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INTERNSHIP REPORT MUHAMMAD HISHAM NASIR 13IN52 INDUSTRIAL ENGINEERING & MANAGEMENT PROJECT: FUEL TANK LIFTER (ERGONOMIC) @ PRODUCTION DIVISION; VFA (VEHICLE FINAL ASSEMBLY) DEPARTMENT CAR LINE SECTION
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Page 1: pak suzuki report

INTERNSHIP REPORT

MUHAMMAD HISHAM NASIR13IN52

INDUSTRIAL ENGINEERING & MANAGEMENT

PROJECT: FUEL TANK LIFTER (ERGONOMIC) @

PRODUCTION DIVISION; VFA (VEHICLE FINAL ASSEMBLY) DEPARTMENT CAR

LINE SECTION

MEHRAN UNIVERSITY OF ENGINEERING & TECHNOLOGY JAMSHORO

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TABLE OF CONTENTS

COMPANY PROFILE ............................................................................

STATICAL PAST DATA OF COMPANY...................................................................

INTRODUCTION ..................................................................................................

1. PRODUCTION DIVISION.................................................................................. (A)VFA (VEHICLE FINAL ASSEMBLY) ....................................................

Car line ST line

PROJECT CHARTER.................................................................. ............

INTRODUCTION OF ERGONOMIC............................................................................

PRINCIPLE OF ERGONOMIC..........................................................

FUEL TANK LIFTER DESIGN ..............................................................................................

BEFORE IMPLEMENTING PERFOMANCE LEVEL

AFTER IMPLEMENTED PERFORMANCE LEVEL (AS EXPACTED)

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COMPANY PROFILE Pak Suzuki Motor Company Limited was formed as a joint venture between Pakistan Automobile Corporation and Suzuki Motor Corporation (SMC) - Japan. The Company was incorporated as a public limited company in August 1983 and started commercial operations in January 1984. The initial shareholding of SMC was 12.5% which was gradually increased to 73.09%.

Pak Suzuki is pioneer in Automobile Business having the most modern and the largest manufacturing facilities in Pakistan with an Annual production capacity of 150,000 vehicles. The vehicles produced include cars, small vans, Pickups, Cargo vans and Motorcycle. Pak Suzuki holds more than 50% Market Share.

Following the aggressive policy of Indigenization, Suzuki vehicles have a healthy local content up to 72%. This was made possible by strong support of our vendors.

Pak Suzuki has the largest Dealers network offering 3S (Sales, Service and Spare Parts) facilities across Pakistan.

Caring for the Environment Pak Suzuki was pioneer in introduction of Factory fitted CNG vehicles.

Pak Suzuki always endeavours to go aggressively for the sound development of the society by increasing motorization, industrialization and creating job opportunities thus improving the people’s living standards with the combined efforts of all the dealers, vendors and Pak Suzuki employees.

Pak Suzuki is also exporting Suzuki Ravi pickup, Liana and components to Bangladesh and Europe thus earning precious foreign exchange for the country.

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Original equipment manufacturing market share for car and light commercial vehicle with respect to other automobile sector:

PAK SUZUKI; 59.60%

ATLAS HONDA CAR; 11.40%

INDUS MOTORS; 28.80%

OTHERS; 0.20%

OEM wise market share for cars & lcv (jan-dec 15)

Pak Suzuki sales result:

2006 2007 2008 2009 2010 2011 2012 2013 2014 20150

20,00040,00060,00080,000

100,000120,000140,000160,000

PAK SUZUKI PRODUCTION RESULT (2006-2015)

Automobile Motorcycle

Automobile Motorcycle2006 114,214 20,3152007 120,899 30,2452008 90,421 26,6922009 51,032 14,5302010 78,840 19,6182011 92,529 20,1192012 96,370 21,3122013 77,142 22,9772014 80,384 23,8712015 134,391 19,610

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Pakistan automobile and motorcycle sales (2005/6-2014/15)

2005-6 2006-7 2007-8 2008-9 2009-10 2010-11 2011-12 2012-13 2013-14 2014-150

200,000

400,000

600,000

800,000

1,000,000

1,200,000

155,514 165,268 147,441 74,180 112,518 114,633 134,785 105,889 104,014 127,55231,922 38,944 39,971

25,130 29,136 31,863 44,354 29,421 32,874 52,4015,200 5,271 6,5453,803 4,277 3,067 3,003 2,458 3,240 4,680

