Date post: | 11-Mar-2015 |
Category: |
Documents |
Upload: | bernard-eugine |
View: | 3,678 times |
Download: | 46 times |
A Report on Inplant Training undergone at
ROOTS INDUSTRIES INDIA LIMITED,
Coimbatore
Submitted by
Bernard Eugine F (10M110)
Danail S (10M111)
PSG COLLEGE OF TECHNOLOGY
Coimbatore – 641 004
ACKNOWLEDGEMENT
We take this opportunity to express our sincere
thanks to Dr.R Rudramoorthy, Principal and Dr.P V
Mohanram, Professor and Head of Department of
Mechanical Engg., PSG College of Technology,
Coimbatore for their support and encouragement.
Also reserved on priority, are our special wishes
and acknowledgement to the Management of Roots
Industries India Limited for consenting us the permission to
undergo training in their organization.
We would like to express our gratitude to Mr.N
Sampath Kumar, Associate head, Training & Development,
Roots Industries India Ltd and all other employees for
their valuable guidance and support. We are so much
thankful to them for their precious time and providing
all necessary information whenever required during our
training.
We would also like to thank Mr Saravanan, Associate
Head HR, for helping us to get this opportunity.
TABLE OF CONTENTS
Contents
Page No
1. Company Profile 1
2. Organization Structure 6
3. Product Mix
7
4. Milestones 8
5. Production Process in Horn Division 10
6. Production Department
11
7. Parts of a typical horn 11
8. The working principle of a horn 12
9. Classifications of horns 12
10.Horns manufactured by Roots 13
11.Press Shop 13
i. Organizational structure of Press shop 14
ii. Raw materials 14
iii. Machines 15
iv. Processes 15
12.Electroplating division 17
13.Powder Coating 19
14.Coil Winding 22
15.Assembly 24
16.Conclusion 25
1
COMPANY PROFILE
Roots Industries India Ltd. is a leading manufacturer of
HORNS in India and the 11th largest Horn Manufacturing
Company in the world. Headquartered in Coimbatore - India,
ROOTS has been a dominant player in the manufacture of
Horns and other products like Castings and Industrial Cleaning
Machines. Since its establishment in 1970, ROOTS has had a
vision and commitment to produce and deliver quality products
adhering to International Standards.
With a strong innovative base and commitment to Quality,
Roots Industries India Limited has occupied a key position in
both international and domestic market as suppliers to leading
OEMs and after market. Similar to products, Roots has leading
edge over competitors on strong quality system base. Now, RIL
is the first Indian Company and first horn manufacturing
company in the world to get ISO/TS 16949 certification based
on effective implementation of QS 9000 and VDA 6.1 system
requirement earlier. RIL has entered into technical collaboration
with Robert Bosch, SA to further enhance the technical
competence. Roots' vision is to become a world-class company
manufacturing world-class product, excelling in human relation.
Roots Industries India Ltd as ISO9001:2000 firm and the
parent company manufacture electric horns currently holding
60% of the Indian Market Share. They are suppliers to leading
automobile manufacturers such as Hindustan Motors, Premier
Automobiles, Telco, Bajaj, Mahindra and Mahindra, Maruthi
2
Suzuki, Unofiat, Hyundai, Hero Honda, LML Vespa etc., are also
the exclusive suppliers of the special type horns to defence.
Their export market covers above 40 countries, which include
United States, Japan, Germany, Holland, far and Middle East,
Latin American countries and South Africa, now the Roots has
expended and concentrated on industrial cleaning machines.
Roots Family
Roots Groups promoted by Mr.K. Ramasamy, A Master
Degree holder in Automobile Engineering from Lincoln
Technical Institute, USA, has its corporate office at Coimbatore
in South India extending the philosophy of quality to all spheres
of its activity in the market leader in India for flagship product
automobile horns.
