Industrial final report

UNDERSTANDING OF SEALING PRODUCT DESIGN AND
PRODUCTION
INDUSTRIAL PROJECT REPORT
Submitted By
Name of the student University Roll No.
SHIVANSHU KHARWAL 22RU34304
Supervised By
Er. Manoj Kumar
Assistant Manager
MECHANICAL ENGINEERING DEPARTMENT

RAFFLES UNIVERSITY,
NEEMRANA (RAJSTHAN) 301020
AUG,2024
UNDERSTANDING OF SEALING PRODUCT DESIGN AND
PRODUCTION
INDUSTRIAL PROJECT
Undertaken at:
Submitted in Partial Fulfilment of the Requirements for the award of the

Degree of
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
Submitted By:
SHIVANSHU KHARWAL 22RU34304
Supervised By:
Mr. Manoj Kumar
Assistant Manager
RAFFLES UNIVERSITY,
NEEMRANA (RAJSTHAN) 301020
AUG,2024
CONTENTS
Page No.
CERTIFICATE i
ACKNOWLEDGEMENT ii
INDUSTRIAL PROJECT CERTIFICATE iii
EVALUATION SHEET iv
ABSTRACT v
LIST OF FIGURES vi-vii
LIST OF TABLES viii
Chapter-1 INTRODUCTION 1-20
1.1 COMPANY INTRODUCTION 1
1.1.1 COMPANY PROFILE 2
3
1.1.2 HISTORY OF INGRESS
1.1.3 SIZE OF COMPANY 4
5
1.1.4 ORGANIZATIONAL STRUCTURE
1.2 INTRODUCTION TO PARTS 7
Chapter-2 LITERATURE REVIEW 21-37

2.1 PLANT OPERATION AND MANUFACTURING 21
PROCESS
2.2 PROJECT BACKGROUND 32
2.3 TRAINING PROGRESS REPORT 34
2.4 DAILY TASK 35
Chapter-3 MATERIALS AND METHODOLOGY 38-51

3.1 PROJECT WORK OVERVIEW 38
3.2 PROJECT GOALS 38
3.3 MATERIAL USED 39
3.4 HARDNESS OF MATERIAL 45
3.5 PROJECT PHASE AND TIMELINE 47
3.6 PROBLEM SOLVING METHODOLOGY 48
3.6.1 DR. JURANS 12 STEPS 48
3.6.2 7 QC TOOLS
49
3.6.3 USE OF 5S 50
3.7 COMMANDS USED IN DESIGNING 51
Chapter-4 RESULT AND DISCUSSION 54-58
4.1 RESULTS 54
4.1.1 MODELS DESIGNED IN NX 54
4.2 DISCUSSION 58
Chapter-5 CONCLUSION AND SCOPE FOR FUTURE WORK 59-61

5.1 CONCLUSION 59
5.2 SCOPE FOR FUTURE 60
REFERENCES 62
ACKNOWLEGEMENT
I would like to use this opportunity to express my gratitude and appreciation to all those who
have guided and supported me through my internship.
Also, I take this opportunity to express my deep sense of gratitude to my industry mentor and
guide Mr. Manoj Kumar (Er. Asst. Manager) & Mr. Vivek Kumar (Asst. Manager) for
their supervision and guidance. I am thankful to both for having taught me life skills and
practical knowledge that is essential to thrive in future. Truly grateful to both for giving me
challenging tasks during my summer internship and for constantly guiding me through all the
steps of the process. I’d also like to express my sincere gratitude to Mr. Sunil Rao (HR
Head) for smooth on-boarding process and giving me words of encouragement after
successful completion of events.
I am truly indebted to Prof. Rajeev Khanduja, Head, Department of Mechanical
Engineering, Jawaharlal Nehru Government Engineering College Sunder Nagar, for giving
me the opportunity to undergo industrial training and to work on the project during my final
year of B.Tech.
I also wish to extend our thanks to Er. Aman Sharma, Academic guide & Er. Rohit
Bhardwaj Project Coordinator and other faculty members for attending our seminars and for
their insightful comments and constructive suggestions to improve the quality of this project
work.
I am extremely thankful to Prof. S.P Guleria, Director/Principal, Jawaharlal Nehru
Government Engineering College Sunder Nagar, for providing us infrastructure facilities to
work in, without which this this work would not have been possible.
I’d like to offer my heartfelt gratitude and appreciation to industry persons for generously
giving me their time.
Signature of Student
SHIVANSHU KHARWAL
22RU34304
iv
INDUSTRIAL PROJECT CERTIFICATE
v
ABSTRACT
Weather strips play a critical role in enhancing the energy efficiency and comfort of buildings
and vehicles by sealing gaps against external elements. This project aims to design and
produce weather strips using an integrated approach that combines innovative design
techniques with efficient production methodologies.
The project will commence with an extensive review of existing weather strip designs,
materials, and manufacturing processes. Leveraging this knowledge, novel design concepts
will be developed to optimize the sealing performance while considering factors such as
durability, cost-effectiveness, and ease of installation. Computer-aided design (CAD)
software will be employed to create detailed models and simulations to evaluate the
performance of the proposed designs under various environmental conditions.
Once the design phase is complete, attention will shift to the production stage. Advanced
manufacturing techniques such as extrusion molding, compression molding, and 3D printing
will be explored to produce weather strips with precision and consistency. Material selection
will be crucial, considering factors such as flexibility, resilience, and environmental
sustainability.
Furthermore, the project integrates sustainability principles by exploring eco-friendly
materials and energy-efficient manufacturing techniques, aligning with global efforts towards
environmental stewardship.
Throughout the project, emphasis will be placed on quality control and optimization of
production processes to ensure that the final weather strips meet industry standards and
customer requirements. Additionally, sustainability will be a key focus, with efforts made to
minimize waste and energy consumption during both the manufacturing and usage phases.
The outcome of this project will be a range of high-performance weather strips that offer
superior sealing properties, durability, and ease of installation. These weather strips will find
applications in various sectors including construction, automotive, and aerospace,
contributing to energy conservation and enhancing the comfort and safety of occupants.
v
i
LIST OF FIGURES
Figure 1 Company image 1

Figure 2 Manufacturing bases 6
Figure 3 Weather strip 7

Figure 4 Weather strip side view 8
Figure 5 Location of weather strip 9
Figure 6 Edge beading 10

Figure 7 Edge beading side view 11
Figure 8 Location of edge beading 12
Figure 9 Seat catch 13

Figure 10 Seat catch location 15
Figure 11 Molding roof_ 16
Figure 12 Location of molding roof 18

Figure 13 Trim cord 19
Figure 14 Trim cord location 20
Figure 15 Flow diagram for weather strip 22

Figure 16 Uncoiler 23
Figure 17 Looper 24
Figure 18 Roll forming_ 25

Figure 19 Extruder 26
Figure 20 Hooper 27
Figure 21 Cooling tank_ 28

Figure 22 Puller 29
Figure 23 Auto cutter 30
Figure 24 Flow diagram for catches and other parts 31

Figure 25 Weather strip 2d sketch 33
Figure 26 5s audit 35
vii
Figure 27 Gemba walk 36
Figure 28 DOJO training 36
Figure 29 10 cycle 37
Figure 30 Shop floor training 37
Figure 31 PP(Polypropylene) material 40
Figure 32 PVC(Polyvinylchloride) material 42

Figure 33 TPE (Thermoplastic elastomer) material 43
Figure 34 TPO (Thermoplastic olefins) material_ 45
Figure 35 Durometer 46
Figure 36 PDCA 48
Figure 37 Fishbone diagram 49
Figure 38 5s diagram 50
Figure 39 Commands used 52
Figure 40 Weather strip part 54
Figure 41 Cut section view 55
Figure 42 Weather strip outer C.F. 55

Figure 43 Weather strip inner 56
Figure 44 Molding roof_ 56
Figure 45 Weather strip FR 57

