Honda car

1. PRESENTED BY:-
MD FIRDOUS ALAM

2. OUTLINE
INTRODUCTION
PROCESS FLOW DIGRAM
PARTS MANUFACTURED
VARIOUS PROBLEMS INVOLVED IN THE PRESS
LINE
DESIGN AND FABRICATION OF FRAME
SAFTEY OF MAN
CONCLUSION

3. INTRODUCTION
Honda Motor company , LTD is a Japanese public multinational
corporation primarily known as a manufacturer of automobiles and
motorcycles.
Honda has been the world`s largest motorcycle manufacturer since 1959 ,
as well as the world`s largest manufacturer of internal combustion engines.
Honda surpassed Nissan in 2001 to become the second-largest Japanese
automobile manufacturer.
Honda is the sixth largest automobile in manufacturer in the world.
The company achieved the number one position among all mass
production cars sold in the USA.

4. PROCESS FLOW DIGRAM

5. PARTS MANUFACTURED

6. PARTS NAME
1. HOOD SKIN
2. TRUNK LID SKIN
3. FR DOOR SKIN R
4. FR DOOR SKIN L
5. RR DOOR SKIN R
6. RR DOOR SKIN L
7. FR FENDER R
8. FR FENDER L
9. ROOF PANEL
10. SIDE PANEL R
11. SIDE PANEL L
12. FR FLOOR
13. RR FLOOR
14. TRUNK LID FRAME
15. HOOD PANEL R
16. FR DOOR PANEL R
17. FR DOOR PANEL L
18. RR DOOR PANEL R
19. RR DOOR PANEL L
20. RR INNER R
21. RR INNER L

7. PRESS SHOP
Salient Features
.1500 Ton - 1Nos
.1000 Ton - 3Nos
No. of Robot : 5
Scrap conveyor : 1
Press Machine : 4

8. Equipments in press line
Honda robot Scrap conveyor machine
Parts handling robotPressed part

9. Key information
April 1995 - mass production started
Production capacity - 14.75 million shots per year
18 million car parts produced per year
All excess metal is sent for recycling
The process
The car manufacturing process begins in the Press Division where we press the
body panels for the cars built on site. To start with we receive blanks: flat metal
sheets that have already been cut into the basic shape of the panel. These are then
loaded onto the press:
The first press draws or forms the panel
The second press trims the panel to remove excess metal
The third press bends the panel to create flanges for later processes
The fourth and final press pierces holes for other fittings
The panels are then inspected and transferred to automatic storage before being
delivered to the Weld Department in Car Plants 1 and 2.
Press division

10. Over 200 lorry deliveries per day
10,000 containers are handled per shift
41 tow trucks and 17 forklifts utilized
The main function of Material Logistics is to receive and deliver parts for the
Weld, Assembly Frame and Paint Departments on a ‘just in time’ basis, two
hours before they are fitted. While some parts are received from multiple local
distribution centers, wheels, seats, door linings and engines are received on a
synchronized basis directly from suppliers.
Large parts are delivered to fitment points on an electronic monorail system.
Parts are also delivered to the line-side via tow trucks following ‘first in first out’
principles. Empty returnable packaging is removed from line-side, sorted and
taken to a specific distribution centre for return to our suppliers.
Material Logistics Division
Key information
The process

11. Over 300 welding and handling robots
Around 2,200 spot welds are performed by
the robots per car body
One vehicle body is produced every 85
seconds
650 bodies in white produced per shift
Weld Division
The Weld Department produces complete welded car bodies from panels supplied
both by our own Press Department as well as external suppliers.
The process begins with the right and left wheel houses welded to the lower dash
and front bulkhead to form the complete engine compartment. This is then
combined with the front and rear floor assemblies to make the floor complete.
The right and left side panels are sub-assembled and transferred to the General
Welder (GW). This is the heart of the department where the parts that have been
produced within the various areas (side panels, floor, roof, upper dash and rear
parcel tray) come together and the GW welds all the parts together to produce a
completed body.
The process
Key information

12. Paint Division
Capability to paint over 1,000 cars per day
in a broad spectrum of colors, complete
with in house moulded bumpers
HUM has one of the fastest bumper
moulding operations in the world,
producing components every 42 seconds
At any one time, over 800 car bodies, of
three different model types, are being
worked on in the Paint Division
 The main objectives of the Paint Division are to provide vehicles with a high
gloss, attractive, colorful finish, with a long term durable resistance to
corrosion.

13. VARIOUS PROBLEMS INVOLVED IN THE PRESS
LINE
.Vacuum miss- Sometimes the pressure in the vacuum cup falls below the required
Value and then cup does not lift the part and this is called vacuum miss.
.Set miss- There are position sensors to sense the accurate position of the sheets
in the dies but when there is difference in the position occurs, sensors operator and
this is called set miss.
.Scrap jam in trim and piercing die- Sometimes the scrap from the parts after
going through trim and piercing die jam there.
.Sheet abnormal fault- Sometimes sheet bend in the die, sometimes two sheets
come together.
.Chip dent problem- Due to dust in the die, dents occurred in the parts.

14. DESIGN AND FABRICATION OF FRAME
 Fabrication is the building of metal structures by cutting, bending, and
assembling processes.
 It is a value added process that involves the creation of machines, parts, and
structures from various raw materials. A fab shop will bid on a job, usually based on
the engineering drawings, and if awarded the contract will build the product. Large fab
shops will employ a multitude of value added processes in one plant or facility including
welding, cutting, forming and machining. These large fab shops offer additional value to
their customers by limiting the need for purchasing personnel to locate multiple vendors
for different services. Metal fabrication jobs usually start with shop drawings including
precise measurements, then move to the fabrication stage and finally to the installation
of the final project.

15. SAFETY OF MAN
Training workshops for safe practices are conducted at regular intervals for
employees at all levels of the production department. Placards at regular
Interval to remind employees about safe practices.
Personal protective equipment
Helmet
Goggle
Ear plug
Apron
Gloves Shoe

16. CONCLUSION
Maintain an international viewpoint ,We
are dedicated to supplying products of
the highest efficiency yet at are a reasonable
price for worldwide Customer
satisfaction.

17. Thank you !......