Project Report-Lg
Project Report-Lg
Project Report-Lg
SUMMER INTERNSHIP
DEPARTMENTS :
SUBMITTED BY :-
KUNAL DHAWAN
IIT GUWAHATI
Acknowledgements
I owe my great many thanks to numerous people who helped and supported me in
completion of the project.
I would like to express my special thanks of gratitude to Mr. Ved Pandey ,Mr Amit
Katre and Mr Suresh Rawat as well as others who gave me the golden
opportunity to complete this wonderful training here at LG, which also helped me
in getting acquainted to the corporate culture and I came to know about so many
new things I am really thankful to them. I learnt a lot about the working
environment here at LG and the corporate culture followed here . I am very much
thankful to them for their wise and synergetic help throughout my training period. I
would really like to extend my gratitude to all the seniors here at LG that made this
training a success for me.
KUNAL DHAWAN
1|Page
CERTIFICATION
2|Page
INDEX
INTRODUCTION 5
LG THE HISTORY . 7
LG PHILOSOPHY 12
LG VISION 12
LG SUCCESS MANTRA .. 18
4M CONVENTION.. 52
PROCESS QUALITY. 55
QUAITY PLANNING. 57
RoHS ..58
SOME DEFINATIONS... 60
PROJECTS :-
3|Page
PROJECT 3 - Checking of Suspected Ok PCBs on JIG. 71
PROJECT 4 - To understand the workflow for function of a LG refrigerator PCB.. 72
PROJECT 5 - Analyzing the errors in field returned Defrost Thermostats ..73
PROJECT 6 - Analysing field returned OLP(overload protector ) and. 75
documenting the findings
PROJECT 7 - Analysing field returned PTC (Positive temperature control .77
resistor / thermistor)
PROJECT 10 - calculating the dimensions of the gasket of a bulb holder using ..81
Vernier Callipers
REFERENCES ..84
4|Page
INTRODUCTION
5|Page
Factory Layout
Fig. 2
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LG THE HISTORY
7|Page
SOME FACTS AT GLANCE ABOUT THE LG
It was rated as the sixth best employer to work for in India by Business
Today in a survey.
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Fig. 3
2001
2002
9|Page
Establishes CDMA handset production line and R&D center in
China.
2003
2004
2005
2006
2007
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Launches 120Hz Full HD LCD TV.
2008
2011
2012
2013
LG Electronics launched a 55-inch OLED TV.
2014
LG Electronics launched 64-inch and 77-inch sizes of OLED TV.
LG Electronics launched latest curved Smartphone G3.
2015
LG Electronics launched 2 new smart watches named LG Watch
Urbane and Urbane LTE.
LG Electronics launched 2 new smart phones named LG G Flex 2
and LG G4.
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LG Philosophy
LG Vision
LG Electronics vision for the 21st century is to become a true global digital
leader through fast growth and fast innovation and to be known as a
company who can make its worldwide customers happy through its
innovative digital products and services.
Slogan
The word L and G in the circle symbolizes the World, Future, Youth and
humanity. The symbol consists of two elements: the LG logo in LG grey and
the stylized image of human face in the unique LG red color. Red the main
color represents our friendliness and also gives a strong impression of LGs
commitment to deliver the best. The circle symbolizes the globe. The stylized
image of the smiling face in the symbol conveys friendliness and
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approachability. LGs vision for the 21st century is to become a true global
digital leader through fast growth and fast innovation and to be known as a
company who can make its worldwide customers happy through its
innovative digital products and services.
Fig.4
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THE PRODUCT PORTFOLIO
LG TELEVISION
LG WASHING MACHINES
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LG REFREGERATORS
LG AIR CONDITIONERS
LG MICROWAVE OVEN
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LG WATER PURIFIERS
LG HOME ENTERTAINMENT
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SOCIAL RESPONSIBILITY
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LG- THE SUCCESS MANTRA
PRODUCT: from the beginning itself the company has focused on state
of art quality and technology in their products. Product innovation in
LG is an ongoing process. Customization of the products is another
characteristic of LG product policy.
