From Workshop to Global Player

(Siemens 1847-2005)
Formed in 1847, the company telegrapher bauanstalt Von
Siemens & Halske grew within the space of a few decades from a
small precision-engineering workshop, producing mechanical warning
bells for railways, wire insulation made of gutta-percha, and electrical
telegraph systems, into one of the words largest companies in
electrical & electronics engineering. Landmark inventions, an
immense

readiness

to

innovate,

and

strong

international

commitment have driven the companys success since its very

beginnings. When in 1866 Werner Siemens (known as Werner Von
Siemens after 1888) discovered the dynamoelectric principle, the
potential applications for electricity were limitless. Heavy-current
engineering began to develop at a breathtaking pace, producing one
triumphant innovation after another. In 1879, Siemens & Halske
presented the first electric railway and installed the first electric street
light in Berlin; in 1880 came the first electric elevator; and in 1881 the
electric streetcar. Following the death of companys founding father,
Werner von Siemens, in 1892, his successors followed the course he
had set, constantly advancing the company with trailblazing
innovations. Lighting, medical engineering, wireless communication,
and, in 1920s household appliances, were followed after world war II
by components, data processing systems, automotive systems and
semiconductors. The guiding principle that had applied since the
companys beginnings-of concentrating solely on the electrical

engineering, but on the whole electrical engineering helped make

Siemens the only company in its industry to operate in both light-and
heavy current electrical engineering, and by the mid 1920s it was
again one of the worlds five leading companies in its field. When
national socialists seized power, Siemens, like the rest of German
industry, was drawn into the system of the war economy. Through to
1944, higher state demand and military orders led to substantial
increases both in sales and in the size of the workforce. In order to fill
its manufacturing quotas, Siemens partly used forced labor. After
World War II, Siemens began rebuilding in Germany first, but
gradually moved into foreign countries from the 1950s on.
Technological advances, expansion into new business segments, and
the reestablishment of a presence in traditional export markets laid
the foundations for the companys return to its old strength in the
world marketplace in the 1960s. To give the company a stronger
identity and constant market presence, Siemens & Halske, SiemensSchuckertwerke AG, and Siemens-Reiniger-Werke AG, the three
main companies in the group, merged in 1966 to form Siemens AG.
In 1969, the companys main business segments were assigned to
six largely independent operating groups, creating an organizational
structure that has been adapted on numerous occasions through to
the present day.
Today Siemens is a transparent and significant contribution to
the future of electrical engineering and electronics.

ABOUT SIEMENS AG
Siemens AG is a world class supplier of electrical and electronics
products and systems serving one of the largest and the most diverse
markets worldwide. Siemens Ltd. in India is a subsidiary of Siemens
AG, Germany. Siemens AG have been closely involved with
developments that are at leading age of electrical and electronics
engineering ever since the pioneering inventions of the founder of the
company- Werner von Siemens.
Siemens strength, acquired over many decades of pioneering
research and practical experience, lies in the development of
advanced technologies and in their timely application to a wide range
of high- quality, innovative and cost effective products. As a global
company, Siemens have manufacturing, sales and service facilities in
more than 170 countries. Employees worldwide in the offices,
factories, laboratories and service organizations total to about
390,600. All committed to providing the highest standard of
technological competence that Siemens has been a Synonym for,
right since inception. Siemens continuing commitment in this
direction is summed up in the organizations corporate mission
statement.
It want to be one of the most competitive companies in the field of
electrical and electronics engineering and set the pace for advances
in technology.

Their aim is to provide products and services of the highest quality

that offer maximum benefits to their customers worldwide.
They have to achieve consistently high profitability to ensure our
corporations future and to increase the value their shareholders.
They want to establish and maintain worldwide business relationship
that are constructive, long-term and based on mutual trust.
They see themselves as an integral part of national economies and
feel strong sense of responsibility towards society and environment.

At the forefront of electrical and electronic

technology
Siemens ranks sixth among the worlds ten largest electrical and
electronics companies in terms of sales, which accounted to DM 81.6
billion in fiscal 1993. If AT & T`s telecommunications operation
(accounting for around 60% of their total revenues) and GE`s
financing activities (GECS account for one- third of GE sales) are
excluded, Siemens would rank 4th in fiscal `93.

In resonance with the challenges of the

future
Siemens is geared to meet the complex challenges of the 90`s and
beyond into the 21st century, which would be an era marked by
dynamic developments and the increased globalization of the
electrical and the electronics market. Siemens corporate structure
has been organized to respond swiftly to technological change,
shorter innovation cycles, and new applications and sales channels
in short to the accelerated demand of the world market. Smaller
sharply focused operating groups have been formed to maintain
clearly defined market profiles in this competitive environment. The
structure brings specialist under one roof, thereby ensuring ready
access to common pool of siemens know-how and services,
generating productive synergies.

Internationally compatible range of products

and systems
Throughout the world, the name stands for an enormous range
of products, systems and services. Although the universal supplier,
Siemens also enjoys a distinguished reputation as a solution
specialist in many fields. The company has accumulated a wealth
know how which it shares through numerous international joint
ventures and alliances.

Energy
Power Generation (KWU)
Power generating facilities, equipment, systems and processes:
Non-nuclear power generation , refuse- fired power plants,
thermal waste recycling plants
Renewable power generation , photovoltaic, electrical
equipment for wind power plants, fuel cells
Industrial power plants and turbines
Nuclear power generations ( nuclear power plants , nuclear
power plant services, nuclear waste facilities)
Nuclear fuel cycle
I & C equipment and systems
Engineered ceramics
Laser technology

Power Transmission and distribution

Products and systems, equipment and services:
High voltage systems
Medium voltage and low- voltage equipment and components
Medium voltage switchboards and systems
Energy meters, substation secondary equipment and power
system control
Power transformers
Distribution transformers

 Power cables
System planning

Transportation
Transportation Systems
Equipments and Systems for rail transportation:
Safety and security systems
Control systems
Transmission lines and catenaries
Complete installations
Rapid- transit vehicles
Main line rolling stock

Automotive System
Electronic , electrical and electromechanical systems and
components:
Control and information system
Air management system
Electric motors and electric motor systems
L & T Vehicle wiring system
Sensor system
Actuators and fuel mixture components

Industry and trade

Industrial and Building Systems
Electrical plant and customer or sector- specified products and
systems for:
Basic industries

 Manufacturing industries, public authorities

Security and building systems
Traffic control and systems
Field services, engineering , workshop operations:
Installations and erection, engineering, commissioning,
customer support, workshop operations

Drives and Standard Products

Variable speed drives; Large drives, Medium machines,
vacuum pumps and compressors; Low voltage motors;
Uninterrupted power supplies;
Switchgears for consumer feeders;
Command and annunciation devices;
Switchgear for power distribution;
Transformers, chokes and fans;
Protection switchgear; Fuse-link systems; Switch and sockets
systems; Installation, distribution and ducting systems; Building
services i-center: Wholesale organization for commerce, trade,
industry and public authorities

