INDUSTRIAL TRAINING

REPORT

SPECTRUM ELECTRICAL INDUSTRIES LIMITED

( Plant No. 1, Gate No. 139/1+139/2, Village Umale Tal. & Dist. Jalgaon – 425003. )
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

GOVERNMENT POLYTECHNIC, JALGAON

(0018)

Program Name and Code : Electronics and Telecommunications

Course Name and Code : Industrial Training (22057)

Academic Year : 2022-23

Semester : Fifth

Submitted on 2022 by the group of 4 students

Sr. Roll
Name of student Enrollment No. Seat No.
No. No.
1 DEVESH RAJESH PATHAK
2 DURVESH RAJESH PATHAK

3 SAGAR SUBHASH JAYKAR

4 AMIT GEORGE KASBE

Mentor

Prof. Bhupendra Chaudhari Sir

 MAHARASHTRA STATE
BOARD OF TECHNICAL EDUCATION
Certificate of Completion
Of Industrial Training
(By respective Head of the Institute & Head of the Department)

This is to certify that Mr. /Ms. Durvesh Rajesh Pathak with Enrollment

No. 2000180080 has successfully completed Industrial Training

(22057) in Spectrum Electrical Industries LTD. from 4th July 2022 to 14th

August 2022 for partial fulfillment towards completion of Diploma

in Electronics And Telecommunication from Government Polytechnic ,

Jalgaon Institute Code 0018

Signature Signature
Seal of
Head of the Department Head of the Institute
the
Institute
 MAHARASHTRA STATE
BOARD OF TECHNICAL EDUCATION
Certificate of Completion
Of Industrial Training
(By respective Head of the Institute & Head of the Department)

This is to certify that Mr. /Ms. Devesh Rajesh Pathak with Enrollment

No. 2000180079 has successfully completed Industrial Training

(22057) in Spectrum Electrical Industries LTD. from 4th July 2022 to 14th

August 2022 for partial fulfillment towards completion of Diploma

in Electronics And Telecommunication from Government Polytechnic ,

Jalgaon Institute Code 0018

Signature Signature
Seal of
Head of the Department Head of the Institute
the
Institute
 MAHARASHTRA STATE
BOARD OF TECHNICAL EDUCATION
Certificate of Completion
Of Industrial Training
(By respective Head of the Institute & Head of the Department)

This is to certify that Mr. /Ms. Sagar Subhash Jaykar with Enrollment

No. 2000180082 has successfully completed Industrial Training

(22057) in Spectrum Electrical Industries LTD. from 4th July 2022 to 14th

August 2022 for partial fulfillment towards completion of Diploma

in Electronics And Telecommunication from Government Polytechnic ,

Jalgaon Institute Code 0018

Signature Signature
Seal of
Head of the Department Head of the Institute
the
Institute
 MAHARASHTRA STATE
BOARD OF TECHNICAL EDUCATION
Certificate of Completion
Of Industrial Training
(By respective Head of the Institute & Head of the Department)

This is to certify that Mr. /Ms. Amit George Kasbe with Enrollment

No. 2000180074 has successfully completed Industrial Training

(22057) in Spectrum Electrical Industries LTD. from 4th July 2022 to 14th

August 2022 for partial fulfillment towards completion of Diploma

in Electronics And Telecommunication from Government Polytechnic ,

Jalgaon Institute Code 0018

Signature Signature
Seal of
Head of the Department Head of the Institute
the
Institute
SR. CONTENT
NO.

1 COMPANY INTRODUCTION

2 COMPANY PRODUCTS

3 DEPARTMENTS

 Store
 Grinding area
 Quality control
 Maintenance
 Production
 Assembly area
 Packaging

4 SAFETY
 1. COMPANY INTRODUCTION

This is an ISO Certified Company, engaged in the business of designing and manufacturing
of electrical, automobile and irrigation components as contract manufactures and as
component suppliers to leading industry players on Business-to-Business (B2B) model

Address:

Spectrum Electrical Industries LTD. is located at Umale, Jalgaon- 425003.

