Professional Documents
Culture Documents
INDUSTRIAL TRAINING
(12/06/2015-31/07/2015)
ME
LSET, Lovely Professional University (Punjab)
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ACKNOWLEDGEMENT
After completing the training report at “INDIA YAMAHA MOTORS LTD.”, it is a great
pleasure for me to thank all those who have helped me during the course of completion
of my project.
I express my sincere thanks to Mr. S.P. Singh of Yamaha Motor Limited for giving me a
unique opportunity to do project in their esteemed organization.
I would also like to thank the training in charge of LOVELY PROFESSIONAL
UNIVERSITY, PUNJAB and all the faculty members of Mechanical Engineering
Department for their effort of constant co-operation, which have been a significant
factor in the accomplishment of my industrial training.
Last but not the least; I would like to place a word of appreciation on record for all those
who directly or indirectly supported me.
PARAS
LSET, LOVELY PROFESSIONAL UNIVERSITY
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ABSTRACT
YAMAHA is the world’s second largest manufacturer of motorcycles but in India there
is still a scope of improvement to catch up with fellow competitors like Hero, Bajaj,
TVS and Honda. To enhance their sales and gain larger market share, YAMAHA needs
to increase their efficiency in production.
This project mainly focuses on the processes required in the company for the
manufacturing of two wheeler’s.
Under the supervision of my industry guide (Mr. S.P. Singh) I have studied all the
important processes which are used in the manufacturing of two wheeler.
I have also visited some major vendors for Yamaha Pvt. Ltd. and studied the machining
process followed by them for manufacturing of the parts.
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CONTENTS
1. ABOUT IYM...................................................................................6
VISION........................................................................................7
MISSION.............................................................................................7
2 WHEELERS
PRODUCED IN IYM.................................................8
2. MACHINING PROCESS.............................................28
3. TOOL ROOM PROCESS.............................................30
4. WELDING PROCESS......................................................31
5. DIE CASTING PROCESS..........................................33
6. PAINT SHOP...................................................................................35
7. ENGINE ASSEMBLY LINE....................................35
8. BODY ASSEMBLY LINE............................................40
9. PACKAGING PROCESS...............................................46
10. TOP VENDORS................................................................47
11. CONCLUSION....................................................................48
12. REFRENCES.........................................................................49
13. IMPORTANT POINTS…………….50
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ABOUT IYM
Yamaha was established in 1887 as a piano and reed organ manufacturer by Torakusu
Yamaha as Nippon Gakki Company, Limited. The company's origin as a musical
instrument manufacturer is still reflected today in the group's logo- a trio of interlocking
tuning forks
Yamaha made its initial foray into India in 1985. In August 2001, Yamaha India became
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)".
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IYM's manufacturing facilities comprise of 2 State-of-the-art Plants at Faridabad
(Haryana) and Surajpur (Uttar Pradesh). The infrastructure at both the plants supports
production of motorcycles and parts for the domestic as well as overseas markets. The
Surajpur plant was established in 1984. The state–of-the-art Assembly plant at Surajpur
was inaugurated on 6th July’09 and is spread over an area of 36,000 sq. mts. It has the
capacity to produce 1 million motorcycles and scooters annually.
This fully integrated assembly plant is built on the lines of Yamaha’s globally tried,
tested and successfully implemented standards and meets the global quality
benchmarks. The plant has 3 vehicle assembly lines and 4 engine assembly lines.
The Faridabad Plant was established in 1965 and was upgraded in 2008 for manufacturing
of machined parts like Gears & shafts, Crank, Clutch Assembly, Crank Case, Body Cylinder
and Head Cylinder. With a strong workforce of more than 2,000 employees, IYM is highly
customer-driven and has a countrywide network of over 400 dealers.
VISION
We will establish YAMAHA as the "exclusive & trusted brand" of customers by
"creating Kando" (touching their hearts) - the first time and every time with world class
products & services delivered by people having "passion for customers".
MISSION
We are committed to:
Be the Exclusive & Trusted Brand renowned for marketing and manufacturing of
YAMAHA products, focusing on serving our customer where we can build long term
relationships by raising their lifestyle through performance excellence, proactive design
& innovative technology. Our innovative solutions will always exceed the changing
needs of our customers and provide value added vehicles.
