This document provides a summary of an industrial training report submitted by Shashank Upadhyay at Motherson Sumi Systems Limited. It includes sections on wiring harness applications, the process of making wiring harnesses and common defects, quality improvement methods like 6S, Kaizen, and Poka-yoke, and concludes with an overview of the training experience. The training covered various production departments involved in manufacturing wiring harnesses including lead preparation, assembly, quality inspection, and dispatch.

1. A REPORT ON
INDUSTRIAL TRANNING AT MOTHERSON SUMI
SYSTEMS LIMITED
SUBMITTED TO
MR. KRISAN PAL SHING
RUDRAPUR INSTITUTE OF TECHNOLOGY
SUBMITTED BY
SHASHANK UPADHYAY
MECHANICAL ENGINEERING
(AUTOMOBILE) 15105260045
RUDRAPUR INSTITUTE OF TECHNOLOGY

2. Table of Contents
1. Certificate
2. Acknowledgement
3. Introduction
4. Wiring Harness Application
5. Process of making wiring harness and defects
6. 6S
7. Kaizen
8. Poka-yoke
9. 3G
10.Conclusion

3. Certificate
This is to certify that Mr. Shashank Upadhyay has successfully completed his Industrial
Training from 20-06-2017 to 20-07-2017. His training report on Process of Making Wiring
Harness in Mother Son Sumi Systems Limited (MSSL), in Production Department under
guidance of Mr. Hemant Kumar Gunwant
During his Tanning we found him Punctual, Sincere and Hardworking.
We wish him good luck and success in life.
Mr. Subhash Tiwari
Head HR
MotherSon Sumi Systems Limited (MSSL)

4. ACKNOWLEDGEMENT
I am really thankful to Mr. Hemant Kumar Gunwant whose knowledge and directions
help me to understand the plant operation smoothly and without any difficulties. He was
constantly available to me and has given valuable time through his busy schedule.
I am also thankful to Mr. Medan Sir who took the job to introduce us. He was always
available to us in case of any help was needed. He cleared all our doubts in easy and
friendly to us.
I always thanks full for Mr. Subhash Tiwari HR Department who accepted my application
in such a short notice and gave me to wonderful chance to have real experience of industry.
Finally I am thankful to the Associates who do the real ground job and allowed me to have
a closer look on their operations.

5. Introduction
Mother Son Sumi Systems Limited (MSSL), the flagship company of the
Samvardhana Mother son Group was established in 1986 in joint partnership
with Sumitomo Wiring Systems, Japan.
MSSL including its subsidiaries and JVs is one of the leading manufacturer
of automotive wiring harnesses, mirrors for passenger cars and a leading
supplier of plastic components and modules to the automotive industry.
Its broad business portfolio includes wiring harnesses, mirrors for passenger
car, injection molded products, modules including dashboards, door trims,
bumpers, blow molded components, liquid silicone rubber molded
components, injection mounding tools, extruded rubber products, precision
machined metal components and waste recycling systems.
Over the years MSSL has successfully collaborated with global technology
leaders to further enhance its competency to create technologically sound
products in state-of-art facilities and infrastructure to ensure superior
efficiencies & total customer satisfaction.

6. Wiring Harness Application
*Automobiles
*Generators
*Computers
*Medical Equipment (ultrasonic machines x-ray machines)
*Home Appliances (Washing Machines etc.)
*Office Equipment’s (Photocopies etc.

7. Department
LPC Lead preparation cell
In LPC department following process occur
*C&C (Cutting stripping & crimping)
*Part Fitting
*Manual Crimping
*Joint Crimping (Terminal joint)
*Ultrasonic joint
*Heat Shrink
*Taping
C & C
In C&C machine cutting stripping &crimping operation are done with the help
of software DWR Daily Working Report.
Different wire size is cut in the C&C machine 0.5mm size to 6mm.
Terminal is also fitted on wire with the help of C & C Machine.
IN C&C
Sensors are fitted for safety of operator
7 sensors are fitted on C&C machine.
5 Emergency stop is also fitted on it

