Internship Report Haseen Habib Corporation

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Internship ReportBY

UMER JAVED

Submitted To

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Naseeb khan (HR Manager)

Acknowledgment

Firstly I would like to thank Mohsin Hassan Akhter for allotting me Haseen Habib Corporation, HR Manager Naseeb Khan who authorize me to have a magnificent industrial experience, I want to thank Arslan Ahmed , Salman javid, Mohammad Nadeem , Naqash Kazmi and Abdul mateen for helping me in the projects , learning and understanding the processes happening in the factory ,in the last I thank the workers(labor) as most of the things I have leant from the workers.

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Abstract

This report is based on the production of Haseen Habib Corporation.it consist off all the details and step of the manufacturing of the fire extinguishers. the working on the fire knock -off tank to reduce its cost .working on the lean production to increase production of the product and save time, basic firefighting training in which we learnt how to use extinguisher and what to do in the alarming situation. In the end there are some recommendations from my side.

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Table of Contents

Company profile………………………………………………………………………………………………………………………..6

Introduction……………………………………………………................................................................................7

Departments in HHC…………………………………………………………………………...............................7

Fire Extinguishers………………………………………………………………………………………………………..………...8

Manufacturing of fire Extinguishers.............................................................................................8

Procedure............................................................................................................................. 8

Steps.........................................................................................................................................8

Degreasing...................................................................................................................................................8

Welding.......................................................................................................................................................9

Grinding & Polishing..................................................................................................................................10

Hydrostatic Testing....................................................................................................................................10

Powder Painting........................................................................................................................................10

Baking........................................................................................................................................................11

Filling.........................................................................................................................................................11

Assembling parts.......................................................................................................................................11

Pressurizing with nitrogen.........................................................................................................................12

Water Dip Testing......................................................................................................................................12

Labeling.....................................................................................................................................................12

Finishing....................................................................................................................................................12

Types of extinguisher................................................................................................................13

Sizes of fire extinguishers...............................................................................................................13

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Fire Knock-off tank System……………………………………………………………………………………………….

Structure..................................................................................................................................................14

Problem with Fire knock –off System........................................................................................15

Old design..................................................................................................................................... 15

New design....................................................................................................................................15

Results......................................................................................................................................... 15

Lean manufacturing……………………………………………………………………………………………………………….15

Flow Sheet diagram & Results:..............................................................................................................16

Basic Firefighting Training…………………………………………………………………………………………………16

Recommendations………………………………………………………………………………………………………………....17

For Production........................................................................................................................................17

Conclusion………………………………………………………………………………………………………………………………..……18

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Company profile

Haseen Habib Corporation is a private limited company, focusing in the manufacturing and trading of the firefighting and industrial safety equipment. Besides producing a wide variety of firefighting and industrial safety equipment in its own factory .HHC also deals in the trade of the good quality firefighting and industrial safety of components for such equipment produced by the third party domestic or foreign producer As such HHC maintain a complete range of firefighting and safety equipment to satisfy the varied requirement of its customers in Pakistan and foreign market.

HHC is a professionally managed company .established in 1965 as a proprietorship concern, which was change into partnership in 1969 and later incorporated as a private limited company in 1977

HHC proudly claims to be the pioneers in Pakistan in the field of firefighting and industrial safety equipment.

Introduction

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Haseen Habib Corporation is firefighting, safety and security equipment, systems and services - maintaining a wide range. It sells the goods in Pakistan as well as internationally in various countries. The Current MD of the company is Atta ur rehman Barry and Vice MD is Amir Ata Barry. About 60% of the Material is produced in the company while 40% is bought from the market. Since the Fire Safety is a major cause now a day in the global world, the company is progressing rapidly as all the commercial and sensitive areas require safety from fire. Haseen Habib Corporation (Pvt.) Ltd. has received the ISO 9001:2008.

Departments in Haseen Habib

Company has Various Departments. Some of them are mentioned below:

Design Sales and Marketing Procurement Accounting Human Resources(Admin) Quality & Production Engineering

Haseen habib manufacture many products to market at national and international level.

