HONDA CARS INDIA LIMITED

HONDA CARS INDIA LIMITED

HONDA CARS INDIA

LIMITED
Industrial Training Report

DURATION OF TRAINING: 01/06/2015 TO 30/06/2015

SUBMITTED BY: ANURAG BHARDWAJ APPROVED

BY: .......................................

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(MR.KAMAL JOSHI)

CHECKED
BY: ..........................................

(MR.SACHIN SHUKLA)

Acknowledgement
This industrial training was a big eye opener for us prospective engineering professionals aiming to gain
knowledge about a mega production plant and this would not have been possible if we did not have support of
many individuals. Therefore we would like to extend our sincere gratitude to all of them.

The internship opportunity we had with HONDA CARS INDIA Ltd. was a great chance for learning and
professional development. Therefore, we consider ourselves very lucky individuals as we were provided with an
opportunity to be a part of it.

We are using this opportunity to express our deepest gratitude and special thanks to Mr. Kamal Joshi ( H.O.D-
Utility), Mr. Raj Kumar Paliwal (Manager-Utility), Mr. Sachin Shukla, Utility Dept. who took time out to hear,
guide us during our training.

We express our deepest thanks to Mr. Gaurav Mathur, Utility Dept. for giving necessary advices and guidance
and arranged all facilities to make our lives & access to different departments a lot easier.

We also express our deepest thanks to Mr. Chandan Bhatia & Mr. Anshul Aggarwal , Utility Dept. for entrusting
us with a project and providing any kinds of help or resources regarding the project.

Last but not the least we would like to thank every department, engineer and operator who let us in and took out
time from their busy schedules to provide valuable knowledge to us students.

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List of Contests
1. Abstract...................................................................................................04

2. HCIL-Brief Profile..................................................................................05

3. Utility Department..................................................................................05

 Compressor House.........................................................................06
 Diesel Generator House.................................................................08
 132 KV Switch House & Substations...........................................10
 Fire Pump House...........................................................................14
 Water Treatment Plant..................................................................15
 Waste Water Treatment Plant.......................................................17
 Yards.............................................................................................19

4. Project Undertaken.................................................................................20

5. A/F Shop.................................................................................................22

6. PA System...............................................................................................24

7. PO Shop...................................................................................................25

8. POPA Shop..............................................................................................26

9. SPC Shop.................................................................................................27

10. Press Shop..............................................................................................28

11. Conclusion..............................................................................................30

12. Bibliography............................................................................................31

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Abstract
As we mentioned earlier that our main purpose for this internship/ industrial training was to gain knowledge and
get perspective regarding the operation of a mega production facility. Our wishes were more than answered
when HONDA CARS INDIA Ltd. provided us with an opportunity like this to intern at the Tapukara plant. This
internship has been really an eye opener for us all. We were placed in the Utility dept. and primarily toured all
the sub divisions coming under them. Utility dept. was responsible for mainly running and aiding the plant
behind the scenes. It provided and helped in maintenance of the 4 major industrial utilities i.e. electricity, water,
natural gas & air. Utility dept. does not manufacture any vehicle but without their aid & behind the scenes hard
work even manufacturing dept. can do nothing. We also had the great opportunity to observe different
departments other than the Utility. It was the first time that we had seen a mega factory up close & personal. One
thing which struck us was that how such a giant manufacturing plant operates, it is so huge that it has several
departments some of which functions individually as a small autonomous unit itself. Each dept. can have many
sections as well, in order to manage them there are section heads and above them there is a consolidated head
called the Head of Dept. (H.O.D) . A plant this big is like an enlarged machine which has individual intelligent
parts which function individually and together to create a final product i.e. a HONDA car.

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HONDA Cars India Ltd.- Brief 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, it began operations in December 1995 as
a joint venture between Honda Motor Company and Usha International of Siddharth Shriram Group. In August,
2012, Honda bought out Usha International's entire 3.16 percent stake for ₹1.8 billion in the joint venture. The
company officially changed its name to Honda Cars India Ltd (HCIL) and became a 100% subsidiary of Honda.

