Acknowledgements

It was indeed a time of great honor and concern, to be at such a corporation

where excellence, performance and reliability of multinational level is being
conveyed in such a supreme transparency. Either it is contribution of labor or the
safety of the environment the performance was continuously being monitored on
its broadest scale.
We are grateful to all the staff of the Dawlance Private Limited, ranging from
laymen to the supervisors who have contributed their best in order to deliver the
fruitful knowledge of nearly each and every single process.
In short, we are indebted to DPL to concerning us at such an initial level.
Although, it sounds hard to deliver such knowledge to younger internees but the
company successfully manipulated the task quite easily.
Table of Contents

1. Production-I (Plastic Molding Section)

2. Production-II (Shearing, Sheet Metal)
3. Production-III (Paint Shop, Cabinet Shop)
4. Production-IV (Handle Preparation, Condenser Mfg.)
5. Production-V (Assembly Line, Pre-Foaming, Foaming)
Deep Freezer (Assembly, Pre-Foaming)
6. Maintenance and Utilities
7. Quality Control
Production-I (Plastic Molding Section)
In production 1 plastic moulding and process related with plastic moulding takes place. In plastic
moulding process. Moulding is the process of manufacturing by shaping liquid or pliable raw material using
a rigid frame called a mould or matrix this itself may have been made using a pattern or model of the final
object. In URIL Under Production-I plastic injection moulding is used for making different parts like
vegetable self, Rap self and other plastic parts which are fitted in the refrigerator. Different plastic injection
moulding machine of different sizes are used to make different parts.
Injection moulding:
Injection moulding (injection moulding in the USA) is a manufacturing process for producing parts
by injecting material into a mould. Injection moulding can be performed with a host of materials, including
metals, glasses, elastomers, confections, and most commonly thermoplastic and thermosetting polymers.
Material for the part is fed into a heated barrel, mixed, and forced into a mould cavity, where it cools and
hardens to the configuration of the cavity. After a product is designed, usually by an industrial designer or an
engineer, moulds are made by a mould maker (or toolmaker) from metal, usually either steel or aluminium,
and precision-machined to form the features of the desired part. Injection moulding is widely used for
manufacturing a variety of parts, from the smallest components to entire body panels of cars. Advances in
3D printing technology, using photopolymers which do not melt during the injection moulding of some
lower temperature thermoplastics, can be used for some simple injection moulds.

Thermoforming:
Thermoforming is a manufacturing process where a plastic sheet is heated to a pliable forming
temperature, formed to a specific shape in a mould, and trimmed to create a usable product. The sheet, or
"film" when referring to thinner gauges and certain material types, is heated in an oven to a high-enough
temperature that permits it to be stretched into or onto a mould and cooled to a finished shape. Its simplified
version is vacuum forming.
In its simplest form, a small table top or lab size machine can be used to heat small cut sections of plastic
sheet and stretch it over a mould using vacuum. This method is often used for sample and prototype parts. In
complex and high-volume applications, very large production machines are utilized to heat and form the
plastic sheet and trim the formed parts from the sheet in a continuous high-speed process, and can produce
many thousands of finished parts per hour depending on the machine and mould size and the size of the
parts being formed.

Thermoforming differs from injection moulding, blow moulding, rotational moulding and other
forms of processing plastics. Thin-gauge thermoforming is primarily the manufacture of disposable cups,
containers, lids, trays, blisters, clamshells, and other products for the food, medical, and general retail
industries. Thickgauge thermoforming includes parts as diverse as vehicle door and dash panels, refrigerator
liners, utility vehicle beds, and plastic pallets.
Edward machine was used to perform the task efficiently and effectively. ABS material was used to
form the inner cabinet with a ratio of 85:15 fresh to scrap ratio.
Production-II (Shearing, Sheet Metal)
Shearing:
To shear off the requires size of sheet is called a shearing process.

