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Overview about the company

MothersonSumi Systems Limited (MSSL) is the flagship company of the SamvardhanaMotherson Group and was established in 1986. It is a joint venture between SamvardhanaMotherson Group and Sumitomo Wiring Systems (Japan). MSSL is a focused, dynamic and progressive company providing customers with innovative and value-added products, services and solutions. The Company is listed at the stock exchanges since 1993. The recent acquisition of mirror business from Visiocorp (now renamed as SamvardhanaMothersonReflectec) has helped MSSL evolve as one of the worlds leading automotive mirror manufacturer. The Company is Indias largest manufacturer of automotive wiring harnesses and mirrors for passenger cars. It is also a leading supplier of plastic components and modules to the automotive industry.

MSSL facility in Noida

MSSL facility in Bangalore

Over the years MSSL has collaborated with global technology leaders and has further leveraged its competency in existing areas to create products fulfilling the technical needs of its customers. MSSL and its joint ventures have invested in state-of-the-art technologies and infrastructure to ensure superior efficiencies & total customer satisfaction. MSSL is strengthening its position as a globally preferred solution provider by offering end-to-end solutions encompassing designing from basic data to prototyping, tooling, molding, assembly and integrated modules. The ability to provide this end-to-end solution in each product category and combine these solutions in the form of full system solutions has enabled the Company to evolve as a preferred supplier. These solutions are supported by the flexibility to supply from any of the alternative manufacturing bases and logistic models best suited to customer requirements. MSSL has developed a network of manufacturing bases, design centers, logistics centers, marketing support and sourcing hubs across a diversified geographical base. MSSL has presence in 21 countries which includes India (Noida , Gurgaon, Manesar, Faridabad , Pune, Bengaluru, Chennai, Kandla, Lucknow&Puducherry), UAE., Sri Lanka, Singapore, China, South Korea, Japan, Germany, UK., Czech Republic, Austria, Hungary, Italy, Spain, France, Ireland, U.S.A, Mexico, South Africa, Australia & Mauritius to provide timely and quality delivery its customers worldwide. MSSL has manufacturing bases across five continents - Asia, Europe, North America, Africa& Australia to support its customers. MSSLs diverse global customer base comprises of almost all leading automobile manufacturers globally.

Product Range
It has been MSSLs endeavour to constantly add new products in its product line with the objective of emerging as a single-service interface for multiple customer needs. MSSL has 9 JV partners with over 14 collaborations. The Company has collaborated with technology leaders in their respective fields to bring relevant technologies for the products required by its customers. MSSLs diversity of product range coupled with the depth within each product portfolio, has helped the company garner leadership in its area of operations. The product range of the company along with its subsidiaries and joint ventures includes: Automotive Rear View Mirrors Wiring Harnesses Wires Seals Grommets Tubes Fuse Boxes

Injection Molded Products Blow Molded Products Liquid Silicone Rubber Molded Components Injection Molding Tools Extruded Rubber Products Precision Machined Metal Components Modules IP/ Cockpit Door Trims Bumpers Air intake manifolds Air filter systems HVAC Systems

Waste Recycling System

History

Motherson was founded

1975

First Cable factory started

1977

1983

Technical agreement with Tokai Electric Co. (Now Sumitomo Wiring Systems - Japan) for Wiring Harness

JV with Sumitomo Wiring Systems Japan

1986

Injection Molding

1989

Cutting Tool Manufacturing

1992

1994

Tool Room for small and Medium sized Molds (upto 650 Tons)

Cockpit Assemblies Automotive Mirrors

1995

Blow Molding

1997

Rubber Injection Molding

1998

First Overseas office established (Austria)

1999

IT and Design Company Representetive Office at Singapore

2000

Liquid Silicon Rubber Injection molding Machined Metal Components

2001

2002

Wiring Harness manufacturing at Sharjah Design Centre at Ireland

Offices in USA & UK established Tool Room at Sharjah

2003

European Headquaters at Germany Sheet Metal Die Design

2004

Injection Molding & metal Machining in Germany JVs for Environment Management Systems Automotive Manufacturing Engineering

2005

Plastic Molding & Metal Machining at Germany PVC Tube Manufacturing

Wiring Harness Manufacturing in UK Bus Airconditioning Systems Auxiliary Equipment for Injection molding machines Cabins for off road vehicles in India Rubber parts Manufacturing in Australia JVs for HVAC Systems, Meterclusters, Body Control Modules & Compressors Bimetal BandSaws Transport & Stationary Refrigeration Systems Thin Film coating metals

