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2. 2. Group no - 01 2 M.haroon afzal bsme-01113017 Akmal hafeez bsme-01113011 Waqas gul bsme-01113066 Rashid munir bsme-01113015
3. 3. Atlas Honda
4. 4. m. Haroon Afzal BSME-01113017 4
5. 5. Overview 5
6. 6. Introduction 6 Atlas Honda Limited is a joint venture between the Atlas Group and Honda Motor Co., Japan. Both these motorcycle manufacturing concerns were established by the Atlas Group. Atlas Honda Limited manufactures and markets Honda motorcycles in collaboration with Honda Motor Company.
7. 7. Plant Departments 7 Atlas Honda follows Process Layout. They have different sections of different operations some of which are: Casting Plant Paint Shop HR Department Finance & Accounts IT Department Logistics Vendor Procurement Maintenance Store QC Department Manufacturing Plant Assembly Plant Engine Plant
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9. 9. Management 9 It is a skill of personal will and humility towards the profession through which a person can lead any institute or organization with well organized manner.
10. 10. Management system 10 In Honda Atlas the Management Style is Benevolent autocracy, Which means the employs are expected to be loyal and co-operative in production. The behavior of top management with the employs is decent and kind but decision making is centralized.
11. 11. Organization?? 11 An Organization is firm which born when a group of persons work on a common goal. Honda is a Private Limited Company. Two or more person can form this type of company and Govt. does not interference the working of the system.
12. 12. Atlas Honda Plants Location 12 Atlas Honda have two main plants in Pakistan. One is in Karachi and the other one on Sheikhupura Road They manufacture Only CD70 in Karachi, while in Sheikhupura Plant they manufacture all of their models i.e. CD70, CD100, CD125, and CD125 Deluxe.
13. 13. Plant Locations RESONS 13 Further more the reason of there more production in Shiekhupura Road. They could also have made there plant in other place then this, but another reason is that they have the most demand in Punjab all over Pakistan. Most of there Vendors & Sub Contractors are also from Lahore and Shiekhupura so there availability also counts a lot.
14. 14. Plant Locations RESONS 14 The reason of manufacturing only One model in Karachi is the plant location as well the demand in Karachi. As we all know that street crimes and car snatching are very common in Karachi. So they prefer to have the cheapest of the motorcycles.
15. 15. Effect of Location 15 Human resources Infra Structure Industrial Culture Material Resources Energy
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17. 17. AKMAL Hafeez BSME-01113011 17
18. 18. Process layout 18 In process layout the machines are grouped on the bases of function in atlas Honda process layout has used
19. 19. Process Layout . 19 PROCESS NO. OPTION OPERATION DESCRIPTION 1 Cutting & Molding Die cutting of metal sheets & shaping of cut parts 2 Die Casting Casting of aluminum parts 3 Welding & Grinding Joining of sheet Metal Parts & Grinding of welds & seams. 4 Machining Finishing of Site Cast & supplied parts 5 Cleaning & Preparation Spraying with Rust inhibiting Compound. 6 Phosphating Surface cleaning & preparation of Mild steel parts 7 Dipping Surface coating in a paint dip tank 8 Anodizing Surface preparation of Cast and Machined Aluminum parts 9 Degreasing Surface cleaning of circular Aluminum parts 10 Drying after Phosphating Oven Drying 11 Drying after Dipping Oven Drying to cure Dip Tank coating 12 Air Drying Drying by Compressed Air 13 Spray Painting Surface Finishing by Air/ Paint spray 14 Buffing Mechanical cleaning of circular Aluminum parts 15 Drying after painting Oven Drying to cure Spray paint coating 16 Engine Assembly Assembly of Engine from parts 17 Final Assembly of Complete Motorcycle
20. 20. Total productive maintenance Application 20 They have: Proper Material Movement Space for the Operator Space for repair & Maintenance Space for temporary storage Space for Loading Unloading Maximization of the use of workspace All the utilities are provided in the proper manner. Proper Safety Rules
21. 21. STORES 21 Stores dept. at AHL performs following functions. Manages the receiving, stacking & issuance of parts & materials to the shop. Ensures the provision & dispatches of required parts to SKP & KHI plant, spares part division & vendors. Handles the rejections & damages from all shops Handles the scraps & wastes generated in the factory
22. 22. Division of stores 22 Stores dept. at AHL has been divided into a no of small stores according to the type of material being stored and functions/services provided by the store. The division is shown as follows At AHL, following handling techniques are used: a) For handling from shop to shop especially designed trolleys, and pallets are used. b) Imported motorcycle components are received in steel & wooden cases &pallets. c) Local vendor parts are received from receiving section in standard carton boxes.
23. 23. Material Handling 23 For in plant material handling, they have Fork Lifters, Trucks, Pick-ups etc. They have Belt conveyor on their assembly line which moves automatically and can be paused if required.
24. 24. Material Handling 24 They also use suspension conveyors on the assembly line to bring the chassis from the paint ED Paint shop onto the assembly line. In their Engine Div. they use Idler roller conveyors to forward the work piece from one machine to another.
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26. 26. PRODUCTION PLANNING 26 PPC deals with managing the details of what & how many products to produce and when, and obtaining the raw materials, parts, and resources to produce those items. PPC does this by managing information. For this purpose PPC has to keep strong interactions in terms of coordination, communication & cooperation with 4 major sections of Production and service departments like. QA, Logistics Maintenance DCC/ Stores PPC Karachi as well.