History:

The Company has 25 Yrs. Establishment and there are different plant located at various
country/city.

Services:

Customer satisfaction is a major focus area for their Company and they strive to provide
required products to the customer exceeding their quality expectations. They constantly plan
and monitor their production processes to ensure timely delivery of the products to
customers. They conduct their entire operations in a transparent manner providing comfort
and ease of dealing for their customers. They also conduct audit and take customers feedback
for further improvements in their operations.

Products:

They manufacture a range of products under electrical components domain having different
applications and utilities. They undertake activities such as designing, fabrication, molding,
powder coating, electroplating and assembling to develop this products. Some of the products
are obtained after passing through all the stages of production while some are obtained at
intermediate stages of production.
 2. COMPANY PRODUCTS

Their products include the following:

Mini MCB Base & Cover

Distribution Board
AC Box

Modular Electric Board Panels

Lamp Angle Holders

Surface Coating
 3. DEPARTMENTS

Plant code 1001

In this plant there are various departments like:

 Store
 Grinding area
 Quality control
 Maintenance
 Production
 Assembly area
 Packaging

 STORE

In the store raw material, packing materials, is stored.

In store FIFO system is used

(FIFO) First In First Out System:-

FIFO stands for “First-In, First-Out”. It is a method used for cost flow
assumption purposes in the cost of goods sold calculation. The FIFO method
assumes that the oldest products in a company’s inventory have been sold first.
The costs paid for those oldest products are the ones used in the calculation.

Name of the raw material – Polycarbonate, Polyvinyl Chloride Resin

(PVC), Formulated polymers, Silicon.
Supplier of raw material

Rukma Plastics

KINGFA SCI & TECH

Covestro Ind. Pvt. Ltd.

DSM Ind. Pvt. Ltd.

Bhansai Engineering Poly.

Apex Techno Polymers

Supreme Petrochem Ltd.

25 KG Net Weight/sack

Every sack includes sticker.

Every bag has labelled like:

GRADE PP3HF

COLOUR BLACK

BAG NO. 20142

LOT NO. F-18AD/073344

 Grinding Area
In the grinding area runners are grind into small pieces. Then the pieces can be
used 2 to 3 times and they are recycled
  Quality control

Quality control is a procedure or set of procedures intended to ensure that a

manufactured product or performed service adheres to a defined set of quality
criteria or meets the requirement of the client or customer. Quality Control is
similar to but not identical with Quality Assurance (QA).

Instrument used in Quality Control: 1. Vernier Caliper

2. Slip gauge

3. Height gauge

4. Precision Measuring Machine

5. Moisture Analyzer

1. Vernier caliper:

Principle:

 Callipers are nothing but the Jaws which are used to fix the given component.
 It consists of two jaws and those are Upper Jaw and the Lower Jaw.
 Upper Jaws are used to measure the Inner diameter of the given specimen
whereas Lower jaws are used to measure the outer diameter of the given
specimen.
 It consists of two scales.

Working: The vernier calipers work on the basic principle of alignment of

measurement markings on the vernier scale and main scale. When a certain
marking on the vernier scale aligns exactly to the marking on the main scale for
a particular object whose dimensions are being measured, the value of the
vernier scale reading is added to the main scale reading to obtain the decimal
value of the reading in millimeters.
2. Slip gauge:

Principle: Slip Gauges: Slip gauges are used to measure the object directly to
find accuracy. This is also used to find the corrections in measuring instruments
like micrometers, vernier calipers etc. Slip gauges are used to find a clear
tolerance which gives a high accurate measurements. This can also be used in
sine bar for angular adjustments.

Working: The Working faces of any slip gauge will be made truly flat and
parallel. The slip gauges will undergo Hardening to resist wear and tear. They
will be further heated and cooled down successively to remove the hardening
stresses induced during the hardening Process. The Slip Gauges can be made up
of Tungsten Carbide because of it is extremely capable of hard and wear
resistance.

