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brazing process, one for cock brazing, one station for drain pipe and two stations for rework.

Fig 5.5.2 (b&c) Cock

Fig 5.5.2 (d) Drain pipe Rework is done at two stations one is just after MFF welding and one is at final inspection. Rework is a necessary process because sometimes at R/L body welding or at MFF welding, occur lots of defects. To remove these defects, rework is necessary. 5.5.2.1 Consumption pattern The figures were measured with skilled worker by measuring number of tanks of a model for each brazing rod. Firstly the number of fuel tanks for 5 brazing rods was recorded and by taking average the number of tanks per brazing rod was obtained:

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FUEL COCK BRAZING WEIGHT OF BRAZIN G ROD (KG.) 0.102 0.102 0.102 0.102 0.102 0.102 0.102 0.102 NO. OF COM P DRAIN PIPE BRAZING PRICE BRAZIN OF G ROD / BRAZIN COMP G ROD (KG.) PER KG. (Rs) 0.0093 0.0026 0.0102 0.0102 0.0116 0.0121 0.01 N/A 556.40 556.40 556.40 556.40 556.40 556.40 556.40 556.40 TOTAL VALUE OF BRAZING ROD (Rs) 13.27 14.93 17.62 19.86 17.36 6.76 5.56 12.15

MODEL

WEIGHT BRAZIN OF NO. G ROD / BRAZIN OF COMP G ROD COMP (KG.) (KG.) 0.0146 0.0243 0.0215 0.0255 0.0196 N/A N/A 0.0218 0.102 0.102 0.102 0.102 0.102 0.102 0.102 0.102 11 40 10 10 8.8 8.4 10.2 N/A

GLAMOUR IGNITOR X PRO CBX KARIZMA KARIZMA FI GLAMOUR FI PASSION

7 4.2 4.75 4 5.2 N/A N/A 4.67

5.5.2.3 Problem and solutions Main problems of high consumption of brazing rod are because of high pressure (means high flow rate) more than required, used for gases and improper welding at R/L body welding and MFF welding.

Fig 5.5.2.3(a) In R/L welding, improper welding produces blow holes at welding joints which makes leakages that makes bad quality of fuel tank, to fill these blow holes brazing is used. So, if these holes can stop, the consumption of brazing rod can be reduced. Main cause of improper welding at MFF
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welding is oily MFF. Oil is used to keep MFF rust-free. For proper welding, oil should be properly removed. Also if gas flow is kept at required level that will also reduce the consumption of these brazing rods. 5.5.3 MIG welding wire 1 mm: MIG welding is a Fusion welding process in which the inert gas is used as a shielding gas. Gas metal arc welding (GMAW) is an AW process in which the electrode is a consumable bare metal wire, and shielding is accomplished by flooding the arc with gas [1]. MIG welding wires are used in different welding operations in weld shop. The company uses a copper coated mild steel wire for the welding operations. They are of different categories, i.e., of different diameters and they are used depending of strength of the welding joint & parts need

Fig 5.5.3(a) to be joined. The wire is bought from different vendor companies, categorized into three: 0.8 mm, 1 mm & 1.2 mm. These all wire used in the form of wire rolls weighing approximately 12.5 kg each or 360 m. The wire of 1 mm is used in Tack welding of all components and then at all manual welding stations. Tack welding is a process of joining all the major components of the frame body together by a temporary welding joint. Tack welding does not involve any kind of permanent joint. After passing the body through robotic welding, the first two manual stations involve welding of the body at the points which are not accessible through the Robot. This operation in done in two stations, on first they do it for left side and on second for right side of the frame body. Third & fourth stations involve the welding of child components on the body. 5.5.3.1 Consumption of MIG welding wire of 1 mm: The figures shown below are done with skilled operator. The initial weight was calculated and then from final weight and number of tanks, the figures were obtained. (Price of MIG welding wire of 1 mm = 65.20 INR per kg)

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BEFORE WEIGHT (Kg) SCOOTER 13.3 PASSION 13.3 GLAMOUR 13.26 GLAMOUR 13.26 FI MODEL MANUAL WELDING AFTER WIRE WIRE/ NO. OF WEIGHT USED COMP COMP. (Kg) (Kg) (Kg) 12.28 1.02 20 0.05 12.8 0.50 10 0.05 12.2 1.06 20 0.05 12.2 1.06 20 0.05

COST/ COMP (Rs.) 3.325 3.260 3.456 3.456

5.5.3.2 Problems & their solutions: The major problem with the welding wire is with their feed rate. The worker does the welding at higher feed rates than they are expected to do, which causes them to use higher amount of wire at each point. Increased awareness among the worker is needed to solve this problem. The cleaning of wire rolls is also a serious issue. It was observed that at some stations due to improper cleaning of wire rolls, there were lots of defects in the welding. This increases the wire consumption due to rework. Proper cleaning of wire roll, this also involves the proper storage of wire roll. These wire rolls must not be kept in an open air. This allows the dust to settle down on their surface. This can cause defects in parts. The worker keeps higher amount of the current and voltage to do the work more quickly. This automatically increases the consumption of the wire as more wire will melt at each point. Allowable current and voltage values can avoid these problems. All the parts of the frame body that comes from vendor companies are applied with oil. The worker directly uses these components without removing the oil. This causes defects in the welding and so, increased wire consumption. Cleaning of parts need to be welded is necessary to avoid defects in the welding. Every time at lunch break or shift change, the worker removes the wire roll to save their time, There were several rolls observed in the trash which are of more than 5-8 meters, which can be used to weld more than 4 frame bodies. Worker awareness can solve these problems. Due to defects in the robotic welding the consumption of the wire in the manual stations might increase. 5.5.4 MIG welding wire of 1.2 mm: The MIG welding wire of 1.2 mm is used only in the Robotic welding station of the frame body plant. This wire is used only for the welding points where the strength is the important factor, and no concern about the beauty. Gantry robot is a pneumatically controlled programmable robot with two welding arms. These welding arms are named as R-side& L-side. Both are used to do the welding at each of side of the frame body. This operation is performed just after the tack welding of the components. This process involves the permanent joining of the components.

