Indsutrial Training in Hero MotoCorp Ltd.

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Hero MotoCorp Ltd.Gurgaon Plant

Aaditya Nagpal401107001

Mr. Supreet Bhullar(Asst. Professor, Thapar University)Faculty Coordinator

Mr. Sanjeev Mittal(Asst. General Manager, Hero MotoCorp Ltd.)Industry Coordinator

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Monday, April 10, 2023THAPAR UNIVERSITY, PATIALA 2

HERO MOTOCORP LTD.

• Started in 1984 as a joint venture

• Largest two wheeler company in India

• In 2010, Honda moved out of venture

• Splendor is company’s most successful model

• 17 different products across 100cc, 125cc, 150cc, 225cc and scooter category

• 3 plants with combined capacity of 6.35 million units

• 6,106 employees all over in India

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THE GURGAON PLANT

• 2nd plant of company

• Produces 7000 bikes per day (18 sec for each bike)

• Most of the new bikes are produced

• Important models: Glamour, Passion (new), Karizma, Ignitor, Pleasure, maestro

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THE WELD SHOP

• In Gurgaon plant, it consist of 2 sections

• 1)Weld Shop I (old) & 2) Weld Shop II (new)

• Fuel tanks (3 lines) & frame body (3 lines)

• Important processes: MIG welding, Grinding, Boring, MFF welding, Sanding, Spot welding, Buffing, Seam welding, Brazing, Leak testing

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PROJECT 1

“ Optimization of Usage of Consumables in the Weld Shop”

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PROCESS FLOW IN FUEL TANK LINE

Body R/L MIG weldng Bead grinding Burring Denting and

belt sanding

MFF MIG WeldingSandingBuffingBody R/L and

bottom tacking

Seam welding Cock drain and pipe brazing Final inspecion Leak testing

Rear numper plate spot welding

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THE EIGHT COMPONENTS

TACKING

ROBOTIC WELDING

MANUAL WELDING

FINE BORING

QC & INSPECTION

IN PROCESS INVENTORY

PAINT SHOP

PROCESS FLOW IN FRAME BODY LINE

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CONSUMABLES IN THE WELD SHOP

• Consumables can be defined as the components of an end product that are used up or permanently altered in the process of manufacturing

• These are categorized into three classes

• ‘A’ class consumables are those consumables that are used on the very important part of the bike from the point of view of beauty and safety

• Costs around Rs. 25 per vehicle

• Excessive consumption is a major problem which is caused by worker mistakes or material

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OBJECTIVE OF THE PROJECT

• Consumption of the consumables:– Observe the processes where the consumables are used and

also to measure the consumption of them in these processes– Define an optimum number for their consumption

• Ways to reduce the consumption: – Make changes in the process to make optimum utilization– Make changes in the material (consumables)

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DELIVERABLES

• The project would be helpful to estimate the cost of various consumables per vehicle for different models

• If the suggested changes are done it will reduce the consumption of consumables as well as increase the quality of the vehicle

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SANDING DISC

• A heavy paper with abrasive material attached to its surface

• Sandpaper is part of the "coated abrasives" family of abrasive products

• It is used to remove small amounts

of material from surfaces, either to

make them smoother (painting and

wood finishing), to remove a layer

of material (e.g. old paint), or

sometimes to make the surface smoother

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• used mainly in weld shop for fuel tank line • mainly to remove the small defects on the

tank, to make surface smoother• four sanding stations on each line, three

rework stations and one final inspection point • grit size 120, but at rework it is 100

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CONSUMPTION PATTERN

The following figures indicate the sanding paper and cost needed per tank to do sanding operation. First the number of tanks per sanding paper was calculated. Based on that these figures are obtained. Value of 1 sanding paper is Rs 29MODEL NO. OF TANKS SANDING DISC/ TANK COST / TANK

(Rs.)

