final honda report

7/31/2019 Final Honda Report

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SUMMER TRAINING REPORT

HONDA SIEL CARS INDIA LTD.SPL-1, Tapukara Industrial Area, Khushkhera

Distt. Alwar, Rajasthan 301707. INDIA

PROJECT REPORT ON

Die Maintenance Study and Chip-Dent Reduction

Trainee- Mentor-Prakul Bansal Mr. Harsh Vardhan

Mr. Pankaj ShrivastavaHOD, Press Shop

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Details of the Trainee:-

Name of Trainee GAURAV CHAUDHARY

Fathers Name Mr. RAM GOPAL CHAUDHARY

Date of Birth 01-08-1991

Course Name & Trade B.Tech, Mechanical Engineering

Name of Institute / Collage NIT KURUKSHETRA

Session 2012-13

Name of Guide (if any) Mr. Harsh Vardhan

Referred by

Permanent Address 3/530, KALA KUAN, ALWAR

E mail [email protected]

Contact No. +91-7206108388

Previous project details (If any):-

Project Name Production of Goods Trucks and Buses

Name of the Organization Ashok Leyland, Alwar

Duration 1 month

Details related to current project:-

Project NameDie Maintenance Study and Chip-DentReduction

Dept. / Section Press Shop

Training Duration 8th June to 20th July

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Acknowledgement

Gratitude is the hardest of emotions to express often one doesnt

find adequate words to convey the feeling of gratefulness. Therewere many people whom I would like to thank for their support. I

sincerely feel that credit of this work could not be narrowed down to

any one individual, by which I have achieved its completion.

Words will not suffice to express my deepest feeling of sincerest

gratitude to my revered MentorMr. Harsh Vardhan for his guidance,

constructive criticism and inspiring attitude resulting in the successful

completion of my Project.

Some persons certainly have more capacity to help others and I

should not loose any opportunity to extend my feeling of profound

gratitude to Mr. Rakesh, Mr. Dipin, Mr. Mandeep, Mr. Puneet, Mr.

Deepak, Mr. Abhishek, Mr. Shiv Narayan for unstinted

encouragement which inspired me to do better.

I wish to acknowledge the sincere co-operation and moral support

rendered to me by HR Department.

In the end it would not be out of place to express sincere thanks tomy Parents for their moral support and encouragement.

(__________)

Dated

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TO WHOM IT MAY CONCERN

This is to certify that GAURAV CHAUDHARYa student ofNational

Institute of Technology, Kurukshetra has undertaken a summer

training project on Die Maintenance Study and Chip-Dent

Reduction under my guidance and mentorship. I assure all the

contents, research work, analysis, and interpretations are genuine

attempt on her/his part. This is also to certify that this project is

neither submitted nor published else where.

I have ensured that this summer training report does not contain any

information which will be detrimental to the interest of the company.

Mentor:- HOD:-

Mr. Harsh Vardhan Mr. Pankaj Shrivastava

Press Shop

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Table of Contents

Sr. Description Page No.

1. Company profile 6-15

2. Executive Summary 16-22

3. Project 1:- Study of Die Maintenance

a. Background of project work 23-31

b.Repair Tools and Use of Standard Hand

Tools32-40

c. Remedy Procedures for Press Die 41-50

d. Die Design 51-58

4. Project 2:- Chip-Dent Reduction

a. Background of project work 59-60

b. Problem identification 61-64

c. Situation analysis using 7 QC tools 65

d. Countermeasure proposal 66

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COMPANY LAYOUT & PROCESS FLOW

HONDA PRODUCTS

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HSCI PRODUCTS

TO SHARE HONDA PHILOSOPHY

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Updated as on 2010


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The driving force behind Hondas growth was the leadership of its

founders Mr. Soichiro Honda and Mr. Takeo Fujisawa. The most

valuable legacy which our founders gave to our company is Honda

philosophy. This Honda Philosophy will continue to serve as the

basis of our daily business action and judgment for all companies and

associates within the Honda Group. It is critical that Honda

Philosophy be fully understood, respected, shared and translated into

action by every Honda associate around the world.

HONDA PHILOSPHY

The Honda Philosophy expressed in this illustration shows the

Company Principle, Management Policies and the Honda Way

based upon the fundamental beliefs of Respect for the Individual

and The Three Joys :

HONDAS MISSION

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COMPANY

PRINCIPLES

COMPANY

PRINCIPLES

THE THREE JOYS

RESPECT FOR THE INDIVIDUAL


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- 9 -

All associates areencouraged to

take initiative whileunderstandingthat they must takeresponsibilityfor the results of thoseactions

Respect for theIndividual

Each individual is unique,independent and possesses

initiative

Initiative Trust

TrustEqualit

y

All associates aretreated fairlyand equal opportunitiesgiven to each individual.

The relationship

amongassociates at HSCItobe based on mutualtrust

THE THREEJOYSJOYS

THE JOY OFBUYING

The joy of buyingis

achieved byproviding

products andservices

that exceed theneeds

and expectationsof the customer.

THE JOY OFSELLING

The joy of selling isattained

when those engaged inselling and servicingHonda products

develop relationshipswith the customerbased on mutual

trust.

THE JOY OFCREATING

The joy of creatingoccurs

when HondaAssociatesand Suppliers

involvedin the design,development ,

engineering andmanufacturing of

products recognize asense of joy in ourcustomers using theproduct and dealers

selling them.


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MANAGEMENT POLICIES

5S- 10 -

Company standardsfor carrying outDaily Operations

are based upon the

Management Policies

Proceed always with ambition and youthfulness.

Respect sound theory, develop fresh ideas and make themost effective use of time.

Enjoy work, and encourage open communications.

Strive constantly for a harmonious flow of work.

Be ever mindful of the value of research and endeavor.


