INDUCTION TRAINING REPORT

ROOTS INDUSTRIES INDIA LIMITED (RIL)

SUBMITTED BY,
K.SURESHKUMAR
TECHNICAL GRADUATE TRAINEE

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 ROOTS GROUP OF COMPANIES

In 1970, Roots was first started with the name American Auto
Service which is now called as ROOTS INDUSTRIES INDIA LIMITED
(RIL). It has the capacity to produce around five lakh's horns per month.
Roots Industries India Ltd. is a leading manufacturer of HORNS in India and
largest Horn Manufacturing Company in the world. With a strong innovative
base and commitment to Quality, Roots Industries India Ltd has occupied a
key position in both international and domestic market as suppliers to
leading OEM's 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. Roots' vision is to become a world class
company manufacturing world class product, excelling in human relation.
The Roots group consists of
 ROOTS POLYCRAFT
 ROOTS CAST PRIVATE LIMITED
 ROOTS METROLOGY AND TESTING LABORATORY
 ROOTS MULTICLEAN PRIVATE LIMITED
 ROOTS PRECISION PRODUCTS PRIVATE LIMITED
 R K NATURE CURE HOME
 ROOTS INDUSTRIES MALAYSIA
 LETRIKA ROOTS PRIVATE LIMITED

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 ROOTS
VISION

Roots vision is to become a world leader in any field that

we Undertake.

MISSION

To be valued as a company that understands Quality & integrates it at

every level to provide world class products and to offer outstanding values
to our customers.

QUALITY POLICY

We are committed to provide world-class products and services with

due concern for the environment and safety of the society.

This will be achieved through total employee involvement,

technology up gradation, cost reduction and continual improvement in

 Quality of the products and services

 Quality Management System
 Compliance to QMS requirements

Quality will reflect in everything we do and think.

 Quality in behaviour
 Quality in governance
 Quality in human relation

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 ROOTS CUSTOMER'S
Roots customers are some of the world’s most familiar and reputed
organizations providing world class products to their customers. Some of
them are:

 BOSCH
 TOYOTA KIRLOSKAR
 HARLEY DAVIDSON
 HINDUSTAN
 SKODA
 TATA
 ASIA MOTOR WORKS
 MAHINDRA & MAHINDRA
 MERCERDES BENZ
 GE HEALTH CARE
 PARKER
 ASHOK LEYLAND
 NACCO
 NAVISTAR
 BHARATH EARTH MOVERS
 CATERPILLAR INDIA, etc.,

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 ENVIRONMENTAL POLICY

With due concern towards maintaining and improving the quality of

the life, Roots is committed for sustainable development by minimizing
pollution and conserving resources.

This will be achieved through continual improvement in

environmental awareness of all employees and associates, legal compliance
and objective towards environmental protection.

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 1. HR/ TRAINING
Date: 21.08.2015
Time: 09.30 am-11.00am Guided by: Mr. Dr. S. Sudhakar
Mr. N. Sampathkumar
OBJECTIVE:
To enhance the skills of all employers and to establish and maintain a
procedure for HR management.
ACTIVITIES:

 To provide the necessary training and constantly improve

the knowledge of employer.

 Preparation of skill matrix & creating awareness about

safety and environmental regulation

 Recruitment policy

 Master list of training program

 Life skills and soft skills

 Technical skills
 System skills

 Preparation of skill matrix & training need identification

 Preparation of competency & legal requirement matrix

 Work instructions for interview & selection

 Work instructions for training

 Work instructions for motivation techniques

 Work instruction for operator training

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  Work instruction for on the job training

 Work instruction for new product technology training for operators

 List of manuals

 Preparation of training calendar

WORK CULTURE
 5S
 Safety
 OJT (On Job Training)
 Suggestions & Kaizen
 Do's & Do not's

TRAINING & DEVELOPMENT

 Corporate functions
 Life skills and soft skills
 Technical skills
 System skills
OTHER SKILLS
 Industrial safety
 Training

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 2. QUALITY SYSTEM

Date: 21.08.2015
Time: 11.00 am-12.00pm Guided by: Mr. G. Prabhu

OBJECTIVE:
To create a defined procedure for product & process standards and
maintain quality in all levels of the organization and attain the necessary
certification.
ACTIVITIES:
Quality is defined as fitness for purpose. So ensure the quality the
department take appropriate activities and steps for quality achieving.
 Quality in all levels of the organization is maintained.
 This is achieved by maintaining all the required Quality System
procedures like,
 Control of Documents
 Control of Records
 Control of Nonconforming Products
 Internal Quality Audit
 Corrective actions
 Preventive actions
 Training (ISO/TS/CSR)
 The key features of quality management services are

 Men
 Material
 Machine
 Method

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  The procedure at quality system followed are based on the certificate
requirement , the certificate followed here is ISO TS 16949

 Activities are done on basis of “standard operating procedure”

AUDIT
First Party
This audit is carried by internal certified auditor for verification, it’s
termed as internal audit.

Second Party
This audit is carried over by O.E.M CUSTOMERS, STACK HOLDER,
its termed as customer audit.

Third party
This audit is carried by general body TUV Rheinland, they are general
professional body members carrying out Certification audit which are
trusted. Yearly once surveillance is carried out. Once for three years
recertification process is done.

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 INTERNATIONAL ORGANISATION FOR STANDARDS

Fig.1. Quality perception triangle

 The pyramid tells about the sector wise specification. These
certifications ensure the customer trust and reputation of company in
market.

 The ISO/TS16949 certificate is awarded for only Automobile

industry; hence it ensures the quality in automobile products.

 ISO 9001 is awarded for the organization which are consistence on

satisfying the need of customer and posses good organizational
practice

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CATEGORIES OF AUDIT
SYSTEM AUDIT (DOCUMENT VERIFICATION ACTIVITIES)
 The system audit comprises of Document Verification in the
Production and Process Line department with TS 9149 activity

 Product Planning uses Non Conformity (NC) , avoiding defect items

reaching to customer

 Process Planning records MR ( management review) no which are

used for verification documents during system Audit

PRODUCT AUDIT (TEST THE REQUIREMENT)

 The product manufacture is Horn. So the Product is checked for
specification, Drawing , Reliability as mentioned on documents

 This audit ensures the reputation of product manufacturing , quality

standards maintain for making quality products

 This mainly activities of three stages

1. Checking

2.Testing

3.Verification

PROCESS AUDIT (COMPLETE REQUIREMENT CHECK)

The process audit mainly focus on the Material, Process Stages, and
Final component to reach the Technical specification as mentioned on
drawing.

