Industrial Internship Report

PROJECT REPORT

WHIRLPOOL OF INDIA LIMITED

FOOD PROCESSING GRINDERS BENCHMARKING

INDUCTION COOK-TOP FIELD FAILURE ANALYSIS

AC DEFECT STUDY

WINE CHILLERS FEASIBILITY STUDY

RO PURIFIER PDI

Submitted by

Ashish Rekhi

Roll No: 101158003

Under the Guidance of

Mr. Devender Kumar Mr. N Krishna

Faculty Coordinator Deputy Manager

NPP PDC DEPTT

Department of Mechanical Engineering

THAPAR UNIVERSITY, PATIALA

June 2014

2 THAPAR UNIVERSITY, PATIALA

DECLARATION

I hereby declare that the project work entitled “FOOD PROCESSING GRINDERS

BENCHMARKING, INDUCTION COOK-TOP FIELD FAILURE ANALYSIS,AC

DEFECT STUDY,WINE CHILLERS FEASIBILITY STUDY AND RO PURIFIER PDI”

Is my own work carried out at Whirlpool Of India Ltd.,Faridabad as requirements of my six

months project semester for the award of degree of B.E. (Mechanical Engineering), Thapar

University, Patiala, under the humble guidance of Mr. N Krishna and Mr. Devender Kumar,

during January to July 2014.

Roll No: 101158003 Ashish Rekhi

Date: 16 July 2014

Certified that the above statement made by the student is correct to the best of our knowledge

and believe.

Mr. Devender Kumar Mr. N Krishna

Assoc. Professor Deputy Manager

Thapar University NPP-PDC Deptt.

Whirlpool of India Ltd, Faridabad


ACKNOWLEDGEMENTS

As I begin to reflect on the magnitude of this project report, i am reminded of the celebrated

quarterback who sprints on to the field in the last quarter of the game, confers in the huddle,

confidently strides out to the line of scrimmage and throws the perfect spiral pass fifty yards

downfield into the end zone to score the winning touchdown. The fans cheer, the coaches are

thrilled and the quarterback joyously revels in the glory of winning the game. But it was a team

effort, for a team makes each individual achieve more. I have never been known to have words

fail me , but as i begin to put on paper the feelings i have towards the people who changed my

heart , soul & thought , I am overwhelmed . There is a difficulty in assigning a hierarchy since it

has been a true team effort from the beginning.

I take this opportunity to acknowledge the invaluable support and guidance given by Mr. Rakesh

Bhatia (sr. Manager) and Mr. N Krishna (Deputy Manager) for putting his faith in me and

leading me through the projects. Sir, thank you for being a light

My humble and heartfelt acknowledgements are also to my esteemed teacher guide Mr.

Devender Kumar, for his guidance and support without which this task would not have been

accomplished.

Ashish Rekhi


Contents

Department of Mechanical Engineering ....................................................................................................... 1

DECLARATION ............................................................................................................................................... 2

ACKNOWLEDGEMENTS ................................................................................................................................. 3

SUMMARY ..................................................................................................................................................... 7

COMPANY PROFILE ....................................................................................................................................... 9

PLANT BLOCK DIAGRAM ......................................................................................................................... 11

ABOUT WHIRLPOOL CORPORATION ....................................................................................................... 11

THE HISTORY ........................................................................................................................................... 12

WHIRLPOOL CORPORATION TODAY ....................................................................................................... 12

THE WHIRLPOOL VISION AND MISSION .................................................................................................. 12

WHIRLPOOL WENT THE GLOBAL WAY .................................................................................................... 13

Worldwide product line ...................................................................................................................... 14

Product Portfolio ................................................................................................................................. 15

Refrigerators ....................................................................................................................................... 16

Washing Machine ............................................................................................................................... 17

100% Dryers ........................................................................................................................................ 18

Air Conditioners .................................................................................................................................. 19

Microwave Ovens ............................................................................................................................... 20

Purafresh RO Range ............................................................................................................................ 21

UPS ...................................................................................................................................................... 21

NEW PRODUCT DEVELOPMENT .................................................................................................................. 22

NPP Department ................................................................................................................................. 24

Block Diagram of the procedure of NPP ............................................................................................. 24

Product Development Steps ............................................................................................................... 25

Press Shop ............................................................................................................................................... 29

Assembly Line ......................................................................................................................................... 36

PROJECT NO. 1 ............................................................................................................................................ 39

FOOD PROCESSING GRINDERS BENCHMARKING AND DESIGN INNOVATION ........................................ 39

BRIEF SUMMARY OF GRINDERS: ......................................................................................................... 40

GRINDER MECHANICS: ........................................................................................................................ 41

TYPES OF BLENDERS: ........................................................................................................................... 43


NEED FOR THIS PROJECT: .................................................................................................................... 44

METHODOLOGY: ................................................................................................................................. 44

NOISE TEST .............................................................................................................................................. 46

POWER TEST............................................................................................................................................ 50

TEST CYCLE NO. 1: ............................................................................................................................... 50

TEST CYCLE NO. 2: ............................................................................................................................... 53

RPM TEST ................................................................................................................................................ 56

OPERATIONAL TEST ................................................................................................................................. 58

DATA SIMLULATION ................................................................................................................................ 60

PROJECT 1[B]: DESIGN INNOVATION ...................................................................................................... 63

LOCKING MECHANISM ........................................................................................................................ 65

PROJECT NO. 2 ............................................................................................................................................ 67

INDUCTION COOK-TOP FIELD FAILURE ANALYSIS ................................................................................... 67

INTRODUCTION ....................................................................................................................................... 68

FIELD FAILURE CAUSE ............................................................................................................................. 70

THEORY 1: Voltage Supply Fluctuation ............................................................................................... 70

THEORY 2: Nature of the Vessel Used ................................................................................................ 70

THEORY 3: Fault in PCB Design ........................................................................................................... 72

DOE OF THE OLD AND NEW PCB DESIGN ............................................................................................... 73

FORMULATING FACTORS ........................................................................................................................ 73

PROJECT NO. 3 ............................................................................................................................................ 75

MANUFACTURING AND FIELD LEVEL DEFECTS IN AIR CONDITIONING UNITS........................................ 75

INTRODUCTION ....................................................................................................................................... 76

MANUFACTURING LEVEL DEFECTS ......................................................................................................... 77

NEED OF THE PROJECT: ....................................................................................................................... 77

JANUARY 2014 .................................................................................................................................... 77

DEFECTS ANALYSIS .............................................................................................................................. 78

PARETO CHART ANALYSIS: TOP 5 DEFECTS ......................................................................................... 78

ISSUES TO BE FOCUSSED ON: .............................................................................................................. 79

PROCESS FLOW CHART: ...................................................................................................................... 79

TROUBLESHOOTING: ........................................................................................................................... 80

COUNTER MEASURES .......................................................................................................................... 82


MEASURE IMPLEMENTATION ............................................................................................................. 83

FEBRUARY 2014 .................................................................................................................................. 85

DEFECTS ANALYSIS: ............................................................................................................................. 85

ISSUES TO BE FOCUSSED ON: .............................................................................................................. 86

TROUBLESHOOTING: ........................................................................................................................... 86

DEFECT CAUSE ANALYSIS AND COUNTER MEASURES IMPLEMENTATION: ........................................ 88

FIELD LEVEL DEFECTS .............................................................................................................................. 91

An overview of the call auditing data managing system .................................................................... 92

OBSERVATIONS: .................................................................................................................................. 98

THEORY ............................................................................................................................................. 100

CAUSE OF DEFECT ANALYSIS ............................................................................................................. 101

PROJECT NO. 4 .......................................................................................................................................... 103

PDI SUMMARY REPORT FOR RO WATER PURIFIER ............................................................................... 103

BRIEF SUMMARY: .............................................................................................................................. 104

NEED FOR THIS PROJECT: .................................................................................................................. 105

METHODOLOGY: ............................................................................................................................... 105

ISSUES ............................................................................................................................................... 106

PROJECT NO. 5 .......................................................................................................................................... 108

WINE CHILLER FEASSIBILITY STUDY ...................................................................................................... 108

NEED OF THE PROJECT: ..................................................................................................................... 109

METHODOLOGY: ............................................................................................................................... 109

THEORY: ............................................................................................................................................ 110

HUMIDITY TEST ................................................................................................................................. 111

CONDENSATION TEST ....................................................................................................................... 116

CONCLUSION: ............................................................................................................................................ 118

REFERENCES: ............................................................................................................................................. 119


SUMMARY

This report is to present all my work and studies during my 6 months training period in

Whirlpool Of India Limited, Faridabad.

I was very priveledged to be associated with the New Product Development Center Department

(NPDC)-Food appliances unit with Mr. N Krishna, who along with his team, gave me knowledge

and an experience that will help me to perform well in the future. During the start of my training,

I had a week long introduction about the working in the department and what our seniors expect

from us as interns. Following this, I did a detailed study about the appliances that are developed

at the Department. Once I was confident about my knowledge regarding the products, I was

given daily exercises which included testing and rectification of otherwise useless products. The

main motive to this was to enhance my knowledge even further about the products so that I can

tackle real life problems associated with them in the industry.

After a month of general exercises and daily work, I began working on my Projects. My first

project was Mixer-Grinder Benchmarking. My department had recently started working on the

design of a Whirlpool food processing grinder. This was the first time the industry was

developing this product and so there was a need to benchmark various properties and

functionalities from our competition companies in the market that manufacture this product. This

benchmarking was done in a 5 Test Plan process wherein the tests namely Power Test, RPM

Test, Noise Test, Operational Test and Data Simulation were performed. This entire procedure

imparted a good sense of team work and leadership quality in me as I was given the overall

management and implementation responsibility of this entire project. This type of dependence of

my department on my work made me strive harder to not disappoint them.

My next project was Induction cook-top field failure analysis which included postulating 3

theories to explain the failure of our cook-top appliance in the market and follow further

rectification.

I was given another major project of AC Defect study. In this, I had to analyze and study the

manufacturing and field level defects of our Air conditioning units. For the manufacturing level

failure analysis, I had to make many trips to The Amber Plant in Kalaamb that manufactures our


air conditioning units based upon on design standards. This project was divided into 3 parts for a

time span of 3 months and the action plans were made on priority basis after identifying the top

defect of the month and counteracting upon it. For the field Failure defects , I followed a system

of call auditing in which I had to do about 20 calls a day for a time duration of 5 months and then

to find the root cause of the top defect arising on the field.

The next project was Pre dispatch inspection of RO Purifier Range Platinum that had recently

been launched in the market. PDI ensures that the production complies with the specifications

and/or the terms of your purchase order or letter of credit. The final Random Inspection (FRI) or

Pre-shipment Inspection (PSI), checks finished products when at least 80% of the order has

produced and export-packed. Samples are selected at random, according to standards and

procedures.

The next project was Wine chillers Feasibility Study .WOIL is planning upon introduction of its

wine chiller range in the Indian market. These chillers are originally manufactured in The

Whirlpool Corporation in China. Before the sales to begin, it was required that a feasibility study

be done in our plant to ensure the satisfactory working of the chillers in India.

The major concerns regarding this were the climatic pattern variations in India and China. So,

the commencement of this project was done by having a few informative sessions with my

seniors, so as to conclude upon which tests need to be performed to justify the feasibility of the

appliance.

The tests performed were:

Humidity test

Condensation test

NLPD (No load Pull Down)


COMPANY PROFILE

The Refrigeration industry in India is fast growing and with the advent of global brands the

Industry has woken up to new opportunities and new challenges. Whirlpool’s association with

India goes back to the year 1987 with the establishment of the joint venture TVS Whirlpool

Ltd.

Whirlpool Corporation is the world’s leading manufacturer and marketer of major home

appliances industry which is fast growing. There has been a rapid entry of global brands which

has resulted in local infrastructure / industry waking up to opportunity and of course the threats.

Whirlpool plans to launch products to suit the Indian customer in various income

Groups. Whirlpool portfolio will follow its top-4 agenda in India:

Refrigerators,

Washing machines,

Air conditioners

Microwaves

All high growth areas, which allow it to leverage WOI’s existing strengths, the

Whirlpool products currently available in the market include Refrigerators, Air conditioners,

Microwaves and Washing machines. Whirlpool guarantees performance, promise and reliability

of its products. All Whirlpool products are backed by suitable warranties and a wide network of

service centers, Emphasis is placed on after sales service and Whirlpool strives to achieve those

goals.

In refrigerators the industry growth has been less than 27%. The 180L occupy around 75%

Segment of market. The main players in the market are LG, Godrej, Samsung, Whirlpool,

Electrolux and Videocon. Whirlpool has a market share of about 30% and is the market leader.


PLANT LAYOUT


PLANT BLOCK DIAGRAM

ABOUT WHIRLPOOL CORPORATION

Whirlpool Corporation is the world’s leading manufacturer and marketer of major home

appliances. Headquartered at Benton Harbor, Michigan and the major brand names in about 140

countries. Though now a global leader, the company began, as a family owned machine shop

located in a small town on Eastern Shore of Lake Michigan.


THE HISTORY

Founded in 1911 as Upton Machine Company produced motor driven wringer washer.

Sold first order of washers in 1916 to Sears Roebuck and Co. our largest retail customer

today.

In 1950 the company was renamed the ‘The Whirlpool Corporation – Automatic dyers

were added to washer line.

In 1958 Whirlpool made its first investment outside North America in Brazil.

Revenues reached $ 1 billion in 1968.

Whirlpool purchased ‘Kitchen Aid’ brand in 1986 and began its globalization efforts

in1980’s.

WHIRLPOOL CORPORATION TODAY

World’s leading manufacturer and marketer of major home appliances.

Full line of major home appliances.

Manufacturer: 12 countries.

Revenue: $ 12 billion.

