INTRODUCTION TO THE COMPANY

Brighter Living

Type Public company

Industry

Founded 1897

Founder(s)

Headquarters India

Area servedWorldwide

Key people(Chairman)

Products Real estate, home appliances, furniture, security,

Revenue 216 billion (US$3.7 billion)(2013)

Employees26,000 (2013)
ABOUT GODREJ GROUP
The Godrej Group is an Indian conglomerate headquartered in Mumbai,
Maharashtra, India, managed and largely owned by the Godrej family. It was
founded by Ardeshir Godrej and Pirojsha Godrej in 1897, and operates in sectors
as diverse as real estate, consumer products, industrial engineering, appliances,
furniture, security and agricultural products. Subsidiaries and affiliated companies
include Godrej Industries and its subsidiaries Godrej Consumer Products, Godrej
Agrovet, and Godrej Properties, as well as the private holding company Godrej &
Boyce.

Established in 1897, the Godrej group has grown in India from the days of the
charkha to nights at the call centres. Its founder, Ardeshir Godrej, lawyer-turned-
locksmith, was a persistent inventor and a strong visionary who could see the spark
in the future. His inventions, manufactured by his brother Pirojsha Godrej, were
the foundation of today’s Godrej Empire. One of India’s most trusted brand,
Godrej enjoys the patronage and trust of around 500 million Indians every single
day.

With 7 major companies with interests in real estate, FMCG, industrial

engineering, appliances, furniture, security and agri care – to name a few – its
turnover crosses 4.1 billion dollars. About 26% of its business is done overseas. Its
presence in more than 60 countries ensures that its customers are at home with
Godrej no matter where they go.
SUBSIDIARIES

Godrej Consumer Products Limited

Godrej Consumer Products Limited (GCPL) is an Indian consumer goods

company based in Mumbai, India. GCPL's products include soap, hair colourants,
toiletries and liquid detergents. Its brands include 'Cinthol', 'Godrej Fair Glow',
'Godrej No.1' and 'Godrej Shikakai' in soaps, 'Godrej Powder Hair Dye', 'Renew',
'ColourSoft' in hair colourants and 'Ezee' liquid detergent. GCPL currently operates
several manufacturing facilities in India spread over seven locations and grouped
into 4 Operating Clusters at Malanpur (Madhya Pradesh), Guwahati (Assam),
Baddi- Thana (Himachal Pradesh), Baddi- Katha (Himachal Pradesh), Pondicherry,
Chennai and Sikkim.

GCPL operates in the domestic and international markets in the 'Personal and
Household Care' segment. Some of the categories are soaps, hair colourants,
toiletries and liquid detergents. Recently, it made an entry into fast-growing air
freshner category by launching a new fragrance product "aer" in the market.

Godrej Infotech Ltd

Godrej Infotech Ltd is a software services and consulting company headquartered

in Mumbai, India. Godrej Infotech, formerly a division of Godrej & Boyce Mfg.
Co. Ltd., commenced operations as a separate corporate entity on April 1, 1999.
Godrej Infotech is a part of the diversified GODREJ group. It was started as
Godrej & Boyce software division to implement ERP.

The Company's quality certifications include SEI-CMM Level 4 and ISO-

9001:2008 Quality Systems Certification. The Company has started re-appraisal
under SEI CMM ML 5 for all of its major software development centres in India
Godrej Industries Ltd

Godrej Industries is an Indian manufacturer of oleo chemicals for use in over

various industries. It also manufactures edible oils, vanaspati and bakery fats. In
addition, it operates real estate. Godrej Industries (Chemicals Division) has its
headquarters in Mumbai, India, and bases in 40 countries; it exports to more than
60 countries.

Godrej Properties Limited

Godrej Properties Limited is a real estate company in India and is a part of

the Godrej Industries Ltd. The company was started in 1990 by Adi Godrej.

Established in 1990, they are one of the major real estate development companies
in India and are based in Mumbai, Maharashtra. They have real estate development
projects in 12 cities across India. Currently, their business focuses on residential,
commercial and township developments. They undertake their projects through in-
house team and by partnering with companies with domestic and international
operations.
Godrej Properties Ltd. (GPL) is listed on the Bombay Stock Exchange (BSE) and
The National Stock Exchange (NSE)
Their parent company, Godrej Industries Limited, is the listed flagship company of
the Godrej group of companies. The Godrej group of companies includes Godrej &
Boyce Manufacturing Company Limited and is one of the major conglomerates in
India.

