1. 1
Company Mission
Promote Reliability in Everything We Do In the Field Of Household Appliances.
Company Vision
Make Dawlance A Global Brand by Practicing Reliability: Make Pakistan Proud
Of Us.
Student Name : Aoun Murtaza
Institute : PAF – KIET
Student ID : 6277
Department : Electrical
Internship Period : 30 Dec 2016 - 15 Jan 2016
Mobile No : +92313-2408693
Email Address : aoun.murtaza@outlook.com

2. 2
PREFACE
This report contains the information about those Departments which
are visited by the internees. Whatever the machinery seen and the
processes are observed, attracting the human mind and realizes the men
what science has achieved and what kind of miracles has been done by it.
Basically United refrigerator company ltd. (Dawlance) is quite attention
attracting industry it provides lot of opportunities to see, to observe, to
achieve and to get the lot of experience about the industry as well as about
the machinery.
The technology installed at united refrigerator company ltd. (Dawlance) is the
latest one and it includes the hardworking labors, employees who give their
best for the overall effectiveness of the company.
This report may also contains the facts and the real figures of the various
departments which are very beneficial for our experience and the also for the
practical knowledge. The functions and the details of their working and the
process as well as the timing and work break down structure is also
mentioned in this report.

3. 3
ACKNOWLEDGEMENT
We are very thankful from the core of my heart to honorable ASSITANT VICE
PRESIDENT, “United Refrigerator company ltd. (DAWLANCE) “ , ABDUL ALEEM
KHAN for providing us opportunity for training and whose intelligent, wise
and sound leadership has converted manpower into winning combination by
this industry into a gold mine.
We wish to express my deep gratefulness to Whole HR) for their consideration
and supervision. It was a memorable time in united refrigerator company ltd.
(Dawlance) due to his kind concern.
We are also thankfulto all concerned manufacturing supervisor and engineers
for their precious advice and for the great encouragement and cooperation,
because of which we have successfully completed our internship training of
UNITED REFRIGRATOR COMPANY LTD. (DAWLANCE) where we learned a lot.

4. 4
CONTENTS
DEPARTMENTS
ProductionII
(shearing, sheet Metal andwelding )
 Shearing section
 Sheet metal section
 Welding section
 Cabinet
 PC sheet
 Freezer door
 Basic panel
 side panel
 Compressor support
 Ref door and many more
PRODUCTION III
( THE PAINTING SHOP )
 CABINET painting shop
 EVAPORATER painting shop
 CONDENSOR painting shop
 DIP- COATING (Shelf painting shop )
PROUCTION IV
(CONDENSOR MANUFACTURING AND OTHERS)
 Shelf making section
 Condenser making
 Iron handing section
 Chrome section
 U-V Light section.
PROUCTION V
( PRE – FOAMING )
 What is PRE – FOAMING??
 Process of PRE – FOAMING & Stages.
PRODUCTION V
( FOAMING )
 What is FOAMING??
 Process of FOAMING??

5. 5
PRODUCTION VI
( ASSEMBLY LINE )
 What is Assembly line???
PRODUCTION I
(PLASTIC MOULDING SECTION)
 Compounding section
 Injection section
 Hot stepping section
 Steam print section.
 Extrudes section
 Cable section
MAINTENANCE
 What is MAINTENANCE??
 Objective of Plant Maintenance??
 Importance of maintenance.
 Methods of maintenance.
 Maintenance at Dawlance.
QUALITY CONTROL DEPARTMENT
 QUALITY AND CONTROL (Definitions)
 What is QUALITY CONTROL???
 Quality Control At Dawlance.
 Quality Engineering Cell.
 Incoming Quality Control.
 Self-Quality Inspection.
SHEARING, SHELF METAL AND WELDING
Shearing
To shear off requires size of sheet is called a shearing process.
Sheet -Metal
The various processes that have been performing over the metal sheet sop that give is
require shape is to be called a sheet metal.
Welding
A process of permanent fastening important type used the most important type used in
Dawlance is tug welding.
 It is the refer color; production eleven is the section where the man body of
refrigerator is to be manufactured.
 Though the production elevens section is used to manufacture a lot of component
put the cabinets is of the important component of production eleven section.

