INDUSTRIAL TRAINING REPORT

Godrej & Boyce Mfg. Co. Ltd.

Submitted in partial fulfilment

Requirements for the award of
Degree of Bachelor of Technology in Engineering

Submitted By: Jeewanjot Singh Submitted To: Mr Sameer Gupta

(Trainee RFA Department) (Head of Department - RFA)

PEC UNIVERSITY OF TECHNOLOGY

CHANDIGARH
 DECLARATION

I hereby declare that the Industrial Training Report held at (Godrej & Boyce Mfg.
Co. Ltd.) is an authentic record of my own work as requirements of 6-months
Industrial Training during the period from 6th Jan 2014 to 2nd May 2014 for the
award of degree of Bachelor of Technology (Production Engineering), PEC
University of Technology, Chandigarh.

Date: _____________
 ACKNOWLEDGEMENT

I Jeewanjot Singh student of Bachelor of Technology am feeling a great sense of

honour in presenting this project file on Six Months Industrial Training done at
Godrej & Boyce Mfg. Ltd. This provided me an exposure to industrial
environment and training on the process of manufacturing of refrigerators.
I worked very hard and tried to take full benefit of opportunity provided to me.
I would like to pay my gratitude to my respected trainer Mr Deepansh who gave
his valuable support throughout my training period.

Jeewanjot Singh
INTRODUCTION TO THE COMPANY

Brighter Living

Type Public company

Industry Conglomerate

Founded 1897

Founder(s) Ardeshir Godrej

Pirojsha Godrej

Headquarters Mumbai, Maharashtra, India

Area served Worldwide

Key people Adi Godrej (Chairman)

Jamshyd Godrej

Nadir Godrej

Products Real estate, FMCG, home appliances, furniture, security, Agri

care

Revenue 216 billion (US$3.7 billion)(2013)

Employees 26,000 (2013)

Subsidiaries GCPL, Godrej Infotech Ltd,

ABOUT GODREJ GROUP
The Godrej Group is an Indian conglomerate headquartered in Mumbai,
Maharashtra, India, managed and largely owned by the Godrej family. It was
founded by Ardeshir Godrej and Pirojsha Godrej in 1897, and operates in sectors
as diverse as real estate, consumer products, industrial engineering, appliances,
furniture, security and agricultural products. Subsidiaries and affiliated companies
include Godrej Industries and its subsidiaries Godrej Consumer Products, Godrej
Agrovet, and Godrej Properties, as well as the private holding company Godrej &
Boyce.

Established in 1897, the Godrej group has grown in India from the days of the
charkha to nights at the call centres. Its founder, Ardeshir Godrej, lawyer-turned-
locksmith, was a persistent inventor and a strong visionary who could see the spark
in the future. His inventions, manufactured by his brother Pirojsha Godrej, were
the foundation of todays Godrej Empire. One of Indias most trusted brand,
Godrej enjoys the patronage and trust of around 500 million Indians every single
day.

With 7 major companies with interests in real estate, FMCG, industrial

engineering, appliances, furniture, security and agri care to name a few its
turnover crosses 4.1 billion dollars. About 26% of its business is done overseas. Its
presence in more than 60 countries ensures that its customers are at home with
Godrej no matter where they go.
SUBSIDIARIES

Godrej Consumer Products Limited

Godrej Consumer Products Limited (GCPL) is an Indian consumer goods

company based in Mumbai, India. GCPL's products include soap, hair colourants,
toiletries and liquid detergents. Its brands include 'Cinthol', 'Godrej Fair Glow',
'Godrej No.1' and 'Godrej Shikakai' in soaps, 'Godrej Powder Hair Dye', 'Renew',
'ColourSoft' in hair colourants and 'Ezee' liquid detergent. GCPL currently operates
several manufacturing facilities in India spread over seven locations and grouped
into 4 Operating Clusters at Malanpur (Madhya Pradesh), Guwahati (Assam),
Baddi- Thana (Himachal Pradesh), Baddi- Katha (Himachal Pradesh), Pondicherry,
Chennai and Sikkim.

GCPL operates in the domestic and international markets in the 'Personal and
Household Care' segment. Some of the categories are soaps, hair colourants,
toiletries and liquid detergents. Recently, it made an entry into fast-growing air
freshner category by launching a new fragrance product "aer" in the market.

Godrej Infotech Ltd

Godrej Infotech Ltd is a software services and consulting company headquartered

in Mumbai, India. Godrej Infotech, formerly a division of Godrej & Boyce Mfg.
Co. Ltd., commenced operations as a separate corporate entity on April 1, 1999.
Godrej Infotech is a part of the diversified GODREJ group. It was started as
Godrej & Boyce software division to implement ERP.

The Company's quality certifications include SEI-CMM Level 4 and ISO-

9001:2008 Quality Systems Certification. The Company has started re-appraisal
under SEI CMM ML 5 for all of its major software development centres in India
Godrej Industries Ltd

Godrej Industries is an Indian manufacturer of oleo chemicals for use in over

various industries. It also manufactures edible oils, vanaspati and bakery fats. In
addition, it operates real estate. Godrej Industries (Chemicals Division) has its
headquarters in Mumbai, India, and bases in 40 countries; it exports to more than
60 countries.

Godrej Properties Limited

Godrej Properties Limited is a real estate company in India and is a part of

the Godrej Industries Ltd. The company was started in 1990 by Adi Godrej.

Established in 1990, they are one of the major real estate development companies
in India and are based in Mumbai, Maharashtra. They have real estate development
projects in 12 cities across India. Currently, their business focuses on residential,
commercial and township developments. They undertake their projects through in-
house team and by partnering with companies with domestic and international
operations.
Godrej Properties Ltd. (GPL) is listed on the Bombay Stock Exchange (BSE) and
The National Stock Exchange (NSE)
Their parent company, Godrej Industries Limited, is the listed flagship company of
the Godrej group of companies. The Godrej group of companies includes Godrej &
Boyce Manufacturing Company Limited and is one of the major conglomerates in
India.

