UNITS OF HEMA GROUP

1.Hema Engg industry ltd.

a.)Unit-I Gurgaon
b.)Unit-II Hosur
c.)Unit-III Manesar

2.Kay-Jay Auto Ltd.,Dharuhera.

3.Tobu India Ltd.
4.Flash Hema Energy Devices Ltd.

Among all of these units Hema Engineering Industries Ltd.,1/3 km,

Khandsa Road Gurgaon, is the major company of HEMA Group of
industries. It is the major ancillary unit of HERO HONDA MOTORS
LTD.

Due to hard work, dedication and the able guidance of Mr .K.K.

Jajoo (Chairman, Hema Group) it has grown up as a major
ancillary unit for Hero Honda Motor Ltd. The unit is dedicated to its
quality policy. It is TS 16949-2002 and ISO14001 certified
company.
 COMPONENTS MANUFACTURING IN HEIL

1. CHSSIS PARTS FOR HEROHONDA MOTORS LTD.

2. REAR FORK (TWO WHEELER) FOR HHML.,TVS MOTOR
COMPANY LTD.,MAJESTIC AUTO LTD.
3. FRONT & REAR PANEL (TWO WHELLER) PARTS FOR
HHML.
4. MUFFLER PARTS FOR HHML.
5. SEAT PARTS FOR HHML.
6. FRONT/RR WHEEL PARTS FOR HHML/ HERO MOTORS
LTD./ YAMAHA MOTORS LTD.
7. SHOCKER PARTS FOR MUNJAL SHOWA LTD., GABRIEL
INDIA LTD., YAMAHA MOTORS LTD., HYDRAULICS LTD.
8. STRUT PARTS (FOUR WHEELER) FOR MARUTI LTD. (ACT
AS A SUB VENDER).
9. RR WHEEL (TWO WHEELER) SUPPORTING PARTS FOR
HHML. TVS MOTORS LTD., MAJESTIC AUTO LTD.
10. POWDER COATING J/W FOR HONDA SIEL LTD.
 CUSTOMERS OF HEIL
1. HERO HONDA MOTORS LTD.,DHARUHERA
2. HERO HONDA MOTORS LTD.,GURGAON
3. TVS MOTORS LTD.,HOSUR
4. TVS MOTORS LTD.,MYSORE
5. MAJESTIC AUTO LTD.,GAZIABAD
6. GABRIEL INDIA LTD.,HOSUR
7. GABRIEL INDIA LTD.,GURGAON
8. HYDRAULICS LTD
9. INDIA METER LTD.,HOSUR
10. GUJRAT CYCLES LTD.,VARODARA
11. RENOWED AUTO PRODUCTS.
12. STALLION SHOX LTD.,NOIDA
13. AUTO FIT LTD.,DHARUHERA
14. EUROTHERM,GERMANY
15. ESCORTS LTD.,FARIDABAD
16. MUNJAL SHOWA LTD.,GURGAON
17. AUTOMAX LTD.,GURGAON
18. DELPHI AUTOMOTIVES NOIDA
19. SANDHAR INDUSTRIES,GURGAON
20. HONDA SIEL MOTORS LTD.,NOIDA
21. MINDA INDUSTRIES LTD.,MANESAR
 THE DEPARTMENTS IN HEIL

1. PERSONNAL & ADMINISTRATION

2. DOCUMENTATION CENTRE
3. COSTING
4. PURCHASE
5. QUALITY ASSURANCE
6. DESIGN/TOOL ROOM
7. MIG WELDING SHOP
8. STURT SHOP
9. PRESS SHOP
10 STANDARD ROOM
11 SPOKE,NIPPLE AND PLATING SHOP
12 EFFLUENT PLANT
13 PAINT AND POWDER COATING
14 CHEMICAL TESTING LABORATORY
15 MAINTENANCE SHOP
16 Q.A (ASSEMBLY AND FINAL)
 PERSONNEL AND ADMINISTRATION

The Personnel and Administration Department of HEIL deal with various

aspects of manpower employed in the plant.

The work of this department starts with the recruitment of the manpower
for the plant whether it is skilled,. Semi skilled or unskilled.
After the recruitment of the manpower they take care of proper training
of every person according to the need so that each and every person
can be an asset to HEIL and can help in increasing the productivity and
profit of the company. For this purpose various type of training is
arranged by the personnel department . For this purpose the
department has to keep a close eye on every employee that where a
person is lagging behind and needs training in the specified field so that
one can give better results.

Along with the recruitment this department keeps the full detailed record
of each employee of HEIL so that in case of any need it can be used..
The various norms regarding the environmental safety are to be taken
care by this department only. Various problems of the employees like
regarding working conditions , pay scale and health are dealt by this
department only.

