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Among all of these units Hema Engineering Industries Ltd.,1/3 km, Khandsa Road
Gurgaon, is the major company of HEMA Group of industries. It is the major
ancillary unit of HERO HONDA MOTORS LTD.
Due to hard work, dedication and the able guidance of Mr .K.K. Jajoo (Chairman,
Hema Group) it has grown up as a major ancillary unit for Hero Honda Motor Ltd.
The unit is dedicated to its quality policy. It is TS 16949-2002 and ISO14001
certified company.
COMPONENTS MANUFACTURING IN HEIL
The work of this department starts with the recruitment of the manpower for the
plant whether it is skilled,. Semi skilled or unskilled.
After the recruitment of the manpower they take care of proper training of
every person according to the need so that each and every person can be an
asset to HEIL and can help in increasing the productivity and profit of the
company. For this purpose various type of training is arranged by the personnel
department . For this purpose the department has to keep a close eye on every
employee that where a person is lagging behind and needs training in the
specified field so that one can give better results.
Along with the recruitment this department keeps the full detailed record of
each employee of HEIL so that in case of any need it can be used..
The various norms regarding the environmental safety are to be taken care by
this department only. Various problems of the employees like regarding
working conditions , pay scale and health are dealt by this department only.
As this department has to deal with the manpower so the work of this
department is a typical one and for it the concerning staff has to work hard.
MIG WELD SHOP
It is the first production shop of the unit. As its name states that MIG (Metal
inert gas welding) welding shop, MIG welding is used to manufactured the
components. A gas is used to prevent the oxidation of weld. CO2 is used as
shielded gas over the work when welding is done. The components produced in
this shop are swing arm for the various models of Hero Honda Motor Ltd., TVS
Motor Company Ltd.
2.End Piece Welding:- The end piece is welded on the other end of pipe. The
end of pipe is already in the shape to sit in end piece easily.
4.Arm Welding: - Now weld is completed for the whole length of the plate.
5.Cross plate, stopper arm, plate B tacking: - At this step the stopper and
plate B are tacked on the cross plate of the swing arm.
8.Collar Alignment: - At this step 1st inspection is held for the alignment of
collar. If there is any misalignment occurs in swing arm, then corrective action
is taken.
9.Stay A Chain Case Tacking: - A Stay for chain case is tacked on swing arm.
12.Collar Boring: -Collar boring is done on the collar after welding. Boring of
collar is done to get the required dimensions after welding.
15.Visual inspection: -The swing arm is inspected visually at this step. Minor
defects are removed in this step also. If any major fault/defects found in the
component, then it is sent back on the line according to the defects.
Thus the weld shop of our concern forms the major workshop requiring the
major part of the work force of HEIL . The weld shop is running all 24 hrs in 3
shifts to match the requirement of our customers.
Tool Room/Design
This department make the drawings of house production component & the
brought out components. We use the software for the drawing are Auto cad &
Pro-e. This department makes the tool & dies also.
The inventory material in the plant is totally managed by the store department
in the plant .
The various operations are to be done on the components and after completing
all the operations on the components they are send to the final assembly so that
the final product can be carved out of the raw material .
After all the assembling operations are done on the components , they are to be
finally checked by the Final Inspection Department. After qualifying all the
standards from the final inspection then only the material is dispatched to the
concerning party.
The customer satisfaction standard is to be maintained by the final inspection
department only as the department has to deal with the customer directly to
solve the problems which the customer is facing if any.
DOCUMENTATION CENTRE
The department keeps all the documents regarding the various polices followed
by the company , various Indian and international standards followed by the
company and regarding all the dealing by the company.
The department head has the various responsibilities like to get the feed back
from the customers regarding quality and timely delivery and other if any.
Other then this the head has to keep a close look on all the employees of the
company that whether all the standards are properly followed by all or not.
The head also cross check the activities of the heads of all the departments that
whether all the norms imposed are being properly followed or not and if there is
any leg behind then he looks what are the corrective measures .
