IMPROVING THE QUALITY CONTROL MEASURES

THROUGH DETAILED ANALYSIS OF QUALITY CONTROLLING TECHNIQUES IN SARK CABLES PVT.LT, KANJICODE, PALAKKAD
Minor Project Report Submitted to University of Calicut
By BIJI.K.R Reg. No. LCALMBA019 IIIrd Semester MBA (2011-13), LEAD College of Management,Palghat

Name of Guide Mr: ARUN.V, Assistant Professor, LEAD College Of Management, Palghat

November 2012

IMPROVING THE QUALITY CONTROL MEASURES

THROUGH DETAILED ANALYSIS OF QUALITY CONTROLLING TECHNIQUES IN SARK CABLES PVT.LT, KANJICODE, PALAKKAD
Minor Project Report Submitted to University of Calicut
By BIJI.K.R Reg. No. LCALMBA019 IIIrd Semester MBA (2011-13), LEAD College of Management,Palghat

Name of Guide Mr: ARUN.V, Assistant Professor, LEAD College Of Management, Palghat

November 2012

LEAD COLLEGE OF MANAGEMENT, DHONI , PALAKKAD

(Affliated toCalicut University)

CERTIFICATE

This is to certify that the record of Project Report IMPROVING THE QUALITY CONTROL MEASURES THROUGH DETAILED ANALYSIS OF QUALITY CONTROLLING TECHNIQUES IN SARK CABLES PVT.LTD, KANJICODE, PALAKKAD submitted by BIJI.K.R is a bonafide work carried out by her in partial fulfillment of the Master of Business Administration during the year 2011-2013

Place : Date :

Signature Name & Designation of the Supervising Teacher

Countersigned

Place : Date :

Signature Head of the Department Of MBA

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DECLARATION
I, BIJI.K.R do hereby that this project work entitled To Introduce Quality controlling Techniques In Sark Cables For improving the Quality Assurance is a bonafide work done by me during my period of study at Lead College Of Management Dhoni, Palakkad and is submitted in 51partial fulfillment of the requirement for the award of the post graduate degree of Master Of Business Administration.

Place: Date:

BIJI.K.R Signature

I certify that the declaration made above by the candidate is true

Signature of the Guide With Name & Designation

ACKNOWLEDGMENT

I take this opportunity first and foremost to thank god almighty, without whose blessings and guidance this work would not have been completed.

I have immense pleasure in acknowledging my heartfelt gratitude to Sri. K.V. Unninarayanan, principal of Lead College of Management, Dhoni Palakkad, for his sound advice whole hearted support.

I am deeply indebted of thank Sri. Arun Velayudhan, assistant professor of LEAD College of Management, who gave me valuable advice and guidance to make my project a success.

I am grateful to the management of Sark Cables Pvt. Ltd., Kanjikode, Palakkad and also express my gratitude to Mr.Sajeev Kumar (MD), Sark Cables for granting me permission to do the project work. I am deeply indebted to Mr.K.P.S Padmanabhan HO-HR, and Mr. Rajesh Production Head of Sark Cables Pvt.Ltd., Kanjikkode for their valuable support assistance in providing sufficient facilities for the successful completion of the study.

No words could express my thanks to all my friends and all others who helped me in presenting this report.

BIJI.K.R

CONTENTS

CHAPTER NO.

TITLE

PAGE NO.

1. 2. 3. 4. 5.

Introduction Review of Literature Data analysis & interpretation Findings & Suggestions Conclusion Bibliography

7-19 20-23 24-46 47-51 52 53

CHAPTER 1

INTRODUCTION

GENERAL INTRODUCTION ORGANISATION PROFILE RESEARCH PROBLEM STATEMENT OBJECTIVE OF THE STUDY RESEARCH METHODOLOGY

GENERAL INTRODUCTION
The project titled Improving the quality control measures through Detailed analysis of quality controlling techniques in SARK Cables pvt.ltd is being conducted with the aim of measuring the quality of cables and thus calculating the Quality Assurance of the company in the years to come Quality is being one of the important factors of the products and it is affects the day to day operations of the firm to a great extent. SARK Cables Pvt. Ltd currently using techniques is not giving enough required quality for products

QUALITY CONTROL
A process through which a business seeks to ensure that product quality is maintained or improved and manufacturing errors are reduced or eliminated. Quality control requires the business to create an environment in which both management and employees strive for perfection. This is done by training personnel, creating benchmarks for product quality, and testing products to check for statistically significant variations. Quality control, or QC for short, is a process by which entities review the quality of all factors involved in production. This approach places an emphasis on three aspects. 1. Elements such as controls, job management, defined and well managed processes, performance and integrity criteria, and identification of records 2. Competence, such as knowledge, skills, experience, and qualifications 3. Soft elements, such as personnel integrity, confidence, organizational culture, motivation, team spirit, and quality relationships. Controls include product inspection, where every product is examined visually, and often using a stereo microscope for fine detail before the product is sold into the external market. Inspectors will be provided with lists and descriptions of unacceptable product defects such as cracks or surface blemishes for example .The quality of the outputs is at risk if any of these three aspects is deficient in any way. Quality control emphasizes testing of products to uncover defects and reporting to management who make the decision to allow or deny product release, whereas quality assurance attempts to improve and stabilize production (and associated processes) to avoid, or at least minimize, issues which led to the defect(s) in the first place. For contract work, particularly work awarded by government agencies, quality control issues are among the top reasons for not renewing a contract.

