Industrial Training Report

CHAPTER 1 COMPANY PROFILE

Established in 1968, O/E/N is the market leader for Electromechanical Components. Manufacturing plants are located in the suburbs of Cochin, Bangalore and Pune with over 20,000 square meters of factory space. They offer a comprehensive range of products with applications in most segments of Electronic Industry including Communications, Automotive, Strategic Industrial Controls, Instrumentation and Consumer Electronics. The quality management systems of the company is covered by ISO 9001 and ISO/TS 16949 Certification. 1.1. HISTORY OF O/E/N O/E/N India Ltd was formed in 1968 as a joint venture with OAK Electro/Netics Corporation, USA under the leadership of founder M.D and Late Mr K A Mathew. At the inception, 45% of the equity shares were held by OAK Industries Inc, USA and 25% by Kerala State Industrial Development Corporation and balance primarily by the directors and their associates. The abbreviation O/E/N was devised out of the name of the collaborator. The OAK group was a pioneer in the field of professional grade rotary switches, keyboards, and push button switches, miniature and power relays, miniature trimmer potentiometers, controls and control systems serving many segments of electronic industriesappliances, manufacturing, industrial, aerospace, military and other fields. Until O/E/N India went into production, entire requirements of the country for these products were being imported from the US and the UK. The major customers of these products were Indian PSUs like BHEL, HAL, ISRO, DRDO, HMT etc. The company started with OAK designs and eventually added new designs in due course. The company reached its break even in 1970 and declared its first dividend in the year 1973. In 1980, the company started a sister concern O/E/N Micro Systems to take up manufacturing of computer peripherals and in 1984 O/E/N Connectors India Ltd in collaboration with FCI

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Connectors, France. By 1985, the company set its second manufacturing plant in Peenya, Bangaloru and in 2010 the company established its third manufacturing plant at Pune. Till 1990s the company was enjoying a monopoly in the market with no competition from the local businesses. However with the liberalization policy of the 90s, the company was forced to face severe competition from the global brands. It took some time for the company to react and change itself from the slow pace culture generated by the monopolistic leadership to that of a flexible innovation culture needed in midst of a competitive market. The growth of the company was dampened though losses were avoided. The company was subsequently merged to the parent company in 2003. FCI also increased its share in O/E/N Connectors to 51% and then to 65% in 1996. The company realizing the faults reinstated its position in the early 2000s entering into tie-ups and technological transfer agreements with major global players to bridge the technological gap. The company had invested in enriching its core competency in electromechanical sub systems development and had entered into contract manufacturing. The policy changes reflected more emphasis on value addition and value creation. 1.2. BUSINESS MISSION, VISION & GOALS 1.2.1. Mission Attain leadership position Create wealth Be the best in the business

1.2.2. Vision Centre of technological excellence Market leader in electromechanical components in country

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1.2.3. Goals To attain a respected presence in the industry To build progressive relationships To improve organizational strengths To fine tune competitive advantage To offer unique services To undertake customizing of products

1.3. MAJOR CUSTOMERS American Power Conversion (APC) GE Medical Systems TATA Motors Mahindra & Mahindra Johnson lifts JCB India ITI Ltd Ford India Pvt Ltd Bharat Electronics Ltd L&T Ltd ABB India Ltd Hyundai

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CHAPTER 2 DEPARTMENTS IN O/E/N

The industry is organized into the following departments

2.1. HUMAN RESOURCE DEPARTMENT

Human Resource Development (HRD) is the framework for helping employees develops their personal and organizational skills, knowledge, and abilities. Human Resource Development includes such opportunities as employee training, employee career development, performance management and development, coaching, mentoring, succession planning, key employee

identification, tuition assistance, and organization development. O/E/N has a an efficient HRD department, which is headed by Asst general manager. HRD as a process occurs within organizations and encapsulates: 1) Training and Development (TD), that is, the development of human expertise for the purpose of improving performance, and 2) Organization Development (OD), that is, empowering the organization to take advantage of its human resource capital. TD alone can leave an organization unable to tap into the increase in human, knowledge or talent capital. HRD does not occur without the organization, so the practice of HRD within an organization is inhibited or promoted upon the platform of the organization's mission, vision and values. Other typical HRD practices include: 1. 2. 3. Executive and supervisory/management development, new employee orientation, professional skills training,

4. technical/job training, 5. customer service training, 6. sales and marketing training, 7. health and safety training.

