Professional Documents
Culture Documents
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ACKNOWLEDGEMENT
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My heartfelt thanks are due for my parents and Ms. Snigdha paul for
their moral and logistic support and constant encouragement without
which it would have been difficult for me to complete my work.
Shreshtha Paul
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Mr. TARUN KHATTAR
Dated : Works Manager
Ordnance Factory, Dehradun
CHAPTERISATION
SECTION A-
STUDY OF THE WORKING OF ORDNANCE FACTORY DEHRADUN
COMPONENT - 1
Introduction
Mission:
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Initially the factory planned for the production of binoculars, telescopes,
compasses, clinometers, and drawing instruments. Subsequently, there has been
considerable diversification in the production activities in as much as that the
factory now meets the requirement of wide ranging optical instruments.
The factory has excellent infrastructure for the manufacture and assembly of
precision optical instruments in controlled atmospheric conditions. Optical
production and assembly building are air-conditioned and dust free.
During the past 67 years of its existence Ordnance Factory Dehradun has been
rendering in its own humble way, service to the country in general and to the
armed forces in particular. A repository of special techniques and processes for
the development and manufacture of precision Optical instruments, it has the
potential of becoming the foremost institution of its kind. This factory has led
the way all along among the industrial units set up for the manufacture of
various types of instruments and will continue to render such services to
instrument industry in the future also.
Vision:
To be the foremost suppliers of world class optical, electro-optic and laser based
instrument to the Indian Armed & Security Forces.
To build up ultra-modern and high accuracy production and testing, and product
evaluation facilities for ensuring quality right from raw-materials, components
& sub-assemblies to the final product.
To maintain Quality Management System as per International Standard.
To evolve a prompt response system to attend to the customer needs in time.
To pay utmost attention to the training needs for human resource development at
all levels.
To explore opportunities for diversification to expand customer base and
product range.
To enhance products range to meet every requirement of the Indian Army &
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other Para-military forces for optical & electro-optic instruments through
acquisition, synergy and in-house R&D.
To continuously improve product designs to complete in the Global Market in
terms of quality, reliability and cost.
To enter into MOU with world renowned design and/or production agencies to
produce the products of mutual interest through codevelopment & coproduction.
To enhance productivity every year by a factor of at least 20% with an ultimate
goal to achieve at least four fold productivity by next decade.
QUALITY POLICY
QUALITY OBJECTIVES:
Customers Satisfaction.
Quality Assurance.
Continual Improvement.
Human Resource Development.
Employees Safety
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DEPARTMENTS IN ORDNANCE FACTORY DEHRADUN
Sections
Ajeya shop
Cementing
CNC
Vacuum coating plant
Assembly I
silvering
Assembly II
Goggles
Shop
Graticule
Optical-III
Fitting
Air light equipment(A.L.E)
Assembly group
Machine shop (M.S) I
Machine shop (M.S) II
CNC
Metal Finishing (M.F)
Photo etching
Optical
CNC
Center-edging room
Roughing room
Planning office
Tool room
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Heat treatment
Work office (W.O) and Industrial Engineering Department (I.E.D)
Wood work foundry(W.W.F)
foundry
2. Engineering department
civil maintenance
electrical maintenance(EM)
engineering office
mechanical maintenance
Water works department
drawing office
5. General administration
bill group
cash office
establishment
pension cell
recruitment cell
human resource department
factory training institute (F.T.I)
labour bureau
vigilance
anticorruption cell
yard and estate
confidential section
7. Offices
I.T.C (computer room)
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Labour Office
Management information system
Marketing
R&D
Stock verification group
Union office
Works committee hall
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PRODUCTS MANUFACTURED IN ORDNANCE FACTORY
DEHRADUN
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9. day light telescope 5.56mm[INSAS]rifle
10. anti material rifle sight
11. sight unit cased 102B
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SECTION B- STUDY OF SIGHT UNIT CASED 102B C2
COMPONENT 1
Optical
Mechanical
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PRODUCT ATTRIBUTES
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COMPONENT 2: STUDY IN ASSEMBLY SECTION
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ASSEMBLY PROBLEMS
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COMPONENT 3:- FINDINGS FROM THE STUDY.
