15ME390L INDUSTRIAL TRAINING

A REPORT

Submitted by

PEARL MALHOTRA [Reg No: RA1611002010367]

in submission for assessment and award

of Grade for the course

BACHELOR OF TECHNOLOGY

in

MECHANICAL ENGINEERING

of

FACULTY OF ENGINEERING AND TECHNOLOGY

S.R.M Nagar, Kattankulathur, Kancheepuram District

MAY 2019
 SRM INSTITUTE OF SCIENCE AND
TECHNOLOGY
(Under Section 3 of UGC Act, 1956)

BONAFIDE CERTIFICATE

Certified that this report titled “ 15ME390L INDUSTRIAL

TRAINING” is the bonafied work of “Pearl Malhotra”, who carried
out the internship in “ Honda Cars India Ltd. Greater Noida, Uttar
Pradesh ” Certified further, that to the best of my knowledge the work
reported herein does not form any other training report on an earlier
occasion on this or any other candidate.

SIGNATURE SIGNATURE

Mr. V.Mathan Raj Mr. S.Dinesh

Assistant Professor (S.G) Assistant Professor (O.G)
Department of Mechanical Department of Mechanical
Engineering Engineering

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 ACKNOWLEDGEMENT
First of all, I would like to thank the almighty for the successful completion of this

Training.

I would like to thank HOD/Mechanical, School of Mechanical Engineering SRM

Institute of Science and Technology for allowing me to undergo internship in Industry

of our of interest pertaining to period of training not less than fifteen days.

I would like to extend our gratitude Honda Cars India Ltd. Greater Noida, Uttar
Pradesh for giving an opportunity to undergo training, which is one of the reputed
organization.

I place my gratefulness to all those departments related people in the organization for

disseminate their knowledge of experience and on task fun

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 ABOUT HCIL

1.1 Introduction

The history of the Honda Motor Company began with the vision of man- Soichiro
Honda. His dream was personal mobility for everyone.

Soichiro Honda states “You don’t have to believe in miracles to believe in the
power of dreams”.

Soichiro Honda founded the HONDA MOTOR COMPANY in 1948.In the same
year, he designed and engineered the first product of this company – 50cc motorized
bike on a bicycle frame- in his small shed at Hamamatsu.

SOICHIRO HONDA, FOUNDER HONDA MOTORS CO.

4
1.2 Company Profile

Honda Cars India Ltd (HCIL) is a subsidiary of

the Honda of Japan for the production,
marketing and export of passenger cars in India.
Formerly known as Honda Siel Cars India Ltd, Type Subsidiary

it began operations in December 1995 as a joint

Industry Automotive
venture between Honda Motor Company and
Usha International of Siddharth Shriram Group.
Founded December 1995
In August, 2012, Honda bought out Usha
International's entire 3.16 percent stake for 1.8 Headquarters Greater Noida, Uttar Pradesh

billion in the joint venture. The company

officially changed its name to Honda Cars India Number of Greater Noida, Uttar Pradesh
locations Bhiwadi, Rajasthan
Ltd (HCIL)
and became a 100% subsidiary of Honda. Key people Katsushi Inoue
It operates production facilities at Greater Noida (President and CEO)[1]

in Uttar Pradesh and at Bhiwadi in Rajasthan.

The company's total investment in its production Products Automobiles

facilities
Parent Honda
in India as of 2014 was over 21 billion.
HCIL's first manufacturing unit at Greater
Website hondacarindia.com
Noida
commenced operations in 1997. Setup at an initial
investment of over 4.5 billion, the plant is spread
over 150 acres (0.61 km2). The initial capacity of
the plant was 30,000 cars per annum, which was
thereafter increased to 50,000 cars on a two-shift basis.
The capacity has further been enhanced to 100,000 units annually as of 2008. This
expansion led to an increase in the covered area in the plant from 107,000 m² to over
130,000 m². The company invested 7.8 billion in Bhiwadi for its second production
plant with an annual production capacity of 50,000 units. It operates under the ISO
9001 standard for quality management and ISO 14001 for environment management

