seminar on industrial training
TRANSCRIPT
8/11/2019 Seminar on Industrial Training
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By
Manisha Trivedi
E.I Final Year
SEMIN R ON
INDUSTRIAL
TRAINING
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BOUT
KORTEK
ELECTRONICS
“ Kohin Electronics” touched the Indian shore way back in 2000
and thus a new era in Indian consumer electronics
began with founding of Kortek Electronics by Mr. Y.M. Yoon.
Kortek Electronics in a short span of six years set up two
state-of- the art manufacturing facilities.
KORTEK provides its customers with world-class electronics products through a network of manufacturing facilities spread
across India.
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Vision
To strive to become the most respected cherished company in our chosen
field through innovative, excellent and quality product with customer
delight at the core of every business process.
Mission
Kortek Electronics has a mission to benefit the society through
innovative and user friendly product which add value to people’s life
striving for human development at all endeavours it undertakes
.
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Manufacturing Facility
Manufactures Export quality products through latest technology SMT units.
KORTEK has one of the largest and most advanced manufacturing facilities in the
country today.
Emerged as a Korean MNC in the field of electronics, making its presence in India by
doubling its turnover year by year, striving for customer delight.
Manufactures export quality DVD player, Video karaoke system, Remote control
of AC & CTV , Auto insertion & manual insertion of CTV & Monitor
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P
RODUCT
C
ATEGORIES
Mp3 player DVD player
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PRODUCT CATEGORIES
Microphone Karaoke system
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C
ERTIFICATION
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KORTEK
has one of the largest and most advanced manufacturing
facilities in the country today. The manufacturing centers are spread
across the following locations.
Set Top Boxes : 1 00 000/Month
Auto Insertion :
1 50 000
PCBs/Month
SMT : 1 00 000/Month
Remote Control :
4 25 000/Month
Manual Deck Assy : 1 25 000/Month
Greater Noida:
Located in the Industrial Area just off Surajpur, Kasna Road, equidistant
from Delhi, Noida & Ghaziabad. It was developed in the late 2000 with a
strong corporate identity.
Capacity:
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Final
Assy.
DVDs :
1 00 000/Month
DVD
Remote
Control :
1 00 000/Month
Karaoke
Mikes :
3 500/Month
Rudrapur:
It is a small and beautiful town with all basic modern
facilities. In vicinity of Nainital, this is the most prosperous town of
Uttarakhand.
Capacity:
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KORTEK ELECTRONICS,
G
REATER
N
OIDA
Auto Insertion Department
Manual Insertion DepartmentSet-Top Box Department
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What is a PCB?
A printed circuit board, or PCB, is used to mechanicallysupport and electrically connect electronic components
using conductive pathways, or traces , etched from copper
sheets laminated onto a non-conductive substrate. It is
also referred to as printed wiring board (PWB) or etchedwiring board. A PCB populated with electronic
components is a printed circuit assembly (PCA), also
known as a printed circuit board assembly (PCBA).
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Forming an AI CTV PCB assembly
Insertion of components :
Surface mount: In this technique components that
had smaller metal tabs or end caps were designed so that they
can be directly soldered onto PCB. This increased the Circuit densities
because the components became much smaller.
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2.Through-hole:
in this technique components that
involve the use of pins are inserted onto the PCB in the holes
drilled into it. These pins are then soldered to pads on opposite
sides . The components that are inserted through this techniqueare as shown:
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The main processes involved in this
department are :
•Eyelet/gripper insertion.
•Sequencing of components.
•Axial insertion.
•
Radial insertion.
•Manual missing testing.
•Check master system.
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Eyelet/gripper insertion:
This process is carried out to insert eyelets and grippers on the PCB.Eyelets are inserted to provide mechanical strength to the PCB in
case any heavy components are inserted on one side which might
disturb its balance.
Grippers are inserted so that they can be used to hold the componentsto the PCB.
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Sequencing of components:The sequencer is a modular that increases the component handling capacity
By joining add on dispensing modules to the machine. Each dispensing has 20
Dispensing stations. These sequences are then put in strips form and fed to
Various machines.
A resistor sequence A ceramic capacitor sequence
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Manual missing testing:In this stage the PCB is visually tested for any errors by a manual
missing testing machine. If any component is missing from the
PCB this machine indicates it by dropping a pin at that point.
A manual missing testing machine
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Check master system CMS):This system checks the PCB for any errors that might have occurred
while sequencing or inserting the values of the components.
A CMS system
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Forming a MI CTV PCB assembly:
The main processes involved are:
•Pre forming area.
•Man mounting line.•Wave soldering.
•Touch up area.
•
In circuit testing.•Final visual
•Functional testing.
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Man-mounting line:
In this men are made to sit in a line and are detailed as to whatcomponents they have to insert on the PCB. A conveyor belt runs in
front of them carrying the PCB from one person to another.
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The last persons sitting in the line is assigned the work of visually
inspecting the PCB for any errors occurred. These people are providedwith electric bracelets having 1 mega ohm of resistance to prevent
them from any kind of electric shocks that might occur.
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Wave soldering:
It is a major process in which the components are soldered to the PCB
by passing it through a molten solder present in a tank. Also added
to the molten solder is a Flux which is a inert at room temperatures,
but becomes strongly reducing at higher temperatures. flux acts as a
wetting agent, reducing the tension of the molten solder and causingit to better wet the parts to be joined. Fluxes now available are
water soluble and no clean fluxes that require no removal at all.
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Touch-up area:
Various problems may arise during soldering process which might lead to joints
Which may become non functional immediately or after a certain period of use. An improperly selected or applied flux can cause joint failure or if not cleaned
Properly off the joint can corrode the metals of the joint and eventually lead to
failure. These and various other problems are removed in this section where
soldering defects are removed manually using soldering guns.
The people doing this task have to wear
masks to avoid inhaling the fumes caused by
it . Also the chimneys are provided to provide
a proper outlet to this air produced.
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In this section the extra leads from the
components soldered onto PCB are also
cut. Only 1 mm of lead length is left andthe rest is cut because only this much of
length is needed for making connections.
In-circuit testing:
in this the PCB is tested through machines for any errors in
component insertion or soldering process.
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Final visual:
In this the PCB is once more tested visually for any mistakes made duringinsertion process.
Functional testing:
The PCB is tested whether or not all the components are working properly. Since
this is a colour television PCB it is important that the audio and videocomponents are all working properly so that no problem is encountered in the
TV afterwards.
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This department manufactures set-top boxes and CFLs.
A set top box is a device that enables a television to become a user
interface to internet and also enables it to receive and decode digital
television broadcasts.
Compact fluorescent light CFL):
A CFL is a type of fluorescent lamp. CFLs generally use less power,have a longer rated life but a higher purchase price.
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The procedure of assembling this PCB is a lot similar to the assembling of CTV
PCB assembling. It involves the following steps:
Component insertion by a man mounting line:
Soldering of PCB:
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