UNIVERSIDAD TECNOLÓGICA BILINGÜE

INTERNACIONAL Y SUSTENTABLE DE PUEBLA

CAPSTONE PROJECT

“Digital visual aids”

PRODUCED IN:

ALPHABET DE SALTILLO S.A DE C.V

PRESENT:
Julio Garcia Castillo
ACADEMIC ADVISOR: BUSSINES ADVISOR:
JORGE MATEO JUAREZ EN PROCESO

SAN JOSE CHIAPA, PUEBLA, PUE. AUGUST, 15. 2022

1
INDICE
GENERAL COMPANY DATA..............................................................................................3
HISTORICAL BACKGROUND.............................................................................................4
COMPANY DESCRIPTION.................................................................................................7
MOTHERSON, MISSION, VISION AND VALUES..........................................................................7

INTERNSHIP AREA...........................................................................................................8
INTRODUCTION...............................................................................................................9
PROBLEM STATEMENT..................................................................................................10
RESEARCH JUSTIFICATION.............................................................................................11
HARNESS TYPES.....................................................................................................................11
COMPONENTS OF A HARNESS...............................................................................................12

OBJECTIVES...................................................................................................................14
METHODOLOGY AND INVESTIGATION DESIGN..............................................................15
Problem definition.................................................................................................................15
Identification of the causes....................................................................................................17
The advantages of using an LCD:............................................................................................18

Project development.....................................................................................................19
Bibliografía...................................................................................................................22
APPENDIX.....................................................................................................................23
GLOSSARY.....................................................................................................................24

2
Chapter I. Company

GENERAL COMPANY DATA.

General questions regarding Motherson can be directed to our six regional

headquarters, the ‘Regional Chairman’s Offices’.
The Motherson Group is expanding at a high pace and to support this growth the
Regional Chairman’s Offices, which are located in the core automotive regions of
the world, were born.
The Regional Chairman’s Offices act autonomously for their respective regions and
cover the following regional departments and responsibilities:
Mergers & Acquisitions
Legal & Corporate Affairs
Treasury, Tax, Finance
Internal Audits
Deep Dive Teams
Performance Enhancement Teams
Human Capital
Communication
Administration
2
Saltillo MSSL

3
Chapter I. Company

HISTORICAL BACKGROUND.

 1975–1982. A family affair.

Motherson was founded as a small family trading company by our current

chairman, Vivek Chaand Sehgal and his late mother, Shrimati Swaran Lata
Sehgal. Within a few short years, the company would move from silver trading to
making electrical wiring for homes.
 1975 - Motherson founded in Delhi, India.
 1977 - First cable factory launches a new direction for the family firm.

 1983–1986. An automotive revolution.

The first affordable car to be assembled locally, the Suzuki Maruti 800, kickstarted
a true revolution in Indian transportation.
“When I learned that the wiring was designed by a Japanese company,” recalls
Vivek Chaand Sehgal, “I got a visa and I was in Tokyo within ten days! I pitched for
the business, but they refused to show me the factory. I came back to India with
samples, and worked day and night to reproduce them.”
Persistence paid off. When the Maruti plant was inaugurated, Motherson’s wiring
harnesses were on proud display as one of the very few Indian-made parts.
Motherson’s automotive journey had begun.
 1983 - First automotive component (wiring harness) produced in India | Maruti
Suzuki.
 1986 - Motherson Sumi Systems Ltd. established in joint venture with Sumitomo
Wiring Systems, Japan.

 1987–1998. Growth in india.

Mercedes was the first luxury car brand to enter the Indian market in 1994. Two
years later, they opened a local assembly line in Pune. In just 39 days, we set up a
whole new plant to produce their wiring harnesses. We won their trust and soon
added dashboard assemblies to our production for them.
By 1997, two milestones allowed us to start building relationships with automakers
from Asia and America. The time was becoming right to go international.

 1991 - First wiring harnesses for commercial vehicles | Tata.

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  1993 - The flagship company of the Group, Motherson Sumi Systems Ltd. (MSSL)
listed on Indian stock exchanges.
 1995 - First partnership with a luxury automotive brand | Mercedes.
 1997 - First parts for models exported from India | Hyundai.
 1997 - First collaboration with a US automaker | Ford.

