Condenser Manufacturing

8/13/2019 Condenser Manufacturing

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Mohit Tomar &

Devinder SinghB.E. (mech)

Graphic Era

University


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Incorporated and promoted in 1992 by Mr Kartar Singh, the Amber Group isamong other things, one of the largest original equipment manufacturer ofwhite goods in India. One factor that has led us this far is our relentlessfocus on quality. At the Amber Group we follow strict quality processes andwe are an ISO 9001 - 2008 certified company. Under the aegis of the AmberGroup there are two distinct entities: Amber Enterprises India Pvt. Ltd. andAmber Aviation India Pvt. Ltd. . Amber Industries is a conglomerate of 9manufacturing units that are involved in producing original equipment for

some of the biggest brands in India while Amber Aviation is engaged inaircraft charters and training of commercial pilots.

Some of top white good brands are L.G Videocon Godrej

Whirlpool Blue Star Philips Voltas


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Chairman

Organization Chart (Unit-6)

Managing Director

V.P(Operation)

G.M(Manufacturing) H.R(Head) G.M(Finance)

Manager

(H.R)

Exec

utive

(H.R)

Manager

Executive

Finance

Manager

(Store)Manager

(Quality)

Manager

(Production)

Manager

(Manufacture)

Executive

(Store)

Senior

Engineer

Engineer Senior

Production

Engineer

Production

Engineer

Senior

Manufacture

Engineer

Executive

Manufacture

Engineer

Senior

Engineer

Total Staff:-100

G.M:-02

Manager:-12

Engineer:-86


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Split & Window Air Conditioners for commercial and residential use . Package Air Conditioners for Indian Railways and commercial use.

Heat Exchangers.

Multi Flow Condensers.

Home appliances like Washing Machines, Refrigerators &

Microwaves. Luminaries for commercial use.

Plastic Extrusion Sheets.

Vacuum Forming Components.

Injection Molding Components.

Sheet Metal Components. Auto Parts.


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Reliability lab

Incoming quality control

Line quality control

Pre dispatch inspection

New Product Development


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Preparing slots in plain pipes in press shop. Fin formation and assembly of condenser in

fin forming and core assembly machine.

Pre-inspection of fixture. Condenser fixture is passed in thermal

degreaser to vaporize oil.

Flux is applied on the condenser for brazing


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Condenser is then passed through preheatchamber to dry the flux.

In heater chamber brazing is done through 5heater zone. Temperature ranges from590oCto 615oC.

Condenser is passed through air cooling

room for cooling of the condenser, liquid N2is used.

Manual brazing of inlet and outlet valve isdone.


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Water leak test and helium test is done tocheck any leakage in the condenser.

Condenser is passed through dry oven

input core handle to dry the condenser fromany liquid.

In final inspection area, through nitrogenflushing it is determined whether the gas is

passing through the inlet valve to the tubesand finally through the exit valve.

Other problems are also checked in the finalinspection area.

Through Nitrogen purging gas is stored inthe condenser.


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1) Check sheet2) Pareto Diagram

3) Fish Bone Diagram

4) Monitoring


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S.No Model

No.

Problems Production Fault

Products

Percenta

ge

Cum.

Perc.

Remarks

Date- 5th-july-2013

1. UD6P Bracket

Shift

300 8 100% 100% -

2. - Bracket

Tilt

- 0 - 100% -

Here we represent our problems in the formof table.

For eg.


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1. Works on 80-20% Rule.2. In this diagram we choose which particular

problems we have to solve.3. It represents in graph form.

4. It has two y-axis. Firstly on left hand sideis represented as primary axis whichcontains fault products, and secondly righthand side is represented as secondary axis

which shows cum. Percentage, and X-axisrepresents problems which we face whilemanufacturing of condensor.

REJECTION PPM TREND JUNE 2013


15/28Leadership Through Innovation Quality,Cost,Deliver

REJECTION - PPM TREND JUNE 2013

80% REJECTION DUE TO 20%

REASON


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1. we collect all the reasons regarding the problems causedby the different factors like man, machines, method ,materials and write these reasons in their columns.

2. Then we relate those problems with the above concerns

whether the problems were actually caused by them or not.

Bracket Tilt

ManMachine

Method Material


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Man


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Machine


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Material


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Method


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Process S No Problem CauseMan 1 Unskilled Worker

O

2 Not Proper HeightO

3 Not Proper Sitting ArrangementO

4 Not Proper Handling of HeaderP

5 Not Proper Handling during assemblyP

6 Error while measuring the distance

through vernier caliperO


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Process S No Problem CauseMethod 1 When worker do not work as

guided by engineerO

2 Wrong method of applying liquidflux

O

3 Wrong method of doinghammering

O

4 When correct spacing is notprovided between two condenser

O

5 Wrong method of packing of

condenserO


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Process S No Problem CauseMachine 1 Machine not work at desired

temperatureO

2 Wrong shape of fixtureO

3 Variation in supply of electricity O4 Not proper maintenance of

machineO

5 Machine can have wear and tearO


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Process S No Problem CauseMaterial 1 Not correct composition

O

2 May melt during brazingO

3 Material may not have low

coefficient of linear expansionO

4 Not highly machinableO

5 Low weldabilityO

6 May not be corrosion resistance

O


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0

20000

40000

6000080000

100000

120000

Bracket Tilt in ppm

Bracket Tilt in ppm


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Here the work which we were doing are beenchecked out by the authority aligned to them.


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Handling of the header should be taken withcare.

After the fitting of bracket the work should behandled properly.

At assembly area the headers should not betouched as it has not been permanently joined.

Inspection should be done properly to avoidwastage after brazing, bracket tilt can bechecked and removed at the inspection areabefore brazing.


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Documents

Condenser Manufacturing