30 DAYS INDUSTRIAL TRAINING REPORT

ON
INDUSTRIAL EXPERIENCE
IN
ELECTRONICS DEPARTMENT
01 August 2023
BHAGWATI TRADERS
SUBMITTED IN PARTIAL FULFILLMENT FOR AWARD OF DIPLOMA IN

ELECTRONICS ENGINEERING

SUBMITTED BY:
SHIVENDU GUPTA

SUBMITTED TO:
SURESH GUPTA

SIGNATURE/STAMP:

1
 ACKNOWLEDGEMENT

I take this opportunity to express my profound gratitude and deep regards to my

guide for his exemplary guidance, monitoring and constant encouragement
throughout the course of this thesis. The blessing, help and guidance given by
him from time to time shall carry me a long way in the journey of life on which I
am about to embark.

I also take this opportunity to express a deep sense of gratitude to Bhagwati

Traders, for his cordial support, valuable information and guidance, which helped
me in completing this task through various stages.

I am obliged to staff members of Bhagwati Traders, for the valuable

information provided by them in their respective fields. I am grateful for their
cooperation during the period of my assignment.

Lastly, I thank almighty, my parents for their constant

encouragement without which this assignment would not be possible

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 INDEX

Sr. No. Content Page No.

01. The introduction of the employer 01-02
02. The entry access in a factory 02-04
03. Connection of a factory to 11KV 3 Phase Line 04-08
04. Metering room in factory 08-11
05. Water pipeline for fire emergency 11-13
06. Cooling tower in factories 13-16
07. Earthing system in factories 16-19
08. Mini Crane for lifting heavy blocks 19-21
09. Melting plastic granules before molding it 22
09. Pen Molding machines & molds 23-26
10. Beginning of new Workshop Experience 26-29
11. Repairing a timer 29-32
Repairing & Rectifying errors in the temperature controller
12. 32-34
13. Conclusion 35

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The introduction of the employer.

Bhagwati Traders is a reputable company specializing in the provision of

industrial equipment to factories, coupled with maintenance support when
needed. The company plays a crucial role in facilitating the smooth operations of
various industries by supplying high-quality machinery and offering maintenance
services to ensure the efficiency of factory processes.

My introduction to Bhagwati Traders began when I recognized the significant

impact they have on the industrial sector. Intrigued by their commitment to
delivering top-notch equipment and services, I sought an opportunity to work with
them and explore the intricacies of the industrial landscape. Fortunately, I was
granted an opportunity to join Bhagwati Traders and contribute to their mission of
enhancing the operational capabilities of factories.

Upon joining Bhagwati Traders, I was given the opportunity to work in their
well-equipped workshop. This experience provided me with valuable insights into
the diverse range of industrial equipment they handle, as well as the meticulous
processes involved in equipment maintenance. The hands-on exposure in their
workshop allowed me to understand the intricate details of various machinery
and the importance of regular upkeep to ensure optimal performance.

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One of the most memorable experiences during my time with Bhagwati Traders
was the chance to work on a project with a renowned pen manufacturing
company. This project involved providing the factory with specialized industrial
equipment and offering maintenance assistance to enhance their production
capabilities. Collaborating with the pen company allowed me to witness firsthand
the impact of Bhagwati Traders' expertise in optimizing factory processes.

Throughout this experience, I gained practical knowledge about the challenges

faced by factories and the role Bhagwati Traders plays in addressing those
challenges. The exposure to the inner workings of a pen company underscored
the importance of reliable industrial equipment and effective maintenance
practices in ensuring the seamless operation of manufacturing units.

In summary, my journey with Bhagwati Traders has been both enlightening and
rewarding. The hands-on experience in their workshop and the opportunity to
contribute to the improvement of a pen manufacturing company have deepened
my understanding of the industrial sector. Bhagwati Traders' commitment to
excellence in providing industrial solutions has not only shaped my professional
growth but has also instilled in me a profound appreciation for the critical role
they play in supporting the efficiency and success of factories.

The entry access in a factory.

Access control rules in a factory are crucial for maintaining security, safety, and
operational integrity. These rules help regulate who can enter the premises and
under what conditions. The specific rules may vary depending on the nature of
the factory, industry regulations, and security protocols. Here are common
access control rules that might be implemented, including the role of security
guards:

Authorized Personnel Only:

Only individuals with proper authorization, such as employees, contractors, or

approved visitors, should be allowed to enter the factory premises.
Security Guards at the Gate:

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Security guards stationed at the entrance are responsible for verifying the identity
of individuals seeking entry. They may check identification, credentials, or use
other verification methods.
Gate Operation:

Security guards are typically the only individuals allowed to operate the entry
gates. This ensures that the entry process is controlled and monitored.
Visitors Protocol:

Visitors should follow a specific protocol, including registering at the gate,

providing identification, and being accompanied by an authorized employee or
guide while inside the premises.
Employee Access Cards or Biometrics:

Employees may be required to use access cards, key fobs, or biometric

verification to gain entry. This adds an additional layer of security and allows for
easy tracking of employee movements.
Delivery and Service Personnel Procedures:

Procedures should be in place for delivery and service personnel. This may
include checking manifests, verifying identities, and ensuring that deliveries are
made only to authorized areas.
Vehicle Access Control:

Access to the factory premises for vehicles may be restricted and controlled.
Drivers may need to provide identification, and vehicle inspections may be
conducted.
Restricted Areas:

Certain areas within the factory may have restricted access. Only personnel with
specific clearance or authorization should be allowed in these areas.
Emergency Access:

Emergency procedures should be established to allow quick and unimpeded

access to authorized personnel in case of emergencies. This may include fire
exits or emergency access gates.
Compliance with Safety Regulations:

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Access control rules should comply with safety regulations and standards to
ensure the well-being of everyone on the premises.
Electronic Surveillance:

Security measures, such as CCTV cameras and other electronic surveillance

systems, may be in place to monitor activities at the entrance and other critical
points.
Training for Security Personnel:

Security guards should undergo training to understand and implement access

control procedures effectively. This includes understanding the importance of
following protocols and treating individuals with respect while ensuring security.
It's essential for factories to establish clear and well-communicated access
control policies to maintain a secure and efficient working environment. These
rules contribute to the overall safety of the facility and its occupants.

The connection of a factory to a 3 Phase 11KV Line.

Figure: 3 Phase line connections to factories

Source: Internet

Introduction:
The purpose of this report is to analyze the connection of a factory in India to an
11kV 3-phase power supply. The availability and reliability of electrical power are

4
critical for industrial operations, and understanding the connection details is
essential for ensuring efficient and safe functioning.

Power Supply Overview:

The factory under consideration is connected to the local power grid, which
provides an 11kV 3-phase power supply. This high voltage is chosen for industrial
applications due to its ability to transmit large amounts of power over long
distances with reduced transmission losses.

Connection Components:
a. Step-Down Transformer:

Figure: Step Down Indoor Type Transformer

Source: Internet

The 11kV supply is first connected to a step-down transformer located within the
factory premises.
The transformer's primary winding is connected to the 11kV supply, and the
secondary winding provides a lower voltage suitable for industrial usage.

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b. Distribution Board:

Figure: Distribution Board

Source: Internet

After stepping down the voltage, the power is distributed to various sections of
the factory through a distribution board.
The distribution board serves as a central point for routing power to different
departments and equipment within the facility.

c. Switchgear and Protection:

Figure: Switchgear
Source: Internet

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Switchgear is employed to control and protect the electrical equipment. It
includes circuit breakers, isolators, and other protective devices.
Overcurrent and overvoltage protection mechanisms are in place to safeguard
the equipment from potential damage.

d. Busbars and Cables:

Busbars are used to carry the 3-phase power from the distribution board to
different sections of the factory.
High-quality insulated cables ensure the safe and efficient transmission of power
within the facility.
Benefits of 11kV Supply:
a. Reduced Transmission Losses:

Higher voltage reduces transmission losses, allowing the factory to receive

power efficiently over longer distances.
b. Equipment Compatibility:

Many industrial machines and equipment are designed to operate optimally at

11kV, enhancing compatibility and efficiency.
c. Cost Efficiency:

Higher voltage transmission is often more cost-effective, especially for large

industrial setups, reducing the overall power distribution cost.
Challenges and Considerations:
a. Safety Measures:

Safety protocols, including proper grounding, are crucial to prevent electrical

hazards.
b. Maintenance:

Regular maintenance of transformers, switchgear, and other components is

necessary to ensure the continuous and reliable operation of the power supply
system.
c. Voltage Fluctuations:

Voltage fluctuations and power quality issues must be monitored and addressed
to prevent damage to sensitive equipment.

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Conclusion:
The 11kV 3-phase power supply to the factory in India is a vital component of its
operations, providing a reliable and efficient source of electrical energy. Proper
design, maintenance, and safety measures are essential to ensure the
uninterrupted functioning of the power supply system, contributing to the overall
productivity and success of the industrial facility.

The metering room in a factory.