THE WHIRLPOOL VISION AND MISSION

‘EVERYHOME, EVERYWHERE WITH PRIDE, PASSION AND PERFORMANCE’

Our pervasive vision, “Every Home, everywhere, with pride, passion and performance”, rests on

the pillars of innovation, operational excellence, customer-centric approach and diversified

talent. These are embedded within our business goals, strategy, processes and work culture.

Be it our products that are the result of innovation and operational excellence to meet every need

of our consumers or the people behind these products that come from a wide spectrum of

backgrounds, everything we do features a distinct Whirlpool way.


WHIRLPOOL WENT THE GLOBAL WAY

Whirlpool strategy has been to remain focused on major home appliances but to expand into

markets not already served by Whirlpool. The goal has been world leadership in a rapidly

globalizing major appliances industry.

Before whirlpool began its expansion into Europe, a move that established the company as a

world leader in major home appliances, it undertook a global analysis of markets and

opportunities in home appliance industry. A conclusion was that the industry would, over time,

become global and a handful of companies would dominate the manufacturer and the sale of

home appliances. Whirlpool determined to lead that globalization process and be one of those

companies.

In 1980’s there was a major acquisition in Europe, joint ventures with companies in Mexico and

India and increased ownership in companies in Canada and Brazil. Throughout the early 90’s the

company continued its expansion in Latin America and Europe and a manufacturing and

marketing presence was established in Eastern Europe.

In Asia, Latin America, North America and Europe, in all the countries where it has presence

was established in Eastern Europe, Whirlpool seeks to set standards against which the global

major domestic appliance industry is measured. To that end the company vigorously pursues the

goal of its worldwide excellence system (WES).

Whirlpool’s strategy to shape and lead the emerging global home appliance industry is working

because the company consistently improves the quality of its products and services while

refining its understanding of customers and what they want from whirlpool.


Worldwide product line

Whirlpool worldwide product line are divided into three major categories they are

Kitchen appliances,

The laundry appliance

Home appliances.

The kitchen appliances includes various models of cooking ranges, cook tops, built in ovens,

microwaves, hoods and vents, dispensers, refrigerators, freezers, icemakers, water coolers,

dishwashers, and disposers.

The company’s laundry products include washers, dryers, combos, and fabric fresheners, drying

cabinets, jetted sinks and ironing stations.

While its home appliances include air conditioners, dehumidifiers, air purifiers and water

treatment products like whole house prefilters, drinking water filter, water coolers and water

soften


Product Portfolio

Whirlpool is the most recognized brand in home appliance globally. Whirlpool’s world class

products are engineered to suit the requirements of “smart, confident and in-control” homemaker

who knows what she wants. The product range is designed in a way that it employs unique

technology and offers consumer relevant solutions.

WHIRLPOOL

OF INDIA

LIMITED


Refrigerators

Whirlpool refrigerators, trusted by homemakers across the globe come with:

6th Sense™ cool system for superior cooling in the peak of summers

Unique utility features to add that 'magic' to homemaking

Range of storage capacity to suit the family needs

Energy efficient technology for cooling retention during power cuts

Sleek designs and contemporary styling


Washing Machine

Whirlpool, the pioneer in washing machine technology brings:

Unique 6th Sense™ technology the next generation in fuzzy logic for Optimum water,

detergent and temperature levels based on wash load

Stain wash : Brings together unique properties of Hot wash and 1-2 , 1-2 hand wash to

completely remove all common household stains

Complete range from Semi-Automatic to Fully Automatic front loading machines to suit

the needs of the discerning homemaker


100% Dryers

Whirlpool with its leadership in fabric care solutions worldwide has incorporated in it product

portfolio a 100% dryer exclusively designed and developed to help cope with the Indian weather

conditions:

The 100 percent dryer comes with a multiple drying programs.

The best of European technology being brought to India for the first time

The energy efficient machines comply with the stringent European safety standards


Air Conditioners

The Whirlpool Mastermind series of Air Conditioners, built to perfection and loaded with host of

unique features, the Mastermind series offers the best of technology, design and unbeatable built

quality to meet the cooling requirements at an unbelievably affordable cost.


Microwave Ovens

Whirlpool microwave ovens are designed to re-define ease, convenience and variety in cooking

with features that help make “Variety KHANA ROZAANA”


Purafresh RO Range

UPS

In addition to its existing product range, Whirlpool has come up with new addition in the range

of power accessories "Elantra" H-UPS. This H-UPS comes with a two year warranty. With

Elantra the customer gets the advantage of a host of features, international quality and an

exciting range to suit your needs.


NEW PRODUCT DEVELOPMENT

Innovation

At Whirlpool, everyone believes that innovative thinking comes from anyone and anywhere

within our company. That's why, in 1999, it launched a worldwide effort to install innovation as

a core competency throughout our organization. Since then, Whirlpool people worldwide have

participated in and contributed to innovation-related activities that have resulted in new ideas,

products and services that deliver real value to its consumers in ways never before seen in either

the company or the industry in general.

Innovation is Whirlpool Corporation's differentiating strategy. It provides the company with a

significant competitive advantage. Innovation also brings the company closer to its consumers

and enables it to meet their unmet needs.

Today, its innovation strategy is both a top-down and bottom-up initiative. Innovation is an

operational requirement with executive compensation explicitly tied to innovation revenue and

earnings. Comprehensive innovation training programs have resulted in certified "I-Mentors" and

"I-Consultants" whose roles are to make innovation a part of every employee's job. The

innovation pipeline from early opportunity identification through the stage-gate development

process and into the growth of ongoing businesses is explicitly tracked and reported on from

both product and brand perspectives in terms of projected value and actual results.

Specifically, Whirlpool defines innovation as how a new product or concept measures up against

the following three criteria:

Is it a new and compelling solution from the consumer's point of view? - Measured in terms

of rate of growth.

Can it be sustained in the competitive environment? - Measured in terms of sustainable

presence and pricing in the market.

Can it deliver differentiated financial results that are substantially better than average?


Whirlpool has manufacturing facilities at three places: -

Washing Machines Pondicherry, Chennai Started April’94

DIRECT COOL Refrigerators Faridabad, Haryana Started Feb’95

NO FROST Refrigerators. Ranjangaon, Pune Started March’98

The whirlpool products currently available in the Indian market include refrigerators, Air

conditioners washing machines and microwave ovens. The global no frost refrigeration plant in

Ranjangaon, Pune, manufactures no frost CFC free refrigerators. The product from this plant is

specifically designed for the Indian customer and are backed with latest world class technology

Whirlpool India's success story began in 1996, with the setting up of a 430,000-sq-ft plant at a

green field site in Ranjangaon, near Pune in the state of Maharashtra. In October 1997, its first no-

frost refrigerator rolled out of the Ranjangaon facility, and commercial production was underway

by February 1998. An investment of U.S. $80 million went into setting up a multi-technology

plant that today manufactures no-frost and direct cool refrigerators, washers, and air-conditioners.

Microwave ovens will begin rolling out of the facility in the not-too-distant future. To date, the

production value of the appliances made in the Ranjangaon facility amounts to $51 million.

The first manufacturing facility set up by Whirlpool in India was in Pondicherry. It was a

joint venture with the TVS group. The facility manufactures washing machine both semi

automatic and fully automatic. The company now plans to convert this unit into a fully export

oriented unit.

Whirlpool in Faridabad

On February 24th

1995, Whirlpool acquired controlling interest in Kelvinator of India,

traditionally the country’s largest manufacturer and marketer of refrigerators. With the

manufacturing base in Faridabad, Haryana, this association also yielded a network of over 3500

trade dealers. Whirlpool is now selling, the Whirlpool brand refrigerator, replacing the

Kelvinator brand name, with the later having reverted to Electrolux in the early 1997.


This plant is also known as Faridabad Refrigeration Operation (F.R.O.) was established in early

1960’s has product ion capacity of about 3000 refrigerators per day. The F.R.O. manufactures

only direct cool (D.C.) products in the range of 165L, 175L, 180L, 170 L, 215 L and 230L

category. Whirlpool FRO has recently become a completely NON-CFC. The FRO also exports

refrigerators in 27 countries throughout the world.

NPP Department

Presently, I am working as the trainee in New Profit Pool (NPP) department of Whirlpool of

India Limited, Faridabad. This department comes under the Product Development Centre (PDC)

of Whirlpool of India Limited. This department is divided into three sections. First one deals

with Air Conditioners, second one deals with Food Preparations and third one deals with Water

Purifiers. In NPP, all the above products are sourced as finish products.

Now days, I am doing training in Water Purifiers Department that further deals.

Block Diagram of the procedure of NPP


Product Development Steps

Step 1: IDEA GENERATION

The first step of new product development requires gathering ideas to be evaluated as potential

product options. For many companies idea generation is an ongoing process with

contributions from inside and outside the organization. Many market research techniques are

used to encourage ideas including: running focus groups with consumers, channel members, and

the company’s sales force; One important research technique used to generate ideas is

brainstorming where open-minded, creative thinkers from inside and outside the company gather

and share ideas. The dynamic nature of group members floating ideas, where one idea often

sparks another idea, can yield a wide range of possible products that can be further pursued.

Step 2: SCREENING

In Step 2 the ideas generated in Step 1 are critically evaluated by company personnel to isolate

the most attractive options. Depending on the number of ideas, screening may be done in rounds

with the first round involving company executives judging the feasibility of ideas while

successive rounds may utilize more advanced research techniques. As the ideas are whittled

down to a few attractive options, rough estimates are made of an idea’s potential in terms of sale

production costs, profit potential, and competitors’ response if the product is introduced.

Acceptable ideas move on to next step.


STAGES OF PRODUCT DEVELOPMENT


Step 3: CONCEPT DEVELOPMENT AND TESTING

With a few ideas in hand the marketer now attempts to obtain initial feedback from customers,

distributors and its own employees. Generally, focus groups are convened where the ideas are

presented to a group, often in the form of concept board presentations (i.e., storyboards) and not

in actual working form. For instance, customers may be shown a concept board displaying

drawings of a product idea or even an advertisement featuring the product. During focus groups

with customers the marketer seeks information that may include: likes and dislike of the concept;

level of interest in purchasing the product; frequency of purchase (used to help forecast demand);

and price points to determine how much customers are willing to spend to acquire the product.


Step 4: BUSINESS ANALYSIS

At this point in the new product development process the marketer has reduced a potentially

large number of ideas down to one or two options. Now in Step 4 the process becomes very

dependent on market research as efforts are made to analyze the viability of the product ideas.

The key objective at this stage is to obtain useful forecasts of market size (e.g., overall demand),

operational costs (e.g., production costs) and financial projections (e.g., sales and profits).

Step 5. PRODUCT AND MARKETING MIX DEVELOPMENT

Ideas passing through business analysis are given serious consideration for development.

Companies direct their research and development teams to construct an initial design or

prototype of the idea. Marketers also begin to construct a marketing plan for the product. Once

the prototype is ready the marketer seeks customer input. However, unlike the concept testing

stage where customers were only exposed to the idea, in this step the customer gets to experience

the real product as well as other aspects of the marketing mix, such as advertising, pricing, and

distribution options (e.g., retail store, direct from company, etc.). Favorable customer reaction

helps solidify the marketer’s decision to introduce the product.

Step 6. MARKET TESTING

Products surviving to Step 6 are ready to be tested as real products. In some cases the marketer

accepts what was learned from concept testing and skips over market testing to launch the idea as

a fully marketed product. But other companies may seek more input from a larger group before

moving to commercialization. The most common type of market testing makes the product

available to a selective small segment of the target market (e.g., one city), which is exposed to

the full marketing effort as they would be to any product they could purchase. In more controlled

test markets distributors may be paid a fee if they agree to place the product on their shelves to

allow for testing. Another form of market testing found with consumer products is even more

controlled with customers recruited to a “laboratory” store where they are given shopping

instructions. Product interest can then be measured based on customer’s shopping response.


Step 7: COMMERCIALIZATION

If market testing displays promising results the product is ready to be introduced to a wider

market. Some firms introduce or roll-out the product in waves with parts of the market receiving

the product on different schedules. This allows the company to ramp up production in a more

controlled way and to fine tune the marketing mix as the product is distributed to new areas.

PLANT DESCRIPTION

The whole plant is broadly classified into six major parts, which are

PRESS SHOP

PAINT SHOP

EXTRUSION

VACCUM FORMING

FOAMING

EVAPORATOR SECTION

ASSEMBLY LINES

Press Shop

In the press shop the refrigerator door and cabin are made

C.R.C.A. Steel Cold Rolled Close Annealed Steel sheet cut to the desired size as per model

and is fed into the Carriage Unit. Rolled conveyer, on Carriage Unit shapes the sheet the roll

forming of sheet is done to get the desired thickness. The thickness of door panel is 0.42 mm.

that of back panel and cabinet is 0.38 mm and for deck, the thickness of sheet is 0.25 mm.

After this sheet is send to Notching and Punching (N/P) unit, where holes are punched into the

sheet. The next operation is roller edge bending. Here the edges of the sheets are bent into U-

shapes, where the liners are later inserted.

The next step is the roller End Bending. Here the ends of the sheet are bended by 90 deg. Next

sheet is folded in the Folding Fixture by the application of Hydraulic Pressure. In the press shop


there are two carriage units, each is followed by an N/P, Edge/end bending and sheet folding

fixture

Next, the folded sheets are sent for various spot welding operations. First, the Back Panel is

welded with the cabin. Then the bottom (deck) is welded. The bottom panel is curved in shape

and has space for the compressor to fit in. Doors are also made here in the Press Shop. Next

operation is of removing sharp edges at the corners cabin and doors are loaded on overhead

conveyer and then are passed on to the Paint Shop for further processing. Apart from these basic

operations, there are some separate units for welding of various reinforcements used in the

cabinet.

