“Internship Report”

Submitted to

SAVITRIBAI PHULE PUNE UNIVERSITY, PUNE

For the Degree of

BACHELOR OF ENGINEERING
In

Electronics and Telecommunication Engineering

By

Dhavale Priti Sanjay

Academic Year: 2023 – 2024

DEPARTMENT OF ELECTRONICS & TELECOMMUNICATION ENGINEERING

SAMARTH GROUP OF INSTITUTES COLLEGE OF

ENGINEERING, BELHE-412410
 SAMARTH GROUP OF INSTITUTIONS COLLEGE OF
ENGINEERING, BELHE – 412410

CERTIFICATE
This is to certify that the project report entitled

“Internship”

is satisfactorily completed by,

Dhavale Priti Sanjay

In partial fulfillment of requirement for the degree of Bachelor of Engineering

(Electronics & Telecommunication Engineering) of Savitribai Phule Pune University, Pune.

Mrs. D. A. Gadge Mr. N. S. Kothari

Internship Guide H.O.D

Prof. Dr. D. E. Upasani

Principal
SGOI COE. Belhe
 Internship Report.

PREFACE

With the ongoing electric revolution where innovation are taking place at the blink of an
eyes, it impossible to keep the pace with the emerging trends, In organization where Making Things
Right in the first instance is the driving motto, perfection and accuracy are inevitable. Excellence is
an attitude that the whole of the human race is born with. It is the environment that makes sure that
whether the result of this attitude is visible or otherwise. A well planed, properly executed and
evaluated industrial training helps a lot in inculcating a professional attitude. It provides a linkage
between the student and industries to develop an awareness of industrial approach to problem solving,
based on a broad understanding of process and mode of operation of organization.
During this period, the students get the real, first-hand experience for working in the actual
environment. Most of the theoretical and practical knowledge that has been gained during the course
of their studies is put to test here. Apart from this, the students get an opportunity to learn the latest
technology, which immensely helps them in building their career. I had the opportunity to have a real
experience on many ventures, which increased the sphere of knowledge for me in a great extent. I was
entrusted with a real-life project, working on which had finally made me step into the ongoing electric
revolution and gradually become a part of it. And all the credit goes to organization FLASH
ELECTRONICS PVT.LTD Industries which is true self made the electronic revolution.

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ACKNOWLEDGEMENT

I am incredibly grateful to my internship supervisor, Mr. Rashidh Sir, for their invaluable
guidance and support throughout my internship. I would like to thank Sir for giving me the
opportunity to do internship within your Organization. We express our sincere thanks to Mrs. Sneha
Mam whose Guidance and inspiration as well as valuable discussion and constructive criticism
provide during the Internship. We shall ever be grateful to her for the encouragement and
suggestions given by her from time to time. She helped us to solve our difficulties.
We are also thankful to Ashok sir, for his constant guidance. Also of this company for providing
necessary facilities during the period of Internship. And finally our heartfelt gratitudeto all our friends
who helped us in completion of this Internship.
In addition I thanks to my colleagues, the staff at FLASH ELECTRONICS PVT.LTD. were always
helpful and efficient in assisting me with any needs or questions I had. I am highly indebted to
Principal, Prof.Dr.D.E.Upasani for the facilities provided to accomplish this internship. I would
like to thank my Head of the Department Mr. N.S.Kothari for his constructive criticism throughout
my internship. I would like to thank , Department internship coordinator Mrs. D.A.Gadge for her
support and advices to get and complete internship in above organization. I am extremely grateful to
my department staff members and friends who helped me in successful completion of this internship.