5
1.3 Models assembled in HCIL (Greater Noida Unit)

 Honda City ( Was Launched 1998)

 Honda Accord ( Was Launched 2001, production temporarily discontinued in
early 2014 in anticipation of all-new model)
 Honda Civic ( Was Launched 2006, production discontinued in 2012)
 Honda Jazz ( Was Launched in 2009, production discontinued in 2013, Re-
launching all new model in May 2015)
 Honda Brio ( Was Launched 2011)
 Honda CR-V (Was Imported since 2003; 2013 model locally assembled)
 Honda Amaze (Was launched April 2013)
 Honda Mobilio (Was launched July 2014)
1.3.1 CR-V
The Honda CR-V is a compact SUV (now called crossover in North America),
manufactured since 1995 by Honda. It was loosely derived from the Honda Civic.
There are discrepancies as to what "CR-V" stands for. Most state that is stands for
"Comfortable Runabout Vehicle”, although sales literature in UK has reportedly made
references to "Compact Recreational Vehicle.
In India, the 4th generation CR-V was launched in February 2013 with 2 variants, a
2.0litre petrol and a 2.4litre, 185bhp petrol. The 2.0litre variant will be equipped with
a six-speed manual five-speed automatic gearbox The 2.4 liter variant will come with
an automatic gearbox, Honda's on demand 4 wheel drive system and an Econ-mode to
increase fuel efficiency.

Fig.1.4 CRV
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1.3.2 CITY
The first generation Honda City was a subcompact car manufactured by the Japanese
manufacturer Honda from 1981. Originally made for the Japanese, European and
Australian and Asian markets, the City was retired in 1994 after the second
generation.
The nameplate was revived in 1996 for use on a series of compact four-door sedans
aimed primarily at developing markets, first mainly sold in Asia outside of Japan but
later also in Latin America and Australia. From 2002 to 2008, the City was also sold
as the Honda Fit Aria in Japan. By mid-2009, cumulative sales of the City has
exceeded 1.2 million units in 45 countries around the world since the nameplate was
revived in 1996.In 2011, the City is also sold as Honda Ballade in South Africa.

Fig.1.6 HONDA CITY

1.4 AWARDS WON

2015

 Best 15 family cars by KELLEY blue book.

 Top safety pick by IIHS.

2014

 Best Indian Company by Business Standard Group

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 Accord earned best car.

2006

 Manufacturer of the Year by NDTV Profit-Car India

 Manufacturer of the Year by CNBC-TV 18 Auto car India
 No 1 Medium Size Car (Honda City); No 1 Entry Luxury Car (Honda Accord)
and No 1 Premium SUV (Honda CR-V) by TNS
 Best Mid-size Car in Initial Quality (Honda City) and Most Appealing Mid-size
car (Honda City) by JD Power
 Best Indian Company (unlisted) by Business Standard Group

2005

 CNBC Auto car of the year 2004 - Honda City

 ICICI Overdrive SUV of the Year 2004 - Honda CR-V
 Business Standard Motoring Car of the Year 2004 - Honda City

1.5 HONDA GREATER NOIDA

8
Honda Siel Cars India Limited (HSCI) is a joint venture between the Honda Motor
Company of Japan and Siel Limited, a Siddharth Shriram Group company. It
currently is the 8th largest car maker in India after Maruti Suzuki, Hyundai, Tata
Motors, Mahindra, Chevrolet, Ford and Toyota. It inception took place in December
1995. The venture began with the aim of delivering Honda’s passenger car models
and technologies to the Indian market. The total investment made by the company in
India till date is over Rs. 2620crore. The company has a capacity of manufacturing
200,000 cars.

1.5.1 OWNERSHIP PATTERN

Honda Siel Cars India Limited (HSCI) was incorporated in December 1995 as a joint
venture between HONDA MOTOR CO. LTD., Japan and Siel Limited, a Siddharth
Shriram Group Company. HSCI currently holds 99.9% ownership and rest 0.1% lies
with Siddharth Shriram Group.

