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PROJECT REPORT

INDUSTRIAL TRAINING
(12/06/2015-31/07/2015)

PROCESSES REQUIRED FOR MANUFACTURING OF TWO WHEELERS


AT
INDIA YAMAHA MOTORS PVT. LTD.

IN PARTIAL FUFILLMENT OF THE REQUIREMENT OF THE DEGREE


OF
B.TECH- MECHANICAL ENGINEERING
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CERTIFICATE

This is to certify that the project titled PROCESSES REQUIRED FOR


MANUFACTURING OF TWO WHEELERS is a record of the bonafide work done
by PARAS (Reg. No. 11209309) submitted in partial fulfilment of the requirements for
the award of the degree of B.TECH (ME) of Lovely School of Engineering &
Technology (LSET), during the academic year 2014-15 is an original work carried out
by the student under my supervision, and this work has not formed the basis for the
award of any Degree, Diploma or other such titles.

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.

TWO WHEELER’S PRODUCED IN IYM


VMAX
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TECHNICAL SPECIFICATIONS

Engine type Liquid cooled, 4-stroke, DOHC, 4-valve,


V-type 4-cylinder

Engine Cooling Liquid cooled

Displacement 1,679cc

Bore & Stroke 90.0 x 66.0 mm

Compression ratio 11.3:1

Maximum output 200.1PS / 9,000 rpm

Maximum torque 166.8Nm / 6,500 rpm

Lubrication system Wet sump

Fuel system Fuel injection

Starter method Electric

Clutch type Wet, multiple-disc

Ignition system T.C.I

Transmission system Constant mesh, 5-speed

Final transmission Shaft drive

Primary/Secondary reduction ratio 1.509/3.082


st nd rd
Gear ratios 1 gear=2.375, 2 gear= 1.81, 3 gear=
th th
1.4, 4 gear= 1.115, 5 gear = 0.935
Fuel tank volume 15 litres

Engine oil volume 5.9 litres

CHASSIS
Aluminum, Diamond-shaped

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Suspension (Front/Rear) Telescopic fork/Swingarm

Wheel travel (Front/Rear) 120/110 mm

Caster angle 31°

Trail 148 mm

Brake Type (Front/Rear) Dual Hydraulic disc Ø 320 mm/Single


Hydraulic disc brake Ø 298 mm

Tyre Size (Front/Rear) 120/70 R18M/C (59V)/


200/50 R18M/C (76V)

Overall Length x Width x Height 2,395 x 820 x 1,190 mm

Seat height 775 mm

Kerb weight 310 kg

Wheelbase 1,700 mm

Minimum ground clearance 140 mm

Service weight 310 kg

YZF R1

TECHNICAL SPECIFICATIONS
Engine type Liquid cooled 4-stroke DOHC, 4-valve
10
Displacement 998 cc

Bore & Stroke 78.0 x 52.2 mm

Compression ratio 12.7:1

Maximum output 182.1PS / 12,500 rpm

Maximum torque 115.5NM / 10,000 rpm

Starting system Electric

Lubrication wet sump

Clutch type Wet multiple-disc

Ignition system T.C.I

Primary/Secondary reduction ratio 65/43 (1.512)- 47/17 (2.765)

Secondary reduction system Chain drive

Transmission type Constant mesh, 6-speed

Final transmission Chain

Maximum Speed (crouched) 285km/h

Minimum turning radius 3500 mm

Cylinder layout In-line 4-cylinder

Radiator capacity(including all routes) 2.773 L

Air filter type Paper

Spark plug model CR9EK

Battery voltage/capacity 12V, 8.6AH(10H)

Gear ratio 1st gear=38/15 2.533, 2nd


gear=33/16 2.063, 3rd
gear=37/21 1.762, 4th
gear=35/23 1.522, 5th
gear=30/22 1.364, 6th gear=33/26 1.269

