Water Purifier Assembly

  Today is the eleventh day of my Industrial Training and today we are going to learn Water Purifier Assembly..
A water purifier removes impurities from water by means of a fine physical barrier, a chemical process or a biological process.A water purifier first sucks up raw water which is contaminated, filter out impurities ranging from sediments to micro-organisms and then dispense clean water. A purifier can remove viruses and bacteria by an electro-static charge to kill or capture viruses.
Reverse Osmosis (RO) system offers a multi-stage filtration of water by combining active carbon and also particle filtration. Here, the tap water is made to pass through a membrane (a polymer film) that has very small-sized pores and this weed out minerals and micro-organisms in water. The impurities collected are then flushed out through an outlet pipe. A RO water purifier improves the taste of water.
In Ultra Violet (UV) filter system UV light (minimum level radiation) is passed on water to kill bacteria and other microbes by attacking the DNA in cells.
Ion exchange resins filter system the water is passed through resins that soften water by absorbing the minerals present. These filters can soften the water by sucking up the salts present and can also completely de-mineralise the water.
And as soon as the water purifier was assembled, safe, clean pure water was reality at the push of a button... truly a miracle of science..."drink healthy, keep healthy"...

Food Processsor Assembly

  Today is the tenth day of my Industrial Training and today we are going to learn Food Processor assembly...
A food processor is a kitchen appliance used to facilitate repetitive tasks in the preparation of food. Food processors are similar to blenders in many ways. The primary difference is that food processors use interchangeable blades and disks (attachments) instead of a fixed blade.
Food processor functions consist of:

•     Slicing/chopping vegetables
•     Grinding items such as nuts, seeds (e.g. spices), meat, or dried fruit
•     Shredding or grating cheese or vegetables
•     Pureeing
•     Mixing and kneading doughs

The base of the unit houses a motor which turns a vertical shaft. A bowl, usually made of transparent plastic, fits around the shaft. Cutting blades can be attached to the shaft; these fit so as to operate near the bottom of the bowl. Shredding or slicing disks can be attached instead; these spin near the top of the bowl. A lid with a "feed tube" is then fitted onto the bowl.The feed tube allows ingredients to be added while chopping, grinding or pureeing. It also serves as a chute through which items are introduced to shredding or slicing disks. A "pusher" is provided, sized to slide through the feed tube, protecting fingers.
Vow and as soon as the food processor was asembled, I was wondering that this robot would assist in cooking and garnishing in minutes...truly a mechanical wonder..."cook healthy, think healthy"...

Food Processsor Assembly

  Today is the tenth day of my Industrial Training and today we are going to learn Food Processor assembly...
A food processor is a kitchen appliance used to facilitate repetitive tasks in the preparation of food. Food processors are similar to blenders in many ways. The primary difference is that food processors use interchangeable blades and disks (attachments) instead of a fixed blade.
Food processor functions consist of:

•     Slicing/chopping vegetables
•     Grinding items such as nuts, seeds (e.g. spices), meat, or dried fruit
•     Shredding or grating cheese or vegetables
•     Pureeing
•     Mixing and kneading doughs

The base of the unit houses a motor which turns a vertical shaft. A bowl, usually made of transparent plastic, fits around the shaft. Cutting blades can be attached to the shaft; these fit so as to operate near the bottom of the bowl. Shredding or slicing disks can be attached instead; these spin near the top of the bowl. A lid with a "feed tube" is then fitted onto the bowl.The feed tube allows ingredients to be added while chopping, grinding or pureeing. It also serves as a chute through which items are introduced to shredding or slicing disks. A "pusher" is provided, sized to slide through the feed tube, protecting fingers.
Vow and as soon as the food processor was asembled, I was wondering that this robot would assist in cooking and garnishing in minutes...truly a mechanical wonder..."cook healthy, think healthy"...

Vacuum Cleaner Assembly

     Today is the ninth day of my Industrial Training and today we are going to learn how to assemble Vacuum Cleaner...
A vacuum cleaner is a device that uses an air pump to create a partial vacuum to suck up dust and dirt, usually from floors, and optionally from other surfaces as well.
The essential components are:

•     An intake port, which may include a variety of cleaning accessories
•     An exhaust port
•     An electric motor
•     A fan
•     A porous bag
•     A housing that contains all the other components

When you plug the vacuum cleaner in and turn it on, this is what happens:

    1The electric current operates the motor. The motor is attached to the fan, which has angled blades.
    2As the fan blades turn, they force air forward, toward the exhaust port.
    3When air particles are driven forward, the density of particles (and therefore the air pressure)increases in front of the fan and decreases behind the fan.

