PROJECT REPORT

SUMMER INTERNSHIP

LG ELECTRONICS INDIA PVT LTD.

DURATION:20 JUNE , 2016 20 JULY,2016

DEPARTMENTS :

R&D REFRIGERATOR , QUALITY ASSESSMENT

SUBMITTED BY :-

KUNAL DHAWAN

B.TECH. ,ELECTRONICS AND COMMUNICTAION ENGINEERING

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

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 CERTIFICATION

This is to certify that Kunal Dhawan , B.Tech , Electronics and Communication

Engineering , 2nd year , has completed his summer internship in R&D Refrigerator
department with full dedication . He worked on numerous projects over his course of
on month and has shown complete interest and devotion to all his undertaking . I
wish him luck for his future endeavors .

Mr. Ved Pandey

Head , RnD Refrigerator

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 INDEX
INTRODUCTION 5

LG THE HISTORY . 7

LG PHILOSOPHY 12

LG VISION 12

THE PRODUCT PORTFOLIO ...14

SOCIAL RESPONSIBILITY .....17

LG SUCCESS MANTRA .. 18

LG- SIGNIFICANCE OF LOGO 20

RESEARCH AND DEVELOPMENT AT LG 22

REFRIGERATION (HISTORY AND ENTIRE PROCESS EXPLAINED) .. 25

PROJECT DEVELOPMENT STAGES ..42

FIELD FAILIURE RATE ...44

LGEIL NOIDA QA ORGANIZATION .49

4M CONVENTION.. 52

PROCESS QUALITY. 55

OUTGOING QUALITY .56

QUAITY PLANNING. 57

RoHS ..58

SOME DEFINATIONS... 60

PROJECTS :-

PROJECT 1 - To understand the method of working of SQA engineer . 64

(refrigerator department) to evaluate new PCBs returned from line

PROJECT 2- Evaluation of faulty PCBs arriving at R&D Ref . 66

and analyzing the error

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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 8 - verification of implementation of new idea suggested by R&D ref ....79

for omega 3,4,5 back plate condenser and SL condenser by cross checking
the new dimensions of the same.

PROJECT 9 - calculating luminous intensity of bulbs installed in 4and 5 star models...80

PROJECT 10 - calculating the dimensions of the gasket of a bulb holder using ..81
Vernier Callipers

PROJECT 11 - Desoldering of correct components from Damaged PCBs .82

PROJECT 12 FFR (Field Failure Rate) 83

REFERENCES ..84

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 INTRODUCTION

LG ELECTRONICS is a South Korean multinational corporation. It is South

Korean second largest electronics maker and the worlds third largest
appliance maker, with headquarters in the LG Twin Towers on Yeouido, Seoul.
LG Electronics is the flagship company of LG group, one of the largest
chaebols. The company has 75 subsidiaries worldwide the design and
manufacture televisions, mobiles, home appliances and telecommunication
devices. LG ELECTRONICS owns Zenith Electronics and controls; LG displays a
joint venture with Philips Electronics.

LG Electronics Plant: Greater Noida

Fig. 1

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 Factory Layout

Fig. 2

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 LG THE HISTORY

The internationally famed company LG started off as Lucky Gold Star, a

small company manufacturing cosmetics. LG entered in to the
electronic business under the Gold star brand name in 1958. In the
same year LG manufactured Koreas first launched telephone,
refrigerator and black & white television. In the succeeding years it
diversified into oil refining, construction biotechnology, semiconductor
and finance.

LG adopted the new name and corporate identity in 1995 from

companys two foremost brands Lucky and Gold star. LG was a merger
of two Korean companies, Lucky and Goldstar from where the
abbreviation of LG was derived. The current LIFE IS GOOD slogan is
acronym.

Before the companys name was changed to LG, household products

were sold under the brand name of Lucky, and the electronic goods
were sold under the brand name of Goldstar. In 1995 Goldstar was
renamed LG ELECTRONICS, and acquired Zenith Electronics of the
United States.

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 SOME FACTS AT GLANCE ABOUT THE LG

LG Electronics India Ltd. is a subsidiary of LG group, which is a 62 year

old business group of South Korea.

LG is a US $80 billion business group with 13000 employees.

It is the third largest Korean company. LG is a company where they

believe that people are the most important resource.

It was rated as the sixth best employer to work for in India by Business
Today in a survey.

LG believes itself to be a global company with presence of over 175

countries across the globe with a champion spirit.

Various Stages in LGs Growth Path

Foundation Stage (1947-1958): Pioneering and establishing Koreas
chemical and electronics industry.

Development Stage (1959-1969): Positive strategies for new enterprises

begin.

Diversification Stage (1970-1988): Exploding growth into a global

corporation.

Renovation Stage (1989-1994): A new management system to meet

the rapidly changing demands of the 21st Century.

Era under new chairmanship (1995): A New Business Culture and

Corporate Identity to pursue super excellence in all fields.

