PROJECT REPORT ON ONE SEMESTER INDUSTRIAL TRAINING

GODREJ & BOYCE MFG. CO. LTD,

APPLIANCES DIVISION, MOHALI, PUNJAB

SUBMITTED BY:
PARMEET SINGH ROLL. NO. 1103335 B.TECH (MECHANICAL ENGG.)

UNIVERSITY COLLEGE OF ENGINEERING PUNJABI UNIVERSITY, PATIALA PUNJAB

INDEX

Sr. No.

DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11

DECLARATION ACKNOWLEDGEMENT INTRODUCTION OF THE ORGANIZATION PRODUCTS PARTICULARS OF THE MOHALI PLANT 5S SYSTEM IN GODREJ KAIZEN INTRODUCTION ABOUT PLANT AND ALLOTED DEPARTMENT PROJECT NO 1 PROJECT NO 2 REFERENCES

DECLARATION

I, Parmeet Singh student of B.Tech (Mechanical Engg) at University college of engg. Punjabi university, Patiala. hereby declare that the report on industrial training and project work entitled GODREJ & BOYCE MFG. CO. LTD is the result of my own work. I also acknowledge the other works / publications cited in the report.

ACKNOWLEDGEMENT

I am extremely grateful to Mr. Abhishek sharma (HOD, CMS & ST Dept.), Godrej And Boyce Mfg. Co. Ltd., and Mohali for providing this opportunity to carry out project work in the company. I would also like to thank, Mr. Gurpreet singh and Mr.Sudhir, for providing me infrastructural facilities to work with, without which this would not have been possible. I would like to express my deepest sense of gratitude to all members of Compressor Plant for their generous guidance, help and useful suggestions as a project guide, and showing faith in my work.

Parmeet Singh UCOE, Punjabi university ,Patiala (11103335)

Introduction of the organization The Godrej Group

Inception Established in 1897, the Godrej group has grown in India from the days of the charkha to nights at the call centers. Our founder, Ardeshir Godrej, lawyer-turnedlocksmith, 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. Our customers mean the world to us. We are happy only when we see a delighted customer smile. With 7 major companies with interests in real estate, FMCG, industrial engineering, appliances, furniture, security and agri care to name a few our turnover crosses 3.3 billion dollars*. You think of Godrej as such an integral part of India like the bhangara or the kurta that you may be surprised to know that 26% of our business is done overseas. Our presence in more than 60 countries ensures that our customers are at home with Godrej no matter where they go. With brands you can believe in, service excellence you can count on and the promise of brighter living for every customer, Godrej knows what makes India tick today. Today, we are at a point in Godrejs history when our amazing past is meeting up with its spectacular future head on. Godrej is learning and relishing being young again. A. PRODUCTS

1. Godrej Appliances Division manufactures and markets, today; a range of refrigerators from 100 liters to jumbo sized 400 liters. The largest selling is the 170 liters size. The 100 liters baby addresses the need of a small family or a second refrigerator for a growing family. It also addresses the needs of the Institutional

and Hotel industry segment. The 300 liters size is the most suitable for the typical large Indian family. 2. Each of the major sizes of the refrigerators is made in different models, primarily created to address the requirements of different segments of customers with differing balance among taste, usage and cost considerations. Cold Gold and Ultra are designed with the taste of the up-market customers, whereas the Classic packs the best value for money for a customer with focus on economy with efficiency and no frills. All the models and sizes are made in a range of colors that reflect the choice of the different segment of customers. 3. Keeping in tune with the changing technology and the distinct needs of the upwardly mobile urban market, GODREJ APPLIANCES DIVISION has launched four models of Frost - Free (165, 240, 260 and 400) refrigerators using indirect cooling technology. These models also are in tune with the latest styling and taste of softer looks and pastel colors, in harmony with the trend's worldwide. 4. The range, colors and the models are never static and it is always the tradition of GODREJ APPLIANCES DIVISION to constantly upgrade the existing products, its range and bring to the market the latest to satisfy the ever changing expectations of customers. The latest model GODREJ APPLIANCES DIVISION introduced is the Jerry model. 5. GODREJ APPLIANCES DIVISION also offers a range of washers from semi-automatic twin tub (5 kg & 3 kg) type to fully automatic or Fuzzy logic and Pulsate type single tub models. As with refrigerators, the washers are also made available in different colors to suit the taste of the customers. Washers are manufactured at Wing Works.

6. GODREJ APPLIANCES DIVISION have introduced a range of ACs (manufactured and sourced) from 0.75 TR to 1.5 TR window AC's and 1.5 TR splits. The AC's are made available with trendy looks (grills) to enhance the interiors and in different colors.

B.

