pel internship report

Pak Elektron Limited (PEL)

Submitted To HR PEL

Submitted By YASIR HUSSAIN

Department Production

Duration 4 weeks

INSITIUTE OF QUALITY & TECHNOLOGY MANAGEMENT THE UNIVERSITY OF THE PUNJAB LAHORE

TABLE OF CONTENTS

Acknowledgement…………………………………………………...…3

Company Profile & Vision……………….…………………………....4

Divisions and Products ………………………………………………..4

Major Departments……………………………………………………6

Production Department…………………….………………………….7

Split A.C & Microwave Oven…………………………………………………………………...7

Plastic Sheet Extrusion…………………………………………………………………….….....9

Thermoforming of Doors & Cabinet…………………………………………………………..10

Injection Molding………………………………………………………………………….……11

Press Shop……………………………………………………………………………………….12

Paint Plant………………………………………………………………………………….…...12

Condenser Section ……………………………………………………………………………...12

Pre Assembly of Refrigerator………………………………………………………………….13

Door Assembly………………………………………………………………………….………13

Gasket Section………………………………………………………………………….……….13

Refrigerator Assembly & Final Line ………………………………………………………….14

R & D……………………………………………………………………………………………14

D & M and Maintenance…………………………………………………………………….…15

Production Planning & Control…………………………………………………………….…16

Quality Assurance & Control …………………………………………………………………17

ACKNOWLEDGEMENT

It is the matter of great pleasure for me to present internship report on Pak Elektron Limited.

This internship report is focused on Pak Electron Limited (PEL) where I completed my four

weeks internship under the supervision of Engr. Ejaz Mansha. I am really thankful and

acknowledge kind cooperation of Engr. Ejaz Mansha who provided me inspiring guidance

during my internship.

Last but not least we also feel please to thanks to the whole management of Pak Elektron

Limited (PEL) in general for their cooperation.

YASIR HUSSAIN

Company Profile;

Pak Elektron Limited (PEL) is the pioneer manufacturer of electrical goods in Pakistan. It was established in 1956 in technical collaboration with M/s AEG of Germany. In October 1978, the company was taken over by Saigol Group of Companies. Since its inception, the company has always been contributing towards the advancement and development of the engineering sector in Pakistan by introducing a range of quality electrical equipments and home appliances and by producing hundreds of engineers, skilled workers and technicians through its apprenticeship schemes and training programs.

Group Profile;

In 1948, the Saigols migrated from Calcutta and initiated their business in Lyallpur (later named to as Faisalabad), the textile city of Pakistan, under the banner of Kohinoor Industries Limited.

Vision;

To excel in providing engineering goods and services through continuous improvement.

Divisions;

The company comprises of two divisions:

Appliances Division Power Division

Appliances Division;

This Division of PEL consists of appliances manufacturing.

PEL Air Conditioners;

PEL window-type air conditioners were introduced in 1981 in technical collaboration with General Corporation of Japan. Ever since their launch, PEL air conditioners have a leading position in the market. PEL air conditioners cooling performance has been tested and approved by Copeland and ITS USA. With the shift of users preference from window type to split type air conditioners, PEL has started manufacturing split type air conditioners.

PEL Refrigerators;

The manufacturing of refrigerators started in 1986-87 in technical collaboration with M/s IAR-SILTAL of Italy. Like the air conditioner, PEL's refrigerators are also in great demand. Today, PEL Crystal has 30% market share. Its cooling performance is tested and approved by Danfoss, Germany and its manufacturing facility is ISO 9002 certified by SGS Switzerland.

PEL Deep Freezers;

PEL deep freezers were introduced in 1987 in technical collaboration with M/s Ariston of Italy. Because of durability and high quality, PEL deep freezers are the preferred choice of companies like Unilever.

Power Division;

PEL Power Division manufactures energy meters, transformers, switchgears, Kiosks, compact stations, shunt capacitor banks etc. All these electrical goods are manufactured under strict quality control and in accordance with international standards.

PEL is one of the major electrical equipment suppliers to Water and Power Development Authority (WAPDA) and Karachi Electrical Supply Corporation (KESC), which are the largest power utilities in Pakistan.

Over the years, PEL electrical equipment has been used in numerous power projects of national importance within Pakistan. PEL has the privilege of getting its equipment approved and certified by well-reputed international consultants such as:

Preece, Cardew and Rider, England Harza Engineering Company, USA Snam Progeti, Italy Societe Dumezm, France Miner & Miner International Inc. USA Ensa, France

In spite of stiff competition from emerging local and multinational brands, PEL Group's appliances and electrical equipments have remained in the spotlight due to constant innovation. Strategic partnership with multinationals of repute have enabled the PEL Group to incorporate new technologies into existing product ranges, thus giving the Pakistani market access to innovative, affordable and quality products.

