TABLE OF CONTENTS

LIST OF CHARTSi LIST OF DIAGRAMS...ii

CHAPTER

TITLE

PAGE NO

INTRODUCTION 1.1 PROFILE OF THE ORGANISATION 1.2 HISTORAL OVERVIEW 1.3 WHIRLPOOL CORPORATION TODAY 1.4 UNIT PROFILE - PUDUCHERRY

II

CORPORATE VISION AND STRATEGY 2.1 WHIRLPOOL VISION 2.2 WHIRLPOOL MISSION 2.3 OBJECTIVES OF THE COMPANY

III

PRODUCTS MANUFACTURED 3.1 PRINCIPAL PRODUCTS 3.2 KITCHEN AID PRODUCTS

IV

DEPARTMENTS AT WHIRLPOOL

4.1 ACCOUNTS DEPARTMENT 4.2 SERVICE DEPATMENT 4.3 SALES DEPARTMENT 4.4 HUMAN RESOURCE DEPARTMENT 4.5 PERSONNEL DEPARTMENT V MANUFACTURING PROCESS 5.1 INTRODUCTION 5.2 RAW MATERIALS 5.3 PROCESS UNDERGONE VI FINANCIAL STATEMENT 6.1 PROFIT AND LOSS A/C 6.2 BALANCE SHEET 6.3 RATIOS VII CONCLUSION

LIST OF CHARTS

CHART NO

PAGE

PARTICULARS

NO

HUMAN RESOURCE ORGANISATION CHART OF WHIRLPOOL - PONDICHERRY

ORGANISATIONAL STRUCTURE OF WHIRLPOOL PONDICHERRY

LIST OF DIAGRAMS

TABLE NO

PAGE

PARTICULARS FABRICATION OF SHEET METAL

NO

VIEW OF A SPIN TUB

FULLY ASSEMBLED WASHING MACHINE

CHAPTER I

INTRODUCTION

1.1

PROFILE OF THE ORGANISATION

Whirlpool Corporation is the worlds leading manufacturer and marketer of major home appliances. The company manufactures in 13 countries on 4 continents namely :-- Canada, United States, Mexico, Argentina, Brazil, Slovakia, Germany, Sweden, France, Italy, South Africa, China and India and markets products in more than 170 countries under major Brands (26 including Affiliates) names such as Whirlpool, Kitchen Aid, Roper, Estate, Bauknects, Ignis, Laden, Inglis, Braotemp, Crolls, Acros and Consul. Whirlpool is also the principal supplier to Searo, Roebuck and company of many major home appliances marketed under the Kenmore brand names. Head

quartered at Benton Harbour, Michigan, U.S.A, Whirlpool Corporation is the worlds leading manufacturer and marketer of major home appliances. Washing Machines, Dryer, Dish-washers, Refrigerators, Freezers, Cookers, Micro-wave Ovens, Room air-conditioners, Small Kitchen Appliances, etc.

Whirlpool of India Limited, a fully owned by Whirlpool Inc, US, ($12 billion), a leading global consumer durable player. Whirlpool of

India limited manufactures and markets refrigerators and washing machines. The company has diversified its product range into Air Conditioners and Microwave Ovens. The growth in the consumer durable industry has slowed down due to lack of demand. The year 2000 has been a bad year for the industry as the overall growth was flat. The refrigerators registered a flat growth; washing machines saw a negative growth while the air conditioner segment performed well exhibiting a growth rate of 20%. Whirlpool Corporation has a management system called WES (Worldwide Excellence System) and a value to aged performance system called HPC (High Performance Culture), which drives, are the actions and initiatives of unit.

1.2 HISTORICAL OVERVIEW OF WHIRLPOOL CORPORATION

Whirlpool Corporation was founded by Louise Upton in 1911. The company was known as upto n Machine Company in its initial

years. It produced wringer washers and sold its first order of washers to Sears Roebuck & Co. in 1916. In 1920s, the Upton machine company had become the exclusive supplier for sears electric & gasoline powered washing machines. While the past 8 decades have seen many sweeping and irreversible changes have obviously altered the very direction and scope of the company Sears remain Whirlpools largest customer even today. In 1936, Upton machine company inching its way into the global market place and entered into Europe and Asia through the relationship of American Steel Exports Company. In 1950, the company was renamed and officially known as the Whirlpool Corporation. The company added Automatic Dryers, Refrigerator, Ranges and Air Conditioners to its product line. Innovation always a Whirlpool Corporation hallmark was especially evident in 1956 with the Whirlpool Miracle Kitchen and expanded its manufacturing locations nationwide during the period. In 1957, the company established the Appliance Buyers Credit Corporation (Later to be known as Whirlpool Finance Corporation) to