PROBABLE REASON
1. The assembly is done in A/C room with the adequate light facilities;
hence working conditions cannot be a problem.
2. the worker posted there have been working for 20-30years or
sometimes even more than that, their promotion is stagnant or
sometimes due to long working time together ,workers are both
frustrated with the same job and at the same time develop friendly
relations with the co-workers. This results in negligence in their
work.
3. since the product is manufactured through assembly the workers do
not have profound knowledge of the end products, a minor error like
gear teeth fitting (should be +/-)is sometimes made(+/+) or (-/-).this
leads to defect in the end product( the disc becomes immovable,
therefore the movable scale becomes stationary)or sometimes
lapping is done improperly, therefore optical path takes elevated
position.
4. Jerky movement of mechanical parts.
Mechanical:
1. gear teething(major)
2. casting body(guide problem)
3. calibration(done in engraving machine-drum scale)
optical:
1. Graticule thickness(photo etching)
2. Centering of the lens (major problem)
3. prism having bad definition(cutting problems and optical
glass problem)
4. focal length of eye lens not proper
5. Images appear to be inclined.
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REMEDIES
The proposed remedy for this problem may be proper training of the
employees briefing them about the product use and few technical details.
It is observed that the workers are well versed with their job but they do not
have any knowledge as to where and how the component fits in the end
product. Therefore it is the utmost requirement of the management to provide
some basic knowledge to the workers so that if at all they manipulate it may
be within the tolerance level.
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COMPONENT 4:- STUDY OF THE MECHANICAL DEFECT.
The major problem in mechanical parts of sight unit cased as reported by the
assembly is in the worm gear supply by tool room. Gear is anything that is used
to transfer motion from on e shaft to another. This is done by fitting the gear
with a spindle. The process of making the gear teeth is known as gear hobbing.
The term hobbing is used because the tool that is used to cut the teeth is known
as hob tool. The machine employed for cutting the teeth is known as Mikron
gear hobbing machine. The time that one Mikron Gear Hobbing Machine takes
is far more than that of a CNC machine performing the same job. Factory has
not yet purchased a CNC for gearing due to economical constraints. Hence the
daily manufacturing of gears is about 5-6 piece. The depreciation life of the
gear hobbing machine is 20 years but they are being used for 40 years.
*If it is found that the concentricity is not uniform the elevated portions
are rubbed with the emery paper.
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DEFECTS FOUND IN THE WORM GEAR
4. The spindle attaches to the gear should also be concentric, i.e. the
thread of the spindle should be concentric with the ball of the spindle.
5. Spindle line should be accurately straight else significant error may
arise in the thread and ball movements resulting in reading errors.
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COMPONENT 5:- FINDINGS FROM THE STUDY.
DEFECT INVESTIGATION
SUGGESTED REMEDIES
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COMPONENT 6:- STUDY OF THE OPTICAL DEFECT.
ROUGHING
1. Glass block is purchased.
2. They are cut into rectangular slides with the help of
diamond edged wheel cutter.
3. Thereafter the slides are cut into circular discs as per the
given specification of the diameter and thickness.
4. When the slides are cut, they are made a bit more than the
specified dimensions so that errors may not arise during
polishing.
5. After rough cutting, edges are smoothened.
6. The required curvature is then given with the help of
machine, but since the machines are old, there is no proper
device to measure the amount of curvature done; hence the
workman employs hit and trial method.
7. After the roughing stage, the lenses go for inspection.
Almost 100% of lenses pass the inspection test here.
Prisms undergo similar manufacturing process, the difference being that
the moulds are purchased and not cut from the slabs.
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SMOOTHENING
1. Before polishing, the lenses are smoothened.
2. They are pitch coated on one side and then they are
smoothened under pressure.
