SUMMER TRAINING PROJECT REPORT

India Yamaha Motor Pvt . Ltd .

SUBMITTED BY

AMAN KUMAR

B.TECH MECHANICAL

SESSION: 2012-2016

JSS Academy Of Technical Education, Noida(Affiliated to Uttar Pradesh Technical University)

INDEX

S no. Description Page

1. Preface 3

2. Acknowledgement 4

3. Purpose of internship 5

4. Introduction 6

5 History of Yamaha 7-8

6 Overview 9-10

7 India Yamaha Motors 11-12

8. Vision 13

9. Mission 13

10. Manufacturing in Yamaha 14

11 Gear Manufacturing 15-16

12. Machine Shop Production 17

13. Machine Shop Processes 18-19

14. Conclusion 20

14. References 21

PREFACE

As a part of course curriculum of Bachelor of Technology we were

asked to undergo 2 months summer training in any organisation so as

to give us exposure to practical skill and competence to get us

familiar with various activities taking place in the organisation.

I have put my sincere efforts to accomplish my objectives within the

stipulated time. I have worked to my optimum potential to achieve

desired goals. Being neophytes in the highly competitive world of

technology, I came across some difficulties to make my objective a

reality. With the kind help and genuine interest and the guidance of

my supervisor. I tried my level best to conduct a research to gain a

thorough knowledge about the project. I put the best of my efforts to

bring out this piece of work. If anywhere something is found

unacceptable or unnecessary to the theme; valuable suggestions are

thankfully acknowledged.

Thanks and regards

Yours sincerely

Aman Kumar

ACKNOWLEDGEMENT

I express my gratitude to all the people at INDIA YAMAHA

MOTOR PVT. LTD who helped me to gain the valuable

knowledge and experience. I have no doubt that my choice of

training at IYM was right. The exposure and experience gained

at IYM has been unique. The Yamaha family teaches strict self

discipline and goal oriented approach.

I would like to thank my mentor at Yamaha Mr. S K GULATI

acquainted with the work ethics of the organization and

motivating me at each and every step so that I achieve my goal

at Yamaha with perfection.

Last but not the least I would like to thank all Machine Shop

department workers and managers for their cooperative

behavior.

PURPOSE OF INTERNSHIP

The importance of practical on the job training in the industry for

engineering student cannot be over emphasized. Industrial training

plays the most important role in an engineering student’s life to make

him a successful engineer. It provides the student with an opportunity

to gain valuable experience on practical application of their technical

knowledge.

At JSSATEN, great emphasis is laid on-the-job training an industrial

training. This is an integral part of curriculum.

This two months industrial summer training (10th Apr to 9th June,

2015), after six semester is in-built in to the B-Tech. program.

INTRODUTION

Yamaha Motor Co. Ltd. Was founded in 1955 with Genichi

kawakami as the first president. Today, Yamaha Motor is the world

second largest producer of motorcycle .It also produces many other

motorized vehicles such as all-terrain vehicle boats snowmobiles,

Outboard motors and personal watercraft .Takashi kajikawa is the

current president of Yamaha Motor Corporation. The corporation has

109 consolidated subsidiaries as on March 31st march, 2008. Yamaha

motor corporation stated aim is to bring people to great joy ,

happiness and to create Kando (touching heart )in their lives As a

company that makes the world its field and offer product for the land ,

the water , the snowfields and the sky , Yamaha motor strives to be a

company that “ offer New excitement and a more fulfillment life for

people all over the world” and to use its ingenuity and passion to

realize people ’dreams and always be the ones they look for “the next

Kando”. Kando is the Japanese world that captures the intense

excitement and deep satisfaction people feel. When they experience

truly of exceptional value. Yamaha motor seeks to make Kando a

distinctive benefit of everything we do by creating product and

services that consistently exceed your expectations.

