Aluminium Machining

Manjeet Budania
2017ABPS1128H
Introduction to Machining
● There are intotal 10 lines at the Machining Shop.
● These lines have over a 126 Machines to produce both Steel and Aluminium Parts.
● Machine Shop has a spread of 8000m2.
● Output from Machining works as an Input at the Sub Assembly area at the Engine Assembly
Section.
● Machining Shop delivers fully machined Crank Cases, Cylinder Components and Cylinder Heads to
the Engine Assembly.
Organisation Structure 5 Unit Leaders

3 Section
Managers

Dept. Manager 13 Team

Steel Leaders

Division Head

Dept. Manager
6 Unit Leaders
Aluminium

3 Section
Managers

17 Team
Leaders

Total line Associates: 423

Insights on Aluminium Machining
● Aluminium Machining is responsible for the machining of Left and Right Crank cases and the
cylinder heads of Honda Activa and Shine(KWP and KTE) at the Tapukara Plant.
● There are three lines for crank cases where both the left and right crank cases are machined
simultaneously, similarly there are two lines for cylinder heads .
● The crankcase lines receive their input(sozai) from the HPDC(High Pressure Die Casting) facility at
the plant.
● The Cylinder Head lines receive their sozai from outside vendors in the form of BOPs(Bought out
Parts).
Right Crankcase Left Crankcase Cylinder Head

Final products of Aluminium

Machining
 Team Corner System at Aluminium Machining
● Team Corners are special meeting areas for Managers and Leaders to discuss the Plans and the shortcomings
in the plans.
● Team Corners also have various boards that basically contain data that helps in monitoring production on a
day to day basis.
● Various topics covered in Team Corner Boards:
○ Safety: Safety Calendar, Past C/M verification, Incident Sharing and BBS
Observation.
○ Quality: MMCs(Microsoft Management Console), Check Sheet and
Associate Skill Chart.
○ Delivery: Production Monitoring, Spare Monitoring, Machine breakdown,
Cycle Time Monitoring.
○ Others: Kaizen Monitoring, Best kaizen, EMP( Environmental Management Plan),
Tank Cleaning Schedule.
○ Manpower Control Board: Deployments, Attendance Monitoring, Overtime
Monitoring, Leave Plan, Training Plan
○ Cost:Tooling Cost, Consumable Cost, Rejection Cost, Cost reduction themes.

Kaizen
 Layout at Crankcase line:

Rough
Drilling Drilling Reaming
Sozai Inspection

boring, Spot
Milling facing and
and and Spot and Fine Tapping
Reaming Reaming facing Boring

Cylinder
RCC
Final Inspection Body Leak Face
Washing Bearing
Testing reaming
press
and milling