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KAIZEN

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HONDA SIEL CARS INDIA, TKR PLANT

Honda Siel Cars India Ltd., (HSCI) was incorporated in December1995 as a joint venture between Honda Motor Co. Ltd., Japan andSiel Limited, a Siddharth Shriram Group company, with a commitmentto providing Hondas latest passenger car models and technologies,to the Indian customers. The total investment made by the companyin India till date is Rs 1620 crores in Greater Noida plant and Rs 784crores in Tapukara, Bhiwadi plant.

HSCIS first state-of-the-art manufacturing unit was set up at GreaterNoida, U.P in 1997. The green-field project is spread across 150

acres of land (over 6,00,000 sq. m.). The annual capacity of thisfacility is 100,000 units. The companys second manufacturing facilityis in Tapukara, Rajasthan. This facility is spread over 600 acres andwill have an initial production capacity of 60,000 units per annum, withan investment of about Rs. 1,000 crore. The first phase of this facilitywas inaugurated in September 2008.

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The companys product range includes Honda Jazz, HondaCity, Honda Civic and Honda Accord which are produced atthe Greater Noida facility with an indigenization level of 77%,76%, 74% and 28% respectively. The CR-V is imported fromJapan as Completely Built Units. Hondas models are stronglyassociated with advanced design and technology, apart fromits established qualities of durability, reliability and fuel-efficiency.

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KEY FEATURES OF THE TAPUKARA PLANT PHASE 1

PRESS FACILITY

The Press Facility comprising of 1500 ton tandem lead press

and 3 other tandem press of 1000 ton each maintain a tact time

of 7 seconds and is equipped with advanced features like

Auto de-stack sheet feeder & online sheet cleaning

Robotized part pick-up and transfer

Safety sensors that stop robot and machine

operation in case of breach of safety fence.

Underground scrap conveyer.

MODERN POWER TRAIN UNIT

30% of the machines in the Power Train Unit have been

procured from local suppliers Crankshaft line having GSN (Gas Soft Nitriding)

operation.

Unique Big end robotized cracking machine for

connecting rod.

GREEN PLANT The new plant is modeled on the lines of Hondas latest

global plants with great emphasis on environment

protection and safety.

Zero Discharge Plant

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PLC

INTRODUCTION TO PRESS SHOP

HSCI(TKR) is producing Sheet metal parts for car body.

The department had automatic tandem press line with first

press machine having capacity of 1500 tonnes followed by 3

Press machines with capacity of 1000 tonnes each. Besides

this, Press line has 5 Robots for parts movement from one

process to next process and a Destackfeeder assembly for

automatic feeding of blanks in press line for processing.

RPSC supplies blanks as raw material as per PRT system

controlled by Production Control Department. The blanks are

stored and preserved press dept. end and loaded on the

press line according to the plan. The blanks are processed in

dies depending upon the number of operations and converted

into parts. The parts are packed in trollies according to their

packing standard after going through check on conveyer by

online quality inspector. The repair parts are shifted to H/W

area for repair and N/G parts put in red coloured scrap bin.

The OK parts trollies are stocked at Trolley stock area. The

PLC dept. receives the OK quality parts from trolley stock

area according to dispatch plan. The parts are packed in PLCtrollies from press production trollies according to their

packing standard and delivered to GNU plant.

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Press dept. has sub dept. of Planning and Production, Quality

Control, Machine Maintenance and Die Maintenance and New

Model.

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PERSONAL PROTECTIVE EQUIPMENTS

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Helmet

Boot Cover

Arm Sleeves

Gloves

Nose Mask

Ear Plu s

Goggles


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Safety Shoes

2AP PRESS PART DETAILS

PARTS INTRODUCTION

14

9

15

3

7

10

12

11

13

2PS 4


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Panel Rear InsidePanel Rear Inside7

Tail Gate FrameTail Gate Frame15.

Tail Gate SkinTail Gate Skin14.

Rear Door Panel R/LRear Door Panel R/L13.

Rear Door Skin R/LRear Door Skin R/L12.

Front Door Panel R/LFront Door Panel R/L11.

Front Door Skin R/LFront Door Skin R/L10.

Rear FloorRear Floor9.

Front Floor8.

Side Panel LHSide Panel LH6.

Side Panel RHSide Panel RH5.

Panel RoofPanel Roof4.

Front Fender R/LFront Fender R/L3.

Hood FrameHood Frame2.

Hood SkinHood Skin1.

2AP PARTS NAME2PS PARTS NAMESRNO


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DRAWING:Drawing is a metal working process which uses tensile forces tostretch the sheet metal by which hollow shapes are formed.

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Die and punch are used in drawing operation.

Drawing is usually done at room temperature, thus classified as acold working process.The flow of material is controlled through pressure applied to theblank and lubrication applied to the die or the blank.If the form moves too easily, wrinkles will occur in the part. To correct

this, more pressure or less lubrication is applied to the blank to limitthe flow of material and cause the material to stretch or thin.If too much pressure is applied, the part will become too thin andbreak.Drawing metal is the science of finding the correct balance betweenwrinkles and breaking to achieve a successful part.Drawing leads to wrinkling and puckering at the edges where thesheet metal is clamped. This is usually removed by a separatetrimming operation.

TRIMMING:Trimming is the operation of cutting away excess metal in a flange or

flash from a piece e.g. when holes are produced in a sheet manually,

first circular blank is cut with a chisel and hammer. Then fine shapes

are trimmed with the help of a sher or snip. This operation i.e. cutting

by snip is called trimming.

FORMING (FLANGE & RE-STRIKE):Forming is the process of producing contoured parts by stretchingmetal sheets. Forming strains the metal beyond the elastic limit, togive the work piece a permanent set.Forming is similar to bending. Complex parts such as U-sections andchannel sections of different profiles can be produced by doingmultiple bends.

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There is no change in thickness. Good dimensional repeatability aswell as close tolerances is possible with this process. Complexbending and re-strike operations can be accomplished using Cams indies.Complicated flanges can be split in different operations.