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2.1.1. Functions Manpower Planning It involves the planning for the future and finding out how many employees will be needed in the future and what types of skills should they possess. It depends on the following factors

The number of people leaving the job The projected growth in sales Technological changes Productivity level of the workers

Job analysis and Job description HR Department is also involved in designing the Job analysis and Job description for the prospective vacancies. A job analysis is the process used to collect information about the duties, responsibilities, necessary skills, outcomes, and work environment of a particular job. Job descriptions are written statements that describe the:

duties, responsibilities, most important contributions and outcomes needed from a position, required qualifications of candidates, and reporting relationship and co-workers of a particular job.

Determining wages and salaries HR Department is also involved in conducting market surveys and determining the wages and salaries for different position in an organization. These decision may be taken in consultation with top management and the Finance department. Recruitment and Selection The recruitment and selection is the major function of the human resource department and recruitment process is the first step towards creating the competitive strength and the

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strategic advantage for the organizations. Recruitment process involves a systematic procedure from sourcing the candidates to arranging and conducting the interviews and requires many resources and time. Performance Appraisal Once the employees are recruited, the HR Department has to review their performance on a regular basis through proper performance appraisals. Performance appraisal is the process of obtaining, analyzing and recording information about the relative worth of an employee. The focus of the performance appraisal is measuring and improving the actual performance of the employee and also the future potential of the employee. Its aim is to measure what an employee does. On the basis of performance appraisal the HR Department will set up an action plan for each employee. If the employees need any training then he provided that. Training and Development HR department is constantly keeping a watch over the employees of the organization. In order to improve the efficiency level of the employees they have go undergo regular trainings and development programmes. All trainings and development needs are carried out by this department. Training might include on the job or off the job training. Employee welfare and motivation Happy employees mean a healthy organization. HR Department conducts various employee welfare activities which might include employees get together, annual staff parties etc. HR department also reviews organizational policies and its impact on the motivation of the employees. Addressing employees grievances HR department is the link between the workers and the management. Employees grievances related work environment are usually entertained and resolved by the HR Department.

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Labour management relations For the smooth operation of any organization, it is crucial to have good labour management relations. HR department has to ensure that these relations are cordial. In case of any labourmanagement conflict the HR Department will play a vital role in bringing both management parties to the negotiation table and resolving the issue. Implementing organizational policies HR Department has to coordinate with line manager and see that the organizational policies are being implemented in a proper manner. Disciplinary action can be initiated against employees who are not following organizational rules and regulations. All these actions are conceived and implemented by the HR department. Dismissal and redundancy HR Department has to take firm actions against employees who are not following the organizational code of conduct, rules and regulations. This can result in the dismissal of the employee. Sometimes, an organization may no more require the services of an employee. The employee may be made redundant. HR Department has to see that organizational and government regulations are being followed in this process.

To carry out these functions, separate sub-departments have been established with the HRD department. The HRD department is headed by the Assistant General Manager (HRD),who is responsible for the efficient working of all the departments under it. The HRD department is thus responsible for maintaining a good and sustaining relation between the management and workers and between management and the public. The department frames various for the welfare and satisfaction of the employees.

2.2. RESEARCH AND DEVELOPMENT DEPARTMENT

Research and development (R&D) department is mainly involved with the design and development and the betterment of existing products. Thus, the major objective of R&D is to develop quality products based on cutt ing-edge technology. The company R&D facility operates

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over a wide range of electronic research and applications. The facility is a self-contained centre with well-equipped laboratories and multi-disciplinary team of professional design engineers. The R&D department is mainly concerned with designing three types of products: a. Products according to customer specifications. b. Existing products not available in the market. c. Existing products with additional features.

