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Session: 2009-10
GONDA-271308 AAIDU-ALLAHABAD
CERTIFICATE
S.S.BISHT
MANAGER (HRED)
ITI Ltd. Mankapur, Gonda
ACKNOWLEDGEMENTS
This project is the outcome of the efforts of several people, apart from the team
members, and it is important that their help be acknowledgement here.
First of all I want to present my sincere gratitude and deep appreciations to Mr.
S.S.BISHT, MANAGER (HRED) to allow me to undertake the industrial
training in ITI Ltd. Mankapur, one of the leading public sector amongst the
Electronics industries in India.
The factory has a beautiful and well organized work environment which made a
great pleasure and an easy task to learn and understand the principles and
theories.
Amit Kumar
B.Tech E.C.E(IIIrd year)
AAI-DU, Allahabad
PREFACE
2. Circuit Divisions: - Where circuits are developed on the base material. It consists
● The mission of the Industry is to be the leader in the domestic market and be an important
player in the global market for voice data and Image communication by providing total
solutions to customers.
● To build core competencies to enter in new business areas.
ELECTRONIC SWITCHING
A CB exchange was divided into an originating side and a terminating side when a user
picked up their handset, the resulting line loop operating the users’ line relay caused the
exchange to connect the users’ telephone to an originating sender, which return the user a dial
tone.the sender then recorded the dialled digits and passed them to the originating marker,
which selected an outgoing trunk & operated the various crossbar switches stages to connect
the calling user to it .
2.4. E 10 B
The E 10 B sys has been developed in terms of an integrated tele.netwk ,rather than in
terms of individual tele exchnges. It is French techno. which is not manufactured now in ITI ,
Mankapur.
It shapes 2 fundamental principles with the original Planton Exchnge:
• Ude of digital PCM techniques.
• Separation of the sw.ng exchng function (at exchng level )from the management
functions(at netwk levels).
2.4.1.Scope –
This engineering instruction deals with the additional facilities incorporated in R.23
version of OCB 283 exchnges.
2.4.2.General –
The following evolutions & changes introduced in R.23 version of OCB 283 sys:
• Hardware changes
• Operation& maintainance
• New parameters
• V5.2 interface
• Intelligent netwk
• Other implementation
Chapter 3
3.1. C - DOT
SEA (switching exchng assembly)division of ITI Mankapur produces exchng for fixed
line .C-DOT is one such exchng .its technology is Indian .
• CDOT DSS MAX IS A UNIVERSAL DIGITAL SW .this can be confifured for diff
appl. As local transit or integrated local & transist sw .
• High traffic / load handling capacity upto 8 LACKS BHCAwith termination capacity
of 40,000 lines . as local exchng or 15000 trunks as Trunk Automatic Exchhg.
• Central module(CM)
• Administrative module(AM)
• In order to realise a RSU ,the normal BM can be modified for remating with the host
exchng via 2Mbps digital links .
• No. Of 2 Mbps links btw main exchng & RSU is primerly determined by the traffic .
• A max 16 PCMs can be provided btw RSU & main exchng . analoge & digital trunk
interfaces are also implemented in RSU to support direct parenting of small exchng
from RSU itself instead of parenting it to the main exchng .
• As far as call processing is concerned ,RSU is an autonomous exchng capable of local
call completion .in the event of failure of PCM links RSU goes to standalone mode of
operation .in case ,it is not possible to process a call request due to unavailability of
links to the host ,the subscriber is connected to appro.tone or announcement.
3.7. Redundancy
To meet the stringent availability CDOT DSS employs “hot standby techniques” for
all processor complxes so that event of the failure of any one security block not more than 8
subscrib . will be effected .
Hardware crosslink btw have been planned in such a way that even failure 2
dissimilar processors donot effect the sys performance . In the event of failure of 1 unit
,other units will share its load preventing the disruption of services.
●EARLY 1980’s:-
European nations were developing cellular solutions but no common standard was
available.
●1982:-
CEPT (Conference of European Posts and Telegraph) formed a study group called the
Group for Special Mobile (G.S.M.) To honor the group the technology is named as
G.S.M.
●1989:-
1. G.S.M. responsibility was transferred to ETSI (European telecom standards
institute.)
2. Global system for Mobile communication.
●1990:-
Phase-1 of G.S.M. specification was published during this period.
● MID-1991:-
* Commercial Service Started;
* G.S.M. facility was launched in four countries:-
1. France
2. Italy
3. U.K.
4. Germany
● 2009:-
Commercial Services available in maximum all countries.
After FDMA each channel is of 200 KHZ. Now 200 KHZ is again divided into same
slots. 125 Channels=125*8=1000 time slots. But out of 125,124 channels are used for speech
transmission. One channel in each frame is left for providing gap to next frame. This one
channel is used as a guard to avoid overlapping between two frames. Hence from 125
channels including TDMA no. of time slots used for traffic=124*8=992 .Hence 992 persons
can talk from one frame. In this way it increases the capacity of traffic.
