INDUSTRIAL TRAINING REPORT

MANUFACTURING OF REFRIGERATOR

Submitted in partial fulfillment of the

Requirements for the award of

Degree of Bachelor of Technology in Mechanical Engineering

Submitted By
Name: KHAN MOHD HASEEB

NASEEM AHMED

University Roll No. 2022756

SUBMITTED TO:

Department of Mechanical Engineering

I.K. GUJRAL PUNJAB TECHNICAL UNIVERSITY,

MAIN CAMPUS, KAPURTHALA, PUNJAB
 DECLARATION

I hereby declare that the Industrial Training Report entitled ("MANUFACTURING OF

REFRIGERATORS") is an authentic record of my own work as requirements of Industrial
Training during the period from 1ST FEB to 30TH APRIL for the award of degree of B.Tech.
(Mechanical Engineering), I.K. Gujral Punjab Technical University, Main Campus,
Kapurthala, Punjab, under the guidance of (DR. VIVEK AGGARWAL ).

Date Signature of student

KHAN MOHD HASEEB

NASEEM AHMED

2022756
 ACKNOWLEDGEMENT

I extend my sincere gratitude to the individuals and departments whose support and
guidance have been instrumental during my Industrial training at IFB Refrigeration Ltd. in
the various department:
I am deeply thankful to Mr. Pravin Patil (Head Of Quality Department), Mr. Amit Sharma
(Head of DQA), Mrs. Pooja Kulkarni (team HR) for providing me with the opportunity to
do industrial training at IFB Refrigeration Ltd. And Also deeply thankfull to Mr. Anil
Gore (Team leader of IQC & NPD), Mrs. Pooja Nalawade (Charge Hand of IQC), Mr,
Deepak kore(Team leader of DQA) for his/her unwavering support and mentorship
throughout my training. [He/She] has been an invaluable source of knowledge and
guidance, offering insights that have significantly contributed to my professional growth
in various department and I would like to express my appreciation to my colleagues
Abhishek Gawde , Sakshi salunke , Alim Mulla , Aditya & bhusan for their collaborative
spirit, willingness to share their expertise, and assistance during my training. Their
camaraderie and support have enhanced my learning experience and facilitated my
integration into the departments.
Finally I express my sincere thanks to all those people who have
contributed towards the completion of this training and cannot be
mentioned here.

Khan Mohd Haseeb.

I extend my sincere gratitude to the individuals and departments whose support and
guidance have been instrumental during my internship at IFB Refrigeration Ltd. in the
Quality Control

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 ABOUT COMPANY

The IFB Group

IFB Industries Limited originally known as Indian Fine Blanks Limited started
their operations in India during 1974 in collaboration with Hienrich Schmid AG
of Switzerland, The product range included Fine Blanked components, tools and
related machine tools like Straighteners, Decoilers, Strip loaders and others.
Mr. Bijon Nag, Chairman, IFB Industries Ltd, pioneered the fine blanking
technology in India and set up the first unit in Kolkata. Since then, the company
has evolved into one of the most respected and trusted engineering group to
meet the growing needs of domestic and international automotive and domestic
international
IFB pioneered the production of fully automatic washing machine in India in
agreement with BOSCH, Germany in the year 1989. Today IFB supplies Fully
Automatic Washing Machines, Micro Wave Ovens, Dish Washers & Dryers
with factories in Goa and Bhopal.
The Engineering divisions are located at Kolkata & Bangalore. The Bangalore
unit, apart from Fine Blanked components, manufactures motors for White
goods as well as Automotive applications.

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The group co.'s are:
1. IFB Industries Ltd.
2. IFB Automotive Ltd.
3. IFB Agro Ltd.
4. IFB Travel Systems Ltd.
5. IFB Refrigeration Ltd.

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 3.

Table of Contents
ACKNOWLEDGEMENT.................................................................................................................................. i

ABOUT COMPANY ....................................................................................................................................... ii

CHAPTER 1: INTRODUCTION TO PRODUCT AND THEIR PARTS OF REFRIGERATION .................................. 8

1.1 INTRODUCTION ................................................................................................................................. 8

1.2 TYPES OF REFRIGERATOR MODEL .................................................................................................... 2

1.3 REF MODEL PARTS AND THEIR WORKING ........................................................................................ 4

1.4 External visible parts of the Refrigerator .......................................................................................... 6

Chapter 2: Production of Refrigerator ..................................................................................................... 10

2.1 Overview of Production Department ............................................................................................. 10

2.2 DEPARTMENTS IN PRODUCTIONS .................................................................................................. 10

2.2.A Door metal line (DML) ............................................................................................................. 11

2.2.B Back panel (SPM) ..................................................................................................................... 11

2.2.C Deck SPM ................................................................................................................................ 12

2.2.D Thermoforming ....................................................................................................................... 13

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 2.2.E CRF (Cold roll forming) ............................................................................................................. 15

2.3 Pre-assembly Area .......................................................................................................................... 16

2.4 Final-assembly Area ........................................................................................................................ 18

CHAPTER 3: INCOMING QUALITY CONTROL ............................................................................................. 23

3.1 Introduction to Incoming Quality Control (IQC) in Refrigeration Manufacturing .......................... 23

3.2 Generation of Sample Inspection Report: ...................................................................................... 26

3.3 INSTRUMENTS USED DURING INSPECTION .................................................................................... 29

3.4 TEST CONSIDERATION DURING SIR: .............................................................................................. 32

Table of Figures
Figure 1 Refrigerator Model ....................................................................................................................... 9

Figure 2 Types of DC Models .................................................................................................................... 2

Figure 3 Types of FF Models ..................................................................................................................... 3

Figure 4 Refrigerant .................................................................................................................................... 4

Figure 5 Compressor ................................................................................................................................... 4

Figure 6 Condenser ................................................................................................................................... 12

Figure 7 Expansive Valve or the Capillary ............................................................................................... 12

Figure 8 Evaporator or chiller or freezer .................................................................................................. 13

Figure 9 Temperature control devise or thermostat .................................................................................. 13

Figure 10 Freezer compartment ................................................................................................................ 14

Figure 11 Thermostat control ................................................................................................................... 14

Figure 12 Refrigerator compartment ........................................................................................................ 15

Figure 13 Crisper ...................................................................................................................................... 15

Figure 14 Refrigerator door compartment ................................................................................................ 16

Figure 15 Switch ....................................................................................................................................... 16

Figure 16 Door metal line (DML) ............................................................................................................ 20

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Figure 17 Wiping press ............................................................................................................................. 22

Figure 18 Back panel (SPM) .................................................................................................................... 22

Figure 19 Back Panel ................................................................................................................................ 23

Figure 20 Deck SPM................................................................................................................................. 24

Figure 21 Deck panel ................................................................................................................................ 25

Figure 22 Thermoforming ........................................................................................................................ 26

Figure 23 HIPS Sheet is converted to cabinet and door liner. .................................................................. 27

Figure 24 Sheet Wrapper .......................................................................................................................... 29

Figure 25 Sheet Wrapper is converted to Cabinet cover .......................................................................... 30

Figure 26 Image Pre-assembly line .......................................................................................................... 33

Figure 27 Image of Cabinet Foaming Machine ........................................................................................ 34

Figure 28 Image of Door Foaming Machine ............................................................................................ 35

Figure 29 OLP and PTC Connection to Compressor ............................................................................... 39

Figure 30 Cycle Time ............................................................................................................................... 41

Figure 31 R600a or Isobutane Charging ................................................................................................... 42

Figure 32 Charging Time .......................................................................................................................... 43

Figure 33 Leak Detection Back Side Procedure ....................................................................................... 44

Figure 34 Leak Detection Front Side Procedure ...................................................................................... 44

Figure 35 Sample Inspection Report ........................................................................................................ 51

