Overview of Operations and Maintenance of Different Departments at an Automotive Lighting Company

NIT KURUKSHETRA
INDUSTRIAL TRAINING REPORT
INDIA JAaPAN LIGHTING PRIVATE LTD
Title of the project:

“THEOVERVIEW OF OPERATION AND MAINTENANCE OF
DIFFERENT DEPARTMENTS OF AN AUTOMOTIVE LIGHTING
COMPANY, IJL BAWAL”
Submitted To- Submitted By-

DR.GULSHAN SACHDEVA RITVIK SAINI
NIT KURUKSHETRA 11816083
IJL, BAWAL| Industrial Training Report Page 1

DECLARATION
I hereby declare that the thesis entitled “The overview and
maintenance of different departments of an Automotive Lighting
Company,IJL BAWAL” submitted by me, for the award of the
degree of Bachelor of Technology,NIT KURUKSHTERA is a
record of bonafide work carried out by me under the supervision of
Mr.Dhirendra Kumar.
I further declare that the work reported in this thesis has not been
submitted and will not be submitted, either in part or in full, for the
award of any other degree or diploma in this institute or any other
institute or university.
Place: Bawal
Signature of the Candidate
CERTIFICATE BY THE EXTERNAL GUIDE

This is to certify that the project report entitled “The overview and
maintenance of different departments of an Automotive Lighting
Company,IJL BAWAL” submitted by Ritvik Saini (11816083) to National
Institute of Technology Kurukshetra in partial fulfillment of the requirement
for the award of the degree of Bachelor of Technology in Mechanical
Engineering is a record of bonafide work carried out by him under my
guidance. The project fulfills the requirements as per the regulations of this
Institute and in my opinion meets the necessary standards for submission.
The contents of this report have not been submitted and will not be submitted
either in part or in full, for the award of any other degree or diploma in this
institute or any other institute or university.
Dhirendra Kumar Signature of the External Supervisor

EXTERNAL SUPERVISOR
Senior Manager - Human Resource
India Japan Lighting Pvt. Ltd

Industrial Model Township, HSIIDC Bawal
District Rewari
Haryana 123501
Phone: 91-9315104253
Email ID: dk@ijl.co.in
(JAN-JUNE 2021)
ACKNOWLEDGEMENT
It is my pleasure to express with deep sense of gratitude to Mr.Dhirendra
Kumar,Senior Manager, for his constant guidance and continual
encouragement. It has been a great opportunity for me to work with an
intellectual and expert in the field of project management.
I would like to thank Mrs.Aradhana Srivastava, Ms.Shreya Mishra,

Mr.Awadhesh and Ms.Lakshmi for providing me with an environment to
work in and guiding me throughout the internship journey.
I express ingeniously my whole-hearted thanks to Dr.Gulshan Sachdeva and

all teaching staff and members working as limbs of our institute for their not-
self-centered enthusiasm coupled with timely encouragements showered on
me with zeal, which prompted the acquirement of the requisite knowledge to
finalize my course study successfully. I would like to thank my parents for
their support.
It is indeed a pleasure to thank my friends who persuaded and encouraged me

to take up and complete this task. At last but not least, I express my gratitude
and appreciation to all those who have helped me directly or indirectly
toward the successful completion of this project.
Ritvik Saini
11816083
TABLE OF CONTENTS

Section Title Page no.
No.
1 Abstract 6-7
2 Introduction about the company 8-9
3 Different Departments of IJL 10
4 Utility Department 11-21
- RO Plant 13-15
- Boilers 16-19
-Cooling Tower 20
-Chillers 21
5 Moulding Department 22-42
-Machine Components 23-27
-Calculating Clamping Force 28
-Different types of defects and problem in 29

mould
30-42
-Different section in molding department
6 Surface Treatment Department 43-48
-Paint Shop 44
-Paint Shop 2 and 3 45-46
-Hard Coat 47
-Antifog 48
7 Assembly Department 49-52
ABSTRACT

The purpose of this project is to have a good overview of different
maintenance departments of a prestigious Automotive Lighting Company,
IJL.
How different types of Automotive Lights are produced? What kind of

machines are being used in Automotive Lighting Industries? What kind of
processes and tests a lamp goes through before use? and how do we take care
of these things by maintenance so we will be dealing about all these stuffs in
this project.The project can be broadly classified into four maintenance
departments which results in fabrication of different types of lamps:
Utility Department
Moulding Department
Surface Treatment Department
Assembly Department
First of all Utility Department provides all the essential things to other
departments for example Water, Electricity,Cold Water, Compressed Air and
steam etc.all these things are consumed by other departments like steam
produced by boilers are used in BMC Moulding.
Molding Department prepare mold for further processes, here injection
moulding machines are used and different types of materials are feeded into
them according to our final product’s needs.
Surface Treatment department, ST is done after molding,processes like
lacquering and aluminizing are done on the molded products.
Assembly department, assembling, at this step the different parts like
reflector lens ,bulb, code assembly push pull motor, tension etc are assembled
together with the help of number of machines and the combination of
machines and devices or motors is called a assembly line assembly of
automotive lamps are done on 2 lines RCL & CHL.

So after going through all these processes we get our final
glowing products,but still Quality team had to check all these lamps whether
they pass out all the parameters or not.

