Monthly Archives: August 2014

One Day inside an Old Incandescent Bulb Manufacturing Unit

During my High School, I  learned the  working of Incandescent Bulb &, Thomas Alva Edison is the man who developed it. From that days itself , I had one serious doubt,  how people are filling Argon Gas inside the Glass bulb? A genuine question from a high school guy, Rite?

And, Today, on 28/08/2014, I got a chance to visit an Incandescent Bulb manufacturing Unit. Infra Lights, One of the Pioneer Incandescent Bulb Manufacturer in Kerala , situated inside the Aroor Industrial Estate. An Old two story-ed Building; seems around 8000 Sq. ft and interestingly, the entrance was guarded by a local Dog!

Oh! Sorry, i forget to tell you that, they are not manufacturing those bulbs right now.  Those poor people couldn’t adapt with the CFL Boom. But they are still keeping all the machinery & Equipment there itself. Thanks God! Otherwise I couldn’t see those all machinery.

The room in which the equipments are kept seems like a haunted space; Dust, Spiders & their web, Rust and all. I walked around each and every machines. Somehow i tried to understand the use of each ones. And, I saw that equipment also; the Gas filling One.

After getting out of the room I thought, why the owner is still keeping all those useless machines? Maybe he has a plan to convert it to a small Museum to teach our children that, once there were something called incandescent bulbs & they are manufactured by all these machines 😀

I heard about Disruptive Innovation. But today, I understood what is it in reality!

By the way,Infra Lights is now trying for a revamping; they started manufacturing  & assembling of LED luminaries. Hope they will catch up the market soon!

I with Team NeoGreen Labs went there to test a 3KVA Three Phase Battery charger (We don’t have a three phase connection) which is developed by one of my Mentor Er. Cherian Issac for Cochin Shipyard.

First day at HINDALCO, Kochi

Don’t think that I got a job in HINDALCO! I went there to Test & Install few Equipments (SafeWeld) that we (NeoGreen Labs) developed for Welder Safety.

HINDALCO ! the Aluminum Gaint of India.

Recently (On 26-08-2014), I visited their Manufacturing Plant in Kalamassery, Kochi. It was for the first time in my life, I  visited such a huge Factory, which spreads over 130 Acres!

The security check and other procedures at their gate make me feel that i am entering a Defense area. At the entrance itself, we can see the vision and Quality policies of Aditya Birla Group. World Class Manufacturing (WCM), is their new mantra and i saw few flex boards explaining WCM.

I walked  through their premises, But, couldn’t see any works going on there (in the initial two blocks). There are huge machines, but they seems like, not used for weeks or months.

I saw lot of Notices, Flex & Writings; not about Aluminum, not about their manufacturing or not about Hindalco, but  all were about one word; SAFETY!

Safety, Safety, Safety… Safety Everywhere!

There were also Poems regarding safety. Both in English & Malayalam. I am remembering few line that i felt interesting.

“Know safety, No Pain, No Safety, Know Pain”

Atlast we reached the area where some works are going on. We can see Huge aluminum Rods, Bars, and some huge blocks of Aluminum like AmmiKallu in front of the Plant . Inside that Plant, there are few Kins in which Aluminum rods are heated.People are working around that and, the temperature in that area was really high, i felt it ,as i walked beside the kin. Even though i couldn’t get much time to view all those things, it was really a great experience for me.

Later I understood that the factory is  working with only 5 to 10% of their full capacity. I don’t know the exact reason. Maybe its the Kerala Effect!

Safe Weld is an Equipment to provide safety for the Welder. It also saves electrical energy. We have systems for both Single Phase & Three Phase ARC Welding Sets.