27. 27. Waqas gul BSME-01113066 27
28. 28. Planning 28 Production planning is done to ensure the budgeted production targets of AHL. The planning is majorly done at AHL, the company sets its production targets. On the basis of these targets following type of planning is done. Aggregate planning Master production schedule
29. 29. Aggregate planning 29 On the basis of forecasting, a schedule from SAP, according to the production capacities & companys strategies, is generated which includes the planning of whole year. It includes the production breakup of motorcycles for whole year into model wise, plant wise & month wise breakups.
30. 30. Master production schedule 30 In Honda Master Production Schedule represent Quantities of individual products Considering demand for cast current inventory and back log. On the basis of aggregate planning, such a monthly schedule is made which includes day wise (2- shift wise), model & color wise breakups.
31. 31. VENDORs 200+ vendors are actively engaged with the company. Apart from the local vendors there is one main foreign supplier for imported components/ parts i.e. Honda Motor company JAPAN which accounts for 30% of its purchases. Trading reputation of the company is excellent since the company is known for its fair dealing and timely payments record to all creditors
32. 32. VENDOR PROCUREMENT The main responsibility if this dept. is ensuring part availability in right quantity & in right time. This department is for local vendors in Pakistan. Purchase orders:- The purpose is to inform developed vendors (in the start of the new year)that during this new year, AHL will buy the parts in such quantities and at such rate. This basically helps vendor to do his aggregate & capacity planning. Trading reputation of the company is excellent since the company is known for its fair dealing and timely payments record to all creditors
33. 33. Batch Production 33 Atlas Honda manufactures motorcycles in Batches. In 2012 they manufactured 6,44,000 Bikes and had a target of 7,50,000 bikes last year. They manufacture bikes on the order of PPC (Production and Planning Control). PPC receives orders from their dealers.
34. 34. Batch Production 34 PPC is the most important department throughout the plant, so as it has to make decisions according to the demand that on which day how many bikes will be manufactured of each model further more of which color, and in what time. And they make it sure that there desired production rate is fulfilled completely. Atlas Honda manufactures 1815 bikes per day on an average.
35. 35. Batch Production 35 There total Lead time on the assembly line is 28sec for One bike. They have only one assembly line, on which they make modifications according to the model to be assembled. Similarly, they do not have different departments(welding, painting, etc.) of every model, they rather just change the jigs accordingly and start to manufacture the next model. There casting plant is Ranked on 1st position in Asia. They have a very good environment over there and very good facilities for the workers too.
36. 36. Production capacity in Pakistan 36
37. 37. Rashid munir BSME-01113015 37
38. 38. Variety Control 38 Planning is nothing without control. PPC(Production planning and control) control ensures & arranges the necessary resources for implementation of production plan. For this purpose PPC has an eye on the in-house, vendor, import items &ensures that all the material for the next day production are available. if there is any shortage, then they collaborate with vendor procurement to ensure availability of part in time. The other function of PPC is that if there are deficiencies in the resources available for production due to any reason, they work to save the company from production loss.
39. 39. Process of Variety Control 39 Honda Atlas Variety Control process is based on Following. Simplification:- Honda Atlas Reducing The Number of type of product. Standardization:- Honda Atlas make the Qualitative values of Significant Product. Specialization:- Honda Atlas Effort on a limited variety of product.
40. 40. QUALITY ASSURANCE 40 QA dept. administers Quality management & quality control functions. QA dept. identifies quality related problems in vendor & in-house parts & takes preventive action for their re-occurrence.
41. 41. WARRANTY & FINALINSPECTION 41 Warranty Claim Data Collection Final inspection Stages of final inspection a) Test bench b) Visual check c) Functional check
42. 42. 42 Visual check: At the second stage visual check is performed. In this test, inspectors check the bike visually according to the criteria & inspection points provided to them. Functional check: It includes the Co & HC emission test & head light testing. Final inspection dept. generates the straight pass of the motorcycles which shows the no of O.K parts as compared to total no of production.
43. 43. Final inspection 43 This section of QA is located in final section of 500K plant. This section is formed for the final analysis of the complete motorcycle that comes out of the frame assy.
44. 44. HR Department 44 In Honda Altus HR is fundamentally an expression of this organization to belief on employee element on the organization success. The current Chief Executive Officer: Saquib H. Shirazi HR is Mr. Razi ur Rehman General Manager Engineering and Projects: Muhammad Noman Khan
45. 45. Human Resources and Succession Plan 45 Honda Atlas Human Resources Policy is to hire young, fresh, energetic and active associates to meet the existing and future workforce requirements and providing its associates maximum opportunities for internal mobility through personal training and development to enable them to take higher positions.
46. 46. HR Philosophy 46 In Honda Altas HR philosophies are following: Respect for Individuals People of organization create its success: Apply Integrity Professionalism Feeling for others Primary job is to provide quality service. They have 3245 employees currently working in their plant in 3 shifts.
47. 47. Atlas Culture 47 Sincerity & Loyalty Time is money Be self assured Dont expect others Members to be helpful Live economically Do charity 3R Respect, recognition, reward Be overall happy, healthy & wealthy Education, experience, expertise & application
48. 48. Recruitment & Separation Policy 48 Minimum Qualification Written Test Primary Interview Final Interview Pre-Employment Medical Test Offer Letter Joining Report Induction Plan Probationary Period Confirmation Letter
49. 49. Training Programs 49 They also arrange several training programs and In house seminars with different institutions like: IBA Karachi LUMS Lahore CMD Lahore PIM Karachi , Lahore PIQC Lahore , Karachi PITAC Lahore NUST Islamabad CNDC
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