Neel Metal Products Ltd. (NMPL)

Gurgaon, Haryana

Project report on:

PRODUCTIVITY IMPROVEMENT PLANHonda line

N-5

SUBMITTED TO-: SUBMITTED BY -:

MR…………………. LOVE GAUTAMHEAD OF PRODUCTION (N-5) B.TECH (MAE)

VIII SEM

STUDENT’S DECLARATIONAmity University Madhya Pradesh, Maharajpura (Opposite Airport)

Gwalior – 474 005 (Madhya Pradesh)Email : info@gwa.amity.edu

I Love Gautam hereby declare that the project report on Production Improvement

Plan(N-5) at NEEL METAL PRODUCTS LIMITED being submitted in partial

fulfillment of … Days Training program to Department Of Mechanical &

Automation Engineering, AMITY University is carried out under the

supervision of Mr. …………………………, Head Of Production (N-5) , NMPL

Gurgaon and also declare that the work carried out by me is authentic and has not

been submitted to any other University in the regard mentioned.

June 30, 2015

Love GautamEnroll no.-A60205411001Department of Mechanical & Automation EngineeringAMITY University

CERTIFICATE APPROVED

This is to certify that the project report entitled Production Improvement Plan

(N-5) on Honda Line at Neel Metal Products Limited submitted by Love

Gautam to the Department Of Mechanical & Automation Engineering,

AMITY University, Madhyapradesh in partial fulfillment of the ……Days

training program is a bonafide record of the project work carried out by him under

my supervision during the year May-June 2015.

Mr. …………………….

Head of Production (N-5)

ACKNOWLEDGEMENT

I have taken efforts in this project. However, it would not have been possible

without the kind support and help of many individuals and organizations. I would

like to extend my sincere thanks to all of them.

I am highly indebted to (………………….) for their guidance and constant

supervision as well as for providing necessary information regarding the project &

also for their support in completing the project.

I would like to express my gratitude towards my parents & member of (Honda line

N-5)for their kind co-operation and encouragement which help me in completion

of this project.

I would like to express my special gratitude and thanks to industry persons for

giving me such attention and time.

My thanks and appreciations also go to my colleague in developing the project and

people who have willingly helped me out with their abilities.

Love Gautam

CONTENTS

1. Company Introduction…………………………………………………6

2. Press Shop…………………………………………………………….10

3. Weld Sho……………………………………………………………...11

4. Project: Productivity improvement plan…………………………..12

5. Plant Layout…………………………………………………………..13

6. Introduction to Robotic MIG Welding………………………………..14

7. Introduction to Spot/Projection Welding……………………………..16

8. Air leakage Inspection and Maintenance……………………………..19

9. Line Breakdown Report………………………………………………22

10.Maintenance report of all lines………………………………………..26

11.Production cycle time…………………………………………………28

12.Inventory Management………………………………………………..30

13.Conclusion…………………………………………………………….32

14.Refrence……………………………………………………………….33

INTRODUCTION

Established in 2001, Neel Metal Products Ltd. (NMPL) is the fastest growing

Company of JBM Group with high-tech plants at various locations in India. NMPL

has earned a leading position in industry with facilities available in press lines up

to 2500 Tons, weld lines and ED coating plant- which are not only limited to auto

world but also fitting for white goods industry.

JBM Group is a focused, dynamic and progressive organization that provides

customers with value added products, services and innovative solutions. The

Group has a diversified portfolio to serve in the field of automotive, engineering &

design services, renewable energy and education sectors and has an infrastructure

of 35 manufacturing plants, 4 engineering & design centers across 18 locations

globally.

With turnover of USD 1.2 billion, JBM Group has broadened its horizons by

focusing on quality delivery, solutions approach, product development processes,

flexible manufacturing systems and contract manufacturing.

JBM Group is primarily a tier- 1 supplier to the automotive OEM industry and

caters services to esteemed clients that include Ashok Leyland, Bajaj Auto Ltd,

Fiat, Ford, General Motors Corporation, Honda, Hero, JCB, Mahindra, Maruti

Suzuki, Renault, Nissan, TATA, Toyota, TVS, Volvo-Eicher, Volkswagen and

many more.

