Chapter I

INTRODUCTION

As a part of our MBA curriculum, organization study is the area where our
theoretical knowledge under study with an organization to find out its overall
working, learn about origin, growth and development of the company,
understand and analyses about the quality policy of the organization and the role
of each department in the organization dealing industrial products and also of
the working culture of the executive and the workers. The organization study at
information of various aspects and has been a valuable help and assistance to

me.

Keltron is India's first and the largest electronics corporation in the State sector.
Keltron has been a catalyst in making electronics work in almost every aspect of
our daily life, since 1973. It is India's leading capacitor manufacturing
company. It offers the widest range of capacitors covering various types of
aluminum electrolytic capacitors, AC motor start capacitors, motor run
capacitors and power factor correction (PFC) capacitors.

The main objective of the study was to get the overall idea about the functions
of an organization. This report provides details about the different departments
and functions of the organization.

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 .QBJECTIVEs OF THE sruoy
> To study th .
-
>T d e orgamzationaJ stru t
o un erstand the fu . c Ure of teh compan y
nctions of vari
> To gain practical kno l ousdep artme nts
w edge about the funct. .
of the organization JOnmg of various deap rtmetns
» To understand the strengtha d
n weakness of th · .
> To understand th e organ1zat10n
e external environment of the organization

METHODOLOGY

The "Organization study'' t KELTR .

a ON 1s based on a descriptive study. The
data collections were both from primary and secondary sources.

PRIMARY DATA SOURCES;

• Interview with managers, office staff and workers

• Informal talk with employees and observations

SEC ONDARY DATA SOURCES;

• Data collected from annual reports, departmental report and catalogues

etc.
• Data collected from company website and Wikipedia
• Data collected from books

SCOPE OF THE STUDY

The study is intended provide managerial insight to a management student. If

able him to take up responsibilities of a manager at ease and provide him

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.. KELTRDN.

more confidence. Th f
e scopeo the study is confined to a few selected
departments and their functions Thet .
· ramee may also get a feel about how
business executives operate in their work settings.

LIMITATIONS OF THE STUDY

• The limited time frame of two weeks in conducting study is the major
constraint.

• More talks with the Top officials of the company were not possible due to
their busy schedule.

• The conclusions and the inference are drawn only on the basis of the
report, received from the interviews and it may be colored by personal

bias.

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 hapter 2

INDUSTRY PROFILE

INTRODUCTION
I
ALUMINIUM ELECTROL YT CAPACITORS

Electrolytic capacitors are passive electronic components whoseb as1·c funct.ion

is to store energy. Fundamentally, it is a charge storage device which consists of
two conducting plates separated by an insulator called dielectric. A variety of
capacitors are in use in electronic and electrical circuits.

A Capacitor is identified by the type of dielectric or plate material used on it.

Some of the most common capacitors which find widespread application in
electronics as well as electrical industries are paper, plastic film (such as
Polystyrene, Polypropylene, Polycarbonate, etc.), Ceramic, Mica, Aluminium
Electrolytic, Tantalum, and others.

A capacitor is expressed in terms of its capacitance, in MF (micro-farads) and

its working voltage in Volts (V). Other parameters which specify its quality are
Leakage Current, Dissipation Factor (also referred to as Loss Factor).

Aluminium Electrolytic Capacitors are being used extensively for consumer

electronic goods all over the world. Like any other type of capacitor the
Aluminium Electrolytic Capacitors (AECs) too have two plates separated witha
dielectric Whil --......,....., capacitors are bi-polar in nature ( any
mtcltollrd iitlc,r of the plates) a good majority of

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 " t-:;ELTRON.

A E Cs are polar. The outstand ing advantgae f I .

. o e ec trolyt1c capacitors is the I
c a p acit ance/volume ratio Th
e la . arge
. . . r g e ca p ac itance in ECs arises from very thin
film of d1electric used of the order of I o-6 cm.

The method of making fim

l ·ts bY makm
. g anodi.c ox.idation. Metals like
Aluminium, Tantalum, yanaa·mm, Magn.esmm, Bismuth and Antimony are

readily coated with a film of dielectric by electrolytic "formin g process". The

forming process consists of the deposition of a thin film of Aluminium Oxide on
the surface of the plate. Aluminium foil enters in the tank of electrolyte with a
constant voltage applied and passes through the tank until the required thickness
of film is produced

The essential parts of electrolytic capacitors and their function sar e :-

PARTS FUNCTIONS

Aluminium foil Positive or anode

Oxide film Dielectric

Electrolyte Negative or true cathode

(Usually a paste of glycol and ammonium tetrabora te )

Necessary to separate the cathode and anode film form

Spacers
direct contact
A second Aluminium Contact electrode to the electrolyte- the cathode

foil
Table:2.1

The etched foil type is similar in construction to the plain foil type but the anode foil
is mildly acid etched before forming with a consequent i nc rea se in the
anode surface area. As the electrolyte is a paste it is able to make contact with

the whole of the thin oxide film that is formed on this undulating surface. It is
9

•
I,
- . '

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 ".: ELTRDN

essential to control the etch·mg process closely so th t' h' '

the foil and also to ensure tht . . a t m spots are not left on
a no acid 1s left h. h ·
The. . w ic m ight contaminate the foil
mcrease m surface area result.s . . .
. bl m a considerable increase in the capacitance
obt ama e.

