honda project file

WELCOME

INDUSTRIAL TRAINING PROJECT

ON

ldquoCAUSES OF BODYCOVER(BDC) SCRATCHES GENERATION POINT AFTER PAINTINGrdquo

HONDA MOTORCYCLE AND SCOOTER

INDIA (PVT) LTD GURGAON

GUIDED BY- PRESENTED BY- Mr DAVINDER DESWAL Sonu Vats SECTION HEAD

PAINT SHOP

HMSI

Geeta Institute Of Management amp Technology

CERTIFICATE

This is to certify that the project entitled ldquoIdentification Of The Causes Of

Body Cover Scratches Generation Pointrdquo is submitted by SONU VATS of the

JCDM COLLEGE OF ENGINEERING SIRSA for the award of the degree in B

Tech (Mechanical Engineering) is a bonafide record of work carried out

by her under my supervision The contents of these in full or in parts

have not been submitted to any other institute or university for award

of any degree

Mr Davinder Deswal Ms Kavita Pandey

Section Head HR Department

Paint Shop HMSI

HMSI

Geeta Institute Of Management amp Technology Page 2

ACKNOWLEDEMENT

I Sonu Vats student of mechanical 3nd year JCDM COLLEGE OF ENGINEERING 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 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 DAVINDER DESWAL Section Head of paint 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

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

[SONU VATS]


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

I came to know about the working of the paint department various processes of paint its motion its functions causes of scratches on body cover

During this project I learned a lot of things about the 5-S rule cause amp effect analysis the 3G approach section performance analysis amp 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 amp understand how the final 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 paint department

Project

Bibliography


1COMPANY

INTRODUCTION

11 HONDA HISTORY

FOUNDER - SOICHIRO HONDA ESTABLISHED AT - HAMAMATSU (JAPAN) ON 24 TH SEP 1948

MR HONDA helliphelliphellip 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 amp 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- and five- and six-cylinder race bikes and participated in the Isle of Man TT race (125 cc motorcycle classes)

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 Suzuki 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 US Automotive Hall of Fame In 1990 Honda wins its fifth consecutive 1st ranking in the JD 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 amp fun to ride SOICHIRO HONDArsquoS dreams changed the world of motorcycling


Time Line of Honda and Its

History





And This Decadehelliphelliphelliphellip

2001 500 World Grand Prix Victories

2002 Race Debut of New 4 Stroke 5 Cylinder

Motorcycle (Called RC211V)

2003 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


12 Hondarsquos Products Around The World

Jet Engine


Honda ndash At a Glance-

1048708 37th on fortune 500 companies (2007 Fortune 500 Global List)

1048708 26th on global most admired

1048708 Capital - yen86 Billion (as of March31 2007)

1048708 Sales (Results of fiscal 2007)

1048708 Consolidated yen11087140 million

1048708 Unconsolidated yen4030881 million

1048708 405 subsidiaries (as of March31 2007)

1048708 Employees HONDA worldwide ndash

1048708 Consolidated 167231 (as of March31 2007)

1048708 Unconsolidated 26652 (as of March31 2007)

Honda Global Network

Six Regional Headquarters

North Central America South America

Afro-Europe

Asia amp Oceania

Japan

China


2 HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD ( HMSI)

Honda Motorcycle amp 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 Itrsquos Symbol ldquoWingsrdquo 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 Hondarsquos 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 85815 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 100000 scooters per year which has reached 6 00000 scooters by the year by 2007 and motorcycle capacity shall be 400000 per annum The total investment outlay for the initial capacity was Rs215crores 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 amp Parts)

Few Key details about Honda Motorcycle and Scooter India Pvt Ltd -

1 Registered office - Plot No 1 Sector 3 IMT Manesar

Dist ndash Gurgaon

2 Incorporation - August 20th 1999

3 Equity capital- Rs 300crores (Approx7500 million yen)

4 Area- Land area 210000 sq m


Covered area 85815 sq m (41 )

