i have done 5 month B.Tech 8th sem practical training in company

1. PROJECT REPORT
ON
A
Dissertation
Submitted in the partial fulfillment of the requirements
For the Award of the Degree of
Bachelor of Technology
In
Mechanical Engineering
Submitted by
RAHUL
Roll No.413745
Under the Guidance of
Mr. Sanjay Kumar
(HOD)
Of
Department of Mechanical Engineering
MATA RAJ KAUR INSTITUTE OF ENGINEERING AND TECHNOLOGY
Saharan was, Rewari, HARYANA -123401
Maharishi Dayanand University, Rohtak (Haryana)
May 2017

2. ACKNOWLEDGEMENT
I, RAHUL a student of Mechanical 8th
sem., M.R.K.I.E.T REWARI. would
like to give my hearties thanks to all under whom I completed my
industrial Training. I would like to express my deep gratitude to Mr.
SANJAY KUMAR who gave me opportunity to do Training Minda
Furukawa Electric Pvt Ltd.
I would like to thanks my project guide Mr. SANJAY KUMAR who
showed me the way throughout.
The acknowledgement would be incomplete if contribution of whole
manufacturing division is not applauded as a whole. I sincerely thank all
of them for their cooperation and guidance during my tenure at HMSI.
RAHUL

3. Acknowledgement
I would like to thank Mr. Deepak Sharma Production Manager (Production Department
C&C and assembly) and Mr. Satpal Singh Process Engineering Manager (PE Department
Head) Minda Furukawa Electric Pvt Ltd, Bawal for giving me this opportunity to work for
my summer training project.
Minda Furukawa Electric pvt. Ltd has a team of engineers, supervisors and mechanics who
were always ready to extend a helping hand. It is along with them, maneuvered towards the
skill of using our theoretical knowledge for practical purpose. It is with the deepest sense
of gratitude that I wish to acknowledgement invaluable guidance of Er Mr. Hitesh Saini
(assembly facility), Er Mr Pawan (assy board, PE),Er Mr Manoj (ECT and CPG M/C for
assy), rendered to me during training time.
I am at loss of words to acknowledge the constant help and guidance rendered by them
during the project, without whose help it would have been difficult to complete the project.
I am also thankful to Mr Sanjay Kumar H.O.D. (mechanical) M.R.K.I.E.T.,Rewari for
giving me opportunity to go into industry and work on the project.
RAHUL
B.Tech. (Mechanical)
M.R.K.I.E.T.,saharanwas
Rewari,Haryana

4. COMPANY PROFILE
COMPANY NAME

5. CORPORATE PROFILE
`
COMPANY SLOGAN
We Challenge “Excellence” with “Team spirit”
COMPANY VISION
(Undertake techanical innovation using technology Furukawa as and skill manship,
employee from Minda to make the highly-efficient and profitable Company in india)
Quality first devoted to customer and grow holistically towards the future.

6. COMPANY PRODUCTION LOCATION IN INDIA

7. INDUSTRIAL TRAINING
&
PROJECT REPORT
AT
MINDA FURUKAWA ELECTRIC PVT. LTD.
BAWAL, REWARI(HARYANA)123401.
SUBMITED BY:
RAHUL
B. Tech.(Mechanical)
M.R.K.I.E.T Sharanwas

8. ABOUT MINDA FURUKAWA ELECTRIC
VISION, MISSION & VALUE
To be a Dynamic, Innovative and Profitable Global Automotive Organization for
emerging as the Preferred Supplier and Employer, to Create Value for all Stakeholders.'
 Philosophy of the Vision Statement- (VISION).
Dynamic:-
As a player the Group is sensitive to the rapidly changing business environment. The
actions of all Group Companies are and will be geared towards meeting stringent
benchmarks and norms that are required and will be required.
Innovative :-
As a group we have been at the forefront of innovation. We intend to increase our focus on
innovation in products and technologies, organizational structure, and optimizing
efficiencies. We also are committed to change management as a way of life to enable us to
meet the emerging challenges of the Industry.
Profitable:-
We want to emerge in the Global arena as a leading automotive player and realize
profitability in business so as to sustain and enhance our efforts towards emerging as a
leader in the industry.
Global
We are already Global and will continue to expand to meet the global requirements of
OEMs and be a significant player globally, in our own domain. In spreading globally we
will not focus on any specific country or region but take decisions based on our core
interests in the automotive sector.

9. Automotive :-
We will stick to being a significant player in the automotive domain and emerge as a
systems supplier. We will not deviate from our core sector but will expand to include
different components and systems that align and have synergy with our products and
technologies.
Emerge as Preferred Supplier and Employer:-
We will be focused towards meeting the two essential areas of endeavor - become a
preferred supplier to global OEMs and also emerge as the preferred employer in our
Industry. For this, we plan to undertake several initiatives such as closely monitoring
every aspect of our move to offer world-class products to our ever-increasing clientele. On
the employee front, we intend to continue with our people-sensitive initiatives so as to
realize a rich and vibrant work-culture and also, continue to nurture employees towards
greater efficiency, through training and development. As a Group, we consider that our
employees are equal owners and stakeholders and this Group belongs to them all. We will
continue to offer participation in the Growth of our Group, to all our employees.
Create Value for all Stakeholders :-
As an Organization we are sensitive towards all stakeholders including our esteemed
Clients, our Employees and their Families, our Suppliers, and the Society within which we
operate. Our core focus is on developing confidence, generating greater thrust towards
undertaking active role in building Customer Trust and Confidence, generating Greater
Returns and Trust for our Investors, undertaking Corporate Social Responsibility for
wider interests of the society and the needs of our Suppliers, as well as, addressing the
holistic Needs and Concerns of our Employees and their Families.

10. 2020 VISION:-
We aim to be a company of global presence by delivering relief and impressive solution to
our customer, making dreams come true.
Furukawa automotive system inc. is dedicated to delivering products that create a future
of aboundance by combining material expertise and technological innovation.
 MISSION:-
'Our mission is to be an automotive System Solution provider and Build a Brand
recognized by vehicle manufacturers progressively all over the world, as an organization
providing products and systems Unparalleled in Quality and Price.
Shareholders:-
We will ensure that our enterprise grows aggressively and earns adequate returns.
Customers:-
We will make customers for lifetime and always strive to exceedtheir expectations.
Partners:-
We will develop long term relationships with our partners based on mutual benefit, trust,
support & transparency.
Employees:-
We will treat our employees as family members and would provide them a safe, healthy,
stimulating and rewarding work environment.
Society:-
We will always be conscious of our responsibilities towards the society at large and
undertake welfare activities for the community.