HCIL's first manufacturing unit was set up at Greater Noida, U.P in 1997. The plant is spread across 150 acres
and has an annual production capacity of 120,000 units. HCIL's second plant in Tapukara is the first car
manufacturing plant in the state of Rajasthan. The state-of the art Power train and Press shop in Tapukara plant
have been operational since September 2008. This facility is spread over 450 acres and has an annual production
capacity of 120,000 units. HCIL started the production of cars from its Tapukara Plant from February 2014.

Utility Department
Utility dept. as we mentioned earlier is the dept. responsible for maintaining & supplying water, electricity,
natural gas & air to the plant where they are utilized in production. The 4 major utilities in industry are
electricity, water, natural gas & air. Without the utilities a plant cannot produce because it's the key component
on which all the machines and tools operate which are then used to convert raw material into finished goods. The
utility dept. has different kinds of treatment plants, substations, switch house, compressor houses, diesel
generator house etc. Basically it deals with energy and its different forms. It's like the fuel that is required to run
a machine, in this case utility dept. is the fuel & the whole plant is the machine.

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Compressor House
Definition: By definition a compressor house is that area of the plant that supplies clean and dry compressed air
to different departments in the plant for further use. There are namely two compressor houses in the Honda plant,
they are compressor house-1 & compressor house-2.

Importance & Uses of Compressed Air: Compressed air, commonly called Industry's Fourth Utility, is air that is
condensed and contained at a pressure that is greater than the atmosphere. The process takes a given mass of air,
which occupies a given volume of space, and reduces it into a smaller space. In that space, greater air mass
produces greater pressure.

Industrial Plant Maintenance: Air tools, such as paving breakers, are used to fix cement floors, to open up brick
walls for assorted service lines, and other comparable work.

For other maintenance work, plants can use air-operated drills, screwdrivers, and wrenches, provided that the air
outlets are well placed throughout the plant. Painting can be done using paint-spraying systems.

On the Production Line: Pneumatic tools are convenient for industrial production because they have a low
weight-to-power ratio, and they may be used for long periods of time without overheating and with low
maintenance costs. Chipping and scaling hammers are used in railroads, oil refineries, chemical refineries,
shipyards, and many other industries for general application. They are also used in the foundry for cleaning large
castings, and to remove weld scale, rust, and paint in other industries.

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Pneumatic drills can be used for all classes of reaming, tapping, and drilling anytime that the work cannot easily
be carried to the drill press and for all classes of breast drill work. These air-powered drills are also often used
for operating special boring bars, and in emergencies, for independent drive of a machine tool where required
horsepower is within their capacity.

Different tools running on compressed air like impact wrench, air ratchet & pneumatic paint sprayer.

(source: www.indiamart.com)

List of Compressors: There are 6 compressors in compressor house-1 & general pressure requirement is around
6.5 bar. There are 3 compressors in compressor house-2 & general pressure requirement is around 5.5 bar.
Compressors from 2 companies are employed in the plant, they are Atlas Copco & Ingersoll Rand. All Atlas
Copco compressors are screw type & are needed where the pressure requirement is high. All Ingersoll Rand
compressors are Centrifugal type & are needed where higher amount of air is required. Following is the list of
compressors employed at the plant.

Compressor House-1

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Maximum Air Pressure

Manufacturer Compressor Type
7.5 bar
Atlas Copco Screw
8.6 bar
Atlas Copco Screw
8.6 bar
Atlas Copco Screw
8.6 bar
Atlas Copco Screw
8.6 bar
Atlas Copco Screw
6.5 bar
Ingersoll Rand Centrifugal

Compressor House-2

Maximum Air Pressure

Manufacturer Compressor Type
8.6 bar
Atlas Copco Screw
6.5 bar
Ingersoll Rand Centrifugal
6.5 bar
Ingersoll Rand Centrifugal

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Diesel Generator House

Definition: A Diesel generator house or D.G. House as it's called is that unit of the plant which houses the diesel
generators to provide electricity whenever the electric supply from the main power grid fails or during a power
cut.

