Project

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA
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CERTIFICATE
This is to certify that the project entitled Study of various parts of Carrier and functions and its problem analysis is submitted by Mr. RAMNEESH SINGLA of the NATIONAL INSTITUTE OF KURUKSHETRA, (HARYANA) for the award of the degree in B. Tech. (Mechanical Engineering) is a bona fide record of work carried out by him under my supervision. The contents of these theses in full or in parts have not been submitted to any other institute or university for award of any degree.
Mr. Vivek Sharma Executive Frame Maintenance HMSI
Ms. Shelly Juneja HR Department HMSI
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ACKNOWLEDEMENT
I, Ramneesh Singla, a student of mechanical 2nd year, National Institute of Technology, Kurukshetra(Haryana) would like to give my heartiest thanks to all under whom I completed my summer training. I would like to express my deep gratitude to Ms. Shelly Juneja & Ms. Kavita Pandey who gave me opportunity to do training at Honda Motorcycle and Scooter India Limited. I feel highly obliged and my heartiest thanks to Mr. K. K. Chauhan, Manager of Maintenance department who give wonderful project to do and a department, which has provided me an immense learning and practicalities of actual problems, faced at the strategic and functional level. I would like to thanks my project guide Mr. Vivek Sharma & Mr. Virender Singh who showed me the way throughout. My sincere thanks to Mr. Vishal Sharma, Mr. Jagtar Singh, Mr. Rajender Dev they actually explained me the system flow and made me well versed with the intricacies of the project and were always available to solve my queries however trifle they may be. The acknowledgement would be incomplete if contribution of whole manufacturing division is not applauded as a whole. I sincerely thank all of them for their cooperation and guidance during my tenure at HMSI.
[RAMNEESH SINGLA]
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EXECUTIVE SUMMARY
Honda Motorcycles and Scooters India (Pvt.) Ltd. (HMSI) - The name speaks for itself and needs no introduction in the field of two-wheelers. This esteemed organization has a name in the field of motorcycles and motor-scooters. After being established in 1999, in a short span of time it has developed a reputation of providing world-class products with a technology to suit Indian conditions. HMSI has always striven to provide the highest quality products in accordance with ISO 9001 for worldwide customer satisfaction. No doubt the policies and procedures followed by HMSI are of world standard but with the growing competition and to cut cost in this price competitive market scope of improvement is always there and welcomed. HMSI is always known for its quality and I feel very proud to be a part of such an esteemed organization. In this span of my summer training I was deputed in the frame maintenance section (Scooter Plant). I was assigned projects, which were of utmost importance to the frame maintenance section i.e. To study the various parts and functions of a carrier and its problem analysis. I came to know about the working of the maintenance department, various parts of a carrier, its motion, its functions, reasons for the breakdown of a carrier and countermeasures and the preventive maintenance of the carrier. During this project I learned a lot of things about the 5S rule, cause & effect analysis, the 3G approach, section performance, analysis & counter measure, TQM (Total Quality Management) etc. which was very important from the industrial point of view. I also got the opportunity to visit various other departments in the motorcycle and scooter plant of the company to know & understand how the final
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vehicle was taking shape. I visited press, weld, paint, machining shops vehicle quality area, engine and frame assembly.
Contents
Company Introduction Introduction to HMSI Plant Overview Flow Chart Products Honda Philosophy Organizational Structure Introduction to Maintenance Department Project Bibliography
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1.COMPANY INTRODUCTION
1.1 HONDA HISTORY
FOUNDER: - SOICHIRO HONDA ESTABLISHED AT :HAMAMATSU (JAPAN) ON 24TH SEP. 1948
MR. HONDA . A MAN AND HIS DREAM
He dreamed of providing people, everywhere in the world an economical means of transportation. He thought of better ways of making piston rings and found a company & began production. Then his company started producing small motorcycles, including one built in 1949 called D-type dream.
Then he thought of making high capacity motorcycles and taking them to racing. So his company made bigger and faster machines, two-, four-, five- and sixcylinder race bikes and participated in the Isle of Man TT race (125 cc motorcycle class). He wanted to share his new motorcycles with the world and therefore he opened American Honda Motor Co. in Los Angeles. Also Honda began manufacturing motorcycles at its Suzuka factory in 1960. Honda launched its first sports car, the S500 in Japan and entered Formula-1 in 1964. In 1989, Soichiro Honda became the first Asian to be inducted into U.S. Automotive Hall of Fame. In 1990, Honda wins its fifth consecutive 1st ranking in the J.D. Power Consumer Satisfaction Index. In 1993, founder Soichiro Honda passed away. He dreamed of changing the way people looked at motorcycles and gave us machines that were powerful & fun to ride. SOICHIRO HONDAS dreams changed the world of motorcycling.
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Time Line of Honda and Its History
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And This Decade

2001 2002 2003 500 World Grand Prix Victories Race Debut of New 4 Stroke, 5 Cylinder Motorcycle (Called RC211V) Mazda RX, First Hydrogen Engine Car Unveiled At Tokyo Car Show Honda Enters Indy Car Series Wins 7th Consecutive Win At Suzuka 8 Hr Endurance Race Market feasibility Study For Air Craft Engine Begins 2005 Asimo Inducted Into Hall of Fame
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1.2 Hondas Products Around The World
Jet Engine
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Honda At a Glance: 37th on fortune 500 companies (2007 Fortune 500 Global List) 26th on global most admired Capital - 86 Billion (as of March31, 2007) Sales (Results of fiscal 2007) Consolidated: 11,087,140 million Unconsolidated: 4,030,881 million 405 subsidiaries (as of March31, 2007) Employees HONDA worldwide Consolidated: 167,231 (as of March31, 2007) Unconsolidated: 26,652 (as of March31, 2007)
Honda Global Network: Six Regional Headquarters:

