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SUMMER TRAINING PROJECT REPORT

I n d i a Yam a h a M o t o r P v t . L t d .

SUBMITTED BY
AMAN KUMAR
B.TECH MECHANICAL

SESSION: 2012-2016

JSS Academy Of Technical Education, Noida


(Affiliated to Uttar Pradesh Technical University)

INDEX
S no.

Description

Page

1.

Preface

2.

Acknowledgement

3.

Purpose of internship

4.

Introduction

History of Yamaha

7-8

Overview

9-10

India Yamaha Motors

11-12

8.

Vision

13

9.

Mission

13

10.

Manufacturing in Yamaha

14

11

Gear Manufacturing

15-16

12.

Machine Shop Production

17

13.

Machine Shop Processes

18-19

14.

Conclusion

20

14.

References

21

PREFACE

As a part of course curriculum of Bachelor of Technology we were


asked to undergo 2 months summer training in any organisation so as
to give us exposure to practical skill and competence to get us
familiar with various activities taking place in the organisation.
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. Being neophytes in the highly competitive world of
technology, 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
Aman Kumar

ACKNOWLEDGEMENT

I express my gratitude to all the people at INDIA YAMAHA


MOTOR PVT. LTD who helped me to gain the valuable
knowledge and experience. I have no doubt that my choice of
training at IYM was right. The exposure and experience gained
at IYM has been unique. The Yamaha family teaches strict self
discipline and goal oriented approach.
I would like to thank my mentor at Yamaha Mr. S K GULATI
acquainted with the work ethics of the organization and
motivating me at each and every step so that I achieve my goal
at Yamaha with perfection.
Last but not the least I would like to thank all Machine Shop
department workers and managers for their cooperative
behavior.

PURPOSE OF INTERNSHIP
The importance of practical on the job training in the industry for
engineering student cannot be over emphasized. Industrial training
plays the most important role in an engineering students life to make
him a successful engineer. It provides the student with an opportunity
to gain valuable experience on practical application of their technical
knowledge.

At JSSATEN, great emphasis is laid on-the-job training an industrial


training. This is an integral part of curriculum.
This two months industrial summer training (10 th Apr to 9th June,
2015), after six semester is in-built in to the B-Tech. program.

INTRODUTION
Yamaha Motor Co. Ltd. Was founded in 1955 with Genichi kawakami
as the first president. Today, Yamaha Motor is the world second
largest producer of motorcycle .It also produces many other motorized
vehicles such as all-terrain vehicle boats snowmobiles, Outboard
motors and personal watercraft .Takashi kajikawa is the current
president of Yamaha Motor Corporation. The corporation has 109
consolidated subsidiaries as on March 31st march, 2008. Yamaha
motor corporation stated aim is to bring people to great joy ,
happiness and to create Kando (touching heart )in their lives As a
company that makes the world its field and offer product for the land ,
the water , the snowfields and the sky , Yamaha motor strives to be a
company that offer New excitement and a more fulfillment life for
people all over the world and to use its ingenuity and passion to
realize people dreams and always be the ones they look for the next
Kando. Kando is the Japanese world that captures the intense
excitement and deep satisfaction people feel. When they experience
truly of exceptional value. Yamaha motor seeks to make Kando a
distinctive benefit of everything we do by creating product and
services that consistently exceed your expectations.
HISTORY OF YIC
The history of Yamaha is a history of unending challenges

YEAR
1955

1959

Mile Stones
Yamaha Motor Co., Ltd. was founded with Genichi Kawakami as the
first President
Kitagawa Motor Co., Ltd. joins Yamaha Motor group.

1960 Yamaha International Corporation (YIC) founded in U.S.


First Yamaha outboard motor "P-7" released
1963
Nationwide Yamaha Kai (authorized dealership organization)
launched
Pearl Yamaha founded in India as tie-up with local
funding & starts production and sales of mopeds
1964 Siam Yamaha Co., Ltd founded in Thailand
1965 First Yamaha FRP fishing boat "3rd Fuji Maru" built
1969 First Yamaha multipurpose engine model "MT100" released
1970 First Yamaha motorcycle mounting a 4-stroke engine "XS1" released
1973

First Yamaha portable generator model "ET1250" released


First Yamaha racing kart model "RC100" released

1975 First Yamaha golf car model "YG292" released


1976

First Yamaha industrial robot model, an "arc welding robot" released


First Yamaha marine diesel "MD35" released

1978

First Yamaha land car model "G1-AD" released


First Yamaha snow-thrower model "YT665" released

1986 First Yamaha personal watercraft (PWC) "MJ-500T" released


1987

First Yamaha-made surface mounter "21 Series" released


First Yamaha gas heat pump (GHP) model "YGC401W" released

1991

Yamaha Motor France S.A. (YMF) founded


Yamaha Motor de Mexico, S.A. de C.V. (YMMEX) founded

Chongqing-Jianshe Yamaha Motorcycle Co., Ltd. (CJYM) founded in


1992 China Yamaha Motor Austria GmbH (YMAG) founded
Yamaha Motor Hungaria Kft. (YMH) founded
1993 Regionally limited release of the electro-hybrid bicycle "PAS"
Wheelchair electric power unit "JW-I" released, bringing Yamaha into
1995 the health and welfare industry
Urban commuter motorcycle "Majesty YP250" released
"Environment 2000 Plan" announced
1996 Yamaha is first domestic manufacturer to be awarded international
ISO9002 certification for motorcycles, snowmobiles, ATVs
1997