PRICE: LG believes in ethical pricing. It believes in value of money to
the customers. LG has always believed in providing Great Products at
Honest Prices.
PLACE: LG has always laid emphasis on proper channel management.
The whole network expansion was done in a planned way. Thought the
company follows strict policies, but it is able to retain dealers due to
efficient management on other fronts.
PROMOTION: LG has always laid importance on the promotion aspect
of marketing. Its positional strategy has been excellent which has
made a place in the minds of the customers.
PEOPLE: at LG it has always been believed that Great people make
Great companies. People are an integral part of LG philosophy and
culture.
PACE: LG has been following a policy of moving at the greatest
possible pace as it believes that if one can ruin at a continuous pace
than only one can face and beat the competition.
PASSION: the most important ingredient contributing to LG success
mantra is the Passion. It is associated with everything that is associated
with LG its products as well as its people.
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LG - THE STRATERGY AND POLICY
LG group has laid its foundation on three core values, which are central to
the company in each and every respect of its business and working. These
three core values are as follows:
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LG LOGO
Our philosophy is based on Humanity. Also, it represents LG's efforts to keep
close relationships with our customers around the world. The symbol consists
of two elements: the LG logo in LG Grey and the stylized image of a human
face in the unique LG Red color. Red, the main color, represents our
friendliness, and also gives a strong impression of LG's commitment to deliver
the best. Therefore, the shape or the color of this symbol must never be
changed. The circle symbolizes the globe. The stylized image of a smiling
face in the symbol conveys friendliness and approachability. Overall, LGs
symbol represents the world, future, youth, human, and technology. The
design is distributed as follows:
The One eye: Goal-oriented, focused, confident.
Upper- right hand space: Intentionally left blank and asymmetric, this
represents LGs creativity and adaptability to changes.
Colors: LG Red, the main color, symbolizes friendliness, and also gives a
strong impression of LG's commitment to be the best. LG Grey represents
technology and reliability.
LG PHILOSPHY:
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LG AND ITS GLOBAL PARTNERS
In particular, with focus of digital management moving towards becoming first
mover in the market and leading the industry standard, LG Electronics is
concentrating on strengthening strategic alliances in the digital TV industry. LG
Electronics is able to enhance not only the status of the company itself, but also
that of the Korean electronics industry in general through the strategic alliances
and collaboration efforts with the worldly renowned electronics companies.
Thanks to the alliances and collaboration coupled with world class technologies,
LG Electronics now has a solid basis for growing into a front runner of the
multimedia industry.
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RESEARCH AND DEVELOPMENT IN LG
With the goal of becoming a Global Top Leader of the 21st century's digital
age, LG Electronics has been focusing our resources and capabilities in the
area of R&D from early on to create a digital world that enriches and
empowers people. Its efforts are now bearing fruits by allowing it to secure
core digital technologies and realizing innovation in product development
and digital R&D.
LG Electronics strategy for R&D is to map out new standards in newly
emerging areas by developing technologies that link the Internet and
network while maintaining efforts to introduce new products that are
global leaders. At the same time, to foster a culture focused on R&D in the
digital area, LG Electronics has formed dynamic cooperative ties with
research organizations in and out of Korea. LG Electronics has also ensured
that outstanding R&D results are recognized by responding with strong
compensation in order to motivate its researchers to do their best in their
respective projects. It is also extending its full support in recruiting and
training the best research resources.
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R&D DEPARTMENT OVERVIEW
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DEVELOPMENT CYCLE AT LG
Feedback from
Feedback from voice of product planning
customer
Concept team
Planning
Feedback from market Feedback from
need market analysis
Brainstorming
Development
Quality Assurance
Market
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REFRIGERATION
Refrigeration may be defined as the process of achieving and maintaining a
temperature below that of the surroundings, the aim being to cool some
product or space to the required temperature. One of the most important
applications of refrigeration has been the preservation of perishable food
products by storing them at low temperatures.