ORGANISATION PROFILE
SARK CABLES PVT.LTD. the only one company of its kind in Kerala promoted over a decade ago in manufacturing various cables as per Indian/International specifications. They commenced its production in 1996, December at new industrial development area (NIDA), Kanjikode , Palakkad District, Kerala as a small scale industrial unit with permanent SSI registration number 090711939, they are also registered with NSIC vide registration number, NSIC/KER/UP/RS/8-53/99. As well as SISI vide KSX registration number KSX/1357/G9 date 5/4/1999.c The company is catering to the needs of public sector undertaking OEMS in INDIA and also executed import substitute requirement as well as very stringent applications like cable for the rocket launching purposes under water communications etc. The company is managed by a board of directors consisting of 6 persons out of whom Mr. K Sajeev Kumar is the Managing Director and Mr. Sunil Joseph, Director (Technical Services) take care of the day today management of the company. the company has a prestigious ISI certificate it has got ISO 9001-2000 certification on 2004. The company has started second unit in Coimbatore which went into production from 1 October 2008. The company has another associate unit in Thodupuzha , namely COCHIN POWER CABLES PVT.LTD, which also produces power cables.
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SARK CABLES is mainly producing the wires and cables for industrial purpose like heavy duty power cables, control cables, telephone cables, switch board cables, coaxial cables as per the requirement of the customers. The company has won many laurels, best entrepreneur by the department of industries and commerce (1998 and 1999) and best entrepreneur by the Management Association and Business Deepika. The mission statement of the company is to provide beneficial and innovative product in time to the customers at competitive prices that represent the high value for the money in the industry. The company is holding BSI license for manufacturing heavy duty underground cables as per IS 1554/1 under license number CM/L6180765 and also light duty cables as per IS 694/1990 license number CM/L6148062. The company was awarded the prestigious ISO 9001-2000 certificate by Phoenix Certification Private Limited who are associated by RVA. SARK CABLES also holding approvals from PWD for using their cables for government works, vide their approval letter number EL2050898 and M/s Kerala State Electricity board vide letter number CE.SSTLC/REC/SKDA approval 2001-02/389 dated 09.05.2001 they are approved vendor with M/s. Cochin Refineries Limited (code number

524135) M/s. Hindustan news print Limited (code number 51023), M/s. BHEL (code number 29766P), M/s. Kerala Minerals and Limited (code number 50025) etc. It wont be out of place to mention here that SARK CABLES have been satisfactorily working at various sites inside and outside Kerala and they have received performance certificate from M/s. Keltron, M/s. Malabar Cements Limited, M/s. Kerala State Electricity Board etc. MISSION OF THE COMPANY The mission statement of the company is provide beneficial and innovative product in time to the customers at competitive prices that represent the high value for money in the industry. VISION OF THE COMPANY The vision of the company is to make it a leading player in the field and to compete with leading, in another two years time. It also aims to give more importance in keeping up the quality of their products. As it is, the company is in the SSI sector. Company is undergoing an expansion program and a second unit of the company has already started functioning, augmenting the manufacturing and supply efficiently.

LOCATION OF THE COMPANY The company is situated in New Industrial Development Area at Kanjikode in Palakkad District. It is located near Kerala Tamilnadu boarder. CAPACITY OF THE PLANT The plant has a capacity to manufacture 8600 core kilometers of various cables per month. OBJECTIVE OF THE COMPANY The company was incorporated with the intention of manufacturing and marketing different kind of cables and wires. The main objective of the company is to supply different types of cables and wires according to the requirement of the customers.

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REGISTERED WITH SSI Reg. No. 0907-11939 NBSIC Reg. No. NSIC/KER/GP/RS/S-53/99

BIS, ITI,KSEB,RELIANCE,YOKOGOVA BLUE STAR, APOLLO TYRES, AMRITHANANTHAMVI GROUP, COCHIN PORT TRUST, KOCHIN SHIPYARD, MALABAR CEMENTS, BHEL, EICL, L & T, COCHIN REFINERIES, TELK, CMRL, BPL, KAMCO, KMML, IREL.

WORK FORCE OF THE SARK CABLES SARK CABLES has around 60 employees. They have 3 shifts in a day. The shifts start from morning 8.30 am. First shift is the general shift. In this shift on an average 45 employees are working it is from 8.30 am to 4.30 pm. Second shift is from 4.30 pm to 12.30 am. In this shift around 10 employees are working. The final shift is the night shift and is from 12.30 am to 8.30 am in this shift 5 employees are working. The company is stocking the final product in the factorial godown. The finished goods are moved out of the company within 15 days. The raw materials are also kept the company. The company has well experienced technicians for the different manufacturing process. There is a manager for production and he controls all the production process.

DEPARTMENTS OF SARK CABLE Purchase department Marketing department Human resource department Account department Production department

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FUNCTIONAL DETAILS OF STORES AND PURCHASE

RECEIVING RAW MATERIALS

PHYSICAL CHECK TESTING

MD

RAW MATERIAL SHORTAGE ACCEPT RELEASE TO PRODUCTION REJECT

FINISHED PRODUCT DESPATCH

DISTINGUISHED COSTOMERS Bharath heavy electrical limited Cochin refineries ltd Cochin shipyard ltd Cochin port ltd Hindustan news print ltd Binani zinc ltd Reliance infocom ltd Transformers electrical Kerala ltd Keltron Trivandrum KSEB Kerala minerals and material ltd Apollo tires ltd Indian telephone industries ltd Vikram sarabhai space centre ltd Share centre, sreeharikotta ltd Andrew Yula & company ltd, Chennai
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Yokagow blue star ltd Tata tea ltd

COMPETITORS Phenolex cables V-guard cables Poly cables Havells India ltd Anchor cables Gloster

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FUNCTIONAL DETAILS OF PRODUCTION DEPARTMENT

COPPER/ALUMINIUM ROD

DRAWING

ANNEALING BUNCHING/STRANDING

EXTRUSION-INSULATION

LAYING UP/TAPPED BEDDING

SHIELDING/BRAIDING

EXTRUSION-INNER SHEATH

ARMOURING (STRIP OR WIRE)

OUTER SHEATH

TESTING

PACKAGING

STORES/DISPATCH
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PRODUCT PROFILE

Sark Cables Pvt Ltd was incorporated for manufacturing and marketing cables and wires. The main products of Sark Cables are; Power and control cables up to 1100 volts Single core flexible cables Multi core flexible cables Submersible or water proof cables Weather proof service wire Single core flexible flame retardant (fr) PVC wires cables. Telephone and switch board cables Recommended cables size for motors with star-delta and dol started

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RESEARCH PROBLEM STATEMENT

A study of Quality Assurance at Sark Cables Pvt.Ltd.is undertaken in order to know the quality controlling techniques of the company and to know the quality level of the products.Demand for a product is always depends on the quality. It is therefore absolutely very important to manage the quality efficiently and effectively in order to overcome unnecessary costs.

