INTERNSHIP REPORT

ATLAS HONDA LDT.

PREPARED BY
THE STUDENTS OF HAMDARD UNIVERSITY KARACHI
ENGR. MUHAMMAD TAYYAB. ENGR. AWAIS YASEEN. ENGR.SHHBAZ IQBAL. ENGR. OSAMA IFTEKHAR.

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INDEX
S.NO.
1 2 3 4 5 6 7 8

DEPARTMENT
DRUM GEAR HUB & PANNEL MAINTENANCE BUFFING SHOP PRESS SHOP DIE AND TOOL WELDING SHOP PAINT SHOP ENGINE ASSEMBLY FRAME ASSEMBLY

PG. NO.
4 8 10 16 18 21 24

9 10

29 34

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Drum Gear
Introduction:Drum gear is an important part of engine which is commonly used for gear shifting. As everyone knows that there are four gears in motorcycle. But now a days five gear motorcycle is also available in market like CG-125 Deluxe of Atlas Honda Company. When motorcycle rider pushes forward or backward the dear paddle, drum is activated and gear shifts accordingly. It is drum like shape (like name) and has number holes on both sides which are tapped through tapping machines and grooves are formed on its surface. It is made up of material called grey-iron-cast.

Drum gear

DRUM-GEAR SHOP:Drum-gear shop of Atlas Honda Karachi plant produces drum of three models of Honda motorcycle. These are CD-70, CD-100 and CG-125. The drum of CD-70 and CD-100 are same in size an weight, but the difference is of grooves made up on the surface. But drum-gear of CG-125 is larger in size as compare to both CD-70 and CD-100. In this shop computerized numeric machines and manual machines are installed which
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is run by the shop management and workers. Here produce 1000 pieces per shift. The process of production in the shop is given below.

Process
First of all, die casted like rough drum shape is come from vendor in store. Here quality is checked according to standard of Atlas Honda. Then they issue the material to drum-gear shop. Then working starts here.

DOUBLE SIDE SPINDLE MACHINE:This machine is CNC machine which drills the collars of both sides of drum and grinds both sides below collar. It makes the 5mm diameter whole on both sides.

CNC OPERATION 1 and 2:These are two separate machines of same type and doing a same job. At this stage, the surface of drum is grinded in two steps. Half work is done by one machine and half another.

MULTI SPINDLE DRILLING MACHINE:It makes five holes. Four at one side and one at other side.

FOUR SPANDLE LEAD GROOVING MACHINE:This is CNC machine which makes grooves on the surface of drum. It can make grooves of all three parts which are produce here. The operator set the machines accordingly with drum model. In this machine, servo motor and drilling motor is operated through PLC programming.

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TAPING MACHINE:A tapping machine cuts a thread on the inside surface of a hole, creating a female surface which functions like a nut. Here manual tapping machines are installed which is easily operate able.

FURNANCE:A household furnace is a major appliance that is permanently installed to provide heat to an interior space through intermediary fluid movement, which may be air, steam, or hot water. (Heating appliances that use steam or hot water as the fluid are normally referred to as a residential steam boiler or residential hot water boiler.) The parts go to furnace to attain hardness. They are hated in about 51 minutes at the temperature of 850 C. Then they go for cooling in cooling oil. Here they are dip in oil for approximate 30 minutes. After that they are washed with water to remove oil particles. Then they are supplied heat to dry them. This heat is approximate 170 C.

CENTERLEESS GRINDING MACHINE:Center-less grinding is a machining process that uses abrasive cutting to remove material from a work-piece to result in a cylindrical surface with a fine finish. Center-less grinding differs from centered grinding operations in that no spindle or fixture is used to locate and secure the work-piece. The work-piece is secured between two rotary grinding wheels, and the speed of their rotation relative to each other determines the rate at which material is removed from the work-piece.
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QUALITY CKECK:This is the final stage. Here quality is checked properly. If any item is faulty, it goes toward the vendor who has supplied. As we know that quality policy is very strick of atlas Honda. So they never compromise on a minor fault. If pieces are OK, then they are sent to engine assembly where they assembled in engines of motorcycles.

