Amritanshu Kumar completed his final year review of electrical work on Unit II's construction project. He oversaw all high voltage and low voltage electrical work including lighting installation. Amritanshu developed methodologies like an electrical log book to track work and ensure all work met standards. He identified opportunities for value engineering that saved over 68 lacs. Amritanshu also studied the feasibility of an on-grid solar power model for the plant and developed plans for a 30 KW pilot project. Through his work on procurement, production planning and factory HR, Amritanshu gained experience and knowledge in these areas applicable to Unit II.

1. Amritanshu Kumar
(GET)
Training Mentor: M. Ramakrishna
Plant : Hosur
Final Year Review

2. Unit II’s Electrical Work
Project Mentor : M. Ramakrishna
Project Guide : Nitin Saxena
End to End supervision of all HT/LT electrical works
 Lighting work of Unit II
Studying Feasibility of Solar On Grid Model in Plant

3. Overview about Unit II’s Electrical
Status
Total Contract Load:- 950 KVA with 3 phase supply at 415 V
Transformer:- 2000 KVA (11KV/440V)
DG Sets:- Two of 500 KVA each & one of 365 KVA along with synchronizing Panel
Unit II’s SLD :-
MAIN SLD.pdf

4. Methodology Adopted
• Job Assigned :-
 To look after end to end all HT/LT works along with maintaining all quality and
safety standards
 To take initiatives towards adopting some new models in electrical like in
lighting, new development etc..
• Methodology adopted :-
• Made electrical log book to track day to
day work as well as material’s flow
• To keep crisp communication with
contractor to smoothen all electrical
processes
• To validate all electrical works are as per
TNEB norms

5. Unit II’s Electrical Works
HT Side Works LT Side Works
1. DP Structure Erection 1.LT Panel Room Work
2. HT Cable Laying 2.MCC Panel Room
Work
3. RMG Unit Installation 3. LT Room to MCC
Room Cable Laying
4. VCB Panel Installation 4. All Light fittings job
5. Transformer Installation 5. All internal cabling
• Examples of HT/LT Side work:-
DP Structure Erection (HT Work)
Motor Cable Laying (LT Work)

6. Learnings LT Cables
PCC Panel
DG Earthing

7. Saving Through Value Engineering
Item Description
New Purchase Value
(Lacs)
Reconditioning Value
(Lacs)
Savings
(Lacs)
2000 KVA Transformer 20 4.5 15.5
HT switch (near transformer) 14 0.5 13.5
PCC panel 36 16.5 19.5
SSB panel 2.5 1.15 1.35
Capacitor panel 2.5 0.95 1.55
Switchgears 17.5 6.25 11.25
Transformer yard fencing 1 0.25 0.75
Old LT Cables re use 5 0 5
Total expenditure in Rs –Lacs 98.5 30.1 68.4
Savings through Value Engineering (Electrical) :- 68.4
Lacs

8. Before & After Pictures
BEFORE AFTER
DP Structure Area
HT Cable Laying
Work

9. Before & After Pictures
BEFORE AFTER
LT / PCC Room
MCC Room

10. Before & After Pictures
BEFORE AFTER
Lighting Works

11. Transformer Installation
• Learnings
 Transformer various parts and
associated parts like OLTC, RTCC
 Transformer Oil Filtration process
 Various test performed before
transformer installation
• Findings
During insulation test, we found
that insulation of LT side was
malfunctioning
However, later faulty insulators
were removed with healthier ones
and test certificate was obtained on
above
LT’s Insulator
2000 KVA Transformer

12. Unit II’s Lighting Works
• Methodology Adopted
 Our objective was to fit lighting system which should have following features :-
1. Low Power Consumption & Better Life
2. Better Efficacy and CRI
3. Optimum Price
 So we decided to go for combination of LED & T5 lights in order to achieve
optimum quality and cost
• Advantages of LED lights
1.Energy savings between 40%-80% and have life up to 5 times than normal lights.
2.Efficacy level is above 100 in both LED & T5 Lights and LED has best CRI

13. Savings & Learnings
• Savings
 Apart from our electrical contractor, parallel we also took quotes from other two
vendors and thus able to bring down lighting price from our contractor.
• Lighting Techno Commercial Sheet :-
• Total Savings after negotiations 3.62 lacs
• Learnings
 Knowledge about various types of light, their working principles, features
 Brief Overview about designing of Light fixtures
 Learnt about Solar Lights & it’s working
Microsoft Excel
97-2003 Worksheet

14. Lighting Fixture
S. No. Area Light Type Description Watt Quantity
1 HARPIC MFG AREA LED
Totally enclosed LED Tubes + LED 2X2 Luminaire
with IP65 Protection
32/39 16 +8
2 LIIZOL & COLIN-Mfg LED Totally enclosed LED Tube 39 16
3 HARPIC FILLING AREA LED
LED 2X2 Luminaire suitable for Recessed on
Grid / POP ceiling with IP65 Protection
32 16
4 LIZOL & COLIN FILLING LED
LED 2X2 Luminaire suitable for Recessed on
Grid / POP ceiling
32 28
5 ALPLA Plant T5 T5 Highbay enclosed type (4X32W) 128 74
6 Packaging Area T5 T5 Highbay enclosed type (4X32W) 128 10
7 FG Store Area
Metal Halide
+T5
Flood Light + T5 Highbay enclosed type (4X32W) 250/128 6+5
8 Quality Lab LED
LED 2X2 Luminaire suitable for Recessed on
Grid / POP ceiling
32 20
9 Street Light Metal Halide Mercury Halide with IP66 Protection 150 15
10 Solar Light LED
26W LED street light with 100W Solar panel, 12
V 80AH Voltamp Make Battery & 20 feet GI Pole
26 5