MAJOR PRODOCT

Complete body assemblies and Painting facilities for 3 and 4 wheelers.

Complete frame assembly, Welding and Painting for 2 wheelers.

Design, Development and manufacturing of precision tooling, Dies and

Welding fixtures for automotive use.

Exhaust manufacturing and painting for 2 wheelers.

Fuel tank manufacturing for 2 wheelers.

Manufacturing of Rims and Wheel assemblies for 2 wheelers.

Manufacturing of ERW and CDW tubes for tubular components.

Manufacturing of skin Panels for 2 wheelers and 4 wheelers.

Manufacturing and Painting of commercial vehicles underbody frames and

parts.

NMPL JBM QUALITY GOALS Zero defect.

First time right, every time right.

No quality control, only quality assurance.

Reduced process variance.

100% customer satisfaction.

Reduction in the cost of product.

Not only functional quality but also competitive commonly expected and

attractive quality.

NMPL JBM MAJOR CUSTOMERS

MARUTI UDYOG LIMITED

DAILMER

TOYOTA

ASHOKA LEYLAND

DEFENCE

DELPHI

PRESS SHOP

The sheet metal component manufacturing capability at NMPL is the finest in our

country. When it comes to the sheet metal, NMPL enjoys a formidable industry

having good reputation.

In-house manufacturing facilities at NMPL includes:

Heavy press shop with hydraulic and mechanical presses equipped with die

cushions with or without moving bolster.

EICHER

ESCORTS

HINDUSTAN MOTORS.

HONDA (2 & 4 WHEELERS)

MAHINDRA & MAHINDRA

YAMAHA MOTORS INDIA

Ltd.

Light press shop is capable of handling the smallest components, requiring

load of 20 tones and onwards.

Facility for die maintenance include the hydraulic DPS(Die Spotting Press)

from KOJIMA, include conventional tool room equipment and skilled

manpower.

TYPES OF PRESSES USED IN THE PRESS SHOP:

Types of presses used in press-shop at JBML are:

Hydraulic Press.

Mechanical Press.

WELD SHOPWelding is a process for joining similar metals. Welding joins metals by melting

and fusing 1, the base metals being joined and 2, the filler metal applied. Welding

employs pinpointed, localized heat input. Most welding involves ferrous-based

metals such as steel and stainless steel. Welding covers a temperature range of

1500º F - 3000º F (800ºC - 1635ºC). Weld joints are usually stronger or as strong

as the base metals being joined.

JBM’s highly development skills in welding operations contribute significantly to

superior quality and reliability of the end product, which is the hallmark of NMPL.

-General Shop Safety Rules-

Safety glasses, cover goggles, or face shields are required when in any shop

area, whether working or not!!

Shoes must be worn in shop area. No one wearing sandals will be allowed to

enter the shop area. The minimum footwear must cover the entire foot.

Do not operate any item of equipment unless you are familiar with its

operation and have been authorized to operate it. If you have any question

regarding the use of equipment ask the area supervisor

No work may be performed using power tools unless at lest two people are

in the shop area and they can see each other.

Do not work in the shop if you are tired, upset, drugged, or in a hurry.

Never indulge in horseplay in the shop areas.

All machines must be operated with all required guards and shields in place.

PROJECT REPORT ON

PRODUCTIVITY IMPROVEMENT

PLAN

HONDA LINE N-5

HONDA LINE (N-5) LAYOUT

Honda line comprises of following sublines:

1. 2 CD (Common) – Honda City2. 2 CD Sub frame (Diesel) – Honda Brio/ Amaze3. Lower Arm assembly line – Honda Brio/ Amaze4. 2 CW Sub frame – Honda Brio/Amaze5. 2 CT Sub frame (Diesel & Petrol – Honda City6. Axle line 1 & 2 – Honda Brio/Amaze7. 2 MD Sub frame – Honda Mobilio

INTRODUCTION TO ROBOTIC MIG WELDING

MIG (Metal Inert Gas) welding, also known as MAG (Metal Active Gas) and in

the USA as GMAW (Gas Metal Arc Welding), is a welding process that is now

widely used for welding a variety of materials, ferrous and non ferrous.

