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INPLANT TRAINING REPORT

ROOTS INDUSTRIES INDIA LIMITED, COIMBATORE.


SNS COLLEGE OF TECHNOLOGY

ELECTRONICS AND COMMUNICATION DEPARTMENT

SUBMITTED BY:
Rushmi priya N (15EC103).

Sri prithi V (15EC122).

Ranjith kumar P (15EC099).


ACKNOWLEDGEMENT

We take this opportunity to express our sincere thanks to Dr. S. Chendur Pandian, Principal
and Dr.T.Ravichandran, Dean and Head of the Department of Electronics and
Communication Engineering., SNS 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 like to express our thanks to Mr.R.Sampathkumar,Associate Head of
Training Development and Dr.Kavidasan, Head HRD, Roots company, Rakkipalayam,
Coimbatore for their support and encouragement. We would like to express our gratitude to 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 and we would like to
sincerely thank Mr.vijaya gopal, for helping us to attaining inplant training.
COMPANY PROFILE
It is a leading manufacturer of HORNS in India and is the 11th largest Horn
Manufacturing Company in the world. It's main branch is situated at Coimbatore. Since its
establishment in the year 1970, Captive component manufacturing arms to sustain the
group’s commitment to quality became imperative. As market demands grew, Roots Cast,
Polycraft and Precision Engineering were the result of this initiative to remain both, self-reliant
and competitive. In time, each of these divisions grew to build an external customer base as well.
Today, in addition to catering to some of the world’s most trusted automobile brands, Roots
companies such as the tooling division, also deliver critical components to aerospace and
medical instrumentation sectors. Roots Multiclean Limited was conceived to deliver world class
mechanised cleaning solutions to the Indian manufacturing and service industry. A technical
partnership with Hako, Germany opened global market opportunities for this division.

ROOTS FAMILY
Roots Groups promoted by Mr.K. Ramasamy, A Master Degree holder in
AutomobileEngineering from Lincoln Technical Institute, USA, has its corporate
office at Coimbatore in South India extending the philosophy of quality to al l
spheres of its activity in the market leader in India forflagship product automobile
horns.Roots single minded pursuit of enhancing the quality of life has led to many
otherdiversifications. Roots today is a multi faced corporate entity with interests in
automobileaccessories 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
 Roots Metrology Laboratory
 Roots industries Malaysia Sdn. Bhd
Corporate Hierarchy

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 byway of selfless and unstinted service.

Mission
The mission of Roots has always been to locate an d 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.

Product Manufacture:

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.
 Wind tone
 Vibrosonic
 Clear tone
 Bosch Range
 Roots 9
 Mega sonic
 Smartone
 Spider
 FSA2
 R7
 Sensors

Milestones

1 970 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 established .

1 990 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
PrivateLimited wins American International Quality Award.

1999 Becomes the first horn manufacturer in Asia to obtain QS 9 000.

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/TS16949 from 1999 version to 2002.

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.


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 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.

Manufacturing Of Horn Departments


These are following horn divisions in Roots company,

 Coil winding.
 Press shop.
 Powder coating.
 Assembly line.
 Electroplating.
Press shop division

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 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 there by
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.

Raw Materials:
The materials which is used for manufacturing the horns are,

 CRCS (Cold Rolled Carbon Sheet)


Used for Housing, Keeper Rings, Grills .
 Aluminium-Zinc
Housing, Mounting Brackets, Tone disc & Diaphragm.
 Spring Steel
Mounting Brackets, Point Plate, Point Holder .

Process:
In this FIFO First in First out is the concept for the tags of materials. There are five raw
materials used for the manufacturing of the products. For the manufacturing process we need
metal parts. Carbon steel, spring steel, aluminium-zinc are the raw materials for the process. If
carbon steel is the material then the next stage of process is stamping process. Then the machines
used are,
 Auto feed
 Hydraulic
 Power Press
 Pneumatic
 Mechanical feeder

Autofeed: In this process it loads and decoiles the raw material into a circular form from the
straightened form. In survo feeder the points of dimensions are 100mm,120mm.

Hydraulic: In this process we use the diaphragm. It reduces the hydraulic energy to operate
balancing operation responsible for producing the sound.

Power press: This process is used for screwing, and tone disc.

Pneumatic: This process is used for Piercing Operation.

Mechanical feeder: This process is used for mounting brackets, point holder,
and point plate.

Housing process:
While the raw materials are given as input for manufacturing the process then
the steps involved are,

 Hour glass cutting.


 Re-strike.
 Piecring.
 Lettering.
 Trimming.

And the output we get it as housing.

Hoursing+SCR Assembly

In this process raw materials which has been sent inside into the
manufacturing process as housing then the steps are,

 SCR Riverting.
 Planishing.
 Lancing.
And the output we get it as Housing+SCR and the next step is tapping as sub
contractors.

Tone Disc:
As usual we used to give the raw materials for manufacturing process then the
steps involved in this is,

 Blanking.
 Lettering.
 Forming.
 Piercing.
 Powder coating.

And the output we gain as tone disc.

