INTERNSHIP REPORT

Manufacturing Department

Submitted To:
AM Sir Abu-Bakker

Abstract
“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.”

Bilal Hassan
Bh2016886@gmail.com/+923402016886
 1. The Company:
Atlas Honda Limited is a public listed company which was incorporated on October 16, 1962. It
is a joint collaboration between Honda Motor Company Limited Japan, the largest and most
reputed motorcycle brand in the world, and Atlas Group, one of Pakistan’s most renowned
business conglomerates. The Company is principally engaged in progressive manufacturing and
marketing of motorcycles and spare parts.

Atlas Honda Limited is the largest motorcycle manufacturer in Pakistan with the strongest brand
value and highest customer loyalty. The Company is considered a pioneer of motorcycle industry
in the country and has been leading two wheeler market successfully for over 50 years.

The Company currently has a production capacity of over 1.35 million units per annum and
continues to maintain its status as market leader both in terms of volume and quality. It also
exports its motorcycles and spare parts to Bangladesh and Afghanistan.

With highest quality products, state of the art manufacturing facilities, largest dealership network
& impeccable after sales service, Atlas Honda Limited is today considered a benchmark for two
wheeler manufacturing. It has been proudly and successfully fulfilling its role as the flag bearer
of motorcycle industry in Pakistan.

As one of the largest tax payers in the private sector and being one of the best employers in the
country, Atlas Honda Limited stands as a beacon of light for the corporate, social and intellectual
sectors of Pakistan.

Further information about the Company is as follows:

2. Establishments
Registered Office:

1-Mc Leod Road, Lahore-54000

1. Manufacturing Facilities:

a. Sheikhupura plant
26-27 KM, Lahore-Sheikhupura Road, Sheikhupura-39321
This plant is the country’s largest in-house manufacturing facility for motorcycles and
related spare parts. It’s a modern state of the art factory that is involved in manufacturing
of all the models of the Company. Its spread over 27 acres.
 b. Karachi plant
F-36, Estate Avenue, S.I.T.E., Karachi-75730
This is the mother plant of the Company. Atlas Honda Limited started its operations
from here back in 1963. It is spread over 5 acres and is used for manufacturing CD70
(one of Company’s most famous models). It also operates as Company’s Head Office.
Branch Offices:
a. 1st Floor, 28-Mozang Road, Lahore
b. Islamabad Corporate Center, Plot No. 784/785, Golra Road, Islamabad
c. 1st Floor, Meezan Executive Tower, 4-Liaquat Road, Faisalabad
d. Azmat Wasti Road, Multan
e. 2nd Floor, Dawood Centre, Autobhan Road, Hyderabad.
f. Makhdoom Altaf Road, West Sadiq Canal Bank, Near City School,
Rahimyar Khan Showroom:

West View Building, Preedy Street, Saddar, Karachi

Warranty & Training Centres:

a. 1st Floor, 28-Mozang Road, Lahore

b. Azmat Wasti Road, Multan

2. Financial

Authorized Share Capital:

Rs. 1,500,000 thousand (150,000,000 shares) Paid

Up Capital:

Rs. 1,240,879 thousand (124,087,935 shares)

Stock Exchange Listings: Pakistan Stock Exchange

Stock Exchange Symbol: ATLH

3. General

Company Registration Number: CUIN 0001569

National Tax Number (NTN): 0801063-3

Sales Tax Number: 02-06-8711-001-37

Auditors: Shinewing Hameed Chaudhri & Co. Chartered Accountants

Legal Advisors:
a. Mohsin Tayebaly & Co.
Tax Advisor:

Ernst & Young Ford Rhodes Sidat Hyder, Chartered Accountants Shares

Registrar:

Hameed Majeed Associates (Pvt.) Limited

H. M. House, 7-Bank Square, Shahrah-e-Quaid-e-Azam, Lahore

Bankers:
a. Allied Bank Limited
b. Askari Bank Limited
c. Bank Al-Habib Limited
d. Bank Alfalah Limited
e. Faysal Bank Limited
f. Habib Bank Limited
g. Habib Metropolitan Bank Limited
h. Khushali Bank Limited
i. MCB Bank Limited
j. Meezan Bank Limited
k. National Bank of Pakistan
l. Standard Chartered Bank (Pakistan) Limited
m. United Bank Limited
Memberships of Major Associations:
a. Pakistan Automotive Manufacturers Association (PAMA)
b. Pakistan Business Council
c. Federation of Pakistan’s Chambers of Commerce and Industry
d. Chambers of Commerce and Industry of:
a. Karachi
b. Lahore
c. Sheikhupura
d. Overseas Investors
 e. Management Association of Pakistan
f. Marketing Association of Pakistan

3. CEO’s Message
Dear Stakeholders,

4. It is my esteemed pleasure to welcome you all on our Company’s website.

Corporate social responsibility remains the guiding principle in all areas of activity. With the
largest manufacturing facilities of motorcycle industry in the country, the Company also has the
most modern systems and processes in place that are reviewed periodically to keep them abreast
with changing needs and requirements of modern day manufacturing. We strive to maintain
highest standards of quality and excellence in all our processes. This dedication to perfection
enables us to manufacture products that are constantly rated as the best in the country, resulting
in maximum customer satisfaction and highest brand equity. All products and production facilities
are environment friendly. Environment is sacred for Atlas Honda. We feel that it is our duty to
protect the environment for future generations.

Additionally, the Company is also helping the Government exchequer by being among the highest
tax payers in the country. It is the pursuit of excellence in all areas of business that defines us.
The compensation / benefit packages and the working environment are among the very best in
the industry. With a consistent payout to shareholders, the Company has been outperforming the
KSE 100 index on stock exchange for several years.

The Company’s real competitive advantage comes from its associates who are technically skilled
and professionally committed. They are the real strength of our manufacturing and marketing
powers. These talented individuals have managed to nurture a unique element we are most proud
of – the culture of Atlas Honda. The work ethics & business practices of the Company have their
roots in more than 50 years of responsibility and dedication. High ideals have been pursued by
the Company at good times as well as through tough times. It is this consistency that has made
Atlas Honda a market leader.

