INDUSTRIAL TRAINING of Aastik Chawla

At

HONDA CARS INDIA LTD, GREATER NOIDA

In partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

In

MECHANICAL

Delhi Technological University

New Delhi India

December-January 2015

ABSTRACT

The ultimate aim of this industrial training is to learn new things,

gain practical experience, to observe the new features followed in design, production, administration, indulge in technical discussion,

and make friends for mutual help at a future date. This training is

undertaken to learn leadership skills, for coming out with innovative ideas for improvement etc. it also aims at learning the

skill of managing men which is very important for an engineer.

ACKNOWLEDGEMENT

I acknowledge that my summer training at HONDA CARS INDIA

Ltd, Greater Noida, has been very lively and informative. It was an enriching experience while training, in sophisticated and

disciplined environment at the Honda’s passenger car

manufacturing plant in India. This has been possible only because of support and help provided by officers and staff of HCIL during

the course of my training at Honda’s plant. I sincerely thank them

for the same. I am especially thankful to Mr. Rohan Bansal under whom I have completed my training. I also thank all the executives

and workers in Engine Assembly who were really helpful and

supportive during the training period.

CERTIFICATE

This is to certify that Aastik Chawla, III Year Mechanical

Engineering Undergraduate at Delhi Technological University has successfully completed the Winter Intern at Honda Car India

from 6th December 2014 to 5th January 2015 under my able

guidance and supervision.

Signature (Head of Painting Department)

History of Honda

Honda is the world’s largest manufacturer of motorcycles as well as the world’s

largest manufacturer of Internal Combustion Engines measured by volume,

producing more than 14 million Internal Combustion Engines each year. Honda

was the first Japanese automobile manufacturer to release a dedicated luxury

brand, Acura in 1986. Since 1986, Honda has been involved with artificial

intelligence (AI) / robotics research and released their ASIMO robot in 2000.

They are also ventured into aerospace with the establishment of GE Honda

Aero Engines in 2004 and the Honda HA- 420 Honda Jet, released in 2011.

Honda spends about 5% of its revenues into R&D. The spirit of Soichiro

Honda, (founder) forever has been inscribed in every car and engine that Honda

builds. Once Soichiro Honda famously said, “I HAVE FAILED 99% OF MY

TRAILS, IN ORDER TO SUCCEED IN THE REMAINING 1%”.

HONDA MOTOR COMPANY LTD

In 1928, Soichiro Honda secured his first of many patents (for automobile

wheel spokes). Then, as World War II ravaged Japan, Honda cornered the

market on badly needed generator motors. His growing capital allowed him to

break ground on the Honda Technical Research Laboratory in 1946. Just two

short years later, the Honda Motor Company, Ltd. would open its doors in

Hamamatsu. The motor world would never be the same. The company initially

found its niche in the manufacture of motorcycles. Following the launch of the

company’s first success-the “C” model motorcycle-Honda and his then-twenty

employees launched themselves into motor history with the three horsepower,

two-speed transmission “D” model. The motorcycle was aptly named the

“Dream D” after jubilant employees allegedly shouted “It’s like dream!” upon

its completion. And a dream it was. The “Dream D” was like a dream come

true for the war-recovering Japanese society: it was inexpensive; it conserved

valuable fuel; and, perhaps most importantly, it provided a temporary escape

from the surrounding troubles. The overwhelming success of the “D” model

and the later “E” model helped Honda build a reputation for quality and design

supremacy, even when an early-1950s economic depression threatened to dim

the company’s shining star. By 1955, Honda had weathered the storm and saw

his dream at least partially realized when his company became the top

motorcycle manufacturer in Japan. When those top sales figures expanded to

include the world in 1959, Honda began to realize the enormous potential in a

global expansion of his empire. While his business associates encouraged him

to open a plant in either Europe or Southern Asia, Honda saw potential in

another market: the American market. Marketing experts pleaded with Honda

to change his mind, citing the low sales figures for motorcycles in the United

States. But Honda and his trusted advisor Fujisawa ignored the pleas, realizing

that America was becoming an increasingly important presence in the global

market place. In 1959, newly appointed Executive Vice President and General

Manager Kihachiro Kawashima officially introduced American Honda Motor

Company to the American public. With a $250,000 allowance, the time was

now or never for Honda America. Due to the disinterest of skeptical American

dealers, AHMC set up shop in various hardware stores and sporting good

stores. The new enterprise faced a hard sell to dealers and the public alike: the

