INDUSTRIAL TRAINING REPORT

Project report submitted in partial fulfilment of the requirements

For the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
By

Name: SPARSH SHARMA

Roll No: 2K17MEUN01034

DEPARTMENT OF MECHANICAL ENGINEERING

MANAV RACHNA UNIVERSITY
SESSION – 2017-2021
 CANDIDATE’S DECLARATION

The work of project is being presented in the partial fulfilment of

the requirements for the award of the degree of BACHELOR OF

TECHNOLOGY (MECHANICAL), of the Manav Rachna College of

Engineering (Currently Known as MRU), Faridabad is an

authentic record of our own work carried out in 8 th Semester

Training in “MOTHERSON” under the supervision of Mr. Rajeev

Dwivedi (senior manager).

The matter embodied in this report has not been submitted by

us for the award of any degree.

NAME – Sparsh Sharma

ROLL No. – 2K17MEUN01034

 AKNOWLEDGEMENT

The internship opportunity I had with MOTHERSON SUMI

SYSTEM LTD was a great chance for learning and professional
development. Therefore, I consider myself as a very lucky
individual as I was provided with an opportunity to be a part of
it. I am also grateful for having a chance to meet so many
wonderful people and professionals who led me though this
internship period.

Bearing in mind previous I am using this opportunity to express

my deepest gratitude and special thanks to Mr. Rajeev Dwivedi
(Senior Manager) who in spite of being extraordinarily busy with
her/his duties, took time out to hear, guide and keep me on the
correct path and allowing me to carry out my training at their
esteemed organization and extending during the training.

I perceive as this opportunity as a big milestone in my career

development. I will strive to use gained skills and knowledge in
the best possible way, and I will continue to work on
improvement, in order to attain desired career objectives. Hope
to continue cooperation with all of you in the future,
Sincerely,

Sparsh Sharma

2K17MEUN01034
 INDEX

ABOUT MOTHERSON

ELECTRICAL DISTRIBUTION SYSTEM (EDS)

POWER MODULES

ELECTRICAL CABINET AND POWER PACK

WIRE HARNESS
 WIRING HARNESS COMPONENT

PRODUCTION PLANNING & CONTROL DEPARTMENT

 STAGES OF PRODUCTION PLANNING & CONTROL
DEPARTMENT

QUALITY CONTROL DEPARTMENT

 WIRE HARNESS MANUFACTURING QUALITY CONTROL  

PRE-WORK ON WIRE IN LPC SECTION

ASSEMBLY POINTS

 SUB ASSEMBLY

 FINAL ASSEMBLY

FINAL INSPECTION
ABOUT MOTHERSON
Motherson Group serves its customers with multiple products
and services through its ten business divisions. With the support
of the customers, these divisions continue to grow stronger and
become more diverse and help Motherson move closer towards
its vision of being a globally preferred solutions provider. These
are the ten business divisions of Motherson

Motherson is one of the world’s largest manufacturers of

components for the automotive and transport industries. Our
name itself signifies a relationship of deep trust- that of a
mother and child. Trust is sacrosanct in all relationships at
Motherson while working towards our vision of being a globally
preferred solutions provider.

arts that come together in a collaborative work of art and

engineering. Our name isn’t on it, and that’s fine with us. We’re
just proud to be part of the world’s most admired automotive
brands

Our industry is highly engineered and constantly evolving. To

embrace rapid change, we need to take the long view. Our Five-
year plans allow us to align with our customers’ strategies for
long-term growth.

For Motherson, being a trusted partner in the years to come,

goes far beyond just economic objectives. With everything we
do, we are committed to act sustainably - for the environment,
for the communities we serve and for all our stakeholders.

Motherson Wiring Harness Division specialises in products that

enable mobility around the world by being part of its customers’
transportation vehicles and helping people and businesses
move around the globe, every single day.

Products supplied by the company ensure the power supply and

data transfer in various modes of transport and they play a key
role in ensuring the safety and reliability of these vehicles.

The company is one of the largest manufacturers of wiring

harnesses and electrical components globally and is a complete
solutions provider to all its customers - from the product and
concept development with complete in-house design capability
& global engineering support to manufacturing and aftersales
service. The division’s vertical integration supports its customers
with increased content and capabilities; components
manufacturing, testing & validation and production engineering
as well as enterprise production planning systems.