Build the Winning Team with capabilities for success, thriving in a climate for action
and delivering results. Our employees are the most valuable assets and we intend to
develop them to achieve international level of professionalism with progressive career
development. As a good corporate citizen, we will conduct our business ethically and
socially in a responsible manner with concerns for the environment.
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Grow through continuously innovating our business processes for creating value and
knowledge across our customers thereby earning the loyalty of our partners &
increasing our stakeholder value.
Displacement 1,679cc
CHASSIS
Aluminum, Diamond-shaped
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Suspension (Front/Rear) Telescopic fork/Swingarm
Trail 148 mm
Wheelbase 1,700 mm
YZF R1
TECHNICAL SPECIFICATIONS
Engine type Liquid cooled 4-stroke DOHC, 4-valve
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Displacement 998 cc
Tachometer Analog
Wheelbase 1,415mm
TECHNICAL SPECIFICATIONS
Displacement 149.8cc
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Lubrication wet sump
Wheelbase 1,345mm
TECHINCAL SPECIFICATIONS
Displacement 153.0 cc
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Maximum torque 13.6 Nm @ 6000 rpm
Wheelbase 1,334mm
FZ16
TECHNICAL SPECIFICATIONS
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Displacement 153.0cc
Wheelbase 1,335mm
Battery 12 V, 5.0 Ah
790mm
Seat height
1,334mm
Wheelbase
160mm
Minimum ground clearance
135 kg
Kerb weight
12 liters
Fuel tank volume
1.2 liters
Engine oil volume
FZS
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TECHNICAL SPECIFICATIONS
Displacement 153.0cc
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Fuel Supply Carburetor
Battery 12 V, 5.0 Ah
Wheelbase 1,334mm
Headlight 12 V, 35/35W
Wheelbase 1,334 mm
SZR
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TECHNICAL SPECIFICATIONS
Displacement 153 cc
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Lubrication wet sump
Caster/Trail 26 degree/99 mm
Wheelbase 1,320mm
YBR
TECHNICAL SPECIFICATIONS
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Engine type Air-cooled, 4-stroke, SOHC
Displacement 123 cc
Headlight
12 V, 5.0 Ah
Suspension(Front/Rear)
12 V, 35W/35 W x 1
Telescopic/Swing arm
Brake Type(Front/Rear)
Drum/Drum
Tyre size(Front/Rear)
2.75-18" 4PR/3.00-18
Wheelbase 1300mm
Machining is any process in which a cutting tool is used to remove small chips of
material from the work piece. To perform the operation, relative motion is required
between the tool and the work. This relative motion is achieved in most machining
operation by means of a primary motion, called "cutting speed" and a secondary motion
called "feed". The shape of the tool and its penetration into the work surface, combined
with these motions, produce the desired shape of the resulting work surface.
TURNING- Turning operations are operations that rotate the work piece as the
primary method of moving metal against the cutting tool. Lathes are the principal
machine tool used in turning.
MILLING- Milling operations are operations in which the cutting tool rotates to
bring cutting edges to bear against the work piece. Milling machines are the
principal machine tool used in milling.
A tool room is a room where tools are stored. In a factory it includes a space where
tools are made and repaired for use throughout the rest of a factory. In engineering
and manufacturing, a tool room is everything related to tool-and-die facilities in
contrast to production line activity.
TOOL MAKING: tools used in machining processes are made with the help of
the specifications provided, and which are useful in the production of the final
product.
JIGS AND FIXTURES: A fixture is a work-holding or support device used in
the manufacturing industry. Fixtures are used to securely locate and support the
work, ensuring that all parts produced using the fixture will maintain conformity
and interchangeability. Using a fixture improves the economy of production by
allowing smooth operation and quick transition from part to part, reducing the
requirement for skilled labour by simplifying how work pieces are mounted, and
increasing conformity across a production run.
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WELDING PROCESS
MIG WELDING: Metal inert gas (mig) welding, is a welding process in which
an electric arc forms between a consumable wire electrode and the work piece
metal, which heats work piece metal, causing them to melt and join.
