PRESENTATION ONOPERATION PROCESSING STANDARD OF

PRESS PARTS PACKING IN TRANSPORTATION TROLLEYS

presented bytamal mukherjee Indus Business Academy (FPG/1012/025)
HONDA SIEL CARS INDIA LTD.

AGENDA
About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

continued.

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings Result Learning Conclusion References

AGENDA
About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

About HSCI, TKR plant

After GNU, 2nd facility was set up in 2008 Spread over 600 acres with investment of 1000cr. Annual capacity- 60000 units Inaugurated in- Sept2008 Press parts & PT parts manufactured Parts supplied to GNU for final assembly Every scope of producing Brio in this facility

AGENDA
About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart allied with press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

Project Premise
Project associated with PLC Dept. of HSCI, TKR plant To ensure ideal & accurate delivery of press parts to GNU To establish checking standards for each transportation trolley used for 2PY, 2AZ & 2CV Setting check points of the transportation trolleys in 3 stages1) Trolleys in dismantled condition 2) Trolleys in assembled condition 3) Trolleys packed with press parts To avoid any damages like scratches, dent, flange bend over the parts Newly set up plant, preparing OPS with respect to PLC Dept.

AGENDA
About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart allied with press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

Introduction of PLC Dept.

Delivers the right quantity, right quality of material on the line at right time & right place to meet the required production target Responsible for supplying all the necessary material for production In PLC team, few private companies are-

AGENDA
About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart allied with press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

PLC Responsibilities

AGENDA
About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

Press parts Identification

continued.

HONDA CITY (2PY) 1) HOOD SKIN 2) TRUNK LID SKIN 3) FR. DOOR SKIN (R) 4) FR. DOOR SKIN (L) 5) RR. DOOR SKIN (R) 6) RR. DOOR SKIN (L) 7) FR.FENDER (R) 8) FR.FENDER (L) 9) ROOF PANEL 10) SPO (RH) 11) SPO (LH) 12) FRONT FLOOR 13) REAR FLOOR 14) TRUNK LID FRAME 15) HOOD FRAME 16) FR. DOOR PANEL(R)

HONDA BRIO (2CV) 1) HOOD SKIN 2) SPOILER 3) FR. DOOR SKIN (R) 4) FR. DOOR SKIN (L) 5) RR. DOOR SKIN (R) 6) RR. DOOR SKIN (L) 7) FR.FENDER (R) 8) FR.FENDER (L) 9) ROOF PANEL 10) SPO (RH) 11) SPO (LH) 12) FRONT FLOOR 13) REAR FLOOR 14) SPOILER FRAME 15) HOOD FRAME 16) FR. DOOR PANEL(R) 17) FR. DOOR PANEL(L) 17) FR. DOOR PANEL(L) 17) FR. DOOR PANEL(L) 18) RR. DOOR PANEL(R) 18) RR. DOOR PANEL(R) 18) RR. DOOR PANEL(R) 19) RR. DOOR PANEL(L) 19) RR. DOOR PANEL(L) 19) RR. DOOR PANEL(L) 20) PANEL RR. INSIDE(RH) 20) PANEL RR. 20) PANEL RR. INSIDE(RH) INSIDE(RH) 21) PANEL RR. INSIDE(LH) 21) PANEL RR. INSIDE(LH) 21) PANEL RR. INSIDE(LH)

HONDA JAZZ (2AZ) 1) HOOD SKIN 2) TAIL GATE SKIN 3) FR. DOOR SKIN (R) 4) FR. DOOR SKIN (L) 5) RR. DOOR SKIN (R) 6) RR. DOOR SKIN (L) 7) FR.FENDER (R) 8) FR.FENDER (L) 9) ROOF PANEL 10) SPO (RH) 11) SPO (LH) 12) FRONT FLOOR 13) REAR FLOOR 14) TAIL GATE FRAME 15) HOOD FRAME 16) FR. DOOR PANEL(R)

AGENDA
About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

Process flow chart with allied press parts

AGENDA
About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

Trolley Introduction

Two or four wheeled carriage Used to carry goods Used to move according to needs In HSCI, TKR plant trolleys are used for dispatching good to GNU

continued.