INTRODUCTION
ABOUT THE COMPANY

India Japan Lighting Pvt. Ltd was incorporated in December 1996.There used
to be a 70-30% joint venture between Koito Manufacturing Company
Limited, Japan and Lucas TVS Limited, Chennai but now it’s fully owned by
Koito Manufacturing Company Ltd.
The company manufactures Headlamps, Rear combination lamps and

various other small lamps for automotive applications.
The headlamp and rear combination lamp are aerodynamically styled and
represent the state-of-the art technology. The company has introduced state of
the-art clear plastic lens, multi-focal reflector headlamp with auto leveling
mechanism, PES Head Lamps, GDHL Lamps with DRL Light Guide and
Edge Lighting facility and Clear lens rear combination lamps, Multi
Colour Rear Combination Lamps and LED Lamps.The company has
already developed and tested successfully Bi-LED head Lamps and will be
supplied to customers in coming months. All products of UL are designed to
meet international levels of quality.
IJL has 4 manufacturing plants. IJL's first and second plant is situated in
Puduchatram Village, near Thiruvellore, about 40 Kilometers from the city of
Chennai. IJL's third plant is at Bawal, Haryana,while the latest plant (non
functional due to pandemic situation) is situated in Gujarat.
IJL has all the infrastructure & facilities requires for in-house Lamp design,
development & manufacturing. The company has a Total capacity of
manufacturing over 2.8Millions Headlamps per annum and 2.7 millions RCL
lamps per annum (Both Chennai and Bawal together).
IJL is Certified with TS 169494 & ISO 14001 JL's Current Sales turnover for
FY 2014-15 was Rs. 433 Crores (USD-66Million).

Products
Head Lamps: Halogen PES Head Lamps, HID PES Head Lamps;
Single/Double Chamber MFR, LED Lamps. Head Lamps with
DRL (Day time Running Lamp) Edge Lighting and Light Guide
technology Tail Lamps: LED Tail Lamps, Bulb Type with Multi
colour Lenses. Small Lamps: Fog Lamps, Side turn signal lamps,
Front turn signal lamps, Room Lamps, Roof Lamps, and High
Mount Stop Lamps.

Different Maintenance Department of IJL
Different departments of IJL are as follow:
Utility Maintenance Department
Mould Maintenance Department
Surface Treatment Department
Assembly Maintenance Department

Utility Department
Utilities (water, electricity and steam) are essential services that play a vital
role in further manufacturing processes. Utility department includes R.O
Plant, Boilers, Air Compressors, Cooling towers, AHU, Power Lines, and
Chillers etc.
Two major sources of electricity in IJL are :-
1) HSEB (Govt.)
2) Caparo (Pvt.)
Both of them supplies electricity to other departments alternately, for

example if there is power cut by the HSEB then a change-over is done and
electricity is supplied by Caparo unit hence they work alternately.
Utility Department Room (Here we can see lot of VCB, MCCB and DG
Breaker)
High Tension/Low Tension Block Diagram

So electricity from the utility departments is now used by different machines
to manufacture desired products so we have different transformers allotted,
for group of machineries
Here is some Energy-Tree view diagram of different transformers.
(HSEB) (CAPARO)

RO PLANT
As we know, reverse osmosis plant is a manufacturing plant where the

process of reverse osmosis takes place. Reverse osmosis is a common
process to purify or desalinate contaminated water by forcing water
through a membrane. Water produced by this RO Plant is used by various
machines like Boilers and also for drinking purposes.
Reverse osmosis plants require a variety of pre-treatment techniques
including softening, dechlorination, and anti-scalent treatment. Following
pre-treatment, high levels of pressure send water through a semi-
permeable membrane, which retains all contaminants but let pure water
pass through. Energy requirements depend on the concentration of salts
and contaminants in the influent water; higher concentrations require more
energy to treat.
NOTE: After going through all these processes this water is now fit for drinking
purpose but we need this water as input in boilers so we need to maintain PH level of
this water so we add softening agent and then we regenerate those salts by adding
regenerating resins.

Mixed bed regeneration
Internal regeneration of a mixed bed unit is more complicated. The steps are:
Backwash resin bed to separate the cation from the anion resin.
Let the resins settle.
Optionally: drain the water down to the resin bed surface.
Inject caustic soda diluted in demineralised water.
Displace the caustic with dilution water.
Inject acid diluted in demineralised water.
Displace the acid with dilution water.
Drain the water down to the resin bed surface.
Mix the resins with clean compressed air or nitrogen.
Refill the unit slowly with water.

Do the final rinse with feed water at service flow rate until the desired treated
water quality is obtained.
So, finally we have water with proper PH value, now this water can be
used for producing steam via boilers which would further be used by
BMC Moulding Machines.
BOILERS
Steam Boiler is mostly used in Mechanical or automotive
engineering and it used for generate steam from water after a complete
process. There are different kinds of steam boiler mostly used in
Mechanical industry.
On the basis of working fuel there are two types of Boilers:
Dual Fuel Boiler: Can be operated by diesel as well as CNG.

