YAMAHA

TRAINING REPORT
(Production Department)

Submitted To: Submitted By

Mr.R.Miglani Sumit
Gauer
Production Dept
B.Tech(ME)
IYM PVT LTD. SIET
Gr.NOIDA

INDEX

S no. Description Page

1. Certificate 3
2. Acknowledgement 4
3. Purpose of internship 5
4. Introduction 6
5 History of Yamaha 7-8
6 Overview 9-10
7 India Yamaha Motors 11-12
8. Vision 13
9. Mission 13
10. Manufacturing in Yamaha 14
11. Quality Engineering 15
12. Paint Shop 16-23
13. Project On Any 24-25
Abnormality in
Pretreatment Process
14. Conclusion 26

CERTIFICATE

This is to certify that the project entitled “Any Abnormality in

Pretreatment Process(Fuel Tank)” has been carried out by

SUMIT GAUR under my guidance in partial fulfillment of the

requirement of the case study during summer training. To the
best of my knowledge and belief this work has not been
submitted elsewhere for any purpose.
 Mr. P.K Arora
Mr R. Miglani
HEAD Deptt.
Head & project leader
Paint Shop (Q.E -
Division)

ACKNOWLEDGEMENT

I express my gratitude to all the people at INDIA

YAMAHA MOTOR PVT. LTD who helped me to gain the
valuable knowledge and experience. I have no doubt that
my choice of training at IYM was right. The exposure and
experience gained at IYM has been unique. The Yamaha
family teaches strict self discipline and goal oriented
approach.

I would like to thank my mentor at Yamaha Mr.

R..Miglani, Mr. P.K Arora acquainted with the
work ethics of the organization and motivating me at each
 and every step so that I achieve my goal at Yamaha with
perfection.

Last but not the least I would like to thank Quality

Engineering department for their cooperative behavior.

PURPOSE OF INTERNSHIP

The importance of practical on the job training in the industry

for engineering student cannot be over emphasized. Industrial
training plays the most important role in an engineering
student’s life to make him a successful engineer. It provides the
student with an opportunity to gain valuable experience on
practical application of their technical knowledge.
At SIET College of Engineering, great emphasis is laid on-the-
job training an industrial training. This is an integral part of
curriculum.
This six week industrial summer training (15th June to 31st July,
2009), after six semester is in-built in to the B-Tech. program.

INTRODUTION
Yamaha Motor Co. Ltd. Was founded in 1955 with Genichi kawakami
as the first president. Today, Yamaha Motor is the world second largest
producer of motorcycle .It also produces many other motorized vehicles
such as all-terrain vehicle boats snowmobiles, Outboard motors and
personal watercraft .Takashi kajikawa is the current president of
Yamaha Motor Corporation. The corporation has 109 consolidated
subsidiaries as on March 31st march, 2008. Yamaha motor corporation
stated aim is to bring people to great joy , happiness and to create Kando
(touching heart )in their lives As a company that makes the world its
field and offer product for the land , the water , the snowfields and the
sky , Yamaha motor strives to be a company that “ offer
 New excitement and a more fulfillment life for people all over the
world” and to use its ingenuity and passion to realize people ’dreams
and always be the ones they look for “the next Kando”. Kando is the
Japanese world that captures the intense excitement and deep
satisfaction people feel .when they experience truly of exceptional value.
Yamaha motor seeks to make Kando a distinctive benefit of everything
we do by creating product and services that consistently exceed your
expectations.

HISTORY OF YIC
The history of Yamaha is a history of unending “challenges”

YEAR Mile Stones

1955 Yamaha Motor Co., Ltd. was founded with Genichi Kawakami as the first
President
1959 Kitagawa Motor Co., Ltd. joins Yamaha Motor group.
1960 Yamaha International Corporation (YIC) founded in U.S.
First Yamaha outboard motor "P-7" released
1963 Nationwide Yamaha Kai (authorized dealership organization) launched
Pearl Yamaha founded in India as tie-up with local funding & starts production
and sales of mopeds
1964 Siam Yamaha Co., Ltd founded in Thailand
1965 First Yamaha FRP fishing boat "3rd Fuji Maru" built
1969 First Yamaha multipurpose engine model "MT100" released
1970 First Yamaha motorcycle mounting a 4-stroke engine "XS1" released
First Yamaha portable generator model "ET1250" released
1973
First Yamaha racing kart model "RC100" released
1975 First Yamaha golf car model "YG292" released
 First Yamaha industrial robot model, an "arc welding robot" released
1976
First Yamaha marine diesel "MD35" released

