1.1: Overview of Automobile Industry in India: Chapter 1: Industrial Profile

Chapter 1: Industrial Profile 1.
1: Overview of automobile industry in India

Starting its journey from the day when the first car rolled on the streets of Mumbai in 1898, the Indian automobile industry has demonstrated a phenomenal growth to this day. Today, the Indian automobile industry presents a galaxy of varieties and models meeting all possible expectations and globally established industry standards. During the early stages of its development, Indian automobile industry heavily depended on foreign technologies. However, over the years, the manufacturers in India have started using their own technology evolved in the native soil. The thriving market place in the country has attracted a number of automobile manufacturers including some of the reputed global leaders to set their foot in the soil looking forward to enhance their profile and prospects to new heights. The automobile sector of India is the seventh largest in the world. In a year, the country manufactures about 2.6 million cars making up an identifiable chunk in the worlds annual production of about 73 million cars in a year. The country is the largest manufacturer of motorcycles and the fifth largest producer of commercial vehicles. Industry experts have visualized an unbelievably huge increase in these figures over the immediate future. The figures published by the Asia Economic Institute indicate that the Indian automobile sector is set to emerge as the global leader by 2012. In the year 2009, India rose to be the fourth largest exporter of automobiles following Japan, South Korea and Thailand. Experts state that in the year 2050, India will top the car volumes of all the nations of the world with about 611 million cars running on its roads. Recently, the automotive giants of India including General Motors (GM), Volkswagen, Honda, and Hyundai, have declared significant expansion plans. On account of its huge market potential, a very low base of car ownership in the country estimated at about 25 per 1,000 people, and a rapidly surging economy, the nation is firmly set on its way to become an outsourcing platform for a number of global auto companies. Some of the upcoming cars in the India soil comprise Maruti A-Star (Suzuki), Maruti Splash (Suzuki), VW Up and VW Polo (Volkswagen), Bajaj small car (Bajai Auto), Jazz & Brio (Honda) and Cobalt, Aveo (GM) in addition to several others.
HONDA SIEL CARS INDIA LTD.
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1.2: Evolution of automobile industry Protectionism- Early 1980s

This was the pre-1980 era where the manufacturing of automobiles especially cars was subject to strict licensing, restrictive tariff structure and limited avenues for expansion. The advent of foreign technology collaboration came with the inception of Maruti Udyog in collaboration with Suzuki of Japan in the passenger car segment. Indian roads saw the launch of Maruti 800. It was still not very easy to own a car, first was affordability and next was a long waiting period.
Liberalization- 1990s
In the early 1990s, with liberalization, some more Japanese manufacturers entered the two-wheeler and the commercial vehicle segment in a collaborative arrangement. These period characterized joint ventures in India and the market started opening up. Automobile Industry was deli censed in July 1991 with the announcement of the New Industrial Policy. The passenger car industry was, however, deli censed in 1993. The abolition of the controls led to an avalanche of demand. The era of controls and protection came to an end. Curbs on capacity were done away with, decrease in customs and excise duties meant that a vehicles started getting affordable. The entry of foreign banks with attractive auto finance schemes helped garner a huge base of middle class population. However the market was still ruled by the sellers.
Globalization- 2000s
Early 2000 however saw globalization of Indian auto industry. Several policy changes were introduced with focus on boosting the auto exports. A Core Group on Automotive Research and Development (CAR) was established in 2003 for encouraging R&D activities. Foreign manufactures started looking at India for sourcing auto components. The buyers started ruling the market due to the availability of choices in the form of models, price points and brands. A vibrant economy meant an increase in the GDP and per capita income. These factors turned out to be significant contributors in pushing up the domestic demand.
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Growth trajectory: Trend of Indian Automobile Industry
This graph shows the vehicle sales in India since 1980. The sharp increase between 2001 and 2006 is the result of government initiatives, growing economy and disbursement of loans for purchase of vehicles. It is estimated that India will see over Rs 30,000 crore being invested by 2010. This is because Indian auto industry is racing ahead with a healthy growth. The graphic below shows the growth trend in the production of automobiles in million units.
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Domination of passenger Cars: Trend in Graphical form
Indian Passenger Vehicle Market trend- Competitive Scenario
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1.3: Segment wise share in the Automobile industry
Domestic Market Share for 2010-11 Passenger Vehicles Commercial Vehicles Three Wheelers Two Wheelers 16.25 4.36 3.39 76.00
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1.4: Contribution of automobile industry to the economy