DESIGN AND DEVELOPMENT

1. GODREJ APPLIANCES DIVISION understands that the quality is built into the product rather than just inspected at the end of the production. Towards this end, GODREJ APPLIANCES DIVISION has a well-qualified and experienced team of design engineers who convert the expectations of the customers into a concrete product. Their knowledge is constantly upgraded through training and exposure as well as access of technology from collaborators. The documented system for design development supports their knowledge, experience and creativity.

2. GODREJ APPLIANCES DIVISION also out sources product designs, designing activities or aesthetics and styling concepts from experts in India or abroad. Although the specific designing activity may be done by such experts, the larger intent of the design and development requirements are supplemented / complemented by design verifications, design validations, design reviews and design changes through the in-house Design, Quality, PMQ and NBD teams. Such external experts / sources are approved by Design in consultation with the management with executive responsibility.

C.

QUALITY

1. Throughout the design, manufacturing and testing of the appliances total attention is paid to the quality aspects of the product. Besides the incoming inspection co-ordinate by the Purchased Material Quality Cell (PMQ) and the in process monitoring by line function of manufacturing, the system has built in audits of the product and the processes at different stages by Quality Eng. Dept. to assure quality and provide fast feedback.

2. The End-of-Line Audit (EOLA) offers feedback on continues basis to the manufacturing as regards the quality of the finished products. The Customer Acceptance Test and Customer Usage Test Laboratory give confidence that the products meet functional and reliability requirements. The Life Testing Laboratory for compressor and other appliances / components provides data and facts about the reliability under adverse operating conditions.

3. The facilities are ably supported by a number of laboratories to analyze the material and other inputs. These consist of the Plastic Lab, the Oil and Fresno Lab, Powder Coating Lab, Metrology Lab, Metallurgy Lab, the Calibration Lab and Shipping test Lab.

4. The data from the laboratories, tests and the audit feedback is constantly analyzed and corrective and preventive actions are taken to improve the performance of refrigerators in the field and processes that build them in house.

5. The documented system in this Apex Quality Manual spells out, in the following chapters, in elaborate details, the procedures, processes and the system in place to support the quality aspects.

D.

MARKETING AND DISTRIBUTION

1. GODREJ APPLIANCES DIVISION understands that availability and access to the consumers is critical for their satisfaction in this business. 19 branches in five regions with the dealership network of app. 1200 direct dealers and over 3000 retailers support the marketing, selling and distribution across the whole country.

The logistics department ensures the physical distribution to feed branches, and they in turn feed the dealer network.

2. The branch and dealer network are also the channels of information to get the feedback on the consumer satisfaction, emerging expectation and the competitive offerings so that the product range and the introduction of varieties of models and colors are in tune with the changing market trends.

E. SERVICE SUPPORT

1. Product in the field, in the hands of the consumers, needs the support of education and training at the time of installation for deriving maximum benefits during use. It is equally essential for the consumers to understand the care and caution to minimize the inadvertent misuse that may lead to product malfunction and possible injury to the users.

2. And should the need arise, the service back up is geared to diagnose and rectify the product problems during and even after the warranty period, either at the user's premises or if required, at the workshop with minimum disturbance to the customers. The service organization is adequately equipped to provide spare parts for the current and prior models in the use in the field through dealers and the branch network. The service set up also provides the training and education support to the dealer network so that they in turn can extend the same level of service to their customers.

3. GODREJ APPLIANCES DIVISION believes that the field personnel are the important source of information and hence seek their feedback on the product

performance on a regular basis, which forms the trigger for continuing improvements of the products and the processes.

F. PURCHASING

GODREJ APPLIANCES DIVISION understands that to be able to satisfy the ultimate consumers, it needs quality inputs from the vendors. Vendors are the partners in this process and therefore, GODREJ APPLIANCES DIVISION puts considerable emphasis on their development through clear communication, education and early involvement in product development stages, rather than just the monitoring and control through feedback from incoming inspection.

G. PEOPLE

People provide the inner strength to GODREJ APPLIANCES DIVISION. The organization takes pride in the fact that it has some of the best people in place to achieve the objectives of Technology leadership, quality and market presence. It has in place, a process of recruitment and training to groom the best talent. The welfare of the people is paramount for GODREJ APPLIANCES DIVISION, accordingly the company has invested substantially in the housing, medical and education support for the employees and their families.

PRODUCTS

Appliances

Offerings in the refrigerator, washing machine, air conditioner and microwave oven ranges.

FMCG

Cinthol, Good Knight mosquito repellent, Hair Color and Hair Dye.

Agri Animal feed, oil palm plantations, agrochemicals and poultry.

