1

INPLANT TRAINING APRIL2019
INPLANT TRAINING
AT
LARSEN & TOUBRO LIMITED
Electrical & Automation Campus, Shil-
Phata Road, MIDC Industrail Area,
Mahape, Navi Mumbai – 400710
SWITCHGEARS MATERIAL DEPARTMENT
Submitted By:
GAYATRI GAUTAM SONAWANE

VIth Semester
Mechanical Engineering
Roll No: SS16ME033
GOVERNMENT POLYTECHNIC MUMBAI

BANDRA (EAST)
Mumbai – 400051
GOVERNMENT POLYTECHNIC MUMBAI Page 1

GOVERNMENT POLYTECHNIC
MUMBAI
BANDRA (EAST), MUMBAI-400051
INPLANT TRAINING REPORT
Gayatri Gautam Sonawane (SS16ME033)

Mechanical Engineering
VIth Semester
College Supervisor : Dr.S.B.Mahagaonkar

Training Supervisor : Anita .D. Raut.
Name of the Organization: Larsen & Toubro Ltd.

e LARSEN & TOUBRO

L arsen & Toubro Limited
Powur Campus. Sdk,-V,hilr Ro.1d
PO Box 8901 , IAumb·" 400072, II/VIA
T<!l +91 2/ 6705 0505
\N'I.IYVI' LaJ:;encovbro com
CPD/AT/IPT/PS N0.20183431 May 8, 2019
CERTIFICATE OF TRAINING
(TO WHOMSOEVER IT MAY CONCERN)
Name Ms. Gayatri Gautam Sonawane
College Government Polytechnic, Mumbai
Branch I Discipline Mechanical Engineering
Category lnplant Trainee
Stipend Rs. 3000/- P.M.
Date of Joining December 10, 2018
Date of Leaving May 8, 2019
Department/Place of Work Electrical & Automation IC-

Production Engineering Department,
Mahape, Navi Mumbai
for LARSEN & TOUBRO LIMITED
(ASHISH WADEKAR)
DEPUTY GENERAL MANAGER
YOUNG PROFESSIONAL TALENT ACQUISITION
CORPORATE HR & PERSONNEL
( _ -l C ..f/t"9!51",!;d0ffJcei 1;/:l>THous,, N M Marg, Ballard f srate, Mumbar - 400 001 . INDIA CIN L99999"vfH/946PLC004768

GOVERNMENT POLYTECHNIC MUMBAI

DEPARTMENT OF MECHANICAL ENGINEERING
CERTIFICATE
This is to certify that the Mrs Gayatri Gautam Sonawane student of
third year mechanical engineering (second shift) have completed the
industrial training at “M/s Larsen& Toubro Limited, Electrical and
Automation Campus”.For the course of Inplant Training , Guided by Dr.
S.B.Mahagaonkar sir. The work has been completed in the academic
year 2018-19. The training report has been approved by project guide as
it satisfies the academic needs as per subject’s curriculum.
Signature of project guide Signature of Head of Dept.

Dr.S.B.Mahagaonkar Prof. Dinesh H. Kamble
Signature of Principal Signature of

Govt. Polytechnic Mumbai External

ACKNOWLEDGEMENT
An acknowledgement is meant to felicitate all those people who have lent support and help for
successful completion of this training and it is never complete without thanking those people
who made it possible and whose constant support has crowned our efforts with success. I take
this opportunity to sincerely thank one and all who have made this happen.
One cannot even imagine the power of force that guides us all and neither can we succeed
without acknowledging it. My deepest gratitude to Almighty God for holding my hands and
guiding me throughout my life.
During the tenure of training period at M/s Larsen & Toubro, one of the India’s esteemed
industries the experience of the industrial culture gained is of high repute. This training provided
me with the best opportunity to put my engineering knowledge to practical use. The knowledge
and experience gained will have a lifelong influence on my career. It gives me immense pleasure
to present this In-plant Training report.
I extent my thank to Mr. O.G. Kakde (Director), Mr. M. R. Nagare and Mr. D.K.
Shinde (Head of Production Engineering Department).Whose efforts culminated in myself
getting this pristine opportunity to undergo training at M/S Larsen And Toubro Limited -
Mahape. It was rewarding experience both in terms of academic and overall personality
development to have got this chance of working in an entrusting environment.
I would like to thank the department head Mr. Gajendra Sane who treated me in most affable
manner and exposed me to new technology.
I would also sincerely thank to Mr. Anita V Raut who showed me the right path of learning,
new technology and concepts and channeling my energy in the right direction. He gave me
thoughts of thinking in new angle towards the technology through which I had undergone. He
maintained good relationship with me and never let me feel out of place.
I would again like to express my highest gratitude and thank Dr S.B.Mahagaonkar , my college
guide who painstakingly helped me on all fronts, giving his valuable advice, inspiration and
helped me on preparing my report and certain problems confronting me throughout the training
period.
I also take the opportunity and thank all the people who are working in the SMD, particularly
Mr.Nitin Sogam, who guided me throughout my project, giving their active co-operation
whenever required and channeling my energy in the right direction. I also place on record my
sincere thanks to each and every employee of L&T – Prod who has helped me directly and in-
directly during my training period.
And last but not the least, I would like to acknowledge my Parents, friends, fellow trainees, and
colleagues to who have provided their assistance & co-operation in every possible manner.
- Gayatri.G.S.

ABSTRACT
I was placed in Manufacturing Department and Switchgears material department of

M/s Larsen & Toubro Ltd. (EAIC Campus, Mahape) for 6 months for my VI th
semester implant training. The training commenced on 10th Dec. 2018 & ended on
8th May 2019.
The training helped me to get an idea about the various manufacturing processes
and the technical instruments which are used in the plant. It develop an awareness
of industrial approach to problem solving, based on broad understanding of
processes and mode of operation of organization. The aim and motivation of this
industrial training is to receive discipline, skills, technical knowledge through
proper training environment, which will help me, as a student in the industry.
A well planned, properly executed and evaluated industrial training helps me in
developing a professional attitude.
The objective of the projects to were to reduce the defects and cost saving &
develop a responsiveness of the self-disciplinary nature of problems in industry.
Working in this department, altogether was a very good experience for me and
from which I feel that I am really benefited from it. Thus I feel that the training,
which I underwent at M/s Larsen & Toubro, was one of my best experiences of life
and I am sure that this would certainly help me in my future career.