COSTING
This Department deals with the cost relating matters of the company like what
shall be cost of any component if the company manufactures it or buys from
outside .
PURCHASE
All the matters of purchase of any thing weather it is consumable or any raw
material to be used in the company is undertaken by this department only.
This department takes the information from all the departments in the company
and get the details of all the items required in the various departments and
forwards it to the various vendors of the company so that they can fulfil all the
requirements on time .
STRUT SHOP
Struts are manufactured in this shop. The struts manufactured in this shop are
for Gabriel Auto Ltd., Hydraulics India Ltd.
Components of Strut
1. Pipe
2. Seal
3. Knuckle Bracket
4. Spring Guide
Processes Performed In Strut Strut Shop
1. Name Rolling:-
This process is performed on rolling machine with some pressure. The name
of the company is engraved on the punch.
2. Reducing Bore:-
In this operation the dia of the pipe is reduced on the press machine.
Machine Make Milap
Size reduced 5 mm.
Length Reduced on pipe 19-20 mm.
Boring size i.e. done on reduced dia 2 mm.
Facing done on pipe 1 mm.
This process is performed on ordinary lathe which has a single point tool.
10.Code Punching:-
The code of product which is produced in the shop is punched in this step.
QUALITY POLICY
1% DIE
3% MOVE AWAY
5% FORM OTHER
INSTRUMENTS USED
INSTRUMENTS USED :-
*MECHANICAL COMPARATORS
WORK INSTRUCTIONS
MINI POWDER COATING
MACHINE SPECIFICATION :-
Water used at back side of the paint process where the extra paint
mixed with water after dropping from gun has been changed after one
year. Hot water generators are used for heating the water and produces
steam to maintain the temperature of the room heaters.
50,000 ltrs. approx. de-mineralised water is used per day at a cost of
1.50 Rs/ltr. in the paint shop.
MAINTENANCE
1. POWER PRESSES
2. PNEUMATIC PRESSES
3. DRILLING MACHINES
PROCESSES PERFORMED ON THE PARTS OF MERANO
OVEN
1. Handle
2. Screw M 5*12 (qty-2)
3. Handle strip (shearing,crome plating after nut welding).
4. Merano furnace.
5. Front closing door assly.
6. Front closing door (punching,corner cutting,bending).
7. Handle locating bolt.
8. Rope resting bkt.RH/LH (shearing ,bending).
9. Rope resting bkt. Top/bottom (shearing,bending).
10.Door spring locating bkt.(shearing,punching).
11.Glass support strip.
12.Pinfor door mtg.
13.Sliding strip assly.
14.Sliding strip.
15.Guide bkt.(shearing,bending).
16.Glass.
17.Handle assly.
18.Handle lock plate.
19.Main body (punching,bending).
20.L-plate top window (round cutting,bending).
21.Door hinge upper.
22.Upr.front plate l-type assly.
23.Upr.front plate l-type (bending).
24.Spacer strip (shearing).
25.Internal tray assly.
26.Internal tray(bending).
27.Spacer strip internal tray (shearing).
28.Support plate.
29.Support plate ring resting assly.(bending).
30.Brick locating bkt. (shearing ,bending).
31.Main window support bkt.bottom (bending).
32.Main window support LH/RH assly.
33.Main window support plate (shearing).
34.Ring resting plate (punching).
35.Door lock pin.
36.Brick resting plate (punching,corner cutting,bending).
37.Tray resting plate assly.
38.Tray resting plate (corner cuting,bending).
39.Tray support strip (shearing,bending).
40.Support bkt.(shearing).
41.Locating sheet (punching).
42.U-bkt.(corner cutting,bending)
43.Side cover RH/LH (punching,bending).
44.Door hinge lower.
45.Top cover assly.
46.Top cover (punching,rolling,bending).
47.Top cover back/front plate (punching).
48.Base frame (punching,bending).
49.Rear cover (punching).
