Roots Industries India Limited Production Process and Products Report

CONTENTS
CHAPTERS TITLE PAGE NO
1 INTRODUCTION
1.1 Company Profile 02
1.2 Organization Structure 07
1.3 Products 08
1.4 Milestones 09
2 PRODUCTION PROCESS
2.1 Production Process in Horn Division 11
2.2 Production Department 12
2.3 Parts of a typical horn 12
2.4 The working principle of a horn 13
2.5 Classifications of horns 14
3 PRODUCTS & MAKING OF HORN
3.1 Horns manufactured by Roots 14
3.2 Press Shop 14
3.2.1Organizational structure of Press shop 15
3.2.2Raw materials 15
3.2.3Machines 16
3.2.4Processes 16
3.2 Electroplating division 18
3.3 Powder Coating 20
3.4 Coil Winding 22
3.5 Assembly & Testing 24
4 CONCLUSION 25
5 REFERENCE 26
6 PHOTO GALLERY 27
INTERNSHIP REPORT 2019 ROOTS INDUSTRIES INDIA LIMITED.,
1 INTRODUCTION
1.1 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
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
KARTHIKEYAN. D, KAVINCHANDER. A &SANJAY KUMAR. N 2

III BSc ECS, Department of Electronics and Communication System
Sri Krishna Arts And Science College, Coimbatore - 08
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
 RK Nature Care Hospital
 SatchidanandaJothiNikethan Matric Higher Secondary School
 Roots Metrology Laboratory
 Roots industries Malaysia Sdn. Bhd

Roots Multi-clean 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 HakoWerke 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. 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
 Dye-casting
 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
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.
CORPORATE OBJECTIVE
Initiate and implement long-term growth strategies that are focused
on holistic development of products, services and organisational goals Ensure
all strategic initiatives reflect positively on all stake holders involved identify
key sectors for new growth initiatives.
VISION
Make a clear difference as a responsible corporate entity that is
committed to technological, social, ethical and environmental betterment. This
is achieved through
 Sustaining a lead position as a trusted solutions provider to
customers.
 Adding value in every way, from technology to quality to customer
relations.
 Creating a free spirited, intellectually challenging work culture
within the organisation.

 Ensuring individual social responsibility plays a collective role in

building impactful corporate social responsibility.
1.2 ORGANISATION STRUCTURE
Executive Chairman/
Managing Director
Director Operations Chief Marketing Vice President

Officer
Horn Divisions Electro Plating
NDP & Trade

Goods Division
Metrology
Division
High Precision
Engineering
Division

Ownership Pattern
Board of Directors
Chairman
Company Secretary
Manager
Assistant Manager
Associates
The Roots Industries have a total paid up Shares of 4, 80,000 Equity Shares of 1
RM each.
1.3 PRODUCTS
Roots Industries specializes in the manufacture of a wide range and line-
up of automobile horns. Roots is a leading supplier to all the major vehicle
manufacturers like Ford, Daimler Chrysler, Mitsubishi Lancer, Mahindra &
Mahindra, Toyota, Tata Motors, Fiat Uno and Siena, TELCO, TVS Motor
Company, Kinetic Honda, etc. Roots Industries Limited places a premium on
original technology and innovation. Roots' indigenous talent has kicked off a
spree of growth unmatched in the history of automobile OE manufacturers. .

Product: - Wind tone, Vibrosonic, Clear tone, Bosch Range, Roots 90, Mega
sonic, Smartone, Spider, FSA2, R 70, Sensors
 Wind tone: W 90, Wind tone Super, Wind tone Trio, Wind tone
Rainbow.
 Vibrosonic : Vibromax, VibrosonicDelux, 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.
1.4 MILESTONES
1970 Promotes American Auto Service for manufacture of Electric

Horns
1972 First to manufacture Servo Brakes for Light Motor Vehicles
1984 Roots Auto Products Private Limited was established to
manufacture Air Horns, Die Casting Unit commences
commercial operations