Godrej Properties Limited is the first real estate company in India to have ISO
certification.
Godrej One and Godrej Eternia have received the Leadership in Energy and
Environmental Design (LEED) Platinum pre-certification.
Godrej Agrovet

Godrej Agrovet Limited (GAVL) is a company engaged in agro based and

poultry based products. It belongs to the Godrej Group.

The Animal Feed business is India’s one of the largest, producing over 10,57,000
tons annually of feed and nutrition products for dairy cattle, poultry & aquaculture.
Its turnover was around 3100 Cr in 2012-13. In 2013 Godrej Agrovet has come up
with the biggest manufacturing Plant of poultry feed in India with a capacity of
around 30,000 MT/month, this plant is catering the demand of the poultry feed
market in North India, this automated plant has been installed in Khanna
(Ludhiana) by Neotech and Buhler–. 4 new automated plants are also being
commissioned with more than 15000 Ton/month capacity each in Kharagpur,
Baramati, Bangalore & Erode to cater the demand of up growing market of animal
feed in all over India. GAVL has also entered Bangladesh through a JV with the
ACI Group, where it is rapidly becoming a key player in animal feed and poultry
breeding.

Godrej Properties and Investments Limited

Godrej Properties provides meticulously planned townships at affordable

prices. The Godrej Group also has overseas establishments in Malaysia, Singapore,
Vietnam, Oman, and Sharjah.

Godrej Efacec

The Company provides warehousing, automated storage and retrieval system

solutions.
BACKGROUND
The Godrej Group was founded in 1897, and has since evolved into one of the
largest and the oldest conglomerates based in Mumbai, India, with a presence in
varied industries, including appliances, precision equipment, machine tools,
furniture, healthcare, interior solutions, office equipment, food-processing,
security, materials handling and industrial storage solutions, construction and
information technology. The Group is headed by Adi Godrej and his brother in law
and cousin, Nadir Godrej and Jamshyd Godrej.
Traditionally, Vikhroli, a suburb to the Northeast of Mumbai has been Godrej's
manufacturing base, but increasingly the group has moved significant production
facilities away from Mumbai. The Godrej group also owns vast land in Vikhroli,
occupying 3500 acres (14 km2) of land on both sides of the Vikhroli section of the
LBS marg.

ACHIEVEMENTS
 In 1897, Godrej introduced the first lock with lever technology in India.
 In 1902, Godrej made the first Indian safe.
 In 1920, Godrej made soap using vegetable oil, which was a huge hit with
the vegetarian community in India
 In 1955, Godrej produced India's first indigenous typewriter
 In 1989, Godrej became the first company to introduce PUF (
Polyurethane Foam)
 Introduced India's first and only 100% CFC, HCFC, HFC free refrigerators
(Claim to be validated)
OPERATIONS
The major companies, subsidiaries and affiliates are

 Chemical & commodities

 Godrej Industries
 Chemicals
 Veg Oils

 FMCG
 Godrej Consumer Products
 Keyline Brands UK
 Rapidol South Africa
 Godrej Global Mideast FZE
 Godrej SCA Hygiene Limited
 Godrej Hershey Foods & Beverages Limited
 Nutrine
 Godrej Sara Lee

 AGRI
 Godrej Agrovet
 Animal Feeds
 Goldmohur Foods and Feeds
 Golden Feed Products
 Higashimaru Feed Products
 Oil Palm
 Agri Inputs
 Godrej Aadhaar
 Nature's Basket
 Integrated Poultry Business
 Plant Biotech

 Services
 Godrej HiCare (Pest Management Services)
 Godrej Global Solutions (ITES)
TIMELINE

 1897 - Godrej is established in 1897

 1902 - Godrej makes its first Indian Safe

 1918 - Godrej Soaps Limited incorporated

 1961- Godrej Started Manufacturing Forklift Trucks in India

 1971- Godrej Agrovet Limited began as an Animal Feeds division of Godrej

Soaps

 1974 - Veg oils division in Wadala, Mumbai acquired

 1990 - Godrej Properties Limited, another subsidiary, established

 1991 - Foods business started

 1994 - Transelektra Domestic Products acquired

 1995 - Transelektra forged a strategic alliance with Sara Lee USA

 1999 - Transelektra renamed Godrej Sara Lee Limited and

incorporated Godrej InfoTech Ltd.

