A

INDUSTRIAL TRAINING PROJECT

On

INDIA YAMAHA MOTOR

Completed at

INDIAN YAMAHA MOTOR PVT.

LTD.
SURAJPUR, UP

Submitted
In partial Fulfillment of the Requirements
For the award of the Degree of

BACHELOR OF TECHNOLOGY
in

MECHANICAL ENGINEERING
Submitted by

JIJO JOSE

1313240069
29/06/2016 to 30/07/016(4 weeks)

GREATER NOIDA INSTITUTE OF

TECHNOLOGY
PLOT NO. 7, K.P.2, GREATER NOIDA, UP-201310
Affiliated to Dr. A.P.J. Abdul Kalam Technical University,
Lucknow
1

(Formerly known as Uttar Pradesh Technical University,

Lucknow)
AUGUST-2016
AN
INDUSTRIAL TRAINING REPORT
AT

INDIAN YAMAHA MOTOR PVT.

LTD.,

SURAJPUR,
UP
Submitted
In partial Fulfillment of the Requirements
For the award of the Degree of

BACHELOR OF TECHNOLOGY
in

MECHANICAL ENGINEERING
Submitted by

JIJO JOSE

1313240069
29/06/2016 to 30/07/016(4 weeks)

DEPARTMENT OF MECHANICAL ENGINEERING

GREATER NOIDA INSTITUTE OF

TECHNOLOGY
Affiliated to Dr. A.P.J. Abdul Kalam Technical
University, Lucknow, UP,
(Formerly Uttar Pradesh Technical University, Lucknow,
U.P)
August-2016

ACKNOWLEDGEMENT
I thankfully acknowledge the encouragement and correct guidance provided by all the
yamaha staff members, who were very kind and generous to their approach.
We specially thank Mrs. Surabhi Dixit (H.R), Mr V.Raina (Division Head), Mr. Bijender
Kaushik (Sr. Manager, Production Department), Mr. D.Bhatti (Sr. Manager,Engine
Assembly), Mr. Sanjeev Chaudhary (Manager, Engine Assembly), Mr. Amit Gupta(Asst.
Manager, Engine Assembly), Mr. Gaurav Verma (Manager in Frame Assembling), Jagbindra
Singh(D.E.T.), Miss Tripti Sharma (D.E.T. ) Mr. Shiv Singh (Trainner, Manufacturing Shop)
and all other staff members who helped us a lot.
We express our sincere gratitude and thanks to the hard working and devoted staff members,
who have helped us a lot to gain some of the technical knowledge, which is surely a boon for
any technical graduate.

ABSTR
ACT
The objectives of the practical training are to learn something about
industries practically and to be familiar
technical

person

to

adjust

simply

with the working style of a

according

to

the

industrial

environment .

It is rightly said practical life is far away from theoretical one. We learn
in

class

room can

give

the

practical exposer real

life experience

no doubt they help in improving the personality of the student ,but

the practical exposure in the field will help the student in long run of life
and will be able to implement the theoretical knowledge.

As a part of academic syllabus of four-year degree course in Mechanical

Engineering, every student is required to undergo a practical training.

I am student of third year mechanical and this report is written on the

basis of practical knowledge acquired by me during the period of practical
training.

TABLE OF CONTENTS
CHAPTER

INTRODUCTION

PAGE NO.
1.1] Overview of Industry as a whole.
1.2] Founding history..
CHAPTER 2 COMPANY PROFILE
2.1]

About

Yamaha

Motor

Pvt.

Ltd.

..
2.2] Yamaha Motor India..
...
CHAPTER 3 PRODUCTION PROCESS
3.1] Manufacturing
shop.
3.2] Paint Shop
3.3] Engine
assembling...
3.4] Frame
assembling
3.5] Pre delivery
inspection
CHAPTER 4 - PROJECTS
5

4.1] Project 1: Any abnormality in pretreatment process of fuel tank...

4.2]Project

Shop

floor

management..
CHAPTER 5 CONCLUSION AND REFRENCES
5.1]
Conclusion.
5.2]
References..

