11th June 2015

INTERNSHIP REPORT - SUMMER

2015

SUBMITTED BY:
Abdus Saboor Khan
Maaz Qayam
Usama Suhail Quddusi
NED University, Karachi

SUBMITTED TO:
HR DEPARTMENT
AGRIAUTOS INDUSTRIES.LTD

ACKNOWLEDGEMENT
The internship opportunity we have with Agriauto Industries Limited has really been honor for us. We
are also grateful for the coordination showed by Immediate/Line Managers and Senior Executive
enabling us to have the great practical exposure in the field of Automobiles sector
By taking this opportunity we would like to express our gratitude to Mr. Nadeem Athar-Technical
Director and Mr. Kalimullah-General Manager Technical who really been so compassionate during entire
period.
Secondly we express our deepest thanks to Mr.Farhan Siddiqui -Manager PE department for taking part
in useful decision & giving necessary advices and guidance and arranged all facilities to make life easier.
It is our radiant sentiment to place on record our best regards, deepest sense of gratitude to Mr. Saeed
Ahmed-GMP, Mr. Zia Alam-DGM, and Mr. Tabish Azmat-Mgr HR for their careful and precious guidance
which were extremely valuable for our study both theoretically and practically.
We believe this opportunity as a big milestone in our career development and we will strive to use skills
and knowledge acquired during the tenure in the best possible way, and we will continue to work on
their improvement, in order to attain desired career objectives. Hope triggers the career path amongst
such dynamic professional team in the most congenial environment.

OBSERVATIONS
CHROME PLANT
1.
2.
3.
4.
5.

Chrome tank is not covered properly and fumes spread in overall area.
Workers do not use leather shoes instead they wear normal sleepers.
No mask protection by workers.
Drag out process is not performed by workers.
The floor is too much wet and chances of slipping quite high.

TWO WHEELER PLANT

1.
2.
3.
4.

Pedastal Grinding machine is not covered properly.

Nickel plating must be done inside industry like chrome plating.
Cleanliness issue was due to improper suction.
Office stairs are not designed properly.

YAMAHA PLANT
1. Dust free area for production.
2. Advance torquing and oil filling machine available.
3. Women oriented plant.

SHOCKS AND STRUTS PLANT

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Oil drums are not properly covered during filling of oil in oil filling machines.
No ear protectors wear by workers paint and press plant.
Scattering of chips of backup milling machine.
Over loading of outer shell in trolley (SHOOTER).
Improper placing of trolley in the morning time (at starting of shift).
No leak test is performed during heavy production load in welding line.
Unsafe robotic arm of spinning machine at KAYABA Cell.
Variation in oil quantity is observed when CPk was studied.
No first aid training for floor staff.
Changing issue of grinding wheel, no jig crane is available.
Rabotic arm should be used for the handling of all the pieces (weld line).
Face guard should be use properly by the worker.
Preventive maintenance schedule is not followed due to heavy load of production.

QUALITY LAB
1. No rack for shoes.
2. Destructive testing machine not in use.
3. Vickers hardness machine not used.
2

RESEARCH & DEVELOPMENT

1. CMM machine not in use.
2. Salt spray test was not carried out.

PRESS SHOP
1. No buffer stock available for the required parts.
2. Preventive maintenance schedule is not followed due to heavy load of production.

EXECUTIVE SUMMARY
The journey in AGRIAUTO industries was full of learning and it proved to be an important part of our
career. Following goals were set by us for our internship period.

TARGET:

Shocks and struts

Rod line

Weld line

Chrome plant

Assembly line

Paint shop

Quality room

R&D lab

Maintenance department

Design & development

TARGETS ACHIEVED:

Shocks and struts is the largest plant in Agriautos which was observed in detail.

Rod line was observed different processes like hardening , tempering, grinding, milling buffing
and polishing were observed.

Weld line processes like Knuckle bracket welding, MIG welding, CD welding, lower cap stacking,
hose bracket welding, hole punching, stabilizer bracket welding and leak test

Tube line processes like chamfering, washing, parting off, necking, boring & threading and
marking etc were observed.

Paint shop processes like washing, drying, painting, curing etc were observed.

Kayaba Gabriel assembly processes like torquing, nut caulking, riveting, base valve stacking, oil &
gas filling damp force testing etc were observed.

Two wheeler plant was observed and manufacturing of pipe fork, piston rod, case damper for
Honda plant and assembly of shock absorbers in Yamaha was observed.

Parting cell is the main plant for providing rods and tubes for shocks and two wheeler plant.

Press shop processes like forming, blanking, piercing, trimming and different type of hydraulic,
pneumatic and mechanical presses were observed.

Shiroki processes for the manufacturing of door hinges and window regulator were observed.

Quality Room inspection was performed by ourselves and different machines operations like
profile projector, surface tester, hardness tester, gauge checking were learned and performed.

R&D lab operations including Damp force testing, GRF testing, Endurance testing, Friction
testing, Temperature testing, Durability and Salt spray testing were learned and observed.

Maintenance Department processes like predictive, preventive, breakdown and corrective

maintenance were studied and analyzing techniques were learned.

Kaizen activities were performed.

Will be working on an on going project and completing it very soon.

TARGETS NOT ACHIEVED:

Design and development department could not be studied due to lack of time.

SAFETY KAIZEN # 1
PROBLEM
No standard criterion is there for changing of grinding and regulating wheel. The grinding wheel shown
below is heavy weight and during maintenance, if wheel drop from certain height then it might risk the
life of workers or the people directly under the wheel.

RECOMMENDATION

To eliminate unsafe and fatigue handling of grinding wheel change.

JIB CRANE and HOIST is recommended for lifting grinding wheel and to rectify the problem
discussed above.

SAFETY KAIZEN # 2
PROBLEM
The grinding machine shown below is harmful for the operator and people in working environment
during operating condition as there is no cover on overall wheel. Especially the person coming from side
wall may suffer a lot.

RECOMMENDATION
Covered grinding machine must be used to overcome the dangers. For this CLARKE GRINDING MACHINE
is recommended.

KAIZEN:
5S has an important role in industry. It improves the workers safety and helps company to increase its
production and reduces process time as well. 5S is defined as:
1.
2.
3.
4.
5.

Sort
Set in order
Shine
Standardize
Sustain

It also improves the quality of product and must be strictly followed in an organization.

Problem

Handling of shell after spot welding is a problem as it is too hot and hard to hold.
Recommendation

Installation of a robotic arm is recommended to lift shell after welding and place it on stand.
It will reduce the time of handling and will increase the safety level.
Any special instrument can also be used for lifting of the shell.

Problem

No cleanliness in manufacturing deparments.

Recommendation

Cleanliness is an important part of safety. Cleanliness level must be improved.

For better quality of parts plants must be made dust free.

Problem

Manual straightening much time consuming and less accurate.

Recommendation

Straightening must be made automatic.

Problem

Cooling issue for tempering

Recommendation

For effective cooling air cooler must be used to reduce tempering time.

Problem

Chips generating as a result of milling are harmful for workers.

Recommendation

Safety level must be increased and milling machine should be properly covered to safe workers from
harmful material chips.
Problem

Drag out tank not properly used.

Recommendation

It must be made necessary for workers to follow all steps in a process as drag tank is necessary to
stabilize chemical in electrolytic tank.

Table Of Contents
ACknowledgement ........................................................................................................................................ 1
Observations ................................................................................................................................................. 2
Chrome Plant ............................................................................................................................................ 2
Two Wheeler Plant.................................................................................................................................... 2
YAMAHA Plant .......................................................................................................................................... 2
SHOCKS And STRUTS Plant ........................................................................................................................ 2
Quality Lab ................................................................................................................................................ 2
Research & Development ......................................................................................................................... 3
Press shop ................................................................................................................................................. 3
Executive Summary....................................................................................................................................... 4
Target: ....................................................................................................................................................... 4
Targets Achieved:...................................................................................................................................... 4
Targets Not Achieved: ............................................................................................................................... 5
SAFETY KAIZEN # 1 ........................................................................................................................................ 6
PROBLEM .................................................................................................................................................. 6
RECOMMENDATION ................................................................................................................................. 6
SAFETY KAIZEN # 2 ........................................................................................................................................ 7
PROBLEM .................................................................................................................................................. 7
RECOMMENDATION ................................................................................................................................. 7
Kaizen: ....................................................................................................................................................... 8
Problem ................................................................................................................................................. 8
Recommendation.................................................................................................................................. 8
Problem ................................................................................................................................................. 8
Recommendation.................................................................................................................................. 8
Problem ................................................................................................................................................. 8
Recommendation.................................................................................................................................. 8
Problem ................................................................................................................................................. 8
Recommendation.................................................................................................................................. 8
10

Problem ................................................................................................................................................. 9
Recommendation.................................................................................................................................. 9
Problem ................................................................................................................................................. 9
Recommendation.................................................................................................................................. 9
Introduction ................................................................................................................................................ 17
Production Area .......................................................................................................................................... 17
Shocks &Struts ............................................................................................................................................ 17
Rod line ................................................................................................................................................... 17
MANUFACTURING PROCESSES ........................................................................................................... 17

Hardening ................................................................................................................................ 17

Hardness test .......................................................................................................................... 18

Straightening ........................................................................................................................... 18

Turning .................................................................................................................................... 18

Threading ................................................................................................................................ 19

Drilling & Punching.................................................................................................................. 19

CPk of Strut Grinding........................................................................................................................... 20

Pre-Plating Test ....................................................................................................................... 21

CHROME PLATING ............................................................................................................................... 21

2.

