DISCOVER 500/SHIFT (PITCH TIME 0.96MIN.

)
STG WORK CONTENT 1 Rear wheel loading on line Rear brake pannel fit. On rear wheel Load kit bin on the conveyor Rear wheel trolley replacement Mudgaurd bolt s/a & put on conveyor Torque checking ( upper dome nut) Torque checking (lower bolt) 2 Wheel insertion on chassis Match rh chain adjuster & cut binding piece Pre fit nut on swing arm 22 mm of rear axle Mudgaurd collar fitment 3 Mudguard s/a with collar & brace fender Put Painted set kit on conveyor Mudguard prefit 4 Mudguard tightning with nut runner Use mudguard spacer Mudguard Torque checking Front br. Pannel locketing on wheel Lift front wheel by tackle & keep in fork legs 5 Apply grease on front axle & prefit on fork. F.Wheel insertion on fork with spacer Prefit fr axle nut Tight front wheel nut 6 Insert & bend the split pin Check the torque Swing arm torque checking Swing arm RH cap fitment Torque rod bolt prefit CDI connection 7 Engine unloading Engine upper bolt insertion help Engine lower bolt nut prefit 8 Engine bracket prefitment. (upper) Engine bracket prefitment. (rear ) Starter motor cable band remove 9 Engine bracket pre fitment. (front lower) Rear Blinker Connection (Two) Engine bolt tightening & torque checking 8,9,10 10 Rear Engine bolt tightening & torque checking 1,2,3,4,5,6,7, Rear Blinker Connection(Two) 11 Rear br pedal insertion with spring,grease Rear brake connection 0.15 0.85 0.2 0.3 35 Engine tightening & torque (7 nut) TIME 0.2 0.1 0.1 0.08 0.2 0.1 0.1 0.88 0.3 0.1 0.1 0.3 0.8 0.2 0.1 0.5 0.8 0.2 0.08 0.2 0.1 0.2 0.78 0.2 0.3 0.08 0.2 0.78 0.2 0.1 0.1 0.1 0.2 0.15 0.85 0.3 0.4 0.1 0.8 0.3 0.3 0.15 0.75 0.4 0.15 0.3 0.85 0.7 34 Engine front upper bkt. Positioning LH. Engine front lower bkt. Positioning LH. Starter motor cable routing 33 Engine lower bolt locating Engine rear upper bkt. Positioning LH. Horn connection & harness routing Carburettor Drain pipe routing 32 Battery insertion Battery drain pipe position Horn harness routing Fuse box insertion Flasher connection Swing arm cap fitment LH. 31 Battery base pad fitment Stater relay one connection & insertion Help to swing arm centre torque Earthing cable routing Battery arrester upper pad fitment 30 Harness routing & Horn cable routing 29 Paint application on no. punch Shock absorber lower nut torque checking Bar code sticker on p.v. card fit. Check no & stick bar code sticker Fork loading on chute Shock absorber dome nut torque checking 28 Declamp fixture Position chassis on conveyor Insert rear wheel axle Apply grease on axle 27 Fork fitment Fork upper nut tightning by gun Fork nut prefit 26 Grease aplication Ball filling on races Bearing cone fitment Dust cover fitment STG WORK CONTENT 24 25 Locate chassis on no.punching m/c with tackle No punching & bearing race pressing Keep chassis on fork fit. Stage Put bearing races on m/c & reset green switch ( Unload kit bin during no punching cycle) 0.7 0.2 0.3 0.1 0.1 0.7 0.4 0.2 0.1 0.7 0.3 0.35 0.1 0.1 0.85 0.2 0.1 0.1 0.1 0.2 0.1 0.8 0.9 0.9 0.1 0.4 0.1 0.1 0.2 0.9 0.3 0.1 0.1 0.1 0.1 0.2 0.9 0.3 0.3 0.1 0.1 0.8 0.3 0.4 0.1 0.8 0.8 0.8 TIME 0.15 0.35 0.1 0.1

Rear brake switch srping conn. Rear brake pedal return spring fitment 12 Br pedal tightning with washer & loctite R.r.unit fitment Rear brake padel torque checking Rear br.padel adjustment bolt nut prefit

0.1 0.2 0.8 0.2 0.4 0.1 0.15 0.85 0.35 0.2 0.2 0.1 0.85

36

Engine tightening & torque (3 nut) Magneto connection & routing Chain case bolt s/a

0.3 0.3 0.2 0.8 0.2 0.2 0.2 0.2 0.8 0.15 0.65 0.8 0.3 0.1 0.15 0.1 0.15 0.8 0.3 0.2 0.2 0.15 0.85 0.2 0.1 0.1 0.1 0.15 0.1 0.15 0.9 0.8 0.8 0.3 0.3 0.1 0.2 0.9 0.1 0.1 0.1 0.3 0.1 0.1 0.8 0.6 0.2 0.8 0.4 0.3 0.1 0.8 0.5 0.2 0.1 0.1 0.9

37

Engine earthing connection Chain routing Battery arrester fitment Handle bar holder s/a

13 Rear br.padel adjustment

Rear br.padel grommet insertion Rear br.light checking. Rear br.light rework 14 Rh H T coil fitment Rear brake switch connection Rh Spark plug fit. Front no plate bkt. Fitment Fork both flap with blinker insertion Fork upper ring Lower rings fitment 15 Prefit fork side bolts Prefit stem nut with washer Fairing blinker & head light wire routing Fairing center bolt insertion OEN Relay fitment Loose fork front bolts 16 Tight upper side bolts & apply torque Tight stem nut & apply torque Tight fork front bolts Fork front bolt torque checking Fairing center bolt nut tightning 17 Prefit front no. plate Fr. No plate tightening H.Bar harness routing Fr brake & Accelerator cable routing 18 Harness connections RH side Head lamp case insertion Head lamp bolt insertion nut prefit Blinker connection KS 19 Below insertion on harness & in Fairing Tight Rear wheel nut & torque checking While Rear wheel alig. Hold brake pedal Fixture locking with mallet Use head light position tool Head lamp case tightning 20 Accl. Connection & play adjustment Clutch cable routing from chassis bkt. Clutch connection prefit

38

Check chain tention & adjust Chain case fitment

39

Cover L.H.R.R s/a fitment Gear shifter lever fitment Push one battery grommet on battery Jelly application on battery Starter motor cable one band

0.3 0.1 0.1 0.3 0.8 0.2 0.1 0.2 0.2 0.1 0.1 0.1 0.15 0.2 0.85 0.2 0.2 0.1 0.2 0.1 0.8 0.1 0.2 0.3 0.3 0.9 0.8 0.8 0.4 0.3 0.2 0.3 0.2 0.2 0.1 0.8 0.2 0.2 0.4 0.1 0.3 0.8 47 46 45 44 43 42 41 40

Battery both connections Stater relay one connection Starter motor grommet insertion Starter motor cable one band Carb. S/A locating on eng Carb. Insertion in A.C. box Carb.clip tightening A. C. box clip tightening Reed switch connection Carb. Drain pipe connection Car. Vent pipe routing H.Bar fit on line with fixture & torque checking Seat cowl insertion Seat cowl tightening Tail lamp connection Fit engine breather pipe & clip 27 mm nut tightening 27 mm nut torque checking Wheel alignment Both chain adjuster locking Harness center band Chain case grommet fit. Choke connection Fairing two connection ( switch) H.bar cable routing .(LH side) Side panel s/a Battery drain pipe routing in arrester Front brake connection Fairing two connection remaining Bellow insertion Fairing LH DG

Head light fitment

0.4

All harness connection(Except blinker) 21 Silencer location on engine with tackle. Silencer front side nut prefitting Locate rear bolt on step holder Silencer front side nut tightning & torq. Check 22 Grab rail bolt prefit & tight Rear bolt tightening (SILENCER) (14 mm) T.rod bolt tightening Snap pin fit Rear bolt torque checking 23 Silencer front nut torque checking Clutch cable play adjustment Clutch cable locking Fit side panel with DG screw Fairing RH DG

0.4 0.25 0.15 0.2 0.15 0.75 0.4 0.15 0.1 0.1 0.1 0.8 0.2 0.1 0.1 0.3 0.1 0.8

48

LH.H. T.coil fitmen & connection Speedometer cable routing Insert speedo grommet Speedometer lower connection

0.3 0.1 0.1 0.3 0.8 0.2 0.1 0.2 0.2 0.2 0.9

49

Petrol tank lock fitment Petrol tank fuel gauge conection Cable routing Petrol tank fitment Snap pin fit.

50

SAP data entry Painted flag removing Side panel locking

SUMMERY
ON LINE P.TANK S/A & HANDLING CARBURETOR S/A GROUP LEADER LINE RECTIFIER P.V.CHECKING RECTIFICATION DYNO TESTING F/OK

500
50 6 2 3 2 2 2 8 1 76

OUTPUT/ MAN DIRECT OUTPUT/ MAN INDIRECT DIRECT = ONLINE + ALL S/A

8.621 6.579

DISCOVER 650/SHIFT (PITCH TIME 0.74MIN. - 44 Sec)

No. 1 WORK CONTENT Rear wheel loading on line Rear brake pannel fit. On rear wheel Load kit bin on the conveyor Rear wheel trolley replacement 2 Wheel insertion on chassis Match rh chain adjuster & cut binding piece Mudgaurd bolt s/a & put on conveyor 3 Mudgaurd collar fitment Mudguard s/a with collar & brace fender Put Painted set kit on conveyor 4 Mudguard prefit Use mudguard spacer Torque checking ( upper dome nut) 5 Mudguard tightning with nut runner Mudguard Torque checking Lift front wheel by tackle & keep in fork legs 6 Apply grease on front axle & prefit on fork. Front br. Pannel locketing on wheel F.Wheel insertion on fork with spacer TIME 0.2 0.1 0.1 0.08 0.68 0.3 0.2 0.2 0.7 0.3 0.2 0.1 0.7 0.5 0.1 0.1 0.7 0.2 0.2 0.2 0.6 0.2 0.1 0.3 0.6 7 Tight front wheel nut Prefit fr axle nut Front wheel nut torque checking. Swing arm torque checking Torque checking (lower bolt) Pre fit nut on swing arm 22 mm of rear axle 8 Insert & bend the split pin Swing arm RH cap fitment Rear Blinker Connection 9 Engine unloading Engine upper bolt insertion help 10 Engine bracket prefitment. (upper) Engine lower bolt nut prefit Engine bracket prefitment. (rear ) 11 Engine bracket prefitment. (front lower) CDI connection Starter motor cable band remove 12 Rear Engine bolt tightening & torque checking 1,2,3,4,5,6,7, 13 Engine bolt tightening & torque checking 8,9,10 Torque rod bolt prefit Br. shaft grease application 0.2 0.08 0.1 0.1 0.1 0.1 0.68 0.2 0.1 0.3 0.6 0.3 0.4 0.7 0.3 0.1 0.3 0.7 0.4 0.15 0.15 0.7 0.7 0.7 46 0.3 0.2 0.1 0.6 Starter motor cable routing Flasher connection Fuse box insertion Engine bkt bolt torque Swing arm cap fitment LH. 45 Engine tightening & torque (7 nut) 44 Engine front upper bkt. Positioning LH. Engine front lower bkt. Positioning LH. 43 Engine lower bolt locating Engine rear upper bkt. Positioning LH. 42 Battery insertion Battery drain pipe position Battery arrester upper pad fitment Earthing cable routing 41 Help to swing arm centre torque Harness routing remening. Horn connection & harness routing 40 Declamp fixture Starter relay one connection & insertion 39 Harness routing Carburettor Drain pipe routing Battery base pad fitment 38 Paint application on no. punch Shock absorber lower nut torque checking Bar code sticker on p.v. card fit. Check no & stick bar code sticker Fork loading on chute 37 Shock absorber dome nut torque checking Position chassis on conveyor Insert rear wheel axle Apply grease on axle 36 Fork fitment Fork upper nut tightning by gun Fork nut prefit 35 Grease aplication Ball filling on races Bearing cone fitment Dust cover fitment 0.2 0.3 0.1 0.1 0.7 0.4 0.2 0.1 0.7 0.1 0.35 0.1 0.1 0.65 0.2 0.1 0.1 0.1 0.2 0.7 0.5 0.1 0.1 0.7 0.3 0.4 0.7 0.1 0.3 0.3 0.7 0.3 0.1 0.2 0.1 0.7 0.3 0.3 0.6 0.3 0.4 0.7 0.8 0.8 0.1 0.1 0.1 0.2 0.2 NO. WORK CONTENT 33 34 Locate chassis on no.punching m/c with tackle No punching & bearing race pressing Keep chassis on fork fit. Stage Put bearing races on m/c & reset green switch ( Unload kit bin during no punching cycle) TIME 0.15 0.35 0.1 0.1 0.7