The auto industry is a major contributor towards the economy of all the major manufacturing countries worldwide. It not only provides countless job opportunities but also has the economic impact. The global automotive industry is highly diverse and comprises of various product segments like engine parts, drive transmission and steering parts, suspension & braking parts, electrical parts and other auto components. Autos industry covers a vast array of vehicles like luxury cars, passenger cars, specialist vehicles, motorcycles, scooters, mopeds, and offroad vehicles manufacturers & dealers of automobile components and accessories, car-care products, environment and safety equipment, garage and service equipment, moulds and dyes, oils & lubricants, petrol vending machines, tires, batteries and auto electrical, upholsteries and much more. The automobile has enabled people to travel and transport goods farther and faster and has opened wider market areas for business and commerce. The auto industry has also reduced the overall cost of transportation by utilizing methods such as making several products at once, rather than one at a time, selling products nationally rather than locally and globalization of production. In the early days of its inception, this invention had to face many problems. There was no real established industry and the manufacturing processes involved were slow. With the automakers and auto buyers' base expanding globally, auto making became the world's largest manufacturing activity. Now this industry is making approximately 58 million new vehicles each year all across the globe. The diverse mobility offered by the automotive industry allowed remote populations to interact with one another, which increased commerce. The transportation of goods to consumers and consumers to goods has become an industry in itself. The automobile however has also brought related problems, such as air pollution, the emission of greenhouse gases that contribute to global warming, congested traffic, and highway fatalities. Nevertheless, the automobile industry continues to be an important source of employment and transportation for millions of people worldwide. The automobile industry directly influences the economies of the United States and other countries around the world. In a typical year, the U.S. automobile industry generates between 12 and 14 percent of manufacturers' shipments of durable goods. The automobile production consumes large amounts of iron, steel, aluminum, and natural rubber. An interesting fact is that it also consumes more copper, glass, zinc, and leather, plastic, lead, and platinum than any other U.S. industry.
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1.5: Growth of automobile industry Automobile domestic sales trends (no. of vehicles)
Category
2004-05
2005-06
2006-07
2007-08
2008-09
2009-10
2010-11
Passenger Vehicles
1,061,572
1,143,076
1,379,979
1,549,882
1,552,703
1,951,333
2,520,421
Commercial Vehicles
318,430
351,041
467,765
490,494
384,194
532,721
676,408
Three Wheelers
307,862
359,920
403,910
364,781
349,727
440,392
526,022
Two Wheelers
6,209,765
7,052,391
7,872,334
7,249,278
7,437,619
9,370,951
11,790,305
Grand Total
7,897,629
8,906,428
10,123,988
9,654,435
9,724,243
12,295,397
15,513,156
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Automobile production trends
(no. of vehicles)
Category
2004-05
2005-06
2006-07
2007-08
2008-09
2009-10
2010-11
Passenger Vehicles
1,209,876
1,309,300
1,545,223
1,777,583
1,838,593
2,357,411
2,987,296
Commercial Vehicles
353,703
391,083
519,982
549,006
416,870
567,556
752,735
Three Wheelers
374,445
434,423
556,126
500,660
497,020
619,194
799,553
Two Wheelers
6,529,829
7,608,697
8,466,666
8,026,681
8,419,792
10,512,903
13,376,451
Grand Total
8,467,853
9,743,503
11,087,997
10,853,930
11,172,275
14,057,064
17,916,035
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Chapter 2: Company profile 2.1: About the company Japan plays a key role as the center of Global Honda, honing the edge in advanced technology. Hondas international plants lead the way in accelerating localization and expanding production. Honda further expands motorcycle production while strengthening auto production capacity. Hondas diesel car lineup expands as Europe shows support for Honda brands. Significant growth in Asian markets leads to localizing R&D and expanding productive capacity. Business steadily expands throughout the area, becoming more flexible to meet diversifying needs. Honda Siel Cars India Ltd., (HSCI) was incorporated in December 1995 as a joint venture between Honda Motor Co. Ltd., Japan and Siel Limited, a Siddharth Shriram Group company, with a commitment to providing Hondas latest passenger car models and technologies, to the Indian customers. The total investment made by the company in India till date is Rs 1620 cr in Greater Noida plant and Rs 784 cr in Tapukara plant. HSCIs first state-of-the-art manufacturing unit was set up at Greater Noida, U.P in 1997. The green-field project is spread across 150 acres of land (over 6, 00,000 sq. m.). The annual capacity of this facility is 100,000 units. The companys second manufacturing facility is in Tapukara, Rajasthan. This facility is spread over 600 acres and will have an initial production capacity of 60,000 units per annum, with an investment of about Rs 1,000 cr. The first phase of this facility was inaugurated in September 2008.
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2.2: Product lines of Honda Siel Cars India Ltd.