. lthough. the capacitors have com mon fun.ct1on of st.onng the electrons/energy,
. A
it 1s used m almost all the sectors of the economy. For instance, capacitors are
used in various appliances l 1"ke a·tr-con ct1· t-10ners, re. frigerators, motors, coolers,
pumps and fans. Railways, power, cement, steel, automotive, electronics--
almost all the sectors make use of them. New projects across different sectors
will have direct impact on the demand of the capacitors. Electrolytic capacitors
are mainly used in radio receiver, tape-recorders, TV (Black & White, Colour),
PA equipment. Hi-fi system, defencecomputer ,communicationequipment's and

industrial applications.

New projects across different sectors will have direct impact on the demand of
the capacitors. More the new projects more will be the demand for capacitors.
Demand is also directly related on demand for consumer durables like
refrigerators and air conditioners. Thus capacitors have universal application
and in some form or the other it is used by both households as well as industries.

GLOBAL SCENARIO
:

'Faster, Better and Cheaper' is the slogan that drives today's electronic industry.
Consumers are buying goods at a faster rate than the past. Electronic industry

now follows the slogan 'Innovate or Perish'. Thus we can see number of novel

and modified products in the market today.

After the record year in 2000 the global capacitor market declined in both 2001
and 2002 and it was not until the second half of 2003 that the market started to

10

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 J
ELTRDN.

show signs of a sustained recove1y. The recovel') 0·

d .
oame momentum m the fir t
half of 2004 fuelled by strong demand and fiirmer pn·cm
· g. However. with
additional capacity coming on stream combined with the potent1·aI b m·id up of
inventories, pricing is once again expected to come under pres ure. T h i '

resulted in a slowing market in 2005 and into the first half of 2006. The market
is expected to experience a period of stronger growth in 2009.

The basic technology for the manufacture of Aluminium Electrolytic Capacitors

has changed a little since the first high performance AECs using formed and
Etched Aluminium Foil was developed in late 1930's. However, over the years,
especially with the advent of modem equipment utilizing integrated circuit and
with the demand imposed by improved and consistent perfonnance over
extended period of time, substantial adaption and process improvement have

been made.

The major global players in electrolytic capacitors are:

•!• Barker Microfarads, Inc. (USA)

•!• Cornell Dubilier Electronics, Inc. (USA)
•!• DuraCap International Inc. (Canada)
•!• Elna Co. Ltd. (Japan)
•!• Epcos AG (Germany)
•!• Guangdong Fenghua Advanced Technology (Holding) Co. Ltd.

(China)
•!• Hitachi AIC, Inc. (Japan)
•!• itano Enterprise Corp. (Taiwan)
•!• HaimenSanconJetwell Electronics Co., Ltd. (China)
•!• Illinois Capacitor, Inc. (USA)
• !•Jacktronics Electronics Company (China)
• !• Arcotronics Group (Italy)

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 KELTRCJN

•:• EvoxRifa Group Oyj (Finland)

•:• Lelon Electronics Corp. (Taiwan)
•:• Nichicon Corp. (Japan)
•:• NIC Components Corp. (USA)
•!• Nippon Chemi-Con (Japan)
•!• Panasonic Corporation (Japan)
•!• Sanyo Electronic Device Company (Japan)

The end-use markets of aluminium electrolytic capacitors are:

> Consumer Electronics

> Computers and Peripherals
> Telecommunications
> Industrial Applications
> Inverters
> General-Use Inverters
> Inverter Air Conditioners
> Other Inverters
ASIAN MARKET TREND: Chinese Capacitor Saga and a comparison with

India

China, considered to be one of the Asian dark horses, has made an astounding
progress in the capacitor industry. The technological, economical, and social
policies adopted by the Chinese government have provideda tremendous boost
and encouragement to the Chinese manufacturers and entrepreneurs. Supportive
import, economic, and development policies have encouraged leading
multinationals in the field to set up development and manufacturing facilities in
conjunction with the local Chinese players. This drive has positioned China,
unknown and unheralded a decade ago, on the world capacitor map

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 !;HAPTER3
COMPANY PROFILE

ABOUT KELTRON:

Keltron, Kerala State Electronics Development Corporation Limited, is a public

sector Electronics Company located in Kerala. It is headquartered at the capital
city of Kerala, Thiruvananthapuram. The company is under the direct control of
the State government ofKerala. The registered name of the company
is Kerala State Electronics Development Corporation Limited (KSEDC). The
name KELTRON was coined from two words, Kerala Electronics and when it
was necessary to use a small word in Telegrams referring to the company.