50.Tray assly.
51.Tray (corner cutting,bending).
52.Bricks.
53.Baffle.
54.Pin for locating sheet.
55.Resting bkt. Front.
56.Exhaust ring (shearing,bending,sizing).
57.Door spring bkt.
58.Glass locating clip.
59.Knob (crome plating).
60.Handle (main tray) (shearing,corner cutting,bending).
61.Front bkt. Assly.
62.Plate-1 (shearing,punching).
63.Plate-2 (shearing).
PROCESSES PERFORMED ON THE PARTS OF OREGON
OVEN
The assembly of the OVEN is made by tacking and then Mig welding
is done on all the parts i.e. front cover, l-plate, back cover, rear plate,
ring, base plate etc. and then packed in polythenes & wooden boxes
for dispatch.
WORKING OF AN OVEN
The main function of this oven is to heat the room. low carbon content
coal is burnt in this oven because it is less harmful for human being
and environment. Coal is burnt at the internal cast iron tray which is
assembled at the bottom part of the oven. Two perforated holes with
open/close arrangement are provided upside of the heating chamber
and one is at lower side. These holes allow the air to come into the
chamber and burning of coal can be done. We can adjust the heating of
the oven or burning of the coal by adjusting the opening of inlet air
providing holes and heating of the room can be done as per
requirement less or more by this hole adjusting method. By
completely shutting off the three perforated holes will not provide
heating and oven will shut off with no burning of coal. At the front of
the coal inserting chamber a glass window is provided. At the front of
the top of the oven L-type plate is covered with surrounding plates
with holes which allows the heat flow in the room. At the center of the
top of the oven Ring is attached which further attaches to the chimney
to allow the exhaust gases out to the atmosphere.
SPOKE,NIPPLE AND PLATING SHOP
In this department spokes and nipples are made which are used in the
rim of the motorcycle. Spoke and nipples are also plated in this shop.
Different types of chemicals are used for plating the spoke and nipple.
Return effluent
To plating overhead
Storage
tank
Stage 2. Acidic :-
• ph 2-3 checked
• sodium meta sulphite
Stage 3. Alkaline :-
• Dosing of sodium hydrochloride
• Check ph above 10
Stage 7.
• Sludge to filter press
• Dry matter separation
1. Ph (1)
2. T.S.S (total suspended solids)
3. Oil and grease
4. Chromium (hexavalent)(2)
5. Total chromium
6. Cyanide
7. COD & other
Q.A (ASSEMBLY AND FINAL)
In this department all the components coming from other
departments (welding, press, and paint shop) are assembled
with the help of nuts and bolts etc. Nuts and bolts are screwed
by nut tightening m/c. Different types of operations are done in
this shop e.g boring, tapping and rubber bush pressing etc.
Boring and tapping operations are done for removing of extra
paint material inside the holes and threading. Oils and greases
are also provided over the required parts so that the components
can prevent from corrosion and can't be damage easily due to
friction etc. final inspection is also done here before packing
and dispatch. Rejected components send back to the
departments for their maintenance. After assembly the
components are packed in polothenes, cartoons and boxes as
per requirement and finally dispatched to other companies.
MACHINES USED
1. Boring machines
2. Tapping machines
3. Nut tightening machines (hand gun)
4. Drilling machines
5. Rubber bush pressing machine(SPM)
.
1. ADHESION TEST :
Adhesion tape is used for checking
the adhesion or sticking of the paint layer over the surface of
the component. The layer of paint is first scratched with the
help of knife to make the grid over the surface and the tape is
stacked and rubbed on that grid surface of the paint layer. Now
remove the tape, If there is no removing of paint from the
surface then the layer of the paint is properly stacked on the
surface and the paint coating is ok.
2. HARDNESS TEST :
A hardness pencil is used for checking the
hardness of the paint layer over the surface of the component.
Mark a line on the painted surface, if there is no removing of
paint layer then the hardness of the paint coating is ok.