Neel Metal Products Ltd.

(NMPL)
Gurgaon, Haryana

Project report on:

PRODUCTIVITY IMPROVEMENT
PLAN
Honda line
N-5

SUBMITTED TO-:

SUBMITTED BY -:

MR.

LOVE GAUTAM

HEAD OF PRODUCTION (N-5)

B.TECH (MAE)
VIII SEM

Amity University Madhya Pradesh, Maharajpura (Opposite Airport)

Gwalior 474 005 (Madhya Pradesh)
Email : info@gwa.amity.edu

STUDENTS DECLARATION

I Love Gautam hereby declare that the project report on Production Improvement
Plan(N-5) at NEEL METAL PRODUCTS LIMITED being submitted in partial
fulfillment of Days Training program to Department Of Mechanical &
Automation

Engineering, AMITY University is carried out under the

supervision of Mr. , Head Of Production (N-5) , NMPL

Gurgaon and also declare that the work carried out by me is authentic and has not
been submitted to any other University in the regard mentioned.

June 30, 2015

Love Gautam
Enroll no.-A60205411001
Department of Mechanical & Automation Engineering
AMITY University

CERTIFICATE APPROVED

This is to certify that the project report entitled Production Improvement Plan
(N-5) on Honda Line at Neel Metal Products Limited submitted by Love
Gautam to the Department Of Mechanical & Automation
AMITY University, Madhyapradesh

Engineering,

in partial fulfillment of the Days

training program is a bonafide record of the project work carried out by him under
my supervision during the year May-June 2015.

Mr. .
Head of Production (N-5)

ACKNOWLEDGEMENT

I have taken efforts in this project. However, it would not have been possible
without the kind support and help of many individuals and organizations. I would
like to extend my sincere thanks to all of them.
I am highly indebted to (.) for their guidance and constant
supervision as well as for providing necessary information regarding the project &
also for their support in completing the project.
I would like to express my gratitude towards my parents & member of (Honda line
N-5)for their kind co-operation and encouragement which help me in completion
of this project.
I would like to express my special gratitude and thanks to industry persons for
giving me such attention and time.
My thanks and appreciations also go to my colleague in developing the project and
people who have willingly helped me out with their abilities.

Love Gautam

CONTENTS

1. Company Introduction6
2. Press Shop.10
3. Weld Sho...11
4. Project: Productivity improvement plan..12
5. Plant Layout..13
6. Introduction to Robotic MIG Welding..14
7. Introduction to Spot/Projection Welding..16
8. Air leakage Inspection and Maintenance..19
9. Line Breakdown Report22
10.Maintenance report of all lines..26
11.Production cycle time28
12.Inventory Management..30
13.Conclusion.32
14.Refrence.33

INTRODUCTION
Established in 2001, Neel Metal Products Ltd. (NMPL) is the fastest growing
Company of JBM Group with high-tech plants at various locations in India. NMPL
has earned a leading position in industry with facilities available in press lines up
to 2500 Tons, weld lines and ED coating plant- which are not only limited to auto
world but also fitting for white goods industry.
JBM Group is a focused, dynamic and progressive organization that provides
customers with value added products, services and innovative solutions. The Group
has a diversified portfolio to serve in the field of automotive, engineering & design
services, renewable energy and education sectors and has an infrastructure of 35
manufacturing plants, 4 engineering & design centers across 18 locations globally.
With turnover of USD 1.2 billion, JBM Group has broadened its horizons by
focusing on quality delivery, solutions approach, product development processes,
flexible manufacturing systems and contract manufacturing.
JBM Group is primarily a tier- 1 supplier to the automotive OEM industry and
caters services to esteemed clients that include Ashok Leyland, Bajaj Auto Ltd,
Fiat, Ford, General Motors Corporation, Honda, Hero, JCB, Mahindra, Maruti
Suzuki, Renault, Nissan, TATA, Toyota, TVS, Volvo-Eicher, Volkswagen and many
more.

MAJOR PRODOCT

 Complete body assemblies and Painting facilities for 3 and 4 wheelers.

