INDUSTRIAL TRAINING REPORT

(09MQ15)

Dissertation submitted in partial fulfillment of the requirements for the degree of

MASTER OF ENGINEERING

Branch: ELECTRICAL & ELECTRONICS ENGINEERING

of Anna University of Technology, Coimbatore

May 2012

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERINGPSG COLLEGE OF TECHNOLOGY

(Autonomous Institution)

COIMBATORE – 641 004

PSG COLLEGE OF TECHNOLOGY(Autonomous Institution)

COIMBATORE - 641 004

12 kW PHASE-SHIFT MODULATED FULL BRIDGE SMPS WITH ZERO VOLTAGE SWITCHING

Bonafide record of work done by

SIVAKUMAR S.(Roll No: O9MQ15)

Dissertation submitted in partial fulfillment of the requirements for the degree of

MASTER OF ENGINEERING

Branch: ELECTRICAL & ELCTRONICS ENGINEERING

of Anna University of Technology, Coimbatore

May 2011

……………………….. …...…………………… Mr. M. Sundaram Dr. P. Navaneethan Faculty Guide Head of the Department

Certified that the candidate was examined in the viva voice examination held on ……...

................ ………… (Internal Examiner) (External Examiner)

ACKNOWLEDGEMENTI express my sincere thanks to

Dr. R. Rudhramoorthy, Principal, PSG

College of Technology and Dr. P. Navaneethan, Head of the Department, Electrical &

Electronics Engineering, who have provided the opportunity and necessary facilities to

carry out the internship in L&T IES for my Master’s thesis work.

I extend my esteemed thanks to my beloved guide Mr.M.Sundaram, Assistant

Professor (Sr.Gr.), Department of Electrical & Electronics Engineering, PSG College of

Technology, whose valuable guidance and inspiration throughout the course made it

possible to complete this project work successfully.

I also extend my sincere thanks to Mrs. Susan Wilson, Senior Project Manager

(Platinum Vertical), L&T IES and my external guide Mr. Jagdish Sahu, Project Manager

(DHM), L&T IES, for their valuable suggestions, guidance, encouragement and immense

help, at all stages of my project work.

I also extend my sincere thanks to L&T Integrated Engineering Services,

Larsen & Toubro Limited, Mysore for providing me a chance to work with world class

engineers.

With great pleasure and deep gratitude, I express my sincere thanks to all the

staff members of Electrical & Electronics Engineering Department whose assistance

played a big role in this project and have been of immeasurable value.

I gratefully acknowledge my indebtedness to my parents and friends who

contributed to this project work directly or indirectly.

Introduction:PSG Industrial Institute is the pioneer in the manufacture of Motors and Pumps in India appreciably contributing to the growth of agriculture and industry for more than eight decades. In addition to this, they are widely acclaimed at the domestic fronts for their domestic motors. PSG Industrial Institute has the facility to design, manufacture and supply Domestic Pumps, Agricultural Pumps, Pumps & Motors and Industrial Motors to the complete satisfaction of the customer. Thecompany has witnessed splendiferous growth since its inception in the year 1926. They are the pioneers in the field of motor manufacturing in India. They have always completely committed our self for the welfare of the society by providing them with the best products that they deserve. Their annual turnover is about Rs. 10 - 25 Crore. The employees working here are around 500 to 1000.

Industrial productsIndustrial products are the products that are manufactired by any industry . It may be a product or a service (as in service industry).The product may be for an end user or again another industry. based on the type of the product and the consumer, they can be classified as

The major classification would be as :consumer goods:These are the good produced for the consumption of the end users, which includes us. example: Mobiles, Automobiles.Product goods:These are that are consumed by the other industries .These are also called as capital goods. Example: Chemical industries

Industrial standardssafety

IMPORTANCE OF INDUSTRIAL SAFETY IN WORK PLACE

Industrial safety saves lives, limbs and money while increasing trust and

teamwork. Any ethical business will place a high emphasis on safety if it

values its employees and future existence.

The problem is that these workplace accidents happen again because of

lack of consideration, especially by employers. Because they lack the

consequences of not knowing the basic safety measures within the office,

many people meet accidents. It can be transmitted more than just a

headache for the company. In fact, some people are going to sue.