INDEX
SR.NO CHAPTER PAGE NO
1 Introduction To L&T 10
2 Introduction To EAIC 13
3 Introduction To Engineering department 15
4 Introduction of Switchgears Material Department 23
5 Study Of Air Circuit Braker 25

5.1 Main Components of ACB 29
6 Study of SAP System 34

6.1 Codes used in SMD 37
7 Learning Outcomes 45
Value Engineering 45
Open-Point Lesson 48
52
5S System
8 Projects Done In Industry 57
58
POKA YOKE For Crank Pin
9 Conclusion 59
10 Bibliography 60

List of Diagrams -:
Chapter Diagram no.& Page no.
Description
1 1. 1. L&T Spectrum 12
2 2. EAIC Picture 13
3 3. Turtle Diagram 16
Flow chart of C2E & C2M 18
Flow chart of C3 19
Flow chart of cradle 20
4 4. SMD Roles and Responsibility 23
5 5.View of Air Circuit Breaker 25

FRCD 28
ARC Chutes 28
Pole 29
Cradle 29
Jaw Assembly 30
Pole shaft 31
Fascia 31
Current Transformer 32
SIC Terminals 32
Motor 33
6 6. Introduction of SAP 37
ME2M Preview 38
MB51 Preview 39
CS03 Preview 40
MMBE Preview 41
VL31N Preview 42

7 7. Value Engineering 43
7.1 Cradle Interlock 43
7.2 Cradle Interlock 43
7.3 Facia Sluggish 44
7.4 Twisted Link 44
7.5 Facia Trail With New Link 44
7.6 Proposed With Twisted Link 44
7.7 Loose Linking 45
7.8 Welding Assembly 45
7.9 Change In Loose Link 45
7.10 Change In Welding Assy 45
7.11 SOP Format 51
7.4 5S (Before & After) 52
7.4 2nd 5S (Before & After) 53
rd
7.4 3 5S (Before & After) 54
7.4 4th 5S (Before & After) 55
8 8. POKA YOKE Fixture 57

8.1 Implemented Gauge 57
8.2 Gauge 58
8.3 Gauge With Mounted Part 58

CHAPTER 1. INTRODUCTION TO L&T
A company was founded in Bombay (Mumbai) in 1938 by two Danish engineers,

Henning Holck-Larsen and Soren Kristian Toubro. The company began as a representative of
Danish manufacturers of dairy equipment. However, with the start of the Second World War in
1939 and the resulting restriction on imports, the partners started a small workshop to undertake
jobs and provide service facilities.
Germany's invasion of Denmark in 1940 stopped supplies of Danish products. The war-
time need to repair and refit ships offered L&T an opportunity, and led to the formation of a new
company, Hilda Ltd., to handle these operations. L&T also started to repair and fabricate ships
signalling the expansion of the company. The sudden internment of German engineers in British
India (due to suspicions caused by the War), who were to put up a soda ash plant for the Tata,
gave L&T a chance to enter the field of installation.
In 1944, ECC was incorporated by the partners; the company at this time was focused
on construction projects (Presently, ECC is the construction division of L&T). L&T decided to
build a portfolio of foreign collaborations. By 1945, the company represented British
manufacturers of equipment used to manufacture products such as hydrogenated oils, biscuits,
soaps and glass.

Corporate re-structuring
In January 2011, its Chairman A.M. Naik announced that the company will
be restructured into nine virtual companies. Each will be called an independent company, and
will have a CEO, CFO and HR head, its own profit and loss account, and a board of directors
with at least three independent directors. Each board will not have any legal or statutory
standing, but will merely advise management.
The nine virtual companies will operate in different segments. The number currently has been
increased to 11 for which companies formed are:
1) Electrical & Automation (E&A) Segment
2) Infrastructure Segment
3) Power Segment
4) Metallurgical & Material Handling (MMH) Segment
5) Heavy Engineering Segment
6) Hydrocarbon Segment
7) Information Technology (IT) & Technology Services (TS) Segment
8) Developmental Projects Segment
9) Financial Services Segment

L&T SPECTRUM
HED Diversified Business
EPC EBG
Construction InformationTechnology
Figure 1

CHAPTER 2. INTRODUCTION TO ELECTRICAL AUTOMATION AND

INDEPENDENT COMPANY (EAIC)
L&T is an international manufacturer of a wide range of electrical and electronic products and
systems. L&T also manufactures custom-engineered switchboards for industrial sectors like
power, refineries, petrochemicals and cement. In the electronic segment, L&T offers a range
of meters and provides control and automation systems for industries.
The Electrical Automation and Operating Company, designated as Group III,
functions as an independent profit centre within the corporate ambit of L&T. L&T is
acknowledged as the industry leader in this field. The group is conscious of the need to
harmonize growth with environmental interests. The innovations in the product design and
process it has introduced reflect this concern. The packaging used for most of its products has
low wood contents and is suitable for recycling.
Figure 2

It’s leadership is based on the preference it has achieved not in terms of volume & values of
sales, but also in other aspects of design innovation, product quality & customer service. The
quality management systems adopted by the group are in line with ISO 9001 Standards
Certificate.
EAIC manufactures a range of custom-built boards to meet the power distribution
& motor control needs of key in industrial sectors. L&T offer the widest range of low-tension
switchgear products in the country. It has resulted in the development of innovative & trend
setting solutions for increasing the safety, reliability as well as ease of operation & maintenance
of equipment. These products also incorporate features specially designed for hot, humid and
dusty conditions.

