Interpreting Refrigerator Production Industry

United Refrigeration Industries Limited

Research Report

By:

Naresh Kumar

Department of Industrial Engineering & Management

MEHRAN UNIVERSITY OF ENGINEERING & TECHNOLOGY

Preface

This Research report includes the information about those departments & work in progress which was visited by us as

internees at Dawlance United Refrigeration Industries Limited .It was duration of one week 02-07-2012 to 07-07-

2012.

Whatever the machinery we had seen and the processes were observed, attracting the human mind and realizes the

men what science has achieved and what kind of material has been done by it. Basically United refrigerator company

ltd. (Dawlance) is quite attention attracting industry it

provides lot of opportunities to see, to observe, to achieve and to get the lot of experience about the industry as well as

techniques which are being utilized there to achieve their goal our of proffers. This report may also contain the facts

and the real figures of the various departments which are

very beneficial for our experience and the also for the skill regarding professional knowledge.

Index

1) Production - II Shearing, sheet Metal, Roll Forming and welding.

2) Production - III Painting shop (Cabinet & Dip-Coating)

3) Production – V Pre-Foaming & Foaming

4) Production – I Plastic Moulding Section

5) Maintenance

6) Quality Control & Health Safety

Environment & Quality

Production – II

This was our very first shop. Initially we had visited Shearing Area, roll forming area & welding area.

We have seen conversion of sheets in many shapes as concern of design of refrigerator & De-refrigerator.

Resource was metal steel & different types of metal as

decided by design. Machines were manufacturing many types of parts used in

refrigerator. Only steel work was there. There are few main machines as under

Olma: - This is first machine which is basically used to cut many steel sheets in different sizes. As we had seen

machine was opening the rolled metallic sheets as they arrived in factory, & than it cut in different sizes & shapes.

Currently there was 715*550, which was sheet of body of

refrigerator.

Roll Forming: - This is like an assembly line a single machine; it was receiving sheets formed by Olma

machines. This machine was doing NOTCHING,

BENDING, FINAL BENDING. As sheet was putting over the machine by series of

activities done by machines bit by bit notching, bending & final bending was done there. At the end of this machine

square shape steel body was there in complete.

Spot Welding: - After roll former the steel body comes at

welding area, here spot welding was being in progress & using electricity they were welding different parts to that

steel body. Bottom Plate, Compressor shapes, Separation plates, FCP plates & ICP plates were joining to main steel

frame body.

As conclusion of this production section “Initially metallic

sheets were receiving, It was being converted to metallic body of refrigerator & different sections in it to be used

further”

Production – III

It is basically the painting section used to paint the various parts of metallic steel made. Cabinets painting & Dip

coating is done here. Generally this is called Painting Shop. Cabinets are being moved here from Production II.

This shop contains five steps in accomplishment of his

work.

Cleaning Drying

Coloring

Oven Quality Control

1) Cleaning: - In this process the cabinets are being

hanged in moving line which take them to a shower

type a hallow cabin. In which a solution is being thrown on hanged cabinets. Solution contains water

along with METAPHOS as a cleaning agent, which extracts rust particles, sand particles, and extra

impurities.

2) Drying: - After cleaning hanged cabinets are moved

towards the Drying section, initially cabinets are given air of high pressure manually by a person & after that

cabinets are being too moved towards drying

coulombs. The coulombs carrying temperature of 140 centigrade for 5 to 6 minutes. After dry and clean

cabinets are ready to be colored.

3) Coloring: - This stage includes the main purpose of

this shop that is coloring. Next there are robots to color. Hanged cabinets are crossed between the

robotic arms, which are used to apply powder color to cabinets. At this stage the cabinets are little bit hot in

touch. Robotics arm are used to color with same depth

on whole surface. Total time taken by this stage is 6 to 7 minutes, at the end of powdering there is person is

to check various parts to be watched for coloring well. Along with beside this painting shop, the powder

color is done in separate section, it was coloring minor

small parts of refrigerator like notch holder, scales, & door locks.