Sheet Metal:
The various process that has been performed over the metal sheet shop result into the final shape on
the piece. Number of Parts are manufactured and shaped in this section. The sheet metal section is basically
based upon the 4 major areas which are as follows.
1. Automatic sheet feed
2. Whole processing and notch (bending)
3. Forming section
4. Pressing section

The sheet metal is basically used to produces number of parts of refrigerator, which include
1. Cabinet
2. PC sheet
3. Freezer door
4. Basic panel
5. Side panel
6. Compressor support
7. Ref door and many more

Welding Section:

Basically welding is the process of permanent fastening therefore is the section all or same part are to
fastened by tug welding so that the required type and shape of cabinets is to be shift the painting shop. At
sheet metal the welding section is used to perform that activity so that the form bended and imposed cabinet
is to be welded with the back panel and sight panel and the it is screwed with the compressor support. At the
end of the welded section the welded cabinet is to be shift to the paint shop for the further paint processing.
OLMA Machine is considered as the heart of sheet metal production shop.
Production-III (Paint Shop)

It is basically the painting section used to paint the various iron so that it could be transferred into the
final assembly shop. It includes

1. CABINET painting shop.

2. EVAPORATER painting shop.
3. CONDENSOR painting shop.
4. DIP- COATING (Shelf painting shop)
We had already discussed the dip-coating (shelf painting) and here now we learned the cabinet and
Evaporator painting.

Cabinet Painting Shop

As we know that whenever we are painting anything first of all we need phosphating process so that
The cabinet is to be easily painted. The cabinet here though the following painted stages.

STAGES # 1: High pressuring over the refrigerator so that to remove as the welded particle.

STAGES # 2: PHOSPHATING
The phosphating if condenser is to be done by passing through the no. of condenser to various
chemicals which is in the tank. First of all, the manufactured condenser is dipped into the met clean 375 tank
and it stayed over there at 1 to 5 min. Now the condenser is then dipped into the fresh rinsing water into the
2nd tank. After that it is to be dipped into the tank of metaphor 247 chemical tank. And after that through
pressure vessel it is to be dried. At the end of phosphating the condenser supports to shift into the dry oven.

STAGE # 3: DRY OVEN

STAGE # 4: POWDER ROOM
STAGE # 5: BACK OVEN
Painting
The painting begins when JOTUN powder is to be paint over the condenser after phosphating on
both sides of condenser and this condenser with the help of crank is to be inserted into the back oven so that
powder is to be converted into the layer of painted colour. The temperature of back oven is about to be of
250 degrees centigrade and it is placed within the back oven for the period of 11 min. It is important that the
JOTUN powder use in condenser painting section if of different form and have its own load.
Production-IV (Assembly Line, Pre-Foaming, Foaming)

Till production we are making, painting the certain parts so that they should combined to form the
original product. The production V ( i-e PRE – FOAMING ) as the name suggest it is the pre of the foaming
that is it the place where the various operation is to carried before it is to be placed to formed. At the pre
foaming the necessary item such as the liner, freezer and ant moisture tube, evaporator are to be inserted into
the actual body of cabinet.
Pre-Foaming Process
The actual process of pre-foaming is a start when the painted cabinets from the cabinet painting shop
are comes to the pre-foaming zone. We can underline the each and every step of pre foaming now,
STEP # 1: First of all the compressor support is un-screwed from the painted cabinet.
STEP # 2: The gum- type material named as slant is to be inserted into the corner edge of the painted cabinet
in order to make proper isolation.
STEP # 3: Washer type material is tape within the four whole if the back panel so that condenser is to be
screwed easily in it.
STEP #4: Bottom profile is inserted within the embossing area in the bottom.
STEP #5: spaces in fixed in the back panel so that the pipe which is fitted in it.
STEP #6: Groomer also fitted with the wholes.
STEP #7: Anti moisture strip a black pipe is to be inserted within the profile cabinet.
The anti-moisture strip has two functions first as the name suggest its used to prevent from the corrosion
effect also the gas kit ( rubber type ) within the door is causes to crack because of cooling inside so it is also
prevent this as it is connected with the compressor.
STEP # 8: the freezer box is to be further includes the following sub- systems Sub – step 1:- the
painted evaporator from the EMD is bend by the press machine.
Sub-step 2:- the bended evaporator is then to be check for the little inspection.

