A

RESEARCH REPORT ON

TRAINING & DEV. W.R.T.

QUALITY CONTROL OF
YAMAHA MOTOR INDIA LTD
SUBMITTED IN PARTIAL FULFILLMENT FOR THE AWARD OF
DEGREE OF MASTER OF BUSINESS ADMINISTRATION

(UNDER MAHAMAYA TECHNICAL UNIVERSITY ,NOIDA)

(2011-12)
SUBMITTED TO: SUBMITTED BY:Mr. Amit Kumar
PRAVESH KUMAR
(H.O.D)
1015870070

Roll No.(MBA)

Janhit Institute of Education And Information

1

Greater Noida-201306 (U.P)

Contents

ACKNOWLDGEMENT
DECLARATION

Introduction
Plant Layout
Various Models and Their Specifications
Welding Shop
Paint Shop
Press Shop
Tool Room
Machine Shop
Electroplating
Engine Assembly
Body Assembly
Stores
Export & Marketing
2

ACKNOWLDGEMENT
I feel an immense pleasure in taking this opportunity to express my
sincere indebtedness and deep gratitude towards our respected
faculty guide Mr. Amit Kumar , for encouraging me to work on
this topic and being a constant source of inspiration and guidance.
I express my sincerest thanks for her constant encouragement
,meticulous ,guidance constructive criticism and invaluable
console throughout the conduct of study.
Further I am highly grateful to Mr. RAHUL SHRAMA
who gave their full support and corporation
in getting good understanding of the topic chosen.

PRAVESH KUMAR
Roll No.- 0915870070

MBA

DECELARATION

I hereby declare that the project

work for
report
is

the

is

solely the

allowed

person.

fulfillment

Prior

to

use ,

work

of

academic
of

copy ,

permission

appropriate authority

of

report is result
the
edit

has
any

to

anything

further

my

requirement .

undersign
be

of
and

by

own

This
nobody

any

taken from
use.

PRAVESH KUMAR
Roll No.- 0915870070

MBA

INTRODUCTION
Company profile :Indian

joint

venture

Motorcycle

manufacturing

company becomes
100 % YMC owned.
Company name changed to :Yamaha Motor India private limited.

Yamaha Motor India ( YMI )

Holding aloft the spirit of commitment to customer
satisfaction - YAMAHA MOTOR INDIA is enriching lives
of people with the same ingenuity and enthusiasm as
its

parent

company

YAMAHA

MOTOR

CORPORATION , JAPAN. Having operated in India as

technology provider for almost two decades, YMI was
incorporated in August 2001 as 100% subsidiary of
YMC , Japan. Since then people at YAMAHA have been
in the process of redefining business processes and
extending the awe and power associated with the
legacy of the YAMAHA group. Adhering to their
7

Corporate Mission - Creating KANDO - Touching

Your Heart People at YAMAHA are striving to touch
every Heart across the length and breadth of India.

Establishing a Corporate environment

that fosters self-esteem.
YAMAHA believes in nurturing and empowering their
employees to the fullest. Whilst cultivating their
employees creativity and all round abilities, they
have

also

established

an

equitable

system

of

evaluation and rewards to encourage their people to

strive towards newer benchmarks.

Fulfilling Social Responsibilities

As

good

corporate

citizens,

people

at

YAMAHA

continually strive towards creating a better social as

well as natural environment.

Technology
Research

and development division

beneath their

is the wind

wings. Model conception, Designing,

Aesthetics, Clay making, Prototype development are

the strong pillars of YAMAHAs R&D.

Since the primary requirements of Indian customers

are good mileage, comfort, durability, style and
affordability - The R&D at YMI ensures a regular
interaction with customers to facilitate future model
development at R&D department -YMI Surajpur &
Faridabad and R&D department - YMC, Japan.
People at YMI

believe in providing their customers

with innovative cutting edge technology, A Truly

world class experience - TRULY YAMAHA . The
MACHINE is developed and tested in accordance with
latest

technological

parameters

to

give

their

customers the BEST. Known all over the world for its
Humachine technology, Yamaha strives to appeal
to human emotion by combining performance with
design in ways never achieved before. Embodied in
this creation ( not mere building ) are the joy,
excitement and pleasure, which are at the core of the
Man-Machine
Equipped

relationship

with

fuel

to

efficient

last
and

lifetime.

environment

friendly technology YAMAHA bikes are created to

ADD

THAT

Indigenized

TANGY

FLAVOUR

development

of

TO
Models

YOUR

LIVES.

like

FAZOR

,Enticer and Crux have been undertaken here at YMI.

At a steady pace, they have plans to develop
YAMAHA MOTOR INDIA as a designing hub in future.
9

Manufacturing: -

YMl's Manufacturing facilities comprises of 2 stateof-the-art

Plants

at

Faridabad

(Haryana)

and

Surajpur (Uttar Pradesh). Currently 10 models roll

out of the two Yamaha Plants.
The

infrastructure

at

both

the

plants

supports

production of motorcycles - for the domestic as well

as oversees market. At the core are the 5-S and TPM
activities

that

fuel

our

agile

Manufacturing

Processes. YAMAHA is having In-house facility for

Machining, Welding processes as well as finishing
processes of Electroplating and Painting till the
assembly line.
The stringent Quality Assurance norms ensure that
YAMAHAs
International

motorcycles
standards

meet
of

the

excellence

reputed
in

every

sphere.
As an Environmentally sensitive organization they
have

the

concept

of

"Environment-friendly

technology" ingrained in our Corporate Philosophy.

The Company boasts of effluent Treatment plant,
Rain water - Harvesting mechanism, a motivated
forestation drive. The ISO-14001 certification is on
10

the anvil - early next year. All their endeavors give

the reason to believe that sustainable development
for Yamaha will not remain merely an idea in
pipeline. People at YAMAHA believe in taking care of
not only the

Motoring Needs but also the needs of

Future Generations to come.

Plant Layout
LAND AREA= 30 HECTARE (303,803 sqm.)
COVERED AREA= 55,600 sqm.
OLD BUILDING AREA = 25,600 sqm.
NEW BUILDING AREA = 30,000 sqm.

Old Building
l.
2.
3.
4.
5.

RAW MATERIAL STORE

DIE MANTAINANCE
WELDING
STORE (PAINT, WELD, PLATING)
MACHINING
11

6. PRESS SHOP
7. PAINTING
8. ELECTROPLATING
9. MACHINE SHOP
10. TOOL ROOM
11. TOOL MAINTAINANCE
12. MACHINE SHOP
13. STORES ( Machined Parts )
14. STORES ( Ni/Cr etc. )

New Building
1.
2.
3.
4.
5.
6.
7.
8.

ENGINE ASSEMBLY
S/P, E/G, B/D PARTS
BODY ASSEMBLY LINE
BSR
ABS PAINTING
PARTS STORES
EXPORT & PACKING
LOADING

12

FAZOR
Technical Specifications :
Code Number
:
5YY
Engine Capacity
:
123.7 cc , 4-stroke, SOHC,
Air cooled.
Bore * Stroke
:
54mm * 54mm
Max Power
:
10.8 BHP @ 7500 Rpm
Max Torque
:
10.4 Nm @ 6500 Rpm
Ignition
:
CDI
Transmission
:
4
speed
,
Constant mesh.
Chasis
:
Single Downtube
Electricals
:
12v D.C
Kerb Weight
:
125 Kg
Top Speed
:
105 Kmph ( solo )
Fuel tank Capacity :
13 liters
Total length
:
2065 mm
Wheel Base
:
1300 mm
Height
:
1060 mm

LiBERO
13

Technical specifications :Code Number

Engine Displacement
Bore * Stroke
Maximum power
Maximum Torque
Maximum Speed
Transmission
Electricals
Overall Length
Height
Wheel Base
Kerb weight
Ignition

5TS
Single Cylinder, 106 cc, air cooled
49 * 56 mm
7.5 BHP @ 7500 rpm
.8 Kgf-m @ 6000 rpm
97 Kmph (solo)
4 speed Constant mesh
12v D.C
2025 mm
1050 mm
1290 mm
109 kg
D.C CDI

Features :Tachometer, 130mm drum brakes, Adjustable Multireflector, Headlamp, Higher Ground Clearance,
Longer Wheel Base for Better stability, ADVANTECH
Engine, Etc.

14

Technical Specifications :Code Number

Engine Displacement
Bore * Stroke
Maximum Power
Maximum Torque
Maximum Speed
Transmission
Electricals
Overall length
Height
Wheelbase
Kerb Weight

- 5US2
Single Cylinder, 123.7 cc, Air cooled
54 * 54 mm
10.8 BHP @ 8000rpm
1.06 Kgf-m @ 6500rpm
105 Kmph ( solo )
4 speed, Constant Mesh.
12v D.C
2090 mm
1125 mm
1380 mm
116 kg

Features :Electric start (optional), Disc brake (optional),Any

gear kick start, Shorter Turning radius, Higher power
to Weight Ratio, Platform type foot rest, Chrome
plated round headlight, double saddle with back seat
15

etc.

CRUX
Technical Specifications :Code Number
Engine Displacement
Bore * Stroke
Maximum power
Maximum Torque
Maximum Speed
Transmission
Electricals
Overall Length
Height
Wheel Base
Kerb weight
Ground Clearance
Electricals

5KA3
Single Cylinder, 106 cc, 4 stroke
49 * 56 mm
7.5 BHP @ 7500 rpm
.8 Kgf-m @ 6000 rpm
97 Kmph (solo)
4 speed Constant mesh
12v D.C
1997 mm
1055 mm
1247 mm
106 kg
150 mm
12v D.C

Features :91 kmpl (USTC) , Wider seat for long drives, Front Telescopic
suspension for smooth ride, Rear suspension with coil springs and oil
dampers, SOHC, Adjustable Multi-reflector headlamp, Etc.
16

Welding
Metal arc welding is popularly employed. This
process Popularly known as Metal -Inert gas (MIG)
welding involves of metal using a consumable metal
electrode in an inert gas atmosphere. The arc is
struck between the metal and work piece and
shielding is provided by the gas evolved during
combustion of flux plus the CO gas fed around the arc
for this purpose.
The electrode in the form of a continuous
wire, which is fed into the arc by an adjustable speed
motor, at the same speed at which it is melted and
deposited in the weld. Electrode used is either flux
cored or magnetized flux coated. This method can be
employed for welding carbon sreel,low alloy steel etc.
Usually M.S. wire of 0.8 mm thickness is used as
filler.D.C.