The companys product range includes Honda Jazz, Honda City, Honda Civic and Honda Accord which are produced at the Greater Noida facility with an indigenization level of 77%, 76%, 74% and 28% respectively. The CR-V is imported from Japan as Completely Built Units. Hondas models are strongly associated with advanced design and technology, apart from its established qualities of durability, reliability and fuel-efficiency. HONDA JAZZ Honda Jazz is the companys first offering in the premium compact car segment. The Jazz is a segment-defining car that has won accolades and adoration all over the world. Widely acclaimed for its dynamic styling, spacious interiors, versatile utility and remarkable performance. HONDA CITY Honda's all-new Third Generation Honda City was launched in September 2008. It comes with a completely new design, new engine, spacious cabin and equipped with various active and passive safety features. The company has also launched the 1.5 V MT & AT version of the City in September 2009. The new Honda City is available as SMT, VMT and VAT. Additionally, all the variants are available in 2 attractive types Elegance and Inspire. HONDA CIVIC The new Civic was launched in September 2009 with more aggressive and sportier look. The new V grade Civic juxtaposes Hondas advanced technology with striking design. The new Curved 5 Point Metallic Front Grille and restyled Front Sporty Bumper add to a pulsating and aggressive appeal of the car. The introduction of stylized Dark Smokey Headlights & Crystalline Octagonal Tail Lights enhances the contemporary look of the car. New Civic is available in 3 variants SMT, VMT & VAT. HONDA ACCORD The Honda Accord was first introduced in India in year 2003. HSCI launched the 8th generation Honda Accord in India in May 2008. The Honda Accord is available in 2.4L and 3.5L V6 engine. HONDA CR-V The all new 3rd generation CR-V was introduced in India in November 2006 which offered its customers a distinctive combination of the comfort o f a sedan with the thrills of a SUV. The Honda CR-V is sold as a Completely Built Unit (CBU) import and is available on confirmed order basis for the customers. The Honda CR-V was first introduced in India in July 2003.
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2.3: Environment Policy Protection of environment is important to Honda Siel Cars India Ltd. Hondas Environmental Policy serves as an important guide for the way they do the business. Encouraging all Associates, as members of both Honda and society, to focus on the importance of preserving human health and the environment, and to do their part to help the Honda fulfill its responsibilities. Having management members demonstrate that environmental protection is a high priority by setting goals and establishing procedures which are protective of people, property and the environment and by auditing all operations to ensure compliance. Providing training for all Associates in order to familiarize them with Honda's Environmental Policy and help them recognize how their job function may impact the environment. Conserving energy and reducing, reusing and recycling materials and natural resources. Implementing new materials, methods and equipment that will minimize process emissions. Striving to achieve, by means of continual improvement, environmental levels of performance governed not only by legislated requirements, but also taking into account the expectations of our community and customers. Working cooperatively with governments and non-government organizations, in developing effective standards, regulations and programs concerning the environment. Encouraging suppliers to protect and preserve the environment.
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Chapter 3: Vision & Mission- Honda Siel Cars India Ltd. Vision Developing a philosophy built on the experience of a practical engineer, Soichiro Honda created a corporate culture that would go on working towards his objective - nothing less than becoming and remaining the world's best motor manufacturer - long after his own active day. The corporate vision statement is like the founder himself, really it is enormously practical & so pragmatic to achieveQuality in all jobs - learn, think, analyze, evaluate and improve, Reliable products - on time, with excellence and consistency, & Better communication - listen, ask and speak up Mission Statement Maintaining a global viewpoint, Honda is dedicated to supply products of the highest quality, yet at a reasonable price for worldwide customer satisfaction. Honda's mission is to Proceed always with ambition and youthfulness Respect sound theory, develop fresh ideas, and make the most effective use of time Enjoy work and encourage open communication Strive constantly for a harmonious flow of work Be ever mindful of the value of research and endeavor
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5S & 3G Principle Being a Japanese concern, HSCI is the avid follower of 5S & 3G principle to achieve the highest quality, reliability & durability. 5S & 3G principle is elucidated further onwards5S Principle: 5S management is defined as an improvement process originated by the Japanese to create a workplace that supports company-wide integration of workplace organization, standardization, visual control, visual display & visual metrics. 5S principle in pictorial form
The techniques for 5S were originally applied to production operations and have recently been extended to safety and office activities. 5S visual management is a key foundation principle for creating the lean enterprise because the concepts of organization and orderliness are focused on achieving cost reductions, waste elimination, zero defects, safety improvements, and accident reductions.
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Literal meaning: 5S Seiri (sort) means to separate needed tools, parts, and instructions from the unneeded. The goal is to keep only what is required and eliminate everything else. Seiton (set in order) means to neatly arrange and identify parts, processes, and tools for ease of use. Seiso (shine) means to clean, shine, and inspect the workplace by eliminating contamination. Seiketsu (standardize) means to require as the norm sort, set in order, and shine activities daily to keep the workplace in perfect condition and also to make use of visual control systems to maintain compliance with the established standards. Shitsuke (sustain) means to maintain the 5S gains by training and encouraging workers to form the habit of always following the first four S's.
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Literal meaning: 3G 3G refers to three Japanese words which guide to decision making. Gemba (real place) Gembutsu (real thing) Genjitsu (real data)
This is the Japanese mindset teaching that when there is a problem somewhere, one should get as close to it as possible before proposing a solution. By observing the actual process at the actual place, the problem solver is able to obtain actual data. This effort will allow for a decision to be based on facts, instead of relying on second hand information collected by others. The 3 real are a fundamental element of kaizen. Eventually it can be stated through 3G to take oneself to the deliberate practice where product is made or where value is otherwise created or service is rendered. For professionals who have risen to their station through hard work, luck, education or some combination thereof, is a career achievement. Yet lean management gently boots these successful professionals back to the real place to find the only reality.
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Chapter 4: HONDA & Technology