HISTORY OF YICThe history of Yamaha is a history of unending “challenges”

YEAR Mile Stones

1955Yamaha Motor Co., Ltd. was founded with Genichi Kawakami as the first President

1959 Kitagawa Motor Co., Ltd. joins Yamaha Motor group.

1960Yamaha International Corporation (YIC) founded in U.S.First Yamaha outboard motor "P-7" released

1963Nationwide Yamaha Kai (authorized dealership organization) launched Pearl Yamaha founded in India as tie-up with local funding & starts production and sales of mopeds

1964 Siam Yamaha Co., Ltd founded in Thailand1965 First Yamaha FRP fishing boat "3rd Fuji Maru" built1969 First Yamaha multipurpose engine model "MT100" released1970 First Yamaha motorcycle mounting a 4-stroke engine "XS1" released

1973First Yamaha portable generator model "ET1250" released First Yamaha racing kart model "RC100" released

1975 First Yamaha golf car model "YG292" released

1976First Yamaha industrial robot model, an "arc welding robot" released First Yamaha marine diesel "MD35" released

1978First Yamaha land car model "G1-AD" released First Yamaha snow-thrower model "YT665" released

1986 First Yamaha personal watercraft (PWC) "MJ-500T" released

1987First Yamaha-made surface mounter "21 Series" released First Yamaha gas heat pump (GHP) model "YGC401W" released

1991Yamaha Motor France S.A. (YMF) founded Yamaha Motor de Mexico, S.A. de C.V. (YMMEX) founded

1992Chongqing-Jianshe Yamaha Motorcycle Co., Ltd. (CJYM) founded in China Yamaha Motor Austria GmbH (YMAG) founded Yamaha Motor Hungaria Kft. (YMH) founded

1993 Regionally limited release of the electro-hybrid bicycle "PAS"

1995Wheelchair electric power unit "JW-I" released, bringing Yamaha into the health and welfare industry Urban commuter motorcycle "Majesty YP250" released

1996"Environment 2000 Plan" announced Yamaha is first domestic manufacturer to be awarded international ISO9002 certification for motorcycles, snowmobiles, ATVs

1997Y's Gear Co., Ltd. Founded PT. Yamaha Motor Nuansa Indonesia (YMNI) founded

1999 2010 Environmental Action Plan "Eco Cite YAMAHA" announced2000 Yamaha Motor Asian Center Co., Ltd. (YMAC) founded in Thailand

2001Yamaha builds temporary pool "Suimu 21" for the main competition pool of the 9th World Swimming Championships in Fukuoka, Japan

2002 Limited regional release of the electric commuter motorcycle "Passol"

2003Yamaha Motor Distribution Singapore Pte. Ltd. (YDS) founded Yamaha Motor Co., Ltd., Moscow Representative Office opened in Russia

2004 Start of "YAMAHA CCS 21 Campaign"

2005Sales company Yamaha Motor CIS (YMCIS) founded in Russia Life Science Laboratory opened in Fukuroi, Shizuoka,as research&development center for YMC's bio-technology business

2006Motorcycle manufacturing factory Yamaha Motor Manufacturing West Java (YMMWJ) founded in Indonesia

2007 Compliance Promotion Committee established.

OVERVIEW

Founded July 1, 1955Capital 48,302 million yen (as of March 31, 2008)

President Takashi KajikawaEmployees

(Consolidated)46,850 (as of December 31, 2007)Parent: 9,019 (as of December 31, 2007)

Sales (Consolidated)

1,756,707 million yen(from January 1, 2007 to December 31, 2007)Parent: 799,209 million yen(from January 1, 2007 to December 31, 2007)

Sales Profile Sales (%) by product category (consolidated)

Sales (%) by region (consolidated)

Major Products &

Services

Manufacture and sales of motorcycles, scooters, electro-hybrid bicycles, boats, sail boats, Water Vehicles, pools, utility boats, fishing boats, outboard motors, diesel engines, 4-wheel ATVs, side-by-side vehicles, racing karts, golf cars, multi-purpose engines, generators, water pumps, snowmobiles, small-sized snow throwers, automotive engines, intelligent machinery, industrial-use remote control helicopters, electrical power units for wheelchairs, helmets. Biotechnological production, processing and sales of agricultural and marine products and microorganisms. Import and sales of various types of products,

Headquarters 2500 Shingai, Iwata-shi, Shizuoka-ken, Japan

Affiliated Companies

Consolidated subsidiaries: 112Non-consolidated subsidiaries: 8(by the equity method)Affiliates: 27(by the equity method)

Yamaha Motor Co., Ltd.

