Professional Documents
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Havells
Havells
Havells
NEEMRANA
BY
CHETAN GOYAL
(ECE 11004)
Project dissertation submitted in partial fulfilment of the requirement for
Summer Training
Work carried out at
Submitted by
CHETAN GOYAL
ECE 11004
B.Tech (ECE), VITH Semester
Under the Guidance of
Mr D.C. LAKHERA
QUALITY MANAGER
Mr R.N. Tiwari
HOD, ECE
ACKNOWLEDGEMENT
Such Thanks I give as near death to those that wish him Live- Shakespeare. A formal
statement of acknowledgement will hardly meet the ends of justice in the matter of
expressing my deep sense of gratitude and obligation to all those who helped me in the
completion of this project report.
First of all I would like to thank Mr R.L. Ruhela (Deputy GM), Havells India Ltd who allowed
me to enrich my skills in Havells India Ltd. (Luminaire Fixture Division).
The experience of past four weeks in Havells under the guidance of my Project Leader and
Guide has greatly influenced my way of thinking towards facing the challenges during
training. This will help me a lot in future as I move further ahead in my professional life in
the days to come. I am especially indebted to my Project Manager, Mr D.C. Lakhera, Quality
Manager without whose precious time & expert guidance, I would not have acquired so
much knowledge about luminaires Fixture. I would also like to thank Mr Pradeep Shukla, Sr.
Engineer His guidance and in depth knowledge of lighting concepts have boosted my
confidence to complete this industrial training successfully. He made the intricacies of the
Luminaire production clear to me. He deserves special thanks for his technical guidance
throughout the training.
I am also extremely thankful to Mr R.N. Tiwari, HOD (ECE) who was gave me this wonderful
break to implement my knowledge in this industrial world. Last but not the least I would
also like to express my gratitude to Havells employees and all my friends who helped me a
lot throughout this training.
DECLARATION
I CHETAN GOYAL student of B.TECH (ECE) hereby declare that the project title
Havells India LTD. which is submitted by me to department of Electronics &
Communication Engineering, School of Engineering and Technology, RAFFLES
UNIVERSITY NEEMRANA in partial fulfilment of requirement for the Summer training
has not been previously formed for the basis of any degree, diploma or other similar title or
recognition.
Place: Neemrana
CHETAN GOYAL
Date:
Signature:
PREFACE
Someone has rightly said that practical experience is far better and closer to the real world than
mere theoretical exposure. The practical experience helps the student to view the real business
world closely, which in turn widely influences his/her perceptions and understanding of the real
situation .Practical work constitutes the backbone of any technical education program. An
engineering student has to do practical work quite frequently during his entire life span.
The present report is a part of the Summer industrial training that contains the work done by me
during the training period at
Havells India Ltd. (Lighting Fixture Division), Neemrana
True to the core, a properly and executed industrial training helps a lot in providing linkage between
the student and the industry. It develops the awareness of industrial approach to problem solving
based on a board understanding of the mode of operation of industrial organization. This vocational
training has offered me an opportunity to put all my efforts and the theoretical knowledge to
practice and enhance my knowledge, and at the same time, given me practical experience in the
field of engineering. It is surely going to help me in my future too. In the preparation of this report, I
have made every effort to ensure that all steps involved in production & quality at Havells are
adequately covered and the report be completed in it .Any suggestions for improvement, if
rendered, will be gratefully accepted .I sincerely hope that this training will prove pure knowledge
imparting and would prove fruitful for me in my near future.
COMPANY PROFILE
QRG ORGANISATION
Havells India Limited is a $1.3 Billion leading Fast Moving Electrical Goods (FMEG) Company
with a strong global footprint. Havells enjoys enviable market dominance across a wide
spectrum of products, including Industrial & Domestic Circuit Protection Devices, Cables &
Wires, Motors, Pumps, Fans, Modular Switches, Home Appliances, Electric Water Heaters,
Power Capacitors, CFL Lamps, Luminaires for Domestic, Commercial and industrial
Applications.