3. Height gauge:

Principle: Height gauges consist of a sliding carriage with a moving stylus or

scribe that is mounted to a vertical axis beam or column that contains a measuring
scale. The beam is configured so that it is perpendicular to the base of the height
gauge, which is typically made using a rigid material to add stability to the
instrument for measurements.

Working: A height gage does exactly as its name indicates measures the height
of a workpiece. A height gage is a measuring instrument in which a slider with a
measuring stylus moves relative to a measuring scale on a beam and in which this
motion is along a single vertical axis nominally perpendicular to a reference plane
on the instrument base.

4. Precision Measuring Machine :

Principle: The basic principle of CMM is to put the measured part into its
allowable measurement space, accurately measure the values of the measured part
in the three coordinate positions of X, Y and Z, and fit the measured elements such
as circle, ball, cylinder, cone and curved surface according to the values of these
points through computer data processing, so as to obtain the shape Position
tolerance and other geometric data.
Working: Used for measuring inner dimensions of component.

5. Moisture Analyzer

Principle: A moisture analyzer is a device that determines the moisture content

with the loss on drying method and consists of a weighing and halogen heating
unit. It suits the needs of quality control and production in food, pharma,
chemical and other industries. Benefit from: Accurate results through precise
weighing and temperature control; Intuitive operation with step-by-step user
guidance; Robust construction ensuring long instrument life, supported by our
global service network.

Working: A moisture analyzer works according to the thermo-gravimetric

principle, also often referred to as the 'Loss on Drying' (LOD) principle. The
moisture analyzer consists of two components, a balance unit and a heating unit.
In order to measure the moisture content the sample's start weight is recorded.

 Maintenance

PAST Maintenance management systems evolved from a need by

manufacturers to improve labor efficiency while reducing costs. Traditional
paper records were too costly to prepare - valuable "wrench time" was lost
while mechanics filled out an extensive paper trail.

Machine maintenance is the work that keeps mechanical assets running with
minimal downtime.

Machine maintenance can include regularly scheduled service, routine checks,

and both scheduled and emergency repairs. It also includes replacement or
realignment of parts that are worn, damaged, or misaligned. Machine
maintenance can be done either in advance of failure or after failure occurs.
Machine maintenance is critical at any plant or facility that uses mechanical
assets. It helps organizations meet production schedules, minimize costly
downtime, and lower the risk of workplace accidents and injuries.

Machines, buildings and other service facilities are subject to deterioration due
to their use and exposure to environmental conditions. If this process of
deterioration is not checked, it may render them unserviceable. It is, therefore,
necessary to attend to them from time to time, to repair and recondition them so
as to enhance their life economically.

Maintenance aspect is more important specially in the case of machines due to

their non-uniform pattern of wear and tear which depends on large number of
factors.

 Mould Maintenance
All mold tools are expensive and easily prone to damage and corrosion if they
are not maintained properly. In most injection molding shops, the mold storage
area often houses a considerable capital investment, often running into millions
of pounds.

Before a mold is stored it should be checked for any repairs that are necessary
and these should be carried out before the next time the mold is used, A few
simple precautions will make sure the mold is in good order for the next time it
is required, A basic checklist is as follows:

 The mold should be cleaned and serviced.

 Waterways should be blown out with air.
 The mold should be lubricated.
 Vents should be cleaned.
 All molding surfaces should be sprayed with a mold protective
 All safety switches should be checked for damage and correct function,
 All electrical circuitry should be checked for safety and function- Molds
should be stored closed if possible, if this is not possible, the two mold
halves should be protected with a wooden or similar cover to prevent
damage.

 Daily Checks

Some maintenance items should be checked daily: i.e.， hydraulic oil levels
lubrication, leaks on pressure lines, hose connections plastic and electrical
wires, including thermocouple leads. Every week the machine should be
cleaned down and the oil checked for cleanliness. A little less frequently，
thermocouples should be checked by inserting the tip in boiling water and
making sure that it indicates 100°C. Timers can occasionally be checked by a
stop watch and the screw non-return valve checked for leakage.