North/ Central America South America Afro-Europe Asia & Oceania Japan China
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2.
HONDA MOTORCYCLES AND SCOOTERS INDIA PVT. LTD. ( H.M.S.I)
Honda
Motorcycle & Scooter India Pvt. Ltd. (HMSI), a wholly owned subsidiary of Honda Motor Company Ltd. was incorporated on 20th August1999 to manufacture two wheelers in India. Its Symbol Wings is recognized all over the world as the symbol of Honda two wheelers with which they promise to initiate changes and make a difference in the lifestyle of the people of India. It represents the flight that HMSI has taken to achieve the goals and targets which conform to the international
standards. Hondas commitment to India is to manufacture world class two wheelers that are designed and best suited for local conditions. Ever since its establishment in 1999, HMSI has striven to offer products of the highest quality at reasonable price by following its fundamental belief of bringing joy to people. In a short span of Eight years, HMSI has emerged as the largest scooter manufacturer and the fourth largest two wheeler company in India. While endeavoring to meet and exceed the expectations of the customers, the critical importance of providing the product, technology and service that benefits the existing employees but also beneficial for the newly entered employees to understand the manufacturing flow process in plant. It is believed at
HMSI
that by meeting these
expectations, HMSI will enhance the quality of life through products and services that reflect the spirit of today. Bringing joy to people and contributing to social development will continue to be the principles that will guide HMSI in future. It came into mass production with Honda Activa in 2001. Since then, the company has continued to grow in the Indian market along with regularly providing world class, advanced and technically sound products. Living up to its illustrious lineage of excelling in the manufacture of two wheelers of global quality, HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products like Twister, Dio, Aviator, Unicorn, Shine, Dazzler and Stunner
Apart from outstanding sales, Honda also caters its customers with excellent service and spare parts support. The HMSI factory is spread over 52 acres, with a covered area of about 85,815 square meters at Manesar, Gurgaon district of Haryana. The foundation stone for the factory was laid on 14thDecember 1999 and the factory was completed in January 2001. The initial installed capacity was 100,000 scooters per year, which has reached 6, 00,000 scooters by the year by 2007 and motorcycle capacity shall be 4,00,000 per annum. The total investment outlay for the initial capacity was Rs.215crores and now the accumulated investment is 800crores.
HMSI mainly deals with: Manufacturing and sales of two wheelers. Manufacturing and sales of two wheeler engines. Service and sales of spare parts and accessories. Export of Honda products (CBU, Engine & Parts).
Few Key details about Honda Motorcycle and Scooter India Pvt. Ltd. :1. Registered office Manesar, Plot No. 1, Sector 3, IMT Distt Gurgaon
2. Incorporation 3. Equity capital yen) 4. Area
August 20th 1999 Rs. 300crores (Approx.7500 million Land area 210,000 sq. m
Covered area 85,815 sq. m (41 %) 5. Employees 6. Product Twister / Dazzler 7. Plant capacity 1,000,000 CBUs per annum SC 600,000 MC 400,000 8. Logo 9. Directors Mizutani (Dir.) Mr. H. Iwakami ( Dir. ), Mr. M. Kato ( Dir. ) , Mr. T. Oyama ( ASH ) , Mr. M.Takedagawa (HSCI), Mr. K. Nakazono ( HM-J ) Special features: ISO 9001: 2000 and 14001 Certified.
3821 Associates Japanese: 15 Scooters Activa / Dio / Aviator Motorcycle- Unicorn / Shine / Stunner /
WINGS Mr. Shinji Aoyama President & CEO Mr. H. Nagata ( Sr.V.P. ) ,Mr. Y
ARAI Emission Lab, Pune Certified. Society Friendly Organization. Worlds No.1 in Engine designing
3.
PLANT OVERVIEW
Area: 210,000 sq. m. Production:1.55 million units/year

Location: IMT Manesar Incorporation: 1999 Employees: 6500
PLANT LAYOUT
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HMSI
deals with the both the products in the two-
wheeler segment. In this plant there are two sections one is scooter plant and other is motorcycle plant. In scooter plant all the models Activa, Dio, Aviator, Lead and Beat are being made. In Motorcycle plant Unicorn, Shine and Stunner, Aviator are being made.
4. FLOW CHART
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5. PRODUCTS:-
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Started with mass production of 1st scooter, Activa.
2001
Scooter of the year award for Activa. ISO-9001-2000 Certification by TUV, Germany. Launched new motor scooter, Dio.
2002
ISO-14000 Certification by TUV, Germany. BBC Wheel Award for Dio. Export started to Latin America. Launched geared scooter Eterno.
2003
Achieved status of No. 1 Scooter manufacturing company in domestic Market. Achieved status of no 1. Exporter in scooter segment Certification by ARAI for emission lab. Scooter of the year award for Eterno. HMSI established new motorcycle plant.
2004
Launched 1st 150 cc motorbike, Unicorn. CKD export to Latin America. Bike of the year award to Unicorn. SO-14001:2004 Certification by TUV, Germany. Unicorn Tops in TNS Consumer Satisfaction Survey in Premium Motorcycle category Activa achieved landmark sales target of 1 million units
2005
HMSI launched its 2nd Motorcycle model, SHINE a 125cc segment Motorcycle.
2006
HMSI successfully launched LEAD in Australian Market.
HMSI launched new variant ACTIVA & BEAT CKD for NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA Page 24 Mexican Market.
2007
Launch of new scooter AVIATOR. It is a E-class scooter
2009
HMSI launched its 4th Motorcycle, TWISTER a 110cc bike which was the first bike in India with lower engine capacity and high style.
2010
HMSI launched a new model of Unicorn with the name Unicorn Dazzler, 150 cc bike.
6. HONDA PHILOSPHY
HONDA PHILOSOPHY Management Policies
Compa ny Principl e
THE THREE JOYS
RESPECT FOR THE INDIVIDUAL