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HUB AND PANNEL INTRODUCTION:Hub is very important part of the motorcycle. It ensures the contact of fix body of motorcycle and moving wheel. it is fixed in the bottom of the framebody at front and rare sides. It also use as a reference point in a breaking purpose of motorcycle. Break-shoes are set in it which performs the breaking operation.

Hub and panel department assemble the front and rear hub of CD-70, HONDA DREAM, HONDA PRIDER, CG-125, and HONDA DELUXE. There are number of machines in this department. Names are given below. 1. 2. 3. 4. 5. Flench machine. NC Grinder. PLC Machine. Shot Blasting Machine. Drilling machines.
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Flench Machine:It is of Nachi company Japan and use to fix the barring in the hub. Barring is kept on the center of hub by hands then it put a particular smooth pressure on the barring to fix it.

SHOT BLASTING MACHINE:Actually the shot blasting machine gives the shining surface to the breakshoes and makes the upper surface slightly rough to ensure the close and hard contact of braking material with the shoes.

NC GRINDER:Break-shoes are to be fixed into the hub. But here the size of break-shoes is slightly greater than the internal diameter of hub. Now the nc grinder machine grinds the surface of break-shoes and the diameter of both becomes equal and then fix it.

DRILLING MACHINES:Manual drill machines are use to drill the particular points of HUB and Break-shoes. On this manual machine, operator is must to operate them.

A type of bond is use to attach the braking material with break-shoes. T his bond take 24 hours to dry. Then the special material is bonded with them. Then grind the extra parts of braking material. Then they are sent to oven to make sure the hardness of material.

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MAINTENNANCE DEPATMENT
INTRODUCTION:Maintenance department is very important in each and every industry which takes care of machines and other equipments everywhere in the industry. As every engineer know that every machine requires maintenance after a particular time period. Continuously maintenance makes the long life of machine and makes it efficient. This department also repairs the faulty equipments which are not working properly or totally failed. There are five sections in ATLAS HONDA Maintenance department which are numbered below. 1. 2. 3. 4. 5. Electrical repairing unit (ERU). Mechanical repairing unit (MRU). Plant services unit (PSU). Primitive maintenance unit (PMU). Building maintenance unit (BMU). There are three types of maintenance occurs here. 1. Corrective maintenance. 2. Preventive maintenance. 3. Predictive maintenance. Corrective Maintenance:Repairing faulty machine is called corrective maintenance. In this situation, machine is not working properly and requires a work to work in desire manner. To bring it into running condition, maintenance is called corrective maintenance.

Preventive Maintenance:Orientation Report Atlas Honda Page 9

As every engineer knows that every machine or its part has a particular life which is defined by manufacturer. If it is replaced before its life end, then that machine gives maximum efficiency. This taking care of machine is called preventive maintenance.

Predictive Maintenance:As everyone heard a sentence experience matters. Off course, it matters. An engineer can predict the life of part of machine. And he maintain machine on his experience base. This type of maintenance is called predictive maintenance.

Categories of Maintenance:There is a form available in every department which is to be filled when they want to repair anything. Categories of work are mentioned at the top of the form. These categories are A, , A,

A and A. These are defined below.

A means fault has occurred and has no alternative available. Work Is

stopped. In this case, 24 hours are available to maintain the condition.

A means fault has occurred and alternative is available to carry on work. In this
case, one week is available to maintain the condition.

A means work is required but not urgently, like tube light, energy saver, air
condition has to be repair or replace.

A. This category is use when a huge amount of work is required, like a building
construction, building repairing and builds a new plant.

MECHANICAL REPAIRING UNIT (MRU):All work related to mechanical machinery is take place in the mechanical repairing unit. It has mechanical labs which consist of machines numbered below. 1. Milling machine. 2. Lathe machine.
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3. 4. 5. 6.

