Internship Report by Adeel Tabassum
Internship Report by Adeel Tabassum
Internship Report by Adeel Tabassum
Acknowledgement................................................................................................................................................................... 4
Historical Background ........................................................................................................................................................... 5
Quality Department ................................................................................................................................................................ 6
1. Incoming Quality Control....................................................................................................................................... 6
1.1) General procedure .......................................................................................................................................... 6
1.2) Local vendors ................................................................................................................................................... 6
1.3) Import (ckd or 3rd source) .......................................................................................................................... 7
1.4) Documents used by IQC ................................................................................................................................ 7
1.5) Procedure of Audit of REF-DF finished goods ...................................................................................... 8
1.6) procedure for control of non-conformity materials/parts ............................................................ 9
1.7) IQC rejection flow chart .............................................................................................................................. 10
2. Process ............................................................................................................................................................................. 11
2.1) U-Shell ..................................................................................................................................................................... 11
2.1.1) Notching........................................................................................................................................................... 11
2.1.2) Semi-notching ............................................................................................................................................... 11
2.1.3) Slotting ............................................................................................................................................................. 11
2.1.4) Punching .......................................................................................................................................................... 11
2.1.5) bending ............................................................................................................................................................ 11
2.1.6) Hemming ......................................................................................................................................................... 11
2.2) Evaporator ............................................................................................................................................................ 12
2.3) Cabinet thermoforming ................................................................................................................................... 12
2.3.1) Thermoforming ............................................................................................................................................. 12
2.4) Cabinet pre Assembly ............................................................................................................................................ 13
2.5) Cabinet and door foaming................................................................................................................................... 13
2.5.1) Free rise density ............................................................................................................................................ 14
2.5.2) Core density ................................................................................................................................................... 14
2.6) Booster line Assembly ......................................................................................................................................... 15
2.7) Door thermoforming........................................................................................................................................... 15
2.7.1) Shelley machine ............................................................................................................................................ 15
2.8) Door bending........................................................................................................................................................... 15
2.8.1) Shearing ............................................................................................................................................................. 15
2.8.2) Punching ............................................................................................................................................................ 16
2.8.3) Bending ............................................................................................................................................................. 16
2.8.4) Notching............................................................................................................................................................ 16
2.9) Door pre-assembly ............................................................................................................................................... 16
2.10) General Assembly line ...................................................................................................................................... 16
2.10.1) Front line ........................................................................................................................................................ 16
2.10.2) Back line ......................................................................................................................................................... 17
2.11) Welding, vacuuming and Gas charging ....................................................................................................... 17
2.11.1) Joining processes ...................................................................................................................................... 17
2.11.2) Vacuuming, gas Charging, safety and leakage tests ................................................................... 19
2.12) Testing room and packing line ....................................................................................................................... 20
2.13) Sample room .......................................................................................................................................................... 20
2.13.1) Low voltage auto re-startability test ................................................................................................. 20
2.13.2) Pull down test ............................................................................................................................................. 20
2.13.3) Temperature rise test ............................................................................................................................... 21
2.13.4) On/off test ..................................................................................................................................................... 21
2.13.5) Pull down test at low ambient .............................................................................................................. 21
2.13.6) High voltage test - WITHOUT load ...................................................................................................... 21
2.13.7) Low voltage test .......................................................................................................................................... 21
2.13.8) Ice making test ............................................................................................................................................ 21
2.13.9) Cooling test at full load ............................................................................................................................ 21
3. Market return unit ....................................................................................................................................................... 22
3.1) Procedure for the categorization of market return units by HNR ................................................. 22
3.1.1) Purpose ............................................................................................................................................................. 22
3.1.2) scope .................................................................................................................................................................. 22
3.2) Procedure: Part (a) Market return units .................................................................................................. 22
3.2.1) B+ category.................................................................................................................................................... 22
3.2.2) B category ...................................................................................................................................................... 22
3.2.3) C Category ...................................................................................................................................................... 23
3.2.4) D Category ..................................................................................................................................................... 23
3.3) Procedure: Part (B) Process defective units ........................................................................................... 23
3.3.1) MRU B Category unit ................................................................................................................................ 23
3.3.2) MRU C Category unit ................................................................................................................................ 23
3.3.3) MRU D Category unit ............................................................................................................................... 24
ACKNOWLEDGEMENT
I am very thankful to Manager QA Mr. Ayaz Khalil for providing me opportunity to work for one
of the best multinational companies in the world. I also appreciate the determination and
whole hearted support of Mr. Abdul Razzaq (Asst. Manager IQC), Mr. Abdul Rasheed (Asst.
Manager), Mr. Muhammad Sajid (Asst. Manager), Engr. Abdul Rehman (MRU) and Engr. Farhan
Ahmed for guiding and helping me through this internship.
HISTORICAL BACKGROUND
Haier Group is a Chinese multinational consumer electronics and home appliances company. Its
Headquarter is in Qingdao, China. It designs, develops, manufactures and sells products
including air conditioners, mobile phones, computers, microwave ovens, washing
machines, refrigerators, and televisions.
