INTERNSHIP REPORT

For Ref and DF (Quality Assurance Department)

Submitted By: Submitted To:

Adeel Tabassum Mr. Ayaz Khalil
(Manager QA)
 CONTENTS

Acknowledgement................................................................................................................................................................... 4
Historical Background ........................................................................................................................................................... 5
Quality Department ................................................................................................................................................................ 6
1. Incoming Quality Control....................................................................................................................................... 6
1.1) General procedure .......................................................................................................................................... 6
1.2) Local vendors ................................................................................................................................................... 6
1.3) Import (ckd or 3rd source) .......................................................................................................................... 7
1.4) Documents used by IQC ................................................................................................................................ 7
1.5) Procedure of Audit of REF-DF finished goods ...................................................................................... 8
1.6) procedure for control of non-conformity materials/parts ............................................................ 9
1.7) IQC rejection flow chart .............................................................................................................................. 10
2. Process ............................................................................................................................................................................. 11
2.1) U-Shell ..................................................................................................................................................................... 11
2.1.1) Notching........................................................................................................................................................... 11
2.1.2) Semi-notching ............................................................................................................................................... 11
2.1.3) Slotting ............................................................................................................................................................. 11
2.1.4) Punching .......................................................................................................................................................... 11
2.1.5) bending ............................................................................................................................................................ 11
2.1.6) Hemming ......................................................................................................................................................... 11
2.2) Evaporator ............................................................................................................................................................ 12
2.3) Cabinet thermoforming ................................................................................................................................... 12
2.3.1) Thermoforming ............................................................................................................................................. 12
2.4) Cabinet pre Assembly ............................................................................................................................................ 13
2.5) Cabinet and door foaming................................................................................................................................... 13
2.5.1) Free rise density ............................................................................................................................................ 14
2.5.2) Core density ................................................................................................................................................... 14
2.6) Booster line Assembly ......................................................................................................................................... 15
2.7) Door thermoforming........................................................................................................................................... 15
2.7.1) Shelley machine ............................................................................................................................................ 15
2.8) Door bending........................................................................................................................................................... 15
2.8.1) Shearing ............................................................................................................................................................. 15
2.8.2) Punching ............................................................................................................................................................ 16
2.8.3) Bending ............................................................................................................................................................. 16
 2.8.4) Notching............................................................................................................................................................ 16
2.9) Door pre-assembly ............................................................................................................................................... 16
2.10) General Assembly line ...................................................................................................................................... 16
2.10.1) Front line ........................................................................................................................................................ 16
2.10.2) Back line ......................................................................................................................................................... 17
2.11) Welding, vacuuming and Gas charging ....................................................................................................... 17
2.11.1) Joining processes ...................................................................................................................................... 17
2.11.2) Vacuuming, gas Charging, safety and leakage tests ................................................................... 19
2.12) Testing room and packing line ....................................................................................................................... 20
2.13) Sample room .......................................................................................................................................................... 20
2.13.1) Low voltage auto re-startability test ................................................................................................. 20
2.13.2) Pull down test ............................................................................................................................................. 20
2.13.3) Temperature rise test ............................................................................................................................... 21
2.13.4) On/off test ..................................................................................................................................................... 21
2.13.5) Pull down test at low ambient .............................................................................................................. 21
2.13.6) High voltage test - WITHOUT load ...................................................................................................... 21
2.13.7) Low voltage test .......................................................................................................................................... 21
2.13.8) Ice making test ............................................................................................................................................ 21
2.13.9) Cooling test at full load ............................................................................................................................ 21
3. Market return unit ....................................................................................................................................................... 22
3.1) Procedure for the categorization of market return units by HNR ................................................. 22
3.1.1) Purpose ............................................................................................................................................................. 22
3.1.2) scope .................................................................................................................................................................. 22
3.2) Procedure: Part (a) Market return units .................................................................................................. 22
3.2.1) B+ category.................................................................................................................................................... 22
3.2.2) B category ...................................................................................................................................................... 22
3.2.3) C Category ...................................................................................................................................................... 23
3.2.4) D Category ..................................................................................................................................................... 23
3.3) Procedure: Part (B) Process defective units ........................................................................................... 23
3.3.1) MRU B Category unit ................................................................................................................................ 23
3.3.2) MRU C Category unit ................................................................................................................................ 23
3.3.3) MRU D Category unit ............................................................................................................................... 24
 ACKNOWLEDGEMENT

