Process Flow Chart.xls

PROCESS FLOW CHART (PRESSURE/ GRAVITY DIE CAST COMPONENT) PAGE : 1 OF 09 PART NAME : PIPE, AIR TRANSFER PART / DRG. NUMBER : 5336251

DATE (Org.) : 12.05.2014 DATE (Rev. 1) : Characteristics

Oper. No.

1

Operation Description

Al. alloy5016 Receipt & Storage

Work Instruction Reference Number

> PE/ WI/ 3.18

Location

Raw Material Store

Fixture / Die Reference Number

-

Product

1) Identification (Colour code)

Process

-

Spl. Char. Class

-

> PE/WI/3.19

Control Method

> Supplier Invoice > Supplier T.C > Raw Materail Verification (Batchwise) > Indent

2) Supplier

-

-

3) Chemical Compositiuon

-

-

> Approved source list > W.I. # 3.19.A

4) Storage

> Third Party Spectro Report > Stock Register for Al. alloy.

CONTD. TO NEXT PAGE

> Different location for different Al. alloy

FORMAT NO. PE-F-QS-PPAP/PFC-036 REV- 01

(SIGNATURE) PROCESS

INSPECTION STORAGE TRANSPORT

PROCESS FLOW CHART PAGE : 2 PART NAME

: PIPE,

AIR TRANSFER

PART / DRG. NUMBER :

5336251

DATE (Org.)

:

12.05.2014

Characteristics Oper. No.

2

Operation Description

Shell Core Making

Work Instruction Reference Number

PE/WI/3.4

Location

Ganesh Shell Core

Fixture / Die Reference Number

Product

Shell Core Die

Process

Spl. Char Class

1) Die Temp

-

2) Zirkote coating

-

3) Curing Time

Control Method

> PCS (F-10) > W.I. # 3.33.A (for Span Core m/c) > W.I. # 3.33 (for Span Core m/c) > Operator awareness > W.I. # 3.33.B (for Span Core m/c)

4) Resin Coated Sand

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FORMAT NO. PE-F-QS-PPAP/PFC-036 REV- 01

-

> Operator awareness

5) Parting line clean

-

Visual Sample displayed on the Shop floor. > Visual Sample displayed on the Shop floor.

6) Parting line mismatch

-

> Visual Sample displayed on the Shop floor.

7) Core Baking

-

> Visual Sample displayed on the Shop floor.

8) Inside Core

-

> Visual Sample displayed on the Shop floor.

9) Outside Surface of Core

-

> Visual Sample displayed on the Shop floor.

10) Damage

-

> PCS (F-10)

>

(SIGNATURE) PROCESS

INSPECTION

STORAGE TRANSPORT

PROCESS FLOW CHART PAGE : 3 PART NAME

Oper. No.

3

: PIPE,

AIR TRANSFER

Operation Description

Work Instruction Reference Number

Location

Fixture / Die Reference Number

Melting of Al. alloy

PE/WI/3.2

Preparation of Al. alloy

Melting Furnace (Electric)

GDC area

-

> Temperatrure Controller

> Molten Metal

-

> W.I. # 3.41 (for Melting Furnace)

> Purification of metal with Al. cover flux.

-

> W.I. # 3.41 (for Melting Furnace)

-

> To avoid Mix-up of different Al. alloy

-

> Different Bins for different alloy. (colour code)

-

> Holding Furnance Temp.

-

> Temperatrure Controller

> Molten Metal Temp.

-

> PCS (F-08)

> Degassing with Tablet

-

> W.I # 3.2.A (For Molten metal)

> Al. Cover Flux

-

> W.I # 3.2.A (For Molten metal)

> Al. Innoculent Tablet

-

> W.I # 3.2.A (For Molten metal)

> Tensile Stength > Hardness Test

-

> Mechanical properties log book

-

-

PE/WI/3.23

Control Method

-

-

PE/WI/3.22

Process

Spl. Char Class

: 12.05.2014

> Holding Furnance Temp.

PE/WI/3.2

DATE (Org.)