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 Fig. 3

1998 - Developed worlds first 60-inch plasma TV.

1999 - Established LG - Philips LCD, a joint venture with Philips.

2000 - Launches world's first Internet refrigerator, Exports synchronous

IMT-2000 to Marconi.

2001

GSM mobile handset Exports to Russia, Italy and Indonesia.

Establishes market leadership in Australian CDMA market.

Launches worlds first Internet washing machine, air conditioner

and microwave oven.

2002

Under LG Holding Company system, separates into LG

Electronics and LG Corporation.

Full-scale export of GPRS color mobile phones to Europe.

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 Establishes CDMA handset production line and R&D center in
China.

2003

Enters Northern European and Middle East GSM handset market.

Achieves monthly export volume above 2.5 million units (July).

Top global CDMA producer.

2004

EVSB, the next-generation DTV transmission technology, chosen

to be the U.S./Canada.

Industry standard by the US ATSC.

Commercializes world's first 55" all-in-one LCD TV.

Commercializes world's first 71" plasma TV.

Develops world's first Satellite- and Terrestrial-DMB handsets.

2005

Becomes fourth-largest supplier of the mobile handsets market

worldwide.

Develops world's first 3G UMTS DMB handset, 3G-based DVB-

Hand Media FLO.

DMB Phone with time-shift function and DMB notebook

computer.

Establishes LG-Nortel, a network solution joint venture with Nortel.

2006

LG Chocolate, the first model in LG's Black Label series of

premium handsets, sells 7.5 Million units worldwide.

Develops the first single-scan 60" HD PDP module and 100-inch

LCD TV.

Establishes strategic partnership with UL.

Acquires the world's first IPv6 Gold Ready logo.

2007

Launches the industry's first dual-format, high-definition disc

player and drive.

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 Launches 120Hz Full HD LCD TV.

Demonstrated the world-first MIMO 4G-Enabled technologies

with 3G LTE.

2008

Introduces new global brand identity: "Stylish design and smart

technology, in products
that fit our consumer's lives.
2010

Another dimension is added to the TV: a THIRD Dimension. LG

launches its 3D TV in India.

2011

LG is listed in Green peaces Guide to Greener Electronics where

it ranked 13th out of 15 leading electronics makers in November
2011, scoring 2.8 out of 10.

2012

LG made a world record in manufacturing worlds first 84-inch HD

Flat Panel

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 globally believes in the philosophy of GREAT COMPANY. GREAT

PEOPLE whereby only great people can create a great company.
Companys growth strategy is based upon fast innovation and fast
growth, through three core capabilities: product leadership, market
leadership and people centered leadership.

The company has a strong corporate culture fostering innovation,

pioneering spirit and transparent management across subsidiary and believes
in empowering employees to leadership. The smiling face logo symbolizes five
key concepts- World, Future, Youth, Human and Technology. LG has been
exploring ways to develop, combine and apply technologies that would
customize products and services to meet customer needs and exceed their
expectations. LG aims at creating a healthy and better life for every family.

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 PLASMA DISPLAY PANELS

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

LG is responsible world citizen. We are committed to develop environment

friendly products as well as caring for those in needs by donating funds to
worthy organizations and providing voluntary services.

A smaller footprint: - LGs environment management strategy includes

a strong commitment to reduce environmental impact and develop
environment friendly products.
Climatic change and energy: - LG work shard tackling climatic change
and reducing
Greenhouse gases emitted from its production facilities.
Environmental safety: - following the creation of LG electronics
environmental declaration the company has established and its
currently enforcing its mid and long term strategies.
Youth care: - the company is committed in providing a better
educational environment for underprivileged children and young
people through its educational support projects. The company
understands how important the youth of today is for the future and will
do all it can to nurture and guide these young ones.
Charitable donations: - the company donates part of its profit towards
supporting public affairs, scholarship programs, culture, art and
promoting physical exercise. In addition money is deducted on a
monthly basis from the salaries of the employees and channeled into
various socially responsible organizations and activities.
Volunteer work: - funds raised by LG electronics are invested in
volunteer works programs which are actively supported by the
employees. Such program include the provision of free meal services
for the homeless or seniors with limited fixed incomes and sincere
classes led by LGs Electronics researchers for the underprivileged
young ones.

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 LG- THE SUCCESS MANTRA

LG has been extremely successful in its operations in India as well as abroad.

The success of LG can be attributed to the success mantra that includes the
strategy of LG regarding the 7Ps of market.

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:

INNOVATION: creating new and unique values.

OPENNESS: responding to changing environment with an open mind
and flexible behavior.
PARTNERSHIP: establishing corporate relationships to ensure the best
performance.