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PROJECTION WELDING: Projection welding is a modification of spot
welding. In this process, the weld is localized by means of raised sections, or
projections, on one or both of the work pieces to be joined. Heat is concentrated
at the projections, which permits the welding of heavier sections or the closer
spacing of welds.
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ROBOTIC WELDING: Robot welding is the use of mechanized programmable
tools (robots), which completely automate a welding process by both performing
the weld and handling the part. The program is provided by the programmer to
the machine. In some cases the loading and unloading of the parts is done by the
worker. A worker is always present for supervision during the process. The final
product is then checked with the help of jigs and fixtures.
Die casting is a metal casting process that is characterized by forcing molten metal
under high pressure into a mold cavity. The mold cavity is created using two
hardened tool steel dies which have been machined into shape and work similarly to
an injection mold during the process. This process allows products to be made with
high degree of accuracy and repeatibility. The die casting process also produce fine
details such as textured surfaces or names without requiring further processing.
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Die casting machine are most often hydraulically actuated and usually in the
horizontal position. There are two principle types of die casting machines in use; the
hot chamber type and the cold chamber type. The hot chamber type is used for the
lower melting temperature alloys like zinc and in some instances magnesium. In
operation, a reservoir of molten metal is seated in a funace from which the metal is
injected into the die.
The cold chamber machine is used primarily for the other alloys due to their higher
melting temperatures. The molten material is ladled, or in some way, fed to the die
from an external furnace.
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Friction roller way takes the mode of continuous running, uses stopper to partition
workspaces and has accurate and reliable positioning.
The Engine Assembly line has been divided into 4 zones for the assembly process. Each
zone has a set of operators and a set of instructions that are carried out before the engine
parts move to the next zone. The instructions are based on the 4M process and the
instructions sheet is called the ‘process check sheet’ in which all the processes to be
carried out are given in complete detail with the tools that are to be used and the
technical specifications.
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All the zones in the above figure have been explained as follows:
1. Engine No. Punching: Here, the crank case is received from the paint shop and an
‘Engine Number’ is punched on it by a computer. Engine number is a unique
identification number for every individual engine that is produced by a company to
keep track of the engines. It is like the PAN Card Number that the government uses
to keep track of every citizen.
For the models that are below the 150 cc segment (like 5YYL or 5TSG), number
punching is done on the Crank Case -2.
For the models that are in the 150 cc segment (like 1CK1 or 45S9), number
punching is done on the Crank Case -1.
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a. Shift shaft fitment which is used for gear shifting is placed.
b. Fitment of wire clutch holder is done.
c. Grade matching of balancer gear and crank gear is done.
d. Balancer gear assembly consists of 4 springs and 2 dovel pins.
e. Oil pump and balancer drive gears are tacked, tightened and torqued.
f. Conical washer and kickshaft are placed.
g. Shift shaft is placed on the segment.
h. Tightening and torquing of shift shaft.
i. Washer is placed on the axle drive.
j. Clutch assembly is placed on axle drive with the top cover kept open.
k. The clutch bolt in the inside is tightened.
l. Push rod and ball is inserted for precise timing.
m. The clutch case is closed and adjusted.
n. Push rod and ball is matched with the outer bolts on the top part of the engine.
o. Crank case 2 cover is put.
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BODY ASSEMBLY LINE
The body assembly line is the most important part of the manufacturing plant. It’s where
the actual production or assembly of the vehicles takes place.
The Body Assembly Line receives material from all the other departments-BOP, Engine
Assembly, Sub Assembly, Welding Shop, Paint Shop, etc. and then the whole process
has been divided into zones for the complete assembly of the vehicles.
The Body Assembly line has been divided into 10 zones for the assembly process. Each
zone has a set of operators and a set of instructions that are carried out before the vehicle
moves to the next zone. The instructions are based on the 4M process and the instructions
sheet is called the ‘process check sheet’ in which all the processes to be carried out are
given in complete detail with the tools that are to be used and the technical specifications.
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Fig: Line layout
As mentioned above, the Body Assembly Line has been divided into 10 zones. The first
Zone is of the Frame Assembly, 8 zones where the actual bike is assembled and the final
zone for Inspection.
