This document provides information about Govind Sharma's training at Honda Motorcycle & Scooter India Pvt. Ltd. in Manesar, Haryana. It discusses that Honda was established in India in 1999 and is a major motorcycle manufacturer. Govind trained in frame assembly, specifically for the Honda Unicorn 160 model. The document outlines the inspection processes used and details several defects identified for the Unicorn 160 at launch, along with the root causes found and countermeasures implemented to reduce defects per vehicle and increase direct pass ratio.

2. SUBMITTED BY
Govind Sharma
HONDA MOTORCYCLE & SCOOTER INDIA
PVT. LTD, MANESAR (HARYANA)

3. HONDA MOTORCYCLE & SCOOTER INDIA PVT.
LTD, MANESAR (HARYANA)

4.  HONDA establish in 1999 at Manesar ( Haryana )
 HONDA is a Japanese Public Multinational .
 HONDA is a largest motorcycle manufacturing company.
 HONDA deals with 2-wheeler, 4-wheeler and power
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 in Ahmadabad ,Gujarat
My training is at HSMI Manesar in frame Assembly

5.  HONDA EMPIRE

6. PRODUCTS
Honda AVIATOR
Honda ACTIVA(110;125;ACTIVA I;3G)
Honda Dio
Honda dream neo
Honda Shine
Honda CBF Stunner
Honda CB Unicorn Dazzler
 Honda Yuga
Honda Unicorn 150
Honda CB trigger
Honda CBR 150R
 Honda CBR 250R
 Honda Unicorn 160 (new model)
Honda CBR 650 (new model)

7.  Low Pressure Die Casting
 Machine Shop
 Press Shop
Weld Shop
Paint Shop
Engine Assembly
Frame Assembly

8.  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

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

11. MY DEPARTMENT
WELD PI

12.  The term PI refers to a pre-inspection in which the
product manufactured in manufacturing process is
inspected before it is transferred to the assembly line in
order to obtain the final product output.
 There are three assembly Line.
◦ The first line is for Activa only.
◦ The second is in Motorcycle plant where both scooter and
motorcycle are assembled.
◦ The third is for the new model line and only meant for only
motorcycles.

13.  I worked on frame assembly line 3 that assembled new
models.
 Modals at Frame Assembly line 3
A/F FRAME ASSEMBLY
KYJM CBR 250KSPP
K-38 KPPR CBR 150

15. 1. First Principle Inspection
2. Gauge Inspection
3. Visual Inspection
4. CMM Inspection

16.  First principle inspection is the inspection in which the
parts are inspected with the help of measuring
instruments so as to ensure the part is accurate as per
the working standards.
 Measuring instruments like Vernier Caliper, Height
Gauge, V-Block etc

17.  Gauge inspection is the inspection tool used to check a
work piece against its allowed tolerances.
 The gauge has two tests; the check involves the work
piece having to pass one test (Go) and fail the other
(No Go).
 It is used in the manufacturing industry to ensure
interchangeability of parts between processes, or even
between different manufacturers.

18.  It is defines as the examination of the material,
component or a product for condition of non
conformance using light and eyes alone or with
conjunction with various aids.
 Visual inspection is commonly employed to support
other NDT methods.
 Several Characteristics about the part being examined
may be determined which include dimensional
conformance, the presence of discontinuities, general
fit and wear.

19.  CMM is defined as Co-ordinate Measuring Machine.
 This machine is imported from Japan which is used to
inspect the co-ordinates of the part randomly.
 A coordinate measuring machine (CMM) is a device
for measuring the physical geometrical characteristics
of an object. This machine may be manually controlled
by an operator or it may be computer controlled.
 A machine which takes readings in six degrees of
freedom and displays these readings in mathematical
form is known as a CMM

20. CMM MACHINE

21.  Sorting (seiro)
 Stabilize (seiton)
 Systematic Cleaning (seiso)
 Standardizing (seiketsu)
 Self-Discipline (shitsuke)

23. The Project is to improve the DPR (direct pass ratio) of
model K-38 (Unicorn 160). DPR is improved by
reducing the defects. By removing of defects DPV
(defects per vehicle) decreases. Unicorn 160 is a new
model on line the mass production of which was started
in Jan 2015. As it is a new model and as per HMSI every
single part of new model is inspected so as to get high
production i.e. improved DPR

24.  Fitment defects
 Appearance defects
 Functional defects
 Routing defects
 Noise defects
 Play defects

25.  Scratches on parts
 Rear light switch spring open
 Handle movement hard
 Fuel tank not set
 Part miss
 Part fitment N/G
 Nut free

26. Target of DPR 75%

27. Target of DPV 0.04

28. Defect ok
Root cause: - The brake paddle stay is 2mm up as per the design of the component.

29. REAR COWL SCRATCH
Rear cowl RCC

30. Root cause
Loading in marshalLoading Unloading from marshal Strip pasting Tail lighting putting
Fitment on frame
Problem Category Why 1
Scratch generation due to
man/method
Improper Handling
Mishandling of parts during loading and
offloading
Awareness not present for defect generation
Scratch generation due to
Tool & Jigs
Machine Scratch generation from Socket of Gun

31. DEFECT REPORT AFTER APPLY THE
COUNTERMEASURE
RESULT
85% defects of rear cowl scratch reduced

32. FUEL TANK SCRATCH
Root cause
Fuel tank loading in
the paint area.
Fuel tank leakage
testing
Fuel tank
unloading from
marshal

33. Problem Category Why 1
Scratch generation due to
man/method
Improper Handling
Mishandling of F/Tanks during loading and
unloading
Scratch generation due to
Jig and Fixtures
Machine
Scratch generation at the time of fitment oil
gauge, nob & Uncovered Fuel Tank
Leakage Testing Container
Countermeasures
92% defects of fuel tank scratch reduced

34. SIDE COVER SCRATCH
Root Cause
Countermeasure
change the
loading position of
the side cover
85% defects of fuel tank scratch reduced

35. Thread of the component damage at the time of
nut tightening.
Root cause Nut taper tightening
85% defects of stem nut reduced

36. DPV REPORT OF MARCH
OVER ALL RESULT
0.51 DPV reduced from month Feb to April

37. DPR REPORT OF MARCH
OVER ALL RESULT
64.4% DPR increase from month Feb to April

38. THANK YOU