Voltas Ltd

Internship Report

Submitted By

Lala Lajpatrai Institute of Management

Mumbai

Company History & Profile

Voltas was incorporated on 6th September 1954. Tata sons Ltd and Volkart brothers, a Swiss company operating in India since 1851 promoted this company and hence the name Voltas. It caters to a wide spectrum of industries as areas such as heating, ventilation and air conditioning, refrigeration, electro mechanical projects, textile machinery, mining and construction equipment, material handling equipment, water management and treatment, cold chain solutions, building management systems and indoor air quality.

The company undertakes management and execution of electro mechanical projects including air conditioning and refrigeration, design and manufacture of industrial equipment, cooling appliances and material handling equipment, sourcing installation and serving industry through representation of global technology leaders.

Voltas offers integrated solutions which enables single window approach, Harmonization of all phases, integrated value engineering solutions, improved serviceability, interface management and enhanced coordination and reliability.

Voltas manufactures virtually full equipment. It has one of the most extensive customer care networks. Voltas leads in air conditioning projects in India. Voltas is India’s largest exporter in field of electro-mechanical project. Voltas leads in sourcing installing and servicing state-of-art textile machinery in India. Voltas is leader in forklift trucks manufactured to in-house design.

2. Manufacturing in Plant

Voltas has three modern manufacturing plants for HVAC&R equipment, located at: Thane (outside Mumbai), Dadra (Union Territory), and Pantnagar (Uttaranchal).

Product engineering Voltas has a very strong product engineering base, with an expert corps of engineers designing and developing new products while improving existing ones.

Their approach of intelligent innovation and customized problem-solving is given full play through use of advanced design software. This includes specialized software for coil designing, digital draughtsman ship, solid modeling and simulation.

To facilitate mass production of packaged and split units, and various types of chiller packages, well laid-out conveyor-equipped assembly lines are utilized.

Component manufacturingThe core strength of Voltas manufacturing is its ability to craft high-precision components of considerable complexity, with state-of-the-art equipment and processes.

Installed manufacturing machinery includes CNC horizontal machining centres and turning centres, and Fanuc tape drills.

Coil manufacturing with aluminium fins and copper tubes utilizes

Fin press and hair-pin benders Vertical and horizontal expanders

Automatic coil brazing machine

This results in coils of the highest quality, offering various options such as louvered fins, slit fins, sine wave and corrugation

Layout of Voltas Ltd. Thane consist mainly 2 units. Working of 2 units is given as follows.

Unit 1 Production of VAM

Vapour Absorption Machine manufacturing

Voltas' manufacturing set-up at Thane has modern fabrication facilities with Tungsten Inert Gas (TIG) welding, controlled tube expanding automatic machines, tube finning machines and CNC drilling machines, among others. High precision helium leak testing machines and electronic leak testing machines carry out stringent leak tests on entire VAM machines for passing in the order.

Voltas’ Vapour Absorption Machines (VAMs) of Lithium bromide - water type are indigenously manufactured with state of the art Paraflow Technology with focus on reliability & efficiency.

It can be operated with variety of heat sources like Steam, hot water, oil, gas, exhaust gas & combination of it. These are extensively used in vide variety of industrial & commercial building for providing chilled water for use in many different applications in process cooling & air conditioning.

An exhaustive capacity range with standardized large numbers of intermediate models are made to suit client nearest needs from 40TR to 2900TR capacity for chilled water upto 4 0 C outlet temperature & slandered as 7 0 C. Models are available on request to cater to the need for sub zero temperature application.

Unit 2 Production of 6D & OTC compressors

6 D Compressor

A 6 D compressor is a sealed mechanical device that is used to regulate gas pressure by varying the volume of the gas. The way a 6 D compressor works is that a motor is energized by current then in turn rotates a crankshaft, during the down stroke, a piston creates low pressure between the cylinder head and the piston and during the upstroke the compressed gas force a high pressure on the outside system.

Open Type Compressor

Compressor in which the crankshaft extends through the crankcase and driven by an outside motor commonly called open type compressor.

Every final product is determined by performance parameters (PP) specified by customer and by technical team.

For example, (1) Ammeter parameters are IP current, front glass, bezel, panel fixing, Safety, Dial, terminal protection, red index pointer etc.

The top management is keen on improving internal processes in above areas to fully exploit the opportunities in present favorable market conditions. They are also appreciative of the fact the process management is key to sustained product improvement.

3. Material handling in Voltas

Material Handling is solving the pragmatic problems involving the movement, storage, control and protection of materials, goods and products throughout the processes of cleaning, preparation, manufacturing, distribution, consumption and disposal of all related materials, goods and their packaging.

In Voltas, material handling is carried out mostly by forklift trucks and over head cranes. To provide one-stop shopping for every domestic materials handling need, Voltas MH markets world-class warehousing equipment based on the parameters of efficiency, lowest life cycle costs, maximum uptime and productivity, driven by a belief in providing the customer with total solutions.