14

Rear br pedal insertion with spring, Rear brake connection Rear brake switch srping conn. Rear brake pedal return spring fitment

0.1 0.3 0.1 0.2 0.7 48 Engine earthing connection Handle bar holder s/a Battery arrester fitment & harness routing 49 Check chain tention & adjust Chain case bolt s/a Chain routing 50 51 Chain case fitment Cover L.H.R.R s/a fitment Gear shifter lever fitment Chain case grommet fit. 52 Push one battery grommet on battery Battery both connections Jelly application on battery 53 Starter relay one connection Starter motor grommet insertion Starter motor cable one band. Battery arrester bolt tight. 54 Carb. S/A locating on eng Carb. Insertion in A.C. box Carb.clip tightening A. C. box clip tightening Carb. Drain pipe connection 55 Reed switch connection Handle bar prefit on veh Car. Breather pipe routing 56 H.Bar fit on line with fixture & torque checking Fit engine breather pipe & clip 57 Seat cowl insertion Seat cowl tightening 58 Harness center band H.bar cable routing . 59 27 mm nut tightening 27 mm nut torque checking Wheel alignment Both chain adjuster locking 60 61 Choke connection Tail lamp connection LH.H. T.coil fitment & connection 0.2 0.4 0.6 0.15 0.35 0.1 0.6 0.2 0.1 0.3 0.1 0.7 0.1 0.3 0.2 0.6 0.2 0.1 0.2 0.5 0.2 0.1 0.1 0.1 0.15 0.65 0.2 0.2 0.2 0.6 0.1 0.2 0.1 0.2 0.1 0.7 0.2 0.4 0.6 0.6 0.1 0.25 0.15 0.1 0.6 0.2 0.2 0.2 0.6 0.6 47 Engine tightening & torque (3 nut) Magneto connection & routing

0.7 0.3 0.3 0.6 0.2 0.2 0.3 0.7 0.15 0.2 0.3 0.7 0.65 0.65 0.4 0.1 0.1 0.6 0.15 0.3 0.1 0.55 0.2 0.2 0.15 0.1 0.65 0.2 0.1 0.1 0.1 0.1 0.6 0.15 0.3 0.15 0.6 0.5 0.2 0.7 0.3 0.3 0.6 0.1 0.5 0.6 0.1 0.1 0.1 0.3 0.6 0.6 0.6 0.1 0.3

15

Br pedal tightning with washer & loctite R.r.unit fitment

16

Rear br.padel adjustment bolt nut prefit Rear br.padel adjustment Rear brake padel torque checking

17 Rear br.light checking.

Rear br.light rework Rh H T coil fitment with connection Rear brake switch connection

18 Rh Spark plug fit.

Front no plate bkt. Fitment Rear br.padel grommet insertion Fork both flap with blinker insertion Fork upper ring Lower rings fitment(Starter motor cable fit.E/S) 19 Prefit fork side bolts Prefit stem nut with washer Fairing blinker & head light wire routing Fairing center bolt insertion OEN relay fitment 20 Loose fork front bolts Tight upper side bolts & apply torque Tight stem nut 21 Tight fork front bolts Fork front bolt torque checking Prefit front no. plate Fr. No plate tightening Fairing center bolt nut tightning 22 Harness routing Head lamp case insertion Handle bar cable routing

23 Stem nut torque checking

H.Bar RH housing cable routine Head lamp case bolt insertion Silencer gasket insertion 24 Head lamp bolt insertion nut prefit Head lamp tightning Use head light position tool Harness connections RH side

25 26

Blinker connection & Below insertion on coupl. Tight Rear wheel nut & torque checking Fixture locking with mallet While Rear wheel alig. Hold brake pedal Bellow insertion in fairing

0.6 0.6 0.2 0.1 0.2 0.1 0.6 0.1 0.4 0.1 0.1 0.7 0.25 0.15 0.2 0.6 0.2 0.4 0.6 0.15 0.1 0.1 0.1 0.1 0.55 68 69 70 71 72 73 82 83 91 92 94 67 66 65 64 63 62

Battery drain pipe routine in battery arrester Front brake connection Fairing LH DG fitment Speedometer lower connection Speedometer cable routing Insert speedo grommet Starter motor cable one band. Fairing LH all connection Bellow insertion Petrol tank fuel gauge conection Petrol tank fitment Snap pin fit. Side panel s/a & locking Petrol tank lock fitment Painted flag removing SAP data entry H.Lamp grommet s/a (Battery connection) Seat cowl s/a Carburettor s/a Fairing s/a & handling Petrol tank s/a & handling Group Leader

0.1 0.5 0.5 0.1 0.6 0.3 0.1 0.1 0.15 0.65 0.4 0.2 0.6 0.1 0.2 0.2 0.5 0.3 0.2 0.1 0.6

27

Accelarator cable routing Accl. Connection & play adjustment Clutch cable routing Clutch cable grommet fitment on cable

28

Silencer location on engine with tackle. Silencer front side nut prefitting Locate rear bolt on step holder

29

Silencer front side nut tightning Grab rail bolt prefit & tight

30

Rear bolt tightening (SILENCER) (14 mm) T.rod bolt tightening Snap pin fit Rear bolt torque checking Rear bolt washer & nut prefit

Head light fitment (Fairing s/a) 31 Clutch cable play adjustment Clutch connection prefit Rear br. Play adjustment 32 Side panel fit with DG Fairing RH DG tightning Silencer front 2 nuts torque checking

0.4 0.1 0.4 0.1 0.6 0.3 0.1 0.2 0.6

105 ON LINE Corrector 106 107 ON LINE Inspection 108 109 MAJOR REPAIR 111 112 KIT BIN FILLING

3 cell members from fairing s/a will come on line for k/s vehicles

SUMMERY 650 / SHIFT DISCOVER

ON LINE FAIRING S/A & HANDLING SEAT COWL S/A & HANDLING P.TANK S/A & HANDLING CARBURETTOR S/A GROUP LEADER ON LINE RECTIFIER ON LINE INSPECTION MAJOR REPAIR KIT BIN FILLING DYNO TESTING F/OK TOTAL OUTPUT/ MAN DIRECT OUTPUT/ MAN INDIRECT 67 10 2 8 2 3 2 2 3 1 11 1 112 7.303 5.804 DIRECT = ONLINE + ALL S/A 67 0 0 5

2 3 2 2 3 0 10 0
94

DISCOVER 500/SHIFT (PITCH TIME 0.96MIN.) ST WORK CONTENT G 1 Rear wheel loading on line Rear brake pannel fit. On rear wheel Load kit bin on the conveyor Rear wheel trolley replacement Mudgaurd bolt s/a 2 Wheel insertion on chassis Match rh chain adjuster & cut binding piece Pre fit nut on swing arm 22 mm of rear axle Put Painted set kit on conveyor Carburattor drain pipe routing Grease aplication Ball filling on races Swing arm center axle torque Rear shock absorber upper torque Fork fitment Fork upper nut tightning by gun & torque checking Bearing cone fitment Dust cover fitment Fr mudgaurd s/a with brace fender & prefit Mudguard tightning with nut runner Mudguard Torque checking Front br. Pannel locketing on wheel Lift front wheel by tackle & keep in fork legs Apply grease on front axle & prefit on fork. Swing arm center cap fitment Rear mudflap bolt & collar s/a Engine unloading Engine upper bolt insertion help Engine lower bolt nut prefit Engine bracket nut prefitment. (upper) Engine bracket prefitment. (rear ) & tightening Engine bracket pre fitment. (front lower) 9 Engine bolt tightening & torque checking 8,9,10 Engine front brkt nuts tightening Torque rod bolt prefit Rh Spark plug fit. 10 Front wheel insertion in fork Prefit plain washer & nut Front wheel tightening Fairing brkt prefit Rear mudflap locating 11 Rear brake connection Rear br.padel adjustment Rear br.padel grommet insertion Rear br.light checking. Rear br.light rework rear brake switch connection Fairing brkt tightening 12 Tight Rear wheel nut & torque checking While Rear wheel alig. Hold brake pedal

TIME 0.1 Mutthu 0.1 0.2 0.1 0.3 0.8 0.3 Ashok 0.1 0.1 0.1 0.07 0.67 0.4 Prasanna 0.2 0.1 0.1 0.8 0.5 Bangare 0.2 0.1 0.1 0.9 0.4 Sachin 0.2 Gurav 0.2 0.8 0.1 Manoj 0.4 0.1 0.05 0.2 0.85 0.3 Anand 0.2 0.2 0.7 0.1 Wagh 0.4 0.2 0.7 0.3 Ankush 0.2 0.2 0.1 0.8 0.2 Mahesh 0.1 0.2 0.1 0.1 0.7 0.2 Dudhal 0.1 0.15 0.1 0.1 0.1 0.1 0.85 0.2 Somnath 0.1

WORK CONTENT 20 Locate chassis on no.punching m/c with tackle 21 No punching & bearing race pressing Put bearing races on m/c & reset green switch ( Unload kit bin during no punching cycle) Bar code sticker on p.v. card fit. Shock absorber dome nut torque checking Chain case bolt s/a Paint application on no. punch 22 Declamp fixture Position chassis on conveyor Insert rear wheel axle Apply grease on axle Help to swing arm centre torque Green clip on A Cbox 23 Shock absorber lower nut torque checking Check no & stick bar code sticker on fork Battery base pad fitment Battery insertion Swing arm cap fitment LH. 24 Engine lower bolt locating Engine upper plate insertion Earthing cable prefit Rear bolt insertion LH spark plug connection 25 Engine front upper bkt. Positioning LH. Engine front lower bkt. Positioning LH. Engine tighteninhg (all 12 mm ) 26 Engine tightening & torque (all 14 mm) Starter motor cable routing Magneto connection & routing 27 Engine earthing connection Starter motor cable two band Battery arrester fitment Chain routing Battery drain pipe routing in arrester 28 Check chain tention & adjust Chain case fitment 27 mm nut tightening 29 Cover L.H.R.R fitment Gear shifter lever fitment Handle bar holder s/a Rear wheel 27 mm nut torque 30 Carburattor below s/a Carb. S/A locating on eng Carb. Insertion in A.C. box Carb.clip tightening A. C. box clip tightening 31 Wheel alignment Both chain adjuster locking Rear mudflap tightening Car. Vent pipe routing Prakasham Selvam

0.1 0.1 0.2 0.1 0.1 Mishra 0.3 0.2 0.1 0.1 0.1 0.1 0.1 0.05 0.3 0.1 0.65 0.2 0.2 0.1 0.1 0.1 0.7 0.2 0.3 0.3 0.8 0.3 0.3 0.2 0.8 0.1 0.2 0.3 0.2 0.1 0.9 0.2 0.5 0.1 0.8 0.3 0.2 0.2 0.1 0.8 0.3 0.1 0.1 0.2 0.1 0.8 0.3 0.2 0.2 0.2 Dinesh