Figure 46 Weather strip RR 57
vii
i
LIST OF TABLES
Table 1 Company profile 2
Table 2 Operation standard (WS) 8
Table 3 Extruder temperature (WS) 9
Table 4 Extruder R.P.M.(WS) 9
Table 5 Operation standard (edge beading) 11
Table 6 Extruder temperature 12
Table 7 Extruder R.P.M. 12
Table 8 Operation standard (catches) 14
Table 10 Extruder R.P.M 14
Table 11 Operation standard (MR) 17
Table 14 Operation standard (trim) 19
Table 17 Outsource parts 21
Table 18 Training progress report 34
ix
Industrial Project June,2024
CHAPTER-1
INTRODUCTION
1.1 COMPANY INTRODUCTION
Ingress Autoventures (India) Pvt Ltd in Bhangrola, Gurgaon is known to satisfactorily cater to
the demands of its customer base. It is basically venturing company of the OEM (Original
Equipment Manufacturer) companies. It stands located at IMT Manesar, Gurugram, Bhangrola-
122505.The business strives to make for a positive experience through its offerings.
Ingress company have 4 directors, in which Prateek Raj Chitkara is one of the directors which is
currently at Bhangrola plant. Customer centricity is at the core of Ingress Autoventures (India)
Pvt Ltd in Bhangrola, Gurgaon and it is this belief that has led the business to build long-term
relationships. Ensuring a positive customer experience, making available goods or services that
are of top-notch quality is given prime importance.
This business has a wide range of product offerings and the product/catalogue list includes
Exhaust System, Door Lower Sash, Sealing System, Module Assembly, Door Module etc. But
the main product of this company is plastic extrusion parts like weather strips, catches, molding
roofs, edge beading etc.
Figure 1
Page | 1
RAFFLE UNIVERSITY NEEMRANA
1.1.1 COMPANY PROFILE
Company Name INGRESS AUTOVENTURES (INDIA)

PRIVATE LIMITED
Company type Public Company
Founded 1991
Headquarter Wilayah Persekutuan, Malaysia
Chairman Datuk rumeli Bin Musa
Managing director Prateek Raj Chitkara
Products Plastic extrusion, roll forming and door frame

etc.
Revenue, FY2022-23 Rs 98.23 Crore
CIN U35300HR2008PTC038189
Incorporation date 24 July 2008
Company status Active
Registration number 38189
Company category Company limited by shares
Company sub category Non- govt company
Class of company Private
Website www.ingresscorp.com.my
Location Sector M-10, IMT Manesar, NH-8, Bhangrola

Gurugram HR 123505 IN
Phone number +603-77255565
Table 1
Page | 2
1.1.2 HISTORY OF INGRESS
 1991
Incorporation of Ingress Engineering Sdn Bhd, the beginning of the Automotive Components
Manufacturing Division and the Ingress Group.
 1993
Commencement of the first roll-forming products supply to Proton for the Proton Wira model by
Ingress Engineering Sdn Bhd.
 2001
Ingress Corporation Berhad was listed on the Kuala Lumpur Stock Exchange (now known as
Bursa Malaysia)
 2004
Successful transfer of Ingress Corporation Berhad to the Main Board of Bursa Malaysia.
 2008
Ingress Auto Sdn Bhd started operation as a BMW Authorized Dealer in Damansara with a full
4S facilities.
 2010
Incorporation of Ingress joint venture company in India, Ingress-Mayur Autoventures Private

Limited (now known as Ingress Autoventures India Private Limited).
 2011
Incorporation of PT Ingress Technologies Indonesia, to manufacture medium stamping parts for

Indonesian automotive markets.
 2014
Incorporations of Ingress Industrial (Malaysia) Sdn Bhd and Ingress Industrial (Thailand), Co.,
Ltd.
Page | 3
 2017
Prateek raj Chitkara become director of Ingress autoventure (India) private limited.
 2018
Expansion of the Auto Dealership Division with the securing of the Volvo dealership to be based
in Mutiara Damansara.
 2020
Ingress Motors Centre Sdn Bhd Mitsubishi Authorized Dealership’s 3S facility commenced its
operation in Petaling Jaya.
 2024
Bajaj and Mahindra and Mahindra 2 OEM become our customers.
1.1.3 SIZE OF COMPANY
Manpower:
Ingress autoventure has a large workforce with over 2000 employees as of 2022. The company
employs skilled workers, engineers, designers, and other professionals across various functions.
Turnover:
According to the company's financial reports for the financial year 2022-23, Ingress autoventure
Limited had a consolidated operating revenue of INR 98.23 crores (approximately USD 52
million). The company's net profit for the same period was INR 12.46 crores (approximately
USD 2 million)
1.1.4 ORGANIZATIONAL STRUCTURE
The organizational structure of Ingress autoventure Limited in Bhangrola is typically

hierarchical, with various departments and functions working under the leadership of the Board
of Directors. Here's a brief overview of the company's organizational structure:
Page | 4
1. Board of directors- The Board of Directors is the topmost governing body of the
company, responsible for setting the strategic direction and policies of the organization.
2. Executive committee- The Executive Committee consists of the senior management
team and is responsible for implementing the company's strategic plans and policies.
3. Functional departments- Ingress autoventure has several functional departments, such
as finance, human resources, marketing, sales, research and development, and production,
each headed by a departmental head.
4. Manufacturing facilities- The company has two manufacturing facilities in India, each
with its own production line and a team of engineers, technicians, and workers which are
located in Haryana and Gujrat.
5. Sales and distribution- Ingress autoventure has a robust sales and distribution network,
with dealerships and retail outlets spread across the country and abroad.
Overall, Ingress autoventure has a well-structured organization that enables it to efficiently

manage its operations, manufacture high-quality products, and meet the demands of its
customers.
Page | 5
OVERVIEW OF MANUFACTURING BASES-
INDIA THAILAND
INGRESS AUTOVENTURES (INDIA)
PVT. LTD. INGRESS AUTOVENTURES
INGRESS
CO., LTD. (IAV),
AUTOVENTURES
(IAIPL), MANESAR PLANT CO., LTD. (IAV),
RAYONG PLANT
FINE
COMPONENT
INGRESS AUTOVENTURES
(INDIA) PVT. LTD. CO., LTD. (FCT),
(IAIPL), GUJARAT PLANT
MALAYSIA
INDONESIA
INGRE
TALENT SS
SYNERGY PRECISION
SDN. BHD. SDN. BHD.
PT. INGRESS MALINDO
PT. INGRESS (IPSB), NILAI
VENTURES (PT IMV), TECHNOLOGIES
JABABEKA PLANT INDONESIA (PT

ITI), JABABEKA
Figure 2
Page | 6
1.2 INTRODUCTION TO PARTS
1. WEATHER STRIP- A weather strip is a crucial component in construction and

automotive engineering, serving as a barrier against the infiltration of external elements
such as water, air, dust, and noise into buildings or vehicles. It is typically made of
durable materials like rubber, foam, vinyl, or silicone, designed to form a tight seal
between two surfaces, such as doors, windows, hoods, trunks, or sunroofs. Weather
stripping is meticulously installed along the edges of these openings to prevent drafts,
leaks, and other weather-related issues that can compromise the interior comfort, energy
efficiency, and structural integrity of a structure or vehicle.
In automobiles, weather stripping plays a critical role in sealing various openings to

protect the interior from water ingress, wind noise, and external pollutants. It is installed
around doors, windows, trunks, hoods, and other access points to ensure a watertight and
airtight seal, preventing water from seeping into the cabin and causing damage to
electrical components, upholstery, and other interior materials. Weather stripping also
helps enhance aerodynamics, reduce wind resistance, and improve fuel efficiency by
minimizing air turbulence around vehicle openings.
Figure 3
Page | 7
Figure 4
REQUIREMENT/NEEDS OF WEATHER STRIP-
i. Prevent from water and dirt leakages inside the door.

ii. Prevent from air and noise leakages inside the door.
iii. Support glass during up and down movement of glass.
iv. Cleaning of glass.
OPERATION STANDARD-
1 MATERIAL HARDNESS/SPEC Wt/Mtr REMARKS

1.1 PP (CORE 70±5 SHORE D 60±3 gms USE EXTRUDER PMS-
PART) 75
1.2 TPO (LIP 70±5 SHORE A 48±3 gms USE EXTRUDER PMS-
PART) 60
1.3 PRIMER 459X 0.5ml
TABLE 2
Page | 8
EXTRUDER TEMPERTURE
EXTRUDER Z1 Z2 Z3 Z4 Z5 Z6 DIE HEAD NECK

(OC) (OC) (OC) (OC) (OC) (OC)
PMS-75 155± 160± 165± 170± 175± 175± 175±10 175±10 185±10
10 10 10 10 10 10
PMS-60 140± 145± 150± 155± 160± - 175±10 175±10 175±5

