Institutional Training report in partial fulfillment of the

Requirements for the degree of 5year MBA

[IMBA]
Institutional Training
Done by
R.M.M!I"#
$%mbi&$5
in
Amara Ra'a Batteries (td
)ara*ambadi
+hittoor,dist- A..
A/*no0ledgement

I express my sincere thanks to Mr.Ashok and Mr.Durga Prasad
HR department, ARBL and special thanks to Mrs.alpana, Mrs.!unitha "#A$, Mr.!atish
"engineer$ , %or their constant encouragement , &alua'le guidance and their extreme
support %or the success%ul completion o% pro(ect )ork.

Here I take this opportunity to express my gratitude to all the
pro%essionals )ho spent their &alua'le time in responding to my *uestions. Also, I
ackno)ledge all those )ho ha&e contri'uted either directly or indirectly %or the
success%ul completion o% pro(ect.

+inally I ackno)ledge the god almighty %or guiding me and
sho)ering his 'lessings throughout this pro(ect and I am inde'ted to my parents %or
their support at all le&els.
Index
".no
+ontents .age no
, Introduction ,
- Mission, .ision and pro%ile o% the company -
/ Detailed study o% all the %unctions in IBD
/., HR ,,
/.- #uality ,0
/./ Marketing -1
/.1 Production /2
/.3 Production 4ngineering 1,
/.5 Research and De&elopment 1/
/.0 +inance 6 Accounts 15
1 7onclusion 33
MISSION STATEMENT:
89o trans%orm our spheres o% in%luence and to impro&e the *uality o% li%e 'y
'uilding institutions that pro&ide 'etter access to 'etter opportunities, goods and ser&ices
to more people all the time.:
1ision 2$253
89hrough Amara Ra(a )ay, and through enduring progressi&e partnerships, )e
)ill 'e glo'al leader in 'atteries and 'attery technologies 6 dominant player in Indian
;cean Rim:.
PROFILE OF THE ORGANIZATION
Brief about the Promoter of Amara Raja Group of Companies:
Dr. Ramachandra <. =alla, a non>resident Indian no) settled in India is the main
promoter. Dr. Ramachandra < =alla is an 4lectrical 4ngineer %rom !ri .enkates)ara
?ni&ersity, 9irupati and has to his credit, Masters degrees in Applied 4lectronics,
Roorkee, India and !ystems !ciences, Michigan !tate ?ni&ersity, ?!A.
Dr. Ramachandra < =alla started his career as an 4lectrical 4ngineer in ?! !teel
7orporation, ?!A and mo&ed on to !argent 6 Lundy, ?!A as a consulting engineer %or
the designing o% <uclear and 7oal +ired Po)er Plant. He initiated &arious pro(ects during
his tenure and mastered the ropes o% this competiti&e 'usiness in a &ery short time.
Ho)e&er, Dr. Ramachandra < =alla )as passionate to set up a 'attery manu%acturing
plant in India. @ith a Aeal and highly %ocused approach, he esta'lished, 8Amara Ra'a
Batteries (imited:, )hich has gro)n to the top league o% 'attery companies in India.
Dr. Ramachandra < =alla had 'een the 4xecuti&e 7hairman and Managing
Director o% the 7ompany %or the period %rom Buly ,CCD to August -22/ and continued as
4xecuti&e 7hairman till August -223. 4%%ecti&e !eptem'er -223, Dr. Ramachandra <
=alla has 'een continuing as the non>executi&e 7hairman o% the 7ompany.
Dr. Ramachandra < =alla )ith his &ast kno)ledge on the 'attery industry is a
source o% inspiration %or the employees o% ARBL. Dr. Ramachandra < =alla has al)ays
'een a pillar o% strength and his inputsEad&ise ha&e 'een in&alua'le %or the gro)th o% the
7ompany. 9he 7ompany also seeks his expertise on &arious technical issues %or )hich he
pro&ides immediate suggestions and acti&ely in&ol&es himsel% in the a%%airs o% the
7ompany on a regular 'asis.
PROFILE OF THE PRODUCT/SERVICE
Battery:
Battery is the porta'le de&ice producing D7 po)er 'y electro>chemical
reaction. A potential di%%erence is de&eloped )hen t)o dissimilar electrodes are
immersed in a conducting solution called electrolyte and a current %lo) is o'ser&ed )hen
the terminals are connected.
Battery is an electro>chemical de&ice in )hich the %ree energy o% chemical energy is
con&erted into electrical energy. @ithin the 'attery, )e can store chemical energy, and on
demand it can 'e con&erted into electrical energy to dri&e an external circuit.
9he 'attery is the %uel tank o% 4lectric .ehicle. It stores chemical energy in the
%orm o% reacti&e species, i.e. "during FchargingG$ and is designed to release this energy as
electrical po)er "during FdischargingG$.
Lead>acid 'attery occupies prominent place 'ecause o% its application in the
automoti&e %ield. 9he lead>acid 'attery is the only acidic 'attery that uses an acidic
electrolyte.
Amara Ra(a Batteries Limited comprises o% t)o ma(or di&isions &iA., Industrial
Battery Di&ision HIBDI, Automoti&e Battery Di&ision HABDI.
Industrial Battery Di4ision ,IBD-3
Amara Ra(a pioneered the application o% .RLA 'attery technology in India )ith
the launch o% .o0er sta/* and Impro4ed .o0er sta/* a high integrity, long li%e 'attery
designed to take care o% 7ritical stand'y applications %or sectors such as tele
communications, rail)ays, po)er generation and distri'ution, de%ense, and the oil and
gas o%%shore. 9he success o% this technology led to its Application in ne) areas such as
moti&e po)er, ?P! and solar energy. Amara Ra(aJs 'rands in the industrial segment
include 5uanta > the long li%e ?P! 'attery.

