Nothing endures,But change.

Heraclitus (540 BC - 480 BC)From Diogenes Laertius, Lives of Eminent Philosophers.

DAWLANCE INTERNSHIP REPORT 2008

PREPARED BY:

INTERNSHIP TRAINEES :

DILAWAR KHAN (07-06IN89)MINHAJ-UR-REHMAN (07IN102)UMAIR HAMEED (07IN109)

SUBMITTED TO:

MR. MUHAMMAD FAROOQUE KHATRI(Deputy Manager, QA & EM Department)

PREFACE

This internship report describes the comprehensive information to draw the attention towards the Industrial development in United Refrigeration Industries Limited (URIL).Dawlance industry is leading company in Pakistan due to its qualitative products in according to the safety of environment that is why it is also certified by ISO-9001 and ISO-14001 standards.

The hidden qualities of this Industry: -

I. Supportive managementII. State-of-art technologyIII. Co-operative staffIV. Skilled and meditative workersV. Quality sign of product

The main purpose of this report is to stretch out our practical knowledge with this experience and also about the latest technologies, which are being used, in order to attain the qualitative product by Dawlance.

We are very thankful to the United Refrigeration Industries Limited (URIL) for providing us this opportunity in order to gain more fieldwork knowledge.

BRIEF INTRODUCTION:

The industry was established in 1982 at Hyderabad s.i.t.e by the efforts of BASHIR Dawood (A leading group of companies in the field of home appliances in Pakistan). The name of industry is found to be United Refrigeration Industries Limited beside Dawlance is the familiar name of this industry. The industry is spread over seven Acers. At this plant, only refrigerators are being manufactured.

This industry has a distinct focus on not only the quality product but also on the clean – environment based product and that is the main reason of the Dawlance Refrigerator being as a leading sale product in all over the country.

Nowadays, proficiency is growing in every field. So the Industry is trying to attain the quality, infact it has attained, because quality reveals the product life, and by the long-lasting efforts of United Refrigeration Industries Limited, the industry has achieved the ISO0-9001 and ISO-14001 standards.

Basically, this industry is alienated into following departments:

1. Manufacturing Department.2. Service Providing Department.3. Quality Control Department.

1. Manufacturing Department:

There are four manufacturing departments:

i. Production I. (Molding Department)ii. Production II. (Sheet Metal)iii. Production III. (Body Preparation and Foaming)iv. Production IV. (Assembling and Packing)

2. Service Providing Department:

The service providing departments are those which make sure to manufacture the qualitative product which provides the service to fulfill the requirements of customer.

The Dawlance Pakistan Limited had planned the internship program schedule in the following departments as per due dates for the period of one week training.

DAYS CONCEREND DEPARTMENTS DATE

01ST QAULITY CONTROL DEPARTMENT 23RD JUNE

02ND PRODUCTION – I 24TH JUNE

03RD PRODUCTION – III & IV 25TH JUNE

04TH PRODUCTION – V & VI 26TH JUNE

05TH PRODUCTION – VII 27TH JUNE

06TH PRODUCTION – VIII 28TH JUNE

QUALITY CONTROL RECEIVING:

In QUALITY CONTROL receiving all the materials that comes from outside the industry is being tested. There are three types of inspection and testing:

1) 100% INSPECTION AND TESTING.2) SAMPLING INSPECTION AND TESTING.3) 5 PIECE INSPECTIONS AND TESTING.

1. 100% INSPECTION AND TESTING:The Inspector like compressor test, heating element test, evaporator test, etc, checks all the pieces.

2. SAMPLING INSPECTION AND TESTING:In this test these pieces, which are selected in

sampling test, are selected and then tested. 3 or 4 pieces are correct. They will say otherwise not standard of accuracy depends upon the given standard of selection.

3. 5 PIECE INSPECTION AND TESTING:When the material come in the Lott. The QUALITY

CONTROL Inspector collects some material from those Lott. Suppose if Lott consist of 1000 parts. The QUALITY CONTROL Inspector has to select 315 parts, which is called as sampling test. The purpose of all these inspection and testing is to ensure that the material is according to the quality standard and requirement. QUALITY CONTROL inspector is responsible to perform inspection and supplier premises according to relevant ITI (inspection test instructions).