The essential feature of the process is the small diameter electrode wire, which is

fed continuously into the arc from a coil. As a result this process can produce quick

and neat welds over a wide range of joints.

Equipment ● DC output power source

● Wire feed unit

● Torch

● Work return welding lead

● Shielding gas supply, (normally from cylinder)

-Welding Positions- In application, there are only four basic welding positions. Often, welding must be

done on the ceiling, in the corner, or on the floor. In view of this, some techniques

were developed to allow welding in any position. Different welding positions are:

Flat position:

In this position, the filler metal is deposited from the upper side of the joint and the

face of the weld is approximately horizontal. In welding terminology this is also

called the down-hand position for both groove welds and fillet welds

Horizontal position:

The position of welding in which the weld is performed on the upper side on a

horizontal surface and against an approximately vertical surface.

Overhead position:

The weld is deposited from the underside of the joint and the face of the weld is

horizontal.

Vertical position:

The weld axis is approximately vertical. The welding direction can be changed up

and down.

INTRODUCTION TO SPOT WELDING

SPOT WELDING-:

Spot welding is a resistance process, relying on the electrical resistance of the

components to generate heat when a current is passed through them. The heat

generated is proportional to

The square of the current (I2)

The resistance of the components. (R)

The time for which the current is passed. (T)

Weld current

Weld currents typically vary from 500A on very thin materials (<0·2mm) up to

30kA for heavy sheet of projection weld applications.

 Weld time

The thicker the material, the longer it will take to heat it up to the required

temperature. In general, therefore, weld times increase in proportion to the

thickness of the components.

 Weld Force

As metal thickness increases, the expansion force increases, so the weld force

must increase. Thicker materials therefore require higher forces.

Spot diameter.

The heat generated must be thought of as ‘heat per unit area’. Spot diameter

increases with material thickness.

PROJECTION WELDING

Projection welding is a variation of the spot welding process in which raised

projections on one or both sheets localize and concentrate the welding energy. This

technique allows for closer weld spacings on thicker materials than are possible

with the conventional approach. Projection welding is commonly used to attach

connector points such as studs and nuts to sheet metalassemblies particularly in the

automobile industry. Materials suitable for the projection welding process include

aluminum, low carbon steel, and stainless steel.

Advantages:

o Quick process and number of welds can be made simultaneously

o No thickness limitation

o Life of electrode is much longer

o If two dissimilar metals, then projection on metal having higher

conductivity

AIR LEAKAGE INSPECTION

AND

MAINTAINENCE IN HONDA LINE

Inspection report of Honda line YASKAWA Welding Robot.The following leakages have been found during the tenure.

Sr. No. Model Operation Problem Status Rechecked status

1 2CT-common 2 Oil leakage from FRL OK OK2 Air leakage from flow meter OK OK3 Air leakage from nozzle cleaning unit OK OK4 Air leakage from cylinder OK OK5 8 Air leakage from flow meter OK OK6 Air leakage from nozzle cleaning unit OK OK7 2CT-Diesel 18 Air leakage from near locater pin OK OK8 Oil leakage from FRL 1st OK OK9 Air leakage from pipe OK OK10 Air leakage from flow meter OK OK11 Air leakage from nozzle cleaning unit OK OK

