Aluminium Machining (2)

Aluminium Machining

Manjeet Budania 2017ABPS1128H

Introduction to Machining ● ● ● ● ●

There are intotal 10 lines at the Machining Shop. These lines have over a 126 Machines to produce both Steel and Aluminium Parts. Machine Shop has a spread of 8000m2. Output from Machining works as an Input at the Sub Assembly area at the Engine Assembly Section. Machining Shop delivers fully machined Crank Cases, Cylinder Components and Cylinder Heads to the Engine Assembly.

Organisation Structure

5 Unit Leaders 3 Section Managers

Dept. Manager Steel

13 Team Leaders

Dept. Manager Aluminium

6 Unit Leaders

Division Head

3 Section Managers

17 Team Leaders

Total line Associates: 423

Insights on Aluminium Machining ● ●

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Aluminium Machining is responsible for the machining of Left and Right Crank cases and the cylinder heads of Honda Activa and Shine(KWP and KTE) at the Tapukara Plant. There are three lines for crank cases where both the left and right crank cases are machined simultaneously, similarly there are two lines for cylinder heads . The crankcase lines receive their input(sozai) from the HPDC(High Pressure Die Casting) facility at the plant. The Cylinder Head lines receive their sozai from outside vendors in the form of BOPs(Bought out Parts).

Right Crankcase

Left Crankcase

Final products of Aluminium Machining

Cylinder Head

Team Corner System at Aluminium Machining ● ● ●

Team Corners are special meeting areas for Managers and Leaders to discuss the Plans and the shortcomings in the plans. Team Corners also have various boards that basically contain data that helps in monitoring production on a day to day basis. Various topics covered in Team Corner Boards:

○ Safety: Safety Calendar, Past C/M verification, Incident Sharing and BBS Observation. ○ Quality: MMCs(Microsoft Management Console), Check Sheet and Associate Skill Chart. ○ Delivery: Production Monitoring, Spare Monitoring, Machine breakdown, Cycle Time Monitoring.

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Others: Kaizen Monitoring, Best kaizen, EMP( Environmental Management Plan), Tank Cleaning Schedule. Manpower Control Board: Deployments, Attendance Monitoring, Overtime Monitoring, Leave Plan, Training Plan Cost:Tooling Cost, Consumable Cost, Rejection Cost, Cost reduction themes.

Kaizen

Sozai Inspection

Layout at Crankcase line:

Milling

Final Inspection

Rough boring, Spot facing and Reaming

Drilling and Reaming

Body Leak Testing

Drilling and Spot facing

Reaming and Fine Boring

Tapping

Washing

RCC Bearing press

Cylinder Face reaming and milling