KARIZMA 21 0.095 2.76

ZMR 22 0.091 2.64

GLAMOUR 31 0.065 1.89

GLAMOUR FI 30 0.066 1.91

PASSION 41 0.049 1.42

X PRO 36 0.056 1.62

IGNITOR 32 0.063 1.83

CBX 33 0.061 1.77

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CAUSE AND EFFECT DIAGRAM

WASTAGE OF SANDING DISC

MATERIAL LARGE BACKUP PADS SIZESHAPE OF

PAPER

HUMAN ERROR

EXCESSIVE CUTTING

REWORK USES MORE PAPER

QUALITY

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PROBLEMS AND SOLUTIONS

• Larger backup pads in new weld shop- reduce backup pad size in both sections

• Cutting should be same in both weld shops• Rework fuel tanks consume more amount of paper,

reduce defects MFF welding & body R/L welding• Polygon sized paper manufactured by vendors directly

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MISCELLANEOUS OBSERVATION

• Two different types of sanding discs were being used : 1.) “CE code” 2.) “YC code”• “CE code” disc predominantly used• Few operators in Weld Shop II were using “YC code

disc”• Output of “YC” disc nearly half.• The use of it immediately stopped and it was sent to

the concerned personnel to find out the causes and costing of the same.

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GRINDING WHEEL

• Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool.

• Grinding practice is a large and diverse area of manufacturing and tool making.

• In mass production contexts it can rough out large volumes of metal quite rapidly.

• It is usually better suited to the machining

of very hard materials than is "regular"

machining

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• Grinding wheel is only used in fuel tank lines• Grinding wheel used has specifications

100*6*15; max speed limit is 72 m/s• In old weld shop one station for grinding just

after R/L body robot welding and two station for

• In new weld shop one station for grinding after R/L

body welding and one for rework• Grinding wheel is also used at seam welding

electrodes for wheel dressing.

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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. Similarly Passion was also studied for long time in the line and was taken as standard. Cost of 1 grinding wheel is Rs. 110/-

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CONSUMPTION PATTERN

MODEL 1 MODEL 2 NO. OF COMPONENTS PER GRINDING WHEEL

NO. OF COMPONENTS OF MODEL 1/WHEEL

NO. OF COMPONENTS OF MODEL 2/WHEEL

PASSION XPRO 160+65 250 180

GLAMOUR KARIZMA 130+39 210 102

GLAMOUR IGNITOR 150+37 210 127

GLAMOUR HUNK 171+19 210 100

GLAMOUR CBX 90+62 210 108

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CONSUMPTION PATTERN

MODEL NO. OF COMPONENTS PER GRINDING WHEEL

GRINDING WHEEL PORTION USED PER COMPONENT

COST OF 1 GRINDING WHEEL(Rs.)

COST OF GRINDING WHEEL PER COMPONENT(Rs.)

PASSION 250 0.0040 110 0.44

XPRO 180 0.0056 110 0.62

GLAMOUR 210 0.0048 110 0.53

KARIZMA 102 0.0098 110 1.08

IGNITOR 127 0.0079 110 0.87

HUNK 100 0.0100 110 1.10

CBX 108 0.0093 110 1.02

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• Pneumatic Grinder Neck damage - worker awareness can solve this issue

• Sharp edges of new grinding wheel - Company should order wheels having less sharpness at edges

• Way of rework at MFF – smaller diameter & higher thickness wheels should be used

• Use of grind wheel for seam welding

dressing - harder grinding wheel

specially designed for wheel dressing

should be used

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BRAZING ROD

• Brazing is a metal-joining process whereby a filler metal is heated above melting point and distributed between two or more close-fitting parts by capillary action

• Filler metal used in brazing is in the shape of rod and it is called brazing rod and made of Bronze Alloy ( in Hero motocorp)

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• Used in fuel tank line only for cock, drain pipe, breather pipe brazing & in rework

• Two stations on each line for cock & drain pipe brazing, and two rework stations

• Rework is done at two stations one is just after MFF welding and one is at final inspection

• Cock is small pipe through which the fuel flows to the engine

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Model

Fuel Cock Brazing

Drain Pipe Brazing

Total Value Of Brazing Rod

(Rs)

Brazing Rod / Comp (Kg.)

Brazing Rod / Comp (Kg.)