Machines and equipments

Power press

Brake press

TIG welding equipment

Spot welding equipment

Roll former

Shearing press

Hand grinding wheel


PRESS SHOP

PAINT SHOP


The Cabinet/Door from the Press Shop is hanged on the overhead conveyor line, manually. The

locking system is deactivated so that the cabin is free to rotate. Then the cabin is rinsed in soap

solution to free all the dirt. Prior to this, the cabin is also soaked in a solution to free all the

grease on the surfaces. This is known as Degreasing.

The next step is Activation, where the cabin/Door is kept in a medium, which allows the

exothermic reaction to take place. After this the cabinet/door is coated with Zinc Phosphate, so

that the pain sticks to the surface nicely. This process is called Phosphating. After Phosphating

the surface which results is very rough and irregular. This is smoothened in the Passivation

stage. Next, the cabin/door is dried properly.

Now, the cabin/door is ready for the actual paining. First, the interior areas of the cabin/door are

painted manually by the painter. This is done because during the process of paining by the

electrostatic gun the interior areas are generally left out.

Next, the cabin/door goes through the process of electrostatic paining where the sides and the top

surface of the cabin or the from side of the door is painted by the electrostatic guns, which are

three in no. Two to paint the sides and one at the bottom to paint the top surface of the cabin.

The painted obtained in this process does not have a proper finishing. So, the cabin/door is

now sent to the curing oven where it is heated to specified temperature, to obtain a shine on

the surfaces. After this process, there is an Inspection process and the passed components are

sent for the foaming process.

Machines and equipments available

Spray phosphating line

Baking oven for spray phosphated components

Powder coating plant

Baking oven for powder coating plant

Dip type phosphating plant

Baking oven for liquid paint line

Single platform type liquid spray painting


Extrusion Plant

In this plant liner for cabinet and door is made. This section is completely automated and

negligible material handling. Constituents of liner are 1.6% master batch for giving the desired

colour, 61.4% HIP which is the main constituent of the liner, 2% 585K is for giving gloss to the

liner and 35% regrind is used which is the obtained from grinding the scrap. This is used for cost

saving. This can be used again and again for not more than six to seven times.

All the materials are put in their respective chambers.585K is heated at a temperature of about

200 to 240 degree centigrade and HIP is heated at temperature of 180 to 225 degrees centigrade.

All the materials are then mixed and heated to a definite temperature through a series of heaters,

which makes the material in a semi solid form

Then this mixture is extruded into a continuous sheet. The thickness of the sheet can be

controlled by adjusting the spacing between the extruding rollers. Then automatic cutting is done

to specified length and breadth by making the adjustments in the cutter. Liner comes out from

the oven in the form of long sheets and at the final stage they are cut to desired length. From

here, the liners are shifted to vacuum forming unit.

In the extrusion plant, the sheet for cabinet and door liner is prepared from: -

HIPS (High Impact Polystyrene)

Master batch

585 provide gloss

Regrind

Vacuum Forming Shop

In vacuum forming, the inner liners of the refrigerator (of both shell and door) are formed.

The following cycle takes place on the machine named ROTAFAST.

The white material visible in the picture is the shell liner being cooled by air pipes directing

cool air on to it. The Rota fast machine is provided with two heaters that make possible the multi-

stage heating of the HIP sheet. Material of the plastic sheet is HIPS for High Impact Polystyrene.


Reason for Two Stages Heating

In case of one stage heating, the other molecules in the sheet can get heated to such a high

temperature that the plastic may melt and drop down on heater. Actually here the temperature of

the entire thickness of sheet is non-uniform. To make the temperature at 120deg.Celsius, the

outer temperature, may go well above 140 deg. Celsius. Therefore, a two stage heating (in Rota

fast) is done. Here, after preheating, the sheet cools down a little bit (because the hot outer

molecules give heat to cooler inner molecules) and then in final heating, the entire sheet attains

almost uniform temperature of 120 degree Celsius. Rigo, a much more advanced and fully

automatic machine uses three stages heating.


Foaming Section

The first stage is to unload the painted shells or cabinets from the overhead conveyer line,

which is done manually. Next, the shells are sent for Pre-Foaming. Here among other things

the liner and the Anti-Moisture Tube (A.M.T.) are fitted into the shell

Next, the shell is heated in the oven to a specified temperature to start the chemical reaction

of foaming. After this the shell is loaded into the Foaming Plugs, 18 in no. Here a mixture of

isocyanides and Polyol are added in between the liner and cabin. The foam expands and

covers all the space in between. After this the shell is unloaded, cleaned and inspected. The

shells, which are O.K, are sent to the assembly line.

Doors are also foamed in the similar manner in Door Drum. Here after addition of

Isocyanides and Polyol, the door liner is placed over the door shell. The foamed doors are

then unloaded, inspected and sent to the assembly line.

Evaporator Section

Various Processes in Evaporator Section

In the evaporator section, the freezer assemblies are made.

The freezer assembly comprises of-


THE SERPENTINE COIL- Processes included in it are tube cutting, deburring, flaring, dot

punching, bending and argon welding.

THE EVAPORATOR BODY-Processes included are cutting aluminium to size, all chroming, clear

coating, dehydration, clinching, folding and riveting the compliments.

THE SUCTION LINE ASSEMBLY-Processes included are copper tube shaping, vapours

degreasing, putting of sleeve with the capillary tube, and heating of suction line assembly in

oven.

THE SOUND DEADENER ASSEMBLY-Processes included are sound deadener formation,

degreasing, butt-welding of sound deadener, butt-welding of suction line, and leak testing and

inserting sleeve on butt-welded joints.

The company is implementing Roll Bond evaporators, which gives much better performance than

clinched evaporators do.

The company is implementing Roll Bond type of evaporators, which is the latest in this field.

Assembly Line

There are three assembly lines. All the assembly line are highly automated and they various models

are produced in the line interchangeable


Various Processes in Assembly Line

Thermostat fixing

Bulb, Bottom hinge, Rear Fixing

Angle tray fixing

Top hinge fixing

COMPRESSOR AND CLAMPS FOR CONDENSER FIXING

FREEZING FIXING

DOOR FIXING

CONDENSER FIXING

AMT CONNECTION, THERMOSTAT KNOB FIXING

BRAZING OF SEALED SYSTEM, FREEZER DOOR FIXING, RELAY FIXING

COMPRESSOR EARTHING, DOOR HANDLE FIXING

VACUUMISATION.

GAS AND OIL CHARGING

SEALING OF THE CHARGING LINE

INSPECTION IN TEST LOOP BY CONNECTING TO THE MAINS SUPPLY


CABINET AND DOOR CLEANING

CRISPER TRAY AND SHELVES FIXING

OUTSIDE CLEANING

PLASTIC PARTS FIXING

FINAL INSPECTION

BAR CODING AND PACKING

Vaccumization is the process where nine vacuum pumps are employed to create complete

vacuum in the compressor

Gas and oil charging is the process by which Galileo machines are used to charge the

compressor with R144 gas and oil.


PROJECT NO. 1

FOOD PROCESSING GRINDERS BENCHMARKING AND DESIGN INNOVATION

PROJECT HEAD

Mr. N Krishna


BRIEF SUMMARY OF GRINDERS:

A grinder is a kitchen and laboratory appliance used to mix, puree, or emulsify food and other

substances. A stationary blender consists of a blender jar with blade at the bottom, rotated by a

motor in the base. The newer immersion blender configuration has a motor on top connected by a

shaft to a blade at the bottom, which can be used with any container.

The blending container can be made of glass, plastic, stainless steel, or porcelain, and often

has graduated markings for approximate measuring purposes. In cases where the blades are

removable, the container should have an o-ring or gasket between the body of the container and

the base to seal the container and prevent the contents from leaking. The blending container is

generally shaped in a way that encourages material to circulate through the blades, rather than

simply spinning around.

The container rests upon a base that contains a motor for turning the blade assembly and has

controls on its surface. Most modern blenders offer a number of possible speeds. Low-powered

blenders require the addition of some liquid to operate correctly. In these blenders, the liquid

helps move the solids around the jar, bringing them in contact with the blades. The blades create

a whirlpool effect which moves solids from top to bottom, ensuring even contact with the blade.

This creates a homogeneous mixture. High-powered blenders are capable of milling grains and

crushing ice without such assistance.

Some of the functions of blenders have been taken over by food processors. In particular, thicker

mixtures such as mayonnaise and hummus are conveniently made in food processors.


GRINDER MECHANICS:

The individual, and often replaceable, components of a blender are pretty basic and consist of the

following:

1. Housing

2. Blade

3. Jar

4. Gasket or seal ring

5. Jar base or jar nut

6. Lid

The base of the blender is the housing, which contains a high-speed, fan-

cooled electric motor as well as the speed controls. The hefty weight of the housing keeps the

blender on the counter during blending. In some models, the blade is permanently attached to the

housing, but in most cases, the blade, gasket and jar base are all separate pieces that fit together

and attach to the jar. The blade sits inside the gasket, which prevents leakage. These two parts fit

snugly into the jar base, which screws onto the jar.

The assembled jar snaps onto a coupler, also known as a clutch or a serrated drive, depending on

the manufacturer, which protrudes from the housing and attaches to the blade. The coupler

connects to the motor, and this is the device that controls the movement and speed of the blender.

The lid forms an airtight seal on the jar -- prepare to wipe down your walls, counter and floor if

you forget the lid on a full blender. The lid usually has a removable piece called a fill cap, which

allows you to add ingredients without stopping the blender. In some models, this piece serves a

dual purpose as a measuring cup.

The blades of a blender are constructed of stainless steel for durability and maximum sharpness.

Most configurations consist of four blades arranged in multiple planes and set at different angles.

This results in more contact between the food and the blades. The shape of the jar plays a part in

the blender's efficiency, too -- tapered jars, the most effective shape, funnel food down into the

blades.


In order to start blending a food item

along with certain ingredients, you

push a button to start the blender,

and the motor begins to turn the

blades.

The circular whirring motion creates a vortex, defined as a spiral movement in a fluid. In the

blender, the fluid includes both liquid ingredients and air. The vortex causes a vacuum at the

center of the jar, which pulls the food to be blended towards the middle, much like a tornado.

Unlike a tornado, though, a blender jar contains the vortex.

As the food item combines with the other ingredients and begins to liquefy, the liquid follows the

blade in a whirling motion around the container, forming a well near its center. The well in the

center of a blender's vortex is shallow, so it displaces the blender's contents as they're drawn

toward the axis at the center of the blade. The whirling motion and lack of space below the

blades forces the liquefied food up and out the sides. This circular pattern continues, whipping

air into the contents, which helps mix the ingredients more quickly, until you stop the blender.


TYPES OF BLENDERS:

In their vast number of makes, models and options, the main features that differentiate one

blender from another are motor speed, controls and design. Manufacturers typically indicate

blender motor speed in watts and occasionally in horsepower -- 1 horsepower equals 746 watts.

The majority of household models fall within 500 to 750 watts, though options range from 300 to

as high as 1,500 watts.

The wattage number displayed by the manufacturer measures the power consumed by the

blender motor. But the power generated by the motor is what dictates performance. You want

enough initial torque -- the force that causes rotation around a central point -- to keep the motor

from straining when it meets resistance. Blender controls are another differentiating factor from

one model to another. While experts say that a three-speed (low, medium, high) blender will do

everything you need it to, a good number of blenders offer seven or more speeds, helping you

choose whether you need to chop, puree or liquefy. Some even expand beyond functions,

suggesting speeds for juices, sauces or milkshakes.

Beyond wattage and controls, the feature that often distinguishes one blender model from

another is the jar. Blender jars come in three materials -- glass, polycarbonate and stainless steel.

Which one to use largely depends on personal preferences. Glass jars are more prone to

breakage, but their weight gives them more stability. They're also scratch-resistant and less likely

to retain odors. Polycarbonate jars are lighter and won't shatter if dropped on the floor, but they

are prone to scratching and can end up smelling like their contents. Stainless steel is sleek and

modern, which makes it aesthetically pleasing, but you can't see inside, so you have to stop the

blender to see if everything's liquefied. In addition, glass and plastic usually have markings you

can use to measure ingredients directly into the jar, but stainless doesn't.


AIM:

Benchmarking of grinders from competition in the market

OBJECTIVE:

The objectives of this product were:

To determine what and where improvements are called for

To analyze how other organizations achieve their high performance targets

To use this information for development of our own product

NEED FOR THIS PROJECT:

Whirlpool of India ltd. is launching its first ever range of food processing grinders into the

market. Since this is our first time developing this product, we require knowledge as to what

customers are we targeting and how do our competition companies meet the demands of these

customers. A market survey conducted by our team suggested that amongst all the companies

manufacturing and marketing this product, the grinders manufactured by Morphy Richards and

Phillips have a relatively well established market. So now, our prime objective was to acquire

these products and run a series of tests on them so as to benchmark certain specifications of each

of them which aid them in meeting their high performance standards, and to use this information

to develop our own product efficiently so as to be at par with these appliances, that have already

been readily accepted in the market.

METHODOLOGY:

Now the question arises how to proceed with this project?

Acting on this, I had many discussions and brain storming sessions with my seniors. Gathering

information from the internet as well as from the Whirlpool Testing Portal, we strategized a plan

for running 4 tests which would significantly broaden our learning on this matter.


