Summer Training Report Rizwan

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

- 1 -

Details of the Trainee:-

Name of Trainee GAURAV CHAUDHARY

Father’s 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 Name Die Maintenance Study and Chip-Dent Reduction

Dept. / Section Press Shop

Training Duration 8th June to 20th July

- 2 -

Acknowledgement

Gratitude is the hardest of emotions to express often one doesn’t

find adequate words to convey the feeling of gratefulness. There

were 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 Mentor Mr. 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 to

my Parents for their moral support and encouragement.

(__________)

Dated………

- 3 -

TO WHOM IT MAY CONCERN

This is to certify that GAURAV CHAUDHARY a student of National

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

- 4 -

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 Tools

32-40

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

- 5 -

COMPANY PROFILE

COMPANY LAYOUT & PROCESS FLOW

- 6 -

HONDA PRODUCTS

HSCI PRODUCTS

- 7 -

TO SHARE HONDA PHILOSOPHY

The driving force behind Honda’s 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’

- 8 -

Updated as on 2010

COMPANY PRINCIPLES

COMPANY PRINCIPLES

THE THREE JOYS

RESPECT FOR THE INDIVIDUAL

All associates are encouraged totake initiative while understandingthat they must take responsibilityfor the results of those actions

Respect for the IndividualEach individual is unique,

independent and possesses initiative

Initiative TrustEquality

All associates are treated fairlyand equal opportunities given to each individual.

The relationship amongassociates at HSCI to be based on mutual trust

based upon the fundamental beliefs of ‘Respect for the Individual’

and ‘The Three Joys’ :

HONDA’S MISSION

- 9 -

THE THREE JOYSJOYS

THE JOY OF BUYINGThe joy of buying is

achieved by providing products and services that exceed the needs

and expectations of the customer.

THE JOY OF SELLINGThe joy of selling is attained

when those engaged in selling and servicing Honda’s products

develop relationships with the customerbased on mutual

trust.

THE JOY OF CREATINGThe joy of creating occurs when Honda Associates and Suppliers involved

in the design, development ,engineering and manufacturing of

products recognize a sense of joy in our

customers using the product and dealers

selling them.

MANAGEMENT POLICIES

- 10 -

Company’s standards for carrying out Daily Operations

are based upon the

Management Policies

Proceed always with ambition and youthfulness.

Respect sound theory, develop fresh ideas and make the most 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.

5S

- 11 -

KAIZEN

- 12 -

HONDA SIEL CARS INDIA, TKR PLANT

Honda Siel Cars India Ltd., (HSCI) was incorporated in December 1995 as a joint venture between Honda Motor Co. Ltd., Japan and Siel Limited, a Siddharth Shriram Group company, with a commitment to providing Honda’s latest passenger car models and technologies, to the Indian customers. The total investment made by the company in India till date is Rs 1620 crores in Greater Noida plant and Rs 784 crores in Tapukara, Bhiwadi plant.

HSCI’S first state-of-the-art manufacturing unit was set up at Greater Noida, 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 this facility is 100,000 units. The company’s second manufacturing facility is in Tapukara, Rajasthan. This facility is spread over 600 acres and will have an initial production capacity of 60,000 units per annum, with an investment of about Rs. 1,000 crore. The first phase of this facility was inaugurated in September 2008.

- 13 -

The company’s product range includes Honda Jazz, Honda City, Honda Civic and Honda Accord which are produced at the Greater Noida facility with an indigenization level of 77%, 76%, 74% and 28% respectively. The CR-V is imported from Japan as Completely Built Units. Honda’s models are strongly associated with advanced design and technology, apart from its established qualities of durability, reliability and fuel-efficiency.

- 14 -

INDIA

HSCI Tapukara

COMPANY PROFILE

HSCI460

Acres

Ho

nda

Tra

din

gHMI

PTPress Ho

nda

Tech. School

Suppliers Companie

s150 Acres

Plant Overview

Total Area = 611 Acres

Press Dept

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 Honda’s latest

global plants with great emphasis on environment

protection and safety.

Zero Discharge Plant

25% of the land in plant with green cover

- 15 -

Plantation of 20,000 trees in 1st year.

Maximum usage on Natural Lighting for energy saving

and healthy environment.

Rain water harvesting.

ASSOSIATES

The new plant employed 250 associates in the starting which

has reached up to 700 in the present year.

SUPPLIER’S CLUSTER

The supplier’s cluster is spread over 150 acres having space for

8 critical and bulky part suppliers. Proximity to the HSCI’s car

plant and use of most updated techniques and features by

these suppliers will make the overall process of car production

more efficient.

DEPARTMENTS IN HSCI TAPUKARA PLANT

Power Train

Engine Control

Parts Quality (PQ)

Power Press

Utility

IPDD

PLC

- 16 -

EXECUTIVE SUMMARYINTRODUCTION 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 PLC trollies from press production trollies according to their packing standard and delivered to GNU plant.