Fire Extinguishers

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A fire extinguisher is an active fire protection device used to extinguish or control small fires, often in emergency situations. Typically, a fire extinguisher consists of a hand-held cylindrical pressure vessel containing an agent which can be discharged to extinguish a fire.

Manufacturing of fire ExtinguishersFire extinguishers are being produce in the several steps in HHC. During the process all steps are important to get good quality result. Following are the steps given below

Procedure

Firstly the cylinders are obtained from the vendors which are ordered by the company .The thick sheet of MS is die punched to produce a cylinder. These cylinders are brought here in the factory and pass through various steps to give it a shape of a fire extinguisher.

Steps

1. Degreasing2. Welding (Co2 for1-12kg)/ (Electric Arc welding for trolley mounted)3. Grinding and polishing4. Hydrostatic testing5. Powder painting6. Baking7. Filling8. Assembling parts9. Pressurizing with N210. Water Dip testing11. Labeling 12. Packing

DegreasingThe cylinder obtained from the vendor is dusted with oil and other impurities .in this process a large container is filed with certain chemical(Washing Soda and casting Soda with half tank water) and cylinder are placed in the chemical and heated at high temperature .Most of the oil and impurities are removed by the process.

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Degreasing of Cylinder

WeldingAfter the degreasing phenomenon welding is carried in which neck ring, barrel and lower dome is welded. Two types of welding processes are being carried out in HHC .One is C02 welding and second Electric Arc Welding.

CO2 Welding of the neck ring of Cylinder

Co2 welding

Co2 welding is use for the cylinders of the1 to 12kg, it produces very fine finish and smooth surface .

Electric arc welding

Electric arc welding is used for cylinder greater than 12kg and trolley mounted.

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Grinding & PolishingAfter the welding stuff the cylinder is grinded with the help of grinding machine and cleaned with the brush in order to make its surface shiny and lustrous.

Hydrostatic TestingThe next step is hydrostatic testing in which the cylinder is pressurized with 25bar pressure for about 5 min. If there is any leakage present it will be revealed in the testing.

Hydrostatic testing of Cylinders

Powder PaintingPowder paint is a next step in which the paint is placed inside and outside the cylinder by electric charge. Inside paint is produced to avoid corrosion in case of water Fire extinguishers.

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Powder painting of the cylinder

BakingBaking is a next step in which a cylinder coated with paint is placed in the oven to firm the paint at about 200®C.

FillingAfter baking filling is taken place in which desired material is placed in the cylinder i-e AFFF or water or halotron etc.

Powder Filling

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Assembling parts Next step is assembling parts, in which valve, pressure gauge, inside pipe and safety pin is attached with cylinder.

Pressurizing with nitrogenAfter assembling the chemical is pressurized with nitrogen gas.

Pressurizing with Nitrogen

Water Dip TestingThe next step is testing leakage by placing the cylinder in water.

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LabelingLabeling is done at the last i-e red for water green for halotron, blue for CO 2, white for DCP and off white for AFFF.

FinishingThe finished product is packed and market to the desired place.

Finished Goods

Types of extinguisher

The Fire extinguishers are classified according to the chemical added in to cylinder. There are following types:

Water filled CO2 filled

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AFFF 4% filled Halotron Filled Dry chemical powder filled

Sizes of fire extinguishers

There are various sizes of fire extinguishers starting from 1 kg which is a single cylinder and there are extinguishers of 6, 8, 12 and 18 kg with respect to their size. These are also classified upon their movement. A trolley mounted extinguisher is also produce here in the factory which is heavy and move by moving the trolley.

Fire knock-off tank systemA large capacity fire extinguisher consist of mixture of AFFF 3%.the companies who cannot afford the fire safety truck are interested in it .as it has all the features it is just need to pull by force from one

place to another.

Fire Knock-off Tank

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StructureThe large tank capacity of 1000 liter is supported by the channel along with the two hoses at the back the hoses are inter-connected by the pipe and to the large tank. the towing hook is attached at the opposite side of the hoses which is used to transport the tank .the man hole is present at the top of the tank, it is used to paint the inner area of the tank .the tank is made up of MS 6mm sheet thickness. Two Nitrogen cylinders are attached at both side of the system to provide pressure to the liquid.it consist of two hooks at the top of the tank to lift it for different purposes and gauge meter are placed to measure the pressure inside the tank.

