Institutional Training report in partial fulfillment of the
Requirements for the degree of 5year MBA
[IMBA] Institutional Training Done by R.M.M!I"# $%mbi&$5 in Amara Ra'a Batteries (td )ara*ambadi +hittoor,dist- A.. A/*no0ledgement
I express my sincere thanks to Mr.Ashok and Mr.Durga Prasad HR department, ARBL and special thanks to Mrs.alpana, Mrs.!unitha "#A$, Mr.!atish "engineer$ , %or their constant encouragement , &alua'le guidance and their extreme support %or the success%ul completion o% pro(ect )ork.
Here I take this opportunity to express my gratitude to all the pro%essionals )ho spent their &alua'le time in responding to my *uestions. Also, I ackno)ledge all those )ho ha&e contri'uted either directly or indirectly %or the success%ul completion o% pro(ect.
+inally I ackno)ledge the god almighty %or guiding me and sho)ering his 'lessings throughout this pro(ect and I am inde'ted to my parents %or their support at all le&els. Index ".no +ontents .age no , Introduction , - Mission, .ision and pro%ile o% the company - / Detailed study o% all the %unctions in IBD /., HR ,, /.- #uality ,0 /./ Marketing -1 /.1 Production /2 /.3 Production 4ngineering 1, /.5 Research and De&elopment 1/ /.0 +inance 6 Accounts 15 1 7onclusion 33 MISSION STATEMENT: 89o trans%orm our spheres o% in%luence and to impro&e the *uality o% li%e 'y 'uilding institutions that pro&ide 'etter access to 'etter opportunities, goods and ser&ices to more people all the time.: 1ision 2$253 89hrough Amara Ra(a )ay, and through enduring progressi&e partnerships, )e )ill 'e glo'al leader in 'atteries and 'attery technologies 6 dominant player in Indian ;cean Rim:. PROFILE OF THE ORGANIZATION Brief about the Promoter of Amara Raja Group of Companies: Dr. Ramachandra <. =alla, a non>resident Indian no) settled in India is the main promoter. Dr. Ramachandra < =alla is an 4lectrical 4ngineer %rom !ri .enkates)ara ?ni&ersity, 9irupati and has to his credit, Masters degrees in Applied 4lectronics, Roorkee, India and !ystems !ciences, Michigan !tate ?ni&ersity, ?!A. Dr. Ramachandra < =alla started his career as an 4lectrical 4ngineer in ?! !teel 7orporation, ?!A and mo&ed on to !argent 6 Lundy, ?!A as a consulting engineer %or the designing o% <uclear and 7oal +ired Po)er Plant. He initiated &arious pro(ects during his tenure and mastered the ropes o% this competiti&e 'usiness in a &ery short time. Ho)e&er, Dr. Ramachandra < =alla )as passionate to set up a 'attery manu%acturing plant in India. @ith a Aeal and highly %ocused approach, he esta'lished, 8Amara Ra'a Batteries (imited:, )hich has gro)n to the top league o% 'attery companies in India. Dr. Ramachandra < =alla had 'een the 4xecuti&e 7hairman and Managing Director o% the 7ompany %or the period %rom Buly ,CCD to August -22/ and continued as 4xecuti&e 7hairman till August -223. 4%%ecti&e !eptem'er -223, Dr. Ramachandra < =alla has 'een continuing as the non>executi&e 7hairman o% the 7ompany. Dr. Ramachandra < =alla )ith his &ast kno)ledge on the 'attery industry is a source o% inspiration %or the employees o% ARBL. Dr. Ramachandra < =alla has al)ays 'een a pillar o% strength and his inputsEad&ise ha&e 'een in&alua'le %or the gro)th o% the 7ompany. 9he 7ompany also seeks his expertise on &arious technical issues %or )hich he pro&ides immediate suggestions and acti&ely in&ol&es himsel% in the a%%airs o% the 7ompany on a regular 'asis. PROFILE OF THE PRODUCT/SERVICE Battery: Battery is the porta'le de&ice producing D7 po)er 'y electro>chemical reaction. A potential di%%erence is de&eloped )hen t)o dissimilar electrodes are immersed in a conducting solution called electrolyte and a current %lo) is o'ser&ed )hen the terminals are connected. Battery is an electro>chemical de&ice in )hich the %ree energy o% chemical energy is con&erted into electrical energy. @ithin the 'attery, )e can store chemical energy, and on demand it can 'e con&erted into electrical energy to dri&e an external circuit. 9he 'attery is the %uel tank o% 4lectric .ehicle. It stores chemical energy in the %orm o% reacti&e species, i.e. "during FchargingG$ and is designed to release this energy as electrical po)er "during FdischargingG$. Lead>acid 'attery occupies prominent place 'ecause o% its application in the automoti&e %ield. 9he lead>acid 'attery is the only acidic 'attery that uses an acidic electrolyte. Amara Ra(a Batteries Limited comprises o% t)o ma(or di&isions &iA., Industrial Battery Di&ision HIBDI, Automoti&e Battery Di&ision HABDI. Industrial Battery Di4ision ,IBD-3 Amara Ra(a pioneered the application o% .RLA 'attery technology in India )ith the launch o% .o0er sta/* and Impro4ed .o0er sta/* a high integrity, long li%e 'attery designed to take care o% 7ritical stand'y applications %or sectors such as tele communications, rail)ays, po)er generation and distri'ution, de%ense, and the oil and gas o%%shore. 9he success o% this technology led to its Application in ne) areas such as moti&e po)er, ?P! and solar energy. Amara Ra(aJs 'rands in the industrial segment include 5uanta > the long li%e ?P! 'attery.
