PROJECT REPORTONONE SEMESTER INDUSTRIAL TRAININGGODREJ & BOYCE MFG. CO. LTD,APPLIANCES DIVISION,MOHALI, PUNJAB

SUBMITTED BY:

PARMEET SINGH ROLL. NO. 1103335B.TECH (MECHANICAL ENGG.)

UNIVERSITY COLLEGE OF ENGINEERINGPUNJABI UNIVERSITY, PATIALAPUNJAB

INDEX

Sr. No.DESCRIPTION

1DECLARATION

2ACKNOWLEDGEMENT

3INTRODUCTION OF THE ORGANIZATION

4PRODUCTS

5PARTICULARS OF THE MOHALI PLANT

65S SYSTEM IN GODREJ

7KAIZEN

8INTRODUCTION ABOUT PLANT AND ALLOTED DEPARTMENT

9PROJECT NO 1

10PROJECT NO 2

11REFERENCES

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 organizationThe Godrej Group

InceptionEstablished 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.

AgriAnimal 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 : 28TH 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.

COMPRESSOR PLANTCOMPRESSOR

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.The various components of reciprocating compressor:-1. Shell 1. Cover 1. Body 1. Stator 1. Rotor 1. Cylinder Head 1. Piston 1. Shaft/Crank 1. Connecting Rod1. Gudgeon Pin 1. Lock Pin 1. Spring 1. Oil Tube 1. Muffler 1. Valve plate 1. Reed 1. Retainer 1. Suction Gasket 1. Suction Reed 1. Discharge Gasket 1. MS Plug 1. Oil Cup 1. Relay Guard 1. Glass Seal Terminal 1. Discharge Tube 1. Suction Tube 1. Charging Tube 1. Coil/Port Cover 1. Nylon Ferrule 1. Bolts 1. Piston Washer 1. Shaft Washer 1. Copper bolt Washer 1. Holding Rubber 1. Stopper 1. Stopper Plate 1. Port Cover Washer 1. Pedestal 1. Muffler Rubber 1. Rubber GST 1. Rubber of suction , discharge, charging tube 1. Pedestal rubber

The compressor plant is divided into various departments Machine Shop Surface treatment Metrology Department Assembly Department Unit Department Maintenance Department Tool Room Store Cutting Section Quality Department

Layout of the Compressor Plant

COMPRESSOR MACHINE SHOP

COMPRESSOR BODY SHAFT VALVE PLATE CONNECTING ROD PISTON G PIN

1.RAW COMPRESSOR BODY:- it is made of cast iron material come from vendor NEWMAN & SATYAM. Machines in cms shop:- 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.noStation Tool descriptionoperation

12HInsert:TCMT 110204Hub facing and outer dia chamfer

22VInsert:M 8065 1204Head face rough milling

33HInsert: OFKR 070408Leg face rough milling

44HCARTRIDGE:STSCL 10CA11Insert:TCMT 110204Shaft hole drill and outer dia turning

54VInsert:M 8065 1204Head face semi finish milling

65VSOLID CARBIDE DRILL DIA24*134Piston hole drilling

76HSTEPPED DRILL- M35Leg hole centering

87HCARTRIDGE:SCGCR12 CA 12INSERT:CCMT120408Leg face facing

98HHSS DRILL DIA 4.5 MMCOUNTER SINK TOOLShaft hole chamfer and leg hole drilling

109HCARBIDE BRAZED HOLE MILLShaft hole milling and leg hole milling

Fig-front view of machine EMT682

Fig body before 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.noStation Tool descriptionoperation

12HCENTER DRILL M-35Gas hole drilling

22VINSERT:CCMT09T308INSERT:CCMT120408Seat facing and chamfering

33HInsert:TCMT 060204HSS DRILL 5.1MM JOBBER SERIESPort hole drilling and conter boring

44HTWIST DRILL M35HSS DRILL 4.5MM LONG SERIESGas hole drilling

55VHSSE SILVER CUT TOP M06Port hole tapping

66VEND MILL CARBIDE BRAZEDU slot milling

77HHSS DRILL DIA 5.1MM JOBBER SERIESLeg relief hole drilling

87VHSS MARKING TOOLBody marking

98HHSS HOLE MILL REAMERGas hole reaming

Fig-front view of machine EMT683

Fig-back view of machine EMT683

Fig-body after machine 2

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.noStation Tool descriptionoperation