1. Frame Assembly: Here, the frame or the ‘chassis’ is received from the paint shop
after it has been welded by the welding shop and then screws are put on it for
footrest and other parts. Also the CHASSIS NUMBER is punched by the computer
here. Chassis No is a unique identification number for every individual bike that is
produced by a company to keep track of the vehicle. It is like the PAN Card Number
that the government uses to keep track of every citizen.
After the Frame punching, there is also a chit pasted on the vehicle which contains
the barcode of the vehicle and the chassis number. This barcode is scanned after
Appearance Checking stage, Final Inspection, at Logistics Department and all other
important stages just to signify the current position of an individual vehicle.
The left and the right side zone operators work in unison but do their individual
operations. The L-1 and R-1 zone operators work simultaneously and so on.
2. L-1 and R-1 Zones: More than 60-70% of a vehicle is completed in these two
zones. Main items like TFF (Telescopic Front Fork) suspension, engine, rear
arm, rear fender, chuck nut, front wheel, lock set etc. are mounted here.
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Fig: Manufacturing Line
3. L-2 and R-2 Zones: In these zones, the Chain sub assembly takes place, engine
connections, muffler assembly, clutch handle, meter, brake handle, air filter, axle
tightening, horn engine stay and fuel tank fitting take place.
4. L-3 and R-3 Zones: Here all the electrical connections, the relay input, indicators
and headlight is done and battery box and battery box are put.
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5. L-4 and R-4 Zones: Here tail covers, side covers, body covers and passenger
seat is placed. Also this zone houses the Appearance Check and small repairing
operators. Operators manually and visually check any damaged, scratched, lose,
broken part and a repairman is present to tighten any screw etc.
6. Final Inspection Zone: Roller testing, CO2 emission testing, speedometer testing,
Dynamometer testing, Engine noise, headlight and indicator checking, brake test
and a number of other tests are performed to ensure that the vehicle is in a good
condition. If there are any faults, it is recorded in the computer and contributes
in SPR calculation. The vehicle is sent to the reworking areas and then tested
again for good working condition after reworking.
After the vehicle is passed from the Final Inspection, it is sent to the Logistics
department where it is packed and sent for further processing.
The Body Assembly Line usually runs on a 72 manpower setup or a 64 manpower
setup.
In a 72 manpower setup, 72 people work actively on the conveyor belt and
additionally 34 people are deployed who work as operators at Frame Assembly,
operators at Final Inspection, workers who do sub assembly of small parts between
the Body Assembly Line and the Sub Assembly bays and delivery boys. So actually
for a 72 manpower setup, 106 operators work on the line.
Also in each zone, there are 9 operators (9x8=72) where in each zone there is a group
leader who has all the technical know how of every individual part and assembly
process and who motivates his team of 8 people to work efficiently, solves their
problems like part shortage and manages these 8 people. The group leaders then reports
to the Line Managers and these Line managers report to the Senior Manager in case of
any shortcomings. Everything is similar for the 64 manpower setup.
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Tact Time/ Pitch Time: The time in which one vehicle gets off of the conveyor belt
when the conveyor is at full capacity.
It may also be defined as the time provided for one operation on the conveyor as
after this allotted time, it moves on to the next operator. This calculated time is
different for different models and manpower setups. For eg: the tact time for FZ-16
is 49 seconds on a 72 manpower setup.
Yamaha India has started a new assembly line for scooters which is run entirely by
women employees. The company has hired around 200 women to run its assembly
line for scooters at the Surajpur plant in Uttar Pradesh. Through this initiative,
Yamaha is also providing them classroom as well as on-the-job training.
Roy Kurian, National Business Head, India Yamaha Motor, said: “This is the first
time in Yamaha’s history, not only in India but also worldwide, that the company has
started an assembly line which is run exclusively by women. Being the pioneers in
this movement, Yamaha certainly hopes to see this initiative being replicated across
the industry.”
The company has also developed a riding training programme for female customers.
This move is in line with the company’s plans to target young urban women with its
recently launched scooter RAY. The company has expanded its dealer network and
specially improved customer care quality for female customers by appointing more
female staffs at customer contact points and introducing female customer care
programs.
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PACKAGING PROCESS
For the bikes that have to be exported to other countries, the bikes are made on the
same assembly lines A or B just like the domestic variants with slight modifications
in the appearance and graphics etc.