Chapter 6
G.S.M.NETWORK ELEMENTS:-
Figure 6.1. G.S.M. Network
The meanings of various components of G.S.M. as used in public land Mobile Network
(PLMN) are:-
MS - Mobile Station
BSS - Base Station Subsystem
NSS - Network Station Subsystem
B.T.S. - Base Transceivers Station
B.S.C. - Base Station Controller
B.C. - Billing Centre
M.S.C.-Mobile Switching Centre
H.L.R. - Home Location Register
V.L.R. - Visiting Location Register
A.U.C. - Authentication Centre
EIR- Equipment Identity Register
OMC- Operation and Maintenance Centre
SMSC- Short Message Service Centre
VMSC- Voice Mail Services Centre
STF- Speech Transcoder Frame
6.5. STF:-
The BCF is then connected to the STF by an M link. In this, signal travel at a rate of
64Kbps. This receives speech at 16Kbps & signals at 64 Kbps. It takes care of the speech
part. It contains certain STU cards which connected to the MSC by A link.
6.6. MSC:-
MSC means Mobile Switching Centre. It provides switching of Cell like PSTN exchange and
is the heart of GSM network. Switching means connecting, maintaining & release of mobile
to mobile, mobile to PSTN &PSTN to mobile Cells. It has data base of all subscribers and
stored in HLR, VLR etc.Database includes identity of subscriber MSC is weighted by no. of
subscribers. For example, MSC of 1 lakh subscriber means that MSC can provide connection
to 1 lakh and beyond which it need another MSC. The MSC perform the switching function
for all mobile station located in its geography area covered by its BSS.
6.6.1. Function of MSC
6.10. EIR:-
It is accessed during the equipment validation procedure when a mobile station access. It
contains identity of mobile station equipment called IMEI.
The three lists corresponding to the status of the equipment are:-
● White list (valid)
● Grey list (suspected)
● Black list (banned)
6.11. OTHER ELEMENTS:-
● BC:. - To collect billing data for Public land Mobile Network (PLMN).
● SC: - To provide special service to mobile subscriber in the Public Land
Mobile Network (PLMN)
Figure 6.2. GSM location updation
● UPLINK
RACH
* Random Access Channel.
* Mobiles seeking attention of the BTS.
● Fast
SDCCH
* Stand Alone Dedicated Control Channel (Duplex).
* Signaling Channel used for service request.
FACCH
* Fast Associated Control Channel.
* Stealing Flag & Preparation.
* Used during cell setup, Handover.
BTS is the main part of the mobile communication.bts consists of mainly three cards.
Whole system of BTS consists:
1. Fan unit (It have 9 fans)
2. Racks
3. FACB (Fan control Board)
BTS RACKS
RACKS ASSEMBLY-As shown in figure a rack has six shelves. In first shelf
there are parts (XIBM, MSCA, POWER SUPPLY (-48V)).Second shelf can be
divided into four parts (4RT)
And third is of two parts for ANC, again four parts for RT and then again two
parts one for SUMA & other for ANC. The last shelf also has four parts for RT.
Upon every RT one fan unit is available for cooling. It also consists of a MSD
unit for maintenance.
FUNCTIONS
1. Digital transmission
5. Remote inventory
1. Setting the LNA Game for the assigned for TREA receiver
The transceiver (TRX) level covers GSM 850, GSM 900, GSM 1800 and GSM
1900 functionalities, including full rate, half rate, enhanced full rate, antenna
diversity, radio frequency hopping (synthesized hopping) and different
ciphering algorithms. For each band, these functions are integrated into one
single module. Inside each TRX module, an RF loop is implemented. The loop
test is performed after downloading the frequencies to the BTS as a supplement
to the autotest. The TRX module also handles the Radio Signaling Link (RSL)
protocol.
This level is ensured by the Station Unit Module (SUM), which is the central
unit of the BTS. There is only one such module per BTS, whatever the number
of sectors and TRXs is; this common control function of the SUM is also called
Station Unit Sharing. The main base station control functions performed are as
follows:
- Generating the clocks for all other BTS modules; the clocks can be
either synchronized to an external clock reference - e.g. A-bis link, GPS
or another BTS - or generated in a pure free-run mode by an internal
frequency generator.
