IN PLANT TRAINING

A REPORT
Submitted by
R.SUMITHRA (1402233)

In partial fulfillment for the award of the degree

of
BACHELOR OF ENGINEERING
in
ELECTRONICS AND COMMUNICATION ENGINEERING

SRI RAMAKRISHNA ENGINEERING COLLEGE

[Educational Service : SNR Sons Charitable Trust]
[Autonomous Institution, Accredited by NAAC with A Grade]
[Approved by AICTE and Permanently Affiliated to Anna University, Chennai]
[ISO 9001-2008 Certified and all eligible Programmes Accredited by NBA]
VATTAMALAIPALAYAM, N.G.G.O. COLONY POST,

COIMBATORE 641 022

AUGUST 2016

BONAFIDE CERTIFICATE
Certified that this Inplant Training report is prepared by R. SUMITHRA (1402233) based on the
training undergone in person at ROOTS INDUSTRIES INDIA LTD., COIMBATORE during the period
from25.05.2016 to10.06.2016.

SIGNATURE

SIGNATURE

Dr.M.JAGADEESWARI, M.E.,Ph.D.,

Mrs.G.DHANALAKSHMI, M.E.,

Professor and Head,

Assistant Professor,

Department of ECE,

Department of ECE,

Sri Ramakrishna Engineering College,

Sri Ramakrishna Engineering College,

Vattamalaipalayam,

Vattamalaipalayam,

N.G.G.O. Colony Post,

N.G.G.O. Colony Post,

Coimbatore 641022.

Coimbatore 641022.

Submitted for the Viva-Voce Examination held on ___________

INTERNAL EXAMINER

EXTERNAL EXAMINER

ORIGINAL CERTIFICATE FROM COMPANY

ACKNOWLEDGEMENT

I put forth my heart and soul to thank the ALMIGHTY for being with
me through my achievements and success. I would like to express my
immeasurable thanks to our esteemed and Honorable Managing Trustee
Shri. R.VIJAYAKUMHAR, B.E., M.S., MBA., and Joint Managing Trustee
Shri. D.LAKSHMI NARAYANANASWAMY for giving me the chance to be
a part of this elite team at Sri Ramakrishna Engineering College, Coimbatore.
I convey my deepest gratitude and thanks to our Director (Academics)
Dr. A. EBENEZER JEYAKUMAR, B.E., M.E., Ph.D., SNR Sons Charitable
Trust, Coimbatore for giving me the opportunity to undergo this training.
I would like to express my sincere thanks to our beloved Principal
Dr.N.R.ALAMELU, B.E (HONS).,M.E.,Ph.D., for the facilities provided to
complete this inplant training.
I take the privilege to thank the Professor and Head of the Department
of Electronics and Communication Engineering, Dr.M.JAGADEESWARI,
M.E.,Ph.D., for her encouragement and consistent support.
I wish to convey my special thanks to the Academic Coordinator
Dr.B.NATARAJ, M.E., Ph.D., Associate Professor and Tutor
Mrs.G.DHANALAKSHMI, M.E., for their support, timely help and valuable
suggestions for the completion of the Non-Essential Academic course.
I would like to express my utmost gratitude to the ROOTS
INDUSTRIES INDIA LTD., for providing an opportunity for me to engage in
the training. Throughout this training, I was fortunate to be helped with the
guidance
and
encouragement
from
my
mentor
Mr.SAMPATHKUMAR,HEAD-TRAINING&DEVELOPEMENT
I extend my sincere gratitude to all the teaching and non-teaching staff of
our department.

ABSTRACT
Roots Industries is a leading manufacturer, exporter and supplier of
horns and 11th largest horn producing company in the world.
The concern was established in 1970 as American Auto Service to
produce coil and winding services to electric producing horn
companies.
It manufactures Precision Plastic Injection molded parts in entire
range of Polymers including Glass Filled grades referring to
International Standards.
Specialized in supplying components to

Automotive Industries
Textile Industries
Medical Industries
Electrical Industries
Pump Industries

PRESS SHOP
The child parts for a typical type horn are manufactured inside the press
shop. The parts include
1.

Blank

2.

