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A Report on Inplant Training undergone at

ROOTS INDUSTRIES INDIA LIMITED, Coimbatore

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Submitted by

Bernard Eugine F (10M110)

Danail S (10M111)

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PSG COLLEGE OF TECHNOLOGY

Coimbatore ² 641 004

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ACKNOWLEDGEMENT

ccccccccccWe take this opportunity to express our sincere thanks to 2


 
, Principal and 2
  
 , 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        for consenting us the permission
to undergo training in their organization.

We would like to express our gratitude to 
 

  , 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.cc

cccccWe would also like to thank    , Associate Head HR, for helping us to

get this opportunity.

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TABLE OF CONTENTS

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.c Company Profile 

2.c Organization Structure 6
3.c Product Mix 7
4.c Milestones 8
5.c Production Process in Horn Division 
6.c Production Department 
7.c Parts of a typical horn 
8.c The working principle of a horn 2
9.c Classifications of horns 2
 .c Horns manufactured by Roots 3
.c Press Shop 3
i.c Organizational structure of Press shop 4
ii.c Raw materials 4
iii. c Machines 5
iv. c Processes 5
2.c Electroplating division 7
3.c Powder Coating 9
4.c Coil Winding 22
5.c Assembly 24
6.c Conclusion 25

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COMPANY PROFILE
Roots Industries India Ltd. is a leading manufacturer of HORNS in India and the th 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 97 , 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 6949 certification based on effective implementation of QS 9 and VDA 6. 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 ISO9 
2 firm and the parent company manufacture
electric horns currently holding 6  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 4 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

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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.

>c Roots Industries Limited

>c Roots Auto Products Private Limited
>c Roots Multiclean Limited
>c Roots Cast Private Limited
>c Roots Precision Products
>c Roots Digital Engineering Services Private Limited
>c Roots Brake System Private Limited
>c Roots Polycraft
>c RK Nature Care Hospital
>c Satchidananda Jothi Nikethan Matric Higher Secondary School
>c Roots Metrology Laboratory
>c Roots industries Malaysia Sdn. Bhd

Roots Multiclean Limited

c 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
994, within the short span of  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.

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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 987 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

ƒc Press tools
ƒc Injection moulds
ƒc Die-casting dies
ƒc Jigs and fixtures

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Roots Polycraft Limited

Roots Polycraft (PC) was established in 988 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.

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Roots Cast Private Limited

Roots Cast Pvt. Ltd., (RCPL) (formerly known as Aruna Auto Castings Private Limited) was
established in 984 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 8 s 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.

±c RSV Governor hsg Injection Pump

±c Heat- Sink For Alternator
±c Pump Body and Pump body Cover
±c Ring Holder for Ring Frame
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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.

ision

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c 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


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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 9 , Mega sonic, Smartone, Spider,
FSA2, R 7 , Sensors

>c 0ind tone
W 9 , Wind tone Super, Wind tone Trio, Wind tone Rainbow.

>c ibrosonic
Vibromax, Vibrosonic Delux, Supersonic, Vibro Mini.

>c Clear tone
Clear tone Delux.

>c Bosch Range of horns
FC4, FD4 Delux.

>c Roots 90
Roots 9 .

>c Mega sonic
Mega sonic.

>c Smartone
Smartone

>c Spider
Spider (Available in 6 Colors).

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>c FSA2
FSA2.

>c R 70
R 7 .

>c Parking Sensors
Parking Sensorsÿc

Milestones

97 Promotes American Auto Service for manufacture of Electric Horns

972 First to manufacture Servo Brakes for Light Motor Vehicles
984 Roots Auto Products Private Limited was established to manufacture Air Horns,
Die Casting Unit commences commercial operations
988 Polycraft, a unit for Plastic Injection Moulding was established
99 Roots Industries Private Limited takes over Electric Horn business
992 RMCL enters into Techno-Financial collaboration with M/s. Hako Werke Gmbh,
Germany
992 Roots Industries Private Limited obtains the National Certification- ISI mark of
quality
994 Production of floor cleaning equipment commences. Roots Industries Private
Limited wins American International Quality Award
999 Becomes the first horn manufacturer in Asia to obtain QS 9
2 Becomes the first horn manufacturer in Asia to obtain VDA 6. and the first in the
world to win ISO/TS 6949
2 The first to introduce digitally controlled air horns and low frequency, low decibel
irritation free Jumbo Air Horns.
2 3 Roots Industries Ltd., Horn Division is accredited with ISO 4 
996