1.5.2 ENVIORNMENT AND SAFETY

The Honda Group is globally recognized for its concern towards environment, safety
and conservation of the society in which it operates. HCIL follows the same in India
for achieving high standards in environmental safety in the various processes of car
manufacturing.

1.5.3 MANUFACTURING FACILITY

HCIL state-of-the-art manufacturing unit was set up in 1997 at Greater Noida, U.P
with an investment of Rs. 450 crores. The initial installed capacity of the plant was
30,000 cars per annum, which was thereafter increased to 50,000 cars on a two-shift
basis. The capacity expansion was necessitated by the excellent performance of all the
Honda models, particularly the growing demand for City in India. The expansion
process also included expansion of the covered area in the plant, from 1, 07,000 sq. m.

9
to 1, 31, 794 sq. m. The company operates under the stringent standards of ISO 9001
for quality management and ISO 14001 for environment management

10
1.6 DEPARTMENTS IN HONDA
1. Parts Logistic Control (PLC)

2. Welding (WE)

3. Paint (PA)

4. Plastic Objects (PO)

5. Assembly Engine (AE)

6. Assembly Frame (AF)

7. Vehicle Quality (VQ)

8. Complete Build Unit (CBU)

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1.7 HONDA PHILOSOPHY

One of the most valuable things, which the founders of HONDA gave to the company, was
philosophy that serves as the basis of business endeavors of HONDA now and in future.
“Action without philosophy is a lethal weapon, philosophy without action is worthless”. The
center of HONDA philosophy is the company principle, which was written in 1956 under
lining the company principle

12
1.7.1 THE THREE JOYS

Fig.1.14

1.7.2 PDCA PRINCIPLE

It stands for PLAN-DO- CHECK-ACT. This is a cyclic process& continues in

reiterating if the proposed solution doesn’t work or taking up a new problem &
implementing.

13
1.7.3 KAIZEN

Fig.1.16

“Kai” means change, and "Zen" means good (for the better). Basically kaizen is for
small improvements, but carried out on a continual basis and involve all people in the
organization. Kaizen is opposite to big spectacular innovations. Kaizen requires no or
little investment. The principle behind is that "a very large number of small
improvements are more effective in an organizational environment than a few
improvements of large value. This pillar is aimed at reducing losses in the workplace
that affect our efficiencies. By using a detailed and thorough procedure we eliminate
losses in a systematic method using various Kaizen tools. These activities are not
limited to production areas and can be implemented in administrative areas as well.

1.7.4 5S (THE KEY TO SUCCESS)

1. SEIRI (Sort Out):-This means sorting and organizing the items as critical,
important, frequently used items, useless, or items that are not need as of now.
Unwanted items can be salvaged. Critical items should be kept for use nearby and
14
items that are not be used in near future, should be stored in some place. For this step,
the worth of the item should be decided based on utility and not cost. As a result of
this step, the search time is reduced.

2. SEITION (Organize):- The concept here is that "Each item has a place and only
one place". The items should be placed back after usage at the same place. To identify
items easily, name plates and colored tags has to be used. Vertical racks can be used
for this purpose, and heavy items occupy the bottom position in the racks

3. SEISO (Shine the Workplace):- This involves cleaning the work place free of
burrs, grease, oil, waste, scrap etc. No loosely hanging wires or oil leakage from
machines.

4. SEIKETSU (Standardization):- Employees has to discuss together and decide on

standards for keeping the work place / Machines / pathways neat and clean. These
standards are implemented for whole organization and are tested / inspected
randomly.

5. SHITSUKE (Self Discipline):- Considering 5S as a way of life and bring about

self-discipline among the employees of the organization. This includes wearing
badges, following work procedures, punctuality, dedication to the organization.

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1.8 HONDA QUALITY POLICY

Honda Cars are best known for their quality and comfort all over the world.

Honda Quality Policy states that,

“Maintaining a Global viewpoint, we are dedicated to supplying the products of

highest quality, yet at a reasonable price, for a worldwide customer satisfaction.”

Or simply, Honda strives for:

Making World Class Products of Highest Quality at reasonable Price and

provide Complete customer satisfaction.

