SUMMER INDUSTRIALTRAINING REPORT

HONDA CARS INDIA LTD.

SPL-1, Tapukara Industrial Area, Khushkhera Distt. Alwar, Rajasthan 301707. INDIA

PROJECT REPORT ON
STUDY OF OPERATIONAL EFFICIENCY OF PRESS LINE

By- SAURABH MUNJAL 2010JE0934 MECHANICAL ENGINEERING 7th SEM

HONDA CARS INDIA LTD., TKR PLANT

Honda Cars India Ltd., (HCIL) was incorporated in December 1995 as a joint venture between Honda Motor Co. Ltd., Japan and Siel Limited, a SiddharthShriram Group company, with a commitment to providing Hondas latest passenger car models and technologies, to the Indian customers. The total investment made by the company in India till date is Rs 1620 crores in Greater Noida plant and Rs 784 crores in Tapukara, Bhiwadi plant.

HCILs first state-of-the-art manufacturing unit was set up at Greater Noida, U.P in 1997. The green-field project is spread across 150 acres of land (over 6, 00,000 sq. m.). The annual capacity of this facility is 100,000 units. The companys second manufacturing facility is in Tapukara, Rajasthan. This facility is spread over 600 acres and will have an initial production capacity of 60,000 units per annum, with an investment of about Rs 1,000 crore. The first phase of this facility was inaugurated in September 2008.

MODELS COVERED IN PRESS SHOP

S.No
MODELS SHAPE MODELS NAME

HONDA CITY

HONDA BRIO 2

HONDA AMAZE

OVERVIEW
Max production Raw Material Type Vendor Finished Product 700 car units in 3 shifts(approx.) Processed Sheet Blank RPSC HCIL-GNU

INTRODUCTION
HCIL (TKR) produces Sheet metal parts for car body in the press dept. The department has an automatic tandem press line with first press machine having capacity of 1500 ton followed by 3 Press machines with capacity of 1000 ton each. It also has 5 Robots for parts movement from one process to next process and a De-stack feeder assembly for automatic feeding of blanks in press line for processing. RPSC supplies blanks as raw material as per Personal RapiD Transportation (PRT) system controlled by Production Control Department. The blanks are stored in press department and loaded on the press line according to the plan. The blanks are processed in dies to be converted into parts. The parts are packed in trolleys after going through check on conveyer. The repair parts are shifted to Handwork area for repair and No Go parts are put in red colored scrap bin. The OK parts trolleys are stocked at Trolley stock area. The parts are packed in PLC trolleys from press production trolleys according to their packing standard and delivered to GNU plant. Press dept. also has sub depts. of Planning and Production, Quality Control, Machine Maintenance and Die Maintenance and New Model. Safety as the first priority is an integral part of the work culture here at HCIL. Safety is promoted through regular training and various awareness workshops regarding safety like KYT are conducted regularly, through presentations for workers at all levels.

PROCESS FLOW DIAGRAM

PRESS SHOP

The first shop in the manufacturing process, the Press Shop is responsible for pressing the outer and inner body panels of the vehicle. The feeding system pushes a strip of metal (as it unrolls from a coil) through all of the stations of a progressive stamping die. Each station performs one or more operations until a finished part is made. The final station is a cutoff operation, which separates the finished part from the carrying web. The carrying web, along with metal that is punched away in previous operations,is treated as scrap metal. The progressive stamping die is placed into a reciprocating stamping press. As the press moves up, the top die moves with it, which allows the material to feed. When the press moves down, the die closes and performs the stamping operation. With each stroke of the press, a completed part is removed from the die. Since additional work is done in each "station" of the die, it is important that the strip be advanced very precisely so that it aligns within a few thousandths of an inch as it moves from station to station. Bullet shaped or conical "pilots" enter previously pierced round holes in the strip to assure this alignment since the feeding mechanism usually cannot provide the necessary precision in feed length. The dies are usually made of tool steel to withstand the high shock loading involved, retain the necessary sharp cutting edge, and resist the abrasive forces involved.The cost is determined by the amount of features, which determine what tooling will need to be used. It is advised to keep the features as simple as possible to keep the cost of tooling to a minimum. Features that are close together produce a problem because it may not provide enough clearance for the punch, which could result in another station. It can also be problematic to have narrow cuts and protrusions

EquipmentsIn Press Line

De-Stack Feeder

Salient Features Press Machine : 4 1500 Ton 1Nos. 1000 Ton 3Nos. No. of Robot : 5 Scrap Conveyor : 1

Parts Handling Robot

Scrap Conveyor

Press Machine

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. The number of sheets loaded is 250. For door panel the number of sheets is less as the door panel consists of 2 sheets of varying thickness of 0.6mm and 1.25mm due to weight and strength considerations. For SPO the number of sheets is less due to weight considerations. Once the number of sheets reduces to 50 the Auto Lifter takes over and the stack lifter is free for the next run of loading. This saves time.