- 17 -

Press dept. has sub dept. of Planning and Production, Quality Control, Machine Maintenance and Die Maintenance and New Model.

- 18 -

PERSONAL PROTECTIVE EQUIPMENTS

- 19 -

Helmet

Boot Cover

Arm Sleeves

Gloves

Nose Mask

Ear Plugs

Goggles

- 20 -

Safety Shoes

2AP PRESS PART DETAILS

PARTS INTRODUCTION

①

②

③

⑤

⑥

⑦

⑧

⑨

⑩

⑪

⑫

⑬

⑭

⑮

③

⑦

⑩

⑪

⑬

⑫

14

915

3

7

10

12

11

13

4

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 PART’S NAME2PS PART’S NAMESRNO

- 21 -

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

- 22 -

Die and punch are used in drawing operation.

Drawing is usually done at room temperature, thus classified as a cold working process.The flow of material is controlled through pressure applied to the blank 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 limit the flow of material and cause the material to stretch or thin.If too much pressure is applied, the part will become too thin and break. Drawing metal is the science of finding the correct balance between wrinkles and breaking to achieve a successful part.Drawing leads to wrinkling and puckering at the edges where the sheet metal is clamped. This is usually removed by a separate trimming 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 stretching metal sheets. Forming strains the metal beyond the elastic limit, to give the work piece a permanent set. Forming is similar to bending. Complex parts such as U-sections and channel sections of different profiles can be produced by doing multiple bends.

- 23 -

There is no change in thickness. Good dimensional repeatability as well as close tolerances is possible with this process. Complex bending and re-strike operations can be accomplished using Cams in dies. 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

- 24 -

- 25 -

Elements of die and their function

5

Reverse double structure

1

76

85

2

3

4

4

Double action structure

3

1

4

2

98

arc

Structure element Principle Rule Standard

1 PunchCreates shape by pressing blank

sheet against die

Standard of panel size accuracy. Accuracy offinishing surface should be 5? or below. It haslocation guide in-between with blank holder

Edge R & controlledsurface: #400 finishing

Not controlled surface: #120finishing

2 DieHolds blank sheet in-between withpunch. Receives pressure of punch

and creates shape.

Thickness of panel should be reduced to maintainpanel size accuracy. However, convex area should

be standard for forming shape



3 Blank holder

Holds blank sheet together with dieface to control influx and prevent

wrinkle

Surface accuracy should be 5? or below and have nopartial unevenness. Has locating guide in-between

with punch



4 Air vent holePrevents panel deformation anddistortion due to pressure change ofair in-between BL material and die

Make a drill-pierced hole of ?4.00 for the easiness ofreleasing panel from punch/die concave and punch

forming part

Minimum pitch: 50 mm

5 Wear plate

Sustains the positional relation ofpunch and blank holder at a certainlevel. Reduce abrasion factor toimprove manufacturing and

maintainability

Normally, SIGR type I, single plate onto punch isused for material

Use 20 t if slide can bedetached. Use 10 t forpermanent contact

6 LifterRemoves a panel steadily from inside

dieThere are ways of unloading: one-side lifting and alllifting. Take a measure of panel deformationprevention using rubber, sponge, etc.

7 Die face

Holds down blank sheet, controlsmaterials influx and prevents wrinkles,

together with bead

Surface accuracy should be 5? or below and have nopartial unevenness. Has locating guide in-between

with blank holder



8 Bead

Controls tensile strength necessaryfor influx amount of blank sheet and

forming

There are two types of bead: one is draw beadcontrolling blank sheet influx, the other is lock beadstopping influx and forming bead only with material

elongation

9 Gauge/Nest

Blank sheet positioning Prevent material deformation by putting edge R3shape on the side that contacts material. Use dowel

pin to fix for positioning

Secure 20 mm linearsection from lower limit - 6spots basically and 8 spotsfor large object and circular

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.

- 26 -

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

DIE WASHING- 27 -

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

- 28 -

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.

- 29 -

(1) Apply red oxide on the surface plate.

　 Dark at early stage and then thinner according to

finish.

- 30 -

(2) Check contact

　 Adjust on sliding pressing on the surface plate and

Checking bedding.

(3) Produce flat surface grinding in different directions alternately

at red oxide applied area.

　 Grind at about 45 degrees against the work.

- 31 -

Bottom finishing

How to use a grinder

for finishing 　Grind not to make concave at the beginning 　 and at the end of grinding.

Grind like scooping.

Grind repeatedly until 80% is marked with red oxide

Example of 80% red oxide applicationExample of 50% red oxide application

Do’s and Don’ts of Grinding

Do’s

• 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

- 32 -

Step 2 - Side square finishing

(1) Rub together parallels which red oxide is applied.

