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CHAPTER:- 1

INTRODUCTION TO SIEMENS

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HISTIRORY OF SIEMENS

It is almost impossible to separate the history of German Industry from the countrys general political and economic development. One-man stands pre-eminent among the pioneers of industrial revolution that had began to transform Germany by the middle of 19th century.

WE

RNER VON SIEMENS JOHANN GEORGE HALSKE

WERNER VON SIEMENS (1816-1892) son of a poor farmer had the courage to strike into the new territory and shape it scientifically, technically and industrially. On 1st October 1847, Werner Siemens formed the partnership with Johann George Halske & his cousin, Johann George Siemens under the name Siemens & Halske Telegraph Construction Company at Berlin. The initial core activity of the company was the manufacture of telegraph equipment. The founder WERNER VON SIEMENS recognized that telegraphy enabled people to overcome time and distance helping to strengthen international relations and fostering world economy. International expansion came about in the 1850s. Technical successors soon made the company well known throughout Europe by executing various -2-

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successful projects, like laying Telegraph lines from Baltic Sea and from Petersburg to Scissile. Siemens soon became an internationally acclaimed contractor. The companys British subsidiary, Siemens Halske and Company, had been founded in West Minister in autumn 1858 to look after companys business in Britain and the whole of its empire. In 1865 after the resignation of Halske the company changed its name to Siemens Brothers. In the year 1966 Siemens Schukertwerke AG and Siemens Reineigeerwerke AG [responsible for all branches of power engineering] was fused with Siemens & Halske AG [responsible for all branches of communications engineering & instrumentation] into SIEMENS AKTIEN GESELLSCHAFT (AG). More than 150 countries and with 240 production facilities outside Germany. Employees worldwide in offices, factories, laboratories and service organizations total around 373000. All committed to the highest standard of electrical technology, that Siemens have been synonym for right from inception. Todays stay ahead in the field of electrical and electronics technology, Siemens puts strong electrical and electronics technology. Siemens puts strong emphasis on Research and Development with over 48000 employees engaged in this key activity and with an annual investment of about 10 % of the turn over. On an average Siemens spends 25 million a day on R & D. Siemens R & D centers are also located outside Germany, in Europe and the U.S.A. Siemens experience and strength lie in developing new technologies and incorporating into its products and systems, which meet the requirement of its customers. It is one of the pioneers of electrical engineering and has grown as a result of it. It is in these areas that it concentrates its activities and will continue to do so in future. Siemens plays a major role in priority sectors like Telecommunication, Modernization, etc. Power Generation, Software Transportation,

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HISTORICAL PERSPECTIVE

1857 1867 1954

SIEMENS was founded in GERMANY. SIEMENS first linkage in INDIA. Assembly and repair undertaken in a small workshop under Mahalakshmi Bridge BOMBAY.

1957 1959 1960 1963 1966 1967 1973 1977 1984 1986 1986

Switchboards manufacture began at Worli Bombay. Medical equipment added to the range at Worli. Manufacture of Switchgear began at Worli Bombay. SWITCHGEAR manufacture at Andheri Chakala. First batch of Electric Motors produced at Kalwa. Centenary year of SIEMENS associates with INDIA. Transfer and expansion of Switchgear production at Kalwa. Manufacture of electronic equipment at Worli Bombay. Manufacture of Switchboard started at Nashik. Manufacture of Railway Signaling products. Heavy investment in Tool room and production shop with the Inception of NC and CNC machine.

1987 1990 1991

New Industrial Electronics factory at Nasik. Sword of Honor from British Safety Council. New Switchgear factory in Aurangabad. -4-

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Assembly workshop-Medical products - Goa. Launching of Mobile phones.

FUTURE
From the outset, the desire to offer products of optimal technical design and quality has been a basic rule of the Siemens Group to which all other considerations are subordinate. To this day, the name of Siemens implies a guarantee of modern technique, reliability and the highest quality. Siemens in future would play a vital role in priority sectors like Telecommunications, Power generation, Software, Transportation, Medical Engineering, Modernization, Technical Up-gradation. All these priority areas will not only receive technical and managerial but also financial assistance. The thrust would be on setting up power plants, software exports and equipment for rolling stocks, equipment, import high- tech medical facilities. The partner would be both in public and private sectors, particularly in software areas, which can become an integral part of Siemens manufacturing activities all over the world.

TRANSPORTATION

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TELECOMMUNICATION POWER GENERATION

MODERNIZATION

SIEMENS IN INDIA
In India, Siemens operates under the following names: SIEMENS LTD.

SIEMENS TELECOM LTD.

SIEMENS BUSINESS COMMUNICATION SYSTEM LTD. SIEMENS COMMUNICATION SOFTWARE LTD.

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AGNEL POLYTECHNIC SIEMENS INFORMATION SYSTEM LTD.

INTRODUCTION TO SIEMENS INDIA

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SIEMENS was established in India in the year 1922. However, the story of SIEMENS association with India began in 1867 when WERNER VON SIEMENS personally supervised the laying of first telegraphic line between Calcutta and London that historic event initiated a long association making countries priorities of its own SIEMENS has put its experience and expertise in major core sectors namely power, industry, transportation, telecommunication and health care. It is incredible but true that the first Siemens workshop in India

started in a small space measuring 180-m sq. under the Mahalaxmi Bridge on 1st may 1955. The only tools were available were turret lathe, a drilling machine, shearing machine and a power saw along with a few portable tools. Starting with mere strength of 10 people, the first few jobs undertaken included the repairs of damaged Switchboards, manufacturing of aluminum grill trays, cable trays, fixing clamps, powerhouse fencing and other fabrication jobs. Most of the components were imported and some parts were fabricated locally. Within six months, the manufacturing activities were shifted to the present Worli Works Complex. Though the world has already begun to feel the presence of the leader, it was not until the early 1954 that India could benefit from this organization.

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A policy decision to manufacture indigenously resulted in the formation Siemens Engineering & Manufacturing Company of India Pvt. Ltd. on 2nd March 1957. On 23rd March 1957, this company entered into a technical collaboration with Siemens & Halske AG and Siemens Schuchestneske AG West German (both together now known as Siemens AG). According to this agreement, the company received manufacturing & patent rights as well as technical know-how for certain products of world reputed Siemens design. On 28th March 1961, the company became a public limited company under the name Siemens India Limited. Thereafter in 1987, the name was change to Siemens Limited. From its humble beginnings in India, Siemens Ltd. has become corporate giant in the last 42 years and has played an active role in the technological progress experienced in the last four decades. One could say that Siemens and India have grown together. By making the countrys priorities own, Siemens had put its experience and expertise in the areas of national importance. Siemens centralized traffic control system ensures safe and efficient railroad operation. Telecommunication equipment made by Siemens is used in countrys telephone and telex networks and in medical engineering Siemens has supplied advance radiological and electromagnetic system to many hospitals. Besides conventional equipment Siemens now vides comprehensive instrumentation and control for power stations and industries. Siemens India has been consolidating its position over the years. It has expanded its networks in the form of factories at Worli (Mumbai), Kalwa, Nashik, Calcutta, Aurangabad, and Goa. It currently employs around 4000 employees and is backed up by an extensive network of 11 sales offices, 23 representatives, 350 dealers, 6 Factories, 8 offices, 11 Stock points and

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system houses are geared to meet the requirements of the customer. Siemens India is the 2nd largest of the manufacturing operations among the Siemens Companies outside Germany with Brazil being numerous into in this regard. Today Siemens India is not just a manufacturing organization. Manufacturing and designing to Indian Standards and international

specifications is just one part of the task; proper installation, commissioning and maintenance services are the others. The company grew out of the nation. Indias rapid strides in the economic and technological fronts would not have been possible without pragmatic investments in electrical power generation. Siemens matched the manufacturing program with the countrys industrial development needs and continued to play a key role in the industrialization, keeping India in the front line of the international technology. Siemens provides its technical competence and experience accumulated from their worldwide operations for their activities in India. In the years to come Siemens activities will continue to contribute increasingly towards the progress of India in the economical and industrial fields. Today Siemens involvement in India reflects the current trends in electrical, telecommunication technology. SIEMENS hi-tech approach in the field of power Engineering and Automation System, Medical Engineering and Telecommunication will continue to provide synergy to co-ordinate efforts to bring India closer to the frontier of accelerated progress.

SIEMENS INDIA-INFRA STRUCTURE

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SIEMENS INDIA HAS A CURRENT INFRASTRUCTURE OF: 10,000 Employees. 6 Factories. 8 Offices. 11 Stock points. 23 Representatives. 300 Authorized dealers. 6 subsidiary companies. THE FIVE MANUFACTURING UNITS ARE LOCATED AT: Mumbai (Worli): Head office Kalwa (Thane district) Nashik Aurangabad Goa THE SIEMENS SETUP CONSISTS OF DIVISIONS, REGIONS, WORKS AND HEAD-OFFICES. 1. Automation & Drives Division (A&D) 2. Components (CMP) 3. Medical engineering (MED) 4. Switchgear (SGR) 5. Motors, Drives and UPS (MDU) 6. Telecommunication (TSM) 7. Power generation (PGE) 8. Power transmission and distribution system (PTD) 9. Railway and transport system (RTS) 10. Finance and administration (F & A) 11. Personnel (PER)

SIEMENS IN KALWA
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HEART OF MANUFACTURING ACTIVITIES IN INDIA INTRODUCTION TO SIEMENS KALWA WORKS

The Kalwa Planning Department was set up in India to do detail planning, to feed back information to the planners in Germany and to execute the plans under the direction of the Works Management of Siemens of India. The foundation stone of the Kalwa Factory was laid in January 1965 & within a record 12 months, the Factory was built & machinery installed & commissioned. Production started in January 1966 of motor. Kalwa achieved a turnover target of Rs. 9.15 million in its very first full financial year & continues to perform brilliantly ever since.

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The Kalwa Factory is equipped with some of the most modern machinery & testing facilities. It started with the production of Motors & later diversified in 1973 to produce Switchgears & in 1975 to produce Switchboards. Today, it is the most important Business Center for Siemens India with almost 40% of the employees of Siemens India working in Kalwa & contributing almost 45% of the total production of Siemens India. SIEMENS, Kalwa Works comprises of three manufacturing units viz. The company has been awarded the ISO 9001 certificate by the international Standards The Kalwa Complex comprises of 3 manufacturing units and they are as follows I. SWITCHGEAR II. MOTORS (WSGR). (WMOT).

SWITCHBOARD (WSWB).