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OBJECTIVE OF THE STUDY

To suggest methods for continually improving the quality management system through better quality control measures. To suggest new methods for measuring changes in effectiveness of quality control system To study the tools and techniques for quality assurance ,adopted by SARK CABLES PVT Ltd

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RESEARCH METHODOLOGY

The basic concept of research methodology refers to the way in which companies conduct their research and how they collect the data they need. Whenever a company or organization needs to investigate a particular area of their business dealings, they need to adapt the most suitable research methodology for the job

RESEARCH DESIGN A detailed outline of how an investigation will take place. A research design will typically include how data is to be collected, what instruments will be employed, how the instruments will be used and the intended means for analyzing data collected.

METHODOLOGY OF DATA COLLECTION

a) Primary data The primary data is collected by personal interviews with officials.

b) Secondary data

Files, annual reports, periodicals, manuals and text book. Which have already been passed through the statistical process are the secondary data used.

c) Field work

This was under taken individually to collect various information regarding the study by visiting following sections.

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Stores department

Information regarding stocking of materials receipts and issues to workshops. Inventory control procedures in various wards inside the department were obtained.

Accounts department

Remaining all the information was obtained from accounts department through personal interviews with section officials.

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CHAPTER 2

REVIEW OF LITERATURE

THEORITICAL REVIEW

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1.Quality Assurance Project Plan Livermore Site and Site 300 Environmental Restoration Projects-this project is done by V. Dibley
He describes that : The projects Quality Assurance records include analytical and Quality Checking results from the analysis of environmental media, ground water sampling data forms, geologist field logs, CoC forms, water level data sheets, completed controlled field logbooks, and hydraulic test data. Other QA records managed by the ERD QAIC are corrective action reports, controlled document distribution lists, and self assessment reports and completed checklists. The Projects must collect data to support the decisions necessary to meet their end goal of site cleanup. To do this, the data must be of a known and sufficient quality level as required for their intended purpose. The types of data collected by the Projects and the intended uses and also indicates the data category, either screening or definitive, that is required for each use. These two data categories are associated with specific quality assurance

2.Quality Control Implementation in Manufacturing Companies:Motivating Factors and Challenges- done by

Hairulliza Mohamad Judi

He says that most of tools and techniques to control quality are statistical techniques. Quality control techniques can be classified into basic, intermediate, and advance level, but there is no consensus among researchers in the classification. For example, Xie and Goh (1999) consider DoE as an intermediate level technique whereas Antony (1998) classified the technique as advanced. Nevertheless, the content is more important than the classification. Among the basic techniques are SPC. SPC is a statistical approach for assisting operators, supervisors and managers to manage quality and to eliminate special causes of variability in a process (Oakland, 2003). The initial role of SPC is to prevent rather than identify product or process deterioration, but Xie and Goh (1999) suggest for its new role to actively identifying opportunities for process improvement. The main tools in SPC are control charts. The basic idea of control charts is to test the hypothesis that there are only common causes of variability versus the alternative that there are special causes By continuously monitoring the process, the manufacturing organisation could prevent defect items to be processed in the next stage and to take immediate corrective action once a process is found to be out of control (Hairulliza et al., 2005).

The study finds that the motivating factors for the companies to apply quality control come internally from the management and parent company or externally from customer. SPC and acceptance sampling are used widely by the companies. Six sigma, DOE, Taguchi methods, and capability studies are left behind from being used in industries, due to lack of knowledge in the technique. The selection of quality control technique in the
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companies is influenced by three factors: ease of use of the technique; ability to measure product specification fulfillment; and ability to improve critical quality and productivity problem.

3. LOUISIANA DEPARTMENT OF TRANSPORTATION AND DEVELOPMENT - CONSTRUCTION PLANS QUALITY CONTROL / QUALITY ASSURANCE MANUAL- done by R. Bainer
QA does not include only periodic reviews to ensure compliance with the QC process but also includes review of several other established processes. The Project Manager shall ensure that appropriate levels of review (and cooperativeness in the review process) have occurred for: Constructabilty Bidability Value Engineering Project Documentation QA also incorporates a general review of personnel to ensure an acceptable level of expertise is maintained for quality design products. All design personnel shall be advised of the details of the QC plan. Communication is also a vital element in all processes. QA includes the review of the level and quality of communications and documentation accomplished during the various processes. The Project Engineer for each construction project is required to prepare a postconstruction checklist to provide feedback as to the quality and accuracy of the construction plans. This feedback is to be provided to the Project Manager to serve as lessons learned to the designer and to be considered in the final rating for consultant designed plans. These checklists will be compiled and categorized and distributed to all of the various design sections to serve as a knowledge base to improve the quality of construction plans. The Construction Section should schedule a semiannual Construction Feedback Meeting with the Design Sections. At this meeting, the Construction Section should provide technical presentations to the designers for updates on construction and production issues as it relates to plan preparation and constructability improvements