Automation
Products, systems, equipments and services:
Programmable controls

 Industry process controls, PDA

Numerical controls
Controls for robots
Drives for machine tools and robots
Measurement and test controls
Process instruments
Production control systems
Analysis systems
Printed circuit boards assembly and production systems
Industrial communications
Serving/Monitoring systems

Communications
Public Communication Networks
Public switching systems
Transmission systems
Mobile radio networks
Mobile radio systems
Telecommunication cables

Private Communication Systems

Small, medium and large sized communication systems

 Applications, networks
Communication terminals

Defense Electronics
Tactical and strategic networks
Radio systems
Products and services for information security
Reconnaissance and air defense systems
Command systems
Air traffic management
Control systems

Audio and Video Systems

Design, construction and automation of professional audio and
video installations and systems:
Electro acoustics
Conference systems
Sound and video studios
Mobile broadcasting vans
Production studios

 Sound and video control rooms

Audio workstations
Master sound switching rooms
Cables TV facilities

Medicine
Medical Engineering
Roentgen systems
Magnetic resonance
Computed tomography
Angiography
Dental system
Life support system
Electrocardiography
Nuclear medicine and Patient monitoring
Radiation therapy
Ultrasound, Cardiac and Audio logical systems

Information
Siemens Nixdorf Information System AG
Large, medium-sized and small DP systems

 Mainframes, peripherals, networking components and terminals

Workstation systems, office computers and personal computers
System software for BS 2000, UNIX/SINIX, NIROS and MSDOS
Application software for vertical-market and office applications
System and solution business for all sectors
Software tools & Consulting, systems & product service,
training

Components
Semiconductors
Application-specific integrated circuits for:
Information technology
Automotive and traffic electronics
Industrial electronics
Entertainment electronics
Microcomputer components
Memory components
Discrete semiconductors:
Transistors, diodes and microwave semiconductors
Sensors
Power semiconductors and modules

Optoelectronics semiconductors:
Light-emitting diodes and displays
Infrared transmitters and receivers
Magnetic field sensors
Optocouplers
Semiconductor lasers
Optical waveguide components

Passive Components and Electron Tubes

Capacitors
EMI suppression components
EMC systems and services
Ferrites
Surface-acoustics-wave devices
Resistors
Thermistors
Varistors
Microwave ceramics
Electron tubes
Surge arrestors
Vacuum components
Magnetic and non-magnetic alloys

 Core and magnet systems

Inductive components
Superconductors
Acoustics and electro-optical products

Electromechanical Components

Relays and synchro generators

Connectors, switches and keys
Hybrids
Optical cable components

Lighting
Standard Products
Office and architectural lighting, Industrial lighting, Exterior lighting,
Light electronics.

Osram GmbH
Lighting technology products:
General lighting service lamps
Fluorescent lamps
High pressure discharge lamps
Traffic/signal lamps & Photo-optics

Siemens in India
Siemens association with India began in 1867 when Wernervon-Siemens personally supervised the laying of the first submarine
telegraph line between Calcutta and London. This historic event
marked the beginning of a long and fruitful association. Siemens and
India have grown together. In making countrys priorities its own,
Siemens has put its experience and expertise in areas of national
importance. Siemens have played an active role in the technological
progress experienced in the last four decades. Siemens grow out of a
response to the needs of the nation. Today, Siemens involvement
reflects the current trends in electronics and electrical technology- in

switchgear, motors, drives, automation systems, power generation

and distribution, projects, transport, medical engineering,
communications and components.

Milestones to progress
1954

Assembly and repairs and a workshop under

Mahalaxmi Bridge

1957

Switchboard manufacture began at Worli, Mumbai.

1959

Medical equipment added at Worli, Mumbai

1960

manufacture of switchgear at Worli, Mumbai

*switchboard production extended to Calcutta workshop

1963

Switchgear manufacture transferred to Andheri

1966

First batch of motors produced at Kalwe

1973

Transfer of switchgear production to Kalwe

1975

Transfer of switchboard production to Kalwe and its

expansion

1977

Manufacture of electronics equipment at Worli, Bombay

1980

Manufacture of switchboards at joka, calcutta

1981

Manufacture of switchboards at Nashik

1991

New switchgear factory at Aurangabad works

1993

Assembly workshop Medical products at Goa

1994

Manufacture of optical fibers and Solar Photo voltaic

panels at Aurangabad

Siemens have about 8000 employees in India and an extensive

network which includes 10 works, 3 training centers/units, 7 sales
offices, 23 representatives, 300 dealers/system houses and service
centers, all geared to meet the requirements of its customers.
Being closely associated with their Principles Siemens AG
Germany, gives Siemens in India access to the worlds latest
development in every field. This combined with its experience in
India makes Siemens the ideal partner for catalyzing the countrys
progress.

SIEMENS: Manufacturing centers in India.

1. Worli Works: Mumbai.
Established in 1957

Products manufactured at Worli works

1. Portable / Mobile- hand / motor operated routine diagnostic
examination Units.
2. Mobile C-Arm image intensifier X-Ray generator.

2. Kalwa Works: Thane.

Products manufactured at Kalwa works
1. The motor Factory was established in 1965.
2. The switchgear factory was established in 1973.

3. The switchboard factory was Established in 1975

3. Joka Works: Kolkatta.

Established in 1973

Products manufactured at Joka works

1. L V Switchboards.
2. Motor Control and power control centers.
3. K 48 resistance boxes.
4. Low voltage current Transformer.

Panels
1. Control Panel
2. Relay Panel
3. Control Desks

4. Goa Works: Goa

Established in 1993

Products manufactured at Goa works

1. CT (computer topography) scanners.
2. Ultrasound equipments.

5. Aurangabad Works: Aurangabad.

Established in 1991

Products manufactured at Aurangabad works

1. Electronic timer relays.

2. Fuse Switches.
3. Low voltage switches.
4. Direct on line starter.
5. Miniature circuit breakers.

6. Saltlake Works: Calcutta

Established in 1991

Products manufactured at Saltlake works

1. Digital electronic switching equipment
2. Radio transmission system

7. Nashik works: Nashik

Established in 1987

Products manufactured in Nashik works

1.

Auxiliary Inverter for Passenger Coaches

2.

Auxiliary Inverter for AC Locos

3.

Traction Inverter for Diesel Locos

4.

Electric control cabinet for Diesel Locos

5.

K-50 Relays and signaling groups

6.

Audio frequency track circuit

7.

Auxiliary warning system

8.

Current and Voltage transducer

9.

Switch mode Power supply

10. Variable speed AC and DC driver

11. Static converter for heater controller

Automation & Drives

Nashik Works

Kalwa Works

Aurangabad Works

Manufacturing of Control
Panels
consisting of

Manufacturing of Switchgears such as:

1. Miniature Circuit Breakers (MCB)
2. Motor Protection Circuit Breakers (MPCB)

1. Switchgears

3. Fuses

2. Drives

4. Fuse Holders

3. Air Circuit Breakers

4. Vacuum Circuit Breakers
5. Automation
6. C.P.U.

DIFFERENT DEPARTMENTS IN SIEMENS

NASHIK WORKS

1.

