CONTENTS

ABOUT THE COMPANY SAFETY IS OUR CONCERN AWARDS & RECOGNITIONS CUSTOMERS SAMPLING PLAN MOULDING SHOP FLOW DIAGRAM OF PRODUCTION PROCESS SETTING PARAMETERS MATRIAL USED PRODUCT GALLERY PRESS SHOP OVERVIEW

ABOUT THE COMPANY

The Mission Statement
WE COMMIT OURSELVES TO DELIGHT OUR CUSTOMERS AND MAINTAIN MARKET LEADERSHIP, THROUGH CONTINUAL IMPROVEMENT OF OUR QUALITY MANAGEMENT SYSTEMS BY : INTRODUCTION OF NEW PRODUCTS UPGRADATION OF QUALITY LEVELS UPGRADATION OF HUMAN RESOURCES COST EFFECTIVENESS OF OUR PRODUCTS AND ACTIVITIES

Vision: To meet and exceed customers expectation by products& services at offering high quality

competitive prices, in time all the time.

To be recognized as the largest & most efficient manufacturer in our product line in the Nation. To be a responsible corporate entity which recognizes and insures that its activities are sustainable and have a positive impact on its employees and society.

COMPANY INTRODUCTION
Year of Establishment Managing Director Chief Executive (Works) Executive (Works) 1969 Sh M.L Sethia ShKishor Sethia Sh Sanjeev Sethia Sh Vikas Sethia Dy Chief Executive General Manager Sh. S.K. Tandon Sh N.C. Agarwal

PRODUCT RANGE
Tape DeckMechanism :For Stereo Players, High-Speed Recorders, Car Stereos, Portable Personal Stereos etc. D.C. Micro Motors : For Tape Deck Mechanisms - Single-Speed, Double-Speed, CD /VCD /DVD loading, Portable Personal Stereos etc.

Synchronous Motors & Stepper Motors :

For Air-conditioner louvers, Micro-wave tables, Rotary display tables etc.

Universal Motors & Eco Motors :

For food processors, Mixer & Grinder.

Free Power Generators :

For Transistors for Philips

Audio Systems :
Complete Audio System as Tape Recorder, Two in One, Walkman and Radio for Philips at Elin, Goa

Home Appliances :
Electric light weight Irons, Toasters, Mixer/Juicer/Grinders for Philips at Elin, Baddi.

Electrical Light Fittings :

ElectricalLuminaires for Philips.

CD Mechanism :
For Audio/Video Systems

Terminal Blocks :
For Refrigeration

Speakers :
For TVs, Audio Systems

Fan Blower Motor :

For Frost Free Refrigerators

Submersible Pump:
For Air Coolers

ISO IMPLEMENTATION: ISO 9001 : 2000 ISO 14001:2004 ISO TS 16949.2002 For Quality since 1996 For Environment since 2002 For specific requirement of

Automobile Industries since 2005 CERTIFIED BY DNV (DET NORKSE VERITAS)

WORKING CONDITION
Canteen Lunch TimingsProvided in Canteen. Shift Timings Punctuality General/ A,B,C. 11:30 to 2:00 PM. Coupens for lunch

100%. 3 times late coming (10 min. ) are

allowed in a month after 3 late coming half day will be marked Attendance marking Punching card has to be punched in

Recording machines which are maintained at main gate and second gate for all persons. Gate Pass System ( Employees)Official / Personal the times for maintaining incoming and out going time of

 Security System and when required. Bus Arrangement -

Workmen are Searched by Security and staff as

Only for Female Employees for which approx.

Rs. 350.00 will be deducted. Compensatory Payment officers are - Jr. Staff upto Senior Engineers and

entitled to compensatory payment if they are continuously

staying on duty for more than 6 hrs. After8 hrs.of working. They will be entitled for one days salary payment. Requisitionfor compensation to be

submitted to HRDdepartment after sanctioned fromHOD and approval of Management. Performance Appraisal - Annually in April, for new person quarterly. Salary / Wages Payments Before 7 th of every month. Workers

are paid by cash and Staff through Bank. Tea Facilities (Staff) - Tea is provided free 2

times in a day. (Workmen) - Workmen have to pay subsidized cost for tea. Traveling Expenses Paid by the accounts deptt by

recommendation of HOD and approval of GM / Dy. C.E., as per rules available at Accounts deptt. Out door duty Authorization slip has to be submitted

in Personnel deptt. before or after finishing of assignment.

