Assigned Project:

Time Motion Study of Vehicle Final Assembly

Group Members:

Muhammad Azhar (Mechanical Eng.)

Muhammad Shayan Tariq (Automotive Eng.)

Muhammad Anas Sohail (Automotive Eng.)

Internship Period:

6th June 2016 to 2nd July 2016.

Internship Report

Pak SuzukiMotors Limited, Karachi.

PREFACE

The purpose of this report is to explain what We did and learned during our internship period with the Pak Suzuki Motors Limited, Karachi, in the Department of Production. The report focuses primarily on the Project handled and shortcomings that the internees did encounter when handling various tasks assigned to him by the supervisor.

Because the various parts of the report reflect the internee’s shortcomings, successes, observations and comments, it would be imperative that the recommendations are also given. Therefore the report gives a number of comments and recommendations on the internship program.

It is hoped that this report would serve as a cardinal vehicle to the improvement of the internship program.

It gives us immense pleasure to convey our thanks and sincere respects to all, who have been instrumental in our successful completion of internship training that was quite eventful providing an inside into better understanding of automobile industry.

We are very much thankful to Sir Humaid ur Rahman for his cooperation in enhancing our related skills.

TABLE OF CONTENT

PREFACE ……..TABLE OF CONTENTS……..1.0 INTRODUCTION……..

1.1 PRESS SHOP ……..1.2 WELDING SHOP……..1.3 PAINT SHOP ……..1.4 VEHICLE FINAL ASSEMBLY (VFA) ……...1.5 PLASTIC SHOP……..1.6 ENGINE SHOP……..1.7 MATERIAL HANDLING DEPARTMENT (MHD)…………1.8 MAINTENANCE DEPARTMENT……...1.9 PRODUCTION PLANNING CONTROL……..1.10 MOTORCYCLE DEPARTMENT (MCD)……….

1.10.1 DIE CASTING SHOP……..1.10.2 MACHINE SHOP……..1.10.3 WELDING SHOP……..1.10.4 PAINT SHOP……..1.10.5 VEHICLE FINAL ASSEMBLY (VFA) ……..

2.0 TIME AND MOTION STUDY……..2.1 TIME AND MOTION EQUIPMENTS & PROCESS……..

3.0TIME MOTION STUDY SHEETS……..

3.1MODEL GD110S-CD……..3.2MODEL GS150-E2……..

4.0 CONCLUSION & RECOMMENDATION:

1.0 Introduction:

Pak Suzuki Motor Company is a well-known Automotive Company in Karachi, Pakistan.

There are total ten main departments of the production, which are as follows:

1.1 Press Shop: Where the main parts of the vehicles like roof, doors etc develop by the metal sheets on the press shop.

1.2 Welding Shop: The parts from the press shop such that vehicle’s roof, door etc. is welded here, and a body shell is produced.

1.3 Paint Shop: In this shop the body shell is cleaned and colored by electrode deposition.

1.4 Vehicle Final Assembly (VFA): In VFA, vehicle complete assembly is done. The parts like engine, Rear/Front lights, tires, and the decoration parts are assembled on the Body shell in this section.

1.5 Plastic Shop: In this section the Plastic Components of Vehicles like Front/Rear Bumper etc. are manufactured through Injection Molding. And these plastics parts are transferred to Vehicle Final Assembly where these parts assembles with the body shell.

1.6 Engine Shop: In this section the Engine of the Four wheel vehicles is assembled and then this assembled engine is delivered to Vehicle Final Assembly where it assembles with the body shell.

1.7 Material Handling Department (MHD): This is the Department which is responsible for the storage & supply of the imported parts to the concerned departments. Note that these imported parts are imported from abroad and known as Complete Knock Down Parts (CKD Parts).

1.8 Maintenance Department: This department is responsible to maintain the Electrical or Mechanical systems of all the departments of the company. They

mainly repairs the Machines or Electrical system which are needed to be repaired.

1.9 Production Planning Control: This department do the planning of production of Vehicles, that how much vehicles should be developed in specific time. This department mainly deals with the tag time of Production departments.