Types of refrigeration:
1. Vapor compression refrigeration
2. Vapor absorption refrigeration
3. Steam jet refrigeration
4. Air refrigeration
REFRIGERATOR
A refrigerator is a machine which extracts heat from small closed space and
rejects heat to the higher temperature. A refrigerator works between two
temperatures; it takes heat from the low temperature body rejects heat to
the high temperature body. It produces cooling effect in the low
temperature body (refrigerated space). A refrigerator is a common
household appliance that consists of a thermally insulated compartment and
a heat pump (mechanical, electronic, or chemical) that transfers heat from
the inside of the fridge to its external environment
so that the inside of the fridge is cooled to a
temperature below the ambient temperature of
the room.
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HISTORY OF REFRIGERATORS:
Snow and ice, cool streams, springs, caves and cellars were long ago
used to refrigerate food. In olden days refrigeration was achieved by natural
means such as the use of ice or evaporative cooling. In earlier times, ice was
either:
1. Transported from colder regions,
2. Harvested in winter and stored in ice houses for summer use or,
3. Made during night by cooling of water by radiation to stratosphere.
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What is an Electric Refrigerator?
One star compartment: The storage temperature is not warmer than -6oC.
Two star compartment: The storage temperature is not warmer than -12oC.
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TYPICAL REFRIGERATOR DOOR OPENINGS
Chest Type (Top opening type): Appliance in which the compartment(s) is
(are) accessible from the top.
Natural Convection Type (Direct Cooling): In this type, Refrigerator & Freezer
Compartment are cooled by conduction & natural convection. Cool air from
the freezer moves downwards and cools the whole compartment.
Fig 15: Natural Convection Type Fig 16: Enforced Circulation Type
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Enforced Air Circulation Type (Indirect Cooling): In this system, cooling is
provided by forced air circulation & the evaporator is defrosted by an
Automatic defrosting system.
REFIGERATION SYSTEM
Evaporator
Drier
Hot line
Capillary tube
Suction pipe
Condenser
Silencer
Fig 17: Refrigeration Cycle
Compressor
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Division of the system
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VAPOR COMPRESSION REFRIGERATION CYCLE:
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the control.
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REFRIGERATOR COMPONENTS:
COMPRESSOR:
It sucks low temperature and low pressure refrigerant gas from the
evaporator and sends it to the condenser after compressing it to a high
temperature and high pressure gas.
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Variable frequency voltage signals are generated through the pcb
and supplied to the motor. As the frequency changes, speed
changes. Thus inverter compressor can run on the different speeds
depending upon the load. When the load is less, it runs at slow speed,
when the load is high it runs at high speed.
CONDENSER
Condenser is a heat exchanger. It converts high pressure and high
temperature refrigerant gas coming from compressor to liquid refrigerant by
discharging heat from the gas. Its large surface area provides path for
efficient hat exchange. The heat transfer in the condenser depends upon the
condenser material, surface area of tubes and temperature difference. Air
cooled condensers are used in domestic refrigerators. Its position may vary
depending on the type of refrigerator but is mainly placed at the rear of
refrigerator or inside of foaming form (adiabatic wall of refrigerator). Natural
circulation and air cooled condensers are used in domestic refrigerators.
In DC Refrigerator, open type wire condenser is used and for better heat
exchange fins are provided on it. In this case condenser is visible from
outside.
Condensers of FF refrigerators consist of three basic types: (1) Drain
condenser (2) Hot line pipe, (3) Wall condenser. Wall condenser includes
back plate condenser, right side and left side condenser. As their names
imply the use of each condenser is as following:
(1) Drain condenser: To evaporate defrosting water.
(2) Hot line pipe : To prevent the dew on cabinet and door
(3) Wall condenser: To condense the hot refrigerant vapor
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Open Type (Wire Condenser)
HOTLINE
Hot line is installed to prevent dewing phenomena at the front part of
refrigerator as a type of
Condenser. We feel it a little hot when touching with the front side of
refrigerator with the hand. It is used to prevent dewing phenomena by
increasing temperature of dewing point, which is hot refrigerant discharged
from the Comp.
