SUMMER TRAINING PROJECT REPORT

ON
PARTS SECTION, ELECTROPLATING ,
ALUMINIZING & MOULDING DEPT.
AT
THE EVEREADY FLASHLIGHT PLANT
(TEFCO)

UNDER THE GUIDENCE OF

MR. SANDEEP GUHA
(Head of the personnel)
THE EVEREADY FLASHLIGHT PLANT LUCKNOW

SUBMITTED BY
ADARSH PANDEY
B.TECH .IN MECHANICALENGINEERING (2ND YEAR)
KAMLA NEHRU INSTITUTE OF TECHNOLOGY
SULTANPUR
 ACKNOWLEDGEMENT

I would like to express my sincere gratitude from the

core of my heart to HOD Mr. Anurag Kushwaha and project
coordinator Mr. Sandeep Guha and all my friends and
colleagues for their tremendous help and cooperation in
completion of this project report.

I have put great efforts in making this project report, I

have tried my level best to be accurate at all points and have
included each and every point regarding Parts section,
electroplating, aluminizing & moulding department .

My efforts have also been in the direction to make my

project report look attractive and represent able.

I hope my hard work will be appreciated by all.

ADARSH PANDEY
B.TECH, 2 ND YEAR
MECHANICAL ENGG .

1
 CONTENT

Introduction
Brand Eveready
Logo of Eveready
Company Profile
Milestones of Eveready Industries India Ltd
Manufacturing Bases of Eveready Industries India Ltd.
Lucknow unit: TEFCO
Products
Manufacturing Eveready digiLED flashlight
Components used in manufacturing of the flashlight
Production process cycle
Raw material store
Casing section
Parts section
Electroplating plant
Moulding section
Aluminizing
Powder coating
Heat treatment
Inspections
Sub-assembly
Assembly
Safety
Conclusion

3
 INTRODUCTION
LED Flashlight Industry in India
LED lights have emerged as powerful source of lighting over
the past several years. Due to their numerous advantages over
conventional lighting technology, they have swiftly gained in
the Indian lighting market. Although Indian LED lighting
market is at a nascent stage, it offers innumerable opportunities
for growth over the next few decades. As India represents one
of the biggest lighting markets, it offers a lucrative option for
LED manufacturers to set their facilities in the region. Skilled
labour, ease of doing business and demographic advantages
provide a sustainable environment for the LED industry.

Currently the demand for LED lighting systems is primarily

concentrated in the north and south regions due to growing
urbanisation rates and increasing number of government
initiatives that encourage the use of LED lights. The
government’s support through various regulations that promote
the investments in energy efficient lighting technologies have
expanded the application of LED lights across various
industrial, commercial and residential sectors. A rapidly
growing automotive industry also provides productive
opportunities for the use of LEDs in head lamps, rear amps, turn
signals and brake lights. Other important factors such as
increasing infrastructure investment, rapid growth of street
lighting systems, decline in average prices of LEDs and various
government and upcoming smart building projects are expected
to drive the demand of LED lights in India. According to new
report published by IMARC Group, the Indian LED lighting
market was worth around US$ 3.7 billion in 2016, growing at a
CAGR of around 17.5% during 2009-2016.

4
Company Profile
About the company

Eveready Industries India Ltd. (EIIL), formerly Union Carbide

India Limited, is the flagship company of the B.M. Khaitan
Group. The Eveready brand has been present in India since
1905.

EIIL’s principal activities are the manufacture and market of

batteries, flashlight cases, electrolytic manganese dioxide and
arc carbons. It also manufactures photo- engravers plates/strips
for printing, casting, hard facing and tube rods, carbon
electrodes and other related products. The company also
produces and markets tea. The Group’s operating facilities are
located at Kolkata, Chennai, Haridwar, Noida, Assam and
Lucknow. During the fiscal year 2002 the group sold its wholly
owned subsidiaries Dufflaghur Investments Limited. Batteries
accounted for 51% of fiscal 2002 revenues; tea, 38%; flashlight
cases, 9%; electrolytic manganese dioxide, 1%; purchased
products, 1% and others, nominal.

EIIL is the world’s third largest producer of carbon zinc

batteries, selling more than a billion units a year. EIIL is India’s
largest selling brand of dry cell batteries and flashlight
(torches), with dominant market shares of about 46% and 85%
respectively.