I am very thankful to Manager QA Mr. Ayaz Khalil for providing me opportunity to work for one
of the best multinational companies in the world. I also appreciate the determination and
whole hearted support of Mr. Abdul Razzaq (Asst. Manager IQC), Mr. Abdul Rasheed (Asst.
Manager), Mr. Muhammad Sajid (Asst. Manager), Engr. Abdul Rehman (MRU) and Engr. Farhan
Ahmed for guiding and helping me through this internship.
 HISTORICAL BACKGROUND

Haier Group is a Chinese multinational consumer electronics and home appliances company. Its
Headquarter is in Qingdao, China. It designs, develops, manufactures and sells products
including air conditioners, mobile phones, computers, microwave ovens, washing
machines, refrigerators, and televisions.

The company has production plants all over the world including Indonesia, Malaysia, United
States, Jordan, Tunisia, Nigeria, Egypt, Algeria and South Africa, Italy, India.

In Pakistan HAIER was established in 2002 and after that it has slowly taken over the HVAC
industry and right now is the biggest seller of Refrigerators and Air conditioners all over
Pakistan with the lowest market complaint rate.
 QUALITY DEPARTMENT
Quality department is further divided into following sections:

1) Incoming Quality Control

2) Process
3) Technique
4) Improvement (Market, data analysis)

1. INCOMING QUALITY CONTROL

1.1) GENERAL PROCEDURE

Drawings of specific part are made by R&D and then send it to IQC and Sourcing dept.
Sourcing department orders materials or parts according to the new drawings made by R&D
Materials comes to Receiving/Inventory department
Complete inspection of material is being done by IQC
Standard procedure is to take 5% random sample from the lot and then test it according to the
drawing and enter its dimensions in material inspection form
If parts/materials are not according to the drawing they are rejected

IQC is receiving material of two categories:

1) Local
2) Import (CKD or 3rd source)

1.2) LOCAL VENDORS

Local materials are bought from vendors in Pakistan and most of them have their manufacturing
facilities in HAIER Factory. Local vendors include:

1) JW
2) SVA Ruba
3) Multi tech
4) EPS
5) AL Fatah
6) Thermin
7) Ravi
1.3) IMPORT (CKD OR 3RD SOURCE)
Imported material is divided into following categories:

1.3.1) CKD (COMPLETE KNOCK DOWN)

Completely disassembled parts are imported from HAIER China and then these parts are assembled
here.

1.3.2) SKD (SEMI KNOCK DOWN)

Half assembled parts are imported and then rest of them are assembled here

1.3.3) 3 RD SOURCE
Parts are imported from the other countries other than China like Korea, Germany etc.

Inspection criteria of local and imported materials are same. 5% samples are randomly drawn and then
checked according to the drawings made by R&D.

If material is completely defected it is sent back to the supplier or claim is sent for the rejected parts. If
material is partially defected in such a way that its usage in unit wouldnt affect any decrease in quality
then Exceptional Release of that material is done.

1.4) DOCUMENTS USED BY IQC

Formats of some of the documents used by IQC are given below:

MATERIAL INSPECTION FORM

Sr. no. Item Model Quality Inspection Sampling Inspection
Characteristics Tools method record

DAILY RECEIVING INSPECTION BOARD

Sr. no. Vendor Part name Model DC# Supplied Rejected
name quantity quantity
 MATERIAL RETURN NOTE (MRN)
Sr. Model Color Description Unit Ok Damaged Total Reason Responsible
no. Quantity Quantity Quantity of
Rejection

OUTWARD GATE PASS (OGP)

Item no. Description UoM Quantity Return Comment

SAMPLE CHECK REPORT

Sr. Critical Dimension Original Tolerance Sample Status Fitting Color
no Dimension description dimension dimension

Part Status: Ok/Not Ok

CLAIM
Sr. Container G.P Part Description Model UoM Packed Rejected Reason
no. no. Code code qty. qty.