2006

2007

2008

JV for Lighting Systems, Pedal Box Assembly & Air Intake manifolds JV for Precision machined metal components

2009

Visiocorp becomes a part of SamvardhanaMotherson Group and renamed SamvardhanaMothersonReflectec (SMR) Gear cutting tool manufacturing through a new venture Motherson Advanced Tooling Solutions Polymer Compounding JV for HVAC Systems for commercial vehicles & Off the highway vehicles JV for Gear Cutting Tools Freezers & Retail Refrigeration

2010

Product Design

MSSL provides design and development support to customers with its large resource-pool of highly trained and qualified design engineers Equipped with the latest design software and prototype development facilities, it has the capability to design from first principles. Support Levels Harness routing and layout study Component Selection Benchmarking Source Identification VA-VE at Design Stage Onsite Engineering Support Design Modifications VA-VE after Launch

Component Development

Component Identification and sourcing New Component design as per specific customer requirement Tool development and prototyping Component Manufacturing

Component Manufacturing

MSSL has a high degree of backward integration for manufacturing of critical components. The synergies with-in group companies enable in-house manufacturing of a wide range of components, resulting in better quality control and shorter development lead times.

Wiring Harness Assembly

MSSL has manufacturing facilities near major customer locations. MSSL has the capability to set up dedicated production facilities for its customers. Expertise in project management and a ready pool of trained human resources enables MSSL to setup green field projects in a very short lead time.

Manufactruing Facilities Multi-unit multi-locational manufacturing Units and assembly lines designed as per specific customer requirements Highly skilled manpower Automatic machines cutting, stripping and crimping

Conveyorised assembly lines 100% electronic testing facilities Online computerised Process control Process and jig designing with maximum Poka Yoke (mistakeproofing) Facilities include specialised processes for varies requirements such as Braiding, Heat Resistance welding, Ultrasonic Welding, Online Printing etc. Process Engineering MSSL has in-house capabilities for design and development of assembly processes. The process engineering activities encompass design and manufacturing of Applicators, Jigs, Fixtures, Assembly Boards, Circuit Checking Boards and Material Handling Systems.

Logistics Support

Strategically located manufacturing facilities of MSSL provide an effective logistics network. MSSL has units located near major customer locations, following the concept of Factory Next Door for high volume supplies. For Overseas supplies, MSSL has locations near major ports in India supported by manufacturing bases in Sharjah, UAE, UK and a network of overseas logistics centers and representative offices. MSSL is supplying to locations in Asia, Middle east, Europe and USA.

Wire Harness

The largest manufacturer of integrated wiring harnesses in India, the SamvardhanaMotherson group holds over 65% share of the Indian passenger car wiring harness market. The group manufactures wiring harnesses for the entire cross-section of the automotive industry - from passenger cars to commercial vehicles, two wheelers and three wheelers, multi utility vehicles, farm, material handling equipment and off-the-road vehicles. The group also manufactures specialised wiring harnesses for white goods, office automation, medical diagnostic equipment, electrical and electronic equipment. Designing and developing wiring harnesses from first principle concepts on latest design software, the group provides total solutions in wiring harness manufacturing. The group has complete backward integration for manufacturing critical wiring harness components. In-house capability for design and manufacturing of applicators, jigs, assembly boards and circuit checking boards enable process design control and flexibility. The Engineering Capabilities for Wiring Harness

Process Design & Development In-house capability of process design and validation Designing & manufacturing of Jigs & Fixtures Applicator design & manufacturing Design & manufacturing of circuit checking & assembly boards Tooling design for wiring harness process equipment, testing & assembly equipment

Elelctrical Distribution System - Products

Cable & Harness Wiring Harness Lead Wire Battery Cable Flat Cable Harness High Tension Cords (Engine Cables)

Wiring Harness Components Wires Terminals Connectors Caps & Sleeves Clamps & Binders Fuse Boxes

A cable harness, also known as a wire harness, cable assembly, wiring assembly or wiring loom, is a string of cables and/or wires which transmit informational signals or operating currents (energy). The cables are bound together by clamps, cable ties, cable lacing, sleeves, electrical tape, conduit, a weave of extruded string, or a combination thereof. An array of insulated conductors bound together by lacing cord, metal bands, or other binding, in an arrangement suitable for use only in specific equipment for which the harness was designed; it may include terminations.
In todays world of technology, the wiring systems for various electrical equipments& machines have been improved & systematized in form of WIRING HARNESSES. The connections to the machines are controlled through machine control panel. The panel switches & passive parts are joined by harnesses covered with UV radiation resistant sleeves. We provide solutions for mainly two types of equipments / machines. The automotive connectors suitable to the specific applications are crimped with wires of size required as per current rating.