Havells in 2007 created history by acquiring worlds renowned lighting company Sylvania
thus registering itself amongst top 4 lighting companies in the world. Today, Havells owns
some of the most prestigious global brands like Havells, Crabtree, Sylvania, Concord,
Luminance and Standard. Its global network constitutes of 6500 professionals across 91
branches & representative offices in over 50 countries. Its 11 state-of-the-art manufacturing
plants in India located at Haridwar, Baddi, Noida, Sahibabad, Faridabad, Alwar, Neemrana
and 7 world class manufacturing plants located in Europe, Latin America, Africa & China are
manufacturing globally acclaimed products, synonymous with excellence and precision in
the electrical industry
A 20000 strong global distribution network continuously strives to set new benchmarks in
prompt delivery and service to customers powering their smiles like none other electrical
brand in the country. Further to this the company pioneered the concept of exclusive brand
showroom in the electrical industry with Havells Galaxy. Today over 210 Havells Galaxies
across the country are helping customers, both domestic and commercial, to choose from a
wide variety of products for different applications. Havells became the first FMEG Company
to offer door step service via its initiative Havells Connect. Thanks to the quality of
products and quicker service, it has minimum customer complaints and highest customer
satisfaction.
Havells along with its brands, have earned the distinction of being the preferred choice of
electrical products for discerning individuals and industrial consumers both in India and
abroad. Havells offers same quality products for both Indian and international markets.
Havells products & processes have acquired a number of International quality certifications,
like BASEC, CSA, KEMA, CB, CE, ASTA, CPA, SEMKO, SIRIUM (Malaysia), SPRING
(Singapore), TSE (Turkey), SNI (Indonesia) and EDD (Bahrain) thus complying with
stringent quality norms at even the most testing markets, worldwide. It is committed to
keep powering the world with its state-of-the-art innovations and energy-efficient solutions.
Currently 70% of its product offering is energy efficient.
In December, 2004 placed 235 fully convertible debentures of Rs. 10 Lacs on M/s.
Shine Ltd., Mauritius and the debenture will be converted in June, 2006.
Attained the CE certificate for CFL.
2005 : Set up manufacturing plant in Haridwar, Uttaranchal for manufacturing Fans.
Awarded the KEMA certification by The Dutch Council for Accreditation, making QRG
the only group to attain this certification.
Set up of R&D Centre in Noida H.O.
Milestones:-
PEOPLE AT HAVELLS-:
Qimat Rai Gupta- Non Independent executive chairman of the Board
Rajesh Gupta- Non-Independent Executive Director, Director - Finance of
Havells India Limited.
Anil Rai Gupta- Joint Managing Director, Supervising marketing and sales
functions of Havells India Limited.
Surjit Gupta- Non-Independent Non-Executive Director of Havells India
Limited. worked as technical head Havells.
Havells Products-:
Building Circuit Protection
o Miniature Circuit Breaker (MCB)
o Isolator Changeover Switch
Motors
Capacitors
o Foot Mounting
o Flange Motor
o Foot Cum Flange
o Inverter Duty Motors with Forced Cooling
o Crane Duty Motors
o Brake Motors
o Normal Duty
o Heavy Duty
o Super Heavy Duty
o Agriculture Duty
o Motor Run Capacitors
Lighting
Fans
o LED Lighting
o Consumer Lighting
o Commercial Lighting
o Down Lighter
o Landscape Bunker Lighting
o Industrial Lighting
o Area Lighting
o Road Lighting
o Specialty Lamps
o Accessories
o Aura Lighting
o Ceiling Fans
o Table Fans
o Wall Mounting Fans
o Pedestal Fans
o Air Circulator Fans
o Ventilating Fans
CFL
o Retrofit
o Non Retrofit
o Higher Range
o FPL
Water Heater
Domestic Appliances
Mission
To achieve our vision through fairness, business ethics, global reach, technological
expertise, building long term relationships with all our associates, customers,
partners, and employees
Values
Customer Delight: A commitment to surpassing our customer expectations.