Diesel Fuel Boiler: Uses Diesel to operate.
Apart from above boilers we have their sub types too i.e Coil type boiler and
Drum type boilers.
Coil Type Boilers: Produces limited steam and have lower efficiency than
drum type boilers , they have low steam producing capacity 500Kg/hr.
Drum Type Boilers: Produces large quantity of steam and have greater
efficiency than Coil Type Boilers and have steam producing capacity of
about 850Kg/hr.
BOILER (850Kg/hr)

Parts of Boiler
The parts of a boiler can be classified into two divisions:
Boiler mounting
These are the essential parts that defined the performance of the boiler.
Water level indicator
This is used to check the water level inside the boiler which is fitted in the
front of the boiler consisting of three cocks and a glass tube.
Pressure gauge
This is used to measure the pressure inside the boiler which is fitted in the
front of the boiler.
Safety valve
This is fitted on the drum and is used to prevent the explosion of the boiler
due to high pressure which blows off when the pressure inside exceeds the
limit. These are always present two.
Stop valve
This is used to control the flow of steam from the boiler to the steam pipe.
Blow off cock
This is fitted at the bottom of the drum and is used to blow off mud and water
and is used to empty the boiler.
Feed check valve
This is used as a Non-Return Valve which is fitted slightly below the normal
water level on the drum. It is used to regulate the supply of water.
Grate
It is the space in the furnace used to burn the fuel.
Boiler accessories
These are the parts that are responsible for the efficiency of the boiler.
Feed pump
It is used to pump the water into the boiler for continuous working. Either
electricity or steam turbine is used for the running of the feed pump.

Super heater
This is used to superheat the steam before it is passed in the turbine as
saturated steam causes corrosion. (Not needed in IJL)
Economizer
It is used to increase the efficiency of the boiler as the flue gases from the
boiler is made to flow through the economizer before releasing it to the
atmosphere.
Air preheater
It is also used to increase the efficiency of the boiler by preheating the air.
The function of Boiler Economiser

The Economizer in Boiler works on the principle of Heat Transfer. Heat
transfer usually takes place from high temperature to low temperature.
In the case of Boilers, flue gases or exhaust from the boiler outlet are at high
temperature and water that needs to be preheated is at low temperature.
So, this temperature difference between water and flue gases helps to
increase the feed water temperature.
Depending on the type of operations, design of Economisers can be smoke

tube type or water tube type.
In smoke tube type flue gases are inside the tubes and water is on the shell
side while in the water tube type, water is in the tube and flue gases are on
the shell side.
ECONOMISER

Doubts I encountered with
Why there is another water filter as water is coming directly from RO

plant?
Ans - Water coming from RO plant is suitable for use in Boilers but as water
is coming from pipeline which might have rust and other surrounding effects
so we need to filter water again.
Why there is need for blow down in a boiler?
Ans- Boiler blow down is the removal of water from a boiler. Its purpose is
to control boiler water parameters within prescribed limits to minimize scale,
corrosion, carryover, and other specific problems. Blow down is also used
to remove suspended solids present in the system. These solids are caused by
feed water contamination, by internal chemical treatment precipitates, or by
exceeding the solubility limits of otherwise soluble salts.
In effect, some of the boiler water is removed (blow down) and replaced with
feed water.
Why could not we use steam coming out and hot water from the boiler for
heat exchanging purpose?
Ans-They (Utility Dept.) already tried but it was not so efficient.

COOLING TOWER
A cooling tower is a heat removal device that uses water to transfer process
waste heat into the atmosphere. All cooling towers operate on the principle of
removing heat from water by evaporating a small portion of water that is
recirculated through the unit. The mixing of warm water and cooler air
releases latent heat of vaporization, causing the water to cool. If you are ever
looking down from a high-rise building, you might notice square units with
fans on top of them on the buildings below. Those are cooling towers.
How Does A Cooling Tower Work?
Air conditioning equipment and industrial processes can generate heat in the
form of tons of hot water that needs to be cooled down. That’s where cooling
towers come in. Overheated water flows through the cooling tower where it’s
recirculated and exposed to cool, dry air. Heat leaves the recirculating
cooling tower water through evaporation. The colder water then reenters the
air conditioning equipment or process to cool that equipment down, and the
cooling cycle repeats over and over again. When the warm condenser goes
into the cooling tower, the water is passed through some nozzles which is
sprayed into small droplets across the fill, which increases the surface area of
water and allows for better heat loss thru greater evaporation. The purpose of
the fan on top of the cooling tower is to bring in air from the bottom of the
tower and move it up and out in the opposite direction of the warm condenser
water of the top of the unit. The air will carry the heat through evaporating
water of the cooling tower into the atmosphere.

CHILLERS
A chiller is a machine that removes heat from a liquid coolant via a vapor-
compression, adsorption refrigeration, or absorption refrigeration cycles. This
liquid can then be circulated through a heat exchanger to cool equipment, or
another process stream (such as air or process water). As a necessary by-
product, refrigeration creates waste heat that must be exhausted to ambience,
or for greater efficiency, recovered for heating purposes. Vapor compression
chillers may use any of a number of different types of compressors. Most
common today are the hermetic scrolls, semi-hermetic screw, or centrifugal
compressors. The condensing side of the chiller can be either air or water
cooled. Even when liquid cooled, the chiller is often cooled by an induced or
forced draft cooling tower. Absorption and adsorption chillers require a heat
source to function.
Chilled water is used to cool and dehumidify air in mid- to large-size
commercial, industrial, and institutional facilities. Water or liquid chillers can
be liquid-cooled, air-cooled, or evaporatively cooled. Water or liquid-cooled
systems can provide efficiency and environmental impact advantages over
air-cooled systems.
CHILLER
Q- So what is the difference between Chiller and Cooling Tower as they both
are being used for cooling purposes?
Ans- In cooling tower we can’t control temperature, moreover it depends on

surroundings while in chillers we can control temperature of cooling water.

