Académique Documents
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Culture Documents
PROJECT REPORT ON
Die Maintenance Study and Chip-Dent Reduction
TraineePrakul Bansal
GAURAV CHAUDHARY
Fathers Name
Date of Birth
01-08-1991
NIT KURUKSHETRA
Session
2012-13
Referred by
Permanent Address
E mail
Grvchaudhary01@gmail.com
Contact No.
+91-7206108388
Duration
1 month
Dept. / Section
Press Shop
Training Duration
-2-
Acknowledgement
Gratitude is the hardest of emotions to express often one doesnt
find adequate words to convey the feeling of gratefulness. There
were many people whom I would like to thank for their support. I
sincerely feel that credit of this work could not be narrowed down to
any one individual, by which I have achieved its completion.
Words will not suffice to express my deepest feeling of sincerest
gratitude to my revered Mentor Mr. Harsh Vardhan for his guidance,
constructive criticism and inspiring attitude resulting in the successful
completion of my Project.
Some persons certainly have more capacity to help others and I
should not loose any opportunity to extend my feeling of profound
gratitude to Mr. Rakesh, Mr. Dipin, Mr. Mandeep, Mr. Puneet, Mr.
Deepak,
Mr.
Abhishek,
Mr.
Shiv
Narayan
for
unstinted
(__________)
Dated
-3-
I have ensured that this summer training report does not contain any
information which will be detrimental to the interest of the company.
Mentor:-
HOD:-
-4-
Table of Contents
Sr.
Description
Page No.
1.
Company profile
6-15
2.
Executive Summary
16-22
3.
4.
23-31
d. Die Design
51-58
32-40
41-50
59-60
b. Problem identification
61-64
65
d. Countermeasure proposal
66
-5-
COMPANY PROFILE
COMPANY LAYOUT & PROCESS FLOW
-6-
HONDA PRODUCTS
HSCI PRODUCTS
-7-
Updated as on 2010
The most
basis of our daily business action and judgment for all companies and
associates within the Honda Group. It is critical that Honda
Philosophy be fully understood, respected, shared and translated into
action by every Honda associate around the world.
HONDA PHILOSPHY
-8-
COMPANY
COMPANY
PRINCIPLES
PRINCIPLES
-9-
Equality
Initiative
Trust
- 10 -
THE JOY O
The joy of c
when Hond
and Suppl
in the design
engine
manufa
products
sense o
custome
product a
sellin
MANAGEMENT POLICIES
Companys standards
for carrying out
Daily Operations
are based upon the
Management Policies
- 11 -
5S
KAIZEN
- 12 -
- 13 -
Press Dept
- 14 -
line
having
GSN
(Gas
Soft
Nitriding)
operation.
Unique
Big
end
robotized
connecting rod.
GREEN PLANT
- 15 -
cracking
machine
for
ASSOSIATES
The new plant employed 250 associates in the starting which
has reached up to 700 in the present year.
SUPPLIERS CLUSTER
The suppliers cluster is spread over 150 acres having space
for 8 critical and bulky part suppliers. Proximity to the HSCIs
car plant and use of most updated techniques and features by
these suppliers will make the overall process of car production
more efficient.
EXECUTIVE SUMMARY
INTRODUCTION TO PRESS SHOP
- 18 -
Goggles
Ear Plugs
Nose Mask
Gloves
Arm Sleeves
- 19 -
Boot Cover
Safety Shoes
PARTS INTRODUCTION
2AP PRESS PART DETAILS
2PS
2AP
13
14
15
11
12
3
- 20 -
10
SRNO
1.
Hood Skin
Hood Skin
2.
Hood Frame
Hood Frame
3.
4.
Panel Roof
Panel Roof
5.
Side Panel RH
Side Panel RH
6.
Side Panel LH
Side Panel LH
8.
Front Floor
9.
Rear Floor
Rear Floor
10.
11.
12.
13.
14.