7
Products
Eveready industries have business interests spreading across
batteries, flashlights, lighting solutions, home appliances and
packed tea.

Batteries
1. Zinc carbon battery : A zinc carbon battery which
is commonly used for toys, cameras, torches,
walkman, CD players, radios, clocks and cordless
mikes.

2. Alkaline battery: Eveready ultima alkaline battery is

one of the most popular batteries used in electronic
gadgets in modern times.

3. Rechargeable battery: Eveready recharge is one of

the pioneers as a brand of rechargeable batteries and
chargers to be introduced in India.

Flashlights

1. digiLED torches: These torches use power efficient

LEDs in place of the incandescent bulbs.

2. Brass torches: Brass torchlight has been a reliable,

durable and repairable, making it a must have evening
companion especially in the villages. It is one of the
most trusted brands in rural India across all product
categories.

12
 3.Aluminium and Plastic torches: These torches have
strong durable bodies, slide switches for easy handing
and come in a wide range of models and colours.

Lighting solutions

1. Compact Fluorescent Lamps: In 2007, Eveready

forayed into the lighting business with the launch of a
range of Compact Fluorescent Lamps.

2. Halogen Lamps: Eveready offers halogen lamps for

outdoor lighting and video-shooting.

3. General lighting sevice /incandescent lamps: A

range of incandescent bulbs in different sizes,
voltages and colours are used widely in household
and commercial lighting, apart from portable,
decorative and advertising lighting.

13
 Eveready Brass Torch

The Eveready Jeevan Sathi brass torch is truly iconic

and a success story in its own right. True to a trustworthy and
constant companion in Indian household in both urban and rural
segments through generations, it is reliable and durable. The
lock-switch has a life of more than one lakh cycles. It is one of
the most trusted brands in rural India across all product
categories.

It has also adapted to the times and progressed and is

now available in LED technology and superior quality lens that
that ensures powerful beams which reach amazing distances.
Eveready Jeevan Sathi torch is available in various wattages for
which number of batteries also varies.

14
 Manufacturing
EVEREADY DigiLED
Brass Flashlight

15
Components Used In Manufacturing Of The
Flashlight

Casing
Bottom cap
Lens ring
Housing
Spring
Switch box
Switch slide
PVC sim
Contact strip holder
Contact strip insulator
Flash button
Rivet
Box spring
Reflector
Retaining washer
Heat sink
PCB
LED
Screw
Name tag
Bail
Shoulder strap
Glass lens

16
 Production Process Cycle

Process cycle: Every flashlight manufacturing cycle involves

three major steps :-

1. Component manufacturing
2. Finishing
3. Assembly

Component manufacturing:

Tefco has fairly a big workshop for manufacturing the

flashlight components. The workshop comprises of 36 power
process ranging from 5-100 tones power and to pneumatically
control integrated lines. The brass sheets are drawn and
machined through these machines. The basic operations are
blanking, drawing, bending, threading, trimming, brazing and
reading. For plastics models the company has five state of art
moulding machines. The workshop is also supported by a well
equipped tool room. These operations are dry processes the
environmental impact is minimum.

Finishing:

Finishing involves techniques to provide a standard

quality, life and decorative shine to final product. Some of the
finishing processes carried out in tefco are :-

a) Electroplating
b) Aluminizing
c) Powder coating

17
Raw Material Store

All the raw materials used to make the torch are stored in the
raw material store.

Raw Materials

Brass Steel wire PCB

tubes
LED
Brass coil

Resistance GPPS

Brass tubes : These are tubes made of brass which are

used to make the casing of the torch.

Brass coil : These are coils of brass which are used to

make parts like bottom caps, lens ring, housing, all switch
components.

18
 Steel wires : Steel wires are used to make springs and
bail which are fitted in bottom caps.

LED : LED is used for illumination.

PCB : Printed circuit boards allow the flow of electric

current and use in head easily.

Resistor : It limits the current through the LEDs and

keeps them from burning out.

GPPS/SAN : General Purpose Polystyrene is used to

make the reflectors.

Processes

Input Brass drawn tube

Cutting
Process
Swaging
Buffing

Processed drawn
Output
tubes

IPQC (In Process Quality Check)

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Casing Section

In casing section, the processes involved in making the casing

of the torch take place.