Headlight bulb type Halogen bulb

Headlight 3312V, 55W ×2


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Auxiliary light 12V, W5W ×2

Brake/tail light LED

Turn signal light(Front) 12V, 10.0 W ×2

Turn signal light(Rear) 12V, 10.0 W ×2

Speedometer LCD Digital

Tachometer Analog

Odometer LCD Digital

Trip meter LCD Digital

Water temperature meter LCD Digital

Clock LCD Digital

Shock absorber assembly type(Front) Coil spring/oil damper

Shock absorber assembly type(Rear) Coil spring/gas-oil damper

Frame type Diamond

Front suspension Telescopic fork

wheel travel (front/rear) 120/120 mm

Rear suspension Swingarm

Brake type (front/rear) 310 /220 mm

Tyre Size (front /rear) 120/70ZR17M/C(58W)/,


190/55ZR17M/C(75W)

Overall length x width x height 2,070mm x 715mm x 1,130mm

Seat height 835mm

Wheelbase 1,415mm

Minimum ground clearance 135mm

Kerb weight 206 kg

Dry weight (with oil and fuel) 206 kg

Fuel tank volume 18 litres

Engine oil volume 3.7 litres


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R15

TECHNICAL SPECIFICATIONS

Engine type Liquid-cooled, 4-stroke, SOHC, 4-valve

Cylinder arrangement Single cylinder

Displacement 149.8cc

Bore & Stroke 57 × 58.7mm

Compression ratio 10.4:1

Maximum power 17PS/ 8,500rpm

Maximum torque 15N.m / 7,500rpmm

Starting system Electric start

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Lubrication wet sump

Fuel tank capacity 12 liters

Fuel supply system Fuel Injection

Ignition system T.C.I

Primary / Secondary reduction ratio 3.042 / 3.133

Clutch type Wet Multiple-disc

Transmission type Return type 6-speed

Gear ratios 1st=2.833, 2nd=1.875, 3rd=1.364,

4th=1.143, 5th=0.957, 6th=0.84

Frame type Delta box

Caster / Trail 26° / 98mm

Tire size (Front / Rear) 90/80-17 / 130/70-R17

Brake type (Front / Rear) Hydraulic, single disc (Front / Rear)

Suspension type (Front / Rear) Telescopic / Linked type Monocross

Headlight Lo beam12V/35W X1, Hi beam12V/35W


X2

Battery 12V, 3.5Ah (10H)

Overall length x width x height 1,970mm x 670mm × 1,070mm

Seat height 800mm

Wheelbase 1,345mm

Minimum ground clearance 160mm

Kerb weight 136Kg


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FAZER

TECHINCAL SPECIFICATIONS

Engine type Air-cooled, 4-stroke, SOHC, 2-valve

Displacement 153.0 cc

Compression ratio 9.5:1

Maximum power 14PS @ 7500 rpm

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Maximum torque 13.6 Nm @ 6000 rpm

Starting system Electric & Kick start

Fuel tank capacity 12 litres

Lubrication type Wet Sump

Fuel Supply Carburetor

Transmission type Constant mesh 5-speed

Clutch type Wet, multiple-disc

Cylinder Layout Forward-inclined Single cylinder

Bore × Stroke 58.0 × 57.9 mm

Battery 12 V, 5.0 AH (10H)

Gear ratios 1st=2.714, 2nd=1.789, 3rd=1.318,


4th=1.045, 5th=0.875

Primary / Secondary reduction ratio 3.409/2.857

Frame type Diamond

Brake type(front/rear) disc / drum

Headlight 12V, 35/35W

Caster / trail 25 degree/ 101 mm

Tyre size (front/rear) 100/80-17 / 140/60-R17

Suspension (front/rear) Telescopic/ Monocross


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Overall Length × Width × Height 2,075mm × 761mm × 1,119mm

