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

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.

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

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

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.

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.

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

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

Standard

2 Core

Wire

Standard

USB Wire

Internet

Connection

Optional:

Android Tablets at each line

Secondary Monitors to Display Down Time Events

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

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

Implementation

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

Tablet View

Data Hourly

OEE Hourly

OEE Graphs

Hourly Production Report with graphs

Hourly Production graph for CTL

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.

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

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

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

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.

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.

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.

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