8. Errors found on C&C MACHINE UNDER OPERATION
#Miss Crimping
Miss crimping occur to wrong fitting of applicator
Due to wrong filling of venire height and crimping height
#Miss Stripping

9. *Part Fitting
After the crimping according to the customer requirement part fitting is done
in wire.
Some examples of part fitting are…..
Gum Seal
Gum seal is used for those wire which are mounted on head lamp terminals.
Gum seal protects wire from water. For water proofing of wire gum seal is
fitted on wire.
*Manual Crimping
In manual crimping according to customer demand crimping is done
manually.
In manual crimping terminal is also fitted on the wire after the crimping.
Generally in manual crimping wire size .5mm to 6mm is crimped and
terminal is fitted.
Parts of manual crimping Machine
Terminal reel stand
Encoder
Motor
Safety Cover
Double Crimping Authorizes machine
Defects in Manual Crimping
#High core
#Low core
#Side deform

10. Joint Crimping
In joint crimping different type of wire is jointed together due to customer requirement.
Joint crimping is of two types
#Terminal joint
In terminal joint wrier is crimped with the help of terminals.
#Ultrasonic joint
In ultrasonic joint join is done with the help of computer software (SCHUNK) is used.
After the joint; the joint diameter is fixed is a specific diameter according to standard fitted
in software.
After the Terminal & Ultrasonic joint the strength of the joint is checked with the help of
puss pull gauge.
Defect on Ultrasonic Joint
#Standards out - when conductor comes from front.
#Standards cut – when standard cut in the cute wire/stripped wire.
#Low Core- when standard are not coming from wire.
#PVC welded with conductor –when PVC welded with conductor during process.
Taping
Taping is done to protect the joint in wires.
Heat Shrink process is costly in compression to tapping so customer demand taping.

11. Assembly Cell
In Assembly department following process occur
*Sub Assembly
*Final Assembly
*Grommet Fitting
*Circuit Check
*Parts Fitting
*Visual inspection
*Packing
*Delivery

12. Sub Assembly
# For making Sub assembly we need sub assembly diagram. Wire matrices component’s
matrices.
# Then wire is fitted according to the sub assembly diagram.
# We have to fit wire from left to right and bottom to top as per assembly diagram.
Defects in Sub Assembly
# Wrong Fitting
#TBO Terminal back out
#Housing Damage
#Wrong wire length
#Wrong vo tube size
#Wrong wire Colour

13. Final Assembly
# as per customer requirement Final Assembly board is made.
#Then we have to mount sub assembly into the Final Assembly Board and then cot,
tapping, clamp, is fitted on the sub assembly.
#then the wiring harness is ready.
Defects of Final Assembly
#Label wrong
#Branch Wrong
#Branch length short
#Branch length excess
Effects
Due to this defects wiring harness there is fitting problem in vehicle of those defected
wiring harness
As per customer requirement following parts are fitted on wiring
harness
Grommet Fitting, Sticker fixing, Clamp Attachment, GRO fixing, Stopper Attachment
etc.
Circuit Inspection
In Circuit checking in wiring harness the flow of current continuity is checked.
Some parts are also fitted in circuit checking process like fuse, relay, Diode, Copular

14. Defect of Circuit Inspection
#Wrong Fitting
#Wrong Accessories
#Connection damage
#Terminal Back out
#Dummy seal missing/crack
Visual Inspection
Visual inspection is done by quality inspectors which look after the quality of the wiring
harness which is produce by Sub Assembly and Final Assembly if any defect is found the
wiring harness is rejected.
Defects found in visual Inspection
#Wrong identification label
#Wrong taping location
#Wrong position of grommet
#Wrong branch length

15. Dispatch
After the visual inspection the wiring harness is send to the FG Area (Finished Goods).
Their wiring harness is ready to dispatch to the customer
Error in Dispatch
#Wrong identification on box

16. Other Helping Departments
*PPC (Production Planning Control)
Production planning and control is a departments which plans in a day how many wiring
harness production will happen.
Production planning control check the daily production report on DWR (Daily working
report) Software which is look over from the head office.
*QPC (Quality Process Control)
Quality inspectors are appointed to check each and every process of production of wiring
harness.
Then the parts inspection is also done to check the parts are correctly fitted on harness or
not.
Quality circle is the group of professional’s quality head.
*Maintenance
Maintenance departments is having skills and professional engineers who shot out the
technical errors in cutting stripping and crimping machine.
Maintenance departments is having 500 applicators for cutting different wire size.