516,640 467,353662,573

507,924737,759 829,893 829,893 820,893 772,046 766,733

PAKISTAN AUTOMOBLIE AND MOTORCYCLE SALES

passenger cars light commerical vehicles trucks and buses motorcycle

CALENDAR YEAR

UN

IT'

passenger cars light commercial vehiclestrucks and buses

motorcycle

2005-6 155,514 31,922 5,200 516,6402006-7 165,268 38,944 5,271 467,3532007-8 147,441 39,971 6,545 662,5732008-9 74,180 25,130 3,803 507,9242009-10 112,518 29,136 4,277 737,7592010-11 114,633 31,863 3,067 829,8932011-12 134,785 44,354 3,003 829,8932012-13 105,889 29,421 2,458 820,8932013-14 104,014 32,874 3,240 772,0462014-15 127,552 52,401 4,680 766,733

Following some past data which show the economy, sales and profit ratio.

NET SALES AND PROFET:(REPUEEES IN MILLION)

Description 2015 2014 2013

Sales & revenue 84,579 53,665 51,061

Growth % (year on year)

57% 5% 13%

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Profit before tax 8,685 2,623 2,353

Growth % 231% 11% 57%

Profit after tax 5,843 1,922 1,849

Growth % 204% 4% 89%

INTRODUTION PSMLC has major fields which acts as a vital role in running the whole company in which some are mentioned below:

Production Division Information Technology Division Supply Chain Division Quality Assurance Division Sales & Marketing Division Finance Division Human Resources Management Division

On the very first day of internship at PSMCL all the internees were allotted specific divisions and around 16 internees including me were assigned the Production Division.

PRODUCTION DIVISION: -It is the largest division in PSMCL leading 10 departments under its umbrella under the supervision of SIR MUHAMMAD ALI LODHI (General Manager) which are mentioned below:

Press Shop Welding Shop Paint Shop Vehicle Final Assembly (VFA) Inventory Maintenance Production Planning Engine Shop Plastic Shop Motor Cycle Department (MCD)

VEHICLE FINAL ASSEMBLY (VFA):-As the name says itself that it is the department where the whole vehicle is assembled from the body shell to the complete car with its all specifications following the method Assembly Line and ready to drive.

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Mainly it has two portions:

1. Car Line2. ST Line

Car Line:-It has 51 stations and these stations are divided into 4 portions:

Trim Line (Workstation no. 1–11) Overhead-1 (Workstation no. 12-24) Overhead-2 (Workstation no. 25-38) Car line Final (Workstation no. 39-51)

Specific codes are assigned to each model and right now 4 models are being assembled here which are given below:

1. Mehran SB3082. Cultus SF4103. Wagon R A1J3104. Swift RS413

Every workstation has its specific task to perform in which the labors fit the parts which are discussed below:

TRIM LINE:Workstation no.1: ABS-ON SIS entry and tail door balancer

Workstation no.2: RHS, front and rear door weather strip

Workstation no.3: Floor wiring

Workstation no.4: Grommet

Workstation no.5: Wiper motor

Workstation no.6: Wiper motor (sub assembly)

Workstation no.7: Master cylinder

Workstation no.8: Door striker

Workstation no.9: Regulator machine

Workstation no.10: Door lock

Workstation no.11: Inspection and repairing

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OVERHEAD 1 :Workstation no.12: Sun visor and door mirror

Workstation no.13: A/C pipe and CNG

Workstation no.14: Door glass

Workstation no.15: Door glass (sub assembly)

Workstation no.16: Parcel tray

Workstation no.17: Front bumper

Workstation no.18: Inspection and repairing

Workstation no.19: Lifting station

Workstation no.20: Fuel lining

Workstation no.21: Rear suspension

Workstation no.22: Inspection and repairing

Workstation no.23: Steering gear case sub-assembly and fitting

Workstation no.24: Engine mounting

OVERHEAD 2:Workstation no. 25: Front disc

Workstation no. 26: Gear lever and front bumper

Workstation no. 27: Balance rod

Workstation no. 28: Underbody inspection (QA)

Workstation no. 29: Torque process

Workstation no. 30: Wheel fitting

Workstation no. 31: Steering column

Workstation no. 32: Brake bleeding process

Workstation no. 33: Brake bleeding process

Workstation no. 34: CNG cylinder pipe fitting

Workstation no. 35: Parking brake

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Workstation no. 36: Inspection