extend credit to thousands of families who are seeking for latest Appliances. In 1958, the company made its first investment outside its home. Its investment in Brasmotor, South America for an equity stake in the Brazilian Appliance market, which later defined its successful global expansion and growth. Today, Whirlpool dominates the whole Latin America. In 1962, Whirlpool Corporation won the contract to develop the feeding and waste management systems for NASAs Gemini project, which made Whirlpool brand name, was strong and well established in the North America market. In 1969, the company was the first to introduce a residential trash compactor, the first new to market Appliances. During the same year the company further consolidated its position by entering the Canadian market with equity interest in Ingles Limited. In 1970, the company established Cool Line, the first toll-free Consumer service support line. In 1980, Whirlpool Corporation began its globalization initiatives to expand its business into rapidly growing markets throughout North America, South America, Europe and Later

Asia. At this juncture, the company was firmly in a position to lead and shape the home Appliances industry worldwide. The company current vision was created in 1986 and changed only once since its creation In 1987, Whirlpool Corporation and Sundaram Clayton of India formed TVS Whirlpool limited to make compact washers for the Indian market (Whirlpool Corporation would acquire majority ownership in 1994). Later, the company builds a manufacturing plant (Washer Unit) in Puducherry, India. The company remained active in North America as well, expanding its brand base by purchasing the Kitchen Aid division of the Hobart Corporation in 1986 and acquiring the Roper Brand name in 1989.In 1989, the Whirlpool Corporation and N.V.Philips of the Netherlands formed a joint venture company and having the way for Whirlpool entry in European market. The three-tiered brand structure now gave customers a clear choice of high-end (Kitchen Aid), Popular (Whirlpool) and Value-Oriented (Roper) home Appliances. The Whirlpool Overseas Corporation was formed in 1990 to pursue global opportunities outside Europe and the United States.

During 1990s, the company created two new subsidiaries to sell and service appliances in Hungary (Whirlpool Hungarian Trading Limited) and Slovakia (Whirlpool Tatramat). Later, Whirlpool Europe opened sales subsidiaries in Poland, the Czech Republic, Romania, Bulgaria and Russia. In mid 1990s, Whirlpool Asia established a corporate headquarters and product development or technology center in Singapore and opened regional offices in Hong Kong, New Delhi, Singapore and Tokyo. Later, the company purchased majority interests in five joint ventures across India and China to expand the Asian manufacturing base. In 1991, Inglis-Brand based in Canada became part of the Whirlpool family and formed in the same year. Whirlpool Corporation won the Star of Energy Efficiency award from the Alliance to save energy, was named Appliance Partner of the Year by U.S.Department of Energy and took home the climate protection and stratospheric Ozone Protection Awards from the Environmental Protection Agency (EPA). the corporate technology organization was

In 1995, the T.V.S.Whirlpool Limited acquired Kelvinator of India. During the year, the company was renamed as Whirlpool Washing Machines Limited. In 1996, Whirlpool of India was formed after attaining the majority of ownership. In 1998, Whirlpool Corporation unveiled its Resource Saver Wash System, a high-efficiency, top-loading washing machine with a spray rinse system and water temperature sensor that helped reduce energy consumption and water usage. Throughout Western Europe, Whirlpool Corporation became a stand-alone brand, and the company became the exclusive supplier of major home appliances to IKEA.

1.3 WHIRLPOOL CORPORATION TODAY

BUILDING CUSTOMER LOYALTY WORLDWIDE

Whirlpool Corporation arrived in the new century and millennium as the worlds leading manufacturer and marketer of major home appliances. Today, Whirlpools global platform provides our operations with resources and capabilities no other manufacturer can match and with brands that consumers trust. To sustain the productivity savings that is being achieved by our operations, they have embedded their Operational Excellence Process - based on Six-Sigma and lean manufacturing skills and capabilities - within each of their worldwide manufacturing facilities. The companys global information technology organization provides Internet tools that cut the complexity and costs of doing business for Whirlpool and its trade partners. Whirlpools unique global platform allows the company to transfer key innovations and processes across regions and brands. Based on the continuing success of he companys global innovation process, which began in 1999, Whirlpool has introduced unique product innovations to consumers worldwide.

