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Mohit Tomar & Devinder Singh B.E.

(mech) Graphic Era University

Incorporated and promoted in 1992 by Mr Kartar Singh, the Amber Group is among other things, one of the largest original equipment manufacturer of white goods in India. One factor that has led us this far is our relentless focus on quality. At the Amber Group we follow strict quality processes and we are an ISO 9001 - 2008 certified company. Under the aegis of the Amber Group there are two distinct entities: Amber Enterprises India Pvt. Ltd. and Amber Aviation India Pvt. Ltd. . Amber Industries is a conglomerate of 9 manufacturing units that are involved in producing original equipment for some of the biggest brands in India while Amber Aviation is engaged in aircraft charters and training of commercial pilots.

Some of top white good brands are L.G Videocon Godrej Whirlpool Blue Star Philips Voltas

Organization Chart (Unit-6)


Chairman Total Staff:-100 G.M:-02 Manager:-12 Engineer:-86 Managing Director V.P(Operation)

G.M(Manufacturing)

H.R(Head)

G.M(Finance) Manager

Manager (H.R)

Executive (H.R)

Executive Finance

Manager (Store)

Manager (Quality)

Manager (Production)

Manager (Manufacture)

Executive (Store)

Senior Engineer

Senior Engineer

Engineer

Senior Production Engineer

Production Engineer

Senior Manufacture Engineer

Executive Manufacture Engineer

Split & Window Air Conditioners for commercial and residential use . Package Air Conditioners for Indian Railways and commercial use. Heat Exchangers. Multi Flow Condensers. Home appliances like Washing Machines, Refrigerators & Microwaves. Luminaries for commercial use. Plastic Extrusion Sheets. Vacuum Forming Components. Injection Molding Components. Sheet Metal Components. Auto Parts.

Reliability lab Incoming quality control Line quality control Pre dispatch inspection New Product Development

Preparing slots in plain pipes in press shop. Fin formation and assembly of condenser in fin forming and core assembly machine. Pre-inspection of fixture. Condenser fixture is passed in thermal degreaser to vaporize oil. Flux is applied on the condenser for brazing

Condenser is then passed through preheat chamber to dry the flux. In heater chamber brazing is done through 5 heater zone. Temperature ranges from 590oCto 615oC. Condenser is passed through air cooling room for cooling of the condenser, liquid N2 is used. Manual brazing of inlet and outlet valve is done.

Water leak test and helium test is done to check any leakage in the condenser. Condenser is passed through dry oven input core handle to dry the condenser from any liquid. In final inspection area, through nitrogen flushing it is determined whether the gas is passing through the inlet valve to the tubes and finally through the exit valve. Other problems are also checked in the final inspection area. Through Nitrogen purging gas is stored in the condenser.

1)
2) 3)

4)

Check sheet Pareto Diagram Fish Bone Diagram Monitoring

Here we represent our problems in the form of table. For eg.


S.No Model No. Problems Production Fault Percenta Cum. Products ge Perc. Remarks

Date- 5th-july-2013 1. UD6P Bracket Shift Bracket Tilt 300 8 100% 100% -

2.

100%

1. 2. 3. 4.

Works on 80-20% Rule. In this diagram we choose which particular problems we have to solve. It represents in graph form. It has two y-axis. Firstly on left hand side is represented as primary axis which contains fault products, and secondly right hand side is represented as secondary axis which shows cum. Percentage, and X-axis represents problems which we face while manufacturing of condensor.

REJECTION - PPM TREND JUNE 2013

80% REJECTION DUE TO 20% REASON

Leadership Through Innovation

Quality,Cost,Deliver

Machine

Man

Bracket Tilt

Method
1.

Material

2.

we collect all the reasons regarding the problems caused by the different factors like man, machines, method , materials and write these reasons in their columns. Then we relate those problems with the above concerns whether the problems were actually caused by them or not.

Man

Machine

Material

Method

Process Man

S. No. 1
2 3

Problem Unskilled Worker


Not Proper Height Not Proper Sitting Arrangement

Cause

4
5 6

Not Proper Handling of Header


Not Proper Handling during assembly Error while measuring the distance through vernier caliper

O O O P P O

Process Method

S. No. 1
2 3 4 5

Problem When worker do not work as guided by engineer


Wrong method of applying liquid flux Wrong method of doing hammering When correct spacing is not provided between two condenser Wrong method of packing of condenser

Cause

O
O O O O

Process Machine 1
2 3 4 5

S. No.

Problem Machine not work at desired temperature


Wrong shape of fixture Variation in supply of electricity Not proper maintenance of machine Machine can have wear and tear

Cause

O
O O O O

Process Material

S. No. 1
2 3 4 5 6

Problem Not correct composition


May melt during brazing Material may not have low coefficient of linear expansion Not highly machinable Low weldability May not be corrosion resistance

Cause

O O O
O O O

Bracket Tilt in ppm


120000 100000 80000 60000 Bracket Tilt in ppm

40000
20000 0

Here the work which we were doing are been checked out by the authority aligned to them.

Handling of the header should be taken with care. After the fitting of bracket the work should be handled properly. At assembly area the headers should not be touched as it has not been permanently joined. Inspection should be done properly to avoid wastage after brazing, bracket tilt can be checked and removed at the inspection area before brazing.