Soak cleaning .......................................................................................................................... 21

3.

Rinsing in Water ...................................................................................................................... 21

4.

Etching..................................................................................................................................... 21

5.

Electroplating .......................................................................................................................... 21

6.

Drag Out .................................................................................................................................. 22

7.

Rinsing ..................................................................................................................................... 22

CPk After Plating ................................................................................................................................. 22

POLISHING ................................................................................................................................... 22

ASSEMBLY LINE ....................................................................................................................................... 23

Gabriel Section .................................................................................................................................... 23
1.

Rod Assembly .......................................................................................................................... 23

2.

Torquing .................................................................................................................................. 23

3.

Oil Filling .................................................................................................................................. 23

11

4.

Spinning & DFT ........................................................................................................................ 23

CPk For Oil Filling................................................................................................................................. 24

Kayaba Section: ................................................................................................................................... 24
2.

Projection Welding.................................................................................................................. 24

4.

Tensile Test ............................................................................................................................. 25

5.

Test For Projection Welded Joints .......................................................................................... 25

6.

Jet Washing ............................................................................................................................. 25

8.

Piston Assembly ...................................................................................................................... 25

9.

Stacking &Torquing ................................................................................................................. 25

11.

Gas Filling ............................................................................................................................ 26

13.

Gas Testing .......................................................................................................................... 26

14.

Damp Force Test ................................................................................................................. 27

Capacity study for KYB Shocks .................................................................................................................... 28

Rear Rod Assembly: ................................................................................................................................ 29
1.

Projection Welding.................................................................................................................. 29

2.

Caulking ................................................................................................................................... 29

3.

Nut Torquing & Riveting.......................................................................................................... 29

4.

Spin Closing ............................................................................................................................. 29

5.

Oil & Gas Filling ....................................................................................................................... 29

6.

Testing: .................................................................................................................................... 29

Capacity study for KYB Struts ...................................................................................................................... 30

Paint Shop ............................................................................................................................................... 32
Process: ............................................................................................................................................... 32
1.

Degreasing .............................................................................................................................. 32

2.

Rinsing ..................................................................................................................................... 32

3.

Phosphating ............................................................................................................................ 32

4.

Rinsing ..................................................................................................................................... 32

5.

Curving Oven ........................................................................................................................... 32

Parts In Quality Gate ........................................................................................................................... 33

Visual Inspection ..................................................................................................................... 33

Gas Force Testing .................................................................................................................... 33

12

Spring Assembly ...................................................................................................................................... 33

For 368A RR......................................................................................................................................... 33
Pressing ........................................................................................................................................... 33
Shock Assembly............................................................................................................................... 33
For 368A FR ......................................................................................................................................... 34
Pressing ........................................................................................................................................... 34
Shock Assembly............................................................................................................................... 34
McPherson Assembly .............................................................................................................................. 35
Visual Inspection In Dispatch Area.......................................................................................................... 35
Tube Line: ................................................................................................................................................ 35
Inner Cylinder:..................................................................................................................................... 35
1.

Chamfering .............................................................................................................................. 35

2.

Washing Of Inner Cylinder ...................................................................................................... 36

Outer Cylinder: .................................................................................................................................... 36

1.

Chamfering .............................................................................................................................. 36

2.

Necking.................................................................................................................................... 36

3.

Boring & Threading ................................................................................................................. 36

4.

Marking ................................................................................................................................... 36

5.

Sizing ....................................................................................................................................... 36

6.

Bulging..................................................................................................................................... 36

7.

Dust Tube ................................................................................................................................ 36

Weld Line: ............................................................................................................................................... 37

2.

Projection Welding...................................................................................................................... 37

5.

Hole Pressing ............................................................................................................................... 37

6.

MIG Welding ............................................................................................................................... 37

7.

Impact And Tensile Testing ......................................................................................................... 37

8.

Leak Test ..................................................................................................................................... 37

11.

Gabriel Section ........................................................................................................................ 38

Capacity study for Weldline: ................................................................................................................... 39

Two Wheelers: ............................................................................................................................................ 41
Honda: ..................................................................................................................................................... 41

13

Process: ............................................................................................................................................... 41
1.

Straightening ........................................................................................................................... 41

2.

Heavy Rough Grinding............................................................................................................. 41

4.

Grinding................................................................................................................................... 41

5.

Pre-Plating Test: ...................................................................................................................... 41

6.

Chrome Plating........................................................................................................................ 41

7.

Polishing & Buffing .................................................................................................................. 41

8.

Visual Inspection ..................................................................................................................... 41

11.

Quality Gate ........................................................................................................................ 42

Yamaha ................................................................................................................................................... 42
Process: ............................................................................................................................................... 42
1.

Washing& Drying .................................................................................................................... 42

2.

Caulking Of Assembled Parts .................................................................................................. 42

3.

Seal Pressing............................................................................................................................ 42

4.

Inner Assembly........................................................................................................................ 42

5.

Leak Testing............................................................................................................................. 42

6.

Oil Filling .................................................................................................................................. 43

PRESS SHOP ................................................................................................................................................. 43

SHOCKS AND STRUTS PART ..................................................................................................................... 43
DIB (DOOR IMPACT BEAM) ................................................................................................................. 43
DIFFERENT PROCESSES ........................................................................................................................... 43
SHEARING PROCESS ............................................................................................................................ 43
FORMING PROCESS ............................................................................................................................. 43
PIERCING PROCESS.............................................................................................................................. 44
CHAMFERING PROCESS....................................................................................................................... 44
Door Component Plant (SHIROKI)............................................................................................................... 44
Door Hinges............................................................................................................................................. 44
Window Regulator .................................................................................................................................. 44
Quality Department .................................................................................................................................... 45
Quality Room .......................................................................................................................................... 45
Profile Projector .................................................................................................................................. 45

14

Internal Micrometer ........................................................................................................................... 45

Vicker Hardness Tester ....................................................................................................................... 45
Rockwell Hardness Tester ................................................................................................................... 45
Plating Thickness Tester (Non Destructive Type)............................................................................... 45
Thickness Tester (Destructive Type) ................................................................................................... 46
Surface Roughness Tester ................................................................................................................... 46
Pressure Gauge Calibrator .................................................................................................................. 46
Torque Calibration Machine ............................................................................................................... 46
Contamination Test............................................................................................................................. 47
Research and Development lab .............................................................................................................. 47
LAB ACTIVITIES .................................................................................................................................... 47
CUSTOMER HANDLING: ...................................................................................................................... 47
For Defected Parts ......................................................................................................................... 48
Stroking ........................................................................................................................................... 48
Cut Off Operation............................................................................................................................ 48
PRODUCT DEVELOPMENT ................................................................................................................... 48
Friction testing ................................................................................................................................ 49
Temperature testing ....................................................................................................................... 49
PRODUCT AUDIT ................................................................................................................................. 49
Endurance testing ........................................................................................................................... 49
Damping & GRF Test ....................................................................................................................... 49
Critical product characteristics ....................................................................................................... 49
Durability testing............................................................................................................................. 49
Salt spray test .................................................................................................................................. 49
Maintenance Derpartment ......................................................................................................................... 50
Predictive Maintenance .......................................................................................................................... 50
Definition ............................................................................................................................................ 50
Techniques .......................................................................................................................................... 50
Importance .......................................................................................................................................... 50
Suitable Applications for Predictive Maintenance:......................................................................... 50
Unsuitable Applications for Predictive Maintenance. .................................................................... 51

15

Advantages Compared With Preventative Maintenance ................................................................... 51

Disadvantages Compared With Preventative Maintenance ............................................................... 51
Preventative Maintenance...................................................................................................................... 51
Definition ............................................................................................................................................ 51
Technique............................................................................................................................................ 51
Importance:......................................................................................................................................... 52
Suitable Applications for Preventative Maintenance ..................................................................... 52
Unsuitable Applications for Preventative Maintenance ................................................................. 52
Advantages and Benefits of Preventative Maintenance ..................................................................... 52
Disadvantages of Preventative Maintenance ..................................................................................... 52
Total productive maintenance ................................................................................................................ 53
Definition ............................................................................................................................................ 53
Phases ................................................................................................................................................. 53
First Phase ....................................................................................................................................... 53
Second phase .................................................................................................................................. 53
Total Maintenance System .................................................................................................................. 54
Determine the Root Cause: 5 Whys ........................................................................................................ 54
Benefits of the 5 Whys ........................................................................................................................ 54
When Is 5 Whys Most Useful? ............................................................................................................ 54
How to Complete the 5 Whys ............................................................................................................. 54
5 Whys Examples ................................................................................................................................ 54
5 Whys and the Fishbone Diagram ..................................................................................................... 55
Why Why Diagram or Flow ..................................................................................................................... 55
MAINTENANCE MANAGEMENT SYSTEM ................................................................................................ 56
PLANNED PREVENTIVE MAINTENANCE: ............................................................................................. 56
BREAKDOWN MAINTENANCE: ............................................................................................................ 56
PREDICTIVE MAINTENANCE: ............................................................................................................... 56

16

INTRODUCTION

Agriauto Industries Limited is a public limited company incorporated in 1981 and quoted on the
stock exchange.
The company is one of the leading automotive components manufacturers in the private sector
and the first company in Pakistan to acquire TS16949 certification. Technical Collaborations with
leading international companies have added to the company's technical versatility. The product
range covers both original equipment manufacturers (OEM) and the after market
The main product of AGRIAUTO industries limited include shock absorbers & struts, camshaft,
pipe fork, McPherson assembly, door & hood hinges, steering box and sheet metal parts.

