Roots Inplant

A Report on Inplant Training undergone at

ROOTS INDUSTRIES INDIA LIMITED,

Coimbatore

Submitted by

Bernard Eugine F (10M110)

Danail S (10M111)

PSG COLLEGE OF TECHNOLOGY

Coimbatore – 641 004

ACKNOWLEDGEMENT

We take this opportunity to express our sincere

thanks to Dr.R Rudramoorthy, Principal and Dr.P V

Mohanram, 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 Roots

Industries India Limited for consenting us the permission to

undergo training in their organization.

We would like to express our gratitude to Mr.N

Sampath Kumar, 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.

We would also like to thank Mr Saravanan, Associate

Head HR, for helping us to get this opportunity.

TABLE OF CONTENTS

Contents

Page No

1. Company Profile 1

2. Organization Structure 6

3. Product Mix

7

4. Milestones 8

5. Production Process in Horn Division 10

6. Production Department

11

7. Parts of a typical horn 11

8. The working principle of a horn 12

9. Classifications of horns 12

10.Horns manufactured by Roots 13

11.Press Shop 13

i. Organizational structure of Press shop 14

ii. Raw materials 14

iii. Machines 15

iv. Processes 15

12.Electroplating division 17

13.Powder Coating 19

14.Coil Winding 22

15.Assembly 24

16.Conclusion 25

1

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

2

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 40 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 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.

Roots Industries Limited

Roots Auto Products Private Limited

Roots Multiclean Limited

Roots Cast Private Limited

Roots Precision Products

Roots Digital Engineering Services Private Limited

Roots Brake System Private Limited

Roots Polycraft

3

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 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.

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 self-sufficient.

4

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

5

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, Experience, Innovation, Integrity,

Introspection, Professionalism, Quality Culture and Team Work.

6

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.

Organization Structure

Director Operations Vice President

Horn Divisions

Chief Marketing Officer

NDP & Trade Goods Division

Electro Plating

Executive Chairman/ Managing Director

7

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

High Precision Engineering

Division

Metrology Division

8

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.

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

9

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 and the first in the world to win

ISO/TS 16949

2000 The first to introduce digitally controlled air horns

and low frequency, low decibel irritation free Jumbo

Air Horns.

2003 Roots Industries Ltd., Horn Division is accredited

with ISO 14001:1996

2003 Roots Industries LTD., upgraded its ISO/TS 16949

from 1999 version to 2002 version

2004 Roots Industries Limited(RIL) opens its 100%

exclusive Export Oriented Unit at their Horn

Division, Thoppampatti, Coimbatore to cater the

needs of Ford, North America

2004

RIL’s EOU commences its supplies to Ford, North

America

10

2004 Roots Multiclean Limited(RMCL) inaugurates its

100% EOU Plant at Kovilpalayam, Coimbatore

2004 Roots Cast Private Limited(RCPL) inaugurates its

Unit II at Arugampalayam, Coimbatore

2004 Roots Auto Products Private Limited(RAPPL)

expands with its Machining Division at

Arugampalayam, Coimbatore

2004 RIL successfully launches its Malaysian Plant

2004 The group company American Auto Service is

accredited with ISO 9001:2000

2005 Roots Industries Limited., is certified with MS 9000,

a pre-requisite for Q1 award for Ford Automotive

Operations

2005 Roots Metrology & Testing Laboratory has been

accredited by National Accreditation Board for

testing & calibration in the field of mechanical-

Linear & Angular

2005 Roots Industries Limited., is awarded Q1 by Ford

Motor Company

2005 Roots Industries Limited., Horn Division upgraded

its ISO:14001 from 1996 version to 2004 version

Production Process in Horn Division

Self Tapping Screwing

11

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 DIVISION

12

Production department of horn division of Roots Industries India

Pvt ltd comprises of the following sections viz.,

Press shop

Coil Winding

Assembly Division

Electroplating

Powder Coating

PARTS OF A TYPICAL HORN

A simple horn consists of the following components.,

Housing with SCR assembly

Terminal base

Coil

Point plate

Point holder

Armature plate & Armature Rod

Diaphragm

Tone disc / Trumpet

Grill

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

13

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

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

distance

HORNS MANUFACTURED BY ROOTS

14

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

Tone disc

Keeper rings & Grills

Mounting brackets

Point holder & point plates

Organizational structure of Press shop

15

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-Zinc

Housing, Mounting Brackets, Tone disc & Diaphragm

Spring Steel

Mounting Brackets, Point Plate, Point Holder

MACHINES

HEAD

ASSOCIATE SYSTEM & TOOLS

MANAGEMENT

ASSOCIATE HEAD MANUFACTURING

ASSOCIATE MANUFACTURING

SHIFT ENGINEERS

16

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

PROCESSES

HOUSING

Raw Material Hour Glass Cutting Output Housing

Re-strike

Piercing

Lettering

Trimming

17

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

18

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

Zinc Plating (Alkaline)

19

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

Barrier Audit

Despatch

20

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 phosphating

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

21

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.

22

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

article "Fusion Bonded Epoxy Coatings"

Cooling the Components

Unloading the Components

Storing the Components

23

COIL WINDING

The processes involved in Coil Winding section are

Point plate and point holder riveting

Coil winding onto the spool

Rooting and Cutting

Cleaning

Coil Winding Machine

24

Coil (back) part of a Horn

25

ASSEMBLY

Spool Assembly locking, point holder &

26

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

27

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.