Chapter -1

1.1 Organization Profile on Schneider Electric India Private Limited

Mysuru

Fig 1.1

1.2 Overview of Schneider

Schneider Electric is a global leader in energy management and automation solutions. With a
strong commitment to sustainability, innovation and efficiency, the company has built a
reputation as the most local of global companies. Operating in over 100 countries, Schneider
Electric integrates world-class energy and process technologies, connecting products, controls,
software and services across the entire lifecycle to drive digital transformation.

Global Reach and Multi-Hub Model

Schneider Electric adopts a multi-hub approach to enhance resilience and agility. This model
enables the company to remain close to its customers and suppliers, ensuring efficient decision
making and operational flexibility. Its operations span the Americas, Europe, Asia-Pacific and
Africa, with a balanced geographical footprint that supports global and regional demands.

Core Offerings

The company offers innovative solutions across several domains, including:

• Buildings: Energy-efficient and automated building management systems.

• Data Centers: Scalable and sustainable energy solutions for growing digital
infrastructure.
• Industry: Advanced automation and digital solutions for manufacturing and
production.
• Infrastructure: Comprehensive solutions for urban and rural infrastructure projects.

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Sustainability at the Core
As a self-proclaimed "impact company," Schneider Electric embeds sustainability into all
aspects of its operations. From product design to supply chain management, the company
leverages technologies like electrification, automation and digitization to help its customers
reduce carbon emissions and achieve energy efficiency. Over 553 million tonnes of emissions
have been saved or avoided for customers since 2018, demonstrating its commitment to
addressing climate change.

Fig 1.2

1.3 Vision and Mission

Vision
Schneider Electric’s vision is to empower individuals and organizations to achieve more with
their energy and resources while advancing sustainability and technological progress. The
company envisions a world where access to energy and digital technologies is a basic human
right, contributing to a more equitable, connected and sustainable planet.

The organization believes in driving the energy transition and industrial revolution through:

• Increased electrification as a means of decarbonization.

• Adoption of circular economy principles to achieve resource efficiency.
• Utilization of artificial intelligence and data-driven insights to optimize performance.

By bridging the gap between progress and sustainability, Schneider Electric aspires to make a
significant climate-positive impact aligned with the United Nations Sustainable Development
Goals (SDGs).

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Mission
Schneider Electric’s mission is to be the premier digital partner for sustainability and
efficiency. The company aims to:

1. Provide innovative technologies and solutions that empower businesses and individuals
to optimize energy use.
2. Drive digital transformation across industries through integrated products and services.
3. Enable customers to achieve operational excellence, sustainability goals and resilience
in the face of global challenges.

In pursuit of this mission, Schneider Electric is focused on combining technology,

sustainability, and human expertise to create a lasting impact on businesses and communities
worldwide.

Fig 1.3

Key Strengths and Values

1. Innovation Leadership
Schneider Electric consistently leads in innovation, with over 1,000 patents filed globally in
2023 alone. Its digital and IoT platforms, such as EcoStruxure™ and software solutions like
AVEVA, have set industry benchmarks.

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2. Empowered Workforce
With a global workforce of over 168,000 employees, Schneider Electric emphasizes diversity,
equity, and inclusion. Its decentralized model empowers teams to make localized decisions,
ensuring agility and customer-centricity.

3. Sustainability and Impact

Schneider Electric's "Impact Company" philosophy guides its initiatives to:

• Drive decarbonization in industries.

• Promote access to clean and affordable energy for underserved populations.
• Deliver measurable progress through its Schneider Sustainability Impact (SSI)
program.

4. Balanced Global Footprint

The company maintains a geographically balanced presence, operating over 100 zero-carbon
sites and leveraging regional hubs to optimize supply chains and customer interactions.

Megatrends Driving Schneider Electric’s Growth

Schneider Electric is uniquely positioned to thrive amidst key global megatrends:

1. Digital Transformation: Accelerating adoption of AI, IoT and cloud computing.

2. Climate Change: Addressing the urgent need for decarbonization through
electrification and energy-efficient technologies.
3. Energy Transition: Providing solutions for renewable energy integration, grid
modernization and sustainable power management.
4. Urbanization: Supporting smart city initiatives and infrastructure development in both
emerging and mature markets.
5. Shift in Global Equilibriums: Adapting to supply chain evolutions and reshoring
trends with automation and localized operations.

Strategic Priorities
Schneider Electric’s strategies align with five global megatrends:

1. Digital Transformation and AI: Accelerating adoption of AI, IoT and software for
energy and operational efficiency.
2. Climate Change: Addressing decarbonization challenges with renewable energy and
efficient technologies.
3. Energy Transition: Driving electrification and grid modernization.