PRODUCTION AREA
Operations were followed for the product 368A FR & RR.

SHOCKS &STRUTS
Basic function of shock absorbers is to absorb the shocks and provide luxury. They are used in rear
portion of the car.
Struts are used in the front portion of the car and are used to support the suspension of the car and
absorb shocks as well.

ROD LINE
MANUFACTURING PROCESSES

Hardening
o Hardening is the first step performed on rod line.
o Machine used for hardening is Induction hardening
machine which uses an induction hardening coil for
hardening the rods. It is not performed on the mounting
end and piston end.
o There are 2 machines for hardening.
o Rods are hardened to a depth of 0.5-1.1 mm.
o Initial length of the rod was 376 mm.
o Diameter of mounting end was 22.1 mm and that of piston
17

end was 22.2 mm.

o Length of mounting end was 48.95mm and that of piston end was 109.32mm.

Hardness test
o Hardness test is performed after hardening.
o Rockwell hardness test is performed in which major
and minor loads are used to check hardness.
o For 368AFR hardness is standard i.e. 80HRA-84HRA.
o Tests are performed randomly.

Tempering
o After hardness testing tempering is performed in electric oven
of 36 KW.
o Electric furnace is used to distribute hardness throughout the
rod and to minimize brittleness.
o Time for tempering is one hour and required temperature is
307 C.
o Length and diameter after tempering remains same.
o After tempering hardness test is again performed but the allowable range after
hardening is 69HRA-73HRA.
Straightening
o After testing straightening of rod is performed to remove
bend in rods from the hardened region due to hardening and
tempering.
o Mechanical press end is the machine used for this purpose.
o Tolerance is 0.01mm or 0.02mm.
o Inspection is 100%.
Turning
o Turning is the next step
in rod line.
o There are 5 turning
machines
DAKAN,
VICTOR,
NEWTOPER,
TOPER
and
VICTOR
respectively.
o There are two types of
CNC machines being used in turning. One is automated having a bad feeder which works
on pneumatic pressure and is used to move rods into the machine. The other one is
manual CNC in which rods are fed manually into the machine. Turret and collet are
18

placed inside the machine at opposite ends and are operated through hydraulic
pressure. It operates at 3000rpm. It is also used for centering and for drilling small depth

holes. It can also perform tapping and special operations. Programs are feed in the form
of number for different rods.
o 2 machines are being used for mounting end and one for piston end.
o Out of5 machines 3 are used for stud and 2 are used for shock. 2 of them are auto
feeder and 3 are manual feeder.
o Mounting diameter of thread and non-thread part after turning is respectively 12.9mm
and 13.9mm.
o Piston diameter off thread and non-thread portion after turning is 9.17mm and 9.97mm
respectively.
o Length of mounting end and piston end after turning is 37.75mm and 25mm
respectively.
Threading
o After turning threading of mounting and piston ends is
performed through roll threading in which different rolls are
used for both ends.
o It is a chip less cold forming process which form threads by
rolling roller against the rod.
o The of piston end after threading becomes 9.85mm and
9.77mm on thread and non-thread part respectively
o

Diameter of mounting end becomes

13.73mm and 13.87mm respectively.
Drilling & Punching
o After threading some rods are
Drilled and punched on drilling
and milling machine while
Other rods are milled on milling
Machine.
Milling
o In rod line section conventional milling is performed on face
milling machine named as NO CHUN milling machine.
o The material is removed from the mounting end in order to
clamp the rod while tightening the screw.
o The machine has a rotational speed of 1200 rpm and a feed
rate of 450mm/min. number of cutter teeth are 7, length of the
milled section is 37mm and depth of cut is 0.67mm.

19

Grinding
o After drilling pitching and milling grinding is performed in which
there are six machines.

o
o

o
o
o
o
o
o
o

Operations performed in grinding are rough grinding, semi

finish grinding and finish grinding.
Machines in rod line section are center less grinding machines
which have a regulating wheel and a grinding wheel. The wheel
having the larger diameter is called grinding wheel and the wheel having smaller
diameter is called regulating wheel.
Grain size of grinding wheel is 700.
Diameter of rod before rough grinding is 22.20mm.
Diameter after rough grinding is 21.952mm.
Diameter before finishing is 21.943mm.
Diameter after super finish is 21.940mm.
Regulating wheel rpm is 27-28 rpm, degree of regulating wheel is 2 degree and work
rest height is 43mm-44mm.
Load is regulated by moving hand wheel which moves buffing wheel up and down to
regulate load. Load ranges between 4KN-6KN.

CPk of Strut Grinding

Process Capability of C1
LSL

USL

Process Data
LSL
21.93
Target
*
USL
21.94
Sample Mean 21.9368
Sample N
20
StDev(Within) 0.00105314
StDev(Overall) 0.00113284

Within
Overall
Potential (Within) Capability
Cp
1.58
CPL 2.14
CPU 1.03
Cpk 1.03
Overall Capability
Pp
1.47
PPL 1.99
PPU 0.96
Ppk 0.96
Cpm
*

21.930 21.932 21.934 21.936 21.938 21.940

Observed Performance Exp. Within Performance Exp. Overall Performance
PPM < LSL 0.00
PPM < LSL
0.00
PPM < LSL
0.00
PPM > USL 0.00
PPM > USL 1014.30
PPM > USL 2059.46
PPM Total 0.00
PPM Total 1014.30
PPM Total 2059.46

20

Pre-Plating Test
o After grinding the rod is passed through a pre plating test in which it is examined if there
are any cracks, scratches, dents, pitting, cut marks, roughness wheel hit and line scratch.
If there is no defect the rod is passed to chrome plating section.

CHROME PLATING

1. There are three sections in chrome plating area for different rods. There are seven tanks in each
section.
2. Soak cleaning is the first process in which rods are dipped into degreaser called Alba to
remove dirt or grease from rods. Soaking time is 5 minutes and soaking temperature is 60C to
70C.
3. Rinsing in Water is the second step. Rods are dipped twice in R.O water and PH of water is
from 6.5 to 8.5. Continuous flow of water is necessary in this process.
4. Etching After rinsing rods are dipped in etching agent. Electrolyte is usually the etching agent.
Temperature is 60 to 70 C. Ampere per rod is 12 ampere and ampere per hanger is 96 ampere.
Current density is 4-10 amp/dm2.
5. Electroplating After these steps the main electroplating takes place which is called drag out in
which rods are dipped in large tank containing electrolyte. Electrolyte used is H2SO4.100 ampere
21

per rod and 400 ampere per hanger. Time is different for different rods and quantity of anodes
at a time is 60sec. Current density is 58amp/dm2.
6. Drag Out After hard chroming drag out takes place in which rods are dipped in chemical to
clean electrolyte from rod. It is performed to create a backup of chemical for electrolytic tank
and it can be used for stabilizing chemical in electrolytic tank. The chemical is collected through
the chemical left on rods.
7. Rinsing After drag out rods are dipped twice in water of PH 6.5-8.5.This is called rinsing.
8. After plating diameter becomes 21.95mm.

CPk After Plating

Process Capability of Dia after Plating

LSL

USL
Within
Ov erall

P rocess Data
LS L
21.943
Target
*
USL
21.973
S ample M ean
21.9625
S ample N
15
S tDev (Within)
0.00619105
S tDev (O v erall) 0.0076706

P otential (Within) C apability

Cp
0.81
C P L 1.05
C P U 0.56
C pk 0.56
O v erall C apability
Pp
PPL
PPU
P pk
C pm

0.65
0.85
0.45
0.45
*

4 5 950 95 5 960 96 5 970 97 5 980

.9
.
.
.
.
.
.
.
1
2
21
21
21
21
21
21
21
O bserv ed P erformance
P P M < LS L
0.00
P P M > U S L 66666.67
P P M Total
66666.67

E xp. Within P erformance

P P M < LS L
802.24
P P M > U S L 45455.50
P P M Total
46257.74

E xp. O v erall P erformance

P P M < LS L
5440.15
P P M > U S L 86202.38
P P M Total
91642.54

POST-PLATING TEST After chrome plating rods are tested again for cracks, line cracks etc in the same
way as pre plating test and are then moved for polishing.