Quanta Poe! Sta"#
I"B6

IBD IMD
,(1R(A-
,M1R(A-
+6"TM7R"3
K 9elecomL
B!<L, B4L, BH4L, <okia, !iemens.
K Po)er controlL
Raichur thermal po)er station, <orth 7hennai po)er station.
K ;il 6 gasL
9he island o% Lakshad)eep is po)ered through Amara ra(a po)er systems. Also
pro&ides 'ack>up po)er %or lo) po)er transmitters %or Doordarshan.
K Moti&e po)erL
AP7"American Po)er 7ontrol$, !iemens, Alstom..
Rail)aysL
ARBL pioneered the use o% maintenance>%ree 'atteries in Indian rail)ays. ;&er 32M
o% Indian rail)ays II 6 III 9ire sel%>generation air>conditioned coaches are po)ered 'y
ARBL. ;&er 12M o% rail)ays signaling and telecom po)er supply solutions are pro&ided
'y ARBL.
+M.7TITR"3
4xide industries Ltd.
Hydera'ad 'atteries Ltd.
=<B.
Automati/ Battery Di4ision ,ABD-3
Amara Ra(a Batteries Limited has prestigious ;4M ";riginal 4*uipment
Manu%acturer$ clients like +ord, Daimler 7hrysler, =eneral Motors, Ashok Leyland,
Hindustan Motors, 9ata Motors, Mahindra 6 Mahindra, +iat, Honda, Maruti and
Hyundai. 9he company entered the replacement 'attery segment )ith the launch o%
Amaron 'rand o% automoti&e 'atteries in Banuary -222.9hese are the %irst Aero>
maintenance, high per%ormance and long li%e 'atteries, )ith long term )arranty periods in
these categories and ha&e 'ecome the 'enchmark %or *uality and relia'ility in their
respecti&e %ields. 9he company has recently entered into the upcountry markets )ith
.o0er 8one 'rand o% economy 'atteries. Po)er None is a chain o% %ormatted retail stores
o%%ering po)er solutions %or automo'ile and household applications. Batteries are made
to the speci%ic standards o% I!; C22,, #! C222 and I!; ,122,and 9! ,5C1C certi%icates
using )orld> class 9echnology and *uality> controlled parameters.
.RD6+T"3
Amaron highli%e
Amaron har&est
Amaron shield
Amaron hi>)ay
+6"TM7R"3
ARBL has prestigious ;4M";riginal 4*uipment Manu%acturer$ clients like +ord =eneral
motors, Dae)oo motors, Mercedes O recently ac*uired a pre%erential supplier alliance
)ith Ashok Leyland , Hindustan motors, 9elco, Mahindra6Mahindra, Hyundai.
R9A!I8ATI! D7"I9! A!D "TR6+T6R73
;rganiAation design is the process o% aligning an organiAationJs structure )ith its
mission. 9his means looking at the complex relationship 'et)een tasks, )ork%lo),
responsi'ility and authority, and making sure these all support the o'(ecti&es o% the
'usiness.
Amara Ra(a Batteries Limited "ARBL$ %ollo)s di&isional structure. In a
di&isional structure, the company is di&ided into 'usiness di&isions, )here each 'usiness
di&ision is autonomous and typically structured along %unctional lines.
D7TAI(7D "T6D: ; A(( T#7 ;6!+TI!" I! IBD
IBD<#R
#6MA! R7"6R+73
9he HR and Administration organiAation o% Amara Ra(a is %ormed )ith an aim to pro&ide
all the support the 'usiness needs at the right time.
9he %irst le&el organiAation structure is illustrated 'elo)

Business #R3
9he role o% 'usiness HR is the %ront %ace o% human resources %or the respecti&e company E
'usiness. 9hey ha&e to handle end to end o% HR %unction at the company E 'usiness le&el
spanning across all locations )here&er the 'usiness operates "e.g. 'ranches, )arehouses,
7;; P 7orporate o%%ice 6 plant$ > %rom recruitment to resignation/retirement.
Talent A/quisition +ell3
9he mem'ers o% this department are responsi'le %or procurement, recruitment and
selection o% candidates in the group companies. Legacy system is the currently existing
system in the organiAation and it is RAM7; system.
4nterprise Resource Planning "4RP$L it is the integration o% all the departments and
modules that are there in the organiAation. It acts as a catalyst in the organiAation.
+or starting any kind o% recruitment in or o%% the organiAation %ollo)ing steps are
%ollo)edL
G!ou$ HR Head
%u&'ne&
& HR
HR
S(a!ed
Se!)'"e&
T!a'n'n* and
De)e+o$,en
t
Ta+ent
A"-u'&'t'o
n Ce++
PMS .
Pe!/o!,an"
e
Mana*e,en
t S0&te,