Quanta Poe! Sta"# I"B6
IBD IMD ,(1R(A- ,M1R(A- +6"TM7R"3 K 9elecomL B!<L, B4L, BH4L, <okia, !iemens. K Po)er controlL Raichur thermal po)er station, <orth 7hennai po)er station. K ;il 6 gasL 9he island o% Lakshad)eep is po)ered through Amara ra(a po)er systems. Also pro&ides 'ack>up po)er %or lo) po)er transmitters %or Doordarshan. K Moti&e po)erL AP7"American Po)er 7ontrol$, !iemens, Alstom.. Rail)aysL ARBL pioneered the use o% maintenance>%ree 'atteries in Indian rail)ays. ;&er 32M o% Indian rail)ays II 6 III 9ire sel%>generation air>conditioned coaches are po)ered 'y ARBL. ;&er 12M o% rail)ays signaling and telecom po)er supply solutions are pro&ided 'y ARBL. +M.7TITR"3 4xide industries Ltd. Hydera'ad 'atteries Ltd. =<B. Automati/ Battery Di4ision ,ABD-3 Amara Ra(a Batteries Limited has prestigious ;4M ";riginal 4*uipment Manu%acturer$ clients like +ord, Daimler 7hrysler, =eneral Motors, Ashok Leyland, Hindustan Motors, 9ata Motors, Mahindra 6 Mahindra, +iat, Honda, Maruti and Hyundai. 9he company entered the replacement 'attery segment )ith the launch o% Amaron 'rand o% automoti&e 'atteries in Banuary -222.9hese are the %irst Aero> maintenance, high per%ormance and long li%e 'atteries, )ith long term )arranty periods in these categories and ha&e 'ecome the 'enchmark %or *uality and relia'ility in their respecti&e %ields. 9he company has recently entered into the upcountry markets )ith .o0er 8one 'rand o% economy 'atteries. Po)er None is a chain o% %ormatted retail stores o%%ering po)er solutions %or automo'ile and household applications. Batteries are made to the speci%ic standards o% I!; C22,, #! C222 and I!; ,122,and 9! ,5C1C certi%icates using )orld> class 9echnology and *uality> controlled parameters. .RD6+T"3 Amaron highli%e Amaron har&est Amaron shield Amaron hi>)ay +6"TM7R"3 ARBL has prestigious ;4M";riginal 4*uipment Manu%acturer$ clients like +ord =eneral motors, Dae)oo motors, Mercedes O recently ac*uired a pre%erential supplier alliance )ith Ashok Leyland , Hindustan motors, 9elco, Mahindra6Mahindra, Hyundai. R9A!I8ATI! D7"I9! A!D "TR6+T6R73 ;rganiAation design is the process o% aligning an organiAationJs structure )ith its mission. 9his means looking at the complex relationship 'et)een tasks, )ork%lo), responsi'ility and authority, and making sure these all support the o'(ecti&es o% the 'usiness. Amara Ra(a Batteries Limited "ARBL$ %ollo)s di&isional structure. In a di&isional structure, the company is di&ided into 'usiness di&isions, )here each 'usiness di&ision is autonomous and typically structured along %unctional lines. D7TAI(7D "T6D: ; A(( T#7 ;6!+TI!" I! IBD IBD<#R #6MA! R7"6R+73 9he HR and Administration organiAation o% Amara Ra(a is %ormed )ith an aim to pro&ide all the support the 'usiness needs at the right time. 9he %irst le&el organiAation structure is illustrated 'elo)
Business #R3 9he role o% 'usiness HR is the %ront %ace o% human resources %or the respecti&e company E 'usiness. 9hey ha&e to handle end to end o% HR %unction at the company E 'usiness le&el spanning across all locations )here&er the 'usiness operates "e.g. 'ranches, )arehouses, 7;; P 7orporate o%%ice 6 plant$ > %rom recruitment to resignation/retirement. Talent A/quisition +ell3 9he mem'ers o% this department are responsi'le %or procurement, recruitment and selection o% candidates in the group companies. Legacy system is the currently existing system in the organiAation and it is RAM7; system. 4nterprise Resource Planning "4RP$L it is the integration o% all the departments and modules that are there in the organiAation. It acts as a catalyst in the organiAation. +or starting any kind o% recruitment in or o%% the organiAation %ollo)ing steps are %ollo)edL G!ou$ HR Head %u&'ne& & HR HR S(a!ed Se!)'"e& T!a'n'n* and De)e+o$,en t Ta+ent A"-u'&'t'o n Ce++ PMS . Pe!/o!,an" e Mana*e,en t S0&te,
