PROJECT TRAINING IN HMSI

CO-OP MODEL OF
EDUCATION
 ABOUT TRAINING PROGRAM- CO-OP MODEL

Benefits for Student

The Co-op Modal is designed in a way that it not only increases likelihood of
employability, but also provides opportunity to students to get to know the
atmosphere of industry.

Benefits for Industry

Any industry wants student, who is ready to industry, will be beneficial.

Benefits for Institute

The institute will, In the long-term, be able to upgrade its content, teaching
methodologies and research capabilities.
 PROFILE

As Student As Summer Trainee

Sagar Soni Sagar Soni

7th Sem B.Tech (Mechanical)
Faculty of Engineering
Dayalbagh Educational
Institute, Agra
Crank Shaft & Crank Case
Line,KWPG
Machine Shop Step-1
Honda Motorcycles And Scooter
India Limited, Tapukara(2F)
 TAPUKARA
PLANT

Production Production Planning &

Power Train Body Production Support
Quality Control

MA1 Weld + Press Maintenance Utility

Maint. 1 (Engine) Power House

MA2 AF

Propane Yard
Maint. 2 (Body)
HPDC Paint Boiler
Maint. 3 (HPDC)
STP

Compressor House
Machine Shop layout

Crank Step-
1

Crank Case
Step-1
PARTS OF MACHINING STEP-1
 LINE LAYOUT
Crank Shaft Step-1

Process Layout

Tread & Key Way Bearing & Timing

Fine Pin
Spline & Oil Hole Hardening Grinding Caulking Sprocket
Boring Pressing
Rolling Drilling Pressing Pressing
.
 PROJECT ALLOTTED

REJECTION ANALYSIS AND

MAINTENANCE OF PREVENTIVE GAUGES
 WORK PLANNING

WORK IN ACTIONS APRIL MAY JUNE JULY AUGUST

Study The Various Processes in
Machine Shop in every Line
Study The Various Parameters in Both
Lines
Identify Machines Preventive gauges
And Check Points
Identify Line Rejections, Problems and
Counter Measures
Thinking about Ideas which can Help to
Reduce Rejections
Suggestions to Line Ex

Make Presentation

PLANNED ACTUAL
 PARAMETERS AND THEIR AFFECTS

 Crank Shaft  Crank Case

Affects Affects
Thread Bolt will not tight Dent on Milled Can cause a Leakage
Key Way Key may not fit Surface
Grinding Dia Bearing will not fit Milling Height Vary Engine Volume
Fine Boring Dia Pin will not properly fit Oil Hole Dia, Depth Engine Siege
Crank Width Cause rubbing in Tapping Bolt will not fit
bearings
Oil Pump Dia Cause Leakage
Taper Height Compression & Tension
forces in crank Fine Boring Dia & Cause improper Bearing fit
Axial Gap Connecting Rod Depth
movement Dowel Hole Dia, Both Cases will not joined
Tsp angle Opening of valves Depth

Run Out Voveling in crank Hole For Studs Cylinder Block will not Fit
 PARAMETERS RESPONSIBLE O1 DIA
FOR ENGINE NOISE

Defects Reasons

Dia Ovality Bearing would not fit properly and

may slip from its position . O1
DIA

Variation In Crank Shaft will not be vertical

then that causes Voveling motion
Depth of Crank Shaft

If Tapping on May Create misalignment

Of Crank Shaft
milled Surface
will center-out
 Upper
Ovality in Dia Control
200 Limit
150
Lower
100
Control
50
Limit
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

R Case L Case

Upper
Control
Depth Variation in Crank Case Limit
100

80

60 Lower
40 Control
20 Limit
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

LCC RCC
AFTER PIN PRESSING CRANK INTERACTS WITH VARIOUS M/C

PIN PRESSING

CAULKING PRESSING

BEARING & GEAR

PRESSING

TSP PRESSING Assembled

 KEY PARAMETERS RESPONSIBLE FOR ENGINE
NOISE
Defects Affects

Crank Width Bearings will create

Compression and
NG Tension forces in Crank.

Axial Gap NG Connecting Rod will

move tightly or
sometimes freely.

