1. INDUSTRIAL TRAINING PROJECT REPORT
On
Press Trolley Management
HONDA MOTORCYCLE & SCOOTER INDIA PVT.
LTD. MANESAR, DISTT. GURGAON
SUBMITTED BY: SUBMITTED TO:-
Angel Bajaj Er. Nishish Andleigh
ROLL NO. 1243289 Leader of Press Dept.
B.TECH (ME) (Quality and Check)
Global Institutes of H.M.S.I.
Management and Technology
Amritsar

2. ACKNOWLEDGEMENT
A summer project is a golden opportunity for learning and self-development. I
consider myself very lucky and honored to have so manywonderful people lead me
through in completion of this project.
I wish to express my indebted gratitude and special thanks to Er. Rajnish Mittal,
Senior at H.M.S.I. , who in spite of being extraordinarily busy with his duties, took
out time to hear, guide and keep me on the correct path and allowing me to carry
out my industrialproject work at this esteemed organization and extending during
the training.
A humble ‘Thank you’ Sir.
I also express my deepest thanks to Er. Nishish Andleigh,leader in press
dept.(quality) atHMSI, for giving necessary advices and guidance throughout the
project work.
Place: Manesar Angel bajaj

3. CERTIFICATE OF APPROVAL
HONDA MOTORCYCLE & SCOOTER INDIA PVT. LTD. MANESAR,
DISTT. GURGAON
This is to certify that Mr. Angel Bajaj has completed the 6 week Industrial
Training during the period from 16 June 2014 to 31 July 2014 in our Organization
as a Partial Fulfillment of Degree of Bachelor of Technology Mechanical
Engineering. During training he successfully completed his project on Press
trolley Management in the maintenance engine department of scooter plant.
Er. Nishish Andleigh,leader
Leader of press dept.(quality)
HMSI, Manesar, Distt. Gurgaon

4. TABLE OF CONTENTS
TOPICS: PAGE.NO
 CERTIFICATE OF COMPLETION.............................................................................02.
 ACKNOWLEDGEMENT.............................................................................................03.
1. INTRODUCTION:...................................................................................................(04 - 30)
 Brief profile of student.................................................................................................04.
 Brief profile of organization.........................................................................................06.
 HONDA Products……................................................................................................07.
 History of HMSI……………………………………………………………………….......08.
 Plant Overview/ Layout…………………………………………………………………..11.
 Flow Chart of Production……………………………………………………………..…14.
 Company Vision and Work Culture…………………………………………………..16-30
2. Raw material……………………………………………………………………………….40
3. Press shop…………………………………………………………………………………….41
4. Weld shop………………………………………………………………………………….45
5. Paint shop………………………………………………………………………………………46
6. Project………………………………………………………………………………………………49

5. INTRODUCTION:
 Brief profile of student:
I am Angel Bajaj, and I am a resident of Amritsar, Punjab. My father Mr. Deep Kumar Bajaj is
a Serviceman and my mother Mrs. Dolly Bajaj, is a house wife. Currently I am pursuing B.tech in
Mechanical at Global Institutes of Management and Technology. I always take a keen part in all
the college activities.. I have done my Schooling from St. Sai Sr. Sec. School Amritsar. I am a
keen worker who likes surfing internet, playing sports, reading Novels. I have participated and
played many outdoor games in my graduation level at my college and presently I am working as
an intern in Honda Motorcycle and Scooter India Pvt. Ltd. for 2 months.
 Brief profile of project mentor at Honda
My project mentor is Er. Nishish Andleigh, leader of press dept.(quality)
HMSI, Manesar, Distt. Gurgaon
Brief profile of organization
HONDA, one of the biggest brand names in the automobile world today was founded by
Soichiro Honda at Hamamatsu, Japan, in 1948. Since then, the company has been