The components i.e. connectors, crimps, sleeves, etc., are chosen according to the following specifications.

Commonly used in automobiles, as well as construction machinery, modern-day cable harnesses provide several advantages over loose wires and cables. For example, many aircraft, automobiles and spacecraft contain many masses of wires which would stretch over several kilometers if fully extended. By binding the many wires and cables into a cable harness, the wires and cables can be better secured against the adverse effects of vibrations, abrasions, and moisture. By constricting the wires into a non-flexing bundle, usage of space is optimized, and the risk of a short is decreased. Since the installer has only one harness to install (as opposed to multiple wires), installation time is decreased and the process can be easily standardized. Binding the wires into a flame-retardant sleeve also lowers the risk of electrical fires.

Production Cable harnesses are usually designed according to geometric and electrical requirements. A diagram is then provided (either on paper or on a monitor) for the assembly preparation and assembly. The wires are first cut to the desired length, usually using a special wirecutting machine. The wires may also be printed on by a special machine during the cutting process or on a separate machine. After this, the ends of the wires are stripped to expose the metal (or core) of the wires, which are fitted with any required terminals and/or connector housings. The cables are assembled and clamped together on a special workbench, or onto a pin board (assembly board), according to the design specification, to form the cable harness. After fitting any protective sleeves, conduit, or extruded yarn, the harness is either fitted directly in the vehicle or shipped. In spite of increasing automation, in general, cable harnesses continue to be manufactured by hand, and this will likely remain the case for the foreseeable future. In part, this is due to the many different processes involved, such as:

routing wires through sleeves, taping with fabric tape, in particular on branch outs from wire strands, crimping terminals onto wires, particularly for so-called multiple crimps (more than one wire into one terminal), inserting one sleeve into another, fastening strands with tape, clamps or cable ties.

It is clearly difficult to automate these processes. In spite of this, these processes can be learned relatively quickly, even without professional qualifications. Thus, manual production remains more cost effective than automation. For certain vehicles, such as trucks, there are also a large number of variants (due to different configurations and the length of the vehicles), which produce very small batch sizes (as low as one). However, the number of variants has been decreasing in recent years due to the use of data bus technology, such as a CAN bus, in conjunction with intelligent control units. In spite of this, different variants are produced on the same assembly board. Even here, man has an advantage over machine, since he can change over to the different variants (no "re-programming" being required). Pre-production, however, can be automated in part. This affects:

Cutting individual wires (cutting machine), crimping terminals onto one or both sides of the wire, partial plugging of wires pre-fitted with terminals into connector housings (module), soldering of wire ends (solder machine), and twisting wires.

Testing the electrical functionality of a cable harness can be done with the aid of a test board. The circuit diagram data are pre-programmed into the test board, where harnesses can be tested individually or in multiple numbers. Complex custom cable and wire harness development often involves the collaboration of various departments and in some cases even organizations which presents a challenge in information sharing and design data propagation through various departments. This challenge is based on the fact that separate departments operate in their spheres of knowledge and responsibilities. It is possible to effectively evaluate and implement inputs from these separate entities through the enterprise-wide integration of modern software solutions, which allow collaborative technical design flow between large numbers of participants. The concept on which such information systems operate is based on what is known as digital continuity and, in the case of wiring components design, this concept allows engineers, designers and other departments of the enterprise to work closely and share pertinent information on all aspects of complex cabling products design and manufacturing. As a result, a wiring harness manufacturer achieves substantial gains in both cost reduction and productivity.

Since design of wiring components takes many stages and frequent changes, the recordkeeping of the data related to the development history is very important to keep the wiring harness development on track. Wide network integration of shared CAD, PDM (Product Development Management) toolsets which support collaborative efforts makes it possible to allow participants to quickly make updates, bridging not only internal departmental boundaries but also geographical division. Modern wiring harness software applications allow creation of specific design rules which are based on OEM specifications for a particular wiring harness or cable assembly piece. These rules are programmed into ECAD software and they allow wiring harness engineers to safely stay within the predefined specs throughout the entire design process. The software intelligently applies the design restrictions to prevent development errors. Most ofwire harness manufacturingis aimed at large production quantities and the difference in manufacturing cost of a single piece can be easily multiplied by hundreds of thousands of units. With the help of predefined design rules it is possible to find a cost saving alternative without sacrificing quality. Checking a new alternative against design rules takes very little time in comparison with manual testing. All of the development participants are provided instant access to critical data which allows expediting decision making and approval processes as well as smooth transition from one development stage to the next.

