PRESENTATION FOR INDUSTRIAL TRAINING

SPARSH SHARMA
BTECH MECHANICAL ENGINEERING
2K17MEUN01034

PRESENTATION
 Motherson Group serves its customers with multiple products and services through nine business divisions. With the
support of the customers, these nine divisions continue to grow stronger and become more diverse.
Together, these business divisions help Motherson move closer towards its vision of being a globally preferred solutions
provider.

These are the nine business divisions of Motherson.

1. Wiring Harness
2. vision system
3. Modules & Polymer Products
4. Metal products
5. Technology & Software
6. Retail & Services
7. Aerospace
8. Logistics
9. Health & Medical
 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 are :

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

 Incoming
Material Store room Assembly Dispatch

Quality control
check Production Finish Goods
Planning
Control

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.

Materials are tested on the basis of ISO 9001:2015 which decides rather a lot is ok or not. If not then the whole Lot is
refused and returned.

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 IPQC - In-process Quality Control

OQA is the inspection of products before IPQC refers to quality control during the assembly
shipping. It's a crucial step in ensuring the process. It is crucial because you can detect and
shipment is defect-free. handle the problem that occurs ahead of time.
Incoming
Material Store room Assembly Dispatch

Quality control Production Finish Goods

check Planning
Control

PRODUCTION PLANNING CONTROL

The main purpose of production planning

and control (PPC) is to establish routes and
schedules for the work that will ensure the
optimum utilization of materials, workers, and
machines and to provide the means for
ensuring the operation of the plant in
accordance with these plans.
 PRODUCTION PLANNING CONTROL Stages of Production Planning & Control
The main objectives of PPC may be summarized as followings:- Production Planning & Control is done in three stages namely,
a) It is used to establish target and check the deviations by comparing on some
performance measures. 1.Pre-planning
2.Planning
b) Decides the nature and magnitude of different input factors to produce the
output. 3.Control

c) Coordinates different resources of production system in the most effective and

economic manner and to coordinate among different departments.
d) Elimination of bottleneck PRODUCTION PLANNING CONTROL
e) Utilization of inventory in the optimal way
f) Smooth flow of material
g) To produce in right quantity and quality at right time
h) Scheduling production activities to meet delivery schedule
i) Expediting the system under production
j) To ensure flexibility in production system to accommodate changes and
uncertainty
k) Optimizes the use of resources for minimum overall production cost
l) To ensure the production of right product at right time in right quantity with
specification rightly suited to customers
m) Stable production system, with least chaos, confusion and undue hurry.
Incoming
Material Store room Assembly Dispatch

Quality control Production Finish Goods

check Planning
Control

ASSEMBLY LINE WHERE WIRING HARNESS IS ASSEMBELLED

Wire harnesses are bundled processed wires

with a protective covering to guard against wear
and tear due to environmental conditions and
other potential damaging factors. They may have
a protective sheath around the wires that is
typically made of thermoset or thermoplastic
material, which provides additional protection
against damage to the individual wires. These
harnesses are important because they organize
wires for easy implementation into equipment
and systems.
How is a Wire Harnesses Manufactured?

The manufacturing process for wire harnesses can go from basic to

very complex. It starts with the design process and making sure that
the harness incorporates any necessary custom features for its
intended application.
The next step usually involves wire cutting, stripping, and
terminating. The wires are stripped and cut at the right length and
metal terminals are attached to the ends of the wires all using a
specialized machine commonly known as a crimp center. If needed,
the wires will then be inserted into a connector housing, allowing the
mating of male and female bundles of wires.

Manual assembly is still the most common method for wire harness
manufacturing because routing cables or wires through sleeves is an
extremely delicate process. The process in Assembly line consists of
1. Wire cutting
Manual operations for wire harness assembly include: 2. Ferrule Printing
•Applying fabric tape in varying locations and amounts 3. Ferrule insertion and sleeve insertion
•Crimping terminals onto wires, which sometimes requires multiple
4. Crimping
crimping operations
•Inserting one sleeve into another
5. Sleeve heating
•Fastening strands of clamps, cable ties, or tape 6. Testing
Wire Harness Assembly Process Wire harnesses are used in far too many applications to list here,
but here are some specific examples of notable use cases for wire
harnesses:
•Installing the wires and/or subassemblies on the assembly board.
•Routing wires and/or subassemblies through any required sleeves. Automotive / Flight simulators
•Applying wraps, ties, or tapes, particularly on any branch-outs. Flat panel displays / Heavy equipment
•Crimping terminals onto wires
Ruggedized computers
•especially if more than one wire goes into one terminal.

It is difficult to automate the processes used in the building of a wire

harness. Manual production remains more cost effective than
automation, especially with small batch sizes. Pre-production or kitting
WIRE HARNESS BEING ASSEMBELED
of a harness can be somewhat automated.

This would impact the following steps:

•Cutting and identifying individual wires (cutting/stripping machine).
•Crimping terminals onto one or both sides of the wire.
•Partial plugging of wires profited with terminals into connector housings.
•Soldering of wire ends (solder machine).
•Twisting wires

After the wire harness is assembled thenwire harness testing is done

Testing the electrical functionality of a wire or cable harness can be

done with the aid of a test board. The test board is pre-programmed with
the required electrical characteristics, and the completed harness can
be plugged into the test board and tested individually or in multiple
numbers.
THANK YOU FOR YOUR PATIENCE