1

PROJECT REPORT ON THE SUMMER

INTERNSHIP PROGRAMME IN

ORDNANCE FACTORY DEHRADUN

TOPIC: DEFECT INVESTIGATION IN SIGHT UNIT
CASED 102B C2 ALONG WITH STUDY OF NIGHT
VISION DEVICES.

Submitted by: Shreshtha Paul (2009MB0001)

ISM, Dhanbad

H.R manager: Project manager:

Mr. K.K. Trivedi Mr. Tarun Khattar

Jt. General Manager Works manager
O.F.D O.F.D

Project guide: Training In charge:

Mr. S.Banerjee Mr. Balram Singh

Chargeman (Technical) Office Superintendent
O.F.D O.F.D

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 ACKNOWLEDGEMENT

First and foremost, I would like to express my deep sense of gratitude

to my university, Indian School of Mines University, Dhanbad, for
giving me the opportunity to work on this project.

I am grateful to my teacher Dr. S.Mondal, Assistant Professor, Indian

School Of Mines, Dhanbad for his inspiring guidance, precious
suggestions, constructive criticism and untiring cooperation which
has helped me throughout the course of this project.

I place on record my sincere gratitude to Shri K.K.Trivedi, Jt. General

Manager, Ordnance Factory Dehradun, for permitting me for the
summer training in Ordnance Factory Dehradun.

I am also thankful to Mr. Tarun Khattar Works Manager, Ordnance

Factory Dehradun, for his kind suggestions, useful discussions and
providing all facilities during my project work.

Deep appreciations are due to Mr. Shankar Banerjee, CM, Ordnance

Factory Dehradun, for helping me in getting information from each
and every section.

I would also like to thank Mr.Rajesh Raypa, Mr.M. Bhattacharya,

Mr.P.C.Joshi, Mr.S.K.Bhandari, and Mr. M.Kumar for giving me their
valuable time and equipping me with all the technical knowledge I
required.

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My heartfelt thanks are due for my parents and Ms. Snigdha paul for
their moral and logistic support and constant encouragement without
which it would have been difficult for me to complete my work.

Shreshtha Paul

REMARKS BY THE PROJECT MANAGER

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 Mr. TARUN KHATTAR
Dated : Works Manager
Ordnance Factory, Dehradun

CHAPTERISATION

1. SECTION A Study of the working of Ordnance Factory Dehradun

Component 1:- Profile of Ordnance Factory Dehradun.

2. SECTION B Study of Sight Unit Cased 102B C2

Component 1:-About Sight Unit Cased 102B C2

Component 2:- Study in the Assembly Section
Component 3:- Findings from the study.
Component 4:- Study of the mechanical defect.
Component 5:- Findings from the study.
Component 6:- Study of the optical defect.
Component 7:- Findings from the study.

3. SECTION C Study of the Night Vision Devices.

Component 1: About night vision device

Component 2: Study of night vision (case studies)
Component 3: Night vision study
Component 5: II tube study
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 Component 4: Analysis of night vision defect
Component 6: Findings from the study

4. SECTION D: Conclusion of the project

SECTION A-
STUDY OF THE WORKING OF ORDNANCE FACTORY DEHRADUN

COMPONENT - 1

Profile of Ordnance Factory Dehradun

Introduction

Ordnance factory Dehradun is located among picturesque surroundings at the

Shivalik foot hills near village, Raipur, east of Dehradun city. It was set up in
1943, under the Ministry Of Defense, government of India, for the manufacture
of optical and scientific instruments. The factory has been adopting new
technologies from time to time and is actively engaged in the development of
new electro-optical instruments based on modern techniques in association with
the designer.

Mission:

To manufacture state-of-the-art Day and Night Vision Devices.

Objectives and activities

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Initially the factory planned for the production of binoculars, telescopes,
compasses, clinometers, and drawing instruments. Subsequently, there has been
considerable diversification in the production activities in as much as that the
factory now meets the requirement of wide ranging optical instruments.

The factory has also established indigenous manufacture of Airport Lightening

Equipments for night landing operations and has International Airport Authority
of India Ltd. as one of its users.

The factory has excellent infrastructure for the manufacture and assembly of
precision optical instruments in controlled atmospheric conditions. Optical
production and assembly building are air-conditioned and dust free.

