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Summer Internship Report

On

TELECOM POWER SOLUTION

“Project on Switching Mode Power Supply (SMPS) manufacturing”

In

DELTA ELECTRONICS INDIA PVT LTD.

Rudrapur

In partial fulfilment of the award of degree of

MBA-TELECOMMUNICATION

From Amity Institute of telecommunication & Mgt. (Amity University)

Submitted To: Submitted By:

Prof. Marshal Sahni Gajesh Holani

Head of Department A1603709075

MBA-Telecommunication 2009-2011

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Table of Contents

1.Cover Page..............................................................................................................................1

2.Table of Contents....................................................................................................................2

3.Certificate (Internship Organisation).......................................................................................3

4.Certificate (Faculty Mentor)....................................................................................................4

5.Internship Summary................................................................................................................5

6.Task Assigned During the Internship......................................................................................6

7.Details of work done...............................................................................................................7

Introduction to Project...........................................................................................................7

Warehouse Management........................................................................................................8

Supply Chain Management....................................................................................................9

Production Planning and Control........................................................................................10

Planning ..............................................................................................................................12

SMPS Working.....................................................................................................................13

8. Learning From Summer Internship......................................................................................18

9. Recommendations on Summer Internship Task...................................................................19

Appendix A: Introduction to Internship Organisation............................................................20

Mission Vision & Goal...................................................................................................................20

Valued Partners..............................................................................................................................23

Financial Statement ......................................................................................................................26

Organisation Structure ..................................................................................................................29

Appendix B : ............................................................................................................................

Appendix C : ............................................................................................................................I

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Certificate from internship organisation

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Certificate from faculty mentor

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Internship Summary

Telecom Power Solution is a project for telecom equipments that are manufactured in delta for the minimum utilization of power and energy.

Delta is a company of Taiwan and they have established a plant in Rudrapur and their corporate office is in Gurgaon. The manufacturing of SMPS is done and for this the modules(rectifiers) are imported from Taiwan and some of the controllers also. Some of the raw materials are taken from the Indian vendors and assembling is done there in Rudrapur.

Under this project Switching mode power supply(SMPS) and Switching mode controller supply(SMCS) were manufactured as per the purchase order(PO) comes. Check Sheet was made by the engineering department and send to the Planning and production department(PPC). After this the modules and the availability of the equipments were checked in sore department and then an approximate date of delivery was told to the customer as per the Delivery order(DO).

The entire work was carried out on the SAP software.The PPC department works as a heart of the production plant the PPC department assingns work to all the departments of the industry and coordinates between them.I was assingned the task of visiting every department of the plant on the weekly basis and to learn the working of every department and finally analyze and give my views and ideas on the productivity of the plant can be increased.

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Tasks assigned during the internship:

1. Warehouse management and functions involved in it : The main objective of warehouse management is to achieve a sustainable competitive advantage inits area of operation. The functions involved were issue of components, rawmaterials from various sources

2. Manual Sales order(SO) for production and shortage analysis: As per the previous orders a forecasting was done and on the basis of which a sales order was released manually and according to that SO stock checking was made. If any shortage was found the fulfilment was done.

3. MPS run and release production order: Master production schedule was made and then the production order was released by the PPC department. We have to run the production as per the schedule.

4. Quality check and finished goods receiving: IP43, IP55 and IP56 quality checking was made and then the finished goods were carried to the finished goods area.

5. Closure of production order and daily office work: The cost varience analysis of order was made and closure of order was updated in SAP. Daily office work was done and was submitted to the mentor

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Details of Work Done :

1. Introduction

Wireless network communication has become an indispensable part of our personal and professional lives. Be it the use of mobile phones, or air-traffic control, or remote industrial monitoring, or military tracking- …wireless communication is a must. But wireless communication, though it makes lives so easy, is not a simple process at all. The establishment and use of wireless networks requires the installation and proper working of several equipments in several areas. For instance, taking the case of mobile communication, the process of data transfer from the sender to the receiver requires one or more of ‘base transceiver stations’(BTS), a ‘ main switching center’(MSC), ‘base switching station’(BSC) etc. at these sites, there are a number of equipments, such as transmitters, receivers,…etc.