LIST OF FIGURES AND TABLES

CHAPTER 1 - INTRODUCTION
1.1. OVERVIEW - INDIAN AUTOMOBILE INDUSTRY
Over a period of more than two decades the Indian Automobile industry
has been driving its own growth through phases. The entry of Suzuki
Corporation in Indian passenger car manufacturing is often pointed as the
first sign of India turning to a market economy. Since then the automobile
sector witnessed rapid growth year after year. By late-90's the industry
reached self-reliance in engine and component manufacturing from the
status of large scale importer.
With comparatively higher rate of economic growth rate index against that
of great global powers, India has become a hub of domestic and exports
business. The automobile sector has been contributing its share to the
shining economic performance of India in the recent years.
With the Indian middle class earning higher per capita income, more
people are ready to own private vehicles including cars and two-wheelers.
Product movements and manned services have boosted in the sales of
medium and sized commercial vehicles for passenger and goods
transport. Side by side with fresh vehicle sales growth, the automotive
components sector has witnessed big growth. The domestic auto
components consumption has crossed rupees 9000 crores and an export
of one half size of this figure.
The Indian automobile industry is going through a technological change
where each firm is engaged in changing its processes and technologies to
sustain the competitive advantage and provide customers with the
optimized products and services. Starting from the two wheelers, trucks,
and tractors to the multi utility vehicles, commercial vehicles and the
luxury vehicles, the Indian automobile industry has achieved tremendous
amount of success in the recent years.

As per Society of Indian Automobile Manufacturers (SIAM) the market

share of each segment of the industry is as follows:

The market shares of the segments of the automobile industry

Fig 1.1
The automobile industry had a growth of 15.4 % during April-January
2007, with the average annual growth of 10-15% over the last decade or
so. With the incremental investment of $35-40 billion, the growth is
expected to double in the next 10 years.
Consistent growth and dedication have made the Indian automobile
industry the second- largest tractor and two-wheeler manufacturer in the
world. It is also the fifth-largest commercial vehicle manufacturer in the
world. The Indian automobile market is among the largest in Asia.

The key players like Hindustan Motors, Maruti Udyog, Fiat India Private Ltd,
Tata Motors, Bajaj Motors, Hero Motors, Ashok Leyland, Mahindra &
Mahindra have been dominating the vehicle industry. A few of the foreign
players like Toyota Kirloskar Motor Ltd., Skoda India Private Ltd., Honda
Siel Cars India Ltd. have also entered the market and have catered to the
customers needs to a large extent.

1.2. FOUNDING HISTORY

Genichi Kawakami was the first son of Kaichi Kawakami, the third-generation president of
Nippon Gakki (musical instruments and electronics; presently Yamaha Corporation). Genichi
studied and graduated from Takachiho Higher Commercial School in March of 1934. In July
of 1937, he was the second Kawakami to join the Nippon Gakki Company.

Fig 1.2 Genichi Kawakami

Fig 1.3 The first Yamaha motorcycle... the YA-1

In 1953, Genichi was looking for a way to make use of idle machining equipment that had
previously been used to make aircraft propellers. He explored producing many products,
including sewing machines, auto parts, scooters, three-wheeled utility vehicles, and
motorcycles. Market and competitive factors led him to focus on the motorcycle market.
Genichi actually visited the United States many times during this period.
In January of 1955 the Hamakita Factory of Nippon Gakki was built and production began on
the YA-1. With confidence in the new direction that Genichi was taking, Yamaha Motor Co.

10

Ltd. was founded on July 1, 1955. Staffed by 274 enthusiastic employees, the new motorcycle
manufacturer built about 200 units per month.
By 1956, a second model was ready for production. This was the YC1, a 175cc single
cylinder two-stroke. In 1957 Yamaha began production of its first 250cc, two-stroke twin, the
YD1.

