dawlance internship report

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UNITED REFRIGRATOR COMPANY LTD. DAWLANCE

PREPARED BY MOHAMMAD YOUNUS (08IN70)

1

(Internship Program Report)

UNITED REFRIGRATOR COMPANY LTD. NO. OF WEEKS :- 1 WEEKS INTERSHIP PROGRAM

Date : 13-06-2011 To 18-06-2011

Submitted To: HUMAN RESORCE DEPARTMENT

Submitted By: MOHAMMAD YOUNUS (08IN70)

JASWANT (09IN03) MANOJ KUMAR THAKUR (09IN46)

DEPARTMENT OF

MEHRAN UNIVERSITY OF ENGINEERING & TECHNOLOGY, JAMSHORO

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PREFACE This report contains the information about those

departments which are visited by the internees. Whatever the machinery

seen and the processes are observed, attracting the human mind and

realizes the men what science has achieved and what kind of mericals has

been done by it. Basically United refrigerator company ltd. (dawlance) is

quite attention attracting industry it provides lot of opportunities to see, to

observe, to achieve and to get the lot of experience about the industry as

well as about the machinery.

The technology installed at United refrigerator company ltd. (dawlance) is

the latest one and it includes the hardworking labors, employess who give

their best for the over all effectiveness of the company.

This report may also contains the facts and the real figures of the various

departments which are very beneficial for our experience and the also for

the practical knowledge. The functions and the details of their working and

the process as well as the timing and work break down structure is also

mentioned in this report. This is edit by the students of the INDUSTRIAL

ENGINEERING AND MANAGEMENT DEPARTMENT of the

nominated university of jamshoro named MEHRAN UNIVERSITY OF

ENGINEERING AND TECHNOLOGY JAMSHORO SINDH

PAKISTAN. The details of the students are as under:-

MUHAMMAD YOUNUS (08IN70).

MANOJ KUMAR THAKUR (09IN46).

JASWANT SINHA (09IN03).

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ACKNOWLEDGEMENT

We are very thankful from the core of my heart to

honorable ASSITANT VICE PRESIDENT , “United Refrigerator

company ltd. (DAWLANCE) “ , ABDUL ALEEM KHAN for

providing us opportunity for training and whose intelligent, wise

and sound leadership has converted manpower into wining

combination by this industry into a gold mine.

We wish to express my deep gratefulness to

Whole HRD)for their consideration and supervision. It was a

memorable time in United refrigerator company ltd. (Dawlance)

due to his kind concern.

We are also thankful to all concerned manufacturing

supervisor and engineer’s for their precious advice and for the

great encouragement and cooperation, because of which We have

successfully completed our internship training of UNITED

REFRIGRATOR COMPANY LTD. (DAWLANCE ) where we

learned a lot.

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CONTENTS

Days of internships

Departments Page no.

Day no. 1 Production II (shearing, sheet Metal and welding )

• Shearing section

• Sheet metal section

• Welding section

• Cabinet

• PC sheet

• Freezer door

• Basic panel

• side panel

• Compressor support

• Ref door and many more

7 to 11

Day no. 1 PRODUCTION III ( THE PAINTING SHOP )

• CABINET painting shop

• EVAPORATER painting shop

• CONDENSOR painting shop

• DIP- COATING (Shelf painting

shop )

12 to 16

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DAY NO. 2 PROUCTION IV (CONDENSOR MANUFACTURING AND OTHERS )

• Shelf making section

• Condenser making

• Iron handing section

• Chrome section

• U-V Light section.

17 to 23

Day no. 3 PROUCTION V ( PRE – FOAMING )

• What is PRE – FOAMING ??

• Process of PRE – FOAMING &

Stages.

24 to 27

Day no. 3 PRODUCTION V ( FOAMING )

• What is FOAMING ??

Process of FOAMING ??

28 to 29

Day no. 3 PRODUCTION VI ( ASSEMBLY LINE )

• What is Assembly line ???

30 to 31

Day no. 4 PRODUCTION I (PLASTIC MOULDING SECTION)

• Compounding section

• Injection section

• Hot stepping section

• Steam print section.

• Extrudes section

• Cable section

32 to 36

Day no. 5 MAINTENANCE

• What is MAINTENANCE ??

• Objective of Plant Maintenance

??

Importance of maintenance.

37 to 39

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• Methods of maintenance.

• Maintenance at Dawlance.

Day no. 6 QUALITY CONTROL

DEPARTMENT

• QUALITY AND CONTROL

(Definations)

• What is QUALITY CONTROL

???

• Quality Control At Dawlance.

• Quality Engineering Cell.

• Incoming Quality Control.

• Self Quality Inspection.

40 to 48

SUGGESTION’S

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SHEARING, SHELF METAL AND WELDING

Shearing => To shear off the requires size of sheet is called a shearing process.

Sheet -Metal => the various process that has been perform over the metal sheet sop that give is the requires shape is to be called a sheet metal.

Welding => A process of permanent fastening important type used the most important type used in dawlance is tug welding.

• It is the refer color; production eleven is the section where the man body of

refrigerator is to be manufactured.

• Though the production elevens section is used to manufacture a lot of

component put the cabinets is of the important component of production eleven

section.

RAW-MATERIAL OF PRODUCTION - II The raw- material of production of to (in the sheet form)

1) Metal steel 2) Galvanized iron 3) Vinyl coated Material (VCM) 4) Aluminum SHEARING SECTION: One the raw-material is receive from the store the sharing section is something

that actually share of the sheet according to the requires size of specifications.