"our/es of Re/ruitment3 K 7ampus Placements "AR=MP, AR=9P$ K ;%% 7ampus K <e)s paper ad&ertisements K Bo' portals K 4mployee Re%errals K Head hunting K 7onsultancies AR9M.>Amara Ra(a =raduate 6 Management 9rainees Program "4ngineering =raduates 6 Management courses students are recruited$ AR9T.> Amara Ra(a =raduate 9rainees Program "All Diploma trades 6 Degree students are recruited$ ART" > Amara Ra(a 9rainee !cheme "!tudents %rom ,2 th 7lass, Intermediate and I9I are recruited$ "ele/tion .ro/ess Budget Preparation (Man power requirement) Approval of Budget from respective LOFs Job escription !dentif"ing sources of recruitment !nformation provided to #P($%) &at'ering ( )crutini*ing %esumes +alling for written test, interview )electing +andidates All the trainees undergo one year training and six months pro'ation period. HRSS HR Shared Services: Service matters & Statutory measures: Service Matters: 9he executi&es o% this department do the 4RP updation o% all the details o% ne)ly (oined, internal trans%erred or trans%erred employees to di%%erent locations. 4RP detailsL K 4mployee 7ode K 4mployee Id M9 "Management 9rainees$ MBAs, B.9echEBBMEBBA>MBA, =49 "=raduate 4ngineering 9rainees$ B.9ech, B4 A9 "Assistant 9rainees$ B.7om 6 BA 99 " 9echnician 9rainees$ All Diploma 9rades 9A9 "9echnician Assistant 9rainees$ B!c 9RAD7" D7"I9!ATI! M, 7hairman 6 Managing Director M, 7hie% +inancial ;%%icer "=roup$ M- .ice President M/ =eneral Manager M1 Deputy =eneral Manager M3 !enior Manager M5 ManagerE Branch Manager M0 Assistant Manager MD !r. 4ngineerE!r. 4xecuti&e MC 4ngineerE 4xecuti&e !, Bunior ;%%icer !- !uper&isor !/ Assistant II !1 9echnician !3 Assistant I @, @orkman @- @orkman @/ @orkman @1 @orkman @3 @orkman Management =rades )taff &rades -or.men &rades Joining Formalities Job specification )ending Offer Letters ( %eceiving ac.nowledgement K Personal in%ormation K +amily Details K Academic Details K 4xperience "tatutory "er4i/es : +i&e ma(or actions are taken care 'y the statutory ser&ice executi&e. 9hese areL K Pro&ident +und "P+$ K Pension K 4mployee !tate Insurance "4!I$ K 4mployment 4xchange "44$ K Payment o% =ratuity K Bonus Time offi/e3 9his department is responsi'le %or the maintenance o% attendance o% all the employees in the Head o%%ice and 'ranches. 9hese people deal )ith Amara Ra(a Attendance Management !ystem "ARAM!$ using so%t)are program called F!olusG. Responsi'ilitiesL K 7ollecting photos and details %or distri'uting Identity cards. K ;pening Bank accounts %or ne)ly (oined employees. K In%orming all the H;DGs to authoriAe the pending applications 'e%ore -3 th o% e&ery month. K !ending attendance details o% all the employees to pay roll %or salaries. .ay Roll3 9he executi&es o% this department are responsi'le %or gi&ing the )ages %or all the employees in the organiAation. Training = De4elopment3 . 9he training needs %or !ta%% and Management grades ha&e 'een identi%ied through the 4lectronic Per%ormance Appraisal !ystem "AR4PA!$. 9his department is responsi'le %or preparing the training calendar and schedules %or the training programs %or the employees across the group companies. Amara Ra(a Training 6 De&elopment +alendar. 9raining is o% t)o typesL ,. ;n the (o' training. -. ;%% the (o' training n the 'ob training ,>T- 4mployee training at the place o% )ork )hile he or she is doing the actual (o'. ?sually a pro%essional trainer "or sometimes an experienced employee$ ser&es as the course instructor using hands>on training o%ten supported 'y %ormal classroom training. ff the 'ob training 4mployee training at a site a)ay %rom the actual )ork en&ironment. It o%ten utiliAes lectures, case studies, role playing, simulation, etc.