Workstation no. 37: Carpet fitting

CAR LINE FINAL:Workstation no. 38: Battery

Workstation no. 39: CONSOL

Workstation no. 40: Glazing

Workstation no. 41: Inspection and repairing

Workstation no. 42: Seat belt

Workstation no. 43: Show grill

Workstation no. 44: Back seat

Workstation no. 45: Front seat

Workstation no. 46: Door trim panel

Workstation no. 47: Door assembly

Workstation no. 48: Wheel nut torque/Splash guard

Workstation no. 49: Back seat carpet, trim opening

Workstation no. 50: LLC/fuel filling

Workstation no. 51: Vehicle off loading

ST LINE:It has 22 stations in which Bolan and Ravi are assembled. These 22 stations are divided into 3 portions:

Trim Line (Workstation no. 1-8) Overhead (Workstation no. 9-16) ST Final Line (Workstation no. 17-22)

Every workstation has its specific task to perform in which the labors fit the parts at particular stations which are discussed below:

Workstation no. 0: Viper lining, roof wiring, dust seal, weather strip, viper motor, valve nozzles

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Workstation no. 1: Tail door assembly/Back light filling

Workstation no. 2: Door glass regulator, glass sheet, glass fitting, back bumper, back lock, stickers

Workstation no. 3: Brake pedal sub assembly and fitting, roof lining fitting

Workstation no. 4: Dashboard, front light, ash tray, head lamp, front door sub assembly

Workstation No 5: Instrument panel, gear lever sub assembly and fitting

Workstation no. 6: Door glass assembly, steering column (sub assembly and fitting)

Workstation no. 7: Seats, battery and battery box

Workstation no. 8: Rear bumper and vehicle transfer from Trim to OHC

Workstation no. 9: Fuel tank, front bumper steering box

Workstation no. 10: Front suspension sub assembly

Workstation no. 11: Rear axle sub assembly and fitting

Workstation no. 12: Front assembly biasis fitment

Workstation no. 13: Engine mounting

Workstation no. 14:

Workstation no. 15: Tyre fitting/Adjustment

Workstation no. 16: Pokayoke & PQCI

Workstation no. 17: Steering, headlight, show grill, air filter, air cleaner, canister bottle

Workstation no. 18: Petrol filling (7 Littre), seat bracket, buckle, front mirror, jack, heat plate, air cleaner bottle

Workstation no. 19: Center door, brake oil

Workstation no. 20: Panel

Workstation no. 21: Panel assembly, radiator coolant

Workstation no. 22: Repair and inspection

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PAK SUZUKI MOTOR COMPANY LIMITED

ERGONOMIC (HUMAN FACTOR ENGINEEING)

PROJECT CHARTER

OVERVIEW

1. Project Background and DescriptionThe project is on FUEL TANK LIFTER which the core process of human factor engineering(ERGONOMICS) which mean to improve the working posture of the worker during performing the task according to the principle of ergonomics. Human factor engineering help out to reduce the fatigue causes behind work in abnormal working posture. Abnormal working posture reduce the working efficiency of the worker with to time.

2. Project ScopeScope of the fuel tank lifter is to provide the easiest working environment to the work. Its helps to increase the working efficiency of worker, improve the working quality, increase the productivity. Which help out to the company to achieve there specify goal which was settled in before, and as help to compete in complicated market.

3. Project GoalMain requirements of this project are: Reduced non-value added activities Less human fatigue Near zero amount of breakdowns Improve working efficiency Increase productivity

4. Implementation PlanImplemented plan is to fabrication of fuel tank lifter, that provide the helpful environment to worker to work without any fatigue and get higher no: of units(product) which fulfil the demand of market.

AssumptionThis project is following a human factor approach and it is assumed that the key stake holders and administration will totally coordinate in order to implement proposed solutions to achieve project goal.

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APPROVAL AND AUTHORITY TO PROCEED

We approve the project as described above, and authorize the team to proceed.

Name Title Date

Approved By Date Approved By Date

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Introduction:- ERGONOMICS (human factor engineering)

What is ERGONOMIC ?

 Ergonomics is Greek word which mean law of working. Today, however, the word is used to describe the science of "designing the job to fit the worker, not forcing the worker to fit the job." Ergonomics covers all aspects of a job, from the physical stresses it places on joints, muscles, nerves, tendons, bones and the like, to environmental factors which can effect hearing, vision, and general comfort and health.

Physical stressors include repetitive motions such as those caused by typing or continual use of a manual screwdriver. Other physical stressors could be tasks involving vibration such as using a jackhammer, or tasks which involve using excessive force, such as lifting a heavy box of books. Working in an awkward position, such as holding a telephone to your ear with your shoulder, can also cause problems. Repetitive motions, vibration, excessive force, and awkward positions are frequently linked to ergonomic disorders; however, the majority of "Cumulative Trauma Disorders" (CTDs) or "Repetitive Strain Injuries" (RSIs), are caused by repetitive motions that would not result in undue stress or harm if only performed once. Carpal tunnel syndrome, Tendonitis, Tenosynovitis, DeQuarvain's Syndrome, Thoracic Outlet Syndrome, many back injuries, and several other conditions may result from repetitive motions.