4) Oven: - As described before those cabinets from paint

are little bit hot & they are having loss color (means

can be removed by touch). After that hanged cabinets are moved to MECHANICAL OVEN. Mechanical

oven is hallow shaped a warm cabin, containing temperature of 185 to 190 centigrade and cabinets

keep there for 5 minutes approximately. After this the

color became so smooth and prominent. The cabinet paint shop has the capacity to paint 1800

to 1900 cabinet paint per 24 hours that’s capacity = 1800 to 1900 cabinets paint per 24 hours.

5) Quality Control: - This stage includes inspection of colored cabinets. Usually this is done by two means 1

st =

by manually (eye & touch), 2nd

= Gloss meter.

Gloss Meter is an instrument used to measure the depth

of colored on any metallic sheet. It measures in micron meters.

As conclusion “The paint shop include painting the

cabinets and other small parts, color used in Dawlance is

ABS powder color, after it is being inspect by two means manually as technically. The Dawlance range of color is

30-70 micron meters”.

Production – V

Till production we are making, painting the certain parts

so that they should combined to form the original product; this section starts after painting shop.

This section includes Pre-Foaming & Foaming.

Pre-Foaming means all work done before foaming of

that’s adding PP twin sheet, water valves, liner freezer, evaporator, anti- moisture tube and slent.

First of all gum- type material named as slent is to be inserted into the corner edge of the painted cabinet in

order to make proper isolation, after that Washer type

material is tape within the four whole if the back panels that condenser is to be screwed easily in it.

Then Washer type material is tape within the four whole if the back panels that condenser is to be screwed easily

in it.

LEAD DETECTOR MACHINE: - A machine which is used to detect the all the pipe and join of the evaporator

by inserted the Freon gas. The detector even has the capability to detect 1.0 micro gram of area. Once the

evaporator is OK then it is to be shifted for the next test.

The statistics show that there are basically 8 to 10 evaporators rejected in lead detector test.

The evaporator from is to be make by joining the evaporator the side plate thorough a silicon type of

material. Now this flow is to be fitted with the freezer

side of the cabinets, the liner which is come form the

thermosetting section is first sized and cut by the press

machine. With the size the whole also produce which is of evaporator and thermocouple. Sub-system 02:- after

that the head after and thermostat cover is taped within the liner freezer.

All stuffs are combined on moving pre-foaming

assembly line. Variety of worker is there to fit the different parts in cabinets. After accomplishment of pre-

foaming, Pre-Foamed cabinets are brought to foaming section.

Foaming: - The foaming section is a place when the pre-foamed cabinet is too foamed by the automated machine.

The foam which is to be inserted within the pre-foamed foam than it is solidifying within a few minutes. The foam

is basically made of two different type of chemicals)

Polyolefin) Iso – cymatia) R141B (a gas which is used as a catalyst) • the foaming section has the capacity to filled 81

mould foam per hour i-e capacity = 81 mould foam per hour. PROCESS OF FAOMING 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.

Production – I

(PLASTIC MOULDING SECTION)

As the name suggest plastic molding the production is said

to manufacture all plastic type of equipment that can be used in refrigerator manufacturing. There are 6 section

includes in moulding each section have its own task to with

they can act these are as follows) Compounding section) Injection section) Hot stepping section) Steam print

section) Extrudes section) Cable section • The compounding and injection are the most basic sections and

these are those which used to produce they different

plastics items in proper quality and quantity. The raw material of various plastics material in the form of

huge grain is received in compounding portion through store room. This raw material includes, PS ABS HIPS LIPS

PC NYLONE & PP. The compounding section used to mix

the raw material with the pigment so that required color of particular item is obtained.

Machines were doing plastic ingestion moulding. There were 52 machines in whole section & variety of different

refrigerator plastic parts were being manufactured.

All were CLF machines with different codes as according to their use,