First Yamaha land car model "G1-AD" released

1978
First Yamaha snow-thrower model "YT665" released
1986 First Yamaha personal watercraft (PWC) "MJ-500T" released
First Yamaha-made surface mounter "21 Series" released
1987
First Yamaha gas heat pump (GHP) model "YGC401W" released
Yamaha Motor France S.A. (YMF) founded
1991
Yamaha Motor de Mexico, S.A. de C.V. (YMMEX) founded
Chongqing-Jianshe Yamaha Motorcycle Co., Ltd. (CJYM) founded in China
1992 Yamaha Motor Austria GmbH (YMAG) founded
Yamaha Motor Hungaria Kft. (YMH) founded
1993 Regionally limited release of the electro-hybrid bicycle "PAS"
Wheelchair electric power unit "JW-I" released, bringing Yamaha into the
1995 health and welfare industry
Urban commuter motorcycle "Majesty YP250" released
"Environment 2000 Plan" announced
1996 Yamaha is first domestic manufacturer to be awarded international ISO9002
certification for motorcycles, snowmobiles, ATVs
Y's Gear Co., Ltd. Founded
1997
PT. Yamaha Motor Nuansa Indonesia (YMNI) founded
1999 2010 Environmental Action Plan "Eco Cite YAMAHA" announced
2000 Yamaha Motor Asian Center Co., Ltd. (YMAC) founded in Thailand
Yamaha builds temporary pool "Suimu 21" for the main competition pool of the
2001
9th World Swimming Championships in Fukuoka, Japan
2002 Limited regional release of the electric commuter motorcycle "Passol"
Yamaha Motor Distribution Singapore Pte. Ltd. (YDS) founded
2003
Yamaha Motor Co., Ltd., Moscow Representative Office opened in Russia
2004 Start of "YAMAHA CCS 21 Campaign"
Sales company Yamaha Motor CIS (YMCIS) founded in Russia
2005 Life Science Laboratory opened in Fukuroi, Shizuoka,as research&development
center for YMC's bio-technology business
Motorcycle manufacturing factory Yamaha Motor Manufacturing West Java
2006
(YMMWJ) founded in Indonesia
2007 Compliance Promotion Committee established.
 OVERVIEW

Founded July 1, 1955

Capital 48,302 million yen (as of March 31, 2008)

President Takashi Kajikawa

Employees 46,850 (as of December 31, 2007)

Parent: 9,019 (as of December 31, 2007)
(Consolidated)
Sales 1,756,707 million yen
(from January 1, 2007 to December 31, 2007)
(Consolidated) Parent: 799,209 million yen
(from January 1, 2007 to December 31, 2007)
Sales Profile Sales (%) by product category (consolidated)

Sales (%) by region (consolidated)

Major Manufacture and sales of motorcycles, scooters,

electro-hybrid bicycles, boats, sail boats, Water
Products & Vehicles, pools, utility boats, fishing boats,
Services outboard motors, diesel engines, 4-wheel ATVs,
side-by-side vehicles, racing karts, golf cars,
multi-purpose engines, generators, water pumps,
snowmobiles, small-sized snow throwers,
automotive engines, intelligent machinery,
industrial-use remote control helicopters,
electrical power units for wheelchairs, helmets.
 Biotechnological production, processing and
sales of agricultural and marine products and
microorganisms. Import and sales of various
types of products,
Headquarters 2500 Shingai, Iwata-shi, Shizuoka-ken, Japan

Affiliated Consolidated subsidiaries: 112

Non-consolidated subsidiaries: 8
Companies (by the equity method)
Affiliates: 27
(by the equity method)

Yamaha Motor Co., Ltd.

Yamaha Motor Co., Ltd.

Public
Type Public
Founded July 1, 1955
Headquarters Iwata, Shizuoka, Japan
Revenue 12 billion US$ (2005)
Operating income 900 million US$ (2007)
Net income 550 million US$ (2007)
Employees 39,300 (2007)
Website Yamaha Motor Global
 INDIA YAMAHA MOTOR (IYM)

Holding the true sprit of commitment to customer satisfaction –India

Yamaha motor is enriching lives of people with same ingenuity and
enthusiasm as its parent company -Yamaha motor corporation Japan.
Having operated in India as technology provider for almost two decade,
IYM was incorporated in August 2001 as a 100% subsidiary of YMC,
Japan. Since then it is in process of the business and extending the awe
and power associated with the legacy of the Yamaha Group.
Adhering to Yamaha Motor Corporation’s corporate Mission –“Creating
Kando-Touching Your Heart” Yamaha motor India is striving to touch
every heart across the length and breadth of India.
YMI`s Manufacturing facilities comprises of 2 state –of –the art plants at
–Surajpur (Uttar Pradesh) , Faridabad (Haryana) currently 10 models
roll out at the two plants of Yamaha . The models manufactured and
assembled at the Surajpur plant are;
1. Gladiator
2. G5
 3. Crux
4. Alba
5. Enticer
6. R-15

The infrastructure at both plants support production of bikes and its parts
for domestic as well as oversees market. At the core of 5-S and TPM
activities that fuel the IYM `s agile manufacturing processes IYM has
in house facility for Machining Welding processes as well as Finishing
processes of Electroplating and Painting till the assembly line .

The stringent quality assurance norms ensure that the bikes meet the
reputed International Standards of excellence in every sphere.

