APQP Gear Shifter Quality

INDUSTRIAL TRAINING REPORT
(15’June-15’July 2o16)
LUMAX MANNOH ALLIED TECHNOLOGIES
Submitted by:-
Suyash Trivedi
(B.tech 3rd
year)
Central Institute of Plastics Engineering & Technology
(C.I.P.E.T.)
Lucknow

TABLE OF CONTENT
CERTIFICATE
ACKNOWLEDGEMENT
PREFACE
COMPANY PROFILE
CUSTOMERS
THE GEAR SHIFTER
R &D
APQP
INTRODUCTION
Benefits Of Using Advanced Product Quality Planning
APQP MAJOR ELEMENTS
APQP- PHASES AND ACTIVITIES
PROCESS OUTPUTS
FFMEA
POTENTIAL FAILURE MODES
FAILURE MODE EFFECTS
POSSIBLE CAUSES OF FAILURE
EFFECTS ANALYSIS
INSPECTION
INTRODUCTION

INSTRUMENTS USED DURING INSPECTION
DIGITAL HEIGHT GAUGE
DIGITAL VERNIER CALIPER
DIGITAL MICROMETER
PROFILE PROJECTOR
RADIUS GAUGE
WORK ALLOTED TO ME
EXPLODED VIEW
BOM
MAIN PART OF HONDA 2SJ
LIVER ROD
LIVER CHANGE
LIVER CHANGE AXLE
PIVIOT BALL
BUSH
BRACKET (Shifer Box)
COVER
SEAT CUSHION
SEAT
BELL CRANK
SPRING
FIXATION SHIFT
WASHER

SILENT BLOCK
COLLAR
LIST OF GAUGE REQUIRED
Pic Of Spacer Assy. Fixture And Its Sub Assembly
PIC OF BUSH, CONNECTING ROD & THEIR ASSEMBLY
PIC OF BELL CRANK FIXTURE SENSOR
SOME OTHER COMPONTENT AND THEIR ASSEMBLY
PIC OF ASSEMBLY FIXTURE
PIC OF FINAL ASSY. GAUGE
HONDA 2SJ
CONCLUSION

ACKNOWLEDGEMENT
First of all, I would like to thank Mrs. Preeti Hooda (Manager HRD) for
granting me permission to undergo training in this company.
Mr. Siddharth Shrivastav (Dr. Manager, R&D) & Mr. Hari Shankar singh (Sr.
Engineer, R&D) for guiding and imparting me knowledge under his
supervision and helping me throughout my training schedule. Moreover, I
would like to pay sincere thanks to Er. Rahul Yadav, Er. Mehak and all the
employees for asserting and helping me in clearing my doubts. I sincerely
think this training schedule will help me in understanding my engineering
branch in the years to come in a much better way.
Date:
(Siddharth Shrivastava)
(Manager R&D)

PREFACE
Indian industries are waking up to the challenges thrown in by
market economy. To survive in this highly competitive world, industries
make efforts to improve quality, enhance productivity, cut down waste and
eliminate inefficiency. These attributes are learnt by the undergraduate
students through industrial training. It is an integral part of engineering
education development. It aims at providing the technical knowledge and
skills required for industrial operations. Industry-Academic interaction is
necessary for the development of students. It gives an opportunity for
interaction between technical institutions, industry and academics. Now a
day, purely academic consideration in a system of professional education
isn’t the criteria in determining about the suitability of personnel for
technical employment.
With the purpose of getting exposure to
the real working environment and acquaintance with the organization
structure, business operations and administrative functions, which is a part
of B-Tech. course, I am undergoing ONE month training at LUMAX
MANNOH ALLIED TECHNOLOGIES LTD.
The following pages contain a
report on the practical training undergoing by me in LUMAX MANNOH
ALLIED TECHNOLOGIES LTD.