Casing Integrated Line

Input Processes Output

Sizing Finished
Processed
drawn casing
Reading

Bottom IPCQ
threading

Top
swaging

Top
threading

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Bottom swaging : Swaging is once again done on the
bottom end of the casing. It increases the diameter of the
tube and to maintain thread diameter.

Reading : It is the process of indenting lines throughout

the length of the casing.

Bottom threading : Threading is done on the bottom end

where the swaging was done.

Beading : Beading is done because it act as a stopper for

the bottom cap. Its diameter is greater than that of the
threading.

Top swaging : After beading swaging is done on the top

end to maintain thread diameter of the casing.

Top threading : After swaging the top end undergoes

threading process.

21
Parts Section

Parts such as bottom cap, housing and lens ring are made parts
section.

Bottom Cap

Input Processes Output

Finished
Brass coil bottom cap

Blanking & IPQC

cupping
Sample Integrated Line
inspection

IPQC Rolling Beading

Threading
Embossing

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 Housing

Input Processes Output

Finished
Brass coil housing
Blank &
cup

IPQC
Final
Sample draw
inspection Integrated Line

Bottom
IPQC Threading &
Beading &
Rolling
Top Threading
& Beading &
Rolling Bottom
Threading &
Trimming
Top Trimming

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 Lens Ring

Input Processes Output

Finished
Brass coil Lens Ring
Blank &
cup

IPQC
IPQC
Sample
inspection Integrated Line

Threading &
Trimming
Octagonal
Rolling

Punching

24
 Electroplating Plant
Electroplating or electro-deposition is the process by
which the coating metal is deposited on the base metal by
passing a direct current through an electrolytic solution
containing the soluble salt of the coating metal.

After being manufactured, all the final parts are sent for
electroplating after which they get a silver shinycolours.

Different type of components needs different type of

plating depending upon the size and their end use. Big
components are plated in racks and small components are plated
in barrels.

Plating Types Base Components

Nickel and Chromium Plating Brass Lens ring, Bottom
cap, Casing, housing

Nickel and Tin-Cobalt Plating Steel Bails, Brass Switches

and Slides

Duplex Nickel Plating (Semi Steel Contact Discs

Bright & Bright)

Zinc Plating Other Steel Contact Discs

25
 Flow Chart

Pouring in Alkali Solution 2 times

Washing

Pouring in Sulphuric Acid

Washing

Nickel Plating

Neutralization

Chromium Plating

Neutralization
Visual inspection

Washing
Washing

Drying through oven

26
 Moulding Section
In moulding section, the reflectors are made by the
process of induction moulding.

Moulding is the process of making the required shape of

any given dimensions by melting the plastics (polymers) or
metals.

For moulding a mould of metal is firstly made and then

divided into two parts. In one part the molten plastics is placed
and the other part applies the required pressure and the desired
shape is thus formed.

Classification of Moulding Machines

Injection Moulding Machines (manual, hydraulic)

CNC Injection Moulding Machines

Sn-6 180 tons

Sn-12 180 tons
Sn-12 218 tons
Sn-12 102 tons

27
 Flow Chart

Reflector Moulding Process

Flow Chart

Input Processes Output IPQC Aluminising

GPPS Finished
reflector

Pre-heating (In
oven)

Automatic
material
feeding system

Passage into
machine

Pre-Heating: GPPS is pre-heated in ovens before

undergoing any further process.

Automatic feeding system: This system automatically

feeds the GPPS to the induction moulding machine.

28
 Aluminising
Aluminising is a process to provide a good, polished, shiny,
highly reflective finish to the surface of reflectors. Vacuum
metalizing is simple, fast and economical and offers facility for
mass metallisation of parts.

At absolute vacuum, vapour particles travel in straight line in

radial directions. Vacuum is produced by the operations of four
pumps step by step. Vacuum of 0.1 microns is generated by a
pumping unit in a closed chamber loaded with reflectors in jigs
and the aluminium crimps clamped in tungsten filaments and
the axis of the chamber is fired to give uniform coating.

The temperature of the aluminizing room should not be more

than 25 degrees and the humidity should not exceed 50%.