We take great pride in our long term partnership with Honda Motor Company Limited Japan and
would like to acknowledge their continued support and cooperation in maintaining high standards
of excellence. I take this opportunity to thank our valued customers for their trust, the
management team for their sincere efforts and Board of Directors for their guidance. I would also
like to acknowledge the contributions of all stakeholders – Bankers, Dealers, Vendors, Associates
and Shareholders for helping build Atlas Honda Limited into a unique Company.

4. Strategic Goals
Customers

Our Customers are the reason and the source of our business. It is our joint aim with our dealers
to ensure that the customers enjoy the highest level of satisfaction from use of Honda motorcycles.

Quality

To ensure that our products and services meet the set standards of excellence.

Local Manufacturing

To be the industry leader in indigenization of motorcycle parts.

Technology

To develop and maintain distinct business advantages through continuous induction of improved
hard and soft technologies.

Shareholders

To ensure health and viability of business and thus safeguarding shareholders’ interest by
maximizing profit. Payment of regular satisfactory dividends and adding value to the shares.

Employees

To enhance and continuously update each member’s capabilities and education and to provide an
environment which encourages practical expression of the individual potential in goal directed
team efforts and compensate them attractively according to their abilities and performance.

Corporate Citizen

To comply with all Government laws, rules and regulations and to maintain a high standard of
ethics in all operations and to act as a responsible member of the society.
 5. Quality Policy

• Commitment to provide high quality motorcycles & parts.

• Right work in first attempt and on time.
• Maintain and continuously improve quality.
• Training of manpower and acquisition of latest technology.
• Safe, clean and healthy environment.
• Market leadership and prosperity for all.

5. Atlas Group of Companies:

Atlas Group of Companies consists of 14 companies. The first ever of them was Shirazi
Investments (Pvt.) Ltd. After the success of which the group continued to grow. At present more
than 2% of the country’s GDP is the contribution of Atlas Group only. The names of the
companies and their years of foundation are shown in the following table:

Name of the Company Year of Foundation

Shirazi Investments (Private) Ltd. 1962
Atlas Honda Ltd. 1963
Atlas Battery Ltd. 1966
Shirazi Trading (Private) Ltd. 1975
Atlas Insurance Ltd. 1980
Atlas Engineering Ltd. 1981
Honda Atlas Cars (Pakistan) Ltd. 1992
Honda Atlas Power Products (Private) Ltd. 1997
Atlas Asset Management Ltd. 2002
Shirazi Capital (Private) Ltd. 2005
Atlas Power Ltd. 2007
Atlas Worldwide General Trading LLC 2007
Atlas Venture 2008
Atlas Autos (Private) Ltd. 2011
Table 01: Atlas Group Growth

Today Atlas is a diversified group dealing in engineering, financial services, power and
trading. It consists of seven public limited companies out of which five are quoted on the
Stock Exchanges in Pakistan, and six private limited companies.
Atlas shareholder’s equity now stands over 25 billion rupees; assets have increased to over
60 billion rupees the last being Atlas Power with over 20 billion rupees; personnel strength
is over 7000 and annual sales have crossed 60 billion rupees. The Group strategic direction
is determined by the Group Executive Committee while each company functions
autonomously within the framework of the predetermined policy.

6. Atlas Honda Private Limited:

Atlas Honda is one of the most prestigious and well established companies of Pakistan. It is
a joint venture of Atlas Group and Honda Japan. The company was founded by Mr. Yusuf
Shirazi in 1963 at Panjdariya. The Atlas Honda Limited is a joint venture between the Atlas
Group of Pakistan and Honda Motor Company of Japan. The Atlas Honda was created in
1988 by the merger of Panjdarya Limited and Atlas Autos Limited.

Both these motorcycle manufacturing concerns were established by the Atlas Group. Atlas
Honda manufactures and markets Honda motorcycles in collaboration with Honda Motor
Company. Atlas Honda also manufactures various hi-tech components in-house in
collaboration with leading parts manufacturers like Showa Atsumitech, Nippon Denso and
Toyo Denso. Atlas Honda Plants are located in Karachi, and Shiekhupura. Honda Atlas
assembles four motorcycles in Pakistan, the CD70, Pridor, CG 125 and CG 125 Deluxe.

Atlas Honda Karachi:

Company mother plant is based in the city of lights and provincial capital of Sindh, The
Karachi city. It is located at F-36, Estate Avenue, and S.I.T.E. Karachi. Atlas Group signed
technical agreement with Honda in 1963 and plant started commercial production
subsequently. Plant spread over an area of 5 acres. In 1964, production began with 7
motorcycles per day. Now plant production has reached to 300 units in a day. Plant
manufactures CD 70 only.

Atlas Honda Shiekhupura:

Another plant is situated in Shiekhupura city, Punjab. It is located at 26-27 KM Lahore-
Shiekhupura Road Shiekhupura. The plant was built in 1981 and spread over an area of 27 acres
with the establishment of modern and synchronized 500K plant in 2006. The plant manufactures
all four models i.e. CD 70, Pridor, CG 125 and CG 125 Deluxe.
Honda motorcycles are by far the LARGEST selling motorcycles in the country with an
unmatched reputation for high quality, reliability and after-sales-service.
AHL has undertaken to develop
local manufacturing capabilities to
the highest, economically feasible
level. While a major role in localization has
been assigned to vendor industries, Atlas has
the country’s largest inhouse manufacturing
capability at its Karachi and Sheikhupura
plants. To support the
production facilities, the company has
established an R&D wing and tool making
facilities through CAD/CAM which are
growing rapidly in size and function as the
company expands. Atlas has managed to
execute 12 Joint Venture/Technical
Assistance Agreements between local
vendors and foreign manufacturers for transfer
of technology. Besides, Atlas has directly executed
9 Joint Venture/Technical Assistance Agreements
other than Honda.
AHL management is striving to modernize company operations by adapting applicable aspects of
research and theory and more specifically, Honda’s unique philosophy of hard/soft technologies
to the realities of Pakistani conditions. The Company training and development programs
encourage all members to develop themselves and contribute to their full potential. AHL is
playing a pioneering role in creating conditions for easy and confident use of motorcycles all over
the country. A vast and growing network of over 1600 sales service and spare parts dealers has
been established. In order to back up this system, Atlas has set up Warranty & Training Centers
(WTC) in Karachi and Lahore which provide several courses of varying duration and complexity
for motorcycle mechanics and users each year. Mobile training facilities take the latest know-
how, technology and maintenance of motorcycles to major rural and urban centers around the
country.