Housing with SCR

3.

Diaphragm

4.

Tone disc

5.

Keeper rings & Grills

6.

Mounting brackets

7.

Point holder & point plates

Different Kinds of Presses

1.

Hydraulic Press

2.

Feeder Press

3.

Auto Feeder Press

4.

Power Press

Tools used
1.

Conventional tools

2.

Progressive tools

3.

Compound tools

Raw Material used

1.

Aluminium-Zinc Galvanized

2.

Cold steel

3.

Carbon steel

4.

Spring

5.

Stainless Steel

Processes carried out in Press Shop

1.

Blanking

2.

Draw

3.

Restrike

4.

Piercing

5.

Notching

6.

Trimming

7.

Forming

8.

Embossing

9.

Flanging

10.

Edge Chamfering

11.

Rib Forming

12.

Collar Draw

13.

Flattening /Planishing

14.

Turning

15.

Riveting

16.

Bending

17.

Lancing

18.

Knurling

19.

Coining

20.

Stress Releiving

Types of machines used

1.

Power Press

2.

Hydraulic Press

3.

Feeder Press

4.

Pneumatic Press

5.

Lathe

6.

Feeder Press with multiple operation

COIL WINDING:
The processes involved in Coil Winding section are
1.

Coil Winding Zone

2.

Coil Routing Zone

3.

Heating Sealing

4.

Defect Checking Zone

Processes carried out

1 .Riveting-Here holder and the Plates are riveted using the point holder.
2 .Coil Winding-Here both circular and the rectangular coils are winded. Copper
and Aluminum materials are used widely. The coils are wound on the plastic spool.
3 .Coil Routing and heat sealing-The next process is coil routing. It means that the
ends of the coils are placed properly and the length is corrected. Heat sealing is
done in order to ensure that the windings are fixed and it does not come out after
the manufacturing. It is done at the pressure of 2 bar and the temperature is
maintained at 285C.
4. Enamel Cleaning-The enamel present on the winding is removed in-order to
make a good contact with other parts of the horn. If the enamel is present it makes
the winding less conductive.
5 .Cleaning and Defect Checking-After the enamel cleaning the winding are
cleaned using the air in-order to remove the dust particles present. And finally the
defects are checked. The possible defects are

1.

Improper enamel cleaning

2.

Acid spillage

3.

Burr observed in enamel cleaning

4.

Heat sealing burr

5.

Excess Twisting of Copper wire

6.

No enamel cleaning

7.

End of the coil wire is not cut

Processes carried out for the rectangular coils

1.

Coil winding done at a pressure of 3.5bar on a rectangular spool.

2.

Length of the coil is corrected.

3.

Enamel cleaning is done.

4.
A PVC wire is connected to it. It consists of a cable lock and a production
terminal.
5.

Molding is done using Nylon at a temperature of 270C.

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 work piece to be painted and the consistency of the
paint.

Flow Chart:

ASSEMBLY:
There are 6 processes carried out in assembly. They are as follows
1 .Spool assembly locking, point holder and tuning screw insertion
This is the first process carried out in assembly. Here a special insulator and a
modular are fixed into the metal housing along with the screw and the rubber
washers. Mercury Hydro Pneumatic Press is used for this process.
2 .Terminal base assembly riveting
Here Teflon and diode checking is done and it is fitted into the housing for the
process 1.
3 .Diaphragm assembly riveting and height measuring
Diaphragm assembling is done and the screws are fixed and riveted. And finally
the height of the diaphragm is checked.
4 .Horn pre-crimping and final crimping
Here the products from the second and third processes are assembled. A special
kind of insulator is placed in-between the housing and the diaphragm. And the
entire product is crimped to get the desired shape.
5 .Air gap measuring and adjusting
Here the air gap between the diaphragm and the curvature of the housing is
measured and adjusted to the desired level.
6 .Sealant application and trumpet locking
In this process sealant is applied to the trumpet type housing and the product
from the process 5 is attached along with it and locked.
7 .Final Inspection and packing
Then finally the horn is checked and packed.

DISPATCH
This is the area from where the finished products are send to the customers
according to their need. It consists of three parts namely,
1.

