YAMAHA TRAINING REPORT

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YAMAHA

TRAINING REPORT

(

Production Department)

Submitted To:

Submitted By

Mr.R.Miglani

Sumit

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Production Dept

B.Tech(ME)

IYM PVT LTD.

SIET

Gr.NOIDA

INDEX

S no. Description

Page

1. Certificate

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. Quality Engineering

15

12. Paint Shop

16-23

13. Project On Any

Abnormality in

Pretreatment Process

24-25

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14. Conclusion

26 CERTIFICATE

This is to certify that the project entitled “

Any Abnormality in

Pretreatment Process(Fuel Tank)” has been carried out by

SUMIT GAUR under my guidance in partial fulfillment of the

requirement of the case study during summer training. To the

best of my knowledge and belief this work has not been

submitted elsewhere for any purpose.

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Mr.

P.K

Arora

Mr R. Miglani

HEAD

Deptt.

Head & project leader

Paint Shop

(Q.E -

Division)

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. I have no doubt that

my choice of training at IYM was right. The exposure and

experience gained at IYM has been unique. The Yamaha

family teaches strict self discipline and goal oriented

approach.

I would like to thank my mentor at Yamaha

Mr.

R..Miglani, Mr. P.K Arora acquainted with the

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and every step so that I achieve my goal at Yamaha with

perfection.

Last but not the least I would like to thank Quality

Engineering department for their cooperative behavior.

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. It provides the

student with an opportunity to gain valuable experience on

practical application of their technical knowledge.

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At SIET College of Engineering, great emphasis is laid

on-the-job training an industrial training. This is an integral part of

curriculum.

This six week industrial summer training (15

th

_{June to 31}

st

_July,

2009), after six semester is in-built in to the B-Tech. program.

INTRODUTION

Yamaha Motor Co. Ltd. Was founded in 1955 with Genichi kawakami as the first president. Today, Yamaha Motor is the world second largest producer of motorcycle .It also produces many other motorized vehicles such as all-terrain vehicle boats snowmobiles, Outboard motors and personal watercraft .Takashi kajikawa is the current president of Yamaha Motor Corporation. The corporation has 109 consolidated subsidiaries as on March 31st_{march, 2008. Yamaha motor corporation}

stated aim is to bring people to great joy , 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 , the water , the snowfields and the sky , Yamaha motor strives to be a company that “ offer

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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”. Kando is the Japanese world that captures the intense excitement and deep satisfaction people feel .when they experience truly of exceptional value. Yamaha motor seeks to make Kando a distinctive benefit of everything we do by creating product and services that consistently exceed your expectations.

HISTORY OF YIC

The history of Yamaha is a history of unending “challenges”

YEAR Mile Stones

1955 _{Yamaha Motor Co., Ltd. was founded with Genichi Kawakami as the first}

President

1959 _{Kitagawa Motor Co., Ltd. joins Yamaha Motor group.} 1960 _{Yamaha International Corporation (YIC) founded in U.S.}

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 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

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1976 First Yamaha industrial robot model, an "arc welding robot" released

First Yamaha marine diesel "MD35" released

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.A. (YMF) founded

Yamaha Motor de Mexico, S.A. de C.V. (YMMEX) founded

1992

Chongqing-Jianshe Yamaha Motorcycle Co., Ltd. (CJYM) founded in China Yamaha Motor Austria GmbH (YMAG) founded

Yamaha Motor Hungaria Kft. (YMH) founded

1993 Regionally limited release of the electro-hybrid bicycle "PAS"

1995

Wheelchair electric power unit "JW-I" released, bringing Yamaha into the health and welfare industry

Urban commuter motorcycle "Majesty YP250" released

1996

"Environment 2000 Plan" announced

Yamaha is first domestic manufacturer to be awarded international ISO9002 certification for motorcycles, snowmobiles, ATVs

1997 Y's Gear Co., Ltd. Founded

PT. Yamaha Motor Nuansa Indonesia (YMNI) founded

1999 2010 Environmental Action Plan "Eco Cite YAMAHA" announced

2000 Yamaha Motor Asian Center Co., Ltd. (YMAC) founded in Thailand

2001 Yamaha builds temporary pool "Suimu 21" for the main competition pool of the

9th World Swimming Championships in Fukuoka, Japan

2002 Limited regional release of the electric commuter motorcycle "Passol"

2003 Yamaha Motor Distribution Singapore Pte. Ltd. (YDS) founded

Yamaha Motor Co., Ltd., Moscow Representative Office opened in Russia

2004 Start of "YAMAHA CCS 21 Campaign"

2005

Sales company Yamaha Motor CIS (YMCIS) founded in Russia

Life Science Laboratory opened in Fukuroi, Shizuoka,as research&development center for YMC's bio-technology business

2006 Motorcycle manufacturing factory Yamaha Motor Manufacturing West Java

(YMMWJ) founded in Indonesia

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OVERVIEW

Founded

July 1, 1955

Capital

48,302 million yen (as of March 31, 2008)