Quality Policy:
The Quality policy of Atlas Honda is shown in the diagram:

Commitment to provide high quality motorcycles &

parts

Maintain and continuously improve

quality

Right work in first attempt and on

time

Safe, clean and healthy

environment

Training of manpower and acquisition of latest

technology

Market leadership and prosperity for

all

Atlas Culture:
Atlas culture is built on the heritage and accomplishments and promotes equality and
harmony amongst the workers of the company. Atlas Culture is the most important factor
that distinguishes it from other companies. This culture creates a unique personality growth
of each of its employee. The basic points of Atlas Culture are summarized in the diagram:
 Integrity and
merit Education Self-assurance
of oneself

Do not become
a burden on Avoid being Live
Atlas or Society Overbearing Economically

Do Charity
Be Happy, Be Happy, Wealthy
Healthy & Do Charity Healthy &
Wealthy

Charity
Be Happy,
Healthy &
Wealthy

Products:
• Honda CD 70
• Honda CD Dream 70

• Honda Pridor
• Honda CG125

• Honda CG125 Self

• Honda CB125F
• Honda CB150F
1) Human Resources/ CA/ Admin:
HR department is responsible for the recruitment of new staff and appraisal and training
of the existing staff. The HR department is working separately for Karachi and Sheikhupura
but the policy is being made in Islamabad. The administration is responsible for managing
the major functions of the organization that include from Security to transport and dining
facility of the staff. The HR of Atlas has made various worker friendly rules that are
facilitating their employers. These rules even include the issuance of a motorcycle to grade
13 and above on easy installments. Atlas is also running many social and welfare
organizations that include a hospital and school as well.

2) Admin and IR:

Admin department of Atlas is responsible for making several policies regarding the
growth of the organization and security as well. The motive of Atlas is to provide customers
with quality products and give a reasonable profit to the shareholder as well. IR and Admin
jointly are responsible for successful and smooth running of the organization.

3) Corporate Affairs:
Corporate affairs department is the major backbone of any organization. In Atlas Honda, the
corporate affairs department is responsible for interlinking all the other departments with one and
other. The department plays an important role in the promotion of concurrent engineering.
4) Finance:
The finance department is responsible for carrying all the work related to accounts and
money. Finance department gives the salaries to the employers and manages the money
received from the dealers after selling them the bikes and money given to the vendors.

5) Logistics
Logistics is the management of the flow of resources between the point of origin and the
point of consumption in order to meet some requirements, for example, of customers or
corporations.

6) Vendor Procurement:
 The vendor procurement department makes arrangements of the vendors. It allows the
vendors to makes bids by offering them the quotation. The vendor with the lowest bid wins.
7) Maintenance:
The maintenance department performs all the maintenance works whether it is about
maintaining the machines or maintaining the plant. The production of the electricity in the
gas and diesel plant also comes under the maintenance department.

8) PPC:
PPC involves all the production plan according to market demand. The production plan
for the entire month is given to the shops at the start of that month. PPC involves the analysis
of the market which determines how much the production of the bikes should be as per
demand.

9) Information Technology (IT):

The IT department is responsible for maintaining all the computer data of the company.
It is performing a lot of works from managing the computers, installing the software and
managing the LAN in the plant and its head offices.

10) Stores:
The store is the department which is situated in front of the security gate of the Atlas
Honda plant. Store is one of the most important department for manufacturing, HPDC &
LPDC, casting and vendors. All the products that are made in a department are stored in the
store before being passed to the other department. For example, all the castings are moved
to the store before being machined in the Hi-tech plant.

11) Quality Assurance:

The quality assurance department is playing an important role in providing the customers
high quality motor bikes. Honda has maintained this tradition for quite a long time now and
that is the reason why they are the major shareholders of the motorbike industry in Pakistan.

12) Assembly Plant:

 Assembly plant is the final department from which the bike passes. All the parts of the
motorbike are collected in the assembly plant and are assembled properly. The bike is
checked before it is sent to the store and to the dealer.

13) Casting Plant:

In casting plant many of the parts are manufactured which are then used as parts in the
motorcycle. The parts that are casted include the crankcase, crank cover, crank shaft and
cylinder head. The casing plant is divided into two parts i.e.

• HPDC

• LPDC

14) Engine Plant:

The engine plant (also called as the Hi-tech) is one of the biggest department and is still
being expanded due to high production rate. The engine plant collects all the parts of the
engine in the raw form which are then machined to form the finished products. The products
are checked for high accuracies and the parts which are up to the mark are sent to the
assembly plant.

15) Manufacturing Plant:

The manufacturing plant includes the paint shop and the shop that makes the body of the
bike. The sheets are brought here and are punched and stamped to form the body of the bike.
The parts include the side covers of the bike. The sheets are then painted in the paint shop
to give the unique look to the bike and stickered to make it more beautiful.
The HR department assigned us the manufacturing plant for our major internship project.
This plant is mainly based on two shops.
 MANUFACTURING
PLANT

FUEL TANK PAINT

SHOP SHOP

Fuel tank shop:

Welding of fuel tank is done in this shop.

Fuel tank welding process:

There are some main processes to make a fuel tank. One by one process performed on it (line
production).

There are three production line in the fuel tank shop.

LINE NO.01 CD 125 PROCESS:

Panel
Ripple Botto Leak
Panel Emble Paper Paper botto Punch Mig Edge
Rough Press Arc m Seam Rear Brazin Final Dead test
check m grindi grindi Brush Table m Table machi weldi grindi
buff 50T weldi assem 2 patch g buff plug machi
ed spot ng 1 ng 2 tracki ne ng ng
ng bling ne
ng
 The fuel tank ready for painting process.

LINE NO.02 Multi fuel tank(CD 100, 125,

150):
First of all, Robot is install for achieving
the specific target. The other manual
process mentioned below.

