Industrial Training Report

At

Grupo Antolin

G-9, SIPCOT Industrial Park, Irungattukkotai, Sriperumbudur, Kancheepuram District,

Tamil Nadu - 602117

Submitted to

Department of Mechanical EngineeringSRM UNIVERSITY

(Under Section 3 of UGC Act, 1956)

S.R.M. Nagar, Kattankulathur, Kanchipuram District – 603203

NOVEMBER, 2012

In Partial fulfillment of the requirements for the degree ofB.Tech in Mechanical Engineering

Submitted by

Hari Prasad. R 1021010123

CERTIFICATE

This is to certify that Mr. HARI PRASAD. R of B.Tech.

(Mechanical Engineering) Reg. No. 1021010123 has completed

/ partially completed / not completed his Industrial Training

during the academic year 2011-2012 as partial fulfillment of the

B .Tech. (Mechanical Engineering) course.

Class Incharge Head of the Department

Examined by: 1) ____________________ 2) _________________________

Date:

Department of Mechanical Engineering,SRM University, Kattankulathur

Self-assessment of Industrial Training by the student

1. Name of Student: HARI PRASAD.R

2. Name and address of GRUPO ANTOLIN PVT.LTD, G-9, SIPCOT

Sponsoring Industry INDUSTRIAL PARK, IRUNGATTUKKOTAI,

SRIPERUMBUDUR - 602117.

3. Guide from Industry V.MADHUKAR, GENERAL MANAGER.

4. Date of commencement 23.05.2012

of Industrial Training

5. Number of days present 15 days out of 15 days.

6. I hereby declare that, I have learnt following skills during my Industrial Training:

a) Using higher-end CAD softwares

b) Industrial Management

c) Wide knowledge about the car interiors

Date: Signature of Student

Acknowledgement

I sincerely thank Mr.V.Madhukar for giving me this opportunity to visit an industry using higher-end equipments for designing car interiors. The industrial team guided me in dealing with real-life applications. I sincerely thank the crew who patiently guided me through out my implant training.

Signature of the student

Table of Contents

Chapter Contents Page No.

1 Introduction to Groupo Antolin

1.1 Nature of business of Groupo Antolin

1.2 Global Management of Groupo Antolin

2 Products of Groupo Antolin

2.1 Overhead Systems

2.2 Door Functions

2.3 Seat Functions

3 What I learned from Industrial Training?

3.1 Innovation and Design

3.2 Process Simulation

3.3 Product Simulation

INTRODUCTION

Grupo Antolin is a Spanish multinational industry operated in 25 countries with 96 plants and 22 technical-commercial offices.

With its team of qualified professionals and the most advanced technologies, the Group has the capacity to seamlessly integrate with the infrastructures of its clients, who it supports on projects all over the world, supplying them with the highest quality products and services “in situ”. 

Financial solidity, innovation, quality and competitive costs are what create the differentiating value of a company like Grupo Antolin, which strives on a daily basis to continue warranting the trust of its clients, investors and suppliers.

GLOBAL MANAGEMENT

Grupo Antolin’s integral approach to its products and its clients, the parts that make up the framework of the company’s industrial excellence need to be broken down into creativity, design and engineering.

HISTORY

The Company was founded in 1950 and started operating in a modest mechanical workshop in Burgos, specializing in brakes and steering / First technological revolution with the invention of a rubber-metal steering joint.

The company ANSA was set up in 1959 by the Antolin family, specializing in manufacturing steering joints and vehicle suspension units / Patent granted for the new steering joint. The capacity of the small workshop was extended to cope with numerous orders coming in from the leading truck manufacturers (Barreiros, Pegaso, etc.).

The company came to an agreement in 1968 with the German company Lemförder, the leading producer of joints, to set up a plant in Burgos which became the highest quality factory in Europe / The strategy of product diversification began with the acquisition of manufacturing licenses for parts of vehicle interiors, as well as the creation of companies for manufacturing seats, doors panels, headliners and mechanisms.

A new business opportunity arose in headliners, in collaboration with the Italian

company Pianfei, introducing the Glasutec ® technology.

The Grupo Antolin holding company was created in order to manage, coordinate and consolidate the activities of its constantly growing companies.

POLICY AND STRATEGY

VISION AND STRATEGY

To be a global leader because of technological and human capacities, bringing competitive interior trim solutions to the automotive sector.

To be the best market option because of capability for innovation and competitiveness, offering attractive profitability to shareholders besides being a sustainable company of reference to our employees and to society.

ENVIRONMENTAL DIMENSION

Starting at the initial phases of Product and Process Design, its Research and Development centers have taken into account the need to minimize the environmental impact of a vehicle’s components throughout its useful life. Likewise, their processes are validated in compliance with the ISO 14001 standard of Environmental Management.