Mulage

Datta

Annaso

Yadav

Vivek

Kutwal

Sagar

Rear mudflap tightening Fairing insertion Fairing lower bolt insertion 13 Prefit fork stem nut Prefit fork side bolts Fork lower bolt loosening Tightening stem nut Tightening fork upper bolts Tightening fork lower bolts 14 Apply torque to stem nut Prefit front no. plate Fr. No plate tightening H.Bar harness routing Fr brake & Accelerator cable routing 15 Harness connections RH side Fairing center bolt nut tightning RH H T Coil fitment 16 Silencer gasket fitment Silencer location on engine with tackle. Silencer front side nut prefitting Locate rear bolt on step holder Silencer front side nut tightning 17 Silencer front nut torque checking Grab rail bolt prefit & tight Rear bolt tightening (SILENCER) (14 mm) T.rod bolt tightening Snap pin fit 18 Accl. Connection & play adjustment Rear brake play adjustment Accelarator cable routing in center band Fixture locking with mallet Rear brake switch connection 19 Clutch cable routing from chassis bkt. Fit side panel with DG screw Fairing RH DG Clutch connection prefit & play adjustment Below insertion on harness & in Fairing

0.2 0.3 0.1 0.9 0.1 0.1 0.2 0.1 0.2 0.2 0.9 0.1 0.2 0.1 0.2 0.2 0.8 0.3 0.1 0.4 0.1 0.1 0.3 0.1 0.2 0.7 0.1 0.4 0.1 0.1 0.1 0.7 0.3 0.1 0.1 0.1 0..05 0.75 0.1 0.2 0.1 0.2 0.2 0.8

32 H.Bar fit on line with fixture & torque checking Insert speedo grommet R R unit only connection Sandesh 33 H.bar cable routing .(LH side) Fairing two connection remaining Side panel s/a 34 Seat cowl insertion Seat cowl tightening Tail lamp connection Chain case grommet fit. 35 Choke connection R R unit prefit Fairing two connection ( switch) Sandeep 36 Battery both connections Stater relay one connection Starter motor grommet insertion R R unit tightening ( condensor & unit conn k/s) Reed switch connection 37 Harness blinker connections Push one battery grommet on battery Jelly application on battery Bellow insertion Avinash 38 Front brake connection Speedometer connection lower 39 OEN relay fitment Fairing LH DG screw tightening Fit engine breather pipe & clip Carbuttor drain pipe connection 40 Harness center band tightening Petrol tank fitment Snap pin fit. Petrol tank lock fitment Petrol tank fuel gauge conection 41 SAP data entry Painted flag removing Side panel locking

Narayan

More

Birappa

Hari

0.9 0.6 0.1 0.1 0.8 0.2 0.2 0.4 0.8 0.3 0.2 0.1 0.1 0.7 0.4 0.2 0.2 0.8 0.3 0.2 0.1 0.2 0.1 0.9 0.2 0.1 0.1 0.3 0.7 0.5 0.3 0.8 0.3 0.1 0.2 0.1 0.7 0.1 0.3 0.1 0.2 0.1 0.7 0.1 0.2

Subramani

Rahul

Prakash

Rajesh Patil

Mahesh Patil

Jayendra

Sandeep Patil

Bharam

Anand

SUMMERY
On Line OnLine P V comp Group Leader Line Rectifier Rectifier Inspector Total Output / man ( Direct) Output / man ( Indirect) 41 2 2 2 2 8 57 12.19 8.77 Tambat, Mukul Nitin , Chikane Pritish, Shewale Raja,

DISCOVER 550/SHIFT (PITCH TIME 0.87MIN.)

NO. WORK CONTENT 1 Rear wheel loading on line Rear brake pannel fit. On rear wheel Load kit bin on the conveyor Rear wheel trolley replacement Mudgaurd bolt s/a & put on conveyor 2 Wheel insertion on chassis Match rh chain adjuster & cut binding piece Pre fit nut on swing arm 22 mm of rear axle Torque checking ( upper dome nut) 3 Mudgaurd collar fitment Mudguard s/a with collar & brace fender Torque checking (lower bolt) Put Painted set kit on conveyor 4 Mudguard tightning with nut runner Mudguard prefit Use mudguard spacer 5 Mudguard Torque checking Lift front wheel by tackle & keep in fork legs Apply grease on front axle & prefit on fork. Front br. Pannel locketing on wheel 6 F.Wheel insertion on fork with spacer Tight front wheel nut Prefit fr axle nut TIME 0.2 0.1 0.1 0.08 0.2 0.68 0.3 0.1 0.1 0.1 0.7 0.3 0.2 0.1 0.1 0.7 0.2 0.5 0.08 0.78 0.2 0.2 0.2 0.1 0.7 0.3 0.2 0.08 37 0.78 7 Insert & bend the split pin Check the torque Swing arm torque checking Swing arm RH cap fitment Torque rod bolt prefit 8 Engine unloading Engine upper bolt insertion help 9 Engine bracket prefitment. (upper) Engine lower bolt nut prefit Engine bracket prefitment. (rear ) 0.2 0.1 0.1 0.1 0.2 0.7 0.3 0.4 0.7 0.3 0.1 0.3 0.7 10 Engine bracket prefitment. (front lower) CDI connection Starter motor cable band remove 11 12 Rear Engine bolt tightening & torque checking 1,2,3,4,5,6,7, Engine bolt tightening & torque checking 8,9,10 Rear Blinker Connection 0.4 0.15 0.15 0.7 0.7 0.7 0.3 0.3 0.6 42 Engine tightening & torque (3 nut) Magneto connection & routing Chain case bolt s/a 41 Engine tightening & torque (7 nut) 40 Engine front upper bkt. Positioning LH. Engine front lower bkt. Positioning LH. Starter motor cable routing 39 Engine lower bolt locating Engine rear upper bkt. Positioning LH. Carburettor Drain pipe routing 38 Battery insertion Battery drain pipe position Battery arrester upper pad fitment Earthing cable routing Help to swing arm centre torque Declamp fixture Battery base pad fitment Stater relay one connection & insertion 0.3 0.1 0.4 0.8 0.3 0.1 0.2 0.1 0.1 0.8 0.3 0.3 0.1 0.7 0.3 0.4 0.1 0.8 0.8 0.8 0.3 0.3 0.2 0.8 36 Harness routing 35 Paint application on no. punch Shock absorber lower nut torque checking Bar code sticker on p.v. card fit. Check no & stick bar code sticker Fork loading on chute 34 Shock absorber dome nut torque checking Position chassis on conveyor Insert rear wheel axle Apply grease on axle 33 Fork fitment Fork upper nut tightning by gun Fork nut prefit 32 Grease aplication Ball filling on races Bearing cone fitment Dust cover fitment 0.2 0.3 0.1 0.1 0.7 0.4 0.2 0.1 0.7 0.1 0.35 0.1 0.1 0.65 0.2 0.1 0.1 0.1 0.2 0.7 0.8 NO. WORK CONTENT 30 31 Locate chassis on no.punching m/c with tackle No punching & bearing race pressing Keep chassis on fork fit. Stage Put bearing races on m/c & reset green switch ( Unload kit bin during no punching cycle) TIME 0.15 0.35 0.1 0.1 0.7

13

Rear br pedal insertion with spring,grease Rear brake connection Rear brake switch srping conn. Rear brake pedal return spring fitment

0.2 0.3 0.1 0.2 0.8 0.2 0.4 0.1 0.7

43

Engine earthing connection Chain routing Battery arrester fitment Flasher connection

0.2 0.2 0.2 0.1 0.7 0.15 0.65 0.8 0.3 0.1 0.2 0.2 0.8 0.15 0.3 0.1 0.55 0.2 0.2 0.3 0.1 0.8 0.2 0.1 0.1 0.1 0.15 0.1 0.75 0.8 0.8 0.3 0.3 0.1 0.7 0.1 0.1 0.1 0.3 0.1 0.15 0.85 0.6 0.2 0.8 0.4 0.3 0.7 0.5 0.1 0.2 0.8 0.1 0.2 0.3 0.1 0.7

14 Br pedal tightning with washer & loctite

R.r.unit fitment Rear brake padel torque checking

44

Check chain tention & adjust Chain case fitment

45

Cover L.H.R.R s/a fitment Gear shifter lever fitment Handle bar holder s/a Swing arm cap fitment LH.

15 Rear br.padel adjustment bolt nut prefit

Rear br.padel adjustment Rear br.padel grommet insertion 16 Rear br.light checking. Rear br.light rework Rh H T coil fitment Rear brake switch connection Rh Spark plug fit. 17 Fork both flap with blinker insertion Fork upper ring Lower rings fitment 18 Prefit fork side bolts Prefit stem nut with washer Fairing blinker & head light wire routing Front no plate bkt. Fitment 19 Loose fork front bolts Tight upper side bolts & apply torque Tight stem nut & apply torque Fairing center bolt insertion 20 Tight fork front bolts Fork front bolt torque checking Prefit front no. plate Fr. No plate tightening Fairing center bolt nut tightning 21 Harness routing Head lamp case insertion Harness connections RH side 22 Head lamp bolt insertion nut prefit Head lamp tightning Use head light position tool Handle bar cable routing 23 24 All harness connection Tight Rear wheel nut & torque checking Head light fitment While Rear wheel alig. Hold brake pedal Bellow insertion & OEN relay fitment

0.15 0.35 0.2 0.7 0.2 0.1 0.3 0.1 0.1 0.8 0.2 0.1 0.2 0.5 0.2 0.1 0.1 0.3 0.7 0.2 0.2 0.2 0.1 0.7 0.1 0.2 0.1 0.2 0.1 0.7 0.3 0.4 0.7 52 0.3 0.2 0.2 0.7 0.8 0.2 0.4 0.2 0.8 55 54 53 51 50 49 48 47 46

Push one battery grommet on battery Battery both connections Jelly application on battery Stater relay one connection Starter motor grommet insertion Horn connection & harness routing Fuse box insertion Carb. S/A locating on eng Carb. Insertion in A.C. box Carb.clip tightening A. C. box clip tightening Reed switch connection Carb. Drain pipe connection H.Bar fit on line with fixture & torque checking Seat cowl insertion Seat cowl tightening Tail lamp connection 27 mm nut tightening 27 mm nut torque checking Wheel alignment Both chain adjuster locking Harness center band Car. Breather pipe routing Choke connection Fit engine breather pipe & clip H.bar cable routing . Stater motar cable two band. Front brake connection Chain case grommet fit. Fairing two connection ( switch) Insert speedo grommet Fairing two connection remaining Speedometer lower connection Speedometer cable routing

25

Acclarator cable routing Accl. Connection & play adjustment Clutch cable routing Clutch cable grommet fitment on cable Fixture locking with mallet

0.1 0.4 0.1 0.1 0.1 0.8 0.25 0.15 0.2 0.6 0.35 0.4 0.75 0.15 0.1 0.1 0.1 0.45 0.1 0.2 0.1 0.3 0.7

56

Side panel s/a & locking petrol tank lock fitment Bellow insertion

0.3 0.2 0.1 0.6 0.3 0.3 0.1 0.2 0.2 0.2 0.7

57 58

LH.H. T.coil fitment&connection Petrol tank fuel gauge conection Cable routing Petrol tank fitment Snap pin fit.

26

Silencer location on engine with tackle. Silencer front side nut prefitting Locate rear bolt on step holder

27

Silencer front side nut tightning & torq. Check Grab rail bolt prefit & tight

59

SAP data entry Painted flag removing

28

Rear bolt tightening (SILENCER) (14 mm) T.rod bolt tightening Snap pin fit Rear bolt torque checking

60 61 62 63 64 65 to 73

H.Lamp grommet s/a Seat cowl s/a

29

Clutch cable play adjustment Clutch connection prefit Rear br. Play adjustment Fit side panel with DG screw

Carburettor s/a

Fairing s/a & handling

3 cell members from fairing s/a will come on line for k/s vehicles 74 to 80 81 57 9 2 7 2 3 2 2 3 1 9 1 98 OUTPUT/ MAN DIRECT OUTPUT/ MAN INDIRECT DIRECT = ONLINE + ALL S/A 7.33 5.612 91 KIT BIN FILLING 88 89 90 RECTIFICATION 86 87 ON LINE CORRECTOR 84 85 PV CHEKING to 83 Group Leader 650 70 11 2 8 2 3 2 2 4 1 11 1 117 Petrol tank s/a & handling

Total cell members required 88

SUMMERY ON LINE FAIRING S/A & HANDLING SEAT COWL S/A & HANDLING P.TANK S/A & HANDLING CARBURETOR S/A GROUP LEADER LINE RECTIFIER P.V.CHECKING RECTIFICATION KIT BIN FILLING DYNO TESTING F/OK

67.36364

550 new 57 0 0 4 2 3 2 2 3 0 8 0 81

500 52 0 0 4 2 2 2 2 2 0 7 1 74

DISCOVER 550/SHIFT (PITCH TIME 0.87MIN.)

