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brazing process, one for cock brazing, one station for drain pipe and two stations for rework.
Fig 5.5.2 (d) Drain pipe Rework is done at two stations one is just after MFF welding and one is at final inspection. Rework is a necessary process because sometimes at R/L body welding or at MFF welding, occur lots of defects. To remove these defects, rework is necessary. 5.5.2.1 Consumption pattern The figures were measured with skilled worker by measuring number of tanks of a model for each brazing rod. Firstly the number of fuel tanks for 5 brazing rods was recorded and by taking average the number of tanks per brazing rod was obtained:
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MODEL
WEIGHT BRAZIN OF NO. G ROD / BRAZIN OF COMP G ROD COMP (KG.) (KG.) 0.0146 0.0243 0.0215 0.0255 0.0196 N/A N/A 0.0218 0.102 0.102 0.102 0.102 0.102 0.102 0.102 0.102 11 40 10 10 8.8 8.4 10.2 N/A
5.5.2.3 Problem and solutions Main problems of high consumption of brazing rod are because of high pressure (means high flow rate) more than required, used for gases and improper welding at R/L body welding and MFF welding.
Fig 5.5.2.3(a) In R/L welding, improper welding produces blow holes at welding joints which makes leakages that makes bad quality of fuel tank, to fill these blow holes brazing is used. So, if these holes can stop, the consumption of brazing rod can be reduced. Main cause of improper welding at MFF
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Fig 5.5.3(a) to be joined. The wire is bought from different vendor companies, categorized into three: 0.8 mm, 1 mm & 1.2 mm. These all wire used in the form of wire rolls weighing approximately 12.5 kg each or 360 m. The wire of 1 mm is used in Tack welding of all components and then at all manual welding stations. Tack welding is a process of joining all the major components of the frame body together by a temporary welding joint. Tack welding does not involve any kind of permanent joint. After passing the body through robotic welding, the first two manual stations involve welding of the body at the points which are not accessible through the Robot. This operation in done in two stations, on first they do it for left side and on second for right side of the frame body. Third & fourth stations involve the welding of child components on the body. 5.5.3.1 Consumption of MIG welding wire of 1 mm: The figures shown below are done with skilled operator. The initial weight was calculated and then from final weight and number of tanks, the figures were obtained. (Price of MIG welding wire of 1 mm = 65.20 INR per kg)
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5.5.3.2 Problems & their solutions: The major problem with the welding wire is with their feed rate. The worker does the welding at higher feed rates than they are expected to do, which causes them to use higher amount of wire at each point. Increased awareness among the worker is needed to solve this problem. The cleaning of wire rolls is also a serious issue. It was observed that at some stations due to improper cleaning of wire rolls, there were lots of defects in the welding. This increases the wire consumption due to rework. Proper cleaning of wire roll, this also involves the proper storage of wire roll. These wire rolls must not be kept in an open air. This allows the dust to settle down on their surface. This can cause defects in parts. The worker keeps higher amount of the current and voltage to do the work more quickly. This automatically increases the consumption of the wire as more wire will melt at each point. Allowable current and voltage values can avoid these problems. All the parts of the frame body that comes from vendor companies are applied with oil. The worker directly uses these components without removing the oil. This causes defects in the welding and so, increased wire consumption. Cleaning of parts need to be welded is necessary to avoid defects in the welding. Every time at lunch break or shift change, the worker removes the wire roll to save their time, There were several rolls observed in the trash which are of more than 5-8 meters, which can be used to weld more than 4 frame bodies. Worker awareness can solve these problems. Due to defects in the robotic welding the consumption of the wire in the manual stations might increase. 5.5.4 MIG welding wire of 1.2 mm: The MIG welding wire of 1.2 mm is used only in the Robotic welding station of the frame body plant. This wire is used only for the welding points where the strength is the important factor, and no concern about the beauty. Gantry robot is a pneumatically controlled programmable robot with two welding arms. These welding arms are named as R-side& L-side. Both are used to do the welding at each of side of the frame body. This operation is performed just after the tack welding of the components. This process involves the permanent joining of the components.
