YAMAHA TRAINING REPORT (Production Department)

Submitted To: Submitted By Mr.R.Miglani Sumit Gauer

Production DeptB.Tech(ME)

IYM PVT LTD. SIET Gr.NOIDA

INDEX

S no. Description Page1. Certificate 32. Acknowledgement 43. Purpose of internship 54. Introduction 65 History of Yamaha 7-86 Overview 9-107 India Yamaha Motors 11-128. Vision 139. Mission 1310. Manufacturing in Yamaha 1411. Quality Engineering 1512. Paint Shop 16-2313. Project On Any

Abnormality in Pretreatment Process

24-25

14. Conclusion 26

CERTIFICATE

This is to certify that the project entitled “Any Abnormality

in Pretreatment Process(Fuel Tank)” has been

carried out by SUMIT GAUR under my guidance in partial

fulfillment of the requirement of the case study during summer

training. To the best of my knowledge and belief this work has

not been submitted elsewhere for any purpose.

Mr. P.K Arora

Mr R. Miglani

HEAD Deptt.

Head & project leader

Paint Shop (Q.E -

Division)

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.

R..Miglani, Mr. P.K Arora 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 Quality

Engineering department 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 SIET College of Engineering, great emphasis is laid on-the-

job training an industrial training. This is an integral part of

curriculum.

This six week industrial summer training (15th June to 31st July,

2009), 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, 1955

Capital 48,302 million yen (as of March 31, 2008)

President Takashi Kajikawa

Employees (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.

VISIONWe 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".

MISSIONYamaha 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.

QUALITY ENGINEERING

HEAD OF DEPARTMENT –MR R.MIGLANI

The Quality Engineering Department works in very close co-ordination of all other as Quality is at the top priority at Yamaha Motor. At each step of production operation quality check is undertaken. If any defect is recorded represented properly with the help of Mean and Range charts and the cause of defect is analyzed in detail. Then the required steps are taken to ensure that the quality problem doesn’t occur. A very important measure of Quality is SPRI (Spare Part Rejection Index). It is the ratio of qualitatively good parts to the total number of produced parts. Quality plans are made and every endeavour aim to only one end: Getting the Quality right the first time.

Machine shop CKD Body Assembly

Quality Engineering

Parts Exports Assembly

Weld shop CBU Engine assemblyPress shop IKDPaint and Electroplating SKD

Project:AnyAbnormality in Pretreatment Process Of Fuel Tank

I. After phosphate process, water rinse the fuel tanks are passed through the vacuum chamber where water droplets are dried out with the help of dry sprayer.

II. Dry Oven(water drying):-In this process fuel tanks are heated so that water can dry out completely from the fuel tanks.

III. Cooling Zone:-In this zone, fuel tanks get sufficient time to get cooled down for easy handling of the fuel tanks for further coming processes.

IV. Masking Zone:-In this zone, drilled parts of the fuel tank are covered by covering material in order to prevent the entry of the paint inside it. If masking is not done then paint will enter inside the hole and it may create problem during assembly process.

V. In this zone, there is a possibility of leakage(alkali sol. in water) in fuel tank. We can remove this leakage by rubbing alcohol on that portion of fuel tank.

VI. Dusting;- Now dusting is done to remove the dust particle by blowing air on the fuel tanks.

VII. Electrostatic Spray Painting:- Here required color coating is done on the substrate with the help of electrostatic charge using Electrostatic Disk.

VIII. After that, remaining part of the fuel tanks is done manually.

.

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.