 Leaves Facility

7 Causal Leave (CL), 7 Medical Leave

(ML,only for the persons out of ESI coverage )Earned Leave - EL (1 day after 20 days working)EL can be accumulated upto maximum 45 days. Leave Available system Leave application is to be submitted

to Personnel deptt after Getting approval of HOD. Grievances Handling procedure has to be followed :1. HOD 2. Personnel3. G.M / Dy. C.E. 4. C.E In case of Grievance , following

Loans and Advance Payment -

Loan may be granted once in two

years to permanent employees . Max. 2 months salary which should be deducted within that year.Eligible person can put forward loan application to Personnel department after recommendation from the management. Advance can between 20th and 22nd of every month. Manpower Requirement required by HOD, and Through Authorization slip be of HOD for approval in 3 months

availed once

approved by the GM. The slip has to be

submitted to Personnel Deptt for arrangement of manpower. Selection of Manpower interview of the candidate Selection committee will take the and if found suitable the application will

be forwarded for approval to the Management for final interview and selection.

SAFETY IS OUR CONCERN

It is advised to use Personal Protective Equipments (PPE) for safe working in the factory Following PPE is being used in the departments. 1. Aprons Use for Painting work 2. Shoes Compulsory in Chemical working area 3. Goggles For machining jobs, welding jobs. 4. 5. 6. 7. Dress Helmet For girls, jacket and cap. Use while working on height or working on crane / lifter. Safety Ropes/ Safety belt Use during construction work , paints of Shad. Mask Where fumes and gasses are used. Use where chemical is being used. Use where cut injury chances are there i.e.

8. Rubber hand globes 9. ThickCotton hand globesWhile unloading of CRCA sheet

SCHEME IMPLEMENTED IN COMPANY

Suggestion Scheme :-We value suggestion given by our employees and expect that every employee will give atleast2 suggestion in a year. To encourage new ideas for improvement a suggestion scheme is running in the organization .The forms for giving suggestions are available in Personnel as well as with the departments head.After filling the forms it has to be put in the suggestion box outside the Personnel deptt. Persons whose suggestion are selected Rs. 300/cash as awardgiven and if the suggestion is fully implemented and has resulted in cost saving an amount equivalent to 10% of saving or Rs. 5000 whichever is lower is given to the employees on 1st of January (Annual day)

A Graphical overview
Group Turnover

TURNOVER OF LUMINAIRE BUSINESS

Turnover(Crores)
80 70 60

Value (Cr.)

50 40 30 20 10 0 Turnover 2009 32.79 2010 39.11 2011 68.12

GSRS RATING

GSRS Rating for Elin

90 80 70 60 50 40 30 20 10 0

63.75 1

78.22

YEAR

SRS Rating of Philips For ELF

100.00 80.00 60.00 40.00 20.00 0.00
79.0 77.0 81.5 79.0 86.5 75.5 84.0 79.5 69.5 77.0 72.0

Scoring

Months

SRS Rating

Awards & Recognitions

1982 1991-92 1993 1994 1994 1996 1997-98 1997-98 1999-00 2001-02 2002-03 2003-04 2006 -07 2007-08 2008-09 2008-09 2009-10 2009-10 2009-10

ELCINA award for Excellence In Exports 1991-92 Philips (C.E.) the Best Co-maker award. Elin R & D Recognised by Deptt. of Science & Technology, Govt. of India. Two Star Industries award from Directorate of Industries Import Substitution award from All India Radio and Electronic Association Excellence in Electronics award from Govt. of India. ISO 9001 certification by DNV (Netherlands) ELCINA award for Indigenous Development of Capital Goods ESC award for Excellence in Export. ELCINA award for Export Growth. ELCINA award for Excellence in Quality. National award for Excellence in Electronic Components from Deptt. of Electronics (Govt. of India) ELCINA award for Indigenisation of Capital Goods for Manufacture of Electronic Products. ELCINA award for Research & Development Work in the field of electronic components. 2001-02 ELCINA award of Excellence for Environment Management ELCINA award for Quality Quality Excellence Award from Institute of Trade & Industrial Development Certificate of Green Partner from Sony Japan (ROHS Compliance) Best Delivery Performance Award from Denso MSME National Award -2008 Ministry of Micro, Small & Medium Enterprises, Govt. of India for outstanding efforts in Entrepreneurship FICCI-SEDF Corporate Social Responsibility Award 2009. Jury Commendation Award Category: Small & Medium Enterprises (SMEs) Award for Best Performance in Outstanding support from Denso Award For Best Performance in Cost from Denso HR Excellence Award for The Year 2009-10 Gold Award for Innovation In RETENTION STRATEGY.