- Ensuring central BTS Operation & Maintenance (O&M) application,
- Handling the A-bis transmission links (up to two A-bis interfaces),
- Handling Operation and Maintenance Link (OML) and Qmux
(transmission equipment supervision) protocols,
- Controlling the AC/DC function when integrated inside theBTS
(Outdoor or Indoor AC configurations),
- Controlling the battery (capacity, voltage, temperature),
- Setting the optimal voltage and current for battery charging
The antenna coupling level is the stage between the antennas and the TRX
level; it handles the combining functions as well as the interface with the
antennas. A single module called Antenna Network Combiner (ANc) performs
these functions for up to 4 TRXs. For configurations of higher capacity, a
Combiner stage can be added. Thanks to the ANc flexibility and this modular
building, the antenna coupling level can be adapted to a wide range of
requirements (reduction of attenuation losses, minimization of the number of
antennas…).
The general functions performed at this level are:
- Duplexing transmit and receive paths onto common antennas;
- Feeding the received signals from the antenna to the receiver front end, where
the signals are amplified and distributed to the different receivers (Low Noise
Amplifier (LNA) and power splitter functions);
- Providing filtering for the transmit and the receive paths;
- Combining, if necessary, output signals of different transmitters and
connecting them to the antenna(s);
- Supervising antennas VSWR (Voltage Standing Wave Ratio).
ISO
ISO STRUCTURE
• Added exposure. Customers will be able to find your product from our
site .Benefits to your customers.
• Confidence that your software is reliable, secure and safe
• Confidence that your software will not install viruses or anti spyware.
ISO’s 9000
ISO 9000 is a family of standards for quality management systems.
ISO 9000 is maintained by ISO, the International Organization for
Standardization and is administered by accreditation and certification bodies.
Some of the requirements in ISO 9001 (which is one of the standards in the ISO
9000 family) include
-A set of procedures that cover all key processes in the business
monitoring processes to ensure they are effective;
- Keeping adequate records;
-Checking output for defects, with appropriate and corrective action where
necessary;
- Regularly reviewing individual processes and the quality system itself for
effectiveness; and
-Facilitating continual improvement
Overview of standards and certification
• ISO 9000:2000
• SEI CMM
• SEI-CMMI
• SIX SIGMA
• ITIL
What is quality?
Quality is an “Ability of a set of inherent characteristics of a product, system, or
process to fulfill requirements of customers and other interested parties.”
SIX SIGMA
The concept of SIX SIGMA was put forward by “MICKEL HARRY” who was
an engineer with Motorola in 1985. He introduced six sigma to his company
which was facing the downfall and after following six sigma principles, the
company got the regular boost in their bottom line.
IMPLANTATION METHODOLOGIES
(2) DMAD
G G
at at
e e
DEFINE- Formally define the process improvement goals that are consistent
with customer demands and enterprise strategy.
G G
at at
e e
G
at
e
MEASURE-To define baseline measurements on current process for future
comparison, map and measure process in question and collect required
process data.
IMROVE- Optimize the process based upon the analysis using techniques
like design of Experiments.
It is used to create new product designs or process designs in such a way that
it results in a more predictable, mature and defect free performance.
GAT GAT
E E
DESIGN-
GAT Develop detail designs, optimize
GAT design, and plan for design
E E
verification. This phase may require simulations.
GAT
E
VERIFY- Design, setup pilot runs, implement production process and
handover to process owners.
• It can measure how good our product, services & processes really are.
SIX-SIGMA CHAIN
Six-Sigma identifies 5 key roles for its successful implementation:
1. Executive leadership: includes CEO & other key top management team
4. BLACK BELTER (to lead the project team fully responsible for
assigned, head of project control team): these are the employees who take
up SIX SIGMA implementation along with their other job
responsibilities.
Motorola, GE, Honeywell, Sony, Nokia, Polaroid, Capara Maruti, Tata SSL,
Whirlpool of India, Hughes, Escorts hospital, Caterpillar, Bharti telecom.
5. For the projects that have the operators or operator training as an input,
focus should be given to reduce the operator variation, thereby making
the process more robust to different or untrained operators.
1. ENLIGHTMENT.
2. ACCEPTANCE.
3. TOOLS.
4. DEPLOYMENT.
5. RESULTS.
6. RENEWAL.
ERP system are software package soothing several module, such as human
resources ,sales , finance& production, marketing, advertising etc. providing
cross organization integration of data through embedded business processes.
These software packages can be customized to accommodate the specific need
of an organization.
COMPETITOR
S
FUNCTIONAL
AREAS
Evolution of ERP
FEATURES OF ERP
• Plan
• Source
• Make
• Deliver
• Return
.
SIMPLE MODEL
• BAAN.
• J. D. Edward.
• SAP.
• Ramco.
• QaD.
• Oracle.
• People soft.
• BOI.
BaaN
• BaaN manufacturing control sys (BMCS) was the 1st package developed
by BaaN for MRP1, CRP& MRP2.
• The company BaaN has become one of the world’s biggest software
group &expects to remain on a fast track for the foreseeable future.
SAP
• Empowered users.
