National Institute of Textile Engineering and Research (NITER)

Nayarhat, Savar, Dhaka

REPORT ON
Industrial Tour
Duration: 17th August 2023, 8:00 am-4.00 pm
with
Walton Hi-Tech Industries Limited
Kaliakoir, Gazipur

SUPERVISING TEACHER

Mahbuba Zannat
Lecturer
Department of Industrial and Production Engineering
National Institute of Textile Engineering and Research(NITER)
Nayarhat, Savar, Dhaka
Submitted By

Name Student ID Session

Afi Ahmad Emon IP 2105078 2020-21

 National Institute of Textile Engineering and Research
(NITER)
Nayarhat, Savar, Dhaka

Course Code: IPE 2208

Course Title: Industrial Tour

Supervising Teacher’s approval:

Supervisor:
Mahbuba Zannat
Lecturer, Department of Industrial and Production Engineering
National Institute of Textile Engineering and Research (NITER)

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 Acknowledgement

I am delighted to express my gratitude for the enriching experience during the Industrial Visit at
Walton Hi-Tech Industries Limited, organized as a vital academic function for the students of the
Industrial and Production Engineering Department at the National Institute of Textile
Engineering and Research (NITER). Heartfelt thanks to the honorable Director sir for granting
me the opportunity to explore the intricacies of industrial operations at Walton's Kaliakoir,
Gazipur facility. Special appreciation goes to our supervising teachers whose guidance was
instrumental in enhancing our understanding during the visit. My sincere thanks extend to the
entire management, administration, and personnel of Walton Group for their warm reception and
willingness to share insights. Lastly, I acknowledge the tireless efforts of the teachers at NITER,
especially the teachers who are related to this industrial visit, whose inspiration and support were
pivotal to the success of this educational endeavor. This industrial visit has undoubtedly
contributed significantly to my academic and practical knowledge.

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 Executive Summary

Summary of the Organization

Walton Hi-Tech Industries Ltd. is the one and only manufacturer of multi-staged
Refrigerator, Freezer, Air Conditioner, Television and Motorcycle technology and is
treated as one of the sophisticated manufacturing plants in Bangladesh and South Asia.
R.B. Group (Parent Company) is one of the top business groups in the country operating
with a great reputation since 1977.Walton has become a sensation in the arena of
Electronics, Electrical & Automobile industries & as signified as one of the top
manufacturing plants in Bangladesh & South Asia. Walton always emphasizes on
supreme priority to achieve customer satisfaction. It has a large sales & after sales service
network in home & abroad. Walton has achieved various standard quality certificates
including ISO 9001:2008 & ISO 14001:2004. Walton service network is the country’s
only ISO 9001:2008 Standard Certified after sales service network. The products of the
company have acquired a significant local market share and are also being exported
globally for its world class quality. Walton sets its vision to take a place among the top
Electronics, Automobiles, and Telecommunication Industries in the world by 2025. In a
nutshell, it has been vehemently proved that Made in Bangladesh is the mark of ultimate
confidence.
Company Name : Walton Hi-Tech Industries Limited
Manufacturing Plant (Factory): Walton Hi-Tech Industries Limited Chandra, Kaliakoir,
Gazipur, Bangladesh.
Type of Company : Public Limited Company
Year of Establishment: 1977
Commercial Production : April 02, 2008
Company Secretary : Partha Protim Das
FCS Products : Refrigerators & Freezers, Air Conditioners, Compressors, Television,
Electrical Appliances, and Home Appliances.
Upcoming Products : Lift & Elevator Annual production
Capacity: 10 million units Paid-Up Capital : 300 Crore
Net Asset Value Per Share : 138.53 (Without Revaluation), 243.16 (With Revaluation)
Different Departments: Administration, Engineering, Quality Assurance, Distribution,
Accounting. Human Resources, Service, Logistics, Inventory

The Major Activities During the Attachment Period

Scope - 1: Supervisor Md. Apel Mahmud, Head of Injection Molding at Walton
❖ Injection Mold Manufacturing
❖ Plastic Injection Process
❖ Part Handling and Assembling

Scope-2: Supervisor-Milon Kanti Raha, Head of Production(Thermoforming)

❖ Vacuum Forming Mold Manufacturing:
❖ Sheet Extrusion
❖ Vacuum Forming Process
❖ Part Handling and Assembling

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 Table of Contents

Contents Page No
Acknowledgement……………………………………………………………… 02
Executive Summary…………………………………………………………….. 03
CHAPTER ONE: Introduction 05
1.1 Description of Organization………………………………………………...
1.2 Remarks……………………………………………………………………..
CHAPTER TWO: Overview of the Production System……………………… 06-11
2.1 Brief description of the production system…………………………………. 06
2.2 Raw materials………………………………………………………………. 08
2.3 Production System …………………………………………………………. 09
2.4 Layouts of the Plant ………………………………………………………... 09
2.5 List of Machineries…………………………………………………………. 10
2.6 Production Flow Chart ……………………………………………………... 11

