1.

INTRODUCTION TO THE INSTITUTION

Nature of the Institution

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
MAGNETICS LIMITED” in the year 1974. In 1977, Keltron acquired the majority
shareholdings of promoters and consequently the name of the company was changed to
“KELTRON ELECTRO CERAMICS LIMITED”.Production of Disc Ceramic Capacitors
was started during 1978 using NPL Technology.The company is also manufacturing NTC
Thermistors ( based on our in house R&D), Metal Oxide Varistors, Piezo Ceramic Buzzers,
Electronic Flashers ,Transducers etc The company started functioning in the year 1974.
Production of Disc Ceramic Capacitors was started during 1978.The company is also
manufacturing NTC Thermistors ( based on in house R&D), Metal Oxide Varistors, Piezo
Ceramic Buzzers. As a part of diversification, the company entered into the manufacture of
custom built Transducers for NPOL and Indian Navy . The company has already executed
Transducer orders worth Rs.901.52 lakhs during the period 2001-02 to 2008-09 and is
envisaging a turnover of Rs.400 lakhs during the year 2009-10. Besides NPOL , the
company is associating with NSTL Vaisakh, NIOT Chennai, Cochin University of science
and Technology (CUSAT) for Transducer orders. The company is expecting good orders
from the above agencies in future also. Another break through in this field is the entry in
BHARATH ELECTRONICS, Bangalore. The company has already received orders for
Moulded Junction Box, HF Stave and LF Stave worth Rs.75 Lakhs.

Personnnel And Administration

The development of the organaisation largely depends upon its workforce. And the human
resource department of the organisation has a great role to play in this. They are the one who
are mainly concerned with the planning of the manpower requirement,organising the
manpower resources,staffing,motivating and controlling them. Thus they are the one who put
the right perso to the right job, motivate the existing employees in order to retain then and
help them to adopt to the changing environment

In the KECL the major function being discharged by the personnel department are

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  Recruitment and placement
 Training employees
 Maintaining of computer section
 Pay and allowance
 Employee benefits
 Other function

Recruitment and Placement

The personnel department has to ascertain clearly the type of person required to fill
the vacancies. KECL is now adequately staffed. And in the organisatio, employees for the
purpose of the selection are divided into three categories. That is (i) Executive (ii)Supervisors
(iii)Workmen. They may be technical or non technical(office staff)

All the workmen except the technician are appointed through PSC and the technicians
are appointed through employment exchange. The qualification required for technical
workmen is that they must have passed from a recognised institute.

The executives and supervisors are recruited through public advertisements.

Executives are generally selected by the coporate office and they must have professional
qualifications. And the interview for the supervisors is conducted in the company itself and
they must atleast hold a diploma in engineering. Every employee has to undergo probation
period of six months training joining.

Training

Once the applicant is selected the organisation has to provide adequate training. Her
the company gives on the job training by which the employee will be benefited . In KECL the
company is providing inplant training, on the job training etc

The newly appointed workers are given on the job training,which may range from one
week to one month. There is also a corporate training department centred at Trivandrum. The
employees will be nominated for attending seminars and class and also some times
executives from other institution to take classes here. This is more helpful as more emplouees
can attend to it.

In Charge Of Computer Section

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 The personnel department head of KECL is the one who controls the computer
section also. All the computer are connected through the LAN and the company is on its way
to computerise every operations and departments.

Performance Appraisal

Performance appraisal is a great asset in the development of human resources in an

organisation. This help in getting a feed back about the employees performance. In KCEL
annula appraisal is done by immediate superior followed by department head and finally by
chief executive. Tha reason for poor performance if any is taken care of

Pay And Allowance

There is a long term settlement arrived by the managmnet of KCEL with the trade
unions.

Welfare Activites

 Festival advance: the employees along with their salaries will be given festival
benefits once ina ayear which has to be paid back in 10 installments without any
interest
 Medical advances: if the employee or his dependants are hospitalised hi s one month
salary will be given to him. Those employees who are not covered under ESI act(ie
earning less than Rs.6500)will have a re-imbursement scheme, which amount to his
one month basic pay plus DA for a financial year. Its unavailed amount will be carried
forward only two years.
 House rent allowance: In KECL 10% of basic pay is allowed as housing rent
allowance.
 Canteen: The KCEL canteen is run on contract basis which provides subsidy for food
and 50% for snacks and 100% for tea
 Marriage advance:This can be available for the workers themselves and it amounts to
2 months salary plus DA playback in 10 instalments with no interest
 Funeral advance: An amount of 1 month salary plus DA payback in 8 instalments
with no interest can be availed even for spouse and children.
 Higher education allowance: In the month of june, Rs. 1000/- will be given to workers
whose children are studying. And if the workers themselves go for higher education in

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 his field a lump sum of 60 increments out of the present grade wil lbe given. And this
is applicable only to workmen and not to any executives or supervisors
 Group insurance scheme:Employees are covered under this scheme as follows
workmen- 50,000;others-1,00,000.