Major Departments;

There are following major departments of PEL

HR department Finance department Procurement department IT department Production department Accounts department Marketing department Import & Export department

Production Department;

Production department’s key responsibility is to develop and create products that are required for the specific department. They also receive a major plan for the whole financial year that indicates the number and models of each brand and the deadline time for each lot. PEL’s production department is comprised of different units according to the products.

Split A.C & Microwave Oven;

The products being assembled in split A.C & MWO department are indoor A.C, outdoor A.C and microwave oven.

Split air conditioners are available in three capacities:

1 ton 1.5 ton 2 ton

The indoor unit is installed inside the room to be air conditioned. It can be mounted on the ceiling, wall or simply as a console unit on the floor. It consists of the following parts:

Evaporator Coil is where the heat exchange is done with the room. It consists of fins and tubes.

Control Panel is where user controls the functions of the air conditioner. Displays at the panel may indicate the mode of operation, timer, on/off status, fan speed and other special functions. Most newer units have remote control feature built into the system.

Air Filter is located in front of the evaporator coil to trap any dust or particles before going into the evaporator. This is usually washable and re-useable. Users are advised to clean it at least once in 3 months or more regularly if the environment is dirty.

Supply and Return Air Grills are where the air enters and discharge from the indoor unit.

Fan Blower together with its motor are used to control the fan speed of the unit. High, Medium, Low and Ultra Low Speeds are usually designed for users to select.

Capillary Tube is used as an expansion device where the flow of the refrigerant depends on the tube internal diameter, shape and its length. This tube is usually used in smaller units. Larger units use thermostatic expansion valve which has a controlling valve to control in greater precision the flow of the refrigerant.

The outdoor unit is installed outside the building and consists of the following parts:

Compressor is the main component of the system and is used to compress the refrigerant.

Condenser Coil is used to reject heat from the refrigerant to the outside air. Condenser Fan is used in air-cooled condenser to help move the air molecules over the

surface of the condensing coil, hence rejecting the heat from the indoor to the space outside the building.

Condenser Motor is located here. The motor usually has two to three speeds. Smaller unit may only have 1 speed of control and turns on/off simultaneously with the compressor.

Microwave Oven;

A microwave oven works by passing non-ionizing microwave radiation, usually at a frequency of 2.45 gigahertz (GHz) a wavelength of 122 millimeters (4.80 in) through the food. Microwave radiation is between common radio and infrared frequencies. Water, fat, and other substances in the food absorb energy from the microwaves in a process called dielectric heating. Many molecules (such as those of water) are electric dipoles, meaning that they have a partial positive charge at one end and a partial negative charge at the other, and therefore rotate as they try to align themselves with the alternating electric field of the microwaves. Rotating molecules hit other molecules and put them into motion, thus dispersing energy. This energy, when dispersed as molecular vibration in solids and liquids (both potential energy and kinetic energy of atoms), is heat.

Microwave heating is more efficient on liquid water than on frozen water, where the molecules are not free to rotate. It is also less efficient on fats and sugars (which have a smaller molecular dipole moment) than on liquid water. Microwave heating is sometimes explained as a resonance of water molecules, but this is incorrect: such resonance only occurs in water vapor at much higher frequencies, at about 20 GHz. Moreover, large industrial/commercial microwave ovens operating at the common large industrial-oven microwave heating frequency of 915 MHz wavelength 328 millimeters (12.9 in) also heat water and food perfectly well.

A microwave oven consists of:

a high voltage power source, commonly a simple transformer or an electronic power converter, which passes energy to the magnetron

a high voltage capacitor connected to the magnetron, transformer and via a diode to the case.

a cavity magnetron, which converts high-voltage electric energy to microwave radiation a magnetron control circuit (usually with a microcontroller) a waveguide (to control the direction of the microwaves) a cooking chamber

Deep Freezers;

Deep Freezer parts are assembled on manual assembly line. The first step is assembling of condenser and compressor assembly on base plate. After that outlet and inlet are fitted. Then leak test is performed by nitrogen gas filling. After that fan motor is wiring is done. Then aluminum sheet is interblending and joining starts. After that inner sealing and coiling is done. After that accumulator and capillary welding and then cabinet foaming is performed. After that wheel plate condensing unit fitting, hing & door fitting, vacuuming and then gas charging is done at .335 kg. Then deep freezer testing is performed and finally packing and dispatch to the store.

