Internship

Report

Submitted To:
HR Department, AHL

Submitted by:
Muhammad Ahsan
MECHATRONICS-07
Saqib Hussain MECHATRONICS-07
Azka Jawaid IEM-07
Zainab Rana IEM-07
 Dated: 13th August, ‘10

Acknowledgement

Above all, thanks to Allah Almighty, the beneficent and the most
merciful who gave us a chance to polish our abilities by letting us
intern at AHL.

We owe a great many thanks to people who helped and supported us.
We express our thanks to Mr. Jamil and Ms. Asma for extending their
support.

Our deepest thanks to Mr. Yawar, A.M. CRANKSHAFT for being the
guide of the project and for mentoring and correcting various
documents of ours with attention and care. He has taken pain to go
through the project and make necessary correction as and when
needed.

Thanks and appreciation to the helpful people at High Tech Plant,

especially GM Plant, Manager Engine Plant and all the AMs.

We would also thank the whole staff at AHL for their help and
coordination, without whom this internship would have been a distant
reality.

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` Preface
The purpose of this report is to explain what we did and
learned during our internship period with the Atlas Honda Limited.
The report is also a requirement for the internship program. The
report focuses primarily on the orientation of the organization,
working environment, successes and short comings that the intern
did encounter when handling various tasks assigned to him by the
supervisor.

Because the various parts of the report reflect the intern’s

shortcomings, successes, observations and comments, it would be
imperative that the recommendations are also given. Therefore
the report gives a number of comments and recommendations on
the internship program.
It is hoped that this report would serve as an important vehicle to
the improvement of the internship program.

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 Table of Contents

Acknowledgement---------------------------------------------------------------------

-------2

Preface------------------------------------------------------------------------------------

--------3

Table of

contents-------------------------------------------------------------------------------4

1. Introduction to Company ---------------------------------------------------------------

01

2. Human Resource Department ---------------------------------------------------------

03

3. Finance/ Accounts ------------------------------------------------------------------------

04

4. Cost---------------------------------------------------------------------------------------------

05

5. Logistic & Purchase Department ------------------------------------------------------

05

6. Vendor Procurement

---------------------------------------------------------------------- 07

4
7. Production, Planning & Control --------------------------------------------------------

07

8. Maintenance ---------------------------------------------------------------------------------

09

9. Stores

------------------------------------------------------------------------------------------- 10

10. Quality Assurance / Final inspection ------------------------------------------------

12

11. Manufacturing Plant --------------------------------------------------------------------

13

12. Assembly Plant ---------------------------------------------------------------------------

15

13. Casting Plant ------------------------------------------------------------------------------

16

14. Engine Plant (Hi-Tech) -------------------------------------------------------------------

16

15. Suggestions-----------------------------------------------------------------------------------

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1. Introduction to the Organization:

1.1 Introduction:
Atlas Honda Limited is a joint venture between the Atlas Group and
Honda Motor Co., Japan. Both these motorcycle manufacturing
concerns were established by the Atlas Group. Atlas Honda Limited
manufactures and markets Honda motorcycles in collaboration with
Honda Motor Company.
The Company also manufactures various in-house hi-tech components.
Their motorcycles are by far the largest selling motorcycles in the
country with an unparalleled status for excellence, high quality and
reliability. AHL is producing 4 models with fulfilling its ISO 9002 & ESH

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(ISO 14001) requirements. AHL is also committed to provide green
products /non hazardous/environment friendly bikes to fulfill its
corporate citizen responsibilities.

Atlas has undertaken to extend local manufacturing capabilities to the

highest and economically feasible level. While a major role in
localization has been assigned to vendor industries, Atlas has the
country’s largest in-house manufacturing capability at its Karachi and
Sheikhupura plants. Sheikhupura Plant is over 27 Acres of total area.
To support the production facilities, the company has established an
R&D wing and tool making facilities through CDA & CAM. The company
has 250 dealers nationwide, who are responsible for the sales of
motorbikes. Further, there are 6400 service dealers throughout the
country, who are providing services of repairing to the customers. They
are also responsible for the sale of spare parts. In this way, directly or
indirectly, Atlas Honda is creating job opportunities for almost 25,000
people. The turn over here is less than 3 percent which is very less as
compared to other industries who expect 10 percent turn over per
year.

