Production Management of Honda

1. PRODUCTION
PROCESS OF
HONDA
MOTERBIKES
PRODUCTION
MANAGEMENT

3. HISTORY OF HONDA BIKES

The 'Honda Motor Company' was found in 1948, by Soichiro
Honda (1906—1991), a mechanic and engineer/inventor who
began as a blacksmith, working at his father, Gihei Honda's
bicycle repair shop. In 1938, at the age of 32, Soichiro Honda
was working at an auto repair-shop in Tokyo, called Art
Shokai, where he began using his self-taught mechanical and
engineering skills. Honda briefly studied mechanical
engineering and design at Hamamatsu Technical High
School, where Honda perfected his new design for the piston
ring.

4. HISTORY OF HONDA BIKES

During the Japanese reconstruction period of the early
1940s, Soichiro Honda began designing motor-driven
bicycles. Honda built his first motor-scooter, known simply
as the "A-Type," in 1947.

One year later he started the 'Honda Motor Company' and
began building small-displacement 'tiddler' style motorscooters. Honda introduced his first motorcycle in 1949; the
'Dream D-Type' with a 3 horsepower, 98cc engine. Hondas
were also sold under the "Benly" name, with "Honda"
appearing on the engine case

5. THE MANUFACTURING PROCESS

According to the need of the company for manufacturing of
motorcycles the material is requisitioned and a purchase order
is sent to the suppliers by the purchase department and the
Honda industry purchases the material from outside the country
as well as within country through local costing. Raw materials
which consist of parts and components arrive at the
manufacturing plant by truck or rail and the transportation
charges are paid by the Honda industry.

6. THE MANUFACTURING PROCESS

The defected materials and parts are returned to the places
from where they come after inspection. Different materials
are sent to the different departments for the further
procedure.

The manufacturing process is completed in three major steps
which are

Paint Shop.

Engine Assembling.

Frame Assembling.

7. PAINT SHOP
 The
raw materials which consist of parts
in the case of motorcycle are sent to the
paint shop for painting.

8. POWDER COATING

Plastic and metal parts and components are painted
in the paint department using a process known as
powder-coating

A powder-coating apparatus works like a large spraypainter, dispersing paint through a pressurized
system evenly across the metal frame.

9. CHARGED PARTICLES

First of all the parts are negatively charged with the
help of the electrons then the positively charged
particles in the form of color are sprayed to these
charged parts.

The paints are not spoiled by sun and rain.

10. PAINTING OF PARTS

The parts which are painted in the a single unit of
motorcycle are

Fuel Tank.

Side Cover set.

Swing Arm.

Hub Front.

Panel Front.

Magnet Front.

Top Bridge.

11. PAINTING OF PARTS

These are the painted body parts of motorcycle

Handle Cover.

Clutch Plate.

Main Stand & Side Stand.

Muffler Stand.

Battery Stand.

Step Bar.

Meter Bracket.

Head Top Cover.

Head Right Cover.

Tappit Covers set

12. LABOUR FORCE
 There
are 18 labourers which work in this
department and they are given hour wise
wages by the Company. Company offers
Rs.25/- per hour to each of their labourer.

13. DIRECT LABOUR
 There
are 10 people who are working in
this department in the production
process

14. INDIRECT LABOUR

The remaining 8 are working as indirect labors. These
6 people includes

3 Supervisors.

2 Sweepers.

3 people which are working on moving trail from one
channel to another for the shifting of materials.

15. DIRECT MATERIAL

The materials which are using in this department as a direct
material and their costs are :-

Theses are the cost for one unit :
Fuel Tank.
Rs.850/-

Side Cover set.
Rs.750/-

Swing Arm.
Rs.460/-

Hub Front.

Panel Front.
Rs.50/-

Magnet Front.
Rs.200/-

Top Bridge.
Rs.175/-

Handle Cover.
Rs.50/-
Rs.140/-

16. 
Clutch Plate.
Rs325/-

Main Stand.
Rs250/-

Side Stand.
Rs150/-

Muffler Stand.
Rs75/-

Battery Stand.
Rs70/-

Step Bar.
Rs125/-

Meter Bracket.
Rs200/-

Head Top Cover.
Rs40/-

Head Right Cover. Rs85/-

Tappit Covers set.