DOCUMENTATION:

Monitoring and measurement Inspection and testing plan Inspection and testing instructions Purchased order (P.O) Material status report (MSR) Confirmation form (C form) Sample test report (STR) Inspection request form (IRF) Rejected material disposition notice (RMDN)

STAGE INSPECTION:

All the parts, which are manufactured inside the factory, are being tested here. It is in process inspection through which parts are offered as stock for inspection to quality control department through planning and production control department.Following types of inspection and test activities are performed:

1) STAGE INSPECTION AND TEST2) INPROCESS INSPECTION AND TEST3) LABORATORY TEST

IN PROCESS I:There are four types of inspection and test in process I

1) 100% INSPECTION AND TEST2) SAMPLING INSPECTION AND TEST3) ROVING INSPECTION AND TEST4) FIRST PIECE INSPECTION AND TEST

The QUALITY CONTROL inspector is responsible for checking the parts at different stages that either these parts are according to the quality standard. At the time of starting the machine the QUALITY CONTROL inspector inspects the first piece if it is according to the quality standard then the mass production is started.

IN PROCESS II:In process II department consists of:

Production 3 Production 4

Production 3

Foaming test a) Density testb) Destructive test c) Risograph testd) Ratio test

The QUALITY CONTROL inspector is checked that foam is completely filled in cabinet and doors by sound testing. This is the responsibility of the QUALITY CONTROL inspector to check the parts at different stages in the body assembly line.

In process II (production-IV)There are different types of inspection

Electric test Proper function checking Leak checking Packing inspection

Vacuuming Leak check Flow rate checking Charging test

1. Foaming checking2. Door alignment checking3. Gasket checking

4. Thermostat checking

MATERIALS:

The different types of processed plastic materials used in molding department are,

S: NO

NAME TEMPRATURE

1 POLYETHYLENE 180C - 200C2 POLYSTYRENE 180C - 200C3 HIGH IMPACT PS 180C - 210C4 POLYACRILONITRILE 240C - 280C5 STYRENE ACRILONITRILE 250C - 300c6 POLYCARBONATE 280C - 340C

7ACRILONITRILE BUTADIENE STYRENE

190C - 220C

In department of production-I:

The three different types of molding process are,

1) INJECTION MOLDING2) EXTRUSION

CRASHING SECTION:

In this section the raw material is mixed according to the color. They mix the fix ratio with polyester material is launched to the molding section.

1) INJECTION MOLDING :

Raw material used in the shape of pallets sized from 2mm to 4mm, drawn into a hopper from which it goes inside the barrel in which a screw rotates.

The rotation of screw produces friction in between raw material so it melts. This hot melt forces to inject in a desired geometrical mold cavity to produce desired shaped part. The raw material is put into the hopper then comes towards injector when the injector move backward the material is filled and when goes forward with certain pressure the material comes out and poured in to cavity.

In URIL, the injection-molding department is consisting 48 injection molding machines & categories in to series SM & CLF because of various categories by weight or by size etc.

2)EXTRUSION:

This department is consisting on following machine:

Twin extruder machine

Twin extruder machine is used in extrusion. The material used in extruder machine is in powder form poured in to the hopper. Screw rotation takes material inside the barrel, where it melts due to the heating and friction of rotation and injects into the die, which has the mold of desired part.

The material takes out from mold and goes through from size where actual size of part developed and cooling takes place.

After which cutter cuts the part in required size. The important thing of this method is that it gives continuous production without brake.

The production III department of Dawlance is divided into following shops.

1) SHEARING SHOP2) SHEET METAL SHOP3) EVAPORATING MANUFACTURING

MATERIAL USED:

S.No. NAME THICKNESS

1 MILD STEEL 0.6 mm2 GALVONIZED IRON 6.5 mm3 ALUMINIUM 0.45 mm

4VANYLE COATED

MATERIAL0.4 mm

1. SHEARING:

In shearing different metal sheets are sheared for making the parts of the refrigerator like front cross piece, intermediate cross piece, compressor support. The process of shearing takes place on highly advanced pneumatic and hydraulic system machine.

In this department these machines are used:

1) Edward2) Marine3) Colgar4) Electron Mechanical5) Femas6) Colmal Machine

2. SHEET METAL:

In sheet metal department whole cabinet of refrigerator is made.

