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COMPANY PROFILE

Roots Industries India Ltd. is a leading manufacturer of HORNS in India

and the 11th largest Horn Manufacturing Company in the world. Headquartered

in Coimbatore - India, ROOTS has been a dominant player in the manufacture of

Horns and other products like Castings and Industrial Cleaning Machines. Since

its establishment in 1970, ROOTS has had a vision and commitment to produce

and deliver quality products adhering to International Standards.

With a strong innovative base and commitment to Quality, Roots Industries

India Limited has occupied a key position in both international and domestic

market as suppliers to leading OEMs and after market. Similar to products, Roots

has leading edge over competitors on strong quality system base. Now, RIL is the

first Indian Company and first horn manufacturing company in the world to get

ISO/TS 16949 certification based on effective implementation of QS 9000 and

VDA 6.1 system requirement earlier. RIL has entered into technical collaboration

with Robert Bosch, SA to further enhance the technical competence. Roots' vision

is to become a world-class company manufacturing world-class product, excelling

in human relation.

Roots Industries India Ltd as ISO9001:2000 firm and the parent company

manufacture electric horns currently holding 60% of the Indian Market Share.

They are suppliers to leading automobile manufacturers such as Hindustan

Motors, Premier Automobiles, Telco, Bajaj, Mahindra and Mahindra, Maruthi

Suzuki, Unofiat, Hyundai, Hero Honda, LML Vespa etc., are also the exclusive

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Roots Polycraft RK Nature Care Hospital Satchidananda Jothi Nikethan Matric Higher Secondary School Roots Metrology Laboratory Roots industries Malaysia Sdn. Bhd

Roots Multiclean Limited

Roots Multiclean Ltd based in Coimbatore, a Southern city in India known

for its textile and light engineering products, is joint venture Roots Industries

Limited with Hako Werke GMBH & Co. Germany is one of the largest

manufacturers of cleaning equipment under license from Hako since 1994, within

the short span of 10 year it has become Indias largest manufacturers of floor

cleaning equipment, manufacturing manually operated and powered suction,

Sweepers, Scrubber Driers and the state of the art Mopping System.

The group comprises of server important manufacturing units with

the state of the art CAD/CAM/EDP/quality assurance centers with advanced

equipments.

Roots Precision Products

Roots Precision Products was established in 1987 to address the in-house

tooling needs of the diverse industries in Roots group. Owing to continuous

improvement and investment into better resources, the company has become

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self-sufficient. It is catering to the needs of various industries. RPP acts as a one-

stop solution for tooling and precision machining. Specialized in design and

manufacture of:

Press tools Injection moulds Die-casting dies Jigs and fixtures

Roots Polycraft Limited

Roots Polycraft (PC) was established in 1988 to manufacture precision

plastic components. It is equipped with latest microprocessor injection moulding

machines to maintain consistent process parameters. Over the years, Polycraft has

gained skills and unique techniques to manufacture small and medium size

components for Automotive, Pump, Textile, and Medical Industries besides

meeting the captive requirements of Roots Group. Being fully equipped to

provide the best service, Polycraft has satisfied customers who have helped

augment its technological advances. The Company's commitment towards the

customer is demonstrated with quality products and service. This has resulted in

continuous growth and product diversification. The process is closely monitored

with proven techniques to obtain consistently good quality parts.

Roots Cast Private Limited

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Roots Cast Pvt. Ltd., (RCPL) (formerly known as Aruna Auto Castings Private

Limited) was established in 1984 to meet the captive requirements of the Roots

group. With its ever probing eye on the needs of the market, the company in the

late 80s expanded its operations to manufacture High Pressure Die Cast

Aluminium and Zinc components to the exacting needs of various customers in

Automobile and Textile Industries with a high degree of Quality and Perfection.

RCPL now has established itself as a major player in the die cast component

manufacturing thanks to the expertise built in the core activities like tool design,

tool making and pressure die cast component manufacturing. RCPL supplies

machined castings and sub-assemblies as per customer requisitions.

RSV Governor hsg Injection Pump

Heat- Sink For Alternator

Pump Body and Pump body Cover Ring Holder for Ring Frame

Mission

The mission of Roots has always been to locate and to mould exceptional

leaders and private with all the sincere effort that solid basics to extend

organization solutions to customers worldwide and there by enhance the Roots

competitive advantage. The company does so thought long team and deeply

committed human relations based on the key values like Activity focus, Discipline,

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Experience, Innovation, Integrity, Introspection, Professionalism, Quality Culture

and Team Work.

Vision

We will stand technologically ahead of others to deliver world-class

innovative products useful to our customers. We will rather lose our business

than our customer satisfactions. It is our aim that the customer should get the

best value for his money.

Every member of our company will have decent living standards. We care

deeply for our families, or our environment and our society. We promise to pay

back in full measure to the society by way of selfless and unstinted service.