I: - SWITCHGEAR PLANT
At the Switchgear plant, Siemens produces a wide range of Low-Tension equipments. It comprises of Contactors, BI-metal Relays, Starters, Air Circuit Breakers, Fuse Switches, HRC Fuses, Motor Protection circuit Breakers, Limit Switches, and Programmable Switches etc. It also manufactures routeinterlocking relays for Indian Railways.

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THE PRODUCTS OF THE SWITCHGEAR ARE: CONTROL AND LIMIT SWITCHES STARTERS & CONTACTORS

PLANT OF

SIEMENS

PUSH BUTTON INDICATORS & SIGNALING EQUIPMENTS HRC FUSES, FUSE SWITCHES & FUSE BASES ELECTRONIC TIMER CIRCUIT BREAKER BIMETAL THERMAL OVERLOAD RELAYS ETC

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II: - MOTOR PLANT

SIEMENS Motors are high quality machines with power and are

economical consumption

resilient enough to withstand wide voltage and frequency fluctuations, a condition

widely prevalent in India. The user-friendly designs are a proof of the fact that Siemens has a considerable knowledge of the industries using their motors. Thus Siemens motors have high flexibility in use and less maintenance. THE VARIOUS PRODUCTS OF MOTOR PLANT:-

DC MOTORS FOR THE FEED DRIVERS OF THE MACHINE TOOL

INDUSTRIES THREE PHASE SLIP RING INDUCTION

MOTORS. MULTISPEED MOTORS. INCREASED SAFETY MOTORS. SUGAR CENTRIFUGE MOTORS FOR

THE CANE CRUSHING PROCESS. MOTORS FOR SHIPPING HIGH TENSION MOTORS UPTO 6.6 KW. MOTORS FOR MATERIAL HANDLING, CHEMICAL AND STEEL MINING

INDUSTRIES.

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III: -SWITCHBOARD PLANT

SIEMENS switchboards have established remarkable leadership in the market. This has through a deep understanding of the customers requirement, resulting in customer oriented products with user friendly design manufactured with latest technology at par with international std. The switchboard plant produces range of low tension and high-tension panels, Outdoor Vacuum Circuit Breakers, Indoor Vacuum Circuit Breakers and Oil Circuit Breakers upto 36 kV. The switchboard is an electrical panel consisting of elements like potential transformers, current transformers, circuit breakers, timers etc. The main function of this unit is to act as safety device or power distribution device. Kalwa works is attached to MVS division. The assembly of various distributing and controlling and indicating equipments at one place situated centrally is a Switchboard. Basically any Switchboard consists of a switching device such as Circuit Breaker.

PRODUCTS

OF SWITCHBOARDS :-

INDOOR & OUTDOOR VACUUM CIRCUIT BREAKER. - 16 -

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MEDIUM VOLTAGE PANEL.

MAIN FUNCTIONS OF THE COMPANY

Three manufacturing units in Kalwa have various main functions and have been very recently reconstructed, orienting towards customers and processes. These functions are additionally supported by central functions. Some of the common functions are described below. TECHNICAL: (PRODUCT DEVELOPMENT) Preparation of Design Drawings Laying down Standards and acceptable norms Assemble and make new designs in Development shop Testing of new design prototypes or design verifications Converting German designs into Indian formats Modify old products to suit new market norms PROCESS PLANNING: (RESOURCE ENGINEERING) Planning related to manufacturing methods Set up manufacturing facilities Selection of machines, technologies and process based upon the product design requirements Designing and ensuring availability of tools, jigs & fixtures

Industrial engineering, fixing time standards, computation of manpower and capacity requirements

LOGISTICS: (MATERIALS MANAGEMENT) Receipt & processing of orders placed by sales division

Scheduling - Involving assignments of priorities based on urgency and material and availability

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Overall co-ordination between marketing, client, excise etc Management of stores Dispatch of completed consignments MANUFACTURING:

Pre-manufacturing - manufacture of components, sub assemblies & painting of parts

Assembly of manufactured & bought out components QUALITY ASSURANCE: Inspection of incoming material

Inspection during stages of manufacturing & assembly processes Verification of the standard of finished goods Routine testing after the products are ready Verify compliance with client requirements COMMERCIAL: Product cost calculation

Cost accounting & control Planning and budgeting Financial accounting Inputs for companys balance sheets MARKETING: Sources customers Studies the requirements of the customers Collaborates with the technical and manufacturing sections Markets products made by the factories. PERSONNEL:

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SIEMENS LTD. Attendance recording and leave. Wage and salary related administration.

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Industrial relation-Maintaining discipline and harmonious relation with unions.

Personnel planning and development. Training and development in co-ordination with HRD.

CHAPTER:-2

INTRODUCTION TO SWITCH-GEAR UNIT

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INTRODUCTION TO SWITCH GEAR

Definition of Switchgear: The control & protection of any electrical system through a range of electromechanical products like relays, fuses etc is collectively termed as switchgear

Switchgear & Protection

A switchgear product can be said to behave like a conductor during normal conditions in an electrical system & like an insulator during abnormal conditions. A switchgear is necessary at every switching point in a power system i.e. generation, transmission, distribution & actual usage. Between a generating station and final load point, there are several voltage levels and fault levels. Hence switching and protective devices have been developed in several forms. When a fault on any power system occurs, it must be quickly detected and disconnected from the system otherwise it will spread into the system causing heavy damage of installation. A switchgear achieves this detection and disconnection. Switchgear is a general term covering a wide range of equipment such as switches, fuses, circuit breakers, relays, contactors, control panels etc. Besides the supply network, switchgear is necessary in industrial works, industrial projects, domestic and commercial buildings.

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The two functions of switchgear in any power system are: To permit plant & distributors (transmission lines) to be conveniently put into

& taken out of service. To enable the same plant & lines when these become faulty to be rapidly & safely isolated by automatic means.

In a switchgear system protection becomes necessary against 2 forms of flowing current i) ii) Overload current Short circuit I. OVERLOAD CURRENT

Before discussing specific control components, it is necessary to review what an overload is and what steps can be taken to limit the damage an overload can cause. Current flow in a conductor always generates heat due to

resistance. The greater the current flow, the hotter the conductor. Excess heat is damaging to electrical components. For that reason, conductors have a rated continuous current carrying capacity. Over current protection devices are used to protect current conductors flow. from

excessive

Thermal

overload relays are designed to protect the conductors (windings) in a motor. These protective devices are designed so that the flow of current in a circuit is at a safe level to prevent the circuit conductors from overheating. The National Electrical Code defines over current as any current in excess of the rated current of

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equipment of a conductor. It may result from overload, short circuit, or earth fault. An overload occurs when too many devices are operated on a single circuit or a piece of electrical equipment is made to work harder than it is designed for. For example, a motor rated for 10 amperes may draw 20, 30, or more amperes in an overload condition. In the following illustration a package has become jammed on a conveyor causing the motor to work harder and draw more current. Because the motor is drawing more current it heats up. Damage will occur to the motor in a short time if the problem is not corrected or the circuit is not shut down by the overload relay.

ii SHORT CIRCUIT
When two bare conductors touch, a short circuit occurs. When a short circuit occurs, resistance drops to almost zero. Short-circuit current can be thousands of times higher than normal operating current. Ohms Law demonstrates the relationship of current, voltage, and resistance. For example, a 240-volt motor with 24 ohms of resistance would normally draws 10 amps of current. When a short circuit develops, resistance

drops. If resistance drops to 24 milliohms, current will be 10,000 amps. The heat generated by this current will cause extensive damage to connected equipment and conductors. This dangerous current must be interrupted immediately when a short circuit occurs.

SIEMENS designed the products keeping the industrial needs in mind. The optimum design and high degree of quality control of the switchgear makes them highly dependable and conforming - 22 to international standards.

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Dependability and durability rectifies all switchgear products such as contactors, fuse-switches, relays, circuit breakers, starters push buttons, HRC fuses and limit switches.

ORGANIZATIONAL STRUCTURE OF WSGR FACTORY

1. Personnel Dept: It looks after the human resource development like maintaining attendance records, wages of employees as well as workers etc. 2. Tool room: Tool room is a dept that looks after the repairing &

maintenance of the various tools used in the factory at various machines. It also manufactures new tools. 3. Maintenance: The maintenance dept looks after any electrical fault in machines or fixtures in the factory. 4. Calibration Lab: As a manufacturing industry, a large number of different

electrical & mechanical instruments are used. It is also necessary for the instruments to be accurate to maintain accuracy & meet the requirements. The various instruments are calibrated at the calibration lab, which has highly equipped machines and standard instruments. 5. Production Cell: The production cell is the complete in charge of the production of the various products manufactured here. 6. Metal shop: The various metal parts or components that are used in the assembly of the various products are manufactured at the metal shop. 7. In process: The various parts manufactured at the metal shop are inspected at the in process inspection dept. 8. Incoming Inspection: Some parts of the products are being brought from the vendors. The different parts are inspected at the incoming inspection department before being available for manufacturing. 9. Plastic shop: The various plastic components used for the various products in the factory are manufactured at the plastic shop. - 23 -

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10. Industrial Engg & Design: Applying MOST at various workplaces. Designing & organizing the layout of the factory.

PRODUCT CELL DEPARTMENT

ORGANISATION OF PRODUCT CELL In switchgear works production department is split up in to 5 different cells. And each one is assigned with an assembly of different products as stated in chapter 3. Each of the cells is called PRODUCT CELL. This product cell office is based on the MILO (Manufacturing Integrated Logistics) principle in which, Manufacturing process is integrated with logistics, process planning and scheduling. Each department works as a decentralized one and each Departmental Head, directly reports to the works manager. EACH OF THE PRODUCT CELL FURTHER DEALS WITH MANY FUNCTIONS LIKE Logistics Scheduling Process Planning Assembly House Keeping PRODUCTION CELLS: The products manufactured under different production cell are as follows: PC 1: - Manufacture the small size contactors PC 2: - Manufacture the big size contactors PC 3: - Manufacture the Bimetal Relays PC 4: - Manufacture the Air Circuit Breakers PC 5: - Manufacture the push buttons and starters. These production cells have its own production line set up where the products are assembled and finished. These departments also concentrate on vendors - 24 -

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performances. Product cell departments are accountable for completion of production and smooth material flow.