Keltron is India's first and the largest electronics corporation in the State sector.
eltron has been a catalyst in making electronics work in almost every aspect of
our daily life, since 1973. The tag line launching a State-owned electronics
enterprise, more than a quarter century ago, read "spearheading an electronics
revolution in Kerala". It was an experiment by Government of Kerala to transform
the laid-back, picturesque Kerala State known for its spices, natural

15

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 beauty, Kathakali and the 0
technological deve l opment Thnam boat races ' to an arena for in dus tr ia l and
. at was how K I
With· fi e tron was born
in Ive years o.f . .
. . its inception, Keltro
every dtstnct of the State M n had set upa production centre in
. m d"trectly by Keltron f, . ore than 5'000 people were engaged directly or
or the manufactur Of 1 .
State-owned electro. e e ectromc goods. The model ofa
mes corporation was
in India followed . sosuccess ful that several other States
ea rs Kelt h su.it - launching the·ir own electro.nics corporations. Over the
bY. ' ron a.s built up a strong. tnfrastructure spread over 7,00,000sqft of
u. 1t- area. Equipped with computer-based fac1..ltty for system design &
up
.
eng1neenng, and software deve1opment tools for embedded systems Keltron today
is fully geared to of£er h1' gh qu.alit.y mtegrated manufacturing solu' t ions.

A r ng infrastructure, enterprising team of people, innovative operational

st 0
methods, accent on quality and customer-orientation are the core competencies
of the organization which has made things happen all these years. Keltron's
expertise in high quality manufacturing is the direct result of the highly skilled,
multi-disciplinary team of graduate engineers, project managers anda skilled
workforce witha proven track record in complex precision manufacturing.
Currently, Keltron employs a work force of 2000 of which 400 are Engineers
who possess extensive hands-on experience in technology integration and
adoption, high-tech manufacturing operations and in managing tum-key
projects. Man power at Space Electronics section has been specially trained at
Indian Space Research Organization (ISRO) in high-reliability soldering,
harnessing and QC. KeJtron also provides technical manpower to major
organizations like oNGC and VSSC, and collaborators like Hitachi, Japan.

g quality isa continuous on-going process at all production units. Each

-'(",t'114!!llt'l"1·
1111

hasa Quality Department whose business is to see that all quality norms
y adhered to in the manufacturing proces·s The manu1c.actu-nng centers

16
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--- ; ELT.RDN
,\ .,
;:;--------
(
ti .....,
..
at Trjvandrum ,Aroor (Ne.ai Coc.hm) Kannur d K ·
are 1SO9001 ·2000 . . ' an ut!ipuram (In Ma/appuram)
. l · certified· Jnspectorate of Nava l Armament (SJNA-T) has
,.mp emented their customized qu.ality systems at Keltron Equipment Com' plex
Tnvandrum. The manufa c1u. nng plants for Capacitors, Crystals & Resistor's

ha_ve been granted LCSO approv.a1 In order to meet the stringent quality
reqwrements ofI S RO
, BSD-control measures have been strictly adopted at the

specified area·s Keltron has an All In. dia Sales Network in place .with full-
fledg e d Marketing O ffcies in Mumbai, Delhi, Kolkata, Chennai, Bang a lore,
Hy dera ba ,d Ahmedabad and Trivandrum to provide the quickest possible

service to customers.
Ke lt ron 's capabilities lie in the following distinct areas:

• Availability of large pool of experienced technical manpower.

• Strong infrastructure and manufacturing experience.

• Commitment to quality.

• Access to top level technology suppo.rt

. The products ofKELTRON consist ofa diversified field like:

• Aerospace Electronics
• security Surveillance Systems like CCTV systems, A ttend an
ce / Access

control systems, security electronic products

• Intelligent Transportation Systems

• Strategic Electronic products for Defence and Space departments
• Infonnation Technology Solutions like Intranet and Inter-office
Communication solutions, Web application development, Website

hosting, IT Training, Support services

• Process Automation Systems

17

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 ELTRD:;_;;;;;---------------------
• ID C ard Project - El ectoral photo ident' .
SMARTC d B t ty caid, Touch screen Kiosks
• p ar s, ar code d ca1·ds, employees ident ity cards '
ow
. er Electron ic s Systems - H.tg h - ri..t equency IGBT converters,
Rectifier ' Industrial Battery Chargers Hig h Capacity Voltage
Sta bilizers' AC & DC di' s.tnbution boards '

• Electronic Components - AIu.m.mmm Electrolytic Capacitors, Motor Start

Capacitors' Metal·lised Pla.st1c film Cap.acitors, Ceramic Disc Capacitors,
Carbon/Metal fim
l Rse·1 stors, .P1ezoelec.tnc Quartz Crystals, Trans ducers,

NTC Thermostats

KELTRON COMPO ENT COMPLEX LTD. (KCCL)

Keltron Component Complex Limited (KCCL) is a Gove rnment of Ker a la

undertaking promoted by Kerala State Electronic Developm ent Co rproa t ion
(KSEDC) and founded by Mr. K.P.P Nambiar. Keltron ComponentComp lex
Ltd is located at Keltron Nagar, 15 km from Kannur in Kerala. The company
hasa land area of 44,100 square meter, and a factory aera of9!50 square meter.
It is India's leading capacitor manufacturing company. It offers the widest
range of capacitors covering various types of aluminium electrolyticcap a ctio rs,
AC motor start capacitors, motor run capacitors and power factor correction

