Executive summary

This report represents the outcome of one month field project undertaken at TDK
India Pvt Ltd Nashik, This report focuses on optimisation of spraying process within
the company’s capacitor manufacturing unit. In the Capitol manufacturing spring
process is a critical step in porting and finishing of the capacitors it is the process on
which the product quality and product efficiency depends the primary objective was
to identify the inefficiencies in the existing process to minimise the material wastage
happening due to that which would result in improved overall productivity of the
process this field project follows a structural approach beginning with a detailed
process mapping which is followed by on ground observation data collection and
interaction with the shop floor employees as well as the supervisors during the ship
Through the use of basic lean manufacturing principles time and motion studies and
Root Causeway analysis we were able to identify the following issues
The inconsistent spraying pattern s due to the usage of different sizes of nut bolts
High cycle time variability
Excessive time consumption due to the constant process of failing the capacitor heads
with nuts and removing them.
Recommendations were made for:
Use of different sizes of trays
Use of an entire new machine with ir sensors To fill the capacitor heads with bolts
Use the plugs to fill the capacitor hole.
By addressing these inefficiencies we could see the process could have been improved
and reduced rework and enhanced throughput although the full implementation of this
process would have required more time we are Expecting reduction of overall time
process elimination productivity increment of this process.
INTRODUCTION
Manufacturing industries across the world have strived on operational efficiency the
reduction of cost and the quality enhancement. During this pursuit the optimization of
process has become a crucial element specifically talking about high decision
industries like electronics and component manufacturing even the small process plays
a very vital role. One of such process that plays an important role in capacitor
manufacturing is spraying. Which involves quoting the components with a specific
material to achieve required electrical conductivity and ensuring smooth flow of
electricity throughout the capacitor.
This report focuses on the project carried out at Tdk India Pvt Ltd nashik which is
specialised in manufacturing of capacitors and other electronic components such as,
inductors, Transformer and coils, Sensors and Sensor systems, RF Components,
Power supply and Energy devices, Pen drives.
The project of one month was aimed to study and improve the spraying process used
in the production line with an emphasis on identification of existing inefficiencies
minimising the workforce required and enhancing the process consistency.
The spraying process directly has an effect on the product quality production speed
and material usage therefore if we are able to optimise this process at this stage it can
contribute significantly to the complete and overall production of the plant.
This project was designed to explore the current practises that are going on in the
market to evaluate the process performance and suggest improvement based on
observation data analysis and industry practises. Through this project there was an
opportunity to understand the practical challenges on the shop floor to be able to have
an interaction with the skilled people and apply industrial engineering concept such as
lean manufacturing time motion study and Root Cause analysis to a real world
scenario.
 TDK India Private Limited (TDK lndia) is a subsidiary of TDK Electronics (formerly
EPCOS) that develops, manufactures and markets electronic components and
systems, focusing on technology markets that include automotive, industrial, and
consumer electronics, as well as information and communications technology. Today,
TDK lndia is a healthy 800+ Crore company with close to 2250 employees in three
factories and five sales offices throughout the country, as well as a strong network of
dealers.
Products made in lndia are most relevant to the current demands in lndia and include
film capacitors and ferrite cores for a wide range of electronics applications. These
products, which are used extensively in energy, power transmission and quality,
industrial electronics and home appliances, serve almost every leading player in these
industries – both Indian companies as well as multi-national corporations. More than
50 percent of the products the company manufactures in lndia are exported across the
globe.
TDK lndia designs, manufactures and markets of a broad range of top-quality
electronic
components and systems, including:
 AC film capacitors
 Low-voltage (LV) power factor correction capacitors (resin, inert gas and oil-filled
designs)
 PFC systems (APFC panels) and key components for PFC systems
 Medium-voltage (MV) capacitors, capacitor contactors and reactive power
compensation systems
 Power electronic capacitors
 DC film capacitors
 High-performance ferrite cores
Besides state-of-the-art film capacitors, the company's lead factory in Nashik also
houses the R&D for film metallization, AC and PFC products and systems, while
Kalyani is Centre of Excellence for soft ferrites. TDK lndia also services the demands
of customers for a wide variety of components from the global factories of TDK.
TDK lndia is actively involved in several transformation initiatives by the
Government of lndia, covering areas such as:
 Energy sufficiency, 24x7 power, rural electrification, power for all, renewable energy
 Road and rail infrastructure
 Smart cities
 Mobile phone manufacturing
 Automotive sector
 Electric vehicles
TDK Group
TDK Corporation is a leading electronics company based in Tokyo, Japan. It was
established in 1935 to commercialize ferrite, a key material in electronic and magnetic
products. TDK's comprehensive portfolio features passive components such as
ceramic, aluminum electrolytic and film capacitors, as well as magnetics, high-
frequency, and piezo and protection devices. The product spectrum also includes
sensors and sensor systems such as temperature and pressure, magnetic, and MEMS
sensors. In addition, TDK provides power supplies and energy devices, magnetic
heads and more. These products are marketed under the product brands TDK,
EPCOS, InvenSense, Micronas, Tronics and TDK-Lambda.
TDK focuses on demanding markets in the areas of information and communication
technology and automotive, industrial and consumer electronics. The company has a
network of design and manufacturing locations and sales offices in Asia, Europe, and
in North and South America.
Values of TDK:
Corporate Motto: Contribute to culture and industry through creativity
Corporate Principles:
“Vision, Courage, Trust”
Vision
Always take a new step forward with a vision in mind.
Creation and construction are not born without vision.
Courage
Always perform with courage.
Performing power is born by confronting contradiction and overcoming it.
Trust
Always try to build trust.
Trust is born from a spirit of honesty and service.