As a result of this work, it has found a solution for recycling headliner substrates by manufacturing composite boards, which is carried out at a new facility where initially some 12 tons of offcuts are treated per day, generated by two plants of the Group in Spain.

Thanks to its outstanding properties, this board can be used as a substitute for wood in numerous applications, such as the core of floating parquet or for walls, floors and ceilings of prefabricated housing.

SOCIAL DIMENSION

Since it joined the Global Compact in 2003, the Group has undertaken various initiatives geared towards supporting human rights, and participates actively in projects that support and spread these rights in the communities in which it operates.

In addition, in 2004 the common procedures in the Quality Management System were revised to integrate the Occupational Health and Safety Management System, which was validated in the first internal audit carried out in line with the OHSAS 18001 standard.

Likewise, all the companies within Grupo Antolin are subject to the relevant Occupational Health and Safety legislation of the country in which they operate.

PRODUCTS

OVERHEAD SYSTEMSEver since its beginnings, the Overhead System has identified Grupo Antolin on a global scale as a pioneer in the research and development of technologies.

In order to maintain its internationally prominent position, Grupo Antolin has incorporated new and complex functionalities to its headliners to create today’s modular systems, which incorporate acoustic, safety, panoramic and lighting elements, amongst others.

Grupo Antolin offers its clients the optimum solution for every program, including the aspects of safety and comfort. This multi-technology approach means the Company can offer any level of integration in its clients’ supply chains, anywhere in the world.

1. modular systems2. Headliner components3. Overhead system new generation

MODULAR SYSTEMS

ERGONOMICSIt improves ergonomics at the assembly stage as it already integrates a large number of functions, thus simplifying the process.

DIVERSITYThe Industry introduces a new way of managing industrial diversity.

LOGISTICSThey introduce sequenced delivery systems.

FUNCTIONAL TESTSBefore supplying the module, they guarantee improved vehicle quality at the production stage, reducing retouching.

HEADLINER COMPONENTSThe overhead system can be adapted to different configurations, from the simplest of headliners through to the most complex modular integration

1. Substrates2. Sunvisors3. Consoles4. Lighting5. Grab Handles6. Air Conditioning Vents7. Solar protection systems8. Electronics9. Wiring10. Fixing Systems11. Safety12. Acoustics and Vibrations

PILLARSThe pillars have become a key element in the interior of the vehicle. For Grupo Antolin, the adjustment of pillars with the headliner substrate is one of the main concerns in the development of the overhead function, not only for safety reasons, airbag deployment, but also in terms of perceived quality and the need for keeping harmony in the interior of the car.

Grupo Antolin controls all these aspects and develops technological solutions bearing in mind key factors such as: head impact regulations, the possibilities that offer its new textiles coverings, and the integration of lighting elements.

SUNVISORSOut of all the components that comprise the headliner function, Grupo Antolin places especial emphasis in the development of sunvisors as a significant element when it comes to evaluating the quality perceived by the end user. The extensive offer meets the requirements of all segments available in the market.Grupo Antolin has developed an innovation plan associated to the sunvisor function in order to adapt it to the new overhead architectures. The complexity of these architectures demands a perfect integration of the sunvisor.

PANORAMIC ROOFThere is a growing trend in the market to use fixed glass panoramic roofs as a replacement for the traditional sheet metal. Grupo Antolin offers a range of solutions for sun blinds based on two basic technologies: manual and electrical.

PANORAMIC WINDSHEILDS

WISH (Windshield Integrated System Headliner) is Grupo Antolin’s response to the current demand for panoramic windshields which offer a new sense of space.This concept surpasses every requirement for ergonomics, safety, comfort and perceived quality.

DOOR FUNCTIONS

The technological synergy enables the company to offer its clients a spectrum of solutions which have positioned the company at the top echelon of the world ranking. The innovative DTM Door Trim Module® is the finest example of door integration at a global level.

MODULAR SYSTEMSThe module is the logical response to such a complex system as the door. This system brings together numerous different features, without forgetting that it is also an essential part of the vehicle’s design. Due to the unique factors of this product, the traditional assembly chain for doors is extremely complex.

They provide solutions which combine technical features with design while at the same time reducing the industrial complexity of the assembly chain. These solutions have enabled the Group to propose its clients an extensive range of technological options which perfectly match their requirements.

DTM (DOOR TRIM MODULE)A prime exponent of this is the DTM Door Trim Module® which offers the most advanced level of integration on the market, stressing to the leading automotive manufacturers the Grupo Antolin’s outstanding project and supplier management capacity.