Complete frame assembly, Welding and Painting for 2 wheelers.
Design, Development and manufacturing of precision tooling, Dies and
Welding fixtures for automotive use.
Exhaust manufacturing and painting for 2 wheelers.
Fuel tank manufacturing for 2 wheelers.
Manufacturing of Rims and Wheel assemblies for 2 wheelers.
Manufacturing of ERW and CDW tubes for tubular components.
Manufacturing of skin Panels for 2 wheelers and 4 wheelers.
Manufacturing and Painting of commercial vehicles underbody frames and
parts.

NMPL JBM QUALITY GOALS

Zero defect.
First time right, every time right.
No quality control, only quality assurance.

 Reduced process variance.

100% customer satisfaction.
Reduction in the cost of product.
Not only functional quality but also competitive commonly expected and

attractive quality.

NMPL JBM MAJOR CUSTOMERS

MARUTI UDYOG LIMITED

DAILMER
TOYOTA
ASHOKA LEYLAND
DEFENCE
DELPHI
EICHER
ESCORTS
HINDUSTAN MOTORS.
HONDA (2 & 4 WHEELERS)
MAHINDRA & MAHINDRA

PRESS SHOP

The sheet metal component manufacturing capability at NMPL is the finest in our
country. When it comes to the sheet metal, NMPL enjoys a formidable industry
having good reputation.
In-house manufacturing facilities at NMPL includes:
Heavy press shop with hydraulic and mechanical presses equipped with die
cushions with or without moving bolster.
Light press shop is capable of handling the smallest components, requiring
load of 20 tones and onwards.
Facility for die maintenance include the hydraulic DPS(Die Spotting Press)
from KOJIMA, include conventional tool room equipment and skilled
manpower.

TYPES OF PRESSES USED IN THE PRESS SHOP:

Types of presses used in press-shop at JBML are:

Hydraulic Press.

Mechanical Press.

WELD SHOP

Welding is a process for joining similar metals. Welding joins metals by melting
and fusing 1, the base metals being joined and 2, the filler metal applied. Welding
employs pinpointed, localized heat input. Most welding involves ferrous-based
metals such as steel and stainless steel. Welding covers a temperature range of
1500 F - 3000 F (800C - 1635C). Weld joints are usually stronger or as strong
as the base metals being joined.
JBMs highly development skills in welding operations contribute significantly to
superior quality and reliability of the end product, which is the hallmark of NMPL.

-General Shop Safety Rules Safety glasses, cover goggles, or face shields are required when in any shop
area, whether working or not!!
Shoes must be worn in shop area. No one wearing sandals will be allowed to
enter the shop area. The minimum footwear must cover the entire foot.
Do not operate any item of equipment unless you are familiar with its
operation and have been authorized to operate it. If you have any question
regarding the use of equipment ask the area supervisor
No work may be performed using power tools unless at lest two people are
in the shop area and they can see each other.
Do not work in the shop if you are tired, upset, drugged, or in a hurry.
Never indulge in horseplay in the shop areas.
All machines must be operated with all required guards and shields in place.

PROJECT REPORT ON

PRODUCTIVITY
IMPROVEMENT
PLAN

HONDA LINE

N-5

HONDA LINE (N-5) LAYOUT

Honda line comprises of following sublines:

1.
2.
3.
4.
5.
6.
7.

2 CD (Common)

2 CD Sub frame (Diesel)

Lower Arm assembly line
2 CW Sub frame
2 CT Sub frame (Diesel & Petrol
Axle line 1 & 2
2 MD Sub frame

Honda City
Honda Brio/ Amaze
Honda Brio/ Amaze
Honda Brio/Amaze
Honda City
Honda Brio/Amaze
Honda Mobilio

INTRODUCTION TO ROBOTIC MIG WELDING

MIG (Metal Inert Gas) welding, also known as MAG (Metal Active Gas) and in
the USA as GMAW (Gas Metal Arc Welding), is a welding process that is now
widely used for welding a variety of materials, ferrous and non ferrous.
The essential feature of the process is the small diameter electrode wire, which is
fed continuously into the arc from a coil. As a result this process can produce quick
and neat welds over a wide range of joints.

