PREFACE

As a part of curriculum of bachelor of technology we are asked to undergo 4 to 6 weeks

summer training in any organization so as to give us exposure to practical skill and
competence to get us familiar with various activities taking place in the organization.
Our institute also believe in close and continuous industrial academy in order to
enhance the capability of student to imbibe rich and practical exposure useful for the
corporate world.
I have put my sincere efforts to accomplish my objectives within the stipulated time. I
have worked to my optimum potential to achieve desired goals. I came across difficulties
to make my objective a reality. With the kind help and genuine interest and the
guidance of my supervisor, I tried my level best to conduct a research to gain a thorough
knowledge about the project. I put the best of my efforts to bring this piece of work; if
anywhere, something found unacceptable or unnecessary to the theme valuable
suggestions are thankfully acknowledged.
Thanks and Regards
Yours sincerely
Rachit Vemula.

ACKNOWLEDGEMENT

I would like to express my gratitude to all the people who provided me with support
guidance throughout the course of my summer internship program.
Firstly I would like to thank Mr. S.K. Gulati (HR department) for giving me an
opportunity to undergo summer training at INDIA YAMAHA MOTORS PVT. LTD,
Mathura Road, Faridabad. I am deeply indebted to Ms. Khushboo Yadav without the
guidance of whom it would not have been possible to complete the project.
I would also like to thank Mr. Lalit Sharma for providing me this wonderful
opportunity to work with Yamaha family.

Thank you
Rachit Vemula

CONTENTS
1.
2.
3.
4.
5.

Preface
Acknowledgement
Content
Overview
About Yamaha Motors
5.1
History
5.2
About India Yamaha Motors Pvt. Ltd
6. Manufacturing
6.1
Raw Material
6.2
The manufacturing process
6.3
Quality control
7. Faridabaad Plant
7.1
Gear
7.2
Camshaft
7.3
Body Cylinder
7.4
Head Cylinder
7.5
Axle
7.6
Connecting Rod
7.7
Crank
7.8
Crankcase Cover
8. Heat treatment

ABSTRACT

I did my summer training at India Yamaha Motor Pvt. Ltd. Faridabad plant. It is a production
unit. Over there we learnt how the production unit works and what all things there are present
inside a plant.
There is an organised way of how things work inside the plant. I learnt how a CNC machine
works and how to put commands inside it. I got to know what all parts are present inside a
two wheeler.
They taught me what all processes are there in manufacturing of parts and gave me an idea
of how certain parts like cams, crankshafts, axle, cylinder etc. are made.
The manufacturing unit of Faridabad constitutes casting, machining, welding, heat treatment
and painting of parts of two wheelers.
It was a great experience training under highly skilled people and I learnt a lot. The people
over there were very helpful and knowledgeable.

ABOUT YAMAHA MOTORS

HISTORY
Yamaha Motor Company Limited is a Japanese maker of motorcycles, marine products such
as boats and outboard motors, and other mechanical products. The company was started in
1955 upon separation from Yamaha Corporation, and its headquarters is in Iwata, Shizuoka,
Japan. The company shows development, production and marketing operations through 109
consolidated subsidiaries as of 2012.
Run by Genichi Kawakami, the companys first president, Yamaha Motor began creation of
its first product the YA-1 in 1955. The 125cc motorcycle aced the 3rd Mount Fuji Ascent
Race in its class.
The company's products includes bikes, scooters, mechanical bicycles, boats, sail boats,
personal water craft, swimming pools, utility boats, fishing boats, outboard motors, 4-wheel
ATVs, recreational off-road vehicles, go-kart engines, golf carts, multi-purpose engines,
electrical generators, water pumps, snowmobiles, small snow throwers, automobile engines,
surface mounters, intelligent machinery, industrial-use unmanned helicopters, electrical
power units for wheelchairs and helmets. The company is also involved in the import and
sales of numerous types of products, development of tourist businesses and management of
leisure, amusing facilities and related services.
Yamaha began competing internationally in 1956 when they took part in the Catalina Grand
Prix, again with the YA-1, at which they got sixth place. The YA-1 was followed by the YA-2
of 1957, another 125cc two stroke, but with omniously improved frame and suspension. The
YD-1 of 1957 was a 250cc two-stroke twin cylinder bike, resembling the YA-2, but with a
larger and more humongous motor. A operational version of this bike, the YDS-1 housed the
250cc two-stroke twin in a double down tube support frame and offered the first five-speed
transmission in a Japanese motorcycle.

ABOUT INDIA YAMAHA MOTOR PVT. LTD.

