DESIGN AND MANUFACTURING OF SOLAR WATER

HEATER

A Project Report

By

Sumit Srivastava

Saba Siddiqui

Mohit Raj Mishra

Piyush Dubey

Manoj Kumar

Department of Mechanical Engineering

Shambhunath Institute of Engineering and Technology,

Allahabad

April, 2018
DESIGN AND MANUFACTURING OF SOLAR WATER
HEATER

A Project Report
submitted in partial fulfillment of the
requirements for the award of the degree

of

Bachelor of Technology

in

MECHANICAL ENGINEERING

By

Sumit Srivastava

Saba Siddiqui

Mohit Raj Mishra

Piyush Dubey

Manoj Kumar

Department of Mechanical Engineering

Shambhunath Institute of Engineering and Technology,

Allahabad

April, 2018
 CERTIFICATE

I hereby certify that the work which is being presented in the B.Tech. Project Report
entitled “DESIGN AND MANUFACTURING OF SOLAR WATER HEATER”, in partial
fulfillment of the requirements for the award of the Bachelor of Technology in Mechanical
Engineering and submitted to the Department of Mechanical Engineering of Shambhunath
Institute of Engineering and Technology, Allahabad, U.P. is an authentic record of my own work
carried out during a period from July 2017 to April 2018 under the supervision of Mr. Abhilash
Gupta, Asst. Professor, Mechanical Engineering Department.

The matter presented in this thesis has not been submitted by me for the award of any
other degree elsewhere.

Sumit Srivastava (1016240054)

Saba Siddiqui (1016240044)
Mohit Raj Mishra (1016240035)
Piyush Dubey (1016240038)
Manoj Kumar(1016240030)

This is to certify that the above statement made by the candidate is correct to the best of my
knowledge.

Date: Full Name & Signature of Project Supervisor

Head
Department of Mechanical Engineering
Shambhunath Institute of Engineering and Technology, Allahabad, U.P.
II
 ACKNOWLEDGEMENT

We take this opportunity to express my deep sense or gratitude and respect towards our
project guide Mr. Abhilash Gupta, Asst. Professor, Department of Mechanical
Engineering, SHAMBHUNATH INSTITUTE OF ENGINEERING & TECHNOLOGY,
Allahabad. We are very much indebted to him for the generosity, expertise and guidance.
We have received his valuable time and guidance while working on this project and
throughout our studies. He has guided us not only with the subject matter, but also taught us
the proper style and technique of working and presentation.

We wish to express profound gratitude to Mr. Ubaid Ahmad Khan, H.O.D of Mechanical
Engineering, SHAMBHUNATH INSTITUTE OF ENGINEERING & TECHNOLOGY,
Allahabad for his inspiration and guidance.

This work is the result of good support and guidance with facilities which were
provided to us by the Department of Mechanical Engineering. At last but not least, we want
to thanks all the members of the department who helped us towards the completion of our
project.

Sumit Srivastava (1016240054)

Saba Siddiqui (1016240044)

Mohit Raj Mishra (1016240035)

Piyush Dubey (1016240038)

Manoj Kumar (1016240030)

III
CONTENTS

Chapter No. Page No.

1. INTRODUCTION 01
2. ABCDEFGH 05
2.1NFDN 45
2.2 XZFDJ 60
3. XYZZXY 75
3.1 FGGJ KJDOGJK 77
3.2 SJJJSHJH 80
4. HGFGHFHGFFFHHJ 90
5. RESULTS AND DISCUSSION 95
REFERENCES 97

IV
 LIST OF FIGURES

Figure 1.1 Maintenance management System Process 05

Figure 2.1 Eight Pillars approach for TPM implementation (Suggested by JIPM) 18
Figure 2.2 Framework of TPM Implementation 20
Figure 2.3 Steinbach and Steinbach model of TPM implementation 23
Figure 2.4 Pirsig model of TPM implementation 24
Figure 3.1 transitivity link 34
ISM Model Showing the Levels of Total Productive
Figure 3.2 43
Maintenance Barriers
Figure 3.3 Cluster Formation by MICMAC Analysis 45
Figure 4.1 Grouping of TPMBs by judge 1 49
Figure 4.2 Grouping of TPMBs by judge 2 55

V
 LIST OF TABLES

Table 1.1 Organization of thesis 13

Table 2.1 Manufacturing Priorities TPM considerations 16
Table 2.2 Issues addressed by various TPM pillar initiatives 18
Table 2.3 Twelve-step TPM implementation methodology 21