CHAPTER 3. Engineering Department
(ACB PRODUCTION)
The ACB Engineering Department is mainly concerned with solving the issues encountered in the
factory. These problems range from requirement of tools, accessories and consumables, bottle
necks in flow line and also carryout innovative development projects. The Engineering Department
is also involved in vendor development to some extent. The department is also involved in
creating Material Masters of various components used and in maintaining the Bill of Materials, etc.
The Engineering Department also co-ordinates with other departments for solving the factory
problems and carrying out projects, namely:
1. Tooling Department for the factory’s requirements of tools and fixtures.
2. Maintenance Department for addressing problems pertaining to equipment and machines
3. used in the factory.
4. Sourcing Group for suggesting vendors and vendor development.
5. Purchase Department for procuring various materials required in the factory.
Like many things in business, ambition is a moving target. Developing and implementing an
engineering technique is important to achieve good outputs in the company. The engineering
department mainly concerns with the development of the product and change of ongoing
process to modified one to achieve better quality.

MAIN ACTIVITIES OF
ENGINEERING DEPARTMENT:-
 Analysis and study of various assembly processes at manufacturing line.

 Looking for different value engineering projects.
 New product development and basic designing.
 Implementation of sample product during assembly and its inspection.
 Generation of TCN (Temporary Change Note) in product if require
 Making of SOP (Standard Operation Procedure) sheets for different assembly lines.
 Creating of BOM (Bill of Material), Routing for different products.
 Looking for new process change without compromising on product quality.
 Selection of the best path in the manufacturing process.
 Provide assistance to designing team to understand technical difficulties at the
assembly line.
 Giving suggestion of design change or process change so as to improvise quality
of the particular product.

 Assessment of various development suggestions from shop floor and sanctioning
them.
 Elimination of unnecessary components from the assembly so as to save cost and
reduce weight of the product.
 Observe various assembly processes and drawing SOP
(Standard Operation Procedure) sheet on the basis of observation.
 Vendor visits for new development and process checking.
 Report to other departments for various ongoing technical activities.
 Update information in the SAP (system application & products)

ASSEMBLY SHOP
In this shop, assembly of breakers and sub-assemblies of different components takes

place. This shop consists of following flow lines and areas for different assemblies:
 C2E Flow Line (Electrical Breaker Assembly),
 C2M Flow Line (Manual Breaker Assembly)
 C3 Area (Complex Breaker Assembly,
 Cradle Line, Pole Line, DN Line, left plate assembly area, SR preparation area, harness
assembly area, matching area, SFG packaging area, and red tag area.
The C2E flow line capable to assemble 30 electric ACB per shift. The C2M flow line
capable to assemble 58 manual ACB per shift. In C3 area, the ACB is manufactured totally by
one person from start to end. Within one and half shift the one breaker is to be assembled.
According to specification of ACB, different types of sub-components are
manufactured in cradle line, pole line, DN line, left plate assembly area, SR preparation area,
machine shop, and harness assembly area. In matching area, the matching of ACB with cradle
(Draw-out type) takes place. After matching ACB is ready for packaging in SFG area. In Red
Tag Area, the unwanted material at the workstation is kept (5S methodology).

The Production Flow Chart for breaker assembly at C2E flow line, C2M flow line, C3 area are
as follows:
C2M & C2E FLOW LINE
Inputs from vendors, C&F shop, Sub-

assembly (Left & Right plate, Pole,
Harness, Shaft, DN, SR, etc.)
C2M Flow Line

C2E Flow Line
NOT OK
Rewor 50 Operation
k Visual Inspection by QC NOT OK
Visual Inspection by QC Rework

Testing (Earth fault
Short Time, Long Time) Testing (Earth fault
Short Time, Long Time)
HV Testing
HV Testing
FACIA
Rewor NOT OK FACIA NOT OK
k Rework
Final Inspection by QC Final Inspection by QC
Breaker Unloading &

movement to matching
area
Breaker & Cradle matching
Final clearance by QC
(Scanning, etc.)
Dispatch for packing
Figure 3.1

C-3 BREAKER ASSEMBLY
Inputs from vendors, C&F shop, Sub-

assembly (Left & Right plate, Pole,
Harness, Shaft, DN, SR, etc.)
C3 Breaker
Assembly
50 OPERATION
NOT OK
Testing (Earth fault

Short Time, Long Time
HV Testing
FACIA
NOT OK
Final Inspection by QC Rework
Breaker Unloading &


area
(Scanning, etc.)
Figure 3.2

CRADLE ASSEMBLY
Inputs from vendors,

C&F shop, Sub-assembly
Individual Cradle
Assembly
HV Testing
Visual Inspection by Shop Rework

NOT OK

NOT OK
Cradle unloading &

area
(Scanning, etc.)
Figure 3.3

C2E Flow Line
C2M Flow Line
C3 Area

Cradle Line
Pole Line
Machine Shop

CHAPTER 4. Purpose of the Department: Production Engineering
Role of the Department Indicators to evaluate the

responsibility
To Quality: - Timely implementation of - Engineering

design changes (PCNs)
ensure - Manufacturing system chart
processes by - Cost Optimization.
smooth - SOP
manufac implementing - FTY loss Process defect for
turing to engineering - Tool budget plan vs actual PCN
achieve solutions. implem
desired Delivery: entation
- Implement design
quality plan(PI
changes in the
at components and P)
optimu products as per -PFMEA
m cost, plan. - Capi
meet the - Development of tal
market new product tool
require variants as per budge
ments plan. ting
with on Productivity: and
time - Plan and monit
impleme implementation of oring
ntation tools, jigs &
- Cost
fixtures,
of Management
equipment to meet
change
manufacturing
manage
requirement.
ment,
Cost:
Standard
- Meet annual
ise the savings plan.
processe Safety:
s and - Ensure process
drive safety.
continuo Morale:
us Involve employees in
improve continuous improvement
ments programs through
knowledge sharing.