 Fulfilling the commitments on the quality and delivery of

products makes Motherson a significant name in the
transportation industry. The company is the market leader in
passenger car wiring harnesses in India and for heavy, medium
and light-duty commercial vehicles in China, North America and
Europe. The company also has a strong presence in European
two-wheeler, material handling equipment, and rolling stock
markets globally. 
Customer segments include:

 Passenger Cars
 Two-wheelers and recreational vehicles
 Agricultural machines
 Commercial vehicles (heavy, medium and light-duty)
 Rolling stock (trains, trams, locomotives, electrical buses)
 Construction and material handling equipment 
 Enterprise Resource Planning (ERP) systems
 Other industrial applications such as medical diagnostic
equipment, white goods, office automation

Partnership with global technology leaders:  

In 1986, a joint venture with Sumitomo Wiring Systems, Ltd., a

global leader in the manufacture of wiring harnesses, harness
components, and other electric wire resulted in Motherson
entering this segment. The joint venture is one of the oldest in
India and has provided Motherson with a robust technology
base and support in building a culture of excellence. 

Motherson continues to embrace the latest market innovations

by combining forces with global technology leaders in major
business areas.  The division formed a joint venture with
Kyungshin Corporation- Korea in 1997. This joint venture was
formed to cater to the needs of integrated wiring harness
manufacturing for one of its most valued customers for its
complete range of cars manufactured in India. 
In addition, the division has three joint venture partners in
China, for the manufacturing of wiring harnesses: Hefei
Jianghuai Automobile Co. Ltd., Hubei Zhengao Auto Accessories
Group Co. Ltd., and Jiangsu Huakai Wire Harness Co., Ltd. 
Electrical distribution systems (EDS)

Motherson is into designing, manufacturing and integrating

cutting edge Electrical & Electronic Distribution Systems (Wiring
Harness Systems) for power supply or data transfer across all
vehicle segments as well as on other industrial applications.
Core strengths include mass customisation and the ability to
integrate into the customer's operating environment and deliver
tailored, cost-efficient solutions that provide a unique
competitive advantage in the market. 

The division follows the principles of just-in-time (JIT) and just-in-

sequence (JIS) manufacturing and delivery as per the
requirements of the customer supply chain. The engineering
centres of the group help develop technologically advanced
solutions as per industry requirements to continuously improve
its processes. 

Digitalisation of the wiring harness manufacturing process

targets zero defect, shorter set up times and reducing rework,
CAPEX and shorter assembly and test times. Digital assembly
boards, colour detection and component presence sensors and
on-line work instruction are few systems developed to simplify
the processes at wiring harness plants. 
Power modules

Power distribution modules are designed to deliver power

intelligently from the main power source to remote systems
throughout the vehicle. DC/DC converters, battery management
systems, and power distribution units are examples in-vehicle
electronics where the company is developing optimised and, in
some cases, customised customer-specific solutions.

Electrical cabinets and power packs

Wiring Harness Division develops and manufactures electrical

cabinets, power packs, converters and drivers’ desks and other
components for rolling stock, the energy industry and the
material handling industry. Electrical cabinets and power packs
applications include passenger trains, light rail vehicles, metros,
locomotives, wind energy, port solutions, machine constructors
and stationary power systems.

The division has also expanded its product portfolio and delivers
high voltage products for electrical buses, contributing to
sustainable transportation.
WIRE HARNESS - A wire harness is an assembly of wires, cables
and connectors that transmit electric power or signals.
Complete on-site services include cutting, stripping, crimping,
soldering, as well as the assembly of wires in a wide range. A
wire harness assembly maximizes efficiency by binding wires
together in a safe and secure routing pattern with the use of
wire management products has as tie wraps, PVC, slit loom
tubing and a wide range of sleeving.

Components
The wiring division is one of the most vertically integrated
business divisions of Motherson, which provides it a huge
competitive advantage. It helps to control the quality of the
products, enables better cost control and aids in reducing the
delivery time. It also reduces the risk of relying on tier II partners
for critical inputs.
The capability of designing mechanical parts and manufacturing
of jigs, fixtures, applicators, circuit checking and assembly
boards, supported by state-of-the-art facilities for the wiring
harness and component testing, makes the company a full
system solutions provider.