Checking

square.

(2) Finish grinding red oxide applied area like bottom finishing.　

• Using damaged mounted wheels.

• Tighten the wheel with full force.

• Grind using undressed wheel.

• Blow off grinding dust using compressed air.

TYPES OF REPAIR TOOLS:-Tool Name Use

Air Porter Finishing of counter and cutting edge.

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

Angle Grinder Rough finishing counter, cutting edge.

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

Hex Wrench Tightening and loosening socket bolts.

T Handle Wrench Tightening and loosening socket bolts.

Copper Hammer Driving dowel pins, blocks, etc.Steel Hammer Peening, Chisel, etc.Wrench Tightening ad loosening nuts.Angle Wrench To replace offset

- 33 -

Screwdriver (+) Tightening, loosening cross recess screws.

Screwdriver (-) Tightening and loosening socket bolts.

Plier Holding, Gripping, cutting partsChisel Cutting, chippingAdjustable Wrench Tightening, loosening nutsDowel pin puller Dowel pin pulling, drivingFile Finishing contourCompass Scribing linesVernier caliper General measurementThickness gage Measuring clearancesRadius gage Measuring radiusImpact wrench Tightening, loosening, socket

boltsPipe wrench Holding, tightening, loosening

round parts..Vise plier Clamping PartsShears Cutting steel, copper sheetsTap handle Tapping holesDie stock Threading partsFlashlight Working in dark areasDiamond file Finishing hardened areasDresser Dressing emery wheelOilstone Polishing contours, cutting edgeCarbide cutter Rough cutting with porterEmery paper Polishing contours, general

surfaceOffset Rough cutting with angle grinderEmery wheel Finishing with porterBuff Finishing with porterEmery compound Rough polishing contour, general

surfaceCopper Bar Die disassembly, driving large

part

Use of Standard Hand Tools:-Tool Name Description Handling PointersHex Wrench,

- 34 -

T handle wrench 1. Preparation for work

2. Tool Usage

3. Completion of operation

4. Others

Inspect and wear specified protective gears.

Inspect conditions of tools.

Set wrench fully into the bolt head

Prevent over/under torquing

Check wrench for wear and crack.

Clean and orderly arrange work area (especially oil)

Refrain from using any damaged tools found.

Cotton gloves

Do not use cracked tools or those worn in excess of 10% or oversize tools, check weld in the T handle.

Use the proper size wrench and seat fully into the head. Check the weld of T handle wrench.

Torque value will differ for bolt material and diameter.

Replace or repair before using, or dispose

Copper Hammer, Steel Hammer1. Preparation for work

Inspect and wear specified

Do not use gloves. Wear safety goggles if necessary.

Do not use hammer with loose - 35 -

2. Tool Usage


4. Others

protective gears.


Caution of injury to other workers.

Refrain from using excessive force.

Check condition of hammer head and handle.

Clean and orderly arrange work area.


handle, missing wedge Do not use copper hammer with

greater than 20% flared head Do not use hammer without an

anti slip end. Do not use hammer with an oily

hand.

Replace or repair before using, or dispose.

Wrench, Offset wrench 1. Preparation for work

2. Tool Usage



Prevent overtorquing

Wear cotton gloves.

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

Use proper tightening torque.

- 36 -


4. Others

or undertorquing.

Check wrench for wear and crack.

Clean and orderly arrange work area (especially oil)



Screwdriver (+), Screwdriver -1. Preparation for work

2. Tool Usage




Do not hammer the screw driver.

Check for loose handle.

Check for cracked or chipped blade.

Clean and

Wear cotton gloves.

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


- 37 -

4. Others

orderly arrange work area.


Plier 1. Preparation for work

2. Tool Usage


4. Others



Check for cracks, loose pin



Wear cotton gloves.

Do not use tool with excessively worn grip area or loose pin.


Chisel1. Preparation for work

2. Tool Usage



Caution for flying of

Wear cotton gloves and safety goggles. (However, do not wear gloves when using set chisel)

Do not use tool with flared head, chipped or cracked point.

Hardness of point shall be less than HRC 55⁰.

- 38 -


4. Others

broken chips. Check for

cracks, loose pin


Refrain from using any damaged tool found.


Adjustable wrench, pipe wrench1. Preparation for work

2. Tool Usage




When using the tool apply force in the direction of the adjusting slide.

Do not use as a hammer.

Check for cracks and looseness.

Clean and orderly arrange work

Wear cotton gloves.

Do not use cracked tools or tool with loose adjusting screw or slide.

Apply proper torque.

Replace or dispose.

- 39 -

4. Others

area.


Pin Puller 1. Preparation for work

2. Tool Usage


4. Others



Caution, prevent pinching the finger.

Check the condition of the pin puller welded bolt.



Wear cotton gloves.

