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PROJECT TRAINING IN HMSI

CO-OP MODEL OF EDUCATION Benefits for Student The Co-op Modal is designed in a way that it not only increases likelihood of employability, but also provides opportunity to students to get to know the atmosphere of industry.

Benefits for IndustryAny industry wants student, who is ready to industry, will be beneficial.

Benefits for Institute The institute will, In the long-term, be able to upgrade its content, teaching methodologies and research capabilities.

ABOUT TRAINING PROGRAM- CO-OP MODEL As Student Sagar Soni 7th Sem B.Tech (Mechanical) Faculty of Engineering Dayalbagh Educational Institute, Agra

Sagar Soni Crank Shaft & Crank Case Line,KWPG Machine Shop Step-1 Honda Motorcycles And Scooter India Limited, Tapukara(2F)

As Summer TraineePROFILE

PLANTAT A GLANCEMachine Shop layout Crank Step-1

Crank Case Step-1Allotted LinePARTS OF MACHINING STEP-1

Crank Shaft Step-1Line layout Process Layout PRODUCTION POWER TRAIN PRODUCES HEART (ENGINE) FOR OUR PRODUCTS. PRODUCTION HAS TWO RULE INCREASING PRODUCTION

DECREASING REJECTION

Rejection Analysis andMaintenance of preventive gauges

PROJECT ALLOTTED WORK IN ACTIONSAPRILMAYJUNEJULYAUGUSTStudy The Various Processes in Machine Shop in every Line Study The Various Parameters in Both LinesIdentify Machines Preventive gauges And Check PointsIdentify Line Rejections, Problems and Counter MeasuresThinking about Ideas which can Help to Reduce RejectionsSuggestions to Line Ex Make Presentation PlannedactualWORK PLANNINGCrank Shaft

Crank Case AffectsThread Bolt will not tight Key WayKey may not fit Grinding Dia Bearing will not fitFine Boring Dia Pin will not properly fitCrank Width Cause rubbing in bearingsTaper Height Compression & Tension forces in crankAxial GapConnecting Rod movementTsp angleOpening of valvesRun OutVoveling in crank AffectsDent on Milled SurfaceCan cause a LeakageMilling Height Vary Engine Volume Oil Hole Dia, DepthEngine Siege Tapping Bolt will not fitOil Pump DiaCause LeakageFine Boring Dia & DepthCause improper Bearing fitDowel Hole Dia, DepthBoth Cases will not joinedHole For StudsCylinder Block will not FitPARAMETERS AND THEIR AFFECTS

O1 DIAO1 DIADefectsReasonsDia OvalityBearing would not fit properly and may slip from its position .Variation In DepthCrank Shaft will not be vertical then that causes Voveling motion of Crank Shaft

If Tapping on milled Surface will center-out May Create misalignment Of Crank ShaftPARAMETERS RESPONSIBLE FOR ENGINE NOISE Upper Control Limit Lower Control Limit Upper Control Limit Lower Control Limit Reason of this type of continuous variation in Dia and Depth of O1, was Cartridge of Fine Boring tool worn out.

After pin Pressing crank interacts with various m/cAssembled

Crank WidthAxial GapRun OutDefectsAffectsCrank WidthNG Bearings will create Compression and Tension forces in Crank.Axial Gap NGConnecting Rod will move tightly or sometimes freely.

Run outCause Voveling motion in crank shaft, create vibrations.KEY PARAMETERS RESPONSIBLE FOR ENGINE NOISEUpper Control Limit Lower Control Limit NORMAL TREND OF RUN OUT JUST AFTER PIN PRESSUpper Control Limit Lower Control Limit

It may be possible that parameters are changing at every machine after pin press.BRAINSTORMINGWith the help of sampling it can be proved.SAMPLING REPORT TO CHECK WHETHER SPEC IS CHANGING AFTER PIN PRESS AFTER PIN PRESS IN CRANK SHAFT AFTER FINAL CHECKING RUNOUTCRANK WIDTHAXIAL GAPRUN OUTCRANK WIDTHAXIAL GAP(L SIDE R SIDEL SIDE-R SIDE2020-400.23525-200.258-200.21525-200.22010-300.22030-400.22015-100.21520-100.22510-200.21530-200.21020-200.254015-500.22510-300.21515-400.2201000.23030-100.253020-200.24030-200.252510-200.2205-100.25Sampling, to know parameter is changing or notMost of the changes comes in run out l-side may be because of larger in length.