A metering room in a factory is a designated area where various meters and
measuring devices are installed to monitor and measure different aspects of the
electrical power distribution system within the facility. The primary purpose of a
metering room is to provide accurate information about the consumption, quality,
and performance of electrical power, allowing the factory management to make
informed decisions regarding energy usage, efficiency, and maintenance. Here
are some key components and functions typically associated with a metering
room in a factory:

Energy Meters:

Figure: Energy Meter

Source: Internet

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Energy meters are installed to measure the total electrical energy consumption of
the factory. These meters record the amount of electricity consumed over specific
periods, often in kilowatt-hours (kWh).
Power Quality Meters:

Power quality meters monitor and analyze various aspects of the electrical
power, such as voltage, current, power factor, and harmonic distortions. This
information helps identify and address issues related to power quality that may
affect the performance of electrical equipment.
Sub-Meters:

Sub-meters are installed to measure the energy consumption of specific sections

or equipment within the factory. This allows for a more detailed understanding of
energy usage and helps in identifying areas for potential energy savings.
Voltage and Current Meters:

Voltage and current meters provide real-time information about the electrical
parameters within the factory. Monitoring these parameters is crucial for ensuring
that the electrical distribution system operates within safe and efficient limits.
Demand Meters:

Demand meters measure the rate at which electrical power is being consumed,
helping the facility management to understand peak demand periods. This
information is valuable for optimizing energy usage and managing peak demand
charges.
Data Logging and Communication Equipment:

Modern metering systems often include data logging capabilities and

communication interfaces. Data logging allows for the collection of historical data,
while communication interfaces enable remote monitoring and control of the
metering system.
Safety Measures:

The metering room may include safety features such as fire detection and
suppression systems, ventilation, and appropriate electrical safety measures to
ensure a secure working environment.

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Integration with Building Management Systems (BMS):

The metering room may be integrated with the overall Building Management
System (BMS) of the factory. This integration allows for centralized monitoring
and control of various building systems, including electrical power distribution.
Compliance with Standards and Regulations:

The design and installation of metering systems in the metering room should
comply with relevant electrical standards and regulations to ensure accuracy,
safety, and reliability.
In summary, a metering room in a factory serves as a centralized location for
monitoring and measuring electrical parameters, providing essential data for
energy management, efficiency improvement, and maintenance planning.

Water Pipeline System for Fire Emergency in a Factory.

1. Introduction:
The purpose of this analysis is to evaluate the water pipeline system
implemented in a factory for addressing fire emergencies. The effectiveness and
reliability of this system are critical to ensuring the safety of personnel, protecting
assets, and minimizing potential damages in the event of a fire.

2. Overview of Water Pipeline System:

a. Source and Supply:
- The water pipeline system is connected to a reliable water source, such as the
municipal water supply or an on-site reservoir.
- Adequate water supply is essential to sustain firefighting efforts for an extended
duration.

b. Distribution Network:
- The water pipeline is strategically laid out across the factory premises to cover
all critical areas, including production units, storage facilities, and administrative
buildings.
- The pipeline layout should adhere to national and local fire safety regulations.

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c. Pump Systems:
- Pump systems are integrated into the water pipeline to ensure sufficient water
pressure for firefighting.
- Regular maintenance and testing of pump systems are essential to verify their
functionality during emergencies.

3. Water Pipeline Capacity and Pressure:

a. Capacity Assessment:
- The capacity of the water pipeline is evaluated based on the factory's size, fire
risk assessment, and potential firefighting requirements.
- The system should have the capacity to deliver an adequate volume of water to
suppress different types and sizes of fires.

b. Pressure Requirements:
- Water pressure is a critical factor in the effectiveness of firefighting efforts.
- The pipeline should maintain sufficient pressure at all outlets to ensure effective
water distribution.

4. Fire Hydrants and Hose Reels:

a. Placement and Accessibility:
- Fire hydrants and hose reels are strategically placed throughout the factory,
ensuring easy accessibility for emergency responders.
- Placement considers the nature of operations and potential fire hazards.

b. Maintenance and Inspection:

- Regular inspections of fire hydrants and hose reels are conducted to identify
and address any issues promptly.
- Routine maintenance ensures that the equipment is operational when needed.

5. Monitoring and Control:

a. Control Valves:
- Control valves are installed to regulate the flow of water within the pipeline
system.
- These valves enable the isolation of specific sections in case of maintenance or
emergencies.

b. Monitoring Systems:

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- Monitoring systems, including pressure gauges and flow meters, are
implemented to provide real-time information on the status of the water pipeline.
- Automated systems may be integrated to alert personnel in case of pressure
drops or anomalies.

6. Emergency Response Protocols:

a. Training and Drills:
- Factory personnel are trained on the proper use of firefighting equipment
connected to the water pipeline.
- Emergency drills are conducted regularly to ensure a swift and coordinated
response in case of a fire.

b. Communication Protocols:
- Clear communication protocols are established to coordinate between on-site
responders, external emergency services, and relevant authorities.
- Emergency contact information is prominently displayed.

7. Compliance with Standards and Regulations:

a. National and Local Regulations:
- The water pipeline system is designed and maintained in compliance with
national and local fire safety regulations.
- Periodic inspections ensure ongoing adherence to evolving standards.