WORK CONTENT 1 Rear wheel loading on line Rear brake pannel fit. On rear wheel Load kit bin on the conveyor Rear wheel trolley replacement Mudgaurd bolt s/a & put on conveyor 2 Wheel insertion on chassis Match rh chain adjuster & cut binding piece Pre fit nut on swing arm 22 mm of rear axle Torque checking ( upper dome nut) TIME 0.2 0.1 0.1 0.08 0.2 0.68 0.3 0.1 0.1 0.1 0.7 0.3 0.2 0.1 0.1 0.7 0.2 0.5 0.08 0.78 0.2 0.2 0.2 0.1 0.7 0.3 0.2 0.08 0.78 0.2 0.1 0.1 0.1 0.2 0.7 0.3 0.4 0.7 0.3 0.1 0.3 0.7 0.4 0.15 0.15 0.7 0.7 0.7 0.3 0.3 0.6 0.2 0.3 0.1 0.2 0.8 0.2 0.4 0.1 0.7 0.15 0.35 46 Push one battery grommet on battery WORK CONTENT 30 Locate chassis on no.punching m/c with tackle 31 No punching & bearing race pressing Keep chassis on fork fit. Stage Put bearing races on m/c & reset green switch ( Unload kit bin during no punching cycle) 32 Grease aplication Ball filling on races Bearing cone fitment Dust cover fitment 33 Fork fitment Fork upper nut tightning by gun Fork nut prefit 34 Shock absorber dome nut torque checking Position chassis on conveyor Insert rear wheel axle apply grease on axle 35 Paint application on no. punch Shock absorber lower nut torque checking Bar code sticker on p.v. card fit. Check no & stick bar code sticker Fork loading on chute 36 Harness routing 37 Declamp fixture Battery base pad fitment Stater relay one connection & insertion 38 Battery insertion Battery drain pipe position Battery arrester upper pad fitment Earthing cable routing Help to swing arm centre torque 39 Engine lower bolt locating Engine rear upper bkt. Positioning LH. Carburettor Drain pipe routing 40 Engine front upper bkt. Positioning LH. Engine front lower bkt. Positioning LH. Starter motor cable routing 41 Engine tightening & torque (7 nut) 42 Engine tightening & torque (3 nut) Magneto connection & routing Chain case bolt s/a 43 Engine earthing connection Chain routing Battery arrester fitment Flasher connection 44 Check chain tention & adjust Chain case fitment 45 Cover L.H.R.R s/a fitment Gear shifter lever fitment Handle bar holder s/a Swing arm cap fitment LH. TIME 0.15 0.35 0.1 0.1 0.7 0.2 0.3 0.1 0.1 0.7 0.4 0.2 0.1 0.7 0.1 0.35 0.1 0.1 0.65 0.2 0.1 0.1 0.1 0.2 0.7 0.8 0.3 0.1 0.4 0.8 0.3 0.1 0.2 0.1 0.1 0.8 0.3 0.3 0.1 0.7 0.3 0.4 0.1 0.8 0.8 0.8 0.3 0.3 0.2 0.8 0.2 0.2 0.2 0.1 0.7 0.15 0.65 0.8 0.3 0.1 0.2 0.2 0.8 0.15

3 Mudgaurd collar fitment Mudguard s/a with collar & brace fender Torque checking (lower bolt) Put Painted set kit on conveyor 4 Mudguard tightning with nut runner Mudguard prefit Use mudguard spacer 5 Mudguard Torque checking Lift front wheel by tackle & keep in fork legs Apply grease on front axle & prefit on fork. Front br. Pannel locketing on wheel 6 F.Wheel insertion on fork with spacer Tight front wheel nut Prefit fr axle nut

7 Insert & bend the split pin Check the torque Swing arm torque checking Swing arm RH cap fitment Torque rod bolt prefit 8 Engine unloading Engine upper bolt insertion help 9 Engine bracket prefitment. (upper) Engine lower bolt nut prefit Engine bracket prefitment. (rear )

10 Engine bracket prefitment. (front lower) CDI connection Starter motor cable band remove 11 Rear Engine bolt tightening & torque checking 1,2,3,4,5,6,7, 12 Engine bolt tightening & torque checking 8,9,10 Rear Blinker Connection

13 Rear br pedal insertion with spring,grease Rear brake connection Rear brake switch srping conn. Rear brake pedal return spring fitment

14 Br pedal tightning with washer & loctite

R.r.unit fitment Rear brake padel torque checking

15 Rear br.padel adjustment bolt nut prefit

Rear br.padel adjustment

Rear br.padel grommet insertion 16 Rear br.light checking. Rear br.light rework Rh H T coil fitment Rear brake switch connection Rh Spark plug fit. 17 Fork both flap with blinker insertion Fork upper ring Lower rings fitment 18 Prefit fork side bolts Prefit stem nut with washer Fairing blinker & head light wire routing Front no plate bkt. Fitment 19 Loose fork front bolts Tight upper side bolts & apply torque Tight stem nut & apply torque Fairing center bolt insertion 20 Tight fork front bolts Fork front bolt torque checking Prefit front no. plate Fr. No plate tightening Fairing center bolt nut tightning 21 Harness routing Head lamp case insertion Harness connections RH side 22 Head lamp bolt insertion nut prefit Head lamp tightning Use head light position tool Handle bar cable routing 23 All harness connection 24 Tight Rear wheel nut & torque checking head light fitment While Rear wheel alig. Hold brake pedal Bellow insertion & OEN relay fitment 25 Acclarator cable routing Accl. Connection & play adjustment Clutch cable routing Clutch cable grommet fitment on cable Fixture locking with mallet 26 Silencer location on engine with tackle. Silencer front side nut prefitting Locate rear bolt on step holder 27 Silencer front side nut tightning & torq. Check Grab rail bolt prefit & tight 28 Rear bolt tightening (SILENCER) (14 mm) T.rod bolt tightening Snap pin fit Rear bolt torque checking 29 Clutch cable play adjustment Clutch connection prefit Rear br. Play adjustment Fit side panel with DG screw

0.2 0.7 0.2 0.1 0.3 0.1 0.1 0.8 0.2 0.1 0.2 0.5 0.2 0.1 0.1 0.3 0.7 0.2 0.2 0.2 0.1 0.7 0.1 0.2 0.1 0.2 0.1 0.7 0.3 0.4 0.7 0.3 0.2 0.2 0.7 0.8 0.2 0.4 0.2 0.8

Battery both connections Jelly application on battery 47 Stater relay one connection Starter motor grommet insertion Horn connection & harness routing Fuse box insertion 48 Carb. S/A locating on eng Carb. Insertion in A.C. box Carb.clip tightening A. C. box clip tightening Reed switch connection Carb. Drain pipe connection 49 H.Bar fit on line with fixture & torque checking 50 Seat cowl insertion Seat cowl tightening Tail lamp connection 51 27 mm nut tightening 27 mm nut torque checking Wheel alignment Both chain adjuster locking Harness center band Car. Breather pipe routing 52 Choke connection Fit engine breather pipe & clip 53 H.bar cable routing . Stater motar cable two band. 54 Front brake connection Chain case grommet fit. Fairing two connection ( switch) 55 Insert speedo grommet Fairing two connection remaining Speedometer lower connection Speedometer cable routing Side panel s/a & locking petrol tank lock fitment Bellow insertion LH.H. T.coil fitment&connection Petrol tank fuel gauge conection Cable routing Petrol tank fitment Snap pin fit. SAP data entry Zenda removing H.Lamp grommet s/a Seat cowl s/a

0.3 0.1 0.55 0.2 0.2 0.3 0.1 0.8 0.2 0.1 0.1 0.1 0.15 0.1 0.75 0.8 0.8 0.3 0.3 0.1 0.7 0.1 0.1 0.1 0.3 0.1 0.15 0.85 0.6 0.2 0.8 0.4 0.3 0.7 0.5 0.1 0.2 0.8 0.1 0.2 0.3 0.1 0.7 0.3 0.2 0.1 0.6 0.3 0.3 0.1 0.2 0.2 0.2 0.7

56 0.1 0.4 0.1 0.1 57 0.1 0.8 58 0.25 0.15 0.2 0.6 0.35 59 0.4 0.75 0.15 60 0.1 61 0.1 62 0.1 0.45 63 0.1 64 0.2 0.1 65 0.3 to 0.7 73

Carburetor s/a

Fairing s/a & handling

3 cell members from fairing s/a will come on line for k/s vehicles

74 Petrol tank s/a & handling to 80 81 Group Leader to 83 84 PV CHEKING 85 86 ON LINE CORRECTOR 87 88 RECTIFICATION 89 90 91 KIT BIN FILLING

Total cell members required 88

SUMMERY ON LINE FAIRING S/A & HANDLING SEAT COWL S/A & HANDLING P.TANK S/A & HANDLING CARBURETOR S/A GROUP LEADER LINE RECTIFIER P.V.CHECKING RECTIFICATION KIT BIN FILLING DYNO TESTING F/OK OUTPUT/ MAN DIRECT OUTPUT/ MAN INDIRECT DIRECT = ONLINE + ALL S/A 57 9 2 7 2 3 2 2 3 1 9 1 98 7.33 5.612

DISCOVER 650/SHIFT (PITCH TIME 0.74MIN. - 44 Sec)

WORK CONTENT Rear wheel loading on line Rear brake pannel fit. On rear wheel Load kit bin on the conveyor Rear wheel trolley replacement Wheel insertion on chassis Match rh chain adjuster & cut binding piece Mudgaurd bolt s/a & put on conveyor Mudgaurd collar fitment Mudguard s/a with collar & brace fender Put Painted set kit on conveyor Mudguard prefit Use mudguard spacer Torque checking ( upper dome nut) Mudguard tightning with nut runner Mudguard Torque checking Lift front wheel by tackle & keep in fork legs Apply grease on front axle & prefit on fork. Front br. Pannel locketing on wheel F.Wheel insertion on fork with spacer Torque checking (lower bolt) Tight front wheel nut Prefit fr axle nut Swing arm torque checking Insert & bend the split pin Check the torque Engine unloading Engine upper bolt insertion help Engine bracket prefitment. (upper) Engine lower bolt nut prefit Engine bracket prefitment. (rear ) Engine bracket prefitment. (front lower) CDI connection Starter motor cable band remove Rear Engine bolt tightening & torque checking 1,2,3,4,5,6,7, Engine bolt tightening & torque checking 8,9,10 Torque rod bolt prefit Br shaft grease application Rear br pedal insertion with spring, Rear brake connection Rear brake switch srping conn. Rear brake pedal return spring fitment TIME 0.2 0.1 0.1 0.08 0.68 0.3 0.2 0.2 0.7 0.3 0.2 0.1 0.7 0.5 0.1 0.1 0.7 0.2 0.2 0.2 0.6 0.2 0.1 0.3 0.1 0.7 0.2 0.1 0.1 0.2 0.1 0.7 0.3 0.4 0.7 0.3 0.1 0.3 0.7 0.4 0.15 0.15 0.7 0.7 0.7 0.3 0.2 0.1 0.6 0.1 0.3 0.1 0.2 0.7 46 Engine earthing connection Engine tightening & torque (3 nut) Magneto connection & routing 45 44 43 Engine tightening & torque (7 nut) Starter motor cable routing Chain case bolt s/a Engine rear bolt torque Swing arm cap fitment LH. 42 Engine front upper bkt. Positioning LH. Engine front lower bkt. Positioning LH. Engine lower bolt locating Engine rear upper bkt. Positioning LH. 41 Battery insertion Battery drain pipe position Battery arrester upper pad fitment Earthing cable routing 0.3 0.1 0.2 0.1 0.7 0.3 0.3 0.6 0.3 0.4 0.7 0.8 0.8 0.1 0.2 0.2 0.2 0.7 0.3 0.3 0.6 0.2 40 Starter relay one connection & insertion Help to swing arm centre torque Harness First band fitment 0.7 0.4 0.1 0.2 0.7 39 Harness routing 38 Paint application on no. punch Shock absorber lower nut torque checking Carburettor Drain pipe routing Battery base pad fitment 37 Shock absorber dome nut torque checking Position chassis on conveyor Insert rear wheel axle Apply grease on axle 36 Fork fitment Fork upper nut tightning by gun Fork nut prefit 35 Grease aplication Ball filling on races Bearing cone fitment Dust cover fitment 0.2 0.3 0.1 0.1 0.7 0.4 0.2 0.1 0.7 0.1 0.35 0.1 0.1 0.65 0.2 0.1 0.1 0.1 0.7 0.6 NO. WORK CONTENT 33 34 Locate chassis on no.punching m/c with tackle No punching & bearing race pressing Keep chassis on fork fit. Stage Put bearing races on m/c & reset green switch ( Unload kit bin during no punching cycle) TIME 0.15 0.35 0.1 0.1 0.7

