A REPORT ON INDUSTRIAL PRACTICAL TRAINING AT

WHIRLPOOL OF INDIA LIMITED PLANT ENGINEERING DEPARTMENT

(WOI-PED)
SUBMITTED BY: RAHUL JAIN ROLL NO: 8 ME 073 MECHANICAL ENGINEERING LINGAYAS INST. OF MGMT. & TECHNOLOGY

.
FARIDABAD
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CERTIFICATION
This is to certify that
Mr. RAHUL JAIN

student of LIMAT,Faridabad

has successfully completed six weeks industrial training in Faridabad Refrigeration Plant of Whirlpool of India Ltd in the PED department under the guidance of Mr . HB TIWARI from 2'June 2009
to 31'July 2009

Under The Guidance Of:

(Mr. HB TIWARI) (Maneger, PED)

Mr. SHOBHIT TYAGI (Senior Engineer, PED)

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ACKNOWLEDMENT
I, at this very outset, thank all those who directly or indirectly helped me in the completion of my project work and encouraged me in moments of my despair. First of all, I would like to express my earnest gratitude to Mr. UTSAV KHANDELWAL ( HR ) who has given me the opportunity to undergo for two months training in this esteemed organization. I take this as an opportunity to acknowledge the invaluable support and guidance given By Mr. HB Tiwari , Senior Manager ( PED) , Mr. Shobhit Tyagi , Senior Engineer ( PED), Mr. Atul Mehta , Engineer ( PED ), Mr.
Deenanath, Dept. Manager (PED) , Mr. Omender Sharma, Senior Technicion Mr. Balwan, senior Technicion from PED department for their able guidance.

My sincere thanks to all the faculty members of LIMAT Nachauli,Faridabad for their support and guidance. I would also like to thank all the workmen of PED department for there technical as well as general guidance and support. Last but not the least I express my thanks to my colleagues and other persons who have directly or indirectly involved in my projects along with me.

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Contents
Preface 1. Introduction to Whirlpool Of India Ltd. (WOIL) 1.1 The Whirlpool Group 1.2 Whirlpool in India 1.3 Vision of WOIL 1.4 Manufacturing facilities in India 1.5 Product Distribution and services 2. Whirlpool Of India Ltd. (WOIL) Faridabad 2.1 Plant Organization 2.2 Management structure 3. Manufacturing processes at WOIL Faridabad 3.1 Basic units 3.2 Plant Process Layout 3.3 Press Shop 3.4 Paint Shop 3.5 Extrusion Plant 3.6 Vaccume Forming 3.7 Foaming Process 3.8 Evaporator Section 3.9 Assembly line 4. P.E.D. at Faridabad 4.1 Introduction 4.2 Type of projects at P. .E.D. 5. Projects Dealt at P.E.D . 5.1 PLC (Programmeble Logic Controller)

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Preface
Industrial training is really a very advantageous exercise as a part of Industrial Design curriculum. It has given me the feel of actual ground level jobs which are required to be performed in a manufacturing industry. This report shares first hand experience of a project summer trainee in Whirlpool of India Ltd. It compares the realities faced against the theoretical experience of a fresher in an industrial atmosphere and comprehends role of the designer and process of object development and manufacture.

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COMPANY PROFILE
The Refrigeration industry in India is fast growing and with the advent of global brands the industry has woken up to new opportunities and new challenges. Whirlpools association with India goes back to the year 1987 with the establishment of the joint venture TVS Whirlpool Ltd. Whirlpool Corporation is the worlds leading manufacturer and marketer of major home appliances the industry is fast growing. There has been a rapid entry of global brands which has resulted in local infrastructure / industry waking up to opportunity and of course the threats. Whirlpool plans to launch products to suit the Indian customer in various income groups. Whirlpool portfolio will follow its top-4 agenda in India: Refrigerators, Washing machines, Air conditioners Microwaves All high growth areas, which allow it to leverage WOIs existing strengths, the whirlpool products currently available in the market include Refrigerators, Air conditioners, microwaves and washing machines. Whirlpool guarantees performance, promise and reliability of its products. All Whirlpool products are backed by suitable warranties and a wide network of service centers, Emphasis is placed on after sales service and whirlpool strives to achieve those goals

In refrigerators the industry growth has been less than 27%. The 180L occupy around 75% segment of market. The main players in the market are LG, Godrej, Samsung, Whirlpool, Electrolux and Videocon. Whirlpool has a market share of about 30% and is the market leader.

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ABOUT WHIRLPOOL CORPORATION Whirlpool Corporation is the worlds leading manufacturer and marketer of major home appliances. Headquartered at Benton Harbor, Michigan and the major brand names in about 140 countries. Though now a global leader, the company began, as a family owned machine shop located in a small town on Eastern Shore of Lake Michigan.

THE HISTORY Founded in 1911 as Upton Machine Company produced motor driven wringer washer. Sold first order of washers in 1916 to Sears Roebuck and Co- our largest retail customer today. In 1950 the company was renamed the The Whirlpool Corporation automatic dyers were added to washer line. In 1958 Whirlpool made its first investment outside North America in Brazil. Revenues reached $ 1 billion in 1968. Whirlpool purchased Kitchen Aid brand in 1986 and began its globalization efforts in 1980s.

