EXERCISE-2

Industry visit report: roots industries India limited, Coimbatore.

INTRODUCTION:
➢ As part of our academic curriculum, I had the opportunity to visit Roots Industries
India Limited, located in Coimbatore, Tamil Nadu. This visit was both insightful and
inspiring, offering a deep understanding of how a large-scale industrial organization
operates with discipline, precision, and innovation. The company is best known for
manufacturing automobile horns but has diversified into precision engineering,
electric vehicles, and ergonomic furniture.

➢ Roots Industries, founded in 1970, is the flagship company of the Roots Group and is
best known for manufacturing automobile horns. However, during the visit, I realized
that the company is not limited to just horns it has diversified into precision
engineering, electronics manufacturing, ergonomic furniture, electric mobility,
and high-end calibration services. The moment we entered the factory premises, we
were welcomed by well-organized infrastructure, systematic workflows, and a strong
sense of discipline that was visible in every section of the plant.

➢ This report is based on the direct observations and explanations provided by the
company’s floor engineers and supervisors. It reflects how the company successfully
integrates industry best practices like 5S, Poka-Yoke, Kanban, and Lean
Manufacturing into their day-to-day operations to maintain efficiency and quality.
The experience also gave me a first-hand view of how global standards are achieved
right here in India, and how professionalism, innovation, and employee coordination
play key roles in the success of a manufacturing unit.

COMPANY OVERVIEW:
➢ Roots Industries was established in 1970 and has now become one of the
largest manufacturers of vehicle horns in India. They also produce high-
precision machined components, electronics, and calibration services. The
factory is fully equipped with modern machinery and follows world-class
standards for quality, safety, and productivity.

➢ During our visit to Roots Industries India Limited, we were introduced to

the rich history and wide operational scope of one of India’s most respected
industrial manufacturers. Founded in 1970 by Mr. K. Ramasamy, Roots

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 Industries started its journey in Coimbatore with a focused vision — to
manufacture world-class vehicle horns that could compete globally. Over the
years, the company has expanded far beyond its initial product line and has
grown into a multi-domain engineering company with international
recognition.

➢ Today, Roots Industries is the flagship company of the Roots Group, which
includes several other business verticals such as Roots Multi clean (cleaning
machines), Roots Syona (ergonomic furniture), Roots Calibration Services,
and Roots Electronics. With its headquarters and major production facilities
located in Coimbatore, Tamil Nadu, the company employs thousands of
professionals across departments such as manufacturing, research and
development, quality assurance, and supply chain management.

➢ What stood out to me during the visit was the diversity of products and high
standards of quality control maintained in each unit. Though the company is
globally known for manufacturing automobile horns used in two-wheelers,
three-wheelers, passenger cars, and commercial vehicles,

It also manufactures:
1. Precision machined components used in automotive and aerospace sectors,
2. Electronic components and printed circuit boards (PCBs),
3. Reverse alarms and safety devices,
4. Electric buggies and carts, and
5. Medical equipment accessories and assemblies.

WORKFLOW PROCESS OBSERVED:

1. Raw Material Handling:

The process begins with the careful procurement and inspection of raw materials. They have
a dedicated inspection team that checks the quality of incoming components using standard
gauges and instruments.

2. Component Manufacturing:

Different parts of the horn (like diaphragms, casings, and coils) are manufactured in-house. I
observed various machines like:

• Press machines for shaping metal components.

• Winding machines for coil production.

• Plastic injection moulding machines for casing.

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3. Assembly Line:

The horn assembly is done in a sequential process involving:

• Mounting of coils

• Fixing diaphragms
• Adjusting the tone

• Screwing and sealing

The company has 17 dedicated horn assembly lines. Each line follows a well-defined
Standard Operating Procedure (SOP).

4. Testing & Quality Control:

Each finished horn goes through an automatic sound frequency tester. If the tone does not
meet standards, it is sent for rework or rejection. The Quality Control (QC) department is
equipped with vibration, endurance, and temperature testing machines.