WORK CONTENT Br pedal tightning with washer & loctite R.r.unit fitment Rear br.padel adjustment bolt nut prefit Rear br.padel adjustment Rear brake padel torque checking Rear br.light checking. Rear br.light rework Rh H T coil fitment with connection Rear brake switch connection Rh Spark plug fit. Front no plate bkt. Fitment Rear br.padel grommet insertion Fork both flap with blinker insertion Fork upper ring Lower rings fitment Prefit fork side bolts Prefit stem nut with washer Fairing blinker & head light wire routing Fairing center bolt insertion OEN relay fitment Loose fork front bolts Tight upper side bolts & apply torque Tight stem nut Tight fork front bolts Fork front bolt torque checking Prefit front no. plate Fr. No plate tightening Fairing center bolt nut tightning Harness routing Head lamp case insertion Handle bar cable routing Stem nut torque checking H.Bar RH housing cable routine Head lamp case bolt insertion Silencer gasket insertion Head lamp bolt insertion nut prefit Head lamp tightning Use head light position tool Harness connections RH side Blinker connection & Below insertion on coupl. Tight Rear wheel nut & torque checking Fixture locking with mallet While Rear wheel alig. Hold brake pedal Bellow insertion in fairing

TIME 0.2 0.4 0.6 0.15 0.35 0.1 0.6 0.2 0.1 0.3 0.1 0.7 0.1 0.3 0.2 0.6 0.2 0.1 0.2 0.5 0.2 0.1 0.1 0.1 0.15 0.65 0.2 0.2 0.2 0.6 0.1 0.2 0.1 0.2 0.1 0.7 0.2 0.4 0.6 0.6 0.1 0.25 0.15 0.1 0.6 0.2 0.2 0.2 0.6 0.6 0.6 0.6 0.2 0.1 0.2 0.1 0.6

NO. WORK CONTENT Chain routing 47 Battery arrester fitment Check chain tention & adjust Flasher connection 48 Handle bar holder s/a Fuse box insertion Stater motar cable one band. Chain case fitment Cover L.H.R.R s/a fitment 49 Gear shifter lever fitment Stater motar cable one band. Push one battery grommet on battery Battery both connections 50 Jelly application on battery Stater relay one connection Starter motor grommet insertion 51 Horn connection & harness routing Carb. S/A locating on eng Carb. Insertion in A.C. box 52 Carb.clip tightening A. C. box clip tightening Carb. Drain pipe connection Reed switch connection Handle bar prefit on veh 53 Car. Breather pipe routing H.Bar fit on line with fixture & torque checking Chain case grommet fit. 54 Seat cowl insertion Seat cowl tightening 55 Harness center band H.bar cable routing . 56 27 mm nut tightening 27 mm nut torque checking 57 Wheel alignment Both chain adjuster locking Choke connection 58 59 Tail lamp connection Fit engine breather pipe & clip LH.H. T.coil fitment & connection Front brake connection Fairing LH DG fitment 60 Speedometer lower connection Speedometer cable routing

TIME 0.2 0.2 0.6 0.15 0.1 0.2 0.1 0.15 0.7 0.65 0.3 0.1 0.15 0.55 0.15 0.3 0.1 0.55 0.2 0.2 0.3 0.7 0.2 0.1 0.1 0.1 0.1 0.6 0.15 0.3 0.15 0.6 0.5 0.1 0.6 0.3 0.3 0.6 0.1 0.5 0.6 0.1 0.1 0.1 0.3 0.6 0.6 0.6 0.1 0.2 0.3 0.6 0.5 0.1 0.6 0.3 0.1

Bar code sticker on0.1 p.v. card fit. Check no & stick bar 0.1 code sticker Declamp fixture 0.3

Fork loading on chute 0.2

Swing arm RH cap 0.1 fitment Pre fit nut on swing 0.1 arm 22 mm of rear axle Rear Blinker Connection 0.3

DISCOVER 550/SHIFT (PITCH TIME 0.87MIN.) ST WORK CONTENT G 1 Rear wheel loading on line Rear brake pannel fit. On rear wheel Load kit bin on the conveyor Rear wheel trolley replacement Mudgaurd bolt s/a 2 Wheel insertion on chassis Match rh chain adjuster & cut binding piece Swing arm center cap fitment Carburattor drain pipe routing Grease aplication Ball filling on races Pre fit nut on swing arm 22 mm of rear axle Rear shock absorber upper torque

TIME 0.2 Mutthu 0.1 0.2 0.05 0.3 0 .85 0.3 Ashok 0.1 0.1 0.07 0.57 0.4 0.2 Prasanna 0.1 0.1 0.8 0.5 0.1 0.05 0.05 0.1 0.8 0.4 0.1 0.05 0.55 0.2 0.2 0.2 0.6 0.2 0.1 0.4 0.1 0.8 0.3 0.2 0.2 0.7 0.1 0.4 0.2 0.7 0.3 0.2 Bangare

WORK CONTENT 22 Locate chassis on no.punching m/c with tackle 23 No punching & bearing race pressing Put bearing races on m/c & reset green switch ( Unload kit bin during no punching cycle) Bar code sticker on p.v. card fit. Shock absorber dome nut torque checking 24 Declamp fixture Position chassis on conveyor Insert rear wheel axle Apply grease on axle Help to swing arm centre torque 25 Shock absorber lower nut torque checking Check no & stick bar code sticker on fork Battery base pad fitment Battery insertion Swing arm cap fitment LH. Paint application on no. punch 26 Engine lower bolt locating Sachin Gurav Engine upper plate insertion Earthing cable prefit Rear bolt insertion LH spark plug connection 27 Engine front upper bkt. Positioning LH. Engine front lower bkt. Positioning LH. Engine tighteninhg (all 12 mm ) 28 Engine tightening & torque (all 14 mm) Starter motor cable routing Magneto connection & routing Anand 29 Engine earthing connection Starter motor cable two band Battery arrester fitment Chain routing 30 Check chain tention & adjust Chain case fitment Mahesh 31 Cover L.H.R.R fitment Gear shifter lever fitment Handle bar holder s/a 27 mm nut tightening 32 Carburattor below s/a Carb. S/A locating on eng Carb. Insertion in A.C. box Green clip on A Cbox Reed switch connection 33 Carb.clip tightening A. C. box clip tightening Carbuttor drain pipe connection Car. Vent pipe routing R R unit only connection Rear wheel 27 mm nut torque 0.1 Mishra 0.3 0.2 0.1 0.1 0.8 0.1 Dinesh 0.1 0.05 0.3 0.1 0.1 0.75 0.2 Mulage 0.2 0.1 0.1 0.1 0.7 0.2 0.3 0.3 0.8 0.3 0.3 0.2 0.8 0.1 0.2 0.3 0.2 0.8 0.2 0.5 0.7 0.3 0.2 0.2 0.1 0.8 0.3 0.1 0.2 0.1 0.1 0.8 0.2 0.1 0.1 0.2 0.1 0.1 Prakasham Selvam

Fork fitment Fork upper nut tightning by gun Bearing cone fitment Dust cover fitment Torque checking Fr mudgaurd s/a with brace fender & prefit Put Painted set kit on conveyor Swing arm center cap fitment Mudguard tightning with nut runner Mudguard Torque checking Chain case bolt s/a handle holder bolts/a Front br. Pannel locketing on wheel Lift front wheel by tackle & keep in fork legs Apply grease on front axle & prefit on fork.

Manoj

Datta

Annaso

Engine unloading Engine upper bolt insertion help Engine lower bolt nut prefit Engine bracket nut prefitment. (upper) Engine bracket prefitment. (rear ) & tightening Engine bracket pre fitment. (front lower)

Yadav

Ankush

Vivek

10 Engine bolt tightening & torque checking 8,9,10 Engine front brkt nuts tightening

11 Front wheel insertion in fork Prefit plain washer & nut Front wheel tightening Rh Spark plug fit. 12 Torque rod bolt prefit Rear brake connection Rear br.light checking. Rear br.light rework

0.8 0.2 0.1 0.2 0.1 0.2 0.2 0.1 0.1 0.6

Dudhal

Kutwal

Somnath

13 Tight Rear wheel nut & torque checking While Rear wheel alig. Hold brake pedal Prefit fork stem nut Prefit fork side bolts Fixture locking with mallet 14 Fairing insertion rear brake switch connection Fairing lower bolt insertion and nut prefit oen relay fitment

0.2 0.1 0.1 0.1 0.1 0.6 0.3 0.1 0.2 0.1 0.7 0.2 0.1 0.2 0.2 0.1 0.8 0.2 0.1 0.2 0.2 0.7 0.3 0.1 0.4 0.8 0.3 0.1 0.1 0.3 0.8 0.4 0.1 0.1 0.1 0.7 0.3 0.1 0.1 0.1 0.1 0..05 0.75 0.2 0.1 0.4 0.1 0.8

Wagh 34 Wheel alignment Both chain adjuster locking Rear mudflap tightening Battery drain pipe routing in arrester Sandesh 35 H.Bar fit on line with fixture & torque checking Insert speedo grommet 36 H.bar cable routing .(LH side) Fairing two connection remaining Side panel s/a Narayan 37 Seat cowl insertion Seat cowl tightening Tail lamp connection Chain case grommet fit. Sandeep 38 Choke connection R R unit prefit Fairing two connection ( switch) 39 Battery both connections Stater relay one connection Starter motor grommet insertion R R unit tightening ( condensor & unit conn k/s) 40 Harness blinker connections Push one battery grommet on battery Jelly application on battery Bellow insertion 41 Front brake connection Speedometer connection lower 42 Harness center band tightening OEN relay fitment Fairing LH DG screw tightening Fit engine breather pipe & clip 43 Petrol tank fitment Snap pin fit. Petrol tank lock fitment Petrol tank fuel gauge conection Hari 44 SAP data entry Painted flag removing Side panel locking

15 Fork lower bolt loosening Tightening stem nut Tightening fork upper bolts Tightening fork lower bolts Apply torque to stem nut 16 Prefit front no. plate Fr. No plate tightening H.Bar harness routing Fr brake & Accelerator cable routing 17 Harness connections RH side Fairing center bolt nut tightning RH H T Coil fitment 18 Silencer location on engine with tackle. Silencer front side nut prefitting Locate rear bolt on step holder Silencer front side nut tightning & torq. Check 19 Grab rail bolt prefit & tight Rear bolt tightening (SILENCER) (14 mm) T.rod bolt tightening Accelarator cable routing in center band 20 Accl. Connection & play adjustment Snap pin fit Rear brake play adjustment Clutch cable routing from chassis bkt. Fixture locking with mallet Rear brake switch connection 21 Fit side panel with DG screw Fairing RH DG Clutch connection prefit & play adjustment Below insertion on harness & in Fairing