President

Takashi Kajikawa

Employees

(Consolidated)

46,850 (as of December 31, 2007)

Parent: 9,019 (as of December 31, 2007)

Sales

(Consolidated)

1,756,707 million yen

(from January 1, 2007 to December 31, 2007) Parent: 799,209 million yen

(from January 1, 2007 to December 31, 2007)

Sales Profile

Sales (%) by product category (consolidated) Sales (%) by region (consolidated)

Major

Products &

Services

Manufacture and sales of motorcycles, scooters, electro-hybrid bicycles, boats, sail boats, Water Vehicles, pools, utility boats, fishing boats, outboard motors, diesel engines, 4-wheel ATVs, side-by-side vehicles, racing karts, golf cars, multi-purpose engines, generators, water pumps, snowmobiles, small-sized snow throwers,

automotive engines, intelligent machinery, industrial-use remote control helicopters,

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Biotechnological production, processing and sales of agricultural and marine products and microorganisms. Import and sales of various types of products,

Headquarters

2500 Shingai, Iwata-shi, Shizuoka-ken, Japan

Affiliated

Companies

Consolidated subsidiaries: 112 Non-consolidated subsidiaries: 8 (by the equity method)

Affiliates: 27

(by the equity method)

Yamaha Motor Co., Ltd.

Public Type Public

Founded July 1, 1955

Headquarters Iwata, Shizuoka, Japan

Revenue 12 billion US$ (2005)

Operating income 900 million US$ (2007)

Net income 550 million US$ (2007)

Employees 39,300 (2007)

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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. Having operated in India as technology provider for almost two decade, IYM was incorporated in August 2001 as a 100% subsidiary of YMC, Japan. Since then it is in process of the business and extending the awe and power associated with the legacy of the Yamaha Group.

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.

YMI`s Manufacturing facilities comprises of 2 state –of –the art plants at –Surajpur (Uttar Pradesh) , Faridabad (Haryana) currently 10 models roll out at the two plants of Yamaha . The models manufactured and assembled at the Surajpur plant are;

1. Gladiator 2. G5

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3. Crux 4. Alba 5. Enticer 6. R-15

The infrastructure at both plants support production of bikes and its parts for domestic as well as oversees market. 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 .

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 company boasts of effluent Treatment Plant, Rain water Harvesting mechanism, a motivated forestation drive. The IYM is ISO-14001 certified. All our endeavors give us reason to believe that sustainable development for Yamaha will not remain merely an idea in pipeline.

We believe in taking care of not only your motoring needs but also the needs of future generation to come.

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VISION

We will establish YAMAHA as the "exclusive & trusted brand" of customers by "creating Kando" (touching their hearts) - the first time and every time with world class products & services delivered by people having "passion for customers".

MISSION

Yamaha is committed to:

Be the Exclusive & Trusted Brand renowned for marketing and manufacturing of YAMAHA products, focusing on serving our customer where we can build long term relationships by raising their lifestyle through performance excellence, proactive design & innovative technology. Our innovative solutions will always exceed the changing needs of our customers and provide value added vehicles.

Build the Winning Team with capabilities for success, thriving in a climate for action and delivering results. 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

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corporate citizen, we will conduct our business ethically and socially in a responsible manner with concerns for the environment.

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

MANUFACTURING IN YAMAHA

IYM's Manufacturing facilities comprises of 2 state-of-the-art Plants at - Faridabad (Haryana) and Surajpur (Uttar Pradesh). Currently 10 models roll out of the two Yamaha Plants.

The infrastructure at both the plants supports production of motorcycles and it's parts for the domestic as well as oversees market. At the core are the 5-S and TPM activities that fuel our agile Manufacturing Processes. We have In-house facility for Machining, Welding processes as well as finishing processes of Electroplating and Painting till the assembly line. The stringent Quality Assurance norms ensure that our motorcycles meet the reputed International standards of excellence in every sphere.

As an Environmentally sensitive organization we have the concept of "Environment-friendly technology" ingrained in our Corporate Philosophy. The Company boasts of effluent Treatment plant, Rain water - Harvesting mechanism, a motivated forestation drive. We

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believe in taking care of not only Your Motoring Needs but also the needs of Future Generations to come.

QUALITY ENGINEERING

HEAD OF DEPARTMENT –MR R.MIGLANI

The Quality Engineering Department works in very close co-ordination of all other as Quality is at the top priority at Yamaha Motor. At each step of production operation quality check is undertaken. If any defect is recorded represented properly with the help of Mean and Range charts and the cause of defect is analyzed in detail. Then the required steps are taken to ensure that the quality problem doesn’t occur. A very important measure of Quality is SPRI (Spare Part Rejection Index). It is the ratio of qualitatively good parts to the total number of produced parts. Quality plans are made and every endeavour aim to only one end: Getting the Quality right the first time.