1.Forklift Trucks

A forklift truck (also called a lift truck, a fork truck, or a forklift) is a powered industrial truck used to lift and move materials short distances.

Today, Voltas MH manufactures in-house designed forklift trucks ranging up to 16 tons in the diesel version, 3.5 tons in battery, and 2 tons in LPG & CNG versions. Voltas MH is capable of designing and manufacturing higher capacity diesel forklift trucks against specific enquiries. Voltas is the first forklift supplier in India and first forklift manufacturer in India. Voltas MH forklift trucks conform to ISO/IS standards for capacity declaration, stability, safety, and performance parameters. Voltas was awarded ISO 9000 Certificate in 1993 by TUV - Germany.

The Certificate was renewed in 1996 & 1999, recertified for the 2000 version of ISO9001 in 2002, 2005 & 2008 and is valid till November 2011. Voltas' forklift plant is presently pursuing certification in Environment Management Systems, viz. ISO 14001. Forklift trucks are also classified as heavy duty forklift, diesel power forklift etc.

2. Overhead Crane

An overhead crane, commonly called a bridge crane, is a type of crane found in industrial environments. An overhead crane consists of parallel runways with a traveling bridge spanning the gap. A hoist, the lifting component of a crane, travels along the bridge. Overhead cranes are typically used for either manufacturing or maintenance applications, where efficiency & downtime are critical factors.

3.Reach Stacker

A reach stacker is a vehicle used for handling intermodal cargo containers in small terminals or medium-sized ports. Reach stackers are able to transport a container short distances very quickly and pile them in various rows depending on its access.

Reach stackers have gained ground in container handling in most markets because of their flexibility and higher stacking and storage capacity when compared to forklift trucks. Using reach stackers, container blocks can be kept 4-deep due to second row access.

4. Power Pallet Truck

A pallet truck, also known as a pallet jack, pallet pump, pump truck, or jigger is a tool used to lift and move pallets.

The front wheels are mounted inside the end of the forks, and as the hydraulic jack is raised, the forks are separated vertically from the front wheels, forcing the load upward until it clears the floor. The pallet is only lifted enough to clear the floor for subsequent travel.

4. Quality Control Tools

Quality control, or QC for short, is a process by which entities review the quality of all factors involved in production. Controls include product inspection, where every product is examined visually, and often using a stereo microscope for fine detail before the product is sold into the external market. Inspectors will be provided with lists and descriptions of unacceptable product defects such as cracks or surface blemishes.

1.Vernier Calliper

A vernier scale is a device that lets the user measure more precisely than could be done by reading a uniformly-divided straight or circular measurement scale. It is scale that indicates where the measurement lies in between two of the marks on the main scale.

Verniers are commonly used in navigation, scientific instruments used to conduct experiments, machinists' measuring tools (all sorts, but especially calipers and micrometers) used to work materials to fine tolerances.

2.Rockwell Hardness Test

The Rockwell scale is a hardness scale based on indentation hardness of a material. The Rockwell test determines the hardness by measuring the depth of penetration of an indenter under a large load compared to the penetration made by a preload. There are different scales, denoted by a single letter, that use different loads or indenters. The result is a dimensionless number noted as HRA, where A is the scale letter.

When testing metals, indentation hardness correlates linearly with tensile strength. This important relation permits economically important nondestructive testing of bulk metal deliveries with lightweight, even portable equipment, such as hand-held Rockwell hardness testers.

3.Brinnel Hardness Test

The Brinell scale characterizes the indentation hardness of materials through the scale of penetration of an indenter, loaded on a material test-piece. It is one of several definitions of hardness in materials science.

By varying the test force and ball size, nearly all metals can be tested using a Brinell test. Brinell values are considered test force independent as long as the ball size/test force relationship is the same.

Applications

Because of the wide test force range the Brinell test can be used on almost any metallic material. The part size is only limited by the testing instrument's capacity

1. One scale covers the entire hardness range, although comparable results can only be obtained if the ball size and test force relationship is the same.

2. A wide range of test forces and ball sizes to suit every application.

3. Nondestructive, sample can normally be reused.

5. Theory of Constaints In Supply Chain Management

In this era of cut throat competition the problem that most of the chain members today face is that whether they should look at their individual profitability & performance, or the overall supply chain’s performance. Often, members of the supply chain tend to implement the procedures which are beneficial for them thereby resulting in poor performance of the supply chain. The real impact on the supply chain of the overall performance is completely. The existing practices which are used in most of the industries are more focused on cost minimization leading to degradation of quality and ultimately lead to poor performance of the chain in totality. To improve the existing level of performance the organizations need to implement new and innovative improvement solutions beyond their internal business processes. Presently many organizations have started the TOC approach to guide their improvement programs to enhance their supply chain performance.