Four models of Honda Motorcycles are being made at AHL namely,

• CD-70.
• CD-100.
• CG-125.
• CG-125 Deluxe.

1.2 Atlas Group of Industries:

1. Atlas Honda Ltd.
2. Honda Atlas Cars (Pak) Ltd.
3. Atlas Bank Ltd.
4. Atlas Battery Ltd.
5. Atlas Insurance Ltd.
6. Total Atlas Lubricants Ltd.
7. Atlas Power Ltd.
8. Sherazi (Pvt) Ltd.

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 9. Sherazi Investment Ltd.
10. Atlas Engineering Industries Ltd.
11. Sherazi Capital Ltd.
12. Atlas Capital Markets

1.3 Market Share of HONDA:

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 1.4 Structure
Chairman

CEO

Finance Marketing Supply chain HRM Quality R&D

Procurement Warehouse Production Control

Imports
RM SAP
Local

2. Internship Programme:
The internship Programme started on 1st July, 2010 & ended on 13th
August 2010.
During internship, we were given a brief introduction of all the
departments of the company including,
• Human Resource Department
• Finance/Accounts
• Cost
• Logistic & Purchase Department
• Vendor Procurement
• Production, Planning & Control
• Maintenance
• Stores
• Quality Assurance / Final inspection
• Manufacturing Plant

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• Assembly Plant
• Casting Plant
• Engine Plant (Hi-Tech)
3. Departments
3.1. Human Resource Department
The department deals with the matters related to the employee of
each and every department. Its key task is” the man power”.
Their main functions are:

1. Recruitment and selection of the employee.

2. Compensations and benefits to the workers.

3. Training and development of the new employees and.

4. Man Power Budgeting is done annually.

5. Performance appraisals of the one giving good performance. They

are based on one of the following characteristics of an employee
• Competencies
• Objectives
• Training needs
• Overall performance

HR develops system known as Training Needs Analysis (TNA) which is a

sheet generated at the end of the evaluation of an employee,
determining which employee needs to excel which type of skill as
suited.
This system of TNA is based on three R’s
• Respect
• Recognition
• Reward

Business plans are made.

3.2 Finance/Accounts
This sector deals with the finance related activities. They maintain the
accounts, trades, imports and exports, assets, banks and market
dealing of the company regarding capital.

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The main modules of the department are given as follow.

• General Ledger

• Fixed Assets of the company

• Cost of the bikes and the cost analysis.

• Account payable to and by company.

• Petty Cash (Day Book) i.e. transaction of the cash into our out of
the organization.

• Pay roll which deals with the salary issues of the employees.

Taxation related activities like Income tax, Sales tax, Special Cost Duty
(SCD).

Its financial function is integrated in SAP which is software, known as

Standard Application & Product in Database.

3.3 Cost
Three factors that this department oversees are

• Production, in which cost components of a product are included,

that come under production
o Material for which a “Bill of Material” (BOM) file is required.
o Labor
o Factory overhead
• Service
o Quality
o Procurement
o Maintenance
• Infrastructure

They imply Absorption Costing methods.

3.4 Logistics & Purchase

3.4.1 Logistics

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It involves planning, managing and controlling the flow of goods and
services, information, real-time data and human resources from the
point of source to the target.

• Commercial Purchase

• Import

• Logistics

Their functions are

• To coordinate with third party logistics.

• Loading and unloading very carefully of bikes.

• To calculate unit cost of each unit.

The logistic department involves

1. Ensuring that the requirements of the customers are met on time in

an efficient and protected manner.
2. To synchronize with third party logistics.
3. To ensure that there is a safe and timely dispatch of goods.
4. To draft plans, policies and procedures for successful
implementation of logistics system.
5. To create and maintain customer support.
6. To maintain coordination with vendors, service providers and
transport carriers.
7. To ensure that no fraud is involved.
8. To ensure timely supply and payment of goods and reduce
inventories.

3.4.2 Dispatching

This involves the functions and responsibilities of the dealers in the

field of marketing.
Any tool that is not available and is to be used in AHL is then Import
trough Honda Japan. It depends on the inventory. They have the stock
of minimum six months so there is no shortage.

3.4.3 Purchasing

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It involves purchasing the parts which are not required in the
production process.