These equipments generally run on a constant DC voltage, and are essential to be operative all the time, for their failure can shut down entire networks and can cause heavy monetary losses, in addition to the great inconveniences and time delays.

To make these equipments work flawlessly, it is essential that the power supply unit that provides them the correct amount of power, is designed and chosen with utmost care. This is where the Telecom Power System, or the DC Power Supply comes in handy. The systems are designed to provide DC power at a constant level, are expected to work continuously for long periods of time, are needed to provide back-up when needed, and are desired to give a warning in advance if there be any problem. In addition, they must be capable of working in

harsh environments, with greatly varying temperatures, humidity and dust.

Work was done with the collaboration of all the departments in the organization such as Supply chain management, planning production and control, purchase, warehouse etc. we been allotted the schedule during the internship to know about the working of each and every department and to know their importance. The work done in departments are explained in the report.

WAREHOUSE MANAGEMENT:

Store Receipt:

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1. Stores directly receives all components after visual checking of material and this is entered in the incoming material gate entry register. A gate entry number is given to each invoice and warehouse in charge is responsible for this.

2. Stores compares the bill invoice with the purchase order placed on supplier, mainly item description and its quantity.

3. Store informs the quality and purchase department for inspection and availability of the raw material in store by updating the SAP. Quality confirms the receipt on same format.

4. The IQC is done by the quality department and then it is been informed to store about the quality check and stores ensures that the sticker is put on each of the raw material checked.

5. Stores keep the material at a specified rack and their location is specified for easy accessibility.

Material issue:

1. PPC informs to warehouse for issue of the raw material for given production order in form of kit.

2. Warehouse issues the raw material against that purchase order(PO) in SAP and give the print out of issue slip to operator for issuing material physically.

3. For issue of material other than production order, a requisition slip is filled by the intender with a proper approval.

4. Warehouse issues the material to the intender’s cost centre.

5. If any of the material is found to be faulty ie is been send back to the warehouse from the production and new one is issued.

For details of department procedure , their incharge and stock location statement refer appendix 2.

Records:

1. Store requisition slip2. Physical inventory format

3. Daily General record schedule register(For inspection)

4. Daily GRS register(For finance)

5. BIN card

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6. Material status tag

SUPPLY CHAIN MANAGEMENT:

A supply chain, as opposed to supply chain management, is a set of organizations directly linked by one or more of the upstream and downstream flows of products, services, finances, and information from a source to a customer. Managing a supply chain is 'supply chain management'

Supply chain management is the most important department of the industry as it links from the time when a SO comes upto the time the production is not over.

The SCM flowchart of Delta electronics is as shown:

 

Apart from management through a common platform within the Group, each business group/unit also maintains its own supplier management system to meet requirements unique

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to their operations. To ensure high quality products from our suppliers and reduce risk, our supplier management framework is based around “Key Suppliers” and “Critical Components”

PRODUCTION PLANNING AND CONTROL:

Production Planning and Control Functions:

The basic phases of control of manufacture are easily identified in production planning and control. The plan for the processing of materials through the plant is established by thefunctions of process planning, loading, and scheduling. The function of dispatching puts the plan into effect; that is, operations are started in accordance with the plant. Actual performance is then compared to the planned performance, and, when required, corrective action is taken. In some instances re-planning is necessary to ensure the effective utilization of the manufacturing facilities and personnel.(Appendix 2)

Process Planning (Routing):

The determination of where each operation on a component part, subassembly, or assembly is to be performed results in a route for the movement of a manufacturing lot through the factory. Prior determination of these routes is the job of the manufacturing engineering function.

Loading:

Once the route has been established, the work required can be loaded against the selected machine or workstation. The total time required to perform the operation is computed by multiplying the unit operation times given on the standard process sheet by the number of parts to be processed. This total time is then added to the work already planned for the workstation.This is the function of loading, and it results in a tabulated list or chart showing the planned utilization of the machines or workstations in the plant.

Scheduling:

Scheduling is the last of the planning functions. It determines when an operation is to be performed, or when work is to be completed; the difference lies in the detail of the scheduling procedure. In a centralized control situation - where all process planning, loading, and scheduling for the plant are done in a central office- the details of the schedule may specify the starting and finishing time for an operation. On the other hand, the central schedule may simply give a completion time for the work in a given department.