Shaper machine. Hacksaw Bench drill. Grinder. An electrical welding plant is also present for welding purpose. Here the labor is must to work with these machines.

Milling Machine:Milling is the machining process of using rotary cutters to remove material. From a work piece advancing in a direction at an angle with the axis of the tool. It covers a wide variety of different operations and machines, on scales from small individual parts to large, heavy-duty gang milling operations. It is one of the most commonly used processes in Atlas Honda and machine shops today for machining parts to precise sizes and shapes.

Lathe machine:A lathe is a machine tool which rotates the work piece on its axis to perform various operations such as cutting, sanding, knurling, drilling, or deformation, facing, turning, with tools that are applied to the work piece to create an object which has symmetry about an axis of rotation.

Shaper Machine:A shaper is a type of machine tool that uses linear relative motion between the work piece and a single-point cutting tool to machine a linear tool path. Its cut is analogous to that of a lathe, except that it is linear instead of helical. A shaper is analogous to a planner, but smaller, and with the cutter
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riding a ram that moves above a stationary work piece, rather than the entire work piece moving beneath the cutter. The ram is moved back and forth typically by a crank inside the column; hydraulically actuated shapers also exist. Other (Bench drill, Hack saw and grinder) machines are very simples as define below. The bench drill is a smaller version of the pillar drill. This type of machine drill is used for drilling light weight pieces of material. A motor is rotating continuously, handle control is given to push down and drill at a particular place. Grinder is a simple machine use to grind surfaces of objects. It has a motor running and a grinder plate is mounted on it shaft which rotates with motor. Hacksaw is simple blade use to cut the sheets. But here in Atlas Hondas MRU, an electric hacksaw is available which run on electricity.

Electrical Repairing Unit (ERU)

Electrical repairing unit playing a very vital role in any industry which takes care of electrical machines in the industry. It repairs the faulty machines as well as maintains all electrical instruments use in the industry. Here in Atlas Honda, an electronic lab is present which has all measuring and repairing instruments that are helpful to repair or maintain the industrial machines. Here in this lab, oscilloscope, function generator, DC power supplies, ampere meter, voltmeter, transformers and other equipments are present which are useful in instrument testing and repairing.

Plant Services Unit (PSU)

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Plant services unit is a unit that handles the power and pressure plants and boiler. Here in Atlas Honda, two KESC power lines, 5 generators, a boiler, and 5 compressors which has to be control the plant services unit?

Boiler:Here a boiler to produce steam that is use to supply heat in different departments where required. Two boiler operators are employees here which are certified from the government of Pakistan as a boiler operator. Other than these operators, no one allow to handle them. This boiler requires pure distilled water. For this purpose, a water filter plant is build which satisfying the requirement. Then water goes into the boiler. Here temperature is given to it and water becomes a steam. The pressure of steam is standarded as 7 bars. But the maximum pressure can goes to ten bars. Here protections are present to prevent the accidents. First protection is at eight bar, second is at nine bars and third one is at ten bars.

Generator:Five diesel generators are installed to ensure the availability of electric power to the plant. One of these is of 500 kva, one of 1200 kva and three are of 750 kva. These all can operate on diesel only. The PSU has to handle then and take care of them. If any problem occurs, PSU has to take action and maintain the condition.

Compressor:An air compressor is a device that converts power (usually from an electric motor, a diesel engine or a gasoline engine) into kinetic energy by compressing and pressurizing air, which, on command, can be released in quick bursts. This compressed air is used in different departments in hydraulic machines, hydraulic grinders etc. Maintenance of this plant is the responsibility of PSU.

Building Control Unit

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Building control unit is unit of maintenance department which provide services of construction, building repairing, plant installment etc. this unit estimates the cost of any project and approve fund from the finance department. They take a reasonable time to complete their project which depends on the quantity of work that they have to do. The main responsibility of the unit is to provide the quality of work which has surety of long life.

