SUMMER TRAINING REPORT

ON
"INDUSTRIAL TRAINING"
AT
Toyota Boshoku Device India Pvt.
Ltd.

REWARI (HARYANA)

IN PARTIAL FULFILLMENT
OF THE REQUIREMENT OF
DIPLOMA STUDENTS FROM
([Link]),
AMBALA CITY

SUBMITTED BY:- VISHESH

ELECTRONICS AND COMMUNICATION ENGG.
ROLL NO. :- 240011000063
SUBMITTED TO:- MR. INDERJEET SINGH SIR
 ACKNOWLEDGEMENT

I would like to express my profound and sincere gratitude to Toyota Boshoku Device
India Pvt. Ltd. for affording me this wonderful opportunity to undertake Industrial
Training and enrich my practical knowledge at their esteemed organization. This four -
week training period was an incredible learning experience, during which I got exposed
to real-world industrial practices and professional work environments.

I take this opportunity to express my deep sense of gratitude to Mr. Om Dutt Yadav,
SGM – HR & Admin, for his encouraging guidance and motivation throughout this
training period. My gratitude goes out to the entire HR and technical teams too, who
provided support at every step, making the learning curve quite smooth and enriching.

I would like to extend my special thanks to all my respected faculty members and
mentors at Govt. Polytechnic College Ambala for their continuous support and
encouragement. Their valuable teachings and advice empowered me to apply my
academic knowledge during my training.

The above experience has been a great contributor to both personal and professional
development. I am very confident that whatever skills and insights I have gained here
will help in my future pursuits. I feel grateful to get an opportunity to be associated with
such a reputed organization and for the opportunities given to learn and grow.

Finally, let me thank all my colleagues and friends who have made this experience
memorable and meaningful.

Name:- Vishesh
Roll Number:- 240011000063
Department:- Electronics and Communication Engg.
Government Polytechnic College, Ambala City
 INDUSTRIAL TRAINING DECLARATION

I hereby declare about my industrial training at Toyota Boshoku Device India Private
Limited, completed as a Diploma student of Govt. Polytechnic College Ambala City, is
an authentic record of my own experience and learning during the practical training
period from 03.07.2025 to 06.08.2025. The information presented in my training report is
based on genuine activities, skills, and knowledge gained over the four weeks of training
in the organization.

This, therefore, means that the report is original and has neither been copied nor
reproduced from any other source. It is presented here to fulfill the requirements of my
Diploma program.
CERTIFICATE
 CONTENT OF REPORT FILE

1. Company Profile
a. About Toyota Boshoku Device India Pvt. Ltd.
b. Location
c. Site Capabilities
d. Layout of Industry
e. Industry Logo
f. Products Manufactured

2. Manufacturing Section
a. Overview of Manufacturing Processes
b. Key Equipment Used
c. Manufacturing Workflow
d. Tools Used
e. Safety Practices
f. Environmental Practices
g. Continuous Improvement (Kaizen)

3. Quality Control
a. Objectives
b. Organization of Quality Control
c. Procedures
d. Documentation and Continuous Improvement
4. Packing Section
a. Purpose
b. Process Overview
c. Quality Control Practices
d. Special Focus Areas

5. Conclusion
a. Summary of training period and performance
b. Future acknowledgment

6. Skills Gained During Workshop Training

a. Technical Skills
b. Soft Skills
 COMPANY PROFILE

1.1. About Toyota Boshoku Device India Pvt. Ltd.

Toyota Boshoku Device India Pvt. Ltd. is one of the respected automotive component
manufacturers located in Haryana, India. Established in May 2014, the company exists as
a wholly owned subsidiary of Toyota Boshoku Asia Co., Ltd. It specializes in seat parts,
seat slides, and seat recliners for the automotive industry. The company serves as an
important part of the global Toyota Boshoku Group, highly recognized for manufacturing
premium interior systems and filters. Located in the IMT Bawal industrial area, the
facility spans over 19,000 square meters of land, with over 11,500 square meters of
building space. With a total employee workforce of over 600 associates, the company
focuses on quality, precision, and innovation in its manufacturing. Toyota Boshoku
Device India Pvt Ltd. is committed to supporting the evolving needs of the automotive
industry through delivering high-performance interiors. The firm meets certifications and
operates under the purview of strict quality management standards that serve both local
and international automobile manufacturers. It continues with further development
through technological advancement and collaboration with the Toyota group to keep pace
with the competitive advantage in the automotive components sector. The leadership
team, led by representatives like Naoki Hiragushi, focuses on sustainable growth and
operational excellence.

