SUMMER TRAINING PROJECT REPORTI n d i a Yam a h a M o t o r P v t . L t d . SUBMITTED BY AMAN KUMAR B.TECH MECHANICAL SESSION: 2012-2016 JSS Academy Of Technical Education, Noida (Affiliated to Uttar Pradesh Technical University) INDEX S no. Description Page 1. Preface 3 2. Acknowledgement 4 3. Purpose of internship 5 4. Introduction 6 5 History of Yamaha 7-8 6 Overview 9-10 7 India Yamaha Motors 11-12 8. Vision 13 9. Mission 13 10. Manufacturing in Yamaha 14 11 Gear Manufacturing 15-16 12. Machine Shop Production 17 13. Machine Shop Processes 18-19 14. Conclusion 20 14. References 21 With the kind help and genuine interest and the guidance of my supervisor. Thanks and regards Yours sincerely Aman Kumar . I tried my level best to conduct a research to gain a thorough knowledge about the project. valuable suggestions are thankfully acknowledged. I came across some difficulties to make my objective a reality.PREFACE As a part of course curriculum of Bachelor of Technology we were asked to undergo 2 months summer training in any organisation so as to give us exposure to practical skill and competence to get us familiar with various activities taking place in the organisation. I put the best of my efforts to bring out this piece of work. I have put my sincere efforts to accomplish my objectives within the stipulated time. I have worked to my optimum potential to achieve desired goals. Being neophytes in the highly competitive world of technology. If anywhere something is found unacceptable or unnecessary to the theme. . I have no doubt that my choice of training at IYM was right. I would like to thank my mentor at Yamaha Mr. The Yamaha family teaches strict self discipline and goal oriented approach. The exposure and experience gained at IYM has been unique. Last but not the least I would like to thank all Machine Shop department workers and managers for their cooperative behavior. S K GULATI acquainted with the work ethics of the organization and motivating me at each and every step so that I achieve my goal at Yamaha with perfection.ACKNOWLEDGEMENT I express my gratitude to all the people at INDIA YAMAHA MOTOR PVT. LTD who helped me to gain the valuable knowledge and experience. great emphasis is laid on-the-job training an industrial training. after six semester is in-built in to the B-Tech. It provides the student with an opportunity to gain valuable experience on practical application of their technical knowledge. .PURPOSE OF INTERNSHIP The importance of practical on the job training in the industry for engineering student cannot be over emphasized. Industrial training plays the most important role in an engineering student’s life to make him a successful engineer. At JSSATEN. This two months industrial summer training (10 th Apr to 9th June. program. This is an integral part of curriculum. 2015). Kando is the Japanese world that captures the intense excitement and deep satisfaction people feel. happiness and to create Kando (touching heart )in their lives As a company that makes the world its field and offer product for the land . Ltd. 2008. Was founded in 1955 with Genichi kawakami as the first president. the snowfields and the sky .INTRODUTION Yamaha Motor Co. The corporation has 109 consolidated subsidiaries as on March 31st march.Takashi kajikawa is the current president of Yamaha Motor Corporation. When they experience truly of exceptional value. HISTORY OF YIC The history of Yamaha is a history of unending “challenges” . Yamaha Motor is the world second largest producer of motorcycle . Yamaha motor strives to be a company that “ offer New excitement and a more fulfillment life for people all over the world” and to use its ingenuity and passion to realize people ’dreams and always be the ones they look for “the next Kando”. Yamaha motor corporation stated aim is to bring people to great joy . Yamaha motor seeks to make Kando a distinctive benefit of everything we do by creating product and services that consistently exceed your expectations. the water . Outboard motors and personal watercraft .It also produces many other motorized vehicles such as all-terrain vehicle boats snowmobiles. Today. YEAR 1955 1959 Mile Stones Yamaha Motor Co. Ltd founded in Thailand 1965 First Yamaha FRP fishing boat "3rd