11.  VALUES:-
Commitment to Stakeholders:-
Demonstrate loyalty and dedication to the organization.
PassionforExcellence:-
Relentlessly improving and continuously raising the bar in everything we do.
Open Communication:-
Reasoning, Knowledge, Experience Sharing, confronting fearlessly for the good of the
organization.
Integrity & Fairness:-
Fair and upright in intention and actions - always complying with conscience.
Nurture Talent, Competency& Willingness:-
Create challenging opportunities and provide support for development of self and team
members. Encourage experimentation & willingness to accept challenges.
Respect& Humility:-
Must be Courteous, Compassionate, Caring, Humane and Humble in all our interpersonal
dealings.
Innovation & Improvement Orientation:-
Challenge status quo. Demonstrate creativity for improvement and break through.

12. Partnering
Leverages Interdependence, Cooperative, Readily provides support and assistance to
others.
Responsibility
Take ownership for the consequences of ones decisions and actions.
Cross Cultural Diversity
Build a vibrant workforce with different ethnicity, cultural orientation with no prejudice
due to sex / caste / creed / color and to cherish our diversity.
 Core Values
Passion for Excellence
Nurture Talent, Competency & Willingness
Respect & Humility

13. OVERVIEW MFE
Minda Furukawa Electric Pvt. Ltd. (MFE) is a Joint Venture between the Spark Minda,
Ashok Minda Group of India and Furukawa of Japan. The Joint Venture is a 51: 49
partnership with Spark Minda, Ashok Minda Group holding 51% and Furukawa holding
49%.
The company develops and produces the entire range of wiring harness for four wheelers
for its customers, and components related to wiring harness e.g. couplers, terminals, relay
box, junction box, and Steering Roll Connectors used for the airbag systems etc.
Our plant is located at Bawal, Haryana, giving us proximity to most of the automotive
OEM,s in India. Our plant has all the state of the art machinery, testing and support
facilities required for making all types of Wiring Harness as per our customer's
requirement.

14. MFE MANAGEMENT TEAM
ASHOK MINDA AVINASH PARKASH GANDHI SHITGENOBU ABE
DIRECTOR DIRECTOR DIRECTOR
TAKANITSU KOZUKA NEERAJ SHARMA MASAHIRO HAEGAWA
DIRECTOR PRESIDENT JOINT PRESIDENT
Management Team
President : Neeraj Sharma
Joint President : Masahiro Hasegawa
Chief Financial Officer : Amit Kumar Dubey
Head HR & Administration : Pravesh Kumar
Bawal Plant Unit Head : Gagan Khurana
Noida Plant Unit Head : Makarand Acharya
Chennai Plant Unit Head : TBR

15. Head Sales and Marketing : Puneet Ralhan
Head Supply Chain Management : Hemant Kumar
Head Quality : TBR
Head Components : K. Kowaka
Head Engineering : Ayumu Nakashima
Head Manufacturing Engineering : Rajeev Tomar
Head Design Development : Riwaz Shankar Kulshrestha

16. ACHIEVEMENTS & MILESTONES MFE
2007 >Joint venture formation.
>Ground breaking.
2008 >Shifted to Bawal from Manesar.
>Business awarded for (MICRA) from NISSAN.
>1st
Conveyor installation
>1st
Dispatch from Bawal to Maruti Suzuki India ltd.
>Certification of appreciation from MSIL.
2009 >1st
dispatch to NISSAN.
>ASES certification from NISSION
2010
2011 >Cost performance Award from NISSAN.
>Shield of focused cost saving from MSIL
>Certificate for excellent delivery performance from MSIL.
>YL-7 assy line new Business awarded from MSIL
>New business award from HONDA SIEL.
2012 > Top position in Kaizen & Poke Yoke’s contribution to Mindakms site.
>Global testing lab approval from FAS
>MBEM bronze award 2011-12
>Gold medal in kaizen 1st
regional comp from AKM group.
>Incoming quality award from MSIL.
2013 >New business awarded for XBA/12 assy line from RENAULT NISSAN.
>Team kaizen 1st
award in AKM group
>SRC (steering roll connector) production in 2013.
>New plant at chennai in 2013.
>5s gold award from HONDA.
>Shield for incoming quality from MSIL.
2014 >New plant setup from Chennai & Noida.
>New business awarded from J.B (junction box) from SUZUKI.

17. 2015-16
>Manufacturing excellence appreciation from MSIL.
>Top rank in MACE audit J.B mass production start in 2015.
2016-17:- JOURNEY AHEAD…
>New line setup in SRC for (New business).
>Upcoming business YHA MSIL.
>Upcoming business MAHINDRA (SRC steering roll connector).
 World class productionprocesses.
 Systematic and continuous process improvement.
 (At MFE success is not a target,it is a continuousprocess.)

18. MINDA FURUKAWA PRODUCT RANGE
WIRE HARNESS
It is a product on which components are fitted (these components are used to protect
electric wire and fit into car.) it’s very necessary for car and other automobiles.

19. Wire harnesses are compactly bundled wires and data circuits that function as the central
nervous system of a vehicle. To ensure safety and basic functions (going, turning and
stopping), as well as provide comfort and convenience, automobiles are equipped with
various electronics which operate using control signals running on electrical power
supplied from the battery. The wire harness is the conduit for the transmission of these
signals and electrical power.
FUNCTION OF WIRE HARNESS
It is use to transmit signals and electricity to electronic components for the body of a car
and engine. The range of complexity for a wiring harness depends by the quantity of wires
and components required for complete its assembly.
Wire harnesses are compactly bundled wires and data circuits that function as the central
nervous system of a vehicle. To ensure safety and basic functions (going, turning and
stopping), as well as provide comfort and convenience, automobiles are equipped with
various electronics which operate using control signals running on electrical power
supplied from the battery. The wire harness is the conduit for the transmission of these
signals and electrical power.
TYPES OF WIRE HARNESS (9 type of wire harness
making in mfe)
 MAIN WIRE HARNESS
 ENGINE WIRE HARNESS
 BATTERY WIRE HARNESS
 INSTRUMENT PANEL WIRE HARNESS
 FLOR WIRE HARNESS
 DOOR WIRE HARNESS

20.  BACK DOOR WIRE HARNESS
 FUEL WIRE HARNESS
 DOME LAMP WIRE HARNESS
BASIC COMPONANT OF WIRING HARNESS
WIRES
COUPLERS
TERMINALS

21. FUSES AND FUSE BOXES
GROMMETS
RUBBER SEAL

22. CLAMP AND BINDER
CAPS AND SLEEVES
PROTECTOR
JUNCTION BOX

23. STEERING ROLL CONNECTOR
These are also manufacture and assembly in SRC production unit at owr company.
(A steering roll connector is the piece of the steering column that connects the column with
the steering wheel. It is not a big piece, but plays an important roll in safety and vehicle
control.)
Steering roll connectors (SRC) are rotating connectors that join the steering wheel to the
vehicle. These communicate the signals that activate airbags within the steering wheel and
use flat cables for the wiring.
The steering roll connector includes a roll stator, a roll rotor, a roller plate, and a locking
unit. The roll stator is fixed to a vehicle. The roll rotor is coaxial to the stator, is rotatable
relative to the stator, and includes a rotor connector provided with a steering wheel
connector.

