Heaven’s Light is Our Guide

Rajshahi University of Engineering

and Technology (RUET), Rajshahi
Report on industrial training

Submitted by,

NAME:

ROLL NO.

COURSE NAME: INDUSTRIAL TRAINING

COURSE NO. ME-3600

SESSION: 2005-06

ROLL OF GROUP MEMBERS:

INFORMATIONS
• NAME OF INSTITUTION: BANGLADESH LAMPS
LIMITED

• LOCATION: SADAR ROAD, MOHAKHALI, DHAKA-1206

• ATTACHMENT PERIOD: FROM 1ST SEPT. TO 23RD

SEPT. 2008

• COURSE DIRECTOR: MR. SHAHZAD ALI

PLANT MANAGER

• COURSE CO-ORDINATOR :

STUDY OF PRODUCTION SYSTEM: MR. SK. A. QUAIUM

PRODUCTION MANAGER

STUDY OF MAINTENANCE: MR. SHAMSUL HUDA

MAINTENANCE MANAGER

BANGLADESH LAMPS LIMITED

2
 Routine for the students of Rajshahi
University of Engineering and Technology
Departments: Production, Maintenance, Q.C., Store and
Packaging
Program schedule from 1st Sept. to 23rd Sept. 2008
Timing: 8.00 AM to 3.00 PM

Date Day Contents Dept.

01.09.0 Mon Description and Orientation N/A
8
02.09.0 Tue Production and process control of Flare Production
8 m/c
03.09.0 Wed Work with Maintenance Dept. Maintenanc
8 e
04.09.0 Thu Production and process control of Stem Production
8 m/c
05.09.0 Fri Weekend N/A
8
06.09.0 Sat Production & process control of Mount Production
8 m/c
07.09.0 Sun Production & process control of Sealing Production
8 & Pumping m/c
08.09.0 Mon Cap filler, Capping mill and Current Production
8 tester
09.09.0 Tue Final Checking & Packing Dept. Production
8
10.09.0 Wed Work with Maintenance Dept. Maintenanc
8 e
11.09.0 Thu Work with Maintenance Dept. Maintenanc
8 e
12.09.0 Fri Weekend N/A
8
13.09.0 Sat Work with Maintenance Dept. Maintenanc
8 e
14.09.0 Sun Work with Maintenance Dept. Maintenanc
8 e
15.09.0 Mon Work with Maintenance Dept. Maintenanc
8 e
16.09.0 Tue Engine Room Maintenanc
8 e
17.09.0 Wed Work with Maintenance Dept. Maintenanc
8 e
18.09.0 Thu Process control from the view Q/C Quality
8
19.09.0 Fri Weekend N/A

3
8
20.09.0 Sat Quality control of lamp making Quality
8
21.09.0 Sun Store management Store
8
22.09.0 Mon Observation of CFL production CFL Unit
8
23.09.0 Tue Conversation day N/A
8

INDEX

CO PAGE
NTENTS NO.

INTRODUCTION 01-05

DETAILS ABOUT 06
FACTORY

PRODUCTION 07-38

MAINTENANCE 39-60

TESTING AND 61-64

PACKAGING

4
CFL SECTION 65-69

QUALITY CONTROL 70-73

SECTION

CONCLUSION 74

Acknowledgment

5
 BANGLADESH LAMPS LIMITED

Introduction of company (history):

Bangladesh Lamps Limited was established in Bangladesh in the
year of 1962 at the time of East Pakistan. They started the
production of PHILIPS GSL lamps under supervision of Dutch officers
until year 1993 when Transcom Electronics Limited took over the
business in Bangladesh region. But they are paying royalty to
PHILIPS Netherlands till today and getting inspected on are regular
basis as they are using the Dutch brand name and there logo.

Over view of the factory:

The factory of Bangladesh lamps limited is divided in to some
important departments. They are,
1. Production department
2. Maintenance department
3. Testing and Packaging department
4. CFL (Compact Fluorescent Lamp) department
5. Quality control department.

6
REP OR T SECTI ON ON
PR OD UCTI ON

7
1. Production:
The production department consists of four individual production
machine belts. They are SU1, SU2, BH1 and BH2. These belts can be
divided in two groups.
A. lower group (SU1, SU2)
B. higher group (BH1, BH2)
Firstly, the SU1 machine belt was installed in 1962 by the Dutch
people at the time of birth of the company in Bangladesh. This is a
manual machine which takes 22 persons to operate and it produces
approximately 1200 lamps per hour. But this machine is operated for
only a single shift daily. The candle and luster bulbs are produced by
this machine belt.
Secondly, the SU2 belt was installed in 1981 which is the 1stsemi-
automatic machine belt which takes 10 persons to operate and it
produces approximately 2300 lamps per hour recent. But it has a
capacity producing 2400 lamps per hour. The 40w-100w lamps are
produced by this machine belt.
Then, the BH1 or the hand operated BH1 machine was installed in
the year 1986 which is the first automatic frequency controlled
machine belt. This automatic machine belt takes 11 persons to
operate and has capacity to produce 4200 lamps per hour but it
produce 3600 lamp per hour as the capping of the lamps are hand
operated in this machine belt. The 40-100 w lamps are produced by
this machine belt.
Finally, the automatic BH2 machine belt was installed in the year
1998. This the 1st machine installed after the takeover by
Transcomelectronics limited in 1993. This machine takes 10 persons
to operate which is one person less then BH1 operating person
quantity. This machine has also the capacity of producing 4200
lamps per hour. But recent production is 3600 lamps per hour as it

8
has hand operated capping system. This automatic belt is controlled
by programmable logic control system (PLC). This is used only to
produce 200w lamp.

The last department is the CFL or compact florescent lamp

department. These lamps are only assembled here. The parts are
imported from other country and the assembling is done by local
labors. These lamps are hand fitted.