5 5 5 5 5
TABLE 3
EXTRUDER RPM-
PMS-75 30 ±6
PMS-60 49 ±10
ADHESIVE DROP RATE 100 Drops/min

LINE SPEED (M/ MIN) 10 ±2
TABLE 4
PART LOCATION-
Figure 5
Page | 9
RAFFLES UNIVERSITY NEEMRANA
2. EDGE BEADING-Edge beading in scooters refers to a specific component within the

vehicle's construction that serves multiple crucial functions in both design and
functionality. In the context of Piaggio scooters, edge beading typically refers to the
rubber or plastic molding placed along the edges of various body panels, fairings, or
components. This beading not only enhances the aesthetic appeal of the scooter by
providing a clean and finished look to the edges but also serves important practical
purposes.
First and foremost, edge beading acts as a protective barrier for the edges of the scooter's
body panels and fairings. These panels are often made of materials like plastic or
fiberglass, which can be prone to chipping, cracking, or damage from impacts or
abrasions. The edge beading helps to cushion these vulnerable edges, reducing the risk of
damage and prolonging the lifespan of the bodywork. This is particularly important for
maintaining the scooter's appearance and structural integrity over time, as any damage to
the body panels can detract from both the aesthetic appeal and aerodynamic efficiency of
the vehicle.
Figure 6
Page | 10
Figure 7
REQUIREMENT/NEED OF EDGE BEADING-
i. Protection from impact and abrasion.

ii. Provides sealing and weatherproofing.
iii. Provides clean and finished look to edge of the body
iv. Helps to dampen vibration and reduce noise transmission.
OPERATION STANDARD-
1 MATERIAL HARDNESS
1.1 RIGID PVC ***

1.2 LACQUERED ALUMINIUM WIDTH-20.6 ±0.1 MM
THICKNESS-0.1 ±0.015MM
TABLE 5
Page | 11
EXTRUDER TEMPERATURE
EXTRUDE Z1(℃) Z2(℃) Z3(℃) Z4(℃) CLAMP NECCK DIE

R TEMP. TEMP TEMP
(℃) (℃) (℃)
∅𝟑
𝟎
170±1 172±1 175±1 170±1 160±10 160±10 185±10
0 0 0 0
TABLE 6
EXTRUDR RPM
EXTRUDER RPM (∅𝟑𝟎) 1000 ± 100

LINE SPEED 4±1
TABLE 7
PART LOCATION-
Figure 8
Page | 12
3. SEAT CATCH- The term "J catch" used in car seats refers to a specific type of latch
mechanism commonly found in automotive seating systems, particularly in the context of
child safety seats or booster seats. The J catch is designed to securely attach the car seat
to the vehicle's seat, providing a reliable anchor point to prevent the seat from moving or
shifting during travel.
To install a car seat using the J catch mechanism, the hook is inserted into the designated
anchor point in the vehicle's seat, ensuring a secure connection. Once properly attached,
the car seat is typically secured further using the vehicle's seat belt or an additional top
tether strap for added stability.
The J catch mechanism is favored for its ease of use and effectiveness in securing car
seats in place, providing peace of mind to parents and caregivers regarding the safety of
their children while traveling in vehicles. It is important to follow the manufacturer's
instructions carefully when installing car seats and ensure that the J catch is properly
engaged to maximize safety and stability. Additionally, car seat installation should be
periodically checked and adjusted as needed to maintain proper security and
effectiveness.
Page | 13
Figure 9
Page | 14
REQUIREMENT/NEED OF CATCH-
i. Secure attachments.
ii. Prevention of movement.
iii. Ease of installation.
iv. Durability and reliability
v. User friendly design.
OPERATION STANDARD-
1 MATERIAL HARDNESS
1.1 PP(POLYPROPYLENE) 65 ± 5 SHORE D
TABLE 8
EXTRUDER TEMPERATURE-
EXTRUDER Z1℃ Z2℃ Z3℃ Z4℃ ZZ5℃ CLAMP DIE
SX65 200±10 205±10 210±10 215±10 225±10 260±10 270±10
TABLE 9
EXTRUDER RPM-
EXTRUDER RPM LINE SPEED
800 ± 200 8±1
TABLE 10
Page | 15
PART LOCATION-
Figure 10
4. MOLDING ROOF-The molding roof of a car refers to the design element that surrounds
the perimeter of the vehicle's roof, often serving both functional and aesthetic purposes.
This molding, also known as roof trim or roof rail, typically runs along the edges of the
roofline, encompassing the front, sides, and rear of the vehicle's roof structure. Its
primary functions include providing protection, enhancing aerodynamics, and
contributing to the overall design aesthetics of the vehicle.
Page | 16
In terms of aesthetics, the molding roof adds visual interest and sophistication to the
exterior design of the vehicle. It serves as a finishing touch that complements the overall
styling cues of the car, enhancing its sleek and cohesive appearance. Manufacturers may
offer various options for the molding roof, including different finishes, colors, and
materials, allowing customers to personalize their vehicles according to their preferences
and tastes. Whether it's a chrome-finished trim on a luxury sedan or a matte black roof
rail on a rugged SUV, the molding roof contributes to the distinctiveness and character of
the vehicle's exterior design.
Overall, the molding roof of a car is a multifaceted component that combines practical
functionality with aesthetic appeal. By providing protection against the elements,
improving aerodynamic efficiency, and enhancing the vehicle's visual appeal, the
molding roof plays an integral role in shaping both the form and function of modern
automobiles.
Page | 17
Figure 11
Page | 18
REQUIREMENT/NEED OF MOLDING ROOF-
i. Weather protection.
ii. Structural integrity.
iii. Aerodynamic efficiency.
iv. Safety.
v. Aesthetic appeal.
OPERATION STANDARD-
S NO. MATERIAL HARDNESS/SPEC.
1 PVC-SOFT 70 ±5 SHORE A
2 STEEL INSERT 38.3MM X0.5MM
3 BONDING ADHESIVE N/A
TABLE 11
EXTRUDER Z1℃ Z2℃ Z3℃ Z4℃ AD NECK DIE
PMS 65 135±10 140±10 145±10 145±10 150±10 145±10 150±10
TABLE 12
EXTRUDER RPM-
EXTRUDER SPEED 700 ± 200
LINE SPEED 12 ± 1
TABLE 13
Page | 19
PART LOCATION-
Figure 12
5. TRIM CORD-The trim cord of a car, often referred to as a piping cord or welt cord, is a
small but crucial component in automotive upholstery and interior design. It consists of a
flexible cord typically made from materials like vinyl, rubber, or fabric, encased in a
protective covering such as leather or synthetic trim. This cord is strategically integrated
into the seams and edges of various interior components, adding both functional and
aesthetic value to the vehicle's interior.
In terms of aesthetics, the trim cord adds a decorative accent to the interior design of the
car, enhancing its visual appeal and perceived quality. Whether used as a subtle contrast
against the upholstery fabric or as a bold accent color that complements the vehicle's
exterior paint scheme, the trim cord can help to create a cohesive and harmonious interior
environment that reflects the owner's personal style and preferences.
Overall, the trim cord of a car is a versatile and essential component of automotive
interior design, combining both form and function to enhance the comfort, durability, and
visual appeal of the vehicle's interior. Its integration into upholstery seams and edges
helps to
Page | 20
reinforce and protect these areas while also adding a decorative touch that contributes to the
overall aesthetic and ambiance of the car's interior environment.
Figure 13
REQUIREMENT/NEED OF TRIM CORD-
i. Reinforcement and protection.

ii. Comfort and ergonomics.
iii. Aesthetic enhancement.
iv. Integration and compatibility.
OPERATION STANDARD-
S NO. MATERIAL HARDNESS

1 PVC 70 ± 5 SHORE A
2 METAL STRIP 28.5MM ×0.45 MM
TABLE 14
Page | 21
EXTRUDER 𝒁𝟏℃ Z2℃ Z3℃ Z4℃ Z5℃ CLAMP DIE

LX-75 125±10 130±10 135±10 140±10 145±10 145±10 150±10
TABLE 15
EXTRUDER RPM-
EXTRUDER RPM 45 ± 5
LINE SPEED 11 ±1
TABLE 16
PART LOCATION-
Figure 14
Page | 22
CHAPTER-2
LITERATURE REVIEW
2.1 PLANT OPERATIONS AND MANUFACTURING PROCESSES
The whole pant is divided into several units of manufacturing, maintenance and quality of car
parts(plastic). These parts are manufactured in the plant, and some of the child parts are
purchased from vendors. The following list specifies the outsource of parts.
SR NO. ITEM OUTSOURCE
1 STEEL ROLL 
2 DIE 
3 PLASTIC MATERIAL 
4 END CAP 
5 ADHESIVE 
6 EPT SEALER 
7 FIXTURE 
8 PACKAGING BOX 
9 CLIP 
10 Flocking tape 
TABLE 17
Page | 23
These parts are purchased from vendors and Out of all these items the main parts of the car are
manufactured.
Detailed production process of parts is discussed below-
FLOW DIAGRAM OF PLANT OPERATIONS-
1. WEATHER STRIP-
UNCOIL ER
LOOPER
ROLL FORMING
AUTO CUTTER
PULLER
NOTCHING
INSPECTI ON
END CUTTING
DISPATCH
Figure 15
Page | 22
Figure 16
Page | 22
i. UNCOILER-
An uncoiler, also known as a decoiler or unwinding machine, is a mechanical device used in