Inspired by their bold innovations and designs, increasing numbers of customers around the globe are trusting Whirlpool to make their lives easier. More than ever before, Whirlpool Corporation employees and brands are connecting with customers in ways that will last a lifetime.

IMPROVING FUNCTION AND PERFORMANCE

At Whirlpool Corporation, they take pride in the quality of appliances to market and manufacture. They are committed to building products that consumers around the world can depend on to meet their daily needs. Their commitment to quality begins in the concept stages and continues throughout the lifetime of the appliance. They are constantly seeking out new and unique ways to improve the function, performance and sustainability of our products. They want our brands to be the brands customers trust in every home everywhere.

1.4 UNIT PROFILE - PUDUCHERRY

Whirlpool of India Limited is a fully owned company by Whirlpool Corporation, USA Head quarters at Benton Harbor, Michigan USA. Whirlpool Corporation is the worlds leading manufacturers and marketer of home appliances. Washing Machines, Dryers, Dish Washers, Refrigerators, Freezers, Cookers, Microwave Ovens, Room Air Conditioners, Small kitchen Appliances, etc.

Whirlpool of India limited, washer unit, Puducherry was the first manufacturing venture of the Whirlpool Corporation, USA, the worlds largest manufacturer of home appliances. In 1987, this unit was formed as a joint venture with M/s Sundaram Clayton limited, a TVS group companies and was named as TVS Whirlpool Limited. This unit is located on a 100 acre sprawling area manufacturing automatic and semi automatic washing machine. This unit is certified ISO 9001 facility by UL. It has also been cleared for S mark certification from Japanese Quality standards for Exports to Japan after our facility approval. In WOIL, washer unit has a total of 11 departments comprising of 220 employees on the whole. Out of which 67 is management executives and rest 153 are production operators.

CHAPTER- II

CORPORATE VISION AND STRATEGY

2.1 WHIRLPOOL VISION

Every Home..Everywhere. With Pride, Passion, Performance

The goal of the corporate is that their product should be in every home, everywhere. They will be achieving this by creating:

Pride --- --- in our work and each other Passion --- --- for creating unmatched customer loyalty for our brands Performance --- --- results that excite and reward global investors with superior returns. Whirlpool in its chosen lines of business will grow with new opportunities and be the leader in the global market. They will be driving their commitment towards the continuous quality improvement by satisfying the customer and their expectations. They

gain their advantage through their effort and marketing strategy. The success of the corporate make whirlpool, a company of worldwide that customer, employees and other stakeholders can depend on. Employees live by the values- based strategy that has made whirlpool the international leader that they are today. Their values represent who they are to their customers, to their investors and other stakeholders. The way they represent the company demonstrates how they do business in the right atmosphere.

2.2 WHIRLPOOL MISSION The mission of the corporate is that the demand of their selves so as to care their customers and they will serve with pride in every home and bring prosperity to their investors and customers. They are prepared to change the standards of their industry and be the Envy of their competitors. They will be leaders in home appliances which all others start to emulate.

2.3 OBJECTIVES OF THE COMPANY To carry on all or any of the business of engineering machinist, tool makers, wire drawers, radio tube manufacturers, electric lamp and bulb manufacturers of all kinds, shapes, voltage wattage, in their various applications, designs, inexistence today or to be invented hereafter and manufacturers of all types of electronic devices in vogue today or to be invented hereafter, electroplates and enamels, etc., To carry on business as manufacturers and makers of and dealers in metals, plastics, wood enamel aluminum alloys and any other products, substances, articles and things of every description and kind and to carry on and conduct workshops and foundries of iron, brass and other metals, wood and any other substances and to buy, sell, export, import, manipulated and deal both wholesale and retail in products, commodities, goods articles and things of all kinds whatsoever. To carry on other business, whether manufacturing or otherwise, which may seem to the company capable of being conveniently carried on in connection with the above or calculated