CUSTOMERS

INCOMING QUALITY CONTROL(I.Q.C) DEPTT.

It is the job of the IQC to conduct inspections and handle quality problem before the manufacturing process starts.

Specific tasks of IQC include:

To perform approved list check To evaluate supplier quality records To perform sampling of incoming material based on the IS-2500 Part-1 1991 ISO2589-1:1989 Verifying accuracy through calibration Assess dimension, visual & functional inspection of significant deviations. Continually Enhance the IQC process Evaluation of online rejection Co-ordination with suppliers for quality problem To short quality related problem in shop floor. Evaluation of new parts & report generation. To recover salvageable class component from broken / damaged To carry out aging test of components. To conduct suppliers end audit for factory evaluation and to made 4M agreement.

VERIFICATION OF PURCHASED PRODUCT

SAMPLING PLAN
LOT SIZE CODE ACCEPTED REJECTED SAMPLESIZE LATTER

2-8 9-15 16-25 26-50 51-90 91-150 151-280 281-500 501-1200 1201-3200 3201-10000 10001-35000 35001150000 150001500000 500000OVER

A B C D E F G H J K L M N P Q

2 3 5 8 13 20 32 50 80 125 200 315 500 800 1250

0 0 0 0 0 0 0 0 0 1 2 3 5 7 10

1 1 1 1 1 1 1 1 1 2 3 4 6 8 11

MOULDING SHOP
Mould: - is the common term used to describe the production tooling used to
produce plastic parts in injection Moulding machines.

MouldDesign: -Mould is
1) Core 2) Cavity

separated into two halves :-

Main Parts of Moulds:S.No. Parts S.No. Parts S.No. Parts

1 2 3 4 5

Mould Base Location Ring Sprue Bush, Core & Cavity insert Ejector pins

6 7 8 9 10

Riser (Spacer) Slider Feeding Bush Core Pin Guide pin

11 12 13 14 15

Limit Bolts Spring Cooling Channerls Nylon Bush Guide Bush

Type of Injection Moulds:S.No. Types Two plate moulds 1 (Standard moulds) Three plate moulds (stripper plate 2 moulds) 3 Split cavity moulds 4 Hot runner moulds

Type of Mould Maintenance:a) Preventive Maintenance :- Each time the mould is removed from the injection moulding m/c preventive maintenance is done. b) Rectification Maintenance :- When any part of mould has broken, damage, bend and wear out then damage parts are repaired or replaced by new .

PLASTIC
Plastics are Macromolecular structured Polymer. Polymer is made up of many repeating simple chemical units, known as Monomer. All Plastics are Polymers- But All Polymers are not Plastics, they may be Fibers , Elastomers (Rubbers) or adhesives. In simple words plastic is one of the family members of polymers. TYPE OF PLASTIC 1. THERMOPLASTICS:-Thermoplastics are materials that can be repeatedly heated, melted and converted into a product. 2. THERMOSETS:-Thermosets undergo a chemical reaction during conversion into a product.The product cannot be re-melted and converted into another product again. CLASSIFICATION OF THERMOPLASTICS :1. Commodity Plastics The Plastics which are used in Non critical applications. 2. Engineering Plastics The Plastics which are used in Engineering applications.
ADVANTAGES OF USING PLASTIC Light in weight Higher strength to weight ratio Wider design freedom Easy Processability Low Energy Required for Manufacturing Minimum post finishing required Corrosion Resistant. Low creep Better aesthetics

Details of Moulding Machines

S.N NAME OF M/C O. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TOSIBA IS 130 TOSIBA IS 80 TOSIBA IS 170 DEMAGE 50 DEMAGE 150 SUPPER MASTER 90 (TOGGLE) SUPPER MASTER 90 (HYDRAULIC) SUPPER MASTER 50 SUPPER MASTER 220 JSW 15 JSW 70 MULTIPLAST SUMITOMO CN 50 CN 75 FEROMATIC 350 NO. OF M/C 1 1 1 2 1 2 2 2 1 1 1 1 1 1 1 1 CLAMPING FORCE 130 TON 80 TON 168 TON 50 TON 150 TON 90 TON 90 TON 50 TON 220 TON 15 TON 70 TON 50 TON 7 TON 50 TON 75 TON 350 TON MIN. MOULD HT.(MM) 265 220 295 210 240 125 200 100 250 145 278 200 145 200 250 300 OPENING STOCK 560MM 400 MM 720 MM 370MM 500 MM 270 MM 500 MM 220 MM 760 MM 200 MM 195 MM 195 MM 150 MM 410 MM 450 MM 675 MM SPACE MAX. BETWEEN TIE DAYLIGHT BAR H*V 750MM 620MM 950 MM 610 MM 950 MM 620 MM 670 MM 540 MM 1000 MM 350 MM 295 MM 295 MM 210 MM 580 MM 610 MM 1475 MM 460*460 MM 390*390 MM 560*510 MM 355*355 MM 490*490 MM 360*360 MM 360*360 MM 310*310 MM 510*510 MM 225*225 MM 320*320 MM 320*320 MM 140*140 MM 320*320 MM 340*340 MM 722*722 MM SHOT WT.(PS) 83GMS 72 GMS 150 GMS 55 GMS 280 GMS 156 GMS 132 GMS 55 GMS 424 GMS 14 GMS 72 GMS 55 GMS 6 GMS 55 GMS 60 GMS 200 GMS