5 Employees- 3821 Associates ndash Japanese 15

6 Product- Scooters ndash Activa Dio Aviator

Motorcycle- Unicorn hine Stunner Twister Dazzler

7 Plant capacity- 1000000 CBUrsquos per annum

SC ndash 600000 MC ndash400000

8 Logo- WINGS

9 Directors - Mr Shinji Aoyama President amp CEO

Mr Kawastu ( SrVP ) Mr Y Mizutani (Dir)

Mr H Iwakami ( Dir ) Mr M Kato ( Dir )

Mr T Oyama ( ASH ) Mr MTakedagawa

(HSCI) Mr K Nakazono ( HM-J )

Special features-

1048708 ISO 9001 2000 and 14001 Certified

1048708 ARAI Emission Lab Pune Certified

Society Friendly Organization

1048708 Worldrsquos No1 in Engine designing


3 PLANT OVERVIEW

Area 210000 sq m

Production155 million unitsyear

Location IMT Manesar

Incorporation 1999

Employees 6500


PLANT LAYOUT

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



5PRODUCT


ActivaActiva 2001-02

DIODIO 2002-03

New UnicornNew Unicorn2004-05


ShineShine 2005-06

StunnerStunner 2005-06

AviatorAviator 2008

HONDA PHILOSPHY

Soichiro Honda Said that ldquoAction without philosophy is a lethal weapon philosophy without action is worthlessrdquo Due to such a thoughts amp its implementation in actual practice Honda starts acquiring the highest position from 1948 amp today it is most successful industry in world


Company

Principle

Company

Principle

THE THREE JOYSTHE THREE JOYS

RESPECT FOR THE INDIVIDUALRESPECT FOR THE INDIVIDUAL

HONDA PHILOSOPHY

Management Policies

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 companyrsquos 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


OUR FUNDAMENTAL BELIEFS-

Respect for the individual The three joys



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 individualrsquos race sex age religion national origin educational background social or economic status have no bearing on the individualrsquos 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 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 companyrsquos 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


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


The Joy of SellingThe Joy of Selling

The Joy of BuyingThe Joy of Buying

The Joy of CreatingThe Joy of Creating

Enjoy your work and encourage open communications

Strive constantly for a harmonious flow of work

Be ever mindful of the value of research and endeavor

HONDArsquoS CORPORATE CULTURE-

Free thinking amp open mindedness Challenging spirit Sincerity amp 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 ldquoat the spotrdquo strengthen the core characteristics that make Honda unique and achieve further growth


ACTION WITHOUT PHILOSPHY IS A LETHAL WEAPON

PHILOSPHY WITHOUT ACTION IS WORTHLESS

SOICHIRO HONDA

HMSI Plant Facilities

Few of the In-House Facilities

High Pressure Die Casting Gravity Die Casting amp Low Pressure Die Casting

Gravity Die-Casting amp 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

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

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



5ORGANISATION STRUCTURE


President and CEO

Sr VP

PurchaseGeneral Affairs

Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop

Paint ShopMaintenance

6 Introduction to PAINT Department

Introduction The paint department is one of the most important departments of the organization where the organization has its own production Paint department of Honda Motorcycle and Scooter India Private Limited (HMSI) is a responsible for all the colors which occur in the market

Paint

There are four shape in paint section two are in scooter plant and two are in motorcycle plant

Paint shop

Paint 1 paint2 paint 3 paint 4


Scooter plant Motorcycle plant

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 Pressndash3

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


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

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 shop layout


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

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW

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

The various processes take place in

PRETRETMENT PROCESS


WR - 1 (Raw Water)

Surface Conditioning

Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)

PhosphatingED Process

Pretreatment

1 degreasing - it is used for removing dust oil grease etc the chemical used id niphathelinin this process soft water is used The temp in this process is about 45 to 55 degree Celsius

2 water rinse 123- this process is used for removing chemical which remain in degreasing process in this process soft water is used

3 surface conditioning - This process is used for roughing the surface in this process niphafines is used In this process deioinised water is used

4 phosphate - This is the main process of the preteretmentin this one accelerator is used which accelerate the process This process is used for prevention the part from rusting the temp is about 45 to 55 degree Celsius