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4.Quality Assurance Project PlanLivermore Site and Site 300Environmental Restoration Projects - done by V. Dibley
Dibley describes that The analytical laboratories that analyze samples for the ERPs are required to perform and document certain internal QC checks. These checks will vary according to the specific analytical method and level of desired data quality. For a high-quality result, the QC usually consists of theanalysis of one method blank, MS and MSD or sample duplicate, and an LCS per batch oftwenty samples. In addition, initial instrument calibration data, continuing calibration data,extraction blank data, surrogate recoveries, retention time windows, method detection limitdeterminations, laboratory QC control charts, and GC/MS tune data may also be reported. At aminimum, these items are kept at the laboratory and reviewed upon request or during an audit ofthe analytical laboratory facilities. Analytical QC checks required by ERD are explained in ERDSOP 4.6, Validation and Verification of Nonradiological Data Generated by Analytical Laboratories and SOP 4.11, Validation and Verification of Radiological Data Generated byAnalytical Laboratories. shows the methods used to analyze the COCs, the QC elements, frequency of analysis, andacceptance criteria. The analytical laboratories set internal QC limits based on EPAmethodology whenever it exists. There fore, the QC Chemists base their data review and qualification of data on the internal control limits provided by the laboratories. quality control chemists determine whether data that is generated by the analytical laboratories are contractually acceptable based on compliance with the service agreements between LLNL and the laboratories. The quality control Chemists also determine the quality of the data based on the performance of associated quality control data provided with the results. Data may be considered usable if it is outside QC control limits but within historical variance. Usability of data outside of QC criteria is determined by the end user on a case-by case basis. The entire data set for the year is reviewed to determine if the data as a whole is of adequate quality for its intended purpose. At the time of data review, the laboratory generated QC data is compared to laboratory specific control limits. These control limits are generated by the laboratories and provided to LLNL.

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CHAPTER 3

DATA ANALYSIS AND INTERPRETATION

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QUALITY CONTROL
Quality control is a process that is used to ensure a certain level of quality in a product or service. It might include whatever actions a business deems necessary to provide for the control and verification of certain characteristics of a product or service. Most often, it involves thoroughly examining and testing the quality of products or the results of services. The basic goal of this process is to ensure that the products or services that are provided meet specific requirements and characteristics, such as being dependable, satisfactory, safe and fiscally sound. Companies that engage in quality control typically have a team of workers who focus on testing a certain number of products or observing services being done. The products or services that are examined usually are chosen at random. The goal of the quality control team is to identify products or services that do not meet a company's specified standards of quality. If a problem is identified, the job of a quality control team or professional might involve stopping production or service until the problem has been corrected. Depending on the particular service or product as well as the type of problem identified, production or services might not cease entirely. XLPE Natural polyethylene (PE) is a compound of Carbon and Hydrogen with lenear molecular structure. This molecular has a form of long flexible chain and independent of each other which can slide easily with respect to one another. This characteristic makes the material thermoplastic having a melting point around 110 0 c. The above property makes the material thermally instable at temperature above 115 o c which normally observed during the short circuit of power cables. If this chain can be cross linked to one anoter by some process, the slipage between the molecular chain can be prevented. The material then can be termed as thermo-setting type. This has been achieved by means of a process by which the molecules were cross linked. As a result of cross linking, it gets greately improved thermal and mechanical properties of PE while its electrical properties largely remain unchanged . The cross-linked polyethylene attains during further rise in temperature.

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Advantages of XLPE cables as compared to thermoplastic cable like PVC are listed below
Higher current capacity : it is possible to use one lower size of cable as compared to PVC Higher short circuit rating : XLPE can withstand short circuit temperature up to 250 0 c where as PVC cables can only withstand up to 160 0 c. Longer service life , because die-electric losses are very small Higher emergency overload withstand capacity: for a short time it can withstand maximum 130 0 c and is favourable to endure short circuit stress Quick method of jointing and termination with simple, non-exposive accessories XLPE cables are not prone to fatigue damage due to vibrations or loading cycle Easy handling during installation because these cables are lighter in weight Resistant to chemicals and corrosive gases etc. hence suitable for installation in polluting atmosphere XLPE cables retain their flexibility down up to -400 c PVC cables have district disadvantages regarding environmental protection, if they burn they gives off corrosive gases. Although XLPE also burns but the combustion products, carbon dioxide and water do not cause damage. Moreover it does not melt like polyethylene. CONDUCTOR The conductor of power cables is generally made from EC grade aluminum and annealed high conductivity copper is used for control cables. All conductors confirm to IS: 8130. Power cables with copper conductor can also be supplied as per customers requirement. The conductor is solid/stranded shaped/bunched as per the requirements INSULATION The conductor is insulated with the XLPE compound by extrusion

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INNER SHEATH The laid up cores are provided with the PVC inner sheath either by extrusion or by wrapping of plastic or proofed tapes. Single core cables do not have inner sheath. Where ever required, filler cords are provided to maintain the circularity to laid up cores ARMOURING Armouring is applied over insulation in case of single core cables and over inner sheath in case of multi core cables. Where the calculated diameter below armouring does not exceed 113 mm, the armouring consists galvanized round steel wire and incase the diameter under armour is more than 13 mm, the armouring consists of galvanized flat steel strip. Single core cables will have non-magnetic armouring. Armouring shall be done as per specification IS :3975 OUTER SHEATH Outer sheath is applied by the required PVC compound by extrusion over insulation in case of unarmoured multicore cables & over armouring in case armoured cables. PVC compound used for SARKPEX cables are of various grades to meet specification IS: 5831. The same SARKPEX is embossed on the outer sheath of the cable at regular intervals. The word ELECTRIC is also embossed to distinguish these cables from telephone cables. The FRLS/FRLS-LH cables bear an additional legend FRLS or FRLS-LH as the case may be. Any other information required by the customer is also embossed. Cables are sequentially marked for length at every meter throughout its length. FR/FRLS/FRLS-LH CABLES SARKPEX has also successfully developed, manufactured, tested and supplied kilometers of new generation FR/FRLS (Fire Retardant/Fire Retardant Low Smoke) cables. These cables with special PVC formulation for sheathing material, prevents the propagation of flame along the length of the cable when exposed to fire. In addition, FRLS (Fire Retardant Low Smoke) cables emit low smoke and halogen emission is also reduced under fire conditions. These properties help immensely in fire fighting operations and prevention of further loss to closely equipments. FRLS-LH cables emit very low smoke and halogen as compared to FRLS cables FINAL TESTING The tests on cables have been broadly classified in to four categories

