Project Report 11

5/25/2018 Project Report 11

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PROJECT REPORTON

thMONTH INDUSTRIAL TRAININGGODREJ BOYCE MFG. CO. LTD,

APPLIANCES DIVISION,MOHALI, PUNJAB

SUBMITTED BY:PARMEET SINGH

ROLL. NO. 11103335B.TECH MECHANICAL ENGG.)

GROUP- 4ME6

UNIVERSITY COLLEGE OF ENGINEERINGPUNJABI UNIVERSITY PATIALAPUNJAB


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INDEX

Sr. No. DESCRIPTION

1 DECLARATION

2 ACKNOWLEDGEMENT3 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

DEPARTMENT9 PROJECT NO 1

10

11

PROJECT NO 2

PROJECT NO 3

12 REFERENCES


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DECLARATION

I, Parmeet Singhstudent 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.


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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)


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Introduction of the organizationThe 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 trustedbrand,

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 careto name a fewour

turnover crosses 3.3 billion dollars*. You think of Godrej as such an integral part

of Indialike the bhangara or the kurtathat 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. Withbrands 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


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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 customerswith 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 indirectcooling 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.


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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.


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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 theproducts 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.


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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


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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.


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PRODUCTS

AppliancesOfferings 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.


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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.


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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.


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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.


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Real Estate

Residential, commercial and township developments.

AV Solutions

Display solutions, audio video conferencing solutions, electronic copy boards.

Chemicals

Oleo chemicals and surfactants.


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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.


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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.

.


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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 : 28THFEBRUARY, 1996.


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5S SYSTEM IN GODREJ


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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.


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KAIZENKaizen(

?), 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.
http://en.wikipedia.org/wiki/Help:Installing_Japanese_character_setshttp://en.wikipedia.org/wiki/Help:Installing_Japanese_character_setshttp://en.wikipedia.org/wiki/Help:Installing_Japanese_character_sets


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There are three plants in this division these are:

1.COMPRESSORPLANT

2.REFRIGERATOR PLANT

3.WASHINGMACHINE


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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


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ASSEMBLEDCOMPERSSOR


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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 Terminal25.Discharge Tube

26.Suction Tube

27.Charging Tube

28.Coil/Port Cover

29.Nylon Ferrule


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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


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Layout of the Compressor Plant


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COMPRESSORMACHINESHOP

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


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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


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Machine 1-EMT 682:- It is a SPM(special purpose machine) doing

variety of different operatins on same workpiece. there are 14 stations onthis 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 ho

drilling

10 9H CARBIDE BRAZED HOLE MILL Shaft hole milling and leg hole


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Fig-front view of machine EMT682

Fig body after 1 machine


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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:


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


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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:


1 HSS DRILL DIA 5MM LONG

SERIES

HSS COUNTER SINK TOOL

DIA 33MM

DRILLING AND CHAMFERING

Fig-body after machine 3 Fig- machine EMT684


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Machine 4-EMT 685:-it is a third machine in body line.it do 5operations 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 operation1 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


Insert:TCMT 06T108KF


Shaft hole semi finish bore

Fig- machine EMT68


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Machine 5-EMT 686:-It is a third machine in body line. It do 7operations on the body. It is also a SPM


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


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Machine 6-EMT 687:-It is a third machine in body line.it do 1operation 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


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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. operations1 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


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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.


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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 thethrough which the finishing of shaft is checked.


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wmw centreless cylindrical grinding machine

MACHINE-2 CNC MACROMATIC GRINDING

MACHINE:-It is a CNC grinding machine with PLC panel installed withit.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 indifferent direction to each other.

CNC MACROMATIC GRINDING MACHINE


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MACHINE-3 PISTON GRINDING:-The piston is the main part ofthe compressor. There is different piston for different compressor according to

the size and capacity of compressor.

PISTON

Piston Grinding Machine


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OTHER COMPONENTS OF COMPERESSOR

1.Oiltube: This is a metallic tube which is used to lubricate the shaft andother 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 thecompressor after the whole cycle completion. There is small restriction on oneside 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


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3.Piston :-The piston is the main part of the compressor.There is differentpiston for different compressor according to the size and capacity of

compressor.

Piston

4. stator and rotor : The stator is rotatory windning of aluminiumwiring. 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


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SURFACETREATMENT

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 sur face treatment, shaft is coming after al l

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.


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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 12. DEGREASING 23. DEGREASING 34. WATER RINSE5. ACTIVATION 16. ACTIVATION 27. PHOSPHATING18. PHOSPHATING 29. WATER RINSE 210.PASSIVATION11.OVEN 112.OVEN 2


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Chemical require in tanks to make Mn.