Moulding Department
Moulding
Moulding is the process of manufacturing by shaping liquid or pliable raw
material using a rigid frame called mould or matrix. This it may have been
made using a pattern or model of the final object.
Here we will basically discuss about injection moulding.
Injection Moulding
Injection Moulding is a manufacturing process for producing parts by
injecting molten material into a Mould for a specific design. Injection
Moulding can be performed with a host of a material mainly including
metals, elastomers, glasses, confections, and most commonly thermoplastics
and thermosetting polymers. There are 3 types of injection Mouldings.
Hand type injection Moulding

Plunger type injection moulding
Reciprocating screw type injection moulding
Here we will be focusing mainly on reciprocating screw type injection
moulding. In a reciprocating screw injection moulding machine, material
flows under gravity from the hopper onto a turning screw. The mechanical
energy supplied by the screw, together with auxiliary heaters, converts the
resin into a molten state at the same time the screw retracts toward the hopper
end. When a sufficient amount of resin is melted, the screw moves forward,
acting as a ram and forcing the polymer melt through a gate into the cooled
mould. Once the plastic has solidified in the mould, the mould is unclamped
and opened, and the part is pushed from the mould by automatic ejector pins.
The mould is then closed and clamped, and the screw turns and retracts again
to repeat the cycle of liquefying a new increment of resin. For small parts,
cycles can be as rapid as several injections per minute.

Machine Components
The injection system consists of a hopper, a reciprocating screw
and barrel assembly, and an injection nozzle. This system confines
and transports the plastic as it progresses through the feeding,
compressing, degassing, melting injection and packing stages.
The Hopper
Thermoplastic material is supplied to Moulder in the form of small pellets
The hopper on the injection Moulding machine holds these pellets. The
pellets are gravity-fed from the hopper through the hopper throat into the
barrel and screw assembly.
The Barrel
The barrel of the injection moulding machine supports the reciprocating
plasticizing screw. It is heated by the electric heater bands. The barrel has 7
temperature zones.
The Reciprocating screw

The reciprocating screw is used to compress, melt, and convey the material.
The reciprocating screw consists of three zones illustrated below):
The Feeding zone

The Compressing (or transition) zone
The Metering zone
While the outside diameter of the screw remains constant, the depth of the
flights the reciprocating screw decreases from the feed zone to the beginning
of the metering zone. These flights compress the material against the inside
diameter of she barrels which creates viscous (shear) heat. This shear heat is
mainly responsible for melting the material. The heater bands outside the
barrel help maintain the material in the molten state. Typically, a Moulding
machine can have three or more heater bands or zones with different
temperature settings.
The figure below is of a reciprocating screw, showing the feeding zone,

compressing (or transition) zone, and metering zone.

The Nozzle
The nozzle connects the barrel to the sprue bushing of the mould and forms a
seal between the barrel and the mould. The temperature of the nozzle should
be set to the material's melt temperature or just below it, depending on the
recommendation of the material supplier. When the barrel is in its full
forward processing position, the radius of the nozzle should nest and seal in
the concave radius in the sprue bushing with a locating ring. During purging
of the barrel, the barrel backs out from the sprue, so the purging compounds
can free fall from the nozzle. These two barrel positions are illustrated below.
Mould system
The mould system consists of the bars, stationary and moving platens, as well
as moulding plates (bases) that house the cavity, sprue and runner systems,
ejector pins, and cooling channels, as shown in Figure. The mould is
essentially a heat. the molten thermoplastic solidifies to the desired shape and
dimensional details defined by the cavity.
Cooling channels (circuits)

Cooling channels are passageways located within the body of a mould,
through which a cooling medium (typically water, steam, or oil) circulates.
Their function is the gulation of temperature on the mould surface. Cooling
channels can also be combined with other temperature control devices, like
bafflers, bubblers, and thermal pins or heat pipes.
Hydraulic system
The hydraulic system on the injection moulding machine provides the power
to open and close the mould, build and hold the clamping tonnage, turn the
reciprocating screw, drive the reciprocating screw, and energize ejector pins
and moving mould cores. A number of hydraulic components are required to
provide this power, which includes pumps, valves, hydraulic motors,
hydraulic fittings, hydraulic tubing, and hydraulic reservoirs.
Control system
The control system provides consistency and repeatability in machine
operation. It monitors and controls the processing parameters, including the
temperature, pressure, injection speed, screw speed and position, and
hydraulic position. The process control has a direct impact on the final part
quality and the economics of parts. Process control systems can range from a
simple relay on/off control to an extremely sophisticated microprocessor-
based, closed-loop control.
Clamping system
The clamping system opens and closes the mould, supports and carries the
constituent parts of the mould, and generates sufficient force to prevent the
mold from opening. Clamping forces can be generated by a mechanical
(toggle) lock, hydraulic lock, or a combination of the two basic types.
ASA Black
II. PC ABS Grey
III. PMMA Red
IV. PMMA Pink
V. PMMA Clear
VI. PBT Natural
VII. PBT Black

VIII. PBT Grey

Calculating Clamping Force
The clamping force calculation of the injection molding
machine is a compulsory course for all the injection molding
engineers. Let’s talk about the calculation method of the clamping
force in injection molding.

