STUDY OF SHOP FLOOR

PRODUCTION PROCESSES OF
VARIOUS AUTO
COMPONENTS USED IN
AUTOMOBILES

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 SUMMER TRAINING
DONE AT:
MITSUBISHI ELECTRIC AUTOMOTIVE INDIA
PRIVATE LIMITED
Plot No. 167-170, Sector-5, IMT Manesar,
Gurugram - 122050, Haryana, India.

Submitted in partial fulfilment

of the requirement for the award of
the degree of

Bachelor of Technology
In
Mechanical Engineering

Submitted by:

Sameer Kumar

D.C.R.U.S.T. Murthal, Sonipat

Haryana

Under the supervision of

Mr. Mohit Dixit

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 ACKNOWLEDGEMENT

I take this opportunity to express my deep sense of gratitude towards my

guide Mr. Mohit Dixit for his expert guidance during entire summer
training.
I would also like to extend my thanks to the production head Mr. Nilesh
Sharma. and all the staff members of production department for their
valuable guidance and encouragement.
I also express my thanks to all of them who directly or indirectly have helped
me in this training.

Sameer Kumar

Department of Mechanical Engineering

D.C.R.U.S.T. Murthal, Sonipat

Haryana

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1. Abstract 1

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 1. Abstract

An essential part of the engineering curriculum is the interaction with

industries. Without industrial training, one cannot develop required skillset
for professional world. The most important element of industrial training is
that it integrates classroom knowledge and theory with practical application
and skills developed in professional domain.

This four-week summer training program is basically on the study of the

production process carried out at the Mitsubishi Electric Automotive India
Pvt. Ltd. located in IMT Manesar, Gurugram.

Mitsubishi Electric Automotive India Pvt. Ltd., Manesar (MEAI) is in the

business of Manufacturing Auto components, which is being supplied to Car
& Two-wheel manufacturers. This production site is leading supplier of
various electric automotive equipments (OEMs).
The motive of this industrial internship is to level the gap between industry
and institute and to observe different manufacturing processes.

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 2. Introduction
2.1 History of Mitsubishi Electric
An ambitious young man named Yataro Iwasaki launched
the first Mitsubishi company, a shipping firm in 1870.The
history of Mitsubishi Electric is the history of the
development of modern Japan. The company was founded
in 1921, when Mitsubishi Shipbuilding Co. (now Mitsubishi
Heavy Industries, Ltd.) spun off a factory in Kobe, Japan that
made electric motors for ocean-going vessels into a new
company called Mitsubishi Electric Corporation. Figure 1 Yataro Iwasaki

In that year, the new company entered the consumer sector by manufacturing and
marketing an electric fan, which became a hit product. Over the next decade the
company succeeded in landing major contracts, including one for the
development of an electric railway substation. In the 1930s Mitsubishi Electric
started manufacturing, installing and maintaining elevators and escalators as well
as producing electric power generation equipment. In the early 1960s the
company also turned its attention to environmentally conscious manufacturing
techniques -- many years before environmental concern became a serious issue.
From 1980 to the present day, the pace at which Mitsubishi Electric has
introduced and refined breakthrough technologies and products for the benefit of
society, industry and individuals has been nothing less than astonishing. Today
Mitsubishi Electric is a global giant, with operations in 35 countries, more than
100,000 employees, and consolidated ne t sales of more than US$32 billion. [1]

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 2.2 Mitsubishi Electric in India:
Since its operations began in India in the mid-1950s, Mitsubishi Electric has
grown to become one of the most highly regarded companies in India.
It offers a wide range of innovative and high-quality products for the Indian
market, including Air Conditioners, Visual Information Systems, Power Devices,
Photovoltaic (solar) Solutions, Power Systems, Transportation Systems and
industrial automation machinery.
Common to all its products and endeavors is MEQ, which stands for 'Mitsubishi
Electric Quality' MEQ promises the best experience in the products, services,
partnerships and people.
Guided by corporate statement, 'Changes for the Better,' the company takes its
responsibility as a corporate citizen very seriously. The products are developed
with superior energy efficiency and the environment in mind. [2]

2.3 Plant Description

Mitsubishi Electric Automotive India Pvt. Ltd.
plant is located in IMT(Manesar) in 21600 m2 area.
Basically, the plant is concerned with
manufacturing and assembly process for OEM
(Original equipment Manufacturer) electronic
parts to cater various automobile needs and
demands. [3]

Figure 2 M.D. Mr. Yoshito Inaya

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 Figure 3 Mitsubishi Electric Automotive India Pvt. Ltd.