CAPILLARY TUBE
A capillary tube is used as a throttling device. It is a fixed length tubing of
small diameter lying between the outlet of the condenser and the inlet of the
evaporator. It reduces the pressure of the refrigerant from the high-pressure
side to the low-pressure-side of the system and controls the flow of refrigerant
to the evaporator. The inside diameter Din is 0.5mm to 1.0mm with a length L
varying from a meter to 3 meters. It s usually made of copper.
Major role of expansion valve
a. Drop pressure of refrigerant beyond room temperature to make it
as two-status of low temperature.
A capillary tube has a certain capability to balance the refrigerant flow when
the refrigeration load changes. At a given condensing pressure, if the
evaporating pressure is lower than normal due to a lower refrigeration load,
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the greater pressure difference causes a higher mass flow rate of the
refrigerant through the capillary tube. Because the refrigerant flow handled
by the compressor is lower due to the lower suction pressure, there is a
decrease in the condensing pressure and liquid level. Some vapor then
passes through the capillary tube into the evaporator. All this reduces the
mass flow rate of refrigerant flowing through the capillary tube and forms a
new balance.
When the evaporating pressure becomes higher because of a greater
refrigeration load, more liquid refrigerant accumulates in the condenser.
Meanwhile, the liquid charge in the evaporator is insufficient. These effects
tend to reduce the heat transfer area in the condenser and the wetted
surface area in the evaporator. Consequently, the condensing pressure is
raised and the evaporating pressure is lowered. A greater high- and low-side
pressure difference results in a higher refrigerant flow and forms a new
balance.
DRIER
Function of drier is to eliminate noxious components from the refrigerating
cycle. Dryer is a filter to filter out foreign materials inside the cycle and is
installed immediately before refrigerants engage in the Capillary-tube to
prevent clogging status of the Capillary-tube. The Molecular Sieve sucks any
moisture present in the cycle and prevents corrosion by moisture and
moisture clogging at the end of the Capillary-tube.
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EVAPORATOR
Low pressure and low temperature liquid refrigerant enter the evaporator
and it evaporates there by extracting heat from the area to be refrigerated.
Evaporator is a heat exchanger. The latent heat required for the evaporation
of refrigerant is taken from the refrigerated space, as a result the temperature
of the refrigerated space decreases. Low temperature, low pressure vapor
enters the compressor.
TYPES:
1) FIN TUBE (INDIRECT COOLING TYPE REFRIGERATOR)
2) ROLL BOND (DIRECT COOLING TYPE OF SMALL REFRIGERATOR)
3) PIPE ON SHEET (DIRECT COOLING TYPE OF COMMERCIAL REFRIGERATOR)
ACCUMULATOR
The function of the accumulator is to prevent the liquid refrigerant from
getting inside the compressor. Accumulator is fitted on the suction line and it
prevents the compressor damage from a sudden surge of liquid refrigerant
and oil that could enter the compressor from the suction line. Accumulators
have a metering ejector device that picks up liquid, vaporizes it, and returns it
to the compressor.
Bimetal Thermostat
Bimetal thermostat turns the
electric contacts on and off by
the expansion and contraction of Fig 22: Defrost Control Assembly
bimetal as shown in the figure, so that it
controls the temperature (as specified on the bimetal thermostat)
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If the temperature reaches the lower set level (- 40C) bimetal deforms
and makes the electric contact, thus during defrost cycle current flows
through the bimetal to heater.
If the temperature reaches higher set level ( + 130C) the bimetal
deforms in reverse direction and opens the contact and stops the
heater.
Thermal Fuse
Thermal fuse is a safety device, which cuts of the electric supply when
defrost heater is over heated.
Melting point of thermal fuse used in LG refrigerator is +720C
When the defrost heater is overheated above +720C fuse melts and
disconnects the heater supply. Otherwise refrigerator may be burnt /
damaged.
THERMOSTAT
The thermostat senses the cooling air temperature at feeler and controls
electrically the flow of air. Temperature in the refrigerator depends on the
amount of storing food and the frequency of door opening, etc.. Two ways to
keep the desired temperature in the cabinet are 1)To control the compressor
operation 2)To control the cold-air flow in the cabinet.