6. 6
RAW-MATERIAL OF PRODUCTION - II
The raw- material of production of to (in the sheet form)
 Metal steel
 Galvanized iron
 Vinyl coated Material (VCM)
 Aluminum
SHEARING SECTION:
One the raw-material is receive from the store the sharing section is something that
actually share of the sheet according to requires size of specifications. The cabinet sheet is
to be share of the sizing of
 Length = 3824mm
 Width = 655mm
 Thickness = 0.4mm
Other thing also shares off according the specifications.
SHEET METAL SECTION:
There are basically no of parts has manufactured in this section.
The sheet metal section is basically best upon the 4 major areas which are as follows.
 Automatic sheet feed
 Whole processing and notch (bending)
 Forming section
 Pressing section
The sheet metal is basically used to produces a no of parts of refrigerator, such as
 Cabinet
 PC sheet
 Freezer door
 Basic panel
 Side panel
 Compressor support
 Ref door and many more
CABINET:
The cabinet is to manufacturing once the sheet is receive from sharing the automatic sheet
feeder suck the sheet and feed the sheet then sheet through came is to be shift into the
forming section where the form of profile and embossing can take place and afterward that
formed embossed is equally bended to form a cabinet.
PC-SHEET:
The pc sheet is the sheet that makes separates the freezer unit ref: a in other word we can
say that the I.C sheet is used to make separate n/n ref and free from the upper side of
refrigerator
PROCESS:
It can be making by follow the following operation.
 Notching process
 Forming process
 Embossing process
 Whole process

7. 7
BACK PANEL:
It is back side of refrigerator body that is to be attached with the cabin net.
It is to be noted that is in small size refrigerate there Is only back panel and there is no need
for the bottom end as it also requirement in the refrigerator.
PROCESS:
The back panel is to be made by the
 Drilling the piece of M.S of sheet
 Notching that piece
 Whole also with the machine
 First bending
 2nd Bending
After that this do of is too welded with the cabinet by spot welding process.
SODE RANGE:
It just like the side panels it also requires 1st cutting and the 2nd cutting and then just and
2nd pending.
FREEZER DOOR:
It is the front door of the refrigerator and it is to be made by the VCD material sheet.
The size of VC sheet used a freezer door
 Length = 546 mm
 Width = 768 mm
PROCESS OF FREEZER DOOR
The freezer door is according following the process
 Notching
 Handle pressing
 Embossing
 First banding
 Final banding
REFRIGRATOR DOOR:
It is also be made with the VCD type of material and it make we of same process as that of
freezer door each and every step in same.
COMPRESSOR SUPPORT:
It is the part that can be placed in the both part of the ailment and it support the
compressor.
PROCESS:
The process to manufacture the compressor is as
 Whole plating
 Further 2 more whole
 Just bending
 Final banding
WELDING SECTION:
Basically welding is the process of permanent fastening therefore is the section all or same
part are to fasten by tug welding so that the required type and shape of cabinets is to be
shift the painting shop.

8. 8
Basically at sheet metal the welding section is used to performthat activity so that the form
bended and imposed cabinet is to be welded with the back panel and Sight panel and it is
screwed with the compressor support. At the end of the welded section the welded cabinet
is to be shift to the paint shop for the further paint processing.
PRODUCTION III THE PAINTING SHOP
It is basically the painting section used to paint the various iron so that it could be transfer
into the final assembly shop.
It includes the,
1. CABINET painting shop
2. EVAPORATER painting shop
3. CONDENSOR painting shop
4. DIP- COATING (Shelf painting shop )
We had already discussed the dip-coating (shelf painting) and were here now we learned
the cabinet and evaporator painting
CANBINET PAINTING SHOP
As we know that whenever we are painting anything first of we need phosphate process so
that the cabinet is to be easily painted. The cabinet here though the following painted
stages.
STAGES # 1
High pressuring over the refrigerator so that to remove as the welded particle.
STAGES # 2 PHOSPHATING
The phosphate process is actually though the following tanks there are basically 4 different
tankers. Out of them 2 of the chemical tank, 1 of water tank and 1 of di-ionized tank. The
phosphate process begins after following the first step now the cabinet is dipped into the
tank 1 (which has the metaphoric chemical) and then dipped into the tank2 (which Laos has
the same chemical).Once the cabinet taken –off from the tank 2 then it is to be dipped into
the tank 3 which has the raw water. Finally the cabinet is to be placed into the di-ionized
tank and then the cabinet is to be phosphate.
STAGE # 3 DRY OVENS
At this stage the phosphates cabinet is placed into the dry even which has the temperature
of 110; 140 degree centigrade.The dry oven has two functions.
First it is use to dry the water and moisture and secondly it is also make able the cabinet
sheet to be attain the more powder (as in next step).
STAGE # 4 POWDER ROOMS
After dry oven the cabinets are to be hanged into the conveyor hanger and it is to be
transferred towards the powder room. A powder room is a highly automated room that is
used for powdering or coating of powder over the cabinets. The powder room has 15 gm
over the cabinets and this powder can be done by the gun systemin a powder room so that
the layer of powder is to be coated over the cabinet. The functioning of powder room is
done by the automated system which is controlled by then computer based systemand it’s
basic to coat a layer of powder over the cabinet. In powder room by gun system the
cabinets are coated with the JOTUN powder of layer 35 to 70 micron.
STEP # 5 BACK OVENS

