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URIL DAWLANCE REFRIGERATORS Ltd HYDERABAD.

Internship Report.

Group Leader: Tahir Ahmed (12ME01)

Other Group Members:

Nazakat Memon (12ME43)

Naimatullah Khushk (12ME147)

Waqas Ahmed Dars (12ME81)

Shahzaib (12ME03)

Dept. of Mechanical Engineering.

MEHRAN UET JAMSHORO.

(Report made by: Nazakat Memon.12ME43).

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Day-1

A little introduction to purpose of this industry. Introduction to Maintenance.

Maintenance:

“ It is the process to increase the service life of any machine or of any object.”

Factory contains a workshop for the maintenance of different machinery parts. There are lathe machines, etc and also welding can be done in that workshop.

For the maintenance of factory vehicles, another shop is built.

Due to crises of electricity in our country, there are about 8 stand by generators in the factory, they can produce about 3.5 Mega watts of electricity by consuming diesel as fuel. Most generators were of CAT Company.

The main product of the factory is “REFRIGERATORS”.

Day-2

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Production-1

This section contain 4 shops like molding (injection molding of plastic) shop, sheet extrusion shop, gas kit shop & the forth one in which the internal frame of the refrigerators was being made from plastic sheets coming from sheet extrusion shop.

Further parts of refrigerator like cabinets, etc were being made in Injection molding shop. In that shop the machines having a die exerts force(pressure) on the melted plastic to get the desired component of desired shape.

In Gas kit shop, the rubber seals i-e air tight seals for the doors of refrigerators were being made. In gas kit shop, the cooling of output material(i-e after processing) was done by a system like a refrigerator, that’s why it is called Gas Kit shop.

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Day-3

Production-II

We moved to the section Production-II.

It includes three sections i-e shearing, sheet metal work, and last one is welding.

In production-II, the whole body of refrigerator is made i-e the whole work of metal is done in this part of the factory.

First of all the standard size sheet & coils of required metals are brought from different factories, from our country and also from foreign countries. These coils & sheets are brought to shearing section in which the metal is cut to required dimensions & sizes, so that these parts can be used in forming the refrigerators.

The materials were of different metals like mild steel, ABS plastic, VCM material, GI, Aluminum, etc.

The sheets were being cut to make different parts of the frame of refrigerators like cabinet sheets, ref: door, freezer door, front cross piece, compressor support sheet, side panel, intermediate cross piece, etc.

Then these required pieces were brought to the sheet metal section, in which further processes were being done on those pieces like knoching, bending to convert these sheet pieces into required 3-D part of the frame. As to convert cabinet sheet into the u-type cabinet sheet, first the knoching was done with the help of a die exerting force on the sheet & then bending was done by a machine with the name OLMA then we move to the

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welding section. After sheet metal working the different individual parts are brought to the welding section, where the spot welding is done to join the parts to make the whole structure of the refrigerator.

Spot welding is a type of welding that joins two materials by melting them at a point. After the joining process i-e welding process these frames or we can say the skeleton of refrigerators were brought to painting section with the help of conveyer belt.

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Day-4

Production-V

Today we moved to the production-v section of the factory. It contain four sections.

i-Pre foaming. (i-e door pre foaming & cabinet pre foaming)

ii-Foaming. (i-e door foaming & cabinet foaming)

iii-Assembly line.

iv-Packing.

Pre foaming is the process that is done on the metallic body of the ref; and door before foaming to prevent leakage of foam.

After painting the cabinet is brought to the pre foaming section then first of all a back side panel is attached to the back side of cabinet body then evaporator & thermo pole frame of refrigerator are fixed to the metallic cabinet and finally taping is done and same is done for doors. Now, the cabinet is brought to foaming section.

The foam is combination of 3 materials, that are inserted into body after mixing with very high pressure in bars. Then undergoing some exothermic reactions into the body, these materials now make the foam in solid form, initially was in liquid form. Same process is done for doors.

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The foam is made by the combination of following three materials:

a) Polyolb) R141B (help to spread and rise the foam)c) Isocynite.

Foam is filled in the body and doors to give the stability and proper shape to the refrigerator.

Day-5

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Assembly line

Now the body and doors moved to the assembly line.

First of all compressor Cabot(support) is fitted at the bottom through nut and bolts.

LEDs and regulators are installed. Bottom condenser is fixed. Doors are attached with hinges. Compressor is fitted, freezer pipe is fixed. After this, condenser is fitted at back side. Then all the wiring is done. Then welding is done join compressor, evaporator lining. Now, cleaning of linings of evaporator and compressor is

done with vacuum cleaning machine, this process continues up to 30 minutes.

After cleaning process, the refrigerant R134 is filled with nozzle for 20 seconds.

Then finally quality is checked(i-e checking electrical faults, etc).

Then cooling temperature and all faults are checked with the help of sensors (process is of 70 minutes).

Then “DAWLANCE” monogram is attached.

Day-6

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Paint shop

First phosphating is done on the cabinets, coming from production-ii through conveyer belts, then powder painting is done by robots with injector slue.

Then cabinet is baked so that painting can be strong.

HSE & COMPLIANCE

Health & Safety Environmental control and Compliance department plays a vital role in prevention from accidental incidents and hazardous chemical reactions during working and minimizing it.

Impact of the heavy machinery and hazardous chemical reactions on our surrounding and the workers can’t be completely finished but it can be minimized and actions for minimizing it, is the responsibility of HSE department and several procedures are made for this purpose, these procedures, logs and documentation of the procedures is maintained by compliance department.

Priority parameters of liquid effluent and gases emissions, drinking water tests, tests of food provided by canteen, medical test of workers, etc are maintained by HSE department. HSE department organize every year tests of HIV, Hepatitis, and other tests for the

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workers who work under the influence of chemical reactions like in plastic molding shop or paint shop, etc. If any impact of chemical reactions or noise effect of machines is observed on any worker of industry causing effect to his health, then workers will be transferred to other departments. If any accident happens, causes damage to worker’s health, there will be facility of first aid or hospitalization in case of emergency and management will pay all the expanses.

PPEs are provided to workers for safety working and sensors are fixed in the machinery to prevent accidents. It is the responsibility of each department to co operate with HSE dept by maintaining the disciplinary actions as directed by HSE.

Several procedures are made to implement in each section of the industry to prevent accidents and documentation of each procedure and the report of each incident and actions taken to remove the thing which can cause incidents, log of all these and documentation will be made by compliance department.

THE END.