The clamping force of the injection molding machine, also known
as the clamping force, is the key to the molding of injection
products. If the clamping force is too small, it will cause the
product to have flash or lack of material.
Too big clamping force will result in a waste resource and will
cause premature aging of hydraulic components and mechanical
structure wear.
There and many injection molding machine tonnage calculation
formulae. Below we will explain how to calculate clamping force
with 4 clamping force formula one by one.
Empirical formula: the core idea-to calculate the clamping force through
the clamping force constant
Calculation formula:
clamping force = clamping force constant x projected area of the product
p=kps
Remarks:
p=clamping force (t);
kp=clamping force constant (t/cm2),
s=projected area of the product on the template (cm2).
Different type of defects and problems in moulding

I. Short moulding
II. Silver
III. Flow marks

IV. Sink marks
V. Waviness
VI. Shrinkage
________________________ Moulding defect

VII. Flash at parting line
VIII. Fitment area flash
IX. Oil mark
X. Scoring mark
_____________________________Mould related problem.
Different Sections in Moulding Department

I. Insert
II. Extension
III. RCL

IV. PC
V. Multicolor
VI. BMC
In every section different Moulds are prepared by using the same principal
injection Moulding. So now we will briefly discuss about each section and
Moulds prepared in them.
INSERT
INS 01 & INS 02
Mould prepared in this section is as follows;
KYJR CHL REF
KYJR CHL EXT
KYJR PC Lens
K43H CHL REF
K43H PC Lens
YAD PES Cover
(PC stands for Poly Carbonate)
Machine used- INS-01 350 ton
-INS-02 350 ton
EXTENTION
Machine used- Injection moulding EXT-1000T
EXT 02:
Moulds prepared in this section are:
YRA N Body
YRA P (B) CHL EXT
YRA N RCL BODY T/R EXT
YRA P RCL EXT
S.O.P. (Standard Operating Procedure)

• YRA RCL (N) Body
First check the following parameter:
MTC confirm all temperature control hoses are connected to the mould
MTC temperature is set. (MOULD TEMPERATURE CONTROLLER)
Cavity 35°C-50°C
Core 30°C-50°C
The temperature of MTC has reached to the set value.
HR Confirm: HR connector is connected to the mould. HR temperature is set

(260 °C).
Robot confirm: Return the robot to the home position.
Now the actual start up procedure
I. Purge material from machine nozzle.
II. Purge 4 times.
III. Touch the nozzle to mould.
IV. The temperature of HR has reached the set value
V. Wait 5 minute when temperature reaches the setting.
VI. Set the holding pressure time to 0 seconds.
VII. Semi-automatic moulding starts.
VIII. After 2 shots return the hold pressure time to the set value(seconds).
IX. Fully automatic starts.

X. Returning the MTC temperature to set value.
(Cavity-35°C) (Core-30°C)
EXT 03
Mould prepared: YHB CHL EXT, YJC LED EXT, YLI
Start-up Procedure
D-1 mist apply
If mould is not getting clean after production timing on applying D-1 mist
then direct shot OK.
10-12 sort production.
D-1 mist removes condition check
D-1 mist remove: Test aluminizing required
D-1 mist not removed: mould cleaning
D-1 mist: - Anti rust agent
EXT 04
Mould prepared
• YJC CHL EXT
• YJC LED EXT
• YRA P. B CHL EXT
• YRA N CHL EXT
START-UP PROCEDURE [YR9 Reflector]

Remove pill guard layer from mould carefully.
Do not make any scratch on mould
Clean parting line of mould by tissue paper & with cleaning spray.

2 times purge material and check actual condition. Take up first short as per
start up procedure.
Check the part quality before and after aluminizing.
Send 3 OK shots for aluminizing.
Stop machine until part is not aluminizing.
Get approval of aluminize part and start production.
EXT 05:
Mould prepared:
YAD LED EXT
YHC EXT
TSVA EXT
CT Tail body
Important precaution to reduce rejection in TSVA EXT.
Mould pre heating must be done for minimum 3 hour at temperature 70°C.
Parting line must be cleaned with hi-DEPO before mould start up.
Set MTC temperature 55°C, core and cavity both at the time of mould start
up. After 10 shot set it 45ºC.
Purge the degraded material from the barrel until ok material come.
Set HRTC (Runner Temperature Controller) temperature 270ºC for all 16