15.
- 21 -
DRAWING:
Drawing is a metal working process which uses tensile forces to
stretch the sheet metal by which hollow shapes are formed.
- 22 -
TRIMMING:
Trimming is the operation of cutting away excess metal in a flange or
flash from a piece e.g. when holes are produced in a sheet manually,
first circular blank is cut with a chisel and hammer. Then fine shapes
are trimmed with the help of a sher or snip. This operation i.e. cutting
by snip is called trimming.
- 23 -
- 24 -
- 25 -
Structure elementPrinciple
Rule
Standard
Edge
R & controlled
Standard
of panel
size accuracy.
Accuracy
of
Creates shape
by pressing
blank
surface:
#400
finishing
surface
should
be
5?
or
below.
It hasfinishing
Punch
sheet against
dieguide in-between with
Notblank
controlled
1
location
holdersurface: #120
finishing
Thickness
of panelwith
should be reduced
Edge R
to &
maintain
controlled
Holds blankpanel
sheetsize
in-between
accuracy.
However, convex
surface:area
#400
should
finishing
pressure
of punch
Die Receives be
standard
for forming shape
Not controlled surface: #120
2 punch.
and creates shape.
finishing
Holds blank Surface
sheet together
accuracy
with
should
die be 5? or Edge
belowRand
& controlled
have no
faceholder
to control
partial
influx
unevenness.
and prevent Has locatingsurface:
guide in-between
#400 finishing
Blank
wrinkle
with punch
Not controlled surface: #120
3
finishing
Prevents panel
Make
deformation
a drill-pierced
andhole of ?4.00Minimum
for the easiness
pitch: 50ofmm
distortion
due
releasing
to
pressure
panel
change
from
punch/die
of
concave
and punch
Air
hole BL material
4 airvent
in-between
forming
and die
part
Sustains the Normally,
positional SIGR
relation
type
of I, single plate
Useonto
20 t punch
if slideiscan be
punch and blank holderused
at a for
certain
material
detached. Use 10 t for
level.plate
Reduce abrasion factor to
permanent contact
5Wear
improve manufacturing and
maintainability
Removes a panel
Theresteadily
are ways
from
of inside
unloading: one-side lifting and all
Take a measure of panel deformation
6 Lifter die lifting.
prevention using rubber, sponge, etc.
Holds downSurface
blank sheet,
accuracy
controls
should be 5? or Edge
belowRand
& controlled
have no
materials influx
partial
and prevents
unevenness.
wrinkles,
Has locatingsurface:
guide in-between
#400 finishing
together with beadwith blank holder
Not controlled surface: #120
7 Die face
finishing
Controls tensile
There
strength
are two
necessary
types of bead: one is draw bead
forBead
influx amount
controlling
of blank
blank
sheet
sheet
and influx, the other is lock bead
forming
stopping influx and forming bead only with material
8
elongation
Blank sheet
positioning
Secure
20
mm
Prevent
material deformation by
puttingfrom
edge
R3linear
section
lower
limit - 6
shape on the side that contacts spots
material.
Use
dowel
basically
and
spots
Gauge/Nest
pin to fix for positioningfor large object and 8circular
9
arc
Place the top die on the die cot wood. Do not place the die on
floor without die cot wood.
DIE WASHING
- 28 -
Blow air and ensure that the die is 100 % moisture free
- 29 -
Die Grinding
Grinding is a highly skilled operation, where the required dimensions
or form is achieved. It requires a tremendous amount of skill and
concentration for grinding.
Grinding is often a secondary or finishing operation. The quality of the
ground surface depends on the selection of type of grinder and type
of wheel.
The next few pages illustrates how to finish a hexahedron block by
grinding.
- 30 -
- 31 -
- 32 -
Don'ts
Using damaged mounted wheels.
Tighten the wheel with full force.
Grind using undressed wheel.
Blow off grinding dust using compressed air.