"our/es of Re/ruitment3
K 7ampus Placements "AR=MP, AR=9P$
K ;%% 7ampus
K <e)s paper ad&ertisements
K Bo' portals
K 4mployee Re%errals
K Head hunting
K 7onsultancies
AR9M.>Amara Ra(a =raduate 6 Management 9rainees Program "4ngineering
=raduates 6 Management courses students are recruited$
AR9T.> Amara Ra(a =raduate 9rainees Program "All Diploma trades 6 Degree
students are recruited$
ART" > Amara Ra(a 9rainee !cheme "!tudents %rom ,2
th
7lass, Intermediate and I9I are
recruited$
"ele/tion .ro/ess
Budget Preparation
(Man power
requirement)
Approval of Budget from
respective LOFs
Job escription
!dentif"ing sources of
recruitment
!nformation provided to
#P($%)
&at'ering ( )crutini*ing
%esumes
+alling for written test,
interview
)electing +andidates
All the trainees undergo one year training and six months pro'ation period.
HRSS HR Shared Services:
Service matters & Statutory measures:
Service Matters: 9he executi&es o% this department do the 4RP updation o% all the
details o% ne)ly (oined, internal trans%erred or trans%erred employees to di%%erent
locations.
4RP detailsL
K 4mployee 7ode
K 4mployee Id
M9 "Management 9rainees$ MBAs, B.9echEBBMEBBA>MBA,
=49 "=raduate 4ngineering 9rainees$ B.9ech, B4
A9 "Assistant 9rainees$ B.7om 6 BA
99 " 9echnician 9rainees$ All Diploma 9rades
9A9 "9echnician Assistant 9rainees$ B!c
9RAD7" D7"I9!ATI!
M, 7hairman 6 Managing Director
M, 7hie% +inancial ;%%icer "=roup$
M- .ice President
M/ =eneral Manager
M1 Deputy =eneral Manager
M3 !enior Manager
M5 ManagerE Branch Manager
M0 Assistant Manager
MD !r. 4ngineerE!r. 4xecuti&e
MC 4ngineerE 4xecuti&e
!, Bunior ;%%icer
!- !uper&isor
!/ Assistant II
!1 9echnician
!3 Assistant I
@, @orkman
@- @orkman
@/ @orkman
@1 @orkman
@3 @orkman
Management =rades
)taff &rades
-or.men &rades
Joining Formalities Job specification )ending Offer Letters (
%eceiving ac.nowledgement
K Personal in%ormation
K +amily Details
K Academic Details
K 4xperience
"tatutory "er4i/es : +i&e ma(or actions are taken care 'y the statutory ser&ice executi&e.
9hese areL
K Pro&ident +und "P+$
K Pension
K 4mployee !tate Insurance "4!I$
K 4mployment 4xchange "44$
K Payment o% =ratuity
K Bonus
Time offi/e3
9his department is responsi'le %or the maintenance o% attendance o% all the employees in
the Head o%%ice and 'ranches. 9hese people deal )ith Amara Ra(a Attendance
Management !ystem "ARAM!$ using so%t)are program called F!olusG.
Responsi'ilitiesL
K 7ollecting photos and details %or distri'uting Identity cards.
K ;pening Bank accounts %or ne)ly (oined employees.
K In%orming all the H;DGs to authoriAe the pending applications 'e%ore -3
th
o% e&ery month.
K !ending attendance details o% all the employees to pay roll %or salaries.
.ay Roll3
9he executi&es o% this department are responsi'le %or gi&ing the )ages %or all the
employees in the organiAation.
Training = De4elopment3
. 9he training needs %or !ta%% and Management grades ha&e 'een identi%ied
through the 4lectronic Per%ormance Appraisal !ystem "AR4PA!$.
9his department is responsi'le %or preparing the training calendar and schedules
%or the training programs %or the employees across the group companies. Amara Ra(a
Training 6 De&elopment +alendar.
9raining is o% t)o typesL
,. ;n the (o' training.
-. ;%% the (o' training
n the 'ob training ,>T-
4mployee training at the place o% )ork )hile he or she is doing the actual (o'. ?sually
a pro%essional trainer "or sometimes an experienced employee$ ser&es as the course
instructor using hands>on training o%ten supported 'y %ormal classroom training.
ff the 'ob training
4mployee training at a site a)ay %rom the actual )ork en&ironment. It o%ten utiliAes
lectures, case studies, role playing, simulation, etc.


