Production

Department
Industrial Visit Report

Waheed Ali (IME-320)

National University of Sciences and Technology
NUST – PNEC
Industrial and Manufacturing Engineering
Semester VI
Vision
“Market leader in the motorcycle industry, emerging as a global competitive center
of production and exports.”

Mission
“A dynamic growth oriented company through market leadership, excellence in
quality and service and maximizing export, ensuring attractive returns to equity
holders, rewarding associates according to their ability and performance, fostering
a network of engineers and researchers ensuing unique contribution to the
development of the industry, customer satisfaction and protection of the
environment by producing emission friendly green products as a good corporate
citizen fulfilling its social responsibilities in all respects.”

INTRODUCTION:
Atlas Honda Limited is a Pakistani motorcycle manufacturer owned by Atlas Group and Honda
Motor Company and based in Karachi, Sindh, Pakistan since 1962. The company was created in
1988 after Panjdarya and Atlas Autos merged. AHL manufactures and markets Honda motorcycles
in collaboration with Honda Motor Company. The company also exports motorcycles to Sri Lanka,
Afghanistan and Bangladesh. Atlas Honda has Pakistan's largest in-house manufacturing capability
at its Karachi and Sheikhupura plants, which include an R&D wing and tool making facilities
through CAD/CAM. The annual assembly production capacity of AHL is 1.35 million units, with
150,000 units from the Karachi plant and 1.2 million units from the Sheikhupura plant.

The company comprises of two major manufacturing plants in Sheikhupura (SKP) and Karachi
(KHI). Atlas Honda limited manufactures seven models of two wheel motorcycles namely
 CD70
 CD70 Dream
 Pridor
 CG125
 Deluxe
 CB150F
 CB250F.
Shop Details:
The shops visited in the production department are as follows:
 Hub and panel
 Buffing Shop
 Frame Assembly
 Press Shop
 Die and tool room
 Welding Shop
 Paint Shop
 Engine Assembly
 Maintenance shop
Hub and Panel Assembly shop Assistant Manager: Mr. Shahnawaz

 Total workforce:
 AHL Associates 14
 JCW 58
 Management staff 11
 16 Parts assembled:
 Hub Front CD-70, Dream, Pridor, Deluxe
 Hub Rear CD-70, Dream, Pridor, Deluxe
 Panel Front CD-70, Dream, Pridor
 Panel Rear CD-70, Dream, Pridor, Deluxe
 Driven Flange CD-70, Pridor
 Equipment Used for Assembly:
 Hydraulic Press (for hub assembly)
 Pneumatic Press (for pinion fitting in Panel front)
 Torque Wrench with 10mm socket (for Panel assembly)
 Fix Spanner 10mm ( for Front and Rear Panels)
 Grease Pump (for Greasing in Panel Front)
 Grinding Machine (for Brake shoe grinding of Panels)
 Equipment Used for Inspection:
 Digital Vernier Calipers (0 ~ 200mm) For Brake Shoe Dia Inspection
 Dial Indicator For Run Out Testing
 Equipment Used for Brake Shoe Manufacturing and Inspection:
 Air less spray unit (for pasting Aral Diet 64-1)
 Air vice bonding machines (for bonding liner and brake shoe body)
 Bonding jigs and strips
 Shot blasting machine
 Drill machines (for reaming and drilling)
 Oven (for baking Brake shoe)
 Brake shoe curve inspection jig with dial indicator
 Temperature indicator (for baking brake shoe in oven)
 Operation steps:
 Drilling
 Brake shoe reaming
 Brake shoe blasting (12mins)
 Brake shoe pasting
 Cemdine (110), MEK thinner
 Bonding of brake shoe (995kgf shearing load)
 Brake shoe braking (250°C for 40mins in oven)
The Buffing shop Assistant Manager : Fida Muhammad

 Total workforce: 56 Including 11 management staff

 Parts processed:
 Panel rear and Hub rear ( Washing  Processing )
 Hub front and Panel front ( Processing  Washing )
 Pridor and Deluxe Parts ( Washing  Wire Brushing  Alloding )
 Chemical Used:
 MetaClean 2300
 MetaChrome
 Nitric Acid ( For brushing )
 Cunning Luster ( For buffing part shining )
 Washing of parts is done at temperatures between 55°C to 65°C.
 Types of Buffing:
 Jeans Buff
 Cotton Buff
 Wire Brush 10” ( For Hub rear )
 Wire Brush 6” ( For Panel rear )
 Buffed Hub:
 Jeans Buff
 Chemical washing
 Wire brushing
 Inspection and loading
 Panel Front:
 Cotton Buff
 Chemical washing
 Wire rinsing
 Inspection and loading
Frame Assembly Shop Assistant Manager: Mr. M Saeed