Ms.Dhavale Priti Sanjay

SGOI College Of Engineering, Belhe

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CONTENTS

Sr.No CONTENTS Page No

1 Introductions
1.1 Basic Information about Company 1-3

1.2 Infrastructure 04

1.3 Company catered to 05

1.4 Training 06
1.5 Customer 07

Products 08
2
2.1 MOSFET RR 09

2.2 AC ignition coil 10

2.3 DC cdi 11

2.4 BLDC Stator 12

2.5 SMT 13

3 Equipment and Machinery 14

4 Infrastructures 15

4.1 Infrastructure of Products 15

4.2 Further to maintain Functioning 15

4.3 Product Range 15

5 Manufacturing Process 16

6 Maintenance 17
6.1 Routine Maintenance 17
6.2 Necessity of Preventive Maintenance 17
7 Production And Control Planning 18
7.1 Production Planning 18
7.2 Steps in Production and Planning 18

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8 Testing of raw materials & components 19

8.1 Finished Products 19
8.2 Quality Assurance 19

9 Practical experience 20
9.1 Practical Experience 20
9.2 Assembly 20
9.3 Testing 20
9.4 Safety Procedure: 20
9.5 Maintenance Breakdown 20

10 Special challenges experience 21

11 Conclusion 22
12 References 23
13 Photographs of Internship 24

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CHAPTER 1

INTRODUCTION

FLASH GROUP is a preferred partner for many Automotive OEMs around the world. FLASH has 6
manufacturing plants across India, Germany & Hungary and is driven by a strong team of 2500+
individuals. FLASH has earned the reputation of being a bankable partner and solution provider for
the automobile industry because of:

 Our ability to offer innovation driven differentiation

 Strong R&D team and state-of-the-art R&D center
 Robust design & manufacturing facilities
 Adherence to stringent quality standards

At it’s inception, Flash started out with the commercial production of AC Flashers. Subsequently
over the last 3 decades more than 150 products like - Regulators, Capacitor Discharge Units,
Magnetos, Alternators, Starter Motors, Wiper Motors, Ignition Coils, E.M.I Suppressors, Spark
Plug Caps, Linear Actuators, Thermostats, Sensors, Throttle Bodies, Brushless DC Motors and E-
mobility products were added to our portfolio

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COMPANY PROFILE

In 2016 & 2018 respectively, FLASH set up highly advanced automated Machining and
Forging plants. We were motivated and supported by our clients to establish these Strategic Business
Units (SBUs). Today these SBUs are our biggest validations for the continuous value we have been
able to create for our customers. Our plants are state-of-the-art and have set new benchmarks in the
industry. At Flash, our core competency is manufacturing of cutting-edge electronic and electrical
auto components. Our first 3 plants located in Chakan Industrial Area in Pune(India), have capabilities
to match international standards in regards to forging, machining, manufacturing and quality control
with the best names in the industry. At present, we manufacture components for 2 , 3 and 4 wheeler
categories.

Our HR is a team of 2500+ people comprising of engineers, managers, professionals in

various techno-commercial functions and front line skilled and semi-skilled employees. Motivated
employees are one of the most critical elements of excellent customer service. Our culture ensures
that our employees feel safe at work, are able to contribute to the value chain and see a well-defined
career trajectory. The fact that more than 50% of our work force are career employees stands
testimony to our dedication to our most critical resource

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Mission :
To partner with our customers in creating innovative products backed by robust
manufacturing systems and adherence to stringent quality standards.

Vision :
To be the preferred partner of modern mobility solution providers worldwide.

1.1 Basic Information about Company

Nature of Business :- Manufactures Automotive, Electronic parts

Additional Business :- EV parts, Electric Mobility
Company CEO :- Rajnish Diwan
Year of Establishment :- 1989
Company Website :- https://www.flashgroup.in
Industry :- Appliances, Electronics Manufacturing
Company size :- 1,001-5,000 employees
Headquarters :- Pune, Maharashtra, India.
Annual Turnover :- Rs. 500 Crore

1.2 Infrastructure
Location Type :- MIDC
Building :- Permanent

1.3 Industries Catered To

BAJAJ Auto
TATA Motors
Tesseract Learning Pvt. Ltd.
Syrma SGS Technology Ltd.
Electronics Industries
Impression Auto Components Pvt. Ltd.
SP Semiconductors Pvt. Ltd.
KAYNES TECHNOLOGY INDIA LIMITED
Skilling India in Electronics

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1.4 5S SYSTEM

5S is a systematic form of visual from visual management utilizing everything from floor tape to
operations manuals. It is not just about cleanliness or organization; it is also about maximizing
efficiency, quality, and profit. 5S is a framework that emphasizes the use of a specific mindset and
tools to create efficiency and value. The 5S checklist guides manufacturers in observing, analyzing,
collaborating, and searching for waste and also involves the practice of removing waste.