IBD < 56A(IT: 5uality Assuran/e3 De%inition o% *ualityL>89he characteristic o% a product or ser&ice that 'ear on its a'ility to satis%y stated or implied needs.: ;r it can 'e simply said as 8%itness %or use: or :con%irmation to re*uirements: or 8D4+479 +R44 PR;D?79:. #uality o% a product or ser&ice can 'e assured i% it is %ree o% de%iciencies. 9he process o% inspecting the *uality can 'e done as sho)n 'elo) a- In0ard Inspe/tions3 Initial checks %or the machines Lathing )ill 'e done %or sample 'e%ore testing in ;ptical 4mission !pectroscopy ";4!$ P Determination o% ma(or alloy and trace elements in lead and lead alloys. /ualit" !nspections !nward !nspections !n process !nspections Atomic A'sorption !pectrophotometer "AA!$ P Determination o% ma(or alloy and trace elements in lead and lead alloys, pure metals, impurities in pasting chemicals and 'attery electrolyte. Determination o% 9hickness o% A=M !eparators Determination o% )icking o% A=M !eparators Acid retention 9est o% A=M !eparator Determination o% Ash content and ignition loss in materials at higher temperatures Moisture AnalyAer %or PP7P granules Determination o% Density %or PP7P M+I "Melt +lo) Index$ tester %or PP7P granules IAod Impact 9ester %or PP7P ?9M"?ni&ersal 9esting Machine$ tester %or PP7P granules .eri%ication o% Percentage particle siAe in po)der materials b- In .ro/ess Inspe/tion3 Verification of Oxide Properties: +ree lead &eri%ication in lead oxide po)der Apparent density o% lead oxide po)der hec!s in "rid asting: =rid @eight .eri%ication 'y using )eighing scale =rid 9hickness .eri%ication 'y using Micrometer hec!s in Pasting: .eri%ication o% Paste density Plate )eight &eri%ication hec!s in #ars/ontainers mou$ding: Bar Height measurement during De>Molding>Immediately a%ter In(ection Molding Bar Height measurement a%ter Ageing !n process !nspection Plate Prepetation paration O0ide Preparation &rid +asting Jars,+ontainer s Moulding Assembl" Formation Finis'ing ( ispatc' hec!s in %ssem&$yL .eri%ication o% =roup 9hickness .eri%ication o% Mounting Height 'y .erniar .eri%ication o% Bar Height 'y .erniar Air pressure 9est on Assem'led cell .eri%ication o% 7ell Dimensions hec!s for 'odu$ar: Lug 7rystalliAation test Lug to !trap 'onding test Post and 9om'stone test Leak 9est on Assem'led 'attery hec!s in (ormation: Acid temperature &eri%ication Acid .olume cali'ration and PL7 setting 4lectrolyte temperature &eri%ication during %ormation ,22M 7apacity &eri%ication hec!s in (inishing: 9hermal 9hread &eri%ication ;7. 6 polarity &eri%ication hec!s in )ispatchL ,22M #uantity &eri%ication o% 7onnectors .eri%ication o% Accessories in the packing 'ox 9ypes o% customer complaints that ARBL"Amara Ra(a Battery Ltd$ deals )ithL +6"TM7R +M.(AI!T" I!T7R!A( 7?T7R!A( ,"e/tion<"e/tion /he/*s @ithin the organiAation- In/oming 0arranty I!+MI!93 Missing o% accessoriesO @ARRA!T:3 Based on customer needs or speci%ications. There are se4eral statisti/al tools 0hi/h help in ta*ing /orre/ti4e a/tions 0hi/h are used in 5uality assuran/e department3 K 7heck sheet K !trati%ication K Pareto analysis K Brain storming K 7ause e%%ect diagram K Histogram K =raphs K !catter diagram K +lo) diagram K 7ontrol charts 9he types o% audits that Amara Ra(a deals )ithL De%inition o% AuditL 9he general de%inition o% an audit is an e&aluation o% a person, organiAation, system, process, enterprise, pro(ect or product. 9he term most commonly re%ers to audits in accounting, 'ut similar concepts also exist in pro(ect management, *uality management, and energy conser&ation. A6DIT"
I!T7R!A( 7?T7R!A( I!T7R!A( A6DIT" P 9o esta'lish )hether practices %ollo) procedures P 9o highlight re*uired changes to procedures to ensure that they accurately re%lect *uality practices P 9o recommend opportunities %or impro&ements Internal audits are conducted once in 5 months %or H; 6 7;; operations. And once in ,- months %or +ield operations T61 A6DIT" P !ur&eillance audit P e&ery year P Re>certi%ication audit P once in / years IBD<MAR)7TI!9 9he marketing department o% Amara Ra(a is di&ided into six regions headed 'y six regional managers and is incorporated )ith -, 'ranches across India ha&ing /, )arehouses, ,52 %ranchises and o&er ,3222 retailers. 9he marketing %unctions and acti&ities that are carried out in 7;;. @hole Marketing section is di&ided into three channels according to 'usiness strategies
Dire/t Business In direct marketing 'usiness products are pro&ided directly to customer. Here %lo) o% product is gi&en 'ello)