More

Jayendra

Avinash

Birappa

0.8 0.3 0.2 0.2 0.1 0.8 0.6 0.1 0.7 0.2 0.2 0.4 0.8 0.3 0.2 0.1 0.1 0.7 0.4 0.2 0.2 0.8 0.3 0.2 0.1 0.2 0.8 0.2 0.1 0.1 0.3 0.7 0.5 0.3 0.8 0.1 0.3 0.1 0.2 0.7 0.3 0.1 0.2 0.1 0.7 0.1 0.2

Sagar

Subramani

Rahul

Prakash

Rajesh Patil

Mahesh Patil

Sandeep Patil

Bharam

Anand

SUMMERY
On Line OnLine P V comp Group Leader Line Rectifier Rectifier Inspector Total Output / man ( Direct) Output / man ( Indirect) 44 2 2 2 2 9 61 12.5 9.01 Tambat, Mukul Nitin , Chikane Pritish, Shewale Raja,

Silencer gasket fitment

0.1

DISCOVER 550/SHIFT (PITCH TIME 0.87MIN.) ST WORK CONTENT G 1 Rear wheel loading on line Rear brake pannel fit. On rear wheel Load kit bin on the conveyor Rear wheel trolley replacement 2 Wheel insertion on chassis Match rh chain adjuster & cut binding piece Pre fit nut on swing arm 22 mm of rear axle Put Painted set kit on conveyor Carburattor drain pipe routing 3 Grease aplication Ball filling on races Swing arm center axle torque Rear shock absorber upper torque 4 Fork fitment Fork upper nut tightning by gun Bearing cone fitment Dust cover fitment 5 Fr mudgaurd s/a with brace fender & prefit Mudgaurd bolt s/a Mudguard tightning with nut runner Mudguard Torque checking Rear mudflap bolt & collar s/a Chain case bolt s/a Front br. Pannel locketing on wheel Lift front wheel by tackle & keep in fork legs Apply grease on front axle & prefit on fork. Swing arm center cap fitment Engine unloading Engine upper bolt insertion help Engine lower bolt nut prefit Engine bracket nut prefitment. (upper) Engine bracket prefitment. (rear ) & tightening Engine bracket pre fitment. (front lower)

TIME WORK CONTENT 0.2 0.1 0.2 0.1 0.3 0.1 0.1 0.1 0.07 0.4 0.2 0.1 0.1 0.5 0.1 0.1 0.1 0.8 0.4 0.3 0.7 0.2 0.2 0.2 0.2 0.8 0.1 0.4 0.1 0.05 0.65 0.3 0.2 0.2 0.7 0.1 0.4 0.2 0.7 0.3 0.2 0.2 0.1 0.8 0.2 0.1 0.2 0.1 0.1 0.7 0.2 0.1 0.15 0.1 0.1 0.65

10 Engine bolt tightening & torque checking 8,9,10 Engine front brkt nuts tightening Torque rod bolt prefit Rh Spark plug fit. 11 Front wheel insertion in fork Prefit plain washer & nut Front wheel tightening Fairing brkt prefit Rear mudflap locating 12 Rear brake connection Rear br.padel adjustment Rear br.padel grommet insertion Rear br.light checking. Rear br.light rework

13 Tight Rear wheel nut & torque checking While Rear wheel alig. Hold brake pedal Front no plate bkt.tightening Rear mudflap tightening Silencer gasket fitment 14 Fairing insertion rear brake switch connection Fairing lower bolt insertion Prefit fork stem nut Prefit fork side bolts 15 Fork lower bolt loosening Tightening stem nut Tightening fork upper bolts Tightening fork lower bolts Apply torque to stem nut 16 Prefit front no. plate Fr. No plate tightening H.Bar harness routing Fr brake & Accelerator cable routing 17 Harness connections RH side Fairing center bolt nut tightning RH H T Coil fitment 18 Silencer location on engine with tackle. Silencer front side nut prefitting Locate rear bolt on step holder Silencer front side nut tightning & torq. Check 19 Grab rail bolt prefit & tight Rear bolt tightening (SILENCER) (14 mm) T.rod bolt tightening Accelarator cable routing in center band 20 Accl. Connection & play adjustment Snap pin fit Rear brake play adjustment Clutch cable routing from chassis bkt. Fixture locking with mallet Rear brake switch connection 21 Fit side panel with DG screw Fairing RH DG Clutch connection prefit & play adjustment Below insertion on harness & in Fairing Locate chassis on no.punching m/c with tackle No punching & bearing race pressing Put bearing races on m/c & reset green switch ( Unload kit bin during no punching cycle) Bar code sticker on p.v. card fit. Shock absorber dome nut torque checking Declamp fixture Position chassis on conveyor Insert rear wheel axle Apply grease on axle Help to swing arm centre torque Shock absorber lower nut torque checking Check no & stick bar code sticker on fork Battery base pad fitment

0.2 0.1 0.1 0.2 0.1 0.7 0.3 0.1 0.1 0.1 0.1 0.7 0.2 0.1 0.2 0.2 0.1 0.8 0.2 0.1 0.2 0.2 0.7 0.3 0.1 0.4 0.8 0.3 0.1 0.1 0.3 0.8 0.4 0.1 0.1 0.1 0.7 0.3 0.1 0.1 0.1 0.1 0..05 0.75 0.2 0.1 0.4 0.1

Tambat, Mukul Nitin , Chikane Pritish, Shewale 0.1 Raja, 0.3 0.2 0.1 0.1 0.8 0.1 0.1 0.05

Battery insertion Swing arm cap fitment LH. Paint application on no. punch Engine lower bolt locating Engine upper plate insertion Earthing cable prefit Rear bolt insertion LH spark plug connection Engine front upper bkt. Positioning LH. Engine front lower bkt. Positioning LH. Engine tighteninhg (all 12 mm ) Engine tightening & torque (all 14 mm) Starter motor cable routing Magneto connection & routing Engine earthing connection Starter motor cable two band Battery arrester fitment Chain routing

0.3 0.1 0.1 0.75 0.2 0.2 0.1 0.1 0.1 0.7 0.2 0.3 0.3 0.8 0.3 0.3 0.2 0.8 0.1 0.2 0.3 0.2

DISCOVER 900/SHIFT (PITCH TIME 0.53 MIN.) ST WORK CONTENT G 1 Rear wheel loading on line Load kit bin on the conveyor Rear wheel trolley replacement 2 Match rh chain adjuster & cut binding piece Rear brake pannel fit. On rear wheel Grease aplication Bearing cage fitment 3 Fork fitment Fork upper nut tightning by gun Bearing cone fitment Dust cover fitment Fork torque checking 4 Swing arm center axle torque Put Painted set kit on conveyor Take the mudgaurd bolt on line. Swing arm center cap fitment 5 Fr mudgaurd s/a with brace fender & prefit

TIM E 0.2 0.2 0.1 0.5 0.1 0.1 0.2 0.1 0.5 0.3 0.1 0.1 0.1

WORK CONTENT 28 Locate chassis on no.punching m/c with tackle Bar code sticker on p.v. card fit. 29 No punching & bearing race pressing Declamp chassis from m/c Chain routing Chain adjustor band removing 30 Position chassis on conveyor Earthing cable bolt s/a 31 Paint application on no. punch Axle insertion with grease aplication Battery base pad fitment

TIME

6 Mudguard tightning with nut runner Mudguard Torque checking 7 Front br. Pannel locketing on wheel Lift front wheel by tackle & keep in fork legs Apply grease on front axle & prefit on fork. 8 Engine unloading Engine upper bolt insertion help 9 Engine bracket nut prefitment. (upper) Engine Front bkt positining with bolt insertion 10 Engine bracket rear tightning Engiine Upper bracket tightening 11 Engine bolt tightening & torque checking ( 14 mm) Br. Rod rubber band removing 12 Engine Front bkt nut prefit & tightning Rear brake connection 13 Front wheel insertion in fork Front wheel tightening & torqe checking 14 Handle holder bolt s/a & put on chassis Torque rod bolt prefit Pre fit nut on swing arm 22 mm of rear axle 15 Fairing insertion with cable routing Fairing lower bolt insertion 16 Tight Rear wheel nut & torque checking Rear brake play adjustment Veh.fixture clamping 17 T.rod bolt tightening Fork lower bolt loosening Tightening fork upper bolts & stem nut Tightening fork lower bolts 18 Fairing lower bolt nut prefit Rh Spark plug fit. Prefit stem nut & side bolt 19 Prefit front no. plate H.T.coil fitment with connection

0.5 0.1 32 C D I Fitment with connection 0.1 Battery drain pipe routing 0.2 Carburattor drain pipe routing 0.1 0.5 33 Check no & application of sticker on chassis 0.4 Battery insertion Battery arrester routing & prefit 0.4 Earthing cable routing 0.3 0.2 34 Battery arrester fitment ( only in E/S ) 0.5 Engine all bkt. Put on conveyor 0.1 Battery drain pipe routing in arrester 0.3 0.1 35 Fixture declamping 0.5 Help to swing arm center torque checking 0.3 Swing arm cap fitment LH. 0.2 Insert bolt in engine bkt. 0.5 0.2 36 Engine lower bolt locating 0.3 Bolt insertion in rear bkt (14) 0.5 Rear bolt insertion 0.2 Magneto cable routine in chassis bkt. 0.3 0.5 37 Engine front lower bkt. Positioning LH.nut prefit 0.4 Engine upper plate insertion 0.1 LH spark plug connection 0.5 0.2 38 Rear bkt.tightning with holding earthing cable 0.3 Engine fr.bkt.nut prefit & tighteninhg ( 12 mm ) 0.5 Engine earthing connection 0.2 0.2 39 Engine tightening & torque (all 14 mm) 0.4 A.C.box clip fitment 0.2 0.2 40 Magneto connection & routing 0.1 Starter motor cable routing with rubber band removing 0.5 0.4 41 Chain routing 0.1 chain adjustor nut loosing 0.5 0.2 42 Check chain tention & adjust 0.2 Chain case prefit. 0.1 Gear shifter lever & r.r.cover keep on conveyor 0.5 0.1 43 Chain case tightening 0.1 Starter motor cable upper band fitment 0.2 Choke nut removing 0.1 0.5 44 27 mm nut tightening 0.2 Cover L.H.R.R fitment 0.1 Gear shifter lever fitment 0.2 0.5 45 Carb. S/A locating on eng 0.2 Reed switch connection 0.3 Carb.clip tightening 0.5

0.1 0.1 0.1 0.2 0.5 0.3 0.1 0.4 0.2 0.2 0.1 0.5 0.3 0.1 0.1 0.5 0.1 0.2 0.1 0.1 0.5 0.3 0.1 0.1 0.5 0.1 0.1 0.1 0.2 0.5 0.2 0.1 0.1 0.1 0.5 0.3 0.1 0.1 0.5 0.2 0.2 0.1 0.5 0.4 0.1 0.5 0.3 0.2 0.5 0.3 0.2 0.5 0.1 0.3 0.1 0.5 0.2 0.2 0.1 0.5 0.2 0.2 0.1 0.5 0.2 0.1 0.2 0.5

20 H.Bar harness routing Fr brake & Accelerator cable routing Accelarator cable routing in band & band tightening 21 Fr. No plate tightening Silencer gasket fitment Apply torque to stem nut

0.2 0.2 0.1 0.5 0.2 0.1 0.1 0.4 0.4 0.1 0.5 0.3 0.2 0.5 0.2 0.2 0.1 0.5 0.1 0.3 0.1 0.5 0.4 0.1 0.5 0.1 0.2 0.2 0.1 0.6