Product

PE/WI/3.1

4

5336251

PART / DRG. NUMBER :

> Mechanical properties

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FORMAT NO. PE-F-QS-PPAP/PFC-036 REV- 01

(SIGNATURE) PROCESS

INSPECTION STORAGE TRANSPORT

PROCESS FLOW CHART PAGE : 4 PART NAME

: PIPE,

AIR TRANSFER

5336251

PART / DRG. NUMBER :

DATE (Org.)

: 12.05.2014

Spl. Char. Class

Control Method

Characteristics Oper. No.

5

Operation Description

Work Instruction Reference Number

Gravity Die. Casting

Location

G.D.C Area ( Holding Furnance)

Fixture / Die Reference Number

G.D.C Die.

Product

Process

-

> Molten metal temp.

-

> PCS (F-08)

-

> Preparation of Die coat

> PE/WI/3.3

-

> Die Coat Spray

-

> W.I. # 3.3 (For Die Coating)

> PE/WI/3.5

-

> Die Temp.

-

> W.I. # 3.5 (For G.D.C)

> PE/WI/3.7

-

>Pouring Time.

> Operator awareness

-

> Solidification Time

> Operator awareness

> W.I. # 3.3 (For Die Coating)

> Dimn Parameter

-

> F.P.A (F-15)

> Grain structure

-

> PCS (F-08)

> Crack / Blow Hole

-

> PCS (F-08)

> Surface finish

-

> Visual Sample displayed on the Shop floor

> Product Identification

-

> Visual Sample displayed on the Shop floor

CONTD. TO NEXT PAGE

FORMAT NO. PE-F-QS-PPAP/PFC-036

(SIGNATURE)

REV- 01 PROCESS

INSPECTION STORAGE TRANSPORT

.

PROCESS FLOW CHART PAGE : 5 PART NAME

:PIPE,

AIR TRANSFER

PART / DRG. NUMBER : 5336251

DATE (Org.)

: 12.05.2014

Characteristics Oper. Operation Description No.

Work Instruction Reference Number

Location

Fixture / Die Reference Number

Product

Process

Spl. Char. Class

Control Method

Cutting of Runner/ Riser 6

PE/WI/3.8

> PE/ M / 49

Cutting fixture

> Cutting blade 10 TPI

> Vibration &

-

> Work Insruction for Bandsaw cutting

-

> Visual Sample Displayed

sharpness of cutting blade > Components free from

-

Runner / Riser 7

8

Fetting

PE/WI/3.9

Fetting Area

-

> Parting line

-

-

>W.I. # 3.9 (for fetting ) > Visual Sample displayed on the Shop floor

-

> Sharp edge

-

-

>W.I. # 3.9 (for fetting ) > Visual Sample displayed on the Shop floor

-

> Unwanted Projection

-

-

>W.I. # 3.9 (for fetting ) > Visual Sample displayed on the Shop floor

-

> Inside surface

-

-

>W.I. # 3.9 (for fetting ) > Visual Sample displayed on the Shop floor

-

> Porosity sealed of component. > Hot Water temp. > Vacuum Pressure at Auto clave > Cycle Time

-

> Daily Check List ( For V.I ) > W.I.# 3.13 for V.I

Vacuum Impregnation > PE / WI / 3.13 V.I. Plant

> Record for V.I > L.P.T

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FORMAT NO. PE-F-QS-PPAP/PFC-036 REV- 01

(SIGNATURE) PROCESS

INSPECTION STORAGE TRANSPORT

.

PROCESS FLOW CHART PAGE : 6 PART NAME

: PIPE,

AIR TRANSFER

PART / DRG. NUMBER : 5336251

DATE (Org.) : 12.05.2014

Characteristics Oper. Operation Description No. 9

Work Instruction Reference Number

Location

Product

Process

Spl. Char. Class

Control Method

Leak proof test Leak Proof Test area.