D.G. House in the plant consists of 5 diesel generators. A diesel generator is the combination of a diesel
engine with an electric generator (often an alternator) to generate electrical energy. A diesel compression-
ignition engine often is designed to run on fuel oil, but some types are adapted for other liquid fuels or natural
gas. The packaged combination of a diesel engine, a generator and various ancillary devices (such as base,
canopy, sound attenuation, control systems, circuit breakers, jacket water heaters and starting system) is referred
to as a "generating set" or a "genset" for short. Together these gensets can provide around 11 kV electric supply
almost equivalent to grid but they are very expensive to run due to high consumption of fuel used.

Generators Present: Out of the 5 gensets, 4 are from Cummins and 1 is from MAN. Out of the 4 gensets from
Cummins, 2 can generate 1.2 MW & other 2 can generate 1.6 MW. They have speeds ranging around 1500 rpm.
Cummins generators are utilizing a V-16 diesel engine which is liquid cooled as well as turbocharged. It also has
2 Fleetguard air filters for filtering purposes. It also has 4 fuel filters out of which 2 are ultra fine filters.

A Cummins diesel generator (source: www.gongyi-generator.com)

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The last genset present is the genset from MAN. It's large genset that is capable of producing 2.5 MW. It's a
pneumatic or air starter generator. Compared to a gasoline ("petrol") engine, diesel engines have very
high compression ratios to improve engine efficiency. An electric starter powerful enough to turn a large diesel
engine would itself be so large as to be impractical, thus the need for an alternative system. When starting the
engine, compressed air is admitted to whichever cylinder has a piston just over top dead centre, forcing it
downward. As the engine starts to turn, the air-start valve on the next cylinder in line opens to continue the
rotation. As this goes on, fuel is injected into the cylinders, the engine is then under way and the air is cut off.
This genset can run on diesel as well as on furnace oil. It's a low speed engines with speed ranging around 750
rpm.

A MAN diesel generator (source: www.trade-romania.ro)

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132 KV Switch House & Substations

Introduction: The present-day electrical power system is A.C. i.e. electric power is generated, transmitted and
distributed in the form of alternating current. The electric power is produced at the power stations which are
located at favourable places, generally quite away from the consumers. It is delivered to the consumers through a
large network of transmission and distribution. At many places in the line of the power system, it may be
desirable and necessary to change some characteristic (e.g. voltage, A.C. to D.C., frequency, Power factor etc.)
of electric supply. This is accomplished by suitable apparatus called sub-station. For example, generation voltage
(11KV or 6.6KV) at the power station is stepped up to high voltage (say 220KV or 132KV) for transmission of
electric power. The assembly of apparatus (e.g. transformer etc.) used for this purpose is the sub-station.
Similarly, near the consumer’s localities, the voltage may have to be stepped down to utilization level. This job is
again accomplished by a suitable apparatus called substation.

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Interior of a substation consisting distribution and controlling panels or altering various parameters (source:
www.blackburn-starling.co.uk)

Types of Substations in Plant:

Transformer sub-stations, sub-stations which change the voltage level of electric supply are called transformer
sub-stations. These sub-stations receive power at some voltage and deliver it at some other voltage. Obviously,
transformer will be the main component in such sub-stations. Most of the sub-stations in the power system are of
this type.

Switching sub-stations, sub-stations that do not change the voltage level i.e. incoming and outgoing lines have
the same voltage. However, they simply perform the switching operations of power lines.