Batteries

Godrej and GP Batteries offer a range of zinc chloride, alkaline & rechargeable batteries and a range of chargers.

Construction

Variety of construction services like real estate development, ready mix concrete, horticulture and enviro-tech.

IT & Software Solutions

Solutions for engineering and service industry.

Material Handling

Counter balance trucks, forklift trucks, tyre handlers, all terrain trucks, attachments and accessories.

Precision Engineering

Critical custom-built precision engineering equipments for multiple applications.

Process Equipment

High pressure vessels, heat exchangers, columns, heavy walled reactors and other custom.

Storage Solutions

Warehousing solutions, automation and consulting.

Vending

High quality table top beverage vending machines, services and beverages.

Furniture

Furniture for home, office, educational institutions, establishments, labs, hospitals, shipyard.

Real Estate

Residential, commercial and township developments.

AV Solutions

Display solutions, audio video conferencing solutions, electronic copy boards.

Chemicals

Oleo chemicals and surfactants.

Electricals and Electronics

Industrial automation, power distribution, compressed air solutions & green business commissioning.

Locks

Locking solutions for different security needs to ensure optimum safety.

Motors

Specialized custom built compressor motors.

Precision Systems

Machining & fabrication, heat & surface treatment, assembly, testing & supply of complex.

Security Solutions

Safes, lockers, banking automation products, electronic security systems, premises security & hi-tech doors.

PARTICULARS OF THE MOHALI PLANT

PLOT SIZE CAPABILITY PRODUCTIVITY INVESTMENT MANPOWER INAUGRATED BY INAUGRATION ON

: : : : : : :

75 ACRES 5 LACS REFRIGERATORS Rs 120 CRORES 1300 S. HARCHARAN SINGH BRAR 28TH FEBRUARY, 1996.

5S SYSTEM IN GODREJ

1. Sort (Organization) Clearly distinguish needed items from unneeded items and eliminate the latter.

2. Set in order (Orderliness) Keep needed items in the correct place to allow for easy and immediate retrieval.

3. Shine (Cleanliness) Keep the workshop swept and clean.

4. Standardize (Standardize clean-up) This is the condition we support when we maintain the first four pillars.

5. Sustain (Discipline) Make a habit of maintaining established procedure.

KAIZEN

Kaizen (?), Japanese for "improvement", or "change for the better" refers to philosophy or practices that focus upon continuous improvement of processes in manufacturing, engineering, and business management.

COMPRESSOR PLANT
COMPRESSOR

A refrigerant compressor is a machine used to compress the vaporized refrigerant from the evaporator and to raise its pressure so that the corresponding saturation temperature is higher than that of cooling medium. It also continually circulates the refrigerant through the refrigerating system. Since the compressor of refrigerant requires some work to be done on it, therefore, a compressor must be driven by some prime mover. Since the compressor virtually takes the heat at low temperature from the evaporator and pump it at high temperature to the condenser, therefore, it often referred as Heat Pump. The various components of reciprocating compressor:1. Shell 2. Cover 3. Body 4. Stator 5. Rotor 6. Cylinder Head 7. Piston 8. Shaft/Crank 9. Connecting Rod 10.Gudgeon Pin 11.Lock Pin

12.Spring 13.Oil Tube 14.Muffler 15.Valve plate 16.Reed 17.Retainer 18.Suction Gasket 19.Suction Reed 20.Discharge Gasket 21.MS Plug 22.Oil Cup 23.Relay Guard 24.Glass Seal Terminal 25.Discharge Tube 26.Suction Tube 27.Charging Tube 28.Coil/Port Cover 29.Nylon Ferrule 30.Bolts 31.Piston Washer 31.Shaft Washer 32.Copper bolt Washer 33.Holding Rubber 34.Stopper 35.Stopper Plate 36.Port Cover Washer

37.Pedestal 38.Muffler Rubber 39.Rubber GST 40.Rubber of suction , discharge, charging tube 41.Pedestal rubber

The compressor plant is divided into various departments

Machine Surface

Shop

treatment Department Department

Metrology Assembly Unit

Department

Maintenance Department Room

Tool Store

Cutting

Section

Quality Department

Layout of the Compressor Plant

COMPRESSOR MACHINE SHOP

COMPRESSOR BODY SHAFT VALVE PLATE CONNECTING ROD PISTON G PIN

1.RAW COMPRESSOR BODY:- it is made of cast iron material

come from vendor NEWMAN & SATYAM.