 2001 - Godrej Consumer Products was formed as a result of the demerger of

Godrej Soaps Limited. Godrej Soaps renamed Godrej Industries Limited

 2002 - Godrej Tea Limited set up

 2003 - Entered the BPO solutions and services space with Godrej Global
Solutions Limited

 2004 - Godrej HiCare Limited set up to provide a Safe Healthy Environment

to customers by providing professional pest management services

 2006 - Foods business was merged with Godrej Tea and Godrej Tea
renamed Godrej Beverages & Foods Limited
  2007 - Godrej Beverages & Foods Limited formed a JV with The Hershey
Company of North America and the company was renamed Godrej Hershey
Foods & Beverages Limited

 2008 - Godrej relaunched itself with new colourful logo and a fresh identity
music

 2010 - Godrej launched GoJiyo a free, browser based 3D virtual world

Godrej and Boyce Mfg. Co. Ltd. Mohali:

 It comes under the appliance division of godrej.

 Refrigerators and Compressors are produced here.
 Its plot size is 75 acres.
 It was inaugurated by Sardar Harcharan Singh Brar
 It was inaugurated on 28TH FEBRUARY, 1996.
HOW DOES A REFRIGERATOR WORK?
The refrigerators work on the principle of the Vapour Compression cycle.

VAPOUR COMPRESSION CYCLE

The vapour-compression uses a circulating liquid refrigerant as the medium which
absorbs and removes heat from the space to be cooled and subsequently rejects that
heat elsewhere. Figure 1 depicts a typical, single-stage vapour-compression
system. All such systems have four components: a compressor, a condenser,
a thermal expansion valve (also called a throttle valve or metering device), and an
evaporator. Circulating refrigerant enters the compressor in the thermodynamic
state known as a saturated vapour and is compressed to a higher pressure, resulting
in a higher temperature as well. The hot, compressed vapour is then in the
thermodynamic state known as a superheated vapour and it is at a temperature and
pressure at which it can be condensed with either cooling water or cooling air. That
hot vapour is routed through a condenser where it is cooled and condensed into a
liquid by flowing through a coil or tubes with cool water or cool air flowing across
the coil or tubes. This is where the circulating refrigerant rejects heat from the
system and the rejected heat is carried away by either the water or the air
(whichever may be the case).

The condensed liquid refrigerant, in the thermodynamic state known as a saturated

liquid, is next routed through an expansion valve where it undergoes an abrupt
reduction in pressure. That pressure reduction results in the adiabatic flash
evaporation of a part of the liquid refrigerant. The auto-refrigeration effect of the
adiabatic flash evaporation lowers the temperature of the liquid and vapour
refrigerant mixture to where it is colder than the temperature of the enclosed space
to be refrigerated.

The cold mixture is then routed through the coil or tubes in the evaporator. A fan
circulates the warm air in the enclosed space across the coil or tubes carrying the
cold refrigerant liquid and vapour mixture. That warm air evaporates the liquid part
of the cold refrigerant mixture. At the same time, the circulating air is cooled and
thus lowers the temperature of the enclosed space to the desired temperature. The
evaporator is where the circulating refrigerant absorbs and removes heat which is
subsequently rejected in the condenser and transferred elsewhere by the water or
air used in the condenser.

To complete the refrigeration cycle, the refrigerant vapour from the evaporator is
again a saturated vapour and is routed back into the compressor.

Thus, Vapor-compression refrigeration is one of the many refrigeration

cycles and is the most widely used method for in domestic and commercial
refrigerators, large-scale warehouses for chilled or frozen storage of foods and
meats, refrigerated trucks .
 Domestic Refrigerator Parts and their Working

1) Refrigerant: The refrigerant flows through all the internal parts of the
refrigerator. It is the refrigerant that carries out the cooling effect in the
evaporator. It absorbs the heat from the substance to be cooled in the evaporator
(chiller or freezer) and throws it to the atmosphere via condenser. The refrigerant
keeps on recirculating through all the internal parts of the refrigerator in cycle.
2) Compressor: The compressor is located at the back of the refrigerator and
in the bottom area. The compressor sucks the refrigerant from the evaporator
and discharges it at high pressure and temperature. The compressor is driven by
the electric motor and it is the major power consuming devise of the
refrigerator.

