Institutional Training report in partial fulfillment of the

Requirements for the degree of 5year MBA

[IMBA]

Institutional Training

Done by

R.M.MONISH

09mbi105

in

Amara Raja Batteries Ltd

Karakambadi

Chittoor(dist) A.P

Acknowledgement I express my sincere thanks to Mr.Ashok and Mr.Durga Prasad HR department, ARBL and special thanks to Mrs.Kalpana, Mrs.Sunitha (QA), Mr.Satish (engineer) , for their constant encouragement , valuable guidance and their extreme support for the successful completion of project work.

Here I take this opportunity to express my gratitude to all the professionals who spent their valuable time in responding to my questions. Also, I acknowledge all those who have contributed either directly or indirectly for the successful completion of project.

Finally I acknowledge the god almighty for guiding me and showering his blessings throughout this project and I am indebted to my parents for

their support at all levels.

Index

S.no Contents Page no

1 Introduction 1

2 Mission, Vision and profile of the company 2

3 Detailed study of all the functions in IBD

3.1 HR 11

3.2 Quality 17

3.3 Marketing 24

3.4 Production 30

3.5 Production Engineering 41

3.6 Research and Development 43

3.7 Finance & Accounts 46

4 Conclusion 55

MISSION STATEMENT:

“To transform our spheres of influence and to improve the quality of life by building institutions that provide better access to better opportunities, goods and services to more people all the time.”

Vision 2025:

“Through Amara Raja way, and through enduring progressive partnerships, we will be global leader in batteries and battery technologies & dominant player in Indian Ocean Rim”.

PROFILE OF THE ORGANIZATION

Brief about the Promoter of Amara Raja Group of Companies:

Dr. Ramachandra N. Galla, a non-resident Indian now settled in India is the main promoter. Dr. Ramachandra N Galla is an Electrical Engineer from Sri Venkateswara University, Tirupati and has to his credit, Masters degrees in Applied Electronics, Roorkee, India and Systems Sciences, Michigan State University, USA.

Dr. Ramachandra N Galla started his career as an Electrical Engineer in US Steel Corporation, USA and moved on to Sargent & Lundy, USA as a consulting engineer for the designing of Nuclear and Coal Fired Power Plant. He initiated various projects during his tenure and mastered the ropes of this competitive business in a very short time. However, Dr. Ramachandra N Galla was passionate to set up a battery manufacturing plant in India. With a zeal and highly focused approach, he established, “Amara Raja Batteries Limited”, which has grown to the top league of battery companies in India.

Dr. Ramachandra N Galla had been the Executive Chairman and Managing Director of the Company for the period from July 1998 to August 2003 and continued as Executive Chairman till August 2005. Effective September 2005, Dr. Ramachandra N Galla has been continuing as the non-executive Chairman of the Company.

Dr. Ramachandra N Galla with his vast knowledge on the battery industry is a source of inspiration for the employees of ARBL. Dr. Ramachandra N Galla has always been a pillar of strength and his inputs/advise have been invaluable for the growth of the Company. The Company also seeks his expertise on various technical issues for which he provides immediate suggestions and actively involves himself in the affairs of the Company on a regular basis.

PROFILE OF THE PRODUCT/SERVICE

Battery:

Battery is the portable device producing DC power by electro-chemical reaction. A potential difference is developed when two dissimilar electrodes are immersed in a conducting solution called electrolyte and a current flow is observed when the terminals are connected.

Battery is an electro-chemical device in which the free energy of chemical energy is converted into electrical energy. Within the battery, we can store chemical energy, and on demand it can be converted into electrical energy to drive an external circuit.

The battery is the fuel tank of Electric Vehicle. It stores chemical energy in the form of reactive species, i.e. (during ‘charging’) and is designed to release this energy as electrical power (during ‘discharging’).

Lead-acid battery occupies prominent place because of its application in the automotive field. The lead-acid battery is the only acidic battery that uses an acidic electrolyte.

Amara Raja Batteries Limited comprises of two major divisions viz., Industrial Battery Division [IBD], Automotive Battery Division [ABD].