Leadership by example: A commitment to set standards in our business and
Transactions based on mutual trusts.
Integrity and Transparency: A commitment to be ethical, sincere and open in our
dealings.
Pursuit of Excellence : A commitment to strive relentlessly, to constantly improve
ourselves, our teams, our services and products so as to become the best in class
R&D AT HAVELLS
Innovation is the hallmark of every vital development at QRG Group. New ideas, inventions
deepen scientific knowledge and give its work force a new impetus towards technical
Progress.
QRGs technological strengths and its endeavour towards continuous Research &
Development have allowed it to fulfil its responsibilities towards its customers. The
responsibility of providing its customers the best products and zero defect services to
enable them to be comfortable and secure in usage of electricity. Havells has recently
invested 50 Crores in the QRG Centre for Research and Innovation, set-up at the company's
Head Office premises in Noida, U.P. The objective of this centre is to provide the theoretical
& experimental foundations for all segments of electrical engineering. The centre closely
cooperates with the various departments so as to provide the best and the latest in terms of
technology and design.
Quality Control
The essence of quality is closely wrapped in the way Havells team think, plan and work. It
finds its true expression when we extend beyond ourselves to exceed our customers
expectations. To deliver products those are safer, faster and simply better.
Each time, every time. Building customer confidence through teamwork is a top priority to
provide a wide variety of products and services. Realising and respecting the basic needs of
customers to feel more secure, Havells have committed themselves to make their products
better, safer and smarter than what he or she is looking for.
That's a passion that began 30 years ago and that's how it continues to be even today.
Havells customers rely on us and it is our responsibility to give them the very best. All
Havells products are as per IEC standards.
QRG has a simple rule on quality. If it doesn't exceed customer expectation, it's
CSR AT HAVELLS
Social and environmental responsibility has been at the forefront of Havells operating
philosophy and as a result the company consistently contributes to socially responsible
activities. For instance, the company is providing mid-day meal in government schools in
Alwar district, covering 35000 students per day. Besides this company has acquired land for
constructing a larger kitchen with all the modern facilities to serve freshly cooked food to
35000 students in the area. The group company, QRG Healthcare runs a 140 bed hospital in
Faridabad and will soon launch another 450 bed hospital in Faridabad by end of the year. In
the past, the company has generously contributed to the society during various national
calamities like the Bihar Flood, Tsunami and Cargill National Relief Fund etc.
The essence of Havells success lies in the expertise of its fine team of professionals, strong
relationships with associates and the ability to adapt quickly and efficiently, coupled with
the vision to always think ahead.
Reducing Risk:Risk should be minimised at workplace to ensure Good Quality, Good performance and good output.
To minimise risk Havells follow various methods such as:-
1. 4 Ts
For greater efficiency and increasing productivity 5S is employed in Havells in each and
every department and line assemblies.
2. 5s
SEIRI Sorting, Separating useful & waste material and removing waste
material.
SEITON - Fix place for everything.
SEISO Cleanliness, clean workplace.
SEIKETSU- Standardisation, making standards and following them.
SHITSUKE- Discipline
5s is helpful in High availability rate, improved safety, reliable deliveries, product
diversification, higher quality and lower costs.
3. 7 Rs
In Havells focus is paid on 7 Rs to reduce cost and improve efficiency
REDUCE- Reducing waste material generation
REVISE- To look back if any mistake has been made
RECYCLE- Recycling material
REPROCESS- to subject to a special process or treatment in preparation for reuse
RE-ENGINEERING- Troubleshooting
RE-DESIGN- Designing product again to meet customer expectation
RE-USE- Use material over and over when economically feasible
PLANT HOUSEKEEPING
Plant housekeeping means cleanliness of plant and arrangement of processes, tools
equipment, storage facilities and supplies. Our elders had also suggested a golden rule for
managing our workplace i.e. jab ka tab aur jha ka wha. In other words housekeeping
means places for every things and everything at its place (5s).It is very effective in increasing
production, reducing cost and improving organisation prestige. General rules for good
housekeeping.