name Japan still held negative connotations for an American society struggling

with its own wartime memories; fuel efficiency was not foremost in the minds

of much of the public; and the vehicles of America were expected to be faster

and leaner than their Japanese counterparts. However, at the same time AHMC

was experiencing the growing pains of a rookie company, Soichiro Honda was

fulfilling his lifelong dream of mastery on the racing circuit.

He won the Isle of Man in the early 1960s, and continued a steadily rising

string of successes on the race course. This publicity helped boost the Honda

image in America, and Honda’s reputation was further boosted when it was

honored with its first manufacturer’s award in 1962. The company also reached

out to a weary public through an ambitious magazine advertising campaign that

emphasized Honda’s strengths: dependability, fuel efficiency, simplicity, easy

maintenance, and a unique (rebellious?) design. AHMC struck one final blow

to the competition with its risky and expensive! Advertising onslaught during

the 1964 Academy Awards. But the ploy worked jump starting sales by

millions. Despite its slow start, AHMC was dominating sales in the same

manner as its Japanese counterpart by the end of its fifth year (matching the

original HMC’s 65%share of the market with its own impressive 62%

share).Soon, the company would become the standard bearer in the industry,

pioneering both the Motorcycle Industry Council and the Motorcycle Safety

Council. It would also solidify its image with a series of philanthropic efforts.

With the success of the American Honda Motor Company, Honda felt more

confident than ever in his next goal: dominance in the automobile industry. He

faced hurdles from the government, which delayed its approval for Honda's

entrance into automobile manufacturing. Part of the reason for this hesitation

was Honda’s subsidization of its US market, which led to questionable pricing

practices in Japan. In spite of the initial delays, Honda unveiled its first

automobile and truck products in 1962. In 1969, American Honda also

introduced its first automobile import, the N600 Sedan. The story was much the

same: initial skepticism (could a motorcycle man really make effective

automobiles?), followed by eventual success. The enormous popularity of

Honda’s “CB” model motorcycles helped convince the public that their faith in

Honda was well-placed. So, when Honda embarrassed the competition with his

environmental-friendly Civic automobile (in a time of growing pollution

concerns) in 1972, both the American public and the American government

were more than receptive. Soon, Honda International Trading was exporting its

now-successful American creations to Japan, closing the circle of success.

When the top-selling Accord made its way onto American streets a few short

months later, the Honda success story was finally complete: Japanese

motorcycle supremacy, worldwide motorcycle supremacy, and now automobile

supremacy. His vision finally fulfilled, Honda retired in 1973, leaving Kiyoshi

Kawashima to carry on his legacy. Honda would witness the birth of yet

another successful corporation (Honda of America Manufacturing in

Marysville, Ohio), which would revolutionize the workplace with its emphasis

on team work and cooperativeness. Honda would also be on hand for a Team

Honda first-place victory in world motocross in 1981, for the crowning of a

new American Honda president (Tetsuo Chino) in1983, for a series of honorary

distinctions (including a clean sweep of the Motor Trend Import Cars of the

Year selections), and for a most fitting 25th anniversary present of record-

setting sales. For all of his contributions and milestones, Soichiro Honda set

another standard when he became the first Asian to be inducted into the U.S.

Automotive Hall of Fame. Today, Honda’s selection of Accords, Civics,

Preludes, Passports, Acura’s, and Odysseys bear the Honda seal of excellence.