(PFC) capacitors.
Keltron Component Complex Limited (KCCL) was incorporated on 8"' October
t 974 as an associated company of Kerala State Electronic Development
Corporation Limited (KSEDC). It started its operation in the year 1976.
KCCL's headquarters is situated at Trivandrum. It isa public limited company
established for the manufacture of Aluminium Electrolytic Capacitors of
KSEDC on2 8 th August 1986. A plant for the manufacture of 18 m1 ·111·0n · piec· es
· ith MIS
of Aluminium Electrolytic Capacitor was established· 1n co 11ab ora·tion w

18
r -_ . '

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 KELT N
• ,1 -t

N.V Sprague Electromag Bel. g tu m wh· h

C ' IC was a b. d'
o. USA. The companyw t . su s1 tary of Sprague Electric
en mto commercia l d .
expansion of capacit I pro uct1on in August 1978. The
. or p ant was undertaken.
pieces by 1984-l9 and . . m a p hase d manner to 55 million
. 85 150 m1Ihon pieces b 1990 .
mcreased to1 . r .. Y -1991. The product10n
45 m11 ton pieces m 1999-2000.

Keltron Component Complex L'u.mted markets its products under the brand
name KELTRON of its parent company. It has a state of the art manufacturing
facility with sophisficated autom.atic mac.hmes from Japan, Taiwan and Europe.
It has the capability to produce all types of Aluminium Electrolytic Capacitors
which conform to national and international standards. The manufacturing
technology is constantly upgraded by R&D Centre of the Company which has
the recognition of the Department of Scientific & Industrial Research, Ministry
of Science& Technology, Govt. of India. The Company's Quality system has

been conferred with the ISO 900 l accreditation.

MISSION
"The company aims at maximum satisfaction of the customers by providing
goods which meets the requirements. And they are committed to achieve goal

with the involvement of employer at all levels"

VISION
Keltrons' corporate vision as the company enters the 21st century is

)> To emerge asa strong and self reliant business enterprise with customer

focus, profit orientation and professional outlook.

)> To build up Keltron as a model PSU in the sunrise Technology Sector of

Electronics and IT.

;.,,. To function as a backbone of electronic industry in the state.

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r- =-:..,:E:L: .:r=RD==N-:----------------------
» To continue to PIay the role of nodal agency of government for
accelerating the growth of deveIopment of .this cor.e industry in this state.

PROSPECTIVE CUSTOMERS;

The Electrolytic Capacitors are widely used in TV se,ts Rad io, Tape
Recorders, Telephone instruments, Electronic exchang,es Communication
equipments, Defenceequipments etc. The present customers include major
Indian manufactures like BEL, IT!, C-DOT, HCL, TATA TELECOM, BPL
TELECOM, BPL, ONIDA, SHARP INDIA, VIDEOCON, CROMPTON
CREAVES, TEXLA, ECIL, INDIAN AIRPORT AUTHORITY etc.

RAW MATERIALS;
The main raw materials used for manufacturing AEC's are:

• Etched aluminium foils 30 to 60 microns thick

• Formed aluminium foils and anodised etched aluminium foils 50 to 90

microns thick.
• Condenser paper, craft and Manila Hemp and Duplex

• Aluminium cans
• Lead tabs.
• Electrolytes
• Rubber bungs, EPDM, EPT rubber.

• Disc covers.
• Adhesive tape, high purity and high temperature.
• PVC heat shrinkable sleeve.
• Aluminium wire
• CP Wire (Copper plated) and Plain aluminium foil.

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'

TECHNOLOGY AND IN-HOUSE R&D·

'
TheechD
noelpoagrtm
y Gent of Scientific and Ind ust1.1·alRes erac ,h M ni is t ryo f Sc ie nce an d
D I ' overnment of India' have approved the in- ho useResea rc h an d
fi eveh odpm
. ent activities of the Cornpany. The company acquired thetec hno log y
, anUiactunng and testing from its collabor a tor s
or t e es1gn, development m c. .
. ag, e gmm. The manufacturing process was mainly
MIS NV Sprague Electrom B .1
uam nature which was subsequently upgraded by the
semi-automatic and man I. .
a e o t e art automatic machinery from Japan and
company by sourcing st t f h .
pans1ons was undertaken. The company also updated the
Taiwan during the ex ·
technology by obtaining information from suppliers on the latest developments
taking place in Japan, Korea and Taiwan on compactness and high temperature

categories of capacitors with its in-houseR & D effects.

PLANT & MACHINERY;

The original machinery for manufacturing 18 million pieces per annum of
capacitors was sourced from MIS NV Sprague Electromag Belgium.
Subsequently, for the expansion project the company sourced automatic state of
the art machinery from MIS JCC Engineering co., Japan, MIS CKD

Corporation, Japan and MIS Dons Enterprises, Taiwan.

The engineers and technicians trained in Japan and Taiwan on the machines
oversee the repair activities. Technicians are provided on the job training,
sufficient stock of spare parts are sourced and stored from the suppliers for

fabrication of spare parts, and tools room facility is also available.