The 4 major factors influencing a grinder performance are:

Blade Material

Power Consumption

Noise Produced

RPM of Motor


NOISE TEST

OBJECTIVE:

To record and analyze the Noise produced by the test grinder for varying loads

REQUIREMENTS:

MORPHY RICHARDS 600 W and PHILIPS [500 W and 600W]

MOTORS: 550W, 650W and 750W

DB meter [PDC DEPARTMENT]

Loads: Chutney Jar [minimum load]

Wet Jar [medium load]

Dry Jar [maximum load]

The Readings associated with this test cannot be shared due to confidentiality of the data


GRAPHICAL REPRESENTATION OF THE DATA:

66

68

70

72

74

76

78

80

82

84

86

SPEED 1 SPEED 2 SPEED 3

No

ise

( in

db

)

WITHOUT JAR

PHILIPS 500W

PHILIPS 600W

MOR RIC 550W

MOR RIC 600W

MOR RIC 650W

MOR RIC 750W

68

70

72

74

76

78

80

82

84

86

88


No

ise

(in

db

)

SMALL JAR

PHILIPS 500W

PHILIPS 600W

MOR RIC 550W

MOR RIC 600W

MOR RIC 650W

MOR RIC 750W


70

72

74

76

78

80

82

84

86

88


No

ise

(in

db

) MEDIUM JAR

PHILIPS 500W

PHILIPS 600W

MOR RIC 550W

MOR RIC 600W

MOR RIC 650W

MOR RIC 750W

72

74

76

78

80

82

84

86

88


No

ise

(in

db

)

LARGE JAR

PHILIPS 500W

PHILIPS 600W

MOR RIC 550W

MOR RIC 600W

MOR RIC 650W

MOR RIC 750W


CONCLUSIONS:

Philips 600 W Model is ideal in terms of minimum noise produced.

Therefore, the Philips 600 W Model should be benchmarked in account of Noise

considerations.


POWER TEST

OBJECTIVE:

To note the power consumption of each grinder under varying load conditions

REQUIREMENTS:

MORPHY RICHARDS 600W grinder

PHILIPS 500W grinder

MOTOR OF POWER – 550W , 650W and 750W

POWER MEASURING SOURCE – [NPP-AC LAB]

TEST CYCLE NO. 1:

This test has been performed on the 600W PHILLIPS and 600W MORPHY RICHARDS GRINDER in

order to analyze the variation in power consumption between the 2 appliances having same

motor rating.

Given below are the graphs associated with the test.


105

110

115

120

125

130

135

140

145

230 V 230 V 230 V

PO

WER

0

50

100

150

200

250

300

230 V 230 V 230 V

PO

WER

135

140

145

150

155

160

165

170

175

230 V 230 V 230 V

PO

WER

0

50

100

150

200

250

300

230 V 230 V 230 V

PO

WER

PHILLIPS 600W MOR RIC 600W

WITHOUT LOAD

SMALL JAR (minimum load)


151

152

153

154

155

156

157

158

159

160

230 V 230 V 230 V

PO

WER

0

50

100

150

200

250

300

230 V 230 V 230 V P

OW

ER

130

135

140

145

150

155

230 V 230 V 230 V

PO

WER

0

50

100

150

200

250

300

230 V 230 V 230 V

PO

WER

MEDIUM JAR (median load)

LARGE JAR (maximum load)


CONCLUSIONS:

The Power Consumption of the grinders increase with increasing load

The rate of power Consumption for different Speeds is nearly Constant for all conditions

of loading

In terms of Power Consumption, PHILIPS 600W grinder is the ideal product.

TEST CYCLE NO. 2:

This test has been performed by replacing the original motor (600W) of the MORPHY RICHARDS

grinder and replacing it with a 550W, 650W and 750W motor respectively in order to

understand the variation in power consumption brought about by the change in Motor rating

for the same appliance.

0

50

100

150

200

250

300

350

W/O JAR SMALL JAR MEDIUM JAR LARGE JAR

PO

WER

MORPHY RICHARDS 550W MOTOR


0

50

100

150

200

250

300

350


PO

WER

0

50

100

150

200

250

300

350


PO

WER




CONCLUSIONS:

The Power Consumption of the grinders increases with increasing load

The rate of power Consumption for different Speeds is nearly constant for all conditions

of loading.

The power Consumption is MAXIMUM in case of the 750 W motor but the grinder is

unstable in terms of vibrations for this case.


RPM TEST

OBJECTIVE:

To record and analyze RPM of the test grinder at varying speeds

REQUIREMENTS:

MORPHY RICHARDS 600 W and PHILIPS [500 W and 600W]

MOTORS: 550 W, 650W and 750 W

The following are the readings and graphs associated with the test:

14000

15000

16000

17000

18000

19000

20000

21000

22000


RP

M

RPM TEST

PHILIPS 500W

PHILIPS 600W

MOR RIC 550W

MOR RIC 600W

MOR RIC 650W

MOR RIC 750W


CONCLUSIONS:

While studying the original 3 Products, without presence of any external Motor, it is

observed that the PHILIPS 600W grinder has the lowest RPM whereas the MORPHY

RICHARDS 600W grinder has the highest RPM. Thus for an equivalent power rating of

600W, the MORPHY RICHARDS grinder offers a larger RPM and thus should be

Benchmarked in account of RPM considerations.

The external motors 550W,650W and 750W show an approximately similar increase in

RPM with increase in the Power Rating of the motor


OPERATIONAL TEST

REQUIREMENTS

Freshly roasted Coffee seeds corresponding to the grading ‘Light Roast’ of IS : 3077-

1972

Mixer Grinder to be tested

TEST PROCEDURE:

The weight of seeds in grams shall be 40% of the rated Capacity in mililitres of the

grinding bowl of the machine under test.

The seeds shall be ground for a operational time of 3 minutes or less and the total time

including periods of rest shall not exceed 5 minutes.

If required, the material adhering to the sides and cover may be scrapped and loosened

with a spoon, once during the test, when the machine is at rest.

At the end of the test the material shall be removed and weighed.

The result of grinding shall be assessed by sieving successively through the following Indian

Standard Sieves:

710,500 and 355 microns

CALCULATIONS:

Material retained on each of the first two sieves shall not be more than 20% of the weight

obtained at the end of the test

The material passing through the third sieve shall not be less than 30% of the same

weight


OBSERVATIONS:

TEST SPEED SIEVE Starting

Weight(gm)

WEIGHT

through

the

Sieve(gm)

Left Out

Weight(gm)

ERROR

ANALYSIS

PHILIPS

600W

SPEED 1

710

50

30.94 19.1 38.12

500 20.66 10.3 20.56

355 9.56 11.1 19.12

SPEED 2

710

50

34.58 15.4 30.84

500 26.83 7.75 15.5

355 17.14 9.69 34.28

SPEED 3

710

50

35.3 14.7 29.4

500 32.9 2.4 4.8

355 6.02 26.9 12.04

PHILIPS

500W

SPEED 1

710

50

36.74 13.3 26.52

500 34.71 2.03 4.06

355 6.39 28.3 12.78

SPEED 2

710

50

35.62 14.4 28.76

500 28.12 7.5 15

355 16.84 11.3 33.68

SPEED 3

710

50

36.5 13.5 27

500 33.05 3.45 6.9

355 5.41 27.6 10.82

NOTE: THE MISSING DATA AND CONCLUSIONS CANNOT BE SHOWN DUE TO

CONFIDENTIALITY CONCERNS


DATA SIMLULATION

After conducting the tests, the next step was to run a DOE keeping in mind all the formulating

factors and then understanding their interdependence on each other.

NEED FOR THIS ACTION:

Once the tests for the components governing the major factors of grinding efficiency were done,

it is essential to co-relate these factors to each other. This is to determine which, amongst the 4

factors, has the greatest/highest magnitude of influence on the machine’s performance so that it

can be set at the utmost priority while further designing our product.

METHODOLOGY:

Constructing a DOE plan to note down the readings.

Collaboration of apparatus and test setups of the experiments.

Using ISI Standards for food processing blenders as our cririteria for conclusions

TERMS USED:

y1 Weight through 1st Seive

y2 Weight through 2nd Seive

y3 Weight through 3rd Seive

y4 (Calc) y1 / x2 % Shall be < 20%

Factors -1 +1

x1 Motor Wattage 550W 750W

x2 Loading Qty 126g 336g

x3 Grinding Speed 1 3

x4 Input Voltage 180 260

x5

Coffee Bean

Type

Café Coffee

Day Star Bucks

x6 Grinding Time 1 min 3 min


y5 (Calc) y2 / x2 % Shall be < 20%

y6 (Calc) y3 / x2 % Shall be > 30%

y7 Noise in dB

y8 Power in Watts

OBSERVATIONS:

Run

Orde

r

Treat

ment

FACTORS

y1 y2 y

3

y

4

y

5

y

6 y7 y8 Motor

wattage

Loadi

ng qty

Grindin

g speed

Input

Voltag

e

Coffee

bean

type

Grindi

ng time

1 -1 -1 -1 -1 1 -1

1 2

-1 -1 -1 1 -1 1 11

7

95

.2

4.

7 - - -

85

.9

6

31

3.

2

2 3

-1 -1 1 -1 -1 1

11

4.

8

93 1 - - - 86

.6

27

1

4 -1 -1 1 1 1 -1 - - -

3 5

-1 1 -1 -1 -1 1

25

8.

8

19

1.

8

1.

2 - - -

86

.8

32

5.

6

6 -1 1 -1 1 1 -1 - - -

7 -1 1 1 -1 1 -1 - - -

4 8

-1 1 1 1 -1 1

29

6.

2

23

0

2.

3 - - -

85

.5

3

47

5.

7

5 9

1 -1 -1 -1 -1 -1

11

3.

8

71

.2

1

0.

2 - - - 86

25

7.

8

10 1 -1 -1 1 1 1 - - -

11 1 -1 1 -1 1 1 - - -

6 12 1 -1 1 1 -1 -1

11

9.

88

.4

1

0. - - - 86

43

8.


1 8 3

13 1 1 -1 -1 1 1 - - -

7 14

1 1 -1 1 -1 -1

20

1.

2

12

0

4.

8 - - - 86

57

5.

1

8 15

1 1 1 -1 -1 -1

29

4.

4

17

2

3.

7 - - - 86

37

1.

4

16 1 1 1 1 1 1

NOTE: THE MISSING DATA AND CONCLUSIONS CANNOT BE SHOWN DUE TO

CONFIDENTIALITY CONCERNS


PROJECT 1[B]: DESIGN INNOVATION

Our company aims to design a food appliance grinder that is at par with our competition in the market in

terms of design and innovation.

My contribution to this was related to design study and innovation.

The conventional mixer-grinders available in the market have a uni-body base frame upon which the

blending jar is attached. The main disadvantage of this type of structure is that it is not easy to clean the

body of the blender after usage.

Due to the restriction of a uni-body frame, a normal user finds it difficult to clean the machine parts

thoroughly which may get dirty during operation.

To aid the customer for this, I devised an Idea for an unconventional

This system has an anti-locking system that allows body to be disassembled into 2 components as shown.

This aids the customer in the cleaning process.

Figure: Solid View Figure: Section View

Figure: Side View of locking system


This is the Adaptor of the blender body. It has an anti-locking system whose detailed explanation

has been shown bellow. The dimensional explanation of the design cannot be shown due to

confidentiality concerns.

The locking system of the appliance

consists of 2 ways locking i.e. base

locking and side locking. The base

locking system attaches the main body

of the appliance with this adaptor

whereas the side locking system

connects the adaptor to the motor

mounting frame / center frame.

Figure: Adaptor body

Figure: side locking system Figure: base locking system


LOCKING MECHANISM

Side locking system illustration

The Adaptor slides over on the main body frame and locks itself on it as shown in the figure

above.

The semi-circular profile on the adaptor key slides on the triangular component on the main body

frame and produces a cliuck sound that gives a feedback to the customer that the adaptor and

main body frame have now been attached successfully.

Figure: Adaptor Figure: Main Body frame showing locking direction

Figure: Key with semi-circular profile on its inner surface on the adaptor

Figure: Depression on main body frame to fit the key from adaptor


Base locking system illustration

Figure: Extruded portion on the motor mounting frame that locks on to the cavity in the main body frame

Figure: Cavity on the main body frame


PROJECT NO. 2

INDUCTION COOK-TOP FIELD FAILURE ANALYSIS

PROJECT HEAD

Mr. N Krishna


INTRODUCTION

An induction cooker transfers electrical energy by induction from a coil of wire into a metal

vessel that must be ferromagnetic. The coil is mounted under the cooking surface, and a

large alternating current is passed through it. The current creates a dynamic magnetic field. When

an electrically conductive pot is brought close to the cooking surface, the magnetic field

induces eddy currents in the pot. The eddy currents flow through the electrical resistance of the

pot to produce heat; the pot then in turn heats its contents by heat conduction.

Figure: inside view of an induction cooker: the large copper coil forms the magnetic field, a

cooling fan is visible below it, and power supply and line filter surround the coil

Whirlpool of India ltd has a well established market for its Induction cook top appliances. It has

recently launched its new product NX-20D2 into the market.


Fig: A few products from the Whirlpool Induction Cook Top Range

However, there were certain issues regarding its working.

Customers, who had purchased this product, had registered a complaint stating that the machine

was not performing up to the mark. The most prominent complaint was that the machine would

stop working after 5 minutes of its first run and would not work at all after that. To get a clear

understanding of this issue, our team held field visits to the houses of the customers in the NCR

region who had registered the complaint.

We took a similar appliance to their homes and tested them over there. The voltage supply at

these homes was ranging from 210Volts to 225Volts at the time of testing.

After conducting a few field visits, we came to the conclusion that the complaint of the

customers was valid and so the failed products were brought to the Factory for further testing and

processing.


FIELD FAILURE CAUSE

THEORY 1: Voltage Supply Fluctuation

Our Whirlpool team at Ranjangaon , Pune had meanwhile conducted a survey across the city to

note the range of variation in Voltage Supply in a normal household .

The results from this data concluded that the voltage in houses ranges from 210-300 Volts.

The upper limit of this voltage range was very unpleasing and so the first theory of Failure of the

appliance that we formulated was that our PCB design was not equipped to perform under

conditions of fluctuating High and Low voltage.

Thus, a setup was created through which the appliance could be made to run under a voltage

ranging from 160Volts up to 290Volts.

This test was first carried out at the lowest achievable voltage, i.e. 160Volts, and then, at the

highest achievable voltage, i.e. 290Volts for a time duration of 3 hours each.

This Theory, however, proved incorrect as the Appliance did not fail at all in the test.