CHAPTER THREE:Procurement…………………………………………….. 13
3.1 Procurement Types and System ……………………………………………. 13
3.2 Storage and Shipment ……………………………………………………… 13
CHAPTER FOUR: Impact of the Internship…………………………………. 14
CHAPTER FIVE:Conclusion ………………………………………………… 15

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 List of Tables
3.1 Procurement Type and System…………………………………………………….. 13

List of Figures

2.1 Vacuum Forming Process Diagram ………………………………………………….. 07

2.2 Sheet Extrusion……………………………………………………………………… 07
2.3: Vacuum Forming Process……………………………………………………………. 08

List of Flow Chart

2.4: Refrigerator Assembly Line Process Flow Diagram…………………………. 10

2.5: Injection Mold Manufacturing Chart…………………………………………. 11
2.6: Vacuum Forming Process Flow Chart ……………………………………….. 12

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 CHAPTER ONE

Introduction

1.1 Description of the Organization

Founded in 2007, Walton Hi-Tech Industries Ltd. was established as a trailblazer in the
technology sector, with its presence firmly established in Chandra, Kaliakoir, Gazipur. A diverse
range of products, including Refrigerators, Televisions, Smartphones, and Industrial Solutions,
was placed under its umbrella, positioning Walton as a comprehensive tech industry leader.

One of the notable strengths of Walton was its substantial annual production capacity, standing at
an impressive 10 million units, flexibly adjusting to market demands. The company's expansive
physical infrastructure spanning 800 acres underscored its commitment to scalability and
innovation.

Walton's commitment to operational excellence was evident through its well-defined

departments, each playing a crucial role in the company's success. The Accounting, Credit,
Marketing, Audit, Inventory, and Administrative Departments were collectively contributing to
the smooth functioning of the organization, ensuring a holistic approach to business operations.

The efficient and effective management of Walton Hi-Tech Industries was reflected in its
strategic location, comprehensive product portfolio, and commitment to staying at the forefront
of technological advancements. This not only positioned Walton as an industry leader but also
underscored its role in shaping the future of technology. The company's dedication to excellence
was encapsulated in the simple yet powerful.

1.2 Remarks
● First Complete Manufacturing & Innovative Bangladeshi Company.
● Strong & Modern R&D Facilities.
● Strong Marketing & Distribution Network.
● Reliable & Efficient After Sales Services.
● Competent Technical Know-how.
● High Capital-Intensive Setup.
● Competitive Price Offering & Superior Quality Products.
● Market Pioneer & Leader in the industry.
● Brand – WALTON & MARCEL are the trusted & prestigious brands

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 CHAPTER TWO

Overview of the Production System

Although our final product is Refrigerator but we didn’t see the whole process of its
manufacturing. We experienced injection mold manufacturing and Thermoforming process.

2.1 Brief Description of the Production System

Injection Mold Manufacturing:Injection Mold Manufacturing is a precise and efficient method

used to produce a wide array of plastic components with intricate designs and shapes. This
process involves the creation of molds, typically made of steel or aluminum, into which molten
plastic is injected. The molds are custom-designed to match the specifications of the desired
product. This manufacturing technique is widely employed for its ability to produce high
volumes of consistent and detailed parts. It is commonly utilized in the production of various
items, ranging from small, intricate components to larger, more complex parts. The versatility
and accuracy of Injection Mold Manufacturing make it an indispensable method for creating
plastic products with a high level of precision and repeatability.

Plastic Injection Process:The Plastic Injection Process is a dynamic and versatile manufacturing
technique used to create a broad range of plastic products. It involves melting plastic resin and
injecting it into a mold cavity, allowing it to cool and solidify. This process is highly efficient for
mass production due to its ability to rapidly produce identical parts with high precision. The
versatility of the Plastic Injection Process allows for the creation of diverse products, including
consumer goods, automotive components, medical devices, and electronic parts. The method's
capability to handle various plastic materials and produce intricate designs makes it a preferred
choice for industries requiring cost-effective and high-quality plastic components.

Part Handling and Assembling Process:Part Handling and Assembling is a critical stage in the
manufacturing process that follows Injection Mold Manufacturing and the Plastic Injection
Process. This involves the careful handling, inspection, and assembly of the individual plastic
parts to create the final product. Automated systems and skilled assembly workers play a crucial
role in ensuring accuracy and efficiency during this stage. The process may include additional
steps such as quality control inspections, testing, and packaging. The meticulous attention to
detail in part handling and assembling ensures that the finished products meet the required
specifications, standards, and customer expectations. This stage is vital in achieving a seamless
and high-quality end result, ready for distribution and use in various industries.