The device used for the above mentioned controls is the Thermostat, which
senses temperature in the refrigerator. The thermostat senses the cooling air
temperature at feeler and controls the flow of air electrically.
DOOR SWITCH
This switch turns the lamp on and off in the freezer and refrigerator
compartments when door is open and closed. In some models, this switch
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also turns the fan motor on and off. In old models mechanical push-type
switch was used. Nowadays, magnetic reed switch is used.
PTC ELEMENT
Positive temperature coefficient is basically a thermister whose electrical
resistance increases as the temperature is increased. PTC element is made of
BaTiO, or zinc oxide, or silicon. BaTiO thermistor is the most widely used. If a
voltage is applied to the PTC element , the electric
SENSORS
2. Defrost Sensor- It senses the evaporator coil temperature & starts and
stops the defrost function. During defrosting supply to the compressor is
cut-off and power supply is given to heater. Sensor senses the
temperature and if temp. is greater than 13C, it stops the heater.
REFRIGERANT
R-134a [CF3CFH2]
R-134a is a polar molecule and it has no Cl radicle.
Properties of R-134a:
ODP (Ozone Depletion Potential): 0.0
GDP(Global Depletion Potential): 0.26
It is non toxic, non flammable and non corrosive.
Its normal boiling point is - 26.1C.
Critical temperature is 122C.
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R-600a [CH(CH3)3]
R-600a is a non- polar mlecule.
Properties of R-600a:
ODP (Ozone Depletion Potential): 0.0
GDP(Global Depletion Potential): 0.0
Its normal boiling point is -11C.
It is flammable.
CONCEPT PLANNING
DESIGN VERIFICATION
PRODUCT VERIFICATION
PRODUCT QUALIFICATION
MASS PRODUCTION
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The laboratory is in charge of this step, which is from commercialization
confirmed meeting to project planning confirmed meeting. It builds-up a
structural organization to accomplish the development target (Q.C.D)
decided at the product concept planning, sets the design standard and
determine the design standard and design Spec. by consulting with the
related department.
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FIELD FAILURE RATE (FFR)
What is FFR?
Failure rate is the frequency with which an engineered system or component
fails Field failure rate is the rate of failure of the product or its components in
the field (customer end). FFR is a good measure of the reliability and the
performance of the product or a component in the field. A low FFR indicated
that the development, manufacturing, testing and the various other
processes that the product passes through before reaching the customer are
in healthy state and functioning properly. A high FFR shows that the testing
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procedures and the quality checks through which the product passes is faulty
or there may be some fault in the design of the component.
The sole aim of FFR team is to reduce the field failure rate of the product.
They analyze the failures occurring the component and provide
countermeasure for these failures. The countermeasure depends upon the
severity of the failures and number of its occurrences in field. A low FFR helps
in improving the brand image in the market which ultimately leads to
increased profit. A low FFR is a direct measure of the overall quality of the
product.
FFR is calculated on the basis of total failures in the product in its warranty
period. Every complaint that is received at customer care centre and the
subsequent action taken, is stored in form of an excel file. We receive and
analyze the data to improve our product to ensure maximum customer
satisfaction.
My job included
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FAILURE OF COMPONENTS
Failure of components in field follow bath- tub curve. In a products life cycle
the chances of failure in early stages are more. In medium stages, chances
of failure reduce. As the last stage is approached, the chances of failure
again rise. Most products go through three distinct phases from product
inception to wear out.
Chance failure / Normal Operating Life: If a component does not fail within its
infancy, it will generally tend to remain trouble-free over its operating lifetime.
The failure rate during this period is typically quite low. This phase, in which the
failure rate is constant, typically represents the useful life of the product.
Wear out / Ageing: After a component reaches a certain age, it enters the
period where it begins to wear out, and failures start to increase. The period
where failures start to increase is called the wear out phase of component
life.
