Atlas Honda Internship report

1. Name: Mohammad Mahad Nadeem
DHA Suffa University
[Internship Report]
BE Electrical Engineering
Year: August 2016

2. Press Shop:
The machines being used in press shop are as following:
HYDRAULIC:
1.) 200 ton
2.) 200 ton x 4
3.) 300 ton
4.) 400 ton
5.) 150 ton x 1
6.) 80 ton x 3
7.) 45 ton x 3
8.) 50 ton x 1
9.) 70 ton x 1
10.)15 ton x 1
SHEARING:
1.) 2 machines
2.) 6 x 4 ft2
3.) 2 x 6ft2
There are 8 different types of sheets being used that are later molded in dies:
 0.8 mm
 1.0 mm
 1.2 mm
 1.6 mm
 2.0 mm
 2.3 mm
 5 mm
The processes involved at the press shop later after pressing are such as - notching, inspection &
quality check.
Store and control:
 Up panel store ( Raw Material Store - RMS)
 Finished part ( Production Plan Store - PPS)
 Plan given by PPS.
Total 48 parts are manufactured at the press shop.
 CG 125 & CD 70 (All parts)
 Pridor ( Panel& Bottom)
 Deluxe (Panel, Bottom & Tank)
 CD Dream ( Fuel tank only)
 CG Dream ( Fuel tank & Bottom)

3. DIE AND TOOL SHOP:
Scope of work subject to shop:
 Maintenance of dies, jigs and fixtures.
 Fixing of any bad/abnormal die, jig and fixtures.
 Die, jig modification (as per demand).
 Manufacturing of dies, jigs and fixtures.
Types of dies:
 Draw die
 Trimming die
 Pressing die
 Bending die
 Notching die
 Compound die
 Embossing die
Noting that a die has 3 main parts:
1.) Punch
2.) Die
3.) Blank holder
Jig types:
 Drill jig
 Welding jig
 Inspection jig
Tool shop:
Machines being used in tool shop are:
1.) Milling machine
2.) Cylindrical machine
3.) Lathe machine
4.) Surface grinding machine ( The biggest machine being used)s
5.) Step drill machine
6.) Drill sharpener machine
7.) Universal cylindrical tool and grinding machine
8.) Sharpener machine

4. WeldingShop:
Process:
The process is divided into 3 main parts mainly:
Line 01: Front fender
Line 02: Fuel tank
Line 03: Frame body
Now each line being explained briefly:
Line 01: FRONT FENDER
 Front fender bracket ( riveting)
 Front fender center rivet wielding (spot welding)
 Front fender bracket rivet wielding (spot welding)
 Bracket and stay spot welding( spot welding)
 Hook spot welding
Line 02: Fuel Tank
 Amlum ( spot welding)
 Tig welding
 Gas welding
 Robot welding ( 20% Argon & 80% CO2)
 Bottom assembly (spot welding)
 Paneland bottom assembly placed together
 Paneland bottom assembly (seam welding)
 Brazing of fuel cook pipe
 Fuel tank stay (MIG welding)
 Leak testing
 Edge grinding
 Final inspection (of the following:
o Leakage
o Welding hole or cut mark
o Scratch or dent
Line 03: Frame Body
 Right hand bottom
 Left hand bottom
 Pin brake pedal
 Side cover stay
 Clip welding
 Right hand bottom panel
 Sider cover stay

5. Decreasing
meta tank
Washing
Phosphating
metaphos
Rinsing
RO Water
Tank
 Left hand bottom and battery pack box
 Left and right panel
 Battery box
 Lock plate welding
 Frame body
 Stays welding
 Drilling and tapping
 Final Inspection
PAINT SHOP:
Before the part is painted it is sent to Phosphating plant to clean the surface and have it roughed ( ; say
grayish in colour) which eases the paint to stick and part be painted.
Parts being painted at paint shop are:
1.) Frame
2.) Side cover
3.) Fuel tank
Phosphating plant:
Hub and Panel Plant:
Lacquer is applied on aluminum parts to protect them from corrosion/rust. It’s a shiny coating applied
and further baked in oven at 160 ~ 180 Centigrade.
Paintingatpaintshop:
1.) Fuel Tank:
Fuel tank arrives from phosphating plant after cooling process,a silver coating is applied and then the
colour (black or red) is applied on it via spray gun (tank -ive charge and paint +ive charge) and later
baked in oven to finally mark the colour on the tank. Then lacquer is applied to make it shiny and
protective from rust.
Oven