Table 3.1 ISM as reported in the literature 31

Table 3.2 SSIM Matrix 32

Table 3.3 Initial Reachability Matrix 33
Table 3.4 Final Reachability Matrix 35
Table 3.5 List of Iterations 37
Table 3.6 Level of TPMBs 42
Table 4.1 Fundamental scale for judgment (saaty,2001) 50
Table 4.2 Random index (RI) for n=1 to 8 (saaty,1980) 52
Table 4.3 Random index (RI) for n=8 to 14 (saaty,1980 52
Table 4.4 pair-wise comparison scale for AHP preferences 54
Table 4.5 pair-wise comparison Matrix (for judge 1) 56
Calculations for priority weight (w) and Eigen Vector λmax(for
Table 4.6 57
judge-1)
Table 4.7 pair-wise comparison scale for AHP preferences 58
Table 4.8 pair-wise comparison Matrix (for judge 2) 60
Calculations for priority weight (w) and Eigen Vector λmax(for
Table 4.9 61
judge-2)
Table4.10 pair-wise comparison scale for AHP preferences 62
Table4.11 Relative weight of Each TPMBs 63
Table 5.1 Compression of results obtained by ISM and AHP 66

VI
LIST OF SYMBOLS, ABBREVIATIONS AND NOMENCLATURE

Management, Maintenance, and Material handling ( 3-M )

Analytic Hierarchy Process (AHP)
Condition Based Maintenance (CBM)
Consistency Index (CI)
Consistency Ratio (CR)
Cost of Ownership (COO)
Failure modes and effects analysis (FMEA)
Japan Institute of Plant Maintenance (JIPM)
Mean Time Between Failure (MTBF)
Mean Time to Repair (MTTR)
Morale (M), Return on Investment (ROI)
Multiple criteria decision-making (MCDM)
Overall equipment effectiveness (OEE)
Overall Plant Efficiency (OPE)
Priority weight (w), Productivity (P), quality (Q), cost (C), delivery (D), safety (S)
Random Index (RI)
Statistical Process Control (SPC)
Structural equation modeling (SEM)
Structural equation modelling (SEM),
Structural self-interaction matrix (SSIM)
Time Based Maintenance (TBM)
Total Effectiveness Equipment Performance (TEEP)
Total Productive Maintenance barriers (TPMBs)
Total Productive Maintenanceor (TPM)

VII
 Chapter-1

INTRODUCTION

In today’s manufacturing world and globalization policies have created a more intensive

competition amongst manufacturers. ………………………………………………………….

1
 Chapter-2

ABCDEFG HIJKLMNO

In today’s manufacturing world and globalization policies have created a more intensive
competition amongst manufacturers. ………………………………………………………….

2
 Chapter3

QWERTY UIOPAS

In today’s manufacturing world and globalization policies have created a more intensive
competition amongst manufacturers. ………………………………………………………….

3
 Chapter-4
SJKJKAJSKJSAAKSJ

We have consulted some experts from Indian engineering industries to discuss about the

contextual relationship among the RLBs identified from the literature review.

………………………………………………………………………………………………….

4
 Chapter -5

RESULTS AND DISCUSSION

5.1
[…………………………………………………………………………………
……………………….....discussion of result…………………………………
………………………………………………………………………………….]

5.2 Conclusion

5.3 Future Direction

5
 REFERENCES

1. AbdulrahmanMuhammad D ( 2012), “Barriers in implementing reverse logistics in

chinese manufacturing sectors: an empirical analysis”poms 23rd Annual Conference
Chicago, Illinois, U.S.A.

2. Fernández E, Kalcsics J, Nickel S, & Ríos-Mercado RZ (2010) A novel maximum

dispersion territory design model arising in the implementation of the WEEE-directive.
Journal of the Operational Research Society 61(3):503-514.

3. Gunasekaran A &Spalanzani A (2011) Sustainability of manufacturing and services:

Investigations for research and applications. International Journal of Production
Economics. doi:10.1016/j.ijpe.2011.05.011.

4. Jindal Anil & Singh KuldipSangwan(2011), “Development of an Interpretive Structural

Model of Barriers to Reverse Logistics Implementation in Indian Industry” Proceedings
of the 18th CIRP International Conference of Life Cycle Engineering, Germany, Springer
Verlag Berlin, 2011

5. Lai K.H. and Wong C.W.Y (2012). Green logistics management and performance: some
empirical evidence from Chinese manufacturing exports. Omega 40: 267-282.

6. Kumar D.S., Engg.Mechanics (5th edition), S.K.Kataria publications

7.Bhavikutti S.S., Engg.Mechanics (13th edition), New Age publications

8. www.ieee.com

9. www.Projecttopics.com

10. www.wikipedia.org

6
 GUIDELINES FOR B.TECH PROJECT
REPORT PREPARATION

Guidelines for preparation of Project Reports Preamble

The aim of this document is to present the basic guidelines on how a report should be
constructed for B.Tech project. Any student must confer to the rules and guidelines that
have been laid out in the following sections while writing their final report. It must also
be kept in mind that the soft copy of the report that any student prepares will also have to
be submitted in the institute library for future reference.