WHIRLPOOL CORPORATION TODAY Worlds leading manufacturer and marketer of major home appliances. Full line of major home appliances. Manufacturer: 12 countries. Revenue: $ 12 billion. THE WHIRLPOOL VISION EVERYHOME, EVERYWHERE WITH PRIDE, PASSION AND PERFORMANCE Whirlpool, in its chosen lines of a business will grow with new opportunities and be the leader in an ever-changing market. We will be driven by our commitment to continuous quality improvement and to exceeding all our customers expectations. We will gain competitive advantage through this by building our existing strengths and developing new competencies. We will be market driven, efficient and profitable. Our success will make Whirlpool a company that worldwide customers, employees and stockholders can depend on

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THE WHIRLPOOL MISSION STATEMENT We will be demanding of ourselves so as to care for our customers like no other brand does. We will serve with pride in every Indian home and bring prosperity to our investors. We will dare to change the standards of our industry and be the envy of our competitors. We will be the leader in home appliances with all others will want to emulate. WHIRLPOOL WENT THE GLOBAL WAY Whirlpool strategy has been to remain focused on major home appliances but to expand into markets not already served by Whirlpool. The goal has been world leadership in a rapidly globalizing major appliances industry. Before whirlpool began its expansion into Europe, a move that established the company as a world leader in major home appliances, it undertook a global analysis of markets and opportunities in home appliance industry. A conclusion was that the industry would, over time, become global and a handful of companies would dominate the manufacturer and the sale of home appliances. Whirlpool determined to lead that globalization process and be one of those companies. In 1980s there was a major acquisition in Europe, joint ventures with companies in Mexico and India and increased ownership in companies in Canada and Brazil. Throughout the early 90s the company continued its expansion in Latin America and Europe and a manufacturing and marketing presence was established in Eastern Europe. In Asia, Latin America, North America and Europe, in all the countries where it has presence was established in Eastern Europe, Whirlpool seeks to set standards against which the global major domestic appliance industry is measured. To that end the company vigorously pursues the goal of its worldwide excellence system (WES). Whirlpools strategy to shape and lead the emerging global home appliance industry is working because the company consistently improves the quality of its products and services while refining its understanding of customers and what they want from whirlpool. WHIRLPOOL IS POSITIONED GLOBALLY North America Latin America Europe Asia
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#1 #1 #3 # Leading Western Company

Latin America: Whirlpool defines the Latin America region as including Central and South America and Caribbean. The Latin America Appliances Group (LAAG) of manufacturing capacity of the region. Whirlpool and its affiliates have the largest market share and one third of the manufacturing capacity of the region. The Latin America home appliances market, which today accounts for some 6% of the global market for the home appliances is expected to expand more rapidly than either North America or Europe in the decade ahead. Whirlpool has been a part of the Brazilian Home Appliances since 1958. Today it holds equity positions in Electrodomesticos, Empressa Brasileirade Multibras Compressors and S.A. holding company, which are leading companies. North America: In 1989, Whirlpool operations in the United States, Mexico and Canada were brought together to form the North America alliance group. Product lines were moved between Whirlpool plants and across borders to improve manufacturing efficiencies. In 1993, NAAG recognized around a strategy focused on delighting customers and giving them compelling reasons beyond price to choose whirlpool built appliances. United States: NAAG maintains its strong U.S. industry position with full line of Kitchen Aid, Whirlpool, Roper, Estate, Coolerator and chambers brand appliances. The Sears sales and marketing group is dedicated to serving sears Roebuck & Co. The largest home appliance retailer. Canada: Inglis ltd. A wholly owned subsidiary is a leading supplier of major home appliances in Canada and markets under seven brand names Inglis, Whirlpool, Kitchen Aid, Admiral, Roper, Estate and Speed Queen. Mexico: Vitromatic S.A. de C.V. is a joint venture company between Whirlpool and Vitro in which Whirlpool holds 49% stake. It is one of the two major appliances companies in Mexico and manufactures under Whirlpool, Across Supermatic, Crolls and Philips brand names. Is also serves as an exclusive Mexicon distributor of full line of Whirlpool, Kitchen Aid and Roper Products built in U.S. Europe: Whirlpool Europe B.V. (WEBV) became the wholly owned European subsidiary of Whirlpool Corporation in July 1991 following Whirlpool purchase of the remaining shares of the JV with Philips NV of Netherlands. With a staff of 11,000 and annual sales of $2.43 billion, WEBV has the third largest marketing presence in Western Europe and has been growing steadily in Central and Eastern Europe, the middle east and Africa.

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Principal brand includes Whirlpool, Bauknecht, Ignis and Laden. With nine factories in 4 countries, WEBV is the third largest producer of major appliances in Europe; it is the second largest white good producer in Italy, second in French market and solid presence in Germany. PRODUCTS WORLDWIDE Washers Refrigerators Microwaves Air conditioners Dryers Dishwashers Freezers Cooking ranges Exhaust fans / ovens / hoods etc.

WHIRLPOOL IN ASIA In 1992, the company decided to focus on the significant growth opportunities in Asia and Latin America. As a result, stand-alone business unit was established in these two major regions of the world. Thus the Whirlpool Asian Appliances Group (WAAG) was formed. In 1993, WAAG began a series of moves to increase its presence in Asia and position the company to aggressively pursue potential business opportunities throughout the region.

