Name: Jai Trivedi

Sap ID: 60005200036

Batch: M12
Subject: PPC

Experiment No: 03 Date: 07/10/23

Aim: To study Capacity Utilization using a real-life example and forecast the
demand/sale of the Company/Organization.
Theory: Capacity planning is the process of determining the production
capacity needed by an organization to meet changing demands for its products.
In the context of capacity planning, the capacity is the maximum amount of
work that an organization is capable of doing in a given period of time. There
are three basic steps of capacity planning: determination of service level or
production level requirements, analysis of the current capacity of the
organization and planning for the capacity required in future.
Capacity Utilization Table:
2021 2022 2023 2024 2025
Demand 144 115 152 144 169
Each Machine Capacity 100 100 100 100 100
No. of Machines Available 4 4 4 4 4
Total Capacity 400 400 400 400 400
HVAC
No. of Operators on each machine 4 4 4 4 4
Unit
Capacity Utilization 0.36 0.2875 0.38 0.36 0.4225
% Capacity Utilization 36 28.75 38 36 42.25
Machines Required 1.44 1.15 1.52 1.44 1.69
Operators Required 5.76 4.6 6.08 5.76 6.76
Table 1.0: Capacity Utilization Table

The above table 1.0 shows the capacity utilization of manufacturing of HVAC
Units by a company.
Manufacturing of HVAC Units:
1. Creating encasement parts from galvanized sheet metal and
structural steel:
Most air conditioners start out as raw material, in the form of structural
steel shapes and sheet steel. As the sheet metal is processed into
fabrication cells or work cells, it is cut, formed, punched, drilled, sheared,
and/or bent into a useful shape or form. The encasements or wrappers, the
metal that envelopes most outdoor residential units, is made of galvanized
sheet metal that uses a zinc coating to provide protection against
corrosion. Galvanized sheet metal is also used to form the bottom pan,
Name: Jai Trivedi
Sap ID: 60005200036
Batch: M12
Subject: PPC

face plates, and various support brackets throughout an air conditioner.

This sheet metal is sheared on a shear press in a fabrication cell soon after
arriving from storage or inventory. Structural steel shapes are cut and
mitered on a band saw to form useful brackets and supports.

2. Punch pressing the sheet metal forms:

From the shear press, the sheet metal is loaded on a CNC (Computer
Numerical Control) punch press. The punch press has the option of receiving
its computer program from a drafting CAD/CAM (Computer Aided
Drafting/Computer Aided Manufacturing) program or from an independently
written CNC program. The CAD/CAM program will transform a drafted or
modelled part on the computer into a file that can be read by the punch press,
telling it where to punch holes in the sheet metal. Dies and other punching
instruments are stored in the machine and mechanically brought to the
punching arm, where it can be used to drive through the sheet. The NC
(Numerically Controlled) press brakes bend the sheet into its final form,
using a computer file to program itself. Different bending dies are used for
different shapes and configurations and may be changed for each
component. Some brackets, fins, and sheet components are outsourced to
other facilities or companies to produce large quantities. They are brought to
the assembly plant only when needed for assembly. Many of the brackets are
produced on a hydraulic or mechanical press, where brackets of different
shapes and configurations can be produced from a coiled sheet and unrolled
continuously into the machine. High volumes of parts can be produced
because the press can often produce a complex shape with one hit.

3. Cleaning the Parts:

4. All parts must be completely clean and free of dirt, oil, grease, and
lubricants before they are powder coated. Various cleaning methods are
used to accomplish this necessary task. Large solution tanks filled with a
cleaning solvent agitate and knock off the oil when parts are submersed.
Spray wash systems use pressurized cleaning solutions to knock off dirt
and grease. Vapor degreasing, suspending the parts above a harsh
cleansing vapor, uses an acid solution and will leave the parts free of
petroleum products. Most outsourced parts that arrive from a vendor have
already been degreased and cleaned. For additional corrosion protection,
many parts will be primed in a phosphate primer bath before entering a
drying oven to prepare them for the application of the powder coating.
Name: Jai Trivedi
Sap ID: 60005200036
Batch: M12
Subject: PPC

5. Powder Coating:
Before brackets, pans, and wrappers are assembled together, they are fed
through a powder coating operation. The powder coating system sprays a
paint-like dry powder onto the parts as they are fed through a booth on an
overhead conveyor. This can be done by robotic sprayers that are
programmed where to spray as each part feeds through the booth on the
conveyor. The parts are statically charged to attract the powder to adhere to
deep crevices and bends within each part. The powder-coated parts are then
fed through an oven, usually with the same conveyor system, where the
powder is permanently baked onto the metal. The process takes less than 10
minutes.