FRASTRUCTURE;
: 44,100 Sq.m
Land Area
: 9150 Sq.m
Factory Area

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 ELTRDN
'

Connected Load ; Ca.ptive powe r

: 2300 KVA / J000KVA
o. Automatic mac hin es : 100 Nos

QUALITY POLICY·
'
Thed cotm
hptany aims at ma.xnn um satisfac fion to th·eir custom ers by providing
g.oo s . ah meet their requirement·s They are commi tted to achieving their

po1icy wit the involvement 0 fem p lo yees at all level through a well refined
quality management syste,m w hi"ch. 1s con .t inuou sly reviewed to enhance its
effectiveness and updated to meet chan. gmg req. mr ements.

AWARDS & RECOGNITIONS;

• !• National Productivity Award for 1988-89 unde rlar g e scalee lec tro nic
components units from National Productiviyt counc , il NewD ehl i.
• •! ELCINAA ward I 993 for excellence in Research& Deve lo p m en t for

work done in the field of forming technology

•!• Department of scientific and Industrial Rsee arc,h Minis tryo f Sc ience
and Technology, Government of India approval for the in-house

Research & Development

•!• ISO 9001-2000 certification from KPMG-QR,US A, only Electrolytic
Capacitor manufacture to have ISO 9001-2000 certification in India

SUBSIDIARIES OF KSEDC;

•:• Keltron Resistors Ltd:

Keltron Resistors Ltd (J(RL) located at Keltron Nagar, Kannur District

was incorporated on 29 April 75 as a subsidiary of Kerala State
tronics Development Corporation Ltd (KEL TRON). The Company

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, LLELT
-... ,1
---------
was promoted to manuf:acture Carbon F"II .
Resistors. The com m ReSistors and Metal Fi Im
pany has as installed ca .
manufactureR · pacity of2 1 7 mi11ion to
es1stors of both t e . . .. .
Resistors inw tt YP Caibon Film Resistors and Metal Film
Th· · a ages 0.125' 0·250' 0.S00, 1.000 and 2.000 per annum.
IS umt manufac tures Metal Fil m R.esistor.s m both profession al Grade

and General Purpose app1-icafIOn. KRL markets its products through its
Holding Company whicl1·15 the Sole Se.llmg Agent viz. Kerala State
Electronics Development Corpor.at10n Ltd (KELTRON).

•:• Keltron Magnetics Ltd:

Keltron Magnetics Ltd (KML) is a subsidiary of Kerala State Electronics

Development Corporation Ltd (KELTRON), established in the year 1975
for manufacture of Electronics/Electrical Components and equipments.
The company is situated at KELTRON NAGAR, Kannur. The products
include Metalized Polypropylene Film Capacitros (MPP Capacitors), A.C
Shunt/ L.T Power Capacitor and Servo Controlled Voltage Stabilizers for

Industrial and Defence application.

•!• Keltron Crystals Ltd:

Keltron Crystals Ltd (KXL) is a subsidiary of Kerala State Electronics

Development Corporation Ltd. The Company is located at KELTRON

NAGAR in Kannur. The Company has been manufacturing various types

of precision pieZo electric Quartz Crystals from 1976. It was the second
Crystal manufacturing Unit to be set up in the country.The Company has
an installed capacity of 2.084 million numbers of Quartz Crystals per
annum. In the HSN classification, the product is termed as M ounted
· ezoelectric Crystals under the head 8541·00· The Company' s product
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 , ' .,1 I 1 , ', '"",,:,I 'I
----
I 7 GIC Ltd 0.13
'
40000 400000
United India Insurance 0.03
8 10000 100000
Co.Ltd
0.14
9 SIDCO 42500 425000
1.12
10 Public 340665 3406650
100
To tal 30357625 303576250

Table 3.1

BOARD OF DIRECTORS

TITLE
I
NAME
CHAIRMAN
C. PRASANNAKUMAR
MAN AGING DIRECTOR
Lt Col. PARESH AGARVAL
DIRECTOR
K. RADHAKRISHNAN
DIRECTOR
U. V. PRAVEEN DIRECTOR
pRJNCESS PARVATHYBHAI
Ta ble 3.2

PRO DUCT RANGE;

TYPES:
.1 Radiacl apac itors - Aluminium Electrolytic Capacitors
.2 Axial lead type -Aluminium Electrolytic Capacitors
.3 AC Motor Star-t Aluminium Electrolytic Capacitors
4. Large Can- A luminium Electrolytic Capacitors
.5 MPP( Metalized Poly Propylene) Capacitors

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KELTl<DN.