They form a Price Committee, which takes decisions related to the

purchasing of goods
It consists of
• Customer representatives
• Cost managers
• Various managers

3.5 Vendor Procurement

This department is for local vendors in Pakistan.

• This department deals with the timing and the schedule for the
vendors

• It assesses the vendor, also checks his capacity.

• Collects the data directly from the vendor manufacturing unit.

• Responsible for the proper amount of the parts in the stock.

o For normal Lead Time, a function of this department is to
keep Buffer Stock.

• Responsible for the cash transactions with the vendors, e.g. bills and
payments.

• Checks the raw material and the stock at the vendors end.

It involves planning of three major factors.

• Production planning
• Outsourcing/outsource planning
• Development, which involves developing “deleted parts” which
were initially made in Japan, but are now manufactured locally

3.6 Production, Planning and Control

PPC manages the details of the parts to be produced that what is
required and when, and to obtain the raw materials, parts, and
resources to produce those items.

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PPC does this by keeping records. For this reason, PPC has to maintain
up-to-date interactions in terms of coordination, communication &
cooperation with major sections of Production and service departments
like
• Quality Assurance,
• Logistics
• Maintenance
• DCC/ Stores and
• PPC Karachi

Further,
• It communicates with sales, marketing to fulfill their day today
requirements.
• The engine and the frame number to the engine are provided by
this department.
• The division of the spare parts division is supported by the PPC.
• It gives warranty to the product.
• It handles transactions related to Dies and Moulds.
• Deals with the excise and taxation.
• The in house production is directly controlled by them.
• They imply the concept of Just in Time (JIT).
• They manage inventory and safe stock.

3.7 Maintenance
It involves maintaining

• Utilities
o Air supply
o Gas supply
o Water supply and waste water treatment plant.
o Electricity generation
• Contractors
• Preventive maintenance
• Troubleshooting

Maintenance of following departments are carried out

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The types of maintenance are:

1. Corrective maintenance:
When there is sudden shutdown, the team of break down maintenance
reaches on the spot and solves the problem in order to run the
machine.

2. Preventive maintenance:
This type of maintenance is done for improving the productivity rate. In
this the part or parts of the machine are changed and capacity and
working of the machine is improved.

3. Scheduled maintenance:
Each machine in each shop is being maintained on the weekly and
monthly basis as in the specified schedule. The master schedule is
planned on monthly and weekly basis for the maintenance. In this all
the general inspection and the working of the machine is analyzed.

3.8 Stores

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The main purpose of the stores are to receive and dispatch the parts
from the vendor and
Import parts. It is also meant to store the safety stock which is about 3
to 5 days of in-house
The material is divided in two types
• Direct materials
They involve MROs which is Maintenance, Repair and Operating
storing.
It involves parts required in the production process
o Oils like hydraulic oil, solicut oil etc.
o Gases
o Chemicals
o Paints
o Steel pipes for shoch absorbers
o Steel sheets for frame of the fuel tank
o Sand for molding
o Aluminium dies

• Indirect materials
o Consumables including gloves, ear plugs, masks etc.
o Manufacturing tools, both local and imported.
o Maintenance spares, which use items from both JIT and
Stock.

3.8.1 Types
There are three stores in the Honda Shiekhupura Plant.
One lies outside the production while two lies in-house.

1. DCC (Delivery Control Center)

2. General stores.

3. Store for the Paints and Kerosene oil.

3.8.1.1 Delivery Control Center:

There are three major sections of the DCC.

• Receiving
Parts from the vendors as well as from different parts of the world.

• Placing

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DCC is divided into two sections. One is for the imported parts
placement and the second is for the placement of parts from Vendors.

• Unpacking and dispatching from the production plant

People carrying outsourced parts, unpack and send them to
Sheikhpura Plant and make them ready for production.

3.8.1.2 General Stores:

The General Stores are responsible for storing the parts which are not
directly used in the assembly but are used for the manufacturing like
tools, holders and the other accessories for the plants usage like tube
lights, pressure pipes etc.

3.8.1.3 Stores for the Paint and Oils:

These stores are used to store the paints; special temperature is

maintained in the store for the preservation of the paints and oils.
Specific measures and instruments are placed in order to control the
fire. Water sprinkles were installed in this area.