Figure 36 DRAWING for SIR .................................................................................................................. 52

Figure 37 DRAWING & ARTWORK Attachment ................................................................................. 53

Figure 38 Visual defect ............................................................................................................................. 54

Figure 39 Artwork for Sir ......................................................................................................................... 55

Figure 40 Different Size of Vernier .......................................................................................................... 57

Figure 41 MICROMETER ....................................................................................................................... 57

Figure 42 PIN GUAGE............................................................................................................................. 58

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Figure 43 FEELER GAUGE .................................................................................................................... 59

Figure 44 RADIUS GUAGE .................................................................................................................... 59

Figure 45 PUSH PULL (FORCE) GAUGE ............................................................................................. 60

Figure 46 TEST CONSIDERATION DURING SIR .............................................................................. 62

Figure 47 Instrument Manual Guide ......................................................................................................... 62

Figure 48 THERMOSTAT BATH ........................................................................................................... 63

Figure 49 Bursting Strength Tester ........................................................................................................... 65

Figure 50 Izod/Charpy Impact Tester ....................................................................................................... 67

Figure 51 NOTCH CUTTER FOR IMPACT TESTER ........................................................................... 68

Figure 52 UNIVERSAL TESTING MACHINE ...................................................................................... 69

Figure 53 The Loading Unit .................................................................................................................... 70

Figure 54 JIG ............................................................................................................................................ 73

Figure 55 JIG ............................................................................................................................................ 74

List of Tables
Table 1 Table no.1 litre wise model dc ..................................................................................................... 11

Table 2 FF Model wise liter ...................................................................................................................... 12

Table 3 HIPS SHEET DIMENSION OF DC Cabinet and Door .............................................................. 28

Table 4 WRAPPER SHEET DIMENSION MATRIX ............................................................................. 31

Table 5 Shows the material used for the part for refrigerator ................................................................... 32

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CHAPTER 1: INTRODUCTION TO PRODUCT AND THEIR
PARTS OF REFRIGERATION
1.1 INTRODUCTION:

In refrigeration companies, products typically consist of various refrigeration systems and

components designed to cool and preserve perishable goods. Here's a basic introduction to
some common products and their parts in refrigeration systems:

Refrigeration is a technology and process used to cool and preserve perishable items,
extend shelf life, and maintain specific temperature conditions. It's essential across
numerous industries, including food and beverage, pharmaceuticals, and manufacturing.

Basic Principle: Refrigeration works by transferring heat from one location to another,
typically from inside a refrigerated space to the external environment. This process relies
on the properties of refrigerants, which undergo changes in pressure and temperature to
absorb and release heat.

• Applications: Refrigeration is used in various applications, including:

• Food preservation and storage in commercial refrigerators and freezers.

• Climate control in air conditioning systems for buildings and vehicles.
• Industrial processes, such as cooling in manufacturing and chemical processes.
• Medical and pharmaceutical storage to maintain the integrity of temperature-
sensitive products.

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 • Types of Refrigeration Systems:

• Vapor Compression: The most common type, used in household refrigerators,

commercial freezers, and air conditioning systems.
• Absorption: Utilizes heat as an energy source to drive the refrigeration cycle, often
used in industrial applications and RV refrigerators.
• Thermoelectric: Relies on the Peltier effect to create a temperature difference,
commonly used in small-scale refrigeration applications.

Environmental Impact: Refrigeration systems can have environmental impacts due to the
use of refrigerants with high global warming potential (GWP). Efforts are ongoing to
develop and transition to more environmentally friendly refrigerants with lower GWP.

1.2 TYPES OF REFRIGERATOR MODEL

In IFB Refrigeration Ltd. there is production of home refrigerator. There are total 2 types of the
refrigerator:

In DC there are 5 models, which is based on litre capacity of the refrigerator. Which are mainly

Generally, FF refrigerator are the double door fridge. In FF there are 3 models which are based on the
litre capacity. Which are mainly
Figure 1 Types of DC Models

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Figure 2 Types of FF Models

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1.3 REF MODEL PARTS AND THEIR WORKING

1. Refrigerant:

R600a (Isobutane) is a refrigerant grade Isobutane used as a replacement for R12 and R134a in a variety
of high-temperature refrigeration applications. R600a (Isobutane) is a hydrocarbon that is becoming
increasingly popular due to its low Global Warming Potential (GWP)

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.

Figure 3 Refrigerant

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.

Figure 4 Compressor

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2. 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

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 drop 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 are 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

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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.

1.4 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,
5) Refrigerator door compartment:

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There are number of smaller subsections in the refrigerator main door compartment. Some
of these are egg compartment, butter, dairy, et

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

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1.5 INSPECTION DURING MANUFACTURING

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 up to this stage is noticed by the line supervisor and
necessary and timely intervention of coordinators along with line supervisor results in
overall improvement in PQI of the manufacturing system. It takes place in two parts.

1. Front Inspection:
One worker of Quality department does complete inspection of the refrigerator from
thefront. He inspects that nothing is missing and everything is placed or fixed properly.
Healso inspects door for dents and scratches. The refrigerators which need repair
areoffloaded 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

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 2. Back Inspection
Simultaneous to the front inspection back inspection takes place. Here it is seen that the
compressor, condenser, drier etc.., are properly fitted. All the bolts and nuts holding
capacitors, supply cord 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

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Chapter 2: Production of Refrigerator

2.1 Overview of Production Department

1. Introduction:
Refrigeration is a critical industry, essential for preserving perishable goods and maintaining
optimal conditions in various settings, from homes to industrial facilities. This report aims to
provide an in-depth analysis of the production line within a refrigeration manufacturing
company, exploring its processes, technologies, and performance metrics.

2. Importance of the Production Line:

The production line is the backbone of the company's operations, where raw materials are
transformed into finished refrigeration products. It plays a crucial role in ensuring
efficiency, quality, and timely delivery of goods to customers.

2.2 DEPARTMENTS IN PRODUCTIONS

There are total 3 departments of production:

1. Machine Shop (SUBSHOP)

2. Pre-assembly Area

3. Final Assembly Area

These department have their own specific role in the production department. As in shop it is the
1st step in production line. In pre assembly line most of the inner parts are fitted. In final
assembly the whole important part of production line. As in final assembly whole fridge gets
assembly and final product comes out.

1. Machine shop (SUBSHOP)

A machine shop is an environment machining, a form of subtractive

manufacturing is performed. Machining involves the use of various tools to
shape, cut, and modify raw material like metal, plastic, or composites into
precise parts and components. So in machine shop of IFB refrigeration ltd. there
are total 5 total machines:

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1. Door metal line (DML)

2. Back panel spm (Special Purpose machine)

3. Deck spm (Special Purpose Machine)

4. Thermoforming

5. Cold Roll Forming (CRF)

2.2.A Door metal line (DML)

It is machine through which we make door panel of a refrigerator of desired shape and
size according to the model of refrigeration. In this machine there are 8 stages :

1. Sheet pickup

2. Notching (lock & handles)

3. Notching (only for UI models)

4. Notching (For corner edges)

5. Centering

6. CNC bender

7. Bending press

8. Wiping press

2.2.B Back panel (SPM)

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Back panel SPM are commonly used for impression and bending on sheet. It is also called as
hydraulic press machine. Total time required to complete this process is 44 sec. and there are
total 11 molds (dies) are used. It is change as per product requirement. There are 3 stages in this
process:

1. Hydraulic press

It is used for punching and for forming impression and bending on sheet.
The pressure that applied on sheet is 212 kg\cm2.

2. Pneumatic bending press

Pneumatic bending press is used to provide bendable structure to the flat

material with defined angles.

3. Inspection

In inspection the back panel is properly check whether there is dent or

not and any improper impression present on it.

2.2.C Deck SPM

It is machine through which we make deck panel of refrigerator.