POLISHING
o Polishing is being performed by two rollers having
a grain size of 600.
o It is used to perform a shiny surface to the wheel.

BUFFING

22

o
o
o

After polishing buffing is performed through a buffing wheel made up of polytext

material.
Kayaba Company manufactures buffing wheels.
Life of the buffing wheels is 5000 parts.

ASSEMBLY LINE
Assembly line is divided into two sections i.e. Kayaba and Gabriel. Moreover there are different
processes for shock and rear rods in assembly section.

Gabriel Section

Gabriel section is divided into two portions i.e. Shox and Gabriel.

1. Rod Assembly
a. In shox portion the first process is sub assembly and rod assembly in which rod packing
and retinal packing takes place.
2. Torquing
a. After packing torquing at a load of 25.1N takes place.
3. Oil Filling
a. Oil filling is then performed by using beaker checking test and comparing from
standards.
4. Spinning & DFT
a. After oil filling spinning and damp force testing are performed.
5. In Gabriel the first step is assembling of spring recoil, recoil by pass valve, piston, white valve,
golden valve, recoil spring.
6. After assembly, torquing and riveting takes place and bumper is attached.
7. Oil is then filled and rest of the body is assembled.

23

CPk For Oil Filling

Process Capability of Oil filling

LSL

USL
Within
Ov erall

P rocess Data
LS L
252
Target
*
USL
258
S ample M ean
256.9
S ample N
10
S tDev (Within)
3.39822
S tDev (O v erall) 3.10734

P otential (Within) C apability

Cp
0.29
C P L 0.48
C P U 0.11
C pk 0.11
O v erall C apability
Pp
PPL
PPU
P pk
C pm

249
O bserv ed P erformance
P P M < LS L
0.00
P P M > U S L 300000.00
P P M Total
300000.00

E xp.
PPM
PPM
PPM

252

255

Within P erformance
< LS L
74661.04
> U S L 373083.11
Total
447744.16

258

261

0.32
0.53
0.12
0.12
*

264

E xp. O v erall P erformance

P P M < LS L
57407.89
P P M > U S L 361669.20
P P M Total
419077.09

Kayaba Section:

1. Spot Welding
a. First step in assembly line is spot welding of the metal
stopper.
b. Time is equal to 5 seconds.
c. Water is used as coolant and temperature of coolant must
not exceed 33 C.
d. Air pressure is 40 bars.
e. Three spots are necessary in spot welding.
2. Projection Welding
a. For rear rod projection welding is performed in which end bolt works as electrode and
copper is used to transfer electric current.
b. Welding takes place through current.
c. End bolt is mounted.
3. Proof Load Test
a. After welding the welded joint is tested through proof load
test.
b. 15 bar pressure is applied on metal stopper to check the
compressive strength of the weld
c. Test rate is 100%.
24

4. Tensile Test
a. A tensile test is also performed on the rod in which rod is
examined through a tensile test.
b. Rod which can bear a load of 20 KN or more are
considered ok.
5. Test For Projection Welded Joints
a. For projection welded joints Impact Testing is
Performed in which a load is dropped from a height of
54 to 55.
b. Tensile Test is also performed having a least limit of
45N.
c. An Out Test is also performed to check the centering
of the gage by diameter& gage out test. This test is 100%.
6. Jet Washing
a. After welding tests the rods are passed through jet washing
where they are washed trough reciprocating motion of
machine up & down for 400 seconds and then rinsing up to
1 minute.
b. Up to 50 rods can be placed in one tray at a time.
c. There are total 3 trays placed at time.
d. Lesser the number of rods greater will be the wash effect.
7. Outer Shell Washing
a. Outer shell washing is performed to wash shells in a tank
containing two portions.
b. 1 portion for washing and 1 for drying.
c. Tank can have 6 shells at a time.
d. The washing time for shell is 1 minute and one minute for
drying.
8. Piston Assembly
a. Piston assembly and compression head are assembled in
assembly section.
b. Compression head after torquing forms the base valve
which is assembled to the inner cylinder.
c. There are shims in the base valve assembly. Shims can
differ up to 13 different types.
9. Stacking &Torquing
a. Piston head assembly is moved to the second machine for stacking
and torquing where piston head assembly in fitted on the rod.
b. Vacuuming also takes place here for removal of unwanted
particles.
25

c. To check torquing first 10 rods are tested on damp force testing machine under a speed
of 0.6m/s. the torquing force must be 490N.cm with a tolerance of 49N.cm. if torque is
greater than that it is considered as over tight and if torque is less than that it is
considered as over lose.

10. Oil Filling

a. After torquing the rod is place in an internal cylinder and is
filled with oil.
b. Different range of oil quantity for different rods.
c. For 368AFR 55 cc of oil is filled with a tolerance of 3 cc.
11. Gas Filling
a. After oil filling the gas is filled inside the cylinder and the
cylinder is bended from corners and sealed under a
pressure of 4.4 MPA and pre crimp pressure is 6 MPA.
b. Primary gas pressure is 8.5 MPA and secondary gas
pressure is 85 MPA.

12. Spin Closing

a. After gas filling the cylinder is spin closed under
an air pressure of 0.5 MPA.
b. Spin close pressure of 4MPA.
c. Seal pusher pressure of 0.5 MPA.

13. Gas Testing

a. After gas filling, gas testing is performed.
b. Gas should not be less than 17kg inside the cylinder.

26

14. Damp Force Test

a. After gas testing damp force test is performed on
damp force testing machine in which rods are
checked through a curve and their compression
and recoil values are compared.
b. The values are compared from set standards.
This test is performed on each cylinder.
c. The weight of the cylinder now becomes around
4 kg. Rods are tested on speed of 0.1 m/s and 0.3
m/s.

27

CAPACITY STUDY FOR KYB SHOCKS

Process

Hardening
Turning
Threading
Grinding
Semi Finish Grinding
Finish Grinding
Pre-Plating Test
Chrome Plating
Plating Test
Polishing
Spot Welding
Proof Load Test
Tensile Test
Rod Washing
Piston Assembly
Compression Head Assembly
Base Valve Assembly
Torquing
Riveting
Lower Cap Pressing
Oil & Gas Filling
Spin Closing
Gas Test
Damp Force Test

Process
time
(secs)

19
30
2.45
10
10
10
10
12
10
6
3.5
5
15
5
20
20
4.33
18
18
5
5
16
3
15

available
time
(sec)/shift

27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000

Efficiency =
80% (20%
allowance)

80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%

Operation
availability

1
2
1
1
1
1
1
1
1
1
1
1
1
0.5
1
1
1
1
1
1
1
1
1
1

Capacity per shift

1137
1440
8816
2160
2160
2160
2160
1800
2160
3600
6171
4320
1440
2160
1080
1080
4988
1200
1200
4320
4320
1350
7200
1440

20 % Allowance :
relaxation = 5%
Breakdown = 5%
Periodic/change over activities =
10%

28

REAR ROD ASSEMBLY:

1. Projection Welding
a. For rear rod projection welding is performed which is discussed above.
2. Caulking
a. Rear rod assembly is a bit different from front rod assembly in which after washing rod
goes for caulking under a pressure of 1000 psi in which rear rod assembly is fitted to the
rod.
3. Nut Torquing & Riveting
a. After caulking nut torquing and nut riveting takes place.
b. On riveting machine rods are also vacuumed for removal of unwanted particles.
c. Nut torquing pressure is 0.2 MPA whereas riveting pressure is 0.26 MPA.
4. Spin Closing
a. After riveting spin closing takes place under an air pressure of 0.5 MPA.
b. Spin close pressure of 4MPA and seal pusher pressure of 0.5 MPA.
5. Oil & Gas Filling
a. Oil and gas are then filled into the cylinder.
b. Oil quantity is 228cc with a tolerance of 2cc and gas force is 120N.
6. Testing:
a. After oil & gas filling gas test and damp force test takes place in similar manner as that
for front rod.