Honda has always believed in giving more excitement and more joy. Be it designing high performance sports cars that are a pleasure to behold and a joy to drive or creating the world's first humanoid robot to walk on two legs or countless other technologies that astonish and delight Honda's spirit of exploration frequently invents the future. Not surprisingly, millions of people worldwide often respond to Honda's spirit of innovation with a sense of delight and amazement. Honda's obsession for technology that continuously improves upon the performance and safety of all Honda vehicles is what sets it apart from other names in the car industry.
4.1: ASIMO
Honda engineers created ASIMO with 34 Degrees of Freedom that help it walk and perform tasks much like a human. One Degree of Freedom is the ability to move right and left or up and down. These degrees of freedom act much like human joints for optimum movement and flexibility. Lightweight materials, like a magnesium alloy structure, combined with powerful computers and 34 servo motors throughout its body help ASIMO move smoothly with ease.
4.2: FCX
The FCX Clarity, a sleekly-styled hydrogen fuel cell-powered sedan, is at the forefront of Honda's efforts to successfully develop, certify and distribute zero emissions hydrogen fuel cell vehicles. Propelled by an electric motor that runs on electricity generated in a fuel cell, the vehicle's only emission is water, and its fuel efficiency is three times that of a modern gasoline-powered automobile and two times that of a gasoline-powered hybrid vehicle.
4.3 JET
Honda Jet is an advanced light jet with revolutionary technology and design attributes that help it achieve far better fuel efficiency, more available cabin and luggage space, and higher cruise speed than conventional aircraft in its class. A patented over-the-wing engine-mount (OTWEM) configuration eliminates the carry-through structure of conventional fuselage-mount designs, allowing for greater use of fuselage space for the cabin and cargo areas.
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Chapter 5: Process flow chart associated with Press Parts
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Chapter 6: Problem Statement Press parts & Power transmission parts produced in the TKR Plant, Rajasthan are finally dispatched to the GNU plant for final assembly. In between KALINGA associates & HELI associates play a major role along with Parts & Logistics Control (PLC) team while packing the parts in to transportation trolley. With respect to this process associated with PLC team, my project concentrate on the transportation trolleys in which press parts are packed with utmost prudence & I am supposed to prepare the Operation Processing Standard for the transportation trolleys used for three particular model HONDA CITY, JAZZ & BRIO. In my project, I am supposed to find out every shortcomings & loopholes in each of the transportation trolley used for the mentioned HONDA model in three stages. For the loopholes existing in the trolley, there may be scratches, flange bend, dents in the press parts after getting packed in to the trolley during transportation. With respect to the above stated intricacies, my project gives its attention to locate the checking items in each of the transportation trolley in three stages with the sole purpose to avoid any damages in the press parts during transportation. The three stages in which the observation has been followed are stated onwards Observing the trolley in dismantled condition without having any press parts in it Observing the trolley in assembled condition while parts of the trolleys are attached to it Observing the trolley while the press parts are loaded into it for the dispatch
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Chapter 7: Parts & Logistics Control (PLC) Initiative 7.1: Team Involved Parts & Logistics control (PLC) team use to deliver the right quantity, right quality of material on the line at right time & right place every time to meet the required target production while keeping the book value & physical quantity as same. The PLC Department of the company is the backbone of the company as it is responsible for supplying all the necessary material for production. Major Operations of PLC are the following Receiving Storage & Packing (for press parts) Transportation In PLC Department some private companies which works, following are-
HELI Honda Express Logistics India Ltd. is a private company which works for the logistics solution of the company
Watarana Watarana provides Forklifts to the company
Kalinga Kalinga provides workers to the company
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PLC Responsibilities In a pictorial form:
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7.2: Methodology The methodology followed to prepare the operation processing standard of the transportation trolleys for press parts are completely on the basis of observation method. Observing each and every transportation trolleys used for three HONDA models CITY, JAZZ & upcoming model BRIO in three stages, loopholes & shortcomings are put to forth. With respect to that recommendations have been made & checking items in three stages have been established. The basic objective of the OPS is to ensure the ideal & accurate delivery of the produced parts to GNU plant without having any damages in the parts, while following the entire check items for each part & sub-parts for each transportation trolleys used for press parts dispatch. 7.3: Press Parts Identification Different code name used for transportation trolleys for different model (HONDA CITY, JAZZ, BRIO) for the dispatch of press parts.
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Press Parts Nomenclature:
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Terminology of Press Parts:
HONDA CITY (2PY) 1) HOOD SKIN 2) TRUNK LID SKIN 3) FR. DOOR SKIN (R) 4) FR. DOOR SKIN (L) 5) RR. DOOR SKIN (R) 6) RR. DOOR SKIN (L) 7) FR.FENDER (R) 8) FR.FENDER (L) 9) ROOF PANEL 10) SPO (RH) 11) SPO (LH) 12) FRONT FLOOR 13) REAR FLOOR 14) TRUNK LID FRAME 15) HOOD FRAME 16) FR. DOOR PANEL(R)
HONDA BRIO (2CV) 1) HOOD SKIN 2) SPOILER 3) FR. DOOR SKIN (R) 4) FR. DOOR SKIN (L) 5) RR. DOOR SKIN (R) 6) RR. DOOR SKIN (L) 7) FR.FENDER (R) 8) FR.FENDER (L) 9) ROOF PANEL 10) SPO (RH) 11) SPO (LH) 12) FRONT FLOOR 13) REAR FLOOR 14) SPOILER FRAME 15) HOOD FRAME 16) FR. DOOR PANEL(R) 17) FR. DOOR PANEL(L) 17) FR. DOOR PANEL(L) 17) FR. DOOR PANEL(L) 18) RR. DOOR PANEL(R) 18) RR. DOOR PANEL(R) 18) RR. DOOR PANEL(R) 19) RR. DOOR PANEL(L) 19) RR. DOOR PANEL(L) 19) RR. DOOR PANEL(L) 20) PANEL RR. INSIDE(RH) 20) PANEL RR. 20) PANEL RR. INSIDE(RH) INSIDE(RH) 21) PANEL RR. INSIDE(LH) 21) PANEL RR. INSIDE(LH) 21) PANEL RR. INSIDE(LH)
HONDA JAZZ (2AZ) 1) HOOD SKIN 2) TAIL GATE SKIN 3) FR. DOOR SKIN (R) 4) FR. DOOR SKIN (L) 5) RR. DOOR SKIN (R) 6) RR. DOOR SKIN (L) 7) FR.FENDER (R) 8) FR.FENDER (L) 9) ROOF PANEL 10) SPO (RH) 11) SPO (LH) 12) FRONT FLOOR 13) REAR FLOOR 14) TAIL GATE FRAME 15) HOOD FRAME 16) FR. DOOR PANEL(R)
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Chapter 8: Research Methodology 8.1: Trolley Introduction What is trolley? Trolleys is wheeled carriage which we use to push according our own requirement Trolleys is used to carry goods In HSCI TKR plant, trolleys are mainly used for loading parts & to dispatch them to GNU The main purpose of the trolley is to deliver maximum parts to GNU plant without having any damages & scratches in the parts Classification of trolleys:
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Brief description:
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Pictorial form of the trolleys used in HSCI, TKR plant:
Among all these trolleys shown in the pictorial form, this project is concerned on the transportation trolleys which are categorized into 2PY, 2AZ & 2CV trolleys.
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Specialty of transportation trolleys:

Each & every trolley has its specific design Every trolley is designed according to the parts dispatched Every trolley has a feature to rest, locate & guide the part to be carried To absorb shocks during transportation, appropriate absorbers are provided in each trolley To enhance the life of the trolley, routine repair & maintenance activities are followed for each trolley To avoid part damages and scratches few special materials like style foam, EVA sheet, PU sheet, PVC pipe are used While loading & unloading of parts, safety norms are strictly considered to avoid any damages of parts & the operator Proper identification to each trolley has been assigned to avoid any confusion on the production line. These identification includes part name, part no, production date, packing date, packing person filled completely in the tag To avoid jerks during transportation shock absorbing wheel are used in the trolley which is known as caster wheel. These wheel are of two typea) Fixed wheel b) Movable wheel For toeing so many trolleys together, toeing bar with toeing hook is provided in each of the trolley In every trolley, there are inner & outer frame but part resting area is always kept free of paint Proper color coating has been done with respect to different model
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Categorization of transportation trolley: For 21 press parts in each model (2PY, 2AZ & 2CV), under mentioned trolleys are used & can be categorized like the following:
Unique/ Different trolleys: FR. FENDER PANEL (R & L) ( ROOF PANEL SPO (R & L) RR. INSIDE PANEL (R & L) FRONT FLOOR REAR FLOOR TRUNK LID SKIN TRUNK LID FRAME Common trolleys: HOOD SKIN HOOD FRAME FR. DOOR SKIN (R & L) RR. DOOR SKIN (R & L) FR. DOOR PANEL (R & L) RR. DOOR PANEL (R & L)
For the overall study of the transportation trolleys used for each model following considerations are to be taken: 2PY trolleys denotes - trolleys for HONDA CITY 2AZ trolleys denotes - trolleys for HONDA JAZZ 2CV trolleys denotes - trolleys for HONDA BRIO For 2AZ- Trunk lid skin is known as Tail gate skin & Trunk lid frame is known as Tail gate frame
For 2CV- Trunk lid skin is known as Spoiler & Trunk lid frame is known as Spoiler frame For 2PY & 2AZ- Front floor trolleys seems to be completely similar
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Identification of Common Trolley: In common trolleys blue, yellow & red colors are used for 2PY, 2AZ & 2CV models respectively Apart from following the tag, we can distinguish the trolleys with respect to its color whether a trolley is packed for 2PY or 2AZ or 2CV Only interchanging the position of parts in the inner frame of a single trolley, it is used for 2PY, 2AZ & 2CV With respect to dimensions, parts & sub-parts, in every context its absolutely similar in common trolleys for 2PY, 2AZ & 2CV Common trolleys are the trolleys in which press parts of three model can be packed in a single trolley & unique trolleys are the trolleys, in which press parts of a single model is packed The above information is supported by the following picture Pictorial form:
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How location wise 2PY, 2AZ & 2CV trolleys can be distinguished, are presented in the pictorial form. For example, Fr. DOOR SKIN trolley has been considered. Likewise in other common trolleys, identification can be possible in the same way.
Pictorial representation for each model : 2PY Common Trolley Identification
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2AZ Common Trolley Identification
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2CV Common Trolley Identification
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Model wise Trolley Identification In PLC Department:

Proper color coating has been done in each trolley used in PLC area with respect to different models.
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8.2: Transportation Trolley Nomenclature 2PY Transportation trolleys: SPO (L & R):
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FR.DOOR SKIN (L & R)
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HOOD SKIN
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FR. FENDER (L& R)
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HOOD FRAME
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FRONT FLOOR
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ROOF PANEL
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TRUNK LID FRAME
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REAR FLOOR
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TRUNK LID FRAME
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PANEL, RR.INSIDE (L & R)
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RR.DOOR PANEL (L & R)
[NOTE: With respect to parts, sub-parts & dimension following pair of trolleys are samea) FR. Door Skin (L & R) and RR. Door Skin (L & R); b) FR. Door Panel (L & R) and RR. Door Panel (L & R). For the same reason, in each pair, only one trolley details have been furnished]
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2AZ Transportation trolleys: NOTE: 2AZ Common Trolleys are completely similar as that of 2PY For the same reason, details of 2AZ common trolleys already have been covered in 2PY Further, details of 2AZ Unique trolleys are being covered For 2AZ, Fr. Fender is not dispatched from TKR plant due to its direct import facility 2AZ Common Trolleys are FRONT FLOOR HOOD SKIN HOOD FRAME FRONT DOOR SKIN(LEFT & RIGHT) REAR DOOR SKIN(LEFT & RIGHT) FRONT DOOR PANEL(LEFT & RIGHT) REAR DOOR PANEL(LEFT & RIGHT)
2AZ Unique Trolleys are named & described onwards FR. FENDER (L & R) ROOF PANEL SPO (LH & RH) PANEL, RR.INSIDE(L & R) REAR FLOOR TAILE GATE SKIN TAIL GATE FRAME
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ROOF PANEL
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SIDE PANEL OUTSIDE (L & R)
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PANEL, RR. INSIDE (L& R)
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TAIL GATE FRAME
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TAIL GATE SKIN
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REAR FLOOR
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2CV Transportation trolleys: Likewise 2AZ Common trolleys, details of 2CV common trolleys already have been covered. Further 2CV Common trolleys are named and unique trolleys are described onwards. 2CV Common trolleys are HOOD SKIN HOOD FRAME FRONT DOOR SKIN(LEFT & RIGHT) REAR DOOR SKIN(LEFT & RIGHT) FRONT DOOR PANEL(LEFT & RIGHT) REAR DOOR PANEL(LEFT & RIGHT)
2CV Unique trolleys are ROOF PANEL SIDE PANEL OUTSIDE(LEFT & RIGHT) REAR INSIDE(LEFT & RIGHT) SPOILER & SPOILER FRAME FR. FENDER (LEFT & RIGHT) REAR FLOOR FRONT FLOOR
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ROOF PANEL
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SIDE PANEL OUTSIDE (L & R)
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PANEL, RR. INSIDE (L& R)
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REAR FLOOR
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FRONT FLOOR
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SPOILER & SPOILER FRAME
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8.3: Checking items in transportation trolleys in two stages For 2PY, 2AZ & 2CV Transportation trolleys: Stage- I: Observing the trolleys in dismantled condition while the parts of the trolley are not attached to it There must not be any welding defects in any of the welded joints present in the trolley There should not be any bending over any of the MS Bar, MS Pipe, bracket used in each trolley Presence of any sharp edges or corners in the trolley will lead to damages on the parts, hence it must be avoided Presence of PVC pipe, EVA sheet, PU sheet, Absorbers, Style foam, cable tie, superlon tube is must in the trolley, wherever its necessary. These items are to be used to avoid the direct contact of the packed parts from metal body in the trolley. PVC pipe, EVA sheet, PU sheet, Absorbers, Style foam should not be in ragged condition while covering any part of the trolley. If any partition or separating or supporting bracket is used in the trolley, then it must be ensured that the bracket is equally spaced in a proper way. For example, in Fr. Fender (L & R) trolley, in part resting frame the grove gap is checked with a jig with a standard of 30-35 mm gap.
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Stage- II: Observing the trolleys in assembled condition while the parts of the trolley are attached to it but the press parts are not packed in the trolley
For 2PY, 2AZ & 2CV Transportation trolleys: All the welding joints should be checked in assembled condition, that whether joints are welded properly or not. There should not be dust or rust on the part rest area in the trolley. Wheels of the trolley should move at ease, very freely. It must be ensured that Toeing bar & Toeing hook are available in proper way in the trolley. In each of the assembled trolley, none of the accessories should be in broken condition. Trolley, in which wire mesh is used, must be in a uniform manner. It must not be in ragged condition. Locking arrangement available in each trolley must be easily operable.
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Chapter 9: Project Premise
9.1: Findings This project is completely based on the observation method. From the observation method, I witness that any deviation found in the trolley, from the above checking standards is not permissible & packing of the parts is not allowed in that trolley. Also at the time of unloading the trolleys from the trucks, which comes back from GNU, if any deviation from the standard checking items are found in the trolley, its considered as NG (not good) trolley. Further, routine repairing and maintenance activities are followed upon the NG trolleys. NG trolley leads to flange bend, dents, scratches and damages on the press parts, packed in the trolley. Thereby, during packing of the press parts, again rigorous observation method has been followed and checking items have been established to avoid any of the damages on the parts to adapt the ideal & accurate delivery of parts. This method is followed while packing press parts of three models 2PY, 2AZ & 2CV.
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9.2: Establishing the checking items during packing of press parts before the dispatch Note: With respect to parts, sub-parts & dimensions following pair of trolleys are same for the 2PY model: a) FR. Door Skin (L & R) and RR. Door Skin (L & R); b) FR. Door Panel (L & R) and RR. Door Panel (L & R). For the same reason, in each pair, check points for one trolley while packing have been furnished.
As
the 2AZ & 2CV Common trolleys are completely similar as that of 2PY, only unique trolleys for the three models have been considered.
Earlier in this report, name of the common & unique trolleys for
three models 2PY, 2AZ & 2CV have been furnished. Further, checking items during packing of press parts for 2PY, 2AZ & 2CV are considered in pictorial form.
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2PY Transportation trolleys Side Panel Outside (L & R):
PACKED TROLLEY
Checking Items: Side locking bar should be fixed tightly with the center pillar End locking bar should be hinged properly with the center pillar to avoid the movement of parts during transportation Absorbers should be equally spaced in between & fixed tightly over the rod Style foam must be there while supporting the tail end of the part to avoid the flange bend Tail support bracket should be covered with hose pipe to avoid direct contact of the parts with metal body in the trolley PVC packing strips should be tied firmly with upper & lower base of the trolley to avoid the jerking during transportation
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FR. Door Skin (L & R):
PACKED TROLLEY