24. OBJECTIVE OF TRAINING
This training sessionis being conducted to develop a understanding level of employees.
So that new employee how join MFE may understand about the product and the
process involved in the manufacturing process of wiring harness.
Finally a new employee will be able to work efficiently with good performance in their
assigned area. It find out suitability of job.
Other than to provide the knowledge base about the product manufactured by the
company manufacturing process involve minimize defects in the process floor
discipline.
TRAINING DISCIPLINE
 Always wear orange cap specially mentioned for trainees.
 Identify card should be visible easily, do not hide your ID card (like in pockets)
 Always wear recommended shoes as reffered in your dress code.
 Dress must be neat and clean daily.
 Carrying and talking on cellphone is not allowed.
 Always follow 5s rules in shop floor.
 Always give respect to other
 Canteen and break timing follow strictly
DAILY MEETING AND ITS PURPOSE
 All employees should be present in their meeting and area before shift start ago
10min.
 Agenda for the meeting and list of attendence.
 For gather all associate input and comments.
 Present the next planning solution developed.
 Target discussed.
 Important issued

25. TYPES OF WIRE IDENTIFICATION
B-BLACK
L-BLUE
BR-BROWN
BE-BEIGE
G-GREEN
GR-GREY
R-RED
P-PINK
VI-VIOLET
O-ORANGE
SB-SKY BLUE
LG-LIGHT GREEN
Y-YELLOW
WIRE
Different type,size,color wire used in the w/h for conductivity as per customer
requirement.
SHIELD WIRE
A shielded cable is an electrical cable of one or more insulated conductors enclosed by a
common conductive layer. The shield may be composed of braided strands of copper (or
other metal, such as aluminium), a non-braided spiral winding of copper tape, or a
layer of conducting polymer. Usually this shield is covered with a jacket. The shield acts
as a Faraday cage to reduce electrical noise from affecting the signals, and to reduce
electromagnetic radiation that may interfere with other devices. (For more, see
electromagnetic interference). The shield minimizes capacitively coupled noise from
other electrical sources. The shield must be applied across cable splices.

26. WIRE CUTTING
Wire cutting instruction must be based on cutting length and terminal crimping
instruction card.
WIRE STRIPING
Instruction must be based on striping length and terminal crimping instruction card.
TERMINAL

27. It is made by the copper and used for the transmit to the signal by the wire one terminal
to other terminal and this is used into the housing in the wiring harness.
5s ACTION IN MFE PVT LTD:-

28. There are five 5S phases: They can be translated from the Japanese as "sort", "set in
order", "shine", "standardize", and "sustain"
5S was developed in Japan and was identified as one of the techniques that enabled Just
in Time manufacturing
Sort (Seiri)
 Make work easierby eliminating obstacles.
 Reduce chances of being disturbed with unnecessary items.
 Prevent accumulation of unnecessary items.
 Evaluate necessary items with regard to cost or other factors.
 Remove all parts or tools that are not in use.
 Segregate unwanted material from the workplace.
 Define Red-Tag area to place unnecessary items that cannot immediately be
disposed of. Dispose of these items when possible.
 Needfully skilled supervisor for checking on a regular basis.
 Waste removal.
 Make clear all working floor except using material.
Set In Order (Seiton)
 Arrange all necessary items so that they can be easily selectedfor use.
 Prevent loss and waste of time by arranging work station in such a way that all
tooling / equipment is in close proximity.
 Make it easy to find and pick up necessary items.
 Ensure first-in-first-out FIFO basis.
 Make workflow smooth and easy.
 All of the above work should be done on a regular basis.
 Maintain safety.
 Place components according to their uses, with the frequently used components
being nearest to the work place.
Shine (Seiso)

29.  Clean your workplace on daily basis completely or set cleaning frequency
 Use cleaning as inspection.
 Prevent machinery and equipment deterioration.
 Keep workplace safe and easy to work.
 Keep workplace clean and pleasing to work in.
 When in place, anyone not familiar to the environment must be able to detect
any problems within 50 feet (15 meter) in 5 secs.
Standardize (Seiketsu)
 Standardize the best practices in the work area.
 Maintain high standards in workplace organization at all times.
 Maintain orderliness. Maintain everything in order and according to its
standard.
 Everything in its right place.
 Every process has a standard.
Sustain (Shitsuke)
 Not harmful to anyone.
 Also translates as "do without being told".
 Perform regular audits.
 Training and discipline.
 Training is goal-oriented process. Its resulting feedback is necessary monthly.
 Self discipline
 To maintain proper order

30. POKE YOKE:-
Poka-yoke [poka joke] is a Japanese term that means "mistake-proofing" or
“inadvertent error prevention”. The key word in the second translation, often omitted,
is "inadvertent". There is no Poka Yoke solution that protects against an operator’s
sabotage, but sabotage is a rare behavior among people.A poka-yoke is any mechanism
in a lean manufacturing process that helps an equipment operator avoid (yokeru)
mistakes (poka). Its purpose is to eliminate product defects by preventing, correcting, or
drawing attention to human errors as they occur.
The concept was formalised, and the term adopted, by Shigeo Shingo as part of the
Toyota Production System. It was originally described as baka-yoke, but as this means
"fool-proofing" (or "idiot-proofing") the name was changed to the milder poka-yoke.

31. KANBAN CARD:-
Kanban (literally signboard or billboard in Japanese) is a scheduling systemfor
lean manufacturing and just-in-time manufacturing (JIT).Kanban is an inventory-
control systemto control the supply chain. Taiichi Ohno, an industrial engineer at
Toyota, developed kanban to improve manufacturing efficiency. Kanban is one
method to achieve JIT.
WAY OF READING KANBAN
1. Machine name
2. Part number
3. Lot number
4. Quantity number
5. Operation date
6. Wire type
7. Wire size
8. Wire color code
9. Wire length
10. Terminal name (auto crimping if no color)
11. Terminal name (manual crimping if color)
12. Applicator name
13. Strip length
14. C/h allowable value (crimping height)
15. I/h allowable value (insulation height)
16. First in component length
17. First in component name
18. Double crimping
19. If (1) means ultrasonic or joint crimping set number
If A.B means twist wire set number
20. Joint number
21. Sub number
22. Wire number
23. Kanban number
24. Comment
25. If there is (*) is means having first in component
26. Page number

32. LEAN MANUFACTURING
Lean manufacturing or lean production, often simply "lean", is a systematic
method for the elimination of waste ("Muda") within a manufacturing system.
Lean also takes into account waste created through overburden ("Muri") and
waste created through unevenness in work loads ("Mura"). Working from the
perspective of the client who consumes a product or service, "value" is any action
or process that a customer would be willing to pay for.
JUST IN TIME MANUFACTURING
`Just-in-time' is a management philosophy and not a technique.
It originally referred to the production of goods to meet customer demand exactly,
in time, quality and quantity, whether the `customer' is the final purchaser of the
product or another process further along the production line.

