PROJECT REPORT

ON
6
th
MONTH INDUSTRIAL TRAINING

GODREJ & BOYCE MFG. CO. LTD,
APPLIANCES DIVISION,
MOHALI, PUNJAB


SUBMITTED BY:

PARMEET SINGH
ROLL. NO. 11103335
B.TECH (MECHANICAL ENGG.)
GROUP- 4ME6





UNIVERSITY COLLEGE OF ENGINEERING
PUNJABI UNIVERSITY, PATIALA
PUNJAB




INDEX


Sr. No. DESCRIPTION
1 DECLARATION
2 ACKNOWLEDGEMENT
3 INTRODUCTION OF THE ORGANIZATION
4 PRODUCTS
5 PARTICULARS OF THE MOHALI PLANT
6 5S SYSTEM IN GODREJ
7 KAIZEN
8 INTRODUCTION ABOUT PLANT AND ALLOTED
DEPARTMENT
9 PROJECT NO 1
10
11
PROJECT NO 2
PROJECT NO 3
12 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-turned-
locksmith, 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 : 75 ACRES
CAPABILITY : 5 LACS
PRODUCTIVITY : REFRIGERATORS
INVESTMENT : Rs 120 CRORES
MANPOWER : 1300
INAUGRATED BY : S. HARCHARAN SINGH BRAR
INAUGRATION ON : 28
TH
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.

















There are three plants in this division these are:

1. COMPRESSOR PLANT
2. REFRIGERATOR PLANT
3. WASHING MACHINE





ALLOTED DEPARTMENT
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.


COMPRESSOR


ASSEMBLED COMPERSSOR







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
32. Shaft Washer
33. Copper bolt Washer
34. Holding Rubber
35. Stopper
36. Stopper Plate
37. Port Cover Washer
38. Pedestal
39. Muffler Rubber

The compressor plant is divided into various departments

Compressor Machine Shop
Surface treatment
Metrology Department
Assembly Department
Unit Shell Department
Maintenance Department
Tool Room
Store
Cutting Section
Quality Department


Layout of the Compressor Plant







COMPRESSOR MACHINE SHOP

In this department , there are various machines are used
to perform various operations on mainly 6 parts of
compressor. These parts are:

COMPRESSOR BODY
SHAFT
VALVE PLATE
CONNECTING ROD
PISTON
G PIN








1. COMPRESSOR BODY :- It is made of cast iron material come
from vendor NEWMAN & SATYAM.

Machines in cms shop in body line :-

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 Station Tool description operation
1 2H Insert:TCMT 110204 Hub facing and outer dia
chamfer
2 2V Insert:M 8065 1204 Head face rough milling
3 3H Insert: OFKR 070408 Leg face rough milling
4 4H CARTRIDGE:STSCL 10CA11
Insert:TCMT 110204
Shaft hole drill and outer dia
turning
5 4V Insert:M 8065 1204 Head face semi finish milling
6 5V SOLID CARBIDE DRILL DIA24*134 Piston hole drilling
7 6H STEPPED DRILL- M35 Leg hole centering
8 7H CARTRIDGE:SCGCR12 CA 12
INSERT:CCMT120408
Leg face facing
9 8H HSS DRILL DIA 4.5 MM
COUNTER SINK TOOL
Shaft hole chamfer and leg hole
drilling
10 9H CARBIDE BRAZED HOLE MILL Shaft hole milling and leg hole milling






Fig-front view of machine EMT682



Fig body after 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 Tool description operation
1 2H CENTER DRILL M-35 Gas hole drilling
2 2V INSERT:CCMT09T308
INSERT:CCMT120408
Seat facing and
chamfering
3 3H Insert:TCMT 060204
HSS DRILL 5.1MM JOBBER
SERIES
Port hole drilling and
conter boring
4 4H TWIST DRILL M35
HSS DRILL 4.5MM LONG SERIES
Gas hole drilling
5 5V HSSE SILVER CUT TOP M06 Port hole tapping
6 6V END MILL CARBIDE BRAZED U slot milling
7 7H HSS DRILL DIA 5.1MM JOBBER
SERIES
Leg relief hole drilling
8 7V HSS MARKING TOOL Body marking
9 8H HSS HOLE MILL REAMER Gas hole reaming