1.10 Motorcycle Department (MCD): MCD department is an important department which has its own Die Casting Shop, Machine shop, Paint shop & Vehicle final Assembly shop. This department mainly deals with the two wheel vehicles and manufactures the vehicles:

i) GS150-E2ii) GD110-CDiii) GD110S-CDiv) ECO110v) GW250-JP

This is the only department of Pak Suzuki Motors where the few parts of the two Wheel vehicles such that which are listed above are manufactured in Die Casting Shop and then these parts are further brought to the proper shapes in the Machine shop and then these parts are subjected to the Welding shop where such main parts like Frame, Fuel tank of the two wheel vehicles is developed through various types of welding, then these parts are transferred to the paint shop where they are colorized after cleaning and the backing process and then finally these parts are shifted to the Vehicle Final Assembly (VFA) where all parts of vehicle including imported parts are assembled together and in this way the two wheel vehicle is developed. Here also not that in MCD’s VFA there is also an Engine shop where the two wheel vehicle’s engine is assembled and then transferred to VFA. Note that Die Casting shop and Machine shop works under MCD, while MCD has also its own Welding shop, Paint Shop, Vehicle final Assembly (VFA) & Engine shop. We can say that the whole summary of the work of the production of whole Pak Suzuki Company can be excellently visualize in only one department that is MCD. As I have already mentioned the name of the shops again these can be defined as:

1.10.1Die Casting Shop:

Die casting shop is the only manufacturing shop in Pak Suzuki motors where the various parts of two wheel & four wheel vehicles are manufactured. In Die Casting shop there are three machines which are used for the manufacturing of various two wheel & four wheel vehicle parts, which are as follows:

i) 350 ton Machine: This machine manufactures a part of mass 1 to 1.5 kg in 40 to 50 seconds. This machine has been installed in shop since many years.

ii) 420 ton Machine: This is the latest machine which has been working in Die Casting shop for 4 to 5 months. This machine manufactures a part of mass 1 to 1.5 kg in 1 minutes

iii) 800 ton Machine: This machine use to manufacture the huge parts of mass 2 to 4.5 kg. It takes 1.5 minutes to manufacture a part.

There are total 31 dies in this shop through which we are able to manufactures 31 parts of two wheel & four wheel vehicles through Die casting process. Among them 4 parts are of four wheel vehicle which are Case distributer, Plate intake manifold, Cap water inlet & Cap water thermostat are produced in this shop. While 27 parts are of two wheel vehicle which are like Magneto Cover, Clutch Cover, Front/Rear Panel, Front/Rear Hub, Gear shifter etc.

These parts are manufacture of Aluminum material which arrived in this shop in the form of ingot by local vender. There is a main Crucible furnace in this shop where Aluminium ingots are melted in temperature range of 650 to 700 degree centigrade. Along with this main furnace there is a main holding furnace which has the 1000kg capacity to hold the melted Aluminium. While this melted Aluminium is transferred as per need to the other holding furnaces which are attached with the Die Casting machines. Note that each machine has its own holding furnace & each holding furnace has material holding capacity of 250 kg. From holding furnace the melted material is brought into the mold cavity through a ladle.

Basically in Die casting machine there is a plunger which operates hydro dynamically & develops a pressure by Air and Nitrogen & due to this a stroke is applied on mold cavity where the melted material is filled & as a

result of applied stroke pressure of plunger, this material attends desire shape of cavity. The melted material cools down and attains a solid shape of the mold while then the plunger returns back to its original position and then the specific manufactured material is taken out. Before each stroke, the plunger & the cavity is showered by the pressurized fluid which is a mixture of water & oil. In this mixture water is used for cooling purpose while oil is used to prevent the attachment of melted Aluminium on surface of plunger & cavity. Actually there are 31 dies & the manufacturing of parts continuous on the daily basis as per the production & need, so in this manner the manufacturing of 31 parts occurred.

1.10.2 Machine Shop:

The parts from the Die Casting shop & other parts which are imported brings here in Machine shop for the machining process. There are 23 Computerized Numerical Control (CNC) & 21 Lathe machine are installed, while 7 more CNC machines will be installed soon in this shop.

Computerized Numerical Control machines are the computerized control machines in which the computer plays an integral part of control. CNC machine is automated with machines tools that are operated with programmed command that are stored on computer. While Lathe machines are in contrast to CNC & are operated manually. In machine shop the operation performed on CNC & lathe machines are drilling, facing, turning, threading & reaming etc.

The jigs, instrumentation test & leakage test is performed on parts after being hosted by machining process. These tests are performed to verify the proper machining of parts.

Machine shop plays a vital role in MCD, because it meets all the dimension of part according to standards and check sheets.