Research & development (R & D)

R & D (Product Development) holds the key to all of the SIEMENSs

endeavors. P.D. group plays a vital role in identifying, absorbing and
adapting state of art of technologies of diverse product development
facilities and in the electronics laboratories of TIC.

2.

Transportation systems (TS)

This department does the work of designing of circuit diagrams. They

usually manufacture the panels of the railways which includes
Auxiliary converters for Locomotives and AC Coaches, traction
converters for locomotives and EMU, control cabinets for
locomotives. They design the structure of the product and the make
the BOM required for it.

3.

Logistics

These departments plan out the working of various departments. So

as to complete the project with in stipulated time limit. It also planes
and orders the quantity of raw material required for it.

4.

Purchase & strategic Purchase

The Purchase department contacts the various vendors & tries to

procure the best material at the least cost. The vendors are selected

only out of the certain approved ones. The authorized buyers from
purchase department creates a Purchase Order (P.O.) when
purchase requisition is received which automatically gets created by
Spiridon when Production Order is created by concerned
departments such as System Logistics.

5.

Receiving

This department receives the material from the vendor. Here the
quantity of the material is checked & then forwarded to the QI for
inspection. The rejected material from QI is also received by receiving
and is then forwarded to the vendors again.

6.

Quality Incoming

QI inspects the material received by the company. The material is

checked according to the specification supplied by the customer.
Once the inspected & accepted the material is then send to the stores
from where it can be taken for use. The rejected material is then send
back to the receiving department.

7.

Stores

The store of Nashik SIEMENS is divided in three categories,

Electronics, Mechanical and direct order stores. The material cleared
by QI is sent in the stores, and is then consumed by various
Manufacturing departments as required. It maintains the record of the
uses of material. Electronic and mechanical stores keep the inventory

for standardized components whereas the direct order store keeps

the components required for the fulfillment of a specific order.
Siemens uses Spiridon for maintaining the entire record of stores.

8.

Manufacturing

This department does the work of assembling the products like

panels, power supplies, signaling group etc. It consists of 2
departments. Viz. Product Department and Systems Department. The
Structure for both the departments is explained below.

9.

Testing

This departments test the final product. They hold the responsibility &
give quality assurance to the Client. During testing if any fault is
detected than that assembly is sent to repairs for repairing. Testing
mainly comprises of HV testing, IR testing and continuity testing.

Nashik Works

Automation &
Drives (A & D)
-System
Department.
Manufactures
Control Panels

Transportation (TS)
-E&S (Electronics & Signaling)
1. K-50 Relays
2. R.S.G. (Railway signaling
group)
3. F.T.G.S.
4. E.M.U. (Electrical Multiple
Unit)
5. T.C.C.1, 2, 3
6. N.C.C.C.
7. E.C.C. 1, 2
8. W.D.G. 4

Production Cell-Systems

Logistics (MPS)

Structure assembly

Manufacturing & Quality

Wiring

Testing

INTRODUCTION TO SYSTEMS BUSINESS

The systems division at Nashik deals with manufacturing customized.

Automation & Drives for various industries such as: Sugar mills.
Steel industry.
Tyre industry.
Cement industry.
State electricity boards.
Textile industry.
Petroleum industry.
Chemical industry.
Engineering companies, etc.
The basic classification of the products is as follows: AC drives.
DC drives.
PLC.
Tel m-cabinets.
The drives can be further classified according to types as: AC drives: CUVC
CUMC
MM4

 DC drive: 6RA22
6RA24
6RA70
PLC
S5
S7
The drives can be further classified according to wattage as: AC Drives: UP to 200KW
200KW-630KW
ABIVE 630KW
DC Drives: UP to 210KW
210KW-600KW
Above 600KW

Systems Structure: -

Production Cell-Systems

Logistics
(MPS)

Mfg. & Quality

Structure assy.

Wiring

Testing

Logistics
Manufacture is one of the key activity is needed to attain fitness
for use and numerous safeguards are employed to help assure that
the resulting product is indeed fit for use.
Manufacturing planning & scheduling (MPS) comprises the activities
needed to put the factory in a state of readiness to produce to quality
and other standards. Responsibility for carrying out these planning
activities varies widely and depends mainly on:

Technological complexity of the product.

Anatomy of the process; i.e.; is it highly concentrated within one
autonomous department or is it divided among many departments?
The technological training of the line supervisors and workmen.
The extent of managerial commitment of the philosophy of separating
planning from execution.
These departments plan out the working of various
departments. So as to complete the project with in stipulated time
limit. It also planes and orders the quantity of raw material required
for it.

Planning activities & Results

Sr

Planning Activity

No.
1.
Review design for clarity of
specification and for

End result of Planning

Producible design, revised product
specification

2.

Proucability; recommend change.

Choose process for manufacture; Economic, feasible process,

3.

operations, sequences
Provide machines and tools

process specification
Capable machines & tools

4.

capable of meeting tolerances.

Provides instruments of accuracy

Capable instrumentation

5.

adequate to control the process

Provides manufacturing

Operation sheet.

information, material, methods,

6.

procedures, and cautions.

Provide system of quality

Control station equipped to provide

control, data collection, feedback, feedback

7.
8.

adjustment
Define responsibilities for quality Agreed pattern for responsibilities.
Select and train production
Quailed production operators

9.

personnel.
Prove adequacy of planning,
tryouts, trail lots.

Proof of adequacy.

ADVANTAGES OF PLANNING
1) Minimize Risks:Planning helps to minimize or reduce risks. Potential risks are
forecasted and necessary protective devices are decided well in
advance. If the risk occurs, then the protective devices are put into
practice. The protective devices may reduce the impact of risks.

2) Facilities Coordination: The plans of one department are coordinated with the plans of all
other concerned departments. This brings in unity among the various
departments of the organization. In the other word, the concerned
departments work in close harmony in the implementation of the
plans.

3) Facilities Organization: Planning enables a manner to organize the resources properly. If

required, ha makes arrangement for additional resources in order to
achieve the planned targets. In other words, the plans give a proper
idea of the required resources to implement the plans. This facilitates
proper organizing of resources.

4) Facilities proper direction: Planning provides proper direction in which the activities need to be
conducted. This facilitates the manager to the direct his subordinates
as and when required. Clear-cut direction is given so that the
subordinates undertaken the right at the right time.

5) Facilitates Control :A plan provides a yardstick against which actual performance can be
compared. Such comparison will enable to find out the deviation from
the plans. If deviations are noticed, the manager may take the right
corrective steps at the right time.

6) Generates efficiency: Planning enables optimum utilization of resources. All the resourcesi.e., physical and human resources are put to their best use. The
optimum utilization of resources enables a company to achieve
highest possible returns at lowest possible costs.
This department mainly deals with:-

Planning for raw material & component

Procurement of it
Maintenance of stores
Vendor development

PROCEDURE FOR SYSTEM LOGISTICS

An input for system logistics is an Advanced
Intimation (AI) with Critical Equipment list (CEL) or C1/C2.
Normally AI/CEL is the first input followed by C1/C2. All
these inputs should come from E & C. Direct input from
sales should not be treated as input. All input regarding the
order should flow through E & C.
On receipt of AI / CEL, which is first input to the logistics,
following steps to be followed?
E-mail containing the fax copy of delivery confirmation based
on AI, should be send to concern sales engineer with copy to
group leader of sales and NW/SYST/L.
Then check in the system whether system related material is
created for particular order. If the system related material is
created in the system then no. Of Production orders to be
created is equal to the no. of system related material for the
particular order. Basically these materials are as per clients PO
and billable item in sales order. This process of creating no. of
production orders will help in two ways. More the production
order will help to staggered loading, easy material handling and
material tracking. If systems related material is not created,
then it will create in the systems.