Panel checked

Emblem spot

Paper grinding 1

Paper grinding 2

Rough buff

Press 50T

Ripple Arc welding

Brush

Bottom assembling

Table

Panel bottom tracking

Table

Seam 2

Rear patch
Punch machine

Brazing

Mig welding

Edge grinding

Final buff

Dead plug

Leak test machine

 Final inspection
LINE NO.03 CD 70 PROCESS:

First, Robot is installed for achieving the

specific target. The other manual
process mentioned below

 Panel checked
 Emblem spot
 Bead grinding
 Paper grinding 1
 Paper grinding 2
 Rough buff
 Press 50T
 Ripple Arc welding
 Brush
 Bottom assembling
 Table
 Panel bottom tracking
 Table
 Seam 2
 Rear patch
 Punch machine
 Brazing
 Mig welding
 Edge grinding
 Final buff
 Dead plug
 Leak test machine
 Final inspection
The fuel tank ready for painting process.
The main processes of welding line are described below.

1) Inspection
The fuel tank body is inspected for scratches and faults this is done visually.
 6. 2) Spot welding

The emblem spot is created by spot welding and some bottom parts are attached via it.

What is spot welding?

Spot welding (also known as resistance spot welding) is a resistance welding process. This
welding process is used primarily for welding two or more metal sheets together by applying
pressure and heat from an electric current to the weld area.
It works by contacting copper alloy electrodes to the sheet surfaces, whereby pressure and electric
current are applied, and heat is generated by the passage of current through resistive materials
such as low carbon steels.
Advantages of spot welding
• In this type of welding the base metal does not undergo to large heat affected area.
• This type of welding is a easy process.
• Spot welding has a high production rate.
• Spot welding can be applied to different metals to join.
• Spot welding is a low-cost process.
• There is a possible to weld multiple metals at a time.
• It can be operated through automatic and manual type.
• Thin metals can be welded more efficiently.
• It does not require more skilled persons at operation Disadvantages of spot welding
• Only thin metals can be welded accurately and efficiently.
• Installment cost is more.
• This type of welding gets deformed.
• Changes in power supply leads to weak welding.
1. 3) Burring
In this process a hole is created in the fuel tank from which fuel is entered into the motorcycle.
2. 4) Deburring
Finishing is done in the hole created by burring.

What is Deburring?
Deburring is the process of removing the small imperfections known as burrs from machined
metal products. Machining processes shape a piece of metal in different ways. Stamping, for
instance, presses the work piece in a die set, while milling uses a rotating tool to shave metal off
a work piece.
Processes like these don't always work perfectly, though — they may leave small ridges or
protrusions of metal known as burrs. Burrs compromise the quality of the finished part if they are
not removed. After machining or welding, deburring removes these imperfections to provide a
smooth, reliable metal part.
3. 5) MIG Welding
Metal Inert Gas (MIG) welding is an arc welding process that uses a continuous solid wire
electrode heated and fed into the weld pool from a welding gun. The two base materials are
melted together forming a join. The gun feeds a shielding gas alongside the electrode helping
protect the weld pool from airborne contaminants.
Advantages of MIG welding
• Higher Productivity
Many welders will enjoy higher productivity due to time saved by not having to constantly
change rods or chip away slag, as well as not having to brush the weld repeatedly. They’re
able to work faster and cleaner.
• Simple to Learn
One of the top advantages of MIG welding is its simplicity. Welders can learn how to MIG
weld in a few hours, and some instructors claim they can provide basic training in twenty
minutes—with the majority of the time being spent on cleaning the weld.
• TIG welding takes a long time to learn, and most welders working on home projects won’t
want to invest the time into it. One instructor described MIG welding as a “point and shoot”
process.
• Simple and Great Welds
MIG provides better weld pool visibility. Add this to the simplicity of the process and better
control offered by the auto-feed wire, and MIG makes it simple to produce a great looking
weld.
• Clean and Efficient
Since MIG uses a shielding gas to protect the arc, there is very little loss of alloying elements
as the metal transfers across the arc. There is no slag to remove, which is typical for stick
welding, and only minor weld spatter is produced. After a brief clean up, MIG welders will
be back on the job in a fraction of the time thanks to the minimal clean-up it requires.
• Versatile
MIG welding is extremely versatile and can weld a wide variety of metals and alloys, while
operating at a variety of ways, such as semi and fully automatic. While MIG welding is
useful for many home welding projects, it is also used by a large number of industries. MIG
 is used for the following metals: aluminum, copper, stainless steel, mild steel, magnesium,
nickel, and many of their alloys, as well as iron and most of its alloys.
• Faster Welding Speed
The continuously fed wire keeps both hands free for MIG welding, which improves the
welding speed, quality of the weld, and overall control.

Disadvantages of MIG welding

• Cost
Welders will notice right away that MIG welding equipment is more complex and costly,
while also sacrificing portability. In addition, shielding gas, electrodes, and replacement tips
and nozzles for MIG welding can add up.
• Limited Positions
The fluidity of the welding puddle and the high heat input of a MIG welder rules it out for
vertical or overhead welding. While some welders would never even think of welding in one
of these positions, take this factor into consideration when deciding whether or not to purchase
a MIG welder to make sure it can accomplish all of the jobs planned for it.
• Unsuitable for Outdoor Welding
Besides not being portable, MIG welders are also unsuitable for working outside since they
use a shielding gas to protect the purity of the weld. Wind will play havoc with the shielding
gas and impact the quality of the weld. A MIG welder also can’t be hauled out into a field to
repair a tractor, but works great in the garage for automotive work.
• Fast Cooling Rates
The welded metal will cool at rates that are higher since they aren’t covered by slag when the
weld is completed.
• Unsuitable for Thick Metals
While MIG welding is suitable for thin metals, it does not deliver proper penetration for thicker
steel that requires a solid weld.
• Shielding Gas
The bottle of shielding gas can take time to replace and can get in the way while welding.
• Metal Preparation Time
Before welding with a MIG welder, the material has to be free of rust or dirt in order to get a
good weld and for safety’s sake. 6) Seam welding
This is done on the sides of the fuel tank and top.
What is Seam welding?
Resistance seam welding is a variant of the basic resistance spot welding process. In spot
welding a weld nugget is produced by passing an electric current through the sheet materials
to be welded while they are held together under a mechanical force between shaped copper
electrodes in a lap configuration.
 Fusion is produced where the sheet surfaces are in contact because this is the point of highest
electrical resistance and hence the point where the temperature is highest. In seam welding a
series of overlapping nuggets is produced, usually by replacing the conventional spot-welding
electrodes by wheels that turn as the parts to be welded are fed between them. The process
thus produces a continuous leak tight seam.