Highlights of 4 belts:
#Belt 1
SU 1

Installation date: In 1962 by the Dutch people

Capacity of production: 1200 bulbs per hour
Recent production rate: 1200 bulbs per hour
Controlling system: Manual
Manpower for operation: 22

#Belt 2
SU 2

Installation date: In 1981

Capacity of production: 2400 bulbs per hour
Recent production rate: 2300 bulbs per hour
Controlling system: Semi-automatic
Manpower for operation: 10

9
#Belt 3
BH 1

Installation date: In 1986

Capacity of production: 4200 bulbs per hour
Recent production rate: 3600 bulbs per hour
Controlling system: Automatic
Manpower for operation: 11

#Belt 4
BH 2

Installation date: In 1998

Capacity of production: 4200 bulbs per hour
Recent production rate: 3700 bulbs per hour
Controlling system: Automatic
Manpower for operation: 10 (1 person less than BH1)

Study of production line:

A. Flare making machine(12 heads)
B. Stem making machine(32 heads)
C. Mount making machine(20 heads)
D. Sealing machine(24 heads) & Pumping machine(32 heads)
E. Cap filler machine (12 heads)
F. Capping mill (54 heads)

10
 A. STUDY OF FLARE MAKING MACHINE

Objective:

To make and glaze flare.

Raw materials:
1. Flange tube (normally 1.1m in length & made of lead glass)
2. Gases (Oxygen, natural gas, air, sulfur dioxide or SO2).

FIG: FLARE

Number of head: 12
Production rate: 2300 flares per hour
Manpower needed: 1 (For loading flange tubes in the
heads)

11
Working procedure of flare making
machine:
The flange tubes are placed in the heads of a flare machine
manually. This machine has 12 step full operation cycles.

The positions are as follow:

Position 1: 2 ways flame heating on flange tube.

Position 2: 2 ways flame heating on flange tube.
Position 3: 3 ways flame heating on flange tube.
Position 4: Flangingthe flare. Sulfur dioxide is used for
lubrication.

Position 5: Cooling the flare through the nozzle for increasing

the surface hardness.

Position 6: Cooling by air.

Position 7: Dropping the flange tube and adjusting the length of
flare.

Position 8: Removing uncut tube.

Position 9: Air cooling through nozzle for shock cutting.
Position 10: Air cooling through nozzle.
Position 11: Heating the tube by flame in the cutting zone.
Position 12: Scratching by knife on tube & shock cutting of flare
(unloading position).

12
Then flares are placed on a glazing turret which is a type of gear and
having 24 head or 12 head (for SU1). There are three burners for
glazing the rough surface of non flanged side of flares .Then the
flares are unloaded and checked manually on a light plate. Finally
checked flares are moved to stem machine.

Block diagram of flare making machine:

A. STUDY OF STEM MAKING MACHINE

13
Objective:
To make stem.

Raw materials:
1. Flare
2. Exhaust tube
3. Lead in wire
4. Gases (Oxygen, natural gas, air, sulfur dioxide)

Number of head: 32
Production rate: 4200 stems per hour
Manpower for operation: 1(for observation)

14
Working procedure of stem making
machine:

NAME: STEM

The stem making machine is an automatic machine which takes1

person to load flares in the flare chute and to load lead in wires in
the wire feeder. This machine has a 32 step full operation cycle.

The positions are as follow:

Position 1:
The flares are fed in stem head from the flare chute. The heads are
sensor checked and proceed for lead in wire fitting. The chute
ensures that only one flare is supplied to the head.

Position 2 & 3:
Insertion of rear lead wires in two stem heads simultaneously
through the wire funnels. Wires are only fed when a stem tube is
present in the holder. It is necessary to supply two wires at a time
because of the short cycle.

Position 4 & 5:
Insertion of front lead wires in two stem holders simultaneously.
Wires are only fed when a stem tube and rear lead wire are present.

Position 6:

15
Insertion of exhaust tube in stem head from a supply cylinder.
Exhaust tube is only fed when a stem tube is present. During supply
the fall of the exhaust tube is restrained to present cracks. To ensure
that exhaust tube feed takes place without giving rise to product
defects. The cylindrical supply system sees to it that only one
exhaust tube is fed per cycle.

Position 7:
Vertical positioning of stem tube and exhaust tube, relative to one
another. A stem tube presence check is also made by a sensor to
ensure that the components are in the correct position is the holder
before they are joined together.

Position 8 to 10:
The 1st, 2nd and 3rd burner pair heat stem tube and exhaust tube
gradually to preheat the components.

Position 11 to 17:
The 4th to 10th burner pairs bring the glass to melting temperature so
it can be joined together and shaped.

Position 18:
During this step the exhaust tube is put on exactly the right level by
a vertically sowing (adjustable) pressure during indexing from step
17to 18. The correct level of the exhaust tube is an important
criterion during sealing and pumping. The holders of the mounting
machine have a fixed stop for the exhaust tube. If there should be a
difference in exhaust tube length. This would lead to serious
difficulties during the formation of the glass button flattening of lead
wires, etc.

16
Position 19 to 20:
Heating and joining of stem components to obtain an airtight seal
between stem tubes and exhaust tube.

Position 21:
14th burner pair and 1st placing position. Heating of the seal and
forming of place with placing unit. Forming of place by placing
blocks, to facilitate alignment in subsequent operation, e.g. on the
mounting machine.

Position 22:
Heating of seal and 1st port blowing to keep seal at the right
temperature and blow an exhaust port where the exhaust tube and
pinch.

Position 23:
Blowing air through the exhaust tube so that the exhaust port is
formed. In this position the stem tube is inflated with preheated air.
To make an exhaust port this is used for flushing and pumping the
sealed lamp and for filling it with argon. The stem tube is inflated to
round off any sharp angles, which improves the strength of the
stem.