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5.5.4.1 Consumption: The figures were obtained based on the robot working at standard working conditions. This process does not involve any manual operations. The data was obtained by observing the final and initial weight of the wire rolls. (Cost of MIG welding wire of 1.2 mm = 63.20 INR per kg) BODY R/L WELDING NO. WIRE/ BEFORE AFTER WIRE COST/COMP COMP OF WEIGHT WEIGHT USED (Rs.) COMP. (KG) (KG) (KG) (KG) A B A B A B A B 13.16 13.28 13.16 13.28 13.26 13.18 12.72 12.62 12.62 12.72 12.62 12.72 12.82 12.60 12.48 12.46 1.10 1.10 1.12 0.4 26 26 26 10 0.042 0.042 0.043 0.040 2.674 2.674 2.722 2.528

MODEL

GLAMOUR GLAMOUR FI PASSION PRO SCOOTER

5.5.4.2 Problems & their solutions: The problems in the MIG welding wire of 1.2 mm & 1 mm are almost similar. Needs cleaning of wire rolls, operator awareness, and feed rate control, proper gas flow is needed to reduce the consumption of wire rolls in robotic welding. Sometimes due to defects in the tack welding, there can be some defects observed in the robotic welding. This might leads to increase consumption of wire rolls. 5.5.5 MIG wire of 0.8 mm: MIG wire of 0.8 mm is used only in the fuel tank line of the weld shop. It involves the welding of the sheet metal components used in the manufacturing of the fuel tank. This consumption depends mainly on the size of the fuel tank. The wire of 0.8 mm is used in the body R/L welding, MFF MIG welding, Base fuel pump welding (only for Glamour-FI). All of these operations are performed by robot. Operators job is to control the parameters of the robot, handling of the components. Body R/L welding: It involves the welding of the two parts of upper body parts of the fuel tank with to form a upper body. The welding is done on the inner side of the upper body. Base Fuel pump: This is a new kind of technology. This involves the fuel pump which controls the fuel flow to the engine. This is used only in the Glamour-FI. This bike does not have a carburetor.

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Fig. 5.5.5 (a & b) MFF MIG welding: MFF, Metal Fuel Filler is a small components used in the fuel tank of each vehicle. This acts as the gate to fuel intake in to the tank. These are of two different in the company. First is cup-shaped, which is an older MFF. This is used only in the older models, like passion, Achiever, Splendor, etc. The newer MFFs are dish-shaped involve the drain pipe attached to them. Drain pipe is attached using brazing operation. It acts a bypass for excess fuel in the tank. Also, in some models they use breather pipe which allows small amount of air to enter the tank.

5.5.5.1 Consumption: These figures were obtained according to the initial and the final weight of the wire roll. The operating parameters were set to standard conditions. (Cost of MIG welding wire of 0.8 mm = 67.20 INR per kg) BODY R/L WELDING BEFORE AFTER WIRE NO. OF WIRE/ MODEL COST/COMP WEIGHT WEIGHT USED COMP. COMP (Rs.) (kg) (kg) (kg) (kg) GLAMOUR 13.12 12.53 0.59 40 0.015 0.991 IGNITOR 13.28 13.12 0.16 10 0.016 1.075 X PRO 12.90 12.70 0.20 20 0.010 0.672 CBX 13.12 12.88 0.24 20 0.012 0.806 PASSION 11.7 11.32 0.38 30 0.013 0.851 KARIZMA 13.15 12.43 0.72 30 0.024 1.613 KARIZMA 13.15 12.43 0.72 30 0.024 1.613 FI GLAMOUR 13.12 12.53 0.59 40 0.015 0.991 FI
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BASE FUEL PUMP (Glamour-FI) AFTER WIRE BEFORE WEIGHT USED WEIGHT (Kg) (Kg) (Kg) 12.24 11.94 0.3

NO. OF WIRE COMP. COMP 25 0.012

/ COST/COMP (Rs.) 0.8064

MFF WELDING MODEL BEFORE WEIGHT (kg) 12.44 12.42 12.62 12.4 11.94 12.24 12.24 12.24 AFTER WEIGHT (kg) 12.24 12.24 12.4 12.24 11.74 12 12 12 WIRE USED (kg) 0.2 0.18 0.22 0.16 0.2 0.24 0.24 0.24 NO. OF COMP 28 28 30 28 30 30 30 30 WIRE / COMP (kg) 0.007 0.006 0.007 0.006 0.007 0.008 0.008 0.008 COST/COMP (Rs.) 0.48 0.432 0.4928 0.384 0.448 0.5376 0.5376 0.5376