By supplying the module through our sequencing plants, the assembly process and the management of quality and diversity are simplified, having an unquestionable impact on overall economic efficiency.

WINDOWS REGULATORThey develop and produce window regulators of any morphology as another component of the Door System. All of them satisfy the quality, cost, weight and ease of assembly demands of each client’s assembly line and offer the very highest standards of reliability thanks to the rigorous validation processes.

ELECTRONICS

Door systems are housing more and more electrical and electronic devices which bring added comfort and safety functions. An example of this is the window regulator motor.

They have extensive experience in designing, validating and implementing motors in its window regulator systems. These motors have changed significantly in recent years, going from being considered as a high-end product to a mass-produced standard in most vehicles.

These motors incorporate an electronic anti-pinch system which enables them to be activated automatically and safely, and also to form part of the vehicle’s electronic communications network.

Grupo Antolin offers its clients full Tier I service in terms of both engineering and industrial supply, getting involved at every level and every phase of the lifetime of these electronic motors (conception, prototyping, validation, implementation and production control) for which it utilizes a top-level network of suppliers.

They offer its clients full Tier I service in terms of both engineering and industrial supply, getting involved at every level and every phase of the lifetime of these electronic motors (conception, prototyping, validation, implementation and production control) for which it utilizes a top-level network of suppliers.

SEAT FUNCTIONS

Grupo Antolin is the technological leader in the development and manufacture of

complete lightweight seat systems, featuring an integrated three-point integrated safety

belt.

As a result of an intensive program of innovation in the areas of lightweight materials,

advanced mechanisms, safety and comfort, these seats, folded and retractable, feature

the highest specifications that enhance the flexibility in the distribution of interior

space.

Furthermore, their integration in clients’ supply chains, using sequencing plants close

to their assembly lines, optimizes their diversity management. They have created the

Drop & Go® concept, an innovative solution which allows the seat to be fixed on floor

rails by simply dropping it effortlessly in any position.

Stow-into-floor seats can be completely hidden into the floor surface in a quick and

simple action without having to remove the headrest. In addition, the use of new user-

friendly kinematics allows the rear space to be adapted to different configurations,

improving access and enhancing the trunk function.

LUGGAGE COMPARTMENT

The multi-product nature of the Company, and in order to give answer to the market

trend of regrouping functions inside the vehicle, Grupo Antolin integrates the Luggage

Compartment Function within its product portfolio where it applies technological

advances from other disciplines. This results in a wide multi-technology offer that

answers the different demands and needs of each of the segments of the automotive

market. 

The new demands for capacity and multi-functionality of the trunk require developing

appropriate trims. In this respect Grupo Antolin develops and manufactures package

trays, boot trims, floor trims and other auxiliary functions using both injection and

thermoforming processes. Grupo Antolin achieves the balance required by the

automakers between the three key factors of cost, weight and acoustic performance.

The products they develops for this function include: mobile and fix package trays, Lift

gate Trim Module (LTM®), load floor trims, side wall trims, insulators, storage

compartments and other hard trim parts.

INNOVATION AND DESIGN

Innovation and Design are the company’s response to a world in constant change, and

the driving forces behind the rapid development of Grupo Antolin.

Innovation means challenging what already exists, seeking constant progress through

the generation of new ideas with which to achieve a clear and differentiating advantage.

This needs to be applied to the whole product cycle, from the Competitive Intelligence

phase through to delivery of the mass-produced product.

Design acts in coordination with Engineering and Manufacturing to offer the best

technical solutions while at the same time guaranteeing quality and customer service.

MATERIAL INNOVATION

Grupo Antolin’s laboratories of organic and non-organic materials allow new materials

to be rapidly homologated, shortening the time needed for them to be introduced into

new products. They also act as a support for fine-tuning manufacturing processes that

incorporate new materials.

INNOVATION IN ACOUSTICS AND VIBRATION

Using the most advanced analysis techniques in this field has allowed Grupo Antolin to

optimize the acoustic comfort of vehicles, working on both the material itself and the

complete vehicle.

Acoustic Absorption

By improving the acoustic absorption properties of their products, they guarantee end

users the utmost acoustic comfort for the end user inside the vehicle.

Acoustic Damping

The acoustic damping products are designed and developed using a combination of

experimentation and simulation techniques, particularizing the product to maximize the

efficiency and minimize the weight.

Acoustic Insulation

The use of acoustic intensity techniques and specific testing measures has enabled to

minimize noise transmission and vibrations in its components.

INNOVATION IN SAFETY

Grupo Antolin boasts the most modern Crash Impact and Dynamic Simulation

facilities.

Active and passive safety is one of the most important factors in automotive design and

is presently one of the areas undergoing the greatest technological evolution.

