1. Requirement Analysis & Design

  • Client requirements, load data, and applications are studied.

  • Engineers design panel layouts using CAD software (like AutoCAD Electrical or EPLAN).

  • Component selection (MCBs, MCCBs, contactors, relays, PLCs, VFDs) is finalized.

2. Material Procurement

  • Enclosures (MS/SS/Aluminum), busbars (Copper/Aluminum), switchgears, terminals, wiring accessories, etc., are sourced.

  • All materials are quality checked upon receipt.

3. Fabrication & Painting

  • The panel enclosure is fabricated by cutting, bending, and welding metal sheets.

  • Holes are made for components, cable entry, ventilation, etc.

  • Then it’s powder-coated or painted for corrosion resistance and proper finish.

4. Busbar Assembly

  • Busbars are cut, drilled, and mounted as per the design.

  • Heat-shrink sleeves or color codes are applied (R-Y-B and neutral/earth).

  • Insulation, spacing, and support clamps are ensured as per IS/IEC standards.

5. Component Mounting

  • All electrical components (breakers, relays, meters, VFDs, PLCs) are fixed on mounting plates or DIN rails.

  • Proper spacing and alignment are maintained for safety and maintenance.

6. Internal Wiring

  • Control and power wiring is done using color-coded wires.

  • Ferrules, cable tags, lugs, and sleeves are applied for identification.

  • Wiring is routed neatly through cable ducts.

7. Testing & Quality Check

  • High-voltage (Hi-pot), insulation resistance (IR), and continuity tests are performed.

  • Control logic is tested if PLC/automation is involved.

  • Panel is energized to check functionality, safety, and tripping features.

8. Labeling & Documentation

  • Component labeling, terminal tags, panel nameplate, and schematic drawings are added.

  • A user manual with wiring diagrams is prepared.

9. Final Inspection & Dispatch

  • Final QA is done.

  • Panel is packed securely and dispatched to the site for installation.