Godrej Properties Limited is the first real estate company in India to have ISO
certification.
Godrej One and Godrej Eternia have received the Leadership in Energy and
Environmental Design (LEED) Platinum pre-certification.
Godrej Agrovet

Godrej Agrovet Limited (GAVL) is a company engaged in agro based and

poultry based products. It belongs to the Godrej Group.

The Animal Feed business is Indias one of the largest, producing over 10,57,000
tons annually of feed and nutrition products for dairy cattle, poultry & aquaculture.
Its turnover was around 3100 Cr in 2012-13. In 2013 Godrej Agrovet has come up
with the biggest manufacturing Plant of poultry feed in India with a capacity of
around 30,000 MT/month, this plant is catering the demand of the poultry feed
market in North India, this automated plant has been installed in Khanna
(Ludhiana) by Neotech and Buhler. 4 new automated plants are also being
commissioned with more than 15000 Ton/month capacity each in Kharagpur,
Baramati, Bangalore & Erode to cater the demand of up growing market of animal
feed in all over India. GAVL has also entered Bangladesh through a JV with the
ACI Group, where it is rapidly becoming a key player in animal feed and poultry
breeding.

Godrej Properties and Investments Limited

Godrej Properties provides meticulously planned townships at affordable

prices. The Godrej Group also has overseas establishments in Malaysia, Singapore,
Vietnam, Oman, and Sharjah.

Godrej Efacec

The Company provides warehousing, automated storage and retrieval system

solutions.
BACKGROUND
The Godrej Group was founded in 1897, and has since evolved into one of the
largest and the oldest conglomerates based in Mumbai, India, with a presence in
varied industries, including appliances, precision equipment, machine tools,
furniture, healthcare, interior solutions, office equipment, food-processing,
security, materials handling and industrial storage solutions, construction and
information technology. The Group is headed by Adi Godrej and his brother in law
and cousin, Nadir Godrej and Jamshyd Godrej.
Traditionally, Vikhroli, a suburb to the Northeast of Mumbai has been Godrej's
manufacturing base, but increasingly the group has moved significant production
facilities away from Mumbai. The Godrej group also owns vast land in Vikhroli,
occupying 3500 acres (14 km2) of land on both sides of the Vikhroli section of the
LBS marg.

ACHIEVEMENTS
In 1897, Godrej introduced the first lock with lever technology in India.
In 1902, Godrej made the first Indian safe.
In 1920, Godrej made soap using vegetable oil, which was a huge hit with the
vegetarian community in India
In 1955, Godrej produced India's first indigenous typewriter
In 1989, Godrej became the first company to introduce PUF ( Polyurethane
Foam)
Introduced India's first and only 100% CFC, HCFC, HFC free refrigerators
(Claim to be validated)
OPERATIONS
The major companies, subsidiaries and affiliates are

Chemical & commodities

Godrej Industries
Chemicals
Veg Oils

FMCG
Godrej Consumer Products
Keyline Brands UK
Rapidol South Africa
Godrej Global Mideast FZE
Godrej SCA Hygiene Limited
Godrej Hershey Foods & Beverages Limited
Nutrine
Godrej Sara Lee

AGRI
Godrej Agrovet
Animal Feeds
Goldmohur Foods and Feeds
Golden Feed Products
Higashimaru Feed Products
Oil Palm
Agri Inputs
Godrej Aadhaar
Nature's Basket
Integrated Poultry Business
Plant Biotech

Services
Godrej HiCare (Pest Management Services)
Godrej Global Solutions (ITES)
TIMELINE

1897 - Godrej is established in 1897

1902 - Godrej makes its first Indian Safe

1918 - Godrej Soaps Limited incorporated

1961- Godrej Started Manufacturing Forklift Trucks in India

1971- Godrej Agrovet Limited began as an Animal Feeds division of Godrej

Soaps

1974 - Veg oils division in Wadala, Mumbai acquired

1990 - Godrej Properties Limited, another subsidiary, established

1991 - Foods business started

1994 - Transelektra Domestic Products acquired

1995 - Transelektra forged a strategic alliance with Sara Lee USA

1999 - Transelektra renamed Godrej Sara Lee Limited and

incorporated Godrej InfoTech Ltd.

2001 - Godrej Consumer Products was formed as a result of the demerger of

Godrej Soaps Limited. Godrej Soaps renamed Godrej Industries Limited

2002 - Godrej Tea Limited set up

2003 - Entered the BPO solutions and services space with Godrej Global
Solutions Limited

2004 - Godrej HiCare Limited set up to provide a Safe Healthy Environment

to customers by providing professional pest management services

2006 - Foods business was merged with Godrej Tea and Godrej Tea
renamed Godrej Beverages & Foods Limited
 2007 - Godrej Beverages & Foods Limited formed a JV with The Hershey
Company of North America and the company was renamed Godrej Hershey
Foods & Beverages Limited

2008 - Godrej relaunched itself with new colourful logo and a fresh identity
music

2010 - Godrej launched GoJiyo a free, browser based 3D virtual world

Godrej and Boyce Mfg. Co. Ltd. Mohali:

It comes under the appliance division of godrej.

Refrigerators and Compressors are produced here.
Its plot size is 75 acres.
It was inaugurated by Sardar Harcharan Singh Brar
It was inaugurated on 28TH FEBRUARY, 1996.
HOW DOES A REFRIGERATOR WORK?
The refrigerators work on the principle of the Vapour Compression cycle.

VAPOUR COMPRESSION CYCLE

The vapour-compression uses a circulating liquid refrigerant as the medium which
absorbs and removes heat from the space to be cooled and subsequently rejects that
heat elsewhere. Figure 1 depicts a typical, single-stage vapour-compression
system. All such systems have four components: a compressor, a condenser,
a thermal expansion valve (also called a throttle valve or metering device), and an
evaporator. Circulating refrigerant enters the compressor in the thermodynamic
state known as a saturated vapour and is compressed to a higher pressure, resulting
in a higher temperature as well. The hot, compressed vapour is then in the
thermodynamic state known as a superheated vapour and it is at a temperature and
pressure at which it can be condensed with either cooling water or cooling air. That
hot vapour is routed through a condenser where it is cooled and condensed into a
liquid by flowing through a coil or tubes with cool water or cool air flowing across
the coil or tubes. This is where the circulating refrigerant rejects heat from the
system and the rejected heat is carried away by either the water or the air
(whichever may be the case).

