Copy Of Anuj Malik Training

UNITS OF HEMA GROUP 1.Hema Engg industry ltd. a.)Unit-I Gurgaon b.)Unit-II Hosur c.)Unit-III Manesar 2.Kay-Jay Auto Ltd.,Dharuhera. 3.Tobu India Ltd. 4.Flash Hema Energy Devices Ltd. Among all of these units Hema Engineering Industries Ltd.,1/3 km, Khandsa Road Gurgaon, is the major company of HEMA Group of industries. It is the major ancillary unit of HERO HONDA MOTORS LTD. Due to hard work, dedication and the able guidance of Mr .K.K. Jajoo (Chairman, Hema Group) it has grown up as a major ancillary unit for Hero Honda Motor Ltd. The unit is dedicated to its quality policy. It is TS 16949-2002 and ISO14001 certified company.

COMPONENTS MANUFACTURING IN HEIL 1. 2.

CHSSIS PARTS FOR HEROHONDA MOTORS LTD. REAR FORK (TWO WHEELER) FOR HHML.,TVS MOTOR COMPANY LTD.,MAJESTIC AUTO LTD. 3. FRONT & REAR PANEL (TWO WHELLER) PARTS FOR HHML. 4. MUFFLER PARTS FOR HHML. 5. SEAT PARTS FOR HHML. 6. FRONT/RR WHEEL PARTS FOR HHML/ HERO MOTORS LTD./ YAMAHA MOTORS LTD. 7. SHOCKER PARTS FOR MUNJAL SHOWA LTD., GABRIEL INDIA LTD., YAMAHA MOTORS LTD., HYDRAULICS LTD. 8. STRUT PARTS (FOUR WHEELER) FOR MARUTI LTD. (ACT AS A SUB VENDER). 9. RR WHEEL (TWO WHEELER) SUPPORTING PARTS FOR HHML. TVS MOTORS LTD., MAJESTIC AUTO LTD. 10. POWDER COATING J/W FOR HONDA SIEL LTD.

CUSTOMERS OF HEIL HERO HONDA MOTORS LTD.,DHARUHERA 2. HERO HONDA MOTORS LTD.,GURGAON 3. TVS MOTORS LTD.,HOSUR 4. TVS MOTORS LTD.,MYSORE 5. MAJESTIC AUTO LTD.,GAZIABAD 6. GABRIEL INDIA LTD.,HOSUR 7. GABRIEL INDIA LTD.,GURGAON 8. HYDRAULICS LTD 9. INDIA METER LTD.,HOSUR 10. GUJRAT CYCLES LTD.,VARODARA 11. RENOWED AUTO PRODUCTS. 12. STALLION SHOX LTD.,NOIDA 13. AUTO FIT LTD.,DHARUHERA 14. EUROTHERM,GERMANY 15. ESCORTS LTD.,FARIDABAD 16. MUNJAL SHOWA LTD.,GURGAON 17. AUTOMAX LTD.,GURGAON 18. DELPHI AUTOMOTIVES NOIDA 19. SANDHAR INDUSTRIES,GURGAON 20. HONDA SIEL MOTORS LTD.,NOIDA 21. MINDA INDUSTRIES LTD.,MANESAR 1.

THE DEPARTMENTS IN HEIL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10 11 12 13 14 15 16

PERSONNAL & ADMINISTRATION DOCUMENTATION CENTRE COSTING PURCHASE QUALITY ASSURANCE DESIGN/TOOL ROOM MIG WELDING SHOP STURT SHOP PRESS SHOP STANDARD ROOM SPOKE,NIPPLE AND PLATING SHOP EFFLUENT PLANT PAINT AND POWDER COATING CHEMICAL TESTING LABORATORY MAINTENANCE SHOP Q.A (ASSEMBLY AND FINAL)

PERSONNEL AND ADMINISTRATION The Personnel and Administration Department of HEIL deal with various aspects of manpower employed in the plant. The work of this department starts with the recruitment of the manpower for the plant whether it is skilled,. Semi skilled or unskilled. After the recruitment of the manpower they take care of proper training of every person according to the need so that each and every person can be an asset to HEIL and can help in increasing the productivity and profit of the company. For this purpose various type of training is arranged by the personnel department . For this purpose the department has to keep a close eye on every employee that where a person is lagging behind and needs training in the specified field so that one can give better results. Along with the recruitment this department keeps the full detailed record of each employee of HEIL so that in case of any need it can be used.. The various norms regarding the environmental safety are to be taken care by this department only. Various problems of the employees like regarding working conditions , pay scale and health are dealt by this department only. As this department has to deal with the manpower so the work of this department is a typical one and for it the concerning staff has to work hard.