Other Function
The company also provide a pair of uniform to all the workmen in the production
floor except office staff
In case of absenteesim disiplinary action will be taken according to the standing order.
The number of casual leaves granted to the worker is 12 days in a year. Besides this
there is 10 days sick leave. One can (encash)30 days earned leave in an financial year.

Promotion
Regarding the promotion of the workera, an agreement is reached between the trade
union and management. And it is generally based on the employees past
performance,discipline ,year of service, educational qualification and attendance.

Trade Unions
The relationship between the managemnet and the trade union in KECL is very
cordial. And the management is of democratic one. All the important decisions regarding the
workers are taken in consultation with trade union leaders. The main union in KECL is
(i)keltron employees association(ii)keltron employees union (iii)keltron employees
organisation

2. ORGANIZATION STRUCTURE AND MISSION

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 KELTRON

Software Projects Electromechanical

Projects

Embedded Project
system & Assistance Capacitor Transducer
VLSI

Windows Thermistor
Based
Application

Personnel &
Personnel & Administration
Administration

Purchase
Finance
Marketing &
Planning
Stores

Testing Marketing &

Planning Planning

QA
Maintenan
ce

Vision
 To rebuild KELTRON into Rs.1000 crores company in five years time frame and
make it a NAVARATNA of the country.

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  To be a world-class enterprise in professional electronics
Mission
 To be a customer focussed, globally competitive company in defence electronics
and in other chosen areas of professional electronics, through quality,technology
and innovation

Values
 Putting customers first.
 Working with transparency, honesty & integrity.
 Trusting and respecting individuals.
 Fostering team work.
 Striving to achieve high employee satisfaction.
 Encouraging flexibility & innovation.
 Endeavouring to fulfill social responsibilities.
 Proud of being a part of the organization

Objectives
 To be a customer focused company providing state-of-the-art products &solutions at
competitive prices, meeting the demands of quality, delivery &service.
 To generate internal resources for profitable growth.
 To attain technological leadership in defence electronics through in-houseR&D,
partnership with defence/research laboratories & academic institutions.
 To give thrust to exports.
 To create a facilitating environment for people to realise their full potentialthrough
continuous learning & team work.
 To give value for money to customers & create wealth for shareholders.
 To constantly benchmark company's performance with best-in-classinternationally.
To raise marketing abilities to global standards.

Awards and recognitions

 National productivity Award for 1988-89 under large scale electronic components
from National productivity council, New Delhi.

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  ELCINA Award for 1993 for excellence in Research and development for work
domain in the field of forming technology.
 Department of scientific, industrial research and ministry of science and technology ,
Government of India approval for inhouse research and development.
 ISO 9001+2000 certification from M/S intertek US.

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 3.PRODUCTS

Production can be defined as process or procedure of transferring a set of input

elements such as material, capital, man power, information and energy into specified output
elements such as finished products in proper quantity and quality to achieve the objectives of
an enterprise. Production is the basic function of a company. So production should me
managed effectively and efficiently.

In Keltron mainly following are produced:

 Ceramic Capacitors
 NTC Thermistor
 Transducers

Production department of KECL is divided into small different departments with various
managers to control and supervise them. Thus there is production department division 1
(PD1) which is concerned with the production of capacitors and production division 2
(PD2)which is concerned with the production of NTC thermistors and metal oxide varistors
and finally the Transducer division which is concerned with the production of transdusers,
buzzers, flasher, surge protector. KECL has well equipped manufacturing setup and well
trained personnel in various levels of production.

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3.1. PRODUCTION DEPARTMENT- DIVISION 1 (PD1)

CERAMIC CAPACITORS

Keltron offers a wide range of low cost disc type ceramic capacitors for application in
Television, communication, push button telephones and other electronic equipments. These
capacitors are available as Class 1, class 2 or class 3 types with working voltage ranging from
16 V to 2 KV.

 Class 1: Temperature compensating

 Class 2: High dielectric constant
 Class 3: Semiconductive type

For class 1 and class 2, voltage range is from 63 V to 2 KV and for class 3 voltarge range is
from 16 V to 63 V.

Technical characteristics of capacitor :

 Working voltage range: For class1 and class 2, range is from 63V to 2KV
For class 3, range is from 16V to 63V
 Temperature range: -40 to 50 degree celcius
 Capacitance value: 1pf to 470 Kpf

RAW MATERIALS

The basic raw material used for the manufacture of ceramic capacitor is dielectric disc which
is round in shape and act as insulator. This disc is coated on both sides by silver which act as
electrode. The other raw materials are silver solder paper base(18.5 mm or 15mm), cap coat
powder, solvents (methanol, aceton, benzene), copper wire(0.6mm), adhesive tape, crape
paper etc.