Plant is divided into various departments:

Human
Quality Information Sales &
Production Maintenance Resource & Finance
Assurance Technology Marketing
Admin

• Production basically comprises of assembly of various small parts which

together make a bigger part.
• Production department has several production lines.
• Maintenance is concerned with repairing and inspection of semi-automatic
and automatic machines working for production.
• Warehouse deals with storage of raw materials & finished goods.
• Accounts Departments has fewer processes like billing taxation.

• HR & Admin. Department does management of Transportation,

fooding, uniforms & salary distribution.

• The plant incorporates basic but very important utilities like fire
hazard prevention technology (Sprinkler System, Fire Hydrant,
Hose Reel), compressor and electrical backup (Diesel Generators)
in case of electrical breakdown.

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2.4 Production Department
2.4.1 Production Overview
Several modern and advanced electric automotive equipments are manufactured
at production facility of the plant. These are as follows: -

• Alternator Current Generator: - Alternators are like A.C. generators

used in automobiles to charge its battery while the engine is running.

Figure 4- ACR

• Electronic control unit/module (ECU):- An electronic control unit is a

device responsible for overseeing, regulating and altering the operation of
a car's electronic systems.

Figure 5- ECU

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• Electric power steering motor (EPS motor): -EPS motor helps in
power steering of an automobile.

Figure 6- EPS Motor

• Motor control unit (MCU) for EPS motor: - Motor control unit
controls the working of EPS Motor.

Figure 7- MCU

• GMR sensor: - It is used as crank and cam positioning sensor to control

the fuel injector in engine.

Figure 8- GMR Sensor

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• Armature: - An armature is the power-producing component of an electric
machine. The armature can be on either the rotor or the stator of the electric
machine.

Figure 9- Armature

• Purge Control Solenoid Valve: - The purge valve is the part of the vehicle
Evaporative Emission Control (EVAP) system. The purge valve precisely
controls the amount of fuel vapor that is purged from the charcoal canister.
In modern cars, the purge valve is an electrically operated solenoid, that is
controlled by the engine computer.

Figure 10- Purge Control Solenoid Valve

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 2.4.2 Production Process

Plant is designed with high sophistication and advanced technical features to keep
production high at profits. All the operations involved in assembly of a part are
carried out by automatic or semi-automatic machines. Machines are generally
operated by pneumatic pressure and equipped with sensors to monitor the
operation.
Some common operations involved in the production line are press fitting of two
mating halves, screw tightening, welding. After assembly, performance check
and noise test are performed on each part.
All the stations and substations involved in assembly process have POKA YOKE
system, which is a mistake-proof system. A poka-yoke is any mechanism in any
process that helps an equipment operator avoid (Japanese-yokeru) mistakes
(Japanese-poka).[4] Its purpose is to eliminate product defects by preventing,
correcting, or drawing attention to human errors as they occur.

3. Alternator Current Generator

Alternators are used in modern automobiles to charge the battery and to power
the electrical system when its engine is running. The alternator works with the
battery to generate power for the electrical components of a vehicle, like the
interior and exterior lights, and the instrument panel. An alternator gets its name
from the term alternating current (AC). Alternators are typically found near the
front of the engine and are driven by the crankshaft, which converts the pistons'
up-and-down movement into circular movement. The power through this circular
movement is transferred to pulley of the alternator to rotate its rotor and generate
current.[5]

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 3.1. Working of an Alternator
Alternator works just like an A.C. generator but the major difference is that in
generator the magnetic field producing part is stationary and current producing
coil rotates. But in alternator the magnetic field producing rotates and current
producing coil is stationary. The current is generated according to Faraday’s law
of Electromagnetic Induction. This results in production of A.C. current. Then
this current passes through the condenser and rectifier and gets converted into
D.C. current. Then it passes through the voltage regulator and attains a constant
voltage and charges the battery.[6] Below shown is the circuit of an alternator: -

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 4. Production of Alternator
4.1. Models Produced
There are three companies for which alternators are produced namely: -

Several models are produced for the companies: -

HONDA NISSAN FORD

A005TJ0891ZM
A005TL0191AM A005TZ0781ZM
A005TJ0491ZM

A005TJ0391ZM
A002TJ0291AM A005TZ0782ZM
A005TZ0181AM

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 4.2. Child Parts
Alternator has following child parts: -

1. Front bracket 20. Terminal

2. Rear bracket 21. Spacer
3. Stator assembly 22. Hexagonal nut
4. Rotor assembly 23. PH screw
5. Rectifier assembly 24. Flange screw
6. Regulator assembly
7. Condenser assembly
8. Pulley
9. Front bearing
10. Retainer
11. Bush
12. Rear bearing
13. Nut washer
14. Hexagonal nut
15. PH screw and washer
16. Flange screw
17. Cover
18. Hexagonal head
19. Bolt

❖ These child parts are for Honda model- A005TJ0491ZM.