The pressure level in the area behind the fan drops below the pressure level outside the vacuum cleaner (the ambient air pressure). This creates suction, a partial vacuum, inside the vacuum cleaner. The ambient air pushes itself into the vacuum cleaner through the intake port because the air pressure inside the vacuum cleaner is lower than the pressure outside.
Vow and as soon as the vacuum cleaner was assembled I was wondering of how spic and span my room would look... Thanks to this magical wonder that eats air...the motto is "the cleaner the healthier"...

Dishwasher Assembly

Today is the eighth day of my Industrial Training and today we are going to learn how to assemble a Dishwasher...
Dishwasher is a mechanical appliance for cleaning dishes and utensils. ­Basically, a dishwasher is a robot that cleans and rinses dirty dishes. Humans have to load the dishes, add detergent, set the proper washing cycles and turn it on, but the dishwasher accomplishes a whole series of functions by itself.
A dishwasher:

•    Adds water

•     Heats the water to the appropriate temperature
•     Automatically opens the detergent dispenser at the right time
•     Shoots the water through jets to get the dishes clean
•     Drains the dirty water
•     Sprays more water on the dishes to rinse them
•     Drains itself again
•     Heats the air to dry the dishes off

Dishwashers monitor themselves to make sure everything is running properly. A timer (or a small computer) regulates the length of each cycle. A sensor detects the water and air ­ temperature to prevent the dishwasher from overheating or damaging your dishes. Another sensor can tell if the water level gets too high and activates the draining function to keep the dishwasher from overflowing. Some dishwashers even have sensors that can detect the dirtiness of the water coming off the dishes. When the water is clear enough, the dishwasher knows the dishes are clean.
And as soon as the dishwasher was assembled, I was thinking how handy the dishwasher is in reducing the work load...sparkling clean dishes at the touch of a button...indeed is a miracle of science...

Refrigerator Assembly

Today is the seventh day of my Industrial Training and today we are going to learn Refrigerator assembly...
A refrigerator is an appliance that maintains a temperature a few degrees above the freezing point of water,Optimum temperature range for perishable food storage.
A refrigerator consists of two storage compartments - one for frozen items and the other for items requiring refrigeration but not freezing. These compartments are surrounded by a series of heat-exchanging pipes. Near the bottom of the refrigerator unit is a heavy metal device called a compressor. The compressor is powered by an electric motor. More heat-exchanging pipes are coiled behind the refrigerator. Running through the entire system is pure ammonia, which evaporates at -27 degrees Fahrenheit (-32 Celsius). This system is closed, which means nothing is lost or added while it is operating.
The refrigeration process begins with the compressor. Ammonia gas is compressed until it becomes very hot from the increased pressure. This heated gas flows through the coils behind the refrigerator, which allow excess heat to be released into the surrounding air. Eventually the ammonia cools down to the point where it becomes a liquid. This liquid form of ammonia is then forced through a device called an expansion valve. Essentially, the expansion valve has such a small opening that the liquid ammonia is turned into a very cold, fast-moving mist, evaporating as it travels through the coils in the freezer. Since this evaporation occurs at -27 degrees F (-32 degrees Celsius), the ammonia draws heat from the surrounding area. This is the Second Law of Thermodynamics in effect. Cold material, such as the evaporating ammonia gas, tend to take heat from warmer materials, such as the water in the ice cube tray.As the evaporating ammonia gas absorbs more heat, its temperature rises. Coils surrounding the lower refrigerator compartment are not as compact. The cool ammonia still draws heat from the warmer objects in the fridge, but not as much as the freezer section. The ammonia gas is drawn back into the compressor, where the entire cycle of pressurization, cooling and evaporation begins anew.
As soon as the refrigerator was assembled I was thinking of the yummy ice creams and chilled cold drinks that could be enjoyed...Indeed a technological boon ...keeps fruits and vegetables as fresh as ever...just chillout friends!!!

Washing Machine Assembly

   Today is the sixth day of my Industrial Training and today we are to learn Washing Machine Assembly...
A washing machine (laundry machine) is a machine used to wash laundry, such as clothing and sheets and is different from dry cleaning or ultrasonic cleaners.
Washing machines get clothing clean by plunging the clothes through the water and detergent mixture. It is the motion that really helps to loosen dirt.In top loading machines the agitator twists back and forth pulling the clothes down to the bottom of the tub. The clothes then work their way back up to the top where the agitator grabs them again. In a front loading machine, the clothes tumble and are plunged into the water over and over again. After the water is pumped out, the inner drum uses centrifugal force to wring out more water from the clothes by spinning at several hundred RPMs. The washer has two tubs, the inner tub with hundreds of holes in it and the outer tub which holds the water. During the spin cycle the inner tub spins, forcing the water out through the holes to the stationary outer tub.
A front loading washing machine comes with a dryer.
The controls consist of a timer, cycle selector mechanism, water temperature selector, load size selector and start button. The mechanism includes the motor, transmission, clutch, pump, agitator, inner tub, outer tub and water inlet valve.
Once the washing machine was assembled I was thinking of how clean and fresh my clothes would smell... truly a scientific wonder ...the washing machine is like a time machine that turns dirty clothes into clean clothes...after all "cleanliness is next to godliness"