Equipment
DC output power source
Wire feed unit
Torch
Work return welding lead
Shielding gas supply, (normally from cylinder)

-Welding Positions-

In application, there are only four basic welding positions. Often, welding must be
done on the ceiling, in the corner, or on the floor. In view of this, some techniques
were developed to allow welding in any position. Different welding positions are:
Flat position:
In this position, the filler metal is deposited from the upper side of the joint and the
face of the weld is approximately horizontal. In welding terminology this is also
called the down-hand position for both groove welds and fillet welds
Horizontal position:
The position of welding in which the weld is performed on the upper side on a
horizontal surface and against an approximately vertical surface.
Overhead position:
The weld is deposited from the underside of the joint and the face of the weld is
horizontal.
Vertical position:
The weld axis is approximately vertical. The welding direction can be changed up
and down.

INTRODUCTION TO SPOT WELDING

SPOT WELDING-:
Spot welding is a resistance process, relying on the electrical resistance of the
components to generate heat when a current is passed through them. The heat
generated is proportional to
The square of the current (I2)
The resistance of the components. (R)
The time for which the current is passed. (T)

Weld current
Weld currents typically vary from 500A on very thin materials (<02mm) up to
30kA for heavy sheet of projection weld applications.
Weld time
The thicker the material, the longer it will take to heat it up to the
required temperature. In general, therefore, weld times increase
in proportion to the thickness of the components.
Weld Force

As metal thickness increases, the expansion force increases, so

the weld force must increase. Thicker materials therefore require
higher forces.
Spot diameter.
The heat generated must be thought of as heat per unit area.
Spot diameter increases with material thickness.

PROJECTION WELDING
Projection welding is a variation of the spot welding process in which raised
projections on one or both sheets localize and concentrate the welding energy. This
technique allows for closer weld spacings on thicker materials than are possible
with the conventional approach. Projection welding is commonly used to attach

connector points such as studs and nuts to sheet metalassemblies particularly in the
automobile industry. Materials suitable for the projection welding process include
aluminum, low carbon steel, and stainless steel.

Advantages:
o
o
o
o

Quick process and number of welds can be made simultaneously

No thickness limitation
Life of electrode is much longer
If two dissimilar metals, then projection on metal having higher
conductivity

AIR LEAKAGE INSPECTION

AND
MAINTAINENCE IN HONDA LINE

Inspection report of Honda line YASKAWA Welding Robot.

The following leakages have been found during the tenure.
Sr. No.

Model

Operation

Problem

Status

Rechecked
status

1
2

2CT-common

Oil leakage from FRL

Air leakage from flow meter
Air leakage from nozzle cleaning
unit
Air leakage from cylinder
Air leakage from flow meter
Air leakage from nozzle cleaning
unit
Air leakage from near locater
pin
Oil leakage from FRL 1st
Air leakage from pipe
Air leakage from flow meter
Air leakage from nozzle cleaning
unit
Air leakage from pressure
controller(DCV)
Oil leakage from FRL
Air leakage from cylinder
Connecter pipe damage
Leakage of air from main
distributer valve of air
Air leakage from FRL
Air leakage from FRL 1st
Air leakage from nozzle cleaning
unit 1st
Oil leakage from FRL 2nd
Air leakage from nozzle cleaning
unit
Locater pin problem

OK
OK

OK
OK

OK

OK

OK
OK

OK
OK

OK

OK

OK

OK

OK
OK
OK

OK
OK
OK

OK

OK

OK

OK

OK
OK
OK

OK
OK
OK

NG

OK

OK
OK

OK
OK

OK

OK

OK

OK

OK

OK

OK

OK

3
4
5

6
7

2CT-Diesel

18

8
9
10
11
19

12
13
14
15
16
17
18

Axel line 2

21
6

19
20

21
22

23
24
25
26
27
28
29
30
31

SF- 2CW

Oil leakage from FRL 2nd

Air leakage from FRL 1st
Oil leakage from FRL 2nd
Oil leakage from FRL 1st
Oil leakage from FRL 1st
Nil
NIL
Oil leakage from FRL
Nil
Air leakage from nozzle cleaning
unit
Oil leakage from FRL
Oil leakage from FRL 1st
Oil leakage from FRL 1st
Oil leakage from FRL 2nd
Oil leakage from FRL 2nd
Oil leakage from FRL 2nd
Air leakage from nozzle cleaning
unit 2nd
Air leakage from nozzle cleaning
unit