8. Conclusion:
The water pipeline system in a factory for fire emergencies plays a pivotal role in
safeguarding the facility and its occupants. Regular maintenance, adherence to
standards, and robust emergency response protocols contribute to the
effectiveness of the system. Continuous monitoring and periodic assessments
are essential to ensure that the water pipeline remains a reliable and efficient tool
in the event of a fire emergency.

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Water tower system for cooling in a Factory.

Figure: Cooling Tower

Source: Internet

1. Introduction:
The objective of this report is to provide a detailed analysis of the water tower
and water cooling system implemented at theBC Manufacturing Facility. These
systems are integral components of the facility's infrastructure, serving essential
functions in the production process.

2. Water Tower Overview:

a. Purpose:
- The water tower serves as a critical component for ensuring a consistent and
reliable water supply throughout the facility.
- It provides water at a constant pressure, necessary for various manufacturing
processes and equipment.

b. Capacity and Design:

- The water tower is designed with a sufficient capacity to meet the peak water
demand of the facility.
- Consideration is given to factors such as production requirements, fire
suppression needs, and overall water usage.

c. Gravity-Driven Distribution:

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- The tower utilizes a gravity-driven distribution system to supply water to
different areas of the facility.
- This design ensures a reliable and continuous water supply, reducing the
dependence on electrically powered pumps.

3. Water Cooling System:

a. Application:
- The water cooling system is primarily employed to dissipate heat generated by
machinery and equipment during the manufacturing processes.
- It plays a crucial role in maintaining optimal operating temperatures for various
industrial applications.

b. Cooling Towers:
- The facility is equipped with cooling towers that facilitate the transfer of heat
from industrial processes to the environment.
- Cooling towers enhance the efficiency and longevity of machinery by preventing
overheating.

c. Closed-Loop System:
- The water cooling system operates as a closed-loop, minimizing water wastage
and environmental impact.
- Cooling water is recirculated through the system, and heat exchange occurs
through the cooling towers.

4. Maintenance and Monitoring:

a. Routine Inspections:
- Regular inspections of the water tower and cooling system components are
conducted to identify potential issues.
- Visual inspections, water quality checks, and structural assessments are part of
routine maintenance.

b. Cleaning and Treatment:

- Water treatment measures are implemented to prevent scale, corrosion, and
microbial growth within the systems.
- Scheduled cleaning of cooling towers ensures optimal heat exchange efficiency.

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5. Energy Efficiency:
a. Variable Frequency Drives (VFDs):
- VFDs are installed in the water pumping systems to optimize energy
consumption.
- The variable speed control allows for adjustments based on demand, reducing
energy wastage during periods of lower usage.

b. Energy Recovery:
- Efforts are made to recover and reuse heat from industrial processes for other
applications, enhancing overall energy efficiency.

6. Environmental Impact:
a. Water Conservation:
- The closed-loop design of the cooling system minimizes water consumption by
recycling cooling water.
- Water conservation practices align with environmental sustainability goals.

b. Emissions Reduction:
- The implementation of efficient cooling systems contributes to the reduction of
greenhouse gas emissions associated with energy-intensive cooling processes.

7. Conclusion:
The water tower and water cooling system at theBC Manufacturing Facility are
integral components of the production infrastructure, ensuring a reliable water
supply and efficient heat dissipation. The commitment to routine maintenance,
energy efficiency measures, and environmental considerations demonstrates the
facility's dedication to sustainable and optimized manufacturing processes.
Ongoing monitoring and adaptation to emerging technologies will further
enhance the effectiveness and sustainability of these crucial systems.

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Earthing system in factories.
Figure: GI Metal Stripe Network below ground
Source: Internet

Figure: Earthing Rod

Source: Internet

1. Introduction:
This report provides a detailed analysis of the earthing system implemented in a
Factory. The earthing system is a critical component of the electrical
infrastructure, designed to ensure the safety of personnel, protect equipment,
and facilitate the proper functioning of electrical systems.

2. Purpose of Earthing:
a. Personnel Safety:
- The primary purpose of the earthing system is to provide a low-resistance path
for fault currents, ensuring the safety of personnel by preventing the buildup of
hazardous voltages.

b. Equipment Protection:
- Earthing helps protect electrical equipment by facilitating the rapid dissipation of
fault currents, reducing the risk of damage and extending the lifespan of
machinery.

3. Components of the Earthing System:

a. Earth Electrodes:

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- Various types of earth electrodes, such as rods, plates, or grids, are
strategically installed in and around the factory to establish a reliable connection
with the ground.

b. Conductors and Bonding:

- Copper or aluminum conductors are used to connect the earth electrodes to the
electrical distribution system.
- Effective bonding ensures a low-resistance path for fault currents and prevents
potential differences between equipment.

c. Grounding Grid:
- In areas where a large amount of electrical equipment is concentrated, a
grounding grid may be installed to ensure uniform grounding potential.