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CORE TOOLS
APQP - ADVANCED PRODUT QUALITY PLANNING
It’s a framework of procedures and techniques used to develop
products in industry, particularly the automotive industry. APQP and PPAP
are twins.
PPAP - PRODUTION PLAN APPROVAL PROCESS
The PPAP process is designed to demonstrate that the component
supplier has developed their design and production process to meet the
client's requirements, minimizing the risk of failure by effective use
of APQP
SPC - STATISTICAL PROCESS CONTROL
SPC is the quality control Process by using the Statistics .The major
functions is to monitor and Control Processes. Checking of product
parameters is done at here.
MSA – MEASURMENT SYSTEM ANALYSIS
A measurement systems analysis (MSA) is a specially designed
experiment that seeks to identify variation in the measurement. FMEA -
FAILURE MODE EFFECTIVE ANALYSIS
It’s systematically analyze postulated component failures and identify
the resultant effects on system operations

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 3. APPLICATION ENGINEERING

Date: 21.08.2015
Time: 12.00 pm-01.00pm Guided by: Mr. V. Sellamuthu

OBJECTIVE:
To apply the Theoretical study and knowledge over Product for
the adding more value and provide solution for complex problem and
Understanding the customer needs and requirements and conveying it to
Cross Functional Team in the organization.

ACTIVITIES:
Application engineering simply defined as “the top person
contact with the customers”

 Identify, define, and model the application requirements

 Define data structures and distribution to satisfy the application solution
 Define application solutions that meet Customer requirements
 Act as the main project team between the Customer Representatives
 Prepare deliverable to support the development and deployment of
the solution such as application guides and test plans
 Provide continuity during the transition from one stage to the next
 Define physical program units and data structures based on the
logical model to satisfy the requirements of the application

 Prepare deployment and post deployment plans to support the

conversion and deployment of the solution

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 Design and build prototypes. On a R&D project, the Application
Engineer builds the Rapid Prototype, which becomes the application
system.

 Application Architect Develops application solutions to meet the

business needs.

 Data Architect Develops an Information Architecture to meet the

business needs.

 Technical Architect Obtains guidance and support on the

implementation of specific technologies.

 Team Leader Reports on the status of assigned tasks and estimates

and raises problems and concerns for resolution. Raises scope issues for
resolution.

 Human Factors Analyst Reviews screen, report, and dialogue

design and provide feedback.

 Developers Provide orientation on the application solution,

explains processing requirements, data requirements, and program unit
processing, and walks through program unit test plans.

 Customer Representatives Define application requirements,

demonstrates application solutions, provides training, and guides testing
activities.

 Quality Assurance Manager Present’s deliverable for quality

control inspections. Engineering change for internal and external
customers is done. They deal with 70% technical issues and 30%
commercial issues. ARAI (Automobile Research Association of India)
Certification process is done through application engineering. BIS (IS
1884) and E-marking certification process is also done through
application engineering.

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 4. PROCESS ENGINEERING

Date: 21.08.2015
Time: 01.30 pm-02.30pm Guided by: Mr. M. Ganesh

OBJECTIVE:
To converting information of design to product & establish ,
determine the process flow & tool design, conducting trial run, preparation
of production documents.
ACTIVITIES:
The drawing (design) is the primary input to this department.
 Pre-launch drawing
 Production drawing

Process department carried out the following activities

Time study
Economics
Line balancing
 Inputs
 Pre-launch engineering release note or change
note.

 Process change request (PCR) from users and

customer complaint.
 Internal rejection and corrective actions.
 Outcome from schedule PFMEA (Process
Failure Mode Effect Analysis).
 Process
 Initial feasibility review
 Process and production flow diagram
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  Listing the tool facilities and tool requirements.
 Finalization of tool design
 Layout preparation
 Preparation of Pre-launch control plan
 Initialization for tool development
 Tool trail and approval
 PFMEA-Process Failure Mode and Effect Analysis
 Pre-launch trial run
 Pre-launch feedback to product engineering
 Initial Capability plan study
 Preparation of production documents
a) Control plan
b) Job inspection
c) Process flow chart
d) Process sheet
e) PRE action plan
f) SOP-Standard Operating Procedure.
 Conducting Production trial run
 Process capability study
 Handing over to user
 Outputs
 Validated process
 Approved tool
 Production documents

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 5. PRODUCT ENGINEERING

Date: 21.08.2015
Time: 02.30 pm-03.30pm Guided by: Mr. N. Manikandan

OBJECTIVE:
To Design and analysis of a new component or changes in existing
design for fulfilling the customer feedback as well as market requirement.

ACTIVITIES:
The input to the department is come from export & STA departments.
Product development activities are carried out here.
 Design and development of new products or design changes in
already existing product.

 Based on customer requirement (like on road, off road

applications) placed vital role in product engineering. If there is
no requirement the feedback is taken in to account.

 The input to the department is come from EXPORT and STA

departments.

 The approval of design is get from customer. Then

development, testing, analysis is done.

 The pre-launch drawing is issued for component development.

The proto type is submitted to the customer for approval.

 If the customer approves the production drawing is done and

issued for production.

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 The CFT team plays vital role in the every stage of production
department activities.

 “Proposal review form” from application engineering

department with customer specification is forwarded to PDE.

 Initial feasibility report from PDE is given to ALE, which is

forwarded to customer.

 In case of new product development APQP (Advanced product

quality planning) is followed.

 APQP has five phases,

 Planning and defining

 Product design and development

 Process design

 product and process validation

 Feedback assessment and market requirement.

 After the completion of these five phases, if the results meet the
requirement then validation test like corrosion resistance test,
endurance test etc are undergone.

 PERN (Pre-launch Engineering Release Note) is released and

feedback report is analyzed.

 After feedback analysis ERN (Engineering Release Note) is

done.

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 Changes in existing product for design improvement PECN and
ECN (Pre-launch Engineering Change Note & Engineering
Change Note) is released.

 Software used in department is for drafting AUTO CAD and

for modeling SOLID WORKS.

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 6. MATERIALS & SUB CONTRACT

Date: 21.08.2015
Time: 03.30 pm-04.30pm Guided by: Mr. B. Sathasivan Mr.
R. Gopalsamy
OBJECTIVE:
Purchase of raw materials, components imports and packing materials
with respect to the demand as well as customers and market requirement.

ACTIVITIES:
PURCHASE
The input for the materials & sub contract department is obtained
from the Bill of materials. Based on the input they start their proceedings.
 Obtaining the demand of materials from the production
department.