The cabinet sheet is to be share of the sizing of

• Length = 3824mm

• Width = 655mm

• Thickness = 0.4mm

Other thing also shares off according the specifications.

SHEET METAL SECTION: There are basically no of parts has manufactured in this section.

The sheet metal section is basically best upon the 4 major area which are as follows.

1: Automatic sheet feed 2: Whole processing and notch (bending) 3; forming section 4. Pressing section The sheet metal is basically used to produces a no of parts of refrigerator, such as

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1. Cabinet 2. PC sheet 3. Freezer door 4. Basic panel 5. side panel 6. Compressor support 7. Ref door and many more

CABINET: The cabinet is to manufacturing once the sheet is receive from sharing the

automatic sheet feeder suck the sheet and feed the sheet then sheet through crame is to

be shift into the forming section where the form of profile and embossing can take

place and after ward that formed embossed is equally bended to form a cabinet. PC-SHEET: The pc sheet is the sheet that makes separates the freezer unit ref :a in other

word we can say that the I.C sheet is used to make separate n/n ref and free from the

upper side of refrigerator

PROCESS: It can be making by follow the following operation.

1. Notching process

2. Forming process

3. embossing process

4. Whole process

BACK PANEL: It is back side of refrigerator body that is to be attached with the

cabin net.

It is to be noted that is in small size refrigerate there Is only back panle and there is

no need for the bottom end as it also requirement in the refrigerator.

PROCESS: The back panel is to be made by the

1) Drilling the piece of M.S of sheet

2) Notching that piece

3) Whole also with the machine

4) first bending

5) 2nd bending

After that this do of is to welded with the cabinet by spot welding process. SODE RANGE:

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It just like the side panel it also require 1st cutting and the 2nd cutting and then

just and 2nd pending.

FREEZER DOOR: it is the front door of the refrigerator and it is to be made by

the VCD material sheet.

The size of VC sheet used a freezer door

• Length = 546 mm

• Width = 768 mm

PROCESS OF FREEZER DOOR The freezer door is according following the process

1: Notching

2: Handle pressing

3: Embossing

4: first banding

5: final banding

REFRIGRATOR DOOR: It is also be made with the VCD type of material and it make we

of same process as that of freezer door each and every step in same.

COMPRESSOR SUPPORT: It is the part that can be placed in the both part of the ailment and it

support the compressor.

PROCESS: The process to manufacture the compressor is as

1: whole plating

2: further 2 more whole

3: just bending

4: final banding

WELDING SECTION: Basically welding is the process of permanent fastening

therefore is the section all or same part are to fastened by tug welding so that the

required type and shape of cabinets is to be shift the painting shop.

Basically at sheet metal the welding section is used to perform that activity

so that the form bended and imposed cabinet is to be welded with the back panel and

sight panel and the it is screwed with the compressor support.

At the end of the welded section the welded cabinet is to be shift to the paint shop for

the further paint processing.

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PRODUCTION III THE PAINTING SHOP It is basically the painting section used to paint the various iron so that it

could be transfer into the final assembly shop.

It includes the,

• CABINET painting shop

• EVAPORATER painting shop

• CONDENSOR painting shop

• DIP- COATING (Shelf painting shop )

We had already discussed the dip-coating (shelf painting) and were here now we

learned the cabinet and evaporator painting

• CANBINET PAINTING SHOP As we know that whenever we are painting any thing first of

we need phosphating process so that the cabinet is to be easily painted. The cabinet

here though the following painted stages.

STAGES # 1 High pressuring over the refrigerator so that to remove as the welded

particle.

STAGES # 2 PHOSPHATING The phasphating process is actually though the following tank There

are basically 4 different tankers. Out of them 2 of the chemical tank , 1 of water

tank and 1 of di-ionized tank.

The phosphating process begins after following the first step now the cabinet is

dipped into the tank 1 ( which has the metaphoric chemical ) and then dipped into

the tank2 ( which Laos has the same chemical ).

Once the cabinet taken –off from the tank 2 then it is to be dipped into the tank 3

which has the raw water.

Finally the cabinet is to be placed into the di-ionbized tank and then the cabinet is

to be phosphated.

STAGE # 3 :- DRY OVEN At this stage the phosphated cabinet is placed into the dry even which

has the temperature of 110 ;140 degree centigrade . the dry oven has two function

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fisrt it is use to dry the water and moisture and secondly it is also make able the

cabinet sheet to be attain the more powder ( as in next step ).

STAGE # 4 :- POWDER ROOM After dry oven the cabinets are to be hanged into the conveyor hanger

and it is to be transferred towards the powder room.

A powder room is a highly automated room that is used for powdering or coating

of powder over the cabinets.

The powder room has 15 gm over the cabinets and this powder can be done by the

gun system in a powder room so that the layer of powder is to be coated over the

cabinet.

The functioning of powder room is done by the automated system which is

controlled by then computer based system and its basic to coated a layer of powder

over the cabinet.

In powder room by gun system the cabinets are coated with the JOTUN powder of

layer 35 to 70 micron.

STEP # 5 :- BACK OVEN This is the end process of painting shop here the powder cabinets

are to be backed into the oven so that the powder is to melted and forming in the

paint over the cabinet.

Actually in back oven the polymerization process takes place because once the

temperature has been provided to the powder tends to polymerized and forming a

chain so that it is to be transmitted over the cabinet.

IMPORTANT TO REMEMBER • The cabinet paint shop has the capacity to paint 1800 to 1900 cabinet

paint per 24 hours i-e capacity = 1800 to 1900 cainets paint per 24 hours.

