Interim Report

Minda Industries

Shivam Sanjay Wankhede

2012ME10723

About N.K. Minda Group

Making its mark in the International Grid of Automobile Components Manufacturing, UNO

MINDA steers ahead as a leading Tier 1 supplier of Proprietary Automotive Solutions to Original

Equipment Manufacturers (OEMs). Spanning three continents and sustaining enterprising business

practices, the technology leader, NK MINDA Group has truly arrived. Incepted way back in 1958

with a meager start-up capital and now notching up a group turnover beyond US$ 525 million,

speaks volumes of the conglomerate that it is today.

For nearly five decades, UNO MINDA has made significant contributions to the automotive

industry supply chain with innovative products, designed and engineered for efficiency with an

emphasis on enhanced comfort levels and fine-tuned response.

A predominantly technical organization, UNO MINDA is poised for exponential growth. All

structured through advanced development tools and support systems. The stringent tests, system

driven processes and development capabilities, driven by the principles of Quality Circles, Kaizen

and 5S certifications catalyze the design and development verticals.

Reckoned a leading associate of Auto Majors around the globe, the NK MINDA Group, elicits

confidence and professional accountability from its business associates and technology partners.

The all-encompassing mantra of reliable, safe, pioneering, efficient, and environmentally

sustainable product line ensures UNO MINDA an edge in the Auto Hub manufacturing dynamics.

UNO MINDA has 37 manufacturing plants in India, Indonesia,Vietnam & Spain, design centers

in Taiwan and Japan, sales offices in USA, Europe and Vietnam. It also has a strategic sourcing

office in China.

With the human edge of a highly motivated workforce of 8500 team members the Group is

headquartered in Manesar, Haryana, India. We have engineering, research and development

centers in Manesar, Pune & Sonepat.

The UNO MINDA strategic alignment ensures the maintenance of leadership in providing the

ideal product support for their customers. Drawing on the benefits of this long-term customer

support relation, UNO MINDA forges ahead.

As a Tier-1 supplier, they manufacture 2 Wheeler Switches and Handle Bar Assemblies,

Electronics & Sensors, 4 Wheeler Switches and Heater Control Panels, Cigar Lighters,

Automotive Lamps, Automotive Horns, Alternate Fuel Systems and CNG-LPG Kits,

Automotive Batteries, Blow Molding Components, Seat Belts, Alloy Wheels, Wheel Covers, Air

Filtration Systems, Die Casting Components, SRC, Cylinders, Steering Wheels, Airbags, Fuel

Caps, Body Sealing, Car Infotainment Systems, Air Brakes, Clutch Actuation Systems and

Automatic Gear Shifters for OEMs Technology and innovation are two key pillars of MINDA

philosophy. Our underlying vision is to create a culture that fosters great ideas that can be the

basis for planning ingenious products, successfully manufactured to deliver value to our

customers.

Minda Acoustics Division-

Established in 2004, Minda Industries Limited - Acoustics Division is the leading manufacturer

of automotive horns in India. With a 47% marketshare, the company is the most preferred

supplier of horns to Indian OEMs.

The division was established with a view to leverage capabilities and technologies of Minda

Industries Ltd. It is aiming aggressively at the export market, with plans of exports contributing

upto 30% of its turnover by 2014-15.

The division recently acquired Clarton Horn S.A.U., Spain from PMAn Domestic AG. The

buyout of Clarton Horn, which manufactures trumpet, disc and electronic horns and supplies to

leading OEMs in Europe including BMW, Volkswagen, Mercedes-Benz, PSA-Peugeot and

Renault, catapults the UNO MINDA Group to the No 2 position among horn manufacturers

worldwide.

This acquisition gives them access to European OEMs and technology while the Group is driving

for growth in the US, China and Mexico. This acquisition will help draw out a global strategy

towards offering a more comprehensive range of products to customers with both the La

Carolina plant in Spain and Manesar plant being complementary in nature.

