SUMMER TRAINING REPORT

ON
AUTOMOBILE AIR-CONDITIONING
AND TIME STUDY
AT

By

SHOAIB SIDDIQUI
Summer Trainee
Production Engineering Department
Sanden Vikas (India) Pvt. Ltd.
Faridabad

Student of

Bachelor of technology (B.tech.)

Mechanical and automation Engineering 6th sem ( MA/07/35)
AL-FALAH SCHOOL OF ENGINEERING AND TECHNOLOGY
Dhauj
(Affiliated to M.D. University, Rohtak)
 ACKNOWLEDGEMENT

With profound respect and gratitude, I take the opportunity

to convey my thanks to complete the training here.

I do extend my heartfelt thanks to Mr. Shabbir Ahmed for

providing me this opportunity to be a part of this esteemed
organization.

I am extremely grateful to all the technical staff of Sanden

vikas (India) ltd for their co-operation and guidance that
helped me a lot during the course of training. I have learnt a
lot working under them and I will always be indebted of them
for this value addition in me.
I would also wish to convey my warm regards to Mr.
Virendra Kumar for providing me with all the knowledge
database that I needed for this report. I would also like to
thank Mr. M.A Faridi TPO- AFSET DHAUJ, for providing
me this wonderful opportunity to work with the Sanden vikas
(India) ltd.

TABLE OF CONTENTS
Pages

1. Preface ……………………………………………………1

2. Introduction……………………………………………. 2-8
2.1. About the Company
2.2. The Group Companies
2.3. Companies Mission, Vision and Management Principles
2.4. Products of Company
2.5. Customers
 3. Basics of Air-Conditioning…………………………… 9-21
3.1. Refrigeration cycle
3.2. Components of AC System
3.3. Functions of various parts

4. Time study………………………………………………22-30
4.1 Productivity improvement on HVAC Assy. Line.
4.2 Takt time calculation.
4.3 Cycle time for various operation in HVAC Assy. Line.
4.4 Graphical representation.
4.5 Understanding the process above takt time
4.6 Suggestions to decrease the time taken in the process

Preface
This six weeks training is a part of our 4-year degree course. Practical
industrial training mainly aims at making one aware of industrial
environment, which means that, gets to know the limitation, constraint and
freedom under which an engineer works. One also gets opportunity to see
from close quarters that indicate management relation. This training mainly
involves industrial and complete knowledge about designing, assembling
and manufacturing of equipments.

Excellence is an attitude that the whole of the human race is born with. It is
the environment that makes sure that whether the result of this attitude is
visible or otherwise. A well planned, properly executed and evaluated
industrial training helps a lot in inculcating a professional attitude. It
provides a linkage between the student and industry to develop an awareness
of industrial approach to problem solving, based on a broad understanding of
process and mode of operation of organization.

During this period, the students get the real experience for working in the
actual environment. Most of the theoretical knowledge that has been gained
during the course of their studies is put to test here. Apart from this, the
students get an opportunity to learn the latest technology, which immensely
helps them in building their career.

I had the opportunity to have a real experience on many ventures, which

increased my sphere of knowledge to a great extent. I got a chance to learn
many new technologies and was also interfaced to many new instruments
and all the credit goes to Sanden Vikas (India) Pvt. Ltd., Faridabad.

About the Company

In 1982, before the widespread use of Air-Conditioning systems in India,
Vikas Group saw the potential for automotive air – conditioning and entered
into a Joint Venture with Sanden Corporation of Japan to establish
manufacturing facilities for world class Sanden Car Air-Conditioning
Systems in India. The company had the distinction of being the pioneer
OE supplier of A/C systems to Maruti Udyog Ltd. for their M800 car and
Omni Van.

Over the last 25 years, Sanden Vikas has established a very strong R&D
team. The company has a fully functional Design Centre having full fledged
CAD/CAM facilities which are supported with the latest software. It has
capabilities to design and develop any type of automotive air-conditioning
requirements to meet the diverse need of the customers as per local climatic
conditions. All quality control and training functions are conducted under
the strict and vigilant eyes of expert Japanese Engineers.

Over the last two decades, SVL and the Group companies have established
and further enhanced its production facilities to manufacture air-
conditioning parts like Compressors, HVACs, Blowers, Receiver Driers,
Hoses & Pipes, High Precision Machined parts and Injection Moulded parts.
It has a strong and fully trained work force at all its manufacturing locations.

