SUMMER TRAINING REPORT

Submitted in partial fulfillment of the

Requirements for the award of
Degree of Bachelor of Technology
(Electrical & Electronics Engineering)

Submitted By
Name: Deepanshu
University Roll No.: 02215004922
Semester/Branch: 5th semester/ EEE

SUBMITTED TO:
Department of Electrical & Electronics Engineering
Maharaja Surajmal Institute of Technology, New Delhi (AFFILIATED TO
GURU GOBIND SINGH INDRAPRASTHA UNIVERSITY, DELHI) NEW
DELHI – 110053

2022-2026
 DECLARATION

I hereby declare that the Industrial Training Report on Name of the Department/ Section,
The industry is an authentic record of my work as requirements of Minor/ Major Industrial
Training during the period from 01.07.2024 to 10.08.2024 for the award of the degree of
B.Tech. (Electrical and Electronics Engineering), Maharaja Surajmal Institute of
Technology, New Delhi, under the guidance of Vivek Kumar.

Deepanshu
02215004922
Date: 23.08.2024

It is certified that the above statement made by the student is correct to the best of
our knowledge and belief.

Examined by:

(Signature)
Name of Faculty Facilitator

(Signature)
Head of Department
 ACKNOWLEDGEMENT

First and foremost, I wish to express my sincere thanks and gratitude to my

esteemed Mentor “Name of Industry Supervisor” who has contributed so
much to the successful completion of my Industrial Training with his
thoughtful reviews and valuable guidance.

Next, I would like to tender my sincere thanks to “Prof. Name of HOD”

(Head of Electrical and Electronics Engineering Department) for his/her
cooperation and encouragement.

Deepanshu
02215004922
 ABOUT THE COMPANY

Samvardhana Motherson International Ltd (SMIL), formerly Motherson Sumi

Systems Ltd, is a leading Indian multinational corporation that manufactures a
diverse range of automotive components. Headquartered in Noida, India, SMIL
has grown to become one of the top global suppliers of automotive
components, serving some of the biggest names in the industry such as Audi,
Volkswagen, BMW, and Ford.

Founded in 1986, SMIL’s core expertise lies in the manufacturing of wiring

harnesses, plastic components, rearview mirrors, and a wide array of interior
and exterior automotive parts. The company is known for its commitment to
innovation, quality, and sustainability, with over 230 manufacturing facilities
spread across 41 countries. SMIL continues to expand its footprint in the global
automotive market by focusing on cutting-edge technology, electric vehicles
(EVs), and lightweight solutions to meet the evolving needs of the automotive
industry.
 TABLE OF CONTENTS

1. Introduction
2. Formal Training Provided
3. Industrial Training
○ Objectives
○ Tools & Technology Used
○ Techniques Studied
○ Software and Tools Used
○ Highlights of Training Exposure
4. Problem Identification/Case Study
5. Recommendations
6. References
7. Data Sheet
8. Appendices
List of Tables

Table 1: SMIL Manufacturing Facilities

Table 2: Wiring Harness Components and Specifications

Table 3: Materials Used in Plastic Component Manufacturing

Table 4: Analysis of Rearview Mirror Design Elements

List of Figures

Figure 1: Wiring Harness Layout in Passenger Cars

Figure 2: Injection Molding Process for Plastic Components

Figure 3: Rearview Mirror Assembly Process

Figure 4: SMIL Manufacturing Plant in Noida

Abbreviations and Nomenclature

SMIL: Samvardhana Motherson International Ltd

OEM: Original Equipment Manufacturer
CAD: Computer-Aided Design
CAE: Computer-Aided Engineering
EV: Electric Vehicle
QC: Quality Control
ABS: Acrylonitrile Butadiene Styrene (Plastic)
Chapter 1: Introduction

1.1 Overview of the Report

The objective of this internship report is to document the work and learning
experiences gained during my summer internship at Samvardhana Motherson
International Ltd (SMIL). The internship focused on analyzing and
understanding key automotive components, specifically wiring harnesses,
plastic parts, and rearview mirrors used in passenger cars. These components
are essential for vehicle functionality, safety, and user experience.

