1. Aditya Auto Products manufactures automotive components like window regulators, door latches, and cables. 2. The production process involves raw materials undergoing rolling, pressing, welding, and assembly into finished products. 3. Quality inspection and testing is conducted at various stages to ensure product quality meets standards before dispatch.

2. Introduction
Aditya Auto Products & Engineering India Private Limited is a privately owned and
professionally managed organization, engaged in the design, manufacture and supply of
systems & sub-systems to meet the requirements of the growing automotive industry.
This industry has started serving since 1999, they are partners to leading automakers and
conceptualize, design and deliver the global tier-1 auto suppliers all over the world and in
India. They work closely with them to provide products and solutions across the globe.
This industry is located at 13E, 13D, KIADB Industrial area Doddaballapura, Karnataka,
561203.
On 15th
of September 2018, the industrial visit was done by the students of 5th
semester
mechanical engineering, G M Institute of Technology, Davanagere.
Purpose of visit
To study about the Layout, Processes, Assembly, Manufacturing, Quality and Testing of
Auto Components.
Products manufactured in Aditya Auto Products:
1. Window regulators
2. Door latches and sub-assemblies
3. Window regulator motors
4. Head rests
5. Parking brakes
6. Connecting cables
7. Retention plates & Back plates
8. Strut Assembly
9. Over moulded connectors
10. Drum & Cable
11. Integrated harness
12. Power cords &
13. Other integrated products

3. FINISHED
PRODUCTS
RAW MATERIAL

4. Flow diagram of the process
(GRN)
Inlet
Pressing Unit
Inlet
Rolling Unit
Waste
Coating
Income Source
Different
Components
from
Different
vendors Non-
conformance
AreaIncoming Quality
Stores WeldingCable
Assembly Line
Window
regulator Motor
Coating
Finished
Dispatch
Validation
Raw Material

5. Description of flowchart
• Raw materials: The main raw materials are coiled steel sheets and sheet metals. These
raw materials are brought in large scale mainly from JSW. As per the requirement of the
production metal sheets are ordered and stored in advance from different venders. Further
these sheets are sent to the pressing and rolling units.
• Rolling unit:
In this unit the rolled coils are converted into Rail guiders which are used in the
window regulators. Under the rolling unit following operations are carried out.
➢ Roll forming:
In this unit, rolling involving the continuous bending of a long strip of sheet
metal (typically coiled steel) into a desired cross-section. The strip passes through sets
of rolls mounted on consecutive stands, each set performing only an incremental part
of the bend, until the desired cross-section (profile) is obtained. Roll forming is ideal
for producing constant-profile parts with long lengths and in large quantities.
For different models different rails are produced as per required dimensions. In this
process drilling a hole of required diameter is carried out.

6. ➢ Deburring:
After rolling process the sheets may contain some extra materials which are buried on
the surface. To make the surface softer. Deburring process is carried out in his unit.
➢ Embossing:
Sheet metal embossing is a stamping process for producing raised or sunken designs
or relief in sheet metal. This process can be made by means of matched male and
female roller dies, or by passing sheet or a strip of metal between rolls of the desired
pattern.
➢ Piercing:
Piercing is shearing processes in which a punch and die are used to modify webs. The
tooling and processes are the same between the two, only the terminology is different:
in blanking the punched out piece is used and called a blank; in piercing the punched
out piece is scrap.
➢ Notching:
Notching is a metal-cutting process used on Sheetmetal or thin bar stock, sometimes
on angle sections or tube. A shearing or punching process is used in a press, so as to
cut vertically down and perpendicular to the surface, working from the edge of a
workpiece.