Pictorial form

2PY TROLLEY

2AZ TROLLEY

2CV TROLLEY

CONROD TROLLEY

PRESS TROLLEY

CRANKSHFT TROLLEY

AGENDA
About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

Classification of Trolley

TROLLEYS

Transportation Trolleys

Press Trolleys

Trolleys for press parts

Trolleys for PT parts

AGENDA
About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

Specialty of transportation trolley

To absorb shocks during transportation, appropriate absorbers are used in each trolley To avoid part damages and scratches, few special materials like style foam, EVA sheet, PU sheet, PVC pipe are used To avoid jerks during transportation, shock absorbing wheel are used in the trolley which is known as caster wheel. These wheel are of two typea) fixed wheel b) movable wheel For toeing so many trolleys together, toeing bar with toeing hook is used in each of the trolley

AGENDA
About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

Classification of transportation trolley

Transportation trolleys

Unique/Different trolleys
(Trolleys in which press parts of a single model is packed)

Common trolleys
(Trolleys in which press parts of each of the three models can be packed)

FR. FENDER (R & L) ROOF PANEL SPO (R & L) PANEL RR. INSIDE (R & L) FRONT FLOOR REAR FLOOR TRUNK LID/TAIL GATE SKIN/SPOILER TRUNK LID/TAIL GATE/SPOILER FRAME

HOOD SKIN HOOD FRAME FR. DOOR SKIN (R & L) RR. DOOR SKIN (R & L) FR. DOOR PANEL (R & L) RR. DOOR PANEL (R & L)

AGENDA
About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

Identification of common trolley

FR.DOOR SKIN(R & L) TROLLEY:

This location is common for 2AZ & 2CV in a single trolley. Yellow color is for 2AZ & Red color is for 2CV parts

This location in trolley (blue color) is used for packing 2PY parts

AGENDA
About HSCI, TKR plant Project premise Introduction of PLC Dept. in HSCI, TKR plant PLC responsibilities Press parts identification Process flow chart with allied press parts Study on trolleys 1) Trolley introduction 2) Classification of trolley 3) Specialty of transportation trolley 4) Classification of transportation trolley 5) Identification of common trolley 6) Model wise trolley identification

Model wise trolley identification

2PY Unique trolleys 2AZ Unique trolleys 2CV Unique trolleys Common trolleys for 2PY, 2AZ & 2CV

AGENDA

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings Result Observation Conclusion References

Checking standards in two stages

For 2PY, 2AZ & 2CV Transportation trolleys:
Stage- I: Observing the trolleys in dismantled condition while the parts of the trolley are not attached to it

a) Must not be any welding defects b) Should not be any bending c) Must not be any sharp edges or corners in the trolley d) Presence of PVC pipe, EVA sheet, PU sheet, Absorbers, Style foam, cable tie, superlon tube is must in the trolley f) Any partition or separating or supporting bracket used in the trolley, must be equally spaced

continued.

Stage- II: Observing the trolleys in assembled condition while the parts of the trolley are attached to it but the press parts are not packed in the trolley

All the welding joints should be checked in assembled condition, that whether joints are welded properly or not. There should not be dust or rust on the part rest area in the trolley. Wheels of the trolley should move at ease, very freely. It must be ensured that Toeing bar & Toeing hook are available in proper way in the trolley. In each of the assembled trolley, none of the accessories should be in broken condition. Trolley, in which wire mesh is used, must be in a uniform manner. It must not be in ragged condition. Locking arrangement available in each trolley must be easily operable.

AGENDA

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings Result Observation Conclusion References

Checking standards at 3rd stage

2CV PANEL RR. INSIDE TROLLEY (L & R)
1

1) SIDE LOCKING BAR

6 2) PART GUIDE ROD 3) DUMMY PART (right) 2 3 4) PART RESTING FRAME

5) FLAT SUPPORTING GAUGE 6) DUMMY PART (left) 5

continued.

Packed RR. Inside Trolley

AGENDA

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings Result Observation Conclusion References

Findings

Any deviation found in the trolley, from the above checking standards is not permissible & packing of the parts is not allowed in that trolley At the time of unloading the trolleys from the trucks, which comes back from GNU, if any deviation from the standard checking items are found in the trolley, its considered as NG (not good) trolley Routine repairing and maintenance activities are followed upon the NG trolleys

AGENDA

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings Result Observation Conclusion References

Result

Before finalizing the dispatch, if these standards are followed, chances of damages like scratches, dents, flange bend on the parts can be depleted to a significant level

AGENDA

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings Result Observation Conclusion References

Observation
HONDA is the synonym of quality Praiseworthy management policies towards the employees which enable them to think, learn, evaluate & analyze problems while working with complete freedom without any domination Admirable healthy culture is prevalent throughout the organization Proper consumables are allocated to every HONDA employees to ensure safety while working

AGENDA

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings Result Observation Conclusion References

Conclusion

Usage of spring lock system over the side locking bar, must be incorporated in each trolley Total trolley making cost can be reduced to some extent while depleting the usage of cable tie, wire locking & reinforcement sheet attached to the trolley

AGENDA

Checking points in transportation trolleys in two stages Checking items at 3rd stage before dispatch Findings Result Observation Conclusion References

References

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