During the past 67 years of its existence Ordnance Factory Dehradun has been
rendering in its own humble way, service to the country in general and to the
armed forces in particular. A repository of special techniques and processes for
the development and manufacture of precision Optical instruments, it has the
potential of becoming the foremost institution of its kind. This factory has led
the way all along among the industrial units set up for the manufacture of
various types of instruments and will continue to render such services to
instrument industry in the future also.

Vision:

To be the foremost suppliers of world class optical, electro-optic and laser based
instrument to the Indian Armed & Security Forces.
To build up ultra-modern and high accuracy production and testing, and product
evaluation facilities for ensuring quality right from raw-materials, components
& sub-assemblies to the final product.
To maintain Quality Management System as per International Standard.
To evolve a prompt response system to attend to the customer needs in time.
To pay utmost attention to the training needs for human resource development at
all levels.
To explore opportunities for diversification to expand customer base and
product range.
To enhance products range to meet every requirement of the Indian Army &

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other Para-military forces for optical & electro-optic instruments through
acquisition, synergy and in-house R&D.
To continuously improve product designs to complete in the Global Market in
terms of quality, reliability and cost.
To enter into MOU with world renowned design and/or production agencies to
produce the products of mutual interest through codevelopment & coproduction.
To enhance productivity every year by a factor of at least 20% with an ultimate
goal to achieve at least four fold productivity by next decade.

QUALITY POLICY

Ordnance Factory, Dehradun is firmly committed to manufacture and supply

mechanical, optical and opto-electronic instruments to achieve customer
satisfaction by meeting their requirements for quality, price and time schedule.
Ordnance Factory, as a team, strives for continual improvement in their
activities by establishing, implementing and reviewing Quality Manage-
ment System inline with IS/ISO 9001:2000.

QUALITY OBJECTIVES:

Customers Satisfaction.
Quality Assurance.
Continual Improvement.
Human Resource Development.
Employees Safety

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DEPARTMENTS IN ORDNANCE FACTORY DEHRADUN

1. Production and Planning Department

Sections

Ajeya shop
Cementing
CNC
Vacuum coating plant
Assembly I
silvering
Assembly II
Goggles
Shop
Graticule
Optical-III
Fitting
Air light equipment(A.L.E)
Assembly group
Machine shop (M.S) I
Machine shop (M.S) II
CNC
Metal Finishing (M.F)
Photo etching
Optical
CNC
Center-edging room
Roughing room
Planning office
Tool room

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 Heat treatment
Work office (W.O) and Industrial Engineering Department (I.E.D)
Wood work foundry(W.W.F)
foundry

2. Engineering department
civil maintenance
electrical maintenance(EM)
engineering office
mechanical maintenance
Water works department
drawing office

3. Motor transport department

4. Safety department
fire brigade
Security Section

5. General administration
bill group
cash office
establishment
pension cell
recruitment cell
human resource department
factory training institute (F.T.I)
labour bureau
vigilance
anticorruption cell
yard and estate
confidential section

7. Offices
I.T.C (computer room)
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 Labour Office
Management information system
Marketing
R&D
Stock verification group
Union office
Works committee hall

8. Store and material management

ALE godown
Assembly godown
Chemical godown
Glass godown
Issue godown
Main store
Main store office
Man store godown
Material control
Material control office
Optical gdn
Provision
1- Central Purchase Group
2- Local Purchase Group
Quality control
Quality assurance cell
Q.C final
Q.C fitting
Q.C material
Q.C MS I
Q.C MS II
Q.C MF
Q.C optical
Q.C optical(roughing)
Q.C tool room

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PRODUCTS MANUFACTURED IN ORDNANCE FACTORY
DEHRADUN

1. binocular prismatic 8*30(103A)

2. high resolution bino 8*30
3. passive night vision binocular
4. passive night vision goggles 102A

Passive Night Vision Goggles 102A

5. passive night sight for AK-47 rifle

6. passive night sight 5.56mm[INSAS]LMG
7. passive night sight for 84mm rocket launcher
8. telescope sight for 84mm[rocket launcher]mkii

Telescopic sight (m-1) for 84 mm rcl

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 9. day light telescope 5.56mm[INSAS]rifle
10. anti material rifle sight
11. sight unit cased 102B