 Purchase includes Indigenous and Imports which again sub

categorized into capital goods, raw components, consumables
etc.,

 Selection of the supplier through Internet or advertisements

given by the suppliers.

 Obtaining the details of supplier through “Supplier Evaluation

Form”.

 The result of evaluation is used to select the appropriate

supplier

 In evaluation form certain questions are asked based on their

results the vendor is evaluated to a percentage system.

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  Minimum 82% of evaluation result is required to select the
supplier.

 There is also some regular vendor list is in the department

based on their previous conducts.

SUBCONTRACT
Generally sub contract is done by following two ways. The two ways
are purchase (bought out) and another is sub contract.
 In purchase the product is fully get from outside. Issue of
purchase order is done on that stage. We called it has bought
out.

 In sub contract we provide all necessary tools and other

facilities to sub contractors for completing the product.

 In sub contract we provide production cost only.

 Components which are semi-finished for further operations may

be some time given to other vendors to complete those.

 We have 60 approved vendors. The process starts from

instructions given from PPC.

PROCESS :

Generally finishing process is done by sub contract nickel-

chrome plating, plating process (zinc, yellow, trivalent), painting and special
process (heat treatment).

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 7. SUPPLIER TECHNICAL ASSISSTANCE

Date: 21.08.2015
Time: 04.30 pm-05.00pm Guided by: Mr. M.Vignesh

OBJECTIVE:
To audit & analyze the quality of suppliers periodically and to provide
suggestions to improve themselves to meet the quality standards.
RESPONSIBILITIES:
Supplier technical assistant department performs activities in the
supplier side apart from commercial.
 Check for the capacity of the supplier
 Process audit for supplier

 Product audit

 Providing procedures and process flow

 Providing tools and maintaining them

 Identification of defects

 Determining the performance of the supplier

 FMEA process

 Implementing 5’s in supplier side

 Safety procedures to the suppliers

 Providing specifications to the suppliers regarding their factory

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TYPES OF SUPPLIER:

Generally there are three types of suppliers, they are

 Approved supplier

 Potential supplier

 New supplier

2.Approved Supplier

 This supplier is already supplying goods to the company

 The supplier has been already audited by the Supplier technical

assistance team and meeting the Roots Standards

3.Potential Supplier

 This supplier is not supplying goods but has been audited by

the STA Team and meeting the Roots Standards

 This supplier will be used as a backup in certain emergency

situations

4.New Supplier

 This supplier is new and is waiting to be audited by the STA

team for supplying goods to the company

o According to Roots Standards, the supplier should have ISO 9001

certification which is mandatory.

o After choosing a supplier for auditing is done

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 o Auditing is of three types,

1.Process Audit

2.Product Audit

3.System Audit

1. Process Audit

In this audit the process characteristics like the efficient use of

materials, rejections/ reworks and cost incurred and its related documents are
verified.

2. Product Audit

In this audit the product characteristics like dimensions, visual

inspection and compliance of product to the standards of the company and
its related documents are verified.

o During auditing the production is also witnessed and those samples

are evaluated both on site and internally.

o If the samples fail, re sampling is done.

o PSW (Product Submission Warrant) is submitted by every supplier

compulsorily

PPAP

o Production Part Approval Process

o There are 5 levels of PPAP

o Roots group of companies follows 5th level PPAP

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 o According to the level 5 PPAP, every supplier must have all the 17
documents as specified in PPAP which is to be submitted for clearance

o These documents after clearance must be possessed by the supplier

o If a supplier has been inactive for over 6 months, Re-PPAP is done.

GRADES FOR SUPPLIER

There are 4 kinds of grades which are given to supplier after their first
auditing. The grades are as follows,

1. C grade – Below 70%

2. B grade – 72% – 82%

3. AB grade – 82% – 92%

4. A grade – above 92%

o The periods through which the suppliers have to be re-audited is done

by using these grades as reference.

Grade Percentage Re audit Period Suggestion Provided

C <70% 1 year Cannot supply

B 72% - 82% 1 year Should improve more

AB 82% - 92% 2 year Need small improvement

A >92% 3 year None

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o According to Roots Standards, a supplier with 82% can definitely
supply good to the company

o Every supplier is provided with cards according to the number of

PPM rejections in each lot the supplier supplies to the company.

Colour PPM limit exceeded for

Yellow 1 month

Orange 3 months

Red 5 months

o If a supplier gets a red card, he cannot supply goods until he gets

permission from the company.

STA AUDIT AREAS

 Packing materials (label, box )

 Sealants, coolants
 Standard fasteners (bolt, nut)
 Bought-out parts
 Value addition process (surface treatment process)
 Raw materials (sheets, rods)

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 8. MARKETING

Date: 22.08.2015
Time: 09.30 am-11.30am Guided by: Mr. P.C. Parameswaran

OBJECTIVE:
To achieve targets, promoting the products and maintain proper
customer interaction, offering suitable product and ensuring time delivery.

ACTIVITIES:
 Marketing department maintains the Invoice and despatching
bills of the customers
 Developing the new ways to sell the products.
 Marketing deals with the markets such as
 Domestic

 Replacement.

 From dispatching section they receive a mail about the Net

weight, Gross weight, No of boxes to be despatched.
 Based on these details they prepare the Invoice to the customer.
 Original copy of the Invoice is sent to the customer by
marketing department through post.
 The process is represented below,
Marketing

Distributors

Sub dealers
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 9. INWARD INSPECTION
Date: 22.08.2015
Time: 11.30 am-01.00pm Guided by: Mr. S. Charles

OBJECTIVE:
To inspect the incoming raw materials and check & ensure for its
quality and dimension specification for quality ensuring.

ACTIVITIES:
In inward inspection there are two types of quality checking
inspection, namely
1) Incoming quality ( for quality assurance)

For suppliers, raw materials, bought out, sub contract,

2) In process quality ( for control)

VCC Chart, poka yoke

To reduce the cost of quality and time for inspection control plan is
issued.
Input chart is primary input document. It includes the
following, Raw material - roots material specification
Job made - engineering drawing
Sub contract - raw material
Inspection types
1) Supplier inspection
2) Internal inspection
3) External inspection

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 In the control plan function parameters are explained based on their
effects, they are
Significant character - safety rules, government norms& rules
Critical character - customer requirement affected parameters
High impact character - sub sequent affected parameters

LAYOUT INSPECTION
The layout inspection includes checking of all parameters without
child parts. We verify every individual part by reverse engineering. The
time duration of the process is 3 months.

TYPES OF DECISION TAKEN

1) Conditional acceptance
Including fit, form, functions
2) Rework
Sampling is carried out.
3) Rejected
Rejection done when major fault occur.

