UNITED REFRIGIRATION INDUSTRIES LTD HYD

SUMMER VACATIONS INTERNSHIP

REPORT June, 2016

Submitted to: Human Resource department, Dawlance

Submitted by:
Sheharyar Qureshi 15 ME 052 (NED)
Abdullah Saad Shaikh 15 ME 06 (MUET)
Muhammad Haseeb Shaikh 15 ME 124 (MUET)
Shafique Rehman 14 ME 60 (QUEST)
Khawar Ali 15 ME 128 (MUET)
Muhammad Ameer Hamza 14 ME 128 (MUET)
Jabir Abbas (QUEST)

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Serial Topics Page No:
No:

1 Introduction to Dawlance 3

1.1 Products 3-4

2 HSE & Compiliance 5-6

3 Production - I 7-8

3.1 Plastic Moulding Department 7-8

3.1.1 Process of Moulding 7

4 Production - II 9-10

4.1 Sheet Metal Department 9-10

5 Production - III 11-12

5.1 The Painting Shop 11-12

6 The condenser Painting 13

7 Productio IV/VI 14

7.1 Pre Foaming of cabinents or doors 14

7.2 Foamimg of cabinents or doors 14

8 Production -V 15

8.1 Assembly Line 15

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 9 Production - VII 16

9.1 Forming of D.F 16

10 Maintaince & Utilities 17

11 Quality Control 18-19

12 Conclusion 20
Contents
DAWLANCE

Dawlance reliable hai.

Pakistan’s number one home appliance brand. Whether Fabric, Food or
Home cares, Dawlance has proven time and again to be the most reliable
home-maker, catering to every need of its consumers.
It’s this ethos of ‘reliability’ which is the differentiating characteristic of
Dawlance and is permeated within all functions of the organization.

Dawlance has the largest set up with respect to manufacturing

capabilities, retail outlets, service centers and distributors. Throughout its
34 years, the company has maintained superior quality standards and can
proudly state it is also the first Pakistani company to have been awarded
the ISO 9001, ISO 14001 and OHSAS 18001.

PRODUCTS:

Food Care
 Refrigerators
 LVS
 Monogram
 Mono+
 H-Zone
 MDS
 Double French Door

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  Top Mount
 Bedroom Series
 Energy Saver Series

 Freezers
 Single Door Freezer
 Double Door Freezer
 Vertical Freezer

 Microwave Ovens
 Classic Series
 Cooking Series
 Baking Series

Fabric Care

 Washing Machines
 Washers - Single Tub
 Semi Automatic - Twin Tub
 Fully Automatic

Home Care

 Air Conditioners
 Energy Saver
 Floor Standing
 Inspire Plus
 Inverter Series
 LVS
 Monogram SL
 Signature Series

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 HSE & COMPILIANCE

HSE management involves managing, controlling and handling all aspects

of health, safety and the environment in the petroleum industry –
with the focus on major accident risk.

And compliance means that the health, safety, and environment of the
industry should be monitored and policies should be made.

HSE and Compliance is a department in DGC (Dawlance group of

companies) which includes following activities:

 Management
 safety economics
 maintenance management
 Acute discharges.

Managing risk is a key element in HSE management

Risk management involves assessing, prioritizing and allocating resources
to areas expected to yield the biggest and best gains. Such work rests on a
recognition that risk exists – and an understanding of what it comprises.

The RNNP process on trends in risk level in the petroleum activity is a

key tool for mapping risk levels and areas, both offshore and at the land-
based plants.

Risk must be reduced as far as possible

Norway’s HSE regulations require that solutions must be chosen which
reduce the uncertainty which arises when knowledge is lacking about
the possible impact of technical, operational or organizational solutions on
health, safety or the environment.

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Areas where considerable uncertainty about consequences may exist
include

 long-term health effects

 Effects on the natural environment.

The companies must not only comply with the regulations but also reduce
risk as far as possible. If insufficient knowledge is available about the
effect of preventive action, the HSE regulations specify that additional
measures must be adopted to avoid possible harmful impacts.

Maintenance management
Installations, facilities and equipment wear out, get used up, and become
damaged or destroyed. Insufficient maintenance may increase the risk of
major accidents, damage and mishaps.

The industry itself is responsible for managing maintenance, and for

distinguishing less important work from safety-critical jobs which could
have consequences for the level of HSE.

According to the main principle in the regulations, facilities must be

maintained in such a manner that they are able to discharge their
intended function in all phases of their operating life.