OK
OK
OK
OK
OK
OK
OK
NG
OK

OK
OK
OK
OK
OK
OK
OK
OK
OK

NG

OK

NG
NG
NG
NG
NG
NG

OK
OK
OK
OK
OK
OK

NG

OK

NG

OK

10

Air leakage(left side downward)

NG

OK

15

Water leakage

NG

OK

Problem

Recheck
status

3
1
2&3
4,5&6
7
8
9

32

10

33
34
35
36
37
38

11
12
13
14
15
16

39
17

40
41
42

Axel comm.
rear
SF front susp.
Ass.

Sr. No.

Model

Operation

LWR arm
assembly

2
3
4
5
6

2 CT-common

12
9

7
8
9
10

Front right side air leakage from

where bed rotate
Back right side air leakage
(connecter and tube prob.)
Back left side air leakage from
air distributer
Oil leakage from FRL
Shutter problem
Leakage of air from shutter
CO2 leakage from main tube
connecter
Oil leakage from FRL
Air leakage near dcv
Oil leakage from FRL

NG

OK

NG

OK

NG

OK

NG
OK
NG

OK
OK
OK

NG

OK

NG
NG
NG

OK
OK
OK

The above problem analysis had been done by inspecting the following components on
robotic weld shop:

FLR Unit
Pneumatic Cylinders
Pressure Control Valve
Jig Fixture Maintenance

LINE BREAKDOWN REPORT

2 MD Line Breakdown Report (1/5/2015 31/5/2015)

2 CT PROBLEM REPORT (01/05/2015 31/05/2015)

S. No.
1
2
3
4

Problem

Operation

L/A 2CT com LH side, L/A N/A ( R/M N/A) RH side

2CT Common

Common 50-200-25 Part N/A

Not Quality in Part Clamping again fit. Adjust
Clamp
2CT Diesel and 2Ct Petrol Line Men Power shift to
SF:2CD

10

Frequency
X(10)

2
X(4)

5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

Common Cell inner linear block inside

SF 2CT(D) Red Switch Collar Clamp not working
Six Time Power Cut, New MP Untrained MP
Collar block weld Robot run without BRKT, Spatter
deposition on Sensor
Wire Shorting again
Air Supply Failure
Proximity Sensor not working
Operator was new, M/P new
Read Switch short (not working)
Problem in Ejection of part

2CT #9
2CT(D) #9
2CT LWR ARM

2CT(P) #17 #18

#18
2CT #2, #10, #21
2CT(P) , (D)
#19(D),(P), #21

X(17)
X(3)

#2

Torch linear Jam

#11

Correction done by quality due to Honda visit

#19

Robot accident by new operator

X(5), (3), (1), (2),

(12), (4)

2CT(D) #9

Line stops to clear hold Material

Line starts after 9 AM
Slower line run due to Honda visit
Line cleaning due to gas fault
Heating problem and water leakage in spot
welding
Ethernet error

2CT (P) & (D)

8&9
7 & 15
2

L/A Collar not available

2CT

Manpower run without information

Common cell stoppage due to manpower shift to
(P) & (D)
Petrol line stoppage due to manpower given to
quality
Person N/A for spot welding

2CT

Stopper BKT weld at fixture at Lower Arm

LH side fixture locates bolt broken
2CT Diesel part NG in R gauge M/P shift to 2MD
Line
Limit switch not working

X
X

2CT Common
2CT
2CT Common #10
2CT (D)
2CT (D) #19

M/P shortage

X(3)
X
XX

2CT common manpower used in Scrap yard

Nut sensor not working

#18

Poka Yoke sensor not working

Punching machine not working

X(2)

Welder not available

2CT (D)