9here is no need o% 7hannel %or Rail)ays 9elecom Po)er control ;4Ms (ist of 7M /ustomers3 +ord India Ltd Huyndai Motor India Ltd Maruthi ?dyog Ltd Ashok Leyland Ltd 9ata Motors Ltd Mahindra 6 Mahindra Ltd MARKETING CHANNEL %USINESS E1PORT %USINESS DIRECT %USINESS H2O 3ARE HOUSE END USER +orce Motors =eneral Motors India Ltd International 9ractors Ltd !)ara( MaAda Ltd Mar*eting ;un/tionsBA/ti4ities ,7MCs-3 Market promotion o% the product. Processing o% customer en*uiries. Preparation and su'mission o% proposals. Processing o% purchase orders and purchase order amendments. Monitor product deli&ery, product per%ormance and ser&ice le&els to customers. Implementing good housekeeping methods at the related areas. Maintenance o% departments recordsE%iles, MI! generation o% )eekly acti&ity reports "@AR$ and monthly reports "MR$. 7ustomer relationship management. +hannel Business In this marketing system product %lo)s thro) a channel. 7Dport Business In it products are exports to outside o% country. ;ur 'atteries are exported to !ingapore , Malaysia , Indonesia , 9ai)an , Philippines , =reece , Australia , u)ait , Du'ai , 7hina and Bapan . 4xport can 'e categoriAed into three Direct Merchant !4N P!pecial 4conomic None H2O 3ARE HOUSE FRANCHISE RETAILER CUSTOMER Mar*eting3 9he marketing acti&ities are per%ormed to meet the customerGs re*uirements. 9he acti&ities includeL 4n*uiry E 9ender Re&ie) !u'mission o% ;%%ers ;rderE 7ontract Re&ie) ;rder Ackno)ledgement ;'taining order amendments Handling o% customer complaints @eekly Acti&ity Report Appointment o% channel partners Re&ie) o% pending payments 4ngineering and Marketing 7oordination meeting b'e/ti4es3 Meeting the sales targets as per the 'usiness plan 7ollection o% payments as per P; 9erms Meeting the customer re*uirements E expectations Pro&iding necessary training programs %or sta%% E customer personnel "er4i/e3 Main acti&ities that are per%ormed 'y ser&ice departmentL 4nsuring 7ustomer !atis%action through prompt 6 e%%icient ser&ice to customers Monitoring Product Per%ormance, %eed'ack to R47 %or product impro&ements Mar*eting "er4i/es3 ;un/tions3 9o assist in planning and execution o% marketing acti&ities 7o>ordination )ith the Ad&ertising agency, 4&ent Management agency, Market Research agency and Pu'lic Relations agency %or Promotions and product de&elopment !upporting %ield o%%ices in promotional acti&ities and e&ents Identi%ying and De&elopment o% Point o% Purchases Monitoring Budgets o% Promotional spends =eneration o% MI! reports> Ad spends monthly and *uarterly 9o assist in planning and execution o% Automoti&e, Industrial, 7orporate, International 6 =roup 7ompanies Mar*eting stru/ture of ARB( IBD MAR)7TI!93 T7(7+M3 In telecom sector )e pro&ide our 'atteries to ;perator> Airtel, .oda%one, B!<L etc. Manu%acturer RAI(@A:"3 Rail)ays !ector Rail coach %actories 4ngine manu%acturer INDUSTRIAL %ATTER4 DIRECT RAIL3A4S P2C E1PORT TELECOM U2P2S CHANNEL .@7R +!TR(3 Po)er sector ,. =eneration -. 9ransmission /. Distri'ution ;il and gas Rene)a'le energy Moti&e po)er !ecurity 7?.RT3 4xports to 7oslight Hopake +iam 4<7I4! "= 6 B$ 76D etc +#A!!7(3 In Industrial Batteries ?.P.! Batteries comes in channel marketing
8!A( ;;I+73 In e&ery Aonal o%%ice there is a Nonal 7hampion "N7$. 9here are total %i&e N7. COO ZONAL OFFICE BRANCH OFFICE CUSTOMER SERVICE H.O AQUA BRA!+# ;;I+73 9here is a Branch Manager in each Branch ;%%ice. 9here are total ,3>,5 B.Ms. Marketing 4ngineer comes under Branch Manager. A56A3 A*ua is (ust like a +ranchise %rom )here either end>user or Retailer can 'uy directly
IBD < .RD6+TI! .rodu/tion of a battery3 About a Battery3 Battery is the porta'le de&ice producing D7 po)er 'y electro>chemical reaction. A potential di%%erence is de&eloped )hen t)o dissimilar electrodes are immersed in a conducting solution called electrolyte and a current %lo) is o'ser&ed )hen the terminals are connected. Battery is an electro>chemical de&ice in )hich the %ree energy o% chemical energy is con&erted into electrical energy. @ithin the 'attery, )e can store chemical energy, and on demand it can 'e con&erted into electrical energy to dri&e an external circuit. 9he 'attery is the %uel tank o% 4lectric .ehicle. It stores chemical energy in the %orm o% reacti&e species, i.e. "during FchargingG$ and is designed to release this energy as electrical po)er "during FdischargingG$. Lead>acid 'attery occupies prominent place 'ecause o% its application in the automoti&e %ield. 9he lead>acid 'attery is the only acidic 'attery that uses an acidic electrolyte. Batteries can 'e 'roadly classi%ied into primary and secondary, depending upon the reactions in&ol&ed )hether irre&ersi'le or re&ersi'le and application. Primary 'atteries are not capa'le o% 'eing charged electrically and hence discharged once and disposed. 9he primary 'attery is con&enient source o% supplying po)er to porta'le electrical and electronic de&ices. !econdary 'atteries can 'e recharged electrically a%ter discharge to their original condition 'y passing electricity through them in the opposite direction to that o% the discharging current. Main +omponents of Battery3 Positi&e acti&e material P Lead dioxide "P';-$ <egati&e acti&e material l P !pongy lead "P'$ 4lectrolyte P Dilute sulphuric acid "H-!;1$ 7urrent collectors "grid$ P Lead alloys !eparator P Polythene, =lass Mat, A'sor' =lass Mat 7ontainer P PP7P, +RPP7P Alloys used in Manufa/turing of Batteries3 (ead3 9he ma(or alloy used in lead>acid 'atteries is lead. 9he density o% casted lead is ,,./1, 'ut this may 'e slightly increased 'y rolling. 9he melting point o% lead is /-0.1 2 7 "5-, +$. It oxidiAes readily in the moist air, 'ecoming a dull gray. Alloying elements to pure lead Antimony 7alcium Aluminum 7admium 9in !il&er IBD .ro/ess flo0 /hart3