ERIE FEATURE OPERATI G WORKI G BODY

TEMPERATURE
1
VOLTAGE COLO R

RANGE CAPACITANCE

l(VDC)
Orange
J
SA Radial lead -40°C to +85°C for 6.3 - 450 V
I
Standard WV 160V
0.1 - 22000 µF
l +g5oc
-25°C to +85°C for

II WV> 160V
Orange
25 - 50 V
SH Radial lead -40°C
type to 1 - 18 µF
Horizontal +85°C

Correction
+85°C
(Nonpolar)
6.3 -450 V Orange
Radial lead - 40°c to +1os°C
SE 0.1,..., 10000 µF
for wv 160v-25° c
+105 °c
to+I05° c for
wv>I60v

SN Radial lead -40°C 6.3 --100 V Orange

Bi-polar
to 0.1 -- 2200 µF
+85°C +85°C
(Nonpolar)
\
Radial lead -40°C 6.3 - 160 V \

I
I

low E.S.R to \
1-4700 µF 1 ,Orange
+85°C +85°C i

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 ELTRD

-4ooc to +sos c for

Axial lead WV 160V 6.-3 450 V Oran ge
Standard
85° C + -25oC to +8o5 C for 0.1 - 22000 µF
WV > 160V I - ---
MS/MD AC
A M o:tor: - +-- - - - - -L- - - - -
Green
Start
-30°C 11S - 330VAC
!Capacitor Aluminiu
ISingle Can to 20 ,..., 250 µF JT}

(MS)& +70°C

Double Can
I
! ( MD) orange
-40°C to +85°C for 10 ,..., 450V
: Snap-in
WV t 60V -25°C 47 ,..,47000 µF
I
+85°C to+85°C
for WV> 160V Green
16-400 V
-40°C to +85° C for
Lug Terminal
WV 160V 150 - 100000 µF
+85°C
-25°C to+85°C for
WV> 160V Greeen
16-450V
0°c to +85°C for
-4
MP Screw
Terminal WV < I60V 220 - 100000 µF

+85°C -25°C to+85°C

for WV> 160V \

Table 3.3

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 -·------

Productio.n i.s the process of conversi.on of a s t f. .

output,. either m the form of fim1s1ed
.l. O
. goods 01e. .1. 1inputs rntoa
. specified set of
thus ·ach1evrng the quality po 1 se v ce s, meetmg the quality and
1natenals, capital employed . c.. icy of
.
an ente1· 1.1· Th · men,
' m101mat10n and
P se. e mputs. are
Th
manufacturing is the bus· . . energy. e product10n or the
of other departme t mess actrv1ty o.f d .t 1 .
·k m USna urnt on which the activities
n s wo1 upon Tl . . . . .
ro duce the end . d . · le mam aim of th1s busmess system 1s to
.P. · h . p1 o ucts e1the.r 111 th e icO . rm of goods or services economically,
ut111smg t e available resom.ces, and thus satisfying the customers for which
they are meant.

This process starts when Onee ·th e d epartment rec.eives the order for produ.ct1n0.

According to the nature of the market, the marketing department of KCCL

analyses the future demand for the capacitors and takes decision along with the
managers of Planning &Control and the Production Depa11ment. The demand
for the capacitors won't be the same throughout the year. It may different
month ly sche dules. The work order is issued to meet the specific demand of the
cus tom re. A batch pro duc tion order is issued for keeping the goods in stores
p en d in g orders or when a number of customers order for the same product.

The m ac hinery use d for the production purpose is fully automated.

DEPARTMENTAL CHART OF PRODUCTION DEPA RTMENT

HOD

SECTION IN CHARGES
PRODUCTION IN CHARGES

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 VARIOU
To produce capacitors witl1 the 1.eq.u1red s . fi .
ca t ho de & ano de fo,il e lec t rolyt p ec 1 tca t 1,0n the raw materials like
· e etc have und erg0ce 11am·
Teh va rious s tep s are follows: stages of production.

•!• SLITTING

oSnlittw
inogrkis oardsec.tion where the etched r.aw mat.enals are cut legnt h- w is e base d
. l. er given from Planm·ng Department. After slitting process the
matena. agam goes to the quar1ty desk where the quality inspector checksan d
approves 1t.

•!• PRINTING
In this section the pr·mt·mg ·m van·ous colour sleeves are carried out. A bn·e f
detail about the capacitors like volt, name, value, brand nam e ect, ..ar e p r in te d
ona PVC strip or a colour sleeve which at last will be stuck to thecap ac ito r.

•!• STITCHING AND ROLLING

Stitching and rolling are two different processes. There are machines which can
perfonn both the work simultaneously or different machines to performt hese
two different works individually.
Stitching is the process by which, a thin needle are stitched to the anode and
cathode foil. The stitching will be of star formation. This is because the star
fonnation will increase the surface area rather than normal or circular stitching.
Now these two needles act as the terminals in the capacitor.
While rolling, the anode foil are separated with a special thick paper and rolled
according to the specifications needed for different capacitors. The length and
the breadth of the foils to be rolled will be different and this defines the
character of the capacitors. i.e. for higher volt & higher temperature capacitors
the foil will be broader and longer than that of the low volt & temperature
capacitor.

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 •:• JMPERGNATION
The rolled up form will not have any va1ue or s . ti .
and rolled capacitors are kept in • pee, ications. For this stitched
a so1ut1on which· II d
process of keeping the capacit d' . JS cae the electrolyte. This
or 1pped m the J t 1 ·
value. The time required for· . ro yte 1s to get the desired
impregnat10n defie ecth 1
it will take atlea s t two ho mes e vo tage of the capacitors
urs.