Material Safety
Improper gripping, improper lifting, carrying too heavy & not wearing PPE (Personal
protection Equipment) are various major causes for invitations to accidents. Important
measures and precautions must be taken to prevent injury, loss of product, effective and
Safe handling of product.
STOREHOUSE
Raw Material Incoming: For production the incoming raw material comes from
different vendors and suppliers. To ensure quality in its products it also ensures quality of
incoming material. IQC (Incoming Quality Check) department take care of these things. It
checks the incoming material are according to standards or not. Then it accepts or rejects
the material from vendor.
After Incoming Quality Check, if the material from different vendors and suppliers is
accepted then it is kept in store and if it is not accepted then it is sent back to the vendor it
belongs. Sometimes material kept on hold for the inspection of production manager so that
they can better decide material can be used in production or not
For e.g. Ballast and drivers coming from the various vendors like Choice, Tridonic, Sylvania,
Helvar are first inspected on various parameters like Electrical, Photometric, and Thermal
properties and then it is decided whether the product is accepted or rejected by production
manager.
DISPATCHING
Authorizing the start of an operation on the shop floor is the function of dispatching. This
function may be centralized or decentralized
REPORTING OR FOLLOWUP
The manufacturing activity of a plant is said to be in control when the actual performance is within
objectives of the planned performance. When jobs are started and completed on schedule,
there should be very little, if any, concern about the meeting of commitments. Optimum
operation of the plant, however, is attained only if the original plan has been carefully
prepared to utilize the manufacturing facilities fully and effectively.
CORRECTIVE ACTION
This is the keystone of any production planning and control activity. A plant in which all
manufacturing activity runs on schedule in all probability is not being scheduled to its
optimum productive capacity. With an optimum schedule, manufacturing delays are the rule,
not the exception.
RE-PlANNING
Re-planning is not corrective action. Re-planning revise routes, loads, and schedules; a new
plans developed. In manufacturing this is often required. Changes in market conditions
manufacturing methods, or many other factors affecting the plan will often indicate that a
manufacturing plan is needed.
PRODUCTION ASSEMBLY
LED ASSEMBLY LINE -: On this assembly line L.E.D. products are manufactured
It Consist of -:
TABLE ASSEMBLY
LED LINE 1
LED LINE 2
LED LINE 3
JOY 5W
POLO 15W
QUANTO 5W/10W
ENDURA LINEAR 10W, 20W
SOLITAIRE 16W
ENDURA DL 7W/15W/18W/22W
ENDURA DL
ENDURA FLAT PANEL 9W/16W/18W/32W
LED PLUTO RECESS
ENDURA 15W SQUARE
PCB Depanelising
Final Packing
Commercial Assembly Line- On this assembly line commercial products are manufactured.
It consist of manly two lines
Domestic Production Line
Export Production Line
Products manufactured on this assembly line are -:
P5 Mirror Optimix 2/2 Surface & Recess
P5 Mirror Optimix 1/2 Surface & Recess
Thimble Assembly
Connecting Assembly
Ballast Fixing
Holder Assembly
Wiring Assembly
Wire dressing
Louver fixing
Rivet Fitment
Ballast fitment
CNC SHOP
Lighting fixture division at Havells is well equipped with magnificent CNC machines like
Amada, salvagnini, Gasparini & much more.
Computer Numerical Control (CNC) is one in which the functions and motion of a machine
tool are controlled by means of a prepared program containing coded alphanumeric data.
CNC can control the motions of the work piece or tool, the input parameters such as feed,
depth of cut, speed and the functions such as turning spindle on/off, turning coolant on/off.
Its applications include lathe, drill press, milling machine, grinding unit, laser, sheet metal
press working machine, tube bending machines etc. Highly automated machine tool such as
turning centre and machining centre which change the cutting tools under CNC control have
been developed. Its advantages are High accuracy in manufacturing, short production time,
simpler fixturing and reduced human error.
