58748063 Roots Inplant
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Transcript of 58748063 Roots Inplant
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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
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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
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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
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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,
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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.
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Organization Structure
Director Operations Vice President
Horn Divisions
Chief Marketing
Officer
NDP & Trade
Goods Division
High Precision
Engineering
Division
Electro Plating
MetrologyDivision
Executive Chairman/ ManagingDirector
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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.
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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 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
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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
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
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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 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
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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 distanceHORNS MANUFACTURED BY ROOTS
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
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Tone disc Keeper rings & Grills Mounting brackets Point holder & point plates
Organizational structure of Press shop
HEAD
ASSOCIATE
SYSTEM & TOOLS
MANAGEMENT
ASSOCIATE HEAD
MANUFACTURING
ASSOCIATE
MANUFACTURING
SHIFT ENGINEERS
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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-ZincHousing, Mounting Brackets, Tone disc & Diaphragm
Spring SteelMounting Brackets, Point Plate, Point Holder
MACHINES
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
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PROCESSES
HOUSING
Raw Material Hour Glass Cutting Output Housing
Re-strike
Piercing
Lettering
Trimming
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
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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
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Zinc Plating (Alkaline)
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
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Barrier Audit
Despatch
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 phosphatingChemical pre-treatments involve the use of phosphates or chromates
in submersion or spray application.
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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.
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.
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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
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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 CleaningCoil Winding Machine
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Coil (back) part of a Horn
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ASSEMBLY
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
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Testing
Stickering & Despatch
CONCLUSION
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 half
a day. 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.