All the 750-800 parts and over 2000 nuts and bolts used in assembling the car are very
carefully and systematically installed so that there is no chance of any problem or sub-
standard quality.

The company operates under the stringent standards of ISO 9001 for quality
management and ISO 14001 for environment management.

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1.9 HONDA TECHNOLOGY

Technology plays an important role in the modern era. Honda always believes in the
best technology.

1.9.1 I-VTEC
I -VTEC stands for Intelligent Variable Valve Timing & Electronic Lift Control.
The last evolution of Honda’s VTEC system was back in 1995 where they introduced
the now-famous- 3 stage VTEC system. The 3-stage VTEC was then designed for an
optimum balance of super fuel economy and high power with drivability. For the next
5 years, Honda still used the regular DOHC VTEC system for their top power models,
from the B16B right up to the F20C in the S2000. Now Honda has announced the
next evolution of their legendary VTEC system, the I-VTEC.

Honda introduced many new innovations in I-VTEC, but the most significant one in
the addition of a variable valve opening overlap mechanism to the VTEC system.
Named VTC for Variable Timing Control, the current (initial) implementation is on
the intake camshaft and allows the valves to be continuously varied during engine
operation. This allows for a further refinement to the power delivery characteristics of
VTEC, permitting fine-tuning of the mid-band power delivery of the engine.

Fig.1.18

17
1.9.2 I-DTEC

The 1.5 L I-DTEC engine in the New City has the best fuel economy in India with 26
km/l as tested by ARAI. It delivers a maximum power of 100ps@3600 rpm and
maximum torque of 200 N-m@1750 rpm. The top Fuel Economy and performance
has been achieved by application of advanced Diesel Engine technology. Low fuel
consumption technology is used for achieving the high fuel economy by reduction in
friction of each part, use of low viscosity oil and improvement of the cooling system.
Emission levels have been reduced by High swirl head port, high intake flow and low
compression ratio. Anew, low viscosity engine oil has been developed for the diesel

Fig.1.19

engine called as HONDA 3D Oil. Compared with the standard oil, the viscosity of the
new engine oil has been reduced at low temperature to maximize all engine
performance parameters. This new oil is highly cost competitive

The key points of this engine are:

o all aluminum open deck high pressure diecast engine block,

o High strength and lightweight crankshaft,
o lightweight piston, and
o low viscosity diesel engine oil.

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1.9.3 THE FUTURE

From now onwards, there will no doubt be countless attempts to second-guess at what
Honda will do to I-VTEC. There is all likelihood that Honda will implement I-VTEC
on its performance engines. The most probable beneficiaries will be the Integra and
the Civic, the two models which have always been at the forefront to carry Honda’s
high performance flag.

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1.10 G-CON

G-Con is Honda Motor Corporation’s internal passive safety standard. G-Con is short
for G-Force Control. The standards incorporated into G-Con are constantly updated to
benchmark against many of the world’s toughest crash safety regulations as well as
against data collected from real-world accident cases. The objective of G-Con is to
control the impact energy (‘G Force’) of a collision and reduce injuries to the vehicle
occupants.

G-Con was first announced in 1998, and all Honda vehicles developed from a new
platform since then are designed with G-Con Technology. G-Con is part of the wider
concept of Honda Advanced Technology.

As of to date, the G-Con test includes:

 55km/h full frontal collision

 64km/h frontal offset collision

 55km/h side collision

 50km/h rear collision

Most Crash testing is done in a controlled laboratory environment, against static

objects and thus many variables that affect a vehicle’s real world crash performance
are not evaluated. One of the main problems with real world collisions is the huge
disparity between weight, dimensions and body types of different vehicles on the
road. When vehicles of different weight and size collide, the vehicle’s passive safety
features may not work as intended. The differences in vehicle designs may cause of
the colliding vehicles to under-ride or over-ride, limiting the vehicle’s frames to
properly absorb/ disperse the impact energy.