Sight unit cased 102 b

12. sights for T-72 tank

PRIMARY CUSTOMERS OF ORDNANCE FACTORY

DEHRADUN
Central ordnance depot-Agra, jabalpur, kanpur,
Assam rifles
Meghalaya police
Airforce
Navy
BSF
CRPF
ITBP
Assam police
DGP chattisgarh
Civil trade-M/S Tata

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SECTION B- STUDY OF SIGHT UNIT CASED 102B C2

COMPONENT 1

ABOUT SIGHT UNIT CASED 102B C2

Optical

Mechanical

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PRODUCT ATTRIBUTES

1. sight unit cased 102B (C2) is a product in which ordnance factory

dehradun claims monopoly in the market(defense)
2. The product is fitted on or near the gunner from where firing is to be done.
3. It is used to measure the angle at which the target is present thereafter
calculating the projectile angle of the fire.
4. C2 comprises of lower mechanical components and upper optical parts.
5. The mechanical components are employed to adjust the optical parts
thereby calculating the angle using drum and scale calibration.
6. The optical components consist of lenses, prism, and objective glass (O.G)
with the help of which proper setting of graticule on the target object is
done.
7. approximately 700 c2 is manufactured annually

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 COMPONENT 2: STUDY IN ASSEMBLY SECTION

REPORT ON ASSEMBLY SECTION VISIT.

In the assembly section of ordnance factory dehradun, the mechanical and

optical components of C2 are fitted together, inspected and tested and then
dispatched.

The final product dispatched is free from errors because as many as 30

readings of each product are taken; it is dispatched only when all the 30
readings are concordant.

Unlike night vision devices, the C2 is carried to the Warfield in cases

provided and once C2 is fitted with the help of dovetail on the mount, it
becomes immovable .hence problems occurring due to mishandling as in the
case of night visions become negligible.

The product is tested for humidity resistance, temperature testing, definition

testing (mechanical and optical axis coinciding) and drop testing.

C2 is made up of gunmetal and steel .Therefore it is very heavy.

PROBLEMS OCCURING AT INSPECTION TIME.

The inspector comes across several mechanical, optical and assembly

problems while testing the product. In the assembly section only assembly
problems are dealt with, if the inspector finds mechanical or optical problem,
it is reported to the machine shops or optical sections respectively.

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 ASSEMBLY PROBLEMS

In the assembly, work is done manually, problem that arises are:-

1. Components appear to be loose during the drop test.

2. Interchanged drums fitted.
3. Gear and spindle not properly fitted hence the lower scale not movable
freely.
4. Back lash errors, (i.e. readings taken clockwise does not match with the
readings taken anti clockwise).
5. Target not in focus, the reason is due to the improper fitting of the
optical parts on mechanical parts (improper fitting on threads).

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COMPONENT 3:- FINDINGS FROM THE STUDY.

PROBABLE REASON

1. The assembly is done in A/C room with the adequate light facilities;
hence working conditions cannot be a problem.
2. the worker posted there have been working for 20-30years or
sometimes even more than that, their promotion is stagnant or
sometimes due to long working time together ,workers are both
frustrated with the same job and at the same time develop friendly
relations with the co-workers. This results in negligence in their
work.
3. since the product is manufactured through assembly the workers do
not have profound knowledge of the end products, a minor error like
gear teeth fitting (should be +/-)is sometimes made(+/+) or (-/-).this
leads to defect in the end product( the disc becomes immovable,
therefore the movable scale becomes stationary)or sometimes
lapping is done improperly, therefore optical path takes elevated
position.
4. Jerky movement of mechanical parts.

Assembly also faces certain mechanical and optical problems

which are communicated to optical and machine shops. this
problem includes

Mechanical:
1. gear teething(major)
2. casting body(guide problem)
3. calibration(done in engraving machine-drum scale)
optical:
1. Graticule thickness(photo etching)
2. Centering of the lens (major problem)
3. prism having bad definition(cutting problems and optical
glass problem)
4. focal length of eye lens not proper
5. Images appear to be inclined.
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 REMEDIES

The proposed remedy for this problem may be proper training of the
employees briefing them about the product use and few technical details.

It is observed that the workers are well versed with their job but they do not
have any knowledge as to where and how the component fits in the end
product. Therefore it is the utmost requirement of the management to provide
some basic knowledge to the workers so that if at all they manipulate it may
be within the tolerance level.

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COMPONENT 4:- STUDY OF THE MECHANICAL DEFECT.