33. FAMILY OF TERMINAL:-
FEMALE TERMINAL
A. End terminal
B. Side terminal
MALE TERMINAL
A. End terminal
B. Side terminal

34. JOINT WIRE TERMINAL
A. End terminal
B. Side terminal
LA-TERMINAL
A. End terminal
B. Side terminal
BATTERY TERMINAL
FAMILY OF WIRES (IMPORTED)
WIRE SIZE WIRE TYPE WIRE COLOR

35. 0.5F MM AVSSH W/G
0.75F MM AVSSH W
0.85F MM AEX B/R
1.25F MM AVSSH B
2.05F MM AVSSH L
8.05F MM AEX W
15.0F MM HEB B/R
20.0F MM HHEB B/R
30.0F MM HEB B/R
FAMILY OF COUPLERS:-
MALE COUPLERS
A. NON-WATER RESISTANT COUPLERS.
B. WATER RESISTANT COUPLERS.
water resist coupler

36. FEMALE COUPLER
A. NON-WATER RESISTANT COUPLER
B. WATER RESISTANT COUPLERS
AIR BAG COUPLER
FAMILY OF DECORATIVE PARTS
A. VINYL TUBE
B. SLIT TUBE

37. C. POX TUBE
D. VINYLE TUBE
E. SOFT TUBE
F. TWT
FAMILY OF COTS
A. N-COTS
B. HN-COTS
FAMILY OF CLAMPS
A. BINDER CLAMPS
B. FIXING CLAMP
TWISTING PROCESS:-
In any case extra wire length to be planned for with concentric twisting.service loops
and bends in the installed wire harness
DEFECTS OF TWISTING

38. A. WIRE LENGTH
B. TURN OF LOOPS
C. PITCH (2 CORE WIRE)
D. PITCH (3 CORE WIRE)
E. WRONG WIRE TWISTING
F. WRONG TERMINAL TWIST
G. TAPING ON TWIST WIRE
H. TERMINAL BEND
I. TERMINAL ROLLING
J. SEAL CUT
CRIMPING PROCESS:-
After the wire cutting and wire striping according to customer and harness.we are
working on crimping in this process strip wire are mounted in auto or manual
applicator macchine and these are strip wire mount to terminal. These are called
crimping process.
Crimped wires should be inspected carefully 3 different ways to verify the
manufacturing process.
1. Crimp height is measured and verified in spec to manufacturer recommendations
2. Pull test either performed as a destructive test or a pull and hold for a period of time
(usually one minute) is performed to measure the force necessary to pull apart the
crimp.
The non destructive hold for a minute test is just that, and then the crimped wire can be
returned to the production run.
3. Visual inspection of the crimped wire should also be done by a trained press set up
operator who knows what a properly crimped terminal should look like. This is
especially important for “F” type crimps.

39. DEFECT IN CUTTING AND CRIMPING PROCESS
When apply operation many time defect are creating different type this are following.
1 Wire type wrong 23 Mouth deform
2 Wrong wire size 24 Miss crimping
3 Wrong color 25 Conductor out
4 Wrong terminal 26 Seal position wrong
5 Wrong crimping height 27 No seal
6 Wrong insulation height 28 Seal cut
7 Seal color wrong 29 Seal damage/seal bitten
8 Wire length wrong 30 Pvc cut
9 Terminal bend up 31 High seal
10 Terminal bend down 32 Low seal
11 High core 33 Bell mouth failure
12 Low core 34 Cut of tab
13 High PVC 35 Terminal damage
14 Low PVC 36 Twisted terminal
15 Conductor cut 37 Stablizer bend
16 Conductor marking 38 Cutting burr
17 Crimping burr 39 Broken core wire
18 Insulation burr 40 No core wire
19 Core flash 41 Lock deform
20 Stripping less 42 Lock press
21 Open barrel 43 Terminal deform
22 Conductor pull out 44 Double crimping
JOINT CRIMPING PROCESS
Joint crimping have two or three wire are striping and these are joint in one terminal at
end of wire and centre striping have joint terminal in centre according to wire harness
design and requirement.
Many defect are creating in joint crimping operation process.these are following.
DEFECT IN JOINT CRIMPING PROCESS:-
1 Middle splashing wrong 11 Core flash
2 Length wrong 12 Crimping burr
3 Wire size wrong 13 Bell mouth failure
4 Core/h wrong 14 Barrel opening
5 Conductor cut 15 Core wire breaking
6 High core 16 Insulation biting
7 Low core 17 Tapping wrong
8 Terminal wrong 18 Joint heat shrinking wrong

40. 9 Joint striping wrong 19 Pvc burn
10 Joint direction wrong 20 Wrong method of fitting terminal
MEASURING INSTRUMENTS:-
1. TORQUE WRENCH
A torque wrench is a tool used to apply precisely a specific torque to a fastener such as a
nut or bolt. It is usually in the form of a socket wrench with special internal
mechanisms.
A torque wrench is used where the tightness of screws and bolts is crucial. It allows the
operator to measure the torque applied to the fastener so it can be matched to the
specifications for a particular application. This permits proper tension and loading of
all parts. A torque wrench measures torque as a proxy for bolt tension. The technique
suffers from inaccuracy due to inconsistent or uncalibrated friction between the
fastener and its mating hole. Measuring bolt tension (indirectly via bolt stretch) is
actually what is desired, but often torque is the only practical measurement which can
be made.torque screwdriver and torque wrenches are same purpose and mechanisms.
2. DIGITAL MICROMETER
sometimes known as a micrometer screw gauge, is a device incorporating a calibrated
screw widely used for precise measurement of components in mechanical engineering
and machining as well as most mechanical trades, along with other metrological
instruments such as dial, vernier, and digital calipers
It is use in measure wire terminal insulation height and terminal crimping height.

41. 3. MEASURING SCALE
It is use in harness cutting parts measure like cot tube,pvc tube,slit tube and other in
wire cutting length measure according to given data length.
4. MEASURING TAPE
Measuring tape are used in assy board validation measure jig length and wire hanger
making use measuring tape.
5. DIMENSION BOARD
It is use for measure the wire harness length according to requirement customer.so
these are using for assy line for dimension board station.
6. HARDNESS TESTER
7. TORQUE TESTER
8. STRENGTH CHECKING INSTRUMENT
9. PUSH-PULL TESTER
10.VERNIER CALIPER
A vernier scale is a device that lets the user measure more precisely than could be
done unaided when reading a uniformly divided straight or circular measurement
scale. It is a scale that indicates where the measurement lies in between two of the
marks on the main scale. Verniers are common on sextants used in navigation,
scientific instruments used to conduct experiments, machinists' measuring tools (all
sorts, but especially calipers and micrometers) used to work materials to fine

42. tolerances, on theodolites used in surveying, and in absolute encoders to measure
linear or rotational displacements
The main use of the vernier caliper is to measure the internal and the external
diameters of an object. It is also used in measuring an object to its lowest decimal
point.these are use for jig width, jig hole size,jig internal dia etc tollerence.