9. 9
This is the end process of painting shop here the powder cabinets are to be backed into the
oven so that the powder is too melted and forming in the paint over the cabinet. Actually in
back oven the polymerization process takes place because once the temperature has been
provided to the powder tends to polymerized and forming a chain so that it is to be
transmitted over the cabinet.
IMPORTANT TO REMEMBER
The cabinet paint shop has the capacity to paint 1800 to 1900 cabinet paint per 24 hours i-e
capacity = 1800 to 1900 cabinets paint per 24 hours.
EVAPORATER PAINTING SHOP
As we know that the evaporator in consider to be the heart of refrigerator and without the
evaporator refraction is not exist. Evaporator is the part that makes cooling within the
refrigerator. Evaporator is fitted inside the refrigerator and it is to be painted in white color.
The process of evaporator painting is as same as that of cabinets one within certain
amendments. However evaporators painting are requires phosphate and powdering etc. We
can put forward the evaporator painting in the following stages.
STAGES # 1 EVAPORATER PHOSPHATING
The evaporator phosphate process is done in 4 different tanks. First of all the evaporator is
dipped into the tank -1 which has the met clean chemical. After that the evaporator stays in
tank-2 and tank-3 which is rinsing water tanks. After that it is to be dipped into the tank-4
which has the metachromatic chemical. Finally again it is to be dipped into the rinsing water
tank.
STAGE # 2 DRY OVENS
After Phophating the evaporator is to be dried into the dry oven which is at the
temperature of 140 to 160 degree centigrade so that to remove all the moisture effect and
also make the evaporator to sustain the powder.
STAGE # 03 POWDER COATING
The powder coating over the evaporator is to be done on both the front and back side of
the evaporator.
STEP # 04 BACKING OVENS
In last the evaporator is to be shifted towards the back oven which is the temperature of
205 to 220 degree centigrade and where the powder is polymerized and evaporator is to be
painted.
CONDERSOR PAINTING
Like all other painting section shops the condenser painting is also followed the same
process as that of other painting process.
PROCESS OF CONDENSOR PAINTING
The process of the condenser painting is being done in the following two different stages.
1. Phosphating
2. Painting
PHOSPHATING
The phosphating if condenser is to be done by passing through the no. of condenser to
various chemicals which is in the tank. First of all the manufactured condenser is dipped

10. 10
into the met clean 375 tank and it stayed over there at 1 to 5 min. Now the condenser is
then dipped into the fresh rinsing water into the 2nd tank. After that it is to be dipped into
the tank of metaphor 247 chemical tank. And after that through pressure vessel it is to be
dried. At the end of phosphating the condenser supposes to shift into the dry oven and
where the all moisture is dried from the phosphate condenser.
PAINTING
The painting begins when JOTUN powder is to be paint over the condenser after
phosphating on both sides of condenser and this condenser with the help of crank is to be
inserted into the back oven so that powder is to be converted into the layer of painted
color. The temperature of back oven is about to be of 250 degree centigrade and it is
placed within the back oven for the period of 11 min. It is important that the JOTUN powder
use in condenser painting section if of different form and have its own load.
Important to Remember
The capacity of condenser paint shop is 1700 condenser paint per day.
Like all other production section the PRODUCTION IV is also one of the most important
sections of refrigerator production. It is use to make some important and value able item of
refrigerator.
There are various sections those are comes under production IV category
1 . Shelf making section
2. Condenser
3. Bottom condenser
4. Iron handle making section
5. Galvanized section
6 . Chrome section
7. U-V light section
Throughout all section of PRODUCTION IV have their own importance and without them
the processing is incomplete but the most importance item produce by production IV is the
condenser because without the functioning of refrigerator is impossible. Now we shall
discuss each section in detail….
SHELF MAKING SECTION
The shelf of the refrigerator is to be manufactured in this section. This shop is used to make
all different type of the shelf of different refrigerator model and its highly depends upon
the customer requirement e.g if the administration of the production Iv receive the plan
from production planning department to manufacture 9175 WBM’s shelf so they supposed
to act according to the requirement.
The capacity of the shelf section is to produce 31000 shelf per day and its make use of 7
different type of machine and also having the strength of 57 peoples.
EQUPMENT IN USE
The shelf manufacturing makes use of different machines and welding device.
 Starter and cutting machine
 Pressing machines of different type
 Tag welding