3.8.2 Outside processing

System Transaction involves OSP schedules which are generated
similar to the other material in SAP. When the parts made in-house are
to be sent to vendors, vendors are informed through vendor
procurement. The proper vendor authority issues the material

Its functions are to from stores for processing.

• Issue material
• Receive material
• Accounts check
• Costing analysis

Material Requirement Planning, which is software, is installed for direct

and indirect materials

• Direct material- annual budgeting, divided on a monthly basis, by

given a certain pace.

• It is carried out depending

o Model wise
o Color wise
o Vendor schedule

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 • STO is applied which is Stock Transport Order, for parts coming
from different plants, e.g., Karachi.

3.8.3 Rejection Parts Stores:

It is divided based on the type of incoming material whether it is made
in-house, is imported or outsourced.

• There is low rejection on imported parts and they are checked

according to Japanese Standard (JIS).

• Faulty parts from vendors are checked by Quality Department.

Vendors are informed of rejected parts through Logistic
Department.

• In-house parts if malfunction, are rejected at line.

3.9 Quality Assurance

They are responsible to assure the quality of each and every part at
each and every step.
The inspection at each step is carried out to insure the quality of the
manufactured parts.
QA department directs Quality management & Quality Control
functions.
It identifies quality related problems in vendor & in-house parts & takes
preventive action in case of their re-occurrence.

There is a Complete Buildup Unit which involves antenna dealers from

various locations who report the rejected parts to the related
department.

The quality standards implied are ISO 9001 and ISO 2008.
Quality is checked according to Honda Motor Standards as well.
Quality checking is done in the Standard Room.

• Co-ordinate Measuring Machine ( μ precision)

• Calibration of the instruments up to the given standards. All the

measurements depends upon it

• Checking the Specifications.

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 • Analyzing the layouts and different samples.

• Final Inspection of the motor-cycle to guarantee the total quality.

• Warranty is given according to market quality.

3.10 Manufacturing plant

Fuel tanks are manufactures and they are painted. The paint shop is
divided into following:

1. Press Shop

2. Fuel tank welding shop.

3. Paint shop.

3.10.1 Press Shop

It is one of the most essential shops in the manufacturing plant. First
the blanks of the metal sheets are cut into the suitable dimensions. For
this a die bending machine is used. It is huge machine whose input is a
metal sheet which is imported. The blanks are then sent to the welding
shop for the welding.

Quality Check:
The quality is checked after they have been cut. The end of the sheets
and the bending is seen if properly done.

3.10.2 Fuel Tank Welding Shop:

This shop contains several welding processes like seam, spot, mig
welding and brazing.
• The seam welding unit is a robotic machine which welds at
17000 Amperes.
• Then rough buffing is done to remove the burs.
• Then it is Ripple Arc welded (Mig welding) for the fuel cap, this
machine is semi-automatic. The butt joint is made with the lower
half of the tank by the main fuel tank part through spot welding.
• Then the block for the adjustment of the lock on fuel tank is
joined through mig welding. Finally the whole assembly is
grinded to make the smooth surface for the paint.

For CG-125 and Deluxe first the blanks are spot welded and then they
are seam welded.

Quality Check:

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 The quality assurance the leakage test is done by dipping complete
assembly into the water tank which also contains the rust free oil and
then 3 to 4 lb per inch square of pressure is applied to check the
leakage in the tank

3.10.3 Paint Shop:

The Paint shop is vital for the manufacturing shop as well as for the
finally assembled motor cycles because it deals with the aesthetics
and outlook of the bike.
It is very delicate and care-demanding work in which the input is in the
form of fuel tanks from the welding shop.
• First of all the anti-rusting oil is done for the prevention.
• Then rinsing is done by dipping the fuel tanks into the water
tank. De-greasing is done to remove the oils from the tanks and
the again rinsing is done.
• A coating of Phosphate and Zinc is done on the fuel tanks so that
the fuel tanks are prevented from rust and rinsing is done.
• Then RO (Reserve Osmotic) water is showered.
• The tanks are the pre-heated and so to make the coating firmed.
Then the first coating of Aluminum is done and the fuel tanks are
dried.
• The tanks are then coated with the Paints of color as per
requirement. The chamber for the paint shop is specially
designed and the water flows on the top to bottom of the walls
so that the paint may not stick onto the walls of the chamber.
• Then the final coating of lacer is coated to make the fuel tank
scratch free, shining and for the surface finish.
• This painted fuel tank is then taken to the Oven for baking.
• The strip is pasted onto the tanks and then the tag of the
company is attached to the fuel tank to give the final shape to
the fuel tank and ready to be installed into the motor-bike.