Use
Air Porter
Hex Wrench
T Handle Wrench
Copper Hammer
Steel Hammer
Wrench
Angle Wrench
Screwdriver (+)
Screwdriver (-)
Plier
Chisel
Adjustable Wrench
Dowel pin puller
File
Compass
Vernier caliper
Thickness gage
Radius gage
Impact wrench
Pipe wrench
Vise plier
Shears
Tap handle
Die stock
Flashlight
Diamond file
Dresser
Oilstone
Carbide cutter
Emery paper
Offset
Emery wheel
Buff
Emery compound
Copper Bar
- 35 -
Description
Hex Wrench,
T handle
wrench
1. Preparation Inspect and
for work
wear
specified
protective
gears.
Inspect
conditions of
tools.
2. Tool Usage Set wrench
fully into the
bolt head
Prevent
over/under
torquing
Handling Pointers
Cotton gloves
3. Completion Check
of operation
wrench for
wear and
crack.
Clean and
orderly
arrange work
area
(especially
oil)
Replace or repair before using,
or dispose
4. Others
Refrain from
using any
damaged
- 36 -
tools found.
Copper
Hammer,
Steel Hammer
1. Preparation Inspect and
for work
wear
specified
protective
gears.
Inspect
conditions of
tools.
4. Others
Check
condition of
Replace or repair before using,
hammer head
or dispose.
and handle.
Clean and
orderly
arrange work
area.
Refrain from
using any
damaged
tools found.
Wrench,
- 37 -
Offset wrench
1. Preparation Inspect and
for work
wear
specified
protective
gears.
Inspect
conditions of
tools.
Refrain
from using
any
damaged
tools
found.
Screwdriver
(+),
Screwdriver 1. Preparation Inspect and
for work
wear
specified
protective
gears.
Inspect
conditions of
tools.
Refrain from
using any
damaged
tools found.
Plier
1. Preparation Inspect and
for work
wear
specified
protective
gears.
Inspect
conditions of
tools.
2. Tool Usage
3. Completion
of operation
Check for
cracks, loose
pin
Clean and
- 39 -
4. Others
orderly
Replace or repair before using,
arrange work
or dispose.
area.
Refrain from
using any
damaged
tools found.
Chisel
1. Preparation Inspect and
for work
wear
specified
protective
gears.
Inspect
conditions of
tools.
2. Tool Usage Caution for
flying of
broken chips.
3. Completion
Check for
of operation
cracks, loose
pin
Clean and
orderly
arrange work
area.
4. Others
Refrain from
using any
damaged
tool found.
Adjustable
wrench, pipe
wrench
1. Preparation Inspect and
wear
for work
specified
protective
- 40 -
gears.
Inspect
conditions of
tools.
2. Tool Usage
3. Completion
of operation
When using
the tool apply Apply proper torque.
force in the
direction of
the adjusting
slide.
Do not use
as a
hammer.
Check for
cracks and
looseness.
Clean and
Replace or dispose.
orderly
arrange work
area.
Refrain from
using any
damaged
tools found.
Pin Puller
Inspect and
1. Preparation
wear
for work
specified
protective
gears.
Inspect
conditions of
tools.
4. Others
Caution,
prevent
pinching the
finger.
3. Completion
of operation
Check the
condition of
the pin puller
welded bolt.
Clean and
orderly
arrange work
area.
4. Others
Refrain from
using any
damaged
tools found.
File
1. Preparation wear
for work
specified
protective
gears.
Inspect
conditions of
tools.
2. Tool Usage
Apply force
only on the
forward
cutting strike.
Work in a
weld
balanced
attitude.
When cutting
- 42 -
edge
becomes
dull, clean
Wire brush
the teeth with
a wire brush.
3. Completion
of operation
4. Others
Check
condition of
handle and
Replace or repair before using,
the crack
or dispose.
stopper ring.
Clean and
orderly
arrange work
area.
