I hereby certify that this thesis report entitled “Study of Industrial Production Management and Maintenance” was prepared by Redoy and Abdul Alim under my direct supervision and this work was carried out in the laboratories of the Department of Electrical and Electronics Engineering, Faculty of Engineering, Daffodil International University at partial fulfillment of the requirements for the Bachelor of Electrical and Electronics Engineering degree. Shamsul Alam, Professor and Dean, Department of Electrical and Electronics Engineering, Daffodil International University for his encouragement and permission to participate in our internship. Dara Abdus Satter, Associate Head, Department of Electrical and Electronic Engineering, Daffodil International University, and Dr.
Junaed Al-Hossain, Lecturer, Department of Electrical and Electronic Engineering, Daffodil International University for their valuable instructions, continuous guidance, constructive criticism and thoughtful advice during the continuation of this internship and preparation of this report. And Special thanks go to the author's fellow classmates from the Department of Electrical and Electronic Engineering, Daffodil International University for their helping hand, continuous support and cooperation during my internship. They have modern plant machinery, accessories for manufacturing different types of components and assembling the refrigerators and air conditioners.
As an Electrical and Electronics Engineering (EEE) student, we can learn the main energy source and distribution system as well as the production and maintenance management of this company. We did our internship at Butterfly Manufacturing Company Ltd from November 15 to January 15 (2 months).
Introduction .............................................................................. 1-4
- Mission & Vision
- Factory Location and Area Information
- REF/RAC Organization Chart
- Specified Objective
- Methodology
- Thesis Outline
To achieve the broad objective, we need to find out from the following objectives.
Materials Department .............................................................. 5-5
Material Department (BMCL)
Work Function
Production Management System ........................................ 6-20
- Cold Roller Forming (CRF) Machine/ Side Plate
- Thermoforming Machine/Body Liner
- Thermoforming Machine/ Door Liner
- Freezing Evaporator Bending Section
- Door Assembly Point
- Roller forming machine/ Door plate
- Door Foaming Machine
- Door foaming chemical measurement
- Gasket Section
- ABS & HIPS Sheet section
- Working Procedure
- Pre-assembly line (Chest freeze)
- Outer part
- Inner part
- Pre-assembly line (Refrigerator)
- Body Foaming
- Post-Assembly Line
- Working Procedure
- Cooling Test
- Packing Line
- Production Management System Flow Diagram
There is a machine called evaporator bending which is used to bend evaporator into body lining. There is an equipment made of wood which helps to shape aluminum sheet for the inside. If there is no problem take it for body foaming otherwise take repair zone if there is any problem.
Then install the back cover with the side plate and protect with the HIPS plate from damage. The first is a cycle line, the second is an assembly line. All work related to the compressor is done on the cycle line. All other work is done on the assembly line.
Quality Management System ........................................... 21-28
- Quality Assurance
- Quality Control
- Incoming Quality Control (IQC)
- Measuring Instruments
- Line quality control (LQC)
- Pre-Assembly inspection
- Kit Inspection
- First Inspection
- Cooling Test Line
- Final Inspection
- Outgoing Quality Control (OQC)
- Benefits of Quality Management Systems
The factories, manufacturers have a special IQC department to check raw materials, components and parts from their suppliers before they are admitted to the warehouse. At the same time, open some boxes randomly and check whether the parts are in good condition or not. They also check the quality, which is taken from the local suppliers and self-made raw materials of various measuring instruments.
First, there is a machine called Inner bending machine which made inner part for breast freezing by aluminum plate. In assembly point they check body for foam gap issue, thread check, foam point check, top cover broken check, dent, crash, broken etc. There are 9 lines in cooling test. 1 line is for repair and 8 lines are for cooling test.
If the body has problems, it goes to repair, if there are no problems, then it goes to packaging. Outgoing quality control (OQC) is the inspection of finished products before delivery to identify defects in the manufacturing process. After the product is finished packing, the outgoing quality control department randomly selects some carcasses from the storage area.
Maintenance Management System ..................................... 29-41
- Objectives of maintenance management
- Maintenance Flow Chart
- Sub-Station
- Types of Sub-Station
- Substation Equipment
- Sub-Station maintenance
- Transformer
- Working Principle
- Types of Transformer
- Transformer maintenance
- Generator
- Types of Generator
- Generator Maintenance
- Air Compressor
- Air Dryer
- Power Distribution Panel Board
- Floor Maintenance System
- Electric Motor
- Benefits of Maintenance Management System
It is also used to change AC voltages from one level to another, and/or change alternating current to direct current or direct current to alternating current. Substation Types: Although there are generally four types of substations, there are substations that are a combination of two or more types. A transformer can be defined as a static device that helps in the transformation of electrical power in one circuit to electrical power of the same frequency in another circuit.
Transformers are most commonly used for increasing low AC voltages at high current (a step-up transformer) or reducing high AC voltages at low current (a step-down transformer) in electrical power applications. It works only on the alternating current because an alternating flux is required for mutual induction between the two windings. Buchholz relay Check the oil level inside the buchholz relay, if oil level should be close below the marked level alarm circuit.
Transformer (HV/LV Bushing) The sealing of the transformer on the high voltage and low voltage side must be checked. Terminal connector The terminal connector must check for loose or loose, if loose it must be connected. Earth terminal The earth terminal should be checked for loss or disconnection, if lost/disconnected it should be connected.
Silica gel breather Silica gel should be checked if it is dirty or clean (blue or black), if it is black, replace it. Compressed air dryers are special types of filtration systems that are specifically designed to remove water that is part of compressed air. There are many machines, generators, lines and entire company buildings that you can control from this distribution board.
It should not be susceptible to corrosion and should be kept away from fire, especially in rooms where food is prepared. Effective maintenance management systems consist of four key elements: people, process, a software program, and behavior. The four ingredients, while adhering to common goals, combine to improve a company's or facility's efficiency and bottom line.
Recommendation & Conclusion ............................................ 42-43
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I learned a lot and gained practical knowledge during our internship at BMCL which will help us in future life.