Industrial Battery Division (IBD):

Amara Raja pioneered the application of VRLA battery technology in India with the launch of Power stack and Improved Power stack a high integrity, long life battery designed to take care of Critical standby applications for sectors such as tele communications, railways, power generation and distribution, defense, and the oil and gas offshore. The success of this technology led to its Application in new areas such as motive power, UPS and solar energy. Amara Raja's brands in the industrial segment include Quanta - the long life UPS battery.

Quanta Power Stack

ISBU

IBD IMD

(LVRLA) (MVRLA)

CUSTOMERS:

♦ Telecom:

BSNL, BEL, BHEL, Nokia, Siemens.

♦ Power control:

Raichur thermal power station, North Chennai power station.

♦ Oil & gas:

The island of Lakshadweep is powered through Amara raja power systems. Also provides back-up power for low power transmitters for Doordarshan.

♦ Motive power:

APC(American Power Control), Siemens, Alstom..

Railways:

ARBL pioneered the use of maintenance-free batteries in Indian railways. Over 50% of Indian railways II & III Tire self-generation air-conditioned coaches are powered by ARBL. Over 40% of railways signaling and telecom power supply solutions are provided by ARBL.

COMPETITORS:

Exide industries Ltd.

Hyderabad batteries Ltd.

GNB.

Automatic Battery Division (ABD):

Amara Raja Batteries Limited has prestigious OEM (Original Equipment Manufacturer) clients like Ford, Daimler Chrysler, General Motors, Ashok Leyland, Hindustan Motors, Tata Motors, Mahindra & Mahindra, Fiat, Honda, Maruti and Hyundai. The company entered the replacement battery segment with the launch of Amaron brand of automotive batteries in January 2000.These are the first zero-maintenance, high performance and long life batteries, with long term warranty periods in these categories and have become the benchmark for quality and reliability in their respective fields. The company has recently entered into the upcountry markets with Power Zone brand of economy batteries. Power Zone is a chain of formatted retail stores offering power solutions for automobile and household applications. Batteries are made to the specific standards of ISO 9001, QS 9000 and ISO 14001and TS 16949 certificates using world- class Technology and quality- controlled parameters.

PRODUCTS:

Amaron highlife

Amaron harvest

Amaron shield

Amaron hi-way

CUSTOMERS:

ARBL has prestigious OEM(Original Equipment Manufacturer) clients like Ford General motors, Daewoo motors, Mercedes ; recently acquired a preferential supplier alliance with Ashok Leyland , Hindustan motors, Telco, Mahindra&Mahindra, Hyundai.

ORGANIZATION DESIGN AND STRUCTURE:

Organization design is the process of aligning an organization's structure with its mission. This means looking at the complex relationship between tasks, workflow, responsibility and authority, and making sure these all support the objectives of the business.

Amara Raja Batteries Limited (ARBL) follows divisional structure. In a divisional structure, the company is divided into business divisions, where each business division is autonomous and typically structured along functional lines.

DETAILED STUDY OF ALL THE FUNCTIONS IN IBD

IBD-HR

HUMAN RESOURCE:

The HR and Administration organization of Amara Raja is formed with an aim to provide all the support the business needs at the right time.

The first level organization structure is illustrated below

Business HR:

The role of business HR is the front face of human resources for the respective company / business. They have to handle end to end of HR function at the company / business level spanning across all locations wherever the business operates (e.g. branches, warehouses, COO – Corporate office & plant) - from recruitment to resignation/retirement.

Talent Acquisition Cell:

The members of this department are responsible for procurement, recruitment and selection of candidates in the group companies. Legacy system is the currently existing system in the organization and it is RAMCO system.

Enterprise Resource Planning (ERP): it is the integration of all the departments and modules that are there in the organization. It acts as a catalyst in the organization.