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 CERAMIC CAPACITOR ASSEMBLY FLOW CHART

PROCEDURE

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  STORE SECTION: When the raw materials are reached in the store, the store
authority informs the quality department for inspection of the same. On getting the
approval from QC the store authority stores it in a proper lace and manner.
 LOOPING: The raw materials are tinned copper wire adhesive tape and paper base.
The tinned copper wire is passed through the looping machines along with the paper
base and crape paper in specified directions thereby forming it into a stripof 30 loops
and this process is called as wire forming. The dye of machine cuts and bend the
copper wire in specified shape. This material is used as the lead of the capacitor.
 DISC LOADING: Here the strip after looping is passed to disc loading machine where
the ceramic disc is loaded into the top of the strip by inserting it into the loop. This
disc is a chemical composition of barium titanate. This composition is mixed with
gum of polyvinyl alcohol dried and fired in the temperature of 1200 degree celcius,
the material is taken into tabulated machine for disc making. Silver oxide is pasted on
both sides of disc which act as electrodes and then it is heated at 80 degree celcius.
Thus we get the silvered disc and its capacitance value depends upon diameter,
thickness, and chemical composition used in that particular disc.
 FLUX DIPPING AND SOLDERING: The disc loaded loop is dipped in a flux solution
(a mixture of 30gm of resin dissolved in a litre of benzene). This gives a strong
seating to the disc in between the loop. After dipping the strip into the flux , the strip
goes to the preheating chamber where it is heated at 100-110 degree celcius. This is
done to prevent the thermal crack of material when it passes from a normal
temperature to a high temperature of 200-210 degree celcius for soldering purposes.
Then the material goes for a dip in molten solder which is a mixture of led and tin.
 CLEANING: the soldered product is washed in isopropyl alcohol to remove al the
impurities if any left after soldering.
 ENCAPSULATION: The soldered disc after inspection goes for encapsulation. The
soldered disc are dipped in a phenolic resin in order to protect the capacity elements
from the environment to give insulation. The solution for encaping contains a mixture
of aceton, methyl ethyl ketone and industrial solvent which is mixed together for 8
hours to form a paste and soldered disc is clipped to this mix and kept for overnight
drying.
 BAKING: The capacitor is heated at 150 degree celcius for 2 hours .

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  VALUE MARKING: The baked capacitor after inspection is then taken for value
marking and printing. The value is printed as 100pf, 200pf etc. Along with the value,
manufactures logo, temperature characteristic and working voltage is also printed.
 LEAD CUTTING AND SORTING: The unwanted leads of the capacitor are cut and
the product goes fo sorting. This is being done to measure the actual capacitance
value in pf and leakage current. After this a high voltage breakdown test is conducted
for each capacitor.
 FINAL INSPECTION: After completing the test of electrical parameters, the products
are taken by Q.A department for the final inspection and if they are satisfied with the
quality they issue a Q.A approved certificate. Then the product is taken for packing.
 PACKING: Packing of product is done manually and it may be of 3 types. The first
one is Ammo packing where product is packed in strips of 30 capacitors in a zigzag
manner and each ammo pack consist of 2000 capacitors.this is the most commonly
used method of packing. Second is real packing where the capacitors are packed in
the form of a reel. Some manufactures may not want their product in a strip. Third is
loss packing in the form of packets. The packet contain code number, value,
tolerance, date of packing, Q.A remarks.
 FINISHED PRODUCTS: After the production is completed , the Q.A department
makes a store credit note and passes it to the stores. People from store take the
finished products from the production department and keep it in the store. Marketing
department issues a despatch billing advice to store and based on this goods are
despatched from the store.

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3.2. PRODUCTION DEPARTMENT- DIVISION 1 (PD2)

NTC THERMISTOR

Thermistor is the short form for thermal resistor. A thermistor is a type of resistor whose
resistance varies significantly with temperature. Thermistors are widely used as inrush
current limiters, temperature sensors, self-resetting overcurrent protectors, and self-
regulating heating elements. Thermistors are of two types, PTC (positive temperature
coefficient) and NTC (negative temperature coefficient). In the PTC, resistance is directly
propotional to the temperatureband in NTC, it is inversely propotional. NTC thermistors are
used

 as resistance thermometers in low-temperature measurements of the order of 10 K.

 as inrush-current limiting devices in power supply circuits.
 to monitor the temperature of an incubator.

Technical Characteristics

 range: 1 ohms to 680 k ohms.

 Tolerance: +/-3% to +/-20%
 Wattage: 0.65 to 3.5 watts

RAW MATERIALS

The basic raw materials used for production of NTC thermistor is manganese carbonate,
nickel caronate, cobalt carbonate and copper oxide.