Yamaha Motor Co., Ltd.

Public

Type PublicFounded July 1, 1955

Headquarters Iwata, Shizuoka, Japan

Revenue 12 billion US$ (2005)Operating income 900 million US$ (2007)

Net income 550 million US$ (2007)Employees 39,300 (2007)

Website Yamaha Motor Global

INDIA YAMAHA MOTOR (IYM)

Holding the true sprit of commitment to customer satisfaction –India

Yamaha motor is enriching lives of people with same ingenuity and

enthusiasm as its parent company -Yamaha motor corporation Japan.

Having operated in India as technology provider for almost two

decade, IYM was incorporated in August 2001 as a 100% subsidiary

of YMC, Japan. Since then it is in process of the business and

extending the awe and power associated with the legacy of the

Yamaha Group.

Adhering to Yamaha Motor Corporation’s corporate Mission

–“Creating Kando-Touching Your Heart” Yamaha motor India is

striving to touch every heart across the length and breadth of India.

YMI`s Manufacturing facilities comprises of 2 state –of –the art

plants at –Surajpur (Uttar Pradesh) , Faridabad (Haryana) currently 10

models roll out at the two plants of Yamaha . The models

manufactured and assembled at the Surajpur plant are;

1. Gladiator

2. G5

3. Crux

4. Alba

5. Enticer

6. R-15

The infrastructure at both plants support production of bikes and its

parts for domestic as well as oversees market. At the core of 5-S and

TPM activities that fuel the IYM `s agile manufacturing processes

IYM has in house facility for Machining Welding processes as well

as Finishing processes of Electroplating and Painting till the assembly

line .

The stringent quality assurance norms ensure that the bikes meet the

reputed International Standards of excellence in every sphere.

As an Environmentally sensitive organization IYM has the concept of

“Environmentally-Friendly Technology” ingrained in its Corporate

Philosophy. The company boasts of effluent Treatment Plant, Rain

water Harvesting mechanism, a motivated forestation drive. The IYM

is ISO-14001 certified. All our endeavors give us reason to believe

that sustainable development for Yamaha will not remain merely an

idea in pipeline.

We believe in taking care of not only your motoring needs but also

the needs of future generation to come.

VISION

We will establish YAMAHA as the "exclusive & trusted brand" of customers by "creating Kando" (touching their hearts) - the first time and every time with world class products & services delivered by people having "passion for customers"..

MISSION

Yamaha is committed to:

Be the Exclusive & Trusted Brand renowned for marketing and manufacturing of YAMAHA products, focusing on serving our customer where we can build long term relationships by raising their lifestyle through performance excellence, proactive design & innovative technology. Our innovative solutions will always exceed the changing needs of our customers and provide value added vehicles.

Build the Winning Team with capabilities for success, thriving in a climate for action and delivering results. Our employees are the most valuable assets and we intend to develop them to achieve international level of professionalism with progressive career development. As a good corporate citizen, we will conduct our business ethically and socially in a responsible manner with concerns for the environment.

Grow through continuously innovating our business processes for creating value and knowledge across our customers thereby earning the loyalty of our partners & increasing our stakeholder value

MANUFACTURING IN YAMAHA

IYM's Manufacturing facilities comprises of 2 state-of-the-art Plants

at - Faridabad (Haryana) and Surajpur (Uttar Pradesh). Currently 10

models roll out of the two Yamaha Plants.

The infrastructure at both the plants supports production of

motorcycles and it's parts for the domestic as well as oversees market.

At the core are the 5-S and TPM activities that fuel our agile

Manufacturing Processes. We have In-house facility for Machining,

Welding processes as well as finishing processes of Electroplating

and Painting till the assembly line.

