REFRIGERATOR

HISTORY OF GODREJ
The Godrej label has come to mean different things to different

people across the length and breadth of India.

Its founder, Ardeshir Godrej, was a staunch nationalist and

believed that the country's economic degradation was even worse than its political subjugation, and that freedom could not be won unless it became self-reliant. Beginning with security equipment and soaps, the group diversified into a wide variety of consumer goods and services, all constructed on the strength of the Godrej brand.
Godrejs new EON Range of Frost Free Refrigerators that have

outstanding features never been witnessed in the Indian refrigerator market before...

MATERIALS
Refrigerators today consist of several basic components: the

exterior cabinet and door, the inner cabinet or liner, the insulation inserted between the two, the cooling system.
The cabinet and door are made of aluminum or steel sheet metal

that is sometimes prepainted. The metal is generally purchased in a coil that is either fed directly into the manufacturing process or cut to size and fed sheet by sheet.
The inner cabinet is made of sheet metal, like the outer cabinet,

or of plastic.
The insulation that fills the gap between the inner and outer

cabinets consists of fiberglass or polyfoam.

MATERIALS

The components of the cooling system (compressor, condenser,

coils, fins) are made of aluminum, copper, or an alloy.

Freon remains the most commonly used refrigerant, and almost

all of the large interior fixtures (door and cabinet liners) are made from vacuum-formed plastic.

Design
The contemporary refrigerator is based on two basic laws of

physics: one that heat flows from warmer material to cooler materials and never the reverse; two that decreasing the pressure of a gas also decreases its temperature.
A refrigerator works by removing the warmth from the air within

its interior compartments and relaying that heat to the air outside. Beginning in the evaporator, the Freon is heated and begins to draw heat from the air within the refrigerator.
The coolant (Freon) accomplishes this transfer as it passes

through a circuit, moving from the evaporator to the condenser. Beginning in the evaporator, which lies inside an insulated cabinet, the freon is heated. Because it has been made to boil, the freon draws heat from the air within the refrigerator.

Design
Having absorbed this heat, the freon is then routed to the

condenser.
In this set of copper coils (usually mounted at the back or on the

bottom of the refrigerator), the freon condensesreturns to a liquid statetransferring its heat into the outside air as it does so. After cooling, the freon then returns to the evaporator, where it is once again heated and begins to absorb heat from the food stored within the refrigerator. Sometimes, to increase their surface area (and thus facilitate thermal transfer), the evaporator and the condenser are fitted with metal fins.
For defrosting, a coil is wrapped around the freezer unit. When

the timer reaches defrost, the refrigerant is passed through this coil while it is hot to raise the temperature and melt the ice.

The Manufacturing Process

Outer cabinet and door
1- Pieces of sheet metal are either welded or clinched

together. Clinching is a process closely resembling stapling in that the two pieces are crimped together under pressure, though no additional pieces such as staples are added. If the part of the cabinet is to be visible, it will be welded and ground down to appear as one piece. The extent to which the welding process is automated depends on the company and the number of refrigerators being produced. 2- If the sheet metal was not purchased in precoated form, it is now painted. Some manufacturers use spray equipment to lay a uniform coat of paint on the metal. Others dip the parts in a paint/solvent mixture before heating them to bake the paint onto the surface.

The Manufacturing Process

Inner cabinet
3- The inner cabinet is sometimes made from sheet metal very

similar to the outer shell. Any seams are caulked to improve insulation and looks. Some manufacturers and some models use plastic for inner liners; for example, the inner door is almost exclusively made from plastic today. The plastic liners are vacuum formed. In this process, a thick piece of plastic slightly larger than the finished part has its outer edges clamped and is then heated. The hot plastic is next pulled by vacuum into a mold and cooled. After trimming, the resulting part is ready for assembly. 4- The inner cabinet is inserted into the outer cabinet, and the two are snapped together before the fixtures are inserted. Some tubes and wires are run through the gap between the two before it is filled with insulation. A dispensing device (sometimes robotically operated, sometimes a manually operated long 'gun') inserts foam between the walls. When heated in an oven, this foam expands to add rigidity and insulation to the cabinet. A similar process is used for the doors.

The Manufacturing Process

Cooling system
5- The refrigeration components are attached to the cabinet using

screws and clips. The tubing is soldered together, and a protective coating is sprayed on the joints. The order of this assembly varies between manufacturers and models. The copper tubing from which the coils (condensers and evaporators) have separately been cut, bent, and soldered is then attached to the refrigerator as a unit.
6- The seal on the refrigerator door is created by means of magnet

laden gaskets that are attached to the doors with screws. Handles and hinges are also screwed onto the door before its hinges are screwed onto the cabinet. Some adjustment is allowed for proper operation of the door.

The Manufacturing Process

Testing and adding accessories
7 Most manufacturers mix testing with manufacturing from this

point on. The unit is leak tested with nitrogen (a safe gas that makes up about 79 percent of the air); if it passes, it is charged with refrigerant and subjected to further testing. Next, the accessories (shelves, crispers, ice trays, etc.) are added and taped down for shipping. The unit is given a final look and then packaged for shipping.