It is also known as compressor fitting area. In this machine there
are total 4 stages:

1. Sheet pickup:

This is a stage where pneumatic suction cups comes and pickup the door panel sheet. And
unloading on the track.

2. Punching station:

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A shearing or punching process is used in a press, so as to cut vertically down and

perpendicular to the surface, working from the edge of a work-piece. It is stage where holes are
given to the door panel for lock and handles.

3. Embossing station:

It is the process whereby sheet metal is reshaped from a flat form. Using bending technology
you can produce almost any component design.

4. Bending station:

A bending press is a stationary device for forming sheet metal. At the bending station sheet is
converted in L shape. They are used to provide bendable flat material with defined angles. The
angles always run from edge to edge. Bending station are simple machines that can be used in
many different ways.

2.2.D Thermoforming

There are two main types of thermoforming vacuum forming and pressure forming. Vacuum
forming uses heat and pressure to draw plastic sheets into its final configuration. Once a sheet
is heated and placed over a mold, a vacuum is used to manipulate it into its desired shape.
Thermoforming is fully automatic machine in machine shop. It is machine through which we
can get refrigerator cabinet & doorliner. There are 12 types of the mold through which we can
desire shape to cabinet and door liner.process for manufacturing cabinet liners and Door liners
from HIPS (High Impact Polystyrene) sheets using a COMI Group machine. Here's a
breakdown of the steps:

1. Sheet Loading: HIPS sheets are loaded into the machine. Each bundle contains 250
sheets.

2. Vacuum Cap: A vacuum cap holds the HIPS sheet in place.

3. Sensor Detection: Sensors detect the amount of HIPS sheet held by the vacuum cap.
This ensures the correct amount is held for processing.

4. Centring: The sheet is positioned or centered appropriately for further processing.

5. Clamping: Once centered, the sheet is clamped to secure it in place.

6. Transport Track: The clamped sheet is then placed onto a transport track for further
processing.

7. Preheating: The sheet undergoes preheating at temperatures ranging from 110 to 120
degrees Celsius for a specific duration, approximately 56.22 to 55.96 seconds. This
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preheating step is crucial for softening the HIPS sheet and making it more pliable for
forming.

8. After the preheating stage, the HIPS sheet proceeds to a final heating stage, where it is
subjected to higher temperatures ranging from 180°C to 200°C for a duration of 1.2
minutes. This final heating stage is crucial for further softening the HIPS sheet and
preparing it for forming.

9. Following the final heating, the HIPS sheet is directed towards the forming process. Here's
how it likely unfolds:

10. Mould Preparation: The mould is prepared for receiving the heated HIPS sheet. This may
involve ensuring the mould is clean and properly aligned.

11. Vacuum Application: Vacuum pressure of 635 mmHg (Mercury) is applied to the mould.
This helps to create suction within the mould cavity.

12. Pressure Application: Pressure of 2 bar is applied to the mould. This pressure, along with
the vacuum, helps in forming the HIPS sheet into the desired shape within the mould
cavity.

13. Forming: The heated HIPS sheet is positioned over the mould, and the vacuum and
pressure are activated simultaneously. The vacuum pulls the softened sheet tightly against
the contours of the mould, while the pressure ensures uniform distribution and shaping.

14. Cooling: After forming, the HIPS sheet is allowed to cool within the mould.
This helps in retaining the desired shape and structural integrity.

15. Release: Once cooled sufficiently, the formed cabinet liner is released from the mould

After the forming process, the HIPS sheet, now molded into the desired shape of the
cabinet liner, is transported out for trimming. Here's how this part of the process might
work:

1. Transport Track: The formed cabinet liner is moved along a transport track, likely a
conveyor belt or similar mechanism, to the trimming station.

2. Trimming: At the trimming station, excess material is removed from the edges or any
areas where it's not needed. This can be done using various methods such as cutting,
milling, or routing, depending on the complexity of the trim and the precision required.
3. Quality Check: After trimming, the cabinet liner may undergo a quality inspection to
ensure that it meets the required specifications in terms of dimensions, shape, and surface
finish.

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4. Final Inspection: Once trimmed and checked for quality, the cabinet liner AND Door liner
may undergo a final inspection before being prepared for packaging or further processing.

2.2.E CRF (Cold roll forming)

a production process for manufacturing refrigerator components using a CRF (Cold Rolled
Forming) machine. Here's a breakdown of the steps you mentioned:

1. Loading Bundle of Sheet Wrapper Metal onto CRF Machine: This involves placing a
bundle of metal sheets onto the CRF machine to be processed.

2. Sheet Picked by Vacuum Cup: The metal sheet is picked up by a vacuum cup system.
This ensures proper handling and positioning of the sheet for further processing.

3. Sheet Centering and Feeding: The sheet is centered and fed into the CRF machine. This
step ensures that the sheet is properly aligned and positioned for subsequent processing.

4. Notching: Notching involves cutting notches or grooves into the metal sheet. This step
may be necessary for creating specific features or shapes in the final product.

5. 180 Turnover: This step likely involves flipping or rotating the sheet by 180 degrees. This
could be necessary to perform certain operations on both sides of the sheet or to change
its orientation for further processing.

6. Roll Forming: Roll forming is a process where a continuous strip of metal is passed
through sets of rolls to gradually shape it into the desired profile. This step is crucial for
forming the metal sheet into the required shape for the refrigerator component.

7. L & Z Bending: L and Z bending refer to specific types of bending

operations. This step involves bending the metal sheet into L or Z shapes
as needed for the refrigerator component

8. Condenser Placing: The condenser is a component of the refrigerator's cooling system.

Placing it likely involves positioning it onto the formed metal sheet as part of the assembly
process.

Each of these steps plays a vital role in the manufacturing process, ultimately leading to
the production of refrigerator components.

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2.3 Pre-assembly Area

In pre-assembly, the various components are prepared and assembled before they move to
the main assembly line where they are integrated into the final product.

The pre-assembly line typically involves tasks such as component assembly, sub-assembly,
and preparation of parts before they are brought together in the Final assembly line.

the assembly process for a refrigeration unit, particularly focusing on the steps before and after
foaming the cabinet. Here's a breakdown of the process based on your description:

Before foaming:

1. Assembly of Surrounders (RHS and LHS): This likely involves putting together the right-
hand side (RHS) and left-hand side (LHS) components that surround the interior of the
cabinet.

2. Centre Hinge Installation: Installing the hinge mechanism that allows the refrigerator door
to swing open and close properly.

3. Lock Retainer: This could be a mechanism to hold the door in place when closed,
ensuring it doesn't swing open unintentionally.

4. Heat Loop: Installing a heat loop, which could be a component related to temperature
regulation or defrosting.

5. Centre Rail and Front Rail Assembly: These may be structural components that provide
support and rigidity to the cabinet.

6. Case Installation: Mounting the main structure of the refrigerator cabinet.

7. Screwing: Fastening the components together securely, likely using screws to ensure
stability and integrity of the assembly.

After foaming:

1. Assembly of Deck Panel and Back Panel: Once the foaming process is complete,
additional components like the deck pana (likely a shelf or surface inside the refrigerator)
and back panel are installed. This step likely involves securing these components within
the foamed cabinet.

This breakdown indicates a sequential process of building up the internal structure of the
refrigerator cabinet.

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In this line it is the assembly of the cabinet and the wrapper of the refrigerator and adding of
heat loop and barcode pasting. In this line back panel is also attached so that it will be ready
for the foaming process.

As in Figure 2.10 shows the image of the cabinet foaming machine. This machine add foam
inside the structure, through it get a strong support and attached tightly.