6. Bending the tubing for the condenser and the evaporator:

The condenser and evaporator both act as a heat exchanger in air
conditioning systems and are made of copper or aluminium tubing bent
around in coil form to maximize the distance through which the working
fluid travels. The opposing fluid, or cooling fluid, passes around the tubes as
the working fluid draws away its heat in the evaporator. This is
accomplished by taking many small diameter copper tubes bent in the same
shape and anchoring them with guide rods and aluminium plates. The
working fluid or refrigerant flows through the copper tubes and the opposing
fluid flows around them in between the aluminium plates. The tubes will
often end up with hairpin bends performed by NC benders, using the same
principle as the NC press brake. Each bend is identical to the next. The
benders use previously straightened tubing to bend around a fixed die with a
mandrel fed through the inner diameter to keep it from collapsing during the
bend. The mandrel is raked back through the inside of the tube when the
bend has been accomplished. Tubing supplied to the manufacturer in a coil
form goes through an uncoiler and straightener before being fed through the
bender. Some tubing will be cut into desired lengths on an abrasive saw that
will cut several small tubes in one stroke. The aluminium plates are punched
out on a punch press and formed on a mechanical press to place divots or
waves in the plate. These waves maximize the thermodynamic heat transfer
between the working fluid and the opposing medium. When the copper tubes
are finished in the bending cell, they are transported by automatic guided
vehicle (AGV) to the assembly cell, where they are stacked on the guide rods
and fed through the plates or fins.
Name: Jai Trivedi
Sap ID: 60005200036
Batch: M12
Subject: PPC

7. Joining the copper tubing with the aluminium plates:

A major part of the assembly is the joining of the copper tubing with the
aluminium plates. This assembly becomes the evaporator and is
accomplished by taking the stacked copper tubing in their hairpin
configuration and mechanically fusing them to the aluminium plates. The
fusing occurs by taking a bullet, or mandrel, and feeding it through the
copper tubing to expand it and push it against the inner part of the hole of the
plate. This provides a thrifty, yet useful bond between the tubing and plate,
allowing for heat transfer. The condenser is manufactured in a similar
manner, except that the opposing medium is usually air, which cools off the
copper or aluminium condenser coils without the plates. They are held by
brackets which support the coiled tubing, and are connected to the
evaporator with fittings or couplings. The condenser is usually just one tube
that may be bent around in a number of hairpin bends. The expansion valve,
a complete component, is purchased from a vendor and installed in the
piping after the condenser. It allows the pressure of the working fluid to
decrease and re-enter the pump.

8. Installing the pump:

The pump is also purchased complete I h from an outside supplier. Designed

to increase system pressure and circulate the working fluid, the pump is
connected with fittings to the system and anchored in place by support
brackets and a base. It is bolted together with the other structural members of
the air conditioner and covered by the wrapper or sheet metal encasement.
The encasement is either riveted or bolted together to provide adequate
protection for the inner components.
Name: Jai Trivedi
Sap ID: 60005200036
Batch: M12
Subject: PPC

Machines Required:
Bite Machine - Press the metal sheet into a special shape so that the parts can be
locked together to form a solid part that will not be easily separated.

Flange forming machine - a flange, which allows rapid connection and

disassembly of pipe parts. Flange forming machine stamps metal sheet into the
flange.

Flanging Machine - Used to bend metal sheets into desired shapes.

Hydraulic Shearing Machine - Use hydraulic pressure sheet to cut metal plate.

Hydraulic rack - used to store and transport metal sheets or coils.

Hydraulic rivet pliers - This is the protruding part used to remove damaged
rivets.

Pian Samsung Roller - can be used for conveying pipes, metal rods, metal
plates, etc., and bend continuously at a specific angle.

Ventilation pipe seaming machine - only need to put the completed duct into the
vertical seaming machine, can complete the last step of the duct - seaming.

Round elbow biting machine - making elbow for round pipe biting joint. The
same machine can bite or close.

CNC plasma cutting machine - used for cutting specific shapes from metal
sheets.

Spiral air duct machine - used to make metal strips into spiral tubes, change
different sizes of die to form different sizes of circular tubes, so that the size of
air duct is more precise and uniform, the size of pipe is stable, sealing
performance and forming effect is good, and the forming process is more stable
and fast.

Fully automatic air duct production line - an integrated air duct production line
composed of multiple systems, which can automatically manufacture air ducts.
Name: Jai Trivedi
Sap ID: 60005200036
Batch: M12
Subject: PPC

The production speed can be adjusted by processing air ducts of different sizes,
shapes, and specifications according to the demand.
Type of Labour Required: Skilled labour is required in order to handle such
machinery and conduct the periodic maintenance as well as intermediate
overhaul maintenance of the machineries.

Quality Control Test: Quality of the individual components is always checked

at various stages of the manufacturing process. Outsourced parts must pass an
incoming dimensional inspection from a quality assurance representative before
being approved for use in the final product. Usually, each fabrication cell will
have a quality control plan to verify dimensional integrity of each part. The unit
will undergo a performance test when assembly is complete to assure the
customer that each unit operates efficiently.