Millions of motorcycle and automobile lovers around the world can attest to

that excellence.

HONDA’S GLOBAL VISION

Soichiro’s vision was international in character. His desire was to lead the

world in technology, and make a significant contribution to the creation of a

better society. As a result, most of the products that Honda developed started

out by making a difference. Whether it was the CVCC (Compound Vortex

Control) engine in the sixties or the solar powered car of the nineties, they all

sought to challenge and overcome conventional wisdom.

HONDA’S MISSION STATEMENT

Honda’s Mission statement is very short, simple and a pragmatic one. WE

CONVERT FUEL TO ENERGY, EFFECIENCY. GLOBALLY, Honda has

manufacturing plants all over the world. It has manufacturing units in five parts

of the globe. And its products are used in every part of the world. Globally

Honda machines are known for their reliability, efficiency and world class

quality. Honda to test their world class stands have been involved in

motorsports all over the world including Formula 1(they exited F1 in 2009 with

the sale of Honda F1 team to Brawn GP), Isle of Mann TT, Indy car racing,

Moto GP, World Super Bike and Motor Cross.

GLOBAL PRODUCT LINE: Honda has a vast list of products to its credit. It

manufactures from lawn movers to Jet engines. Honda has carried on the sprit

and legacy that Mr. Soichiro Honda has left behind in anything and everything

they build and comes out of Honda’s factory line all over the world. Here is a

list of product line of Honda machines:

* Automobiles

* Motorcycles

* Scooters.

* All-Terrain vehicles (ATV’s)

* Electrical generators

* Robots

* Marine equipment

* Jets.

* Jet engines

* Lawn and garden equipments.

INDIAN PRODUCT LINE:

* Automobiles

* Motorcycles

* Electric generators.

FUNDAMENTAL BELIEFS AT HONDA

I. RESPECT FOR THE INDIVIDUAL

INITIATIVE: Initiative means not to be bound by preconceived ideas, but

think creatively and act on your own initiative and judgment, while

understanding that you must take responsibility for the results of those actions.

EQUALITY: Equality means to recognize and respect individual differences

in one another and treat each other fairly. Our company is committed to this

principle and to creating equal opportunities for each individual. An individuals

race, sex age religion, national origin, educational background, social or

economical status have no bearing on the individuals opportunities.

TRUST: The relationship among associates at Honda should be based on

mutual trust. Trust is created by recognizing each other as individuals, helping

out where others are deficient, accepting help where we are deficient, sharing

our knowledge, and making a sincere effort to fulfill our responsibilities.

II. THE THREE JOYS

* THE JOY OF BUYING: The joy of buying is achieved through products

and services that exceed the needs and expectations of each customer.

* THE JOY OF SELLING: The joy of selling occurs when those who are

engaged in selling and servicing Honda products develop relations with a

customer based on mutual trust. Through this relationship, Honda associates,

dealers and distributors experience pride and joy in satisfying the customer and

in representing Honda in the customer.

* THE JOY OF CREATING: The joy of creating occurs when Honda

associates and suppliers involved in the design, development, engineering and

manufacturing of Honda products recognize a sense of joy incur customers and

dealers. The joy of creating occurs when quality products exceed expectations

and we experience pride in the job well done.

HONDA MANAGEMENT CONCEPTS:

1. The concept of 5’S:

* Sort (Sieri):- Distinguishing between needed & un-needed items & disposing

of the un-needed items in a systematic manner

* Simplify (Seition):- Arrangement of necessary items into good order so that

they can be easily selected for use

* Shine (Seiso):- Cleaning of workplace so that there is no dust in the

workplace

* Standardize (Seiketsu):- To cultivate a disciplined workplace where everyone

does something on his/her own to maintain a clean environment & correctly

understand the 5S philosophy.