11. 11
PROCESS OF SHELF MAKING
The processing of shelf manufacturing begins when the raw coil of thickness 2.5 mm is been
receive through store and then the starter cutting machines first make starter the coil and
then cutted of required size (depends upon the requirement), now the cutted coil is then
bended and it is to be welded now the frame of the shelf is bean and also ready for the
further processing. Now again the no. of strip is also to be cutted so that there can fixed
into the shelf and then the shelf is to be welded by the tug welding process. Now in order
to support the shelf various section of straight shapes, L – shapes, Z- shapes, the basic
purpose of these section is that they used to provide the support to the shelf of the
refrigerator.
DIP- COATING / PAINTING SHOP
It is basically the shop which is use to painting the manufactured shelf but very few other
parts are also been painted in this shop.
PROCESS OF DIP COATING PAINITNG
The actually process is begins with the PHOSPHATING. The phosphate process is based
upon the various chemical in different tanks, therefore first of all the manufactured shelf is
first dipped into the tank -1 ( which contain the dioxide chemical ) within 10 to 15 min , the
shelf is to be placed in this tank and then it is dipped into the 2nd tank (which contain only
raw water ) and within few minutes the it is to be dipped into the 3rd tank ( which is of
Guadine 20 chemical ) and it is placed up to 5-7 min and finally again dipped into the rinse
water. Once the phosphating the next is the coating painting The phosphated shelf is then
placed within the Backing oven (which has the temperature of 225 degree centigrade) after
a few min these shelf are then to be dipped into the powder (JOTUN POWDER) and then
these are placed into the dry oven (has the temperature of 225 degree centigrade) and in
last it is to be dipped into the water.
Capacity of DIP-COATING section is 1000 shelf paint per day CONDESNSOR
MANUFACTURING
Every manufacturer knows the importance of condenser in refrigeration process and
without condenser the existence of the refrigerator is almost impossible because it is
something that maintain the refrigeration cycle. Therefore in order to make the condenser
manufacture the condenser much careful analysis is required. This section is use to make
two different condenser.
i) Back panel condenser (actually called as condenser)
ii) Bottomcondenser
The actually the first step towards condenser manufacturing is taken by the engineering
department.
Engineering department through critical analysis used to check the actual condenser and
then give the effective and efficient proposed way to manufacturing in the shape of
drawings, equipment’s etc.
BOTTOM CONDENSOR
Most of people even don’t know is there any condenser in the refrigerator
that place in the bottom of the refrigerator. The basic function of this condenser is also to
reduce the temperature like other condenser do so .

12. 12
PROCESSING OF MANUFACTURING THE BOTTON CONDENSOR
The process of manufacture a bottom condenser requires a drawing and the drawing varies
from model to model of refrigerator therefore the size and coil of bottom condenser also
varies. With the help of different pressing machine to complete the sheet and bending the
coil as per requirement through tug welding is then to be fitted.
BACK PANEL CONDENSOR (ACTUAL CONDENSOR)
It is one of the most important and more meaningful part of the refrigerator and the
effectiveness of condenser is necessary for the active life of the refrigerator.
PROCESS TO MANUFACTURE A CONDENSOR
Once the plan has receive by the PPC to the production IV section and according to this plan
the condenser of particular quantity of particular model has to manufacture. The first is to
make use of MS sheets cutting strips then with the help of shutter machine a late form in
which certain operation carried out one by one such as embossing, fins making is to be
done. The bending section first to cut the coil and straight it with the straighter shutter
machine and then bend the coil through is winches and dies is that the required bending is
to be obtained. Once the plate and bending is prepared now with the help of tug welding
there plate with bended is to be welded. Now the end plate of condenser that has been
manufactured by pressing machine is also to be welded by tug welding process. Now at the
end the strip of MS also welded so that to provide the proper reinforcement to the
condenser. By following the above stages the condenser is said to be manufactured.
GALVANIZED SECTION
It is the very little type of section and its purpose is to nickel the various parts such as
i) Leg holder
ii) Top middle bottomhinchees.
iii) Screws and others parts.
The basic behind this section is to do the nickel plating so that to remove all the abrasive
material, oil, Greece etc.
CHEMINCAL IN USE
Following are he chemical those are used in this section
• Zinc brightener
• Zinc Californiazinc anodenitric acid
ALUMINIUM HANDLING SECTION
It is the section which is bound to make the aluminum handling for the refrigerator for the
opening and closing of the door.
PROCESS OF ALUMINIUM HANDLING SECTION
Already manufactured profile of aluminum is to be purchased from abroad and then this
profile is cutted according to specification of handle requirement. Once the size is to be
cutted then with the help of numerically control milling machine a profile is being made to
provide groove type of section so that the handle is to be fixed.
CHROME SECTION
Once the handle cover is been made by the modeling section to make the handle cover
then the crossing of that part is to be taken place.