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Organization Structure

Director Operations Vice President

Horn Divisions

Chief Marketing

Officer

NDP & Trade

Goods Division

High Precision

Engineering

Division

Electro Plating

MetrologyDivision

Executive Chairman/ ManagingDirector

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Product Mix

Roots Industries specializes in the manufacture of a wide range and line-up

of automobile horns. Roots is a leading supplier to all the major vehicle

manufacturers like Ford, Daimler Chrysler, Mitsubishi Lancer, Mahindra &

Mahindra, Toyota, Tata Motors, Fiat Uno and Siena, TELCO, TVS Motor Company,

Kinetic Honda, etc.

Roots Industries Limited places a premium on original technology and innovation.

Roots' indigenous talent has kicked off a spree of growth unmatched in the

history of automobile OE manufacturers. . Product: - Wind tone, Vibrosonic, Clear

tone, Bosch Range, Roots 90, Mega sonic, Smartone, Spider, FSA2, R 70, Sensors

Wind tone : W 90, Wind tone Super, Wind tone Trio, Wind tone Rainbow.

Vibrosonic : Vibromax, Vibrosonic Delux, Supersonic, Vibro Mini.

Clear tone : Clear tone Delux.

Bosch Range of horns : FC4, FD4 Delux.

Roots 90 : Roots 90.

Mega sonic : Mega sonic.

Smartone : Smartone

Spider : Spider (Available in 6 Colors).

FSA2 :FSA2.

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R 70 :R 70.

Parking Sensors : Parking Sensors.

Milestones

1970 Promotes American Auto Service for manufacture of Electric

Horns

1972 First to manufacture Servo Brakes for Light Motor Vehicles

1984 Roots Auto Products Private Limited was established to

manufacture Air Horns, Die Casting Unit commences commercial

operations

1988 Polycraft, a unit for Plastic Injection Moulding was established

1990 Roots Industries Private Limited takes over Electric Horn business

1992 RMCL enters into Techno-Financial collaboration with M/s. Hako

Werke Gmbh, Germany

1992 Roots Industries Private Limited obtains the National Certification-

ISI mark of quality

1994 Production of floor cleaning equipment commences. Roots

Industries Private Limited wins American International Quality

Award

1999 Becomes the first horn manufacturer in Asia to obtain QS 9000

2000 Becomes the first horn manufacturer in Asia to obtain VDA 6.1

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2005 Roots Industries Limited., is certified with MS 9000, a pre-requisite

for Q1 award for Ford Automotive Operations

2005 Roots Metrology & Testing Laboratory has been accredited by

National Accreditation Board for testing & calibration in the field

of mechanical- Linear & Angular

2005 Roots Industries Limited., is awarded Q1 by Ford Motor Company

2005 Roots Industries Limited., Horn Division upgraded its ISO:14001

from 1996 version to 2004 version

Production Process in Horn Division

Self Tapping Screwing

Spool Assembly Locking

Point Holder Assembling

Diaphragm Assembling & Tightening

Horn Pre Crimping & Final Crimping

Air gap Measuring & Adjusting

Terminal Connector Bending & Mounting

Bracket Assembling

Tuning Range Measuring & Sealant

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Mounting bracket Turning Screws Gasket

THE WORKING PRINCIPLE OF A HORN

The AC supply to the terminal base lead to the flow of current through the

coil via the contact points between the point plate and point plate holders which

in turn induces an electro motive force inside the coil.

The magnetic field thus created pulls in the armature rod connected to the

diaphragm until it breaks the contacts of the point plate and the point plate

holder that breaks the flow of current thereby demagnetizing the coil. This

pushes the armature rod to its original position that strikes the diaphragm

producing sound at certain desired frequency that is amplified by the tone disc.

CLASSIFICATIONS OF HORNS

Horns are of two major categories,

Air horns Electric horns (Manufactured in ROOTS) Screw type Crimp type Rivet type

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On the basis of the tone type it may be,

High tone: Sharp, focused and covers a long distance

Low tone: Wide, blunt, less focused and covers a shorter distanceHORNS MANUFACTURED BY ROOTS

Windtone Vibrosonic Cleartone Bosch Range Roots 90 Megasonic Smartone Spider FSA2 R 70

THE PRESS SHOP

The child parts for a typical type horn are manufactured inside the

press shop. The parts include.,

Blank Housing with SCR Diaphragm

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Tone disc Keeper rings & Grills Mounting brackets Point holder & point plates