Oraganization Sturcture
Head LCM Engg.
Total Man power-4
Department Head Engineering
Engineer 1 Engineer 2 Engineer 3
Figure 4

CHAPTER 5. STUDY OF AIR CIRCUIT BREAKER (ACB)

Introduction
A circuit breaker is an automatically operated electricalswitch designed to protect an electrical
circuit from damage caused by overload or short circuit and earth fault conditions. Its basic
function is to detect a faulty condition and interrupt current flow.
An air circuit breaker is for power distribution as well as protection against faults
such as short-circuit, overload, earth faults etc. L&T manufactures ACB’s with current ratings of
640A, 800A, 1000A, 1250A, 3200A, 4000A, and 6400A.
Figure 5.1

IDENTIFICATION OF AIR CIRCUIT BREAKER

1. Front Fascia
2. Lifting Lug
3. Arc Chutes
4. Top Cover
5. Bezel (To Be Mounted On Panel Door)
6. Breaker
7. Rating Label
8. Trip’ Push Button
9. Close’ Push Button
10. Close’ Push Button
11. Sealable Sliding Shutters
12. ‘On-Off’ Position Indication
13. Spring ‘Charge/Discharge’ Indication
14. Overcurrent Release Type SR21
15. Operating Handle
16. Racking Interlock
17. Position Indication
18. Lock For ‘Isolated Position ’
19. Racking Handle
CLASSIFICATION OF ACB
Air Circuit Breakers
Manually Type Electrical Type
Fixed Draw-out Draw-out Fixed
Figure 5.2

 Manually Operated Breaker - When tripping action is completed there is need to close
the breaker. For this purpose spring is to be charge. It should have some stored energy to
generate closing force. This energy is provided by manually operatinghandle.
 Electrically Operated Breaker
In manual breaker, closing force can be given manually, but in electrically operated
breaker this closing is done by a spring, which stores energy. The universal motor fitted on the
breaker charges the spring through free return charging device (F.R.C.D.). This device converts
the rotational motion of the motor into linear motion of the spring. When the spring gets fully
charged and closing signal is given to the breaker, an electromagnet releases the latch through
mechanical links. As the latch gets released, the spring gets discharged. But at the same time the
spring force is applied on the main shaft of the breaker and this force acts on the fulcrum of the
poles via connectors and the breakers gets closed.
 Draw-out Breaker - In draw out type the breaker is mounted on cradle telescopic rails
and can be moved in and out on the cradle. The cradle carries terminals for the supply.
Spring loaded contacts jaws are fitted on the breaker which automatically engage with the
cradle terminals when the circuit breaker is racked in.
The main advantages of the draw-out breakers are:
1. The supply may not be cut off during maintenance as the breaker can be racked out and locked
in isolated position (In this position the breaker is completely isolated from the main as well as
the auxiliary supply terminals.) It can also be fully racked out for routineinspection.
2. If a breaker creates a problem a spare breaker can easily replace it.
3. It is possible to check the operation of the control circuit without switching on the main circuit
power supply by racking the breaker in the test position.
 Fixed Breaker
In this type, the breaker terminals are connected directly to the bush bars through
nuts and bolts. The advantage of such type of breaker is that of low cost. But for mainpower
supply of the system must be cut off and the breaker must be disconnected from the bus bars.
This is the main disadvantages of the fixed breakers.

5.1Main Components of ACB

 F. R. C. D.
Figure 5.3
FRCD (free return charging device) mechanism forms the most important part of the left
electrical mechanism plate. The mechanism transmits the trip or close signal the bottom of the
breaker. FRCD converts rotational motion of the motor into linear motion (charging &
discharging) of the spring.
 Arc Chutes
Figure 5.4
These arc chutes encloses the contact and serve cool and quench the arc during breaking. The arc
fixed to the breaker with latch, which permits easy removal for inspection. Arc chutes are
equipped with de- ion plates. The upper half of the de-ion plates are covered with a special arc
resistant coating which ensures that arc is positively extinguished within the arc chute.

 Poles
Figure 5.5
It is the conducting part of the breaker consisting of contact fingers. The main and arcing
contacts are fitted on these contact fingers. The contact fingers are individually spring loaded to
reduce the contact bounce and guarantee longer life. Each finger is provided with a
compensating fulcrum and latch. The assembly is connected to the main shaft by insulating
connectors. The pole assembly is held between insulating chassis, which has excellent dielectric
properties. Main contacts are made of silver cadmium oxide while; arcing contacts are of
tungsten-based alloy with superior anti-welding properties. During opening, the contact finger
swivels around the main contacts. Arcing contact therefore touch each other just before the main
contacts open. Thus a very good transition of current and corresponding arc to the arcing
contacts is achieved.
 Cradle
Figure 5.6

These are made of welded steel sheets having two telescopic rails on which the breaker is
supported. The rails slide over ball bearing, which makes the movement of breaker on the rails
extremely smooth.
The breaker can occupy three different positions on the cradle by means of rotating handle. They
are:
 Service position: - In this position the main and control contacts areengaged.
 Test position: - Main contacts are isolated but control contacts are engaged.
 Isolated position: - Both main and control contacts are isolated.
An automatic indication is provided to show the position of the breaker. A scrapping

earth is provided to ensure positive earthing of breaker in all positions. Safety shutters are
provided on cradle terminals, which close when the breaker is racked out. This prevents
accidental contact with live parts.
 Jaw Assembly
Figure 5.7
The jaw assembly is used only in case of draw out ACB. These are to be mounted on the top and
bottom terminals of the cradle and can be slid on and off the breaker terminals. Input & output
supply to Breaker is provided through jaws in draw-out Breaker.

 Pole Shaft
Figure 5.8
The pole shaft assembly extends throughout the length of the Breaker. It is supported on the side
plates in smooth reamed holes. It plays a vital role in opening and closing of the poles of the
breaker. It is connected to the pole mechanism by insulating connectors through the cranks.
These connectors are adjustable to achieve simultaneous motion of the closing and opening of
the pole assembly during operation. The outer end is connected to the spring mechanism which
when charged converts the linear motion of the spring into rotational motion of the shaft. The
movement of the shaft in clockwise direction closes the poles and in anti-clockwise direction
trips the breaker.
 FASCIA
Figure 5.9
The operating handle, the trip and close push buttons, the on-off indicator and other controls of
ACBs are grouped together in a control. Box located at the front of the breaker. A steel gasket is
provided around the control box, which seals the cubicle door and makes it dust proof.

