INDUSTRIAL TRAINING REPORT

(09MQ15)

Dissertation submitted in partial fulfillment of the requirements for the degree of

MASTER OF ENGINEERING
Branch: ELECTRICAL & ELECTRONICS ENGINEERING

of Anna University of Technology, Coimbatore

May 2012

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

PSG COLLEGE OF TECHNOLOGY

(Autonomous Institution)

COIMBATORE 641 004

PSG COLLEGE OF TECHNOLOGY

(Autonomous Institution)
COIMBATORE - 641 004

12 kW PHASE-SHIFT MODULATED FULL BRIDGE SMPS WITH ZERO

VOLTAGE SWITCHING
Bonafide record of work done by

SIVAKUMAR S.
(Roll No: O9MQ15)

Dissertation submitted in partial fulfillment of the requirements for the degree

of

MASTER OF ENGINEERING
Branch: ELECTRICAL & ELCTRONICS ENGINEERING

of Anna University of Technology, Coimbatore

May 2011

..

Mr. M. Sundaram
Faculty Guide

...

Dr. P. Navaneethan
Head of the Department

Certified that the candidate was examined in the viva voice examination held on ...

................
(Internal Examiner)

(External Examiner)

ACKNOWLEDGEMENT
I express my sincere thanks to

Dr. R. Rudhramoorthy, Principal,

PSG

College of Technology and Dr. P. Navaneethan, Head of the Department, Electrical &
Electronics Engineering, who have provided the opportunity and necessary facilities to
carry out the internship in L&T IES for my Masters thesis work.

I extend my esteemed thanks to my beloved guide Mr.M.Sundaram, Assistant

Professor (Sr.Gr.), Department of Electrical & Electronics Engineering, PSG College of
Technology, whose valuable guidance and inspiration throughout the course made it
possible to complete this project work successfully.

I also extend my sincere thanks to Mrs. Susan Wilson, Senior Project Manager
(Platinum Vertical), L&T IES and my external guide Mr. Jagdish Sahu, Project Manager
(DHM), L&T IES, for their valuable suggestions, guidance, encouragement and immense
help, at all stages of my project work.
I also extend my sincere thanks to L&T Integrated Engineering Services,
Larsen & Toubro Limited, Mysore for providing me a chance to work with world class
engineers.

With great pleasure and deep gratitude, I express my sincere thanks to all the
staff members of Electrical & Electronics Engineering Department whose assistance
played a big role in this project and have been of immeasurable value.

I gratefully acknowledge my indebtedness to my parents and friends who

contributed to this project work directly or indirectly.

Introduction:
PSG Industrial Institute is the pioneer in the manufacture of Motors and Pumps in India
appreciably contributing to the growth of agriculture and industry for more than eight
decades. In addition to this, they are widely acclaimed at the domestic fronts for their
domestic motors. PSG Industrial Institute has the facility to design, manufacture and
supply Domestic Pumps, Agricultural Pumps, Pumps & Motors and Industrial Motors to
the complete satisfaction of the customer. The
company has witnessed splendiferous growth since its inception in the year 1926. They
are the pioneers in the field of motor manufacturing in India. They have always
completely committed our self for the welfare of the society by providing them with the
best products that they deserve. Their annual turnover is about Rs. 10 - 25 Crore. The
employees working here are around 500 to 1000.
Industrial products
Industrial products are the products that are manufactired by any industry . It may be a
product or a service (as in service industry).The product may be for an end user or again
another industry. based on the type of the product and the consumer, they can be
classified as
The major classification would be as :
consumer goods:
These are the good produced for the consumption of the end users, which includes us.
example: Mobiles, Automobiles.
Product goods:
These are that are consumed by the other industries .These are also called as capital
goods. Example: Chemical industries

Industrial standards
safety
IMPORTANCE OF INDUSTRIAL SAFETY IN WORK PLACE
Industrial safety saves lives, limbs and money while
increasing trust and teamwork. Any ethical business will
place a high emphasis on safety if it values its employees
and future existence.
The problem is that these workplace accidents happen
again because of lack of consideration, especially by
employers. Because they lack the consequences of not
knowing the basic safety measures within the office, many
people meet accidents. It can be transmitted more than
just a headache for the company. In fact, some people are
going to sue.
Well-trained employees are valuable. If they are lost or
injured in accidents, that is a personal and an industrial
loss. Protecting employees with safety plans is the
protection of an investment as well as a human thing to do.
The industrial safety is classified in to two parts,
1. Personal safety
2. Equipment safety