zones for first 4 shots after that set it 250°C.
Take the first shot, no change required in data.
Check the part quality & make FPA.
Parting line clean after every 4 hours and also when silver streak problem
occur.
EXT 6
Mould prepared:-YC5 T.A,YL7
EXT 7
Mould prepare:-YRA PREMIUM RCL LENS
• If machine is stopped for more than 5 minutes then purge the material 5
shots. Set HRTC temperature 265ºC for first 3 shots after that set it for
250°C.
RCL
In RCL lamps are often categorized as:
Normal
Premium
RCL 01
Mould prepared in this section is YC5 RCL LENS, YP8, YC5,YC5 FOG
LENS, YP8,LENS, YRA (BOTH YRA CHL &YRA RCL).
RCL 02
Moulds prepared are:-YP8, YP5, YL7, YRA P,2 CT LED
RCL 03
Moulds prepared are:-YRA N RCL LENS, YR9, YN4
RCL 04
Moulds prepared are:-YRA (Premium), YL7
MULTICOLOUR
Machine name: - ENGILE
In multicolor section double mould are prepared. Double mould refers to:
• 2 core
• 2 cavity
• 2 hopper
In hopper, 1st section is INSERT (White part in BUL design) and 2nd section
is body (red part).
Moulds prepared in MULTICOLOUR are:
YL1 BUL
YL1 RCL
YAD BUL
YAD RCL
2 CT TAIL LENS
PC
> S.O.P (Standard Operating Procedure)
[Operating procedure for reducing the lumps of PC material]
When we stop the machine for mould change barrel temperature is set in hold
for 20°C.By this barrel temperature will go down 20ºC and material will not
burn. When we start the machine, purge the 50 mm material 3 times and take
next shot.
Note: - No need of purging if we start before an hour.
→ PC 01
Moulds prepared are: -
1. TG2 CHL Lens
2. YL7 CHL Lens

3. YL8 CHL Lens
4. YL1 CHL Lens
5. YJC LED Lens
6. YHC CHL LENS
7. FL2 CHL LENS
8. TSVA LENS
9. TSVA B/D
10.YJC CHL Lens
PC 02
1. YAD CHL/LED Len
2. YJC LED Lens
3. YJC CHL Lens
PC 03
1. YL8 CHL Lens
2. YL1 CHL Lens
3. TG 2 HONDA Lens
PC 04
1. YRA CHL N/P Lens

2. HONDA CHL LENS
3. YHB CHL LENS
4. YJC LENS
BMC [Bulk Moulding Compound]

Bulk molding compound (BMC) is a bulky mixture of chopped glass fibers,
resin paste and fillers. Even though other fibers such as sisal, asbestos,
carbon, aramid, chopped nylon rag and wood are used, the most
common reinforcing fiber in BMC is E-glass fiber. As BMC is usually mixed
in a dough-like form rather than as a sheet, it is also called dough molding
compound (DMC), and is sold in a log or rope form. The resin formulation of
BMC materials is similar to that of SMC materials. Chopped glass fibers are
compounded with the resin paste in an intensive mixer and extruded in the
form of a continuous log. The extruded log is cut to the desired length by a
pneumatic cutter located outside the extruder. The glass fiber content of
BMC is generally 5 ~ 10% lower than that of SMC, and the fibers are shorter
(generally less than 25 mm). Therefore, the mechanical properties of BMC
are lower than those of SMC. The impact strength is highly dependent on
the fiber length. This improvement in the impact resistance by the increase in
fiber length becomes less significant above the fiber length of 12.7 mm (0.5
inch). Moreover, fiber lengths over 12.7 mm result in mixing and molding
problems. Therefore, the fiber lengths of BMC seldom exceed 12.7 mm, and
the most common fiber length is 6.23 mm (0.25 inch). Sometimes, BMC is
mixed at the molding location whereas it also can be purchased from
commercial manufacturers that sell the material as a ready-to-mold premix
In this section moulding unit of injection moulding machine have more

temperature than the injection unit (i.e. barrel is cool).
Approximate temperature in moulding unit is usually 150°C-170°C.

For quality check of reflector- Red dye and foam is used.
Defects usually occur in BMC are:
Roughness
Crack
Material stick
Short moulding
S.O.P. (Standard Operating Procedure) To reduce

Lumps of BMC material
1. Mainly in BMC there is no need to purge the material upto8 hours if
machine nozzle tip is open.
2. If you are going from high weight part to low weight part after mould
change, then purge the material up to less weight shot size and start the
machine.
3. Only purging allowed when machine barrel have some material hard issue
inside if maintenance person request for it.
BMC 01
Reflector moulds prepared are:
1. YJC REF
2. YC5 REF
3. YRA REF
4. YAD REF
5. TG2 HONDA REF
6. ML2 REF
7. TSVA REF
BMC 02
1. YL7
2. YL8 REFLECTOR LHD/RHD
3. YL1
BMC 03
1. YIC
2. YHB
3. TSVA
4. FL2
5. YAD
6. YLS
7. YL7
BMC 04
Reflector moulds prepared are: -
1. YRA N

2. TSVA
3. YAD
4. YRA CHL N
NOTE: BMC is a thermosetting plastic so we can’t reuse it.

Capacity of molding machine in tons is actually the reaction
pressure not Mg of mould.
DOUBTS I ENCOUNTERED WITH

What will happen in case of power cut off or changing over while
mould is in clamping position?

Ans- There won’t be any kind of effect as we use one way valve so in case of
power cut off that valve doesn’t allow fluid to come back.
We recycle and reuse PC compounds, but its property will change

simultaneously after reusing?
Ans-Yes their property changes, but we keep an eye over them.
Is there any kind of rule that cavity shape will be at stationary plate
while core at moving plate and vice-versa?
Ans-No there is not any kind of rule but it depends upon customer’s choice
and convenience to robot grip.