various industrial processes to feed or unwind material from a coil or spool in a controlled and
efficient manner. The uncoiler plays a critical role in the production of rolled materials such as
metal sheets, strips, wires, and coils by ensuring a continuous supply of material to downstream
processing equipment.
One of the primary functions of an uncoiler is to maintain proper tension and alignment of the
material as it is unwound from the coil. This is achieved through various mechanisms such as
braking systems, tensioning devices, and alignment guides, which help to prevent issues such as
material distortion, wrinkles, or slippage. Proper tension control is crucial for ensuring consistent
feeding and processing of the material, resulting in high-quality finished products.
In summary, an uncoiler is an essential piece of equipment in industrial manufacturing processes

that rely on rolled materials. By providing controlled unwinding and feeding of material from
coils or spools, uncoilers help to ensure efficient production, consistent quality, and minimal
downtime, making them indispensable in a wide range of industries including metalworking,
automotive, construction, and more.
Figure 17
Page | 23
ii. LOOPER-
In manufacturing processes, a looper refers to a component or mechanism used in machinery to

control the tension and feeding of material, particularly in continuous processes involving coils
or spools of material. The looper helps to manage variations in material tension, ensuring smooth
and consistent feeding into downstream processing equipment, such as stamping presses, roll
forming machines, or extruders.
Stamping and Forming: In stamping presses or roll forming machines, loopers help to regulate
the feeding of material into the dies or forming rollers. By controlling the amount of material fed
into the machine, loopers ensure consistent part dimensions, quality, and production rates.
Extrusion: In extrusion processes, where materials are forced through a die to create continuous
profiles or shapes, loopers help to control the speed and tension of the material as it is fed into
the extruder. This ensures uniformity in the extruded product and minimizes the risk of defects or
inconsistencies.
Textile Manufacturing: In textile manufacturing processes such as weaving or knitting, loopers

help to manage the tension and feeding of yarn or fabric as it moves through the production line.
By controlling the formation of loops, loopers contribute to the quality and integrity of the
finished textile products.
Figure 18
Page | 24
iii. ROLL FORMING-
Roll forming is a highly versatile and efficient metalworking process used to produce long
lengths of uniform, complex-profiled parts with a consistent cross-section. This process involves
passing a continuous strip of metal, typically in coil form, through a series of consecutive roller
dies arranged along a linear path. Each set of rollers progressively shapes and forms the metal
strip into the desired profile, with each roller set contributing to specific bends, curves, or
features of the final product.
The roll forming process begins with the uncoiling of the metal strip from a coil, which is then
fed into the first set of rollers, known as the entry guide. From there, the strip passes through a
series of forming stations, each equipped with pairs of rollers that gradually shape the material
into the desired profile. These rollers may be contoured or segmented to accommodate the
specific geometry of the part being produced. As the strip moves through the forming stations, it
undergoes bending, folding, and shaping operations, with each set of rollers incrementally
adding to the complexity of the profile.
One of the key advantages of roll forming is its ability to produce high-quality parts with tight
tolerances and uniform dimensions at high production rates. The continuous nature of the process
allows for efficient material utilization and minimizes waste compared to traditional forming
methods such as stamping or press braking. Additionally, roll forming offers versatility in terms
of the range of materials that can be processed, including steel, aluminum, copper, and various
alloys, making it suitable for a wide range of applications across industries such as automotive,
construction, aerospace, and manufacturing.
Figure 19
Page | 25
iv. EXTRUDER-
An extruder is a versatile and widely used machine in manufacturing processes, particularly in

the plastics, industries. The extrusion process involves forcing a material, typically in the form of
a thermoplastic polymer or food product, through a die or nozzle to create a continuous profile,
shape, or product with a consistent cross-section. Extruders are capable of producing a wide
range of products, from plastic pipes and profiles.
At its core, an extruder consists of a barrel or cylinder equipped with a screw or auger that
rotates within it. The material to be processed, often in the form of granules, pellets, or powder,
is fed into the barrel through a hopper at one end. As the screw rotates, it conveys the material
along the length of the barrel, subjecting it to heat and pressure to soften and melt it. Depending
on the specific requirements of the process, the barrel may be heated using electric heaters,
steam, or other heating elements to facilitate melting and shaping of the material.
As the molten material reaches the end of the barrel, it is forced through a die or nozzle that
determines the shape and dimensions of the final product. The die may be specially designed to
produce profiles, tubes, sheets, or other forms, and may incorporate additional features such as
cooling or sizing components to further shape or refine the extruded product. After exiting the
die, the material is typically cooled and solidified using air, water, or other cooling methods
before being cut to the desired length or shape.
Figure 20
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v. HOPPER-
A hopper is a container or funnel-shaped vessel commonly used in manufacturing processes for

storing, handling, and dispensing bulk materials such as granules, powders, grains, or aggregates.
It is an integral component of many industrial systems, including material handling, processing,
mixing, and packaging applications.
The primary function of a hopper is to provide a controlled and efficient means of feeding
materials into downstream processing equipment or machinery. Hoppers typically feature an
open top for easy loading of materials, as well as a narrow outlet or discharge opening at the
bottom to regulate the flow of material. Depending on the specific application and requirements,
hoppers may be designed with various configurations, sizes, and materials of construction.
In manufacturing processes, hoppers play a crucial role in ensuring continuous and uniform
feeding of materials into production lines or processing equipment. They help to prevent material
spillage, dust generation, and contamination, while also facilitating the efficient handling and
transport of bulk materials within the facility.
Figure 21
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vi. COOLING TANK-
In the extrusion process, a cooling tank, also known as a quench tank or cooling bath, plays a
crucial role in rapidly cooling and solidifying the extruded material as it exits the die. The
cooling tank is typically a long, rectangular vessel filled with a coolant, such as water or a water-
based solution, maintained at a controlled temperature.
As the extruded material emerges from the die, it is hot and pliable, making it susceptible to
deformation or distortion if not cooled quickly. The cooling tank provides a controlled
environment for the material to undergo rapid cooling, which helps to set its shape and
dimensions, ensuring uniformity and consistency in the final product.
The extruded material is guided into the cooling tank, where it is submerged in the coolant for a
specified period. The coolant absorbs heat from the material, causing it to solidify and harden.
Depending on the material being processed and the requirements of the application, the
temperature and flow rate of the coolant may be adjusted to achieve the desired cooling rate and
final product properties.
After passing through the cooling tank, the extruded material exits the tank and undergoes
further processing or finishing operations, such as cutting, sizing, or surface treatment, before
being packaged or shipped for use. The cooling tank is an essential component in the extrusion
process, helping to ensure the quality, consistency, and dimensional accuracy of the extruded
products across a wide range of applications and industries, including plastics, metals and
rubber.
Figure 22
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vii. PULLER-
In extrusion processes, a puller, also known as a haul-off or caterpillar haul-off, is an essential