Vacuum Forming Mold Manufacturing:In the realm of plastic manufacturing, Vacuum

Forming Mold Manufacturing is a crucial process that involves creating molds capable of
producing intricate and precise plastic shapes. These molds serve as the foundation for the
Vacuum Forming Process, ensuring the final products meet exact specifications. The precision

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and durability of these molds are paramount to the success of the entire manufacturing process.

Figure 2.1: Vacuum Forming Process Diagram

Sheet Extrusion:Sheet Extrusion is a versatile technique employed in plastic manufacturing to

create continuous sheets of plastic. This process involves melting raw plastic material and
shaping it into flat, uniform sheets. These sheets serve as the raw material for various
applications, such as packaging materials, signage, and construction components. Sheet
Extrusion ensures consistency in thickness and quality, providing a foundation for the subsequent
manufacturing processes

Figure 2.2: Sheet Extrusion

Vacuum Forming Process:The Vacuum Forming Process utilizes the molds created in Vacuum
Forming Mold Manufacturing to shape heated plastic sheets into desired forms. Through the
application of vacuum pressure, the softened plastic conforms to the mold, resulting in precise
and intricate shapes. This process is widely used in manufacturing products like plastic
packaging, trays, and custom-molded components for industries ranging from automotive to
consumer goods.

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 Figure 2.3: Vacuum Forming Process

Part Handling and Assembling Process: The Part Handling and Assembling process plays a
crucial role in bringing together the various components produced through Vacuum Forming.
This stage involves meticulous handling of molded parts and assembling them into final
products. Whether it's constructing complex plastic assemblies for electronic devices or crafting
functional components for industrial machinery, the Part Handling and Assembling process
ensures the seamless integration of individual parts into cohesive, high-quality products.

2.2 Raw Materials

I. Metals: Steel,aluminum and copper are used for the cabinet, compressor housing,
condenser coils, and other structural components.
II. Plastics: ABS plastic is commonly used for the interior lining, door panels, and handles
due to its durability and resistance to moisture.
III. Insulation Materials: Polyurethane foam or fiberglass insulation is used to maintain the
cold temperature inside the refrigerator.
IV. Refrigerants: Hydrofluorocarbons (HFCs) or other refrigerants are used to absorb and
transfer heat, creating the cooling effect.
V. Electrical Components: Motors, compressors, thermostats, and electrical wiring are
essential for powering and controlling the refrigeration process.
VI. Packaging Materials: Cardboard boxes, foam inserts, and protective wrapping are used
to safely transport and store refrigerators during shipping and distribution.These materials
are completely comes from recycling of internal wastes

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2.3 Production System:

I. Component Manufacturing:Component manufacturing is the process of creating

individual parts or components for a larger product or assembly. This can be done using a
variety of methods, such as machining, molding, casting, and forging.
II. Refrigerant System Assembly: A refrigerant system assembly is a group of components
that work together to cool or heat a space.
III. Electrical System Integration: Electrical system integration is the process of connecting
and configuring various electrical components and systems to ensure they work together
seamlessly. It involves a wide range of tasks, from planning and design to installation,
testing, and commissioning.
IV. Interior and Door Assembly:An interior door assembly is a framing system that
supports and surrounds an interior door. The assembly typically consists of a door jamb,
casing, and trim. It may also include a header and sill.
V. Testing and Quality Control: Testing and quality control (QC) are essential processes in
any industry that produces products or services. They help to ensure that products meet
customer requirements and specifications, and that they are safe and reliable.
VI. Packaging and Shipping:Packaging and shipping are two essential components of the
supply chain, ensuring that products are safely and efficiently transported from
manufacturers to consumers.

2.4 Plant Layout

Plant layout refers to the arrangement of physical facilities, such as machinery, equipment,
furniture, storage space, and material handling equipment, within a production facility. It is a
crucial aspect of manufacturing operations, influencing production efficiency, workflow
optimization, and overall cost-effectiveness.