3) Condenser: The condenser is the thin coil of copper tubing located at the back
of the refrigerator. The refrigerant from the compressor enters the condenser
where it is cooled by the atmospheric air thus losing heat absorbed by it in the
evaporator and the compressor. To increase the heat transfer rate of the condenser,
it is finned externally.

Condenser of a domestic refrigerator

4) Expansive valve or the capillary: The refrigerant leaving the condenser enters
the expansion devise, which is the capillary tube in case of the domestic
refrigerators. The capillary is the thin copper tubing made up of number of turns
of the copper coil. When the refrigerant is passed through the capillary its pressure
and temperature drops down suddenly.

5) Evaporator or chiller or freezer: The refrigerant at very low pressure and

temperature enters the evaporator or the freezer. The evaporator is the heat
exchanger made up of several turns of copper or aluminum tubing. In domestic
refrigerators the plate types of evaporator is used as shown in the figure above.
The refrigerant absorbs the heat from the substance to be cooled in the evaporator,
gets evaporated and it then sucked by the compressor. This cycle keeps on
repeating.
6) Temperature control devise or thermostat: To control the temperature inside
the refrigerator there is thermostat, whose sensor is connected to the evaporator.
The thermostat setting can be done by the round knob inside the refrigerator
compartment. When the set temperature is reached inside the refrigerator the
thermostat stops the electric supply to the compressor and compressor stops and
when the temperature falls below certain level it restarts the supply to the
compressor.

7) Defrost system: The defrost system of the refrigerator helps removing the
excess ice from the surface of the evaporator. The defrost system can be operated
manually by the thermostat button or there is automatic system comprising of the
electric heater and the timer.

External Visible Parts of the Refrigerator

1) Freezer compartment: The food items that are to be kept at the freezing
temperature are stored in the freezer compartment. The temperature here is below
zero degree Celsius so the water and many other fluids freeze in this
compartment. If you want to make ice cream, ice, freeze the food etc. they have to
be kept in the freezer compartment.
2) Thermostat control: The thermostat control comprises of the round knob
with the temperature scale that help setting the required temperature inside the
refrigerator. Proper setting of the thermostat as per the requirements can help
saving lots of refrigerator electricity bills.

3) Refrigerator compartment: The refrigerator compartment is the biggest part

of the refrigerator. Here all the food items that are to be maintained at temperature
above zero degree Celsius but in cooled condition are kept. The refrigerator
compartment can be divided into number of smaller shelves like meat keeper, and
others as per the requirement.

4)Crisper: The highest temperature in the refrigerator compartment is

maintained in the crisper. Here one can keep the food items that can remain fresh
even at the medium temperature like fruits, vegetables, etc.

5) Refrigerator door compartment: There are number of smaller subsections

in the refrigerator main door compartment. Some of these are egg compartment,
butter, dairy, etc.

6) Switch: This is the small button that operates the small light inside the
refrigerator. As soon the door of the refrigerator opens, this switch supplies
electricity to the bulb and it starts, while when the door is closed the light from the
bulb stops. This helps in starting the internal bulb only when required.
 STEPS INVOLVED IN REFRIGERATOR PRODUCTION

DOOR FOAMING REFRIGERATOR COMPRESSOR

FINAL

PRESS SHOP PC
STAGE -4
INSPECTION
CABINET FOAMING

LSD & LEAK

DETECTION -1

EVACUATION
AND CHARGING

LEAK
DETECTION 2

PLUG IN & PLUG

OUT

LD 3& NOISE
TESTING

STAGE -5

STAGE-6
VARIOUS DEPARTMENTS IN REFER PLANT
PRESS SHOP:
Here the various panels are formed. Left Side Panel, Right Side Panel and back
sheet.

The sheets required to be fixed in front of the doors are also formed here.

There are two types of sheets:

 Pre Coated Sheets

 The Sheets which are to be sent for powder coating.

After the operations at press shop the sheets are sent for further operations.

The sheets are sent to following places according to their requirements:

 Cabinet foaming
 Powder Coating
 Door Foaming

POWDERCOATING:
Here the sheets to be powder coated are powder coated. It takes place in the
following steps:

1. Loading of component on conveyor belt.

2. Pre-treatment of component.
3. Water Drying of components
4. Powder Coating of components.
5. Powder curing of components.
CABINET FOAMING:
Here the cabinet of the refrigerator is formed. Panels are joined together and liner
is placed in it. Then the foam is filled in it and required slots for wires and pipes
are cut in it.