Local

2.

Export

3.

Trading

Local- In this area the products are being send to the customers within India
according to the orders placed.
Export- Here the products are exported to the foreign countries according to the
requirements asked for.
Trading- Apart from Horn manufacturing and selling, ROOTS Industries is also
involved in the trading of the following products.
1.

Battery

2.

Clutch Plate

3.

Pressure Plate

4.

Halogen Lamp

5.

Miniature Lamp

6.

Brake shoes

7.

Brake Pads

PROCESS DESCRIPTION OF GRAVITY DIE CASTING GDC

The Gravity Die Casting (GDC) process is moulding technique which is widely
used for the manufacture of castings parts .This is mainly due to the low melting
temperatures not exceeding 1000C.

For this type of casting, metal is poured at atmospheric pressure in a permanent

mould, made from two machined steel blocks. Cavity, which will form the final
part, is machined from solid block. The parting line position is essential to remove
the part without damaging the mold or the piece after the solidification phase.
To reach the required production rate for high volume markets such as automotive,
it is necessary to provide grip moulds, and cooling to accelerate the solidification
phase.
Before starting a series of moulding, the mould must be prepared by a step of die
coating. This prevents adhesion of the molten metal on the mould, and control
thermal behaviour of the part.
A holding furnace is filled with the molten alloy to flow, and the moulds basin is
poured by a ceramic ladle.
When the ladle is empty and the moulds basin is full, mould switches to distribute
the metal still in the liquid phase in the mould cavity.
The two parts of the mould are opened, and the part is removed.
To finish, the gates are cut and we have a casting part. Depending on the
specifications, the part must be heat treated in order to reach the mechanical
properties, in most cases the heat treatment is a precipitation hardening of the
aluminium matrix.

PRODUCTION METHODS:

Plastic Moulding
Injection Moulding
Ultrasonic Moulding
Vertical insert Moulding

PLASTIC MOULDING
Plastic moulding is the process of shaping plastic using a rigid frame or mould.
The technique allows for the creation of objects of all shapes and sizes with huge
design flexibility for both simple and highly complex designs. A popular
manufacturing option, plastic moulding techniques are responsible for many car
parts, containers, signs and other high volume items.
The underlying concept of plastic moulding is placing liquid polymer into a hollow
mould so that the polymer can take its shape, often with various ranges of pressure
and heat required. There are different plastic moulding techniques available to
accomplish this including rotational moulding, injection moulding, blow moulding,
and compression moulding to name just a few. Each technique has its benefits and
is best suited for the creation of specific items.
Polymers used in the plastic moulding industry are polyethylene compounds
namely High Density Polyethylene (HDPE), LDPE (Low Density Polyethylene),
LLDPE (Linear-Low Density Polyethylene). Although Poly-vinyl chloride (PVC),
nylons, and polypropylene compounds are also used
INJECTION MOULDING
The first step to the injection moulding process is the clamping of the mould. This
clamping unit is one of three standard parts of the injection machine. They are the
mould, the clamping unit and the injection unit. The clamp is what actually holds

the mould while the melted plastic is being injected, the mould is held under
pressure while the injected plastic is cooling.
Next is the actual injection of the melted plastic. The plastic usually begins this
process as pellets that are put into a large hopper. The pellets are then fed to a
cylinder; here they are heated until they become molten plastic that is easily forced
into the mould. The plastic stays in the mould, where it is being clamped under
pressure until it cools.
The next couple of steps consist of the dwelling phase, which is basically making
sure that all of the cavities of the mould are filled with the melted plastic. After the
dwelling phase, the cooling process begins and continues until the plastic becomes
solid inside the form. Finally, the mould is opened and the newly formed plastic
part is ejected from its mould. The part is cleaned of any extra plastic from the
mould
ULTRASONIC MOULDING
The machine name used hee is RINCO.In this process engineering plastics are
welded using ultrasonic sound.The Principle used in ultrasonic moulding is
remotting that is otherwise called air pressure principle.The pressure to be used
inbuilt in the machine as per the spec.Ultrasound is used as the melting agent.thus
the melted plastic produced using ultrasound has lower viscousity allowing the
production of thinner walled parts.The energy director in the trumpet is melted
using ultrasound.The material used here is ABS(Acrylo Butadiene Styrene)
VERTICAL INSERT MOULDING
Vertical injection moulding machine set up in the vertical set up and horizontal set
up.Vertical injection moulding also has the same working as the horizontal
injection moulding.
The raw material is first inspected and stored in the storage area.Then the raw
material is preheated in the preheating oven.Material preheated is placed in the
aluminium trays and FIFO method is used while loading for production.Thus the
moisture is removed from the raw material.

