OPERATIONS MANAGEMENT

PROJECT

Anika Mary Varkey

PGDM15 | ASB
Roll No: 18

CONTENTS
SLIDE NO:
Overview

3-5

Power Electronics Group

6-10

Location

11-12

Products Mix

13

600 KV UPS

14-15

Components

16

Opportunity

17

Work Flow

18-19

Layout

20-21

Process Flow

22-34

Packing and Dispatching

35

Material Handling

36

Bottlenecks

37
2

CONTENTS
SLIDE NO.
Technology

38

Information System

39

Environment Issues

40

HR strategy

41

Work Scheduling

42

Work Classification

43-44

Job Design

45

Conclusion

46

OVERVIEW
Keltron, Kerala State Electronics Development Corporation

Limited is a public sector Electronics Company located in

Kerala, headquartered at the capital city of
Thiruvananthapuram.
Keltron, is Indias first and the largest electronics corporation
in the State sector.
From 1973, Keltron has been a catalyst for the development of
electronics industry in Kerala.
The company is under the direct control of the State
government of Kerala.

OVERVIEW Contd
Keltron was formed with Shri. K. P. P. Nambiar as

its first chairman and MD and he is remembered

as the architect of electronic revolution in Kerala.
Within five years of its inception, Keltron had set
up a production centre in every district of the
State.
They produce a wide range of products starting
from discrete electronics components to complex
equipment and systems.
5

OVERVIEW Contd
More than 2,000 people are engaged directly or indirectly by Keltron for the
manufacture of electronic goods.
Keltron products are brought to the customers through a nation-wide marketing
and sales network with Marketing Offices in Mumbai, New Delhi, Kolkata,
Chennai, Bangalore, Ahmedabad, Hyderabad and Trivandrum.
All production centers and business units of Keltron are
ISO 9000 certified.

KELTRON GROUP
1.Keltron Equipment Complex, Karakulam, Thiruvananthapuram
2.Keltron Communication Complex, Kulathur, Thiruvananthapuram
3.Keltron Lighting Division, Moodadi, Kozhikode
4.Keltron Controls, Aroor-Alappuzha
5. Keltron Electro Ceramics Limited, Malappuram
6.Keltron Component Complex, Kannur
7.Information Technology Business Group, Vellayambalam, Thiruvananthapuram
7

KELTRON EQUIPMENT COMPLEX

KELTRON Equipment complex (KEC) is one of the major manufacturing units located
at Karakulam. KEC is classified into Five Strategic Business Units (SBU).

PEG
SSG

SPG
Keltron
Equipmen
t Complex

IDPC,
Training
Centre

SEG
iTAC

POWER ELECTRONICS GROUP

(PEG)
The Power Electronics Group (PEG) of Keltron is a pioneer in the field of UPS
Systems in the country designing and manufacturing to a diverse range of applications.
Keltron provides seismic qualified UPS Systems of up to 1000 KVA capacity based on
state-of-the-art technology.
The Government of Kerala, by a Government Order has identified Keltron as a nodal
agency for implementation of solar power projects in Government Offices, Industries
Department and LSGD.
9

POWER ELECTRONICS GROUP

(PEG)
Keltron has now embarked into the renewable energy sector.
The Power Electronics Group (PEG) of KELTRON is a pioneer in the field of UPS
Systems in the country designing and manufacturing to a diverse range of
applications.
KELTRON is a preferred vendor for NPCIL and is approved by leading organizations
such as EIL, NTPC, ONGC and GAIL for supply of UPS Systems, Battery Chargers,
Rectifiers, Distribution Panels and related products.
10

LOCATION
The Keltron Equipment Complex is situated in Karakulam, a village that is located
15 km to the north-east of Thiruvananthapuram city, on the way to
Thiruvananthapuram-Tenkasi state highway.
The Govt. of Kerala had acquired 19 acres of this land way back in 1973 with an
aim of developing this area.
Shri. C. Achutha Menon, the then CM of Kerala was very much interested in this
project and helped expedite many formalities associated with the same.
His idea was to have this area developed and create job opportunities for people
living nearby.
11

LOCATION

12

PRODUCT MIX
Seismically qualified IGBT based uninterruptable power supply system up to 1000kVA
High frequency IGBT converters
Rectifiers
Industrial Battery chargers
High capacity voltage stabilizers
AC& DC Distribution boards
Static compensator
Solar Inverters and many more.