Combining Functions:

While it is easy to define “where” as process planning, “how much work” as loading, and “when as scheduling, in actual operations these three functions are often combined and

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performed concurrently. How far in advance routes, loads, and schedules should be established always presents an interesting problem. Obviously, it is desirable that a minimum of changes be made after schedules are established. This objective can be approached if the amount of work scheduled for the factory or department is equal to or slightly greater than the manufacturing cycle. For optimum control, it should never be less than the manufacturing cycle.

Dispatching:

Authorizing the start of an operation on the shop floor is the function of dispatching. This function may be centralized or decentralized. Again using our machine-shop example, the departmental dispatcher would authorize the start of each of the three machine operations – three dispatch actions based on the foreman’s routing and scheduling of the work through his department. This is decentralized dispatching.

Reporting or Follow – up:

The manufacturing activity of a plant is said to be “in control” when the actual performance is within the objectives of the planned performance. When jobs are started and completed on schedule, there should be very little, if any, concern about the meeting of commitments. Optimum operation of the plant, however, is attained only if the original plan has been carefully prepared to utilize the manufacturing facilities fully and effectively.Corrective Action:

This is the keystone of any production planning and control activity. A plant in which all manufacturing activity runs on schedule in all probability is not being scheduled to its optimum productive capacity. With an optimum schedule, manufacturing delays are the rule, not the exception.

Re-planning:

Re-planning is not corrective action. Re-planning revise routes, loads, and schedules; a new plan is developed. In manufacturing this is often required. Changes in market conditions, manufacturing methods, or many other factors affecting the plant will often indicate that a new manufacturing plan is needed.

TYPE OF PRODUCTION SYSTEM:

Job or Unit production:

It involves production as per customer'sspecification each batch or order consists of a small lot of identical products and is different from other batches. The system requires comparatively smaller investment in machines and equipment. It is flexible and can be adapted to changes in product design and order size

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without much inconvenience. This system is most suitable where heterogeneous products are produced against specific orders.

PLANNING:

To maintain uninterrupted flow of materials to support the development schedules purchase department is there. It procure materials economically at a cost consistent with the quality and service required. However, generally all purchases may be attempted at the lowest cost. It provides the necessary expertise, advice, information to the Curators and Education Officers with regard to the best quality of material available in the market, supplier capability and performance etc and develop and maintain good buyer-seller relationship.

FUNCTIONS :

The main functions of the Purchase Department are defined as follows:

1. Procurement of stores through indigenous and foreign sources as required in accordance with the rules in force

2. Checking of requisitions/purchase indents. 3. Selection of suppliers for issue of enquiries. 4. Issuing enquiries/tenders and obtaining quotations. 5. Analysing quotations and bids etc., and preparation of comparative statement (quotation

charts). 6.Accounts Officer for pre-audit. 7. Negotiating contracts. 8. Checking legal conditions of contracts. Consulting Administrative Officer or Secretary, NCSM – where necessary. 9. Issue of Purchase Orders. 10. Follow-up of purchase orders for delivery in due time 11. Verification and passing of suppliers’ bills to see that payments are made promptly. 12. Correspondence and dealing with suppliers, carriers etc., regarding shortages, rejections

etc., reported by the Stores Department. 13. Maintenance of purchase records. 14. Maintenance of progressive expenditure statement, sub-head wise. 15. Maintenance of vendor performance records/data. 16. Arrangement for Insurance Surveys, as and when necessary. 17. Clearance of foreign consignments.

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SMPS WORKING

Block diagram of a mains operated AC-DC SMPS with output voltage regulation

Input rectifier stage:

If the SMPS has an AC input, then its first job is to convert the input to DC. This is called rectification. The rectifier produces an unregulated DC voltage which is then sent to a large filter capacitor. An SMPS with a DC input does not require this stage. An SMPS designed for AC input can often be run from a DC supply, as the DC passes through the rectifier stage unchanged.