The condensed liquid refrigerant, in the thermodynamic state known as a saturated

liquid, is next routed through an expansion valve where it undergoes an abrupt
reduction in pressure. That pressure reduction results in the adiabatic flash
evaporation of a part of the liquid refrigerant. The auto-refrigeration effect of the
adiabatic flash evaporation lowers the temperature of the liquid and vapour
refrigerant mixture to where it is colder than the temperature of the enclosed space
to be refrigerated.

The cold mixture is then routed through the coil or tubes in the evaporator. A fan
circulates the warm air in the enclosed space across the coil or tubes carrying the
cold refrigerant liquid and vapour mixture. That warm air evaporates the liquid part
of the cold refrigerant mixture. At the same time, the circulating air is cooled and
thus lowers the temperature of the enclosed space to the desired temperature. The
evaporator is where the circulating refrigerant absorbs and removes heat which is
subsequently rejected in the condenser and transferred elsewhere by the water or
air used in the condenser.

To complete the refrigeration cycle, the refrigerant vapour from the evaporator is
again a saturated vapour and is routed back into the compressor.

Thus, Vapor-compression refrigeration is one of the many refrigeration

cycles and is the most widely used method for in domestic and commercial
refrigerators, large-scale warehouses for chilled or frozen storage of foods and
meats, refrigerated trucks .
 Domestic Refrigerator Parts and their Working

1) Refrigerant: The refrigerant flows through all the internal parts of the
refrigerator. It is the refrigerant that carries out the cooling effect in the evaporator.
It absorbs the heat from the substance to be cooled in the evaporator (chiller or
freezer) and throws it to the atmosphere via condenser. The refrigerant keeps on
recirculating through all the internal parts of the refrigerator in cycle.
2) Compressor: The compressor is located at the back of the refrigerator and in
the bottom area. The compressor sucks the refrigerant from the evaporator and
discharges it at high pressure and temperature. The compressor is driven by the
electric motor and it is the major power consuming devise of the refrigerator.

3) Condenser: The condenser is the thin coil of copper tubing located at the back
of the refrigerator. The refrigerant from the compressor enters the condenser where
it is cooled by the atmospheric air thus losing heat absorbed by it in the evaporator
and the compressor. To increase the heat transfer rate of the condenser, it is finned
externally.

Condenser of a domestic refrigerator

4) Expansive valve or the capillary: The refrigerant leaving the condenser enters
the expansion devise, which is the capillary tube in case of the domestic
refrigerators. The capillary is the thin copper tubing made up of number of turns of
the copper coil. When the refrigerant is passed through the capillary its pressure
and temperature drops down suddenly.

5) Evaporator or chiller or freezer: The refrigerant at very low pressure and

temperature enters the evaporator or the freezer. The evaporator is the heat
exchanger made up of several turns of copper or aluminum tubing. In domestic
refrigerators the plate types of evaporator is used as shown in the figure above. The
refrigerant absorbs the heat from the substance to be cooled in the evaporator, gets
evaporated and it then sucked by the compressor. This cycle keeps on repeating.
6) Temperature control devise or thermostat: To control the temperature inside
the refrigerator there is thermostat, whose sensor is connected to the evaporator.
The thermostat setting can be done by the round knob inside the refrigerator
compartment. When the set temperature is reached inside the refrigerator the
thermostat stops the electric supply to the compressor and compressor stops and
when the temperature falls below certain level it restarts the supply to the
compressor.

7) Defrost system: The defrost system of the refrigerator helps removing the
excess ice from the surface of the evaporator. The defrost system can be operated
manually by the thermostat button or there is automatic system comprising of the
electric heater and the timer.

External Visible Parts of the Refrigerator

1) Freezer compartment: The food items that are to be kept at the freezing
temperature are stored in the freezer compartment. The temperature here is below
zero degree Celsius so the water and many other fluids freeze in this compartment.
If you want to make ice cream, ice, freeze the food etc. they have to be kept in the
freezer compartment.
2) Thermostat control: The thermostat control comprises of the round knob with
the temperature scale that help setting the required temperature inside the
refrigerator. Proper setting of the thermostat as per the requirements can help
saving lots of refrigerator electricity bills.

3) Refrigerator compartment: The refrigerator compartment is the biggest part of

the refrigerator. Here all the food items that are to be maintained at temperature
above zero degree Celsius but in cooled condition are kept. The refrigerator
compartment can be divided into number of smaller shelves like meat keeper, and
others as per the requirement.

4) Crisper: The highest temperature in the refrigerator compartment is maintained

in the crisper. Here one can keep the food items that can remain fresh even at the
medium temperature like fruits, vegetables, etc.

5) Refrigerator door compartment: There are number of smaller subsections in

the refrigerator main door compartment. Some of these are egg compartment,
butter, dairy, etc.

6) Switch: This is the small button that operates the small light inside the
refrigerator. As soon the door of the refrigerator opens, this switch supplies
electricity to the bulb and it starts, while when the door is closed the light from the
bulb stops. This helps in starting the internal bulb only when required .
 STEPS INVOLVED IN REFRIGERATOR PRODUCTION

DOOR FOAMING
REFRIGERATOR COMPRESSOR
FINAL
ASSEMBLY
PRESS SHOP PC
STAGE -4
INSPECTION
CABINET
FOAMING
LSD & LEAK
DETECTION -1

EVACUATION
AND CHARGING

LEAK
DETECTION 2

PLUG IN & PLUG

OUT

LD 3& NOISE
TESTING

STAGE -5

STAGE-6
VARIOUS DEPARTMENTS IN REFER PLANT
PRESS SHOP:
Here the various panels are formed. Left Side Panel, Right Side Panel and back
sheet.

The sheets required to be fixed in front of the doors are also formed here.

There are two types of sheets:

Pre Coated Sheets

The Sheets which are to be sent for powder coating.

After the operations at press shop the sheets are sent for further operations.