13

600 KVA UPS

The major clients of Keltron for 600KVA UPS are NPCIL, BHEL, NTPC, BARC

14

FEATURES
1.Indigenously developed highest capacity UPS
2.600kVA single module system
3.12 pulse charger
4.IGBT based PWM technology
5.DC bus supported by 2250 AH, 360V Plant battery
6.Capable of starting 132kw Induction motor
7.IP 31 protection
8.Fault diagnosis on PCB front plate itself
9.24x7 power supply even when servicing
15

COMPONENTS
1.Rectifiers and Charger
2.Transformers
3.Capacitors
4.PCB
5.Battery
6.Inverter
7.Static Switch
8.Maintenance Bypass
9.External Maintenance Bypass
16

OPPORTUNITY
Rs. 5000 crores industry.
Rise in number of power based industries in India.
Less number of players in medium and high scale UPS industry

17

WORK FLOW
1.Client request initiated
2.Marketing Dept Tender
3.Marketing Dept issues ESO based on Purchase Order
4.Copies of ESO sent to Planning, Finance and QA departments.
5.Engineering department prepare BOMs based on the ESO
6.Based on ESO, Purchase Requisition is prepared
7.Enquiry form sent to prospective vendors
Order of approval of the purchase committee is as follows: Head (purchase), Head (Planning),
Head (QA), Head (Finance), Group Head, Unit Head, Head (corporate finance) and Managing
Director
18

WORK FLOW
10.Vendor delivers proposed materials to inward store
11.GRCIR generated at Inward Store; sent to QA dept.
12.After inspection, sent to Holding Store
13.Defective materials are identified, noted in Rejection Control Register
14.Store Requisition generated by Planning Dept.
15.Materials get issued to respective sub sections accordingly.

19

LAYOUT
The layout followed is a process layout.
The machines are arranged according to the nature or type of the operations.
The process layout is particularly useful where low volume of production is needed.
Same type of operation facilities are grouped together such as fabrication machines are
placed at one place, all the transformer winding machines are at another place and so on.

20

SHOPFLOOR LAYOUT

21

PROCESS FLOW CHART

CABINET
MANUFACTURING

TRANSFORMER
MANUFACTURING
PCB ASSEMBLING
ASSEMBLING

QA/ QC

TESTING
PACKING/
DISPATTCH

22

PROCESS FLOW CHART Contd

1.

PURCHASE OF RAW MATERIAL

2.

CABINET MANUFACTURING:

. The acquired raw materials are taken to the

fabrication shop.
. Most of the welding processes take place
here.

23

PROCESS FLOW CHART Contd

From the fabrication shop, the racks are introduced to four treatments:
a)DEGREASING
b)DERUSTING
c)PHOSPHATING
d)PASSIVATION:

24

PROCESS FLOW CHART Contd

e)

ELECTROPLATING SHOP

Electroplating is a process that uses electrical current

to reduce dissolved metal so that they form a coherent
metal coating on an electrode.
The various types of electroplating done in Keltron
are:
1. Gold plating

2. Cadmium plating

3. Zinc plating

4. Aluminum plating (Anodizing)

5. Silver plating 6. Zinc yellow plating

25

PROCESS FLOW CHART Contd

After all the above process, the machine part is
kept in oven and gets heated for some time.
After that it is painted to prevent corrosion of the
material. Usually spray painting is preferred.
After painting, the materials are taken to the
production floor, where the transformers, IGBT
components, rectifiers, chargers, batteries, etc. are
kept.

26

PROCESS FLOW CHART Contd

3.

TRANSFORMER MANUFACTURING:

.Transformer manufacturing section produces

transformers as per the requirements.
.Once the winding s over transformer is tested to be
defect free

27

PROCESS FLOW CHART Contd

TRANSFORMER TESTING CENTER

TRANSFORMER WINDING
28

PROCESS FLOW CHART Contd

4.

PCB MANUFACTURING:

The PCB section manufactures the PCBs for

the UPS.

PCB design is done by the engineers in-house.

Designs are send to a firm in Bangalore to

manufacture PCB and send back.

Components are assembled on the PCB in the

section

29

PROCESS FLOW CHART Contd

5. ASSEMBLING:
. The engineers take utmost care during this stage.
. After the parts are assembled in the rack, the wiring is carefully completed under the
supervision of the electrical engineer.

30

PROCESS FLOW CHART Contd

ASSEMBLING
31

PROCESS FLOW CHART Contd

6.

The QA/QC engineer from Keltron then checks the UPS for any defects that might have
crept in during assembly.

7.

Next, it is taken to the internal testing facility at Keltron which consists of more expert
engineers and professionals.

8.

When the engineers at the testing facility approve the UPS, a Final QC inspection is
done by a team of engineers, out of which one engineer would be an external engineer.