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ROUTINE TESTS Tests carried out on each cables to check the requirements which are likely to vary during production
TYPE TESTS

Tests carried out to prove conformity with the specification. These are intended to prove the general qualities and design of a given type of cable ACCEPTANCE TEST Tests carried out on samples taken from a lot for the purpose of acceptance of the lot OPTIONAL TESTS
Special tests to be carried out when required by agreement between the purchaser and the manufacture

CURRENT CARRYING CAPACITY AND RATING FACTORS The current carrying capacity or loading of cables is limited by the thermal, electrical and other associated losses provided by the conductor, insulation, protective covering and surrounding. Thus, the current carrying capacity of cables not only depends upon size, type, voltage grade, material design and manufactures but also on a number of varied conditions of installation and use. It is desirable to determine the correct current carrying capacity on actual service conditions for each and every case. Any over loading leads to uneconomic utilization of their capacity. The current rating given in tables are based on normal conditions of installations described below for normal size of XLPE cables Maximum conductor temperature for continuous operation (0 C) Ambient Air Temperature (0 C) Ground Temperature(0 C) Thermal resistivity of soil(0 C CM/Watt) Thermal resistivity of insulation (0 C CM/Watt) Depth of laying PVC 70 40 30 150 650 75 cm XLPE 90 40 30 150 350 75 cm

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CABLE CODE CONSTITUENT Aluminium Conductor XLPE Insulation Steel Round Wire Armour Steel Strip Armour Steel Double Round Wire Armour Steel Double Strip Armour PVC Outer Sheath CODE A 2X W F WW FF Y

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QUALITY CONTROLLING TECHNIQUES

Some of the major Testing process conducted as per IS / International Standards are: Annealing test for copper conductor Conductor resistance and High voltage test Tensile and Wrapping test for Aluminium conductor Insulation resistance test Tensile and Elongtion ,Thermal Ageing Heat shock and deformation test Cold bend and impact test Hot set test & water absorption test for XLPE Torsion test for armouring materials

ANNEALING TEST FOR COPPER CONDUCTOR

Annealing, in metallurgy and material science, is a heat treatment wherein a material is altered, causing changes in its properties such as hardness andductility. It is a process that produces conditions by heating to above the critical temperature, maintaining a suitable temperature, and then cooling. Annealing is used to induce ductility, soften material, relieve internal stresses, refine the structure by making it homogeneous and improve cold working properties. In the cases of copper, steel, silver, and brass, this process is performed by substantially heating the material (generally until glowing) for a while and allowing it to cool. Unlike which must be cooled slowly to annealcopper, silver and brass can be cooled slowly in air or quickly by quenching in water. In this fashion the metal is softened and prepared for further work such as shaping, stamping, or forming.

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CONDUCTOR RESISTANCE AND HIGH VOLTAGE TEST Insulation resistance tests shall be made when wires or cables are installed and at least once every ten years thereafter. Insulation resistance tests shall be made between all conductors and ground, between conductors in each multiple conductor cable, and between conductors in trunking. Insulation resistance tests shall be performed when wires, cables, and insulation are dry. High voltage testing on cable & wire insulation is an important process for all cable manufacturers. Ahigh voltage cable test includes AC withstand, partial discharge, DC hipot and much more. The main purpose of these high voltage cable tests is to verify the cables insulation integrity before it is installed in the field. Todays cables must be able to carry higher voltages, weigh less and be more durable than in the past and this is why high voltage test equipment is such a crucial aspect of the cable & wire industry.

TENSILE AND WRAPPING TEST FOR ALUMINIUM CONDUCTOR

Tensile testing, also known as tension testing, is a fundamental materials science test in which a sample is subjected to uniaxial tension until failure. The results from the test are commonly used to select a material for an application, for quality control, and to predict how a material will react under other types of forces. Properties that are directly measured via a tensile test are ultimate tensile strength, maximum elongation and reduction in area. One specimen cut from each of the samples of aluminium wires shall be wrapped round a wire of its own diameter to form a close helix of 8 turns. Six turns shall then be unwrapped and closely wrapped in the samedirection as before. The wire shall not break or show any crack. INSULATION RESISTANCE TEST

A leakage current test performed at rated voltage with values not exceeding 5mA . Alternatively, measure insulation resistance values are not less than 1M , to avoid the equipment apparently failing the test because the metal oxide varistors (MOVs), or electromagnetic interference (EMI) suppression has triggered, for equipment containing voltage limiting devices such as MOVs, or EMI suppression, at 250 V d.c. Leakage Current testing is performed using a PAT by applying a nominal voltage to the live conductors (active and .neutral) of an appliance,;Nominal voltage is 230V AC. (therefore it cannot be performed with a digital multimeter)Insulation Resistance testing is performed using an ohmmeter or portable appliance tester by applying a nominal voltage to the live conductors (active and neutral) of an appliance
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;Nominal voltage is 500V d.c (250 V d.c. may be used for equipment containing MOVs / EMI filtering)A deficiency of the Insulation Resistance (500V/250V d.c) test is that the d.c voltage will not activate electromagnetic switches or internal relays etc. that are common in many modern power tools, computers, TVs etc. and therefore it can only test the appliance up to that point. Appliances with these components / design should be tested used the leakage current test.