1.2. Location

Toyota Boshoku Device India Pvt. Ltd.

Work Plant: Plot No. 192 C, Phase II Sector 4, IMT Bawal, Rewari-123501, Haryana,
India.

1.3. Site Capabilities

• Manufacturing of automotive seats, frames, filtration systems, and interior
components.

• Equipped with advanced production lines and a state-of-the-art quality testing

facility.

• Certified in ISO 9001 and TS 16949 standards.

1.4. Layout of Industry

 • Development of automotive interior systems
• Manufacturer of Toyota Corolla Doors Panels
• Quality control lab
• Packing and storage
• Manufacturing of Seat Slider
• Manufacturing of Seat Recliner

1.5. Industry Logo

1.6. Products Manufactured

• Automotive Seats
• Air Filters
• Door Trim Panels
• Cabin Filtration Systems
• Window Regulators
• Seat Slides
• Seat Recliners
• Automobile Seat Parts
 2. MANUFACTURING SECTION

Manufacturing at Toyota Boshoku Device India Pvt. Ltd. is focused on producing high -
quality automotive interior components, including seats, door trims, air filters, and
various cabin-related products. The manufacturing process combines advanced
technology, precision machinery, and strict quality standards to ensure products meet
both customer expectations and international regulations.

2.1. Overview of Manufacturing Processes

The key manufacturing processes at the plant include: -

• Component Fabrication: Cutting, molding, and shaping of raw materials such as

steel, foam, plastics, and textiles to form seat frames, cushions, and trim panels.

• Assembly Operations: Systematic integration of fabricated parts (frames, covers,

foam, mechanisms) into complete seat or trim assemblies using both manual and
automated assembly lines.

• Welding and Machining: Use of MIG/TIG welding, robotic arms, and CNC
machines for joining metals and ensuring dimensional accuracy of critical
components.

• Foam Molding: Polyurethane foam is molded into shape for seat cushions and
backrests through high-pressure injection molding machines.

• Cover Sewing and Upholstery: Automated sewing machines and skilled operators
stitch seat covers and assemble upholstery, followed by fitting onto foam and
frame.

• Painting / Surface Finishing: Some components undergo surface treatment,

painting, or powder coating for enhanced appearance and rust resistance.

2.2. Key Equipment Used

• Stamping Presses: For cold forming of sheet metal into seat frame structures.
• Injection Molding Machines: Used for manufacturing plastic trim and filter
housings.
• Foam Injection Molding Units: Create seat cushions and backrests with high
comfort and uniformity.
• Robotic Welding Cells: Perform precision welding for seat frames and other
structures.
• Automated Assembly Lines: Improve production rate and consistency while
reducing manual errors.
• Sewing Machines: For seat cover stitching and overlocking.
2.3. Manufacturing Workflow

• Material Preparation: Raw materials such as steel, polyurethane, plastic granules,

and textile rolls are received, inspected, and stored.
• Component Production: Metals are stamped/welded, plastics molded, foam injected,
covers sewn to create individual parts.
• Sub-Assembly: Major subcomponents like seat frames, backrests, and headrests are
assembled.
• Final Assembly: All subcomponents are integrated into finished assemblies as per
vehicle specifications.
• In-Process Quality Checks: Visual inspections, measurements, and load testing are
conducted at key points to ensure parts meet standards.
• Packing and Logistics: Finished products are packed using protective materials and
prepared for shipment to automotive OEMs.

2.4. Tools

• Hand Tools:
o Torque wrenches for precise tightening of bolts in seat and mechanism
assembly.
o Screwdrivers and Allen keys for assembly/dismantling tasks.
o Measuring tapes and calipers for accurate measurements.
o Pliers and cutting tools for wiring harness preparation and circuit assembly.

• Specialized Power Tools:

o Pneumatic and electric impact wrenches for efficient bolting in production
lines.
o Electric drills, tapping tools, and rivet guns for component fitting.