 Total workforce: 87 including 11 management staff

 Work is done in single general shift
 The Frame assembly comprises of three sections:
 The wheel assembly
 Frame assembly mainline
 Quality control
 The wheel assembly:
 Spoke filling in hub (Front and Rear)
 Spoke net making with hub in rims (Front and Rear)
 Spoke tightening on machine (Front and Rear)
 Rim alignment manually (Front and Rear)
 Tyre mounting on rim (Front and Rear)
 Air filling in tube (Front and Rear)
 The Main line
 Frame Body and Chain Sprocket
 Swing arm and breather pipe
 Ignition coil and Rear cushion
 Battery band and Chain Case
 Wiring of tail light and Winker and CDI
 Front fork and Steering Handel lock
 Speedometer and Top bridge
 Front Brake cable and Sleeve Nut
 Fuel tank and Seat
 Headlight and L. cover
 Gear change pedal and Front axle
 Cap fuel tank and Load off conveyor
 Rear cushion and Regulator
 Bolt torque link and Brake rod with rear panel
 Spring brake pedal and ACG wiring
 Top bridge and Carburator
 Rear wheel and Brake rod
 Steering handle and Carburator slid
 Front winker and Speedometer wiring
 Left stop switch wiring
 Front stop switch wiring
 Kick starter and Front wheel
 Tightening of muffler and Front wheel
 Clutch cable and Emblum product
 Assembly of left and right side cover
PRESS SHOP Assistant Manager: Raamis Khan
 Number of workers:
 Management staff 17+2
 AHL Workers 8
 Contract Workers 83
 Temporary Workers 12
 Produces for both Karachi and SKP plant.
 Parts made:
 Frame body
 Fuel Tank
 Clutch
 Children parts
 Equipment:
 Mechanical Presses: 200 tonsx2, 150 tons, 80 tons, 70 tons, 50 tons, 45 tons, 15 tons.
 Hydraulic Presses: 400 tons (advanced numeric control), 400 tons, 300 tons
 Shearing Machines
 Maximum capacity-400 tons
 Minimum capacity-15 tons
 Processes involved:
 Shearing
 Grinding
 Blanking
 Trimming
 Piercing
 Bending
 Levelling
 Deburring
 Drawing
 Notching
 Embossing
 Material Used:
 Mild steel sheets.
 Maximum thickness-2.3 mm
 Minimum thickness-0.8 mm
 Mainly used-2.0 mm
 Defects:
 Scratches
 Dents
 Burrs
 Tears
 Wrinkles
DIE AND TOOL SHOP Assistant Manager: Mr. Shahmim

 Number of workers: 14
 Equipment:
 Hardening Furnace
 Hardness Tester
 Drill Machine
 Lathe
 Power Saw
 Two-head Grinder
 Overhead Crane
 Universal Milling Machine
 Shaper Machine
 Surface Grinding Machine
 Filler rods for TIG welding; T-600, HS-5
 Tool Cutter
 Milling Machine
 Tool and Die shop carries out two types of maintenance:
 Corrective
 Preventive (69 jigs, 86 dies)
 Preventive maintenance is scheduled weekly, monthly, quarterly, semi-annually, or annually.
 Types of Dies:
 Blank die
 Bending die
 Embossing die
 Draw die
 Trim die
 Piercing die
 Notching die
WELDING SHOP Assistant Manager: Mr. Ahmed Masood

 Number of workers: 70 including 11 management staff

 Parts Welded:
 Fuel Tank
 Frame Body
 Fender
 Processes:
 Bottom Sub Assembly
 Bottom Tacking
 Seam Welding
 Robotic welding
 Bead grinding
 Paper grinding
 Ripple Arc welding
 Reworking
 Leak Testing
 Deburring Press
 Side covers
 Final Inspection
 Riveting
 Brazing
 Edge Grinding
 Rear Patch
 Final Buffing
 Welding Defects:
 Pin holes
 Blow holes
 Incorrect welding
PAINT SHOP Assistant Manager: Mr. Usama Zakir