 1999–2007. Arrival in Europe.

By 1999, we were growing steadily and strongly. But we were still operating only in
India. We opened our first overseas office in Europe, but the real breakthrough
came in 2002.
A customer asked us to look at taking over a bankrupt supplier. In the end, we
couldn’t save the company, so we bought the plant. And shipped 3500 miles from
Dublin to Sharjah in the UAE. In just 10 weeks, we moved and installed over 500
tons of equipment — and the customers’ assembly lines never stopped. We could
now supply to customers in Europe in one-third of the time.
This was the acquisition of Wexford Electronics in Ireland and this was our first in
our string of acquisitions to follow later. Between 2002 to 2007 there were six
acquisitions, of which five were from Europe. In this period Motherson expanded to
ten more countries- Singapore, Mauritius, Ireland, Sri Lanka, UK, USA, Sharjah,
Germany, Czech Republic.
 1999 - First overseas office in Graz, Austria.
 2000 - 5-year plan announced publicly for the first time.
 2001 - First partnership in the off-road segment | Caterpillar.
 2002 - First acquisition by Motherson Group I Wexford Electronics.
 2002 - First overseas plant in Sharjah, UAE.
 2003 - First Motherson operation in Europe | Ford.
 2004 - European headquarters opened in Germany.

 2008–2021. Going global

Since 2008, the group has grown multi- dimensionally. We continued to focus on
the three-fold growth strategy – organic, collaborations and inorganic. This resulted
in expanding our footprint to 41 countries, diversifying our product portfolio, forging
new partnerships and acquiring companies that have synergies with us. Since our
first acquisition in 2002, we’ve welcomed 21 more companies into the Motherson
family. But our international expansion really took off with the acquisition of mirror
maker SMR — a company that was twice our size at the time.
That was followed by SMP, a major producer of polymer modules, which doubled
the size of the Motherson Group. Through SMR and SMP we became supplier to
the global top automotive OEMs. These landmark acquisitions propelled us into the
top league of automotive suppliers worldwide.
 2009 - Acquisition of Visio Corp (rearview mirror business), SMR established.
 2011 - Peguform acquisition, SMP established.

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  2014 - Acquisition of wiring harness division of Stoneridge Inc, entering CV
segment in USA.
 2017 - PKC acquisition, leadership position in American, European and Chinese
CV market.
 2018 - Reydel acquisition, closer relations with French OEMs.
 2019 - Acquisition of Bombardier’s UK rolling stock electrical component business.
 2020 - Proposed Motherson Group reorganization.
 2021 - Acquisition of Plast Met Group, Turkey.
 2021 - Acquisition of Bombardier’s Electrical Wiring Interconnection Systems
(EWIS) business in Huehuetoca, Mexico.
 2021 - Acquisition of majority stake in Nanchang JMCG Mekra Lang Vehicle Mirror
Co., Ltd.

 2022 – Present.

Starting a new chapter. Motherson was restructured with the objective of creating
value for all stakeholders.
More simplicity, synergy and unity that will help us to grow further.
2022 - Group Reorganisation Completed.
2022 - Motherson Sumi Wiring India Limited (MSWIL) listing on stock exchanges.
2022 - Samvardhana Motherson International Limited (SAMIL) was merged into
Motherson Sumi Systems Limited (MSSL) and the new combined entity renamed
and is known as Samvardhana Motherson International Limited.
2022 - Two listed companies under the Motherson umbrella: Samvardhana
Motherson International Limited (SAMIL) and Motherson Sumi Wiring India Limited
(MSWIL)
2022 - Acquisition of CIM Tools Private Limited for machining and sub-assembly of
components for the aerospace industry.

6
Chapter I. Company

COMPANY DESCRIPTION.

Motherson is one of the world’s largest manufacturers of components for the

automotive industry. Our name itself signifies a relationship of deep trust- that of a
mother and child. Trust is sacrosanct in all relationships at Motherson while
working towards our vision of being a globally preferred sustainable solutions
provider.
The company manufactures high-precision turned parts for fuel injection pumps
and assembles metal and plastic components. The firm has nine business
divisions: wire harnesses, visibility systems, polymer modules and products,
technology and software, metal products, retail and services, aerospace, logistics,
and healthcare and medicine.
The Polymer Products division is the largest and is responsible for developing and
producing a highly diversified range of products: from simple plastic parts to highly
integrated systems and modules, with which the company supplies OEMs around
the world. The Motherson Group also has capabilities for mold design, tooling and
elastomer processing.