 Reporting Faults

Any reports of malfunctioning should be noted and the first convenient

opportunity taken to put them right. Among the items that should receive
regular, though not necessarily frequent, inspection is tie bars tie bar bushes
carriage tracks and bushes toggle link bushes and lever pins. Hydraulic
cylinders should be checked for leakage at the glands. If any undue wear is
apparent time may be saved at a crucial moment by taking the first available
opportunity to put matters right. If this procedure is followed it should not be
necessary to carry out the planned maintenance exercise of stripping equipment
and replacing worn parts at intervals of six or twelve months. However minute
inspection of all working parts of the machine at three-monthly intervals will
generally pay dividends in ensuring steady production.

  Spare Parts

Nothing is more frustrating than having to wait for parts to be sent from a
distant supplier. The agent will often be able to recommend which items are
most likely to fail and should be kept in stock. Often money is well spent in this
respect as a great deal of time can be saved in waiting for spares. There is a
good case for having several machines in the moulding shop from one supplier
as this obviates the necessity for carrying too many spares. It is not always good
practice however to “tool up” with only one make of machine, particularly in
the custom-moulding field. Not all machines have the same versatility and
having only one make can be a limitation. However, it is very unwise to go to
the other extreme and have a dozen different makes. Perhaps three different
makes in a factory of 25 or 30 machines is a good compromise，particularly
from the point of view of storing spare parts.

 Ancillary Equipment

Planned maintenance concerns not only the injection moulding machines. All
ancillary equipment, such as mould temperature controllers, granulators,
stacking or conveying equipment，is also important. The main factory water-
cooling installation should also be cleaned annually and de-scaled if necessary.
In this respect, too, occasional descaling of mould coolant channels and cooling
channels on the machine oil coolers can bring nothing but benefit.
  Production Department
In our plant there are 80 Injection Molding machine (IMM)

An injection molding machine (also spelled as injection moulding

machine in BrE), also known as an injection press, is a machine for
manufacturing plastic products by the injection molding process. It consists of
two main parts, an injection unit and a clamping unit.

Operation:

Injection molding machine molds can be fastened in either a horizontal or

vertical position. Most machines are horizontally oriented, but vertical machines
are used in some niche applications such as insert molding, allowing the
machine to take advantage of gravity. Some vertical machines also do not
require the mold to be fastened. There are many ways to fasten the tools to
the platens, the most common are manual clamps (both halves are bolted to the
platens); however, hydraulic clamps (chocks are used to hold the tool in place)
and magnetic clamps are also used. The magnetic and hydraulic clamps are used
where fast tool changes are required.
The person designing the mold chooses whether the mold uses a cold runner
system or a hot runner system to carry the plastic and fillers from the injection
unit to the cavities. A cold runner is a simple channel carved into the mold. The
plastic that fills the cold runner cools as the part cools and is then ejected with
the part as a sprue. A hot runner system is more complicated, often
using cartridge heaters to keep the plastic in the runners hot as the part cools.
After the part is ejected, the plastic remaining in a hot runner is injected into the
next part.

Types of injection molding machines

Machines are classified primarily by the type of driving systems they use:
hydraulic, mechanical, electrical, or hybrid
Hydraulic
Hydraulic machines have historically been the only option available
to molders until Nissei Plastic Industrial introduced the first all-electric injection
molding machine in 1983.Hydraulic machines, although not nearly as precise,
are the predominant type in most of the world, with the exception of Japan.
Mechanical
Mechanical type machines use the toggle system for building up tonnage on the
clamps of the machine. Tonnage is required on all machines so that the clamps
of the machine do not open due to the injection pressure. If the mold partially
opens up, it will create flashing in the plastic product.
Electric
The electric press, also known as Electric Machine Technology (EMT), reduces
operation costs by cutting energy consumption and also addresses some of the
environmental concerns surrounding the hydraulic press. Electric presses have
been shown to be quieter, faster, and have a higher accuracy, however the
machines are more expensive.
Hybrid injection (sometimes referred to as "Servo-Hydraulic") molding
machines claim to take advantage of the best features of both hydraulic and
electric systems, but in actuality use almost the same amount of electricity to
operate as an electric injection molding machine depending on the
manufacturer.
A robotic arm is often used to remove the molded components; either by side or
top entry, but it is more common for parts to drop out of the mold, through a
chute and into a container.