* Sustain (Shitsuke):- Sustain refers to training to all & communication to all

associates to ensure 5’s application

2. Kaizen:

Kai = Change + Zen = Good / For the better

Kaizen = Continuous Change for the betterment

3. HO-REN-SO:

HO:- Report status/ Progress to seniors

Ren:- Inform all those who may be concerned

SO:- Consult to refine one’s own thoughts/ideas

CONTENTS

1. Body construction – unit body & frame body

2. Manufacturing processes

A. Welding Process

B. Painting Process

PT-Ed Line

Sealer Line

Mid Coat

Top Coat

3. Air Supply Unit

4. Engine Assembly

5. Pre-Delivery Inspection

BODY CONSTRUCTION

Body Construction is of two types

1. Unit construction

2. Body on frame Currently, most Honda vehicle bodies use the unit construction.

Before this technology became popular, frame constructions

widely used. With frame construction, major components such as the engine, transmission, and suspension were mounted onto the

bare bones of the vehicle – the frame. Then the body (essentially

the skin of the vehicle) was mounted on top. This type of construction is actually still used today for trucks and some off-

road vehicles. On the other hand unit construction vehicles, do not

have special frames. They are composed of body panels which have been designed to provide the required body strength without

the use of a frame.

Rather than a separate, ladder-style frame, as is used in body-on-frame construction, the unibody vehicle’s integral floor pan (the metal that forms

the vehicle’s underside) provides the main structural element to which the

mechanical components attach. Also known as unit body, unitized or unitary

construction, this design makes for a lighter vehicle overall and is the basis for virtually all passenger cars.

Vehicles with unit construction use thin, press-formed steel panels

of about 1 or 2 mm in thickness. Spot welding is used at locations

where these panels overlap and a boxtype structure is created. Certain parts of this basic structure (such as the locations where the

engine or suspension are to be mounted) are required to have extra

strength and rigidity. Common methods used to improve the strength characteristics of the steel panels, include adding rids,

recesses, and other similar indentations. Further increases can be

achieved by welding stiffening material to the relevant areas or by the addition of smaller, individual sub-frames

ADVANTAGES:

1. Structurally poor utilization of material 2. Crumple zone - lower rate of death and serious injury. 3. More resistant to torsional flexing 4. Lighter than body-on-frame.

DISADVANTAGES:

1. Complicated to design.

2. Noisier (stresses may pass into the body.) 3. Difficult to repair after accidents

From a safety point of view, the first benefit of unit construction is

that it provides increased ability to absorb impact forces. This is achieved by efficiently distributing forces acting on the body and

not allowing them to concentrate in one area. In addition, parts of the body have been designed to be crushable in order to improve

the ability to absorb impact forces even further. Energy from a

collision is absorbed as a section is crushed, and therefore, the amount of energy which is directed to the driver or passengers is

reduced.

It would be pointless to design a body which would be completely

crushed in a collision. A survival space for the driver and passengers must be provided. Various methods such as reinforcing

the floor of the cabin, installing door beams, and strengthening

pillars have been implemented for this purpose.

Based on the above description, Honda vehicle’s bodies are

complicated constructions that have been designed with a number of different objectives in mind. Consequently, a much higher level

of expertise will be required when repairing these bodies than

would be required when repairing frame-type bodies.

MANUFACTURING

WELDING PROCESS

Primary function of welding is to assemble and weld all parts to

form the basic structure of a car. Assembly of parts in welding

takes place in specially designed fixtures.

The type of welding employed to weld the parts is known as spot welding. The process of part fixing and metal finishing is also

carried out in the welding department.

Welding is divided into four sections.

* Floor spot line – A zone

* The GW line – B zone

* The metal finish line – C zone

* Hemming line – D zone

The parts supplied by the material department are welded into sub assemblies which are later welded to form the basic structure of a

car. In different sections different sub assemblies are welded. In

floor line the structure of the floor of the car is welded from different sub assemblies.