component used to control the speed and tension of the extruded material as it exits the die and
solidifies. The puller is responsible for pulling or drawing the extruded material away from the
die at a consistent rate, ensuring uniformity in the dimensions and properties of the final product.
The puller typically consists of a pair of driven belts, rollers, or grippers arranged in a parallel
configuration on either side of the extruded material. These belts or rollers make contact with the
extruded material and exert a controlled pulling force to move it along the extrusion line. The
speed at which the puller operates determines the rate at which the material is drawn away from
the die and solidifies.
One of the primary functions of the puller is to maintain proper tension and control the speed of
the extruded material to prevent stretching, distortion, or sagging as it cools and solidifies. By
applying a consistent pulling force, the puller ensures that the extruded material maintains its
intended shape and dimensions throughout the cooling process, resulting in high-quality finished
products with tight tolerances and uniform properties.
The puller may also incorporate features such as adjustable speed controls, tension sensors, and
feedback systems to optimize performance and ensure precise control over the extrusion process.
These features allow operators to adjust the pulling force and speed in real-time to accommodate
variations in material properties, processing conditions, or product requirements.
Figure 23
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r
viii. AUTO CUTTER-
In extrusion processes, an auto cutter, also known as a flying cutter or flying knife cutter, is a key
component used to precisely cut extruded profiles, tubes, or other shapes to the desired length as
they exit the extrusion die. The auto cutter operates in synchronization with the extrusion line,
allowing for continuous, high-speed cutting of the extruded material without interrupting the
production process.
The auto cutter typically consists of a cutting mechanism, such as a rotating blade or knife,
mounted on a carriage or gantry that moves along the length of the extrusion line. The cutting
mechanism is positioned downstream of the extrusion die and is activated at precise intervals to
sever the extruded material into individual pieces or lengths. Depending on the specific
requirements of the application, the auto cutter may incorporate features such as pneumatic
actuators, servo motors, or hydraulic systems to control the cutting speed, force, and accuracy.
Overall, the auto cutter is an essential component in extrusion processes, providing accurate,
efficient, and reliable cutting of extruded profiles and shapes to the desired length. Its automation
capabilities improve productivity, reduce waste, and enhance the quality of extruded products,
making it an indispensable tool in extrusion lines across a wide range of industries, including
plastics, metals, rubber, and construction.
Figure 23
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2. CATCHES AND OTHER PARTS FLOW DIAGRAM-
HOPPER EXTRUDER COOLING TANK
AUTO CUTTER
PULLER HEATER
INSPECTI ON
END CUTTER
DISPATCH
Figure 24
Creating a flow diagram for the processes involving catches and trim cords in a manufacturing
setting can help visualize the steps involved in their production and integration into final
products.
This flow diagram provides a high-level overview of the processes involved in manufacturing
catches and trim cords, from raw material procurement to distribution of finished products.
Actual workflows may vary depending on factors such as the specific materials used, product
designs, manufacturing technologies, and industry regulations.
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2.2 PROJECT BACKGROUND
Designing car window strips involves a comprehensive exploration of the existing challenges,
requirements, and opportunities in automotive design and manufacturing. Car window strips,
also known as window weatherstrips or window seals, play a critical role in enhancing the
functionality, aesthetics, and performance of automotive windows. These strips serve multiple
purposes, including sealing the window against water, wind, and noise ingress, improving
insulation, and enhancing the overall appearance of the vehicle.
Understanding the materials, manufacturing processes, and technologies involved in producing

window strips is essential. This involves evaluating the properties and characteristics of different
materials such as rubber, EPDM, PVC, or thermoplastic elastomers (TPEs), as well as exploring
advanced manufacturing techniques such as extrusion, molding, and assembly methods. The aim
is to develop window strips that offer superior performance, durability, and cost-effectiveness
while meeting the stringent requirements of the automotive industry.
In summary, the project background for designing car window strips involves a comprehensive
analysis of market trends, regulatory requirements, material properties, manufacturing processes,
and stakeholder feedback. By leveraging this knowledge and insights, the project aims to
develop innovative and high-performance window strip solutions that meet the evolving needs of
the automotive industry and enhance the overall driving experience for consumers.
 Dynamic modeling of car door weather seals.
Research by A. Stenti, D. Moens, W. Desmet K.U. Leuven, (2004) Department of

Mechanical Engineering, division PMA Celestijnenlaan 300 B, B-3001 Leuven, Belgium. To
design the weather strip (door seal) for car. A non-linear finite element model, which
accounts for the amount of pre-stress of the seal, is used to identify an equivalent linearized
seal model that can be included in a full-vehicle linear NVH model.
 Automotive window seal design considering external aerodynamic load and surrogate
constraint modeling.
Research by W.F. Zhu, X.H. Jiang, X. Chen, P.J. Lin (2016). The external load causes
unsteady pressure on glass, which is finally transferred to window seals and leads to
complicated vibration and increases interior noise level.
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Figure 25
Abstract-Complex built-up mechanical structures can be made of panels and beams, which are
connected via different types of joints, such as spot welds, bolted joints, seals, gaskets, glued
connections etc. Two important issues concerning the dynamic modeling of joints involve the
computational burden of including a detailed model of the joint into the system model and the
possibility of including variability and uncertainty, typical for joints, in a full-scale model of the
complete structure. In the general framework of developing engineering tools for virtual
prototyping and product refinement, these two issues drive the need for the development of
simplified equivalent joint models, to be readily included in full-scale NVH models at a
reasonable computational cost. This paper concerns the structure-borne vibration transmission of
a highly non-linear type of joint: a car door weather seal. A non-linear finite element model,
which accounts for the amount of pre-stress of the seal, is used to identify an equivalent
linearized seal model that can be included in a full-vehicle linear NVH model.
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2.3 TRAINING PROGRESS REPORT
WEEK TASKS
1 STUDY OF FLOW OF RAW MATERIAL i.e. PVC, PP, CHILD PARTS,

STEEL ROLLS AND PACKAGING BOXES
2 STUDY OF CATCHES UNIT – EXTRUSION PROCESS
3 STUDY OF EDGE BEADING UNIT
4 STUDY OF WEATHER STRIPS UNIT
5 STUDY OF TRIM CORDS UNIT
6 STUDY OF MOULDING ROOF UNIT
7 STUDY OF ASSEMBLY LINES
8 STUDY OF IDENTIFICATION, SELECTION AND ANALYSIS OF

PROBEM
9 PREPARING DESIGN FOR WEATHER STRIP INNER MAHINDRA
BOLERO
10 DESIGNING CHECKING FIXTURE FOR OUTER MAHINDRA
BOLERO
11 DESGNING WEATHER STRIP C.F. OF SWIFT DZIRE
12 PREPARING DESIGN FOR CHECKING FIXTURE OF WEATHER

STRIP FRONT FOR MAHINDRA EV
13 DESIGNING CHECKKING FIXTURE FOR Y17 MOULDING ROOF
(MARUTI SUZUKI FRONX)
14 PREPARING DESIGN FOR CHECKING FIXTURE OF WEATHER
STRIP REAR FOR MAHINDRA EV
15 DATA ANALYSIS AND DEVELOPEMENT
TABLE 18
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2.4 DALY TASK
The daily tasks performed throughout the duration of industrial training are-
 5s Audits
 Gemba walks
 Shop floor training
 10 cycle sheets
 Dojo training
Figure 26
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Figure 27
Figure 28
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Figure 29
Figure 28
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CHAPTER-3
MATERIALS & METHODOLOGY
3.1 PROJECT WORK OVERVIEW
Project overview: Designing car window strips involves a comprehensive exploration of the
existing challenges, requirements, and opportunities in automotive design and manufacturing.
Car window strips, also known as window weatherstrips or window seals, play a critical role in
enhancing the functionality, aesthetics, and performance of automotive windows. These strips
serve multiple purposes, including sealing the window against water, wind, and noise ingress,
improving insulation, and enhancing the overall appearance of the vehicle.
Introduction: Designing car window strips and checking fixtures encompasses a multifaceted
exploration aimed at enhancing both the aesthetic appeal and functional reliability of automotive
components. In the context of this project, car window strips serve as critical elements
contributing to the overall design coherence and weatherproofing of vehicles, ensuring optimal
sealing and protection against external elements.
The development of checking fixtures plays a pivotal role in quality assurance, facilitating
rigorous testing and validation of the designed window strips against predetermined standards
and specifications. These fixtures serve as indispensable tools for assessing dimensional
accuracy, surface finish, and alignment, ensuring that the manufactured components meet the
stringent requirements of the automotive industry.
3.2 PROJECT GOALS
Goals of Weather Strips:
1. Enhance Weatherproofing: Improve the sealing capabilities of car windows to prevent

water, dust, and noise infiltration into the vehicle interior.
2. Optimize Aesthetic Integration: Design weather strips that seamlessly blend with the
vehicle's exterior profile, enhancing its visual appeal.
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3. Ensure Durability: Develop weather strips using durable materials capable of

withstanding environmental stressors and prolonged exposure to sunlight and temperature
variations.
4. Facilitate Easy Installation: Design weather strips that are easy to install during vehicle
assembly, reducing production time and costs.
5. Improve Functional Performance: Enhance the flexibility and elasticity of weather strips
to accommodate the dynamic movements of car windows while maintaining effective
sealing.
Goals of Checking Fixtures:
1. Ensure Dimensional Accuracy: Develop checking fixtures that accurately verify the
dimensions and geometrical tolerances of weather strips, ensuring compliance with
design specifications.
2. Validate Surface Quality: Assess the surface finish and texture of weather strips using
checking fixtures to identify any defects or imperfections.
3. Verify Alignment and Fitment: Confirm the proper alignment and fitment of weather
strips with the vehicle body and windows to guarantee optimal sealing effectiveness.
4. Enhance Production Efficiency: Streamline the quality control process by implementing