INDUSTRIAL PRACTICES OBSERVED:

5S Implementation

Roots Industries follows the 5S methodology across all departments. Here's how I noticed it
in practice:

• Seiri (Sort): Each workstation had only the tools needed, and unnecessary items were
removed.

• Seiton (Set in Order): Tools and materials were labelled and placed in fixed
locations for easy access.

• Seiso (Shine): The shop floor was spotless; cleaning was done at regular intervals.

• Seiketsu (Standardize): Colour coding and standard signage were visible

everywhere.

• Shitsuke (Sustain): Employees were actively maintaining these practices without

supervision.

Poka-Yoke (Error Proofing)

The company uses Poka-Yoke techniques to avoid human errors in production. Some
examples I observed:

• Fixtures that allow parts to be assembled in only one orientation.

• Sensors that stop the line if a part is missing.

• Visual indicators that show if a step has been skipped.

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This drastically reduces rework and ensures product reliability.

Kanban System

They follow the Kanban system for inventory control and workflow management. Each part
bin had Kanban cards, which signal the need to replenish components. This pull-based
system avoids overproduction and maintains lean inventory levels.

I was able to see how Kanban boards were used to track work progress, material movement,
and timelines across departments.

Lean Manufacturing

Roots Industries has successfully implemented Lean Manufacturing principles. Their aim is
to eliminate waste in every form – whether it’s time, motion, or material. For instance:
• They use Value Stream Mapping (VSM) to identify non-value-added steps.

• They follow Just-In-Time (JIT) production to reduce inventory holding costs.

• Workers are trained to multitask and take ownership of quality, which minimizes idle
time.

EMPLOYEE TRAINING AND SAFETY:

One of the key aspects that stood out during my visit to Roots Industries India Limited was
their strong emphasis on employee training and workplace safety. It was evident that the
company not only focuses on producing high-quality products but also gives equal
importance to the growth, safety, and skill development of its employees. This balance
between performance and people was inspiring to witness.

1. Structured Employee Training Programs

Roots Industries has a well-established training and development department that handles
everything from induction programs for new recruits to upskilling sessions for experienced
staff. We were told that every new employee, whether a fresher or experienced, must undergo
a detailed orientation program before they are assigned to the shop floor.

They have a dedicated training centre within the campus, equipped with demo models, charts,
safety gear, and training kits. During our tour, we got to see a classroom-like setting where
operators were being trained on:

• Operating CNC and winding machines

• Reading technical drawings

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 • Following standard operating procedures (SOPs)

• Quality control checkpoints

Employees are also trained in Lean Manufacturing principles, 5S methodology, and Kaizen
activities. These aren't just theoretical — the practices are visibly followed on the floor.
Regular on-the-job training and skill assessments ensure that employees stay updated with the
latest practices and technologies.

There are also cross-functional training sessions where employees from different departments
are encouraged to learn tasks outside their usual responsibilities. This builds flexibility and
helps reduce production delays when one department is short-staffed.
2. Safety Practices and Culture

Workplace safety is not treated as an afterthought at Roots — it's deeply integrated into the
company culture. Right from the entrance, we noticed:
• Mandatory PPE (Personal Protective Equipment) like helmets, safety shoes, gloves,
and earplugs.
• Clear safety signage in all work zones.

• Fire extinguishers, emergency exits, and first aid kits placed at regular intervals.

The company follows ISO 45001 – Occupational Health & Safety Standard, which ensures
that all safety norms are strictly implemented and monitored.

We observed several safety practices on the floor such as:

• Sensor-based machines that automatically shut down in case of abnormalities.

• Two-hand control systems on press machines to avoid accidental hand injuries.

• Anti-slip mats and proper lighting in workstations.

There were also posters and visual boards displaying recent safety metrics such as “X days
without accident,” which encourages a safety-first mindset.