Organizational structure of Press shop

HEAD

ASSOCIATE

SYSTEM & TOOLS

MANAGEMENT

ASSOCIATE HEAD

MANUFACTURING

ASSOCIATE

MANUFACTURING

SHIFT ENGINEERS

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RAW MATERIALS

The raw materials used in the preparation of the components are namely.,

CRCS (Cold Rolled Carbon Sheet)Used for Housing, Keeper Rings, Grills

Al-ZincHousing, Mounting Brackets, Tone disc & Diaphragm

Spring SteelMounting Brackets, Point Plate, Point Holder

MACHINES

Automatic Press

Used for Housing alone

Mechanical feeder Press

Used for Point plate, Point holder, Blank, Mounting Brackets

Power Press

Used for Housing, Tone disc, Screws

Hydraulic Press

Used for Diaphragm

Pneumatic Press

Used for Tone disc, Piercing Operation

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PROCESSES

HOUSING

Raw Material Hour Glass Cutting Output Housing

Re-strike

Piercing

Lettering

Trimming

HOUSING + SCR ASSEMBLY

Raw material Output (Housing + SCR)

(Housing)

Powder coating

TONE DISC

Raw Material Output

(Tone disc)

SCR RIVETING

PLANISHING

LANCING

TAPPING (SUB CONTRACTORS)

BLANKING

LETTERING

FORMING

PIERCING

POWDER COATING

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ELECTROPLATING DIVISION

Goods Inwards

Incoming Inspection

Storage

Loading

Soak Cleaning 1

Soak Cleaning 2

Anodic Cleaning

Water Cleaning (2 stages)

HCl Acid Pickling

Water Rinsing (2 stages)

Caustic Dip

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Zinc Plating (Alkaline)

Water Rinsing (3 stages)

Nitric Acid (Activation)

Nitric Acid (Rinse)

Yellow Passivation

Water Rinse (3 stages)

Oven Drying

Unloading

Final/Random Inspection

OK Not OK

Storage of finished goods Loading

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Barrier Audit

Despatch

POWDER COATING

Loading the component Chemical treatments

Removal of oil, soil, lubrication greases, metal oxides, welding

scales etc. is essential prior to the powder coating process.

It can be done by a variety of chemical and mechanical methods.

The selection of the method depends on the size and the material of the

part to be powder coated, the type of soil to be removed and the

performance requirement of the finished product.

Zinc phosphatingChemical pre-treatments involve the use of phosphates or chromates

in submersion or spray application.

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These often occur in multiple stages and consist of degreasing, etching,

de-smutting, various rinses and the final phosphating or chromating of the

substrate.

The pre-treatment process both cleans and improves bonding of the

powder to the metal. Recent additional processes have been developed that

avoid the use of chromates, as these can be toxic to the environment.

Titanium zirconium and silanes offer similar performance against

corrosion and adhesion of the powder.

Different powder coating applications can require alternative methods of

preparation such as abrasive blasting prior to coating. The online consumer

market typically offers media blasting services coupled with their coating services

at additional costs.

Powder Coating

The most common way of applying the powder coating to metal objects

is to spray the powder using an electrostatic gun, or corona gun.

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The gun imparts a positive electric charge on the powder, which is then

sprayed towards the grounded object by mechanical or compressed air spraying

and then accelerated toward the workpiece by the powerful electrostatic charge.

There is a wide variety of spray nozzles available for use in electrostatic

coating. The type of nozzle used will depend on the shape of the workpiece to

be painted and the consistency of the paint.

Oven Heating

The object is then heated, and the powder melts into a uniform film, and

is then cooled to form a hard coating.

It is also common to heat the metal first and then spray the powder

onto the hot substrate. Preheating can help to achieve a more uniform finish but

can also create other problems, such as runs caused by excess powder. See the

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article "Fusion Bonded Epoxy Coatings"

Cooling the Components

Unloading the Components

Storing the Components

COIL WINDING

The processes involved in Coil Winding section are

Point plate and point holder riveting Coil winding onto the spool

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Rooting and Cutting CleaningCoil Winding Machine

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Coil (back) part of a Horn

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ASSEMBLY

Spool Assembly locking, point holder &

Tuning screw Assembly

Terminal Base Assembly Tightening

Diaphragm Assembly Tightening

& Height Measuring

Gasket Selection &

Pre Horn Assembly

Horn side screw Tightening

Horn Pre Tuning &

Mounting Bracket Assembly

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Testing

Stickering & Despatch

CONCLUSION

Roots gave us that perfect chance to experience the Industrial atmosphere

which no book would have provided. We also became aware of our role as a

Mechanical Engineer in making this possible.

During our stint at Roots, we have learnt several things besides

engineering which include interaction and communication skills, analytical skills,

importance of safety in industry, time management and the most important fact

that no work is small.

Roots has provided its staffs & employees the perfect environment to

work. Many modern ideas like Lean Manufacturing has been employed which is

of great importance for improving the efficiency of the organization.

It was a pleasure to experience the industrial functioning of Roots for half

a day. Through this training we were able to gain new insights and more

comprehensive understanding about the real industry working condition and

practice. As a result of the program now we are more confident to enter the

industrial world and build our future career.