Diesel line stoppage due to FG material pending

Manpower shifted to 2MD line
Weld at fixture due to operator mistake

2CT

Operator not regular

2CT

Diesel line stoppage due to hold material cleared

Spot machine not working (Breakdown), Shank
Broken
Lower electrode change and carbon test NG
Area sensor NG
Power trip due to gas supply low
Diesel line retouching manpower, all welding

14, 15 & 1

X(4)

14
2CT (P) #19

X(4)
X

reset
Striker under maintenance material movement
not possible
SF line approx. 90 pcs hold then cleared all
material in whole shift
Lot of material in hold from B shift, line stoppage
to clear it
Welder new

49
50
51
52
53
54
55
56
57
58
59
60
61
62
63

2CT (P) & (D)

SF 2CT(P) lower half and upper half N/A

2CT (D)

2CT (P)

2CT (D)

Electrical problem in robot controller

SF stiffener N/A
Part no. 31 not available
Slide sensor pin stuck in every piece

#2

Gas pallet change

Nut feeder not working

Gas cylinder change

Nugget NG of spot welding
Robot gas valve not working

1, 4 & 6

X(2)

19

2 Hrs. wastage in emptying

2 CW PROBLEM REPORT (1/5/2015 31/5/2015)

S.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

Problem

Operation

Manpower shortage due to labor day

Nut missing, fixture and sensor adjustment done
2 new manpower at nut check
Nut check and no manpower
Only 3 manpower on SF 2CW line

X(1T),
4(T)

6 time power cut, 3 manpower extra deployed

2CW SF pending material
Axel manpower shift to 2CW line
Air supply not proper
Spot machine shorting problem
Ejector broken
Shutter cylinder problem
Part not okay in receiving gauge
Problem in part fitment
Projection machine not working
Read switch not working
Tapping person was new
Slide unit not working
Projection machine not working

Frequenc
y
x(2)

#11
#15
#14, #15
X
#13
#13
#16
#16
#2

X
X

20
21

23
24
25
26
27
28
29
30

Manpower leaves at 05:30

R2 torch insulation burn and torch shorting
Right hand side fixture read switch and sensor
problem
Spot machine fixture adjustment
Manpower shift to 2CD
BKT out at receiving gauge
SF L/A not available
New Manpower
BKT sit pin broken 2 times
BKT LH side sensor not working
Power trip due to gas pressure low

31

Untrained manpower

32
33
34
35

W.I.P cleaning
M14 nut not available and line stoppage
Line starts late
Shut down due to plant meeting

22

#08
#08
X

X(3)
#15
#13,14,15,
16

x(2)
X

2 CD PROBLEM REPORT (01/05/2015 31/05/2015)

S.
No.

Problem

manpower shift

*******

line start late

new manpower ,new operator online

****

projection machine not working properly

#2

#15

bkt stiffener sensor not working

2 manpower on making and gauging due to unskilled
operator
locating pin L H side not working

lower half finished

m/c stoppage due to rework material pending

10

robot torch disturbed by operator

#15

11

complete teaching of stiff bkt

#16

Operation

#15

Frequency

12

upper half n/a

13

lifter not working

14

lower half n/a

15

gas cylinder change

16

ejector cylinder not working

17

electrical connection not done by maintenance

18

read switch not working

#14

19

R1 wire not flow in line properly

#14

20

R1 bkt sensor change

#15

21

line stop due to M14 nut n/a

22

power cut

23

shut down due to plant meeting

#15

MAINTAINENCE REPORT OF ALL LINES

S.No.

Model

Operation

2 CT (Petrol)

#21

#19

Problem
i.

(Air Leakage),main line control valve

Status
OK

ii. Left Bracket holding magnet

OK

i.

OK

Left Ammeter

ii. (Air Leakage), Right T-valve after flow regulator

OK

#18

i.

(Air Leakage), Right side manipulator (bottom)

OK

2 CD (Diesel)

#8

i.

(Air Leakage), Flow Regulator Right side

OK

2 CW (Petrol)

#16

i.

(Air Leakage) , left side under air container in pipe joint

OK

Rework area

i.