PERSONAL SAFETY
PREVENTING EYE INJURIES IN THE WORKPLACE
More than 2,000 people injure their eyes at work every
day, making eye incidents one of the most common work-

related injuries. 1 out of every 10 of these cases requires

missed recovery days, and 10 to 20 percent of all cases
lead to temporary or permanent blindness.
The easiest way to instantly reduce the risk of eye injuries
is to provide adequate safety eyewear to all employees.
Proper eye protection addresses all of the common causes
of eyeinjuries: flying objects, particles, chemicals, and
tools. Make a careful assessment of the hazardous areas in
your workplace, and then provide at-risk employees with
safety goggles,full-face respirators, glasses, or welding
helmets depending on the conditions.

WHAT TO DO IN CASE OF AN EYE INJURY

If you get dust, a wood chip or another small particle in
your eye, look down and flush it out with eyewash solution.
Use water if eyewash solution is not available.
If a pesticide gets into your eyes, immediately use a
portable eye flush dispenser or call for help if needed to
get to an eyewash station.
Flush your eye with eyewash solution for 15 minutes. Have
someone call for medical attention while you are flushing.
The Material Safety Data sheet and label will give first aid
instructions.
PREVENTING HEARING LOSS IN THE WORKPLACE

 Hearing loss is another common condition that can be

prevented by taking simple safety precautions. Address
hearing safety by providing employees who work in loud
environments with ear plugs or ear muffs designed for their
level of exposure.
Make sure to routinely check hearing equipment for wear
and tear that might reduce its effectiveness.Some tasks
require time spent in an environment louder than 85
decibels. If your employees work in these conditions,
provide frequent breaks in addition to mandatory hearing
protection.

Make sure that employees who work in loud industrial

environments

have

their

hearing

tested

regularly.

Experienced ear specialists and audiologists can diagnose

conditions in their early and most treatable stages.

PREVENTING FALLS IN THE WORKPLACE

 To prevent dangerous falls in the industrial workplace,

examine work areas

carefully to uncover hazardous

conditions before employees ever step foot near them.

Address obvious hazards with safety railings, harnesses,
ropes, nets, or scaffolding.
Routinely check these safety measures to make sure they
are in good functioning order. If any unsafe conditions
develop, do not wait to fix them! Prioritize safety and take
care of them immediately, and do not allow any employees
near the work area until the hazard is removed.
You can also take preventative measures against falls by
ensuring proper lighting throughout the workspace. The
easier it is to see, the less chance of a misstep or
accidental fall. Staircases should be well-lit and completely
free of any obstacles.
Make an effort to educate workers continuously about
safety in the workplace. Use appropriate signage in higherrisk areas, and make sure employees are well-trained in
the

proper

use

of

safety

equipment.

Workers

will

appreciate your efforts to keep them out of harms way.

PREVENTING HEAD INJURIES IN THE WORKPLACE

Many head injuries occur when workers slip, trip, or fall so

its important to follow the fall prevention guidelines
outlined above. In addition, head injuries can be prevented
by distributing hard hats and head safety equipment to
protect workers in areas where objects are being moved
overhead. Outline expectations to employees to make sure
that objects are never moved when unprotected workers
are present.

 Hard hats should always be used in environments with

exposed beams, pipes, or low hanging obstacles. Its easy
for busy employees to get distracted in the midst of work
and bang their heads in these types of conditions, so make
hard hats mandatory.

TRAINING EMPLOYEES AND PROMOTING THE SAFETY FIRST MIND SET

Complimenting effective safety gear with high-quality

training significantly cuts the risk of industrial workplace
accidents. Establish a focus on safety and consistently
promote a safety first message to all employees as soon
as they start working for your company. By encouraging
this mindset, you can train employees to maintain a high
level of awareness and caution that will help them
naturally avoid accidents.
Its a good idea to schedule regular audits to stay on top of
important safety issues throughout the year. Information
gathered from these comprehensive safety checks can be
used to create updated training and educational material
that will further reduce the risk of accidents.
Its your responsibility to dictate a responsible and safetyoriented mindset in all employees. Use regular internal

communication to your advantage and reinforce the

message repeatedly. When safety is clearly the companys
number one priority, it becomes the top priority of its
employees as well.