Length of main unit shall be less than 300mm.Sliding weight hole diameter should be less than 15% of the diameter of the main unit slide.Flare of the main unit head section shall be less than 35%.Main unit and head shall be single piece.Normally, the pin screw end should not be welded.

Repair before use.

- 40 -

File1. Preparation for work

2. Tool Usage


4. Others

wear specified protective gears.


Apply force only on the forward cutting strike.

Work in a weld balanced attitude.

When cutting edge becomes dull, clean the teeth with a wire brush.

Check condition of handle and the crack stopper ring.



Length shall be at least 150mm.

Wear cotton gloves only on hand which holds the tip. Do not use tool with loose handle or cracked handle.

Wire brush


- 41 -

REMEDY PROCEDURE FOR PRESS DIE (DRAWING DIE)

SYMPTOM CAUSE REMEDY1. Overall

wrinkles Blank holder

pressure low Adjust blank holder

pressure2. Localized

wrinkles Blank holder not

level Blank holder not

flat. Blank stock

improperly positioned

Blank holder pressure low

Adjust blank holder

Grind blank holder flat

Adjust blank positioner

Adjust blank holder pressure

3. Crack or tear along part periphery

Blank holder pressure too large

Punch/Die radius too small

Insufficient clearance between punch and die.

Incorrect positioning of blank stock

Scoring on the bead and die radius

Incorrect slit timing

Defective blank


Increase Die/Punch radius (observe part dimension)

Adjust clearance C= t+ (2/10 – 6t/10)

Adjust blank positioner

Polish

Adjust timing

Defective stock

- 42 -

stock(work hardened)

4. Radial tear Defective blank stock

Blank holder pressure low due to unevenness

Blank stock improperly positioned

Defective stock

Regrind holder

Adjust blank position

5. Radial scratches

Scoring on the bead and die radius

Polish

6 Shiny spots on drawn surface

Insufficient clearance

Improper shut height

Improper die set-up

Adjust clearance C=1.2-1.5t

Adjust shut height

Reset up

7. Drawn surface depression

Excessive clearance

Adjust clearance between punch and die.

8. Inside scratches

Groove scratches on flange holder and bead

Polish

9. Streak depression along drawn surface (Starting mark)

Insufficient ie radius

Poor material slip property

Bead lacks pull Excessive cushion

pressure Defective blank

stock

Adjust die radius

Polish

Adjust bead (observe part) Adjust cushion

Replace stock

10.

Les along drawn surface

Insufficient blank pull

Defective die bend surface

Reduce pressure increase bead pull force

Correct bend surface

11.

Line shift Improper cushion pressure

Improper blank

Adjust cushion pressure

Adjust bead- 43 -

pull force (improper bead)

Slit improperly timed

Excessive shut height

Adjust slit timing

Adjust shut height

12.

Insufficient flange width

Insufficient material

Insufficient cushion pressure

Insufficient blank pull force (bead)

Replace material

Adjust cushion pressure Adjust bead

13.

Caused by vacuum created during die separation

Punch rise speed too high

Improper air bleed hole size, quantity

Reduce punch speed. (double action)

Change size, number, location of air bleed.

Adjust stretch ratio Adjust oiling condition.

14.

Develops during pressing due to uneven distribution of stress during press operation.

Uneven clearance Unbalance tension

produced by the bead.

Adjust clearance. Adjust location and height

of the bead. Adjust processing and

cushion pressure. Straightening process. (by

use of jig during assembly)

15..

Depression develops during processing due to insufficient pull on the material

Insufficient bead pull

Insufficient blank holder pressure.

Uneven blank holder surface

Reinforcement of bead. Adjust the blank holder

pressure Repair of blank holder

surface

16.

Excessive curvature develops during processing due to insufficient

Insufficient blank holder pressure

Punch contour


Improve finish of the punch

- 44 -

pull on the material.

17.

Irregular spots formed by foreign objects on the die surface.

Foreign objects on the die.

Foreign objects on the blank stock.

Burrs on sheared edge.

Clean the die. Clean the blank stock

Remove burrs.

18.

Crease develops along the corner during drawing and bending due to concentration of stress

Insufficient bead pull and blank holder pressure

Excessive clearance

Adjust bead shape and blank holder pressure

Adjust clearance

19.

Condition that develops on the inside surface of the sheet due to uneven distribution of stress.

Large die corner radius

Excessive clearance

Insufficient spring back allowance

Insufficient blank holder and cushion pressure.

Insufficient material

Remedy due corner radius Adjust clearance Adjust spring back

allowance

Adjust blank holder and cushion pressure

Use material of larger dimension

20.

During initial drawing phase the friction of the die caused excessive material stretch at the radius and subsequent increase in

Irregular radius on the die and punch surface

Improper bead pull

Improve he finish of the die and punch radii (smooth)

Adjust the bead timing Increase the profile radius

with consideration to blank holder contour, pressure direction.