For starting any kind of recruitment in or off the organization following steps are followed:

Group HR Head

Business HR

HR Shared Services

Training and Development

Talent Acquisition Cell

PMS – Performance Management System

Sources of Recruitment:

♦ Campus Placements (ARGMP, ARGTP)♦ Off Campus♦ News paper advertisements♦ Job portals♦ Employee Referrals♦ Head hunting♦ Consultancies

ARGMP-Amara Raja Graduate & Management Trainees Program (Engineering Graduates & Management courses students are recruited)

ARGTP- Amara Raja Graduate Trainees Program (All Diploma trades & Degree students are recruited)

ARTS - Amara Raja Trainee Scheme (Students from 10th Class, Intermediate and ITI are recruited)

Selection Process

Budget Preparation (Man power requirement)

Approval of Budget from respective LOFs

Job Description

Identifying sources of recruitment

Information provided to VP(HR)

Gathering & Scrutinizing Resumes

Calling for written test/ interview

Selecting Candidates

Joining FormalitiesJob specification Sending Offer Letters & Receiving acknowledgement

MT (Management Trainees) MBAs, B.Tech/BBM/BBA-MBA,GET (Graduate Engineering Trainees) B.Tech, BEAT (Assistant Trainees) B.Com & BATT ( Technician Trainees) All Diploma TradesTAT (Technician Assistant Trainees) BSc

All the trainees undergo one year training and six months probation period.

HRSS – HR Shared Services:

Service matters & Statutory measures:

Service Matters: The executives of this department do the ERP updation of all the details of newly joined, internal transferred or transferred employees to different locations.

ERP details:

♦ Employee Code♦ Employee Id♦ Personal information♦ Family Details ♦ Academic Details

GRADES DESIGNATIONM1 Chairman & Managing DirectorM1 Chief Financial Officer (Group)M2 Vice PresidentM3 General ManagerM4 Deputy General ManagerM5 Senior ManagerM6 Manager/ Branch ManagerM7 Assistant ManagerM8 Sr. Engineer/Sr. ExecutiveM9 Engineer/ ExecutiveS1 Junior OfficerS2 SupervisorS3 Assistant IIS4 Technician S5 Assistant IW1 WorkmanW2 WorkmanW3 WorkmanW4 WorkmanW5 Workman

Management Grades

Staff Grades

Workmen Grades

♦ Experience

Statutory Services : Five major actions are taken care by the statutory service executive. These are:

♦ Provident Fund (PF)♦ Pension♦ Employee State Insurance (ESI)♦ Employment Exchange (EE)♦ Payment of Gratuity♦ Bonus

Time office:

This department is responsible for the maintenance of attendance of all the employees in the Head office and branches. These people deal with Amara Raja Attendance Management System (ARAMS) using software program called ‘Solus’.

Responsibilities:

♦ Collecting photos and details for distributing Identity cards.♦ Opening Bank accounts for newly joined employees. ♦ Informing all the HOD’s to authorize the pending applications before 25 th

of every month.♦ Sending attendance details of all the employees to pay roll for salaries.

Pay Roll:

The executives of this department are responsible for giving the wages for all the employees in the organization.

Training & Development:

. The training needs for Staff and Management grades have been identified through the Electronic Performance Appraisal System (AREPAS).

This department is responsible for preparing the training calendar and schedules for the training programs for the employees across the group companies. Amara Raja Training & Development Calendar.

Training is of two types:

1. On the job training. 2. Off the job training

On the job training (OJT)

   Employee training at the place of work while he or she is doing the actual job. Usually a professional trainer (or sometimes an experienced employee) serves as the course instructor using hands-on training often supported by formal classroom training.

Off the job training

   Employee training at a site away from the actual work environment. It often utilizes lectures, case studies, role playing, simulation, etc.

IBD - QUALITY

Quality Assurance:

Definition of quality:-“The characteristic of a product or service that bear on its ability to satisfy stated or implied needs.” Or it can be simply said as “fitness for use” or ”confirmation to requirements” or “DEFECT FREE PRODUCT”.

Quality of a product or service can be assured if it is free of deficiencies.

The process of inspecting the quality can be done as shown below

a) Inward Inspections:

Initial checks for the machines

Lathing will be done for sample before testing in Optical Emission Spectroscopy (OES) – Determination of major alloy and trace elements in lead and lead alloys.

Atomic Absorption Spectrophotometer (AAS) – Determination of major alloy and trace elements in lead and lead alloys, pure metals, impurities in pasting chemicals and battery electrolyte.

