The document discusses two projects undertaken by Nikhil Srivastava at Hella India Lighting: 1) Developing an online data monitoring system to track production data from assembly lines and provide real-time access to reports. 2) Eliminating re-threading work required on 7-inch round headlamps by changing from spot-welded studs to hexagonal screws, validated through testing and customer approval. The project standardizes the new design and provides benefits like reduced rework and improved productivity.

1. HELLA INDIA LIGHTING
NH22, Bhagat Singh Nagar, Derabassi, Punjab-140507
A PROJECT REPORT ON
“ONLINE DATA MONITORING”
&
“STUD RE-THREAD PROCESS ELIMINATION FROM THE 7 inch
ROUND HEADLAMP”
Submitted by
NIKHIL SRIVASTAVA
PRODUCTION DEPARTMENT

2. ACKNOWLEDGEMENT
 I would like to express my deepest sense of gratitude for the people who
have guided me and constantly been with me throughout my training
tenure here. Without their guidance, I could not have had accomplished
all that has been presented hereafter.
 I would first of all like to thank Mr. Manoj Singh, Operation Head,
Hella India Lighting, for allowing me to undergo training at this
prestigious firm.
 I would like to take this opportunity to thank Mr. Mayank Garg
(Deputy Manager ,Production) for having provided me with the
wonderful and conductive environment to work in. They have been ever
helpful and supportive.
 With profound sense of gratitude I acknowledge my sincere thanks to our
project guide Mr. Rajdeep Prasad Pant (Manager, Operational
Excellence & New Projects) for providing the facilities and incessant
encouragement and adding new dimension to my knowledge in making
the task successful. I am very grateful to him for his kind help, skilled &
talented suggestion extended to me time to time.
 Special thanks to Mr. Ambrish Rai and Mrs. Aditi Sharma for
providing the guidance throughout the training tenure.

3. CERTIFICATE
This is to certify that Nikhil Srivastava from Production
Department has successfully completed the project given to him
during the training at Hella India Lighting, Derabassi plant,
Punjab.
The project was on:
 ONLINE DATA MONITORING SYSTEM
 Stud re thread process elimination in cut doom in 7 inch
Round Headlamp assembly line
Ambrish Rai Manoj Singh Mahender Singh
Deputy Manager HOD, Operation Plant Head

4. Introduction to Hella
Hella KGaA Hueck & Co. (the company's preferred spelling: 'HELLA') is an internationally
operating German automotive part supplier with headquarters in Lippstadt, North Rhine-
Westphalia. The company develops and manufactures lighting and electronic components
and systems for the automotive industry, and also has one of the largest trade organizations
for automotive parts, accessories, diagnosis and services within Europe.
Hella is one of the top 50 global automotive suppliers and belongs to the 100 largest
industrial companies in Germany. Worldwide, about 30,700 people are employed in more
than 100 locations in over 35 countries. Thereof work more than 5,800 engineers and
technicians in research and development.
Products & Services
The main businesses of Hella can be divided into three segments:
Automotive, Aftermarket and Special Applications. The Automotive Segment consists of the
development, production and marketing of lighting and electronic components and systems
both for vehicle manufacturers and for other suppliers. In the Aftermarket Segment the
company develops, produces and markets products for the independent aftermarket and for
garages. The Special Applications Segment serves target groups ranging from the producers
of construction machinery through boat builders right up to municipalities and energy
suppliers by providing them with innovative lighting and electronic products.
In the division lightning, Hella develops and manufactures headlamps, refulgence and
interior lighting. Recent innovations include headlights that adapt to the prevailing driving
and weather situation. Headlamps with LEDs as light sources for low beam and high beam
are already produced in series. An example would be the beams in the Cadillac Escalade
Platinum. As daytime running lights, they are in many middle and upper class vehicles often
been voted as standard. Camera-based driver-assistance systems provide the next level of
innovation. They create new opportunities for optimum light distribution, depending on the