With

reverse

polarity

is

used

in

welding.
The main equipment used in this process is as
follows: 1. WELDING GUN: - It resembles a piston with a
trigger to start The process. It carries a ceramic
nozzle through which the wire electrode and
shielding gas exits.
17

MIG

2. WIRE DRIVE: - The welding wire, drawn from the

spool, is fed through drive rollers, the wire feed rate
being controlled to maintain a constant arc voltage.
3.GAS SUPPLY: - The gas is supplied from the
cylinder through a flaw meter, regulator and
automatic operated solenoid valve:
4. WELDING MACHINE: -A proper source with constant
arc voltage Characteristics is connected to the
contact tube in the welding gun and to the work
piece
5.CONTROL UNIT: - It co-ordinate the functioning of
the power supply wire drive and movement of the
gun, and regulate the gas supply and flow of water.
6. SHIELDING GAS:- It is used to protect the molten
metal

contamination from the atmosphere the

choice of shield gas is determined by an arc and

metal transfer characteristic weld deposition
characteristics. penetration width of the fusion,
shape of reinforcement, speed of the welding and
undercut tendency C02 alone is used for welding
mild steel.

Gas Nozzle
Contact tube
18

Shielding Gas
Arc
Weld Pool

MIG Welding Shielding Gas

The shielding gas, forms the arc plasma, stabilizes
the arc on the metal being welded, shields the arc
and molten weld pool, and allows smooth transfer of
metal from the weld wire to the molten weld pool.
There are three primary metal transfer modes:
1. Spray transfer
2. Globular transfer
3. Short circuiting transfer
The primary shielding gasses used are:
1. Argon
19

2. Argon - 1 to 5% Oxygen
3. Argon - 3 to 25% C02
4. Argon/Helium
COZ is also used in its pure form in some MIG welding
processes.

However,

in

some

applications

the

presence of COZ in the shielding gas may adversely

affect the mechanical properties of the weld.

Weld Discontinuities
1. Undercutting
Excessive

2. Melt-through Incomplete
3. Fusion Incomplete joint
4. Penetration
Porosity
5. Weld metal cracks
20

6. Heat affected zone cracks

MIG Welding Benefits

1. All position capability
2. Penetration of an arc is quite high
3. Higher deposition rates than SMAW
4. Less operator skill required
5. Minimum edge preparation is required particularly in
butt
joint
6. Long welds can be made without starts and
stops
Minimal post weld cleaning is required

MIG Welding Problems

1. Heavily oxidized weld
deposit
2. Irregular wire feed
3. Burn back
4. Porosity
5. Unstable arc
6. Difficult arc starting

TIG Welding
GTAW Welding
Gas Tungsten Arc Welding (GTAW) is frequently
referred to as TIG welding. TIG welding is a commonly
used high quality welding process. TIG welding has
become a popular choice of welding processes when
21

high quality, precision welding is required.

In TIG welding an arc is formed between a nonconsumable tungsten electrode and the metal being
welded. Gas is fed through the torch to shield the
electrode and molten weld pool. If filler wire is used,
it is added to the weld pool separately

Helium is generally added to increase heat input

22

(increase welding speed or weld penetration).

Hydrogen will result in cleaner looking welds and also
increase heat input; however, Hydrogen may promote
porosity or hydrogen cracking
1. Argon
2. Argon + Hydrogen
3. Argon/Helium

Shielding Gases

Weld Discontinuities

Undercutting
Tungsten inclusions
Porosity
Weld metal cracks
Heat affected zone cracks

TIG Welding Problems

Erratic arc
Excessive electrode consumption
Oxidized weld deposit
Arc wandering
Porosity
Difficult arc starting
23

TIG Welding Benefits

Superior quality welds
Welds can be made with or without filler
material
Precise control of welding variables (heat)
Free of spatter
Low distortion

GTAW Welding Limitations

Requires greater welder dexterity than MIG or stick
welding
Lower deposition rates
More costly for welding thick sections

Resistance Seam Welding

Description :-

24

The seam welding process is an adaptation of

resistance spot welding and involves making a
series of overlapping spot welds by means of
rotating copper alloy wheel electrodes to form a
continuous leak tight joint. The electrodes are
not opened between spots. The electrode wheels
apply a constant force to the work pieces and
rotate at a controlled speed. The welding current
is normally pulsed to give a series of discrete
spots, but may be continuous for certain high
speed applications where gaps could otherwise
occur between individual spots. Seam welding
equipment is normally fixed and the components
being welded are manipulated between the
wheels. The process may be automated;

25

CONVENTIONAL WIDE FIELD SEAM

WELDING

Wide wheel seam

Wheel contact width normally 5t mm flat (where t
is single sheet thickness in mm).
General purpose welding (domestic radiators up to
about 6
m/min).

Wide wheel seam

Narrow wheel seam

Wheel contact shape typically 6mm radius.
Knurl drive on wheel edge with contact surface
continuously plan shed.
Controls electrode contamination when welding
coated steels, such as for vehicle fuel tanks.

26

Narrow weld seam

Consumable wire seam welding

Shaped, consumable copper wire fed between the
wheels and sheets to be joined to give consistent
clean contact.
Used for welding coated steels such as tin cans
and vehicle fuel tanks.

Consumable wire seam

27

Mash seam welding

Narrow overlap of sheet edges, which are partly
crushed together during welding.
High speed welding of tin cans and drums (0.2mm
tinplate up to 100m/min).
Wide wheel or consumable wire processes used.

Mash seam welding

Foil butt seam welding

Foil welded on to each side of the butted edges of
the sheets to be joined.
Typically 4mm wide stainless steel foil used to
preserve corrosion
resistance on coated steel.
Virtually flush finish with no crevice and used to
produce wide panels.

28

Important Issues
The main issues concerning seam welding are in weld
quality control
Welding speeds.
High speed welding of coated steels is of particular
importance in manufacturing of tin cans. Specialist
consumable wire seam welding machines are used.
Quality monitors have been developed for these
applications and welding speeds up to 100m/min
are possible. Steels with alternative coating to tin,
for canning applications, present difficulties due to
their high surface resistance.
Weld quality is controlled mainly by tight process
control together with periodic testing of samples.
Factors such as materials and pressing quality and
alignment of the electrodes to the material are
critical to achieve high speed, quality welding, for
example in coated steels for fuel tanks.

Benefits
Seam welding enables high welding speeds to be
obtained compared with many other techniques,
but can be limited by component shape and
wheel access.

Limitations:
There are some limitations on material weld ability
but attention to correct setting up and good process
control can solve most production problems. The
main hazards are
29

1. The risk of crushing fingers or hands.

2. Burns or eye damage from splash metal. Little
fume is produced but may need attention when
welding coated steels or when oils or organic
materials are present

Muffler Assembly

SHEET

ROLLING

TIG

WELDING
SIZING(MILLING)
CUTTING
TAPER BODY+MUFFLER
BODY PIP
TESTING

BRACKET FOR BODY

ASSEMBLY

SIZING BY MILLING FOR ALLIGNMENT

TAPER BODY+MUFFLER BY AUTO MIG WELDING
BODY PIPE (FOR LOW POLLUTION)
30

 TESTING BY PRESSURE

Fuel Tank
PRESS SHOP

SPOT WELDING

FINAL GRINDING
GRINDING

PRESS OPERATION
BENDING

SPOT WELDING

SEAM WELDING
BREAKING

ROLLING

ROUGH

PIERCING

AUTO MIG

SEAM WELDING

FRONT

REAR BENDING

REAR PATCHIN

MIG

TESTIN
FILLING

SEAM WELDING (COPPER ALLOY)

D.M. WATER IS USED AS COOLENTT
ROUGH GRINDING (GRADE SIZE=120)
FINAL GRINDING (GRADE SIZE=220)
PRESS OPERATION (CUTTING FOR FUEL INLET)
31

 AUTO MIG (INNER PANNEL AND OUTER PANNEL

ASSEMBLY)
TESTING BY PRESSURE (IN MICRONS)
ANTI RUST OIL (RUSTILO DW-901)

32

Paint Shop

The paint shop is solely responsible for painting all

the components such as fuel tanks, mudguards etc.
paint is done on a component to enhance its beauty
and anti-corrosion property.
In paint shop each component undergoes initial
stages of degreasing, cleaning and finally priming
and painting. The defects in the paints are reworked
and again inspected. The various components, which
are painted in these shops, are polymer parts and
metallic parts.

NEW PAINT SHOP

Parts (ABS: -ACRONITRILE BUTADIENE STYRENE)
OUTER COVER
TAIL COVER (1,2,3)
METER COWLING
TAIL COWLING
SIDE COVER
HEAD LIGHT
LEG GUARD

33

PROCESS CHART

New Paint Shop-

LOADING

PRE-TREATMENT

FLASH OFF
DRYING

AIR BLOW

TOPCOAT PAINTING

BASE COAT PAINTING

OFF-1

WATER

WIPING AND CLEANING

FLASH

UPLOADING AND DEMASKING

BACKING

NAME
LOADING
OF PARTS

EQUIPMENT

INSPECTION ITEM METHOD

HANGER

HANGER

VISUAL

HANGER

HANGER

VISUAL

HANGER
TANK
SURF
(POW.)

ACTUAL PART

CONVEYOR

SPEED (2.5M/MIN)
TEMP.GAUGE

(60+-2) CENTI.
PRESSURE

GAUGE
(0.5-0.8kg/cm.2)

VISUAL
VISUAL

VISUAL

TEMP.