Plastic Sheet Extrusion;

Plastic sheet for refrigerator inner cabinet and deep freezer door is extruded in this section. This is totally automated plant.

PEL used two types of sheets;

ABS ( Shinning and Soft) Hips ( Hard )

Process;

Raw material HIPS in the form of small beads is mixed with colour master batch M-36 prior to the hopper. Then it is transferred to storage chamber, from storage chamber it sucked into extruder Hopper through auto loader. After that material is dried in the hopper and travels in the barrel along with screws. During this three independent PID controlled heater zones gradually increase the temperature of the barrel from 175-210 C0. The material is melted and is extruded into sheet through T Die. After that it passes through roller unit around which water circulates and it is cooled and stretched. Then passes through cutting unit and is cut into desired length. After that sheet is transferred to conveyor and finally unloaded for storage. Thickness of sheet for refrigerator cabinet is 4.7 mm while for deep freezer door is 2.25mm.

Thermoforming of Doors & Cabinet;

Thermoforming is a manufacturing process where a plastic sheet is heated to a pliable forming temperature, formed to a specific shape in a mold, and trimmed to create a usable product. The sheet, or "film" when referring to thinner gauges and certain material types, is heated in an oven to a high-enough temperature that it can be stretched into or onto a mold and cooled to a finished shape.

PEL following Vacuum Thermoforming commonly known by people as vacuuforming, is a simplified version of thermoforming, whereby a sheet of plastic is heated to a forming temperature, stretched onto or into a single-surface mold and held against the mold by applying vacuum between the mold surface and the sheet. The vacuum forming process can be used to make most product packaging, speaker casings and even car dashboards.

Injection Molding;

In this section refrigerator and deep freezer parts are manufactured through injection molding process. In this process imported material in granular form is sucked through autoloader into the hopper. A.B.S Material is heated at 220-195 F, it can vary with the type of material. After that material is passed through screw through a process called as choking. In the screw five heaters melt the material and through runner it is injected into the mold cavity in 5 sec. After that material is cooled which take 15 sec after cooling desired piece is obtained.

Press Shop;

A machine press, commonly shortened to press, is a machine tool that changes the shape of a workpiece. In this section cutting and pressing of imported sheets take place through different die and molds. Vertical and hydraulic presses are used here. A hydraulic press is a machine using a hydraulic cylinder to generate a compressive force. Sheets take desire shape through such operations:

shearing bending notching blanking piercing drawing side forming grinding Welding operations.

Paint Plant;

In this department there are four paint plants which are totally automatic. Doors and side panel of refrigerator and freezer are painted with different colours by Electrostatic spray painting process. Firstly doors and side panels are prepared for paint in treatment line. In this line dust and other particles are remove. Before paint doors are heated at 45 C0.In paint booth charged particles of paint are spray on parts which are also charged. After Paint parts are dried at 220 C0.

Condenser Section;

In this section condenser for refrigerator is manufacture. The condenser is a series of tubes with fins attached to them, similar to a radiator. It's always somewhere on the outside of the refrigerator. The raw material is Copper tube. Louver is prepared at louver press machine then spot welding is performed to join tube and louver.

Pre Assembly of Refrigerator;

The first step is evaporator bending on bending machine then side plates are fixed. After that freezer frame, freezer support and cabinet support is assembled. Meanwhile base assembly and anticondensate pipe are prepared. After preparation these parts are assembled. Then back plate, back panel, side panel and top panels are assembled. The next step is foaming to make refrigerator body more rigid. The material used for foaming is polyol, isocyanate and cyclopentane as blowing agent.

Door Assembly;

In this section refrigerator and deep freezer doors are assembled. The first step is fixing end cap and concede handle. Then gasket fitting, after that foaming is done. The material used for foaming is iso-cyanate and polyol. Then lock assembly is done and finally the doors are dispatched to the relevant assembly line.

Gasket Section;

There gasket for deep freezer and refrigerator doors is made through extruder. On the extrusion line Polyvinylchloride grains are sucked through vacuum system into the hopper of the extruder. Then these are melted by heaters and are passed through T Die. The desired gasket is cooled for its shape retention. After that it is pressed for getting compact shape. Then Auto sensors are there which cut the desired length of gasket and after that magnet is passed through refrigerator gasket and finally it is dispatched to deep freezer and refrigerator doors assembly.