LG believes its core competencies as-

DESIGN: the ability to plan projects and business effectively to maximize

results.
TECHNOLOGY: the ability to develop unique product concept with new
proprietor technology ahead of others and then commercialize them.
MARKETING: the ability to clearly understand and analyze customer
needs and then link them to business, continuously controlling the
brand image.
NETWORKING: the ability to create win-win relationship opportunities
based on ones strengths in specific sectors and makes them into
assets.

LG-The Significance of Logo

The letters "L" and "G" in a circle symbolize the World, Future, Youth, Humanity,
and Technology.

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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:

The management philosophy is To create value for customers through

management based on esteem of human dignity. LGs vision is to bring a
smiling face to every home across the globe. The logo of LG is in harmony
with their vision. The smiling face logo symbolizes five key concepts World,
Future, Youth, Human and Technology. LG believes that an effective
combination of these elements would make better future a reality for the
organization. LG has been exploring ways to develop, combine and apply
technologies that would customize products and services to meet customer
needs and exceed their expectations. LG aims at creating a healthy and
better life for every family.

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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

Objective of the Department:

Development & Modification of products suitable to the Indian

Customer or Indian conditions.
A customized focus for the changing magnetic, electrical,
environmental & cultural conditions.

Functions of the Department:

Product Merchandising Planning & Product Development

Control of Development activities according to events.
All product development related information collection / preparation
Drawing preparation
Preparation of Specification Change Note & BOM Change Note
Production & Field Service Report
Maintain information according to R & Ds SOPs for respective
product groups
Documentation of sample storage & issue of service bulletin

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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

R&D Drawing Primary Tests Pilot Lot

Quality Assurance

Procurement Production Materials

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.

Pioneers in refrigeration included Dr. William Cullen, a Scotsman whose

studies in the early 1700s dealt with the evaporation of liquids in a vacuum,
Michael Faraday, a Londoner who in the early 1800s liquefied ammonia to
cause cooling, and Dr. John Goorie of Apalachicola, Florida, who built a
machine to make ice to cool the air for yellow fever patients in 1834.

Today's compression refrigeration system operates on a concept adapted

from Faraday's experiments. It involves compressing gas into a liquid which
will then absorb heat. In so doing it returns to gas. This is a simplified
description of what happens in a home refrigerator, freezer, air conditioner or
dehumidifier. Refrigerators from the late 1800s until 1929 used the toxic gases
ammonia (NH3), methyl chloride (CH3Cl), and sulfur dioxide (SO2) as
refrigerants. Several fatal accidents occurred in the 1920s when methyl
chloride leaked out of refrigerators. Three American corporations launched
collaborative research to develop a less dangerous method of refrigeration;
their efforts lead to the discovery of Freon. Two of the first home refrigerators
both appeared in Fort Wayne, Indiana, where, in 1911, General Electric
Company unveiled a unit

Invented by a French monk. In 1915 the first "Guardian" refrigerator - a

predecessor of the Frigidaire - was assembled in a wash house in a Fort
Wayne backyard. Today, the refrigerator is the world's most used appliance.
Cooling is a popular food storage technique in developed countries. Lower
temperatures in a confined volume lower the reproduction rate of bacteria,
so the refrigerator reduces the rate of spoilage.

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What is an Electric Refrigerator?

Household refrigerator: Appliance having one or more compartments

intended for the preservation of food, one at least of which is suitable for the
storage of fresh food. A direct cooling refrigerator having single-door usually
fall under this category.

Household refrigerator-freezer: Appliance having two or more compartments

.The fresh food storage compartment is suitable for the storage of fresh food.
The food freezer compartment is suitable for freezing fresh food and for the
storage of frozen food under three star storage conditions.

Household food freezer: Appliance having one or more compartments

suitable for freezing a quantity of at least 4.5kg of test packages per 100Litres
of its storage volume in 24hours and in no case less than 2kg. under ISO
freezing capacity test and which is also suitable for the storage of frozen food
under three star storage conditions.

The Frozen food storage compartment

Compartments intended specifically for the storage of frozen food are

classified according to their temperature, as follows;

One star compartment: The storage temperature is not warmer than -6oC.

Two star compartment: The storage temperature is not warmer than -12oC.

Three star compartment: The storage temperature is not warmer than -

18oC.

Food freezer compartment: Suitable for freezing a quantity of at least 4.5kg

of test packages per 100Litres of its storage volume in 24hours and in no case
less than 2kg. Under ISO freezing capacity test and which is also suitable for
the storage of frozen food under three star storage conditions.

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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.

Upright Type: Appliance in which the compartment(s) is (are) accessible from

the front.

- TOP MOUNT TYPE - Appliance in which freezer compartment is located at

the top.

- BOTTOM FREEZER TYPE - Appliance in which the freezer compartment is

located at the bottom.

DIRECT COOLING & INDIRECT COOLING

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.

Characteristics of a Frost Free System are:

-The system is automatically operated to prevent the permanent formation of

frost on all refrigerated surfaces.

-No accumulation of frost on stored food.

-The defrosting water is disposed off automatically.