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It provides every Honda associate around the world with a vision. It tells us the values of our business. It bonds everyone together towards a common mission. It provides a constant standard for correct action and ethical behavior. It shows the link between the companys past, present and future. It challenges the organization to strive for the realization of its vision It helps our organization to maintain its sense of uniqueness.
COMPANY VISION: Maintaining a global viewpoint, they are dedicated to supplying products of the highest quality yet at a reasonable price for worldwide customer satisfaction.
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OUR FUNDAMENTAL BELIEFS: Respect for the individual The three joys
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The Human Being is born as a free and unique individual with the capacity to think, reason and
create ---- and the ability to dream. "Respect for the individual" calls on Honda to nurture and promote these characteristics in our company by respecting individual differences and trusting each other as equal partners.
Respect for the Individual recognizes the following core concepts: Initiative: Initiative means not to be bound by preconceived ideas, but think creatively and act on your own initiative and judgment, while understanding that you must take responsibility for the results of those actions. Equality: Equality means to recognize and respect individual differences in one another and treat each other fairly. Our company is committed to this principle and creating equal opportunities for each individual. An individuals race, sex, age, religion, national origin, educational background, social or economic status have no bearing on the individuals opportunities. Trust: The relationship among associates at Honda should be based on mutual trust. Trust is created by recognizing each other as individuals, helping out where others are deficient, accepting help where we
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are deficient, sharing our knowledge, and making a sincere effort to fulfill our responsibilities. Honda is comprised of individuals working together for a common purpose. Each individual, acting appropriately within his or her role, must translate the philosophy into actions. It is this contribution from each associate that contributes to the companys success. And every associate should be honored for these efforts.
THE THREE JOYS: Our goal is to provide Joy through our business: for those who buy our products ("The Joy of Buying"), engage in selling our products and services ("The Joy of Selling"), and are involved in business of creating our products ("The Joy of Creating"). The Joy of Buying is achieved through providing products and services that exceed the needs and expectations of each customer. The Joy of Buying is essentially the establishment of a relationship with the customer, initiated through the products and continued through the sales and service experience. Importantly, the Joy of Selling and the Joy of Creating
cannot be achieved without first bringing joy to the customer. The Joy of Selling occurs when those who are engaged in selling and servicing Honda products develop relationships with a customer based on mutual trust. Through this relationship, Honda associates, dealers and distributors experience pride and joy in satisfying the customer and in representing Honda to the customer. The Joy of Creating occurs when Honda associates and suppliers involved in the design, development, engineering and manufacturing of Honda products recognize a sense of joy in our customers and dealers. Formerly known as the "Joy of Producing," the Joy of Creating occurs when quality products exceed expectations and we experience pride in a job well done
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THE HONDA COMPANY PRINCIPLE:Maintaining a global view point, we are dedicated to supplying products of highest quality yet at a reasonable price for world-wide customer satisfaction. HONDA MANAGEMENT POLICIES: Proceed always with ambition and youthfulness. Respect sound theories, develop fresh ideas and make the effective use of time. Enjoy your work and encourage open communications. Strive constantly for a harmonious flow of work.
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Be ever mindful of the value of research and endeavor. HONDAS CORPORATE CULTURE: Free thinking & open mindedness Challenging spirit Sincerity & Integrity Co-evolution
JAPANESE WORK CULTURE A typical Japanese office is an open space with an over-crowding of desks or very little private work space. There are very few private offices An Employee for Life Other-centered, work centered long term relationships How work is done often matters more than what is accomplished. Honda Motor Co., Ltd. announced specific plans and initiatives in the following three areas, which will enable Honda to accelerate its efforts to strengthen Honda at the spot, strengthen the core characteristics that make Honda unique, and achieve further growth.
ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON; PHILOSPHY WITHOUT ACTION IS WORTHLESS.
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SOICHORO HONDA
HMSI Plant Facilities

Few of the In-House Facilities: High Pressure Die Casting, Gravity Die Casting & Low Pressure Die Casting Gravity Die-Casting & Low pressure Die Casting Sections are for manufacturing critical engine parts.
Welding Robots: Weld Shop has spot welding, seam welding and MIG welding machines to weld various sheet metal parts to form the basic frame and other scooter panels.
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Paint Shop Robots: Paint Shop has a conveyor system, which is unique amongst all Honda Factories in the world. The conveyor car carrying the parts is rotated and dipped so as to enable good paint adhesion, high gloss and superior paint finish. Robots are used in painting for improved paint finish.
Engine Assembly: Engine Assembly is done in an enclosed air pressurized area to protect the engine from dirt and dust. Each of the engines is then inspected for various parameters.
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Frame Assembly: Frame Assembly is done at the slat conveyor. After the Frame Assembly line is the roller tester to check the final scooter quality before handing over to dispatch.
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7.ORGANISATION STRUCTURE
President and CEO Sr. V.P.
Purchase
General Affairs
Manufacturi ng
Sales & Marketing
Finance & Account
Engg.
Engine Mfg.
Assembl y
PPC
Frame Mfg.
Quality
Press Shop
Weld Shop
Paint Shop
Maintenance Utility
K K CHAUHAN
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8. Introduction to Maintenance Department