6. growing by leaps and bounds satisfying customers all over the world with its comfortable
world class products having most advanced technology.
Honda Global Network : Six Regional Head Quarters
WITH 6 OPERATINGREGIONS
 North/ Central America
 South America
 Afro-Europe
 Asia & Oceania
 Japan
 China
PRODUCT CATEGORIES:-
Scooters
Motorcycles
Automobiles
Power Products
Robots (ASIMO)
Jet Engines(In developing stage)
Honda Motor Company, Japan with its headquarters in Tokyo, has manufacturing
operations in 32 countries with 109 production bases. It has 3 business divisions namely 2-
wheelers, 4-wheelers and Power Products. Apart from HMSI that manufactures 2-
wheelers, the other business divisions in India include Honda Siel Cars India Limited
(HSCI) and Honda Siel Power Limited (HSPLThe company principal of Honda Worldwide
is dedication to supplying products of the highest quality at a reasonable price for
worldwide customer satisfaction. The various group companies of Honda in India are:
 Honda Motorcycle and Scooter India Private Ltd. (HMSI)
 Honda Siel CarsIndia Limited (HSCI)
 Honda Siel Power Products Limited (HSPP)

7.  Honda R & D (India) Pvt. Ltd
Honda's Products around the World
JET ENGINE

8. HONDA MOTORCYCLES AND SCOOTERS INDIA PVT.
LTD. (H.M.S.I)

9. Honda Motorcycle & Scooter India Pvt. Ltd. (HMSI), a wholly owned subsidiary of
Honda Motor Company Ltd. was incorporated on 20th August 1999 to manufacture two
wheelers in India. It’s Symbol “Wings” is recognized all over the world as the symbol of
Honda two wheelers with which they promise to initiate changes and make a difference in
the lifestyle of the people of India. It represents the flight that HMSI has taken to achieve
the goals and targets which conform to the international standards. Honda’s commitment
to India is to manufacture world class two wheelers that are designed and best suited for
local conditions. Ever since its establishment in 1999,
HMSI has striven to offer products of the highest quality at reasonable price by following
its fundamental belief of bringing joy to people. In a short span of Eight years, HMSI has
emerged as the largest scooter manufacturer and the fourth largest two wheeler company
in India. While endeavoring to meet and exceed the expectations of the customers, the
critical importance of providing the product, technology and service that not only benefits
the customer but also the society in areas such as environment preservation and riding

10. safety is also realized. It is believed at HMSI that by meeting these expectations, HMSI
will enhance the quality of life through products and services that reflect the spirit of
today. Bringing joy to people and contributing to social development will continue to be
the principles that will guide HMSI in future. It came into mass production with Honda
Activa in 2001. Since then, the company has continued to grow in the Indian market along
with regularly providing world class, advanced and technically sound products. Living up
to its illustrious lineage of excelling in the manufacture of two wheelers of global quality,
HMSI has revolutionized the multi-dimensional Indian two-wheeler market with products
like Eterno, Dio, Unicorn and Shine. Apart from outstanding sales, Honda also caters its
customers with excellent service and spare parts support. The HMSI factory is spread
over 52 acres, with a covered area of about 85,815 square meters at Manesar, Gurgaon
district of Haryana. The foundation stone for the factory was laid on 14th December 1999
and the factory was completed in January 2001. The initial installed capacity was 100,000
scooters per year, which has reached 6, 00,000 scooters by the year 2007 and
motorcycle capacity shall be 4,00,000 per annum. The total investment outlay for the
initial capacity was Rs. 215 crores and now the accumulated investment is 800 crores.
HMSI mainly deals with:-
 Manufacturing and sales of two wheelers.
 Manufacturing and sales of two wheeler engines.

11.  Service and sales of spare parts and accessories.
 Export of Honda products (CBU, Engine & Parts).
PLANT OVERVIEW
FACTORY ( 52 ACRES )
LAND AREA – 210540sq mtr
COVERED AREA – 85815sq mtr

12. PLANT LAYOUT
HMSI deals with the both the products in the two-wheeler segment. In this
plant there are two sections one is scooter plant and other is motorcycle
plant. In scooter plant all the models Activa, Dio, Eterno, Lead and Beat are
being made. In Motorcycle plant Unicorn , Shine and Stunner, Aviator are
being made.

