Evaluation of how safety measures and modern

techniques in operations management enhance the

product excellence at RIL.

ADARSSH. M
JANSONS SCHOOL OF BUSINESS
 1. INTRODUCTION

Roots Industries India Limited (RIL) established in 1970 is the flagship

company of the Roots Group and its products find pride of place in some
of the world’s most respected automobile brands. RIL has a full-fledged
manufacturing facility in India, Malaysia, Russia and has offices in
strategic locations across the world.
The company manufactures a wide range of Electric Horns, backup alarm
and electronic horns with multi-functional capabilities for passenger
vehicles, off-road vehicles and material handling equipment.
It has subsequently added to its product offerings with halogen bulbs, disc
brake pads, brake shoes, clutch plates, batteries and reverse sensors.
RIL established a High Precision Engineering Division (HPED) in 2005
to manufacture Highly Critical Parts, Sub-Assemblies and High Level
Assemblies for the Medical, Aerospace, Flow Control, Automobile &
Other Engineering Industries.
RIL established ROOTS METROLOGY and got accredited by NABL in
2005. It also addresses the Group’s calibration requirements and opened
up branches in Chennai and Bangalore. In addition to calibration other
services rendered by metrology division are Third Party inspection and
Training & Development.
RIL established a commercial furniture manufacturing division ROOTS
SYONA in 2013 to manufacture ergonomically designed furniture’s.
Syona currently has more than 5 models of commercial chairs and will
unveil other furniture products in a phased manner.
In the dynamic world that is driven by technology, a successful presence
depends on the way you mould that technology to fit popular needs,
Indigenous talent, a daring attitude, courage to accept and learn new
things and the simple spark of an idea. That is the genesis of ROOTS.
1.1 PRODUCTS

Roots 70

Roots Mini
Roots 75

Vibro Mini

Windtone 75
1.2 QUALITY
The quality journey starts from raw material inspection to pre
dispatch inspection of finished goods and confirms only quality products
reaches the customer hand.

The compliance to various Quality System Certification speaks about

company’s passion for Quality.

 First horn manufacturing company in India to get ISO 9001

certification

 First horn manufacturing company in Asia to get QS 9000

certification

 First horn manufacturing company in Asia to get VDA 6.1

certification

 First horn manufacturing company in the world to get ISO/TS 16949

 First horn manufacturing company in India to get ISO 14001

certification for EMS

1.2.1 Quality check

1. Setup approval (1 – 5 units)

2. Patrol check (once in 4 hrs.)
3. Last component inspection (final quality check)
 2. MACHINE SHOP

In press shop 27 child parts are produced for a horn.

2.1 Raw materials:

 Aluminum zinc gal steel
 Carbon steel
 Spring steel
 Stainless steel
 Cold rolled carbon steel

2.2 Types of Machines:

 Power press
 Hydraulic press
 Feeder press
 Lathe
 Feeder press (multiple operation’s)

2.3 Process involved:

 Blanking
 Draw
 Restrike
 Piercing
 Notching
 Trimming
 Forming
 Embossing
 Hanging

2.4 Inventory management technique

RUNNER

REPEATER

STRANGER
3. Production flow chart

START

Requirement and capacity

planning

Shop floor capacity analysis

(manpower machine tools)

Daily production plan

Production process

Inspection

Final stage & move to

barrier audit

Dispatch & delivery

 4. ASSEMBLY

Process No

1 TUNING SCREW, SPOOL ASSEMBLY & POINT SET ASSEMBLY

2 TERMINAL BASE ASSEMBLY RIVETING

3 DIAPHRAGM ASSEMBLY RIVETING AND HEIGHT MEASURING

4 PRE HORN ASSEMBLY, PRE AND FINAL CRIMPING

5 AIRGAP MEASURING & ADJUSTING

6 MOUNTING BRACKET ASSEMBLY

7 HORN TUNING AND TESTING

8 TUNING RANGE MEASURING, BATCHCODING & ADHESIVE APPLICATION

9 100 % QA INSPECTION

10 PACKING & PALLETING

11 PREDISPATCH INSPECTION

12 DOCUMENT VERIFICATION & DISPATCH

 5.MODERN TECHNIQUES IN OPERATIONS
MANAGEMENT AT RIL

5.1 Kaizen
3KAIZEN PRINCIPLES

1.GEMBA- “the actual place of work”

In production, the shop floor.
“value” is created at gemba, in manufacturing.
People working in the gemba know best how to improve
2.GEMBETSU: “the actual product”
Parts, tools machines and equipment provide scope for improvement.
3.GENJITSU: “the actual facts”
Reliable data collected by observation at gemba.

5.2 JISHUKEN
Voluntary self-study
 Analyze
 Improve
 Implement
5.3-5’S
5S ELEMENT TERMS ENGLISH OBJECTIVE
TERM OF THE
ELEMENT
1S SEIRI Sort To eliminate
unwanted items
2S SEITON Systematize To provide
place for needed
items
3S SEISO Shine To keep
everything
clean
4S SEIKETSU Standardize To practice all
the above
regularly
5S SHITSUKE Sustain To make 5s a
way of life

5.4 KIKENYOCHI
KikenYochi (hazard prediction) training, is a Japanese activity used to
motivate members to recognize and predict hazards. It develops
sensitivity to unsafe conditions or hazardous situations. Thus, improving
the ability to better recognize.
5.5 KANBAN
It is used to reduce idle time in production process. KANABN system is
deliver what the process needs exactly when it needs it.
5.6 TPM
5.7 Stop, call, wait, process, flow
This concept refers to an operator’s responsibility to “stop” a process
when something abnormal (defective) occurs, “call” for support and
“wait” for the support to arrive before proceeding.