 Request for creating the work scheduling view and a routings

to be send to NW/TOP/IE. The mail to TOP/IE should include
following information.
1. Material number on which the production order is to
create.
2. Order type i.e. AUTS or DRVS.
3. No. of panels and make of the panels.
4. Major/critical components, which decide the amount of
work, involved. For PLC it can be number of front
connectors and for drives it can be number of drives with
rating (KW in case of AC drives And Amperes in case of
DC Drives.)
5. Based on the above information NW/TOP/IE will be put
approximate SMH (Standard Man Hour) in the routing.
These approximate SMHs will be within 10% tolerance of
actual SMH (which will be calculated bases on actual
drawing).
6. NW/TOP/IE will inform concern order processor of activity.
Create the production order / orders of the system related
material. While creating the production orders following steps
should be followed.
1. The finished date of production order should be the
delivery confirmed on AI. If the delivery confirmed in the
form of the week, then we will consider the delivery date
as first day of the week.

2. Then schedule the order using the schedule key. System

will suggest the starting date of the production order.
Normally the system will consider one operator for one
work station (structure, wiring, testing, finishing). But
considering volume of work and the no. of panel, the
number of operation can be decided using past
experience. The same should put in the system. For
putting the no. of operators (this is called as splitting) in
the system go to operations. Select the operation in which
you want to put the split. Then go to operation details.
Then select splitting and put no of splits as what you have
decided. Then select Splitting and put no. of split as
what you have decided. Again come back to the main
screen and schedule the order again. This is your final
requirement date. The scheduling type must be 2 for all
production orders.
3. Populate the components in the production order as per
CEL. In case of PLC only rack, power supply and rails
should be entered in the production order.
4. Segregate the components by activity as follows.
0010

Structure

0020

Wiring

0030

Testing

0040

Finishing

Inform purchase regarding creation of production order to

purchase with detailed schedules. Kindly ask imported
drive and module delivery in the month when the
dispatch of order is planned. This is not applicable for
the material, which is MUST for structure assembly.
As per the procedure, after 3-4 days take order report of the
production order using transaction MD4C. Check whether all PRs are
converted into PO. If not, give reminder to purchase for the same.
Keep track till all POs are converted to PO.
Take note of the schedule for submission of C1/C2 as per
AI.Using your own tools of follow up, shoot an mail to E&C if C1/C2
do not received on the committed date. Keep follow up with E&C for
C1/C2. If the C1/C2 drawings are getting further delayed, ask
purchase to re schedule the order. Our normal lead-time for C1/C2
received to ready for inspection is 60 days. According re-scheduling
the deliveries of imported items. Keep on doing this activity till C1/C2
are received.
The re scheduling of purchase order is must for all the
C1/C2 delayed cases.

Following procedure to be followed on receipt of

C1/C2:
E-mail containing the fax copy of delivery confirmation based
on C1/C2, should be send to concern sales engineer with copy
to group leader of sales and NW/SYST/l. The original copies to
be sent to concern sales engineer through internal mail.
One copy of drawing to be sends to TOP/IE for estimation of
exact SMH immediately. The entry of this outgoing document to
be kept in the department.
If number of items is more in one production order, it is perfect
to make consolidation of material required.
After consolidation is over, in case of more than one item, open
the production order & make Production order change using
CO02 transaction.
After entering BOM in systems (making of PRs) information is
to be sending to the purchase.

The detail introduction to the documents used for

System Logistics.
What is BOM?
The Bill Of Material (BOM) module specifies what
materials; components, assemblies and sub-assemblies are used in

making the product. Each component in the BOM is linked in parent

child component relationship. The record of the BOM module are
usually oriented in the tree structure with level zero being the product
and each consecutive level breaking the product into sub-assemblies.
It offers you the ability to see where the part is used, how many are
required and what level of assembly is needed.
Uses of BOM: The BOM module is being the core one that accessed by the
different programs to generate the order, PR, an invoice and any
other report that needs itemized product information.
Assumption: 1. BOM is entered, maintained, changed by engineering
group concerned with the relevant product.
2. Other users in planning, production and finance etc., will
access the relevant programs to extract data from the
BOM.
3. SAP

is

responsible

for

the

enhancement

and

maintainance of programs. SAP will also provide the

facilities for long printouts and debugging.

What is PR?
Purchase Requation should be prepared when material is created
and the BOM is planned. It is forwarded to only corresponding
vendor.

The planning department is planned out the quantity

required for the completion of the project. It first calculates the initial
requirement, which is forwarded to the purchase department for
purchasing. The planning department also plans the schedule for
different consignments of the project to be dispatched. It also
monitors the working of the various departments, especially
concerning with the production of the project.

Purchase Order (P.O.): Once the source is finalized, the buyer places the P.O.,
-i.e.; purchase order. It is the document, which gives the GO AHEAD
instruction to the vendor for commencing the manufacturing the items
listed in it.

ENTERPRISE RESOURSE PLANNING

Enterprise Resource Planning(ERP) system has installed
the Systems Application Product (SAP) For Worldwide SIEMENS.
This is the German Package.
As the name indicates, this SAPsystems is an organized
method of collecting, storing, Analyzing and reporting information on
quality to assist decision makers at all levels i.e. planning level.
Production level. Purchase level, etc.

Inputs for a SAP include:

Information on purchase parts and materials: Examples are receiving inspection data, data on store
records, vender survey information, and vender rating data, item
codes and description of material.
Process data:
These data cover the entire in-plant manufacturing
inspection system from the beginning of manufacturing upto final
dispatch clearance.
Final inspection data
This data is the routine data at a final inspection.
Result of Audits

This includes both product audit and system audits.

Thus, the scope of SAP may vary from a simple system covering inprocess inspection data to a broad system covering all information
applicable to the overall effectiveness of a product.
SAP attempts to provide all the information need of
management through one integrated system.

Impact of SAP on Planning

The SAP provides material information that can be useful as
bases for Planning.
Example: - Item code, Description, Challan No, GRN no., location in
the stores etc.
Information on quality and the quantity can be stored in the
SAP and changes can be entered directly. The information can be
drawn out as needed.
Example: - Making purchase requisition report and make changes
according in it with BOM i.e. bill of material released by project
groups.
Data analysis module can be incorporated in the SAP.
Example: - Bill of Material entry.
Recently developed hardware and methods for data
collection and transmission can be applied to material information.

THE SAP TRANSACTIONS USED IN LOGISTICS FOR

PRODUCTION:-

MM01:- Create Material.