STUDY OF WORM GEAR USED IN SIGHT UNIT CASED C2

The major problem in mechanical parts of sight unit cased as reported by the
assembly is in the worm gear supply by tool room. Gear is anything that is used
to transfer motion from on e shaft to another. This is done by fitting the gear
with a spindle. The process of making the gear teeth is known as gear hobbing.
The term hobbing is used because the tool that is used to cut the teeth is known
as hob tool. The machine employed for cutting the teeth is known as Mikron
gear hobbing machine. The time that one Mikron Gear Hobbing Machine takes
is far more than that of a CNC machine performing the same job. Factory has
not yet purchased a CNC for gearing due to economical constraints. Hence the
daily manufacturing of gears is about 5-6 piece. The depreciation life of the
gear hobbing machine is 20 years but they are being used for 40 years.

PROCEDURE FOR GEAR TEETHING

1. The job, i.e. the worm wheel id fitted on the fixture.

2. Below the job, hob tool is specified no. of teeth is fitted.
3. Pressure angle, pitch, pitch dia, addendum is fixed as per requirements.
4. The job is then tested for concentricity with the help of dial indicator.*
5. A fluid acting as a lubricating agent is run-in between the job and the
tool. (Fluid generally used in such case is cutting fluid but since it is not
easily available and is costly therefore mobile oil is used after diluting
it with kerosene.
6. The machine is run with the help of electricity.

*If it is found that the concentricity is not uniform the elevated portions
are rubbed with the emery paper.

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 DEFECTS FOUND IN THE WORM GEAR

1. Gears are found to be rough maximum number of times.

2. After hobbing the radius from the imaginary axis was not found to be
uniform that is, the bore or root dia, the pitch dia, throat dia, and top dia,
were not found to be concentric.
3. It is sometimes found that the cutting comes out to be non uniform.

The distance a should lie within the

tolerance limit (approx 10u)
Effective Dia

4. The spindle attaches to the gear should also be concentric, i.e. the
thread of the spindle should be concentric with the ball of the spindle.
5. Spindle line should be accurately straight else significant error may
arise in the thread and ball movements resulting in reading errors.

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COMPONENT 5:- FINDINGS FROM THE STUDY.

DEFECT INVESTIGATION

1. The concentricity can be easily checked and adjusted by rubbing with

emery paper. This activity is commonly done
2. Roughness was found to be a major problem occurring frequently.
3. Roughness resulted from defective hob tool.
4. In a hob tool the following problems are found.
Rack angle is not proper.
The groove is not parallel to the mother axis.
Groove is not smooth.
Flutes are not equi-spaced.
5. A hob tool is manufactured by using 2 machines.
1st threads are cut-in this machine errors may arise but they are
rectified manually.
The 2nd machine employed is the cutter grinding machine.
6. In the cutter grinding machine, flutes are equi-spaced by properly
adjusting the index spacing by using mathematical formulae.
7. Smoothing is done by tightening the turning part.
8. Rack angle is presently set with the help of naked eye by experience.

SUGGESTED REMEDIES

1. CNC if employed in place of the presently used Mikron gear hobbing

machine will increase the efficiency of production of gear.
2. Rack angle of hob is set with naked eye on the basis of experience. If a
measuring device is attached to the cutter grinder then the rack angle
will be set accurately thereby reducing the error that is arising due to
improper rack angle.

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COMPONENT 6:- STUDY OF THE OPTICAL DEFECT.

STUDY OF THE MANUFACTURING OF LENSES AND PRISM IN

ORDNANCE FACTORY DEHRADUN

The optical section of Ordnance factory Dehradun is employed in

manufacturing prisms and lenses for various defense equipments. The
prism/lens undergoes multiple operations before finished product is obtained.
The factory is still working with obsolete machines which are there in use since
the inception of the organization. Because of the age-old technology, the
efficiency and effectiveness of the organization is suffering a lot. The working
condition required for the production of the prism and lenses is not being met.
Even though a/c rooms are provided, they are not properly regulated.