For foaming chemical like MDI (Methylene Diphenyl Di Isocyanate), Polyether and Cyclo
Pentane is used. There are two containers red and yellow. In red container MDI is stored and
in yellow container mixture of polyether and cyclo pentane is stored with proper coating as it is
highly flammable

In door foaming there is a mold in which upper side the door liner is kept and in lower side the
door outer frame is kept. Through this when is machine start it pour the mixture of red and
yellow containers in it. After pouring the mold get closed and locked. Its cycle time is for 240
seconds. After 240 seconds the mold gets open and final door is removed. After removing the
door gasket is fitted to it. After that the foamed door is send toward the final assembly line for
assembling the door to the refrigerator. Figure 2.8 shows the images of door foaming area and
door foaming machine.

the assembly process for a refrigeration unit. After the cabinet liner has been foamed, the next
steps typically involve assembling various components to complete the refrigerator.

1. Bottom Hinge Assembly: This involves attaching the bottom hinge mechanism to the
refrigerator cabinet. The hinge is crucial for allowing the door to open and close
smoothly.

2. Deck Installation: The deck is the base or platform on which the compressor and other
components will be mounted. It provides structural support for the internal workings of
the refrigerator.

3. Compressor Mounting Plate Installation: The compressor mounting plate is fixed onto
the deck. It provides a stable platform for the compressor unit to be attached securely.

4. Compressor Installation: The compressor, which is the heart of the refrigeration

system, is then installed onto the mounting plate. This involves connecting refrigerant
lines, electrical connections, and ensuring proper alignment and fastening.

Each of these steps requires precision and attention to detail to ensure that the refrigerator
functions efficiently and reliably. Following a systematic assembly process helps maintain
quality and consistency in the final product.

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2.4 Final-assembly Area

After the compressor installation, the assembly continues with the fitting of various
components:

1. Roll Bond Evaporator Installation: The roll bond evaporator is an essential component
responsible for cooling the refrigerator. It's installed in a specific location within the cabinet
to optimize cooling efficiency.

2. Freezer Backplate Fitting: The freezer backplate is installed, providing structural support
and insulation for the freezer compartment.

3. LED Bulb and Lens Mounting: LED lighting is becoming increasingly common in
refrigerators due to its energy efficiency and longevity. Mounting the LED bulb and lens
provides illumination inside the refrigerator.

4. Thermostat Installation: The thermostat, a crucial component for temperature regulation,

is installed and calibrated to ensure the refrigerator maintains the desired temperature.

5. Thermostat Knob Assembly: The thermostat knob, which allows users to adjust the
temperature settings, is attached to the thermostat.

After these components are installed, the cabinet and door are attached to enclose the
refrigerator. Then, the final assembly line involves fitting various accessories and
compartments:

1. Chiller Tray Installation: The chiller tray, typically located at the top of the refrigerator
compartment, provides a colder storage area for items like dairy products and beverages.

2. Toughened Glass Installation: Shelves made of toughened glass are installed at various
levels within the refrigerator to provide storage space and support for items.

3. Vegetable Box and Cover Fitting: The vegetable box, along with its cover, is fitted into
its designated space in the refrigerator to store fruits and vegetables.

4. Crisper Installation: The crisper drawer, designed to maintain optimal humidity for
preserving produce, is installed in the refrigerator.

5. Ice Box, Egg Tray, Bottle Tray, etc.: These additional accessories are fitted into the
refrigerator door according to its design and specifications, providing organized storage
for different types of items.

This comprehensive assembly process ensures that all components are properly installed and
functioning before the refrigerator is ready for quality testing and shipment.

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Attaching the power cord is a critical step in the assembly process, as it provides the electrical
connection necessary to power the refrigerator and its components. Here's how it typically fits
into the assembly:

1. Power Cord Connection: The power cord is usually connected to a terminal block or
junction box within the refrigerator. This terminal block serves as a central point where
electrical connections are made.

2. Thermostat Connection: One end of the power cord is connected to the thermostat, which
regulates the refrigerator's temperature. The thermostat is responsible for turning the
compressor on and off based on temperature settings.

3. Compressor Connection: The other end of the power cord is connected to the
compressor, the primary component responsible for cooling the refrigerator. When
powered, the compressor circulates refrigerant through the system, removing heat from the
interior of the refrigerator.

4. Various Electrical Parts: In addition to the thermostat and compressor, the power cord
may also be connected to other electrical components, such as fans, defrost heaters, and
control boards, depending on the refrigerator's design and features.

By connecting the power cord to these key components, the refrigerator can be powered on,
allowing it to start cooling and functioning as intended. Proper electrical connections are
essential for the safe and reliable operation of the appliance.

The earthing wire serves an important safety function in the refrigerator's electrical system by
providing a path for electrical current to flow safely to the ground in the event of a fault or
malfunction. Here's how it typically fits into the assembly:

1. Connection to Compressor: One end of the earthing wire is securely connected to the
compressor. The compressor, being a major electrical component within the refrigerator,
requires proper grounding to ensure safety and prevent electrical hazards.

2. Connection to Base Plate: The other end of the earthing wire is connected to the base
plate or chassis of the refrigerator. The base plate, being a large metal component that
forms the structural foundation of the refrigerator, serves as a suitable grounding point.

By connecting the earthing wire between the compressor and the base plate, any electrical
faults or excess current that may occur in the compressor or other components can safely
dissipate into the ground, reducing the risk of electric shock or fire hazards.

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The overload protector (OLP) and positive temperature coefficient (PTC) are important
components for the safe and efficient operation of the compressor in a refrigerator. Here's how
they typically fit into the assembly process:

1. OLP and PTC Connection to Compressor: Both the overload protector (OLP) and
positive temperature coefficient (PTC) are connected directly to the compressor.

• The overload protector (OLP) is a safety device that helps protect the compressor from
overheating or excessive current draw. It automatically interrupts the electrical circuit to
the compressor if it detects abnormal conditions such as high current or temperature.

• The positive temperature coefficient (PTC) is a type of thermistor that acts as a starting
device for the compressor. It helps provide the initial boost of power needed to start the
compressor motor.

2. Capacitor Connection: The capacitor, another essential component in the refrigerator's

electrical system, is connected in parallel with the compressor and is typically mounted
nearby.

3. Power Cord Connection: The power cord, which supplies electrical power to the
refrigerator, is connected to the compressor and capacitor via a wiring harness or terminal
block.

4. Spring Wire Connection: The spring wire of the power cord is connected to the
capacitor. This connection helps provide a secure electrical connection between the
power source and the compressor circuit.

By connecting the OLP, PTC, capacitor, and power cord in this manner, the refrigerator's
compressor motor can operate safely and efficiently. The OLP protects the compressor
from electrical faults, while the PTC assists in starting the compressor motor. The
capacitor helps improve the efficiency of the compressor motor by providing additional
power when needed. The spring wire ensures a reliable electrical connection between the
power source and the compressor circuit. Overall, this assembly configuration helps
ensure the reliable operation of the refrigerator's cooling system.

The vacuum pump coupling process you described is a crucial step in ensuring the
integrity and efficiency of the refrigeration system. Here's how the process typically works:

1. Vacuum Pump Coupling: A vacuum pump is connected to the refrigeration system, often
via a coupling or hose connection. The vacuum pump creates a vacuum within the
system, removing air and moisture that may be present.

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2. Moisture Removal: Moisture can be detrimental to the performance and longevity of the
refrigeration system. During the vacuuming process, the low pressure created by the
vacuum pump causes moisture to evaporate and be drawn out of the system.

3. Cycle Time: The vacuuming process typically takes around 30 minutes to complete. This
duration allows sufficient time for the vacuum pump to remove air and moisture from the
system effectively.
4. Micron Level Monitoring: The micron level is a measure of the vacuum level within the
system. A lower micron level indicates a higher level of vacuum, meaning that more air
and moisture have been removed. On the screen, if the micron level reads below 30
microns after the 30-minute cycle, it indicates that the vacuuming process has been
successful, and the system is free of significant air and moisture contamination.