Oxide Preparation Assembly Formation Plate Cleaning Grid Casting Paste Preparation Pasting Finishing Dispatch Curing & Drying & A. ?ID7 .R7.ARATI!3 BaloD lead oDide plant3 Barton pot process is used to make leady oxide po)der. CC.C0M pure lead is used to prepare oxide po)der. ;xide plants ,6- )orks on Barton process )here the lead ingots )ere melted and oxidiAed in the presence o% air. 9he %ollo)ing are the process parameters that are maintained during the preparation o% oxide po)der. Melting pot temp L 553Q,3+ Reactor pot preheating temp L 1-3Q,3+ <ormal operation temp L 0,3Q,3+ Reactor motor load L /3 to 13 amp Bag house temp L -22Q-2+ .ro/ess flo0 /hart3 .ro/ess3 Lead ingots are placed on ingot con&eyor through (i' crane )hose max capacity is 322 kgs. Ingot con&eyor is a po)er dri&en roller con&eyor )hich con&eys the ingots to the melting pot Lead ingots Melt pot %eactor pot +"clone Bag 'ouse )torage silo )here the lead ingots )ere melted )ith the help o% heaters. 9he temperature is maintained at 532 to 5D2+ in the melting pot. 9he centri%ugal pump collects the molten lead and pumps it to reactor pot through the lead trough. 9he molten lead is %ed into the reactor pot and is 'roken up into droplets 'y re&ol&ing paddle. A stream o% air 'lo)n o&er the droplets oxidiAes the lead. In the classi%ier the re*uired particle siAe range is separated and the coarser material is returned to the reactor pot.9he resulting oxide po)der is carried 'y air stream into the cyclone )here the po)der %urther disintegrated due to the )hirling action.9hen it is mo&ed to 'ag house )hich consists o% num'er o% %ilters. It separates the air %rom the po)der )ithout the loss o% oxide po)der. silos )ere used to store the leady oxide. 4ach silo is ha&ing a capacity o% -3 ton. oxide po)der is stored in the silos 'e%ore the paste preparation. 9he %ollo)ing are tested to e&aluate the *uality o% leady oxide. ,. +ree lead percentage "speci%ic limits are ,D to -DM$ -. Apparent density "speci%ic limits are ,./ to ,.DgmEcc$ /. Acid a'sorption"speci%ic limits are ,52 to -22mgEg$ * +. "R,) %S-,.": Model //2c grid casting machine Melt the ingots in the lead pot. Maintain the lead pot at a temp o% 103 to 3-3+. !tart the %eed line heaters. 9his molten metal is pumped to the ladle through solenoid &al&e. 9his actuates the lead &al&e to dispense the lead into the mould. Ladle is maintained at a temp o% 132 to 322+. 7ooling circulation system %eeds cold )ater during the solidi%ication and e(ection o% mould. 9he casted grid is passed through the rollers to make it %lat or to remo&e any de%ormation in the grid. =rid centering mechanism centers the grid. Hydraulic mechanism actuates the trimmer )hich remo&es the gates o% grid. Types of grids3 ,.Po)er stack type >>> -2, /2, 12, 32, 52, D2, C2 -.IP series >>>>>>>>>>>>>>> IP,, IP- +ommon defe/ts in grids High thickness Lo) thickness !hrinkage Miss trimming Blo) holes +lashes @ire missing Testing of grids 3 =rid thickness, !trength, @eight. Bend Test3 9o %ind strength grid is 'ent and checked %or any cracks and then at C2 degrees to the %irst. I% there are any consecuti&e cracks, then it )ill 'e re(ected. B6" BAR +A"TI!93 9he copper inserts are threaded into the holder and are dipped in %lux %or 3sec. 9hen dip these inserts in tinning pot %or /2sec. 9his tinning pot consists o% molten alloy o%% tin> lead "12>52$. Place the insert along )ith the holders in the mould. Pour the molten lead alloy )ith -Mtin pouring should 'e completed in a time a span o% D>,3sec.the molten metal is solidi%ied the mold and they can 'e remo&ed %orm the moulds. 9he 'us 'ars are remo&ed %ormed %rom the holders. 9he tinning pot is maintained at a temperature o% /-2Q-3 2 7 )hile the lead cruci'le temperature is 152Q,3 2 7. 9hese 'us 'ars are sent %or group 'urning is assem'ly stage. 2. .A"T7 .R7.ARATI!3 ;or .ositi4e .aste3 Lead oxide ,222kg Binder 2.3g !P9H -g DM )ater ,-5lt !ul%uric acid ,,2kg"!p. gra&ity ,.1$ ;or !egati4e .aste3 Lead oxide ,222kg Binder 2.3g Barium !ulphate -2g .anisperse -g 7ar'on Black -g DM )ater ,,5lt !ul%uric acid ,,2kg"!p. gra&ity ,.1$ .ro/ess flo0 /hart3 #uality tests %or pasteL ,. Density test -. Penetration capacity /. Moisture content .A"TI!93 Pasting is done on Industroma/ pasting ma/hine. Paste mix prepared in the oDmaster plant is trans%erred to the hopper o% the pasting machine. 