Recognizing this, Honda built the world’s first indoor car-car Omni-directional crash
test facility in its Tochigi R&D Center in year 2000. This allows Honda to now
simulate collisions between multiple vehicles of any body type, from any direction.
With results from tests done from this facility, Honda was able to further build on its
G-Con technology to incorporate Advance Compatibility Engineering, Honda’s term
for crash compatibility body

20
 ASSEMBLY FRAME

2.1 INTRODUCTION

The Assembly Frame is the Final Line where the Final Assembly of the car is done.
Each process is performed strictly according to its OPS. Assembly Frame consists of
9 major Sections & 13 Line Quality points. Manufacture of complete car units with
KD, local parts, and other assemblies/subassemblies after receiving painted body
sheet and Engine Assemblies. These all are done in assembly frame.

First of all painted body from paint is received is called AF on. After this trim -1 &
trim-2 lines are there .All the trim parts are attached air with painted body. In between
there is dashboard assembly. In which complete dashboard is assembled. Then there is
chassis line & after that there is final line. There is also engine sub assembly. In it
some KD & local parts are assembled to it. Then this sub assembly is sent to chassis
line

The Assembly Line is U-Shaped and mainly 4types of Conveyors are used to carry
the cars forward on the line. These types are:

 Carrier Type Conveyor.

 Friction Conveyor.
 Slat Conveyor.
 Power & Free (P&F) Conveyor.

1. Carrier Type Conveyor consists of hanging jigs on which the car is rested. This
type of conveyer is used when the work to be done is mainly under the body. Carrier
Type Conveyer is used at the Chassis and AF-ON sections.

2. Friction Conveyor consists of flat metallic electrically driven heavy capacity

carriers. These are quiet and clean, with no chain. The car rests on the flat surface
while moving smoothly forward. This conveyor is designed for use with high
production rates (20% faster than P&F). It can be easily installed and requires low
maintenance. It is used at the Wiring and Interior sections.

21
3. Slat Conveyor drive unit consists of a motor, chain wheels, drive chains, slat
chains, a chain coupling, pillow units and a shaft. Slat conveyor is used at Exterior
and Complex sections.

4. Power & Free Conveyor is realized on extremely simple operating principles

using only one source of energy (electromechanical functioning). The number of parts
used for disengagement is reduced to a minimum and consists of only rotation around
fixed pin. Transfer from one chain to another is in most cases performed by the chains
of the conveyor and therefore without the use of complex transfer devices. It is used at
the Engine Sub-Assy.

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2.2 GENERAL PROCESS SEQUENCE

WIRING INTERIOR

VEHICLE EXTERIOR CHASSIS

QUALITY

Fig.2.2

2.2.1 WIRING

Station 1: Rear Wire Harness, Trunk Open Cable, Cushion Wire Harness, Trunk
Cable Installation.

Station 2: Engine Mounting Install, Cabin Wire Harness, Earth Bolt Install.

23
 Fig.2.3 Master Power Cylinder

Station 3: Door Removal. The doors removed from the car are held onto jigs and are
transported to the Door Sub-Assy via overhead conveyor.

Station 4: Wiper Install, Master Power Cylinder, Side Indicator Install.

Station 5: Hood open wires, Light (number plate) install.

Station 6: Auto Radio Antenna install.

Station 7: Roof Lining, Roof Handle, Map Light, Hood Open Switch Install.

Station 8: Horn, Fuel Lid Lock, Trunk Lock Installation.

WIRING LQ

2.2.2 INTERIOR

Station 1: SRS Unit, Seat Belt Install.

Station 2: Rear Damper Install

Station 3: Wiper Water Tank, Air Duct, RHS Tail Light, Sun Visor Install.

24
 Fig.2.4 Rear Damper

Station 4: Floor Mat, Radiator Install.

Station 5: Accelerator, Brake, Clutch Pedal, Head Light, Door Trim, Left Tail Light
Install.

Station 6: Dash-board Installation.

Dash-board is installed with the help of In-Panel Assist Robotic Arm. It is helpful in
lifting and carrying the heavy Instrument Panel into the car.

25
2.2.3 CHASSIS

Station 1: Inner Fender, Complex Fuel Filler Pipe from fuel lid to the fuel tank, Fuel
Tank Install.

Station 2: Rear Suspension Docking using mechanical jig, Rear wheels install,
bearing assembly, hub unit, Rear Brake Drum Install.