Position 24:
Annealing of pinch to keep it at the right temperature and prevent
cracking due to temperature drop.

17
Position 25:
Annealing of pinch by the 18th burner pair. The pinch is reshaped by
the 2nd pinching unit by making the ‘T’ mark which is the trade mark
of the company. In position 24 and 25 air is blown into the stem tube
to keep its model intact and to cool the seal.

Position 26 to 28:
A movable cooler cools both sides of the pinch to lower the
temperature of the metal –glass joint gradually, so as not to induce
any extra tension.

Position 29 & 30:

Fixed cooling position in which the hot steam is cooled. Cooling air
may be heated up be formed by burners.

Position 31:
In position 31 the stems are taken from the holder by a six head
turret. A memory in the control unit determines whether the stems
are placed in the Lahr or removed through a reject chute as faulty
stems.

Position 32:
Any stems still in the machine after position 31 are ejected by a
remover (e.g. stem with broken exhaust tube). A sensor between
position 32 and 1 detects the presence of any stem after position
32.
There is also a sensor on the entering side of the conveyer chain to
check if there is any stem left in the conveyer. If the sensor senses a
stem, no stem is unloaded in the chain in that particular position in
position 31.

18
Block diagram of stem making machine:

B. STUDY OF MOUNT MAKING MACHINE

19
Objective:
Mounting the filament with stem or making a mount. Also removing
the impurities from the filament.

Raw materials:
1. Stem
2. Filament (material: tungsten)
3. Supporting wire
4. Gases (Oxygen, natural gas, air)
5. Getter (mixture of isopropanol & phosphorus nitrate or P3N5 )

Number of head: 20
Production rate: 4200 mounts per hour

20
 FIGURE: MOUNT

Manpower for operation: 2 (one person for observing

the coil feeder and other for overall observation)

Working procedure of mount making

machine:
The mount making machine is an automatic machine which has 20
heads and takes 2 persons to operate. One for loading the filament
in the coil feeder and other for loading the shells in the conveyer
chain. This machine has a 20 step full operation cycle.

The positions are as follow:

Position 1: Loading of stem from chain conveyer through an

annealing oven.

Position2: Spreading the lead in wires. There is a sensor which

checks the position of stem in the head and gives signal to the coil
feeder to load the filament.

Position3: Flattering the lead in wires (nickel coated part) to

enlarge the head for clamping the filament.

Position4: Bending the flattened end of lead in wire (nickel

coated part) to hold the filament.

Position5: Feeding of filament with the help of coil feeder and

clamping the nickel coated part of lead in wire.

Position6: Protecting the filament by compressed air blowing

through a nozzle.

Position7: Moving of lead in wire and filament attachment

backward to save the filament from heat.

21
Position8, 9, 10: Heating on exhaust tube (lower part) to make
the button for inserting the supporting wire. Supply compressed air
for saving the jaw of the head when there is no stem.

Position11: Inserting the supporting wires in the button.

Position12: Normal air cooling.
Position13: Moving the lead in wire and filament attachment
forward.

Position14: Hold the filament with supporting wires by making

pig tail.

Position15: Moving lead in wires and supporting wires backward

for final shape adjustment between all four wires. For 40w and 60w
lamps, the gap between the lead in wires are adjusted by 23 to 25
mm and for 100w the gap is 27 mm.

Position16: Soaking the filament in the solution of getter

(phosphorus nitrate, isopropanol) to remove impurities from the
filament.

Position17, 18: Drying the getter with hot air.

Position19: Unloading the mount.
Position20: Blank

22
Block diagram of mount making machine:

C.STUDY OF SEALING MACHINE

23
Objective:
To seal the lamp (marked shell and the mount).

Raw materials:
1. Mount
2. Shell (brand name marked)
3. Gases (Oxygen, natural gas, air)

FIGURE: SEALED BULB

Number of head: 24
Production rate: 3600 sealed lamps per hour
Manpower for operation: 2(Loading unmarked shells
and observation)

Working procedure of sealing machine:

The sealing machine is an automatic machine which has 24 head
and takes 2 persons to operate. A person used for loading the
unmarked shells on a conveyer chain which carries the shells
through a marking machine which marks the brand name. The other
person observes the full operating process as this is one of the soul
parts of the machine belt of production. This machine has 24 step
full operation cycles.

The positions are as follow:

Position1: Loading of mount from chain conveyer after checking

through a sensor in the conveyer chain.

24
 FIG: LOADING MOUNT

Position2: Loading of marked shell over mount through chain

conveyer. If mount is not present in the chain, shell will not be
loaded.

FIGURE:
SHELL

Position3-13: Heating and dropping of lamp shell.

25
 FIG: HEATING &
DROPPING

Position14: Cutting off cullet by a pair of pencil burners.

FIG: CUTTING OFF CULLET

Position15-17: Glazing of the sealed lamp.

Position18: Seal shaping by seal shaper and blowing air from
below. A pressure arm holds the sealed lamp from above to prevent
it from moving upward while sealing by seal shaper.

Position19-20: Annealing of sealed lamps to prevent cracking

due to sudden temperature drop.

Position21-22: Normal air cooling.

26
Position23: Unloading of sealed lamp by a 3 head sucker.

FI G:
UNLOADING

Position24: Unloading of cullet.

FI G: UNLOADING
CULLET

There is a sensor in the conveyer chain to check the position of

mount on the chain. If a mount is missing in a certain position, the 2
head sucker will not load the marked shell on that certain position in
the sealing head. Similarly if a marked shell is not loaded, mount will
not also be loaded in that certain position. This is called a two way
sensor system which is only present only in BH-2 machine belt. The
sealing machine of the BH-1 machine belt has 1 way sensor that

27
only works if a mount is not loaded in a position, marked shell will
also not be loaded in that certain position.