IBD < 56A(IT:
5uality Assuran/e3
De%inition o% *ualityL>89he characteristic o% a product or ser&ice that 'ear on its
a'ility to satis%y stated or implied needs.: ;r it can 'e simply said as 8%itness %or use: or
:con%irmation to re*uirements: or 8D4+479 +R44 PR;D?79:.
#uality o% a product or ser&ice can 'e assured i% it is %ree o% de%iciencies.
9he process o% inspecting the *uality can 'e done as sho)n 'elo)
a- In0ard Inspe/tions3
Initial checks %or the machines
Lathing )ill 'e done %or sample 'e%ore testing in ;ptical 4mission !pectroscopy
";4!$ P Determination o% ma(or alloy and trace elements in lead and lead alloys.
/ualit" !nspections
!nward
!nspections
!n process
!nspections
Atomic A'sorption !pectrophotometer "AA!$ P Determination o% ma(or alloy and
trace elements in lead and lead alloys, pure metals, impurities in pasting
chemicals and 'attery electrolyte.
Determination o% 9hickness o% A=M !eparators
Determination o% )icking o% A=M !eparators
Acid retention 9est o% A=M !eparator
Determination o% Ash content and ignition loss in materials at higher temperatures
Moisture AnalyAer %or PP7P granules
Determination o% Density %or PP7P
M+I "Melt +lo) Index$ tester %or PP7P granules
IAod Impact 9ester %or PP7P
?9M"?ni&ersal 9esting Machine$ tester %or PP7P granules
.eri%ication o% Percentage particle siAe in po)der materials
b- In .ro/ess Inspe/tion3
Verification of Oxide Properties:
+ree lead &eri%ication in lead oxide po)der
Apparent density o% lead oxide po)der
hec!s in "rid asting:
=rid @eight .eri%ication 'y using )eighing scale
=rid 9hickness .eri%ication 'y using Micrometer
hec!s in Pasting:
.eri%ication o% Paste density
Plate )eight &eri%ication
hec!s in #ars/ontainers mou$ding:
Bar Height measurement during De>Molding>Immediately a%ter In(ection Molding
Bar Height measurement a%ter Ageing
!n process !nspection
Plate
Prepetation
paration
O0ide
Preparation
&rid
+asting
Jars,+ontainer
s Moulding
Assembl"
Formation
Finis'ing (
ispatc'
hec!s in %ssem&$yL
.eri%ication o% =roup 9hickness
.eri%ication o% Mounting Height 'y .erniar
.eri%ication o% Bar Height 'y .erniar
Air pressure 9est on Assem'led cell
.eri%ication o% 7ell Dimensions
hec!s for 'odu$ar:
Lug 7rystalliAation test
Lug to !trap 'onding test
Post and 9om'stone test
Leak 9est on Assem'led 'attery
hec!s in (ormation:
Acid temperature &eri%ication
Acid .olume cali'ration and PL7 setting
4lectrolyte temperature &eri%ication during %ormation
,22M 7apacity &eri%ication
hec!s in (inishing:
9hermal 9hread &eri%ication
;7. 6 polarity &eri%ication
hec!s in )ispatchL
,22M #uantity &eri%ication o% 7onnectors
.eri%ication o% Accessories in the packing 'ox
9ypes o% customer complaints that ARBL"Amara Ra(a Battery Ltd$ deals )ithL
+6"TM7R +M.(AI!T"
I!T7R!A( 7?T7R!A(
,"e/tion<"e/tion /he/*s
@ithin the organiAation-
In/oming 0arranty
I!+MI!93 Missing o% accessoriesO
@ARRA!T:3 Based on customer needs or speci%ications.
There are se4eral statisti/al tools 0hi/h help in ta*ing /orre/ti4e a/tions 0hi/h are
used in 5uality assuran/e department3
K 7heck sheet
K !trati%ication
K Pareto analysis
K Brain storming
K 7ause e%%ect diagram
K Histogram
K =raphs
K !catter diagram
K +lo) diagram
K 7ontrol charts
9he types o% audits that Amara Ra(a deals )ithL
De%inition o% AuditL 9he general de%inition o% an audit is an e&aluation o% a person,
organiAation, system, process, enterprise, pro(ect or product. 9he term most commonly
re%ers to audits in accounting, 'ut similar concepts also exist in pro(ect management,
*uality management, and energy conser&ation.
A6DIT"

I!T7R!A( 7?T7R!A(
I!T7R!A( A6DIT"
P 9o esta'lish )hether practices %ollo) procedures
P 9o highlight re*uired changes to procedures to ensure that they accurately
re%lect *uality practices
P 9o recommend opportunities %or impro&ements
Internal audits are conducted once in 5 months %or H; 6 7;; operations. And once in
,- months %or +ield operations
T61 A6DIT"
P !ur&eillance audit P e&ery year
P Re>certi%ication audit P once in / years
IBD<MAR)7TI!9
9he marketing department o% Amara Ra(a is di&ided into six regions headed 'y six
regional managers and is incorporated )ith -, 'ranches across India ha&ing /,
)arehouses, ,52 %ranchises and o&er ,3222 retailers.
9he marketing %unctions and acti&ities that are carried out in 7;;. @hole Marketing
section is di&ided into three channels according to 'usiness strategies

Dire/t Business
In direct marketing 'usiness products are pro&ided directly to customer.
Here %lo) o% product is gi&en 'ello)