43. WIRING HARNESS
(PRODUCT AND PROCESS DEFECT GALLERY
In wire harness assembly sometime create defects in harness
1. Double lock open.
2. Wire cut.
3. Dimension short.
4. Vo length short.
5. P.V.C scratch (green).
6. T.B.O (terminal back out).
7. Wrong clamp fixing.
8. Clamp damage.
9. Vinyl tube cut.
10. Wrong fixing method.
11. Double lock open.
12. Grommet fixing wrong.
13. Rubber seal cut.
14. Clamp fixing method wrong.
15. Wrong way of clamp fixing.
16. Grommet cut
17. Clamp miss
18. Taping condition is not good on branch
19. Part miss (vinyl tube)
20. Branch direction change.
KAIZEN
Kaizen (改善?) It mean (change for better) is Japanese word for "continuous
improvement ". In business, kaizen refers to activities that continuously improve
all functions and involve all employees from the CEO to the assembly line
workers. It also applies to processes, such as purchasing and logistics, that cross
organizational boundaries into the supply chain. It has been applied in
healthcare, psychotherapy, life-coaching, government, banking, and other
industries.these are main concept is given new ideas and suggestion for better
working
improving standardized programmes and processes, kaizen aims to eliminate
waste (see lean manufacturing)
Two kaizen approaches have been distinguished
1. Flow kaizen

44. 2. Process kaizen
The former is oriented towards the flow of materials and information, and is
often identified with the reorganization of an entire production area, even a
company. The latter means the improvement of individual workstands.
Therefore, improving the way production workers do their job is a part of a
process kaizen. The use of the kaizen model for continuous improvement
demands that both flow and process kaizens are used, although process kaizens
are used more often to focus workers on continuous small improvements. In this
model, operators mostly look for small ideas which, if possible, can be
implemented on the same day. This is in contrast to traditional models of work
improvement, which generally have a long lag between concept development and
project implementation. In the traditional model, the time between concept
development and project implementation is very long. In the kaizen model,
workers mostly look for small ideas and improvements which can be implemented
on the same day.

45. WIRE HARNESS MANUFACTURING PROCESS IN(
C&C Dept):-
PROCESS FLOW
WIRE CUTTING WIRE STRIPPING PARTS FITTING
JOINT CRIMPINGMIDDLE
STRIPPING
TERMINAL
CRIMPING
ULTRASONIC
WELDING
JOINT TAPPING SILICON (HEAT
SHRINKING)
TWISTINGCHARGING TROLLY (wire
holding hanger)

46. PROCESS IN C&C (CUTTING AND CRIMPING)
AREA MACINE PROCESS:-
1. WIRE CUTTING PROCESS
first process is wire cutting according to given dimension and use according to
harness requirement.these are using manual cutting machine and auto cutting
machine both are working .but auto cutting machine have good accuracy and less
time consuming. So these are better than manual cutting machine.
The auto cutting machine are work operation based on programme install and
work continuously.the cutting machine change feed rate,cycle time,speed etc.
2. WIRE STRIPPING PROCESS
A wire stripper machine it is used to strip the electrical insulation from electric wires
based on given insulation length and according to use like joint crimp,welding etc.
Types
2.1 Manual stripping machine
2.2 Automatic stripping machine
2.3 Laser Wire Stripper machine
MANUAL STRIPPING MACHINE
A simple manual wire stripper is a pair of opposing blades much like scissors or
wire cutters. The addition of a center notch makes it easier to cut the insulation
without cutting the wire. This type of wire stripper is used by rotating it around
the insulation while applying pressure in order to make a cut around the
insulation. since the insulation is not bonded to the wire, it then pulls easily off the
end. This is the most versatile type of wire stripper. Another type of manual wire
stripper is very similar to the simple design previously mentioned, except this type
has several notches of varying size. This allows the user to match the notch size to
the wire size, thereby eliminating the need for twisting. Once the device is
clamped on, the remainder of the wire can simply be pulled out, leaving the
insulation behind.
AUTOMATIC WIRE STRIPPING
an automatic wire stripper first simultaneously grips the wire in one side and in
the other side closing its shaped cutting blades cutting the insulation around the

47. conductor. After the sides have completed their stroke the two sides of the
mechanism spread apart to push the cut tube of insulation from the end of the
conductor. To use it, one simply has to place the wire in the jaws in the cutting
slot the size of the conductor and squeeze the handles together. This device allows
even a novice to strip most wires very quickly.
Although in principle applicable to wire of any size, automatic wire strippers that
are widely available have cutters that can accommodate conductors in a range of
sizes no larger than 8 AWG nor smaller than 26 AWG, but not the entire range.
LAZER WIRE STRIPPING
A laser wire stripper is a computer-controlled machine, much like a CNC router,
which uses a laser to burn off the insulation of the wire. Laser wire stripping
machines are used mostly for very fine gauge wires since they do not damage the
conductor. A typical CO2 laser wire stripping machine should be capable of
stripping the insulation from any size wire
3. PART FITTING PROCESS
After the wire cutting and stripping we are mounted rubber seal in wire striping
end its protect wire and does not enter water in coupler.these are water resist
coupler and to prevent short circuit.

48. 4. TERMINAL CRIMPING PROCESS
A contact whose crimp barrel is a hollow cylinder that accepts the
conductor.After a conductor has been inserted, a tool is used to crimp the contact
metal firmly onto the conductor.
Crimp:- The physical compression (deformation) of a contact barrel around a
conductor to make an electrical and mechanical connection to the conductor.
Crimping. A method of mechanically compressing or securing a terminal, splice,
or contact to a conductor.and fit the strip wire into the terminal.
two type of machine are using manual crimping and auto crimping machine.
5. MIDDLE STRIPPING PROCES
This process is same as wire stripping but this type wire are strip in center according to
the use in harness.

49. 6. JOINT CRIMPING PROCESS
This process are using after the wire stripping in center and end stripping ,then joint
the two or three wire so we use these operation.
7. ULTRASONIC WELDING AND RESISTANCE WELDING
PROCESS
Ultrasonic Wire Splicing
Ultrasonic welding technology bonds multiple wires together or wire to any other metal
parts by applying the energy of high frequency vibrations to the product or parts to be
welded together.
Ultrasonic Spot Welding
Ultrasonic spot welding is our newest addition of wire processing technology. WIth this
state of the art equipment, our specialized techs can spot weld wire to terminals and or
brakets for special applications. A spot weld produced by this high energy process is
stronger than any solder joint and requires only the components you wish to bond
together.
Wide Range of Applications
 End splices / butt splices
 Inline splices / head to head splices
 Inline splices with middle stripped wires
 Protection for single wire ends
 Wire to terminal connections

50. Ultrasonic welding wire
Resistance welding
lectric resistance welding (ERW) refers to a group of welding processes such as spot and
seam welding that produce coalescence of faying surfaces where heat to form the weld is
generated by the electrical resistance of material combined with the time and the force
used to hold the materials together during welding. Some factors influencing heat or
welding temperatures are the proportions of the workpieces, the metal coating or the
lack of coating, the electrode materials, electrode geometry, electrode pressing force,
electrical current and length of welding time. Small pools of molten metal are formed at
the point of most electrical resistance (the connecting or "faying" surfaces) as an
electrical current (100–100,000 A) is passed through the metal. In general, resistance
welding methods are efficient and cause little pollution, but their applications are
limited to relatively thin materials and the equipment cost can be high (although in
production situations the cost per weld may be low.
resistance welding example.