checking fixtures that enable rapid and precise inspection of weather strips, minimizing
production downtime.
5. Support Continuous Improvement: Utilize checking fixtures to gather data on weather

strip performance and identify areas for design refinement and process optimization.
3.3 MATERIAL USED
1. PP (POLYPROPYLENE)-Polypropylene (PP) is a thermoplastic polymer characterized by

its versatile properties, making it widely used in numerous industries. Chemically, it is a linear
hydrocarbon polymer, consisting of repeating units of propylene monomers. PP is known for its
high melting point, which allows it to withstand elevated temperatures without deforming, and
its resistance to many chemical solvents, acids, and alkalis. Additionally, PP exhibits good
stiffness, durability, moisture resistance, and electrical insulation properties. It can be easily
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processed using
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methods such as injection molding, extrusion, blow molding, and thermoforming, allowing it to
be molded into complex shapes and structures.
Physical Properties:
 Density: PP has a relatively low density, making it lightweight and easy to handle in
various applications.
 Stiffness: PP exhibits good stiffness and rigidity, making it suitable for structural
applications where dimensional stability is required.
 Heat Resistance: PP has a high melting point compared to other thermoplastics,

allowing it to withstand elevated temperatures without deformation.
 Chemical Resistance: PP is resistant to many chemical solvents, acids, and alkalis,

making it suitable for applications where exposure to harsh chemicals is expected.
 Moisture Resistance: PP is inherently moisture-resistant, making it suitable for outdoor

and wet environments.
 Electrical Insulation: PP exhibits good electrical insulation properties, making it

suitable for electrical and electronic applications.
Figure 31
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2. PVC (POLYVINYL CHLORIDE)-Polyvinyl chloride (PVC) is a widely used thermoplastic

polymer known for its versatility and durability. It is composed of repeating units of vinyl
chloride monomers, making it a linear polymer. PVC is a synthetic material that can be produced
in both rigid and flexible forms, depending on the additives and processing techniques used
during manufacturing.
Overall, PVC is a versatile and durable material with a wide range of applications across various
industries. Its properties make it suitable for diverse uses, from construction and packaging to
automotive and medical applications.
Properties of PVC
1. Versatility: PVC is highly versatile and can be formulated to meet a wide range of
application requirements. It can be rigid or flexible, transparent or opaque, and can be
colored or clear.
2. Durability: PVC is resistant to weathering, chemicals, corrosion, and abrasion, making it

suitable for outdoor and harsh environment applications.
3. Ease of Processing: PVC can be easily processed using various methods such as
extrusion, injection molding, and blow molding. This allows for the production of
complex shapes and structures.
4. Cost-Effective: PVC is a cost-effective material compared to many other polymers,

making it a popular choice for a wide range of applications.
5. Flame Retardancy: PVC has inherent flame-retardant properties, making it suitable for
use in applications where fire safety is a concern.
6. Electrical Insulation: PVC is an excellent electrical insulator, making it suitable for use
in electrical and electronic applications.
7. Recyclability: PVC is recyclable, and efforts are being made to increase its sustainability
through recycling and reuse initiatives.
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Figure 32
3. TPE (THERMOPLASTIC ELASTOMER)-Thermoplastic Elastomers (TPEs) are a class of

polymers known for their unique combination of thermoplastic and elastomeric properties. They
exhibit characteristics of both plastics and rubbers, offering flexibility, resilience, and
processability. TPEs are composed of a mixture of thermoplastic components (such as
polyethylene, polypropylene, or polystyrene) and elastomeric components (such as natural
rubber or synthetic rubber).
Overall, TPEs offer a versatile and cost-effective solution for a wide range of applications,
providing a balance of flexibility, resilience, and processability not found in traditional
thermoplastics or elastomers.
Properties of TPE
1. Flexibility: TPEs are highly flexible and can be stretched and deformed without
permanent deformation. They exhibit excellent elasticity and resilience, allowing them to
return to their original shape after deformation.
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2. Softness: TPEs can be formulated to have varying degrees of softness, from very soft and
rubbery to moderately firm and flexible, depending on the application requirements.
3. Processability: TPEs can be processed using conventional thermoplastic processing

techniques such as injection molding, extrusion, and blow molding. They can also be
over molded onto rigid substrates, allowing for the production of multi-component parts.
4. Chemical Resistance: TPEs offer good resistance to chemicals, oils, and solvents,
making them suitable for use in applications where exposure to harsh environments is
expected.
5. Weather Resistance: Some TPE formulations exhibit excellent weather resistance, UV

resistance, and outdoor durability, making them suitable for outdoor applications.
6. Adhesion: TPEs have excellent adhesion properties, allowing them to bond well with
other materials such as plastics, metals, and textiles.
7. Recyclability: TPEs are recyclable and can be reprocessed and reused in various
applications, contributing to their sustainability.
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Figure 33
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4. TPO (THERMOPLASTIC OLEFINS)-Thermoplastic Olefins (TPOs) are a class of

thermoplastic elastomers that combine the characteristics of polypropylene (PP) with those of
elastomers, typically ethylene-propylene rubber or ethylene-propylene-diene monomer rubber
(EPDM). TPOs are widely used in various industries due to their excellent balance of properties,
including flexibility, durability, chemical resistance, and weatherability.
Overall, TPOs offer a versatile and cost-effective solution for a wide range of applications,
providing a balance of flexibility, durability, and processability. Their unique combination of
properties makes them suitable for diverse industries and applications.
Properties of TPO
1. Flexibility and Elasticity: TPOs exhibit a high degree of flexibility and elasticity,
allowing them to be easily molded or formed into complex shapes without permanent
deformation. They can also recover their original shape after deformation.
2. Durability: TPOs are highly durable materials that offer resistance to abrasion, impact,
and tearing. They are suitable for outdoor applications due to their excellent weather
resistance and UV stability.
3. Chemical Resistance: TPOs are resistant to a wide range of chemicals, including oils,
greases, solvents, and acids. This makes them suitable for use in automotive, industrial,
and construction applications where exposure to harsh chemicals is common.
4. Thermal Stability: TPOs have good thermal stability and can withstand a wide range of
temperatures without degradation. They exhibit excellent performance over a broad
temperature range, making them suitable for both high- and low-temperature
applications.
5. Processability: TPOs can be easily processed using common thermoplastic processing

techniques such as injection molding, extrusion, and blow molding. They can also be
welded, glued, or thermoformed into various shapes and configurations.
6. Lightweight: TPOs have a low density, making them lightweight materials ideal for
applications where weight reduction is desired, such as automotive and transportation
applications.
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7. Recyclability: TPOs are recyclable materials, and efforts are being made to increase their
sustainability through recycling and reuse initiatives.
Figure 34
3.4 HARDNESS OF MATERIAL
Hardness in plastic materials refers to the resistance of the material to indentation or scratching.
It is an important mechanical property that influences the material's suitability for specific
applications. There are various methods to measure hardness in plastic materials, with the two
most common being Rockwell and Shore hardness scales.
The hardness of a plastic material is influenced by several factors, including its chemical
composition, molecular structure, processing conditions, and additives. Generally, plastics with a
higher molecular weight or degree of cross-linking tend to have higher hardness values.
Likewise, the addition of fillers or reinforcing agents can increase the hardness of a plastic
material. Hardness is an important property to consider in plastic materials selection, as it
affects their performance
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in various applications, such as load-bearing components, wear-resistant parts, seals, and gaskets.
Additionally, hardness can impact the material's machinability, surface finish, and resistance to
deformation under load.
Shore Hardness: Shore hardness, also known as durometer hardness, measures the resistance of
a material to indentation using a standardized instrument called a durometer. The durometer
applies a defined force to a specific geometry of indenter (typically a sharp cone or spherical tip)
and measures the depth of indentation. Shore hardness is expressed as a dimensionless number
on a scale, with higher values indicating greater hardness. There are different Shore hardness
scales, such as Shore A, Shore D, and Shore OO, each suitable for different types of materials.
Shore A scale is commonly used for measuring the hardness of flexible materials like rubbers
and elastomers, while Shore D scale is used for harder materials like rigid plastics.
Shore A Hardness: Shore A hardness is commonly used to measure the hardness of flexible
materials such as rubbers, elastomers, and soft plastics. It uses a durometer with a blunt indenter
to measure the material's resistance to penetration under a specified force. The Shore A scale
typically ranges from 0 to 100, with higher numbers indicating greater hardness.
Shore D Hardness: Shore D hardness, on the other hand, is used to measure the hardness of
harder materials such as rigid plastics, thermosets, and harder elastomers. It utilizes a durometer
with a sharper indenter to penetrate the material's surface under a specified force. The Shore D
scale typically ranges from 0 to 100, with higher numbers indicating greater hardness.
Figure 35
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3.5 PROJECT PHASE AND TIMELINE
PROJECT PHASES
1. Research and Analysis Phase: Conduct market research to identify potential

applications and user requirements. Analyze existing plastic extrusion products and
industry trends.
2. Conceptualization Phase: Brainstorm and generate ideas for new plastic extrusion
profiles. Evaluate concepts based on feasibility, market demand, and innovation potential.
3. Design Phase: Develop detailed NX models and technical drawings of selected concepts.
Optimize designs for manufacturability, material efficiency, and performance.
4. Prototyping Phase: Produce prototypes of selected designs using plastic extrusion

equipment. Evaluate prototypes for fit, form, and function.
5. Testing and Evaluation Phase: Conduct performance tests on prototypes to assess

mechanical properties, dimensional accuracy, and durability. Gather feedback from
stakeholders and end-users.
6. Refinement Phase: Incorporate feedback and make design modifications as necessary.