Seat height 790mm

Wheelbase 1,334mm

Minimum ground clearance 160mm

Kerb weight 141 kg

FZ16

TECHNICAL SPECIFICATIONS

Engine type Air-cooled, 4-stroke, SOHC

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Displacement 153.0cc

Bore & Stroke 58.0 × 57.9mm

Compression ratio 9.5:1

Maximum output 14PS / 7500 rpm

Maximum torque 13.6 N.m / 6000 rpm

Starting method Electric & Kick

Lubrication type Wet sump

Fuel Supply Carburetor

Clutch type Wet, multiple-disc

Primary/secondary reduction ratio 3.409 / 2.857

Transmission type Constant mesh 5-speed

Gear ratio 1st=2.714 2nd=1.789 3rd=1.318 4th=1.045


5th=0.875

Cylinder layout Single Cylinder

Frame type Diamond

Suspension (front/rear) Telescopic/ Swingarm

Wheelbase 1,335mm

Brake type(front/rear) Disc/Drum

Tire size (front/rear) 100/80-17 / 140/60-R17


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Headlight 12 V, 35/35W

Battery 12 V, 5.0 Ah

Caster / trail 25 degree/ 101 mm


Overall Length × Width × Height 1973mm x 770mm x 1045mm

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

Engine type Air-cooled, 4-stroke, SOHC

Displacement 153.0cc

Bore & Stroke 58.0 × 57.9mm

Compression ratio 9.5:1

Maximum output 14PS @ 7500 rpm

Maximum torque 13.6 N.m @ 6000 rpm

Starting method Electric & Kick

Lubrication type Wet Sump

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Fuel Supply Carburetor

Clutch type Wet, multiple-disc

Primary/secondary reduction ratio 3.409 / 2.857

Transmission type Constant mesh 5-speed

Gear ratio 1st=2.714 2nd=1.789 3rd=1.318 4th=1.045


5th=0.875

Cylinder layout Single Cylinder

Battery 12 V, 5.0 Ah

Frame type Diamond

Suspension (front/rear) Telescopic/ Swingarm

Wheelbase 1,334mm

Brake type(front/rear) Disc/Drum

Tire size (front/rear) 100/80-17 / 140/60-R17

Headlight 12 V, 35/35W

Caster / trail 25 degree/ 101 mm

Overall Length × Width × Height 1,973 mm × 770 mm × 1,090 mm


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Seat height 790 mm

Wheelbase 1,334 mm

Minimum ground clearance 160 mm

Kerb weight 135 kg

Fuel tank volume 12 liters

Engine oil volume 1.2 liters

SZR
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TECHNICAL SPECIFICATIONS

Engine type Air cooled, 4 stroke, SOHC, 2-Valve

Displacement 153 cc

Bore & Stroke 58.0 X 57.9mm

Compression ratio 9.5:1

Maximum output 12.1PS/7500rpm

Maximum torque 12.8Nm/4500rpm

Starting system Electric Start/Kick Start

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Lubrication wet sump

Cylinder layout Single cylinder

Clutch type wet, multiple disc

Ignition system C.D.I

Fuel supply Carburettor

Battery 12V,5 AH(10H)

Headlight Halogen bulb (12 V, 35/35 W)

Primary/Secondary reduction ratios 3.409/3.000

Tranmission type Constant Mesh 5 - Speed

Caster/Trail 26 degree/99 mm

Gear ratios 1st=2.714, 2nd=1.789, 3rd=1.318,


4th=1.045, 5th=0.916

Frame type Diamond

Suspension (Front/Rear) Telescopic/Swingarm

Brake Type (Front/Rear) Disc /Drum

Tyre size (Front/Rear) (2.75- 17 41P )/ (100/90-17 55P)

Overall length x width x height 2050 x 730 x 1100 mm


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Kerb Weight 134 Kg

Seat Height 802mm

Wheelbase 1,320mm

Minimum ground clearance 165mm

Engine oil volume 1.2 L

Fuel tank capacity 14 liters

YBR

TECHNICAL SPECIFICATIONS
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Engine type Air-cooled, 4-stroke, SOHC