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BUFFING SHOP
Buffing shop is actually the department of Atlas Honda which degreases the surface of metallic parts for paint. These parts then go to paint shop for paint. This shop degreases as well as washes the parts with different chemicals to make ideal condition for paint. The detail of these chemicals is given in this report. Buffing and wire brushing machines are also present here which buff and wire brushes the surfaces of metallic part. The parts processed in the shop are listed below. Half front CD-70 and CG-125. Panel front CD-70 and CG-125. Half rare CD 70 and CG-125. Panel rare CD-70 and CG-125. These parts are come from their departments and processed here and then go to the paint shop for paint.

Process: First of all parts bring from their department to buffing shop. Then it is wire brushed here to make surface rough. Then they are buffed with a buffer of jeans. Then it is degrees with metaclean 2300 chemical. Then it is dipped into the hot water. Then it is dipped into the normal water. Then temperature is given to dry them. Then sent into the paint shop.

But here note is pointed here that rare parts first washed and then wire brushed and then buffed. Jeans and rugged material is used with a motor for buffing purpose. What is metaclean?

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Alkali, emulsion, emulsifiable and acid based metal cleaners, predegreasers and degreasers for iron and steel zinc coated steel and aluminum. Used in either spray or immersion processing plants. Hot water is use to remove the particles of meatclean. And cold water for cooling the parts. Temperature is given to water and metaclean from steam which is produced by the boiler installed in the industry. That boiler convert water into steam which is use to supply temperature where required anywhere within the industry.

Dust collector:Dust collector is a fan installed at the roof of the shop which collects the dust particles in the air through the tubes that are installed in the shop and go out. It is only to keep the environment clean and healthy. A large motor with a fan blades are present which sucks the dust in air and throughout.

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Press Shop
In press shop, heavy press machines and sheet cutting machines are installed which cuts the sheet and press to produce a particular form of item. There are about sixteen machines which are all Japan manufactured. These machines produce the parts of all five (CD-70, CD DREAM, CD-100, CG-125 and CG-125 DELUXE) models of Honda motorcycle. The sheets which are used in process are imported from Japan to provide a quality which we are required. There are machines having press of 400 tons, 300 tons and 200 tons which are use accordingly with required part and thickness of sheet. Dies of different models are replaceable on same machine as we have discussed parts of all models are manufactured here. Die is changed when the items of different models are to produce.

DIE:Die of all models are different and changed when production changed. There are four types of dies for four models. These dies are imported from Japan. According to Japanese standard, these dies expire after five lac (500000) stokes. After this figure, die is to replace or repair. Otherwise it cannot produce a quality.

Process
First of all sheets are issued from the store. Then they are cut into particular shape depending on a part. Then they go to press a machine which gives shape to it.

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Next step is trimming. In this step, pressed sheet goes to the trimming machine. It cuts the extra part from the body. Then they go for quality check. If any fault is detected, they repair it. At last, they are sent to welding shop. The frame body and fuel tank and frame body is manufactured in different parts. Then welding shop weld it to complete them. Frame-body is pressed by two separate dies. Left and right dies are separate. One produce the right side and other produce left side of frame body. The small parts of frame-body are produced by the other machines. Similarly fuel-tank is completed in three steps. One die form right side and other left. For a bottom part, a separate machine with a different die. The parts which produce this shop are given below.