Study of Die Maintenance

Role of Die maintenance Technicians:-

1. Troubleshooting and repair of dies

Draw dies.

Trim and piercing dies, cam trim and pierce dies.

Flange and Re-strike correction in forming dies.

Blanking dies.

2. Preventive maintenance of dies

Conducting weekly PM as per schedule

Conducting monthly PM as per schedule

Conducting yearly PM as per schedule

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Die opening and Closing

Die opening is a process of parting two halves of the die. Generally,

the top die is parted from the bottom die using a over head crane.

Die opening procedure:-

Centralize the crane to the die centre

Place all four noose of the crane rope in the rope slot of the top

die.

Lock the rope in the slot using die pins.

Confirm that the die pins are locked rigidly

Raise the crane hoist in inch mode.

Once the top die is disengaged from the guide. Raise the hoist

in rapid mode till there is a gap of ft between the die halves.

Place the top die on the die cot wood. Do not place the die on

floor without die cot wood.

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Die closing is a process of assembling the two halves of the die.

Generally, the top die is assembled on the bottom die using a over

head crane.

Die closing procedure:-

Centralize the crane centre to the top die centre

Place all four noose of the crane rope in the rope slot of the top

die.

Lock the rope in the slot using die pins.

Confirm that the die pins are locked rigidly

Raise the crane hoist upto 2mt from ground level.

Check the flow direction of the top and bottom dies are pointing

towards same direction

Move the top die to the center of the bottom die.

Check if locators are hitting against the top die.

Move the crane hoist down in inch mode till the gauides are

engaged. Bring the hoist down till the distance block is touched.

Remove the crane ropes from the slot

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Why do we need to wash dies ?

To remove atmospheric dirt which causes quality issues like dent

and bumps.

To remove the grits which gets deposited on the die surface

after polishing or after carrying out repairs?

If the dies are not cleaned it will result in scoring on die

surface, which in turn results in chrome peel off.

Procedure for die washing

Wash the die only on designated washing area

Apply Kerosene on the guides and panel area of the die

Wash the die with warm water 60-80 deg

Blow air and ensure that the die is 100 % moisture free

Apply a thin uniform layer of anti corrosion oil on the die

surface before closing the die.

Die Grinding

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Grinding is a highly skilled operation, where the required dimensions

or form is achieved. It requires a tremendous amount of skill and

concentration for grinding.

Grinding is often a secondary or finishing operation. The quality of the

ground surface depends on the selection of type of grinder and type

of wheel.

The next few pages illustrates how to finish a hexahedron block by

grinding.

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Dos and Donts of Grinding

Dos

Dress the wheel straight.

Grind in criss cross direction.

Lubricate the grind periodically.

Keep the grinder nozzle away from dust.

Grind in swinging motion to avoid deep grinding

marks.

Use the max length of the wheel while grinding.

Don'ts

Using damaged mounted wheels.

Tighten the wheel with full force.

Grind using undressed wheel.

Blow off grinding dust using compressed air.

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TYPES OF REPAIR TOOLS:-Tool Name Use

Air Porter Finishing of counter and cuttingedge.

Air Porter (mini) Finishing small counter, holes,cutting edges

Angle Grinder Rough finishing counter, cuttingedge.

Angle grinder (mini) Rough finishing small counter,cutting edge.

Hex Wrench Tightening and loosening socketbolts.

T Handle Wrench Tightening and loosening socketbolts.

Copper Hammer Driving dowel pins, blocks, etc.

Steel Hammer Peening, Chisel, etc.

Wrench Tightening ad loosening nuts.

Angle Wrench To replace offset

Screwdriver (+) Tightening, loosening cross

recess screws.Screwdriver (-) Tightening and loosening socketbolts.

Plier Holding, Gripping, cutting parts

Chisel Cutting, chipping

Adjustable Wrench Tightening, loosening nuts

Dowel pin puller Dowel pin pulling, driving

File Finishing contour

Compass Scribing lines

Vernier caliper General measurement

Thickness gage Measuring clearances

Radius gage Measuring radius

Impact wrench Tightening, loosening, socketbolts

Pipe wrench Holding, tightening, looseninground parts..

Vise plier Clamping Parts

Shears Cutting steel, copper sheets

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3. Completionof operation

4. Others

Checkwrench forwear andcrack.

Clean andorderlyarrange workarea(especiallyoil)

Refrain

from usingany damagedtools found.

Replace or repair beforeusing, or dispose

CopperHammer,Steel Hammer1. Preparationfor work

2. Tool Usage

Inspectand wear

specifiedprotectivegears.

Inspectconditions oftools.

Caution ofinjury to otherworkers.

Refrainfrom usingexcessiveforce.

Do not use gloves. Wearsafety goggles if necessary.

Do not use hammer withloose handle, missing wedge

Do not use copper hammerwith greater than 20% flaredhead

Do not use hammer withoutan anti slip end.

Do not use hammer with anoily hand.

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4. Others

Checkcondition ofhammer headand handle.

Clean andorderlyarrange workarea.

Refrainfrom usingany damagedtools found.

Replace or repair before using,or dispose.

Wrench,

Offset wrench1. Preparationfor work

2. Tool Usage


Inspectand wearspecifiedprotectivegears.


Preventovertorquingorundertorquing.

Checkwrench forwear and

crack. Clean andorderlyarrange workarea(especiallyoil)

Wear cotton gloves.

Do not use wrench withworm opening(greater than 5%)or with cracks.

Use proper tighteningtorque.

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4. Others Refrainfrom usinganydamaged

toolsfound.

Replace or repair beforeusing, or dispose.

Screwdriver(+),Screwdriver -1. Preparationfor work

2. Tool Usage

3. Completion

of operation

4. Others



Do nothammer thescrew driver.

Check for

loose handle. Check forcracked orchippedblade.