13. 13
PRCESS OF CHROMESECTION
The chroming is to be done by following the certain steps
STEP # 1 ETCHING BATH
First of all the handle cover is dipped into the chromic acid in the etching bath which is all
the temperature of 65 degree centigrade.
STEP # 2 WATER TANK
After the etching process the handle cover is to be dipped into the raw water.
STEP # 3
After that it is to be dipped into the HCL and also into the neutralization drum.
STEP # 4
After wards it is to be placed into the activation bath which also includes certain amount of
HCL.
STEP # 05
Now at this the nickel sulphate electroplating is to be done.
STEP # 06
After that it is to be dipped into the copper the layer of copper in comes over the handle.
STEP # 07
Nickling is to be done at this stage hence the nickling also to be placed over the handle.
STEP # 08
At the very last stage the chroming is to be done over the handle.
U-V LIGHT SECTION
The only haxon model of refrigerator inn which there is type of fan placed within the
refrigerator. The function of that fan s that when door is closed it’s used to provide the air
sot that the ice is to be melted for the effective cooling of refrigerator. So in this section
fan with its parts to be assembled here.
PRODUCTION V (PRE- FOAMING)
Till production we are making, painting the certain parts so that they should combined to
form the original product.
•The production V ( i-e PRE – FOAMING ) as the name suggest it is the pre of the foaming
that is it the place where the various operation is to carried before it is to be placed to
formed.
•At the pre foaming the necessary item such as the liner, freezer and anti- moisture tube,
evaporator are to be inserted into the actual body of cabinet.
PREFOAMING PROCESS
The actual process of pre-foaming is starts when the painted cabinets from the cabinet
painting shop are comes to the pre-foaming zone. We can underline the each and every
step of pre foaming now
STEP # 01
First of all the compressor support is un-screwed from the painted cabinet.
STEP # 02
The gum- type material named as silent is to be inserted into the corner edge of the
painted cabinet in order to make proper isolation.

14. 14
STEP # 03
Washer type material is tape within the four whole if the back panel so that condenser is to
be screwed easily in it.
STEP 04
Bottom profile is inserted within the embossing area in the bottom.
STEP 05
Spaces in fixed in the back panel so that the pipe which is fitted in it.
STEP 06
Groomer also fitted with the wholes.
STEP 07
Anti-moisture strip a black pipe is to be inserted within the profile cabinet. The anti-
moisture strip has two functions first as the name suggest its used to prevent from the
corrosion effect also the gas kit ( rubber type ) within the door is causes to crack because of
cooling inside so it is also prevent this as it is connected with the compressor.
STEP # 08
The freezer box is to be further includes the following sub- systems Sub – step 1:- the
painted evaporator from the EMD is bending by the press machine. Sub-step 2:- the bended
evaporator is then to be check for the little inspection. There are basically two different
inspection tests,
i) A LEAD DETECTOR MACHINE:-
A machine which is used to detect the all the pipe and join of the evaporator by inserted
the Freon gas. The detector even has the capability to detect 1.0 micro gram of area. Once
the evaporator is OK then it is to be shifted for the next test. The statistics show that there
are basically 8 to 10 evaporators rejected in lead detector test. Once the purpose is
established hen the Freon gas is to be ejected and stored and from the evaporator.
ii) The 2nd inspection include is to check the mass flow rate within the evaporator and it is
to be done by inserting the Nitrogen gas from the capillary. It is also gives the benefits in
the shape that it tends to clean the evaporator by the nitrogen gas.
Sub- stage 03
Obtaining a evaporator frame. The evaporator from is to be make by joining the evaporator
the side plate thorough a silicon type of material. Now this flow is to be fitted with the
freezer side of the cabinet.
STEP # 10
The ref portion of the refrigerator is to be undertaken and it can be divided into the
following sub steps.
Sub – step 01
The liner which is come from the thermosetting section is first sized and cutted by the press
machine. With the size the whole also produce which is of evaporator and thermocouple.
Sub-system 02
After that the head after and thermostat cover is taped within the liner.
Sub- system 03
A light pipe is having the wire which is the fitted with the thermostat on one hand and head
after on the other hand.
STEP # 11
Liner is fitted within the cabinet i-e liner completely fitted within the cabinet. That’s the
end of the pre-foaming suction.