TENSILE AND ELONGTION, THERMAL AGING

The increase in a samples gauge length measured after a rupture or break divided by the samples original gauge length is reffered to as elongation. The greater the elongation, the higher the ductility or elasticity of the material

Elongation cannot be used to predict the behavior of materials subjected to sudden or repeated loading. Some non-rigid materials like rubber and some plastics have very high elongations prior to break. Cross-head travel can be used to measure elongation of specimens with uniform width dimensions. If the specimen is in a dog-bone or dumb-bell shape with a reduced cross-sectional region called gage length, an extensometer will be required to measure elongation within the gage length region by attaching it directly to the specimen and tracking movement as the material is stretched to failure Thermal aging testing is designed to monitor degradation of the insulation system. It involves aging the proposed Electrical Insulation System at three or more elevated temperatures with intermittent dielectric proof testing. After each heat cycle, samples are also subjected to a repeated series of environmental exposures, such as cold shock, mechanical stress and humidity. Test results for the proposed EIS are then compared to a field-proven control EIS, running concurrently. At the conclusion of the aging program, the performance of the proposed EIS is compared to the control EIS. Ultimately, the rating issued to the proposed EIS is relative to the control EIS' previously established rating.

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HEAT SHOCK & DEFORMATION TEST

Heat deformation and heat shock tests are performed on insulating or jacketing materials to ensure they can perform well even at higher temperatures than normally experienced. Cold impact or bend tests are performed on finished cables to ensure they can perform well even at lower temperatures than normally experienced. COLD BEND & IMPACT TEST The apparatus will be able to bend the sample backward and forward in a direction perpendicular to the plane of the conductors, the two extreme positions making an angle of 90 on both sides of the vertical.Rate of flexing will be 60 per minute. A flexing is a movement through 180.A weight having mass of 0.5 kg will be provided with suitable grips for hanging to the sample.The apparatus will have a provision for fixing the sample of tinsel cord (Flat) in the apparatus.A 6 Digit reset able type counter with battery backup (rechargeable) for retaining the information in case of power failure up to 72 hours will be provided for counting each flexing cycle.The standard motors used in the apparatus.The apparatus will be able to operate on single phase 230 V, 50 Hz. AC supply.

Impact resistance is one of the most important properties for a part designer to consider, and without question, the most difficult to quantify. The impact resistance of a part is, in many applications, a critical measure of service life. More importantly these days, it involves the perplexing problem of product safety and liability. Impact testing is testing an object's ability to resist high-rate loading. An impact test is a test for determining the energy absorbed in fracturing a test piece at high velocity. Most of us think of it as one object striking another object at a relatively high speed.

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HOT SET TEST & WATER ABSORTION TEST FOR XLPE

Water absorption gives an idea of strength of aggregate having more water absorption are more porous in nature and are generally considered unsuitable unless they are found to be acceptable based on strength, impact and hardness tests. Object To determine the specific gavity and water absorption of aggregates by perforated basket. TORSION AND ZINC COATING TEST FOR ARMOURING MATERIALS Torsion tests are made on materials to determine such properties as the modulus of elasticity in shear, the torsion yield strength and the modulus of rupture. Often used for testing brittle materials and can be tested in full-sized parts, i.e., shafts, axles and twist drills which are subjected to torsional loading in service.

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FUNCTIONAL DETAILS OF QUALITY ASSUARANCE DEPARTMENT

PURPOSE The purpose of this procedure is to establish the quality system of quality assurance department SCOPE This procedure specifies the method of testing activities at rawmaterial, in-process and final stages of manufacturing FLOWCHART:

1. RAWMATERIALS RAWMATERIAL

INSPECTION AND TESTING

MD

RAWMATERIAL STORES
ACCEPT REJECT

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2. IN-PROCESS

RAWMATERIAL

INSPECTION AND TESTING

MD

RAWMATERIAL STORES
REWORK T SCRAP ACCEPT

3. FINISHED PRODUCTS

FINISHED PRODUCTS

INSPECTION AND TESTING MD FINISHED GOODS STORES REW ORK T

SCRAP

ACC EPT

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PROCEDURE 1. RAW MATERIALS In case of PVC granules for insulation and sheath, received vide good received note or delivery note are accepted or rejected after receiving the suppliers test report All other raw material received vide goods received note or delivery note are inspected & tested by QAD as per the quality plan and the observations are recorded in the raw material test register After the inspection, the approval/ rejection is indicated in the GRN/DN and sent back to stores for further action The materials which , meet the specified requirements, are released to production for further process The materials which do not meet the specified requirements are put under HOLD tag signed by QA Inspector is attached with the material for trace ability and identification purpose Non conforming materials are segregated and kept in the NCR allocated area.

2. IN PROCESS In process inspection is carried out by the QA Inspector / Production Supervisor as per quality plan and the observations are recorded in the route work order The materials meeting the specified requirements are released to next process. Such as materials are identified by QA APPROVED seal with QA Inspectors / Production Supervisor Signature on the route work order / tags The materials which do not meet the specified requirements are put under HOLD tag, signed by QA Inspector is attached on such material for trace ability and identification purpose 3. FINAL TESTING Final testing is carried out by the QA department or as per quality plan and the observations are recorded in the routine test register , type test register and optional test register The materials which, meet the specified requirements, are released for packaging. Such materials are identified by QA APPROVED seal with QA Inspectors signature on the route work order /tags Drum number and Batch number is allotted for approved materials by the QA Department.