Fuji Maru" built 1969 First Yamaha multipurpose engine model "MT100" released 1970 First Yamaha motorcycle mounting a 4-stroke engine "XS1" released 1973 First Yamaha portable generator model "ET1250" released First Yamaha racing kart model "RC100" released 1975 First Yamaha golf car model "YG292" released 1976 First Yamaha industrial robot model. First Yamaha outboard motor "P-7" released 1963 Nationwide Yamaha Kai (authorized dealership organization) launched Pearl Yamaha founded in India as tie-up with local funding & starts production and sales of mopeds 1964 Siam Yamaha Co. Ltd. joins Yamaha Motor group.. was founded with Genichi Kawakami as the first President Kitagawa Motor Co. 1960 Yamaha International Corporation (YIC) founded in U. an "arc welding robot" released First Yamaha marine diesel "MD35" released .S.. Ltd.. Ltd. S. Ltd. de C. (YMH) founded 1993 Regionally limited release of the electro-hybrid bicycle "PAS" Wheelchair electric power unit "JW-I" released.V. (YMAC) founded in Thailand .A. bringing Yamaha into 1995 the health and welfare industry Urban commuter motorcycle "Majesty YP250" released "Environment 2000 Plan" announced 1996 Yamaha is first domestic manufacturer to be awarded international ISO9002 certification for motorcycles.A. (YMMEX) founded Chongqing-Jianshe Yamaha Motorcycle Co. Founded PT.. (YMF) founded Yamaha Motor de Mexico.. Ltd.1978 First Yamaha land car model "G1-AD" released First Yamaha snow-thrower model "YT665" released 1986 First Yamaha personal watercraft (PWC) "MJ-500T" released 1987 First Yamaha-made surface mounter "21 Series" released First Yamaha gas heat pump (GHP) model "YGC401W" released 1991 Yamaha Motor France S. snowmobiles.. ATVs 1997 Y's Gear Co. Yamaha Motor Nuansa Indonesia (YMNI) founded 1999 2010 Environmental Action Plan "Eco Cite YAMAHA" announced 2000 Yamaha Motor Asian Center Co. (CJYM) founded in 1992 China Yamaha Motor Austria GmbH (YMAG) founded Yamaha Motor Hungaria Kft. (YDS) founded 2003 Yamaha Motor Co. Shizuoka. Japan 2002 Limited regional release of the electric commuter motorcycle "Passol" Yamaha Motor Distribution Singapore Pte.. Ltd.as research&development center for YMC's bio-technology business Motorcycle manufacturing factory Yamaha Motor Manufacturing West Java (YMMWJ) founded in Indonesia 2007 Compliance Promotion Committee established.. Ltd. Moscow Representative Office opened in Russia 2004 Start of "YAMAHA CCS 21 Campaign" Sales company Yamaha Motor CIS (YMCIS) founded in Russia 2005 Life Science Laboratory opened in Fukuroi.2001 Yamaha builds temporary pool "Suimu 21" for the main competition pool of the 9th World Swimming Championships in Fukuoka. 2006 . golf cars. pools. 2007) Sales (%) by product category (consolidated) Sales (%) by region (consolidated) Major Products & Services Headquarters Manufacture and sales of motorcycles. industrialuse remote control helicopters. 2500 Shingai.OVERVIEW Founded Capital President Employees (Consolidated) Sales (Consolidated) Sales Profile July 1.707 million yen (from January 1. small-sized snow throwers.302 million yen (as of March 31. 2007) Parent: 799. 2007) Parent: 9. processing and sales of agricultural and marine products and microorganisms. multi-purpose engines. helmets. 2007) 1. generators. electrical power units for wheelchairs. Japan . 2008) Takashi Kajikawa 46. diesel engines. 2007 to December 31.019 (as of December 31. 4-wheel ATVs. water pumps. Iwata-shi.756. Biotechnological production. 2007 to December 31. Water Vehicles.850 (as of December 31. sail boats. utility boats.209 million yen (from January 1. electrohybrid bicycles. Import and sales of various types of products. snowmobiles. Shizuoka-ken. outboard motors. 1955 48. fishing boats. intelligent machinery. boats. racing karts. automotive engines. side-by-side vehicles. scooters. Ltd. Shizuoka.. Yamaha Motor Co.300 (2007) Yamaha Motor Global . Japan 12 billion US$ (2005) 900 million US$ (2007) 550 million US$ (2007) 39.. Public Type Founded Headquarters Revenue Operating income Net income Employees Website Public July 1. Ltd.Affiliated Companies Consolidated subsidiaries: 112 Non-consolidated subsidiaries: 8 (by the equity method) Affiliates: 27 (by the equity method) Yamaha Motor Co. 1955 Iwata. IYM was incorporated in August 2001 as a 100% subsidiary of YMC. YMI`s Manufacturing facilities comprises of 2 state –of –the art plants at –Surajpur (Uttar Pradesh) . Since then it is in process of the business and extending the awe and power associated with the legacy of the Yamaha Group. The models manufactured and assembled at the Surajpur plant are.INDIA YAMAHA MOTOR (IYM) Holding the true sprit of commitment to customer satisfaction –India Yamaha motor is enriching lives of people with same ingenuity and enthusiasm as its parent company -Yamaha motor corporation Japan. 