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Inverter stage:

The inverter stage converts DC, whether directly from the input or from the rectifier stage described above, to AC by running it through a power oscillator, whose output transformer is very small with few windings at a frequency of tens or hundreds of kilohertz (kHz). The frequency is usually chosen to be above 20 kHz, to make it inaudible to humans. The output voltage is optically coupled to the input and thus very tightly controlled. The switching is implemented as a multistage (to achieve high gain) MOSFET amplifier. This section refers to the block marked "Chopper" in the block diagram.

Voltage converter and output rectifier:

If the output is required to be isolated from the input, as is usually the case in mains power supplies, the inverted AC is used to drive the primary winding of a high-frequency transformer. This converts the voltage up or down to the required output level on its secondary winding. The output transformer in the block diagram serves this purpose.

If a DC output is required, the AC output from the transformer is rectified. For output voltages above ten volts or so, ordinary silicon diodes are commonly used. The rectified output is then smoothed by a filter consisting of inductors and capacitors.

Simpler, non-isolated power supplies contain an inductor instead of a transformer. This type includes boost converters, buck converters, and the so called buck-boost converters. These belong to the simplest class of single input, single output converters which utilize one inductor and one active switch (MOSFET). The buck converter reduces the input voltage, in direct proportion, to the ratio of the active switch "on" time to the total switching period, called the Duty Ratio. A feedback control loop is employed to maintain (regulate) the output voltage by varying the duty ratio to compensate for variations in input voltage. The output voltage of a boost converter is always greater than the input voltage and the buck-boost output voltage is inverted but can be greater than, equal to, or less than the magnitude of its input voltage.

A feedback circuit monitors the output voltage and compares it with a reference voltage, which is set manually or electronically to the desired output. If there is an error in the output voltage, the feedback circuit compensates by adjusting the timing with which the MOSFETs are switched on and off. This part of the power supply is called the switching regulator. The "Chopper controller" shown in the block diagram serves this purpose.

The feedback circuit needs power to run before it can generate power, so an additional non-switching power-supply for stand-by is added.

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SMPS TOPOLOGIES

Different topologies of SMPS are referred to as forward or flyback.

- Feed forward SMPS circuits supply energy to the output capacitor when switching element (transistor) is ON.

- Flyback SMPS transfer energy to the output capacitor when the switching element is OFF.

TPS Manufacturing:

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These are the two flow charts for the Telecom Power Solution manufacturing. The production is done as per this flow chart and the charts for main assembly and sub assembly are also there. Any problems occurred during the manufacturing is been controlled as it is been indicated in work in progress(WIP) sheet and then improved instantly.

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Sub Assembly and Main Assembly:

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Learning from Summer Internship:

1. Time Management: Learnt about benefits of being punctual in time, how to priorities the work according to need and time and how effective scheduling reduces workload

2. Operations Management skills: Learned about how operations management is helpful in production

3. Leadership skills: Learnt that through patience and hard work only one can be good leader. Only good leader make right decision at right time.

4. Lean Management: Lean management teaches to handle work in given time.

5. Decision Making Ability: Learnt that decisions are taken keeping in mind some standard specific norms. Example : Pareto Analysis(Choosing what to Change), Grid Analysis(keeping in mind various factors)

6. Problem Solving Techniques: Flowchart(to understand process).

7. Project Management: having sound knowledge of all above skills helps in project management.

8. To tackle with the issues (like no one having the enough time to guide anyone, unclear goals, lack of resources) proactively and creatively.

9. Learning about softer skills like attitude and teamwork.

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10.To keep the industry mentor as well as college mentor posted about the activities done and to get updated with them.

Recommendation on Summer Internship task:

1. Implementation of the 5’S in the plant so that the space can be utilized efficiently and thus improve the productivity.

2.Installation of the conveyer belts so that movement is minimized and the productivity is increased.

3. Installation of the alarm in each and every cell line so that whenever the line is empty the raw material can be supplied instantly

4.The finished goods department should be in close proximity to the exit gate of the plant so that the transportation time is reduced.

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APPENDIX A

INTRODUCTION TO INTERNSHIP ORGANIZATION

Company Vision & Mission:

Mission: To provide innovative, clean and efficient energy solutions for a better tomorrow.

Vision: Delta continues to be a leading corporation in the electronics industry due to sensitivity and instant response to the market in this rapidly changing world, which is full of uncertainty and risks.