51. 8. JOINT TAPING PROCESS
After the wire striping and joint in center other wire ,these wire are without
insulation and these prevent to short circuit and other things so we are use
taping in wire joint
9. SILION RUBBER PROCESS (HEAT SHRINKING) (in
multiwire connecting)
Silicon rubber mountng after the multi wire connecting with the help of heat shrinking
machine.its protect water,corrosion,and short circuit.

52. 10. WIRE TWISTING PROCESS
The programmable wire harness twisting machine is designed for twisting multiple
wires together, each section can set winding direction and speed...based on which type
wire use and size ,length.
wire twisting machine
11.CHARGING (After all process complete ,this wire holds in
trolly
Charging is a wire holding trolly and wire terminal hold in cup to prevent
wire damage,and hanging in charging trolly.

53. PROCESSING ENGINEERING (DEPT):-
Process engineering focuses on the design, operation, control, optimization and
Intensification.
Also it include maintenance,new project development setup.etc
Dailymorning meeting in PE dept before working.and to given new task and new
project development according to assy line requirement.
PE(PROCESS ENGG)
ASSEMBLY BOARD ECT M/C CPG M/C APPLICATOR M/C
ASSY DEPT FOR PE ACTIVITY AND RESPONSIBILITY:-
 INVENTRY AND DOCUMENT CONTROLLING
INVENTRY CONTROL
Inventory control is also about knowing where all stock is and ensuring everything is
accounted for at any given time. An inventory control system or a computerized
inventory system is a process for managing and locating objects or materials. In
common usage, the term may also refer to just the software components. Many shops
now use stock control systems. The term "stock control system" can be used to include
various aspects of controlling the amount of stock on the shelves and in the stockroom
and how reordering happens.
Check rack bins and check quantity of child parts,jig,checker pin ,checker jig etc
Advantages of Inventory Control
inventory-control-scanner The ultimate goal of your inventory control should be to
maximize your organization’s use of inventory. When you maintain proper inventory

54. levels, you can rest easily knowing that your capital is not unnecessarily tied up in your
inventory. If you are in manufacturing, inventory control also protects production if
there are problems with bottlenecking or the supply chain.
BENEFIT INVENTORY CONTROL IN WAREHOUSE STOCK.
1. Increased profitability
2. Having enough stock on hand so that you don’t run out
3. Barcodes to track inventory efficiently
4. Reduction or elimination of inventory write-offs
5. The ability to conduct audits more quickly and efficiently
DOCUMENT CONTROLLING
In document controlling all files are daily update based on file report given and
updation online system software like preventive maintenance file,line problem
breakdown,new jigs inspection file,validation report file are controlling.
 FACILITY AND IMPROVEMENT
Making new hanger and modification of hanger other than new design improvement
of hanger asto requirement of assy line.many types of hanger are making like
1. Sub-assy hanger
2. Boundry trolley
3. Parts trolley
4. Pc system hanger
5. Dimension,visual board facility etc.
 BREAKDOWN AND PREVENTIVE MAINTENANCE
i. BREAKDOWN (line problem)
When assembly production line continue running and motion and suddenly mechanical
or electrical problem are create in line like assembly board jig loose ,damage or broken
the jig so this type of line problem are breakdown and this problem solve at minimum
time or less time,or after solve so line continuously working. “run till failure”
Machine breakdown like Electric circuit testing board ,assy board,Compact point guide
m/c etc.
ii. LINE PROBLEM

55. Daily check line problem in production line in morning and before line start and solve
based on problem given.or update line problem report.
Many types problem are creating and solve like:-
Damage assembly drawing,looseness of the jigs,bend of the jigs,jig damages,availability
of red tag,check nd history sheet. Etc these problem are inform line operator in PE
employees and sloving.
iii. PM (PREVENTIVE MAINTENANCE):-
Preventive maintenance is overall maintenance of assy line like assy board,ect
board,cpg machine etc. these have monthly plan setup at different assembly line.
ECT pm,Assy board pm,dimension board pm etc
1. The work carried out on equipment in order to avoid its breakdown or
malfunction. It is a regular and routine action taken on equipment in order to
prevent its breakdown.
2. Maintenance, including tests, jig measurements, jig adjustments, parts jig
replacement, and cleaning, performed specifically to prevent faults from
occurring
Preventive maintenance is regularly performed maintenance on a piece of equipment to
reduce the likelihood of failure. In the same way you would not wait until your car’s
engine fails to get the oil changed, machines, equipment, buildings and anything of
value to your organization need consistent maintenance to avoid breakdowns and costly
disruptions.
This work is called Planned or Preventive Maintenance (PM). Preventive Maintenance
is performed while the equipment is operating normally to avoid the consequences of
unexpected breakdowns, such as increased costs, downtime and more.
 NEW PROJECT DESIGN AND DEVELOPMENT:-
When Maruti Company,Nissan,Renault (customer) are yearly Launch new upgrade
version of Cars,so these changment all things like design,structure,etc and vender
companies are also change the design of wire harness,jigs design,assy board drawing
change according to requirement and needed to customer like.
1. YSD –LHD (left hand drive)_new setup
These assembly line new project in 2017 (swift dzire wire harness) this project are
complete and start of production.
2. YSD-RHD (right hand drive) new setup

56. RHD is drive in india so these harness making for indian version car swift dzire.this
project event also done till mid apirl 2017.and currently working production and start
of production according to customer.Maruti audit visit new line setup and in MFE and
given Green signal for production
3. YSD-Hatch Back (H/B) new event
These line are setup in running and complete till mid may so all these three line big
project in 2017.
3lines production capacity is 1600 harness/day in running time.
4. ISUZU line set up battery harness setup this line replace chennai palnt to bawal
palnt MFE.its start production may 2017 (SOP).
5. YHB-LINE NEW EVENT coming:-this line project starting in may last week or
june 2017.