Well-trained employees are valuable. If they are lost or injured in

accidents, that is a personal and an industrial loss. Protecting employees

with safety plans is the protection of an investment as well as a human

thing to do.

The industrial safety is classified in to two parts,

1. Personal safety2. Equipment safety

PERSONAL SAFETY

PREVENTING EYE INJURIES IN THE WORKPLACE

More than 2,000 people injure their eyes at work every day, making eye

incidents one of the most common work-related injuries. 1 out of every

10 of these cases requires missed recovery days, and 10 to 20 percent of

all cases lead to temporary or permanent blindness.

The easiest way to instantly reduce the risk of eye injuries is to provide

adequate safety eyewear to all employees.

Proper eye protection addresses all of the common causes of eyeinjuries:

flying objects, particles, chemicals, and tools. Make a careful assessment

of the hazardous areas in your workplace, and then provide at-risk

employees with safety goggles,full-face respirators, glasses, or welding

helmets depending on the conditions.

WHAT TO DO IN CASE OF AN EYE INJURY

If you get dust, a wood chip or another small particle in your eye, look

down and flush it out with eyewash solution. Use water if eyewash

solution is not available.

If a pesticide gets into your eyes, immediately use a portable eye flush

dispenser or call for help if needed to get to an eyewash station.

Flush your eye with eyewash solution for 15 minutes. Have someone call

for medical attention while you are flushing.

The Material Safety Data sheet and label will give first aid instructions.

PREVENTING HEARING LOSS IN THE WORKPLACE

Hearing loss is another common condition that can be prevented by

taking simple safety precautions. Address hearing safety by providing

employees who work in loud environments with ear plugs or ear muffs

designed for their level of exposure.

Make sure to routinely check hearing equipment for wear and tear that

might reduce its effectiveness.Some tasks require time spent in an

environment louder than 85 decibels. If your employees work in these

conditions, provide frequent breaks in addition to mandatory hearing

protection.

Make sure that employees who work in loud industrial environments

have their hearing tested regularly. Experienced ear specialists and

audiologists can diagnose conditions in their early and most treatable

stages.

PREVENTING FALLS IN THE WORKPLACE

To prevent dangerous falls in the industrial workplace, examine work

areas carefully to uncover hazardous conditions before employees ever

step foot near them. Address obvious hazards with safety railings,

harnesses, ropes, nets, or scaffolding.

Routinely check these safety measures to make sure they are in good

functioning order. If any unsafe conditions develop, do not wait to fix

them! Prioritize safety and take care of them immediately, and do not

allow any employees near the work area until the hazard is removed.

You can also take preventative measures against falls by ensuring proper

lighting throughout the workspace. The easier it is to see, the less chance

of a misstep or accidental fall. Staircases should be well-lit and

completely free of any obstacles.

Make an effort to educate workers continuously about safety in the

workplace. Use appropriate signage in higher-risk areas, and make sure

employees are well-trained in the proper use of safety equipment.

Workers will appreciate your efforts to keep them out of harm’s way.

PREVENTING HEAD INJURIES IN THE WORKPLACE

Many head injuries occur when workers slip, trip, or fall – so it’s

important to follow the fall prevention guidelines outlined above. In

addition, head injuries can be prevented by distributing hard hats and

head safety equipment to protect workers in areas where objects are

being moved overhead. Outline expectations to employees to make sure

that objects are never moved when unprotected workers are present.

Hard hats should always be used in environments with exposed beams,

pipes, or low hanging obstacles. It’s easy for busy employees to get

distracted in the midst of work and bang their heads in these types of

conditions, so make hard hats mandatory.

TRAINING EMPLOYEES AND PROMOTING THE “SAFETY FIRST” MIND SET

Complimenting effective safety gear with high-quality training

significantly cuts the risk of industrial workplace accidents. Establish a

focus on safety and consistently promote a “safety first” message to all

employees as soon as they start working for your company. By

encouraging this mindset, you can train employees to maintain a high

level of awareness and caution that will help them naturally avoid

accidents.