1.5) PROCEDURE OF AUDIT OF REF-DF FINISHED GOODS

PURPOSE:
Its purpose is to implement a smooth and controlled mechanism to avoid cosmetic, aesthetic
and quality complaints from market

PROCEDURE:
To resolve problems from marketing regarding Ref-DF finished goods

An audit of packing line is conducted on weekly basis in Ref-DF factory in which HPK CSD, HPK
logistics, HNR audit will also participate
In audit if problem found will be categorized in three ways A, B and C
If problem in category A is found, then production of that product will be immediately stopped
If problem in category B found, then 5 marks will be deducted
 If problem in category C found, then 3 marks will be deducted
Standard of 80 marks is set by QA department
If total marks after B and C are found 80, then product is ok.

1.6) PROCEDURE FOR CONTROL OF NON-CONFORMITY MATERIALS/PARTS

PURPOSE:
The purpose of this method is to implement smooth and controlled mechanism for material
rejection handling.

PROCEDURE:
PART A: NON CONFORMITY PARTS AND MATERIALS FROM SUPPLIER

Inventory store in charge QA department QA dept.

Receiving Material inspection yard Audit of rejected material

Inventory/ IQC

Feedback to PPC/Souring

PART B: REJECTION ON THE PRODUCTION FLOOR

QC department Material department Audit team

Inspection on Material rejection and Audit of rejection
production floor requisition
IQC

Disposal of rejection/ scrap

 1.7) IQC REJECTION FLOW CHART

Local Return to supplier

Rejection
Import Claim Close

IQC

Quality Discuss solution Rejection Return

issue with supplier

After Import
Inventory Ok
rework material

Claim and adjust

cost of rejection
material
2. PROCESS
After the material is cleared by IQC, it is stored by inventory and then issued to the production line
according to the production plan made by PPC (Production and planning control). Processes that are
happening on the process line are as follows:

2.1) U-SHELL
U-Shell is made of CR (Cold rolled) sheet whose thickness varies from 0.6 mm. U-Shell is made on U-Shell
bending machine. Sheet metal processes that are happening on U-Shell bending machine are as follows:

2.1.1) NOTCHING

It is the process in which portion of metal is cut from the side of sheet or strip.

2.1.2) SEMI-NOTCHING

This process involves cutting of portion of metal from the inside of the sheet.

2.1.3) SLOTTING

This process involves punching rectangular holes in the sheet

2.1.4) PUNCHING

This process involves formation of holes in the sheet.

2.1.5) BENDING

1st bending is done on the side of the CR sheet and then bending of sheet is done at the end by U-Shell
bending machine to turn it into U shape material

2.1.6) HEMMING

This process involves bending of the sheet over on itself in more than one bending step. This is often
done to eliminate the sharp edge on the piece, to increase stiffness, and to improve appearance
2.2) EVAPORATOR
Evaporators are bent into the required shape according to Ref. and Freezer unit
Freezer evaporator is joined with Ref. evaporator and Capillary tube is brazed with freezer
evaporator line using Oxy-LPG brazing method
The joint is copper to copper joint.
After that nitrogen gas is filled to flush all the dust particles that could cause the blockage
Vacuuming is done
Now after vacuuming, helium is gas is filled in the evaporator.
Now the evaporator is passed through helium testing machine to check the leakage in
evaporator
Welding rod used has 94% copper in it
Distance between torch and joint is 25mm
Inside dia. of evaporator line is 7-8mm