The company has production plants all over the world including Indonesia, Malaysia, United
States, Jordan, Tunisia, Nigeria, Egypt, Algeria and South Africa, Italy, India.
In Pakistan HAIER was established in 2002 and after that it has slowly taken over the HVAC
industry and right now is the biggest seller of Refrigerators and Air conditioners all over
Pakistan with the lowest market complaint rate.
QUALITY DEPARTMENT
Quality department is further divided into following sections:
1) Local
2) Import (CKD or 3rd source)
1) JW
2) SVA Ruba
3) Multi tech
4) EPS
5) AL Fatah
6) Thermin
7) Ravi
1.3) IMPORT (CKD OR 3RD SOURCE)
Imported material is divided into following categories:
1.3.3) 3 RD SOURCE
Parts are imported from the other countries other than China like Korea, Germany etc.
Inspection criteria of local and imported materials are same. 5% samples are randomly drawn and then
checked according to the drawings made by R&D.
If material is completely defected it is sent back to the supplier or claim is sent for the rejected parts. If
material is partially defected in such a way that its usage in unit wouldnt affect any decrease in quality
then Exceptional Release of that material is done.
CLAIM
Sr. Container G.P Part Description Model UoM Packed Rejected Reason
no. no. Code code qty. qty.
PURPOSE:
Its purpose is to implement a smooth and controlled mechanism to avoid cosmetic, aesthetic
and quality complaints from market
PROCEDURE:
To resolve problems from marketing regarding Ref-DF finished goods
An audit of packing line is conducted on weekly basis in Ref-DF factory in which HPK CSD, HPK
logistics, HNR audit will also participate
In audit if problem found will be categorized in three ways A, B and C
If problem in category A is found, then production of that product will be immediately stopped
If problem in category B found, then 5 marks will be deducted
If problem in category C found, then 3 marks will be deducted
Standard of 80 marks is set by QA department
If total marks after B and C are found 80, then product is ok.
PURPOSE:
The purpose of this method is to implement smooth and controlled mechanism for material
rejection handling.
PROCEDURE:
PART A: NON CONFORMITY PARTS AND MATERIALS FROM SUPPLIER
Inventory/ IQC
Feedback to PPC/Souring
Rejection
Import Claim Close
IQC
After Import
Inventory Ok
rework material
2.1) U-SHELL
U-Shell is made of CR (Cold rolled) sheet whose thickness varies from 0.6 mm. U-Shell is made on U-Shell
bending machine. Sheet metal processes that are happening on U-Shell bending machine are as follows:
2.1.1) NOTCHING
It is the process in which portion of metal is cut from the side of sheet or strip.
2.1.2) SEMI-NOTCHING
This process involves cutting of portion of metal from the inside of the sheet.
2.1.3) SLOTTING
2.1.4) PUNCHING
2.1.5) BENDING
1st bending is done on the side of the CR sheet and then bending of sheet is done at the end by U-Shell
bending machine to turn it into U shape material
2.1.6) HEMMING
This process involves bending of the sheet over on itself in more than one bending step. This is often
done to eliminate the sharp edge on the piece, to increase stiffness, and to improve appearance
2.2) EVAPORATOR
Evaporators are bent into the required shape according to Ref. and Freezer unit
Freezer evaporator is joined with Ref. evaporator and Capillary tube is brazed with freezer
evaporator line using Oxy-LPG brazing method
The joint is copper to copper joint.
After that nitrogen gas is filled to flush all the dust particles that could cause the blockage
Vacuuming is done
Now after vacuuming, helium is gas is filled in the evaporator.
Now the evaporator is passed through helium testing machine to check the leakage in
evaporator
Welding rod used has 94% copper in it
Distance between torch and joint is 25mm
Inside dia. of evaporator line is 7-8mm
2.3.1) THERMOFORMING
Thermoforming is a process in which a flat thermoplastic sheet is heated and
deformed into the desired shape. Thermoforming consists of two main steps: heating and
forming. Heating is usually accomplished by radiant electric heaters, located on one or both
sides of the starting plastic sheet at a distance of roughly 125mm (5in). Duration of the heating
cycle needed to sufficiently soften the sheet depends on the polymerits thickness and color.
Methods by which forming is accomplished can be classified into three basic categories:
1- Vacuum Thermoforming
2- Pressure Thermoforming
3- Mechanical Thermoforming
Since Vacuum thermoforming is used here, so I will discuss vacuum thermoforming procedure
only.
In Cabinet thermoforming mold is preheated so that ABS sheet doesnt get stuck with it while
thermoforming. A separate circuit of water is used which is used to preheat the mold and when the
temperature of mold get past the required temperature, hot water supply to the mold is turned off by
the automatic valves and an alternative supply of cold water is turned on. Both these circuits of water
help us to maintain the temperature of mold according to our requirement.