MIG WELD SHOP It is the first production shop of the unit. As its name states that MIG (Metal inert gas welding) welding shop, MIG welding is used to manufactured the components. A gas is used to prevent the oxidation of weld. CO2 is used as shielded gas over the work when welding is done. The components produced in this shop are swing arm for the various models of Hero Honda Motor Ltd., TVS Motor Company Ltd. Machine Used Consumable Electrode coating Shielded Gas Used

Special Purpose M/C Steel Wire With Copper Carbon Dioxide

Main Models Produced By HEIL :Model Customer Name

Customer Model

Name P-11 P-17 P-21 P-40 P-60 P-70 CDN P-90 KTNA KTRA

CD-100 SPLENDER PASSION CBZ AMBITION KARIZMA DAWN SPLENDER SUPER ACHIVER GLAMOUR

HHML HHML HHML HHML HHML HHML HHML HHML HHML HHML

Tool Room/Design This department make the drawings of house production component & the brought out components. We use the software for the drawing are Auto cad & Pro-e. This department makes the tool & dies also.

Machines in Tool Room Conventional Machine : Machine Name 1. Milling Machine 2. Lathe 3. Lathe 4. Lathe 5. Drilling Machine 6. Drilling Machine 7. Drilling Machine 8. Cylinderical Grinding Machines 9. Surface Grinder 10.Surface Grinder 11.Shaper Machine 12.Shaper Machine 13.Power Hack Saw

Machine Make HMT Ltd. H-M/c Tools Kirloskar M/c ltd. HMT Ltd Ghalley ltd. Machliss ltd. Machliss ltd. RRM/c tools Gaziabad Praga M/c Tools Ltd. GuruArjun M/cTools Sagar Engg.Works ltd. Copper Engg.Industries Sagar Engg.Works ltd.

Non Conventional Machines : Machine Name 1.Vertical Machining Centre(CNC) 2.EDM Wire Cut 3.EDM Wire Cut 4.Zig Boring (INC)

Machine Make BFW Electra DL-25 Sodic Wire Cut M/c Precicut M/cvTools

Quality Assurance The major parts of the QA department are initial or bought out inspection and final inspection. In bought out inspection, we inspect the quality of the bought out components which we are using as the raw material in our plant like the pipe of P-90,P-70 etc based on the standards set by the various parties and the international and the and national standards which our plant is following. After proper inspection of the material the material is kept as the inventory in the plant and used according to the need . The inventory material in the plant is totally managed by the store department in the plant . The various operations are to be done on the components and after completing all the operations on the components they are send to the final assembly so that the final product can be carved out of the raw material . After all the assembling operations are done on the components , they are to be finally checked by the Final Inspection Department. After qualifying all the standards from the final inspection then only the material is dispatched to the concerning party. The customer satisfaction standard is to be maintained by the final inspection department only as the department has to deal with the customer directly to solve the problems which the customer is facing if any.

DOCUMENTATION CENTRE Documentation Center of HEIL is head by Management Representative. The function of documentation center is to keep all the records related to company and to represent the company in the market at various stages. The department keeps all the documents regarding the various polices followed by the company , various Indian and international standards followed by the company and regarding all the dealing by the company. The department head has the various responsibilities like to get the feed back from the customers regarding quality and timely delivery and other if any.Other then this the head has to keep a close look on all the employees of the company that whether all the standards are properly followed by all or not. The head also cross check the activities of the heads of all the departments that whether all the norms imposed are being properly followed or not and if there is any leg behind then he looks what are the corrective measures .

STRUT SHOP Struts are manufactured in this shop. The struts manufactured in this shop are for Gabriel Auto Ltd., Hydraulics India Ltd. Machine

SPM Welding Machine

Type of Welding

Mig Welding

Shielded Gas used

Carbon dioxide

Components of Strut 1. 2. 3. 4.

Pipe Seal Knuckle Bracket Spring Guide

Processes Performed In Strut Strut Shop 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Name Rolling:Reducing Bore:Facing & Boring:Sealing Cap Welding:Leakage Testing (I) :Spring Guide Welding:Knuckle bracket pressing:Knuckle bracket Welding:Leakage Test (II):Code Punching:-

STANDARD ROOM As Quality is the heart of the company, Standard Room is the heart beat of the company. In standard room we have done the inspections of samples of the components and gauges.

INSTRUMENTS USED Rockwell hardness tester 2. Profile projector 3. Micrometers 4. Height gauge 5. Varnier caliper 6. Dial indicator 7. Slip gauges 8. Filler gauges 9. Bore gauges 10.Angle protector 11.Co-ordinate measuring machine 1.

