A report on

Preventive Maintenance Check-sheet

BY:

Samaksh Gulati 2015B3A4498G

Instructor-in-charge

AT:

HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD.

A Practice School I station of

BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE PILANI,

July, 2017
 A Report on

Preventive maintenance Check-sheet

BY

Samaksh Gulati 2015B3A4498G

Submitted in partial fulfilment of the Practice School I course

AT

HONDA MOTORCYCLES AND SCOOTERS INDIA PVT LTD.

A Practice School I station of

BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE,

PILANI June, 2017
ACKNOWLEDGEMENT

In carrying out this study, I had to take the help and guideline of some respected persons, who

deserve greatest gratitude. I would like to show gratitude to my mentor Mr.Shailenra Pal,

Assistant Manager, Honda Motors Pvt. Ltd. and instructor Ashish Narang, BITS Pilani for giving

me guidance for the study through numerous consultations. I would also like to thank all those

who have directly and indirectly helped us in this project.

 BIRLA INSTITUTE OF TECHNOLOGY AND
SCIENCE PILANI (RAJASTHAN)

Practice School Division

Station: Honda Motorcycle Plant Centre: Gurgaon

Duration:8 weeks Date of Start: 1, 2017

Date of Submission:15 July, 2017

Title of the Project: Preventive Maintenance Check-sheet
ID No./Name(s)/Discipline(s)/of the student(s): 2015B3A4498G/ Samaksh Gulati/
M.Sc. Economics and B.E. Mechanical

Name(s) and designation(s) of the expert(s): Mr. Shailendra Pal (Assistant Manager)

Name(s) of the PS Faculty: Ashish Narang

Key Words: Leak Testing Machine, Checksheet, Maintenance
Project Areas: Preventive Maintenance Check-sheet

Abstract:
The aim of this study is to understand the mechanism of Leak-Testing Machine. The study has
included an analysis of the Leak Testing Manuals available at Honda Plant given by the supplier
Fanuc. The study helps to cater the missed points in the already existing check-sheet.
The modifies Checksheet would help in better inspection of the machines

Signature of PS Faculty:
Signature(s) of Student(s):

Date: Date:
 BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE
PILANI (RAJASTHAN)

Practice School Division

Response Option Sheet

Station: Honda Motors Plant . Center: Gurugram

ID No. & Name: 2015B3A4498G Samaksh Gulati

Title of the Project: Preventive Maintenance Check-sheet

Usefulness of the project to the on-campus courses of study in various disciplines.

Project should be scrutinized keeping in view the following response options. Write
Course No. and Course Name against the option under which the project comes.

Code No. Response Option Course No.(s) & Name

1. A new course can be designed out of this project. No
2. The project can help modification of the course
No
content of some of the existing Courses
3. The project can be used directly in some of the
existing Compulsory Discipline Courses (CDC)/
No
Discipline Courses Other than Compulsory
(DCOC)/ Emerging Area (EA), etc. Courses
4. The project can be used in preparatory courses like
Analysis and Application Oriented Courses
No
(AAOC)/ Engineering Science (ES)/ Technical Art
(TA) and Core Courses.
5. This project cannot come under any of the above-
mentioned options as it relates to the professional Yes
work of the host organization.

Signature(s) of Student(s): Signature of PS Faculty

Table of Contents

1. INTRODUCTION............................................................................................................................... 1

2. GENERIC SYSTEMS...................................................................................................................... 2

3. SEQUENCE OF OPER. ....................................................................................................................... 4

4. CHECK-SHEET.................................................................................................................................. 5

4.1 Dos and Dontss............................................................................................................................. 5

4.2 Self-analysis................................................................................................................................... 6

5. CONCLUSIONS................................................................................................................................. 7

6. REFERENCE.................................................................................................................................... 8

List of Figures
1. Figure 1: Generic LTM Mechanism . 1
2. Figure 2: Leak Testing Machine in Honda Plant 3
3. Figure 3: Use of Pressure in checking leaks in the body 4
4. Figure 4: A graph depicting change in pressure inside the body tested. 5
5. Figure 5: Existing Check-sheet in Honda 6
6. Figure 6: Check-points analyse....... 7
 1. INTRODUCTION

Leak Testing - what technique should be used?