Advantages of Seam welding

• Little Instances of Overlapping
If you are concerned about overlapping of the weld, seam welding might be your ideal
technique. It produces less overlap than projection and spot welding. Overlap produced during
seam welding rarely exceeds 10mm.
• Easy to Operate
This process is quite easy and requires basic operation skills. Compared to spot and plasma
arc welding processes, the welder can do it without any complications. Because of its
simplicity, seam welding helps achieve high production rates. It’s reliable and offers very few
challenges to the welder. Also, this process can be used to join similar and dissimilar metals.
• Maximum Utilization of Current
Distortion of heat is minimal because heating is confined to a small area. Current is only turned
on at regular intervals reducing wastage. Current passes intermittently through the electrodes
to form a series of overlapping welds. The use of low current means electrodes can have a
longer life compared to spot welding.
• Suitable for Liquid and Gas Tight Containers
Resistance seam welding works perfectly for liquid and gaseous joints. Steel drums, radiators,
and tin cans are produced through this process. It creates airtight and watertight seals and is
the best process for fabricating welds that need water or air leakage protection. Because of the
creation of continuous welds, gases and liquids cannot leak.
• Seam Welding Is Fast
If you want a fast weld process, seam welding is everything. With the whole process
automated, seam welding seam faster than both spot and projection welding. Automatic
transfer, loading, and unloading of components make the entire process easy and fast. Also,
automation reduces labor input while multiplying output. Weld speeds are set for machines
rather than human operation.
• Minimal Pollution
Seam welding is one of the processes with no gas formation. Also, seam welding does not
emit any fumes. Filler material, which causes pollution, is not utilized in seam welding.
• Formation of Clear and Durable Welds
 It gives a sturdy, durable weld with excellent reliability. Seam welds generally have better
external appearance due to the absence of indentations. Joints are forged due to pressure and
heat applied forming a durable weld. Tools produced through seam welding have excellent
mechanical properties. Seam welds join a large surface area thus making strong welds.
Besides, it is possible to produce parallel and seam welds simultaneously.
Disadvantages of Seam welding
• Cost of equipment is high as compared to spot welding set.
• Welding can be done only along a straight or uniformly curved line.  It is difficult to weld
thickness greater than 3 mm.

7. 7) Brazing

Fuel tank nozzle is attached using brazing. Oxygen and diethylene gas are used.
What is Brazing?
Brazing is a joining process traditionally applied to metals (but also to ceramics) in which
molten filler metal (the braze alloy) flows into the joint.
Difference between Brazing and Welding
Brazing is also classified by the AWS as liquid-solid phase bonding processes. Liquid means
that the filler metal is melted, and solid means that the base material or materials are not
melted.
Unlike welding, brazing does not involve melting the work pieces. The main difference
between brazing and arc welding is the heat source. Brazing is applied via torch, furnace,
induction, dipped, or resistance as heat sources occurring at a temperature above 840°F
(450°C) whereas arc welding uses electricity as a heat source reaching temperatures of roughly
10,000 degrees Fahrenheit.
4. 8) Edge grinding
Edges of the fuel tank body are made smoother by grinding.
What is grinding?
Grinding is a method of reducing the size of hard materials or sharpening tools, generally
accomplished in several stages. To produce desired fineness of end products, grinding is done
after crushing.
For example, through crushing the mineral ore to below a certain size and finishing by grinding
it into powder, the ultimate fineness depends on the fineness of dissemination of the desired
mineral.
Grinding can be done wet or dry, depending on the process in use, but for dry grinding the
materials first may need to be dried in cylindrical, rotary dryers. Many machines are used for
grinding, including:
• Hand-cranked knife-sharpening stones (grindstones)
• Handheld power tools such as angle grinders and die grinders
• Various industrial machines known as grinding machines
• Bench grinders often found in residential garages and basements
Grinding can produce very fine finishes and very accurate dimensions. It is usually better suited
to the machining of very hard materials than is "regular" machining.
Property changes due to grinding include:
• Martensitic layer may form on the part, which leads to reduced material strength from
microcracks.
• Possible loss of magnetic properties on ferromagnetic materials.
• Increased susceptibility to corrosion because of high surface stress.
Grinding machines remove material from the work piece by abrasion, which can generate
substantial amounts of heat. To cool the work piece so that it does not overheat and go
outside its tolerance, grinding machines incorporate a coolant.
5. 9) Rough and Final buffing
Buffing is done for a fine surface.
What is buffing?
Buffing is the act of leveling out residue or excess of a certain applied product. In many cases
it will either increase the gloss, or even out the residue to create a uniform look.
6. 10) Leak test
The fully welded part fuel tank is inserted in water. 29 kPa pressure is exerted and if bubbles
are created in water that means there is leakage, and our part is defected.
Now the part is ready to be painted. Paint
shop process flow:
Some process that’s performed on the final fuel tank.
 Inspection & wiping
 Degreasing
 Rinsing
 phosphating
 Rinsing & Ro showering
 Drying & unloading
 Loading & masking
 Wiping & cleaning
 Basecoat painting
 Initial coat painting
  Final coat painting
 Baking
 Unloading & inspection
 Inspection & stripe pasting
 Loading & cleaning
 Initial clear coat
 Final clear coat
 Baking
 Unloading & inspection
 Inspection & buffing
 Sub-Assembly
Briefly explaining some paint shop process:
• First, wiping of fuel tank with thinner chemical.  After it we final inspection of fuel tank.
• If any fuel tank has any types of (pin hole, sharp edges, scratches) that’s were moved from the
other process(rejected) .
• And the final fuel tank from inspection we are loading it on phosphate trolley.
• After it we cover the fuel inlet cap with masking & rear point of fuel tank lock with lock pin.
• After that fuel tanks are loaded on a trolley and they are lifted by crane for degreasing

• Degreasing tank no.1

Water 4700 litter

Chemical meta clean2325
Temperature 70 ~ 80ᴼC
Dipping time 8mint
• Degreasing tank no. 2

Water 4200 litter

Chemical water
Temperature 65 ~ 70ᴼC
Dipping time 1mint
• Degreasing tank no.3

RO water Showering
• Phosphate tank

Water 4700 litter

Chemical meta phose +AC one
 Temperature 65 ~ 70ᴼC
Dipping time 5mint
• RO Degreasing tank