Assembly process:
These are the process involved in horn manufacturing,
Spool Assembly locking point holder &Tuning screw Assembly

Terminal base assembly tightening

Diaphragm assembly and height measuring

Gasket selection and pre-horn assembly

Horn side screw tightening

Horn pre-tuning and mounting bracket assembly

Horn tuning and testing

End of auto machine, identifaction printing horn

Packing
1. In the first spool assembly process is the thermal base process.
2. After the diaphragm process gasket is kept while placing the diaphragm and housing is
placed.
Housing

diagphragm

gasket
3. While testing the horn in machine 50-70 voltage (1160A) current is tuned. For the
checkline metal outer layer is placed with seal.

4. Normally in battery we have positive and negative so, here also by using this we connect
the horn and it will be operated between 7.5-14.5V and it will be available.

5. 7.5V is kept minimum because a horn needs to operate under both in low and high battery
levels.13V is the ideal voltage for horn testing.

6. SQL, current-launche, frequency are the controlling parameters of horn.

7. Range: 105 to 108Hz, Frequency: 400 to 450, Current: Max 5amps.

Horns are of different categories,

 Air horns.
 Electric horns (Mainly which is manufactured in this company).
 Screw type.
 Crimp type.
 Rivet type.

8. High tone: Sharp, focused and covers a long distance. And it will be in yellow
colour.

Low tone: Wide, blunt, less focused and covers a shorter distance. And it will
be in blue colour.

9. At the last stage of process by using anabond it is sealed and batch number,
company logo seal will be sealed and sent.

10. While printing the roots logo and the letters by launching triangular symbol in
which to degenerate heat and water while the horn operates.

Electro Plating:
The process involved in this is,
Taking the products inside

checking the products

Storing and loading the products

Soak Cleaning 1

Furniture Section:
This furniture section is used for manufacturing of chairs, tables,wheelers that are specialised in
equipments and automation.

The section contains it's own machines and operators fully supporting the unit to run the
company's daily needs.

The materials which are being used are wood and fibre.

Electronic division:
In this division the subassembly parts are assembled together to give the whole part.

The division yields;

1. Backup alarm
2. USB charger
3. DC to DC converter
4. Electronic horn

In this unit the process stops when the parting condition is achieved after which they are
assembled.

PCB board becomes the main component whose programming is done by the NPDT team.The
components are assembled after careful selection.
BACKUP ALARM:
There are two types of alarms;

1. Type B
2. Type C

The type B alarm has a frequency of 107db and type C alarm has a frequency of 90db.

The program is feeded according the type of alarm requested by the customer.A resonant
frequency of 1200hz is maintained for which the speakers are imported from china.

In the next process the cyclone pro-kit links the PCB board with the adequate
programming.These are then sent into the testing chamber.During this time the connecting wires
are connected to the bear speaker and then linked with the board.

The speaker along with the board is checked and then given for soldered.The final process is
porting.

In this process chemicals are filled in the appropriate ratio.It takes normally a duration of 24 hrs
for the chemicals to settle down on the board.

The chemicals used are resin and harner.

There are two types of porting.

They are:
1. Soft porting
2. Hard porting

In the soft porting the ratio of resin and harner is 100:13.

The duration of the soft porting is 12 hrs which makes it easier to form a surface of
rubber like structure .It is then easier to remove the substance incase of any failures in
the product.

Anabond becomes the primary component in soft porting and Encasting is the primary
componentin the hard porting.

During the checking process 9 – 30 V is the operating range in the after checking and
14- 32 V is the range for before checking.

The HMI(human machine interface) plays the major role in helping the operators to
organize the machine. The Tracability Process is done to check the machines for proper
working. Every PCB has a barcode which is scanned before and after the assembling.
Once this is done the label is generated.
TYPE C:
In this the frequency alone varies from 1000-1200Hz .We then choose the apt bandwidth
to get the desired frequency .The type c alarm has a smaller size than the Type B alarm.

DC TO DC CONVERTER:
When we get a 13V supply voltage, at times we may need only 5V to operate our
machinery .At such times this converter may prove useful.It converts the high voltage to
low voltage .The main buyer of such converters are Valvovich who produce a 12V and
5amps even when given a 20-33V input supply.

While the process of manufacturing remains the same the design of the board alone
changes.

USB CHARGER:

The main buyer of the charger are from the US –NAVISTER.

This charger also called the smart charger has 4 operating modes.The four modes vary
according to the type of the mobile used.They are:

1. APPLE
2. SAMSUNG
3. DEFAULT MOBILES
4. BATTERY CHARGERS(BC 1.2)

The PCB board is already programmed by the NPDT team and the top and bottom
casings are alone fixed.The casing is only assembled here.It is then barcoded and then
packed.

ELECTRONIC HORNS:
The NPDT team designs the PCB boards for the horns used here.The ranges for the
horns are:

1. 12-24V
2. 24-48V
3. 48-72V
4. 72-80V

The modulus forms the heart component for the electro-mini horns which is the
successor of the mechanical horns which produces wear and tear easily. Hence its life is
also short. The electronic horns are automated with codings and the porting process is
carried out. These become the highest manufactured product of this division. Every part
has its own mating part which is fixed along with the original.

COIL WINDING:
The process involved in this are;

Radial riverting-coil winding-heat sealin-point set-tighting-assembly.

The next process in which involved in this is subassembly.


CONCLUSION:
Thus the entire unit has its own divisions operating under their own regulations. The
assembling is the main part of the successful operation of the unit.

We hereby thank the institution and the company for taking their greatest
effort and their concern in imparting us knowledge and training regarding their
products and procedures. It is our immense delight in getting your permission for
this training which proves really useful in our career.