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CAUSES OF COMPONENT FAILURE IN FIELD
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QUALITY IMPROVEMENT PROCESS
Quality issue
Define Defect
Make Countermeasure
NG
Verify
Countermeasure
Apply Countermeasure
NG
Monitor
Countermeasure
Prevent Reccurence
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LGEIL Noida QA Organization
Team mission catch up the global quality level (Field failure rate<17% by
2017).This department assures that there is no compromise with the quality
anywhere or at any instant at time for all LG products manufactured here. It
has a few jobs as follows-
Main Jobs
Quality management
Q system Audit
Q KPI management
Compliance risk management
Part Reliability assurance
FFR management-Field failure rate, FFR monitoring, cost
improvement
Q-bank management
Supplier quality assurance
Outgoing inspection
Early life test
Short life test
3f test
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Development quality assurance
CONCEPT OF QUALITY
Performance, design
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Good quality from companys view
Increase in revenue
But all these steps taken into the account have to be monitored on regular
basis else the result can be sale stagnation i.e. though company might be
seeming to earn profit but actually it might be lagging in its present new
sets of quality which can result in degrading image and degrading sales
revenue
Parts Quality
Part Inspection:
Improvement Activity:
LG raise the non-conformity ratio for each not good (NG) lot.
Vendor analyze failure reason
Submit course of action taken by vendor to LG
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LG verify that action
The process for parts quality is vendor makes parts and passes it from its OQA
If lot is ok it is dispatched to LG where it passes from its sqa if not good a
NCR is sent back to vendor If set ok it is issued to the store.
Man it means an operator working on critical stage (CTQ, time check etc.)
who may affect quality. You must assign the right worker to a job. The
worker should be able to maintain good relations with other workers
when working on group projects. Workers must be qualified to do the
work to which they are assigned and have appropriate experience. They
must follow the standards set for their activities and their efficiency must
be acceptable. They mustproblem-conscious; that is, they must stay alert to
the potential for waste and take responsibility for seeking solutions to problems.
Material the raw materials and subsidiary which may affect quality.
Quality standards for materials must be adequate, and you must check the
materials as they arrive from the supplier for impurities, irregularities, damage
or waste. While kaizen proposes minimizing the number of suppliers, this
allows a suppliers quality problems to propagate through your system.
Several companies that relied on a single supplier for materials or systems,
including Boeing, Caterpillar and Toyota, sustained significant difficulties
when those materials and systems failed. An adequate supply of the
correct materials is essential to sustain the service or manufacturing
process. Workers and management must also make adequate provision
for storage and material handling.
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Method the methodology of work and inspection which may affect
quality. In evaluating methods, you must determine whether the work
standards are adequate and safe. You must find an efficient method that
provides a good product. The sequence of the steps used in the work must
allow for the most efficient assembly of the product or for providing the
service efficiently. The physical setup of the work area whether a desk or
a factory workstation should maximize the flow of the project, and there
should be sufficient lighting and ventilation for workers to perform their
work efficiently. Arrange workstations so that the work flows evenly with a
minimum of disruption and adequate communication .So if any change
occur in 4M it needs to be verified to avoid any effect on quality.
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Process Quality
The line quality check or LQC comes under this process quality. With the highlights-
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Below is given the flow chart for the LQC process.
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Outgoing Quality
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Quality Planning
LG quality policy
LG electronics India Ltd. Shall consistently secure the best quality and
customer satisfaction in products and services by continual improvement in
Quality management systems.
Quality objectives
Continual reduction in Field Failure Rate and Failure Cost Rate.
Improvement in service call closure rate
Compliance to statutory and regulatory requirements of products
Enhance quality culture in organisation.
Quality planning
Systematic process that translates quality policy into measurable
objectives and requirements, and lays down a sequence of steps
for realizing them within a specified timeframe
Developing and maintaining quality system to achieve goals
involving customer satisfaction
Setting quality goals, establishing and maintaining quality
system, managing Q KPI
Enhancing quality capability to achieve customer satisfaction.