Different Components of Substation

a) Lightening Arrestors: Lightening arrestors are the instruments that are used in the incoming feeders so that to
prevent the high voltage entering the main station. This high voltage is very dangerous to the instruments used in
the substation. Even the instruments are very costly, so to prevent any damage lightening arrestors are used. The
lightening arrestors do not let the lightening to fall on the station. If some lightening occurs the arrestors pull the
lightening and ground it to the earth. In any substation the main important is of protection which is firstly done
by these lightening arrestors.
The lightening arrestors are grounded to the earth so that it can pull the lightening to the ground.

Lightning arresters (source: www.osha.gov)

b) Earthing : The earthing practice is adopted at generating stations, sub-stations and lines should be in such a
manner as to provide:
1)Safety to personnel
2)Minimum damage to equipment as a result of flow of heavy fault currents
3)Improve reliability of power supply

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c) Capacitor Voltage Transformer (CVT): A capacitor voltage transformer (CVT) is a transformer used in power
systems to step-down extra high voltage signals and provide low voltage signals either for measurement or to
operate a protective relay.

A Capacitor Voltage Transformer (source: www.trenchgroup.com)

d) Isolators with Earth Switches (ES):Isolators are the no load switches and used to isolate the equipment.
(Either line equipment, power transformer equipment or power transformer). With the isolators, we are able to
see the isolation of the equipment with our naked eye. The line isolators are used to isolate the high voltage from
flow through the line into the bus. This isolator prevents the instruments to get damaged. It also allows the only
needed voltage and rest is earthed by itself.

An Isolator with Earth Switch (www.electrical4u.com)

e) Current Transformer(C.T.): Current transformer is a current measuring device used to measure the currents in
high voltage lines directly by stepping down the currents to measurable values by means of electromagnetic
circuit.

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A Current Transformer (www.muradnagar.infoisinfo.co.in)

f) Potential Transformer(P.T.): Potential transformer or voltage transformer gets used in electrical power system
for stepping down the system voltage to a safe value which can be fed to low ratings meters and relays.
Commercially available relays and meters used for protection and metering, are designed for low voltage.

A Potential Transformer (www.tucsontransformer.com)

g) Circuit Breaker: The circuit breakers are used to break the circuit if any fault occurs in any of the instrument.
These circuit breaker breaks for a fault which can damage other instrument in the station. For any unwanted fault
over the station we need to break the line current.
This is only done automatically by the circuit breaker. These are load switches. It is able to make or break the
normal load current as well as the fault currents.

Types of Circuit Breakers used in Plant

1)Natural air (called air circuit breakers-ACB) (415v)
2)Vacuum (called vacuum circuit breaker-VCB)
3)SF6 gas (called Sulphur Hexafluoride-SF6 gas CB)

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A Circuit Breaker (www.cccme.org.cn)

h) Bus: The bus is a line in which the incoming feeders come into and get into the instruments for further step up
or step down. The first bus is used for putting the incoming feeders in la single line. There may be double line in
the bus so that if any fault occurs in the one the other can still have the current and the supply will not stop.

A set of bus bars (source: www.wikipedia.com)

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Fire Pump House

Definition: Fire pump house as the name states is responsible for providing water supply to fight the fire in case
of a fire hazard or a calamity. The supply of water from this dept. is connected to various fire hydrants located in
vicinity of every dept. in the plant.

Pumps Present: There are total of 7 pumps present in the fire pump house. There's a large tank that stores about
2000 KL of water at an instant. These seven pumps are responsible for transporting the water from pump house
to the hydrants. The 2 Jockey pumps are required when small volume of water is required otherwise there are 3
main pumps present which act as primary pumps to deliver water in case of fire. They run on electricity therefore
there are 2 diesel operated pumps that can be operated even during a power outage.

Pump Name Output (in m^3/hour)

Jockey 1 17.1 m^3/hr

Jockey 2 16.3 m^3/hr

Main Pump 1 273 m^3/hr

Main Pump 2 273m^3/hr

Main Pump 3 410 m^3/hr

D.G Pump 1 273 m^3/hr

D.G Pump 2 410 m^3/hr

An industrial fire hydrant (source: www.mentor.com)

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Water Treatment Plant

Definition: Water treatment treats the ground water/water from bore well so that it can further utilised for
different purpose around the plant.