Charging the compressor with the appropriate gas is a critical step in the refrigeration
manufacturing process. Here's how it typically works:

1. Gas Charging Process: After the vacuuming process is completed and the refrigeration
system is deemed free from moisture and air, the compressor is charged with gas. This
process involves introducing a specific type and quantity of gas into the compressor to
facilitate the refrigeration cycle.

2. Nitrogen Charging: Initially, nitrogen gas is charged into the compressor at a pressure of
5 to 6 bar. Nitrogen is commonly used for pressure testing and leak detection purposes.
Charging the compressor with nitrogen helps ensure that there are no leaks in the system
and that it can withstand the operating pressures.

3. R600a or Isobutane Charging: Following the nitrogen charging, the compressor is then
charged with R600a (isobutane) refrigerant gas. R600a is a hydrocarbon refrigerant
commonly used in domestic refrigerators due to its low environmental impact and
excellent thermodynamic properties. The refrigerant is charged into the compressor at a
pressure of 16 to 17 bar.

4. Quantity Calculation: The quantity of refrigerant to be filled into the compressor is

determined based on the model and size (in liters) of the refrigerator being manufactured.
Each refrigerator model may have specific requirements regarding the amount of
refrigerant needed to achieve optimal cooling performance.

5. Charging Time: The gas charging process typically takes around 14 to 15 seconds to
complete. This duration allows for the precise injection of the required quantity of gas into
the compressor while maintaining safety and efficiency.

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By charging the compressor with the appropriate gases according to the specified pressure
and quantity requirements, manufacturers can ensure that the refrigeration system operates
efficiently and reliably, providing optimal cooling performance for the refrigerator unit.
Additionally, adherence to safety protocols during the gas charging process is essential to
prevent leaks and ensure product quality.

1. Leak Detection Procedure: Once the compressor has been charged with the appropriate
gases, the refrigerator unit undergoes a leak detection test to identify any potential leaks
in the refrigeration system.

2. Electronic Leak Detectors: Specialized electronic devices are used to detect refrigerant
leaks by sensing trace amounts of refrigerant in the surrounding air.

CHAPTER 3: INCOMING QUALITY CONTROL

3.1 Introduction to Incoming Quality Control (IQC) in Refrigeration Manufacturing

Within the domain of refrigeration manufacturing, the quality of raw materials and components
directly influences the performance, reliability, and longevity of refrigeration systems.
Incoming Quality Control (IQC) serves as the frontline defense in ensuring that materials meet
stringent standards before they are integrated into refrigeration units. IQC encompasses a
systematic process of inspection and evaluation conducted upon the arrival of materials from
suppliers, playing a pivotal role in upholding the company's commitment to delivering superior
refrigeration solutions.

At our refrigeration company, IQC begins with collaborative efforts between our Research and
Development (R&D) team, the IQC department, and our trusted suppliers. Detailed parts
drawings and specifications are shared, serving as blueprints that outline the exact requirements
for materials and components. These specifications cover critical aspects such as dimensions,
material composition, thermal properties, and adherence to regulatory standards.

Upon receipt of materials, our dedicated IQC team meticulously examines each component
using a range of precision instruments and inspection techniques. Instruments such as calipers,
thermometers, pressure gauges, and thermal imaging devices are employed to verify
dimensional accuracy, thermal conductivity, pressure resistance, and other essential parameters.
This comprehensive evaluation ensures that materials not only meet but exceed our stringent
quality standards.

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The primary objectives of IQC include:

1. Ensuring Compliance: IQC ensures that incoming materials conform to the specified
requirements outlined in the drawings or specifications provided by the R&D team. This
involves verifying dimensions, tolerances, material composition, and other critical
parameters.
2. Preventing Defects: By detecting and addressing any deviations or defects early in the
production process, IQC helps prevent the incorporation of substandard materials into
finished products. This proactive approach minimizes rework, scrap, and potential product
failures, thereby enhancing overall efficiency and cost-effectiveness.
3. Maintaining Consistency: Consistency in material quality is essential for maintaining
product reliability and meeting customer expectations. IQC helps establish and maintain
consistent quality standards across incoming materials, ensuring uniformity in the
manufacturing process and the final products.
4. Supplier Collaboration and Improvement: IQC fosters collaboration with suppliers by
providing timely feedback on material quality and performance. This feedback loop
enables suppliers to address any issues promptly, implement corrective actions, and
continuously improve their processes, ultimately strengthening the overall supply chain. In
summary, IQC serves as a cornerstone of quality assurance within our refrigeration
manufacturing processes. By upholding stringent standards, leveraging advanced
inspection techniques, and fostering collaboration with suppliers, IQC reinforces our
commitment to delivering superior refrigeration solutions that meet the highest industry
standards and customer expectations.

Incoming Quality Control (IQC) involves a series of processes aimed at ensuring that materials
and components meet predefined quality standards before they are used in production. Here are
the various processes typically involved in IQC:
Sharing of Parts Drawings: The process begins with the Research and Development (R&D)
team sharing detailed parts drawings with both the IQC department and the supplier. These
drawings outline the specifications, dimensions, tolerances, and other requirements for the parts
to be manufactured.

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Manufacturing by Supplier: Based on the provided drawings, the supplier manufactures the
parts or materials. They are responsible for ensuring that the produced parts conform to the
specifications outlined in the drawings.

Receipt of Raw Parts or Materials: Once the parts are manufactured, they are sent to the IQC
department for inspection. This step marks the beginning of the IQC process.

Inspection Using Precision Instruments: Upon receipt of the raw parts or materials, the IQC
team inspects them thoroughly using precision instruments such as vernier calipers,
micrometers, thickness gauges, radius gauges, height gauges, and others. These instruments
enable accurate measurement of dimensions and assessment of physical attributes against the
specifications provided in the drawings.

Decision Making: Based on the findings documented in the sample inspection report, the IQC
team makes decisions regarding the acceptance, rejection, or further action required for the
inspected parts. If the parts meet the specified criteria, they are accepted for further processing
or assembly. If there are deviations or defects, decisions may include rejection of the parts,
requesting corrective actions from the supplier, or initiating other quality control measures.

Continuous Improvement: The IQC process is iterative and aims for continuous
improvement. Feedback may be provided to the supplier to address any recurring issues or
discrepancies identified during inspections, helping to enhance the overall quality of the
supplied parts over time.

Specification Review: The IQC process begins with a thorough review of the specifications
provided by the Research and Development (R&D) or Engineering team. These specifications
outline the required dimensions, material properties, tolerances, and other critical
characteristics of the incoming materials.

Sampling Plan Development: Based on the specifications, a sampling plan is developed to

determine the number of samples to be inspected from each incoming batch or lot. The
sampling plan considers factors such as lot size, criticality of the materials, and acceptable
quality levels.

Receiving Inspection: Upon receipt of materials from suppliers, the IQC team performs a
receiving inspection. This involves visually inspecting the materials for any obvious defects or
damage during transit.

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Fitment Assessment: In addition to dimensional inspection, the IQC process includes

assessing the fitment of parts. This involves verifying that the dimensions and tolerances of the
incoming materials allow for proper assembly and integration into the final product. Fitment
assessment ensures that parts align correctly, interface smoothly, and function as intended
within the assembly process, contributing to overall product performance and reliability.

Functional Testing: Functional testing is performed to verify that the materials or components
operate as intended. This may involve conducting electrical, mechanical, or performance tests
based on the nature of the materials.

Material Testing: Material testing assesses the physical and chemical properties of the
materials, such as tensile strength, hardness, corrosion resistance, and thermal conductivity.
Various testing methods and equipment are employed to evaluate material properties.

Documentation and Record Keeping: Throughout the IQC process, detailed documentation is
maintained, including inspection reports, test results, and any deviations from the
specifications. This documentation serves as a record of the inspection activities and provides
traceability for quality assurance purposes.