•!• §EALING SLEEVING HOT SRINKING AND ASSEMBLING

Aft.er impTreh.gnation' the above se.mi- f. im1shed goods are sent for sealing and
s evmg. e impregnated capacitor will be manually put into an aluminum can
1
with one end ope·n This open end .will be closed using a rubber bunk. The
rubber bunk. will. be hav·mg two ·tmy pores through w.hich the two ter.nunals
come out. This entire process is called sealing.
After sealing, the capacitors are sent for bot shrinking. The printed colour
sleeve is rolled over the capacitor and pressure is given over it along with
temperature so that the sleeve remains stuck over and around the can of the

capacitor.
•!• AGEING AND TESTING
Ageing is the testing process through which electric voltage is given to the
capacitor. Then it is tested to see whether it is working properly and bas the
right voltage and there is no short. Toe sealed coil goes for ageing and then it is
tested. If the capacitor is good it is sent for Quality Assurance. If it is tested bad
then if re-ageing is possible, then re-ageing is done and it is tested. If it cannot
be re-aged, it is rejected. Ageing and testing can be done both automatically and
manually the capacitors are put in a trolley and loaded, voltage is passed. Then
it is tested. Sometimes capacitors are tapped. This is manually done for
computer motherboards etc; only customer requirement.

•:• QUALITY CONTROL

After the testing of capacitors, it is sent to the Quality Assurance Department.
So that it can be checked for proper functioning in order to get l 00%
satisfaction from customer.

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Only passed items are pack ed. mto multiples 0 f h
goods store. It may be pack d . un dre ds an d sent to finished
e accordmg to
cu Sotmers req u ir emen ts l ike tape
.
packing, bulk packing etc.

T apeafciritsotrs is tbhen _sed to to sotre, from where it is sold tode a le rs

onhethfeinfiisrhstedcocm
serve aSis 1.e., FIFO method.

WASTE MANAGEMENT IN KCCL

In KCCL the overall percentage of waste in production is just 2%.

To bring the waste to minimum, KCCL bas fonned a separate Material Review
Board, under the cbainnanship of Production Manager and one representative
from Research and Development, Quality Assurance and Planning Departments.
The main aim of this MRB is to avoid scrap by reviewing the reviewing the
rejected capacitors through various developments. The board may recommend
further process to make those rejected into acceptable products. But still there
may be some, which can't be reprocessed and they are rejected as scraps.

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 .. t-,ELTR' DN -----------,- ----

[ STORE (RM) l
!
SLITTING &
PRINTING

STITCHING
&ROLLING

,
I IMPREGNATION
I
SEALING SLEEVING- HOT SHRINKING,
ASSEMBLING

AGEING& TESTNG

QUALITY CONTROL

PACKING

STORE (FG)

' Fig:5.13

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 t,i;ELTRDN
' '

ETCHING AND FORMING DEPARTEMENT

. Kelt.ron a.lso entered into etching and Dor.mmg of aluminium foil as parto f
d1vers1ficat10n, modernization and expa.nsion plan.

-Etching
ETCHING
IC
is the process b y w·h h h t e effe.cttve surface area of the anode foil is

electrochemically etched t0· mcrease the surface area by about 50 times for most
conventional foi·l In recent years, research and development· 1s done·m t·his
department and considerable increase in surface area is obtained which result in

capacitors of compact size.

f ORMING
In making capacitors the first process is forming. It is an electrochemical
oxidation process to develop aluminium oxide polarized barrier on the etched
foil at different volts to make use of the capacitors to different working voltage.

E THING METHODS
The following are the etching methods followed:

• AC etching
• DC etching
• Superimposed DC with AC

RESP ONSIBILTY OF HOD

• To ensure that suitable equipment are used for process.

• Marinating production equipment

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:: t-=iELTf<PN
'

• Control and co-ordinate function of chemical laboratory

• To issue documented procedure containing workingnis t ructoins

DEPARTMENTAL STRUCTURE OF ETCHING AND FORMI G

-DEPARTMENT
HOD

l 1
MAINTENANCE
FORMING OF CHEMICAL AND
ALUMINIUM FOIL PROCESS CONTROL LAB

! EFFLUENT
DEIONISED WATER TREATMENT
PRODUCTION PLANT

Fig:5.14

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 r1-1ELTRDN

ALIBRATION DEPARTME

Measurements are made using a variety of instrument s ranging from very

simp let extremely sophisticated. We must have confidence that all those
measuring instruments are giving us valid useful data. That confidence is
proved by Calibration. Calibration is the set of operation of determining the
values of errors of measuring devic es to traceable standard. The set of operation
which establish under specific condition, the relationship between values of
represented by a material measures or a reference material and the
corresponding values by the standards.

ELEMENTS IN CALIBRATION DEPARTMENT

Adequacy of standards
Calibration procedure
Traceability
Recall system
Calibration report
) Labelling practice
) Calibration intervals& adjustments techniques

ORG ANI SATI O N CHART OF CALIBRATION DEPARTMENT

[ HOD l
OIC/SIC

Assistant Typist/ Assistant

Assistant

71

i;. . . .---- - - - - - -,- &:.4.----- - - - - - -"- - "'-'- · - '=..-.._,,,..