2.3) CABINET THERMOFORMING

2.3.1) THERMOFORMING
Thermoforming is a process in which a flat thermoplastic sheet is heated and
deformed into the desired shape. Thermoforming consists of two main steps: heating and
forming. Heating is usually accomplished by radiant electric heaters, located on one or both
sides of the starting plastic sheet at a distance of roughly 125mm (5in). Duration of the heating
cycle needed to sufficiently soften the sheet depends on the polymerits thickness and color.
Methods by which forming is accomplished can be classified into three basic categories:

1- Vacuum Thermoforming
2- Pressure Thermoforming
3- Mechanical Thermoforming

Since Vacuum thermoforming is used here, so I will discuss vacuum thermoforming procedure
only.

2.3.1.1) VACUUM THERMOFORMING

Machine used for Cabinet thermoforming is COMI machine
It is completely automatic machine
Now to start a thermoforming process ABS sheet is placed in storage compartment of COMI
machine
This sheet is picked up and transferred to Pre-heating compartment where sheet is heated for
590 degree Celsius
Then sheet is transferred by transfer shoulder to heating compartment where radiant electric
heaters located on both sides of the sheet heat it up to 690 degree Celsius.
Now Thermoplastic material (ABS) is in between its Solidus and Liquidus region
 Now mold come close to the sheet and negative pressure is drawn by vacuum pumps through
the holes in the mold whose dia. is 0.8mm
Now sheet took the form of the mold, 8 blowers on the top of the machine are present that
automatically turn themselves on to cool the sheet.
Now air is pushed through the holes for detachment or mold releasing
Now the cabinet is again picked up by transfer shoulder and transferred to cutting area where
cutting of all of its sides is done and then it is transferred outside of the machine

In Cabinet thermoforming mold is preheated so that ABS sheet doesnt get stuck with it while
thermoforming. A separate circuit of water is used which is used to preheat the mold and when the
temperature of mold get past the required temperature, hot water supply to the mold is turned off by
the automatic valves and an alternative supply of cold water is turned on. Both these circuits of water
help us to maintain the temperature of mold according to our requirement.

2.4) CABINET PRE ASSEMBLY

In Cabinet Pre-Assembly, first of all slot is cut in cabinet of freezer compartment for the booster
line to pass and double tape is placed on the cabinet so that evaporator could perfectly stick
with it to perform its required function
Evaporator is placed over the cabinet and put it in the press machine for 16 sec so that
evaporator is completely joined with cabinet
After that booster line is placed in the slot of the freezer
Mid beam is placed to attach freezer and Ref. compartment
Drain pipe is placed
A small heater is placed on the evaporator tubes to take care the problem of defrosting
Harness cable and thermostat sensor tube is also placed
Now U-Shell is placed on top and sides of cabinet
Bottom quider is placed
Now it is turned over and arror plate is attached
Evaporator tube with capillary tube and booster line are passed through the holes of arror plate
A Khass-mass is placed so that evaporator line doesnt touch U-Shell and back panel. It avoids
formation of rust on tubes because of the moisture present
Now back panel is attached with body

2.5) CABINET AND DOOR FOAMING

The chemicals used for foaming process are:

1. Polyol
2. Iso-Cyanate
3. Cyclo-pentane
 Polyol and Cyclo-pentane are mixed with each other in the ratio of 8.3:1
They are then transferred here and stored in the container
Agitating motor is used to mix the mixture of Polyol and Cyclo-pentane
The pressure maintained in the container is 2-4 bar
Then this mixture of Polyol and Cyclo-pentane and Iso-Cyanate is transferred to the injection
head
Both of these come in different nozzles and then when the stroke is made they mix with each
other
The injection pressure is 110-150 bar
Ratio between Polyol and Iso-Cyanate is 1.28 for door and 1.26 for the cabinet
Mass flow rate for door is 490 g/s and for cabinet is 1400 g/s
The amount of injection of is different for different type of Refrigerators and Deep Freezer
Free rise density is calculated and it came out to be 24 kg/m3
Core density was calculated and it came out to be 37 kg/m3
Gelation time for the door foam was 50 sec and for the cabinet foam was 51 sec
Pouring temperature is 18-24 degree Celsius and it reaches up to 60 degree Celsius when it is let
to expand freely in an open air
After foaming jig is kept closed for about 6 min. This is called Curing time
Surface temperature of the jig is 35-50 degree Celsius
Surface temperature of the mold is 40-50 degree Celsius