29

CAPACITY STUDY FOR KYB STRUTS

Process

Hardening
Tempering
Straightening
Piston End Turning
Mounting End Turning
Threading
Milling
Grinding
Semi Finish Grinding
Finish Grinding
Pre-Plating Test
Chrome Plating
Plating Test
Polishing
Buffing
Spot Welding
Proof Load Test
Tensile Test
Rod Washing
Outer Shell Washing
Rod Washing
Piston Assembly
Compression Head Assembly
Base Valve Assembly
Torquing and Stacking 1
Oil Filling
Gas Filling
Spin Closing
Gas Test
Damp Force Test

Process time
(secs)

19
7.2
7
30
35
2.45
4.5
10
10
10
10
33.75
10
6
5
3.5
5
15
11
20
8
20
20
4.33
18
5
15
16
3
15

available time
(sec)/shift

27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000
27000

Efficiency =
80% (20%
allowance)

80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%
80%

Operation
availability

Capacity
per shift

1
1
1
1.5
1.5
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
0.5
1
1
1
2
1
1
1
1
1

20 % Allowance :
relaxation = 5%
Breakdown = 5%
Periodic/change over activities = 10%
30

1137
3000
3086
1080
926
8816
9600
2160
2160
2160
2160
1280
2160
3600
4320
6171
4320
1440
1964
1080
1350
1080
1080
4988
2400
4320
1440
1350
7200
1440

31

PAINT SHOP
Process:

1. Degreasing
a. First the shocks are passed through degreaser having a temperature of 70C for 2
minutes; concentration is 35g/lit.
2. Rinsing
a. It is then rinsed for 2 minutes in water of PH 8.5.
3. Phosphating
a. Phosphating is then performed for 2 minutes in a temperature of 50C and
concentration of 22gm/lit.
4. Rinsing
a. It is then again rinsed in water for two minutes and after drying at a temperature of
200F and using air pressure, it is spray painted for 8 seconds.
5. Curving Oven
a. It is then passed through curing oven having the same temperature as drying oven and
then moved for further assembly.

32

Parts In Quality Gate

Visual Inspection
o After taken out the shocks from paint shop, all articles are send to quality gate for visual
inspection.
o 100% inspection is done visually to see defects of kinds paint flow, dents, spirals,
scratches, wheel hit etc on piston rod, spring seat and on other areas.
o Overall testing of article is done.
Gas Force Testing
o Here gas force testing is also done to check G.R.F. the condition for 368A FR should be
(146-166N) and for 368A RR is (80-100N).
o From here the article move onto spring assembly.

SPRING ASSEMBLY

For 368A RR

Pressing
For in case of 368A RR,all articles are send to a hydraulic press where seat and bumper is pressed into
shocks.
Machine name: MILLS HYDRAULIC PRESS (50 ton)
Cycle Time: 27 sec
Shock Assembly
After pressing seal and bumper, it moves to spring assembly where these entire thing are fitted:

33

1)
2)
3)
4)
5)
6)
7)
8)

Susp assembly
Spring coil RR
Bumper RR spring
Support assy. RR suspension
Bracket sub assy. Spring
Support assy suspension
Washer RR shock
Nut flange

Cycle time: 27 sec.

For 368A FR

Pressing
In case 368A FR the part after inspection is send into press where bumper and metal stopper is fixed
into the part on hydraulic press (56 ton).
Shock Assembly
After fixing bumper and stopper the good is move onto assembly where following parts are fixed:
1)
2)
3)
4)
5)
6)
7)

Lower insulator
Helical spring coil
Upper insulator
Spring seat
Front support
Small ring
Nut

Cycle time:27 sec

Now from here it is move on to McPherson Assembly.

34

MCPHERSON ASSEMBLY

Now assembled part is send to McPherson Assembly and first of all knuckle is
fitted with bolt jet and bearing is fitted.
After this ring lock and the disk cover are fitted with the screw, hub is pressed in
bearing with the help of hydraulic press.
After fitting of disk in hub the assembled part is send to next counter where
clipper is fitted in previous assembled part with the help of clipper bolts.
Now damper is fitted in assembly with the help of damper bolts and after that it
moves to dispatch area.
Cycle time of McPherson Assembly: 1min 5sec

VISUAL INSPECTION IN DISPATCH AREA

Shocks after complete assembly is send into dispatch area where visual inspection is done to
check that all the parts are in order.
After inspection the ok parts are loaded and send to customer.

TUBE LINE:
Inner Cylinder:

1. Chamfering
a. Chamfering of inner cylinder is performed for 3 seconds.
b. Machine for chamfering is auto chamfering machine.
c. Inner and outer chamfering is performed.

35

2. Washing Of Inner Cylinder

a. After chamfering washing of inner cylinder is performed.
b. Washing process is same for both cylinders.
c. First the tubes are passed through degreaser at a temperature of 60C having a
concentration of 35gm/lit for 20 minutes.
d. After degreasing rinsing is performed for 2 minutes.
e. If rods are rusted they are dipped into de-ruster rather than de-greaser having a
concentration of 35gm/lit and then rinsing is performed.
f. After rinsing passivation is performed at 70C for 1 minute to plate cylinders.
Concentration is 15gm/lit.
Outer Cylinder:

1. Chamfering
a. After parting off chamfering is performed on ginger parting machine for 3 seconds.
2. Necking
a. Necking is then performed on hydraulic press having a pressure of 260 bar.
b. Necking is performed for holding outer cylinder.
3. Boring & Threading
a. Boring & threading is then performed.
b. For 368 only boring is performed.
c. Upper end boring and lower end boring is performed.
d. In upper end boring more material is removed.
e. CNC lathe machine is used for this purpose having rpm around 1800 rpm.
4. Marking
a. After boring, marking is performed through hydraulic press on marking machine.
b. Table pressure is 500lbs.
c. It is divided in 2 portions, master block (Upper & lower).
5. Sizing
a. After marking, sizing is performed for rear shocks with a pneumatic press of 100PSI and
a stroke of 230mm.
b. It is performed to form brackets.
6. Bulging
a. Bulging is performed to create a bulge in cylinder.
b. Hydraulic press is used for this purpose having a pressure of 200psi.
c. Machine name is auto sizing machine.
d. Two machines are used for sizing one is pneumatic having a pressure of 100 psi and
other is hydraulic press having a pressure of 200 psi.
7. Dust Tube
a. Other than inner & outer tube there is another tube called dust tube used to save inner
tube from dust.

36

WELD LINE:
1. End Cap Stacking
a. First process in weld line is end cap stacking on mechanical hand press for 5
seconds
b. After end cap stacking it is stacked to the cylinder by a mechanical press or
fly.
2. Projection Welding
a. Inner and outer bracket or knuckle bracket is formed via projection welding
by pressing outer bracket against inner bracket under a pressure of 460Psi
and then welding it through projection welding.
b. Time for projection welding is 7 seconds.
3. Chisel Load Test
a. Chisel load test is performed to check penetration of welding.
Brackets are separated with the help of a Chisel.
b. If brackets spate without penetration the weld is NG.

4. Inner And Outer Bracket Pressing

a. Inner and outer bracket is then pressed against the shell with a hydraulic
press.
b. A cap is used during operation to ensure proper pressing of bracket
5. Hole Pressing
a. Hole pressing is performed after bracket pressing in which 4 holes are
punched on knuckle bracket.
6. MIG Welding
a. After hole punching MIG welding is
performed.
b. It is automated welding performed on CNC
welding machine in which lower plate and
bracket both are welded on the same time
with two electrodes at different position.
c. There are two MIG welding machines in
Kayaba section.
7. Impact And Tensile Testing
a. After MIG welding load tests such as impact tests and tensile tests are performed.
8. Leak Test
a. After load test leak test is performed in which shell is poured in water and checked.
b. If bubbles form this means that the shell is leaked.
37

9. Hose Bracket Welding

a. Hose bracket is welded on projection
welding machine on outer shell under a
pressure of 100 psi.
b. It is welded on rear rods.
c. Time is 5 seconds.
d. It is tested for gauge size on fixtures.
10. Stabilizer Bracket Welding
a. After hose bracket stabilizer bracket is welded on the shell
through CO2 welding in which copper wire and carbon dioxide
is used.

11. Gabriel Section

a. Same processes are being performed in Gabriel section. There are separate machines
for both sections.