REFIGERATION SYSTEM

A flow diagram of a simple Refrigeration system is shown below:

Evaporator

Drier

Hot line
Capillary tube

Suction pipe

Condenser

Silencer
Fig 17: Refrigeration Cycle
Compressor

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Division of the system

A refrigerating system is divided into two parts according to the pressure

exerted by the refrigerant in the two parts.
The Low pressure part of the system consists of the refrigerant flow
control, the evaporator, and the suction pipe. The pressure exerted by the
refrigerant in these parts is the low pressure under which the refrigerants
vaporizing in the evaporator.
The High pressure part of the system consists of the compressor, the
condenser, the hot line, and the capillary tube inlet. The pressure
exerted by the refrigerant in this part of the system is the high pressure
under which the refrigerant is condensing in the condenser.

The principal parts of the system are:

1. Evaporator, whose function is to provide a heat transfer surface
through which heat can pass from the refrigerated space or product
into the vaporizing refrigerant.
2. Suction pipe, which conveys the low pressure vapor from the
evaporator to the suction inlet of the compressor.
3. Compressor, whose function is to raise the temperature and pressure of
the vapor to a point such that the vapor can be condensed with
normally available condensing media.
4. Condenser, whose purpose is to provide a heat transfer surface
through which heat passes from the hot refrigerant vapor to the
condensing medium.
5. Hot line, whose purpose is to prevent the dew on cabinet and door.
6. Drier, whose purpose is to remove the moisture and contaminant in the
cycle.
7. Capillary tube, whose function is to provide the proper amount of
refrigerant to the evaporator and to reduce the pressure of the liquid
entering the evaporator, so that the liquid will vaporize in the
evaporator at the desired low temperature.

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 VAPOR COMPRESSION REFRIGERATION CYCLE:

As the refrigerant circulates through the system, it passes through a number of

changes in state or condition, each of which is called a process. The
refrigerant starts at some initial state or condition, passes through a series of
process in a definite sequence, and returns to the initial condition. This series
of processes is called a cycle.

A simple saturated Refrigerating Cycle is a theoretical cycle wherein it is

assumed that the refrigerant vapor leaves the evaporator & enters the
compressor as saturated vapor (at vaporizing temperature & pressure) & the
liquid leaves the condenser & enters the refrigerant control as the saturated
liquid (at the condensing temperature & pressure). Although the refrigerating
cycle of an actual refrigerating machine usually deviates slightly from simple
saturated cycle, the analysis of simple saturated cycle is nonetheless
worthwhile.

Refrigeration cycle consists of the following processes:

1) The Compression Process

Process C-D takes place in the compressor as the pressure of the vapor is
increased from the vaporizing pressure to the condensing pressure by the
compressor. For the simple saturated cycle, the compression process, C-D, is
assumed to be isentropic.

2) The Condensing Process

Usually, both the processes D-E & E-A take place in the condenser as the hot
gas discharged from the compressor is cooled to the condensing
temperature & condensed. During process D-E, the pressure of the vapor
remains constant & the point E can be located on the P-h Chart by following
the line of constant pressure from point D to the point where the constant
pressure line intersects the saturated vapor curve.

3) The Expansion Process:

In the simple saturated cycle there is assumed to be no change in the
properties (condition) of the refrigerant liquid as it flows through the liquid line
from the condenser to the refrigerant control, and the condition of the liquid
approaching the refrigerant control is the same as its condition at point A.
The process described by the initial and final state points A-B occurs in the
refrigerant control when the pressure of the liquid is reduced from the
condensing pressure to the evaporating pressure as the liquid passes through

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the control.

4) The Vaporizing Process

The process B-C is the vaporization of the refrigerant in the evaporator. Since
vaporization takes place at a constant temperature and pressure, B-C is
isothermal and isobaric. Therefore, point C is located on the chart by
following the lines of constant pressure and constant temperature from point
B to the point where they intersect the saturated vapor curve. At point C the
refrigerant is completely vaporized and is a saturated vapor at the vaporizing
temperature and pressure.
The enthalpy of the refrigerant increases during process B-C as the refrigerant
flows through the evaporator and absorbs heat from the refrigerated space.
The quantity of heat absorbed by the refrigerant in the evaporator
(refrigerating effect) is the difference between the enthalpy of the refrigerant
at points B and C.

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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.

Fig 18: Compressor

OPERATION PRINCIPLES AND CHARACTERISTICS

Compressor is the heart of vapor compression refrigeration system. It
compresses low pressure refrigerant vapor coming from the evaporator to a
high pressure and temperature. The sequence of gas movement is: Intake -
Compression - Discharge - Expansion.
The efficiency of cooling cycle depends on the performance of compressor,
condenser, and evaporator. Hermetic compressors are used in domestic
refrigerator.