 Current Transformer
Figure 5.10
It is assembled in the terminals of the breaker. They are step down transformer. Its function is to
convert the primary current to some Suitable lower current while measuring the current through
the terminals. Epoxy resin is used as a material for CT. Working of CT is based on Electro
Magnetic Induction theory. In this, terminal acts as a core for transformer. When current flows
from the terminals flux induces in CT which then step down to SR. CT’s are of different types.
Type of CT depends on the rating of Breaker. When we use breaker for protection purpose we
use CT & SR in our breaker.
 SIC Terminals
Figure 5.11
Secondary Isolating Contacts (SIC) are provided for controlling various operations on breaker
like closing, tripping, indications, operating rotary switch etc. these are spring-loaded contacts
attached on left and right frames of the breakers. When the breaker is racked in to the cradle,
these terminals get engaged with the corresponding terminals on the cradle. When the breaker is
in service and test position, the SIC terminals on cradle and breaker are in contact with each
other. When the breaker is brought in to isolated position, these get disengaged.

 Motor
Figure 5.12
Motors are used only in electrical breakers. A motor is used for auto charging of the main spring.
The rotational movement of the motor is converted in to linear movement of the spring by the
F.R.C.D. Mechanism. Generally two types of Motors are used in Breaker 240 v AC & 240 V
DC.
Applications of Air Circuit Breaker

1) It is used in different industrial plants, factories, ships, etc.
2) It is used for common protection of electrical machines.
3) It used for protection of transformers, capacitors and generators.
4) Also used in Low as well as High voltage and Currentsapplication.

CHAPTER 6.STUDY OF SAP SYSTEM
SAP HAS BEEN DERIVED FROM:

“SYSTEMS, APPLICATIONS, PRODUCTS in Data Processing.
In the past decade the business environment has changed dramatically. The world has
become a small and very dynamic marketplace. Organizations today confront new markets, new
competition and increasing customer expectations. This has put a tremendous demand on
manufacturers to:
 Lower total costs in the complete supply chain
 Shorten throughput times
 Reduce stock to a minimum
 Enlarge product assortment
 Improve Product quality
 Provide more reliable delivery dates and higher service to the customer
 Efficiently coordinate global demand, supply and production.
However, since most of the organizations have a `Functional Structure' what happens in
practice is that each function/department works towards their own goals and objectives, rather
than the organizational goals.
Thus today's organizations have to constantly requirements-engineer their business
practices and procedures to be more and more responsive to customers and competition. These
are the issues addressed by `Enterprise Resource Planning' software solutions providing a
common, consistent system to capture data organization wide, with minimum redundancy.
SAP has come up with mySAp.com to integrate the supply chain.
INTRODUCTION TO SAP:
Although there is much ERP software in the market like SAP, BAAN but SAP is the
most famous among them. It was developed and is being continuously upgraded by SAP AG
Company located in Walldorf in Germany. Four former IBM employees established it in 1972.
The company name stands for ‘Systems Applications and Products in Data Processing’. Since
the introduction of SAP R3 in the market SAP AG has become the world’s leading vendor.

standard application software. One of the reasons for SAP’s success is that since it is a standard
package it can be configured in multiple areas and adapted to the specific needs of a company.
It is the 4th largest independent software vendor of the world. International
applicability is another important part of the strategy to meet today’s complex and global
business needs. SAP software take these issues into account and thus is multilingual and covers
different aspects of various countries like, currency, taxes, legal practices concerning human
resources, import/ export regulations etc. thus enabling users from a multinational companies to
work simultaneously in the same system using their own language, currency and taxes.
In addition, when new input is made into the system the logical application links will
concurrently update related modules so that business can react to immediate information and
changes. This type of updating reduces the overhead of manual processing and communication
enables companies to react quickly in the nonstop and complex business world, which makes
SAP software systems a very valuable tool for executive planning and decision making.
FINANCIAL APPLIATIONS:
SAP financials module give customers the whole picture of the accounting functions, with
extensive report facilities to allow fast decision making support. It includes Financial accounting,
Controlling, treasury etc.
BASIC CONCEPTS:
 Transaction:
It is an operation that lets a user make changes to database. The whole data flow that runs
across application modules is executed using transactions only. In SAP a transaction is a sequence of
related steps. These logically related steps known as dialog steps are screens in which data is introduced
causing a generation of other events. SAP Dispatcher takes care of handling the sequence of those steps.
The transaction contains two phases: an interactive and update phase i.e. first database records are
prepared that can update the database and then the data is updated. Since many users have access to
the same information, so a lock mechanism is provided during the time transaction takes place.

 Client:
A client is defined as a legally and organizationally independent unit within a SAP system e.g.
here in Petrol Pump we can log on as various clients like production, scheduling, quality inspection etc.
The buffer manager of the application service allocates the hardware appropriately to all the clients so that
the hardware system can work to its maximum capacity.
 Communication Interface:
Inside SAP, communication is an overall process which involves most of the components of the
systems both internally and to the exterior world. All this is based on protocols. At the operating system
level, the protocol used is TCP/IP. Communication with the database is accomplished using SQL and
between applications we have CPIC (common programming interface communication).
USES:
 Together with bills of material and routings, work centers belong to the most important master
data in SAP production planning and control system. Work centers are used in task list operations
and work orders. Task lists are for example routings, maintenance task lists, inspection plans and
standard networks. Work orders are created for production, quality assurance, plant maintenance
and for the Project System as networks. Data in work centers is used for
 Scheduling
 Operating times and formulas are entered in the work center, so that the duration of an operation
can be calculated.
 Costing
 Formulas are entered in the work center, so that the costs of an operation can be calculated. A
work center is also assigned to a cost center.
 Capacity planning:-
 The available capacity and formulas for calculating capacity requirements are entered in the work
center.
 Simplifying operation maintenance, various default values for operations can be entered in the
work center.