DOOR FOAMING:
It takes place in two steps:
1. Vacuum Forming:
 Firstly the HIP sheets are fed into linear ASANO.
 Then these are pre heated
 Then they are finally heated to the required temperature.
 Then the die containing the shape to be formed moves down to the heated
sheet. It gives the required shape to the sheet by creating vacuum.
 The temperature required differs from model to model.
Models Temperature (Final)
Edge (180ltrs,200 litres, 215 ltrs,250 litres) 350°c to 390°c
300 litres 400°c to 420°c
100 litres 400°c to 420°c

Temperature Required
2. Door Foaming

After the vacuum forming the door foaming for two different models take place
in two different ways:

For Axis Model:

 The PDP formed is firstly trimmed and punching is done.

 Then the gasket is fixed to it.
 Then the door sheet and the PDP are filled with foam with the help of drum.
 Then the screws are fixed to the PDP to fix it to the door firmly.
 Anabond is also used to fix the gasket.
 For Edge Model:

 After trimming and punching, the scrivets are fixed to the PDP.
 Then the foam is filled in the door.
 Then the gasket is snug fit on the door.

REFRIGERATION FINAL ASSEMBLY:

Here the whole Refrigerator is assembled on moving conveyer belt while worker
work standing on the sides of it. There are three assembly lines at one place and
fourth at another place. The three assembly lines joined together to one line. The
different models are built on different assembly lines which are according to the
order received by the company.

It takes place in two parts.

 Front assembly
 Back Assembly

These two takes place simultaneously.

FRONT ASSEMBLY:
1. Tape Removed :

Here the tapes on the cabinet of the refrigerator are removed by the workers. These
tapes are fixed before filling the cabinet with foam.

2. Foam Removed:

Here the foam on all the corners which is coming out of the liner and side panel
intersection is removed.
3. Legs Fitment :

Legs are fixed to the front of the refrigerator with the help of pneumatic guns.

4. Thermocol Fitment:

Thermocol is placed under the refrigerator. The placement of thermocol under the
refrigerator is done so as to ensure easy movement and enhanced mobility of the
refrigerator which is essential towards the later stages of its manufacturing
especially during its offloading.

5. Table Top Front Piece Fitment:

Here the table top Front piece is placed on the refrigerator. The wires for the
thermostat and bulb switch which are in the plastic covers are pulled out.
Thermostat and bulb switch are fitted and connected to the wires.

6. Evaporator Insertion :

The Evaporator is inserted in its place in the cabinet of the refrigerator with its wire
going out of the holes in the back sheet.

7. Evaporator Frame Fitment and Roller Fitment:

Evaporator frame is inserted to hold the evaporator in its place firmly. It is inserted
with the help of pneumatic gun. Here the rollers required for the free movement of
the chiller tray are also fixed.

8. Bulb Fitment :

Then the bulb is fitted in its place with its connector. Its space is formed in the
liner during cabinet forming. The wires required for it are also given during cabinet
forming. Aluminium sticker is used and stacked to the wall at the back of the bulb.
It helps to reflect the light coming out of bulb which increases light’s intensity. The
bulbs used are of 10 W and 15 W.

9. Bulb Channel Fitment :

The bulb channel is fitted below the evaporator and it is connected to the
thermostat. The thermostat works as the device to cut the current supply when the
temperature in the refrigerator reaches below certain limit. Bulb channel is used to
sense the temperature in the refrigerator. The thermostat cut the current supply to
relay which switch off the compressor.

10. Cabinet Accessories Insertion:

Here the cabinet accessories are fitted to the refrigerator. The following accessories
are fitted:

 Glass Slider
 Chiller Tray
 Liner Shelves
 Ice Tray

11. Crisper Assembly :

Crisper assembly is done here .The crisper is used to keep the vegetables in the
refrigerator. Firstly the crisper is placed and then the glass is placed on it.

There are two types of crispers used for different models.

 GPPS crisper
 PP Crisper
12. Door Fitment :

Door is fitted here. The doors are formed in the door foaming department then they
are brought to the door fitment area with the help of the trolleys.