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MODEL
5.5.4.2 Problems & their solutions: The problems in the MIG welding wire of 1.2 mm & 1 mm are almost similar. Needs cleaning of wire rolls, operator awareness, and feed rate control, proper gas flow is needed to reduce the consumption of wire rolls in robotic welding. Sometimes due to defects in the tack welding, there can be some defects observed in the robotic welding. This might leads to increase consumption of wire rolls. 5.5.5 MIG wire of 0.8 mm: MIG wire of 0.8 mm is used only in the fuel tank line of the weld shop. It involves the welding of the sheet metal components used in the manufacturing of the fuel tank. This consumption depends mainly on the size of the fuel tank. The wire of 0.8 mm is used in the body R/L welding, MFF MIG welding, Base fuel pump welding (only for Glamour-FI). All of these operations are performed by robot. Operators job is to control the parameters of the robot, handling of the components. Body R/L welding: It involves the welding of the two parts of upper body parts of the fuel tank with to form a upper body. The welding is done on the inner side of the upper body. Base Fuel pump: This is a new kind of technology. This involves the fuel pump which controls the fuel flow to the engine. This is used only in the Glamour-FI. This bike does not have a carburetor.
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Fig. 5.5.5 (a & b) MFF MIG welding: MFF, Metal Fuel Filler is a small components used in the fuel tank of each vehicle. This acts as the gate to fuel intake in to the tank. These are of two different in the company. First is cup-shaped, which is an older MFF. This is used only in the older models, like passion, Achiever, Splendor, etc. The newer MFFs are dish-shaped involve the drain pipe attached to them. Drain pipe is attached using brazing operation. It acts a bypass for excess fuel in the tank. Also, in some models they use breather pipe which allows small amount of air to enter the tank.
5.5.5.1 Consumption: These figures were obtained according to the initial and the final weight of the wire roll. The operating parameters were set to standard conditions. (Cost of MIG welding wire of 0.8 mm = 67.20 INR per kg) BODY R/L WELDING BEFORE AFTER WIRE NO. OF WIRE/ MODEL COST/COMP WEIGHT WEIGHT USED COMP. COMP (Rs.) (kg) (kg) (kg) (kg) GLAMOUR 13.12 12.53 0.59 40 0.015 0.991 IGNITOR 13.28 13.12 0.16 10 0.016 1.075 X PRO 12.90 12.70 0.20 20 0.010 0.672 CBX 13.12 12.88 0.24 20 0.012 0.806 PASSION 11.7 11.32 0.38 30 0.013 0.851 KARIZMA 13.15 12.43 0.72 30 0.024 1.613 KARIZMA 13.15 12.43 0.72 30 0.024 1.613 FI GLAMOUR 13.12 12.53 0.59 40 0.015 0.991 FI
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MFF WELDING MODEL BEFORE WEIGHT (kg) 12.44 12.42 12.62 12.4 11.94 12.24 12.24 12.24 AFTER WEIGHT (kg) 12.24 12.24 12.4 12.24 11.74 12 12 12 WIRE USED (kg) 0.2 0.18 0.22 0.16 0.2 0.24 0.24 0.24 NO. OF COMP 28 28 30 28 30 30 30 30 WIRE / COMP (kg) 0.007 0.006 0.007 0.006 0.007 0.008 0.008 0.008 COST/COMP (Rs.) 0.48 0.432 0.4928 0.384 0.448 0.5376 0.5376 0.5376
5.5.5.2 Problems Problem & their solution: The main problem is related to the oil. The parts from vendors were kept oiled to keep them rust-free. This causes defects in the welding. This causes higher consumption of other consumable. Parts must be properly cleaned to avoid these defects. The proper cleaning of the wire rolls & their proper storage can reduce the problems in welding. Sometimes the operator parameters set to higher values. And also they keep robot overdrive mode which allows the faster welding with higher operating parameters. But this leads to
increase in the consumption of the welding wire. Proper values of operating parameters might be helpful in reducing the consumption.
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Fig 5.5.6 (a) Grinding practice is a large and diverse area of manufacturing and tool making. It can produce very fine finish and very accurate dimensions; yet in mass production contexts it can also rough out large volumes of metal quite rapidly. It is usually better suited to the machining of very hard materials than is "regular" machining [1]. In Hero motocorp grinding wheel is only used in fuel tank lines. It is not used in frame body line.