It’s a good idea to schedule regular audits to stay on top of important

safety issues throughout the year. Information gathered from these

comprehensive safety checks can be used to create updated training and

educational material that will further reduce the risk of accidents.

It’s your responsibility to dictate a responsible and safety-oriented

mindset in all employees. Use regular internal communication to your

advantage and reinforce the message repeatedly. When safety is clearly

the company’s number one priority, it becomes the top priority of its

employees as well.

EQUIPMENT SAFETY

Accidents in the workplace happen for a variety of reasons, but poorly

maintained equipment is a major cause. Equipment-related accidents can

occur when the equipment doesn't operate as it should or when people

use equipment they are not properly trained to operate.

Equipment-safety procedures should be implemented in the workplace

to keep operators safe and to keep the equipment functioning properly.

TRAINING

Insufficient training is a main cause of accidents. Poorly trained

equipment operators unknowingly mishandle equipment, and they are

not prepared to react correctly if something goes wrong. Implement a

training program that consists of both classroom training and hands-on

training. Classroom training gives participants knowledge of critical

emergencies they won't necessarily encounter during training, such as

what to do if the equipment catches fire. Hands-on training teaches

participants the proper techniques for using workplace equipment.

PREVENTIVE MAINTENANCE

Implement a preventive-maintenance program to keep your equipment

running smoothly. Preventive-maintenance programs help to keep

equipment in top shape and allow maintenance crews to detect

preventable errors. As part of effective preventive-maintenance

programs, employees schedule routine maintenance of equipment.

They check the internal workings of the equipment, making sure that all

fluids are clean and at capacity and that vital parts of the equipment,

such as the brakes, are fully functioning. Crews should test equipment

while it is running to detect potential problems. Maintenance crews may

test bearings, gears, engines and electrical wires as part of the

preventive-maintenance program.

INDUSTRIAL DISCIPLINES

Discipline is the process of changing a behavior to make it conform to a

rule or standard. For many people, discipline has a negative connotation

to it, especially when it is their behavior that is being adjusted. In truth,

though, discipline is more than repeating the standard and doling out

punishment.

IMPORTANCE

Discipline in industry is an absolute necessity for efficiency.

If every employee does as he pleases the productivity process will not be

conducted effectively.

Such situation will not only be disadvantageous to the employer, but also

to the employees at large and to their union.

GENERAL SET OF WORK RULES

All workers must punch/swipe their individual punch cards before and

after work times. A person caught performing this activity for another

employee is liable to immediate dismissal.

All employees must start work punctually.

The following acts will be taken as misconduct,

Disobedience to any lawful and reasonable order of a superior.

Theft, fraud or dishonesty with respect to the employer’s business

or property. Habitual absence without leave. Habitual late

attendance.

Drunkenness, taking illegal drugs fighting riorous or disorderly or

indecent behavior.

Bullying or harassing in any way, or person with whom the

employee has business-related contacts.

Sleeping during working hours.

Negligence.

Smoking in prohibited areas of the company.

Failure to follow safety rules and regulations.

Taking industrial action or inciting others to take industrial action

against the provisions of the IRA or of any other law.

Introduction to 5S

In japanese In english

seiri Sort outseiton Set iin orderseiso Shineseiketsu Standardiseshitsuke Sustain

There are a lot of factores that must be included while implementing hthe 5S.These factores include preparing the layout, Identifying the prrocess flow,Maintaining the changes that occored etc.These factors will be elaboratd while discussing each seperately

SORT OUTThe process of sorting the required and the inventory items seperately.This happens after the completion of work order.The remains of the preios work ordeer are accounted and they are bagged to INVENTORY.Based on the new work order the required items will be taken from the inentory and it will be accounted and then it will b sent to the approprate workstations.

ADVANTAGEESReduces confusion for the employeses.Provides more workspaceProper accounting of goods can be made at the end of each order work order.