Refrain from
using any
damaged
tools found.
Overall
wrinkles
Localized
wrinkles
CAUSE
Blank holder
pressure low
Blank holder not
level
Blank holder not
flat.
- 43 -
REMEDY
Adjust blank holder
pressure
Adjust blank holder
Grind blank holder flat
3.
4.
Crack or tear
along part
periphery
Radial tear
5.
Radial
scratches
Shiny spots
on drawn
surface
Blank stock
improperly
positioned
Blank holder
pressure low
Blank holder
pressure too large
Punch/Die radius
too small
Insufficient
clearance
between punch
and die.
Incorrect
positioning of
blank stock
Scoring on the
bead and die
radius
Incorrect slit
timing
Defective blank
stock(work
hardened)
Defective blank
stock
Blank holder
pressure low due
to unevenness
Blank stock
improperly
positioned
Scoring on the
bead and die
radius
Insufficient
clearance
Improper shut
Adjust clearance C= t+
(2/10 6t/10)
- 44 -
Defective stock
Regrind holder
Adjust blank position
Polish
Adjust clearance C=1.21.5t
Adjust shut height
7.
8.
9.
Drawn
surface
depression
Inside
scratches
Streak
depression
along drawn
surface
(Starting
mark)
10 Les along
.
drawn surface
11 Line shift
.
12 Insufficient
.
flange width
13 Caused by
.
vacuum
height
Improper die setup
Excessive
clearance
Groove scratches
on flange holder
and bead
Insufficient ie
radius
Poor material slip
property
Bead lacks pull
Excessive cushion
pressure
Defective blank
stock
Insufficient blank
pull
Defective die
bend surface
Improper cushion
pressure
Improper blank
pull force
(improper bead)
Slit improperly
timed
Excessive shut
height
Insufficient
material
Insufficient
cushion pressure
Insufficient blank
pull force (bead)
Punch rise speed
too high
- 45 -
Reset up
Adjust clearance between
punch and die.
Polish
Adjust die radius
Polish
Adjust bead (observe part)
Adjust cushion
Replace stock
Reduce pressure increase
bead pull force
Correct bend surface
Adjust cushion pressure
Adjust bead
Adjust slit timing
Adjust shut height
Replace material
Adjust cushion pressure
Adjust bead
Reduce punch speed.
(double action)
created
during die
separation
14 Develops
.
during
pressing due
to uneven
distribution of
stress during
press
operation.
Uneven clearance
Unbalance
tension produced
by the bead.
15 Depression
.. develops
during
processing
due to
insufficient
pull on the
material
16 Excessive
.
curvature
develops
during
processing
due to
insufficient
pull on the
material.
Insufficient bead
pull
Insufficient blank
holder pressure.
Uneven blank
holder surface
Insufficient blank
holder pressure
Punch contour
17 Irregular
.
spots formed
by foreign
objects on the
die surface.
Foreign objects on
the die.
Foreign objects on
the blank stock.
Burrs on sheared
edge.
Insufficient bead
pull and blank
holder pressure
18 Crease
.
develops
along the
corner during
- 46 -
Remove burrs.
Adjust bead shape and
blank holder pressure
Adjust clearance
drawing and
bending due
to
concentration
of stress
19 Condition that
.
develops on
the inside
surface of the
sheet due to
uneven
distribution of
stress.
20 During initial
.
drawing
phase the
friction of the
die caused
excessive
material
stretch at the
radius and
subsequent
increase in
rigidity
produced a
marked line.
Excessive
clearance
Burrs
CAUSE
Excessive
clearance
Insufficient
clearance
- 47 -
REMEDY
Hardface C=
t*5/100~7/100
Adjust cutter edge
clearance
2.
3.
4.
5.
Edge
condition
different for
sides.
Material not
sheared
square
Projection
along the
cutting edge.
Depression
along cutting
edge
6.
Depression of
the normally
flat surface
7.