1. G5 3. Crux 4. Gladiator 2. Faridabad (Haryana) currently 10 models roll out at the two plants of Yamaha . Japan. Enticer 6. Having operated in India as technology provider for almost two decade. R-15 . Alba 5. Adhering to Yamaha Motor Corporation’s corporate Mission –“Creating Kando-Touching Your Heart” Yamaha motor India is striving to touch every heart across the length and breadth of India. All our endeavors give us reason to believe that sustainable development for Yamaha will not remain merely an idea in pipeline. . The stringent quality assurance norms ensure that the bikes meet the reputed International Standards of excellence in every sphere. As an Environmentally sensitive organization IYM has the concept of “Environmentally-Friendly Technology” ingrained in its Corporate Philosophy.The infrastructure at both plants support production of bikes and its parts for domestic as well as oversees market. a motivated forestation drive. The IYM is ISO-14001 certified. We believe in taking care of not only your motoring needs but also the needs of future generation to come. The company boasts of effluent Treatment Plant. At the core of 5-S and TPM activities that fuel the IYM `s agile manufacturing processes IYM has in house facility for Machining Welding processes as well as Finishing processes of Electroplating and Painting till the assembly line . Rain water Harvesting mechanism. we will conduct our business ethically and socially in a responsible manner with concerns for the environment. Our employees are the most valuable assets and we intend to develop them to achieve international level of professionalism with progressive career development. As a good corporate citizen. Build the Winning Team with capabilities for success. Our innovative solutions will always exceed the changing needs of our customers and provide value added vehicles. MISSION Yamaha is committed to: Be the Exclusive & Trusted Brand renowned for marketing and manufacturing of YAMAHA products.. thriving in a climate for action and delivering results. Grow through continuously innovating our business processes for creating value and knowledge across our customers thereby earning the loyalty of our partners & increasing our stakeholder value .VISION We will establish YAMAHA as the "exclusive & trusted brand" of customers by "creating Kando" (touching their hearts) . proactive design & innovative technology. focusing on serving our customer where we can build long term relationships by raising their lifestyle through performance excellence.the first time and every time with world class products & services delivered by people having "passion for customers". Rain water . We believe in taking care of not only Your Motoring Needs but also the needs of Future Generations to come. As an Environmentally sensitive organization we have the concept of "Environment-friendly technology" ingrained in our Corporate Philosophy.Harvesting mechanism. The infrastructure at both the plants supports production of motorcycles and it's parts for the domestic as well as oversees market.Faridabad (Haryana) and Surajpur (Uttar Pradesh). . We have In-house facility for Machining.MANUFACTURING IN YAMAHA IYM's Manufacturing facilities comprises of 2 state-of-the-art Plants at . At the core are the 5-S and TPM activities that fuel our agile Manufacturing Processes. a motivated forestation drive. The stringent Quality Assurance norms ensure that our motorcycles meet the reputed International standards of excellence in every sphere. The Company boasts of effluent Treatment plant. Currently 10 models roll out of the two Yamaha Plants. Welding processes as well as finishing processes of Electroplating and Painting till