directly or indirectly to enhance the value of our render profitable, any of the companys property or rights? To purchase or otherwise acquire or undertake the whole or any part of the business, property a liability of any person, corporation or company, carry on any business which this company is authorized to carry on or possessed of property suitable for the purpose of the company. To make, build, construct, provide, maintain, any carry on, use and work in Indian or elsewhere, roads, railways, tramways, telegraph lines, telephones, electric lights, heat and power work, canals, reservoirs, water-works, wells, aqueducts, water-courses, furnaces, gasworks, piers, wharves, docks, quartz, saw and other mills, hydraulic works, factories, warehouses and other works and buildings which may be deemed expedient for the purpose of the company and to contribute to the cost of making, constructing, providing , carrying on, using and working the same. To acquire by purchase or otherwise for the business of the company in India or elsewhere, any lands, manufactories, buildings, plants, engines, machinery or other things and to erect and maintain or reconstruct and adapt buildings, mills, plant engines, machinery and other plant

and things found necessary or convenient for the purpose of the company.

CHAPTER-III

PRODUCTS MANUFACTUED

3.1 PRINCIPAL PRODUCTS Air Purifiers Automatic Dryers Automatic Washers Built-in Ovens Cookers (gas and electric) Dehumidifiers Dishwashers Dryers Freezers (upright and chest) Hot Water Heaters

 Microwave Ovens Ranges (Gas and Electric, Freezers, Side-by-Side) Refrigerators (built-in, combis and side-by-side) Room Air Conditioners Trash Compactors Washers (front and top loading)

3.2 KITCHEN AID PRODUCTS Blenders Food Processors Hand Mixers Hot-water Dispensers Stand Mixers Toasters Coffee Makers

 Juicers

CHAPTER-IV

VARIOUS DEPARTMENTS

Administration Department Finance Department Human Resource Department Materials Department Production Department Medical Department Stores Department Plant Maintenance Department (PMD) Regional Technology Center (RTC) Process Engineering Development (PED) Quality Assurance Department (QAD)

4.1 ACCOUNTS DEPARTMENT

Accounting policies

Basis of Preparation of Financial Statements

The financial statements have been prepared to comply in a ll material respects with the Indian Accounting Standards as notifiedd by Companies (Accounting Standards) Rules, 2006,(as amended))) and the relevant provisions of the Companies Act, 1956. Thee

financial statements have been prepared under the historical costtt convention on an accrual basis except in case of fixed assets for which revaluation is carried out. The accounting policies have been consistently applied by the Company and are consistent with those used in the previous year.

Use of Estimates

The preparation of financial statements in conformity with Generally Accepted Accounting Principles requires management to make estimates and assumptions that affect the reported amounts of assets and liabilities and disclosure of contingent liabilities at the date of the financial statements and the results of operations during the reporting period end. Although these estimates are based upon managements best knowledge of current events and actions, actual results could differ from these estimates.

Fixed Assets

Fixed assets are stated at cost (or revalued amounts, as the case may be), less accumulated depreciation and impairment

losses, if any. Cost comprises the purchase price and any attributable cost of bringing the asset to its working condition for its intended use. Borrowing costs relating to acquisition of fixed assets which takes substantial period of time to get ready for its intended use are also included to the extent they relate to the period till such assets are ready to be put to use.

Depreciation

Depreciation on fixed assets is provided pro- rata from the date of addition using the Straight Line Method at the rates based upon useful life of assets estimated by management, which are greater than or equal to the corresponding rates prescribed in Schedule XIV of the Companies Act, 1956.

Premium on Leasehold Land is amortised over the period of the lease and depreciation on leasehold improvement which includes temporary structures is provided over the unexpired period of lease or estimated useful life, whichever is lower.

Extra Shift Depreciation on the qualifying assets is charged at the rates prescribed in Schedule XIV of the Companies Act.

In respect of revalued assets, the difference between the depreciation calculated on the revalued amount and original cost is recouped from the Revaluation Reserve Account.

Intangible assets

Software

Cost of software is amortized over its useful life of 60 months starting from the month of project implementation.

Retirement and other Employee benefits

1.Provident Fund

Retirement benefit in the form of Provident Fund is a defined contribution scheme and the contributions are charged to the Profit and Loss Account of the year when the contributions to the respective funds are due. There are no other obligations other than the contribution payable to the fund.

2.Superannuation Fund

Retirement benefit in the form of Superannuation Fund is a defined contribution scheme and the contributions are charged to the Profit and Loss Account of the year when the contributions to the respective funds are due. There are no other obligations other than the contribution payable. The Company has s arrangements with an Insurance Company to administer its superannuation scheme.