CHAPTER 2 - COMPANY PROFILE

2.1. ABOUT YAMAHA MOTOR PVT LTD
Japanese manufacturer of motorcycles, marine products such as boats
and outboard motors, and other motorized products. The company was
established in 1955 upon separation from Yamaha Corporation (however
Yamaha Corporation is still the largest shareholder with 12.21%, as of
June 30, 2015), and is headquartered in Iwata, Shizuoka, Japan. The
company conducts development, production and marketing operations
through 109 consolidated subsidiaries as of 2012.
Company Name
Founded
Capital
President
Employees

Yamaha Motor Co., Ltd

July 1, 1955
85,797 million yen (as of June 30,2016)
Hiroyuki Yanagi
53,306 (as of December 31, 2015)

(Consolidated)
Headquarters
Group Companies

Parent : 10,440 (as of December 31, 2015)

2500 Shingai, Iwata-shi, Shizuoka-ken, Japan
Consolidated subsidiaries : 110
Non-consolidated subsidiaries : 3 (by the
11

equity method)
Affiliates : 28 (by the equity method)
Table 1

LIST OF DIRECTORS
Directors of Yamaha Motor Co., Ltd. are as follows:
Title

Name

President and Representative Director

Hiroyuki Yanagi

Representative Director

Takaaki Kimura

Director

Toyoo Ohtsubo

Director

Yoshiteru Takahashi

Director

Masahito Suzuki

Director

Hiroyuki Suzuki

Director

Kozo Shinozaki

Director (Outside)

Yuko Kawamoto

Director (Outside)

Masamitsu Sakurai

Director (Outside)

Mitsuru Umemura

Standing Corporate Auditor

Yutaka Kume

12

Standing Corporate Auditor

Shigeki Hirasawa

Corporate Auditor (Outside)

Naomoto Ohta

Corporate Auditor (Outside)

Norihiko Shimizu

Corporate Auditor (Outside)

Tetsuo Kawawa
Table 2

2.2. YAMAHA MOTOR INDIA

Yamaha made its initial foray into India in 1985. Subsequently, it entered into a 50:50 jointventure with the Escorts Group in 1996. However, in August 2001, Yamaha acquired its
remaining stake becoming a 100% subsidiary of Yamaha Motor Co. Ltd, Japan (YMC). In
2008, Mitsui & Co., Ltd. entered into an agreement with YMC to become a joint investor in
the motorcycle manufacturing company "India Yamaha Motor Private Limited (IYM)".
IYM operates from its state-of-the-art-manufacturing units at Surajpur in Uttar Pradesh and
Faridabad in Haryana and produces motorcycles both for domestic and export markets. With
a strong workforce of more than 2,000 employees, IYM is highly customer-driven and has a
countrywide network of over 400 dealers.
INDIA YAMAHA MOTOR INAUGURATED NEW PLANT AT SURAJPUR
(GREATER NOIDA)
The new Surajpur plant has been inaugurated by Mr. T.Kazikawa C.E.O & MD Yamaha
Global on 6th July 2009, which have capacity to produce 6 lakh motorcycles annually
including Fazer followed by FZ-16, FZ-S, YZF-R15 and other models. The plant capacity can
be augmented up to 1 million units.
This fully integrated assembly plant is built on the lines of Yamahas globally tried, tested and
successfully implemented standards and meets the global quality benchmarks. At the core are
the 5-S and TPM activities that fuel its Manufacturing Processes. The plant has 3 vehicle
assembly lines and 4 engine assembly lines including one dedicated for export engines. The
13

engine and vehicle assembly lines are synchronized and incorporate concepts of Unit
Assurance i.e. Complete Product Assurance, Parts Assurance through 100% kit supply on
lines and synchronization of parts storage, supply and production. The innovative production
processes along with high tech final assurance processes are aimed to achieve Zero Claims at
our dealers and thus, a highly satisfied customer base.

2.3. YAMAHAs PLAN FOR INDIA

Yamaha witnessed a huge demand for exports from India which grew at 73
percent in the past year when, at the same period, demand for Yamaha
bikes in India grew at 25 percent. Yamaha registered 66,904 units of two
wheelers in 2010 fiscal in global exports against 38,639 units supplied in
2008-09.
These units include Gladiator, FZ, YZF R15, Crux, Fazer, Alba, Ray, Alpha
and Libero G5 range of bikes from India. Yamaha exports bikes to
countries like Kenya, Indonesia, Sri Lanka, Colombia, Bangladesh and
Philippines from India. Though Yamaha did not reveal what premium
motorbikes it is planning to manufacture here in India, this news indicates
the grave interest of the firm and the lower cost of manufacturing
advantage which India provides to companies. And if we are thinking in
the right direction than this could mean cheaper and affordable super
luxury sports bikes from the company which currently retail at insane
price tags majorly due to the tax and surcharges associated with
importing a bike from other countries
NEO, FINO & SPARK IN INDIA
There was news the other day that Yamaha is going to launch scooters in
to Indian market. Guess what, Yamaha has even initiated proceedings for
bringing three scooters to India. The three scooters currently included in
the portfolio are Neo, Fino and Spark. This is great news for all those
scooter lovers who wanted to experience scooters made by Yamaha.