• Quality Inspection Tools:

o Profile projectors for dimensional checks.
o Material hardness testers (Vice, PU Hardness).
o Clamp meters for electrical checks.
o Inspection tables with rulers and gauges for visual and mechanical
inspection.

• Karakuri Tools (Lean/Japanese Innovation):

 o Mechanically clever, energy-free devices designed for tasks like belt
positioning, bolt tightening, workpiece handling, and ergonomic
improvement—using principles of gravity, leverage, gears, pulleys, and jigs
for efficiency and safety.
o Examples include device holders, conveyor-positioned tightening tools,
spring-loaded jigs, and ergonomic manipulators.

• Packing Tools:
o Industrial tape dispensers, strapping tools, carton sealers, shrink wrap guns,
and labeling devices for the packing section.

• Maintenance Tools:
o Tool kits for machine maintenance, including lubricators, cleaning brushes,
and diagnostic adapters.

2.5. Safety Practices

• Foster a “Safety First” corporate culture through labor-management cooperation.

• Implement Occupational Safety and Health Management System (OSHMS)

globally.

• Conduct risk assessments for machines, equipment, chemical substances, and work
operations.

• Carry out safety and fire prevention cross-checks involving top management.

• Promote STOP6 Project focusing on preventing six categories of accidents.

• Hold Five-step Toolbox Meetings daily to prevent accidents during work changes.

• Conduct global safety inspections by the Health & Safety Center at multiple plants.

• Organize continuous safety training, including VR-based fire extinguisher drills.

• Maintain global standards for fire prevention across all plants.
2.5. Environmental Practices
• Commit to carbon neutrality with a target to reduce CO2 emissions by 50% by
2030.

• Promote energy-saving activities and use of renewable energy sources like solar
power.

• Implement waste reduction, recycling, and water conservation initiatives.

• Manage chemical substances strictly to minimize environmental impact.

• Ensure compliance with global environmental standards such as ISO 14001.

• Conduct continuous monitoring and risk management for environmental hazards.

• Engage environmental and safety committees to oversee sustainability efforts.

• Align sustainability practices with global sustainable development goals.

2.5. Continuous Improvement

Guided by the Kaizen concept for continuous improvement, since its establishment,
which is deeply rooted in the principles of Sakichi Toyoda, Toyota Boshoku has
progressed over the years through unceasing improvement in operational processes,
increasing workforce skills, and introducing new technology, including AI and IoT.

Starting with a focus on quality control and atomic-level process improvements in its
early years, Toyota Boshoku expanded into global MONOZUKURI innovation —
integrating planning, design, manufacturing, and logistics to surpass competitors in
quality, cost, and delivery by 2025. More recently, the company developed efficient
improvement cycles such as Karakuri Kaizen, which emphasizes simple, energy -saving
innovations empowering frontline workers to identify and resolve production
inefficiencies.

The journey of continuous improvement has helped Toyota Boshoku stay competitive and
deliver quality interior automotive products globally, aligned with its vision to become an
"Interior Space Creator" by 2030 through continuous quality, innovation, and human
resource development.
 3. QUALITY CONTROL

Quality Control (QC) at Toyota Boshoku Device India Pvt. Ltd. is a central pillar of its
reputation for world-class automotive components. Strict adherence to both internal
standards and global automotive industry requirements ensures that every product
delivered performs reliably, contributes to vehicle safety, and meets customer
satisfaction.

3.1. Quality Control Objectives

• Ensure all products meet or exceed specifications for safety, durability, and
appearance.
• Detect and correct defects early in the production process.
• Maintain compliance with ISO 9001, IATF 16949, and OEM requirements.
• Continually monitor, document, and improve quality performance.
3.2. Organization of Quality Control

The QC system is divided into several interconnected departments, each responsible for
overseeing quality at different stages:

• Incoming Quality Control (IQC): Inspection of raw materials and components

before they enter production. Materials are checked for appearance, dimensions,
mechanical properties, and accompanying certificates.

• In-Process Quality Control (IPQC): Ongoing inspection during production to

monitor critical dimensions, assembly processes, and to catch process deviations
early.

• Final Quality Control (FQC): Comprehensive checks of finished products,

including functional testing, visual inspection, fit, and finish, to ensure they meet
customer requirements.

• Laboratory Testing: Specialized tests (e.g., tensile strength, flammability, fatigue

testing) performed in dedicated in-house labs.

