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COMPANY PROFILE
1.1 INTRODUCTION
O/E/N India Ltd., fore runner of O/E/N group of companies came into existence in the 1968 as a joint venture with Oak Electro Netics Corporation, USA, to manufacture electromechanical components such as relays, switches, potentiometers etc. O/E/N has core team of highly skilled professionals who have an in depth expertise with several years of experience to take up the projects involving design and development providing integrated system solutions. They have worked in collaboration with world leaders like OAK industry and their subsidiaries. Their team of professionals is well versed with latest design methodologies, development tools and documentation procedures that are incompliance with international standards. Most of the new products are the result of the intensive ongoing Research and Development within. With four manufacturing locations two in Cochin and one each in Banglore and Pune, O/E/N India Ltd. has 20,000 square meters of factory space. The company offers a comprehensive range of products with applications in most segments of Electronics Industry including Communications, Automotive, Strategic Industrial Controls, Instrumentation and Consumer Electronics. The factory infrastructure includes fabrication plants for pressed parts, plastic moulded parts, electroplating facilities, Research and Development Laboratory.

Sophisticated Tool Room and Quality Assurance and Test Labs. The quality management system of the company is covered by ISO 9001:2000 Certification. The Quality Assurance (QA) Lab is equipped with state of the art testing equipments required for inspection and testing of products to Joint Services Specifications.

1.2 OBJECTIVES
O/E/N was established with the primary objective of providing effective and efficient solutions to all customers at an optimal cost with time delivery and they explore the leverage the state of the art technologies to achieve excellence in their objectives. The main products manufactured in the company (relays and switches) are in a variety of styles and designs according to the needs of the users. Apart from regular production, O/E/N offers facilities for contract manufacturing and already exports considerable volumes. Their focus is to cater to both Indian market and overseas by providing high quality products.

2. HRD DEPARTMENT
Human Resources Development (HRD) is framework for the expansion of human capital within an organization through the development of both the organization and individual to achieve performance improvement. It is the integrated use of training, organization and career development efforts to improve individual, group and organizational effectiveness. HRD develops the key competencies that enable individuals in organizations to perform current and future jobs through planned learning activities. It ensures a match between individual and organizational needs. The HRD department has the following functions: 1. Welfare activities. 2. Training and Development. 3. Recruitment, Maintenance and Separation. 4. Personal Administration. 5. Security Services and 6. Cleaning activities. To carry out these functions, separate sub-departments have been established with the HRD Department. The HRD department is headed by the Assistant General Manager (HRD), who is responsible for the efficient working of all the departments under it. The HRD department is thus responsible for maintaining a good and sustaining relation between the management and workers and between the management and the public. The department frames various policies for the welfare and satisfaction of the employees. The policies are discussed with the management and the workers unions and if found acceptable, are put into practice. The various policies include: 1. Promotion policies. 2. Incentive Schemes. 3. Environmental, organizational health and safety policies. Along with these policies quality is given utmost importance as well.

3. PRODUCTS
Following are some of the products which are developed and manufactured in O/E/N. Relays. Switches.

3.1 RELAYS
Relays are an essential part of an electronic industry. A relay is an electromagnetically operated switch. Many relays use an electromagnet to operate switching mechanism mechanically. They are used where it is necessary to control a circuit by a low power signal or where several circuits must be controlled by one signal. Primary functions of Relays: The galvanic separation of the primary or actuating circuit and the load circuits. Single input/multiple output capability. Separation of different load circuits for multi-pole relays. Separation of AC and DC circuits. Interface between electronic and power circuits. Multiple switching functions, e.g. delay, signal conditioning. Amplifier functions.

Applications of Relay: Laboratory instruments. Telecommunication systems. Computer interfaces. Air conditioning and heating. Automotive electronics. Traffic control. Lighting and electric power control. Control of motors and solenoid.

Basic design and operation:

Figure: Simple electromechanical relay. The most important components are: Contact system/Secondary side: Fixed contacts. Moving contacts. Contact springs.

Magnetic system: Coil (to generate necessary magnetic field to actuate the armature and contacts.) Core (highly magnetic permeable, concentrates magnetic field.) Yoke (to establish the magnetic circuit.) Armature (moving part of the system which closes and opens the circuit and acts via an actuator and moving relay contacts.) Return spring (for quick return of moving contact to normal spot.)