- 45 -

rigidity produced a marked line.

REMEDY PROCEDURE FOR PRESS DIE (TRIMMING DIE)

SYMPTOM CAUSE REMEDY1. Burrs Excessive

clearance Insufficient

clearance Primary cutter

wear Protruding

secondary edge.

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

Adjust cutter edge clearance

Hardface the cutter edge Grind secondary edge.

2. Edge condition different for sides.

Punch and die off center

Remedy die offset.

3. Material not sheared square

Dull or worm punch

Build up worm area by hardfacing

4. Projection along the cutting edge.

Damaged or chipped cutting edge of punch

Regrind or build up by hardfacing the punch cutter

5. Depression along cutting edge

Damaged or chipped cutting ede of die.

Regrind or build up by hardfacing the die cutter.

6. Depression of the normally flat surface

Part not properly set in the die.

Bushing surface too low.

Incorrect drawing depth

Check the matching of the dies and make correction

Install spacer and regrind height of bushing

7. Punch breaks Stripper not set parallel.

Loose punch

Adjust stripper Enlarge mounting

diameter of the punch to provide good fit.

- 46 -

Punch off center Interference with

reverse hold down Incorrect material

or hardening

Realign the punch Adjust

Change material or heat treat to proper hardness.

8. Scrap clogging

Restriction of the hole.

Scrap chute hole requires polishing

Burrs

Provide proper clearance Polish hole

Lap punch and bushing

9. Part adheres to upper die

Weak stripper spring or damage to the urethane

Excessive cutting stroke causing part to bind

Replace

Adjust stroke

10.

Shift of cut line

Contour not matched between drawn part and trimming punch

Punch and stripper contour not matched

Damaged reverse holder spring

Match punch to the part contour

Match stripper to punch contour

Replace spring.

- 47 -

REMEDY PROCEDURE FOR PRESS DIE(HOLE PIERCING)

Symptom Cause Remedy1. Burrs Worn slide core

Loose punch mount

Incorrect secondary finish

Incorrect clearance

Adjust slide core clearance

Correct mount to proper diameter

Remedy Adjust clearance

2. Blocked hole Clogged scraps Loose fixed cam Loose back up

block Insufficient stroke.

Match the punch, clean scrap 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 hole

during pilot hole piercing

Defective material

Increase size of pilot hole so as to reduce the amount of burring

Match the punch

2. Incorrect burring height

Punch and die off center.

Hole in part not aligned to the die.

Incorrect burring hole bushing radius

Improper drawing depth

Improper burring pilot shape.

Adjust

Adjust shut height Match pilot to shape of

part hole.

- 48 -

REMEDY PROCEDURE FOR PRESS DIE(CURLING DIE)

SYMPTOM CAUSE REMEDY1. Reverse bend Binding in the

curling groove Curling groove off

center

Polish groove Reposition curling groove

by build up facing

2. Broken punch Punch and bushing misaligned

Punch over hardened

Worn guide

Align punch and bushing Temper to proper

hardness Replace guide, post,

bushing

Periodic Inspection and Maintenance GENERAL:-

The purpose of periodic inspection and maintenance (hereafter referred as periodic maintenance) is to perform control of the dies to prevent them from aging and wear so that the accuracy of the parts they produce will be maintained at the specified 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 on preventive maintenance for the respective processes.

ESTABLISHING SHOT QUANTITY BASED ON MAINTENANCE INFORMATION:-

Durability of the dies will depend upon many factors such as shape of product, sheet thickness, die design, die material. Normally, it would be desirable to maintain die accuracy for each product by the respective process, or to perform control within the range that products of uniform quality (acceptable product quality) can be supplied. However, based on past experience with die repair, control is established for each process based on the number of press shots.

- 49 -

PERIODIC MAINTENANCE CYCLE:-

PROCESSType, repair

70,000Shots

140,000Shots

210,000Shots

280,000shots

350,000shots

REMARKS

DRAW Normal Important Plating

Y

Y

Y

Y

Y

Y

Y

Y

YYY

Bead Wear countermeasure

TRIMNormal

Important

Y Y YY

Y YCutter Wear countermeasure

PIERCENormalImportant

Y Y YY

Y YAdjust accuracy of shoulder punch fit section

SIDE CUTNormalImportant

Y Y YY

Y Y

BENDNormalImportant

Y Y Y Y YY

Bend punch wear countermeasure

1. Normal Periodic Maintenance:- Perform- check of the steel dies for defects and damages In accordance with the maintenance procedure specified in the following attached sheets, and make any repairs as necessary.

2. Important Periodic Maintenance:- In addition to the periodic maintenance, look for areas of the steel die that indicate excessive wear from die aging, and perform the designated preventive 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 and then replating. Replating will restore excellent wear resistant property of the die (minimizing the depressions and scratches) and enable the continued production of quality products.