Plastic Component

Process:-

Al crimp melted under firing process

Comes in vapour form

Loading the plastic reflectors directly from the injection

moulding to appropriate

Fix the real into the vacuum chamber

Start high tension discharge at 200 micron and continue for

2-3 minutes

Fire at the pressure of line and then 0.1 microns

29
 Brass Component

For the cleaning of brass reflectors firstly using the hot tri-
chloro ethylene after that cold tri-chloro ethylene.

And further, lakering process is done with the help of laker’s

spray gun. And after that it is heated in oven at 255-260
degrees. After that aluminising process applied on that.

Powder Coating

It is a substitute for painting. It provides highly decorative and

remarkably protective finish in wide colour ranges. They are
durable protective and decorative and provide high quality
insulation. Dry thermosetting powders like epoxy, polyesters,
acrylics, polyurethane or their combination are used. Works
under electrostatic fluidized bed techniques.

These dry powder when electrostatically charged and dispersed,

either by spray or fluidised bed applicator, form a charged
powder cloud between electrode having high negative potential
and earthed article. Under the electrostatic field the powder gets
attracted to the article and adheres to it loosely, forming a
uniform layer. This powderizes and form a tough, resilient non
corrosive film when cured in oven at 200 degree Celsius for 10
minutes.

30
 Heat Treatment
Hardening
Tempering

Hardening is used to increase the hardness quality of metals.

Tempering is used to softened the hardened metal.

Process

Put on the hardening furnace, set the temperature as per

the material to be hardened.

After the required temperature is attained put the job

inside the furnace use tray for smaller jobs.

After desired soaking time take at job and quench it in the

quenching oil for two hours.

Take out the job from oil tank and wipe with the job or
clothes.

Load the jobs in the tempering bucket put the bucket in

tempering furnace at required temperature.

After required soaking time take out of jobs and allow it to

cool in open atmosphere clean the jobs and check the
hardness using Rockwell hardness testing machine.

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Material Temp(+10°) Soaking Temp Soaking Hardness
time (+10°) (+5
(+2 min)
min)
N.p.s./hccr 850°C 0.5 hr 200°C 1.5 hr 60-62

K-4/ohns 850°C 0.5 hr 200°C 1.5 hr 55-58

Silver 850°C 0.5 hr 200°C 1.5 hr 55-56

steel

Quenching oil classifications

Quenching oil h.p.

Fas quenching oil veedol

Alb quenching oil castrol

32
 Inspections

Sampling Inspection

Sampling inspection involves inspecting a relatively small

number of items from a batch or lot and then using the results of
this sample to either accept or reject the entire lot.

The inspection frequency is 10 pieces per lot.

The parts which undergo sampling inspection and the

instruments which are used to measure following quantities are:

1. Brass Coil
Width –Vernier
Thickness – Micrometer
Hardness – Hardness testing machine
Cupping value – cupping testing machine
Grain size –

2. Drawn Tube
Outer diameter – Ring guage
Thickness – Micrometer
Hardness – Hardness testing machine

3. Steel Wire
Diameter – Guage
Tensile strength – Tensile testing machine

IPCQ

In Process Quality Check involves the inspection of parts during

process.
33
The parts which undergo sampling inspection and the
instruments which are used to measure following quantities
are:-

1. Housing- frequency : 2 hours

Blank : Outer Diameter- Ring gauge
Height- Vernier

Final Draw : Height- Vernier

Inner Diameter- Plug gauge
Draw – Template gauge
Integrated Line - Frequency : 1 hour
Height – Limit gauge
Thread OD – Ring gauge
Thread Profile –Thread gauge
Thread Depth – Comparator

2. Bottom Cap

Blank : OD- Ring gauge

Height- Vernier
Final Draw : Height- Vernier
ID- Plug gauge
Draw- Template gauge
Integrated Line : Threading- Thread gauge
Bead- Vernier
Notching- Notching gauge
Step Depth- Vernier

3. Lens Ring

Blank : ID- Plug gauge

Surface – Visual
Integrated Line : Height – Limit gauge
Across flat distance - Vernier

34
 Across corner distance – Vernier
Thread ID – Plug gauge
Lip distance – Vernier
Number of threads – Visual
Thread depth – Comparator
Step depth – Vernier
Step diameter – Vernier
Punching diameter – Vernier

4. Spring

Height – Gauge
Bottom side OD – Gauge
Number of coils – Visual
Top side OD – Vernier

Finished Goods Inspection

It involves inspection of the finished goods.