1988 Polycraft, a unit for Plastic Injection Moulding was established

1990 Roots Industries Private Limited takes over Electric Horn
business
1992 RMCL enters into Techno-Financial collaboration with M/s.
HakoWerkeGmbh, 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
RIL’s EOU commences its supplies to Ford, North America
2004
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) expandswith 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
2 PRODUCTION PROCESS
2.1 PRODUCTION PROCESS IN HORN DIVISION
Self Tapping Screwing
Spool Assembly Locking
Point Holder Assembling

Diaphragm Assembling & Tightening
Horn Pre Crimping & Final Crimping
Air gap Measuring & Adjusting
Terminal Connector Bending & Mounting
Bracket Assembling
Tuning Range Measuring & Sealant
Application &Inspection
2.2 PRODUCTION DEPARTMENT OF HORN DIVISION

Production department of horn division of Roots Industries India Pvt
ltdcomprises of the following sections viz.,
 Press shop
 Coil Winding
 Assembly Division
 Electroplating
 Powder Coating

2.3 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
2.4 THE WORKING PRINCIPLE OF A HORN
The AC supply to the terminal base lead to the flow of current through
the coil via the contact points between the point plate and point plate holders
which in turn induces an electro motive force inside the coil.
The magnetic field thus created pulls in the armature rod connected to the
diaphragm until it breaks the contacts of the point plate and the point plate
holder that breaks the flow of current thereby demagnetizing the coil. This
pushes the armature rod to its original position that strikes the diaphragm
producing sound at certain desired frequency that is amplified by the tone disc.

2.5 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.
3 PRODUCTION DEPARTMENT
3.1 HORNS MANUFACTURED BY ROOTS
 Windtone
 Vibrosonic
 Cleartone
 Bosch Range
 Roots 90
 Megasonic
 Spider

 FSA2
 R 70
3.2 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
3.2.1 Organizational structure of Press shop
HEAD
ASSOCIATE ASSOCIATE HEAD ASSOCIATE

SYSTEM & TOOLS MANUFACTURING MANUFACTURING
MANAGEMENT
SHIFT ENGINEERS

3.2.2 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.
3.2.3 MACHINES
 Automatic Press
Used for Housing alone.
 Mechanical feeder Press
Used for Point plate, Point holder, Blank, Mounting Brackets.
 Power Press
Used for Housing, Tone disc, Screws.
 Hydraulic Press
Used for Diaphragm.
 Pneumatic Press
Used for Tone disc, Piercing Operation.

3.2.4 PROCESSES
HOUSING
Raw Material Hour Glass Cutting Output

Housing
Re-strike
Piercing
Lettering
Trimming
HOUSING AND SCR ASSEMBLY
SCR RIVETING
Raw material PLANISHING Output
LANCING
(Housing & SCR)
(Housing)
TAPPING (SUB CONTRACTORS)
Powder coating

TONE DISC
BLANKING
LETTERING
Raw Material FORMING Output
PIERCING
(Tone disc)
POWDER COATING
3.3 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)
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 goodsLoading

Barrier Audit
Despatch
3.4 POWDER COATING
 Loading the component
The obtained raw material is now set to load in the powder coating process.
 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 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.
 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 Component
 Storing the Components
3.5 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

Coil (back) part of a Horn
3.6 ASSEMBLY
Spool Assembly locking, point holder &
Tuning screw Assembly
Terminal Base Assembly Tightening
Diaphragm Assembly Tightening
& Height Measuring
Gasket Selection &
Pre Horn Assembly

Horn side screw Tightening
Horn Pre Tuning &
Mounting Bracket Assembly
Testing ,
Stickering & Despatch

4 CONCLUSION
In a dynamic world that is driven by technology, a successful presence

depends on the way we mould that technology to fit popular needs. Indigenous
talent, a daring attitude, courage to accept and learn new things and the simple
spark of an idea. That is the genesis of ROOTS.
As a Third year electronics 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 an Electronics students in making this possible.
During our stint at Roots, we have learnt several things besides

engineering which include communication skills, analytical skills, importance
of safety in industry, time management and the most important fact that no work
is treated less.
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 15

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 we are more confident to enter the industrial
world and build our future career.