1. Organization of the Project Report

This project report shall be presented in a number of chapters, starting with Introduction
and ending with Summary and Conclusions. Each of the other chapters will have a
precise title reflecting the contents of the chapter. A chapter can be subdivided into
sections, subsections and sub subsection so as to present the content discretely and with
due emphasis. When the work comprises two or more mutually independent
investigations, the project report may be divided into two or more parts, each with an
appropriate title. However, the numbering of chapters will be continuous right through.

1.1 Introduction
The title of Chapter 1 shall be Introduction. It shall justify and highlight the problem
posed, define the topic and explain the aim and scope of the work presented in the project
report. It may also highlight the significant contributions from the investigation.

1.2 Review of Literature

This shall normally form Chapter 2 and shall present a critical appraisal of the previous
work published in the literature pertaining to the topic of the investigation. The extent
and emphasis of the chapter shall depend on the nature of the investigation.

1.3 Report on the present investigation

The reporting on the investigation shall be presented in one or more chapters with
appropriate chapter titles.
 Due importance shall be given to experimental setups, procedures adopted,
techniques developed, methodologies developed and adopted.
 While important derivations/formulae should normally be presented in the text of
these chapters, extensive and long treatments, copious details and tedious
information, detailed results in tabular and graphical forms may be presented in

7
 Appendices. Representative data in table and figures may, however, be included in
appropriate chapters.
 Figures and tables should be presented immediately following their first mention
in the text. Short tables and figures (say, less than half the writing area of the page)
should be presented within the text, while large table and figures may be presented
on separate pages.
 Equations should form separate lines with appropriate paragraph separation above
and below the equation line, with equation numbers flushed to the right.

1.4 Results and Discussions

This shall form the penultimate chapter(second last) of the project report and shall
include a thorough evaluation of the investigation carried out and bring out the
contributions from the study. The discussion shall logically lead to inferences and
conclusions as well as scope for possible further future work.

1.5 Summary and Conclusions

This will be the final chapter of the project report. A brief report of the work carried out
shall form the first part of the Chapter. Conclusions derived from the logical analysis
presented in the Results and Discussions Chapter shall be presented and clearly
enumerated, each point stated separately. Scope for future work should be stated lucidly
in the last part of the chapter.

1.6 Appendix
Detailed information, lengthy derivations, raw experimental observations etc. are to be
presented in the separate appendices, which shall be numbered in Roman Capitals (e.g.
“Appendix IV”).

8
 2 PROJECT REPORT FORMAT

2.1 Paper

2.1.1 Quality
The project report shall be printed on white bond paper, whiteness 95% or above, weight
70 gram or more per square meter (70gsm).
2.1.2 Size
The size of the paper shall be standard A 4; height 297 mm, width 210 mm.

2.1.3 Type Setting, Text Processing and Printing

The text shall be printed employing LaserJet or Inkjet printer, the text having been
processed using a standard text processor. The standard font shall be Times New Roman
of 12 pts. with 1.5 line spacing.

2.1.4 Page Format

The Printed Sheets shall have the following written area and margins:

Top Margin:1 inch

Bottom Margin:1 inch
Left Margin:1 inch
Right Margin:1 inch

2.1.5 Pagination
Page numbering in the text of the project report shall be Hindu Arabic
numerals(1,2,3…) at the center of the footer. The subsequent chapters shall begin on a
fresh page. Pagination for pages before the Introduction chapter shall be in lower case
Roman numerals, e.g., “ii”.

2.1.7 Paragraph format

Vertical space between paragraphs shall be about 2.5 line spacing

2.2 Chapter and Section Format

2.2.1 Chapter
Each chapter shall begin on a fresh page with an additional top margin of about 75mm.
Chapter number (in Hindu Arabic) and title shall be printed of font size (16pt) in bold
face using UPPERCASE. A vertical gap of about 25mm shall be left between the
Chapter number and Chapter title lines and between chapter title line and the first
paragraph.

2.2.2 Sections and Subsections

9
A chapter can be divided into Sections, Subsections and Sub subsections so as to present
different concepts separately. Sections and subsections can be numbered using decimal
points, e.g. 2.2; 2.3; 2.2.1; 2.2.2

2.2.3 Table / Figure Format

Small size table and figures (less than half of writing area of a page) should be
incorporated within the text, while larger ones may be presented on separate pages. Table
and figures shall be numbered chapter wise. For example, the fourth figure in chapter 5
will bear the number Figure 5.4. Table number and title will be placed above the table
while the figure number and caption will be located below the figure. Reference for Table
and Figures reproduced from elsewhere shall be cited in the last and separate line in the
table and figure caption.

3 Auxiliary Formats

3.1 Binding
The evaluation copies of the project report may be hard bound with black Rexene cover.
The final hard bound copies to be submitted before the viva voce examination .