3.Gratuity

Gratuity liability is defined benefit obligation and is provided for on the basis of an actuarial valuation on projected unit credittt (PUC) method made at the end of each financial year. The Company has created an approved Gratuity Fund, which has taken a group gratuityy cum insurance policy with an Insurance company to cover thee gratuity liability of the employees and premium paid to LIC iss charged to Profit & Loss account. At the end of accounting yearr, difference between obligation as per actuarial valuation and thee fair value of plan asset is further provided for and any excesss amount in plan assets over obligation is recognised as an loans and advance recoverable.

4.2 SERVICE DEPARTMENT

Service under Warranty

1. Service under Optional Service Contract

Liability under optional service contract in respect of the concractd period is provided on the basis of valuation carried out by an independent actuary as at the year end.

2. Service under Warranty/ Extended Warranty

Liabilities in respect of warranties including extended warranties other than on microwave ovens are accrued and provided on thee basis of valuation carried out by an independent actuary as at yearrr end. In case of warranty on microwave ovens, expenses likely to be incurred during the warranty period are provided on reasonable estimates. The estimates are based on past experience.

SAS 4.3 SALES DEPARTMENT

Usually sales are under the control of the general manager, to whom the sales manager reports. The sales manager is, of

course, in direct charge of all activities of the sales department. It is not unusual for one of the chief executives of a company to be in general charge of sales. "Vice-President in Charge of Sales" is a title frequently met with. Very often the term "sales" includes advertising, and both the sales and advertising managers, coordinate in rank, report to the vice-president in charge of sales. Usually under this plan of organization, the vice-president in turn reports to the president or other general manager. In some instances the sales manager exercises the function of advertising manager; in others the advertising manager is subordinate; in somewhat rarer instances the sales manager is subordinate to the advertising manager; and in others there is a separate advertising department whose manager is on an equal footing with the sales manager and reports only to the general manager.

AUTHENTIC DEALERS OF WHIRLPOOL

1. Bharath electronics 2. Mani electronics 3. Naresh electronics 4. Rupwani appliances 5. Vasanth & co. 6. Darling next home appliances

MARKETS SERVED United States Canada Mexico Europe Middle East Africa and Asia India

4.4 HUMAN RESOURCE DEPARTMENT

The comprehensive Leadership to Dominance business strategy was communicated to all employees across the company in a structured manner that has succeeded in internalizing this strategic intent. In order to create resources to implement this key activity were divested or outsourced. The six-sigma initiatives, which were launched in 1995, were perused with further intensity wherein 26 employees were trained as Black Belts. These employees are working on approximately so projects, which should yield substantial financial and quality benefits to the organization in year 2002. Company continued its focus on the philosophy that the consumer is at the center of our business and consistently delivered best in class product quality and consumer service. The on going operations excellence programme with special focus on six-

sigma initiatives to improve manufacturing quality has ensured that exacting standard of quality is maintained at all our factories and our product quality is benchmarked with the best in the Whirlpool world. The absence of growth and low demand pricing pressure but companys unwavering focus on cost productivity ensured that business margins were maintained. The cost productivity initiatives at the factories achieved a highest ever. In line with Whirlpool worldwide initiatives Innovation

workshops were conducted for employees throughout the country. These resulted in discovery of some potential business opportunities for the company in future, some of that have already started yielding results. A Human Resource functions as a primary key to production improvement in the factory. The company has a policy to show their uniformity in workplace by wearing the same type of uniform dress code form top to bottom line of management. It motivates the employees for their and firms better future. Has a part of motivation company displays: two corners namely Excellence Corner and Birthday Corner. Firm takes interest in

employees self growth. It extends flexibility to workers during business hours. Firm provides free food and transportation to all workers. Many functions are conducted as a part of employee involvement in other activities. Star Awards are given away to the best performers during the last fiscal year. Quality Month is celebrated in month of June every year. During this month consumers were greeted to the factory to check the quality of production. The customers difficulties and problems in the machine were analyzed. Free service campaign is set during this month for the consumer.