VISUAL

SPRAY
PRESSURE

CONDITION
OF HANGER
PART
LOADING

PRETREATMENT

CONTROL
ITEM

34

CONDITION
OF PARTS
TIME

AIR BLOW
WATER
DRYING

WIPING AND
CLEANING

BASE COAT

PAINTING

FLASH OFF1

CONDUCTIVITY
(<10micro S)
CONTAMINATION
(CLEAR WATER)
ACTUAL PART
CONVEYOR SPEED
TEMP. GAUGE

TOPCOAT
PAINTING

VISUAL

VISUAL

BATH
DISCARD
CYCLE
VISUAL
AIR BLOW
VISUAL DRYING TIME(15min)
VISUA TEMP. (70+-2)dc
L

DEIONISED
AIR BLOW

ACTUAL PART

VISUAL

ACTUAL PART
STATIC CHARGE

ON PART

STATIC
METER

VISUAL
ELECT
ROFIELD

WIPING
WITH IPA
AIR BLOW
DEIONOISE
D
AIR BLOW

VISCOSITY

SPRAY

VISCOSITY

FORD

CUP
VISUAL

FLASH OFF
ZONE

CONVEYOR
SPEED METER

VISUAL

SPRAY
GUN

VISCOSITY

FORD
CUP

VISUAL

FLASH OFF2

FLASH OFF
ZONE

CONVEYOR
SPEED METER

VISUAL

BACKING

OVEN

TEMP. GAUGE

VISUAL

VISUAL

UPLOADING
AND
DEMASKING

WATER

AIRGUN
OVEN

GUN

CONVEYOR
SPEED
ACTUAL
TROLLEY

35

AIR
PRESS.(3.5
4.5 k cm.s .)
PROCESS
TIME (6
8min.)
VISCOSITY
(BASE
COAT)
PRESSURE
GAUGE(3.5
4.5
kg/cm.sq.)
PROCESS
TIME(6-8
min)
PROCESS
TIME(40
min.)
TEMP.
EMPTY
TROLLEY

Old Paint Shop

Metal Components Paint Shop
This paint shop is also known as Old paint shop. This
shop is situated next to the welding shop so that the
transfer of the CHASIS, FUEL TANK from the welding
shop to the Paint shop is easy. Painting of parts is
done in the following steps:
LOADING OF PARTS: Parts are loaded on Hangers.
There should not be any damage in the hangers. And
also, there should not be any excess paint on the
hangers. Avoid rust grease and excess oil on the
parts to be painted.
MASKING ( Only for the FUEL TANK ) : There should
not be any damage in the masking material and it
should be properly fit to the fuel tank.

PRE-GREASING :
CONTROL ITEM
Spray Temperature
Spray Pressure
Free Alkali
Process Time

CONTROL RANGE
60c
1.0 kgf/cm.squ
18 ml
1 min.

DEGREASING :
CONTROL ITEM
Spray Temperature
Spray Pressure
Free Alkali
Process Time

CONTROL RANGE
60c
1.0 kgf/cm.squ
18 ml
1 min.
36

WATER RINSE -1
CONTROL ITEM
Spray Temperature
Spray Pressure
Total Alkali
Process Time

CONTROL RANGE
45c
1.0 kgf/cm.squ
18 ml
0.5 min.

WATER RINSE - 2
CONTROL ITEM
Spray Temperature
Spray Pressure
Total Alkali
Process Time

CONTROL RANGE
45c
1.0 kgf/cm.squ
18 ml
0.5 min.

SURFACE CONDITIONING : It is done to remove all

the impurities left on the surface of the component
conveyer speed is fixed to 3m/min.
CONTROL ITEM
Spray Temperature
Spray Pressure
Total Alkali
Process Time
PH value

CONTROL RANGE
40c
0.5-0.7 kgf/cm.squ
20-25 ml
0.5 min.
8.0-9.5

37

PHOSPHATING :
CONTROL ITEM
Spray Temperature
Spray Pressure
Total Alkali
Process Time
Free Alkali

CONTROL RANGE
45-50c
1.0 kgf/cm.squ
18-20 ml
2.5 min.
.6 - .8 ml

WATER RINSE - 3
CONTROL ITEM
Spray Temperature
Spray Pressure
Total Alkali
Process Time

CONTROL RANGE
45c
1.0 kgf/cm.squ
18 ml
0.5 min.

WATER RINSE - 4
CONTROL ITEM
Spray Temperature
Spray Pressure
Total Alkali
Process Time

CONTROL RANGE
45c
1.0 kgf/cm.squ
18 ml
0.5 min.

FRESH DE-MINERALISED WATER MIST :

CONTROL ITEM
Spray Temperature
Conductivity
Process Time
PH value

CONTROL RANGE
40c
10 micro s/sec
0.1 min
6.5 - 7.5

DEMASKING : There should not be any damage in

the masking material and should be properly fitted to
the fuel tank.
38

VACUUM SECTION :
CONTROL ITEM
Suction Capacity

CONTROL RANGE
4000 mm of Hg

OVEN ( Water Drying ) :

CONTROL ITEM
Temperature
Process Time

CONTROL RANGE
120-130 c
10 - 12 min.

DUSTING : Now dusting is done by blowing air on

the components at the pressure of 70-80 psi.

ELECTROSTATIC PAINT BASE COAT :

CONTROL ITEM
Base Coat Viscosity
Voltage
Air Motor Pressure

CONTROL RANGE
18-20 seconds of ford cup.
90000 Volts
0.4-0.5 kgf/cm.squ

BASE COAT TOUCH UP : It is done manually by

spraying guns.
CONTROL ITEM
Base Coat Viscosity
Air Motor Pressure

CONTROL RANGE
18-20 seconds of ford cup.
0.5-5.5 kgf/cm.squ

ELECTROSTATIC PAINT TOP COAT :

CONTROL ITEM
Base Coat Viscosity
Voltage
Air Motor Pressure

CONTROL RANGE
18-20 seconds of ford cup.
90000 Volts
0.4-0.5 kgf/cm.squ
39

TOP COAT TOUCH UP :

CONTROL ITEM
Base Coat Viscosity
Air Motor Pressure

CONTROL RANGE
18-20 seconds of ford cup.
0.5-5.5 kgf/cm.squ

After topcoat touch up, parts are baked in oven at

140-150c . Then Parts are unloaded from conveyer
line and sent to their destinations. Now fuel tank is
sent for Scuffing and Graphic applications.
LACQUERING: It is a process of applying special type
of transparent paint to the fuel tank for its shining.
After lacquering, fuel tank is sent to BODY
ASSEMBLY.

40

Press Shop
The Shop is situated next to the welding shop to ease
the transfer of parts from Press Shop to Welding
Shop. The press shop deals mainly with the cutting of
metal sheets into the required shape. The machines
are classified according to the loads they provide for
various press operations. There are 12 press
machines on which different dies may be fixed for
carrying
out different operations on
various
components. The different machines in the Press
Shop are :

One 300 T Hydraulic Press

Three 250 T semi Hydraulic crank type
One 60 T Electromechanical crank type
Two 120 T Electromechanical crank type
One 80 T Electromechanical crank type
Two 75 T Electromechanical crank type
One 55 T Electromechanical crank type
Three pipe bending machine
Two drilling machines

41

Sheet Metal of mild steel is cut into the required size

on shearing machine. It is then sent to the
corresponding press machine. The various
operations being carried out on press machines
are :
DRAWING : Drawing is the process of making a cup,
shells and similar articles from Blank.
BLANKING : Blanking is the process in which the
punch removes a portion of material from the
stock, which is a strip of sheet metal of necessary
thickness and width. The removed portion is called
a blank and is usually further processed to be of
some uses.
PIERCING : Also sometimes called punching, the
piercing is making a hole in the sheet. It is identical
to blanking except of the fact that the punching out
of the portion coming out through the die in piercing
is scrap.
BENDING : Sheet metal is required to be bent at
different angles and curvature to shape it into
required form The bending operation involves
stretching of metal on the Outer surface and
compressing it on the inner surface along the neutral
line which remain unchanged in length; sheet metal
can be bent by hammering Over the base by the hand
or by means of bending or rolling machine.
EMBOSSING : It is the process through which the
blank of sheet metal are stretched to shape under
pressure by means of a punch and a die. A large
number of the Ornamentals wares, such as a plate, in
sheet metal are produced by Embossing.
The various components being formed in the press
shop are:
42

OUTER PANEL:
Operation Performed : Drawing Operation
Purpose : Sheet Thinning , Appearance
Operation Performed : Final Trimming
Purpose : Burrs, Appearance and Gauge Fitment

INNER PANEL:
Operation Performed: Drawing Operation
Purpose: Burrs, Appearance, and Gauge Fitment

REAR FENDER:
Operation Performed: Drawing Operation
Purpose: Sheet Thinning, Appearance
Operation Performed: Trimming Operation
Purpose: Burrs, Appearance
Operation Performed: End Cutting
Purpose: Burrs, Appearance
Operation Performed: Rear Bending
Purpose: Flange Width, Appearance
Operation Performed: Side Bending 1
Purpose: Flange Width, Appearance
Operation Performed: Side Bending 2
Purpose: Flange Width, Appearance
Operation Performed: Final Bending
Purpose: Band Width, Appearance, and Gauge
Fitment

FRONT FENDER:
Operation Performed: Drawing Operation
43

Purpose: Sheet Thinning, Appearance

Operation Performed: Trimming Operation
Purpose: Burrs, Appearance
Operation Performed: Piercing and Bending
Operation
Purpose: Hole Diameter, Appearance
Operation Performed: Rear Bending
Purpose: Flange Width, Appearance
Operation Performed: Side Bending 1
Purpose: Flange Width, Appearance
Operation Performed: Side Bending 2
Purpose: Flange Width, Appearance
Operation Performed: Final Bending
Purpose: Band Width, Appearance, and Gauge
Fitment

SHEET SIZE
S.N

Name of
Model
the
Componen
t

Model
name

Material
size

Outer panel
Outer panel

Crux
Libero

840*860*0.8
840*860*0.8

OOM
YBR

44

3
4
5

Outer panel
Outer panel
Outer panel

YBX
5YY
RXZ

YBX
Fazer
RXZ

800*800*0.8
870*900*0.8
900*900*0.8

6
7
8
9
10

Inner
Inner
Inner
Inner
Inner

panel
panel
panel
panel
panel

OOM
YBR
YBX
SYY
RXZ

Crux
Libero
YBX
Fazer
RXZ

590*670*0.8
600*635*0.8
620*645*0.8
560*670*0.8
725*485*0.8

11 _
12
13
14
15
16

Body
Body
Body
Body
Body
Body

1-2
1-2
1-1
1-2
2-3
1-2

OOM
YBR
YBX
5YY
YBA
RX-100

Crux
Libero
YBX
Fazer
Enticer
RX-100

480* 1050*0.8
472*631 *0.8
674*528* 1.2
502* 1260* 1.2
416* 1020* 1.6
626*518*1.0

17
18
19
20
21

Body
Body
Body
Body
Body

1-1
1-1
1-1
1-1
1-1

OOM
YBR
SYY
RX-100
RXZ

Crux
Libero
Fazer
RX-100
RXZ

227.5*_900*1.2
225.5*545*1.2
236*550*1.2
267*1100*1.2
272* 1100* 1.2

22
23
24
25
26

Front fender
Rear fender
BKT-En ine
BKT-En ine
BKT-Member

OOM/Rx
OOM/Rx
Rx
YBX
Rx

Crux/Rx-100
Crux/Rx-100
Rx-100
YBX
Rx-100

270*820*0.8
335*600*0.8
265*600*0.8
250*900*2.0
163*1200*2.0

TOOL ROOM
Tool room manufacturing the various tools, designed
by tool design section like press tool, jigs & fixtures,
gauge templates, cames, boring bars,
etc.
45

Tool breakdown & wears out after certain quality

of production. These tools are repaired in this
section. This section consist of the following
machines:
1. Centre Lathe

3 NoS

2. Milling Machine

2 NoS

3. Shaper Machine

1 NoS

4. Cylinderical &Surface
grinder
5. Pedistal Grinder

3 NoS Grinder
2 NoS

This section designs press tools, welding fixtures,

functional gauges, setting templates etc. The
design drawing are released for tool fabrication, in
the tool room through process engg. and
production planning & control
6. Power Saw
1 NoS
This section plans & procures the machine
identified in the process specification sheet. These
machines are mostly purchased from outside source
such as HMT, XLO etc. or imported from abroad, if no
suitable indigenous source exists. In addition some of
the machines are developed in our SPM section
depending on the cost, sophistication & urgency.