This transaction is used to create the new material after
receiving the AI or C1/C2. We are copying the any old material and
linked on it to create the new one.
For creating we have to select the Views regarding MRP,
Logistics, Accounting, and Costing & Delivery

MM03:- Display Material

This transaction gives us the detailed information of created
material in this we are come to know the basic data, MRP, Price,
Stock Qty; Material Purchase Document, Work scheduling etc.
information.

CA01:- Create Routing.

When the new material is created Logistics is informed that to
TOP+ / IE . They collect the material no., Panel type, Panel qty.,
major/critical components list etc. based on this they will put
approximate SMH & create the routing.

VA03:- Display sales order.

This transaction is giving us the information about the material
entered in this. I.e. Clients name, qty, description of the panel
(material) etc. This helps us to see the details but we cannot process
in this.

CO01:- Production Order Create.

To enter the BOM & to make production order change we use
this transaction. After creation of material in MM01 the order was
released. Then to make PO we create the Production order number.
We are scheduled the order in this transaction.

CO02:- Production order change

We have to use this transaction after creating the Production
order in CO01. Entire BOM is entered & material is planned through
this order. Sometimes the CI (clarification indents) is received after
BOM then to make the change in the production order CO02
transaction Is used.

CO03:- Read production order.(Production order

display)
The changed production order is visible in this transaction. But
we are not able to make the production change.

VL01:- Create Delivery.

This transaction is used for creating the delivery & to take the
output. After taking the output the DI is printed & the order is declared
as technically & commercially completed.

Transaction used for Material resources & Planning

LS24:- Stock Per Material.

By using of this transaction we are able to find the out the
material Storage Location (Bin) as well as stock quantity. After putting
the command we have to run the transaction. In SAP systems there
is a item code for each material, we have to pyt that no. in the space
given to material.

MD04:-Current stock/requirement list

By using this transaction we are come to know the stock of
particular material and we are also find out the reservation of the
particular order for that material.
Above, the initial screen is shown & the screen on which the
available Qty is seen & the reservation seen that is ahead.

ME5K: - Purchase Requisitions

When the material is created after receiving the AI or C1/ C2.
we are making the purchase requisition. By using this transaction
we are came to know, all PRs are made or not.
This also gives us the record of converted PRs to POs.

ME2K :- Purchase Document

Here we can find out the material received in the Nashik works
on PO, we also come to know that any PO is opened for particular
order.

MB51 :- Display Material Document

This transaction is useful to find out the documentation data of
any material. Its incoming quantity, reserved quantity in plant etc.

Structure assembly or Manufacturing Dept.: This is the very basic department of System. It deals with the
component mounting in the panel.
In the structure assembly of the panel the components are
mounted on GI (Galvanized iron) Sheet, in which all the heavy
components are involve, like Drives, Switch Fuse Units, Main
Contactors & Auxiliary Contactors, PVC (Poly Venal Chloride) cable
channel for cable bunches, MCBs & MPCBs etc.
This mounting is carried out on the basis of Front View &
Equipment layout given in the main drawing. This layout is prepared
considering suitable wiring Routine of that panel. The front view &
equipment layout is shown ahead.
The bus baring is also a main job in structure assembly. In this
activity jointing & its marking is done. Some important precautions
are taken during bus bearing. This activity is carried out to increase
the current rating of bus bar.
The fully structured panel is then forwarded to the wiring
section.

Complete Assembled GI Sheet

Panel Surface Finish

The standard 8mu design panels are powder coated having
RAL 7032 shade.
Pretreatment of ferrous material: Operation sequence for 7-tank
process:
Degreasing.
Water Rinsing.
Derusting.
Water Rinsing.
Activator.

 Phosphating.
Passivation.
Drying.
Powder coating is done after the pretreatment.
After powder coating:
No area of surface of the component should be without powder coat.
The coating thickness should be 50-60 microns. (Avg. 55 microns)

PANEL ENCLOSURE
1. Panels are offered with IP20 / IP41 degree of protection as a
standard execution.
2. In case of any other degree of protection, the same is to be
discussed first with A & D-NW before finalizing the order.
3. Basic structure of 8MU panels remains the same. The doors,
covers are suitably modified for archiving different degree of
protection.
4. IP20 enclosure
a) No gaskets on doors / covers.
b) Doors (front & Rear) are provided with suitable louvers.
5. IP 41 enclosure
a) White felt for doors, side covers.
b) Doors (front/rear) are provided with suitable louvers.

c) Louvers fitted with perforated sheets from inside.

6. IP51 enclosures (special execution).
a) Neoprene gaskets on door side covers and on door for
DP (Dust Protection) channel.
b) Doors (Front /Rear) are provided with suitable louvers. On
front side, protective vent assembly is mounted .The slot
are not accessible thereafter.
For boustain Panels only IP20 protection is provided.
Following points to be considered while finalizing the layouts.
Heat dissipation in the panel.
No. Of terminals / type of terminals.
Doors Front / Rear.
Cable entry top/ bottom/ side-Generally; cable entry from
bottom is a standard feature.
In case of cable entry from Top / sides, the feasibility should be
studied with respect to:
Mounting of P.S. unit / fan unit / mounting of terminals strips.
A dimension of the equipments used in the panel.
Control room in which the panel will be installed at site.

BUSBAR MARKING
As per IS 11353-1985 marking for bus bars used for main
connections should be as follows:
Bus bar for Main

Marking tape Color

Letter

Three-phase

Red-Yellow-Blue

R, Y, B

Two phase

Red & Blue

R, B

Single phase

Red

Neutral connection

Black

Connection to Earth

Green

Connection
For AC
Phase connection:

For DC
Positive

Red

Negative

Blue

Connection to earth

Green

BUSBAR JOINTING

1. Types of bus bar joints are:

o Aluminum to Aluminum
o Aluminum to Copper
o Aluminum to Silver platted copper
o Copper to Copper / Silver plated copper

2. Manufacturing Precautions:
It should be checked whether any deformation like burr, bulging,
dents exist on contact surface. These defects give rise to higher
contact resistance & consequently higher temperature rise at the
joint. Hence they should be removed before proceeding further.

3. Preparation of contact surface:

In case of joints mentioned under point no 1 above, the
following procedure should be followed except that silver platted
contact surface should not be brushed.

Brushing:
Contact surface should be thoroughly brushed with steel

wire brush so that Aluminum oxide film is removed which is nonconducting. Brushing may also be necessary in case of copper bus

bar to ensure clean surface. For handling of copper & aluminum, it is

absolutely necessary to use separate sets of tools. Use a steel brush
for cleaning contact face until the surface is well roughened. Sand,
glass & emery paper or cloths are not allowed. The cleaned surface
must be larger than the connecting faces.

Greasing

The contact surface should be covered with thin layer of conducting

grease to prevent ingress of dust, moisture, and chemicals.
The greasing is necessary to avoid oxidation of contact surface due
to air & moisture. The oxidation of Aluminum leads to higher contact
resistance & heating. Hence the contact surface should be greased
immediately after brushing.
4. In case of joints between Aluminum & Silver plated copper, only
Aluminum surface should be brushed. The greasing, jointing, &
tightening procedures remain same as given above. However,
copper Aluminum Bimetallic sheet have to be inserted
between two contact surfaces. It should be of same size of
overlapping surface of joints. Both sides of these Cupal sheets.
The Cupal sheet is necessary to avoid corrosion due to
galvanic action.