Main components of injection molding machine

Injection unit

Consists of three main components:

1. Screw motor drive

2. Reciprocating screw and barrel

3. Heaters, Thermocouple, Ring plunger

Clamping unit
Consists of three main components:

1. Mold

2. Clamping motor drive

3. Tie bars, the sender is clamped onto the edge of a workbench

 Fig. Schematic of Injection Molding Machine

Process of Injection Molding Machine:

Step 1: The mold closes

Step 2: Injection – The heated plastic is injected into the mold
Step 3: cooling
Step 4: Plasticizing Resin
Step 5: Ejection
Step 6: Removing the runner and packaging

INJECTION MOULDING MACHINE WORKING (IMM):

The molding machine heats the plastic until it is liquid. The nozzle of the
injection molding machine then it injects the melted plastic into the mold
(injection pressure). The cavity of the mold in now filled with the plastic liquid.
This will then cool down to form a solid product.
 Auxiliary Equipments:

1. Mold Temperature Controller (MTC):

MTC are widely used in plastic moulding, tyre moulding, Rubber

moulding industries etc. The process of injection moulding thermoplastics, hot
melt is periodically injected into a cold mold.

WORKING:

The mold temperature controller circulates fluid through the mold’s

cooling circuits t provide equilibrium to the heat flux experienced by the mold
for every cycle. It is common to run separate mold temperature controllers for
each half. This set-up allows for greater process control and processibility. For
injection molding, the injection pressure can be between 15,000 and 20,000 psi
(103-138 MPa). The average pressure of injection molding machine has 20,000
psi.

Types of MTC:

 Water MTC
 Oil MTC

2. Temperature Controller:

A temperature controller installed on the injection molding machine can

ensure the proper temperature is maintained during processing. Temperature
controllers, or control units, preheat the mold before the melted plastic is pushed
into the mold.

3. Cooling Fixture:
 A wooden or metal block used to hold the shape or dimensional accuracy
of a molding until it cools enough to retain its shape.

4. Chiller:

An Injection Molding Chiller is used for lowering the temperature of

injection molding applications. An injection Molding Chiller is a refrigeration
system, that can be utilized to provide cooling, heat transfer out of the mold
temperature controller, hydraulic heat exchanger, and the feed throat of
injection molding machines.

 Assembly area
In assembly area the parts are assemble.

Parts like: 1M NRI, 2M NRI, 3M NRI, 4M NRI, 6M NRI, 3P Base, Mini

MCB, Holder, etc.

 Packaging area:
All the components assembled are packed in cartons and the tags are stacked
on that carton and sent to the company for sale.

4. Safety

Safety rule of operation of injection moulding machine

1. Safety Shoes are compulsory

2. Keep the injection molding machine and its surrounding environment clean.

3. The space around the injection molding machine should be kept as smooth as

possible. After adding lubricating oil or pressure oil, the leaked oil should be
wiped out as soon as possible.
4. Check if the emergency button is pressed or the safety door is opened during
operation.

5. When the shooting table is moved forward, the molten rubber leaking from
the nozzle should not be removed by hand to prevent the handle from being
sandwiched between the shooting table and the mold.

6. Wear helmets while doing maintenance / filling material in hopper dryer.

7. Do not cancel the safety door or safety door switch in order to increase
production speed.

8. Before operating the injection molding machine, it must be checked whether

the mold is firmly installed on the movable platen and the head plate of the
injection molding machine.
9. Pay attention to whether the ground wire and other wiring of the injection
molding machine are connected securely.

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