Machines in cms shop:Machine 1-EMT 682 Machine 2-EMT 683 Machine 3-EMT 684 Machine 4-EMT 685 Machine 5-EMT 686 Machine 6-EMT 687

Machine 1-EMT 682:- it is a spm(special purpose machine)

doing variety of different operatins on same workpiece. there are 14 stations on this machine. The description of machine tool and its operation is as follows: s.no 1 2 3 Station 2H 2V 3H Tool description Insert:TCMT 110204 Insert:M 8065 1204 Insert: OFKR 070408 operation Hub facing and outer dia chamfer Head face rough milling Leg face rough milling

4 5 6 7 8 9 10

4H 4V 5V 6H 7H 8H 9H

CARTRIDGE:STSCL 10CA11 Insert:TCMT 110204 Insert:M 8065 1204

Shaft hole drill and outer dia turning Head face semi finish milling SOLID CARBIDE DRILL DIA24*134 Piston hole drilling STEPPED DRILL- M35 CARTRIDGE:SCGCR12 CA 12 INSERT:CCMT120408 HSS DRILL DIA 4.5 MM COUNTER SINK TOOL CARBIDE BRAZED HOLE MILL Leg hole centering Leg face facing Shaft hole chamfer and leg hole drilling Shaft hole milling and leg hole milling

Fig-front view of machine EMT682

Fig body before 1 machine

Machine 2-EMT 683:-it is a second machine

of body line.it do

11 operations on the body. It is also a SPM. The description of machine tool and its operation is as follows:

s.no Station 1 2H 2 2V 3 3H

4H

Tool description CENTER DRILL M-35 INSERT:CCMT09T308 INSERT:CCMT120408 Insert:TCMT 060204 HSS DRILL 5.1MM JOBBER SERIES TWIST DRILL M35

operation Gas hole drilling Seat facing and chamfering Port hole drilling and conter boring Gas hole drilling

5 6 7 8 9

5V 6V 7H 7V 8H

HSS DRILL 4.5MM LONG SERIES HSSE SILVER CUT TOP M06 END MILL CARBIDE BRAZED HSS DRILL DIA 5.1MM JOBBER SERIES HSS MARKING TOOL HSS HOLE MILL REAMER

Port hole tapping U slot milling Leg relief hole drilling Body marking Gas hole reaming

Fig-front view of machine EMT683

Fig-back view of machine EMT683

Fig-body after machine 2

Machine 3-EMT 684:-it is a third machine in body line.it do 2

operations on the body. It is also a SPM The description of machine tool and its operation is as follows: s.no 1 Station Tool description HSS DRILL DIA 5MM LONG SERIES HSS COUNTER SINK TOOL DIA 33MM operation DRILLING AND CHAMFERING

Fig-body after machine 3

Fig- machine EMT684

Machine 4-EMT 685:- it is a third machine in body line.it do 5

operations on the body. It is also a SPM It is also a SPM The description of machine tool and its operation is as follows: s.no 1 2 3 4 Station 2H 3H 3V 4H Tool description FACE MILL DIA 80MM INSERT:CCMT09T308 Insert:CCMT 060204 Insert:TCMT 110208 Insert:CCMT 060204 Insert:TCMT 090208 CARTRIDGE:STSCR 08CA 09 Insert:TGCT 060104 CARTRIDGE:STSCR 08CA 09 Insert:TCMT 06T108KF CARTRIDGE:STSCR 08CA 09 operation Head face finish milling Piston hole semi finish bore Shaft hole semi finish bore Piston hole finish bore

4V

Shaft hole semi finish bore

Fig- machine EMT685

Fig-body after machine 4

Machine 5-EMT 686:- it is a third machine in body line.it do 7

operations on the body. It is also a SPM s.no 1 2 3 4 5 6 7 Station 2H 2V 3H 4H 5V 6V 7H Tool description CENTER DRILL STEPPED DRILL TWIST DRILL M-35 TWIST DRILL M-35 REAMER M-35 HOLE MILL M-35 MACHINE TAP M-35 operation Gas hole center drill Head hole centering Gas hole drilling Head hole reaming Gas hole reaming Head hole milling Head hole tapping

Fig - Front view of machine EMT686

Machine 6-EMT 687:- it is a third machine in body line.it do 1

operation on the body. It is also a SPM. s. no 1 Station no. 1 Tool description MACHINE TAP M-35 Operation Legs tapping

Fig -machine EMT687

Fig-body after machine 6

Grinding Room
MACHINE-1 WMW

:- It is a centreless cylindrical grinding

machine with PLC panel installed with it. There are basically two grinding wheels which are to grind the large end of the shaft in microns. The different units installed are lubrication unit, hydraulic unit, electrical panel unit. The main grinding wheel rotate in clockwise direction while shaft large end rotate in anti clockwise direction and counter wheel rotate in clockwise direction. For safety of workers the safety gaurds are installed at the front of the machine.for checking the grinding cut in microns . There is bakers gauge installed for checking the finishing of shaft large end after grinding. 6 jet of air are located insinde the through which the finishing of shaft is checked.