The sheets are sent to following places according to their requirements:

Cabinet foaming
Powder Coating
Door Foaming

POWDERCOATING:
Here the sheets to be powder coated are powder coated. It takes place in the
following steps:

1. Loading of component on conveyor belt.

2. Pre-treatment of component.
3. Water Drying of components
4. Powder Coating of components.
5. Powder curing of components.
CABINET FOAMING:
Here the cabinet of the refrigerator is formed. Panels are joined together and liner
is placed in it. Then the foam is filled in it and required slots for wires and pipes
are cut in it.

DOOR FOAMING:
It takes place in two steps:
1. Vacuum Forming:
Firstly the HIP sheets are fed into linear ASANO.
Then these are pre heated
Then they are finally heated to the required temperature.
Then the die containing the shape to be formed moves down to the heated
sheet. It gives the required shape to the sheet by creating vacuum.
The temperature required differs from model to model.
Models Temperature (Final)
Edge (180ltrs,200 litres, 215 ltrs,250 litres) 350c to 390c
300 litres 400c to 420c
100 litres 400c to 420c

Temperature Required
2. Door Foaming

After the vacuum forming the door foaming for two different models take place
in two different ways:

For Axis Model:

The PDP formed is firstly trimmed and punching is done.

Then the gasket is fixed to it.
Then the door sheet and the PDP are filled with foam with the help of drum.
Then the screws are fixed to the PDP to fix it to the door firmly.
Anabond is also used to fix the gasket.
 For Edge Model:

After trimming and punching, the scrivets are fixed to the PDP.
Then the foam is filled in the door.
Then the gasket is snug fit on the door.

REFRIGERATION FINAL ASSEMBLY:

Here the whole Refrigerator is assembled on moving conveyer belt while worker
work standing on the sides of it. There are three assembly lines at one place and
fourth at another place. The three assembly lines joined together to one line. The
different models are built on different assembly lines which are according to the
order received by the company.

It takes place in two parts.

Front assembly
Back Assembly

These two takes place simultaneously.

FRONT ASSEMBLY:
1. Tape Removed :

Here the tapes on the cabinet of the refrigerator are removed by the workers. These
tapes are fixed before filling the cabinet with foam.

2. Foam Removed:

Here the foam on all the corners which is coming out of the liner and side panel
intersection is removed.
3. Legs Fitment :

Legs are fixed to the front of the refrigerator with the help of pneumatic guns.

4. Thermocol Fitment:

Thermocol is placed under the refrigerator. The placement of thermocol under the
refrigerator is done so as to ensure easy movement and enhanced mobility of the
refrigerator which is essential towards the later stages of its manufacturing
especially during its offloading.

5. Table Top Front Piece Fitment:

Here the table top Front piece is placed on the refrigerator. The wires for the
thermostat and bulb switch which are in the plastic covers are pulled out.
Thermostat and bulb switch are fitted and connected to the wires.

6. Evaporator Insertion :

The Evaporator is inserted in its place in the cabinet of the refrigerator with its wire
going out of the holes in the back sheet.

7. Evaporator Frame Fitment and Roller Fitment:

Evaporator frame is inserted to hold the evaporator in its place firmly. It is inserted
with the help of pneumatic gun. Here the rollers required for the free movement of
the chiller tray are also fixed.

8. Bulb Fitment :

Then the bulb is fitted in its place with its connector. Its space is formed in the
liner during cabinet forming. The wires required for it are also given during cabinet
forming. Aluminium sticker is used and stacked to the wall at the back of the bulb.
It helps to reflect the light coming out of bulb which increases lights intensity. The
bulbs used are of 10 W and 15 W.

9. Bulb Channel Fitment :

The bulb channel is fitted below the evaporator and it is connected to the
thermostat. The thermostat works as the device to cut the current supply when the
temperature in the refrigerator reaches below certain limit. Bulb channel is used to
sense the temperature in the refrigerator. The thermostat cut the current supply to
relay which switch off the compressor.

10. Cabinet Accessories Insertion:

Here the cabinet accessories are fitted to the refrigerator. The following accessories
are fitted:

Glass Slider
Chiller Tray
Liner Shelves
Ice Tray

11. Crisper Assembly :

Crisper assembly is done here .The crisper is used to keep the vegetables in the
refrigerator. Firstly the crisper is placed and then the glass is placed on it.

There are two types of crispers used for different models.

GPPS crisper
PP Crisper
12. Door Fitment :

Door is fitted here. The doors are formed in the door foaming department then they
are brought to the door fitment area with the help of the trolleys.

13. Table Top Fitment :

Table Top is placed on the already placed thermocol and fitted with the help of the
pneumatic gun.

14. Door Accessories Insertion :

Here the door accessories are inserted in the door. The space for insertion of door
accessories is already given in the PDP. PDP shelves provide the space for placing
different things. Egg Racks and key is also places here during assembly.

15. Handle Fitment :

Door handle is then fitted to the door with the help of pneumatic gun.

16. Logo Fitment :

Then the stickers are places on the front of the door.

There are 3 stickers that are placed on the door:

Energy Sticker:

It tells about the energy consumption of the refrigerator i.e. units it is going to
consume in a year. It also tells about the rating of the refrigerator i.e. 3 star rating
or 5 star rating.
 ZOP :

It tells about the range of the voltage between which the refrigerator can work
efficiently without any need of repair.

The third sticker tells about the model of the refrigerator. Examples are:

1. Axis

2. Edge

3. Edge SX

BACK ASSEMBLY:

1. Base Fitment: Here base plate is fitted to the bottom of refrigerator.

2. Compressor Fitment :

Here the Compressor fitment takes place. The compressor is fitted to the base
plate. Grommet is placed between the compressor and the Base plate so that
vibrations are not transferred from the compressor to the refrigerator.

Here relay pin is also fixed .It is used to hold the relay which controls the working
of the refrigerator.

Compressor works as a pump to control the circulation of the refrigerant and it

adds pressure to refrigerant, heating it up.

Compressor has three ports:

Suction Port: It pulls the refrigerant from the evaporator.