46 Starter motor cable lower band fitment Starter motor cable lower band fitment Carbuttor drain pipe connection 47 Wheel alignment Both chain adjuster locking Car. Vent pipe routing with band 48 Put handle bar on veh. Prefit handle holder bolts. 49 Handle bar tightening & position adjustment Speedo cable routing & oil seal fitment 50 H.bar cable routing .(LH side) Seat cowl insertion 51 Choke connection

22 Harness connection Rh. All Below insertion on harness & in Fairing 23 Silencer location on engine with tackle. Silencer front side nut prefitting 24 Silencer front side nut tightning Locate rear bolt of silencer on step holder Clutch cable routing from chassis bkt. 25 Rear bolt tightening (SILENCER) (14 mm) & torque checking Grab rail bolt prefit & tight Torque rod Snap pin fit 26 Accl. Connection & play adjustment Kit bin removing 27 Clutch connection prefit Clutch connection play adjustment Fit side panel with DG screw Fairing RH DG screw tightenimg

0.2 0.2 0.1 0.5 0.2 0.2 0.2 0.6 0.3 0.2 0.5 0.4 0.1 0.5 0.2 0.3 0.5 0.4 0.4 0.2 0.2 0.1 0.5 0.4 0.1 0.5 0.4 0.1 0.1 0.6 0.1 0.2 0.1 0.1 0.5 0.4 0.1 0.5 0.3 0.1 0.1 0.5 0.5 0.4 0.1 0.5 0.1 0.2 0.1 0.4

52 Fit engine breather pipe & clip Seat cowl tightening Tail lamp connection 53 Below connections ( All ) Below insertion 54 Battery both connections Jelly application on battery Push one battery grommet on battery 55 Fairing LH DG screw tightening Stater relay one connection Starter motor grommet insertion Fairing lower bolt nut tightning 56 Side panel lock s/a O.E.N. fitment & fuel gauge coupler removing 57 Petrol tank fitment Petrol tank fuel gauge conection Snap pin fit. 58 Front brake connection 59 Speedometer connection lower Painted flag removing 60 SAP data entry Petrol tank lock fitment Side panel locking

1 2 3 4 5 6

SUMMARY ON LINE ON LINE P.V. CHECKING ON LINE COMPLITION GROUP LEADER RECTIFIER INSPECTOR TOTAL DIRECT OUT PER MAN INDIRECT OUT PER MAN

60 2 2 2 2 12 80 16 11.4

49 16.36363636 16.32653061

DISCOVER 800/SHIFT (PITCH TIME 0.60 MIN.) ST WORK CONTENT G 1 Rear wheel loading on line Load kit bin on the conveyor Rear wheel trolley replacement Mudgaurd bolt s/a 2 Match rh chain adjuster & cut binding piece Swing arm center axle torque Rear brake pannel fit. On rear wheel Carburattor drain pipe routing 3 Grease aplication Ball filling on races 4 Fork fitment Fork upper nut tightning by gun Bearing cone fitment Dust cover fitment Fork torque checking 5 Fr mudgaurd s/a with brace fender & prefit Put Painted set kit on conveyor 6 Mudguard tightning with nut runner Mudguard Torque checking Chain case bolt s/a 7 Front br. Pannel locketing on wheel Lift front wheel by tackle & keep in fork legs Apply grease on front axle & prefit on fork. Rear shock absorber upper torque Swing arm center cap fitment 8 Engine unloading Engine upper bolt insertion help 9 Engine bracket nut prefitment. (upper) Engine Front bkt positining with bolt insertion Engine bracket rear tightning

TIM E 0.2 0.2 0.1 0.2 0.7 0.1 0.1 0.1 0.2 0.5 0.2 0.4 0.6 0.3 0.1 0.1 0.1 0.1 0.6 0.4 0.1 0.5 0.3 0.2 0.2 0.7 0.1 0.3 0.1 0.1 0.1 0.5 0.3 0.2 0.5 0.1 0.3 0.2 0.6 0.5 0.1 0.6 0.3 0.1 0.1 0.5 0.2 0.2 0.2 0.6 0.3 0.2 0.1 0.1 0.7 0.4 0.1 0.1 0.6 0.2 0.2 0.1 0.1 0.6

STAGE OWNER

WORK CONTENT 25 Locate chassis on no.punching m/c with tackle Bar code sticker on p.v. card fit. 26 No punching & bearing race pressing Put bearing races on m/c & reset green switch Declamp chassis from m/c Battery base pad fitment A.C.box clip fitment 27 Position chassis on conveyor Help to swing arm center torque checking Engine all bkt. Put on conveyor 28 Paint application on no. punch Insert bolt in engine bkt. Insert rear wheel axle 29 Check no & application of sticker on chassis Battery insertion Fixture declamping Battery arrester routing & prefit Rear br. Switch cable routine 30 Engine lower bolt locating Bolt insertion in rear bkt (14) Rear bolt insertion Magneto cable routine in chassis bkt. 31 Engine front lower bkt. Positioning LH.nut prefit Engine upper plate insertion LH spark plug connection 32 Rear bkt.tightning with holding earthing cable Engine fr.bkt. tighteninhg ( 12 mm ) 5 bolt Starter motor cable routing with rubber band removing 33 Engine tightening & torque (all 14 mm) Starter motor cable lower band fitment Swing arm cap fitment LH. 34 Engine earthing connection Battery drain pipe routing in arrester Battery arrester fitment ( only in E/S ) 35 Chain routing Magneto connection & routing Check chain tention & adjust 36 Chain case prefit. Chain case tightening 37 27 mm nut tightening Cover L.H.R.R fitment Gear shifter lever fitment 38 Carb. S/A locating on eng Carb.clip tightening Reed switch connection Choke nut removing

TIME

0.1 0.1 0.1 0.3 0.1 0.1 0.5 0.2 0.1 0.2 0.5 0.1 0.2 0.1 0.1 0.1 0.6 0.2 0.1 0.1 0.1 0.5 0.3 0.1 0.1 0.5 0.2 0.1 0.3 0.6 0.3 0.15 0.1 0.55 0.2 0.1 0.3 0.6 0.2 0.2 0.2 0.6 0.3 0.3 0.6 0.1 0.3 0.2 0.6 0.2 0.2 0.1 0.1 0.6 0.2 0.2 0.2 0.6

10 Engiine bracket tightening (14) Engine Front bkt nut prefit Engine bolt tightening & torque checking ( All 12 mm ) 5 nut 11 Rh Spark plug fit. Br. Rod rubber band removing 12 Front wheel insertion in fork Front wheel tightening & torqe checking Handle holder bolt s/a & put on chassis 13 Rear brake connection Torque rod bolt prefit Rear br.light checking. Rear br.light rework 14 Fairing insertion with cable routing Fairing lower bolt insertion Fairing lower bolt nut prefit 15 Tight Rear wheel nut & torque checking Prefit stem nut & side bolt Pre fit nut on swing arm 22 mm of rear axle Veh.fixture clamping

39 Wheel alignment Both chain adjuster locking Car. Vent pipe routing with band

16 Rear brake switch connection Fork lower bolt loosening Tightening fork upper bolts & stem nut Tightening fork lower bolts 17 Prefit front no. plate H.T.coil fitment with connection Silencer gasket fitment 18 Fr. No plate tightening H.Bar harness routing Fr brake & Accelerator cable routing 19 Apply torque to stem nut Harness connection Rh. All Below insertion on harness & in Fairing 20 Silencer location on engine with tackle. Silencer front side nut prefitting Locate rear bolt of silencer on step holder 21 Silencer front side nut tightning Clutch cable routing from chassis bkt. Rear bolt tightening (SILENCER) (14 mm) & torque checking T.rod bolt tightening 22 O.E.N. fitment Grab rail bolt prefit & tight Accelarator cable routing in band & band tightening 23 Accelarator cable routing in band & band tightening Accl. Connection & play adjustment Kit bin removing

0.1 0.1 0.2 0.2 0.6 0.2 0.3 0.1 0.6 0.2 0.2 0.2 0.6 0.1 0.4 0.1 0.6 0.3 0.2 0.1 0.6 0.2 0.2 0.1 0.1 0.6 0.1 0.4 0.1 0.6 0.1 0.4 0.1 0.6 0.1 0.2 0.2 0.1 0.6

40 Put handle bar on veh. Prefit handle holder bolts. Speedo cable routing & oil seal fitment 41 Handle bar tightening & position adjustment H.bar cable routing .(LH side) 42 Choke connection Fit engine breather pipe & clip 43 Side panel lock s/a Carbuttor drain pipe connection Fairing LH DG screw tightening 44 Seat cowl insertion Seat cowl tightening Tail lamp connection 45 Below connections ( All ) Starter motor cable upper band fitment 46 Battery both connections Chain case grommet fit. 47 Push one battery grommet on battery Jelly application on battery Stater relay one connection Starter motor grommet insertion Fairing lower bolt nut tightning 48 Petrol tank fitment Petrol tank fuel gauge conection Snap pin fit. Central band tightening & routine 49 Speedometer connection lower Front brake connection 50 SAP data entry Below insertion Petrol tank lock fitment Other activities * Side panel locking Painted flag removing On line inspection On line complition

24 Clutch connection prefit Clutch connection play adjustment Fit side panel with DG screw Fairing RH DG screw tightenimg

Rear brake play adjustment On line inspection On line complition SUMMARY ON LINE ON LINE P.V. CHECKING ON LINE COMPLITION GROUP LEADER RECTIFIER INSPECTOR TOTAL DIRECT OUT PER MAN INDIRECT OUT PER MAN

0.2

0.3 0.3 0.1 0.6 0.4 0.2 0.6 0.4 0.2 0.6 0.4 0.1 0.1 0.6 0.3 0.2 0.1 0.6 0.4 0.15 0.55 0.4 0.1 0.5 0.1 0.1 0.2 0.1 0.1 0.6 0.35 0.1 0.1 0.05 0.6 0.1 0.5 0.6 0.2 0.1 0.1 0.2 0.6 0.2 0.1

1 2 3 4 5 6

50 2 2 2 2 12 70 16 11.4

STAGE OWNER

DISCOVER 800/SHIFT (PITCH TIME 0.60 MIN.) ST WORK CONTENT G 1 Rear wheel loading on line Rear brake pannel fit. On rear wheel Load kit bin on the conveyor Rear wheel trolley replacement 2 Wheel insertion on chassis Match rh chain adjuster & cut binding piece Put Painted set kit on conveyor

Remark

WORK CONTENT 30 Locate chassis on no.punching m/c with tackle 31 No punching & bearing race pressing 32 Put bearing races on m/c & reset green switch ( Unload kit bin during no punching cycle) Bar code sticker on p.v. card fit. 33 Declamp fixture Position chassis on conveyor Insert rear wheel axle 34 Shock absorber lower nut torque checking Shock absorber dome nut torque checking Paint application on no. punch Carburattor drain pipe routing Help to swing arm center torque checking 35 Fork torque checking Battery base pad fitment Battery insertion Swing arm cap fitment LH. 36 Engine lower bolt locating Engine upper plate insertion Rear bolt insertion 37 Earthing cable prefit Engine front upper bkt. Positioning LH. Engine front lower bkt. Positioning LH. 38 Engine tighteninhg (all 12 mm ) LH spark plug connection 39 Engine tightening & torque (all 14 mm) Starter motor cable routing

Remark

3 Grease aplication Ball filling on races 4 Fork fitment Fork upper nut tightning by gun Bearing cone fitment Dust cover fitment 5 Mudgaurd bolt s/a Rear mudflap bolt & collar s/a Pre fit nut on swing arm 22 mm of rear axle 6 Fr mudgaurd s/a with brace fender & prefit Swing arm center axle torque 7 Mudguard tightning with nut runner Mudguard Torque checking 8 Front br. Pannel locketing on wheel Lift front wheel by tackle & keep in fork legs Apply grease on front axle & prefit on fork. Rear shock absorber upper torque 9 Engine unloading Engine upper bolt insertion help