Punch breaks
8.
9.
Scrap
clogging
Part adheres
Primary cutter
wear
Protruding
secondary edge.
Punch and die off
center
Dull or worm
punch
Damaged or
chipped cutting
edge of punch
Damaged or
chipped cutting
ede of die.
Regrind or build up by
hardfacing the punch
cutter
Regrind or build up by
hardfacing the die cutter.
Adjust stripper
Enlarge mounting
diameter of the punch to
provide good fit.
Realign the punch
Adjust
Change material or heat
treat to proper hardness.
Provide proper clearance
Polish hole
Lap punch and bushing
Replace
to upper die
10 Shift of cut
.
line
spring or damage
to the urethane
Excessive cutting
stroke causing
part to bind
Contour not
matched between
drawn part and
trimming punch
Punch and
stripper contour
not matched
Damaged reverse
holder spring
Adjust stroke
Burrs
Cause
Remedy
2.
Blocked hole
mount
Incorrect
secondary finish
Incorrect
clearance
Clogged scraps
Loose fixed cam
Loose back up
block
Insufficient stroke.
diameter
Remedy
Adjust clearance
Match the punch, clean
scrap escape hole
Tighten bolt, install key
Tighten bolt, install key
Adjust stroke
Ragged hole
edge
2.
Incorrect
burring height
CAUSE
Pilot hole too
small.
Ragged hole
during pilot hole
piercing
Defective material
Punch and die off
center.
Hole in part not
aligned to the die.
Incorrect burring
hole bushing
radius
Improper drawing
depth
Improper burring
pilot shape.
REMEDY
Increase size of pilot hole
so as to reduce the
amount of burring
Match the punch
Adjust
Reverse bend
CAUSE
Binding in the
curling groove
- 50 -
REMEDY
Polish groove
Reposition curling groove
2.
Broken punch
by build up facing
Align punch and bushing
Temper to proper
hardness
Replace guide, post,
bushing
Type,
repair
DRAW
Normal
Important
Plating
TRIM
Normal
Shots
Shots
shots
Important
PIERCE
Normal
Y
Important
SIDE CUT
Normal
Y
Important
BEND
Normal
Y
Important
Y
Y
shots
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Bead Wear
countermeasure
Cutter Wear
countermeasure
Adjust accuracy of
shoulder punch fit
section
FEEDBACK:-
DIE DESIGN
1. STEEL DRAWING DIE:- 53 -
Draw die- The rolled steel sheet is formed into the shape of the die
by applying a force perpendicular to the surface of the sheet.
Ref.
Part Name
a.
Die set
b.
c.
Die
Bead
d.
e.
Balancer
block
Blank holder
f.
g.
Punch
Cushion Pin
h.
i.
Pilot
Guide
Function
To simplify the mounting of the die (some are made
integral with the die)
Forces the sheet stock to form around punch contour.
Prevents wrinkles and distortion of press part, prevents
slipping
Used for adjusting the holding force of the die and blank
holder. Used mainly for motorcycle.
Maintains the blanked stock in place and holds the stock
during drawing (prevents wrinkles)
Forces the sheet stock into the die to form the shape.
A component of the press which function as a support
for the blank holder
Performs the positioning of the stock sheet
Performs the positioning of the blank holder to the die.
Inspection
Points
1.
Guide post
2.
Guide bushing
3.
Punch, Die,
Blank
Description of
Inspection
Galling, wear,
bend
Galling, wear,
crack
Galling, wear
Inspection
Standard
0.1-0.2
- 54 -
Inspection
Method
0.1-0.2
Micrometer,
Inspection jig
Cylinder gage
0.05-0.1
Thickness gage
Maintenance
Method
Replace with new
parts
Replace with new
parts
Grind, Liner repair
4.
6.
Holder, guide,
plate
Guide plate
mounting bolt
Punch
7.
Die
8.
9.
Die plating
Die mounting
bolt
Bead
5.