Amada EM2510NT is a metal sheet punching machine. It has a press capacity of 200 KN. It is
an AC servo direct twin drive press drive system which ensures high functionality &
productivity. It is easily controlled by menu-driven AMNC controller.
Specifications
Press capacity (kN)
Press drive system
Maximum Material Thickness (mm)
Maximum punch size
Axis travel (mm)
Axis speed X.Y m/min
Punching Accuracy
200
AC servo direct twin drive
3.2(brush table)
114.3
1270 x 2500
X100,Y80
0.1(mild mode 0.07)
Accuracy- 99.98%
Tolerance- 0.02mm
Operation Bending
Neemrana Fixture Plant is a replica of Sylvania plant in France and one of its first kind. It
completes the job in 45 seconds with zero human intervention. It has a capacity of 1300
pieces in a day (one shift).
Different parts:
Manipulator: Has the capability to rotate the job 720 to fit it according to the requirement.
Clamping.
Bending Unit
Hydraulic Unit.
Sheet thickness that can be used: 0.4mm to 3 mm
The P2Xe is the compact hybrid Salvagnini panel bender and it has been developed for
companies that want to improve their competitiveness, quality and lead-times.The
technological solutions used in the design and construction of the P2Xe, such as making
widespread use of high performance motors and electrical components, make this machine
an extremely competitive, cost-effective and ecologically responsible solution for all
companies in the world of sheet metal processing.
350(35)
1250
100
55
9.5
40
1900
PUNCH PLATE
JOB
Therefore according to our requirements we first make the die and then attach
the die with machine for their opera
PAINT SHOP
Lighting Fixture division of Havells has its own paint shop. The paint Shop is well equipped
with the ITW GEMA the Powder Coating Machine from Switzerland. The technology for
powder coating is very advanced and wastage of paint powder is very less. The Conveyor
length is about 350 meters.
The substance contains few carbonates and phosphates which cements the cracks on
the surface.
PH- 4-6
Ambient Temperature- 30-35 C
Pressure 0.8-1.5 kg/cm2
Spray Time 30 seconds
Conveyor Speed- 3-3.5 m/min
Flash OFF Zone: This process includes rejection of extra chemicals from the
previous process using electrostatic charge.
Dry off Zone: Housing is dried in the ovens.
Powder Coating Booth: The painting booth is provided with powder guns containing
positively charged powder paint particles which sticks on negatively charged housing.
This principle work on FARADAYS PRINCIPLE.
Voltage- 70-100 kV
Air Pressure 3.5-5 kg/cm2
Paint material- epoxy polyester powder
Powder Curing Oven: This process is also called baking.
Air temperature of 195 C is maintained in the powder curing oven through properly
designed vents at each junction.
Unloading: Unloading the material from the conveyor & taking them for inspection
Each housing spends around 13 min in the curing oven to complete the process.
Housing is cured at a temperature of 185 C which is maintained with the help of
SCADA
Temperature rise in the curing process:
100C within 5 minutes
180C in next 8 minutes
Passivation
v
Powder coating booth
Quality Inspection
Ok
Accept
Material Unloading
REJECT
REWORK
QUALITY IN HAVELLS
Quality is first priority in Havells. Havells ensures quality of its product at each
stage of production right from raw material to finish goods. Before product
reaches to customer it passes a whole bunch of test to confirm that customers
get best. Quality department of Havells uses latest instruments in its lab &
takes proper steps to meet expectations of their customers. Quality
department at Havells have a no. of Labs each checking product on a definite
parameter.
Company Policy-:
It is the policy of our company to design & produce products and services that
meet or exceed our customers requirements and comply with all statutory
and regulatory requirements. We accomplish this by adhering to our
management system and operational methods that recognize customer
satisfaction as a primary goal.
Quality Policy:
Our Quality Policy is building customer confidence by providing wide range of quality
products and services through continual improvement of quality management system.
Quality Objectives
Quality of products should need to be confirmed according to the
LED DRIVER TESTER: This intrument is used to check the electrical parameters of LED
Drivers. It is specially designed for LED driver to monitor its Input & output characteristics.