The engine remains the same and fender or fuel tank or body graphics differ and no
number plate is mounted for the export models.
After Final Inspection, when the bike is OK for dispatch, it is thoroughly cleaned
and polished. The front cowl, muffler and fuel tank are covered in plastic packing to
avoid scratches.
The vehicle is now in custody of the Logistics Department. The bikes for domestic
use are tagged and then sent to the warehouse for storage and dispatch to the dealers
as per demand.
The bikes for export are sent to the export department. At the export department, the
bike is disassembled on a disassembly lines. Mostly the front cowling (headlight),
front tyre and a few other projecting out parts are taken out differing from model to
model. The vehicle is then packed in a large crate and kept in storage for further
transport.
The countries to which bikes are exported, besides domestic use are:
a. Australia
b.Sri Lanka
c. Nepal
d.Philippines
e.Mexico
f. Singapore
g.Korea
h.Angola
i. Columbia
j. Bangladesh
k.Ecuador
l. And few others.
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MAJOR YAMAHA VENDORS
1. FIEM INDUSTRIES LTD.
2. VARROC ENGINEEERING PVT. LTD
3. AVLIGHT AUTOMOTIVES LTD.
4. LUMAX INDUSTRIES LTD.
5. AVLIGHT AUTOMOTIVES LTD.
6. M/S MINDA INDUSTRIES LTD.
7. ROOP POLYMERS LTD.
8. RIKKI PLASTIC PVT. LTD.
9. JAYEM AUTO INDUSTRIES PVT. LTD.
10. M/S HEMSONS ENGINEERS
Some parts (metal, plastic, electronic) are made by the outside vendors which are
selected by Yamaha Pvt. Ltd. Some of these products made by the vendors are DOL
(direct on line) i.e. these parts are directly sent to the assembly line without any
inspection. The rest of the material is first sent for the quality inspection and then to
the line. The rejected material is waste for the company and is sent to scrap.
The material is first stored in the storage area, and is used when it is required.
People are appointed with the duty to take the material to the line (wherever
required) on time so that there is no delay in the production of motorbikes.
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CONCLUSION
After doing our training in IYM, We felt the importance of training in the industry and
the practical applications involved.
During our training period in IYM, we got an exposure of the industrial culture and
work environment which is prevalent in the organization. All the staff members and
associates were very co-operative throughout the training and it was a learning
experience in all the way. IYM is a highly professional company with very strong
management fundamentals and extremely forward looking and cohesive approach
with a strong emphasis on total quality management.
Wishing IYM and its family all the best for the future endeavours and we look forward
to being associated with the company for giving positive contribution in any way
possible.
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REFERENCES
http://en.wikipedia.org/wiki/Machining
http://en.wikipedia.org/wiki/Honing_(metalworking)
http://en.wikipedia.org/wiki/Die_casting
http://en.wikipedia.org/wiki/Robot_weldin
http://www.google.com/
http://www.yamaha-motor-india.com/
Mr. Ajay Kr. Jain (senior manager- purchase) Yamaha Motor Limited
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IMPORTANT POINTS
Three Plants of Yamaha are in India that are at Surajpur, Faridabad and
Chennai.
Chennai Plant is newly installed in India.
Manufacturing of Engine Critical Part is in Faridabad Plant.
Manufacturing of Body Critical Part is in Surajpur Plant.
There are total 7 shops in Surajpur Plant.
The Old Models of Yamaha are manufactured by Manual Welding.
The New Models of Yamaha are manufactured by Robotic Welding that is
done by Programming.
There are Mainly 3 export condition.
*CKD- Complete Knock Down
*SKD- Semi Knock Down
*SPD- Spare Part Division
Employees of Yamaha works in 2 Shifts each 8 hours.
Yamaha makes approximately 2500 bikes in one shift.
Yamaha’s Crux Model is manufactured in 44 seconds by 72 men power.
Yamaha’s R15 Model is manufactured in 58 seconds by 72 men power.
The New Technology that is implemented by Yamaha is Blue Core
Technology. It is used in Yamaha scooters.
The New transmission process is CVT(Compact Variable
Transmission) used in 110cc, 125cc, 150cc bikes.
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