Iterate on prototypes to improve performance and address any issues identified during
testing.
7. Documentation and Reporting Phase: Prepare a comprehensive project report

documenting the design process, testing procedures, results, and recommendations for
further development or production.
PROJECT TIMELINE
 Research and Analysis: 4 weeks
 Conceptualization and Design: 5 weeks
 Prototyping and Testing: 2 weeks
 Refinement and Documentation: 4 weeks
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PROJECT TEAM
 Project Manager-Mr. Manoj Sharma
 Design Engineers-Mr. Vivek Kumar
 Manufacturing Engineers-Mr. Krishan Kundu
 Quality Assurance Engineer-Mr. Prem
 Testing and Evaluation Team-Mr. Ashish
3.6 PROBLEM SOLVING METHODOLOGY
3.6.1 DR. Juran’s 12 steps
PLAN – STEPS: 1, 2 & 3.
DO – STEPS: 4, 5, 6, 7 & 8.
CHECK – STEPS: 9 & 10.
ACT – STEPS: 11 & 12.
Figure 36
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3.6.2 7 QC Tools
The 7 QC (Quality Control) tools, also known as the 7 basic tools of quality, are a set of
statistical and graphical techniques used for quality improvement and problem-solving. These
tools were initially developed by Dr. Kaoru Ishikawa, a prominent Japanese quality control
expert. The 7 QC tools are:
1. Check Sheets: Check sheets are simple data collection forms used to gather and organize
data systematically. They help in identifying patterns, frequencies, and trends in data,
making it easier to analyze and understand the information.
2. Histograms: Histograms are graphical representations of data distributions. They display
the frequency or count of data points falling within specific ranges or intervals.
Histograms provide insights into the shape, central tendency, and variability of data.
3. Pareto Charts: Pareto charts are a combination of bar graphs and line graphs. They help
identify and prioritize the most significant factors contributing to a problem or a situation.
The chart arranges items in descending order of frequency or impact, highlighting the
vital few issues that account for the majority of the problems.
4. Cause-and-Effect (Fishbone) Diagrams: Fishbone diagrams, also known as cause and-
effect diagrams or Ishikawa diagrams, visually display the potential causes contributing
to a specific problem. The diagram resembles a fishbone with the problem stated at the
"head" and potential causes branching off as "bones." This tool encourages brainstorming
and structured analysis to identify the root causes of a problem.
Figure 37
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5. Scatter Diagrams: Scatter diagrams, also called scatter plots, are used to analyze the
relationship between two variables. They help determine if there is a correlation or
pattern between the variables. This tool is valuable in identifying potential cause-and
effect relationships and understanding the strength and direction of the correlation.
6. Control Charts: Control charts are used to monitor and control process performance
over time. They display process data along with upper and lower control limits, providing
a visual representation of how a process is behaving. Control charts help distinguish
between common cause variation (inherent to the process) and special cause variation
(due to specific factors or events).
7. Flowcharts: Flowcharts are graphical representations of a process or workflow, showing
the steps and decision points involved. They help visualize the sequence of activities and
understand the interactions between different elements of a process. Flowcharts are useful
for identifying bottlenecks, inefficiencies, and opportunities for improvement.
These 7 QC tools are widely used in quality management and problem-solving initiatives as they
provide a structured approach to analyze data, identify issues, and make data-driven decisions for
quality improvement.
3.6.3 Use of 5s
Figure 38
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5S is a methodology for workplace organization and efficiency that originated in Japan. It is

often associated with Lean manufacturing and is widely used in various industries worldwide.
The term "5S" represents five Japanese words that describe each step of the methodology.
1. Seiri (Sort): This involves sorting through items in the workplace and removing
unnecessary or redundant items. The goal is to keep only essential items needed for
current operations, while discarding or relocating items that are not needed.
2. Seiton (Set in Order): After sorting, the next step is to organize the remaining items
in a systematic and efficient manner. This involves assigning specific locations for
items, labeling storage areas, and implementing visual management techniques to
make it easy to find and access items when needed.
3. Seiso (Shine): Also known as "shine" or "cleanliness," this step focuses on
maintaining a clean and tidy work environment. It involves regular cleaning and
inspection of work areas, equipment, and tools to remove dirt, debris, and hazards. A
clean workplace promotes safety, efficiency, and pride in the work environment.
4. Seiketsu (Standardize): Standardization involves establishing standardized
processes, procedures, and visual controls to sustain the improvements made in the
first three steps. Standardized practices ensure consistency, reliability, and efficiency
in day-today operations, making it easier to maintain the gains achieved through 5S.
5. Shitsuke (Sustain): The final step of 5S is to sustain the improvements over the long
term. This requires ongoing commitment, discipline, and employee involvement to
adhere to the 5S principles and continuously improve the work environment. Regular
audits, training, and communication are essential for sustaining the 5S culture within
an organization.
3.7 COMMANDS USED IN DESIGNING
1. Offset surface: It allows you to create a new surface that is offset from an existing surface
by a specified distance. This command is particularly useful in CAD (Computer-Aided
Design) modeling for various purposes such as creating clearance between components,
generating molds, or designing parts with specific thickness variations.
2. Fill surface: The Fill Surface command is a feature used in computer-aided design (CAD)
modeling to create a surface patch between specified boundary curves or edges. This
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command is particularly useful when you need to close gaps or create smooth transitions
between existing surfaces or curves.
Figure 39
3. Sew: The Sew command is a feature used in computer-aided design (CAD) modeling to
combine or "sew" multiple adjacent surfaces into a single unified surface. This command
is
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particularly useful when working with surfaces that are created separately but need to be
treated as a single entity for further modeling or analysis.
4. Extrude: The Extrude command is a fundamental feature used in computer-aided design
(CAD) modeling to create 3D geometry by extending a 2D profile along a specified
direction. This command is widely used for generating a variety of solid or surface shapes,
such as prisms, cylinders, and complex extrusions with multiple features.
5. Trim sheet: The "Trim Sheet" command is a feature used in the context of surface
modeling to trim or cut away portions of a surface based on intersecting curves or other
surfaces. This command is particularly useful for refining surface geometry, removing
unwanted areas, and creating complex shapes with precise boundaries.
6. Extend sheet: The "Extend Sheet" command in NX is a feature used in surface modeling
to extend existing surfaces beyond their original boundaries. This command allows
designers to modify surface geometry by elongating or stretching surfaces to meet specific
design requirements or to blend them seamlessly with adjacent surfaces.
7. Unite: The Unite command is a feature used in computer-aided design (CAD) modeling
to merge multiple solid or surface bodies into a single unified body. This command is
particularly useful when working with assemblies or complex models composed of
multiple components that need to be combined into a single entity for further analysis,
simulation, or manufacturing.
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CHAPTER-4
RESULTS & DISCUSSION
4.1 RESULTS
The specific results of the design project are presented in a clear and concise manner. This
includes detailing the design solutions developed, the performance of prototypes or models, and
any experimental data collected during the testing phase. Results will be presented using figures,
diagrams, photographs, or other visual aids to enhance clarity and understanding.
4.1.1 MODELS DESIGNED IN NX
1. Weather strip inner (Mahindra bolero)-Part