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• EVAPORATER PAINTING SHOP As we know that the evaporator in consider to be the heart of

refrigerator and without the evaporator refraction is not exist. Evaporator is the part

that makes cooling within the refrigerator.

Evaporator is fitted inside the refrigerator and it is to be painted in white color.

The process of evaporator painting is as same as that of cabinets one within certain

amendments. However evaporator painting are requires phosphating and

powdering etc.

We can put forward the evaporator painting in the following stages.

STAGES # 1 :- EVAPORATER PHOSPHATING The evaporator phosphating process is done in 4 different tanks.

First of all the evaporator is dipped into the tank -1 which has the met clean

chemical.

After that the evaporator stays in tank-2 and tank-3 which is rinsing water tanks.

After that it is to be dipped into the tank-4 which has the metachrome chemical.

Finally again it is to be dipped into the rinsing water tank.

STAGE # 2 :- DRY OVEN After phophating the evaporator is to be dried into the dry oven which

is at the temperature of 140 to 160 degree centigrade so that to remove all the

moisture effect and also make the evaporator to sustain the powder.

STAGE # 03 :- POWDER COATING The powder coating over the evaporator is to be done on both the front

and back side of the evaporator.

STEP # 04 :- BACKING OVEN In last the evaporator is to be shifted towards the back oven which is al

the temperature of 205 to 220 degree centigrade and where the powder is

polymerized and evaporator is to be painted.

• CONDERSOR PAINTING Like all other painting section shops the condenser painting is also follwed

the same process as that of other painting process.

PROCESS OF CONDENSOR PAINTING The process of the condenser painting is being done in the following two

different stages.

i) Phosphating

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ii) Painting

PHOSPHATING The phosphating if condenser is to be done by passing through the no. of

condenser to various chemicals which is in the tank .

First of all the manufactured condenser is dipped into the metaclean 375 tank and it

stayed over there at 1 to 5 min.

Now the condenser is then dipped into the fresh rinsing water into the 2nd tank.

After that it is to be dipped into the tank of metaphor 247 chemical tank. And after that

through pressure vessel it is to be dried.

At the end of phosphating the condenser suppose to shift into the dry oven and where

the all moisture are dried from the phosphate condenser.

PAINTING The painting begins when JOTUN powder is to be paint over the

condenser after phosphating on both sides of condenser and this condenser with the

help of crank is to be inserted into the back oven so that powder is to be converted into

the layer of painted color. The temperature of back oven is about to be of 250 degree

centigrade and it is placed within the back oven for the period of 11 min.

It is important that the JOTUN powder use in condenser painting section if of different

form and have it own load.

Important to Remember …..

• The capacity of condenser paint shop is 1700 condenser paint per day.

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Like all other production section the PRODUCTION IV is also on e of the

most important section of refrigerator production. It is use to make some important and

value able item of refrigerator.

There are various sections those are comes under production IV category

i) Shelf making section ii) Condenser iii) Bottom condenser iv) Iron handle making section v) Galvanized section vi) Chrome section vii) U-V light section Through out all section of PRODUCTION IV have their own importance and

without them the processing is incomplete but the most importance item produce

by production iv is the condenser because without the functioning of refrigerator is

impossible.

Now we shall discuss each section in detail….

SHELF MAKING SECTION The shelf of the refrigerator is to be manufactured in this section. This

shop is used to make all different type of the shelf of different refrigerator model

and its highly depends upon the customer requirement e.g if the administration of

the production Iv receive the plan from production planning department to

manufacture 9175 WBM’s shelf so they suppose to act according to the

requirement.

� The capacity of the shelf section is to produce 31000 shelf per day and its make use of 7 different type of machine and also having the strength of 57 peoples.

EQUPMENT IN USE The shelf manufacturing makes use of different machines and welding

device.

• Starter and cutting machine

• Pressing machines of different type

• Tag welding

PROCESS OF SHELF MAKING The processing of shelf manufacturing begins when the raw coil of

thickness 2.5 mm is been receive through store and then the starter cutting

machines first make starter the coil and then cutted of required size ( depends upon

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the requirement ) , now the cutted coil is then bended and it is to be welded now

the frame of the shelf is been and also ready for the further processing.

Now again the no. of strip is also to be cutted so that there can fixed into

the shelf and then the shelf is to be welded by the tug welding process.

Now in order to support the shelf various section of straight shapes, L –

shapes, Z- shapes, the basic purpose of these section is that they used to provide the

support to the shelf of the refrigerator.

DIP- COATING / PAINTING SHOP It is basically the shop which is use to painting the manufactured shelf

but very few other parts are also been painted in this shop.

PROCESS OF DIP COATING PAINITNG The actually process is begins with the PHOSPHATING.

The phosphate process is based upon the various chemical in different tanks,

therefore first of all the manufactured shelf is first dipped into the tank -1 ( which

contain the dioxide chemical ) within 10 to 15 min , the shelf is to be placed in this

tank and then it is dipped into the 2nd tank (which contain only raw water ) and

within few minutes the it is to be dipped into the 3rd tank ( which is of Guadine 20

chemical ) and it is placed up to 5-7 min and finally again dipped into the rinse

water.

Once the phosphating the next is the coating painting

The phosphated shelf is then placed within the Backing oven ( which has the

temperature of 225 degree centigrade) after a few min these shelf are then to be

dipped into the powder ( JOTUN POWDER ) and then these are placed into the dry

oven ( has the temperature of 225 degree centigrade) and in last it is to be dipped

into the water.