The internship provided me with the opportunity to gain hands-on experience

in the production environment of a leading automotive component
manufacturer. I was exposed to various departments, including design,
manufacturing, and quality control, and I was able to observe the intricate
processes involved in the development of automotive parts. This report will
highlight the objectives, tools, and technologies used, techniques learned, and
problems identified during my internship. It will also include recommendations
for improving certain processes based on my observations.
Chapter 2: Formal Training Provided

2.1 Overview of Formal Training

At the beginning of my internship, SMIL organized several formal training
sessions to ensure that interns had a clear understanding of the company’s
operations, safety protocols, and manufacturing processes. These sessions were
aimed at providing a theoretical foundation before transitioning to practical
work in the different departments.

2.2 Training Sessions

2.2.1 Introduction to Automotive Components

This session provided an overview of the various components manufactured at
SMIL, including wiring harnesses, plastic components, and rearview mirrors.
The significance of each component was explained in terms of its role in the
overall functioning of a passenger car.

2.2.2 Safety Protocols

Safety is a top priority at SMIL, and this session focused on the company’s
safety guidelines and procedures. Interns were trained in the use of Personal
Protective Equipment (PPE), emergency response protocols, and the
importance of maintaining a safe work environment.

2.2.3 Manufacturing Processes and Technology

This session introduced us to the various manufacturing processes used at
SMIL, such as injection molding, wire cutting, and precision assembly. We
were also introduced to the advanced tools and machinery used in the
production of automotive components.

2.2.4 Quality Control and Standards

Quality control is a critical aspect of automotive manufacturing, and this
session highlighted the importance of maintaining high standards to meet OEM
requirements. We were taught the basic principles of quality control, including
testing techniques and the use of specialized equipment to ensure product
reliability.

2.2.5 Lean Manufacturing Principles

The final session focused on lean manufacturing principles, including concepts
like Just-In-Time (JIT), waste reduction, and continuous improvement
(Kaizen). The session provided insights into how SMIL optimizes its
production processes to minimize waste and maximize efficiency.
Chapter 3: Industrial Training

3.1 Objectives of the Training

The primary objective of my industrial training was to analyze the production
processes of three key automotive components: wiring harnesses, plastic
components, and rearview mirrors. The goal was to understand the
technologies used in their manufacture, the quality control measures
implemented, and how these components contribute to the overall vehicle
design.

3.2 Tools and Technology Used

3.2.1 Wiring Harness Manufacturing

● Wire Cutting Machines: Automated machines used to cut wires to
precise lengths.
● Crimping Tools: Used to attach terminals and connectors to the
wires.
● Testing Equipment: Used to ensure the wiring harness is functioning
properly before it is shipped to the OEM.

3.2.2 Plastic Component Production

● Injection Molding Machines: These machines are used to
manufacture plastic parts such as dashboards and door panels by
injecting molten plastic into molds.
● Material Handling Equipment: Various tools and machines are used
to handle the raw plastic materials (e.g., ABS and polypropylene)
and ensure proper quality.
3.2.3 Rearview Mirror Assembly
● Precision Tools: Tools used to assemble the mirrors and adjust them
to meet the required specifications.
● Computer-Aided Design (CAD) Software: Used to design the
mirrors and ensure they meet ergonomic and safety standards.
● Automated Inspection Systems: Ensure the accuracy and
functionality of each rearview mirror.

3.3 Techniques Studied in Different Departments

3.3.1 Wiring Harness Department

The wiring harness is a critical component that connects various electrical and
electronic systems in a vehicle. In this department, I learned about the
following:

● Wire Cutting and Assembly: Wires are cut to the required length and
assembled with connectors and terminals.
● Crimping and Soldering: Terminals are crimped onto the wires, and
in some cases, soldering is used for a more secure connection.
● Quality Testing: The wiring harnesses undergo electrical testing to
ensure there are no defects and that they function properly within the
vehicle’s electrical system.

3.3.2 Plastic Component Department

In the plastic component department, I gained an understanding of the injection
molding process, which is used to produce various plastic parts for the car's
interior and exterior. I learned the following:

● Material Selection: Different types of plastics, such as ABS and

polypropylene, are chosen based on their strength, durability, and
weight.
 ● Injection Molding Process: Molten plastic is injected into a mold
cavity where it cools and hardens into the desired shape.
● Defect Analysis: Defective parts are identified and rejected based on
factors such as warping, shrinkage, or poor surface finish.