SURFACE TREATMENT
In this section mould received from moulding section are here aluminized,
painted, hard coated and anti-fogged.
DIRECT ALLUMINIZING
In this section of surface treatment, the mould available from the moulding
section is aluminized without the need of lacquering.
Machine name: RCL 2 Vacuum Metalizing Plant with accessories.
Asset code: BW-P-M-006-AG-2014
Inside the machine, there is a filament on which aluminium coil is placed
When the machine is closed, current of 3500 4800A is introduced which

causes bombarding in the machine leading to aluminizing.
Moulds directly aluminized are:
1. YAD PES COVER
2. 2 CT TAIL BODY
3. 2 CT LID BODY
4. YRA N RCL BODY LH/RH
5. YRA P EXT. LH/RH
6. YL1 RCL BODY LH/RH
7. YL1 BUL BODY LH/RH
S.O.P. Standard Operating Procedure]

Operation name: Aluminizing
PAINT SHOP
We have 3 paint shops -Paint Shop 1, Paint Shop 2, and Paint Shop 3
respectively.
Paint Shop 01
In this section the mould/parts are manually painted (mainly lens). In this
section end after hard coat is brought there and black paint is applied.
Moulds/ Parts painted: -
1. YL1 (A) & YL1(B)
2. KYJR & KYJF
3. K43H (OUTER LENS)
4. K43H (INNER LENS)
Lacquer used in paint shop 1 are
1. TG Gun metallic
2. Thinner
3. Hardener
Standard Operating Procedure

1. First set painting gun as per standard (paint volume- 3 round open, paint
round) and set part in jig mask properly.
2. Start paint as per sequence. Take 1.5second to complete one step.
3. Repeat the same sequence 3 times on same part.
4. After every time mask change, first and last part check properly after paint
[paint line, pain drain, not cover].
5. Check light leak after paint.
6. Keep part on curing conveyor.
Paint Shop 02 & 03

In this section the mould brought here after aluminizing is painted.
First the moulds/parts are brought to air blow booth where dust is removed by
using Ion blow gun and DE static air blow.
Standard Operating Procedure [S.O.P.] for AIR BLOW

BOOTH
Operation name: De-static input area
1. First take the part from input trolley with correct handling method.
2. Then do de-static air 3-5 seconds for remaining the static charge.
3. Put the part in input conveyor with sequence and correct handling method.
Rework Procedure for painting components:
1. Check and keep defective parts separately for rework by rubbing soft
emery paper no.1600.
2. Rub smoothly with emery paper otherwise scratches generate.
3. After rework, keep components on input conveyor for painting.
4. Keep reworked components on paint jig for painting again.
5. After painting again keep in output conveyor for inspection.
6. Inspection parts quality, after marking quality stamps on parts & material
keep in WIP location.
Rule for IPA[Isopropyl Alcohol]

1. Do not keep IPA in open condition.

2. IPA is inflammable, so avoid fire.
3. Use only IPA standard bottle
4. Keep bottle on their bottle place.
5. Do not keep more than 2bottle.
6. Do not use IPA in different bottle like water bottle.
7. Do not spread IPA on the floor.
8. Protect eye from IPA.
9. IPA is water type so when drinking water ensure it.

HARD COAT
In this section of surface treatment the mould [most commonly lenses] is
made scratch proof
1. Since the mould [lens] collected is relatively hot and static which means it
tends to attract dust particles.
2. So first the dust is removed in air blow booth using ion blow gun and de-
static air blow.
3. Then the mould is cleaned again using IPA.
4. This part is again treated with ion blow gun.
5. The part is then putted on the input conveyor which is collected by the
robot and is made scratch proof using chemical [lacquer] 5328.
6. UV lamps are used for curing.
7. Then the lens is inspected manually.
8. Then the lens is placed on output conveyor sticky mat for dust catching]
for packing.
Commonly appearing defects:

Dust
Fibre dust
Lacquer drain
Scratch
Foreign part [any color]

White mark
Non-wet
Moulds [lenses] hard coated

Every lens produced in the moulding department is hard coated here.
ANTI-FOG
This section of lacquering is done at the lower surface of the lens. It is done
so that lens doesn't become vulnerable to fog.
1. In this the dust is removed in air blow booth using ion blow gun and de
static air blow.
2. Then it is placed on input conveyor which is collected in the robot room &
it is placed on the jig present there and lacquering is done.
3. After the lacquering it is placed on the hot air boiler for curing.
After the curing the part is placed on output conveyor & inspected manually
before packing.
4. Lacquer used in anti-fog is mixture of many lacquer .i.e. H-9600, Thinner

P, Thinner R, Modifier Q[catalyst] which are in the ratio as follow:
H-9600: Thinner P: Thinner R: Modifier Q
1:0.350: 0.350: 0.100
Moulds/lens anti-fogged
YRA [P]
YAD [P]
YJC [P]
KYJR [P]
YHB [P]
YHC 6[P]

ASSEMBLY
Final manufacturing step of lamps is known as assembly. At this step the
different parts like reflector lens ,bulb, code assembly push pull motor,
tension etc are assembled together with the help of number of machines and
the combination of machines and devices or motors is called a assembly line
assembly of automotive lamps are done on 2 lines RCL & CHL.
RCL assembly lines are 11 in numbers and CHL are 10.
RCL
In this section assembly of rear combinational lamps is done using hot plate
welding.
• Stud bolt insert machine
In this machine body is fitted on jig on which stud bolt is inserted. These
bolts are first heated and then fitted. While inserting the bolt it is alongside
treated with air cooling for 12 seconds.
• Reflector assembly table
In this section reflector is assembled over the body.
• Hot Plate welding machine
In this section the assembled body is fitted along with the lens.
Both body and the lens are fitted on their respective jig and melted as per
their cycle time.
After the end of the cycle time both the body and lens are welded together.
Then the lamp is placed on IR Annealing oven where it is further heated.

