Index

S.no Contents Page no

1 Introduction 1
2 Company profile 9

3 Detailed study of all the functions in IBD

3.1 HR 11
3.2 Quality 17

3.3 Marketing 23
3.4 Production 30
3.5 Production Engineering 45
3.6 Research and Development 47

3.7 Finance & Accounts 50

4 Theory vs practice 53

5 Conclusion

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

Vision 2025:
“Through Amara Raja way, and through enduring progressive partnerships, we
will be global leader in batteries and battery technologies & dominant player in Indian
Ocean Rim”.

PROFILE OF THE ORGANIZATION

Brief about the Promoter of Amara Raja Group of Companies:
Dr. Ramachandra N. Galla, a non-resident Indian now settled in India is the main
promoter. Dr. Ramachandra N Galla is an Electrical Engineer from Sri Venkateswara
University, Tirupati and has to his credit, Masters degrees in Applied Electronics,
Roorkee, India and Systems Sciences, Michigan State University, USA.
Dr. Ramachandra N Galla started his career as an Electrical Engineer in US Steel
Corporation, USA and moved on to Sargent & Lundy, USA as a consulting engineer for
the designing of Nuclear and Coal Fired Power Plant. He initiated various projects during
his tenure and mastered the ropes of this competitive business in a very short time.
However, Dr. Ramachandra N Galla was passionate to set up a battery manufacturing
plant in India. With a zeal and highly focused approach, he established, “Amara Raja
Batteries Limited”, which has grown to the top league of battery companies in India.
Dr. Ramachandra N Galla had been the Executive Chairman and Managing
Director of the Company for the period from July 1998 to August 2003 and continued as
Executive Chairman till August 2005. Effective September 2005, Dr. Ramachandra N
Galla has been continuing as the non-executive Chairman of the Company.
Dr. Ramachandra N Galla with his vast knowledge on the battery industry is a
source of inspiration for the employees of ARBL. Dr. Ramachandra N Galla has always
been a pillar of strength and his inputs/advise have been invaluable for the growth of the
Company. The Company also seeks his expertise on various technical issues for which he
provides immediate suggestions and actively involves himself in the affairs of the
Company on a regular basis.

PROFILE OF THE PRODUCT/SERVICE

Battery:
 Battery is the portable device producing DC power by electro-chemical
reaction. A potential difference is developed when two dissimilar electrodes are immersed
in a conducting solution called electrolyte and a current flow is observed when the
terminals are connected.
Battery is an electro-chemical device in which the free energy of chemical energy is
converted into electrical energy. Within the battery, we can store chemical energy, and on
demand it can be converted into electrical energy to drive an external circuit.
The battery is the fuel tank of Electric Vehicle. It stores chemical energy in the
form of reactive species, i.e. (during ‘charging’) and is designed to release this energy as
electrical power (during ‘discharging’).
Lead-acid battery occupies prominent place because of its application in the
automotive field. The lead-acid battery is the only acidic battery that uses an acidic
electrolyte.
Amara Raja Batteries Limited comprises of two major divisions viz., Industrial
Battery Division [IBD], Automotive Battery Division [ABD].

Industrial Battery Division (IBD):

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

Quanta Power Stack

ISBU
 IBD IMD
(LVRLA)
(MVRLA)

CUSTOMERS:
♦ Telecom:
BSNL, BEL, BHEL, Nokia, Siemens.
♦ Power control:
Raichur thermal power station, North Chennai power station.
♦ Oil & gas:
The island of Lakshadweep is powered through Amara raja power systems. Also
provides back-up power for low power transmitters for Doordarshan.
♦ Motive power:
APC(American Power Control), Siemens, Alstom..
Railways:
ARBL pioneered the use of maintenance-free batteries in Indian railways. Over 50%
of Indian railways II & III Tire self-generation air-conditioned coaches are powered by
ARBL. Over 40% of railways signaling and telecom power supply solutions are provided
by ARBL.