46

The tools manufactured are tried out for their

performance and if necessary information for tool
modification is conveyed to the concerned tool
design section & tool room The tool are handed over
to PP& C department only after satisfactory results
have been achieved. Production Planning & Control
department then issues the tool to the respective
production shops This section prepares cost & time
estimate of the tools to be manufactured in the tool
room from outside parties. It also prepares complete
schedule of the tool manufacturing working out its
priorities based on the project in hands. This section
also maintains proper upkeep of all drawing and
provides necessary blue prints of the drawing to be
concerned departments & sections.
Tool room have the various tools used for
machining like reamers, single point cutting tool,
milling cutters, drills etc.

MILLING CUTTER:
Traditional mold making can be a slow, multi-step
process, especially if the mold maker uses the "drill
and whittle" method. This operation requires the
mold maker to drill an access hole in the work piece
and then, after changing tools, slowly whittle away
material with an end mill. Productivity drops with
each tool change, and it can be impaired further if
excess tool overhang, cutter vibration, or insecure
fixturing forces the mold maker to reduce cutting
speed.
Some manufacturers producing medium-to-large
molds are tackling these problems by using a high
performance line of milling cutters. These cutters
eliminate the need to drill an access hole by offering
a variety of work piece entry methods. Where space
permits it, the tool can machine holes in solid
material using helical interpolation. In other
47

situations, the cutter can ramp into the work at an

angle or plunge into it in the z-axis.
Once one of these preliminary steps is completed, the
same tool can cut into the work along the x- and yaxes the way a standard face mill can. A mold maker
with a single ramp/plunge/face mill cutter and CNC
programming can perform operations that formerly
might have taken a number of tools and setups and
significantly longer machining time.
When ramping and plunging, the inserts cut with
their inside and outside edges at the same time. This
simultaneous cutting action can reduce machining
time by as much as 80% in cavity production
operations compared to other types of cutters, which
incorporates high-shear insert geometry to promote
free cutting action and improve the surface finish, as
well as by large chip gullets and screw-on inserts to
facilitate chip flow. Because the high-positive
geometry of the tools expels chips well their
performance is nearly equivalent on either horizontal
or vertical milling machines.

48

Single-Point Cutting Tool: There are many types of cutting tools for different
operations. Below is shown a few of the variety, here
shown with a tool holder adapter that fits into a
larger tool post fixture.

49

KNURLING: -Knurling is an operation used to

produce a texture on a turned machine part. Handles
are often knurled in order to provide a gripping
surface. The two wheel inserts shown on the tool
below contact the work piece, and with pressure,
cold-form a pattern into the surface of the part.

BROAD NOSE FINISHING TOOL

It is not practically possible to produce a hole of the
exact size through drilling, In order to achieve this,
i.e to produce the exactly round and smooth hole of
correct size, the same is drilled a little size and
then reamed. Reaming can be done both by hand
50

and machine. This operation of reaming involves

the use of a multitude tool called REAMER.

HAND REAMER: -

51

rollers with diamond pattern on edges

52

REAMERS : SHELL REAMERS :

NNIANIM

53

EXPANSION REAMERS:

TAPERED REAMERS: -

JOBBERS REAMERS: -

HIGH SPEED STEEL REAMERS

The Center Lathe is used to manufacture cylindrical
shapes from a range of materials including; steels
and plastics. Many of the components that go
together to make an engine work have been
manufactured using lathes. These may be lathes
54

operated directly by people (manual lathes) or

computer controlled lathes (CNC machines) that have
been programmed to carry out a particular task. A
basic manual center lathe is shown below. This type
of lathe is controlled by a person turning the various
handles on the top slide and cross slide in order to
make a product / part

THE CENTER LATHE

HEADSTOCK:

55

HEADSTOCK

The headstock of a center lathe can be opened,

revealing an arrangement of gears. These gears are
sometimes replaced to alter the speed of rotation of
the chuck. The lathe must be switched off before
opening, although the motor should automatically cut
off if the door is opened while the machine is running
(a safety feature).
Using the gear levers usually sets the speed of
rotation of the chuck. These are usually on top of
the headstock or along the front and allow for a
wide range of speeds.
However, sometimes the only way to set the lathe to
a particular speed is to change the gear arrangement
inside the headstock. Most machines will have a
number of alterative gear wheels for this purpose.

56

CYLINDRICAL GRINDER

Technical details:
Max diameter external grinding: 400 mm
Max diameter internal grinding: 340 mm
Distance between centers: 2000 mm
Max weight of work piece in chuck / between
centers: 250 / 30 kg
Longitudinal travel of the table: 1 - 690 mm
Max turning angle of the table: 8 deg
Longitudinal feed of the table ( stepless): 50 - 5000
mm/min
Automatic transversal stroke of the grinding wheel
headstock during reverse of the table range: 0.005 57

0.05 mm
Hydraulic rapid stroke of the grinding wheel
headstoke: 60 mm
Max turning angle of the work piece headstock: 90
deg
Revolution speed of the grinding wheel spindle:
1470 RPM
Spindle cone: 5 Morse' a
Tailstock cone: 5 Morse' a
Grinding wheel dimensions: 500 x 80 x 203 mm
Main engine power: 7.5 kW
Dimensions: 5350 x 2320 x 1770 mm
Weight of the machine: 6550 kg

TOOL RESHARPENING SECTION :

In this shop different types of tools like drill,
reamers, milling cutters etc are resharpened and
grind on different machines like tool and cutter
grinding machine etc. Honing and honing tools are
not resharpened in this section, these are sent to
central lab of the company. The dies used in Deep
Drawing process in press shop are also maintained
here only. This shop is located just opposite to Press
shop.

58

MACHINE SHOP
In this shop, various forged and cast components of
the engine are machined after machining process,
they are sent to engine assembly shop. There are
around 260 machines, mostly COMPUTER NUMERICAL
CONTROL ( CNC ) Machines. Most of the machines are
imported from Japan. Some of the special purpose
machines are of X.L.O. made, brought from Mumbai.
CNC Machines use FANUC-6T or ATB programming.
In this shop, a great importance is given to precision
and quality of the component. This is due to the fact
that if there is a slight difference in the engine parts
for e.g in case of Cylinder head, it can cause
difference in the net displacement of the engine,
which can vitiate the engine performance of same
model, which is not desired.
Various components being manufactured here are as
follows:

Crank

Body Cylinder

Cylinder Head

Crank Case 1 & 2

Crankcase Cover
Machine shop has been divided into various lines for
59

manufacturing the above components. In each line,

Machines are arranged in systematic sequence for
the operation to be performed. Various operations
being carried out on different components are as
follows :

Centering

Grinding

Drilling

Chamfering

Tapping

Reaming

Boring

Hardening

Milling

Thread Cutting

Face Milling
Coolant used for most of the operations is Alusol -B
( 8% in water )

CRANK CASE COVER - I :

OPERATION
Face Mill, End Mill, O.D.
Turn,
Chamfer, Ream
Spot Face, Chamfer, R.G.
Bore, End
Mill, Tap
Drill, Tap, End Mill, O.D.
Turn, Spot
Face, Ream
Washing

MACHINE

ENSHU 5300

ENSHU S300

ENSHU 5300
K & Ray Washing Machine
60

Deburr, No Marking, Air

Blow

K & Ray Washing Machine &

manual
Manual

CRANK CASE COVER - II :

OPERATION
Face Mill, Rough End Mill,
Tap,
Fine Bore
End Mill, Chamfer, Back
Bore,
Center, Drill, Ream
Face Mill, Groove, Fine
Bore, Ream,
Back Bore
Washing
Plug Fitting
Leak Test
Deburr, No Marking, Air
Blow

MACHINE

ENSHU S300
ENSHU S300

ENSHU 5300
K & Ray Washing Machine
Manual Pressing Jig
SPMIL Leak Test Machine
K & Ray Washing Machine &

HEAD CYLINDER :
OPERATION
Central Drill, Drill, Spot
Face, Ream
Face Mill, Central Drill,
Drill, Ream
Face & Dome, Spot Face,
Center, Drill
Center, Drilling, Spot

Manual
MACHINE
ENSHU S300
ENSHU

S300

ENSHU

S300

ENSHU

S300

61

Facing
Spot Face, Bore, Chamfer, ENSHU S300
Thread
Spot Face, Chamfer, Drill, ENSHU S 300
Tap
Mill, Chamfer, Center, Drill, ENSHU S300
Tap
Side Mill, Rough Mill, End ENSHU S300
Mill
End Mill, Rough Bore, Fine ENSHU S300
Bore
Center, Drill, Chamfer,
ENSHU S300
Spot Face, Tap, Ream
Washing
Washing Machine
Heating
Heating Equipment
Press Fit Inlet and Exhaust Valve Seat and Guide Press
Valve Guide and Seat
Cooling and Gap Check
Cooling Equipment
Face Mill, Bore, Chamfer, ENSHU S300
Center, Spot Face, Drill,
Tap
Center, Chamfer, Drill,
ENSHU 5300
Ream, Fine Bore
End Mill, Ream
ENSHU 5300
Deburr
Manual
Final Washing
K & Ray Washing Machine
Plug Fitting
Manual Pressing Jig