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 Figure 2.4: Refrigerator Assembly Line Process Flow Diagram

2.5 List of Machinery:

1. Injection Mold Machine: An injection molding machine (IMM), also known as an

injection press, is a machine used to manufacture plastic products by the injection
molding process. It consists of two main parts, an injection unit and a clamping unit.
2. Thermoforming CNC Machine: A thermoforming CNC machine is a
computer-controlled machine used to shape thermoplastic materials into
three-dimensional objects. It is a versatile machine that can be used to produce a wide
variety of products, including packaging, automotive parts and medical devices.
3. Capillary tube cutter: A capillary tube cutter is a specialized tool used to precisely cut
capillary tubes, which are thin-walled tubes made from various materials like glass,
plastic, or metal. They are commonly used in scientific research, medical applications,
and industrial processes.
4. Digital clamp meter : A digital clamp meter is an electrical test tool that combines the
functions of a basic multimeter with a current sensor. It is used to measure electrical

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 current, voltage, resistance, and other electrical parameters. Clamp meters are particularly
useful for measuring current without the need to disconnect a circuit.
5. Vacuumed pump: A vacuum pump is a device that removes gas molecules from a
sealed volume in order to create a vacuum.
6. Rotary compressor: A rotary compressor is a type of positive displacement compressor
that uses rotating components to compress gas. It works by trapping gas in a small
volume and then reducing the volume of the space to compress the gas.
7. Condenser: A condenser is a heat exchanger that converts a gas into a liquid by
removing heat from it. This process is often used in refrigeration and air conditioning
systems to cool air or other fluids.
8. Helium leak check machine: A helium leak check machine is a device that detects and
measures leaks in sealed systems by using helium gas as a tracer.

2.6 Production flow chart:

Figure 2.5: Injection Mold Manufacturing

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Figure 2.6: Vacuum Forming Process Flow Chart

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 CHAPTER THREE

Procurement

Procurement is the acquisition of goods and services for an organization. It is a critical function
in any industry, as it ensures that the organization has the supplies and resources it needs to
operate effectively.Procurement is a complex process that requires a high level of expertise.
Procurement professionals must have a deep understanding of the organization's needs, as well as
the market for goods and services. They must also be able to negotiate effectively and manage
supplier relationships.Effective procurement can have a significant impact on an organization's
bottom line. By sourcing goods and services competitively, procurement teams can help to
reduce costs. They can also help to improve quality and reduce risk by working with qualified
suppliers.

3.1 Procurement Type and System

Table 3.1: Procurement type and System

Source Supplying Goods Type System

Korea, Japan Copper,Aluminium Import By cargo Plane or

Shipment

Korea Copper Pipe Import By cargo Plane or

Shipment

Germany,Korea Gas for Pipe Import By cargo Plane or

Shipment

Germany HIPS,Nano Import By cargo Plane or

Silver,Resin,Cyclo-Pentane Shipment

3.2 Storage and Shipment

The procurement raw materials are stored in the ground floor of the main building in the
procurement section. From here after sorting materials as per requirement, they are sent for
production. Then desired final products shipment or delivery to the customers or to custom port
or showrooms as per order via cargo or truck/mini truck.

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 CHAPTER FOUR

Impact of the Internship

The Industrial Visit to Walton Hi-Tech Industries Limited, organized as a crucial academic
function for the students of the Industrial and Production Engineering Department at the National
Institute of Textile Engineering and Research (NITER), had resulted in the acquisition of various
technical skills and qualifications by us. Insights into refrigerator products had been gained by
us, along with hands-on experience in plastic injection molding, sheet extrusion, vacuum
forming, and thermoforming related to refrigerator manufacturing. The diverse manufacturing
processes involved in refrigerator production had been actively observed and learned about by
us, and the different stages of the manufacturing process had been analyzed by us to identify
potential areas for improvement or optimization. Discussions with factory personnel had helped
gather information and clarify doubts regarding the manufacturing process by us. The attachment
had reinforced interest in production engineering by us and had provided valuable insights into
the practical application of theoretical concepts by us. The hands-on experience and technical
skills gained from the attachment had made us more competitive candidates for production
engineering positions. Furthermore, exposure to different manufacturing processes and the
understanding of inventory and marketing strategies had broadened our career prospects in
production engineering by us. The attachment had provided a platform to apply theoretical
knowledge learned in the classroom to real-world manufacturing scenarios by us. Our
understanding of production principles and the intricacies of refrigerator manufacturing had been
deepened by us. The exposure to current manufacturing practices and industry trends had helped
us identify areas for further learning and professional development by us. Similarities had been
found by us in some stages with the course Manufacturing Process-1, which is molding.

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 CHAPTER FIVE

Conclusion

The industrial attachment at Walton Hi-Tech Ltd. had an enriching experience that provided
valuable hands-on experience, technical knowledge, and process understanding . The exposure to
different manufacturing processes and the understanding of inventory and marketing strategies
had been broadened. The attachment reinforced interest in production engineering and provided
practical insights into the application of theoretical concepts. The knowledge and skills gained
during the attachment will undoubtedly benefit to the future endeavors in the field of production
engineering . Overall, the industrial attachment at Walton Hi-Tech Ltd.'s Fridge section had been
a valuable learning experience that enhanced employability and deepened understanding of
production principles and industry trends.

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