1) Sort / seiri.
2) Set in Order / Seiton.
3) Shine /Seiso.
4) Standardize / Seiketsu.
5) Sustain / Shitsuke.

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1.5 TPM(Total Productive Maintenance)-

T: TOTAL –
 Participation of all Employees.

 Include all Departments,operation, equipment and process.

P: PRODUCTIVE –
 Pursue the maximization of efficiency of the production system by making all loses zero.

 Zero accidents Zero defects Zero breakdowns.

M: MAINTENANCE –
 To improve the efficiency of the equipment.

 Maintenance means the entire life cycle of the production system.

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1.6 PPE(personal protective equipment)-

Personal protective equipment, commonly referred to as "PPE", is equipment worn to minimize

exposure to hazards that cause serious workplace injuries and illnesses. These injuries and illnesses
may result from contact with chemical, radiological, physical, electrical, mechanical, or other
workplace hazards. Personal protective equipment may include items such as gloves, safety glasses
and shoes, earplugs or muffs, hard hats, respirators, or coveralls, vests and full body suits.
Employers are also required to train each worker required to use personal protective equipment to
know:
When it is necessary
What kind is necessary
How to properly put it on, adjust, wear and take it off
The limitations of the equipment
Proper care, maintenance, useful life, and disposal of the equipment

If PPE is to be used, a PPE program should be implemented. This program should address the hazards
present; the selection, maintenance, and use of PPE; the training of employees; and monitoring of the
program to ensure its ongoing effectiveness.

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2.4 SMT (Surface Mount Technology) -

Fig 2.5 BAJAJ, Chetak control & power board.

Product -BAJAJ, Chetak control & power board.

Step 1. Loader –
o PCB arrange manually in loader tray that’s called Maxin
o Maxin loader machine sends one by one or in fast mode.

Step 2. QR code printing- Time (3pm)

o QR get print on PCB

o QR contain information with

e.g GL301031107607BT34923150333 sr. no. no.of job

here BT stands for A=0
B=1
& T = Top

Year(2023)

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Step 3. Cleaning-
o Cleaning machine clean the PCB remove dust from PCB.
o Close Loop System.

Fig. PCB Cleaner

Step 4. Pasting-

o Pasting machine is an solder paste is in liquid form

o Which is use to solder components
o Leaded solder paste 5100
o It take 14 sec to pasting

Step 5. Solder Paste Inspection-

o It detects that solder paste pasted on PCB is in proper manner or not & proper quantity
or not .
o When it paste well then it pass good

Fig. Solder Paste

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Step 6. Pick &Place-

o Machine mount component automatically on PCB
o Machine divided into chembers
1&2nd chember contain small components such as register, diode, etc
3rd – MOSFET
4th – capacitor

Fig. Peak & Place

Step 7. Reflow soldering-

o PCB comes from last station with mounted components
o At the middle of power board we manually insert connector component &sends to
reflow soldering with the help of conveyer machine.
o It have zones
10 heating zone
4 cooling zone
o When PCB pass through RSS it solder the PCB components tightly with hot air
o The cooling chember is cooles PCB & pass to next stage

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Fig. Reflow Soldering

Step 8. Auto optical Inspection-
o It check QR & compare it IMG. with past IMG.
o It is visual inspection on our knowledge power

Fig. Auto Optical Inspection

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Step 9. ICT Testing-

o It check QR scan QR & writing QR code no on a Registor manual.
o It check connecting terminals to power & check whether all components are working .
o It is an master test.

Step 10. Conformal coating-

o In which PCB is coating by an solution
o It increase lifespam of an PCB
Chemicals-
 Humiseal -1B18

Step 11.MCU UV Light Inspection-

o Coated PCB visually check on this site under blue light.