Refrain fromusing anydamagedtools found.

Wear cotton gloves.

Do not use tool with loosehandle or with chipped, cracked,worn tip.


Plier1. Preparationfor work

Inspectand wear

Wear cotton gloves.

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2. Tool Usage


4. Others

specifiedprotectivegears.

Inspect

conditions oftools.

Check forcracks, loosepin

Clean and

orderlyarrange workarea.

Refrainfrom usingany damagedtools found.

Do not use tool withexcessively worn grip area orloose pin.


Chisel1. Preparationfor work

2. Tool Usage




Caution forflying ofbroken chips.

Check forcracks, loosepin


Wear cotton gloves and

safety goggles. (However, donot wear gloves when using setchisel)

Do not use tool with flaredhead, chipped or cracked point. Hardness of point shall beless than HRC 55.

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4. Others Refrain fromusing any

damagedtool found.

Replace or repair before

using, or dispose.

Adjustablewrench, pipewrench1. Preparationfor work

2. Tool Usage


4. Others

Inspectand wearspecifiedprotective

gears. Inspectconditions oftools.

When usingthe tool applyforce in thedirection ofthe adjustingslide.

Do not useas ahammer.

Check forcracks andlooseness.

Clean andorderly

arrange workarea.


Wear cotton gloves.

Do not use cracked tools or

tool with loose adjusting screwor slide.

Apply proper torque.

Replace or dispose.

Pin Puller Inspect Wear cotton gloves.

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1. Preparationfor work

2. Tool Usage


4. Others

and wearspecifiedprotectivegears.


Caution,preventpinching thefinger.

Check thecondition of

the pin pullerwelded bolt.



Length of main unit shall beless than 300mm.Sliding weight hole diametershould be less than 15% of thediameter of the main unit slide.Flare of the main unit headsection shall be less than 35%.Main unit and head shall besingle piece.Normally, the pin screw end

should not be welded.

Repair before use.

File1. Preparationfor work

wearspecifiedprotectivegears.

Inspectconditions of

Length shall be at least150mm.

Wear cotton gloves only on

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2. Tool Usage


4. Others

tools.

Apply force

only on theforwardcutting strike.

Work in aweldbalancedattitude.

When cuttingedgebecomes

dull, cleanthe teeth witha wire brush.

Checkcondition ofhandle andthe crack

stopper ring. Clean and

orderlyarrange workarea.


hand which holds the tip. Do notuse tool with loose handle orcracked handle.

Wire brush


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REMEDY PROCEDURE FOR PRESS DIE(DRAWING DIE)

SYMPTOM CAUSE REMEDY1. Overall

wrinkles Blank holderpressure low

Adjust blank holderpressure

2. Localizedwrinkles

Blank holder notlevel

Blank holder notflat.

Blank stockimproperly

positioned Blank holder

pressure low

Adjust blank holder

Grind blank holder flat

Adjust blank positioner


3. Crack or tearalong partperiphery

Blank holderpressure too large

Punch/Die radiustoo small

Insufficient

clearancebetween punchand die.

Incorrectpositioning ofblank stock

Scoring on thebead and dieradius

Incorrect slittiming

Defective blankstock(workhardened)


Increase Die/Punch radius(observe part dimension)

Adjust clearance C= t+

(2/10 6t/10)

Adjust blank positioner

Polish

Adjust timing

Defective stock

4. Radial tear Defective blankstock

Blank holder

Defective stock

Regrind holder

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pressure low dueto unevenness

Blank stockimproperly

positioned

Adjust blank position

5. Radialscratches

Scoring on thebead and dieradius

Polish

6 Shiny spotson drawnsurface

Insufficientclearance

Improper shutheight

Improper die set-up

Adjust clearance C=1.2-1.5t

Adjust shut height

Reset up

7. Drawnsurfacedepression

Excessiveclearance

Adjust clearance betweenpunch and die.

8. Insidescratches

Groove scratcheson flange holderand bead

Polish

9. Streakdepressionalong drawn

surface(Startingmark)

Insufficient ieradius

Poor material slip

property

Bead lacks pull

Excessive cushionpressure

Defective blankstock

Adjust die radius

Polish

Adjust bead (observe part)

Adjust cushion

Replace stock

10.

Les alongdrawn surface

Insufficient blankpull

Defective die bend

surface

Reduce pressure increasebead pull force

Correct bend surface

11.

Line shift Improper cushionpressure

Improper blankpull force(improper bead)

Slit improperlytimed

Adjust cushion pressure

Adjust bead

Adjust slit timing

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Excessive shutheight

Adjust shut height

12.

Insufficientflange width

Insufficientmaterial

Insufficientcushion pressure

Insufficient blankpull force (bead)

Replace material

Adjust cushion pressure

Adjust bead

13.

Caused byvacuumcreatedduring dieseparation

Punch rise speedtoo high

Improper air bleedhole size, quantity

Reduce punch speed.(double action)

Change size, number,location of air bleed.

Adjust stretch ratio

Adjust oiling condition.14.

Developsduringpressing dueto unevendistribution ofstress duringpressoperation.

Uneven clearance

Unbalance tensionproduced by thebead.

Adjust clearance.

Adjust location and heightof the bead.

Adjust processing andcushion pressure.

Straightening process. (byuse of jig duringassembly)

15.. Depressiondevelopsduringprocessingdue toinsufficientpull on thematerial

Insufficient beadpull

Insufficient blankholder pressure.

Uneven blankholder surface

Reinforcement of bead. Adjust the blank holder

pressure

Repair of blank holdersurface

16.

Excessivecurvature

developsduringprocessingdue toinsufficientpull on thematerial.

Insufficient blankholder pressure

Punch contour


Improve finish of thepunch

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17.

Irregularspots formedby foreignobjects on thedie surface.

Foreign objects onthe die.

Foreign objects onthe blank stock.

Burrs on shearededge.