5. traffic situation. For this reason, the company took over AGLAIA, the Berlin-based specialist
for visual sensor systems, in 2006.
Systems to increase efficiency and safety and comfort systems dominate the electronic
product portfolio. These include Data-enabled electronic control units and roof modules as
complex light-electronic modules, as well as Vehicle access and driving authorization.
Modules for power management to optimise the energy balance of the electrical system and
improve the battery charge balance. Innovation and growth area are electronic driver
assistance systems. With infrared (lidar), 24-GHz radar and camera and ultrasonic sensors,
Hella offers here a powerful technology portfolio and the corresponding series experience.
Another important business segment are electronic components such as position sensors,
actuators, vacuum pumps and wash water systems.
Hella is one of the world's largest companies selling automotive parts and accessories with its
own sales companies and partners in more than 100 countries. Thus Hella supplies the
automotive aftermarket and garages with comprehensive and continually growing parts
ranges in the core areas of lighting, electrical, electronics and thermal management. In
addition, the aftermarket and garages are provided with effective sales support and expert
technical service. In 2005, the joint venture Behr Hella Service was established for the
collective processing of the global independent aftermarket for vehicle air conditioning and
engine cooling.
Through strategic partnerships with companies such as Behr and Plastic Omnium, Hella is
well established in other areas, such as front-ends (joint venture HBPO GmbH, Lippstadt),
and climate control systems and engine cooling (joint venture BHTC GmbH, Stuttgart).
In addition to car accessories designed for civilian cars, Hella also manufactures special
signaling for official emergency vehicles. These include flash beacons and beacons (in blue
and yellow), Visual Warning Systems (OWS) and all-round sound combinations (RTK).
These are compact roof structures that combine the two blue lights, sirens, and possibly
several additional issues. Police, emergency services, fire departments, agencies for technical
aid and numerous other operators of deployment and use special vehicles use them. Also part
of the product range of authorities, are headlights on the bumper and some other products
(e.g., covert special signal for civilian emergency vehicles).
The New Zealand subsidiary, Hella New Zealand Limited, provides the Hella marine lights
program for marine use. These include not only the mast and interior lighting with LED
technology and lighting systems for boat trailers.

6. In the 'Industries' segment Hella transfers existing technologies from the automotive sector to
new target groups. As a first pilot project some cities in China have been provided with these
new street lights. Another project is the LED-airport beacons, which can be found at the
airports of Luxembourg, Paderborn/Lippstadt and Stavanger. Despite, new components for
LED-interior lighting are being offered.
In 2012 Hella started a cooperation with the Chinese automobile manufacturer BAIC to
develop and produce light systems, particularly designed for the Chinese market.

8. Introduction
Online Data monitoring system deals with collection of production data from the assembly
lines and molding through the test module at each line which are retrieved by server module
and thereby stored in cloud storage. These data can be easily accessible through cloud on
computers and linked with telegram as well so that concern department can be made aware of
the downtime at very instant of time.
Features
 Cloud based
o Access the Factory Dashboard, Production Charts, Downtime Reports, from
anywhere, any device (Laptop, tablet or phone) with an internet connection
o Real Time Live – less than 10 second delay between shop floor and
dashboard, even when thousands of miles away
 Google Drive Based
o The most open software architecture in the world, so no dependence on one
particular software developer
o All data stored on Google Servers – so no server downtime and no risk of data
loss
 Computer Based
o Tracking software runs on a simple Windows XP, Vista, 7 or 8 PC, with no
special performance requirements
o No need to invest in proprietary hardware and be dependent on the software
company
o In case of computer failure– time to set up on a fresh computer is less than 15
minutes
 Based on the latest Atmel AVR microcontroller technology developed at the
Norwegian Institute of Technology, Trondheim, Norway

9. o Best computing performance, much higher than PLCs, so one controller can
capture entire factory
o Very power efficient, so no separate power supply needed
o Code efficient architecture, so lowest cost of programming and set up
 Push in terminals – very easy to wire by your operators – no special electrical
engineer required – very tight and immune to vibrations – Wago, made in Germany,
used by the Deutsche Bahn (German Railways)
 USB Based – no need to invest in serial/parallel port wires and hubs – only one USB
socket required
 Simplest 2 core wires for all connections

10. Standard
2 Core
Wire
Standard
USB Wire
Internet
Connection

11. Optional:
Android Tablets at each line
Secondary Monitors to Display Down Time Events

12. Software Description
Reports accessible on cloud:
 Dashboard Module: To ensure hourly production targets are met and if not, action can
be taken on RealTime Basis. On one screen:
o Realtime OK/DOWN status of all machines
o Minute by minute production target to achieve hourly target vs actual
production (deviation from target takt time)
o Recent hours production vs hourly target (auto adjusting for lunch and tea
break) (last few hours – can be configured)
o Coloured Graphical representation
o Optional: Intelligent pattern recognition system to determine hourly
production targets and downtime thresholds based on past data
 Machine wise recent (last few hours – can be configured) production report and
charts (Hourly and Minute by Minute)
 Machine wise historic (last 10000 pieces) production report and charts (Hourly and
Shift wise), Uptime and Production Efficiency Reports based on Hourly Targets
 DownTime Report and Pareto Charts (Weekly and Monthly) (last 30000 events on
cloud and infinite data possible using Ms Excel or OpenOffice)
Manual data entry directly from Line using android tablets:
 WorkOrder Selection Module
o Line Men select production order/work order from line using android tablet
and StartTime is recorded
 DownTime Reason Selection from Line
o DownTime event starts (Line is down for number of seconds exceeding
defined threshold limit (unique for each job))
o Line men select Reason (multiple choice format) using android tablet