 Discharge Port: It discharges the refrigerant to the condenser.
Charging Port: By this port the compressor is filled with the refrigerant.
Relay: It is used to control the working of the refrigerator.

3. Capacitor Fitment :

Then the Capacitor is fitted at the side. It is used to start the compressor.

4. Condenser Fitment:

Then the condenser is fitted at the back of the refrigerator. It is fitted with the help
of condenser clamps. Four condenser clamps are used to hold the condenser in its
place. Condenser is used to for heat transfer. It gives out the heat to the
surroundings and cools the refrigerant.

5. Flushing and Drier Fitment :

Flushing of the condenser is done once before fitting the drier to it. Then the drier
is fitted to the condenser. It also has capillary attached to it.

6. Lokring Fitment:

The lokrings are fitted to the suction port of the compressor, discharge port of the
compressor and drier

7. Supply Chord Fitment :

Here the supply chord is fitted to the back of the refrigerator and its wires are fitted
to the compressor. It is used to provide the electricity to the refrigerator.
8. Coupler Fitment :

The couplers are fitted to the charging port and drier. They are fitted as they are
used in Leak Detection -1 and Evacuation and Charging Loop for evacuation
and charging of refrigerant.

INSPECTION DURING MANUFACTURING

Inspection of the refrigerator during its manufacturing takes place at STAGE 4.

It is done so as to reduce any recurring defect which may reduce the overall
PQI(percentage quality index) of the refer plant. Any defect during the initial
manufacturing of the refrigerator upto this stage is noticed by the line
supervisor and necessary and timely intervention of coordinators along with
line supervisors results in overall improvement in PQI of the manufacturing
system .

After assembly the inspection takes place of the complete refrigerator at

Stage -4

It takes place in two parts.

Front Inspection :

One worker of Quality department does complete inspection of the refrigerator

from the front. He inspects that nothing is missing and everything is placed or
fixed properly. He also inspects door for dents and scratches. The refrigerators
which need repair are offloaded and repaired by the workers of Refrigeration
Final Assembly Department.

The usual defects are:

Dent
PDP Shelf Broken
Evaporator Frame broken
Gasket Gap
 Chiller Tray Broken
Foam Seepage
Sticker miss
Scratch on Table Top
Deodorizer missing
Ice Tray Missing
Front Piece Cap Improper
Bolt Loose
Caution Sticker miss
Glass Improper
Evaporator Frame Bolt Missing

Back Inspection:

Simultaneous to the front inspection back inspection takes place on stage-4.

Here it is seen that the compressor, condenser, drier etc are properly fitted.

All the bolts and nuts holding capacitors, supplycord is in proper place.

All the wires connecting with the compressor are properly connected.

The usual defects are:

Compressor mounting pin improper fitment

Condensor clamp improper fitment
Suction line sticker missing
Grimmet missing
 ELECTRICAL DEFECTS:
The various electrical defects which occurs during the manufacturing of the
refrigerators are taken care at the light switch defect stage aka LSD defect stage.

At LSD the electrical connections are checked. The wires are inserted for various
equipment before this stage and inspection of those connections are done here.

It is checked that the refrigerator is working properly .This is done before filling
gas i.e. refrigerant to compressor. Firstly electricity is provided at 220 V and 50 Hz
frequency and it is checked that current flows through the refrigerator. Current
reading must be between (0.40A-2A).

If there is no ampere reading or the bulb does not work properly. Then the
refrigerator is offloaded.

Then it is again checked by the worker doing repair. If there is defect in proper
working of the bulb it can be of the following reasons

1. Improper Thimble connections: Thimbles are not connected properly with the
light switch or there is foam seepage in thimbles.

2. Improper fitting of bulb: It can be also because of improper bulb.

3. Bulb Fuse

If there is no ampere reading then there can be two problems:

1. Either there is problem in thermostat.

2. Or there is problem in relay.

Thermostat problem can be because of the following reasons:

Improper Thimble connections: Thimbles are not connected properly with

the thermostat or there is foam seepage in thimbles.
It may be also improper working i.e. thermostat is damaged.
Thermostat missing: LSD defects are also introduced if thermostat is
missed in the refrigerator body.
Reasons of relay problem:

Improper Thimble connections: Thimbles are not connected properly with

relay or there is foam seepage in thimbles.
Relay missing: If the relay is missing in the refrigerator, the compressor
doesnt work.

UNIT CELL (USS)

EVACUATION LOOP:

It is the process of removal of the all the gases in the compressor and cleaning of
the complete path through which the refrigerant has to flow.

When the compressor is manufactured in the compressor plant N2 is filled in it.

We use nitrogen gas because of the following worth mentioning reasons:

One is that it is inert gas.

Secondly the minimum temperature we want to obtain in refrigerator is -
37C which is higher than the dew point of nitrogen gas.

Firstly the Nitrogen gas is removed with the help of vacuum pump.

Then the two pipes of the vacuum pump are employed on two places i.e. at drier
and charging port of compressor.

The pumps used are rotary type and motors used to drive them are of 0.75
horsepower (HP).
 Pipe that is used at the drier cleans the condenser of all the gases and the
contaminants.
While the Pipe used at the compressor cleans the compressor completely.

The whole process takes almost 20 to 30 minutes to take place.

Here at the starting of the evacuation loop the refrigerators have to be moved so
that they can be arranged in front of the pumps being used for evacuation and
certain distance has to be maintained between refrigerators. If the distance is not
maintained between them there will be occurrence of dents on the purging bends as
the refrigerators will come close to each other. If the refrigerators collide it will
result in the dents on the refrigerators.

So the following points are to be taken into consideration:

Maintenance of distance between refrigerators.

Cushions are to be used on the side panels.
Foam cover is to be placed on the handles.

CHARGING OF THE REFRIGERATOR:

Charging of the refrigerator is done with the help of the Galileo. The refrigerant
filled is R600a (Isobutene). Refrigerant is filled in different amount in different
refrigerators according to the size of the refrigerator. It varies from 24 grams to 55
grams for different refrigerators.

LEAK DETECTION-2 AND PRE HIGH VOLTAGE TESTING:

The first leak detection was without filling the refrigerant in the refrigerator.
It was done with the help of nitrogen gas (N2).Now the leak detection takes place
after filling the refrigerant R600a.