1HSS DRILL DIA 5MM LONG SERIESHSS COUNTER SINK TOOL DIA 33MMDRILLING 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.noStation Tool descriptionoperation

12HFACE MILL DIA 80MMHead face finish milling

23HINSERT:CCMT09T308Piston hole semi finish bore

33VInsert:CCMT 060204Insert:TCMT 110208Shaft hole semi finish bore

44HInsert:CCMT 060204Insert:TCMT 090208CARTRIDGE:STSCR 08CA 09Piston hole finish bore

54VInsert:TGCT 060104CARTRIDGE:STSCR 08CA 09 Insert:TCMT 06T108KFCARTRIDGE:STSCR 08CA 09Shaft hole semi finish bore

Fig- machine EMT685

Fig-body after machine 4

Machine 5-EMT 686:- it is a third machine in body line.it do 7 operations on the body. It is also a SPMs.noStation Tool descriptionoperation

12HCENTER DRILLGas hole center drill

22VSTEPPED DRILLHead hole centering

33HTWIST DRILL M-35Gas hole drilling

44HTWIST DRILL M-35Head hole reaming

55VREAMER M-35Gas hole reaming

66VHOLE MILL M-35Head hole milling

77HMACHINE TAP M-35Head 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. noStation no.Tool descriptionOperation

11MACHINE TAP M-35Legs tapping

Fig -machine EMT687 Fig-body after machine 6

Grinding RoomMACHINE-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.

Fig-12wmw centreless cylindrical grinding machineMACHINE-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.

Fig 13 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.

Fig-14 piston Fig-15piston grinding machine

Shaft CellMachine 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.noStation no.operations

12hDrill of 2mm at lower side of counter at large end Drill of

23hDrill 3mm at upper side of counter at small end

34hSmall grooveat upper side of counter at small end

45hDrill 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.

Fig-16kingsburry 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.

Fig -20 deep hole dfrilling machin

Other Components Of Comperessor1.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.

Fig-21 oil tube2.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

Fig 22 muffler cap3.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.

Fig 23 piston4. 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.

Fig 24 rotor fig 25 stator

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. In surface treatment, shafts 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 RINSE5. ACTIVATION 1 6. ACTIVATION 2 7. PHOSPHATING1 8. PHOSPHATING 2 9. WATER RINSE 210. PASSIVATION 11. OVEN 112. OVEN 2

Chemical require in tanks to make Mn. Phospating system : TANKCHAMICALQUANTITYCHANGE IN

1. DE GREASING-1Nutrapon1 Ltr.After 1 week

2. DE GREASING-2Nutrapon1 Ltr. After 1 week

3. De GREASING-3Nutrapon Ltr. After 1 week

4. WATER RINSE-1

D.M waterFully tankOver flow

5. ACTIVATIONParocolinMn.(Powder)1K.gAfter 3 days

6 . PHOSPATINGParcolubricate+ Nutralizer(Powder)20 Ltr.+20 cup(And check pointage)After 15 days

7.WATER RINSE-2

D.M waterFully tank

Over flow

8. PASSIVATIONNutrapon1 Ltr.After 3 days

Testing of Tanks:-

1. PHOSPATING: There is 3 type of testing is:

* FREE ACID (FA) * TOTAL ACID (TA) * IRON POINT.

*FA: 2ml. chamical ph. + 5-6 drop of water + 5-6 drop of Bromo Green solution + sodium hydroxide (NaOH) [Actual pointage = 0.8-1.2] *TA: 2ml. ph. chamical + 5-6 drop of water + 5-6 drop of Phenol pythylon + sodium hydroxide (NaOH) . [Actual pointage = 6-8] *IRON POINT: 100ml. chamical ph. + 5-6 drop orengr methylene Pottesium permagnet. [Actual pointage = 1-3] 2. WATER RINSE -1: 100 ml. W.R + 5-6 drop of orengr methylene + sulphuric acid (H2SO4). [Actual pointage = 1-3] 3. WATER RINSE-2: 100 ml. W.R + Phenol pythylon + sodium hydroxide (NaOH).[Actual pointage =