38

CAPACITY STUDY FOR WELDLINE:

Process

End cap stacking

Knuckle Bracket
Knuckle Bracket pressing
Hole Punching
MIG Welding
Leak Test
Hose Bracket
Stabilizer
Bracket
(CO2
Welding)

Process time
(secs)

available time
(sec)/shift

Efficiency =
80% (20%
allowance)

Operation
availability

Capacity
per shift

5
7
4
8
25.5
17
5

27000
27000
27000
27000
27000
27000
27000

80%
80%
80%
80%
80%
80%
80%

1
1
1
1
2
2
1

4320
3086
5400
2700
1694
2541
4320

40

27000

80%

1080

20 % Allowance :
relaxation = 5%
Breakdown = 5%
Periodic/change over activities
= 10%

39

PRD/PED/PFC/76/01

PRODUCTION ENGINEERING DEPARTMENT

PROCESS FLOW OF TOYOTA 368A FRONT STRUT RH/LH
Date: 1ST Oct 13
INNER
CYLINDER

PISTON ROD

MATERIAL
RECEIVING

16

MATERIAL
RECEIVING

OUTER SHELL
ASSY

OUTER SHELL

20

27

MATERIAL
RECEIVING

PARTING OFF
2

17
PARTING OFF

INDUCTION
HARDENING

3
INSPECTION

18

TEMPERING

STRAIGHTENING

21

19

22
I.D CHAMFERING
(BOTH SIDES)

TURNING
MOUNTING END

28

NECKING

BORING L.
END

30

TURNING
PISTON END &
CENTER DRILL

31

INSPECTION

24

GOTO 41

BORING U.
END

INSPECTION

THREADING
PISTON END

25

THREADING
MOUNTING END

26

WASHING

10

MILLING
MOUNTING END

GOTO 27

SEMIFINISH
GRINDING

12

FINISH GRINDING

13

SUPER FINISH
GRINDING

NUT
TORQUING

GOTO 46

41

BASE VALVE
PRESS INTO
INNER TUBE

MIG WELD
END CAP,
KNUCKLE
BRACKET &
SPRING
GUIDE

INSPECTION

GOTO 48

35

REINF WELDING
(CO2) HOSE BKT.
STABLIZER BKT.
PROJ WELDING
CLEANING
GOTO 48

FINAL ASSEMBLY OF STRUT

BUFFING

48
GOTO 45
49

46

40

PLATING

INSPECTION

45

4 HOLE
PUNCHING

PROJ WELDING
HOSE BKT.

37

INSPECTION

44

PISTON
ASSEMBLY

43

34

36

INSPECTION

15

BASE VALVE
ASSY.

BKT. SIZING

INSPECTION

14

39

ULTRASONIC
CLEANING

LEAK TEST

33

11

KNUCKLE
BRACKET
PRESSING

32

INSPECTION

MARKING

42

38

INSPECTION

INSPECTION

ULTRASONIC
CLEANING

PISTON
ASSEMBLY

LOWER CAP
STACKING

29

PROJ.WELD
INNER &
OUTER BKT.

INSPECTION

23

WASHING

PARTING OFF
& OD
CHAMFERING

BASE VALVE
ASSEMBLY

SPOT WELDING
REBOUND
SUPPORT
ULTRASONIC
WASHING

TORQUING &
STACKING

54

INSERT
CYLINDER INTO
OUTER SHELL

55

OIL FILLING

56

GAS FILLING &

CRIMPING

57

PAINTING
PROCESS

59

BUMP STOPPER
PRESSING

60

50

51

SPRING ASSY

INSPECTION

PACKING

40

INSPECTION

INHOUSE
52

TWO WHEELERS:
Two wheelers are divided into two portions. Honda and Yamaha section. In Honda section both
manufacturing and assembly is done while in Yamaha section only assembly is done.

HONDA:
In Honda section three pipes are being manufactured CD70, CD125 and PK2 pipes.
Process:

1. Straightening
a. First process in pipe manufacturing is straightening on straightening machine.
2. Heavy Rough Grinding
a. After straightening heavy grinding is performed on grinding machine.
b. Depth of cut 0.3mm.
c. 1200 rpm of grinding wheel and 1500 rpm of regulating wheel.
3. Turning, Tapping & Boring
a. After rough grinding, turning and
boring on both sides is performed
and tapping (internal threads) on
only one side is performed.
b. Inserts used for all three processes.
4. Grinding
a. After these operations grinding is again performed that is rough, semi finish and
finished.
5. Pre-Plating Test:
a. A pre plating test in which rust, scratches, wheel hit, dents spiral and concentricity cut is
checked.
6. Chrome Plating
a. After these tests rod is chrome plated in the same way as plated in shocks and struts
plant.
7. Polishing & Buffing
a. After chrome plating polishing and buffing is performed.
b. Load for polishing is 3 amperes.
c. Buffing is performed on 5 rods at a time.
8. Visual Inspection
a. After all these inspection 100% visual inspection is performed.
b. Inner diameter is checked with plug gage i.e. GO and NO-GO gauge.
c. Outer diameter is checked with ring gauge and snap gauge.
41

9. Piston rod is also manufacture in this section.

10. Operation of piston rod includes rough grinding, finish grinding, plating, polishing, buffing and
quality check.
11. Quality Gate
a. At quality gate thread check and outer diameter check is performed.
b. 100% checking with snap gauge and thread gage is performed.
12. Main Pipe is also manufactured here. After parting cell it is passed through chamfering process
having an outer chamfer of length 0.6mm and inner chamfer of length 0.8mm. Main pipes are
checked with height gauge and internal diameter gauge.
13. Chamfer lengths and dents are also checked at quality gate for main rod.
14. Another product manufactured in this section is Case Damper for Honda.
15. First step of case damper manufacturing is inserting a ring into the tube and then welding it
through spot welding.
16. Tube assembly is then pressed against the tube through a pneumatic press. After pressing seam
welding is performed on the pressed section after which leak test is performed.
17. After leak check rod is passed to quality gate where spot welding is checked and after that the
tube is passed to vendor for Nickel plating from where it comes back and again checked on
quality gate for spiral, ring, dents etc.

YAMAHA
Two products are being assembled In Yamaha plant. 2TB and B83.
Process:

1. Washing& Drying
a. First step in Yamaha assembly plant is automatic washing for 2 minutes and then drying
it manually for 5 to 7 minutes.
2. Caulking Of Assembled Parts
a. After washing assembly is placed on inner tube and caulking is performed under a load
of 12KN on caulking machine.
3. Seal Pressing
a. After caulking seal pressing is performed on outer tube. Oil seal, spring ring and dust
seal is attached to the tube.
b. Oil seal is pressed, spring ring is placed manually and dust seal is pressed.
4. Inner Assembly
a. After seal pressing inner assembly is assembled like piston, piston ring, spindle taper,
outer tube etc.
5. Leak Testing
a. Leak testing and oil filling is then performed.
b. Oil quantity standard is 163ml with a tolerance of 3ml.
c. Leakage testing pressure is 2.5kgf/cm2.
42

6. Oil Filling
a. Oil filling is followed by spring assembly and bracket assembly.
7. Spring Assembly
a. Spring assembly includes left fork, spring,
washer, spacer, bolt cap and ring.

8. Bracket Assembly
a. Bracket assembly includes under bracket assembly, left fork,
right fork, bolt2, plug inner tube etc.
b. 25-35 N.m torque is used for bracket assembly.

PRESS SHOP
INSTRUMENT PANEL (IP) two assembly pack1 has 7 parts (individual 11) and pack2 has 10 parts
(individual 18)
ASC (Agri stamping company)

SHOCKS AND STRUTS PART

No of parts 12
5500 parts manufacture per month

DIB (DOOR IMPACT BEAM)

No parts 5
5500 parts production

DIFFERENT PROCESSES
SHEARING PROCESS

In this process the sheet is sheared into blank and plank and then send into press line.

FORMING PROCESS

Blank part is send into mechanical press for forming and different desired shape is produced.
43

Forming is also done on hydraulic press (100 ton).

PIERCING PROCESS

Piercing is done on mechanical press (70 ton) and pneumatic press.

CHAMFERING PROCESS

Chamfering of one part is also done here on simple lathe and milling machine.

DOOR COMPONENT PLANT (SHIROKI)

Door component plant is divided into two sections. One for door hinges and other for window regulator.
Door hinges are manufactured for both GLI and XLI whereas window regulator is manufactured only for
XLI.

DOOR HINGES
Two coupling are used for each door means a single car consume total eight couplings.

First step in door hinges manufacturing is ferrule or bush pressing.

Next step is pin insertion. Pin insertion machine is both pneumatic and hydraulic. One side is
pneumatic and other is hydraulic. Capacity of pneumatic pressure is 0.6 bar whereas that of
hydraulic pressure is 18 MPA.
After pin insertion corners are swaged (flattening bolt head) on swaging machine and hinges are
marked.
100% visual inspection is then performed and first 5 pieces are checked on checking fixture.
Checking fixture test is performed to check alignment of hinge with the door and to check the
angle to which hinge can move.

WINDOW REGULATOR

First step for window regulator is the two points stacking in which two rollers are stacked at
different places.
Next is lift arm placing, greasing and nail bending. Greasing is temperature dependent to resist
friction between the components and nail bending is performed to lock lift arm. Lift arm is the
place where window rest and it moves window up and down.
Next is equalizer arm greasing and one point roller stacking.
Gear arm greasing is then performed only on gear not on gear arm. Stopper case greasing is also
performed.
Next is torsion spring assembly of left and right spring and shaft and pinion insertion.
Base plate stacking on 3 corners and gear pin stacking on left and right.
The part is then placed on shipping position machine for proper positioning of regulator.
Balance stacking is then performed by placing spring and tightening it.
Part is then packed and dispatched.

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QUALITY DEPARTMENT
Quality department is one of the most important department in any sort of industry as it determine the
efficiency and accuracy of any part being formed. The department follows testing of goods to the
standards.