Wiring harness components

 Wires
 Terminals 
 Connectors 
 Caps and sleeves 
 Grommets 
 Clamps and binders 
 Junction boxes 
 Fuse boxes 
 Protectors 
 Relay boxes 
 Wire seals 
 High tension cords 
 Battery cables 
 Mechanical assemblies in house production of mechanical
parts
Production planning and control Department

is defined as a work process which seeks to allocate human

resources, raw materials, and equipment/machines in a way
that optimizes efficiency. ... It enables efficiency, coordination,
and the leveraging of production-related data to drive
improvement.

Stages of Production Planning & Control

Production Planning & Control is done in three stages namely,

1. Pre-planning
2. Planning
3. Control.

Stage 1: Pre-Planning Under this phase of production

planning, basic ground work on the product design, layout
design and work flow are prepared. The operations relating to
the availability scope and capacity of men, money materials,
machines, time are estimated.

Stage 2: Planning This is a phase where a complete analysis

on routing, estimating and scheduling is done. It also tries to
find out the areas of concern for short time and long-time so
that prominent planning can be prepared.

Stage 3: Control Under this phase, the functions included

are dispatching, follow up, inspection and evaluation. It tries to
analyse the expedition of work in progress. This is one of the
important phases of the Production Planning and Control.
The objectives of Production Planning Control are as
follows:

1. to ensure safe and economical production process

2. to effectively utilize plant to maximize productivity

3. to maximize efficiency by proper coordination in production

process
4. to ensure proper delivery of goods
5. to place the right man for the right job, at right time for right
wages.

6. to minimize labour turnover

7. to reduce the waiting time

8. To ensure flexibility in production system to accommodate

changes and uncertainty

9. Optimizes the use of resources for minimum overall

production cost

10. To ensure the production of right product at right time in

right quantity with specification rightly suited to customers

11. Stable production system, with least chaos, confusion and

undue hurry.
QUALITY CONTROL DEPARTMENT

So, Quality control is a process intended to ensure that

product quality or performed service adheres to a defined set of
criteria or meets the client's requirements. The product quality
will be maintained through the quality control process, and the
manufacturing defects will be examined and refined.

ISO is an organization that sets standards for quality

management that focuses on training manufacturers how to
provide their customers with consistent, high-quality results. A
manufacturer with an ISO certification has an efficient
manufacturing process that will ultimately save you time and
money while still producing a reliable product.

The quality control process is divided into three separate

processes, which are

IQC (incoming quality control)

IPQC (in-process quality control)

OQC (outgoing quality control)

IQC (incoming quality control)

Incoming quality control is the process of inspecting the raw and

component materials from suppliers upon arrival. When you
found the defective parts, you need to negotiate with the
supplier for return or exchange, and the ultimate purpose is to
make sure your product quality will not be affected. Below is a
sample flowchart of the IQC process.

OQC - Outgoing Quality Control

OQA is the inspection of products before shipping. It's a crucial

step in ensuring the shipment is defect-free.

IPQC - In-process Quality Control

IPQC refers to quality control during the assembly process. It is

crucial because you can detect and handle the problem that
occurs ahead of time.
WIRE HARNESS MANUFACTURING QUALITY CONTROL
We perform testing on cables and wire harness assemblies for
every order. Therefore, quality control strongly impacts the
bottom line with the wire harness assembly process.

High accuracy during the assembly process is the key to

maintaining competitive pricing and reliability. We take every
step to ensure accuracy at the time of assembling and
producing the wires. Instituting a strict wire harness quality
control system during production brings significant benefits to
our customers.