The goals of maintenance management in Dawlance URIL include

 identifying critical functions

 Ensuring that safety-critical barriers function when they are needed.

Errors in planning, execution or checking of maintenance could cause

faults to occur in a system. Inadequate maintenance may mean that an
existing fault or degradation is not detected and corrected.

In other words, inadequate maintenance could be a contributory

factor in production shutdowns, work mishaps or major accidents.

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 PLASTIC MOULDING
DEPARTMENT
(Production-I)

Plastic molding department of Dawlance URIL include 42 injection

molding machines though which 250 different plastic parts are formed
which are used in refrigerator or deep freezer. The aim of the department
is to complete its target within time and budget. It also includes quality
check of product.

Processes in plastic molding shop:

1-Color mixing and compounding:

It is process of mixing or making compound of color pigment
(required color of plastic) and plastic. Here specific amount of plastic is
mixed with specific amount of color .Specific amount means the amount
which is calculated by engineering techniques. Here the perfect compound
is prepared for the molding operation.

2-Molding :( injection molding)

In this process the compound of plastic and color sucked by

machine then machine made compound in liquid form and then it into a
mold to it a specified shape then cooled. The whole process is fully
automated only one worker is required to set the machine and remove the
finish product from the machine, as shown in figure.

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 Different machines and molding dies are used depending upon size, type
and model of the required product.

3- Screen printing:
After molding process screen printing process occurs. In this
process the numbers, labels or monograms of the company is printed.

This process is done by machine called stamping machine or by manual

method.

: 4-Gas kit Extrusion:

In this process the compound of PVC is used by machine for
making rubber type rib which is used in refrigerator seal the door for
avoiding leakage of cooling. 1100 pieces are produced in one hour, as

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shown in figure.

5- Cable manufacture:
In cable manufacture following operations are carried out:
- Wire stripping-core stripping- pin molding by vertical mold
machine –pin punching by punching machine-plug molding vertical
mold machine.

For mould purpose PVC compound is used. Different machines and dies
are used for different moulds.

SHEET METAL
(Production-II)

In this production line cabinet of refrigerator or deep freezer are formed

from mild steel sheets by some machining, cutting processes. In this line
cabinet of the refrigerator is formed.

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 This cabinet is
formed by sheets,
as shown in figures.

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ROLLED SHEETS MILD STEEL.

DIFFERENT PART FORMED FROM SHEET METALS.

DIES MACHINES USED FOR SHAPING SHEETS.

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 THE PAINTING SHOP
(PRODUTION – III)

In painting shop various parts are painted so that they could be transfer
into the final assembly shop.
It includes:
-Cabinet Painting
-Condenser Painting

 Cabinet painting:
In this section cabinet is painted by passing through following
processes:

-Phosphating
-Drying
-Powder coating
-Baking

Phosphating:
The Phosphating process is actually through the following
tanks there are basically 4 different tankers, out of them 2 of the chemical
tanks and 2 of them water tanks.
The Phosphating process in which the chemical used is metaphors 247.

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Dry oven:
At this stage the phosphate cabinet is done into dry oven
which has the temperature of 160 degree centigrade.

Powder Coating:
At this stage powder coating is done by moveable guns
in a powder room so that the layer of powder is to be coated over the
cabinet. The powder is bought from outside.
There are 2 powder rooms used in paint shop. A RECYCLER is used
with which each room which extracts wasted powder from the room;
recycle useful powder and garbage the remaining.

Backing oven:
This is the end process of painting shop here the powder
cabinet are to be backed into the oven so that the powder is to be melted
and from the paint over the cabinet. It has temperature about
220centigrade.

Flow chart of Cabinet paint shop:

PHOSPHATING (2 metaphors 247 chemical tanks 2 Water tanks Dry oven)

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 Paint Coating 1 Paint Coating 2

Back oven

Flow Char of Condenser Paint Shop:

Chemical wash for ant rusting Water wash Phosphating wash

Powder
coating Dry oven
Baking oven

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 CONDENSER PAINTING

Like all other painting shops, condenser painting also follows the same
process as the other painting process.

It consists of following steps:

-Chemical removing defects:

The condenser is dipped into the chemical called metical 2325 chemical
for rusting.

-Washing:
After that it is dipped into the fresh water for wash up to 1 to 5 minutes.

-Phosphating:
After that is to be dipped into the tank of metaphors 247 chemical tank.
And after that through pressure vessel it is to be dried.
At the end of Phosphating the condensers supposed to shift into the dry
oven and where the all moisture is dried from the phosphate condenser.