Displacement 123 cc

Bore & Stroke 54.0 × 54.0 mm

Compression ratio 10.0:1

Maximum power 10.88PS@7,500 rpm

Maximum torque 10.40N.m / 6,500 rpm

Starting system Electric Start

Lubrication wet sump

Cylinder layout Forward inclined Single cylinder

Clutch type Wet, multiple disc

Ignition system DC CDI

With Oil and Fuel 126kg

Fuel Supply Carburettor

Primary/Secondary reduction ratio 3.400/3.214

Transmission Type Constant mesh 4-speed

Gear ratios 1st=3.000, 2nd=1.687, 3rd:=1.200,


4th=0.875

Caster/Trail 26.4 degree/90 mm


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Frame type Battery Diamond

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

Seat Height 6PR 795mm

Overall length x width x height 2,065mm x 730mm × 1,100mm

Wheelbase 1300mm

Minimum ground clearance 180mm

Engine oil volume Fuel 1.1 liters

tank capacity 13.6 liters


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MACHINING PROCESS
Machining is any of various processes in which a piece of raw material is cut into a
desired final shape and size by a controlled material-removal process. The many
processes that have this common theme, controlled material removal, are today
collectively known as subtractive manufacturing, in distinction from processes of
controlled material addition, which are known as additive manufacturing. Exactly
what the "controlled" part of the definition implies can vary, but it almost always
implies the use of machine tools.

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.

TYPES OF MACHINING PROCESSES IN YAMAHA:

 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.

 DRILLING- Drilling operations are operations in which holes are produced or


refined by bringing a rotating cutter with cutting edges at the lower extremity into
contact with the work piece. Drilling operations are done primarily in drill presses
but sometimes on lathes or mills.
 TAPPING- Taps and dies are cutting tools used to create screw threads, which is called
threading. A tap is used to cut the female portion of the mating pair (e.g., a nut). A die is
used to cut the male portion of the mating pair (e.g., a bolt). The process of
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cutting threads using a tap is called tapping, whereas the process using a die is called
threading. Both tools can be used to clean up a thread, which is called chasing.
 GEAR HOBBING: Hobbing is a machining process for gear cutting, cutting splines,
and cutting sprockets on a hobbing machine, which is a special type of milling. The
teeth or splines are progressively cut into the work piece by a series of cuts made by
a cutting tool called a hob. Compared to other gear forming processes it is relatively
inexpensive but still quite accurate, thus it is used for a broad range of parts and
quantities. It is the most widely used gear cutting process for creating spur and
helical gears and more gears are cut by hobbing than any other process since it is
relatively quick and inexpensive.
 LAPPING: Lapping is a machining process, in which two surfaces are rubbed
together with an abrasive between them, by hand movement or by way of a
machine. This produces microscopic conchoidal fractures as the abrasive rolls about
between the two surfaces and removes material from both.
 HONING: Honing is an abrasive machining process that produces a precision
surface on a metal work piece by scrubbing an abrasive stone against it along a
controlled path. Honing is primarily used to improve the geometric form of a
surface, but may also improve the surface texture.
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TOOL ROOM PROCESS

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.

TYPES OF TOOL ROOM PROCESS IN YAMAHA:

 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

Welding is a fabrication or sculpture process that joins materials, usually metals or


thermoplastics, by causing coalescence. This is often done by melting the work pieces
and adding the filler material to form a pool of molten material that cools to become a
strong joint, with pressure sometimes used in conjunction with heat, or by itself, to
produce the weld. This is in contrast with soldering and brazing, which involve melting
a lower-melting-point material between the work pieces to form a bond between them,
without melting the work pieces.

WELDING PROCESS IN YAMAHA:

 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.

 SPOT WELDING: Spot welding is a process in which contacting metal surfaces


are joined by the heat obtained from resistance to electric current.

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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.

TYPES OF WELDING USED IN YAMAHA:

 MANUAL WELDING: Manual welding is the welding process which is carried


out by a person (labour). The whole welding process is carried out by the person,
which includes loading, unloading, and the process.

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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 PROCESS

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.