Blank Size for sharing Machine CD-70 FRAME BODY:

F/Body Bottom plate Patch Plate Fuel Tank Stay Setting Battery Box Bottom Mudguard SPHC SPCE-N SPCC SPCE-N SPCE-N SPCE-N SPCE-N SPCC SPHC SPCE-N 2.3 2.0 2.0 0.8 0.8 R (305x941) L (303x914) 115x915 66x118 257x1220 126x1220 675x415 610x480 135x1220 121x1220 675x450

Fuel Tank:
Panel Bottom Patch Rear Cluch Plate A+C Panel GGJH 0.8 0.8 1.6 1.6 0.8

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CG-125
PARTS SPECIFICATION SHEET SPECIFICATION BLANK SIZE

FUEL TANK:
Panel Bottom Patch Rear Stay Rear Stay Front Cluch Plate Fuel tank KYHF Fuel tank bottom KYHF SPCE-N 0.8 SPCE-N 0.8 SPCC 1.6 SPCC 1.6 SPCC 1.2 SPCC 1.6 SPCE-N 0.8 SPCE-N 0.8 640x390 610x459 182x1220 124x1220 123x1220 121x1220 450x690 515x658

Front Fender:
Stay (R/L) Bracket SPCC 1.2 (1) 549x1220 (2) 549x1281 SCRAP

SPCE-N 2.0

PRIDOR FUEL TANK:

Panel Bottom Patch Rear SPCE-N 0.8 SPCE-N 0.8 SPCC 1.2 730x505 656x520 65x1220

CG-125(PK-2) FUEL TANK:

Panel Bottom
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SPCE-N 0.8 SPCE-N 0.8

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495x750 670x480
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DIE AND TOOL ROOM

Tool Room:
There are five machines in this room.

i)

Internal And External Grinding Machine:That Kind of machine making the tools and that tool are use to measure the part of engine.

Milling Machine:
Milling is the machining process of using rotary cutters to remove material from a work-piece advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide variety of different operations and machines, on scales from small individual parts to large, heavy-duty gang milling operations. It is one of the most commonly used processes in industry and machine shops today for machining parts to precise sizes and shapes.

Drill Grinding machine:

A drill is a tool fitted with a cutting tool attachment or driving tool attachment, usually a drill bit or driver bit, used for boring holes in various materials or fastening various materials together with the use of fasteners. The attachment is gripped by a chuck at one end of the drill and rotated while pressed against the target material. The tip, and sometimes edges, of the cutting tool does the work of cutting into the target material. This may be slicing off thin shavings (twist drills or auger bits), grinding off small particles (oil drilling), crushing and removing pieces of the work-piece (SDS masonry drill), countersinking, counter-boring, or other operations.
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Tool Grinding Machine:

A grinding machine, often shortened to grinder, is a machine tool used for grinding, which is a type of machining using an abrasive wheel as the cutting tool. Each grain of abrasive on the wheel's surface cuts a small chip from the work-piece via shear deformation. Three Machines are available in the other tool room that are: I) Shaper machine. ii) Lathe Machine. (Made in Japan) Iii) Lathe Machine (Made in Pakistan)

Die Shop:
Die Room: Flow Process in die Shop
Work Requisition comes from production shops for repairing of dies, Jigs and fixtures and preventive maintenance Repaired According to prescribed fault in work order and check ACCR to PM Plan

Die Checked by the shop foreman and returned back to the shop

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*) The above given chart is for the corrective maintenance and for preventive maintenance we follow the PM monthly schedule and fill the work sheets accordingly. Preventive maintenance of dies, jigs, fixtures,and special equipments.

A)
i) ii) iii) iv) v) vi) vii)

Slop Of Work:
Preventive maintenance of all. Corrective maintenance of all. New die/ jigs machining. As and when required. Press die Jig/fixture. Inspection Jigs The organization chart and layout of dies machine and tool is attached.

B)

Purpose:

Regular updating of dies. Jigs, fixtures, and special equipment to make and check products within specified accuracy/conformance.

C)
i)

Procedure:
A master list of above equipment is available with MR master list DF-05-03

(Die) DT-05-02 (Jigs) DT-05-03 (Inspection Jigs) ii) The regular inspection schedule of preventive maintenance are prepared for: A) All Die.
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B) All Jigs (prod). C) All jigs (insp). iii) The shop manager/area manager is informed of their preventive maintenance schedule month wise by mgr.tool room/die. iv) Die shop carries out necessary inspection/preventive checkup using check list. v) After due inspection and necessary repair/maintenance the equipment is returned to user with OK starts record on form. vi) The PM competed is record In master equipment maintenance schedule files. Dies, Jigs/Fixtures, Inspection Jigs.

