REFRIGERATOR FINLAL ASSEMBLY at GODREJ & BOYCE Pvt. Ltd. MOHALI, PUNJAB
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01-01-2011, 05:01 PM
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GODREJ Company was established in the year 1897 by Sheth Ardeshir Burjorji Godrej. The very first product of their colossal national establishment was lock. These were developed to perfection by initially experimenting & gradually devising improvement on imported ones.
REFRIGERATOR FINAL ASSEMBLY (RFA)
R.F.A is the designate area where the final assembly of refrigerator is made. All the work is done manually.
Stages in R.F.A:-
Plug-in & Plug-out section
Defect analysis stage
Final inspection stage
There are two assembly lines line1 & line2. All the parts( compressor, condenser, door, cabinet ect.) of a refrigerator assembled here. All the work is done manually.
The working in this section is initiated by merging of refrigerators of line1 and line2 on to the common line, this is generally a machine operated mechanism, the machine used for this purpose is commonly known as “auto merger”.
Other operations on common line
1. Door fitment of line1 refrigerator
2. Handle fitment line1 refrigerator
3. Logo fitment line1 refrigerator
Leakage testing area
leak detection is made by circulating nitrogen gas in to the particular refrigerator, if any signs of leakage is detected( ie. Change in pressore) it is transferred on to the repair area immediately in purpose to avoid any delay in the running procedure.
Evacuation Section is one of the most important phase in this assembly cycle. In this section the refrigerators are evacuated using vacuum pumps in order to remove air from it ,for the purpose that air contains moisture and the system will not condense under refrigeration pressure thus causing high operating pressure .This process take app. 45min. If there is large no. of refrigerator on the line then loading and unloading of bodies will take place.
After all the possible leak testing and proper evacuation the system are passed on to the charging section ,where each system is filled with refrigerant namely CARE30(ISOBUTANE+PROPANE).
Plug-in & plug-out section
In plug-in section the system are given power supply to inspect its working mode. The complete plug-in procedure is of approximately of 20 to 22 min. . This section is also manually done i.e. unloading and loading of the system are done here, so handling should be in a proper manner. This section also comprises of noise testing and cooling testing area where noise detection and cooling temperature of the system are made to be checked respectively. This section ends with the plugging out of system.
Defect analysis stage
In this section all the technical defect are checked. The main defect are
4. High voltage
5.Compressor not working
6.Dent & scratches on the refrigerator body
Defective bodies are taken away from the line and remaining are send to the stage5.
Analysis of Dents and scratches on line
The one and only and also the major problems in affecting the production rate are “Dents And Scratches” on the external body of the system. They actually mean a deformation on the external body of the system due to some reasons. These are not a problem until they are repairable but if not they just turn body of the system to be nothing but scrap.
Dents and scratches are the main problems in any sheet metal operating system unit. They result in a great production loss and a increase in manufacturing cost. According to data found, a single door dent leading to the system rejection causes a loss of about Rs.1200. Dents and scratches are found on side panels, doors and handles covers of the system.
Dents and scratches Analysis methodology:-
My motive was to find the most affected area of dents and scratches. For this I initiated my analysis by marking 25 systems on the line and inspected these systems at each and every stage under the R.F.A cycle.
After going through the following methodology, I have concluded that dents and scratches are mainly formed in the evacuation section, which is mainly due to improper handling of the system due to which there is a great production rate loss and an increase manufacturing cost.