3. The pitch is then removed by putting the lenses in benzol.
Thereafter they are cleaned using ethyl alcohol.
POLISHING
1. polishing is done to increase the transparency of the optics
2. It is done with the help of cerium oxide.
3. Then they are checked for angle accuracy using reference
/master lens/prism.
COATING
Coating is the process by which we try to reduce the amount of light reflected
thereby increasing the amount of transmitted light. In a day sight telescope, 17
optics are used, without coating, an optic reflects 4% of the light incident on it
hence it transmits 96%of the light. The same applies to all the optics set inside
the telescope. It is found that at the end only 205 of the light is transmitted out
of the telescope. This results in blurred image formation.
Therefore coating is done with MgF2. this reduces the reflected light to 0.5%.
For reflection to be 0%, we need to coat with TiO2 +SiO2 or TaO2+SiO2. But
these are very costly. In night vision they are used since at night we have no
light in the visible range, the night vision works in the infra red range therefore
no ray could be afforded to be reflected. The thickness of the coating is kept to
be 1450 angstorm.i.e. (Lambda/4).
The coating of lenses is done in a computerized coating machine.
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CENTERING AND EDGING
Centering came out to be a major problem in assembly.i.e the lenses were found
to be eccentric or in other words, their center was found to be out.
Centering means that the mechanical axis (i.e. the barrel) and the
optical axis (the axis passing through the center of curvature) should be parallel
to each other; else image formed will be out of the barrel.
Mechanical
Rifle Axis
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1. The tool used for centering is known as Mendel.
2. In a centering machine, 2 Mendel are placed with their axis aligned.
3. The 2 axis are aligned manually.
4. The spindle along with the Mendel is placed in a pedaled machine.
5. The machine is pedaled and a glass is put in front of it.
6. cosmeticity is done(i.e. giving appropriate angle to the rim of the
Mendel)manually, approximately 300.
7. The reflection of a table lamp kept in front of the Mendel is seen.
8. The Mendel will be accurately aligned only if the lamp image is still i.e. it
will not vibrate.
9. In the centering machine, lens will be placed. The machine will cut the
lens where optical axis and mechanical axis is parallel. Simultaneously the
extra edges are cut.
1. Roughing, smoothening, polishing, coating did not show any problem, the
problem was seen during the centering stage.
2. It was found that the bell clamping method was used even when the angle
is < 190.this is because the workers find this method more convenient and
less time taking.
3. When pedaled machine is used, the reflection of the lamp is seen by naked
eyes. There may instances when out of fatigue the workers find it difficult
to determine whether the image formed is still or not.
4. The workers are not concerned about the accuracy rather they are more
concerned about the amount of job done.
5. The work environment of the optical section does not meet the
requirements, like the temperature should be maintained round 220C, but it
is actually around 27-28oC.
SUGGESTED REMEDIES
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SECTION C STUDY OF THE NIGHT VISION DEVICES.
The indigenous binocular night vision passive, light weight is designed and
developed by Instruments Research and Development Establishment, Dehradun
for surveillance at the company and platoon level and for use by patrols
commandos. This binocular would provide vision at night using the night
ambient low level of illumination due to stars and moon. The range of
recognition PNVB is human being-300m, vehicles/tanks-500m.under clear
starlit night medium contrast. The magnification of PNVB is 4X.
This product is used to read maps. At night when soldiers are required to read
maps, they cannot light torches else the enemy will be able to locate them.
GNVP cased 101A is equipped with II tube. This glows in dark and thus helps
in reading maps.
Sight night vision prominently has a graticule since they are used for sighting;
they are mounted on the weapon.
84mm carl gustav is a rocket launcher, LMG-light machine gun, 5.56mm rifle is
used by infantry.