It is one before plug in and plug out loop so that refrigerator is completely checked
of any leakage before the refrigerant starts flowing in the refrigerator.

So the refrigerators that are having leak are offloaded before the plug in plug out
loop.

The leak can be at the following places;

Condenser pipes
Drier
Capillary
Suction of the compressor
Discharge of the compressor

The leak is checked with the help of the leak testing machine. It beeps when there
is a leak in the refrigerator and it is offloaded. The point of leak is checked with the
help of the soap solution. When soap solution is applied wherever there is leak in
the refrigerator the bubbles start coming out from that point. Then it is sent for
repair.

High Voltage Testing:

Here 1100 volts is provided to the refrigerator. The current leakage should not be
more than 1mA (milliampere) .If it is more than 1 milliampere then the machine
beeps and refrigerator is offloaded before plug in plug out stage. This test is
important because if refrigerator having current leakage goes through the plug in
plug out loop without getting checked then it can cause an accident.
PLUG IN PLUG OUT LOOP
Here the refrigerator are plugged in with the plugs hanging from the bus bar above
.It is a loop of 20 minutes. There are two persons working at the starting of the
plug in loop.

Ones work is to plug in the refrigerator.

The second persons work is to check whether the bulb is switched on or not

Here lot of attention is given to the safety of the workers.

Rubber mat is used; both the workers have to stand on the mats. They are also
required to wear gloves for their safety.

The refrigerator moves on the conveyer belt in a plug in plug out loop while being
plugged in .So during this time refrigerator is switched on, it traverses the full path
provided to it i.e. compressor compresses the refrigerant then it passes the
condenser where it is cooled, then it is passed through the drier and capillary tube
which result in decrease of pressure of refrigerant. In evaporator heat exchange
again takes place, the refrigerant gains heat while it cools the vegetables etc in
refrigerator and come back to the compressor. This results in cooling of the
refrigerator. It is desired that during this plug in plug out loop the temperature in
the evaporator should reach below -18C.

Then the thermo hunter is used at plug out to check the temperature in the
evaporator. It should be below -18C.
The refrigerators whose temperature is below -18C are given okay tags and they
continue to move on the conveyor belt, but if the temperature inside the evaporator
is above -18C then refrigerator is offloaded and again plugged in.

Refrigerators that are offloaded have following defects:

Bulb not working

Compressor not working
Less cooling
No cooling
Or there me be problem with the supply cord

They all are repaired at tripping Stage.

NOISE TESTING:

During the plug in plug out loop the noise testing of the refrigerators compressor
take place with the noise testing machine. The compressor whose noise comes out
to be less than 70 dB is passed while those producing noise more than 70 dB are
offloaded at the plug out stage. They are again put on the conveyor belt and
offloaded at the noise testing chamber.

Noise testing chamber is present just before the noise testing area.

This chamber is a closed room having walls which are fixed with noise absorption
material so that no external noise comes in and no internal noise goes out. The
refrigerator is plugged in there and again noise testing takes place.
LEAK DETECTION -3:

It also takes place during the plug in plug out loop. Here the refrigerators are again
checked for leakage with leak testing machine. Here the refrigerators with leakage
are sent for repair.

TRIPPING STAGE:

Here all the refrigerators offloaded at the plug out stage are repaired.

The major defects that are removed are:

Light Switch defect

No cooling defect
Less cooling defect
Compressor not working
High voltage defect

Light Switch Defect:

The light switch defect may be due to improper connection of bulb or the Light
switch.

Sometimes the bulb gets fuse or its connection with its holder is not proper. It also
occurs when there is foam in the thimble connecting to the light switch.

No cooling defect: No cooling occurs due to improper relay connection or if there

is no refrigerant in refrigerator.
Less cooling Defect:

It occurs if there is less refrigerant used in the refrigerator. The amount of

refrigerant varies with the size and capacity of the refrigerator. It varies from 24
grams to 55 grams.

Compressor Not Working:

It may be due to two reasons:

Relay connection improper.

Thermostat connection improper or thermostat not working.

High voltage defect:

It is due to current leakage somewhere in the whole wiring .It is also removed here.

STAGE - 5:

Here at Stage 5 the front and back inspection takes place.

The inspectors are of Quality department. They check whether all the equipments
are properly installed at their required places. There is no fault in installation of the
various equipments.

If there is problem in installation and something is missing the workers of the

Refrigeration Final Assembly Department (RFA) offload the refrigerator and work
on the defect .After the repair is properly done the refrigerator is again put on the
conveyer belt.
STAGE-6:

It is the last stage before the refrigerator goes for packing.

Here the following things are done.

The cushions on the side panels of the refrigerator are removed.

The foam covers on the handles of the doors are removed.

Final inspection of the refrigerators.

Final repair of the refrigerators.

The RFA department workers do the entire repair and place the missing
components while the quality department workers have to just indicate the defect.
PROJECT ON LIGHT SWITCH DEFECTS
What is Light switch defect?
A light switch defect is an electrical defect in which the overall electrical
system of the refrigerator maybe hampered due to certain
problems/defects in various electrical components such as bulb, relay,
thermostat, compressor, wires, thimbles used in the refrigerator.

Common Problems
The common problems due to which electrical defects in a refrigerator
occurs are:
MAN MADE ERRORS:
Human is prone to mistakes. Thus, certain defects can be categorised as
man induced defects such as:
1. Loose bulb/switch/ thermostat connections due to improper fitment
2. Loose bulbs
3. Swapping of the terminals in case of relay
4. Distortion in geometry of the thimbles due to application of high force
by the worker.