HR ORGANISATION CHART

A H B NARAYANA REDDY DIRECTOR

M.V.MURALI MANAGER

K PRAKASH DEPUTY MANAGER

ORGANISATIONAL STRUCTURE
MANAGING DIRECTOR

Our Mission
VICE PRESIDENT GENERAL MANAGER

Plant Operations

RAGUBATHY

EXECUTIVE

SENIOR MANAGER

PURCHASE MANAGER

PRODUCTION QUALITY MANGER MANGER

FINANCE MANGER

HUMAN RESOURCE MANGER

PROCESS ENGINEERING DEVEOLOPMENT MANGER

S1

S2

S3

S4

S5

S6

MEDICAL MANGER

REGIONAL TECH. CENTER MANGER

S7

S8

4.5 PERSONNEL DEPARTMENT

Office staffs

Director Manager
Deputy Manager Executive HR Manager

- A.H.B. Narayana reddy - M.V.Murali

- K.Prakash - Ragubathy - Prakash

Accounts Department staffs Finance Manager -1

No.of accountants No.of clerks

-4 -2

Sales Department staffs Sales Manager Sales Man -1 -4

Production Department staffs Production Manager -2

Executive level employees - 10 Workers Security Guard 50 5

CHAPTER-V MANUFACTURING PROCESS

5.1 INTRODUCTION The washing machine operates by a motor, which is connected to the agitator through a unit called a transmission. The motor and transmission are near the bottom of the machine, while the agitator extends up through the middle of the machine. The transmission is similar to the transmission in your automobile in that it changes the speed and direction of the agitator. In one direction (agitate), the

transmission changes the rotation of the agitator and spin tub and inside tub with small holes in it into a back-and-forth motion. When the motor is reversed by the controls (spin), the transmission locks up and the agitator, transmission, and spin tub all rotate as a unit. Without the transmission changing the speed or direction, the unit uses centrifugal force to remove as much water from the clothes as possible. The motor is also connected to a pump. When the motor is moving in the spin direction, the pump removes the water from the tub and discards it through the drain pipe. Models designed for use in other countries offer different features. One component required on all models sold in England (and possibly soon in the rest of Europe) is called the lid lock. Normally when the lid is raised the washer must stop for safety reasons. However, in England, when the washer is operating the lid must be locked closed.

5.2 RAW MATERIAL Many parts of a washing machine are manufactured from sheet steel, usually coated with zinc to improve rust resistance. The steel manufacturer supplies the metal in a coil, which allows the material to be cut to size with minimum waste or automatically fed into the forming process. On some models made by Speed Queen, the spin tub is made of stainless steel. All other models use a steel (called enameling iron) designed for a porcelain coating. For the wash tub, Most sheet metal parts, including the body, are formed by a machine that presses a piece of sheet metal between two halves of a mold (die). Because metal in parts shaped by only one die tends to wrinkle, crack, or tear, multiple dies are generally used to form each component. The tub sub-assembly is manufactured automatically. After being rolled into a drum shape, the side is welded. The weld is then smoothed out and the drum is placed on an expander, which stretches the tub into its final shape. A bottom is then welded onto the drum, and this weld is also smoothed.

The Sheet metal isn't visible unless you open the machine cabinet, enameling iron with a porcelain coating is generally used. Whirlpool is the exception, using plastic instead of enameling iron for the outer wash tub. Many other parts are plastic as well. Manufacturers receive raw plastic from which they fabricate parts in pieces about the size of a small ant, using them for machine components that do not bear weight and/or require extremely good rust resistance. Such parts include the pump, the tub guards (which prevent your clothes from being thrown out of the spin tub into the wash tub or the cabinet area), and the agitator. The transmission is generally made from cast aluminum, which arrives from the manufacturer in ingot 20 pound slabs of aluminum. Scrap parts are usually remelted and reused. Hoses, controls (timers, switches, etc.), and motors are purchased in prefabricated form from other manufacturers.

5.3 PROCESS UNDERGONE

The manufacturing process is split into fabrication (making parts), sub-assembly (putting parts together to make components), and assembly (putting the components together to form the final product). The fabrication process comprises several different procedures, each specific to a particular type of raw materialsheet metal, plastic, or aluminum. Once the constituent parts have been made, they are assembled; major sub-assemblies, or components, include the transmission, the pump, the spin and wash tubs, the balance ring, and the painted parts. Finally, the sub-assemblies are put together inside the shell of the washer, which is then complete
.