10.
11.
13.
Bead mounting
bolt
Ejector retainer
pin
Ejector spring
14.
Pilot pin
15.
Scrap chute
box
Upper/lower
holder
Hook hole
Mounting bolts
12.
16.
17.
18.
Galling, wear
0.05-0.1
Thickness gage
Break, loosening
None permitted
Wrench
Worn radius,
galling
Worn radius,
galling
Peeling
Break, loosening
0.5max.
Section gage
0.5max.
Section gage
None permitted
None permitted
Visual
Wrench
Galling, crack,
wear
Break loosening
Determine from
Die and
None permitted
Part
Galling,
deformation
Break, bend
Not permitted
Visual
Not permitted
Visual
Break,
deformation,
looseness
Damage
deformation
Surface condition
Not permitted
Visual
Not permitted
Visual
60-70% contact
Straight edge
1mm max.
Not permitted
Vernier caliper
Wrench
Wrench
- 55 -
Ref.
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
Gn.
Part Name
Die set
Dowel pin
Stripper
Guide bushing
Stroke end pin
Guide post
Punch plate
Spring ellipse
(Spring urethane)
Shoulder punch
Bushing
Die cutter
Punch cutter
Punch
Scrap cutter
Function
Upper die mounting plate (Some are made integral with the die)
For the die positioning (accuracy 0.15-0.24)
Holding the part in position, prevent part from lifting
For aligning upper and lower die, to maintain die accuracy
Die reference (normally 0.5mm clearance exists)
For matching the upper and lower die, maintain die accuracy
Shoulder punch mounting plate, maintains punch position
Serve as auxiliary punch function.
(When large force required in small space)
Mate with the bushing and performs hole piercing
Mate with Shoulder punch and performs hole piercing
Mate with punch cutter and performs punching
Match with die cutter and performs punching
Serve as positioner for drawn parts
Inspection
points
Description of
inspection
Inspection
Standard
Inspection
method
Maintenance
Method
1.
Guide post
0.05-0.1
Micrometer, in
- 56 -
2.
Guide bushing
3.
4.
5.
Heel guide
Wear plate
Wear plate
mounting bolt
Male cutter,
Flat
Male cutter,
Vertical Cut
6.
7.
8.
Cracks
Galling, Wear, Bend,
Cracks
Galling, Wear
Galling, Wear
Break, looseness
0.05-0.1
inspection jig
Cylinder gage
0.05-0.1
0.05-0.1
Not permitted
Thickness gage
Thickness gage
Wrench
Visual
Break, Looseness
Chip not
permitted
Clearance
0.05-0.08 of
sheet thickness
Sagging edge
not permitted
Overcut 0.5-2.0
+ sheet
thickness
Chip not
permitted
Clearance
0.05-0.08 of
sheet thickness
Sagging edge
not permitted
Overcut .5-2.0
+ sheet
thickness
Not permitted
Break, Looseness
Not permitted
Wrench
Chip not
permitted
Edge sag
Visual
Overcut =
t + 0.5~2.0
Vernier Calliper
Thickness gage
Male cutter
head pipe
Male cutter
countered
section
Female cutter
flat
Female cutter
vertical cut
16.
Female cutter
head pipe
Female cutter
countered
section
Punch block
mounting bolt
Die block
mounting bolt
Punch
17.
Punch holder
18.
Bushing
19.
Loose mounting,
Galling
Damaged contour
Looseness
0.01 max
Not permitted
Cylinder gage
20.
Bushing
holder
Ejector
21.
Ejector Spring
Not permitted
Visual
22.
Not permitted
Visual
23.
Ejector
Urethane
Lifter
Not permitted
Visual
24.
Cylinder
Knock out pin
26.
Knock out
spring
Scrape chut
Normal
operation
Deform not
permitted
Not permitted
Test Stand
25.
Damage, Deform
Not permitted
Visual
9.
10.