13. FLOW CHART
PRODUCTS:

14. 2001 Started with mass production of 1st
scooter, Activa. ‘Scooter of the year
award’for Activa.
ISO-9001-2000 Certification by TUV,
Germany
2002 Launched new motor scooter, Dio.
ISO-14000 Certification by TUV,
Germany.
BBC WheelAward for Dio.
Exportstarted to Latin America
2003 Launched geared scooter Eterno.
Achieved status of No. 1 Scooter
manufacturing
company in domestic Market.
Achieved status of no 1. Exporter in
scooter segment Certification by ARAI
for emission lab
2004 Scooter of the year award for Eterno.
HMSIestablished new motorcycle
plant.
Launched 1st 150 cc motorbike,
Unicorn.
CKD exportto Latin America. Bike of
the year award to Unicorn

15. 2005 ISO-14001:2004 Certification by TUV,
Germany.
Unicorn Tops in TNS Consumer
Satisfaction Survey in “Premium
Motorcycle” category
Activa achieved landmark sales target
of 1 million units
2006 HMSIlaunched its 2nd Motorcycle
model, SHINE a 125ccsegment
Motorcycle.
HMSIsuccessfully launched LEAD in
Australian Market.HMSIlaunched new
variantACTIVA & BEATCKD
2007 Launch of new scooter AVIATOR. It is a
E-class scooter
2008 Hondalaunched a new bike, Stunner a
125ccbike with a sporty look.
2009 HMSIlaunched its 4th Motorcycle,
TWISTER a 110ccbike which was the
first bike in Indiawith lower engine
capacity and high style.
2010 HMSIlaunched a new modelof
Unicorn with the name Unicorn Dazzler,
150 cc bike.

16. 2011 HMSIwowed Indian customerswith
its latest offering – CBR 250R
2012 HMSIintroduced seven new bikes
&scooters.
CBR 150R, DIO, DREAMYUGA, CB
SHINE, VT1300CX, CBR1000RR
FIREBLADE & CBR 250R (Red, Blue&
White).
COMPANY VISION:-
 Maintaining a globalviewpoint, they are dedicatedto supplying products
of the highest quality yet at a reasonable pricefor worldwide customer
satisfaction.

17. WORK CULTURE:-
It providesevery Honda associate around the world with a vision.
1. It tells us the values of our business.
2. It bonds everyone togethertowards a commonmission.
3. It provides a constantstandard for correct action and ethical behavior.

18. 4. It shows the link betweenthe company’spast,presentand future.
5. It challenges the organizationto strive for the realizationof its vision.
6. It helps our organizationto maintain its sense of uniqueness.
HMSI being a company of Japanese origin, I also got acquainted
with the Japanese principles of manufacturing like
 JIT (Just in Time)
 TQM (Total Quality Management)
Cause & effect analysis
 PDCA (Plan Do Check Act) cycle
HONDA PHILOSOPHY
HONDA PHILOSOPHY
MANAGEMENT POLICIES
Compan
y
Principl
e
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
THE THREE JOYS
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
RESPECT FOR THE INDIVIDUAL

19.  5-S rule:
Seiri = Organization
Seiton = Neatness
Seiso = Cleaning
Seiketsu = Standardization
Shitsuke = Self-discipline
 3-G principle:
Gemba = Go to actual place
Genbutsu = See actual problem
Genjitsu = Take realistic solution
 3-K principle:
Kiken = Dangerous
Kitanai = Dirty
Kitsui = Inconvenient
Our fundamental beliefs (Company’s Mission):-
 Respect for the individual

20.  The three joys
RESPECT FOR INDIVIUAL:
The Human Being is born as a free and unique individual with the
capacity to think reason and create -- and the ability to dream.
"Respect for the individual" calls on Honda to nurture and promote
these characteristics in our company by respecting individual
differences and trusting each other as equal partners.
Respect for the Individual recognizes the following core
concepts:
Initiative
Respect
For the
Individual
TrustEquality

21. Initiative: Initiative means not to be bound by preconceived
ideas, but think creatively and act on your own initiative and
judgment, while understanding that you must take responsibility
for the results of those actions.
Equality: Equality means to recognize and respect individual
differences in one another and treat each other fairly. Our company
is committed to this principle and creating equal opportunities for
each individual.
Trust: The relationship among associates at Honda should be
based on mutual trust.Trust is created by recognizing each other as
individuals, helping out where others are deficient, accepting help
where we are deficient, sharing our knowledge, and making a
sincere effort to fulfill our responsibilities.
Honda is comprised of individuals working together for a common
purpose. Each individual, acting appropriately within his or her role,
must translate the philosophy into actions. It is this contribution from
each associate that contributes to the company’s success. And every
associate should be honored for these efforts.