12 19 Air leakage from pressure controller(DCV) OK OK

13 Oil leakage from FRL OK OK14 Air leakage from cylinder OK OK15 Connecter pipe damage OK OK

16 Leakage of air from main distributer valve of air NG OK

17 21 Air leakage from FRL OK OK18 Axel –line 2 6 Air leakage from FRL 1st OK OK

19 Air leakage from nozzle cleaning unit 1st OK OK20 5 Oil leakage from FRL 2nd OK OK21 Air leakage from nozzle cleaning unit OK OK22 4 Locater pin problem OK OK23 Oil leakage from FRL 2nd OK OK24 Air leakage from FRL 1st OK OK25 3 Oil leakage from FRL 2nd OK OK26 SF- 2CW 1 Oil leakage from FRL 1st OK OK27 2&3 Oil leakage from FRL 1st OK OK28 4,5&6 Nil OK OK29 7 NIL OK OK30 8 Oil leakage from FRL NG OK31 9 Nil OK OK32 10 Air leakage from nozzle cleaning unit NG OK33 11 Oil leakage from FRL NG OK34 12 Oil leakage from FRL 1st NG OK35 13 Oil leakage from FRL 1st NG OK36 14 Oil leakage from FRL 2nd NG OK37 15 Oil leakage from FRL 2nd NG OK38 16 Oil leakage from FRL 2nd NG OK39 Air leakage from nozzle cleaning unit 2nd NG OK40 17 Air leakage from nozzle cleaning unit NG OK41 Axel comm. rear 10 Air leakage(left side downward) NG OK42 SF front susp. Ass. 15 Water leakage NG OK

Sr. No. Model Operation Problem Recheck status

1 LWR arm assembly 1 Front right side air leakage from where

bed rotate NG OK

2 Back right side air leakage (connecter and tube prob.) NG OK

3 Back left side air leakage from air distributer NG OK

4 2 CT-common 12 Oil leakage from FRL NG OK5 9 Shutter problem OK OK6 Leakage of air from shutter NG OK7 CO2 leakage from main tube connecter NG OK8 Oil leakage from FRL NG OK9 Air leakage near dcv NG OK10 8 Oil leakage from FRL NG OK

The above problem analysis had been done by inspecting the following components on robotic weld shop:

FLR Unit Pneumatic Cylinders Pressure Control Valve Jig Fixture Maintenance

LINE BREAKDOWN REPORT

2 MD Line Breakdown Report (1/5/2015 – 31/5/2015)

2 CT PROBLEM REPORT (01/05/2015 – 31/05/2015)

S. No. Problem Operation Frequency1 L/A 2CT com LH side, L/A N/A ( R/M N/A) RH side 2CT Common X(10)

2 Common 50-200-25 Part N/A 10

3 Not Quality in Part Clamping again fit. Adjust Clamp 2

4 2CT Diesel and 2Ct Petrol Line Men Power shift to SF:2CD X(4)

5 Common Cell inner linear block inside 2CT #9

6 SF 2CT(D) Red Switch Collar Clamp not working 2CT(D) #9

7 Six Time Power Cut, New MP Untrained MP 2CT LWR ARM X(5), (3), (1), (2), (12), (4)

8 Collar block weld Robot run without BRKT, Spatter deposition on Sensor

9 Wire Shorting again 2CT(P) #17 #18

10 Air Supply Failure #18

11 Proximity Sensor not working 2CT #2, #10, #21

12 Operator was new, M/P new 2CT(P) , (D) X(17)

13 Read Switch short (not working) #19(D),(P), #21 X(3)

14 Problem in Ejection of part #2

15 Torch linear Jam #11

16 Correction done by quality due to Honda visit #19

17 Robot accident by new operator 2CT(D) #9 X

18 Line stops to clear hold Material

19 Line starts after 9 AM

20 Slower line run due to Honda visit 2CT (P) & (D)

21 Line cleaning due to gas fault 8 & 9

22 Heating problem and water leakage in spot welding 7 & 15

23 Ethernet error 2 X

24 L/A Collar not available 2CT

25 Manpower run without information 2CT X

26 Common cell stoppage due to manpower shift to (P) & (D)

27 Petrol line stoppage due to manpower given to quality

28 Person N/A for spot welding 2CT Common

29 Stopper BKT weld at fixture at Lower Arm 2CT

30 LH side fixture locates bolt broken 2CT Common #10

31 2CT Diesel part NG in R gauge M/P shift to 2MD Line 2CT (D) X(3)