Station 3: Engine Docking, Front Suspension, Wheels install.

Station 4: Brake Hose Tighten, ATF Hose Connection, Cover Control Wire
Installation.

Station 5: Exhaust Pipe (from engine), return pipe (with gearbox) connection.

Station 6: Splash Shield Install.

Station 7: 4 tires + Spare tire install.

Station 8: Brake Bleeding

Here the brake oil is filled with the help of Brake Oil Machine. Also the ABS
Modulator is energized by using an ABS Coupler.

26
2.2.4 EXTERIOR

Station 1: Trunk Garnish, Gear Select Lever, Tool Kit Install.

E.P.S. (Electric Power Supply) Unit is installed at this station. It is used to supply
electric power from the battery to all the electronic devices, lights etc.

Station 2: Seat side Garnish, Rear Seat Install.

Station 3: Central Console, Air Cleaner/Filter Install.

27
Station 4: Windshield Transfer.

Station 5: Front & Rear Windshield Install.

Station 6: Battery Install.

Station 7: Front Seat installation. It is done with the help of Robot as heavy lifting is
involved, Emblem, and Speaker cover install.

Station 8: Door Installation. The doors coming via overhead conveyor are installed
back onto the car. Door Checker Install.

Station 9: First Aid kit, User Manual, Accessories install, Bumper & Fender Cover
Removal.

Station 10: Petrol Filling.

Station 11: Coolant Filling.

Station 12: Rear Wiper, Steering Install. Car is started for the first time.

28
 CAR ENTERING COMPLEX SECTION

2.2.5 INT-FUN COMPLEX LQ

Station 1: Overall checkup.

Station 2: Complex Repair Area.

This marks the end of the Assembly Frame Department area. If any defect is found in
the car, it is sent to the CQA (Car Quality Assurance) area where the required repairs
and amendments are done.

From here onwards, the car is handed over to the VQ (Vehicle Quality) Department
where the car is even more rigorously and closely checked for quality.

29
2.3 SUB ASSEMBLY LINES

Besides the main assembly line, there are a few sub-assembly lines where various
parts of the car are pre-assembled and then transferred to the main line for the final
assembly. These Sub-Assembly lines are:

o Door Sub-Assy.

o Instrument Panel Sub-Assy.

o Engine Sub-Assy.

2.3.1 REAR SUSPENSION SUB ASSEMBLY

Two stations used for assembling rear suspensions. These stations are present in the
beginning of the chassis line.
The Various parts assembled are:
 Knuckle
 Caliper
 Bearing Fitment
 Sensor bracket
 ABS sensor
 Flash guard
 Half bearing
 Brake Plate fitment
 Hand brake wire
 Trailing arm

2.3.2 INSTRUMENT PANEL SUB ASSEMBLY

Nine stations are used for complete assembly of the instrument panel. These stations
are present in DCC1. The Various parts assembled are:

1. Beam Comp Steering Hanger

2. Dashboard Fuse Box
3. Dashboard wire harness

30
 4. Dashboard fuse box
5. Instrument panel installation
6. Combi-meter
7. Speedometer
8. Sensor Fitment
9. Pad Assembly fitment
10. SRS airbag unit
11. Center panel Heater Control
12. Steering Column Assembly
13. Meter display cover

2.3.3 WIND SHIELD SUB ASSEMBLY

Wind shield sub-assembly is also done in DCC1. Two stations are used:
The Various parts assembled are:
1. Clip fitment
2. Dang fitment
3. Molding fitment
4. Seal fitment
5. Primer application
6. Fastener fitment (for rear mirror)

2.3.4 TYRE SUB ASSEMBLY

1. Tire sub-assembly is done in DCC1.

2. Three stations are used. Assembly of all four wheels of the car is done
here.
3. The Various parts assembled are:
4. Alloy wheel mounting
5. Soap solution application
6. Tire inflation (44 Psi)
7. Wheel balancing

2.3.5 DOOR SUB ASSEMBLY

31
Twelve stations are used for door subassembly. Doors are removed from the painted
body frame entering TRIM 1 and are sent to the sub-assembly stations. On complete
assembly they are reassembled in the car at the final assembly line.