2.2.1. Roles and Responsibilities of R&D Section

Prototyping and batch production are the main responsibilities of the R&D department. The department first receives a New Product Development Request (NPDR). The design development is based on the Advanced Product Quality Planning (APQP).

The 5 major phases of new product development are: 1. Plan and define the program: This stage is the initial stage in the long process of R&D department. The initial stage is concerned with identifying what kind of product is to be made and it is feasibility in creation (financial, conceptual and process). Risk analysis and feasibility review. In this they note all the risk faced by the company during the planning time. It also consist of the analysis of the different other product with the companys product. This is based on consumer specifications. Risk analysis also consist of the different problems faced by the company in the recent days, any frequent quality rejections, any launch performance is poor, will the product requirements be difficult to achieve etc. in feasibility review they look up on a number of details. Contract review check list Define the scope R&D: Design the relay, issue drawing etc. Marketing: Interaction with customer. Tool room: Design and make tools for fabrication. Fabrication: Production of parts. Manufacturing: Assembly.

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Quality assurance: Ensure the quality of components and products. Materials. Data from marketing and QAD Watermarks, customer plant report and rejections, field return, product analysis, customer feedback etc. Internal quality report, supplier feedback, process capability, problem resolution reports etc. Design goals targeting reliability, life, maintainability, timing and cost. Preliminary bill of material. Preliminary process flow chart Product assurance plan First phase review and management support

2. Product design and development: In this stage, the department usually uses the PRO-E software to design the finished product. Along with this the product and the tools are also designed. The manufacturing of the tools also take place in this stage. A review on the progress of the process is done bringing to an end the second phase of the NPD process. Design failure mode and Effect Analysis(DFMEA) Analysis of various parts of the relay and problems at the time of manufacturing. Design for manufacturability and assembly. Design concept, functions and sensitivity to manufacturing variations. Manufacturing and assembly process. Number of components. Material handling. Design verification. Different dimensions such as length, width, height, NO-terminal, NC-terminal, coil terminal etc. are verified. Design review checklist. Prototype build. Engineering drawing and specification. Drawing specification changes.
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New equipments tooling and facilities. Tool Design. Material specification. Sheet metal strip procurement. Tool manufacturing. Gauges/Testing equipment procurement. Bill of materials. Testing equipment requirements. Team feasibility commitments. Second phase review and management support. 3. Process, Design and Development: In this phase the process sequence, labour characteristics, room characteristics etc. are identified and developed. Manufacturing process design output. Targets for productivity, process capability and cost. Process flow chart checklist. Packing standards. Flow plan checklist. Process FMEA and checklist. Prelaunch control plan and checklist. Process instructions. Process approval acceptance criteria. Data for quality, reliability and measurability. Error proofing activities. Method of proofing detection and feedback. Measurement of system analysis plan. Preliminary process capability study plan. Packing specifications. Third phase review and management support.

4. Product & Process Validation: The validation and testing of the products made are conducted in this phase along with the final designing of the product. The design made up in

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this phase goes into the pre-production run in the fifth stage. The relay values, dropout volts, withstand, life, ampere, etc. are tested validated to the benchmark. A review is conducted after this phase. Production trial run. Measurement system evaluation. Preliminary process capability study. Product approval process. Production validation testing. Packaging evaluation. Production control plan. Quality planning and sign off. Fourth phase review and management support

5. Feedback Assessment and Corrective Action: A preproduction run for 20,000 to 30,000 units are conducted. For the first three months the R&D team along with production team would be constantly monitoring the production process and the mistakes are taken care immediately without any delay. Field trials and valuation Multiple batch production for confirming the result. Samples with PPAP Batch production The average time taken for a new product to be designed and developed is six months.