Phospating system :

TANK CHAMICAL QUANTITY CHANGE IN

1. DEGREASING-1

Nutrapon 1 Ltr. After 1 week

2. DEGREASING-2

Nutrapon 1 Ltr. After 1 week

3. DeGREASING-3

Nutrapon Ltr.

After 1 week

4. WATERRINSE-1

D.M water Fully tank Over flow

5. ACTIVATION ParocolinMn.(Powder) 1K.g After 3 days6 . PHOSPATING Parcolubricate+Nutralizer(Powder)

20 Ltr.+20 cup(And checkpointage)

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



PH.= 1. FA= 2.TA= iron point

=grain size

0.8-1.2 }6-8} ratio=6-10

1-3


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Tank of Chemical require to make BODY LINE

TANK CHAMICAL QUANTITY CHANGE IN

1.HOT SPRYDEGRESING

NUTRPON 2 LTR. IN EVERYPRT

After 1 week

2. HOTDEGRESING

NUTRPON 1 Ltr. After 1 week

3. WATERRINSE

D.M water Fully tank After 1 days

4. ACID TNK RESTOKAM 270 Ltr. After 4/5 days

5. supprypssivtion

WCI 02 1-1 ltr in evry prt One shift

6DERUSTLK-1 DERUSTLK-1 30 LTR. After 1 week

7 supprypssivtion

supprypssivtion

1-1 ltr in evry prt One shift

8 Pssivtion WCI 02 1 Ltr. After 1 week


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UNITSHELL

The process flow diagram for a compressor in the compressor unit

shell department is shown below.

Raw materialfrom supplier to

PMQ

Degreasing ofshell and cover

Spot andProjectionWelding

Shell and cover

cleaning

Assembly

Feeding

MAG Welding

Leak Testing

Dip PaintingDehydration

loop1

1stPurging

Dehydrationloop 2

2ndPurging Oil Charging

Final Testing(P.D.I.)

Storage andDispatch


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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


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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 andthen 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 190oC.

Degreasing of shell & cover


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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 broken2. 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.


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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 2000oCto 3000

oC with current ranging from 20KA to 46KA.


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Shell and Cover CleaningThe 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 11th

tank

is the air blower.

Hot waterSurfakleen 399X

Normal water

Normal water

Surfapickle-77

Normal water

Normal water

Protobond 40/5

Normal water

Surfalyte 8M

Air blower


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Functions of different chemicals:-

Surfakleen 399X The major ingredient in this chemical is Caustic Soda. Itsfunction 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. Itsfunction 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 40/5This chemical enters into the pores present on shell and cover.

Surfalyte 8MIt is used as a passivation chemical so that the shells and coversdont react when come in contact with air or other particles.


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Assembly Feeding StationHere discharge tube is bent to 90

oand 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 andputs 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


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MAG WeldingIt 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 gasCO2

ElectrodeCopper 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

machinenumber

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.)


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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 PaintingRubber 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.


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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) ovenwhich heats the compressor at 250oC 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 250oC 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.


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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 compressorfrom 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 ensurean entirely moisture free compressor. The temperature in this oven is again set at

250oC.


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2nd Purging

Similar to 1stpurging, 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 preventexternal 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.


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1) CENTRIFUGAL PROCESS:

It is used for removing the moisture and impurities present in oil.

Firstly the oil is heated to a temperature of 100oC 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.


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Storage and Dispatch

The OK compressors from PDI move to storage area from where they are

dispatched to various customers.


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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 .


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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 weightinitial weight (mg.)

Chemical use in testing Tetrachloroethylene or Plorochloroethylene.

How to clean bodyThere 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 028.PASSIVATION WCI 02

9.HOT PASSIVATION WCI 02


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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.


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PROJECT2: 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


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PROJECT3:Analysis of defects seen in components

CRANK SHAFT

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

Casting defect Small groove (drill not working proper)


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Connecting rod

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

Reamer step not clean Lining (honing not proper)


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Valve plate

Seat damage Plate burnt (due to heating)

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


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REFERENCES

www.godrej.com

www.wikipedia.com

www.micromaticgrinding.com

www.docstoc.com
http://www.godrej.com/http://www.godrej.com/http://www.wikipedia.com/http://www.wikipedia.com/http://www.micromaticgrinding.com/http://www.micromaticgrinding.com/http://www.docstoc.com/http://www.docstoc.com/http://www.docstoc.com/http://www.micromaticgrinding.com/http://www.wikipedia.com/http://www.godrej.com/

Project Report 11

Documents

Transcript of Project Report 11