• Leak Testing Machine
Part after being collected from the annealing oven it is moved for leak
testing.
Before turning on the machine sheet packing is done.
When passed in leak testing LOK sign is stamped.
• Sheet packing and Chord assembly
Here chord, bulb is fitted and sheet foams are placed.
Light testing Machine
Here light testing is done with the help of light testing machine
Finally Inspection
Part is finally inspected for any possible defects
CHL
In this section Combinational Head Lamp is assembled using glue dispersing
machine. The body is first collected and treated with air.
Plasma Flaming Machine [only in case of YAD Lamps]
The body after air treatment is treated with plasma which is done to provide
some roughness which is helpful during glue dispersing.
• Push on Fix Machine
In this section pivot and adjuster are fitted on the body. Spring nut and push
on fly is fitted. The motor and big o ring is placed on the body.
• Chord Assembly
Chords are fitted.
• Reflector sub assembly
H-7/H-4 filament PES unit is fitted on reflector 'A' using SS bearing, self
locking nut and 8mm edge tape screw.
• Pre-Aiming machine
Reflector B and inner lens is installed.
• Then lens is treated with air and fixed with extension using screw
• Glue dispersing and Lens pressing.
Screwing and cooling conveyor machine.
Leak testing
Photometry Testing
Final Inspection

Assembly Line Process Flow Diagram

Overview of Operations and Maintenance of Different Departments at an Automotive Lighting Company

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Overview of Operations and Maintenance of Different Departments at an Automotive Lighting Company

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NIT KURUKSHETRA

INDUSTRIAL TRAINING REPORT

INDIA JAaPAN LIGHTING PRIVATE LTD

Title of the project:

Submitted To- Submitted By-

IJL, BAWAL| Industrial Training Report Page 1

Signature of the Candidate

CERTIFICATE BY THE EXTERNAL GUIDE

Dhirendra Kumar Signature of the External Supervisor

Senior Manager - Human Resource

India Japan Lighting Pvt. Ltd

I would like to thank Mrs.Aradhana Srivastava, Ms.Shreya Mishra,

I express ingeniously my whole-hearted thanks to Dr.Gulshan Sachdeva and

It is indeed a pleasure to thank my friends who persuaded and encouraged me

IJL, BAWAL| Industrial Training Report Page 4

-Machine Components 23-27

-Calculating Clamping Force 28

-Different types of defects and problem in 29

-Paint Shop 2 and 3 45-46

IJL, BAWAL| Industrial Training Report Page 5

How different types of Automotive Lights are produced? What kind of

IJL, BAWAL| Industrial Training Report Page 6

IJL, BAWAL| Industrial Training Report Page 7

ABOUT THE COMPANY

The company manufactures Headlamps, Rear combination lamps and

IJL, BAWAL| Industrial Training Report Page 8

IJL, BAWAL| Industrial Training Report Page 9

Different departments of IJL are as follow:

Utility Maintenance Department

Mould Maintenance Department

Surface Treatment Department

Assembly Maintenance Department

IJL, BAWAL| Industrial Training Report Page 10

Two major sources of electricity in IJL are :-

Both of them supplies electricity to other departments alternately, for

High Tension/Low Tension Block Diagram

IJL, BAWAL| Industrial Training Report Page 11

Here is some Energy-Tree view diagram of different transformers.

IJL, BAWAL| Industrial Training Report Page 12

As we know, reverse osmosis plant is a manufacturing plant where the

IJL, BAWAL| Industrial Training Report Page 13

IJL, BAWAL| Industrial Training Report Page 14

On the basis of working fuel there are two types of Boilers:

Dual Fuel Boiler: Can be operated by diesel as well as CNG.

IJL, BAWAL| Industrial Training Report Page 16

IJL, BAWAL| Industrial Training Report Page 17

The function of Boiler Economiser

Depending on the type of operations, design of Economisers can be smoke

IJL, BAWAL| Industrial Training Report Page 18

Why there is another water filter as water is coming directly from RO

Why there is need for blow down in a boiler?

IJL, BAWAL| Industrial Training Report Page 19

How Does A Cooling Tower Work?

IJL, BAWAL| Industrial Training Report Page 20

Ans- In cooling tower we can’t control temperature, moreover it depends on

IJL, BAWAL| Industrial Training Report Page 21

Here we will basically discuss about injection moulding.

Hand type injection Moulding

IJL, BAWAL| Industrial Training Report Page 22

The Reciprocating screw

The Feeding zone

The figure below is of a reciprocating screw, showing the feeding zone,

IJL, BAWAL| Industrial Training Report Page 24