2.3. TOOL ROOM

O/E/N has a well equipped modern tool room with all facilities. The specialty is in the design and manufacture of tools and moulds for electromechanical components. Tool room is managed by a team of expert engineers in tool design and in manufacturing a group of well trained tool room makers and mechanics, a well equipped press and molding shop attached to the tool room provide facility for providing the tool and moulds. Tool room works in four wings:

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Tool design Machining Tool assembly Maintenance The tool room is equipped with CAD facility and a machine shop having the following

special machines in addition to conventional machine tools. The tool room can accept orders for design and manufacture of the following types of tools and moulds, for fabrication of components to customers design. Press tools progressive, compound and single operation tools Injection moulds Compression moulds Transfer moulds Assembly tools Jigs and fixtures

2.3.1. Procedure

The drawing for a particular tool will be issued from design section with respect to the work order. After getting the drawing, the routing for the entire will be done by the shift supervisors. After routing, the supervisor will hand over the drawing copy to respective toolmakers for pre-machining the work pieces. Work piece are taken from raw material store by giving store requisition slip. Then the work piece will undergo pre-machining. The pre-machining includes shaping, milling, and surface grinding. Work piece are then loaded in micron milling and jig boring for pre-drilling holes, boring, cavity milling, steps, slots etc. to the required dimensions as per the drawing. These work pieces will handover to tool makers for tapping, relive holes etc. after that work piece will undergo heat treatment. Heat treatment will help the work piece to become hard. Heat treated work piece are then taken to further operations like surface grinding, profile grinding, spark erosion, wire cut and final EDM. After the final operation EDM, the work piece will take for inspection. The work piece will inspect as per the drawing.
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By finishing the inspection the tool makers will assemble the work piece as per the drawing. The assembled tool will take for trial. Five thousand parts will produce and handover to QA for inspection. If QA approved the part, then the tool will handover to concern department. Bench workers are for maintaining and repairing the tools. For each tool and mould they keep a record. In that record the tool maker will note down the actions that he took for repairing the tool.

2.3.2. Operations In Tool Room

1. Cutting: Power hack saw are using for cutting the work piece to required dimension. 2. Shaping: Shaper machine are using for shaping process. Machining of flat work piece to the required size by keeping 0.5 allowances for further operations. 3. Milling: Vertical and horizontal milling machines are using for this process. We can do milling and drilling process on this machine. 4. Micron milling: Numerical control milling machine are using for this process. In this machine e can do drilling, milling, boring etc. with accurate dimensions. 5. Jig boring: Digital Read Out(DRO) is used for maintaining the accurate and perfect output. Jig boring machine maintain 2 micron accuracy. Drilling and boring of holes to required dimensions are doing with this machine. 6. Surface grinding: Work pieces are grounded to magnetic chuck for grinding. By grinding the surface will be smooth. By this machine we can do flat, vertical, horizontal grinding. We can maintain perpendicularity. 7. Cylindrical grinding: This machine is used to grind the cylindrical work piece like cylinders, pillars etc.. By this machine we can grind internal and external round work piece. 8. Profile grinding: The image of the work piece is projected to the projector, with the help of projected image. Flat, vertical, concave and any other irregular forms can be grind to the given dimension. The accuracy of this machine is 1 micron. 9. Spark erosion: It is a method of drilling holes in hardened work piece by sparking. Before wire cut the holes for the wire passage are drilling by this method. Brass and copper rods are using as electrodes for sparking.

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10. WEDM: EDM means Electro Discharge Machine. Stabilized current is used for this process. Brass, copper with zinc coating wires are using. The required diagram is drawn in computer and inserts the floppy to the machine. The machine will cut the work piece as per the drawing. The work piece is dipped in chilled water to avoid over heating of piece. 11. EDM: By sparking the work piece to required dimension. Copper and tungsten are using as electrode. The work piece is dipped in dielectric fluid to avoid short circuits. Types of metals used are:-Mild steel, Orvar supreme, Ohns etc.