IS2500 is indicates as sampling method

48 hours lead time is provided to check for quality of sample parts.

In the department supplier quality report is taken in to account and we

cross verify them. For additional support third party testing report is also
taken in to account.

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 No of sample to Accept the lot if
Reject the lot if
Range of lot size be selected from the acceptance
number is
the lot number is
Up to 1000 5 0 1

1001 - 3000 8 0 1

3001 - 10000 13 0 1

10001 - 35000 20 0 1

35001&above 32 0 1

Initially the incoming materials are to be inspected. The components

are entered in the SAP. Based on the sampling plan the material has to be
inspected. The inspection report is updated in SAP. General Inspection

Raw materials like Metallic Sheets, rods had defects like

scales, rust, blisters, lamination, pitting, porosity, cracks, rust, torn edges, or
any other defect which will impair uniform appearance of
painted/electroplated surface up to the thickness.
Physical test it includes test the Tensile, Hardness, Yield strength,
Elongation of material.
TYPES CONTROL PLAN:
Incoming control plan – product affect parameters
In process control plan –process affect parameters
TESTING INSTRUMENTS
ECV- Ericsson cupping value test
ECV – (Ericsson cupping value) test also done in inward inspection. It
represents the material drawability of measurement.

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 Range =0 to 20mm
Least count =0.01mm
Ball intender material = steel
To determine the ability of metallic sheets and strip to undergo plastic
deformation in stretch drawing.
BREAK DOWN VOLTAGE TESTER
It is used only for enamel coated wires. This test is used for
determine the voltage at which electrical insulation ruptures and permit
current,
Copper – 3200V
Aluminium – 4800V
Range= 0 to 5000V
Resolution= 0 to 100V
COULOSCOPE MEASURING INSTRUMENT
It is used for measuring the metallic coating thickness value. Reverse
of electro plating principle. Coating will be melting and placed in the anode
OHM METER
Ohm meter is used for measuring the electrical resistance in a circuit.

RESISTANCE (R) ,
= Where,
=Resistivity of material
L= Length of coil
A=Cross section area of wire

Other testing instruments like AC current leakage test, leakage current

floe test, dial gauge test, micro hardness test also carried out.

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 10. PRESS SHOP

Date: 22.08.2015
Time: 01.30 pm-02.30pm Guided by: Mr. D.M. Selvaraj

OBJECTIVE:
To produce the component by using different operations as per
the requirement from the production planning and control.

ACTIVITIES:
Production planning and control is the primary input to press
shop. PPC Prepare the component requirement plan. A monthly plan is given
to the press shop. Based on the plan day- wise production is prepared. A
capacity plan which checks for the availability of tools, machine, man power
and number of working days. If there is a lacking then a contingency plan is
made and necessary action is taken out.
The monthly production work is given to the supervisor who decides
which machine has to be loaded. In press shop operations like blanking,
drawing, restrike, piercing, trimming etc., in press shop produces so many
components diaphragm, tone disc, point plate, point holder, and housing
with SCR.
During the process if any problems occur the component will be drop
the Non conformity box. After inspected the corrected work piece it will
dispatch to the powder coating, plating, and directed to assembly.

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 Preventive FLOW CHART
maintenance
schedule MR/076
START

Monthly horn
requirement plan from
Machine utilization PPC through mail/SAP
data like breakdown,
tool problem etc

Converting as component
requirement plan through
Any other
SAP-YBOMSTK
constraints in
mfg
Shop floor capacity
analyzing (man power,
machine tool& material
Stock verify at Ok
availability)
various locations
through SAP
Daily machine loading
plan preparation
Daily Raw materialRecords
production requisition
review meeting Production
process
Raw material stores
NC BOX
Inspection

Raw material with

Move to NC Next stage component status
area with NC tag process (or) card MR/619
final stage

REWORK/rejection as Dispatch with accepted Tool issue to

per NC Handling tag MR/169 production &
procedure WI/MRF/02 tool handling as
per tool handling
Monthly delivery
performance report
monitoring sheet MR/273

Monthly delivery non

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conformance advice-
MR/252 from PPC
VISUAL INSPECTION – HOUSING
1) Blank cut

2) Black shade

3) Scoring mark

4) Line mark

5) Wrinkles

6) Mis location

7) More oil

8) Rust

9) Scr riveted gap

10) Improper riveted

11) Collar draw damage

12) Slug impression mark

13) Turning burr

14) E- core riveting gap

15) E – core oil

16) Terminal hole damage

17) Improper turning

18) Lettering riveting punch chipped

19) Material defect

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 20) Rib formation

VISUAL INSPECTION – KEEPER RING

1) Blank cut

2) Line mark

3) Rust

4) Mislocation

5) Impression mark

6) Flank height variation

7) Crack

8) Burr wrinkles

9) More oil

TONE DISC
1) blank cut

2) line mark

3) rust holes offset

4) holes burr

5) bend

6) profile offset
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 7) black shade

8) more oil dust

9) white rust

DIAPHRAGM
 blank cut

 line mark

 improper notching

 blank burr

 wrinkles

 holes burr

 oil shade

 scoring mark

TYPES OF RAW MATERIAL

 Aluminium Zinc Galvanished Steel

 Cold Rolled Carbon Steel

 Spring Steel

 Stainless Steel

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TYPES OF PARTS
 Housing with SCR assembly

 Housing with e core assembly

 Diaphragm

 Tone disc

 Point plate

 Point holder

 Grill

 Keeper ring

 Mounting bracket

 Mounting bracket assembly

 Horn cover

 Connector

 Condenser bracket

 C clamp

 Piercing & bracket

 Piercing & bracket & notching

 Piercing & bracket &bending

 Piercing & bracket &cropping

37
  SCR Riveting, planishing& lancing

 SCR Riveting, flanging

 Edge chamfering & lancing

 Hour glass cutting

 Draw I-II-III Restrike

 Collar draw piercing

 Lettering & trimming

 Blanking &forming

 Forming& flanging

 Piercing, lettering& blanking.

TYPES OF PROCESS
 Blanking

 Drawing

 Restrike

 Piercing

 Notching

 Trimming

 Forming

 Embossing

38
  Flanging

 Edge chamfering

 RIB forming

 Collar draw

 Flattening/planishing

 Turning

 Riveting

 Bending

 Lancing

 Knurling

 Coining

 Stress relieving

In press shop Target rejected PPM/day is 25 PPM

PPM = (Rejection Quantity/Production Quantity) *100

39
 11. ASSEMBLY

Date: 22.08.15
Time: 2.30pm – 3.30pm Guided by: Mr. N. Gopalakrishnan

OBJECTIVE:
To assemble the horn by receiving components from various
departments, tune and test the horn for customer requirement and pack the
assembled horns and to send them for barrier audit and despatch.
OVERVIEW:
In assembly monthly 3 segment productions is carried out, they are
 Replacement

 OEM

 Export

 Export OEM

 Export

 There are 2 assembly divisions in plant.

