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Havells Report Intern PDF
Havells Report Intern PDF
NEEMRANA
BY
CHETAN GOYAL
(ECE 11004)
Submitted to
Submitted to
RAFFLES UNIVERSITY, NEEMRANA
Submitted by
CHETAN GOYAL
ECE 11004
B.Tech (ECE), VITH Semester
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.
SCHOOL OF ENGINEERING AND TECHNOLOGY
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.
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
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.
Qimat Rai Gupta is the founder, Chairman and Managing Director of Havells India Ltd.
Founder Chairman and Managing Director of Havells India Ltd.
On a sultry day in the electric wholesale market in Old Delhi in the summer of 1958, a 21-
year-old school teacher traded education for entrepreneurship and never looked back.
Driven more than by the economic necessity of helping his family, Qimat Rai Gupta
swapped the security of a classroom in Punjab for the uncharted waters of a small trading
company selling fixtures and electric cable to businesses in and around Delhi. With an
investment of Rs.10000, he started Guptajee and Company and began writing one of the
most compelling businesses in the history of the electrical manufacturing and supply
business in India. His unmatched leadership and vision has led him to create QRG
Enterprises as one of the major players in the power distribution equipment industry as well
as make its mark on the global scape.
PEOPLE AT HAVELLS-:
Havells Products-:
Building Circuit Protection Industrial Circuit Protection
Motors Capacitors
o Foot Mounting o Normal Duty
o Flange Motor o Heavy Duty
o Foot Cum Flange o Super Heavy Duty
o Inverter Duty Motors with Forced Cooling o Agriculture Duty
o Crane Duty Motors o Motor Run Capacitors
o Brake Motors
Lighting Fans
Domestic Appliances
VISION, MISSION & CORE VALUES OF HAVELLS
Vision
"To be a globally recognized corporation that provides best electrical & lighting
solutions, delivered by best-in-class people."
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
not quality performance.
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.
SAFE & SECURE WORKPLACE OF HAVELLS
Havells as a leading electrical goods manufacturer also ensure environment, health and safety at its
work premises along with its quality product. It strictly follows to the Occupational Health & Safety
Assessment Series (OHSAS) a British Standard for occupational health and safety management
system. It helps all kind of organisation to put in place demonstrably sound and occupational
health& safety performance. It is widely used as the Worlds most recognized occupational health
and safety management system standard.
Accident: - OHSAS (18001) says accident is an undesired event giving rise to death, ill health
injury, damage or other loss.
Incident: - An event that gave rise to an accident or had the potential to lead to an accident
(OHSAS 18001).
Near Miss: A near miss is an unplanned event that did not result in injury, illness or
damage- but had the potential to do so other familiar terms for these event is a close call
or near collision in case of moving objects.
Safety: - Freedom from un-acceptable risk of harm (OHSAS-18001)
Hazard:- Source or situation with a potential for harm in terms of human injury or ill health,
damage to property, damage to the workplace environment or the combination of these.
Risk-: Combination of the likely hood & consequences of a specified hazardous event
occurring.
Havells India Limited is committed to conduct business with strong conscience ensuring
sustainable safe environment & workplace and enrichment of quality of life of employees,
customers and the community. HIL manufacture the electrical products keeping in view of
environment, health and safety performance are an integral part of efficient and profitable
business management.
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
Terminate - Stop doing the activity all together.
Treat - Re-engineer, Substitute a less harmful substance
Tolerate - Accept the residual level of risk.
Transfer Use Specialist Contractor/Person.
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
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
Use of Tobacco, Gutkha, Biddi, and Cigarette strictly prohibited in plant premises.
Wear appropriate footwear/shoes in plant premises. (Slipper not allowed)
Loose clothes are not allowed.
Obey all safety signage.
Do not run on plant gang way & roads
Do not enter in restricted area.
Do not play with any machine/equipment.
Do not taste, touch, smell any material/chemical in plant
Vehicles maximum speed Limit in plant road is 10Km/Hr
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.
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.