Types of compressor used in LG:

1. DC Compressor: This is simple reciprocating type compressor. It runs on
AC Induction motor. It works at a constant speed throughout the
cycle and works in On- Off cycle. It takes high current at the time of
starting, so more work is required to drive this compressor. When a
certain temperature is reached in the refrigerator the supply to the
compressor is cut off by a thermostat.

2. Inverter Compressor: Inverter compressor are also of reciprocating

type. They can work on a variable speeds and variable frequencies.

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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

Close Type (Wall Condenser)

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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.

b. To control flow quantity of refrigerant flowing through the system.

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,
36 | P a g e
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.

Fig 21: Drier

Principles of moisture elimination of drier.

The size of moisture absorber (M/S) of drier is bigger than that of water
molecule but smaller than that of refrigerant. Refrigerant will pass, but
moisture will be caught into M/S hole and be absorbed.

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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)

In DC Refrigerator, plate type evaporator is used. The refrigerated space is

cooled by natural convection, cold air being heavier goes to the bottom
and the hot air from the space being heavy rises above.
In FF Refrigerator, finned evaporator is used. The refrigerated space is cooled
by the forced circulation by using a fan. Fan circulates the cool air in the ref
section as well as freezer section.

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.

DEFROST CONTROL ASSEMBLY

The defrost control assembly consists of
bimetal thermostat and thermal fuse
both sealed in a plastic cover to
protect it from moisture.

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.

Operation Principles and characteristics

The capillary tube of thermostat is sealed with gas (R22, R134a) and
combined with bellows.
If the temperature of the capillary tube increases, the pressure of
sealed gas shall be increased. The increased pressure elongates
bellows and moves the operating plate in order for the contact to be
on.
If the temperature of the capillary tube decreases, the contact shall be
off.
Thermostat controls the temperature of the refrigerator by switching
compressor ON/OFF explained as above.

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

39 | P a g e
also turns the fan motor on and off. In old models mechanical push-type
switch was used. Nowadays, magnetic reed switch is used.

OVER LOAD PROTECTER

O.L.P. protects motor by breaking circuit when overload is applied to the
compressor motor or when compressor motor is over heated. It consists of
bimetal and heater connected in series. When current flows through the
heater, heat is generated and radiated to the bimetal. Bimetal deforms and
disconnects the power supply.

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

resistance of the element increases very rapidly above a certain temperature

and the electric circuit is cut off. PTC thermistor is generally used in
compressor starting circuit.

SENSORS

The following sensors are used in the refrigerator:

1. R-sensor- It senses the ref-compartment temperature &

provides necessary information to the compressor
micom to cut-off or cut-in compressor power supply.

Fig 23: R-Sensor

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.

3. Room Temperature Sensor: It senses the ambient

temperature around the refrigerator & provides
information to the micom to operate compressor
efficiently at different frequencies. If room temp.

40 | P a g e Fig 24: RT-Sensor

 is less than 38C, compressor will run at low frequency(30Hz). If room
temp. is more than 38C, compressor will run at high frequency(50Hz).

REFRIGERANT

A refrigerant is a substance used in a heat cycle usually including, for

enhanced efficiency, a reversible phase transition from a liquid to a gas.
Traditionally, fluorocarbons, especially chlorofluorocarbons, were used as
refrigerants, but they are being phased out because of their ozone depletion
effects. Other common refrigerants used in various applications are
ammonia, sulphur dioxide, and non-halogenated hydrocarbons such as
propane. Many refrigerants are important ozone depleting and global
warming inducing compounds that are the focus of worldwide regulatory
scrutiny.
Nowadays R-12a has been completely replaced by R-134a refrigerant in
refrigerators as R-12a is has high ozone layer depletion potential and high
global warming potential of 1 and 8500 respectively whereas R-134a has a
ozone layer depletion potential of 0 and global warming potential of 1300.But
as even R-134a has a high global warming potential, It will be completely
replaced by R-600a in the near future.

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.

PROJECT DEVELOPMENT STAGES

CONCEPT PLANNING

DESIGN VERIFICATION

PRODUCT VERIFICATION

PRODUCT QUALIFICATION

MASS PRODUCTION

1) Concept Planning (CP) Step

Product planning group (division) is in charge of this step, which is from

Product Concept Planning to commercialization confirmed meeting
completed. This step to establish a development plan based on the
collected market information, evaluate sales price, design SPEC. and
function of competitive product to correspond to the market demand, set
the target Q.C.D of the product to be developed with competitiveness and
finally determine it. That is advance preparation step for design.

2) Project Planning (PP) Step

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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.

3) Design Verification (DV) Step

The laboratory is in charge of this step, which is from project planning

confirmed meeting completed to design verification (DV) fair. It embodies
the various input data to accomplish the decided development target
(Q.C.D) and design Spec., produce a specimen before issuing the drawing
and prevent the problems expected in mass production in advance by
verifying and correcting the specimen based on the design standard.