Clean the die.

Clean the blank stock

Remove burrs.

18.

Creasedevelopsalong thecorner duringdrawing andbending duetoconcentration

of stress

Insufficient beadpull and blankholder pressure

Excessiveclearance

Adjust bead shape andblank holder pressure

Adjust clearance

19.

Condition thatdevelops onthe insidesurface of thesheet due tounevendistribution ofstress.

Large die cornerradius

Excessiveclearance

Insufficient springback allowance

Insufficient blank

holder andcushion pressure.

Insufficientmaterial

Remedy due corner radius

Adjust clearance

Adjust spring backallowance

Adjust blank holder andcushion pressure

Use material of larger

dimension

20.

During initialdrawingphase thefriction of thedie caused

excessivematerialstretch at theradius andsubsequentincrease inrigidityproduced a

Irregular radius onthe die and punchsurface

Improper beadpull

Improve he finish of thedie and punch radii(smooth)

Adjust the bead timing

Increase the profile radius

with consideration to blankholder contour, pressuredirection.

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marked line.

REMEDY PROCEDURE FOR PRESS DIE

(TRIMMING DIE)SYMPTOM CAUSE REMEDY1. Burrs Excessive

clearance

Insufficientclearance

Primary cutterwear

Protruding

secondary edge.

Hardface C=t*5/100~7/100

Adjust cutter edgeclearance

Hardface the cutter edge

Grind secondary edge.

2. Edgeconditiondifferent forsides.

Punch and die offcenter

Remedy die offset.

3. Material notshearedsquare

Dull or wormpunch

Build up worm area byhardfacing

4. Projectionalong thecutting edge.

Damaged or

chipped cuttingedge of punch

Regrind or build up by

hardfacing the punchcutter

5. Depressionalong cuttingedge

Damaged orchipped cuttingede of die.

Regrind or build up byhardfacing the die cutter.

6. Depression ofthe normallyflat surface

Part not properlyset in the die.

Bushing surfacetoo low.

Incorrect drawingdepth

Check the matching of thedies and make correction

Install spacer and regrindheight of bushing

7. Punch breaks Stripper not setparallel.

Loose punch

Punch off center

Adjust stripper

Enlarge mountingdiameter of the punch toprovide good fit.

Realign the punch

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Interference withreverse hold down

Incorrect materialor hardening

Adjust

Change material or heattreat to proper hardness.

8. Scrapclogging

Restriction of thehole.

Scrap chute holerequires polishing

Burrs

Provide proper clearance

Polish hole

Lap punch and bushing

9. Part adheresto upper die

Weak stripperspring or damageto the urethane

Excessive cutting

stroke causingpart to bind

Replace

Adjust stroke

10.

Shift of cutline

Contour notmatched betweendrawn part andtrimming punch

Punch andstripper contournot matched

Damaged reverseholder spring

Match punch to the partcontour

Match stripper to punchcontour

Replace spring.

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(HOLE PIERCING)Symptom Cause Remedy

1. Burrs Worn slide core

Loose punchmount

Incorrectsecondary finish

Incorrect

clearance

Adjust slide coreclearance

Correct mount to properdiameter

Remedy

Adjust clearance

2. Blocked hole Clogged scraps

Loose fixed cam

Loose back upblock

Insufficient stroke.

Match the punch, cleanscrap escape hole

Tighten bolt, install key

Tighten bolt, install key

Adjust stroke

REMEDY PROCEDURE FOR PRESS DIE(BURRING DIE)

SYMPTOM CAUSE REMEDY1. Ragged hole

edge Pilot hole too

small.

Ragged holeduring pilot holepiercing

Defective material

Increase size of pilot holeso as to reduce theamount of burring

Match the punch

2. Incorrectburring height

Punch and die offcenter.

Hole in part notaligned to the die.

Incorrect burringhole bushingradius

Improper drawingdepth

Improper burring

Adjust

Adjust shut height

Match pilot to shape of

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pilot shape. part hole.


(CURLING DIE)SYMPTOM CAUSE REMEDY

1. Reverse bend Binding in thecurling groove

Curling groove offcenter

Polish groove

Reposition curling grooveby build up facing

2. Broken punch Punch andbushingmisaligned

Punch overhardened

Worn guide

Align punch and bushing

Temper to properhardness

Replace guide, post,bushing

Periodic Inspection and Maintenance GENERAL:-

The purpose of periodic inspection and maintenance(hereafter referred as periodic maintenance) is to performcontrol of the dies to prevent them from aging and wear so thatthe accuracy of the parts they produce will be maintained at thespecified uniform quality.

PERIODIC MAINTENANCE CONTROL METHOD:-Basic for die control is by press shot (number of parts

produced). Refer to the separate sheets for the details onpreventive maintenance for the respective processes.

ESTABLISHING SHOT QUANTITY BASED ONMAINTENANCE INFORMATION:-

Durability of the dies will depend upon many factorssuch as shape of product, sheet thickness, die design, diematerial. Normally, it would be desirable to maintain dieaccuracy for each product by the respective process, or toperform control within the range that products of uniform quality(acceptable product quality) can be supplied. However, based

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on past experience with die repair, control is established foreach process based on the number of press shots.

PERIODIC MAINTENANCE CYCLE:-PROCESSType,repair

70,000Shots

140,000Shots

210,000Shots

280,000shots

350,000shots

REMARKS

DRAWNormalImportan

t

Plating

Y

Y

Y

Y

Y

Y

Y

Y

YYY

Bead Wearcountermeasure

TRIMNormalImportan

t

Y Y YY

Y YCutter Wearcountermeasure

PIERCENormalImportant

Y Y YY

Y YAdjust accuracy ofshoulder punch fitsection

SIDE CUT

NormalImportant Y Y YY Y Y

BENDNormalImportant

Y Y Y Y YY

Bend punch wearcountermeasure

1. Normal Periodic Maintenance:- Perform- check of the steeldies for defects and damages In accordance with themaintenance procedure specified in the following attachedsheets, and make any repairs as necessary.