4nsure that the grids ha&e under gone aging %or R&e -1 hrs. +ill the hopper /E1 th each time. =rids )ere made to pass through )ith the help o% con&eyor. Paster pastes grids to a thickness e*ual to ori%ice opening. It is the gap 'et)een hopper ori%ice plate and 'ottom ori%ice plate. As the grid panel gets close to hopperGs entrance it is pulled a)ay %rom chain dogs 'y a set o% accelerator rollers. 9he panel is then pushed into dri&e rollers that mo&e it into paste application area. 9he paste is applied through the grid structure 'y paste %eed roller that is located in upper ori%ice Binder Oxide dumping Dry mix Acid dumping Wet mix Water dumping Final mixing Paste For Pasting plate. 9he 'ottom ori%ice plate rollers tro)el the paste on the underside o% grid. A%ter stacking, the stacked plates )ere trans%erred to curing and drying o&ens. Be%ore that the plates are to 'e undergo aging period. 7uring and drying is the process 'y )hich satis%actory le&els o% cohesion and adhesion are imparted to the acti&e material prior to plate %ormation and are maintained there a%ter. In addition, curing ensures a highly de&eloped sur%ace area. E. +6RI!9 A!D DR:I!93 7uring and drying is done at three stages. . 7uring Intermediate stage Drying 7uring and drying process is carried out to impart cohesion and adhesions are imparted to the acti&e material prior to %ormation. 7uring is determined 'y the nature and degree o% interlocking 'et)een the crystals o% the paste. Adhesion is dependent upon the strength o% the 'ond, )hich is %ormed 'et)een the paste and the grid. 9hese essential properties are the 'est accomplished 'y conducting the curing procedure in the %ollo)ing se*uence. !teaming periodL !team is applied to e*ualiAe the moisture content in all the plates and it supports %or the de&elopment o% lead sulphates. Drying process is to 'ring do)n the )ater content "moisture$ to the lo) le&el %or the acti&e material to ha&e good sta'ility. During the process physical, chemical and morphological changes take place )ithin the acti&e material. 5. A""7MB(:3 .ro/ess flo0 /hart3
Plates, eparator, !op shields Group tac"ing #ars Group Burning Group trapping Post Burning $eat ealing Group %nsertion &ea" !esting Co'ers Bus Bars Du(( Cells A. 9roup sta/*ing3 Bottom shield is place in the %ixture this pre&ent the plate damage. +irst an un)rapped negati&e plate is placated the in the %ixture. 9hen a hal%>length separator is placed on the negati&e plate. 9he separator is sheared 'y acti&ating the cutter 'lade a%ter getting the prede%ined length. 9hen positi&e plate is place and separator is %olded o&er this plate. Place the hal%> length separator on the last positi&e plate and then place un)rapped negati&e plate on the top o% the hal% length separators complete the stack. !hields are pro&ided on positi&e plates to a&oid direct contact 'et)een positi&e and negati&e plates. B. 9roup burning3 Aligning o% 'us 'ars )ith lugs is called group 'urning. By using the protection o% (igs these com's can 'e shield rightly. Ad(ust the oxy>acetylene gas torch %or neutral %lame and length o% inner cone is -.3cm Positi&e strap is 'urnt %irst as i% re*uires more time %or cooling. 9he molten metal is stirred )ith them. 9he post protection (igs are chilled )ith D.M )ater and then they )ere remo&ed. +. 9roup strapping3 Plates )ere strapped on strapping machine )ith poly>propylene. 9hese straps held the stacks together. D. 9roup insertion3 9he strapped plates are inserted into (arsEcontainers shield in )rapped on the plates 'e%ore insertion. 7. #eat sealing3 9he co&er is placed o&er the (ars such that the posts can slide inside the 'ushing. 9he heaters are maintained at a temperature o% range 112>1D2+. +irst takes ,2sec %or melting and other ,2sec %or )elding them together. 9he co&ers must 'e positioned so that the polarity marking on the co&er corresponds to proper postE'using location. ;. .ost burning3 +ix the dummy &ent plug. 7opper inserts )ere pre>heated using inner %lame until the post lead starts melting. ;rthophosporic acid is applied on post and 'ush o% the co&er. 7ontinue the process until good sur%ace is o'tained. 9. (ea* testing3 9he pressure inside the cell is increased to 53kpa %or the range o% -2>/2sec. )hile it is placed in )ater 'ath. ;'ser&e %or air 'u''les i% any leak exists mark the area %or re)ork. I% &ent is )eak replace the &ent.!erial num'er is punched on the cell 7DL 20 ,E- CCCCCC 20 indicates year ,E- indicate assem'ly line CCCCCC indicate type or model "i.e. the no o% 'attery coming out o% the line in the year$ F. ;RMATI!3 +ell pa/*ing3 9he cells are placed in tu' and packed )ith PP7P spacers and strapped )ith metallic 'ale the cells are connected in series using ca'le connectors and 'olts. .ro/ess flo0 /hart3 Du(( Cell Acid Filling %nitial Charge Formation Discharge Capacity )echarge Capacity Discharge Formation Charge Bac" Float Charge Formed Cell A/id filling3 At the %irst the &olume &essel is %illed up to the present &olume. 