BODY CYLINDER :
Leak Test

SPMIL Leak Testing

62

Machine
MACHINE

OPERATION
Face Mill, Chamfer, Ream,
Rough
End Mill, Rough Bore
ENSHU 5300
Face Mill, Drill, Chamfer,
Tap,
Chamfer, Spot Face, End
ENSHU 5300
Mill
End Mill, RG Bore, Counter,
Ream,
Fine Bore
ENSHU S300
Washing
K & Ray Washing Machine
Leak Test
SPMIL Leak Testing
Machine
Air Blow, Sleeve Press
SPMIL Sleeve Press
Face Mill, Drill
ENSHU S300
Fine Boring
Widia 2 Spindle SPM
Pre Cooling, Honing,
Cooling,
Grading
Gehring 2P Honing Machine
Cold Washing
K & Ray Washing Machine
Deburr, No. & Grade
K & Ray Washing Machine &
Marking, Air
Blow, Oiling
Manual

CRANK - I :
OPERATION
Centering, Facing
Turning, Facing

MACHINE
Widia 2 Spindle SPM
LMW CNC LATHE LAL2
63

Boring, Facing
Thread Rolling
Key Way Cutting
Hardening & Tempering
External Grinding
Thrust Facing
Internal Grinding
Washing

LMW CNC LATHE LAL2

PRAGA Thread Rolling
Machine
Techno Aid
EMA Induction Hardening
Shigiya External Grinder
Wheel EA 80 K 7V 75S
LMW CNC LATHE LAL2
Toyo Internal Grinder
Wheel EA 60 K 8V 53S
K & Ray Washing Machine

CRANK - II :
OPERATION
Centering, Facing
Chamfer
Thread Rolling

MACHINE
Widia 2 Spindle
LMW CNC LATHE LAL2
PRAGA Thread Rolling
Machine
Key Way Cutting & Rolling ENSHU S300
Drilling, Reaming
ENSHU S300
Hardening & Tempering
EMA Induction Hardening
External Grinding
Shigiya External Grinder
Wheel EA 80 K 7V 75S
Thrust Facing
LMW CNC LATHE LAL2
_ Internal Grinding
Toyo Internal Grinder Wheel
EA 60 K 8V 53S
Washing
K & Ray Washing Machine
Ball Pressing
SPM Press

64

CRANK CASE - I
OPERATION
Face Mill, Drill, Tap, End
Mill,
Ream
Face Mill, Drill, Spot Face,
End
Mill, Ream
Drill, Tap, End Mill, Bore,
Chamfer
Tap, End Mill, Rough
Boring
Reaming, Fine Boring
Centering, Spot Facing,
Reaming,
Fine Boring
Face Mill, Drill, End Mill,
Tap,
Bore, Ream
End Mill, Groove, Ream,
Fine Bore,
Tap
Washing
Leak Test

MACHINE
ENSHU S300

ENSHU S300

ENSHU S300
ENSHU S300
ENSHU S300

ENSHU S300
ENSHU S300

ENSHU S300

K & Ray Washing Machine

SPMIL Leak Testing
Machine
65

CRANK CASE - II
Air Blow, Oiling
OPERATION
Face Mill, End Mill, Spot
Face,
Ream
Face Mill, Drill, Spot Face,
End
Mill, Ream
Drill, Mill, Tap
Spot Face, Drill, Tap,
Rough Bore,
Chamfer
Centering, Drill, End Mill,
Tap,
Rough Bore
Reaming, Fine Boring
XY Probe, Ream, Fine
Boring
Z Probe, Face Mill, Drill,
Tap, End
Mill, Ream, Bore
Drill, End Mill, Ream, Fine
Bore,
Tap, Chamfer
Washing OPERATION
MACHINE Centering,
Facing Widia 2 Spindle
SPM Turning, Facing LMW
CNC LATHE LAL2 Boring,
Facing LMW CNC LATHE

Manual
MACHINE
ENSHU S300

ENSHU S300

ENSHU S300
ENSHU S300

ENSHU S300

ENSHU S300
ENSHU S300
ENSHU S300

ENSHU S300

K & Ray Washing Machine

66

LAL2 Thread Rolling

PRAGA Thread Rolling
Machine Key Way Cutting
Techno Aid Hardening &
Tempering EMA Induction
Hardening External
Grinding Shigiya External
Grinder Wheel EA 80 K 7V
75S Thrust Facing LMW
CNC LATHE LAL2 Internal
Grinding Toyo Internal
Grinder Wheel EA 60 K 8V
53S Washing K & Ray
Washing Machine CRANK II OPERATION MACHINE
Centering, Facing Widia 2
Spindle Chamfer LMW CNC
LATHE LAL2 Thread
Rolling PRAGA Thread
Rolling Machine Key Way
Cutting & Rolling ENSHU
S300 Drilling, Reaming
ENSHU S300 Hardening &
Tempering EMA Induction
Hardening External
Grinding Shigiya External
Grinder Wheel EA 80 K 7V
75S Thrust Facing LMW
CNC LATHE LAL2 _ Internal
Grinding Toyo Internal
Grinder Wheel EA 60 K 8V
53S Washing K & Ray
67

Washing Machine Ball

Pressing SPM Press
Washing
Leak Test
Air Blow, Oiling

SPMIL Leak Testing

Machine
Manual

ENSHU S300:
ENSHU 5-300 "completely synchronized operation
mechanism", one pitch per spindle rotation, enables
fast and accurate tapping from small to large
diameter and the specified tap depth to be definitely
obtained. A function that the spindle returns ten
times faster than the speed during tapping has been
added, resulting in reduced tapping time and
improved accuracy.

Moving Axes
X-Axis
Y-Axis
z-Axis
Number of

TC-S2A
Table
Table
Spindle
14

TC-22A
Table
Table
Spindle
12
68

S-300
Spindle
Spindle
Spindle
16

ports

69

ELECTROPLATING SHOP
CORROSION: - Corrosion may be defined as gradual
eating away or disintegration or deterioration of
metal by chemical or electrochemical reaction with its
environment.

PREVENTION: - To prevent metal from corrosion

various
preventive
measures
are
taken.
Electroplating is one of process used to prevent
corrosion of metal.

In electroplating the freshly cleaned base metal is

made cathode in a bath of Suitable composition
containing, along with other constituents, a solution
of compound of metal being deposited. In other
words we define electroplating is the process to
deposited one metal to another metal by ionization.
The nature of deposited depends upon current
density, the bath composition, the temperature and
the presence of other additives in many cases anodes
of metal being deposited are used and conditions are
adjusted in such a way that rate of dissolution of
anode is same as the rate of metal deposited at
cathode. However, insoluble anodes (e.g. pb or sb-pb
alloy) are used in chromium plating and bath
composition is maintained by adding chromic acid
periodically the electroplating shop is solely
responsible for all zinc, nickel or chrome coatings on
the component. Electroplating is done on component
to enhance its beauty and anti corrosion properties.
There are three types of plating
ZINC PLATING
NICKEL PLATING
CHROME PLATING
70

Nickel coating is done as protective and basic coating

as it has excellent adhesive properties, which form
good base for chrome plating. The nickel plating is
corrosion resistant and also enhances the looks of
the component. It is done on most of components like
rims, front and rear fenders, mufflers etc. the zinc
plating is done generally on sprockets etc. It acts as
anti rust coating.
Once the buffing process is complete on muffler, it is
sent to Electroplating shop.
Operations performed in Electroplating Shop on
Muffler.

Operation - 1
Cleaning of the Muffler using Caustic Soda. It is done
to remove oil or other chemicals from the surface
of muffler.
Soak Cleaner being used currently- SK100
Density - 6 - 10
Concentration - 80 - 100 g/liter

Operation - 2
Water rinse. It is done to avoid contamination of one
tank to another.
The process is carried out at room temperature.

Operation - 3
Anodic cleaning using electricity.
Electrolyte being used currently- Gin Bon -808
Density - 6 - 10, Temperature - 70 - 80C
Alkali Degreasing. Muffler acts as Cathode.
Anode - Mild Steel Plates.
Time - 8 mins.

Operation - 4
71

Water rinse

Operation - 5
Acid Dip.
Acid Used - H2SO4
Concentration - 10% - 15% in water.
H2SO4 acts as Neutralizer.

72

Operation - 6
Water rinse

Operation - 7
Semi Bright Nickel coating.
Contents - Nickel Sulphate- 250-260 gm/liter, Nickel
Chloride - 40-45 gm/liter, Boric acid- 35-45 gm/liter,
Brightener - Antek, G&W.
All above items are mixed in prescribed proportion in
Distill Water.
Temperature- 48-52C , Density - 18-22, pH value 3.8 - 4.2
Anode - Nickel Plates, Cathode - Muffler, Current
Supply - 4amp/decimeter2
Time- 15 mins.

Operation - 8
Tri Nickel coating.
The quantity of Ni2SO4 Decreased but the quantities
of Nickel chloride and Boric acid are increased.

Operation - 9
Bright Nickel - I
In this Operation the quantity of Ni2SO4, NiCl and
Boric acid are in same quantity as in Operation - 7Semi Bright Nickel coating.
Current is kept same at - 4 amp/decimeter2. The
purpose of nickel coating for three times is to
increase the plating life.

Operation - 10
Drag out - This is a container just after operation -9
which is to save solution of Operation - 9. While the
mufflers are taken out of the Operation - 9 container,
the solution left inside the muffler is collected in
Drag out. This solution can be reused.

Operation - 11
73

Water Rinse.

Operation - 12
Chrome coating.
Anode - Lead tin plates, Cathode - Muffler, Electrolyte
- Chromic Acid - Concentration of Chromic acid - 280300gm /liter.

Operation - 13
Water Rinse.

Operation - 14
Neutralizing.
An acid called Chrome kill is used to remove chrome
solution from the surface of Mufflers.

Operation - 15
Water rinse

Operation -16
Hot Air Drier.