❖ Child parts and their presence in assembly may differ according to the model.
❖ Rectifier used is half wave rectifier.

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The child parts mentioned previously can be realized in picture shown below: -

Figure 11- Exploded view of an Alternator

4.3. Workstations
Production facility has the following workstation: -

1. Front bearing press fit / Rear bearing press fit / Bush press fit
2. Regulator assembly table
3. Bearing holder assembly / Bush press fit / Rear bearing press fit
4. Retainer screw tightening table
5. Pulley nut tightening table
6. Friction check and visual inspection table
7. Stator assembly table
8. Rear bracket assembly press fit table
9. Silicon application table
10. Rectifier screw tightening table / T. Bolt tightening table
11. Regulator screw tightening table / Rectifier Screw tightening table
12. TIG welding machine
13. B-Nut screw tightening and retightening

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 14. Stator press fit machine
15. Flange screw / Terminal screw tightening table
16. Brush pin insertion table
17. Front and rea assembly press fit and brush pin removal
18. Brush holder screw tightening / Through Bolt tightening
19. Rear cover assembly table
20. Name plate attachment table
21. Performance check machine
22. Noise chamber
23. Final inspection and packing

❖ All the press fit machines work on air pressure at a pressure between 0.4 to 0.5 MPa.
❖ B-Nut screw tightening gun also works on air pressure.
❖ Screw tightening machines have torque sensors. When a screw is sufficiently
tightened it produces a back torque of nearly 4N-m which when sensed by torque
sensor beeps an alarm so that worker can stop the tightening gun.

4.3.1. TIG welding

TIG stands for tungsten inert gas welding or sometimes this welding is known as
gas tungsten arc welding. In this welding process, the heat required to form weld
is provided by a very intense electric arc which is form between tungsten
electrode and work piece. In this welding a non-consumable electrode is used
which does not melt. Mostly no filler material is required in this type of
welding but if it required, a welding rod fed into the weld zone directly and melted
with base metal.[7]

• Principle:
TIG welding works on same principle of arc welding. In a TIG welding process,
a high intense arc is produced between tungsten electrode and work piece. In this
welding mostly work piece is connected to the positive terminal and electrode is
connected to negative terminal. This arc produces heat energy which is further
used to join metal plate by fusion welding. A shielding gas (mainly Argon gas)
is also used which protect the weld surface from oxidization.[8]

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 • Equipment’s:

• Power Source:
The first unit of equipment’s is power source. A high current power source needed
for TIG welding. It uses both AC and DC power source. Mostly DC current is
used for stainless steel, Mild Steel, Copper, Titanium, Nickel alloy, etc. and AC
current is used for aluminum, aluminum alloy and magnesium. Power source
consist a transformer, a rectifier and electronic controls. Mostly 10 – 35 V is
required at 5-300 A current for proper arc generation. [9]

• TIG Torch:
It is a most important part of TIG welding. This torch has three main parts,
tungsten electrode, collets and nozzle. This torch is either water cooled or air
cooled. In this torch, collet is used to hold the tungsten electrode. These are
available in varying diameter according to diameter of tungsten electrode. The
nozzle allows the arc and shielded gases to flow into welding zone. The nozzle
cross section is small which gives high intense arc. There are passes of shielded

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gases at nozzle. The nozzle of TIG needs to replace in regular interval because it
wears out due to presence of intense spark. [10]

• Shielding Gas Supply System:

Normally argon or other inert gases are used as shielded gas. The main purpose
of shielded gas to protects the weld from oxidization. Shielded gas does not allow
coming oxygen or other air into welded zone. The selection of inert gas depends
upon metal to be welded. There is a system which regulates the flow of shielded
gas into welded zone. [11]

• Filler Material:
Mostly for welding thin sheets no filler material is used. But for thick weld, filler
material is used. Filler material is used in form of rods which are directly feed
into weld zone manually. [12]

• Working:
Working of TIG welding can be summarized as follows: -

➢ First, a low voltage high current supply supplied by the power source
to the welding electrode or tungsten electrode. Mostly, the
electrode is connected to the negative terminal of power source and
work piece to positive terminal.