Quality Check:
The fuel tanks are the most critical part of the motor-bike. It is carefully
analyzed and the quality is assured at each and every step. It is
assured that the fuel tank is scratch free. There is dent on the tank.
The welds are not visible. The stickers are properly placed and tanks
are dispatched properly.

3.10 Assembly Plant:

Assembly plant is further divided into four plants

• Welding Shop
• ED Paint Shop
• Engine Assembly

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 • Frame Assembly

3.10.1 Welding Shop:

There are three basic welding types being used in this shop

• • TIG Welding
• • MIG Welding
o It uses a copper plated wire of steel to add
conductivity.
• • Spot Welding

Carbon dioxide causes oxidation, which is minimized by

adding silicon to the filler.

3.10.2 Electrode Deposition Paint Shop

In Electrode deposition (ED) line ED painting is being done in

frame assembly. The ED line is the most recent development
added to the AHL plant. Paint is deposited on the parts by giving
positive charge to the paint and negative charge to the frame.

The welded frames from the frame welding shop are shifted to
the ED (electrode deposition) paint shop for painting. The parts
which are painted here are:

• Frame body

• Bracket muffler

• Swing arm

• Side & main stands

Processes involved are:

3.10.2.1 Loading:
The parts to be painted are carried on hangers where they
are cleaned with the help of thinners.

3.10.2.2 De-greasing:
It involves avoidance of corrosion due to the coated oil by
removing it.

3.10.2.3 Rinsing:

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 Here the parts are washed so that washing agents for the
process of de-greasing can be removed.

3.10.2.4 Phosphating:
After rinsing, parts are treated with ZnPO4 in phosphating
line.

3.10.2.5 Rinsing with RO:

Now, parts are rinsed with RO (reverse osmosis) water. The
reason of using RO water is such that nutrient free water
should be used so that chemical reactions could be
avoided.

3.10.2.6 Dripping Zone:

Here, the parts are allowed to drip for a while in order to
remove water present on their surfaces

3.10.2.7 ED painting:
These parts after being rinsed with RO are then passed to
main ED tank where parts are dipped.

3.10.2.8 Baking:
After giving some time for settling, the parts are to be send
in
• Pre-heat oven (temperature ~950C) for 900sec.
• Main oven (temperature ~1650C) for 1800 sec.

3.10.2.9 Sanding, inspection & dispatch to respective shop:

After baking the parts are sanded. Then after inspection
they are handed over to engine & frame assembly.

Parts painted through this way have certain advantages:

• They have 10 times better quality than typical
painting methods.
• They are environment friendly.
• They are lead-less, hence not health hazardous.
• They are water based.

3.10.3 Engine Assembly Shop:

The whole engine is assembled here. The place is totally air
conditioned to avoid dust. Here the raw material for the engine
assembly line comes from CKD, Vendors and In-house in the form
of kits. It also has sub-assembly zones where engine parts are
assembled and then later shifted to the main engine assembly
line.

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 This is the most critical shop of the assembly plant. The
assembly line consists of a conveyor belt.
All four models CD 70, CD 100, CG 125 and CG 125 Deluxe
engines are assembled here. Pneumatic guns are provided for
the workers to mount nuts and bolts on the engine.
Checks and testing areas are provided at many places for
leakage of the engine. If any fault is found, engine is sent to the
re-work area where problem is removed.

3.10.4 Frame Assembly Shop:

The frame assembly line at the AHL is the longest assembly line
(100m) of motorbikes in the world. There are total 92 jigs. These
jigs are used to clamp the casing of the bikes. This shop is also
divided into sub assembling zones. This frame assembly has
three QUALITY GATES. The purpose of each quality gate is to
check and repair the faults in the assembled bike. It has the
capacity of producing a bike after every 26 seconds.