Company Profile:

Delta Electronics was established in 1971, with a corporate mission to provide innovative, clean and efficient energy solutions for a better tomorrow and is operating in India since 1992. Delta has marked its presence with some very significant achievements and today commands a market leadership status. Delta is committed to environmental protection and has implemented green, lead-free production and recycling and waste management programs for many years. Delta Electronics is head quartered and R&D centre at Taipei (Taiwan).

Presently, Delta Electronics is manufacturing various products at various locations in India as well as abroad. Delta Electronics (India) is part of the Delta Group, a leading multinational with 5.34 billion USD revenue for 2008

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The founders of the delta group believed in some basic principles which formed the cornerstones of the organization and guide all associated with it till this day. These are:

1) Customer satisfaction: customer is king. It is delta’s foremost effort to satisfy customer’s demands and fulfill their needs.

2) Quality: at delta, an effort is made to minimize errors. They believe in doing things the right way the first time. This improves efficiency and makes things happen quicker, besides boosting the morale of the employees.

3) Innovation: in today’s nail-biting competition, innovation is the key to success. These days, when a product becomes obsolete as soon as it enters the market, one has to keep developing new ideas.

4) Teamwork: organization is not one man’s job. All work is done in a team. To achieve one’s ends, there should be proper and effective communication, delegation and collaboration among the various members.

5) Agility: one cannot act slowly in today’s fast-changing world. The market changes in no time. Opportunities come and go in a flash. At delta we believe one should be quick enough to grab them when they come.

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Delta electronics has been ranked no.1 in worldwide merchant power supply sales every year since 2002, including OEM AC-DC power supplies and telecom power supplies.

Delta is the world’s no. 1 company in manufacturing switching power supplies.

Major products:

1) power management: - Server/workstation switching power supplies.- Desktop switching power supplies- Networking switching power supplies- Display power supplies- AC-DC adapters- Energy saving ballasts/ballasts for HID lamps/LED drivers- Uninterruptible power systems(UPS)- Telecom power systems- DC-DC converters (voltage regulation modules)

2) renewable energy:- solar inverters- fuel-cell inverters- fuel-cells- solar-cells

3) visual displays:- DLP TVs- LCD TVs- Business projectors- Large venue- DLP rear projection video walls- Home theatre projectors

4) Components:- EMI filters- Networking components- Flat fluorescent lamps( mercury-free backlights)- Solenoids and magnetics- RF/microwave components- CCFLs for LCD displays- Stepping motors and spindle motors- DC brushless fans- DC-AC backlight inverters- Fiber-optic transceivers(PON/P2P)

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- Thermal management products- Optical components and modules

5) Industrial automation:- RS- 455/ RS-422 communication modules- Optical incremental encoders- Temperature controllers- AC servo drives and motors- AC motor drives(AMD)- Human machine interfaces(HMI)- Programmable logic controllers(PLC)

6) Networking- wireless client adapters/ wireless USB solutions- AP/ wireless routers with PoE solutions/ broadband router and FTTH

solutions- ADSL/VDSL/VoIP solutions- Gigabit Ethernet solutions- Powerline adapters- Managed/ unmanaged switches with PoE options- Chassis switches systems/ L2 /L3 stackable switches- 24 port server blades- WiMAX subscriber stations

7) Automotive products- infotainment displays- power memory seat control units- vehicle data recorders- tyre pressure monitoring systems- rear window sunshade controllers- engine control modules

Valued Partners:

Acer airtel Alcatel Apple BSNL Canon Cisco Dell Ericsson GE Hitachi

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Haier HP IBM INDUS Intel Lenovo LG Microsoft Motorola Nokia Philips Samsung Siemens Sony Toshiba etc.

Today the Delta group is a global force with operations in three continents. The delta branches are to be found in China, Thailand, Mexico, Germany, Slovakia, Japan, Korea and India.

Today, delta is a 4000 million dollar industry across the world with an impressive growth rate of 48% per annum.

About the Company

Delta is comprised of several departments which each perform a dedicated task and work together in perfect sync to achieve the best results.

Various departments at Delta Energy Systems

1. Purchase Department: This department handles the purchase of Raw materials and semi-finished product or components required for the manufacturing of the final products. It is their responsibility to make available the parts of the required specifications and characteristics in due time to the other departments, in the most economic and beneficial way. This department has access to all suppliers, both at home and abroad.