Aim of ergonomic:

o Ensures that human needs for safe and efficient working are met in the design of work system

o To design Appliances Technical Systems Tasks In such a way to improve

o Human Safety o Health o Comfort and o Performance

Benefits of ergonomics:

Productivity Product quality Safety Health Reliability Job satisfaction

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Principle of ergonomics:

Principle 1Work in Neutral Postures

Your posture provides a good starting point for evaluating the tasks that you do. The best positions in which to work are those that keep the body "in neutral."

Maintain the "S-curve" of the spine

Your spinal column is shaped more or less like an "S."

It is important to maintain the natural S-curve of the back, whether sitting or standing. The most important part of this "S" is in the lower back, which means that it is good to keep a slight "sway back,"

When standing, putting one foot up on a footrest helps to keep the spinal column in proper alignment.

Working for long periods with your back in a “C-curve” can place strain on your back.

Good lumbar support is often helpful to maintain the proper curve in the small of your back.

         

The “Inverted V-curve” creates an even greater strain on your back.  Even without lifting a load, bending over like this creates a great deal of pressure on the spine. 

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One common improvement is to use a lifter or tilter.  Or there may be other ways of making improvements depending upon the situation.

Keep the neck aligned

The neck bones are part of the spinal column and thus are subject to the same requirements of maintaining the S-curve. Prolonged twisted and bent postures of the neck can be as stressful as its equivalent for the lower back.

The best way to make changes is usually to adjust equipment so that your neck is in its neutral posture.

  

Keeps elbows at sides

The neutral posture for your arms is to keep you elbows at your sides and your shoulders relaxed.  This is pretty obvious once you think about it, but we don’t always do it.

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Here’s an example of changing a workstation to get the arms in neutral. In the illustration at the left, the product is too high, and the employee is hunching her shoulders and winging out her elbows.

In the right-hand illustration, the product has been reoriented and the shoulders and elbows drop to their relaxed position.

Keep Wrists in Neutral

There are several good ways to think about wrist posture. One way is to keep the hand in the same plane as the forearm, as this person is doing here by using a wrist rest along with the computer mouse.

A slightly more accurate approach is to keep your hands more or less like they would be when you hold the steering wheel of your car at the 10 and 2 o’clock position — slightly in and slightly forward.

Here’s an example of how this principle applies to tool design. Working continuously with the pliers as shown in the left-hand picture can create a lot of stress on the wrist. By using pliers with an angled grip, however, the wrist stays in its neutral posture.

   

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Principle 2Reduce Excessive Force

Excessive force on your joints can create a potential for fatigue and injury.  In practical terms, the action item is for you to identify specific instances of excessive force and think of ways to make improvements.

For example, pulling a heavy cart might create excessive force for your back. To make improvements it might help to make sure the floor is in good repair, that the wheels on the cart are sufficiently large, and that there are good grips on the cart. Or a power tugger might be needed.

Or another example of reducing force is to use a hoist for lifting heavy objects, like this vacuum hoist in the drawing.

Another kind of example is having handholds on boxes or carrying totes. Having the handhold reduces the exertion your hands need to carry the same amount of weight.

Point:

There are thousands of other examples and the field of ergonomics includes much information on conditions that affect force. The basic point is to recognize activities that require excessive force, then think of any way you can to reduce that force.

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Principle 3Keep Everything in Easy Reach

The next principle deals with keeping things within easy reach.  In many ways, this principle is redundant with posture, but it helps to evaluate a task from this specific perspective.

Reach Envelope

One concept is to think about the "reach envelope." This is the semi-circle that your arms make as you reach out. Things that you use frequently should ideally be within the reach envelope of your full arm. Things that you use extremely frequently should be within the reach envelope of your forearms.

Much of the time, problems with reach are simply matters of rearranging your work area and moving things closer to you. This is not exactly a hard concept to grasp; what is difficult is having the presence of mind to notice and change the location of things that you reach for a lot.

Often it is a matter of habit — you are unaware that you continually reach for something that could be easily moved closer.

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Or sometimes, the work surface is just too big, causing you to reach across to get something. One option is just to get a smaller surface. Another option is to make a cutout — this way your reaches are cut, but you still have plenty of space for things.

Or another common problem is reaching into boxes. A good way to fix this is to tilt the box.