9here is no need o% 7hannel %or
Rail)ays
9elecom
Po)er control
;4Ms
(ist of 7M /ustomers3
+ord India Ltd
Huyndai Motor India Ltd
Maruthi ?dyog Ltd
Ashok Leyland Ltd
9ata Motors Ltd
Mahindra 6 Mahindra Ltd
MARKETING
CHANNEL %USINESS E1PORT
%USINESS
DIRECT %USINESS
H2O 3ARE HOUSE END USER
+orce Motors
=eneral Motors India Ltd
International 9ractors Ltd
!)ara( MaAda Ltd
Mar*eting ;un/tionsBA/ti4ities ,7MCs-3
Market promotion o% the product.
Processing o% customer en*uiries.
Preparation and su'mission o% proposals.
Processing o% purchase orders and purchase order amendments.
Monitor product deli&ery, product per%ormance and ser&ice le&els to customers.
Implementing good housekeeping methods at the related areas.
Maintenance o% departments recordsE%iles,
MI! generation o% )eekly acti&ity reports "@AR$ and monthly reports "MR$.
7ustomer relationship management.
+hannel Business
In this marketing system product %lo)s thro) a channel.
7Dport Business
In it products are exports to outside o% country. ;ur 'atteries are exported to !ingapore ,
Malaysia , Indonesia , 9ai)an , Philippines , =reece , Australia , u)ait , Du'ai , 7hina
and Bapan .
4xport can 'e categoriAed into three
Direct
Merchant
!4N P!pecial 4conomic None
H2O 3ARE HOUSE FRANCHISE RETAILER CUSTOMER
Mar*eting3
9he marketing acti&ities are per%ormed to meet the customerGs re*uirements.
9he acti&ities includeL
4n*uiry E 9ender Re&ie)
!u'mission o% ;%%ers
;rderE 7ontract Re&ie)
;rder Ackno)ledgement
;'taining order amendments
Handling o% customer complaints
@eekly Acti&ity Report
Appointment o% channel partners
Re&ie) o% pending payments
4ngineering and Marketing 7oordination meeting
b'e/ti4es3
Meeting the sales targets as per the 'usiness plan
7ollection o% payments as per P; 9erms
Meeting the customer re*uirements E expectations
Pro&iding necessary training programs %or sta%% E customer personnel
"er4i/e3
Main acti&ities that are per%ormed 'y ser&ice departmentL
4nsuring 7ustomer !atis%action through prompt 6 e%%icient ser&ice to customers
Monitoring Product Per%ormance, %eed'ack to R47 %or product impro&ements
Mar*eting "er4i/es3
;un/tions3
9o assist in planning and execution o% marketing acti&ities
7o>ordination )ith the Ad&ertising agency, 4&ent Management agency, Market
Research agency and Pu'lic Relations agency %or Promotions and product
de&elopment
!upporting %ield o%%ices in promotional acti&ities and e&ents
Identi%ying and De&elopment o% Point o% Purchases
Monitoring Budgets o% Promotional spends
=eneration o% MI! reports> Ad spends monthly and *uarterly
9o assist in planning and execution o% Automoti&e, Industrial, 7orporate,
International 6 =roup 7ompanies
Mar*eting stru/ture of ARB(
IBD MAR)7TI!93
T7(7+M3
In telecom sector )e pro&ide our 'atteries to
;perator> Airtel, .oda%one, B!<L etc.
Manu%acturer
RAI(@A:"3
Rail)ays !ector
Rail coach %actories
4ngine manu%acturer
INDUSTRIAL
%ATTER4
DIRECT
RAIL3A4S P2C E1PORT TELECOM U2P2S
CHANNEL
.@7R +!TR(3
Po)er sector
,. =eneration
-. 9ransmission
/. Distri'ution
;il and gas
Rene)a'le energy
Moti&e po)er
!ecurity
7?.RT3 4xports to
7oslight
Hopake
+iam
4<7I4! "= 6 B$
76D etc
+#A!!7(3 In Industrial Batteries ?.P.! Batteries comes in channel marketing

8!A( ;;I+73
In e&ery Aonal o%%ice there is a Nonal 7hampion "N7$. 9here are total %i&e N7.
COO
ZONAL OFFICE
BRANCH OFFICE
CUSTOMER
SERVICE
H.O
AQUA
BRA!+# ;;I+73
9here is a Branch Manager in each Branch ;%%ice.
9here are total ,3>,5 B.Ms. Marketing 4ngineer comes under Branch Manager.
A56A3
A*ua is (ust like a +ranchise %rom )here either end>user or Retailer can 'uy directly

IBD < .RD6+TI!
.rodu/tion of a battery3
About a Battery3
Battery is the porta'le de&ice producing D7 po)er 'y electro>chemical reaction. A
potential di%%erence is de&eloped )hen t)o dissimilar electrodes are immersed in a
conducting solution called electrolyte and a current %lo) is o'ser&ed )hen the terminals
are connected.
Battery is an electro>chemical de&ice in )hich the %ree energy o% chemical energy is
con&erted into electrical energy. @ithin the 'attery, )e can store chemical energy, and on
demand it can 'e con&erted into electrical energy to dri&e an external circuit.
9he 'attery is the %uel tank o% 4lectric .ehicle. It stores chemical energy in the %orm
o% reacti&e species, i.e. "during FchargingG$ and is designed to release this energy as
electrical po)er "during FdischargingG$.
Lead>acid 'attery occupies prominent place 'ecause o% its application in the
automoti&e %ield. 9he lead>acid 'attery is the only acidic 'attery that uses an acidic
electrolyte.
Batteries can 'e 'roadly classi%ied into primary and secondary, depending upon the
reactions in&ol&ed )hether irre&ersi'le or re&ersi'le and application.
Primary 'atteries are not capa'le o% 'eing charged electrically and hence discharged
once and disposed. 9he primary 'attery is con&enient source o% supplying po)er to
porta'le electrical and electronic de&ices.
!econdary 'atteries can 'e recharged electrically a%ter discharge to their original
condition 'y passing electricity through them in the opposite direction to that o% the
discharging current.
Main +omponents of Battery3
Positi&e acti&e material P Lead dioxide "P';-$
<egati&e acti&e material l P !pongy lead "P'$
4lectrolyte P Dilute sulphuric acid "H-!;1$
7urrent collectors "grid$ P Lead alloys
!eparator P Polythene, =lass Mat, A'sor' =lass Mat
7ontainer P PP7P, +RPP7P
Alloys used in Manufa/turing of Batteries3
(ead3
9he ma(or alloy used in lead>acid 'atteries is lead. 9he density o% casted lead is
,,./1, 'ut this may 'e slightly increased 'y rolling. 9he melting point o% lead is /-0.1
2
7
"5-, +$. It oxidiAes readily in the moist air, 'ecoming a dull gray.
Alloying elements to pure lead
Antimony
7alcium
Aluminum
7admium
9in
!il&er
IBD .ro/ess flo0 /hart3