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MCU Assembly line

Step 1. Power board testing
o Connect board to testing bench
o Select appropriate program and model
o All parameter must be selected during testing
o Start the testing
o Press reset switch if unit shows faulty
o If unit passes all test mark it as ok tested

Step 2. AFT TAPE & Magnet core application on control PCB

o Take foam from storage
o Place magnet core over foam tape fixed on holding fixture
o Check magnet core properly fixed on foam tape.& if ok then pass to next stage.

Fig.control PCB

Step 3. Microcontroller programming-

o Start machine & select program
o Load PCB on fixture
o Start operation of programming
o Unload PCB with marking on PCB & if its ok then pass to next stage

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Step 4. Base cleaning-

o MCU base should be cleaning at PCB resting area Treebond syper cleaner
o Then load inspected MCU base on machine below stensil
o Then start machine cycle
o Check grease quantity weight up 1.8-2.3gm

Step 5. Power board Tightening –

o Power board will fix on MCU base with screw fitting.

Fig.Power Board Tightening

Step 6. Tightening of all terminals-

o Power board will fix on all terminals MCU base.

Step 7. Retightening of PCB & all terminals-

o All screw get tightened by machine with maximum torque.
o If job ok then mark with yellow marker.

Step 8. PCB Assembly Testing-

1. IR testing
2. MOSFET testing
3. Resistance testing
4. Final result pass

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Step 9. Control PCB tightening-

o On power board control board get fixed on it with screw & connected both by male
female switch

Step 10. Laser marking of QR code on base of MCU-

o It make combine QR code of power board & control board & print on base board

Step 11. Current sensor calibration-

o It provide current & pass through sensor
o It checked with its provide parameters

Step 12. PRE-EOL Testing-

o It checked all parameters perform on previous stages
o If ok then it pass to next stage

Step 13.Sealeant filling in base groove & Around terminals-

o It apply solution around a terminals & n space of a base for air pack tightening of a
cover

Step 14.Cover tightening-

o On applied three bond solution cover will applied & tightened with screw

Step 15. Cavity filling around the terminals with sealent-

o Around a terminals apply three bond solution for air tightening & it store to rack for
natural curring for 72hrs.

Step 16. Burn in testing-

o Run tested job for more capacity than its max capacity
o It is an 30 min cycle

Step 17. EOL Testing-

o It is an final testing
o It checked all parameters
o If job is final mark on base with white marker

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Step 18. Leakage Testing-
o It checked with air pressure machine that job have an any where air passes through
any small hole
o It check vaccum leakage from MCU
o It mark with green marker

Step 19. IR Testing-

o It is an final testing
o It check that job ok or not
o That it check job passes through all stages successfully or not

Step 20. Flashing-

o On a job QR code sticker is get stick
o Red, yellow, blue colour sticker also sick on job
If sticker is stick on a job then if any difficulty happened with job then we cant
decode that job directly even we can’t use, we have to decode that job with customers
permission.

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Fig. Sticker

Fig. QR Printing Machine

Fig. Code Sticker

Step 21. Dispatch-

o At this stage job is get packed and dispatch to customer.

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CHAPTER
23
EQUIPMENT AND MACHINERY

Types of equipment used

Sr. No Equipment
1 2D Laser Barcode Printer
2 PCBA Flipper
3 3D X-ray Inspection
4 Automatic Wave Soldering Pallets
Cleaning

Fig. 2D Laser Barcode Printer Fig. PCBA Flipper

Fig. 3D X-ray Inspection

Fig. Automatic Soldering Pallets Cleaning

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CHAPTER
24
INFRASTRUCTURES

4.1 Infrastructure of Product:-

Covered area of 15000 sq meters. Latest generation SMT line with Auto Loaders, untouched by
human hand. Computerized In-Circuit & functional testers. Computerized testing of CDI, Motors,
Ignition coils and Magnetos. Fully atomized potting with convey oven. Fully Air conditioned, dust
and humidity controlled environment. State of the Art R&D Center with in-house reliability test
equipment. Latest winding and balancing machines. Comprehensive in-house type test facilities.
Tool Room facilities. Standards room.

Apart from these our sound infrastructural facilities enables us to offer:

 Strong In-house R & D for designing the products as per customer as well as vehicle
specifications.

 Consistent top Quality which gives us the winning edge over competition. 