14

The scooters viz. 50 cc Neo, 115 cc Fino and 135 cc Spark are currently
very popular in Thailand and thus Yamaha decided to test them out in

Indian market

Fig 2.1
Confirming this news Mr. Pankaj Dubey (Head of Marketing and Sales) said
that the company is studying the market conditions after that it will be
decided on which model perfectly complements the Indian customer base.
Speaking of the scooters, all the three are unique as far the looks and the
features are concerned. There is no word from the company officials
regarding the costs of these scooters but they are expected to be priced
high in India.
15

Yamaha has got gear less scooters starting from 50 cc and above. All the
three scooters viz. Neo, Fino and Spark are gear less. While Neo and Fino
are air cooled scooters, Spark is a liquid cooled one.

CHAPTER 3 PRODUCTION PROCESS

3.1. MANUFACTURING SHOP

16

India Yamaha Motors manufacturing facilities comprises of 2 state-of-the-art Plants at

Greater Noida (Haryana) and Surajpur (Uttar Pradesh). The infrastructure at both the plants
support of motorcycles and its parts for the domestic as well as overseas market. It has Inhouse facility for Machining, Casting, Welding process as well as finishing processes of
Electroplating and Painting till the assembly line.
The stringent Quality Assurance norms ensure that its motorcycles meet the reputed
International standard of excellence in every sphere.
RAW MATERIAL:The primary raw materials used in the manufacture of the body of motorcycle are metal,
plastic and rubber. The motorcycle frame is composed almost completely of metal. The frame
may be overlaid with plastic. The tires are composed of rubber. The seat is made from a
synthetic substance, such as polyurethane.
The cylinder piston, made of aluminium alloy is an essential component of engine. It is fitted
with piston rings made of cast iron. The crankshaft and crankcase are made of aluminium.
The engine also contains a cylinder barrel, typically made of cast iron or light alloy.

THE MANUFACTURING PROCESS:1. Raw materials as well as parts and components arrive at the manufacturing plant by truck.
As part of just-in-time delivery system on which many plants are scheduled, the materials
and parts are delivered at the place where they are used or installed.
2. Manufacturing begins in the weld department with computer-controlled fabrication of the
frame from high strength frame materials. Components are formed out of tubular metal
and/or hollow metal shells fashioned from sheet metal shells fashioned from sheet metal.
The various sections are welded together. This process involves manual, automatic and
robotic equipment.
3. In the plastic department, small plastic resin pellets are melted and injected into molds
under high pressure to form various plastic body trim parts. This process is known as
injection molding.
4. Plastic and metal parts and components are painted in booths in the paint department
using a process known as powder-coating. A powder coating apparatus works like a large
17

spray-painter, dispersing paint through a pressurized system evenly across the metal
frame.
5. Painted parts are sent via overhead conveyors or tow motor to assemble department where
they are installed on the frame of the motorcycle.
6. The engine is mounted in the painted frame, and various other components are fitted as
the motorcycle is sent down the assembly line.
7. Wheels, brakes, wiring cables, foot pegs, exhaust pipes, seats, saddlebags, light, radios
and hundreds of other parts are installed on the motorcycle frame.

3.2. PAINT SHOP

The paint department is one of the most important departments of the organization where the
organization has its own production. The paints are the most important and critical area of
any automobile industry. Paint department of yamaha motor is responsible for all the
colors which occur in the market. Paint department is the only department which covers the
fifty percent area of the plant. Industry is incomplete without Paint Shop. And Paint Shop is
only responsible for appearance of the vehicles. It gives colors to the vehicles. The raw
materials which consist of parts in the case of motorcycle are sent to the paint shop for
painting.
NECESSITY OF PAINTING
1. Colour and appearance.