COMPANY PROFILE
Formed in the year 1997, LUMAX DK is
an integral part of the D.K. Jain Group of companies. It forms 55:45 joint
venture with Japan's Mannoh Industrial Co Ltd to design and manufacture
complete gear shift lever systems for manual, automatic, AMT & CVT
transmissions in India LUMAX Mannoh specializes in design, manufacturing
and supply of Gear Shifters, Parking Brakes, Precision Components and
Plastic injection trim parts. These are complimented by a range of two
wheeler lighting parts. These are manufactured to the highest
standards and stringent quality control procedures.
LUMAX Mannoh - an ISO 9001:2000
and ISO/TS 16949:2002 certified company, endeavour to
provide our customers with quality automotive parts at a
competitive price.
TECHNOLOGY:-
Technology support from Mannoh, Japan especially for Gear Shifters.
 Precision Engineering - CAD systems with AutoCAD Inventor &
Unigraphics NX3, CATIA, and Tool room with all required machines
and fixtures for Tool development and prototyping.
 Robust Manufacturing - 3-AXIS Tube Bending and Copping,
Hydraulic Pressing, Robotic MIG Welding Stations, Plastic Injection
Moulding, Robot Writing for Gear Shifter Knob, and Cellular Assembly
Lines
 Stringent Testing setup - Endurance Testing for Parking Brake, Tensile
Testing, Weld Penetration Check, Hardness Testing, Profile Checking,
and Strength Testing.

THE GEAR SHIFTER
For those of you who don’t know, it’s that rod like
thing with a knob on top you must have seen sticking out from the floor of
your car. And you use it to shift gears while driving.
Nomenclature for Basic Cable Type Gear Shifter

R & D
 Research and Development department has to actually “create” the product as per the requirements of
the customer, as stated in the LOI.
 ADVPR
o Analysis/Development/Validation Plan and Report (ADVPR): A timeline with different steps from LOI
to final product is made with respective target times.
 DESIGN
 DesignDrawing
o Design team prepares the 3-D drawing of model as per requirements using software CATIA or UG.
o FEA (Finite Element Analysis) is done at different load conditions, and any changes, if required are
made.
o Build of Material (BOM) sheet is prepared.
1. Shows part picture, material, weight and quantity.
2. BOM is forwarded to the Purchase department for costing.
 Costing
o Design Costing is done to project the estimated cost of the product for the buyer.
o It includes the cost of material, cost of molding; machining etc. Whatever is required to make it,
packaging and a profit? Adding all of these gives the cost price.
 DEVELOPMENT
o After the designing is done and design approved, product development begins. Different child parts for
the shifter are procured and prototype is made for trial. If it is approved then go ahead is given for
tooling.
o Further testing is done on the parts and if OK, process is developed. Product and process validation is
then done by customer.

Introduction
Advanced Product Quality Planning (APQP)
enables product quality to improve and ensure that customer needs and
wants are satisfied. APQP includes a number of procedures structured in
such a manner that it satisfies customers. Here is a closer look at the basics
of APQP and how it works to benefits our business.
APQP is uses extensively in a number of
industries including automotive and manufacturing industries as a means to
improve product quality. The end goal is to ensure that the quality of the
final product is top – notch by using a number of tools and techniques.

Benefits of using Advanced Product Quality Planning:-
 To direct resources to satisfy customer
 To promote early identification of required changes
 To avoid late changes
 To promote a quality product on time at the lowest price
 Identify ways to improve.
 Means for tracking and checking.
 Continual improvements.
 Reduction in time cycle by upfront planning.
 Better communication.
 On time output.
 Do it right, first time and every time.

APQP Major Elements
 Understand customer need. This is done using voice of the customer techniques
to determine customer needs and using quality function deployment to organize
those needs and translate them into product characteristics/requirements.
 Proactive feedback & corrective action. The advance quality planning process
provides feedback from other similar projects with the objective of developing
counter-measures on the current project. Other mechanisms with verification
and validation, designreviews, analysis of customer feedback and warranty data
also satisfy this objective.
 Designwithin process capabilities. This objective assumes that the company has
brought processes under statistical control, has determinedits process capability
and has communicated it process capability to its development personnel. Once
this is done, development personnel need to formally determine that critical or
special characteristics are within the enterprise's process capability or initiate
action to improve the process or acquire more capable equipment.
 failure modes and effects analysis or anticipatory failure determination

APQP- PHASES AND ACTIVITIES
The Advanced Product Quality planning
process consists of four phases and five major activities along with
ongoing feedback assessment and corrective action.