Problem with Fire knock –off SystemFire knock-off system is a best system a company can have for the fire safety but now its design is old and costly. I worked with the team of Engineers to reduce its cost and made a fresh design and more profitable.

Old designThe previous and old design consist of a full towing system ,a complete triangular assembly at one end of the fire knock off system ,the hose are present at the opposite side of the towing hook system on the checker sheet .

New designThe fresh design is nothing but some changes in the old design. The whole system of the towing is removed and replaced with rod of 3ft,a towing hook at the end along with tow moveable rods used to move the tank sideways .another change thick which cause its design more graceful is removing hoses from the one end and put them on both side of the tank. Checker sheet is removed and a 6mm thick sheet of MS is welded on the tank to place an L joint to support the swing hoses on it. Hoses are connected with each other with a cylinder and T joint and connect with the tank.

ResultsWe had done the cost analysis of our new and old design and it showed that about 20-25 thousand can be saved by implementing these changes and indeed it’s new design was better than the old design and I named it the elephant design due to two hoses on both side illustrating as ears of elephant.

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Lean manufacturing:As I started working in the production I realized that in manufacturing of the fire extinguisher there was a lot of waste like transport, time etc. .the worker had to move a lot as the process is not in the continuous manner rather it is in discrete way so moving to different machines in order to fulfill the task takes a lot of time.

I had worked to make it a continuous process so there would be less waste and more production and more benefits to the labor.

Below is a flow sheet diagram which I made to get a lean production.

ResultsIf we follow this chart waste will be much reduced and production will increase. Originally the material insert is starting from upper side of power paint but I have suggested it to be start in the center making it a U shaped continuous production.

Material insertDegreasingCO2 weldingGrinding

Powder paint

Hydrostatic testing

InventoryPower filling

Assembling N2 fillingLeakage testing

Finished goods

Lathe

LabelingElectric Welding

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Basic Firefighting training

Basic firefighting training is important now a day when fire safety is a major cause. This training makes a person what to do in the emergency situation regarding fire, required all the information regarding extinguishing the fire of any kind.

The training started with the brief introduction to why safety is important and how fire is made (heat oxygen and fuel) moving on to how much to time takes to fire up the room (2min 45 sec) moving further we learnt different type of fires i-e fire from wood, from chemical like petrol, from electronic machines and from the kitchen .then we learnt the importance of leader in the crew of firefighting .the main I learnt was the leader is the one whom you blindly trust.

We played a game regarding trusting the leader which we have listen to the leader to put the pencil into the bottle strings attached and other member’s faces were towards the wall. It was indeed a learning game regarding trust your in every walk of life.

In the last we used the fire extinguisher by our hand and put off the fire which was deliberately burnt.

Recommendations

For Production

No Lean manufacturing in the factory .HHC should adopt Lean manufacturing in order to increase its production.

Lathe machines are requires to be replace by new machine. In current machines chucks are not working properly.

Filling Machines needs to be added in the process because too much filling agent (DCP) is wasted in manual filling.

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Degreasing method needs to be reformed because current process takes a lot of time in heating and cooling of the system.

Hydrostatic Testing system needs maintenance, water pipelines and water pumps needs to be replace by new pipelines and pumps.

Oven temperature gauge and alarm system needs to be replace by new one .it consumes too much time of labor while standing idle.

Expert welder should be appointed because welding quality is not good enough as there are many complaints coming regarding welding stuff.

A proper structure should be design for the welding of fire knock-off tank because in current process it takes much time in rotating and welding.

Hydraulic lifter should be introduced for carrying the goods. Infrastructure should be improved.

ConclusionThe industrial experience of 6 weeks was magnificent and full of learning and gaining knowledge, seen many processes. I have learnt minimizing the cost of the product and making Cost analysis during working on the fire knock-off tank. I implemented the technical skills that I had learnt in the institute. Making the processes in a continuous way .Learnt about basic firefighting in the training overall it was best experience to learn and get familiar with the industrial work.