The different processes such as bending of sheets in desired shape, notching, embossing, making holes, designing on the up door, folding of the corners are take place on the different separate parts of the metals by latest pneumatic and hydraulic machinery. Roller form machine is used for making the cabinet. This machine is automatic machine in which different dies are fixed.In this department 28 machines are used,Names of some machines are given below.

1) 25 ton machine2) Hydraulic press machines3) Balconi4) Fermoreboldi5) Omag6) Dang Bang7) Cabinet roll former8) Olma9) Shinohara10) Wetori

3. EVAPORATING MANUFACTURING SHOP:

In this process first evaporator plate is hanged on the hanger then it goes for the cleaning purpose .The process of cleaning starts from meta-cleaner the evaporator is past then washed by cold water after cold water it goes to normal water then it goes meta-crone. After meta-crone the evaporator is passed again through water the purpose of meta-crone is to catch the polyester color after these processes now evaporator is dried into the drawing section. In drawing section the range of temperature is 150c to 160c. Then the polyester color is colored to evaporator with the help of gunpowder then after polyester color goes to baking oven where the temperature range is 200c to 220c.

CABINET PAINT SHOP WELDING SHOP GRINDING SHOP CONDENSOR MANUFACTURING & PAINT SHOP

CABINET PAINT SHOP: First the cleaning of the cabinet is taken place with the

help of thinner after which the process of phospheting takes place in which chemicals used are metaphos and granodene and cabinet is washed first by normal water and then DI water, before drawing process the air pressure is used for removal or water from cabinet then the cabinet moves towards dry oven where the temperature ranges from 110cto150c.The polyester color is sprayed in paint booth and baked into baking oven at the tempreture ranges from 220cto250c.The time taken by single cabinet for completing of this process is two hours.

WELDING SHOP: Welding is performed for the permanent joint of the two plates, here after the sheet metal where different parts are prepared. At this stage the parts are welded by electric welding like front cross piece or intermediate cross piece welded with cabinet.

GRINDING SHOP: Grinding is performing to removing the extra material of the welding.

CONDENSOR SHOP:Condenser is one of the main parts of refrigerator. In refrigerator there are two types of

condenser are used.i) Rare condenser.ii) Bottom condenser.

Rare condenser:First of all the small strip roll are come in condenser manufacturing shop. These strip are made of mild steel then small strip roll making the wings on the metal roll strip it called as shutter then the shutter cut by the required size then make the right and left side or rare condenser and then joint .We pass the copper tube and welded by the help of spot welding then it goes for coloring process.

Bottom condenser:Also in this process we make the same procedure mention in rare condenser. It is small in size and adjusted in bottom.

Production-V is divided into two major sections, are as under:

1.PRE- FOAMING2.FOAMING:

1. PRE- FOAMING:Pre – foaming is divided into three sub-division:

1. Cabinet preparation2. Liner preparation3.Evaporator preparation

2. FOAMING:

Foaming is carried out for the purpose of insulation.The materials used for foaming are:

ISO SYNITE POLYOL R141B

These three materials are mixed according to fixed ratio, fixed pressure and also fixed temperature. First of all ISOSYNITE and R141B is mixed in the mixer tank by Elastograin machine. When these chemicals are mixed then the POLYOL is mixed with these chemicals now this chemical appears in the form of liquid. Now there were two sections the 1st one where cabinet was filled with foam the filling of foam was injected by the injector in 4 to 6 seconds according to model size.

This process is completed in 5 minutes and another section the refrigerator and freeze door foam filling was performed.

The process involve in the door filling was crazole process, the time filling 3-4 seconds and after filling the material was spread out and risen in the free space and become solid after 5 minutes.

The production - VI department of Dawlance is described as following:

1) BODY ASSEMBLING

In this section the manufacturing parts are assembled. First of all, the holes was pressed for rare condenser on back panel also was connected the main electric wire, then bottom condenser and compressor support plate. The thermostat and heating element are the heating cover and tight up evaporator by the screw. Then adjust the CT cover for hiding the wires. Now the cabinet is ready for fitting the door. The workers fit the refrigerator and freezer door. Now these are converted towards the fitting by conveyor lifter. Then evaporator was checked by help of Micron-meter Machine. This machine measure reading up to maximum 25 microns as necessary. In case of this reading the meters cross the limit, it means the evaporator is leaked. Now the workers clean the valves with nitrogen gas. Then connect the valves in compressor with the help of brazing welding. Those valves were made of copper material; in this position the welder welds the copper electrode. And in case of the material is made of copper and iron silver electrode was used.With the help of flow rate machine the worker measures the vacuum gas in whole circuit. The reading comes to 2.20 between 2.45 and the vacuuming gas is nitrogen. Another Q/C Inspector checks the cabinet leakage and attaches the compressor tray. Then the inspector fills the Freon gas (R12). The weight of gas is depending on the model. In 9170 WB model the weight of gas is 250 grams.After filling the R12 gas then electrical test. Finally the refrigerator moves to functional test. The cycle from electrical test to functional test was completed in 70 to 90 Seconds. The standard temperature is +5 to -5 in functional test. And in last check all the joins of welding by the help of Leak Detector Machine.

2) PACKING:

In the packing section all the refrigerators comes to pack. Before the packing the Q/C Inspector checks the missing items and bad spots inside refrigerators. Then the workers take the refrigerator with plastic cover, foam and company name box.

THERMOFORMING:In this production, Door-liner and Body-liner

preparation takes place through a specific process, called as Thermoforming.The working machines, which are being used

for manufacturing, are ITALIAN made by a company i.e. “PARCO”.

ABOUT MACHINE:It is a vacuum-forming machine, works on the

principles on pneumatic and hydraulic system, totally computerized operating system.

MAIN PARTS OF MACHINE:There are some main parts of these

machines, which are given below:

PLC UNIT (This is the computer-based unit) HEATING UNIT (Heater bank is used in this unit) THERMO REGULATOR (To maintain the temperature) VACCUME PUMP (It controls the pressure exhaust)

The heater bank has two main parts i.e. Upper bank and Lower bank. Both have 160 heaters attached in it.

The melting point is between 115 to 155oC, and the pressure is of 6 bars.

SHELF PREPERATION:In this production, the material of rod is mild-steel

(MS).

PREPERATION PROCESS:First of all, the rod is to be straight and cutting operation with

the help of straight cutting machine. The thickness of the rod is found to be 2.4 mm (the inner rod) and 5.2 mm (the outer rod).

Then the frame is to be prepared with the help of butt joint, and the supported rod is weld together to make a shelf. In the last, cutting the outer edges or extra material in order to make the proper shelf.

When the shelf is completed through these processes, then it is to be passed to the paint shop.

CONDENSOR SHOP:Condenser is one of the main parts of refrigerator. In

refrigerator there are two types of condenser are used.

iii) Rare condenser.iv) Bottom condenser.

Rare condenser:First of all the small strip roll are come in condenser manufacturing

shop. These strip are made of mild steel then small strip roll making the wings on the metal roll strip it called as shutter then the shutter cut by the required size then make the right and left side or rare condenser and then joint .We pass the copper tube and welded by the help of spot welding then it goes for coloring process.

Bottom condenser:Also in this process we make the same procedure mention in rare

condenser. It is small in size and adjusted in bottom.

Though, some areas of thoughts are to be taken accordingly the nature and circumstances, but here I, personally, admit some sentiments, to which I suppose myself taken as a good, on this industry’s behalf…Firstly, what I saw, that is to be define here is the industry has so many critical points, which are the most cautious points rather than distinct points…Secondly, the management in several areas of the industry, by itself, is so curable and the most it will grip itself the most it will attain…

Here, I am going to show-off some points, which I think I should:

There should be some actions, taken in accordance to the worker’s comfort. Like in paint shop, the painter was standing between both heating areas and the powder color paint, which is too harmful, was flying in the air, it can probably damage the worker’s internal system.

There should be some time-rest for the workers, as they are doing their task continuously.

One thing, which I have seen in canteen shop, was that the canteen-workers were not behaving adequately.

The main thing, which is the most-important thing, that is when the internship takes place then the management should prepare the proper day-training-schedule for trainees, as we had the first day in Quality Control Department, although we had not any idea about the production and we were in QC department!!!!!

Second main thing is that there must be training on the first day of trainees, in order to teach the trainees how to make an internship well…

everyday, there should be a small meeting between internship-trainees and management for the period of minimum 30 minutes, and this will help the trainees and management too.

Last word…We are very grateful to the top-management for their unbreakable

support and assisting. We are also very thankful to the workers, who guided us in according to make this internship more and more effective.

What we play is life.Louis Armstrong (1900 - 1971)