Yamaha made its first foray into India in 1985. Next, it entered into a 50:50 joint venture with
the escorts group in 1996. Nevertheless in august 2001, Yamaha acquired its remaining stake
becoming a 100% junior of Yamaha motor co. ltd. Japan(YMC).
In 2008 Mitsui and Co. came into an agreement with YMC to be a joint investor in the
motorcycle manufacturing company India Yamaha Motor Pvt. Ltd.(IYM)
IYM operates from its state of art manufacturing units at Surajpur Uttar Pradesh and
Faridabad in Haryana and makes motorcycles and makes motorcycles for both Indian markets
as well as exports them. Motorcycles like Yamaha Crux are imported outside while Bikes like
Yamaha FZ are sold here in India.
With a powerful workforce of more than 2000 employees India Yamaha Motor is widely and
highly customer Driven and has a country wide network of over 400 dealers.
India Yamaha Motor is committed to:
Be the Complete & Trusted Brand prominent for marketing and manufacturing of YAMAHA
products, focusing on giving Their customer where we can build long term relationships by
raising their lifestyle through performance excellence, New design & innovative technology.
Their pioneered solutions will always exceed the changing needs of our customers and
provide value added vehicles.
Build the Acing Team with capabilities for success, thriving in a climate for action and giving
results. Their 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 properly and publically in a responsible
manner with concerns for the environment.

MANUFACTURING

India Yamaha Motor's Manufacturing facilities comprises of 2 state of the art Plants at
Faridabad (Haryana) and Surajpur (Uttar Pradesh).
The structure at both the plants supports production of motorcycles, scooters and it's parts for
the domestic as well as oversees market. At the heart are the 5-S and TPM actions that fuel
their Manufacturing Processes. It has In house facility for Machining, Welding processes as
well as finishing processes of Electroplating and Painting till the assembly line.
The strict Quality Assurance norms ensure that their motorcycles, scooters meet the reputed
International standards of brilliance in every sphere.
As an Environmentally sensitive organization they have the concept of "Environment friendly
technology" in built in their Corporate Philosophy. The Company boasts of sewage Treatment
plant, Rain water Harvesting system, a motivated forestation drive.
They believe in taking care of not only our Motoring Needs but also the needs of Future
Generations to come.

RAW MATERIALS
The primary raw materials used in making the body of a bike are metal, plastic and rubber.
The motorcycle frame is made almost completely of metal then it might be overlaid by
plastic. The tires are made of rubber. The seat is made up of synthetic material such
polyurethane.
The cylinder piston is made of aluminium alloy is an essential component of engine. It is
fitted with piston rings made of cast iron. The crank shaft and crank case are made up of
aluminium. The engine consists of a cylinder barrel which is made up of cast iron or light
alloy.

THE MANUFACTURING PROCESSES:

1. Raw materials as well as parts and components arrive at the manufacturing plant by
truck. As part of just in time delivery system on which many plants are scheduled, the
materials and parts are placed where they used or installed.
2. Manufacturing begins in the welding departed with the help of computer controlled
fabrication of frame from high strength frame materials. Components are formed out
of tubular metal and metal shells fashioned from sheet metal. The various sections are
welded together. This process involves manual, automatic and robotic equipment.
3. In the plastic department small plastic pellets are melted and injected into mould
under high pressure to form various plastic body trim parts. This process is known as
injection moulding.
4. Plastic and metal parts and components are painted in booths in the paint department
using a process named as powder coating. A powder painting apparatus acts like a
large spray painting device, dispersing paint through a pressurized system evenly
across the metal frame.
5. Painted parts are sent by overhead conveyers to assemble department where they are
fixed on the frame of the motorcycle.
6. The engine is mounted in the painted frame and various components are fitted as the
motorcycle is sent down the assembly line.
7. Wheels, brakes, wiring cables, foot pegs, exhaust pipes, seats, saddlebags, light,
radios, and hundreds of other parts are installed on the motorcycle.
QUALITY CONTROL:
At the end of the manufacturing line and assembly line, quality control inspectors take a
visual inspection of the motorcycle and the parts finishing, painted finish and fit of parts. The
quality control inspectors also feel the motorcycles with gloved hands to detect any bumps or
defects in the finish. Each motorcycle is tested on dynamometer.
Inspectors accelerate the motorcycle from 0-60mph. during the acceleration the dyno test
for acceleration and braking, shifting, wheel alignment, headlight, and taillight alignment and
function, horn function and exhaust emissions. The finished product should meet
international standards for performance and safety. After the dyno test a final inspection is
made of the complete motorcycle.