Glamour 0.0146 0.0093 13.27

Ignitor 0.0243 0.0026 14.93

X Pro 0.0215 0.0102 17.62

CBX 0.0255 0.0102 19.86

Karizma 0.0196 0.0116 17.36

Karizma Fi N/A 0.0121 6.76

Glamour Fi N/A 0.01 5.56

Passion 0.0218 N/A 12.15

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CONSUMPTION PATTERN

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MIG WELDING WIRE 1mm

• 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

• Copper coated mild steel wire

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• wire of 1 mm is used in Tack welding of components

• It is also used in all manual welding stations just after robotic welding

• Tack welding is a process of joining all the major components of the frame body together by a temporary welding joint

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CONSUMPTION PATTERN

MODEL BEFOREWEIGHT(KG)

AFTER WEIGHT(KG)

WIRE USED(KG)

NO. OF COMPONENTS

WIRE / COMPONENT (KG)

COST / COMPONENT (Rs.)

PASSION 13.30 12.80 0.50 10 0.050 3.30

GLAMOUR 13.10 12.00 1.10 20 0.055 3.63

GLAMOUR FI

13.26 12.20 1.06 20 0.053 3.50

KARIZMA 13.30 12.65 0.65 10 0.065 4.29

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.Cost of 1 KG wire is Rs. 66

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EXCESSIVE USE OF 1 mm wire

MATERIAL

OILED PARTS

HUMAN ERROR

WASTAGE IN TRASH DURING CHANGING

DEFECTS DURING ROBOTIC WELDING

QUALITY

IMPROPER CLEANING AND STORAGE OF WIRE ROLLS

HIGH CURRENT AND VOLTAGEPROCESS

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• Higher current & voltage used at stations – worker awareness can solve this issue

• Improper cleaning & storage of wire rolls – suggested a storage facility as well as packaged shipping of rolls, glass covers on the rolls

• Oil problem: oiled parts cause several

defects in welding. They must be

cleaned before welding• While changing of wire rolls lot

of wire is thrown in trash• Defects in robotic welding

cause consumption of wire

in manual stations

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MIG WELDING WIRE 1.2mm

• MIG welding wire of 1.2 mm is used for higher strength joints

• Used in gantry robotic welding in the frame body line

• Gantry robot is a pneumatically controlled programmable robot with two welding arms

• The temporary joints in the tack welding are made permanent in this process.

• Two robotic arms use separate wire rolls

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CONSUMPTION PATTERN

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)

MODEL BEFORE WEIGHT (kg)

AFTER WEIGHT(kg)

WIRE USED(kg)

NO. OF COMPONENTS

WIRE / COMPONENT

COST / COMPONENT (Rs.)

GLAMOUR 13.1613.28

12.6212.72

1.1 26 0.042 2.67

GLAMOUR FI

13.1613.28

12.6212.72

1.1 26 0.042 2.67

PASSION PRO

13.2613.18

12.8212.60

1.12 26 0.043 2.70

SCOOTER 12.7212.62

12.4812.46

0.4 10 0.040 2.52

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• Similar problems as in wire roll of 1 mm like improper cleaning, storage and high voltage current, oil problem

• Defects in tack welding can lead to defects in robotic welding which increases the consumption in manual welding stations

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WELDING WIRE 0.8mm

• Used only in the fuel tank line• Body R/L welding, MFF MIG welding, Base fuel pump welding

in form of wire rolls; all of these are robotic welding processes• 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• 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.

• Base fuel pump: the fuel pump which controls the fuel flow to the engine (used in Glamour-FI only)

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CONSUMPTION PATTERN

Model

Body R/L Welding

WIRE / COMP (Kg) COST/COMP (Rs.)

GLAMOUR 0.015 0.991

IGNITOR 0.016 1.075

X PRO 0.010 0.672

CBX 0.012 0.806

PASSION 0.013 0.851

KARIZMA 0.024 1.613

KARIZMA FI 0.024 1.613

GLAMOUR FI 0.015 0.991

The initial and final weight of the wire roll was recorded. Based on that the consumption of wire roll per fuel tank was obtained. Cost of one wire roll= 67.20 Rs.

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TRIAL OF BHH MAKE

• Usha Martin wire rolls used• Trial on BHH conducted• Trial passed

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• Oil problem- cleaning of parts is needed to solve this problem

• Proper cleaning of wire rolls & storage facility is needed

• Robots in overdrive mode cause higher consumption – proper operating parameters can solve this problem

• Improper placement of MFF & bypass lock- assure the proper clamping of both the parts

• Near MFF, welding in body R/L can be avoided to reduce wire consumption

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ARGON GAS

• Produced industrially by the fractional distillation of liquid air

• Mostly used as an inert shielding gas in welding

• In other high-temperature industrial processes where ordinarily non-reactive substances become reactive

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• Used at body R/L robot and MFF robot welding• Used in the fuel tank line as a mixture with carbon

dioxide mixture contains 20% carbon dioxide and 80% Argon gas.

