INTRODUCTION

KELTRON ELECTRO CERAMICS LIMITED a state PSU under industries Dept., Govt. Of Kerala is a subsidiary of Kerala State Electronics Development Corporation Ltd(KELTRON). The company was incorporated in the name and style DIELECTRO MANGNETICS LIMITED in the year 1974. In 1977 Keltron acquired the majority share hold of promoters and consequently the name of the company was changed to Keltron Electro Ceramic Limited production of disc ceramic capacitor was started during 1978 using NPL technology. The company also manufacturing NTC thermistors, metal oxide resistors, piezo ceramic buzzers, electronic flashers, transducers etc.

MANUFACTURING PROCESS OF CERAMIC CAPACITOR

STEPS FOR MANUFACTURING OF CERAMIC CAPACITOR: 1. Looping 2. Disk loading 3. Flux dipping 4. Soldering 5. Cleaing 6. Coating 7. Value printing 8. Testing 9. Lead cutting 10. Packing 1. Looping: Looping machine is used to holding the ceramic disc in the copper wire, it is arranged in the form of a loop. In this process first of all the copper is cut in the form U shape by adjusting the length. Then the copper wire is pasted in a paper roll, and is moved into the punched by a punching machine and is punched into a twisted form. Then the paper roll is cut into a 30 numbered strip. 2. Disk loading Here the ceramic disk is loaded into the end twisted wire. Here the process is done by both manually and mechanically. Here also the disk is looped by a 30 numbered case. The disks made of silver and it is the electrode. 3. Flux Dipping In this process the flux is made up of IPA (iso propyl alcohol) and Resin. The loaded disk is dipped into the flux in a pre-heater at a heat of 1000C and is then to the soldering machine. 4. Soldering Here the disk is solder to the Copper wire at a temperature of 2050C height, pressure and speed adjusting appropriate values. The capacity of the machine at a time 900.

5. Cleaning In cleaning process IPA is used to clean the soldered material to remove the impurities. 6. Coating Here the coating mix is made up of a mixture of Resin, Aceton, Industrial solvent, MEK( Methane Ethane Ketone). In this process the mix is showed to the disk. After 3 minutes the process is repeated then it is air dryed for one day and ovened at a temperature of 1300C for 4 days. 7. Value printing Capacitor value is printed on the capacitor. If the printing is not corrected it is cleaned by acetone in few seconds. 8. Testing Here the manufactured capacitors use tested for the following for the following parameters. Voltage amphere. The tolerance will be (-22-+80)the process is done at a room temperature of 250C. if this is any defect that are removed at the at the same time. 9. Lead Cutting After testing, the length of the capacitor leads are the arranged by cutting according to the orders. There are two types of lead cutting. 1. Strip cutting(Maual) 2. Reel Cutting(Automatic) 10. Packing One pack will contain 1000 numbers (there will be a variation). This is done by checking the weight of that pack and then others are packed according to that pack.

MANUFACTURING OF NTC THERMISTORS

They are from a variety of diameter size ranging from 3mm-5mm.Disk typed thermistors are used in automobiles. The row materials used for making thermistors is, Mangnese carbonate Nickel oxide Cobalt oxide Cupric oxide Lithium carbonate

The first process in making thermistors is milling. It is done for about 4hrs. The equipment used for this purpose is jarmill. The materials used in this process is chemicals, water and steel balls in this process purified water is re120 0c. PVA (Poly vinyl Alcohol) is used as the gum. After the process a slurry like material is obtained as the product. From this slurry the steel balls are removed. Steel balls are used to mix the ingredients well. Then the slurry is taken to the oven drying which is the second process. The 3rd process is in pre firing furnace. In this the material is heated 2 hours in 8500C. After this the product is taken only on next day. The 4th process is called IInd milling which is done for 8 hours. In this process the water is sucked using vaccum pump. From slurry then it is heated in oven. After heating a powder will be obtained and into this PVA is added. The mixture of PVA and powder is made into flour knead. After that comes the 5th process in which the mixture after IInd milling is taken into a machine called granulator. In this machine the mixture is made into a disk form. It has lower punch and upper punch to punch the mixture into disk form. After this the disk are heated in 1200C in sintering furnace to get strong. In this process to avoid the joining of tablets together while heating we use zinconium dioxide. Since when temperature increases diameter decreases. 3 hours use needed for this purpose. It is layer by layer in which after a layer zinconium oxide we keep tablet and so on. Sincon sand and acetone is used to remove zinconium oxide after that silver dielectric is coated on each disk then the value is recorded on the thermistors after fixing leads and it is tested. The remaining process are some that of a capacitor. When thickness increases its value increases. When temperature increases its value increases. When printing area increases the value decreases. When diameter increases the value decreases.