The company has been aggressively pursuing its Asian Strategy, which focuses on: Partnering to build wins win relationships. Attracting, retaining and developing the best people. Ensuring quality in all respects of business. Offering four key products: refrigerators, washers, microwaves and air conditioners. Exceeding customer needs and satisfaction.

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Also in 1994 Great Techno Whirlpool Ltd. A marketing joint venture in Taiwan formed with great Techno Trade Co. Ltd.

was

In 1995 Whirlpool entered the fast growing home appliance market in the Peoples Republic of China through four majorities owned joint ventures. From a small volume exporter to niche markets thirty weeks ago, WAAG today comprises 12000 people in 25 countries. With six manufacturing sites in India and China and more coming up and over $US350 million in investments, Whirlpool is well on its way to achieving its objectives in Asia. WHIRLPOOL IN ASIA Western Company $250 million in sales Brands: Whirlpool, Ingis Kitchen Aid, Bauknecht, SMC and Snowflake. WHIRLPOOL IN INDIA Whirlpools association with India goes back to the year 1987 with the establishment of joint venture TVS Whirlpool Washing Machines Ltd. Headquartered at Madras, with manufacturing base in Pondicherry. Whirlpool management expertise and transfer of technology has helped to expand manufacturing capabilities and product lines for increased market shares throughout region. On February 24, 1995, Whirlpool acquired controlling interest in Kelvinator of India, traditionally the countries largest manufacturer and marketer of refrigerators. With the manufacturing base in Faridabad, Haryana this association has also yielded a network over 3500 trade dealers. Whirlpool is now selling the Whirlpool brand and Opera Brand Refrigerators, replacing the Kelvinator brand name, with the largest investor in MDA industry in India with financial commitments in access of INR 350 crores. Whirlpool sees a tremendous opportunity in white good segments in India. The emerging market holds promise and we believe that estimates of market potential are yet to be defined totally. To meet the growing trend Whirlpool is expanding its local production capabilities in both Washing Machines and refrigerators. A new project in the Global No-Frost refrigerator plant in Ranjangoan, Pune, plant is manufacturing no frost CFC Free Refrigerators. The product form this plant is specifically designed for the Indian consumer and is backed with latest world-class technology.
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WHIRLPOOLS GOAL IN INDIA TO BECOME THE MOST PROFITABLE PRODUCER OF T-2 PRODUCTS; REFRIGERATORS, THE INDUSTRY The industry is fast growing. There has been rapid entry of global brands, which has resulted in the local infrastructure/ industry waking upto opportunity and of course the threats. In refrigerators the industry growth has been less than 27%. The 180L occupy around 75% segment of the market. The main players in the market are Godrej, BPL, Whirlpool, Electrolux and Videocon. Whirlpool has a market share of around 30% while the market leader. OUR PRODUCTS DISTRIBUTION AND SERVICES The Whirlpool products currently available in the Indian markets include refrigeration, air conditioners, microwaves, and washing machines. The distribution of the entire whirlpool range is through an integrated sales network, which resulted from the merger of Kelvinator of Indias network and Whirlpool washing machines Ltd. Sales network. With the combined strengths, Whirlpool aims to achieve critical in their distribution with over 4000 dealers. Whirlpool calls them trade partners, an integral part of the chain of the partners in progress . Thus our sales team and trade partners form a formidable team in the market with network across the country. Whirlpool guarantees performance and promises reliability of all its products. In fact, suitable warranties and a wide network of service centers back all Whirlpool products. Emphasis is placed on after sales services and Whirlpool strives to achieve 90% customer satisfaction by servicing products within 24 hours of receiving the call. Whirlpool has its own 17 consumer service branches all over the country and to cover other towns, there are 100 service partners. Trade partners are also used for customer service. At Whirlpool, consumer feedback is given a great deal of thought while designing the products. All whirlpool products are suited to local customers needs while conforming to international standards of quality and safety. Whirlpool is driving the entire market of home appliances by launching products to suit consumers in various income groups. AIR CONDITIONERS, MICROWAVES AND WASHING

MACHINES, IN INDIA.

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MANUFACTURING FACILITIES Whirlpool has manufacturing facilities at three places: Washing Machines Refrigerators CFC free ref. Pondicherry, Madras Faridabad, Haryana Ranjangoan, Pune Started April94 Started Feb95 Started March98

WHIRLPOOL IN FARIDABAD On February 24th 1995; Whirlpool acquired controlling interest in Kelvinator of India, traditionally the countrys largest manufacturer and marketer of refrigerators. With the manufacturing base in Faridabad, Haryana, this association also yielded a network of over 3500 trade dealers. Whirlpool is now selling, the Whirlpool brand refrigerator, replacing the Kelvinator brand name, with the later having reverted to Electrolux in the early 1997. PRODUCTION CAPACITY IN FRO PLANT The production capacity in Faridabad Refrigeration Organization Plant is 1095000 lakhs annually. Whirlpool is expanding its local production capacities in both washing machines and refrigerators RAW MATERIAL AND POWER CONSUMPTION Whirlpool of India, Faridabad caters to its power requirements through its own powerhouse, which has 7-DG sets out of which 4 remain functional at a time. It also consumes electricity from Haryana Electricity board. Its monthly power requirement is around 1000000 KW/hr per month out which it takes wound 200000 KW/hr from Haryana Electricity Board and produces rest of the power in its own powerhouse. This power consumption varies widely with season. In summers this rate is as high as 1300000 KW/hr and it falls down to around 7500000 KW/hr in months of December and January. Whirlpool, Faridabad mainly deals with the assembly of refrigerators. They outsource raw material from different vendors and give the shape of refrigerator. They have more than 200 vendors. Their main raw material and supplier are as listed above