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 "'€."'1ELTR. DN
":

ALIBRATIO PROCE

Calibration makes sure react·mgs are correct v · st

calibration process for thec · anous eps make up whole
ompany.

Calibration. bis .used worldwid e. In Keltron, the calibration process starts with

.external ca.l1 ra.tion. All the meters f Keltron are being calibrated using the
°
different calibration devices · These c.alibr.ation devices are first calibrated
externally from Fluid Contr0 1 R esearch In.stitute, Palakad and Electronic
Regional Test Laboratory (south), Trivandrum. Then all the meters of Keltron
are checked with these meters are c.a11brated .w1.thm .this p.enod. In short, they
make sure that each meter ·gives the accurate rea·dmg. The firm makes sure that
all the equipments in the company are calibrated before the guarantee period of

the calibrating devices.

At the beginning of every year all the department gives a list of equipments to
be calibrated. Based on this list the calibration department preparesa schedule
of when to calibrate. The listed equipments are calibrated according to the

schedule.
Every calibrated meter is labeled to make aware the workers about the reading

status of the meter.

THE METERS ARE LABELLED AS FOLLOWS

The labels used by the calibration department are as follows:

• GREEN -valid calibration

• YELLOW-cleared for limited use
• RED-instrument shall not be used for measurement
• B OE-calibration not required (for indication purpose only

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 QUALITY A URA CE DEPARTME T

The. duties of Quality Assurance depart men. ! mclude central examination of raw
matenals, components and finished products. All type organizations are trying
to increase their quality so that the cuStomers w
· ill be loyal to their products and
they will purchase the products ag·am and ag·am and they may also tell others
about this product.

If found the quality is satisfactory and the components and finished goods
conforms to the pre determined specification the department issues acceptable
certificate. For this the department has qualified and competent staff. The
company has strict and unfaultable system of quality control right from the
procurement of raw material to the sale of finished goods, ensuring that only
good quality material is passed to the next stage. Absolute traceability is
maintained right from the raw material supplier to the finished goods, to analyze
the cause of defects whenever they occur. Quality of the product is very
important for the existence of the company. It will increase the good will of the

company.

fUNCTION
The quality appraisal of the department is carried stages as follows:

1) Raw material inspection

2) patrol inspection
Final inspection

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 ,",-.: t-,ELTRDN
' '
'

Finish.ed p.roducts (Capac itors) acr. i nspected for the def', . .

categorized mtot rhee, namely: cc ts, w h ci h Hr c :.sli o

1) Critical defects
2) Major defects
3) Minor defects

RAW MATERIAL INSPECTION

The materials which are ·tmporte d 1r.or produc. tion are being inspected and
the quality is assured· The maten·a1s are accepted only when the qu.ality of the
different material are assured. some reqm·re 100% conformance as s.pecified.
Those materials that do not give 100% conformance are not accepted because it
may adversely affect the quality of the finished product. Minor deviations from
the standard are overlooked. After the raw materials are imported it will be
checked with the company's own standard. If there is a major deviation from
the standard, sometimes they are also cleared for use if end products are
m arke ta b l e. This acceptance is called conditional clearance.

PATRO L OR IN-PROCESSINSPECTION

In, KCCL, the quality assurance continues when the production is in

progress. Here the inspector goes to the plant and check whether the products,
after each process, satisfies the accepted standard. The person assigned for this
purpose is named Patrol Inspector. If there is any critical problem it will be
reported to the HOD and action will be taken depending upon the nature of the

4efect.XU>ticed.

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 ---
()lJT(,01

'I hi. i' carried ut n the lini hcd g ods. I [ere the inspection starts after
ug ing nnd t sting procc arc d ne to the capacit rs. K L produces around
oo K-600 K apacitor per day .Quality controller checks the output by asamp le
5
r parti ular batch under the standard I - I 0673. This is the standard which is
u ed by the overnm nt of the India for all electronic equipment. The defects are
· pr ssd inp rcentage level. It will be withdrawn and further rework will be
mad. In case of capacitors, the major parameter is the electrical parameter, and is
I 00% vested by ageing and testing. Other parameters are checked bya subsection
of manufacturing depa11ment by method of sampling

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 ------

J( Itron ha. s initiated steps to create knowIed ge an.d innov.a ttons in the
e . . cap acitor manufacturing companies
ctronic field. It 1s the on e of the leading .
1n mpany. 1t as been always been
. 1 Ie( flall. It 1s ISO 9001 certified functioning co h
able to provide high quality pmducts. It has alsoa super Design& Research
section that help in providing capacitors according need of the customers. And
also theY havea well experienced technical experts and supporting staffs for the

accornplisbrllent of the goals of the company.

fbe Organization study in Keltron helps me to understand the various
jiJJICtions in an organization and bow it is connected with our management
(heories.- I geta good idea about the history and profile of "KELTRON" to
enlarge mY idea in the business world. And also the study bas given me an
insight into the working of an organization engaged in the production of
electronic equipments. Here in this study I also found the problems faced by
most public sector undertakings. I wish all the very best for the company and1
once again express my gratitude to the entire persons who helped me to

complete the organizational study.

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