Mechanical components: Case and base. Insulator. Actuator (translates the motion of magnetic system to contact system.) Pins/Terminals. A simple electromagnetic relay consists of a coil of wire wrapped around a soft iron core, an iron yoke which provides a low reluctance path for magnetic flux, a movable iron armature, and one or more sets of contacts. The armature is hinged to the yoke and mechanically linked to one or more sets of moving contacts. It is held in place by a spring so
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that when the relay is de-energized there is an air gap in the magnetic circuit. In this condition, one of the two sets of contacts in the relay pictured is closed, and the other set is open. When an electric current is passed through the coil it generates a magnetic field that activates the armature, and the consequent movement of the movable contact either makes or breaks a connection with a fixed contact. If the set of contacts was closed when the relay was de-energized, then the movement opens the contacts and breaks the connection, and vice versa if the contacts were open. When the current to the coil is switched off, the armature is returned by a force, approximately half as strong as the magnetic force, to its relaxed position. Usually this force is provided by a spring. Relay assembly: The section where the relays are assembled from its parts is called the assembly. Relay assembly consists of many steps. 1. Coil terminal assembly. 2. Coil winding. 3. Contact staking. 4. Yoke, core and coil assembly. 5. Tinning. 6. Continuity check. 7. Base assembly. 8. Final assembly. 9. Calibration. 10. Inspection. 11. Packing.

Types of Relays: Industrial relays. Telecommunication/signal relays. Power relays. Automotive relays.
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Industrial Relays Series 33 Relay Mounting Style: Panel/ Plug-In Contact Form: 2C, 3C Rating: 30A at 24VDC/230VAC Coil: 6-48VDC, 115, 230VAC

Series 37 Relay Mounting Style: Plug-In Contact Form: 2C, 4C Rating: 5A at 24VDC/230VAC Coil: 12-110VDC, 110, 230VAC

Series 38 Relay Mounting Style: Plug-In Contact Form: 2C Rating: 10A at 24VDC/230VAC Coil: 12-110 VDC, 110, 230 VAC

Telecommunication/Signal Relays Series 30-X Hermetically Sealed Relay Mounting Style: PC Contact Form: 2C, 4C Rating: 1A at 24 VDC Coil: Sensitive Adjusted

Series 42 Signal Relay Mounting Style: PC Contact Form: 1C Rating: 1A at 24VDC/230VAC Coil: 12, 24VDC

Series 67 Cradle Relay Mounting Style: Solder/Plug in/PC Contact:2- 8C Rating : 3, 5 and 7A at 24VDC/115VAC Coil AC: 115, 230V Coil DC: Various

Power Relays Series 57 Relay Mounting Style: PC Contact Form: 1C, 2C Rating: Up to 6A at 24VDC/230VAC Coil DC: 5-115VDC

Automotive Relays Series 73 Relay Mounting Style: Panel/Plug-In/PC Contact Form: 1A,1C Rating: Up to 30A at 12VDC Coil: 6-24VDC

3.2 SWITCHES
A switch is an electrical component that can break an electrical circuit, interrupting the current or diverting it from one conductor to another. The most familiar form of switch is a manually operated electromechanical device with one or more sets of electrical contacts. Each set of contacts can be in one of two states: either closed meaning the contacts are touching and electricity can flow between them or open meaning the contacts are separated and the switch is non-conducting. O/E/N undertakes contract manufacture of switches according to customer design and specifications. Different types of switches manufactured by O/E/N are: Rotary Switches: Series 11 (AM) Switches Series 12 (J/JC) Switches Series 13 (OM) Switches Series 16 (LORLIN CK) Switches

Other Switches: Series 22 Micro Switch Series 25 Rocker Switch

Series 11 (AM)

Angle of throw (in degrees) - 30, 45, 60, 90 No. of Positions: Up to 12 position Contact Rating: Up to 1A at 28VDC and 0.5A at 110VAC

Series 16 (CK)

Angle of throw (in degrees) - 30 Contact Rating: 150mA at 250VAC No: of Positions: Up to 12 positions

Process flow chart of a Rotary Switch: 1. Rotor blade trimming 2. Rotor blade splitting 3. Trimming 4. Eyeleting 5. Shaft and star wheel assembly staking 6. C-washer clinching 7. Ball and spring assembly 8. Final assembly 9. Mounting hardware assembly All these operations are based on the drawing which is provided which contains all the necessary views and specifications of the required product.