Disposition of Non-Conforming Materials: If any materials or components fail to meet the

specified requirements during inspection or testing, a decision is made regarding their
disposition. Non-conforming materials may be rejected, returned to the supplier, reworked, or
subjected to further analysis to determine the root cause of the deviation.

Supplier Feedback and Continuous Improvement: Feedback is provided to suppliers based

on the inspection results to address any recurring issues or quality concerns. This feedback loop
fosters collaboration with suppliers and promotes continuous improvement in the quality of
incoming materials.
By following these processes systematically, IQC ensures that only materials and components
meeting the required quality standards are used in production, thereby maintaining product
quality, reliability, and customer satisfaction.

3.2 Generation of Sample Inspection Report:

Following the inspection, the IQC team compiles the results into a sample inspection report.
This report documents various aspects of the inspection, including measurements taken, any

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deviations from the specified requirements, and the overall quality of the received parts. It
serves as an official record of the inspection findings.

Sample inspection reports are essential documents in the IQC process, providing detailed
records of the inspection findings for different parts or materials. Here's an outline of how
sample inspection reports can be structured for various types of parts:

Header Information:

• Report title: Sample Inspection Report

• Date of inspection
• Part name or description
• Supplier information
• Inspector's name or ID
1. Part Details:
o Part number or code o Drawing or specification reference o Quantity received

2. Inspection Criteria:
o List of inspection criteria based on the part's specifications or drawing requirements. This
may include dimensions, tolerances, surface finish, material properties, and any other
relevant attributes.
3. Measurement Data:
o Detailed measurements for each inspection criterion, including actual dimensions,
tolerances, and any deviations from the specified requirements. Measurements may be
recorded in tabular format, with columns for nominal values, measured values, and
deviations.
4. Visual Inspection Results:
o Description of any visual defects or anomalies observed during inspection, along with
photographic documentation if applicable.
5. Functional Testing Results (if applicable):
o Summary of any functional tests conducted and the corresponding results, including
pass/fail status and any relevant observations.
6. Material Testing Results (if applicable):
Summary of material testing performed, such as tensile strength, hardness, or chemical
composition analysis. Results should indicate compliance with specified material
properties.

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7. Disposition: o Decision regarding the acceptance, rejection, or rework of the inspected

parts based on the inspection findings. This section may also include instructions for
further action, such as contacting the supplier or initiating corrective measures.
8. Remarks: o Any additional comments, observations, or notes relevant to the inspection

process or the quality of the inspected parts.

9. Conclusion: Overall assessment of the inspected parts' quality and compliance with
specifications. This section may also include recommendations for process improvement or
supplier feedback.

10. Approval and Sign-off:

Signatures or electronic approvals from the inspector, quality assurance personnel, and any
other relevant stakeholders involved in the inspection process.

11. Attachments:

Additional documentation, such as photographs, test certificates, or supplier

correspondence, that support the inspection findings or provide further context.

By following this structured format, sample inspection reports effectively document the results
of IQC inspections for different parts or materials, facilitating traceability, decision-making,
and continuous improvement efforts.
On next page you will get to see a sample inspection report for the DOOR GLASS DC 203L LOTUS
CHARM on the basis of above

ARTWORK
During the sample inspection report creation, we compare physical parts with provided artwork
to ensure design consistency. Using detailed drawings, we visually inspect and measure
dimensions, documenting any differences. This analysis informs corrective actions and is
reviewed with stakeholders to maintain quality standards.

After the completion of the sample inspection report, it is imperative to promptly forward it to the
Research and Development (R&D) team. Their pivotal role encompasses two primary responsibilities:

Tolerance Adjustment: If any non-conforming dimensions (NG dimensions) are identified in the
inspection report, the R&D team may need to adjust the tolerances for those dimensions. This involves
determining whether the tolerance limits need to be revised to accommodate the variations observed in
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the samples. Adjusting tolerances can help ensure that future production runs meet the desired quality
standards.
Final Judgment: The R&D team reviews the inspection report to make a final judgment on the quality
of the sampled products. They assess whether the products meet the required standards and
specifications. If everything is satisfactory, they approve the products for further production or
distribution.

3.3 INSTRUMENTS USED DURING INSPECTION

During the creation of a sample inspection report, a variety of instruments and tools are utilized to
accurately assess the quality and specifications of the sampled products. These instruments collectively
enable inspectors to thoroughly evaluate the sampled products and compile detailed reports regarding
their quality, dimensional accuracy, surface finish, material properties, and overall conformance to
specifications .These instruments may include:

1.DIGITAL VERNIER CALLIPER: In refrigeration companies, precise measurement of

dimensions is paramount to ensure the functionality and efficiency of equipment. Digital vernier
calipers are essential tools for this task. They accurately measure various dimensions such as the
length, width, and thickness of components like pipes, fittings, and valves. These measurements
are crucial for ensuring that each part meets the specified tolerances and fits seamlessly within
the refrigeration system. By providing precise measurements, digital vernier calipers help
maintain the quality and reliability of refrigeration equipment, ultimately contributing to its
optimal performance.

• MEASURING MODES: Very easy to use. Switch between inches or millimeters for accurate
measurements with one button.
• PRECISION: Measurement tool for performance. Measuring range between 0-6” or 0 – 150 mm.
ACCURACY: Resolution: 0.01mm / 0.0005 in. Accuracy +/- 0.02 mm / 0.001 in
• EASY TO READ: Display is an Extra large LCD screen for easy, quick and clear reading. BATTERY
INCLUDED with auto on off feature.
• VERSATILITY: With this micrometer set you can take measurements for outside, inside, depth and
step with two sets of jaws, the probe and depth gauge.
• Stainless Steel Calipers are hardened palastic metal frame with thumb roller and locking screw for
smooth sliding and accuracy.
• STORAGE CASE: Store and put away your electronic digital caliper with the custom fit plastic case.

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2. MICROMETER: Capable of measuring the thickness of objects quickly and

accurately, digital micrometers are perfect for all kinds of applications. Whether you
need to know the thickness of paper or how deep a film coating is, digital micrometers
are a great choice.

Micrometers are tools designed for measuring the depth, width, or length of a material. These thickness
measuring tools give precise results and there are both traditional and digital versions available

To use a digital micrometer, you simply need to place the sample between the calipers. If you have a
manual micrometer, you will need to tighten the calipers yourself. If you have an automated testing
machine, it will do this for you once the sample is in place and the process is initiated. Once the calipers
meet the material being tested, the result will be displayed for you to read.

The least count of a micrometer is the minimum measurement it is capable of recording,

and this is 0.01 mm for analog and 0.001 mm for digital micrometers.

:
3. PIN GUAGE Pin gauges are cylindrical pin shaped plugs sized to a high

precision. The main function of a pin gauge is to inspect the inner diameters of your
workpiece. They are commonly used similarly to a Go and No-Go gauge to qualify
whether a hole is within a certain specification. You can also use it to test for geometric
deviations in measurements. Pin gauges are useful for checking the straightness of a deep
hole.

They can be made of many types of materials: Steel, Carbide, Ceramic, Zirconia, Hard
Metal Alloy. LFC is the authorized distributor of Eisen Pin Gauges. Eisen pin gauges
are made of the following materials:

• Steel
• Ceramic (Zirconia)
• Tungsten carbine

Pin gauges in a set come in assorted sizes with small increments. These increments can be in 0.01 mm
or 0.001 mm depending on your requirements. These small increments are minute as pin gauge are
typically used in smaller holes applications, which requires high precision and accuracy. Every pin is
marked with its exact size so that the user can easily identify these pins.

