Air Conditioner Division

Presentation on:

SERVICE & QUALITY

OUTLOOK
 Index
• Details to Verify.
• Description & Details Section.
• Received Samples Analysis.
• Analysis And Counter-Measures.
• Monthly FCR Analysis- Oct’13.
• SDR Mapping & Job Card Filling.
• Defective Component Checking Methods.
• Material Handling.
 Details to Verify
Customer Name, Address, Tel No , Mobile No
Verify Customer Details

Technical Problem or Explanation

Call type repair / Demo

 Exact Model no & Set Serial No (From ID Label),

Verify Set Details Purchase Date, Warranty Status (I,O,A,E,P)

Corresponding matching Symptom code

Check actual Symptom

To get first hand information of failure while attending

Enquire with Customer call

SVC Engineer analysis/opinion

Find reason of failure

To decide the best suitable Defect Code

Check other conditions also

 Choose best suitable repair code & Mention exact

Exact Action Taken details/Additional Q Information in Remarks to VIL
 Details to Verify
J/Sheet data & Data entered in System must Match
System entry as per J/Sheet
Verify if codes / Data written on J/Sheet is correct
Information on J/Sheet If not correct inform Engineer about the correction
Engineer to take care in future

Parts, Defect Tag & system information must match

Information on Defective Tag Part must match with that particular claim
No mixing of part with other claim having same part

Defective parts Re verification Need to verify the failure of major parts

1. ASC Name, City

Defect Tag 2. Branch
3. Part No & Name
4. Claim No
1~10 Item : To be filled by ASC
5. Model No.
Minimum 6. Set Serial No. Engineer.
*Defect Tag Defective Tag Information 7. Date of Purchase 11th Item : To be filled by
Information Common Format required on 8. Date Of Repair Branch Store person
All India 9. Defect observed (after verification)
Tag 10.Engineer Name,Mobile
11.Receipt No.
 Description & Details
General Remarks Quality Information Required
•Adjustment done set ok • Actual item/ Part / Parameter adjusted
•Gas leakage from flare nut with details, Leakage point, sub part
• Wiring Adjusted. failure.
•Other Repair • What Adjusted?
•Internal adj done • What Setting done??
•External adj done • What did to make set ok
•Wiring done, set ok • What happen to wiring. (rat bite of
•Wiring adj done something else, mention)
•Part replaced set ok • Parts manufacturer name like Kohsan
•Wrong installation Coil
No Information
•Set ok…………………. • What wrong installation, what did
• Cancel such calls if there is no problem?
•Explanation given • What function explain
 Received Sample Analysis & Problems
As per list Actual Ok for ok Rej.
Component Qty testing Remark
qty(no's) (no's) (no's)
(no's) (no's)

1)Suction & discharge open qty: 54

no's
Comp. 460 460 44 0 460
2)Suction & discharge direct seal
qty: 31 no's

One coil not videocon model, leak

Al. Coil 7 7 0 0 7
coil having damage mark.

2 NO’S not videocon model

Motor O/D& I/D MOTOR 37 37 0 0 37 Motor wire cut 8nos,11 no’s w/o
tag, Remaining rusty & shaft jam.
 1. COMPRESSORS:
Tag missing
Sr. No. Defect Details Comp. Qty
1 Accumulator pinched 4
2 Terminal Burst 74

Tag not readable 3 Ground Fail 38

4 High Current 85
5 Not start 23
6 Open 55
Accumulator cut
7 Port seal 159
8 T.C. Damaged 22
  Total qty no's 460
Direct port seal
1)Terminal damage +Direct port seal qty 181
no’s which can’t check.
Accumulator 2) Tag missing qty 4 no’s
pinched 3) Tag not readable 268 no’s
 2. CONDENSER COIL:

Qty
This coil not Sr. No. Coil Defect details (No's)
videocon model
Not as per Videocon
1 model coil 1

2 Leak 6

  Total Qty 7

Remark: All field leak coil found

damage at leak location
Field return
item packing
condition not
proper
 3. ODU/IDU MOTORS:

Motor Wire Motor

cut in received Sr. No. Defects Qty (No's)
condition 1 Wire cut 8
2 Shaft rusty 14
3 Jam 12
4 Not working 3
   Total qty 37

Remark :
1) 2 no's motor not videocon model
2) 11 no's motor tag missing
These motors 3) 8 No's can't check due to wire cut
are not
videocon
model
 Analysis & Counter Measures
Defect Name Counter-Measures
Group Sub-Group Factory Photos
Analysis done.
1. Flare Nut No defect found.
Ser. Remarks req.