Wire Harness Manufacturing Testing Check List

Wire Harness Testing requires extreme caution. This is due to it

involving live wires. Unfortunately, electric shock and burns can
turn a great day into a really bad day quickly. It is mandatory to
use personal protective equipment on the job such as safety
glasses when testing a wire assembly.
Wire Harness Manufacturing Checklist for Testing Wires:
1.Accurate Labelling
2.Check for Damaged Insulation or Defective Wires
3.Continuity
4.Correct Wire Gauge
5.Also, Check for Proper Crimps
6.Free of Moisture as well as Corrosion
7.Optimum Wire Placement Within Connectors
8.Pull Test
9.Test for Broken Wires
10.Finally, Test for Shorts

Consequences when continual improvement and quality are

NOT the top priority:
 High defect rates
 Underutilized equipment
 Poor productivity
 Poor inventory management
 Safety concerns
 Finally, low morale with employees
PRE-WORK ON WIRE IN LPC SECTION

LPC stands for Lead Production Cell

Wires are cut into dimensions according to labels provided.

Strip the Wire: Use the wire stripper to remove a small part of

the insulation from one end of the wire. The wires will be
attached to terminals, so you need to make sure that the length
of the cut is according to the terminal size.

Cut the Heat Shrink: Cut the heat shrink tubing of a length a
little longer than that of the stripped wire. Insert the heat shrink
over an unstripped area of the wire.

Attach a Terminal: Take a terminal, place its seam into the

crimp pliers, and crimp the terminal slightly. Insert the terminal
into the wire, then use the pliers to squeeze the wire and
terminal together. Use enough force such that the two parts will
be crimped, but not so much that the wire gets damaged.

Cover the Wire: Once the above step has been completed, pull
the heat shrink over the crimped wire edge and terminal seam.
Ensure that the tubing closes tightly over the two parts.

Shrink the Tubing: This is where the heat gun needs to be

used. Turn on the gun, set it to the required temperature, and
allow it to warm up. Direct the gun’s hot air over the heat shrink
tubing. The tubing will reduce to the appropriate size, thus
protecting the parts
Then SEMI AUTOMATIC CRIMPING machines is used to crimp
the lugs to the wires which have already been inserted with the
ferrule, this whole process is known as CRIMPING
SEMI AUTOMATIC CRIMPING MACHINE generates around 20
KILO NEWTON STANDARD crimping force and it has a fixed 40
MM stroke

ASSEMBLY LINE

Manual assembly is still the most common method for wire

harness manufacturing because routing cables or wires through
sleeves is an extremely delicate process.

Manual operations for wire harness assembly include:

• Applying fabric tape in varying locations and amounts

• Crimping terminals onto wires, which sometimes requires

multiple crimping operations

• Inserting one sleeve into another

• Fastening strands of clamps, cable ties, or tape

THERE ARE TWO ASSEMBLY POINTS

1) SUB ASSEMBLY

2) FINAL ASSEMBLY

SUB ASSEMBLY

In sub assembly, coupler and terminals are fitted in wire.

Fiseable link are connected as it is the main part of sub
assembly.

Before moving wire to final assembly another check is made to

make sure if the wires and component are OK.
Then it is moved to “Final assembly”

FINAL ASSEMBLY

Different wires, connectors are laid out on the final board, then
quad and PCV tubes are put on the table and the harness takes
a shape and on the remaining area taping is done.

In final assembly a stamp table is put on the harness (where

stamps are put after passing every process)

Then clamps are attached (it helps in putting harness in car)

Clamps on wire harness

After clamps are put then whole circuit is checked (this is

continuity testing process)

Continuity testing from SHINE detects the presence of a

complete path for current flow. From simple two-wire cables to
custom cable assemblies and complex wires harnesses, SHINE
uses electrical testers made by Cirris Systems to ensure
reliability and performance.

After this process “Part Attachment”

In this soft tape, opener fixing, protector and tapes are added to
harness.
FINAL INSPECTION

Once production is complete, each individual wire harness must

undergo electrical safety testing for any specifications it may be
subject to in real-world operation. This step is crucial in ensuring
the final product performs 100% reliably.

In final inspection, a visual test is done in this process a board

with master harness is there and the harness which came from
assembly is compared with master harness

Then If the harness is found “OK” in the visual inspection then it

is moved to finish good section

Now, if there is any defect generated between sub assembly and

final inspection. then the harness is moved to the rework area,
then again, all processes are done on the wiring harness until
the entire process is completed.
INDUSTRIAL TRAINING REPORT BY SPARSH SHARMA

2K17MEUN01034