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 4. Urbanization: Supporting smart city infrastructure and development.
5. Global Equilibrium: Strengthening local supply chains and reshoring operations.

Business Model and Key Offerings

Schneider Electric drives digital transformation by integrating:

1. Electrification: End-to-end energy solutions for decarbonization.

2. Automation: Advanced automation solutions for grid, buildings, and industrial
processes.
3. Digitization: AI-powered insights and software platforms like EcoStruxure™ and
AVEVA for lifecycle management.

Key markets served include:

• Buildings: Smart energy and automation systems.

• Data Centers: Scalable, energy-efficient solutions.
• Industry: Digital and automated process management.
• Infrastructure: Solutions for urban development and energy transition.
Core Technologies
• EcoStruxure™: An open, interoperable IoT-enabled system architecture offering
connected products, edge control and software analytics for buildings, data centers,
industries and grids.
• AVEVA™: A software platform for engineering, operations and industrial processes,
enhancing operational efficiency and sustainability.
• CONNECT Platform: Launched in 2023, it combines data, AI and industrial expertise
to deliver agile, resilient and sustainable operations.

Major Achievements and Milestone

1. financial Performance (2023)

 Revenue: $35.9 billion (+12.7% organic growth).
 Net Income: $4.0 billion (+15% growth).
 Adjusted EBITA Margin: 17.9% (record profitability).

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2. Sustainability Impact
• 578,709 people trained in energy management since 2009.
• Over 46.5 million people provided access to green electricity.
• Reduction of CO₂ emissions by 27% from its top 1,000 suppliers' operations.

3. Recognition
• Ranked #1 in the Gartner Supply Chain Top 25 (2023).
• Included in the Dow Jones Sustainability Index for 13 consecutive years.
• EcoVadis rated Schneider Electric in the top 1% of 85,000 assessed companies.

4. Strategic Initiatives
In 2023, Schneider Electric:

• Launched EcoStruxure™ Resource Advisor Copilot, an AI-driven tool for

sustainability data insights.
• Entered into a $3 billion agreement with Compass Datacenters for modular solutions.
• Invested €300 million in U.S. manufacturing facilities to support energy transition
efforts.

Future Outlook
Recognition
Schneider Electric has been acknowledged for its sustainability and innovation:

 13 consecutive years on the Dow Jones Sustainability Index.

 Top 1% rating by EcoVadis out of 85,000 assessed companies.
 Named an Industrial Tech Leader for its role in electrification and digitization.

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 Future Goal

• Achieve €50 billion in revenue by 2027.

• Increase digital revenues to 60-65% of total by 2027.
• Focus on organic growth in areas like AI, automation, and software-led solutions.

Fig 1.4

1.4 Organization Structure

Governance structure

Schneider Electric is a European company with a Board of Directors. On May 4, 2023, the
Board of Directors decided to implement a new governance structure that splits the office of
Chairman from that of Chief Executive Officer. Since then, Jean-Pascal Tricoire has remained
Chairman of the Board of Directors while a Chief Executive Officer was appointed becoming
responsible for the general management of the Company, as the sole executive corporate
officer. On November 1st, 2024, the Board of Directors appointed Olivier Blum as Chief
Executive Officer of Schneider Electric SE.

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Board of Directors and its Committees
The Board of Directors shall determine the business strategy of the Company and monitor its
implementation by its corporate interest and while considering its social and environmental
aspects. Subject to the powers expressly conferred to annual general shareholders’ meetings
and within the limit of the corporate purpose, it shall deal with all matters regarding the smooth
running of the Company and settle issues concerning the Company. At any time in the year,
the Board carries out the controls and verifications it deems appropriate.

Fig 1.5

Senior Management - The Chief Executive Officer

On November 1st, 2024, the Board of Directors decided to appoint Mr. Olivier Blum as Chief
Executive Officer of Schneider Electric SE.

The Chief Executive Officer has the broadest powers to act in all circumstances in the name
of the Company. The Chief Executive Officer represents the Company in its relationship with
third parties. He exercises his powers within the limitations of the corporate purpose and is
subject to any powers expressly attributed by law to the Shareholders’ Annual General Meeting
and Board of Directors.

1.5 Roles and Responsibilities in the Organization

1. PCB Assembly Operator

Responsibilities:

• Inspect printed circuit boards (PCBs) for damages, defects or irregularities.

• Perform soldering repairs on identified defects to ensure proper functionality and
quality compliance.

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2. Enclosure Assembly Operator

Responsibilities:

• Securely fit the assembled PCB into the designated enclosure or box.
• Operate screw machines to fasten the PCB using screws, ensuring stability and
adherence to assembly standards.