3.2 Front Covers

The front covers shall contain the following details:
 Full title of project report in 6 mm 22 point's size font properly centered and
positioned at the top.
 Full name of the candidate in 4.5 mm 15 point's size font properly centered at the
middle of the page.
 A Institute emblem (logo) followed by the name of department, name of the
Institute and the year of submission, each in a separate line and properly centered
and located at the bottom of page.

3.2.1 Lettering
All lettering shall be embossed in gold.
3.2.2 Bound back
The degree, the name of the candidate and the year of submission shall also be embossed
on the bound (side) in gold.
3.3 Blank Sheets
In addition to the white sheets (binding requirement) one white sheets shall be put at the
beginning and the end of the project report
3.4 Title Sheet
This shall be the first printed page of the project report and shall contain the submission
statement: the Project Report submitted in partial fulfilment of the requirements of the

10
Degree B. Tech, the name and Roll No. of the candidate, name of the Supervisor,
Department, Institute and year of submission. Sample copy of the 'Title Sheet' is
appended .

3.5 Contents
The contents shall follow the Abstract and shall enlist the titles of the chapters, section
and subsection using decimal notation, as in the text, with corresponding page number
against them, flushed to the right.

3.5.1 List of Figures and Tables

Two separate lists of Figure captions and Table titles along with their numbers and
corresponding page numbers against them shall follow the Contents.

3.9 Abbreviation Notation and Nomenclature

A complete and comprehensive list of all abbreviations, notations and nomenclature
including Greek alphabets with subscripts and superscripts shall be provided after the list
of tables and figures. (As far as possible, generally accepted symbols and notation should
be used). Auxiliary page from dedication (if any) to abbreviations shall be numbered
using Roman numerals in lower case, while the text starting from the Introduction shall
be in Hindu Arabic. (The first pages in the both the cases shall not bear a page number).

11
 Salient Points For Preparing Project Report

1. Project report should contain minimum 100 pages with hard binding having black Rexene
cover.

2. All pages of Project report must be in portrait layout.

3. The main heading should be of font size 16 with bold style and without underline.

4. The sub-heading should be of font size 14 with bold style and without underline.

5. The content should be of font size 12 in Times new roman.

6. The main heading should be written with right justification.

7. The sub-heading should be written with left side justification.

8. The matter of each page should be written with both side justification.

9. The margin (Top/Bottom;Left/Right)of each page should be standard (by default margin).

Top Margin: 1 inch

Bottom Margin: 1 inch
Left Margin: 1 inch
Right Margin: 1 inch

10. Do not use border for any page.

11. Do not use any funny symbols or design.

12. Only relevant figures should be attached, do not attach unnecessary figures.

13. All pages should be in black in white including cover page.

14. Insert page no. at bottom center of each page excluding cover page, certificate and
contents.

15. Start each sentence with capital letter.

16. The main heading should be written in UPPERCASE and the sub-headings are written in
lowercase.

17. The line spacing should be 1.5.

18. Pagination for the pages before introduction should be in lower case roman (e.g. i, ii,iii….)

12
19. Pagination for the pages after introduction should be in hindu- Arabic numerals (e.g. 1, 2,
3…..)

The report should be arranged in following order:

COVER PAGE

(i) CERTIFICATE

(ii) ACKNOWLEDGEMENT

(iii)CONTENTS

(iv) LIST OF FIGURES

(v) LIST OF TABLES

(vi) LIST OF SYMBOLS, ABBREVIATIONS AND NOMENCLATURE

CHAPTER:1 INTRODUCTION

CHAPTER:2 FGHHJJJJJKKK

CHAPTER:3 FHJHJKJFJJJ

CHAPTER:4 FHJHJKJFJJJ

CHAPTER:5 RESULTS AND DISCUSSION

REFERENCES

APPENDIX (if any)

Note: Project report must contain 5 chapters. The first chapter of report should be
INTRODUCTION and the last chapter should be RESULTS AND DISCUSSION. Content
for Chapter-2, Chapter-3 and Chapter-4 will depend upon the project.

13
 List of Faculty Members of Mechanical Engg. Dept.

S.No. Name Designation

1. Mr.Ubaid Ahmad Khan Head of the Department
2. Dr.Anshuman Srivastava Professor
3. Mr.Ashish Kumar Srivastava Associate Professor
4. Mr.Ashutosh Chandra Sharma Associate Professor
5. Mr.Sushil Kumar Singh Associate Professor
6. Mr.Amit Kumar Singh Asst.Professor
7. Ms.Aanchal Yadav Asst.Professor
8. Mr.Vikas Gupta Asst.Professor
9. Mr.Krishna Kumar Shukla Asst.Professor
10. Mr.Abhilash Gupta Asst.Professor
11. Mr.Zeeshan Nusrat Asst.Professor

14