In the TOC approach the main focus is on constraints – finding the constraints and finally resolving the problems. This kind of approach is continual and it requires a lot of effort from all the members of the chain. Application of TOC for supply chain management is quite new and unique approach to tackle the problems. The problem the supply chain members face is conflict of interest –all the members look for their own profitability at the expense of other member. This can be resolved by changing the strategy followed by the manufacturers and the retailers. The focus of the approach should be delivery of the product to the end customer and finding the constraint at each level.

The first step is to identify what is preventing the chain members from satisfying the desired level of performance or profitability. This step of TOC approach in known as constraint identification. The constraint can be any of the following types -

• Internal or external

• Physical or non- physical

• Dependent or independent

The process of constraint identification involves a lot of analysis and collaboration between the chain members .The constraints can be at a very individual level or at a macro level (market forces). The constraints can also be a result of human behavior- the role of employees/ managers becomes critical and they may be the cause of the constraint. For example- The “no risk approach” taken by senior production manager to produce goods based on the previous forecasts only and not analyzing the need to change strategy due to market dynamics. This approach followed by the manager may result in non-availability of goods to the retailer which in turn causes loss to both retailer and manufacturer. The constraints developed in a system can also be a result of the policies and procedures followed by the organization for day-to-day operations. There are a lot of interdependencies between a numbers of factors which ultimately leads to a constraint.

Identification of the constraint leads to second step of the approach which is exploiting the constraint. This step is essential for the overall implementation of TOC and requires a lot of brain storming from the chain members. This step involves optimizing the existing capacity at the constraint. For example- if a company manufactures three different types of products (A, B and C), non-availability of type C product is the problem then supplier has to observe the constraint and replenish the constraint without delays. This change of continuous replenishment is initiated by the change of production schedule and product mix manufactured at the facility.

The third step is to sub ordinate all other activities to the constraint. This means that changes may be required to the existing rules and procedures which used to cause the problem. Hence all activities or procedures which used to cause problems will be eliminated or changed, which in turn helps in exploiting the constraint.

The next step (fourth) is to elevate the constraint .This step involves increasing of the capacity of the constraint to a higher level. And this step often involves the creation/ identification of a new constraint.

The fifth and the last step essentially deal with managing the problems which hamper the improvement process. This is the constraint based approach which can be followed to tackle the problems associated and enhance the overall performance of the supply chain.

The ultimate aim of the supply chain management is to bridge the gap between demand and supply. In a supply chain of make to order type products the constraints is the end customer, so to exploit this constraint of the supply chain one needs to have the right product in the right place at the right time. For this to happen the kind of collaboration required is huge and it involves a lot of information sharing. This step will require information sharing of overall supply chain about each and every level and finally taking decisions at the local level. This decision is dependent on the factors such as non availability of any particular resource and other forces which may be internal or external to the system. For these types of problems the application of D-B-R (Drum buffer rope) solution can give desired results, overall planning and scheduling problems can be tackled by implementing the solution.

Although there are both internal and external forces hampering the overall performance of the supply chain, the solution developed must be internal in nature. This doesn’t mean that there should be no collaboration between the chain members; it means the desired level of performance of the supply chain will not be achieved until and unless there are policy and procedure changes at the local level. Directly looking at the big picture and ignoring the internal problems will not lead to overall supply chain effectiveness. Effective implementation of TOC approach requires perfect integration and alignment of the business strategy & supply chain

strategy to achieve business goals & objective which in turn will lead to overall supply chain’s effectiveness and improved performance.

6.CONCLUSION

Voltas is India's largest air conditioning company, and one of the world's premier engineering solutions providers and project specialists. Founded in India in 1954, Voltas Limited offers engineering solutions for a wide spectrum of industries in areas such as heating, ventilation and air conditioning, refrigeration, electro-mechanical projects, textile machinery, mining and construction equipment, water management & treatment, cold chain solutions,

building management systems, and indoor air quality.

The Company's strengths lie principally in management and execution of electro-mechanical projects, including air conditioning and refrigeration, sourcing, installation and servicing of diverse technology-based systems serving Indian industry through representation of global technology leaders.

Voltas MH has been catering to the needs of the materials handling market for over 45 years. Making a modest beginning in 1964 as a licensee of Yale - USA, for manufacturing and marketing of diesel-driven forklift trucks (up to 3 tons) and battery-operated trucks (up to 2.5 tons), Voltas MH has come a long way in establishing itself as a market leader, meeting the ever-changing needs of clientele through continuous upgradation of products and their features.

Benefits to trainee are practical experience in deciding the future area of focus for a company as well as to learn how to differentiate product offering. Also trainee gets opportunity to understand strategic planning new businesses and corporate initiatives i.e, Corporate strategy.