Checking Items: EVA sheet fixed in upper locking bar must be supporting the parts packed in the trolley, it helps to avoid the direct contact of the parts with metal body Upper locking bar must be hinged properly with the lock pin, otherwise there will be movement in the parts during transportation Foam must be inserted in each of the partition for avoiding the flange bend in the parts Part locking bar must be supporting the parts while being covered with PVC pipe
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Hood Skin:
PACKED TROLLEY
Checking items:
It must be ensured that there must not be rust or dust over the part resting area in the trolley Style foam must be attached over each part to avoid the flange bend & it must be supporting parts to avoid the movement PVC packing strip should be holding the locking bar tightly & the bar covered with PVC pipe must be supporting parts To avoid the jerking of parts during transportation, necessary wire locking must be ensured over each bar
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FR. Fender (L & R):
PACKED PACKEDTROLLEY TROLLEY
Checking items:
PVC pipe must be covering the round pipe in the trolley inner frame to avoid the direct contact of parts with the metal body PVC packing strip is necessary to tighten the center & upper locking bar Presence of style foam is useful to support parts after getting packed in the trolley Each U-bracket welded for the part resting, must be covered with superlon tube & superlon tube must not be ragged
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Hood Frame:
PACKED TROLLEY
Checking items:
EVA sheet fixed with the cable tie in the part resting inner frame must be touching the parts after getting packed, to avoid the direct contact of parts with metal body PVC pipe in the part resting frame must not be ragged while covering the round pipe Front stopper must hinged tight with the locking arrangement provided to avoid the jerking and movement of parts during transportation
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Front Floor:
PACKED TROLLEY
Checking items: PVC pipe must be covering the locking chain throughout EVA sheet fixed over each stopper provided in the trolley must ensure that the parts not touching the metal body directly Damping pad must be inserted between each part while packing, to avoid direct contact between each part Wire locking & locking pin provided over each bar, must be tightened properly Locking hook & U-bracket for clamping, must be welded properly
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Roof Panel:
PACKED TROLLEY
Checking items: Absorber must be bolted properly in the part resting frame while supporting parts after getting packed There must not be rust or dust over the part resting area Part locking door must be locked properly to avoid the play or any movement among parts during transportation Wire locking must be there for extra caution, as the part locking door does not get open.
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Trunk Lid Skin:
PACKED TROLLEY
Checking items: Presence of absorber over the round pipe is necessary while touching the part to avoid the direct contact of parts with metal body It must be ensured that every part is resting upon the EVA sheet, to avoid flange bend on the part. In end support frame wire lock & lock pin should be tightened in proper manner PVC pipe must be covering the round pipe on the inner frame throughout & cable tie should be holding the PVC pipe tightly
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Rear Floor:
PACKED TROLLEY
Checking items: PVC pipe must be covering the locking chain and it should not be ragged in between to avoid any dent over the part Locking hook must be clamped in the U-bracket provided, in a proper manner Cable tie must be holding the EVA sheet over each stopper provided in the trolley & it must be ensured that EVA sheet, touching the part to avoid the direct contact of parts from the metal body
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Trunk Lid Frame:
PACKED PACKED TROLLEY TROLLEY
Checking items: Front stopper must be supporting the parts in the trolley, with the style foam Cable tie must be holding the PVC pipe tightly over the round pipe in the part resting inner frame & PVC pipe must not be ragged Hose pipe must be covering the U-bracket provided in the trolley, to avoid the direct contact of parts from metal body Part front stopper must be fixed properly with lock pin & chain provided in the trolley
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Panel, RR. Inside (L & R):
PACKED TROLLEY
Checking items: Part must be supported with style foam fixed tightly in the trolley Lashing belt must be clamped tight with the foam over parts to avoid the movement of parts during transportation Lashing belt clamping U-bracket must be welded properly Wire lock & locking pin must be fixing the side locking bar in a proper manner
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RR. Door Panel:
Checking items: Part resting bar must be covered with PVC pipe without getting ragged Bar supporting frame must be covered with EVA sheet without getting ragged Z-bracket provided in the bar supporting frame must be supporting the part in proper way to avoid the movement of parts Upper bar resting frame must be tightened properly with the lock pin provided in the trolley
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2AZ Transportation trolleys: Roof Panel:
PACKED TROLLEY
Checking items: Part must be touching the PU sheet fixed over the front stopper being equally spaced while separating the parts in a proper order Absorbers must be fixed properly over the part locking door & it must be supporting parts There should not be dust or rust over the part resting area Side locking bar must be hinged properly with the lock pin provided in the trolley
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Side Panel Outside (L & R):
Checking items: Hose pipe should be covering the tail support bracket while separating parts End locking bar must be supporting the part while being covered with PVC pipe throughout Side bar & side locking bar must be hinged properly with the center pillar Absorbers must be supporting the part while separating them PU sheet must be touching the parts being equally spaced, to avoid dents or flange bend over the part
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Tail Gate Frame:
Checking items: PVC pipe & EVA sheet must be touching the part, resting in the inner frame to avoid the direct contact of parts from metal body Part front stopper must be welded properly with the bracket provided in the trolley Part front stopper must be hinged with the chain provided in the trolley & side lock bar must be locked with lock pin to avoid any movement among parts during transportation
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Tail Gate Skin:
Checking items: Side lock bar must be hinged with the locking arrangement provided in the trolley Center support bar must be supporting the part being covered with PU sheet It must be ensured that PU sheet grooves must be equally spaced, & separating the parts in a proper way PVC pipe must be touching the part to avoid dents & flange bend on the part while covering the round pipe in the part resting inner frame
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Rear Floor:
PACKED TROLLEY
Checking items: PVC pipe must be covering the locking chain and it should not be ragged in between to avoid any dent over the part Locking hook must be clamped in the U-bracket provided, in a proper manner Cable tie must be holding the EVA sheet over each stopper provided in the trolley & it must be ensured that EVA sheet, touching the part to avoid the direct contact of parts from the metal body Damping pad must be inserted between each part to avoid direct contact among parts which can lead to have dents on the part
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2CV Transportation trolleys: Roof Panel:
PACKED TROLLEY
Checking items: Part must be touching the PU sheet fixed over the front stopper being equally spaced while separating the parts in a proper order Absorbers must be fixed properly over the part locking door & it must be supporting parts There should not be dust or rust over the part resting area Side locking bar must be hinged properly with the lock pin provided in the trolley