Machine shop consists of 2 lines:

1) COMPUTER NUMERIC CONTROL LINE (CNC)

2) MANUAL MACHINE LINES

COMPUTER NUMERIC CONTROL LINE (CNC):

CNC Computer Numerical Control machines are widely used in manufacturing industry. Traditional machines such as vertical millers, centre lathes, shaping machines, routers etc. operated by a trained engineer have, in many cases, been replaced by computer control machines.

In MCD machine shop 21 parts is machine on CNC. This includes intake manifold, case distributor, crank case, cylinder head and many more. Machine shop contain higher number of CNC machines than manual machines and in future pak Suzuki convert whole machine shop on CNC machines , because it has a great impact on production. How on production? Let’s take a overview of CNC machines.

1. CNC machines can be used continuously 24 hours a day, 365 days a year and only need to be switched off for occasional maintenance. 2. CNC machines are programmed with a design which can then be manufactured hundreds or even thousands of times. Each manufactured product will be exactly the same.3. Less skilled/trained people can operate CNCs unlike manual lathes / milling machines etc. which need skilled engineers.4. CNC machines can be updated by improving the software used to drive the machines.

5. One person can supervise many CNC machines as once they are programmed they can usually be left to work by themselves. Sometimes only the cutting tools need replacing occasionally.

6. It reduces labour cost and man power.

MANUAL MACHINES:

There are five lines of manual machines which include:

1) 1st LINE:

HUB CLUTCH SLEEVE

2) 2ND LINE:

CLUTCH COVER (SD110)

3) 3RD LINE:

REAR PANEL

4) 4TH LINE:

FRONT PANEL.

5) 5TH LINE:

GS MAGNET COVER.

1.10.3 Welding Shop:

In Welding shop total eighteen types of two wheeler parts such that main frame, fuel tank, center stand, swinging arm & mount brackets etc are developed through various types of welding like spot welding, seam welding etc. Actually the parts imported in this shop for welding purpose are from machine shop. There are total three main lines on which different parts are developed through various types of welding, which are as:

i) Fuel Tank Assembly Line:

In this line the fuel tank assemblies of SD-110, GD-110 & GS-150 are produced by spot & seam welding processes.

First two separate halves of fuel tank is joined together by means of spot welding which is done on SSW machine. Then it is followed by seam welding, rolling press, sanding process, hydraulic pressing, soldering, and CO2 welding & final leakage test. Then fuel tank is ready to go to paint shop for a better look.

ii) Main Frame Assembly Line:

There are two lines for producing this assembly, one line is exclusively dedicated for producing main frame assembly of GS-150 & on the other line, & main frame assemblies of SD-110 & GD-110 are produced. The sequence of operations involves nut welding, spot welding, CO2 welding, MIG welding & finally boring.

iii) Battery Holder Assembly Line:In this line the battery holder is developed by only going through spot welding process.

1.10.4 Paint Shop:

This is the paint shop where various parts of two wheeler vehicles are painted. There are two types of material which are Aluminum & Sheet Metal (Stainless Steel) which are imported in this shop either from Welding shop like fuel tank, or from Machine shop like Rear/Front Hub, or they can be the vendarize parts like fenders etc.

There are total seven main lines where main process of cleaning, painting & baking takes place which are as:

i) Pre-treatment Line:In this line the various process occurred on the parts which are:a) Degreasing one process.b) Degreasing two process.c) Water rinsing one process.d) Surface Conditioning process.e) Phosphate process.f) Water rinsing two process.g) Water rinsing three process.h) Phosphate process (only in case of Aluminum material).i) Water rinsing four process.j) Water rinsing five process (deionize water).k) Checking of parts.

ii) Dry off Oven:Where materials is dried.

iii) Booth Preparation Area:Where the sand paper is applied on parts surface.

iv) Paint Booth:Paint is applied on material or parts surface.

v) Paint Baking Oven:Where the material is baked & paint is permanently joined along with material’s surface.

vi) Sticker Pasting:Sticker or label is pasted here.

vii) Quality Activities:The quality of parts is checked here. Then if the material is OK then it is transferred to Vehicle final assembly shop.

1.10.5 Vehicle Final Assembly (VFA):

In this shop the complete assembly of two wheeler vehicle is carried out through various main & sub assembly stations. Corresponds to VFA there is an Engine Assembling line where the complete assembly of two wheeler vehicle’s Engine is done, & then engine is transferred too main line of VFA where it is mounted on main frame of vehicle.