Processes:

a) Basic treatment: First stage of treatment consists of passing the groundwater through basic filters so that the
treated water can be further filtered for specialized purposes.

GROUND WATER FIRE TANK D.M.F

(OVERFLOW (DUAL MEDIA

TANK) FILTER)

TREATED FLOURIDE
WATER
FILTER
TANK

b) Water softening: It's a process which decreases the hardness of the treated water to a value that is permit able
for use in the plant.

TREATED WATER SOFT WATER

WATER TANK SOFTENER TANK HARDNESS: 2PPM

BRINE
SOLUTION

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c) U.V treatment: It's a process in which treated water is passed through U.V (ultra violet) filters so that harmful
bacteria present in water are eliminated and the water becomes fit for drinking.

TREATED U.V (ULTRA U.V TREATED WATER

WATER TANK VIOLET)/
INTENSITY: 70W/m^2
CANDLE FILTERS

d) R.O(Reverse Osmosis) treatment: It's a water purification technology that uses a semi-permeable membrane
to remove large particles from water. In the plant it's used to alter conductivity of water according to the
requirement.

RO TREATED WATER
TREATED RO-1
CONDUCTIVTY<10
WATER

TANK
ANTISCALANT, PH
BOOSTER, HCl

RO TREATED WATER
RO-2
CONDUCTIVTY>40

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Waste Water Treatment Plant

Definition: Waste water treatment is a process to convert waste water which is water no longer needed or
suitable for its most recent use. It treats the waste water coming from the paint shop and purifies it so that treated
water can be further used for gardening, flushing etc. purposes.

Processes:

a) Chemical Treatment: it's the process that is used to treat waste water coming from electric discharge & coat
forming processes.

MANUAL E.D. E.D EMULSION

BAR EQUALISATION BREAK TANK
SCREENING CATCH PIT
TANK

D.A.F (DISSOLVED
AIR FLOATATION)

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b) Biological Process: a mechanical biological treatment system is a type of waste processing facility that uses
micro/ biological organisms to treat water for harmful bacteria, foul smell etc. which can't be done using
traditional chemical processes.
FLOCULATION REACTION
TANK
FROM BREAK TANK
AERATION CLARIFIER FILTER
TANK TANK TANK
FEED TANK

TO
GARDENING BREAK TANK
& DISCHARGE SAND A.C.F (ACTIVATED
FILTER
FLUSHING TANK CARBON FILTER)

COAT C.F FLOCULATION TUBE

FORMING REACTION SETTLER
TANK
TANK TANK

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Yards
Definition: Yards are the storage areas which contain different gases, fuels etc. that are required for general
operation of the plant.

Name Number of Capacity Application

Bullets/Tanks
Propane Yard 2 50 MT X 2 Used in die casting, paint shop furnaces etc.
as fuel
Ammonia Yard 2 10 MT X 2 Used in heat treatment plant(G.S.M)
H.S.O (High speed 2 50 Kl X 2 Used as a fuel to run gensets in D.G house
diesel)
Furnace Oil 1 200 Kl Used as a fuel to run 2.5 MW 'MAN' genset
Nitrogen & Argon 2 19.41 CUM Used in heat treatment & for maintaining
Yard 5.45 CUM inert atmosphere in furnaces

MT: Metric tonnes, Kl: Kiloliters, CUM: Cubic metres

Colour Coding in a Yard: Pipelines used to transport gases & liquids around the plant are colour coded.

Air: sky blue

Water: green

Gases: yellow

Fire hazard water line: red

Components:

a) Pressure regulation valve or P.R.V is a valve which is used to regulate pressure in lines if it drops below or
increases beyond a certain working range.