FEW IMPORTANT SMD DAY TO DAY CODES THAT I HAVE WORKED :
1.1. INTRODUCTION PAGE OF SAP
Enter Transaction.
Figure 6.1

0.2. ME2N -PURCHASE ORDER AS PER PO NO
Figure 6.2

0.3. MB51 - MATERIAL DOCUMENT LIST
Figure 6.3

.0.4 ZCPR – PRINT REQUEST
Figure 6.4
0.5. CS03-DISPLAY MATERIAL BOM
Figure 6.5

07 MMBE – STOCK OVERVIEW
This transaction gives details of how much stock is there in different location
such as with vendor, in storage place, shop floor etc.
Mtl. Code
Plant
Figure 6.6

08.VL31N – INBOND DELIVERY NO.
By using this transaction we can do the challen parking for different materials.
Vendor Code
Figure 6.7

CHAPTER 7. LEARNING OUTCOMES

Value Engineering
Value Engineering (VE) or Value Analysis (VA) method is very important and useful
in driving down the product cost which helps companies retain market share and sustain their
profitability.I complete value engineering project of door interlock of cradle
Figure 7.1 Figure 7.2
Cradle have door interlock which have normally function of to lock breaker when it finally
reach to its last position on cradle .This door interlock is remove hardware like screw internal
threading and washer which are unnecessary. So new modified spring have 90 bend which
eliminate all components. This project saves 0.17 lacks per year.
Importance of FTY
First Time yield ( FTY) is very important because it shows details related to first time
assembly defects which affects lead time related to assembly. Thus Engineer have focus
reduces FTY as early as possible
I Solve 2 FTY problem Which are highlighted from last 6 months
1. Welding assembly angle problem
2. Twisted link interference with Facia sluggish problem.

1. Facia sluggish
Problem
Facia have rib which sluggish by twisted link as shown in Fig .The portion of twisted link
marked red is contact with portion of facia marked red. Thus this is required to cut &
unnecessary manpower waste on that.

Facia sluggish Twisted lin
Solution
To avoid this portion of link get contact with fascia removed by 2mm from center then not
get mark on fascia.
Fascia trial with proposed link Proposed Twisted Link

2. Welding Assembely angle problem

Problem
Welding assembly is connect with latch. Portion which contact with latch have angle out of Tolerance
.Thus it is inserted in pin of latch by light hammering. But this linking get loose while tripping
.
Loose linking Welding assembly with angle defect
Solution Angle of welding assembly get shift by 1’ Then it insert properly and have
tight connection.
Figure 7.10
Figure 7.9

2.One-point lessons (OPL)

What is OPL?
1. OPL is a 5 to 10 minutes (normally take less than 15 minutes) lesson one topic on one sheet
2. -means only One Point illustrated on a sheet of paper as many senses as possible should be
3. addressed.
4. It must be written As Simple As Possible.
5. The Point or Topic Can Be the Function of Equipment, Installation of Jigs, Cleaning Method,
6. Types of Lubrication and Methods of Inspection etc.
7. It Is Generally Prepared by Supervisors or Group Leaders and Sometimes By Operators.
Types of OPL
 Basic information sheet: essential basic information – practical know-how and know-
how of Maintenance activities as e.g. filter changing
 Small repair works
 Setting of machine functions
 Cleaning and checking
 Lubricating
 Problem case study sheet: teaches how to prevent recurrence of an actual equipment problem
 Improvement / Kaizen lessons study case: describes the approach and key measures
in a successful improvement case study
Which method used to deliver OPL?
Use all sense of people: tasting, feeling, smelling, hearing, seeing; the gathering of
information occurs in
 83% by seeing: pictures, sketches, graphs, drawings
 11% by hearing: whistling, rattling, squeaking
 3.5% by smelling: chemicals, smell of fire
 1.5% by feeling: surfaces, roughness, heat
 1% by tasting: sweet, bitter, salty, sour (food industry).
We have applied OPL for inserting ferrules according to proper sequence of CT connector:
 A common mistake occurs between the workers that ferrules are not inserted properly
 according to sequence.

3. SOP – Standard Operating Procedure
Standard operating procedures (SOPs) are comprehensive, job-specific procedures developed

by companies for their own step-by-step procedures for daily operations and regulatory
compliance. These procedures are designed for all personnel ranging from newly trained
employees to long-term, experienced personnel. These SOPs should cover every aspect of the
process operation.
It has a set of instructions that have been developed to define or standardize the exact
steps to perform specific tasks. These steps have been found to provide consistent,
repeatable results regardless of who is performing the task. Controlling costs and
assuring quality are keys to being successful in any business. SOPs help accomplish
both of these objectives.
Where are SOPs applied?

In manufacturing, SOPs should be in-place for:
 Equipment startup and operation
 Equipment set up and change over
 Product assembly
 Inventory tracking
 Material ordering
 Material receiving
 Maintenance procedures
 Material processing (e.g., mixing, batching) 
 Quality control
 Any business or process step that needs to be controlled 
SOP’s made by me.