Once again, there are thousands of other examples of ways to reduce long reaches. The point is for you to think about when you make long reaches, then figure out how to reduce that reach.

Principle 4Work at Proper Heights

Working at the right height is also a way to make things easier.

Do most work at elbow height

A good rule of thumb is that most work should be done at about elbow height, whether sitting or standing.

A real common example is working with a computer keyboard. But, there are many other types of tasks where the rule applies.

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 Exceptions to the Rule

There are exceptions to this rule, however. Heavier work is often best done lower than elbow height. Precision work or visually intense work is often best done at heights above the elbow.

Sometimes you can adjust heights by extending the legs to a work tables or cutting them down. Or you can either put a work platform on top of the table (to raise the work up) or stand on a platform (to raise YOU up).

Or to be a little more complicated, there are ways to make stands and work tables instantaneously adjustable with hand cranks or pushbutton controls.

Principle 5Reduce Excessive Motions

The next principle to think about is the number of motions you make throughout a day, whether with your fingers, your wrists, your arms, or your back.

One of the simplest ways to reduce manual repetitions is to use power tools whenever possible.

Another approach is to change layouts of equipment to eliminate motions. In the example here, the box is moved closer and tilted, so that you can slide the products in, rather than having to pick them up each time.

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Or sometimes there are uneven surfaces or lips that are in the way. By changing these, you can eliminate motions.

As always, there are more examples, but you should be getting the idea.

Principle 6Minimize Fatigue and Static Load

Holding the same position for a period of time is known as static load. It creates fatigue and discomfort and can interfere with work.

A good example of static load that everyone has experienced is writer’s cramp. You do not need to hold onto a pencil very hard, just for long periods. Your muscles tire after a time and begin to hurt.

In the workplace, having to hold parts and tools continually is an example of static load.

 

In this case, using a fixture eliminates the need to hold onto the part.

Having to hold your arms overhead for a few minutes is another classic example of static load, this time affecting the shoulder muscles. Sometimes you can change the orientation of the work area to prevent this, or sometimes you can add extenders to the tools.

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Having to stand for a long time creates a static load on your legs. Simply having a footrest can permit you to reposition your legs and make it easier to stand.

We’re going come back to this point later.

Principle 7Minimize Pressure Points

Another thing to watch out for is excessive pressure points, sometimes called "contact stress."

A good example of this is squeezing hard onto a tool, like a pair of pliers. Adding a cushioned grip and contouring the handles to fit your hand makes this problem better.

Leaning your forearms against the hard edge of a work table creates a pressure point. Rounding out the edge and padding it usually helps.

We’ve all had to sit on chairs that had cushioning and so understand almost everything we need to know about pressure points. A particularly vulnerable spot is behind your knees, which happens if your chair is too high or when you dangle your legs. Another pressure point that can happen when you sit is between your thigh and the bottom of a table.

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A slightly more subtle kind of pressure point occurs when you stand on a hard surface, like concrete. Your heels and feet can begin to hurt and your whole legs can begin to tire. The answer is anti-fatigue matting or sometimes using special insoles in your shoes.

Like the other basic principles that we’ve covered so far, pressure points are things that you can look for in your work areas to see if there are ways to make improvements.

Before work load stress on worker during performance:

1 2 3 4 5 60

1

2

3

4

5

6

7

1

2

3

4

5

6

3.2 3.364.04

3.53 3.484.01

Chart Title

Axis Title

Axis

Title

hour 15min 30min 45min 60min average hours performance(min)1 3.1 3.1 3.2 3.7 3.2 1 3.22 3.3 3.8 3.32 3.1 3.36 2 3.363 4.7 3.9 4.3 3.4 4.04 3 4.044 3.16 4.1 3.4 3.18 3.53 4 3.535 3.32 3.19 4.06 3.12 3.48 5 3.486 4.52 3.98 3.9 3.1 4.01 6 4.01

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Proposed fuel tank lifter design:

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After work load stress on worker during performance:

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As Expected:

1 2 3 4 5 60123456789

10

Chart Title

hours performance(min)

hoursperformance(min)

1 3.22 3.363 3.34 3.25 3.36 3

This graphical evaluation shows that the level of fatigue and the efficiency level of worker while during the work. Above first graph is between time and performance which shows that according to the level of performance the efficiency of worker is reduce with respect to the time. In first graph the variation shows that the reduction in efficiency of worker. Whereas the second graph haven’t any variation which try to show that after implementing proposed design at the problematic place. Its helps to:

Reduce level of fatigue Increase productivity Reduce muda Reduce hazards Increase efficiency


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