• Both of these gases act as a shielding gas to avoid the oxidation of the welding bead.

• These gases are fed to the faying surfaces using Gas Metal Arc Welding process.

• Use of an inert gas helps to get a better control in welding

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CONSUMPTION PATTERN

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. Cost of air per LTR is Rs. 30.

MODELTOTAL CONS. Of

AIR (LTR)

Ar (M3) 1 LTR = 10-3 M3 COST OF

ARGON/TANK (10-3 *Rs.) 80%

IGNITOR 13.83 0.011 0.332

XPRO 5.06 0.004 0.122

KARIZMA FI 6.60 0.005 0.158

GLAMOUR FI 7.00 0.006 0.168

GLAMOUR FI 13.87 0.011 0.333

KARIZMA 6.49 0.005 0.156

PASSION 9.36 0.007 0.225

CBX 13.47 0.011 0.323

Body R/L robot

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MODELTOTAL CONS. OF AIR USED (LTR)

ARGON (M3) 1 LTR = 10-3 M3 COST OF ARGON/COMP

(10-3 * Rs.)

80%

IGNITOR 13.95 0.011 0.332

XPRO 11.78 0.004 0.122

KARIZMA FI 13.09 0.005 0.158

GLAMOUR 14.39 0.006 0.168

GLAMOUR FI 14.39 0.011 0.333

KARIZMA 13.09 0.005 0.156

PASSION 10.66 0.007 0.225

ACHIEVER 11.20 0.009 0.269

CBX 21.84 0.011 0.323

MFF MIG welding:

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WASTAGE OF ARGON GAS

MATERIAL LARGE BACKUP PADS SIZEOILY PARTS

HUMAN ERROR

IMPROPER PLACEMENT OF MFF

EXCESSIVE FLOW OF GASES

METHOD

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• Excess flow of gases – Regula gas savers should be used properly

• Oily parts – proper cleaning is needed

• Improper placement of the MFF - proper clamping of the MFF & bypass lock should used

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CARBON DIOXIDE

• Most widely used gas in the welding department.

• when consumed, a semi-inert gas that is an acceptable shielding gas for welding steel.

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• 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 one 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.

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CONSUMPTION PATTERN The gas flow meters were attached with each of the welding stations showing the flow rate

for the gas. 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. BODY R/L

MODELTOTAL CONS. OF GAS USED (LTR)

CO2 (KG) 1 LTR = 0.000616 KG COST OF

CO2/COMP (10-3 * Rs.)

20%

IGNITOR 13.95 0.0017 0.0086

XPRO 11.78 0.0015 0.0073

KARIZMA FI 13.09 0.0016 0.0081

GLAMOUR 14.39 0.0018 0.0089

GLAMOUR FI 14.39 0.0018 0.0089

KARIZMA 13.09 0.0016 0.0081

PASSION 10.66 0.0013 0.0066

ACHIEVER 11.20 0.0014 0.0069

CBX 21.84 0.0027 0.0135

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MFF

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

MODEL TOTAL CONS. (LTR)

CO2 (KG)

1 LTR = 0.000616 KG COST OF CO2/TANK (10-3 *Rs.)

20%

IGNITOR 13.83 0.0017 0.0085

XPRO 5.06 0.0006 0.0031

KARIZMA FI 6.60 0.0008 0.0041

GLAMOUR FI 7.00 0.0009 0.0043

GLAMOUR FI 13.87 0.0017 0.0085

KARIZMA 6.49 0.0008 0.0040

PASSION 9.36 0.0012 0.0058

CBX 13.47 0.0017 0.0083

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Frame Body Stations

Frame Body StationsModel Operations Total Cons. (Ltr)

Co2 (Kg) 1 Ltr = 0.000616

Kg

Cost Of Co2/ Comp

(10-3 *Rs)