74

ENGINE ASSEMBLY
The Engine assembly is located in the New Plant. A
separate hall is provided for assembling engines of
all models. The shop is totally dust proof and
maximum care is taken while assembling engines.
There are two conveyers : - One conveyer is used to
assemble only Four stroke engines and another
conveyer is used to assemble both two and four
stroke engines.
There is SUB ASSEMBLY inside the ENGINE ASSEMBLY
SHOP.
Before various parts are moved to conveyer, various
things are pre fixed. Sub Assembly shop fixes those
components and parts which can not be assembled
on conveyer. Also to save time various parts are
assembled, then they are sent to the conveyer.
Various parts which are assembled in sub assembly
are :CYLINDER HEAD :Cylinder head from machine shop reaches this
section. Various things are fitted in cylinder head.
Firstly Camshaft and bearings bought from vendor
are assembled using pressing machine.
Then valves and oil seals are put into the cylinder
75

head.
Camshaft fitted with bearing is placed in Cylinder
head.
Rocker arm is placed and adjusted precisely.
After all above things are assembled, the sub
assembled cylinder is sent to conveyer.
CRANK SHAFT 1 & 2 :Crank shafts from Machine shop are sent to this
section. Crank shaft 1 & 2 are assembled here only
along with various other things. Then the sub
assembly is sent to conveyer.
Bearings fixed onto the crank shaft.
Camshaft timing chain sprocket fixed onto the crank
1.
Connecting rod along with sleeve bearing fixed onto
the crank and two Crankshafts 1 & 2 are joined using
pressing machine.
CRANKCASE 1s COVER AND MAGNETO :Crank case 1 cover ( made up of aluminium alloy )
from paint shop is sent to this section.
Magneto bought from local vendor is fixed and
tightened. Wire with connectors of magneto are
taken out from the groove provided.
Various other things are also sub assembled here like
Gear shift and Stopper lever, Axel main, Primary gear
shaft, clutch hub with clutch plates and pressure
plates etc.
76

ASSEMBLING ON MAIN CONVEYER: Ball bearings for various shafts are pressed into
crankcase 1 using pressing machine.
Axel main shaft put onto its location.
Crank shaft put onto its location.
Main axel drive fixed.
Ratcheting drum with ball pin fixed.
Balancer for controlling the vibrations placed.
Crank shaft 2 installed.
Star segment placed.
Oil seal for small sprocket, in crank case 1 placed
and fixed.
Crank case 2 bolts are located and tightened.
Oil pump gasket and gear placed and fixed.
Gear stopper ( to stop movement of gear shaft after
4th gear has been locked ) fixed.
Oil stainer fixed.
Kick shaft and Gear fixed at their respective
location.
Gear shifter shaft fixed.
Oil pump gear and rotary filter fixed.
Primary gear located and fixed accurately.
Primary gear connected to Clutch housing gear.
Crank case cover 2 located and tightened.
Kick start lever located and tightened.
Body cylinder ( from machine shop ) with piston
fixed to connecting rod using Dowel pin.
Camshaft chain connected to camshaft in Head
cylinder.
Rotor located and tightened to crankshaft.
Crankcase 1s cover fitted with magneto fixed onto
77

crankcase 1.
Valve clearance checked.
Camshaft timing chain tightened.
Vent for carburetor fixed.
Plug straight screw fixed.
Spark plug fixed and tightened at its location.
Carburetor fixed.
Engine assembling is complete. The conveyer is
connected to Testing Rig. Where engine is checked
on various parameters. Once the engine is given
clean chit, it is ready for Body assembly or to be
exported.

A.I.S - Air Induction System.

Its a small device used by YAMAHA to control the
emissions and to make the engine breath easily while
increasing Fuel Efficiency.
Its a small device which is connected to Intake
Manifold, Exhaust Manifold and Air Filter.
WORKING - Clean Air from Air Filter enters into this
device. There is a small diaphragm inside which
forces the air into 2 pipes- one towards Intake
Manifold and one towards Exhaust Manifold. So in
other words there is one inlet pipe from Air filter and
there are two outlet pipes to Intake and Exhaust
Manifolds. There are two reed valves inside the A.I.S
which does not allow Air Fuel mixture ( From Intake
Manifold ) and Hot Exhaust Gases ( From exhaust
Manifold ) to reverse the working of A.I.S. In other
78

words while air is being forced into the Intake

Manifold, the reed valve does not allow the Air fuel
Mixture in Intake Manifold to enter into the A.I.S.

BENEFITS 1. Connection to Intake Manifold.

Once the Fuel ( petrol ) is mixed in right
proportion with air in Carburetor , the mixture enters
into the Intake Manifold, where fresh air is being
supplied in small quantity via A.I.S system. So while
cruising on high speeds air fuel ratio increases
further, Thereby increasing the Fuel Efficiency.
2. Connection to Exhaust Manifold.
After the Power Stroke the exhaust gases
proceeds towards the Exhaust Manifold - during Last
Stroke and from there it proceeds to the muffler pipe.
The exhaust gases contains CO2 , CO and other
harmful gases. YAMAHA R&D department studied and
found that the CO content in Exhaust Gases can be
reduced in a very simple way. Carbon mono-oxide
which is much harmful in comparison to CO2 , can be
converted to CO2 in a simple manner. From the simple
chemical equation2CO
+
O2

2CO2
We can see that on supplying oxygen to Exhaust
Manifold the Carbon mono-oxide present in Exhaust
Gases easily combines with Oxygen molecule to form
79

Carbon di-oxide, which is not very harmful to the

nature. So pipe from A.I.S , connected to exhaust
manifold helps in reducing the Carbon mono-oxide
content in Exhaust gases.

80

D.C CDI
Direct Current Capacitor Discharge
Ignition.
It is a device which has been manufactured precisely.
CDI is very accurate. CdI is connected to the Ignition
coil. And Ignition coil is connected to Spark Plug. CDI
works on Direct current.
WORKING - To get the maximum power from the
amount of air fuel mixture present in Combustion
Chamber, it is very important that the spark plug
produce the spark at exact timing at the end of
Compression stroke. If the spark plug misfires then
the combustion will not be appropriate, which will
lead to more un-burnt gases, there by increasing
exhaust gases, decreasing the overall performance of
the engine. The life of the engine will be affected and
the efficiency of the engine will be less. But if there is
proper combustion inside the combustion chamber
thereby utilizing the amount of air fuel mixture
present in Combustion chamber, then the efficiency
and life of engine will increase with minimal exhaust
gases. This thing is looked after well by CDI. Also
with increase in engine rpm the spark plug firing
(between two consecutive strokes) time has to be
decreased, otherwise mis-firing will take place. Again
this thing is looked after well by CDI. Its function is to
alter and look after the Spark timing according to the
engine rpm. All this is done by Digital Ignition
Mapping and complex mathematical calculations. So
the exact spark timing is stored in CDI using
81

computer, according to engine rpm. So with the

increase in Engine rpm, spark timing or ignition
timing is controlled by CDI.

BODY ASSEMBLY SHOP

Here different sub assembled parts are either
brought from the vendors or different shops of the
factory and the final product is assembled and
tested. The shop has two lines common to all the
models:
1. Body Sub Assembly
2. Body Main Assembly
The sub assembly line mainly deals with the
production of fully assembled parts, which are parts
of motorcycle body. These parts are then fitted to the
motorcycle body and the main assembly line.

SUB ASSEMBLY LINE:

Here different parts are sub assembled and then sent
to the main assembly line because it is not
convenient to do all the assembly operations on the
main line when the production requirement is large.
So to avoid these difficulties, various sub assemblies
are set up small assemblies are set up in the area of
the body assembly so that the small assemblies
82

(which are not easy to be made on the main conveyor

line and also are time consuming) can be brought
quickly, conveniently and according to the
requirement. For subassemblies raw material is
brought from outside or from other shops of the
company like machine shop. Various processes of the
sub-assembly are discussed below:

83

CLUTCH HUB SUB ASSEMBLY:

A clutch hub takes drive from the clutch and
transmits it to the wheel. The assembly is done in the
following sequence:
Clutch
Washer
lock
Nut bolts

Sprocket rear wheel

Collar
Circlip
Shaft sprocket
Oil seal
Bearings
The clutch is common to all the models but the no. of
teeth on the sprocket wheel differs as follows:
Model

No. Of teeth

RX-100

39

CRUX

39

YBX-125

44

YB-125

44

YD-125

44

FAZOR

45

ENTICER

47

REAR ARM SUB ASSEMBLY:

Bar tension is attached to the rear arm and this is
locked by a lock pin. Bar In the arm sub first a bush is
attached to the topside holes. This bush has a rubber
lining in between for some free play of the rear arm
84

due to the shocks. Now tension stops the brake from

rotating with tyre when the brake is applied. Then a
seal guard is fitted, which prevents the chain from
touching the rear arm.

HUB COVER FRONT / REAR BRAKE SUB

ASSEMBLY:
Here front and rear brakes are assembled. Brake
shoes, which come in pair, are joined with the help
of spring. This is then put into the hub cover. The
shaft then comes in the gap between the two shoes,
which attach it to the hub cover. The shoe lever is
attached to the shaft by means of nuts and bolts.
Both the brakes are similar process of assembling
except the slight difference in the shape of hub
cover, shaft and lever.

REAR FENDER OR ASSTT. GRIP SUB ASSEMBLY:

Here rear fender indicators are attached along with
the taillight and number plate.

YBX METER COWLING SUB ASSEMBLY:

This assembly is meant for YBX model. Here
headlight is attached to the windshield of YBX. Meter
cowling and windshield is placed on a three-way drill
machine with two drills on each chuck i.e. a total of
six drills. Now with the windshield held in the
machine, we switch on the machine to drill all the six
holes simultaneously, on the meter cowling and the
windshield. Then the two are fastened by means of
rivets followed by a rubber lining on the windshield.
85

METER SUB ASSEMBLY:

Here the complete meter assembly is made. Ignition
switch is attached to the pilot lamp. The meter, which
is brought from the vendor, is fixed to the crown
handle with the speedometer wire.

MUFFLER SUB ASSEMBLY:

Here the entire assembly of silencer takes place, in
which assembly of the silencer, silencer pipe and
muffler protector takes place. Here a rubber stopper
if fitted to the side, which acts as the stopper for the
main stand.

BRACKET 1-2 SUB ASSEMBLY:

Here a rubber cover is put on both left and right foot
rests and both these footrests are fastened to the
bracket by means of locking pin.

FRONT FENDER SUB ASSEMBLY:

Here stay fender, which contains the mudguard, is
made. Here stay and the fender are attached to the
mudguard. Stay is used to support the clutch wire.

HANDLE SUB ASSEMBLY:

Here both right and left handles are attached to the
86

holders. Suitable attachments are given on the sides

to support the brake, clutch lever and also to support
their wires. Handles are dipped into adhesive and
covers are put on them.

STAY HEAD LIGHT SUB ASSEMBLY:

Here indicators are fitted on the stay light frame
along with the flasher, which is used to blink the
indicators. Here earth wire is also set with the
flasher.

PEDAL SHIFT SUB ASSEMBLY:

Here on pedal bolts are attached and a rubber cap is
put on to its rear side.

FRAME SUB ASSEMBLY:

Here the frame of the main stand along with the
mudguard is fitted: Damper locators are also fitted
on the frame for side cover and fuel tank. Sub
assembled parts are then brought to the main
conveyor line on respective stages where they are
required. Some accessories such as nut, bolt, battery,
flasher, wires etc. are brought from the stores or
various other shops according to the production plan
of that particular day.