The Company and the Group companies have a very strong focus on quality
and customer satisfaction. Most group companies are accredited with
ISO/TS16949 certifications. SVL is on its way to challenging the Deming
Award, which it hopes to accomplish by 2009. In order to deliver quality
products to its customers, the company has set a minimum criterion of ISO
9001 certification for all its vendors as well.

The Group Companies

Companies Mission
- To be India’s leading automotive air conditioning company.
- Be globally competitive.
- Benchmark with best and be top of the class in technology – design
manufacturing and quality.
 - Delight and exceed customer expectation.

Companies Vision

- Let us develop with wisdom and prosper in harmony

- Create value through challenge and innovation.
- Sustain growth and gain for all stake holders.

Management Principles
- Challenge and Innovation.
- Customer is king.
- Benchmark with the best and be top-of-the class.
- Decision making – Transparency, Employee Participation and
Consensus Building.
- Implementation of decisions and Adherence to Targets.
- Discipline.
- Cost Consciousness.
- Proper Attitude.
- Work Environment.
- Employee growth and Development.

Products of Company
Compressors
The compressor is the heart of any air conditioning system.
Sanden has the unique feature of being the only air-con manufacturer in
India to supply three different types of compressors.
1). Fixed Displacement
• Wobble plate type compressor.
• Available in 80 to 150 cc configurations.
• Suitable for passenger car, MUV, SUV, Commercial vehicles and
heavy duty truck application.
• Available in 12V and 24V applications.
• SVL also offers 150 cc compressors for heavy duty truck application.

2). TR-Compressors
• Uses a unique design with two inter-locked scrolls, one is fixed and
the other is movable.
• Gives continuous compression allowing operation at very high speeds,
whilst maintaining a compact size and high volumetric efficiency.
• Scroll is a rotary compressor, suitable for low NVH (Noise, Vibration
& Harshness) & low power consumption.
• Provides jerk-free, easy drivability.
• Available in 50cc, 70cc & 90 cc configurations.
• Suitable for up to 12000 rpm applications.

3). Variable Displacement

• Wobble plate type, internally controlled variable compressor
containing 6 or 7 pistons.
• Offers superior performance, better drivability and low Noise,
Vibration & Harshness (NVH) across all operating conditions.
• Available in 100cc, 125cc & 165cc configurations.
• Suitable for efficient cooling and low power consumption application.
• Capacity of the compressor can be controlled from 6 % to 100%.
• Used in all high end vehicles like Skoda, Logan, Maruti Swift diesel,
Ford Fiesta Diesel.

HVAC Unit : Heating Ventilation Air-

conditioning Unit
• Provide high degree of comfort and reliability, supported by state-of-
the-art technology.
• HVAC are designed according to vehicle specific requirements.
 • Applications are available as HVAC, only A/C and only Heating
units.
• Suitable for passenger car, SUV, MUV, LCV and Heavy Duty truck
applications.
• Are always dashboard mounted for small vehicles.
• Special features: Electrically controlled HVAC are available for few
selected models.

Evaporators
PAF Evaporators
• Aluminium layer type evaporators.
• PAF (Plate and Fin) makes flexible design possible with evaporators
becoming smaller, lighter and enhancing performance with minimum
pressure drop for the specified air flow.
• Available in 50 mm width.
• Used in all latest generation cars.

Hose and Pipes

• Hose and pipes are used in air-conditioning systems for
interconnecting the compressor, condenser, receiver drier and cooling
unit as a close circuit
• Refrigerant gases with special characteristics need hoses with special
nylon internal coating
• All the hoses are connected by aluminium pipes through end fittings
• Special features include low refrigerant permeability, high bursting
pressure and long product life
• All joints contain shaft seals and pads

Condensers
Multi-Flow/Parallel-Flow Condenser
• The performance of a condenser is related to its ability to dissipate
heat.
 • Multi flow condensers are the latest in technology and innovation,
containing parallel cooling circuits and a slim design that help to
utilize less space, save energy and thereby enhance the overall
performance.
• Available in 16/18mm thickness, suitable for R134a refrigerant.
• The design minimizes air pressure drop and radiator heat load due to
supper-thin profile.

