3. Roots Industries India Ltd. is a leading manufacturer of
HORNS in India and the 11 th largest Horn
Manufacturing Company in the world.
Headquarter is at Coimbatore - India, ROOTS has
been dominant player in the manufacture of Horns and
other products like Castings and Industrial Cleaning
Machines.
Since its establishment in 1970 ROOTS has had a vision
and commitment to produce and deliver quality
products adhering to International Standards.
4. REDUCTION OF OPERATOR
INCREASE THE PRODUCTIVITY
TIME REDUCTION
SKILLED OPERATOR IS NOT NECESSARY
SEMI AUTOMATIC OPERATION
INTERCHABILITY
COST REDUCTION
5. Two operators are required to operate the two
fixtures which involves the assembly of the
diaphragm and for measurement of the height of the
armature rod
This causes a time delay in the manufacturing
because process is done manually .
Combining both the process will increase the
efficiency and reduce the work load.
Only skilled operator can operate .
6. On account of the time, it takes some extra ideal time
such as component movement from one station to
another station , loading, unloading.
Since the operation is performed manually ,the labour
spend much time to correct the height with the help of
dial gauge and screw driver.
These extra time can be eliminated by the proposed
methodology.
7. OPREATIONS NO OF
OPERATORS
AVERAGE
TIME (sec
)
DELAY
TIME(sec)
SPOOL ASSEMBLY LOCKING , POINT
AND TUNING SCREW ASSEMBLY
1 15.16 -
TERMINAL BASE ASSEMBLY
TIGHTENING
1 14.53 15
DIAHRAGM ASSEMBLY TIGHTENING 2 20.54 10
HEIGHT MEASURING 1 16.37 23
GASKET ASSEMBLY,PRE CRIMPING
AND FINAL CRIMPING
1 23.4 15
AIR GAP MEASURING AND
ADJUSTING
1 14.81 9
PRE TUNING AND MOUNTING
BRACKET ASSEMBLY
1 15.56 10
HORN TUNING AND TESTING 1 17.83 12
8. Spool Assembly locking, point holder &
Tuning screw Assembly
Terminal Base Assembly Tightening
Diaphragm Assembly Tightening
Gasket Selection &
Pre Horn Assembly
Height
measuring
Diaphragm assembly
tightening di
9.
10.
11. In the existing methodology , the operator assembles
the parts of the diaphragm and then tights the parts with
a normal pneumatic gun which doesn’t have accuracy
of the height .
The assembly then moves through the conveyor and the
next operator manually measures the height of the
diaphragm with the help of a manual screw driver with
reference to a screw driver .
12. Instead of tightening the Diaphragm using an ordinary
pneumatic tighter a pneumatic gun with a pre fixed
torque is used in order to obtain the required height in
the diaphragm of the horn
13. When the height is fixed as per the requirement
(13.5mm ) it is then placed in the newly designed
fixture which consists of a sensor which measures the
height of the diaphragm .
The frequency of the horn depends upon
on the height which is present in the
diaphragm When the height varies the horn
sound and efficiency varies .
15. • Dial gauge is replaced by a linear
variable differential transducer
• LVDT is used to measure the
distance between the diaphragm
and the armature rod end .
• It give accurate measurement than
the dial gauge used before.
22. The normal elastic strain is very minimum and deformation rate is also very low
when a 500 N pressure applied to the material .
23. The total deformation obtained for the pressure of 5 bar is very
negligible . thus it is very efficient compared to other materials being
used .
24. Redesigning of horn assembly line using
ECRS priniples . Authors –Sindhuja.D ,
Mohandas Gandhi.N , Madhumathi.P
Optimization of assembly line based on work
study “Industrial Engineering and engineering
management .-Authors – Shauang Lan , Xue
Wang