-The process of drying, powder coating and backing as same as

cabinet.

The temperature is also same as in cabinet. Dry oven has 160 centigrade,
back oven has 180 centigrade. In condenser painting coating is to be done
manually.

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 PRODUCTION- IV/VI
(Pre-foaming, foaming of cabinet or doors)

The production four or six is the place where the various operations are
carried out like pre foaming and foaming of cabinet or doors.

PRE-FOAMING SECTION:
At the pre-foaming stage, the necessary items such as the
liner, freezer and anti moisture tube, and evaporator are to be inserted into
the actual body of the cabinet. The actual process of pre-foaming starts
when the painted cabinets from the cabinet paint shop come to the pre-
foaming zone.

PRE-FOAMING PROCESS:
It consists of following steps:
Step1: first of all the compressor support is unscrewed from the painted
cabinet.
Step2: The gum type material named as slants is inserted into the corner
into the corner edge of the painted cabinet in order to make proper
isolation.
Step3: Washer type material is tape within the four whole if the back panel
so that condenser is to be screwed easily in it.
Step4: Bottom profile is inserted within the embossing area in the bottom.
Step5: Spaces in fixed in the back panel so that the pipe which is fitted in
it.
Step6: Groomer also fitted with the wholes.
Step7: Anti moisture strip and a black pipe is to be inserted within the
profile cabinet.

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FOAMING SECTION:
The foaming section is a place when the pre-foamed
cabinet is to be foamed by the automated machines.
The foam which is to be inserted within the pre-foamed body, it is
solidified within a few minutes.
The foam is basically made of different type of chemicals like iso –
cyanate, polyol and R141B (a gas which is used as catalyst)

PROCESS OF FOAMING:
The process of foaming section begins by fixing the jigs
and fixture within the ref section so that while foaming the inside the
refrigerator is not bend etc.
After that the highly automated the mixture of foam is to be inserted
within the cabinet. The URIL has 9molding foaming hangers which are
fully automated and used to operate according to sensors and actuators
and various other equipments. Basically the mixing of chemicals as form
the foam is to be as,
12 60% of iso-cyanides.
16% R141B.

PRODUCTION -V
(ASSEMBLY LINE)

After the foaming the foamed cabined are passed over the assembly line
where different jobs are assigned to different workers at different at
different shops are as under:

COPRESSOR FITTING:

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At shop1 two persons are assigned the job to fit compressors of required
size inside the body of cabinet of refrigerator.

BULB FITTING:
At shop 2 one person is assigned the job of the fitting bulb inside the door
of the refrigerator.

CONDENSOR AND CONDENSER GRILL FITTING:

At shop 3 one or two persons are assigned the jobs to fit the condensers
grill at the back side of the cabinet.

DOOR FRONT HANDLES FITTING AND INITIAL SCREW

TIGHTINING:
At shop 4 one person is assigned the job to fit front handles of door of the
refrigerator and for initial tightening of screw at different places of a
refrigerator.

THERMOSTAT FITTING:
AT shop 5 one person is assigned the job of fitting thermostat inside the
cabinet of refrigerator.

GAS FILLING:
At shop6 two persons are assigned jobs to fill gases in grams quality
inside the compressors through the inlet according to different size of
refrigerator.

GAS WELDING:
At shop 7 two persons are assigned jobs to close the inlet valve through
gas welding.

GAS LEAKAGE CHECHING:

At shop 8 one person is assigned the job to ensure that there is no leakage
of gas from the inlet of compressor.

COPRESSOR’S GRILL FITTING:

At shop 9 two persons are assigned the duty to fit the compressor grill.

SCREW TIGHNING:

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AT shop10 two persons are assigned the job of screw tightening at
different parts of refrigerator.

QUALITY CONTROL:
At shop 11 three persons are assigned to check the quality of the product
made , if it fits to the requirement it will be sent to the next shop otherwise
will be sent the start of the production house i-e Coiling of sheet metal.

SENT TO STORE HOUSE: After final packing the products are sent to
store house through lifters.

Production –VII
(Forming of Deep freezer)

The Manufacturing of deep freezer is same as refrigerator.

It consists of following steps:

- Sheet metal cutting for DF

- Pre- foaming of DF
- Foaming of DF
- Assembly of DF
- Quality Check of DF
- Sent to store.

