LEARNING & DEVELOPMENT SESSION

FOR PRODUCTION 2023

 Manufacturing section
In this session we will discuss the problems and their possible countermeasures of all
the stations of manufacturing side & related shops:
1) Thermoforming
2) CPA
3) Cabinet foaming
4) Paint plan
5) PIM
6) DPA
7) Press shop
 Cabinet Thermoforming Station
Sr. No Problem Possible Reasons Temporary countermeasure Permanent Remarks
countermeasure

1 Thickness 1. Heaters malfunction 1. Must check heater from the 1. Parameters record
problem in 2. Heaters design problem machine panel before starting can be made with
cabinets 3. Parameters issue production respect to ambient
4. Operator didn’t check 2. Regular production must not be temp, humidity etc.
5. QC person didn’t perform started until the required 2. Heaters of larger
FPI thickness is achieved in all areas size, smaller heaters
6. Wrong stacking, handling of cabinet recommended for
issue 3. Regular production must not be localized heating.
started until the problem is Better results can
resolved be obtained
4. Every piece cabinet/door must 3. Same as point 1
be checked by the production 4. Every operator
operator must be made
5. QC inspector will perform responsible for his
sampling of all the running production like QC
machines on hourly basis and person
will keep the signed sample on 5. FPI stands will be
the respective machine made for FPI
6. Minimum handling of cabinets 6. Standardization of
must be done, cabinets must stock areas
not be inserted into each other.
 Cabinet Thermoforming Station
Sr. Problem Possible Reasons
No
2 Moisture Placement of ABS sheets in
problem open environment for
extended time (depending
upon the humidity level) can
cause moisture problem
Temporary Permanent countermeasure Remarks
countermeasure
Accurate planning 1. Heating room can be made in order to
should be done in order increase the shelf life of ABS sheets up to 15-
to resolve this issue. 20 days in all ambient temperatures and
Extra sheets shouldn’t humidity levels.
be produced at extrusion 2. This will also help in cutting the operational
machine cost of extrusion machine as bulk production
can be done and machine can be turned off
for few days

3 Cabinet 1. Less thickness No rework must be done No rework must be done on cabinet liner for any
crack 2. Rework on cabinet liner on cabinet liner for any reason. If any rework needs to be done then must
problem 3. Chemicals used for reason. If any rework take the approval of concerned QA Engineer
cleaning of liner needs to be done then
must take the approval
of concerned QA
Engineer
 CPA
Sr. Problem Possible Reasons Temporary countermeasure Permanent countermeasure Remarks
No
1 Freezer 1. Manufacturing fault Freezer evaporator pressure Communication with supplier to improve
evaporator 2. Pressure check not done check must be done of every the quality of product & development of
plate leak at CPA plate & if pressure is less it alternate vendor
means there is leakage at some
point. In case of less pressure
issue these plates must be kept
separate for leak check with
nitrogen
 Cabinet Foaming Station
Sr. Problem Possible Reasons Temporary countermeasure Permanent countermeasure Remarks
No
1 Cabinet bottom 1. Jigs temperature are 1. Jigs temperature will be 1. Same as temp. countermeasure
pressing not ok verified on hourly basis by 2. Same as temp. countermeasure
problem/pressing 2. No holes in cabinet QC inspector 3. Design review especially in 2350
problem for air release 2. Holes in cabinet inner side cabinet
3. No hot melt (not visible) will be ensured
especially in 2350 by foaming QC inspector
cabinet 3. Hot melt must be placed on
4. Cabinet pressing bottom of 2350 cabinet to
from front side in counter this problem
2000 cabinet because
of cabinet thickness
less issue

2 Moisture problem 1. Cabinet foam weight

in cabinet less
2. Cabinet crack issue
3. Spot moisture
because of suction
pipe touching the
side panel