3.3. Quality Control Procedures

• Standard Operating Procedures (SOPs): Every test and inspection follow clearly
documented SOPs to maintain consistency and traceability.

• Sampling and Testing: Adoption of statistical sampling plans for routine

inspections as well as 100% checks for critical parameters or new product
launches.

• Measurement Tools: Use of precise measurement devices such as calipers,

micrometers, CMMs (Coordinate Measuring Machines), hardness testers, and
surface finish meters.

• Functional Testing: Operational simulation (e.g., seat adjustability, load tests) to

verify comfort and durability.

• Appearance and Fit Inspections: Visual and tactile checks for fabric quality,
stitching, paint finish, and alignment.

• Traceability: Unique identification labels and batch records for tracking each
product from raw material to delivery.
3.4. Documentation and Continuous Improvement

• QC Records: All inspection data, test results, and corrective actions are
documented and retained for audits and traceability.

• Non-Conformance Handling: Products failing any test are quarantined, investigated

through root cause analysis, and corrective actions are documented.

• Customer Feedback: Warranty returns, and customer complaints are tracked and
analyzed to keep improving product quality.

• Kaizen & Internal Audits: Regular review of processes, participation in continuous

improvement initiatives, and internal audits ensure standards keep rising.

4. PACKING SECTION
At Toyota Boshoku Device India, the packing section is one of its critical sections in the
automotive component manufacturing process. It ensures careful packing of products like
seat slides and seat recliners, among other body components, for dispatch to customers
and also to the assembly plants.
4.1. Purpose
The packing section ensures finished products are securely and correctly packed,
protecting them from damage during storage or transportation.

• Process Overview:
o Inspection: Every part goes through final quality checks before entering the
packing area to ensure only defect-free products are packed.
o Cleaning: Products are typically cleaned, dusted, and sometimes wrapped to
avoid contamination.
o Packing Material Selection: Usage of proper packing materials such as
cartons, foam, bubble sheets, or custom trays as per the part type.
o Methodology: Packing standards (e.g., automotive OEs) specify stacking,
arrangement, and cushioning requirements so that products remain secure
and easy to identify/unpack at the customer’s plant.
o Labeling: Each packed unit is labeled with product details, batch number,
inspection status, and sometimes barcodes for tracking.
o Documentation: Packing slips, checklists, and export documentation (if
applicable) are prepared.
o Storage/Dispatch: Packed units are kept in designated zones, waiting for
shipment, following FIFO (First-In, First-Out) principles to avoid old stock
retention.
• Quality Control Practices:
o The packing process also includes checks for proper labeling, completeness,
and adherence to packing standards to avoid mix-ups or product damage.
o Packing quality audits are performed periodically, and necessary
improvements are implemented using Kaizen principles for continuous
process enhancement.
o Employees in the packing section are trained in standard operating
procedures (SOPs) for handling and packing sensitive automotive parts.

• Special Focus Areas:

o For export or high-value parts, extra measures like moisture-proof
packaging, edge protection, tamper-evident seals, and secured palletization
are used.
o Lean manufacturing principles ensure minimal waste of packing materials
and efficient space utilization.
 CONCLUSION
The certificate issued by Toyota Boshoku Device India Private Limited declares that Mr.
Vishesh has completed four weeks of industrial practical training at the company, from
July 3 2025 to August 6 2025. During the period of training, his performance was found
satisfactory, and the organization highly acknowledges his participation. The company
wishes him all success in future assignments, portraying his skills and dedication during
the training positively.

Skills Gained During Workshop Training

Technical Skills:
• Understanding of quality control procedures in the automotive industry.

• Knowledge of packing processes and standards for automotive components.

• Familiarity with various machines used in manufacturing (e.g., sewing machines, welding
equipment, robotic arms).

• Ability to use hand tools and power tools (torque wrench, screwdrivers, calipers).

• Basic troubleshooting and maintenance of machines.

• Adherence to safety protocols and use of personal protective equipment (PPE).

• Understanding of kaizen (continuous improvement) and lean manufacturing principles.

Soft Skills:
• Teamwork and communication with supervisors and colleagues.

• Time management and following work schedules.

• Problem-solving during defect detection or packing challenges.

• Attention to detail in inspection and packing processes.

• Adaptability and willingness to learn new tasks or operate new equipment.