3. Quality Assurance

Responsibilities:

• Scan barcodes and perform functional testing on assembled energy meters to verify
performance against specified criteria.
• Document test results, categorizing units as either 'pass' or 'fail' based on their
performance.
• Ensure energy meters that meet quality standards proceed to the calibration stage in the
production line.
• Identify and segregate defective units, directing them to the repair department for
further analysis and correction.

4. Repair Technician

Responsibilities:

• Receive failed energy meters from the Quality Assurance (QA) department.
• Diagnose issues and perform necessary repairs to rectify defects.
• Retest repaired units to confirm compliance with quality standards before reintegrating
them into the production process.

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1.6 Company Products & Services :

Fig 1.6

1.7 Market Performance of Schneider Electric:

Schneider Electric has demonstrated consistent growth and resilience, underpinned by its
strong market presence, innovation and ability to capitalize on global megatrends. Below are
key highlights and performance metrics reflecting its market strength:

1. Revenue Growth
• 2023 Revenue: €35.9 billion, a 12.7% organic increase compared to 2022.
• Growth was driven by increased demand in key markets, including data centres,
infrastructure and automation.
• Significant contributions from mature economies (North America, Western Europe) and
emerging markets (India, Asia-Pacific, Middle East).

2. Regional Market Contributions

North America

• Generated €10.4 billion, contributing 37% to total revenue in 2023.

• Achieved +19.5% organic growth, driven by:
◦ High demand in Data Center and Grid Infrastructure segments.
◦ Increased investment in energy transition and sustainability initiatives.

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Western Europe

• Revenue of €6.7 billion, contributing 28% to total revenue.

• Achieved +11.6% organic growth, supported by:
◦ Strong performance in non-residential technical buildings and Data Centers.
◦ Double-digit growth in key countries like the UK, Germany and Italy.

Asia-Pacific

 Contributed €7.8 billion (23% of total revenue).

 Recorded +8.3% organic growth, with:

 Mid-single-digit growth in China despite construction market challenges.

 Strong double-digit growth in India is driven by industrial and infrastructure demand.

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 Chapter-2
2.1 OJT-1
2.2 Intern’s Ability to Apply Skills and Technical Knowledge during :
During the On-the-Job Training (OJT-1), I was able to effectively apply my academic
knowledge and technical skills in the following areas:

During my On-the-Job Training (OJT-1) at Schneider Electric India Pvt. Ltd., Mysore, I had
the opportunity to apply my academic knowledge in a practical industrial environment. I gained
hands-on experience in manufacturing processes, quality control, and testing of energy meters.
By working closely with experienced engineers and technicians, I enhanced my understanding
of energy meter design, calibration, and performance optimization. My ability to troubleshoot
minor technical issues and interpret technical documentation improved significantly during the
training period.

Understanding Manufacturing Processes: Gained insights into the assembly line for energy
meters, including surface-mount technology (SMT) and through-hole technology (THT).
 Quality Control Techniques: Applied knowledge of statistical process control (SPC)
and Six Sigma methodologies to analyse and improve production efficiency.
 Technical Documentation and Compliance: Assisted in preparing technical
documentation and ensuring compliance with industry standards (like IEC and ISO).
 Problem-Solving and Troubleshooting: Utilized problem-solving techniques to
troubleshoot and resolve minor issues in the assembly line under the guidance of the
supervisor.
 Collaborative Learning: Worked collaboratively with cross-functional teams,
enhancing my ability to communicate technical information effectively.

2.3 Intern’s Performance on Assigned Tasks and Projects:

During the internship, I was assigned various tasks and projects that contributed to my
professional growth:
 Process Improvement Project: Contributed to a project aimed at reducing production
downtime by identifying bottlenecks and suggesting process optimization techniques.
 Data Analysis and Reporting: Collected and analyzed production data to monitor key
performance indicators (KPIs) like yield, efficiency, and defect rates.
 Assisting in New Product Introduction (NPI): Assisted the engineering team during
the NPI phase, ensuring the seamless transition from prototype to mass production.
 Inventory Management: Helped in maintaining an accurate inventory of raw materials
and finished goods, contributing to better supply chain management.
 Compliance and Safety: Ensured adherence to safety protocols and compliance with
environmental regulation

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2.5 Extent of Intern’s Ability to Add Value to the Organization:
Throughout the internship, I strived to add value to Schneider Electric Mysore in the following
ways:
 Increased Efficiency: Suggested minor process modifications that improved the
production line's efficiency by approximately 5%.
 Cost Reduction: Identified waste in the manufacturing process, contributing to cost
reduction initiatives.
 Knowledge Sharing: Conducted a knowledge-sharing session for fellow interns on
industry best practices and lean manufacturing principles.
 Innovation and Improvement: Proposed ideas for automation in testing and quality
assurance, which are under consideration by the management team.
 Team Contribution: Actively participated in team meetings and brainstorming
sessions, contributing fresh perspectives and ideas.

