder and camshaft manufacturers choose to make the
camshaft from steel billet. One example being EN40b. When
manufacturing a camshaft from EN40b, the camshaft will also
be heat treated via gas nitriding, which changes the microstructure of the material. It gives a surface hardness of 55-60
HRC. These types of camshafts can be used in highperformance engines.
Processes
Various process involve in the manufacturing of cam shaft
according to operating machines are: Facing
Turning operation
Keyway drilling and tapping operation
Oil hole drilling operation
Cam grinding operation
Grinding operation
Lapping operation
Washing operation

BODY CYLINDER
Body of cylinder of engine in made of aluminium in Casting
shop of Faridabad plant. In casting liquid aluminium is poured
into the mold, which contains the hollow cavity of desired
shape, and then allowed to solidify. The solidify part is known as
casting which is ejected or broken out of the mold to complete
the process.
Initially it has poor surface finish and defects, so it is brought to
the Machining shop for giving desired accurate dimension and
surface finish. Machine/Operator-wise operation done on the
Body cylinder are:-

 Camera Vision testing

Face milling, drilling and boring A face
Milling, dowell and drilling B face
Milling, drilling and tapping C face
Dowell and rough boring B face
Fine boring
Internal diameter honing
Internal diameter testing
Air plug gauge setting
Oil extracting machining
Date code marking
Washing and air cleaning
Leak testing

HEAD CYLINDER
Like Body cylinder it is also made up of Aluminium in casting
shop and according to its desired shape then it is also brought
to the Machine shop for removal of defects, giving more
accurate dimension and surface finish.
Machine-wise process involve in the manufacturing of Head
cylinder are: Spot facing and drilling
Milling and drilling
Right fixture Exhaust facing, rough guide hole drilling & Left
side inlet facing/guide hole drilling
Right side exhaust, left side inlet facing and threading
Right side exhaust, left side exhaust boring and threading
Right side facing, left side inlet facing, drilling and tapping
Right side exhaust, left side inlet rocker milling
Right side exhaust, left side inlet parent boring
Parent bore inspection
Right side spark hole facing, threading, left side hole drilling
and reaming
Rough cambore, face milling, drilling and threading
Mid-washing
Air blow procedure
Air plug gauge inspection
Seat and guide press

 Exhaust valve seat machining

Inlet valve seat machining
Cambore fine boring, drilling and reaming
Deburring
Final washing
Air blow procedure
Leak inspection

AXLE MAIN
The method includes heating a billet at a heating station to a
predetermined temperature, forging the heated billet at a
forging station to form a machined axle. This axle is brought to
the Faridabad plant from vendor and processed in machining
shop for desired accurate shape, dimension and surface finish.
The process involves are: Turning
Deburring
Drilling
Oil hole drilling
Washing
Hobbing
Threading

CONNECTING ROD
A standard shape of connecting rod with poor surface finish is
brought from vendor to the Faridabad plant where whereas
operation is done on it in Machining and heat treatment shop to

give it proper accurate dimension, good surface finish and

hardness.
Operation carried out in Machining shop are: Small end drilling
Small end internal diameter drilling
Small end champering
Big end boring and champering
Small end oil hole drilling

Heat treatment: In heat treatment shop for carburizing it is kept for 9 hours at 930
degree celsius and then for diffusion it is kept for 4 hours

Then again it is brought to the machine shop for:

Both end face grinding
Honing
Washing

CRANK
Like some other parts forged crank is also bought from vendor
of standard shape and poor surface finish. In machining shop
it various operations are done on it to give it a defect less and
accurate dimension and also good surface finish. The
machine-wise operations done over it are: Centering and facing
Pin turning
Pin hole boring
Thread rolling
Keyway milling
Induction hardening
Outer diameter grinding

 Thrust facing
Internal diameter grinding

COVER CRANKCASE
Like engine cylinder it is also manufactured in casting shop of
Faridabad plant by melting the metal and poring it into the mold
and then extracting the solidify casting from the the mold. From
casting shop this cover crankcase is brought to the machine
shop for the following process to give it a good surface finish
and preparing its desired dimensions: Milling, dowell and boring
Drilling, tapping, boring of screw hole
Drilling and chamfering
Washing
Air-blow
Visual inspection

HEAT TREATMENT
Heat treating is a group of industrial and metal working
processes used to alter the physical and sometimes chemical
properties of a material. The most common application is
metallurgical. Heat treatments are also used in the manufacture
of many other materials such as glass, Heat treatment involves
the use of heating or chilling normally to extreme temperatures
to achieve a desired result such as hardening or softening of
material. Heat treatment techniques include annealing, case
hardening, precipitation strengthening, tempering and
quenching. It is noteworthy that while the term heat treatment

applies only to processes where heating and cooling are done

for specific purpose of altering properties intentionally, heating
and cooling often occur incidentally during other manufacturing
processes such as hot forming or welding.

TECHNIQUES:
The heat treatment techniques used for manufacturing of parts
of two wheeler in Faridabad plant are:Annealing
It consists of heating a metal to a specific temperature and then
cooling at a rate that will produce a refined microstructure. It is
often used to soften a metal for cold working to improve
machinability or to enhance properties like electrical
conductivity
Normalizing
Normalizing is a technique used to provide uniformity in grain
size and composition throughout an alloy. The term is often
used for ferrous alloys that have been heated above the upper
critical temperature and then cooled in open air.
Stress relieving
Stress relieving is a technique to remove or reduce the internal
stresses created in a metal. These stresses may be caused in a
number of mays, ranging from cold working to non-uniform
cooling. Stress relieving is usually accomplished by heating a
metal below the lower critical temperature and then cooling
uniformly.
Aging
Some metal are classified as precipitation hardening metals.
When a precipitation hardening alloy is quenched, its alloying
elements will be trapped in solution, resulting in a soft metal. A
solutionized metal will allow the alloying element to diffuse
through the microstructure and form intermetallic particles.
These intermetallic particles will nucleate and fall out solution
and act as a reinforcing phase, thereby increasing the strength
of the alloy. Alloys may age naturally meaning that the
precipitates form at room temperature, or they may age
artificially when precipitates only form at elevated
temperatures. In some applications, naturally aging alloy may

be stored in a freezer to prevent hardening until after further

operation-assembly of rivets, for example, may be easier with a
softer part.
Quenching
Quenching is a process of cooling a metal very quickly. This is
most often done to produce a martensite transformation. In
ferrous alloys, this will often produce a harder metal, while nonferrous alloys will usually become softer than normal.