GLAMOUR IGNITOR X PRO CBX PASSION KARIZMA KARIZMA FI GLAMOUR FI

5.5.5.2 Problems Problem & their solution: The main problem is related to the oil. The parts from vendors were kept oiled to keep them rust-free. This causes defects in the welding. This causes higher consumption of other consumable. Parts must be properly cleaned to avoid these defects. The proper cleaning of the wire rolls & their proper storage can reduce the problems in welding. Sometimes the operator parameters set to higher values. And also they keep robot overdrive mode which allows the faster welding with higher operating parameters. But this leads to

increase in the consumption of the welding wire. Proper values of operating parameters might be helpful in reducing the consumption.

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Improper placement of MFF & bypass lock can lead to the defects in the MFF welding. Assurance of proper placement clamping of both parts can solve this problem. At the point near the MFF, the welding can be avoided in case of body R/L welding at points 2 & 3 shown in fig. This will reduce consumption of the grinding wheel as well as the welding wire. (this can be done only in P-21 tank) 5.5.6 Grinding Wheel Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool [1].

Fig 5.5.6 (a) Grinding practice is a large and diverse area of manufacturing and tool making. It can produce very fine finish and very accurate dimensions; yet in mass production contexts it can also rough out large volumes of metal quite rapidly. It is usually better suited to the machining of very hard materials than is "regular" machining [1]. In Hero motocorp grinding wheel is only used in fuel tank lines. It is not used in frame body line.

Fig 5.5.6 (b) Grinding Wheel

Fig 5.5.6 (c) used Grinding Wheel

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Grinding wheel used in Hero motocorp has specification 100*6*15 & max speed is 72 m/s. In old weld shop for two lines of fuel tank there is one station for grinding just after R/L body robot welding and two station for rework at which grinding is being done. o Grinding wheel is used just after body R/L welding to remove welding bead, for seam welding and MFF welding. If this welding bead is not removed, it will cause mismatching of both parts, which will lead to rejection of that fuel tank. o Grinding wheel is used to remove the bead due to rework brazing. Rework is done to remove defects in MFF or any R/L body welding. In new weld shop, one station for grinding after R/L body welding and one for rework at which grinding is done. Grinding wheel is also used at seam welding electrodes for wheel dressing. 5.5.6.1 Consumption Pattern A different technique was used to calculate the consumption of grinding wheel. All the figures were obtained with skilled operator and number of fuel tanks per grinding wheel is calculated. As the readings were obtained on production line, the readings were obtained as a combined of two models. Glamour was the only model which can be observed for long time. So, assuming it as a base we calculated the number of fuel tanks for grinding wheel. Consumption of grinding wheel Number of No. of components of components per Model 1 per grinding grinding wheel wheel (P) (X+Y) 104+82 312 176+121 312 130+96 312 293+29 150 price of 1 grinding wheel (Rs.) 109.96 109.96 109.96 109.96 109.96 109.96

Model 1 Glamour Glamour Glamour Passion

Model 2 Karizma Ignitor CBX X-pro Number of components per grinding wheel 123 278 165 172 312 150

Number of components of model 2 per grinding wheel (Q) 123 278 165 172 value for each model of grinding wheel (Rs.) 0.89 0.39 0.67 0.64 0.35 0.73

Model Karizma Ignitor CBX X-pro Glamour Passion

grinding wheel portion used for each model 0.0082 0.0036 0.0061 0.0059 0.0032 0.0067

5.5.6.3 Problem and Solutions First problem in grinding is vibration of pneumatic grinder neck at which grinding wheel is mounted. These vibrations are because of workers way of operating it and these vibrations

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may lead to cause damage to grinding wheel and also it can make dents on fuel tank, for that rework has to done and that will increase the consumption of other consumables.

Fig. 5.5.6.3 (a) o To solve this problem workers are doing is taking support of R/L body part by putting grinders neck on the R/L body part. That cause to damage to the neck, like some pneumatic grinders has damages like hole at neck, deep cuts on neck because of material removal from neck. And these pneumatic grinders go to scrap. Although sometimes they put a metal plate on handle neck and reuse it. But this is clearly wastage. o This problem can only be solved by giving proper training to workers and make them do it properly. Also, it will be helpful for worker if company provides them a support to keep the grinder steady. Second problem or cause of high consumption of grinding wheel is that when workers mount new grinding wheel on grinder, it has very sharp edges that can cut the fuel tank or can damage it. To solve this problem workers run the wheel on some other surface. Company should order wheels having less sharpness at edges and workers also play a big role to reduce this consumption to solve this problem. Third problem is that while rework at MFF, grinding wheel is used in the perpendicular direction of the rotation that cause high consumption of grinding wheel. Also, sometimes when grinding wheel doesnt fit in the MFF, worker uses the grinding wheel on a surface to reduce it in diameter. A new kind of grinding wheel is needed which will have smaller diameter & higher thickness to solve this problem. For wheel dressing of seam electrodes, they use grinders. This causes high consumption of grinding wheel. A harder grinding wheel specially designed for wheel dressing must be used in order to solve the issue. 5.5.7 Seem Welding Lower and Upper Wheel (Electrode) Seam welding is a resistance welding (RW) process of continuous joining of overlapping sheets by passing them between two rotating electrode wheels. This is a low voltage and high current process [1]. Seam welding is a high speed and clean process which is used when continuous tight weld is required (fuel tanks, drums, domestic radiators) [3].