4. Compliance with Standards:

a. National and International Standards:
- The earthing system is designed and implemented in compliance with relevant
national and international standards, such as IEEE, IEC, or local electrical codes.
- Adherence to standards ensures that the earthing system meets safety and
performance requirements.

5. Types of Earthing:
a. System Grounding:
- The factory may employ system grounding, where one of the conductors
(neutral) is connected to the ground to create a reference point for the system
voltage.
- System grounding helps in voltage stabilization and fault current path
establishment.

b. Equipment Grounding:
- Equipment grounding involves connecting the metal frames of electrical
equipment to the earth to prevent accumulation of voltages on the equipment.
- It enhances the safety of personnel by minimizing the risk of electric shock.

6. Resistance Measurement:
a. Periodic Testing:

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- Periodic resistance measurements of the earthing system are conducted to
ensure that the resistance to earth is within acceptable limits.
- Testing helps identify any deterioration or corrosion in the grounding
components.

7. Lightning Protection:
a. Lightning Rods and Surge Protection:
- Lightning rods are installed at strategic points to divert lightning strikes away
from critical equipment.
- Surge protection devices are integrated to safeguard sensitive electronics from
transient overvoltages.

8. Maintenance and Inspection:

a. Scheduled Inspections:
- Regular inspections of the earthing system are scheduled to identify and rectify
any issues promptly.
- Visual inspections, thermal imaging, and resistance measurements are part of
routine maintenance.

b. Record Keeping:
- Comprehensive records of earthing system installations, maintenance activities,
and test results are maintained to track the system's performance over time.

9. Employee Training:
a. Safety Awareness:
- Employees receive training on the importance of electrical safety and the role of
the earthing system in preventing electrical hazards.
- Emergency response protocols are communicated to ensure a swift and safe
response in case of electrical faults.

10. Conclusion:
The earthing system in a Factory is a crucial element in ensuring the safety and
reliability of the electrical infrastructure. Compliance with standards, regular
maintenance, and employee training contribute to the effectiveness of the
earthing system, minimizing risks associated with electrical faults and creating a
safe working environment for all personnel in the factory.

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A mini crane arranged inside a factory, which is controlled by a
control switch for moving heavy pen molds.

Figure: Mini Crane

Source: Internet
1. Introduction:
This report outlines the integration and utilization of a mini crane equipped with
remote control technology within the manufacturing facility of a Company. The
primary purpose of this mini crane is to facilitate the movement of heavy pen
molds with precision and efficiency.

2. Mini Crane Overview:

a. Purpose:
- The mini crane has been strategically introduced to streamline the handling and
transportation of heavy pen molds within the factory premises.
- It is designed to enhance operational efficiency and reduce manual effort in the
material handling process.
b. Load Capacity:
- The mini crane is selected based on its load-bearing capacity to ensure it can
effectively handle the weight of various pen molds used in the manufacturing
process.

c. Compact Design:
- The crane is designed to be compact, allowing it to navigate through tight
spaces within the factory, reaching locations where larger cranes may face
challenges.

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3. Remote Control System:

Figure: Control Switch

Source: Internet
a. Wireless Technology:
- The mini crane is equipped with a wireless remote control system for operator
convenience and flexibility.
- The wireless technology allows the operator to control the crane from a safe
distance, ensuring optimal visibility during material handling.

b. User Interface:
- The remote control features an intuitive user interface with easy-to-use buttons
and controls.
- It is designed to provide precise and responsive movements for the crane,
allowing for accurate positioning of heavy pen molds.

c. Safety Features: - Safety features, such as emergency stop buttons and

collision detection sensors, are integrated into the remote control system to
enhance operational safety.
- These features mitigate the risk of accidents and damage to equipment.

4. Operational Efficiency:
a. Time Efficiency:
- The mini crane significantly reduces the time required for the movement of
heavy pen molds compared to traditional manual handling methods.
- This contributes to increased overall operational efficiency in the manufacturing
process.

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b. Reduced Manual Labor:
- Automation of the material handling process reduces the reliance on manual
labor, minimizing the risk of injuries and fatigue-related issues among factory
workers.

5. Adaptability and Versatility:

a. Versatile Applications:
- The mini crane is versatile and can be adapted for various applications within
the factory, catering to the diverse needs of pen mold handling.
- It can handle different types and sizes of pen molds efficiently.

b. Ease of Configuration:
- The crane's configuration can be easily adjusted to accommodate specific
production requirements or changes in the factory layout.

6. Maintenance and Support:

a. Routine Inspections:
- Regular inspections and maintenance checks are conducted to ensure the mini
crane operates at optimal performance.
- Any issues identified during inspections are promptly addressed to minimize
downtime.

b. Operator Training:
- Operators undergo comprehensive training on the operation of the mini crane
and the remote control system.
- Training includes safety protocols, troubleshooting procedures, and efficient use
of the crane for various tasks.