PRODUCT MOLDED CASE CIRCUIT BREAKER

SERIES

3VL, 3VT 3TH, 3TF, 3TB. 3WB, 3WL, 3WT 3SE 3WN 3SB 3TE, 3TW 3RP 3UA, 3UW, 3UR

CONTACTORS AIR CIRCUIT BREAKERS LIMIT SWITCHES GUIDE FRAMES PUSH BUTTONS & PILOT LAMPS STARTERS ELECTRONIC TIMERS BIMETALLIC RELAYS

PROGRAM SWITCHES

3LA

PRODUCT SERIES OF SWITCHGEAR

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DESCRIPTIONS OF VARIOUS PRODUCTS

CONTACTORS With the growth of automation and

industrialization in the country, contactors are being used in large numbers and different ranges. A contactor is an electromagnetic device, which makes, breaks and carries rated current at relevant commands. It is different from a switch as it protects the system from overload and other failures by using the respective relay, which is not possible by a fuse switch unit. Contactors are used in motor control; capacitor Switching, heating and lighting in single phase and three phase AC as well as DC circuits.

BIMETAL OVERLOAD RELAYS The relay is protective device, which is extensively used, in electrical circuits in conjunction with contactor and other motor control equipment, they provide accurate and reliable

protection against overload, single phasing and overloading due to locked rotor conditions. The relays

are suitable for frequency operation up to 15 switching cycles per hour.

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When installed individually, relays are unaffected by ambient temperature of 200 C to 550 C.

PUSH BUTTONS & PILOT LAMPS Push buttons are basically simple switches used to make or break certain control systems. Pilot lamps are devices which indicate the status of the control circuits i.e., whether on or off.

LIMIT SWITCHES Limit switches with special contacts are available for operation at extra low voltage in very dirty and dusty location. They are used in automatic control circuits where mechanical position has to be converted into electrical signals for controlling remote starters, contactors and electromagnetic clutches.

The general working of a limit switch can be explained with help of the fig. ahead. Thus a hydraulic actuated cam is operating the Limit switch. The switch is kept fixed with a specific reference and the cam is moved linearly to push the plunger or the roller of the limit switch to get the desired angle or stroke. This

mechanism is being used frequently used in machines and apparatus where in the ram motion is guided by the stroke of the Limit switch. Thus Limit switches form an important part of almost every machine, which are being used in

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industries. Actuation of any limit switch must be for at least for 0.1 sec to ensure that the control command is transmitted.

CIRCUIT BREAKERS AS the name implies they are used for making or breaking circuits. These breakers are used for putting ON or OFF the power lines, with provision for automatic tripping in adverse

conditions like short circuit or overload current, ground fault or line fault. The operating

mechanisms are designed for a service life up to 100000 make and break operations. Owing to the short quenching distances, there is only a little arc erosion. LOW VOLTAGE HRC FUSES HRC fuses are in protective electrical

equipment

used

systems. These are usually used in conjunction and overload and single phasing protective relays for any electrical system. HRC fuses offer protection to cables, switchgear, control gear and other apparatus from electromagnetic and stresses which arise under short circuit conditions. The HRC fuse is widely used in low voltage system. L.T. CONTROL SWITCHES

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L.T. control switches are used for starting and control of three phase AC motors. The switches are known for their versatile design, high making and breaking capacity and long mechanical life.

PROGRAM SWITCHES The switches are used for programmed control of machine tools, switchboards, control boards etc. They can be used in main circuit for direct control of feeders or motors and in various drives according to the desired program. STARTER A Motor starter has two basic functions to perform: 1.) Starting and stopping the Motor 2.) Providing adequate protection to Motor and safeguarding it in event of sustain overloads, single phasing, locked rotor condition and under Voltages. CONTACT BLOCKS These devices are suitable for installation in any control and Auxiliary circuit AC/DC. There are separate Models for rear and front connection. They have high contact reliability, operator safety, reduced labour input, electronic compatibility and compactness. They are ideal for panels, control desks, control station and machine tools etc. BIMETAL RELAY TIMER

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The bimetal relay timer is a modification of the overload relay unit so as to perform the time delay function. The timer is used in automatic star-delta starters for changing over connection from star to delta after the motor has reached the rated speed. The timer is available with adjustable setting ranges.

TOGETHER IN A CIRCUIT (WORKING DIAGRAM OF ALL SWITCHGEAR PRODUCTS)

Thus the products namely Relay, Contactor, Motor, Fuse, Switch working together in a circuit can be explained with the help of the fig as shown below. The various components are, 1. MOTOR 2. ANKER 3. YOKE 4. COIL 5. CONTACTOR 6. SINGLE PHASE SUPPLY 7. HRC FUSE 8. SWITCH` 9. BI-STRIP 10. RELAY 11. THREE-PHASE SUPPLY WORKING PRINCIPLE The motor requires three-phase current for its working since it is meant for operating at very high ratings. If this high current is directly supplied to the motor then at the time of overload current the motor may get damaged due to excessive current. Thus the motor requires safety, which is provided the contactor and relay. The contactor consists of a male electromagnet called ANKER and a female electromagnet called YOKE. Below the Yoke is a coil which is in a single - 30 -

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phasing circuit with the relay. The relay consists of a NO and a NC contact, bistrip, rocker-lever mechanism. The single phasing circuit also consists of a fuse to protect the relay, and a switch for switching ON and OFF the circuit. The threephase current required to run the motor is first passed through the bistrip of the relay and then passed on to the motor through the contactor. Initially when the switch is put ON, the circuit is completed and the current flows through the NC contact of the relay to the coil. The coil then gets magnetized and develops electro magnetic flux. Meanwhile the three-phase current is passed through the bistrips and flows to the contacts of the coil of the contactor. Due to the flux developed in the coil the yoke gets magnetized and attracts the Anker towards itself. Thus the three-phase current of the Yoke is passed on to the Anker and then to the motor. When overload current passes through the bistrip, the bistrip due to its physical property bend on overload. Thus the slider on the bistrip is pulled with the bistrips, which in turn pulls the lever. The lever further pushes the rocker and due to spring action the rocker is tripped thus converting the NC contact to the NO contact. Due to this the single phasing circuit is put OFF and the coil gets demagnetized. Thus no flux is developed and the Yoke also loses its magnetic property. Still the three-phase current is passing through the bistrip to the contacts of the coil but the Yoke is not attracted to the Anker and hence current does not reach the motor. Thus the motor is being protected from overload current and hence from damage. Further when the overload current comes to the normal again the bistrip come back to their normal position and the NO contacts become NC contact. Thus the single-phase circuit is again completed and the coil develops flux to attract the Yoke, which in turn attracts the Anker and runs the motor on the threephase current from the Yoke. Thus the relay and the contactor form the main part of the circuit. Since the three-phase current is passing through the relay directly to protect the relay an HRC fuse is connected in circuit with the relay, which has a low cut-off - 31 -

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characteristics and thus protects the relay from damage. Thus all the switching devices cannot go alone and work together in the circuit thus making the circuit full proof.

Manufacturing process of switchgear

The manufacturing of the switchgear factory is a sophisticated process combining efficiency, quality & optimum utilization of the machines. The premanufacturing section consists of the metal parts shop, plastic shop, and galvanic shop, brazing & welding shop & tool room. Components that are critical in design and dimensions like contacts, magnets, bi-relay components etc are manufactured in this section. PRESS SHOP The metal working presses (mechanically & hydraulically operated) installed in the press shop range from 30 tons up to 125 tons. The raw materials like copper, brass, phosphor bronze, and spring steel are received in coil, strip or sheet form and are fed through pneumatic feeders into press working dies where the final shape of the part is obtained. This shop also has special processes such as magnet manufacturing etc. The parts made are either sent for surface treatment, machining or welding. MACHINE SHOP This shop has various machines performing operations like drilling, tapping, milling, grinding, and turning of raw materials like

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castings or bar stock. Manual operations like debarring and cleaning are perform after machining of parts.

WELDING / BRAZING SHOP This shop has processes such as resistance brazing for contact joining, manual arc welding for manufacturing structural items of switchgear. This process is used for joining two parts of the contacts. Generally copper and silver parts are joined at the brazing shop. Contacts of 34-57 contactor ranges are brazed here. PLASTIC SHOP Raw materials like and resin is the

thermoplastic thermosetting molded

using

compression, transfer, or injection molding

processes to form the final desired shape of the components. The parts are formed using molding dies made as per the required shape. Subsequent to molding, processes such as debarring, belt grinding, and shot blasting are performed for finishing the parts, which are sent for assembly. GALVANIC SHOP This shop deploys processes such as silver, nickel, zinc plating which form the surface coating on switchgear components as a protective layer against rusting.

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Degreasing and pickling of parts is also done here. Efficient water purification and neutralization plants form an essential part of this process.

ASSEMBLY This consist of various processes such as riveting, spot welding, soldering through which various in-house and bought out parts are assembled to form subgroups which are fed to the main product assembly line after testing. The final product is assembled in the well lay out and balanced lines. The product is thoroughly tested and packed before dispatch.

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CHAPTER:-3

INTRODUCTION TO QUALITY ASSURANCE DEPARTMENT (QA)

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INTRODUCTION TO QUALITY ASSURANCE DEPARTMENT

Quality is said to be the eye of the manufacturing company. The need of Quality assurance came into existence due to the principle SURVIVAL OF THE BEST. Since the customers are always in the want of best & the cheapest product. Quality control in its simplest term is the control of quality of raw material, during manufacturing of the product (i.e. Optimum output by using the best process), quality of the finished product. Both Quality Control & Inspection are used to assure quality. Inspection is the determining function, which determines materials, supplies parts of finished products, etc. as acceptable or unacceptable. As the control determines the cause for variations in the characteristics of products, & gives solution by which these are to be contracted. It is economical in its purpose, objectives in its procedures, dynamic in its operation & helpful in its treatment. Coordination between the quality control groups & other departments such as Production, Production Planning, & Inspection is of vital importance. With proper managerial support & co-ordination, the Quality Control program will be more successful. ROLE OF QUALITY IN INDUSTRY The Quality of a product is the 'Degree of Perfection'. Every product is manufactured according to certain specifications specified by certain common standards and the industry. The quality of a product depends upon a number of factors such as dimensions, appearance, etc. To control the quality of the - 36 -

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product, all these factors must be controlled. Quality control is an industrial management technique by means of which products of uniform acceptable quality are manufactured. It mainly involves making things right by finding out causes responsible for the deviations. A simple way to control the quality is to conduct 100% inspection. But this procedure is very costly and time-consuming, thus not feasible. Hence industry uses statistics and this method is known as Statistical Quality Control. It involves the technique of applying statistical methods based on the theory of probability to establish quality standards and maintain it.