32 Limit switch not working 2CT (D) #19 X

33 M/P shortage XX

34 2CT common manpower used in Scrap yard

35 Nut sensor not working #18

36 Poka Yoke sensor not working X

37 Punching machine not working X(2)

38 Welder not available 2CT (D) X

39 Diesel line stoppage due to FG material pending

40 Manpower shifted to 2MD line

41 Weld at fixture due to operator mistake 2CT

42 Operator not regular 2CT

43 Diesel line stoppage due to hold material cleared

44 Spot machine not working (Breakdown), Shank Broken 14, 15 & 1 X(4)

45 Lower electrode change and carbon test NG 14

46 Area sensor NG 2CT (P) #19 X(4)

47 Power trip due to gas supply low

48 Diesel line retouching manpower, all welding reset X

49 Striker under maintenance material movement not possible

50 SF line approx. 90 pcs hold then cleared all material in whole shift 2CT (P) & (D)

51 Lot of material in hold from B shift, line stoppage to clear it 2CT (D) X

52 Welder new

53 SF 2CT(P) lower half and upper half N/A 2CT (P) X

54 Electrical problem in robot controller

55 SF stiffener N/A 2CT (D) X

56 Part no. 31 not available

57 Slide sensor pin stuck in every piece #2

58 Gas pallet change

59 Nut feeder not working 1

60 Gas cylinder change

61 Nugget NG of spot welding 1, 4 & 6 X(2)

62 Robot gas valve not working 19

63 2 Hrs. wastage in emptying

2 CW PROBLEM REPORT (1/5/2015 – 31/5/2015)

S. No. Problem Operation Frequency1 Manpower shortage due to labor day x(2)2 Nut missing, fixture and sensor adjustment done3 2 new manpower at nut check4 Nut check and no manpower5 Only 3 manpower on SF 2CW line6 6 time power cut, 3 manpower extra deployed X(1T), 4(T)7 2CW SF pending material8 Axel manpower shift to 2CW line9 Air supply not proper

10 Spot machine shorting problem #1111 Ejector broken #1512 Shutter cylinder problem #14, #1513 Part not okay in receiving gauge X14 Problem in part fitment #1315 Projection machine not working #1316 Read switch not working #1617 Tapping person was new

18 Slide unit not working #16 X19 Projection machine not working #2 X20 Manpower leaves at 05:3021 R2 torch insulation burn and torch shorting #0822 Right hand side fixture read switch and sensor problem #0823 Spot machine fixture adjustment24 Manpower shift to 2CD X25 BKT out at receiving gauge26 SF L/A not available27 New Manpower X(3)28 BKT sit pin broken 2 times29 BKT LH side sensor not working #1530 Power trip due to gas pressure low31 Untrained manpower #13,14,15,16 x(2)32 W.I.P cleaning33 M14 nut not available and line stoppage X34 Line starts late35 Shut down due to plant meeting

2 CD PROBLEM REPORT (01/05/2015 – 31/05/2015)

S. No.

Problem Operation Frequency

1 manpower shift * * * * * * *

2 line start late *

3 new manpower ,new operator online * * * *

4 projection machine not working properly #2 *

5 bkt stiffener sensor not working #15 *

62 manpower on making and gauging due to unskilled

operator7 locating pin L H side not working #15

8 lower half finished

9 m/c stoppage due to rework material pending

10 robot torch disturbed by operator #15

11 complete teaching of stiff bkt #16

12 upper half n/a

13 lifter not working #15

14 lower half n/a

15 gas cylinder change

16 ejector cylinder not working

17 electrical connection not done by maintenance

18 read switch not working #14

19 R1 wire not flow in line properly #14

20 R1 bkt sensor change #15

21 line stop due to M14 nut n/a

22 power cut

23 shut down due to plant meeting

MAINTAINENCE REPORT OF ALL LINES

S.No. Model Operation Problem Status

1 2 CT (Petrol) #21 i. (Air Leakage),main line control valve OK

ii. Left Bracket holding magnet OK

#19 i. Left Ammeter OK

ii. (Air Leakage), Right T-valve after flow regulator OK

#18 i. (Air Leakage), Right side manipulator (bottom) OK

2 2 CD (Diesel) #8 i. (Air Leakage), Flow Regulator Right side OK

3 2 CW (Petrol) #16 i. (Air Leakage) , left side under air container in pipe joint OK