As this department has to deal with the manpower so the work of this
department is a typical one and for it the concerning staff has to work
hard.
 MIG WELD SHOP
It is the first production shop of the unit. As its name states that MIG
(Metal inert gas welding) welding shop, MIG welding is used to
manufactured the components. A gas is used to prevent the oxidation of
weld. CO2 is used as shielded gas over the work when welding is done.
The components produced in this shop are swing arm for the various
models of Hero Honda Motor Ltd., TVS Motor Company Ltd.

Machine Used Special Purpose M/C

Consumable Electrode Steel Wire With Copper
coating Shielded Gas Used Carbon Dioxide

Main Models Produced By HEIL :-

Model Customer Name Customer Model
Name
P-11 HHML CD-100
P-17 HHML SPLENDER
P-21 HHML PASSION
P-40 HHML CBZ
P-60 HHML AMBITION
P-70 HHML KARIZMA
CDN HHML DAWN
P-90 HHML SPLENDER SUPER
KTNA HHML ACHIVER
KTRA HHML GLAMOUR
 Tool Room/Design

This department make the drawings of house production component &

the brought out components. We use the software for the drawing are
Auto cad & Pro-e. This department makes the tool & dies also.

Machines in Tool Room

Conventional Machine :
Machine Name Machine Make
1. Milling Machine HMT Ltd.
2. Lathe H-M/c Tools
3. Lathe Kirloskar M/c ltd.
4. Lathe HMT Ltd
5. Drilling Machine Ghalley ltd.
6. Drilling Machine Machliss ltd.
7. Drilling Machine Machliss ltd.
8. Cylinderical Grinding Machines RRM/c tools Gaziabad
9. Surface Grinder Praga M/c Tools Ltd.
10.Surface Grinder GuruArjun M/cTools
11.Shaper Machine Sagar Engg.Works ltd.
12.Shaper Machine Copper Engg.Industries
13.Power Hack Saw Sagar Engg.Works ltd.

Non Conventional Machines :

Machine Name Machine Make
1.Vertical Machining Centre(CNC) BFW
2.EDM Wire Cut Electra DL-25
3.EDM Wire Cut Sodic Wire Cut M/c
4.Zig Boring (INC) Precicut M/cvTools
 Quality Assurance
The major parts of the QA department are initial or bought out inspection
and final inspection.
In bought out inspection, we inspect the quality of the bought out
components which we are using as the raw material in our plant like the
pipe of P-90,P-70 etc based on the standards set by the various parties
and the international and the and national standards which our plant is
following. After proper inspection of the material the material is kept as
the inventory in the plant and used according to the need .

The inventory material in the plant is totally managed by the store

department in the plant .

The various operations are to be done on the components and after

completing all the operations on the components they are send to the
final assembly so that the final product can be carved out of the raw
material .

After all the assembling operations are done on the components , they
are to be finally checked by the Final Inspection Department. After
qualifying all the standards from the final inspection then only the
material is dispatched to the concerning party.

The customer satisfaction standard is to be maintained by the final

inspection department only as the department has to deal with the
customer directly to solve the problems which the customer is facing if
any.
 DOCUMENTATION CENTRE

Documentation Center of HEIL is head by Management

Representative.

The function of documentation center is to keep all the records related

to company and to represent the company in the market at various
stages.

The department keeps all the documents regarding the various polices
followed by the company , various Indian and international standards
followed by the company and regarding all the dealing by the company.

The department head has the various responsibilities like to get the feed
back from the customers regarding quality and timely delivery and other
if any.Other then this the head has to keep a close look on all the
employees of the company that whether all the standards are properly
followed by all or not.

The head also cross check the activities of the heads of all the
departments that whether all the norms imposed are being properly
followed or not and if there is any leg behind then he looks what are the
corrective measures .
 STRUT SHOP
Struts are manufactured in this shop. The struts manufactured in this
shop are for Gabriel Auto Ltd., Hydraulics India Ltd.

Machine SPM Welding Machine

Type of Welding Mig Welding
Shielded Gas used Carbon dioxide

Components of Strut

1. Pipe
2. Seal
3. Knuckle Bracket
4. Spring Guide

Processes Performed In Strut Strut Shop

1. Name Rolling:-
2. Reducing Bore:-
3. Facing & Boring:-
4. Sealing Cap Welding:-
5. Leakage Testing (I) :-
6. Spring Guide Welding:-
7. Knuckle bracket pressing:-
8. Knuckle bracket Welding:-
9. Leakage Test (II):-
10. Code Punching:-
 STANDARD ROOM

As Quality is the heart of the company,

Standard Room is the heart beat of the company. In standard room we have
done the inspections of samples of the components and gauges.

INSTRUMENTS USED

1. Rockwell hardness tester

2. Profile projector
3. Micrometers
4. Height gauge
5. Varnier caliper
6. Dial indicator
7. Slip gauges
8. Filler gauges
9. Bore gauges
10.Angle protector
11.Co-ordinate measuring machine
 CALIBRATION LAB.
In this lab. We have done the inspections and calibrations of gauges and
instruments used in the company.