MANUFACTURING OF TRANSDUCER
Transducer is an electronic device which convert one of energy into another form. In Keltron they built number of various transducers for Indian Navies under water communication purpose. Manufacturing: In a HF transducer it is having 2 parts. 1. Head mass 2. Tele mass 1. Head Mass: it is made up of joining the capacitor disks. It is joined by a special gum called thuma cement (made in ISRO, Thumba TVM) after joining ceramic disks enclosed in a case. 2. Tele mass: it is made up of Alumininum. The important features in the production of HF transducer is that the weight of the Head mass should be grater than tele mass. The reason that is increased the weight less will be the frequency response. Working: HF transducers is same as an amplifier. It is used for under water communication. The input is given to the head mass and the amplified output is from the tele mass. In under water communication the frequency of the sound should be greater than 120db. But the original transmitting frequency did not be disclosed because of national security. These are two types. Test for the working , 1. RS test(receiving sensitivity) 2. TVR test(transmitting voltage response) Type of Transducers: 1. HF Transducer 2. UWT (under water telephone) 3. ATDS (Anti torpedo detection system)/MAREESH 4. MINE Hunting sonar/obstacle analyzing sonar 5. FLUX Tensional: used in sea harbours Oceanographic experiments ships 6. Vector Sensor(eg: 3 phase projector) 7. NP 30(standard) 8. LF transducers for low frequency transmission 9. HF wide hand

Hydrophone: These are worked on the principle of piezo electric effect. It is also used as communication causes. The crystals are used as are ceramic crystals. 1. Type A: Radially polarized- here the information is traveled in radially so that it can only be arranged in vertically. 2. Type B: 3. Type C 4. Type D 5. Type E (the sensitivity is negative 196) 6. Passive sonar Array It is tested in water, oil, and air. 7. Program based ground mine detector 8. Tadpole Hydrophone sensitivity is -170 9. Seismic Hydrophone (tsunami detection) 10. Sanjeevani life detector

MARKETING
Marketing means communication and finding the customers through branding and advertising. The customers of thermistor and capacitor are the electronic manufactures. For the transducers Indian Navy is the main customer. For Keltron there are seven marketing officers (Delhi, Munbai, Allahabad, Culcutta Etc) the capacitor and thermistors are called public products. The products are marketing through dealers, they are known as OEM (original equipment manufactures). These duty is to find the customers and extracting the sales. For uni industry the sale of the product is depending on haw the product is marketed. How a Product is marketed: It is a company demanding a product first they will contact the dealers and the dealers send a document known as dispatch billing advice. To the marketing department in the accounts. Then the accounts enquire to the marketing head if the stock is have or not. If not the marketing head will inform the PPC and the PPC is approved the production department. Then start the production. After production the products will be market through the dealers.

STORE
In an industry there will be two stores. 1. Raw material store 2. Finished good store The main function of raw material store is receipt, storage, issue handling, preservation, abc analysis, recorder level. Receipt It means how the parcel is getting from the providers and to check the defect and damages of that parcel. If parcel is insured in any damage is happened to the material the insurance claim will be allowed the document given by the providers along with the parcel is open delivery certificate. For parcel service mainly depends on following ways; Carrior Registered post parcel receipt By ship Railway receipt By air (AWB, air way bill) By road (lorry receipt)

After receiving the parcel the QA team is verified the materials through physical verification. If any damage to the materials that are rejected. In this report include serial number code number, description of material unit and quantity etc. for rejecting a material a scientific reason is given to the provider through GRCIR. Storage In storage how the materials used stored in this process there are to main documents 1. Ledger 2. Monthly stock statement Ledger includes opening balance, receipt issues closing balance etc. Monthly stock statement means that the amount of sailing. Issues In this also a document that is Storage Requisition issuing a product is based on a FIFO.

Handling How a material is handled in a store there will be lots of people that they dont know how to handle the material. So the manager should be vigilant about the handling of the equipments. Preservation It means how to keep a material is not damaged for chemicals w should keep it in a safe manner. Each chemical as its on shelf life. ADC Analysis It is a scientific method. It a method to classify the material in order to the availability. A class- rare to obtain and high cost item B class- simple to obtain and low cost C class- level item and cheap rate Re order level To keep the production in a standard manner and keep the stock in a design level.

Finished good store Here the manufactured products are stored

FINIHED