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4. RESEARCH AND DEVELOPMENT

Research and development (R&D) department is mainly involved with the design and development and the betterment of existing products. Thus, the major objective of R&D is to develop quality products based on cutting-edge technology. The company R&D facility operates over a wide range of electronic research and applications. The facility is a self contained centre with well equipped laboratories and multi disciplinary team of professional design engineers. The R&D department is mainly concerned with designing of three types of products: a. Products provided by the customer according to their specifications. b. Existing products available in the market. c. Existing products with additional features. The major phases of new product development are: 1. Planning and defining program or project: This stage is the initial stage in the long process of R&D. The initial stage is concerned with identifying what kind of product is to be made and it is feasibility in creation (financial, conceptual, and process). 2. Product design and development: In this stage, the department usually uses the PROE software to design the finished product. Along with this the product and the tools are also designed. The manufacturing of the tools also take place in this stage. A review on the progress of the process is done bringing to an end the second phase of the NPD process. 3. Process design and development: In this phase the process sequence, labor characteristics, room characteristics, etc. are identified and developed. 4. Product and process validation: The validation and testing of the products made are conducted in this phase along with the final designing of the product. The design made up in this phase goes into the pre-production run in the fifth stage. The relay values, drop out volts, withstand, life, ampere, etc. are tested and validated to the benchmark. A review is conducted after this phase. 5. Feedback, assessment and corrective action: A preproduction run for 20,000 to 30,000 units are conducted. After this regular production is done. For the first three months the R&D team along with production team would be constantly monitoring the production process and the mistakes are taken care immediately without any delay.
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5. MANUFACTURING DEPARTMENT
Manufacturing is the main department in any organization and the major impetus of any company also goes into this function of manufacturing. O/E/N has a manufacturing space of 18,000 m2 in three locations; Mulanthuruthy, Vytilla in Kerala and Peenya in Karnataka. The manufacturing department consists of

5.1 TOOL ROOM

O/E/N has a well equipped modern tool room with all facilities. The specialty is in the design and manufacture of tools and moulds for electromechanical components. Tool room is managed by a team of expert engineers in tool design and in manufacturing a group of well trained tool room makers and mechanics, a well equipped press and moulding shop attached to the tool room provide facility for providing the tool and moulds. Tool room works in four wings: Tool design Machining Tool assembly Maintenance The Tool Room is equipped with CAD facility and a machine shop having the following special machines in addition to conventional machine tools. Charmilles Wire EDM Charmilles Spark EDM Wickman CNC Profile Grinder WMW Optical Profile Grinder WMW Jig Boring Machine Mikron Milling Machine The Tool room can accept orders for design and manufacture of the following types of tools and moulds, for fabrication of components to customers design. Press Tools Progressive, compound and Single operation tools Injection Moulds
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Compression moulds Transfer moulds Assembly Tools Jigs & Fixtures

5.2 FABRICATION ROOM

The main assembly is supported by comprehensive fabrication facilities with power press for pressed piece parts, a plating plates that handles plating of conventional as well as precious metals. This has three divisions. Actual fabrication Electro plating Moulding shops

5.3 ASSEMBLY ROOM

This department is mainly related to the manufacturing and assembly of relays, switches and potentiometers. This department works 24 hours in a day as three shifts. Their main objective is to reduce process scrap, improve group index and achieve programmed production.

Relays: Relays are differentiated based on materials used, temperature and pressure
withstanding ability, electrical parameters, type of moulding, etc. List of operations in manufacturing relays are: Coil terminal insertion and bending Coil winding Coil tinning and cleaning Coil terminal straightening Core head correction Coil, core yoke assembly, staking NO/NC contact terminal signaling and cleaning Moving spring bending Moving terminal

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Armature correction Armature/retainer/base plate assembly Cover printing Calibration and cover insertion Base plate and cover staking Scaling, hole checking/filling and terminal cleaning Terminal cutting Terminal tinning and cleaning

Switches: O/E/N manufactured switches are mainly used by the Ministry of Defense. The
series 13 switches are exclusively created for a company in the U.K. Switches are differentiated based on materials used, temperature and pressure withstanding ability, electrical parameters, type of moulding, etc. The main processes in switch manufacturing are: Rotor blade trimming Rotor blade splitting Staking Eyeleting Shaft and star wheel assembly staking C washer cylindering Ball and spring assembly Final assembly Mounting hardware assembly

Potentiometers: As per orders, assembly of potentiometers is undertaken. Therefore the

manufacturing of these are less compared to other products. This product is used in electronic circuits for getting desired voltage drops. All the parts of the potentiometers are imported.

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6. AUTOMATION DEPARTMENT
Automation is the use of control systems and information technologies to reduce the need for human work in the production of goods and services. In the scope of industrialization, automation is a step beyond mechanization. Whereas mechanization provided human operators with machinery to assist them with the muscular requirements of work, automation greatly decreases the need for human sensory and mental requirements as well. Major aims of automation are: Productivity gain Cost reduction Reliability and precision Health and environment Convertibility and turnaround time.