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Theoretical diagram of seam welding both wheel are of same diameter [3].
Lower wheel

y AC power supply
Weld Lower wheel

Fig 5.5.7 (a) In hero motocorp, seam welding is a part of fuel tank line. This is used to seal the upper body part with the bottom part. Water is used as coolant in this process. To avoid water entering in the fuel tank air cap is used, through which compressed air is thrown to the fuel tank which will remove the water. This is very important as water present in fuel tank can produce problem if it enters into the engine.

Fig 5.5.7 (b) In this plant, shape of these wheels is different. Upper wheel is bigger in size than lower wheel. This is because of the curved surface of the fuel tank, so to enter in these concave shapes diameter of this wheel should be small. Fuel tank is convex from upper side and concave from lower side thats why lower wheel is small than upper wheel. This makes very high consumption of lower wheel with respect to upper wheel.

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Fig 5.5.7 (c) After some time when wheel became small in diameter, which needs to be replaced. In this plant use limit of wheel i.e. how much wheel can be used is decided by gear box housing, i.e. when the two gear box housing touches each other these wheels are removed. 5.5.7.1 Consumption pattern: As the seam electrodes run for more than 2 shifts, it was almost impossible to calculate their consumption. Also, there is no mark on the vehicle to know that the wheel is used. So, the consumption pattern for seam electrodes has not been calculated. 5.5.7.2 Problems and solutions: Excess pass of voltage that damages the wheels. For voltage regulation thyristor is present in the machine. Water supply is used to cool the thyristor. Sometimes due to some blockage in water supply, the thyristor heats up and gets blasted. This cause higher voltage to pass through the electrodes than required. This damages the electrodes and fuel tank.

Fig 5.5.7.1 (a) o Some solutions I suggested are allowing a continuous filtered supply of water to transfer in place of current closed loop supply. Then blockage problem will be reduced.

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o Second solution is that use a sensor alarm to show that there is lesser amount of water supply i.e. if water flow falls below certain limit the alarm will sound and operator will stop the machine or machine can be stopped automatically. Second problem is that electrodes are not completely used due to the gear box housing.

Fig 5.5.7.1 (b) o Gear box housing can be made in a shape so that they will match each other. This will allow us to use the max part of wheels. Air cap from which air is passed in the fuel tank is remains open even when welding is not being done, this lead to wastage of compressed air. Some times when worker operates machine at high voltage than required in seam welding, electrode become burred, because Zn stuck on the lower electrode from the sheet. These burrs create leakage problem, as well as reduces the life of wheel as if wheel will be grinded for number of times. Use of sheets having coating on one sided can solve this problem.

Fig 5.5.7.1 (b&c) 5.5.8 Consumption of gases- Argon: Argon is produced industrially by the fractional distillation of liquid air. Argon is mostly used as an inert shielding gas in welding and other high-temperature industrial processes where
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ordinarily non-reactive substances become reactive [1]. Argon gas is used in the fuel tank line of the weld shop as a mixture with carbon dioxide. Both of these gases act as a shielding gas for the welding to avoid the oxidation of the welding bead. These gases are fed to the faying surfaces using Gas Metal Arc Welding process. The mixture contains 20% carbon dioxide and 80% Argon gas. As the welding process in fuel tank section requires a proper and more intricate welding, Argon gas is used in mixture with Carbon dioxide. Also, the use of an inert gas helps to get a better control in welding. It is supplied through the large cylinders placed outside of the weld shop through pipes. 5.5.8.1 Consumption: The flow meters were attached with each of the welding robot. By recording the time of welding for each fuel tank, the gas flow in liters can be estimated. (Note that the gas flow will obtained as a mixture of both the gases, so it is needed to calculate the separate consumption of both gases) (Cost of Argon gas per m3 is 30 INR) Body R/L robot : GAS TOTAL FLOW CONS. RATE (LTR) (LPM) 25 8 14 14 25 13.5 17 24 13.83 5.06 6.60 7.00 13.87 6.49 9.36 13.47 Ar (M3) COST OF 1 LTR ARGON/TANK = 10-3 (10-3 *Rs.) M3 0.011 0.004 0.005 0.006 0.011 0.005 0.007 0.011 0.332 0.122 0.158 0.168 0.333 0.156 0.225 0.323

S.NO. MODEL

WELDING TIME SEC 33.19 37.96 28.28 30 33.28 28.84 33.05 33.67 MIN 0.55 0.63 0.47 0.50 0.55 0.48 0.55 0.56

Ar (LTR) 80% 11.06 4.05 5.28 5.60 11.09 5.19 7.49 10.77

1 2

IGNITOR XPRO KARIZMA 3 FI GLAMOUR 4 FI GLAMOUR 5 FI 6 KARIZMA 7 PASSION 8 CBX MFF MIG welding:

S.NO.