Block diagram of sealing machine:

D.STUDY OF PUMPING MACHINE

Objective:
To flush with Nitrogen gas and pump Argon gas into lamp. Also
making a suitable environment for filament to emit light.

Raw materials:
1. Sealed lamp
2. Gases (Oxygen, natural gas, air)

Number of head: 32
Production rate: 3600 per hour

Manpower needed: 1 (for observation)

Working steps of pumping machine:
The pumping machine is an automatic machine which has 32 heads
and takes only 1 person for observation. The sealed lamps are
transferred to the pumping machine by a transfer table or transfer
turret and a 3 head sucker. There is a sensor in the loading position
of the turret which checks the placing of sealed lamp by checking
the length of the exhaust tube. If a sealed lamp is missing, or a
defective lamp is present, a remover removes it before unloading at
the unloading position. Also the left hand screw lever of the Nitrogen
pump is locked by the sensor at that certain position in the pumping
machine. This machine has a 32 step full operation cycle.

28
The positions are as follow:

Position 1: Loading of seal lamp from transfer turret after

checking of exhaust tube length by sensor.

FIG: LOADING & SENSING

Position 2: Connection to rough vacuum.

29
Position 3, 5, 6, 9, 11, 13, 15, 17, 19, and 21:
Pumping with decuple vacuum pump (10 fold pumps).

FI G: PUMPING

Position 6: Leak detection by leak detecting device which is a

sensor to check leakage in sealed lamps.

Position 4, 7, 8, 10, 12, 14, 16, 18 and 20: Flushing

with Nitrogen gas supplied through capillary. The supplied Nitrogen
gas is also purified by flowing through purifying chips. This ensures
vapor free Nitrogen gas.

Position 22-24: Preheating exhaust tube and Argon flushing

through capillary.

Position 25: Final filling of Argon and pinching of exhaust tube.

Position 26: Cooling by compressed air.
Position 27: Unloading gas filled lamp.
Position 28: Blank.

30
Position 29: Breaking the defective lamp.
Position 30: Removal of extra exhaust tube part.
Position 31 & 32: Blank
Block diagram of pumping machine:

E.STUDY OF CAP FILLER MACHINE:

Objective:
To fill cap with cement.

Raw materials:
1. Cap (material: stainless steel or SS)
2. Cement (mixture of resin cement powder, butanol and spirit).

Number of head: 12
Production rate: 3600 per hour
FIGURE: CAP

31
Manpower needed: 1 (to fill cement in the cement feeder)

Working procedure of cap filler machine:

The cap filler machine is an automatic machine which has 12 heads
and takes only 1 person to operate that is feeding cement in the
cement feeder. The caps are fed to the turret from a cap feeder
through a channel line. The cap feeder machine has a 12 step full
operation cycle.

The positions are as follow:

Position 1: Loading of cap by a cap feeder through a channel

line.

Position 2: Blank.
Position 3: Setting of cap in the turret by a rotating adjuster.
Position 4: Blank.
Position 5: Setting of cap again by a vertical adjuster.
Position 6: Blank.
Position 7: Filling of cement in the cap.
Position 8 to 11: Blank.
Position 12: Unloading of cement filled cap by a conveyer belt
to the capping mill.

32
Blockdiagram of cap filler machine:

F. STUDY OF CAPPING MILL

Objective:
Capping of seal & pumped lamp, flashing (both in low and normal
voltage) and soldering.

Raw materials:
1. Pumped lamp

33
 2. Gases (Oxygen, natural gas, air)
3. Solder
4. Solder flux.

Number of head: 54
Production rate: 4200 lamps per hour
Manpower needed: 2

Working steps of capping mill:

Position1-13: the lamps are loaded manually in the heads of

the machine after fitting cemented caps with the lamps.

Position14-25: heating for hardening the cement.

Position26-29: normal air cooling.
Position30-36: flashing of the lamps.
Position37: blank.
Position38: cutting of the fuse wire by pencil burner.
Position39-43: blank.
Position44: resin or soldering flux is put on cap eye.
Position45: soldering on inner eye of the cap.
Position46: soldering on outer eye of the cap.
Position47-50: cooling by blow air.
Position51: final checking.
Position52: Blank
Position53: unloading the lamp.
Position54: blank.

34
Block diagram of capping mill:

35
 REP OR T SECTI ON ON
MAI NTE NANCE

2. Maintenance:
Maintenance section mainly handles all of periodic maintenance. It
consists of cleaning, repair, replacement, lubrication system
handling, some other crucial events related to production belt.

Classifications of Maintenance:

36
Maintenance works in periodical time in some important types.
These maintenances are,

• Breakdown Maintenance
• Preventive Maintenance
• Corrective Maintenance
• Maintenance Prevention

This type handles in definite periodical time stated by maintenance

section. Working times are deals in production site are,

• Weekly maintenance
• Monthly maintenance
• Half-yearly maintenance
• Yearly maintenance
• Two-yearly maintenance

Details of the types of maintenance are given below,

Breakdown Maintenance:
Breakdown maintenance describes the measures, the purpose of
which is to correct faults i.e. to restore damaged equipment to its
proper functional state.
It is often referred as repair work.

Preventive maintenance:
Direct preventive maintenance to all measures aimed at preventing
development of faults in equipment. Examples of direct preventive
maintenance are cleaning, lubrication planned replacement and
renewal, overhauling. Direct preventive maintenance is often carried
out after certain number of certain number of operating hours.

Indirect preventive maintenance or condition monitoring cover all

operation intended to determine the need for direct preventive
maintenance or repairs. Indirect preventive maintenance works are
carried out in-response to a significant deterioration in a machine /

37
equipment indicated by a change in a monitored parameter of the
equipment condition or performance. This is also known as condition
based maintenance.