BaaN SAP
• Very strong for discrete • Very strong for process
• PCB PLANT
• HYBRID PLANT
PCB PLANT
BASE MATERIAL
CUTTING
DRILLING
ELECTROLESS PLATING
PUMICING
LAMINATION
EXPOSURE
DEVELOPMENT
ELECTROPLATING
STRIPPING
ETCHING
ROUTING
TESTING
QUALITY CONTROL
BASE MATERIALS:
PCB unit is meant for producing printed circuit boards of various dimensions.
The most common dimension of which PCBs are generally made of:
• 240×400 Sq. mm.
The raw material used for the manufacturing of the PCB is “COPPER CLAD
EPOXY LAMINATE”.
The dimensions are:
• 920×1220 Sq. mm.
CUTTING:
It is carried out by saw cutting machine. Cutting is done by two types of blades.
One is used for cutting copper clad glass epoxy. This blade has diamond in its
circumference shape, which serves as the cutting edge & the blade is circular in
shape. Other blade used is for the entry sheet & the back up sheet. The blade
used for this purpose is carbide blade.
BAKING:
After cutting the base material to required sizes, in order to make the surface
coating of Cu even, to remove the volatile impurities, vapours & moistures &
moreover to make the sheet plane, the raw sheet of glass epoxy with Cu clad
laminate is baked in oven at 3 different temperatures depending upon thickness
of raw material. The process requirement time and temperatures are given
below:
DEBURRING:
After drilling holes, burrs left over the sheet & on the edges are removed by
deburring. Deburrring removes unwanted materials & makes holes perfect.
Also, the board surface gets smoothened.
ELECTROLESS PLATING:
It is purely a chemical process which is done to make the epoxy area between
the two Cu clad plates conducting. A 2 micron Cu layer is formed over the holes
as a result of electroless plating. In this process, the surface of Cu also gets
evened. This is also called alkaline plating & is done with the help of chemicals.
As no electrode is used for plating purpose, so called as “electroless plating”.
PUMICING:
Gem stones are crushed to powdered form which is dissolved in a container &
sprayed over the Cu sheet to make it little rough for better lamination & for
removing any hand marks, grease or dust which may have accumulated during
the process.
LAMINATION:
The polymer film to be laminated is first mounted onto a roller and after the
blank board is inserted from below, the film gets laminated on to the blank Cu
sheet. The polymer film used is a special kind of consisting of 3 layers. The
lowest one is called myler. One of the sheets inside has glue attached to it,
which holds the film to the Cu sheet
EXPOSURE:
The sheet prepared so far is now placed under circuit layer (Diazo; Photo Tool)
& UV rays are passed through it. The part through which the UV rays pass
becomes hard & the rest remains soft (tracks).
DEVELOPMENT:
In this process, the unexposed sensitive photo resist is removed & so we finally
get the tracks printed on the Cu sheet. In this process, the sheet is passed
through 1% Na2CO3 solution which removes the soft, unpolymerized layer.
Then inspection is carried out under 10× magnifying glass.
ELECTROPLATING:
After development, card is fed to electroplating apparatus. Sn-Pb plating is
done on the Cu plate. Here current is passed on the plate, so is called as
electroplating. The thickness of Sn-Pb to be applied is 12.5 micron. On open
tracks, Cu plating of about 25 micron is done. Current is passed through a
mixture of Sn-fluberate, Pb-fluberate & fluberic acid. DYNATRON F is the
machine used for electroplating. In PTH (Plated Through Holes) lane,
deposition of Cu is done inside the hole to establish the continuity between two
surfaces. Electroplating involves following processes:
• Cleaning chemical.
• Acid cleaning.
STRIPPING:
In this process, the electroplated sheet is passed through the solution of NaOH
which removes the hard layer or the polymerized layer.
ETCHING:
After stripping the polymerized layer, the Cu becomes visible. This Cu layer is
then removed by etching. Etching is done using Ammonical Cu solution.
SOLDER STRIPPING:
In this process, solder Sn-Pb layer is stripped off leaving circuit pattern that is,
Cu over epoxy layer. HNO3 is used for this purpose.
PISM (Photo Image Solder Masking):
In this process, ink is put over the developed board like dying. Board is inserted
from bottom & ink is poured from top & with the help of leveler, it is leveled
properly. Then it is cured at a temperature of 800C for 30 minutes to make ink
adhere properly to the board. After curing, a photo tool is placed over the sheet
& UV Rays are passed through it. The points where holes are to be formed
remains soft as light can’t pass through it. After exposure, passing through
Na2CO3 solution due to which we get an impression of the holes on the board.
Then, again it is baked at temperature 1200C for 4 hrs.
SRCEEN MASKING/PRINTING:
A polyester cloth of size 100×100 sq. cm is used. The ink is coated on this
screen to be called as skin mesh. Then screen printing is done by special type of
chemical fersol-29. The screen developing & cleaning is done using water,
which is made to fall on the screen to remove excess ink.
