Manufacturing of Condenser

Mohit TomarB.E. (mech)

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 

Amber Enterprises Pvt. Ltd.

Chairman

Organization Chart (Unit-6)

Managing Director

V.P(Operation)

G.M(Manufacturing) H.R(Head) G.M(Finance)

Manager (H.R)

Executive (H.R)

Manager

Executive Finance

Manager (Store)

Manager (Quality)

Manager(Production)

Manager(Manufacture)

Executive (Store)

SeniorEngineer

Engineer SeniorProductionEngineer

ProductionEngineer

SeniorManufactureEngineer

ExecutiveManufactureEngineer

SeniorEngineer

Total Staff:-100G.M:-02Manager:-12Engineer:-86

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.

Partial Product List

Reliability lab

Incoming quality control

Line quality control

Pre dispatch inspection

New Product Development

Quality

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

Manufacturing of Condenser

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) Check sheet 2) Pareto Diagram3) Fish Bone Diagram4) Monitoring

Problem Solving Tools

Check Sheet

S.No Model No.

Problems Production Fault Products

Percentage

Cum. Perc.

Remarks

Date- 5th-july-2013

1. UD6P Bracket Shift

300 8 100% 100% -

2. - Bracket Tilt

- 0 - 100% -

Here we represent our problems in the form of table.

For eg.

1. Works on 80-20% Rule.2. In this diagram we choose which

particular problems we have to solve.3. It represents in graph form.4. 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.

Pareto Diagram

Leadership Through Innovation Quality,Cost,Delivery

REJECTION - PPM TREND JUNE’ 2013

80% REJECTION DUE TO 20% REASON

1. 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.

2. Then we relate those problems with the above concerns whether the problems were actually caused by them or not.

Fish Bone Diagram

Bracket Tilt

Man Machine

Method Material

Causes of Bracket Tilt

Man

Machine

Material

Method

Process S. No. Problem CauseMan 1 Unskilled Worker O

2 Not Proper Height O 3 Not Proper Sitting Arrangement O

4 Not Proper Handling of Header P5 Not Proper Handling during assembly P6 Error while measuring the distance

through vernier caliper O

Validation

Process S. No. Problem CauseMethod 1 When worker do not work as

guided by engineer O2 Wrong method of applying liquid

flux O3 Wrong method of doing

hammering O4 When correct spacing is not

provided between two condenser O5 Wrong method of packing of

condenser O

Process S. No. Problem CauseMachine 1 Machine not work at desired

temperature O2 Wrong shape of fixture O3 Variation in supply of electricity O4 Not proper maintenance of

machine O5 Machine can have wear and tear O

Process S. No. Problem CauseMaterial 1 Not correct composition O

2 May melt during brazing O3 Material may not have low

coefficient of linear expansion O4 Not highly machinable O5 Low weldability O6 May not be corrosion resistance O

Graph plotting between bracket tilt and Date of monitoring

4-Jul

6-Jul

8-Jul

10-Ju

l12

-Jul

14-Ju

l16

-Jul

020000400006000080000

100000120000

Bracket Tilt in ppm

Bracket Tilt in ppm

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

Monitoring

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