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Component 1. 2 2. 4 5. 6. 7 Compressor CRCA Steel Masterbatch HIPS Granules Wireharness Condenser Packaging

Supplier Tecumseh Bushan Steel SCJ Supreme Dudeja & Deltron STI Box & Carton, Kemeka

PRODUCT RANGE IN FRO Existing Models are: 180L RANGE Genius supreme Genius Premier Genius Royal

175L RANGE Master Piece Sanyo Coke

FUSION RANGE 200L Royal 200L Premier 230L Royal 230L Premier 260L Premier 310L Maxigerator

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GENIUS XL RANGE 200L Royal 200L Premier 230L Royal 230L Premier

EXPORT RANGE Nigeria export Philippines export Venus Nakai OBJECTIVES AND FUTURE PLANS 5star energy rating by April 2009. LGT of 90% (assembly and foaming) Total calls reduction by 10%. Total saving of 250Rs on 180L Genius supreme. Culture of quality, discipline and ownership though natural work groups. To improve productivity and discipline at the plant.

ANALYSIS OF WHIRLPOOL FRO PLANT STRENGTHS: Its technology Its manpower and their dedication towards work Training and education Its sophisticated paint shop Whirlpool LOGO 5-S conscious Implementation of 6 sigma.

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WEAKNESSES: Resistance to change Not much effective team work High rejections in door High rework in door High rework of Sealed system

CAPACITY OF THE PLANT

The company works in three shifts of eight hours duration each for seven days a week. The actual production time is around 7hours 10 minutes. The FRO has production capacity of about 4500 refrigerators per day but the demand is not that high, therefore the company also manufactures for some other companies. On an average around 3000-3500 refrigerators are produced everyday. Maximum daily production till date has been 4524pcs. These days (March to June) the production is around 4500pcs everyday. This year record production of 135000pcs is done in the month of May.

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PLANT PROCESS LAYOUT

PRESS SHOP

Shell/ wrapper and door for painting PAINT SHOP Painted door Painted Shell/ wrapper

Door liner

EXTRUDER

VACCUME FORMING

DOOR FORMING

Main liner

Painted Shell/ wrapper

CABINET FORMING

Finish cabinet Finish Door

Important component an STORE

ASSEMBLY LINE

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ABOUT THE PLANT The whole plant is broadly classified into five major parts, which are PRESS SHOP PAINT SHOP VACCUM FORMING EXTRUSION ASSEMBLY LINES

PRESS SHOP In the press shop, cabinet and door are made from C.R.C.A. Steel Cold Rolled Cold Annealed Steel sheet cut to the desired size as per model and is fed into the Carriage Unit. Rolled conveyer, on Carriage Unit shapes the sheet the roll forming of sheet is done to get the desired thickness. The thickness of door panel is 0.42 mm, that of back panel and cabinet is 0.38 mm and for deck the thickness of sheet is 0.25 mm. After this sheet is send to Notching and Punching (N/P) unit, where holes are punched into the sheet. The next operation is roller edge bending. Here the edges of the sheets are bend into U-shapes, where the liners are later inserted. The next step is the roller End Bending. Here the ends of the sheet are bended by 90 deg. Next sheet is folded in the Folding Fixture by the application of Hydraulic Pressure. Next, the folded sheets are sent for various spot welding operations. First, the Back Panel is welded with the cabinet. Then the bottom (deck) is welded. The bottom panel is curved in shape and has space for the compressor to fit in. Doors are also made here in the Press Shop. Next operation is of removing sharp edges at the corners cabin and doors are loaded on overhead conveyer and then are passed on to the Paint Shop for further processing. Apart from these basic operations, there are some separate units for welding of various reinforcements used in the cabinet.

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A VIEW OF PRESS SHOP

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Process flow-chart of Press Shop A) Formation of Shell

This involves following steps:

Bhushan Company, Noida Sopplies CRCA Sheet (0.25m thickness)

The Carriage unit picks the sheet

The sheet is then moves into Roll Former & sheet is bent through required angles as it moves through the rollers.

Roller conveyor moves the sheet to the Notching & Punching Unit, which punches the necessary holes and notches.

Bending Ends

Bending Starts

These rollers push the sheet at both edges

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Parting unit parts the sheet into two halves. So the machine does not operate & the sheet simply passes through it.

The sheet then passes through edge-bending unit, which is also not working.

C1

Folding Fixture folds the sheet at points 1 & 2 as shown in the figure. The sheet is then taken into spot welding unit.

End Bending Unit bends the sheet at the both ends. The sheet acquires the shape as shown in figure 3.