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The materials which do not meet the specified requirements are put under HOLD And recorded in non conformance register. HOLD tag, signed by QA Inspector is attached with the material for trace ability and identification purpose

QUALITY SYSTEM PROCEDURE

PROCEDURE FOR CONTROL OF DOCUMENTS PURPOSE: To control all the system document ensuring proper implementation of all the processes as planned and to ensure uniform practices throughout the organization. To control the system documents on the computer, to transfer the entire documents to a CD to be kept in the safe custody of the MD. SCOPE This procedure is applicable to all document used within the organization RESPONSIBILITY The responsibility for implementation of this procedure lies with the Management Representative along with the identified officers PROCEDURE All the system documents shall be controlled by identifying the appropriate authority for preparation, approval and issue of documents. The controls shall also be extending to documents of external origin. The documents shall be originated by the authorized personnel depending up on type of the document control matrix. All the system documents shall be approved before issue as per the distribution list. Anyone can propose changes or modification in the documents. The proposed change shall be made effective only after the approval by the same authority for approval of the original document obsolete documents retained for any purpose will be identified a obsolete A master list of documents indicating current revision status will be maintained by the MR
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Only controlled copies, which are identified as controlled are subjected to document control procedures. Unauthorized marking or changes are not permitted In case of amendments the concerned section of the manual will be revised and for amendments of the procedures and work instruction new revision status will be given for the whole documents

Document control matrix

Type of document Quality manual System procedures Organizational procedure Documents of external origin Forms and labels Specification Work instructions Prepared by MR MR MR MR Section file HODQA HODPD Approved by MD MD MD MR MR MR MR Issued by MR MR MR MR MR HODQA MR

Documents of external origin will be updated by MR through correspondence with the authorities issuing them.

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NUMBERING OF DOCUMENTS A. Quality Manual Each page of the quality manual has the following 1. Section No. 2.Revision No. and Date 3.Approved by 4. Page No. B. Procedures Procedures are numbered as given below: QSP,OP 1.Here QSP indicates Quality System Procedure and OP stands for Organizational Procedures

REFERENCE Master List of Documents

PROCEDURE FOR CONTROL OF RECORDS PURPOSE To control the records as identified in the Annexure. To control the records on the computer as identified in the Annexure, to transfer the entire records to a CD to kept in the safe custody of the MD. SCOPE Covers all the records generated under the quality management system

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RESPONSIBILITY The responsibility of maintaining the records shall be with the concerned process In- large PROCEDURE All the records will be maintained for a period of two years unless otherwise stated After completion of the retention period the records shall be shifted to the records room. The records are: Identified by code marks Indexed for easy identification Filed and stored properly for easy retrieving Maintained properly and cleanly for legibility Protected from damage or deterioration by keeping it in safe custody RELATED DOCUMENTS 1. Master list of document 2. List of records PROCEDURE FOR CONTROL OF NON CONFIRMING PRODUCTS OR SERVICES PURPOSE To control non-conforming products or services and prevent its unintended use SCOPE Covers the method of controlling non-conformity at all stages of production and service, which include: a. Identification b. Documentation c .Evaluation d. Segregation RESPONSIBILITY The HOD QA is responsible for the above activity

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METHOD The non-conforming products are identified and kept separately and non-conforming services are recorded According to the accuracy required for the operation it may be rejected, reworked or salvaged. Non-conforming products that are reworked or reprocessed are retested as per Quality Plans before accepting. In case of non-conforming service, action will be taken and to rectify the situation after discussion with the customer. In cases of non-conforming services offered , the customer would be taken in to confidence and concurrence obtained regarding the mode of disposal The non-conforming in-coming ,in-process and finished products are stored in designated areas till decision regarding their disposition is taken All non-conforming materials are stored separately to prevent unauthorized use HOD QA provides the details of non-conforming materials to the production supervisor Raw materials found to be non-conforming are returned to the suppliers Finished products found to be non-conforming are scrapped Reprocessing is undertaken during the in-process stage for non-conformities observed Similarly rework may be carried out for non-conforming finished products The above activities are recorded

RELATED DOCUMENTS Non-conformity register PROCEDURE FOR CORRECTIVE AND PREVENTIVE ACTION PURPOSE This procedure is to establish corrective and preventive action systematically so as to avoid repetition of non-conformities and also to prevent potential non-conformity SCOPE Covers the entire organization and deficiencies of products, services and system are to be removed and prevented in order to enhance effectiveness RESPONSIBILITY The section in charge will be responsible for products and service related action and the MR would be responsible for the system related aspects

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METHOD All the complaints received will be recorded in the complaint register. Detailed investigation will be done by the HOD PD and if possible in the presence of Department Heads and appropriate corrective action taken. The information from the complaint investigation is being used to take any possible preventive action. Effectiveness of corrective and preventive action shall also be verified Findings and suggestions are placed before the Management Review Committee All the non conformities observed on services or in project executions are recorded. The MR along with the concerned section head will decide on the necessary corrective and preventive action Corrective action taken will be to a degree appropriate to the magnitude of the problem and commensurate to the risk encountered. Any action taken shall include : Appropriate source of information Determination of steps needed to deal with the problem Initiation of action after ensuring its effectiveness Submission of details for Management Review The MR shall verify the corrective action taken based on the non-conformities observed during the internal quality audits. Effectiveness of corrective action shall be verified. Any major deficiency in implementation of the system will be immediately brought to the notice of MD A report on the preventive action taken shall be brought up for the Management Review meeting RELATIVE DOCUMENT Corrective and Preventive Action Register

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BATCH NUMBER & DRUM NUMBER 1. CABLES OTHER THAN HOUSE WIRING CABLES Batch number consist of 6 digits . first two digits representing the year of manufacturing , third and fourth digits representing the month of manufacturing and fifth and sixth two digits representing the date of manufacturing Drum number will bear continuous serial number 2. HOUSE WIRING CABLES

BATCH NUMBER Batch number consist of 6 digits . first two digits representing the year of manufacturing , third and fourth digits representing the month of manufacturing and fifth and sixth two digits representing the date of manufacturing

DRUM NUMBER 1 2 3

COLUMN 1- Alphabet represents the size of cable A -1.0 SQMM B -1.5 SQMM C -2.0 SQMM D -2.5 SQMM E -4.0 SQMM F -6.0 SQMM G -10.0 SQMM H -16.0 SQMM I -25.0 SQMM J -35.0 SQMM K -50.0 SQMM L -70 SQMM M -95 SQMM N -120 SQMM O -150 SQMM P -185 SQMM Q -240 SQMM R -300 SQMM