The main role of quality control involves the following:

Quality control is used to set up quality standards. It involves locating and identifying the process faults in order to control number of defectives and rejects. Taking necessary corrective measures to maintain the product quality. Ensuring that good quality products reach the customer. Achieving better utilization of raw materials and equipments. QUALITY SYSTEMS IN KALWA WORKS The Quality Policy is integrated and implemented through an active involvement requirements of the entire organization. and It is ensured the that customer are determined met, with aim of enhancing

customer satisfaction. Quality policy of Siemens includes a commitment to comply with requirements and continually improve the effectiveness of the Quality management system, and provides a framework for establishing and reviewing quality objectives. Quality Objectives stated in Quality Policy. Commitment to consistent Quality. Timely Procurement and delivery. Striving for performance leadership. - 37 -

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Top most priority to Customer needs and Shareholders value. Employee driven integration and implementation of Quality Policy in the entire organization. QUALITY CONTROL & ITS OBJECTIVE: Quality means fitness for use at the most economic level. And control can be defined as a process by which we can observe the actual performance and can compare it with some standard. If there is any, then it is necessary to take corrective action. Quality Control can be defined as operational technique and activities that are used to fulfill the requirement for quality. OBJECTIVES OF QUALITY CONTROL To see that only the uniform & standard quality is allowed to go further. To suggest methods & ways to prevent the manufacturing difficulties. To reject the defective goods, so that the products of poor quality may not reach to the customer. To find out the points where the controls is breaking down & investigate the causes of it. To salvage or rework the rejected goods, if possible. To improve the companies income by making the product more acceptable to the customers by providing long life, aesthetic aspects etc. To improve quality and productivity by process control and customer feedback. Judging the conformity of the process to the established standard and taking suitable action where there is a deviation. To reduce the companies cost through reduction of loss due to defect(scrap, rework) To provide optimum quality at minimum price.

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To ensure satisfaction of customers by supplying products of high quality levels to built customer goodwill. Developing procedure for good vendor relations. Developing quality consciousness in the organization

Advantages of Quality Control: Improved quality of product, which increases the sales. Scrap, rejection & rework is minimized, thus the cost of manufacturing reduces. God quality product improves reputation of the company in the market & its market share. Inspection cost reduces to great extent. Uniformity in quality can be achieved. .Improvement in manufacturer & customer relations Improvement in technical knowledge & manufacturing design.

ROLE OF TOP MANAGEMENT WITHIN THE QUALITY MANAGEMENT SYSTEM Through leadership and actions, Top management can create an environment where people are fully involved and in which a Quality Management system can operate effectively. The quality management principle can be used by top management as the basic of this role. 1. To establish and maintain the Quality policy and Quality the organization. 2. To promote the quality policy and Quality objectives throughout the objectives of

organization to increase awareness, motivation and involvement.

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3. To insure focus on customer requirements throughout organization. 4. To insure that appropriate processes are implemented to enable

requirements of customers and other interested parties to be fulfilled and Quality objectives to be achieved . 5. To ensure that an effective and efficient Quality Management system is implemented, established objectives. 6. To assure the availability of necessary resources. 7. To review the Quality Management system periodically. 8. To decide on actions regarding the Quality policy and Quality objectives. and maintained to achieve these quality

9. To decide on actions for improvement of the quality management system. INSPECTION Inspection is part of QC. Quality control comprises of the stages as observation, recording, analyzing and suggest corrective & preventive actions. Observing is in broader sense deals with inspection procedure. Definition:- The process of measuring , examining testing , gauging or otherwise comparing the unit of product with the applicable requirement Unit of product is the item inspected in order to determine its

classification or to count number of non-confirmations. OBJECTIVES OF THE INSPECTION PROCEDURE:1) Inspection procedure separates out defective and non-defective components and ensures adequate quality of production. 2) It detects defect in raw material and flows in process that can affect future machining procedure or final assembly of the product. Thus it eliminated the problem before they arise. 3) It prevents the further machining operations on defective component so the operation cost, labour cost etc. are saved. - 40 -

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It ensures safe operation of the part in relation to the other parts or customer needs. It detects sources of weakness and troubles in finished products and thus checks the work of designer. It improves the relationship with customer by assuring him of good quality.

THE FOLLOWING DEPARMENTS FORMS THE PART OF QUALITY ASSURANCE

QUALITY ASSURANCE

INCOMMING INSPECTION

INPROCESS INSPECTION

FINAL INSPECTION

INCOMING INSPECTION: The outsourced components are inspected in this division. Raw material inspection Components inspection A number of physical, chemical & metallurgical test are conducted to check the quality by the inspectors. IN PROCESS INSPECTION : The components internally manufactured and during assembly are inspected in this division. The process is carried out in three stages as follows:

Sample inspection:

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This is the first stage inspection in which the components being manufactured initially after the tool change is inspected to confirm the proper position of the tool and the component manufactured are as per dimension specified.

In process Inspection: This is the second stage inspection in which the inspection of the component is regularly carried out at particular interval to see the working of the tool. This is previously fixed.

Release: This is the last stage in which after final verification of the components as per drawing the components are released on to the line for assembly. FINAL INSPECTION: In this inspection procedure the life testing (in millions of life) as well as packed good audit of the product is carried out. Packed good audit is to keep a check on the finished product released from the assembly line. Whether it is according to specification or standard mentioned. Packed good audit is likewise a very critical operation from quality point of view. Various steps performed in packed good audit are as follows: Randomly pick up the quantity of product for audit. Check the products packing material used for packing. The number of quantity mentioned on the packing label of the box is checked for the quantity present inside.

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Then the product is removed from the packet and checked for the MFLB, the CE mark and the execution of the product as per the specification. If any of the above steps is found faulty I-report for the product is made. This report is handed over to the Production manager and assembly line incharge giving them the intimation for sorting out of the whole PD. Only after the sorting of the whole PD, it is allowed for dispatching.

CALIBRATION DEPARTMENT The calibration of the switchgear unit is responsible for the calibration of the instruments used in the shop floor on the machines and for the inspection by the inspectors. The calibration of various instruments is carried out according to the calibration due date given by the calibration department. In case of any instrument being used frequently in the shop, the calibration department is given the instruction to carry out the calibration that particular instrument in a short period of time. The department gives a recall list to each and every department using instruments, at the end of the month. ROUTINE INSPECTION / TESTING ACTIVITIES OF QA Product cell in charge will be responsible for regular routine inspection & testing of switchgear product and component.
1)

The inspector & Tester shall do the routine inspection and testing as per the

controlled plan or relevant inspection chart.

2)

The releasing / signaling of part delivers shall be done by the respective line

foremen or group leaders authorized by him. 3) The daily inspection details along with the fault codes shall be made available to QA personnel by the product line incharge. This shall be done every morning & the records will be of previous working day. - 43 -

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Preparation of monthly summary sheet, on the basis of fault diagram of

different products will be done by QA personnel who will convey monthly along with the respective product incharge to chalk out preventive measures to minimize / prevent rejection. 5) Ordering / procuring & maintaining of necessary inspection / test instruments & equipments shall be the responsibility of the respective product incharge. 6) The product incharge are entirely responsible for the outgoing quality of the product. 7) Planning of facilities / training of people shall be the responsibility of the

product incharges with the help of QA personnel and PD. 8) QA personnel shall inspect / check the testing facility including fixtures &

panels & reports about the healthiness of them to product incharge. 9) Even if the outgoing products / spears do not indicate any visible defects, if procedures / process are violated, the entire batch may have to be withdrawn even after party delivery signature.
10)

Make good for the damage at sites / clients ends due to manufacturing

defects / quality defects shall be the responsibility of the product group in charge.
11)

Product group incharge shall be responsible initiating and implementing various corrective measures /actions/improvements process as deemed necessary from time to time.

12)

Scrapping of materials / reworks management & extra cost shall be entirely

being responsibility of the product groups. However monitoring & reporting of extra cost continues to be a QA function.
13)

Calibration of meters gauges & ordering new gauges will be the responsibility

of the product in charges.

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A year marked place shall be provided in every product line for displaying

the rejection / Fault analysis.

15) 16)

A pocket shall be provided in each line for displaying fault diagrams charts. Procurement of new testing schedules shall continue to be provided by product development department.

17)

The control plan shall continue to be made & provided by QA. DIFFERENT AUDITS CARRIED OUT

PRODUCT AUDIT Here the particular product is taken for audit and studied thoroughly to assure that all its parameters are according to the design SPECIFICATION. The reference for audit is the control plan and Inspection & Testing (I & T) schedule .Apart from these if any point is found noteworthy, it is recorded as deviation and corrective action is registered under the name of the person responsible for it. This activity is important because it checks if the products are manufactured according to the design standards and testing is done according to the specific control plans or not.

PROCESS AUDIT Various processes on the assembly line are classified as routine and special process. The special processes are audited after a specific duration. This is to check if the workers are following the work instructions or not. Similarly any discrepancy in the process is also noted and acted upon. The reference for this Process Audit is method instruction sheet. VENDOR AUDIT The vendors are audited regularly. The nature of the audit is similar to packed goods audit and process audit. This helps in keeping a check on the quality of the material supplied by the vendors. - 45 -

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This is a daily activity done for all the products .Finally, completely packed products that are ready for dispatches are audited. Various check points are given for different products and the audit is done accordingly .If any deviation is found in the audit, an I-report is prepared and corrective action is implemented. This activity holds immense importance from the point of view that faulty product are prevented from going outside the company. It is also steps towards reducing customer complaints. The record of packed goods audit report and its I report in case of deviation is preserved for a period of six months. The report serves as reference whenever customer complaints received. MECHANICAL LIFE TEST LABORATORY: The mechanical life test lab is set up for ensuring the mechanical reliability of contactors. Here, along with their life their endurance is also tested. Daily checking is done to ensure the physical & aesthetic appearance of contactor. The parameters like coil & contacts are checked properly. The erosion of contacts & burning of coils are taken note of seriously & corrective actions are taken. There are two modes of testing, continuous & flash mode the contactor is kept on CONTINUOUSLY, WHEREAS in flash mode the contactor closes & opens CONTINUOUSLY. There are specifications given as to which contactor is to be operated at what frequency and what voltage. However there is provision for changing frequency and voltage if required .The mode of operation can also be changed. VDE TESTING LABORATORY: The relays at Siemens undergo various tests, one of which is VDE Testing. Here relays are mounted on the respective type of contactors. The soldering of contactor is done so as not to produce flashing action & only continuous flow of current - 46 -

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through them. This test can be carried out in auto mode as well as manual mode & program is fed to the computer. There are two type of test being carried out. 1) SINGLE PHASE TEST.
2)

THREE PHASE TEST.