Indirect Preventive Maintenance Direct Preventive Maintenance

(Condition Monitoring)
1. Measurement of bearing
clearance.
2. Measurement of ball-
bearing shock pulse.
1. Adjustment of bearing
clearance.
2. Replacement of ball-
bearing.

Corrective Maintenance:
Here the preventive maintenance approach is further improved to
take steps that same breakdown is not repeated.

Maintenance Prevention:
This is a development from corrective maintenance; it is done at the
design phase so that equipment needs less maintenance and if
needed it becomes easier.

Maintenance during Industrial training:

Some important maintenance were happened during industrial
training which are given below in details,

• Study of a gear box

Objectives:
1. Open and separate gear box.
2. Assemble gear box.
3. To find out the type of gear box.

Apparatus:

38
 1. Allen key.
2. Puller.
3. Screw driver.
4. Ball pin hammer & Plastic hammer.
5. Different type of wrench.

Observation:
Type of gear: Worm gear.

Power transmission:
Right angle (90 deg. Axis)

Bearings in gear box:

1. Two ball bearings and one thrust bearing with worm of the gear
box.
2. Two ball bearings with worm gear of the gear box.

Bearing details:

Type of ball bearing

Manufacture- Japan (NTN Company)
Bearing No. 6007

Type-Ball bearing
Manufacture- Japan (NTN Company)

39
 Bearing no - 6022

Number of teeth in worm gear:

40 teeth & 7 threads.

Gear ratio:
mg = ng / nt where,
=40 / 7 ng = No. of teeth of
gear =40
=5.7148 nt = No. of threads =
7

Material of worm gear:

Cast iron

Introduction of worm gear:

Worm gear used to transmit power between nonintersecting shafts,
nearly always at right angles to each other. Comparatively high
velocity ratios maybe obtained satisfactorily in a small space,
through perhaps at a sacrifice in efficiency as compared to other
types of gear.

• Self shaper unit:

40
Category: Sealing unit.
Owner machine: BH-1

Self shaper unit mainly used to finalize the shape of sealing lamp. It
is important in adjustment with cap in capping mill. It is mainly built
in cast iron. It consists,
A. Two arm connected with a hinge
B. Two roller bearings acted as follower

OPERATION:
The accuracy of self shaper unit was getting lower from the desired
value because of the defect in hinge section. This defect mainly acts
devastative when cap join with sealed lamp in capping mill. The
problem was solved by replacing the hinge parts in maintenance
section.

• Oven of pumping machine:

Category: To clean out the moisture and vacuum the lamp.

Owner machine: BH-2

Oven of pumping machine mainly used for cleanout the moisture

and vacuum the sealed lamp fully for preparing nitrogen (N2)
flashing.

OPERATION:

41
Oven mainly faces defect in its layer, which is built by SS sheet. This
sheet damaged for continuously heat treatment during operation.
This damaged part was replaced by newly made with SS sheet in
maintenance room.

• Arc welding:

Job: MS bar & table.

Joint type: Bar joint

Pressure tube or Manometer:

For balance air, gas & liquid oxygen through the machine-
Oxygen: 1500-1400 mm of water
Air: 1400-1200 mm of water
Gas: 400-300 mm of water

• Different parts of machine

Gas Traps:
It is mounted on the pumping machine turrets to prevent glass
remounted entering between the two discs of distributor valve.

Drying Bottles:
It is included in the filling and flashing gas lies to absorb any
moisture. The moisture content glasses must be reduced to <=1
ppm H20. If the drying bottles section filled with molecular sieves
has changed color for 2/3 or more the bottle must be exchanged.

42
 • Burners:
Introduction:
A burner shapes the flame so that it can be aimed at the right spot
optimum heat supply, thus transforming the product handled to the
state desired in the prescribed time.
A machine burner is equipment capable of producing one or several
clearly distinguishable flame cores, and mounted on the machine for
mechanical glass processing.
A machine burner can be fed with combustible mixture made at
some distance from the burner port in a mixing device.
Burner and mixing device are interconnected by a mixture feed line.
Such a burner is a pre-mix burner.

A mixing device can be serving one or several burners. There are

also machine burners which have their fuel gas and oxygen supplied
separately.
If the combustible mixture is formed by the injector principle, the
injector outlet being at the same time the burner port, we spark of
mix burner.
Burner for which the combustible mixture is formed beyond the
burner the burner port is parallel-flow burners.

Pre-mix burners:
The combustible mixture which is to feed a pre-mix burner has a
certain combustion rate, depending on its composition.
The pre-mix burner depends on the combustion rate (gauze, slot, or
no stabilization).

If combustion rate between 0.25 and 0.7 m/s, a burner with gauze
stabilization must be used.

43
For combustion rate between 0.6 and 3 m/s, a burner with slot
stabilization must be used.
Non-stabilized burners can be used for combustion rates above 2.5
m/s.

These limits for each burner types are to be regarded as pilot

values.

1. Burner with gauze stabilization (G.S burner):

A roll of nickel gauze gives the mixture flowing at low speed from
the stabilization

FIG:
G.S. BURNER
port a homogenous flow rate. This gives a stable auxiliary flame
which stabilizes the main flame.

2.Burner with slot stabilization ( S.S burner ) :

A combustible mixture with a combustion rate of at least 0.6 m/s
flows through slot at such a low flow rate that a stable auxiliary
flame is formed. This stabilizes the main flame.

44
 FIG: S.S. BURNER

3. Burner without stabilization (N.S burner):

Burner operating on combustible mixture with combustion rate of at
least 2.5 m/s needs no stabilization devices.
The main flame is sufficiently stable at the burner pressures and
flow rates ordinary use.

FIG: N.S. BURNER

Mix-Burners (MP):
These are self mixing Pencil-shaped burners. The
mixture is formed in the burner itself. I.e. the injector is incorporated
in the burner. This type of burner is mostly used as a cutting torch. It
is suitable for mixture with combustible rate of 3 m/s and upward.
Suitable mixture is: all fuel gases + oxygen.