 Cost Effective products through technology and in-built systems. 

 On Time direct on line delivery to our customers. 

4.2 Further to maintain functioning, infrastructure in following department

 Manufacturing unit 
 Quality control Department
 Sales and Marketing Division
 Administrative unit 

4.3 Product Range

We are engaged in supplying a wide range of Electrical part, Electric Mobility | Gears,
Shafts, Sprockets & Transmission | Throttle Bodies | Exhaust, Gas & Temperature Controls |
Emissions Controls for 2,3 & 4 Wheelers etc.
We are successfully ranked amongst the top manufacturers and suppliers of Electrical Vehicle
parts.

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CHAPTER
25
MANUFACTURING PROCESS

At Flash, our core competency is manufacturing of cutting-edge electronic and electrical auto
components. Our first 3 plants located in Chakan Industrial Area in Pune (India), have capabilities to
match international standards in regards to forging, machining, manufacturing and quality control
with the best names in the industry. At present, we manufacture components for 2 , 3 and 4 wheeler
categories. We are delighted to share that Flash Electronics & Flash Viven received the prestigious
Quality Award in the Gold Category and Flash Viven received BAL TPM Award at the Bajaj Auto
Vendors Association (BAVA) Convention 2023-24.

Our teams have achieved the following awards:

- Sunrisers Magneto: Excellence Award

- Spartans: Excellence Award
- Flash Forward: Excellence Award
- Flash Warriors: Distinguished Award

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CHAPTER
26
MAINTENANCE

6.1 Routine Maintenance

Routine maintenance refers to any maintenance task that is done on a planned and ongoing basis
to identify and prevent problems before they result in equipment failure.
Maintenance is the key to ensuring your Industrial parts runs efficiently. Proactive maintenance can
prolong the life of the job and reduce hazardous situations. Develop a regular maintenance schedule,
and partner with a business that will send a professional technician to your facility to inspect the ICP
and other equipment.

6.2 Necessity of preventive maintenance

i. Preventive maintenance is a proactive approach to maintaining equipment and facilities.

ii. It involves regularly scheduled inspections, tests, and other activities that are designed to
identify and correct potential problems before they can cause failures or other issues.
iii. To reduce the loss of production from equipment failure.
iv. To prompt better safety, health and environmental conditions for our workforce.
v. To use timely, routine repair to bring about fewer large scale repairs.
vi. The wiring and components of your Industrial motors should be labeled and organized. This
makes it easier to maintain and repair.

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CHAPTER
27
PRODUCTION AND CONTROL PLANNING

7.1 Production Planning

Production planning is the planning of production and manufacturing modules in a

company or industry. It utilizes the resource allocation of activities of employees, materials and
production capacity, in order to serve different customers.
The five steps of making your production plan are:
 Forecast product demand.

 Map out production steps and options.

 Choose a plan and schedule production.
 Monitor and control.
 Adjust accordingly.
The Seven Steps of Action Planning
 Define the Problem(s)

 Collect and Analyz the Data.

 Clarify and Prioritize the Problem(s)
 Write a Goal Statement for Each Solution.
 Implement Solutions: The Action Plan.
 Monitor and Evaluate.
 Restart with a New Problem, or Refine the Old Problem

Production control ensures optimum performance from the production system by using different
control techniques for better throughput targets.
Production planning helps manufacturers work smarter by efficiently managing internal
resources to meet customer orders or demands. It solves what, when, and how much to produce. It
establishes production capacity and identifies what raw materials, bill of materials, or alternate bill of
materials are needed to meet demand. Then it prepares a workable production plan.

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CHAPTER 8
TESTING OF RAW MATERIALS & COMPONENTS

8.1 Finished Products:-

 Test insulation resistance of MCC bus with a 1-minute test (phase to phase and phase to
ground).
 Test insulation resistance of instrument transformers and control power with a 1 minute test at
appropriate voltage.
 Test insulation resistance of contactor (closed position) with a 1-minute test (phase to phase
and phase to ground).
 Test contactor contact resistance with micro-ohmmeter.
 Test reliability of every vacuum interrupter on a vacuum contactor in agreement with
manufacturer’s standards.
 Calibrate and test each protective relay with settings on devices being in accordance with
approved relay settings summary or coordination study.
 Test contactor drop out time if power disturbance ride through is indicated.
 Test operation of all space heaters including switching and indicating devices.
 Test CT circuit by applying current to the CT primary circuit and verifying operation of all
applicable relays and metering devices.