THERMISTOR ASSEMBLY PROCESS CHART

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 Weig-hing 1ST milling Filteration drying Pre fi-ring 2nd milling Filter-ation

drying

RM STORE
PVA mixing

Granul-ating

Looping Soldering ng Cleaning inspectio Coating

n
Tabletting

Value marking Lead cutting

testing inspection baking

inspection

Sinte-ring

Disc cleaning
FG STORE

inspection

packing inspection Value testing Silver printing

inspection

PROCEDURE

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  RAW MATERIAL WEIGHIING: Raw materials are weighed using balance. Here the
major raw materials include chemicals like manganese carbonate, nickel carbonate
and copper oxide are mixed in hydrogen oxide in an appropriate ratio.
 FIRST BALL MILLING: The mixture formed is milled with ceramic or stainless steel
bals, chemical and water. This is done with the help of rollers. This process continues
for 4 hours.
 FIRST DRYING: Then the product is filtered and kept into oven for drying at a
temperature of 120 degee. After this process, the mixture will turn into the form of a
cake.
 CALCINING: The dried mixture is fired in prefiring furnace. This is to convert
carbonate to oxide stateband the furnace temperature is around 850 degree. This is
done for two and half hrs and the product is black powder.
 SECOND MILLING: This process is same as that of first ball milling with only
difference that, here duration is 8 hrs.
 SECOND DRYING: After second milling, the product is again dried in the oven.
 BINDER ADDITION: The mixture is then mixed with poly venyl alcohol known as
binder and heated in oven at 120 degree for half hours. Then it powdered, this process
is known as granulation.
 TINDERING: the powder is then changed to tablets by punching and drying. Tablets
may be of various diameters and thickness like 16,14,12,10,5,3 which largly depends
on the order from customers. In this process tablets are burned at 1200 degree to
remove PVA which goes by 600 degree.
 ELECTRODING: The tindered discs are cleaned by zircon sand. Afterwords using a
screen printer and appropriate screen size the tindered tablets are electrode on both
sides using silver paste. For this the disc is mounted on a magazine which is kept
above the vaccum pumb on the screen printing machine which contain a scxreen
inside over which a silver paste will be there and this will be pasted onto the disc
using a blade inside the printing machine.
 SILVER FIRING: After plating of silver, the disc is heated under infra red rays and
then fireed at 800 degree.
 DISC SORTING AND TESTING: For sorting and testing the disc is tested at a
standard temperature of 25 degree. The thermistor are sorted as per their specification
when the room temperature is exactly 25 degree. For this we have a thermometer to
measure the temperature inside the room and the air conditioner is adjusted to

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 maintain the temperature at 25 degree. The value of disc increases with increase in
temperature and viceversa. The temperature character is set according to the customer
need.
 PACKING: If the customer needs the thermistor as discs, then it is packed in small
polythene packets. If customer needs coated thermistor, then disc is passed for powder
coating, then the coated thermistor is soldered, coated and value is marked. The
packet contains the resistance value, batch , quantity, tolerance and power rating of
disc.

3.3. PRODUCTION DEPARTMENT- DIVISION 1 (PD3)

TRANSDUCER

A transducer is a device that converts one form of energy to another. Energy types
include (but are not limited to) electrical, mechanical, electromagnetic (including light),
chemical, acoustic or thermal energy. While the term transducer commonly implies the use
of a sensor/detector, any device which converts energy can be considered a transducer.
Transducers are widely used in measuring instruments.

Efficiency is an important consideration in any transducer. Transducer efficiency is defined

as the ratio of the power output in the desired form to the total power input

SONAR

Sonar (originally an acronym for SOund Navigation And Ranging) is a technique that uses
sound propagation (usually underwater, as in submarine navigation) to navigate,
communicate with or detect objects on or under the surface of the water, such as other
vessels. Two types of technology share the name "sonar": passive sonar is essentially
listening for the sound made by vessels; active sonar is emitting pulses of sounds and
listening for echoes. Sonar may be used as a means of acoustic location and of measurement
of the echo characteristics of "targets" in the water. The study of underwater sound is known
as underwater acoustics or hydroacoustics. Sonar may be used as a means of acoustic
location and of measurement of the echo characteristics of "targets" in the water. Acoustic
location in air was used before the introduction of radar. Sonar may also be used in air for
robot navigation, and SODAR (an upward looking in-air sonar) is used for atmospheric
investigations. The term sonar is also used for the equipment used to generate and receive

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the sound. The acoustic frequencies used in sonar systems vary from very low (infrasonic) to
extremely high (ultrasonic).

Keltron Electro Ceramics Ltd is one of the Transducer manufacturing company in India.
They are manufacturing Piezo Ceramic based (PZT) Transmitter/Receiver and receivers for
air and under water .

PZT contains Lead, Titanium and Zirconium and is made by company named Sparkler in
India.

Product ranges:

Transmitter/Receiver

Frequency : 5kHz to 80kHz

Transmitting response : 100dB to 150dB ref 1upa/v @ 1mtr

Receiving sensitivity : -170dB to -200dB ref 1V/uPa @ 1mtr

Receivers :

Frequency : 10Hz to 80Hz

Receiving sensitivity : -170 dB to -210 dB ref 1V/uPa @ 1mtr

Sonars are divided into two: active and passive

Active sonars includes both transmitting and receiving sections and is commonly known as
transducers.