1.C3 Line Station
 C3 H2 Breaker
 C3 Pole Assembly
 C3 Test Breaker
 C3 Facia
2. Left Plate Assembly
3. FN Assembly
4. Spin Press Workshop
5. Reviting Workshop
6. SR Release Mouting
7. SOP Indicator
8. Machine Workshop

My Role in SOP making

A standard Operating Procedure (SOP) is a document that contains accurate
and detailed instructions to perform a process or procedure. So I ensured that the
procedure is performed the same way each time and the same way by each person.
Without relevant SOPs in place, whilst everyone may want to do the right
thing, often everyone’s version of that right thing is likely to be slightly different. So
how things are done are likely to vary according to who is doing that thing. If the
expectation is that everyone is to follow the rules, then everyone needs to know what
those rules are. That means that the rules need to be written down. So I wrote down
basic rules and basic instructions to follow
while inspecting various assembly lines.
L&T had their own SOP template. The main sections of a usual templat e are SOP
number, title, purpose, list of equipment or material used in the procedure, roles
and responsibilities, scope, procedure steps, summary and change history. While
starting to write an SOP that I defined the procedure about which it will be written.
At this point only I defined the critical and non-critical steps of the SOP, then listed
the steps in sequence to be executed.I always kept the reader in my mind while
writing the content. By understanding that will be reading it, and thinking about
their experience and background I wrote it. I used active voice that makes an SOP
more direct which can also be helpful to the reader.
I used tables and flowcharts in some SOPs that can be very useful and can give readers
a proper guideline.After writing it down, I sent it for review to appropriate individual
for that specific SOP. Then reviewers included colleagues who will be using the SOP,
Quality Assurance (“QA”) managers, research facilitators, line supervisor. If any
mistakes found in that SOP, reviewer informed me that. He made sure that I will
correct that mistake and will make it again with no mistakes.
Then at the end the approved SOPs were ready to distribute at shop floor.

Summary:-
Some organizations have an online system which lists and logs SOPs, SOP users and alerts when
SOPs are due to be reviewed etc. Systems vary, but it is important to think about how you
communicate SOPs to the relevant individuals. Also think about how these individuals will
communicate back to you, e.g. as to how well the SOPs are functioning and when changes may need
to be made to update the SOPs as requirements change.
SOPs can seem a little daunting when you are first asked to produce one! But once you start, you
begin to learn to art and science of producing a document that is clear and brief and allows the
reader to carry out a task or process with confidence and ease.
SOP format for

Figure 7.11
L&T

4 .5S work
5S is the name of a workplace organization method that uses a list of five Japanese words: seiri, seiton,
seiso, seiketsu, and shitsuke. Transliterated into Roman script, they all start with the letter "S". The list
describes how to organize a work space for efficiency and effectiveness by identifying and storing the
items used, maintaining the area and items, and sustaining the new order. The decision-making process
usually comes from a dialogue about standardization, which builds understanding among employees of
how they should do the work.
In some quarters, 5S has become 6S, the sixth element being safety.
The 5 S
There are five 5S phases: They can be translated from the Japanese as "sort", "set in order",
"shine", "standardize", and "sustain". Other translations are possible.
1th S
(Sorting)
 Make work easier by eliminating obstacles.

 Reduce chances of being disturbed with unnecessary items.
 Prevent accumulation of unnecessary items.
 Evaluate necessary items with regard to cost or other factors.
 Remove all parts or tools that are not in use.
 Segregate unwanted material from the workplace.
 Define Red-Tag area to place unnecessary items that cannot immediately be disposed of.
Dispose of these items when possible.
 Need fully skilled supervisor for checking on a regular basis.
 Waste removal.
Before After

2nd S
Set In Order
 Arrange all necessary items so that they can be easily selected for use.
 Prevent loss and waste of time by arranging work station in such a way that all tooling /
equipment is in close proximity.
 Make it easy to find and pick up necessary items.
 Ensure first-in-first-out FIFO basis.
 Make workflow smooth and easy.
 All of the above work should be done on a regular basis.
 Maintain safety.
Before After

3 rd S
(Shine ) Shine
 Clean your workplace completely.

 Use cleaning as inspection.
 Prevent machinery and equipment deterioration.
 Keep workplace safe and easy to work.
 Keep workplace clean and pleasing to work in.
 When in place, anyone not familiar to the environment must be able to detect any problems
within 50 feet in 5 secs.
Before After

4th S
Standardize
 Standardize the best practices in the work area.

 Maintain high standards in workplace organization at all times.
 Maintain orderliness. Maintain everything in order and according to its standard.
 Everything in its right place.
 Every process has a standard.
(Prepare Standard Operating Procedure) (SOP)

Figure 7.18
5th S (Sustain)
Sustain
 Not harmful to anyone.

 Also translates as "do without being told".
 Perform regular audits.
 Training and discipline.
 Training is goal-oriented process. Its resulting feedback is necessary monthly.
 Self discipline

s.Audit check list
e
Month:
GENERIC CHECKLIST FOR GMP AUDIT
Zone to: Subzone No: Area:
1 .....-.
.N METHOD MAX DATE:

MARK
1 SHE (Health-safety-environment) s Major Observations
Are the fire e tinguishers in working condition,within due date

1
for testing,at designated locations and easily accessible?
2 Is there administration of First-Aid box? 5
3 Is there any loose wire,hanging wire,undressed w ire, open 5

I junction bo?
4 Is exhaust fan w orkin g?
Is there any material in front of panels I junction box /switch
5 5
box /sr etcher and touching it ?
Is there any non usage of personal protective equipments (

6 sa fety shoes, gloves, helme.ts,gog:gles,masks,ear plugs 5
etc.) noticed during audit ?
Is there disposal system for Coolant/oil rejection/empty

7 5
container of orease and is ef fective?
8 Is there rubber mat in front of electrical panels?
9 Is Safety gaurds are available at desired pla ces?