3.3.3 Rearview Mirror Department

In the rearview mirror department, I observed the production and testing of
side mirrors and rearview mirrors used in passenger cars. I learned the
following:

● Design and Ergonomics: The design of the mirrors is crucial for

ensuring proper visibility for the driver. CAD software is used to
create precise designs.
● Assembly Process: The mirrors are assembled using precision tools
and automated systems to ensure that they meet safety standards.
● Quality Control: Each mirror undergoes rigorous testing to ensure
clarity, alignment, and durability before being shipped to the OEM.

3.4 Software and Tools Used

During the internship, I had the opportunity to work with various software and
tools that are commonly used in the automotive industry. Some of the key
software and tools included:

● Computer-Aided Design (CAD) Software: Used to create 3D models

of components such as wiring harness layouts and rearview mirror
designs.
● Computer-Aided Engineering (CAE) Software: Used for simulations
and testing of automotive components to ensure they meet safety and
performance standards.
● Testing Equipment: Electrical testers, vision inspection systems, and
other testing tools used to ensure product quality.
3.5 Highlights of Training Exposure
● Hands-on Experience: I gained practical experience in the assembly,
testing, and quality control of wiring harnesses, plastic components,
and rearview mirrors.
● Cross-Departmental Learning: I was able to work across multiple
departments, gaining insights into various aspects of automotive
component manufacturing.
● Understanding Industry Standards: I learned about the stringent
quality standards that must be adhered to to meet the demands of
leading OEMs.
Chapter 4: Problem Identification/Case Study
During my internship, I identified a few challenges that could impact the
production efficiency and quality of automotive components at SMIL. These
challenges are discussed below, along with possible solutions.

4.1 Problem Identification

4.1.1 Wiring Harness Quality Control Issues

One issue observed in the wiring harness department was related to occasional
defects in crimped connections. Defective crimping can lead to poor electrical
connections, which could affect the vehicle's performance.

4.1.2 Plastic Component Defects

In the plastic component department, warping and shrinkage were occasionally
observed in parts such as door panels and dashboard components. These
defects can compromise the structural integrity and aesthetic appeal of the
vehicle's interior.

4.1.3 Rearview Mirror Assembly Time

The assembly of rearview mirrors involved several manual steps that increased
the production time. Although the quality of the final product was high, the
manual assembly process could be streamlined to improve efficiency.

4.2 Case Study: Reducing Wiring Harness Defects

During my internship, I participated in a project aimed at reducing wiring
harness defects, particularly those related to crimping. We identified that the
issue was often caused by inconsistencies in the crimping process. By
introducing more stringent quality checks and automating certain steps in the
crimping process, we were able to reduce defects by 10%.
Chapter 5: Recommendations
Based on my observations and learning during the internship, I would like to
suggest the following recommendations for improving production processes at
SMIL:

5.1 Enhanced Automation

Introducing more automation in the assembly of wiring harnesses and rearview
mirrors could help reduce human error and improve production efficiency.
Automated crimping machines and robotic arms for mirror assembly could
speed up production and ensure more consistent quality.

5.2 Continuous Material Research

To address the issue of warping and shrinkage in plastic components, SMIL
could invest in research on advanced plastic materials that offer better stability
under high temperatures. This would help in producing more durable and
defect-free parts for vehicle interiors.

5.3 Improved Employee Training

Providing ongoing training for employees, especially in the use of advanced
tools and technologies, would improve efficiency and ensure that the company
maintains its high-quality standards. Regular workshops on lean manufacturing
principles could also help employees find new ways to reduce waste and
improve productivity.
 APPENDICES

The Wiring Harness System Used In A Passenger Car

Diagram of Plastic Components like dashboards, door
panels, and bumpers.
 Photograph of Rearview Mirrors

The manufacturing process of wiring harness

 REFERENCES

1. Samvardhana Motherson International Ltd. (2023). “Company

Overview.” Retrieved from SMIL’s official website.
2. “Injection Molding Techniques in the Automotive Industry.”
Journal of Automotive Manufacturing, 2023.
3. “Wiring Harness Production and Quality Control.” Automotive
Engineering Review, 2023.
4. “Rearview Mirror Design and Ergonomics.” Automotive
Components Journal, 2023.