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WELDING SHOP
Q) What is welding?
Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the work-pieces and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. This is in contrast with soldering and brazing, which involve melting a lower-melting-point material between the work-pieces to form a bond between them, without melting the work pieces. Welding shop Welding shop of Atlas Honda welds different type of pressed parts which are come from press shop, to give final shape. They use different type of welding techniques for joining the parts. This shop produces very important parts of motorcycle. The list of these parts is given below. fuel tank CD-70 Frame body CD-70. Rare fender CD-70. Bracket CG-125. Front and rare fender of CG-125.

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These parts are manufactured through different types of weldings which are listed below. Spot welding Organ welding. Mig welding. Tig welding. Arc welding

Spot welding:Resistive spot welding (RSW) is a process in which contacting metal surfaces are joined by the heat obtained from resistance to electric current. Work-pieces are held together under pressure exerted by electrodes. Typically the sheets are in the 0.5 to 3 mm (0.020 to 0.118 in) thickness range. The process uses two shaped copper alloy electrodes to concentrate welding current into a small "spot" and to simultaneously clamp the sheets together. Forcing a large current through the spot will melt the metal and form the weld. The attractive feature of spot welding is that a lot of energy can be delivered to the spot in a very short time (approximately 10 - 100 milliseconds).That permits the welding to occur without excessive heating of the remainder of the sheet

Mig welding:MIG welding is an automatic or semi-automatic process in which a wire connected to a source of direct current acts as an electrode to join two pieces of metal as it is continuously passed through a welding gun. A flow of an inert gas, originally argon, is also passed through the welding gun at the same time as the wire electrode. This inert gas acts as a shield, keeping airborne contaminants away from the weld zone.

Organ welding:Organ welding is able to separate clean soft water (H2O) into hydrogen and oxygen gases, using a small amount of electric power through a special process. These gases are then mixed and delivered for use in a wide variety of applications, such as heating, brazing, cutting, etc. which currently use LPG or other gas for fuel. When burned, this fuel generates no green house gases or pollutants, and burns at virtually 100% efficiency.
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Tig welding:Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc welding process that uses a non-consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric contamination by an inert shielding gas (argon or helium), and a filler metal is normally used, though some welds, known as autogenous welds, do not require it. A constant-current welding power supply produces energy which is conducted across the arc through a column of highly ionized gas and metal vapors known as a plasma.

Arc welding:Arc welding is a type of welding that uses a welding power supply to create an electric arc between an electrode and the base material to melt the metals at the welding point. They can use either direct (DC) or alternating (AC) current, and consumable or nonconsumable electrodes. The welding region is usually protected by some type of shielding gas, vapor, or slag. Arc welding processes may be manual, semi-automatic, or fully automated.

Process
Fuel tank:First of all, two sides join together. Then grids the edges. Reburring process. Giving shape tofule tank. Then paper grinding. Then coller welding to form fuel inlet. Then again paper grinding. Then bottom side welds through spot welding. Then goes for inspection.
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Here leakage test takes place through water. Then it is sent to paint shop.

Frame body:frame body is most basic part of bike on which all the pars are assembled. This frame body is made up of iron sheet which is imported from japan to just meet the quality of Honda.

It is manufactured by applying all the welding techniques on it. All the parts are attached process wise by different welding techniques. After completion the process, it is sent to paint shop for paint

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ENGINE ASSEMBLY
Engine assembly is a shop of atlas Honda Karachi plant where the engine of CD-70 is assembled. All parts are come from their departments. Some of parts produce by Shekhupura plant and some parts are manufactured here in the Karachi plant. These all parts come here and assembled process wise to form a complete engine of Honda CD-70 motor-cycle.