2. Important Periodic Maintenance:- In addition to the periodicmaintenance, look for areas of the steel die that indicateexcessive wear from die aging, and perform the designatedpreventive maintenance.

3. Plating:- Check the hard chrome plated areas for the loss(peeling) of the plating as the result of polishing and galling.Perform repair by building up the worn surface with welding andthen replating. Replating will restore excellent wear resistant

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property of the die (minimizing the depressions and scratches)and enable the continued production of quality products.Furthermore, the drawing property of the die is improved by thesmoothness of the plated surface.

FEEDBACK:-The information derived from the periodicmaintenance provides valuable information on thecharacteristics of each die (die design inadequacies, repairs)which can be used in the design and manufacture of future steeldies.

KEEPING OF DIE MAINTENANCE AND REPAIRRECORDS:-

All the periodic maintenance record sheets, and

repair and modification record sheets shall be kept in the file byparts (process) and in the order of maintenance performed.

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DIE DESIGN

1. STEEL DRAWING DIE:-Draw die- The rolled steel sheet is formed into the shape of the dieby applying a force perpendicular to the surface of the sheet.

Ref. PartName Function

a. Die set To simplify the mounting of the die (some aremade integral with the die)

b. Die Forces the sheet stock to form around punchcontour.

c. Bead Prevents wrinkles and distortion of press part,prevents slipping

d. Balancer block

Used for adjusting the holding force of the dieand blank holder. Used mainly for motorcycle.

e. Blankholder

Maintains the blanked stock in place and holdsthe stock during drawing (prevents wrinkles)

f. Punch Forces the sheet stock into the die to form theshape.

g. CushionPin

A component of the press which function as asupport for the blank holder

h. Pilot Performs the positioning of the stock sheet

i. Guide Performs the positioning of the blank holder to- 51 -


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the die.

Draw Die Periodic Maintenance Inspection Standard:-

S.No. Inspection

Points

Description

ofInspection

Inspection

Standard

Inspection

Method

Maintenance

Method

1. Guide post Galling, wear,bend

0.1-0.2 Micrometer,Inspection jig

Replace withnew parts

2. Guidebushing

Galling, wear,crack

0.1-0.2 Cylinder gage Replace withnew parts

3. Punch, Die,Blank

Galling, wear 0.05-0.1 Thicknessgage

Grind, Linerrepair

4. Holder, guide,plate

Galling, wear 0.05-0.1 Thicknessgage

Grind, Linerrepair

5. Guide platemounting bolt

Break,loosening

Nonepermitted

Wrench Replace withnew parts

6. Punch Worn radius,galling

0.5max. Section gage Weld build upworn spot

7. Die Worn radius,galling

0.5max. Section gage Weld build upworn spot

8. Die plating Peeling Nonepermitted

Visual Plating

9. Die mountingbolt

Break,loosening

Nonepermitted


10. Bead Galling, crack,wear

Determinefrom Die and

Part Weld build upworn spot orreplace

11. Bead

mounting bolt

Break

loosening

None

permitted

Wrench Replace with

new part12. Ejector retainer pin

Galling,deformation

Not permitted Visual Replace withnew part

13. Ejector spring Break, bend Not permitted Visual Replace withnew part

14. Pilot pin Break,deformation,looseness

Not permitted Visual Replace withnew part

15. Scrap chutebox

Damagedeformation

Not permitted Visual Replace withnew part orrepair

16. Upper/lower holder

Surfacecondition

60-70%contact

Straight edge Grind

17. Hook hole Screw threadwar

1mm max. Vernier caliper

Machine newhole

18. Mountingbolts

Break,looseness

Notpermitted


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2. STEEL SHEAR DIE ( Blanking, Trim, Pierce):-Trim-pierce die

For cutting off excess material

Ref. Part Name Function

a. Die set Upper die mounting plate (Some are made integral with the die)

b. Dowel pin For the die positioning (accuracy 0.15-0.24)

c. Stripper Holding the part in position, prevent part from lifting

d. Guide bushing For aligning upper and lower die, to maintain die accuracy

e. Stroke end pin Die reference (normally 0.5mm clearance exists)f. Guide post For matching the upper and lower die, maintain die accuracy

g. Punch plate Shoulder punch mounting plate, maintains punch position

h. Spring ellipse(Springurethane)

Serve as auxiliary punch function.(When large force required in small space)

i. Shoulder punch Mate with the bushing and performs hole piercing

j. Bushing Mate with Shoulder punch and performs hole piercing

k. Die cutter Mate with punch cutter and performs punching

l. Punch cutter Match with die cutter and performs punching

m. Punch Serve as positioner for drawn parts

n. Scrap cutter

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Trim Die Periodic Maintenance Inspection Standard:-

No. Inspectionpoints

Description ofinspection

InspectionStandard

Inspectionmethod

MaintenanceMethod

1. Guide post Galling, Wear, Bend,Cracks

0.05-0.1 Micrometer, ininspection jig

Replace withnew part.

2. Guidebushing

Galling, Wear, Bend,Cracks

0.05-0.1 Cylinder gage Replace withnew part.

3. Heel guide Galling, Wear 0.05-0.1 Thicknessgage

Repair wear

4. Wear plate Galling, Wear 0.05-0.1 Thicknessgage

Repair wornliner.