Y's Gear Co., Ltd. Founded


PT. Yamaha Motor Nuansa Indonesia (YMNI) founded

1999 2010 Environmental Action Plan "Eco Cite YAMAHA" announced


2000

Yamaha Motor Asian Center Co., Ltd. (YMAC) founded in Thailand

2001

Yamaha builds temporary pool "Suimu 21" for the main competition
pool of the 9th World Swimming Championships in Fukuoka, Japan

2002 Limited regional release of the electric commuter motorcycle "Passol"


Yamaha Motor Distribution Singapore Pte. Ltd. (YDS) founded
2003 Yamaha Motor Co., Ltd., Moscow Representative Office opened in
Russia
2004 Start of "YAMAHA CCS 21 Campaign"
Sales company Yamaha Motor CIS (YMCIS) founded in Russia
2005 Life Science Laboratory opened in Fukuroi, Shizuoka,as
research&development center for YMC's bio-technology business
Motorcycle manufacturing factory Yamaha Motor Manufacturing
West Java (YMMWJ) founded in Indonesia
2007 Compliance Promotion Committee established.
2006

OVERVIEW
Founded
Capital
President
Employees
(Consolidated)
Sales
(Consolidated)
Sales Profile

July 1, 1955
48,302 million yen (as of March 31, 2008)
Takashi Kajikawa
46,850 (as of December 31, 2007)
Parent: 9,019 (as of December 31, 2007)
1,756,707 million yen
(from January 1, 2007 to December 31, 2007)
Parent: 799,209 million yen
(from January 1, 2007 to December 31, 2007)
Sales (%) by product category (consolidated)

Sales (%) by region (consolidated)

Major
Products &
Services

Headquarters

Manufacture and sales of motorcycles, scooters, electrohybrid bicycles, boats, sail boats, Water Vehicles, pools,
utility boats, fishing boats, outboard motors, diesel
engines, 4-wheel ATVs, side-by-side vehicles, racing
karts, golf cars, multi-purpose engines, generators,
water pumps, snowmobiles, small-sized snow throwers,
automotive engines, intelligent machinery, industrialuse remote control helicopters, electrical power units
for wheelchairs, helmets. Biotechnological production,
processing and sales of agricultural and marine products
and microorganisms. Import and sales of various types
of products,

2500 Shingai, Iwata-shi, Shizuoka-ken, Japan

Affiliated
Companies

Consolidated subsidiaries: 112


Non-consolidated subsidiaries: 8
(by the equity method)
Affiliates: 27
(by the equity method)

Yamaha Motor Co., Ltd.


Yamaha Motor Co., Ltd.
Public
Type
Founded
Headquarters
Revenue
Operating income
Net income
Employees
Website

Public
July 1, 1955
Iwata, Shizuoka, Japan
12 billion US$ (2005)
900 million US$ (2007)
550 million US$ (2007)
39,300 (2007)
Yamaha Motor Global

INDIA YAMAHA MOTOR (IYM)


Holding the true sprit of commitment to customer satisfaction India
Yamaha motor is enriching lives of people with same ingenuity and
enthusiasm as its parent company -Yamaha motor corporation Japan.
Having operated in India as technology provider for almost two
decade, IYM was incorporated in August 2001 as a 100% subsidiary
of YMC, Japan. Since then it is in process of the business and
extending the awe and power associated with the legacy of the
Yamaha Group.
Adhering to Yamaha Motor Corporations corporate Mission
Creating Kando-Touching Your Heart Yamaha motor India is
striving to touch every heart across the length and breadth of India.
YMI`s Manufacturing facilities comprises of 2 state of the art
plants at Surajpur (Uttar Pradesh) , Faridabad (Haryana) currently 10
models roll out at the two plants of Yamaha . The models
manufactured and assembled at the Surajpur plant are;
1. Gladiator
2. G5
3. Crux
4. Alba
5. Enticer
6. R-15

The infrastructure at both plants support production of bikes and its


parts for domestic as well as oversees market. At the core of 5-S and
TPM activities that fuel the IYM `s agile manufacturing processes
IYM has in house facility for Machining Welding processes as well
as Finishing processes of Electroplating and Painting till the assembly
line .
The stringent quality assurance norms ensure that the bikes meet the
reputed International Standards of excellence in every sphere.
As an Environmentally sensitive organization IYM has the concept of
Environmentally-Friendly Technology ingrained in its Corporate
Philosophy. The company boasts of effluent Treatment Plant, Rain
water Harvesting mechanism, a motivated forestation drive. The IYM
is ISO-14001 certified. All our endeavors give us reason to believe
that sustainable development for Yamaha will not remain merely an
idea in pipeline.
We believe in taking care of not only your motoring needs but also the
needs of future generation to come.