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Side Panel Outside (L & R):
PACKED TROLLEY
Checking items: Hose pipe should be covering the tail support bracket while separating parts End locking bar must be supporting the part while being covered with PVC pipe throughout Side bar & side locking bar must be hinged properly with the center pillar Absorbers must be supporting the part while separating them PU sheet must be touching the parts being equally spaced, to avoid dents or flange bend over the part
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PACKED TROLLEY
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Rear Floor:
PACKED TROLLEY
Checking items: Cable tie must be holding the EVA sheet over each stopper provided in the trolley & it must be ensured that EVA sheet, touching the part to avoid the direct contact of parts from the metal body Damping pad must be inserted between each part to avoid direct contact among parts which can lead to have dents on the part Side locking bar must be hinged with lock pin provided in the trolley
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Front Floor:
Checking items: PVC pipe must be covering the locking chain and it should not be ragged in between to avoid any dent over the part Locking hook must be clamped in the U-bracket provided, in a proper manner Cable tie must be holding the EVA sheet over each stopper provided in the trolley & it must be ensured that EVA sheet, touching the part to avoid the direct contact of parts from the metal body Damping pad must be inserted between each part to avoid direct contact among parts which can lead to have dents on the part
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Spoiler & Spoiler Frame:
PACKED TROLLEY
Checking items: In the part resting inner frame, it must be ensured that PVC pipe & EVA sheet touching the part to avoid direct contact from metal body Presence of rubber cushion between each part is necessary to avoid direct contact between parts Being equally spaced, EVA sheet must be separating parts in a proper manner Side locking bar must be clamped properly with the lock pin
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9.3: Result
Observation in the first stage, elucidates the check points in the trolley in dismantled condition Observation in the second stage, depicts the checking standard while the trolley is in assembled condition, but parts are not loaded into the trolley Observation in the third stage, highlights the checking items during the packing of press parts in the trolley Before finalizing the dispatch, if these standards are followed, chances of damages like scratches, dents, flange bend on the parts can be depleted to a significant level.
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9.4: Learning
Being a management trainee for the period of two months in the HSCI, TKR plant, I have experienced a lot from the learning perspective which is furnished further. I would like to highlight the viewpoints from different aspects as in terms of cost, quality, management, delivery & safety.
a) QualityHONDA is the synonym of quality. Being the trainee at PLC Dept. in HSCI, TKR plant, I witness how PLC team ensures quality while serving the PLC responsibilities. Any deviation from the checking standards found in the transportation trolley while packing of press parts, is not permissible and further packing is not allowed in the same trolley. Even at the time of unloading the trolleys which return from GNU, trolleys are checked thoroughly. If any digression found in the trolley, its considered as NG (not good) trolley & hence routine repair & maintenance activities are followed on NG trolleys before packing. Thereby, quality comes the first priority to avoid any imperfection occurred while packing.
b) ManagementFrom management perspective, I witness quite praiseworthy management policies towards the employees which enable them to think, learn, evaluate & analyze problems while working with complete freedom without any domination. Voicing the mission statement together with respective departments along with all the team members at the very morning brings some additional commitment while working for the whole day. A very laudable healthy culture is prevalent throughout the organization. Even after Japanese counting at the morning, mission statement is voiced in English & Indias national Hindi language, which the Japanese also u se to tune. Day to day meeting with presence of all the team members indicate an effective communication throughout the premise.
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c) DeliveryTo ensure the ideal & accurate delivery of parts to GNU, checking standards are rigorously followed while packing of parts into the transportation trolley before dispatch, where HELI, KALINGA associates along with PLC team members play a major role. To avoid any damages like scratches, flange bend, dent over the parts, its made certain that necessary parts & sub-parts such as PVC pipe, EVA sheet, PU sheet, Style foam are attached in transportation trolleys.
d) SafetyThe techniques for 5S were originally applied to production operations and have recently been extended to safety and office activities. 5S visual management is a key foundation principle for creating the lean enterprise because the concepts of organization and orderliness are focused on achieving cost reductions, waste elimination, zero defects, safety improvements, and accident reductions. Proper consumables are allocated to every HONDA employees to ensure safety while working. Even proper marking has been done on the floor & roads beside the pavement, which is supposed to be followed by everyone inside the plant while walking.
e) CostFrom the thorough observation, I find total trolley making cost can be reduced to some extent while depleting the usage of cable tie, wire locking & reinforcement sheet attached to the trolley. I notice, either gum or cable tie is enough to fix the necessary PU sheet, EVA sheet in the trolley where usage of the two seem to be unnecessary. Only spring lock system is adequate in a trolley to hold the side lock bar during transportation, while practice of wire locking can be avoided. Parts packed in the trolley dont set such a load on it, that reinforcement sheet are incorporated in the part resting inner frame in few trolleys. Hence usage of reinforcement sheet for withstanding the load seems to be additional for me.
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Chapter 10: Conclusion Following the Operation Processing Standards of the transportation trolleys while maintaining the safety norms, ideal & accurate delivery of parts of each model 2PY, 2AZ & 2CV can be ensured Chances of damages like scratches, dents, flange bend over the parts can be reduced, while following the checking standards established during the packing of press parts before the dispatch. On the basis of the observation method, which has been followed throughout the project, in the conclusion part I would like to recommend that usage of spring lock system over the side locking bar, must be incorporated in each trolley. In few trolleys, I witness that instead of spring locking system, side locking bar is only attached to the trolley with the support of L-bracket & wire locking. Hence, there is every possibility of the side bar to get open during transportation. To avoid this circumstance, I recommend spring lock system along with wire locking can be implemented in each of the transportation trolley.
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References
http://www.hondacarindia.com/ http://www.entrepreneurswebsite.com/2010/05/26/automobile-industry-inindia/ http://www.surfindia.com/automobile/automobile-industry.html http://www.india-reports.com/articles/Auto-Industry-India-EvolutionGrowth.aspx http://docs.google.com/viewer?a=v&q=cache:b5XZZyFuylYJ:www.autone ws.com http://www.siamindia.com/scripts/market-share.aspx http://ezinearticles.com/?Impact-of-the-Auto-Industry-on-the-Economy-andJob-Market&id=2094372 http://www.honda.ca/honda-in-canada/manufacturing/environmental-policy http://www.bexcellence.org/5S-visual-management.html
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1.1: Overview of Automobile Industry in India: Chapter 1: Industrial Profile