MODEL

WELDING TIME SEC 46.49 41.59 MIN 0.77 0.69 0.82 0.78

GAS FLOW RATE (LPM) 18 17 16 18.5

TOTAL Ar CONS. (LTR) (LTR) 13.95 11.78 13.09 14.39 80% 11.16 9.43 10.47 11.51

Ar (M3) COST OF ARGON/COMP 1 LTR = 10-3 (10-3 * Rs.) M3 0.011 0.004 0.005 0.006 0.332 0.122 0.158 0.168

1 2 3 4

IGNITOR XPRO KARIZMA 49.07 FI GLAMOUR 46.68

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5 6 7 8 9 GLAMOUR FI KARIZMA PASSION ACHIEVER CBX 46.68 49.07 45.68 51.67 54.6 0.78 0.82 0.76 0.86 0.91 18.5 16 14 13 24 14.39 13.09 10.66 11.20 21.84 11.51 10.47 8.53 8.96 17.47 0.011 0.005 0.007 0.009 0.011 0.333 0.156 0.225 0.269 0.323

5.5.8.2 Problems & their solutions: The main problem is an increased flow rate of the gases. This is done due to different reasons. Main reason behind this is to complete the welding more quickly. But, this leads increase in consumption of gases. A solenoid valve is used to control the gas flow. But, the gas flow remains constant throughout the welding process. For body R/L welding, at some points the gas flow can be reduced. Regula gas savers are used at some stations. It is advised to use them at all the stations. This can reduce the gas consumption up to 45%. This can save a lot of gas as well as cost behind them. These gas savers allows to control the flow based on the current, voltage. This will also reduce the consumption of the gas at body R/L welding by allowing variable gas flow. Oiled parts from vendor companies can cause defects in the welding. To avoid this problem the operator increases the gas flow which leads to increase the consumption. Proper cleaning of the faying surfaces is important. Improper placement of the MFF causes the defects for which the worker increases the gas flow. Assurance of the proper clamping of the MFF & the bypass lock can avoid this problem. 5.5.9 Consumption of gases- Carbon Dioxide: Carbon dioxide is the most widely used gas in the welding department. It acts as a shielding gas. Carbon dioxide is very easily available in the industry as it can be obtained from various reactions. It is used in both sections of the weld shop. In fuel tank line it is used as a mixture with Argon gas & in frame body it is used as the only single gas. In fuel tank line, it is used at the Body R/L welding, MFF welding and Base fuel pump welding. In frame body line, it is used at all the welding stations. It is supplied through the large gas cylinders placed outside of the shop, via pipes. 5.5.9.1 Consumption: The gas flow meters were attached with each of the welding stations showing the flow rate for the gas. By recording time of the robotic welding the gas consumption was calculated in fuel tank line, then from mixture proportion the gas flow of Carbon dioxide in kg was calculated. Then, by knowing the density of the gas, the gas required for each fuel tank in Kg was calculated. In case of the frame body line, the direct value of gas flow in liters can be obtained by noting the welding time. It was then converted to Kg by conversion factor. (Note that for the frame body line the readings were taken with a skilled worker in the welding) (Cost of carbon dioxide gas per KG is 5 INR)

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Body R/L welding Fuel tank: WELDING TIME SEC 46.49 41.59 49.07 46.68 46.68 49.07 45.68 51.67 54.6 MIN 0.77 0.69 0.82 0.78 0.78 0.82 0.76 0.86 0.91 GAS FLOW RATE (LPM) 18 17 16 18.5 18.5 16 14 13 24 TOTAL CONS. (LTR) 13.95 11.78 13.09 14.39 14.39 13.09 10.66 11.20 21.84 CO2 (LTR) CO2 (KG) 1 LTR = 0.000616 KG 20% 0.0017 0.0015 0.0016 0.0018 0.0018 0.0016 0.0013 0.0014 0.0027 COST OF CO2/COMP (10-3 * Rs.)

S.NO.

MODEL

1 2 3 4 5 6 7 8 9

IGNITOR XPRO KARIZMA FI GLAMOUR GLAMOUR FI KARIZMA PASSION ACHIEVER CBX

2.79 2.36 2.62 2.88 2.88 2.62 2.13 2.24 4.37

0.0086 0.0073 0.0081 0.0089 0.0089 0.0081 0.0066 0.0069 0.0135

MFF MIG welding Fuel tank: GAS WELDING TIME FLOW RATE (LPM) SEC MIN 33.19 0.55 25 37.96 0.63 8 28.28 30 33.28 28.84 33.05 33.67 0.47 0.50 0.55 0.48 0.55 0.56 14 14 25 13.5 17 24 TOTAL CONS. (LTR) 13.83 5.06 6.60 7.00 13.87 6.49 9.36 13.47 COST OF CO2 (KG) 1 CO2 CO2/TAN LTR = (LTR) K (10-3 0.000616 KG *Rs.) 20% 2.77 0.0017 0.0085 1.01 0.0006 0.0031 1.32 1.40 2.77 1.30 1.87 2.69 0.0008 0.0009 0.0017 0.0008 0.0012 0.0017 0.0041 0.0043 0.0085 0.0040 0.0058 0.0083