Roots single minded pursuit of enhancing the quality of
life has led to many other diversifications. Roots today is a
multi faced corporate entity with interests in automobile
accessories cleaning equipment, castings, precision tools, hi-
tech engineering services, healthcare & education.
Roots Industries Limited
Roots Auto Products Private Limited
Roots Multiclean Limited
Roots Cast Private Limited
Roots Precision Products
Roots Digital Engineering Services Private Limited
Roots Brake System Private Limited
Roots Polycraft
3
RK Nature Care Hospital
Satchidananda Jothi Nikethan Matric Higher
Secondary School
Roots Metrology Laboratory
Roots industries Malaysia Sdn. Bhd
Roots Multiclean Limited
Roots Multiclean Ltd based in Coimbatore, a Southern city
in India known for its textile and light engineering products, is
joint venture Roots Industries Limited with Hako Werke GMBH &
Co. Germany is one of the largest manufacturers of cleaning
equipment under license from Hako since 1994, within the
short span of 10 year it has become India’s largest
manufacturers of floor cleaning equipment, manufacturing
manually operated and powered suction, Sweepers, Scrubber
Driers and the state of the art Mopping System.
The group comprises of server important
manufacturing units with the state of the art
CAD/CAM/EDP/quality assurance centers with advanced
equipments.
Roots Precision Products
Roots Precision Products was established in 1987 to
address the in-house tooling needs of the diverse industries in
Roots group. Owing to continuous improvement and investment
into better resources, the company has become self-sufficient.
4
It is catering to the needs of various industries. RPP acts as a
one-stop solution for tooling and precision machining.
Specialized in design and manufacture of:
Press tools
Injection moulds
Die-casting dies
Jigs and fixtures
Roots Polycraft Limited
Roots Polycraft (PC) was established in 1988 to
manufacture precision plastic components. It is equipped with
latest microprocessor injection moulding machines to maintain
consistent process parameters. Over the years, Polycraft has
gained skills and unique techniques to manufacture small and
medium size components for Automotive, Pump, Textile, and
Medical Industries besides meeting the captive requirements of
Roots Group. Being fully equipped to provide the best service,
Polycraft has satisfied customers who have helped augment its
technological advances. The Company's commitment towards
the customer is demonstrated with quality products and
service. This has resulted in continuous growth and product
diversification. The process is closely monitored with proven
techniques to obtain consistently good quality parts.
Roots Cast Private Limited
5
Roots Cast Pvt. Ltd., (RCPL) (formerly known as Aruna
Auto Castings Private Limited) was established in 1984 to meet
the captive requirements of the Roots group. With its ever
probing eye on the needs of the market, the company in the
late 80s expanded its operations to manufacture High Pressure
Die Cast Aluminium and Zinc components to the exacting
needs of various customers in Automobile and Textile
Industries with a high degree of Quality and Perfection. RCPL
now has established itself as a major player in the die cast
component manufacturing thanks to the expertise built in the
core activities like tool design, tool making and pressure die
cast component manufacturing. RCPL supplies machined
castings and sub-assemblies as per customer requisitions.
RSV Governor hsg Injection Pump
Heat- Sink For Alternator
Pump Body and Pump body Cover
Ring Holder for Ring Frame
Mission
The mission of Roots has always been to locate and to
mould exceptional leaders and private with all the sincere effort
that solid basics to extend organization solutions to customers
worldwide and there by enhance the Roots competitive
advantage. The company does so thought long team and
deeply committed human relations based on the key values like
Activity focus, Discipline, Experience, Innovation, Integrity,
Introspection, Professionalism, Quality Culture and Team Work.
6
Vision
We will stand technologically ahead of others to deliver
world-class innovative products useful to our customers. We
will rather lose our business than our customer satisfactions. It
is our aim that the customer should get the best value for his
money.
Every member of our company will have decent living
standards. We care deeply for our families, or our environment
and our society. We promise to pay back in full measure to the
society by way of selfless and unstinted service.