Passive sonars have only receiving section and is called as hydrophones.

Active sonars

1) High frequency transducer element

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2) Under water communication system
3) Under water telephone
4) Anti torque detection system
5) Marine hunting sonar
6) Flux tensional transducer element
7) Low frequency transducer element.
8) Vector sensor
9) LFDS transducer array
10) NP30
11) High frequency wide band transducer
12) 3D projector
13) Electro acoustic test projector

Passive sonars

1) Radially polarized Type A hydrophones

2) Radially polarized Type B hydrophones
3) Radially polarized Type C hydrophones
4) Radially polarized Type D hydrophones
5) Radially polarized Type E hydrophones
6) Passive sonar array hydrophone
7) Program based ground mine detector
8) Tadpole hydrophone
9) Seismic hydrophone
10) Mini bouy
11) Sanjeevani life detector
12) Vertical array hydrophone assembly
13) Digital array
14) 12 element hydrophone assembly
15) HF Stave Assembly
HF STAVE ASSEMBLY PROCESS CHART

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 Crystal Pairing stacking Temerory
soldering

torqueing

heating

Aging 21 days
Wiring &
varnishing

Testing parameters

Finished stack

Moulded Horn Stress rod fixing Horn assembly

Aging 7 days Torqueing

Female
connector & Assembled tuning
holder fixing cup

Moulded cup Element assembly

Coil inserting
Finished Stave asembly
stave

Acoustic Parameter stencling Pressure test

test checking

4. QUALITY AND CUSTOMER CARE

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4.1. QUALITY ASSURANCE AND MAINTENANCE

It is an important element which determines the success of company. If the product is of

good quality the customers will always place order for it which in turn affects the company’s
rate of production.

Quality policy

The quality policy of KECL as per ISO 9002 is that “ the management and employees of
KECL are committed to provide products satisfying all the stated needs of customers”.

Functions

The quality assurance has to do the following functions:

 Inspections
a) Receiving inspection
b) In process/ patrolling inspection
c) Outgoing inspection
 Quality ratings
 Quality complaints

Inspection

Inspection is a continuous process as far as an industry is concerned. It is done from the time when raw
materials enters the store till it goes as finished products. Thus it is never ending. And generally the
Q.A. conducts the inspection in three stages .

a) Receiving inspection
Whenever goods are purchased from outside the Q.A. department takes the raw materials for
inspection. This is generally done to ensure that the products being purchased from is as per
the order placed.
b) In process inspection
The materials are also inspected from the shop floor. This is also called patrol inspection
because it is similar to a policeman patrolling the city to check whether there is any
mishappening. similarly the inspector of Q.A. department identifies the process stages and
determines the parameters to be checked during patrolling inspection.
c) Final inspection

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 The manufactured product from the production passes to store and from there it reacts Q.A.to
check quality with reference to entries in register. Here also sampling plans are used for
deciding the quality. The inspectors carry out the inspection and compare the result with
standards set if the product is up to the, accept the lot otherwise reject. If deviations are minor
report to Q.A. (HOD) with appropriate recommendations and if deviations are major refer to
NCRB for disposal.

Chart

ISO 2500 – Part I 1992

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 General inspection level II

Max no.of
Lot size Code Sample rejection
Letter size allowed

2-8 A 2 0

9-15 B 3 0

16-25 C 5 0

26-50 D 8 0

51-90 E 13 0

91-150 F 20 0

151-280 G 32 0

281-500 H 50 1

501-1200 J 80 1

1201-3200 K 125 2

3021- L 200 3
10000

10001- M 315 5
35000

35001- N 500 7
150000

150001- P 800 10
500000

500001- Q 1250 14
above

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 (1) Attributable sampling – where the decision as to be accept or reject the lot is made on the
basis of number of defects found in that particular lot and there is chart which sets the
maximum rejections which can be made from a particular batch. If the lot contains more
than the standard set , the lot is rejected. The chart is prepared as above.
But if it is not possible to measure the standard to be accepted or rejected on the basis of
attribute sampling we go for another type of sampling known as variability unknown
standard deviation method. Here the quality of product is given prime importance. This is
also prepared on the basis of standard set in a chart.
Chart
ISO 2500 Part II-1965
AQL 0.65%. Single planning level – I
For variability unknown – standard deviation method

Sl.No Lot size Sample size K’ value S/U–L

value
1 2-8 3 - -

2 9-15 3 - -

3 16-25 4 - -

4 26-50 5 1.63 0.294

5 51-100 7 1.75 0.266

6 101-150 10 1.84 0.248

7 151-300 15 1.91 0.235

8 301-500 20 1.96 0.229

9 501-1000 25 1.98 0.225

10 1001-3000 30 2 0.223

11 3001-10000 35 2.03 0.220

12 10001- 40 2.03 0.219

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above & Research Centre 23
Acceptance Criteria