MAIN LINE ASSEMBLY:

87

The word assembly clarifies all about the assembly

line shop. Here all the components are attached to
their respective positions, their results in complete
working bike, From here the loading of motorcycle
takes place, All the components are brought to line
from different shops, after undergoing different
operation with the help of different types of trolleys.
In the assembly line the frame moves on the
conveyor. Conveyor consist of fixtures attached to it ,
in which the frame is clamped. This fixture has
function of central stand The frame has pass from
different stages. In each stage particular operation is
done.

CONVEYOR SPECIFICATIONS:
Conveyor Length
Conveyor Speed
Pitch Time
Total Running Time
Production in One Shift
Production Rate

75m
2.04 m/min
67 sec/vehicle
445 min/shift
670 Vehicles
80 Vehicles/hour

The main line specifications are as follows:

Main stand is fixed to the frame along with
the spring for side stand.
Rubber support for the petrol tank is placed.
88

The bearings in it with the help of frame no

Serial no. is punched on the frame along with
Punching machine.
Now frame is clamped on the conveyor line.
Rear Fender is fixed.
Front fender is fixed to the shocker assembly (
bought from vendor )
Front shockers are fixed on to the frame.
Foot-rest & Side stand are fitted.
Wiring with connectors are placed on the
frame and tightened using tape.
Check nut along with ball bearing placed at
handle point.
Rear Shockers with swing arm located into
their respective position.
Parts of rear fender is fixed.
Swing arm Bracket is fixed.
Tail light assembly is fixed.
Engine Mounted onto the frame.
Front wheel is taken, brakes are located in the
drum and fixed and tightened.
Barcode reader is used to maintain the record
of engine no. and its frame no.
Apply black paint on the chassis no.
Ignition coil and the Horn unit connected with wiring
harness.
Rear Sprocket is placed.
Front no. Plate bracket fixed.
Chain puller or chain tensioner fixed in the rear
swing arm.
Rear tyre with brakes fixed.
Head light stay fixed.
89

A.I.S unit and R.R unit fixed.

Engine Bracket fixed and tightened.
Speedometer sub assembly located and tightened.
Air filter placed and connected to the venturi side of
carburetor.
Meter wire connected to meter assembly
A.S.I connected to intake manifold, Exhaust
manifold and Air filter.
Handle tightened using clamps.
The race wires from the handle bar is connected to
the engine
Chain Locked and rear brake pedal fixed, adjusted
and tightened.
Chain cover fixed.
Indicators both front and rear are fixed and wires
connected.
Sari Guard located and tightened.
Nuts and bolts are checked regularly, tightened.
Rear wheel nut bolt tightened and cotter pin bent.
Silencer side bracket fixed.
Silencer located and fixed, connected to exhaust
manifold.
Battery case placed and nut are tightened.
CDI connected.
Front Brake fixed and tightened.
Small sprocket cover fixed.
Gear pedal placed and adjusted to its desired
position.
Fuel tank, rubber support under seat fixed.
Fuel tank fixed and side scoop located and
tightened.
Front wheel nut tightened and cotter pin bent into
90

the hole.
Seat placed and fixed.
Head light assembly and front number plate fixed.
Side panel placed and locked.
After the assembling is done Bike is checked like
engine noise, lights, indicators, throttle response,
meters, pick up, chain noise. Bike is taken to speeds
above 60 kmph on the testing rig.
Bikes are thoroughly checked. Also it is ensured that
there is no scratch on the body, fuel tank, muffler
and other parts. Pollution levels are checked.
Once thorough Inspection is done Bikes are ready to
be dispatched.
Marketing department maintains the record of every
bike and the dealer name where the bike is being
sent.
If the bike is to be Exported as Complete Built unit
then it is sent to Export Department.

91

STORES
Raw Material Store
This store is situated near press shop. Here sheet
metals ( mild steel sheets ) of different thickness are
imported from Germany or bought from local vendor.
For casting of different components aluminium alloy which is a combination of Aluminium, Copper and Iron
, is either imported or purchased from international
market or bought from local vendor. This metal is
then sent to Faridabad plant for casting, where
different components are made in various firms.
Metal Pipes for frame are bought from TATA Steel ,
Jamshedpur.

Store For Welding/Paint/Plating parts

This store is situated near Welding shop. Here more
than 300 parts ( large and small ) are bought from
industries situated in Delhi, Faridabad and Yamuna
nagar. Some Components such as Muffler, Front and
rear fenders and Rim are sent for Buffing and
polishing in some nearby industry.

Other Manufactured ( Bought ) parts store

This store is situated near Body assembly so that
direct feeding can be done to main body assembly
and sub-assembly. Some of the materials such as
Tyre, Head light, Front fork, double seat etc are
92

directly sent to body assembly after inspection. Most

of the industries supplying these materials are
situated in Gurgaon, Faridabad, Delhi and Noida.
Engine Parts in which high quality and precision is
required are imported from Japan. Some of these
parts are Carburetor, spark plug, primary and drive
gear, piston, piston rings, oil pumps etc.

Machine Shop Parts

Here casting material such as crankcase, clutch,
cylinder head, body cylinder, crank etc bought from
vendors in Patiala and Faridabad.

Route For B.O.P

VENDOR

GRE

COUNTING
IDENTIFICATION

RECEIVING

TAG

ENTRY

INSPECTION

RECIEPT

No.
ok
PICK UP

INSPECTION

LINE
SAMPLES
reject

93

IF

VENDOR

REJECTION

INFORM
STORE
PURCHASE

Non Productive Store :

In this store various raw material, stationeries,
dhotis, globes etc are stored which are not used
directly in production but necessary for production
such as- stationeries are used for paper work in the
plant for cleaning purpose of machine and other
things. Globe are used by workers for working.

EXPORT AND MARKETING

The Export and Marketing division is situated with
Body Assembly Shop. The marketing division is in
Faridabad Plant. In this plant only vehicles are
packed for export to various countries. The countries
to which bikes are exported are :SKD ( Semi Knock Down )
Singapore
South Africa
Paraguy
Nicaragua
Kenya
Sudan
Jamaica
EL Salvador
Ecuador
Cuba
Costa Rica
94

Peru

 Congo
Angola
IKD
France
Colombia

Chile
Sri Lanka

Philippines

CKD ( Complete Knock Down )

Mexico
Nigeria
Bangladesh

The export is on order basis. Various models being

exported are Libero, RX-100, Crux, Fazor, 5RE, YBX,
YD-125.
The year digit are not punched on the chasis frame
and also on the engine of the bike, which are to be
exported.
The Packing of the vehicle in wooden box follows the
following procedure :-

95

Anti Rust Spray Operation:

Vehicle is loaded on the platform. Cleaned with a
cloth to remove any kind of rust.
Anti rust oil is sprayed on all the parts of vehicle
except seat.

Dismantling Conveyer
First the bike is loaded on the conveyer and the bike
is fixed from stand using jigs and support. The engine
is also supported. The bike is then dismantled - head
light, speedometer, rear light, front and rear fender,
handle bar, footrest sub-assembly
, front wheel, rear wheel, handle bar. All these parts
are packed in different polythene packs. Seat is
packed in a box. Head light, tail light, all wires,
speedometer and all other small components along
with owners manual are packed in one big box in
pairs, for two vehicles. The left vehicle parts are also
covered by polythene paper and asbestos foam
individually. Now the vehicles are placed on a
wooden block platform in pair. The two boxes are
placed on the front and rear side. The front and rear
fenders along with handle bar are placed on the
block. The four wheels are placed on the side panels.
First whole assembly is covered with polythene cover
and then the wooden block is covered from the top,
front and rear. Now the wooden block are ready to de
dispatched.
96

Engine :
Engines of few models such as 5RE, are also exported
to other countries and also to the M.S.D Faridabad.

97

Anti Rust Oil Spray Operation :

Engine is placed on the platform and cleaned by
compressed air.
Anti rust oil is sprayed.
Then engine is packed in polythene packet, all the
details are maintained and then engine is placed in a
Thermo coal box.

Loading of Bikes :
In this shops the vehicles to be dispatched are placed
in rows. There are three Hydraulic lifts for loading the
bikes onto trucks.

98

A
SPECIAL
REPORT
On

YAMAHA
FAZOR
GET GOING

99

YAMAHA FAZOR
YAMAHAs latest offering for 125cc
Segment.
With the Indian consumer shifting on the bikes
with greater engine capacity, which not only provide
power and better top speeds but are also
economical. With the 125cc segment getting more
Hot day by day, and launch of various bikes in this
segment like VICTOR 125 , KAWASAKI BAJAJ WIND
125, LML FREEDOM PRIMA , FAZOR is YAMAHAs
answer to other companies.
Fazor with most Unconventional looks and high
quality levels has raised the eyebrows in
automobile field. FAZOR name being carried out
100

from the World famous YAMAHA FAZOR which is a

sports bike. Yamaha Fazor has been designed in
Japan but keeing in view the mindset of Indian
people. So it can be said that FAZOR is Japenese
bike with Indian SOUL.

101

DESIGN & ENGINEERING

With the most unconventional Head light fairing
Yamaha has tried to give Fazor an altogether
different look, and have succeeded in that. Head
light fairing sets it apart from its competitors which
is very FUTURISTIC. With the headlight generating
reviews, The designing is either Love it or Hate it
type as quoted by famous automobile magazine
AUTOCAR. Yamaha has used Electrostatic Painting
Technique which gives Fazor high quality Lustrous
finish. The paint is deep. Yamaha has preferred not
to use any stickering or decals which again gives a
different appeal among bikes of similar category.
The dummy side scoops on fuel tank give Fazor a
muscular look.
Another different thing about the Fazor is the
Styling of MUFFLER ( silencer ). Silencer looks good
with bike along with decreasing the sound
effectively. The quality of plastics is very good and
instrument panel is easy to use and of good quality.
Another eye catching feature is Tail light with
integrated indicators.

102

ENGINE AND PERFORMANCE :

Fazor is having single cylinder, Four stroke, 125cc

air cooled engine. Engine breathes through two
valves. And Fazor meets 2005 emission norms,
making it a more preferable bike. The engine has
been designed to generate 10.8 bhp @7500 rpm
and 1.06 kgm of torque @ 6500 rpm. To make more
environment friendly Yamaha has installed A.I.S
system in the bike which not only increases
efficiency but also helps in reducing CO content in
exhaust gases.
Ignition system is operated using CDI, which is
another device helping increase efficiency. The
carburetor is Mikuni BS 25 unit with Butterfly and it
employs a valve to read variable cylinder-suction
and accordingly compensate air fuel mixture. This
ensures smoothness under any riding condition.