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b) Remote operated valve or R.O.V is a valve which can be operated pneumatically and electrically.

c) Vaporisers are present to create vapours artificially inside the bullets when they are not present naturally.

d) Pressure transmitter is a device that transmits a signal when the pressure drops below a certain working range.

e) Safety relief valve is a valve which opens when the pressure increases beyond a certain value.

Project Undertaken: MSDS Label Making & Evaluation

During our second week of training we issued a project by Anshul Aggarwal san regarding MSDS labels &
evaluation of chemicals used in Utility department.

Definition: A Material Safety Data Sheet (MSDS) is a document that contains information on the potential
hazards (health, fire, reactivity and environmental) and how to work safely with the chemical product. It is an
essential starting point for the development of a complete health and safety program. It also contains information
on the use, storage, handling and emergency procedures all related to the hazards of the material.

Problem: MSDS is hard to read. Traditionally the intended readers of MSDSs were occupational hygienists and
safety professionals. Now the audience also includes employers, workers, supervisors, nurses, doctors,
emergency responders and workers.

Solution: To ensure that MSDS users can quickly find the information that they need, the information should be
in an easy-to-read format and written in a clear, precise and understandable manner.

Therefore, we designed an easy to understand MSDS label using NFPA(National Fire Protection Agency)
standard diamond, used graphic images in PPE(personal protective equipment) & created an information column
so that even a layman can understand. We also labelled the diamond with alphabets to prevent identification
problems in case of a black & white printout.

We were also given a list of chemicals in the form of an Excel sheet. These chemicals are used in Utility
department. Our task was to correctly evaluate the chart. We corrected any wrong information and added any
missing information regarding the chemicals.

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RATING SPECIAL HAZARD

SYMBOL(A)
ALK ALKALINE
ACID ACIDIC
COR CORROSIVE
OX OXIDISING
RADIOACTIVE

REACTS
VIOLENTLY WITH
WATER
REACTS
VIOLENTLY WITH
WATER & OXIDISES

MSDS LABEL
CHEMICAL NAME:

RATING NUMBER HEALTH HAZARD FLAMMABILITY INSTABILITY

(B) HAZARD (C) HAZARD (D)
4 CAN BE LETHAL WILL VAPORIZE MAY EXPLODE AT
AND BURN AT NORMAL

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NORMAL TEMPERATURE OR
TEMPERATURES PRESSURE
3 CAN CAUSE CAN BE IGNITED MAY EXPLODE AT
SERIOUS OR UNDER ALMOST HIGH
PERMANENT ALLAMBIENT TEMPERATURE OR
INJURY TEMPERATURE SHOCK
2 CAN CAUSE MUST BE HEATED VIOLENT
TEMPORARY OR HIGH AMBIENT CHEMICAL
INJURY TEMPERATURE TO CHANGE AT HIGH
BURN TEMPERATURE OR
PRESSURE
1 CAN CAUSE MUST BE NORMALLY
SIGNIFICANT PREHEATED STABLE. HIGH
IRRITATION BEFORE IGNITION TEMPERATURE
CAN OCCUR MAKES UNSTABLE
0 NO HAZARD WILL NOT BURN STABLE

PERSONAL
PROTECTIV
E
EQUIPMENT

Assembly Frame Shop

Definition: An assembly line is manufacturing process in which parts are added as semi finished assembly
moves from work station where parts are added in sequence unit assembly is produced.

The main assembly line consists of exterior, wiring, interior and chassis which at various points are connected to
sub assemblies including door, tires, instrument panel engine and rear axle. The efficient layout with
synchronized sub-assembly conveyors are made for more efficient control over human, machine interaction and
logistics.