5 water rinse 4 56 - This process is used for removing extra phosphate in this process demonized water is used

PT Spray


SrNo

1

2

Booth Water Pit Detail

Circulation pump Capacity Sludge feed pump CapacityMake- KSB Make- KSBModel - MEGA-G-125-250 Model - KWPZ-GC-100-400Water floe rate lpm 3750 Water floe rate lpm 2000Total Head (mH) 20 Total Head (mH) 14Revolation (RPM) 1460 Revolation (RPM) 965

Discharge Pressure 19 kgcm2 Discharge Pressure 09 kgcm2

Motor 185 kwCurrent 335 A Motor 11 kwMake Bharat Bijlee Current 22 A

Paint over spray 65 Paint consumption day -650 kgType of paint used - TSA

Flow rate ETP 2m3 Hour


Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6

PT Process Spray Zone

To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4

A line booth circulation pump-1


B line booth circulation pump-2


Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing

Electro-Deposition process 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

1 Predip tank

This process is for cleaning In pretreatment process cleaning is done by spray process so some part is remain in which cleaning is not done So in this process the body is dip in the tank

2 Electro Deposition tank


In this tank the mixture of resin and pigment is used The ratio of the resin and pigment is 14in this process DI water is used The temp is about 27 to 29 degree Celsius In this process high voltage is used and the voltage is about 140 to 170 voltage

3 Ultra filteration1amp2

This is the spray process It is used for removing extra ED remaining in ed process In this DI water is used

4 Ultra filtration 3

In this also extra ED is removed but this is removed by dip the body

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


PAINT BOOTH PROCESS

SANDING ZONE- In this zone dust is removed by the sanding paper then tag rag paper is used to clean

PRIMER ZONE-In this zone primer is done to prevent the body part from rust to prepare the body part for painting

BASE COAT- This area define the color of the body part which we are required

TOP COAT- To the give the clear coat shining etc

Painting Process


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

Inspection-

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

ETP plant- In the Ed plant the mixture of paint and water come In this mixture the water is purified and this water used in agriculture


SECO

NDA

RY

DUAL TUBE SETTLER

p

p

TO TREATED WATER TANK

p

Na CaC POL

SLUDGE p

AIR

CAPACITY - 4000 Liter Hour

PROJECT

Identification Of The Causes Of Body Cover Scratches Generation Point

1- Before Inspection (A Line Or B Line Or Both)

Causes-

A- Jig loose or bendB- Damage carrier on which body cover fitted


Loose carrier with bodycover

2- Time of Unloading (from carriers)

Causes

A- Damage trolleys on which body cover placed


B- Unskilled workers(Rough way of unloading resulting into scratches)


3- PBS (paint body storage) area

Causes-

A- Unskilled workers (rough way of loading on hangers)


C- Collision between two hangers or more


Scratch on bodycover(BDC)


4- Attachment removal area

Causes-

A- Improper way of placing BDC for attachment removal



5- Gun slips during attachment removal


5- Touch-up area (Stock area)

Causes-

A- Rough condition of floor on which body cover placed


Scratches on BDC


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 Causes

Of Body Cover Scratches I came to know the importance of paint shop and

the production problems caused by the paint in the industry


BIBLIOGRAPHY

Website

wwwHonda2wheelersindiacom

References

MrDavinder deswal Mr Varun Chawla Mr bhosle San

Sources

Workshop of HMSI

Paint Department of HMSI


EXECUTIVE SUMMARY


CERTIFICATE

This is to certify that the project entitled ldquoIdentification Of The Causes Of

Body Cover Scratches Generation Pointrdquo is submitted by SONU VATS of the

JCDM COLLEGE OF ENGINEERING SIRSA for the award of the degree in B

Tech (Mechanical Engineering) is a bonafide record of work carried out

by her under my supervision The contents of these in full or in parts

have not been submitted to any other institute or university for award

of any degree

Mr Davinder Deswal Ms Kavita Pandey

Section Head HR Department

Paint Shop HMSI

HMSI


ACKNOWLEDEMENT




[SONU VATS]