Evaluation of the defects:

1. Critical defects
Light defects
Cracking of components
Pop off defects
Missing any functional part
Prominent peeling of plated components
Peeling of aluminizing layer in the reflector

2. Major defects
Early or late lighting
Poor fitting of components
35
 Missing of non functional part
Broken glass lens
Rainbow or blooming in the reflector
Deep dents in the casing
Excessive gap between housing bottom and casing
top bead

3. Minor defects
Light dents
Poor wiping of flashlight
Poor buffing in anodized casing
Peeling defect in the rivet
Finger marks, dirty or light scratches on the lens
Dust on the reflector
Mark on rivet
Switch visual defects

36
 QA AND ISO

Company is certified from ISO.

9001 – Quality management system (all component checked by

quality inspector)

14001 – Environmental and pollution (noise pollution control

and water pollution control)

18001 – Health and safety (each workman)

Testing Machine

Vickers optical hardness testing machine

Brass coil hardness checked

Tensile testing machine

Spring tensile test

Cupping testing machine

Brass coil cupping checked

Switch life testing machine

Switch life checked

Ohsas – This occupation health and safety assessment series.

ISO –The international organisation for standardization.

37
Sub-assembly
Collection of parts put together as a unit, to be used in the
marking of a larger assembly or a final or higher item. What
may be sub-assembly at one point, however may be an
assembly at another point.

It is the assembly of small parts like spring, bail, heat sink,

switch etc.

Assembly

Component or end item comprising of a number of parts or sub-

assemblies put together to perform a specific function, and
capable of disassembly without destruction. What may be an
assembly at one point, however, may be a sub-assembly at
another.

It is the assembly of all the parts to make the final finished

product.

38
 Safety

Safety is the one of the most important aspects to be considered

inside any industry. For every industry there are some common
as well as specialized set of instructions which should be
followed inside the factory by each and every person present
working or not working.

The point which should be taken into account are as follows:

Proper insulation of the cables etc.

Proper earthing should be there.

The operator should be trained before working on the

machine.

Always wear rubber shoes.

The insulation of tool should be there.

The operation of machine should be checked time to time.

Two men should always be there at the place of fault.

Fire control system should be there and thoroughly

explained to the personnel.

39
 Conclusion
Every industry is a place where the production is done at a very
large scale and thus many processes are there and so increase
the chance of learning for the engineers who undergoes the
industrial training.

I am glad that I got a chance to do my summer training there

and I learnt a lot about many processes. Every person there was
very helping and told me theoretically and gave me practical
knowledge as well.

It was a pleasure learning there. The processes were not only

based on electrical principles but also mechanical engineering
was also combined with it and it made the training more
interesting.

Every part of the factory was with some different working and
different principles.

Workers and operators were also willingly telling about the

operations and principles of the machines.

40
 MANUFACTURING BASES OF
EVEREADY INDUSTRIES INDIA
LIMITED

Name of the Plant Location

1. Chennai
Battery Plants 2. Hyderabad
3. Cossipore
4. Tarantula (Kolkata)
5. Noida
6. Dehradun

Flashlight Plant Lucknow

Electrolytic Manganese Navi Mumbai

Dioxide Plant

Metal and Ores Plant METCO (Kolkata)

Plastic Processing Plant Noida

10
EVEREADY INDUSTRIES INDIA LTD

LUCKNOW UNIT: TEFCO

The Eveready Flashlight Company Organisation (TEFCO)

is the only flashlight plant of its parent company EIIL,
“Eveready Industries India Ltd has its head office at Kolkata.”

Mr. V.V. Giri formally inaugurated this plant on 19 February

1958. TEFCO is a light metal engineering and doing most of the
sheet metal work. TEFCO makes only the Eveready brand
flashlight plant in whole Asia. Today it produces over 10
million torches annually and employees are approximately 400
including staff members and workmen. The manufacturing is
fully automatic in this plant.

No other flashlight manufacturing company in the country

provide this kind of effluent pollution control and safety
measure as TEFCO’s main competitor is Geep, Nippo and
Novino. Due to strong marketing background and efficient sales
support TEFCO has remain a head.