10 Engine lower bolt nut prefit Engine bracket nut prefitment. (upper) Engine rear bracket prefit only 11 Engine bracket pre fitment. (front lower) Engiine rear bracket tightening 12 Engine bolt tightening & torque checking ( All 12 mm ) Swing arm center cap fitment 13 Engine tightening & torque checking (All 14 mm ) Torque rod bolt prefit 14 Front wheel insertion in fork Front wheel tightening Rh Spark plug fit. 15 Rear brake connection Rear br.light checking. Rear br.light rework 16 Rear brake switch connection Tight Rear wheel nut & torque checking While Rear wheel alig. Hold brake pedal Rear brake padel torque 17 Fairing insertion Fairing lower bolt insertion Fairing lower bolt nut prefit 18 Prefit fork stem nut Prefit fork side bolts Fork lower bolt loosening 19 Tightening stem nut Tightening fork upper bolts Tightening fork lower bolts Apply torque to stem nut

40 Engine earthing connection Starter motor cable two band 41 Battery arrester fitment ( only in E/S ) Chain routing Green clip on A Cbox 42 Check chain tention & adjust Chain case prefit. 43 Chain case bolt s/a Chain case tightening 27 mm nut tightening 44 Cover L.H.R.R fitment Gear shifter lever fitment 45 Carb. S/A locating on eng Carb. Insertion in A.C. box Reed switch connection 46 Carb.clip tightening A. C. box clip tightening Carbuttor drain pipe connection Car. Vent pipe routing 47 Wheel alignment Both chain adjuster locking Battery drain pipe routing in arrester 48 Put handle bar on veh. Prefit handle holder bolts. 49 Handle bar tightening & torque checking Magneto connection & routing 50 H.bar cable routing .(LH side) Below connections ( All )

20 Prefit front no. plate Fr. No plate tightening Silencer gasket fitment 21 H.Bar harness routing Fr brake & Accelerator cable routing Fairing lower bolt nut tightning 22 Harness connections RH side RH H T coil fitment 23 Silencer location on engine with tackle. Silencer front side nut prefitting 24 Locate rear bolt of silencer on step holder Silencer front side nut tightning & torq. Check Fixture locking with mallet 25 Rear bolt tightening (SILENCER) (14 mm) T.rod bolt tightening Torque rod Snap pin fit 26 Grab rail bolt prefit & tight Accelarator cable routing in band & band tightening 27 Accl. Connection & play adjustment Clutch cable routing from chassis bkt. 28 Clutch connection prefit & play adjustment Below insertion on harness & in Fairing 29 Fit side panel with DG screw Fairing RH DG screw tightenimg Rear brake play adjustment

51 Seat cowl insertion Seat cowl tightening 52 Choke connection 53 Tail lamp connection & routing Fit engine breather pipe & clip Chain case grommet fit. 54 Battery both connections Fairing LH DG screw tightening 55 Push one battery grommet on battery Jelly application on battery Stater relay one connection Starter motor grommet insertion 56 Bellow insertion Side panel lock s/a 57 Front brake connection Speedo cable grommet fitment 58 Petrol tank fitment Petrol tank fuel gauge conection 59 Snap pin fit. Petrol tank lock fitment Side panel locking 60 Speedometer connection lower Painted flag removing 61 SAP data entry

DISCOVER 800/SHIFT (PITCH TIME 0.60 MIN.) ST WORK CONTENT G 1 Rear wheel loading on line Load kit bin on the conveyor Rear wheel trolley replacement Mudgaurd bolt s/a 2 Match rh chain adjuster & cut binding piece Swing arm center axle torque Rear brake pannel fit. On rear wheel Carburattor drain pipe routing 3 Grease aplication Ball filling on races 4 Fork fitment Fork upper nut tightning by gun Bearing cone fitment Dust cover fitment Fork torque checking 5 Fr mudgaurd s/a with brace fender & prefit Put Painted set kit on conveyor 6 Mudguard tightning with nut runner Mudguard Torque checking Chain case bolt s/a 7 Front br. Pannel locketing on wheel Lift front wheel by tackle & keep in fork legs Apply grease on front axle & prefit on fork. Rear shock absorber upper torque Swing arm center cap fitment 8 Engine unloading Engine upper bolt insertion help 9 Engine bracket nut prefitment. (upper) Engine Front bkt positining with bolt insertion Engine bracket rear tightning

TIM E 0.2 0.2 0.1 0.2 0.7 0.1 0.1 0.1 0.2 0.5 0.2 0.4 0.6 0.3 0.1 0.1 0.1 0.1 0.6 0.4 0.1 0.5 0.3 0.2 0.2 0.7 0.1 0.3 0.1 0.1 0.1 0.5 0.3 0.2 0.5 0.1 0.3 0.2

STAGE OWNER

WORK CONTENT 25 Locate chassis on no.punching m/c with tackle Bar code sticker on p.v. card fit.

TIME

26 No punching & bearing race pressing Put bearing races on m/c & reset green switch Declamp chassis from m/c Battery base pad fitment A.C.box clip fitment 27 Position chassis on conveyor Help to swing arm center torque checking Engine all bkt. Put on conveyor 28 Paint application on no. punch Insert bolt in engine bkt. Insert rear wheel axle

0.1 0.1 0.1 0.3 0.1 0.1 0.5 0.2 0.1 0.2 0.5 0.1 0.2 0.1 0.1 0.1 0.6 0.2 0.1 0.1 0.1 0.5 0.3 0.1 0.1 0.5 0.2 0.1 0.3 0.6 0.3 0.15 0.1 0.55 0.2 0.1 0.3 0.6 0.2 0.2 0.2 0.6 0.3 0.3 0.6 0.1 0.3 0.2 0.6 0.2 0.2 0.1 0.1 0.6 0.2 0.2 0.2 0.6

MUTHUSAMI

ASHOK MOKAL

BANGRE

DINESH PATIL

29 Check no & application of sticker on chassis Battery insertion Fixture declamping Battery arrester routing & prefit Rear br. Switch cable routine 30 Engine lower bolt locating Bolt insertion in rear bkt (14) Rear bolt insertion Magneto cable routine in chassis bkt. 31 Engine front lower bkt. Positioning LH.nut prefit Engine upper plate insertion LH spark plug connection 32 Rear bkt.tightning with holding earthing cable Engine fr.bkt. tighteninhg ( 12 mm ) 5 bolt Starter motor cable routing with rubber band removing 33 Engine tightening & torque (all 14 mm) Starter motor cable lower band fitment Swing arm cap fitment LH. 34 Engine earthing connection Battery drain pipe routing in arrester Battery arrester fitment ( only in E/S ) 35 Chain routing Magneto connection & routing Check chain tention & adjust 36 Chain case prefit. Chain case tightening 37 27 mm nut tightening Cover L.H.R.R fitment Gear shifter lever fitment 38 Carb. S/A locating on eng Carb.clip tightening Reed switch connection Choke nut removing

ASHPAK

MAHESH PATIL

SAMI

ANKUSH

10 Engiine bracket tightening (14) Engine Front bkt nut prefit Engine bolt tightening & torque checking ( All 12 mm ) 5 nut 11 Rh Spark plug fit. Br. Rod rubber band removing 12 Front wheel insertion in fork Front wheel tightening & torqe checking Handle holder bolt s/a & put on chassis 13 Rear brake connection Torque rod bolt prefit Rear br.light checking. Rear br.light rework 14 Fairing insertion with cable routing Fairing lower bolt insertion Fairing lower bolt nut prefit 15 Tight Rear wheel nut & torque checking Prefit stem nut & side bolt Pre fit nut on swing arm 22 mm of rear axle Veh.fixture clamping

0.6 0.5 0.1 GAJANAN 0.6 0.3 0.1 0.1 RAHUL 0.5 0.2 0.2 0.2 DATTA DHUDHAL 0.6 0.3 0.2 0.1 0.1 PRASANNA 0.7 0.4 0.1 0.1 * 0.6 0.2 0.2 0.1 0.1 ABHIJIT PAWAR 0.6

39 Wheel alignment Both chain adjuster locking Car. Vent pipe routing with band

16 Rear brake switch connection Fork lower bolt loosening Tightening fork upper bolts & stem nut Tightening fork lower bolts 17 Prefit front no. plate H.T.coil fitment with connection Silencer gasket fitment 18 Fr. No plate tightening H.Bar harness routing Fr brake & Accelerator cable routing 19 Apply torque to stem nut Harness connection Rh. All Below insertion on harness & in Fairing 20 Silencer location on engine with tackle. Silencer front side nut prefitting Locate rear bolt of silencer on step holder 21 Silencer front side nut tightning Clutch cable routing from chassis bkt. Rear bolt tightening (SILENCER) (14 mm) & torque checking T.rod bolt tightening 22 O.E.N. fitment Grab rail bolt prefit & tight Accelarator cable routing in band & band tightening 23 Accelarator cable routing in band & band tightening Accl. Connection & play adjustment Kit bin removing

0.1 0.1 0.2 0.2 0.6 0.2 0.3 0.1 0.6 0.2 0.2 0.2 0.6 0.1 0.4 0.1 0.6 0.3 0.2 0.1 0.6 0.2 0.2 0.1 0.1 0.6 0.1 0.4 0.1 0.6 0.1 0.4 0.1 0.6 0.1 0.2 0.2 0.1 0.6

40 Put handle bar on veh. Prefit handle holder bolts. Speedo cable routing & oil seal fitment
SAGAR

41 Handle bar tightening & position adjustment H.bar cable routing .(LH side)
AVINASH

42 Choke connection Fit engine breather pipe & clip 43 Side panel lock s/a Carbuttor drain pipe connection Fairing LH DG screw tightening 44 Seat cowl insertion Seat cowl tightening Tail lamp connection 45 Below connections ( All ) Starter motor cable upper band fitment 46 Battery both connections Chain case grommet fit.

NARAYAN SAMI

RAHUL DESHPANDE

BIRAPPA

JAY

GANESH KUTWAL

47 Push one battery grommet on battery Jelly application on battery Stater relay one connection Starter motor grommet insertion Fairing lower bolt nut tightning 48 Petrol tank fitment Petrol tank fuel gauge conection Snap pin fit. Central band tightening & routine 49 Speedometer connection lower Front brake connection

ABDULLAH

24 Clutch connection prefit Clutch connection play adjustment Fit side panel with DG screw Fairing RH DG screw tightenimg

WAUGH

50 SAP data entry Below insertion Petrol tank lock fitment Other activities

Rear brake play adjustment On line inspection On line complition SUMMARY ON LINE ON LINE P.V. CHECKING ON LINE COMPLITION GROUP LEADER RECTIFIER INSPECTOR TOTAL DIRECT OUT PER MAN INDIRECT OUT PER MAN

0.2

GIRISH TAMBAT

* Side panel locking Painted flag removing

0.3 0.3 0.1 0.6 0.4 0.2 0.6 0.4 0.2 0.6 0.4 0.1 0.1 0.6 0.3 0.2 0.1 0.6 0.4 0.15 0.55 0.4 0.1 0.5 0.1 0.1 0.2 0.1 0.1 0.6 0.35 0.1 0.1 0.05 0.6 0.1 0.5 0.6 0.2 0.1 0.1 0.2 0.6 0.2 0.1

SANDESH

On line inspection On line complition

1 2 3 4 5 6

50 2 2 2 2 12 70 16 11.4

STAGE OWNER MANISH

RAHUL

AMBUMANI

SELVAM

GANESH MULGE

MAHESH KADAM

GANESH BADE

S ANAND

ABHI KANSE

ANNA LAGARE DATTA JADHAV

SOMNATH

SANTOSH KANSE

SUBRAMAN I

* SANTOSH JADHAV

RAJA PATIL

SANDIP RATHOD

PRAKASH JADHAV

MAHENDRA SANDIP PATIL

DATTA SELVE

RAHUL BAWALKAR

HARI

RAJA PAWAR SUNIL MORE