4) Product Verification (PV) Step

Production Engineering Group is in charge of this step, which is from Design

Verification fair to Product Verification (PV) fair completed. It develops mold
and new part based on issued drawing, assembles and inspects the
approved parts at a production line according to QC process, verifies and
improves the decided target Q.C.D.(including design quality and
manufacture quality), and clarifies the management conditions in mass
production.

5) Production Qualification (PQ) Step

Manufacturing division is in charge of this step, which is from Product

verification (PV) fair to Production Qualification fair completed. It decides a
regular mass-production and shipping by verifying and improving mass-
production ability with mass-production more than 50ea) according to the
regular production system.

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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

44 | P a g e
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

- Detect problem from the data received from the field.

- Detect the root cause by analyzing the feedback of customer and
service engineer.
- Provide a counter measure to remove the issue.

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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.

Fig 27: Bath Tub Curve

PHASES OF PRODUCT LIFE

Infancy / Green / Debugging / Burn-in-period: Many components fail very

soon after they are put into service. Failures within this period are caused by
defects and poor design that cause an item to be legitimately bad. These
are called infant mortality failures and the failure rate in this period is relatively
high. Good system vendors will perform an operation called "burn in" where
they put together and test a system for several days to try to weed out these
types of problems so the customer doesn't see them.

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.

46 | P a g e
CAUSES OF COMPONENT FAILURE IN FIELD

1. Faulty design: Failures can occur in component if there is any fault in

designing of the component. If there is a design failure component will
fail in early stages of its life cycle, generally within one year. The faulty
design will be corrected and rectified by R&D team with proper testing
and analysis.
2. Production department negligence: These failures occur due to human
negligence. If there is major issue the product will fail within one or two
months. These failures can be avoided by proper vigilance and quality
checks.
3. Quality department negligence: These failures occur due to human
negligence, using faulty testing methods or skipping necessary quality
tests. These failures can be avoided by doing proper quality checks by
using latest machinery and technology.
4. Negligence during transportation: This is one of the major causes of
product failure mainly in rural areas. During transportation fragile parts
break due to shock loads due to uneven load or transporters
mishandling. This failure can be reduced by proper reliability testing of
the product packing. A little increase in the cost of product can save a
lot of product failures
5. Customer misuse: Mishandling of the product by customer or running
the product in abnormal conditions can cause product failure. This
failure can be reduced by properly educating the customer about the
product usage.

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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

Manage part quality-incoming part assessment

First part approval-new parts
Supplier process audit

Line quality assurance

100% line check

Daily reflection meeting
Line stop and check

Outgoing quality assurance

Outgoing inspection
Early life test
Short life test
3f test

49 | P a g e
 Development quality assurance

New model validation

Standard upgrade

CONCEPT OF QUALITY

Quality means the standard of something as measured against other

things of a similar kind; the degree of excellence of something.Or meeting
customers requirements and users satisfaction . Meeting customer
requirement means that level of quality is indicated by the receiving
end i.e. the customers.And good or better quality is indicator of the
fulfilment of customers need andrequirements as price does not matter if
one get the equivalent amount of quality.In view for customer quality is
changing from satisfying then to impress and to customers success.

Good Quality from markets view

Performance, design

Improvement in product reputation

Improvement in market share and higher prices

Increase in sales and increase in revenue

50 | P a g e
 Good quality from companys view

Improvement on trust and conformance

Productivity increases, rework/ scrap cost decrease,

Reduction in manufacturing cost

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:

The supplier has to check as per LG set standards.

LG SQA inspection - SQA means supply quality assurance which is
done as per military standard 105D. Also OQA(outgoing quality
assurance) for supplier and SQA at LG end are done on same parts
but both have different tests and standards to follow.

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

51 | P a g e
 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.

One important term comes into role in parts quality that is

4M change 4M stands for :-

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.

Machine it means production equipment and mold, jig, inspection

equipment which may affect quality. Your equipment or facilities must be
adequate for the job, both in capacity and capabilities. If there is
enough of the right type of equipment to do the job, ensure it is in
working order or procure additional equipment to handle an excess load. If
equipment problems can interrupt the process, consider using suitable
machinery that does not require frequent adjustment. If the equipment
requires precision adjustments, make the adjustments in a timely manner.
Equipment that requires fuel, lubrication or inspection must be adequately
fuelled and lubricated, and required inspections must be kept up-to-date.

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

It has an inspection known as sequential inspection where inspection is

divided into sequential phases in which workers check there own works.

It follows the procedure-

1. Set inspection point
Set inspection point for each process, like critical
processes/works easily mistakable; or work with frequent changes.
2. Self-inspection
Attach defect tags on defective parts.
Feedback on process which defect occurs.
Record repairing details.
3. Self-reflection meeting
Perform self-reflection meeting for worst time of the day

The line quality check or LQC comes under this process quality. With the highlights-

Part matching through input barcode scanning in LQC 100%

Lux level maintained at all inpection stages 1500 to 2000 lux.
Pictorial inspection standard in LQC for more and easy
understanding of defects
Inspectors detection skill upgradation

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Below is given the flow chart for the LQC process.