1) Value of the expression on S/U-L) should be less than or equal to the value specified in the
chart for a particular sample size.
2) The value of expression x+k* s should be less than or equal to the upper tolerance limit.
3) The value of expression x-k’s should be greater than or equal to lower tolerance limit.
Where x=AM of sample lot
s=SD for the sample
U=upper tolerance limit
L=lower tolerance
The Q.A department along with the help of other departments and inspectors conducts the
inspection and records results and compare the actual results with the standard set up and note
down the deviations of any. If the material is as per standard then Q.A passed label or sticker
which is green in colour on the GRCIR (Goods Received Cum Inspection Report)in the
presence of OIC (stores) or his authorized and Q.A accepts the lot. If the product is not as per
standard then a red stcker is fixed on GRCIR form and send to stores. If the defect is
negligible Q.A generally accepts the lots back but information regading this will be send to
customers.
d) In process inspection
The materials are also inspected from the shop floor. This is also called patrol inspection
because it is similar to a policeman patrolling the city to check whether there is any
mishappening occurring anywhere similarly the inspector of Q.A. department identifies the
process stages and determines the parameters to be checked during patrolling inspection. And
the head of Q.A department specify the predetermined interval for inspection for each
identified process and conducts inspection during this interval and make reports regarding the
same. And if there is any deviation or non-conformance is noticed the inspector informs the
supervisor of the department and ask him to rectify the mistake. Supervisor then stop the
process and rectify the mistake in time so that if may not spread to other production process.
The supervisor then identify and segregate the products produced immediately after in
process inspection and checks the quality and if satisfied pass it to further processing. NCRB
determines the disposal action for non – conforming products if any. Inspectors again verify

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 the process modified to eliminate non – conformance during next schedule visit. Records
regarding inspection is kept by HOD(Q.A).
The in process inspection is carried out for the following stages:
 Looping
 Soldering
 Coating
 Baking
 Printing
 Sorting
 Packing
There is no compromise for quality at this final stage because it ultimately passes to
consumers. It’s carried out for the finished products. The inspection is also based on sampling
and it is according to an AQL chart. For eg: The AQL chart for 2 lot sizes is as follows:

Lot size Sample size Max. no of rejection

allowed

0 - 20 All 0

301 – 1000 80 1

But in all this stages of production process the quality assurance checks the quality of the
products and rejects defects if any.
e) Final inspection
The manufactured product from the production passes to store and from there it reacts Q.A.to
check quality with reference to entries in register. Here also sampling plans are used for
deciding the quality. The inspectors carry out the inspection and compare the result with
standards set if the product is up to the, accept the lot otherwise reject. If deviations are minor
report to Q.A. (HOD) with appropriate recommendations and if deviations are major refer to
NCRB for disposal.
Quality ratings
This is another important function of Q.A. This stage helps in rating the product according to the
quality. Thus
Q1 = Quantity accepted
Q2 = Accepted with deviation

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Q3 = Quantity accepted with rework/ segregation
Q4 = Quantity rejected
QL = Line rejection
QR = (1.0*Q1+0.8*Q2+0.5*Q3+0.00*Q4-1*QL*100)/(Q1+Q2+Q3+Q4)
And this process gives assurance to the customers that the final product coming to his hand is of good
quality
Quality complaints
KECL provides a good mechanism for re dressal of complaints from customers in time. For this they
prepare a parito diagram in which the complaints coming through marketing department is collected
and explanation for the same if any is given from here. This parito diagram is generally prepared once
in six months
About ISO
The KECL is ISO 9002 certified company. ISO is an international standard and 9002 certificate is
given to companies having manufacturing.

4.2. CUSTOMER BASE

It is one of the most important operative functions of management. Marketing is a human
activity directed as satisfying needs and wants through exchange. This can be explained part
by part as followed:

Sales branch offices

KECL has got eight branch offices operating in major cities like Trivandrum, Hyderabad,
Madras, Bangalore, Bombay, Delhi, Culcutta and Ahmedabad. Each branch is headed by
branch manager and supported byvarious sales officers , sales engineers,, sales
representatives etc. Everyone is interested with canvassing and procuring orders also
collection of payments.the order so collected will be sent to manufacturing units for
execution.

Marketing process in KECL

All marketing activities of KEXL is done on a cotract basis by KSEDC. And as per the
contract the holding company carries out the functions of marketing for which they charge a
selling commission of 6.25% to the subsidiary company. Order procurement and collection of
money is responsibility of KSEDC with the help of its 8 sales branch offices.

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Sales promotion activities

The co-operate marketing department of KSEDC does advertisement and other sales
promotional activities. All the expenses relating to this sre to be done by coperate marketing
department from the allotted commission to KSEDC.