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RoHS
Lead (Pb)
Mercury (Hg)
Cadmium (Cd)
Hexavalent chromium (Cr6+)
Polybrominated biphenyls (PBB)
Polybrominated diphenyl ether (PBDE)
Bis(2-ethylhexyl) phthalate (DEHP)
Butyl benzyl phthalate (BBP)
Dibutyl phthalate (DBP)
Diisobutyl phthalate (DIBP)
DEHP, BBP, DBP and DIBP were added as part of DIRECTIVE (EU)
2015/863 which was published 31 March 2015.
Products within scope of the RoHS2 directive must display the CE mark, the
manufacturers name and address and a serial or batch number. Parties
needing to know more detailed compliance information can find this on the EU
Declaration of Conformity for the product as created by the manufacturer
(Brand owner) responsible for the design or the EU representative. The
regulation also requires most actors in the supply chain for the product
(importer and distributors) to keep and check this document, as well as
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ensuring a conformance process has been followed and the correct language
translation for instructions are provided. The manufacturer must keep certain
documentation
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SOME DEFINATIONS:
4. FIELD FAILURE RATE (FFR): Field failure rate is a measure of failure of the
product at the customer end. Product failure in the warranty period is
considered for calculating FFR. FFR can be calculated on the basis of
production basis or sales basis.
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as seal, slit, and laminate thermoplastic films and fabrics. Ultrasonic
components can be easily integrated into automated systems. The
process is based on a conversion of friction and vibration energy into
heat. Using a welding tool called a sonotrode, the high-frequency
vibrations generated by the ultrasonic system, in combination with
pressure, are transferred to the parts to be joined, which lead to relative
vibrations in the jointing zone. The micro melt resulting from the friction
heat presents a vibration barrier, which causes vibration energy to be
absorbed and converted into heat, which then causes the weld
contour to melt in fractions of a second and thereby form a molecular
connection.
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lubricator. All bearing surfaces will prematurely wear. Overheating will
result.
11. BOM: Bill of material. It is the list of all the raw material that is used in
making a product and their cost.
12. SERVICE BULLETIN: Guideline for service is issued in service bulletin. Service
bulletin contains the set of instructions/ guidelines for the service team
that they need to follow if any components in the field. It tells the
service engineer how to repair a damaged part.
14. Primary sales: Primary sales include the sale of product to the dealers
and distributors.
15. Secondary sales: Secondary sales include the sales to the end user or
consumer.
17. RELIABILITY: it is the probability that a component will not fail in its
designed lifetime. Reliability is an engineering discipline for applying
scientific know-how to a component, assembly, plant, or process so it
will perform its intended function, without failure, for the required time
duration when installed and operated correctly in a specified
environment. Reliability is "quality changing over time. Reliability is a
measure of the result of the quality of the product over the long run.
18. TDR (TEAR DOWN RE-ENGINEERING): It is a key tool for achieving TPI 50. It
focuses the attention of managers at all levels, on bottlenecks in
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operations & processes. A TDR team is formed that looks into the
processes & bottlenecks & finds / innovates ways & means to improve it.
20. 5S: 5S stands for 5 Japanese words , which means proper arrangement,
orderliness, cleaning, cleanliness and discipline 5S is the name of a
workplace organization method that uses a list of five Japanese words:
Seiri (Sort), Seiton (Systematic Arrangement), Seiso (Shine), Shiketsu
(Standardize), Shitsuke (Sustain).
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Project 1
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Figs FCT for PCBs
Fig: JIG for PCB Fig: Lab conditions to be maintained for testing
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Project 2- Evaluation of faulty PCBs arriving at R&D Ref
R&D Department had to analyze the faulty PCBs arriving from 2 sources :
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Fig : Unpacking PCBs returned from field/line
1. Fuse : The first failure point of the device , which prevents the PCB to
get damaged from excessive current and voltage . Test : Checking
continuity of Fuse
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2. IPM( Intelligent Power Module) : It is the internal power supplier for the
various tasks of the PCB. Test: Checking the status of the diodes which
constitute of IPM using multimeter
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4. Bridge Diode Test :Checking the working of the diode using
multimeter and power supply.