7. Conclusion:
The implementation of a mini crane with a remote control system for handling
heavy pen molds in the Factory demonstrates a commitment to enhancing
operational efficiency, safety, and adaptability. This technological advancement
contributes to a streamlined manufacturing process, reducing manual labor and
improving overall productivity. Continued monitoring, maintenance, and operator
training will ensure the sustained success and effectiveness of this innovative
solution within the factory environment.

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Melting plastic granules before molding it.

Figure: Melting machine for granules Figure: Granule cutter

Source: Internet Source: Internet
Melting Pipe for Plastic Granules:
Converts plastic granules into molten form, allowing for reuse in the
manufacturing process. Reduces dependence on new materials, minimizing
environmental impact.

Chopping Machine for Recycling:

Recycles rejected plastic components, transforming them into reusable granules.
Cuts costs and reduces environmental footprint.

Benefits:

Resource Efficiency: Recycles plastic waste within manufacturing.

Cost Savings: Minimizes the need for new raw materials.
Environmental Impact: Lowers carbon emissions and promotes a circular
economy.
Sustainability Practices: Aligns with global efforts to address plastic waste.
Challenges:
Equipment costs, initial setup investments, and employee training.

Conclusion:
Melting pipes and chopping machines offer a sustainable solution for pen
manufacturers, contributing to a circular economy and demonstrating a
commitment to responsible production practices.

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Pen molding machines and molds.

Figure: Pen molding machine

Source: Internet
Figure: Pen Mold
Source: Internet

1. Introduction:
This analysis report provides an
in-depth examination of the pen molding
machines and molds utilized in the
manufacturing processes at theBC
Company. These components play a
crucial role in the production of high-quality pens and significantly impact the
efficiency and precision of the manufacturing operations.

2. Pen molding Machines:

a. Machine Types:
- The Company employs various types of pen molding machines, including
injection molding machines, to create different components of pens.
- The selection of machines is based on the specific requirements of pen designs
and production volumes.

b. Automation and Integration:

- The pen molding machines are designed with a high degree of automation to
optimize production efficiency.

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- Integration with control systems allows for precise control over temperature,
pressure, and injection speed, ensuring consistent and high-quality outputs.

c. Energy Efficiency:
- Energy-efficient features, such as variable frequency drives (VFDs) and
optimized heating elements, are incorporated to minimize energy consumption.
- Continuous monitoring and adjustments contribute to sustainable manufacturing
practices.

3. mold Design and Manufacturing:

a. Customization and Flexibility:
- Pen molds are designed to accommodate a variety of pen styles and
specifications.
- The mold design allows for easy customization to meet changing market
demands and design preferences.

b. Material Selection:
- High-quality materials, often tool steel or other durable alloys, are used in the
fabrication of molds to withstand the rigors of repeated use and maintain
precision.
- Corrosion-resistant coatings may be applied to extend the lifespan of the molds.

c. Precision Machining:
- Advanced machining technologies, such as CNC machining, are employed to
achieve the required precision in mold design and fabrication.
- Tight tolerances are maintained to ensure uniformity and consistency in pen
production.

4. Maintenance and Monitoring:

a. Regular Inspections:
- Routine inspections of both pen molding machines and molds are conducted to
identify wear and tear, damage, or any deviations from specifications.
- Preventive maintenance is carried out to address issues before they impact
production.

b. Condition Monitoring:

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- Condition monitoring systems may be implemented to track the performance of
molds in real-time.
- Sensor data and analytics aid in predicting maintenance needs and minimizing
unexpected downtime.

5. Quality Control:
a. Dimensional Accuracy:
- Quality control measures ensure that pen molding machines and molds
maintain dimensional accuracy to meet design specifications.
- Periodic sampling and measurement checks are conducted to validate the
quality of produced pens.

b. Material Consistency:
- Consistent material quality is crucial for achieving uniform pen production.
- Raw material checks and stringent quality standards are applied to maintain
material consistency in the molding process.

6. Technological Advancements:
a. Industry 4.0 Integration:
- Integration of Industry 4.0 technologies, such as IoT sensors and data analytics,
allows for smart monitoring and predictive maintenance.
- Real-time data contributes to continuous improvement and optimization of the
manufacturing process.

b. Automation of Changeovers:
- Automated changeover systems are implemented to reduce downtime during
transitions between pen designs.
- Quick and efficient changeovers enhance overall production flexibility.

7. Conclusion:
The pen molding machines and molds at the Company exemplify a commitment
to precision, efficiency, and quality in pen manufacturing. Continuous
advancements in technology, rigorous maintenance protocols, and a focus on
quality control contribute to the success of these critical components in the
production process. The integration of smart technologies positions the company
for ongoing innovation and competitiveness in the dynamic market of pen
manufacturing.

25
My industrial experience with Bhagwati Traders.

This was my industrial experience with Bhagwati Traders, in which I learned a lot
of things. Now it was time to work with them in their workshop.