Marketing plans and strategy

Marketing department every year fixes a yearly target with its authorized dealers in
consultation with the production department and the estimared demand for the product in the
market. The company is planning to capture the market share by offering products with high
quality, increased quantity, low price and latest technology.

Distribution pattern

KECL depends on all the methods of transportation i.e; through road, rail or water. For
transportation within the state it depends on KTC, couriers etc.

Pricing policy

The price for the products is fixed by considering the prices being charged by the
competetors. In KECL there is standard price list for all the products. The price list and sales
policies are made by Central Marketing Division.

Selling pattern

Among the Indian manufactures KECL is enjoying almost 50% of the share in the sale of
ceramic capacitor as they are high in quality, quick delivery, brand name etc. which attract
the customers. In KECL, 75% of sales is to direct customers and 25% through dealers. They
have got dealers in almost all major cities in India. They also export smal orders of 2-3 lacks
to Iran.

Customers facility

Since modern market belongs to customers, manufactures should take care of their needs,
KECL is ensuring it by prompt supply and by maintaining good quality of their products. The
customers of KECL may be on two categories i.e; consumer electronic manufactures and
telecommunications.

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Payment facility

KECL is giving following deductions in payment for its regular customers:- days credit,
discount of 25-35% on bulk purchase. But for few customers no credit facility is available
and the supply of product is through company’s bank or against delivery of materials.

Compensation and threats for KECL

At present KECL is facing a major threat because of globalization. Various foreign

companies are entering to the Indian market there by decreasing the company’s sale.

5. TRAINING DETAILS

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 Once the applicant is selected the organisation has to provide adequate training. Her
the company gives on the job training by which the employee will be benefited . In KECL the
company is providing inplant training, on the job training etc

The newly appointed workers are given on the job training,which may range from one
week to one month. There is also a corporate training department centred at Trivandrum. The
employees will be nominated for attending seminars and class and also some times
executives from other institution to take classes here. This is more helpful as more employees
can attend to it.

5.1. PRODUCTION PLANNING AND CONTROL

The three main important functions of this department are:

Preparation of production intent

The marketing department of KECL prepare the sells intent which contains various orders
received from different Original Equipment Manufacture (O.E.M). Customers like BPL,
DOT, ITI etc for the products being produced in KECL and the required quantity along with
type of products.

On the basis of this sales intent is being prepared which contains the details of various
purchase of the products to be made from outside for the production of materials within
KECL and after this production intent is being prepared.

Production intent is generally prepared on a monthly basis or it is prepared for htree months
but, in this case the details of rest of the two months will be on an assumption basis. And this
form is divided into weekly basis which helps in determining the amount of workto be done
in each week. On this basis the worker order forms is filled.

Raw material consumption and control

The imported raw materials being brought by the company are:

 Tinned copper wire

 Paper base white 18.5 mm (width)
 Paper basse 14.55 (width)
 Crape paper tape 10/12 mm (width)

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  Crape paper tape 6 mm (width)
 Burez resin

The Indian raw materials being brought by the company are:

 Solder stic 2% silver

 Solder stic 5% silver; combination of tin, led and silver
 Cape coat resin

Sub contracting

It is a method by which different products which are required for the production of buzzers,
flashers etc. are assembled by outside agency authorised by the company and brought to
KECL for final assembling and inspection. The other semi finishded goods are assembled
here into a final product

5.2. STORE DEPARTMENT

Store is the place for storimg the essential goods at various stages of production. This in
terms necessities time and place utilization. Moreover an efficient store department is
necessary to make proper intimation to purchase department in time so that least hindrances
are caused to production process. The stores manager is generally the person in change of this

The stores of KECL is divided into two section:

(1) Raw Materials

(2) Finished Goods

The various procedure involved in this section is as follows:

The stores department department gines intent for purchasing materials and the
materials received will be matched with the purchase order and kept for inspection in the
places allotted. Based upon the intent and the copy of the materials received, a GRCAR is
prepared. Then the materials comes to the store and goes for QA inspection and if QA
approves, the goods are given back to store for storage. The materials are segregated into
accepted/rejected/rework.

Issue:

Start after the department receives the store requistion.

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Finished goods:

These are collected from department as per store credit note from production
department and verifies with quality ,rate etc

Dispatch:

Is done on the basis of DBA (DESPATCH BILLING ADVICE) from the marketing
department

Records maintained:

For finished goods-

 Cardex system
 Store credit note
 DBA

For raw materials-

 Store requisition note

 Bin card
 Store return note
 Material gate pass
 Purchase requisition

5.3. PURCHASE DEPARTMENT

Availability of raw materials is an important thing which is required for the smooth
flow of operations in an industry. Purchasing department ensures that the purchase inputs
confirm to the specified requirements used in the production inputs. In KECL the head of the
department is responsible for implementation and maintenance of procedures.