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MAINTANCE

The main aim of maintance is to remove the faults if any occur as well as
maintain the machineries like oil level, lubrication e.t.c.
There are two main types of maintance

1: PREVENTING MAINTANCE: Remove the faults without disturbing

production.
2: BREAK DOWN: In this production should stop.
The main factor which can be noted during maintance
MTTR: mean time to repair.
MTBF: mean time between failures.

UTILITIES:
The main function of this department is to provide the basic things which
are essential for production like air for some machines, electricity e.t.c.
The main supplies are:

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COMPRESSOR ROOM: It provide the compress air to whole industry.
The pressure produce by the compressor is 7 bar which is 1 bar more than
machine requirement in order to avoid line loses.
NITROGEN ROOM: In this section nitrogen is filtered from air and
store in the nitrogen tank later supply to the whole factory where its
needs.
GENERATORS: To overcome the load shading 6 heavy duty generators
are install

3 out of 6 are 650 KW

Load units 500-250
Fuel consumption 200 lit/hour/ frequency 50 Hz.
Other 3 are 1000 KW generators
Average load sustained is 1500AMP
Fuel consumption 500 lit/hour.

QUALITY CONTROL

The main purpose of this department is that customer can get the product
which is free from all defect no matter it is very minimum. The quality of
product is checked at different section before packing. Some quality
checked we discuss here.

QUALITY CHECKED AT ASSEMBLY LINE:

CHARGING STATION:

VACCUM: Sucking pump use to sucks moisture, dust particles from the
whole body.
Time for vacuuming 22 min.
Male couples insert in the compressor or (charging line) female couples is
on the pump.

CHARGING PROCESS: 200 micron pressure required

Leak test charging panel checked if any leakage the pressure is increased

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INJECTION: R 134 –A gas is injected. Model 70 LVS -150 gm of R 134
a charge then punch off the compressor openings.

MARTORANA TEST (ELECTRIC TEST):

30 sec
5 things check
 Ground continuity ( proper earth flow)
 Strength ( voltage )
 Insulation (insulation of wire)
 Leakage ( cut off region)
 Ampere( 1.6) 70 lb’s

FUNCTION LINE (1-6)

COMPUTARIZED PROP SYSTEM:

Thermo couple wires in ref section centre for 45 min.
Ambient Temperature (36 C) atmospheric temperature
The temperature of ref is check according to it. At this movement A.T is
36 C. the temperature of ref is 20 C.
FAULTS:
Cooling down check on LINE TREND.
Mostly cooling down occurs due to leakage of gas or under charging.
Incase cabinet is block no cooling occurs.
Some more Faults:
Over Charging: Ice freezes on the outer side of suction pipes.
Under Charging: Ref plate doesn’t give proper cooling
Blockage: Due to moisture, dust particles, brazing joint flesh come inside
the joints and block the path of refrigerant.

HIGH PRESSURE LEAK TEST

After charging by Infigen leak test machine.
Sensitivity of machine: 1 gram /year leakage can be detected.
Joints checked by this machine : Extra upper ,extra lower ,oil in /out
,charging punch ,discharge ,suction, suction extra upper ,anti upper, anti-
lower, capillary joint and some other joints.

HIGH SIDE LEAK TEST (final leak test)

2 joints are checked in this stage in the off condition
Charging Punch and Suction joint is checked

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Also checked back side of product and ensure not any part is missing from
back side.
It can take 45 sec to 1 min

QUALITY CHECK AT FOAMING:

Design standard are already standardized about 200 faults
Line crack. Line frame, puncture evaporation tube (scrap) e.t.c
Foam leak, line, gap, leakage and some other faults they are removable.
FARMING STANDARDS
 Linear gaps, front notching ( less than 1 mm)
 Back side notching 2-3 mm
 Frame and I.C.P gap 1.5 mm
 Linear gap 1.5 mm
 Notching gap < 1mm
 Fez frame gap <1.5mm
 Linear gap < 1.7
 D shape <7mm
 Fez drain gap <0.4mm
 f/ profile angle 90+2
 pp sheet minor dent line mark only allow behind the Cond:

Evaporate gap
Dent, scratch, linear out, foam leak, foam drain.
First fire pieces, are checked if any fault occurs in the molds or e.t.c then
it can be set at a time and the normal productions starts.
SHORT FAULTS: in case short not completed

CONCLUSION:

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Expending 6 days in the factory will get us in the new world of applied
technology and we know what is organization and organizational
behavior.
How thousands of small and large process work together in uniform
manner to gave us a thing of our desire and we get the excellent quality
product which is very reliable and long lasting and someone rightly said
“Great things come with great efforts “
And at last
Dawlance realiable hai……

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