22. THE THREE JOYS:
Our goal is to provide Joy through our business:for those who buy our
products ("The Joy of Buying"), engage in selling our products and services
("The Joy of Selling"), and are involved in business of creating our products
("The Joy of Creating").
 The Joy of Buying
is achieved through providing product and services that exceed the needs
and expectations of each customer.The Joy of Buying is essentially the
establishmentof a relationship with the customer,initiated through the
products and continued through the sales and service experience.
Importantly, the Joy of Selling and the Joy of Creating cannot be achieved
without first bringing joy to the customer
.
 The Joy of Selling
occurs when those who are engaged in selling and servicing Honda
products develop relationships with a customerbased on mutual trust.
Through this relationship, Honda associates,dealers and distributors
experience pride and joy in satisfying the customerand in representing
Honda to the customer.
 The Joy of Creating
occurs when Honda associates and suppliers involved in the design,
development,engineering and manufacturing of Honda products recognize
a sense of joy in our customers and dealers. Formerlyknown as the "Joy of
Producing," the Joy of Creating occurs when quality products exceed
expectations and we experience pride in a job well done.

23. The Joy of Selling The Joy of Creating
The Joy of Buying

24. HONDA MANAGEMENT POLICIES:-
1. Proceed always with ambition and youthfulness.
2. Respectsound theories,develop fresh ideas and make the effective
use of time.
3. Enjoy your work and encourage opencommunications.
4. Strive constantly for a harmonious flow of work.
5. Be evermindful of the value of researchand endeavor.
HONDA CORPERATE CULTURE:-
1. Free thinking & openmindedness.
2. Challenging spirit
3. Sincerity & Integrity
Co-evolution

25. JAPANESE WORK CULTURE:-
1. A typical Japanese office is an open space with an over-crowding
of desks or very little private work space.
2. An Employee for Life.
3. Other-centered,work centered long term relationships.
4. How work is done often matters more than what is accomplished.
(Patient thoroughness,especially in preparation,is valued overspeed or
creativity,Thorough documentationallows contextto speak)
Working Preference:-
1. Safety:- Man,Machine, Environment.
2. Quality:-Component,Product,vehicle.
3. Quantity:- Daily Productiontarget.

26. HONDA PRODUCTS
1. HONDA ACTIVA
2. HONDA DIO
3. Activa125

27. 4. ACTIVA i
5. AVIATOR

28. 6. HONDA UNICORN
7. HONDA SHINE

29. 8. CD 110
9. CBR250
10. CBR1250

30. 11. TRIGGER
Raw Material
1. ScooterRaw Material:-
1. KVT CRCEDD 0.7*515*540
2 KWP CRCEDD 0.8*650*745
3 K24 CRCEDD 0.7*545*550

31. 2.Motorcycle Ram Material:-
S no. Model RH/LH Plate Bottom
1. KSP 0.8*510*800 0.8*565*690
2. KWF 0.8*530*750 0.8*500*680
3. KYJ/KPPR 0.8*540*720 0.8*500*610
4. K21 0.8*550*805 0.8*610*690
5. K23 0.8*515*760 0.8*590*690
For Motorcycle model EGIF (JNC270E)
Grade material used for all tanks
EG (Electro Galvanized)
IF (Interstitials Free)
Single side coated (Zn+Ni)
Coating mass standard 20MG/m2
CRCA:-cold Rolled Closed Annealing
Press Section
Classification of presses:-
1. Mechanical press:-
In this press, the load generation thro motor, flywheel, gear, transmission
through connecting rod. High productionrate.
2. Hydraulic press:-
Load generation thro motor driven hydraulic pumps and transmission
through hydraulic cylinders. Generally, low production rate.

32. There are 4 mechanical presses:-
Scooter Parts MotorcycleParts
P1, P2, P3 & P4 are the mechanicalpresses. They are used
because of their high productive rate.
There is also a hydraulic press which
is used for the die maintenance. The productive rate of this
press is less than that of mechanicalpress. That’s why,
mainly mechanicalpresses is used for the press operations
in the industries.
Note:-

33. The P2 is used for drawing operation and P1 is used for
Trimming, Piercing and bending.
The reason is that because the P2
press machine has double pads and cushions which absorb
the force exerted by the die.
Whereas, in the P1 only Trimming,
Piercing and bending which occurs at the principle on the
cam and the followerthat’s why we don’t do the drawing
operation on the P1 Press.
Press PPE’s:-
1. Helmet 4. Hand gloves
2. Arm guard 5. Safety shoes
3. Ear gloves 6. Goggles
Press Operation
1. Scooter line:-
Blank sheet  Draw Part  Trim & Piercing
Hemming  Side Bending  Front bending
Rework  Supply to Paint

34. 2. Motorcycle line:-
R/M sheet  Draw Operation  Trimming
Rework  Quality Guide Inspection
Rework Quality Guide Inspection
MaterialMovement to Weld
Defects in Press operation:-
1.Dent:- Due to presence of foreign substancein
die.
2.Crack:- Due to high pressureand tight pins.
3.Wrinkle:- Due to tight feed.