2. Covering the gaps between the weld joints.

3. Corrosion resistance

4. Makes Components Rust free.

5. Makes surface appearance shiny and good.

18

POWDER COATING:
Plastic and metal parts and components are painted in the paint
department using a process known as powder-coating (this is the same
process by which automobiles are painted). A powder-coating apparatus
works like a large spray-painter, dispersing paint through a pressurized
system evenly across the metal frame.

CHARGED PARTICLES:
First of all the parts are negatively charged with the help of the
electrons then the positively charged particles in the form of color are
sprayed to these charged parts. As we know that the positive and
negative charged particles attract each other so these charged particles
attract each other in the form of paint and thus the parts are painted. The
numbers of the negatively charged particles are equal to the number of
the positive charged particles so we can see smooth paints on the parts of
the motorcycle. And this is the reason that the paints are not spoiled by
sun

and

parts
painted
single

rain.

The

which
in

the

unit

are
a
of

motorcycle are
Fuel Tank.
Side Cover set.
Swing Arm.
Hub Front.
Panel Front.
Magnet Front.
Top Bridge.
Handle Cover.
19

 Clutch Plate.
Main Stand.
Side Stand.
Muffler Stand.
Battery Stand.
Step Bar.

These are the painted body parts of motorcycle

Meter Bracket.
Head

Top

Cover.

Fig 3.1

Head Right Cover.

Tappit Covers set.

3.3.ENGINE ASSEMBLING
Engine is the most important part of the motorcycle. All working of the
motorcycle depends upon this part. There are 17 steps which take place in
assembling of the engine. The parts of the engine which are purchased in
the form of raw material are sent to the engine assembling room.

PISTON CONNECTION:

fig

3.2

The first step in the assembling of engine is connecting the piston with
push rod. A cylindrical piston, made of aluminum alloy (preferred because
it is lightweight and conducts heat well), is an essential component of the
engine.
VALVE LIFTER:
20

In second step, It is fitted with piston rings made of cast iron. Then the
valve lifter is placed below the piston and the push rod and spark lead is
installed.
INLET AND COMBUSTION CHAMBER:
In third step, the inlet part is established in the combustion chamber
which is fitted with the piston. The cooling fan is also placed which helps
the piston to remain cool at time when the motorcycle is driven more by
the driver.
CRANKCASE:
Crankcase is plugged then the oil pump is installed with the engine
mountain belt and oil passage way is placed in the engine on the
crankcase which circulates the oil in the whole engine which helps the
engine to be work more smoothly and efficiently. The crankshaft and
crankcase are made of aluminum.
TIMING GEAR WITH THE PISTON:
The one of the important step in the assembling of the engine is the
establishment of timing gear with the piston through engine mountain belt
hole. Crankshaft and Camshaft gear is placed on the crankcase.. The
engine also contains a cylinder barrel, typically made of cast iron or light
alloy.
EXHAUST PORT:
The exhaust port is placed at the mouth of combustion chamber which
throws all the heat out from the engine. Finally the rocker arm is placed
and the screws are placed in the rocker arm. These are the steps which
are taken place in the assembling of the engine.

3.4. FRAME ASSEMBLING:

21

This is the last step in the manufacturing process of motorcycle. In this process the framing of
the motorcycle takes place and all the parts of the motorcycle are combined by labor energy.
The framing consists of 12 steps.
The motorcycle frame is composed almost completely of metal, as are the wheels. The frame
may be overlaid with plastic. The tires are composed of rubber. The seat is made from a
synthetic substance, such as polyurethane. The power system consists of a four-stroke engine,
a carburetor to transform incoming fuel into vapor, a choke to control the air-fuel ratio,
transmission, and drum brakes. The transmission system contains a clutch, consisting of steel
ball flyweights and metal plates, a crankshaft, gears, pulleys, rubber belts or metal chains, and
a sprocket. The electrical system contains a battery, ignition wires and coils, diodes, spark
plugs,
Fig 3.3

head-lamps and taillights, turn signals and a horn. Wheels, brakes, wiring cables, foot pegs,
exhaust pipes, seats, saddlebags, lights, radios, and hundreds of other parts are installed on
the motorcycle frame.