Determination of Thickness of AGM Separators

Determination of wicking of AGM Separators

Acid retention Test of AGM Separator

Determination of Ash content and ignition loss in materials at higher temperatures

Moisture Analyzer for PPCP granules

Determination of Density for PPCP

MFI (Melt Flow Index) tester for PPCP granules

Quality Inspections

Inward Inspections In process Inspections

Izod Impact Tester for PPCP

UTM(Universal Testing Machine) tester for PPCP granules

Verification of Percentage particle size in powder materials

b) In Process Inspection:

Verification of Oxide Properties:

Free lead verification in lead oxide powder

Apparent density of lead oxide powder

Checks in Grid Casting:

Grid Weight Verification by using weighing scale

Grid Thickness Verification by using Micrometer

Checks in Pasting:

Verification of Paste density

In process Inspection

Plate Prepetation

paration

Oxide Preparation

Grid Casting

Jars/Containers Moulding

Assembly

Formation

Finishing & Dispatch

Plate weight verification

Checks in Jars/Containers moulding:

Jar Height measurement during De-Molding-Immediately after Injection Molding

Jar Height measurement after Ageing

Checks in Assembly:

Verification of Group Thickness

Verification of Mounting Height by Verniar

Verification of Jar Height by Verniar

Air pressure Test on Assembled cell

Verification of Cell Dimensions

Checks for Modular:

Lug Crystallization test

Lug to Strap bonding test

Post and Tombstone test

Leak Test on Assembled battery

Checks in Formation:

Acid temperature verification

Acid Volume calibration and PLC setting

Electrolyte temperature verification during formation

100% Capacity verification

Checks in Finishing:

Thermal Thread verification

OCV & polarity verification

Checks in Dispatch:

100% Quantity verification of Connectors

Verification of Accessories in the packing box

Types of customer complaints that ARBL(Amara Raja Battery Ltd) deals with:

CUSTOMER COMPLAINTS

INTERNAL EXTERNAL

(Section-Section checks

Within the organization)

Incoming warranty

INCOMING: Missing of accessories;

WARRANTY: Based on customer needs or specifications.

There are several statistical tools which help in taking corrective actions which are used in Quality assurance department:

♦ Check sheet♦ Stratification♦ Pareto analysis♦ Brain storming

♦ Cause effect diagram♦ Histogram♦ Graphs♦ Scatter diagram♦ Flow diagram♦ Control charts

The types of audits that Amara Raja deals with:

Definition of Audit: The general definition of an audit is an evaluation of a person, organization, system, process, enterprise, project or product. The term most commonly refers to audits in accounting, but similar concepts also exist in project management, quality management, and energy conservation.

AUDITS

INTERNAL EXTERNAL

INTERNAL AUDITS

– To establish whether practices follow procedures

– To highlight required changes to procedures to ensure that they accurately reflect quality practices

– To recommend opportunities for improvements

Internal audits are conducted once in 6 months for HO & COO operations. And once in 12 months for Field operations

TUV AUDITS

– Surveillance audit – every year

– Re-certification audit – once in 3 years

IBD-MARKETING

The marketing department of Amara Raja is divided into six regions headed by six regional managers and is incorporated with 21 branches across India having 31 warehouses, 160 franchises and over 15000 retailers.

The marketing functions and activities that are carried out in COO. Whole Marketing section is divided into three channels according to business strategies

Direct Business

In direct marketing business products are provided directly to customer.

Here flow of product is given bellow

There is no need of Channel for

Railways Telecom Power control OEMs

List of OEM customers:

Ford India Ltd Huyndai Motor India Ltd Maruthi Udyog Ltd Ashok Leyland Ltd Tata Motors Ltd Mahindra & Mahindra Ltd Force Motors General Motors India Ltd International Tractors Ltd Swaraj Mazda Ltd

Marketing Functions/Activities (OEM’s):

Market promotion of the product. Processing of customer enquiries. Preparation and submission of proposals.

MARKETING

CHANNEL BUSINESS EXPORT BUSINESSDIRECT BUSINESS

H.O WARE HOUSE END USER

Processing of purchase orders and purchase order amendments. Monitor product delivery, product performance and service levels to customers. Implementing good housekeeping methods at the related areas. Maintenance of departments records/files, MIS generation of weekly activity reports (WAR) and monthly reports (MR). Customer relationship management.