COMPETITORS:
Exide industries Ltd.
Hyderabad batteries Ltd.
GNB.

Automatic Battery Division (ABD):

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

PRODUCTS:
Amaron highlife
Amaron harvest
Amaron shield
Amaron hi-way
CUSTOMERS:
ARBL has prestigious OEM(Original Equipment Manufacturer) clients like Ford General
motors, Daewoo motors, Mercedes ; recently acquired a preferential supplier alliance
with Ashok Leyland , Hindustan motors, Telco, Mahindra&Mahindra, Hyundai.

ORGANIZATION DESIGN AND STRUCTURE:

Organization design is the process of aligning an organization's structure with its
mission. This means looking at the complex relationship between tasks, workflow,
responsibility and authority, and making sure these all support the objectives of the
business.Amara Raja Batteries Limited (ARBL) follows divisional structure. In a
divisional structure, the company is divided into business divisions, where each business
division is autonomous and typically structured along functional lines.
DETAILED STUDY OF ALL THE FUNCTIONS IN IBD
 IBD-HR

HUMAN RESOURCE:
The HR and Administration organization of Amara Raja is formed with an aim to provide
all the support the business needs at the right time.
The first level organization structure is illustrated below
 Group HR Head

Business HR Training and Talent PMS –

HR Shared Development Acquisition Performance
Services Cell Management
System

Business HR:
The role of business HR is the front face of human resources for the respective company /
business. They have to handle end to end of HR function at the company / business level
spanning across all locations wherever the business operates (e.g. branches, warehouses,
COO – Corporate office & plant) - from recruitment to resignation/retirement.
Talent Acquisition Cell:
The members of this department are responsible for procurement, recruitment and
selection of candidates in the group companies. Legacy system is the currently existing
system in the organization and it is RAMCO system.
Enterprise Resource Planning (ERP): it is the integration of all the departments and
modules that are there in the organization. It acts as a catalyst in the organization.
For starting any kind of recruitment in or off the organization following steps are
followed:

Budget Preparation (Man

power requirement)

Approval of Budget from

respective LOFs
 Information provided to VP(HR)
Job Description

Identifying sources of
recruitment

Sources of Recruitment:
♦ Campus Placements (ARGMP, ARGTP)
♦ Off Campus
♦ News paper advertisements
♦ Job portals
♦ Employee Referrals
♦ Head hunting
♦ Consultancies
ARGMP-Amara Raja Graduate & Management Trainees Program (Engineering
Graduates & Management courses students are recruited)
ARGTP- Amara Raja Graduate Trainees Program (All Diploma trades & Degree
students are recruited)
ARTS - Amara Raja Trainee Scheme (Students from 10th Class, Intermediate and ITI are
recruited)

Selection Process

Gathering & Scrutinizing Calling for written test/ Selecting Candidates

Resumes interview

Job specification Joining Formalities Sending Offer Letters &

MT (Management Trainees) MBAs, B.Tech/BBM/BBA-MBA,
Receiving acknowledgement
GET (Graduate Engineering Trainees) B.Tech, BE
AT (Assistant Trainees) B.Com & BA
TT ( Technician Trainees) All Diploma Trades
TAT (Technician Assistant Trainees) BSc
All the trainees undergo one year training and six months probation period.
GRADES DESIGNATION
M1 Chairman & Managing Director
M1 Chief Financial Officer (Group)
M2 Vice President HRSS – HR Shared Services:
M3 General Manager Service matters & Statutory
M4 Deputy General Manager measures: Management Grades
M5 Senior Manager
M6 Manager/ Branch Manager Service Matters: The executives
M7 Assistant Manager of this department do the ERP
M8 Sr. Engineer/Sr. Executive updation of all the details of newly
M9 Engineer/ Executive joined, internal transferred or
S1 Junior Officer transferred employees to different
S2 Supervisor locations.
Staff Grades
S3 Assistant II ERP details:
S4 Technician
S5 Assistant I ♦ Employee Code
W1 Workman ♦ Employee Id
W2 Workman ♦ Personal
Workmen Grades
W3 Workman information
W4 Workman ♦ Family Details
W5 Workman ♦ Academic Details
♦ Experience
Statutory Services: Five major actions are taken care by the statutory service executive.
These are:
♦ Provident Fund (PF)
♦ Pension
♦ Employee State Insurance (ESI)
♦ Employment Exchange (EE)
♦ Payment of Gratuity
♦ Bonus