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➢ This current supplied form a spark between tungsten electrode and
work piece. Tungsten is a non –consumable electrode, which give a
highly intense arc. This arc produced heat which melts the base metals
to form welding joint.

➢ The shielded gases like argon, helium is supplied through pressure

valve and regulating valve to the welding torch. These gases form a
shield which does not allow any oxygen and other reactive gases into
the weld zone. These gases also create plasma which increases heat
capacity of electric arc thus increases welding ability.

➢ For welding thin material no filler metal is required but for making
thick joint some filler material used in form of rods which fed manually
by the welder into welding zone. [13]

• Advantages:
➢ TIG provides stronger joint compare to shield arc welding.
➢ The joint is more corrosion resistant and ductile.
➢ Wide verity of joint design can form.
➢ It doesn’t required flux.
➢ It can be easily automated.
➢ This welding is well suited for thin sheets.
➢ It provides good surface finish because negligible metal splatter or weld
sparks that damage the surface.
➢ Flawless joint can be created due to non-consumable electrode.
➢ More control on welding parameter compare to other welding.
➢ Both AC and DC current can be used as power supply. [14]

• Disadvantages:
➢ Metal thickness to be weld is limited about 5 mm.
➢ It requires highly skilled labor.
➢ Initial or setup cost is high compare to arc welding. [15]

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 4.4. Procedure:
Assembly process will be discussed for 2 models. One of Honda (A005TJ0491ZM)
and Ford (A005TZ0782ZM).

• Honda (A005TJ0491ZM):
Bearing holder Bearing is press
Bushes are press
and bearing is fittted to the back
fitted into rear
press fitted into end of rotor
bracket.
front bracket. assembly.

Retainer is fitted
Rotor and pulley Regulator
to hold the
are fitted to front assembly is
bearing in front
bracket. prepared.
bracket.

Friction check is Silicon is appiled

Rectifier is fitted
done on the inside rear
into rear bracket.
pulley. bracket.

Brush pin is Stator is press Regulator

inserted into the fitted into rear assembly is fitted
rear assembly. bracket. into rear bracket.

Front and rear

assembly are Brush holder
Through bolts are
press fittted and screws are
tightened.
brush pin is tightened.
removed.

Final inspection is
Noise check is Performance
done and packing performed. check is done.
is done

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• Ford (A005TZ0782ZM):

Bearing holder and Bearing is press

Bushes are press
bearing is press fittted to the back
fitted into rear
fitted into front end of rotor
bracket.
bracket. assembly.

Stator is press Rotor and pulley Retainer is fitted to

fitted into front are fitted to front hold the bearing in
bracket bracket. front bracket.

rear bracket is Bolts are tightened

Rectifier is fitted to
press fitted to the between front and
the rear bracket.
stator. rear bracket.

Brush holder is Terminals of stator

Regulator is fitted
fitted to rear and rectifier are
to rear bracket.
bracket. welded.

Cover and terminal

Performance check is Noise check is
are fitted to rear done done.
bracket.

Final inspection is
Packing is done. done and pulley
cover is put.

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4.5. Appearance check defects and not good part
Conditions

• Scratch and dent and coating defect on pulley surface.

• Printing, misalignment, peeling off, scratch, wrinkle and misprint on name
plate.
• Short moulding, crack scratch and dent on connector.
• Short moulding, crack, scratch and dent on B-mould.
• Spark mark on B-Nut is NG condition.
• Breakage, crack in bracket.
• Blow holes in bracket.
• Welding defects in bracket.
• Chip off and short moulding in bracket.
• Machining defects (machining misalign of bracket at area like bush area).
• Rough surface in bracket.

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 5. GMR Sensor
Giant magneto resistance (GMR) is a magneto resistance effect observed
in multilayers composed of alternating ferromagnetic and non-magnetic
conductive layers. The effect is observed as a significant change in the electrical
resistance depending on whether the magnetization of adjacent ferromagnetic
layers are in a parallel or an antiparallel alignment. The overall resistance is
relatively low for parallel alignment and relatively high for antiparallel alignment.
The magnetization direction can be controlled, for example, by applying an
external magnetic field. The effect is based on the dependence of electron
scattering on the spin orientation.[16]