57. ASSEMBLY BOARD PANEL MAKING PROCESS
AREA IN (PE):-
The assembly board are use in wire harness assembly line conveyor (mounting on wire
according to jig set) and taping process after the sub-assembly of wire and terminal.
We are discuss assy board making all procedure .
DRWAING LAYOUT ON BOARD AND DRAWING LAMINATION
Firstly design engineer making drawing layout according to intruction,dimension or
harness length or tollerence or customer requirement.when this are complete drawing
layout. This layout are mount in 2meter or 3m and 4m wooden board before drwaing
layout lamination with the help of lamination machine.and pasting or setup drawing on
board.
DRILLING HOLE ON BOARD:-
According to drawing in board jigs location drilling hole bit use these sizes
8mm,10mm,12mm .all points drilling according to information given on drawing layout.
 JIGS:- Custom made device used for holding the piece to be worked-on in a
correct position relative to its associatedtool.
JIG MOUNTING ON BOARD :-
after drill hole jigs are fit and set on board ,different types of jigs are mounting on
board like case jig,dressing jig

58.  ASSY BOARD JIG OTHER PARTS TYPES:-
 D-shaft
 EA-10,20 etc
 TLD-use for taping fixing
 Straight shaft
 UD- for holiding DM and DY jigs are wire divide three or four sides in assy.
 ORE- join DM and DY jigs
 E-wire dividing two sides jig
 Y-SOP set in jig for holding extra wire on assy.
 Case jig and dressing jig:- fit the wire couplers on this jigs.
All jigs are set and tight nut and bold in assy board. This board is complete and
validation and quality assurance verfication are required.
 VALIDATION:- verfication and validation in engineering, confirming that a
product or service meets the needs of its users. the action of checking or proving
the validity or accuracy of something.
ASSY BOARD VALIDATION (PE ENGG):-
assy board check the dimension jigs and measure jig center and correct location of
jigs.the tollerence will be given –or+ this according given length and tollerence.when
validation complete after quality assurance engineer verfication the validate board
ASSY BOARD VERFICATION (QA ENGG):-
measure the jigs dimension and check length less or more and the under the tollerence
or out of tollerence.
 VERFICATION the process of establishing the truth, accuracy, or validity of
something.confirmation and validation and affirmation.
 TOLERANCE:- Engineering tolerance is the permissible limit or limits of
variation in: a physical dimension, a measured value or physical property of a

59. material manufactured object, system, or service, other measured values
In assembly line conveyor 12,16 boards quantity are setup for wire harness assembly
process.
VISUAL BOARD MAKING:-
DIMENSION BOARD MAKING:-Jigs use–CL-1682 SIDE,CL-1682
DOWN,CL-1681 SIDE,CL-1682 DOWN,DM,DY etc.
200% INSPECTION BOARD MAKING
OPTIONAL TAPPING BOARD MAKING:-

60. ECT BOARD AND M/C MAKING PROCESS AREA
IN(PE):-
ECT (Electric Circuit Testing) M/c:-
After the wire harness is constructed, it is tested for any faults. The two main tests
carried out are the continuity testing and insulation resistance testing. A continuity test
will verify the flow of current in the electrical circuit,meaning that the circuit is
continuous. This test is performed by placing a small voltage between two or more end
points of the circuit. An insulation resistance test uses an applied DC voltage to test for
current resistance and to keep the current on its path along the conductor. The wire
harness is then sent for dressing out.
ECT MACHINE MAKING
In board according to drawing layout, scatch draw in board and checker jig point mark
on board and drill hole on board after this PVC sheet fix in the layout board to prevent
dust and other things.
Setup the checker jigs in the board and wire connection on board.also mount fuse box
checker jig in the board
ECT MACHINE PARTS:-
 OMI-10 ,OMI-100, DYNALAB
 ECT-BOARD
 CHECKER JIG
 CLAMP JIG
 ADAPTOR FOR PROGRAMME INSTALL
 DISPENSER
 PC
CHECKER JIG PARTS

61. Rear cover, checker housing, cam refainer, checker pin, metal bush, guide key, guide
shaft, slide spring, base plate, grip cover, lever pin etc.
ECT MACHINE VALIDATION
After complete ECT machine need validation these are verfication all things in machine
like-position of jig,name of checker jig,fixing method of jig height and direction,wiring
of checker,connection of back lead wire with connection,verfication of ECT
programme,etc
OMI-10 ,OMI-100 & DYNALAB WHAT USE IN ECT
OMI-100 Its use for maximum wire continuity checking like 800wire plus other than
OMI-10 is use for minimum wire checker continuity less than 800, and DYNALAB is
require where very less point wire continuity check like door wire harness it’s a small
type wire harness.
TAPE DISPENSER
When complete circuit pass harness ,the dispenser are given pass tape to fix in pass wire
harness.

62. CPG MACHINE MAKING AREA IN PE:-
TWO TYPE CPG MACHINE (remote control and manual machine
control)
PARTS OF CPG MACHINE
 PC GUIDENCE CHECKER
 HANGER
 LED
 MICROSWITCH
 WIRE
FEATURES AND FUNCTION OF CPG M/c
(Its use for wire sub-assembly and different wire assembly in coupler)
 WIRE PICK-UP:- its means given the information of which wire choose in
hanger firstly step by step and insert in the terminal. So these advance given
information wire color code.
 WIRE INSERTION GUIDENCE:-these are guide location of wire which fit in
terminal according to set the programme.and insert terminal in the coupler.
 CONTINUITY CONFIRMATION AND GUIDE WIRE LOCATION:- its check
the wire continuity and guide the correct wire terminal location in the coupler.
 TBO (Terminal Back Out) confirmation:-after coupler set in pc guidence
checker and pull the checker jig with wire and confirm the terminal loose or fit
in the coupler.and give TBO information in the screen and not pass the wire.
CPG USING FOR CONTROL or PREVENT THE DEFECT
Many type defect are creating in wire sub-assembly ,so these defect are controlling with
the help of these machine.
 CROSS WIRE:-its stop the cross wire in the terminal example –when 2 and 4
these two cavity and two color wire white and red,when white wire set in 2 no

63. cavity and red wire set in 4no cavity but wrongly we set wire white wire in 4no
and red wire in 2no so these are cross wire in coupler its also inform cpg
machine.
 TBO (terminal back out):-its stop TBO
 WRONG WIRE:-cpg also inform and find wrong wire fit in coupler.
 WIRE MISS:-its also notice wire miss in the coupler.example-when coupler
cavity 10 wires and fit only 9 wire so these notice also in given screen.
 EXTRA WIRE:-these find extra wire fit in coupler.
 WIRE DAMAGES:- cpg machine holding back side pipes is prevent wire
damages.
 CAVITY DAMAGED:-cpg are find coupler cavity damages defect in sub-
assembly.
CPG machine making:-firstly making hanger design and pc guidence checker jig are set
in this and wire holiding cavity fix led.
Set the two micro switch and remote .after that all parts are fix and set in cpg machine
so install programme and sofware in cpg machine .and its working according to install
software.
MAINTENANCE of CPG:-check hanger condition and all parts of hanger.
Force check (PC guidence)
Wire contiuity check
All led check
Jig direction and jig condition check
APPLICATOR MACHINE MAINTENANCE
applicator

64. APPLICATOR:-it is a part of crimping machine and its important part or tool of
crimp machine. When terminal size and shape change so change the applicator on the
machine before crimping operation.
Terminal type and wire parameters depend on the production requirement. Both open
barrel and closed barrel terminals are supplied on continuous strips. Crimping is
performed by an applicator, a mechanism that performs the functions of feeding the
terminal, cutting the terminal from the strip, and crimping wire and insulation.
Crimping force is provided by a terminator in which the applicator is mounted.
Terminators and other
Its two types machine uses applicator
A. Fully automatic crimping and striping machine
B. Manual crimping machine
Firstly install the applicator in crimping machine and check the wire crimping sample
and these sample when good accuracy so given in quality to final check and start the
machine for wire crimping.