2 3 Roots Industries LTD., upgraded its ISO/TS 6949 from 999 version to 2 2

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version
2 4 Roots Industries Limited(RIL) opens its   exclusive Export Oriented Unit at
their Horn Division, Thoppampatti, Coimbatore to cater the needs of Ford, North
America
RIL·s EOU commences its supplies to Ford, North America
2 4
2 4 Roots Multiclean Limited(RMCL) inaugurates its   EOU Plant at Kovilpalayam,
Coimbatore
2 4 Roots Cast Private Limited(RCPL) inaugurates its Unit II at Arugampalayam,
Coimbatore
2 4 Roots Auto Products Private Limited(RAPPL) expands with its Machining Division at
Arugampalayam, Coimbatore
2 4 RIL successfully launches its Malaysian Plant
2 4 The group company American Auto Service is accredited with ISO 9 
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2 5 Roots Industries Limited., is certified with MS 9 , a pre-requisite for Q award
for Ford Automotive Operations
2 5 Roots Metrology & Testing Laboratory has been accredited by National
Accreditation Board for testing & calibration in the field of mechanical- Linear &
Angular
2 5 Roots Industries Limited., is awarded Q by Ford Motor Company
2 5 Roots Industries Limited., Horn Division upgraded its ISO
4  from 996 version
to 2 4 version
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Production Process in Horn Division

Self Tapping Screwing

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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 DIISION

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Production department of horn division of Roots Industries India Pvt ltd comprises of the following
sections viz.,

Àc Press shop
Àc Coil Winding
Àc Assembly Division
Àc Electroplating
Àc Powder Coating

PARTS OF A TYPICAL HORN

A simple horn consists of the following components.,

>c Housing with SCR assembly

>c Terminal base
>c Coil
>c Point plate
>c Point holder
>c Armature plate & Armature Rod
>c Diaphragm
>c Tone disc / Trumpet
>c Grill
>c Mounting bracket
>c Turning Screws
>c Gasket

THE WORKING PRINCIPLE OF A HORN

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ccc 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 HORNSc
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categ
es,

±c Air horns
±c Electric horns (Manufactured in ROOTS)
±c Screw type
±c Crimp type
±c Rivet type

O the basis  the t e type it may be,

>c High tone: Sharp, focused and covers a long distance

>c Low tone: Wide, blunt, less focused and covers a shorter distance

HORNS MANUFACTURED BY ROOTS

>c Windtone
>c Vibrosonic

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>c Cleartone
>c Bosch Range
>c Roots 9
>c Megasonic
>c Smartone
>c Spider
>c FSA2
>c R 7
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THE PRESS SHOP

c c The child parts for a typical type horn are manufactured inside the press shop. The
parts include.,

±c Blank
±c Housing with SCR
±c Diaphragm
±c Tone disc
±c Keeper rings & Grills
±c Mounting brackets
±c Point holder & point plates
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Organizational structure of Press shop

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RAW MATERIALSc
The raw materials used in the preparation of the components are namely.,

±c CRCS (Cold Rolled Carbon Sheet)

Used for Housing, Keeper Rings, Grills
±c Al-Zinc
Housing, Mounting Brackets, Tone disc & Diaphragm
±c Spring Steel
Mounting Brackets, Point Plate, Point Holder

MACHINES

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±c Automatic Press

Used for Housing alone

±c Mechanical feeder Press

Used for Point plate, Point holder, Blank, Mounting Brackets

±c Power Press

Used for Housing, Tone disc, Screws

±c Hydraulic Press

Used for Diaphragm

±c Pneumatic Press

Used for Tone disc, Piercing Operation

PROCESSES
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ELECTROPLATING DIISION

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Goods Inwards

Incoming Inspection

Storage

Loading

Soak Cleaning 1

Soak Cleaning 2

Anodic Cleaning

0ater Cleaning (2 stages)

HCl Acid Pickling

0ater Rinsing (2 stages)

Caustic Dip

Zinc Plating (Alkaline)

0ater Rinsing (3 stages)

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Nitric Acid (Activation)

Nitric Acid (Rinse)

Yellow Passivation

0ater 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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±c Loading the component

±c Chemical treatments c
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.

±c Zinc phosphating c
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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±c 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.

±c 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"

±c Cooling the Components

±c Unloading the Components

±c Storing the Components

COIL WINDING

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±c Point plate and point holder riveting

±c Coil winding onto the spool

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±c Rooting and Cutting

±c 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.