Oxide Preparation
Assembly
Formation
Plate Cleaning
Grid Casting
Paste Preparation Pasting
Finishing Dispatch
Curing & Drying
& A. ?ID7 .R7.ARATI!3
BaloD lead oDide plant3
Barton pot process is used to make leady oxide po)der. CC.C0M pure lead is used to
prepare oxide po)der.
;xide plants ,6- )orks on Barton process )here the lead ingots )ere melted and
oxidiAed in the presence o% air.
9he %ollo)ing are the process parameters that are maintained during the preparation o%
oxide po)der.
Melting pot temp L 553Q,3+
Reactor pot preheating temp L 1-3Q,3+
<ormal operation temp L 0,3Q,3+
Reactor motor load L /3 to 13 amp
Bag house temp L -22Q-2+
.ro/ess flo0 /hart3
.ro/ess3
Lead ingots are placed on ingot con&eyor through (i' crane )hose max capacity is 322
kgs.
Ingot con&eyor is a po)er dri&en roller con&eyor )hich con&eys the ingots to the melting
pot
Lead ingots Melt pot
%eactor pot
+"clone
Bag 'ouse
)torage silo
)here the lead ingots )ere melted )ith the help o% heaters. 9he temperature is
maintained at 532 to 5D2+ in the melting pot. 9he centri%ugal pump collects the molten
lead and pumps it to reactor pot through the lead trough.
9he molten lead is %ed into the reactor pot and is 'roken up into droplets 'y re&ol&ing
paddle. A stream o% air 'lo)n o&er the droplets oxidiAes the lead. In the classi%ier the
re*uired particle siAe range is separated and the coarser material is returned to the reactor
pot.9he resulting oxide po)der is carried 'y air stream into the cyclone )here the
po)der %urther disintegrated due to the )hirling action.9hen it is mo&ed to 'ag house
)hich consists o% num'er o% %ilters. It separates the air %rom the po)der )ithout the loss
o% oxide po)der. silos )ere used to store the leady oxide. 4ach silo is ha&ing a capacity
o% -3 ton. oxide po)der is stored in the silos 'e%ore the paste preparation.
9he %ollo)ing are tested to e&aluate the *uality o% leady oxide.
,. +ree lead percentage "speci%ic limits are ,D to -DM$
-. Apparent density "speci%ic limits are ,./ to ,.DgmEcc$
/. Acid a'sorption"speci%ic limits are ,52 to -22mgEg$
* +. "R,) %S-,.":
Model //2c grid casting machine
Melt the ingots in the lead pot. Maintain the lead pot at a temp o% 103 to 3-3+.
!tart the %eed line heaters. 9his molten metal is pumped to the ladle through solenoid
&al&e. 9his actuates the lead &al&e to dispense the lead into the mould. Ladle is
maintained at a temp o% 132 to 322+.
7ooling circulation system %eeds cold )ater during the solidi%ication and e(ection
o% mould.
9he casted grid is passed through the rollers to make it %lat or to remo&e any
de%ormation in the grid.
=rid centering mechanism centers the grid.
Hydraulic mechanism actuates the trimmer )hich remo&es the gates o% grid.
Types of grids3
,.Po)er stack type >>> -2, /2, 12, 32, 52, D2, C2
-.IP series >>>>>>>>>>>>>>> IP,, IP-
+ommon defe/ts in grids
High thickness
Lo) thickness
!hrinkage
Miss trimming
Blo) holes
+lashes
@ire missing
Testing of grids 3 =rid thickness, !trength, @eight.
Bend Test3
9o %ind strength grid is 'ent and checked %or any cracks
and then at C2 degrees to the %irst. I% there are any
consecuti&e cracks, then it )ill 'e re(ected.
B6" BAR +A"TI!93
9he copper inserts are threaded into the holder and are
dipped in %lux %or 3sec. 9hen dip these inserts in tinning pot
%or /2sec. 9his tinning pot consists o% molten alloy o%% tin>
lead "12>52$.
Place the insert along )ith the holders in the mould.
Pour the molten lead alloy )ith -Mtin pouring should 'e
completed in a time a span o% D>,3sec.the molten metal is
solidi%ied the mold and they can 'e remo&ed %orm the
moulds. 9he 'us 'ars are remo&ed %ormed %rom the holders.
9he tinning pot is maintained at a temperature o%
/-2Q-3
2
7 )hile the lead cruci'le temperature is 152Q,3
2
7.
9hese 'us 'ars are sent %or group 'urning is assem'ly stage.
2. .A"T7 .R7.ARATI!3
;or .ositi4e .aste3
Lead oxide ,222kg
Binder 2.3g
!P9H -g
DM )ater ,-5lt
!ul%uric acid ,,2kg"!p. gra&ity ,.1$
;or !egati4e .aste3
Lead oxide ,222kg
Binder 2.3g
Barium !ulphate -2g
.anisperse -g
7ar'on Black -g
DM )ater ,,5lt
!ul%uric acid ,,2kg"!p. gra&ity ,.1$
.ro/ess flo0 /hart3
#uality tests %or pasteL
,. Density test
-. Penetration capacity
/. Moisture content
.A"TI!93
Pasting is done on Industroma/ pasting ma/hine.
Paste mix prepared in the oDmaster plant is trans%erred to the
hopper o% the pasting machine. 4nsure that the grids ha&e
under gone aging %or R&e -1 hrs.
+ill the hopper /E1
th
each time. =rids )ere made to pass
through )ith the help o% con&eyor. Paster pastes grids to a
thickness e*ual to ori%ice opening. It is the gap 'et)een
hopper ori%ice plate and 'ottom ori%ice
plate. As the grid panel gets close to hopperGs entrance it is
pulled a)ay %rom chain dogs 'y a set o% accelerator rollers.
9he panel is then pushed into dri&e rollers that mo&e it into
paste application area. 9he paste is applied through the grid
structure 'y paste %eed roller that is located in upper ori%ice
Binder Oxide dumping Dry mix
Acid dumping
Wet mix
Water dumping
Final mixing Paste
For Pasting
plate. 9he 'ottom ori%ice plate rollers tro)el the paste on the
underside o% grid.
A%ter stacking, the stacked plates )ere trans%erred to
curing and drying o&ens. Be%ore that the plates are to 'e
undergo aging period. 7uring and drying is the process 'y
)hich satis%actory le&els o% cohesion and adhesion are
imparted to the acti&e material prior to plate %ormation and
are maintained there a%ter. In addition, curing ensures a
highly de&eloped sur%ace area.
E. +6RI!9 A!D DR:I!93
7uring and drying is done at three stages. .
7uring
Intermediate stage
Drying
7uring and drying process is carried out to impart
cohesion and adhesions are imparted to the acti&e material
prior to %ormation. 7uring is determined 'y the nature and
degree o% interlocking 'et)een the crystals o% the paste.
Adhesion is dependent upon the strength o% the 'ond, )hich
is %ormed 'et)een the paste and the grid. 9hese essential
properties are the 'est accomplished 'y conducting the curing
procedure in the %ollo)ing se*uence.
!teaming periodL !team is applied to e*ualiAe the moisture
content in all the plates and it supports %or the de&elopment o%
lead sulphates.
Drying process is to 'ring do)n the )ater content "moisture$
to the lo) le&el %or the acti&e material to ha&e good sta'ility.
During the process physical, chemical and morphological
changes take place )ithin the acti&e material.
5. A""7MB(:3
.ro/ess flo0 /hart3