7. • Pressing Unit:
Pressing is the process of placing flat Sheet Metal in either blank or coil form into a
Stamping press where a tool and die surface forms the metal into a net shape. The process
is usually carried out on sheet metal.
Pressing unit contains four different capacity machines, the capacities of the machines are
110, 160, 200 and 350 tons. The drive used to run these machines is hydraulic type.
Along with the press setup, three in one mechanism is used in three 350 and 200 tons
capacity machines. The feeds used are Roll feeding, straightening and crushing using
servo motors. The following processes are carried out in pressing unit (350 capacity
Machine).
1.Piercing 10.Coining
2.Cone forming (450
) 11.Excrusion (4mm)
3.Cone forming (90 0
) 12.Excrusio (6mm)
4.Cone Extruction 13.450
Bending
4.Cone Extruction 14.900
Bending
5.Excution Cutting 15.450
Side Bending
6.Profile Facing 16.900
Side Bending
7.Embossing 17.Coining
9.Excrusion 18.cut-off
• Scrap:
A small piece or amount of something, especially one that is left over after the greater
part has been used.
These waste material mainly, metal pieces from rolling & pressing unit are sent to
recycling process (scrap area).
• Coating:
The complete finished products from rolling & pressing units are sent for Metal Coating
to different vendors to avoid corrosion and rust the metals.
• Incoming Source:
Different components from different vendors are brought in and those components are
thoroughly inspected by Quality Department

8. • Quality Department:
The thorough examination and inspection of different components are done in three
stages.
➢ Visual Inspection:
The components are visually tested by inspector, either if the components seem to
be defect then they are sent to the non-conformance area or they are taken into
further inspection criteria.
➢ Dimensional inspection:
In this inspection the sample components are thoroughly compared with the
drawings, masterpieces and standard gauges. If they found any defects then they
are rejected, defects may include change in length, diameter angle and etc.
➢ Destructive Type inspection/Testing:
In this level Components are tested in highly sophisticated equipments to check
the varies material properties of the components, such as chemical composition
shear, tensile, compression, twist and etc.
NOTE: If any components are rejected under any of these inspection criteria,
these components are sent back to the vendors reporting the component rejection,
and suggest to overcome the failure. Further, from upcoming 3 lots of components
are inspected thoroughly from the particular vendor from whom the previous
components are failed.
This thorough inspection of components ensures the best quality of intake sources,
certified components are sent to Goods Receive Note (GRN)
GRN is generated as per required batches, then sent to the Store Room.
• Stores:
After receiving note from GRN the components are segregated and arranged as per the
below colour code of bin in which the components are kept (Example of the bin’s colour
code is shown below).
SL.NO MONTH COLOUR CODE
1 JANUARY
2 FEBRUARY
3 MARCH
4 APRIL
5 MAY
6 JUNE
7 JULY
8 AUGUST
9 SEPTEMBER
10 OCTOBER
11 NOVEMBER
12 DECEMBER
As per requirement, components are sent to assembly and welding unit for further
process. First In First Out principle is followed in the stores, it states that the successive
bins are used unless the previous bins are totally emptied.

9. • Joining Process:
Joining Processes are the processes that are used for joining metal parts and metal fabrication
work. in the joining process it may be categorised as reverting, welding, clinching.
o clinching: Clinching or press-joining is a bulk-sheet metal-forming process aimed
at joining thin metal sheet without additional components, using special tools to
plastically form an interlock between two or more sheets. The process is generally
performed at room temperature but in some special cases the sheets can be pre-
heated to improve the material ductility and thereby avoid the formation of cracks
during the process.
o Riveting: Riveting is a forging process that may be used to join parts together by
way of a metal part called a rivet the rivet acts to join the parts through adjacent
surfaces. A straight metal piece is connected through the parts. Then both ends
are formed over the connection, joining the parts securely.
there are different riveting processes are carried out in the various assembly lines,
few are mentioned below:
▪ Black Roller riveting
▪ White Roller riveting
▪ Big Riveting
▪ Retention Plate riveting
▪ Back Plate riveting
o Welding: spot welding is "the welding of overlapping pieces of metal at small
points by application of pressure and electric current." Electrodes seated in a weld
head are brought to the surface of the parts to be joined and force (pressure) is
applied. Copper is used as consumable electrode, after certain cycle welding
electrodes are filed to obtained the perfect welding. welded joints are inspected for
proper quality level then it is sent for coating to avoid corrosion of welded area.
At last it is sent to assembly line.
• Assembly line:
Assembly line mainly includes the assembly of AISIN Window Regulator, Actuators,
Scorpio latch, TATA Winger Latch, and Cable linings.
The Poka-Yoke method is used in the workstation of the assembly lines. Poka-Yoke is
the Japanese approach to mistake proofing in aspects of manufacturing, customer
service, procurement, etc. It employs visual signals that make mistakes clearly stand
out from the rest, or devices that stop an assembly line. This helps to overcome the
issues of mal-assembling of components.
The below pie charts and workstation diagram show the cycle time and sequence
operations of every assembly line of respective regulators and latches.