Is there any spitting of pan,gutkha and pouch ,cigarate buts
10 5
livino on floor ?
11 Ar e the broken pallets used on shop floor ?. 5
SUBTOTAL 35
PERCENTAGE(%) SCORE 0
MAX
2 1S (sorting out unnecessary items), MARK Observations
s
Ar e all unwanted items r emoved from work area?(e.g.-
1 5
unwanted fiXIures,tools,equipmemts etc.)
2 Are the empty bins or boxes laying on floor? 5

Is there out dated OS/documentslinsp sheets and
3
stationary in dra wer/cupboard?
4 Is there Excess material ?. 5

Is Rejected material /excess materialmoved to r ed tag
5 5
l r.,.A ?
Is the empty containers of thinner,grease etc.laying
6
in work area?
Figure 7.18

CHAPTER 8.PROJECTS DONE IN INDUSTRY

Gauge Implementation
This gauge goes under the POKE YOKE theory ,GO NO Gauge was brought in
process.
Telescopic shaft had defects due to mismatch of the alignment the
telescopic shaft used to get mounted and a bent or a cross.to avoid this error the
NO GO gauge was designed
Drawbacks of the component(Telescopic shaft)

 Quality decreases.
 Costumer complaints.
 Product liability.
 Defects in design.
 Defects in manufacturing.
Figure 8.1

Figure 8.2
Figure 8.3
Defective piece will not pass through the gauge .Accurate component as per
the drawing will be able to rest

CHAPTER 9. CONCLUSION
It has been an outright pleasure for me to get a chance to work in one of the prestigious
companies in India. At the end of my training period, which I refer to as most exciting,
enriching, and challenging experience ever in engineering curriculum, I wish to summarize the
benefits over a period of six months. The training has certainly helped me in bridging the gap
between theory and practical knowledge.
It provided me with an opportunity to learn under different environment. I gained quite a lot of
things from this training. This training offered an exposure to industrial environment, which
cannot be stimulated in engineering college.
I got the opportunity to work in the Production department which plays a pivotal role in the
manufacturing carried out at L&T Electrical and Automation Independent Company. I
understood the scope and job responsibilities of various departments of an organization. I came
in contact with some latest fields of technology, which were unknown to me and thus broaden
my knowledge base.
Apart from general objectives achieved through this training, there have been significant
contributions that this training helps to become a successful engineer. Handling various pressures
while working & facing various problems & completing the work on time shows one’s ability to
cope with different situations & makes one mentally stronger & helps one to come out
triumphant facing various difficulties. These have extreme importance and seldom recur in one’s
career.
Such training not only gives commercial and management exposure but also enables one to
visualize work situations better. It acts as a silver lining of knowledge to create confidence in a
trainee. This training will definitely enhance our rate of progress and will make our future
working more easily.
Lastly, I would take this opportunity and thank Mrs.Anita Raut Mr. Nitin Gajendragadkar ,
Mr. Nitin Sogam,. who has given me complete support, guidance, insights and shared his
knowledge and experience with me.
Thus I confidently conclude that this was the most beneficial and enlightening experience which
is bound to help me in future.

CHAPTER 10. BIBLIOGRAPHY

Refrences-:
1. www.larsentoubro.com
2. C-power manual
3. www.wikipedia.org
4. 172.18.107.30/intranet/ebg
5. www.atl.ltindia.com
5. www.value-eng.org
6. www.supplychainmetric.com
7. SAP logon software
8. www.leanmanufacturingtools.org

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INPLANT TRAINING APRIL2019

SWITCHGEARS MATERIAL DEPARTMENT

GAYATRI GAUTAM SONAWANE

GOVERNMENT POLYTECHNIC MUMBAI

GOVERNMENT POLYTECHNIC MUMBAI Page 1

INPLANT TRAINING REPORT

Gayatri Gautam Sonawane (SS16ME033)

College Supervisor : Dr.S.B.Mahagaonkar

Name of the Organization: Larsen & Toubro Ltd.

GOVERNMENT POLYTECHNIC MUMBAI Page 2

e LARSEN & TOUBRO

CPD/AT/IPT/PS N0.20183431 May 8, 2019

Name Ms. Gayatri Gautam Sonawane

College Government Polytechnic, Mumbai

Branch I Discipline Mechanical Engineering

Category lnplant Trainee

Stipend Rs. 3000/- P.M.

Date of Joining December 10, 2018

Date of Leaving May 8, 2019

Department/Place of Work Electrical & Automation IC-

for LARSEN & TOUBRO LIMITED

GOVERNMENT POLYTECHNIC MUMBAI Page 3

GOVERNMENT POLYTECHNIC MUMBAI

Signature of project guide Signature of Head of Dept.

Signature of Principal Signature of

GOVERNMENT POLYTECHNIC MUMBAI Page 4

GOVERNMENT POLYTECHNIC MUMBAI Page 5

I was placed in Manufacturing Department and Switchgears material department of

GOVERNMENT POLYTECHNIC MUMBAI Page 6

3 Introduction To Engineering department 15

4 Introduction of Switchgears Material Department 23

5 Study Of Air Circuit Braker 25

6 Study of SAP System 34

GOVERNMENT POLYTECHNIC MUMBAI Page 7

4 4. SMD Roles and Responsibility 23

5 5.View of Air Circuit Breaker 25

GOVERNMENT POLYTECHNIC MUMBAI Page 8

8 8. POKA YOKE Fixture 57

GOVERNMENT POLYTECHNIC MUMBAI Page 9

CHAPTER 1. INTRODUCTION TO L&T

A company was founded in Bombay (Mumbai) in 1938 by two Danish engineers,

GOVERNMENT POLYTECHNIC MUMBAI Page 10

GOVERNMENT POLYTECHNIC MUMBAI Page 11

HED Diversified Business

GOVERNMENT POLYTECHNIC MUMBAI Page 12

CHAPTER 2. INTRODUCTION TO ELECTRICAL AUTOMATION AND

GOVERNMENT POLYTECHNIC MUMBAI Page 13

GOVERNMENT POLYTECHNIC MUMBAI Page 14

CHAPTER 3. Engineering Department

GOVERNMENT POLYTECHNIC MUMBAI Page 15

 Analysis and study of various assembly processes at manufacturing line.

of the particular product.

reduce weight of the product.

 Observe various assembly processes and drawing SOP

(Standard Operation Procedure) sheet on the basis of observation.

 Vendor visits for new development and process checking.

 Report to other departments for various ongoing technical activities.

 Update information in the SAP (system application & products)

GOVERNMENT POLYTECHNIC MUMBAI Page 16

In this shop, assembly of breakers and sub-assemblies of different components takes

GOVERNMENT POLYTECHNIC MUMBAI Page 17

C2M & C2E FLOW LINE

Inputs from vendors, C&F shop, Sub-