Glamour

Tacking 1 4.8 0.003 0.0152Tacking 2 3.75 0.003 0.0149Robot 1 8.59 0.005 0.0265Robot 2 7.87 0.005 0.0242

Full Welding 1 7.90 0.005 0.0243Full Welding 2 8.70 0.005 0.0268Full Welding 3 1.48 0.001 0.0045Full Welding 4 2.72 0.002 0.0084

Total Gas Used 0.028 0.1325

Passion

Tacking 1 3.9 0.0024 0.0125Tacking 2 2.52 0.0016 0.0113Robot 1 10.42 0.006 0.0321Robot 2 15.00 0.009 0.0462

Full Welding 1 15.00 0.009 0.0462Full Welding 2 15.00 0.009 0.0462Full Welding 3 3.75 0.002 0.0116

Total Gas Used 0.038 0.1896

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Model OperationsTotal Cons.

(LTR)Co2 (Kg)

1 Ltr = 0.000616 Kg

Cost Of Co2/ Comp

(10-3 *Rs)

Scooter (Manual Line)

Tacking 1 3.02 0.002 0.0093

Tacking 2 3.41 0.002 0.0105

Tacking 1 3.97 0.002 0.0122

Tacking 2 3.97 0.002 0.0122

Tacking 1 3.66 0.002 0.0113

Tacking 2 4.07 0.003 0.0125

Full Welding 1 7.65 0.005 0.0236

Full Welding 2 7.45 0.005 0.0229

Full Welding 3 7.10 0.004 0.0219

Total Gas used 0.027 0.1365

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• Excess flow – fixed flow regulators can be used

• Spattering – proper welding

• Proper current and voltage should used

• Other same as Argon gas

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OXYGEN AND DISSOLVED ACETYLENE

• Used in brazing operations in fuel tank line of the weld shop. • The brazing is done to fit the cock, drain pipe and breather

pipe at the base of the fuel tank. • 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.

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CONSUMPTION PATTERN

It is not possible to estimate the gas flow at a station from there, as 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

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• Excess pressure that produced excess flow

• Excess flow - this increases the gas consumption

• Fix pressure regulator can be used

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PROJECT - 2

“Elimination of Defects in Weld Shop in fuel tank line”

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OBJECTIVE OF THE PROJECT

To eliminate or reduce defects in welding. It was proposed to make line-1 of fuel tank welding a zero defect line .Once this is done, It would be compared with other lines and then the required steps would be taken on the other lines also.

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METHODOLOGY

• To make line -1 a zero defect line, we need to eliminate the defects generated in this line, apart from that we need to reduce the material and time loss in the line.

• First step was to identify the defects generated on the

parts during welding operation and also other operations. Once that was done data was collected for over a period of 7 days in both shifts. Once that was done the data was analysed to find the reasons for the defects and finally necessary proposals were provided.

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LEAK TESTING EXCEL


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LEAK TESTING OBSERVATIONSMODEL Passion X Pro Glamour Achiever Karizma R Ignitor Xtreme

TOTAL INSPECTED 245 150 170 80 80 100 140

R/L DEFECTS 25 16 19 11 4 8 3(%) 10.2040816 10.6666667 11.1764706 13.75 5 8 2.14285714

SEAM DEFECTS 19 11 21 4 5 3 5(%) 7.75510204 7.33333333 12.3529412 5 6.25 3 3.57142857

MFF DEFECTS 12 5 8 2 3 20 9(%) 4.89795918 3.33333333 4.70588235 2.5 3.75 20 6.42857143

CORK DEFECTS 3 0 2 0 0 3 15(%) 1.2244898 0 1.17647059 0 0 3 10.7142857

MASKING DEFECTS 4 2 1 0 0 0 0(%) 1.63265306 1.33333333 0.58823529 0 0 0 0

PIPE DEFECTS 0 2 5 0 5 2 22(%) 0 1.33333333 2.94117647 0 6.25 2 15.7142857

SHROUD DEFECTS 0 0 0 0 1 0 0(%) 0 0 0 0 1.25 0 0

TOTAL DEFECTS 63 36 56 17 18 36 54(%) 25.7142857 24 32.9411765 21.25 22.5 36 38.5714286

NO OF DEFECTED PIECES 55 33 51 17 18 32 48(%) 22.4489796 22 30 21.25 22.5 32 34.2857143

QUALITY (%) 77.5510204 78 70 78.75 77.5 68 65.7142857

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OBSERVATIONS

• Maximum no. of defects are Seam defects, Body R/L defects and MFF defects

• Pareto Principle holds true here. Nearly 80% defects are caused by very few causes.