13. Table Top Fitment :

Table Top is placed on the already placed thermocol and fitted with the help of the
pneumatic gun.

14. Door Accessories Insertion :

Here the door accessories are inserted in the door. The space for insertion of door
accessories is already given in the PDP. PDP shelves provide the space for placing
different things. Egg Racks and key is also places here during assembly.

15. Handle Fitment :

Door handle is then fitted to the door with the help of pneumatic gun.

16. Logo Fitment :

Then the stickers are places on the front of the door.

There are 3 stickers that are placed on the door:

 Energy Sticker:

It tells about the energy consumption of the refrigerator i.e. units it is going to
consume in a year. It also tells about the rating of the refrigerator i.e. 3 star rating
or 5 star rating.
  ZOP :

It tells about the range of the voltage between which the refrigerator can work
efficiently without any need of repair.

The third sticker tells about the model of the refrigerator. Examples are:

1. Axis

2. Edge

3. Edge SX

BACK ASSEMBLY:

1. Base Fitment: Here base plate is fitted to the bottom of refrigerator.

2. Compressor Fitment :

Here the Compressor fitment takes place. The compressor is fitted to the base
plate. Grommet is placed between the compressor and the Base plate so that
vibrations are not transferred from the compressor to the refrigerator.

Here relay pin is also fixed .It is used to hold the relay which controls the working
of the refrigerator.

Compressor works as a pump to control the circulation of the refrigerant and it

adds pressure to refrigerant, heating it up.

Compressor has three ports:

 Suction Port: It pulls the refrigerant from the evaporator.

  Discharge Port: It discharges the refrigerant to the condenser.
 Charging Port: By this port the compressor is filled with the refrigerant.
Relay: It is used to control the working of the refrigerator.

3. Capacitor Fitment :

Then the Capacitor is fitted at the side. It is used to start the compressor.

4. Condenser Fitment:

Then the condenser is fitted at the back of the refrigerator. It is fitted with the help
of condenser clamps. Four condenser clamps are used to hold the condenser in its
place. Condenser is used to for heat transfer. It gives out the heat to the
surroundings and cools the refrigerant.

5. Flushing and Drier Fitment :

Flushing of the condenser is done once before fitting the drier to it. Then the drier
is fitted to the condenser. It also has capillary attached to it.

6. Lokring Fitment:

The lokrings are fitted to the suction port of the compressor, discharge port of the
compressor and drier

7. Supply Chord Fitment :

Here the supply chord is fitted to the back of the refrigerator and its wires are fitted
to the compressor. It is used to provide the electricity to the refrigerator.
8. Coupler Fitment :

The couplers are fitted to the charging port and drier. They are fitted as they are
used in Leak Detection -1 and Evacuation and Charging Loop for evacuation
and charging of refrigerant.

INSPECTION DURING MANUFACTURING

Inspection of the refrigerator during its manufacturing takes place at STAGE 4.

It is done so as to reduce any recurring defect which may reduce the overall
PQI(percentage quality index) of the refer plant. Any defect during the initial
manufacturing of the refrigerator upto this stage is noticed by the line
supervisor and necessary and timely intervention of coordinators along with
line supervisors results in overall improvement in PQI of the manufacturing
system .

After assembly the inspection takes place of the complete refrigerator at

Stage -4

It takes place in two parts.

 Front Inspection :

One worker of Quality department does complete inspection of the refrigerator

from the front. He inspects that nothing is missing and everything is placed or
fixed properly. He also inspects door for dents and scratches. The refrigerators
which need repair are offloaded and repaired by the workers of Refrigeration
Final Assembly Department.

The usual defects are:

 Dent
 PDP Shelf Broken
 Evaporator Frame broken
 Gasket Gap
  Chiller Tray Broken
 Foam Seepage
 Sticker miss
 Scratch on Table Top
 Deodorizer missing
 Ice Tray Missing
 Front Piece Cap Improper
 Bolt Loose
 Caution Sticker miss
 Glass Improper
 Evaporator Frame Bolt Missing

Back Inspection:

Simultaneous to the front inspection back inspection takes place on stage-4.

Here it is seen that the compressor, condenser, drier etc are properly fitted.

All the bolts and nuts holding capacitors, supplycord is in proper place.

All the wires connecting with the compressor are properly connected.