1. Polyol
2. Iso-Cyanate
3. Cyclo-pentane
Polyol and Cyclo-pentane are mixed with each other in the ratio of 8.3:1
They are then transferred here and stored in the container
Agitating motor is used to mix the mixture of Polyol and Cyclo-pentane
The pressure maintained in the container is 2-4 bar
Then this mixture of Polyol and Cyclo-pentane and Iso-Cyanate is transferred to the injection
head
Both of these come in different nozzles and then when the stroke is made they mix with each
other
The injection pressure is 110-150 bar
Ratio between Polyol and Iso-Cyanate is 1.28 for door and 1.26 for the cabinet
Mass flow rate for door is 490 g/s and for cabinet is 1400 g/s
The amount of injection of is different for different type of Refrigerators and Deep Freezer
Free rise density is calculated and it came out to be 24 kg/m3
Core density was calculated and it came out to be 37 kg/m3
Gelation time for the door foam was 50 sec and for the cabinet foam was 51 sec
Pouring temperature is 18-24 degree Celsius and it reaches up to 60 degree Celsius when it is let
to expand freely in an open air
After foaming jig is kept closed for about 6 min. This is called Curing time
Surface temperature of the jig is 35-50 degree Celsius
Surface temperature of the mold is 40-50 degree Celsius
Following are the operations that are performed on door bending line:
2.8.1) SHEARING
In this process sheet of Refrigerator and Freezer compartment is separated from each other by the
shearing action and cut into two halves.
2.8.2) PUNCHING
2.8.3) BENDING
2.8.4) NOTCHING
1- Front line
2- Back line
After foaming door is transferred to after foaming station where compressor mass is placed and body is
generally cleaned and then transferred to general assembly line
Thermostat is placed inside the cabinet and its connections are made with the harness cable
Lock hinge at the mid beam is placed
Vegetable box is placed and crisper plate is placed over it
Shelves are placed inside the cabinet
Gift box is placed
Doors of freezer and Ref. compartments are placed
Door handles are placed
2.10.2) BACK LINE
Compressor is placed
Drain pipe extension of freezer compartment is placed
Connection of harness cable with compressors are done
Gasket is placed and condenser is bolted to the body through that gasket
1- Welding
2- Brazing
3- Soldering
In brazing and soldering, base metal doesnt melt and joint is made by melting filler rod. While in
welding joint is made by melting the base metal and then filler metal is added to it to make the joint.
As in brazing and soldering base metals doesnt melt so the difference among them exists in working
temperatures. If the melting temperature of filler metal is greater than 450 degree Celsius and less than
melting point of base metal then this process is called brazing and if the melting temperature is less than
450 degree Celsius then it is called Soldering.
2.11.1.1) BRAZING
Brazing is a joining process in which a filler metal is melted and distributed by capillary action between
the faying surfaces of the metal parts being joined. No melting of the base metals occurs in brazing; only
the filler melts.
There are various methods used in brazing. Referred to as brazing processes, they are differentiated by
their heating sources. Torch Brazing is used here, so we will discuss the process of torch brazing only.
Copper filler rod is generally used when base metal is copper and Silver filler rod is generally
used when base metal is titanium, Nickel, Steel etc. In our case silver rod is used when the base
is Mild steel because our condenser is composed up of Mild steel.
For
Welding
For
Brazing
Normally Acetylene, Hydrogen, MAPP (methyl-acetylene propadiene) are closely associated with
welding processes while on the other hand propane and natural gas are more closely associated
with brazing and soldering.
After cooling system is transferred to packing line where cleaning of unit is done and then system is
packed into their cartons and they are sealed tight by packing strip
1- Insulation strength
2- Performance at load shedding
3- Cooling speed
1- Compressor restart
2- Performance in load shedding condition
3.1.1) PURPOSE
Its purpose is to implement smooth and controlled mechanism for categorization and sale of
market return and process defective units
3.1.2) SCOPE
The procedure is applicable on following departments:
QA HNR
Audit dept. HNR
Finance dept. HNR
Logistics dept. HNR
3.2.1) B+ CATEGORY
This category is based on the following problems:
Moisture problem
Any sale return made by product manager
Warehouse return unit
Discontinued model
Sale return made on no fault
Display units
Slightly yellow liner
3.2.2) B CATEGORY
This category is based on following problems:
body deformed
Low cool
Liner cracked (not repairable)
Rusted (repairable)
Sheet loose
3.2.3) C CATEGORY
This category is based on the following problems:
Internal leakage
System completely choked
3.2.4) D CATEGORY
This category is based on the following problems:
Completely rusted
Completely damaged
These kind of units are broken down for analysis and to study the root cause of the problem by QA
and R&D. Rest of the units are sold as per HNR policy.
Liner yellow
Line cracked
Short foaming
Liner or body loose
R&D samples
HQ samples
SKD defective units
Any trial defective units
Damage in process
Damage during trial production
Dummy units
Internal leakage
Body mid beam press
Liner press
Fins press
3.3.3) MRU D CATEGORY UNIT
All those cabinets and doors that are severely damaged during process would be considered in HNR
D category units
MRN will be made for the process related damages and process defective units (C and D) except the
B+ category units and submit it to inventory department