Sub Cool Condenser

• Multi-Flow Condensers that have inbuilt Receiver Driers for all types
of vehicles.
• It can sub cool up to 15 degree.
• Increase the system performance by greater efficiency without
additional power consumption.
• Contains less piping and joints.
• Available in 18mm and 16 mm width.

Receiver Driers
• Primary purpose is to remove moisture and filter out dirt.
• Secondary function is to separate the gas and liquid.
• Also act as storage tanks for the refrigerant.

Intake Manifolds
• SVL has injection moulding and assembly facilities for Intake
Manifolds for group companies
• Are supplied to large OE manufacturers such as Maruti Suzuki, Tata
Fiat and Mahindra

Customers
 Basics of Air-Conditioning

Air-conditioning is the process to control temperature, humidity,

purification and circulation of air simultaneously. Irrespective of the
outside temperature, AC maintains a constant temperature inside the cabin
and thus aids human comfort.
Human Comfort Control
The human body is a heat-generating device. But in spite of all the various
metabolic processes taking place inside our body, a constant body
temperature of 98.6o F (Fahrenheit) is maintained.
Our body is actually analogous to an Air conditioner. It can maintain this
constant temperature principally by 4 methods: Conduction, Convection,
Radiation and Evaporation.

We generally feel comfortable under the following environmental

conditions.
Temperature : 23 + 3o C (20oC – 26oC)
Humidity (RH) : 50 + 5%
Purification of air : 10 – 30 Microns (air particles)
Circulation of air : 2-3 M/sec
Ventilation – To regulate fresh air requirement

Units of Air-conditioning
We have often heard of people say “ Mine is a 1.5 ton (18400 BTUH
CAPACITY) AC. What’s yours”
What is ‘Ton’ ?
‘Ton’ is the unit for measuring Air Conditioning and can be defined as
follows:
Ton Refrigeration: This is the amount of heat removed/given to convert
1000-kg water at 0oC into ice (00C) and vice versa in 24 hrs.
1 Ton ≈ 12000 BThU/Hr or 3000 Kcal/Hr
≈ 200 BThU /Min or 50 K cal/Min

Components of AC System

AC System consists of the following parts

• Compressor
 • Condenser Assembly
• Receiver Drier
• TXV ( Thermo Expansion Valve)
• Cooling Coil Assembly ( Blower & Cooling Coil)
• Pressure Switch
• Hose & Pipes
Electrical components
 AC switch
 Thermo volume switch
 Thermostat
 Thermo amplifier & Thermistor
 Condenser fan Assembly
 Electro Magnetic Clutch
 Electrical circuit / Wiring Harness

Functions of Various Parts

Compressor
 • The compressor is a pump which raises the pressure of the
refrigerant for heat movement through the condenser and
evaporator.
• The compressor separates the low pressure side and the high
pressure side of the system.
• The high temperature differential between the refrigerant and the
outside air temperature is necessary to aid rapid heat flow in the
condenser from the hot refrigerant gas to much cooler outside air.
• To create high-pressure concentration, the compressor pistons, draw
in the refrigerant through the suction valve and force it to through
the discharge valve.
• With the piston on the down side, the suction valve is opened to
allow low pressure gas to enter. With the piston in the upstroke,
refrigerant is compressed and forced out through the discharge
valve which divides the high side of the system from the low side of
the system.

Condenser
• The condenser receives the high pressure, high temperature
refrigerant vapour from the compressor and condenses it to a high
temperature liquid.
• The designs allows heat movement from the hot refrigerant vapour
 to the cooler outside air. The cooling of the refrigerant changes the
vapour to liquid. Heat exchange is accomplished using cooler air
flowing through the condenser.
• Location : The condenser is usually located in front of the car’s
radiator. Refrigerant temperature in the condenser varies from 50o C
to 75oC with pressures ranging from 10 kg/cm2 to 21 kg/cm2.
• Condensing of the refrigerant is the change of state of the
refrigerant from a vapour to a liquid. This action is affected by the
pressure of the refrigerant in the coil.
• Condensing pressure in an air conditioner system is the controlled
pressure of the refrigerant which affects the temperature at which it
condenses to a liquid, giving off large quantities of heat in the
process.