Run out Cause Voveling motion

in crank shaft, create
vibrations.
 NORMAL TREND OF RUN OUT JUST AFTER PIN
PRESS
Upper
Run Out L Side Control
50
45 Limit
40
35
Microns

30
25 Lower
20
15 Control
10 Limit
5
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Run Out R Side Upper
35
Control
30
Limit
25

20

15 Lower
10 Control
5 Limit
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
BRAINSTORMING

It may be possible that

parameters are
With the help of changing at every
sampling it can be machine after pin
proved. press.
 SAMPLING, TO KNOW PARAMETER Width
IS CHANGING OR NOT 40

microns
30
20
10
0
1 2 3 4 5 6 7 8 9 10
SAMPLING REPORT TO CHECK WHETHER SPEC IS CHANGING AFTER PIN PRESS
AFTER PIN PRESS IN CRANK SHAFT AFTER FINAL CHECKING
Axial gap
RUNOUT RUN OUT
CRANK WIDTH AXIAL GAP CRANK WIDTH AXIAL GAP 60
(L SIDE R SIDE L SIDE- R SIDE

microns
40
20 20 -40 0.2 35 25 -20 0.2
20
5 8 -20 0.2 15 25 -20 0.2
0
20 10 -30 0.2 20 30 -40 0.2
1 2 3 4 5 6 7 8 9 10
20 15 -10 0.2 15 20 -10 0.2
25 10 -20 0.2 15 30 -20 0.2
10 20 -20 0.25 40 15 -50 0.2
Run Out
50
25 10 -30 0.2 15 15 -40 0.2 40
20 10 0 0.2 30 30 -10 0.25 30
20
30 20 -20 0.2 40 30 -20 0.25 10
25 10 -20 0.2 20 5 -10 0.25 0
1 2 3 4 5 6 7 8 9 10

Runout L side Runout R side

 CONCLUSIONS

MOST OF THE EVERY TIME CRANK AXIAL GAP DOES NOT

CHANGES COMES IN WIDTH REDUCES TO CHANGES TO LARGE
RUN OUT L-SIDE MAY SOME EXTENT BUT EXTENT, ALTHOUGH IT
BE BECAUSE OF SOME TIMES IT HAS HIGH
LARGER IN LENGTH. REACHES TO ITS TOLERANCE LIMIT.
LOWER LIMIT.
BRAINSTORMING
1. WHICH MACHINE IS
RESPONSIBLE FOR
THIS
2. WHETHER IT VARIES
PARAMETERS OUT OF
ITS TOLERANCE LIMIT
SAMPLING AFTER
EVERY MACHINE
WOULD SHOW ALL
VARIATION IN
PARAMETERS
 SAMPLING AFTER EVERY MACHINE
Variation from Pin Press to Variation from Caulking to
Caulking Press Bearing Press
30 60
20 40
10
0 20
-10 1 2 3 4 5 0
-20 1 2 3 4 5
-30 -20
-40 -40
-50
-60 -60

Crank Width runout l side runout r side axial gap Crank Width runout l side runout r side axial gap

Variation from Bearing press to Variation from Tsp Press to Final

Tsp Press 10
15 5
10 0
5 -5 1 2 3 4 5

0 -10
1 2 3 4 5 -15
-5
-20
-10
-25
-15
-30
Crank Width runout l side runout r side axial gap
Crank Width runout l side runout r side axial gap
 CONCLUSIONS
AFTER PIN AFTER IT CLEARLY
PRESSING BEARING SHOWS,
PARAMETERS PRESSING, AFTER
CHANGES RUN OUT MAKING
ABRUPTLY . CHANGES . INVENTORY, T
HERE ARE
CHANCES TO
VARY
PARAMETERS
DEPEND ON
MATERIAL
HANDLING
MAINTENANCE OF PREVENTIVE GAUGES

PRESSURE
GAUGES

SYSTEM
PRESSURE

HYDRAULIC
TOTAL LEVELS
PREVENTIVE
MAINTENANCE
SHEETS (TPM) ABNORMAL
NOISE

COOLANT
CONCENTRATION

VISUAL
 SOME OBSERVATIONS

Equipments Normal Reading

System Pressure 50-100 kg/cm2
Hydraulic Pressure 2-5 MPa
Hydraulic Level Between H and L limit
Coolant Concentration Mostly Between 3- 6

Coolant Concentration
6
Conc.