Their extensive product base and multi-faceted technological capacity give it a highly

advantageous perspective on interior safety features.

Firstly, being integrated in the project teams to guarantee that the product meets the

technical requirements of passive safety:

1. Client’s internal specifications.

2. Regulations of the country where the vehicle is to be sold.

3. Product validation, from the point of view of safety.

Secondly, developing internally effective solutions to be included in its product range:

1. Integrated energy absorbing elements / new materials.

2. Latest-generation airbags in overhead, door and seat systems.

3. Seats with integrated multi-point seatbelts.

4. Window regulators with anti-pinch systems.

ELECTRONICS AND ENGINES

The electrification and automation of Grupo Antolin’s mechanical systems give the

vehicle three absolutely essential functions: they make driving easier, they enhance

interior comfort and they offer greater safety to passengers.

Electronics

Grupo Antolin has an Electronics Design Department encompassing every activity in

terms of hardware and software design, CAN/LIN communications, diagnoses,

software quality, static and dynamic validation of software and the functional and

electrical validation of modules making up its modular door and overhead systems.

Grupo Antolin is an expert in all kinds of electronic door control modules, whether

integrated in the motor or stand-alone. From which, all the functions in the door system

are controlled, including window regulators with anti-pinch function, mirrors, locks,

button panels, lighting functions and multiplexed communications via CAN/LIN with

other electronic modules in the vehicle.

Motors

Grupo Antolin constantly monitors technological developments in order to incorporate

all the latest technological improvements and innovations in the field of electric motors

guided electronically in its products.

1. New and more compact designs

2. Use of smaller, less expensive motors

3. New types of gears and levers

4. Use of more compact electronics that are easier to integrate

5. Own control algorithms

FLAT CABLING

Flat Cabling is used as an interconnecting system between different components.

The advantages of flat cabling compared to conventional cabling in this system are:

1. Weight and space savings. 

2. Greater automation degree in the manufacturing process of the cable, enhancing

product quality.

Integrated light sources system (Mood light):

Its flexibility and ability to adapt to different surfaces, together with the advantages

mentioned above, make this technology the perfect support for integrating light sources

in Mood light functions, allowing a greater degree of freedom when it comes to design

as well as their positioning inside the modular systems.

LIGHTING

Grupo Antolin is inspired by nature, by the architectural concepts that allow natural

light into artificial environments, creating light effects which: affect our mood, enhance

geometrical shapes and transform our surroundings.

Grupo Antolin designs, develops and manufactures front and rear consoles with LEDs

and sunglass holders.

Grupo Antolin’s lighting systems use powerful white HB-LEDs as light sources,

featuring a totally innovative optical design with adjustable reading lights which helps

to distribute the light optimally through the most appropriate lamp location. Activation,

using discreet push-button switches, gives the optimum perception of the electronic

controls.

The electroluminescent light guides, the LEDs integrated in the headliner substrate and

the fibre optics produce environmental lighting for optimum vision in the most

appropriate colours.

PROCESS SIMULATION

Increasingly complex designs from engineers oblige us to take the human factor into

consideration explicitly and systematically, reflected in the physiological and

psychological laws of human behaviour, as well as the operational limits imposed by

the requirements and conditions of the working environment. Based on the concepts of

employee safety and the organization of industrial manufacturing processes, the need

has arisen for more in-depth studies to be made on production lines in order to optimize

them at every level:

1. Definition of Assembly Processes.

2. Tools Design.

3. Ergonomic Analysis and Definition of Workcells.

4. Simulation of Production Flows

Grupo Antolin uses new simulation tools, CAD design and its own in-house

methodology to generate a virtual 3D environment for studying, analysing, evaluating,

validating and improving the production processes of its products.

PRODUCT SIMULATION

1. Acoustic performance.

2. Static response.

3. Dynamic performance.

4. Kinematic analysis.

5. Thermo-mechanical response (insulation).

DESIGN

Up until now, the exterior has always been the most important part of a vehicle, but

today the interior plays a key role, not only from an aesthetic point of view but also

from the perspective of other sociological factors.

Design adds value to Grupo Antolin’s products and it carefully examines the aspects of

most importance to the end user, taking into consideration aesthetics, sensations,

ergonomics and comfort…all towards guaranteeing an onboard life experience that

meets the present and future needs of vehicle manufacturers and their end users. 

Design is the interface between our clients’ Design Studios and the different

engineering departments, enabling to transform design and innovation into an industrial

reality.

MAIN STRENGTHS

1. Studying trends and the end user.

2. Concept design

3. Design feasibility 

4. 3D modelling. Class A surfaces

5. Colour & Trim.

6. Development of new fabrics

7. Ergonomics and comfort