FABRICATION Most sheet metal parts are formed by a machine called a press. This name is quite descriptive, as the machine actually presses (or squeezes) a piece of sheet metal between two halves of a mold called a die. The metal will take the form of the space between the halves of the die. Because metal in parts shaped by only one die tends to wrinkle, crack, or tear, multiple dies are generally used to

form each component. Where possible, the metal is fed directly from a coil into the press. When this is not possible, the metal is cut to length and manually (or, with larger parts like the cabinet, automatically) placed into the die.

FABRICATION OF SHEET METAL

Plastic parts are formed in an injection molding machine, a metal mold with one or more cavities in the shape of the desired part. After being heated to its melting point, the

plastic is forced into the mold under high pressure. Next, water is passed through the mold to cool and solidify the part. The mold is then opened and the part pushed out by ejector pins. When you look at a plastic part, you often can see small circles created by these pins. Aluminum transmission parts are formed into a rough shape in a die cast machine, which works much like an injection mold except that it does not use pressure.

VIEW OF A SPINNER

 Most of the key componentstransmission, motor, broke assemblyare housed below the agitator. The balance ring is a weighted ring that keeps the washer from moving around during operation. Molten metal is mechanically ladled into the mold and cooled. The ensuing rough casting is then given its final

shape by various machines which drill holes, shave excess metal off critical surfaces, or cut metal away from the part . SUB-ASSEMBLES The transmission is assembled manually by workers who bolt, snap, or press (tight fit) several shafts and gears together. Workers then add a metered amount of oil and bolt the unit together. The pump is assembled automatically. Robots place the impeller and seals in the cover and body, and seal the pump. Some manufacturers use heat and others vibration (which generates heat) as a sealant. The tub parts are made in presses, and the sub-assembly is manufactured automatically. After being rolled into a drum shape, the side is welded. The weld is then smoothed out and the drum is placed on a unit called an expander, which stretches the tub into its final shape. A

bottom is then welded onto the drum, and this weld is also smoothed. If the tub is stainless steel it is polished so it won't snag the clothes. Otherwise the tub is dipped in a solution called a ground coat and heated to about 1600 degrees until this coating hardens. If the tub will not be visible (the wash tub), the unit is done. If the tub will be visible (the spin tub), a finish coat is applied following the same procedure used with the ground coat; this final coat gives the tub either a white or blue color. The balance ring is a large weight that stabilizes the washer. Its outside structure is plastic, with a ring of metal melted into the plastic for strength. Cement is added and balanced precisely. This ring, which weighs more than twenty pounds, keeps the machine from "walking," or moving about, when it is in use. Washing machine manufacturers use any one of several painting processes. One manufacturer uses steel that has been prepainted by the steel manufacturer. Although cheaper, this type of steel does not offer the best rust

protection because the cut edges are not painted. Other companies treat their parts with various chemicals to clean and ready them before applying paint. In some cases, the paint comes in a powder with a flour-like consistency. Mixed with air and given an electrical charge, the powder is sprayed on the part, which is hung from an overhead conveyor and given an opposite charge so that it and the powder will attract one another. After spraying, the conveyor moves the part into an oven that melts the paint; when the part cools, the paint process is completed. ASSEMBLY This process begins with mounting the transmission on the balance ring. The transmission is set on a bearing that is bolted on the wash tub; the wash tub is sitting on a conveyor. Another bearing (the lower bearing), the brake assembly, and the drive pulley are put on the end of the transmission. Next, a pivoting mechanism called the pivot

dome and legs are bolted on the assembly to hold all the pieces together. Using a hydraulically operated mechanism, workers then lift this assembly, called the module, onto the washer base. Springs are added to hold module and base together. A seal is added, the spin tub is bolted to the transmission inside of the wash tub, and its plastic covers are snapped into place. A plastic hub, which attaches the agitator to the transmission, is bolted onto the output end of the transmission shaft. Then the agitator is snapped onto the hub. The pump and a mounting bracket are now bolted onto the motor, which is then fitted with a shield to protect against potential leaks. This assembly is bolted to the base of the washing machine and connected to the transmission module with a belt and hoses. Next, the lid hinges are attached to the lid and the top. The top of the washer is bolted to the cabinet with a hinge

for easy maintenance. A mixing valve to control the mixture of hot and cold is bolted to the back of the cabinet. The graphics panel, which provides words and pictures to explain the controls, is mounted on the control panel; the controls themselves are attached from the back. The wiring, connected as one unit, is called a harness. The harness is clipped to the control connectors at one end, and the other end is passed through a hole in the top to be mounted to the motor. Because of its large size and weight, the cabinet assembly is then placed in the washer by a robot. The cabinet is bolted to the base, and the controls are snapped together with the mating connectors on the module and motor. The drain hose is pulled through the cabinet and a part called the gooseneck is added. This part is what gives the hose its hook shape so that it will fasten into the drain. After being tested, the front panel is bolted on, and a packet of information and accessories is added.