The usual defects are:

 Compressor mounting pin improper fitment

 Condensor clamp improper fitment
 Suction line sticker missing
 Grimmet missing
 ELECTRICAL DEFECTS:
The various electrical defects which occurs during the manufacturing of the
refrigerators are taken care at the light switch defect stage aka LSD defect stage.

At LSD the electrical connections are checked. The wires are inserted for various
equipment before this stage and inspection of those connections are done here.

It is checked that the refrigerator is working properly .This is done before filling
gas i.e. refrigerant to compressor. Firstly electricity is provided at 220 V and 50 Hz
frequency and it is checked that current flows through the refrigerator. Current
reading must be between (0.40A-2A).

If there is no ampere reading or the bulb does not work properly. Then the
refrigerator is offloaded.

Then it is again checked by the worker doing repair. If there is defect in proper
working of the bulb it can be of the following reasons

1. Improper Thimble connections: Thimbles are not connected properly with the
light switch or there is foam seepage in thimbles.

2. Improper fitting of bulb: It can be also because of improper bulb.

3. Bulb Fuse

If there is no ampere reading then there can be two problems:

1. Either there is problem in thermostat.

2. Or there is problem in relay.

Thermostat problem can be because of the following reasons:

 Improper Thimble connections: Thimbles are not connected properly with

the thermostat or there is foam seepage in thimbles.
 It may be also improper working i.e. thermostat is damaged.
 Thermostat missing: LSD defects are also introduced if thermostat is
missed in the refrigerator body.
Reasons of relay problem:

 Improper Thimble connections: Thimbles are not connected properly with

relay or there is foam seepage in thimbles.
 Relay missing: If the relay is missing in the refrigerator, the compressor
doesn’t work.

UNIT CELL (USS)

EVACUATION LOOP:

It is the process of removal of the all the gases in the compressor and cleaning of
the complete path through which the refrigerant has to flow.

When the compressor is manufactured in the compressor plant N2 is filled in it.

We use nitrogen gas because of the following worth mentioning reasons:

 One is that it is inert gas.

 Secondly the minimum temperature we want to obtain in refrigerator is -
37ᶱC which is higher than the dew point of nitrogen gas.

Firstly the Nitrogen gas is removed with the help of vacuum pump.

Then the two pipes of the vacuum pump are employed on two places i.e. at drier
and charging port of compressor.

The pumps used are rotary type and motors used to drive them are of 0.75
horsepower (HP).
  Pipe that is used at the drier cleans the condenser of all the gases and the
contaminants.
 While the Pipe used at the compressor cleans the compressor completely.

The whole process takes almost 20 to 30 minutes to take place.

Here at the starting of the evacuation loop the refrigerators have to be moved so
that they can be arranged in front of the pumps being used for evacuation and
certain distance has to be maintained between refrigerators. If the distance is not
maintained between them there will be occurrence of dents on the purging bends as
the refrigerators will come close to each other. If the refrigerators collide it will
result in the dents on the refrigerators.

So the following points are to be taken into consideration:

 Maintenance of distance between refrigerators.

 Cushions are to be used on the side panels.
 Foam cover is to be placed on the handles.

CHARGING OF THE REFRIGERATOR:

Charging of the refrigerator is done with the help of the Galileo. The refrigerant
filled is R600a (Isobutene). Refrigerant is filled in different amount in different
refrigerators according to the size of the refrigerator. It varies from 24 grams to 55
grams for different refrigerators.

LEAK DETECTION-2 AND PRE HIGH VOLTAGE TESTING:

The first leak detection was without filling the refrigerant in the refrigerator.
It was done with the help of nitrogen gas (N2).Now the leak detection takes place
after filling the refrigerant R600a.

It is one before plug in and plug out loop so that refrigerator is completely checked
of any leakage before the refrigerant starts flowing in the refrigerator.

So the refrigerators that are having leak are offloaded before the plug in plug out
loop.

The leak can be at the following places;

 Condenser pipes
 Drier
 Capillary
 Suction of the compressor
 Discharge of the compressor

The leak is checked with the help of the leak testing machine. It beeps when there
is a leak in the refrigerator and it is offloaded. The point of leak is checked with the
help of the soap solution. When soap solution is applied wherever there is leak in
the refrigerator the bubbles start coming out from that point. Then it is sent for
repair.