13. o Downtime duration, Timestamp, reason recorded in Downtime Log Report
o Reason selection possible upto 2 minutes after downtime event ends
o Reason becomes default reason for DownTime events upto 5 minutes in
future, however, different reason can be chosen using tablet
o DownTime Reason Sheet will be used to alert (visual only, no sound) relevant
departments of DownTime event on their laptop/desktop computers,
secondary monitors, or tablets
 Rejection Module:
o Entry of partwise rejection and rework at the time of changeover to new
part/mould

14. Implementation

16. The recorded pulses passed through the auxiliary router are received at the Server end
through the Receiver antenna & uploaded in the Server computer.
Live Monitoring

17. Tablet View

18. Data Hourly
OEE Hourly

19. OEE Graphs
Hourly Production Report with graphs
Hourly Production graph for CTL

21. Introduction
7” Round headlamp is the assembly line where variants of round headlamps for
Mahindra & Mahindra, Ashok Leyland and markets are assembled. Some of the
variants consist of cut doom which requires pre-processing at the press shop for
spot welding of studs. Each cut doom consists of three studs which are welded
at the press shop in plant are thereby painted and send to the assembly line for
assembly. These variants are produced from last 15-20 years for the same
customers. During the spot welding of the studs at the press shop 100% rework
has to be done at the assembly line for the removal of the spatter.This project
emphasis on the complete removal of the rework on the assembly line of
rethreading.
Causes from Brainstorming
 Unskilled operator.
 New operator.
 High current in the machine.
 Less surface contact between cut doom and screw
 High pressure of the machine.
 More ESO (Electro Stock Out): Distance between the contact tip to the
work piece.
 Clearance between the screw outer diameter and cut doom hole
diameter.
 Screw head thickness less.

22.  Projection point insufficient.
 Cut doom thickness less.
 Magnetic flux produced is less.
 Rise in water temperature of the electrode (water as coolant)
 Electrode material.
 Screw material.
 Cut doom material.
 Process i.e. Projection welding
Cause & Effect Diagram

23. Validation of the probable Root Causes
S.No Cause Validation Method Result
1 Unskilled Manpower Operator skilled, Have>18 Years
experience
Invalid
2 New Operator Operator skilled, Have>18 Years
experience
Invalid
3 High Current Checked, Found as per SOP Invalid
4 Less Surface contact Checked, Contact OK Invalid
5 High Pressure Checked, Found as per SOP Invalid
6 ESO More Checked Visually, Found OK Invalid
7 Depth of the electrode
more
Conducted trails with less depth of the
electrode. No effect (Spatter still
found)
Invalid
8 More Clearance
between Cut doom
housing and stud
locating diameter
Against 0.2 mm clearance 1 mm Valid

24. S.No Cause Validation Method Result
9 Inefficient projection
points on the screw for
Projection welding.
Conducted trails and found sparks
generation on welding visually
Valid
10 Cut doom thickness
less
Checked, Found OK Invalid
11 Inefficient cooling of
the electrode when in
operation.
Rise in the temperature of the water
acting as coolant, Found OK
Invalid
12 Magnetic flux
generated by the
machine
Checked, Found OK Invalid
13 Screw material Checked, Found as per SOP Invalid
14 Electrode material Found as per SOP Invalid
15 Cut doom material Checked, Found as per SOP Invalid
Conclusion- All valid causes are root causes

25. Alternatives Consideration
S.No Alternatives Result
1 New sample screw used.
 With similar diameter (6mm) .
 With out necking.
Spatter found and due to
inefficient projection
weld breaking found on
all the pieces.
2 Thickness of the head of the new sample screw
reduced (equal to the original screw).
Spatter observed on the
threads of the cut doom.
3 New hexagonal screw M6 (6X24) full threaded taken
for experiment.
No spatter found on the
threads during the trials.

26. In house Fitment check of cut dooms
H/L containing New Hex screws M6
The OK sample of the new hex screws are assembled to the
headlamp and sent to the customer end for approval. Below
pictures are received from the customer end which verifies their
approval regarding change in the screw.

27. Standardization
 New drawing to be updated.
 Bill Of Material (BOM) to be updated by raising Engineering Change
Note (ECN)
 Work Instructions (WI) to be updated
 Control Plan to be update
 Incoming quality Inspection sheet to be made.

28. Benefits from the Project
Tangible benefits (Quantitative)
 Zero inventory between two stations
 100 % rework eliminate from the line
Intangible benefits (Qualitative)
 People motivation, Mind set to think out of box
 Suggestion drive created
 Internal Communication improved
 Increased the morale of employees
 Learning new and technical things