2.3.3. Tool Room Process Flowchart

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2.4. FABRICATION/PLATING DEPARTMENTS

The main assembly is supported by comprehensive fabrication facilities with power press for pressed piece parts, a plating plate that handles plating of conventional as well as precious metals. This has three divisions: Actual fabrication Electro plating Moulding shops

2.4.1. Fabrication Shop This is the department where all the components are manufactured which includes making of all the minor and major components of relays and electroplating as per customer requests. About 90% of the parts such as the armature, yoke, core etc required to manufacture the relays and switches at O/E/N India Ltd is made by the company itself. Fabrication refers to build metal structures by cutting, bending and assembling. The cutting part of a fabrication is via sawing, shearing, or chiseling; torching with handheld torches; and via CNC cutters. The bending is via hammering (manual or powered) or via press brakes and similar tools.

2.4.2. ELECTRO PLATING Plating is an important step which is the final step of fabrication. Plating has different steps that includes degreasing ,hot soak, water rinse , acid pickling, water rinse, anodic cleaning ,water rinse ,cyanide bath ,copper bath ,water rinse and unloading. For plating different metals such as copper, nickel, gold, silver, cadmium, zinc, chromium etc. are used. Plating procedure include 1. Receiving of items along with the production report 2. Items are selected according to the shortage list 3. Plating is done as required by the drawing specification The plated parts are transferred for inspection .Plating thickness is measured and entered in the plating process control sheet before transferring the parts. An important factor to be noted is

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that O/E/N India Ltd has developed an automatic plating system which is established in the plating unit. This system was developed by the automation department of O/E/N.

2.5. ASSEMBLY DEPARTMENT

This department is mainly related to the manufacturing and assembly of relays, switches and potentiometers. This department works two shifts in a day. Their main objective is to reduce process scrap and achieve programmed production. The piece parts which is the fabrication unit outputs and materials which are directly purchased undergone several processes in order to develop the final product. 2.5.1 Relays Relays are electromagnetically operated switches. An actuating current on a coil operates one or more galvanically separated contacts or load circuits. Relays are differentiated based on materials used, temperature and pressure with standing ability, electrical parameters, type of moulding etc. Different types of relays such as automotive, industrial etc are developed. The assembly steps of 73-relay is given below: Coil pin insertion Coil winding Coil lead tinning and hooking Welding of terminal 30 with yoke Yoke, core and assembly staking Staking of terminal 85 and 86 into base Staking of NO/NC contact with terminal 87 Staking of NO/NC contact with terminal 87a Staking of base terminal assembly Insertion of coil assembly into base assembly Soldering of coil terminals and resistor Staking of moving contact with contact blade c Welding of armature assembly with base assembly Cover printing Relay-cover assembly

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2.5.2 Potentiometers As per orders, assembly of potentiometers is undertaken. Therefore the manufacturing of these are less compared to other products. This product is used in electronic circuits for getting desired voltage drops. All the parts of the potentiometers are imported. Procedures inside Assembly Room: a) Information and scheduling system: This is to provide information on the functioning and daily targets at the assembly room; There are mainly two types of information boards inside the assembly room manually written board and digital information boards. b) Daily meeting at work place: A meeting between supervisor and the assembly workers happens before each shift to discuss on previous days production. The discussion may go up to ten minutes. c) Integration with production planning department. d) Operation control procedures.

2.6. QUALITY ASSURANCE DEPARTMENT

Quality assurance (QA) refers to the engineering activities implemented in a quality system so that requirements for a product or service will be fulfilled. It is the systematic measurement, comparison with a standard, monitoring of processes and an associated feedback loop that confers error prevention. 2.6.1 Departmental Structure Quality products and services to the customers is the primary task but the ultimate aim is to offer customers improving products and services. The QA department is involved in inspection of parts, incoming materials and financial products and also in maintenance of quality records. QA lab facilities are used by other companies too underlining the quality and standards kept by the company in maintaining its QA department. Major functions of this department are given below: Incoming Inspection: Inspection of first sample is done by incoming inspection executive after receiving reports along with samples. Inspection of vendor supplied parts is done according to specifications. Criterion for incoming inspection is that if five items randomly taken are qualified