Water 4700 litter

Chemical RO water
Temperature 100ᴼC
Dipping time 1mint
• Final showering must be fuel tank free from the TDS of phosphate and other chemicals.
• Next the fuel tank stays in dry oven for a required time.
• To remove the water contents & other chemical from the fuel tank the given temperature of
the oven is 130 the achieving temperature of it 129.05.
• The above process is that basically coating of phosphate on the surface of fuel tank for
achieving max efficiency of paint quality.
• Next paint process is performed on it.
• Fuel tank is insert in the suspending hangers. Max capacity of hanger is 6 fuel tan in one time.
 After suspending the tanks, we clean it clearly and cover the fuel tank inlet and fuelcock by
masking.
• These all cleaning through high pressure of air.
• Now first coating of paint with the mixture of silver and red color.
• Then again double coating of paint on it.
• Then the 3rd and last coating performed on it to achieve the final color.
• After all coating of paint, we given the specific temperature to the tank to remove the thinner
and other liquid for better quality.
• The fuel tank is then sent to Striping where sticker is attached to the tank. Before sticker
application grinding is done to remove dust particles.  It is then sent for lacquer application.
What is lacquer?
Lacquer also known as varnish is a transparent, hard, protective finish or film primarily used in
wood finishing but also for other materials. Varnish is traditionally a combination of a drying oil,
a resin, and a thinner or solvent. Varnish finishes are usually glossy but may be designed to
produce satin or semi-gloss sheens by the addition of "flatting" agents. It is applied to the fuel
tank after paint is done in a paint Bothe.
• Inspection & buffing in which the final fuel tank is inspected again and grinded with emery
paper.
• Sub-Assembly Emblem is attached to the bike
Pain testing lab
One fuel tank from each batch is tested to see its paint quality. If there is a problem with the paint
it is sent back to the vendor.
The main testing methods are as following:
1) Gloss test
Gloss checker is used to check gloss of paint. The usual gloss should be between the ranges 72-
80. Any lower gloss results in the part being rejected
2) Crosshatch test
100 scratches are done on the paint and then tape is applied to that area then removed. If paint is
only removed from the scratches area, then the part is OK otherwise it is rejected.
3) Hardness test
F grade lead pencil with a flat tip is used to put 5 lines on body. If paint is removed from none of
the lines or only one, then the fuel tank paint is OK otherwise it is rejected.
4) Xylene test
Xylene is rubbed on fuel tank. If paint dissolves it is defected.
5) Gasoline test
Fuel tank is inserted in gasoline for 6 hours. If the paint is still perfectly on the fuel tank after
this time, there is no defect.

6) Salt Spray test

Draw X cut at 30 degrees and place fuel tank in SST for (F/T48) (R/C 24) hours, after rinsing
and two hours of testing perform peel off test. If peel is lesser than 2 mm situation is OK.
Paint mixing room
Paint is mixed here. Paint should have a resistivity of 0.5Mohm-0.8Mohm. For red paint the
mono-coat is created by mixing red paint with silver paint in 50 percent proportions each. For
Black paint the mono-coat is created by mixing black paint with thinner.
There are three main types of paints used in the paint mixing shop which are:
1) Stoving paint
This paint bakes at 150 degrees Celsius.
2) PU paint
This paint is more expensive than stoving paint and it bakes at 70 degrees Celsius. It is
used to paint plastic parts and fuel tanks in the case of white bikes. Hardener is added to
this paint to allow it to bake at lower temperatures.
3) Achilleic paint
 This paint is an upgrade from stoving paint.
After the paint is allowed in the paint booths and it is sent to the baking oven algometer is applied
to it to see whether the paint is perfectly baked, under baked or over baked.
Viscosity test is performed in the paint mixing room to get the perfect concentration of paint.
Paint is filled in viscosity cup F-4 size. When cup is taken out of paint container time is measured
in which it empties. The ideal time we should get is 17 s if its more we add thinner to the paint.
If it is less we add more paint to it.
Titration
Titration is done to get the correct concentration of solvents in degreasing tanks. 10 mL meta
clean and indicator 9 is added to a beaker. Titration is done with testing solution 9.
When the color of the solution changes from yellow to red we record the pointage. It should be
between 50-55 cm3. If its is more than water is added. If the pointage is less than required 2 kg of
meta-clean is added to increase pointage by 1cm^3.
For metaphose tank, titration is done with testing solution 1 in burette. Indicator 1 is added to the
beaker that has metaphose solution. The pointage should be between 30-35 cm3. 8 kg metaphose
required to change pointage by 1 cm^3. Testing solution 8 is added to accelerator and it is tested
with testing solution 6. Color changes from colorless to purple and the pointage should be
between 1-5 cm^3. 210 g added to change pointage by 1 cm3.

Project Objective:
To automate degreasing tank crane for more efficiency.
Problems with manual degreasing tank crane:
1. Workers do not wait for trolley to stabilize before dipping it in tank.
2. Dipping in water tanks is lesser than a minute.
3. There is human error.
4. It takes time for crane to attach to trolley.
My IDEA:
The use of CNC and sensors to automate crane. For that a code would be written in PLC. Our
task was to calculate the time required for the crane to move vertically and horizontally
throughout the degreasing tank process.

1. CNC Milling Machine

Originally milling machines were manual in operation. Movement of the part or tool was often
accomplished by manually turning handles that turned the ball screws or manipulated various
levers of the machine. Basic automation allowing the machine to move in one direction, once
the part location was set by the machinist. CNC is an acronym for Computer Numerical
Control, where a computer is connected to the mill, along with electrical drives and sensors for
a complete system. This computer controls the movement of the machine axis. CNC machines
are very precise, with precision and repeatability that can exceed what is possible through
manual movements. CNC mills can vary in size from just a few inches of travel, to having
hundreds and sometimes even thousands of inches of travel. The idea for CNC machines is
often credited with John T. Parsons, who was a machinist and salesman at his father’s
machining company. He wanted a way to make aerospace parts that were lower in cost and
more consistent than traditional methods. After various false starts, collaboration between
Parson’s, the United Stated Air Force and MIT led to the development of the first NC machines
which were run from a punch tape.