4
2
0
Shift A Shift B Shift A Shift B
Continuous 2 Days
 CORRECTION IN TPM SHEETS
Machine Parameters Readings
Spline & Thread Rolling Lub. Oil Gauge Pressure 1-2 MPa
Tail Center Pressure 0.2 MPa
MTE Thread Rolling System Pressure 40-120 Kg/Cm2
Washing Air Pressure gauge 4-7 Kg/Cm2
Pin Pressing System Pressure 7.5-8.5 Kg/Cm2

Caulking Plate Press System Pressure 30-50 Kg/Cm2

BFW Drilling System Pressure 35-45 Kg/Cm2
Air Pressure 4-7 Bar
Lub. Oil Pressure 0-15 Kg/Cm2
Shigiya grinding Machine Air Pressure 0.35-0.6 MPa
Lub. Oil Pressure 1.5-1.7 MPa

Fine Boring Hydraulic Pressure 3-5 MPa

Lub. Oil Pressure 1.5-1.7 MPa
Air Pressure 3-4 Bar
 ANOTHER PROBLEM OBSERVED

 Crank Shaft Dismantling when rejected from Engine Assembly or

Vehicle Quality.

 Process takes 4-5 Min to

Dismantle
CONTINUED

Most of time expend to

remove Bearing

Apparatus for it employed

with Hammering
SOLUTION FOR IT

Apparatus that can

easily pull all the
Bearings

BEARING
PULLAR
 CONTINUED

BUT ON
DISMANTLING,
CAULKING Any common Apparatus
PLATE ALWAYS that can pull Bearings
GET and Caulking Plate both
DESTROYED
ONE OF THE 120
Pareto Analysis For Crank Shaft

MAJOR
REJECTION 100
92
95
98 100 100

COMES FROM 80
85

76

PIN PRESSING
60 62

MACHINE AND
45
IT ALSO 40

CONTROLS 20

FURTHER
0
PARAMETERS Pin Press Thread Rolling Grinding Fine Boring Hardening Keyway Caulking Tsp Press Br Press
CONNECTING ROD ASSEMBLING PATTERN

Crank pin Con. Rod Grade Con. Rod Clearance(µ)

Bearing(µ)
11 2
WhiteA Blue 4 0~12
7
Brown 711 Blue 7
3 White 4
6
0~8

WhiteA 711 Re d 02 0~12

2
7 Blue 37 Blue 4 0~12
Blue 3 Green 3 White 4
6
0~8
1

Blue 37 Re d 02 0~12
Green 13 Blue 42 0~12
3
White 1 Black 51 White 64
0~12
 EFFICIENCY OF ACTIVA ON ANALYSIS BASIS Efficiency of
Activa Based
on Certain
 Volume of combustion chamber(clearance
volume)=10 cc (decided by company) Assumptions
 Bore diameter=5 cm
 Position of TDC from upper point of cylinder Upper
block=0.393 cm point

 Position of BDC from upper point of cylinder block= TDC

5.588 cm
 Volume above TDC= 3.14x2.5x2.5x0.393=7.7 cc
BDC
 Volume above BDC=3.14x2.5x2.5x5.588=109.5 cc
 Compression Ratio =(10+7.7+109.6)/(10+7.7)=7.16
1
 Efficiency = 1 (where n can be taken as 1.44)
Rn 1

=57.9%
VARIOUS TYPES OF ENGINE NOISES

Cylinder Head
Noise
Self
Starter Cam noise
Noise
Muffler noise
Air cleaner
Mission noise
Case
Noise Lifter noise
Brake shoe
Kick noise
Noise
Flywheel noise
Brief idea about following topics learned in Maintenance Internal
Training
Variable Frequency Drives
Mechanical Drawings
Pumps and Hydraulic Systems
Safety Training
CNC Equipments
CONTINUED

 Basic Knowledge of G and M Coding, Catia 3D and prepare G codes

using Catia.
 Some operations in CNC interfacing Using FANUC control panel

like Tool Change, Offsetting, G Code Editing, Single Block Mode

MDI Mode, Manual Mode.
 Production Log Book
 MSQCD Board
 KAIZEN
VARIOUS
 SAFETY FIRST, THEN PRODUCTION
VALUABLE
 5S Technique
 7 QC Tools
WORD IN
 TPM
HMSI
 Inspection Sheet
 New Honda Circle
 Three joys Buying, Creating and Selling
 Respect for Individual Initiative, Equality and
Trust