Both type of machines will use a cylindrical pressure vessel, called an


“accumulator”, which is charged with nitrogen and will boost injection pressure.
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PAINT SHOP
The bodies, which are produced in welding shop, enter into paint shop for not
only coloring of the outer surface but also making special coverings which
provide sound-proofing and corrosion-resistance. This process is carried out for
making the body resistant against ultraviolet rays and for increasing the surface
quality of top coat paint with the help of robots. All the movements of the bodies
inside the paint shop are done by automatic conveyor system. At final process
bodies painting quality check and then send to Assembly. All the wastes in paint
shop are collected carefully so as not to effect the environment adversely.

ENGINE ASSEMBLY LINE


Automobile engine assembly line mainly includes general assembly line, sub-assembly line,
apparatus on each working-stage, on-line tools, etc. At present, flexible transfer line is widely used to
transmit work pieces on general assembly line and sub-assembly line and automated assembly
equipment is configured on the line to improve the efficiency. Flexible transfer line is mainly divided
into friction roller way transfer
line and start-stop-type motive roller way transfer line.

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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.

2. Zone 1: The processes in this zone are as follows-


a. 2 bearings are pressed in the crank case. One bearing is without seal which is put
for axle main and the other bearing is put for the axle drive which is with a seal.
b. Crank is fitted in the crank case.
c. Sprocket is fit onto crank with the help of pulling machine.
d. Gear fitment takes place in Crank Case- 1 where in, the axle drive has the
st th
largest gear-the 1 gear and the axle main has the 4 gear has the largest gear.
e. Crank Cases 1 and 2 are fixed together with the help of an adhesive bond which
is applied and pressed through a machine.
f. The segment is then fitted on it. The gear shaft is to be placed on it later on.
g. Oil seal is fit in crank case 1.
h. Sprocket drive gear is fixed.
i. Idle gear is mounted which is used to give rotation to a ‘rotor’.
j. Final Inspection of Transmission is done, magic marking completed and the
whole assembly is passed onto the Second Zone.

3. Zone 2: The processes in this zone are as follows-

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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.

4. Zone 3: The processes in this zone are as follows-


a. After the cover has been placed, kick is put on the engine meshing with the kick
shaft.
b. The piston is then fitted on top.
c. The piston cylinder in which it reciprocates is mounted.
d. The head bolts are tacked, tightened and torqued.
(Sometimes at particular stages, there is an auto-cut gun which tightens and
torques the bolt without the need of a torque wrench and also gives out a sound
signaling that the process is done correctly.)
e. A chain is put on the sprocket which is on the crank shaft to connect the
decompressor. A decompressor is a mechanism which releases the extra force
applied while kick starting the bike.
f. After this process, rotor is put on the crank shaft with gears underneath-all on
the crank shaft and a self start motor on the outside.
g. The rotor is covered with an outer case that has copper coils on it. The basic
principle of a magnetic field rotating with copper coils producing electricity. This
spark is the one utilized to fire the charge during self start instead of a spark plug.
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5. Zone 4: The processes in this zone are as follows-
a. After the rotor assembly, the attention shifts to the valves.
b. The inlet and outlet valves are separated from their seats at a distance of 8-10
mm and 12-14 mm respectively for them to work efficiently. This is also known
as tappet gap.
c. The cylinder head side and top covers are placed.

6. Final Inspection Zone: The processes in this zone are as follows-


a. After the engine assembly is complete, leakage testing is done through a
machine. If leakage is found, it goes for reworking; if not then engine oil is
filled, visual inspection and barcode scanning is done.
b. The engine is then taken to the engine testing room where a complete setup of a
bike is present. The engine is mounted and every aspect is checked. If any
problem arises, a mechanic looks after it on the spot.
c. The final tested engine goes for a final visual inspection and barcode scanning
and then forwarded to the different body assembly lines.

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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.

Fig: Material received at B/A line

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.

Fig: Manufacturing Line

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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.

Fig: Manufacturing Line


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Fig: Manufacturing Line

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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