Contents



Plant Overview

Flow Chart

Products

Honda Philosophy



Project

Bibliography


1COMPANY

INTRODUCTION

11 HONDA HISTORY










History










Tokyo Car Show







Jet Engine
















Afro-Europe

Asia amp Oceania

Japan

China

















Dist ndash Gurgaon











8 Logo- WINGS






Special features-






3 PLANT OVERVIEW

Area 210000 sq m



Incorporation 1999

Employees 6500


PLANT LAYOUT








4 FLOW CHART



5PRODUCT



DIODIO 2002-03



ShineShine 2005-06


AviatorAviator 2008

HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


ACKNOWLEDEMENT




[SONU VATS]






Contents



Plant Overview

Flow Chart

Products

Honda Philosophy



Project

Bibliography


1COMPANY

INTRODUCTION

11 HONDA HISTORY










History










Tokyo Car Show







Jet Engine
















Afro-Europe

Asia amp Oceania

Japan

China

















Dist ndash Gurgaon











8 Logo- WINGS






Special features-






3 PLANT OVERVIEW

Area 210000 sq m



Incorporation 1999

Employees 6500


PLANT LAYOUT








4 FLOW CHART



5PRODUCT



DIODIO 2002-03



ShineShine 2005-06


AviatorAviator 2008

HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY






Contents



Plant Overview

Flow Chart

Products

Honda Philosophy



Project

Bibliography


1COMPANY

INTRODUCTION

11 HONDA HISTORY










History










Tokyo Car Show







Jet Engine
















Afro-Europe

Asia amp Oceania

Japan

China

















Dist ndash Gurgaon











8 Logo- WINGS






Special features-






3 PLANT OVERVIEW

Area 210000 sq m



Incorporation 1999

Employees 6500


PLANT LAYOUT








4 FLOW CHART



5PRODUCT



DIODIO 2002-03



ShineShine 2005-06


AviatorAviator 2008

HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


1COMPANY

INTRODUCTION

11 HONDA HISTORY










History










Tokyo Car Show







Jet Engine
















Afro-Europe

Asia amp Oceania

Japan

China

















Dist ndash Gurgaon











8 Logo- WINGS






Special features-






3 PLANT OVERVIEW

Area 210000 sq m



Incorporation 1999

Employees 6500


PLANT LAYOUT








4 FLOW CHART



5PRODUCT



DIODIO 2002-03



ShineShine 2005-06


AviatorAviator 2008

HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY







History










Tokyo Car Show







Jet Engine
















Afro-Europe

Asia amp Oceania

Japan

China

















Dist ndash Gurgaon











8 Logo- WINGS






Special features-






3 PLANT OVERVIEW

Area 210000 sq m



Incorporation 1999

Employees 6500


PLANT LAYOUT








4 FLOW CHART



5PRODUCT



DIODIO 2002-03



ShineShine 2005-06


AviatorAviator 2008

HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY










Tokyo Car Show







Jet Engine
















Afro-Europe

Asia amp Oceania

Japan

China

















Dist ndash Gurgaon











8 Logo- WINGS






Special features-






3 PLANT OVERVIEW

Area 210000 sq m



Incorporation 1999

Employees 6500


PLANT LAYOUT








4 FLOW CHART



5PRODUCT



DIODIO 2002-03



ShineShine 2005-06


AviatorAviator 2008

HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY



Jet Engine
















Afro-Europe

Asia amp Oceania

Japan

China

















Dist ndash Gurgaon











8 Logo- WINGS






Special features-






3 PLANT OVERVIEW

Area 210000 sq m



Incorporation 1999

Employees 6500


PLANT LAYOUT








4 FLOW CHART



5PRODUCT



DIODIO 2002-03



ShineShine 2005-06


AviatorAviator 2008

HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY
















Afro-Europe

Asia amp Oceania

Japan

China

















Dist ndash Gurgaon











8 Logo- WINGS






Special features-






3 PLANT OVERVIEW

Area 210000 sq m



Incorporation 1999

Employees 6500


PLANT LAYOUT








4 FLOW CHART



5PRODUCT



DIODIO 2002-03



ShineShine 2005-06


AviatorAviator 2008

HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY

















Dist ndash Gurgaon











8 Logo- WINGS






Special features-






3 PLANT OVERVIEW

Area 210000 sq m



Incorporation 1999

Employees 6500


PLANT LAYOUT








4 FLOW CHART



5PRODUCT



DIODIO 2002-03



ShineShine 2005-06


AviatorAviator 2008

HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY








8 Logo- WINGS






Special features-






3 PLANT OVERVIEW

Area 210000 sq m