1) SINGLE PHASE TEST:This test is done to check the tripping time of the relays when any one phase goes off. The current progression is as follows:1st half hr.:- SOURCE A rated current SOURCE B 0.9 times the rated current. 2nd half hr.:- SOURCE A 1.15 times rated current. Source B no current supply. The relays are supposed to trip within 2nd half hour. 2) THREE PHASE TEST:The three phase test is carried out to check the tripping time of the relays when over loaded with current PROGRESSION AS follows:Rated current for 1st half hour. 5% over load for 2nd half hour. 20% over load for next 10 min. 25% over load for next 10 min. 30% over load for next 10 min. Relays are supposed to trip within 20% of over load.

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MATERIAL FLOW DIAGRAM

CUSTOMER ORDER P.C.O

STOCK
RESERVE MANUFACTURE

IMC REQ.
PROD. ORDER PURCHASE ORDER MANUFACTURING BY VENDOR
CHALLAN

BOC REQ.

VENDOR
REJECTION CHALLAN

RECEIVING MATERIAL
G.R.N.

INCOMING INSPECTION
INSPECTION ACCORDING TO CONTROL PLAN

REJECT
YES

WHETHER OK

INSPECTION REPORT

WHETHER SERIOUS
NO

RELEASED

MFG. PROCE SS
INSPECTION

WHETHER URGENT

YES YES

DECISION TO BE TAKEN BY QUALITY MANAGERS

MFG. SHOP
WHETHER OK
NO YES YES

APPROVED MAIN STORE

ASSEMBLY LINE

CAN BE

PROD. ORDER ASSEMBLY INSPECTION & TESTING

RECTIFY

RECT
NO

RECTIFY

SCRAP B.D.C PACKING

YES

IFY

CAN BE RECT IFY

NO

INSPECTION STAMP

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WHETHER OK

NO

SCRAP

DEALER

CUSTOMER

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MATERIAL FLOW
The flowchart shows how material flow takes place within the industry. First of all, the end customer or the dealer, if it is a bulk order, places an order with the sales office. In other cases, the sales engineer goes on site requesting customers to place orders with them. The sales office then contacts the Order Execution Cell (O.E.C) and books the sales order. At the beginning of each month, the OEC gives Planned Independent Requirements to the various Product Cells. This PIR is calculated from the Sales forecast given by the Marketing Department, the Data from the past and are given for a period of 3 months. Then, the BDC checks the stock with them. If the required products are in stock the BDC it to the dealer or the customer. On no stock availability, order is given to the assembly line. To manufacture these orders, Internally manufactured components (IMC) as well as brought out components (BOC) are required. For IMCs, requirement is given to the plastic shop and the pre- manufacturing parts shop. For BOCs, Purchase order is to be given to the vendor. The material is then send by the vendor by a challan and is received in the Receiving Department. After the material is counted, given a location i.e. is kept in a Schaffer box or a cage box, a Goods Received Note is prepared. The Quality Inspectors according to the Control plan then inspect the material. If the material is to the required quality standards it is released and sent - 49 -

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to the stores with the white copy of the GRN stamped and signed by the Inspector. Posting is then by the incoming inspector and then by the Stores In charge and given a proper location in the stores. If it is urgent then it is taken on the assembly line. If the material is not okay, an Inspection (I) report is made. If serious, a decision is taken by the Quality managers. A decision is taken whether the material can be sorted and used or whether it has to be rejected. In the latter case, a rejection challan is made and material is sent back to the vendor. The same procedure is followed for the internally manufactured components. After the material reaches the assembly line, a Production order is made to produce the required quantity. The assembly of product begins, followed by inspection and testing. If the tested products are found to be defective, they are rectified for the given errors. All the finished product are packed and sent to BDC, which dispatches it to the dealer who, sends it to the customer.

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CHAPTER:-4

PRODUCT STUDY BIMETAL RELAY

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BIMETAL OVERLOAD RELAY

These relays operate on the thermal effect of electric current. Generally they do not measure the temperature directly. Thermal relays sense the current by temperature rise produced by the current. The simplest thermal relay used in motor starters overload protection devices employ a bimetallic strip mounted above a resistance wire. The passage of excessive current through the coil causes the bimetallic strip to deflect and thereby close the relay contacts. A system of lever which is to be adjusted with respect to the compensating strip is arranged to obtain the closer compensation for ambient temperature usually provided by another bimetallic strip .The bimetallic strip consists of two metals, which have different coefficients of expansion joined together. TYPES OF SIEMENS BIMETAL OVERLOAD RELAYS: Relays for contactor mounting . (1) 3UA50 (2) 3UA52 (3) 3UA55 (4) 3UA58

Relays used in starters. (1) 3UW50

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1). 3UA50/52 RELAYS: The 3UA50/52 relay have two NO (normally open) contacts; namely NO1 + NO2. They have one NC (normally closed) contact. Connections are bent and they have all the four screws for auxiliary connections. For bistrip winding both the strip and wire designs are being used. Hence winding is being done on bistrip winding machine. They are designed for a number of current ranges ranging from 0.1A

to 25A. 2). 3UW50 RELAY: The 3UW50 relay has one NO (normally open) contacts. It has one NC (normally closed) contact. Connections are straight and it has only two screws for auxiliary connections. For bistrip winding both the strip and wire designs are being used. Hence winding is being done on bistrip winding machine. It is designed for a number of current ranges ranging from 0.1A to

25A. It is being used in Raja starters.

3). 3UA55 RELAY:

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The 3UA55 relay has two NO (normally open) contacts; namely NO1+NO2. It has one NC (normally closed) contact. Connections are parallel and it has all the four screws for auxiliary connections. For bistrip winding both the strip and wire designs and also the heating strip design are being used. Hence winding is being done on bistrip winding machine as well as manually. It is designed for a number of current ranges ranging from 0.1A to

45A. 4). 3UA58 RELAY: The 3UA58 relay has two NO (normally open) contacts; namely NO1+NO2. It has one NC (normally closed) contact. Connections are larger and are named as Z1 & Z2 connections and it has all the four screws for auxiliary connections. For bistrip winding the heating strip design are being used. Hence winding is being done manually. It is designed for a number for higher current ranges ranging from 16A

to 120A. 3UA58 Relay salient features are visible from the snap.

5). C.T OPERATED RELAYS: Siemens C.T operated relays provide accurate overload and

accelerated single phasing protection for three phase motors having rated currents up to 630A/400A. Type 3UC comprises of current tripping unit

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which makes use of dual slider principle for faster tripping under single phasing. The C.T operated relay consists of a current transformer, which

comes into circuit before the relay. Thus C.T operated relays are being used in circuits where higher current ranges are required. The primary coil of the C.T converts the three-phase current to the required range current of the secondary coil by means of the current transforming ratio.

SALIENT FEATURES OF BIMETAL OVERLOAD RELAYS: BUILT IN SINGLE PHASING PROTECTION : Besides three-phase overload protection, the relays offer a built in single phasing protection using differential slider principle.

TEMPERATURE COMPENSATION: The relays are temperature compensated between service temperatures of 25 degree Celsius to 55 degree Celsius.

OVERLAPPING SETTING RANGES: For proper selection of overload relays to match the current drawn by the motors, a number of overlapping ranges are incorporated which can be adjusted with the help of setting dial provided at the top of the relay.

SHORT-CIRCUIT PROTECTION: The relays protect themselves against overload up to 10 times the maximum setting. Beyond this i.e. in the short circuit zone, the relays must be protected by a short circuit protection device (HRC fuses). APPLICATIONS:

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3UA5 and 3UA6 are triple pole adjustable bimetal overload

relays with built in single phasing protection. In conjunction with contactors and other motor control equipment, they provide accurate and reliable protection to the motors against overloads and single phasing. They also offer protection against unbalanced voltages. 3UC5 and 3UC6 are triple pole adjustable, saturable C.T operated bimetal overload relays (with built in single phasing protection feature). They are ideal for heavy starting applications, when heavy masses are to be put in motion with the resultant long starting period. In conjunction with contactors and other motor control equipment, they provide accurate and reliable protection to the motors; with an acceleration time up to 30 sec and starting current up to 6 times the rated current, against overload and single phasing. The 3UC5/6 relays comprises of three saturable current transformers, a resistance unit and a special bimetal relay connected to the secondary winding of the C.T. It is a composite unit with bimetal relay mounted on the CTs. The saturable current transformers linearly transform the current up to approximately twice the set current but above this value the transformer core gets saturated and the secondary current is proportionately less. Thus these relays permit heavy starting conditions of motors and offer dependable protection against overload.

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MOUNTING: Relay types 3UA50, 52, 55, 58 are suitable for mounting on SICOP power contactors as shown in the snap below.

CONTACTOR

RELAY

However, a simple accessory is available for converting contactormounting relay to individual mounting as shown in the snap below and suitable for screw type mounting and DIN RAIL mounting.

PARTS OF A RELAY:
Various components used in the Relay and their use:1) Scale: - The scale represents the current range of the relay for, which the relay is designed. It is used for adjusting the relay to the required current setting. Scale has a cam type arrangement, which moves the compensating strip & thus - 57 -

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moves, the releasing lever. By moving the compensating strip the gap between the lever and the tension spring increases or decreases.

2) U clip: - U Clip is used, which holds the scale in the housing.

3) Red Knob: -The red knob is used to test the tripping of the relay. It actuates the rocker, having a snap action.

4) Blue Knob: - The blue knob resets the relay once the relay is tripped. Also these relays have an auto reset function, once the relay is kept on auto-reset mode it directly resets after tripping. This is one of the most important features of the 3UA relays. 5) Green Indicator: It indicates whether the relay has tripped or not (only when the relay is in manual resetting condition). It is just for an indication purpose. 6) NO1 Contact Complete: - No1 contact complete comprises of No1 contact, contact spring 1 & silver rivet. First the silver rivet is riveted with the contact spring 1 and then this assembly is again riveted with NO1 contact. This whole assembly forms the NO1 contact complete. This assembly is flared in the housing.

7) NO2 Contact Complete: -No2 contact complete comprises of No2 contact, contact - 58 -

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spring 2 & silver rivet. First the silver rivet is riveted with the contact spring 2 and then this assembly is again riveted with NO2 contact. This whole assembly forms the NO2 contact complete. This assembly is riveted in the housing. 8) NC Contact: - This contact is also known as Silver contact. This contact is riveted inside the housing below the NO1 and NO2 contacts. This contact together with bearing bracket forms the NC contacts. It is mainly a copper contact, which has silver plating.