5.1. GMR sensors used in automobiles

GMR sensor is used in angle and circular position detection in various
applications. Thus, this type of sensor can be used as crankshaft position (CKP)
sensor, camshaft position (CMP) sensor and automatic transmission (AMT)
speed sensor. Mitsubishi is the first who used this technology in automotive
application purpose.[17]
A crank sensor is an electronic device used in an internal combustion engine, both
petrol and diesel, to monitor the position or rotational speed of the
crankshaft. This information is used by engine management systems to control
the fuel injection or the ignition system timing and other engine parameters.
Before electronic crank sensors were available, the distributor would have to be
manually adjusted to a timing mark on petrol engines.
The crank sensor can be used in combination with a similar camshaft position
sensor to monitor the relationship between the pistons and valves in the engine,
which is particularly important in engines with variable valve timing. This
method is also used to "synchronize" a four stroke engine upon starting, allowing
the management system to know when to inject the fuel. It is also commonly used
as the primary source for the measurement of engine speed in revolutions per
minute.

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GMR type camshaft position sensor consists of a GMR, a magnet and a sensor.
The direction of the magnetic field changes due to the profile (protruding and
non-protruding portions) of the timing rotor, which passes by the sensor. As a
result, the resistance of the GMR changes, and the output voltage to the ECM
changes to high or low. The ECM detects the camshaft position based on this
output voltage.[18]

Figure 12- GMR Sensor

6. Production of GMR Sensor

6.1. Models Produced

GMR sensor is produced only for Maruti company: -

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Model numbers: -

J5T34371ZM

J5T34771ZM

J5T34871ZM

J5T35072ZM

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 6.2. Child Parts
GMR Sensor has following child parts: -

1. Magnet
2. Guide
3. Holder
4. Base assembly
5. Cap
6. Terminal
7. Plastic mould
8. Bush
9. O-ring

❖ Cap and plastic mould are made using injection moulding machine at the production line
itself.
❖ Material used for making the cap and plastic mould is Polyphenylene sulphide.
❖ Magnet is a ferro-magnetic material that is not magnetized initially.

6.3. Workstations
1. Horizontal injection moulding machine
2. Magnet and guide press fit machine
3. Base assembly press fit machine
4. Cap-press fit machine
5. Terminal Welding machine (Resistance spot welding)
6. Tie bar cut and terminal bending machine
7. Vertical injection moulding machine
8. Gate cutting and deburring machine
9. Terminal height checking machine
10. Laser marking and magnetizing machine
11. High temperature performance checker
12. Pulse checking machine
13. O-ring leak checking machine
14. Terminal inclination checking machine
15. Final inspection table.

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 6.3.1. Terminal welding machine

There are three terminals in base assembly. Terminals

are welded to insert which is a three-legged structure.
Insert is welded by Electrical resistance welding
(ERW) technique.
Resistance spot Welding is a thermo-electric process
where heat is generated at the interfacing of two
different parts to be joined by passing an electrical
current through under a controlled pressure and
time.[19] Figure 13- Resistance spot welding
machine

Figure 14- Diagram of Resistance spot welding

6.3.2. Injection moulding process

Injection moulding is a manufacturing process for producing parts by injecting
molten material into a mould. Material for the part is fed into a heated barrel,
mixed using a helical shaped screw, and injected into a mould cavity, where it
cools and hardens to the configuration of the cavity.

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 Figure 15- Moulded GMR Sensor

Injection moulding consists of the high-pressure injection of the raw material into
a mould which shapes the polymer into the desired shape. Moulds can be of a
single cavity or multiple cavities. In multiple cavity moulds, each cavity can be
identical and form the same parts or can be unique and form multiple different
geometries during a single cycle. Moulds are generally made from tool steels,
stainless steels and aluminium.[20]

❖ Horizontal injection moulding machine

Moulding of cap and holder is carried out in a horizontal injection moulding
machine which is fully automated. A robot grips the part after the ejector pins
have been extended to free the part from the mould. It then moves them into a
holding location.
This machine uses a multicavity mould with eight cavities each for single part.
The raw material is Polyphenylene Sulphide (PPS) which offers high strength,
dimensional accuracy and excellent toughness.

➢ Injection Process

In injection moulding, granular plastic is fed by a forced ram from a hopper into
a heated barrel. As the granules are slowly moved forward by a screw-type
plunger, the plastic is forced into a heated chamber, where it is melted. As the
plunger advances, the melted plastic is forced through a nozzle that rests against
the mould, allowing it to enter the mould cavity through a gate and runner system.
The mould remains cold so the plastic solidifies almost as soon as the mould is
filled.