OTHER ERRORS:
1. Some defects maybe introduced during the transportation of the
equipments.
2. Errors are also introduced during the loading and unloading of the
refrigerator from the conveyor belt.
The LSD data was collected for a number of days so that the main
problem can be pinpointed. The data collected is as shown below:

Nomenclature:

A- Light switch connection improper

B- Thermostat connection improper
C- Bulb fuse
D- Bulb holder defective
E- Supply chord defective
F- Relay connection improper
G- Thermostat defective
H- Thimble missing/cut

The following Data is collected:

LSD DEFECTS:

S.No. A B C D E F G H
Day 1 8 5 2 3 0 2 1 3
Day 2 5 5 2 4 0 3 0 2
Day 3 7 4 4 1 2 1 0 1
Day 4 6 7 4 2 1 2 2 2
Day 5 4 3 2 1 0 2 1 2
Total 30 24 14 11 3 10 5 10
Parts Per Million:

Parts per Million (Defects): (Total Number of defects/Total refrigerators)

x 10, 00,000

Total refrigerators manufactured during the period ~ 9000

Total number of defects =30+24+14+11+3+10+5+10=107

PPM = (107/9000) X 10, 00,000 ~12000

Percentage = 1.2%

Suitable steps were taken to decrease the overall defect PPM such as:

1. Deployment of an experienced permanent worker at critical positions

Experienced permanent workers were deployed at critical positions such as at

Table top front piece fitment, bulb fitment, and light switch fitment so as to reduce
the possibility of an error.

2. The workers at various connections positions were instructed not to apply more
than required force on the thimble while connecting it to the pins.

3. The wires for the thermostat and bulb switch were placed in the plastic cover in
such a way such that its connection with the required pins became easy.

4. The positions of a number of workers were swapped and altered so as to find the
perfect combination of workload division and also to reduce boredom among
workers inculcated due to monotonous work.

5. The correct way to load/unload the refrigerator on/ off the conveyor belt was
taught to the newly recruited workforce.

6. The vendors of various equipment were contacted in case of any recurring defect
in their components.

7. Abrupt stopping of lines was initiated in case any recurring defect occurs.
 Result:

After sometime again data was collected to see whether the defect has been
removed or not

Following data was collected:

LSD DEFECTS:

S.No. A B C D E F G H
Day 1 3 2 1 2 1 0 1 2
Day 2 2 3 3 0 0 1 2 1
Day 3 4 2 2 1 0 0 0 0
Day 4 1 1 0 2 2 1 0 1
Day 5 4 2 3 1 0 3 1 2
Total 14 10 9 6 3 5 4 7

Parts Per Million:

Parts per Million (Defects): (Total Number of defects/Total refrigerators)

x 10, 00,000

Total refrigerators manufactured during the period ~ 8700

Total number of defects = 14+10+9+6+3+5+4+7 = 58

PPM = (58/8700) X 10, 00,000 ~ 6700 & Percentage = 0.67%

The Light switch defects is reduced from 12000 ppm to 6700 ppm (Or from
1.2% to 0.67%)
It improved the quality and productivity speed.
CAUSES AND REDUCTION OF DENTS
Problem of Dents:

Dents are found on the door and side panels. The refrigerators having dents are
offloaded at Stage 5 and Stage 6.

Sometimes Dents are so severe such that doors are to be scrapped. Each scrap door
costs Rs3/refrigerator which is a very high cost.

Firstly it was required to find the causes of dents. Firstly, data was collected at
Stage 5 where refrigerators having dents are majorly offloaded.

Causes of Dents:

For Dents:

A- No. of Dents On the front of the door

B- No. of Dents on the left side of the door

C- No. of Dents on the right Side of door

D- No. of Dents on the Right Panel

E- No. of Dents on the Left panel

S.No. A B C D E
Day 1 7 6 4 6 5
Day 2 6 4 7 3 1
Day 3 8 3 6 1 2
Total 21 13 17 10 8

Data of Dents at Stage-5

 Pictorial Representation of Data Collected at Stage 5:

10 %
A
30 %
14 % B

E
25 % 21 %

Data of Dents at Stage-5

1. Plug in Plug Out Stage:

As it was found large number of dents were coming at stage 5.So it was found
that the causes of dents must be before Stage5.

It was found large numbers of refrigerators are being offloaded on Plug out stage
.So it was one of the cause of the dents. The refrigerators were being offloaded
because of the following reasons:

Light Switch defect

 No cooling defect

Less cooling defect

Compressor not working

High voltage defect

Leakage

Data collection was again done here:

S.No. A B C D E
Hour1 2 1 1 1 2
Hour2 1 2 0 1 1
Hour3 0 0 1 0 0
Total 3 3 2 2 3

Data of Dents at Plug in Plug out Stage

Pictorial Representation of Data at Plug in Plug out Stage:

 23 % 23 % A

15 % D
23 %
E

16 %

Data of Dents at Plug in Plug out Stage

This proves that this stage is also the cause of dents.

Now we were two trainees working on this project. One was assigned duty on the
LSD Stage and one was collecting data on Plug in Plug out Stage.

The following Data was collected.

Data Collected at Plug in Plug Out Stage:

S.No. A B C D E
Day 1 7 6 4 3 2
Day 2 5 4 5 2 0
Day 3 8 7 6 5 3
Day 4 5 3 5 2 1
Total 25 20 20 12 6

Data collected at Plug in Plug out Stage

Pictorial representation of Data collected at Plug in Plug out Stage:

 8%
14% A
30%
23 % B
23 %
%
% C

D
24%
E
24%

Data on dents at Plug in Plug out Stage

Data Collected at LSD (Light Switch Defect)

S.No. A B C D E
Day 1 5 4 2 1 1
Day 2 4 3 4 1 0
Day 3 6 6 5 5 2
Day 4 4 3 5 2 1
Total 19 16 16 9 4

Dents on LSD Stage

 Pictorial Representation of Data on LSD Stage:

6%
14% 30% A

D
25%
E
25%

Dents on LSD Stage

The difference in the data collected at two different stages i.e. increase in the
number of dents between two stages indicate that dents are also being caused in
between stage. So dents are also being caused at starting of Evacuation and
Charging Loop.

Evacuation and Charging Loop:

Here at the starting of the evacuation loop the refrigerators are to be moved so that
they can be placed in the front of evacuation pump. Some space between two
refrigerators is required to be kept.

As the refrigerators are moved by the workers, sometimes during handling

of the refrigerators they collide with each other as a result there can be dent
on side of the door or side panel.
 When there is very less gap given between refrigerators some refrigerators
are to be offloaded at this stage. The offloaded refrigerators have the
couplers protruded outward .when the protruded coupler strike the side panel
or front door it causes dent on it.