8.2 Quality Assurance

Quality is the heart of our organization and all are activities are centered on it. For
manufacturing a premium range of panels, we manufacture them from high grade raw material that is
procured from reliable vendors. To ensure the quality of our products, we conduct various tests that
include:
 Thorough electrical testing such as high voltage, temp. rise test etc.
 System simulations as per requirement
 Continuity test

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CHAPTER
29
PRACTICAL EXPERIENCE

9.1 Practical Experience

During the production of sleeping’s many times our Production Experience is a full of
experience which make us more confident and positive. here are many difficult tasks are performed
and get output successfully under guidance of our supervisor. In production first we make planning
and then finalized our target.

9.2 Assembly:
An assembly line is a manufacturing process in which interchangeable parts are added
to a product in a sequential manner to create an end product. Assembly line methods were originally
introduced to increase factory productivity and efficiency.

9.3 Testing:
Product testing is any process by means of which a researcher measures a product's
performance, safety, quality, and compliance with established standards. In industry after
manufacturing of different products it is necessary to test them before selling. After testing and
analyzing the products, faults of products are corrected and ready them. Due to testing we can supply
better products to customer.

9.4 Safety Procedure:

Step 1: Demonstrate Company’s Commitment to Workplace Safety
Step 2: Assess Workplace Risks and Hazards
Step 3: Create a Written Protocol for Employees
Step 4: PPE
Step 5: Implement and Evaluate

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CHAPTER 30
SPECIAL CHALLENGES EXPERIENCE
Special Challenges:

Challenges faced during manufacturing of products are:

1) Regulation and traceability.

2) Product development and innovation.
3) The manufacturing skills gap.
4) Healthcare costs.
5) Environmental concerns and considerations.
6) Balancing maintenance with throughput.
7) Skilled Labor.
Workplace Challenges
 Making Mistakes.
 Time Management.
 Slackers.
 Disagreeable Coworkers.
 Office Bullies.
 Gossipers and Trouble Makers.
 Take care of yourself.
 Take care of your body.

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CHAPTER 31

CONCLUSION

In a nutshell, this internship has been an excellent and rewarding experience. I can conclude
that there have been a lot I’ve learnt from my work at FLASH ELECTRONIC PVT. LTD. Needless
to say, the technical aspects of the work I’ve done are not flawless and could be improved provided
enough time. Two main things that I’ve learned the importance of are time-management skills and
self-motivation. Throughout my internship, I faced various challenges that demanded learning
industry knowledge and technical skills. Balancing the demands of a unique sales environment while
diving deep into the complexities of financial services was challenging but provided remarkable
opportunities for growth. The most valuable lesson I learned was the importance of effective
communication. Learning how to conversate with my co-workers and advisors about financial
concepts and presenting them underscored the necessity of clear and tailored communication.

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CHAPTER 12

REFRENCE

1. www.google.com
2. https://www.flashgroup.in/
3. https://www.financialexpress.com/business/express-mobility-flash-electronics-appoints-
rajnish-diwan-as-ceo-3118380/
4. https://in.linkedin.com/company/flash-electronics-india-pvt-ltd
5. https://www.indiamart.com/flash-electronics/aboutus.html
6. https://www.ambitionbox.com/overview/flash-electronics-overview
7. https://www.justdial.com/Kozhikode/Flash-Electronics-Near-RIYA-TRAVELS-Mavoor-
Road/0495PX495-X495-160704165638-R7Y7_BZDET
8. https://www.amazon.in/b?ie=UTF8&node=26039264031
9. Supervisor.
10. Shift in-charge.
11. Daily diary .
12. Operators .
13. Development head .
14. Plant manager & HR Team.

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CHAPTER 13

PHOTOGRAPHS OF INTERNSHIP

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THANK YOU ……

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