5. Tightening:

The bus bar connections should be done by using plane/spring

washers on bolt side as well as on nut side & high tensile bolts /nuts.
This is necessary to achieve required torque of 55-70 NM.

6. Re tightening:
On account of the yield of aluminum, all screw joints are to be retightening 24 hours after commissioning & again after 4 weeks as
well as once every year.
Whenever joints is opened for a long time proper precautions as
mentioned in above points 2 to 5.

Wiring
The wiring is another main function in the panel manufacturing. The
wiring is done on the basis of the wiring diagram given in the drawing.
There are basically two main types of wiring diagram.
i. Single line diagram.
ii. Three line diagram.
1. Single line diagram :
This gives the basic idea of the automation Systems. The flow of
supply & the Drive action is described in this.
2. Three line diagram :
This is the main wiring diagram. It is divided in three parts i.e.
i. Power Wiring.
ii. Control wiring
iii. Signal wiring.

WIRE ROUTING
In general the wiring in the panels can be divided in three broad
categories.

1. Power Wiring:

This includes wiring of main incoming MCCB / Switch

Fuse Unit, chokes, converters, fuses, main AC -DC contactors,
outgoing fields etc. Care should be taken not to run the control
wire bunches or the signal wire bunches parallel to the wiring.
2. Control Wiring:
Control wiring is the wiring done mostly on control circuit,
auxiliary contacts of main contactors, circuit breakers, overload
trips, push buttons, incoming of fuse monitors etc. This bunch
should run separately and away from power & signal cables.
3. Signal Wiring:
Signal Wiring is the one that carries a voltage that is
generally less than 60V ac or 75V dc. This wire bunch has to be
run separately and away from the other two.
4. Since it is difficult for the wiremen to know the voltages carried
by the wires, all wires going to electronic circuit, Input / output
and analog module of simatic S5 and S7. But not all the wires
are signal wires going to the electronic cards, drives etc. There
are some wires that go to relay contacts or power supply
transformer in the electronics circuit and carry 415V or 240V ac.
These wires are necessarily control wires and have to be
separated from the other signal wires.
In short

Power wiring, control wiring and signal wiring should be

separated from each other.
The bunches should be run as far from each other as
possible. If they have to come neater then they should be
perpendicular to each other and in case it is unavoidable that
they run parallel to each other then as far as possible there
should be a minimum distance of 100mm between the two.
Sometimes the connections are so far & the wiring
between that points are difficult for wireman, at that time the
wires are connected to the control terminals & from there it is
forwarded to the main end point.

WIRING & CONTROL TERMINALS DETAILS

1. The length of the din rail shown in the layout should be able to
incorporate the number of terminals required to be mounted in
the panel.
Physical sizes of the terminals generally used (Make-Connect
well) are as follows: Size
4 sq. mm
10 sq.mm.

Width
6mm
10 mm

If terminal of any other make are to be used, check the physical

dimension in the respective catalogue.
2. Care should be taken that the control terminals are not coming
near switch fuse unit or any other power terminals.
3. If the number of terminals cannot be accommodated in the
given space then distribution bus (like Rapid terminals bus
which is suitable for power distribution up to rating 10A, 4way,
6way & 12 way) can be used.
4. The terminals of electronics and control should be segregated.
As far as possible, terminals for electronics signal cables shall
be mounted on the left hand side & other control terminals shall
be mounted on right hand side of the panel.
5. The terminals of AC/DC or with different voltage levels, shall be
segregated using partition plate or by spacing them apart.

The size and color of multistrand cables used for PLCs & drive
systems:

Signal
For PLC
For Digital Input 0.5 sq mm PVC Red
For Digital output- 0.5 sq mm PVC Red (or
depending upon the current rating mentioned).
For Analog input & output 0.22 sq mm multicore
shielded cable.

For Drive
For digital as well as analog signals 0.22 sq mm
multicore shielded cables are used.

Power
R-Phase Black cable with RED Insulation tape
Y-Phase Black cable with YELLOW Insulation
tape.
B-Phase Black cable with BLUE Insulation tape.
Neutral Black cable with BLACK Insulation tape.

Control
1.5 sq mm PVC Grey wire is used for control circuit

with Red sleeve for voltage levels mentioned below:

110V AC Phase
220V AC Phase
110V/220 V DC +ve
1.5 SQ MM PVC Grey wire is used for control circuit
with Black sleeve for voltage levels mentioned below:
110V AC Neutral
220V AC Neutral
110V / 220V DC ve --- Blue sleeve

Electronics Power supply (2 / 5 Amps rating)

24/15/10 V DC +ve -- RED PVC 0.75 sq mm cable
with RED PVC

sleeve

24/15/10 V DC ve -- BLUE PVC 0.75 sq mm cable

with BLUE PVC sleeve.
M

-- BLACK PVC 0.75 sq mm

cable with BLACK PVC sleeve

For higher rating Black PCP cable with same marking are used.

1.5 sq mm Grey cable is used with RED sleeves for

Potentional free contacts where voltage & current is not

mentioned.

For all the direct reading panel meters (Voltmeter,

Ammeter, KW meter etc) minimum 2.5 sq mm multistrand

copper grey PVC wire is used.

Ferruling method: Local End ferruling unless specified otherwise

in the Manufacturing Instruction sheet of the drawing set.

Ferrule type used: a. Round type 0.5 sq mm & 0.75 sq mm for cables used for signal
wiring.
b. T-type 1.5 & 2.5 sq mm for cables for control wiring.

EMERGENCY SWITCH IS PROVIDED THEN IT WILL

MOUNTED IN THE CENTRE OF SECOND ROW

PILOT LAMPS
1. The color GREEN should be used for pilot lamp to indicate the
motor is STOPPED or the circuit is OPENED
2. Where there are two pilot lamps the pilot lamp for STOP
should be colored as GREEN and pilot lamp for ON should
be colored as RED
3. If there is a pilot lamp for indication of stop and several other for
start, as for example forward and reverse, for full speed and
reduced speed, only the stop pilot lamp should be colored
GREEN
MOUNTIG POSITION FOR PILOT LAMP

Description

Color

OFF

ON

RED

GREEN

RESET

BLACK

Description

Color

OFF

RED

ON

RAISE

GREEN

BLUE

LOWER

AMBER

RESET

BLACK

TEST FIELD
The testing of the automation panels to reach the international
standards is performed in this dept.
The various tests carried out are as follows:

Visual test:
This test involves visually checking the structure of the
panel and components according to the part list (BOM),sometimes
the components like MCBs or Fuse links are shortfall then such
components are assembled other than real one in Partlist,that is
called Dummy Supply.

Lay out checking:

This test involves checking whether the components
mounted are as per the part list.

 Continuity test:
This test is carried out to check whether there is continuity in
the circuit, there is no short circuit, loose connection etc.