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

Responsibilities:
♦ Collecting photos and details for distributing Identity cards.
♦ Opening Bank accounts for newly joined employees.
 ♦ Informing all the HOD’s to authorize the pending applications before 25 th
of every month.
♦ Sending attendance details of all the employees to pay roll for salaries.
Pay Roll:
The executives of this department are responsible for giving the wages for all the
employees in the organization.

Training & Development:

. The training needs for Staff and Management grades have been identified
through the Electronic Performance Appraisal System (AREPAS).
This department is responsible for preparing the training calendar and schedules
for the training programs for the employees across the group companies. Amara Raja
Training & Development Calendar.

Training is of two types:

1. On the job training.
2. Off the job training
IBD - QUALITY
Quality Assurance:
Definition of quality:-“The characteristic of a product or service that bear on its
ability to satisfy stated or implied needs.” Or it can be simply said as “fitness for use” or
”confirmation to requirements” or “DEFECT FREE PRODUCT”.
Quality of a product or service can be assured if it is free of deficiencies.

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

 Quality Inspections

Inward Inspections In process

Inspections

a) Inward Inspections:
Initial checks for the machines

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

 Atomic Absorption Spectrophotometer (AAS) – Determination of major alloy and

trace elements in lead and lead alloys, pure metals, impurities in pasting
chemicals and battery electrolyte.

 Determination of Thickness of AGM Separators

 Determination of wicking of AGM Separators

 Acid retention Test of AGM Separator

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

 Moisture Analyzer for PPCP granules

 Determination of Density for PPCP

 MFI (Melt Flow Index) tester for PPCP granules

 Izod Impact Tester for PPCP

 UTM(Universal Testing Machine) tester for PPCP granules

 Verification of Percentage particle size in powder materials

b) In Process Inspection:

In process Inspection

Oxide Plate Preparation Grid Casting

Preparation

Jars/Containers Assembly
Moulding

Formation

Finishing &
Dispatch

Verification of Oxide Properties:

 Free lead verification in lead oxide powder

 Apparent density of lead oxide powder

Checks in Grid Casting:

 Grid Weight Verification by using weighing scale

 Grid Thickness Verification by using Micrometer

Checks in Pasting:

 Verification of Paste density

 Plate weight verification

Checks in Jars/Containers moulding:

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

  Jar Height measurement after Ageing
Checks in Assembly:

 Verification of Group Thickness

 Verification of Mounting Height by Verniar

 Verification of Jar Height by Verniar

 Air pressure Test on Assembled cell

 Verification of Cell Dimensions

Checks for Modular:

 Lug Crystallization test

 Lug to Strap bonding test

 Post and Tombstone test

 Leak Test on Assembled battery

Checks in Formation:

 Acid temperature verification

 Acid Volume calibration and PLC setting

 Electrolyte temperature verification during formation

 100% Capacity verification

Checks in Finishing:

 Thermal Thread verification

 OCV & polarity verification

Checks in Dispatch:

 100% Quantity verification of Connectors

 Verification of Accessories in the packing box

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

CUSTOMER COMPLAINTS
INTERNAL EXTERNAL
(Section-Section checks
Within the organization)

Incoming warranty

INCOMING: Missing of accessories;

WARRANTY: Based on customer needs or specifications.