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then the entire lot is approved and if three items are rejected the entire lot is rejected. Following processes are done in incoming inspection Inspection of raw material Inspection done during fabrication of parts, samples are tested on an interval of one hour Inspection of in-house processed parts Inspection of packing boxes, mould tray Product specification testing Parts after plating and processing Customer supplied parts are tested Finished Product Inspection: This process is done to ensure and certify that the required quality is maintained for finished products. Finished products are tested by checking random samples offered by product inspectors by subjection appropriate routine life tests as per work instruction for ensuring product reliability and performance against relevant specifications at regular intervals. 2.6.2 Inspection Modes Normal Inspection mode: This mode is carried out in early stages of quality inspection. Normal to tightened Inspection mode: When two out of five or more consecutive lots of a part gets rejected in normal inspection, there is a switch over to tightened inspection. Tightened to Normal Inspection mode: When five consecutive lots of a part get accepted enlightened inspection mode, normal inspection mode is resorted back. 2.6.3 Calibration Section This section functions within the QA but performs a distinct function. In this section, chiefly, tools and equipments used in assembly line and QA parts are checked or calibrated. Calibration means testing the measuring equipment, their precision as well as their conformity. This helps to check timely decadence and wear and tear of equipment used in product inspection. In the calibration observation sheet which is tagged along with the tool, the observations are noted

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down as P or F for pass or fail. A colour label is stuck on the equipment after calibration signifying the following: Green- O.K Red- Out of Use Yellow- Limited Use In case of yellow, users are to use the equipment carefully and correction in measurement is made manually. Equipment of various departments is sent for calibration and a copy of the calibration observation sheet is sent to the concerned department along with the calibrated tool.

2.7. MATERIAL/PURCHASE DEPARTMENT

The materials purchase department is an important department in O/E/N. The hectic procedures concerning the purchase of materials, choosing suppliers of materials, etc are decided by this department. O/E/N India Ltd. Attempts to acquire materials, goods, and services to accomplish the goals of the company. This process is referred to as purchasing. Though there are several organizations that attempt to set standards in the purchasing process, processes can vary greatly between organizations. Purchasing managers and procurement managers guide the organizations acquisition procedures and standards. Purchasing includes activities like discussing prices, discounts, delivery load time and specifications with supplier, chase data deliveries and sanction payments to deliveries. They will seek out competitive source and maximize quantity and quality. 2.7.1. Sections There are mainly 3 sections for this department: Material planning Material procurement Material utilization

2.7.2. Functions And Procedures 1. Approval of new suppliers: New sources are identified through various inputs like publications, ads, introductory letters, references through internet, through correspondence etc. A request for quotation is sent to new sources along with specifications, drawings, samples,
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supplier evaluation forms etc wherever applicable . On receipt of quotations and other details offers are evaluated. If required, further correspondence/ negotiations / request for samples is made and new suppliers for ordering are identified. Trial order is placed with new suppliers based on terms and conditions. Trial order item receipts are forwarded to QA for evaluation and inspection report is forwarded to suppliers. Based on acceptance of trial batches, new suppliers are included in Approved Suppliers List. 2. Supplier monitoring : For suppliers , supplier performance is monitored based on the

following for automotive parts: Quality Delivery Price Premium freight incidence Customer line description Quality issues for customers Documentation 40% 10% 15% 10% 10% 10% 5%

For suppliers of non- automotive parts supplier performance is monitored based on Quality Delivery Price Responsiveness 40% 25% 25% 10%

Performance rating is done during April and September every year for suppliers made during the previous six months . Based on rating suppliers are classified into five grades : Grade A : Rating >=90 Grade B : Rating >=80 and <90 Grade C : Rating >=70 and <80 Grade D :Rating >=60 and <70 Grade E : rating <60 Suppliers belonging to group E are removed from approved suppliers list. Suppliers are reevaluated every three years based on their performance rating for previous three years. Those

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who have not supplied for three consecutive years are discarded from approval list .Suppliers removed are prequalified per procedure for approval of new suppliers.