15. 15
FOAMING SECTION
The foaming section is a place when the pre-foamed cabinet is too foamed by the
automated machine.
The foam which is to be inserted within the pre-foamed foam than it is solidifying within a
few minutes.
The foam is basically made of two different types of chemicals.
i) Polyoal
ii) Iso – cynate
iii) R141B (a gas which is used as a catalyst)
The foaming section has the capacity to filled 81 mold foam per hour i-e capacity = 81
mould foam per hour.
PROCESS OF FAOMING
The process of foaming section begins by fixing the jigs and fixture with in the ref section so
that while foaming the inside the refrigerator is not bend etc. After that the highly
automated the mixture of foam is to be inserted within the cabinet. The Dawlance has 9
molding foam hangers which is highly automated and used to operate according to the
sensors and actuators and various other things. Basically the mixing of chemicals as to form
the foam is to be as
100 % of polyoal
1260 % of iso –cyanides
16 % of R141B.
It can be termed as,
P : g : I
100 : 16 : 1260
ASSEMBLY LINE
This is the very last portion of this shop also the refrigerator manufacturing. At this stage the all
parts that we have made in deferent section such as sheet items or main body items we
made in sheet metal section, plastic items we have marked in molding, condenser we have
made in production IV, shelf we have make in production IV, freezer and ref door also
assembled Therefore is assembling shop we are the assemble all items to make the
refrigerator. At the end certain inspection made refrigerator takes such as vacuum
generation and then the Freon gas is also inserted into the refrigerator. At the end of
assembled line the refrigerator are to be packed and transferred to the store room as an
inventory so that it is it be distributed
As the name suggest plastic molding the production is said to manufacture all plastic type
of equipment that can be used in refrigerator manufacturing. There are 6 section includes
in molding each section have its own task to with they can act these are as follows,
o Compounding section
o Injection section
o Hot stepping section
o Steam print section.
o Extrudes section
o Cable section

16. 16
The compounding and injection are the most basic sections and these are those which used
to produce they different plastics items in proper quality and quantity.
COMPOUNDING SECTION
The raw material of various plastics material in the form of huge grain is received in
compounding portion through store room. These raw materials includes,
 PS
 ABS
 HIPS
 LIPS
 PC
 NYLONE &
 PP.
The compounding section used to mix the raw material with the pigment so that required
color of particular item is obtained. The mixing can be done by two different type of
devices.
i) DRUM MIXTURE
ii) VERTICAL MIXTURE
DRUM MIXTURE
Drum mixture is a device which consist of two different drum and b/w the there is a motor
that has the rotatory function. The motor used to rotate the drum. Each drum has the
capacity to take two beg ( each beg of 25 kg i-e 50 kg ) so we can say that drum mixture can
take 100kg of a material in a time.
PROCESSING OF DRUM MIXTURE
The processing of mixing of material through drum mixture is such that mixture the beg of
25 kg of material insert into the drum then the amount of
pigment according to the standard weighted and insert into the drum and then again
another beg also inserted into the drum and similarly the next drum also filled.
Now the drum mixture start rotating and mixed the material with the pigment and in 5 min
the material is kept out just within the 5 min.
Therefore we can say that the drum mixture has the capacity of 100 kg of material to be
mix in 5 min.
VERTICAL MIXTURE :
It is also the mixing device and used to mix the material with the
pigments go that the required material can be obtained.
Though it can be used to mix all type of material but in compounding section of dawlance it
is specifically used to mix the poly storing (IS) material with the pigment of T- brown , T
green, smooth gray. Height impact poly strien (HIPS) material with the pigment of brilliant
white.
INJECTION SECTION:
• It is heart of the moulding section here all plain parts are been manufacture
through injection mould mallina.
• The highly automated machine CLF- INJECTION MOULDING MACHINE
use in this section.
• The machine can varies clapping force i.e the injection moulding machine (CLF- 8OT)
has the minimum clapping force injection moulding machine (CLF- 800T) has the maximum
clapping force.

17. 16
• There are basically 52 CLF-MOULDING MACHINE’S are used and can vary in diff:
clapping force to make very small item to the heavy plastic item.
PROCESS OF CLF (INJECTION MOULDING MACHINE)
Basically the processing of CLf is based in the four different sections.
1. Hooper
2. Bassell
3. Injection side
4. Eject side
1. HOOPER:
First of all material (mixed material) has come from the compounding
section. Hooper actually use to collected the inserted material alive is the shifted in to into
the bassel.
2.BASSEL:
After Hooper the material hydraulic piers machine comes into the bassel. In bassl this
material first heated thorough 7- different zone and reach zone has two heaters.
3. INJECTION:
Once the material is to be melted with the help of heated now the material is to
be injected through layer 6 to 7 different stage into the injected mould.
EJECT:
After completing the ague the make part in then eject from the machine so that to perform
the work. From all these other part i-e. Carriage is used to be mixed
HOT STEPPING SECTION:
It is little section in which chosen stepping is to be done over the freezer door pocket that
desirable the various sign.
EXTRUADES SECTION:
It is of section actually injection molding process and it is also used to make the profile that
has been mould plastic material and give the shape of profile.
CABEL SECTION:
The refrigerator wire connection from the electric requires a plug and cable so in this there
things are too manufactured. Once the wire (cables to be purchased that first of on this
cable are cables are to cutted the required size and then the folly steps are to be taken
1. Core stepping
2. Wire stepping
3. Pinch molding
4. Pinch folding
5. Pinch molding machine
SCREEN PAINTING:
As one has seen that there is numbering over thermometer regulator, also we have is
painting over the shelf “wider shelf “similarly these are certain coding we have seen, so in
thing reaction i-e “screen painting, there coating has been painted over the items. Today,