5 REFERENCE
1. http://www.rootsindustries.com/
2. https://www.rootsmulticlean.com/
3. https://in.linkedin.com/company/roots-industries-india
4. https://en.wikipedia.org/wiki/Powder_coating
5. "The "Voice" of the "Queen Mary" can be heard ten miles away!". Retrieved 2011-11-28
6. https://en.wikipedia.org/wiki/Coil_winding_technology
7. http://9.yahs.constantinctief.de/ger/horn-relay-circuit-diagram.html

6 PHOTO GALLERY


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CONTENTS

CHAPTERS TITLE PAGE NO

1.1 COMPANY PROFILE

Roots Industries India Ltd. is a leading manufacturer of HORNS in India

With a strong innovative base and commitment to Quality, Roots

KARTHIKEYAN. D, KAVINCHANDER. A &SANJAY KUMAR. N 2

Roots Groups promoted by Mr. K. Ramasamy, A Master Degree holder

 Roots Industries Limited

KARTHIKEYAN. D, KAVINCHANDER. A &SANJAY KUMAR. N 3

Roots Multi-clean Limited

Roots Multiclean Ltd based in Coimbatore, a Southern city in India

The group comprises of server important manufacturing units with

Roots Precision Products

Roots Precision Products was established in 1987 to address the in-house

KARTHIKEYAN. D, KAVINCHANDER. A &SANJAY KUMAR. N 4

Roots Polycraft Limited

Roots Polycraft (PC) was established in 1988 to manufacture precision

Roots Cast Private Limited

 RSV Governor hsg Injection Pump

KARTHIKEYAN. D, KAVINCHANDER. A &SANJAY KUMAR. N 5

 Heat- Sink For Alternator

KARTHIKEYAN. D, KAVINCHANDER. A &SANJAY KUMAR. N 6

 Ensuring individual social responsibility plays a collective role in

1.2 ORGANISATION STRUCTURE

Director Operations Chief Marketing Vice President

Horn Divisions Electro Plating

NDP & Trade

KARTHIKEYAN. D, KAVINCHANDER. A &SANJAY KUMAR. N 7

KARTHIKEYAN. D, KAVINCHANDER. A &SANJAY KUMAR. N 8

 Vibrosonic : Vibromax, VibrosonicDelux, Supersonic, Vibro Mini.

 Clear tone: Clear tone Delux.

 Bosch Range of horns : FC4, FD4 Delux.

 Roots 90 : Roots 90.

 Mega sonic : Mega sonic.

 Spider : Spider (Available in 6 Colors).

 Parking Sensors : Parking Sensors.

1970 Promotes American Auto Service for manufacture of Electric

KARTHIKEYAN. D, KAVINCHANDER. A &SANJAY KUMAR. N 9

1988 Polycraft, a unit for Plastic Injection Moulding was established

KARTHIKEYAN. D, KAVINCHANDER. A &SANJAY KUMAR. N 10

2004 Roots Cast Private Limited(RCPL) inaugurates its Unit II at

2.1 PRODUCTION PROCESS IN HORN DIVISION

Self Tapping Screwing

Spool Assembly Locking

Point Holder Assembling

KARTHIKEYAN. D, KAVINCHANDER. A &SANJAY KUMAR. N 11

Diaphragm Assembling & Tightening

Horn Pre Crimping & Final Crimping

Air gap Measuring & Adjusting

Terminal Connector Bending & Mounting

Tuning Range Measuring & Sealant

2.2 PRODUCTION DEPARTMENT OF HORN DIVISION

KARTHIKEYAN. D, KAVINCHANDER. A &SANJAY KUMAR. N 12

2.3 PARTS OF A TYPICAL HORN

A simple horn consists of the following components.,

 Housing with SCR assembly

2.4 THE WORKING PRINCIPLE OF A HORN

KARTHIKEYAN. D, KAVINCHANDER. A &SANJAY KUMAR. N 13

2.5 CLASSIFICATIONS OF HORNS

Horns are of two major categories,

On the basis of the tone type it may be,

 High tone: Sharp, focused and covers a long distance.