• Maximum quality is achieved in Achiever, while maximum no. of problems are encountered in CBZ extreme.

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MIG WELDING

MIG BODY R/L WELDING

ROBOT NO. 9300049 ROBOT NO. 9300050 ROBOT NO. 9300051

puncture pinhole Gas prob undercut OK puncture pinhole Gas prob undercut OK puncture pinhole Gas prob undercut OKSHIFT A B A B A B A B A B A B A B A B A B A B A B A B A B A B A BDAY-1 13 13 8 4 0 0 0 0 10 8 25 20 7 3 1 1 0 0 5 3 12 2 0 0 0 0 0 0 14 23DAY-2 10 5 8 1 0 0 0 0 12 19 13 8 9 3 0 0 0 0 13 14 11 3 5 0 0 0 0 0 9 22DAY-3 14 3 0 0 0 0 1 0 10 22 14 10 0 0 0 0 0 0 11 15 0 2 0 0 0 0 0 0 25 23DAY-4 6 16 7 7 0 0 1 0 11 12 13 16 4 6 0 1 0 0 9 11 3 6 1 3 0 0 0 0 21 20DAY-5 9 11 8 2 0 0 1 1 11 11 18 14 4 3 0 1 0 1 7 7 1 5 1 1 0 0 0 0 23 19DAY-6 2 2 0 6 0 0 0 0 23 16 12 10 13 3 0 0 0 0 6 12 2 2 0 4 0 0 0 0 23 19DAY-7 4 0 0 0 21 16 0 0 0 9 1 0 0 0 24

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Robot no. 9300049

0

5

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1 2 3 4 5 6 7

days

quan

tity

punchure

pinholes

undercut

gasproblem

ok

Robot no. 9300049

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1 2 3 4 5 6

days

qu

antit

y

punchure

pinholes

undercut

gasproblem

ok

SHIFT A SHIFT B

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0

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1 2 3 4 5 6 7

quan

tity

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Robot no. 9300050

punchure

pinholes

undercut

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Robot no. 9300051

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This process uses 3 robots. Work involved is both automated and manual. However inspection is done visually. From the data it average ok parts were calculatedRobot no OK parts average

shift A Shift B

9300049 12.42 14.66 149300050 8.57 10.33 99300051 19.85 21 20

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DEFECTS

Puncture: It is caused when the gap between the parts exceeds 0.8mm.thus causing a gap

more than the diameter of the feed wire and these results in the formation of bigger hole due to melting of sheet adjacent to the flame of welding rod.

The gaps can be caused due to• Denting of surface causing deformation of welding profile.• Direct deformation of the welding profile due to mishandle and over stacking of

the parts.• Spatters from the weld in adjacent region results in improper welding.

environment

humanmethod

PUNCTURE

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REMEDIES PROPOSED

• Proper handling of parts. Avoid placing parts on floor.

• Proper cleaning of the parts.• Gap between the parts should be less than 0.8

mm.• Over stacking to be reduced in trolley.

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Pinholes: It is caused when a region remains unwelded or welding is not done in the welding profile.

Reasons:• Unclean surface like presence of oil may cause welding trouble.• Improper feeding of wire.• Dust in feeding tube and wire.• Improper alignment of the parts.• Defect in die.• Programming error• Play in the axis of robot arm

PINHOLES

ENVIRONMENTHUMAN ERROR

EQUIPMENT ERROR METHOD

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REMEDIES PROPOSED

• Proper cleaning of feed rod after ever 50 parts produced.

• Inspection of dies and robotic arms on a regular basis.

• Mishandling of parts to be avoided.• Laser inspection can be installed to check the

alignment of the parts

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• Gas Problem: This is mainly caused due to entrapment of shielding gas in the welding zone.

• Reasons: • Pressure of the argon gas must be optimum or else it results

in defect.• Problems in tube.• Remedies proposed• Worker should be able to check correct pressure of the gas.