Long-term Vision
TDK Transformation
Accelerating transformation for a sustainable future
・ Contribute to the transition towards a sustainable future by accelerating the
transformation of society and advancements in technology enabled by electronic
devices developed through leveraging cutting-edge innovation in materials, processes,
and software technology.
・ Become the No.1 partner growing alongside our worldwide customers by pursuing
continuous “transformation”.
Seven seas
The “Seven Seas” are the seven fields that TDK will tackle over the medium to long
term. They are Beyond 5G, IoT, Robotics, AR/VR, Medical/Health Care, Mobility
ADAS/EV, and Renewable Energy. In each of these seven fields, TDK will contribute
to achieve a sustainable future through providing innovative products.
 Beyond 5G
 IOT
 Robotics
 AR/VR
 Medical health care
 Mobility ADAS/EV
 Renewable energy

Key leadership roles:

Representative Director Representative Director

Noboru Saito Tetsuji Yamanishi

Director Director

Shigeki Sato Kozue Nakayama

 Director Director
Mutsuo Iwai Shoei Yamana

Director

Toru Katsumoto
OBJECTIVES:
To understand the existing spraying process and workflow
To collect relevant data for performance measurement
To determine root causes of inefficiencies using analytical tools
To suggest practical and low-cost process improvements
SCOPE OF THE PROJECT
This field project was conducted over a period of the one month at TDK India
Pvt. Ltd. Nashik (Satpur), with a focused study on the optimisation of spraying process used
in capacitor manufacturing unit. The role of Operations Management in to day to day
working of the organisation as TDK uses lean manufacturing principles to minimize waste
and improve efficiency, the main focus of TDK is on Quality assurance and customer
satisfaction. TDK continuously improved its process of manufacturing by optimization, and
improved technology in automation to maintain quality and efficiency with high precision.
In this project the optimisation of spraying process is done to increase the
efficiency of the process by evaluating various possible solutions, the feasibility of such
solutions is calculated and then most feasible and practical solution is advised that is for
preventing it from spraying of Aluminium and Zinc spray to enter into core of the capacitor.
And observed the manufacturing process of the capacitor and during which we identified the
issue and analysed the root cause and recommended solution for it.
Capacitor Manufacturing Process at TDK India Pvt. Ltd.
The manufacturing of capacitors involves a series of precise, quality-controlled steps to
produce components that are essential for electronic circuits. At TDK India Pvt. Ltd., this
process is carried out using a combination of automated systems, skilled labour, and high-
grade materials. The following steps describe the typical flow in ceramic or film capacitor
production, with a special focus on the spraying stage relevant to your project.

1. Raw Material Preparation

 The base material (ceramic powder or plastic film) is prepared with precise chemical
composition.
 For ceramic capacitors, materials like barium titanate are used.
 The raw materials are mixed, milled, and dried to form a uniform base.

2. Electrode Application
 For ceramic capacitors: Electrodes (usually silver or palladium) are screen-printed
onto thin ceramic layers.
 For film capacitors: A thin metallic layer is vapor-deposited or sprayed onto plastic
films.

3. Layering / Stacking
 Multiple layers of ceramic material and electrodes are stacked together in a defined
sequence to form the capacitor body.
 In film capacitors, metallized films are wound into rolls (called "windings").

4. Lamination and Cutting

 The stacked or wound elements are pressed, laminated, and cut into the required sizes.
 Precision is critical here to ensure consistency in capacitance values.

5. Spraying Process (Focus Area of Your Project)

 The capacitor body is held in place while conductive silver or aluminium paste is
sprayed onto both ends.
 This forms the terminals where the internal electrodes are connected.
 Uniformity in spraying is critical to:
o Ensure proper electrical contact
 o Avoid excess material waste
o Prevent quality issues like poor connectivity or contamination
Common issues:
 Over-spraying
 Under-spraying
 Nozzle clogging
 Variation in coating thickness due to operator error or machine inconsistency

6. Drying and Sintering

 Sprayed capacitor bodies are dried in ovens.
 For ceramic capacitors, sintering is done at high temperatures (~1200–1400°C) to
solidify and bond the layers.
 This step gives the capacitor its mechanical strength and electrical characteristics.

7. Lead Attachment and Termination

 Leads (wires or metal legs) are soldered or welded onto the sprayed ends.
 Terminations are coated with a protective layer to prevent oxidation and corrosion.

8. Encapsulation
 Capacitors are encapsulated using epoxy resin or plastic cases to protect them from
environmental conditions like moisture and heat.

9. Testing and Quality Control

 100% of the capacitors are tested for:
o Capacitance
o ESR (Equivalent Series Resistance)
o Leakage current
o Insulation resistance
o Withstanding voltage
 Defective pieces are rejected or reworked based on failure type.
10. Marking and Packaging
 Approved capacitors are printed with technical information like value, tolerance, and
batch code.
 They are packed in trays, tapes, or reels for dispatch to customers.