Regular safety audits, mock drills, and first-aid training are conducted to keep employees
prepared for any emergencies. Supervisors and safety officers perform daily walkthroughs to
identify risks and resolve them immediately.

Roots also conducts monthly safety talks and workshops, where workers are made aware of
fire safety, electrical hazards, chemical handling, and ergonomic practices. These programs
are sometimes led by external experts or certified trainers.

3. Health and Well-Being Initiatives

Apart from operational safety, Roots Industries also invests in the overall well-being of
employees. They have:
• A clean and hygienic canteen with subsidized meals.

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 • A medical centre with basic facilities and a visiting doctor.

• Tie-ups with nearby hospitals for emergency care.

• Health check-up camps and wellness sessions held periodically.

During our interaction with HR staff, we learned that employees are also encouraged to
participate in fitness, yoga, and sports activities, which are sometimes organized during
weekends or special occasions.

My Reflection:
What impressed me most was that safety and training are not just rules but part of the
everyday routine at Roots. From the way employees followed safety norms without being
told, to the clean and organized environment, everything showed that the company has
instilled a culture of discipline and care. As a student, this gave me a real-world
understanding of how critical human resource development and safety management are in
any successful industry.

CONCLUSION:
➢ The visit to roots industries not only taught how to work and implement techniques,
but it also taught me how to be discipline in a industry. The experience of roots
industries is 4 hours, but I gained knowledge for my lifetime.

➢ Visiting Roots Industries gave me a clear picture of what a professionally managed

manufacturing unit looks like. From raw materials to finished goods, every step was
handled with precision. The use of industrial engineering concepts and modern
management techniques like 5S, Kanban, and Poka-Yoke proves why Roots is a
trusted brand worldwide. This experience has deepened my interest in manufacturing
systems and industrial management.

DESCRIPTION MAX MARKS MARKS OBTAINED

PRESENTATION 3

NOVELTY 2

CONTENT 3
ARRANGEMENT
VIVA VOCE 2

TOTAL 10

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 EXERCISE-3
Energy efficiency and management report - Roots industries
India limited, Coimbatore.

Introduction:
➢ Energy efficiency is a critical aspect of modern manufacturing, playing a vital role in
reducing operational costs, enhancing sustainability, and minimizing environmental
impact. During my visit to Roots Industries India Limited, I observed how the
company has adopted various strategies and technologies to improve energy
efficiency across its manufacturing processes.

➢ During our industrial visit to Roots Industries India Limited, I was able to witness
how a successful manufacturing company can combine engineering excellence with
environmental consciousness. Roots Industries, headquartered in Coimbatore, is not
just known for its high-quality automobile horns and precision products, but also for its
thoughtful implementation of energy management practices that align with global
sustainability standards. What made this visit particularly meaningful was the
opportunity to see how energy efficiency is achieved not only through machines and
technology but also through employee awareness, lean systems, and real-time
monitoring. It was clear that energy management at Roots is not treated as a one-time
project but as an ongoing, continuously improving process that is embedded into the
company’s core operations. this report presents my detailed observations and
understanding of the various energy-saving measures employed by Roots Industries,
the infrastructure supporting these efforts, and the cultural practices that sustain them.
It also reflects on how industries can improve their environmental impact while
remaining economically strong and globally competitive.

Current Energy Management Practices:

Energy Conservation Awareness and Culture:

One of the first things that struck me during the visit was the company’s focus on energy
conservation as a shared responsibility. Roots Industries has cultivated an energy-conscious
culture by educating employees about the importance of saving energy. Throughout the factory,
posters and visual reminders encourage staff to switch off equipment and lighting when not in
use, avoid unnecessary energy consumption, and adopt sustainable habits in their daily work
routines.

This awareness program is supported by routine training sessions where employees learn
simple but effective energy-saving practices, helping to embed energy efficiency into the

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