ISO 9001:2000 Quality Management System

It was indeed a moment of pride when, some time ago, Godrej

Appliances Ltd. became one of the first few companies in India to be certified to the revised ISO-9001:2000 Standard. They are the first company in the world, certified by RWTUV, to the revised standard. The scope of re-certification audit was for all Appliances, all sites covering Vikhroli, Mohali, Wing, Dadra, and functions including branch Operations. There Quality Management System (QMS) was based on the Process approach. Process, as such, is an interaction and inter-relation of the elements of the system. Our documented processes thus had clearly defined the purpose of each process, the process owners, process inputs, process steps, process outputs and process measures to derive continuous improvement.

ISO 9001:2000 Quality Management System

ISO 9001-2000 is a Company-wide business initiative. It needs to

be re-emphasized that QMS process must be constantly reviewed and aligned to business and customer needs, using the PDCA cycle for continual improvement.
A vibrant and dynamic QMS requires firm commitment,

involvement and discipline from each one of them to enable them to deliver the desired business results and fulfill customer expectations.
The famous US President, the late J. F. Kennedy, said: Dont ask

what the country can do for you, ask what you can do for your country.

ISO 9001:2000 Quality Management System

Today, GAL is at a juncture when we have to seriously introspect

and think creatively how each one of us implements and improves our QMS and brings about a quick turnaround in organizational performance through concerted and enlightened teamwork.

Environmental Concerns
Scientists began to understand that as gases in the

chlorofluorocarbon (CFC) group, which includes freon, waft upward into the stratosphere
Which contribute to the destruction of the ozone layer Efforts to reduce the CFC emissions from refrigerators are

presently continuing on two fronts, as manufacturers attempt to find alternatives to both the coolant freon and the insulator polystyrene.

 The space between the inner and outer cabinets is filled with foam

insulation, usually polystyrene, which can be inserted manually or automatically by a robot. When heated in an oven, this foam expands to add rigidity and insulation to the cabinet.

MATERIAL HANDLING
The earliest units used toxic refrigerants, typically ammonia (R-

717), sulfur dioxide (R-764), or methyl chloride (R-40) as their refrigerant.

In the 1930s R-12 was used to replace sulphur dioxide as the most

commonly used refrigerant. Trademark name for the product was Freon.
A Monitor Top refrigerator was sent on a submarine voyage to the

North Pole with Robert Ripley (the originator of 'Believe It or Not') in 1928, the year after its introduction..
The millionth Monitor Top refrigerator was presented to Henry

Ford in a special radio broadcast in 1931.

Storage & Material Handling Design

Safe storage & handling of stock, accessibility with minimal effort and Throughputs desired form the very basis of our Storage and Handling System decisions. We consider all the available options to decide on the best-suited solutions, adequately supported by Cost-Benefit analysis.

MARKETING STRATEGIES
Currently 96% of it total revenue of Rs 5473 million is from

refrigerator business.
The name godrej enjoy tremendous brand equity in the India

refrigerator market.
Godrej-GE has enter all the segments in the refrigerator market,

and has the widest possible range of refrigerator it is the only player strong in both direct cool and in frost free segment.
The GE brand name is not yet not recognized in the market

except in the premium. Hence the GE brand of refrigerator has been introduced in the premium segment only also, it help create brand awareness of GE as a quality product.

MARKETING STRATEGIES

Godrej has very strong distribution and after sales set-up with 30 stocking offices.

Over1000 wholesale dealer and 400 retail dealer. It has captured about 76% of direct cool segments and is well

placed in frost-free segment.

According to FICCI Survey April-March 2003-2004 Whirlpool and

Godrej are the top two players with market shares of 27 per cent and 20 per cent respectively.

MARKETING STRATEGIES
COMPANY Electrolux Kelvinator LG Videocon Samsung BPL Voltas Akai Rank 3 4 5 6 7 8 9 Share 16% 14.5% 11%

GROWTH OF GODREJ
The appliances division of Godrej & Boyce expects to record a

turnover of Rs 1,400 crore in the fiscal ending March 31, 2008.

In 2006-07 the division registered a turnover of Rs 1,100 crore],

according to George Menezes, Chief Operating Officer. Addressing a news conference on Saturday to announce the launch of a direct-cool refrigerator range with 5-star energy rating, Menezes said that [during calendar year 2007 the refrigerator market in India grew 13.3 per cent compared to 2006.
While the frost-free segment grew at 31.4 per cent, the larger

direct-cool segment grew at 6.7 per cent.

GROWTH OF GODREJ
Last year, the company earned a revenue of Rs 1,100 crore on sale

of its consumer durables

The company was expecting a 40 per cent rise in total revenue in

the coming financial year.]

the all-India refrigerator market recorded a growth of 13.3 per cent

during January-December (2006-07), of which the larger direct cool segment grew at 6.7 per cent and the frost-free at 31.4 per cent.
in West Bengal, while the refrigerator category grew by 12 per

cent, Godrej recorded double the industry growth at 26 per cent. "This phenomenal growth supported by the launch of new products