If there is any defect line has to be stopped as

Receive quality issue

Issue line stop note
Verify and if ok start the line
Take permanent measures to prevent that kind of error
Record history

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 Outgoing Quality

Various inspection tests are included in this outgoing quality as

General/aesthetic inspection
Safety inspection
ELT inspection
Detail inspection
Packing inspection
3F inspection

Its process is as follows

Review production plan
Sampling and random pick
OQA inspection
If ok then make a report and dispatch to market
If not ok make a NCR - non conformity report and send it for
rework

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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.

Quality management follows the following trilogy -

Quality planning developing process to achieve goals involving
customer satisfaction.
Quality control holding onto gains, controlling variation,
preventing waste.
Quality improvement lowering cost of poor quality achieving
innovation in performance.

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 RoHS

RoHS stands for restriction of hazardous substances. The Restriction of

Hazardous Substances Directive 2002/95/EC, (RoHS 1), short for Directive on
the restriction of the use of certain hazardous substances in electrical and
electronic equipment, was adopted in February 2003 by the European
Union.

RoHS is often referred to (inaccurately) as the 'lead-free directive', but it

restricts the use of the following ten substances:

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

58 | P a g e
ensuring a conformance process has been followed and the correct language
translation for instructions are provided. The manufacturer must keep certain
documentation

to demonstrate conformity, known as a technical file or technical records. The

directive requires the manufacturer to demonstrate conformity by the use of
test data for all materials or by following a harmonised standard (EN50581:2012
is the only standard at the time of writing). Regulators may request this file or,
more likely, specific data from it as it will likely be very large.

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SOME DEFINATIONS:

1. QUALITY FUNCTION DEPLOYMENT: Quality function deployment aims to

find out what the customer wants. QFD is tool which is used to
generate data in the form of taking feedback from the customer
through quality matrix, converting those requirements into Tech
changes in the Process through Quality Matrix. QFD translates the voice
of consumer into the voice of engineer.
It is defined in two steps:
a. Converting consumers voice into engineers voice.
b. Converting engineers voice into technical specifications.

2. 6 SIGMA: 6 Sigma is a business management strategy originally developed

by Motorola, USA in 1986. Six Sigma seeks to improve the quality of
process outputs by identifying and removing the causes of defects
(errors) and minimizing variability in manufacturing and business processes.
It is a technique to achieve total quality management. It aims to reduce
defects to 3.4 ppm. Six sigma aims at reducing the variation.

3. ENGINEERING CHANGE NOTE (ECN): Whenever any change or

modifications done in any part of the product, ECN is generated. All the
modifications in the part drawing are shown against a unique ECN
number. The modified drawing of part is uploaded in the system after
approval.

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.

5. ULTRASONIC WELDING: In ultrasonic welding, high-frequency vibrations

are applied to two parts or layers of material by a vibrating tool,
commonly called a horn or sonotrode. Welding occurs as the result of
heat generated at the interface between the parts or surfaces. This
technique is fast, efficient, non-contaminating and requires no
consumables. In addition to welding, ultrasonic processes can be used
to insert, stake, stud weld, degate, and spot weld thermoplastics as well

60 | P a g e
 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.

6. CRITICAL CHARGE: Critical charge is a definite amount of refrigerant

that is put into the refrigeration system so that in the eventuality of all of
it accumulating in the evaporator, it will just fill the evaporator up to its
brim and never overflow from the evaporator to compressor.

7. SLUGGING: Flow of liquid refrigerant in compressor. When large

quantities of liquid refrigerant enter the compressor and then mix with
the lubricating oil in the compressors sump. The resulting liquid/oil mixing
and diluting, then creates major amounts of liquid and oil droplets in a
frothy foam mixture. During extreme cases, this foam/oil/liquid mixture
can be carried into the suction gallery and then through the suction
valves and into the cylinder. This Wet mix will wash the cylinder
lubricant away and can also cause the valve reeds to break. Due to this
liquid/oil mixture carrying non compressible particles this can cause the
valve plate to deflect to the point where it breaks. The Suction valve
plate will show small dents or even holes through the plate. The valve
plate then falls into the cylinder and on to the piston crown. As the
piston travels up to the top of the cylinder during the compression cycle
the valve plate is then smashed up into the discharge valve plate. This
can cause a hole to be punched through the piston crown and
damage to the discharge valve assembly occurs as there is almost no
clearance between the top of the piston crown and the discharge
valve, which gives the compressor its high efficiency rating. The
discharge valve assembly can also be completely smashed to pieces in
certain instances.

8. FLOODING: Flooding is the continuous return of liquid refrigerant as

droplets in the suction vapor instead of all super-heated vapor. This
floodback washes oil off bearing surfaces. Refrigerant is a lousy

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 lubricator. All bearing surfaces will prematurely wear. Overheating will
result.