11.
12.
13.
14.
15.
27.
- 57 -
part.
Replace with new
part.
Repair wear
Repair worn liner.
Replace with new
part
Repair by weld
build-up
Repair by weld
build-up
Check product
shear edge
Scale
Visual
Weld build up
wear area
Repair by
welding
Thickness gage
Check product
shear edge
scale
Repair by
welding
Scale repair by
welding
Wrench
Visual
Visual
Visual
Visual
Repair by jig
boring
Weld build-up,
Replace with new
part
Jig boring
machining
Repair by
welding
Replace with new
part
Replace with new
part
Replace with new
part or repair
Replace with new
part or repair
Replace with new
part
Replace with new
part
Replace with new
part or repair
28.
29.
30.
31.
Upper/Lower
holder
Upper/Lower
mounting bolts
Hook hole
Jig model
Surface condition
60-70% contact
Straight edge
Grind
Break, Looseness
Not permitted
Wrench
Vernier caliper
Visual
- 58 -
Inspection
Description of
Inspection
- 59 -
Inspection
Maintenance
1.
points
Guide Post
Inspection
Galling, wear, bend
Standard
0.05-0.1
2.
Guide bushing
0.05-0.1
3.
Punch
4.
Punch holder
5.
Bushing
6.
Bushing holder
7.
Burring punch
8.
Burring holder
9.
10.
Burring
bushing
Burring holder
11.
12.
Ejector
Slit male cutter
13.
Slit female
cutter
14.
Blank holder
15.
16.
Blank plating
Blank bead
groove
Peeling
Galling, wear
17.
Blank
mounting bolt
Blank set pin
Break, loosening
Blank bottom
surface
Ejector
Depression
Chip not
permitted
Overcut =
t+ 0.5~2.0
Looseness
0.01 max.
Clearance t
0.05~0.08
Galling not
permitted
Looseness
0.01 max.
Wear 0.05
max.
Wear 0.05
max.
Not permitted
Determine
from die and
part sheared
edge
Determine
from die and
part sheared
edge
Determine
from die and
part sheared
edge
Not permitted
Determine
from die and
part sheared
edge
None
permitted
None
permitted
0.5 max.
Break, loosening
22.
Ejector
mounting bolt
Knockout
23.
Knock spring
18.
19.
20.
21.
Mounting looseness,
Galling
Galling, wear
Mounting looseness,
Galling
Contour damage
Chip, galling, wear
Malfunction
- 60 -
Determine
from die and
part sheared
edge
None
permitted
Pin free from
bend
None
method
Micrometer,
inspection jig
Cylinder gage
Visual
Method
Replace with new
part
Replace with new
part
Grind, Replace
Vernier Caliper
Jig boring
Cylinder gage
Visual
Repair by welding,
replace
Jig boring
Visual
Grind, Replace
Cylinder gage
Jig boring
Micrometer
Micrometer
Visual
Repair by welding
Repair by welding
Repair by welding
Weld build-up
worn spot
Visual
Plating
Weld build-up spot
Wrench
Visual
Vernier caliper
Repair by welding
Wrench
Visual
Visual
24.
Hook hole
Worn threads
25.
Upper, lower
holder
Flatness, irregular
surface
26.