Refrigerator Assembly & Final Line;

For refrigerator assembly there are two lines A & B. at assembly line ‘A’ lower henge, centre henge, upper henge, thermostat, condenser, compressor, and door assembly is done. After that vacuuming, gas charging and then testing is performed. The test is of two types.

Short test Long test

In short test power, suction and discharge test is performed. This test shows results on software PLIS, where control limits are already defined if values cross the limits then unit is reworked. While in long test randomly units are selected and attest of 2 hours is performed to check the cooling of the unit.

At assembly line ‘B’ chilled box, glass shelf, bottle shelf, vegetable box, door handles, drain tray, freezer balcony, egg tray, utility pocket, etc are fitted. And then again same electrical test as in line ‘A’ is performed.

At final line ice scraper, drip tray, water container, wooden base skid, door protector is fitted. Then finally packing is done the unit is dispatched to the store.

R & D;

The phrase research and development (R and D) refers to "creative work undertaken on a systematic basis in order to increase the stock of knowledge, including knowledge of man, culture and society, and the use of this stock of knowledge to devise new applications".

Research and development is often scientific or towards developing particular technologies and is frequently carried out as corporate or governmental activity.

This department has three portions

1. Designer2. Vendor development

3. Marketing

R & D contributes for changes in existing model and addition of new features. For this purpose market survey is conducted. When there is need to make changes or add new features. Feasibility study is done whether production equipment, labor and capacity is available. After these considerations the new model is designed by the designers. The new design is verified and a sample is prepared. Then sample is validated. After successful validation bulk production is started.

D & M;

Dies & molds are used to manufacture identical items in large quantity. Drafts man makes drawings using Del CAM software after approval from research & development department. Then machining process starts using planner, shaper, drilling, lathe, EDM and CNC machining centre. NC program is transferred to CNC machine through card. After this parts are assembled to make dies & molds.

A die is a specialized tool used in manufacturing industries to cut or shape material using a press. Like molds, dies are generally customized to the item they are used to create. Products made with dies range from simple paper clips to complex pieces used in advanced technology.

A mold or mould is a hollowed-out block that is filled with a liquid like plastic, glass, metal, or ceramic raw materials. The liquid hardens or sets inside the mold, adopting its shape. A mold is the opposite of a cast.

Maintenance Department;

Maintenance department is responsible of repair, and involves fixing any sort of mechanical or electrical device should it become out of order or broken. It also includes performing routine actions which keep the device in working order or prevent trouble from arising. Maintenance may be defined as, "All actions which have the objective of retaining or restoring an item in or to a state in which it can perform its required function. The actions include the combination of all technical and corresponding administrative, managerial, and supervision actions."

Types of Maintenance

Preventive maintenance scheduled maintenance Breakdown maintenance

Production Planning & Control;

A production planning and control is

concerned with planning and controlling all aspects of manufacturing, including materials,

scheduling machines and people, and coordinating suppliers and customers. An effective PPC

system is critical to the success of any company. It should be adaptive to respond to changes in

the competitive arena, customer requirements, strategy, supply chain and other possible

problems.

For production of specific model of home appliances material is issued by the production

planning & control (PPC) department. IR/operational plan is given to the PPC by marketing

department after forecasting and receiving orders from the customers. There is a specific number

called “FB#” for each model. This “FB#” number is opened on “MRCS” software. This software

calculates the number of components required to make a required model. Then finance

department opens this “FB#” on “CCS” software and calculates the cost to manufacture the

required the model. Then sales price of required model is set and the sales department is

informed of that price.. And then the model is sold on that price. Moreover PPC also has access

to the material available at production line and demands material consumption report from the

production line. So this was how PPC works.

Quality Assurance & Control;

Quality control, or QC for short, is a process by which entities review the quality of all factors

involved in production. This approach places an emphasis on three aspects;

Elements such as controls, job management, defined and well managed processes,

performance and integrity criteria, and identification of records

Competence, such as knowledge, skills, experience, and qualifications

Soft elements, such as personnel integrity, confidence, organizational culture, motivation,

team spirit, and quality relationships.

There are four divisions.

Market quality

Process quality

Techniques

Incoming quality control

For insuring quality online inspection is performed in each production line. To control the

quality pareto analysis is done in which percentage of defects and their type is analyzed and then

action plan is made to minimize the defects.

Quality system procedures are and work instructions are prepared by each relevant department

and are implemented practically as well. Moreover for approval of new samples quality

department contribution is also needed.

pel internship report

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