103

Another new thing by Yamaha in Fazor, is YTPS TM

-which stands for YAMAHA THROTTLE POSITION
SENSOR which is responsible to give good fuel
efficiency in any driving condition. Ignition timing
does vary with engine rpm , but throttle position
also assists the same. When the engine is revving
high but the throttle is shut, fuel will be saved and
not sent rushing in. On the other hand, YTPS
benefits the engine when rpm is low and throttle is
cracked wide open.
There is a Balancer added in the engine, crank
shaft which throws equal and opposite force back
to the crankshaft to flatten out the vibrations. The
engine is refined, knock free.
The light clutch using asbestos free friction plate
gives good feel when let go. On leaving the clutch,
in 1st gear the bike lunges ahead with ease. But lack
of fifth gear does make it feel slow while reaching
top speeds. The top speed is around 105 kmph (solo
).
RIDE AND HANDELING :The frame is Single Down tube type. Which
effectively makes the bike stable at any speed.
Wheel base at 1300 mm is the longest in its
segment and makes cornering very easy. The bike
rides on Dunlop Zebra, which gives the bike very
104

good grip on any surface.

One of the strongest point of Fazor is the
comfortable seat, which is preferable for long
drives without giving any fatigue. Short handle
makes controlling of bike easy. Front 150 mm drum
brakes does the every job of stopping the bike
without any problem. Rear brakes at 130 mm are
also effective.
FUEL ECONOMY :Various features like YTPS , CDI are not just sale
gimmicks, they do help bike give all round good fuel
efficiency. With 60 Kmpl in city conditions, Fazor is
going to give good head aches to other bikes.
CONCLUSION :A good effort by YAMAHA for most competitive
segment these days. A bike with all good features
which are desired to be present in 125 cc Urban
Commuter. Excellent ride quality, International
styling, good fuel efficiency, Finest build quality in its
segment, good suspension makes FAZOR all rounder.
HATS OFF to YAMAHAs creativity.

105

106

TWO PROJECTS WERE COMPLETED

DURING THE COURSE OF TRAINING.
One was regarding the Noisy muffler of Fazor. And
it was completed under the guidance of Mr. Kamal
Khurana, from Tool Design Department.
Second one was designing of a JIG for riveting
machine in Engine Sub-Assembly Department. And
the designing was done under the guidance of Mr.
Kamal Khurana & Mr. Uday , from tool design
department.

107

Report - 1
Till 20th July 2004, 6000 Fazor bikes were out in
the Market. The people have given warm response
to the bike, keeping in view good Sales & Service
provided by Yamahas dealers. Yamaha
understands the needs and requirements of Indian
consumer. Yamaha believes in providing world-class
products to its loyal customer. While manufacturing
and assembling, it is always ensured that nothing
goes wrong in manufacturing, maintaining high
quality levels. All the parts are checked thoroughly
for quality levels, if there is any defect in part it is
taken into scrap. After assembling the bikes are
checked various times, before they are sent out to
the market.
But after all bike is a machinery, and sometimes
things go do wrong.
It was reported by one of the dealers that - in one
of the Fazor, a customer reported an irritating
noise. So people in marketing department
consulted to Quality department. It was decided
that to bring the noisy muffler to plant and conduct
testing about what actually went wrong. Yamaha
also satisfied the customer by replacing the
silencer with new one.
The silencer was brought to the R&D department.
For me, It was a great opportunity to work under
such experienced engineers.

STUDY OF THE PROBLEM :

After the Noisy muffler was brought into the plant
for testing, it was fixed to a new bike for the study
of the problem.
108

It was observed that after few kilometers of

running, there was a different noise from the
muffler, like of metal striking, which was abnormal
phenomenon. The reason for such noise was
unknown. It was found that once the muffler heats
up, the noise continues.
VARIOUS POSSIBLE REASONS :
1. Reinforcement for the perforated pipe might
be vibrating.
2. Some loose pipe in Partition 1-2, 1-3, 1-4.
3. Welding or Electroplating spatter might be
vibrating.
4. The outlet pipe at mufflers end might not
have been pressed fit
properly.
5. Catalytic converter might not have been
welded properly.
6. Some dimensional inaccuracy can also be
the possible reason.
As to produce
mufflers with same sound quality, the overall
dimensions of all the mufflers have to be same.
For better testing the muffler was
disassembled, like it was before assembling.

Lets just have a look at various parts inside

the muffler.

109

110

MUFFLER IS MADE UP OF VARIOUS PARTS

1. Muffler end, cap with pipe press fit and welded.
2. Body 1-1, outer pipe of diameter- 100 mm.
3. Muffler heat shield.
4. Partition 1-2, 1-3, 1-4 (responsible for
cancellation of noise).
5. Reinforcement for perforated pipe ( not visible
here in the picture).
6. Conical part , Body 1-2.
7. Joint of Body 1-3 and Body 1-2. At this point
there is a Catalytic converter to control the
emissions.
8. Bent pipe, Connected to exhaust manifold,
consist of two pipes, outer pipe dia - 35.20
mm.Inner pipe dia - 22.36 mm. The reason for
using two pipes as exhaust pipe - It is generally
seen that electroplating on the exhaust pipe,
turns yellow after some time. Reason for faded
electroplating is that- the temperature of
exhaust gases are very high, on regular heating
and cooling of exhaust pipe the electroplating on
the exhaust pipe burns. The burning of
electroplating is avoided by having two pipes of
different diameters with air as insulating
medium between them. On providing two pipes,
the outer pipe does get heated up but
temperature is relatively very less to cause
burning of electroplating.

111

DATA COLLECTION :
Data was collected about various parts and
various things were checked. Like..
Dia of pipes.
Bend angle of Body 1-3.
Presence of spatter checked.
It was also checked that there could have been a
loose particle which might have gone inside
unknowingly while the usage of the bike.
The pipe at muffler end, which is press fit in
partition 1-4 - might be loose and vibrating at
partition 1-4 - inside the body 1-1.
Reinforcement provided for perforated pipe at
point 5 (in picture) might not have been weld
properly by operator and could be the possible
reason for noise, because of the vibrations.
Catalytic converter might not have been weld
properly and might be vibrating.
The outer pipe of bent tube is made to grab the
inner pipe using press fit machine. It was quite
possible that the press fit was not done properly
and according to the accurate dimensions.
Any unknown reason also not ruled out.
DATA ANALYSIS :
After considering all the aspects & analyzing all
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the data collected, it was found that - there was no

welding spatter or any particle inside the muffler,
the pipe diameters were found to in tolerance zone,
catalytic converter was welded properly, the pipe at
muffler end was pressed fit properly, reinforcement
was not vibrating, bend angle was accurate. But the
press fit in Bent pipe at point 2 was found to be not
done properly.

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Now the problem was known.

BENT PIPE

In the above picture, shown is the bent pipe. The

outer pipe at is pressed fit to inner pipe at points 1
& 2. It was measured that, at point 2 the diameter
were beyond tolerance zone.
The outer pipe is compressed using press fit
machine, so as to hold the inner pipe tightly. The
hold should be sufficiently strong so that the inner
pipe should not displace till loads above 120 kg are
applied when tested on UTM.
The actual figures of press fit are shown on next
page. The total region of press fit is 8 mm - 12 mm.
But it was found that the press fit region in faulty
silencer was 7mm only.
Also the inner pipe allowed out of the press fit
region is 0.5mm - 4 mm. But it was observed that in
case of faulty mufflers bent pipe it was 5 mm.
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It was also observed on measuring Outer dia. of

outer pipe in press fit region, it was found out to be
24.86 mm ( avg.) but the required dia. 24.60 mm.
Also some ovalty was observed in inner pipe after
press fit operation, which is undesirable.
LIST IF POSSIBLE SOLUTION :
Replace die with new one.
Assign the job to a more skilled operator.
Clean the die thoroughly if not worn out.
Check for the pipe dia. regularly.
Check the viscosity of hydraulic oil used in press
fit machine.
Check various other parameters of the machine.
SOLUTION IMPLEMENTED :
The die was cleaned thoroughly. It was found that
lot of small iron particles were sticking to the wall
of die, stopping it from getting compressed
properly. When data was collected again it was
found that Outer dia. of Outer pipe in press fit
region was coming out to be 24.74 mm, which was
still not in tolerance zone.
So the die was dis-assembled and cleaned more
thoroughly using petrol. After cleaning the die was
assembled properly. On recollecting the data again
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the Outer dia. of outer pipe was found to be 24.68

mm - which is in tolerance zone.
RESULT REVRIFICATION :
The data for more than 30 pipe were taken. The
average reading came out to be 24.66 mm. So the
problem was solved.
DATE OF IMPLEMENTATION :
25th July 2004.

REPORT - 2
BACKGROUND:
It was informed to Tool Design department, by
Supervisor of Engine Sub-Assembly shop, about the
frequent breakage of riveting punch, used to perform
riveting operation on Gear shift and stopper lever of
Two stroke engine.
STUDY OF PROBLEM :
On the inspection of machine, it was found that, the
rivet formation was not accurate. After 100-110
rivets, the riveting punch got blunt and broke on
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further usage. It was recorded that, around 4 - 5

punches were replaced in each shift. The average life
of each riveting pin is around 200 - 225 rivet.
DATA COLLECTION :
Various aspects were looked. And the dimensions
were recorded.

Stopper Lever

DATA ANALYSIS :
It was found that while riveting the operator was
using his hand to hold the stopper. Due to which the
job moved leading to irregular and non-uniform
riveting. This also lead to blunting of Riveting punch
and of further use, the riveting punch broke. So
frequent riveting punch replacement were carried
out, which lead to slow production rate and being
more costly affair.
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LIST OF POSSIBLE SOLUTION :

Providing a proper JIG for the operation.
Replace the Riveting punch with a punch of harder
material.
Proper holding tool to ensure the job does not move
while riveting is done.

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SOLUTION IMPLEMENTED :
Since designing a new jig was the most efficient
solution so a new jig was designed. Since Gear shifter
lever was also Riveted on same machine with the
help of a different Jig, which was removable with out
needing any tool, so a new JIG for stopper lever was
designed, which could also be removed without
needing any tool. The design of the jig is shown on
the next page.
The new jig design was approved and sent to Tool
Room for manufacturing.

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