Total cost for direct material =

If we are going to produce 150 units then the cost will be Rs.583050/-
Rs100/Rs3887/-

17. ENGINE ASSEMBLING

Engine is the most important
part of the motorcycle. All
working of the motorcycle
depends upon this part. There
are 17 steps which take place
in assembling of the engine.
The parts of the engine which
are purchased in the form of
raw material are sent to the
engine assembling room.

18. PISTON CONNECTION

The first step in the assembling of engine is connecting
the piston with push rod. A cylindrical piston, made of
aluminum alloy (preferred because it is lightweight and
conducts heat well), is an essential component of the
engine.

19. VALVE LIFTER

In second step, It is fitted with piston rings made of cast
iron. Then the valve lifter is placed below the piston and
the push rod and spark lead is installed.

20. INLET & COMBUSTION CHAMBER

In third step, the inlet part is established in the combustion
chamber which is fitted with the piston. The cooling fan is
also placed which helps the piston to remain cool at time
when the motorcycle is driven more by the driver

21. CRAKCASE

Crankcase is plugged then the oil pump is installed with
the engine mountain belt and oil passage way is placed
in the engine on the crankcase which circulates the oil in
the whole engine which helps the engine to be work more
smoothly and efficiently. The crankshaft and crankcase
are made of aluminum.

22. TIMING GEAR WITH PISTON

The one of the important step in the assembling of the
engine is the establishment of timing gear with the piston
through engine mountain belt hole.

Crankshaft and Camshaft gear is placed on the
crankcase.

The engine also contains a cylinder barrel, typically
made of cast iron or light alloy.

23. EXHAUST PORT

The exhaust port is placed at the mouth of combustion
chamber which throws all the heat out from the engine.

Finally the rocker arm is placed and the screws are
placed in the rocker arm. These are the steps which are
taken place in the assembling of the engine.

25. FRAME ASSEMBLING

This is the last step in the manufacturing process of
motorcycle. In this process the framing of the motorcycle
takes place and all the parts of the motorcycle are
combined by labor energy. The framing consists of 12
steps.

The motorcycle frame is composed almost completely of
metal, as are the wheels. The frame may be overlaid with
plastic. The tires are composed of rubber. The seat is
made from a synthetic substance, such as polyurethane.

26. FRAME ASSEMBLING

The power system consists of a four-stroke engine, a
carburetor to transform incoming fuel into vapor, a choke to
control the air-fuel ratio, transmission, and drum brakes. The
transmission system contains a clutch, consisting of steel ball
flyweights and metal plates, a
crankshaft, gears, pulleys, rubber belts or metal chains, and
a sprocket. The electrical system contains a battery, ignition
wires and coils, diodes, spark plugs, head-lamps and
taillights, turn signals and a horn. Wheels, brakes, wiring
cables, foot pegs, exhaust
pipes, seats, saddlebags, lights, radios, and hundreds of
other parts are installed on the motorcycle frame

27. PRE DELIVERY INSPECTION (PDI)

At the end of the assembly line, the pre-delivery inspection
takes place in which inspectors undertake a visual inspection
of the motorcycle's painted finish and fit of parts.

The inspectors also feel the motorcycles with gloved hands
to detect any bumps or defects in the finish.

Each motorcycle is tested on a dynamometer. Inspectors
accelerate the motorcycle from 0-60 mph.

28. PRE DELIVERY INSPECTION (PDI)

During the acceleration, the "dyno" tests for acceleration
and braking, shifting, wheel alignment, headlight and
taillight alignment and function, horn function, and exhaust
emissions.

After the dyno test, a final inspection is made of the
completed motorcycle.

29. STORE ROOM

After inspection the finished goods are sent to the store
room and then from there these are shipped to the
customers from where these are demanded.

30. THANK
YOU