35. 4.Thinning:- Decreasingin the thickness of the
product due to stretchingand uneven pressure.
5.Overlap:- Overlappingof the sheet on itself.
6.Burr:- Occur at the piercing.
7. Turn up:- Bending at the corners.
Rework Operation
Random tool
Rotary tool

36. Hammer
Producer:-
1.Firstly, the dent is removed with the help of
hammer.
2.Then, with the rotary tool, which rotate at
18000rpm is usedfor cutting.
3.At the last, with random tool, which rotate at
12000rpm is usedfor finishingof the rework
material.
Note: - The Rotary tool and random tool work on the
principleof the compressed gas.
Standardization:-
All the components that are manufactured are HMSI
has to go through the test of three standards:-
1.ISO-9001:-
Belong to quality standard
2.ISO-14001:-
Belong to environment/ safety
3.ISO-27000:-
Belong to containingsecrecy

37. Weld Shop
There are 4 types of welding done in HMSI:-
1. MIG welding
2. TIG welding
3. Spot welding
4. Seam welding
The filler metal used in the welding is mild steel coated
with copper metal for the preventing it from corrosion.

38. Robots are used for doing MIG welding and in the rework
it is done manually.
Then this all frames are checked at the inspection shop.
The fame is manufactured in the weld
shop.
Defects:-
1.Cracks
2.Beats
3.Blow holes
4.Coricity
5.Holes
6.Less penetration
Paint Shop
After then, the frames are put in the carrier on the
conveyer for the painting.
Before painting, the fames are washedin
the ionizedwater then dried in the oven at 500
temperatures.
Then ED coating (electrode deposition)is done on
them. Then, at paint booth the base coating and top
coating is done by the robots.

39. But for finishingand parts which are not painted is
done manually.
Then, these frames are allowed to
enter at the oven for drying of the paint. The ED
coating will get depositand the paint will got
attached metal.
Then, this paint coated is checked at
the inspectionbooth.
The defected frame are sent to
the manually paint shop.
Then, all the OK frames are sendingto the assembly
line for the manufacturing of the product.
Note:-
There are 4 conveyer line with different
temperatures and components.
The metallic frames are kept at 1700 temperature
where as fiber frames are kept at 800
temperatures
The heat is generated in the
conveyer by C.N.G and steam is also usedto create
the heat for the drying of the paint on components.

40. Project Report:-
Press Trolley Management
Plate Bottom:-
Trolley
no.
Wheel Cup
Broken
Mesh Hook Hole
1
2
3
4

41. 5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

42. 28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
Result

43. No. of ok trolleys =36
No. of mesh broken trolleys =10
No. of cup broken trolleys =1
Half Outer RH/LH Bin:-
Trolley
no.
Wheel Cup
Broken
Mesh Hook Hole
1
2
3
4
5
6
7

44. 8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

45. 30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51

46. 52
53
Result
No. of ok trolleys =30
No of mesh broken trolleys =23
FENDER (SMALL SIZE) BINS:-
Trolley
no.
Wheel Cup
Broken
Mesh Hook Hole
1
2
3
4
5

47. 6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

48. 28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Result
No. of ok trolleys =29
No. of mesh broken trolleys =6
No. of cup broken trolleys =6
No. of NG- hole trolleys =1

49. Total Result
Total no. of OK trolleys =36+30+29=>95
Total no. of mesh broken trolleys =10+23+6=>39
Total no. of cup broken trolleys =1+6=> 7
Causes & Prevention:-
1.Maintenance of the trolleys periodically.
2.Maintaininga suitablegap between the trolleys at
the storage area.

50. 3.Lubricationof the hook and the wheels after every
period of time.
4.Keep the trolleys in the queue.
5.Painting or Coating of the trolleys for their
prevention from rust.