2. Components of CNC

Most milling machines have some similar components. First you have the machine base. This
usually includes the work table and gearing, typically ball screws, for machine movement. This
can also include the electric drives that move the various components of the machine. CNC
machines also require what is usually called the “controller”, or the computer part of CNC. This
computerized controller utilizes the programmed input values, and data from the feedback
loops, to control the movements of the machine. Additionally, milling machines include a
spindle of some sort. The spindle either spins the cutting tools for milling, or in the case of a
lathe, it spins the actual part for the lathe tooling. Lastly, to successfully CNC mill parts, you
will need cutting tools compatible with your mill and material being cut.

3. Programing a CNC Machine

Location data for CNC milling can be entered into the controller manually, usually via the
keyboard and built-in screen, often this is done from a blueprint or drawing. Alternatively, a
CAD/CAM system can be used to design and program the part, with the resultant program
being loaded or fed into the CNC controller. The code used to run the mill is often referred to as
Geometry code, or more commonly, “G-Code”. Controllers also have “M-codes” or
miscellaneous codes, such as a code to turn on or off the spindle, or coolant. This code was
developed in the 1960’s when computers had small amounts of memory, and a short hand
notation of commands for CNC controllers was needed, to fit larger programs.
4. What is CNC Milling Machine (Machine Center)?
The term “machining centres” describes almost any CNC milling and drilling machine that
includes an automatic tool changer and a table that clamps the workpiece in place. CNC
machine centre is a advance manufacturing machine tool which performs wide range of
machining operation with accuracy and good quality surface finish. The orientation of the
spindle is the most fundamental defining characteristic of a CNC machining centres.
Various mechanisms used in CNC machining centers, there main aim is to reduce the
production time and gives the best quality results.
1. ATC (Automatic tool changer)
2. APC (Automatic Pallet changer)
3. Feedback systems
4. Servo motors systems
5. Re-circulating Ball screw and Nut

5. CNC Milling Machines Functions

The primary function of a CNC Milling Machine is that your tool will be doing the rotating and
moving while your workpiece stays in one spot (generally).
• Milling is a more specific process that is similar to drilling and cutting.
• These machines can also be either horizontal or vertical, again depending on the tolerance and
weight of your workpiece.
• This process has many axes that allow for a variety of shapes, holes, and slots to be cut into
the workpiece at many angles.
• These axes provide many different maneuvers, either by the spindle or the bed, to cut the part
desired to the exact specifications.

6. CNC Cranes:
This single girder overhead crane is designed and manufactured according to advanced
FEM/DIN standard. FEM/DIN single girder overhead crane has compact structure with small
wheel pressure, which efficiently uses limited space in workshops to reduce structure
investment.
The goal of this research is to move the liquid inside a container in a short time and less spill for
process effectiveness and safety. For controller design, a nonlinear mathematical model is
developed to represent the actual system. A cost-effective, smooth continuous command shaper
is presented to suppress sloshing vibration. The designed shaper is a multisine-wave function
with adjustable and independent time maneuvering used to design the acceleration profile. The
coefficients that control the shaper profile are obtained by solving a nonlinear constrained
optimization problem using particle swarm algorithm. Simulation and experimental
comparative results proved that the proposed command shaper can reduce transient peak slosh
amplitudes. Moreover, it can simultaneously cancel both residual sloshing vibrations and
container oscillations at the end of the transportation process which cannot be achieved using
conventional zero-vibration (ZV), zero-vibration derivative (ZVD), and jerk-limited shaper.
Furthermore, sensitivity analysis demonstrates that the proposed command shaper is robust to
model parameters variation such as liquid depth, suspension length, or moving distance of the
trolley.

In this work, a GPC based on transfer function model was adapted to calculate an explicit PWA
controller that guarantees the same performance as the constrained controller but with low
computational cost.

Results showed that the proposed controller was able to control the presented Gantry Crane
System reducing payload swing, while positioning the trolley at desired position. When
compared with the Unconstrained GPC, the EGPC was able to respect both input and output
constraints which derive in better overall performance. When EGPC is compared to CGPC,
Table 3 evaluation indexes show same results; however online EGPC calculation needs lower
computational effort during simulation.

In comparison with Quadratic Programming, multiparametric Quadratic Programming storage

need is higher. Also, online programming is more flexible to parameter changes. In other words,
when using an identification algorithm the control action calculation that uses Quadratic
Programming may be less expensive than the calculation by multiparametric programming,
since the design step has higher computational cost.

Future work shall do a further investigation onto multiparametric formulation so the parameter
becomes independent of the prediction and control horizon size. In the proposed formulation,
whenever this tuning parameters increase, the vector also grows, enlarging the amount of
necessary memory and time to solve the mp-QP. Moreover, future works also shall address the
control law adaptation with a recursive multiparametric programming algorithm, which would
improve the algorithm performance. Finally, the proposed GPC controller needs to be better
investigated and applied in different scenarios and problems
euro-single-girder-crane

FEM/DIN single girder overhead crane is widely used in machinery manufacturing, metallurgy,
ports, rail stations and warehouses to supply more efficient logistic solutions, especially suitable
for the places need precise positioning.

euro-single-girder-crane

Mechanisms of FEM/DIN Single Girder Overhead Crane:

1. Computer optimized design of box-typed main girder, the full length of web plate is cut and
formed through numerical control and its deflection is accurate.

2. Low clearance structure of trolley and reasonable size of hook allowing the crane wide
application scope.

3. Arc wheels or flat wheels, anti-friction bearings, honey-typed buffers and anti-derailment
devices.

4. Three-in-one motor drive, steeples speed control, hardened reducer, safety disc brake.

5. Good performance, runs smoothly with the steeples speed control

6. Shot blasting grade reaches Sa2.5 after welding and releasing internal stresses to insure the
best performance of main girder.

7. Painting epoxy zinc-rich primer, and the thickness of oil film is 140 μm.

European-standard-overhead-crane
Electric System:

1. Power supply through conductor rails.

2. Phase protection; automatically disconnect main power when phase stagger occurs.

3. The crane and hoist are mutually independent and could travel at the same time.

4. Sliding condutor rails meets the requirement of power supplying and adapts shaking.

5. Etch-proof control handle with protection degree IP54.

6. Heavy-duty aviation plug.

7. Electrical components are equipped in position that convenient to maintain, and with good
protection to avoid inadvertent contact.