Model 2 Karizma Ignitor CBX X-pro Number of components per grinding wheel 123 278 165 172 312 150
Number of components of model 2 per grinding wheel (Q) 123 278 165 172 value for each model of grinding wheel (Rs.) 0.89 0.39 0.67 0.64 0.35 0.73
grinding wheel portion used for each model 0.0082 0.0036 0.0061 0.0059 0.0032 0.0067
5.5.6.3 Problem and Solutions First problem in grinding is vibration of pneumatic grinder neck at which grinding wheel is mounted. These vibrations are because of workers way of operating it and these vibrations
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Fig. 5.5.6.3 (a) o To solve this problem workers are doing is taking support of R/L body part by putting grinders neck on the R/L body part. That cause to damage to the neck, like some pneumatic grinders has damages like hole at neck, deep cuts on neck because of material removal from neck. And these pneumatic grinders go to scrap. Although sometimes they put a metal plate on handle neck and reuse it. But this is clearly wastage. o This problem can only be solved by giving proper training to workers and make them do it properly. Also, it will be helpful for worker if company provides them a support to keep the grinder steady. Second problem or cause of high consumption of grinding wheel is that when workers mount new grinding wheel on grinder, it has very sharp edges that can cut the fuel tank or can damage it. To solve this problem workers run the wheel on some other surface. Company should order wheels having less sharpness at edges and workers also play a big role to reduce this consumption to solve this problem. Third problem is that while rework at MFF, grinding wheel is used in the perpendicular direction of the rotation that cause high consumption of grinding wheel. Also, sometimes when grinding wheel doesnt fit in the MFF, worker uses the grinding wheel on a surface to reduce it in diameter. A new kind of grinding wheel is needed which will have smaller diameter & higher thickness to solve this problem. For wheel dressing of seam electrodes, they use grinders. This causes high consumption of grinding wheel. A harder grinding wheel specially designed for wheel dressing must be used in order to solve the issue. 5.5.7 Seem Welding Lower and Upper Wheel (Electrode) Seam welding is a resistance welding (RW) process of continuous joining of overlapping sheets by passing them between two rotating electrode wheels. This is a low voltage and high current process [1]. Seam welding is a high speed and clean process which is used when continuous tight weld is required (fuel tanks, drums, domestic radiators) [3].
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y AC power supply
Weld Lower wheel
Fig 5.5.7 (a) In hero motocorp, seam welding is a part of fuel tank line. This is used to seal the upper body part with the bottom part. Water is used as coolant in this process. To avoid water entering in the fuel tank air cap is used, through which compressed air is thrown to the fuel tank which will remove the water. This is very important as water present in fuel tank can produce problem if it enters into the engine.
Fig 5.5.7 (b) In this plant, shape of these wheels is different. Upper wheel is bigger in size than lower wheel. This is because of the curved surface of the fuel tank, so to enter in these concave shapes diameter of this wheel should be small. Fuel tank is convex from upper side and concave from lower side thats why lower wheel is small than upper wheel. This makes very high consumption of lower wheel with respect to upper wheel.
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Fig 5.5.7 (c) After some time when wheel became small in diameter, which needs to be replaced. In this plant use limit of wheel i.e. how much wheel can be used is decided by gear box housing, i.e. when the two gear box housing touches each other these wheels are removed. 5.5.7.1 Consumption pattern: As the seam electrodes run for more than 2 shifts, it was almost impossible to calculate their consumption. Also, there is no mark on the vehicle to know that the wheel is used. So, the consumption pattern for seam electrodes has not been calculated. 5.5.7.2 Problems and solutions: Excess pass of voltage that damages the wheels. For voltage regulation thyristor is present in the machine. Water supply is used to cool the thyristor. Sometimes due to some blockage in water supply, the thyristor heats up and gets blasted. This cause higher voltage to pass through the electrodes than required. This damages the electrodes and fuel tank.
Fig 5.5.7.1 (a) o Some solutions I suggested are allowing a continuous filtered supply of water to transfer in place of current closed loop supply. Then blockage problem will be reduced.
