4D Study on the Vehicle Assembly lines Conveyor B (Discover Line) Operations Chassis unloading Number punching Rear wheel

loading Kit bin loading Putting brg. race on no. punching m/c Loading chassis on fixture Painting the punched no. Putting engine mtg. bolts Greasing the brg. race Putting in the ball cage Rear brake drum fitment Rear axle fitment Putting 4 bolts on conv. for mudguard Front Fork insertion Brg. cone, dust cap, fork nut fitment A.C. box clamp fitment Carb. drainpipe routing Loading panel jig on conveyor Batt. drainpipe routing Batt. pad & batt. fitment Swingarm cap fitment Brass fender & front mudguard free fitting CDI unit fitment Handlebar holder preparation Front mudguard bolt tightening Front brake drum fitment (HP) Spacer fitment on front wheel Front axle greasing and placement Front wheel fitment Engine insertion Front left bracket fitment 2 nos mtg. bolts insertion Upper left bracket fitment Upper right bracket & nut free fitting Rear right plate bolts free fitting RH side spark plug connection 4D Study on the Vehicle Assembly lines Distance Danger / / / / / / x x x x x x x / x x / x / x x x x x x x x x x x x x x x x x / x x x x x x x x x / x x x x x x x x x / x / x x x x x x x x x x x x x Difficulty Dirt x x / x / x x x x x x x x / x x x x x x x x x x x x x x x x / x x x x x x x x x x x / x x x x x x x x x x x x x / x / x x x x x x x x x x x x x Suggestions Reposition of lift; Sensor or more powerful warning arrangemnt, Helmet Portable no. punching; Progressive action switch 4-wheel castor setup or auto trolley loader; Provision of tackle

Rubber gloves instead of cotton; Paint in a pen or tube, not an open bin Grease container should be placed in front of/at the side of L.E. Ball cage conatiner should be placed in front of/at the side of L.E.

It should arrive loosened from the vendor end

Tray hight should be increased

To prevent missing bolts, permanent magnet arrangement on conveyor Bolt tray should be placed higher

4-wheel castor setup or auto trolley loader; Tackle adjustment Reloading engine onto table; Snap lock arrangement for tackle

Conveyor B (Discover Line) Operations Front left bracket bolt tightening Crankcase earthing connection Batt. bracket bolt tightening Magneto cable coupling Engine front left bracket bolt tightening Engine rear plate bolt tightening Engine rear lower bolt tightening Front right bracket bolt tightening Holding all the nuts when bolt is tightened Chain routing over engine side sprocket Chain tension adjustment on LH side Front axle insertion & front wheel fitment Rear brake rod insertion Brake nut fitment Torque rod free fitting Starter motor connection (JN/ESHP) Rear brake pedal play adjustment Chain case fitment Rear axle LH side nut tightening RR cover fitment Gear shift lever fitment Front fairing placement Front fairing nut free fitting Speedo cable routing Carb. fitment after removing choke nut Carb. drainpipe connection A.C. box clamp tightening Intake manifold clamp tightening Front brake caliper & bolts free fitting (JN) Speedo connection (HP) Stem nut & fork side bolts free fitting Exhaust manifold gasket placement Rear axle RH side nut tightening RH side chain adjustment nut tightening LH side spark plug connection Handle bar insertion 4D Study on the Vehicle Assembly lines Distance Danger x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x / x x x x x x x x x x x x x x x x x x x x x x x x x x x Difficulty Dirt x x x x / x x x x x x x x x x x x x x x x x x x x x x x x x / x x x x x x x x x x x x x x x x x x x x x x x x x / x x x x x x x x x / x x x x x Suggestions

2 bolts per cycle dispenser

Nut should be opened in some earlier stage, as in Pulsar line

Nut tray should be in front of/at the side of L.E.

2 bolts per cycle dispenser

Opearation should be moved over to the other side

Conveyor B (Discover Line) Operations Handlebar holder free fitting Handlebar holder bolt tightening LH side fairing cable routing Stem nut & fork side bolts tightening Torque rod nut tightening No. plate free fitting CDI connection H.T. coil bolt tightening RH side fairing cable routing No. plate bolt tightening All elec. connections on RH side Seat cowl placment & tail light connection Seat cowl bolt tightening Front brake lever fitment (JN) All elec. connections on LH side Silencer rear bolt placement Torque rod snap pin fitment Grabrail placement Silencer placement & front nut free fitting Silencer rear nut free fitting Batt. terminal connection Front brake caliper bolt tightening Silencer front nut tightening Silencer rear bolt & nut tightening Clutch cable placement Fairing LHDG screw tightening Fairing centre bolt tightening Putting petroleum jelly on batt. Terminals Throtle cable play adjustment Grabrail tightening Fairing RHDG screw tightening Clutch play adjustment RH side panel fitment Fuel tank placement & fuel gauge coupling Putting in filler cap key, washer, sanp pin LH side panel lock preparation & fitment 4D Study on the Vehicle Assembly lines Conveyor B (Discover Line) Distance Danger x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x / x x x x x / x / x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x Difficulty Dirt x x / x x x x x x x x x x x / x x x x x x x x x x x x x x x x x / x x x x x x x / x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x Suggestions Visual marker on handlebar for accurate positioning (Indentation)