Fig-12wmw centreless cylindrical grinding machine

MACHINE-2 CNC MACROMATIC GRINDING MACHINE:-It is a CNC grinding machine with PLC panel installed
with it.The different units installed are lubrication unit, hydraulic unit, electrical panel unit. There is only one grinding wheel for grind the small end of the shaft. The shaft is inserted into the jaws of adjustable chuck(adjusted according to the different models of compressor).The main grinding wheel and shaft rotate in different direction to each other.

Fig 13 CNC MACROMATIC GRINDING MACHINE

MACHINE-3 PISTON GRINDING:-The piston is the main

part of the compressor.There is different piston for different compressor according to the size and capacity of compressor.

Fig-14 piston

Fig-15piston grinding machine

Shaft Cell
Machine 1kingsburry-it is a simple machine used for drilling
operations. There are basically 4 stations on this machine. The kingsburry machine is used for drilling opretations.the description of machine is as follows: s.no 1 Station no. 2h operations Drill of 2mm at lower side of counter at large end Drill of Drill 3mm at upper side of counter at small end Small grooveat upper side of counter at small end Drill of 4mm at lower side of counter at large end

3h

4h

5h

In above table 2h,3h,4h.5h are various stations here H is direction in which machine works i.e horizontal.

Fig-16kingsburry machine

Different models of shaft :-

Fig-17 shaft model i8

Fig-18 shaft model i9

Fig-19 shaft model i10

Machine 2:-deep hole drilling

This machine is second machine in shaft cell. This machine is used for drilling the hole of 5mm at the large end of shaft. There are basically two machines in this unit .the other machine will make the hole of 6mm at the top of small end of shaft. These shafts are differentiated according to their mdeli.e i8,i9,i10. The major difference is in the counter of the shaft. More heavier the counter more will be the suction and discharge capacity of the compressor.

Fig -20 deep hole dfrilling machin

Other Components Of Comperessor 1.Oiltube :- This is a metallic tube which is used to lubricate the
shaft and other components like conn rod, piston, G pinEtc. As the rotor rotates the centrifigual force will be produced as oil tube is fitted in bottom end of shaft and it sucks oil to lubricate.

Fig-21 oil tube

2.Muffler cap:-Muffler cap is used for directioning the gas into

the compressor after the whole cycle completion. There is small restriction on one side of this cap so that even a single particle of dust containing moisture will be eliminated.the one ond is attached to the cylinder head and a rubber cap is fitted at one lower end of muffler

Fig 22 muffler cap

3.Piston :-The piston is the main part of the compressor.There is

different piston for different compressor according to the size and capacity of compressor.

Fig 23 piston

4. stator and rotor :-The

stator is rotatory windning of aluminium wiring. The rotor is fitted in stator with the help of hydraulic press in assembly shop. As the voltage of 170 watts is given to the comperessor the rotor rotates in stator and rotate other assembly with itself.

Fig 24 rotor

fig 25 stator

SURFACE TREATMENT
After machining of the component, the components are sent for a surface treatment. Surface treatment is done in order to prevent the component from the rust and coating of shaft. The components are treated with various chemicals like Nutrapon, Rustoken 25. In a surface treatment area, the small components like oil tube, spring etc are cleaned in a small component cleaning machine. In surface treatment, shafts is coming after all maching operation coating is done in various steps.

Wet tumbling
This is a vibrater in which ceramic media is vibrating along with shafts . This is used to remove the burr on shafts.

Dry tumbling
After dry tumbling , shafts is again vibrating with dry media for polishing and finishing the shafts. Then shafts is degreasing in ultrasonic heater for removing some amount of dirt etc .

Mn. PHOSPHATING COATING SYSTEM OF SHAFTS

In the system , there are 12 no. of tanks . It provide coating on shafts . These Tanks are: 1. DEGREASING 1 2. DEGREASING 2 3. DEGREASING 3 4. WATER RINSE 5. ACTIVATION 1 6. ACTIVATION 2 7. PHOSPHATING1 8. PHOSPHATING 2 9. WATER RINSE 2 10. PASSIVATION 11. OVEN 1 12. OVEN 2

Chemical require in tanks to make Mn. Phospating system :

TANK 1. DE GREASING-1 2. DE GREASING-2 3. De GREASING-3 4. WATER RINSE-1 5. ACTIVATION 6 . PHOSPATING CHAMICAL Nutrapon Nutrapon Nutrapon D.M water QUANTITY 1 Ltr. 1 Ltr. Ltr. Fully tank CHANGE IN After 1 week After 1 week After 1 week Over flow

ParocolinMn.(Powder) Parcolubricate+ Nutralizer(Powder) D.M water

7.WATER RINSE-2

1K.g 20 Ltr.+20 cup (And check pointage) Fully tank

After 3 days After 15 days

Over flow

8. PASSIVATION

Nutrapon

1 Ltr.

After 3 days

Testing of Tanks:1. PHOSPATING: There is 3 type of testing is:

* FREE ACID (FA) * TOTAL ACID (TA) * IRON POINT.