 Part flow through SAP.

 There are around 20 assembly lines which are named in

alphabetical order

 Every month around 5 lakh’s horns are produced

 3 types of horns , namely

 Wind tone type
 Vibrating type
40
  Electronic type

 Trumpet type horns are named as WINDTONE and are one of the
most fast moving and highly demanded products in market. These
kinds of horns can be found in VOLKSWAGEN, SKODA. Etc.,

 Vibrating type horns are named as VIBROSONIC, VIBROMINI,

and MEGASONIC. Etc and is one of the loudest horns produced in
RIL and sound pressure confines to the Government Regulations.

 Electronic type horns are named as SMARTONE which uses

diodes in its working and is known for its endurance. This type of
horn is supplied as OE to one of the largest automobile manufacturer
TKML (Toyota Kirloskar Motor Limited)

 Depending on the market, there are three types,

 OEM (Original Equipment Manufacturer)

 Replacement

 Export

 Export market is classified into two types as

 Export replacement

 Export OEM

 HARLEY DAVIDSON is one the largest Export OE customer of RIL.

ASSEMBLY LINE CHARACTERISTICS:

 For assembling an horn there are usually 10 steps

41
 Each station is provided with a process data check sheet, Standard
Operating Procedure and NC Box

 Process data check sheet provides the parameters to be checked

before starting the assembly in each station.

 Details for Parameters like air pressure for pressing, air gap to be
maintained, height of diaphragm. Etc., are provided in the check sheet
depending on station

 Each station has jigs and fixtures for easy and quick placement and
assembly of components which are designed by PRE (Process
Engineering)

 Every components produced in every assembly line is frequently

checked by PATROL INSPECTION for dimensional characteristics

 Each station is provided and controlled by PLC and load cells.

These PLCs are programmed with sensors which sense the parts
picked by the operator and the air pressure used for tightening or
pressing the component. Any component which is assembled failing
the operating conditions should be placed in NC box. Otherwise the
pneumatic devices will not work.

 When more than 5 defective products are found during testing, the
assembly line is stopped, FEEDBACK TO CAUSE process is done
and each station is analyzed.

42
 GENERAL WORKING OF ASSEMBLY

Some of the assembly lines which were observed during the induction
program were:
 Wind tone W75
 R75

 Vibrosonic

 Clear tone

43
AUTOMATED PROCESS
Vibro sonic horns are also made by using automated process in which
the machines were designed by FDA (Facility Development and
Automation), a department of RIL and made by SIEMENS.
This system is used only when the demand for VIBROSONIC horns are
more as this system is capable of producing horns nearly 2 to 3 times greater
than manual production process. The rejection/rework of horns produced in
this process is less or NIL.
The steps in automated process are as given below:
 Locking of rectangle spool with coil in bottom cup

 Bridge assembly tightening  Terminal screw part

tightening

 Torque tightening of terminal screw

 Insulation resistance testing

 Ecore to point set assembly gap inspection and housing depth

measurement

 Gasket assembly and air gap rework

 Diaphragm pre assembly

 Height adjustment and diaphragm rotation

 Diaphragm final assembly

 Diaphragm assembly tightening

 Final measurement – height and parallelism

44
  Diaphragm assembly loading

 Grill assembly

 Screw loading

 Nut loading and side screw tightening

 Mounting bracket pre assembly

 Mounting bracket assembly tightening

 Horn pre tuning

 Horn tuning and testing

 Paint marking

 Sealant dispensing

 Terminal connector assembly and

tightening  QA inspection and horn

unloading  Packaging

CHARACTERISTICS:

 In each station, inductive proximity sensors are provided which

indicates the operator to choose the part to be assembled and the next
bulb glows only after picking up the previous component

45
46
 12. COIL WINDING

Date: 22.08.2015
Time: 03.30 pm-05.00pm Guided by: Mr. D.M.Selvaraj

OBJECTIVE:
To maintain production of the coil winding, point plate and point
holder and deliver to assembly department at right time.
ACTIVITIES:
 Coil winding is done on the spool which is produced from
“ROOTS POLYCRAFT”.

 Based on Dimensions Two type of spools are used , they are

 Circular

 Rectangular

 Coil made with different materials. Generally three types of

materials used , they are

 Aluminum

 Copper

 Copper- clad

 Number of turns of the coil differs for varying diameters of the

spool. Mostly copper is used for winding process.

 At some cases, Aluminum is used for winding process

according to the customer requirement. The gauge range is also
place important factor in coil winding. There are 22 types
standard wire gauge range is available.
47
 Spools are made up of with the following colors.

 Black

 Blue

 Yellow

 Brown

 White

 Totally 8 radial point riveting machines used. In these one is hot

radial rivet machine and other machine is self fixture machine. So
number of defect is very less in self fixture machine.

 In the winding push pull gauge is used for provide necessary

tension for winding. The value is 20n-m for tension.

 The main problem raised in riveting is gap in rivet and crack.

 After the winding process the resistance of the coil is tested.

The resistance tester is used for check the resistance of the coil.

 The specified value of the resistance is 920Ω (ohms).

 Heat sealing process is carried out on spool is done to avoid

slipping of the edges of coil from spool.

 The temperature of heat sealing process is 285oC and air

pressure is 2 bars.

 Then enamel of the wire is removed (manually) by using strip

and as well as chemical to ensure the conductivity/continuity.

48
 The chemical used is ENAMEL ENDCONNECTOR
REWINER -101. The time required for the process is 3-6
seconds.

 Rectangular spools outsides are moulded with vertical

moulding machine. The temperature of the process is 250 oC.

 The process time is 5 seconds.

 The following are some of the problem raised in moulding

process they are flash, short mould, wire damage.

 The crimping process is also done at the department. Cable lock

side and production side terminals processed at the stage.

 The process time is 40 seconds and air pressure required is 3.5

bar.

 Point plate assembly is carried out in this department. Tungsten

tip used for riveting.

 Riveting of the contact points over point plate and point holder
is done.