8. Electric cable is suspended in cable trolley which slides flexibly and smoothly on a C-type
steel.

single-girder-overhead-crane-euro

Safety Protection:

1. Locked fall-proof reducer;

2. Outdoor hoist with rain-cover;

3. Alarm indicator lights;

4. Infrared anti-collision
Data:
Reading Time Time for Trolly Time for Trolly Time for Time for
No for trolly to stabilization trolly to stabilization trolly to trolly to
trolly to move time/s move time/s move move
move horizontal horizontal vertically vertically
upwards to 1st to 2nd downwards downwards
from meta meta in 1st meta in 2nd meta
start clean clean clean clean
point/s tank/s tank/s tank/s tank/s
1 16:01 6:16 5 11:08 5 16:59 15:37
2 15:54 6:06 5 11:04 5 16:85 15:50
3 15:31 6:01 5 10:87 5 15:90 16:02
4 15:76 5:50 5 10:40 5 16:42 15:96
5 14:85 7:01 5 12:43 5 15:49 16:10
6 15:66 5:59 5 10:62 5 16:06 14:39
7 16:95 6:17 5 11:17 5 14:91 17:05

Time for Time for Time for Time for

trolly to trolly to trolley to trolley to Time for
move move move move trolly to
vertically vertically horizontally horizontally move
Reading No
upwards upwards to 1st water to 1st water downwards
from 1st from 2nd tank from 1st tank from in 1st water
meta clean meta clean meta clean 2nd meta tank/s
tank/s tank/s tank/s clean tank/s
1 16:80 16:80 14:18 9:19 17:33
2 16:87 16:65 14:07 9:20 17:14
3 16:95 16:54 13:96 8:84 16:55
4 16:49 15:94 15:03 9:10 16:71
5 16:12 16:15 14:43 9:05 16:02
6 15:99 16:10 15:12 10:11 15:37
7 16:55 17:07 14:45 9:43 15:69

Reading Time Time for Time for Time for Time for Time for
No for trolly to trolly to trolly to trolly to move trolly to
trolly to move move move horizontally move
move horizontally downwards upwards to 3rd water vertically
upwards to 2nd water to 2nd from 2nd tank/s downwards
from 1st tank/s water water in 3rd
water tank/s tank/s water
tank/s tank/s
 1 16:87 4:40 17:05 16:40 4:48 16:66
2 16:67 4:32 17:14 16:87 4:14 16:44
3 16:95 4:51 16:67 16:90 4:32 16:97
4 16:91 4:57 16:53 16:43 4:21 16:49
5 16:45 3:03 17:33 16:07 4:20 16:70
6 16:39 3:89 17:14 16:73 4:19 16:84
7 16:81 4:09 16:56 16:79 4:34 16:86

Reading Time to Time to Time to Time to Time to Time to s Time to

no move move move move move move move
vertically horizontally vertically vertically horizontally vertically vertically
upwards to downwards upwards to 1st RO downward upwards
from 3rd phosphate into from tank/s into 1st from 1st
water tank/s phosphate phosphate RO tank RO tank
tank/s tank/s tank/s
1 23:08 7:48 18:61 14:91 3:87 13:62 15:59
2 23:17 7:40 17:54 15:42 4:04 14:09 15:78
3 22:56 7:54 16:82 16:36 3:95 16:12 15:32
4 23:18 7:39 17:10 15:92 4:19 14:44 15:98
5 22:33 7:51 16:66 16:56 3:69 14:78 16:55
6 21:81 7:28 16:98 17:03 4:09 14:39 16:86
7 22:09 7:48 16:63 16:91 4:13 16:54 16:73

Reading no Time to Time to move Time to Time to move Time to move

move vertically move horizontally to vertically downwards
horizontally downwards vertically end point/s to end point/s
to 2nd RO to 2nd RO upwards
tank/s tank/s from 2nd
RO tank/s
1 4:81 16:30 15:59 4:90 15:27
2 4:59 16:24 15:82 5:10 15:32
3 5:05 16:77 16:34 4:95 15:57
4 4:84 16:85 15:91 4:96 16:05
5 5:12 16:93 16:68 5:15 15:76
6 4:92 16:71 16:82 4:76 14:82
7 4:97 15:91 16:31 5:20 14:27
Data Analysis:
Taking averages of all the readings for finding the ideal time the conveyer should take to carry trolly through
various positions.

 Time for trolly to move upwards from start point: 15:73 s

 Time for trolly to move horizontal to 1st meta clean tank: 6:07 s
 Trolly stabilization time: 5 s
 Time for trolly to move horizontal to 2nd meta clean tank: 11:09 s
 Trolly stabilization time: 5 s
 Time for trolly to move vertically downwards in 1st meta clean tank: 16:03 s
 Time for trolly to move vertically downwards in 2nd meta clean tank: 15:77 s  Time for trolly to move
vertically upwards from 1st meta clean tank: 16:54 s
 Time for trolly to move vertically upwards from 2nd meta clean tank: 16:46 s
 Time for trolley to move horizontally to 1st water tank from 1st meta clean tank: 14:46 s
 Time for trolley to move horizontally to 1st water tank from 2nd meta clean tank: 9:27 s
 Time for trolly to move downwards in 1st water tank: 16:4 s
 Time for trolly to move upwards from 1st water tank: 16:72 s
 Time for trolly to move horizontally to 2nd water tank: 4:12 s
 Time for trolly to move downwards to 2nd water tank: 16:92 s
 Time for trolly to move upwards from 2nd water tank: 16:6 s
 Time for trolly to move horizontally to 3rd water tank: 4:27 s
 Time for trolly to move vertically downwards in 3rd water tank: 16:71 s
 Time to move vertically upwards from 3rd water tank: 22:6 s
 Time to move horizontally to phosphate tank: 7:44 s
 Time to move vertically downwards into phosphate tank: 17:19 s
 Time to move vertically upwards from phosphate tank: 16:16 s
 Time to move horizontally to 1st RO tank: 4 s
 Time to move vertically downwards into 1st RO tank: 14:85 s
 Time to move vertically upwards from 1st RO tank: 16:13 s