Plates, eparator,
!op shields
Group tac"ing
#ars
Group Burning
Group trapping
Post Burning
$eat ealing
Group %nsertion
&ea" !esting
Co'ers
Bus Bars
Du(( Cells
A. 9roup sta/*ing3
Bottom shield is place in the %ixture this pre&ent the plate damage. +irst an un)rapped
negati&e plate is placated the in the %ixture. 9hen a hal%>length separator is placed on the
negati&e plate.
9he separator is sheared 'y acti&ating the cutter 'lade a%ter getting the prede%ined
length.
9hen positi&e plate is place and separator is %olded o&er this plate. Place the hal%>
length separator on the last positi&e plate and then place un)rapped negati&e plate on
the top o% the hal% length separators complete the stack.
!hields are pro&ided on positi&e plates to a&oid direct contact 'et)een positi&e and
negati&e plates.
B. 9roup burning3
Aligning o% 'us 'ars )ith lugs is called group 'urning.
By using the protection o% (igs these com's can 'e shield rightly.
Ad(ust the oxy>acetylene gas torch %or neutral %lame and length o% inner cone is -.3cm
Positi&e strap is 'urnt %irst as i% re*uires more time %or cooling.
9he molten metal is stirred )ith them.
9he post protection (igs are chilled )ith D.M )ater and then they )ere remo&ed.
+. 9roup strapping3
Plates )ere strapped on strapping machine )ith poly>propylene. 9hese straps held the
stacks together.
D. 9roup insertion3
9he strapped plates are inserted into (arsEcontainers shield in )rapped on the plates 'e%ore
insertion.
7. #eat sealing3
9he co&er is placed o&er the (ars such that the posts can slide inside the 'ushing. 9he
heaters are maintained at a temperature o% range 112>1D2+. +irst takes ,2sec %or melting and
other ,2sec %or )elding them together.
9he co&ers must 'e positioned so that the polarity marking on the co&er corresponds to
proper postE'using location.
;. .ost burning3
+ix the dummy &ent plug. 7opper inserts )ere pre>heated using inner %lame until the post
lead starts melting. ;rthophosporic acid is applied on post and 'ush o% the co&er. 7ontinue
the process until good sur%ace is o'tained.
9. (ea* testing3 9he pressure inside the cell is increased to 53kpa %or the range o% -2>/2sec.
)hile it is placed in )ater 'ath. ;'ser&e %or air 'u''les i% any leak exists mark the area %or
re)ork. I% &ent is )eak replace the &ent.!erial num'er is punched on the cell
7DL 20 ,E- CCCCCC
20 indicates year
,E- indicate assem'ly line
CCCCCC indicate type or model "i.e. the no o% 'attery coming out o% the line in the year$
F. ;RMATI!3
+ell pa/*ing3
9he cells are placed in tu' and packed )ith PP7P spacers and strapped )ith metallic 'ale
the cells are connected in series using ca'le connectors and 'olts.
.ro/ess flo0 /hart3
Du(( Cell Acid Filling
%nitial Charge
Formation Discharge
Capacity )echarge
Capacity Discharge
Formation Charge Bac"
Float Charge Formed Cell
A/id filling3
At the %irst the &olume &essel is %illed up to the present &olume. 9he cycle starts 'y
pulling the &acuum in the 'attery until preset &acuum le&el is reached. 9hen the acid is
trans%erred %rom &olume &essel to the expansion &essel.
9he &enting &al&e pro&ided on top o% the machine )ill open and 'ecause o% &acuum in
the 'attery causes an air stream )hich )ill %orce do)n the acid into the 'attery. I% there is still
electrolyte in expansion &essel another &acuum pulse )ill 'e pulled.
G. ;I!I"#I!9 = D7".AT+#I!93
9he %ormed 'attery is closed )ith &ent plug and )ashed )ith )ater to remo&e any acid
present in the 'attery container outside.
9hen it is checked %or their prescri'ed integrity in 8;<>LI<4 HI=H RA94 DI!7HAR=4:
tester. 9he 'atteries, )hich satis%y the speci%ication is packed and la'eled.In dispatching the
cells )ere packed and the necessary accessories re*uired %or %unctioning o% the cells is
supplied to the customer. 9he accessories include connectors, 'olts, )ashers, ca'les etc.
9his %inished product is sent to Market through shipment 'y lorries, trucks, etc.