49
 13. POWDER COATING

DATE: 24.08.2015
TIME: 9.30 am – 11.30 am GUIDED BY: Mr. R.Murugesan

OBJECTIVES:
To provide aesthetic look of the horn by coating on the surface
and to improve the corrosion resistance of the component

ACTIVITIES:

 Total time required for the whole process to be completed is 2.5 hours.

Around 10,000 components are produced in one shift

Thickness of the powder coating is 4 to 7 microns
 Concentration of chemicals and pH of water is maintained
throughout the process for maximum efficiency of powder coating

 Tone disc and Housing are parts which are usually subjected for
powder coating

 The pH value is maintained at 5-7 at all stages of water rinsing.

 The speed of conveyor is 1.3 meter per minute.

50
 PROCESS FLOW CHART

 All the parameters in the Process data check sheet are checked and
verified and signed before the start of each shift

51
  Acid pointage(concentration level) in the bath are checked for
every shift at four places of the path according to the SOP (Standard
Operating Procedure)

PROCESS DESCRIPTION:

1. Components are obtained from the press shop in bins

2. Components are checked for rusting and the rusted components are
separated and stored in bins

3. Rusted components are subjected to derusting operation followed by

water rinsing. Water mixed with Defiance-D in the ratio of 9:1 is used
for derusting process

4. Components without rust are loaded in jigs (J-jig for housing and
Screw jig for tone disc)

5. Components are subjected for degreasing where THELNIKAL LD

(ratio of 100: 7.5 at 12000 liters of water) used for oil remover

6. The components are rinsed in water

7. Components are subjected to zinc phospating where zinc is for about

a thickness of 2 micron

8. Components are rinsed in water again

9. Then the components are subjected for passivation using DUROFIX

NC to obtain a smooth surface

10.The components are then cured using IR bulbs where the number of
bulbs are 24 in which each bulbs operate at temperature around 500 C

52
11.Components are cleaned and the subjected for a pretreatment
inspection

12.Components are subjected to powder coating using (EPOXY

POLYESTER) powder coating gun. A gap of 2 to 5 inches is
maintained between the gun and the component. The air flow through
the gun is at the rate of 0.5 to 3.5 m/min. ratio of mixing recycle
powder: virgin powder (1:3). Cycle time for 100 components (30 to
40 sec) for more than 100 components( 40 to 70 sec)

13.The Ecore/ SCR of the housing are cleaned and are free from powder
coat. In some critical maskants are applied where the powder coat
does not stick to it.

14.Coated Components are then oven cured at 220oC to 270oC for 60

minutes

15.Components are subjected to visual inspection where the common

defects occurring are:

i. Improper application of powder coat

ii. Thickness of powder coat is not uniform

iii. Over application of powder coat

16. Components are unloaded and stored in bins with tag.

53
 14. EXPORTS
Date: 24.08.2015
Time: 11.30 am-01.00pm Guided by: Mr. S. Raghuprakash

OBJECTIVE:
The objective of exports is to promote product, establish
customers internationally and to provide services to them such as payment,
shipping, etc., thereby selling the products globally by satisfying the
requirements.

ACTIVITIES:
PRODUCT PROMOTION
The customers or traders available in international market are
reached through auto-expos, automotive exhibitions and various other ways
of advertising.
CONTACT ESTABLISHMENT
The company establishes contact with the customer or trader
through mails, visiting cards got during exhibitions. CUSTOMER
INTERESTED
The feedback from the customer is obtained by giving samples
for free of cost. Based on the feedback the product is manufactured.
CUSTOMER DESIGN REQUIREMENTS
The customer may have different requirements on the product
like aesthetic, function, etc. Based on that the design feasibility is checked
and then product is manufactured.

54
NEGOTIATION
The customer decides the mode of shipping which determines the
cost of the purchase. It is based on INCO terms.

INCO TERM (International commercial)

It is a series of predefined commercial term to communicate
clearly the costs and responsibilities of a selling company to take while
exporting goods to abroad. It involves 3 terms namely: DDU (Delivery Duty
Unpaid)
The manufacturing company takes the responsibility of
paying custom clearance at loading port and also cost involved in
shipping freight. The customer pays the custom duties at the
unloading port.
DDP (Delivery Duty Paid)
The manufacturing company takes the responsibility of
paying custom clearance at loading port and also cost involved in
shipping freight. The customer pays the custom duties at the
unloading port.
FOB (Free On Board)
The manufacturing company takes the responsibility of
paying custom clearance at loading port. The customer pays the
custom duties at the unloading port and also cost involved in
shipping freight.

55
PAYMENT TERMS
Based on the type of negotiating term the price of the
shipping goods is billed. The customer chooses his facilitating type of INCO
term.
MODE OF PAYMENT
There are three modes of payment.
(i) Advanced Payment
In this payment is done by buyer before the goods are
dispatched to the customer.
(ii) Partial Payment
In this 50% payment is done by buyer before the goods are
dispatched to the customer which is advance payment and remaining
50% money after dispatch of goods
(iii) Credit
In this payment is done after 30 to 90 days of invoice. This
type of payment is done by OEMs.

DOCUMENTATION
(i) PROFOMA INVOICE
It involves billing of the goods requested by the customer.
This invoice indicates what the customer needs to pay based on the type
of negotiation chose.
(ii) BILL OF LADDING
While the goods are stuffed in shipping freight this bill is
provided by the custom office ensuring that the goods are shipped by the
manufacturer.

56
(iii) PACKING LIST
This letter is enclosed inside the packed goods box which
indicates where the quantities in the Profoma are located as per the type
of the product. So that customer after receiving the goods can check and
locate the goods easily.
(iv) LETTER OF CREDIT
To receive payment from the customer from abroad this letter
is issued to bank which acts a third party and gets payment from the
customer and credits the manufacturer.
(v) CERTIFICATE OF ORIGIN
The EXPORT COUNCIL from MINISTRY OF EXTERNAL
AFFAIRS awards this certificate to the manufacturing industry to ensure
that the products are manufactured in the original location.

FUNCTION OF EXPORTS PROCESS

(i) CUSTOMER COMMUNICATION
The activities from product promotion to product received
takes place here.
(ii) DOCUMENTATION
Generating PROFOMA invoices, Bill of ladding, Packing list
and letter of credit takes place here.

57
 15. BARRIER AUDIT

Date: 24.08.2015
Time: 01.30 pm-02.30pm Guided by: Mr. S. Charles

OBJECTIVE:
The objective of Barrier audit is to prevent products from fail at
the customer end & ensure the 100% quality.

ACTIVITIES:
Before dispatch, the barrier audit conduct the tests at following
areas Functional – operating voltage
Dimensional – bolt size, outer diameter
Visual – cracks, burrs, etc.,

 After the product is packed in box it is kept for barrier audit.