The new beginning of experience at their workshop.

I am excited to document my upcoming experience at Bhagwati Traders, where I

am set to work in their electronics workshop. This opportunity will involve
hands-on engagement with a range of critical instruments that form the backbone
of electronic systems. The workshop is well-equipped with essential devices such
as the multimeter, galvanometer, capacitor meter, clamp meter, soldering iron,
and a vacuum pump designed for soldering wire removal.

Key Instruments:

Multimeter and Galvanometer:

Figure: Digital Multimeter

26
Source: Internet
These instruments will be pivotal in measuring voltage, current, and resistance,
offering valuable insights into the electrical characteristics of components.

Capacitor Meter:

Figure: Capacitor meter

Source: Internet
The capacitor meter will be utilized for assessing and verifying capacitor values,
contributing significantly to the quality control processes in electronic circuitry.

Clamp Meter:

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Figure: Clamp Meter
Source: Internet
This device is instrumental for non-intrusive current measurements, providing
efficiency and safety during troubleshooting and maintenance activities.

Soldering Iron and Vacuum Pump:

Figure: Soldering iron and wire

Source: Internet
The soldering iron will be a primary tool for intricate soldering tasks, ensuring
precision in component connections. The vacuum pump will complement this
process by efficiently removing excess soldering wire.

Anticipated Learning:
I look forward to gaining practical experience with these instruments, honing my
skills in electronics, and understanding their applications in various projects. The
hands-on exposure within Bhagwati Traders' dynamic workshop environment
promises to be a valuable and enriching experience.

Conclusion:
As I embark on this journey within the electronics department at Bhagwati
Traders, I am eager to contribute my skills, learn from industry experts, and
actively participate in innovative projects. This report will serve as a
documentation of my progress and insights gained during this significant phase
of my professional development.

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Error encounters when troubleshooting and repairing a timer,

Introduction:
This detailed report chronicles the intricate journey undertaken to diagnose and
repair a malfunctioning timer. The process unfolded from an initial suspicion of an
open resistor to a comprehensive exploration of various components. The
ultimate discovery, a faulty 12V relay, highlights the importance of meticulous
troubleshooting and a systematic approach to electronic repairs.

I. Diagnosis: The Open Resistor Misjudgment

Figure: Resistors of different values at 0.25W rating

Source: Internet
The investigation commenced with a visual inspection that focused on a visibly
damaged resistor. The burst resistor suggested a potential open circuit,
prompting the decision to replace several resistors of the same value in the
anticipation of resolving the issue. However, the persistence of the malfunction
after the replacement indicated that the problem extended beyond the initially
identified faulty resistor.

II. Capacitor Check: A Thorough Examination

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Figure: Capacitor of different types
Source: Internet
The exploration then shifted to the capacitor section, where each capacitor
underwent meticulous examination using a capacitor meter. This step was crucial
in ruling out potential issues with capacitance. Surprisingly, all capacitors were
found to be within their specified parameters, eliminating them as the source of
the problem and requiring a more comprehensive investigation into other
components.

III. Rectifier Section Scrutiny: All Diodes Operational

Figure: Rectifier circuit

Source: Internet
With capacitors eliminated as potential culprits, attention turned to the rectifier
section. Each diode was subjected to rigorous testing to ensure proper
functionality. Despite the burst resistor suggesting a potential issue in this
section, all diodes were found to be operational. This raised further questions
about the root cause of the malfunction, necessitating a more thorough
examination.

IV. Choker Inspection: No Fault Detected

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The examination proceeded to the choker, a critical component in the power
supply. Despite initial suspicions, a detailed inspection revealed no signs of faults
in the choker. Its integrity was confirmed, eliminating another potential source of
the problem. Faced with persistent issues, the decision was made to take a more
drastic step: desoldering and replacing components from a known working timer.

V. Replacement of Components: A Temporary Solution

In an attempt to isolate the faulty component, all components were desoldered

and replaced with parts from another timer known to be in working order.
However, to our surprise, the issue persisted. This indicated that the problem
was not inherently within the replaced components but rather in a deeper layer of
the circuitry, prompting the need for a more exhaustive investigation.

VI. Identifying the True Culprit: TNY612PN IC Suspicions

Suspecting a potential fault in the TNY612PN IC, a comprehensive examination

was conducted. Despite initial suspicions, the IC was found to be functioning
correctly. This realization forced a reevaluation of the diagnostic process,
suggesting that the malfunction might be more elusive and intricate than initially
thought.

VII. The Hidden Culprit: A Faulty 12V Relay

Figure: 12V Relay

Source: Internet
After an exhaustive investigation that spanned various components, the true
culprit was identified: a faulty 12V relay. The relay, responsible for controlling the
flow of power within the timer, exhibited irregularities that were not immediately
apparent. The replacement of the faulty relay resulted in the timer exhibiting
normal functionality, conclusively confirming that the malfunction was rooted in
this seemingly inconspicuous component.