The Various parts assembled are

1. Sub Seal
2. Regulator
3. Harness installation
4. Door Checker
5. Door Seal
6. Sealer Application
7. Outer Handle fitment
8. Inner Handle fitment
9. Quarter glass
10. Door lock
11. Run channel
12. Mirror fitment

2.3.6 FUEL AND BRAKE PIPE ASSEMBLY

The Various parts assembled are:

1. All Locks Are Numbered Body Instruction Card No.

2. Fuel Pipes Assembled
3. Brake Pipes Assembled

2.4 USE OF MANPOWER & MACHINES TO ACHIEVE A

COMMON GOAL

The assembly processes are performed in a set sequence. The sequence is designed in
such a way that each part can be easily fitted into the car and there is no need to
remove any other previously installed part to do the same.

The assembly is done both manually and with robotic help. Pneumatic machines are
used at stations which require heavy load lifting, precision or delicate work which if

32
otherwise done manually may require large man-power or may lead to damage or loss
of precious time.

At HCIL Assembly Frame, Pneumatic machines are used at various stations such as,
Door Removal, Instrument Panel Installation, Rear Suspension Docking, Engine
Docking, Brake Bleeding, Door Installation, and Fuel& Coolant Filling Stations.

These machines may be Robot assisted Pneumatic jigs, Heavy lifting machines or
Automatic Coolant, Fuel, Water filling machines.

Pneumatic jigs are used at In-Panel Assist, Suspension & Engine Docking. Heavy
lifting is done at Suspension & Engine Docking and Door Removal/Installation
Stations.

Fig.2.10 A ROBOTIC ARM USED TO ASSIST IN ASSEMBLY

33
 LET REDUCTION

3.1 INTRODUCTION

LET stands for line electrical tester.

It test whether all the electrical components of the cars are working properly or not.

LET Errors are caused due to some fault in any part of the vehicle from department
like VQ, AF or AE etc or when vehicle comes to CQA, any particular part is opened
then also LET errors may appear.

LET errors are Checked with the help of OBD between the VQ and the Q-UP Line.

OBD displays the code which is then written on CVIC(Complete Vehicle Instruction
Sheet).

Then the LET Errors are checked in the CQA with the help of HDC and sent to
respective department for repairing.

3.2 LET Error Data for CR-V :

After the LET errors are identified and eliminated, a graphical report is made which
shows from which department LET errors were caused. It was seen the 32.075% of
the CR-V’s was having LET errors. Below is the graphical representation of Honda
CR-V LET errors from different departments.

34
 LET Errors from different departments

12%
17%

AF
18%
VQ
AE
PART

53%

3.3 THE STEPS TAKEN TO ELIMINATE LET ERRORS AT

THEIR VERY SOURCE.

The list of the most common LET Errors was prepared and sent to the respective
department so that from now onwards associates will be more cautious while the
vehicle is prepared.

Following is the list of most common LET errors caused from the following
department.

1. VQ :
a. 12VBCHECKG2
b. BK SP CHECK
c. ACCSI(SW)
d. DI PUMPER
2. AF :
a. ABS VSA DTC

35
3. AE:
a. Mission Shift
4. Part: LET NG

36
 CONCLUSION

The above project was undertaken and carried out on the assembly frame and CQA
and as an outcome the LET errors on the cars are minimized. This further resulted in
increased efficiency on the line thus reducing operation costs.

This training was a great learning experience for me. It has been a pleasure to be a
part of technological superior organization like Honda Ltd. This training period was
one of the best times of my engineering curriculum. I had the opportunity to come
along with some of the latest technologies used extensively in the manufacturing
industry. It helped me assimilate the fundamentals that are required in dealing with
people.

It has also helped me to bridge gap between the theoretical and practical aspects of
looking at a technical problem.

I am sure that after this training and practical knowledge I will be able to visualize
work situations better. This training definitely will enhance my rate of progress in
future. This will help in building my personality in my professional career in a
better way .

37