RESISTANCE WELDING

In this process electric current flows through a resistive circuit to

generate enough heat between two pieces of sheet metal so that the

metal reaches molten stage. The resistance to the flow of current is

provided by work piece. The maximum heat is generated at the

point of maximum resistance.

The commonly used electrodes shapes are p and cr types.

SPOT WELDING

Spot welding is a resistance welding method used to join two to three overlapping metal sheets, studs, projections, electrical wiring

hangers, some heat exchanger fins, and some tubing. Usually

power sources and welding equipment are sized to the specific thickness and material being welded together. The thickness is

limited by the output of the welding power source and thus the

equipment range due to the current required for each application. Care is taken to eliminate contaminants between the faying

surfaces. Usually, two copper electrodes are simultaneously used

to clamp the metal sheets together and to pass current through the sheets. When the current is passed through the electrodes to the

sheets, heat is generated due to the higher electrical resistance

where the surfaces contact each other. As the electrical resistance of the material causes a heat buildup in the work pieces between

the copper electrodes, the rising temperature causes a rising

resistance, and results in a molten pool contained most of the time between the electrodes.

As the heat dissipates throughout the workpiece in less than a

second (resistance welding time is generally programmed as a

quantity of AC cycles or milliseconds) the molten or plastic state grows to meet the welding tips. When the current is stopped the

copper tips cool the spot weld, causing the metal to solidify under pressure.

The water cooled copper electrodes remove the surface heat

quickly, accelerating the solidification of the weld. since copper is

an excellent conductor. Resistance spot welding typically employs electrical power in the form of direct current, alternating current,

medium frequency half-wave direct current, or high-frequency half

wave Direct current.

If excessive heat is applied or applied too quickly, or if the force between the base materials is too low, or the coating is too thick or

too conductive, then the molten area may extend to the exterior of

the work pieces, escaping the containment force of the electrodes (often up to 30,000 psi). This burst of molten metal is called

expulsion, and when this occurs the metal will be thinner and have

less strength than a weld with no expulsion. The common method of checking a weld's quality is a peel test. An alternative test is the

restrained tensile test, which is much more difficult to perform, and

requires calibrated equipment. Because both tests are destructive in nature (resulting in the loss of salable material), non-destructive

methods such as ultrasound evaluation are in various states of early

adoption by many OEMs. The advantages of the method include efficient energy use, limited workpiece deformation, high

production rates, easy automation, and no required filler materials.

When high strength in shear is needed, spot welding is used in preference to more costly mechanical fastening, such as riveting.

While the shear strength of each weld is high, the fact that the weld

spots do not form a continuous seam means that the overall strength is often significantly lower than with other welding

methods, limiting the usefulness of the process. It is used

extensively in the automotive industry— cars can have several thousand spot welds. A specialized process, called shot welding,

can be used to spot weld stainless steel.

PAINTING PROCESS

At PA-ON, the white body is received from the weld shop and

inspected for the following welding defects:

1. Black sealer 2. Metal dust

3. Dent and ding

4. Sanding marks 5. Rust

6. Spatter

7. Burrs 8. Scratch

Also the body is earthed to eliminate any static charge on the car

body.

The entire painting process is divided into four lines. Each line has

a specific purpose.

These lines are

* PT-ED line

* Sealer line

* Mid coat line

* Top coat line

PT-ED Line

Jet spray

At this station the body is spray washed with RO water in order to

remove loose dust, metal particles and excess oil and grease from the body surface.

Also the body holding jigs are fitted to lift the car and carry out the

PT-ED process.

Pretreatment

The purpose of coating and plating is to form a dry film on the

automobile body using various methods of coatings and plating so that the body is resistant to weather, rust and contamination and

also looks beautiful with colored, glossy and smooth surface giving

cubic effect. Therefore coating and plating are final methods of finishing. Automobile bodies are very important because they can

greatly affect the grade and value of the product.