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Fig 5.5.7.1 (b) o Gear box housing can be made in a shape so that they will match each other. This will allow us to use the max part of wheels. Air cap from which air is passed in the fuel tank is remains open even when welding is not being done, this lead to wastage of compressed air. Some times when worker operates machine at high voltage than required in seam welding, electrode become burred, because Zn stuck on the lower electrode from the sheet. These burrs create leakage problem, as well as reduces the life of wheel as if wheel will be grinded for number of times. Use of sheets having coating on one sided can solve this problem.
Fig 5.5.7.1 (b&c) 5.5.8 Consumption of gases- Argon: Argon is produced industrially by the fractional distillation of liquid air. Argon is mostly used as an inert shielding gas in welding and other high-temperature industrial processes where
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S.NO. MODEL
WELDING TIME SEC 33.19 37.96 28.28 30 33.28 28.84 33.05 33.67 MIN 0.55 0.63 0.47 0.50 0.55 0.48 0.55 0.56
Ar (LTR) 80% 11.06 4.05 5.28 5.60 11.09 5.19 7.49 10.77
1 2
IGNITOR XPRO KARIZMA 3 FI GLAMOUR 4 FI GLAMOUR 5 FI 6 KARIZMA 7 PASSION 8 CBX MFF MIG welding:
S.NO.
MODEL
WELDING TIME SEC 46.49 41.59 MIN 0.77 0.69 0.82 0.78
TOTAL Ar CONS. (LTR) (LTR) 13.95 11.78 13.09 14.39 80% 11.16 9.43 10.47 11.51
Ar (M3) COST OF ARGON/COMP 1 LTR = 10-3 (10-3 * Rs.) M3 0.011 0.004 0.005 0.006 0.332 0.122 0.158 0.168
1 2 3 4
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5.5.8.2 Problems & their solutions: The main problem is an increased flow rate of the gases. This is done due to different reasons. Main reason behind this is to complete the welding more quickly. But, this leads increase in consumption of gases. A solenoid valve is used to control the gas flow. But, the gas flow remains constant throughout the welding process. For body R/L welding, at some points the gas flow can be reduced. Regula gas savers are used at some stations. It is advised to use them at all the stations. This can reduce the gas consumption up to 45%. This can save a lot of gas as well as cost behind them. These gas savers allows to control the flow based on the current, voltage. This will also reduce the consumption of the gas at body R/L welding by allowing variable gas flow. Oiled parts from vendor companies can cause defects in the welding. To avoid this problem the operator increases the gas flow which leads to increase the consumption. Proper cleaning of the faying surfaces is important. Improper placement of the MFF causes the defects for which the worker increases the gas flow. Assurance of the proper clamping of the MFF & the bypass lock can avoid this problem. 5.5.9 Consumption of gases- Carbon Dioxide: Carbon dioxide is the most widely used gas in the welding department. It acts as a shielding gas. Carbon dioxide is very easily available in the industry as it can be obtained from various reactions. It is used in both sections of the weld shop. In fuel tank line it is used as a mixture with Argon gas & in frame body it is used as the only single gas. In fuel tank line, it is used at the Body R/L welding, MFF welding and Base fuel pump welding. In frame body line, it is used at all the welding stations. It is supplied through the large gas cylinders placed outside of the shop, via pipes. 5.5.9.1 Consumption: The gas flow meters were attached with each of the welding stations showing the flow rate for the gas. By recording time of the robotic welding the gas consumption was calculated in fuel tank line, then from mixture proportion the gas flow of Carbon dioxide in kg was calculated. Then, by knowing the density of the gas, the gas required for each fuel tank in Kg was calculated. In case of the frame body line, the direct value of gas flow in liters can be obtained by noting the welding time. It was then converted to Kg by conversion factor. (Note that for the frame body line the readings were taken with a skilled worker in the welding) (Cost of carbon dioxide gas per KG is 5 INR)
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S.NO.