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.

SPECIFICATIONS
The specifications and material of blanks goes inside the feeder areMATERIAL OF BLANK COLD ROLLED STEEL SHEETS, HEAT ROLLED STEEL SHEETS, HIGH TENSILE STRENGTH STEEL SHEETS, SURFACE TREATED STEEL SHEETS, TAILORED BLANK

THICKNESS ONE BLANK MAXIMUM SIZE MINIMUM SIZE STACK WEIGHT BLANK SHEET WEIGHT STACK HEIGHT No. OF STACK PASS LINE HEIGTH 4000mm 1800mm 800mm 500mm

0.5- 2.3mm TWO BLANK 1800 1800mm 800 500 MAXIMUM 2500 kg./ 1 STACK MAXIMUM 15 kg./ 1 BLANK

MAXIMUM 5000 kg./ 1 STACK MAXIMUM 30 kg./ 1 BLANK

MAX. 400mm 2 STAGES ABOVE FLOOR LEVEL 1600m

DE STACKER CUP

De stacker cups

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. This sheet is moved to D.B. positioned. Tolerance of this thickness measuring

sensor is 0.1 mm. These cups move the first and last blank to D.B. basket which is on the back side. It collects the first and last blank of all stacks after a time these sheets are sent for reuse in stacks. This is because of dust particles on the first sheet and deformation due to all sheets on the last sheet.

MAGNETIC FLOATER

MAGNETIC FLOATER

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 doesnt change the position of the sheet.

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.

Pinch roller: It feeds the sheet used for directing. Brush roller: On their top there are nozzles which keep spraying oil on the blanks and brushing the blanks. Wasted oil is collected below into the drain. Winger roller: These rolls were used for cleaning and forwarding of blanks. They take out excessive oil from the blanks and forward them to the centering movement. There is an option to bypass the washing unit.

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 3. Side stopper

ROBOTS

Stopper

SPECIFICATIONS OF PRESS
FIRST PRESS MACHINE 1500 T DRAW:

In this press machine drawing process is carried out.

MAKE CAPACITY LIMIT OF CAPACITY SLIDE STROKE STROKE PER MINUTE SLIDE ADJUSTMENT DIE HEIGHT SLIDE AREA HITACHI ZOSEN FUKUI 15000 kN = 1500 T 13 mm 900 mm 12 18 spm 500 mm 1250 mm 4500 2200 mm

BOLSTER AREA AIR PRESSURE MAIN MOTOR ADJUST MOTOR

4500 2200 mm 0.98 MPa AC 250 kW ; 4P AC 15 kW; 6P

PRESS MACHINE 2, 3&4 1000 T In this press machines operations like trimming,bending, piercing and punching is done.

MAKE CAPACITY LIMIT OF CAPACITY SLIDE STROKE STROKE PER MINUTE SLIDE ADJUSTMENT DIE HEIGHT SLIDE AREA BOLSTER AREA AIR PRESSURE MAIN MOTOR ADJUST MOTOR

HITACHI ZOSEN FUKUI 10000 kN = 1000 T 13 mm 900 mm 12 20 spm 500 mm 1350 mm 4500 2200 mm 4500 2200 mm 0.98 MPa AC 160 kW ; 4P AC 11 kW; 6P

ROBOTS

There are 5 robots present in the press machine which help in facilitating the movement of sheet metal part from one press to another and finally the finished part onto the conveyor belt. The primary function of the robots is to facilitate the movement of parts from one die to the other. The robots are attached with jigs and fixture specific to the part being produced. The jigs contain vacuum cups which lift the component to be transferred. The robot arms move about the axes which allow their movement.
Make Number of Robots Number of axes S L U R B T Motoman 5 6 Spin (270) Lower Arm Upper Arm Rotate Bend Twist

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

BLANK

DRAWN PART

2.) TRIMMING For cutting excess material from a part made by drawing.

DRAWN PART

TRIM PART

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.

PARTS MANUFACTURED
S.NO. PART NAME Hood skin CITY BRIO AMAZE

1.

2.

Hood frame

3.

Fr. Fender RH

4.

Fr. Fender LH

5.

Roof panel

6.

SPO RH

7.

SPO LH

8.

Fr. Door Skin RH

9.

Fr. Door skin LH

10.

Rr. Door skin RH

11.

Rr. Door skin LH

12.

Fr. Door panel RH

13.

Fr. Door skin LH

14.

Rr. Door skin LH

15.

Rr. Door skin RH

16.

Trunk lid skin

17.

Trunk lid frame

19.

Rr .inside LH

20.

Rr. Inside RH

SEQUENCE OF PRODUCTION
The predetermined sequence of parts is followed while production to avoid confusion and to facilitate easy coordination between various departments.