ROUTING:
Here, unwanted portion of the plate is removed & only desired circuit is left
behind.
TESTING:
This is done to detect any anomaly. Error detected is shown by printer & it can
be rectified if within limits, otherwise discarded. Visual inspection is done to
check any discrepancy crack or any connection fault. Bare board testing (BBT)
is done for very sophisticated result.
QUALITY CONTROL:
In the end, quality inspection of the PCB plate is done. Plate is visually
inspected to meet the desired specifications like conduction area must be totally
covered by solder resist, overlapping of solder resist must be admissible, solder
must pass adhesive test etc.
HYBRID PLANT
• Firing
• LASER trimming
• Assembly
• Encapsulation
• Final testing
PROCESS OF HYBRIDIZATION
SCREE FINAL
N
PRINTIN TEST
G
FIRING ENCAPSULA
TION
ASSEM
LASER BL-
TRIMMIN Y
G
SCREEN PRINTING:
In this section, 1st steel mesh is prepared by cutting plates into required sizes.
Then, they are held in clamps from all sides & appropriate tensile strength is
maintained. The frame is oriented at 450. This is done to prevent viscous paste
from flowing. The different materials used for conduction & resistors are:
• A silver coloured paste of Silver Palladium for conduction.
FIRING:
Substrate after printing of every component is sent to the firing section. In this
section, the substrate is put into the firing machine where it is subjected to high
temperature, as per requirement. Conductors and resistors are subjected to a
temperature of 8500C for 90 minutes. When the protective cover is printed on
the substrate, it is sent to this section & is subjected to a temperature of 5500C
for 45minutes.
LASER TRIMMING:
The resistive networks are always made of value lower than the required value.
This is done because the manufactured value of resistive networks can be
increased to required value by LASER trimming based on following formula:
R = S×L/A; where R = Resistance, S= Resistivity, L= Length, A= Area.
ASSEMBLY:
In this section, lead pins of conductive materials are inserted in the chip for
making contacts. The pins are soldered using a material that consists of lead, tin,
silver.
ENCAPSULATION:
The resistive network covered with Epoxy Powered network is inserted into the
bar of powder coating machine. Air is rotated for uniform cooling. The network
is sent to the masking section where various specifications like file, batch
number, rating are masked on the network.
FINAL TESTING:
The resistive network before being used is subjected to different climatic
conditions artificially created. The conditions are:
• Temperature : (21±7)0C
18
1
12 1
13 10
11
2
3 4
8
9 7 6 5
1
KEYS:
1. GATES
2. CANTEEN
3. OFFICES
4. NCM & RELAY
5. CM OFFICE(P.I.)
6. MANUFACTURING OF NCM PARTS
7. OFFICES
8. STORE
9. C & T
10.SHOE RACK
11.TOILET & WATER
12.U.P.S. SYSTEM
13.TOOL ROOM
14.PAINTING
15.PLATTING
16.WELDING
17.PUNCHING MACHINES
18.DIFFERENT TYPES OF PUNCHING MACHINES
Component division is concerned with the mechanical work being carried out in
the industry. Here many piece parts and shelves are made for exchange. The
work assign to this division is t manufacture and assemble different components
that are utilized in production of exchange.
COMPONENT DIVISION
MANUFACTURING ASSEMBLY
1) Moulding 1) Connector
Assembly
2) Punching 2) Coil &
Transformer
3) CNC 3) MDF
Assembly
4) Metal part 4) Relay
Assembly
5) NCM
CONNECTOR ASSEMBLY:
Here 4 T types of connectors are manufactured handing different sizes,
dimensions, number of pins etc. Assembly of connector requires
• Plastic raw material(insulator)
• Metallic piece(conductive)
Plastic raw material is manufactured in moulding shop and metallic pieces are
manufactured in punching shop. Different type of tools and machine used in this
shop are:
• Hand press tool
• Combination separation tool
• Assembly machine
• Locking machine
PRODUCTION UNIT 2
MOULDING:
In this shop various components of plastics are manufactured that are used in
manufacturing of racks of exchanges. Component of NCM, antennal clamps and
other miscellaneous components are also made. Components used in NCM are
cam, damper cover, damper unit, gears, and several other big parts that are not
manufactured here. Other important parts are charger case and carbon rings etc.
for relay unit socket, pilling support and other insulating parts are
manufactured. For this purpose a machine called AIMM (Automatic Injection
Moulding Machine) is used. The moulding has three main parts:
• Injection unit
• Mould unit
• Control unit
PUNCHING:
In punching shop, conductors are made. Raw materials are copper, bronze,
brass, stainless steel etc. There are several steps to manufacture a product. these
are as follows:
• Planning and control department decides the total quantity of products
and fixes quality at which it should be manufactured.
• After this we decide that which raw material would be used and then
choose an appropriate tool for a particular product.