EQUIPMENT SAFETY
Accidents in the workplace happen for a variety of reasons,
but poorly maintained equipment is a major cause.
Equipment-related

accidents

can

occur

when

the

equipment doesn't operate as it should or when people use

equipment they are not properly trained to operate.
Equipment-safety procedures should be implemented in
the workplace to keep operators safe and to keep the
equipment functioning properly.
TRAINING
Insufficient training is a main cause of accidents. Poorly
trained

equipment

operators

unknowingly

mishandle

equipment, and they are not prepared to react correctly if

something goes wrong. Implement a training program that
consists of both classroom training and hands-on training.
Classroom training gives participants knowledge of critical
emergencies they won't necessarily encounter during
training, such as what to do if the equipment catches fire.
Hands-on

training

teaches

participants

the

proper

techniques for using workplace equipment.

PREVENTIVE MAINTENANCE
Implement a preventive-maintenance program to keep
your equipment running smoothly. Preventive-maintenance

programs help to keep equipment in top shape and allow

maintenance crews to detect preventable errors. As part of
effective preventive-maintenance programs, employees
schedule routine maintenance of equipment.
They check the internal workings of the equipment, making
sure that all fluids are clean and at capacity and that vital
parts of the equipment, such as the brakes, are fully
functioning. Crews should test equipment while it is
running to detect potential problems. Maintenance crews
may test bearings, gears, engines and electrical wires as
part of the preventive-maintenance program.
INDUSTRIAL DISCIPLINES
Discipline is the process of changing a behavior to make it
conform to a rule or standard. For many people, discipline
has a negative connotation to it, especially when it is their
behavior that is being adjusted. In truth, though, discipline
is more than repeating the standard and doling out
punishment.
IMPORTANCE
Discipline in industry is an absolute necessity for efficiency.
If every employee does as he pleases the productivity
process will not be conducted effectively.
Such situation will not only be disadvantageous to the
employer, but also to the employees at large and to their
union.

GENERAL SET OF WORK RULES

All workers must punch/swipe their individual punch cards
before and after work times. A person caught performing

this activity for another employee is liable to immediate

dismissal.
All employees must start work punctually.
The following acts will be taken as misconduct,
Disobedience to any lawful and reasonable order of a

superior.
Theft, fraud or dishonesty with respect to the
employers business or property. Habitual absence

without leave. Habitual late attendance.

Drunkenness, taking illegal drugs fighting riorous or

disorderly or indecent behavior.

Bullying or harassing in any way, or person with

whom the employee has business-related contacts.

Sleeping during working hours.
Negligence.
Smoking in prohibited areas of the company.
Failure to follow safety rules and regulations.
Taking industrial action or inciting others to take
industrial action against the provisions of the IRA or
of any other law.

Introduction to 5S
In japanese

In english

seiri
seiton
seiso
seiketsu
shitsuke

Sort out
Set iin order
Shine
Standardise
Sustain

There are a lot of factores that must be included while implementing hthe 5S.These
factores include preparing the layout, Identifying the prrocess flow,Maintaining the
changes that occored etc.These factors will be elaboratd while discussing each seperately
SORT OUT
The process of sorting the required and the inventory items seperately.
This happens after the completion of work order.
The remains of the preios work ordeer are accounted and they are bagged to
INVENTORY.
Based on the new work order the required items will be taken from the inentory and it
will be accounted and then it will b sent to the approprate workstations.
ADVANTAGEES
Reduces confusion for the employeses.
Provides more workspace
Proper accounting of goods can be made at the end of each order work order.
SET IN ORDER:
The material sent to the inventory should be properly tagged.
The tag encloses the details like(no.of items,work order no.)
There should be a lost which encloses the details of all the tags that which is kept at
which point of the store room.
Similarly, the material that are sent to the workstations should be also catalouged and
cross checked.
A the workstation in the material should be arranged in a fashion so that the raw material
in on the one side and the other finished products are on the other side.
All the tools should be placed on the work station.
Proper color cooding should be given to each itemm on the workstation so that the
worker can work withour any confusion.
This method also helps in reduction of time.
Efficiency can also be improved.
SHINE
The working environments should be kept clean.
This reduces wastage.
This improves productivity
This helps in getting license for the poduct.
This also invokes customer satisfaction.
STANDARDIZE
Proper standars should be created
A standard way should be created for each product ,each pprocess, each item inside the
plant.
SUSTAIN