PROCEDURE FOR PRISM/LENS MANUFACTURE

ROUGHING
1. Glass block is purchased.
2. They are cut into rectangular slides with the help of
diamond edged wheel cutter.
3. Thereafter the slides are cut into circular discs as per the
given specification of the diameter and thickness.
4. When the slides are cut, they are made a bit more than the
specified dimensions so that errors may not arise during
polishing.
5. After rough cutting, edges are smoothened.
6. The required curvature is then given with the help of
machine, but since the machines are old, there is no proper
device to measure the amount of curvature done; hence the
workman employs hit and trial method.
7. After the roughing stage, the lenses go for inspection.
Almost 100% of lenses pass the inspection test here.
Prisms undergo similar manufacturing process, the difference being that
the moulds are purchased and not cut from the slabs.

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 SMOOTHENING
1. Before polishing, the lenses are smoothened.
2. They are pitch coated on one side and then they are
smoothened under pressure.
3. The pitch is then removed by putting the lenses in benzol.
Thereafter they are cleaned using ethyl alcohol.

POLISHING
1. polishing is done to increase the transparency of the optics
2. It is done with the help of cerium oxide.
3. Then they are checked for angle accuracy using reference
/master lens/prism.

COATING

Coating is the process by which we try to reduce the amount of light reflected
thereby increasing the amount of transmitted light. In a day sight telescope, 17
optics are used, without coating, an optic reflects 4% of the light incident on it
hence it transmits 96%of the light. The same applies to all the optics set inside
the telescope. It is found that at the end only 205 of the light is transmitted out
of the telescope. This results in blurred image formation.
Therefore coating is done with MgF2. this reduces the reflected light to 0.5%.
For reflection to be 0%, we need to coat with TiO2 +SiO2 or TaO2+SiO2. But
these are very costly. In night vision they are used since at night we have no
light in the visible range, the night vision works in the infra red range therefore
no ray could be afforded to be reflected. The thickness of the coating is kept to
be 1450 angstorm.i.e. (Lambda/4).
The coating of lenses is done in a computerized coating machine.

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 CENTERING AND EDGING

Centering came out to be a major problem in assembly.i.e the lenses were found
to be eccentric or in other words, their center was found to be out.
Centering means that the mechanical axis (i.e. the barrel) and the
optical axis (the axis passing through the center of curvature) should be parallel
to each other; else image formed will be out of the barrel.

Mechanical
Rifle Axis

Lens Optical axis

Edging is done after centering, this means, the cutting of the extra glass
encircling the lens
.
PROCEDURE FOR CENTRE-EDGING

1. There are 3 methods that could be used for centering

Bell clamping method
Optical centering method(good accuracy)
Laser centering method(good accuracy)

BELL CLAMPING METHOD

This method should only be used if the angle between the 2 lenses is
x>190.

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1. The tool used for centering is known as Mendel.
2. In a centering machine, 2 Mendel are placed with their axis aligned.
3. The 2 axis are aligned manually.
4. The spindle along with the Mendel is placed in a pedaled machine.
5. The machine is pedaled and a glass is put in front of it.
6. cosmeticity is done(i.e. giving appropriate angle to the rim of the
Mendel)manually, approximately 300.
7. The reflection of a table lamp kept in front of the Mendel is seen.
8. The Mendel will be accurately aligned only if the lamp image is still i.e. it
will not vibrate.
9. In the centering machine, lens will be placed. The machine will cut the
lens where optical axis and mechanical axis is parallel. Simultaneously the
extra edges are cut.

OPTICAL CENTERING METHOD

1. In this method, the pedaled machine is used not only for aligning the
mendels but also centering the lenses.
2. The lenses are placed before the Mendel and the 2 images of the lamp that
are formed are observed.
3. If the 2 images are found to be overlapping and still, then it was
concluded that the lens is centered.
4. Thereafter the lenses are taken for edging.
5. Edging is done using diamond fitted ring which cuts the extra glass in the
lens.

LASER CENTERING METHOD

1. This method employs the use of completely automatic centering machine
with the use of laser technology.
2. The lens is placed in between the Mendel and then laser ray is passed
through the set up.
3. The monitor alongside shows the orientation of the lens.
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 4. The worker then commands center the lens.
5. In this machine edging is done automatically once the centering is done.

COMPONENT 5:- FINDINGS FROM THE STUDY

1. Roughing, smoothening, polishing, coating did not show any problem, the
problem was seen during the centering stage.

2. It was found that the bell clamping method was used even when the angle
is < 190.this is because the workers find this method more convenient and
less time taking.