5.8 JUST IN TIME:

Making only what is needed. Only when it is needed, and only in the
amount that is needed,

5.9 JIDOKA:
“Automation with a human touch”
 6. COIL WINDING
1. Riveting zone
2. Coil winding zone
3. Heat sealing

Roots – 70
Number of turns = 223
Megasonic
Number of turns = 88
Vibrasonic
Number of turns = 55

6.1 Quality problems in coil winding

 Improper heat sealing
 Enamel cleaning
 Coil wire cut
 Plate crack
 7. ELECTRONICS

7.1 Products
 Backup alarm (Fixed auto single tone, dual)
 Smart usb charger (single port. Dual port, aux)
 Dc-dc convertor (10 A, 5 A)
 Electro mini horn
 Alternator trigger switch
 Connector
 Piezo buzzer
 Resonating horn

7.2 ESD
Electrostatic discharge (ESD) is the sudden flow of electricity between
two electrically charged objects caused by contact, an electrical short,
or dielectric breakdown
ESD can cause harmful effects of importance in industry, including
explosions in gas, fuel vapor and coal dust, as well as failure of solid
state electronics components such as integrated circuits. These can suffer
permanent damage when subjected to high voltages. Electronics
manufacturers therefore establish electrostatic protective areas free of
static, using measures to prevent charging, such as avoiding highly
charging materials and measures to remove static such as grounding
human workers, providing antistatic devices, and controlling humidity.
 8. FURNITURE DIVISION

8.1 Syona
Syona is the commercial furniture manufacturing and marketing division
of RIL established in the year 2013, Syona is an embodiment of our
vision to create innovatively designed world class furniture product.

8.2 VARIANT
 Venus
 Pluto
 Executive chair

8.3FURNITURE ASSEMBLY
1. Glide seat / castor feet assembly.
2. Seat & stacker pad riverting.
3. Arm rest & handle assembly.
4. Back rest with arm rest.
5. Cap tightening.
 9. POWDER COATING
Powder coating is a dry finishing process that uses finely ground
particles of pigment and resin that are electrostatically charged and
sprayed onto electrically grounded parts.

9.1 Pre-treatment
 Derusting, water rinsing
 Component loading
 Degreasing
 Water rinsing- I
 Zinc phosphating (bonding)
 Water rinsing-II
 Passivation (to close pores)
 IR bulb cleaning
 Cleaning inspection

9.2 Process flow chart of powder coating

1. Primer coating
2. Powder coating
3. Ecore/scr cleaning
4. Oven curing
5. Component inspection
6. Unloading
 10. DATA ANALYSIS

OPERATIONS OF HORN ASSEMBLY IN A SHIFT

07 01

06 02

05 03

04

01-07- For each operation 2 operator per shift

01-Spool assembly
02-Terminal base assembly
03-Diaphragm Assembly
04-Gasket and pre horn assembly
05-Horn side screw tightening
06-Horn pre tuning and mounting bracket
07-Horn tuning and testing
 10.1 Calculation for Relevant Cycle times for
(A) Present average production
(B) Present maximum (Targeted) Production
(C)Possible production in Future

(A)Approximate Average Cycle time

= (420x60sec)/1575
=16Seconds
Average condition:
Cycle time -16Sec
Production-1575/shift

(B)Present Maximum (Targeted) production

= (420x60sec)/1710
= 14.74 Seconds
14.75Seconds is possible they have produced.
Maximum Condition:
Cycle Time=14.75Sec
Production=1710/Shift
(C) Possible Production in Future
420 x 60
=
14
= 1800 Pieces
(14seconds is recommended)

Recommended Condition:
Cycle Time=14Sec
Production=1800/Shift
11.FINDINGS:
1) Present production details,
Average present production per shift 1575 wind tone super
horns per shift.

2) Targeted production per shift is 1710.

3) Cycle time at present = 16 seconds / wind tone super horn.

4) Desired cycle time is 14.75 seconds / wind tone super horn.

5) It is possible to bring down the cycle time to 14 seconds / wind

tone super horn and get a production of 1800 wind tone super horn
per shift.

6) There is enough scope to reduce time of spool assembly,

diaphragm assembly, horn screw tightening and horn tuning.

7) There is possibility of coupling to assembly operation and save

time.

8) Bottle neck – wind tone stage 20.

9) In one assembly line nearly 1710 (wind tone) units are produced.
Electronic horns
Manpower = 11
Takt time = 46 sec
Shift demand = 500 no’s
R – 70
Manpower = 19
Takt time = 18 sec
1300 horns
W – 90
Manpower = 16
Takt time = 22 sec

12.RECOMMENDATIONS:

1) Filling locker, spool assembly, diaphragm assembly can be

automated. This will make them achieve the desired production at
the earliest.

2) There is possibility of coupling the spool assembly and diaphragm

assembly and we can save time. First few trial runs can be
executed and changes can be done to save time.
3) Respondent feels that there are possibilities to save in all seven
operations.
 4) They adopting TPM (Total Productive Maintenance) and 5S, it is
recommended that, by effective utilization of each techniques in a
systematic way, the cycle time per wind tone super horn can be
reduce to even less 14 seconds.

13. IMPROVEMENT POINTS

 Lead time high

 No cycle time balancing
 w/p between process
 no defect feedback system
 more space utilization
 FIFO not followed
 14. CONCLUSION

I had the great opportunity to work for ROOTS INDUSTRIES INDIA

LTD during my internship program. I got to observe that the industry
runs with great safety measures and highly automated machines. All
activity are system driven with poke yoke in every critical stage to
ensure flawless product to reach the customers. Roots relies strongly on
quality. They are market driven with world class technologies.