Mohit Tomar

B.E. (mech)
Incorporated and promoted in 1992 by Mr Kartar Singh, the Amber Group is
among other things, one of the largest original equipment manufacturer of
white goods in India. One factor that has led us this far is our relentless
focus on quality. At the Amber Group we follow strict quality processes and
we are an ISO 9001 - 2008 certified company. Under the aegis of the Amber
Group there are two distinct entities: Amber Enterprises India Pvt. Ltd. and
Amber Aviation India Pvt. Ltd. . Amber Industries is a conglomerate of 9
manufacturing units that are involved in producing original equipment for
some of the biggest brands in India while Amber Aviation is engaged in
aircraft charters and training of commercial pilots.

Some of top white good brands are
L.G
Videocon
Godrej
Whirlpool
Blue Star
Philips
Voltas

Chairman

Organization Chart (Unit-6)
Managing Director
V.P(Operation)


G.M(Manufacturing)
H.R(Head) G.M(Finance)
Manager
(H.R)
Executive
(H.R)
Manager
Executive
Finance
Manager
(Store)
Manager
(Quality)
Manager
(Production)
Manager
(Manufacture)
Executive
(Store)
Senior
Engineer
Engineer
Senior
Production
Engineer
Production
Engineer

Senior
Manufacture
Engineer

Executive
Manufacture
Engineer
Senior
Engineer
Total Staff:-100
G.M:-02
Manager:-12
Engineer:-86
Split & Window Air Conditioners for commercial and residential use .
Package Air Conditioners for Indian Railways and commercial use.
Heat Exchangers.
Multi Flow Condensers.
Home appliances like Washing Machines, Refrigerators &
Microwaves.
Luminaries for commercial use.
Plastic Extrusion Sheets.
Vacuum Forming Components.
Injection Molding Components.
Sheet Metal Components.
Auto Parts.

Reliability lab
Incoming quality control
Line quality control
Pre dispatch inspection
New Product Development
Preparing slots in plain pipes in press shop.
Fin formation and assembly of condenser in
fin forming and core assembly machine.
Pre-inspection of fixture.
Condenser fixture is passed in thermal
degreaser to vaporize oil.
Flux is applied on the condenser for brazing


Condenser is then passed through preheat
chamber to dry the flux.
In heater chamber brazing is done through 5
heater zone. Temperature ranges from
590
o
Cto 615
o
C.
Condenser is passed through air cooling
room for cooling of the condenser, liquid N
2

is used.
Manual brazing of inlet and outlet valve is
done.
Water leak test and helium test is done to
check any leakage in the condenser.
Condenser is passed through dry oven
input core handle to dry the condenser from
any liquid.
In final inspection area, through nitrogen
flushing it is determined whether the gas is
passing through the inlet valve to the tubes
and finally through the exit valve.
Other problems are also checked in the final
inspection area.
Through Nitrogen purging gas is stored in
the condenser.

1) Check sheet
2) Pareto Diagram
3) Fish Bone Diagram
4) Monitoring
S.No Model
No.
Problems Production Fault
Products
Percenta
ge
Cum.
Perc.
Remarks
Date- 5
th
-july-2013
1. UD6P Bracket
Shift
300 8 100% 100% -
2. - Bracket
Tilt
- 0 - 100% -
Here we represent our problems in the form
of table.
For eg.
1. Works on 80-20% Rule.
2. In this diagram we choose which particular
problems we have to solve.
3. It represents in graph form.
4. It has two y-axis. Firstly on left hand side
is represented as primary axis which
contains fault products, and secondly right
hand side is represented as secondary axis
which shows cum. Percentage, and X-axis
represents problems which we face while
manufacturing of condensor.
Leadership Through Innovation Quality,Cost,Deliver
y
REJECTION - PPM TREND JUNE 2013
80% REJECTION DUE TO 20%
REASON
1. we collect all the reasons regarding the problems caused
by the different factors like man, machines, method ,
materials and write these reasons in their columns.
2. Then we relate those problems with the above concerns
whether the problems were actually caused by them or not.

Bracket Tilt
Man
Machine
Method
Material




Man




Machine




Material




Method
Process S. No. Problem Cause
Man 1 Unskilled Worker
O
2 Not Proper Height
O
3 Not Proper Sitting Arrangement
O
4 Not Proper Handling of Header
P
5 Not Proper Handling during assembly
P
6 Error while measuring the distance
through vernier caliper
O
Process S. No. Problem Cause
Method 1 When worker do not work as
guided by engineer
O
2 Wrong method of applying liquid
flux
O
3 Wrong method of doing
hammering
O
4 When correct spacing is not
provided between two condenser
O
5 Wrong method of packing of
condenser
O
Process S. No. Problem Cause
Machine 1 Machine not work at desired
temperature
O
2 Wrong shape of fixture
O
3 Variation in supply of electricity
O
4 Not proper maintenance of
machine
O
5 Machine can have wear and tear
O
Process S. No. Problem Cause
Material 1 Not correct composition
O
2 May melt during brazing
O
3 Material may not have low
coefficient of linear expansion
O
4 Not highly machinable
O
5 Low weldability
O
6 May not be corrosion resistance
O
0
20000
40000
60000
80000
100000
120000
Bracket Tilt in ppm
Bracket Tilt in ppm
Here the work which we were doing are been
checked out by the authority aligned to them.