CALIBRATION LAB. In this lab. We have done the inspections and calibrations of gauges and instruments used in the company.

INSTRUMENTS USED :*SURFACE FINISH TESTER *DIAL CALIBRATION TESTER *PRESSURE GAUGE TESTER *MECHANICAL COMPARATORS

PAINT AND POWDER COATING HEIL has a largest paint and powder coating plant in India. In paint shop Paint is done on the outermost parts of the automobiles which needs better look and prevent the parts from corrosion. paint is done with an electrostatic gun. Powder coating is the process of making a layer over the components. which prevents the component from corrosion. It is done on the innermost or bottom parts. It has more life than paint coating. In powder coating process powder is

sprayed on the components with an electrostatic gun. After spraying, powder melts on the surface of the component by heating process and makes a layer on the surface. Water used at back side of the paint process where the extra paint mixed with water after dropping from gun has been changed after one year. Hot water generators are used for heating the water and produces steam to maintain the temperature of the room heaters. 50,000 ltrs. approx. de-mineralised water is used per day at a cost of 1.50 Rs/ltr. in the paint shop.

MAINTENANCE This department is to take care of all the industry, i.e maintenance of each and every thing including production parts, machines, various plants (like gas, filter etc.)electric works and utility. Its work is to keep a regular check on the working of the system, machines etc. installed in the industry. Studying why the accident/breakdown occurred, what possible preventive measures can be adopted so that in future no such problems occur. They also have to take care of the infrastructure, machine repairs, their life so that work can done smoothly and more efficiently, taking care that company does not go into losses (i.e useless expenditures ). Various data analysis are carried out like kaizen,o/t chart, operational research management(ORM). Do regular preventive maintenance and productive maintenance for reducing accidents/breakdowns. Regular improvement at all plant e.g (department)that called kaizen.

PRESS SHOP In this department different types of presses are used for shearing, bending, cutting and punching etc. operations on sheets and components. The components or parts of export OVEN are made in this shop. The ovens are mainly exported to FRANCE. Oven made in this shop are mainly used for room heating. Coal burns in this oven and produces heat which helps to heat the room according to the requirement.

MACHINES USED IN PRESS SHOP 1.POWER PRESSES 2.PNEUMATIC PRESSES 3.DRILLING MACHINES

SPOKE,NIPPLE AND PLATING SHOP In this department spokes and nipples are made which are used in the rim of the motorcycle. Spoke and nipples are also plated in this shop. Different types of chemicals are used for plating the spoke and nipple. SPOKE :- High carbon steel wire is used for making spokes. It is used in rim of the motorcycle.

OPERATIONS

MACHINES USED

1.Cutting of wire SPM cutting machine 2.Head making spoke SPM machine 3.Bending of head ---------do-----------4. Threading of spoke tail ---------do------------NIPPLE :- Cold drawn steel wire is used for making nipples. It is used in rim of motorcycle with spoke assembly. First of all cutting of the wire is done on header machine for making nipples. Nipple SPM machine has 8 tools ,all other operations are done on this machine as below:1. Holding and removing of component. 2. Chamfering. 3. Counter drilling. 4. Drilling dia 3.3 5. Drilling dia 3.4 6. Burr cleaning to make the complete throughout hole. 7. Cutting slot on head. 8. Threading.

Q.A (ASSEMBLY AND FINAL) In this department all the components coming from other departments (welding, press, and paint shop) are assembled with the help of nuts and bolts etc. Nuts and bolts are screwed by nut tightening m/c. Different types of operations are done in this shop e.g boring, tapping and rubber bush pressing etc. Boring and tapping operations are done for removing of extra paint material inside the holes and threading. Oils and greases are also provided over the required parts so that the components can prevent from corrosion and can't be damage easily due to friction etc. final inspection is also done here before packing and dispatch. Rejected components send back to the departments for their maintenance. After assembly the components are packed in polothenes, cartoons and boxes as per requirement and finally dispatched to other companies.

MACHINES USED 1. Boring machines 2. Tapping machines 3. Nut tightening machines (hand gun) 4. Drilling machines 5. Rubber bush pressing machine(SPM)

ACKNOWLEDGEMENT I would like to dedicate my work to Mr. P.L.Sharma ( Manager P&A) who allowed me for two months industrial training in his esteemed organization. I would like to special thanks to Mr. Bhashiya Kamboj & Mr. Rajnesh Yadav who helped me in my training with his highly technical work experience. The process chart displayed on every machine or work station and practical experience of the workers also helped me in making my training report. I am highly obliged to all the experienced staff members of HEIL who helped me in my training.