Activities of purchase department

1. Identification of the requirements of production

2. Selection of proper sources of supply
3. Deciding the quality and quantity
4. Finalising the price
5. Placing purchasing order

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6. Supplies
7. Transporting the goods
8. Receiving the goods in store
9. Accept the good for consumption if it is of appropriate standards
The objectives of all Purchase activity are to
ensure:-

 that the required materials to prescribed specifications are purchased from reliable
sources, in required quantities and at the appropriate time and at the minimum
prices,

 that fair and consistent practices are followed in making the purchases,

 that the financial and legal interests of the organisation are safeguarded at all times,
and

 that timely supplies are guaranteed.

 It shall be the responsibility of the Purchase Staff to ensure that the above objectives
are met at all times and to bring any non-adherence to the notice of the Management
at appropriate levels.

Procedure

 A purchase requisition is got regarding the various materials required.

 Based on this, additional information shall be collected from the vender and decides
the mode of tendering.
 From the vendors list the approved vendors are selected based on their quality,
technical capability, commercial capability etc.
 Invite quotation on the basis of the classification of goods
 If the vendor is new to the organization or not an approved vendor , then the company
asks for samples and the samples for trial run and if satisfied the order is placed. But
if the vendor is a regular one , then usually the company does not ask for the samples.
 On the basis of the quotion the most advantageous vendor with reference to cost,
quality, delivery terms and payment terms gets the approval from the authorities.
 A purchase proposal is submitted by the HOD and based on the proposal, the
purchase order will be placed which contains the mode of delivery, payment terms

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 etc. The company is following criteria like perpetual inventory, ABC analysis etc
while buying raw materials.
 A follow-up procedure will be taken with the vendor to check the timely delivery of
goods wherever required.
 After getting clearance of goods and completing all other formalities, the goods are
deposited to the store.
 As soon as the goods reaches the store , it is checked or inspected by the Q.A.
department to ensure the quality of the goods.

Acceptance of stores

All items shall be inspected by the Inspection Group concerned within three days and
shall be taken into stock only after their approval.

Terms of payment

Normal terms of payment are 95% within 30 days from the date of receipt of materials at
our stores and 5% after acceptance. Wherever possible additional credit must be
negotiated without increase in the prices.

Payments ranging up to 100% against proof of despatch may be agreed, taking into
consideration aspects like the proprietary nature, monopoly source of the material
supplied, the standing and reputation and/or previous performance of the supplier, pre-
inspection of the goods at the supplier’s premises.

Any other terms of payment may be accepted in exceptional cases in consultation with
the Head of Finance Department and the Unit/ Business Centre Head.

Mode of transport

The delivery of materials should be arranged by the cheapest mode of transport, subject to the
safety of the materials. But if the materials are required urgently or if there is difficulty or delay in
getting the cheapest mode of transport, a faster mode of transport may be sanctioned by the Head
of the Business Centre/Unit.

Insurance

Insurance cover for the materials dispatched shall be arranged as per the procedures/policy of the
Corporation. However wherever the supplier quotes the price on FOR destination basis, the

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 insurance cover shall be arranged by the suppliers themselves.

Deviations

In case where deviations from the prescribed purchase procedure are considered necessary, prior
approval of the Unit/ Business Centre Head shall be obtained by furnishing sufficient
justifications for such deviations and the reasons thereof should be recorded in writing. All such
proposals shall be routed to the Business Centre/Unit Head through the Head of Finance
Department. Wherever there is a deviation involving financial implication, the same should be
referred to Corporate Office.

5.4 FINANCE DEPARTMENT

Finance is an important element, which keeps the business running. In KECL a separate
department itself is maintained with the finance manager as the head. The accounting
procedures are fully computerized.

The KECL finance department maintains various books for recording the cash
details such as : cash book, purchase journal, sales journal, general ledger, profit and loss
account and balance sheet.

The share capital of the company is Rs.318.28 lakhs of which Rs.135000 is got as
unsecured loans from the co-operate office (KSEDC) at the rate of 14% interest. Working
capital finance for a maximum limit of 65 lakhs is granted as cash credit from Canera
bank. The company follows a policy of reinvesting its profit and no dividend or other
benefits are not being issued to share holders. This profit is used for meeting the various
requirements of the company itself.

During the last year company has contributed to the government a revenue of
Rs.187.18 lakhs as customs duty, sales tax and excise duty.The accounts have been
prepared on historical cost and accrual basis and they are audited by the chartered
accounts appointed by the central government in terms of section 619(2) of the Companies
Act of 1956.

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 6. CONCLUSION

Industrial Training refers to work experience that is relevant to professional

development prior to graduation. Industrial Training is an essential component in the
development of the practical and professional skills required for an Engineer and an aid to
prospective employment. Industrial training at KECL helps to understand how a company
runs. . KECL is a company Which is contribiting much to the development of electronics
industry of India. KECL an ISO 9001:2008 certified company is the market leaders in
ceramic capacitors in India.

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