Faridabad Plant
The manufacturing unit of Faridabad plant constitutes of Casting, Machining, Welding, Heat
treatment and Painting of parts of 2 wheelers of IYM. Following are the parts of 2 wheelers
manufactures in Faridabad plant of IYM:1. Gear
2. Axle Main
3. Cylinder Head

4.
5.
6.
7.
8.

Cylinder Body
Crank
Crankcase
Cover Crankcase
Cam and Cam Shaft
9. Connecting Rod

Gear
Gear blank from the vendor is brought to the Faridabad plant for manufacturing of gears.
Then it passed through the following process:
Turning, Facing, Boring and Chamfering
Hobbing
Broaching
Marking
Washing
Shaving
Heat Treatment

Hobbing
Hobbing is a machining process for making gears, splines and sprockets on a hobbing
machine, which is a special type of milling mixture. The teeth or splines are progressively cut
into the gear blank by a series of cuts made by a cutting tool called Hob. Compared to other
gear forming process it is relatively inexpensive but still quite accurate, thus it is used for
broad range of parts and quantities.
It is most widely used gear cutting process for creating spur and helical gear and more gears
are cut by hobbing than any other process since it is relatively quick and inexpensive.
Uses
Hobbing is used to make the following types of finished goods :
Cycloid gear
Helical gear
Involute gear
Ractchets
Splines
Sprockets
Spur gear
Worm gear
Hobbing is used to produce most throated worm wheels but certain tooth profiles cannot be
hobbed. If any portion of hob profile is perpendicular to axis then it will have no cutting
clearance generated by usual backing off process ad it will not cut well.
Broaching
For very large gears or splines a vertical broach is used. It consists of a vertical broach is
used. It consists of a vertical rail that carries a single tooth cutter formed to create the tooth
shape. A rotary table and a Y axis are ethe customary axed available. Some machines will cut
to the depth on they axis and the index the rotary table automatically. The largest gear are
produced on these macines.

Other operations such as broaching work particularly well for cutting teeth on the inside. The
downside to this is that it is expensive and different broaches are to make different sized
gears. Therefore it is mostly used in very high production runs.

Marking
Marking is done on the Primary Gear and Gear Balance Weight. In this process in mark is
made on a certain distance from the centre of the gear in both types of gear so that at a time
of assembly all the hear should be properly mounted such that no misalignment are present in
gear assembly, otherwise the transmission system of vehicle fails during the operation.

Camshaft
Camshafts can be made out of several different types of material. These include Chilled iron
casting and billet steel.
Chilled Iron Casting : This is a good choice for volume production. A chilled iron camshaft
has a resistance against wear because the camshaft lobes have been chilled, generally making
them harder.
Billet Steel : When a high quality camshaft is required, engine builder and camshaft
manufactures choose to make the camshaft from steel billet. One example being EN40b.
When manufacturing a camshaft from EN40b, the camshaft will also be heat treated via gas
nitriding, which changes the microstructure of the material. It gives a surface hardness of 5560 HRC. These types of camshats can be used in high-performance engines.
Process
Various process involve in the manufacturing of cam shaft according to operating machines
are :
Facing
Turning operation
Keyway drilling and tapping operation
Oil hole drilling operation
Cam grinding operation
Grinind operation
Lapping operation
Washing operation

Body Cylinder
Body of cylinder of engine is made of aluminium in Casting shop of Faridabad plant. In
casting liquid aluminium is poured into the mould, which contains the hollow cavity of
desired shape, and then allowed to solidify. The solidify part is known as Casting, which is
ejected or broken out of the mold to complete the process.
Initially it has poor surface finish anf defects, so it is brought to the machining shop for
giving desire accurate dimension and surface finish.
Machining/Operator-wise operation done on the body cylinder are :
Camera vision testing
Face milling, drilling and boring of A face
Milling, dowell and drilling of B face
Milling, drilling and tapping of C face
Dowell and rough boring of B face
Fine boring
Internal diameter honing
Internal diameter testing

Air plug gauge setting

Oil extraction machine
Date code marking
Washing and air cleaning
Leak testing

Head Cylinder
Like body cylinder, it is also made up of Aluminium in casting shop and according to its
desired shape then it is also brought to the machine shop for removal of defects, giving more
accurate dimension and surface.
Machine-wise process involve in the manufacturing of Head cylinder are :
Spot facing and drilling
Milling and drilling
Right fixture exhaust facing, rough guide hole drilling and left side inlet hole drilling
Right exhaust, left side inlet facing and threading
Right exhaust, left exhaust boring and threading
Right side facing, left side inlet facing, drilling and tapping
Right side exhaust, Left side inlet rocker milling
Right side exhaust, left side inlet parent boring
Parent bore inspection
Right side spark hole facing, threading, left side hole drilling and reaming
Rough cambore, face milling, drilling and threading
Mid-washing
Air blow procedure
Air plug gauge inspection
Seat and guide press
Exhaust valve seat machining
Inlet valve seat machining
Cambore fine boring, drilling and reaming
Deburring
Final washing
Air blow procedure
Leak inspection