2.5.1) FREE RISE DENSITY

Stroke of foaming material is made in polythene bag and it is allowed to expand freely and time is
noted down. After 51 sec it stops to expand freely. At this point its sample is taken and its density is
calculated which is mentioned in the table below:

Category Mass g Volume Density Gelation time

(m*1000) m3 Kg/m3 sec
D-1 2.10 86.22 24.35 51
D-2 2.07 85.7 24.15 51
C-3 2.56 105.15 24.34 52
C-4 3.59 149.02 24.09 52

2.5.2) CORE DENSITY

Core density is calculated by breaking the unit door and cabinet down and then calculating the
density of the sample taken which is mentioned in the table below:

S. no. Mass g Volume Core Density

(m*1000) m3 Kg/m3
1 3.47 92.51 37.50
2 3.55 93.93 37.79
3 3.77 98.08 38.43
4 4.18 108.10 38.66
2.6) BOOSTER LINE ASSEMBLY
Booster line is made up of Iron
Booster line is fitted inside a freezer compartment
High temperature high pressure gas flows through it from the compressor thus it doesnt allow
the door to get jammed during extreme cold condition
Heat sleeve is applied to that part only which is passing through Ref. compartment
Temperature standard for heat sleeve is 190 degree Celsius

2.7) DOOR THERMOFORMING

2.7.1) SHELLEY MACHINE

Door liner thermoforming is done on Shelley Machine
It is a semi-automatic machine
Four blowers are present on top of it for cooling of the liner
Difference between Shelley and COMI machine is that in Shelley machine ABS sheet is placed on
top of the jig by operator manually while in COMI machine it is automatically picked up by
transfer shoulder
Rest of the procedure is same as in COMI machine
Vacuum thermoforming is also done in Shelley machine similar to COMI machine. Procedure of
Vacuum thermoforming is mentioned in Cabinet thermoforming

2.8) DOOR BENDING

Sheet used for Doors of Ref. and DF is PCM (Paint Coated Material)

Following are the operations that are performed on door bending line:

2.8.1) SHEARING

In this process sheet of Refrigerator and Freezer compartment is separated from each other by the
shearing action and cut into two halves.
2.8.2) PUNCHING

In this process hole is punched into the Refrigerator sheet

2.8.3) BENDING

1st and 2nd bending of sheet is done at bending machine

2.8.4) NOTCHING

In this process slot from the side of sheet is cut

2.9) DOOR PRE-ASSEMBLY

After door bending, it is transferred in to door pre-assembly line
Here end cap is fitted on the door
Door lock are placed
Spunch is placed so that foaming material doesnt leak through the door
After that door is taken to door foaming machine, where foaming of door is done.
Procedure for door foaming is mentioned in section 2.5

2.10) GENERAL ASSEMBLY LINE

General assembly consists of two lines:

1- Front line
2- Back line

After foaming door is transferred to after foaming station where compressor mass is placed and body is
generally cleaned and then transferred to general assembly line

2.10.1) FRONT LINE

Thermostat is placed inside the cabinet and its connections are made with the harness cable
Lock hinge at the mid beam is placed
Vegetable box is placed and crisper plate is placed over it
Shelves are placed inside the cabinet
Gift box is placed
Doors of freezer and Ref. compartments are placed
Door handles are placed
2.10.2) BACK LINE

Compressor is placed
Drain pipe extension of freezer compartment is placed
Connection of harness cable with compressors are done
Gasket is placed and condenser is bolted to the body through that gasket

2.11) WELDING, VACUUMING AND GAS CHARGING

2.11.1) JOINING PROCESSES

Process of joining can be categorized in three different ways:

1- Welding
2- Brazing
3- Soldering

In brazing and soldering, base metal doesnt melt and joint is made by melting filler rod. While in
welding joint is made by melting the base metal and then filler metal is added to it to make the joint.