3.11 Casting Plant:

Casting Plant is further divided into four shops:
• Low Pressure Die Casting (LPDC)
o Cylinder Head
• High Pressure Die Casting (HPDC)
o Crank Case + Right Cover
• Gravity Die Casting (GDC)
o Case bottom
• Cushion Shop

The ingots are melted in the furnace. Two types of ingots are being
used for casting.
• HIS-S (Aluminum + 10 elements)
• HD2 BS-1 (Aluminum + 08 elements)

There is also a metal analyzer which uses the concept of spectrometry,

which gives accurate reading of the composition of the metals in 17
seconds up to three decimal places.

This plant supplies castings in raw form for the engine plant to do
machining operations on it.
PPC gives monthly plan to casting shop. The casting shop takes daily
target from customer shop i-e cylinder head machining shop. Then
according to their requirement they generate their own schedule. They
decide that how many castings and shot blasts the casting shop will
produce.

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There are three types of castings done in this plant they are:

3.11.1 LOW PRESSURE DIE CASTING:

Atlas Honda is the only Pakistani Company where LPDC is carried out.
Here, four parts are made:

• Cylinder Head of CD 70

• Cylinder Head of CD 100

• Cylinder Head of CG 125

• Cylinder Head of CG 125 Deluxe

Processes involved use:

3.11.1.1 Melting of Aluminium ingots:

First of all, raw aluminum alloy in form of ingots is melted in
MELTING FURNACE. The furnace is an automatic controlled
furnace which melts Al ingots at 7300C.

3.11.1.2 Gas Bubbling Filtration:

A fork lifter takes the liquid aluminum out of the furnace and
pours it into Gas bubbling Filtration machine which removes
air/hydrogen contents from molten aluminium.

3.11.1.3 LPDC:
After GBF, the liquid aluminum is poured into the LPDC machine
where dies are present. The liquid metal goes into the die to
form the casting. The pressurizing time for the die is 120
seconds. After this, water is passed through the die to cool the
aluminum for 15 seconds. There are sand pores placed inside the
die for giving shape to the casting.

3.11.1.4 Chipping:
After this, the casting is removed from the die and sand pour is
removed by a process called sand breaking on chipping machine.

3.11.1.5 Gate cutting:

After chopping, gate cutting machine is utilized to cut the gate
with the casting. The gate represents the way for the liquid
aluminum and has to be removed.

3.11.1.6 TIG Welding:

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 Then welding is performed on TIG Welding Plant. This is done
only when required. It is mostly not used. Workers then perform
finishing of the casting by dry grinders.

3.11.1.7 Heat Treatment process:

Heat Treatment process is then performed to toughen the
material of the cylinder head casting. Quenching is done by
heating the casting up to 500 degree centigrade and then
immediately dipping it in water at temperature of 50 degree
centigrade.

3.11.1.8 Shot blasting:

Next, shot blasting machine is used to coat the part with steel. In
shot blasting machine, steel balls are fired on the casting with
high momentum. They strike the part and leave their impact on
the casting in form of steel coating. The part is now ready to
deliver.

3.11.1.9 Core preparation section:

There is another section in LPDC where dies are coated with
special material and their service is performed.
The sand cores used in the dies are also prepared in a machine.
This machine utilizes special sand called TSC to prepare sand
cores. This sand is imported from Malaysia and Taiwan at cost of
rupees 20 per kg through HONDA TRADING. Sand is first roasted
at 300 degree centigrade and then compressed to a compact
form to give it desired shape.

3.11.2 GRAVITY DIE CASTING:

This section produces three parts:
 Case Bottom for CD 70
 Case Bottom for CG 125
 Case Bottom for CG 125 Deluxe

The sequence of operations is as following:

• First of all, aluminium alloy is melted in melting
furnace. The furnace used is same as that of LPDC section.

• Then liquid aluminium alloy is poured into the dies by

the help of Gravity Die Casting Machines.

• Afterwards, gate cutting operation is performed on

the casted part by the help of gate cutting machine.

• Then glow pasting operation is performed.

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 • Crack detection is made to check if any crack has
been developed in the casting during its production.

• Then finishing is done. If required, repairing can also

be performed.

• Final inspection of the castings is done to ensure

there is no defected part produced. Now, part is ready to
be delivered to CKD.

• There is another section in this GDC, where shock

absorbers of all four models are assembled. SHOVA
technology is best in the world for manufacturing of shock
absorbers. This technology is utilized here for assembling.
The parts are imported from Japan. After assembling is
done, they are painted, dried and then cleaned by
methylene.