- 50 -

Furthermore, the drawing property of the die is improved by the smoothness of the plated surface.

FEEDBACK:- The information derived from the periodic

maintenance provides valuable information on the characteristics of each die (die design inadequacies, repairs) which can be used in the design and manufacture of future steel dies.

KEEPING OF DIE MAINTENANCE AND REPAIR RECORDS:-

All the periodic maintenance record sheets, and repair and modification record sheets shall be kept in the file by parts (process) and in the order of maintenance performed.

- 51 -

DIE DESIGN

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

Ref.

Part Name

Function

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

b. Die Forces the sheet stock to form around punch contour.

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

d. Balancer block

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

e. Blank holder

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

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

g. Cushion Pin

A component of the press which function as a support for the blank holder

h. Pilot Performs the positioning of the stock sheeti. Guide Performs the positioning of the blank holder to

the die.

- 52 -

Draw Die Periodic Maintenance Inspection Standard:-

S.No.

Inspection Points

Description of

Inspection

Inspection Standard

Inspection Method

Maintenance Method

1. Guide post Galling, wear, bend

0.1-0.2 Micrometer, Inspection jig

Replace with new parts

2. Guide bushing

Galling, wear, crack

0.1-0.2 Cylinder gage Replace with new parts

3. Punch, Die, Blank

Galling, wear 0.05-0.1 Thickness gage

Grind, Liner repair

4. Holder, guide, plate

Galling, wear 0.05-0.1 Thickness gage

Grind, Liner repair

5. Guide plate mounting bolt

Break, loosening

None permitted

Wrench Replace with new parts

6. Punch Worn radius, galling

0.5max. Section gage Weld build up worn spot

7. Die Worn radius, galling

0.5max. Section gage Weld build up worn spot

8. Die plating Peeling None permitted

Visual Plating

9. Die mounting bolt

Break, loosening

None permitted


10. Bead Galling, crack, wear

Determine from Die and

Part Weld build up worn spot or replace

11. Bead mounting bolt

Break loosening

None permitted

Wrench Replace with new part

12. Ejector retainer pin

Galling, deformation

Not permitted Visual Replace with new part

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

14. Pilot pin Break, deformation, looseness

Not permitted Visual Replace with new part

15. Scrap chute box

Damage deformation

Not permitted Visual Replace with new part or repair

16. Upper/lower holder

Surface condition

60-70% contact

Straight edge Grind

17. Hook hole Screw thread war

1mm max. Vernier caliper

Machine new hole

18. Mounting bolts

Break, looseness

Not permitted


- 53 -

2. STEEL SHEAR DIE ( Blanking, Trim, Pierce):-Trim-pierce die For cutting off excess material

Ref. Part Name Functiona. 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 liftingd. Guide bushing For aligning upper and lower die, to maintain die accuracye. Stroke end pin Die reference (normally 0.5mm clearance exists)f. Guide post For matching the upper and lower die, maintain die accuracyg. Punch plate Shoulder punch mounting plate, maintains punch position h. Spring ellipse

(Spring urethane)

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 piercingk. Die cutter Mate with punch cutter and performs punchingl. Punch cutter Match with die cutter and performs punching

m. Punch Serve as positioner for drawn partsGn. Scrap cutter

- 54 -

Trim Die Periodic Maintenance Inspection Standard:-

No. Inspection points

Description of inspection

Inspection Standard

Inspection method

Maintenance Method

1. Guide post Galling, Wear, Bend, Cracks

0.05-0.1 Micrometer, in inspection jig

Replace with new part.

2. Guide bushing

Galling, Wear, Bend, Cracks

0.05-0.1 Cylinder gage Replace with new part.

3. Heel guide Galling, Wear 0.05-0.1 Thickness gage

Repair wear

4. Wear plate Galling, Wear 0.05-0.1 Thickness gage

Repair worn liner.