MOTHERSON, MISSION, VISION AND VALUES

 Mission status.

Over the years the Group has forged long term partnerships and collaborations
with global technology leaders for different products, technologies and customer
requirements.
 Vision statement

Vision is to strengthen these collaborations and partnerships in order to continue

providing best customer support.
 Values
Focus on innovation
Continuous efficiency improvements
Integrated solutions for customers

Manufacturer of automotive wiring harnesses and mirrors for passenger cars in

India. The company has presence in 25 countries and has manufacturing bases in
six continents - Asia, Europe, North America, South America, Africa & Australia.
(Motherson, 1997)

7
Chapter I. Company

INTERNSHIP AREA.

What I can briefly explain about my area is that where I was is called doors,
the area is divided into 2 parts, one is called LT and the other is called MB, it was
also divided into another third part which was called bergstrom in MB, which What
the area was doing was that I ran different types of harnesses which varied
depending on what the line manager asked us for and in LT there were only 2
different types of harnesses which were number 729 and 633 where I spent the
most At the time of my work where I was the taping board where we put the
diapers on the harness and we passed it to another board that at a certain moment
they also put me there, in the next board where they put me was in the electrical
test board on that board They sent the harnesses already taped, what I did was
connect the harness to the dashboard, put the ties or straps on it and test it with
the dyna lab, which gave us a label that we have to put on that same harness. With
the electrical test done, they went to another board that was a clip test where the
clips obviously had to be put on and at the end they still gave us a label after that
we had to give it to GP 12, who was in charge to check that the harness had
everything and that it was in good condition also in the area. There were Sub-
assembly tables which were in charge of assembling the connectors in order to
pass it on to a special board where the skeleton of the harness was made, after
making the skeleton it was it went to a molder where they put the grommet on it
and the aforementioned process was repeated again.

Chapter II. Project

8
 INTRODUCTION.

The present project refers to the change of visual aids of the

electrical test boards that are a tool for the inspection of the harness
holders, in the same way the project covers notorious changes in the
construction of leads and the rapid test of the same, as well as the
inspection process as part of a major improvement for the quality area.
The main characteristic of the boards is that it is an extremely deficient
inspection process, it was easily manipulated by the operators and it
did not follow a reliability process, which are an important process,
since the visual aids of the area were found on them. because a
rigorous control process is not followed, no department is responsible
for control or by quality personnel. In order to analyze this problem, it is
necessary to mention its causes, one of which is the constant
complaints from customers, whether due to a missing component,
mislabeled, a damaged circuit or even damaged connectors.
Complaints were as follows: Missing or wrong clip, Mislabeling,
Damaged circuit. Damaged connector. Another important cause is the
extremely high increase in downtime in the area when trying to solve
the problem.

9
Chapter II. Project

PROBLEM STATEMENT.

The problem that occurred the most in the area was the problem of
misplaced leads as well as poorly assembled terminals.

When the harnesses come out with the wrongly assembled terminals, the
operators in charge of weighing the electrical test take too long since they are
poorly placed and when trying to read the visual aids on the board it turns out that
they are in deplorable conditions due to the passage of time. misuse of the same
operators.

10
 So, my project for this type of problem is to solve it with a mini screen
prototype so that I can reproduce the visual aids electronically at an average height
of the operators' eyes so that they leave behind the problem of bad visual aids.

Chapter II. Project

RESEARCH JUSTIFICATION.

In order to know the development of the resolution of the problem, we will

have to delve deeper into the issues related to an automotive harness. What is a
harness? It is a set of one or more electrical circuits, to which additional
connectors, clips, terminals, tapes, foams, leatherettes, conduits and other
products can be assembled.

HARNESS TYPES

Within the existing types of harnesses range from battery and door
harnesses to complex design and high-tech harnesses such as instrument panel,
floor and engine harnesses.