18. 16
in modern industry, equipment and machinery are a very important part of the total
productive effort than was the case years ago. Moreover, with the developments of special
purpose and sophistical machines, equipment and machinery cost a lot more money and
therefore their and does time becomes much more expensive. For this reason, it is vitally
important that the plant machinery should be properly maintained.
OBJECTIVES OF PLANT MAINTENANCE
i) The objective of plant maintenance is to achieve minimum breakdown and to keep the
plant in good working condition at the lowest possible cost.
ii) Machines and other facilities should be kept in such a condition which permits them to
be used at their optimum (profit making) capacity without any interruption or
hindrance.
iii) Maintenance division of factory ensures the availability of the machines, buildings,
and services required by other section of the factory for the performance of their
function at optimum return on investment whether this investment be in material,
machinery or personnel.
IMPORTANCE OF THE MAINTENANCE
i) The importance of the plant maintenance is varies with the type of the plant and its
production.
ii) Equipment breaks down leads to the inevitable loose of production.
iii) An improperly maintained or neglected plant will sooner or later requires expensive
and frequent repairs, because with the passage of the time all machines or other facilities
(such as transportation facilities), buildings, etc. wear out and need to be maintained to
function properly.
iv) Plant maintenance plays a prominent role in production management the plant breaks
down create problems such as,
• Loss in production
• Rescheduling of production
• Split material (because s udden s toppag e of proces s damag es in-process
materials).
• Failures to recover overheads (because of loss in production hours).
• Need for over time.
• Temporary work shortage- workers require alternative work.
METAINENCE METHODS
There is basically two different maintenance methods i-e
i) Tribology
ii) Tero technology
TRIBOLOGY
It is the method of maintenance that deals with the lubrications impact of the machine by
proper maintenance. It includes oiling, greasing etc.
TETO-TECHNOLOGY

19. 16
It is also the methods of maintenance that deals with the mechanical effect of the
maintenance such as repairing of the part of machine, overhauling of the machine.
MAINTENACE AT DAWLANCE
(United Refrigerator Company)
At Dawlance there is a separate maintenance which constitute of several engineers,
technicians, and a skilled labors. Their work is basically based upon the team efforts in
which each person has certain responsibilities. This section is centrally connected but all
other section of industry by means of computer network software (ORACLE) and also within
the telephone. They use to work into different format first they have collect the data of all
bug to small machines procession and divided these data of each part of machine into
various activities and also assign a scheduled of maintenance of each activity so that to
work accordingly. The second format on which they work is that whenever any break down
occur in a production as per receive the compliance of particular maintenance they work
upon it. Except production work there are other areas such as puncher shop, compressor
maintenance shop, generator maintenance, electrical maintenance department.
QUALITY CONTROL DEPARTMENT
Though there are no. of definition of quality but in very simple works it can be term as “To
meet the customer’s specification “.
CONTROL:-
The provision to control the action or plan is to be control so that to meet the requires as
per planned.
QUALITY CONTROL:-
Quality control refers to the control level of quality is that to lead to the customer
satisfaction.
• It is the provision under which the proper and effective quality it to be obtain so
that to lead the market position.
• In an organization the term quality is as big as it can and under a no. of quality units
are working their work to inspect the ongoing activity as per standard and then mark as OK,
HOLD, USAI, and REOWRK & SCRAPE.
QUALITY CONTROL AT DAWLANCE
The quality is given the major reliability at Dawlance and therefore the central quality
control department is been devised in different quality section
i) Quality engineering cell
ii) Incoming quality control
iii) Quality assurance
iv) Self quality at each manufacturing section
v) Quality process lab.
And many other departments ……
QUALITY ENGINEERING CELL
It is basically the quality section is which all the documentation is to be taken places