9) Bearing Bracket Complete: It comprises of bearing bracket, bearing pin, adjusting screw, terminal plate & connecting wire. First the bearing pin is riveted in the bracket. This bearing pin engages the compensating strip and releasing lever. Adjusting screw is screwed inside the bracket. Screw holds the tension spring, which is engaged with rocker. Terminal plate is spot welded with the use of connecting wire from the bracket. This terminal plate with the silver contact forms the NC contacts. 10) Rocker Complete: -This is the most important part of relay on, which the tripping of the relay is dependent. This part comprises of rocker dolly, insulated piece & silver rivet. Silver rivet is riveted with rocker dolly. Then the rocker dolly is inserted inside insulated piece, both are ultrasonically welded. Rocker does the snap action while tripping.

11) Tension spring: - The tripping force of the relay is mainly depended on this spring. So the tension of this spring should be very accurate. Normally the

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force is 7.2 N. Tension springs one end is engaged in the rocker dolly ant the other end is with adjusting screw of the bearing bracket.

12) Compensating Strip Complete: - U Clip and Compensation strip comprise the sub assembly of the compensation strip complete. U clip and Compensation strip both are spot-welded. Then they are tempered for releasing stresses, which are developed during spot welding. This strip is used to compensate the effect of normal atmospheric temperature. Compensation strip is mounted on the bearing pin of the bearing bracket; in between this the releasing lever is placed. One thing is kept in mind that the compensating strip should be free to move. 13) Releasing Lever Complete: - Adjustment lever, adj. Screw & releasing lever together form the sub assembly of releasing lever complete. Adjustment screw is screwed in the releasing lever. It is mounted in the u clip of compensating strip. It should be free to move. Releasing lever complete is coupled with bistrips with the use of change over lever, which is engaged in the forward and backward slider. Any movement of the bistrips will in turn move the releasing lever, which in turn moves the tension spring and the rocker dolly and the relay is tripped. 14) Slider Assembly: - This slider assembly consists of forward slider, backward slider and change over lever. As told earlier backward slider is placed first in the housing than on it, the bistrip assembly. On top forward slider change over lever is placed and than forward slider is locked in the change over lever. So bistrips and this lever forms a coupling. Any movement in the

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bistrip will result in the corresponding movement in the sliders. These sliders move the releasing lever and thus the relay is tripped when the bistrips bend.

14) Bistrip Complete: - Bi holder, Bistrip, Resistance strip and Insulating piece together forms the Bistrip complete. Bistrip is made up of 2 different metals, which has different co-efficient of expansion. When the current passes through the bistrip, it gets heated and the bistrip bends. The bending is in the direction of that metal, which has a low co-efficient of expansion. First the shunt strip is spot welded on the bistrip (only in some high ranges to increase the resistance). Than insulation piece is placed over the bistrip. This assembly is placed in the auto winding m/c, where the winding of strips and wire is done for different ranges. Here no of turns and pitch are maintained as specified. One end of wire spot-welded with the bistrip it self. This bistrip complete is spot welded with the biholder. Backward slider is placed first and than whole assembly is screwed inside the housing. The other end, which was left open is TIG welded with the connections. Tempering is done for stress removal, which is developed during spot and TIG welding. This process is being used for relays of type 3UA/3UW50, 3UA52 and 3UA55, for 3UA58 the heating strip design is used which is done by manual folding patterns and then clamped.

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OPERATING PRINCIPLE OF BIMETAL RELAY.

The operation of a birelay depends upon the deformation of a bimetallic strip or coil, which is heated by a current proportional to that in the circuit, which the relay controls. The strip is composed of two metals having different coefficients of expansion, & firmly fixed together throughout the length so that different rates of expansion of the two layers of metals cause the strip to bend when heated. The strip may get heated by the passage of current through it directly, or by radiation & convection from another heating element, or by immersion in an oil bath heated by the operating current. Overload protection is accomplished with the use of a bimetal strip. This component consists of a small heater element wired in series with the motor and a bimetal strip that can be used as a trip lever. Under normal operating conditions the heat generated by the heater element will be insufficient to cause the bimetal strip to bend enough to trip the overload relay. As current rises, heat also rises causing the bimetal strip to bend enough to trip the overload relay. Some overload relays that are equipped with a bimetal strip are designed automatically reset the circuit when the bimetal strip has cooled and reshaped itself, restarting the motor. If the cause of the overload still exists, the motor will trip again and reset at given intervals. Care must be exercised in the selection of this type of overload, as repeated cycling will eventually damage the motor.

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THE WORKING OF THE RELAY IS DEPENDENT UPON THE FOLLOWING FACTORS: 1) Bimetal heater assembly:Three bimetals are used, which are spot welded at one end to one terminal (connection) of the relay. The other end is free to move. There are two sliders, Top slider & Bottom slider. The free end of the bimetal is inserted between these two sliders. Strips of Nichrome called heater coils are wound over the bimetal. Insulation strips separate the bimetal and heaters (to prevent short circuit conditions). The material of the heater is so selected as to withstand the starting current as well as the short circuit current. 2) Tripping Mechanism:-

This is the most important and critical mechanism in the relay in which the gaps between bimetal strips and slider, trip force etc. are to be maintained accurately to control the trip time variations. The force that develops due to deflection of bimetal strips is transferred through the differential movement of the slider to operating lever to open the trip circuit. 3) Auxiliary contact and push buttons

There are two push button test push button and reset push buttons. One trip contact is available in the control circuit of the relay. It gives tripping signal to the contactor coil in abnormal conditions. The electrical life of the relay depends upon these auxiliary contacts. Auto / manual reset facility is also provided in the same type of relays. - 63 -

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AGNEL POLYTECHNIC

WORKING PRINCIPLE OF BI-RELAY: Current dependent thermally delayed overload relays have got three bimetal strips. The motor current that flows through the heater elements or windings heats these indirectly. For motor currents above 180 amperes, the secondary current of a transformer is used to heat up the bi-strips. On one hand this reduces the losses, while on the other hand it increases the short circuit with stand capacity. The following will help in better understanding of working of the relay: 1. As the bimetal strips are heated by the motor current flowing through

the heater windings L1/T1, L2/T2 and L3/T3, the strips bend and the tripping bar (slider) is moved. 2. The tripping bar operates the tripping lever via the ambient temperature

compensation strip; the ripping lever in turn transfers the force to the springloaded snap action moving contact (Rocker). Prior to the tripping, the NC

contact (95 / 96) is closed and the NO contact (97 / 98) is opened. 3. In the event of an overload the tripping lever pushes the snap action

moving contact so that the NC contact is opened and the NO contact closed. Mechanical switch position indicator signals tripped state. If the reset selector is on Manual reset position, the snap action moving contacts is pushed beyond its dead center position (re-closing lock out). After sufficient cooling of the bistrips the reset button must be used to push the snap action moving contact back over its dead center position to reset the relay. If the selector is in the Automatic reset position, the NC contact is opened and the NO contact closed, even through the snap action moving contact is not moved beyond its dead center position. In this case the moving contact returns to its original position automatically once the bimetal strip have cooled down. - 64 -

SIEMENS LTD.

AGNEL POLYTECHNIC

AMBIENT COMPENSATED OVERLOAD RELAY

In certain applications, such as a submersible pump, the motor may be installed in a location having a constant ambient temperature. The motor

control, along with the overload relay, may be installed in a location with a varying ambient temperature. The trip point of the overload relay will vary with the temperature of the surrounding air as well as current flowing through the

motor. This can lead to premature and nuisance tripping. Ambient compensated overload relays are designed to overcome this problem. A compensated bimetal strip is used along with a primary bimetal strip. As the ambient temperature changes, both bimetal strips will bend

equally and the overload relay will not trip the motor. However, current flow through the motor and the heater element will affect the primary bimetal strip. In the event of an overload condition the primary bimetal strip will engage the trip unit. (Refer Diagram) The tripping mechanism of the bistrips can be well understood with the help of the following diagram shown below: FIGURE 1 2 98 9 7 9 5

6 3 4

9 6 1

L 1
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T 1

L 1

T 1

L 1

T 1

SIEMENS LTD.

AGNEL POLYTECHNIC

FIGURE 2
95 2 97 95

3 4 6 5 96

L1 T1 L1 T1 L1 T1

When overload current flows through the bistrip and the heating element the bistrip bend from their normal position and thus the slider (4) is pushed towards the left which in turn pushes the releasing lever unit (1). The NC contact (95) now becomes NO. the lever pushes the rocker towards the left. When it crosses the Dead center the NO contacts (97 & 98) become NC and the blue knob is tripped i.e. the relay trips. While in production for checking the proper snapping of the relay the red knob (3) is used for resetting.

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In this load the relay in self-resetting position. The distance adjustment is then done which can be explained with the help of the following slides.

NO2 NO1

PROB

ECTION ANALYSISits gives the

Initially the contacts NO1 and NO2 are OFF and the probe is not touching the NO1 contact

NO 1

NO2

PROBE
Red The probe is then slowly moved towards the NO1 contact and as soon as it touches the contact the red light glows. Then the probe pushes towards the contact further towards NO2. As soon as NO1 touches NO2 a green light goes ON. At this point on the setting dial zero is set. Now the probe is moved in the opposite direction i.e. away from the NO1 contact. The dial needle rotates. Initially the green light goes OFF as soon as contact between NO1 and NO2 breaks. Then the probe travels some distance and as soon as it leaves the NO1 contact the red light goes - 67 -

SIEMENS LTD.

AGNEL POLYTECHNIC

OFF. At this point the reading on the dial gauge is taken which is the distance between NO1 and NO2.

NO1

NO2

PROBE
Red Green

SET ZERO

The tension adjustment done at station 7 can be explained briefly as below. In this position the relay is in self-resetting position. The tension adjustment is done at this station, which can be explained with the help of the slide shown overleaf. A Torque-meter (1) is used to measure the spring tension. The probe of the torque-meter is made to touch the lever and the meter is rotated with the help of a hand knob at the top. As soon as the probe touches the lever a red light goes ON. The lever is then pushed to get the lever tripping force (LTF) on the torque-meter.