45
Parallel-Flow Burners:
The parallel flow burners can be subdivided into:
1. Burners of the sandwich type – type S.
2. Burners of the round type –type PP ( Pipe / Pipe )
3. Burners of the round type –type CP ( Concentric / Pipe )
4. Burners of the combination type –type PS ( Pipe / Sandwich )
Types of PP & PS are not used at present.

• Injector
For burners connected to a premixed, combustible gas mixture in a
injector. The use of such injectors has been laid dawn in instructions
for reason of safety. Injector prevents the gas streams for preheating
into their mutual lines the combustible mixture is found only
between injector and burners.
In case of flash back, explosion will not propagate beyond the
injector, an additional advantage in that the injector permits a better
regulation of the auxiliary supplies.

Auxiliary supply:
Class I gas Class II gas Other auxiliary
supplies
Coal gas Natural gas Oxygen
Mine gas Propane LP air
Hydrogen Methane
Butane

Auxiliary supply pressure:

For trouble free operation of injectors and burners, the pressure of
auxiliary supplies should lie between the values below
These values are set with reducing values and can measure with
pressure gauges on the operating machine.

46
 From-To From-To
Pressure
Mm WG-mm WG Pa-Pa

Auxiliary supply
Class I gas 150---------300 147090-294180
Class II gas 250---------350 247150-343210
Air 1000-------1150 980665-1127690
Oxygen 1200-------1500 1176720-1470900

Auxiliary supply Pressure

mm WG
Coal gas
Mine gas 150-300
Town gas
Hydrogen 400-600
Natural gas 250-350
Propane 200-350
Butane
Air 1000-1150
Oxygen 1200-1500

• Manometer:
A manometer is an improved form of a piezometer tube. With the
help of a manometer, we can measure comparatively high pressures
and negative pressures also. It consists of a tube bent in U-shape,
one end which is attached to the gauge point and other is open to
the atmosphere as shown in figure:

47
 FIGURE: MANOMETER

Practical reading in manometer:

Auxiliary supply Pressure

mm WG
Gas 340
Air 1260
Oxygen 1410
Vacuum 60 (mm of Hg)

48
 • Study of Engine Room
Introduction:
The most important part of any factory is engine room. All power
supplies are come from this engine room. In this factory this room
has compressor, blower, dryer & vacuum. The supplies are given by
pipe line which has a suitable design .Flows are maintained by
regulator. There are also alternator pipe lines which are used if the
main pipe line damaged though periodic checking are taken. This
preparation is taken so that the production unit must not be
hampered by any uncertainty.

Generation units:
• Three Compressors, two compressor always
running when production continue and one
standby for immediate support.
• Three Blowers, two blowers always running
and one standby.
• Three vacuum units, two units always
running and one standby.

FIG: BLOWER AND

DRYER

49
Others supplies:
• One Dryer, all compressed air dry in this unit
and then store in the receiver cylinder.
• Liquid oxygen supplies from the out side of
the factory and regulate it at the engine
room then supply to the production unit.
• Tetas gas supply from the out side of the
factory and regulate it at the engine room
then supply to the production unit.

FIG: VACUUM

Fuel of engine room:

All through generation unit generate the required product only
consume electricity. So, the electricity is mainly used as fuel at the
engine room.

Description of Generation units:

Compressor:
Every compressor runs with one high power motor.
The motor drive the compressor unit and air compressed and then
dry in dryer unit and next store in the receiver cylinder. There are
two receiver cylinders for three compressors. After receiver cylinder,

50
compressed air regulates by valve regulator and then passes
through the production lines and other.

FIG: COMPRESSOR

The rating of motor of compressor I:

V 400± 10% Cos Q 0.88

Hz 50 n 2978
1/min
A 130 Gew / wt 475 Kg
KW 75 Temp max 45’
3- MOT

The rating of motor of compressor II:

51
Manf. in Belgium Type GA45plus
Manf year 2007 Qmotor 45kw-60hp
N0 AP1511707 Nmotor 2965 r/min
Pmax 7.5 bar Qv 1427 l/s

The rating of motor of compressor III:

Manf. in India Pmax 7.5bar
Manf. year 2008 Free air delivery 246 l/s
Type GA75AWP Qmax 75KW

The rating of vacuum machine:

Manf. in Germany P1 abs 0.15 bar
Manf. year 1979 P2 1.0 bar
Type RV46 N 960 r/min
Q 274 m3/h

The rating of blower machine:

Manf. in Germany Pt 250 m bar
Type RV226HIG P2 1.25 Kg/m3
V1 0.3333 m3/s N 1020 r/min
T1 15.00C Pw 11.7 KW
P1 1.2 Kg/m3

52
Blog diagram of engine room:
Production line Factory

Regulato Receive Receive

CH4
r r r2 CH4
1 Control
Governor Control
unit
Compressor unit
(main)
Blower2 2 (main)
Drye
r
Vacuum
2

Blower
1 Compresso
r1
53
 Vacuum
Vacuum 3 Liquid
1 o2
Blower Compresso Control
3 r3 unit
(main)
Fr
om outside Reserve
Switch Cabinet
boards Titas gas supply

Gases,
power
All machine control board (electrically)
Lubrication system of the machines:The system used
to lubricate a machine is called lubrication system.

Types of lubrication:
1. Liquid lubricants
2. Solid lubricants
In this factory both liquid and solid lubricants are being used. Grease
is used as liquid lubricant and carbon or Graphite is used as solid
lubricant.

Liquid lubricant:
Types of liquid lubricant:
1. High temperature grease
2. Low temperature grease

Low temperature grease is used in the gear boxes.