Channel Business

In this marketing system product flows throw a channel.

Export Business

In it products are exports to outside of country. Our batteries are exported to Singapore , Malaysia , Indonesia , Taiwan , Philippines , Greece , Australia , Kuwait , Dubai , China and Japan .

Export can be categorized into three

Direct Merchant SEZ –Special Economic Zone

Marketing:

The marketing activities are performed to meet the customer’s requirements. The activities include:

Enquiry / Tender Review Submission of Offers Order/ Contract Review Order Acknowledgement Obtaining order amendments Handling of customer complaints Weekly Activity Report Appointment of channel partners Review of pending payments Engineering and Marketing Coordination meeting

Objectives:

Meeting the sales targets as per the business plan Collection of payments as per PO Terms Meeting the customer requirements / expectations

H.O WARE HOUSE FRANCHISE RETAILER CUSTOMER

Providing necessary training programs for staff / customer personnel

Service:

Main activities that are performed by service department:

Ensuring Customer Satisfaction through prompt & efficient service to customers Monitoring Product Performance, feedback to REC for product improvements Marketing Services:

Functions:

To assist in planning and execution of marketing activities Co-ordination with the Advertising agency, Event Management agency, Market

Research agency and Public Relations agency for Promotions and product development

Supporting field offices in promotional activities and events Identifying and Development of Point of Purchases Monitoring Budgets of Promotional spends Generation of MIS reports- Ad spends monthly and quarterly To assist in planning and execution of Automotive, Industrial, Corporate,

International & Group Companies Marketing structure of ARBL

IBD MARKETING:

INDUSTRIAL BATTERY

TELECOM:

In telecom sector we provide our batteries to

Operator- Airtel, Vodafone, BSNL etc. Manufacturer

RAILWAYS:

Railways Sector Rail coach factories Engine manufacturer

POWER CONTROL:

Power sector 1. Generation2. Transmission3. Distribution

Oil and gas Renewable energy Motive power Security

EXPORT: Exports to

Coslight Hopake Fiam ENCIES (G & B) C&D etc

CHANNEL: In Industrial Batteries U.P.S Batteries comes in channel marketing

DIRECT

RAILWAYS P.C EXPORTTELECOM U.P.S

CHANNEL

ZONAL OFFICE:

In every zonal office there is a Zonal Champion (ZC). There are total five ZC.

BRANCH OFFICE:

There is a Branch Manager in each Branch Office.

There are total 15-16 B.Ms. Marketing Engineer comes under Branch Manager.

AQUA:

Aqua is just like a Franchise from where either end-user or Retailer can buy directly

COO

ZONAL OFFICE

BRANCH OFFICE

CUSTOMER

SERVICE

H.O

AQUA

IBD - PRODUCTION

Production of a battery:

About a Battery:

Battery is the portable device producing DC power by electro-chemical reaction. A potential difference is developed when two dissimilar electrodes are immersed in a

conducting solution called electrolyte and a current flow is observed when the terminals are connected.

Battery is an electro-chemical device in which the free energy of chemical energy is converted into electrical energy. Within the battery, we can store chemical energy, and on demand it can be converted into electrical energy to drive an external circuit.

The battery is the fuel tank of Electric Vehicle. It stores chemical energy in the form of reactive species, i.e. (during ‘charging’) and is designed to release this energy as electrical power (during ‘discharging’).

Lead-acid battery occupies prominent place because of its application in the automotive field. The lead-acid battery is the only acidic battery that uses an acidic electrolyte.

Batteries can be broadly classified into primary and secondary, depending upon the reactions involved whether irreversible or reversible and application.

Primary batteries are not capable of being charged electrically and hence discharged once and disposed. The primary battery is convenient source of supplying power to portable electrical and electronic devices.

Secondary batteries can be recharged electrically after discharge to their original condition by passing electricity through them in the opposite direction to that of the discharging current.

