AN INDUSTRIAL TRAINING REPORT – 1

Done by

ATMODEEP SEN
Reg No: RA1711011010107

At
Napino Auto & Electronics Ltd
Sector-3, Plot No. 7
Gurugram, Haryana

Submitted to

Department of Automobile Engineering

Faculty of engineering and technology,
SRM Institute of Science and Technology
(Under section 3 of UGC Act, 1956)
SRM Nagar, Kattankulathur- 603203
June -2019
 BONAFIDE CERTIFICATE

Certified that this industrial training report – 1 is a work of ATMODEEP SEN

(RA1711011010107) who carried out the work at Napino Auto & Electronics,
Sector-3, Plot No. 7, Gurugram, Haryana, India.

Class In-Charge

(Mr. G.Naresh)
 ACKNOWLEDGEMENT

It is always a pleasure to remind the fine people in the Engineering

program for their sincere guidance I received to uphold my practical as
well as theoretical skills in engineering.

Firstly I would like to thank Dr. C.Muthamizhchelvan (Director of E&T,

SRM University) for meticulously planning academic curriculum in such a
way that students are not only academically sound but also industry ready
by including such industrial training patterns.

I would also like to thanks Mr. G. Naresh (Class In-charge) for the
positive attitude he showed for my work, always allowing me to question
him and giving prompt replies for my uncertainties in all the fields
including educational, social and managerial work.

I express my immense pleasure and deep sense of gratitude to Mr. Leenus

Jesu Martin (H.O.D, Autmobile engineering) who helped me in
completion of task.
 CHAPTER – 1
INTRODUCTION

I had been assigned the job of Production in the Production line of harness manufacturing at
Napino Auto & Electronics. This is an automobile electronics manufacturer leader in
producing various fundamental electronic devices for vehicles like ECU, Wiring harnesses,
Switches and Switch systems. They are also proficient in making innovative wiring solutions
both for two and four wheelers.

The company serves as a crucial sub-part of many bigger companies like Ford, Nissan,
Volkswagen, Bajaj etc. It produces OEM integrated in the mass produced vehicles in such
companies,

The Gurugram plant is headed by Mr. Jeet Singh, who assigned me the job at the production
line. The H.R head of the plant is Mr. Ashok Sharma.

The production line is capable of producing at a high rate. The workers are professionally
trained and are given 2 months of prior training before starting the work at the actual
production line.

The plant coordinator Mr. Satyendra is the head of training of the staff and assigning specific
jobs to the workers.
The plant is equipped with both automatic and manual harness producing machines. The
automatic machines are more specialised and are used for cutting, crimping and installation
of connectors and terminals. The machines withdraws the wires from reels and feeds them
into the crimping machine.

The picture above shows the manual prodcution line wherein the workers assemble the
harness by hand and the line moves accordingly.

Details about the project and assembly line are discussed further in the report.
 CHAPTER 2

Company Background and structure

ABOUT

Napino Auto and Electronics is a proud contributor to the progress of the Indian Auto
Industry, the success of Napino lies in the ability of the organization to seamlessly adapt to
the requirement of its clients through aggressive developments in technology and design.

Napino Auto & Electronics Ltd. is a focused and dynamic company committed to achieving
greater value for its customers in the field of auto electrical and electronic products.
Appreciating the continually evolving needs of the automotive industry, the company has
kept abreast with the leading global technologies and consistently developed innovative
products and variants for its customers. Moving into the future, Napino aims to expand its
presence globally as a one-point solution provider from concept to manufactured products
and enhance value for its customers.
Napino’s profound understanding of the automotive sector and its consistent focus on
innovative application for over two decades is what drives the company towards the future of
automotive electronics. We believe that electronic components are the key to improved
energy efficiency in an eco-friendly environment as we gradually turn our beliefs into reality
by bringing out the best of innovative engineering.

The company was founded in 1997 and started with the production of capacitor discharged
ignition systems regulators and rectifiers in 1998. The Manesar plant was established in 2002
and has been in production ever since. It received the Direct in line certification from hero in
2003. In 2012 it established a whole new R & D department which specialised in the research
of Electronic control unit of vehicles and also worked on electric vehicle propulsion systems
simultaneously.
KEY PRODUCTS AND SOLUTIONS:

1. Wiring harnesses
2. Mechatronic products
3. E-mobility solutions
4. Solid state automotive lighting
5. Engine Management Systems
6. ECU
7. CDI systems
8. Rectifiers and relays
 STRUCTURE

The plant consists of two sections, the main building is the production and manufacturing
facility. The second building consists of the research and development area.

The manufacturing facility consists of high end devices including the X-Ray machine, Micro
Analysis Test Lab & Automatic Optical Inspection Equipment installed at our facilities, we
guarantee accuracy in performance.

Rigorous endurance tests are done on all samples, which in turn enhances reliability and
lengthens relationships with prestigious clients.

Napino's Research and Development Centre is designed to meet the complex challenges of
the continuously evolving Automotive World, In-house facilities and competencies cater to:-
 Electrical & Electronic Design

 Component Design

 PCB Design

 Embedded Hardware & Software Design

 Simulation and Virtual Testing

 Physical Prototype & Testing

 Mechatronics

 Validation, Endurance & Reliability Testing

Napino's Research and Development team provides strong support to customers for new
product development , enhancement of quality of existing products and cost reduction
through VA/VE activities. Wide range of latest softwares are employed in the Research and
Development section to facilitate world wide transfer of design.