QUALITY ROOM
Quality department has different apparatus for testing which are:
Profile Projector

This instrument is used for the different dimensions that

cannot be taken from apparatus like vernier caliper,
micrometer screw guage, etc. The result is of high accuracy.
It divide the component into x and y axis. When circular and
main scale zero coincides the axes are at 90.
The least count of projector is 0.01mm.
Almost all sort of measurement can be check on machine.
The angular measurement can also be check, angle can be trace
out by screen indicator

Internal Micrometer

The instrument is used to measure internal diameter of tubular objects.

It is a three jaw work holding device and give the result of high accuracy.
The threads diameter can also measure.
The least count is 0.005mm and 25-30mm diameter can be checked with this.

Vicker Hardness Tester

It is used to check hardness of brittle material and

objects like chrome parts are tested.
Diamond indenter is used for indentation.

Rockwell Hardness Tester

The Rockwell test is generally easier to perform and more accurate than other
types of hardness testing methods and can be used on almost all metals.
The Rockwell method measures the permanent depth of indentation
produced by load on indenter. First a preliminary load is applied which set
zero and after that major load is applied and indentation is marked on the
surface. This distance converted into hardness number.

Plating Thickness Tester (Non Destructive Type)

It is a non-destructive type thickness testing of chrome plated materials.

This is used to check the thickness of chrome being coated.
TESTING PROCEDURE:
o First of all set the zero by placing sensor on non-chrome area.
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o
o

Now place the sensor on chrome plated area press on calculate button.
The answer will be the thickness (5-25micron).

Thickness Tester (Destructive Type)

It is a destructive type testing for thickness of

Chromed object in which THA-IIA chemical is
Applied on object and then testing is made.

Surface Roughness Tester

It is a test to encounter the surface of objects especially like

piston rod.
It is the most important test because the surface roughness
should be in acceptable limit.
It is also called as CLA tester.
TESTING PROCEDURE:
o Place the rod on stand of which roughness is
examined.
o Place the testing rod in which sensor is present and placed it on rod.
o Press calculate button (0.2-0.3Rmax acceptable).

Pressure Gauge Calibrator

All pressure gauges are calibrated with this calibrator.

The oil operated deadweight testers are supplied with a hand screw
pump.
This pump has a large displacement of 26cc.

Torque Calibration Machine

All torques are calibrated on torque calibration

machine.

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Contamination Test

Contamination test is done to check dust, oil, metal particles and other contaminant in the oil.
Operational process are the source of dust particles in the other contaminant. To avoid all these
contaminant, the oil should be use of good quality and other safety measures should be taken.
USB microscope is used to check the contaminant on filter paper for examination.
POROCESS TO CHECK CONTAMINENT:
o Cut down the pieces of filter paper in round shape minimum diameter of 60mm.
o Dry in oven at 80C for half an hour.
o Weight filter paper.
o Measure oil volume.
o Wipe off oil from rod.
o Place filter paper in filter machine.
o Collect oil on filter paper.
o Dry filter paper and weight it again to measure weight of contamination
o Contamination=final weight of paper initial weight of paper

RESEARCH AND DEVELOPMENT LAB

LAB ACTIVITIES

1. Customer handling
1. Product development
2. Product audit

CUSTOMER HANDLING:

THE COMPLAIN FROM CUSTOMERS IS CONCIDERED IN FOLLOWING MANNER.

Visit customer for warranty and complain

Look into problems nature
Segregate OK and NG parts
Send NG parts to laboratory
After visual inspection OK parts are send back to customer
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For Defected Parts

Several things are determined for NG parts.

First of all damping force test is applied and gas reaction force is also check.
If damping and GRF is ok then stroking is done.

Stroking

Stroking is done to check whether the seal is leak or not.

The leakages observed by seeing the piston rod during stroking.
It is done on shock absorber testing machine by mounting shock on machine and stroke it for 3
minutes at 0.3 m/s.
If it is not leak then after few hours again GRF and damping is check again and compare the
values with the previous data .
If GRF is low then gas is leak.
If value does not change then part will be weight as there will be change in values.
If during damping test improper graph come then it means part having assembly problem or oil
is missing up to standard value.

Cut Off Operation

The inspection of shocks is done to check due to which reasons the seal was leak.
For this the part is cut off from top.
Procedure:
o The part is cut with the help of pipe cutter by clamping it in vise.
o During cut off oil seal is first of part off.
o The second step is to check oil quantity upto standards. to check quantity, the rod is
stroke 2-4 times to drain all oil.
o Tiltness of rod is inspected.
o Inner cylinder head is taken out from tube with the help of fork.
o If inner tube coincides with the outer tube, tiltness is there and check by dropping the
inner tube in outer tube.
o Pictures are taken if contaminant is present in any of the part.

PRODUCT DEVELOPMENT

It is done in procedure of:

Product dimension checking
Product damping checking.
Damping checking is same for parts as it is done on machine and graph is on computer.

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Friction testing

In friction test we clamp the part with the help of a holder and weight is are placed over it
and friction value is checked .the test is of two types with weight and without weight.

Temperature testing

In temperature testing we check the values of damping at different temperatures as per

Toyota and JASO standards. The checking temperatures are -22C, 20C and 80C.

PRODUCT AUDIT

Product audit is sometime called as self-checking. It is done to check if the parts are made upto
standards or has some flaws. It is done in following manner:
Dimension inspection
Damping and GRF checking
Damping checking procedure is same as for NG parts as discussed earlier.
GRF testing is done on universal testing machine
The shock is mounted between fixture and load cell
At 10mm of recoil and compression recheck load which should come in the range of standard value for
368A RR is (50-70N)
Endurance testing

The part is operated up to 10 lac cycles on endurance testing machine and observations are
made

Damping & GRF Test

Damping and GRF test after endurance test.

Damping and GRF values should 30 percent change min or max after endurance test

Critical product characteristics (checking as per control plan)

The standards for checking are Toyota and as per JASO standards.

Durability testing

In durability test two rubbers are mount in machine and machine is started hitting the
rubber part continuously.
In this rubber is stationary and upper fixture in and out.
The deformation and the breaking of rubber are check as per standards (time
dependent operations)

Salt spray test

In this test special type of salt is sprayed on different parts for a particular period and
observations are made.
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In cupric acetic acid salt spray test water has acetic acid and sprayed on chrome plated
objects for sometimes and after spraying outlook of part is examined as per standards.
If rust appears than the part is NG.

MAINTENANCE DERPARTMENT
PREDICTIVE MAINTENANCE
Definition

The aim of predictive maintenance is two-fold. Firstly, to predict when equipment failure might
occur, and secondly, to prevent occurrence of the failure by performing any required
maintenance.
The task of monitoring for future failure allows maintenance to be planned before the failure
occurs.
Ideally, predictive maintenance allows the maintenance frequency to be as low as possible to
prevent unplanned reactive maintenance, without incurring costs associated with doing too
much preventative maintenance.

Techniques

Predicting failure can be done with one of many techniques.

The chosen technique must be effective at predicting failure and also provide sufficient warning
time for maintenance to be planned and executed.
The techniques include vibration analysis, oil analysis, thermal imaging, and equipment
observation.
Choosing the correct technique for performing condition monitoring is an important
consideration that is best done in consultation with equipment manufacturers and condition
monitoring experts.

Importance

When predictive maintenance is working effectively as a maintenance strategy, maintenance is

only performed on machines when it is required. That is, just before failure is likely to occur.
This brings several cost savings
Minimizing the time the equipment is being maintained.
Minimizing the production hours lost to maintenance.
Minimizing the cost of spare parts and supplies.
These cost savings come at a price, however. Some condition monitoring techniques are
expensive and require specialist and experienced personnel for data analysis to be effective.

Suitable Applications for Predictive Maintenance:

Applications that are suitable for predictive maintenance include those that:
o Have a critical operational function.
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Have failure modes that can be cost-effectively predicted with regular monitoring.

Unsuitable Applications for Predictive Maintenance.

Unsuitable applications for predictive maintenance include those that:

o Do not have a critical function.
o Do not have a failure mode that can be cost-effectively predicted.

Advantages Compared With Preventative Maintenance

Compared with preventative maintenance, predictive maintenance: equipment that requires

maintenance is only shut down before imminent failure.
This reduces the total time spent maintaining equipment.

Disadvantages Compared With Preventative Maintenance

Compared with preventative maintenance, the cost of the equipment for condition monitoring
needed for predictive maintenance is often high.
The skill level and experience required to accurately interpret condition monitoring data is also
high. Combined, these can mean that condition monitoring has a high upfront cost. Some
companies engage condition monitoring contractors to minimize the upfront costs of a
condition monitoring program.
Not all equipment have failures that may be more cost-effectively maintained using
preventative maintenance or a run-to-failure maintenance strategy. Judgment should be
exercised when deciding if predictive maintenance is best for a particular asset. Techniques such
as Reliability Centered Maintenance provide a systematic method for determining if predictive
maintenance is a good choice as an asset maintenance strategy for the particular asset of
interest.