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 Figure 16- Horizontal Injection Moulding Machine

➢ Specifications
1. Mould temperature: -
▪ In fixed side- 140°C ± 5°C
▪ In moving side- 140°C ± 5°C

2. Barrel temperature: -
▪ NH2 - 285°C ± 10°C
▪ NH1 - 290°C ± 5°C
▪ H3 - 300°C ± 5°C From right zone to left zone
▪ H2 - 290°C ± 5°C in reff. to Fig. 16
▪ H1 - 280°C ± 5°C
▪ HP - 80°C ± 5°C

3. Injection: -
▪ Injection pressure- 80 -120 MPa
▪ Injection time- 1.1 – 1.3 secs
▪ Cushion position- 4 - 6 mm

4. Production capacity: - 9000 parts in 8 hrs.

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 ❖ Vertical Injection Moulding Machine

Housing over magnet and base assembly

is manufactured by vertical injection
moulding machine. The machine is
automated but inner assembly and bush are
introduced in the mould cavity by a trained
operator. The raw material used is PPS
same as used in horizontal moulding
machine.

Before starting the operation, the purging

of material is done to clean the barrel of
Figure 17- Vertical Injection Moulding
machine machine and for proper moulding.

Injection moulding machines consist of a

material hopper, an injection ram or screw-type plunger, and a heating unit.
Platens hold the moulds in which the components are shaped. Presses are rated by
tonnage, which expresses the amount of clamping force that the machine can
exert. This force keeps the mould closed during the injection process.

➢ Injection moulding cycle

The sequence of events during the injection mould of a plastic part is called the
injection moulding cycle. The cycle begins when the mould closes, followed by
the injection of the polymer into the mould cavity. Once the cavity is filled, a
holding pressure is maintained to compensate for material shrinkage. In the next
step, the screw turns, feeding the next shot to the front screw. This causes the
screw to retract as the next shot is prepared. Once the part is sufficiently cool, the
mould opens and the part is ejected cycle.

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 ➢ Machine equipments: -
▪ Material tank: It is a container that is filled with virgin PPS
material in the shape of granules.

▪ Dehumidifier: A dehumidifier is used to remove moisture content

present in raw material so that mould defects may be avoided.
▪ Granulator: Granulator is used to grind the sprue and runner part
of the moulded part so that it does not get wasted and reused for
moulding.
▪ Blender: Blender is used to mix the virgin and ground material.
▪ Loader: Loader is used to load the material into hopper situated
above the tank. Another loader is used for blending of virgin and
ground material.

➢ Specifications
1. Mould temperature: - 150°C ± 5°C

2. Barrel temperature: -

▪ LNH - 275°C ± 5°C

▪ NH - 290°C ± 5°C
▪ H3 - 310°C ± 5°C From top zone to bottom
▪ H2 - 300°C ± 5°C zone
▪ H1 - 300°C ± 5°C
▪ HP - 80°C ± 10°C
3. Injection: -

▪ Injection pressure: - 155 – 195 Mpa

▪ Injection time: - 1.27 – 1.47 secs.
▪ Cushion position: - 1.7 – 3.7 mm
4. Production capacity: - 310 parts/hr.

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 ❖ Mould cleaning process
Moulds are cleaned after 4000 shots. The plastic resigns, gaseous particles and
other foreign particles stick to the mould due to its long use. Cleaning is done in
following manner: -

▪ It is done in a separate mould maintenance area.

▪ Mould is disassembled into base and blocks.
▪ Block is disassembled into various inserts.
▪ These inserts are put into Clipica Ace, a mould cleaning machine.
▪ After 20 mins they are taken out and kept in water.
▪ Then they are dried and reassembled.

➢ Clipica Ace machine

It is a popular mould cleaning machine. The inserts are dipped into the cleaning
agent present in the machine and go under electrolysis in order to get cleaned.
The cleaning agent is acidic in nature and loses its acidity over time. Standard
replacement timing of cleaning agent varies depending on the cleaning frequency
and dirt, but the timing can be controlled using the attached pH test paper (pH
should not be greater than 4.8).

Figure 18- Clipica ace machine

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 6.4. Assembly Process
The assembly process is same for all the models.

Cap and holder are Magnet and guide are Base assembly is
prepared in press fitted to the
holder to prepare
press fitted to the
horizontal injection
holder assembly. holder assembly.
moulding machine

Tie bar is cut and Cap is presfitted to

Terminal is welded
terminal is bent to the base assmebly
to cap and holder
prepare sensor to prepare cap and
assmebly
assembly. holder assembly.