There are several statistical tools which help in taking corrective actions which are
used in Quality assurance department:
♦ Check sheet
♦ Stratification
♦ Pareto analysis
♦ Brain storming
♦ Cause effect diagram
♦ Histogram
♦ Graphs
♦ Scatter diagram
♦ Flow diagram
♦ Control charts
The types of audits that Amara Raja deals with:
Definition of Audit:

AUDITS

INTERNAL EXTERNAL
INTERNAL AUDITS
– To establish whether practices follow procedures
– To highlight required changes to procedures to ensure that they accurately
reflect quality practices
– To recommend opportunities for improvements
Internal audits are conducted once in 6 months for HO & COO operations. And once in
12 months for Field operations

TUV AUDITS
– Surveillance audit – every year
– Re-certification audit – once in 3 years
 IBD-MARKETING

The marketing department of Amara Raja is divided into six regions headed by six
regional managers and is incorporated with 21 branches across India having 31
warehouses, 160 franchises and over 15000 retailers.
The marketing functions and activities that are carried out in COO. Whole Marketing
section is divided into three channels according to business strategies

MARKETING

DIRECT BUSINESS CHANNEL BUSINESS EXPORT BUSINESS

Direct Business
In direct marketing business products are provided directly to customer.
Here flow of product is given bellow

H.O WARE HOUSE END USER

There is no need of Channel for

 Railways
 Telecom
 Power control
 OEMs
List of OEM customers:

 Ford India Ltd

 Huyndai Motor India Ltd
 Maruthi Udyog Ltd
 Ashok Leyland Ltd
 Tata Motors Ltd
 Mahindra & Mahindra Ltd
 Force Motors
 General Motors India Ltd
 International Tractors Ltd
 Swaraj Mazda Ltd
Marketing Functions/Activities (OEM’s):

 Market promotion of the product.

 Processing of customer enquiries.
 Preparation and submission of proposals.
 Processing of purchase orders and purchase order amendments.
 Monitor product delivery, product performance and service levels to customers.
 Implementing good housekeeping methods at the related areas.
 Maintenance of departments records/files,
 MIS generation of weekly activity reports (WAR) and monthly reports (MR).
 Customer relationship management.
Channel Business
In this marketing system product flows throw a channel.
 H.O WARE HOUSE FRANCHISE RETAILER CUSTOMER

Export Business
In it products are exports to outside of country. Our batteries are exported to Singapore ,
Malaysia , Indonesia , Taiwan , Philippines , Greece , Australia , Kuwait , Dubai , China
and Japan .
Export can be categorized into three
 Direct
 Merchant
 SEZ –Special Economic Zone

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

 Enquiry / Tender Review

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

 Meeting the sales targets as per the business plan

 Collection of payments as per PO Terms
 Meeting the customer requirements / expectations
Providing necessary training programs for staff / customer personnel
Service:
Main activities that are performed by service department:

 Ensuring Customer Satisfaction through prompt & efficient service to customers

 Monitoring Product Performance, feedback to REC for product improvements
Marketing Services:
 Functions:

 To assist in planning and execution of marketing activities

 Co-ordination with the Advertising agency, Event Management agency, Market
Research agency and Public Relations agency for Promotions and product
development
 Supporting field offices in promotional activities and events
 Identifying and Development of Point of Purchases
 Monitoring Budgets of Promotional spends
 Generation of MIS reports- Ad spends monthly and quarterly
 To assist in planning and execution of Automotive, Industrial, Corporate,
International & Group Companies
Marketing structure of ARBL

IBD MARKETING:

INDUSTRIAL BATTERY

DIRECT CHANNEL

RAILWAYS TELECOM P.C EXPORT U.P.S

TELECOM:
In telecom sector we provide our batteries to
 Operator- Airtel, Vodafone, BSNL etc.
 Manufacturer

RAILWAYS:

 Railways Sector
 Rail coach factories
 Engine manufacturer

POWER CONTROL:

 Power sector
1. Generation
2. Transmission
3. Distribution
 Oil and gas
 Renewable energy
 Motive power
 Security