Air Conditioner Assembly

Today is the fifth  day of my Industrial Training and today we are to learn how to assemble an Air Conditioner...
Air conditioning (AC) is the process of altering the properties of air, primarily temperature and humidity, to more comfortable conditions, typically with the aim of distributing the conditioned air to an occupied space to improve thermal comfort and indoor air quality.
Window unit air conditioners are installed in an open window. The interior air is cooled as a fan blows it over the evaporator. On the exterior the heat drawn from the interior is dissipated into the environment as a second fan blows outside air over the condenser.
.The main component of an AC are:
COMPRESSOR: Compresses the refrigerant from low pressure (low temperature) to high pressure (high temperature). This conversion raises the boiling point to higher temperature levels, facilitating elimination of the heat brought by the outdoor air.
CONDENSER: This component receives gas at high pressure and high temperature from the compressor. In air-cooled condensers, the metallic surfaces cool the gas which changes status and turns to liquid. In the case of water-cooled condensers, it is the circulation of the water that produces the same cooling effect.
EVAPORATOR: A fan blows the warm air (which is to be cooled) across the evaporator, causing the liquid part of the cold refrigerant mixture to evaporate as well, further lowering the temperature. The warm air is therefore cooled.
CONTROL PANEL: Where you select the temperature, quantity and location of air to come from the heater/ conditioning system

Some of the Process applications include these:
Chemical and biological laboratories, Cleanrooms, Environmental control of data centers,Facilities for breeding laboratory animals, Food cooking and processing area,Hospital operating theatres
I realized that not only the air is conditioned but our life is conditioned too... truly an Engineering wonder enables cool, pure, fresh air at your finger tips...the motto is "feel cool, think cool"...

Microwave Oven Assembly

Today is the fourth day of my Industrial Training and today we are going to learn how to assemble microwave oven...
A microwave oven is a kitchen appliance that heats and cooks food by bombarding it with electromagnetic radiation in the microwave spectrum causing polarized molecules in the food to rotate and build up thermal energy in a process known as dielectric heating.

A microwave oven consists of:

•  a high voltage power source, commonly a simple transformer or an electronic power converter, which passes energy to the magnetron
•     a high voltage capacitor connected to the magnetron, transformer and via a diode to the chassis
•     a cavity magnetron, which converts high-voltage electric energy to microwave radiation
•     a magnetron control circuit (usually with a microcontroller)
•     a short waveguide (to couple microwave power from the magnetron into the cooking chamber)
•     a metal cooking chamber
•     a turntable or metal fan

Modern microwave ovens use either an analog dial-type timer or a digital control panel for operation
A variant of the conventional microwave is the convection microwave. A convection microwave oven is a combination of a standard microwave and a convection oven. It allows food to be cooked quickly, yet come out browned or crisped, as from a convection oven

Some current plastic containers and food wraps are specifically designed to resist radiation from microwaves and glass utensils are microwave safe.

Vow and as soon as the microwave was assembled I was wondering about the yummy and delicious food that can be savored...this is truly a magical wonder...the motto is "cook smart, think smart"...

Chip fabrication lab

Today is the third day of my Industrial training and today we are to visit the chip
fabrication plant...

Semiconductor device fabrication is the process used to create the integrated circuits that are present in everyday electrical and electronic devices. It is a multiple-step sequence of photo lithographic and chemical processing steps during which electronic circuits are gradually created on a wafer made of pure semiconducting material like Silicon.

In semiconductor device fabrication, the various processing steps fall into four general categories: deposition, removal, patterning, and modification of electrical properties.
Deposition is any process that grows, coats, or otherwise transfers a material onto the wafer. Available technologies include physical vapor deposition, chemical vapor deposition, electrochemical deposition, molecular beam epitaxy and more recently, atomic layer deposition among others. The logic gates are deposited as sandwich layer.
    Removal is any process that removes material from the wafer; examples include etch processes (either wet or dry) and chemical-mechanical planarization.
    Patterning is the shaping or altering of deposited materials, and is generally referred to as lithography. In conventional lithography, the wafer is coated with a chemical called a photoresist; then, a machine called a stepper focuses, aligns, and moves a mask, exposing select portions of the wafer below to short wavelength light; the exposed regions are washed away by a developer solution. After etching or other processing, the remaining photoresist is removed by plasma ashing.
    Modification of electrical properties has historically entailed doping transistor sources and drains (originally by diffusion furnaces and later by ion implantation). These doping processes are followed by furnace annealing or, in advanced devices, by rapid thermal annealing; annealing serves to activate the implanted dopants. Modification of electrical properties now also extends to the reduction of a material's dielectric constant in low-k insulators via exposure to ultraviolet light in UV processing.