Introduction: The maintenance department is one of the
most important departments of the organization where the organization has its own production. Maintenance department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the breakdowns which occur in the machines or where there is any production loss so when to overcome the problem of production loss, maintenance team has to work efficiently so that there is no mistake committed by them by which production loss occurs.
Some important definitions used by maintenance:
Maintenance: Action necessary for retaining or restoring

an equipment, machine or system to the specified operable condition to achieve its maximum useful life. It includes planned and preventive maintenance.
Planned Maintenance: Preventive maintenance carried

out according to a fixed plan is called planned maintenance.
Preventive Maintenance: Systematic inspection,

detection, correction and prevention of incipient failures, before they become actual or major failures is called as preventive maintenance.
Breakdown Maintenance: Repair or replacements

performed after a machine has failed to return to its functional state following a malfunction or shutdown is called as breakdown maintenance.
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Predictive Maintenance: Type of preventive

maintenance performed continuously or at interval according to the requirement to diagnose and monitor, a condition or system also called condition based maintenance is called as predictive maintenance.
Mean Time To Repair (MTTR): Basic measure of

maintainability of repairable items, it represents the average mean time required to repair a failed component or device is defined as mean time to repair.
Mean Time Between Failures (MTBF): Basic

measure of the reliability of repairable items it represents the average number of a life units during which all parts of a device or system perform within their specified limits under specified conditions are called as mean time between failures.
Down Time: Period during which an equipment or

machine is not functional or cannot work. It may be due to technical failures, mechanical adjustments, maintenance, or non availability of inputs such as materials, labor and power etc is called as down time.
Maintenance Department
Engine Maintenance
Frame Maintenance
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Frame Maintenance: In this department there are three

sections, 1. Press Section 2. Weld Section 3. Paint Section
PRESS SECTION: Press section has mainly four machines.

Komatsu Press3 AIDA Press -1 CNC bending machine Hind Press These presses are mechanical presses and on this press mudguard, fuel tank, nose, and body cover of the scooters like activa, aviator, dio, shine, twister, unicorn and twister. Process like blanking, coining and bending of pipes is done. Blanking is cutting up a large sheer of stock into smaller pieces suitable for next operation. Coining is the process of removal of extra material or to make work piece up to the limit. All these mechanical presses are of 500 ton and there only one hydraulic press and this press are used to repair the dyes. CNC pipe bending machines are used to bend the pipes which later used in the manufacturing of the frame.
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WELDING SECTION: In welding section, there are six types

of welding machines used in manufacturing of frames and body covers.
1.
Gantry System: Gantry system is a system in which

gantry crane is used for transporting the frame and welding is done by the robots and welding is finished by the robots the gantry crane picks up the frame and body covers and puts them on the conveyer or the hanger which goes to the weld body storage. On gantry system seam welding is done on the body covers and on the frames with the help of the welding robots. This system is fully automatic and there is no involvement of human being it picks up the frame and body covers from the location defined to it then does all the processing on it and then passes it to the conveyer.
2.
MIG Welding: Metal inert gas welding in this inert gas

argon is used and argon acts as a shielding gas. 1-5% oxygen is used. This type of welding uses consumable wire electrode during the welding process that is fed from the wire spool. MIG welding has some advantages over the other welding techniques. It provides a uniform weld, it provides a slag free weld beam and needs little clean up.
3.
Spot Welding: Spot welding is a process in which

contacting metal surface are joined by the heat obtained from resistance to electric flow and this type of welding is done on the body covers of the scooter.
4.
Seam Welding: It is a process that welds at a surface of

overlapped parts along a length of a joint. Weld made by overlapping nuggets, this type of welding is done on the fuel tanks and mudguards of scooter.
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5.
Portable Spot Welding: It is a portable gun which can

be taken to specified range where other spot welding machine faces difficulty in welding. This type of the welding is done on body covers of scooters.
6.
Fine Boring: Fine boring is done on the frame where

handle has to fit after fine boring handle is attached to it.
When various operation of the welding on the different components of the scooter that is frame, mudguard, body covers and fuel tank is over then this welded body parts are loaded on to a conveyer hanger which takes these body parts to the weld body storage and in the weld body storage and in weld body storage there are three sections one for model 1, one for model 2 and the last for model 3. When welded body is loaded on to a conveyor then the person who loads these bodies on to the hanger select in which model hanger has to go and the selection is done with a selector switch present. Up to 300 hangers can be stored in the storage area that means around 600 frames and 600 body covers can be stored in the weld storage area. From storage area, hangers move to the unloading area and from unloading area, these body covers and frames are loaded on to a Carrier which takes them to the paint section. Unloading of the frames and body covers depends on the requirement of the assembly line and which model they are making according to their requirement, unloading of model frames and body covers is done. Unloading of the model is again done by the selector switch that is when there is requirement of model 1 the person who unloads the frame presses model switch and from storage model 1 moves to the unloading area. Similarly, when there is requirement of model 2, then operator presses model 2 switch and same goes for the model 3 when the requirement is of model 3, the operator presses the model 3 switch and then from storage model 3 moves to unloading bay.
PAINT SECTION: Paint section is very important section. In