2 bolts per cycle dispenser

Bolt tray should be in front of/at the side of L.E. Lighting arrangement/operation repositioning Nut tray should be in front of/at the side of L.E. Nut tray should be in front of/at the side of L.E. Batt. terminal redesign

Operations Scanning bar codes (2) Fitting the front brake cable (HP) Speedo connection (JN) Putting air pressure sticker on swingarm Total =

Distance Danger x x x x x x x x 13 04

Difficulty Dirt x x x x x x x x 14 01

Suggestions

4D Study on the Vehicle Assembly lines Conveyor A (Pulsar Line) Operations Chassis unloading Number punching Rear wheel loading Kit bin loading Footrest preparation Putting brg. race on no. punching m/c Loading chassis on fixture Painting the punched no. Greasing the brg. race Putting in the ball cage Rear brake drum fitment Rear axle fitment Front Fork insertion Brg. cone, dust cap, fork nut fitment Hraness clamp fitment Carb. drainpipe routing Batt. Placement Fixture release No. plate free fitting Loading panel jig on conveyor Front mudguard RH side bolt tightening No. plate tightening Spacer firment on front wheel Front axle greasing and placement Pace meter fitment on front wheel Front wheel fitment Front axle nut free fitting Engine earthing cable routing Engine insertion Engine mtg. bolt insertion (6) Magneto cable coupling Front fairing fitment Fornt brake hose routing Front blinker coupling Starter connection lubrication Engine mtg. bolt tightening 4D Study on the Vehicle Assembly lines Distance / / / x / / x x x / x x x x x x x x x x x x x x x / x x x x x x x x x x Danger / / x x x x / / x x x x x x x x x x x x x x x x x x x x / x x x x x x x Difficulty x / / x / / x x x x x / x x x x x x x x x x x x x / x x / x x x x x x x Dirt x x x / x x x / x x x x x x x x x x x x x x x x x x x x x x x x x x x x Suggestions Reposition of lift; Sensor or more powerful warning arrangemnt, Helmet Portable no. punching; Progressive action switch Repositioning the control panel; 4-wheel castor; Provision of tackle Provision for some cleaning arrangement Bolt tray should be in front of/at the side of L.E. Repositioning the brg. race dispenser Padded guardrail disinction between this & the next stage Rubber gloves instead of cotton; Paint in a pen or tube, not an open bin Ball cage conatiner should be placed in front of/at the side of L.E. Missing slot of spacer in some kit bins

4-wheel castor setup or auto trolley loader

Replace/repairment of tackle rods

Conveyor A (Pulsar Line) Operations Chain routing over engine side sprocket Centre bracket tightening Magneto cable coupling Strap fitment Chain tension adjusting Rear axle LH side nut tightening RH side step holder placement Chain case fitment RR cover fitment Putting on rubber & metal ring on fork side Gear shift lever fitment Removal of starter motor nut RH side footrest fitment Rear brake connection LH side footrest fitment RH side chain adjustment nut tightening Holding rear axle for nut tightening Rear brake nut tightening Rear brake pedal play adjustment Torque rod bolt insertion Rear axle RH side nut tightening Step holder nut tightening Torque rod nut free fitting Handlebar insertion Handlebar cable routing Rear blinker connection Handlebar bolt tightening Throttle cable routing Starter motor connection Front brake caliper free fitting Front brake lever fitment Front mudguard tightening Fork bracket tightening Frok bromide A.C. box clamp fitment Carb. insertion 4D Study on the Vehicle Assembly lines Distance Danger x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x Difficulty Dirt / x x x x x x x x x x x x x x x x x x x x x x x x x x x x x / x x x x x x x x x x x x x x x x x x x x x x x x x / x x x x x x x x x x x / x x x Suggestions Engines should be in neutral before leaving engine assembly

Opearation should be moved over to the other side

To prevent missing nuts, permanent magnet arrangement on conveyor

It should arrive loosened from the vendor end

Conveyor A (Pulsar Line) Operations Batt. -ve terminal bromide Seat cowl fiment Tail light connection All elec. connections on RH side Carb. Fitment A.C. box clamp tightening CDI unit connection Carb. drainpipe fitting Batt. Band fitting Silencer placement & front nut free fitting Silencer rear nut & bolt free fitting Batt. terminal connection Harness band fitment for carb. All elec. connections on the LH side Front brake caliper bolt tightening Silencer front nut tightening Silencer rear bolt & nut tightening Torque rod bolt tightening Torque rod snap pin fitment Brake switch connection Intake manifold clamp tightening Seat cowl bolt tightening Clutch cable fitment & play adjustment Fuel tank placement & fuel gauge coupling Fuel tank drainpipe connection Grabrail tightening Fuel tank bolt tightening LH side decal placement RH side panel fitment Putting in filler cap lock RH side decal placement LH side panel fitment Scanning bar codes (2) Total = Distance Danger x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x Difficulty Dirt x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x Suggestions

07

05

11

02