2.5.1. Key Learnings and Takeaways

 Industry Exposure: Gained valuable exposure to the energy meter manufacturing
industry and its challenges.
 Technical Proficiency: Enhanced technical proficiency in manufacturing processes,
quality control, and automation technologies.
 Professional Development: Developed soft skills such as teamwork, communication,
and leadership.
 Problem-Solving Abilities: Improved

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2.6 What is an Energy Meter?
A device that is utilized to measure the amount of energy consumed in a particular period is
known as an energy meter. The primary idea behind these meters is to measure energy
consumption to find out the electricity cost of a particular place.
As you now know what an energy meter is, you must be curious to know how it works. Let’s
find these out in the next section of this blog.

2. Energy Meter Working

How does an energy meter work? Let’s understand. Energy meter working is easy to
understand. Its working principle follows Faraday's law of electromagnetic induction. This
law states that a magnetic field gets generated around a conductor when current flows through
it. Electrical energy consumption is measured in these meters using this principle. Its working
involves three steps, as explained below.
3. Current Measurement
The first step in energy meter working involves measuring the current flowing through it. For
this, the meter has a wire that connects its current coil with the power source. Now, whenever
the current flows through this coil, a magnetic field is generated around it.
4. Voltage Measurement
An energy meter also measures voltage to calculate the electrical energy consumption. To
measure voltage, the voltage is directed to the voltage coil of the meter from the power source.
This voltage coil creates a magnetic field with a magnitude proportional to the voltage.
5. Electric Energy Calculation
Now comes the final step in energy meter working- calculation of electrical energy
consumption. This is the core function of an electrical energy meter and is done by establishing
an interaction between the magnetic fields created around current and voltage coils. Such an
interaction leads to the production of a torque that spins the rotating component of the meter,
which is usually a metal disk. The spinning speed of this rotating component is proportional
to the product of voltage and current, resulting in the calculation of electrical energy
consumption.
After understanding the workings of energy meters in detail, move on to the next part of this
blog, which will list the various types of energy meters.

Schneider Electric manufactures a wide range of energy meters catering to different industrial,
commercial, and residential applications. Some of the key types include:

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2.7 Types of Energy Meters Manufactured at Schneider Electric India Pvt.
Ltd. Mysore:

Energy meter
The role of energy meters is indispensable in this world. From measuring the consumption of
electrical energy to monitoring it and enabling fair billing, these meters perform several
functions. Do you know energy meters come in different types? Yes, they do come in different
types. This blog will introduce you to everything related to these meters. Starting from what
they are to the different types of meters and their working principle. So, start reading below to
dive into this comprehensive guide on energy meters.

1. Single-Phase Energy Meters

1.1 Used for residential and small commercial applications.

1.2 Measures active energy consumption with high accuracy.
1.3 Available in both analog and digital versions.
1.4 single-phase energy meters are used for home appliances. They are connected directly
between the load and line.
1.5 Single-phase meters have two electromagnets: one is a series magnet, and the other is a
shunt magnet.

2. Three-Phase Energy Meters

2.1 Designed for industrial and large commercial users

2.2 Measures active and reactive power, demand, and power factor.
2.3 Provides advanced monitoring capabilities and remote communication features.
2.4 The Three phase energy meter that is used for industrial and commercial applications.
2.5 The energy consumption in these places is quite high. Therefore, a current transformer is
used here to step down the current and protect energy meters from high currents. These
energy meters consist of one neutral wire and three phase wires.

3. Digital Energy Meters

3.1 Energy meters measure electricity consumption, providing precise data for monitoring
usage patterns and optimising energy efficiency.
3.2 They support cost management, encourage sustainable practices, and enable accurate
billing.
3.3 Modern models often include smart features for remote access and real-time updates.

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4. Smart Meters

Description: These advanced meters provide real-time data, enabling efficient energy
management, and support remote monitoring and control. They are pivotal in
implementing smart grid solutions.

4.1 Applications: Residential, commercial, and industrial energy management.

4.2 Features:

1. Two-way communication for accurate billing.

2. Remote disconnection and reconnection capabilities
3. Integration with IoT platforms for enhanced analytics

1. Role: Single-Phase Energy Meters:

Fig 1.7

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Safety information

Fig 1.8

Fig1.9

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 Role:
3-phase Energy Meters

Accuracy, precision, and performance

• High quality, reliability, and accuracy: 3-phase power and energy measurements with
power quality compliance monitoring, data and event logging, and alarming
• Industry-leading: Class 0.2 revenue metering and network management data
• Regulatory compliance: meets all North and South American requirements for utility
metering
• Built-in intelligence: RTU polls downstream devices like relays or other telemetry devices
• Exceptional adaptability: integrates into existing billing/SCADA systems
• Reduces downtime: pinpoints disturbances with disturbance direction detection as upstream
or downstream of the meter
• High degree of visibility to data and assets: allows for cost savings, rapid response time,
and better decisions