Predegreasing and degreasing

This is mainly done to remove the oil and grease particles that

come attached to the car’s body after the welding process. This step is basically a cleaning step that removes dust and oil particles

from metal surface and makes the body more suitable for paint

adhesion.

In this the body is dipped for 3-5 minutes in an alkali solution as a result of this the oil and dust particles get stuck to the degreasing

alkali particles and get off the surface.

After this step the white body is thoroughly rinsed in water tanks to

remove excess alkali on body to carry out further steps.

Surface conditioning and zinc coating

The surface of body is activated for zinc phosphate coating.

Phosphating is done to improve corrosion and adhesion of the electro deposit coat.

Rinsing & Electrode deposition process

In this step excess phosphate sludge formation, if any, is removed

during 2 stage rinsing. Further the car body is manually washed &

prepared for ED coat.

ED paint dispersed in water is electrically deposited on surface of substrate (body) to form a uniform and water insoluble film.

Deposition of film takes place by increase in pH.

Paint gets deposited continuously through concurrence of four

different phenomenon:

1. ELECTROPHORESIS

2. ELECTRODEPOSITION 3. ELECTROLYSIS

4. ELECTROSMOSIS

Rinsing, baking and defect inspection

It’s a 5 step rinsing in which excess ED coat/ drop/ paint gets

removed from the car body to avoid any carry forward of the ED paint.

Further the body is sent to baking oven where it’s heated at 160o

for around 35mins. Then thinner is applied to remove oil and dust

to avoid paint peel off from that area later.

Also the body is checked for any defects like ED drop, jig marks,

metal dust & deformity.

ADVANTAGES OF ED COATING

Corrosion resistance of car body increases.

Paints are deposited even on surfaces inaccessible to

conventional methods of painting.

Uniform film of desired thickness is obtained easily by

adjusting voltage.

Quantity of drag out solids is small since bath paint being

diluted with water is low in solid content.

The voltage application is 220-260 v (per unit area).

Sealer Line

Sealer application and cleaning

Sealers are used in Honda vehicles for the following purpose

* It fills a gap between two or more substrates.

* It forms a barrier through the physical properties of the sealant itself and by adhesion to the substrate.

* It maintains sealing properties for the expected lifetime, service

conditions and environments.

PVC application & baking

After applying the sealer at the joint areas PVC is sprayed under

body to give the protection to the body against any rust and damages from underneath.

Later the body is baked at 160 degrees for 8mins.

Mid Coat Line

Sanding paper is used to clean hood, fender, door, roof, trunk, door inside, quarter panel, trunk inside. Then the surface is blown with

pressurized air to clean the surface and then it is cleaned with tag

rag before applying mid coat.

MID COAT COLOURS – mid coat is applied in 3 stages and there are 3 colors for mid coat. White for white color, light grey for light

colors and dark grey for dark colors.

Then the body is sent to oven and heat treated at 160o for 24mins.

Top Coat Line

Body is inspected for mid coat defects like MC sag, dust, wiping

marks, ED marks, sanding marks, film thickness, popping. Sanding paper of 800/ 1500/ orbital sander is used to remove the defect.

Wipe with tag rag and air is blown to keep the surface clean.

For solid white color only base coat is applied and for metallic

colors top coats and clear coats are applied in layers. Then it’s sent to oven for baking at 180 degrees.

CHECK AND REPAIR DEFECTS

After the top coat, the sealer defects are checked with soap

solution. Then the body is thoroughly inspected from outside and inside for paint defects like sagging, DUP, crater, film thickness,

lint dust, sanding marks, orange peel, dent, ding.