SET IN ORDER:The material sent to the inventory should be properly tagged.The tag encloses the details like(no.of items,work order no.)There should be a lost which encloses the details of all the tags that which is kept at which point of the store room.Similarly, the material that are sent to the workstations should be also catalouged and cross checked.A the workstation in the material should be arranged in a fashion so that the raw material in on the one side and the other finished products are on the other side.All the tools should be placed on the work station.Proper color cooding should be given to each itemm on the workstation so that the worker can work withour any confusion.This method also helps in reduction of time.Efficiency can also be improved.

SHINEThe working environments should be kept clean.This reduces wastage.This improves productivityThis helps in getting license for the poduct.This also invokes customer satisfaction.

STANDARDIZEProper standars should be createdA standard way should be created for each product ,each pprocess, each item inside the plant.

SUSTAIN Constant review should be made.Everything should be maintained.

PSG INDUSTRY DIVISIONSThe PSG industry has the following two divisions The heavy engineering division (HED)The rotating machinery division (RMD)

THE HEAVY ENGINEERING DIVISION:The HED is where all the machining is being done for the pars of the LATHE.

THE LAYOUT OF THE HED

1.Design Department

2.Electrical Assembly for Lathe

3.Metrology Lab

4.Incoming Inspection

5.Final Inspection

6.Lathe Main Assembly

7.Students Workplace

8.Stores

9.Heavy Shop

10.Cutting Machine

11.Lathe PRE/SUB Assembly

12.Shaft Cell

13.Small Parts Cell

14.CNC Machining Centre

15.Stores for Raw Material

16.Tool & Cutter Grinders

17.Tool Crib

18.Sheet Metal Cutting Machine

19.Lathe Final Testing Section

1.Honing Machine

2.Line Boring Machine

3.Horizontal Boring Machine

4.Horizontal Boring Machine

5.Horizontal Boring Machine

6.Horizontal Boring Machine

7.Slotting Machine

8.Cylindrical Grinding Machine

9.Shaping Machine

10.Shaping Machine

11.Drilling Machine

12.Hobbing Machine

13.Universal Milling Machine

14.Shaping Machine

15.Drilling Machine

16.Surface Grinding Machine

17.Drilling Machine ( Angular Swivel)

18.Radial Drilling Machine

19.Universal Milling Machine

20.Bombay Lathe

21.Guideway Grinding Machine

22.Manager Table

1.Apron Box Sub Assembly

2.Thread & Feed Box Sub Assembly

3.Finished Sub Assembly

4.Head Stock Sub Assembly

5.Gear Box Sub Assembly

6.Final Finishing of Assembly ( Blue Matching)

7.Sub-Assembly Test Rigs

8.Drilling Machine

9.Grinding Machine

The products of the HED are:PSG - 141 / A 141 (Light Duty Precision)PSG - 124 / A 124 (Heavy Duty Precision)PSG CNCT T 110 LATHEPSG VMCElectrospinning Machine

PSG-141 / A 141(ALL GEARED PRECISION CENTRE LATHE)  PSG 141 / A 141 is a light duty precision lathe which is renowned for its quality and performance. Ideally suited for production jobs and training purposes alike, its proven design guarantees several years of trouble-free service. The main spindle runs on precision taper roller bearings. The built-in safety features ensure reliable operation. The main drive gears are made from nickel-chromium steel, hardened and precision ground.

PSG-124 / A 124(ALL GEARED HEAVY DUTY PRECISION CENTRE LATHE) 

PSG 124 / A 124 type lathe is a heavy duty precision lathe renowned for its productivity in turning accurate components. Ideally suited for general engineering and other production shops, its proven design guarantees several years of trouble-free service. The main spindle runs on precision taper roller bearings. The built-in safety features ensure reliable operation. The main drive gears are made from nickel-chromium steel, hardened and precision ground. The bed guideways are also flame hardened and precision-ground. To improve productivity, attachments like hydraulic copying attachment or taper turning attachment can be fitted.

Electrospinnning MachinePSG Electrospinning machine is ideally suitable for industries and educational institutions. Nanofibres' diameter and other physical properties can be modified by adjusting the process parameters such as solution concentration, voltage, flow rate and the distance between needleand collector. Thus,this machine would help the researchers and students to learn the nanofiber processing techniques in detail. Customized set up canals° be supplied.