EXPORT: Exports to

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

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

H.O

COO

ZONAL OFFICE
 BRANCH OFFICE SERVICE

AQUA

CUSTOMER

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

BRANCH OFFICE:
There is a Branch Manager in each Branch Office.
There are total 15-16 B.Ms. Marketing Engineer comes under Branch Manager.
AQUA:
Aqua is just like a Franchise from where either end-user or Retailer can buy directly
 IBD - PRODUCTION

Main Components of Battery:

Positive active material – Lead dioxide (PbO2)
Negative active material l – Spongy lead (Pb)
Electrolyte – Dilute sulphuric acid (H2SO4)
Current collectors (grid) – Lead alloys
Separator – Polythene, Glass Mat, Absorb Glass Mat
Container – PPCP, FRPPCP

Alloys used in Manufacturing of Batteries:

Lead:
 The major alloy used in lead-acid batteries is lead. The density of casted lead is
11.34, but this may be slightly increased by rolling. The melting point of lead is 327.4 0C
(621 F). It oxidizes readily in the moist air, becoming a dull gray.

Alloying elements to pure lead

 Antimony
 Calcium
 Aluminum
 Cadmium
 Tin
 Silver

IBD Process flow chart:

 Oxide Preparation

Paste Preparation Pasting

Grid Casting

Curing & Drying

Plate Cleaning

Assembly

Dispatch Finishing Formation

1 A. OXIDE PREPARATION:
Balox lead oxide plant:
Barton pot process is used to make leady oxide powder. 99.97% pure lead is used to
prepare oxide powder.
Oxide plants 1&2 works on Barton process where the lead ingots were melted and
oxidized in the presence of air.
The following are the process parameters that are maintained during the preparation of
oxide powder.

 Melting pot temp : 665±15F

 Reactor pot preheating temp : 425±15F
 Normal operation temp : 715±15F
 Reactor motor load : 35 to 45 amp
 Bag house temp : 200±20F
Process flow chart:

Lead ingots Melt pot

Reactor pot

Cyclone

Bag house

Storage silo

Process:
Lead ingots are placed on ingot conveyor through jib crane whose max capacity is 500
kgs.
Ingot conveyor is a power driven roller conveyor which conveys the ingots to the melting
pot
where the lead ingots were melted with the help of heaters. The temperature is maintained
at 650 to 680F in the melting pot. The centrifugal pump collects the molten lead and
pumps it to reactor pot through the lead trough.
The molten lead is fed into the reactor pot and is broken up into droplets by revolving
paddle. A stream of air blown over the droplets oxidizes the lead. In the classifier the
required particle size range is separated and the coarser material is returned to the reactor
pot.The resulting oxide powder is carried by air stream into the cyclone where the
powder further disintegrated due to the whirling action.Then it is moved to bag house
which consists of number of filters. It separates the air from the powder without the loss
of oxide powder. silos were used to store the leady oxide. Each silo is having a capacity
of 25 ton. oxide powder is stored in the silos before the paste preparation.
The following are tested to evaluate the quality of leady oxide.
1. Free lead percentage (specific limits are 18 to 28%)
2. Apparent density (specific limits are 1.3 to 1.8gm/cc)
3. Acid absorption(specific limits are 160 to 200mg/g)
1 B. GRID CASTING:
 Model 330c grid casting machine
Melt the ingots in the lead pot. Maintain the lead pot at a temp of 475 to 525F.
Start the feed line heaters. This molten metal is pumped to the ladle through solenoid
valve. This actuates the lead valve to dispense the lead into the mould. Ladle is
maintained at a temp of 450 to 500F.

 Cooling circulation system feeds cold water during the solidification and ejection
of mould.
 The casted grid is passed through the rollers to make it flat or to remove any
deformation in the grid.
 Grid centering mechanism centers the grid.
 Hydraulic mechanism actuates the trimmer which removes the gates of grid.