Sensor assembly and bush

are put into mould and
housing aroung it is made
using injection moulding in
verticla injection moulding
machine.
Gates are cut and
Terminal height is
gate points are
checked
deburred.

The assembly is Model no. , Company

Performance check heated upto no., and Lot no., are
is done at room 135°C(max 155°C) and laser marked on the
temperarure. performace check is assembly and magnet
done. is magnetised

O-ring is put on the Terminals are Final inpection is

assermbly and
assembly is checked
checked for any done through visual
for any air leakage inclination inspection.

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 7. EPS Motor
EPS motor stands for electric power
steering motor. It uses an electric
motor to assist the driver of a vehicle.
Sensors detect the position and torque of
the steering column, and a computer
module applies assistive torque via the
motor, which connects to either the
steering gear or steering column. This
allows varying amounts of assistance to Figure 19- EPS Motor
be applied depending on driving
conditions. Electric systems have an advantage in fuel efficiency because there is
no belt-driven hydraulic pump constantly running, whether assistance is required
or not, and this is a major reason for their introduction. Another major advantage
is the elimination of a belt-driven engine accessory, and several high-pressure
hydraulic hoses between the hydraulic pump, mounted on the engine, and the
steering gear, mounted on the chassis. This greatly simplifies manufacturing and
maintenance. By incorporating electronic stability control electric power steering
systems can instantly vary torque assist levels to aid the driver in corrective
maneuvers.[21]

7.1. Models produced

Eps motor is produced for 2 companies namely: -

Nearly 16 to 17 models are produced.

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 7.2. Child parts
EPS motor has following child parts: -

1. Front housing
2. Rear housing
3. Magnet pieces
4. Holder
5. Seal plate
6. Front bearing
7. Brush holder
8. Brush holder tightening screws
9. Armature
10. Boss
11. Rear bearing
12. Yoke tightening screws

7.3. Workstations and Assembly Process

Front bearing pres fit m/c

Bearing is press fitted into the front housing.

Brush holder assembly installation m/c

Brush holder is press fitted into the housing.

Brush holder screw tightening m/c

Brush holder screws tightened.

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 Armature asm. press fit m/c
Armature is press fitted into front housing.

Boss press fit m/c

Boss is press fitted to the shaft of armature.

Rear bearing press fit m/c

Bearing is press fitted to rear shaft of armature.

Magnet asm. dust collection

Pig tail forming station m/c
Wires of brush holder are formed into pig tail.
Holder, seal plate and magnet are
shape assembled together to from magnet
assembly.
Grease application m/c
Grease is applied to rear bearing.

Yoke asm. press fit and dust

Yoke asm. press fit m/c collectionand yoke asm.
Yoke asm. is press fitted to front housing. magnetization m/c
Magnet asm. is press fitted into yoke
asm. to form yoke asm. and magnet
Yoke asm. screw tightening pieces are magnetized.
Yoke asm. Screws are tightened/

Performance testing m/c

Performance test is done

Boss runout measurement and adjustment m/c

Asm. is tested for boss runout

Vibration testing m/c

❖ Up till yoke asm. press fit
Asm. is tested for any unwanted vibrations dust is collected is collected
from asm. at every stage.
Noise Checking room
Asm. is checked for any unwanted noise.

Name plate labelling and final inspection table

Nameplate is put on the motor and is inspected visually.

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 8. SMT Line
Surface-mount technology (SMT) is a
method for producing electronic circuits
in which the components are mounted or
placed directly onto the surface of printed
circuit boards (PCBs). An electronic
device so made is called a surface-mount
device (SMD). In industry, it has largely
replaced the through-hole technology
construction method of fitting components
with wire leads into holes in the circuit Figure 20- PCB Board
board. Both technologies can be used on the same board, with the through-hole
technology used for components not suitable for surface mounting such as large
transformers and heat-sinked power semiconductors.
By employing SMT, the production process speeds up, but the risk of defects also
increases due to component miniaturization and to the denser packing of boards.
In those conditions, detection of failures has become critical for any SMT
manufacturing process.[22]
Here at SMT line PCB board are produced for MCU (Motor Control Unit) of EPS
motor and also for ECU (Electronic Control Unit) of EPS-ECU motor system. As
both EPS motor and EPS-ECU motor system are manufactured in the industry
itself, these PCB boards are utilized here only.