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SIEMENS LTD. 2

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4
At this point the red light goes OFF. If the tripping force is not in range then the screw (4) on the lever is loosened to get the required tripping force. The levers return force is calculated by releasing the lever. Similarly the rocker tripping force (RTF) and the rocker return force (RRF) is calculated with the help of another torque-meter (6) placed at the rocker (5) end. After the distance and tension adjustment is done then the relay is

said to be partially complete since the distance and tension are the important parameters, which are to be adjusted with accuracy without which the relay wont function properly and would encounter problems in tripping while in circuit. At station 9 the hot tempering of the bistrip is done. In this operation of tempering, 10 times more current is passed through the bimetallic strips so that when overload condition occurs bistrips should bend and it should not break. Without the tempering of the bistrips the relay will not function - 69 -

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AGNEL POLYTECHNIC

properly. In the pre-assembly unit for making bistrip complete unit the bistrip to bi holder welding and also the spot welding of heating strip to the bistrip is being done. The part of the bistrip where welding is being done gets heated and expands such that at molecular level the crystal structure of the bistrip gets distorted. Due to this process stresses are developed in the bistrip. To relieve these stresses the tempering process is done in the assembly line. Here a high current is passed through the bistrip so that it gets heated throughout and expands evenly and then the bistrip is allowed to cool slowly so that it comes to the room temperature. Due to this heat developed the molecules get expanded evenly throughout the bistrip and on cooling a stable molecular structure is attained. At station 10 the cold calibration of the bistrips done, which can be explained briefly as below. After hot tempering the bistrips are kept for cooling for about 24 hrs. When they get cooled they do not come back to their normal position and are also not parallel to each other. In cold calibration fixture there are three calibrated meters corresponding to the three bistrips. The relay is placed inside for testing. Then the overlapping needle corresponding to each bistrip is checked for parallelism and if not parallel then the bistrips are manually bent with the help of a tool and simultaneously the parallelism is observed in the meter. After this the X-value is checked which can be understood from the fig shown below. X-value is the distance the master slide is to be moved after the three green lights corresponding to the three bistrips glow to push the releasing lever so that changeover of contacts from NO to NC occurs and the red light glows.

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AGNEL POLYTECHNIC

RED

NC

X-value

Initially when the master slide is touching the releasing lever the red light glows. This is due to the releasing lever making the changeover of contacts from NO to NC. Then the slide is moved in the opposite direction and observed when all the three indicators corresponding to the bistrips glow. These three lights should glow within 0-5 reading.
Green Green Green

NO

Y-value is the distance between the two probes i.e. the distance between the probe corresponding to the master slide and the probe corresponding to the releasing lever. - 71 -

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AGNEL POLYTECHNIC

At station 12 the hot checking of the relays done can be explained briefly as below. The relays are placed in the panel and current is passed through the relay twice the value of the lower range of the rated current. The relay should trip in the specified time range i.e. the tripping time of the relay is checked. If the tripping does not occur properly then the setting dial is adjusted and again the hot checking is done. A small lot of the group of relays is then sent to the quality control department for V.D.E test.

PRODUCTION LINE OF RELAY

WORK-STATION 1:ON THIS WORK-STATION FIRST THE LOWER SLIDER IS

INSERTED IN THE HOUSING OF RELAY & THEN THE BISTIPS ARE FIXED BY APPLYING FORCE. ALSO THE SETTING-DIAL IS FIXED IN THE HOUSING WITH THE HELP OF U-CLIP PIN. Input:- Relay Sub-assembly, Forward Slider, Bi-strips and Screws, Setting Dial, U-Clip WORK-STATION 2:- DISTANCE ADJUSTMENT ON THIS WORK-STATION SPECIFIED DISTANCE IS ADJUSTED BETWEEN THE NO1-NO2 CONTACTS & ALSO BETWEEN ROCKER & LEVER Input: Sub-assembled Relay from Work station 1

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SIEMENS LTD. WORK-STATION 3:- TENSION ADJUSTMENT

AGNEL POLYTECHNIC

ON THIS WORK-STATION THE TENSION OF SPRING IS ADJUSTED. THE FOLLOWING PARAMETERS ARE ALSO ADJUSTED ON THIS FIXTURE:1. 2. ROCKER TRIPPING FORCE & ROCKER RETURN FORCE. LEVER TRIPPING FORCE & LEVER RETURN FORCE.

Input : Distance adjusted Relay from Work station 2

WORK-STATION 4:- CONNECTION PRESSING ON THIS WORK-STATION THE CONNECTIONS ARE FIXED IN THE HOUSING OF RELAYS BY APPLYING FORCE. Input: Tension adjusted Relay from Work station 3, Connections (3x), Cheese Head Screws (3x) WORK-STATION 5:- TIG WELDING & TERMINAL SCREWING ON THIS WORK-STATION TIG WELDING IS CARRIED ON INORDER TO JOINT CONNECTIONS TO THE BISTRIPS.THE TERMINAL SCREWING IS ALSO DONE ON THIS WORK-STATION. Input: Tension adjusted Relay from Work station 4 WORK-STATION 6:- COLD CALIBRATION ON THIS WORK-STATION ALL THE 3 BISTIPS ARE ARRANGED AT EQUAL DISTANCES FROM EACH OTHER INORDER TO OBTAIN PROPER BENDING DURING OPERATION. INPUT:- TIG welded Relay from Work station 5

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WORK-STATION 7:- CHANGE OVER LEVER, BACKWARD SLIDER, AND BACKCOVER FIXING ON THIS WORK-STATION THE CHANGE OVER LEVER, BACKWARD SLIDER & BACKCOVER ARE FIXED IN RELAY Input : Cold calibrated Relay from Work station 6, Change over lever, Backward slider, Back cover, Self tapping screw

WORK-STATION 8:- CUTTING AND BENDING ON THIS WORK-STATION THE CONNECTIONS ARE CUT IN EQUAL LENGTH BEND AS PER THE SPECIFICATIONS. Input: Relay from Work station 7.

WORK-STATION 9:- HOT CHECKING ON THIS WORK-STATION SPECIFIED CURRENT IS PASSED THROUGH THE RELAY & ITS TRRIPING TIME IS CHECKED.

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SIEMENS LTD.

AGNEL POLYTECHNIC

CHAPTER: - 5

FIRST PASS YIELD

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INTRODUCTION TO FIRST PASS YIELD

THE CONCEPT: In this competitive market, even when it is in recession for any production unit to get maximum output from minimum input needs best ways to control its cost on every aspect involved in this manufacturing process. On of the best ways is to control the cost involved in rework and salvage. Hence this concept of first pass yield (F.P.Y.) was introduced in Siemens to reduce the rejections and save cost on rework & scrap involved in it. First pass yield is calculated on the basis of no of tested products to the no of products passed in the first attempt. THE NEED & REQUIREMENT: As the concept clearly gives the idea of the need of first pass yield it indicates optimum savings on rework & salvage of every component & product manufactured or assembled within the manufacturing unit. The basic requirements for maximum F. P. Y. is better process capability, quality of material supplied by the vendor well within the tolerances, minimum deviations of critical dimensions & better control over rejection. CALCULATION FOR F. P. Y: First pass yield is calculated on the basis of no of tested products to the no of products passed in the first attempt. F. P. Y. gives the percentage of products passed as per the Inspection & Testing (I&T) schedule in the first attempt, hence its gives the efficiency of the unit.

TOTAL DEFECTIVES F.P. Y. = 100 ---------------------------------- X 100 TOTAL TESTED

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TARGET: To attain the maximum F. P. Y. a certain target is set, on the basis of average previous months F.P.Y. so that the work is being done accordingly to reduce the no of rejections. A lot of efforts are being taken to achieve maximum F.P.Y. ADVANTAGES OF F.P.Y.: -

The various advantages of obtaining better F. P. Y. are:

1) Reduces cost of rework: Extra cost is required in rework of a product or component after it has been failed in certain test due to a specific reason. The cost of material and the labor cost involved in it can be saved. 2) Reduces cost of scrap: - The cost involved in the salvage of the product

or component if it has been failed in certain test and cannot be rectified (e.g.: broken components), this cost can be saved. 3) Ensures timely delivers: - Timely deliveries can be assured if all the

products are passed in the first attempt and no rework is required. 4) Ensures better quality: - Better quality of products can be assured if all

the products pass in certain limits well within the tolerance limits. 5) Reduces rejections: - The main advantage of F. P. Y. is that it reduces

the number of rejections and better Production Control can be achieved. 6) Improves productivity: - The overall advantage of improving the F.P.Y.

is that it improves the overall productivity.

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Reduces cost of rework:

Ensures timely delivers

F. P. Y

Ensures better quality

Improves producti vity

Reduces rejections

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AGNEL POLYTECHNIC

CHAPTER:-6

REJECTION ANALYSIS

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REJECTION ANALYSIS IS A PROCESS IN WHICH REJECTED MATERIALS ARE ANALYSED IN ORDER TO FIND THE CAUSE OF REJECTION AND TO PREVENT IT

THE MAJOR REJECTIONS IN BIMETAL RELAYS: After assembly of every Bimetal relay the tester checks them. The test consists of series of visual, mechanical and electrical tests. There is a list of possible faults that can occur in a Bimetal relay and each fault is given a fault code. This list is called as the fault chart and is issued by the quality assurance department. Although there are number of possible faults, some faults are observed consistently and these faults are noted in the record book, which is checked by an authorized person form the quality assurance department.

LIST OF FAULTS OCCURRING ON THE ASSEMBLY LINE

16.5: Not resetting when dial is 2mm below the bottom limit of the range. During final inspection the tester sets the setting dial to 2mm below the bottom limit of the specified current range and then checks for continuity after resetting. This checking is done just as a precautionary measure so that even if the customer sets the setting dial 2mm below the specified range by mistake the relay should still trip and protect the circuit. REASON OF REJECTION (16.5): 1. Cold calibration may not ok

2. Tension adjustment may not be ok

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SIEMENS LTD. 3. Distance adjustment may not be ok. 4. Burn on rocker. 5. Bend in bearing bracket.

AGNEL POLYTECHNIC

7.10: No continuity between NO1 + NO2 and NC This fault is checked before 16.5. As the name suggest in this fault No continuity is observed between NO1+NO2 and NC contacts. REASON OF REJECTION (7.10) : 1. Burr is Top cover indicator or housing. 2. Two-compression spring on Indicator. 3. Improper Tension. 4. Rocker not placed properly. 16.4: Indictor not coming in HR Position/not going in Sticky. This is a visual test in which the tester just observes whether the movement of the green indicator. There should be no obstruction to the movement of the green indicator and the movement should not be sluggish. The main function of the green indicator is to indicate whether the relay is in trip or set position. REASON OF REJECTION (16.4): 1. Burr present in housing, indicator or top cover. 2. Tension adjustment not proper 3. Rocker not placed properly. 6.18: Rocker does not snap Every time the relay is tripped or reset the rocker snaps i.e. it makes a sound. This sound indicates that the Distance and Tension adjustment in the relay is proper. - 81 -

SIEMENS LTD. REASONS OF REJECTION (6.18): 1. Burr present on the rocker. 2. Tension adjustment not within specified range.