Overall, in Lucknow plant around 30 models of flashlights

which are commonly known as torches are made. It was
surprising for me to know that every flashlight consists of about
30 different components. The Lucknow unit of EIIL is the only
manufacturer of torches made of aluminium, brass and plastic.

11
 CERTIFICATE

This is certify that ADARSH PANDEY student of B.tech

ш semester has completed his project titled “ Parts section,
electroplating, aluminizing & moulding department In
TEFCO” at Eveready Industries India Limited (The Eveready
Flashlight Company), Lucknow (Uttar Pradesh) under my
supervision.

He was sincere and hard working to the work assigned to

him and had a sense of responsibility towards the interest of the
organisation. I am satisfied with his project work. I wish him
best of luck for all the future endeavours.

Mr. Sandeep Guha Date: .

(Senior Personnel Manager)
The Eveready Flashlight Company, Place: .
Lucknow.

2
 BRAND EVEREADY
Eveready Industries India Limited is one of the India’s most
reputed FMCG companies. The company has a portfolio
comprising dry cell batteries (carbon zinc batteries,
rechargeable batteries and alkaline batteries), flashlights
(torches) and packed tea. It has recently forayed into the
mosquito repellent industry under brand name, ‘Poweron’.

Eveready is India’s largest selling brand of dry cell batteries and

flashlights (torches), with dominant market shares of about
46%. Eveready industry now has about 8200 employees in the
group. Eveready is certified with ISO-9002 certification for
most of its plants. Customers are well satisfied with products of
the company, and the plant is licensed by Bureau of Indian
Standards for Manufacturing of all its batteries. The new tagline
“The Next Century Of Power” affirms Eveready committed to
being technology well into the future, evolving with consumers
to meet their changing needs.

From small beginnings with an import consignment in 1905 of

Rs.500, Eveready today dominates the Indian market and stands
for portable power and light to millions of consumers. Eveready
Industries India Ltd, was originally founded in 1926 with the
name “Eveready Company (India)”. This company was taken
over by a joint stock company called “Eveready Company
(India) Limited”. On June 30, 1941 the name of the company
was changed to “National Carbon Company (India) Limited”.
On December 24, 1959, the name of the company was further
changed to “Union Carbide India Limited (UCIL)”. Recently on
April 24, 1995 UCIL was renamed as Eveready Industries India
Limited.

5
 LOGO OF EVEREADY

Story behind Eveready’s Logo, a cat jumping

through a number nine.

There has been a popular saying that cat’s have nine lives,
implying that they are hard to kill, keep coming back for more.

Eveready was trying to have you believe that their batteries

would outlast things that killed other batteries, may be by even
nine times. It was of course, a marketing exaggeration but an
effective and memorable one.

VISION OF EVEREADY

Improve the quality of the life of people

Through cutting edge, portable energy and
Lightning solution to strengthen the
Timeless appeal of our brand.
6
Milestones Of Eveready Industries India
Limited
1905: National Carbon starts its Indian operations with sale
of batteries imported from USA.

1926: Ever Ready Company India sets up the first arc

carbon factory at Canal Road, Kolkata.

1934: Eveready Company incorporated as a private

company on 12 November.

1939: Camper Down Work- first modern battery plant

established at Cossipore in Kolkata.

1941: Union batteries merges with Eveready Company and

name is changed to National Carbon Company.

1951: Renamed as Union Carbide India Limited, a

subsidiary of worldwide multinational, Union carbide
corporation.

1958: Company set its torch manufacturing plant in

Lucknow, one of the largest in south Asia.

1959: Name of the company changed to Union Carbide

India Limited.

1984: Bhopal disaster at Union Carbide India Limited plant

in Bhopal.

1996: Mc Leod Russel (India) Ltd merged with EIIL, bulk

tea business brought into EIIL fold.
8
2000: Bishnauth Tea Company merged with Eveready
Industries India Limited.

2004: Amitabh Bachhan became the brand ambassador.

2005: Brand Eveready is a hundred years old.

2009: EIIL acquires controlling stake in Uniross SA of

France, which is a leading rechargeable battery
manufacturer.

2011: Akshay Kumar became the new face of brand.

2012: The new rechargeable lantern portfolio launched.

2013: Eveready Industries launched portable power

products.

2014: Eveready Industries launched Range of LEDs.