ALL MACHINE ARE PROGRAMABLE LOGIC CONTROL MACHINE

Measuring Instruments Details

Sl.
1 2 3 4 5 6 7 8

Instruments
Dial/DIGI. CALIPER Micrometer DIGI. HT. GAUGE Height Gauge Pappy Dial Profile Projector Std.Pin Gauge Std Slip Gauge

Least Count
0.01 mm 0.001mm 0.001 mm 0.01mm 0.01 mm 0.001 mm 0.01mm 0.01

Range
0-150 mm 0-25mm 0-50 mm 0-10 mm 0-0.80 mm 1.50-7.00 mm

Characterstic
Length,Width,Thickness O.D.Thickness Depth,Height Depth,Height FRO FRO,RRO,Radius,Angle I.D Slot

Calibration Frequency
6 Month 6 Month 6 Month 6 Month 6 Month 6 Month 6 Month 6 Month

Flow Diagram of Production

Monthly Production Plan from PPC
Not O.K.

Receipt of Work Order from PPC Receipt of Raw material from Store

Check the availability & condition of tools

Corrective Action

Short

Capacity Assessment
OK

Make the alternate Arrangement

Preparation of Daily M/c Loading Plan

Provide drgs., specs., process inspn. Sheets, Work Instructions etc.

Loading of Tools & take the Set up samples

Not O.K.

Corrective Action

Set up sample Inspection

O.K.

Component Production
Yes

Parts Process Inspection

Scrap

If reusable
No

Deposit to Store Send to Scrap Yard

Unloading of Tools & send to Tool

Final Inspection O.K.

Not O.K.

Rework Scrap

Component Deposit in Stores/Excise

Process Setting Parameters

S.NO. 1 2 3 4 5 6 7 8 9 10 11 Process Parameter Ejector Temperature Material Injection pressure Injection speed Injection time Holding pressure Holding time Cooling time Back pressure Screw rotation LESS Comp.not eject proper EFECTS MORE Ejector mark &mould not closed Material burn Flash Flash Burn mark Catching problem Flash &catching problem Catching problem Production loss Nozzle choke Flash

Filling problem&screw broken problem Shrinkage&short moulding Short moulding& weld line Weld line Comp. Not fill properly Dim. Varying &Warpage Warpage & ejector mark Warpage Silver mark No effect

PROCESS FLOW CHART FOR PREVENTIVE MAINTENANCE OF MOULDS

Receipt of Tool with History Card after Production

OK

Condition of Tool & Quantity Produced

NG

Only Cleaning and Lubrication required

Complete Preventive Maintenance Required

Sent to M/s Maint. Dept.

Cleaning, Lubrication and Preservation ( Shrink Film Wrapping)

Performing Preventive Maintenance as per checklist and other Problem noticed

Updating Tool History Card

Handing over to Tooling

History Card to Comp. file

Storage and Updating Tool Storage register Updating Tool History Card

PHOTO GALLERY OF MOULDING SHOP:-

CNC MOULDING MACHINE

MOULDING SHOP

PART MANUFACTURED IN MOULDING SHOP

MATRIAL USED Material Thickness Used for Problem

UV Motor CRCA-Cold Rolled Comtrolled Annealed 0.5-2 mm E.L.F(Electro Light Fitting) Thickness variation

EGCC-Electrical Gr. Carbon Content

0.4-2 mm

Deck Port Auto Part

Width Variation Rust Problem

GPSP-Galvanized plated Skin Pass

1.5-3 mm

Auto Part

Deep Scratches

Aluminum

0.4-1 mm

Steam Cover

Dent

0.2 mm Phosphorous Bronze

Leaf Switch

Blackish Shed

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Press Shop Overview