Vehicle bodies are here to run on FDS(Friction drive system) conveyor of overhead type making it easier for
operator to work on sub-assemblies. The integrated nature of assembly line also results in lower physical fatigue
for operators, thereby inc. their efficiency.
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Flow diagram for A/F shop

WIRING INTERIOR CHASSIS EXTERIOR VEHICLE

ZONE ZONE LINE ZONE QUALITY

a)Wiring zone: The complete vehicle wiring is done in wiring zone. The wiring for tail amps, headlamps
and dashboard circuiting is done in this zone.

b)Interior zone: The floor and ceiling matting, instrument panel is installed in the interior zone.

c)Chassis line: It is a critical line and conveyors are fast moving in this line or this line engine docking,
suspension mounting, breaks installation is done.

d)Exterior zone: wheels from the wheel subassembly come through conveyors and are installed on the
vehicle. A final inspection of the vehicle is being done and electrical corrections checked. After this the
vehicle is sent to vehicle quality.

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An example of overhead conveyor (source: www.automoation.fivesgroup.com)

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Public Announcement System

Definition: In case of an emergency or a natural calamity, PA system operator makes announcements use the PA
microphone which transmits that signal in every department. Upon hearing this announcement all the employees
gather around the designated meeting point in garden area of every department. After that a head count is done to
determine the number of employees who are safe and those who are still in danger.

Public announcement system (source: www.toa.jp)

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PO (Injection Moulding Shop)

Definition: PO shop is an alias for injection moulding shop. Injection moulding is a manufacturing process for
producing parts by injecting material into a mould. Injection moulding can be performed with a host of
materials, including metals, glasses, thermoplastic and thermosetting polymers. Material for the part is fed into a
heated barrel, mixed, and forced into a mould cavity, where it cools and hardens to the configuration of the
cavity. Injection moulding is widely used for manufacturing a variety of parts, from the smallest components to
entire body panels of cars.

Working: The injection unit takes plastic raw material granules, heats them until molten, and injects them into
the mould. Machines have a barrel that contains a screw, the barrel has heater bands around the outside which
raises the temperature(200~280℃), to the correct level to melt the plastic. The rotating screw(50-150 rpm)
forces the plastic along the barrel (at about 3500 tonnes pressure). This in turn forces the screw back as the
molten material collects at the end of the screw. When the right amount of material for the next shot has
accumulated the screw stops rotating. The screw then acts like a plunger moving forward and forcing the molten
plastic into the mould tool. The clamping end with moving platen takes half of the mould tool. This opens and
closes the mould and supplies sufficient force to keep the mould closed when molten plastic is injected under
pressure.

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Mitsubishi injection machine (source: www.mhie.com)

POPA (Bumper Painting) Shop

Definition: POPA dept. is nothing but an alias for bumper painting shop. Freshly produced bumpers are
transferred from plastic injection to the bumper painting shop, there bumpers of different models are painted
according to the requirement of assembly frame department.

Operation: As we mentioned earlier freshly produced bumpers come from plastic injection shop, these bumpers
have information tags on them regarding model number, colour, finish etc. information on them.

The bumpers are not metallic in nature and constructed from plastic granules. Therefore, the first coat on the
bumper is the primer coat or the undercoat. Priming ensures better adhesion of paint to the surface, increases
paint durability, and provides additional protection for the material being painted. The second coat is the base

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The base coat is applied after the primer coat. This coat contains the visual properties of colour and effects, and
is usually the one referred to as the paint. Usually sprayed on top of a coloured basecoat, clear coat is a glossy
and transparent coating that forms the final interface with the environment. For this reason, clear coat must be
durable enough to resist abrasion and chemically stable enough to withstand UV light. When the painting
process is completed the bumper goes through a polishing zone and it's also cured under the ultra violet lights
also called the zebra checking point. The completely finished bumpers are then sent to operators for attaching the
font grills and headlights( tail lights in case of rear bumper ). The finished part i.e. the front end or rear end is
then sent to the assembly frame shop.

Bumper painting booth (source: www.prismsurface.com)

Spin Casting
Definition: Casting is a manufacturing process by which a liquid material is usually poured into a mould, which
contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a
casting, which is ejected or broken out of the mould to complete the process.