 Number of workers: 107 including 30 management staff

 Paint shop operates in three shifts
 Pre-Treatment Processes:
 Degreasing ( Meta Clean, 60-80°C, 15-20mins )
 Rinsing (0.5mins Tap Water)
 Phosphating (Metaphos 440, 60-70°C, 5-7mins)
 Rinsing (0.5mins Tap Water TDS 550ppm)
 R.O. Water (100ppm TDS , 0.5mins )
 Drying Oven (10mins, 120-140°C )
 Main line processes (For metal parts):
 Loading
 Masking
 Cleaning
 Air Wiping
 Spraying
 Baking
 Unloading
 Inspection
 Stripe Pasting:
 Sanding
 Inspection
 Pasting
 Inspection
 Testing of painted parts:
 Thickness test
 Cross hatch test
 Bend test
 Impact test
 Gasoline test
 Water resistance test
 Hardness test
 Defects:
 Paint overflow
 Pinholes
 Dust
 Dent
 Scratch
 Grinding mark
 Die mark (vender’s fault)
Engine Assembly Shop Assistant Manager: Mr. Nazar Hussain

 Total workforce: 34 including 2 in charges

 Work is done in single general shift
 Process flow for engine assembly main line:
 Crank case Left, Transmission, Kick Starter Spindle and crank shaft piston Assembly
 Crank case right and clamper over flow pipe Assembly
 Assembly of sprocket drive 12T
 Spindle assembly kick starter and retainer kick spring Assembly
 Assembly of plate shift drum stopper, gear primary driven and clutch assembly
 Assembly of nut lock 14mm and cover clutch outer
 Assembly of right crank case cover
 Assembly of cylinder and cam chain
 Assembly of cylinder head and cylinder head cover
 Assembly of sprocket cam and tensioner push rod
 Assembly of ACG
 Assembly of hole cap tappet adjusting
 Assembly of cover left, cylinder head side and contact neutral switch
 Leak testing and oil filling
 Engine is assembled with vendor, in house and imported parts issued from CKD store
 Engine assembly line’s cycle time is kept in line with the frame assembly line which is 52 sec
per CD70 motorcycle.
Maintenance Shop Assistant Manager: Mr. M Khan

 Total workforce: 58
 Management staff 23
 Non-management staff 11
 Job Contract 24
 The job of plant maintenance can be divided into following distinct areas:
 Corrective/Breakdown maintenance
 Preventive maintenance
 Spare parts records
 Civil work (special projects)
 Miscellaneous electrical/electronic design and fabrication work
 PM and CM of household appliances
 Modification and extension of plant as per present and future needs
 Record keeping and monitoring of utility bills (Gas, Electric, Water)
 To carry out risk and opportunities based assessment of maintenance department
 Power Service Unit (PSU):
 Maintenance and operation of generator and fork lifters
 Feeding work request and preventive system on daily basis
 Generate the reports on daily and monthly basis
 Control the work order system
 Inventory control of plant service parts
 Mechanical Repair Unit (MRU):
 Control of manufacturing equipment
 Breakdown and preventive maintenance of mechanical system
 Fabrication of material handling equipment
 Breakdown and corrective maintenance of hydraulic and pneumatic system
 Arrange machines parts on emergency basis from local sources
 Responsible to W/R feeding of MRU/FAU on daily basis, make charts/documents on
computer as per department requirements
 Electric Repair Unit (ERU):
 Break down and preventive maintenance of electrical system of production/non-production
machines
 Maintenance of power distribution system
 Control of HT and LT sub-station and power generation
 Maintenance of all light fitting and fans
 Record keeping of utility bills like K Electric, Sui gas and water
 Improvement Suggestions
 Buffing Shop:
 The buffing stations can be added with a transparent screen before the buffing wheel to
avoid small particles being inhaled by the workers

 Hub and Panel:

 The temperature of the blasting area is high so the ventilation system may be revised for
fresh air supply

 Press Shop:
 All large mechanical and hydraulic presses, which are already installed with sensors for
protection, may be given a regular update on semiannual basis to benefit from the
advancing technologies.

 Welding Shop:
 The water flow system must also be installed in the frame body section of the shop
especially where wire brushing is done.

 Maintenance Shop:
 Localized exhaust may be installed in the mechanical repair section to remove welding
fumes
 Conclusion

This Visit was a useful experience. I have gained new knowledge, skills and met many new
people. I got insight into professional practice. I achieved several of my learning goals, however
for some the conditions did not permit.

Lastly, I would thank Atlas Honda Limited and the Production department for providing an
opportunity to get aware of the practical industrial environment through this industrial Visit.