Upper
mounting bolt
Break, looseness
permitted
Not more than
1mm wear
60-70%
surface
contact
None
permitted
Vernier caliper
part
Machine new hole
Straight edge
Grind
Wrench
TO RESOLVE CHIP-DENT
PROBLEM TO INCREASE THE
QUALITY
- 61 -
CHIP
OK PANEL
CHIP
- 62 -
TOTAL
PRODUCTIO
N
HANDWOR
K
% H/W
2PS
79661
1050
2AP
36396
690
2CV
96686
1760
TOTAL
212743
3500
NOS
REJECTE
D
%
REJECTIO
N
CRACK
NOS
%
CRACK
1.32
82
0.10
51
0.06
1.90
137
0.38
82
0.23
1.82
186
0.19
62
0.06
1.65
405
0.19
195
0.09
2PS
2AP
2CV
79661
36396
96686
1.32
1.84
1.81
1.81
2CV
2AP
2PS
1.84
1.32
- 63 -
2 CV HandWork Trend
May'12
AVERAGE
1.8
S. NO
Part Name
ACTUAL
TARGET
ROOF
12.0
1.5
RR DR PNL L
9.6
1.5
SPO L/H
7.7
1.5
SPO R/H
5.8
1.5
RR DR PNL R
4.2
1.5
FR DR SKIN R
3.5
1.5
HOOD SKIN
3.2
1.5
FR DR SKIN L
2.9
1.5
HOOD FRAME
2.5
1.5
10
FR FNDR L
2.4
1.5
11
RR DR SKIN L
2.2
1.5
12
RR DR SKIN R
1.4
1.5
13
FR FNDR R
0.0
1.5
14
T/L SKIN
0.0
1.5
15
FR DR PNL R
0.0
1.5
16
FR DR PNL L
0.0
1.5
17
FR FLOOR
0.0
1.5
18
RR IN SIDE L
0.0
1.5
19
RR IN SIDE R
0.0
1.5
20
RR FLOOR
0.0
1.5
21
T/L FRAME
0.0
1.5
- 64 -
H/W %
4.0
2.0
0.0
1.4
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Defect Wise
SCRATC
H
OTHER
S
RUST
SCRAP
JAM
WRINKL
E
BUR
R
0
54
134
80
66
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
85
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
105
60
45
88
44
44
35
17
18
56
26
30
150
150
347
347
PART NAME
TOTAL
DENT
DING
HOOD SKIN
HOOD FRAME
FR FENDER R
FR FENDER L
ROOF PANEL
S P OUT R/H
S P OUT L/H
PANEL RR IN
SIDE R
PANEL RR IN
SIDE L
FR FLOOR
RR FLOOR
FR DOOR SKIN
R
FR DOOR SKIN
L
FR DOOR PANEL
R
FR DOOR PANEL
L
RR DOOR SKIN
R
RR DOOR SKIN
L
RR DOOR
PANEL R
RR DOOR
PANEL L
108
85
0
107
445
244
232
54
0
0
53
311
164
166
54
- 65 -
SPOI.LER SKIN
SPOILER FRAME
2002
895
525
85
497
TOTAL
TOTAL
DENT
DING
WRINKL
E
SCRA
P JAM
SCRATC
H
OTHER
S
RUST
BURR
2002
895
525
497
85
DENT
WRINKLE
SCRATCH
RUST
DING
SCRAP
JAM
OTHERS
BURR
MARC
H
2.42
0.67
1.35
1.62
12.55
7.16
9.29
APRIL
MAY
3.01
0.00
1.89
1.47
6.46
3.69
7.14
3.16
2.49
0.00
2.45
11.97
5.81
7.74
0.00
0.00
0.00
0.00
0.61
0.00
1.57
1.67
0.92
0.52
1.75
1.25
27.00
4.10
0.00
0.00
0.00
0.00
1.48
1.73
0.30
0.00
2.69
2.64
6.63
12.75
0.40
0.00
0.00
0.00
3.50
2.94
0.00
0.00
1.40
2.24
4.17
9.64
0.00
0.00
0.00
0.00
- 66 -
14
12
10
8
6
4
2
0
12.55
11.97
7.16
5.81
6
6.46
3.69
4
2
0
MARCH
APRIL
MAY
MARCH
- 67 -
APRIL
MAY
10
9.29
7.14
7.74
6
4
2
0
MARCH
APRIL
MAY
14
12.75
12
10
9.64
4.10
4
0
MARCH
APRIL
- 68 -
MAY
PART WISE
- 69 -
- 70 -
- 71 -
- 72 -