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2. Marketing and Sales Department: This department is responsible for monitoring current market conditions. It deals with the various dealers of Delta products, takes care of the outgoing goods, has a say in price control, and, in short, could be referred to as the external interface of the company.

3. HR department: This department is responsible for all the manpower management of the company. Training, recruitments, in-service monitoring of employees etc. comes within their jurisdiction. This department has the charge of seeing to it that Delta comprises of a healthy, motivated and efficient work-force.

4. Engineering Design and Development Department: this department consists of two parts- the Technical branch, which deals with the development of the optimal design of the products to be manufactured in terms of their specifications, components, and materials used etc., and the Documentation Center, which undertakes the responsibility of keeping all paperwork up-to-date and intact for future use. This department undertakes a case- by-case study of the individual products to be supplied, and takes care of all the aspects related to the design of the product.

5. Production Department: this department carries out the actual production of the desired goods. It employs a large work-force whose job is to deliver the goods on time.

6. Quality- check Department: the finished goods are always checked for various quality standards and safety issues. Stringent measures are taken to assure that the customer is well- satisfied with what he gets. It sees that international norms of quality and safety are satisfied.

7. R&D Department: this department has been set up to look into creative solutions for bettering the products concerned. General level research is undertaken to improve performance and allow cost-cutting.

8. IT Department: it takes care of all the software needs of the company. It is responsible for maintaining secure communication channels between the various Delta branches and the internal databases of the company.

9. Customer support Department: to deal with customer queries, a helpdesk has been created which provides all kinds of customer support- technical, software issues, general-purpose and troubleshooting.

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Financial Statements

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Organizations Structure

 

Delta's efforts towards high quality corporate governance are well recognized. In 2006 parent company Delta Electronics received the CSR award from Global Views Magazine for the 2nd successive year. It was named as one of the best corporate citizens and awarded as a benchmark company in the electronics industry for the 5th year in a row by Commonwealth Magazine. In addition, Delta Electronics was graded A for "Information Transparency and Disclosure" by the Securities & Futures Institute. Standard & Poor's also ranked Delta as one of Taiwan's top 50 companies with best credit ratings. We do not intend to rest on our laurels however and will continue

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to improve the quality of our corporate governance to fulfill our commitment to all stakeholders.

The Delta Code of Conduct describes Delta's expectations for all employees around the world, defines the standards expected of all employees and asks all employees to protect Delta's assets, rights and image by committing to legal and ethical behavior.

Key provisions in the Delta Code of Conduct include the following:

The integrity of records shall be maintained:

 

Generally accepted accounting principles must be complied with in Taiwan and in every country in which Delta business is conducted, and all transactions involving Delta must be executed in accordance with Delta policies and procedures. It is strictly prohibited to establish any undisclosed or unrecorded Delta fund or asset for any purpose.

Misuse or illegal use of Delta assets is strictly prohibited.

Business gifts and entertainment shall be appropriate:

 

All employees must exercise care in providing gifts and entertainment to customers or suppliers in consistence with generally accepted ethical standards and business practices. All employees are forbidden to request or accept any gift, payment, special treatment or entertainment from suppliers or customers.

All employees are prohibited to attend any activity that conflicts with Delta's interests:

 

All employees are prohibited to attend any activity that conflicts with the company's interests and are also not allowed to engage or participate in any outside activities that interfere with his/her employment duties at Delta. Employees shall not receive any personal profit or advantage other than his/her compensation from Delta in connection with any transaction involving Delta.

All employees have the obligation to comply with copyright laws.

All employees shall keep the company's proprietary information confidential:

 Every employee has the responsibility to keep the company's proprietary information confidential and employees are not allowed to disclose this information, whether for profit or not.

All employees shall protect the company's intellectual property rights:

 Every employee has the obligation to protect the company's intellectual property rights (including but not limited to inventions, technical information, product design) and any other Delta proprietary rights.

Insider trading is prohibited:

  Every employee shall not take advantage of inside information to profit third parties or to obtain

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personal benefits. Financial results and business transaction information shall not be released without prior authorization in order to protect shareholders' interests.

   

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