10. AISIN Window Regulator line
The Above Workstation diagram shows the arrangement of machines in AISIN window
regulator assembly line that carryout respective operation Witten in the pie chart.
17
18
16
16
16
14
17
Cycle Time
Black Roller Reveting Nut Clinching White Roller Reveting Big Reveting
Long Chanel Bending Fire Wall (Inspection) Packing & Batch Coding

11. Actuator Assembly line
The Above Workstation diagram shows the arrangement of machines in Actuator assembly
line that carryout respective operation Witten in the pie chart.
25
24
35
35
28
10 6
Cycle Time (seconds)
Clutch and Pinion Assembly Lower Case Assembly
Upper Case Assembly Final Assembly
Screw Fixing Testing
Batch Coding

12. Scorpio Latch line
The Above Workstation diagram shows the arrangement of machines in Scorpio latch
assembly line that carryout respective operation Witten in the pie chart.
35
12
12
6
6
3
3
630
12
40
10 10
Cycle Time (seconds)
Housing Assembly Retentation Plate Reveing
Outside Lever Assembly Back Plate Assembly
Back Plate Assembly (a) Release Link Assembly
Back Plate Reveting Final Assembly
Actuator And Dapmer Pad Assembly Batch Coding
End Of Function (EOL) Fire Wall (Inspection)
Packing

13. Scorpio Window Regulator
The Above Workstation diagram shows the arrangement of machines in Scorpio Window
Regulator assembly line that carryout respective operation Witten in the pie chart.
8
20
24
14
32
8
17
12
Cycle Time (seconds)
Pully Reveting C D Checking
Carrier Plate Assembly Motor Fixing
Winding End Of Line (EOL)
Fire Wall (Inspection) Batch Coding & Packing

14. TATA Winger latch
The Above Workstation diagram shows the arrangement of machines in TATA Winger
assembly line that carryout respective operation Witten in the pie chart.
• End Of Line:
➢ Red-bin: after the completion of assembling of all the components, At End Of Line
(EOL) inspection of assembled component is done by using computer, experts and
various equipments, if there is malfunctioning of assembled product is noticed
(buzzing). Then these products are dropped in Redbin. The reason for the
malfunctioning of the product is identified to overcome such issues which may be seen
in further days.
➢ Batch Coding & Packing: It is the process of printing of information on the surface of
any component, the information may be Made, Year of made, Capacity and etc. later the
components are sent for packing. These packed components are stored in finished
product stores and they are dispatched to the customers.
20
40
8
8
24
Cycle Time (seconds)
Reveting Housing End Pin Pressing
Crimping Lever Inspection Fire wall & Packing