Main Components of Battery:

Positive active material – Lead dioxide (PbO2)

Negative active material l – Spongy lead (Pb)

Electrolyte – Dilute sulphuric acid (H2SO4)

Current collectors (grid) – Lead alloys

Separator – Polythene, Glass Mat, Absorb Glass Mat

Container – PPCP, FRPPCP

Alloys used in Manufacturing of Batteries:

Lead:

The major alloy used in lead-acid batteries is lead. The density of casted lead is 11.34, but this may be slightly increased by rolling. The melting point of lead is 327.40C (621 F). It oxidizes readily in the moist air, becoming a dull gray.

Alloying elements to pure lead

Antimony

Calcium

Aluminum

Cadmium

Tin

Silver

IBD Process flow chart:

1 A. OXIDE PREPARATION:

Balox lead oxide plant:

Barton pot process is used to make leady oxide powder. 99.97% pure lead is used to prepare oxide powder.

Oxide plants 1&2 works on Barton process where the lead ingots were melted and oxidized in the presence of air.

The following are the process parameters that are maintained during the preparation of oxide powder.

Melting pot temp : 665±15F Reactor pot preheating temp : 425±15F Normal operation temp : 715±15F Reactor motor load : 35 to 45 amp Bag house temp : 200±20F

Process flow chart:

Oxide Preparation

Assembly

Formation

Plate Cleaning

Grid Casting

Paste Preparation Pasting

FinishingDispatch

Curing & Drying

Process:

Lead ingots are placed on ingot conveyor through jib crane whose max capacity is 500 kgs.

Ingot conveyor is a power driven roller conveyor which conveys the ingots to the melting pot

where the lead ingots were melted with the help of heaters. The temperature is maintained at 650 to 680F in the melting pot. The centrifugal pump collects the molten lead and pumps it to reactor pot through the lead trough.

The molten lead is fed into the reactor pot and is broken up into droplets by revolving paddle. A stream of air blown over the droplets oxidizes the lead. In the classifier the required particle size range is separated and the coarser material is returned to the reactor pot.The resulting oxide powder is carried by air stream into the cyclone where the powder further disintegrated due to the whirling action.Then it is moved to bag house which consists of number of filters. It separates the air from the powder without the loss of oxide powder. silos were used to store the leady oxide. Each silo is having a capacity of 25 ton. oxide powder is stored in the silos before the paste preparation.

The following are tested to evaluate the quality of leady oxide.

1. Free lead percentage (specific limits are 18 to 28%)2. Apparent density (specific limits are 1.3 to 1.8gm/cc)3. Acid absorption(specific limits are 160 to 200mg/g)

1 B. GRID CASTING:

Lead ingots Melt pot

Reactor pot

Cyclone

Bag house

Storage silo

Model 330c grid casting machine Melt the ingots in the lead pot. Maintain the lead pot at a temp of 475 to 525F. Start the feed line heaters. This molten metal is pumped to the ladle through solenoid valve. This actuates the lead valve to dispense the lead into the mould. Ladle is maintained at a temp of 450 to 500F.

Cooling circulation system feeds cold water during the solidification and ejection of mould.

The casted grid is passed through the rollers to make it flat or to remove any deformation in the grid.

Grid centering mechanism centers the grid. Hydraulic mechanism actuates the trimmer which removes the gates of grid.

Types of grids:

1.Power stack type --- 20, 30, 40, 50, 60, 80, 90

2.IP series --------------- IP1, IP2

Common defects in grids

High thickness Low thickness Shrinkage Miss trimming Blow holes Flashes Wire missing

Testing of grids : Grid thickness, Strength, Weight.

Bend Test:

To find strength grid is bent and checked for any cracks and then at 90 degrees to the first. If there are any consecutive cracks, then it will be rejected.

BUS BAR CASTING:

The copper inserts are threaded into the holder and are dipped in flux for 5sec. Then dip these inserts in tinning pot for 30sec. This tinning pot consists of molten alloy off tin-lead (40-60).

Place the insert along with the holders in the mould. Pour the molten lead alloy with 2%tin pouring should be completed in a time a span of 8-15sec.the molten metal is

solidified the mold and they can be removed form the moulds. The bus bars are removed formed from the holders.

The tinning pot is maintained at a temperature of 320±250C while the lead crucible temperature is 460±150C. These bus bars are sent for group burning is assembly stage.