65. SOME FEW POINTS REMEMBER IN MIND AND
ALWAYS REPEAT OR MORE THAN ONCE USES IN
(PE DEPT):-
 JIG RECEIVING AND INSPECTION OR MATERIAL
WAITING FOR INSPECTION:-
When new jigs are receive in vender company according to order given .so these jigs
inspection is very important because sometime jigs are not proper design and dimension
or damages problem .when jig cavity are not accurate so refinish and rework on jig and
return to vender company.
 JIG SHORTAGE OR MATERIAL SHORTAGE:-
It mean A state or situation in which something needed cannot be obtained in sufficient
amounts. sometime jig or material like nut,bolt,clamps etc finish or empty and shortage
material for making assy line machines so these situation can handle jig shortage list
making and given engineer and immediately inform engineer for import material.
 ASSEMBLYBOARD JIG AND NON-RUNNING PARTS:-
Non running parts or jig are those parts which are not in use in present and currently
.these are old line parts those line stop after 2 or 3 year running when customer
complete production contract .
 UPDATION(assembly board drawing )
Assembly board drwaing updation or changement in drwaing layout. when wire
harness branch length short or changement of branch location direction. Its important
when customer inform problem and based on requirement.
 MODIFICATION:-

66. According to (ECN) engineer change notice modify the hanger design and
change the cpg hanger design or assy board design etc .its change because
improvement of quality and control defects.
 HISTORY CARD:-
It is use in boards for all information about assy board like assembly board
manufacturing date ,validation of board,drawing layout changement board
etc.
ASSEMBLY PROCESS AREA AFTER (C&C)
MAIN WIRE HARNESS ASSEMBLY CONVEYOR LINE
 YE3,YL7,YP8 VDI,YP8 VXI,XBA,YSD-1 (RHD),YSD-2
(LHD),YSD-3 H/B
ASSEMBLY PROCESS FLOW:-(after C&C process)
SUB-ASSEMBLY
(CPG MACHINE)
FINAL ASSEMBLY
CONVEYOR(ASSY
BOARD)
GROMMET
FIXING
CLAMP ATTACH
CLAMP
INSPECTION
ECT –TESTING
INSPECTION
DUMMY
STATION
DIMENSION
INSPECTION
FUSE AND RELAY
STATION
FUSE BOX
VISION
MACHINE
GREASING
MACHINE
STATION
OPTIONAL
TAPPING
STATION
PACKING 200% VISUAL

67. ASSEMBLY PROCESS ALL STATION OPERATION
AND WORKING
ASSEMBLYCHARGING HANGER:-
Wire holding in hanger and terminal in the cup its prevent terminal bend and damage.
Before sub-assembly of wire harness.
 CPG (COMPACT POINT GUIDE)SUB-ASSEMBLY
STATION:-
Its first station to start assembly process. according to machine instruction and machine
guidance checker wire with terminal insert in coupler cavity.so all terminal wire insert
in coupler according to guide machine in show pc display. and its given which color
wire insert in coupler.so this process is complete in sub-assembly in CPG machine
hanger. Total per assembly line 5 CPG machine are require in different wire insertion.
Also check wire continuity .
 PART TROLLEY:-
Part trolley are using for all parts location in one place in line according to needed parts
given in different station for wire harness making.
 FINAL ASSEMBLY (CONVEYOR IN MOTION PROCESS) :-
assembly board instant panel:-
In the assembly board according to drawing layout wire are insert in jigs and attach
clamp and other parts. In conveyor assy line have 12 boards are motion cycle
continuous. This motion have tapping in wire and all branches and approx. 75% wire
harness is complete.

68.  GROMMET INSERT STATION:-
This station grommet are insert and fix in wire harness .grommet set in machine and
machine are pulling grommet hole according to force apply and wire harness insert in
the hole. Its important in wire harness .these are protect harness to branch damage or
cut wire with touch metal corner or friction for metal in car.
 CLAMP ATTACH BOARD:-
In board wire harness insert and according to jig in board clamp are fix in different
branch and cut clamp extra length. The different type clamp are use in harness because
these clamp are fix in car body to set harness in car.
 DIMENSION INSPECTION :-
In dimension inspection board, wire harness and it’s all branch dimension measure
according to measurement of drawing layout and jig set in layout. When Branch length
short so it’s not accept in quality and customer other than reject wire harness.so it’s
important to measure the dimension of wire harness.
 DUMMY STATION:-
Wire harness check coupler water leak test with the help of air vacuum pressure in
water resist coupler. These are protect water in rainy days .
 ECT STATION:-
ECT means Electric Circuit Testing. When harness set and coupler are insert in
checker In the ECT board .These are test and check wire harness continuity in different
branch.
 CLAMP CHECKING STATION:-
Wire harness all clamp check in this station. It’s given data clamp miss or damage in
wire harness location.
 FUSE AND RELAY STATION:-
This station working wire harness fuse box all the fuse are insert in the box according to
location given or cavity, and relay also insert in fuse box according to voltage capacity.
The fuse box are use because sometime short-circuit of wire so this situation protect the
fuse. Stop the current in harness.
 VISION MACHINE STATION:-

69. Check and scan fuse in fuse box location according to design and voltage require, fuse
miss or extra fuse insert etc. are check.
 GREASING MACHINE STATION:-
In wire harness few terminal couplers require greasing because these are without grease
in environment produce corrosion and carbon in terminal metal face.so these are
protect corrosion other things.
 OPTIONAL TAPPING STATION:-
In this process in wire harness some branch long and this branch fold to use optional
tapping. before when install harness in car body fold branch open optional tapping .
 VISUAL INSPECTION:-
In this station all parts visually or external check, like test pass tape, barcode, clamps,
and marking white marker.
 200% INSPECTION:-
200% Mean overall externally or deeply check and after visual inspection again check
the wire harness. When any issue in harness immediately inform line leader.
 PACKING ANG DISPATCH:-
When all process complete and wire harness packing in bins. These bins place in
warehouse and dispatch to customer according to stock requirement
SOME FEW POINTS USES IN PRODUCTION
RED CARD:-it is use for non-confirming parts identification tag like-taping problem,
wrong part insert, part missing, crimping defects, T.B.O., wrong dimension etc.to attach
with wire harness.
ZERO DEFECTS:-this system focuses on getting the product right the first time,
rather than spending extra time and money fixing poor-quality products. By using the
zero defects system, you’ll reinforce the notion that no defect is acceptable, and
encourage people to do things right the first time that do something.

70. REWORKING AREA:-in this process when the wire harness branch short and
cross wire terminal in coupler, taping miss in branch, clamp wrong attach etc, some
problem are solving in reworking process .