IBD H .RD6+TI!
7!9I!77RI!9
+ompanyCs produ/tion engineering
A%ter the order o% the products %rom the customers reach the marketing department, the entire
details )ill 'e gi&en to Production 4ngineering people. 9he &arious departments in
Production 4ngineering are as %ollo)sL
Product )eve$opment:
9his department is responsi'le %or
Design and de&elopment o% a ne) product as per the speci%ications gi&en 'y the
customer.
Ma(or design changes in the existing product.
7reation o% master product structures in !AP.
Process ,mprovements:
9o change the existing process o% designing to increase the e%%iciency.
9his department is completely responsi'le %or process +M4A, Process Audits.
%pp$ication /ngineering:
Design and de&elopment o% Accessories such as containers o% 'atteries )ill 'e done.
Battery siAing.
<e) application study o% the products )ill 'e done.
Production 1ngineering
Product
evelopment
Process !mprovement Application
1ngineering
IBD H R7"7AR+# A!D
D717(.M7!T
+ompanyCs R=D
9he 7ompanyGs research and de&elopment %ocuses on %uturistic energy solution that enhances
the price>&alue proposition. 9he R6D team consistently %ocused on technology excellence,
creating products complying )ith exacting standards and customer needs.
9he ;rganiAation structure o% R6D is as %ollo)sL
,$ +undamental Material De&elopment ,$ 9esting department
!tudies department -$ Process De&elopment
-$ 7ali'ration La'
/$ 7hemical La'
(undamenta$ Studies )epartment:
9his department is completely responsi'le %or impact analysis o% the change that )ill
'e done. +or example, i% the composition o% the lead alloy in the 'attery should 'e
changed and tasted, then the impact o% that change need to 'e analysed and study
reports should 'e prepared.
9his impact analysis )ill 'e gi&en to Material De&elopment department.
a$i&ration 0a&:
Instruments used )ill 'e checked in the la' to o'tain accuracy.
hemica$ 0a&:
Reports o% chemical analysation )ill 'e prepared.
#P
&M
Manager 1ngineer Manager
'ateria$ deve$opment:
9his acti&ity is 'asically %or impro&ing product per%ormance. 9he responsi'ilities in this
department are
7hecking the output o% the 'attery a%ter replacing the main component o% the 'attery
)ith alternati&e material.
Recei&ing the existing materials %rom ne) suppliers and checking.
De&eloping di%%erent com'inations o% lead and other components.
-esting )epartment:
Bench marking o% competitor 'atteries )ill 'e done.
De&eloping testing en&ironment and conditions as per the customer re*uirement.
Process )eve$opment:
De&elopment o% import su'stitutions and ne) products %or di%%erent applications.
IBD<;I!A!+7
+!+(6"I!3
+inally I )ould like to conclude that the institutional training helped me in enhancing the
practical kno)ledge as )ell as to gain personnel skills to sustain in the organisation.
I ha&e o'ser&ed some aspects that in %ollo)ed in the ARBL like the discipline , the culture in
the organisation, )orking en&ironment, code o% conduct, and the %acilities pro&ided and also
the sa%ety measures and ecological sa%ety taken at the )orkplace.
Amara Ra(a 'atteries Limited %ollo)s the hierarchial organiAation structure, )herein )hen
su'di&ided %ollo)s the di&isional structure, )here the organiAation is di&ided into 'usiness
units )ith its managers headed 'y the MD, )ith its respecti&e %unctional lines under 'usiness
unit heads.
9his structure suites the %lo) o% the organiAation as it has main ad&antage )here each
di&ision is %ree to concentrate on its o)n per%ormance.