As an Environmentally sensitive organization IYM has the concept of

“Environmentally-Friendly Technology” ingrained in its Corporate
Philosophy. The company boasts of effluent Treatment Plant, Rain water
Harvesting mechanism, a motivated forestation drive. The IYM is ISO-
14001 certified. All our endeavors give us reason to believe that
sustainable development for Yamaha will not remain merely an idea in
pipeline.
We believe in taking care of not only your motoring needs but also the
needs of future generation to come.
 VISION
We will establish YAMAHA as the "exclusive & trusted brand" of
customers by "creating Kando" (touching their hearts) - the first time
and every time with world class products & services delivered by people
having "passion for customers".

MISSION
Yamaha is committed to:

Be the Exclusive & Trusted Brand renowned for marketing and

manufacturing of YAMAHA products, focusing on serving our customer
where we can build long term relationships by raising their lifestyle
through performance excellence, proactive design & innovative
technology. Our innovative solutions will always exceed the changing
needs of our customers and provide value added vehicles.

Build the Winning Team with capabilities for success, thriving in a

climate for action and delivering results. Our employees are the most
valuable assets and we intend to develop them to achieve international
level of professionalism with progressive career development. As a good
corporate citizen, we will conduct our business ethically and socially in
a responsible manner with concerns for the environment.

Grow through continuously innovating our business processes for

creating value and knowledge across our customers thereby earning the
loyalty of our partners & increasing our stakeholder value

MANUFACTURING IN YAMAHA
IYM's Manufacturing facilities comprises of 2 state-of-the-art Plants at -
Faridabad (Haryana) and Surajpur (Uttar Pradesh). Currently 10 models
roll out of the two Yamaha Plants.

The infrastructure at both the plants supports production of motorcycles

and it's parts for the domestic as well as oversees market. At the core are
the 5-S and TPM activities that fuel our agile Manufacturing Processes.
We have In-house facility for Machining, Welding processes as well as
finishing processes of Electroplating and Painting till the assembly line.

The stringent Quality Assurance norms ensure that our motorcycles meet
the reputed International standards of excellence in every sphere.

As an Environmentally sensitive organization we have the concept of

"Environment-friendly technology" ingrained in our Corporate
Philosophy. The Company boasts of effluent Treatment plant, Rain
water - Harvesting mechanism, a motivated forestation drive. We
believe in taking care of not only Your Motoring Needs but also the
needs of Future Generations to come.

QUALITY ENGINEERING

HEAD OF DEPARTMENT –MR R.MIGLANI

The Quality Engineering Department works in very close co-ordination

of all other as Quality is at the top priority at Yamaha Motor. At each
step of production operation quality check is undertaken. If any defect is
recorded represented properly with the help of Mean and Range charts
and the cause of defect is analyzed in detail. Then the required steps are
taken to ensure that the quality problem doesn’t occur. A very important
measure of Quality is SPRI (Spare Part Rejection Index). It is the ratio
of qualitatively good parts to the total number of produced parts. Quality
plans are made and every endeavour aim to only one end: Getting the
Quality right the first time.
 Quality Engineering

Parts Exports Assembly

Machine shop CKD Body Assembly

Weld shop CBU Engine assembly
Press shop IKD
Paint and Electroplating SKD

Project:AnyAbnormality in Pretreatment
Process Of Fuel Tank

I. After phosphate process, water rinse the fuel tanks

are passed through the vacuum chamber where water
droplets are dried out with the help of dry sprayer.

II. Dry Oven(water drying):-In this process fuel tanks

are heated so that water can dry out completely from
the fuel tanks.
 III. Cooling Zone:-In this zone, fuel tanks get sufficient
time to get cooled down for easy handling of the fuel
tanks for further coming processes.

IV. Masking Zone:-In this zone, drilled parts of the fuel

tank are covered by covering material in order to
prevent the entry of the paint inside it. If masking is
not done then paint will enter inside the hole and it
may create problem during assembly process.

V. In this zone, there is a possibility of leakage(alkali

sol. in water) in fuel tank. We can remove this
leakage by rubbing alcohol on that portion of fuel
tank.

VI. Dusting;- Now dusting is done to remove the dust

particle by blowing air on the fuel tanks.

VII. Electrostatic Spray Painting:- Here required color

coating is done on the substrate with the help of
electrostatic charge using Electrostatic Disk.

VIII. After that, remaining part of the fuel tanks is done

manually.
.
 CONCLUSION

The period of my training at Yamaha Motor India Pvt. Ltd. has

been a very positive one. It has given me a very good
understanding of the engineering profession which could not
have been achieved by theoretical study. The experience at IYM
has greatly advanced my understanding of the practical aspects
of engineering, both technical and organizational.

The vital part that the organizational skills of an engineer play in

today’s industry is an area that is often missed by some. I too
had very little idea as to what an engineer’s job in a high-tech
industry entails. But this internship at IYM made me see the
maximum range of jobs performed by engineers. It has given me
a solid foundation to build my career upon. I am certain that the
experience gained through this internship will be helpful to me
throughout my professional career and in all my future
endeavors.