Organization Structure
Director Operations Vice President
Horn Divisions
Chief Marketing Officer
NDP & Trade Goods Division
Electro Plating
Executive Chairman/ Managing Director
7
Product Mix
Roots Industries specializes in the manufacture of a wide
range and line-up of automobile horns. Roots is a leading
supplier to all the major vehicle manufacturers like Ford,
Daimler Chrysler, Mitsubishi Lancer, Mahindra & Mahindra,
Toyota, Tata Motors, Fiat Uno and Siena, TELCO, TVS Motor
Company, Kinetic Honda, etc.
Roots Industries Limited places a premium on original
technology and innovation. Roots' indigenous talent has kicked
off a spree of growth unmatched in the history of automobile
OE manufacturers. . Product: - Wind tone, Vibrosonic, Clear
tone, Bosch Range, Roots 90, Mega sonic, Smartone, Spider,
FSA2, R 70, Sensors
High Precision Engineering
Division
Metrology Division
8
Wind tone : W 90, Wind tone Super, Wind tone Trio, Wind
tone Rainbow.
Vibrosonic : Vibromax, Vibrosonic Delux, Supersonic,
Vibro Mini.
Clear tone : Clear tone Delux.
Bosch Range of horns : FC4, FD4 Delux.
Roots 90 : Roots 90.
Mega sonic : Mega sonic.
Smartone : Smartone
Spider : Spider (Available in 6 Colors).
FSA2 :FSA2.
R 70 :R 70.
Parking Sensors : Parking Sensors.
Milestones
1970 Promotes American Auto Service for manufacture
of Electric Horns
1972 First to manufacture Servo Brakes for Light Motor
Vehicles
1984 Roots Auto Products Private Limited was
established to manufacture Air Horns, Die Casting
Unit commences commercial operations
1988 Polycraft, a unit for Plastic Injection Moulding was
9
established
1990 Roots Industries Private Limited takes over Electric
Horn business
1992 RMCL enters into Techno-Financial collaboration
with M/s. Hako Werke Gmbh, Germany
1992 Roots Industries Private Limited obtains the
National Certification- ISI mark of quality
1994 Production of floor cleaning equipment
commences. Roots Industries Private Limited wins
American International Quality Award
1999 Becomes the first horn manufacturer in Asia to
obtain QS 9000
2000 Becomes the first horn manufacturer in Asia to
obtain VDA 6.1 and the first in the world to win
ISO/TS 16949
2000 The first to introduce digitally controlled air horns
and low frequency, low decibel irritation free Jumbo
Air Horns.
2003 Roots Industries Ltd., Horn Division is accredited
with ISO 14001:1996
2003 Roots Industries LTD., upgraded its ISO/TS 16949
from 1999 version to 2002 version
2004 Roots Industries Limited(RIL) opens its 100%
exclusive Export Oriented Unit at their Horn
Division, Thoppampatti, Coimbatore to cater the
needs of Ford, North America
2004
RIL’s EOU commences its supplies to Ford, North
America
10
2004 Roots Multiclean Limited(RMCL) inaugurates its
100% EOU Plant at Kovilpalayam, Coimbatore
2004 Roots Cast Private Limited(RCPL) inaugurates its
Unit II at Arugampalayam, Coimbatore
2004 Roots Auto Products Private Limited(RAPPL)
expands with its Machining Division at
Arugampalayam, Coimbatore
2004 RIL successfully launches its Malaysian Plant
2004 The group company American Auto Service is
accredited with ISO 9001:2000
2005 Roots Industries Limited., is certified with MS 9000,
a pre-requisite for Q1 award for Ford Automotive
Operations
2005 Roots Metrology & Testing Laboratory has been
accredited by National Accreditation Board for
testing & calibration in the field of mechanical-
Linear & Angular
2005 Roots Industries Limited., is awarded Q1 by Ford
Motor Company
2005 Roots Industries Limited., Horn Division upgraded
its ISO:14001 from 1996 version to 2004 version
Production Process in Horn Division
Self Tapping Screwing
11
Spool Assembly Locking