9he cycle starts 'y pulling the &acuum in the 'attery until preset &acuum le&el is reached. 9hen the acid is trans%erred %rom &olume &essel to the expansion &essel. 9he &enting &al&e pro&ided on top o% the machine )ill open and 'ecause o% &acuum in the 'attery causes an air stream )hich )ill %orce do)n the acid into the 'attery. I% there is still electrolyte in expansion &essel another &acuum pulse )ill 'e pulled. G. ;I!I"#I!9 = D7".AT+#I!93 9he %ormed 'attery is closed )ith &ent plug and )ashed )ith )ater to remo&e any acid present in the 'attery container outside. 9hen it is checked %or their prescri'ed integrity in 8;<>LI<4 HI=H RA94 DI!7HAR=4: tester. 9he 'atteries, )hich satis%y the speci%ication is packed and la'eled.In dispatching the cells )ere packed and the necessary accessories re*uired %or %unctioning o% the cells is supplied to the customer. 9he accessories include connectors, 'olts, )ashers, ca'les etc. 9his %inished product is sent to Market through shipment 'y lorries, trucks, etc.
IBD H .RD6+TI! 7!9I!77RI!9 +ompanyCs produ/tion engineering A%ter the order o% the products %rom the customers reach the marketing department, the entire details )ill 'e gi&en to Production 4ngineering people. 9he &arious departments in Production 4ngineering are as %ollo)sL Product )eve$opment: 9his department is responsi'le %or Design and de&elopment o% a ne) product as per the speci%ications gi&en 'y the customer. Ma(or design changes in the existing product. 7reation o% master product structures in !AP. Process ,mprovements: 9o change the existing process o% designing to increase the e%%iciency. 9his department is completely responsi'le %or process +M4A, Process Audits. %pp$ication /ngineering: Design and de&elopment o% Accessories such as containers o% 'atteries )ill 'e done. Battery siAing. <e) application study o% the products )ill 'e done. Production 1ngineering Product evelopment Process !mprovement Application 1ngineering IBD H R7"7AR+# A!D D717(.M7!T +ompanyCs R=D 9he 7ompanyGs research and de&elopment %ocuses on %uturistic energy solution that enhances the price>&alue proposition. 9he R6D team consistently %ocused on technology excellence, creating products complying )ith exacting standards and customer needs. 9he ;rganiAation structure o% R6D is as %ollo)sL ,$ +undamental Material De&elopment ,$ 9esting department !tudies department -$ Process De&elopment -$ 7ali'ration La' /$ 7hemical La' (undamenta$ Studies )epartment: 9his department is completely responsi'le %or impact analysis o% the change that )ill 'e done. +or example, i% the composition o% the lead alloy in the 'attery should 'e changed and tasted, then the impact o% that change need to 'e analysed and study reports should 'e prepared. 9his impact analysis )ill 'e gi&en to Material De&elopment department. a$i&ration 0a&: Instruments used )ill 'e checked in the la' to o'tain accuracy. hemica$ 0a&: Reports o% chemical analysation )ill 'e prepared. #P &M Manager 1ngineer Manager 'ateria$ deve$opment: 9his acti&ity is 'asically %or impro&ing product per%ormance. 9he responsi'ilities in this department are 7hecking the output o% the 'attery a%ter replacing the main component o% the 'attery )ith alternati&e material. Recei&ing the existing materials %rom ne) suppliers and checking. De&eloping di%%erent com'inations o% lead and other components. -esting )epartment: Bench marking o% competitor 'atteries )ill 'e done. De&eloping testing en&ironment and conditions as per the customer re*uirement. Process )eve$opment: De&elopment o% import su'stitutions and ne) products %or di%%erent applications. IBD<;I!A!+7 +!+(6"I!3 +inally I )ould like to conclude that the institutional training helped me in enhancing the practical kno)ledge as )ell as to gain personnel skills to sustain in the organisation. I ha&e o'ser&ed some aspects that in %ollo)ed in the ARBL like the discipline , the culture in the organisation, )orking en&ironment, code o% conduct, and the %acilities pro&ided and also the sa%ety measures and ecological sa%ety taken at the )orkplace. Amara Ra(a 'atteries Limited %ollo)s the hierarchial organiAation structure, )herein )hen su'di&ided %ollo)s the di&isional structure, )here the organiAation is di&ided into 'usiness units )ith its managers headed 'y the MD, )ith its respecti&e %unctional lines under 'usiness unit heads. 9his structure suites the %lo) o% the organiAation as it has main ad&antage )here each di&ision is %ree to concentrate on its o)n per%ormance.