Working in O/E/N from 1995, the department helps others especially the assembly unit by providing automated machines and technology integration. Automations in progress are the systems for coil tinning and continuity testing and for staking yoke and terminal 30 components of a relay. While doing the trial run, an observation sheet is maintained by the supervisor that contains the following data: Starting time Damages found Stoppage time Total machine hours

After trial ruin is conducted for each day, operations are stopped and executives from QA and Process engineering are called in along with the supervisors, to rectify damages. This may require changes in equipment and process and this is taken care off.

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7. MATERIALS PURCHASE DEPARTMENT

The materials purchase department is an important department in O/E/N. The hectic procedures concerning the purchase of materials, choosing suppliers of materials, etc are decided by this department. Functions and procedures of the department include i. Approval of new suppliers: New sources are identified through various inputs like publications, ads, introductory letters, references through internet, through correspondence, etc. A request for quotation is sent to new sources along with specifications, drawings, samples, supplier evaluation forms, etc, where ever applicable. On receipt of quotations and other details, offers are evaluated. If required, further correspondence/negotiations/request for samples is made and new suppliers for ordering are identified. Trial order is placed with new suppliers based on terms and conditions. Trial order item on receipt are forwarded to QA for evaluation and inspection report is forwarded to suppliers. Based on acceptance of trial batches, new suppliers are included in Approved Suppliers List ii. Supplier Monitoring: For suppliers, supplier performance is monitored based on the following for automotive parts: Quality Delivery Price Premium freight incidence Customer line description Quality issues for customers Documentation 40% 10% 15% 10% 10% 10% 5%

For suppliers of non-automotive parts supplier performance is monitored based on: Quality Delivery Price Responsiveness 40% 25% 25% 10%

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Performance rating is done during April and September every year for suppliers made during the previous six months. Based on rating suppliers are classified into five grades: Grade A: Rating >= 90 Grade B: Rating >= 80 and < 90 Grade C: Rating >= 70 and < 80 Grade D: Rating >= 60 and < 70 Grade E: Rating < 60 Suppliers belonging to group E are removed from approved suppliers list. Suppliers are reevaluated every three years based on their performance rating for previous three years. Those who have not supplied for three consecutive years are discarded from approval list. Suppliers removed are prequalified per procedure for approval of new suppliers. In case of rejection of supplied items suppliers are informed along with inspection report/Corrective and Preventive Action Report (CPAR) and asked to submit counter measures and ensure implementation of measures depending on severity of problem. Suppliers are instructed to present the counter measures for major problems in a meeting at O/E/N. Even after counter measures if suppliers are rejected no further orders would be placed. 1. Purchase of Materials: For raw materials and precious metal parts, suppliers are instructed to send Material Test Certificate along with supplies which are forwarded to QA on receipt. 2. Receipt: Material s coming to receiving stores are moved to for checking. 3. Storage areas are: a. Piece parts store b. Raw materials store c. Consumable tools store d. Tools and mould store e. Air conditioned store f. Precious material store g. Metal scrap yard and waste material store

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8. QUALITY ASSURANCE DEPARTMENT (QA)

Quality products and services to the customers is the primary task but the ultimate aim is to offer customers improving products and services. The QA department is involved in inspection of parts, incoming materials and financial products and also in maintenance of quality records. Major functions of this department are given below: 1. Incoming Inspection: Inspection of first sample is done by incoming inspection executive after receiving reports along with samples. Inspection of vendor supplied parts is done according to specifications. Criterion for incoming inspection is that if five items randomly taken are qualified then the entire lot is approved and if three items are rejected the entire lot is rejected. Following processes are done in incoming inspection: a. Inspection of raw material b. Inspection done during fabrication of parts, samples are tested on an interval of one hour c. Inspection of in-house processed parts d. Inspection of packing boxes, mould tray e. Product specification testing f. Parts after plating and processing g. Customer supplied parts are tested 2. Finished Product Inspection: This process is done to ensure and certify that the required quality is maintained for finished products. Finished products are tested by checking random samples offered by product inspectors by appropriate routine life tests as per work instruction for ensuring product reliability and performance against relevant specifications at regular intervals.

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9. CONCLUSION
The training provided by O/E/N India Ltd. Provided a comprehensive coverage on various products manufactured such as relays and switches, various machines, operations, product information about the nature and characteristics of the material used and also imparted knowledge about the various technologies used by the company. The industrial exposure gave a sense of knowledge about the day to day activities and workings of a fully fledged electronics company. The R&D department provided an opportunity to view the industry level norms of hardware and software development helped bridge the gap in the thinking level between students and industrys expectations. It also helped me to visualize the research and development process that is undergoing in the design of a product.

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