(Air Leakage) main line pipe burst

OK

2 CW (Axle)
Line 1

OK
#6

i.

(Air Leakage), Flow Regulator

ii. (Air Leakage), left side pipes jig fixture

OK
OK

2 CT (Diesel)

2 CD (Diesel)

2 CW (Petrol)

OK

i.(Air Leakage), Main distributor pipe T- joint

OK

ii. (Air Leakage), Inlet manipulator pipe

OK

iii. (Air Leakage), Right side manipulator leakage

OK

iv. (Air Leakage), Center back bottom pipe

OK

#18

i. (Air Leakage), Right side upper joint

OK

#15

i. (Air Leakage), Front cylinder connecting pipe

OK

ii. (Air Leakage), center back pipe

OK

#8

i. (Air Leakage), Upper control valve T-joint

OK

#17

i. (Air Leakage), Right side nozzle cleaner box

OK

#19

OK

2 CW (Axle)
Line 1

iii. Welding overlapping

2 MD (Diesel)

#3

i. (Air Leakage), right side pneumatic cylinder

OK

#4

i.(Air Leakage), left side pneumatic cylinder

OK

#10

i.(Air leakage), behind center pillar pipe

OK

PRODUCTION CYCLE TIME

The period required to complete one cycle of an operation; or to complete
a function, job, or task from start to finish. Cycle time is used in differentiating
total duration of a process from its run time.

Or
the period during which the objects of labor (raw products and materials) remain in
the production process, from the beginning ofmanufacturing through the output of
a finished product. In addition to the working time, the production cycle includes i
nterruptions inproduction owing to physical, chemical, and biological (natural) pro
cesses (for example, the period required for tanning leather); the characterof the ob
jects of labor; or the technology and organization of production.

AXLE LINE 1 CELL NO. #4

AXLE LINE 1

CELL NO. #3

AXLE LINE 1

CELL NO. #5

INVENTORY MANAGEMENT
Inventory management is primarily about specifying the size and placement of
stocked goods. Inventory management is required at different locations within a
facility or within multiple locations of a supply network to protect the regular and
planned course of production against the random disturbance of running out of
materials or goods.

The scope of inventory management also concerns the fine lines between
replenishment lead time, carrying costs of inventory, asset management, inventory
forecasting, inventory valuation, inventory visibility, future inventory price
forecasting, physical inventory, available physical space for inventory, quality
management, replenishment, returns and defective goods and demand forecasting
and also by replenishment Or can be defined as the left out stock of any item used
in an organization. Inventory is liabilities of a business.

All above inspection of machines done, under guidelines of

Mr. Ravi Ranjan, Head of Production, Honda Line N-5, JBM.
After detecting problems are resolve by MAINTENANCE and JIGS &
FIXTURE MAINTENANCE department as follow:

MAINTAENANCE:
Mr. Sumit Kumar

JIGS & FIXTURE MAINTENANCE:

Mr. Dilbag Rai
Mr. Ravi Prakash Pandey

CONCLUSION

I would like to say that this training program is an excellent opportunity for us
to get to the ground level and experience the things that we would have never
gained through going straight into a job. I am grateful to the Government
Engineering College, Ajmer and NMPL (JBM) for giving us this wonderful
opportunity.
The main objective of the industrial training is to provide an opportunity to
undergraduates to identify, observe and practice how engineering is applicable in
the real industry. It is not only to get experience on technical practices but also to
observe management practices and to interact with fellow workers. It is easy to
work with sophisticated machines, but not with people. The only chance that an
undergraduate has to have this experience is the industrial training period.
I feel I got the maximum out of that experience. Also I learnt the way of work in an
organization, the importance of being punctual, the importance of maximum
commitment, and the importance of team spirit. The training program having three
destinations was a lot more useful than staying at one place.
In my opinion, I have gained lots of knowledge and experience needed to be
successful in a great engineering challenge.

REFERENCE

I.
II.
III.
IV.
V.
VI.
VII.
VIII.

J.B.M. Industries
www.indiastydychannels.com
www.wikipedia.org
www.ehow.com
www.scribd.com
(N-5) Production Report
(N-5) Design Report
Head of department