*FA: 2ml. chamical ph. + 5-6 drop of water + 5-6 drop of

Bromo Green solution + sodium hydroxide (NaOH) 1.2] [Actual pointage = 0.8-

*TA: 2ml. ph. chamical + 5-6 drop of water + 5-6 drop of

+ sodium hydroxide (NaOH) . [Actual pointage = 6-8]

Phenol pythylon

*IRON POINT: 100ml. chamical ph. + 5-6 drop orengr methylene

Pottesium permagnet. [Actual pointage = 1-3]

2. WATER RINSE -1: 100 ml. W.R + 5-6 drop of orengr methylene +
sulphuric acid (H2SO4). [Actual pointage = 1-3]

3. WATER RINSE-2: 100 ml. W.R + Phenol pythylon + sodium hydroxide

(NaOH).[Actual pointage = <2] 100 ml. Activation ch. + Bromo solution + sulphuric acid (H2SO4). [Actual pointage = 10-16]

4.ACTIVATION :

ACTUAL pointage,ph AND temp. OF :

SOURCE POINTAGE DEGREASING1 DEGREASING2 DEGREASING2 PH.= 1. FA 0.8-1.2 } = 2.TA 6-8} ratio=6= iron 10 point 1-3 =grain size <5 WATER 1-3 RINSE- 1. WATER <2 RINSE- 2. ACTIVATION 10-16 PASSIVATION -

PH 8-10 8-10 8-10

TEMP. 50-60 50-60 50-60

90-95

8-10 9-11

50-60 50-60

Tank of Chemical require to make BODY LINE

TANK 1. HOT SPRY DEGRESING 2. HOT DEGRESING 3. WATER RINSE 4. ACID TNK 5. suppry pssivtion

CHAMICAL

QUANTITY 2 LTR. IN EVERY PRT

CHANGE IN After 1 week

NUTRPON

NUTRPON D.M water RESTOKAM WCI 02

1 Ltr. Fully tank 270 Ltr. 1-1 ltr in evry prt

After 1 week After 1 days After 4/5 days One shift

6DERUSTLK-1 7 suppry pssivtion

DERUSTLK-1 suppry pssivtion

30 LTR. 1-1 ltr in evry prt

After 1 week One shift

8 Pssivtion

WCI 02

1 Ltr.

After 1 week

UNIT SHELL

The process flow diagram for a compressor in the compressor unit shell department is shown below.

Raw material from supplier to PMQ

Dip Painting

Dehydration loop1

Degreasing of shell and cover

Leak Testing

1st Purging

Storage and Dispatch

Spot and Projection Welding

MAG Welding

Dehydration loop 2

Final Testing (P.D.I.)

Shell and cover cleaning

Assembly Feeding

2nd Purging

Oil Charging

Raw Material From the Supplier

There are two suppliers for the raw shell and cover namely Satyam and Newman. The material is first inspected for quality by the PMQ(Purchase Material Quality) Department before it is transferred to USD(Unit Shell and Dome) Department for processing. The defective or poor quality material is rejected by PMQ. Only the ok material is transferred to the USD.

Degreasing of Shell and Cover (Pre Treatment)

The raw shell and cover that arrive from the supplier are oily and dusty, so they need to be cleaned before they can be processed. So, they are passed through a shower of chemical known as Surfakleen 399X and then the excess chemical is rinsed off through a shower of normal water. This all happens in a tunnel. The chemical and water are stored in tanks so that they can be recirculated as the process continues. The tanks are cleaned and refilled with chemical and fresh water after a week. After this, they pass through an oven known as Pre Treatment oven for drying of water. The temperature in the oven is set at 190oC.

Spot and Projection Welding

Various child parts are welded on the shell and cover for proper functioning and ease of manufacturing. Child part on cover In cover, two hook type stoppers are welded in order to keep the internal compressor assembly in position. Following table shows the defects and there effects on compressor:Defects Effects

Poor weld strength Stopper height variation / tilt

1. Stopper broken 2. Compressor motor damage

1. Compressor body touching 2. Compressor jam

All these lead to the absolute failure/rejection of compressor. Electrode material used is Be-Cu alloy because of its hardness. Previously Cu-Zn-Cr alloy was used but it was softer, so it weared out quickly.