POLISHING AND WAXING

After removing the defects the body is sent for polishing that is

done in 3 stages:

1. glaze paste on sanded areas + wool pad 2. grey polish + orange pad

3. fine polish + swirl mark pad

AIR SUPPLY UNIT

Air Supply Unit (ASU) is equipment used to circulate, supply

or replace air from spray paint booth. Air Supply Unit is

commonly known as Air Replacement Plant (ARP), Air

Handling Unit (AHU), and Air Makeup Unit (AMU) etc. Air

Supply Unit or Air Handling Unit was very popular in areas

where the air has low humidity, and hotter climate, mainly to

comfort the human conditions in such climate. As technology

has changed for better development, even in the field of paint

and painting equipment, more and more expansions have

added up to make a dust free painted product .To attain such

a clean paint film on the product free from dust above 5

micron, Air Supply Units and Air Handling have become a

necessity of today’s market.

Air Supply Unit (ASU) comprises of series of filters &

eliminators. Air Supply Unit (ASU) uses the atmospheric air

from outside, refines the air, and supplies it to the Paint booth

via ducting, thus creating a constant flow of dust free air into

the paint booth. The volume of air supplied from the Air

Supply Unit (ASU) also helps to maintain a positive pressure

in the paint booth, thus not allowing external dust around the

paint booth to enter into the paint booth. Air Supply Unit

(ASU) creates an enclosed environment safer for workers by

facilitating the elimination of toxic fumes.

Air Supply Unit (ASU) are not only used to provide make up

air for the paint booth, but also used as a spot cooling device

for the workers in molding shops, assembly shops and other

hotter areas. It is capable to manufacture customized Air

Replacement Plants (ARP), in metallic & civil constructions.

ENGINE ASSEMBLY

Honda vehicles in India use various four stroke petrol engines.

Engines based on the four-stroke ("Otto cycle") have one power

stroke for every four strokes (up-down-up-down) and employ spark plug ignition. Combustion occurs rapidly, and during

combustion the volume varies little ("constant volume"). They are

used in cars, larger boats, some motorcycles, and many light aircraft. They are generally quieter, more efficient, and larger than

their two-stroke counterparts.

The steps involved here are:

1. Intake stroke: Air and vaporized fuel are drawn in.

2. Compression stroke: Fuel vapor and air are compressed and

ignited.

3. Combustion stroke: Fuel combusts and piston is pushed downwards.

4. Exhaust stroke: Exhaust is driven out. During the 1st, 2nd, and

4th stroke the piston is relying on power and the momentum

generated by the other pistons. In that case, a four-cylinder engine would be less powerful than a six- or eight-cylinder engine.

Major components of a four stroke petrol engine are * Cylinder: A

cylindrical vessel in which a piston makes an up and down motion.

* Piston: A cylindrical component making an up and down movement in the cylinder * Combustion chamber: A portion above

the cylinder in which the combustion of the fuel-air mixture takes

place

* Intake and exhaust ports: Ports that carry fresh fuel-air mixture into the combustion chamber and products of combustion away *

Crankshaft: A shaft that converts reciprocating motion of the

piston into rotary motion * Connecting rod: A rod that connects the piston to the crankshaft * Spark plug: An ignition-source in the

cylinder head that initiates the combustion

PRE-DELIVERY INSPECTION

Vehicle quality check

PDI is the final inspection prior to the delivery to the customer.

The customer expects a very high level of quality from the product

being purchased.

The following checks are done on the car in the final step:

Exterior inspection – alignment inspection, parts gap inspection, fitment inspection, flushness inspection

Paint inspection – dent and ding inspection, dust inspection, crater inspection, sag inspection

Interior inspection – parts fitment inspection, parts gap inspection, parts model mismatch inspection

Function check – door glass operation, center locking inspection, keyless function inspection

R swat & head light – toe angle adjustment, headlight profile adjustment.

Turning angle – turning angle check, hazard operation

check, side indicators check, and fog lamp inspection.

Multi drive test – speed check, speedometer check, brake

force check, ABS & VSA inspection

Side slip inspection

U/B & eng room – oil leakage inspection, torque marking, pipe fitment inspection, oil level inspection.