 For OEMs (100 % inspection is carried out) all the products

packed in box are inspected while for exports and other customers
checking is based on sampling plan.

 Pre-dispatch inspection is carried out only for OEM customers

before delivery. ( Eg: Harley Davidson)

 For export products they check randomly 2 lots. Sampling

inspection is carried out.

 If there are no defects from samples taken then the lot is approved
for storing in store.

58
 If there are defects from samples taken then NC tag is pinned on
the lot and then informed to Quality department.

 After that all the products are inspected and the Quality department
will look for root causes for the defects in manufacturing.

 Based on that the lot is reworked for defective products or rejected

if cannot be reworked and sent to scrap yard.

 In the Barrier Audit there is check sheet provided which involves

checking of Dimensions, Function and Visual inspection in case of
products to be exported or other customers.

 In the case of some OEMs, they itself provide a report to be filled

by inspecting the lot by the Barrier Audit to prevent line rejection.

 After Barrier Audit the goods are transferred to finished goods

storage.

 Before the products are given to the hands of customer PRE-

DISPATCH inspection is done because goods kept in storage may get
rusted or even it won’t function. Hence it is done.

59
 16. TOOL MAINTENENANCE

Date: 24.08.2015
Time: 2.30pm – 3.30pm Guided By: Mr. D.M. Selvaraj
OBJECTIVE:
To store the tools that are used in the press shop in tool crib and to
provide them to the respective machines whenever required and maintain the
tools by servicing periodically and keep track the status of the tool

ACTIVITY:
Tool maintenance process involves the storage of tools that are used
in press shop like press tools, milling tools, drilling tools, lathe tools and
also some measurement tools like vernier caliper and plug gauges.
DETAILS:
No. of tools = 928
No. of tools in press shop = 611
No. of tools in subcontract = 317
Total No. of instruments = 219
Plug gauges = 99
Attribute gauges = 91
Others (Vernier, micrometer, etc.,) = 29
Tool life maximum (Piercing, Blanking & Bending) = 2700000 strokes
Average preventive maintenance interval (Feeder press tools) = 100000
strokes
Preventive maintenance interval maximum (Diaphragm forming) = 1000000
strokes

60
MAINTENANCE TYPES:
1. Breakdown maintenance

2. Preventive maintenance

3. Under maintenance

TOOL CONDITION
S. No Condition Colour code
1 Most critical Red
2 Critical Yellow
3 Need for production Blue
4 Preventive Maintenance Grey

TOOL STATUS
Colour Code Status
Green PRD Issued to production
Send for breakdown
Red BRD
maintenance
Send for preventive
Yellow PM
maintenance
Issued to tool room
Blue RRP
maintenance
White TRL Issued for trial run

61
GENERAL INSTRUCTIONS FOLLOWED:
1. In each shift after the completion of production the last component
made by using each tool is placed in the tool crib with the last
component tag where the condition of tool and dimensions of the
component are inspected and approved by the quality department.

2. Every tool in tool crib is provided with a tool status card which tells
whether tool is ready for production or not.

3. Tool history card is provided for each tool which shows the history of
the tool like maintenance periods, number of strokes in which the tool
was used. Etc.,

DOCUMENTS:
1. Tool History card

2. Preventive maintenance check sheet

3. Last Component Tag

4. Tool status card

TOOL CRIB (TOOLS STORAGE AREA)

Tool history Card is maintained for each tool which has produced
quantity, location, problems if any and reasons for the problems. Tool
managing activities, preventive measures, tool life monitoring, preparation
of tool status card are carried out in tool crib.

62
 17. PLANT ENGINEERING

Date: 24.08.2015
Time: 03.30 pm-05.00pm Guided by: Mr. P.Boopathy

OBJECTIVE:
The main objective of plant engineering is machine maintenance
civil, carpentry, fabrication and general engineering activities.
ACTIVITIES:
 Break down hours
 MTTR(Mean time to repair)
 MTBF(Mean time between failure)
 Preventive maintenance VS adherence maintenance
 CIP(Continues improvement plan)  ICS(Internal
customer satisfaction)
 IQA(Internal quality audit)
 Minimize the maintenance cost.
ICS (internal customer satisfaction):
 The performance of the plant engineering department is validated by
getting feedback from the departments in which it is functioning like
press shop, coil winding, assembly etc, Carried out 4 months once.
 Internal customer satisfaction is conducted quarterly

 Internal quality audit is audited by plant engineering every six months

for maintaining quality of machines. Carried out 6 months once.

63
MAINTENANCE:
 Break down maintenance.
 Preventive maintenance.

 Predictive maintenance

 Time based maintenance.

Break Down Maintenance:

Break down maintenance is carried out after the machine failure.
Plant engineer know about this failure through SAP, E-mail, message.
Example:
When there is any break down in press shop, machine details, name of
the person who reported the problem, at what time the machine failure etc.,
will be intimate to the plant engineer through SAP.
Preventive Maintenance:
Preventive maintenance is nothing but to carry out before the
machine failure. Preventive maintenance is carried out may be hourly based
or monthly or yearly or whenever necessary.
Example:
For checking the oil level of machine may be hourly, monthly
yearly. Predictive Maintenance:
Predictive maintenance is to predict the machine failure
condition.
Example:
Bearing noise
Lubricating oil level
checking. Inventory target
For plant engineering 4.75 lakh’s for monthly maintenance.

64
 Time based maintenance:
Based on the time the machine maintenance to be carried out is
called as time based maintenance.
Example:
Mainly it is used for generator and compressor.
SAP:
SAP stands for system application product.
The machine status, machine history, machine breakdown and machine
rectification details are updated in SAP.
PROCESS FLOW
EQUIPMENT/MACHINE INSTALLATION
1. Equipment installation
2. Machine capability study
3. Preparation of
preventive/predictive/daily
maintenance
MACHINE MAINTENANCE
1. Preventive-
monthly schedule.
2. Predictive
3. Breakdown-repeated
breakdown analysis
4. Daily

PACKAGING AND PRESERVATION OF

UNUSED MACHINES

SPARE PARTS MANAGEMENT

MAINTENANCE RECEPIT OF
INDETIFICATION OF ISSUE OF MATERIALS
OF SPARES STOCK INCOMING
CRITICAL SPARE PARTS
PARTS

65
 18. OVERVIEW OF ROOTS POLYCRAFT
Date: 25.08.2015
Time: 09.30 am-01.00pm Guided by: Mr. S.Srinivasan
Mr.M.Muthukaruppan
OBJECTIVE:

The objective of ROOTS POLYCRAFT is to manufacture plastic

products like spools, oil filters, wires, etc., through injection moulding and
extrusion process

ACTIVITIES:

Roots Polycraft gets two types of orders namely,

Job Order

Sales Order

In Job Order type the raw materials and dies will be provided by the
customer itself whereas in the sales order only the design specification will
be given by the customers.