3. When pedaled machine is used, the reflection of the lamp is seen by naked
eyes. There may instances when out of fatigue the workers find it difficult
to determine whether the image formed is still or not.

4. The workers are not concerned about the accuracy rather they are more
concerned about the amount of job done.

5. The work environment of the optical section does not meet the
requirements, like the temperature should be maintained round 220C, but it
is actually around 27-28oC.

SUGGESTED REMEDIES

1. Centering needs a lot of precision. In the reflection method used, the

workers make a lot of mistakes. Since the alignment of Mendel and the
lens is of utmost importance therefore the factory should employ CNC for
this job.
2. The workers are paid on the basis of the number of lens they manufacture
irrespective of the accuracy, instead of this; the factory should pay
workers on the quality of the lenses produced.
3. The workers decline to give their 100% when they compare their working
environment with other private companies.

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SECTION C STUDY OF THE NIGHT VISION DEVICES.

COMPONENT 1 : ABOUT NIGHT VISION DEVICES.

PASSIVE NIGHT VISION BINOCULAR

The indigenous binocular night vision passive, light weight is designed and
developed by Instruments Research and Development Establishment, Dehradun
for surveillance at the company and platoon level and for use by patrols
commandos. This binocular would provide vision at night using the night
ambient low level of illumination due to stars and moon. The range of
recognition PNVB is human being-300m, vehicles/tanks-500m.under clear
starlit night medium contrast. The magnification of PNVB is 4X.

GOGGLES NIGHT VISION PASSIVE CASED 101 A

This product is used to read maps. At night when soldiers are required to read
maps, they cannot light torches else the enemy will be able to locate them.
GNVP cased 101A is equipped with II tube. This glows in dark and thus helps
in reading maps.

SIGHT NIGHT VISION (84mm CARL GUSTAV, 5.56mm LMG (INSAS),

5.56mm RIFLE 101A)

Sight night vision prominently has a graticule since they are used for sighting;
they are mounted on the weapon.
84mm carl gustav is a rocket launcher, LMG-light machine gun, 5.56mm rifle is
used by infantry.

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 COMPONENT 2: STUDY OF NIGHT VISION (CASE STUDIES)

CASE #1
Customer central ordnance depot, Agra. (COD Agra)
Complaint date-20-03-10
1. crew served weapon sight(MMG)passive cased 101A
Manufactured -243
Defective-59
Defect-tube not glowing
2. goggles night vision passive
Manufactured -901
Defective-186
Defect-tube not glow
3. bino night vision passive 101A
Manufactured-221
Defective-147
Defect-tube not glowing
4. sight night vision passive 84mm Carl Gustav
Manufactured-557
Defective-134
Defect-
a) II tube not glowing
b) Dirt on optics
c) Body damaged
d) Hinge broken
e) Switch broken
5. sight night vision passive 5.56mm LMG(INSAS)
Manufactured-5600
Defective-1078
Defect-
a) II tube problem
b) Body oxidation

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 CASE #2
Customer-COD Agra
Complaint date-18-12-09

Product # rejected Defects

II tube other defects

PNS 5.56mm 39 24 15
LMG
PNS 21 8 13
5.56mm rifle
CSWS 5 5 0
PNVB 17 12 5
SNVP 84mm 30 7 23
GOGGLES 14 6 8

CASE #3
Customer- COD Agra
Complaint date-30-04-09

Product #rejected defects

PNS LMG 27 24-I I tube
03-body oxidation
SNVP 84mm 26 01-switch broken
06-I I tube problem
04-body damage
10-OG dirty
04-hinge broken
CSWS 05 II tube problem
PNS Rifle 10 09-I I tube problem
01-cover broken in
battery housing
Goggles 06 Battery housing
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 broken
PNVB 13 I I tube problem

CASE #4
Customer-COD Agra
Complaint date-11-07-08
Product- PNS rifle 5.56mm

DEFECTS FREQUENCY
Battery connection strip 1
detached
Black patch 1
On/off switch 1
Paint particles 1
Dirt on optics 1

1) PNS goggles 102A

DEFECTS FREQUENCY
Body loose 29
Dust on optics 2
Focusing ring sticky 3
Paint particles 4
I.R not glow 3
On/off switch 2
O.G loose 1

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 CASE#5
Customer-COD Agra
Complaint date-30-06-08
Product-sight night vision passive 84mm Carl Gustav & passive night
vision bino