9.

After client inspection, the Marketing department is again intimated in order to issue the
Dispatch and Billing Advice (DBA) to the Dispatch Department.

8.

After their team gives the final approval, the UPS is packed and finally dispatched to
the client.
32

PROCESS FLOW CHART Contd

Cabinet Manufacturing: 1month
Transformer Manufacturing: 6 weeks
PCB Manufacturing: 1 week
Final Assembling: 6 weeks
Testing: 2 weeks

33

PROCESS FLOW CHART Contd

34

MATERIAL HANDLING
FOUR WHEEL DOLLY
Four wheel dollies are used to transfer raw materials and unfinished products (work in
progress) from one section to another within PEG.

35

PACKING AND DISPATCHING

UPS is given a plastic coating after manufacturing and placed in a wooden
box
Once the UPS is fully manufactured, owing to the huge dimensions of the
UPS, a crane is used to lift the UPS and place it in the truck for transporting it
to the client.

36

BOTTLENECKS
The chance of failure of any of the components in the UPS
The chance of late delivery of the order
Sourcing batteries for the UPS
The battery that is sourced widely is the Ni-Fe battery. They have to be customised in a way
that makes them different from a typical deep cycle. Absorbent Glass Mat (AGM) batteries we
are the ones that we buy at the hardware store.

37

TECHNOLOGY
IGBT (Insulated- gate bipolar transistor)
based PWM (Pulse width modulation)

DSP (Digital Signal Processor) based resistor

Tie up with C-DAC and IIT, Karaghpur

38

INFORMATION SYSTEMS
The information system used is ORACLE.
All departmental data are stored in ORACLE databases.
The data stored include finance, order processing,
manufacturing, and customer relationship management
systems.
Some of the data would be visible across departments
Sensitive data, pertaining to a department, might at
times, be visible to that department alone.

39

ENVIRONMENTAL ISSUES
Since this is a purely electronics industry, it is
classified as a 0 % waste producing entity.
No wastes that are hazardous to the earth are
produced.
The only wastes produced in minimal amounts are
E-wastes.
These wastes are collected by a mobile E-waste
collecting vehicle which is sent on a monthly basis
by Clean Kerala Company, an initiative by the Govt.
of Kerala to collect E-wastes from municipalities.
40

HUMAN RESOURCE STRATEGY

The company does have a stable workforce.
There are 180 permanent employees at the Keltron Equipment Complex in
Karakulam.
When a particular work is awarded, they take in contract employees pertaining to that
work.
The employees undergo an intensive training conducted by the National Safety
Council.
There is also a separate ISO training given to executives, once in every six months,
prior to yearly internal audits.
Constraints: There seems great difficulty in sourcing skilled fitters.
41

WORK SCHEDULING
The work schedule is normally from 9:00 AM to 5:00 PM Monday -Friday, adding up
to 40 hours a week.
Employees do not work in shifts in Keltron. Instead, they are given overtime pay,
depending on the extra hours worked.
Scheduled according to the work order received by Marketing Department from client
Each machine and each operator is allotted work separately keeping productivity in
mind.

42

WORK CLASSIFICATION

MD

CHIEF CGM

CGM (PEG)

DGM (ERP)

MANAGER
(HR)

GM
(FINANCE)

GM
(PURCHASE)

MANAGER
(MIS & CDS)

43

MANAGER
(P&S)

WORK CLASSIFICATION

CGM (PEG)

DGM
(MARKETING)

DGM
(OPERATIONS)

DGM (QA/QC)

Marketing Manager

Senior Engineer

Senior Engineer

Operators
44

JOB DESIGN
Job rotation/job enlargements are less since the jobs are scientifically-specific.
The approach at Keltron is more or less that of scientific management which
emphasizes work simplification and explicit specifications regarding the job tasks.
The jobs are usually defined by the scientific management team.
The advantages to this type of work are that it allows all workers to understand
their tasks and create efficient production due to repetitive, precise work.
The big disadvantage is that it does not allow for any worker thought or creativity.
This would eliminate worker feedback, which helps with job productivity.

45

CONCLUSION
The operations of the Power Electronics Group were studied effectively.
The company has made its national presence felt and it could very well be
attributed to the excellent operations planning at both the assembly line and at
the product and process level.
Learnt that operations embraces all the activities required to create and deliver
an organisation's goods or services to its customers or clients.
Significant analysis and planning are required to ensure that a potential
location will properly support the long-term strategy and objectives of the firm.
The future outlook for the company appears o be bright but the company
would have to make the changes in the technologies accordingly.
46

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