3.11.3 HIGH PRESSURE DIE CASTING:

In this section, following four parts are casted:
 R Crank Case of CD 70
 L Crank Case of CD 70
 R Cover for CD 70
 Cylinder for CG 125

The sequence of operations is as follows:
• Aluminum alloy of HD2BS1 grade is melted in the
electric furnace.

• Then liquid aluminium alloy is poured in the HPDC

machines to form casting. There are three machines used
in this section. Two machines have pressure of 650 tons
each. One machine has pressure of 500 tons. There is
water cooling system in the die for cooling the die. Cycle
time is 49 seconds. The machines are automatic i.e. they
themselves pick up the liquid aluminium from a tank and
pour them at the inlet. Then a cylinder pushes the liquid
aluminium into the die which consists of two parts. These 2
parts clamp each other with immense pressure as high as
650 tons. The life cycle of one die is 1,25,000 shots.

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 • Then finishing of the casting is performed which
includes removing burrs on the casting. There is die
maintenance section in HPDC which checks the quality of
die and decides whether it is to be repaired or not.

• Die is sprayed from inside after each cycle with a

separate material so that casting does not sticks with the
die.

3.12 Engine Plant (Hi-Tech):

Engine Plant is Also Called the Hi-Tech Area. It is the one of the
largest plants in Pakistan for the CNC machines under one roof. It
is highly automated.
Basically the engine plant is divided into 8 sections.
• Gears
• Cam Shaft
• Crank Shaft
• Crank Case
• Cylinder head
• Die Tool
• Grinding Shop
• CAD/CAM

3.12.1 GEAR MANUFACTURING SHOP:

This shop produces following products:
Gear train for CD 70
Gear train for Cd 100
Gear train for CG 125
Gear train for CG 125 Deluxe
Transmission shafts and main shafts of CD 70, CD 100 and CG
125
Total 33 parts are manufactured here. The gear trains of CD 70
and CD 100 consist of 9 gear pieces. The gear train of CG 125
consists of 8 parts while that of Deluxe 7 parts. All the parts are
provided by the vendors. Following processes are performed on
the parts:
• Lathe processes like turning, boring and facing are
performed on the gears initially in CNC machines. Two such
machines are installed which perform these processes.

• Two broaching machines are present to performing

broaching operations on the gears to form holes at the
center of the gears for main shaft.

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 • Teeth are being cut on the gear profile in teeth
cutting machines. This process is done on 2 types of
machines i.e. GEAR SHAPING MACHINE and HOBBING
MACHINE. In a Hobbing machine, a set of gears is operated
at a time. Mainly, 5-8 gears are operated at a time. In gear
shaper, teeth cutting of only one gear are performed at a
time.

o In finishing section, grinding, honing and final inspection is

made of the parts. Honing is done for grinding internal
diameters of gears. It is done to lessen the wear between
gear and shaft. Final inspection is made to check if there is
any error in the gear profile. This is done on special testing
machines which draw the graphs of the gear and represent
the tooth profile of the gear.

o Then Heat treatment is done on the gear to increase its

surface hardness. There are two types of heat treatment
operations performed here; by carbonizing and by carbo-
nitrite. First of all, tempering is done to release stresses in
the part. Then shot blasting is done to coat it with steel.

3.12.2 CAMSHAFT MACHINING:

This shop performs the operation of machining and finishing the
camshaft for the bike engine. Camshafts for all four models are
machined here. The camshaft castings are imported from Japan.
Following sequence of operations are performed here:
• First of all, facing operation is done on the casting to
remove material on the shaft leaving the cams.

• Then cylindrical profile grinding operation is

performed to machine the cam profile in a special
machine.

• Then holes are made for lubricating oil passage.

Drilling, turning and reaming operations are performed.
The holes are checked for the oil passage by passing
coolant through them.

• After final inspection, the camshaft is forwarded to

be used.

3.12.3 CYLINDER HEAD MACHINING:

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 The cylinder head is casted in the casting plant and supplied to
this shop by the stores department. Here following sequence of
operations are performed:
Face milling and end milling of the upper and lower sides is
performed
Drilling operations along with reaming, boring and counter boring
is done. After this, extra parts are attached to the cylinder head.
They include valves, springs and other small accessories.
In the end, again the part is checked for the quality.