8.1. Child Parts

An SMD has following child parts: -
1. Capacitor: -
▪ Electrolytic capacitor
▪ Ceramic capacitor
▪ Film capacitor
▪ Tantalic capacitor
2. Diode: -
▪ K- type diode
▪ Simple diode
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 3. Resistor: -
▪ Simple resistor
▪ Jumper resistor
4. I-C board: -
▪ Small outline package
▪ Quad flat no.
▪ Quad flat pack
5. Transistor: -
▪ Minimode transistor
▪ Power transistor
▪ Double lead transistor
▪ Field effect transistor
6. Coil
7. Thermistor
8. Crystal
9. Bare PCB board

8.2. Workstations and assembly process

Each bare PCB panel has 2 sides S side and C side. C side contains. The difference
between the two is that C side has no I-C boards and ROM where as S side has
I-C boards and ROM also. There are separate assembly lines for both of the sides.
Assembly line 1 works on the S side and assembly line 2 works on the C side.

The workstations and assembly process for S side are in the given order: -

➢ Production line: -

1. Loader – Collects the bare panels and transfers it to further machines.

2. Dust collecting machine – Collects dust from bare panels
3. Screen printer – Applies soldering paste on bare panels at points where
components have to mounted.

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4. Solder paste inspection machine – It checks the quality of solder
application (surface area, volume, height)

5. Chip mounter (3 in quantity) – It mounts small components on the

panel e.g. resistors, ceramic capacitors.

6. Multimounter (2 in quantity) – It mounts both small and large

components.

7. Reflow oven – It melts the solder paste and then cools it to solidify it.
▪ It is divided into 4 zone, 4th zone is cooling zone. The rest three zones
are heating zones.
▪ These three zones are also divided into several temperature zones to
minimize the risk of thermal shock on the components. The heating
is done gradually.

8. PCB invert conveyor – It flips the PCB board to the C side.

9. Unloader – It collects the panels.

❖ Now panels are transferred to assembly line 2 to mount components on C

side.
❖ Same machines are present and same assembly process is followed.

➢ Inspection line: -
1. Loader - Collects the PCB panels and transfers it to further machines.

2. ICT (In Circuit Testing) machine – It checks if all the

components are working properly or not.

3. AOI (Auto Optical Inspection) machine (C side) – It checks

the physical condition of components and looks for physically
damaged components.

4. AOI machine (C side) - It checks the physical condition of

components and looks for physically damaged components.

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5. Unloader – It collects the panels.

6. Final visual inspection table – Trained workers visually inspect

the SMD for any damage and missing components.

Figure 21- Chip Mounter

Figure 22- Multimounter

Figure 23- Reflow Oven Figure 24- Screen Printer

Figure 25- AOI Machine

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 9. Summary
The project is based on the study of various auto components and its production
process. The whole process can be summarized in the following way:
• Bringing the raw materials in plant.
• Dispatching them to the respective departments or
production line.
• Starting the assembly of parts systematically.
• Inspecting the finished goods.
• Taking out goods of poor quality for further examining.
• Deducing the faults whether they are result of different errors-
➢ Systematic errors
➢ Random errors
➢ Human errors
• Performing the necessary re-work & rejecting NG parts.
• Dispatching the finished goods to the buyers.
• Dispatching to respective Customers.

10. Conclusion
In this industrial training, all the standard manufacturing processes implemented
at the industrial level are studied and observed. Among various production lines,
A.C.R. production line, GMR production line, EPS motor line, SMT line are the
focus area. The detailed production process along with the parts and tools
required is studied.

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 11. Bibliography

[1] www.mitsubishielectric.in/history-of-mitsubishi-group.php
[2], [3] https://www.mitsubishielectric.in/company.php
[4] https://en.wikipedia.org/wiki/Poka-yoke

[5], [6] https://auto.howstuffworks.com/alternator1.htm

[7], [8], [9], [10], [11], [12], [13], [14], [15]

https://www.twiglobal.com/technical-knowledge/job-knowledge/tungsten-inert-
gas-tig-or-gta-welding-006
[16] A brief introduction to giant magnetoresistance Hycorelle Co., Ltd.,
Beijing, China
[17],[18] https://wikivisually.com/wiki/Crankshaft_position_sensor
[19] https://en.wikipedia.org/wiki/Spot_welding
[20] https://en.wikipedia.org/wiki/Injection_moulding
[21] https://en.wikipedia.org/wiki/Power_steering
[22] https://en.wikipedia.org/wiki/Surface-mount_technology

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