15. Images of finished products:
Actuator
Bracket Assemblies
Cross Arm

16. Compact Latch Drum Cable
Retention Plate & Back Plate
Window Regulator
Double lift Image Source:
Company’s Website

17. Product Validation lab:
Aditya Auto`s R&D Centre in Doddaballapura, Bangalore includes a Validation Lab for
comprehensive Product Validation.
To develop any new component, samples of that component are prepared in the R&D
section. These samples are sent to the customers, based on the customer’s appraisal mass
production of that particular component will be started.
In this lab the product’s performance, quality, life cycle is tested in various environmental
conditions.
In this lab the following tests are carried out:
1. Manual Endurance Test Rig: This equipment is used to check the performance of
manual window regulator by applying different loads on it. The load is applied on the
drum cable or cross arm based on the window regulator being tested.
2. Universal Testing Machine: A universal testing machine is used to test the tensile
stress and compressive strength of materials. It is named after the fact that it can
perform many standard tensile and compression tests on materials, components, and
structures.
3. Shower Endurance Test Machine: It is an enclosed machine, in which artificial rain
is made, the properties and performance of different window regulators and door
latches are tested under such a condition, they check weather the components of the
different assemblies undergo rust, work efficiently and to check at what duration the
rust occurs during the test.
4. Dust Test Chamber: It is an enclosed chamber used to create dust field in which sand
and dust stream is let in to hit the different assemblies to be tested, dust and sand test
are mainly performed to test the functioning of electric components under such a
condition.
5. Heat Chamber: This equipment is used to create and maintain temperature range 900
C to 1500
C, in which different window regulators and door latches tested under
running and idle conditions to check the performance under such a condition.
6. Environment Chamber: An environmental chamber, also called a climatic chamber,
is an enclosure used to test the effects of specified environmental conditions on
components (small plastic components), these components are subjected to the
temperature range of -140
C to 400
C later the properties such as brittleness, elasticity,
toughness and stiffness.
7. Salt Spray Test Chamber: The salt spray test is an accelerated corrosion test used to
measure the comparative corrosion resistance of materials exposed to a salt spray or
salt fog at high temperature.
8. Vibration Test: In this test, the assembly of different window regulators and door
latches are fixed to the vibrating body. This test is done to check the sustainability of
the components when the car is on high speeds and when running on rough roads.
9. Hood Latch Endurance Test: Endurance testing refers to tests typically done to find
out whether an application of hood latch can withstand the processing load. It is
expected to have to endure for a long period. This test is conducted by fixing a latch to
a body such that, it keeps on locking and unlocking for given number of cycles.

18. 10. ANECHOIC Test: It is the highly sound constrained room, in which the automatic
window regulators are run for predefined cycles. This test is carried out to check
whether the motor makes needless (unnecessary) sounds or releases needless magnetic
flux and etc.
Description about Window Regulator and Door Latches:
Window regulator:
The mechanism that moves the window up and down is called the window regulator.
There are two types of window regulators, Automatic or Power window regulator and
Manual window regulator.
About Automatic or Power Window regulator:
DC Motors are used to drive the motion of the window shield. Having a power
window in the vehicle provides great convenience. The window regulator allows the
passenger to raise or lower the window at their own will. This window regulator
performs the process automatically at a touch of the button. The below pictures show
the automatic Window regulators.
About Manual Window Regulator:
A manual window regulator is the most basic of window lifting mechanisms. It always
has some type of handle sticking through the door panel that regulates the up and down
motion of the glass window. A manual window regulator in which a pinion rotatably
carried by a window glass and driven by a manual handle is held in engagement with a
rack which is fixed to extend in the direction of movement of the window glass, so that
a manual rotation of the handle causes the pinion to roll along the rack in meshing
engagement therewith so as to drive the window glass thereby opening and closing a
window. The transmission of rotation from the handle to the pinion is affected through
a tape stretched between a drive gear rotationally driven by the handle and driven gear
coaxially fixed to the pinion.

19. Latches:
Most vehicle doors are secured closed to the vehicle body with latches which may be locked
to prevent unauthorized access from the exterior. There are a variety of car door locking
systems. Door locks may be manually, or automatically operated, and may be centrally or
individually operated. Also, they may be operated by remote control, with the transmitter
often integrated into the main vehicle access / ignition key. Door switches are simple on/off
mechanisms connected to the interior light (dome light), and may also be connected to a
warning light, speaker or other device, to inform the driver when the door is not closed. The
door light is standard equipment on all cars.

20. Image Source:
Internet

21. Brand Customers of Aditya Auto products

22. We are grateful to the Heads of Aditya Auto Products &
Engineering (I) Pvt Ltd, who facilitated our visit and
permitted us to be in their premises.
We thank our Head of Department, Department of
Mechanical Engg
Guided By:
Mr. Rajkamal (HR Dept)
Mr. Murali (Production Quality Dept)
Mr. Harish (Production Dept)
Mr. Sunil (Quality Dept)
Reported By:
Mr. Abhishek Patne
Mr. Adarsh S Mathad
Mr. Anuroop R
Mr. Darshan D
Mr. Hussain S I

23. Permission letter

24. Group Photo
Thank you