• Then appropriate machine is selected.
• After manufacturing the product it is sent to quality control for quality
check.
FEATURES:
Capacity - 30 tones
Table travel - 1270 mm (Y-axis) on change
Carriage travel - 1830 mm(X-axis) adjusted X2
Stroke/min - 350
Maximum rate - 200
Maximum sheet size - 1270 × 3660
Relative humidity - 75%
FEATURES:
Capacity - 400 tones
Table length - 4000mm
Ramp travel - 300 mm
Max sheet thickness - 10 mm
operating temperature - 00C to 350C
Relative humidity - 75%
SEA PLANT
(SWITCHING EXCHANGE ASSEMBLY)
WAY TO COMPONENT
DIVISION
13
14 15 2
1
3
2
4
11 5
9 8
6
12
17 20
7
19 10
18 17
1
16
1
16
KEYS:
1. GATES
2. TOILET AND WATER
3. STORE ROOM
4. COMPONENT INSERTION-I & TESTING
5. SOLDERING (CSN)
6. INSERTION - II & QC
7. TESTING (FINAL)
8. RACK ASSEMBLY
9. SYSTEM INTEGRATION TESTING
10.QC & QA
11.CANTEEN
12.CWM OF ICE (SIT)
13.CWM OF ICE (RACK)
14.CWM OF ICE (CARD)
15.CM OFFICE
16.SHOE RACK
17.OFFICE CWM(CSN or NP) & MODEL EXCHANGE
18.NP & CSN OR TABA HALL
19.WAY TO COMPUTER DIVISION
20.BTS MANUFACTURING
In SEA plant where the entire integration takes place and final product is
assembled. This plant takes input from the PCB, hybrid, component divisions and
these inputs are processed according to need and final product is given as output.
Currently this section goes both telecom and non-telecom products are being
assembled.
TELECOM PRODUCTS:
As it has already being specified that the major telecom products of ITI
Mankapur are exchanges. These exchanges may be of E10B, CSN and C-DOT
technology. Currently C-DOT and CSN exchanges are being made and repair.
As the E10B technology is outdated only repairing of these exchanges are being
carried out according to request of Customer. The main processes of SEA plant
are as follows:
1. COMPONENT PREPERATION:
Components are cut to desired size by instruments like:
• RCD CUTTER: Which is a machine for manual cutting two terminal
medium and large size components like capacitor, resistor. This machine
can cut a maximum 556 components per hour.
• MK6 CUTTER: This is used for cutting small size two terminal
components. It has a C058 Cutter: It is used for cutting connectors.
Connectors are inserted and cut when pedal is pressed.
• REDIAL SUPER: It is also a component cutting machine with a maximum
capacity of 3600 components per hour. It is a radial cutter.
2. PCB PREPERATION:
Preparation of PCB involves:
• Marking of PCB with suitable codes
• Heat sinks and connectors are connected
• Masking is done on the holes, which are drilled for component to be
inserted during second insertion
• Baking of PCB plates is done at temperature of 10ºC for a period of 10
4. VISUAL INSPECTION:
Before soldering, the cards are manually checked for error.
5. SOLDERING:
The soldering of components of first stage is done after visual inspection. The
soldering is done with the help of WAVE SOLDERING MACHINE. This
machine has been imported from CIT Alcatel France. The parameters of the
machine are as follows:
• Name of machine - Ultrapak with Wave Dynamic (machine parameter
with no-clean flux).
• Flux density maintained at .810 to .815.
• Conveyer speed - 9m/min; tolerance - 0.1.
• First preheated temperature - 400 degree Celsius; variation - 20 degree
Celsius.
• Solder bath temperature - 243 degree Celsius; variation - 05 degree
Celsius.
In this machine, the PCB with the lose component is passed through the heater
first. Then the flux is applied to the leads to be soldered. After this the PCB
passed through the solder bath & the components get soldered. This machine
uses two waves to provide reliable fixation. It has a moving wave along with a
stationary wave.
6. SECOND INSERTION:
The components which cannot withstand high temperature of the solder bar
are inserted manually in the hole of the PCB. If the cards contain some SMD
components it sends to CSN section for this purpose. The card is then tested
and sent to the store.
7. TESTING:
The cards are tested for their conductivity, continuity and other parameter.
Each tester has achieved an ideal card on its CPU. If the difference of
parameter is greater than the tolerance with respect to ideal card then card is
sent to the repair section.
8. QUALITY CHECK:
Before the cards are inserted in the racks. They are randomly checked for
their ideal performance. The pass cards are inserted in the racks and the other
are sent back.
9. RACKS ASSEMBLY:
In the racks assembly the output of components and SEA PLANT are
integrated. The racks which house the exchanges are manufactured in
component division. their connectors, MFD & other components are installed
and then they are sent to rack assembly. In rack assembly the quality checked
cards are inserted and after connection
C-DOT Exchanges are being tested in SEA PLANT.