Folded Sheet

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B) Formation of Bottom Deck

Sheet punched and notched with Notching & Punching press of capacity 63 ton

Embossing on 40 ton press

Bending of sheet (involving three bending operations) on a 40 ton brake

C2

Welding of the front cross piece (supplied by an external supplier) to the bent sheet

C) Formation of Back Panel

Punching of sheet on a 40 ton punch

Spot welding of small square pieces on back panel sheet in order to provide a bearing screw surface for screws

Drilling for screws

C3

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C1 C2

In the spot welding unit, shell, back panel and bottom are all spot welded together. At the moment, spot welding machine is hand operated, but now, company has brought automatic spot welding machinery also.

C3

Welded cabinet

To the paint conveyor D) Formation of Opera Shell The entire process for the manufacturing of Opera Shell is exactly the same as that for the other shells. As already described, except for one difference- its manufacturing takes place on a older version of the shell making (used by Kelvinator earlier) machine which is different from the newer version in the following respects:

No lateral movement in the carriage unit Bending and folding on the same fixture

E) Formation of door panel Carriage unit picks sheet Cutting in the cutting unit Notching & punching in the notching & punching unit

To the paint conveyor

Bending in the bending unit

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Following Machines and equipments are used in the press shop: Power press Brake press TIG welding equipment Spot welding equipment Roll former Shearing press Hand grinding wheel Door metal line

THE PAINT SHOP The Cabinet/Door from the Press Shop is hanged on the overhead conveyor line, manually. The locking system is deactivated so that the cabin is free to rotate. Then the cabin is rinsed in soap solution to free all the dirt. Prior to this the cabin is also soaked in a solution to free all the grease on the surfaces. This is known as Degreasing. The next step is Activation, where the cabin/Door is kept in a medium, which allows the exothermic reaction to take place. After this the cabinet/door is coated with Zinc Phosphate, so that the pain sticks to the surface nicely. This process is called Phosphating. After phosphating the surface, which results, is very rough and irregular. smoothened in the Passivation stage. Next, the cabin/door is dried properly. Next, the cabin/door goes through the process of electrostatic paining where the sides and the top surface of the cabin or the from side of the door is painted by the electrostatic guns, which are five in no. Four to paint the sides and one at the bottom to paint the top surface of the cabin. The painted cabinet obtained in this process does not have a proper finishing. So, the cabin/door is now sent to the curing oven where it is heated to specified temperature, to obtain a shine on the surfaces. After this process, there is an Inspection process and the passed components are sent for the foaming process. This is

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A VIEW OF PAINT SHOP

Machines and equipments used in the various painting operations: Spray phosphating line Baking oven for spray phosphated components Powder coating plant Baking oven for powder coating plant Dip type phosphating plant Baking oven for liquid paint line Single platform type liquid spray painting Oven for small component

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Vacuum Forming Shop In vacuum forming, the inner liner of the refrigerator (both of shell and door) is formed. The following cycle takes place on the machine named:

ROTAFAST

The white material visible in the picture is the shell liner is being cooled by air pipe direct cool air on to it. The rotafast machine is provided by two heaters that make possible multiple stage heating of the HIP sheet Material of the plastic sheet is HIPS for High Impact Polystyrene.

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Pre Heating of the sheet

Final heating of the sheet at 120 degree Celsius.

Sheet placed and formed liner taken out and goes for visual inspection

a) Air blown to form a bubble b) The forming die comes up into the bubble c) The material is sucked in through vacuum through holes in die to make the contour d) Die moves down

Necessary cutting, punching of holes and fastening of assemblies.

a) Tape the back, bottom and LH/RH with anti blister tape b) Position and tape plastnut, snap type lock retainer, drain cup and tube.

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The process flow chart for liner manufacture on Rigo is shown below:

Loading (Vacuum)

Flanks square sheet

Upper and lower thickness pressure point measure sheet thickness

If ok

A Line goes for punching and trimming

Vacuum forming

Three stage heating

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EXTRUSION PLANT In the extrusion plant, the sheet for cabinet and door liner is prepared from: HIPS (High Impact Polystyrene) Masterbatch 585 to provide gloss Regrind

VIEW OF EXTRUSION PLANT

The three components HIPS, Masterbatch and regrind are fed to different pipes and finally the mixture is prepared. The mixture contains 61.4 % HIPS, 1.6 % Masterbatch, 35 % regrind and 2 % 585. The mixture of these components is fed into a CNC Extrusion Machine in above-mentioned proportions. The extruded material from the machine moves past the two cylinders and takes the form of a sheet. The cabinet or door liner sheets of definite size are cut by means of adjustable cutting knifes. The sheets produced are then sent to Vacuum Forming plant.

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CABINET FOAMING SECTION VARIOUS PROCESSES IN FOAMING: -

The first stage is to unload the painted shells or cabinets from the overhead conveyer line. This is done manually. Next, the shells are sent for Pre-Foaming. Here among other things the liner and the anti-moisture tube (A.M.T.) are fitted into the shell. Next, the shell is heated in the oven to a specified temperature to start the chemical reaction of foaming. After this the shell is loaded into the Foaming Plugs, 18 in no. Here a mixture of Isocyanate and Polyol is added in between the liner and cabin. The foam expands and covers all the space in between. After this the shell is unloaded, cleaned and inspected. The shells, which are O.K, are sent to the assembly line. Doors are also foamed in the similar manner in Door Drum. Here after addition of Isocyanate and Polyol, the door liner is placed over the door shell. The foamed doors are then unloaded, inspected and sent to the assembly line.