3.12.4 CRANKSHAFT MACHINING:

Crankshaft is an important part of bike engine. It is the
responsibility of this part to transfer the force of the cylinder to
the wheels. So, special attention is required while manufacturing
this part.
Following sequence of operations are performed on it:
• Plain turning of the shaft.

• Facing operation.

• Gun drilling operation is used to drill holes in the shaft for

mounting it.

• Boring is done

• Profile grinding is performed as a finishing process.

• After completion, run-out is observed by hit and trail

method. It is done to balance the crankshaft during its
performance.

3.12.5 TOOL GRINDING SHOP:

This is the only service department in the engine shop. The
purpose of this shop is to regrind the tools so that they can be
used again for cutting. Following machines are present in this
shop:
• Two universal grinding machines.
• One broach grinding machine.
• Two bench grinding machines.
• One gear drill grinding machine.
• One dia regrinding machine.
• One projector.
• Drills, reamers, taps, insert, broach and center drill tools
are grinded in this shop.
• Tools mostly are of carbide tips or diamond tips.

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 • The bench grinding machine uses diamond wheel to
perform its task.

3.12.6 DIE TOOL SHOP:

Following equipment is present in this shop:
• Four manual lathe machines.
• One shaper machine.
• One surface grinding machine.
• Four bench grinding machines.
• Four bench drills.
Different machine parts which are damaged are repaired here.

3.12.7 CRANKCASE MACHINING SHOP:

Following parts are machined here:
• L/R cases for CD 70 and CD 100.
• R cover for CD 70 and CD 100.
• L/R case for CG 125 and Deluxe.
• L.R cover for CG 125 and Deluxe.
The L cover for CD 70 and CD 100 are machined in Karachi. The
sequences of operations are:

• First, dry facing is performed on the upper and lower portions of

the castings.

• Then operations like drilling, reaming, tapping etc. are performed

on the parts.

• Then part is washed in the washing machine.

• Sub assembly fitting is performed to fit different small parts like

cone plug, joint breather, plug seals, oil seals and bearings.
These parts are mostly imported from Japan.

• Then inspection is performed e.g. leak tests and other

observations. If any fault is found, part is rejected.

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 Suggestions
Since, AHL is a plant where all the processes and functions are already highly optimized
and giving off best results, so to suggest ways for its improvement was a hard task to do.
Thus, despite of AHL’s being a highly productive and successful plant; we still managed
to find a few suggestions for its further improvement.

1. Treated water from water treatment plant should be used in any suitable process
being carried out in the plant.

2. In fuel tank welding shop & in paint shop, the cooling water & the water for
washing & rinsing should be reused as per environmental standards & sustainable
development.

3. All the vendors of the AHL should be quality certified in order to meet AHL’s
demand for the quality.

4. In the High Tech, separate exhaust from each machine should be directed out into
the open air and not into the plant because there are some machines which
produce very irritating dust and smell, sometimes unbearable for the operators.

5. Although the Environment Standards are already being met properly in the High
Tech, but the level of noise is not harmful, but irritating. So “noise absorbers”
should be installed at specific places in the plant.

6. Manufacturing of this tool holder in the die-tool shop has proved that it can be
localized. So, its localization should be carried out at a larger scale so that the cost
of importing such tool holders can be minimized.

7. Proper ventilation practices should be implemented in all the plants.

8. The pans in which the coolant is contained should be covered in order to avoid
splashes and smell.

9. Company should support research projects with different universities under a

program known as “Atlas Research Program”.

10. Smoking should be strictly prohibited during lunch hours in the canteen.

11. Students should be given an orientation about R&D department as well.

12. During orientation, the time for visits to different departments should be equally
divided its span for each department’s individual orientation should be reasonably

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 long so that internees can have a better understanding of each and every process
and department without being over-exhausted.

13. Instead of one section of internship, if industry arranges two sessions, then
maximum students can avail the opportunity. For implementation, internship
period can be reduced to one month.

14. Internees must have the right to select their shops according to their interests and
field requirements.

15. Company is still using 10 years old operating system for their computers. It must
be updated according to the need of the hour because old operating systems
cannot support the latest versions of software like MS OFFICE, which are more
user-friendly.

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