A Report on Inplant Training undergone at

ROOTS INDUSTRIES INDIA LIMITED, Coimbatore

Submitted by Bernard Eugine F Danail S (10M110) (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
1. Company Profile 2. Organization Structure 3. Product Mix 4. Milestones 5. Production Process in Horn Division 6. Production Department 7. Parts of a typical horn 12 12 13 13 14 14 15 15 17 19 22 24 25 10 11 11 1 6 7 8

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8. The working principle of a horn 9. Classifications of horns 10. Horns manufactured by Roots 11. Press Shop i. ii. iii. iv. Organizational structure of Press shop Raw materials Machines Processes

12. Electroplating division 13. Powder Coating 14. Coil Winding 15. Assembly 16. Conclusion

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 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  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 Indias 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. 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

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.

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

Executive Chairman/ Managing Director

Director Operations

Chief Marketing Officer

Vice President

Horn Divisions

Electro Plating

NDP & Trade Goods Division Metrology Division High Precision Engineering Division

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

 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 1972 1984 Promotes American Auto Service for manufacture of Electric Horns First to manufacture Servo Brakes for Light Motor Vehicles Roots Auto Products Private Limited was established to manufacture Air Horns, Die Casting Unit commences commercial operations 1988 1990 1992 Polycraft, a unit for Plastic Injection Moulding was established Roots Industries Private Limited takes over Electric Horn business 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 2000 Becomes the first horn manufacturer in Asia to obtain QS 9000 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 RILs EOU commences its supplies to Ford, North America 2004 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 2004 2005 RIL successfully launches its Malaysian Plant The group company American Auto Service is accredited with ISO 9001:2000 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 2005 Roots Industries Limited., is awarded Q1 by Ford Motor Company Roots Industries Limited., Horn Division upgraded its ISO:14001 from 1996 version to 2004 version

Production Process in Horn Division

Self Tapping Screwing

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

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Production department of horn division of Roots Industries India Pvt ltd comprises of the following sections viz., y Press shop y Coil Winding y Assembly Division y Electroplating y 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

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The AC supply to the terminal base lead to the flow of current through the coil via the contact points between the point plate 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

 Windtone  Vibrosonic

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 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

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HEAD

ASSOCIATE SYSTEM & TOOLS MANAGEMENT

ASSOCIATE HEAD MANUFACTURING

ASSOCIATE MANUFACTURING

SHIFT ENGINEERS

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

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 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 Re-strike Piercing Lettering Trimming Output Housing

HOUSING + SCR ASSEMBLY

SCR RIVETING PLANISHING LANCING

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Raw material (Housing)

Output (Housing + SCR)

TAPPING (SUB CONTRACTORS)

Powder coating

TONE DISC
BLANKING LETTERING Raw Material FORMING PIERCING POWDER COATING Output (Tone disc)

ELECTROPLATING DIVISION

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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)

Water Rinsing (3 stages)

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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

POWDER COATING

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 Loading the component  Chemical treatments

Removal of oil, soil, lubrication greases, metal oxides, welding 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. scales etc. is essential

 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 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.

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 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.

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.

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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

COIL WINDING
The processes involved in Coil Winding section are
 Point plate and point holder riveting  Coil winding onto the spool

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 Rooting and Cutting  Cleaning

Coil Winding Machine

Coil (back) part of a Horn

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ASSEMBLY

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Spool Assembly locking, point holder & 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

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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.