Point Holder Assembling
Diaphragm Assembling & Tightening
Horn Pre Crimping & Final Crimping
Air gap Measuring & Adjusting
Terminal Connector Bending & Mounting
Bracket Assembling
Tuning Range Measuring & Sealant
Application
Inspection
PRODUCTION DEPARTMENT OF HORN DIVISION
12
Production department of horn division of Roots Industries India
Pvt ltd comprises of the following sections viz.,
Press shop
Coil Winding
Assembly Division
Electroplating
Powder Coating
PARTS OF A TYPICAL HORN
A simple horn consists of the following components.,
Housing with SCR assembly
Terminal base
Coil
Point plate
Point holder
Armature plate & Armature Rod
Diaphragm
Tone disc / Trumpet
Grill
Mounting bracket
Turning Screws
Gasket
THE WORKING PRINCIPLE OF A HORN
The AC supply to the terminal base lead to the flow of current
through the coil via the contact points between the point plate
13
and point plate holders which in turn induces an electro motive
force inside the coil.
The magnetic field thus created pulls in the armature rod
connected to the diaphragm until it breaks the contacts of the
point plate and the point plate holder that breaks the flow of
current thereby demagnetizing the coil. This pushes the
armature rod to its original position that strikes the diaphragm
producing sound at certain desired frequency that is amplified
by the tone disc.
CLASSIFICATIONS OF HORNS
Horns are of two major categories,
Air horns
Electric horns (Manufactured in ROOTS)
Screw type
Crimp type
Rivet type
On the basis of the tone type it may be,
High tone: Sharp, focused and covers a long distance
Low tone: Wide, blunt, less focused and covers a shorter
distance
HORNS MANUFACTURED BY ROOTS
14
Windtone
Vibrosonic
Cleartone
Bosch Range
Roots 90
Megasonic
Smartone
Spider
FSA2
R 70
THE PRESS SHOP
The child parts for a typical type horn are
manufactured inside the press shop. The parts include.,
Blank
Housing with SCR
Diaphragm
Tone disc
Keeper rings & Grills
Mounting brackets
Point holder & point plates
Organizational structure of Press shop
15
RAW MATERIALS
The raw materials used in the preparation of the
components are namely.,
CRCS (Cold Rolled Carbon Sheet)
Used for Housing, Keeper Rings, Grills
Al-Zinc
Housing, Mounting Brackets, Tone disc & Diaphragm
Spring Steel
Mounting Brackets, Point Plate, Point Holder
MACHINES
HEAD
ASSOCIATE SYSTEM & TOOLS
MANAGEMENT
ASSOCIATE HEAD MANUFACTURING
ASSOCIATE MANUFACTURING
SHIFT ENGINEERS
16
Automatic Press
Used for Housing alone
Mechanical feeder Press
Used for Point plate, Point holder, Blank, Mounting
Brackets
Power Press
Used for Housing, Tone disc, Screws
Hydraulic Press
Used for Diaphragm
Pneumatic Press
Used for Tone disc, Piercing Operation
PROCESSES
HOUSING
Raw Material Hour Glass Cutting Output Housing
Re-strike
Piercing
Lettering
Trimming
17
HOUSING + SCR ASSEMBLY
Raw material Output (Housing + SCR)
(Housing)
Powder coating
TONE DISC
Raw Material Output
(Tone disc)
SCR RIVETING
PLANISHING
LANCING
TAPPING (SUB CONTRACTORS)
BLANKING
LETTERING
FORMING
PIERCING
POWDER COATING
18
ELECTROPLATING DIVISION
Goods Inwards
Incoming Inspection
Storage
Loading
Soak Cleaning 1
Soak Cleaning 2
Anodic Cleaning
Water Cleaning (2 stages)
HCl Acid Pickling
Water Rinsing (2 stages)
Caustic Dip
Zinc Plating (Alkaline)
19
Water Rinsing (3 stages)
Nitric Acid (Activation)
Nitric Acid (Rinse)
Yellow Passivation
Water Rinse (3 stages)
Oven Drying
Unloading
Final/Random Inspection
OK Not OK
Storage of finished goods Loading
Barrier Audit
Despatch
20
POWDER COATING
Loading the component
Chemical treatments
Removal of oil, soil, lubrication greases, metal oxides,
welding scales etc. is essential prior to the powder
coating process.