Fig-front view of machine EMT683

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 Station Tool description operation
1 HSS DRILL DIA 5MM LONG
SERIES
HSS COUNTER SINK TOOL
DIA 33MM
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 Station Tool description operation
1 2H FACE MILL DIA 80MM Head face finish milling
2 3H INSERT:CCMT09T308 Piston hole semi finish bore
3 3V Insert:CCMT 060204
Insert:TCMT 110208
Shaft hole semi finish bore
4 4H Insert:CCMT 060204
Insert:TCMT 090208
CARTRIDGE:STSCR 08CA 09
Piston hole finish bore
5 4V Insert:TGCT 060104
CARTRIDGE:STSCR 08CA 09
Insert:TCMT 06T108KF
CARTRIDGE:STSCR 08CA 09
Shaft hole semi finish bore


Fig- machine EMT68

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 Station Tool description operation
1 2H CENTER DRILL Gas hole center drill
2 2V STEPPED DRILL Head hole centering
3 3H TWIST DRILL M-35 Gas hole drilling
4 4H TWIST DRILL M-35 Head hole reaming
5 5V REAMER M-35 Gas hole reaming
6 6V HOLE MILL M-35 Head hole milling
7 7H MACHINE TAP M-35 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 Station no. Tool description Operation
1 1 MACHINE TAP M-35 Legs tapping


machine EMT687

body after machine 6

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 Station no. operations
1 2h Drill of 2mm at lower side
of counter at large end
Drill of
2 3h Drill 3mm at upper side of
counter at small end
3 4h Small grooveat upper side
of counter at small end
4 5h Drill of 4mm at lower side
of counter at large end
In above table 2h,3h,4h.5h are various stations here H is direction in
which machine works i.e horizontal.


kingsburry 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.




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.



wmw 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.

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.


PISTON


Piston Grinding Machine






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.

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

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.

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.


Stator Rotor



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.
I n surface treatment, shaft 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

CHAMICAL

QUANTITY

CHANGE IN
1. DE
GREASING-1
Nutrapon 1 Ltr. After 1 week
2. DE
GREASING-2
Nutrapon 1 Ltr. After 1 week
3. De
GREASING-3
Nutrapon
Ltr.
After 1 week
4. WATER
RINSE-1

D.M water Fully tank Over flow

5. ACTIVATION ParocolinMn.(Powder) 1K.g After 3 days
6 . PHOSPATING Parcolubricate+
Nutralizer(Powder)
20 Ltr.+20 cup
(And check
pointage)
After 15 days
7.WATER RINSE-
2

D.M water Fully tank


Over flow

8. PASSIVATION Nutrapon 1 Ltr. After 3 days

ACTUAL pointage,ph and temp. of tanks :
SOURCE POINTAGE PH TEMP.
DEGREASING-1 - 8-10 50-60
DEGREASING-2 - 8-10 50-60
DEGREASING-2 - 8-10 50-60
PH.= 1. FA
= 2.TA
= iron point
=grain size
0.8-1.2 }
6-8} ratio=6-10
1-3
<5

-

90-95
WATER RINSE- 1. 1-3 - -
WATER RINSE- 2. <2 - -
ACTIVATION

PASSIVATION
10-16

-
8-10

9-11
50-60

50-60


Tank of Chemical require to make BODY LINE

TANK CHAMICAL QUANTITY CHANGE IN


1.HOT SPRY
DEGRESING

NUTRPON

2 LTR. IN EVERY
PRT
After 1 week
2. HOT
DEGRESING
NUTRPON

1 Ltr. After 1 week
3. WATER
RINSE
D.M water Fully tank

After 1 days
4. ACID TNK

RESTOKAM 270 Ltr. After 4/5 days
5. suppry
pssivtion



WCI 02

1-1 ltr in evry prt One shift


6DERUSTLK-1

DERUSTLK-1 30 LTR.