the assembly line. the cutter called a form cutter travels axially along the length of the gear tooth at the appropriate depth to produce the . The initial operations that produce a semifinishing part ready for gear machining as referred to as blanking operations. Two machining operations. Selection of materials The gear material should have the following properties: High tensile strength to prevent failure against static loads High endurance strength to withstand dynamic loads Low coefficient of friction Good manufacturability Gear manufacturing processes There are multiple ways in which gear blanks can be shaped through the cutting and finishing processes. shape and surface finish in the gear. the cutting edge of the cutting tool has a shape identical with the shape of the space between the gear teeth. Form milling In form milling. however. milling and broaching can be employed to form cut gear teeth. and blanking. extrusion. forging. powdermetallurgy. machining is applied to achieve the final dimensions. the starting product in gear machining is called a gear blank. Gear forming In gear form cutting. including casting. As a general rule. Gears can be manufactured by a variety of processes.Gear manufacturing Gear manufacturing refers to the making of gears. gear tooth. and lapping. There are several modifications of these processes for different cutting tool used. the surface finish and dimensional accuracy may not be accurate enough for certain applications. the cutter is withdrawn. However. and a number of abrasive operations. including grinding. All motions in hobbing are rotary.. Several finishing operations are available. including the conventional process of shaving.this method is suitable mainly for high-quantity production. Broaching Broaching can also be used to produce gear teeth and is particularly applicable to internal teeth. The process continues until all teeth are cut. The process is rapid and produces fine surface finish with high dimensional accuracy. and the hob and gear blank rotate continuously as in two gears meshing until all teeth are cut. honing. the tooth flanks are obtained as an outline of the subsequent positions of the cutter. because broaches are expensive and a separate broach is required for each size of gear. Gear hobbing Gear hobbing is a machining process in which gear teeth are progressively generated by a series of cuts with a helical cutting tool. There are two machining processes employed shaping and milling. the gear blank is rotated. . Finishing operations As produced by any of the process described. After each tooth is cut. Gear generation In gear generating. which resembles in shape the mating gear in the gear pair. and the cutter proceeds to cut another tooth.. MACHINE SHOP PRODUCTION The Following products are machined at the Machine Shop: Cam Shaft Crank Shaft Cylinder Head Body Cylinder Axle main Axle drive 5th gear wheel Pinion and PDN 3rd Gear wheel Crankcase . MACHINE SHOP PROCESSES The following are the processes which are used in Machine Shop: Turning Centering Facing Chamfering Spot Facing Surface Grinding Milling Face milling . Shaving Honing Drilling Boring Counter Boring Reaming Tapping Inspection Grading – Color coding Labelling Leak test . Dibbering Keyway Milling Quality check Inspection Maintenance . Ltd.CONCLUSION The period of my training at Yamaha Motor India Pvt. I am certain that the experience gained through this internship will be helpful to me throughout my professional career and in all my future endeavors. both technical and organizational. The experience at IYM has greatly advanced my understanding of the practical aspects of engineering. . has been a very positive one. I too had very little idea as to what an engineer’s job in a hightech industry entails. It has given me a very good understanding of the engineering profession which could not have been achieved by theoretical study. It has given me a solid foundation to build my career upon. The vital part that the organizational skills of an engineer play in today’s industry is an area that is often missed by some. But this internship at IYM made me see the maximum range of jobs performed by engineers. wikipedia. www.com www.yamaha.com .REFERENCES Machine Shop of IYM-faridabad plant.