FFMEA
FFMEA - FAST Failure Modes and Effects Analysis .
 This approach to problem solving and product/process improvement
uses FAST Modeling as a beginning point to identify functions to be
analyzed using the FMEA approach.
 FMEA & FAST: Describe the product/process and its function. An
understanding of the product or process under consideration is
important to have clearly articulated.
 Create a Block Diagram of the product or process. A block diagram
[FAST Model] of the product/process should be developed. This diagram
shows major components or process steps [Functions] as blocks
connected together by lines that indicate how the components or steps
are related.
 Identify Failure Modes. A failure mode is defined as the manner in
which a component, subsystem, system, process, etc. could potentially
fail [or has failed] to meet the design intent.
 A failure mode in one component can serve as the cause of a failure
mode in another component. [This is a basic premise of FAST]
 Failure modes should be listed for functions of each component or
process step. At this point the failure mode should be identified
whether or not the failure is likely to occur.

Potential Failure Modes:-
 Corrosion Hydrogen embrittlement
 Electrical Short or Open
 Torque
 Fatigue
 Deformation
 Cracking
 Failure Mode Effects:-
 Injury to the user
 Inoperability of the product or process
 Improper appearance of the product
or process
 Odors
 Degraded performance Noise.

Possible Causes of failure:-
 Improper torque applied
 Improper operating conditions
 Contamination
 Erroneous algorithms
 Improper alignment
 Excessive loading
 Effects Analysis:-
 A numerical weight should be assigned to each cause that
indicates how likely that cause is. A common industry standard
scale uses 1 to represent not likely and 10 to indicate
inevitable.
 Identify controls. Testing, analysis, monitoring, and other
techniques should be identified that can or have been used on
the same or similar products/processes to detect failures.
 Each of these controls should be assessed to determine how
well it is expected to identify or detect failure modes.

INTRODUCTION
The term Inspection has been defined in
different ways by different authors:
“Inspection is the art of comparing
materials, product, or performances with established standards”
-KIMBALL
“Inspection is the art of
applying tests preferable by the aid of measuring appliances to observe
whether a given item of product is within the specified limits of
variability” -ALFORD AND BEATTY
“Inspection is the process of measuring the
qualities of a product or services in terms of established standards”
-SPIGEL AND LANSBURG
In simple words,” Inspection is the act of comparing a
product with accepted specification or other recognized standards”.
Thus inspection means checking the
acceptability of the manufactured product.
Inspection measures the
qualities of a product or service in terms of predecided standards.
Product quality may be specified by the strength, shape, hardness,
surface finish, dimensions or by other parameters.

INSTRUMENTS USED DURING INSPECTION:
1) Digital Height Gauge
2) Digital Vernier Caliper
3) Digital Micrometer
4) Profile Projector
5) Radius Gauge
6) Internal Micrometer
7) Depth Vernier
8) Low Force Vernier
9) Bevel Protector
10) Level Meter
11) Thread Ring Gauge
12) Thread Plug Gauge
13) Hardness Tester

DIGITAL HEIGHT GAUGE :- A digital height gauge is a
measuring device used either for determining the height of
objects, or for marking of items to be worked on. Height gauges
may also be used to measure the height of an object by using the
underside of the scriber as the datum. The datum may be
permanently fixed or the height gauge may have provision to
adjust the scale, this is done by sliding the scale vertically along
the body of the height gauge by turning a fine feed screw at the
top of the gauge; then with the scriber set to the same level as the
base, the scale can be matched to it. This adjustment allows
different scribers or probes to be used, as well as adjusting for any
errors in a damaged or resharpened probe.
Digital Height Gauge

 DIGITAL VERNIER CALIPER:- The Digital
Calliper (sometimes incorrectly called the Digital Vernier Calliper) is a
precision instrument that can be used to measure internal and external
distances extremely accurately. The example shown below is a digital
calliper as the distances/measurements, are read from a LCD display.
The most important parts have been labelled.
Earlier versions of this type of measuring instrument had to be read by
looking carefully at the imperial or metric scale and there was a need for
very good eyesight in order to read the small sliding scale. Manually
operated vernier callipers can still be bought and remain popular because
they are much cheaper than the digital version. Also, the digital version
requires a small battery whereas the manual version does not need any
power source.
Digital callipers are easier to use as the
measurement is clearly displayed and also, by pressing the inch/mm button
the distance can be read as metric or imperial.
Digital Vernier Calliper

 DIGITAL MICROMETER:- A micrometer sometimes
known as a micrometer screw gauge, is a device incorporating a
calibrated screw widely used for precise measurement of
components in mechanical engineering and machining as well as
most mechanical trades, along with other metrological instruments
such as dial, vernier, and digital calipers. Micrometers are usually,
but not always, in the form of calipers (opposing ends joined by a
frame), which is why micrometer caliper is another common
name. The spindle is a very accurately machined screw and the
object to be measured is placed between the spindle and the anvil.
The spindle is moved by turning the ratchet knob or thimble until the
object to be measured is lightly touched by both the spindle and the
anvil.
Basic types:-
 Outside micrometer (aka micrometer caliper), typically used to
measure wires, spheres, shafts and blocks.
 Inside micrometer, used to measure the diameter of holes.
 Depth micrometer, measures depths of slots and steps.