INSTRUMENTS USED :-

*SURFACE FINISH TESTER

*DIAL CALIBRATION TESTER

*PRESSURE GAUGE TESTER

*MECHANICAL COMPARATORS

PAINT AND POWDER COATING

HEIL has a largest paint and powder
coating plant in India. In paint shop Paint is done on the outermost parts of the
automobiles which needs better look and prevent the parts from corrosion. paint
is done with an electrostatic gun.

Powder coating is the process of making a layer over the components. which
prevents the component from corrosion. It is done on the innermost or bottom
parts. It has more life than paint coating. In powder coating process powder is
sprayed on the components with an electrostatic gun. After spraying, powder
melts on the surface of the component by heating process and makes a layer
on the surface.

Water used at back side of the paint process where the extra paint mixed with
water after dropping from gun has been changed after one year. Hot water
generators are used for heating the water and produces steam to maintain the
temperature of the room heaters.
50,000 ltrs. approx. de-mineralised water is used per day at a cost of 1.50 Rs/ltr.
in the paint shop.

MAINTENANCE
This department is to take care of all the industry, i.e maintenance of
each and every thing including production parts, machines, various plants (like
gas, filter etc.)electric works and utility. Its work is to keep a regular check on
the working of the system, machines etc. installed in the industry. Studying why
the accident/breakdown occurred, what possible preventive measures can be
adopted so that in future no such problems occur. They also have to take care
of the infrastructure, machine repairs, their life so that work can done smoothly
and more efficiently, taking care that company does not go into losses (i.e
useless expenditures ).
Various data analysis are carried out like kaizen,o/t chart, operational research
management(ORM). Do regular preventive maintenance and productive
maintenance for reducing accidents/breakdowns. Regular improvement at all
plant e.g (department)that called kaizen.
 PRESS SHOP
In this department different types of presses are used for shearing, bending,
cutting and punching etc. operations on sheets and components. The
components or parts of export OVEN are made in this shop. The ovens are
mainly exported to FRANCE. Oven made in this shop are mainly used for room
heating. Coal burns in this oven and produces heat which helps to heat the
room according to the requirement.

MACHINES USED IN PRESS SHOP

1.POWER PRESSES

2.PNEUMATIC PRESSES

3.DRILLING MACHINES
 SPOKE,NIPPLE AND PLATING SHOP
In this department spokes and nipples are made which are used in the rim of
the motorcycle. Spoke and nipples are also plated in this shop. Different types
of chemicals are used for plating the spoke and nipple.

SPOKE :- High carbon steel wire is used for making spokes. It is used in rim of
the motorcycle.

OPERATIONS MACHINES USED

1.Cutting of wire SPM cutting machine

2.Head making spoke SPM machine
3.Bending of head ---------do------------
4. Threading of spoke tail ---------do-------------

NIPPLE :- Cold drawn steel wire is used for making nipples. It is used in rim
of motorcycle with spoke assembly. First of all cutting of the wire is done on
header machine for making nipples. Nipple SPM machine has 8 tools ,all
other operations are done on this machine as below:-
1. Holding and removing of component.
2. Chamfering.
3. Counter drilling.
4. Drilling dia 3.3
5. Drilling dia 3.4
6. Burr cleaning to make the complete throughout hole.
7. Cutting slot on head.
8. Threading.
 Q.A (ASSEMBLY AND FINAL)
In this department all the components coming from other departments
(welding, press, and paint shop) are assembled with the help of nuts
and bolts etc. Nuts and bolts are screwed by nut tightening m/c.
Different types of operations are done in this shop e.g boring, tapping
and rubber bush pressing etc. Boring and tapping operations are done
for removing of extra paint material inside the holes and threading. Oils
and greases are also provided over the required parts so that the
components can prevent from corrosion and can't be damage easily due
to friction etc. final inspection is also done here before packing and
dispatch. Rejected components send back to the departments for their
maintenance. After assembly the components are packed in polothenes,
cartoons and boxes as per requirement and finally dispatched to other
companies.

MACHINES USED

1. Boring machines
2. Tapping machines
3. Nut tightening machines (hand gun)
4. Drilling machines
5. Rubber bush pressing machine(SPM)
 ACKNOWLEDGEMENT

I would like to dedicate

my work to Mr. P.L.Sharma ( Manager P&A) who allowed
me for two months industrial training in his esteemed
organization. I would like to special thanks to Mr.
Bhashiya Kamboj & Mr. Rajnesh Yadav who helped me in
my training with his highly technical work experience. The
process chart displayed on every machine or work station
and practical experience of the workers also helped me in
making my training report. I am highly obliged to all the
experienced staff members of HEIL who helped me in my
training.