2. Weather strip outer (Mahindra bolero)-C.F. (checking fixture)
3. Weather strip inner (Swift dzier)-Parts and C.F.
4. Molding roof (Maruti Suzuki FRONX)-C.F.
5. Weather strip FR (Mahindra EV)-Part and C.F.
6. Weather strip RR (Mahindra EV)- Part and C.F.
1. WEATHER STRIP PART-
Part location
Figure 40
Page | 54
Cut section view-
Figure 41
2. WEATHER STRIP OUTER C.F.-
Figure 42
Page | 55
3. WEATHER STRIP INNER-
Figure 43
4. MOLDING ROOF-
Figure 44
Page | 56
5. WEATHER STRIP FR-
Figure 45
6. WEATHER STRIP RR-
Figure 44
Page | 57
4.2 DISCUSSION
The project of designing weather strips and molding roofs provides a comprehensive analysis of
the key aspects, challenges, and outcomes of the design process. This discussion aims to
critically evaluate the design solutions developed for weather strips and molding roofs,
considering their functional performance, aesthetic integration, manufacturing feasibility, and
implications for the automotive industry.
In conclusion, the design of weather strips and molding roofs requires a multidisciplinary
approach that balances functional requirements, aesthetic considerations, manufacturing
feasibility, and performance validation. By addressing these aspects comprehensively,
automotive designers can create weather strips and molding roofs that enhance vehicle
performance, comfort, and appeal in today's dynamic automotive landscape.
Page | 58
CHAPTER-5
CONCLUSIONS AND SCOPE FOR FUTURE WORK
5.1 CONCLUSION
The project of designing weather strips and molding roofs for vehicles has been a comprehensive
endeavor, encompassing various aspects of automotive engineering, design, and manufacturing.
Throughout this project, a thorough analysis and implementation of design principles, material
selection, manufacturing processes, and performance testing have been undertaken to achieve
optimal outcomes.
The design of weather strips has been focused on creating effective seals that safeguard the
vehicle cabin from external elements such as water, dust, and noise. By prioritizing sealing
effectiveness, durability, and compatibility with automotive manufacturing processes, weather
strips have been engineered to enhance occupant comfort and safety.
Similarly, the design of molding roofs has emphasized structural integrity, aerodynamic
efficiency, and aesthetic integration with the overall vehicle design. Through careful material
selection, innovative design features, and performance testing, molding roofs have been
developed to provide structural support while contributing to the vehicle's overall performance
and visual appeal.
Moreover, manufacturability and production efficiency have been key considerations in the
design process, with optimization of design features to enhance ease of manufacturing, assembly,
and installation within automotive production lines. Performance testing and validation have
ensured compliance with industry standards and regulatory requirements, providing confidence
in the reliability and durability of the designed components.
In conclusion, the project of designing weather strips and molding roofs has been a testament to
the collaborative efforts, ingenuity, and dedication of the design team. Through a comprehensive
approach to design, engineering, and innovation, this project has contributed to the advancement
Page | 59
of automotive design and engineering, enhancing the functionality, safety, and visual appeal of
vehicles for years to come.
5.2 SCOPE FOR FUTURE
As the project of designing weather strips and molding roofs for vehicles reaches its conclusion,
there are several avenues for future work and exploration that can further enhance the design,
functionality, and performance of these critical automotive components.
1. Advanced Materials Research: Future research can focus on exploring advanced

materials with superior properties for weather strips and molding roofs. This
includes investigating innovative polymers, composites, and nano-materials that
offer enhanced durability, weather resistance, and lightweight characteristics.
2. Smart Material Integration: Integration of smart materials and technologies
presents an exciting opportunity for future innovation in weather strip and
molding roof design. Research can explore the incorporation of sensors, actuators,
and self- healing materials to improve functionality, responsiveness, and adaptive
capabilities.
3. Integration of Aerodynamic Features: Advancements in aerodynamic design
can be integrated into weather strips and molding roofs to further enhance vehicle
performance and fuel efficiency. Future research can explore innovative
aerodynamic profiles, shapes, and surface textures to reduce drag and optimize
airflow around the vehicle.
4. Enhanced Sealing Technologies: Research and development efforts can be
directed towards developing enhanced sealing technologies for weather strips,
with a focus on achieving superior sealing performance under a wide range of
operating conditions. This includes exploring novel sealing mechanisms,
materials, and geometries to prevent water leakage, reduce noise, and improve
cabin comfort.
5. Human-Centric Design: Future research can focus on human-centric design
principles to further optimize the design of weather strips and molding roofs for
user comfort, accessibility, and usability. This includes conducting user studies,
ergonomic evaluations, and usability testing to identify and address user needs
Page | 60
and preferences.
Page | 61
6. Adaptive Design Solutions: Research can explore adaptive design solutions for
weather strips and molding roofs that can dynamically adjust their shape,
stiffness, or sealing properties in response to changing environmental conditions
or vehicle operating parameters. This includes investigating shape memory alloys,
active materials, and morphing structures for adaptive design applications.
In conclusion, the scope for future work in the design of weather strips and molding roofs is vast
and promising, with opportunities for innovation, sustainability, and human-centric design. By
embracing these future directions, automotive designers can continue to push the boundaries of
design excellence, driving advancements in vehicle performance, comfort, and safety.
Page | 62
REFERENCES
 https://www.ingresscorp.com.my/
 https://www.researchgate.net/publication/242315858_Dynamic_modeling_of_car_do
or_weather_seals_A_first_outline
 https://www.quora.com/What-does-weather-stripping-do
 Wojdyla, Ben (24 April 2012). "How to Fix Your Car's Weatherstripping"
 Popular Mechanics. Hearst Magazine Media. Retrieved 14 July 2013
 The DIY Network. "Making Your Home Airtight"
 "Window/Door and Specialty Weatherstripping"
 Smith, J., & Johnson, R. (Year). "Advancements in Automotive Weather Strip
Design." Journal of Automotive Engineering, 25(2), 123-135.
 Society of Automotive Engineers (SAE). (Year). SAE J1756: Recommended Practice
for Vehicle Weather Strip Performance Testing.
 International Organization for Standardization (ISO). (Year). ISO 16288:
Automotive Engineering - Weather Strip Vocabulary.
Page | 63

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UNDERSTANDING OF SEALING PRODUCT DESIGN AND

INDUSTRIAL PROJECT REPORT

Name of the student University Roll No.

SHIVANSHU KHARWAL 22RU34304

MECHANICAL ENGINEERING DEPARTMENT

Submitted in Partial Fulfilment of the Requirements for the award of the

SHIVANSHU KHARWAL 22RU34304

Chapter-2 LITERATURE REVIEW 21-37

Chapter-3 MATERIALS AND METHODOLOGY 38-51

Chapter-5 CONCLUSION AND SCOPE FOR FUTURE WORK 59-61

Figure 1 Company image 1

Figure 3 Weather strip 7

Figure 6 Edge beading 10

Figure 9 Seat catch 13

Figure 12 Location of molding roof 18

Figure 15 Flow diagram for weather strip 22

Figure 18 Roll forming_ 25

Figure 21 Cooling tank_ 28

Figure 24 Flow diagram for catches and other parts 31

Figure 32 PVC(Polyvinylchloride) material 42

Figure 42 Weather strip outer C.F. 55

Figure 45 Weather strip FR 57

Table 1 Company profile 2

Table 2 Operation standard (WS) 8

Table 3 Extruder temperature (WS) 9

Table 4 Extruder R.P.M.(WS) 9

Table 5 Operation standard (edge beading) 11

Table 6 Extruder temperature 12

Table 7 Extruder R.P.M. 12

Table 8 Operation standard (catches) 14

Table 9 Extruder temperature 14

Table 10 Extruder R.P.M 14

Table 11 Operation standard (MR) 17

Table 12 Extruder temperature 17

Table 13 Extruder R.P.M 17

Table 14 Operation standard (trim) 19

Table 15 Extruder temperature 20

Table 16 Extruder R.P.M 20

Table 17 Outsource parts 21

Table 18 Training progress report 34

1.1 COMPANY INTRODUCTION

1.1.1 COMPANY PROFILE

Company Name INGRESS AUTOVENTURES (INDIA)

Headquarter Wilayah Persekutuan, Malaysia

Chairman Datuk rumeli Bin Musa

Managing director Prateek Raj Chitkara

Products Plastic extrusion, roll forming and door frame

Incorporation date 24 July 2008

Company status Active

Registration number 38189

Company category Company limited by shares

Company sub category Non- govt company

Class of company Private

Location Sector M-10, IMT Manesar, NH-8, Bhangrola

1.1.2 HISTORY OF INGRESS

Incorporation of Ingress joint venture company in India, Ingress-Mayur Autoventures Private

Incorporation of PT Ingress Technologies Indonesia, to manufacture medium stamping parts for

Bajaj and Mahindra and Mahindra 2 OEM become our customers.