 The finished unit is crated automatically. A machine opens the cardboard box, which was flat for shipment, and drops it over the washer. The top and bottom flaps are simultaneously folded over and glued. Then the machine applies pressure on the top and bottom of the crate to make sure the glue sets properly. After the glue has set, the machine puts a banding strap around the top of the crate to add strength for lift truck transportation (the units are carried from the top to reduce the risk of damage).

FULLY ASSEMBLED WASHING MACHINE

QUALITY CONTROL All parts purchased from outside manufacturers are spot checked before use, and most sub-assemblies are checked as well. For instance, all transmissions are automatically tested for operation,

noise,

and

vibration.

All

pumps

are

leak-tested

using

air,

automatically if their assembly was automated and manually if it was manual. All painted parts are visually inspected for defects. Daily samples are put in detergent, bleach, and steam baths for corrosion testing. Once it has been completely assembled, the machine is filled with water and tested for noise, vibration, and visual defects, as well as properly functional controls and mechanisms. After packaging, some units are put through severe tests to simulate the transportation conditions to test the cartoning process.

BYPODUCTS/ WASTE Leftover scraps of sheet metal are sold to metal recycling centers, and leftover aluminum is remelted for use. The leftover plastic is ground into small chunks and reused on non-visible parts because the color cannot be kept consistent. The unused paint (in powder form) is reclaimed and reused automatically. The chemicals from processes such as paint are reacted into forms of harmless waste and disposed of safely.

IN FUTURE As motors become less expensive and more durable, it will become economical to offer washing machines driven directly by motors instead of by belts, making the washers more versatile and less noisy. Another likely trend will be the gradual displacement of top-load washers by front-load washers, which, because they require less water, satisfy government restrictions on water use. In Japan, a washer is being tested that cleans with bubbles rather than with an agitator. Using a computer, this machine "senses" how soiled each load of clothing is and then generates the bubble activity necessary to remove that amount of dirt. This is called "fuzzy logic" because it imitates human logic more closely than normal computers. If successful, these machines will become available elsewhere. Further in the future people may use washers that clean using ultrasonics sound waves that, vibrating at higher frequencies.

CHAPTER - VII

CONCLUSION

The growing middle class population is largely emphasizing on consumer electronic products that are more convenient to use and more efficient. Indian washing machine market clearly substantiates this fact. Currently, accounting for around 63% of volume sales, semiautomatic twin-tub category dominates the washing machine market. But in terms of growth, the fully-automatic category is performing extremely well in the Indian market. The volume sales of fullyautomatic washing machines are expected to surpass that of semiautomatic washing machine in coming few years.

RATIO ANALYSIS FOR THE YEAR 2010

1. CURRENT RATIO: Current ratio is the ratio of total current assets to total current liabilities. It is calculated by dividing current assets by current liabilities. Current ratio = current assets / current liabilities = 642.64 / 694.40 = 0.92 The ratio is not satisfactory because it does not fulfill the principle of 2:1 ratio. Thus the company has to improve its performance.

2. LIQUID RATIO: Liquid ratio is the ratio between quick current assets and current liabilities. It is calculated by dividing the quick assets by current liabilities.

Liquid ratio = quick assets / current liabilities = 180.15 / 694.40 = 0.25 The principle 1:1 ratio is not satisfied thus the company has to increase its liquid assets. 3. NET PROFIT RATIO: It is also known as net margin. This measures the relationship between net profits and sales of a firm. Net profit ratio = net profit / net sales *100 = 145.02 / 2541.04 *100 = 5% 4. GROSS POFIT RATIO: It is also known as gross margin. It is calculated by dividing gross profit by sales of a firm. Gross profit ratio = gross profit / net sales *100 = 156.99 / 2541.04 *100

= 6% 5. STOCK TUNOVER RATIO: It is also known as inventory turnover ratio. It is calculated by dividing cost of goods sold by average stock. Stock turnover ratio = cost of goods sold / avg. stock = 2384.05 / 381.18 = 6 times