Incorporation 1999

Employees 6500


PLANT LAYOUT








4 FLOW CHART



5PRODUCT



DIODIO 2002-03



ShineShine 2005-06


AviatorAviator 2008

HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


3 PLANT OVERVIEW

Area 210000 sq m



Incorporation 1999

Employees 6500


PLANT LAYOUT








4 FLOW CHART



5PRODUCT



DIODIO 2002-03



ShineShine 2005-06


AviatorAviator 2008

HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


PLANT LAYOUT








4 FLOW CHART



5PRODUCT



DIODIO 2002-03



ShineShine 2005-06


AviatorAviator 2008

HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


4 FLOW CHART



5PRODUCT



DIODIO 2002-03



ShineShine 2005-06


AviatorAviator 2008

HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY



5PRODUCT



DIODIO 2002-03



ShineShine 2005-06


AviatorAviator 2008

HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY



ShineShine 2005-06


AviatorAviator 2008

HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


HONDA PHILOSPHY



Company

Principle

Company

Principle



HONDA PHILOSOPHY

Management Policies



COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY




COMPANY VISION-















THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY














THE THREE JOYS




























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY

























SOICHIRO HONDA






Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


Welding Robots


Paint Shop Robots



Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


Engine Assembly


Frame Assembly






President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY





President and CEO

Sr VP


Manufacturing

Sales amp Marketing

Finance amp Account

Engg Engine Mfg

Assembly

PPC Frame Mfg

Quality

Press Shop

Weld Shop




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY




Paint


Paint shop





1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY



1 Press Section

2 Weld Section

3 Paint Section


Komatsu Pressndash3

AIDA Press -1

CNC bending machine

Hind Press
















Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY












Paint shop layout



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY



Loading

Pre-Treatment

Electro-Deposition

ED Oven

Booth

Top Coat Oven

Inspection Zone

Unloading


1 Sanding Zone

2 Under Coat

3 Top Coat

PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


PAINT PROCESS FLOW






PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY





PRETRETMENT PROCESS


WR - 1 (Raw Water)


Degreasing

WR - 6 (DI Water)

WR - 3 (Raw Water)

WR - 2 (Raw Water)

WR - 5 (DI Water)

WR - 4

(DI Water)


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


Pretreatment






PT Spray


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


SrNo

1

2








Phosphate

Stage

3

Degreasing

Nipacel 4704

Nipaphos 3150 R

Neutraliser 4055

Chemical Used

Nipaklin 364 S

Nipafin GN ZS

Water rinse-1

Degressing Tank

Body

Water rinse-2

water rinse-3

Surface Cond

Phosphat tank

water rinse-4

water rinse-5

water rinse-6


To Drain ETPTo ETP

1

2

3

4

5

1

2

5

3

4





Sludrer feed Pump

6200

5965

5400

1700

Water level

PIT SKETCH


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


PT Testing


1 Predip tank














PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY












PAINT BOOTH PROCESS





Painting Process



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY



Inspection-


Unloading -






SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY





SECO

NDA

RY

DUAL TUBE SETTLER

p

p


p

Na CaC POL

SLUDGE p

AIR


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


PROJECT



Causes-





Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY




Causes






Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY





Causes-








Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY







Causes-







Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY






Causes-



Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


Scratches on BDC


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


Conclusion






BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


BIBLIOGRAPHY

Website


References


Sources

Workshop of HMSI



EXECUTIVE SUMMARY


honda project file

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