High Voltage Testing:

Here 1100 volts is provided to the refrigerator. The current leakage should not be
more than 1mA (milliampere) .If it is more than 1 milliampere then the machine
beeps and refrigerator is offloaded before plug in plug out stage. This test is
important because if refrigerator having current leakage goes through the plug in
plug out loop without getting checked then it can cause an accident.
PLUG IN PLUG OUT LOOP
Here the refrigerator are plugged in with the plugs hanging from the bus bar above
.It is a loop of 20 minutes. There are two persons working at the starting of the
plug in loop.

 One’s work is to plug in the refrigerator.

 The second person’s work is to check whether the bulb is switched on or

not Here lot of attention is given to the safety of the workers.

Rubber mat is used; both the workers have to stand on the mats. They are also
required to wear gloves for their safety.

The refrigerator moves on the conveyer belt in a plug in plug out loop while being
plugged in .So during this time refrigerator is switched on, it traverses the full path
provided to it i.e. compressor compresses the refrigerant then it passes the
condenser where it is cooled, then it is passed through the drier and capillary tube
which result in decrease of pressure of refrigerant. In evaporator heat exchange
again takes place, the refrigerant gains heat while it cools the vegetables etc in
refrigerator and come back to the compressor. This results in cooling of the
refrigerator. It is desired that during this plug in plug out loop the temperature in
the evaporator should reach below -18°C.

Then the thermo hunter is used at plug out to check the temperature in the
evaporator. It should be below -18°C.
The refrigerators whose temperature is below -18°C are given okay tags and they
continue to move on the conveyor belt, but if the temperature inside the evaporator
is above -18°C then refrigerator is offloaded and again plugged in.

Refrigerators that are offloaded have following defects:

 Bulb not working

 Compressor not working
 Less cooling
 No cooling
 Or there me be problem with the supply cord

They all are repaired at tripping Stage.

NOISE TESTING:

During the plug in plug out loop the noise testing of the refrigerator’s compressor
take place with the noise testing machine. The compressor whose noise comes out
to be less than 70 dB is passed while those producing noise more than 70 dB are
offloaded at the plug out stage. They are again put on the conveyor belt and
offloaded at the noise testing chamber.

Noise testing chamber is present just before the noise testing area.

This chamber is a closed room having walls which are fixed with noise absorption
material so that no external noise comes in and no internal noise goes out. The
refrigerator is plugged in there and again noise testing takes place.
LEAK DETECTION -3:

It also takes place during the plug in plug out loop. Here the refrigerators are again
checked for leakage with leak testing machine. Here the refrigerators with leakage
are sent for repair.

TRIPPING STAGE:

Here all the refrigerators offloaded at the plug out stage are repaired.

The major defects that are removed are:

 Light Switch defect

 No cooling defect
 Less cooling defect
 Compressor not working
 High voltage defect

Light Switch Defect:

The light switch defect may be due to improper connection of bulb or the Light
switch.

Sometimes the bulb gets fuse or its connection with its holder is not proper. It also
occurs when there is foam in the thimble connecting to the light switch.

No cooling defect: No cooling occurs due to improper relay connection or if there

is no refrigerant in refrigerator.
Less cooling Defect:

It occurs if there is less refrigerant used in the refrigerator. The amount of

refrigerant varies with the size and capacity of the refrigerator. It varies from 24
grams to 55 grams.

Compressor Not Working:

It may be due to two reasons:

 Relay connection improper.

 Thermostat connection improper or thermostat not working.

High voltage defect:

It is due to current leakage somewhere in the whole wiring .It is also removed here.

STAGE - 5:

Here at Stage 5 the front and back inspection takes place.

The inspectors are of Quality department. They check whether all the equipment’s
are properly installed at their required places. There is no fault in installation of the
various equipment’s.

If there is problem in installation and something is missing the workers of the

Refrigeration Final Assembly Department (RFA) offload the refrigerator and work
on the defect .After the repair is properly done the refrigerator is again put on the
conveyer belt.
STAGE-6:

It is the last stage before the refrigerator goes

for packing. Here the following things are done.

• The cushions on the side panels of the refrigerator are removed.

• The foam covers on the handles of the doors are removed.

• Final inspection of the refrigerators.

• Final repair of the refrigerators.

The RFA department workers do the entire repair and place the missing
components while the quality department workers have to just indicate
the defect.