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Spin casting: Spin casting is a special casting technique which uses centrifugal force to produce hollow casting.
Due to the centrifugal force involved no core is required in this process which makes it very convenient and
advantageous.

Process: Metal (or alloy) to be casted is melted in a furnace by heating it to the required temperature (1200-
1500°C) and this molten metal is the passed to the holding furnace. A permanent mould is rotated continuously
about its axis at high speeds (1000-1500 rpm) as the molten metal is poured. The molten metal is centrifugally
thrown towards the inside mould wall, where it solidifies after cooling. The casting is usually a fine-grained
casting with a very fine-grained outer diameter, owing to chilling against the mould surface. After the process is
complete, we obtain 1 long tube which is passed through shot blast in which the surface impurities are removed
by small steel shots bombarded on the surface of the tube. This tube is then passed through a CNC cutting
machine which is programmed for cutting is into the desired no. Of cylinder liners (14 in case of petrol and 12 in
case of diesel engine).

After the desired length is obtained these liners are finish machined which involves boring and chamfering. The
process is concluded with quality inspection which involves inspection for any deformity, defects and
dimensional accuracy. The manufactured cylinder liners are then sent to engine assembly for installation.

SPC machine in operation (source: www.ccmcotulsa.com)

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Press Shop
Definition: A forming press, commonly shortened to press, is a machine tool that changes the shape of a work
piece by the application of pressure. Presses can be classified on various parameters for example, according to
their mechanism: hydraulic, mechanical, pneumatic etc.

Operation: There are 2 types of press machines are being used in plant. One is mechanically operated and other
is servo motor operated. The output is measured in strokes per minute or SPM. the mechanical press has 9 SPM
& servo operated press has 11 SPM. The production of a vehicle begins in the press shop, where sheet metal is
integrated into the manufacturing process and the first shapes of the later vehicle are created.

An industrial press machine (source: www.hamlintool.com)

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a)Mechanical Press: As the name suggests, a mechanical press's ram is run by reciprocating pistons which
controlled via clutches.

SHEET DRAWING CUTTING

METAL
PRESSURE:1500 TONNE PRESSURE: 1000 TONNE

FINISHED PIERCING BENDING

DOOR
PANEL PRESSURE: 1000 TONNE PRESSURE: 1000 TONNE

b)Servo Operated Press: As the name suggests, a servo operated press's ram is controlled and run by servo motor
which is nothing but an electric motor with reduction gears. It uses a feedback mechanism in order to control
precisely timed repetitive automatic tasks.

SHEET DRAWING CUTTING

METAL
PRESSURE: 1500 TONNE PRESSURE: 1000
TONNE

FINISHED DOOR PANEL BENDING AND PIERCING

PRESSURE: 1000 TONNE

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Conclusion
This internship was a great opportunity for us engineering students & we again would like to thank HONDA for
providing this to us. As we have mentioned earlier our main purpose coming here was to gain experience, get a
feel how a large manufacturing plant operates, what is the code of conduct etc. It's safe to say that our
expectations were blown away, coming here we realized how much hard work and their precise management is
required to run the plant round the clock. For a layman it must be difficult to comprehend how this plant works
but being here we realized it's possible because every employee from each department does his/her designated
task efficiently in shortest possible without compromising on quality. We were placed in the Utility department,
in simple terms we can say that Utility department is the fuel if this plant is a machine & a HONDA vehicle is
finished product. Utility department doesn't aid in production of vehicles directly but supplies the other
department that are directly involved in production with the resources that are critically needed for the
completion of their task. Our time at HONDA was a great learning experience for us & we hope we can apply
some knowledge in our future workplaces.

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Bibliography

www.google.com

www.wikipedia.com

www.academia.edu

www.electrical4u.com

www.jameco.com

www.daifukuna.com

www.asme.org

www.a4mods.com

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