20. 16
It is use to keep the documentation like of each section and even each section’s item that
has produces….
a) Quality instruction
b) Work instruction
c) ITI (Instruction Testing Inspection)
d) Sampling Inspection
e) Quality status
Now we shall discuss each section in detail.
QUALITY STATUS
While inspected anything the duo full item are to be taken into 4 basic consideration rather
than just to be called as scraped i-e by reviewing whole parameter the decision regarding
the item is to be taken.
There is basically four quality status.
i) HOLD
ii) UAI (use as is)
iii) REWORK
iv) S CRAPED
It can be ills trade as ,
USE AS IS (UAI) = Though the part is not fully mismatched with the standard but the
negotiation between the manufacture and quality in charge is to be taken and the item is it
be USE AS IS (UAI).
REWORK = There are few items those are require to rework so that to be come into
the required expectation.
SCRAPE = the item is to be scared.
QUALITY CONTROL MANUAL
It is basically a manual that can help the operator to perform the work takes as it includes
all type of activities. These are those type of manual which use to perform the training
function to the operation because its includes set of instruction of every used item.
SAMPLING TABLE
As we know when raw material receive there are basically a no. of lots and each lot having
a no. of item therefore is extremely difficult to check each and every item and also time
consuming because if we are doing to inspect every item so it is very difficult for us to meet
the required demand. Therefore the process begins by checking first 3 lots completely i-e
100 % and then if the fault rate is same or reducing the accordingly move toward the
sample mood in which according to lot size the item are randomly selected. The sampling
mood sheet can be illustrate as ,
SAMPLING TABLE
LOT SIZE ACCEPTQUALITY LEVEL
SAMPLESIZE ACCEPT REJECT
2 to 8 2 0 1
51 to 90 3 0 1

21. 16
500001 to
over
13 1 2
• ITI (INTRUCION TESTING INSPECTION)
It is basically a document in which whole process and way of doing of
each and every part is given.
It is a document which includes all the defects even that has observed before in the form of
major and minor defects.
Basicallythere are 872 type of ITI’S are there.
• DC / IDC FORM
DC = DECIPLANE CHECK
IDC = INTER DECIPLANE CHECK
It is the document which bund to check the discipline of particular item i-e
the item like sheet coil is been check by the sheet metal inspector. After that it is inter
disciplinarycheck by the concerned related section.
• R E L IAB IL I T Y IN AN ACTION PROGRAM (RIAP)
It includes basicallya program which describes how training programs are to be
undertaken. What is the progress of training i-e how to be calculated? What is the
procedure of doing the basic task etc?
• IN C O M IN G QUALITY CONTROL DEPARTMENT
Incoming quality control is basicallya quality section whose function is to inspect all
incoming raw material that can be utilized for different purpose in different place. They
used to work according to the instruction has given in ITI of particular item and each ITI is
different for different items.
We also know the Dawlance (united refrigerator) can purchase the material both expert
from other countries and also taken from the local suppliers.
PROCESS OF INCOMING Q.C
The procedure of incoming quality control section to inspect the raw item can be under line
in the following steps.
STEP # 1:- RECEIVE PROCESS
It is the visually process once the raw material is receive the preform that has been given
within the raw material by the supplier is to check whatever written in the form of quality is
placed or not.
STEP # 2:- QUALTY INSEPCTION
It is the main inspection in which the raw material quality is to be inspect to mismatch with
the standards Initially the first three lot are to fully inspected i-e 100 % checking and after
that the defect level over in first 3 lots are satisfactory the we shall proceeds to the sample
mood when according to the lot size sample is randomly selected and then be inspected.
It is very much important to remember the incoming Q.C is not able to inspect all items just
like chemical type of material is to be inspected in Q.C lab and hence the C-FORMis to be

22. 16
making for that. Incoming Q.C usually make visual dimensional inspection. Now we shall
discuss the item as follows,
• E V AP O R AT E R
Evaporator is the type of item which is no. of time to be inspected starts from the Q.C and
then final assembly inspection. The Dawlance exports evaporator from china the suppler
name “Jau-su-shanfe”. Though testing supplier are also inspected but the existing supplier
“Jau-su-shanfe” is the major and more reliable supplier of evaporator. Evaporator is 100%
inspected and there is no concept of sample mood.
PROCESS OF EVAPORATER INSPECTION AT INCOMING Q.C
First of all the sizing of evaporator is to be inspected visually and then observe the dent to
be placed over the evaporator more importantly if that case the dent to be over the
bended area ( as is pre-foaming shop) the evaporator is to be rejected because no more risk
is to be taken.
• J O TUM POWDER
We know the usage of JOTUN powder i-e its use for the paining purpose if items. The
inspection of JOTUN is begins by batch the powder in term of their respective code and
colors. After that the C- form is made and its sample of every batch shifted to the Q.C lab
where the chemical is to be inspected in order to match the existing composition with the
standard one.
• C AB L E ASSEMBLYLINE SWITCH
As we have seen in pre-foaming stage when liner is prepared for fixed into the cabinet so
the hold assemblywith thermo state is taped over there. Therefore the cable is to be
termed as cable assemblyswitch and it is to be inspected in terms of equal dimension.
The multimeter is used to check continuity of cable etc. And many other item are to be
inspected at Incoming Quality Control (we are not in a position to describe each).