2. PASTE PREPARATION:

For Positive Paste:

Lead oxide 1000kg Binder 0.5Kg SPTH 2Kg DM water 126lt Sulfuric acid 110kg(Sp. gravity 1.4)

For Negative Paste:

Lead oxide 1000kg Binder 0.5Kg Barium Sulphate 20Kg Vanisperse 2Kg Carbon Black 2Kg DM water 116lt Sulfuric acid 110kg(Sp. gravity 1.4)

Process flow chart:

Binder Oxide dumping Dry mix

Acid dumping

Wet mix

Water dumping

Final mixingPaste

For Pasting

Quality tests for paste:

1. Density test2. Penetration capacity3. Moisture content

PASTING:

Pasting is done on Industromac pasting machine. Paste mix prepared in the oxmaster plant is transferred to the hopper of the pasting machine. Ensure that the grids have under gone aging for +ve 24 hrs.

Fill the hopper 3/4th each time. Grids were made to pass through with the help of conveyor. Paster pastes grids to a thickness equal to orifice opening. It is the gap between hopper orifice plate and bottom orifice

plate. As the grid panel gets close to hopper’s entrance it is pulled away from chain dogs by a set of accelerator rollers. The panel is then pushed into drive rollers that move it into paste application area. The paste is applied through the grid structure by paste feed roller that is located in upper orifice plate. The bottom orifice plate rollers trowel the paste on the underside of grid.

After stacking, the stacked plates were transferred to curing and drying ovens. Before that the plates are to be undergo aging period. Curing and drying is the process by which satisfactory levels of cohesion and adhesion are imparted to the active material prior to plate formation and are maintained there after. In addition, curing ensures a highly developed surface area.

4. CURING AND DRYING:

Curing and drying is done at three stages. .

Curing Intermediate stage Drying

Curing and drying process is carried out to impart cohesion and adhesions are imparted to the active material

prior to formation. Curing is determined by the nature and degree of interlocking between the crystals of the paste. Adhesion is dependent upon the strength of the bond, which is formed between the paste and the grid. These essential properties are the best accomplished by conducting the curing procedure in the following sequence.

Steaming period: Steam is applied to equalize the moisture content in all the plates and it supports for the development of lead sulphates.

Drying process is to bring down the water content (moisture) to the low level for the active material to have good stability.

During the process physical, chemical and morphological changes take place within the active material.

5. ASSEMBLY:

Process flow chart:

Plates, Separator,

Top shieldsGroup Stacking

Jars

Group Burning

Group Strapping

Post Burning

Heat Sealing

Group Insertion

Leak Testing

Covers

Bus Bars

Duff Cells

A. Group stacking:

Bottom shield is place in the fixture this prevent the plate damage. First an unwrapped negative plate is placated the in the fixture. Then a half-length separator is placed on the negative plate.

The separator is sheared by activating the cutter blade after getting the predefined length.

Then positive plate is place and separator is folded over this plate. Place the half-length separator on the last positive plate and then place unwrapped negative plate on the top of the half length separators complete the stack.

Shields are provided on positive plates to avoid direct contact between positive and negative plates.

B. Group burning:

Aligning of bus bars with lugs is called group burning. By using the protection of jigs these combs can be shield rightly. Adjust the oxy-acetylene gas torch for neutral flame and length of inner cone is 2.5cm Positive strap is burnt first as if requires more time for cooling. The molten metal is stirred with them. The post protection jigs are chilled with D.M water and then they were removed.

C. Group strapping:

Plates were strapped on strapping machine with poly-propylene. These straps held the stacks together.

D. Group insertion:

The strapped plates are inserted into jars/containers shield in wrapped on the plates before insertion.

E. Heat sealing:

The cover is placed over the jars such that the posts can slide inside the bushing. The heaters are maintained at a temperature of range 440-480F. First takes 10sec for melting and other 10sec for welding them together.

The covers must be positioned so that the polarity marking on the cover corresponds to proper post/busing location.

F. Post burning:

Fix the dummy vent plug. Copper inserts were pre-heated using inner flame until the post lead starts melting. Orthophosporic acid is applied on post and bush of the cover. Continue the process until good surface is obtained.