Flexible and modular

• Integrates into existing billing/SCADA systems

• Out-of-the-box connectivity with open, scalable StruxureWareTM PowerSCADA and Power
Monitoring Expert software
• Extensive data access options: utility-focused HMI, ANSI Type 2 optical port, USB port,
multiprotocol communications (including IRIG-B), and calibration pulsing
• Dual-port Ethernet supports daisy-chaining, redundant loops, and multiple protocols
• Digital I/O for status monitoring, alarming, count metering, or analog I/O to track sensors or
fuel levels
• Modbus Master, Ethernet-to-serial gateway capabilities

PQ compliance reporting, PQ analysis

• Monitors and logs parameters in support of multiple international PQ compliance

measurement standards
• Harmonics: high-resolution waveform captures and Flicker influence

Alarming and control

• 50+ definable alarms to log critical event data, trigger waveform recordin

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2.8 Schneider Electric has a manufacturing in Energy meters facility in
Mysore
2.9 Component Preparation:
 Sourcing: High-quality electronic components like microcontrollers, sensors,
communication chips, and display units are sourced from reliable suppliers.
 Testing: Incoming PCBs components are rigorously tested for quality and
functionality to ensure they meet specifications and Damages Components Missing etc
 Preparation: Components may undergo processes like cleaning, soldering, or coating
to prepare them for assembly.

2.10 Assembly Line Production:

 Automated Assembly: Modern manufacturing facilities like Schneider Electric’s
utilize automated assembly lines. Machines precisely place and solder components onto
printed circuit boards (PCBs).
 Manual Assembly: Some steps may still require manual assembly, especially for
larger or more complex parts. Skilled technicians carefully assemble these components.
 Enclosure Preparation: Meter enclosures, typically made of durable plastic or metal,
are prepared. This may involve cleaning, painting, or labelling.

2.11 BCA Testing Energy Meters:

BCA testing on energy meters likely refers to tests conducted by the Building and Construction
Authority (BCA) in Singapore to ensure the accuracy and reliability of energy meters in
buildings. This is important for:
 Fairness: Accurate meters ensure that consumers are billed correctly for their energy
usage.
 Energy Efficiency: Reliable data from energy meters allows building owners to track
and optimize their energy consumption, leading to potential cost savings and
environmental benefits.
 Compliance: BCA may mandate certain testing and certification standards for energy
meters to ensure compliance with regulations.

The specific tests conducted by BCA may vary, but they likely include:
1. Accuracy testing: Comparing the meter’s readings against a known standard to ensure it
measures energy consumption accurately
2. Functional testing: Checking that the meter is functioning correctly and recording data
reliably.

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3. Durability testing: Assessing the meter’s ability to withstand environmental factors and
maintain accuracy over time.

2.12 Calibration and Testing:

 Calibration: Each energy meter is individually calibrated to ensure accurate
measurement of electricity consumption. This involves using specialized equipment to
adjust the meter’s readings to match precise standards.
 Functional Testing: Meters undergo a series of tests to verify their functionality,
including communication, display, and data logging capabilities

2.13 Meters testing Failed go to Meters Rework is Debug

1. Quality Control: Throughout the assembly and testing process, strict quality control
measures are in place to identify and rectify any defects.

2. Debugging energy meters and Rework:

Can be a complex process, as there are many potential issues that can arise. Some of the most
common problems include:
 Communication issues: Energy meters often communicate with a central system via
a wired or wireless connection. If there is a problem with the communication link, the
meter may not be able to send data to the system.
 Hardware failures: Energy meters can fail due to a variety of hardware problems,
such as faulty sensors, damaged circuits, or power supply issues.
 Software bugs: Energy meters often have embedded software that controls their
operation. If there are bugs in this software, the meter may not function correctly.
 Installation errors: Energy meters must be installed correctly in order to function
properly. If the meter is not installed correctly, it may not be able to measure energy
consumption accurately.
If you are experiencing problems with an energy meter, there are a few things you can do to
troubleshoot the issue. First, check the communication link to make sure it is working properly.
If the communication link is working, check the meter for any signs of physical damage. If
you find any damage, the meter may need to be repaired or replaced.
If you do not find any physical damage, the problem may be with the meter’s software. In this
case, you may need to contact the manufacturer for assistance. Finally, if you suspect that the
meter was not installed correctly, you may need to contact an electrician to have it inspected.