5. Wear platemounting bolt

Break, looseness Not permitted Wrench Replace withnew part

6. Male cutter,

Flat

Chip, Clearance,

Wear, Over-cut

Chip not

permitted

Visual Repair by weld

build-up7. Male cutter,Vertical Cut

Chip, Clearance,Wear, Over-cut

Clearance0.05-0.08 ofsheetthickness

Thicknessgage

Repair by weldbuild-up

8. Male cutter head pipe


Sagging edgenot permitted

Check productshear edge

Jig model repair

9. Male cutter counteredsection


Overcut 0.5-2.0 + sheetthickness

Scale Jig model repair

10. Female cutter flat


Chip notpermitted

Visual Weld build upwear area

11. Female cutter

vertical cut

Chip, Clearance,

Wear, Over-cut

Clearance

0.05-0.08 ofsheetthickness

Thickness

gage

Repair by

welding

12. Female cutter head pipe


Sagging edgenot permitted

Check productshear edge

Repair bywelding

13. Female cuttercounteredsection


Overcut .5-2.0+ sheetthickness

scale Scale repair bywelding

14. Punch blockmounting bolt

Break, Looseness Not permitted Wrench Replace withnew part

15. Die blockmounting bolt

Break, Looseness Not permitted Wrench Replace withnew part

16. Punch Chip, wear, overcut,

loose mounting

Chip not

permitted

Visual Wear replace

17. Punch holder Loose mounting,Galling

Edge sag Visual Repair by jigboring

18. Bushing Chip, Wear, Overcut,Loose mounting

Overcut =t + 0.5~2.0

VernierCalliper

Weld build-up,Replace withnew part

19. Bushingholder

Loose mounting,Galling

Looseness0.01 max

Cylinder gage Jig boringmachining

20. Ejector Damaged contour Not permitted Visual Repair bywelding

21. Ejector Spring

Break, bend, Deform Not permitted Visual Replace withnew part

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22. Ejector Urethane

Break, Bend, Deform Not permitted Visual Replace withnew part

23. Lifter Deform, Bend,damage

Not permitted Visual Replace withnew part orrepair

24. Cylinder Air leak, Operatingcondition Normaloperation Test Stand Replace withnew part orrepair

25. Knock out pin Malfunction Deform notpermitted

Visual Replace withnew part

26. Knock outspring

Break, Bend, Deform Not permitted Visual Replace withnew part

27. Scrape chut Damage, Deform Not permitted Visual Replace withnew part orrepair

28. Upper/Lower holder

Surface condition 60-70%contact

Straight edge Grind

29. Upper/Lower

mountingbolts

Break, Looseness Not permitted Wrench Replace with

new part

30. Hook hole Screw threadcondition

1mm maxwear

Verniercaliper

Drill new hole

31. Jig model Defective contour,Chip

Not permitted Visual Repair or makenew

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Steel Bending Die (Bend) & Steel Form Die (Restrike,Curling, Burring):-

Bend die is used to produce bend to the stock material with the die.

Curling die is used bend up the flange of stock material

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Pierce/Burring die periodic maintenance InspectionMethod:-

No. Inspectionpoints

Description ofInspection

InspectionStandard

Inspectionmethod

MaintenanceMethod

1. Guide Post Galling, wear, bend 0.05-0.1 Micrometer,inspection jig

Replace withnew part

2. Guidebushing

Galling, wear, crack 0.05-0.1 Cylinder gage Replace withnew part

3. Punch Chip, wear, overcut,hole looseness

Chip notpermitted

Visual Grind, Replace

4. Punch holder Galling, Mountinglooseness

Overcut =t+ 0.5~2.0

VernierCaliper

Jig boring

5. Bushing Chip, wear, mountinghole looseness

Looseness0.01 max.

Cylinder gage Repair bywelding, replace

6. Bushingholder

Galling, mountinglooseness

Clearance t0.05~0.08

Visual Jig boring

7. Burringpunch Galling, wear, bend Galling notpermitted Visual Grind, Replace

8. Burringholder

Mounting looseness,Galling

Looseness0.01 max.

Cylinder gage Jig boring

9. Burringbushing

Galling, wear Wear 0.05max.

Micrometer Replace withnew part

10. Burringholder

Mounting looseness,Galling

Wear 0.05max.

Micrometer Jig boring

11. Ejector Contour damage Notpermitted

Visual Repair bywelding

12. Slit malecutter

Chip, galling, wear Determinefrom die andpart

shearededge

Repair bywelding

13. Slit femalecutter

Chip, galling, wear Determinefrom die andpartshearededge

Repair bywelding

14. Blank holder Galled surface, wear Determinefrom die andpartshearededge

Weld build-upworn spot

15. Blank plating Peeling Notpermitted

Visual Plating

16. Blank beadgroove

Galling, wear Determinefrom die andpartshearededge

Weld build-upspot

17. Blankmounting bolt

Break, loosening Nonepermitted

Wrench Replace withnew part

18. Blank set pin Break, bend,looseness

Nonepermitted


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19. Blank bottomsurface

Depression 0.5 max. Vernier caliper Grind

20. Ejector Damaged contour,worn radius

Determinefrom die andpartsheared

edge

Repair bywelding

21. Ejector mounting bolt

Break, loosening Nonepermitted


22. Knockout Malfunction Pin freefrom bend


23. Knock spring Break, bend, deform Nonepermitted


24. Hook hole Worn threads Not morethan 1mmwear

Vernier caliper Machine newhole

25. Upper, lowerholder

Flatness, irregularsurface

60-70%surfacecontact

Straight edge Grind

26. Upper mounting bolt

Break, looseness Nonepermitted


- 58 -

EFF

ECTON

APPE

ARANCE:

AFT

ER

EFFECTON

APPE

AR

ANCE:

AF

TE


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TO RESOLVE CHIP-DENT PROBLEM TO

INCREASE THE QUALITY

WHAT IS CHIP DENT?