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The process flow-chart for the cabinet foaming:

Unloading of cabinet from paint shop through overhead conveyor

Apply clay, foam tape, paper tape and BOPP tape to prevent PU leak

Assemble wire harness Assemble corner fillers Fit thermo bulb & suction grommet in position

Position AMT inside cabinet flange channel

Position HIPS strips inside flange channel Assemble mainliner in the cabinet

Unload the cabinet & load on the foaming conveyor

Preheating of the cabinet

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Loading in foaming fixtures through Auto Carriage

Foaming of the cabinet as per the shot weights specified Foaming process parameters as per PCP

Scrap

NOT OK NOT OK Rework

Unloading and visual inspection

OK

Loading on trolley and transfer to assembly lines

OK

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ASSEMBLY LINE There are three assembly lines. VARIOUS PROCESSES IN ASSEMBLY LINE: THERMOSTAT FIXING BULB, BOTTOM HINGE, REAR FIXING ANGLE TRAY FIXING TOP HINGE FIXING COMPRESSOR AND CLAMPS FOR CONDENSER FIXING FREEZER FIXING FREEZER DOOR FIXING CONDENSER FIXING AMT CONNECTION, THERMOSTAT KNOB FIXING BRAZING OF SEALED SYSTEM, RELAY FIXING COMPRESSOR EARTHING, VACUUMISATION: Here, a loop of nine vacuum pumps is employed to vacuumise the compressor completely. GAS AND OIL CHARGING: Here, the Galileo Machine is employed for the Gas and Oil charging. The machine has to be calibrated before use. For this purpose, three parameters are set to evaluate the amount of gas charge in the Compressor. These parameters are: Weight Pulse Temperature Weight here means the gas specification; Pulse is the value of R.P.M x No of Blades in the turbine, or in other words the number of blades passing through a point in a minute. Temperature is the gas temperature at the junction of the cylinder and the Galileo Machine.

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During calibration the following data has been used for line no.3:

SR NO. 1 2 3

WEIGHT 87 97 118

PULSE 705 863 1020

TEMPERATURE 36 36 36

Apart from above, other parameters used in the setting of a program for a particular slot are: Evacuation Time Vacuum Testing Time Leak Testing Time Vacuum Upper and Lower Limits Recovery Time Reference Pressure

EVACUATION TIME is the time set for the compressor to be evacuated to the Upper limit of Vacuum. The Compressor should be evacuated to the upper limit in the specified time; otherwise the machine gives an alarm and stops the further process. It is kept at around 40-60 seconds.

VACUUM TESTING TIME is the time specified for the compressor to be further vacuumised from the upper specification limit to the lower specification limit. Again, if the compressor is not vacuumised in the prescribed time the machine gives a signal and further process is stopped. It is kept at around 40-60 seconds. LEAK TESTING TIME the machine stops the vacuumisation process and checks the pressure in the compressor. If the pressure drops below the lower specified limit in a time less than equal to the Leak Test Time, the machine gives a Group Leak Signal and the process again stops. It is kept at around 5 seconds.

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RECOVERY TIME is the time specified for the excess gas in the filler tubes to be recovered by the machine. This reduces wastage of the refrigerant. The Upper and Lower limits are set in such a manner that the Lower specified limit is above the

REFERENCE PRESSURE in the machine. The Reference Pressure is the lowest level of Vacuum that the machine can obtain. All the pressures are measured in terms of micrometers of mercury, where 760 mm of mercury corresponds to 1 Atmosphere. The upper limit is generally set above 1000 micrometers of mercury and the lower limit is set around 300 micrometers of Mercury.

DOOR FIXING SEALING OF THE CHARGING LINE INSPECTION IN TEST LOOP BY CONNECTING TO THE MAINS SUPPLY CABINET AND DOOR CLEANING CRISPER TRAY AND SHELVES FIXING DOOR HANDLE FIXING OUTSIDE CLEANING PLASTIC PARTS FIXING FINAL INSPECTION BAR CODING AND PACKING

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ONLINE QUALITY ASSURANCE FOR OUTGOING PRODUCTS AT W.O.I FRO In todays competitive environment no organization can exist with defective products. The aim of Whirlpool is to produce minimum defectives to please the customer. They have made their own standards to make sure that no defective is passed on. They have made a lab in which each employee acts as a customer and evaluates the product as a customer. All the defects in the product are find out and out going quality index is evaluated. Defects have been classified into the following three classes according to their degree of severity. 1. A defect. 2. B defect. 3. C defect.

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A defect: The defects that are most severing are grouped into this class. Following defects are classified into this group: Liable to cause personal injury or property damage under normal condition of use eg. Live wire exposed parts with sharp edges. Which can cause failure of unit in service, which cannot be readily corrected in field? E.g. Leaks Chokes. Those, which can cause inconvenience to the user while the machine, are in use. E.g. irritating compressor noise, door noise etc.