Types of grids:
1.Power stack type --- 20, 30, 40, 50, 60, 80, 90
2.IP series --------------- IP1, IP2

Common defects in grids

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

Testing of grids : Grid thickness, Strength, Weight.

Bend Test:
To find strength grid is bent and checked for any cracks
and then at 90 degrees to the first. If there are any
consecutive cracks, then it will be rejected.
BUS BAR CASTING:
The copper inserts are threaded into the holder and are
dipped in flux for 5sec. Then dip these inserts in tinning pot
for 30sec. This tinning pot consists of molten alloy off tin-
lead (40-60).
Place the insert along with the holders in the mould.
Pour the molten lead alloy with 2%tin pouring should be
completed in a time a span of 8-15sec.the molten metal is
solidified the mold and they can be removed form the
moulds. The bus bars are removed formed from the holders.
The tinning pot is maintained at a temperature of
320±25 C while the lead crucible temperature is 460±150C.
0

These bus bars are sent for group burning is assembly stage.

2. PASTE PREPARATION:
For Positive Paste:

 Lead oxide 1000kg

 Binder 0.5Kg
 SPTH 2Kg
 DM water 126lt
 Sulfuric acid 110kg(Sp. gravity 1.4)
For Negative Paste:

 Lead oxide 1000kg

 Binder 0.5Kg
 Barium Sulphate 20Kg
 Vanisperse 2Kg
 Carbon Black 2Kg
 DM water 116lt
 Sulfuric acid 110kg(Sp. gravity 1.4)
Process flow chart:

Binder Oxide dumping Dry mix

Water dumping

Wet mix

Paste Final mixing Acid dumping

For Pasting
Quality tests for paste:
1. Density test
2. Penetration capacity
3. Moisture content

PASTING:
Pasting is done on Industromac pasting machine.
Paste mix prepared in the oxmaster plant is transferred to the
hopper of the pasting machine. Ensure that the grids have
under gone aging for +ve 24 hrs.
Fill the hopper 3/4th each time. Grids were made to pass
through with the help of conveyor. Paster pastes grids to a
thickness equal to orifice opening. It is the gap between
hopper orifice plate and bottom orifice
plate. As the grid panel gets close to hopper’s entrance it is
pulled away from chain dogs by a set of accelerator rollers.
The panel is then pushed into drive rollers that move it into
paste application area. The paste is applied through the grid
structure by paste feed roller that is located in upper orifice
plate. The bottom orifice plate rollers trowel the paste on the
underside of grid.
After stacking, the stacked plates were transferred to
curing and drying ovens. Before that the plates are to be
undergo aging period. Curing and drying is the process by
which satisfactory levels of cohesion and adhesion are
imparted to the active material prior to plate formation and
are maintained there after. In addition, curing ensures a
highly developed surface area.

4. CURING AND DRYING:

Curing and drying is done at three stages. .

 Curing
 Intermediate stage
 Drying
Curing and drying process is carried out to impart
cohesion and adhesions are imparted to the active material
prior to formation. Curing is determined by the nature and
degree of interlocking between the crystals of the paste.
Adhesion is dependent upon the strength of the bond, which
is formed between the paste and the grid. These essential
properties are the best accomplished by conducting the curing
procedure in the following sequence.
Steaming period: Steam is applied to equalize the moisture
content in all the plates and it supports for the development of
lead sulphates.
Drying process is to bring down the water content (moisture)
to the low level for the active material to have good stability.
During the process physical, chemical and morphological
changes take place within the active material.

5. ASSEMBLY:
Process flow chart:
Plates, Separator,
Group Stacking
Top shields

Bus Bars Group Burning

Group Strapping

Jars Group Insertion

Covers Heat Sealing

Post Burning

Leak Testing Duff Cells

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

 The separator is sheared by activating the cutter blade after getting the predefined
length.
 Then positive plate is place and separator is folded over this plate. Place the half-
length separator on the last positive plate and then place unwrapped negative plate on
the top of the half length separators complete the stack.
 Shields are provided on positive plates to avoid direct contact between positive and
negative plates.
B. Group burning:

 Aligning of bus bars with lugs is called group burning.