this section, different treatments are done on the body covers and frames and it is a step by step process done as follows.
Loading
Pre-Treatment
Electro-Deposition
ED Oven
1. Sanding Zone
Booth
2. Under Coat 3. Top Coat
Top Coat Oven
Inspection Zone
Unloading
PAINT PROCESS FLOW
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Loading: In this process, frames and body covers are

mounted on the carrier of the conveyor line. There are two lines for the paint that is paint A line and paint B line both the lines are very much important because in A line loading of frames and front body left right cover and rear body covers are loaded and on B line mudguard and front cowl is loaded and after loading of these parts then the carrier moves to the pretreatment zone.
Pre-Treatment: In pre-treatment, degreasing and dust

cleaning is done. In pre-treatment bodies have to undergo two operations first wasting with the soft water by this process degreasing is done and all the dust particles are removed from the frames and body covers. In general first we get hard water is converted to soft water by ion exchange mechanism. Secondly on bodies and frames phosphate cleaning is done by this method any dust particle or any grease particle left on the frames and body cover is removed.
Electro-Deposition: In electro deposition carrier

which carries frame and body covers turn down into the electro deposition chamber and in electro deposition chamber is filled with the base paint or primer. When carrier turns down it strikes high voltage wire and it gets negatively charged and become cathode and paint in the chamber becomes anode then a uniform thin film of base
paint is deposited on the body covers and frames of the scooter. This process is repeated twice and after that it is passed to ED oven.
ED Oven: In electro deposition oven, base coat done on

the frame and body covers is heated to 150 degree temperature and this base coat is dried here and after that is passed to paint booth.
Paint Booth: Paint booth has three sections first one is

sanding zone, second primary coat or under coat and third is top coat. In sanding zone, sanding of the frames and body covers is done and after that it is sent to under coat zone in under coat zone single coat of the paint is done on frames and body covers and in this zone coat of paint is done with the help of robots and after that frames and body covers then sent to top coat zone here in this zone second coat of the paint is done and this second coat of paint is done with the operator and after that these frames and body covers are sent to top coat oven.
Top Coat Oven: In top coat oven, these frames and

body covers are heated up to 170 degree temperature and dried and then allowed to cool naturally to room
temperature and from there it is sent to the inspection zone.
Inspection Zone: In inspection zone, body covers and

frames have to pass infra-red zone. Here IR testing machine checks for irregularities in the paint done and after that these body covers and frames are manually checked by hand for any errors in the paint jobs. Parts which pass these tests get the OK mark and move to unloading area.
Unloading: In this area, unloading of frames and body

covers takes place. Frames and body covers having OK mark are loaded to the paint body store and body covers and frames not having OK mark on them are sent to the repair work station and there they fix the problems which frames and body covers have. They are then unloaded and then loaded on to the hanger and the parts go to the paint body storage. In storage final or finished body covers and frames are stored which from storage area moves to the final assembly line.
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9. Project
Project Definition:
To study the various parts of the carrier being used in the paint shop and its problem analysis.
Project Introduction:
Carrier is defined as a thing which supports or holds up a part during its movement. It is used to carry parts to the paint shop where various processes can be performed. Carrier forms the basis of the Paint Shop because the movement of the parts from one point to another in the paint shop takes place only due to carrier. The parts are loaded on the carrier with the help of a jig and then the motion takes place. Paint shop carrier is the most important moving part in the paint process. Most problems and the breakdowns in the paint shop occur due to the carrier only. It causes loss to the net production. Bends or breaks due to load of body part applied on carrier causes distortions which ultimately results in the breakdown. Carrier is a part of the conveyer system being used in the paint shop. The other components of the conveyer system are: the prime mover drive (works as the input motion source for chain), chain and chain
track, carrier, carrier turn (for turning the carrier), carrier revolution (for revolving the carrier), stopper (it temporarily stops the carrier on line), carrier locks, auto feeder cylinders and drop lifters which support the motion of carrier.
Part Description Of Carrier:
Rail: Rail can be of two types i.e. pre rail and power rail. Pre rail is used to drive trolley of the carrier. Power rail is used to drive the conveyer system.
Gear Box:
Gear Box acts as a Speed Reducer. It consists of a worm and worm-wheel arrangement which turns the axis of rotation by 90 and reduces the speed of the parts. The gear box is coupled with the small sprocket. Gear transmits power to small sprocket which helps for carrier turn, this is also called as reduction gear. The relation between the torque and diameter of worm shaft is given by: T (Kg-m) = /16*d where is the twisting moment. Velocity Ratio = 1:60 Tensile Strength of Material = 60 Kg/mm
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Trolley:
There are two trolleys present in a carrier namely Front and the Rear Trolley. Front Trolley stops the carrier at a specified position by the actuation of stopper while Rear Trolley stops the next carrier by engaging with the Front trolley of next carrier. Trolley Wheel contains ball bearings. The outer race serves as a wheel. A grease fitting is installed as a greasing port. Guide Roller is installed to reduce friction against free rail. Pivoting Dog is lifted by the own weight. The chain pusher engages to the Pivoting dog for transport. To stop the carrier the stopper (installed on the line) pushes down the Pivoting Dog to release the engagement with the pusher.
Swivel Pipe:
Swivel pipe is used to drive carrier during carrier revolution. Swivel pipe is connected to the shaft of worm gear, thus it also gets its power from the gear box.
Big Sprocket:
It comes in contact with the chain of the carrier turn and is responsible for rotation of the carrier. It is mounted on the spindle on which the pan cover is fixed. Four carrier dogs are attached to it which control the rotation of the carrier. Big sprocket is attached to the spindle shaft plate.
Small Sprocket:
It is attached to the shaft connected to gear box. It comes in contact with the chain of carrier revolution and is responsible for the revolution of the carrier.
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Tension Spring:
Spring is used to lock turning plate thus stopping carrier revolution. It happens when there is no load on the spring. But when the load is applied, turning plate opens and hence carrier revolution occurs.
Insulator Collar:
It provides insulation to the carrier in ED process so that there is no current in the frame. To avoid the flow of current in the rail of the conveyer system and to avoid damage to the whole system, insulator collars are provided.
Post:
It is mounted on the pan cover and holds the jig by locking it at its position. Post mainly has three parts: post cover, post spacer and post spacer.
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Coupling:
Bush Coupling transfers the motion from small sprocket shaft to input shaft. To avoid overloading at the gear box, bush coupling is provided.
Guide Pin Arm:

It locks the turning of the Big Sprocket by elongating the spring connected to it. It has three contact points: one is the spring, one touches the guide pin of the carrier turn and third is for the engagement and disengagement of big sprocket.
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ED Collector:
ED collector is used to collect current during ED process and transmits it through the cables to the body parts.
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End Striker & Turn Striker:

They are used to control the turning and revolution of the carrier respectively. While end striker controls the revolution of the carrier, turn striker controls the rotation of the carrier.
Pan Cover:
It is a cover which protects the carrier from paint and ED. It acts as a shield for carrier. It is 480*480 mm.
Pan Cover
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Preventive Maintenance of Carrier:

Preventive Maintenance can be described as maintenance of equipment or systems before fault occurs. Preventive Maintenance for the case of carriers is done semi-annually. Maintenance of 28 carriers is done in a month. Preventive maintenance is the systematic inspection, detection, correction and prevention of incipient failures, before they become actual or major failures.
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Preventive Maintenance Procedure

1.) OPEN RAIL OF CONVEYER LINE: Tool Used: D Spanner (size 18-19 mm) Time Taken: approx. 2 min. Procedure: Open the nuts of the rail bracket by using the spanner of the above mentioned size. 3.) LIFT AND TAKE OUT THE CARRIER FROM THE LINE: Tool Used: Hoist Time Taken: approx. 2 min. Procedure: Lift the carrier with the hook of the hoist and remove it from the line. Then put it on the rail where preventive maintenance is to be done. 5.) CLEAN THE ARM: Tool Used: Scrapper Time Taken: approx. 5 min. Procedure: Clean the arm of the carrier by removing the paint deposited with a scrapper. 2.) TIE CARRIER WITH THE HOIST: Tool Used: Hoist Time Taken: approx. 2 min. Procedure: Fix the first attachment with the gearbox bracket, small hook in the frame above the front trolley and big hook in the shaft pipe which is 4.) DISASSEMBLE THE POST: Tool Used: Ring Spanner (size 16-17 mm) Time Taken: approx. 10 min. Procedure: Open the bolts with the specified tool which fasten the post with the big sprocket.
6.) CLEAN THE BIG SPROCKET: Tool Used: Scrapper Time Taken: approx. 12 min. Procedure: Clean the big sprocket of the carrier by removing the paint deposited by using a scrapper.
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7.) CLEAN THE BIG SPROCKET DOGS: Tool Used: Scrapper Time Taken: approx. 5 min. Procedure: Clean the four dogs at the big sprocket of the carrier by removing the paint deposited with a scrapper. 9.) REMOVAL OF BIG SPROCKET FROM THE CARRIER: Tool Used: Time Taken: approx. 1 min. Procedure: Lift the big sprocket from spindle shaft panel.
8.) OPEN THE END PLATE OF THE BIG SPROCKET: Tool Used: Allen Wrench (size 4 & 6 mm) Time Taken: approx. 5 min. Procedure: Insert the Allen wrench and rotate them to open up the Allen bolts which fasten the 10.) OPEN THE SPLIT PIN OF ARM ROLLER: Tool Used: Long nose plier Time Taken: approx. 2 min. Procedure: Straighten up the fixed pin and pull them out of the castle nut of the roller using a long
11.) OPEN THE SPLIT PIN OF LOCKING ROLLER:

Tool Used: Long nose plier Time Taken: approx. 2 min. Procedure: Straighten up the crossed pin and pull them out of the castle nut of the roller using a long nose plier.
12.) OPEN THE SPLIT PIN OF ARM PIN:

Tool Used: Long nose pliers Time Taken: approx. 2 min. Procedure: Straighten up the crossed pin and pull them out of the castle nut of the roller using long nose pliers.
13.) OPEN THE CASTLE NUT OF ARM ROLLER: Tool Used: 18-19 mm) mm) Ring spanner (size
14.) OPEN THE CASTLE NUT OF LOCKING ROLLER: Tool Used: Ring spanner (size 18-19 mm) mm) D spanner (size 20-22 Page 63
D spanner (size 20-22
Time Taken: approx. 2 min. Procedure: Open the castle nut
Time Taken: approx. 2 min. Procedure: Open the castle nut
15.) OPEN THE CASTLE NUT OF ARM PIN: Tool Used: 18-19 mm) mm) Time Taken: approx. 2 min. 17.) TIGHTEN THE CASTLE NUT OF SPINDLE SHAFT PANEL: Tool Used: 18-19 mm) mm) Ring spanner (size Ring spanner (size
16.) OPEN THE SPLIT PIN OF SPINDLE SHAFT PANEL: Tool Used: Long Nose Pliers
Time Taken: approx. 5 min. Procedure: Straighten up the crossed pins and pull them out by using long nose pliers. 18.) INSERT NEW SPLIT PINS: Tool Used: Long Nose Pliers
Time Taken: approx. 5 min. Procedure: Insert new split pins and cross them up.
Time Taken: approx. 5 min. Procedure: Support the castle nut from bottom using D-spanner and tighten it up using a ring spanner.
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19.) CLEAN THE SMALL SPROCKET: Tool Used: Scrapper Time Taken: approx. 3 min. Procedure: Clean the small sprocket of the carrier by using a scrapper.
20.) CLEAN THE BACK TROLLEY: Tool Used: Scrapper Time Taken: approx. 10 min. Procedure: Clean the paint sticking to back trolley from top first and then clean the whole trolley by lifting carrier with hoist. 22.) CHANGE PIVOTING DOG PIN: Tool Used: Punch and Hammer Time Taken: approx. 15 min. Procedure: Take out the old pin inserted in the pivoting dog of the front trolley by hammering with a punch.
21.) CLEAN THE FRONT TROLLEY: Tool Used: Scrapper Time Taken: approx. 10 min. Procedure: Clean the paint sticking to front trolley from top first and then clean the whole trolley by lifting carrier with hoist.
23.) INSERT NEW PIN: Tool Used: Hammer Time Taken: approx. 2 min. Procedure: Insert the new pin by hammering it with a hammer.
24.) CLEAN THE ARM PIN: Tool Used: Amery Paper Time Taken: approx. 2 min. Procedure: The pin is first clamped to the fixture and then is rubbed by emery paper to clean the dirt sticking to it.
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25.) GREASE THE LARGE ROLLER: Tool Used: High Temp. Grease Time Taken: approx. 1 min. Procedure: Grease the roller with high temperature grease.
26.) GREASE THE SMALL ROLLER: Tool Used: High Temp. Grease Time Taken: approx. 1 min. Procedure: Grease the roller with high temperature grease.
27.) GREASE THE PIN HOLES OF ARM: Tool Used: High Temp. Grease Time Taken: approx. 1 min. Procedure: Grease the holes of arm with high temperature grease.
28.) GREASE THE ARM PIN HOLE OF SPINDLE SHAFT PLATE PANEL:
Tool Used: High Temp. Grease Time Taken: approx. 1 min. Procedure: Grease the roller with high temperature grease.
29.) ASSEMBLE THE ARM ROLLERS AND INSERT NEW SPLIT PINS: Tool Used: Ring spanner (size 18-19 mm) mm) mm) D spanner (size 20-22 (size 30-32 Long nose pliers Time Taken: approx. 10 min. Procedure: Rollers are fastened
30.) ASSEMBLE THE ARM ON THE SPINDLE SHAFT PLATE: Tool Used: Ring spanner (size 18-19 mm) D spanner (size 24-27 mm) Time Taken: approx. 4 min. Procedure: The arm pin is inserted in the pinhole of the spindle shaft panel and the new spring is attached to the arm.
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31.) GREASE THE SPINDLE SHAFT: Tool Used: High Temp. Grease Time Taken: approx. 1 min. Procedure: Grease the spindle shaft with high temperature grease. 33.) ASSEMBLE THE BIG SPROCKET ON SPINDLE SHAFT: Tool Used: Time Taken: approx. 1 min. Procedure: Put the big sprocket back on the spindle shaft and clean the excess grease coming out of the sides of hole. 35.) OPEN THE GRUB SCREW OF GEAR BOX: Tool Used: Allen Wrench (size 6 mm) Time Taken: approx. 1 min. Procedure: Open the grub screw of the gear box to change the old lubricating oil present in gear box using Allen wrench.
32.) GREASE THE BIG SPROCKET HOLE: Tool Used: High Temp. Grease Time Taken: approx. 1 min. Procedure: Grease the roller with high temperature grease.
34.) ATTACH THE END PLATE OF BIG SPROCKET: Tool Used: Allen Wrench Time Taken: approx. 2 min. Procedure: Fasten the end plate back on the big sprocket using Allen wrench.
36.) COLLECT THE OLD OIL IN A BIN: Tool Used: Time Taken: approx. 3 min. Procedure: Collect the old lubrication oil in a bin with proper handling.
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37.) REASSEMBLE GRUB SCREW: Tool Used: Allen Wrench (size 6 mm) Time Taken: approx. 4 min. Procedure: The grub screw is 39.) POUR NEW OIL IN GEAR BOX: Tool Used: Mug and Grade 220 oil Time Taken: approx. 2 min. Procedure: Pour new lubrication oil in the gear box. 41.) GREASE ROLLER BEARING OF GUIDE ROLLER: Tool Used: High Temp. Grease Time Taken: approx.1 min. Procedure: Grease the bearing with high temperature grease.
38.) OPEN THE GEAR BOX OIL CAP: Tool Used: Time Taken: approx. 2 min. Procedure: Open the gear box oil cap 40.) GREASE THE FLANGE BEARING OF SMALL SPROCKET: Tool Used: High Temp. Grease Time Taken: approx.1 min. Procedure: Grease the bearing with high temperature grease. 42.) GREASE THE TROLLEY BEARING: Tool Used: High Temp. Grease Time Taken: approx.1 min. Procedure: Grease the bearing with high temperature grease.
43.) GREASE THE ROLLER BEARING: Tool Used: High Temp. Grease Time Taken: approx.1 min. Procedure: Lift the carrier with belt of hoist and attach the greasing gun rod with the bearing cap and push it inside.
44.) REWRITE THE NUMBER OF CARRIER: Tool Used: Marker Time Taken: approx.1 min. Procedure: Rewrite the number of carrier with permanent marker on the gear box, frame and gear box bracket.
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Problem Analysis Of Carrier