B defect: These are the moderate defects, which are not as serious as A defects. Following defects are classified into this group: Which can probably affect the performance of unit but can be corrected in the field? E.g. Gasket rolling, door sealing. Defects of appearance or finish that is extreme in intensity and require finish. e.g. dent, improper paint rework. Noticeable but not functional defects like door safe part missing.

C defect: These are the defects related to appearance, finish of goods, incompleteness of accessories etc. Sample size is taken as 6-8% of daily production. Samples are drawn randomly from line in such a manner that it is uniformly distributed. Minimum quantity checked per model is 10 per shift per line. Each class of defect has got different penalty. Class A being the most severe has the penalty of 10, B has penalty of 5 and C has got 1. Based on the number of defects and their degree of severity the quality index is evaluated using the following expression.

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Q= 100 10x(10xA+5xB+C)/n Where Q= quality index. A= Number of A defects found. B= Number of B defects found. C= Number of C defects found.

Remedial actions: If an A defect is detected then the production and dispatch of products units is stopped and following actions are taken: All the products produced in last 45 minutes with minimum of 25 units are checked and if no defective units are found then the production again starts. If in case same defect is detected then hold order is given to all the products produced in the shift. Analysis of the problem is done to find the root cause and the action is taken accordingly.

If a B defect is detected then 10 immediate machines are checked for similar kind of defect in an assembly line. If the defect is detected then action similar to that of an A defect is taken. If a C defect is observed then production incharge is informed about the defect and the process from where the defect is coming is audited. If in case the similar defect is observed fifth time in a shift, then remedial actions similar to that of type '' defects are taken.

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PLANT ENGINEERING DEPARTMENT

PED stands for Plant Engineering Department. This department is the Research & Maintenance center of (WOI) Whirpool of India which caters to the need of up-time and project improvement in Whirlpool. PED gives support and contribution to new projects.

The Aim and scope of work of PED platform can be summarized below 1. Up-Time Improvement 2. Improvements in Project undergoing 3. Cost Reduction

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The Aim & Scope of work of PED Platform can be summarized below:
1. up-time improvements 2. cost reduction 3. Efficiency improvements of machine 4. Availability of equipments 5. Performence improvements 6. In-House recovry 7. Erection & Commissioning of new machine 8. Improvements in project undergoing

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Projects in PED are mainly of three kinds

Related to TCR (Total Cost Reduction)

The main motivation in this project is to reduce the cost by using diffrent kinds of tools in machine design. This provide major saving in the company.

TCR is mainly in two areas:

Area 1 in which cost reduction is acheived by using advance n cheaper tools in machine. Area 2 in which cost reduction is measure by implement new machine designing process.

Related to increasing the efficiency of machine

Efficiency improvement on machine is acheived by Lowering the Cycle time.

Related to Up-Time improvement

Up-Time improvement can be acheived by reducing the Breakdowns in the plant. and reducing the time to overcome the breakdown.

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BASICS OF DIRECT COOL REFRIGERATOR Direct cool refrigerator is the one in which the provision compartment is cooled by the natural circulation of the air. The cold air in contact with the evaporator is heavier as compared to the lower portion of the provision compartment and the warm air rises upward from the front side towards the evaporator being cooled. The air circulates in the provision compartment due to natural convection current caused by this natural temp difference. Whirlpool has 170L, 180L, 200L, 230L, 260L, 310L capacity of refrigerators that fall under the category of DC refrigerators.

METHOD OF REFRIGERATION Vapor absorption system Vapor compression system

VAPOUR ABSORPTION CYCLE In vapor absorption system, heat energy is used to circulate the refrigerant. The heat energy is obtained from a gas flame, an electric heater, or a kerosene flame. It does not have a moving part; therefore the maintenance cost is minimum. Components in use are: Boiler and generator Condenser Evaporator Absorber connecting to suction pump

VAPOUR COMPRESSION CYCLE In vapor compression system the low-pressure refrigerant is compressed to high pressure by the compressor, using mechanical energy in the form of motor. It is then condensed to the liquid state in the condenser and then again evaporated to the gaseous state by extracting heat from the evaporator area. Most of the modern refrigerators fall under this category. The main components used in the refrigerator are: Condenser Capillary Charging line Dip tray

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Anti moisture tube Evaporator Drier and accumulator Compressor

In refrigerators the cycle is continuous. In this example, we will assume that the refrigerant being used is pure ammonia, which boils at -27 degrees F. this is what happens to keep the refrigerator cool:

1. The compressor compresses the ammonia gas. The compressed gas heats up as it is pressurized (orange). 2. The coils on the back of the refrigerator let the hot ammonia gas dissipate its heat. The ammonia gas condenses into ammonia liquid (dark blue) at high pressure. 3. The high-pressure ammonia liquid flows through the expansion valve. You can think of the expansion valve as a small hole. On one side of the hole is high-pressure ammonia liquid. On the other side of the hole is a low-pressure area (because the compressor is sucking gas out of that side). 4. The liquid ammonia immediately boils and vaporizes (light blue), its temperature dropping to -27 F. This makes the inside of the refrigerator cold. 5. The compressor sucks up the cold ammonia gas, and the cycle repeats.