2. LSD Stage (Light Switch Defect):

It is also the source of dents.

Here the refrigerators are offloaded because of the following reasons:

Improper bulb connections

Relay problem
Thermostat problem

Problem:

The main problem is that near to LSD Stage there is stage 4 line 2, LD 1 and the
refrigerators after repairing are again put on the conveyor belt which causes
congestion of space. Every worker tries to make space on the line for refrigerator
he want to put on the line.

As a result refrigerators move very closely to each other and at the purging bend
before the starting of the evacuation loop they sometimes collide and result into
dents.
Path for refrigerators after repairing

LD1

Common Line

LSD

LSD Stage

2. Auto merger :

Here the refrigerators coming from the three lines get collected and merge into one
line.

So there is chance of collision of the refrigerator coming from Line -1 with

refrigerator coming from Line 2 or 3. It was observed that in about 100 refrigerator
one refrigerator definitely collide which results into dents.

3. Dents due to Guns:

Pneumatic guns are used for fixing door handles and also fixing screws on the
refrigerator.
There are three types of guns used:

Vertical hanging guns used in the front.

Horizontal guns hanging used in the front.
Guns used at the back of the refrigerator.

Already the mechanism is made for controlling the motion of the gun but
sometimes as it is not fixed; it continues to move to and fro so it collides with the
refrigerator and causes dent at the back, side panel and door.

4. Dents due to difference in height of the Stage and Trolley :

There is difference in the height of stage (where doors are fixed to the refrigerator)
and trolleys used for bringing them from the door foaming department.

The height of the trolley is lower than the height of stage or there is
mismatch in the height so when the worker lifts the door it collides with the
edge of the stage and causes dent.
5. Dents due to Supply Cord :

Supply cords of the refrigerators sway when the refrigerator is moved manually.

It strikes the side panel

It can also strike the door of other nearby refrigerator.
6. Dents due to less Gaps between the Refrigerators:

When very less gap is kept between the refrigerators, they definitely collide with
each other at purging bends. Very less gap occurs when large numbers of offloaded
refrigerators are put on the line.
5.3 METHODS SUGGESTED FOR REDUCING DENTS:

1. Increase in the size of the Thermocol Base :

Thermocol base thickness from the sides must be increased by 1inch on both sides.
It will result in decrease in number of dents at the purging bends even if the gaps
between the refrigerators become less.

2. Motion Limiters for Guns :

The motion limiters should be used for guns i.e. for horizontal gun horizontal
motion stopper should be used.

Gun

Horizontal Limiter

Horizontal Motion Limiter

3. Tape on the Supply Cord :

Swaying of supply Cord causes lots of dents.

Small piece of cloth with the small magnetic strip can be folded around the small
portion of the supply cord and it will help it to fix it with the back of the
refrigerator .So it will not sway and no dent will be caused.
4. Levelling of the Stage and Trolley :

New trolleys must be made according to the size of the stage so that there is no
dent caused due to the difference in the height of the stage and trolley.

5. Increase in the Size of the Stage at the Starting of the Evacuation Loop:

Here the large numbers of refrigerators are offloaded from time to time. There is
space at left side of the stage. It can be used to increase the size of the stage as it
can accommodate more number of refrigerators easily .It will result in less
collision of refrigerators.

6. Finding new method to indicate the refrigerator having Leakage at Plug

In Plug Out Stage:
When the refrigerator having leakage is to be offloaded at Plug in plug out stage
.The worker at the leak detection pull out the drier to indicate that refrigerator is
to be offloaded .But the pulled out drier strikes the doors of the other doors and
causes dents .We can use tape to indicate leakage. White tape is being used for
indicating other defects so coloured tape can be used.

7. Increase in the size of Side Cushions :

The size of the side cushions must be increases as they save refrigerator from
dents but they dont cover the complete side.

They must be of such size that they even cover the side of the door.

8. Cushions on the front of the door

9. Cushions must be put on the front of the door to save them from the dents.
 Monitoring of Dents:
After Finding the cause and ways to reduce dents monitoring of dents is done.
For this following steps were taken
Firstly the worker putting cushion is guided to put the cushion in the proper
way so that dents can be reduced and there is less chance dents.
Then at LSD Stage it was seen that the refrigerators do not accumulate. They
should be repaired as they are offloaded. Accumulation leads to dents.
At Starting of the evacuation loop worker is guided to keep proper distance
between the refrigerators .He is guided to bend the coupler protruding out of the
refrigerators that are offloaded.
At the Plug in Plug out Stage the refrigerators are required to be offloaded and
again put on the conveyor belt due to different defects. It is a continuous
process.
So 5 workers must be permanently present there .They should not be moved from
that stage for any other work.
Workers are required for the following works.
One for plugging in the refrigerator.
Second for checking whether bulb is working or not.
Third at Plug out to check the temperature in the evaporator.
Fourth for Plugging out the refrigerator.
Fifth for moving refrigerator from Plug out to plug in and from High Voltage
Testing.

It was monitored that the proper handling of refrigerator takes place at Plug in plug
out loop.

So during monitoring of Dents the above mentioned points are monitored. Also the
supervisor is informed about the location of dents which are coming and it was
seen that the cause of the dent is removed. So that further same dent does not
come.

It was observed it is a continuous process and it requires active participation of

workers. So the workers were given guidance regarding this
Results:

After monitoring is done for few days again data is collected at Stage 5:

S.No. A B C D E
Day 1 4 2 2 4 3
Day 2 3 1 4 1 0
Day 3 5 3 3 0 0
Total 13 6 9 5 3

Data collected at Stage -5

On comparing with Table -5.1 it is found that the frequency of dents has
decreased.
Earlier total dents for 3 days were 69. Now it has decreased to 36.
There is a decrease of 47.826%
The rejection cost of RFA (Refrigeration Final Assembly) Department was
reduced to 3.17/refrigerator and rejection cost of door was reduced to
Rs 1.3/refrigerator for fiscal year 2013-2014.