Key questions at the start of any leak test requirement are:

What size is the component and what is its internal volume?

What is the leak limit?

Does it have hidden internal volumes that may affect leak measurements?

Are the parts clean and dry?

Is there access to inside or is it a sealed unit?

Is it rigid or flexible?

Are parts at ambient temperature?

What is the surface finish of any sealing surfaces?

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 2. Generic System Leak Testing Machine

Figure 1: Generic LTM Mechanism

Pressure / vacuumThe test piece and the reference volume are simultaneously pressurised
(or evacuated) to a preset pressure. The air in the system is then allowed to stabilise, with the
supply valves all closed. The Differential Pressure Transducer is automatically zeroed. After
this stabilisation time, the pressure change in the test piece is compared to the pressure change
in the reference volume, using the Transducer. If the test piece is leaking, the difference will
increase and be measured, an alarm limit may be set for a pass/fail decision.
The sequence is fully automatic, the accuracy and sensitivity of the system is defined by the
method of setting the preset pressure together with the quality and type of control valves and
Differential Pressure Transducer.
Here are some pictures of the leak testing machine in Honda plant.
xc

Figure 2: Leak Testing Machine in Honda Plant

2
PRIN CI PLE OF DI RECT PRESSURE (DRO P) TY PE AIR LEAK TEST

In this method, a leak is detected by charging test pressure to the work and measuring the
change in the test pressure in the work after a given time.

Figure 3: Use of Pressure in checking leaks in the body

Relationship of pressure change and leak inside the work

Pressure change inside the work during the air leak test is shown in the right figure.
Pressure inside the work sharply increases during the pressurization process. This is
because the temperature inside the work increases by pressurization and affects the
pressure. The pressure change by temperature and other effects is stabilized (balancing
process) and then the leak is measured (detection process). Constant value will be
maintained and no pressure change in work will be detected when the work has no leak.
However, the value will decrease at a constant rate due to decrease of pressure inside
the work when the work has a leak. The direct pressure type air leak tester detects leak
of work through this pressure change and judges the result.

3
 Figure 4: A graph depicting change in
pressure inside the body tested

3. Sequence of Operations
As observed, these are the sequence of Operation observed in the working of LTM.

Mains on

Press Two Hands

Push Button

Component Sensor
senses
IF NOT OK Load the
Ok
component
Top Clamps cycls.
FWD

Inlet port sealing

Mains on
cycl.

AI port sealing cycl

FWD

IF NOT OK
Test Valve 1 OFF Inlet test failed

Test Valve 2 ON
4
Chg 0.3 bar press

Chg 0.3 bar press

EXhaust

OK IF NOT OK
Exhaust test failed
Test Valve 2 OFF

AI port sealing cyc

Rev

Inlet and Exhaust

cycling rev

Component
declamp

END OF CYCLE

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4.) Preventive Maintenance Check-Sheet
The Checksheet available at Honda plant has two components: Electrical (E) and Mechanical
(M). For a particular machine, there would be several components that need to be checked.
For that particular component, there are many checkpoints. My work would to analyse the
already existing Checksheet for Leak Testing Machine and to remove any redundant
checkpoints and checkpoints which doesnt have any importance. Also, analysing the work
done on Leak Testing Machine to introduce (if any) new check points in the checklist.This is
how a checklist looks for the Leak Testing Machine.

Figure 5: Existing Check-sheet in Honda

6
4.1) Check-points analysed
These are the some of the faults that could hamper the normal functioning of the leak testing
machine. The inspection could be classified on the basis on the criticality of the machine.
I feel, some daily inspections should also be carried out like:

Daily inspection
1. Are the necessary valves open?
2. Is the filter drain clean?
3. Does the tester judge good and bad sample works correctly?
4. Are the time + NG evaluation rate, and test pressure setting value adequate?