Brazing is used here so we will discuss the process of brazing only.

As in brazing and soldering base metals doesnt melt so the difference among them exists in working
temperatures. If the melting temperature of filler metal is greater than 450 degree Celsius and less than
melting point of base metal then this process is called brazing and if the melting temperature is less than
450 degree Celsius then it is called Soldering.

2.11.1.1) BRAZING
Brazing is a joining process in which a filler metal is melted and distributed by capillary action between
the faying surfaces of the metal parts being joined. No melting of the base metals occurs in brazing; only
the filler melts.

There are various methods used in brazing. Referred to as brazing processes, they are differentiated by
their heating sources. Torch Brazing is used here, so we will discuss the process of torch brazing only.

2.11.2.2) TORCH BRAZING

Neutral flame is used here for welding. In Neutral flame oxygen and LPG are used in 1:1
First of all, base metal is pre heated by using the inner cone of the neutral flame. Temperature
of the inner cone in neutral flame varies from 2500-3300 degree Celsius in Oxy-fuel welding
processes.
 After the work part joint surfaces are heated to suitable temperatures, filler rod is added to the
joint in the rod form and brazing is done by using the outer cone.
Before adding it to the joint first it is dipped in the flux bottle, where flux is present in the
powder form
Two types of filler rods are used here
Copper rod
Silver rod
Flux is used for silver filler rod only
Copper filler rod is composed of 94% copper and 6% phosphorus. So in copper rod phosphorus
serve as fluxing agent
Appropriate brazing temperatures of copper is 1120 degree Celsius and that of silver is 730
degree Celsius

Copper filler rod is generally used when base metal is copper and Silver filler rod is generally
used when base metal is titanium, Nickel, Steel etc. In our case silver rod is used when the base
is Mild steel because our condenser is composed up of Mild steel.
For
Welding

For
Brazing

Normally Acetylene, Hydrogen, MAPP (methyl-acetylene propadiene) are closely associated with
welding processes while on the other hand propane and natural gas are more closely associated
with brazing and soldering.

2.11.2) VACUUMING, GAS CHARGING, SAFETY AND LEAKAGE TESTS

After brazing, nitrogen is again charged in the system at a pressure between 0.7-0.8Mpa to
check the blockage and remove the dust particles
After that Helium is again charged in the system at a pressure of 6.18 bar and then leakage test
is done with the standard of the machine set at 2*10-7 mbar/s
After that Helium recovery is done at a pressure of 7 bar
After that all the brazed joints are cleaned with brush dipped in the hot water
Vacuuming of the whole system is done and this procedure takes 20 minutes
If the gauge pressure is between 0-5 Pa then the unit is considered vacuumed and the gas
charging of that unit is done
If the unit is not properly vacuumed the machine wont charge the refrigerant in it and rings the
alarm
After vacuuming, unit is charged with the refrigerant R134a
The amount charged is different for different units depending upon the model
 After the gas charging, drier filter tube is punched by using the Ultrasonic punching machine and
the punch thickness must be less than 1 mm
After that, five electrical safety tests are done
Electrical safety tests include
Earth resistance
Insulation resistance
Electrical strength
Startup with low voltage
Leakage current
After that again the leakage test of the unit is done to know that refrigerant is not leaking from
any joint

2.12) TESTING ROOM AND PACKING LINE

In testing room, cooling test of the unit is done
Two sensors are placed, one in Ref. compartment and one in the Freezer compartment
There cooling curves are observed from the system
Cooling test is done for 45 min
Cooling test standards for different units are different. One of them is given below:

Sr. no Ref. Model Freezer temp. Ref. Temp. Power Ambient

consumption temperature
range range
1 HRF-340M, -17.2130 C 19.413 0C 15010 watt 24-28 0C
342

After cooling system is transferred to packing line where cleaning of unit is done and then system is
packed into their cartons and they are sealed tight by packing strip

2.13) SAMPLE ROOM

Temperature in sample room is maintained at 43 0C to check the working of unit under extreme
conditioning. Following are tests done in sample room:

2.13.1) LOW VOLTAGE AUTO RE-STARTABILITY TEST

This test is done in order to check the auto restartability of unit for voltage fluctuation situations

2.13.2) PULL DOWN TEST

This test is done with or without load at continuous supply of 220 Volts. In order to check:
 1- Cooling test
2- Cooling depth
3- Auto-cutting of compressor

2.13.3) TEMPERATURE RISE TEST

This test is done in order to check:

1- Insulation strength
2- Performance at load shedding
3- Cooling speed

2.13.4) ON/OFF TEST

This test is done without load in order to check:

1- Compressor restart
2- Performance in load shedding condition

2.13.5) PULL DOWN TEST AT LOW AMBIENT

This test is done with or without load at continuous supply of 220 Volts at ambient temperature of 16 0C
in order to check the performance at low ambient

2.13.6) HIGH VOLTAGE TEST - WITHOUT LOAD

To check performance at high voltage keeping the ambient temperature 43 0C

2.13.7) LOW VOLTAGE TEST

To check performance at low voltage 170 Volts at 43 0C ambient temperature with and without load

2.13.8) ICE MAKING TEST

To check the making of ice at ambient temperature 43 0C. 4 liters of water should be converted into
ice.

2.13.9) COOLING TEST AT FULL LOAD

To check the cooling performance at full load in ambient conditions 43 0C
3. MARKET RETURN UNIT

3.1) PROCEDURE FOR THE CATEGORIZATION OF MARKET

RETURN UNITS BY HNR

3.1.1) PURPOSE
Its purpose is to implement smooth and controlled mechanism for categorization and sale of
market return and process defective units

3.1.2) SCOPE
The procedure is applicable on following departments:

QA HNR
Audit dept. HNR
Finance dept. HNR
Logistics dept. HNR

3.2) PROCEDURE: PART (A) MARKET RETURN UNITS

Units arrived to HNR after declared sale would be categorized as B+, B, C and D category

3.2.1) B+ CATEGORY
This category is based on the following problems:

Moisture problem
Any sale return made by product manager
Warehouse return unit
Discontinued model
Sale return made on no fault
Display units
Slightly yellow liner

3.2.2) B CATEGORY
This category is based on following problems:

body deformed
Low cool
Liner cracked (not repairable)
Rusted (repairable)
Sheet loose
3.2.3) C CATEGORY
This category is based on the following problems:

Internal leakage
System completely choked

3.2.4) D CATEGORY
This category is based on the following problems:

Completely rusted
Completely damaged

These kind of units are broken down for analysis and to study the root cause of the problem by QA
and R&D. Rest of the units are sold as per HNR policy.

3.3) PROCEDURE: PART (B) PROCESS DEFECTIVE UNITS

All those units that are not repairable in the process side will be considered into following
categories

3.3.1) MRU B CATEGORY UNIT

This category of units has following problems:

Liner yellow
Line cracked
Short foaming
Liner or body loose
R&D samples
HQ samples
SKD defective units
Any trial defective units

3.3.2) MRU C CATEGORY UNIT

This category of units has following problems:

Damage in process
Damage during trial production
Dummy units
Internal leakage
Body mid beam press
Liner press
Fins press
3.3.3) MRU D CATEGORY UNIT
All those cabinets and doors that are severely damaged during process would be considered in HNR
D category units

MRN will be made for the process related damages and process defective units (C and D) except the
B+ category units and submit it to inventory department