INWARD INSPECTION

It involves visual inspection which is the colour of raw material and

supplier name. Inward inspection is carried out in store itself.

MATERIALS USED

It involves storage of raw materials obtained from suppliers. The raw

materials obtained are

66
 PP - Polypropylene

HDPE - High Density Polyethylene

ABS - Acrylonitrile Butadiene Styrene

Nylon 66

MACHINES FOR MANUFACTURING

In Roots Polycraft only moulding and extrusion process are done. It

has 7 Horizontal Injection Moulding machine and 4 Vertical Injection
moulding machine and 1 extrusion machine.

Horizontal Injection moulding machines

Fu Chun Chin

Ferromatik

Sumitom

ENGEL

Ferromatik

Windsor

EXTRUSION

It involves continuous production of plastic hoses and tubes for air

horns.

DE-FLASHING

It is the removal of burrs and runners (extra material) from the

moulded part. It is carried out manually by plastic knife.

67
ULTRASONIC WELDING (use of ultrasonic wave energy)

For joining plastic trumpet to plastic housing ultrasonic welding is

carried out. It consists of transducer to produce ultrasonic waves by inverse
piezo electric effect which is converted to heat for joining the parts. During
welding for every 2hrs 3 products are checked. Process time is 450 m.

FINAL INSPECTION

There are various measuring instruments used for final inspection of

manufactured product namely:

(i) Digital Vernier: (0-300)mm

(ii) Vernier Height Gauge: (0-600)mm

(iii) Push Pull Gauge

(iv) Plug Gauge

(v) GO NOGO Gauge

PRE-DISPATCH INSPECTION

The products stored are checked before dispatch of products to the

customer as per check sheet to prevent products to fail in the hands of
customer.

CHECKING PARAMETERS

o Pressure, Temperature

o Short weight & process time

o Colour & material

68
 19. OVERVIEW OF RPP
Date: 25.08.2015
Time: 02.30 pm-03.30pm Guided by: Mr. A. Chellathurai

OBJECTIVE:
To manufacture high precision components with the use of
conventional and non-conventional machines.

ACTIVITIES:
 RPP – ROOTS PRECISION PRODUCTS manufactures the high
precision components.

 They use precision & conventional machines and tools to

manufacture these components.

 Casting products to be machined is produced from the casting

plant RCPL.

 For the development of this process they maintain a development

cycle.

 Analysis of the process, inspection, and process planning

documentation is done in development cycle.

 Progressive compound combination draws tools used.

 The materials used in tools are HSS, HCHCr

 They provide injection moulds and die cast tools.

 Manufactured press tool and injection mould for RIL and also
other customers

69
  Used various types of machines like CNC, EDM, conventional
machines.

 Tool enquiry sheet from the customer and customer requirement

 Design a tool with the help of tool design data sheet and CFT
team.

 It contains piller required, type of machine, holder type, cavity

type, no of spares and productivity of the tool per month.

 Finally tool approval sheet will be prepared and send to the

quality for validation and approval.

FACILITIES

 Tool design department with CAD/CAM, SOLID

WORKS

 CNC Machines with CAM software

 Conventional machines

 Electrical Discharge Machine

 Components produced are sent to GE health care unit for

assembling health equipments.

 Some of the components produced are assembled in HPED unit

itself.

 Components produced are of high cost in materials and as well

as the machining process.

70
  Components are inspected using vernier and other Gauges to
check the dimensions and then final inspection is done.

 After these process the components is sent to packing.

 It has vertical machining center- 11 No’s and Turning centers – 3

Nos.

 G codes and M codes are used as input language to CNC

machines.

 Tools used in CNC machines are HSS, Tungsten carbide,

ceramics.

ELECTRICAL DISCHARGE MACHINE (EDM)

In EDM two electrodes are used to create the electrical spark

between electrode and work piece.
TYPES
 Wire EDM

 Die sinking EDM

The temperature of the removing zone is nearly around 12000 oC. The
removal rate of machine is,
For rough machining = 0.35mm
For surface finish = 0.01 mm

71
 20. METROLOGY

Date: 25.08.2015
Time: 03.30 pm-05.00pm Guided by: Mr. R.Kamalakannan

OBJECTIVE:
To calibrate the instruments against standards and measuring
dimension of the product

ACTIVITIES:
 They perform the calibration against with standards and
measurement in fields like Mechanical, Electrical and Thermal.
In metrology lab three field of calibration is to done.
1) Mechanical
2) Electrical
3) Thermal
Mechanical Calibration
Mechanical calibration instruments are
1) Vernier caliper (L.C = 0.02)
2) Vernier height gauge (L.C = 0.02)
3) Dial gauge
4) Micrometer
5) Gauge calibrator
6) Universal length measuring system (10-100)
7) Scale calibrator
8) Pressure calibrator
9) CMM (Coordinating measuring machine)

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IS 3651 Standard is used to calibrate the linear instruments
IS 2967 Standard is used to calibrate the micrometer instrument
Slip gauges are used as the standard part to calibrate the instruments.
Parallelism of instruments also checked against the standards.
Gauge calibrator
Grade
 k - Means three type slip gauge for checking.
 0 - denotes equipment calibrate
 1 - tool room
 2 - Machine shop.

Electro technical calibration:

1) Multi product calibrator
It is made from United Kingdom
It is used for calibrating multimeter, voltmeter, and
ammeter 2) Decade Megohm Box
It is used for measuring
resistance 3) Tachometer
It is used for measuring speed.
4) Watt meter
It is used for measuring energy
1) Profile projector

10 to 100 times magnification for checking of small minute

products.

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THERMAL:
1) Dry Well Calibrator

Range= -25 C to 1500oC

o

2) Torque Wrench Calibration

Range= 2.5N-M to 11 N-M

Metrology department is accredited by “National Accreditation Board for

testing Laboratory (NABL)”
The temperature and humidity is maintained as the NABL norms

Scale calibrator
It is used to calibrate the length measuring devices.
Pressure calibrator
Used to calibrate the pressure gauges.
Electronic weighing machine
Used to check the weight and for balancing of weights.

CONCLUSION:
Thus the induction training program has been completed as
per schedule and knowledge about different processes has been gained
and the report for induction has been prepared.

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