� Capacity of DIP-COATING section is 1000 shelf paint per day

CONDESNSOR MANUFACTURING Every manufacturer knows the importance of condenser in refrigeration

process and without condenser the existence of the refrigerator is almost

impossible because it is something that maintain the refrigeration cycle. Therefore

in order to make the condenser manufacture the condenser much careful analysis

are required.

This section is use to make two different condenser.

i) Back panel condenser ( actually called as condenser ) ii) Bottom condenser

� The actually the first step towards condenser manufacturing is taken by

the engineering department.

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� Engineering department through critical analysis used to check the

actual condenser and then give the effective and efficient proposed way

to manufacturing in the shape of drawings, equipments etc.

�

BOTTOM CONDENSOR Most of people even don’t know is there any condenser in the refrigerator

that place in the bottom of the refrigerator. The basic function of this condenser is

also to reduce the temperature like other condenser do so .

PROCESSING OF MANUFACTURING THE BOTTON CONDENSOR The process of manufacture a bottom condenser requires a drawing and

the drawing varies from model to model of refrigerator therefore the size and coil

of bottom condenser also varies.

With the help of different pressing machine to complete the sheet and bending the

coil as per requirement through tug welding is then to be fitted.

BACK PANEL CONDENSOR (ACTUAL CONDENSOR) It is one of the most important and more meaningful part of the refrigerator

and the effectiveness of condenser is necessary for the active life of the

refrigerator.

PROCESS TO MANUFACTURE A CONDENSOR Once the plan has receive by the PPC to the production IV section and

according to this plan the condenser of particular quantity of particular model has

to manufacture.

The first is to make use of MS sheets cutting strips then with the help of

shutter machine a late form in which certain operation carried out one by one such

as embossing, fins making is to be done.

The bending section first to cut the coil and straight it with the straighter

shutter machine and then bend the coil through is winches and dies is that the

required bending is to be obtain.

Once the plate and bending is prepared now with the help of tug welding

there plate with bended is to be welded.

Now the end plates of condenser that has been manufactured by pressing

machine is also to be welded by tug welding process.

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Now at the end the strip of MS also welded so that to provide the proper

reinforcement to the condenser .

By following the above stages the condenser is said to be manufactured.

GALVANIZED SECTION It is the very little type of section and its purpose is to nickel the various

parts such as

i) leg holder

ii) top middle bottom hinchees.

iii) Screws and others parts.

The basic behind this section is to do the nickel plating so that to remove

all the abrasive material, oil, Greece etc.

CHEMINCAL IN USE

Following ar he chemical those are used in this section

• Zinc brightener

• Zinc Californiazinc anodenitric acid

ALUMINIUM HANDLING SECTION It is the section which is bound to make the aluminum handling for the

refrigerator for the opening and closing of the door.

PROCESS OF ALUMINIUM HANDLING SECTION Already manufactured profile of aluminum is to be purchased from abroad

and then this profile is cutted according to specification of handle requirement.

Once the size is to be cutted then with the help of numerically control milling

machine a profile is being made to provide groove type of section so that the

handle is to be fixed.

CHROME SECTION Once the handle cover is been made by the modeling section to make the

handle cover then the crossing of that part is to be taken place.

PRCESS OF CHROMESECTION The chroming is to be done by following the certain steps

STEP # 1 :- ETCHING BATH First of all the handle cover is dipped into the chromic acid in the etching bath

which is al the temperature of 65 degree centigrade.

STEP # 2 :- WATER TANK After the etching process the handle cover is to be dipped into the raw water .

STEP # 3 :- After that it is to be dipped into the HCL and also into the

neutralization drum.

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STEP # 4 :- After wards it is to be placed into the activation bath which also

include certain amount of HCL.

STEP # 05 :- Now at this the nickel sulphate electroplating is to be done.

STEP $ 06 :- after that the it is to be dipped into the copper the layer of copper

in comes over the handle.

STEP # 07 :- Nickling is to be done at this stage hence the nickling also to be

placed over the handle.

STEP # 08:- At the very last stage the chroming is to be done over the handle.

U-V LIGHT SECTION The only haxon model of refrigerator inn which there is type of fan placed

within the refrigerator.

The function of that fan s that when door is closed its used to provide the air sot

that the ice is to be melted for the effective cooling of refrigerator.

So in this section fan with its parts to be assembled here.

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PRODUCTION V (PRE- FOAMING) Till production we are making, painting the certain parts so that they

should combined to form the original product.

• The production V ( i-e PRE – FOAMING ) as the name suggest it is the pre

of the foaming that is it the place where the various operation is to carried

before it is to be placed to formed.

• At the pre foaming the necessary item such as the liner, freezer and anti-

moisture tube, evaporator are to be inserted into the actual body of cabinet.

PREFOAMING PROCESS The actual process of pre-foaming is starts when the painted cabinets

from the cabinet painting shop are comes to the pre-foaming zone.

We can underline the each and every step of pre foaming now

STEP # 01:- First of all the compressor support is un-screwed from the

painted cabinet.

STEP # 02:- The gum- type material named as slent is to be inserted into the

corner edge of the painted cabinet in order to make proper isolation.

STEP # 03:- Washer type material is tape within the four whole if the back panel

so that condenser is to be screwed easily in it.

STEP 04:- Bottom profile is inserted within the embossing area in the bottom.

STEP 07:- spaces in fixed in the back panel so that the pipe which is fitted in it.