54
Study and Observation of Clutch:

A clutch is a mechanism for transmitting rotation, which can be

engaged and disengaged. Clutches are useful in devices that have
two rotating shafts. In these devices, one shaft is typically driven by
a motor or pulley, and the other shaft drives another device. In a
drill, for instance, one shaft is driven by a motor, and the other
drives a drill chuck. The clutch connects the two shafts so that they
can either be locked together and spin at the same speed
(engaged), or be decoupled and spin at different speeds
(disengaged).

Single plate friction clutch FIG: TEFLON

PLATE CLUTCH
This type of clutch is used almost exclusively in automobiles and
trucks and has three main parts:
1. Driving member
2. Driven member
3. Operating member

55
The clutch plate is lined with a friction material with the output shaft
running through the center. This type has the advantage of a lever
that allows the operator to manually engage and disengage the
drive via the pressure plates. This type of clutch allows for a smooth
take away and gear changes.

Multiple plate friction clutch

This type of clutch has several driving members interleaved with
several driven members. It is used in motorcycles and in some diesel
locomotive with mechanical transmission.

Wet and dry

A 'wet clutch' is immersed in a cooling lubricating fluid, which also
keeps the surfaces clean and gives smoother performance and
longer life. Wet clutches; however, tend to lose some energy to the
liquid. A 'dry clutch', as the name implies, is not bathed in fluid.
Since the surfaces of a wet clutch can be slippery (as with a
motorcycle clutch bathed in transmission oil), stacking multiple
clutch disks can compensate for the lower coefficient of friction and
so eliminate slippage when fully engaged.

56
REP OR T SECTI ON ON TE STIN G
AN D PACK AGI NG

57
3. TESTING AND PACKAGING:

Testing:

Operative m/c : Testing Board

M/c Status : Manual (Human operated)

No. of testing boards: 4

Operative persons :4
In this stage of production, the GLS lamps are being tested on a
testing board after being quarantined for 24 hours. The process of
quarantining is necessary to ensure that the lamps will not fail when
they’re temperature is reduced to normal state.
There are four operational testing boards. Generally 3 of them are
used for GLS lamps and the other is used for testing the Luster and
Candle lamps.
Testing boards are consisted of several lamp holders. Around the
holders there is a box area which is colored black to justify the glow
colors of the lamps properly. Operators stand in front of the board
and test the produced lamps. Usually this testing operation is done
manually by the operators.
First, the Lamps are placed on the holder of testing board and
electricity is supplied to ensure the glow of the lamps. This glow
ensures that the lamps are seal tight and the coils are well clamped
to the stem. If the lamps are not seal tight, after being quarantined,
they will instantly become oxidized when connected with electricity.
If the coils are not clamped properly, the glow will not be as it should
be. Usually the lamps show light yellow color while glowing.

58
Then the lamps are turned on and off frequently to ensure that a
lamp will not fail if it is turned on and off frequently by the
consumers. The lamps are also tested by glowing them both in high
and low voltage.
Later comes the glow test. The equipment used for glow test is
called ‘glow’ which is a very high voltage plate. This plate is slide
over the lamps which create an arc between the mount point of the
tungsten coil and the contact point of the glow on the surface of the
shell. This operation is called glowing. If one of the lamps does not
glow properly, it is considered to be rejected. This glow test is done
by high voltage and low current supply. Usually 11,000 Volts and low
current supply is ensured during glow testing. In this stage the
lamps show bright violet color. If any of the lamps does not show
the proper color, it is rejected. Lamps which glow properly and show
the perfect color during glow test, are send to the next and final
stage of production, packaging.

Packaging:

Operative m/c : N/A

No. of human workers: 10-15
After being tested, the lamps are ready for packaging. Usually lamps
are packed manually by operators. There is an automatic packing
machine which is used only when work load is heavy.
Before the lamps are packed markings are ensured on the shell
which shows its manufactured date, model of the machine it was
produced from, brand name and the trade marking. Similar
operations are done with the packets in the storage department.
Markings are made on the packets describing the lamps
manufacturing date and efficiency of the lamp which it contains.
This operation is done for both GLS and CFL lamps.

59
For GLS lamps Markings on the shell are done while they are
conveyed from pumping m/c to capping m/c. In case of CFL lamp
markings are done after production on a printing turret which has
printer fixed at certain point. This marking m/c for CFL lamps marks
the manufacturing date and a serial no. on each CFL lamps. The
sensor on the printer ensures that the serial of marking is
maintained strictly.
The final packaging is done by placing the lamps in the supply
cartoons and sealing them for to be opened by the customers. The
trays carry lamps and the cartoon carries lamps. This is the figure
for GLS lamps. For CFL, each tray carry 10 units and the cartoon
carry 5 trays.

60
RE PO RT SE CTIO N ON COM PACT
FL U O ROS C ENT LAMP

61
4. REPORT ON CFL PRODUCTION DEPARTMENT:
The CFL or compact fluorescent lamp is the latest attachment in the
production products of Transcom Electronics limited. They have
started to assemble the CFL in September of the year 2007 in the
brand name of Transcom CFL. Today the production rate is
approximately 5000 per day. The parts of the lamp are imported
from abroad and assembled manually in the assembling section of
the factory. The parts are mainly imported from China and India.

FI G: CFL LAMPS

Approximately 54 persons work in the CFL assembling section

including assembling, marking and packaging. Almost 40 persons
work in assembling the CFL, 2 persons work for finishing that is

62
sealing the cap, 6 persons work in soldering and rest of the people
work in the marking and packaging section.

The marking system is divided in two categories:

1. Marking with hologram sticker of brand mark.
2. Marking of manufacturing date and serial number by printer.
Marking with hologram sticker on the body of CFL is done to ensure
the customers of the original product as it is said that the hologram
sticker cannot be copied. Marking of serial and manufacturing date
is done to ensure the identity of the lamp as it is a valid Transcom
Electronics product. There is an electronic sensor attached to the
printing point to ensure that every CFL is printed serially and if a
head is empty, then the printer will not response.