Sensor can be installed in the robot for pressure check and warning.

• Proper cleaning should be done.

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Undercut: It is a long cut which occurs rarely and has same reasons as that of puncture. As visible in the data it is scarce so it is clear that it is caused due to human error which may be alignment problem or the reason may be the voltage and current fluctuation.

As far as remedies are concerned human errors are

to be reduced. Although laser inspection will help to even further reduce it.

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MFF MIG WELDING

Robot no 9300084

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Robot no 9300084

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Robot no 9300087

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Robot no 9300087

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Robot no 9300305

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Robot no 9300305

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Robot no OK parts averageshift A Shift B

9300084 24.5 23.2 249300087 24 23.8 249300305 23.14 23.2 23

The defects are minimum because :• welding profile is a circle• there is no movement in the robotic arm during welding• Instead the tank rotates about the axis of the profile circle to be welded

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DEFECTS

• The defects generated in this process is same as that of the MIG body R/L welding like puncture ,gas problem undercut. Since the welding profile is not complex pinholes are not generated.

• The basic cause for the defects are same but the reasons to these defects is slightly different due to change in the procedure of welding. In MFF welding the welding tip remains stationary and the MFF is placed over the r/l body and the body rotates. The parts are held in position by the clamper.

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REMEDIES PROPOSED

• Clamper to be provided.• Welding tip cleaning to prevent gas problem.• Gas flow should be optimum to prevent gas problem.• Buffing (remove coating to ensure welding is properly done) on MFF

component should be done properly.• Gap between Body R/L and MFF should be minimum.• Automatic air supply system after every stroke on hydraulic press to prevent

cut at MFF welding area.• Play in jig rotating bearing.• Play in axis motor to be reduced.• Wire roll should be of good quality.• Worn out brass locators to be replaced and schedule to be made for the

same.• Cleaning of MFF locator after every 50 component.

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LEAKAGE IN WELDING

1 2 3 4 5 6 70

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leakage in fuel tanks

"9300027":

"9300046"

"9300060"

"9300417"

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SHIFT B

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leakage in fuel tanks

"9300027":

"9300046"

"9300060"

"9300417"

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• Leakage is caused due to defect in the welding of the parts. The tank is tested for leakage by filling it with pressurized gas and then placing it in clear water, bubbles indicates the presence of leakage and if the leakage is present it is sent for brazing where it is rectified.

• The method of testing is effective however as the parts are continuously dipped in water the water becomes dirty and inspection becomes tough. So to increase the efficiency of the testing water must be changed on a regular basis.

• The types of leakage that occurs are• Body R/L Leakage• MFF Leakage• Seam Leakage• Spot Leakage• Cock Leakage

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Of the entire leakage problem, Body R/L Leakage occurs in majority. The reason being simple that the majority of the defects are generated in Body R/L Welding. From the data collected it was inferred that almost 10 out of every 20 tanks were having leakage. The data for body R/L Leakage suggests it is a major problem

Mean number of defected parts in A Shift B Shift Mean 7.63 4.79 6 Thus to reduce the leakage problem the defects in the Body

R/L welding are to be reduced

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CONCLUSION

The project on elimination of defects is basically a step to increase the productivity by reducing time and money on rework and rejection. Under this project we have come up with ideas to prevent these defects and if the ideas can be successfully implemented it can result in increase in productivity.

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PROJECT – 3 (Miscellaneous)

“Study of the plant, industry and organization from an Industrial Engineering and Entrepreneurial Perspective”

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Why Hero is no 1?

• First company to make motor cycles popular in India

• Technological advantage because of JV with Honda from Japan

• Great marketing campaigns• Understanding the needs of the customer• Huge product variety and range across all

segments as opposed to competition• Strong dealer network and service network

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VENDOR DEVELOPMENT

• Strong and old supplier base and vendors• Vendors have grown with the company• Huge investments are required• Mostly friends and relatives of the promoters• Difficult to match the economies of scale• Huge penalty if there is a delay• Every vendor is a vendor for a specialised product only• Final price is determined by Hero• Rising inputs and material costs

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THANK YOU

Indsutrial Training in Hero MotoCorp Ltd.

Engineering

Transcript of Indsutrial Training in Hero MotoCorp Ltd.