STEP 06:- Groemr also fitted with the wholes.

STEP 07 :- Anti moisture strip a black pipe is to be inserted within the profile

cabinet.

The anti-moisture strip has two functions first as the name suggest its used to

prevent from the corrosion effect also the gas kit ( rubber type ) within the door is

causes to crack because of cooling inside so it is also prevent this as it is connected

with the compressor.

STEP # 09 :- the freezer box is to be further includes the following sub- systems

Sub – step 1:- the painted evaporator from the EMD is bend by the press

machine.

Sub-step 2:- the bended evaporator is then to be check for the little inspection.

There are basically two different inspection tests,

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i) A LEAD DETECTOR MACHINE :- A machine which is used to detect the all the pipe and join of the

evaporator by inserted the Freon gas.

The detector even has the capability to detect 1.0 micro gram of area.

Once the evaporator is OK then it is to be shifted for the next test.

The statistics show that there are basically 8 to 10 evaporators rejected in lead

detector test.

Once the purpose is established hen the Freon gas is to be ejected and stored and

from the evaporator.

ii) The 2nd inspection include is to check the mass flow rate within the evaporator

and it is to be done by inserting the Nitrogen gas from the capillary. It is also gives

the benefits in the shape that it tends to clean the evaporator by the nitrogen gas.

Sub- stage 03:- Obtaining a evaporator frame.

The evaporator from is to be make by joining the evaporator the side plate

thorough a silicon type of material.

Now this flow is to be fitted with the freezer side of the cabinet.

STEP # 10:- The ref portion of the refrigerator is to be undertaken and it can be

divided into the following sub steps.

Sub – step 01:- the liner which is come form the thermosetting section is first

sized and cutted by the press machine. With the size the whole also produce which

is of evaporator and thermocouple.

Sub-system 02:- after that the head after and thermostat cover is taped within

the liner.

Sub- system 03:- a light pipe is having the wire which is the fitted with the

thermostat on one hand and head after on the other hand.

STEP # 11:- Liner is fitted within the cabinet i-e liner completely fitted within

the cabinet.

That’s the end of the pre-foaming suction.

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FOAMING SECTION The foaming section is a place when the pre-foamed cabinet is to foamed by

the automated machine.

The foam which is to be inserted within the pre-foamed foam than it is solidifying

within a few minutes.

The foam is basically made of two different type of chemicals.

i) Polyoal ii) Iso – cynate iii) R141B ( a gas whch is used as a catalyst )

• The foaming section has the capacity to filled 81 mould foam per hour i-e capacity = 81 mould foam per hour.

PROCESS OF FAOMING The process of foaming section begins by fixing the jigs and fixture within

the ref section so that while foaming the inside the refrigerator is not bend etc.

After that the highly automated the mixture of foam is to be inserted within the

cabinet.

The dawlance has 9 moulding foam hangers which is highly automated and used to

operate according to the sensors and actuators and various other things.

Basically the mixing of chemicals as to form the foam is to be as

100 % of polyoal

1260 % of iso –cyanides

16 % of R141B. It can be termed as ,

P : g : I

100 : 16 : 1260

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ASSEMBLY LINE

This is the very last portion of this shop also the refrigerator

manufacturing.

At this stage the all parts that we have made in deferent section such as sheet

items or main body items we made in sheet metal section, plastic items we have

marked in moulding, condenser e have made in production IV , shelf we have

make in production IV , freezer and ref door also assembled

Therefore is assembling shop we are the assemble all items to make the

refrigerator.

At the end certain inspection made refrigerator takes such as vacuum generation

and then the Freon gas is also inserted into the refrigerator.

At the end of assembled line the refrigerator are to be packed and transferred to the

store room as a inventory so that it is it be distributed.

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PRODUCTION I (PLASTIC MOULDING SECTION)

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As the name suggest plastic molding the production is said to manufacture

all plastic type of equipment that can be used in refrigerator manufacturing.

There are 6 section includes in moulding each section have its own task to with

they can act these are as follows,

i) Compounding section ii) Injection section iii) Hot stepping section iv) Steam print section. v) Extrudes section vi) Cable section

• The compounding and injection are the most basic sections and these are

those which used to produce they different plastics items in proper

quality and quantity.

COMPOUNDING SECTION The raw material of various plastics material in the form of huge grain is

received in compounding portion through store room.

These raw materials includes,

� PS � ABS � HIPS � LIPS � PC � NYLONE & � PP.

The compounding section used to mix the raw material with the pigment so

that required color of particular item is obtained.

The mixing can be done by two different type of devices.

i) DRUM MIXTURE ii) VERTICAL MIXTURE

DRUM MIXTURE Drum mixture is a device which consist of two different drum and b/w the

there is a motor that has the rotatory function. The motor used to rotate the drum.

Each drum has the capacity to take two beg ( each beg of 25 kg i-e 50 kg ) so we

can say that drum mixture can take 100kg of a material in a time.

PROCESSING OF DRUM MIXTURE The processing of mixing of material through drum mixture is such that

mixture the beg of 25 kg of material insert into the drum then the amount of

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pigment according to the standard weighted and insert into the drum and then again

another beg also inserted into the drum and similarly the next drum also filled.

Now the drum mixture start rotating and mixed the material with the pigment and

in 5 min the material is kept out just within the 5 min.

Therefore we can say that the drum mixture has the capacity of 100 kg of material

to be mix in 5 min.

VERTICAL MIXTURE : It is also the mixing device and used to mix the material with the

pigments go that the required material can be obtained.