The acoustics division continually creates new capacities and scales up operations to meet the

market needs. With plants in Manesar and Pantnagar and 600 plus employees, it is a supplier to

all OEMs in 2 Wheelers, 4 Wheelers, Off-road and Commercial Vehicles segment like Bajaj

Auto Ltd., Honda Motorcycle and Scooter India, Royal Enfield Motorcycles, India Yamaha

Motor, Suzuki Motorcycle India, TVS Motor Company, Maruti Suzuki India, Renault India, Tata

Motors, General Motors, Mahindra & Mahindra, Ashok Leyland, Ford India, Hyundai Motors,

Fiat India Automobiles, Swaraj, Escorts Group, Sonalika Group etc.

Exports to Mazda, BMW, Renault, Ford, Piaggio, Torica, GM - Global, Hino Motors, Piaggio

and Kawasaki make up 29% of its sales revenue.

Minda Industries Limited Acoustic division designs and produces Automobile Horns for

optimum sound performance & high durability. The acoustic products are available in different

Bracket Designs and different Color Combinations for good aesthetic looks. The division also

develops in-house Customer Specific Bracket Designs.

The division offers unique features in its Horns, like;

Lesser Weight

Smaller Size

Robust Water Proof Design

ELV Complaint.

The types of horns produced by the company are-

Electro-Mechanical horns

Electronic Horns

Trumpet Horns

In the first week we spent at Minda Industries, we learned about the company and the different

areas in the company.

There are two assembly divisions there -

EOU (Export Oriented Unit) This division mainly manufactures for foreign companies like

Ford. The assembly line here is almost fully automated and very high product standards are

maintained here.

DTA (Domestic Tariff Area) This division focuses on domestic clients. The assembly line here

is semi-automated. Lower standards compared to EOU are maintained here as this costs lesser

investment.

We visited both EOU and DTA assembly lines and studied the process starting from intake of

raw material to dispatch of finished product. First the raw from suppliers in loaded, then it is

inspected for defects. The raw material is then stored in store. From the store it goes to the

assembly line. On the assembly line products defectively manufactured products are rejected at

every stage. After manufacturing is completed, it is tested and tuned. Then the product is packed

and shipped to the customer.

In the lab processes like benchmarking and testing are done for development of new products.

The test performed included environment test, heat shock test, salt spray test, endurance test.

They also have an anechoic chamber built for accurate measuring of sound pressure level.

Benchmarking techniques like Process, Product and Performance Benchmarking are performed

by them for development of new products. Before launching a new product in market many

different tests are performed like Environment test in which the product is tested in harsh

environments, Endurance test in which the horns are tested automatically for a large number of

cycles and Thermal Shock test, Salt Water test, Shower test, Dip test.

We interacted with people working in engineering department which consist of about 45 people

understanding the work division, and how each team carry out their tasks. They are allotted

different companies like Ford, Maruti etc. They have some predefined routine activities which

everyone has to carry out apart from their project work ranging from file maintain to review of

their previous day work. The project tasks include C.A.D. modelling, material composition

planning, production line planning and other tasks which also include client service.

We also studied the different types of horns they manufacture which are categorized into

electromechanical and electronic horns. In electromechanical horns, there is a solenoid which

attracts a metal nucleus attached to the diaphragm. After reaching a certain distance, the nucleus

pushes a contact breaker which breaks the solenoid circuit. This results in a vibrating motion of

the diaphragm. In electronic horns a PCB breaks the circuit. Electronic horns are costly, but they

have a larger life. We studied electromechanical horns which are categorized on the basis of

diameter of diaphragms. We met Mr. Rohit who told us about various techniques used in

industries for management and quality assurance like Poka Yoke, APQP, QMS (quality

management system), FMEA (Failure Modes Effect and Analysis) .

Project

Sunil Bhat sir gave us a task to study various departments of horn divided on the basis of

manufacturing and functioning which are Mechanical, Acoustics, Electrical and Magnetic. I

performed literature review related to the mechanical field. The mechanical part of the horn was

very vast and consisted of the material selection, stress analysis, vibrational analysis of all the

components of the horn. All the components of the horn which could have been analyzed were

diaphragm, resonator, contact breaker, housing, moving nucleus, fixed nucleus etc. Mr. Sunil

Bhat now told us to make a mathematical model of the horn. This mathematical model could be

used to determine the behavior of the horn before manufacturing and testing any new prototype.