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2.14 Packaging and Shipping:
 Packaging: Finished meters are carefully packaged to protect them during
transportation. This may involve using custom-designed boxes and protective
materials.
 Labelling: Packages are labelled with relevant information, including product codes,
seri

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 Chapter-3
3.1OJT-2:
3.2Ability to Apply Skills and Technical Knowledge on Strengths: The intern
demonstrated a solid grasp of technical concepts and effectively applied their skills during
on-the-job training. They quickly adapted theoretical knowledge to practical scenarios,
particularly in troubleshooting and optimizing energy meter functionalities.

 Improvements: Continued exposure to advanced technical challenges will further

enhance their ability to integrate complex systems and innovate within the domain.

3.3 Performance on Assigned Tasks and Projects:

 Strengths: The intern consistently delivered high-quality work on time. They
showcased excellent problem-solving skills and attention to detail while handling both
routine tasks and project-specific assignments. Their proactive approach led to several
valuable insights during project development.

 Improvements: Greater involvement in cross-functional projects could provide broader

exposure and further refine their project management and collaborative skills.

Ability to Add Value to the Organization:

 Strengths: The intern contributed meaningful ideas that improved the overall workflow
and efficiency of the team. Their ability to analyze challenges and propose innovative
solutions added measurable value, especially in enhancing the performance of energy
meter systems.

 Improvements: Encouraging the intern to take a more active role in strategic planning
and process improvement initiatives could amplify their impact on the organization.

3.4 Job Role : Circuit Breaker Testing:

Fig 2.0

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Circuit breakers are essential electrical switches. The function of the circuit breaker is to
prevent an electrical circuit from potential damage due to overflow of current through it, or
overload or short circuit. Their fundamental function is to interrupt the current flow to prevent
the circuit from damaging. Circuit breaker testing involves testing the operation of the
switching systems. It helps to test the programming of the entire tripping structure. This testing
is essential to ensure the safety and reliability of a circuit breaker and its performance.
If you wish to learn about circuit breaker testing in detail, continue reading this post. It will
introduce you to all you must know about this testing.
3.5 Importance of Testing Circuit Breaker:
A circuit breaker might remain idle for many years, but every time a fault occurs, it should
rapidly separate significant currents, typically in the assortment of a vast number of amperes,
in milliseconds. If it breaks, the result might be catastrophic. Issues that are common with
circuit breakers typically include poor operation, coil brief circuits, physical damage or wear,
and also degraded insulation. They should be rigorously and routinely tested to guarantee these
crucial devices work if needed.
Circuit breakers are crucial to protecting high-value gear from electrical faults by connecting
and disconnecting power quickly. Given this essential role, regular field tests during consistent
maintenance checks and installation throughout their service life are essential to stay away
from costly breakdowns and keep substations safe.
Testing isn't just needed for reliability but additionally cost-effective in preventing damage
that is severe and also ensuring uninterrupted service. Conventional circuit breaker tests focus
on measuring timing and motion, providing important insights into the breaker's condition.
Nevertheless, the advanced testing solutions provide a breakthrough in circuit breaker
evaluation.
3.6 Procedure for Testing Circuit Breakers:
Before diving into the procedure of testing circuit breakers, you must know about the different
testing methods or steps involved in the process. Below are the circuit breaker testing methods.
Type tests of circuit breakers
1. Mechanical test
 Thermal test
 Dielectric test
 Short-circuit test

2. Routine tests of a circuit breaker

3. Preventative Maintenance of Circuit Breaker, Inspection, and Testing
4. Circuit breaker trip test

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5. Insulation resistance test
6. Connection tests
7. Contact resistance test
8. Overload tripping test
9. Instantaneous magnetic tripping
Different special tools are used to assess the functionality and condition of circuit breakers
within power systems. To test a circuit breaker involves a selection of equipment and methods
to make certain these crucial devices function correctly. This guide is going to walk you
through the various test methods and the kinds of testing instruments used to look at circuit
breakers under operational scenarios and various conditions. Find out about the crucial testing
tools and the way they're applied to ensure the reliability and security of the circuit breakers.
The following factors are considered when testing a circuit breaker.
 How it works
 Its tolerances
 Reference values of previous tests
 Initial values to compare the actual results
 Established settings or initial features given by the manufacturer

The following equipment can be used to conduct a short circuit test:

 Testing with Circuit Breaker Analyzer

 Testing with a Micro-ohmmeter
 Testing with a High Current Primary Injection Tester

3.8 List of the Requirements to Perform the Circuit Breaker Test:

To perform a comprehensive circuit breaker test, the following requirements should be in
place:
1. Trained Personnel
2. Personal Protective Equipment (PPE)
3. Test Instruments
 Timing Testers for circuit breaker timing test
 Contact Resistance Metres
 Insulation Testers (Megohmmeters)
 Secondary Injection Testers
 Primary Injection Testers
 Motion Analysers