3.5. PRE DELIVERY INSPECTION

At the end of the assembly line, the pre-delivery inspection takes
place in which inspectors undertake a visual inspection of the
motorcycle's painted finish and fit of parts.
The

inspectors

also

feel

the

motorcycles
with

gloved

hands to detect
any

bumps

defects

in

or
the

finish.
Each motorcycle
is tested on a
dynamometer. Inspectors accelerate the motorcycle from 0-60 mph.

22

 During the acceleration, the "dyno" tests for acceleration and

braking, shifting, wheel alignment, headlight and taillight alignment
and function, horn function, and exhaust emissions.
After the dyno test, a final inspection is made of the completed
motorcycle.

After inspection the finished goods are sent to the store room and then
from there these are shipped to the customers from where these are
demanded.
PRODUCTION DETAILS OF THE PLANT
Total vehicles produced in a day = 1000
Production list includes FZ, Fazer, R15, SZ, Saluto, Alpha, Ray-Z
FZ covers the 40% of the total production of the Surajpur plant. R15, SZ covers 20%
each, whereas the rest 20% of the production is covered by other produced vehicles
altogether.
FZ is the most selling two-wheeler of the plant, without any doubts.

CHAPTER 4 - PROJECTS
PROJECT NO. 1 : ANY ABNORMALITY IN PRETREATMENT
PROCESS OF FUEL TANK
I.

After phosphate process, water rinse the fuel tanks are passed through the vacuum
chamber where water droplets are dried out with the help of dry sprayer.

II.

Dry Oven(water drying):-In this process fuel tanks are heated so that water can dry
out completely from the fuel tanks.

23

III.

Cooling Zone:-In this zone, fuel tanks get sufficient time to get cooled down for easy
handling of the fuel tanks for further coming processes.

IV.

Masking Zone:-In this zone, drilled parts of the fuel tank are covered by covering
material in order to prevent the entry of the paint inside it. If masking is not done then
paint will enter inside the hole and it may create problem during assembly process.

V.

In this zone, there is a possibility of leakage(alkali sol. in water) in fuel tank. We can
remove this leakage by rubbing alcohol on that portion of fuel tank.

VI.

Dusting;- Now dusting is done to remove the dust particle by blowing air on the fuel
tanks.

VII.

Electrostatic Spray Painting:- Here required color coating is done on the substrate
with the help of electrostatic charge using Electrostatic Disk.

VIII.

After that, remaining part of the fuel tanks is done manually.

PROJECT NO. 2- SHOP FLOOR MANAGEMENT

2.1 - SCHEDULE FOR TROLLEY CLEANING
RULE FOR TROLLEY CLEANING
1. Trolley should be cleaned by movement operator daily.
2. Unwanted material in the trolley should be removed.
3. Each line manager will check the sheet timely.
IMPLEMENTATION

24

1. Paint the trolley.

2. Each trolley should be given proper sequence number.
3. Proper cover seat should be provided to each and every trolley
CHECK SHEET
S.No

Activity

Date

NG

OK

Remark

Description
1

Paint condition

Seat cover

Wheel condition

Dust and oil

Table 3

2.2 - TOOLS MANAGEMENT-MINI TOOL CRIB

OPERATION STANDARD OF SUPPLEMENTARY MATERIAL MANAGEMENT

25

BEFORE

AFTER

Fig 4.1

Fig 4.2

CHAPTER 5 CONCLUSION AND REFRENCES

26

5.1. CONCLUSION
After doing our training in IYM, I felt the importance of training in the industry and the
practical applications involved.
During my training period in IYM, i got an exposure of the industrial culture and work
environment which is prevalent in the organization. All the staff members and associates were
very co-operative throughout the training and it was a learning experience in all the way. IYM
is a highly professional company with very strong management fundamentals and extremely
forward looking and cohesive approach with a strong emphasis on total quality management.
Wishing IYM and its family all the best for the future endeavors and we look forward to
being associated with the company for giving positive contribution in any way possible.

5.2. REFERENCES
Engine department of IYM-Surajpur plant(Greater Noida).

27

 Mr. Bijender Kaushik (Sr. Manager, Engine Assembly)

www.yamaha.com

www.wikepedia.com

28