15. Lighting Contd..
Harpic Filling Area Harpic Mfg. Area
Street Light
Quality Lab
SolarStreetLight

16. Solar Auto-Grid Project
Energy Cost has Increased by
about 93 %
• About Solar On Grid Project :-
Works on principle of Net Metering System
Can Install Solar Panel Grid either on roof top or
ground
Have life of about 25 years with very less
degradation in it’s efficiency
Maintenance free operation
Levellized Cost Of Electricity (Solar) is
between Rs 5-6

17. Solar Auto-Grid Project Contd..
• Hosur Plant Potential
 Each KW of Solar Panel can generate about 5 Units per day and require about
100 Sq. Feet of area
 In Unit II, we are having roof top area of about 2000 sq. mts above LT Panel
room while having land availability of about 5600 sq. mts on the south west
• Work Progress on Solar On-Grid
 Already talked with three vendors and we decided to 1st
install 30 KW of Solar
Panel Grid System as a pilot project
 Techno Commercial Sheet :-
 Cost Of Installation :- Rs. 25 lacs
 Payback Period :- Rs. 5 years
Microsoft Excel
97-2003 Worksheet

18. Benefits & Learnings
• Benefits
• Learnings
Learnt about Solar On Grid System, working
principle etc..
Knowledge about various types of solar panels,
their features etc..

19. Factory Procurement & Planning
Project Guide : M. Shujauddin
 Learnings about Procurement & Logistic various functioning
 Project on RM & PM Planning of Unit II

20. Learnings
• Steps Involved In material movement inside Plant

21. Learnings
• Various documents required for FG transfer
For Stock Transfer For FG Sales
1. Stock Transfer Copy 1. Sales Invoice Copy
2. Excise Invoice Copy 2. Delivery Challan/Gate Pass
3. Delivery Challan/Gate Pass 3. Road Permit
4. Form JJ ( By TN Govt.)
5. Road Permit

22. RM PM Planning (Unit II)
• Why needed ??
 As to start production in Unit II, we need to have a system to manage the
RM/PM stocks as per our production plan
 A Planning sheet was need to be developed which gives all RM/PM
requirements as per no. of cases to be produced as per plan.
 Products going to be manufactured under Unit II
1. Harpic (Harpic Power Opti Thick)
2. Lizol (Pine, Citrus, Lavender, Sandal, Floral)
3. Colin (Colin Blue)

23. Methodology Adopted
Microsoft Excel
Worksheet
Microsoft Excel
97-2003 Worksheet

24. Learnings & Outcomes
 Learnings
 Basic knowledge about master BOM & Bulk BOM
 Knowledge regarding terms like scrap factor, why to include it etc..
 Brief overview about how production planning is done
 Outcomes
 On the basis of RM/PM planning sheet made, RM/PM requirement (for July-
Dec’15) as per our tentative production plan was forecasted
 Forecasted sheet validate the logic used behind RM/PM planning sheet
formation

25. Factory HR
Project Guide : Pavan Kumar
 Learnings about various Factory & Labour Laws
 Job Description & Skill Matrix formation for Unit II

26. Job Description & Skill Matrix
Making
• Job Description Sheet
 To carry out various operations inside Unit II, new requirement was required &
accordingly Job Description for various post were made.
 JDs were made for the following posts:-
1. Trainee Associate – Electrical
2. Trainee Associate – Mechanical
3. Trainee Associate – Production
4. IPQC (Contractual)
5. DG & LT Room (Contractual)
6. RODM Plant (Contractual)
7. Unskilled labours (Contractual)
Microsoft Excel
97-2003 Worksheet

27. Job Description & Skill Matrix
Making
• Skill Matrix Making
 To evaluate the performance of all operators, chemist in nearby future; skill
matrix was made
 Color Coding system is used to show the performance of each individual as it
makes skill matrix tracking lot easier and simpler
 Whole Unit II operators and chemist performance figure was summarized on
single sheet
Microsoft Excel
97-2003 Worksheet

28. Contract Labour Act 1970

29. Employees Provident Fund Act 1952
Rates Of Contribution
Scheme Employee’s Employers Central Govt.
PF 12 % 3.67 % NIL
EDLI NIL 0.5 % NIL
PS NIL 8.33 % 1.16 %

30. Employees State Insurance Act 1948

31. Factories Act 1948

32. Factory Act 1948
• Audit Findings
 A certified doctor must visit the plant twice in a week, eight times a month but only
3 visit in a month is taking place
 One qualified & trained dresser cum compounder on duty throughout working
period not available
 In safety practices, plant’s level of safety is up to the mark & every process is
going as per standard safety procedure
 In welfare section & working hour of adults all process are carrying out through
standard procedure
 Person below 18 years are not allowed to work, so employment of young person
not applicable
Microsoft Excel
Worksheet

33. Thanks