Digital Micrometer
 PROFILE PROJECTOR:- A profile projector is also
referred to as an optical comparator, or even known as a
shadowgraph, a profile projector is an optical instrument utilized for
measuring. It is a valuable item in a small parts machine shop or
manufacturing line for the quality control assessment staff. The
projector magnifies the profile of the specimen, and shows this on
the built-in projection screen. From this screen there is usually a
grid that could be rotated 360 degrees therefore the X-Y axis of the
screen could be aligned correctly using a straight edge of the
machined part to analyze or measure. This projection screen shows
the profile of the sample and is zoomed for better ease of
computing linear dimensions. An edge of the sample to analyze
could be aligned using the grid on the screen. After that, basic
measurements could be obtained for distances along with other
points. This is being carried out on a zoomed profile of the
specimen. It could be easier and also lessen mistakes by
measuring on the magnified projection screen of a profile projector.

Profile Projector

RADIUS GAUGE:- A radius gauge, also known as a fillet
gauge, is a tool used to measure the radius of an object.
Radius gauges require a bright light
behind the object to be measured. The gauge is placed against the edge
to be checked and any light leakage between the blade and edge
indicates a mismatch that requires correction.
A good set of gauges will offer both
convex and concave sections, and allow for their application in awkward
locations.
Every leave has different radius. The
material of the leaves is stainless steel. It is of two types: 1. Internal 2.
External. It is used to check the radius of inner and outer surfaces.

Radius Gauge
THE WORK ALLOTTED TO ME…….
I am Working on HONDA 2SJ.
Under the guidance of
Mr. Rahul Yadav

MAIN PART OF Honda 2SJ (HCIL):-
 LEVER ROD
 Lever Change
 Arm Axle
 Piviot Ball
 Bush
 Bracket/Shifter Box
 Cover
 Seat
 Cushion
 Bell Crank
 Spring
 Fixation Shaft
 Washer
 Silent Block
 Collar
 Grease

PART NAME – Lever Change
Finish Weight (Gram):- 255gm
Material:- S35C or equi.
PART NAME - Axle
Material:- S35C or equi.

PART NAME – Piviot Ball
Material:- PA66-GF-15.
PART NAME – Bush
Finish Weight (Gram):- 2.1gm
Material:- POM (Natural

PART NAME – BRACKET (SHIFTER BOX)
PART NAME – COVER

PART NAME – SEAT CUSHION
Material:- NBR.
PART NAME – SEAT
Material:- POM.

PART NAME – BELL CRANK
PART NAME – SPRING
Material:- Stainless steel (4454P-1GR3).

PART NAME – FIXATION SHAFT
Material:- S45 or equi.
PART NAME – WASHER
Material:- SPS65.

PART NAME – SILENT BLOCK
Material:- EPDM Hs50.
PART NAME – COLLAR
Material:- SAE1010 or equi.

LIST OF GAUGE REQUIRED:-
1. SPACER ASSY. FIXTURE
2. BUSH FIXTURE
3. BELL CRANK FIXTURE SENSOR
4. ASSEMBLING FIXTURE
5. FINAL ASSY. GAUGE.

PIC OF SPACER ASSY. FIXTURE AND ITS SUB ASSEMBLY

PIC OF BELL CRANK FIXTURE SENSOR AND ITS SUB ASSEMBLY

CONCLUSION
Lumax Mannoh Allied Technologies was a challenging
place for students to do their internship program. By this
internship program, I have gained a wide knowledge of
technical job scope and also the technical works from my
superior, Rahul Yadav Sir and colleagues from other
department.
The company provides me with the real working
environment. Not only learning the general work scope
here but the practical students also have got the
opportunities to implement the work scope with their own
strength and abilities during the internship. It was an
advantage for me to be in the R &D Division where I have
boosted up my skills and abilities. The conclusion that I
can make is that Lumax Mannoh Allied Technologies is the
right place for students to do their industrial training.

APQP Gear Shifter Quality

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