10.QUALITY CONTROL:
In this section of SEA PLANT, manufactured cards or assembly of racks are
tested or Q.C. checked. If card performs right operation then it is OK & sent to
the quality assurance department. If card or rack is not performing right
operation then it is sent for repairing and after that, again tested.
11.QUALITY ASSURANCE:
When quality is tested then it is assured that the product has performed right
operation. For this some cards or racks are randomly picked and tested. Again
if it performs right operation then we mark Q.A. & whole lot is ready to go to
customer’s hand. If it does not perform right operation then we return the
cards or racks to Q.C.
NON-TELECOM PRODUCTS:
The Non-Telecom products of ITI Mankapur include:
1. NCM (Note Counting Machine)
2. NBM (Note Bundling Machine)
3. FNDM (Fake Note Detector Machine)
4. Inverter
5. Energy meter
6. UPS (Uninterrupted Power Supply)
FNDM:
As the name indicates, this machine is used for detecting whether the note is
true or fake. This machine is used to provide Banking Automation. This
machine consists of 2 tubes. One is normal DL tube & other is UV tube. On the
upper side of the metal body, the UV tube is put on the lower side the DL is
present. The working of machine is very simple. The note to be tested is placed
on the machine. First, DL tube is ON & the face which is not clearly visible
become visible after this the UV lamp is switched ON & the water marks on the
note become visible. Thus fake note can be detected if the is aware of the
correct identification marks of the note. The main disadvantage of this machine
is that it tests one note at the time. An advance of this machine is being
developed in which several bundles of the notes can be tested at the same time.
In the advance version 2 sets of UV lamps are present, one above & one below.
The bundles of notes to be tested are passed through these lamps, the fake note
can be clearly detected as its entire length shines in contrast to the true note,
shines at one point of its length.
SEA division of ITI, Mankapur produces exchange for fixed line. The main type
of exchange which is manufactured here is E10B and C-DOT. E10B is French
technology where as C-DOT is Indian. The use of E10B is absolute. So,
nowadays only mode of C-DOT is taken in. The assembly is done here.
C-DOT:
• C-DOT DSS MAX is universal digital switch. This can be configured for
different application as local transit or integrated local and transit switch.
• High traffic/load handling capacity up to 8,00,00 BHCA with termination
capacity of 4000 lines as local exchange or 15,000 trunks as trunk automatic
exchange the C-DOT DSS family is ideally placed to meet the different
requirement of any integrated digital network.
• The design of C-DOT DSS MAX has envisaged a family concept. The
advantages of family concept are standardized components, commonly in
hardware documentation, training installation and field support for all
products and minimization of inventory of spaces. In fact this modular
design has been consciously achieved by employing appropriate hardware,
software equipment practices
FLEXIBLE ARCHITECTURE:
C-DOT DSS is a modular and flexible digital switching. System which provides
economical means of serving metropolitan under and rural environments. It
incorporates all important and mandatory services needed by user with option of
up gradation to add new features and services in future.
• The architecture for C-DOT DSS is such that it is possible to upgrade a
working C-DOT SBM or MBM exchange to provide ISDN service by
adding a minimum additional hardware while retaining the existing
hardware.
• Another factor of the architecture is its support to ISDN subscribers
through remote switching unit (RSU). The processor architecture is
characterized by distributed control and message-based communication in
order to achieve a loosely coupled network for flexible system
architecture.
• Software is written in high level language ‘c’ and distributed over various
processors and is structural as hierarchy of virtual machine.
TECHNOLOGY:
The system employs a T-S-T switching configuration and is based on a 32
channel PCM structure. It uses a basic rate of 64 Kbps and 2 Mbps primary
multiplexing rate. It uses a basic rate control is distributed over the system
by using 32-bit, 16 bit, 8 bit microprocessors. All the critical central
circuitry has built-in-redundancy.
System hardware utilities advanced concepts in micro-electronics form a
compact and optimum design. Basic memory unit has been implementing as
16 MB dynamic Ram board.
Single chip digital processors are used for implementing DTMF and MF
receivers. High performances, high densities VLSI chip detect multiple
tares and simultaneously perform signal filtering or four channels. This
approach reduces costs, power dissipation and saves PCB space.
A to D carburetion is done by CODEC chips and ASICS/FPGA’s which
makes cards small & compact.
BASE MODULE:
It interfaces the external world to the switch through subscriber lines like analog
& digital trunks, CCM (Coin Collection & Metering) & PBX lines. Each BM
can interface up to 2024 terminations. It carries out majority of call processing
functions along with maintenance & operation functions with the help of IOM.
In Single Base Module (SBM) exchange configuration, the BM acts as
independent switch system & provides connections to 1500 lines &128 trunks.