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COMPONENTS OF A HARNESS

Terminal
The terminals are another essential component in the harnesses, since they
are the ones that indicate the beginning or end of a circuit and facilitate the
introduction of the cable into the cavities of the connectors in order to conduct the
signal to the destination connector terminal. Usually are made of copper or
aluminum, because these materials are good conductors therefore, they have
greater facility to transfer the signal.

Connector
The function of the connector is to ensure that the electrical signal is
transmitted through its terminal to the other receiving terminal, to achieve this the
connectors can be sealed or not, that is, may have a layer of plastic around the
mouth of the connector to prevent the infiltration of water or dust, vibration
protection should also be considered if the area of the automobile demands it, or
against temperature taking into account the material so that it can resist high
temperatures avoiding damage to the cable. In addition to protection, each
connector must to maintain an adequate position during a certain period of life of
the vehicle ensuring that the signal is constant; the lock lever is a lever that
functions as a safety and that embraces the connector to prevent it from moving.
The CPA is another element that also it has the same purpose, which I will mention
later. Due to the wide variety of connectors that exist, connectors are rated

12
according to temperature, vibration, or pressure it supports and if they are sealed
or not.

Clip

To secure the route of the harnesses to ensure that they do not rub, tangle
or break with another part of the car are the clips, which are fixed to pieces of
metal or other harness. The clips in turn consist of two parts, the fastener that is
the part that is fixed to the metal or harness and the headband that will hold the set
of circuits.
The clips are classified according to several characteristics, according to the
type of fastener which It can be in the form of a tree, arrow, clamp or tubular and
that vary depending on the element to where it will be fixed (hole, sheet, harness or
post).

13
 Grommet
The grommet is a piece that guides and covers the circuit branch by means
of a tubular-shaped rubber which crosses the mobile or sharp object like a blade
metal that divides two areas of the car and also has the function of sealing the hole
for prevent the passage of dust or water between areas. So, if the passage is
between two sheets of metal eleven which move, for example, the doors, the
grommet consists of a rubber tube that has at the ends two seals in the shape of
the holes in the sheets to be able to hold and avoid the passage of other agents
that may impair the safety of the harness.

Chapter II. Project

OBJECTIVES.

General objectives: adapt a

mini screen to be able to display visual aids to
any operator on duty with the help of a
1.8-inch LCD

14
 Chapter II. Project

METHODOLOGY AND INVESTIGATION DESIGN.

Problem definition.

15
CAUSE CAUSE HOW IS IT WHO IS WHERE? WHEN?
CHECK GOING GOING TO
TO BE DO IT?
DONE?

1. Damaged visual aids audit in the Audit all those final 05/08/22
lines responsible assembly 03/12/22
for the area
in said
mention
2. Misassembled operator Audit all those final 05/08/22
connector audit responsible assembly 03/12/22
for the area
in said
mention
3. Conveyor speed audit Audit all those final 05/08/22
engineers responsible assembly 03/12/22
and other for the area
leaders in said
mention
4. Lack of test in dynalab mtto audit Audit all those final 05/08/22
responsible assembly 03/12/22
for the area
in said
mention
5. Connector rework operator Hire more all those final 05/08/22
feedback specialized responsible assembly 03/12/22
staff for the area
in said
mention
6. Confusion in stations take the better train all those final 05/08/22
necessary staff responsible assembly 03/12/22
time for the area
in said
mention
7. Outdated methods joint with general all those final 05/08/22
engineering meetings responsible assembly 03/12/22
for the area
in said
mention
8. Wrong part number General Audit all those final 05/08/22
meeting responsible assembly 03/12/22
for the area
in said
mention
9. The numbers do not audits with Audit all those final 05/08/22

16
 indicate the NP of the leaders responsible assembly 03/12/22
connector for the area
in said
mention
10. Lack of material in the meeting contact all those final 05/08/22
area with the and meet responsible assembly 03/12/22
materials with for the area
area materials in said
area mention

Identification of the causes.

Chapter II. Project

17
The advantages of using an LCD:

They take up less physical space: something that stands out at first glance
in LCD monitors is not having to carry the "classic box" that accompanies CRT
monitors. With much less thickness than CRTs, LCD monitors can be placed in
different places, taking up much less space than previous models.