It is a multifunctional & high accuracy instrument
Leakage Current Tester- Leakage current test voltage, leakage current and test time can be
displayed simultaneously; True RMS AC/DC conversion; Alarm value can be set
continuously, freely Phase automatic switching, Audible and visual alarm with out of
limits,Compliant with GB4706.1-2005/IEC60335 standard requirements
High Voltage Tester (CS2672C)- The purpose of this test is to ensure that electric strength of
the luminaire is as per specifications. This test is done to ensure that
the earth is working properly , and
]the earth is working properly , and
The luminaire should withstand 1.5 KV for 60 sec.
Endurance Lab-:
The motive of endurance lab is to check the behavior of product when
subjected to thermal and electrical stress simultaneously. In endurance lab
luminaires are checked for their tolerance to withstand continuous long
burning hours. It does not require any particular machine for this purpose
except a temperature controller to maintain ambient temperature .Endurance
test is performed over luminaire in following manner.
Luminaire is mounted in a thermal enclosure with means for controlling
the ambient temperature within the thermal enclosure. It can also be
positioned on a supporting surface as for normal operation.
The ambient temperature is maintained within 2C of (2510) C unless
otherwise marked on the luminaire. During the test. The initial heating
period of luminaire is included as part of test duration.
Luminaire is tested for a total duration of 168 hours, made up of seven
successive cycles of 24 hours. Supply voltage is applied to luminaire
during each cycle.
Luminaire is switched off for a continuous period of 3 hours at same
point in each 24 hours cycle
The circuit conditio0n for the luminaire is normal operation for first six
cycles and abnormal operation for the seventh cycle
During operating periods supply voltage for filaments lamps must be
1.050.015 times voltage at which rated wattage of lamp is obtained
and 1.10 0.015 times (the rated voltage or the maximum of the rated
voltage range) for tubular fluorescent and other discharge lamp
luminaires
After the above mentioned test luminaire is visually inspected. No part
shall have become unserviceable and luminaire shall not have become
unsafe. It must be free from any cracks, scorches and deformation.
Plastic ES lamp holders shall not be deformed. The luminaire shall not
have become unsafe and shall not have caused damage to the track
system.
THERMAL LAB-:
Thermal Test-: To check temperatures of critical components in a luminaire
when subjected to voltage.
Draught proof enclosure (Ambient within can be from 10C to 30C) is
used for the luminaire; variation not more than (1C)
Thermocouple wire of low conductivity. 80/20 Ni-Cr paired with 40/60
Ni-Cu are used for measurement of temperature
Thermocouples on the critical components / as per the customers
request
are attached..
Mount the luminaire as per MI Sheet.
Switch on the luminaire at 100% of the rated voltage and wait for
thermal stabilization.
Measure winding temp. Of the ballast @ 100% of nominal voltage.
Repeat the test @ 105% of rated voltage (for halogen, GLS Lamp) / 106%
of rated voltage (for other lamps) tom measure component
temperatures.
Measure winding temp. Of ballast and case temp. Of capacitor @ 110%
of rated voltage.) For TL based luminaire the starter is to be shorted to
measure abnormal condition temp.
Reading are taken down when thermal stabilization is obtained i.e. less
than 1C variation over 1hr period.
During the test and immediately before a measurement the supply
voltage should be maintained between 1% and preferably within
0.5% of the test voltage.
If the luminaire ceases to operate because of a defective part of the
luminaire (including the lamp), the part should be replaced and the test
continued.
Measurements already made need not be repeated but the luminaire
shall be stabilized before further measurements are made. If, however, a
hazardous condition has arisen, or if any part becomes unserviceable as
a type defect, then the luminaire is deemed to have failed the test.
The temperature shall not exceed the standard values by more than
5C.This allowance is made to take into account the inevitable variability
of temperature measurement in luminaires.
Stability is said to be achieved when the rate of rise of temperature is
1C/hr
For determination of case temperature of a component with Tc marking
the test voltage shall be times the rated voltage