Modern chips have up to eleven metal levels produced in over 300 sequenced processing steps.


Once the front-end process has been completed, the semiconductor devices are subjected to a variety of electrical tests to determine if the device functions properly


Once tested, a wafer is typically reduced in thickness before the wafer is scored and then broken into individual dies, a process known as wafer dicing.


Plastic or ceramic packaging involves mounting the die, connecting the die pads to the pins on the package, and sealing the die.

Soon it was time to leave and I had decided to take up my project work based upon the chip fabrication process. Indeed it was quite exciting and challenging. I learned how fast and computerized life has become thanks to wonderful chips...indeed they provide food for thought...

Fan Manufacturing Plant

Today is my second day of Industrial Training and today we will visit the fan manufacturing plant.
A ceiling fan is a mechanical fan, usually electrically powered, suspended from the ceiling of a room, that uses hub-mounted rotating paddles to circulate air.
The key components of the ceiling fan are:
An electric motor , metal blades, metal arms, called blade irons,which hold the blades and connect them to the motor, flywheel, a metal or tough rubber double-torus which is attached to the motor shaft, and to which the blade irons may be attached. The flywheel inner ring is locked to the shaft by a lock-screw, and the blade irons to the outer ring by bolts that feed into tapped metal inserts, rotor, alternative to blade irons,
A mechanism for mounting the fan to the ceiling such as, ball-and-socket system or J-hook (Claw hook) system , decorative lights hanging on fan.
Fan is operated with a variable-speed control.This is mounted on wall, digital control or wireless remote control
The manufacturing components we observed are:

• Lathe machine 
• Drill machine 
• Air compressor & gun for painting
• Oven for baking paint 
• Automatic winding machine 
• Automatic coil winding machine
• Automatic paper insertion machine
• Coil & wedge inserting machine
• Coil shaping machine
• Lacing machine
• Automatic progressive die Stamping power press
• High pressure die casting machine

After the fan is assembled it undergoes rigorous testing.
The component for testing  fan were:

• Watt meter (manual)
• RPM meter
• Test chamber to check the air delivery 

        As we left the premises of the plant I took a last glimpse of the plant...the magic was fading... I will never forget how cool and airy life becomes with machines... indeed I have become a great fan of the manufacturing process...

Bulb Manufacturing Plant

It was the first day of my industrial training and today we were to visit the bulb manufacturing plant...
The first attempts at using electric light were made by English chemist Sir Humphry Davy. In 1802, Davy showed that electric currents could heat thin strips of metal to white heat, thus producing light. This was the beginning of incandescent (defined as glowing with intense heat) electric light.
Now for the actual process...
In the high-speed manufacture of incandescent bulbs on the Corning ribbon machine (Tooley, 1971), glass flows from the furnace fore hearth between two rotating, water-cooled, rollers and onto the Ribbon machine as a horizontal ribbon of glass. This ribbon travels  between two belts - the top belt consisting of a series of blowing heads and the bottom belt consisting of a corresponding series of moulds.
As the belts and the glass ribbon pass through the belts, the glass is blown by the blowheads on the top belt into the moulds on the lower belt which have been sprayed with water and are rotating. As the glass is blown into  the mould a 'blister' forms into bulb envelope. The steam cushion formed between the glass and the mould leaves the bulb with a polished surface whilst the rotation eliminates mould seams. The shaped bulb is release from its mould, cooled by air jets and then finally tapped off (or cracked) from the ribbon and dropped onto an annealing conveyor. This carries it through an annealing and air cooling. After the filament and stem assembly are inserted into the bulb, the air inside the bulb is evacuated and an argon/nitrogen mixture is pumped in. Finally, the base is sealed on.
The inside of the bulb is coated with silica to remove the glare caused by a glowing, uncovered filament. The company emblem and bulb wattage are then stamped onto the outside top of each casing. The bulbs undergo rigorous testing.
Compact Fluorescent light bulbs, also known as CFLs, are an eco friendly alternative to standard incandescent light bulbs. CFLs can be screwed into the same sockets as other light bulbs and provide very comparable lighting. CFLs are easily recognizable due to their distinct twisting shape. These “green” light bulbs have a host of benefits that can help improve the planet, our home and finances. One of the greatest benefits of compact fluorescent light bulbs is their energy efficiency. A CFL uses 50 to 80 percent less energy than other light bulbs.
      We spent the evening at the plant. The experience was thought provoking
and I have penned down from the notes I had taken. I learnt how machines
brighten up our lives...