They offer larger screens: in addition to the possibility of having screens of

different proportions (the classic 4:3 or the 16:9 or 16:10 widescreen), LCD
monitors offer us a much wider range in terms of dimensions of screen. Although
we can find LCD screens of different sizes, it is currently possible to get models
that exceed 22" and even some exceptional 30" model, for the most demanding
(although larger alternatives have already been presented in terms of to screen).

They have lower consumption: LCD screens have a really important

advantage over CRTs and that is that they require several times less energy
consumption. This also makes them emit less heat and, in turn, makes them more
friendly to ecology and the environment.

They can provide digital connection: While some low-end LCD monitors still
maintain the analog VGA connection that characterized CRT monitors, the DVI
connection found in mid-range and high-end monitors offers all the advantages of
having a digital connection between the video card and the screen. We can also
find modern models that offer HDMI input.

They present more elegant and modern designs: although there are people
who do not pay much attention to the design of the monitor, there are fans who pay
a lot of attention to this factor. It is also important for the image of the companies,
since it is not the same to enter a reception where a smiling secretary uses a
"careless" 14" monitor than in a place where an elegant and "ultrathin" LCD screen
of 17”. (luca, 2009)

18
 (Motherson, 1997)

Chapter II. Project

Project development

The problem caused by visual aids is focused on the delay of several things,
for example, the transfer of material to be able to deliver it to quality personnel, as
well as the bad assemblies caused by visual aids directly affect the company since
waste is generated. cost administration and sustainability for so much waste.

we will work with the vi 1.8 tft screen since its programming is similar to the
1.77 screen that we have already seen. a micro SD cd card with its respective
adapter at the bottom and in this way it makes playing images on the screen much
easier and it is precisely to work with the screen we are going to see 2 parts the
first will be the connection and the second part is going to be the programming or
the code in the connection part we have here the screen connects to the arduino
and we also have four pins to work with the micro SD card in its pins that are here
on the left we have the connections and here too We show the circuit:

19
20
 Now we have to choose the appropriate format. Notice that it is in jpg but it
has to be in a format. Bmp for this we go to paint we drag the image that we have
downloaded to the paint we solder first we change the size remember that this
screen has a maximum resolution of 160 pixels here we frame this by 128 so that
would be the maximum resolution that we can display yesterday now we can also
choose a smaller value but since we want the entire screen to be displayed we are
going to choose the maximum we accept now we put file save as and I have also
saved it on the desktop with the name of they have to be 24 bits bmp 24 and here I
put it, save and close we can see that the image will be here the image that we are
going to copy to the card would be this here we remove the adapter from the
screen and we are going to take it to the computer to copy the image we open the
card and here we simply drag the image, close, We extract the card and we put it
back on the display after this the memory is inserted again from the bottom and we
connect the ruined to the comp Important user here is to remember the name of
the drawing that we have copied to the micro SD card, we compile and upload and

21
we are going to see the result of our code and well the problem is that lines appear
that can be solved here and the lines that appear are Through the program, a law
of 1500 appears at the end, that is, 1.5 seconds. This is because the program is

displaying every 1.5 seconds and it is as if it were overwriting the same image. To

solve, we can increase the delay, for example, and 100 100 seconds 100 seconds
deley, we would have to change to change it we have to go to the library the library
is in the following directory in my case it is on the c disk program files for 86
arduino.

If one stops to think about where visual management techniques can be

applied, one immediately realizes that visual management is applicable in any area
of the company. Consequently, it allows you to work with greater efficiency.

22
From a spreadsheet, applying color codes, to a complex process that requires a
more in-depth analysis to apply visual management techniques to be more
efficient, such as our LCD screen.