Every time Crank width reduces to some extent but some times it reaches to its lower limit.

Axial gap does not changes to large extent, although it has high tolerance limit.CONCLUSIONS

Which machine is responsible for this Whether it varies parameters out of its tolerance limit BRAINSTORMING

Sampling after every machine would show all variation in parametersSAMPLING AFTER EVERY MACHINEAfter pin Pressing parameters changes abruptly .

After bearing pressing, run out changes .

It clearly shows, after making inventory, there are chances to vary parameters depend on material handling

CONCLUSIONSMAINTENANCE OF PREVENTIVE GAUGES Main CategoriesSOME OBSERVATIONS EquipmentsNormal ReadingSystem Pressure 50-100 kg/cm2 Hydraulic Pressure 2-5 MPaHydraulic LevelBetween H and L limitCoolant Concentration Mostly Between 3- 6

Machine Parameters ReadingsSpline & Thread Rolling Lub. Oil Gauge Pressure Tail Center Pressure 1-2 MPa0.2 MPaMTE Thread Rolling System Pressure 40-120 Kg/Cm2 WashingAir Pressure gauge 4-7 Kg/Cm2 Pin PressingSystem Pressure 7.5-8.5 Kg/Cm2

Caulking Plate PressSystem Pressure 30-50 Kg/Cm2BFW Drilling System PressureAir PressureLub. Oil Pressure35-45 Kg/Cm24-7 Bar0-15 Kg/Cm2Shigiya grinding Machine Air Pressure Lub. Oil Pressure 0.35-0.6 MPa1.5-1.7 MPa

Fine Boring Hydraulic Pressure Lub. Oil Pressure Air Pressure 3-5 MPa1.5-1.7 MPa3-4 Bar

CORRECTION IN TPM SHEETS

Crank Shaft Dismantling when rejected from Engine Assembly or Vehicle Quality.

Process takes 4-5 Min to Dismantle ANOTHER PROBLEM OBSERVED

CONTINUED

Apparatus that can easily pull all the Bearings SOLUTION FOR ITBEARING PULLAR BUT ON DISMANTLING, CAULKING PLATE ALWAYS GET DESTROYED

Any common Apparatus that can pull Bearings and Caulking Plate both CONTINUEDOne of the major rejection comes from pin pressing machine and it also controls further parametersSOME MAJOR DEFECTS IN CRANK SHAFT LINE Crank pinCon. Rod Grade Con. Rod Bearing()Clearance()0~120~80~120~120~80~120~120~12

CONNECTING ROD ASSEMBLING PATTERN

Efficiency of Activa Based on Certain AssumptionsVolume of combustion chamber(clearance volume)=10 cc (decided by company)Bore diameter=5 cmPosition of TDC from upper point of cylinder block=0.393 cmPosition of BDC from upper point of cylinder block= 5.588 cmVolume above TDC= 3.14x2.5x2.5x0.393=7.7 ccVolume above BDC=3.14x2.5x2.5x5.588=109.5 ccCompression Ratio =(10+7.7+109.6)/(10+7.7)=7.16Efficiency = (where n can be taken as 1.44) =57.9%

TDCBDCUpper pointEFFICIENCY OF ACTIVA ON ANALYSIS BASISVARIOUS TYPES OF ENGINE NOISES Brief idea about following topics learned in Maintenance Internal Training Variable Frequency Drives Mechanical Drawings Pumps and Hydraulic Systems Safety Training CNC Equipments

CO-CURRICULAR LEARNING IN HMSI Basic Knowledge of G and M Coding, Catia 3D and prepare G codes using Catia.Some operations in CNC interfacing Using FANUC control panel like Tool Change, Offsetting, G Code Editing, Single Block Mode MDI Mode, Manual Mode. CONTINUED Production Log BookMSQCD BoardKAIZENSAFETY FIRST, THEN PRODUCTION5S Technique7 QC ToolsTPM Inspection SheetNew Honda CircleThree joys Buying, Creating and SellingRespect for Individual Initiative, Equality and Trust

VARIOUS VALUABLE WORD IN HMSI

STUDENTPROFESSIONALTHANK YOU TO BRING CHANGES INSIDE ME