 By using the protection of jigs these combs can be shield rightly.
 Adjust the oxy-acetylene gas torch for neutral flame and length of inner cone is 2.5cm
 Positive strap is burnt first as if requires more time for cooling.
 The molten metal is stirred with them.
 The post protection jigs are chilled with D.M water and then they were removed.
C. Group strapping:
Plates were strapped on strapping machine with poly-propylene. These straps held the
stacks together.
D. Group insertion:
The strapped plates are inserted into jars/containers shield in wrapped on the plates before
insertion.
E. Heat sealing:
The cover is placed over the jars such that the posts can slide inside the bushing. The
heaters are maintained at a temperature of range 440-480F. First takes 10sec for melting and
other 10sec for welding them together.
The covers must be positioned so that the polarity marking on the cover corresponds to
proper post/busing location.
F. Post burning:
Fix the dummy vent plug. Copper inserts were pre-heated using inner flame until the post
lead starts melting. Orthophosporic acid is applied on post and bush of the cover. Continue
the process until good surface is obtained.
G. Leak testing: The pressure inside the cell is increased to 65kpa for the range of 20-30sec.
while it is placed in water bath. Observe for air bubbles if any leak exists mark the area for
rework. If vent is weak replace the vent.Serial number is punched on the cell
Ex: 07 1/2 999999
07 indicates year
 1/2 indicate assembly line
999999 indicate type or model (i.e. the no of battery coming out of the line in the year)
6. FORMATION:
Cell packing:
The cells are placed in tub and packed with PPCP spacers and strapped with metallic bale
the cells are connected in series using cable connectors and bolts.
Process flow chart:

Duff Cell Acid Filling

Initial Charge

Formation Discharge

Formation Charge Back

Capacity Discharge

Capacity Recharge

Float Charge Formed Cell

Acid filling:
 At the first the volume vessel is filled up to the present volume. The cycle starts by
pulling the vacuum in the battery until preset vacuum level is reached. Then the acid is
transferred from volume vessel to the expansion vessel.
The venting valve provided on top of the machine will open and because of vacuum in
the battery causes an air stream which will force down the acid into the battery. If there is still
electrolyte in expansion vessel another vacuum pulse will be pulled.
7. FINISHING & DESPATCHING:
The formed battery is closed with vent plug and washed with water to remove any acid
present in the battery container outside.
Then it is checked for their prescribed integrity in “ON-LINE HIGH RATE DISCHARGE”
tester. The batteries, which satisfy the specification is packed and labeled.In dispatching the
cells were packed and the necessary accessories required for functioning of the cells is
supplied to the customer. The accessories include connectors, bolts, washers, cables etc.
This finished product is sent to Market through shipment by lorries, trucks, etc.
 IBD – PRODUCTION
ENGINEERING

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

Product Process Improvement Application

Development Engineering

Product Development:
This department is responsible for

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

 Major design changes in the existing product.

 Creation of master product structures in SAP.

Process Improvements:
 To change the existing process of designing to increase the efficiency.

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

Application Engineering:
 Design and development of Accessories such as containers of batteries will be done.

 Battery sizing.

 New application study of the products will be done.

 IBD – RESEARCH AND
DEVELOPMENT

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

VP

Manager Engineer
DGM Manager
 1) Fundamental Material Development 1) Testing department ö9

Studies department 2) Process Development

2) Calibration Lab

3) Chemical Lab

Fundamental Studies Department:

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

 This impact analysis will be given to Material Development department.

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

Chemical Lab:
Reports of chemical analysation will be prepared.

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

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

 Receiving the existing materials from new suppliers and checking.

  Developing different combinations of lead and other components.

Testing Department:
 Bench marking of competitor batteries will be done.

 Developing testing environment and conditions as per the customer requirement.

Process Development:
Development of import substitutions and new products for different applications.