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1.1: Overview of Automobile Industry in India: Chapter 1: Industrial Profile

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Chapter 1: Industrial Profile 1.

1: Overview of automobile industry in India

1.2: Evolution of automobile industry Protectionism- Early 1980s

HONDA SIEL CARS INDIA LTD.

Growth trajectory: Trend of Indian Automobile Industry

HONDA SIEL CARS INDIA LTD.

Domination of passenger Cars: Trend in Graphical form

Indian Passenger Vehicle Market trend- Competitive Scenario

HONDA SIEL CARS INDIA LTD.

1.3: Segment wise share in the Automobile industry

HONDA SIEL CARS INDIA LTD.

1.4: Contribution of automobile industry to the economy

HONDA SIEL CARS INDIA LTD.

Automobile production trends

HONDA SIEL CARS INDIA LTD.

HONDA SIEL CARS INDIA LTD.

2.2: Product lines of Honda Siel Cars India Ltd.

HONDA SIEL CARS INDIA LTD.

HONDA SIEL CARS INDIA LTD.

HONDA SIEL CARS INDIA LTD.

HONDA SIEL CARS INDIA LTD.

HONDA SIEL CARS INDIA LTD.

Chapter 4: HONDA & Technology

HONDA SIEL CARS INDIA LTD.

Chapter 5: Process flow chart associated with Press Parts

HONDA SIEL CARS INDIA LTD.

Watarana Watarana provides Forklifts to the company

Kalinga Kalinga provides workers to the company

HONDA SIEL CARS INDIA LTD.

PLC Responsibilities In a pictorial form:

HONDA SIEL CARS INDIA LTD.

HONDA SIEL CARS INDIA LTD.

Press Parts Nomenclature:

HONDA SIEL CARS INDIA LTD.

Terminology of Press Parts:

HONDA SIEL CARS INDIA LTD.

HONDA SIEL CARS INDIA LTD.

HONDA SIEL CARS INDIA LTD.

Pictorial form of the trolleys used in HSCI, TKR plant:

HONDA SIEL CARS INDIA LTD.

Specialty of transportation trolleys:

HONDA SIEL CARS INDIA LTD.

HONDA SIEL CARS INDIA LTD.

Pictorial representation for each model : 2PY Common Trolley Identification

HONDA SIEL CARS INDIA LTD.

2AZ Common Trolley Identification

HONDA SIEL CARS INDIA LTD.

2CV Common Trolley Identification

HONDA SIEL CARS INDIA LTD.

Model wise Trolley Identification In PLC Department:

HONDA SIEL CARS INDIA LTD.

HONDA SIEL CARS INDIA LTD.

HONDA SIEL CARS INDIA LTD.

FR.DOOR SKIN (L & R)

HONDA SIEL CARS INDIA LTD.

HONDA SIEL CARS INDIA LTD.

FR. FENDER (L& R)

HONDA SIEL CARS INDIA LTD.

HONDA SIEL CARS INDIA LTD.

HONDA SIEL CARS INDIA LTD.

HONDA SIEL CARS INDIA LTD.

TRUNK LID FRAME