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COLUMN 2 -4 Digit continuous numbers

COLUMN 3 - Alphabet represents the colour of cable RED - R YELLOW - Y BLUE - BL BLACK - BK GREEN - GR GREY - GY WHITE - WT

NON CONFORMING MATERIAL

Materials which do not meet the requirements of quality plan , are non-conformance materials. A non- conformance report is prepared for such materials and forwarded to MD for review MD will review the NCR and decades about taking proper corrective & preventive actions to avoid recurrence of non conformance as well as for disposition of NCM materials In case of raw materials MDs disposition will be either to accept the material on concession or reject the material and return to the supplier In case of in process / finished material, MDs disposition will be accept, rework or scrap the material All the instruments are duly calibrated once in a year and records are properly maintained. Calibration stickers are affixed on all instruments. CONTROL OF RECORDS All testing & calibration records are maintained by QA Department with proper trace ability through Batch number, Drum number & work order number

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RESPONSIBILITY

Head of quality assurance department is responsible for the quality system inspection and testing and releasing the materials from raw material, in - process & finished stages of manufacturing.

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CHAPTER 4

FINDINGS , SUGGESTIONS & CONCLUSION

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FINDINGS They are not testing the temperature index and oxygen index There is no test they are using to determine the cable is halogen free or not Not measuring the smoke density Poor internal quality auditing There is no procedure for quality auditing

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SUGGESTIONS From these findings my suggestions to the SARK CABLES Pvt. Ltd are : The Company can adopt these SPECIAL TESTS for cables ,this will helpful to them for improving the quality in manufacturing. the tests are as follows : Oxygen Index test & Temperature index Halogen acid gas emission test Smoke density test

OXYGEN INDEX TEST & TEMPERATURE INDEX

An oxygen index test was conducted on thirteen different electric cable samples, to determine the limiting oxygen index (i.e., LOI) of each cable composite, its sheath and its insulated wire. A statistical comparative analysis for the data pairs has shown that the LOI of the cable composite correlated significantly well with that of its sheath material whereas it hardly had any significant correlations with that of its insulated wire. This implies that the LOI of a cable composite may be an alternative to that of its sheath material in some cases, though it should be considered that the former tends to be a little higher than the latter. Adoption of the oxygen index test on electric cable composites instead of that on the sheath coverings could only have merit in simplification and convenience of the sample preparation for the test. Oxygen index is the minimum concentration of oxygen in an oxygen/nitrogen mixture in which the material will burn. As air contains approximately 21 % oxygen it is stated that a material with an oxygen index greater than about 26% will be self extinguishing. In general, a particular oxygen index value offers no guarantee of resistance to the spread of flames. In practice materials having identical oxygen indices may have widely different burning properties especially if base polymers or additive are of different types

The temperature index of a materials is the minimum temperature at which the material supports combustion in air containing 21% oxygen when tested under controlled conditions. The test is useful for the comparison of similar materials but no correlation with flammability under other fire conditions is implied

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Oxygen and temperature indices are to some extent inter related. The engineers specify such cable requirements should not pick out the most faavourable parameters from different manufacturers literature and expect them to comply. For example , a high oxygen index using a particular combination of materials may result in a slightly less favourable temperature index rating. In some cases where manufacturers have been requested to provide cables with a temperature index of 2800 Cor above this requirement was only met at the expense of other important parameters such as tensile properties and water permeability.

HALOGEN ACID GAS EMISSION TEST This specifies a test for determination of the amount of halogen acid gas, other than the hydrofluoric acid, evolve during combustion of compound based on halogenated polymers and compounds containing halogenated additives taken from cable constructions. Halogen includes Florine, Chlorine, Bromine, Iodine and Astatine. All these elements are toxic by its nature. In this test, when the burner is heated to 800C, 1g sample is placed inside and the HCL is absorbed into water inside the chamber fed with air flow. The water is then tested with its acidity. If the hydrochloric acid yield is less than 5%, the cable is categorized as LSOH. If the hydrochloric acid yield lies between 5% to 15%, the cable is categorized as LSF. IEC 60754-1 cannot be used for measuring the exact HCL yield if it is less than 5% and thus cannot tell if the cable is halogen free or not. To determine if the cable is halogen free, IEC 60754-2 should be used.

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SMOKE DENSITY TEST

The smoke density measurement taken from a material under fire conditions gives an indication of the visibility through the smoke, this is important as reduced visibility in a real fire situation makes it more difficult to escape from a fire hence increasing the threat to human life from the toxic gases , flames and heat. And the next one is the company should take care of the INTERNAL QUALITY AUDIT PART. My suggestions for that is :

To lay procedure for planning and implementing internal Quality Audit All departments under the quality system Give full responsibility to a Management Representative (MR)

PROCEDURE FOR THE AUDIT IS: Minimum two internal quality audits should be carried out in year as per the schedule It is carried out by internal Quality Auditors independent of the department being audited. Details of audit is recorded and reported to MR and non-conformities are recorded This will form an input for the next Management Review meeting Corrective action and follow up audit will be done. MR will verify the reports and appropriate action will be taken

The documents need to prepare are : Internal Quality Audit schedule Internal Audit Report Non Conformance Report

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CONCLUSION

Quality is an important factor for every product, SARK CABLES Pvt. Ltd is having a good number of customers which shows their products quality. If the organization is taking my suggestion they can continually improve the quality of cables The proper internal auditing will helpful for improving the efficiency in all the departments of the organization. The auditing documents will helpful to the management for reviewing the overall performance level

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BIBLIOGRAPHY

www.google .com www.wikipedia.com www.investopedia.com Ahmed, S. & Hassan, M. (2003). Survey and case investigations on application of quality management tools and techniques in SMIs. International Journal of Quality &Reliability Management, 20(7), pp. 795-826 SARK Cables manufactures test report Company records and manual

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