Receiver Drier
• Receiver drier is an important part of the air conditioning system.
• The drier receives the liquid refrigerant from the condenser and
removes any moisture and filters any foreign matter present which
may have entered in the system at the time of gas charging.
 • Receiver section of the tank is designed to store extra refrigerant
until it is needed by evaporator. The storage of this refrigerant is
temporary and is dependent on the demand of the expansion valve.

The Desiccant
• A desiccant is a solid substance capable of removing moisture from
gas, liquid or solid. It is held in place within the receiver between
two screens, which also act as a strainer.

Thermo Expansion Valve

• The thermostatic expansion valve controls the amount of refrigerant
entering the evaporator coil. Both internally and externally
equalizer type of expansion valves are used.
• Location : It is located near the inlet of the evaporator and provides
 the function of throttling, modulating and controlling the flow of
liquid refrigerant to the evaporator coil.
• The refrigerant flow is restricted creating a pressure drop across the
valve. Since the expansion valve also separates the high side of the
system from the low side, the state of refrigerant entering the valve
is high pressure liquid, exiting it as low pressure vapour liquid.
• The amount of refrigerant metered into the evaporator varies with
different heat loads.
• The expansion valve is controlled by both the temperature of power
element bulb and the pressure of the liquid in the evaporator. As
the load increases, the valve responses by opening wider to allow
more refrigerant to pass into the evaporator. As the load decreases,
the valve re-acts and allows less refrigerant into the evaporator.
• It is this controlling action that provides the proper pressure and
temperature control in the evaporator.

Cooling Coil
• The cooling coil assembly comprises cooling coil and blower
• The cooling coil / evaporator cools and dehumidifies the air before
it enters the car’s interior. Cooling a large area requires large
 volumes of air to be passed through the evaporator coil for heat
exchange. Therefore, a blower becomes a vital part of the
evaporator assembly. It not only draws heat-laden air into the
evaporator, but also forces this air over the evaporator fins and coils
where the heat is surrendered to the refrigerant. The blower forces
the cooled air out of the evaporator into the car’s interior.
• When low-pressure liquid refrigerant enters the evaporator, it boils
(expands) and vaporizes immediately. The latent heat of
evaporation is the heat absorbed by the expanding refrigerant in the
evaporation process.
• As the process of heat loss from the air to the evaporator coil
surface is taking place, any moisture (humidity) in the air condenses
on the outside surface of the evaporator coil and is drained off as
water.

Pressure Switch
It is the safety device of A.C. system. This switch is used to stop the
compressor if and excessively high or low discharge pressure in
refrigeration cycle is detected by the diaphragm.
Dual function pressure switch is used in the air-conditioning unit.
a)Low Pressure Cut out b)High Pressure Cut out
If the low discharge pressure in the refrigeration cycle that is in the
condensing pressure of refrigeration decreasing excessively because of
gas leakage in the system while A/C is operating. The L.P. Switch
operates and disconnects the compressor.
If the discharge pressure in the refrigeration cycle increases excessively
because of clogging or poor cooling of condenser while ac is in operating,
there is chance of busting of system parts. The H.P. Switch operates and
disconnects the compressor and prevent any damage.

Hose and Pipes

Hoses and pipes are used for interconnection between the various
components of refrigeration cycle.
They are like veins and artilleries for the refrigerant.

The Electrical Circuit

• The air conditioner’s electrical circuit is fed from an accessory
circuit and is fused with a 15 ampere fuse or circuit breaker.
• The electrical circuit is complete with the following components:
  AC Switch
 Thermo Volume Switch
 Thermostat (Electrical /Mechanical)
 Fan Motor

AC Switch
• The blower control is a switch, which provides a range of blower
speeds from fast to slow. When the blower switch is turned on,
current is fed to the thermostat.

Thermo Volume Switch

It is used to set the cooling range for thermostat.

The Thermostat
• The function of thermostat is to control the grill temperature.
• It may be of two type : Mechanical or Electrical
• Electrical thermostat is a combination of as Thermo Amplifier and
Thermistor.
• The electro magnetic clutch, is controlled by a thermostat in the
evaporator, which is set initially by the driver to a predetermined
point. Coil temperature is then maintained by the cycling action of
the clutch.
• The thermostat is simply a thermal device, which controls an
electrical switch. When warm the switch is closed; when cold, it is
open.
Blower Fan Motor
• This is broadly divided into:
a) Blower Motor Fan
 b) Condenser Motor Fan
• Blower Motor Fan sends sends heat to Evaporator, for Heat
exchange in Evaporator while the Condenser Motor Fan sends wind
to condenser for Heat Exchange in Condenser.
• The motor fundamentally consists of field and armature. The field
supplies magnetic flux and the armature consists of a kind of
winding
• The reciprocal action between the electric current running to
armature’s conductor and the field magnetic flux brings torque to
action resulting in rotation of armature.