Frame Hole NG:
During the motion of the carrier, when it is suddenly stopped by the stopper, vibrations are produced in it and the pin inserted in the hole of the frame enlarges the size of the hole thereby causing the problem of frame hole NG.
To reduce this problem, an anti back-up system is applied to reduce the vibrations. The NG frame hole is repaired by welding a bush at the site of the hole which is a newly developed Kaizen.
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Problems Caused By Loading:

Improper loading of the frame body on the carrier damages the insulator collar because an unbalanced force acts upon it and insulator collars being the non-metallic parts are severely affected.
R is the resultant vector This is a production problem which causes the bending of jigs, unbalancing of the carrier thereby causing improper motion at the carrier turns and revolutions and also resulting in the body parts falling in the oven.
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Gear Box Failure:

Gear box of the carrier also fails some time due to overloading or improper coupling.
Bending of Striker:
Overloading at CTs and CRs causes the bending of the strikers which result in altered motion of the carrier.
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Breaking of Post:
The post of the carrier can be broken due to variable and unbalanced load acting on the carrier. The stresses are developed in the post which leads to its breaking. Moreover, hammering of the nut for the proper locking can also cause the breaking of nut.
Overloading:
Overloading is the state when the load on a part of the carrier is higher than its tolerance value. Its causes are: If any object interrupts the motion of chain, chain is not able to move forward properly causing overloading of chain.
Improper position of the jig may lead to unbalancing of the carrier and overload may occur.
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Guide pin may not properly interact with the arm which may lead to non-alignment. Chain of the carrier turn may not be in proper position leading to overload at CT. Breaking of any of the carrier dogs will lead to improper revolution of the carrier.
Other Problems:
Cable breaks -> Current does not reach to body part ED COLLECTER burns out -> It would not collect current Threading of endplate striker wear out -> Striker would not hit limit switch. Bush between coupling is cut. Bearing sometimes disrupts system. Swivel pipe bends -> Carrier wouldnt be leveled. Insulator sometimes fails to stop current End plate threading wears. Spindle shaft bends -> Carrier wouldnt be leveled. Striker and arm also bends.
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Conclusion
From my project of one month here in HMSI, I came to know that how work goes on in the organization. As far as my project of study, maintenance and breakdown analysis of carrier is concerned, I came to know the importance of carrier in paint shop and the production problems caused by the carrier in the industry. The carrier being used in the paint shop is the best possible system for proper painting of parts. By knowing the various specifications, problems related to it can be solved.
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BIBLIOGRAPHY
Website:
www.Honda2wheelersindia.com
References:
Mr.Virender Singh Mr. Vivek Sharma Mr.Vishal Sharma Mr.Jagtar Singh Mr. Rajender Dev
Sources:
Workshop of HMSI Frame Maintenance department of HMSI
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NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

Mr. Vivek Sharma Executive Frame Maintenance HMSI

Ms. Shelly Juneja HR Department HMSI

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

MR. HONDA . A MAN AND HIS DREAM

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

Time Line of Honda and Its History

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

And This Decade

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

1.2 Hondas Products Around The World

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

Honda Global Network: Six Regional Headquarters:

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

HONDA MOTORCYCLES AND SCOOTERS INDIA PVT. LTD. ( H.M.S.I)

that by meeting these

2. Incorporation 3. Equity capital yen) 4. Area

Area: 210,000 sq. m. Production:1.55 million units/year

Location: IMT Manesar Incorporation: 1999 Employees: 6500

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

deals with the both the products in the two-

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

Started with mass production of 1st scooter, Activa.

HMSI successfully launched LEAD in Australian Market.

Launch of new scooter AVIATOR. It is a E-class scooter

RESPECT FOR THE INDIVIDUAL

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON; PHILOSPHY WITHOUT ACTION IS WORTHLESS.

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

HMSI Plant Facilities

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

Sales & Marketing

Finance & Account

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

8. Introduction to Maintenance Department

Some important definitions used by maintenance:

Maintenance: Action necessary for retaining or restoring

Planned Maintenance: Preventive maintenance carried

Preventive Maintenance: Systematic inspection,

Breakdown Maintenance: Repair or replacements

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

Predictive Maintenance: Type of preventive

Mean Time To Repair (MTTR): Basic measure of

Mean Time Between Failures (MTBF): Basic

Down Time: Period during which an equipment or

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

Frame Maintenance: In this department there are three

PRESS SECTION: Press section has mainly four machines.

NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA

WELDING SECTION: In welding section, there are six types