Rework area i. (Air Leakage) main line pipe burst OK

4 2 CW (Axle) OK

Line 1 #6 i. (Air Leakage), Flow Regulator OK

ii. (Air Leakage), left side pipes jig fixture OK

iii. Welding overlapping OK

5 2 CT (Diesel) #19 i.(Air Leakage), Main distributor pipe T- joint OK

ii. (Air Leakage), Inlet manipulator pipe OK

iii. (Air Leakage), Right side manipulator leakage OK

iv. (Air Leakage), Center back bottom pipe OK

#18 i. (Air Leakage), Right side upper joint OK

6 2 CD (Diesel) #15 i. (Air Leakage), Front cylinder connecting pipe OK

ii. (Air Leakage), center back pipe OK

7 2 CW (Petrol) #8 i. (Air Leakage), Upper control valve T-joint OK

#17 i. (Air Leakage), Right side nozzle cleaner box OK

8 2 CW (Axle) OK

Line 1 #3 i. (Air Leakage), right side pneumatic cylinder OK

#4 i.(Air Leakage), left side pneumatic cylinder OK

9 2 MD (Diesel) #10 i.(Air leakage), behind center pillar pipe OK

PRODUCTION CYCLE TIME

The period required to complete one cycle of an operation; or to complete

a function, job, or task from start to finish. Cycle time is used in differentiating

total duration of a process from its run time.

Or

the period during which the objects of labor (raw products and materials) remain in 

the production process, from the beginning ofmanufacturing through the output of 

a finished product. In addition to the working time, the production cycle includes i

nterruptions inproduction owing to physical, chemical, and biological (natural) pro

cesses (for example, the period required for tanning leather); the characterof the ob

jects of labor; or the technology and organization of production.

AXLE LINE 1 CELL NO. #4

AXLE LINE 1 CELL NO. #3

AXLE LINE 1 CELL NO. #5

INVENTORY MANAGEMENT

Inventory management is primarily about specifying the size and placement of

stocked goods. Inventory management is required at different locations within a

facility or within multiple locations of a supply network to protect the regular and

planned course of production against the random disturbance of running out of

materials or goods.

The scope of inventory management also concerns the fine lines between

replenishment lead time, carrying costs of inventory, asset management, inventory

forecasting, inventory valuation, inventory visibility, future inventory price

forecasting, physical inventory, available physical space for inventory, quality

management, replenishment, returns and defective goods and demand forecasting

and also by replenishment Or can be defined as the left out stock of any item used

in an organization. Inventory is liabilities of a business.

All above inspection of machines done, under guidelines of

Mr. Ravi Ranjan, Head of Production, Honda Line N-5, JBM.

After detecting problems are resolve by MAINTENANCE and JIGS &

FIXTURE MAINTENANCE department as follow:

MAINTAENANCE:

Mr. Sumit Kumar

JIGS & FIXTURE MAINTENANCE:

Mr. Dilbag Rai

Mr. Ravi Prakash Pandey

CONCLUSION

I would like to say that this training program is an excellent opportunity for us

to get to the ground level and experience the things that we would have never

gained through going straight into a job. I am grateful to the Government

Engineering College, Ajmer and NMPL (JBM) for giving us this wonderful

opportunity.

The main objective of the industrial training is to provide an opportunity to

undergraduates to identify, observe and practice how engineering is applicable in

the real industry. It is not only to get experience on technical practices but also to

observe management practices and to interact with fellow workers. It is easy to

work with sophisticated machines, but not with people. The only chance that an

undergraduate has to have this experience is the industrial training period.

I feel I got the maximum out of that experience. Also I learnt the way of work in an

organization, the importance of being punctual, the importance of maximum

commitment, and the importance of team spirit. The training program having three

destinations was a lot more useful than staying at one place.

In my opinion, I have gained lots of knowledge and experience needed to be

successful in a great engineering challenge…….

REFERENCE

I. J.B.M. Industries

II. www.indiastydychannels.com

III. www.wikipedia.org

IV. www.ehow.com

V. www.scribd.com

VI. (N-5) Production Report

VII. (N-5) Design Report

VIII. Head of department