AGNEL POLYTECHNIC

1.5: Cover fixing screw Defective / loose The main function of the cover is to protect all the internal components in the relay for safety reasons and to protect the relay from dust. The operator visually checks whether the cover has been screwed properly or whether the cover is loose. 6.9: Rocker tripping force greater than x N: The tests checks this force manually by pressing the red knob, if the operator has apply more force for tripping the red knob then he concludes that this relay is defective.

6.8: Rocker tripping force less than y N In this case the relay trips very quickly when the blue knob is pressed.

8.1: Red knob in press position In this case the red knob does not come back to its original position when it is pressed REASONS OF REJECTION (8.1): 1. Spring tension may be less. 2. Length of red knob may be less. 3. Rocker tripping force and return force not ok. 8.2: Red knob Sticky In This fault the movement of the red knob is very slow and more force is required to press it. - 82 -

SIEMENS LTD. REASONS OF REJECTION (8.2): 1. Burr in red knob. 2. Burr in top cover. 3. Burr in housing. 4. Red knob is damaged. 1.1: Housing broken

AGNEL POLYTECHNIC

In this case either there are cracks on the housing or the housing is broken. 2.5: Scale too loose. In this case the setting dial moves very easily. REASONS OF REJECTION (2.5): 1. U- spring used for holding scale may be broken. 2. U-spring may not be proper or may get deformed. RECORDING OF DATA: Every line has been provided with a record book. The data is recorded in the following format. Types of Relays Total no of rejected relays Total no. of tested relays No. of relays passed.

Types of faults

The data from this table is converted into fault chart by a authorized person from Quality Assurance department. Every line has its fault chart. Fault charts are made every month. The fault Old charts are maintained by Quality assurance department as a quality department as a quality document.
N o of defec tives
400 350 300

Cum ulative %
1 20.0 1 00.0 80.0 60.0 40.0

No of defects

250 200 1 50 1 00 50 0 A B C D E OT H E R S

- 83 Fau lt co d e

20.0 0.0

% Rejection

SIEMENS LTD.

AGNEL POLYTECHNIC

CHAPTER: - 7

8 D REPORT & IMPLEMENTATION OF 5S PRINCIPLES.

8D METHODOLOGY - 84 -

SIEMENS LTD. DEFINITION;-

AGNEL POLYTECHNIC

The 8D reporting method provides a team-oriented and standardized procedure for problem analysis.

The 8D Method includes the following steps. 1. Establish a team. 2. describe the problem 3. develop interim containment actions 4. define and verify the root causes 5. select permanent corrective actions 6. implement permanent corrective actions 7. prevent recurrence 8. conclusion THE 8D REPORT CHECKLIST CONTAIN THE FOLLOWING POINTS 1. Processing team. 2. Description of problem a) Topic b) Problem. c) Statistics 3. Immediate corrective actions 4. Analysis of root causes. 5. Permanent corrective actions. 6. Verification of effectiveness. 7. Preventive actions.

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FORMAT OF 8 D-REPORT

IMPLEMENTATION OF 5S PRINCIPLE
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SIEMENS LTD. ABOUT 5S PRINCIPLES.

AGNEL POLYTECHNIC

Thirty years ago researchers started studying the secret of success of Japanese manufacturing companies. 5S turned out to be the most impressive "secret" in their observation. Because the factories were so well organized that abnormal situations were readily apparent to everyone. The equipments were so clean and well maintained that any problem such as a loose bolt or leaking oil could be easily seen. This passion of cleanliness and orderliness became a hallmark of Japanese organizations. So 5s is the effective housekeeping technique developed by Japanese people to create a better working environment and a consistently high quality process. The technique is a base for any improvement. Even before you plan the direction you need to take, one must have to remove obstacles to get a clear view of the current situation. It is based upon a simple but an important concept that a neat and clean factory has higher productivity, and produces fewer defects as well as it is a much safer place to work.

Advantages of 5S If tools and materials are conveniently located in uncluttered work areas - 87 -

SIEMENS LTD. Operators spend less time looking for items

AGNEL POLYTECHNIC

This leads to higher workstation efficiency, a fundamental goal in mass production A clean and tidy workplace leads to greater well being and increased motivation Company image improves Health and Safety is ensured Machine maintenance Quality Productivity Lean Manufacturing Results In A Place Easier To Manage Smooth Working No Obstruction

No Deviation, No Problems Time Saving Quick Retrieval Accidents & Mistakes Minimized Increases Space Creates Workplace Ownership Foundation Of All Qc Tools Continuous Quality Improvement Lean Manufacturing Kindergarten Of Quality Tools & Techniques

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SIEMENS LTD. PROBLEMS THAT ARE COMMONLY

AGNEL POLYTECHNIC ENCOUNTERED AT THE

DEPARTMENT: High absenteeism High turnover Demotivated employees Disordered/ cluttered environment Mistakes/errors

In order to achieve high levels of quality, safety, and productivity, workers must have a conducive working environment. It is a housekeeping technique to enhance productivity and safety.

THE 5S PRINCIPLES:

SEIRI Organisation/Sort out SEITON Orderliness/Systemize SEISO The Cleaning/Shining SEIKETSU standardize SHITSUKE - Sustain/Discipline

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1.

SEIRI ORGANISATION/SORT OUT

We sorted out the material as notched, bent and the blanks which have approximately same length. According to that we designed separate material storage rack for all types of doors, and separate one for all types of top and bottom blanks. Same technique was used for back and partition also. These decisions were taken as per frequency of material to be used.

RED TAG TECHNIQUE:

Give staff red labels Ask staff to go through every item in the work place Ask if needed & those that are needed, in what quantity Not needed - red tag it Store in the red tag area

For wavering items- 90 -

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Place the suspected items in the red tag area for one week Allow the staff to reevaluate the needed items At the end of week those who need items should be returned

The material which had dents or wrongly bent or had some dimensional errors used to be red tagged by us and written over it was NOT OK. Most of the time the material from notching department had defects in it and we had to send it back. All the unnecessary clutter is removed in the form of scrap. A particular space was defined for the unwanted material.

2. SEITON- ORDERLINESS
It signifies the simple concept that "Everything has a place and everything in its place." Neatness focuses on the layout and structure of the office and workplace. It involves where and how the necessary items are placed. Obstructions to work flow will be easily identified and removed by having a clearly defined layout. Safe storage should also be practiced, like storing heavy items at the bottom. Other than storage, attention must also be paid to the other aspects of workplace layout. The position and height of the tools and equipment should enable the worker to maintain good posture for his comfort while making process movements. Organise layout of tools and equipment Designated locations Use tapes and labels Ensure everything is available as it is needed and at the point of use.

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For maintaining orderliness i.e.; SEITON, various task had to be undertaken like: To ensure position of aisle and storage places clearly marked or not. Tools classified and stored as per their respective frequency of use.

Ballets kept properly at specified places for use. Safety equipments were kept right beside the LVD machines like safety pad for small material.

Floors had to be maintained in good condition and it was ensured that there were no ups and downs on the aisle as it was difficult for workers to carry the trolley over it.

3.

SEISO - (CLEAN/SHINE)

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Cleanliness of the area is visible to everyone. To maintain a good image of cleanliness, everyone should be individually responsible for cleaning. Throwing out things that are unnecessary will uncover areas for inspections. Discarding unwanted items will make the area clear and uncluttered. Daily inspection, lubrication and cleaning of equipment are part of preventive maintenance that will increase efficiency of the machinery. Cleaning must thus be done daily and inspections can be incorporated to ensure that this is done religiously. Cleaning should be extended even to areas not usually obvious, such as the washroom. To make the work place look better and clean following things were done: A fixed position of trolleys and racks was decided and they were placed

accordingly on their respective places with help of fork lift driver. The workers were told their responsibilities to keep the workplace clean

like their own home and using this fact, everyday in morning half hour was spent for cleaning machines, tools, punches, dies and arranging trolleys etc. Every worker who does the setting has been provided with his own

precision equipments like vernier , ninety degree Allen key etc. The area of the department is divided into LVD section WELDING

section and MECHANICAL PRESS BRAKE section and all the areas were kept in neat and proper condition.

4. SEIKETSU - (standardise)
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Seeing is believing; thus emphasis must be placed on visual management. Standardized conditions on site must be achieved so that work can be done quickly. Standardizing the way you process or assemble the product so that everybody performs the operation the same way. An essential step in getting Lean. Standardization of all the necessary things needed to be done:-

Firstly the primary task was to ensure proper application of above three S . Proper procedures, tasks , schedules needed to be made and carried out. Continue to assess the use and disposal of items Regularly audit using checklists and measures of housekeeping Real challenge was to keep it clean. of Fume hood We also made the SOP (Standard operating procedure) and other material also.

5. SHITSUKE- (SUSTAIN / DISCIPLINE)

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Discipline means instilling the ability to do things the way they are supposed to be done. This involves training and inculcating good habits and having everyone practise them, thus encouraging the continuity of good habits. As the final S in the 5-S, it propagates the 5-S practice by ensuring that the former 4-Ss are carried out

conscientiously. The discipline to maintain the improvements and continue to improve. Probably the hardest of the five elements. Focus on maintaining the revisions and continue to improve without slipping back into old habits. Setting up the 5-S is useless if it is not followed through, as things will return to being bad if they are not well maintained. Taking a further step, discipline also includes reviewing current practices and revising them to keep them relevant. It also means striving for kaizen, which is the Japanese equivalent for continuous improvement. Inoculate courtesy & good habits Make it a way of life Part of health and safety Involve the whole workforce Develop and keep good habits Make the workers realize that its good for them only.

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SIEMENS LTD. Followings can be harnessed form the 5S

AGNEL POLYTECHNIC

1. Neat & Clean Workplace

2. Smooth Working

3. No Obstruction

4. Safety Increases

5. Productivity Improves

6. Quality Improves

7. Wastage Decrease

8. Machine Maintenance

9. Visual Control System

10. Employees Motivated

11. Workstations Become Spacious

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