There are three categories of parts which are listed below. 1. Import: - which is imported from outside. 2. In-house:-which is produced by the plant itself. 3. Vendor:-which is taken from the local market. There are 25 workers works in this department, one foreman which takes care of work and one assistant manager whose takes care of all the activities in the shop. The production of shop is 450 engines per shift without any overtime. If more than 450 engines are required, then then they take overtime. This condition occurs when production plant control takes more orders from market than normal routine. In a routine work, one engine takes 58 seconds to complete.
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There are two lines named as. 1. Sub assembly line. 2. Main assembly line.

Sub assembly:Sub assembly line is the line where the engine parts assemble together and forward to main assembly line where the complete engine assembled.

Main assembly:Main assembly line is the line where the whole engine is assembled from the fresh parts and sub-assembled parts. At the end of this line, the whole engine is completed and checked then forward to frame assembly line. The engine is complete in eleven processes.

Process
i) sub assembly conveyor crank case:Oil seal, clutch, spindle, kick starter are assembled by pneumatic jig. ii)

Sub assembly conveyor crank case:Other parts assembly is done by process.

GEAR ASSEMBLY:Main gears, main shaft assembly, counter gears and counter shaft subassembly is done by the help of circlip fitting jig and placed in assembled gear jig.

Process of sub assembly line:Orientation Report Atlas Honda Page 29

Subassembly of the following parts is carried put in six different processes separately namely s1------> s6 and delivered to main assembly line. S1= L-crank case sub assembly. S2=piston-crank case sub assembly. S3=R-crank case sub assembly. S4=clutch and R-cover sub assembly. S5=cylinder head sub assembly. S6=AC generator sub assembly.

Main assembly line:M1= Transmission and which In L-crank case assembled on left gear case. M2= derive sprocket (14 length) drum belt and crank case belt. M3= Drum pin, spindle gear shifter and primary gear drive. M4=collar, bush clutch assembly and outer cover. M5=oil through, R-cover. M6=cylinder cam chain, cylinder head and cover head. M7=cap-nut 6mm, cylinder side bolt and valve timing adjustment. M8=push-rod o-ring and ACG fitting.
M9=nut flange 10mm, tap-nut adjustment and cap tappet cover.

M10=cover L-cylinder head, bolt 6*10, plug rubber and neutral switch. M11=air leakage test and oil filling.

Engine fire test bench:Orientation Report Atlas Honda Page 30

Assembled engines after leakage test and oil filling shift to fire test bench where engine sound, oil-pump clutch, gear neutral light working is tested.

Dispatch Frame Assembly Shop:OK engines are transported to frame assembly through conveyor which synchronous frame assembly conveyor with engine assembly conveyor.

Leakage Test:In this test, air pressures is supplied to the engine, and keep it into the water. If air bubbles forms, it means that the seals of engine are not properly set. These become in faulty pieces and have some rework required for proper operation.

Engine Repairing:In case of any defect in engine during inspection of QA (final inspection), engine sent to repair section of engine assembly and after rectification, delivered to final inspection for confirmation of the defect.

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Frame Assembly
There are two lines in frame assembly . i) ii) Main Line assembly. Sub assembly. In sub assembly there are following zone. i) ii) iii) iv) v) vi) Zone A. Zone B. Zone C. Zone D. Zone E. Zone F.

Zone A : i) ii) iii) iv) Front Fender. Rear Fender. Rear Fork. Step Bar.

Zone B : i) ii) iii) Front Tork. Head Light Case. Front /Rear Pannel.

Zone C : i) ii) iii) iv) Muffler. Stearing Handle. Front Rear. Mud seal.

Zone D : i) ii) Fuel Tank. Side Cover.

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iii)

Cowl.

Zone E : i) Front Rear Wheel.

Zone F : i) ii) iii) iv) v) Tail Light. Sprocket. Speedo Meter. Switch. Carburetor.

The different types of machine are worked there like: Machine that paste the engine no. on the frame ,Rim alignment machine, etc..

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