Though it can be used to mix all type of material but in compounding section of

dawlance it is specifically used to mix the poly storing (IS) material with the pigment

of T- brown , T green, smooth gray. Height impact poly strien (HIPS) material with

the pigment of brilliant white.

INJECTION SECTION: • It is heart of the moulding section here all plain parts are been manufacture

through injection mould mallina.

• The highly automated machine CLF- INJECTION MOULDING MACHINE

use in this section.

• The machine can varies clapping force i.e the injection moulding machine

(CLF- 8OT) has the minimum clapping force injection moulding machine

(CLF- 800T) has the maximum clapping force.

• There are basically 52 CLF-MOULDING MACHINE’S are used and can vary

in diff: clapping force to make very small item to the heavy plastic item.

PROCESS OF CLF (INJECTION MOULDING MACHINE) Basically the processing of CLf is based in the four different sections.

1. Hooper 2. Bassell 3. Injection side 4. Eject side

1. HOOPER: First of all material (mixed material) has come from the compounding

section. Hooper actually use to collected the inserted material alive is the shifted in to

into the bassel.

2. BASSEL:

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After Hooper the material hydraulic piers machine comes into the bassel. In

bassl this material first heated thorough 7- different zone and reach zone has two

heaters.

3. INJECTION: Once the material is to be melted with the help of heated now the material is to

be injected through layer 6 to 7 different stage into the injected mould.

EJECT: After completing the ague the maked part in then eject from the machine so

that to perform the work.

From all these the other part i-e. carriage is used to be mixed

HOT STEPPING SECTION: It is little section in which chosen stepping is to be done over the

freezer door pocket that desirable the various sign.

EXTRUADES SECTION: It is the of section actually injection moulding process and it is also

used to make the profile that has been mould plastic material and give the shape of

profile.

CABEL SECTION: The refrigerator wire connection from the electric require a plug and

cable so in this there things are to manufactured.

Once the wire (cables to be purchased that first of on this cable are cables are to cutted

the required size and then the folly steps are to be taken

1. Core stepping 2. Wire stepping 3. Pinch moulding 4. Pinch foulding 5. Princh moulding machine

SCREEN PAINTING: As one have seen that there is numbering over thermometer regulator,

also we have is painting over the shelf “wider shelf “ similarly these is certain

coding we have seen, so in thing reaction i-e “ screen painting , there coating has

been painted over the items.

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MAINTENANCE

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Today, in modern industry, equipment and a machinery are a very

important part of the total productive effort than was the case years ago. Moreover,

with the developments of special purpose and sophistical machines, equipment and

machinery cost a lot more money and there fore their and does time becomes much

more expensive. For this reason, it is vitally important that the plant machinery

should be properly maintained.

OBJECTIVES OF PLANT MAINTENANCE i) The objective of plant maintenance is to achieve minimum breakdown and to keep the

plant in good working condition at he lowest possible cost.

ii) Machines and other facilities should be kept in such a condition which permits them to

be used at their optimum (profit making) capacity without any interruption or

hindrance.

iii) Maintenance division of factory ensures the availability of the machines, buildings,

and services required by other section of the factory for the performance of their

function at optimum return on investment whether this investment be in material,

machinery or personnel.

IMPORTANCE OF THE MAINTENANCE

i) The importance of the plant maintenance is varies with the type of the plant and its

production.

ii) Equipment breaks down leads to the inevitable loose of production.

iii) An improperly maintained or neglected plant will sooner or later requires expensive

and frequent repairs, because with the passage of the time all machines or other

facilities (such as transportation facilities), buildings, etc wear out and need to be

maintained to function properly.

iv) Plant maintenance plays a prominent role in production management the plant break

down create problems such as,

• Loss in production

• Rescheduling of production

• Split material (because sudden stoppage of process damages in-process

materials).

• Failures to recover overheads (because of loss in production hours).

• Need for over time.

• Temporary work shortage- workers require alternative work.

METAINENCE METHODS There are basically two different maintenance methods i-e

i) Tribology

ii) Tero technology

TRIBOLOGY

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It is the method of maintenance that deals with the lubrications impact of

the machine by proper maintenance.

It includes oiling, greasing etc.

TETO-TECHNOLOGY It is also the methods of maintenance that deals with the mechanical

effect of the maintenance such as repairing of the part of machine, overhauling of

the machine.

MAINTENACE AT DAWLANCE (United Refrigerator Company)

At dawlance there is a separate maintenance which constitute of several

engineers, technicians, and a skilled labors.

Their work is basically based upon the team efforts in which each persons has

certain responsibilities.

This section is centrally connected but all other section of industry by means of

computer network software (ORACLE) and also within the telephone.

They use to work into different format first they have collect the data of all bug to

small machines procession and divided these data of each part of machine into

various activities and also assign a scheduled of maintenance of each activity so

that to work accordingly.

The second format on which they work is that whenever any break down occur in a

production as per receive the compliance of particular maintenance they work upon

it.

Except production work their are other areas such as puncher shop, compressor

maintenance shop, generator maintenance, electrical maintenance department.

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QUALITY CONTROL DEPARTMENT QUALITY:- Though there are no. of definition of quality but in very simple works it can

be term as “ To meet the customer’s specification “.

CONTROL:- The provision to control the action or plan is to be control so that to meet

the requires as per planned.

QUALITY CONTROL:- Quality control refers to the control level of quality si that to lead to the

customer satisfaction.

• It is the provision under which the proper and effective quality it to be obtain so

that to lead the market position.