17. 6S
In MSSL 6S is used
Sort (Seiri)
#Make work easier by eliminating obstacles.
#reduce chances of being disturbed with unnecessary items.
#prevent accumulation of unnecessary items.
#Evaluate necessary items with regard to cost or other factor.
#Remove all parts or tools that are not in use.
#Segregate unwanted materials from the workplace.
#Waste removal.
#Make clear all working floor except using material.
#Sort bad and good things.
Set in Order (Seiton)
#Arrange all necessary items so that they can be easily selected for use.
#prevent loos and waste of time by arranging work station on such a way that all tooling
equipment’s in close box.
#Make it easy to find and pick up necessary items.
#Ensure first in first out FIFO basis.
#Make workflow smooth and easy.

18. Shine (Seiso)
#clean your workplace on daily basis completely or set cleaning frequency.
#Use cleaning as inspection.
#prevent machinery and equipment deterioration.
#Keep workplace safe and easy to work.
#Keep workplace clean and pleasing to work in.
Standardize (Seikestsu)
#Standardize the best practices in the work area.
#Maintain high standard in workplace organization all time.
#Everything in its right place.
#Every process has a standard.
Sustain (Shitsuke)
#No harmful to anyone.
#Also translates as do without being told.
#Perform regular audits.
#Training and discipline.
#Self-discipline.
#To maintain proper order.
Habbit(Sukan)

19. KAIZEN
Kaizen is the practical of continuous improvement improvement Kaizen was originally
Introduced to the West by Masaaki Imai in his book Kiazen the key of japan s Competitive
Success in 1986 Today Kaizen is reorganized worldwide as an important pillar of an
organization long – term competitive strategy.
Kaizen is continuous improvement that is based on certain guiding principles.
*Good process bring good results
*Go see for yourself to grasp the current situation
*Speak with data manages by facts
*Take action to contain and correct not causes of problems
*Work as a team
*Kaizen is everybody business
*And much more!
One of the most notable feature of Kaizen is that big result come from many small changes
accumulation over time. However this has been misunderstood to mean that kiazen equals
small changes infract, Kaizen means everybody involved in making improvement. While
the majority of changes may be small, the greatest impact may be kaizen that are led by
senior management as transformation projects or by cross functional terms as kaizen.

20. POKA-Yoke
A poka-yoke is a mechanism that is put place to prevent human error. The purpose of a
poka-yoke is to inhibit, correct or highlight an error it occur .Poke-yoke rough means
avoid
Unexpected surprise or avoid blunders in Japanese. In English a poke-yoke is sometimes
referred to as Mistake-proof

21. 3G
GEMBA Go to Spot
GENBUTSU Look at Things
GENJITSU Grab the facts and take realistic action

22. Conclusion
After the completion of industrial training I enhance competencies and
Competitiveness in my respective area of specialization. I tried to relate the experience in
the workplace with our knowledge learned in the institute & applied the knowledge on the
job under supervision.
Here I gain the experience and knowledge that can be used for suitable job without delay
after studies.
I learn to hone soft skills appropriate to the work environment. Also get improvement in
communication skills. I assessed career ability, knowledge and confidence as well
enhanced my marketability to be more competitive.
With experience, knowledge and skills acquired during industrial training i will be better
prepared to face working world.

23. THANK YOU
SHASHANK UPADHYAY
MECHANICAL ENGINEERING (AUTOMOBILE)
15105260045
RUDRAPUR INSTITUTE OF TECHNOLOGY