THEORY 2: Nature of the Vessel Used

The next theory that we postulated was that the nature of the vessel used might have an influence

on the working of the Induction cook top.

Even though clearly specified in our User Manual, the normal customer tends to neglect the

information regarding the type of vessel that can be used on the induction cook top.

Vessels can be broadly classified into 2 major categories i.e. Magnetic and Non – Magnetic

vessels. In context to Induction cooking, however, a Magnetic vessel should always be preferred.

The cooking vessel made of magnetic material such as stainless steel or Iron has

increased magnetic permeability. This decreases the skin depth, concentrating the current near the

surface of the metal, and so the electrical resistance is further increased. Some energy will be

dissipated wastefully by the current flowing through the resistance of the coil. To reduce the skin


effect and consequent heat generation in the coil, it is made from litz wire, which is a bundle of

many smaller insulated wires in parallel. The coil has many turns, while the bottom of the pot

effectively forms a single shorted turn.

This forms a transformer that steps down the voltage and steps up the current. In turn, most of the

energy becomes heat in the high-resistance steel, while the driving coil stays cool. On the other

hand, Non - Magnetic vessels, being bad heat conductors, will not get heated as efficiently as

Magnetic vessels and so are less preferred.

We now ran another test, in which we created a Setup having 2 NX20D-2 Machines, both of

which were made to run continuously for 3 hours. On one, a Magnetic vessel, and on the other, a

non- magnetic vessel filled with water up to its brim, was placed.

OBSERVATIONS:

The water in the magnetic vessel got heated up at a much faster rate in comparison to the

non-magnetic vessel.

The machine carrying the non- magnetic utensil started to show E0 error after 15 minutes

of its running. E0 error is an error displayed on the user interface when the cook top has

been switched on without any vessel being placed on it.

CONCLUSION:

The observations of the above test concluded that the PCB of the induction cooker had a

fault in its sensing system that was unable to sense the Non – magnetic utensil placed on

the cook top.


THEORY 3: Fault in PCB Design

Though our theory number 2 did leave us with some clarity about the reason of failure of the

Product in household implying to use of non-magnetic vessels , it did not give us a clear

understanding as to why our machine was failing within 5 minutes of its initial run. So we

postulated a new theory stating that there may be a problem with the PCB design of our

appliance.

Thus, our product development team developed a new and improved PCB Design.

The next step in the process was to test the machine with the new PCB and so a DOE system was

generated to expand our learning on the matter.


DOE OF THE OLD AND NEW PCB DESIGN

Pattern CY1 CY2 CY3 L2 IGBT Voltage Utensil

−−−−−−− -1 -1 -1 -1 -1 -1 -1

−−−++++ -1 -1 -1 1 1 1 1

−−+−++− -1 -1 1 -1 1 1 -1

−−++−−+ -1 -1 1 1 -1 -1 1

−+−−+−+ -1 1 -1 -1 1 -1 1

−+−+−+− -1 1 -1 1 -1 1 -1

−++−−++ -1 1 1 -1 -1 1 1

−++++−− -1 1 1 1 1 -1 -1

+−−−−++ 1 -1 -1 -1 -1 1 1

+−−++−− 1 -1 -1 1 1 -1 -1

+−+−+−+ 1 -1 1 -1 1 -1 1

+−++−+− 1 -1 1 1 -1 1 -1

++−−++− 1 1 -1 -1 1 1 -1

++−+−−+ 1 1 -1 1 -1 -1 1

+++−−−− 1 1 1 -1 -1 -1 -1

+++++++ 1 1 1 1 1 1 1

FORMULATING FACTORS

Factor -1 +1

CY1 0.1μ 2μ

CY2 0.27μ 0.33μ

CY3 Small Pac Big Pac

L2 20mm 30mm

IGBT 15A 20A

Voltage 180V 270V


After running the tests based on this theory, we came to the conclusion that the major problem in

our Induction Cookers was with the PCB design and so the new design had been sent to the

supplier and brought into production shortly. Due to confidentiality clauses, the data related to

this theory cannot be shared.


PROJECT NO. 3

MANUFACTURING AND FIELD LEVEL DEFECTS IN AIR CONDITIONING UNITS

PROJECT HEAD

Mr. N Krishna


INTRODUCTION

This project involves my detailed survey and analysis into the defects occurring in our Air

conditioning units. The 2 broad categories into which the various defects can be grouped into

are:

Manufacturing Level Defects

Field Level Defects

Fig: Types of defect and survey methodology

Following this, is a detailed study and analytic report of all my finding associated with the

project.

DEFECT

MANUFACTURING DEFECT FIELD DEFECT

These are the defects arising

at the stage of manufacturing

and are detected at the

Customer acceptance Lab in

the manufacturing line

These are the defects arising

after the product has been

purchased by the customer.

These type of defects are

detected by the customer

COLLECTION AND ANALYSIS

OF DATA FROM AMBER

PLANT, DEHRADUN

METHOD OF SURVEY

COLLECTION OF DATA

THROUGH CALL AUDITTING

SYSTEM


MANUFACTURING LEVEL DEFECTS

NEED OF THE PROJECT:

As of now, Whirlpool of India ltd does not have its own Air Conditioner Manufacturing Unit

setup in India. Instead, it gets its machines manufactured from companies which already have

their manufacturing unit’s setup in the country, by giving them their designs requirements,

specifications and other relevant data to aid the company to manufacture the machines according

to the standards set by WOIL. Whirlpool of India ltd, Faridabad, has a bond with 2 such

manufacturers, namely Lyyod and Amber.

Initially, I began collecting data from the Amber Plant in Dehradun in the form of Check sheets

maintained in their production line. The next step was to study these check sheets and to

summarize all the data obtained from it so as to get a clear understanding into the defects arising

in the manufacturing line. I created monthly reports of the same and developed a monthly

counter measure system to suggest and implement action plans in accordance to the most

prominent defect arising in that particular month.

The time duration of this project was 2 months which were dedicated to a full-fledged collection

of data and implementation of measures to eliminate the major defects arising during

manufacturing of the product.

JANUARY 2014

I started this project from 10th

January 2014 Onwards. My first objective was to highlight the

TOP 5 Defects arising in the production line for the month of January.


DEFECTS ANALYSIS:

Fig: Defects and Top 5 Defects contribution

PARETO CHART ANALYSIS: TOP 5 DEFECTS

Fig: Pareto graph showing occurrence of top 5 defects

53

14 11 11 11

53

67

78

89

0

10

20

30

40

50

60

70

80

90

100

0

10

20

30

40

50

60

70

80

90

100

Scratch Broken Not working Missing Leakage

Cum

Rej Type


Rej Type Rej Qty Rej % Cum rej %

Scratch 19 53 53

Broken 5 14 67

Not working 4 11 78

Missing 4 11 89

Leakage 4 11 100

ISSUES TO BE FOCUSSED ON:

Focus must be needed to resolve scratch defects due to 53% contribution out of Top 5

defects

Broken shows the unawareness of operator during assembly

Leakage test efficiency must be improved in LQC stages

PROCESS FLOW CHART:

The following flow chart depicts the various processes in the production of the Air Conditioning

units. According to our team , the major areas of concern regarding the Scratch issue are

subjected to the Visual Inspection and FQC process level stage.

In process-

press shop

Powder

Coating

Visual

inspection

Assy.

Line

LQC FQC PACKIN

G

DESPA

TCH


TROUBLESHOOTING:

In an attempt to reduce / eliminate the root causes for the occurrence of Scratch defects, we

decided to take the help of 2 widely accepted problem solving tools i.e.

4-M Method

WHY – WHY Analysis

4-M METHOD

In this method, we use the 4 essential components involved in every production process i.e. Man

, Method , Machine and Material. Furthermore, we list down the problems associated with each

component that cause the Scratch defect in our products.

Given below is a flow Chart depicting our Scratch problem solving approach through the 4-M

Method Module.

STANDARD ACTUAL GAP PROBLEM

Part should be free from Scratch

Found

Miss handling & Equipment not acceptable

Dent,Scratch,paint-Ng over flow of material due to scratch


WHY-WHY ANALYSIS

ITEM W1 W2 W3 W4 W5

Occurrence Scratch Collisions between 2 parts Worker not aware

WIS and guide

line

during handling in paint-

shop about this problem

was not

displayed

Outflow Scratch Paint-shop supervisor

Lux value not

enough

for visual

inspection

negligence in final stage

(apx 200 Lux)

Material Handling was not

adequate

Inspector negligenc

e

Visual Inspection sample for Scratch not

displayed

MAN

METHOD

MACHINE

MATERIAL

SCRATCH


COUNTER MEASURES

After collecting the data and understanding the causes for the most prominent defect for the

month of January, i.e. Scratch , the next step was to suggest and implement certain measures to

reduce this problem.

This was done in a 2 part process wherein we first laid our focus on the issues causing scratches

during Occurrence i.e. during manufacturing of the product, and then to the issues related to

outflow i.e. inspection of the manufactured product.

OCCURRENCE

Counter measures adopted:

Material handling trolley modified & separator provided between two parts

WIS & master sample displayed in Paint-Shop

Part will be in proper thickness of poly bags

Quantity reduced during handling

Part should be arranged from the opposite side of it.

Trolley modified with rubber cover as shown in figure.


MEASURE IMPLEMENTATION

Part will be in proper thickness of poly bags:

BEFORE

AFTER


Part should be arranged from the opposite side of it and Trolley modified with rubber

cover as shown in figure

BEFORE

AFTER


FEBRUARY 2014

DEFECTS ANALYSIS:

Fig: Defects and Top 5 Defects contribution

Defect Occurrence Occurrence % cum%

Jerking 39 50 50

Broken 10 13 63

Loose 10 13 76

Missing 10 13 89

Touching 9 11 100

Total 78

From these charts, the major inference was that the Missing defect was the most common type of

defect arising in the manufacturing line for the month of February.


So now, the next step was to further broaden the issues occurring under Missing defects i.e. find

out the components that were missing in the highest frequency when checked in FQC.

ISSUES TO BE FOCUSSED ON:

• Jerking & Missing consistent from last two months

• Part missing is showing unawareness of product to operators ?

• Application of Self and sequential is a concern again ?

TROUBLESHOOTING:

In an attempt to reduce / eliminate the root causes for the occurrence of Scratch defects, we

decided to take the help of 2 widely accepted problem solving tools i.e.

4-M Method

DEFECT-CAUSE Flow Chart

4-M METHOD

In this method, we use the 4 essential components involved in every production process i.e. Man

, Method , Machine and Material. Furthermore, we list down the problems associated with each

component that cause the Scratch defect in our products.

Given below is a flow Chart depicting our Scratch problem solving approach through the 4-M

Method Module.


Figure: 4M Method

DEFECT – CAUSE FLOW CHART

LOUVER JERKNG

DESIGN ISSUE

REJECTED PART

USED

Louver window not as per drawing

Rib height manual grind at Dehradun end to match rib height

Rib height manual grind at Rajpura end to match rib height

Vertical Louver Bent


DEFECT CAUSE ANALYSIS AND COUNTER MEASURES IMPLEMENTATION:

After collecting the data and understanding the causes for the most prominent defect for the

month of February, i.e. Rib height variation, the next step was to suggest and implement certain

measures to reduce this problem.

The reason for this issue was that the mould being used by our suppliers to manufacture the ribs

was not matching with the design specifications given to them by our company. The mould used

by them had a slight variation in height between the 2 ribs on which the louver is mounted due to

which the louver was not being able to fit in the ribs properly.

A diagram showing the variation of the manufactured ribs from the original Ribs design provided

to the supplier is shown below.

Fig: Original Ribs Design with rib height = for both ribs

Fig: Manufactured Ribs Design with variation in rib height


To eliminate this issue, our manufacturers were performing manual one rib grind at Rajpura and

Dehradun end. Due to the manual grinding procedure, Burr was being observed on the Rib top as

shown below.

Fig: Burr on Ribs due to manual grinding procedure

Though the manual grinding managed to eliminate the issue of fitting of the louver on the ribs,

the burr created on the top circuferencial area of the ribs was restricting the movement of the

louvers when the unit was used in Swing mode.

So to counter act on this issue,

We contacted our suppliers and highlighted this issue

A meeting was held to brief the suppliers about the concequences of rib height variation

in the overall working of the unit

An immediate change in Mould design was formulated to ensure equal rib height in

coming lot

Greasing on the already existing defective ribs was instructed to be done to ensure

minimal damage to louver due to the burr as well as to reduce losses due to wastage of

already existing lot


BEFORE COUNTER ACTION

1. Manual one rib grind at Rajpura

and Dehradun end

2. Burr observed due to manual

grinding.

3. No Grease used.

AFTER COUNTER ACTION

1. Rib height modified in mould

2. No burr available

3. Grease used


FIELD LEVEL DEFECTS

After studying and analyzing the defects during production, it was essential to now study the

field failure causes. For this, I was made to do Call Auditing and talk to the customers

personally, who had registered a complaint about our product at our customer care helpline.

This exercise was carried out for time duration of 5 months and based upon the Data received

from the call auditing; I had to assist my mentor, Mr. Chandresh Grover , in designing an

action plan to eliminate the major causes of field failure.

Primary objectives of my Call auditing project:

To understand the causes of failure of Whirlpool Air Conditioners in the market

To tabulate these causes and point out the top 5 Defects

To satisfy the customers who have registered a complaint against our product by

providing them with required knowledge about the product and ensuring sales dealer

visits to the houses of these customers to ensure immediate rectification of the Air

conditioning unit

To study the collected data and device an action plan along with the Aircon Quality head

of WOIL , Mr Krishan L. Verma ,to reduce / eliminate the occurrence of these defects in

the future

To study the region-wise defect

This Project had been thoroughly studied and strategized before its commencement.

I completed this project by dividing my work into a 3-Step Process.

Step 1: Analyze and Tabulate the Data obtained from Call Auditing after first month.