5. Wear plate mounting bolt

Break, looseness Not permitted Wrench Replace with new part

6. Male cutter, Flat

Chip, Clearance, Wear, Over-cut

Chip not permitted

Visual Repair by weld build-up

7. Male cutter, Vertical Cut


Clearance 0.05-0.08 of sheet thickness

Thickness gage

Repair by weld build-up

8. Male cutter head pipe


Sagging edge not permitted

Check product shear edge

Jig model repair

9. Male cutter countered section


Overcut 0.5-2.0 + sheet thickness

Scale Jig model repair

10. Female cutter flat


Chip not permitted

Visual Weld build up wear area

11. Female cutter vertical cut


Clearance 0.05-0.08 of sheet thickness

Thickness gage

Repair by welding

12. Female cutter head pipe


Sagging edge not permitted

Check product shear edge

Repair by welding

13. Female cutter countered section


Overcut .5-2.0 + sheet thickness

scale Scale repair by welding

14. Punch block mounting bolt

Break, Looseness Not permitted Wrench Replace with new part

15. Die block mounting bolt


16. Punch Chip, wear, overcut, loose mounting

Chip not permitted

Visual Wear replace

17. Punch holder Loose mounting, Galling

Edge sag Visual Repair by jig boring

18. Bushing Chip, Wear, Overcut, Loose mounting

Overcut = t + 0.5~2.0

Vernier Calliper

Weld build-up, Replace with new part

19. Bushing holder

Loose mounting, Galling

Looseness 0.01 max

Cylinder gage Jig boring machining

20. Ejector Damaged contour Not permitted Visual Repair by welding

- 55 -

21. Ejector Spring

Break, bend, Deform Not permitted Visual Replace with new part

22. Ejector Urethane

Break, Bend, Deform Not permitted Visual Replace with new part

23. Lifter Deform, Bend, damage

Not permitted Visual Replace with new part or repair

24. Cylinder Air leak, Operating condition

Normal operation

Test Stand Replace with new part or repair

25. Knock out pin

Malfunction Deform not permitted

Visual Replace with new part

26. Knock out spring

Break, Bend, Deform Not permitted Visual Replace with new part

27. Scrape chut Damage, Deform Not permitted Visual Replace with new part or repair

28. Upper/Lower holder

Surface condition 60-70% contact

Straight edge Grind

29. Upper/Lower mounting bolts


30. Hook hole Screw thread condition

1mm max wear

Vernier caliper

Drill new hole

31. Jig model Defective contour, Chip

Not permitted Visual Repair or make new

- 56 -

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

- 57 -

Pierce/Burring die periodic maintenance Inspection Method:-

No. Inspection points

Description of Inspection

Inspection Standard

Inspection method

Maintenance Method

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

Replace with new part

2. Guide bushing

Galling, wear, crack 0.05-0.1 Cylinder gage Replace with new part

3. Punch Chip, wear, overcut, hole looseness

Chip not permitted

Visual Grind, Replace

4. Punch holder Galling, Mounting looseness

Overcut = t+ 0.5~2.0

Vernier Caliper

Jig boring

5. Bushing Chip, wear, mounting hole looseness

Looseness 0.01 max.

Cylinder gage Repair by welding, replace

6. Bushing holder

Galling, mounting looseness

Clearance t 0.05~0.08

Visual Jig boring

7. Burring punch

Galling, wear, bend Galling not permitted

Visual Grind, Replace

8. Burring holder

Mounting looseness, Galling

Looseness 0.01 max.

Cylinder gage Jig boring

9. Burring bushing

Galling, wear Wear 0.05 max.

Micrometer Replace with new part

10. Burring holder

Mounting looseness, Galling

Wear 0.05 max.