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COMPONENT 2: STUDY OF NIGHT VISION (CASE STUDIES)
CASE #1
Customer central ordnance depot, Agra. (COD Agra)
Complaint date-20-03-10
1. crew served weapon sight(MMG)passive cased 101A
Manufactured -243
Defective-59
Defect-tube not glowing
2. goggles night vision passive
Manufactured -901
Defective-186
Defect-tube not glow
3. bino night vision passive 101A
Manufactured-221
Defective-147
Defect-tube not glowing
4. sight night vision passive 84mm Carl Gustav
Manufactured-557
Defective-134
Defect-
a) II tube not glowing
b) Dirt on optics
c) Body damaged
d) Hinge broken
e) Switch broken
5. sight night vision passive 5.56mm LMG(INSAS)
Manufactured-5600
Defective-1078
Defect-
a) II tube problem
b) Body oxidation
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CASE #2
Customer-COD Agra
Complaint date-18-12-09
CASE #3
Customer- COD Agra
Complaint date-30-04-09
CASE #4
Customer-COD Agra
Complaint date-11-07-08
Product- PNS rifle 5.56mm
DEFECTS FREQUENCY
Battery connection strip 1
detached
Black patch 1
On/off switch 1
Paint particles 1
Dirt on optics 1
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CASE#5
Customer-COD Agra
Complaint date-30-06-08
Product-sight night vision passive 84mm Carl Gustav & passive night
vision bino
DEFECTS FREQUENCY
Excessive grt light on II tube 2
Grt not glow 3
Battery cover hinge broken 1
Moisture on optics 1
Mounting bkt defective 1
On/off switch 5
Image not in focus 1
Dust on optics 1
Eye piece defective 1
CASE#6
Customer COD Agra
Complaint date- 23-06-08
Product-SNVP 84mm Carl Gustav & PNVB
DEFECTS FREQUENCY
Body loose 15
IR not glow 2
ON/off switch 3
Paint particles 2
Dust on optics 1
Potmeter broken 2
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Grt not on 1
CASE #7
Customer complaint- COD Agra
Complaint date -14-06-08
Product- SNVP5.56mm rifle& LMG (INSAS) 101A
DEFECT-
01. Major defect that was pointed out in almost 100% of the
product supplied was that the battery insulator was stripped off.
2. Secondly, the sight was not functioning in the products.
CASE#8
Customer- COD Agra
Complaint date-05-05-08
Product-PNVG cased 102 A
DEFECTS FREQUENCY
Dust on optics 1
Focusing ring sticky 3
On/off 2
Paint particles 5
Body loose 7
I.R lamp not glow 1
O.G loose 1
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COMPONENT 4: ANALYSIS OF NIGHT VISION DEFECT
From the given data available, the following conclusions can be drawn:-
1. A total of 1220 times it was reported that defects in the I I tube led to the
rejection of the product.
2. Other than the I I tube defect, the products show mechanical and optical
problems as well.
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COMPONENT 5: I I TUBE STUDY
I I Tube is the image intensifier tube that is planted in night vision devices. It is
imported from Germany. This I I tube helps in intensifying the electron flux
thus increasing the amount of light reaching the photocathode. The electron flux
is intensified with the help of micro-channel plates.
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probable reasons for rejection of 18mm I I tube
Defects
Black spot>600um 3
problem at emission point 4
wire cut 2
Flickering 2
dent on anode 6
Black spot>400um 3
less resolution 7
Black patch 1
dark area 3
Black spot>500um 3
Black spot>800um 2
no glow 10
bright spot 2
less glow 1
brightness more 2
Black spot>1000um 2
Black spot>300um 2
physically damaged 1
Black spot>700um 1
Black spot>2000um 1
blurred image 1
vacuum leak 3
Shade 2
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COMPONENT 6: FINDINGS FROM THE STUDY
SUGGESTED REMEDIES
1. The body used in the night vision was magnesium, which gets oxidized
easily, more over it leads to heavy weight of the product.
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SECTION D: CONCLUSION OF THE PROJECT
1. Even though there is quality control checking at each and every stage of
manufacturing, rejection does takes place.
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