Foaming Section
The foaming section is a place when the pre-foamed cabinet is to for the automated machine. The
foam which is to be inserted within the pre-foamed foam than it is solid within a few minutes. The foam is
basically made of two different type of chemicals.
1. Polyol
2. Iso–cyanide
3. R141A (a gas which is used as a catalyst) or CP (Cyclo pentane)
The foaming section has the capacity to filled 81 mould foam hour i-e capacity = 81 mould foam
per hour.
Process of Foaming

The process of foaming section begins by fixing the jigs and fixture the ref section so that while
foaming the inside the refrigerator is not bend After that the highly automated the mixture of foam is to be
inserted within cabinet.
The Dawlance has 9 moulding foam hangers which is highly automated and operate according to the sensors
and actuators and various other things. Basically the mixing of chemicals as to form the foam is to be as:
100 % of polyol
126 % of iso-cyanide
16 % of R141A or CP

Assembly line

This is the very last portion of this shop also the refrigerator manufacturing. At this stage the all parts
that we have made in deferent section such as sheet items or main body items we made in sheet metal
section, plastic items we have marked in moulding, shelf we have made in respective productions, freezer
and ref door also assembled Therefore is assembling shop we assemble all items to make the refrigerator. At
the end certain inspection made refrigerator takes such as vacuum generation and then the Freon gas is also
inserted into the refrigerator. At the end of assembled line, the refrigerator is to be packed and transferred to
the store room as an inventory so that it is it be distributed.
There are various sections those are comes under production V category Shelf
making section
1. Condenser
2. Bottom condenser
3. Iron handles making section
4. Galvanized section
5. Chrome section
6. U-V light section

Production-V Deep Freezer (Assembly, Pre-Foaming, Foaming)

The each and every process followed here was same as in the case of refrigerator; the matter that is
of our major concern is the shapes of inner cabinet and its accessories and integrated parts.
Maintenance and Utilities
Today, in modern industry, equipment and machinery are a very important part of the total
productive effort than was the case years ago. Moreover, with the developments of special purpose and
sophistical machines, equipment and machinery cost a lot more money and therefore their and does time
becomes much more expensive. For this reason, it is vitally important that the plant machinery should be
properly maintained.

Objectives of Plant Maintenance

1) The objective of plant maintenance is to achieve minimum breakdown and to keep the plant in good
working condition at the lowest possible cost.
2) Machines and other facilities should be kept in such a condition which permits them to be used at
their optimum (profit making) capacity without any interruption or hindrance.
3) Maintenance division of factory ensures the availability of the machines, buildings, and services
required by other section of the factory for the performance of their function at optimum return on
investment whether this investment be in material, machinery or personnel.

Importance of Plant Maintenance

1) The importance of the plant maintenance varies with the type of the plant and its production.
2) Equipment breaks down leads to the inevitable loose of production.
3) An improperly maintained or neglected plant will sooner or later requires expensive and frequent
repairs, because with the passage of the time all machines or other facilities (such as transportation
facilities), buildings, etc. wear out and need to be maintained to function properly.
4) Plant maintenance plays a prominent role in production management the plant breaks down create
problems such as, Loss in production Rescheduling of production Split material (because sudden
stoppage of process damages in-process materials). Failures to recover overheads (because of loss in
production hours). Need for over time. Temporary work shortage- workers require alternative work.

Maintenance at DLP
At Dawlance DPL there is a separate maintenance which constitute of several engineers, technicians,
and a skilled labor. Their work is basically based upon the team efforts in which each person’s has certain
responsibilities. This section is centrally connected but all other section of industry by means of computer
network software (ORACLE) and also within the telephone. They use to work into different format first they
have collect the data of all bug to small machines procession and divided these data of each part of machine
into various activities and also assign a scheduled of maintenance of each activity so that to work
accordingly. The second format on which they work is that whenever any break down occur in a production
as per receive the compliance of particular maintenance they work upon it. Except production work there are
other areas such as puncher shop, compressor maintenance shop, generator maintenance, electrical
maintenance department.

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Quality Control
Quality
Though there are no. of definition of quality but in very simple works it can be term as “To meet the
Customer’s specification”.

Control
The provision to control the action or plan is to be control so that to meet the
requires as per planned.

Quality Control
Quality control refers to the control level of quality is that to lead to the customer satisfaction.
• It is the provision under which the proper and effective quality it to be obtain so that to
lead the market position.
• In an organization the term quality is as big as it can and under a no. of quality units are
working their work to inspect the ongoing activity as per standard and then mark as OK,
HOLD, USAI, REOWRK & SCRAPE.

Quality Control at DPL

The quality is given the major reliability at Dawlance and therefore the
central quality control department is being divided in different quality section
i) Quality engineering cell ii) Incoming quality control iii) Quality assurance
iv) Self quality at each manufacturing section v) Quality process lab.
And many other departments

Quality Control Manual

It is basically a manual that can help the operator to perform the work takes as it includes all type of
activities. These are those type of manual which use to perform the training function to the operation
because its includes set of instruction of every used item

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