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Conclusion: A Lesson in Systematic Troubleshooting

The repair of the timer served as a profound lesson in systematic

troubleshooting. The initial misjudgment of an open resistor led to a meticulous
examination of each component, eliminating potential causes one by one. In the
end, it was the seemingly inconspicuous 12V relay that proved to be the source
of the malfunction. This experience underscores the importance of patience,
attention to detail, and a methodical approach in diagnosing and resolving
electronic issues, showcasing the intricate and multifaceted nature of electronic
system diagnostics and repairs.

Repairing & Rectifying errors in the temperature controller.

Introduction:
Temperature controllers play a crucial role in various industries, ensuring precise
control of temperature in processes to maintain optimal conditions. This report
outlines the repair and restoration process of a temperature controller that
utilized a thermocouple as its input sensor. During the diagnostic phase, it was
discovered that the rectifier circuit, a critical component in the controller, was
damaged, leading to erratic temperature readings and operational failures.

Working and Theory of the Temperature Controller:

The temperature controller under consideration operates based on the principle
of feedback control. It employs a thermocouple as its primary input sensor. A
thermocouple is a temperature-sensing device that generates a voltage
proportional to the temperature difference between its two junctions. This voltage
is then processed by the controller to make adjustments and maintain the desired
temperature setpoint.

The temperature controller typically comprises a comparator circuit, a

microcontroller or digital signal processor, and an output control mechanism such
as a relay or a solid-state switch. The comparator constantly compares the actual
temperature from the thermocouple with the setpoint temperature. Any deviation
triggers the controller to adjust the output to maintain the set temperature.

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Discovery of the Damaged Rectifier Circuit:
Upon initial inspection of the malfunctioning temperature controller, it was
observed that the temperature readings were inconsistent, and the output control
mechanism was not responding as expected. To identify the root cause, a
systematic approach to troubleshooting was adopted.
The thermocouple was tested and found to be functioning correctly. The attention
then turned to the power supply section, where the rectifier circuit is essential for
converting AC voltage to DC voltage, providing the necessary power for the
controller's electronics.

The rectifier circuit is crucial for maintaining a stable DC voltage, ensuring the
proper operation of the microcontroller and associated components. Upon closer
examination, it was evident that the rectifier circuit had suffered damage, likely
due to electrical surges or component aging.

Rectifier Circuit Repair Process:

The damaged rectifier circuit was carefully removed, and a detailed inspection
revealed burnt components and a visibly damaged PCB trace. Replacement
components were sourced, considering the specifications of the original rectifier
circuit. The damaged PCB trace was repaired using soldering techniques,
ensuring a reliable connection.

Post-repair, the entire temperature controller was subjected to rigorous testing.

The thermocouple readings were monitored against a calibrated reference, and
the output control mechanism was observed for responsiveness. The repaired
temperature controller demonstrated consistent and accurate temperature
control, confirming the successful restoration of functionality.

Conclusion:
The repair and restoration of the temperature controller highlighted the
importance of a systematic approach to troubleshooting electronic systems. The
identification and replacement of the damaged rectifier circuit were instrumental
in bringing the temperature controller back to optimal operational conditions. This
experience emphasizes the significance of regular maintenance and inspection
to prevent and address potential issues in industrial control systems, ensuring
the reliability and efficiency of temperature control processes.

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 CONCLUSION

In this training report, the culmination of experiences in electronic repairs and

factory operations underscores the multifaceted nature of troubleshooting and
industrial processes. The repair of a malfunctioning timer provided valuable
insights into systematic troubleshooting, emphasizing the importance of patience,
attention to detail, and a methodical approach. The exploration of various
components, from resistors to relays, showcased the intricate nature of electronic
systems and the persistence required to identify elusive faults.

The factory tour enriched the training by offering a firsthand glimpse into diverse
industrial elements. From cooling towers ensuring optimal temperatures to molds
shaping products with precision, and mini cranes exemplifying efficient internal
logistics, the tour illuminated the complexities of modern manufacturing
operations. This exposure contributes to a broader understanding of the interplay
between technology, machinery, and logistics within a production environment.

Additionally, the personal experience of diagnosing and repairing a temperature

controller further expanded the scope of this training. The identification of a
damaged diode highlighted the nuanced challenges encountered in electronic
diagnostics, emphasizing the need for a comprehensive understanding of
circuitry and components.

Collectively, the training experience encapsulates the dynamic and

interconnected aspects of electronic repairs and industrial operations. It
reinforces the importance of a systematic approach to problem-solving,
adaptability in the face of unforeseen challenges, and a holistic understanding of
the technologies at play. This training equips individuals not only with technical
skills but also with the mindset and knowledge necessary to navigate the
complexities of electronic systems and manufacturing environments effectively.

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