STORE PROCESS FLOW
Process Planning
The determination of where each operation on a component part subassembly is to be
performed results in a route for the movement of a manufacturing lot through the factory
LOADING
Once the route has been established, the work required can be loaded against the
selected machine or workstation. The total time required to perform the operation is
computed by multiplying the unit operation times given on the standard process sheet by
the number of parts to be processed. This total time is then added to the work already
planned for the workstation.
SCHEDULING
Scheduling is the last of the planning functions. It determines when an operation is to be
performed, or when work is to be completed; the difference lies in the detail of the
scheduling procedure In a centralized control situation where all process planning, loading,
and scheduling for the plant are done in a central office the details of the schedule may
specify the starting and finishing time for an operation. On the other hand, the central
schedule may simply give a completion time for the work in a given department.
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
LED PROCESS FLOW FOR JOY 5W
PCB Depanelising
Final Packing
Commercial Assembly Line- On this assembly line commercial products are manufactured.
It consist of manly two lines
Thimble Assembly
Connecting Assembly
Ballast Fixing
Holder Assembly
Wiring Assembly
Wire dressing
Louver fixing
Elite Maglev 14W/28W, T5, FTL (With Diffusor & Mono packing)
Elite Desire 28W, T%5,FTL (With Diffusor & Mono packing)
Rivet Fitment
Ballast fitment
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) 200
Press drive system AC servo direct twin drive
Maximum Material Thickness (mm) 3.2(brush table)
Maximum punch size 114.3
Axis travel (mm) 1270 x 2500
Axis speed X.Y m/min X100,Y80
Punching Accuracy 0.1(mild mode 0.07)
Salvagnini P2XE (MADE IN ITALY)
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.
Specification-:
KAIZEN Milling 1 MTR-: Used for many operations like facing, tapering boring,
Remmuring, angle cutting, drilling etc. for making dies of required shapes.
Metal used for making die is steel EN31.
Press Shop-
There are many presses in press shop with capacity ranges from 40 tons to 110
tons which is used for punching, pressing and then blanking in different shapes
as per requirement like towels, Lilliput Electra siders, clamps etc.
PUNCH PLATE
JOB
GUIDE STRIPPER PLATE
LOWER PLATE MILD STEEL
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.
Hot Water Rinse: This process is done to discard any unwanted oil on the metal
piece, dirt or impurity which may hinder in the quality procedure.
Ambient Temperature- 50-55 C
Pressure 0.8-1.5 kg/cm2
Spray Time 30 seconds
Conveyor Speed- 3-3.5 m/min
Cleaner Coater 1: Cleaning and Coating is a two way process which has two stages.
First stage comprises of further cleaning with water to remove the oil left on the
metal. Two jet water pumps to throw water with high velocity to reject the minute oil
particles on the piece.
Cleaner Coater2: This process is repeated in the second stage also to ensure that
every piece has been coated properly
All other condition same as in cleaner coater 1.
Water Rinse 1: This process is done to discard the extra chemical that might be
present and is flowed down with the solvent.
Ambient Temperature- 50-55 C
Pressure 0.8-1.5 kg/cm2
Spray Time 40 seconds
Conveyor Speed- 3-3.5 m/min
Water Rinse 2: The process is repeated to ensure maximum efficiency. All other
condition are same as in Water Rinse 1.
Passivation: After the coating stage the surface is not totally smooth and becomes
porous Passivation process acts as sealing process for the porous surface developed.
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.
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
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.
Passivation
REJECT
Quality Inspection REWORK
Ok Accept
Material Unloading
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
requirements of ISO 9001:2008.
Specifications-:
Luminous accuracy: national first-grade standard
Angle accuracy: 0.2 degree
principal axis goniometer resolution: 0.02 degree
Dimension of elliptical mirror: 1.5m2.0m
Largest specifications of measurement lamp: current: 20A
Weight: 50kg
Lamp radius: R80cm
Measurement distance: can be adjusted freely upon the luminous
intensity of lamp
Weight: about 1000kg
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 circuit conditio0n for the luminaire is normal operation for first six
cycles and abnormal operation for the seventh cycle