Child parts on shell

In shell, various child parts like MS Pin, Oil Cup, Shell Mounting Bracket, GST (Glass seal Terminal) and Relay Guard are spot welded. Charging, Discharge and Suction tubes are projection welded. Below table shows various defects in child parts on shell and their effects on compressor and its working.

Child Part MS Pin

Defects Poor weld strength. CD out Poor weld strength. Position out Poor weld strength. Position out Poor weld strength. Glass seal broken Poor weld strength. Position out Poor weld strength Position out

Oil Cup Bracket GST Relay Guard Tubes

Effects Broken pin leading to instability of compressor assembly Compressor getting noisy Broken oil cup Oil pin hits oil cup. Fitting of assembly not possible. Broken bracket Problem in mounting on refrigerator GST broken Leakage from GST. Leads to rejection of compressor Relay Guard broken Problem in mounting on refrigerator. Tubes broken Leakage from tubes

The welding temperature at various spot welding machines is in the range of 2000oC to 3000oC with current ranging from 20KA to 46KA.

Shell and Cover Cleaning

The shells and covers are installed on conveyers and they move through 10 different tanks as a cleansing process. Following table show the tanks in order from 1 to 10. The 11 th tank is the air blower.

Hot water Surfakleen 399X Normal water Normal water Surfapickle-77 Normal water Normal water Protobond 40/5 Normal water Surfalyte 8M Air blower

Functions of different chemicals: Surfakleen 399X The major ingredient in this chemical is Caustic Soda. Its function is to remove the grease and oil initially prevails on the shell and cover. Surfapickle 77 The major ingredient in this chemical is Phosphoric acid. Its function is to avoid rusting and provide invisible pores on the surface of shells and covers so that the further chemical can form a coat on them. Protobond 40/5 This chemical enters into the pores present on shell and cover. Surfalyte 8M It is used as a passivation chemical so that the shells and covers dont react when come in contact with air or other particles.

Assembly Feeding Station

Here discharge tube is bent to 90o and the cover is punched with appropriate code according to the model before being fed to the assembly. After these operations, the operator cleans the surface of the shells and covers and puts them on the conveyer that takes it to the assembly.

Cover Punching Machine It is used to punch the codes on the cover. These codes represent the models of the compressors. This is a hydraulically operated machine. Some of the punches with their models are shown below:Punch A2 B2 Z Y X U Model A1-1 B1-1 I8CC I9CC I10CC I8AA

MAG Welding
It is a welding process in which an electric arc forms between a consumable wire electrode and the work piece metal, which heats the work piece, causing them to melt, and join. Along with the wire electrode, a shielding gas is fed through the welding gun, which shields the process from contaminants in the air. There are a total of 8 MAG Welding machines. Some important points Shielding gas CO2 Electrode Copper coated MS wire Overlap is done to prevent leakage Anti spatter gel is used to avoid the formation of spatters Properties of gel Silicon free Non-toxic Inflammable Odourless

Time taken by 8 MAG machines in welding a single compressor is shown below-

MAG machine number

Including lanter

Excluding lanter Average Only welding 46.00

Total production

Lap 1 1

Lap 2

Lap 3

54.66 53.97 52.63 53.75

315(approx.)

2 3 4 5 6 7 8

51.53 51.57 51.19 51.43 53.88 53.41 53.62 53.64 50.22 49.12 50.12 49.82 43.53 42.97 42.36 42.62 47.62 47.75 47.94 47.77 46.28 47.53 49.90 47.90 42.48 41.78 42.06 42.11

47.37 46.13 46.94 42.09 46.31 46.97 39.00

315(approx.) 320(approx.) 320(approx.) 400(approx.) 400(approx.) 400(approx.) 400(approx.)

Leak Testing
The welded compressors are then checked for leakages by immersing in water. If a leak is found it is repaired and then again leak tested.

Dip Painting
Rubber caps are applied on the tubes, the GST and the Relay Guard in order to prevent them from paint. Also to prevent the paint from entering inside the compressor through tubes. After that, it is loaded on the other conveyer which takes it to the paint tank for dip painting.

Dip painting is done so that an even coat of paint is applied on the compressor and to ensure cost effectiveness. The paint is the normal door paint that is used at our homes. Immediately after that the compressor enters the P.D. (paint drying) oven which heats the compressor at 250oC in order to dry off the paint.

Dehydration Loop 1
Immediately after drying of paint, an operator removes the rubber caps and the compressor enters the dehydration oven. This oven heats the compressor at 250oC in order to remove moisture from the inner assembly of the compressor. Removal of moisture from the compressor is necessary in order to prevent rusting or any kind of a chemical reaction of the inner parts because that would lead to improper functioning of the compressor and therefore would result in absolute rejection of the compressor.