IMAGE 1 DESCRIPTION The flow of the wiring component design from its inception to manufacturing. The chart shows information accumulation and distribution throughout the entire enterprise.

Wire Harness Development Stages


Just like any product, the design of the wire harness or custom cable starts with its function definition. What this particular wire harness supposes to do and how? What kind of features will it have? Since we are discussing the design of a complex wiring component, most likely there are a few functions and features which have to be thoroughly defined. Therefore the first step in custom cable assembly design is an exact definition of its features and functions.

The environment in which wiring component will be operating plays a significant role in material selection. This includes external factors such as temperature, moisture, pressure, etc. These factors will define the materials and components as well as types of connector assembly and terminals. In some instances, it may be required to develop a custom crimping or soldering process. All this information flows from the OEM and used for the creation of predefined rules in the software. All records of the design and development, as stated earlier, have to be securely stored and accessible through the networks to all parties involved. As the development process proceeds to the next stage, all information will be passed on to accommodate the next step. The amount of data accumulates as the development process goes further and all information is being intelligently managed by the software system. In the next step, developers will engage in defining the physical architecture of the wiring component which is driven by the earlier defined features and functions. This will include components and wire selection, dimensions and type of terminal, splicing, etc. Once physical architecture is determined, we enter into the next step which starts the actual design process. In this stage we have to merge the electrical engineering design data with physical design specifications. Here we can create mock ups in both actual and digital format, and further contemplate on the weight, appearance, connector and splicing types and cost. This also includes the consideration of the installation of the wiring component in the manufactured product, may it be automobile, airplane or a dishwasher. The aim of the design definition or the design intent is to produce a technical drawing of the wire harness which defines all the details needed to produce at least a working prototype being as close as possible to a technical drawing of the finished product ready for mass production. The next step is the preparation of the design results for production. There is a distinction between the engineering of a wire harness piece and its design. Wire harness designers provide a product definition based on the research and requirements but their data does not contain necessary information to have a ready-for-production wiring component specs. Engineers are responsible for taking all the data passed on by the wiring harness designers and delivering a production-ready, compliant documentation. In this step wiring component engineers must define the exact cost of production of the wire harness. Again, this is a critical task given the fact that mass production may involve thousands and possibly millions of units and any error may result in substantial additional costs. While designers may use 3D design software tools, the engineers have to translate the three dimensional design into 2D (two dimensional) technical drawings. This includes technical drawings of all elements, such as connector components, cavity components, clips, etc. Following are the areas of the

wire harness engineers involvement:


Splicing Definitions:

Specifications of shielding, water proofing, solder sleeve position, cable stripping options, etc. These definitions derive from the manufacturing and QC guidelines and also may include custom manufacturing operations.
Wire Harness/Custom Cable Component Selection:

This includes types of wire and cable used, plugs, terminals, connector types, tubes and others. It may also include the exact specification of the assembly of the individual elements because not all of the definitions provided by the OEM may contain exact specifications.
Wire and Cable Color Definition:

All of the wire components included in the wire harness must have an exact color definition. In some cases, where the wire inventory levels do not allow accommodating the tight production schedules, engineers may find substitutes and get OEM approval. This illustrates that engineers are also responsible for component outsourcing and logistics when defining production-ready technical specs of the wiring component.
Production Estimates:

Engineers also are engaged in estimating the production timeline, tooling, assembly setup and other factors that contribute to wire harness production lead time. This brings us to the next area of wire harness engineers involvement.
Component Outsourcing Confirmation:

All the components involved in the wire harness assembly have to be priced and delivered for cable assembly mass production. All sourcing and pricing information has to be entered into the system which also should accommodate comparison of alternatives. All technical documentation may be perfect but if a supply chain is not thoroughly inspected and the delivery of the components is not assured, the production schedules are at risk. In this stage, engineers work closely with procurement departments and pass gathered relevant data further into the next step.
Bill of Materials:

BOM calculation is performed at this stage and all data is saved in the system. To comply with the OEM specification and delivery terms, the engineering team, production management team and procurement department are working closely together to achieve a reliable production schedule and secure all required components in time. Since wire harness manufacturing operates on small profit margins, all of the sourcing related

factors must be taken in consideration and confirmed. Often a custom cable manufacturerhas to deal with the multiple variants of the wiring component which may include different lengths, terminal types, wire colors and electrical specifications. Understandably, this places an array of additional requirements on the production scheduling and outsourcing. Because of the complexity and a large number of logistical and engineering data, a modern computerized enterprise-wide solution is a great help for a modern wire harness manufacturer. Not only does it help managing large loads of information but it also expedites the tasks associated with the manufacturing planning and production scheduling, securing materials and accommodating OEM requests.