S.N O. 1 2 3 4 5 6 7 8

MODEL

IGNITOR XPRO KARIZMA FI GLAMOU R FI GLAMOU R FI KARIZMA PASSION CBX

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Frame body stations: WELDING S.NO MODEL OPERATIONS TIME SEC Tacking 1 Tacking 2 Robot 1 Robot 2 Glamour Full welding 1 Full welding 2 Full welding 3 Full welding 4 Total Gas used Tacking 1 Tacking 2 Robot 1 Robot 2 Full welding 1 Full welding 2 Full welding 3 Total Gas used Tacking 1 Tacking 2 Tacking 1 Tacking 2 Tacking 1 Tacking 2 Full welding 1 Full welding 2 Full welding 3 Total Gas used 9.89 9.26 20.62 21.46 15.8 17.39 2.95 7.42 8.03 8.24 25 30 30 30 15 9.3 9.3 11.92 11.92 12.2 12.2 15.3 14.9 14.2 MIN 0.16 0.15 0.34 0.36 0.26 0.29 0.05 0.12 0.13 0.14 0.42 0.50 0.50 0.50 0.25 0.16 0.16 0.20 0.20 0.20 0.20 0.26 0.25 0.24 GAS FLOW RATE (LPM) 30 25 25 22 30 30 30 22 30 18 25 30 30 30 15 19.5 22 20 20 18 20 30 30 30 CO2 (KG) 1 LTR = 0.000616 KG 0.003 0.003 0.005 0.005 0.005 0.005 0.001 0.002 0.028 0.0024 0.0016 0.006 0.009 0.009 0.009 0.002 0.038 0.002 0.002 0.002 0.002 0.002 0.003 0.005 0.005 0.004 0.027 COST OF CO2/ COMP (10-3 *Rs) 0.0152 0.0149 0.0265 0.0242 0.0243 0.0268 0.0045 0.0084 0.1325 0.0125 0.0113 0.0321 0.0462 0.0462 0.0462 0.0116 0.1896 0.0093 0.0105 0.0122 0.0122 0.0113 0.0125 0.0236 0.0229 0.0219 0.1365

TOTAL CONS. (LTR) 4.8 3.75 8.59 7.87 7.90 8.70 1.48 2.72 3.9 2.52 10.42 15.00 15.00 15.00 3.75 3.02 3.41 3.97 3.97 3.66 4.07 7.65 7.45 7.10

Passion

Scooter (Manual Line)

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5.5.9.2 Problems & their solutions: An increased gas flow rate is a major problem in the weld shop. As explained for the Argon gas, same factors are applicable for the consumption of Carbon dioxide gas in fuel tank line. For the frame body line, the gas used in excess at all the stations irrespective of whether it is needed or not. For oiled components in tack welding the gas flow at the welding is increased to reduce the defects in welding. The proper cleaning of parts will help to solve the problems. Spattering is one of the major problems in welding at frame body line. To avoid this problem the gas flow is increased. This leads to higher gas consumption. Proper current and voltage parameters will reduce spattering. Also it will reduce gas consumption, better welding control, increased tool life. 5.5.10 Consumption of gases Oxygen & Dissolved acetylene: Oxygen gas is used in brazing operations in fuel tank line of the weld shop. In Hero motocorp, the brazing is done to fit the cock, drain pipe and breather pipe at the base of the fuel tank. The oxygen gas is used as a mixture with dissolved acetylene gas which is used as a fuel gas in brazing. The proportion of two gases depends on the operator working on the station. The two gases are fed separately from cylinders kept outside the weld shop area. These gases can be controlled for their flow using flow controllers on brazing torch. 5.5.10.1 Consumption: The gases are supplied through the cylinders placed outside the weld shop. It is not possible to estimate the gas flow at a station from there, as these cylinder supplies the gas to every brazing station in the weld shop. Also, there are no flow meters on the gas pipes. Only operating parameter mentioned there is the pressure. From pressure it was not possible to calculate the consumption. So, there is no data available for the consumption of these gases. 5.5.10.2 Problems & their solutions: It was observed that the gas pressure was always kept higher than the required. This causes excess gas consumption. The higher pressure means higher gas flow rate which can cut through metals. That means keeping the pressure high can damage the fuel tank. Keeping the pressure at appropriate level can help to reduce the gas consumption. 5.5.11 Abrasive Sanding Belt: A belt sander is a sander used in shaping and finishing materials. It consists of an electric motor that turns a pair of drums on which a seamless loop of sandpaper is mounted [3]. In Hero Moto corp. sanding belt is used for fuel tank line, just after denting. Sanding belt is used to remove the welding bead from upper part of fuel tank. So that at the time of sanding by sanding disk time for each fuel tank should be less and consumption of sanding disk also is lesser.

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Fig 5.5.11(a) Sanding belt specifications are MAR 13, electro-coated Aluminum oxide cloth R/R ; 120 grit size Sanding belt in Hero motocorp is mounted on rubber roll. So that consumption of these roll should be less. 5.5.11.1 Consumption pattern Technique used for measurement of sanding belt is same as grinding wheel. Consumption of Sanding belt Number of No.of components of components per Model 1 per Sanding Sanding belt (X+Y) belt (P) 121+102 250 174+81 250 120+113 250 160+97 120