9. CHOKING: Accumulation of some dirt or dust particles in refrigeration

cycle is called choking.

10. KPI (KEY PERFORMANCE INDEX) : To objectify performance, each

department chooses & defines its performance parameters in
consensus with the M.D. & respective VPs that are quantifiable. This
ensures high performance & any improvements that are measurable &
quantifiable. The Numeric Output Index after performing responsible
duty through innovation ways. It can show the final result of working of a
certain organization.

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.

13. PPM: Parts per million

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.

16. CTQ: CRITICAL TO QUALITY

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.

19. TPI 50: TPI 50 (Total Productivity Innovation) is a management

philosophy to improve total productivity by 50%.

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

To understand the method of working of SQA engineer(refrigerator

department) to evaluate new PCBs returned from line

SQA(Supplier quality assurance ) , also known as IQC (incoming quality check

) is the department that is responsible for evaluating the correctness of the
incoming parts from the supplier (thermostat , PCBs etc) . It also looks into the
rejected parts that are returned from the line before they are they are put on
the product . I was assigned to assist the engineer who was responsible for
checking of PCBs. First on the job , there is a check sheet to be filled
regarding the conditions of the testing area , like checking whether the earth
condition provided on the table is fine , value of resistence across table is
within the give range and other such conditions so that the PCBs are not
damaged anyhow during testing . Testing of PCBs can be done in two ways :-
a) On the Jig , b) on the FCT (pictures of both are attached)

Fig: SQA check sheet Fig: Steps to reduce ESD

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 Figs FCT for PCBs

Fig: JIG for PCB Fig: Lab conditions to be maintained for testing

Fig : SQA Workspace

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 Project 2- Evaluation of faulty PCBs arriving at R&D Ref

and analyzing the error

R&D Department had to analyze the faulty PCBs arriving from 2 sources :

1. From field (ie Faulty PCBs collected by engineers from homes of

customer)
2. From SQA (faulty PCBs from line that cleared the initial tests are sent
here for further verification before they are sent back to the line)

Fig: PCB for double door (FF) refrigerator

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 Fig : Unpacking PCBs returned from field/line

There are 6 major components to be checked in faulty PCBs(Along with

pictures of each component) :

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

3. SMPS(Switched-Mode Power Supply) : It is an electronic power supply

that incorporates a switching regulator to convert electrical power
efficiently.

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 4. Bridge Diode Test :Checking the working of the diode using
multimeter and power supply.

5. Lighting LEDs : Test: Checking of transistors involved in the functioning

of lighting LEDs as per PCB design

6. SDS(smart buzzer ): Test: Checking of transistors involved in the

functioning of SDS as per PCB design

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 Pics : Documentation of PCB data

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 Project 3- Checking of Suspected Ok PCBs on JIG

JIG is a special device built to check the working of a PCB. It consists of

Power supply to the PCB and small modules to test for the working of :

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 .

The method of checking working of compressor portion of PCB is the give it

power supply and measure the output voltage at the compressor terminals .
The ideal voltage between the terminals(between ground and CON201
terminal) should be > 85V. Faulty PCB give the above output as ~15V.

The various components can be seen in the following picture:

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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

Thermostat is a device that automatically regulates temperature, or that

activates a device when the temperature reaches a certain point. A defrost
thermostat opens the heater circuit when the evaporator temperature rises above a
preset temperature, 40F (5C) or more, thereby preventing excessive heating of the
freezer compartment. The defrost timer is such that either the compressor or the
defrost heater is on, but not both at the same time.

The analysis of defrost thermostats is done following the given steps:-

1. Originality : Our suppliers are

Shin Han electro
Changzhou Thermoster electrical appliances co. ltd.
2. Connectivity: To simply check that the terminals are in conducting state when
the thermostat is in active state
3. Press Test: The defrost button should be easy to press and should get off
automatically at the required temperature

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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

OLP is used for compressor protection. When compressor temperature gets

higher than its range , the compressor cuts the electric supply from
compressor motor . The analysis of OLP consisted of the following checks -

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

3) Checking for any burn marks : a common problem due to excessive

current /voltage through the device

Pics: OLP of double door refrigerators

Pics: OLP of single door refrigerators

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 Pic : Documentation of OLP data

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Project 7 - Analysing field returned PTC (Positive temperature control resistor /
thermistor)

A PTC is a thermistor which increases its resistance with increasing

temperature.The PTC resistance specification in LG fridges is (26-40 ohms)

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

3) resistance value check : checking that the value of resistance between

terminals of PTC at room temperature(28 degree Celsius) should lie in the
range 26 to 40 ohms .

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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.

Pic: Vernier Calliper Pic: Bulb Holder

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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

Pic : Components removed

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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.

Questions asked to service engineer(for cases in which PCB was changed):

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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