2. Other Repair Ser. Remarks req.

Gas Leakage

3.Suctn jt. leak

Additional HLD added

after performance test.
4. Brazing jts. leak
 Analysis & Counter Measures
Defect Name Counter-Measures

Group Sub-Group Factory Photos

New vendor ‘Pranav

1. Internal Leakage Vikas’ has been
developed.

Condenser
Coil
2. Inlet/Outlet Joint Additional HLD added
Leakage. after performance test.
 Analysis & Counter Measures
Defect Name Counter-Measures

Group Sub-Group Factory Photos

1. Main winding 1. Cut open analysis

burn. done.

2. New vendor ‘GMCC’

2. Intermittent has been
Compressor dead. developed.
Defective
3. Accumulator
3. Noise. position changed
(30⁰) which
eliminates the
4. Dead incorporation of
adapter plate.
 Analysis & Counter Measures
Defect Name Counter-Measures

Group Sub-Group Factory Photos

1. New type of motor

1. Fan motor noise. bushes are
developed so as to
Fan Motor accumulate the
Noise 2. Fan motor undesired noise.
defective.

2. New vendor
‘Butterfly’ has been
developed
 Monthly FCR Analysis- Oct’13
Total Calls Calls Registered
Registered till Sept.- During October-
13 13

H C S H C S

3867 2402 1049 389 28 169

6

Total = 7318 Total = 875

SDR Mapping & Job Card filling

Service training
 Checking Method: Motor
1) Wire Status :Check Is any wire comes out from connector ,
Is wire anywhere cut .
2) Capacitor status :With multi meter, Check the Capacitance
value of capacitor between capacitor Common & F terminal .
Capacitor Value :2.5 μ F .

3) Motor Winding Resistance

Vendors Black Red Black blue* Red blue*

HAIR/ 123Ω 98Ω 194 Ω
BUTTERFLY

4) Shaft Jam in Bearing :After removing motor from m/c, rotate the motor
Shaft with hand & Check whether the motor jammed or rotates with any noise .

5) Shaft of motor
After removing motor from m/c pull the shaft upward to check
play of shaft Play should not be more than 3 mm.
 Checking Method: Compressor
1) Capacitor :With multimeter Check the Capacitance
value of capacitor between capacitor common & H
terminal: 35 μ F (Depend on compressor model)

2) Ground checking :
After removing compressor, check body to terminal
resistance it should be zero.

3) Comp. Resistance Method:

Compressor CR(Ω)5% CS(Ω)±5%

model
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PowerPoint Presentation
4) PUMPING CHECKING : Check compressor pumping by give electrical
supply through Capacitor to compressor put thump on suction tube it sucking
inner side it means pumping is OK.
 Checking Method: Condenser

•Seal one side inlet or

outlet of coil.
•Fill HP(300psi) Air / N2
in the coil.
•Dip that coil in fresh
water tank.
•Even a Minor leak is
detected by this method.
Material Handling: MOTORS
Basic Requirements :
1) Resistance of Winding Should be OK.
2) No wire cut or No any mechanical damage to motor .
3) Rotor should not jammed.
4) Use of only rated Capacitor.
5) Motor wires should be covered with specified length sleeve.
Handling :
1) Should not lift with wire. should not drop from height.
Storage:
1) Should not storage in single bin. Separator needed between two motors .

Do’s Don’t
Material Handling: COMPRESSORS
Basic Requirements :
1) No Ground fail.
2) Accumulators tubing should not Damage .
3) Compressor suction & discharge should be seal with copper tubing .
4) Component with proper filled tag, Tag should be readable.
Handling
1) Should not direct port seal .
2) Should not drop from height.
3) Should not pinched actuator, terminal, leg, suction, discharge, cap shaft .
Storage
1) Should not storage in single bin. Packed in Single box with Cushing
Do’s Don’t
Material Handling: COIL
Basic Requirements :
1) Inlet & outlet should be proper position .
2) Each coil having no damage during removing from unit.
Handling
1) Should not lift with inlet & outlet .
2) Should not drop from height.

Storage
1) Store in proper size box with partition .
2) All coil inlet & outlet should be seal by bush .

Do’s Don’t
 Thank You

Queries…???