Step 2: Lay greater focus on complaints with higher occurrence when observed from the

Tabulated Data done in Step 1 and make a state-wise Defect Intensity Map to illustrate the

regions where majority of the defects have occurred

Step 3: Study the cause of the defects with the highest frequency of occurrence and devise an

Action Plan to reduce / eliminate the occurrence of these defects.


An overview of the call auditing data managing system

Date SR Number SR Priority SR Channel SR Status Branch SP Code SP Name TP code TP Name Customer Name Address -Complete

7 & 8th Apr. HR0514002714 Normal Dealer Inbound Gas Charging Haryana 91904933 LAMBA SERVICE CENTRE 12468 jain enterpriese RADHEY SHAYM AGRWAL COLONY,AGRWAL COLONY,CHAKKI WALI GALI,FATEHABAD,FATEHABAD-999999,Haryana,IN

7 & 8th Apr. PN0514001650 Normal Dealer Inbound Adjustment Pune 91903865 MAITRI SERVICES MR BHARNE M YESHWANT COLONY,YESHWANT COLONY,TAL SHIRUR DIST PUNE,MAHARASTRA,SHIRUR,PUNE - UPCONTRY-999999,Rest of Maharashtra,IN

7 & 8th Apr. KL0514004079 Normal Dealer Inbound Adjustment Kolkata 91900279 SPEED SERVICE PUI CHAKARWARTI 63 A / 1 / A J N LAHURI RAAD,63 A / 1 / A J N LAHURI RAAD,NA,SERAMPORE,HOOGHLY DISTRICT ALL AND UPCOUNTRIES-999999,West Bengal,IN

7 & 8th Apr. CH0514003925 Normal Dealer Inbound Gas Charging Chandigarh 91903725 SUPER TECH ENGINEERS RAM GARG 11262/1,11262/1,NR HAIBOWAL KALA,HAIBOWAL,LUDHIANA-999999,Punjab,IN

7 & 8th Apr. AH0514003473 Normal Telephone Adjustment Ahmedabad 91904972 MICRO CARE SERVICES JITU BHAI PATEL 64 VRAJ VIHAR BAPU NAGAR,NEAR CHIRAG DIAMOND,BAPUNAGAR,AHMEDABAD-999999,Gujarat,IN

7 & 8th Apr. AH0514003502 Normal Telephone Gas Charging Ahmedabad 91903438 Shiv Sai Services 19277 Water product available-no BHOGILAL D PATEL H 402, SWAPAN SHRUSHTY APRT,,H 402, SWAPAN SHRUSHTY APRT,,BHARUCH,BHARUCH,BHARUCH-999999,Gujarat,IN

7 & 8th Apr. GB0514003544 Normal Trade Partner Adjustment Ghaziabad 91905012 STAR ENTERPRISES 3381 j p sales DR RK VEMA GANDHI ROAD,GANDHI ROAD,NA,BAGHPAT,BAGHPAT-999999,East - Uttar Pradesh,IN

7 & 8th Apr. AH0514003559 Normal Dealer Inbound Adjustment Ahmedabad 91904972 MICRO CARE SERVICES CHIRAG N MODI E /2,E /2,BINJIPURA CHAR RASTA,OPP DENA BANK,NAWA WADAJ,AHMEDABAD-15-999999,Gujarat,IN

7 & 8th Apr. CN0514009474 Normal Telephone Adjustment Chennai 91903736 SRI RAGAVENDRA SERVICES ARASAN V NO 2 3RD STREET,NO 2 3RD STREET,ENNORE,-,ENNORE,CHENNAI-999999,Tamilnadu,IN

7 & 8th Apr. LK0514003274 Normal Telephone Gas Charging Lucknow 91903564 Prayas Sales and Service MK AGGARWAL NW303,NW303,PARK ROAD,NA,HAZRATGANJ,LUCKNOW-999999,East - Uttar Pradesh,IN

7 & 8th Apr. CO0514002770 Normal Dealer Inbound Gas Charging Kochi 91904659 GRAZIA SERVICES YUSUF VE S VELIYA VEETIL HOUSE,VELIYA VEETIL HOUSE,EDAPALLI ERNAKULAM,-,EDAPPILLY,COCHIN-999999,Kerala,IN

15-Apr KL0314015348 Normal Dealer Inbound Gas Charging Kolkata 91904179 Zen Appliances Sales and Service DIPANKAR ROY ROY PRASANA CHATERJEE ROAD2NDLANE,PRASANA CHATERJEE ROAD2NDLANE,G/D 78B BUS TERMINUS,NR UDAY SANSKRIT SANGO,SODEPUR,KOLKATA-700110,West Bengal,IN

17-Apr DL0414002441 Normal Dealer Inbound Part replacement Delhi 91900002 GOEL ENTERPRISES RADHE SHYAM PLOT NO 182 ISMITT INDUSTRIAL CORP,PLOT NO 182 ISMITT INDUSTRIAL CORP,NA,MAYUR VIHAR PHASE -1,DELHI-999999,Delhi,IN

17-Apr AH0414006687 Normal Dealer Inbound Compressor replacementAhmedabad 91900478 ROYAL SERVICE 949 Sarvoday Sales Corporation NILESH BHAI JAYANTI BHAI MISTRI3-MANGLAM PARK,3-MANGLAM PARK,VIDYA DAIRY RD,,SHIVDARSHAN NA KHACHA MA,,ANAND,ANAND-999999,Gujarat,IN

17-Apr IN0414002107 Normal Dealer Inbound Compressor replacementIndore 91902641 CLASSIC CARE CHANDRA PRAKASH JADWANIH NO 2,SUMITRA PARISAR,FAVE 3,,H NO 2,SUMITRA PARISAR,FAVE 3,,BHOPAL,NA,KOLAR ROAD,BHOPAL-999999,Madhya Pradesh,IN

17-Apr HR0414004662 Normal Telephone Compressor replacementHaryana 91903062 Arian Enterprises AMAN ENTERPRISES NEW COLONY,NA,SEC 4,GURGAON-999999,Haryana,IN

17-Apr GB0414004800 Normal Telephone Compressor replacementGhaziabad 91903205 Nishi Care Center ADESH JI 344,344,KACHEHRI UP,PURANI STATE BANK WALI GALI,ETAH,ETAH-999999,East - Uttar Pradesh,IN

17-Apr AH0414009315 Normal Dealer Inbound Compressor replacementAhmedabad 91903438 Shiv Sai Services 18570 unknown deler PARISA IBRAHIM AKBAR AA/1, SHAHIN AVENUE, SHERPURA RD,,AA/1, SHAHIN AVENUE, SHERPURA RD,,NA,BHARUCH,BHARUCH-999999,Gujarat,IN

17-Apr PN0414000164 Normal Trade Partner Compressor replacementPune 91903522 Shree Balaji Refregeration 13442 UNKNOWN DEALER S JAY VASTU NIRMITI PVT LMTFLAT NO 1 SHIV HIGHT RING RD,FLAT NO 1 SHIV HIGHT RING RD,PHALTAN,NA,PHALTAN,PUNE - UPCONTRY-999999,Rest of Maharashtra,IN

17-Apr PN0414000165 Normal Trade Partner Compressor replacementPune 91903522 Shree Balaji Refregeration 13442 UNKNOWN DEALER S JAY VASTU NIRMITI PVT LMTFLAT NO 1 SHIV HIGHT RING RD,FLAT NO 1 SHIV HIGHT RING RD,PHALTAN,NA,PHALTAN,PUNE - UPCONTRY-999999,Rest of Maharashtra,IN

17-Apr LK0414003633 Normal Dealer Inbound Compressor replacementLucknow 91903564 Prayas Sales and Service BAKSHI RAM ALIGARJ,ALIGARJ,UP,NR GOYAL CHORAHA,ALIGANJ,LUCKNOW-999999,East - Uttar Pradesh,IN

17-Apr KL0414008519 Normal Telephone Compressor replacementKolkata 91904031 HOME CARE CENTRE PREM NATH KHANNA 4/11 GT ROAD SOUTH GRND FLOR,4/11 GT ROAD SOUTH GRND FLOR,NR BY BELELIAS ROAD CROSSING,HOWRAH MAIDAN,HOWRAH ALL DISTRICT-999999,West Bengal,IN

17-Apr HR0414005175 Normal Dealer Inbound Compressor replacementHaryana 91904045 Home Care Service Center 12750 NEW MADAAN ELECTRONICESSANJAY KUMAR CIVIL HOSPITAL,CIVIL HOSPITAL,HARYANA,NA,BAHADUR GARH,BHADURGARH-999999,Haryana,IN

17-Apr HR0414005176 Normal Dealer Inbound Compressor replacementHaryana 91904045 Home Care Service Center SANJAY KUMAR CIVIL HOSPITAL,CIVIL HOSPITAL,HARYANA,NA,BAHADUR GARH,BHADURGARH-999999,Haryana,IN

17-Apr HR0414005177 Normal Dealer Inbound Compressor replacementHaryana 91904045 Home Care Service Center ANIL KUMAR H NO 1508,H NO 1508,BAHADURGARH 124507,NA,BAHADUR GARH,BHADURGARH-999999,Haryana,IN

17-Apr JP0414000643 Normal Dealer Inbound Compressor replacementJaipur 91904110 ARIZ COOL CUSTOMER CARE 15455 GANESHAM ISHRATULLA KHAN PATHAN SO HIDAYAT ULLA KHANSILWATWADI PRITHIGANJ MAJSID KE WALA,SILWATWADI PRITHIGANJ MAJSID KE WALA,327001,NA,BANSWARA,BANSWARA-999999,Rajasthan,IN

17-Apr KL0414005390 Normal Telephone Compressor replacementKolkata 91904179 Zen Appliances Sales and Service HOLY PHASE PVT LTD 2 FLOUR MADHAM GARAM BAJAR,2 FLOUR MADHAM GARAM BAJAR,KOL 700130,NR SBI ATM,MADHYAMA GRAM,KOLKATA-700129,West Bengal,IN

17-Apr KL0414006848 Normal Telephone Compressor replacementKolkata 91904179 Zen Appliances Sales and Service ABHISHEK NAYYAR B 8 4 UTTRAYAN FIRST FLOOR 100 BT ROAD,B 8 4 UTTRAYAN FIRST FLOOR 100 BT ROAD,WEST BANGEL,OPPOSITE ISI KOLKATA,DUN LOP,KOLKATA-700108,West Bengal,IN

17-Apr KL0414001951 Normal Telephone Compressor replacementKolkata 91904186 PENGUIN SERVICE B GHOSH 27 VIVEKANAND NAGAR COLONY,27 VIVEKANAND NAGAR COLONY,NA,REGENT PARK,KOLKATA-700040,West Bengal,IN

17-Apr KL0414010755 Normal Telephone Compressor replacementKolkata 91904186 PENGUIN SERVICE SUVASISH RAY 389 BANSHDRONI PARK HL SARKAR ROAD,389 BANSHDRONI PARK HL SARKAR ROAD,KOL 70,NR BANSDRONI MASJID,BANSDRONI,KOLKATA-700070,West Bengal,IN

17-Apr HR0414004197 Normal Trade Partner Compressor replacementHaryana 91904933 LAMBA SERVICE CENTRE 8791 AMIT ELEC DEPARTMENT BALAJI COVVECTOY BATTU MANDI,NA,FATEHABAD,FATEHABAD-999999,Haryana,IN

1st may DL0414017019 Normal Trade Partner Gas Charging Delhi 91900006 HANDA REFGN 12402 Ms Kapila Electronics DEEPAK MITTAL D 36 ADHAYAPAT NAGAR,D 36 ADHAYAPAT NAGAR,110041,NR NARAN DHARM KATA,NANGLOI,DELHI-999999,Delhi,IN

1st may DL0414003562 Normal Telephone Gas Charging Delhi 91900011 VIKAS REFGN WORKS ADESH JI HNO 200 STORE WALI GALI,HNO 200 STORE WALI GALI,NR,PALLA NR NARELA,DELHI-999999,Delhi,IN

1st may GB0414006608 Normal Telephone Gas Charging Ghaziabad 91900014 ANNU ELECTRONICS AMIT MISHRA 899B SEC F,899B SEC F,MATHURA,BEHIND LADU GOPAL GUEST HOUSE,GOVIND NAGAR,MATHURA-999999,East - Uttar Pradesh,IN

Phone Numbers FG Code FG Description Product Catg CodeProduct Catg Code DescriptionDOP of MachineCall Date Days Days2 Machine Rectification Descrption Customer voice Fault in Machine Full Descriptions

94,666,847,149,466,600,000 1999 2.0 Ton Split A/C 40 AC 7/15/2013 5/6/2014 295 >60 days Leak Condenser leak,Gas Charging done No Display No Display There is no display PCb problem,,Sp rectified it at same time

98,225,121,259,822,500,000 12690 1.5 Ton Chrome III Coral red (N) 40 AC 5/7/2013 5/6/2014 364 >60 days Blower Noise - Rectified Noise problemNoise

sp anylyzed the problem of blower noise from IDU..then he opened the door

and rectified it..