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. The trolleys of three cars are differed by their color coding given below: 1. White for brio 2. Green for city 3. Yellow for Amaze The structures of trolleys are differed according to the parts they are holding. For e.g. trolleys holding hood skin contains panels whereas trolleys holding door frames have rods.

Different types of trolleys: S. No. TROLLEY Type of trolley

1.

HORIZONTAL SLIDING

2.

3 POINT SUPPORT TROLLEY (FR FENDER)

3.

SLIDING (TRUNK LID)

4.

HANGING(SPO)

5.

SLIDING(SPOILER)

6.

VERTICAL PILING

SAFETY
Safety has been an integral part of the HONDA work culture. Safety First has been the primary motto at every stage of the production process. Every worker is given safety training at regular intervals related to safety.

SAFETY ON MACHINE: Every machine is equipped with various kinds of sensors such as laser sensors, presence detectors, motion detectors at various levels. At any stage of production process any irregularity such as dislocation of sheet or multiple sheet or absence of sheet the entire line comes to a halt immediately.

Safety measures: Photo sensor: To stop movement of crane saver if someone is on the line. It is also present before crane saver washing unit before and after each die.

Maintenance key: Turn it on to enter the machine when it is on then press is stopped and upper die is locked.

Maintenance key

Die sensors at boundary:If the blank is not placed correctly by the robot, the sheetmiss button lights up and the upper die stops in the press.

PHOTO SENSORS

SAFETY OF MAN
Training workshops for safe practices are conducted at regular intervals for employees at all levels of the production department. Placards are placed at regular intervals to remind employees about safe practices.

Personal Protective Equipments

Helmet

TSHHEL
Goggles

Ear Plugs

Gloves

ARM SLEEVES

SHOES

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 overcomethis, die cleaning is done.

VARIOUS PARTS OF DIE: SR No: 1.

ILLUSTRATION

NAME Spring plunger: used to eject part from the die.

2.

Air header block: connects air hose to certain parts of die.

3. Distance plate

4.

Disappearing gauge: used to align part on the die.

5.

Vacuum cup

6.

Tanker cylinder: present on lower die, used as spring function to support upper die.

7.

Side pin stopper

8.

Silencer: attached to the air cylinder in the die.

9.

Coil springs

10.

Wear plate

TYPES OF GRINDERS

Grinding is a highly skilled operation, where the required dimensions or form is achieved. It requires a tremendous amount of skill and concentration for grinding. Grinding is often a secondary or finishing operation. The quality of the ground surface depends on the selection of type of grinder and type of wheel.

EFFICIENCY The following data represents the stoppage time of machine in 2 hours.

S.NO. 1. 3. 4. 6. 7. 10. 11. 12. 13.

MACHINE STOPPAGE 8:48 am 8:57 am 9:03 am 9:15 am 9:19 am 9:35 am 9:57 am 10:10 am 10:30 am

STOPPAGE TIME PROBLEM (min : sec) 1:40 Draw upper die problem 1:30 3:00 1:40 1:00 4:20 2:00 1:50 2:20 18 min. Die cleaning Sheet abnormal fault Die cleaning Centering unit clamp/ unclamp problem Automatic die change(ADC) Die cleaning Stack and sheet abnormal fault Die cleaning

Net loss time

=(120-18)/120*100 =85% Similarly the efficiencies calculated for 3 more days were 80.5% , 79% and 87%. So, the average efficiency = (85+80.5+79+87)/4 =82.8%

PROJECT:
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.

COMBINED FRAME

FRAME-1FRAME-2,3

FRAME-2FRAME-3
There was two pneumatic cylinders fitted in the frame 2 and with the help of pneumatic cylinders, the movement of sliding frame (frame-3) is controlled. Pneumatic cylinders was of 130mm stroke length. To get the 390 mm stroke from 130 mm cylinder a revolving joint was placed in the lower height frame and an attachment was such made that we can get movement of sliding frame by 390 mm. Sliding frame was also fabricated and fitted in frame-2. There is a weight sensor also, which will sense the weight and when the weight comes, pneumatic cylinders operate and when the weight goes they will operate in different direction.

Mechanism (How it works) First, the part after getting trimmed in the press 2 will come on the frame-1 and frame-3 with the help of robots. When the weight (part) will come on the frames, pneumatic cylinders will operate (due to weight sensor). And then the parts will be get separated by 390 mm. Separated parts will move to press 4 with the help of robots. Now again due to weight sensors the frame 3 will come to its original position and in this way the parts will be get separated by 390mm.

BIBLIOGRAPHY 1) HCIL manual for Safety equipment, operation, maintenance. 2) Hitachi Zosen Fukui corporation (H&F) instruction manual 1500 Ton Press. 3) Hitachi Zosen Fukui corporation (H&F) instruction manual 1000 Ton Press. 4) H & F Robot maintenance manual.

5) DAYTON Press die components catalog 2010. 6) MISUMI standard component for press dies. 7) HCIL Die maintenance manual.