It can be done by a variety of chemical and mechanical
methods.
The selection of the method depends on the size and the
material of the part to be powder coated, the type of soil to
be removed and the performance requirement of the finished
product.
Zinc phosphating
Chemical pre-treatments involve the use of phosphates
or chromates in submersion or spray application.
These often occur in multiple stages and consist of
degreasing, etching, de-smutting, various rinses and the
final phosphating or chromating of the substrate.
The pre-treatment process both cleans and improves
bonding of the powder to the metal. Recent additional
processes have been developed that avoid the use of
21
chromates, as these can be toxic to the environment.
Titanium zirconium and silanes offer similar performance
against corrosion and adhesion of the powder.
Different powder coating applications can require
alternative methods of preparation such as abrasive blasting
prior to coating. The online consumer market typically offers
media blasting services coupled with their coating services at
additional costs.
Powder Coating
The most common way of applying the powder coating to
metal objects is to spray the powder using an electrostatic gun,
or corona gun.
22
The gun imparts a positive electric charge on the
powder, which is then sprayed towards the grounded object
by mechanical or compressed air spraying and then
accelerated toward the workpiece by the powerful electrostatic
charge.
There is a wide variety of spray nozzles available for use
in electrostatic coating. The type of nozzle used will depend on
the shape of the workpiece to be painted and the consistency
of the paint.
Oven Heating
The object is then heated, and the powder melts into a
uniform film, and is then cooled to form a hard coating.
It is also common to heat the metal first and then spray
the powder onto the hot substrate. Preheating can help to
achieve a more uniform finish but can also create other
problems, such as runs caused by excess powder. See the
article "Fusion Bonded Epoxy Coatings"
Cooling the Components
Unloading the Components
Storing the Components
23
COIL WINDING
The processes involved in Coil Winding section are
Point plate and point holder riveting
Coil winding onto the spool
Rooting and Cutting
Cleaning
Coil Winding Machine
24
Coil (back) part of a Horn
25
ASSEMBLY
Spool Assembly locking, point holder &
26
Tuning screw Assembly
Terminal Base Assembly Tightening
Diaphragm Assembly Tightening
& Height Measuring
Gasket Selection &
Pre Horn Assembly
Horn side screw Tightening
Horn Pre Tuning &
Mounting Bracket Assembly
Testing
Stickering & Despatch
CONCLUSION
27
As I year Mechanical Engg., students we were eagerly
awaiting an opportunity to be a part of activities of a firm.
Roots Industries India Ltd., provided us that great opportunity
helping us to relate theory to practice.
Roots gave us that perfect chance to experience the
Industrial atmosphere which no book would have provided. We
also became aware of our role as a Mechanical Engineer in
making this possible.
During our stint at Roots, we have learnt several things
besides engineering which include interaction and
communication skills, analytical skills, importance of safety in
industry, time management and the most important fact that
no work is small.
Roots has provided its staffs & employees the perfect
environment to work. Many modern ideas like Lean
Manufacturing has been employed which is of great importance
for improving the efficiency of the organization.
It was a pleasure to experience the industrial functioning of
Roots for 5 days. Through this training we were able to gain
new insights and more comprehensive understanding about the
real industry working condition and practice. As a result of the
program now we are more confident to enter the industrial
world and build our future career.