• In an organization the term quality is as big as it can and under a no. of quality

units are working their work to inspect the ongoing activity as per standard and

then mark as OK, HOLD, USAI, REOWRK & SCRAPE.

QUALITY CONTROL AT DAWLANCE The quality is given the major relaibnility at dawlance and therefore the

central quality control department is been devied in deffrent quality section

i) Quality engineering cell

ii) Incoming quality control

iii) Quality assurance

iv) Self quality at each manufacturing section

v) Quality process lab.

And many other departments ……

QUALITY ENGINEERING CELL It is basically the quality section is which all the documentation are to be

taken places

It is use to keep the documentation like of each section and even each section’s

item that has produces….

a) Quality instruction b) Work instruction c) ITI ( Instruction Testing Inspection ) d) Sampling Inspection e) Quality status

Now we shall discuss each section in detail..

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QUALITY STATUS While inspected anything the doud full item are to be taken into 4 basic

consideration rather than just to be called as scraped i-e by reviewing whole

parameter the decision regarding the item is to be taken.

There are basically four quality status .

i) HOLD ii) UAI (use as is) iii) REWORK iv) S CRAPED It can be illus trade as ,

HOLD = During inspection the defective part is to be hold.

UAI

HOLD

REWORK

SCRAPED

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USE AS IS (UAI) = Though the part is not fully mismatched with the

standard but the negotiation between the manufacture and quality incharge is to be

taken and the item is it be USE AS IS (UAI).

REWORK = There are few items those are require to rework so that to be

come into the required expectation

.

SCRAPE = The item is to be scarped.

QUALITY CONTROL MANUAL It is basically a manual that can help the operator to perform the work takes

as it includes all type of activities.

These are those type of manual which use to perform the training function to the

operation because its includes set of instruction of every used item.

SAMPLING TABLE As we know when raw material receive there are basically a no. of lots and

each lot having a no. of item therefore is extremely difficult to check each and

every item and also time consuming because if we are doing to inspect every item

so it is very difficult for us to meet the required demand.

Therefore the process begins by checking first 3 lots completely i-e 100 % and then

if the fault rate is same or reducing the accordingly move toward the sample mood

in which according to lot size the item are randomly selected.

The sampling mood sheet can be illustrate as ,

SAMPLING TABLE

LOT SIZE ACCEPT QUALITY LEVEL

SAMPLE SIZE ACCEPT REJECT

2 to 8 2 0 1

51 to 90 3 0 1

500001 to

over

13 1 2

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• ITI (INTRUCION TESTING INSPECTION) It is basically a document in which whole process and way of doing of

each and every part is given.

It is a document which includes all the defects even that has observed before in the

form of major and minor defects.

Basically there are 872 type of ITI’S are there.

• DC / IDC FORM DC = DECIPLANE CHECK

IDC = INTER DECIPLANE CHECK It is the document which bund to check the discipline of particular item i-e

the item like sheet coil is been check by the sheet metal inspector. After that it is

inter disciplinary check by the concerned related section.

• RELIABILITY IN AN ACTION PROGRAM (RIAP) It includes basically a proframa which describe how training programs are to

be undertaken.

What are the progress of training i-e how to be calculate.

What is the procedure of doing the basic task etc.

• INCOMING QUALITY CONTROL DEPARTMENT Incoming quality control is basically a quality section whose function is to

inspect all incoming raw material that can be utilized for different purpose in

different place. They used to work according to the instruction has given in ITI of

particular item and each ITI is different for different items.

We also know the dawlance (united refrigerator) can purchase the material both

expert from other countries and also taken from the local suppliers.

PROCESS OF INCOMING Q.C The procedure of incoming quality control section to inspect the raw item

can be under line in the following steps.

STEP # 1:- RECEIVE PROCESS It is the visually process once the raw material is receive the proforma that

has been given within the raw material by the supplier is to check whatever written

in the from of quality is placed or not.

STEP # 2:- QUALTY INSEPCTION It is the main inspection in which the raw material quality is to be

inspect to mismatch with the standards

Initially the first three lot are to fully inspected i-e 100 % checking and after that

the defect level over in first 3 lots are satisfactory the we shall proceeds to the

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sample mood when according to the lot size sample is randomly selected and then

be inspected.

It is very much important to remember the incoming Q.C is not able to

inspect all items just like chemical type of material is to be inspected in Q.C lab

and hence the C-FORM is to be make for that.

Incoming Q.C usually make visual dimensional inspection.

Now we shall discuss the item as follows,

• EVAPORATER Evaporator is the type of item which is no. of time to be inspected starts

from the Q.C and then final assembly inspection.

The dawlance exports evaporator from china the suppler name “Jau-su-shanfe”.

Though testing supplier are also inspected but the existing supplier “Jau-su-shanfe”

is the major and more reliable supplier of evaporator.

Evaporator is 100% inspected and there is no concept of sample mood.

PROCESS OF EVAPORATER INSPECTION AT INCOMING Q.C First of all the sizing of evaporator is to be inspected visually and then observe the

dent to be placed over the evaporator more importantly if that case the dent to be

over the bended area ( as is pre-foaming shop) the evaporator is to be rejected

because no more risk is to be taken.

• JOTUM POWDER We know the usage of JOTUN powder i-e its use for the paining purpose if items .

The inspection of JOTUN is begins by batch the powder in term of their respective

code and colors.

After that the C- form is made and its sample of every batch shifted to the Q.C lab

where the chemical is to be inspected in order to match the existing composition

with the standard one.