In such configuration, BM directly interfaces with IOM for bulk data storage,
operations & maintenance functions. Clock & synchronization is provided by
the source within BM.
CENTRAL MODULE:
Consists of message switch space to provide inter module communication &
performs voice & data switching between BMs. It also provides clock &
synchronization on a centralized basis.
ADMINISTRATIVE MODULE:
Performs system level resource allocation & processing function on a
centralized basis. It performs all the memory & time intensive call processing
support functions & also administration & maintenance functions. It
communicates with the BM via the CM. It supports the IOM for providing man
machine interface. It also supports the Alarm Display Panel (ADP) for the audio
visual indication of faults in the system.
REDUNDANCY:
To meet the stringent availability CDOT DSS employs “hot standby
techniques” for all processor complexes so that event of the failure of any one
security block not more than 8 subscribers will be affected.
Hardware crosslink btw have been planned in such a way that even failure 2
dissimilar processors do not affect the system performance. In the event of
failure of 1 unit, other units will share its load preventing the disruption of
services.
the bottom part of the car. This gluing machine has two parts:
Gluing unit
Pick and place unit
2) CURING: This card is then put to oven which is divided into six
zones. There are two plates at upper side and lower side and there is a
covering for these plates.
Parameters for curing:
Conveyer speed: 60 cm per minute
Temperature zone:
1H 2H 3H 4H
440 250 270 280
After this, the card goes to the manufacturing area where the component, which
can not be placed on the card, is placed manually. Then soldering is done with
the help of wave soldering machine.
WAVE SOLDERING:
After assembly manual inspection of components is done. Then after this, it is
put in the baking oven to remove moisture. After that, it comes to wave
soldering machine. This wave soldering machine is little different from the
machine used in C-DOT soldering. It has a real wave like solder flowing in it to
solder the component. After placing the cards on conveyer, at first flux is
sprayed on the card by nozzle. This smoothen the plate and device the leads of
components for soldering. Then it passes through 3 pre-heaters maintained at
gradually increasing temperature of 250 degree centigrade, 350 degree
centigrade, 400 degree centigrade. The flux is completely vaporized which is
necessary for better soldering.
Then it passes through the solder bath having two waves of solder flowing in
opposite direction. The tank of solder bath contains 400 Kg of solder. The
solder has following composition: Sn 63%, Pb 37% with melting point 170°C to
180°C.
The temperature of both is kept at 243°C so that the solder comes in molten
form. At the output, air cooling is done for a while and then the card is sent for
marking which specifies the card.
This shop controls and checks the quality of the products manufactured
by the plant.
• Quality is fitness for use.
QC is of types:
• IGI (Inwards Goods Inspection): Function of IGI to check the
supplied goods. Steps in IGI are:
To check the qualification of the supplier
Visual check(damage, value and marking of the
components)
Electrical test
It passed, given to PPC(production, planning and control)
• IPQC:
In this process, quality of the finished and unfinished products is
checked by the sampling process.
The vital point is how much sample should be taken and how much
should be passed so that whole sample is considered to be passed.
For this we have sampling plan.
ITI (SEA) QC follows the standard MIL STD.105 D. This is
military standard.
Apart from sample size the other two criteria are there to pass the
sample lot:
AQL (Acceptable Quality Level): It is that quantity which
customer would always accept.
(QL: Quality level: percentage defective)
Level: Amount of inspection. This gives the sample size of
inspection.
INSPECTION:
It is the process by which we check the product whether it confirms or
don’t confirm the given specification.
RELIABILITY:
It is measured in terms of quality & time.
QUALITY ASSURANCE
RETESTING:
If the lot is successfully passes all the above tests then the lot is offered to DOT
(Department Of Telephone). Quality assurances along with the reports received
from SEA plant and the reports regenerated during the quality assurances
checks along with LEQ.
BSNL QUALITY ASSURANCES TESTING:
The BSNL quality assurance carries out the following checks before acceptance
& issuing clearance for dispatch.
100% administration checks of 2 racks picked up from the lot after
removing the wrapping remaining racks are checked without the scale
/wrapping.
One of the two racks is subjected to rack visual check.
Visual checks of cards are carried out as per the sample plan(III) on
samples taken from two racks with 4%AQL(acceptable quality level) for
major defects and 10% AQL for minor defects.
Cards in the lots are grouped as logic and analogic cards and samples are
taken for the functional test by cards in card test from the second rack of
the lot as per the sample plan.
30% of the rack is subjected to RI test.
CONCLUSION
Naturally, highly automated system does not require as many people as manual
methods. Therefore, there has been significant reduction in the number of
people required for performing manual task in the organization.
Knowledge and ideas are the heart of the development process and are
increasingly over shadowing the natural resource base because knowledge
generation and information processing are at the roots of new productivity. IT
based processes enhanced countries access to global knowledge, market and
capital.