After 1 week
7 suppry
pssivtion


suppry
pssivtion

1-1 ltr in evry prt 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
Degreasing of
shell and cover
Spot and
Projection
Welding
Shell and cover
cleaning
Assembly
Feeding
MAG Welding
Leak Testing
Dip Painting
Dehydration
loop1
1
st
Purging
Dehydration
loop 2
2
nd
Purging Oil Charging
Final Testing
(P.D.I.)
Storage and
Dispatch

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.





Raw material

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 190
o
C.




Degreasing of shell & cover



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
1. Stopper broken
2. Compressor motor damage
Stopper
height
variation / tilt
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
Defects Effects

MS Pin
Poor weld strength.
CD out
Broken pin leading to instability of compressor
assembly
Compressor getting noisy

Oil Cup
Poor weld strength.
Position out
Broken oil cup
Oil pin hits oil cup. Fitting of assembly not possible.

Bracket
Poor weld strength.
Position out
Broken bracket
Problem in mounting on refrigerator

GST
Poor weld strength.
Glass seal broken
GST broken
Leakage from GST. Leads to rejection of compressor

Relay
Guard
Poor weld strength.
Position out
Relay Guard broken
Problem in mounting on refrigerator.

Tubes
Poor weld strength
Position out
Tubes broken
Leakage from tubes

The welding temperature at various spot welding machines is in the range of 2000
o
C
to 3000
o
C 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 90
o
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 Model
A2 A1-1
B2 B1-1
Z I8CC
Y I9CC
X I10CC
U 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 CO
2

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
Total
production
Lap 1 Lap
2
Lap 3 Average Only welding
1 54.66 53.97 52.63 53.75 46.00 315(approx.)

2 51.53 51.57 51.19 51.43 47.37 315(approx.)
3 53.88 53.41 53.62 53.64 46.13 320(approx.)
4 50.22 49.12 50.12 49.82 46.94 320(approx.)
5 43.53 42.97 42.36 42.62 42.09 400(approx.)
6 47.62 47.75 47.94 47.77 46.31 400(approx.)
7 46.28 47.53 49.90 47.90 46.97 400(approx.)
8 42.48 41.78 42.06 42.11 39.00 400(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 250
o
C 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 250
o
C 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
250
o
C.




2nd Purging

Similar to 1
st
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 100
o
C 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 Qty. Ideal Residue Value Max. accept value
BODY 5 9mg. 9mg.
CYLINDER HEAD 25 12mg. 25mg.
OIL TUBE 25 10mg. _
SPRING 50 13mg. _
PORT BOLTS 50 12mg. _
STATOR BOLTS 50 15mg. _
NYLON FERRUIE 100 12mg. _
LOCK PIN 25 8mg. _

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 CHEMICALS
1. HOT SPRAY DEGREASING NUTRAPON
2. HOT DEGREASING NUTRAPON
3. WATER RINSE D.M WATER
4. ACID RESTOKAM
5. SPRAY PASSIVATION WCI 02
6. DERUSTALK-1 DERUSTALK-1
7. SPRAY PASSIVATION WCI 02
8. PASSIVATION WCI 02
9. HOT PASSIVATION 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.


PROJECT 2 : Modification in stopper to reduce
stopper defects.

Modification in stopper

The stopper currently being used prevents the spring out situations of the compressor
assembly.

Recently a large increase in rejection of the compressor was observed due to not pumping
defect. This defect is a cause of broken discharge tube. The reason for breaking of
discharge tube is still being searched. In order to reduce the rejection, something had to
be made to prevent the body from touching the discharge tube.

So, a new stopper design was made that would prevent both horizontal and vertical
movement of the body in extreme conditions. This design is still in process of analysis
and has yet not been finalised.



BEFORE AFTE



PROJECT 3 : Analysis of defects seen in components

CRANK SHAFT


Left out (operator mistake) under size (operator mistake)



Casting defect Small groove (drill not working proper)



Connecting rod



Blow hole (casting defect) over size (large cut)




Reamer step not clean Lining (honing not proper)





Valve plate



Seat damage Plate burnt (due to heating)




Left out (grinding not proper) Seat burnt (due to heating)






REFERENCES


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