MODEL
1 2 3 4 5 6 7 8 9
MFF MIG welding Fuel tank: GAS WELDING TIME FLOW RATE (LPM) SEC MIN 33.19 0.55 25 37.96 0.63 8 28.28 30 33.28 28.84 33.05 33.67 0.47 0.50 0.55 0.48 0.55 0.56 14 14 25 13.5 17 24 TOTAL CONS. (LTR) 13.83 5.06 6.60 7.00 13.87 6.49 9.36 13.47 COST OF CO2 (KG) 1 CO2 CO2/TAN LTR = (LTR) K (10-3 0.000616 KG *Rs.) 20% 2.77 0.0017 0.0085 1.01 0.0006 0.0031 1.32 1.40 2.77 1.30 1.87 2.69 0.0008 0.0009 0.0017 0.0008 0.0012 0.0017 0.0041 0.0043 0.0085 0.0040 0.0058 0.0083
S.N O. 1 2 3 4 5 6 7 8
MODEL
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TOTAL CONS. (LTR) 4.8 3.75 8.59 7.87 7.90 8.70 1.48 2.72 3.9 2.52 10.42 15.00 15.00 15.00 3.75 3.02 3.41 3.97 3.97 3.66 4.07 7.65 7.45 7.10
Passion
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Fig 5.5.11(a) Sanding belt specifications are MAR 13, electro-coated Aluminum oxide cloth R/R ; 120 grit size Sanding belt in Hero motocorp is mounted on rubber roll. So that consumption of these roll should be less. 5.5.11.1 Consumption pattern Technique used for measurement of sanding belt is same as grinding wheel. Consumption of Sanding belt Number of No.of components of components per Model 1 per Sanding Sanding belt (X+Y) belt (P) 121+102 250 174+81 250 120+113 250 160+97 120
Number of components of model 2 per Sanding belt (Q) 192 267 218 137
Number of components per Sanding beltl 192 267 218 137 250 120
Sanding belt portion used for each model (NO.) 0.0052 0.0037 0.0046 0.0073 0.0041 0.0083
price of 1 Sanding belt (Rs.) 39.96 39.96 39.96 39.96 39.96 39.96
value for each model of Sanding belt (Rs.) 0.21 0.15 0.18 0.29 0.16 0.33
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Flap wheel is used to finish the lining or scratches made while sanding. Flap wheel is used just after sanding is big in size than the flap wheel for rework.
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6.1 PROFESSIONALISM Company works in a highly professional environment. Starting from entry point, if someone came late or forgot his ID, he/she will not be allowed to enter the company. In production lines too they maintain a good quality by doing a good work at each station and still completing the assigned number of target in given time. The high quality is the main factor behind the company success. For this purpose company assumes the worker satisfaction as a important factor. Company provides a fan or air blower to each worker so that they can work in a good environment. Also, the assigned line in-charge, Section engineers keep track on the quality in a specific interval of time. At end of every line there is an inspection point where they observe the part for any kind of defect. Defective parts are sent back to the rework stations. Major defects in part can lead to the rejection. In the main assembly line they test the vehicle at a specific speed limit. Some other tests are also performed to assure the good quality of the bike. The company is committed at all levels to achieve high quality in whatever they do, particularly in their products and services which will meet and exceed customer's growing aspirations through [2]: Innovation in products, processes and services Continuous improvement in our total quality management systems. Teamwork and responsibility 6.2 Ethical conduct Company is provided with a code of conduct on all employees. This code of conduct for employees enables the company to maintain the standards of the business conduct, thereby bringing efficiency, responsiveness and consistency in an employees behavior and decision making. It also reduces risk by decreasing the possibility of harmful conduct. The code outlines the values that become the basis of this standard. It is based on the eight principles that have been identified through research, as being fundamental to all codes. Each of the employees should read and understand the code, and incorporate it in day-to-day behavior [2]. 6.3 Award/Rewards The Company keeps a track record of all the employees. The hard working employees are spotted by the management and they are rewarded accordingly by increments in their salary from time to time.
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Utility block
Scrap yard
Lacquer plant
Assembly line3
Press shop
Paint shop
Trolley stores
Component store
Engg Assy-1 Engg Assy-2 Engg Assy-3 Engg ppc Aluminum phase
Frame assembly line 1 Veh. Rectification area Frame assembly line-2 Store room Steel Phase
Heat treatment
Aluminum phase
Tool room
Gear section
Aluminum phase Engine Transfer Finished component Material from vendor Material from store to resp. shop Finished product
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Tack welding
Truing
Bead grinding
Buring
Sanding
Brazing
Belt Sanding
Denting
Buffing
Cleaning
Upper Body
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12. References:
1) http://en.wikipedia.org/wiki/ 2) www.heromotocorp.com/en-in/ 3) Company charts & guide books
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