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
Yamaha is 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.
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

MANUFACTURING IN YAMAHA
IYM's Manufacturing facilities comprises of 2 state-of-the-art Plants
at - Faridabad (Haryana) and Surajpur (Uttar Pradesh). Currently 10
models roll out of the two Yamaha Plants.
The infrastructure at both the plants supports production of
motorcycles and it's parts for the domestic as well as oversees market.
At the core are the 5-S and TPM activities that fuel our agile
Manufacturing Processes. We have In-house facility for Machining,
Welding processes as well as finishing processes of Electroplating and
Painting till the assembly line.
The stringent Quality Assurance norms ensure that our motorcycles
meet the reputed International standards of excellence in every sphere.
As an Environmentally sensitive organization we have the concept of
"Environment-friendly technology" ingrained in our Corporate
Philosophy. The Company boasts of effluent Treatment plant, Rain
water - Harvesting mechanism, a motivated forestation drive. We
believe in taking care of not only Your Motoring Needs but also the
needs of Future Generations to come.

Gear manufacturing
Gear manufacturing refers to the making of gears. Gears can be
manufactured
by
a
variety
of
processes,
including casting, forging, extrusion, powdermetallurgy,
and blanking. As a general rule, however, machining is applied to
achieve the final dimensions, shape and surface finish in the gear. The
initial operations that produce a semifinishing part ready for gear
machining as referred to as blanking operations; the starting product
in gear machining is called a gear blank.
Selection of materials
The gear material should have the following properties:

High tensile strength to prevent failure against static loads

High endurance strength to withstand dynamic loads

Low coefficient of friction

Good manufacturability

Gear manufacturing processes


There are multiple ways in which gear blanks can be shaped through
the cutting and finishing processes.
Gear forming
In gear form cutting, the cutting edge of the cutting tool has a shape
identical with the shape of the space between the gear teeth. Two
machining operations, milling and broaching can be employed to
form cut gear teeth.
Form milling
In form milling, the cutter called a form cutter travels axially along
the length of the gear tooth at the appropriate depth to produce the

gear tooth. After each tooth is cut, the cutter is withdrawn, the gear
blank is rotated, and the cutter proceeds to cut another tooth. The
process continues until all teeth are cut...
Broaching
Broaching can also be used to produce gear teeth and is particularly
applicable to internal teeth. The process is rapid and produces fine
surface finish with high dimensional accuracy. However, because
broaches are expensive and a separate broach is required for each size
of gear,this method is suitable mainly for high-quantity production.
Gear generation
In gear generating, the tooth flanks are obtained as an outline of the
subsequent positions of the cutter, which resembles in shape the
mating gear in the gear pair. There are two machining processes
employed shaping and milling. There are several modifications of
these processes for different cutting tool used.
Gear hobbing
Gear hobbing is a machining process in which gear teeth are
progressively generated by a series of cuts with a helical cutting tool.
All motions in hobbing are rotary, and the hob and gear blank rotate
continuously as in two gears meshing until all teeth are cut.
Finishing operations
As produced by any of the process described, the surface finish and
dimensional accuracy may not be accurate enough for certain
applications. Several finishing operations are available, including the
conventional process of shaving, and a number of abrasive operations,
including grinding, honing, and lapping.

MACHINE SHOP PRODUCTION


The Following products are machined at the Machine
Shop:
Cam Shaft

Crank Shaft
Cylinder Head
Body Cylinder
Axle main
Axle drive
5th gear wheel
Pinion and PDN
3rd Gear wheel
Crankcase

MACHINE SHOP PROCESSES


The following are the processes which are used in Machine
Shop:

Turning

Centering

Facing

Chamfering

Spot Facing

Surface Grinding

Milling

Face milling

Shaving

Honing

Drilling

Boring

Counter Boring

Reaming

Tapping

Inspection

Grading Color coding

Labelling

Leak test

Dibbering

Keyway Milling

Quality check

Inspection

Maintenance

CONCLUSION
The period of my training at Yamaha Motor India Pvt. Ltd.
has been a very positive one. It has given me a very good
understanding of the engineering profession which could not
have been achieved by theoretical study. The experience at
IYM has greatly advanced my understanding of the practical
aspects of engineering, both technical and organizational.
The vital part that the organizational skills of an engineer play
in todays industry is an area that is often missed by some. I
too had very little idea as to what an engineers job in a hightech industry entails. But this internship at IYM made me see
the maximum range of jobs performed by engineers. It has
given me a solid foundation to build my career upon. I am
certain that the experience gained through this internship will
be helpful to me throughout my professional career and in all
my future
endeavors.

REFERENCES

Machine Shop of IYM-faridabad plant.

www.yamaha.com

www.wikipedia.com