Constant review should be made.

Everything should be maintained.
PSG INDUSTRY DIVISIONS
The PSG industry has the following two divisions
The heavy engineering division (HED)
The rotating machinery division (RMD)
THE HEAVY ENGINEERING DIVISION:
The HED is where all the machining is being done for the pars of the LATHE.
THE LAYOUT OF THE HED

1.Design Department
2.Electrical Assembly for Lathe
3.Metrology Lab
4.Incoming Inspection
5.Final Inspection
6.Lathe Main Assembly
7.Students Workplace
8.Stores
9.Heavy Shop
10.Cutting Machine
11.Lathe PRE/SUB Assembly
12.Shaft Cell
13.Small Parts Cell
14.CNC Machining Centre
15.Stores for Raw Material
16.Tool & Cutter Grinders
17.Tool Crib
18.Sheet Metal Cutting Machine
19.Lathe Final Testing Section

1.Honing Machine
2.Line Boring Machine
3.Horizontal Boring Machine
4.Horizontal Boring Machine
5.Horizontal Boring Machine
6.Horizontal Boring Machine
7.Slotting Machine
8.Cylindrical Grinding Machine
9.Shaping Machine
10.Shaping Machine
11.Drilling Machine
12.Hobbing Machine
13.Universal Milling Machine
14.Shaping Machine
15.Drilling Machine
16.Surface Grinding Machine
17.Drilling Machine ( Angular Swivel)
18.Radial Drilling Machine
19.Universal Milling Machine
20.Bombay Lathe
21.Guideway Grinding Machine
22.Manager Table

1.Apron Box Sub Assembly

2.Thread & Feed Box Sub Assembly
3.Finished Sub Assembly
4.Head Stock Sub Assembly
5.Gear Box Sub Assembly
6.Final Finishing of Assembly ( Blue Matching)
7.Sub-Assembly Test Rigs
8.Drilling Machine
9.Grinding Machine
The products of the HED are:

PSG - 141 / A 141 (Light Duty Precision)

PSG - 124 / A 124 (Heavy Duty Precision)
PSG CNCT T 110 LATHE
PSG VMC
Electrospinning Machine
PSG-141 / A 141
(ALL GEARED PRECISION CENTRE LATHE)
PSG 141 / A 141 is a light duty precision lathe which is renowned for its quality and performance. Ideally suited for
production jobs and training purposes alike, its proven design guarantees several years of trouble-free service. The main
spindle runs on precision taper roller bearings. The built-in safety features ensure reliable operation. The main drive gears
are made from nickel-chromium steel, hardened and precision ground.

PSG-124 / A 124
(ALL GEARED HEAVY DUTY PRECISION CENTRE LATHE)
PSG 124 / A 124 type lathe is a heavy duty precision lathe renowned for its productivity in turning accurate components.
Ideally suited for general engineering and other production shops, its proven design guarantees several years of troublefree service. The main spindle runs on precision taper roller bearings. The built-in safety features ensure reliable
operation. The main drive gears are made from nickel-chromium steel, hardened and precision ground. The bed
guideways are also flame hardened and precision-ground. To improve productivity, attachments like hydraulic copying
attachment
or
taper
turning
attachment
can
be
fitted.

Electrospinnning Machine
PSG Electrospinning machine is ideally suitable for industries and educational institutions. Nanofibres' diameter and other
physical properties can be modified by adjusting the process parameters such as solution concentration, voltage, flow rate
and the distance between needleand collector. Thus,this machine would help the researchers and students to learn the
nanofiber processing techniques in detail. Customized set up canals be supplied.