After talking to Mr. Sunil Bhat, he told me to select one component and analyze it in detail. As

the diaphragm of the horn is one of the crucial components functionality-wise and also it is one

of the components which fails frequently in the horn. I decided to work on the diaphragm of the

horn.

Diaphragm is a plate like component which acts like a stiff spring and causes the oscillatory

motion of the moving nucleus. In the mathematical model, I would have to make the vibration

model of diaphragm which could be then used to for acoustics analysis. Also, I would need

magnetic force acting on the moving nucleus for the forced response. Also, fatigue analysis of

the diaphragm can be done to determine the number of cycles it can withstand before failure.

For the modelling of diaphragm, I started by reading about plate theory as the diaphragm can be

considered as a thin plate whose thickness is very small compared to its radius. In plate theory,

this feature of plates is used as an advantage by converting the three dimensional equation to two

dimensions. There are two widely used plate theories

Kirchoff Love Plate Theory

Mindlin Reissner Plate Theory

I concentrated on the Kirchoff Love plate theory as the Mindlin Reissner theory takes into

account the transverse shear deformation which becomes effective only thick plates.

I needed a tool to solve the differential equation. My colleagues told me that I can solve an ODE

in Matlab. So I started learning matlab. After learning it sufficiently, I started trying to solve the

fourth order ODE. It took me a lot of time to do it as Matlab was giving errors and I was new to

use it. After solving the ODE, I found the stiffness of the diaphragm of dia. 95 horn. I took the

required data which was the material properties and dimensions from Kuldeep Sir. I chose dia.

95 horn as, they had tested the stiffness of the horn and had the experimental results.

The stiffness as calculated by my Matlab code was coming out to be 320 N/mm. Whereas the

experimental stiffness was 250N/mm. This error is 28 percent which is very large and can be

attributed to improper material data.

Then, I made a Simulink model to combine Electrical, Mechanical and Magnetic Models. The

electrical model consisted L-R circuit in which the inductance and the applied voltage varied

with the displacement of the moving nucleus. The magnetic model found the magnetic force

which depended on the displacement of the moving nucleus. The current vs time plot from the

model was very close to the experimental results.

Figure 1-Simulink Model

Figure 2 Current Vs Time plot from Simulink Model

Mechanical Engineering Department, IIT Delhi Practical Training

Summer 2015 FORM A. Personal Information

1. Student particulars

Name SHIVAM S. WANKHEDE Entry no. 2012ME10723

Address C 16 , NILGIRI HOSTEL, I.I.T DELHI, HAUZ KHAS, NEW DELHI, 110016

Program B-Tech. four year

Course Mechanical Engineering

Tel (H)

Tel (M) 9873992465

E-mail shivamwankhede123@gmail.com Tel (other)

Blog PIN 110016

2. About the organization

Name UNO MINDA INDUSTRIES

CEO name N.K. MINDA

Address Minda Industries ltd. (Acoustic Division) Tel

Village Nahapur Kasan, P.O. Nakhrola Tel (M)

Gurgaon, Haryana-122004, India Tel (other)

FAX

Blog PIN 122004

3. Training program (week wise)

Start date Weekly off Working timings 5-day working

Week no. From To Training assignment particulars

1 12/5 18/5 Observational Training (Brief introduction to company) 2 19/5 25/5 Observational Training (Learning about products)

3 26/5 1/6 Project (Literature Review) 4 6/6 12/6 Project

5 13/6 19/6 Project 6

7

8 9

10

4. Executive whom you report to

Name Sunil Bhat Tel (W) 91-124-2291621

Designation General Manager (Engineering and R&D) Tel (M) +91 9818427220

Address Minda Industries ltd. (Acoustic Division) Tel (other)

Village Nahapur Kasan, P.O. Nakhrola FAX

Gurgaon, Haryana-122004, India Tel (other)

E-mail sunilbhatt@mindagroup.com PIN 122004