Main component of a CFL:

1. Cap
2. Holder
3. Curved tube
4. Circuit board
All the 4 components are now imported from abroad that is either
India or China. The cap used in the CFL is made of aluminum alloy.
The holder are curved tube holder are made of plastic. All these
parts are being imported till now, but from now the circuit board of
the CFL is to be manufactured in this country.

Components of the cap:

1. Aluminum alloy body
2. Gun metal made eye
3. Black glass (to separate aluminum body from solder)

Components of the holder:

Plastic made holder (without thread).

Components of the curved tube:

63
 1. Plastic holder (to attach with the holder)
2. Curved glass tube filled with mercury vapor and Argon gas
3. Tungsten filament (quantity: 2)
4. Wires (to be soldered in with the circuit board)

Components of the circuit:

1. Diode
2. Transistor
3. Resistor
4. Capacitor
5. Transformer
6. Insulator

Working procedure of CFL:

The CFL or compact fluorescent lamp is a kind of electronic ballast
started light. The heart of the CFL is the circuit inside the holder
which is a kind of inverter circuit. The principle of the inverter circuit
is to convert AC current to DC and again convert it to AC current.
The input voltage of the circuit is 220V and frequency is 50Hz and
the output voltage and frequency are 110-140V & 6-10 KHz
respectively.

Briefly:
Voltage Frequency

Input: 220V 50Hz

Output: 110V – 140V 6 KHz – 10 KHz

64
The curved tube has 2 points which hold 2 filaments. One of them
works as an anode and other works as a cathode when placed in a
circuit.
The principle of working of this anode and cathode is that anode
emits the electron and cathode receives it. But in order to start this
process the starter in the circuit creates a spark in between the two
points by high voltage of Mercury vapor and the whole environment
gets electron charged. The charged environment carries the
electrons from anode to cathode and in this process energy is being
emitted from the electrons in the form of ultraviolet or UV light. The
white halo phosphor coating on the inner body part of the curved
tube makes the invisible UV light visible.

Production process of the CFL:

1. Circuit soldering
2. Plastic cover fixing and checking
3. Cap punching
4. Cap soldering
5. Ageing
6. Cleaning and marking
7. Packaging

Circuit soldering:
The curved tube filled with Mercury vapor and Argon gas has two
tungsten filaments at two points of the tube that has four wires
which are soldered with the circuit board. This whole operation is
done manually.

Plastic cover fixing and checking:

The soldered circuit and the tube are now fit with the plastic holder
manually. Then the lamp is checked by fitting it to a socket.

Cap punching:

65
Before soldering the cap eye, the lamps are punched at the neck of
the holder for strong hold as there is neither thread nor cement to
hold the cap with holder strongly for long time period. Then the
punched lamps are preceded for soldering.

Cap soldering:
The punched lamps are then soldered manually. There are 6 workers
appointed for soldering the cap eyes.

Ageing:
Then the finished lamps are placed in the ageing belt for glowing
before packing. This is necessary for obtaining accurate lumen from
the lights. The ageing belt has 52 positions and takes 50 minutes to
complete a full rotation. The initial position has low voltage but the
other 51 positions have same voltage that is the normal supply
voltage of 220V. At the end of the rotation of 50minutes, the lamps
are removed from the holders and preceded for marking and
packing.

Cleaning and marking:

The lamps from supplied from the ageing belt are then placed on a
conveyer chain for marking of the serial no. and the manufacturing
date on the body of the holder by an inkjet printer. There is sensor
fixed to the injecting point of the printer to ensure every CFL is
printed serially. If a point is empty, the printers will not response.
Then the marked lamps are cleaned by cloth to satisfy customers’
eye and preceded for final packaging.

66
Packaging:
The CFL are packed manually by approximately 6 persons. The
packaging is done in two steps.
First, a tray is filled with 10 units and then, 5 trays are packed in a
cartoon. Thus 50 units are packed in a cartoon and preceded further.

REP OR T SECTI ON ON Q UALIT Y

CON TR OL

67
 5.Quality control:
Quality control department mainly works with the quality stages of
GLS bulb and its components like flare, stem, mount, sealed lamp
etc. For checking the standard margin of making a bulb Quality
department contains some specific schedule of checking and
inspection. These are as follows,
(A)Machine wise checking
(B)Strength of glass test
(C)Vacuum test
(D)Lumen test
(E)Longevity test
(F)Torsion test of cap

(A)Machine wise checking:

In machine wise checking some samples are randomly taken from
machines and then these samples were taken for investigations. In
checking, quality control operators check the precision and compare
these with standard value of GLS bulb.

(B)Strength of Glass test:

From the taken samples, flare, stem, mount and sealed lamps are
goes to check the glass strength by using some methods. Flares are
checked by dropping from a definite height on solid base. For shell, a
steel ball dropped over shell with a specific height to observe the
strength. If these samples overcome during testing operations and
assures the standard level then all the products declares O.K.

(C)Vacuum test:

68
For vacuum test, a sealed bulb taken from the samples and
operators measures its internal pressure by using moderated
manometer which contains mercury. Standard value of pressure is
quite below (around 65-72 mm of Hg) of normal atmosphere.

(D)Lumen test:
For lumen test a sample bulb taken into the lumen test machine to
calculate the lumen of bulb by the help of a computer.

(E) Longevity test:

For longevity test sample bulbs are lighten in various voltages over
some times and gradually calculate the bulb life. In standard level,
bulb life value is 1000 hrs.

(F) Torsion test of cap:

In these test operators checks the condition of a bulb that is capped.
Mainly cement quality, position of cap and torsion strength of cap is
observed.

69
Conclusion:

70