IMAGE 2 DESCRIPTION A master file of a wiring harness can accommodate multiple variations for related products. Any changes in design rules are automatically applied to all related product derivatives. A true enterprise-wide wire harness design system accommodates product variations which provide savings on tooling charges and production scheduling because it can pass the information of the related wire harness variations to production management department, allowing faster and more flexible production scheduling. A master design file and its variations provide a tree-like structure of the manufacturing procedure variations and the software can separate the assembly process into batches while optimizing production scheduling and providing an exact data on

quantities and manufacturing instructions to all stages of the assembly line. Defining wire harness variants as children of the master file allow making changes to the entire family of wiring components on the fly. For example, if in the design process, the length of a particular wiring component has changed, this automatically updates all the variants which contain that particular piece.

Design and Engineering Integrity of a Wiring Component


In the initial stages of wiring component design, a set of rules is entered into the computer assisted design tools. These rules are defined by the OEM specs of the wiring component. A fully integrated system passes these rules from one stage of the wire harness development to the next and this allows staying within OEM specs at any development stage. Shall a design rule be broken in the process, the software issues an automated alert which allows wire harness engineers to correct an error immediately.

IMAGE 3 DESCRIPTION Wiring harness design data from multiple sources provided for engineers to create technical drawings for wire harness production. Passing wiring component design data to the wire harness assembly line for both equipment and human labor. In some instances, the OEM engineering team decides to update the wiring component specs and requests that the wire harness manufacturer

comply with the changes. If a wire harness contractor does not have a fully integrated system in place, this can create a huge amount of additional work for many departments. A fully integrated wiring harness design system, on the other hand, can adjust all subsequent steps simply by changing some of the design rules and that will pass all the design changes and update the project files automatically. Design rules can apply to physical product architecture, safety requirements, wire and termination selection, data transfer protocols, electrical engineering standards, etc. You can view design rules as the logic behind the design intent. Through the proper integration of the design rules, engineers can also control the cable assembly manufacturing process for wire cutting, stripping, type of crimping, molding, etc. While there are many pre-set design rules in most cable design software packages it is critical that they are fully customizable for each particular project and the wire harness designers and engineers are highly skilled in defining the custom rules and understanding their actions and affects.

Custom Cable and Wire Harness Prototyping and Manufacturing


At this point we have all the data and technical drawings necessary to build a working prototype worthy of manufacturing. Since all of the aspects of the wiring components procurement has been secured, we have the BOM calculated and our manufacturing process is predefined and we have a pretty good idea of the production cost, we can prototype the wiring component with confidence. All of the steps taken previously come together; we have a virtual cable assembly prototype in the system and all we have to do is to produce a template of the form board and assemble the physical wire harness. To develop a complex wire harness form board is not an easy task but the software can do it instantly and provide a template (an exact scale map) with critical data to ensure manufacturing accuracy. This data can include such things as visual aids and instructions for the product assembly. Again, since all the design and engineering information of various development stages is passed on and checked through the application design rules, we have a complete manufacturing documentation related to every step of production. Furthermore, advanced systems can pass this information to the assembly line equipment directly eliminating manual equipment setup. This can be used for an automated setup of cutting, testing and crimping equipments. Fully integrated wire harness design solution allows faster turnaround in building complex cabling prototypes and production setups. It also expedites the manufacturing of wire harnesses through generating operational instructions for each part of the assembly line whether it is human labor or automated process. Changes in the wiring component design are propagated through the entire

chain of the wire harness development and easily checked against predefined rules this ensures design integrity. Modern systems also allow ease of recycling of previous wire harness design data of similar products and a full or partial integration of that data into a new project. Comparing traditional methods of a custom cable assembly design with a modern approach involving wiring components software tools integration shows advantages in both cost reduction associated with design and engineering of a wiring component and shortened development timelines. Design data sharing across the entire wire harness contractor enterprise eliminates redundant tasks such as double data entry, manual data reviews, etc. and allows to expedite OEM orders.

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