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Pics : Documentation of PCB data
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Project 3- Checking of Suspected Ok PCBs on JIG
1. Shower LED
2. SDS(Smart Buzzer)
3. Fan
4. Display LED
5. Compressor
The motive was to check each suspected OK PCB (the ones that cleared
the first tests on multimeter) and document the findings in an excel file .
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Project 4- To understand the workflow for function of a LG refrigerator PCB
As per my understanding of the various parts of a refrigerator PCB , their function and
interlink , I have drawn the following flow chart :
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Project 5- Analyzing the errors in field returned Defrost Thermostats
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Pic: Documentation of Thermostat data
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Project 6- Analysing field returned OLP(overload protector ) and
documenting the findings
1) Connection test :checking that there are no loose connection in the OLP
2) Continuity test: checking the continuity between the terminals once the
device should be conducting
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Pic : Documentation of OLP data
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Project 7 - Analysing field returned PTC (Positive temperature control resistor /
thermistor)
The analysis of faulty PTCs are done through the following checks-
1)loose connection test : checking that there are no loose connection in the
PTC
2) continuity test: checking the continuity between the terminals once the
device should be conducting
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Pic: Documentation of PTC data
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Project 8 - verification of implementation of new idea suggested by R&D ref
for omega 3,4,5 back plate condenser and SL condenser by cross checking
the new dimensions of the same
RnD ref had advised our supplier to adjust some of the dimensions of omega
3,4,5 back plate condenser to improve efficiency. My job was to crosscheck
that the ideas had been correctly implemented . I collected samples of the
above back plate condenser s directly from line and measured required
dimensions using scale and vernier calliper(see pictures).
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Project 9- calculating luminous intensity of bulbs installed in 4and 5 star
models
The motive of above project was to check the luminous intensity of our new
supplier china for bulbs used in 4 star and 5star double door refrigerators and
compare it with current suppliers Korea . The checking standard was to
measure luminous intensity of bulbs in a dark room using a lux meter from a
distance of 120mm horizontally and vertically. The readings were taken and
documented properly so that they could be analysed further .
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Project 10- calculating the dimensions of the gasket of a bulb holder using
Vernier Callipers
A gasket is a shaped sheet or ring of rubber or other material sealing the junction
between two surfaces in an engine or other device . The aim of the project was to
analyse the current dimensions of the gasket of 4 star and 5 star refrigerator bulb
holders and document the data so that it could be forwarded to higher authorities
to improve the design for better efficiency.
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Project 11- Desoldering of correct components from Damaged PCBs
This project was carried out with the aim of learning to desolder components
from a PCB without destroying it and also preserve ok components from
damaged PCBs which would later be dumped . The final result is as follows
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Project 12 FFR (Field Failure Rate)
FFR stands for field failure ratio and it means as a quality index to know the
current quality level of the product on sale in the market.
It is the ratio of field complaints including product failure or inconvenience in
using the product by the customer. It is used for identifying issues of current
selling models, making improvement plans, developing focus areas for
improvement of next new models. Because only that product survives which
evolves with new problems that customers face all the time. It contains of
part and non part faults where part faults arise due to any error in product
where it can be any little manufacturing error And non part is where a fault is
there due to customer negligence or any fault during installation etc.
The FFR management is done as follows:
Measure FFR close calls by conforming the problem from service centres
Analysis differentiate between part and non-part defects because non
part may arise due to customer negligence hence company cannot do
anything against that.
Improvement worst part/non part improvement by thru tusk or 6 sigma,
or direct improvement.
Monitoring monitor if the change made was able to survive on the field or
not.
Project aim : To call the service engineer and confirm the fault in a double
door(FF) Refridgerator, so as to differentiate the Part fault from the non Part
fault and close the call. Which further will help to look the common issues in
especially the leakage of gas from compressor and how to improve it so as
to reduce the same kind of faults that were found in the field.
Complaint by customer,
What service eng observed.
What action he took, before replacing PCB
Voltage condition?
Earthing at home.?
Any surge/thunderstorm in that area?
Which portion of PCB burnt?
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REFERENCES
http://www.lge.com
http://www.lgindia.com
http://www.wikipedia.com
http://www.bee-india.nic.in
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