In case of rejection of supplied items suppliers are informed along with inspection report/Corrective and Preventive Action Report (CPAR) and asked to submit counter measures and ensure implementation of measures depending on severity of problem. Suppliers are instructed to present the counter measures for major problems in a meeting at O/E/N. Even after counter measures if suppliers are rejected no further orders would be placed. Quality assurance (QA) refers to the engineering activities implemented in a quality system so that requirements for a product or service will be fulfilled. It is the systematic measurement, comparison with a standard, monitoring of processes and an associated feedback loop that confers error prevention.

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CHAPTER 3 PRODUCTS

3.1. RELAYS
3.1.1. Relay Basics Relays are electromagnetically operated switches. An actuating current on a coil operates one or more galvanically separated contacts or load circuits. The electromechanical relay is a remote controlled switch capable of switching multiple circuits, either individually, simultaneously or in sequence. The primary functions of relay are 1. The galvanic separation of the primary or actuating circuit and the load circuits 2. Single input/multiple output capability 3. Separation of different load circuits for multi-pole relays 4. Separation of ac and dc circuits 5. Interface between electronic and power circuits 6. Multiple switching functions 7. Amplifier function 3.1.2. Application of Relays Typical applications of relays include laboratory instruments, telecommunication systems, computer interfaces, domestic appliances, air conditioning and heating, automotive electronics, traffic controls, lighting controls, building controls etc 3.1.3. Electromechanical Relays In electromechanical relays, the switching elements are a mechanical contact, actuated by an electromagnet. This is the most widely used type of design. The principal internal function of the electromagnet relay is

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1. Conversion of electrical current (input, coil current) to the magnetic field 2. Conversion of magnetic field into mechanical force 3. This force operates the contacts 4. Contact switch and the conduct electrical current 3.2. ELECTROMECHANICAL RELAY DESIGN The most important components are Contact system or Secondary side 1. Fixed contact 2. Moving contact (contact being moved between magnetic system to switch) 3. Contact springs (Holding the contact but sufficiently flexible to allow the contacts to move) Magnetic system 1. Coil ( To generate the necessary magnetic field to actuate the armature and contact) 2. Core ( Highly magnetic permeable concentrates the magnetic field) 3. Yoke ( To establish the magnetic circuit) 4. Armature 5. Return spring ( For quick return of the moving contact to normal condition on removal of the coil spring) Mechanical Components 1. Case and Base ( To protect the relay against external influences and for the protection against electric shock) 2. Insulation ( Within the relay to separate the primary circuit from the secondary side) 3. Actuator (used in the relay to translate the motion of the magnetic system to the contact system) 4. Pins and terminals ( to connect between the contact system and the load) 5. Mounting devices( Sockets in brackets or PCB) 3.3. RELAY CONTACTS The contacts are the most important element of the relay construction. Contact performance is influenced by the contact material, voltage and current values applied to the contacts, the type of load, frequency of switching, ambient atmosphere, form of contact.

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The contacts are practically not clean because the surfaces are covered by thin layers of low conductivity, semiconductor properties or even isolating characteristics. These layers of oxides, sulphides other compounds will be formed on the surface of metals by absorption of the gas molecules from the ambient atmosphere within a very short time. The growth of these layers will be slow down and eventually stopped as the layer itself prevents further chemical reaction. The resistance of these layers increases with thickness. To get a reliable electrical contact these layers have to be destroyed. This can be done by mechanical or electro-thermal destruction. 3.4. MECHANICAL CLEANING When the contacts are closing, the metal surfaces will collide and hit against each other several times (bouncing), causing elastic deformation of the contact area and the mechanical destruction of thin layers. With high contact pressure also this could be obtained. The design of the most relays allows the contact surfaces to wipe across each other destroying the non-conductive films on the contact surfaces. This contact wipe often enough to clean the surface and to reduce resistance to an acceptable level, as well as keeping the resistance stable throughout the electrical life of the relay. 3.5. ELECTRICAL CLEANING The low and non-conductive layers can also be destroyed by the effects of 1. Electrical voltage (Fritting) 2. Current ( Heating of contact points) 3. Thermal effects (High temperature due to electrical arc) 3.5.1. Fritting The term fritting means the electrical breakdown of oxide or foreign layer when a sufficiently high voltage is applied across a closed contact. Due to the applied voltage and very short distance between the low potentials a high electric field is generated. This electric field destroys the thin non-conductive layer and the establishes a metal bride electrically linking the two surfaces