High voltage test:

This test is given to check whether the circuit can be
operated properly at high voltage ranging from 0.5-2.5 KV, which is
applied depending on the capacity.

Function test:
Giving the supply & connecting the output of the drive to the
motor and checking whether the automation panel is functioning
properly carry out this test.
If there is a PLC in the circuitry the programming it
accordingly & then checking the output.
After all these tests are performed then the panel is
stamped and sends for dispatch.

TEST PROCEDURE AND QUALITY

ASSURANCE

Step#1: Documentation

Engineering drawing documentation

Check availability of all pages

Reading Engg. Documents / wiring manual carefully

Special emphasis on manufacturing instructions

Check for the no. of amendments

Check that the amendments are marked on the drawing

Step#2: Visual channel outside panel

Check front view , rearview and side view.
Check for cut-outs for fans/louvers/Acs and the other door
mounting equipments.
Check for the conformation of IP class protection
Check for the alignment of doors, side-covers, locks,etc.
Check for the base channel, anti vibration pads, type and
thickness of gland plates

Step#3: Visual checking inside the panel

Check lay-out of the components as per the drawing
Check the presence of labels for all the components
Check for the tightness of bolts and mounting screws
Check for the quality of the galvanization of the mounting
plates

 Check for the quality of crimping and tightness of the power

cables
Check for the firmness of the lug+ control wire crimping
Check for the burr and dust inside the panel and remove it
Check the positioning of the i/p and o/p bus bars for easy
access of the cables
Space heater must be away from cables or it will cause
damage to cables

Step#4: Bill of material check

Part list or BOM is available item-wise or panel location wise
Each component must have label as per BOM
Check for the correct MLFB or product type number, make
and quantity
Special attention to letters and no.`s indicating V/I rating.
Available supply (415V,3 phase/2phase, 220/230/240 V AC,
28/48V DC) and equipment must be confirmed
Special attention should be given to coil voltages of relay,
contractor, snubbers.
In case of drives, optional boards, S/W, optional cables to be
checked
In case of contractors/ MCCB, Auxillary contacts must be
varified

Step#5: Continuity check

Remove all fuse links, shorting links before continuity check
Remove connections wherever necessary- control trafo Pri &
Secondary
Put all switches in Normal/OFF position
Continuity check to be performed section wise- Power,
Control and electronic
BEWARE: Due to non removal of links certain alarms are
possible
BEWARE: Due to parallel paths like NC or trafo, false
alarms are possible
During continuity check inspect ferrule , lug , sleeve and
label
Mark the checked connections with special ink on drawing
Mark single wire at point with one mark and two wires with
double mark
No point should have more than two wires terminated at it.
Two wires should be crimped in one lug only at terminals
No two wires/ lugs of different size must be put in single
terminal
When not shorted externally EE,BS, & PE bus must show
electric isolation
Some small rating MCB contacts and fuse links may not
show continuity due to higher resistance. In such case go for
resistance measurement

 NC/NO contacts of the contractor/MCB to be checked by

operating them manually during continuity
Most important check: Between different phases and
neutral/ earth at i/p & o/p.
All non-conformance points to be noted in test report & same
to be rectified before next test ie HT is taken up.

Step#6: Insulation resistance check

Preparation for IR test:
Replace all fuse links, shorting links. Restore all removed
connections
Switch ON all MCBs. Short i/p & o/p terminals of all
contractors.
Remove connections going to electronic module like cards
on drives
Remove i/p & o/p connections to drive. Short them together
using shorting wire. Note that IR test of wiring is to be taken,
not that of electronic modules and drives.
All power connections to drives is to be removed & shorted
together & IR to be checked between PE and power ckt.
terminals. IR should be greater than or equal to
10 Megaohms.

 In case IR is smaller than or equal to 10 megaohm or dead

short, section wise inspection to be done.
For control circuit similar steps to be repeated applicable for
power section
Supply/ signal cables to electronic equipment to be removed
Earth connections to star connected lamps / CT`s to be
removed
IR to be measured between shorted control cables and PE
IR for electronic section to be carried out on similar basis as
for control circuit.

Step#7: HV test
HV test to be carried out separately for power section,
control section and electronic section. All test with respect to
PE.
Connections to be kept as were done for ir test.
HV test for 1 Minute- 1st attempt. High voltage
=2Vm+1KVDC for power and control section (Vm is the
operating voltage of the circuit.)
For electronic section where the operating voltage is <100V,
HV =500V DC
After successful HV test, IR test to be repeated
IR and HV test are hazardous

 During IR and HV test notify people working with and

around you. Cardon-off the area with chain link and
suitable sign.
Do not forget to earth panel and IR/HV test equipment.
HV equipment can prove to be fatal, if not earthed or
handled properly.
HV equipments must be equipped with HV probes and
holders
Ordinary and low voltage cables on HV & IR equipments
can be dangerous
HV test causes insulation deterioration. So carry it out
for one minute only. For second attempt reduce time &
HV by 25%.

Step#8: Function test

Before function test remove all shorting wires used
during HV test and restore all necessary connections.
Function test can be carried out first for control+electronic
section and next for power section
Control section voltage (24/48/110/120/230/240 V AC) to be
given separately or through control transformer
Ensure that all the contractors and relays should get
energized as required in the scheme
Programming of LOGO! may be required during this check
Shorting links at the terminal strips may also be required

 Switch set-up for REMOTE CONTROL simulations may be

required.
If chattering noise from the contractors/relays is heard,
check for coil voltages & presence of burr inside of
relay /contractor
Time setting in timers is important, if used
After successful control section check, power section can be
checked
Three phase power supply 415V/690V/750V to fed upto SFU
i/p bus bar.
Switch ON supply to control section first & than to power
section.
Drive can be reset to factory values first & can be run
independently if control logic permits.
Important parameters for drives:
Supply voltage, Motor voltage, Motor current, Motor
frequency, Motor rpm, field current, current limits, power
factor, Tacho voltage, etc.
Source of ON/OFF command, main set-point, type of setpoint, etc.
For DC drive optimization & necessary modifications are
important.

Repairs
It is the department which deals with the repairing of faulty
equipments and assemblies. The repaired assemblies are than
dispatched to their respective departments for mounting into panels.
The test sequence for the repairs department is of two types:

1. Visual inspection
1. Removal of dust and clean the PCB.
2. Checking for general placement and soldering of component
3. Check for proper connections and color code of the wires

going from one module to another

2.

Functional testing
1. It is carried out after visual testing. Separate test Jigs are
available for different cards and assemblies.
2. By connecting proper power supplies and signal to these
cards we check that the proper output is there or not
3. This is done by connecting CRO and multimeter and
observing the response of device on that. If any card is faulty
it is detected that which section of the card is faulty.
Eg. Problem in the over voltage section we find the faulty
component in the section and replace the faulty
component.
4. Than that card is sent for pre-testing.
In pre-testing we check the assembly without load and see
the response of its output with respect to the input and check
whether they are properly working or not.
If the assembly is OK, it is sent for the final testing. If the
ckt. is not OK than the functional testing is again repeated.

4. Final testing
It comprises ON load testing of assembly for half an hour
and if the assembly works properly, the OK tested sticker is
marked on it and sent to their corresponding department.