In Engine Line the assembly of engine starts from number punching on crank case & then after going through various sub-assemblies the assembly of Engine ends at Engine Testing Process which is carried out on a test bench where the engine runs between 500 to 700 rpms & thus the engine sub assembly ends & Engine is transferred to conveyer where it is fitted on vehicles frame.

In VFA there are total 8 main stations each of 2.5 meter of length. There are total 16 labors which are working in VFA, 7 labor on Engine Line & 5 officers. Among 8 main stations of VFA, 2 stations are manual while remaining six are automatic operated through a conveyer. The tact time of VFA depends upon the production of the specified product. In Ramadan Karim the total working time is 380 minutes, so the tact time is governed through the production planning. The synchronization of a station or sub assembly with another station is most important thing for the best & less time utilizing production.

Actually in VFA there are two types of line, on a line the assembly of GS150, GD110 & SD110 is carried out while for the assembly of GW

vehicle there is a separate line which is used for its assembling. The two main stations which are manual are Station 1A & Station 2A. While the stations on conveyers are Station 1, Station 2, Station 3, Station 4, Station 5 & Station 6. While there are also two other stations which are station 7 & Station 8 on conveyer which deals with Production Quality Control Inspection (PQCI) & work under Vehicle Inspection Department (VID). The eight stations can be defined as:

Station 1A: First frame comes from paint shop in trolley, where number punch and all its main wiring is completed then it transfer to station 2A.

Station 2A; At station 2A rear shocks, rear fender, center stand, prop stand, swinging arm and rear tire are fitted then it transfer to station 1,2 of conveyer.

Station 1, 2: At this station front fork, head lamp housing, engine, brake rod, bar footrest is fitted.

Station 3: At this station fitment of handle bar, clutch wire and head lamp wiring takes place.

Station 4: At this station fitment of muffler, euro (2), side footrest and carburetor takes place.

Station 5: Fitment of lower chain case, throttle cable, speedometer, air cleaner, starter motor and CDI TAKES PLACE.

Station 6: Fitment of fuel tank, side covers sprocket cover, seat, reflector, battery holder, tool box and choke cable takes place. We have done the Time Motion Study on VFA. So the description of each station & each worker is mentioned in sheets which are attached with this report.

2.0 Time and Motion Study

Time and motion study is a work measurement technique for recording the times of performing a certain specific job or its elements carried out under specified conditions. For analyzing the data so as to obtain the time necessary for an

operator to carry it out at a defined rate of performance. Functions of Time and Motion Studies in Libraries Establish work

standards in libraries. Set expectations which are fair to both employee and Library. Identify sources of error and difficulties. Improve existing processes, tools or work environments of library. Determining schedules and planning of work. Determining standard costs of a particular work. Estimating the cost of a product before manufacturing it. Determining machine effectiveness.

2.1 Time and Motion Study Equipment’s & Process.

Main equipment is a stop-watch Time study.Other Equipment’s: A study board Audio and Video Tape recorder Stationary

Preparing for a Time Study, the steps in the process studied must already be standardized: e.g. sequences have been determined. All the information about staff members should be available in library.

Operator must be fully qualified, trained, and acquainted with standardized process being studied. Must inform supervisor and department head. Make sure all materials are available for the process.

Procedure of Time and Motion Study Secure and record information about the operation and operator being studied.

Divide the operation into elements and record a complete description of the method. (Before you start study).

4.0 Conclusion & Recommendations:

In conclusion, We really appreciate the way we have been guided through this internship program with Pak Suzuki Motors, beginning from the opportunity to take the time we needed to refresh and expand our knowledge in several issues concerning Engineering & Industrial Manufacturing like Time Motion study, over a somehow protected period where we could discover and learn to value our new working environment, and finally earned the confidence to deal with assignments our self. It is through them that I did enjoy my work every day.

We recommend PSMCL for the increment in continued financial support to the interns, it would be even more generous if PSMCL can review its financial support to interns to reflect the ever changing economic situation in our country.

From our experience we can wholeheartedly recommend PSMCL internship program to everyone who would like to experience a Successful Automotive organization that has in our opinion realized their vision to find the balance between being progressive, able to balance human concerns, technical considerations and nevertheless being highly successful. What you have to bring with you, is the willingness to improve knowledge about the latest technologies, your work experience and you have to be able to work independently, self-motivated and you must solve smaller problems on your own. Anyhow, if you’ve got into some serious trouble you will always find somebody assisting you to work it out.