Micrometer Jig boring

11. Ejector Contour damage Not permitted

Visual Repair by welding

12. Slit male cutter

Chip, galling, wear Determine from die and part sheared edge

Repair by welding

13. Slit female cutter

Chip, galling, wear Determine from die and part sheared edge

Repair by welding

14. Blank holder Galled surface, wear Determine from die and part sheared edge

Weld build-up worn spot

15. Blank plating Peeling Not permitted

Visual Plating

16. Blank bead groove

Galling, wear Determine from die and part sheared edge

Weld build-up spot

17. Blank mounting bolt

Break, loosening None permitted


- 58 -

18. Blank set pin Break, bend, looseness

None permitted


19. Blank bottom surface

Depression 0.5 max. Vernier caliper Grind

20. Ejector Damaged contour, worn radius

Determine from die and part sheared edge

Repair by welding

21. Ejector mounting bolt

Break, loosening None permitted


22. Knockout Malfunction Pin free from bend


23. Knock spring Break, bend, deform None permitted


24. Hook hole Worn threads Not more than 1mm wear

Vernier caliper Machine new hole

25. Upper, lower holder

Flatness, irregular surface

60-70% surface contact

Straight edge Grind

26. Upper mounting bolt

Break, looseness None permitted


- 59 -

LOWER DENT PANEL

OK PANEL

UPPER DENT PANEL

CHIP

CHIP

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,GENERATE THE DENT

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

- 60 -

Hand Work Contribution, All Models May’12

MODEL

TOTAL PRODUCTIO

N

HANDWORK

% H/WNOS

REJECTED

% REJECTIO

N

CRACK NOS

% 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

- 61 -

1.32

1.84

1.81

Handwork Contribution, All models MAY'12Overall H/W - 2.1%

2PS 2AP 2CV

2 CV HandWork Trend May'12

AVERAGE 1.8

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

ROOF

RR DR

PNL L

SPO L/H

SPO R/H

RR DR

PNL R

FR DR

SKIN R

HOOD

SKIN

FR DR

SKIN L

HOOD

FRAME

FR FNDR L

RR DR

SKIN L

RR DR

SKIN R

FR FNDR R

T/L SKIN

FR DR

PNL R

FR DR

PNL L

FR FLOOR

RR IN

SIDE L

RR IN

SIDE R

RR FLOOR

T/L FRAME

ROOF

RR DR

PNL L

SPO L/H

SPO R/H

RR DR

PNL R

FR DR

SKIN R

HOOD

SKIN

FR DR

SKIN L

HOOD

FRAME

FR FNDR L

RR DR

SKIN L

RR DR

SKIN R

FR FNDR R

T/L SKIN

FR DR

PNL R

FR DR

PNL L

FR FLOOR

RR IN

SIDE L

RR IN

SIDE R

RR FLOOR

T/L FRAME

ACTUAL

12.0 9.6 7.7 5.8 4.2 3.5 3.2 2.9 2.5 2.4 2.2 1.4 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

TARGET

1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

1.0

3.0

5.0

7.0

9.0

11.0

13.0 12.0

9.67.7

5.84.2 3.5 3.2 2.9 2.5 2.4 2.2

1.4

0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

2CV HANDWORK TREND - MAY'12

H/W

%

Defect Wise- 62 -

PART NAME TOTAL DENT DING SCRATCH

OTHERS

RUST SCRAP JAM

WRINKLE

BURR

HOOD SKIN 108 54 54 0 0 0 0 0 0

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 0PANEL RR IN

SIDE R 0 0 0 0 0 0 0 0 0PANEL 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 0FR DOOR SKIN

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

L 88 44 44 0 0 0 0 0 0FR DOOR PANEL R 0 0 0 0 0 0 0 0 0FR DOOR PANEL L 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 0RR 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 DENT DINGWRINKL

ESCRAP JAM

SCRATCH

OTHERS RUST BURR

2002 895 525 497 85 0 0 0 0

DENT DING

WRINKLE SCRAP JAM

SCRATCH OTHERS

RUST BURR

- 63 -

2CV Hand Work PART NAME MARC

HAPRIL MAY

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

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 7.74PANEL RR IN SIDE

R 0.00 0.00 0.00PANEL 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

MARCH APRIL MAY

0

5

10

15 12.55

6.46

11.97

ROOF PANEL

MARCH APRIL MAY

0

2

4

6

8 7.16

3.69

5.81

SPO RH

- 64 -

MARCH APRIL MAY

02468

10 9.29

7.14 7.74

SPO LH

MARCH APRIL MAY

0

5

10

15

4.10

12.759.64

RR DR PANEL LH

- 65 -

HAND WORK TREND (2CV) MAY’12

More handwork than target due major handwork in Rr Dr Pnl, Panel Roof and SPO LH.

1

2

34

5

PART WISE

- 66 -

1

2

SUMMARY (2CV)

Rr Door Panel L/R

SPO LH2

1

1

After

C/M

2

SUMMARY (2CV)

3 Panel Roof

1

- 67 -

- 68 -

2CV G/H Spoiler to SPO NF at LH Side

Problem Contents Analysis Contents Countermeasure

Spoiler is 1.0 mm -VE TO SPO

1) Fukugo is analyzing the Root cause.

2) On MOM(WE, Fu, PR) Basis spoiler NF Improved

from -0.9 to +0.5C/M done in 2 Steps:-

STD-0.5± 1.0 SPO +VE

ACT - 2.1 SPO +VE

ACTION PLAN

Apr’12 ~

May’12

TEMP. C/M 1) Mom done

with WE & Fu.

2) Temp. H/W done to

and dispatch to GNU.

17PERM. C/M

3) On CBU Result basis, Die modification studied4) Die modified & Trial 5) Dispatch to GNU on IPP

H/W and CBU Result

1) On checking single part by Fukugo on Scanning M/C,

hem flange and datum surface found –ve and +ve respectively,

Data is as given below:-

2) After checking scan data, MOM was done to do H/W

on parts by Press to find the Die modification required.MOM for

Temporary Trial

Conclusion:- After H/W on parts as per MOM,

Improvement Observed, Further MOM was done

for Part improvement with WE and Fukugo.

a) Part data checked on Kengu, based on data welding done in Trim Die hem flange area.

MOM for Perm. C/M

b) Datum surface area lower die (3RD Process) polishing done. Before - - 0.9

After - +0.4 ~ +0.5

18

19

20

23

24

25

26

27

28

30

01

02

04

05

07

08

09

10

11

14

H/W was done on 15 Parts as per MOM and Send for CBU Check

Again Meeting done, C/M

decided as per Weld/Fu

Instructions

Die modified :-1) For Datum

surface 2) For Hem

Flange Surface

CBu Result OK as per

Weld & VQ Judgment

- 69 -

Summer Training Report Rizwan

Documents

Transcript of Summer Training Report Rizwan