Model 1 Glamour Glamour Glamour Passion

Model 2 Karizma Ignitor CBX X-pro

Number of components of model 2 per Sanding belt (Q) 192 267 218 137

model Karizma Ignitor CBX X-pro Glamour Passion

Number of components per Sanding beltl 192 267 218 137 250 120

Sanding belt portion used for each model (NO.) 0.0052 0.0037 0.0046 0.0073 0.0041 0.0083

price of 1 Sanding belt (Rs.) 39.96 39.96 39.96 39.96 39.96 39.96

value for each model of Sanding belt (Rs.) 0.21 0.15 0.18 0.29 0.16 0.33

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5.5.11.2 Problems and Solutions In past belt size was 50 mm and the full size of belt was not used for sanding then it was reduced to 35 mm but still 15-20 mm of this belt is being used. This shows much of part of belt is not being used. o What they can do to reduce this consumption is to further reduce the size of belt to optimum utilization of sanding belt. Roller wheels on which sanding belt roll is changed from hard material to rubber material because hard material causes scratches and dents on the fuel tank. For rubber disk one problem is that workers uses one side of belt more than other side of belt. So disk becomes tapered and belt starts sliding from it, that may lead to major accident or it can damage the fuel tank. o Solution of this problem is solely depends on the worker. He should do it in proper way so that disk will not become tapered. Above problem also increases the consumption of sanding belt. Because one side of belt is not used and goes into scrap. o Solution to this problem is that one belt should be used twice one by simply mounting from one side and second by mounting on opposite side. This will reduce the consumption of sanding belt almost by half. 5.5.12 Flap wheel Flap wheels are an ideal choice for a wide variety of blending, deburring and finishing applications common in the metal fabrication, welding and polishing industries [3]. Flap wheels are conformable to intricate shapes and contours. Designed to deliver a consistent finish with a uniform rate of cut, flap wheels wear away, continually exposing fresh abrasives. In Hero motocorp, flap wheel is used in fuel tank line. At two stations, one station after sanding and one station for rework. Flap wheel is also known as buffing wheel and this process is called buffing.

Fig 5.5.12 (a) Flap wheel for rework

Fig 5.5.12(b) Flap wheel for normal operation

Flap wheel is used to finish the lining or scratches made while sanding. Flap wheel is used just after sanding is big in size than the flap wheel for rework.

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5.5.12.1 Problems and Solution Larger flap wheels is a bit harder, so if worker applies more pressure than required while buffing, it may cause dents or scratches on the fuel tank that needs to rework, which will increase the consumption. Solution to this problem depends on the workers way of operation. So, giving them proper training can reduce the consumption. Second problem in buffing is that sometimes buffing also makes some deep scratches on the fuel tank to remove these lining lots of rework has to done that is also a wastage of rework materials. This also depends on the workers, means they should do it in proper way. 6 EVALUATION OF THE ORGANIZATION:

6.1 PROFESSIONALISM Company works in a highly professional environment. Starting from entry point, if someone came late or forgot his ID, he/she will not be allowed to enter the company. In production lines too they maintain a good quality by doing a good work at each station and still completing the assigned number of target in given time. The high quality is the main factor behind the company success. For this purpose company assumes the worker satisfaction as a important factor. Company provides a fan or air blower to each worker so that they can work in a good environment. Also, the assigned line in-charge, Section engineers keep track on the quality in a specific interval of time. At end of every line there is an inspection point where they observe the part for any kind of defect. Defective parts are sent back to the rework stations. Major defects in part can lead to the rejection. In the main assembly line they test the vehicle at a specific speed limit. Some other tests are also performed to assure the good quality of the bike. The company is committed at all levels to achieve high quality in whatever they do, particularly in their products and services which will meet and exceed customer's growing aspirations through [2]: Innovation in products, processes and services Continuous improvement in our total quality management systems. Teamwork and responsibility 6.2 Ethical conduct Company is provided with a code of conduct on all employees. This code of conduct for employees enables the company to maintain the standards of the business conduct, thereby bringing efficiency, responsiveness and consistency in an employees behavior and decision making. It also reduces risk by decreasing the possibility of harmful conduct. The code outlines the values that become the basis of this standard. It is based on the eight principles that have been identified through research, as being fundamental to all codes. Each of the employees should read and understand the code, and incorporate it in day-to-day behavior [2]. 6.3 Award/Rewards The Company keeps a track record of all the employees. The hard working employees are spotted by the management and they are rewarded accordingly by increments in their salary from time to time.

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6.4 Promotion Schemes Engineers and managers are promoted to higher posts by reviewing their performance. For other employees based on their qualification and experience in their respective field, the respective posts were allotted. 6.5 Potential Employer Recruitments are done from HR department based on the qualification of the applicant. Company takes B.E., B.Tech. students for project engineering or R & D department. MBA qualified applicants are allotted to the managerial posts. And for the line in-charge, operator posts they allot the diploma- holders or ITI holders with some experience. 7. SOME NEW TECHNICAL ASPECTS OBSERVED DURING THE TRAINING: 7.1 Regula gas saver In this plant, for R/L body robot welding a gas saver is being used, it keeps the gas flow rate at fix level so that consumption of welding wire and gas can be reduced. Because at some lines in the plant the fuel saver is not being there worker keeps flow rate at maximum level that is clearly wastage of gas. 7.2 Drain Pipe Drain pipe is used to remove the extra oil spilled on the fuel tank. Drain pipes throws this oil to ground without touching any part of the engine or bike. Because if this oil touches any hot part of engine this may cause to make fire and major accident can happen. This drain pipe is connected to MFF and it goes through the fuel tank to the lower part of the fuel tank and from there to the ground. 7.3 Electrostatic process for painting For painting on the fuel tanks, electrostatic process is used in which paint is charged positively and fuel tank is earthed means, neutrally charged. This process ensures the very little wastage of paint because paint will forcibly goes to fuel tank and stuck on it. Paint is thrown by nozzles to the fuel tank by pressure and velocity so it is possibility that paint hit the fuel tank and then goes to ground so to minimize this problem this process is being used 7.4 Lacquer painting This painting uses a transparent paint which dries instantly. After putting stickers on the fuel tank, lacquer painting is done, so that it can be clearly seen and also it would not remove. This painting also gives shiny effect of the fuel tank. 7.5 Base fuel pump For Glamour-FI base fuel pump is used, it is used to regulate the fuel going to the engine. In other models air is regulated by carburetor and by air regulation fuel is regulated but in the case of base fuel pump, fuel is directly regulated by pump for acceleration. This pump sucks the fuel from the fuel tank in the amount that is required for that particular speed.