The management is committed towards R&D initiatives and provides advanced technical and
commercial resources for development activities. knowledge and competencies of engineers
are constantly upgraded through training and awareness programs to keep abreast with latest
technologies and trends that prevail in the market.
 CHAPTER 3
WEEKLY JOB SUMMARY

WEEK 1:
The job first week was to get familiarized with all the different machines which were being
used in the production line.
These machines include:
1. Automatic Cutting and crimping machine
2. Lathe machine
3. Manual crimping machine
4. Wire sorter
5. Running production line
6. Wire numeration

The wire cutting and crimping is done in the AWT section which is a part of the production
line. The cut wires are further sent to the wire sorters where they are sorted according to the
specified harness. The wires are further hand bound and assorted in the production line by
technicians.
The tools which are used in manual cutting and crimping are lathed and provided to the
technicians.

WEEK 2:
The job second week was to understand the innumerable defects that can occur during the
production.
The main defects occur at the automatic wire crimping and cutting stage and are listed as
follows:
Crimping defects:
1. Low core
2. Low insulation
3. No bell mouth
4. Up bend
5. Down bend
6. Terminal cut
7. Double crimping
8. Lock deform

Such defects should be identifies by the worker during the production itself and should be
separated from the good wires. It needed a keen eye to observe such defects and rectify it
on the spot which took several days to be proficient in.
WEEK 3 :
The job third week was to lay the hands on experience on the production line where we made
a full wiring harness from scratch.
It included the whole process starting from cutting and crimping the wores, sorting them into
appropraite wire sorters, then proceeding on to the assembly, where manual cutting is done,
then taping assortment of the harness, installing the connectors and recitfiers.
WEEK 4:
The final week was only for the submission of the work done. Each day the officials noted
each thing that we learnt including all the machinery and all the technical stuff. Finally the
H.R head Mr. Ashok Sharma reviewed our work and handed over our certificates.
 CHAPTER 4
TECHNICAL CONTENTS

NECCESSITY OF WIRING HARNESS IN A VEHICLE

What is a wiring harness :

A wiring harness is a system of wires designated to do a specific job in a vehicle’s electronic
System. The harness consists of crucial components like the ECU, MAP sensor, CKP sensor,
Temperature sensors, all bunched together as a single unit. These sensors and the ECU
Connect to the connectors provided on the vehicle. This harness is responsible for
Withdrawing information from the engine from the sensors, feeding it to ECU and then
Getting a suitable output from the ECU that regulates the performance of the engine. Thus it
Becomes very important for the wiring harness to work efficiently so that the vehicle can
Work properly and the engine can work with its maximum potential.

Components of a wiring harness:

Various components of a wiring harness listed below:
1. ECU: The ECU or the electronic control unit of a vehicle serves as the brain of the vehicle. It
is designed to do jobs from controlling the amount of fuel going into the combustion chamber
to controlling the lighting and infotainment system of the vehicle. A modern car can have up
to 100 or more ECU systems integrated into the vehicle all meant to do specific set of tasks.
The ECU is also known as the engine control module when it is specifically designed to do
jobs related to the engine. Without the ECU, it would be impossible for vehicles to run and
maintain an efficient working cycle and thus it becomes pone of the most important aspects in
the vehicles wiring harness.
2. CKP sensor: The CKP or the crankshaft position sensor is another important sensor in a
vehicle. It notes the angle of the crankshaft that is its position and inputs it into the ECU so
that it knows exactly where the piston is in the cylinder block and subsequently when to inject
fuel and when to initiate the spark which would combust the fuel.
3. TPS sensor:

STEPS IN PRODCUTION
1. Wire is crimped and cut in the automatic crimping and cutting device. It can be step
cut or terminal cut according to the needs.
2. Reels are paced in the spool covers taken up by the wire guides
3. It is fed into the Crimping machine
4. Simultaneously, a worker feeds the terminals into the terminal feed which punches the
terminals on the wires.
5. Wire seals are fed by hand time to time
6. Wires can be of variety of sizes and diameters.
7. Each technician notes down the required wire size from a given chart and feeds it into
the machine.
8. Crimped wires are then stacked and sent through the conveyor belt to the wire sorter.
9. The machine is set up differently for different needs of harnesses.
10. Workers again refer to a chart and sorts wire according to the specific wiring harness.
The wires are sorted according to the colour, rating and types.
11. The assembly table is a table consisting of jig like structures meant for holding the
wires in place while the worker assembles it.
12. In the initial assembly, the connectors are installed which were not done in the
automatic machine.
13. All the connectors are installed according to the specifications given by the companies
14. At a specific time, only a specific type of harness is produced, no other harness is
assembled that time.
15. After connecting the terminals, the still incomplete harness is sent for further
assembly where the wires are carefully selected and taped together to make sure the
harness is perfectly insulated.
16. After this process, the final covering of the harness is done to ensure resistance from
water and dust and so that the connectors don’t get damaged.
17. After the final assembly, the harness is sent for first technical inspection.
18. In the technical inspection, a device is present which checks for proper current and
voltage flow in the wiring harness.
19. If it encounters a problem in the harness, a beep sound is generated which notifies the
workers about the fault.
20. After the first technical inspection, the harness is sent for a final quality check where
all the connections, the terminals and the connectors are checked before being packed.
21. After the final quality check, the harnesses are packed and sent for shipping.

TECHNICAL INFORMATION ABOUT MACHINES

Automatic cutting and crimping machine:

The automatic wire cutting and crimping machine is used for the crimping process of the
wires i.e removing the insulated part from the wire from a specific point for attaching the part
to another wire, or a connector, or a terminal.

The wire is withdrawn by the wire guide and is fed into the crimping machine where it is
crimped. Further it is cut to an appropriate length. Terminals are attached and then sent
through the conveyor belt.
The image above shows the wires produced after cutting and crimping process where in the
terminals and the connectors are attached.
The above image shows a manual crimping machine.