G. Leak testing: The pressure inside the cell is increased to 65kpa for the range of 20-30sec. while it is placed in water bath. Observe for air bubbles if any leak exists mark the area for rework. If vent is weak replace the vent.Serial number is punched on the cell

Ex: 07 1/2 999999

07 indicates year

1/2 indicate assembly line

999999 indicate type or model (i.e. the no of battery coming out of the line in the year)

6. FORMATION:

Cell packing:

The cells are placed in tub and packed with PPCP spacers and strapped with metallic bale the cells are connected in series using cable connectors and bolts.

Process flow chart:

Duff Cell Acid Filling

Initial Charge

Formation Discharge

Capacity Recharge

Capacity Discharge

Formation Charge Back

Float Charge Formed Cell

Acid filling:

At the first the volume vessel is filled up to the present volume. The cycle starts by pulling the vacuum in the battery until preset vacuum level is reached. Then the acid is transferred from volume vessel to the expansion vessel.

The venting valve provided on top of the machine will open and because of vacuum in the battery causes an air stream which will force down the acid into the battery. If there is still electrolyte in expansion vessel another vacuum pulse will be pulled.

7. FINISHING & DESPATCHING:

The formed battery is closed with vent plug and washed with water to remove any acid present in the battery container outside.

Then it is checked for their prescribed integrity in “ON-LINE HIGH RATE DISCHARGE” tester. The batteries, which satisfy the specification is packed and labeled.In dispatching the cells were packed and the necessary accessories required for functioning of the cells is supplied to the customer. The accessories include connectors, bolts, washers, cables etc.

This finished product is sent to Market through shipment by lorries, trucks, etc.

IBD – PRODUCTION

ENGINEERING

Company’s production engineering

After the order of the products from the customers reach the marketing department, the entire details will be given to Production Engineering people. The various departments in Production Engineering are as follows:

Product Development:

This department is responsible for

Design and development of a new product as per the specifications given by the customer.

Major design changes in the existing product.

Creation of master product structures in SAP.

Process Improvements:

To change the existing process of designing to increase the efficiency.

This department is completely responsible for process FMEA, Process Audits.

Application Engineering:

Design and development of Accessories such as containers of batteries will be done.

Battery sizing.

New application study of the products will be done.

Production Engineering

Product Development

Process Improvement Application Engineering

IBD – RESEARCH AND

DEVELOPMENT

Company’s R&D

The Company’s research and development focuses on futuristic energy solution that enhances the price-value proposition. The R&D team consistently focused on technology excellence, creating products complying with exacting standards and customer needs.The Organization structure of R&D is as follows:

1) Fundamental Material Development 1) Testing department

Studies department 2) Process Development

2) Calibration Lab

3) Chemical Lab

Fundamental Studies Department:

This department is completely responsible for impact analysis of the change that will be done. For example, if the composition of the lead alloy in the battery should be changed and tasted, then the impact of that change need to be analysed and study reports should be prepared.

This impact analysis will be given to Material Development department.

Calibration Lab:

Instruments used will be checked in the lab to obtain accuracy.

Chemical Lab:

Reports of chemical analysation will be prepared.

Material development:

VP

DGM

Manager Engineer Manager

This activity is basically for improving product performance. The responsibilities in this department are

Checking the output of the battery after replacing the main component of the battery with alternative material.

Receiving the existing materials from new suppliers and checking.

Developing different combinations of lead and other components.

Testing Department:

Bench marking of competitor batteries will be done.

Developing testing environment and conditions as per the customer requirement.

Process Development:

Development of import substitutions and new products for different applications.

IBD-FINANCE

CONCLUSION:

Finally I would like to conclude that the institutional training helped me in enhancing the practical knowledge as well as to gain personnel skills to sustain in the organisation.

I have observed some aspects that in followed in the ARBL like the discipline , the culture in the organisation, working environment, code of conduct, and the facilities provided and also the safety measures and ecological safety taken at the workplace.

Amara Raja batteries Limited follows the hierarchial organization structure, wherein when subdivided follows the divisional structure, where the organization is divided into business units with its managers headed by the MD, with its respective functional lines under business unit heads.

This structure suites the flow of the organization as it has main advantage where each division is free to concentrate on its own performance.