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8. Engineering drawings: 8.1 Plant layout [3]

New weld shop

Utility block

New paint shop

Scrap yard

Paint shop area

Lacquer plant

Assembly line3

Press shop

ABS Paint shop

Paint shop

Trolley stores

Weld shop Tech office

Weld shop Atrium

Painted sheet, Metal parts

Frame sub assembly area

Component store

Engg Assy-1 Engg Assy-2 Engg Assy-3 Engg ppc Aluminum phase

Frame assembly line 1 Veh. Rectification area Frame assembly line-2 Store room Steel Phase

Finished vehicle storage area

Heat treatment

Aluminum phase

Tool room

Gear section

Aluminum phase Engine Transfer Finished component Material from vendor Material from store to resp. shop Finished product

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Tack welding

Robot R/L MIG welding

Manual welding 1 (right side)

Manual welding 2 (Left side)

Manual welding 3 (Clamps & other small components)

Manual welding 4 (Clamps & other small components)

Fine Boring (for steering head)

Truing

Final inspection (visual and with guages)

To Paint shop and assembly line

Process flow diagram for Frame body manufacturing

Drawing of sheet metal (t=0.8 mm)

Blanking & Trimming

Upper Fuel tank Body R/L & Bottom

Press shop pre-processing of sheet before it goes to weld shop

Upper Body R/L parts

Robotic R/L MIG welding

Bead grinding

Buring

Sanding

Brazing

MFF Robot MIG welding (Thumup Joining)

Belt Sanding

Denting

Buffing

Spot welding (Clamps)

Cleaning

Upper Body

Process flow diagram for Fuel tank manufacturing (weld shop)

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9. Time management by a junior/senior engineer and by a manager A day time distribution (out of 8 hours for each work): Activities Manager Engineer Technical work 25% 6.25% Analytical work 25% 6.25% People management 12.5% 12.5% Discussions 12.5% 25% Meetings 12.5% 12.5% Time spent working in a team 12.5% 37.5% Manager: Mr. Anuj Agarwal Engineer: Mr. Navin Malik 10. SUGGESTIONS TO IMPROVE THE COURSES: 1) MEL 202 (Manufacturing of metallic materials): The practical applications of the processes explained in the course can be observed in the company. This will help for better understanding of these topics. 2) MEL 203 (Manufacturing of non-metallic materials): The transfer line concept explained in the company can be easily understood by observing the company line of work. Some of the technical aspects such as time & work management, also difficulties during the line can be explained in the course in brief. 3) CYL 250 (Environmental chemistry): Company uses eco-friendly production. This allows lesser pollution to the environment. Some of these techniques can be explained in the course. 4) MEL 416 (Tribology): Some of the new aspects of Tribology can be observed in the company. Some of the new surface cleaning processes, new techniques for measuring the surface properties, etc can be added to the course. 5) MEL201 (Fluid mechanics): Some of the new flow techniques are used in paint shop to control the better flow of the water in the paint shop. Also, new techniques like ASFS, ATFI technologies can be added to the course. 11. THREE PROBLEMS THAT ARE WORTH SOLVING: 11.1 Industrial relations: The most serious issue with any organization is the relations within the company. The operator, manager, worker all must work well at their respective positions. Anyones bad performance will hurt every other person in the company. Operator must remain friendly with the worker so that they can work fine. It is found that many times the system fails with this issue. So, it is important to get a solution for this problem. 11.2 Inventory problem: Storage is one of the serious issues for the plant. The plant produces variety of vehicles. These vehicles will only be shipped as per the customers demands. The demand varies according to the market. If company is manufacturing a certain model of bike, and the customer orders some other variety, the company needs a raw material for that other bike. The vendor companies will take their time to supply the parts or sometimes due to traffic,
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weather problems they couldnt supply the parts in time. Company continues to manufacture the different vehicle. This makes problem of inventory. Serious issue of the inventory must be solved. 11.3 Rejection at final point: Even after several tests, inspection at each point, it is observed that there are lots of vehicle rejected at the final inspection point. These issues are not so common; every rejected vehicle is sent back to the respective rework stations. This is one of the most serious issues that need attention.

12. References:
1) http://en.wikipedia.org/wiki/ 2) www.heromotocorp.com/en-in/ 3) Company charts & guide books

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