The stringent Quality Assurance norms ensure that our motorcycles

meet the reputed International standards of excellence in every sphere.

As an Environmentally sensitive organization we have the concept of

"Environment-friendly technology" ingrained in our Corporate

Philosophy. The Company boasts of effluent Treatment plant, Rain

water - Harvesting mechanism, a motivated forestation drive. We

believe in taking care of not only Your Motoring Needs but also the

needs of Future Generations to come.

Gear manufacturingGear manufacturing refers to the making of gears. Gears can be manufactured by a variety of processes, including casting, forging, extrusion, powdermetallurgy, and blanking. As a general rule, however, machining is applied to achieve the final dimensions, shape and surface finish in the gear. The initial operations that produce a semifinishing part ready for gear machining as referred to as blanking operations; the starting product in gear machining is called a gear blank.

Selection of materials

The gear material should have the following properties:

High tensile strength to prevent failure against static loads High endurance strength to withstand dynamic loads Low coefficient of friction Good manufacturability

Gear manufacturing processes

There are multiple ways in which gear blanks can be shaped through the cutting and finishing processes.

Gear forming

In gear form cutting, the cutting edge of the cutting tool has a shape identical with the shape of the space between the gear teeth. Two machining operations, milling and broaching can be employed to form cut gear teeth.

Form milling

In form milling, the cutter called a form cutter travels axially along the length of the gear tooth at the appropriate depth to produce the gear tooth. After each tooth is cut, the cutter is withdrawn, the gear blank is rotated, and the cutter proceeds to cut another tooth. The process continues until all teeth are cut...

Broaching

Broaching can also be used to produce gear teeth and is particularly applicable to internal teeth. The process is rapid and produces fine

surface finish with high dimensional accuracy. However, because broaches are expensive and a separate broach is required for each size of gear,this method is suitable mainly for high-quantity production.

Gear generation

In gear generating, the tooth flanks are obtained as an outline of the subsequent positions of the cutter, which resembles in shape the mating gear in the gear pair. There are two machining processes employed shaping and milling. There are several modifications of these processes for different cutting tool used.

Gear hobbing

Gear hobbing is a machining process in which gear teeth are progressively generated by a series of cuts with a helical cutting tool. All motions in hobbing are rotary, and the hob and gear blank rotate continuously as in two gears meshing until all teeth are cut.

Finishing operations

As produced by any of the process described, the surface finish and dimensional accuracy may not be accurate enough for certain applications. Several finishing operations are available, including the conventional process of shaving, and a number of abrasive operations, including grinding, honing, and lapping.

MACHINE SHOP PRODUCTION

The Following products are machined at the Machine Shop:

Cam Shaft

Crank Shaft

Cylinder Head

Body Cylinder

Axle main

Axle drive

5th gear wheel

Pinion and PDN

3rd Gear wheel

Crankcase

MACHINE SHOP PROCESSES

The following are the processes which are used in Machine

Shop:

Turning

Centering

Facing

Chamfering

Spot Facing

Surface Grinding

Milling

Face milling

Shaving

Honing

Drilling

Boring

Counter Boring

Reaming

Tapping

Inspection

Grading – Color coding

Labelling

Leak test

Dibbering

Keyway Milling

Quality check

Inspection

Maintenance

CONCLUSION

The period of my training at Yamaha Motor India Pvt. Ltd.

has been a very positive one. It has given me a very good

understanding of the engineering profession which could not

have been achieved by theoretical study. The experience at

IYM has greatly advanced my understanding of the practical

aspects of engineering, both technical and organizational.

The vital part that the organizational skills of an engineer play

in today’s industry is an area that is often missed by some. I

too had very little idea as to what an engineer’s job in a high-

tech industry entails. But this internship at IYM made me see

the maximum range of jobs performed by engineers. It has

given me a solid foundation to build my career upon. I am

certain that the experience gained through this internship will

be helpful to me throughout my professional career and in all

my future

endeavors.

REFERENCES

Machine Shop of IYM-faridabad plant.

www.yamaha.com

www.wikipedia.com