PREVENTATIVE MAINTENANCE
Definition

Preventative maintenance (or Preventive Maintenance) is maintenance that is regularly

performed on a piece of equipment to lessen the likelihood of it failing.
Preventative maintenance is performed while the equipment is still working, so that it does not
break down unexpectedly.
Preventative maintenance is planned so that any required resources are available.

Technique

The maintenance is scheduled based on a time or usage trigger.

A typical example of an asset with a time based preventative maintenance schedule is an airconditioner which is serviced every year, before summer. A typical example of an asset with a
usage based preventative maintenance schedule is a motor-vehicle which might be scheduled
for service every 10,000km.

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Importance:

Preventative maintenance is more complex to coordinate than run-to-failure maintenance

because the maintenance schedule must be planned.
Preventative maintenance is less complex to coordinate than predictive maintenance because
monitoring strategies do not have to be planned nor the results interpreted.

Suitable Applications for Preventative Maintenance

Applications that are suitable for preventative maintenance include those that:
o Have a critical operational function.
o Have failure modes that can be prevented (and not increased) with regular
maintenance.
o Have a likelihood of failure that increases with time or use.

Unsuitable Applications for Preventative Maintenance

Unsuitable applications for preventative maintenance include those that:

o Have random failures that are unrelated to maintenance (such as circuit boards).
o Do not have a critical function.

Advantages and Benefits of Preventative Maintenance

Planning is the biggest advantage of preventative maintenance over less complex strategies.
Unplanned, reactive maintenance has many overhead costs that can be avoided during the
planning process. The cost of unplanned maintenance include lost production, higher costs for
parts and shipping, as well as time lost responding to emergencies and diagnosing faults while
equipment is not working. Unplanned maintenance typically costs three to nine times more
than planned maintenance. When maintenance is planned, each of these costs can be reduced.
Equipment can be shut down to coincide with production downtime. Prior to the shutdown, any
required parts, supplies and personnel can be gathered to minimize the time taken for a repair.
These measures decrease the total cost of the maintenance.
Safety is improved because equipment breaks down less often than for less complex strategies.
Preventative maintenance does not require condition based monitoring. This eliminates the
need to conduct condition monitoring as well as the need (and cost) to interpret the condition
monitoring data and act on the results of that interpretation. It also eliminates the need to own
and use condition monitoring equipment.

Disadvantages of Preventative Maintenance

Unlike reactive maintenance, preventative maintenance requires maintenance planning. This

requires an investment in time and resources that is not required with less complex
maintenance strategies.
Maintenance may occur too often with a preventative maintenance strategy. Unless, and until
the maintenance frequencies are optimized for minimum maintenance, too much or too little
preventative maintenance will occur.
The frequency of preventative maintenance is most likely to be too high. This frequency can be
lowered, without sacrificing reliability when condition monitoring and analysis is used. The
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decrease in maintenance frequency is offset by the additional costs associated with conducting
the condition monitoring.

TOTAL PRODUCTIVE MAINTENANCE

Definition

Total Productive Maintenance (TPM) is a maintenance philosophy that requires the total
participation of the work force.
It was first developed and implemented in Japan.
TPM incorporates the skills and availability of all employees to focus on improving the overall
effectiveness of a facility.
Effectiveness is improved by eliminating the wastage of time and resources.
Typically, TPM is a concept that is most easily applied to a manufacturing facility.

Phases

TPM is built upon 2 phases. The first phase, the 5 S, is a platform. The second phase is the 7 pillars of
TPM. These are built upon the 5 S platforms.
First Phase

The platform for TPM is the 5S. Originally these are 5 Japanese phrases beginning with S, but
there is an English translation of these. They all relate to the place where production is occurring
and are most obvious for the operators of the equipment.
o Sort Determine which items are used frequently and those that are not. The ones used
frequently should be kept close-to-hand, others should be stored further away.
o Systemize Each item should have one place to be stored, and only one place to be
stored.
o Shine The workplace needs to be clean, without it problems will be more difficult to
identify, and maintenance will be more difficult to perform.
o Standardize - The workplace should be standardized and labeled.
o Self-discipline Effort should be made to continually perform each of the other steps at
all times.

Second phase

Autonomous Maintenance. Operators are required to attend to the day-to-day maintenance of

their equipment, without engaging the dedicated maintenance team.
Focused Improvement
Planned maintenance instead of reactive maintenance
Quality maintenance
Education and Training
Safety, health and Environment
Office TPM

At the beginning of a TPM program the focus will be on the 5 S and on developing an Autonomous
maintenance plan. This will free the maintenance staff to begin larger projects and perform increasing
amounts of planned maintenance.
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Total Maintenance System

TPM requires a focus on the total maintenance system, from equipment design to asset
maintenance strategies.
Equipment should be designed to be maintenance free, as far as this is possible.
Improvements in maintenance techniques should be pursued wherever this is possible.
Preventative and predictive maintenance
strategies
should
be
implemented
to
eliminate reactive maintenance.

DETERMINE THE ROOT CAUSE: 5 WHYS

The 5 Whys is a technique used in the Analyze phase of the Six Sigma DMAIC (Define, Measure,
Analyze, Improve, Control) methodology. It is a great Six Sigma tool that does not involve data
segmentation, hypothesis testing, regression or other advanced statistical tools, and in many
cases can be completed without a data collection plan.
By repeatedly asking the question Why (five is a good rule of thumb), you can peel away the
layers of symptoms which can lead to the root cause of a problem. Very often the ostensible
reason for a problem will lead you to another question. Although this technique is called 5
Whys, you may find that you will need to ask the question fewer or more times than five before
you find the issue related to a problem.

Benefits of the 5 Whys

Help identify the root cause of a problem.

Determine the relationship between different root causes of a problem.
One of the simplest tools; easy to complete without statistical analysis.

When Is 5 Whys Most Useful?

When problems involve human factors or interactions.

In day-to-day business life; can be used within or without a Six Sigma project.

How to Complete the 5 Whys

Write down the specific problem. Writing the issue helps you formalize the problem and
describe it completely. It also helps a team focus on the same problem.
Ask why the problem happens and write the answer down below the problem.
If the answer you just provided doesnt identify the root cause of the problem that you wrote
down in Step 1, ask why again and write that answer down.
Loop back to step 3 until the team is in agreement that the problems root cause is identified.
Again, this may take fewer or more times than five Whys.

5 Whys Examples

Problem Statement: There was a heating problem in a unit.

o 1. Why is the problem?
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it may due to heating.

o Why Is the heating problem?
It may be due to heating unit problem or chiller problem or controlling problem.
o Why it is due to controlling problem?
It may be due to problem is controlling supply or equipment faculty or
controlling cards.
o Why it is due to controlling equipment faculty?
It may be due to problem is relay, coils or IGBTs.
In this case only four Whys were required to find out that a non-value added signature authority
is helping to cause a process breakdown.

5 Whys and the Fishbone Diagram

The 5 Whys can be used individually or as a part of the fishbone (also known as the cause and
effect or Ishikawa) diagram. The fishbone diagram helps you explore all potential or real causes
that result in a single defect or failure. Once all inputs are established on the fishbone, you can
use the 5 Whys technique to drill down to the root causes.

WHY WHY DIAGRAM OR FLOW

Heating
Unit
Problem

Controlling
Supply
Problem

Controlling
Unit
Problem

Controlling
Cards
Problem

Relays

Heating
Problem

Controlling
Equipment
Faulty

Coils

IGBT Faulty

IGBTs

Chiller
Problem

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MAINTENANCE MANAGEMENT SYSTEM

Maintenance management system is divided into preventive, predictive and breakdown plan.
PLANNED PREVENTIVE MAINTENANCE:

Planned preventive maintenance is scheduled into year plan, monthly plan and weekly plan and task list
is made of that plan and the n distributed into job planning centre. in job planning centre first
assessment of machine is made and work plan is also made and execution of work is done as per task
list. Customer satisfaction is most important part thats why after execution of work team waits for
feedback. If customer is satisfied then job is completed otherwise the whole cycle will be repeated.
It is done to avoid any breakdown in machine and to avoid sudden failure. Preventive maintenance is
planned on breakdown trends. The higher the breakdown of any machine the frequent schedule of
preventive maintenance is made.
BREAKDOWN MAINTENANCE:

First of all the complaint is launched on SAP which is received by maintenance department. On that
complain response is made in assessment of machine is made and plan is executed and all necessary
work is performed and wait for customer feedback. If customer is satisfied then the work order is
completed otherwise is again repeated.
It is done when machine has stopped production due to some problem. The breakdown can be avoided
upto some extent by daily patrolling of machine.
PREDICTIVE MAINTENANCE:

In this maintenance procedure first of all availability of machine is checked then inspection of machine
as per check list and predictive plan is made. If any abnormality is found in machine then the work plan
is made and execution of work is done and waits for customer satisfaction. If customer is satisfied the
job is closed otherwise is again repeated.
It is done to avoid any sort of failure of machine. It is done by daily patrolling of member on machine

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