Documente Academic
Documente Profesional
Documente Cultură
Improvement of Deep
Freezer Top frame
production
Table of contents
Acknowledgements
Executive summary
Company Profile
1.0 Deep
Freezer
1
1.1
Process
.1
1.2 Problems
faced
..1
2.0 Available options
.1
2.1 Manual
Process
..1
2.2 Automated
Process
..2
3.0 Factors to be
considered
..3
3.1 Injection
Molding
..3
ACKNOWLEDGEMENT
With the deep sense of gratitude, bow my head before God for
enabling me to complete this internship Project. Im also thankful to
Mr.Ahmad Ayub Bhatti and Engr. Asad Rasool who helped me in doing this
project and completing it. I am also thankful to PEL Staff which really
coordinated and supported me in doing this project.
EXECUTIVE SUMMARY
I recently got a chance to do internship at PEL. I was inducted in
Deep Freezer Production Section, under the supervision of Mr.Ahmad Ayub
Bhatti. My internship project was to improve the process of production of
Deep Freezers Top Frames. The management wanted to increase the
production capacity while also minimizing the safety under strict low budget.
COMPANY PROFILE
Pak Elektron Limited is a pioneer manufacture of electrical
goods in Pakistan. In 1956 the company was established by Malik Brothers in
technical collaboration with M/s AEG Germany to manufacture transformers,
switch gears and electric motors. AEG relinquished their share of PEL to Malik
Brothers in late 1960s which was subsequently acquired by Saigol Group of
Companies in 1978.
Since its inception the company has always been contributing
toward the advancement and development of the engineering sector in
Pakistan introducing the range of quality electrical equipment and home
appliances.
Until the acquisition by Saigol Group, PEL was solely catering the
power equipment market. The company ventured into home appliances
market in 1981 after acquisition as a part of the groups long term strategy
for diversification
DEEP FREEZER
Objective
The task assigned to me was to improve the making of the top frames of
Deep Freezers. The management wanted to increase the production capacity
while also minimizing the safety under strict low budget
1.0 Process
The top frames are made by thermal forming the abs plastic sheet and then
cut into its precise dimensions.
The part which has been cut are recycled by crushing and then feed it into
the extruder, converting it into sheet again.
Dimensional accuracy
Human error (wastage of piece)
Safety (cutting incidents)
Cutting tool adjustment problem.
To use flexible ball bearing that would not cause the wear of
wooden frame and thus affecting the cutting of outer edges.
Cut resistant gloves should be used by workers to minimize
safety hazards.
Pros
Cheap
Increase in dimensional accuracy.
PKR 4000
PKR 300
PKR 4300
Pros
Fast
production
Low waste
Low labor cost
Cons
High Initial cost
Part Design restrictions
Separate mold is required for each design which can add
too much initial cost.
Total cost
Pros
Excellent accuracy
Fast production
Cons
High initial cost
Overpowered in case of
our operation.
Melting of ABS plastic
may occur
Total cost
Pros
Cold cutting
can cut in any
direction
No thermal stresses
Fast production
Cheaper than Injection molding
Cons
High Initial cost.
Total cost
Pros
Fast production.
Accurate up to 0.2mm.
can run 24hrs with periodic changing of cutting tools
Cheaper than other available options.
Minimizes the risk of injury.
Workers are familiar with this process.
Cons
Basic training is required to operate CNC router.
If milling cutters are not replaced on time. It can affect the
quality of the finished product.
Total cost
PKR 600,000
situationPforPall.
Top
View
Isometric View
By considering, different types of available milling cutters. I have listed two
cutters that can be used
Pros
Familiarity with the
cutter.
Durable
Cons
Sides of thermoformed
Pros
Smooth finishing.
Accuracy up to 0.02mm.
In our cutting process, process of sides cutting of sheet can be
eliminated by giving depth of 12mm at the outer edges to CNC.
Cons
Reweldment can occur if feed speed is slow.
Before(current
process)
150 units max.
After(proposed
process)
320 units max.
New process
2
PKR 24000
1
PKR 12000
PKR 288,000
PKR 144,000
2
PKR 24000
No worker is required
Zero
PKR 288,000
Zero
PKR 576,000
PKR 144,000
PKR (576,000-144,000)
PKR 436000
6.3
Safety risk
The CNCs is being used widely, with no noticeable safety incident recorded.
By using CNC, The job of the worker would be to replace the sheets once the
machine has performed its working on it. That would reduce the involvement
of the worker in the process and thus minimize the safety risk.
Conclusion
After carefully studying all the cutting process available, and
considering the budget and safety risks, the process that can
reasonably increase the production capacity , and is under budget
and also minimizes the safety risk is automated CNC milling with
slitter cutter. The initial cost is PKR 600,000 and can be recovered in
a period of 1year 4months and 19 days. The ROI in 5 years would be
1.58 million.
The production capacity would increase more than 100%.
I.e. producing from 150 units in one shift to 300units. And it also
minimizes the safety risks.