987,425,173,189,026,000,000,000,000,000 14258 1.2 T MAGICOOL V WHITE 40 AC 3/14/2014 5/6/2014 53 30-60 days Filter cleaned / Filter Cleaning Led Blinking No cooling No cooling/ Low cooling Customer complained of no cooling but technician came and gave demo about swing features , now working fine

9,988,448,523,988,830,000,000,000,000,000,000,000,000 13529 1.5 T Chrome Turbo III White (UK) 40 AC 5/26/2013 5/6/2014 345 >60 days Leak in cupper system tubes,gas charging done No cooling No cooling/ Low cooling Customer said that there was gas leakage in the machine and so sp came and rectified it, unaware of details

7,383,896,509,738,380,000,000,000,000,000,000,000,000 14017 1.5 T 3Dcool V Silver 40 AC 6/5/2013 5/6/2014 335 >60 days AC Service /Drain pipe bend/clean No cooling No cooling/ Low cooling Customer said that there was gas leakage in the machine and so sp came and rectified it, unaware of details

97,277,369,589,727,700,000 14235 1.5 T Magicool III White 40 AC 10/29/2013 5/6/2014 189 >60 days Leak Evaporator Leak,Gas Charging done No coolingNo cooling/ Low cooling

Cust said that thee is no cooling from the low gas..sp charged the gas only..no leakage/no brzing done/no m/c opened

98,370,432,389,837,000,000 13525 1.5 Ton Royale IV (UK) 40 AC 8/31/2013 5/6/2014 248 >60 days Fan Blade Adjusted M/c not working No fault there is complaint only for the demo

2,764,208,498,792,030,000,000,000,000 12688 1.5T Chrome III Silver (N) 40 AC 8/5/2013 5/6/2014 274 >60 days AC Service /Drain pipe bend/clean No cooling No cooling/ Low cooling Customer said that the sp came and said that there was no gas in the AC so it was not working

98,849,585,459,884,900,000 13925 1.5 T 3Dcool III Silver (UK) 40 AC 10/4/2013 5/7/2014 215 >60 days AC Service /Drain pipe bend/clean Water leakage Water leakage Customer said water was leaking from unit and so sp came and said that pipe connections were loose and cleaned the pipes

30,762,405,223,076,200 14337 1.5 T Magicool III White 40 AC 5/20/2013 5/7/2014 352 >60 days Leak Evaporator Leak,Gas Charging done No cooling No cooling/ Low cooling Sp came and said there was gas leakage because nut was slightly open . So nut was tightened and gas was filled

98,474,275,499,847,400,000 14233 1.0 T Magicool III White 40 AC 3/19/2014 5/7/2014 49 30-60 days Leak in cupper system tubes,gas charging done User Busy User busy User Busy

983,037,423,098,303,000,000,000,000,000 14339 1.5 T Magicool III Wine 40 AC 2/8/2014 3/30/2014 50 30-60 days Leak Condenser leak,Gas Charging done Not pick up User busy Not pick up

98,103,782,049,810,300,000 13524 1.5 Ton Deluxe II (UK) 40 AC 5/15/2013 4/4/2014 324 >60 days Display Board defective,PCB replaced No Display No Display Repalace PCB by SP

99,799,785,809,979,900,000 13533 1.5 T 3Dcool III White (UK) 40 AC 11/18/2013 4/12/2014 145 >60 days Filter cleaned / Filter Cleaning Led Blinking No cooling No cooling/ Low cooling Sp came and open only IDU,clean filter beacuse they did not use it from long time..now properly working..C

9,424,414,075,942,440,000,000,000,000,000,000,000,000 14235 1.5 T Magicool III White 40 AC 1/21/2014 4/14/2014 83 >60 days Fan Blade Adjusted Noise problem Noise Fab blade touching to fan hosue...Sp came and do some adjustment..now properly working..first visit

981,016,551,398,101,000,000,000,000,000 13525 1.5 Ton Royale IV (UK) 40 AC 10/8/2013 4/15/2014 189 >60 days Condensor Replaced , Gas charging Done No cooling No cooling/ Low cooling Customer words"Sp change the condenser or charged the gas only..2nd visit

84,105,191,898,410,500,000 13533 1.5 T 3Dcool III White (UK) 40 AC 8/27/2013 4/13/2014 229 >60 days Leak Process tube joint,Gas Charging done Not pick up User busy Not pick up

762,397,103,597,252,000,000,000,000,000 13545 1.5 T 3Dcool III White 40 AC 9/15/2013 4/17/2014 214 >60 days House wiring / Stabiliser Problem /Rat bite Not pick up User busy Not pick up

90,118,326,049,011,800,000 14233 1.0 T Magicool III White 40 AC 8/13/2013 4/1/2014 231 >60 days Leak Condenser leak,Gas Charging done No cooling No cooling/ Low cooling Customer words" M/c installed by Tp,m/c has no gas from the date of DOP..due to lack of knowledge,we were totally depends on Tp..so rectification not done..finaly sp came and charged gas only..

90,118,326,049,011,800,000 14233 1.0 T Magicool III White 40 AC 8/17/2013 4/1/2014 227 >60 days Leak Condenser leak,Gas Charging done No cooling No cooling/ Low cooling Customer words" M/c installed by Tp,m/c has no gas from the date of DOP..due to lack of knowledge,we were totally depends on Tp..so rectification not done..finaly sp came and charged gas only..

99,353,712,529,935,300,000 13531 1.5T Chrome Turbo 3 Gun Metal(UK) 40 AC 10/28/2013 4/8/2014 162 >60 days Other leaks/chokes,Gas charging done Low cooling No cooling/ Low cooling Customer words"Sp came and analyze the problem of leakage,charged the gas 2times and revert back without satisfy us..then on 3rd visit Sp came,bind the joints with tape..

8420247915..8274986616,9.33102072089617E+29 14339 1.5 T Magicool III Wine 40 AC 8/7/2013 4/13/2014 249 >60 days Leak Condenser leak,Gas Charging done No cooling No cooling/ Low cooling Condenser joint leak,Sp came with brazing and gas charging kit..braze the leak joint and charged gas

83,968,881,118,396,800,000 14235 1.5 T Magicool III White 40 AC 8/22/2013 4/17/2014 238 >60 days Leak in cupper system tubes,gas charging done No cooling No cooling/ Low cooling Flair nut leakage,sp came with gas charging kit and charged the gas only..

83,968,881,118,396,800,000 14235 1.5 T Magicool III White 40 AC 8/22/2013 4/17/2014 238 >60 days Leak Evaporator Leak,Gas Charging done No cooling No cooling/ Low cooling Flair nut leakage,sp came with gas charging kit and charged the gas only..

94,666,270,519,466,600,000 14235 1.5 T Magicool III White 40 AC 9/8/2013 4/17/2014 221 >60 days Leak Condenser leak,Gas Charging done No cooling No cooling/ Low cooling Condenser leak,Sp came with brazing and gas charging kit..braze the leak joint and charged gas

94,142,172,229,414,200,000 12691 1.5T Chrome V Silver (N) 40 AC 8/16/2013 4/3/2014 230 >60 days House wiring / Stabiliser Problem /Rat bite Remote control not working Not working Complaint pending

94,344,167,039,434,400,000 13537 2.0 T 3Dcool III White (UK) 40 AC 2/7/2014 4/8/2014 60 30-60 days remote not Working,remote replaced Remote control not working Not working Remote control replaced by SP

98,740,332,829,874,000,000 14235 1.5 T Magicool III White 40 AC 2/6/2014 4/11/2014 64 >60 days Flair Nut Leak No cooling No cooling/ Low cooling Installed by TP (flair nut loose)..then Sp came and charged the gas only..now it is working properly

9,831,691,666,983,020,000,000,000,000,000,000,000,000 13534 1.5 T 3Dcool III Silver (UK) 40 AC 8/26/2013 4/3/2014 220 >60 days Fan Blade Adjusted recall User busy recall done

93,397,584,229,339,700,000 14235 1.5 T Magicool III White 40 AC 2/22/2014 4/16/2014 53 30-60 days Leak Condenser leak,Gas Charging done Wrong Number User busy Wrong Number

94,162,480,809,416,200,000 13534 1.5 T 3Dcool III Silver (UK) 40 AC 9/9/2013 4/14/2014 217 >60 days Fan motor defective,Fan motor Changed Fan motor not working Not working Fan motor changed

9,811,389,896,921,200,000,000,000,000,000,000,000,000 13533 1.5 T 3Dcool III White (UK) 40 AC 5/7/2013 4/24/2014 352 >60 days Leak Condenser leak,Gas Charging done Not pick up User busy As I told him that I am calling from whirlpool,he disconnect phone same time

9,999,503,536,997,150,000,000,000,000,000,000,000,000 14235 1.5 T Magicool III White 40 AC 12/21/2013 4/6/2014 106 >60 days Leak Evaporator Leak,Gas Charging done Not pick up User busy User busy

8,791,091,001,879,100,000,000,000,000,000,000,000,000 13533 1.5 T 3Dcool III White (UK) 40 AC 10/25/2013 4/17/2014 174 >60 days Leak Condenser leak,Gas Charging done Not pick up User busy User busy


STEP 1: Analyze Data obtained from Call Auditing after first month

NOT WORKING

Product Wiring issue 5

Comp. Def 4

remote not working 4

House wiring issue 3

Louver Not working 3

Swing not working 3

Voltage issue 3

Installation issue 2

Motor Def. 2

Remote control def. 2

Fan motor def. 1

Fan shaft jam 1

M/c not working 1

PCB connector reconnect 1

Swing motor def. 1

Thimble loose 1

Total 38

14% 11%

11%

8%

8% 8%

8%

5%

5%

5%

3% 3%

3% 3% 3% 3%

Product Wiring issue

Comp. Def

remote not working

House wiring issue

Louver Not working


NO COOLING

Flair nut leakage 96

Copper Joint Leak 14

Demo 10

Service 8

Bigger room size/Top floor 6


M/c def. 4

User busy 3

Comp. Def 3

Capacitor def. 1

Condenser Def. 1

Fan motor def. 1

Voltage issue 1

Total 169

63% 9%

6%

5%

4% 3%

2% 2%

2% 1%

1%

1%

1% Flair nut leakage

Copper Joint Leak

Demo

Service

Bigger room size/Top floor Installation issue

M/c def.

User busy


NOISE

Blower touching 14

fan blade Touching 9

Pending 8

Fan motor def. 1

Fan motor loose 1


Motor Def. 1

Swing noise 1

Voltage issue 1

Fan motor loose 1

Blower broken 1

Comp. noise 1

Total 40

35%

22%

20%

2%

2% 2%

2% 3%

3% 3% 3%

3% Blower touching

fan blade Touching

Pending

Fan motor def.

Fan motor loose

Installation issue

Motor Def.

Swing noise

Voltage issue

Fan motor loose

Blower broken

Comp. noise


NO FAULT

Voltage issue 8

Demo 7

No fault 7

House wiring issue 5

installation done 2

Service 2


Total 33

25%

22%

22%

16%

6% 6% 3%

Voltage issue

Demo

No fault

House wiring issue

installation done

Service

Installation issue


7% 7%

57%

15%

14% Demo

Drain tray broken

Installation issue

Pending

Service

43%

57%

PCB connector Loose

PCB def.

100%

1

WATER LEAKAGE

Demo 1

Drain tray broken 1


Pending 2

Service 2

Total 14

NO DISPLAY

PCB connector Loose 9

PCB def. 12

Total 21

SERVICE NEEDED

Service 2


OBSERVATIONS:

Make a state-wise Defect Intensity Map to illustrate the regions where majority of the defects

have occurred after 5 months survey


CITY NO. OF COMPLAINTS

Ahmedabad 72

Bangalore 36

Bhubaneshwar 72

Chandigarh 217

Chennai 54

Dehradun 8

Delhi 106

Ghaziabad 137

Goa 2

Guwahati 6

Haryana 147

Hyderabad 38

Indore 13

Jaipur 77

Jammu 11

Kochi 77

Kolkata 147

Lucknow 164

Mumbai 38

Nagpur 5

Patna 53

Pune 19

Raipur 7

Grand Total 1506


THEORY

From the collected Data , I targetted the Issue of No cooling and deviced an Action Plan to

minimise/eliminate this issue.

In terms of Marketting , a Company has an established link with 2 types of sources i.e. the

Trade Partner (T.P) and the Service Partner (S.P) . A Trade Partner is a source , like a

Dealer, that legally owns the franchise of our products in a particular area and sells our

products in their stores. A Service Partner , on the other hand , is somewhat a part of our

own Organisation , and is linked to the Customer Care Centre of our Company. There are

S.Ps assigned to each Dealer and the job of the Dealer is to inform the S.P about customers

who have purchased our Products, so that the S.P can give these Customers satisfaction in

terms of installation and Demo of the Product. The Main role of the S.P is to ensure that the

product has been installed properly in the Customer’s house and also that the Customer has

no complaints regarding it.

Though this system exists in the books, it has failed to achieve success in terms of reality.

The major reasons for this being :

When a Customer purchases a Product from the Store , he interacts with the Dealer

regarding information about installation, working, transportation etc of the product

instead of contacting the Customer Care of the Company that has manufactured the

product.

The Customer Care Centers , in our country, are usually seen as incapable of

meeting our needs and so the usual Customer tends to avoid interaction with them.

Customers, who ask the dealer about Customer Care related information, are told by

the Dealers that it is the job of the Dealer to contact their S.P’s and to arrange for

technicians from the Company who will install the products in the Customer’s

homes.

Even though it is legally specified as the job of the Dealers to contact their Service Partners

whenever a Customer demands for Installation or Servicing of their product, a large

majority of our Dealers tend to avoid this procedure. But why ? How does this benefit our


Dealers ? To understand the motives of our Dealers in doing so , I started collecting

information about service charges relating to Gas charging. Following this , a had a meeting

with my Seniors,Mr Chandresh Grover and MR K.L. Verma regarding the cost of

installation and servicing of our Air Conditioner Units.

CAUSE OF DEFECT ANALYSIS

The Customer registers a complaint of No cooling with the Dealers , who sends a

Technician to the Customer’s house to check the AC unit. The dealer is supposed to ensure

that the machine is rectified and then provide our company with all the related information

about the Complaint and the action taken by the technician to rectify the error occuring in

our unit.

The Major Scam takes place over here. The Dealers have began manupulating this data in an

attempt to increase their profits.

Our Company , gives our Dealers a Sum of Rs 2100/- for every Gas Charging done.

Now, What the dealer does is that he sends technicians to the customer’s house who check

the machine and rectify it . After this , the Dealer sends us information about this

mentioning the fault in the AC. The dealer specify the issue as Gas leakage, which may or

may not be true. However , according to the system , our company is forced to pay the

dealer the amount set for gas charging.