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4. Documentation and Test Procedures
5. Calibrated Equipment
6. Spare Parts and Tools
7. Testing Environment
8. Power Supply
9. Communication Equipment
10. Safety Procedures and Permits
3.9 Benefits of Circuit Breaker Test:
Regular circuit breaker testing is crucial, and the following benefits perfectly highlight its
significance.
 Increased Safety- Testing ensures that the circuit breakers function appropriately if an
electrical fault occurs. This reduces the risk of fires, accidents and equipment damage.
 Reduced Downtime- Testing allows you to identify and address issues with breakers
in a timely. As a result, they will prevent unplanned outages. Testing also ensures
increased operational stability and continuous power supply.
 Prolonged Equipment Lifespan- Regular testing helps extend the lifespan of circuit
breakers. It minimises wear and tear on components and avoids costly replacements.
 Cost Savings- Early detection of issues with circuit breakers allows you to prevent
expensive breakdowns of the circuits and circuit breakers. Therefore, you will not need
to spend on costly repairs.
 Improved Reliability- Regular testing offers you peace of mind that you can rely on
the circuit breakers in case of faults in the electrical systems.
Some other advantages of the CRM test of circuit breaker and other tests are as follows.
 Quick and easily performable on-site
 Tests overall timing of the tripping system
 Can be tested on or off-load
 Tests the performance of the entire tripping cycle
 Identifies the need for maintenance
 Provides early indications of possible issues
 Avoid issues
 Build up a test record database

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3.10 What Is MCCB?
An MCCB is so called because it is a type of circuit breaker that uses moulded cases to house
the internal parts. This makes them more resistant to shock and vibration and helps protect
them from environmental damage. They come in a variety of shapes and sizes and can be used
for a variety of applications.
3.11 Types of MCCB
There are many different types of MCCB that you can use in your home or office. The most
common type is the standard Moulded case circuit breaker. It's a simple, inexpensive way to
protect your home or office from electrical fires and appliance damage.
But there are also other types of MCCB that you can use, depending on your needs. There are
thermal-magnetic moulded case circuit breakers, which are designed for higher-amperage
circuits. There are also electronic moulded case circuit breakers, which offer additional
protection against power surges and lightning strikes.
3.12 Benefits of Using MCCB
Using Moulded case circuit breakers can be beneficial in a number of ways. For one thing,
they are more compact and lighter than traditional circuit breakers, making them easier to
install and convenient to use. Some of the other benefits of using MCCBs include:
1. Being moulded into a protective casing, MCCBs are also more resistant to environmental
influences like moisture and dust, which can shorten the lifespan of other circuit breakers. For
the same reason, they are also more reliable. Because they are self-contained, there is less
opportunity for moisture and dust to cause a failure by damaging the circuit breaker.
2. MCCBs are also less likely to trip accidentally, which can be frustrating and time-
consuming. Also, MCCB s provide high-current interrupter switches and are extremely easy
to install on the panel.
3. using an MCCB can help protect all types of electrical circuits from short circuits, overloads,
and power surges. This makes them suitable for securing anything from large industrial
systems to small domestic appliances. MCCB can sense faults and secure the system from
risky situations. It works as a protective and switching device for feeder circuits as well.
4. MCCBs can also be used to safely shut down any kind of system in the event of an
emergency or an unexpected power failure. This makes them very useful in case of power
outages or any other situation where quick action is needed to prevent damage or injury.
5. Additionally, many MCCB s come with a reset feature that allows you to quickly restore the
circuit after there has been a short-circuit or overload issue. This feature comes as a relief for
those working in hazardous environments as it eliminates the need to constantly monitor the
system and detect any potentially dangerous issues.
MCCBs are increasingly adaptable and offer a scope of advantages that make them valuable
in an assortment of applications. Hence, you see why installing MCCBs is an incredible
decision for those hoping to secure their electrical equipment.

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Types of circuit breakers and their importance

Fig 2.1
As beneficial electricity is to our sustenance, unless it is dealt with proper precautionary
measures, electricity can pose a serious threat to expensive devices, as well as to our loved
ones. So, to avoid accidents caused by electrical hazards, sufficient preventive measures must
be adopted. And one of the most common measures used in households for protection against
electrical hazards is a circuit breaker.