6. 2.) Side cover:
As in ABS plant, the paint is applied (red or black) then sent to be baked at 70 to 80 centigrade.
 Paint being used is of Berger,ICI and Nippon companies.
 Viscosity: 18 to 20 dynes.
Buffing Shop:
It consists of buffing and chemical process shop.
Polishing of hub and panel the left and right crank case is done at the buffing shop.
There are 2 areas in the shop basically:
1.) Washing area
2.) Buffing area
There are 3 typesof buff used:
1.) Jeans: For hub front (CD-70 and CG-125)
2.) Cotton: For panel front (CD-70 and CG-125)
3.) Wire Brush:
a. 10” for hub front (CD-70 and CG-125)
b. 8” for crank case cover (CD-70 and CG-125)
c. 6” for panel rear (all models)
There are chemical process of Allodine and Washing process section In allodine section there are
parts being processed in the chemical of bike models:
1.) Pridor = 3 parts
2.) Deluxe= 3 parts
3.) Engine= left and right sides
For brake shoe Nitric acid is used.
There are 6 tanks altogether being used here:
1.) 1ST
tank: Decrading alloy:
 Kept for 2 – 3 min treatment.
 150 Litre
 55 – 65 Centigrade
2.) 2nd
tank:
 30 second treatment
 Filled with tap water
 Washing is done
3.) 3rd
tank:
 Nitric Acid (break shoe)

7. 4.) 4th
tank:
 RO water to wash off nitric acid
5.) 5th
tank:
 Allodine tank
 Meta chrome 3 chemical
6.) 6th
tank:
 RO water to wash off.
HUB AND PANEL:
Parts made here are:
 Panelrear
 Driven flange
 Panelfront
 Hub front
 Hub rear
The following model bikespartsare made here:
 Hub front, hub rear, panel front, panel rear and driven flange are made of CD-70, Dream,
Pridor and Deluxe.
 Hub front and back of Deluxe.
 Panelrear of CG-125 and Deluxe
Equipment forbrake shoe manufacturing:
 Shot blasting
 Air vice bonding machine
 Air less spray unit
 Drill machines
25% of brake shoe is manufactured here.
The baking is done at 180 Centigrade for 35 minutes of the braking shoe.

8. The chain followed here is this:
Engine Assembly Shop:
Parts:
Parts are issued from store and paint shop for assembly of CD-70 engine.
Process:
 Sub-Assembly cover R crank case:
Oil seal, clutch and kick starter fitted.
 Gear Assembly:
Main gears,main shaft assembly, conveyer gear and counter shaft sub assembly is done.
 Punching:
No. Punching on crank case L with help of hydraulic machine.
 Sub-Assembly line:
 Sub assembly of following engine parts is done in six processes called S to S6.
 Main-Assembly line:
Assembly of main engine is carried out here where there are jigs which slide over the roller coveyor .
The process carried out in 11 steps known as M1 to M11.
Buffing Paint Assembly DCC
Countrywide
distribution.

9. Frame Assembly Shop:
Here the CD-70 final thing is done from fitting the tyre on the axle, speedometer fixing wiring, and
indicator light wiring to the very last bit of the bike assembly. Lastly the bike on the rolling belt and
each worker wiring the bike and fixing the exhaust silencer of the bike to the very last moment of
testing the bike lights and most importantly the bike speed at maximum 50 km/h.
Maintenance Department:
Here all the major electrical work is done and also plumbing to mechanical works are done.
This being the very major department at the plant which is responsible for smooth supply of
electricity to the factory so that the process doesn’t stop.
The generator facility which is self-reliance rather KE only, and pressurized air (air compressor)
supply for the pneumatic gun which is used in different shops.