10

Fixture / Die Reference Number

> PE/FIX/LPT/32

Machining (C.N.C)

> PE / WI / 3.11 > PE/M/82/60

> PE/FIX/LM-34

-

> Air Pressure

-

> Calibration of Gauge > W.I. # 3.14 for L.P.T

> Leak Proof

> Dipping in water

-

> LPT Record

> Ф 54.0 ± 0.10 (Diameter) > Ф 56.0 ± 0.25 (Diameter)

> Clamping of component in fixture

> Ф 65.85 ± 0.15 (Diameter)

> Tool change frequency

> PCS (F-11) > PDS > Cpk (major)

> RPM & FEED of m/c > 3.22 ± 0.10 (Width) > 2.0 ± 0.08 (Depth) > 2.33 ± 0.13 (Height) > 3.65 ± 0.05 (Width) CONTD. TO NEXT PAGE

>

/ 0.10 (Flatness)

> 155.8 ± 1.02 (C. H) > 0.5 ± 0.2 x 45º (Chamfer) > 0.5 ± 0.2 x 45º (Chamfer)

FORMAT NO. PE-F-QS-PPAP/PFC-036 REV- 01

(SIGNATURE) PROCESS

INSPECTION

STORAGE TRANSPORT

PROCESS FLOW CHART PAGE : 7 PART NAME

: PIPE,

AIR TRANSFER

PART / DRG. NUMBER :

5336251

DATE (Org.)

: 12.05.2014

Characteristics Oper. Operation Description No.

Work Instruction Reference Number

Location

> PE/WI/3.11

> Drilling m/c

Fixture / Die Reference Number

Product

Process

Spl. Char. Class

Control Method

11 -

> Facing surface

-

-

-

> Component Cleaning (free from burrs, dust oil particles)

-

-

-

Deburring

12

High Pressure Cleaning

PE/WI/3.12

High Pressure Cleaning M/c

> Millipore Test

> Filtration

-

> Solvent Temp.

-

> Daily Check list (For H.P.C)

> Compressed air pressure

-

> Daily Check list (For H.P.C)

CONTD. TO NEXT PAGE

FORMAT NO. PE-F-QS-PPAP/PFC-036 REV- 01 PROCESS

INSPECTION

STORAGE TRANSPORT

(SIGNATURE)

PROCESS FLOW CHART PAGE : 8 PART NAME

: PIPE,

AIR TRANSFER

PART / DRG. NUMBER :

5336251

DATE (Org.)

: 12.05.2014

Characteristics Oper. No.

13

Operation Description

Final Inspection/ Pre Dispatch Insp.

Work Instruction Reference Number

> PE/ WI/3.17

Location

> Final Insp. area

Fixture / Die Reference Number

-

Product

Process

> Diameter Ф 54.0 ± 0.10

-

> Diameter Ф 65.85 ± 0.15

-

> Width 3.22 ± 0.10

-

> Depth 2.0 ± 0.08

-

>

-

/ 0.10 (Flatness)

Spl. Char. Class

Control Method

> PDI Report (F-6) -

> Quality Plan (F-37) > Log Book for Final Inspection (PE-LB-QS-FI -004)

> Diameter Ф 76.7 ± 0.76

-

-

> Center Height 155.8 ± 1.02

-

-

> Smooth > Free from sand particles (inner surface)

-

-

> Smooth

-

-

> Free from burrs / Sharp edge & Casting defect.(outersurface)

CONTD. TO NEXT PAGE

FORMAT NO. PE-F-QS-PPAP/PFC-036 REV- 01

(SIGNATURE) PROCESS

INSPECTION STORAGE TRANSPORT

PROCESS FLOW CHART PAGE : 9 PART NAME

: PIPE, AIR TRANSFER

PART / DRG. NUMBER : 5336251

DATE (Org.)

: 12.05.2014

Characteristics Oper. No.

14

Operation Description

Packaging

15

Work Instruction Reference Number

> PE/ WI/ 3.18

> PE/ WI/ 3.18

Location

Fixture / Die Reference Number

Product

Dispatch

> PE/ WI/ 3.18

Control Method

Packaging area

-

-

> Labeling with bar code sticker

-

-

Ware - House

-

-

> Tagging for Material Identification

-

> Presence of 100% Tagging

Ware - House

-

-

Storage

16

Process

Spl. Char. Class.

-

-

> PDI Report

> Packing slip

> Dock Audit

FORMAT NO. PE-F-QS-PPAP / PFC-036 REV- 01

(SIGNATURE) PROCESS

INSPECTION STORAGE TRANSPORT