A data collected from our marketting team showed that for the year 2013 , our company

spends a sum of Rs 8,70,000/- on gas refilling in the air conditioning units included in the

warrenty period of One year.

To reduce these losses, I , along with my Project supervisor ,Mr Chandresh , deviced an

action plan to verify with customers whose complaint was closed under the Action of Gas

charging , whether gas charging was actually done in the AC units of these Customers.To

make this simple for our customers, we would ask them questions such as “Where the

technicians carrying cylinders when they visited your house ? “ and if yes , “Did you see the

technician fill gas into your air conditioner or did you go by their word ? “

After collecting this data and Comparing it with the data given to us by our dealers , we

found a 15-20% error in the data.


So we contacted our Dealers immidiately, giving priority to the Dealers who had the highest

amount of Gas leakage complaints registered. They were then directed to contact their

assigned S.Ps in the future for every complaint registered, instead of taking Action on their

own.

However, The remaining 80% of the Data that suggested that our units actually had gas

leakage was an alarming figure and needed to be dealt with at the earliest.

After instructing the dealers about how to manage the complaints in the future, the dealers

began to contact our S.Ps more often everytime a complaint was registered under No

cooling. S.Ps began to send technicians from their end to the field to check what the

problem was.

After studying the data collected from my Call Audit, I came to the conclusion that the most

prominent technical reason for complaint under No cooling was Flair Nut leakage which

comprised to 96 of the total 128 technical reasons for No cooling defects i.e. 75% of the

defects.

This is an Installation – time Error and suggests no fault in the Product directly. It is a

common trend for a Customer to purchase his Products from a Dealer and then have the

product delivered to their doorstep along with a Technician who installs the product in the

customer’s house and also provides him with a Demo of the product to ensure Customer

Satisfaction. What the Dealers were doing over here was that they were instructing their

technicians to not tighten the flair nut completely during installation so that gas leakage

would take place eventually from the unit and the customer would then complaint about no

cooling, following which the dealers would earn the prefixed sum for every gas charging

done.

To fight this problem, we decided to make Identity proofs to be shown by our S.P

Technicians to our customers so as to ensure to the customers that the technicians have been

sent by the company directly.

However , this is a long term action and cannot be implemented in the entire country so fast.

So , we decided to implement it over the NCR region first and note the reduction in the

number of complaints registered.


PROJECT NO. 4

PDI SUMMARY REPORT FOR RO WATER PURIFIER

PROJECT HEAD

Mr. Ravi Sharma


OBJECTIVE:

Inspection of Product and its quality for future improvement

BRIEF SUMMARY:

Whirlpool of India ltd has recently launched a new model of RO water purifier into the

market. The production of this purifier took place in Kaalamb and a total lot of 800 Purifiers

has been stored at our warehouse in Palwal. The prime objective of this project was to visit

the warehouse in Palwal and carry out a Pre-Dispatch Inspection of the RO Purifiers stored

there. For this, it was required to first list down the major check points to be inspected during

the visit. After discussing the same with my mentor for the project, Mr. Ravi Sharma, we

listed down the following as the major critical check points.

Critical check points

1. Water tank & its cover

2. Spacer & nut of faucet

3. Booster pump with supporting cushion

4. Bar codes & carton stickers

PRODUCT DETAILS

Model name : Purafresh platinum (RO)

Sample size : 10

Selection of sample: random selection

date:-16/05/2014


NEED FOR THIS PROJECT:

The platinum range of RO purifiers have been recently launched in the market. The

production of this product takes place at the GenPure Plant in Kalaamb.

PDI ensures that the production complies with the specifications and/or the terms of your

purchase order or letter of credit. The final Random Inspection (FRI) or Pre-shipment

Inspection (PSI),checks finished products when at least 80% of the order has produced and

export-packed. Samples are selected at random, according to standards and procedures.

METHODOLOGY:

A PDI is normally agreed between a buyer, a supplier , and a bank, and it can be used to

initiate payment for a letter of credit. A PDI can be performed at different stages:

Checking the total amount of goods and packaging

Controlling the quality and/or consistency of goods

Verifying compliance with the standards of the set country


ISSUES

I. WATER TANK COVER : Uneven fitting or Poor support

CORRECTIVE ACTION: Improve design of tank and add support for cover

II. WATER TANK COVER : Gaps

CORRECTIVE ACTION: Improve design of tank and add support for cover


III. CARTON AND PACKAGING : Damaged Carton

CORRECTIVE ACTION: Careful handling and transportation of product

IV. MANUFACTURING DEFECT : Damage of water tank edge

CORRECTIVE ACTION: Proper inspection of back and front panel edges before allowing

it in the assembly line


PROJECT NO. 5

WINE CHILLER FEASSIBILITY STUDY

PROJECT HEAD

Mr. N Krishna


NEED OF THE PROJECT:

WOIL is planning upon introduction of it’s wine chiller range in the Indian market. These

chillers are originally manufactured in The Whirlpool Corporation in China. Before the sales

to begin, it was required that a feasibility study be done in our plant to ensure the satisfactory

working of the chillers in India.

The major concerns regarding this were the climatic pattern variations in India and China. So,

the commencement of this project was done by having a few informative sessions with my

seniors, so as to conclude upon which tests need to be performed to justify the feasibility of

the appliance.

The tests performed were:

Humidity test

Condensation test

NLPD (No load Pull Down)

METHODOLOGY:

1. Wine chillers model no. ARC 1300 and ARC 1400 imported from China Plant.

2. Weather condition pattern study of China and India to understand variation.

3. Concluded upon the test conditions to be maintained while performing the tests.

4. Commencements of tests:

a. Humidity test: The wine chillers were exposed to the humidifier maintaining

a humidity of 63%RH

This product was projected to be launched in NCR Region initially and based

upon sales results, the product would then be launched in other zones of the

country.

The average temperature in Beijing, China is 49%RH i.e. 14%RH value drop

from NCR Region’s value.

b. Condensation test: The External Condensation @ 85 to 90% RH and ambient

Temp 32 to 38 Deg were maintained for this test in accordance to the

temperature and condensation rate value standards in India


c. NLPD: No load pull down test performed for a time duration of 16hours with

8 hourly inspections to check for defects, if any.

THEORY:

The ideal temperature range is between 45° F and 65° F (and 55° F is often cited as close to

perfect), though this isn’t an exact science.

According to alcohol temperature standards, the temperatures at which each type of alcohol

should be stored is as follows:

Beer: 45-60 degrees F

Wine: 45-55 degrees F

Whiskey: Room Temperature

The shelves in the wine chillers have been numbered from 1 to 6, to illustrate the later

mentioned test results properly.


HUMIDITY TEST

Model no.

ARC 1300

Climate category

ST

Refrigerant

R600a

Amount

25g

Insulation blowing

gas

C-Pentane

Rated voltage

220-240

Rated frequency

50Hz

POWER INPUT

74W

rated current

0.45A

power lamp

0.7W

net weight

28.5kg


Pn

t

Para

met

er

TIME M

AX

MI

N 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6

1 SHEL

F 1

4

3

40.

2

35.

4

31.

3

28.

5

26.

8

25.

7

25.

1

24.

7

24.

5

24.

4

24.

3

24.

3

42.

5

24.

3

2 SHEL

F 2

4

3

37.

8

30.

8

26 23.

2

21.

6

20.

6

20 19.

7

19.

4

19.

4

19.

3

19.

3

42.

5

19.

3

3 SHEL

F 3

4

3

35.

9

27 21.

6

18.

7

17.

2

16.

3

15.

7

15.

4

15.

2

15.

1

15.

1

15.

1

45.

5

15.

1

4 SHEL

F 4

4

3

33.

6

24 18.

5

15.

4

13.

8

12.

8

12.

2

11.

9

11.

7

11.

6

11.

6

11.

6

42.

6

11.

5

5 SHEL

F 5

4

3

28.

3

17.

5

12.

1

9.4 8.1 7.3 6.8 6.6 6.4 6.3 6.3 6.4 42.

7

6.3

6 SHEL

F 6

4

3

20.

8

10 5.9 4.1 3.3 2.7 2.5 2.3 2.3 2.3 2.3 2.3 42.

2

2.2

7 DO

ME

4

3

71.

3

48.

3

48.

6

49.

4

49.

7

49.

6

49.

4

48.

8

48.

2

47.

5

47.

5

48.

4

78.

9

43.

2

8 DISC

HAR

GE

4

3

52.

4

59.

3

61.

9

63.

1

63.

9

64 63.

9

63.

7

63.

8

63.

8

63.

8

63.

7

64.

5

40.

9

AVERA

GE

43.

0

32.

8

24.

1

19.

2

16.

6

15.

1

14.

2

13.

7

13.

4

13.

3

13.

2

13.

2

13.

2

50.

2

20.

4

COOLI

NG

GRADI

ENT

0.0 23.

8

43.

9

55.

3

61.

5

64.

8

66.

9

68.

1

68.

8

69.

2

69.

3

69.

4

69.

4

NA

COOLING

RATE (in

⁰C/hour)

0

.

0

47.

6

43.

9

36.

8

30.

8

25.

9

22.

3

19.

5

17.

2

15.

4

13.

9

12.

6

11.

6


PERCENTAGE

COOLING

20.

47

18.

88

15.

84

13.

23

11.

15

9.5

9

8.3

7

7.3

9

6.6

1

5.9

6

5.4

3

4.9

7


Model no.

ARC 1400

Climate

category

ST

Refrigerant

R600a

Amount

30g

Insulation

blowing gas

C-Pentane

Rated

voltage

220-240

Rated

frequency

50Hz

POWER

INPUT

85W

rated

current

0.5A

power lamp

0.7W

net weight

32.5Kg


Pn

t

Paramete

r

TIME M

AX

MI

N 0 0.

5

1 1.

5

2 2.

5

3 3.

5

4 4.

5

5 5.

5

6

1 SHELF 1 4

3

41

.5

37

.5

33

.5

30

.2

27

.8

26

.2

25

.3

24

.7

24

.2

24 23

.8

23

.7

45

.5

23

.7

2 SHELF 2 4

3

39

.3

32

.3

26

.6

22

.6

20

.1

18

.5

17

.5

16

.9

16

.4

16

.2

16

.1

15

.9

45

.2

15

.9

3 SHELF 3 4

3

36

.9

28 21

.8

17

.8

15

.3

13

.7

12

.7

12

.1

11

.7

11

.4

11

.3

11

.2

44

.8

11

.2

4 SHELF 4 4

3

34

.8

24 17

.4

13

.5

11

.2

9.

9

9 8.

5

8.

1

7.

9

7.

8

7.

6

45

.5

7.

6

5 SHELF 5 4

3

29

.5

17

.9

11

.7

8.

3

6.

4

5.

2

4.

4

4 3.

7

3.

5

3.

4

3.

3

44

.8

3.

3

6 SHELF 6 4

3

23

.9

11

.4

5.

6

2.

5

0.

9

-

0.

2

-

0.

8

-

1.

2

-

1.

4

-

1.

6

-

1.

7

-

1.

8

44

.5

-

1.

8

7 DOME 4

3

59

.5

68 71

.9

73

.5

74

.2

74

.3

74

.3

74

.3

74

.3

74

.2

74

.2

74

.2

74

.4

43

.1

8 DISCHAR

GE

4

3

65

.3

73

.1

76

.2

77

.6

78 77

.9

77

.8

77

.8

77

.7

77

.6

77

.6

77

.6

78

.1

42

.3

AVERAGE 43.

0

34.

3

25.

2

19.

4

15.

8

13.

6

12.

2

11.

4

10.

8

10.

5

10.

2

10.

1

10.

0

52.

9

18.

2

COOLING

GRADIENT

0.0 20.

2

41.

4

54.

8

63.

2

68.

3

71.

6

73.

6

74.

8

75.

7

76.

2

76.

5

76.

8

NA

COOLING

RATE (in

⁰C/hour)

0.0 40.

4

41.

4

36.

5

31.

6

27.

3

23.

9

21.

0

18.

7

16.

8

15.

2

13.

9

12.

8

PERCENTAGE

COOLING

17.

37

17.

82

15.

71

13.

59

11.

75

10.

26

9.0

4

8.0

4

7.2

3

6.5

5

5.9

8

5.5

0


CONDENSATION TEST

Both machines cleaned thoroughly and dried before test

Flowing water droplet found after 8hrs run @ 85 to 95 % RH


No Condensation found on side walls Condensation observed on side walls

Condensation observed on rear walls

NOTE: The conclusions of this project cannot be shown due to confidentiality concerns.


CONCLUSION:

As an undergraduate of Thapar University, I would like to say that this training program is an

excellent opportunity for us to get to the ground level and experience the things that we

would have never gained through going straight into a job. I am grateful to Thapar university

and WOIL for giving me this wonderful opportunity. The main objective of the industrial

training is to provide an opportunity to undergraduates to identify, observe and practice how

engineering is applicable in the real industry. It is not only to get experience on technical

practices but also to observe management practices and to interact with fellow workers. It is

easy to work with sophisticated machines, but not with people. The only chance that an

undergraduate has to have this experience is the industrial training period. I feel I got the

maximum out of that experience. Also I learnt the way of work in an organization, the

importance of being punctual, the importance of maximum commitment, and the importance

of team spirit. The training program having three destinations was a lot more useful than

staying at one place throughout the whole six months. In my opinion, I have gained lots of

knowledge and experience needed to be successful in a great engineering challenge, as in my

opinion, Engineering is after all a Challenge, and not a Job


REFERENCES:

www.google.co.in

www.whirlpoolindia.com

www.wikipedia.org

www.wportal.com

http://www.google.co.in/

http://www.whirlpoolindia.com/

http://www.wikipedia.org/

http://www.wportal.com/

Date post:	15-Apr-2017
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Industrial Internship Report

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