Stores
Siemens stores is divided into three categories, ie. Electronic,
Mechanical and Direct Order store. All the records of the transaction
are kept on SAP. Whenever and material is added or removed from
the store its entry is made on SAP. Thus at any time SAP gives the
information regarding the quantity of material present.
In stores the material is kept in special cases known as Bins.
Each Bin is associated with the corresponding Bin no.and has a
material removal or addition record sheet. At the time of removal of
material the corresponding entry of the quantity of material is made in
it. This is than later compared with the SAP entry.
The material in stores is divided into three categories:

1. A-type material:
it consists of materials which are most costly but least in
utilization. They are kept in the upper or distant bins. Eg. Masterdrives, DC converter, etc.
2. B-type material:
It consists of materials which are moderately expensive and
moderate in utilisation. They are kept in the middle bins. Eg. Current
transformer, DC Amplifiers, etc.
3.C-type materials:
It consists of materials which are least expensive but most in
utility. They are kept in the lower bins which are easy in reach .
Eg. Capacitors, diodes, transistors, resistors,etc.

Flowchart for raw-material storage

Receive material with GRN from
NW/C-QI

Is physical
quantity
available on
Is the
GRN
storage
location
available on
GRN
A

Get the physical quantity

from the material from
NW/C-QI

Item received for first time,

assign the storage
location & update the
same in SAP

Is item no.
and
description
on GRN
matching
with Bin Card

Is
use- before
sticker
affixed to the
component?

Refer to stores incharge for corrective

actions

Refer to stores in charge for

corrective actions E.g. Return
to NW/C-QI

A
Bin the item respective
storage location

Enter Binning date, GRN no. and

Physical quantity of item on respective
Bin Card
Confirm the binning activity in SAP
Keep the GRN record in the record file
Period for retention of GRN is six months

Flow chart for IMC and finished goods storage

Receive material with
SDS
Find storage location using SAP.
If location not assigned in SAP, assign new
location and update the same in SAP

Is mlfb and
item
description
on SDS
matching
with that on
Bin Card

Refer to stores incharge for

corrective actions

Bin the items in respective storage location

Confirm the binned item quantity in SAP
A

Keep the SDS in record file

Records of SDS retained for six months

Flow Chart for Normal issue of material

Production order
released by Production
Cells through SAP

Receive Production order file

from Production Cells

Print MRS for Production Orders

Distribute MRS for material
removal
Remove Material from storage
location as shown on MRS
Update Bin-Card for each
issued quantity
A

A
Store Material In

Al Bins/Cartoons
Plastic Bins/Pallets /Trolleys

for electronic components

for mechanical & electrical
components

Verify quantity and position numbers

for each item referring to production
order file(Tray preparation)
Keep the removal order in
Area of Removal Order
Hand over second copy and
shortfall report for removed
order to stores in-charge

Confirm material removal onto SAP

Records for MRS retained for six months.

Note:
1.
2.
3.
4.
5.

All ESD sensitive items are removed in Antiststic

protective sticks, packages, covers, casings.
Do not remove material by hand when they carry ESD
symbol.
Ensure all PCB`s are wrapped in Sulphur free
paper/Polythene bags.
All Transformers, Chokes, Connectors with leads, to be
inserted in Tharmacole/ Packed in Polythene bags to
prevent bending of leads.
Attach MRS copy to respective items.

Flowchart for issue of Mat. through ECR/manual

MRS
ECR/MRS from
different dept.

Collect ECR/MRS from

Find storage location from SAP
Remove material from storage
location as shown on ECR/MRS

Attach second copy of

ECR/MRS to material
Put material on o/p tray of
respective Dept.
Hand over first copy of ECR/MRS
to stores in-charge
Confirm material removal onto SAP
Records for ECR/MRS for six months

Guidelines and working instructions for items

having Special Storage/Shelf life

Purpose & scope:

For the items whose characteristics deteriorates over the period of
time.

Definitions:
Nil

References:
------------

Responsibilities:
as per the Activity

Activity:
A.1 Material received at the Incoming Inspection
1. Items are identified in table specified under A.2
2. After routine test of items as per AQL & Sampling plan following
points additionally to be checked.
Date of manufacturing
Date of expiry
3. Based on above data, the shelf life of respective item should
only be referred in table specified under A.2
4. Fix the USE BEFORE green label with MONTH/YEAR written
on each packet/ reel/cartoon containing local / imported items
Where date of expiry is not mentioned.
A.2

Unused Material received from stores with Expired Shelf

Life
Working instructions as per the following table:

Mat. DescriptiClass on

Shelf
life

Storage Working
location instructions

months

335

332

---

PCB

12

Diodes
Transistor
Thyristors 18
(THT only)

SMD
Solder
Paste

---

Electro.
stores

Electro.
Stores

Fridge
NW/PC
B

Ident.
for
loca
-tion

Check the PCB

for expiry of one
year from week of
manufacturing as
per week/year
code etched on
them.
If found beyond
one year, check
solderability test
Not
by passing over
req.
the wave
soldering machine
Based on results
decide on
acceptance or
rejection
Check all
solderability of
leads as per
procedure.
All non
conforming
components
should be
scrapped
All bottles crossed
Manufacturer`s
expiry date should
be scrapped

Yellow
Sticker

Not
req.

Description
Material
class

330

331

---

Wire
wound
resistors
(THT only).
Resistors
(THT only)
Makes:MFR
Thermax
Draloric
Welwyn
Roederstin
Beyschlag
(BC Comp.)
Vitramon
Others
Capacitors
(THT only)
Makes:S+M(Epco)
Roederstin
Beyschlag
(BC Comp.)
Vitramon
Others

SMD
Adhesive

Shelf Storage
life
location
(mont
hs)
6

12
24
24
12
60
24

Working
instruction

-Check the
solderability
of leads as
per
procedure
NW/PR/ISP/
Electro. 11,dated ___
Stores all non
conforming
components
should be
scrapped.

Ident.
for
location

Green
sticker

24
6

24
60
24
24
6

---

-Check the
solderability
of leads as
per
Electro. procedure
Green
Stores NW/PR/ISP/ Stick11, dated __
er
All non
conforming
components
should be
scrapped
All syringes
Fridge crossed
Not
NW/
manufacturer requiPCB
expiry date
red
should be
scrapped

Mat.
clas
s

Description

Shelf Storage
life
locati(months)
on

143

Sticker
label

503

Packing
material

221

chemical
lacquers
Paints

Working
instruction

All stickers having

expired use
Electro.
before period
Stores
should be
scrapped
-Adhesive tapes
should be
subjected to peel
test on the
specified surface
like cardboard
cartoons.
-Adhesive should
Tapes
show no sign of
electro.
drying or tape
Store
should not crack
when placed over
Boxes
folded surface.
mech.
-Packing boxes
store
should be visually
checked for signs
of cracking on
folding and
discoloration.
-All non
conforming
material should be
scrapped

Mech.
stores

All items, if not

consumed beyond
stipulated time
should be
scrapped

Ident.
for
location
Not
required

Not
required

Not
required