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But change.
Heraclitus (540 BC - 480 BC)
From Diogenes Laertius, Lives of Eminent Philosophers.
DAWLANCE INTERNSHIP REPORT 2008
PREPARED BY:
INTERNSHIP TRAINEES:
SUBMITTED TO:
I. Supportive management
II. State-of-art technology
III. Co-operative staff
IV. Skilled and meditative workers
V. Quality sign of product
Manufacturing Department:
There are four manufacturing departments:
DOCUMENTATION:
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 TEST
2) INPROCESS INSPECTION AND TEST
3) LABORATORY TEST
IN PROCESS I:
There are four types of inspection and test in process I
1) 100% INSPECTION AND TEST
2) SAMPLING INSPECTION AND TEST
3) ROVING INSPECTION AND TEST
4) FIRST PIECE INSPECTION AND TEST
IN PROCESS II:
In process II department consists of:
• Production 3
• Production 4
Production 3
• Foaming test
a) Density test
b) Destructive test
c) Risograph test
d) 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 • Vacuuming
• Proper function checking • Leak check
• Leak checking • Flow rate checking
• Packing inspection • Charging test
1. Foaming checking
2. Door alignment checking
3. Gasket checking
4. Thermostat checking
MATERIALS:
The different types of processed plastic materials used in molding department are,
S: NAME TEMPRATURE
N
O
1 POLYETHYLENE 180C - 200C
2 POLYSTYRENE 180C - 200C
3 HIGH IMPACT PS 180C - 210C
4 POLYACRILONITRILE 240C - 280C
5 STYRENE ACRILONITRILE 250C - 300c
6 POLYCARBONATE 280C - 340C
ACRILONITRILE
7 190C - 220C
BUTADIENE STYRENE
In department of production-I:
1) INJECTION MOLDING
2) 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.
1) SHEARING SHOP
2) SHEET METAL SHOP
3) EVAPORATING MANUFACTURING
MATERIAL USED:
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.
1) Edward
2) Marine
3) Colgar
4) Electron Mechanical
5) Femas
6) 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 machine
2) Hydraulic press machines
3) Balconi
4) Fermoreboldi
5) Omag
6) Dang Bang
7) Cabinet roll former
8) Olma
9) Shinohara
10) Wetori
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- FOAMING
2.FOAMING:
1. PRE- FOAMING:
Pre – foaming is divided into three sub-division:
1. Cabinet preparation
2. Liner preparation
3. 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.
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.
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…
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.