PROCESS DESCRIPTIONS FOR PRESSURE DIE CASTING

CLAMPING
First the preparation and clamping of the two halves of the die. Each die half is
first cleaned from the previous injection and then lubricated to facilitate the
ejection of the next part. Also, lubrication may not be required after each cycle, but
after 2 or 3 cycles, depending upon the material. After lubrication, the two die
halves, which are attached inside the die casting machine, are closed and securely
clamped together.
INJECTION
The molten metal, which is maintained at a set temperature in the furnace, is next
transferred into a chamber where it can be injected into the die. Once transferred,
the molten metal is injected at high pressures into the die. Typical injection
pressure ranges from 1,000 to 20,000 psi. This pressure holds the molten metal in
the dies during solidification. The injection time is the time required for the molten
metal to fill all of the channels and cavities in the die.
COOLING
The molten metal that is injected into the die will begin to cool and solidify once it
enters the die cavity. When the entire cavity is filled and the molten metal
solidifies, the final shape of the casting is formed. The die cannot be opened until
the cooling time has elapsed and the casting is solidified. The cooling time can be
estimated from several thermodynamic properties of the metal, the maximum wall
thickness of the casting, and the complexity of the die. A greater wall thickness
will require a longer cooling time. The geometric complexity of the die also
requires a longer cooling time because the additional resistance to the flow of heat.
TRIMMING
During cooling, the material in the channels of the die will solidify attached to the
casting. This excess material, along with any flash that has occurred, must be
trimmed from the casting either manually via cutting or sawing, or using a

trimming press. The scrap material that results from this trimming is either
discarded or can be reused in the die casting process.
SURFACE TREATMENT VIBRTORY POLISHING
The Vibratory Finishing process is used for both very small and very large
workpieces with either simple or very complex geometries.
Vibratory Finishing is used for:

Deburring: Removing the particles and shavings (known as burrs) that

appear when metal Is machined or worked

Polishing: Producing a smooth, bright, reflective surface finish

Smoothing: Improving the surface finish and blending of any defects or

sharp edges

Super finishing: Production of a high quality smooth surface

QUALITY ASSURANCE DEPARTMENT

The fully equipped QAD carries out the inspection and test activities as per the
Control plans and Quality plans in the following stages.
1.

Raw materials inspection and tests

2.

In process inspections and tests

3.

Sub-contracted products inspections and tests

4.

Final product inspections and tests

The sophisticated equipment available at QAD/QCD are

1.

Spectroscope for Alloy Composition Testing

2.

X-Ray Equipment for porosity checking

3.

Coordinate measuring machine

4.

Height Measuring System

5.

Coating Thickness Tester

DISPATCH
The approved products are packed with proper identification like model, brand
name, labelling as per the requirements. The approval is issued by QCD to the
despatch section.
The vehicle arrangements are planned well in advance and the approved
transporters are requisitioned to send a vehicle for the consignment.
The readiness of the goods is communicated to the HO for preparation of the
respective bill and despatch documentation. In case of export consignments,
additional shipping documentation are also prepared at the HO and sent to the unit.
The quantity is verified along-with the condition of packing (sea-worthy packing
for export consignments) to ensure the allotted items are only loaded in the vehicle.
.
CONCLUSION
I made use of the inplant training period in ROOTS INDUSTRIES INDIA
LIMITED.I gained knowledge in the sectors like production of horn,its
components,working and its applications.Roots gave me that perfect chance to
experience the Industrial have learnt several things besides engineering which
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. Through this training i was able to gain new insights and more
comprehensive understanding about the real industry working condition and
practice.