Precaution Inspection
1. Is the leak test fixture (system and jig) stable? (Are the scaling jigs leaking or
showing signs of disintegrating?)
2. Is each signals/indicators working properly?
3. Is the air leak testers unit function correct
4. Check if filter element replacement is necessary.
5. Has the air leak tester maintained a sensitivity?

Apart from these Daily and Precautionary inspections, there are certain dos and donts
that should be followed for optimum efficiency
.

DOS
1.) Clean the machine at the end of shift.
2.) Periodic inspection and maintenance as per instructions sheet.
3.) Operate the machine as per the instruction and operation manual.
4.) Connect hoses, coupling as per label and tags.

DONTS
1.) Operate the machine in auto cycle without components.
2.) Operate the machine without sealing pads.
3.) Disturb the position of lock nuts of cylinders.
4.) Put your hands in the jig area while clamping of components.
5.) Change the tags and labels of hoses, solenoid coils cables etc.
6.) Temper the sensor and automatic pressure regulators.

7
Now, apart from these DOs and DONTs I could analyse certain check points which are
essential in the working of the Leak Testing Machine.

Sr. No Inspection Inspection Inspection Judgement Action Inspection

Area Unit Method Standard frequency
1 Main area Pressure Visual Within Adjust Daily
PR gauge specified
pressure
2 Air Oil Visual To lower Filling Daily
lubricator Volume level line
3. Area PR Pressure Visual Within Adjust Daily
gauge specified
4. Water tank Water Visual To lower NA Daily
Volume line level
5. Machine Dirt Chips Visual Free from Cleaning Daily
Area Chips
6. Water Turbidity Visual Free from NA Weekly
Tank turbidity
7 All Piping Leaks Visual Free from Retighten Weekly
leaks
8. Sealing Cracks Visual Free from Replace Each time
pads damages cracks
9. Jig Area Damage Visual Free from Replace Each time
damage
10. Pneumatic Operation Visual Smooth Replace Each time
cylinders and leaks
11. Oil units Tightened Spanners Should be Retighten Each time
condition tight
12. Electrical Tightened Screw Free from Retighten Each time
Terminals condition drivers looseness

Figure 6: Check-points analysed

8
Conclusion
Apart from the check-points mentioned in the check sheet,I feel minute daily inspections
should be carried out as mentioned in the report. Operator should carefully follow all the
DOs and DONTs. Some of the check points that I think should be included in the check
sheets are:
1.) Checking for turbidity in water pipes.
2.) Checking for water volumes in water tank.
3.) Checking for oil volume in air lubricator.
The rest of check points in the pneumatic circuit are already mentioned in the existing check-
sheet.
Following these precautions and preventive measures can lead in greater efficiency of the
machine and can reduce breakdown which will save both time and money.

9
References:
1. CMW Tech Technologies(July,2015),Automatic Air leak testing machine,
Link:http://www.cmwtec.de/fileadmin/_migrated/content_uploads/automatic_air_leak
_test_machine.pdf

2. Darshan Dabholkar , Dipak Shenvi, Nitinkumar Anekar,Onkar Joshi(March,2016)

Design of wet leak testing plant
Link:http://inpressco.com/wp-content/uploads/2016/03/Paper69343-346.pdf

3. Oerlikon helium Vacuum(June,2015)Helium leak air tester,

Link:http://www.idealvac.com/files/literature/17_Oerlikon_Leybold_Vacuum_Catalo
g_2010_Helium_Leak_Detectors.pdf

4. Inficon(January,2017) Leak testing in the Automotive Century,

Link: http://www.inficon.com/Portals/0/PDF/e-book_-
_leak_testing_in_the_automo.pdf

5. N. Hilleret(February,2014),Leakage zero report,

Link: https://cds.cern.ch/record/455564/files/p203.pdf

6. Real zero(Septmeber,2013),Refrigerant
Emision,Link:ttps://www.epa.gov/sites/production/files/documents/RealZeroGuideto
GoodLeakTesting.pdf

7. Dr. Graham Rogers(March,2017),Helium Leak Testing

Machine,Link:http://www.vacuum-uk.org/pdfs/vs4/oerlikon_rogers.pdf

10