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 Chapter-4

4.1 Case.1

1. Manufacturing Process of Energy Meters

1.1 Design & Development
Before manufacturing, the product design and specifications are finalized. This stage includes:
 Market Research & Requirements Analysis
 Circuit Design & PCB Layout
 Microcontroller & Software Development
 Prototyping & Testing
1.2 Raw Material Procurement
Essential components are sourced from suppliers, including:
 Microcontrollers & Integrated Circuits (ICs)
 Current & Voltage Sensors
 Printed Circuit Boards (PCBs)
 Plastic or Polycarbonate Enclosures
 Connectors, Displays, and Mechanical Parts
1.3 PCB Assembly (SMT & THT Process)
 Surface Mount Technology (SMT): Automated placement of SMD components on the
PCB.
 Through-Hole Technology (THT): Insertion of larger components manually or through
wave soldering.
 Soldering Process: Uses reflow soldering (SMT) and wave soldering (THT).
1.4 Assembly & Integration
 PCB Mounting into Casing
 Connection of Sensors & Displays
 Wiring & Integration of Communication Modules (Wi-Fi, GSM, LoRa, etc.)
1.5 Calibration & Testing
 Initial Functional Testing: Checks basic working condition.

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  Accuracy Calibration: Ensuring correct energy measurement according to IEC/IS
standards.
 High Voltage & Insulation Testing: Ensuring safety compliance.
 Temperature & Environmental Testing: Ensuring durability in various conditions.
1.6 Quality Control & Compliance
 ISO 9001 & IEC Standards Compliance
 Defect Detection & Fault Analysis
 Final Acceptance Testing (FAT)
1.7 Packaging & Dispatch
 Packaging with Anti-Static Protection
 Labeling & QR Code for Tracking
 Shipping to Distribution Centers

2. Challenges in Energy Meter Manufacturing

 Accuracy & Calibration Issues
 Component Supply Chain Constraints
 Cybersecurity in Smart Meters
 Regulatory Compliance & Testing Complexity
 Counterfeit Components & Reliability Issues

3. Technological Advancements in Energy Meters

 Smart Meters with IoT & AI Integration
 Bidirectional Meters for Renewable Energy
 Tamper-Proof Meters with Advanced Security
 Prepaid & Postpaid Metering Systems

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 4.2 Case.2

Schneider Electric's Mysuru facility plays a pivotal role in advancing India's energy
management and smart metering initiatives. This state-of-the-art plant not only underscores
the company's commitment to innovation but also highlights its dedication to sustainability
and community development.
 Facility Overview:
Located in Mysuru, Karnataka, the Schneider Electric plant boasts a manufacturing capacity
of 17 million energy meters annually. Over the past decade, it has produced and supplied
more than 70 million electricity meters and over 300,000 smart prepaid meters across India.
The facility integrates various functions, including research and development, testing,
manufacturing, quality assurance, and procurement.

 Technological Advancements:
The Mysuru plant exemplifies Schneider Electric's commitment to digital transformation. It
features an integrated digital manufacturing system that ensures process compliance, quality
checks, traceability, and efficient supply chain management. The facility also offers
sophisticated metering infrastructure, comprising Headend Systems (HES) and Meter Data
Management (MDM), all fortified with robust cybersecurity measures.

 Support for India's Smart Metering Initiative:

Aligned with the Government of India's Smart Meter National Programme (SMNP),
Schneider Electric leverages its global expertise to support the rollout of smart meters
nationwide. The Mysuru facility has already supplied over 300,000 smart prepaid meters and
has secured orders for an additional 1.4 million smart meters, reflecting its capacity to meet
the escalating demand for advanced metering solutions.

 Community Engagement and Skill Development:

Beyond manufacturing, Schneider Electric is deeply invested in community development
and skill enhancement. In October 2023, the company committed to supporting skilling
initiatives at the Government Industrial Training Institute (ITI) in Belavadi, Mysuru. This
includes providing modern infrastructure and increasing the hiring of women graduates from
the institute. The initiative aims to recruit over 200 women students annually for the Mysuru
facility, promoting gender diversity in technical roles.
Additionally, Schneider Electric operates approximately 45 skill development centers across
Karnataka, including 16 dedicated to women, training over 20,000 youth in fields such as
electricity, automation, and solar energy.

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 Industry Collaborations:
The facility also serves as an educational hub. For instance, in December 2024, students
from the Post Graduate Diploma in Management (PGDM) 2023-25 batch visited the Mysuru
plant. This visit provided them with insights into how innovation and research drive
operations at Schneider Electric, emphasizing the company's role in shaping future industry
leaders.

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 Conclusion

Schneider Electric's Mysuru facility stands as a testament to the company's dedication to

technological innovation, sustainable practices, and community empowerment. Through its
advanced manufacturing capabilities and proactive community engagement, the plant
significantly contributes to India's energy sector and the broader goal of sustainable
development. The energy meter manufacturing process is a highly technical and regulated
process that ensures precise measurement of electricity consumption. Advancements in IoT
and AI are revolutionizing the industry, making energy meters smarter and more efficient.

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