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3.5.2. High Currents High continuous currents and increased contact resistance due to the layers causes heating of the contact. The layers will eventually be destroyed thermally be destroyed thermally and a larger effective contact area is created, reducing the constriction resistance 3.5.3. Arc Sparks Under certain circumstances an electric spark or arc will be generated during contact making or breaking under load. The extremely high temperature of these arcs may destroy the contact layers and burn or disintegrate other components or particles in the vicinity of the point of contact. 3.6. BASICS OF RELAY HANDLING 1. Avoid ultrasonic type cleaning of all type of relays 2. To obtain initial performance throughout life, avoid dropping the relay 3. Case of the relays cannot be removed 4. Always apply rated voltage to relay 5. Do not switch voltage and currents that exceeds the designated values 6. Use flux resistant or sealed relays for automatic soldering. 3.7.1. INDUSTRIAL RELAYS Series 31(1R/2R) Rating: 10 A at 24 VDC/230 VAC Coil: 6-220 VDC, 6-230 VAC Series 31(3R/4R)

Mounting Style: Plug in Contact Form: 2C, 3 C Mounting Style: Solder/Plug in Contact Form: 1-3 C Rating: 10 A at 24 VDC/230 VAC Coil: 6-220 VDC, 6-230 VAC
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Series 33

3.7.3 CRADLE RELAYS Series 67

Mounting Style: Panel / Plug in Contact Form: 2C, 3 C Rating: 30A at 24VDC/230VAC Coil: 6-48 VDC , 115 , 230 VAC 3.7.2 SIGNAL RELAYS Series 42 LCSO Approved Style: Solar/plug in/PC Contact: 2-8C Rating:3.5 and 7A at 24 VDC and 115VAC Coil AC: 115,230V Coil DC: Various 3.7.4. POWER RELAYS Series 26

Mounting Style: PC Contact Form: 1C Rating: 1A at 24 VDC / 230VAC Coil: 12, 24VDC Series 46 Mounting Style: PC Contact Form: 1C, 2C, 1CK Rating: Up to16A at 24VDC / 230 VAC Coil: 6 - 48 VDC Series 55H

Mounting Style: PC Contact Form: 2 C Rating: 2A at 30 VDC /125 VAC Coil: 5 - 48 VDC
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Mounting Style: PC

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Contact Form: 1A Rating: 25A at 24VDC/230 VAC Coil: 12, 24 VDC 3.7.5. AUTOMOTIVE RELAYS Series 35

Rating: 40A at 12VDC / 20 A at 24VDC Coil: 6 - 48VDC Series 35HT

Mounting Style: PC Contact Form: 1A Mounting Style: PC Contact Form: 1A, 1C Rating: 20 A at 12 VDC Coil: 6-48 VDC Series 35H Rating: 70A at 12 VDC (Glow Plug Load) Coil: 6 - 24VDC Series 3572

Mounting Style: PC Contact Form: 1A, 1C Mounting Style: PC Contact Form: 1A Rating: Up to 45A at 12VDC Coil: 6-24 VDC

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Industrial Training Report

CHAPTER 4 CONCLUSION

O/E/N India ltd is one of the leading manufacturer of relays switches potentiometers etc. Their main customers are Maruthi, Ford ,Nissan etc. O/E/N India ltd was established in 1968. Their facilities located in shrubs of cochin and bangalore.11000 square meter factory space. Products of this company found application in communication, automotive, consumer electronics instrumentation etc.ISO 9001,ISO/TS16949,ISO14001 and OHSAS18001 certified and variety of end use products approvals. They are the customer link for future. They help to turn/transform customer concepts to product application. The hard earned reputation for quality products &services had helped them to enhance customer base. Customer care and satisfaction is part of their work culture. They had successfully established customer loyalty by working towards establishing lesser gap between customer needs and product services they delivered. In fact they are the virtual supplier of electromechanical components.

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