• CABLE ASSEMBLY LINE SWITCH As we have seen in pre-foaming stage when liner is prepared for fixed

into the cabinet so the hold assembly with thermo state is taped over there.

Therefore the cable is to be termed as cable assembly switch and it is to be

inspected in terms of equal dimension.

The multimeter is used to check continuity of cable etc

And many other item are to be inspected at Incoming Quality Control ( we are not

in a position to describe each ).

SELF QUALITY SECTION

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Every manufacturing side have its own self quality section whose

purpose is to check the quality of manufactured item that make in his section as per

required specification.

There are basically two different type of inspection is to be taken place

i) First piece Inspection ii) Roval inspection

FIRST PIECE INSPECTION As the name suggest the inspected that has been taken from the first

piece according to the required drawing specification

Then the first piece is to be filled into the shape of document certificates are as

follows ,…..

FRONT SIDE

BACK SIDE

REQUIRED FOUND SIZE VARIATION MEASURING

UNITED REFRIGRATION INDUSTRIES LTD IN PROCESS QUALITY CONTROL DEPARTMENT

(SHEET METAL)

FIRST PIECE / MACHINES SETTING CERTIFICATE

DATE___________________SHIFT______________________ TIME_______________________

MACHINE:______________________________________________________________________

PART____________________________OPERATION____________________________________

DIE/ MACHINE SETTER__________________________________________________________

DRAWING NO.___________________________MODEL_________________________________

SIGNATURE PROD. SUPERVISOR _________________________________________________

REMARK BY QC INSPECTOR ______________________________________________

Certificate no. -----

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SIZE TOOL NAME

ROVAL INSPECTION As we know that the variation over the item can be occur at any stage because of any

fault in an machine therefore after first piece inspection the roval inspection i-e after

every hour of same item also done to maintain the quality.

The roval inspection certificate is filled according to the dimension.

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SUGGESTION NO. 1:-

There should be a supply chain department.

A supply chain is a process that includes the chain of supply

from purchasing of raw material to the shifting to end consumer. It

defines as the supplier-customer interaction and intermediaries’ b/w

them.

I have seen while doing internship at dawlance there is no

concept of supply chain management and there is no supply chain

department and instead of having the separate supply chain department

the PPC ( production planning and control ) dealing with the affairs of

supply chain .

IFFECT OVER THE INDUSTRY IN THE ABSENCE OF SUPPLY CHAIN DEPARTMENT In dawlance the process of manufacturing is to be start when

the tentative schedule is been given to each manufacturing section that

they has to produce this much amount of this and this much amount of

that in a particular period of time. Every manufacturing within the

industry is been produce its own tentative work plan on which they

have to work but unfortunately this tentative plane does not define the

interaction b/w two manufacture i-e supplier –customer relationship.

For example :- Pre-foaming is the customer of cabinet painting shop

and cabinet painting shop and cabinet painting shop is the customer of

sheet metal and welding section hence its form a chain of supplier and

customers.

For example :- thermo foaming is the supplier of pre-forming or in

other words pre-foaming is the customer of thermo foaming but the

supplier of thermo foaming is out siders .

In dawlance (united refrigerator company) instead of having a supply

chain department there is general meeting among the supervisors and

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engineers of manufacturing staff and this meeting every supplier is

interacting with his customer so that to know the current situation of

each other and share their problems to each other.

Hence just based on the general meeting the result as any

stoppage or draw back in production they used to blaming to one

another which in term leads to create conflict.

Therefore if there will be a supply chain department so I think is a

perfect accountability of each section and hence over all performance

get improved.

SUGGESTION # 2 :-

There should be an effective maintenance department. As we have discussed that there is a maintenance department

but to be very much frank it is not suppose to fulfill the required

production expectation which in tern causes to create the conflict b/w

the maintenance and manufacturing section.

Manufacturing section complains that ,

• Maintenance not working properly .

• They don’t find the root mean cause of the problem instead they just

try to put their effort so that the production has start.

• They donot react on time usually we call them a lot and at the end

they used to react.

On the other hand,

The maintenance compliance that,

• They don’t have enough work force to reduce the causes of

unhappenings.

• Manufacturing too easily too band toward their improvemental

thinking and its being extremely difficult to maintenance to meet

all this.

And there are various other factor that lead to create the conflict among

the manufacturing and maintenance section.

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SOLUTION The main dramatic lack is also that there is no shutdown

maintenance of machine been allow by administration because

shutdown maintenance required 2 to 4 hours and obviously while

doing shutdown maintenance the production gets stops and

management not want any action that leads to stop the production . But

if wee look from a close eye the machines get stops any time because of

any lack then to give ordering to the maintenance and then it assign the

optimal crew according to the work and then act this also requires a lot

of time and in this period also gets stops therefore I think there ha to be

same period of shutdown maintenance.

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PREPARED BY

Name: Mohammad Younus

Fathers Name: Mohammad Anwar Qureshi

Surname: Qureshi

Nationality: Pakistani

Date of birth: 24th November 1988

Place of Birth: Hyderabad

Domicile: Hyderabad Urban

Profession: Student

Degree: Graduation (B.E Industrial Engineering & Management)

Year of Study: Final year.

Roll No. 08IN70

University: Mehran University of Engineering and Technology (M.U.E.T) Jamshoro.

dawlance internship report

Business

united refrigerator

section condenser

mohammad younus 08in70

production elevens section

sheet metal

section cable sectionday

muhammad younus 08in70

process of foaming