HOW IT GENERATE: WHEN DURING DRAW OR TRIM OPERATION

SOME DUST OR CHIP PARTICLE COMES ON THE DIE,GENERATETHE DENT

EFFECT ON APPEARANCE: AFTER PAINT, DENT IS CLEARLYVISIBLE WHICH AFFECTS OUR CBU APPEARANCE QUALITY

Hand Work Contribution, All Models May12

- 59 -

AINT,DENTI

SCLE

ARLYV

ISIBLEWHIC

HAFFECTSO

URCBU

APPE

A

RA

EFFECT ON

APPEARANCE: AFTERPAINT, DENT ISCLEARLY VISIBLEWHICH AFFECTS OURCBU APPEARANCEQUALITY

EFFECT ONAPPEARANCE:AFTER PAINT,DENT ISCLEARLYVISIBLE WHICH

AFFECTS OURCBU

APPEARANCEQUALITY

EFFECTONAPPEARANCE:AFTERPAINT,

DENTISCLEARLYVISIBLEWHICHAFFECTS

OURCBUAPPEARANCEQUALITY

EFFECTON

APPEARANCE:

AFTERPAINT,DENTIS

CLEARLY

VISIBLEWHICH

AFFECTSOUR

CBU

APPEARANCE

QUALITY

EFFECTON

APPEARANCE:AFTERPAINT,DENTIS

CLEARLYVISIBLE

WHICHAFFECTSOUR

CBUAPPEARANCE

QUALITY

LOWER DENT PANEL

OK PANEL

UPPER DENT PANEL

CHIP

CHIP

P

AINT,DENTISCLE

A

RLYVISIBLEWHICH

A

FFECTSOURC


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MODELTOTAL

PRODUCTIONHANDWORK % H/W

NOSREJECTED

%REJECTION

CRACKNOS

%CRACK

2PS 79661 1050 1.32 82 0.10 51 0.06

2AP 36396 690 1.90 137 0.38 82 0.23

2CV 96686 1760 1.82 186 0.19 62 0.06

TOTAL 212743 3500 1.65 405 0.19 195 0.09

2PS 2AP 2CV

79661 36396 96686

1.32 1.84 1.81

2 CV HandWork TrendMay'12

AVERAGE 1.8

- 60 -

CEQU

ALITY

U

APPE

AR

ANCEQU

ALI

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S. NO Part Name ACTUAL TARGET

1 ROOF 12.0 1.5

2 RR DR PNL L 9.6 1.5

3 SPO L/H 7.7 1.5

4 SPO R/H 5.8 1.5

5 RR DR PNL R 4.2 1.5

6 FR DR SKIN R 3.5 1.5

7 HOOD SKIN 3.2 1.5

8 FR DR SKIN L 2.9 1.5

9 HOOD FRAME 2.5 1.5

10 FR FNDR L 2.4 1.5

11 RR DR SKIN L 2.2 1.5

12 RR DR SKIN R 1.4 1.5

13 FR FNDR R 0.0 1.5

14 T/L SKIN 0.0 1.5

15 FR DR PNL R 0.0 1.5

16 FR DR PNL L 0.0 1.5

17 FR FLOOR 0.0 1.5

18 RR IN SIDE L 0.0 1.5

19 RR IN SIDE R 0.0 1.5

20 RR FLOOR 0.0 1.5

21 T/L FRAME 0.0 1.5

Defect Wise

HOOD SKIN 108 54 54 0 0 0 0 0 0

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HOOD FRAME 85 0 0 0 0 0 85 0 0

FR FENDER R 0 0 0 0 0 0 0 0 0

FR FENDER L 107 53 54 0 0 0 0 0 0

ROOF PANEL 445 311 134 0 0 0 0 0 0

S P OUT R/H 244 164 80 0 0 0 0 0 0

S P OUT L/H 232 166 66 0 0 0 0 0 0

PANEL RR IN

SIDE R 0 0 0 0 0 0 0 0 0

PANEL RR IN

SIDE L 0 0 0 0 0 0 0 0 0

FR FLOOR 0 0 0 0 0 0 0 0 0

RR FLOOR 0 0 0 0 0 0 0 0 0

FR DOOR SKIN R 105 60 45 0 0 0 0 0 0

FR DOOR SKIN L 88 44 44 0 0 0 0 0 0

FR DOOR PANEL

R 0 0 0 0 0 0 0 0 0

FR DOOR PANELL 0 0 0 0 0 0 0 0 0

RR DOOR SKIN R 35 17 18 0 0 0 0 0 0

RR DOOR SKIN L 56 26 30 0 0 0 0 0 0

RR DOOR PANEL

R 150 0 0 0 0 0 0 150 0

RR DOOR PANEL

L 347 0 0 0 0 0 0 347 0

SPOI.LER SKIN 0 0 0 0 0 0 0 0 0

SPOILER FRAME 0 0 0 0 0 0 0 0 0

TOTAL 2002 895 525 0 0 0 85 497 0

TOTAL

2002 895 525 497 85 0 0 0 0

2CV Hand Work

HOOD SKIN 2.42 3.01 3.16

HOOD FRAME 0.67 0.00 2.49

FR FENDER R 1.35 1.89 0.00

FR FENDER L 1.62 1.47 2.45

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ROOF PANEL 12.55 6.46 11.97

S P OUT R/H 7.16 3.69 5.81

S P OUT L/H 9.29 7.14 7.74

PANEL RR IN SIDE R 0.00 0.00 0.00

PANEL RR IN SIDE L 0.00 0.00 0.00

FR FLOOR 0.61 0.00 0.00

RR FLOOR 0.00 0.00 0.00

FR DOOR SKIN R 1.57 1.48 3.50

FR DOOR SKIN L 1.67 1.73 2.94

FR DOOR PANEL R 0.92 0.30 0.00

FR DOOR PANEL L 0.52 0.00 0.00

RR DOOR SKIN R 1.75 2.69 1.40

RR DOOR SKIN L 1.25 2.64 2.24

RR DOOR PANEL R 27.00 6.63 4.17

RR DOOR PANEL L 4.10 12.75 9.64

T/L SKIN 0.00 0.40 0.00

T/L FRAME 0.00 0.00 0.00

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final honda report

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