Honda Motorworks manufactures motorcycles, scooters, automobiles and power products. It has several manufacturing plants across India. The document discusses Honda's manufacturing division and processes involved in press shop operations at its Manesar plant. It describes the key stages in sheet metal forming from blanking to trimming and various issues faced like vacuum misses, set misses, scrap jams and solutions adopted.

1. HONDA MOTORWORK
“MANUFACTURING DIVISION”
DEPARTMENT OF MECHINICAL ENGINEERING
Galgotias college of Engineering and Technology, Gr. Noida(U.P.)
PRESENTED BY:
NITISH KUMAR
1900970400077

2. ● HONDAestablish in 1999 at Manesar ( Haryana )
● HONDAis a Japanese Public Multinational .
● HONDAis a largest motorcycle manufacturing company.
power
● HONDA deals with 2-wheeler, 4-wheeler and
products.
● Honda motorcycle and scooter India (HMSI)
● Honda Siel Cars India Ltd (HSCI)
● Honda Siel Power Products Limited (HSPP)
● First plant of HSMI in Manesar (Haryana).
● Second plant in Tapukara ,Dist.:-Alwar, Rajasthan
● Third plant in Narsapura, Bengaluru
● Forth plant inAhmadabad ,Gujarat
● My training is at HSMI Manesar in frameAssembly

3. MODELS COVERED IN PRESS SHOP
S. No MODELS SHAPE MODELS NAME
1 HONDA CITY
2
HONDA BRIO
3
HONDA AMAZE

4. ● HR (Human Resource
and Development)
● IR(Industrial relation)
● A/F(Frame assemble)
● A/E(Engine assembly)
● Paint Shop
● P I (Part inspection)
● Utility
● Maintenance
● BOP
● Weld
● Steel machining
● Aluminum machining
● Safety
● Purchase
● Casting
● PPC(Production planning)
● VQ (Vehicle quality)
● Logistic
● Store
● Finance
● R & D
● Technical center
● SQA

5. Raw material Press
BOP WELD CASTING
PAINT PAINT SHOP
ENGINE
ASSEMBLY
BOP
FRAME ASSEMBLY
VQ
LOGISITICS
DISPATCH
MACHINING

7. Salient Features
Press Machine : 4
● 1500 Ton – 1Nos.
● 1000 Ton – 3Nos.
No. of Robot : 5
Scrap Conveyor : 1
Equipments In Press Line
Press Machine
Scrap Conveyor
Parts Handling Robot
De-Stack Feeder

8. BLANK STACK:- The stack feeder unit loads the sheet blanks into the unit to be forwarded
to the washing unit. The position of the sheets to be loaded is governed
by the laser pointer guides and stack feeder guides.
DE-STACK FEEDER:- A blank of sheet goes inside the De-stack feeder . There are position
and photographic sensors for the correct position of blanks and to
ensure the safety.

9. DE STACKER CUP:-
MAGNETIC FLOATER:-
These cups left the blank sheet to magnetic rollers. Then those rollers
hold the sheet and these cups leave them. There is a rubber
belt/conveyor belt on these magnetic rollers which take the sheet a bit
forward where thickness of sheet is measured using a sensor.
In a stack sheets are already washed by oil and when Die Stacker
cups come down and lift a sheet, it lifts two sheets together to
remove another sheet we use magnetic floater and stop motion.
The magnetic floater blows air towards the sheet to separate them
and it is magnetic so blowing air doesn’t change the position of
the sheet
MAGNETIC FLOATER

10. WASHING UNIT:-The washing unit is located in the initial state. The primary function of
this unit is to remove dust and dirt from the sheets. Before oil is supplied to the rollers for
cleaning the blanks, it goes through a filtering process

11. Centering unit
These kinds of stoppers are used to match the centre of the blank with the centre of die.
It is of three types:
1. Front stopper
2. Rear stopper
Side stopper

12. OPERATIONS OF THE PRESS:-
1.) DRAWING
 Draw Die:-Die for forming a hollow vessel from a flat sheet metal with use of punch and
die without application of heat.
 Draw Die Clearance:-The Clearance b/w die and punch shall be thickness of sheet
material plus 0.1 mm
 Draw Force:-The force required for drawing depends upon the shape of punch. For
general applications a simple load calculation is made by following formula
Drawing Force = L * t *35 (Numerical Constant)
L= Drawing Circumference
t=Sheet Thickness
2.) TRIMMING
For cutting excess material from a part made by
drawing.

13. 3.) PIERCING
Piercing is the operation of cutting internal features (holes or slots) in stock.
 Trimming operations are generally combined with piercing operation and
accommodated in the same die.

14. PARTS STORAGE& HANDLING
Parts after production are needed to be stored safely to avoid small deformities such as
dent, ding etc. This is where the trolleys come into play.
Forklift: It is used to transport the trolleys from production area to the storage area.
Forklifts used in HCIL are mainly Toyota. It has a capacity of carrying 3 trolleys at a time.
It has a speed limit of 10 km/hr.
TROLLEY
A structure used to stack parts such as hood skin, SPOs, FR Fender, etc. for storing
purposes. After part stacking trolleys are in turn stacked upon each other according to the
name or code of the trolley. In HCIL, the parts manufactured are of brio, city and jazz.

15.  DESIGN AND FABRICATION OF FRAME.
Design and fabrication of frame.
DESCRIPTION: Frame was to be fabricated for the new model which is to be used in the
press no. 3. Jig is to be such designed that part after getting trimmed in the 2nd press is
placed in the press no. 3 and part are to be separated by a certain distance (390 mm) so
that bending process can be done at press no. 4.
FABRICATION:
 Keeping in mind the bolster area as well as the new part, THREE frames were
fabricated on which part is to be placed with the help of robots.
 There was the height difference between frame-1 and frame-2 and the smaller frame
(frame-2) contains a sliding frame (frame-3) above it which will be displayed 390 mm
with the help of a pneumatic cylinder.

16. COMBINED FRAME
FRAME-1FRAME-2,3

17. 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 operate 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 jams 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. To overcome this,
die cleaning is done.