By the way, if you have ever turned your car off on a hot summer day when you have had the air conditioner running, you may have heard a hissing noise under the hood. That noise is the sound of high-pressure liquid refrigerant flowing through the expansion valve. Pure ammonia gas is highly toxic to people and would pose a threat if the refrigerator were to leak, so all home refrigerators don't use pure ammonia. You may have heard of refrigerants know as CFCs (chlorofluorocarbons), originally developed by Du Pont in the 1930s as a nontoxic replacement for ammonia. CFC-12 (dichlorodifluoromethane) has about the same boiling

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point as ammonia. However, CFC-12 is not toxic to humans, so it is safe to use in your kitchen. Many large industrial refrigerators still use ammonia. In the 1970s, it was discovered that the CFCs then in use are harmful to the ozone layer, so as of the 1990s, all new refrigerators and air conditioners use refrigerants that are less harmful to the ozone layer. Parts of a Refrigerator As we learned in the introduction, the basic idea behind a refrigerator is to use the evaporation of a liquid to absorb heat. You probably know that when you put water on your skin it makes you feel cool. As the water evaporates, it absorbs heat, creating that cool feeling. Rubbing alcohol feels even cooler because it evaporates at a lower temperature. The liquid, or refrigerant, used in a refrigerator evaporates at an extremely low temperature, so it can create freezing temperatures inside the refrigerator. If you place your refrigerators refrigerant on your skin it will freeze your skin as it evaporates. There are five basic parts to any refrigerator Compressor Heat-exchanging pipes - serpentine or coiled set of pipes outside the unit Expansion valve Heat-exchanging pipes - serpentine or coiled set of pipes inside the unit Refrigerant - liquid that evaporates inside the refrigerator to create the cold temperatures Many industrial installations use pure ammonia as the refrigerant. Pure ammonia evaporates at -27 degrees Fahrenheit (-32 degrees Celsius).

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The basic mechanism of a refrigerator works like this: 1. The compressor compresses the refrigerant gas. This raises the refrigerant's pressure and

temperature (orange), so the heat-exchanging coils outside the refrigerator allow the refrigerant to dissipate the heat of pressurization. 2. As it cools, the refrigerant condenses into liquid form (purple) and flows through the expansion valve. 3. When it flows through the expansion valve, the liquid refrigerant is allowed to move from a highpressure zone to a low-pressure zone, so it expands and evaporates (light blue). In evaporating, it absorbs heat, making it cold. 4. The coils inside the refrigerator allow the refrigerant to absorb heat, making the inside of the refrigerator cold. The cycle then repeats.

FLOW OF REFRIGERANT
Compressor AMT Condenser Drier

Suction tube

Evaporator

Capillary

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ANATOMY OF DC REFRIGERATOR

COMPRESSOR

The compressor is the heart of the refrigerator. It pumps the refrigerant through the entire system. It draws cool refrigerant gas through suction line from the evaporator coils. At the same time it compresses the gas and pumps it into the discharge line. The compressed air sharply rises in temperature. Oil is charged into the compressor to: Provide lubrication to the moving parts Cool the compressor body The efficiency of the compressor mainly depends on two things: BTU (British thermal units) EER (Energy efficiency ratio)

CONDENSER

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The condenser is the cooling coil for the hot refrigerant. It expels the heat of the refrigerant to the atmosphere and changes refrigerant to liquid state. It may be noted that support wires are used in the condenser tube and the whole assembly is painted black. This is done to increase the heat transfer area and reflect the atmosphere at the faster rate. The supporting wires act as the fins for the condenser more the surface area more is the heat rejection through condenser.

DRIER

The hot liquid refrigerant from the condenser enters the drier. The drier contains synthetic zeolite composed of soda, alumina and silica. The function of the drier is to remove the moisture present in the liquid refrigerant.

EVAPORATOR

The liquid refrigerant at the low pressure leaves the capillary and enters the large tubing of the evaporator. Due to sudden increase in tube diameter, expansion takes place and the temp of the refrigerant drops rapidly. In the process of passing through the evaporator, the refrigerant absorbs heat gradually and changes into gaseous form at the same pressure.

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CAPILLARY The capillary is a small diameter tube connecting the condenser to the evaporator. The capillary tube is carefully calibrated in length and internal diameter. Its resistance or pressure drop due to length of the tube and diameter regulates the exact amount of refrigerant into the evaporator.

ACCUMULATOR Rate of evaporation of the refrigerant in the evaporator changes with the heat load on the evaporator. It evaporates at a faster rate on high load and at a slower rate on low load. Accumulator serves the purpose of a storage vessel that stores the unevaporated excess liquid when the load is low and supplies extra liquid to the evaporator when the load is high. It also prevents liquid refrigerant from flowing into the suction line and also into the compressor.

ANTI MOISTURE TUBE The AMT is in contact with the cabinet sidewalls of the refrigerator near the door. The basic purpose of the anti moisture tube is as follow It prevents external condensation in the front of the cabinet near the door Prevents heating of the gasket

THERMOSTAT

Thermostat ensures that the temperature in the freezer and the fresh food storage compartment are maintained as per specified requirements. The thermal capillary senses the freezer plate temperature and cuts off the compressor when the temp is attained and cuts in when temp rises for a particular setting.

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