If you own a complete set of pin gauge, you can start by inserting the pin gauge with the smallest
diameter into the workpiece hole. You can then insert the pin gauge in increasing order of size until you
find the pin gauge that fits nicely into the workpiece bore. You should not push the pin gauge into the
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bore by force. Ideally, the minimum or “Go” pin is use for the lower limit of the bore. It should fit
nicely with no force. The maximum or “No Go” pin gauge is for the upper limit. It will not fit even if a
small force is applied to push it in.

4. FEELER GAUGE:

A feeler gauge is a tool used to measure gap widths. Feeler gauges are mostly used in engineering to
measure the clearance between two parts. They consist of a number of small lengths of steel of different
thicknesses with measurements marked on each piece. They are flexible enough that, even if they are all
on the same hinge, several can be stacked together to gauge intermediate values. It is common to have
two sets for imperial units typically measured in thousandths of an inch and metric measurements.
Manufactured using high carbon steel and chrome vanadium steel for strength, durability
and resistance to corrosion. This master feeler gauge is constructed of durable harden
steel that won t wear down over time.
It's 26 blades provide accurate measurement of clearances. Each blade has easy to read etched markings.
Every blade with its thickness clearly on it, easy to select.

5. RADIUS GUAGE:

Radius gauges are instruments that are used to measure the radius of the object. The radius gauge is
combined with another gauge known as fillet gauge which in mechanics means a rounding of the part
design. Radius gauge is a radius measurement tool that can be used to measure the inner radius whereas
the outer radius is measured by the fillet gauge. The construction of the radius gauge consists of two
gauges having a number of steel strips or blades screwed together in one single holder. The screw is
known as the lock screw. The radius measurement is usually in metric form and measured in
mm(millimeter). The material used is entirely made up of stainless steel, but a layer or finish of satin
chrome can be added since it keeps the radius gauge corrosion free and gives them more rust resistance.
The blades used are of the concave and convex shape. It may be swung out of the holder case when
necessary readings need to be taken as per the requirement.

6. PUSH PULL (FORCE) GAUGE: A push-pull force gauge is a device used to

measure
the force applied in either direction (push or pull) to an object. It's commonly used in various
industries for quality control, research, and development purposes.
These gauges typically consist of a body with a built-in load cell that measures the force
applied.

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They often have a display screen to show the measured force in units such as Kilogram-force,
Newtons or pounds-force. Some may also feature additional functions like peak hold, which
captures the maximum force applied during a test.

Push-pull force gauges come in various designs and sizes depending on the application
requirements. They can be handheld for portable use or mounted onto testing equipment for
more specialized tasks. Some may also feature attachments or grips to facilitate different types
of force measurements.

Overall, push-pull force gauges are versatile tools used in a wide range of industries including
manufacturing, automotive, aerospace, and healthcare, among others, for testing the strength
and durability of materials, components, and products.

3.4 TEST CONSIDERATION DURING SIR:

1. Rockwell Hardness Tester: A Rockwell hardness tester is a device used to measure the

hardness of materials, primarily metals. It operates based on the depth of penetration of an indenter
into the material under a certain load. The Rockwell hardness test involves applying a minor load
(preliminary force) followed by a major load (total force) onto the surface of the material using a

specific indenter, usually a spherical or conical diamond or hard metal ball. After the major load is

removed, the depth of penetration of the indenter into the material is measured, and this depth
correlates with the material's hardness.

There are different scales within the Rockwell hardness test, denoted by a letter, such as A, B, C, etc.
Each scale uses a different combination of loads and indenter types, making them suitable for

different materials and hardness ranges.

2.THERMOSTAT BATH

describing different types of thermostats and their components. To test a

thermostat in different conditions (normal, cold, warm), you typically need to
follow specific procedures to ensure accurate results.

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For a DC thermostat with Changzhou sleeve and white wire, and a longer length, you might
follow these steps:
1. Normal Condition (ACE 11004-00-NORMAL):

• Ensure the room temperature is within normal range.

• Connect the thermostat as per its installation instructions.

• Check if the thermostat accurately controls the temperature within the

desired range.

2. Cold Condition (ACE 11004-00-COLD):

• Lower the room temperature significantly, perhaps by using air conditioning or opening
windows.

• Monitor the thermostat's response to this colder environment.

• Verify if the thermostat effectively triggers the heating system to maintain the desired
temperature.

3. Warm Condition (ACE 11004-00-WARM):

• Increase the room temperature, for instance, by using a heater or closing windows to
retain warmth.

• Observe how the thermostat reacts to this warmer setting.

• Ensure it accurately signals the cooling system to maintain the desired temperature level.

For the FF thermostat with a Robertshaw component (light green wire) and Changzhou (dark
green wire), you'd follow similar steps tailored to its specific features.

Got it. Here's a step-by-step guide to starting the test for the Changzhou DC thermostat using
the 77 software:

1. Start Test 77 Software:

• Open the Test 77 software on your computer.

2. Click on Parameter:

• Within the Test 77 software, locate and click on the "Parameter" option. This should be in
the main menu or toolbar.

3. Click on Menu:
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• In the parameter settings, find and click on the "Menu" option. This should open a
submenu with various choices.

4. Select Changzhou DC:

• From the submenu, choose the option labeled "Changzhou DC." This selects the specific
type of thermostat you're testing.

5. Click on Model:

• After selecting Changzhou DC, locate the option to choose the thermostat model.

Click on it.

6. Choose Model WSFE27E:

• From the list of available models, select WSFE27E. This specifies the exact model of the
Changzhou DC thermostat you're testing.

7. Select Test Condition:

• Choose the test condition based on whether it's normal, cold, or warm. You mentioned
ACE 11004-00-NORMAL, ACE 11004-00-COLD, and ACE 1100400WARM for the
conditions.

8. Set Speed Level:

• Adjust the speed level to 4. This likely controls how quickly the thermostat reacts to
temperature changes.

9. Preparation Fast:

• Set the preparation mode to fast. This likely speeds up the preparation phase before the
actual testing begins.

10. Click First, Prepare, and Start:

• Follow the sequence to click on "First," "Prepare," and then "Start." This initiates the test
procedure.

Now, the test for the Changzhou DC thermostat should begin, following the specified
parameters and conditions you've set. Make sure to monitor the test process closely for
any deviations or abnormalities

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4. Bursting Strength Tester

Working mechanism of Bursting Strength Tester Genie 2.0
The determination of the force required for the bursting or complete rupture of a material is
conducted using a Digital Indicator. This bursting strength is a crucial parameter that sets the
quality of the material in comparison to others. The Digital Bursting Strength Tester, offered
by, operates by applying hydraulic pressure under a rubber diaphragm with a specified area
onto the test sample. This bursting strength test machine is versatile and can accurately
assess the bursting strength of various materials such as paper, corrugated cardboard, carton
boxes, cardboard, leather, cloth, or synthetic leather. The resulting bursting strength value is
quantified in kg/cm².

Test Equipment Setting Guide (Step wise)

This instrument is used to measure Bursting strength of Corrugated / Packing Box

1. Prepare sample 100mm x 100mm & switch ON the Power

2. Press TEST button on Display Panel to start the test

3. Machine Will return to Its origin and the upper pressure plate clamps the sample and starts
pressurization

4. Once the sample is destroyed, pressurization will be stopped and pressure relief will start

5. The upper pressure plate then releases the pressure plate

6. Data is Viewed on the screen

Note: 1. If the upper pressure plate doesn't clamp the sample then press STOP immediately

2.Air Pressure shouldn't be zero

bursting strength tester machine is specifically designed for measuring the bursting strength of paper
and strong paperboard. The testing procedure involves preparing the specimen and securing it between
two circular clamps. Using the geared handle provided, the specimen is tightened. The hydraulic
pressure is incrementally applied by manipulating the handle until the specimen ruptures. The digital
display then indicates the bursting strength of the test specimen in kg/cm²

5. Izod/Charpy Impact Tester: The IZOD impact test is used to determine the
impact resistance

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(toughness) of a material, or the material’s tendency to resist breaking when subjected to a sudden force
or impulse. The IZOD impact test method, also known as the notched IZOD test, is standardized under
the ASTM International test procedure. The test is often used in the polymer industry to determine the
toughness of plastics but can be used on any material. The materials needed to complete an IZOD
impact test are: a rectangular test specimen with a machined notch, a pendulum impact test fixture, and
a vise or similar holding device to fix the test specimen.