The Magnetic Clutch

• An electro-magnetic clutch is used in conduction with the
thermostat to disengage the compressor when it is not needed.
 • When the thermostat is on and closed, current is fed to the field.
This sets up a magnetic force between the field and armature,
putting it into the rotor. When the armature becomes engaged with
the rotor, it becomes one piece and the complete unit turns while
the field remains stationary. This causes the compressor crankshaft
to turn, starting the refrigeration cycle.
• When the thermostat is on but opens /cuts off , current is cut off.
The armature snaps back out and stops while the rotor continues to
turn. Pumping action of the compressor is stopped until current is
again applied to the field.

N u t C ap F ro n t P late R o to r P u lley F ield C o il

Electrical Circuit / Wiring Harness

All electrical circuits are connected through a system of wires together
referred to as Wiring Harness
Red lines indicate the network of wires.

TIM

TIME STUDY
Time and motion study, analysis of the operations required
to produce a manufactured article in a factory, with the aim
of increasing efficiency. Each operation is studied minutely
and analyzed in order to eliminate unnecessary motions and
thus reduce production time and raise output, which
increases productivity. The first effort at time study was
made by F. W. Taylor in the 1880s. Early in the 20th cent.,
Frank and Lillian Gilbreth developed a more systematic
and sophisticated method of time and motion study for
industry, taking into account the limits of human physical
and mental capacity and the importance of a good physical
environment.
 TAKT TIME CALCULATION.

Total online operators 22

Total support staff 11

Total Man power 33

Shift time 9 AM to 05:30 PM

Total Time 510 MINS

Tea Time 30 MINS

Lunch Time 30 MINS

Available Time 450 MINS

REQ./ DAY 517 Kits

TAKT TIME = NET AVAILABLE TIME/ CUSTOMER REQUIREMENT

= 450*60/517 = 27000/517 =52.2 secs

Cycle time for various operation in HVAC Assy.

Line
Operation Cycle Time

1.Cooling coil assy. 45 secs

 2.Blower case and resistor assy. 36 secs

3. Blower motor assy. 54 secs

4.Heater core foam pasting. 39 secs

5.Heater case assy B. 48 secs

6.Heater case assy A. 45 secs

7.Link and Lever fitment. 46 secs

8.Case intake assy leak test. 46 secs

9.Case intake sub assy. 47 secs

10.Hvac assy. 38 secs

11.Case intake assy. 44 secs

12.Current power and air flow intake. 43 secs

13.Noise and vibration testing. 44 secs

14.Lever force testing. 43 secs

15.Casing joint leak test. 44 secs

16.Damper leak test. 41 secs

17.Joint and foot duct assy. 38 secs

18.Receiving gauge inspection. 32 secs

19.Part missing check. 25 secs

20.Visual inspection. 45 sec

GRAPHICAL REPSENTATION
UNDERSTANDING THE PROCESS ABOVE TAKT TIME

There is only one process above Takt Time ie. Blower motor Assy.
Now by analyzing this operation by time study.

Blower Motor Assy.

1. Picking the piece from assembly and keeping on da work station.- 3

seconds
2. Placing the motor.- 6 seconds
3. Screw tightening.- 31 seconds
4. Foam pasting.- 6 seconds
5. Dispose foam.- 5seconds
6. Picking the piece and keeping on the next station.- 3 seconds
SUGGESTIONS TO DECREASE THE TIME TAKEN IN
THE PROCESS.

1. Instead of picking up the piece from assembly line on

his work station, if the worker gets the piece
automatically on his work station it will save time.
2. SCREW TIGHETING. If the operator gets the screw
there it self with the screw tightener he don’t have to
pick up screw’s one by one.
3. Waste Management. Foam sticker waste can be
disposed by attaching a pipe above the dust bin to the
level of work station, so that the operator don’t hav to
bend down every time he applies the foam. He can
stand stil and dispose off the waste.