DEFECTS FREQUENCY
Excessive grt light on II tube 2
Grt not glow 3
Battery cover hinge broken 1
Moisture on optics 1
Mounting bkt defective 1
On/off switch 5
Image not in focus 1
Dust on optics 1
Eye piece defective 1

CASE#6
Customer COD Agra
Complaint date- 23-06-08
Product-SNVP 84mm Carl Gustav & PNVB

DEFECTS FREQUENCY
Body loose 15
IR not glow 2
ON/off switch 3
Paint particles 2
Dust on optics 1
Potmeter broken 2
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Grt not on 1

CASE #7
Customer complaint- COD Agra
Complaint date -14-06-08
Product- SNVP5.56mm rifle& LMG (INSAS) 101A
DEFECT-
01. Major defect that was pointed out in almost 100% of the
product supplied was that the battery insulator was stripped off.
2. Secondly, the sight was not functioning in the products.

CASE#8
Customer- COD Agra
Complaint date-05-05-08
Product-PNVG cased 102 A

DEFECTS FREQUENCY
Dust on optics 1
Focusing ring sticky 3
On/off 2
Paint particles 5
Body loose 7
I.R lamp not glow 1
O.G loose 1

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 COMPONENT 4: ANALYSIS OF NIGHT VISION DEFECT

From the given data available, the following conclusions can be drawn:-

1. A total of 1220 times it was reported that defects in the I I tube led to the
rejection of the product.

2. Other than the I I tube defect, the products show mechanical and optical
problems as well.

3. Out of the reported mechanical problems, 66 times it is observed that the

body of the product is loose and this is most prominent in goggles night
vision passive cased 101A. Secondly, the switch was also reported to be
broken 23 times.

4. Out of the reported optical problems, dirt on optics was observed 18

times, 13 times paint particles were observed in the optics.

5. Maximum number of defects was observed in sight night vision passive

5.56mm rifle, next being in goggles night vision passive cased 101A.

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 COMPONENT 5: I I TUBE STUDY

I I Tube is the image intensifier tube that is planted in night vision devices. It is
imported from Germany. This I I tube helps in intensifying the electron flux
thus increasing the amount of light reaching the photocathode. The electron flux
is intensified with the help of micro-channel plates.

Micro channel plates

Anode photo cathode

Incident receiving lens

Ray(mainly
I.R during night)

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probable reasons for rejection of 18mm I I tube

Defects

Black spot>600um 3
problem at emission point 4
wire cut 2
Flickering 2
dent on anode 6
Black spot>400um 3
less resolution 7
Black patch 1
dark area 3
Black spot>500um 3
Black spot>800um 2
no glow 10
bright spot 2
less glow 1
brightness more 2
Black spot>1000um 2
Black spot>300um 2
physically damaged 1
Black spot>700um 1
Black spot>2000um 1
blurred image 1
vacuum leak 3
Shade 2

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 COMPONENT 6: FINDINGS FROM THE STUDY

1. I I tube is not manufactured in the organization so the defects have to be

carried.
2. Secondly, the manufacture of night visions have come to a stand still
because other companies are manufacturing advanced versions of night
visions.
3. Hence the defence forces prefer to purchase from private companies at a
lower price.
4. The night visions that were manufactured were very heavy and their body
got oxidized easily.
5. The body was found to be loose and battery housing was found to be
broken maximum number of times.

SUGGESTED REMEDIES

1. The body used in the night vision was magnesium, which gets oxidized
easily, more over it leads to heavy weight of the product.

2. if plastic body is used these problems of oxidization and heavy weight

may be solved.

3. This may give the organization a competitive advantage over other

companies which may once again attract its customers.

37
 SECTION D: CONCLUSION OF THE PROJECT

1. Even though there is quality control checking at each and every stage of
manufacturing, rejection does takes place.

2. Quality checking is done by sampling i.e. the complete

population of the components are not checked. It was seen
that no proper sampling method was used.

3. The workers working in the organization are piece workers

and are paid on the amount of job completed. Therefore it
becomes more important for the workers to be efficient
rather than effective. Hence they use their own
conventional ways of completing a job. The management
can make a slight change that workers will be paid on the
basis of quality of the job rather than the quantity of the
jobs.

4. Use of modern technology may also improve the

productivity of the organization.

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