The IZOD/CHARPY impact test is important because it:

1. Allows engineers to determine the toughness of candidate materials, permitting parts and structures
to be designed with appropriate materials, dimensions, and safety factors.

2. Enables engineers to observe how materials perform when subjected to impact loading.

Test Equipment Setting Guide (Step wise) - Izod Impact Test

This instrument use to measure toughness of material by Izod hammer impact.

1. Prepare sample Size 63.5 x 12.7mm to perform Izod test and cut the notch 2.0mm mtn. at the
center & switch on the power.
2. Hold the Izod hammer at the top of Wc. Put specimen at the holder. After put the thickness of
specimen. Weight of Izod hammer in display unit
3. Close the safety door and push to manual release button to perform test

4- Take reading from display in unit of degree or Joule per meter square.

5. Retnove the tested speamen from holder. and clean the mic.

Note: 1. Ensure door should be closed during perform the test.

First, the height of the pendulum hammer is set. The potential energy of the pendulum at this height is
recorded. Second, the pendulum is dropped and then strikes the test specimen. Third, the kinetic energy
of the pendulum is determined when the specimen breaks. The law of conservation of energy is used to
determine the kinetic energy at breakage. The impact strength of a material is considered the kinetic
energy absorbed by the specimen at breakage

NOTCH CUTTER FOR IMPACT TESTER:

Test Equipment Setting Guide (Step wise)

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This instrument is used as supplementary instrument of impact tester

1.Cut the sample of size (63.5*12.7),

2.Place the sample at provided position and Tight the screws as per picture 2.

3.Now adjust the specimen with Micrometer

4.When specimen in in contact with the cutter assume this reading as zero preference

5.Start the motor by pressing power switch.

6.Now adjust the required depth (1.5mm) With micrometer by rotating clockwise
7.Remember, one round of micrometer = 1/2 mm

8.after cutting of requited slot switch off the power switch.

9.Take the micrometer back to its Initial position and remove the sample Clean the Machine

UNIVERSAL TESTING MACHINE:

A universal testing machine, also known as a universal tester, materials testing machine ormaterials test
frame, is used to test the tensile stress and compressive strength of materials. It is named after the
fact that it can perform many standard tensile and compression tests on materials, components, and
structures. The primary objective of this investigation is to conduct a standard tensile test for
determining the stressstrain behavior of a material sample (mild steel or aluminum) and to analyze the
results of the tensile test to find the mechanical/material properties of the sample.
The following tests can be performed with it:-
1. Tension Test.
2. Compression Test.
3. Bending Test.
4. Hardness Test.

Parts of Universal Testing Machine

The Universal Testing Machine consists of two main parts, the loading unit and the control panel.

1. The Loading Unit:

The loading unit consists of a robust base at the center of which is fitted the main cylinder and piston. A
rigid frame consisting of the lower table, the upper cross head and the two straight columns is connected
to this piston through a ball and socket joint. A pair of screwed columns mounted on the base pass
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through the main nuts to support the lower cross-head. This cross head is moved up or down when the
screwed columns are rotated by a geared motor fitted to the base.
Each cross-head has a tapering slot at the center into which are inserted a pair of racked jaws. These
jaws are moved up or down by the operating handle on the cross-head face and is intended to carry the
plate (grip) jaws for the tensile test specimen. An elongation scale, which measures the relative
movement between the lower table and the lower cross-head, is also provided with the loading unit.
2. The Control Panel:

The control panel contains the hydraulic power unit, the load measuring unit and the control devices.
a. The Hydraulic Power Unit:

The Hydraulic Power Unit consists of an oil pump driven by an electric motor and a sump for the
hydraulic oil. The pump is of the reciprocating type, having a set of plungers which assures a continuous
non-pulsating oil flow into the main cylinder for a smooth application of the test load on the specimen.
Hydraulic lines of the unit are of a special design to enable them to perform various functions
b. The Load Measuring Unit:
The load measuring unit, in essence is a pendulum dynamometer unit. It has a small cylinder in which a
piston moves in phase with the main piston under the same oil pressure. A simple pendulum connected
with this small piston by a pivot lever thus deflects in accordance with the load on the specimen and the
pivot ratio. This deflection is transmitted to the load pointer which indicates the test load on the dial.
The pivot lever has four fulcrum -knife- edges, giving four ranges of test load. The required range can
be selected by just turning a knob provided for the purpose. The overall accuracy of the machine
depends mainly on the accuracy of the measuring unit.
c. Control Devices:-
These include the electric control devices, the hydraulic control devices and the load indicating devices.
The Electric Control Devices are in the form of four switches set on the left side of the panel face. The
upper and lower push switches are for moving the lower cross-head up and down respectively. The
remaining two are the ON and OFF switches for the hydraulic pump. o The Hydraulic Control Devices
are a pair of control valves set on the table or the control panel. The right control valve is the inlet valve.
It is a pressure compensated flow control valve and has a built-in overload relief valve. If this valve is in
the closed position, while the hydraulic system is on, oil flows back into the sump. Opening of the valve
now, cause the oil to flow into the main cylinder in a continuous non-pulsating manner. The left control
valve is the return valve. If this valve is in the closed position, the oil pumped into the main cylinder
causes the main piston to move up. The specimen resists this, movement, as soon as it gets loaded up.
Oil pressure inside the main cylinder (and elsewhere in the line) then starts growing up until either the
specimen breaks or the load reaches the maximum value of the range selected. A slow opening of this
valve now causes the oil to drain back into the sump and the main piston to descent. o The Load
indicating Devices consist of a range inflating dial placed behind a load indicating dial. The former

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move and sets itself to the range selected when the range adjusting knob is turned. The load on the
specimen at any stage is indicated by the load pointer which moves over the load indicating dial and
harries forward with it a dummy

Problem solving:

Logo alignment

During a routine inspection of our refrigeration units, we identified an issue with one specific
glass door on a refrigerator. Upon closer examination, it became apparent that the logo
displayed on the glass door was noticeably tilted. This misalignment not only compromised the
aesthetic appeal of the refrigerator but also raised concerns about product presentation
standards.

Recognizing the importance of rectifying this issue promptly, I took the

initiative to devise a solution. Drawing upon my problem-solving skills, I
conceptualized the creation of a specialized tool known as a jig. This jig was
designed to aid in the inspection and subsequent adjustment of the logo
alignment on the glass door.

To construct this jig, I selected high-impact polystyrene (HIPS) as the primary

material due to its durability and suitability for the task at hand. With careful
precision, I crafted the jig to accommodate the dimensions of the glass door and
ensure a snug fit during usage.

Once the jig was completed, we proceeded with the inspection and correction process. By
utilizing the jig as a guiding tool, we were able to systematically assess the alignment of the
logo and make necessary adjustments to achieve the desired straightened position.

Following the implementation of the corrective measures, we conducted a thorough evaluation

to verify the effectiveness of our efforts. It was gratifying to observe that the logo on the glass
door now appeared aligned and aesthetically pleasing, in accordance with our quality standards.

In conclusion, the creation and utilization of the HIPS jig proved to be an instrumental solution
in addressing the tilted logo issue on the refrigerator glass door. This experience underscores
the significance of proactive problem-solving and innovation in maintaining product integrity
and customer satisfaction within our operations.

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