23
Chapter III. Bibliography

Conclusion

The present work presents a whole process of improvement to the logistics

system and the assignment of harnesses in the production process of cars, with a
very specific objective as its purpose: to ensure the assembly of harnesses to the
production lines. The method that has been used to achieve this objective has
other collateral benefits, such as the reduction in response time to replace a
missing harness, the assurance of correspondence or similarity between
harnesses and better customer service, the latter punto summarizes in different
words the main objective of this work, and it is that well, if the continuity of the
production processes is of vital importance, the purpose of our work is to give the
customer a product or service with the quality they require. Through a systematic
and simple analysis of information, it is possible to generate a tool that helps the
operator to contain a situation of lack of materials and therefore to maintain
continuity in the automobile production process, for this reason it is important to
have this tool, since if it is not in daily use, its effectiveness in identifying identical
harnesses has proven to be indispensable for said personnel. And it is that, as
explained throughout the work, a wiring harness is a complex component which is
made up of up to 1000 different components, which makes the identification of
similar harnesses a quite difficult process, even more so if we take Keep in mind
that up to 5,000 harnesses are produced weekly and among these we can find up
to 2,000 different variants. This degree of complexity makes the availability of a
tool to identify identical harnesses essential, since although these similarities can
be identified manually, the time required to do so is quite high and the experience
necessary to do so requires that the person who performs it have previous
knowledge in the manufacture and construction of harnesses, which is an obstacle
if the support does not have a background in the harness industry in the
Engineering, Quality or Production departments. With this tool we ensure that
regardless of the skill or experience of the operator in the harness industry, a
harness reassignment or replacement can be carried out quickly and reliably, since
the method is systematic and uses resources that are specific to the work. Finally, I
would like to emphasize that the assurance of materials in the client's production
lines is the responsibility of the coordinator, and the tool described here helps him
to have more control options over the materials and therefore to give better results.

24
Chapter III. Bibliography

Bibliografía

luca, D. d. (05 de 08 de 2009). Obtenido de https://damiandeluca.com.ar/5-ventajas-

monitores-lcd: https://damiandeluca.com.ar/5-ventajas-monitores-lcd

Herrero, P. (10 de 09 de 2021). Sage Advice. Obtenido de

https://www.sage.com/es-es/blog/gestion-visual-para-trabajar-de-manera-mas-
eficiente/#:~:text=Apoyarse%20en%20gr%C3%A1ficos%2C%20esquemas%2C
%20tablas,que%20permiten%20ganar%20en%20eficiencia.

Media, G. B. (20-22 de 06 de 2023). FITMA. Obtenido de

https://www.pf-mex.com/noticias/post/invierte-motherson-en-nueva-linea-de-
produccion-en-san-luis-potosi

Motherson. (30 de 04 de 1997). Motherson Group. Obtenido de

https://www.motherson.com/

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Chapter III. APPENDIX

APPENDIX

Appendix A: Photographs

Title: myself working

Description: This photo was taken by a college classmate so I could support her.

Title: work area.

Description: The following photographs were taken by me to be able to have my work
area as a reference.

Chapter III. GLOSSARY.

26
 GLOSSARY

1. Grommet: An electrical grommet, also called a "connectivity box", is a module or

junction box that is installed directly on the surface of a table or desk, in such a way
that it allows electrical connections and internet connectivity directly on the
furniture.
2. LCD: Liquid crystal display, it is a thin, flat display made up of a number of color or
monochrome pixels placed in front of a light or reflective source.
3. SD card: is a removable flash memory card that allows you to save information and
content digitally.
4. Connector: Automotive connectors are industrial accessories that are used to fix sensors in
cars and join electrical circuits.
5. electronic harnesses: It is a set of one or more electrical circuits, to which additional
connectors, clips, terminals, tapes, foams, leatherettes, conduits and other products can
be assembled.
6. Dynalab: The Calibration Verification Device is used to verify that the NX Tester is properly
calibrated and to support quality assurance programs that require equipment to be
validated using NIST-validated measurement devices.
7. visual aids: are learning tools that educators and presenters use to convey an idea more
effectively. It is important that visual aids are tailored for a particular audience, depending
on their needs.
8. Arduino: Open source electronics creation platform, which is based on free hardware and
software, flexible and easy to use for creators and developers.
9. Programming code: set of instructions that a developer orders a computer to execute. Said
code is structured according to the guides corresponding to a specific programming
language.
10. electrical tests: they are carried out during a start-up, preventive, corrective and/or
diagnostic maintenance of electrical power distribution equipment; their objective and
purpose is to verify the conditions in which they are found.
11. Automotive harnesses: Automotive harnesses are the "nervous system" of cars: the
harnesses conduct information between electronic and electrical components.
12. operators: The operator is the technical professional who manipulates machines or more
complex technical devices.
13. electrical terminals: devices that provide a connection point in circuits, it can be the final
connection of a cable. They provide security and protection to the circuits in which they
are installed, as well as to the user himself. They are easy and quick to install.

27