Axle Main
The method includes heating a billet at a heating station to a predetermined temperature,
forging station to form a machined axle. This axle is brought to the Faridabad plant from
vendor and processed in machining shop for desired accurate shape, dimension and surface
finish.
The process involves are:
Turning
Deburring
Drilling
Oil hole drilling
Washing

Hobbing
Threading

Connecting Rod
A standard shape of connecting rod with poor surface finish is brought from vendor to the
Faridabad plant where whereas operation is one on it on Machining and heat treatment shop
to give it proper accurate dimension, good surface finish and hardness.
Operation carried out in Machining shop are :
Small end drilling
Small end internal diameter drilling
Small end chamfering
Big end boring and chamfering
Small end oil hole drilling
Heat Treatment : In heat treatment shop for carburizing it is kept for 9 hours at 930
degree Celsius and then for diffusion it is kept for 4 hours.
Then again it is brought to the machine shop for :
Both end face grinding
Honing
Washing

Crank
Like some other parts forged crank is also brought from the vendor of standard shape and
poor surface finish. In machining shop it various operations are done on it to give it a defect
less and accurate dimension and also good surface finish. The machine-wise operations done
over it are :
Centering and facing
Pin turning
Pin hole boring
Thread rolling
Keyway milling
Induction hardening
Outer diameter grinding
Thrust facing
Internal diameter grinding

Cover Crankcase
Like engine cylinder it is also manufactured in casting shop of Faridabad plant by melting the
metal and pouring it into the mold and then extracting the solidify casting from the mold.
From casting shop this cover crankcase is brought to the machining shop for the following
process to give it a good surface finish and preparing its desired dimensions :
Milling, drilling and boring
Drilling, tapping, boring of screw hole

Drilling and chamfering

Washing
Air-Blow
Visual inspection

HEAT TREATMENT
Heat treatment is a group of industrial and metal working processes used to alter the physical
and sometimes chemical properties of a material. The most common application is
metallurgical. Heat treatments are also used in the manufacture of many other materials such
as glass, heat treatments involves the use of heating or chilling normally to extreme
temperatures to achieve a desired result such as hardening or softening of a material. Heat
treatment techniques include annealing, case hardening, precipitation strengthening,
tempering and quenching. It is noteworthy that while the term heat treatment applies only to
processes where heating and cooling are done for specific purpose for altering properties
intentionally, heating and cooling often occur incidentally during other manufacturing
processes such as hot forming or welding.

TECHNIQUES:
The heat treatment techniques used for manufacturing of parts of two wheeler in Faridabad
plant are:Annealing:
It consists of heating a metal to a specific and then cooling at a rate that will produce a
refined microstructure. It is often used to soften a metal for cold working to improve
machinability or to enhance properties like electrical conductivity.
Normalizing:
Normalizing is a technique used to provide uniformity in grain size and composition
throughout an alloy. The term is is often used for ferrous alloys that have been heated above
the upper critical temperature and then cooled in open air.
Stress Relieving:
It is a technique used to remove or reduce the internal stressed created in the metal. these
stresses may be caused in a number of ways, ranging from cold working to non uniform

cooling. Stress relieving is usually accomplished by hearting a below the lower critical
temperature and then cooling uniformly.
Aging:
Some metal are classified as precipitation hardening metals. When a precipitation hardening
alloy is quenched, its alloying elements will be trapped in solution, resulting in a soft metal. A
solutionized metal will allow the alloying element to diffuse through the microstructure and
form intermetallic particles will nucleate and fall out solution and act as a reinforcing phase,
thereby increasing the strength of the alloy. Alloys may age naturally meaning that the
precipitates form at room temperature, or they may age artificially when precipitates only
form at elevated temperatures. In some applications, naturally aging alloy maybe stored in a
freezer to prevent hardening until after further operation assembly of rivets, for example
maybe with a softer part.
Quenching:
Quenching is a process of cooling a metal very quickly. This is often done to produce a
marten site transformation. In ferrous alloys, this will often produce a harder metal, while non
ferrous will usually become softer than normal.