1st Purging
In this process, dry air is made to pass through the compressor assembly in order to remove any amount of moisture left after dehydration loop 1. It is made to enter the compressor from charging tube and exits the compressor from discharge and suction tubes.

Dehydration Loop 2
The purged compressor enters dehydration oven 2 for dehydration again. The reason for dehydration again is the quality aspect of the compressor and to ensure an entirely moisture free compressor. The temperature in this oven is again set at 250oC.

2nd Purging
Similar to 1st purging, dry air is made to pass through the compressor assembly in order to remove any amount of moisture left in the compressor. Immediately after this rubber caps are applied on the tubes in order to prevent external air from entering the compressor.

Oil Charging
When the dew point of the compressor becomes -38, it comes to the Oil Charging area where 2 different types of oils are charged depending upon the type of the compressor. These are shown below. R134a Compressor Saffson oil (250ml) Isobutane Compressor Freezol oil (170ml)

Oil Cleaning Station

The oil that comes from the supplier contains moisture quantity of 100ppm. This needs to be purified to an appropriate level (50-60ppm) in order to be charged in the compressor.

1) CENTRIFUGAL PROCESS: It is used for removing the moisture and impurities present in oil. Firstly the oil is heated to a temperature of 100oC which removes most of the moisture present in the oil. Then it is made to fall on a rotating disc in which the impurity particles are removed. It is a 10 hour long process during which the oil is re circulated in the tank. 2)CLEANTANK: Cleantank is used to remove the carbon and some other impurity particles that remain in the oil after the centrifugal process. In this process current is passed through the oil in a tank which is containing filters. During the process the impurity particles are collected on the filters due to the generation of magnetic field inside the tank.

Final Testing (Pre Dispatch Inspection)

The compressor is finally checked at this station for visual and internal defects. It is made to run at 200 volts at 2850 rpm. The operator checks for the discharge pressure and compressor efficiency at this station.

Storage and Dispatch

The OK compressors from PDI move to storage area from where they are dispatched to various customers.

Project 1: To Reduce The Residue of Body

And Small Components . Residue level of body and small components .
Components BODY CYLINDER HEAD OIL TUBE SPRING PORT BOLTS STATOR BOLTS NYLON FERRUIE LOCK PIN Qty. 5 25 25 50 50 50 100 25 Ideal Residue Value 9mg. 12mg. 10mg. 13mg. 12mg. 15mg. 12mg. 8mg. Max. accept value 9mg. 25mg. _ _ _ _ _ _

Procedure to check the Residue level

For testing the residue level of sub components . There are following steps:
First of all measure the initial weight of filter paper .

 Take component in proper quantity and wash with

Tetrachloroethylene (300mg.) in beaker . Attach filter paper in conical shape with funnel . After washing components chemical is filter by this filter paper Take 4-5 hours for dry the filter paper . Then take final weight of filter paper. So, Residue level = Final weight initial weight (mg.)

Chemical use in testing

Tetrachloroethylene or Plorochloroethylene.

How to clean body

There are 9 no. of tanks in body line for cleaning the body. These are:

TANKS
1. 2. 3. 4. 5. 6. 7. 8. 9. HOT SPRAY DEGREASING HOT DEGREASING WATER RINSE ACID SPRAY PASSIVATION DERUSTALK-1 SPRAY PASSIVATION PASSIVATION HOT PASSIVATION

CHEMICALS
NUTRAPON NUTRAPON D.M WATER RESTOKAM WCI 02 DERUSTALK-1 WCI 02 WCI 02 WCI 02

How to reduce body residue

First of all, maintain the temp. of tank no.1, 2 & 3 at (50-60). Proper working of diaphragm pumps of tank no. 5 & 7. Proper level of chemical in tanks. Proper working of blowers. Attach new shower in tank no. 1, 5 & 7 for proper spray on body. Change chemical at particular day.

How to reduce residue of small components

There are 2 ultrasonic heaters for cleaning of small components. There are trays and hangers for attach components separately. Temp. Of heater at 50-60. Chemical uses are nutrapon and neutralizer. Always ON ultrasonic when dip the components. Dip these components at min. 120 sec.

Improvement in residue
After collecting the data, we obtain body residue 7.5mg. , 5.5mg. , 6.4mg. , 8.1mg. , spring 8.7mg. , oil tube 8.2mg. , cylinder head 15.2mg. etc.

REFERENCES

www.godrej.com www.wikipedia.com www.micromaticgrinding.com

www.docstoc.com