Process Flow Chart.xls

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PROCESS FLOW CHART

PAGE : 1 OF 09

DATE (Org.) : 12.05.2014

DATE (Rev. 1) :

Characteristics

Operation Description

Location

Product

Process

Control Method

> PE/ WI/ 3.18 Raw Material Store - 1) Identification (Colour code) - - > Supplier Invoice

1

> PE/WI/3.19 > Supplier T.C

> Raw Materail Verification (Batchwise) > Indent

2) Supplier - - > Approved source list

> W.I. # 3.19.A

3) Chemical Compositiuon -

-4) Storage > Stock Register

for Al. alloy.

CONTD. TO NEXT PAGE > Different location

for different Al. alloy

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

(SIGNATURE)

REV- 01

PROCESS

INSPECTION STORAGE TRANSPORT

(PRESSURE/ GRAVITY DIE CAST COMPONENT)

PART NAME :

PIPE, AIR TRANSFER

PART / DRG. NUMBER :

5336251

Oper.

No.

Work

Instruction

Reference

Number

Fixture / Die

Reference

Number

Spl.

Char.

Class

> Third Party Spectro Report

Al. alloy- 5016 Receipt & Storage

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PROCESS FLOW CHART

PAGE : 2

DATE (Org.) : 12.05.2014

Characteristics

Operation Description

Location

Product

Process

Control Method

1) Die Temp

-2 PE/WI/3.4 Ganesh Shell Core Shell Core Die 2) Zirkote coating - > W.I. # 3.33 (for Span Core m/c)

3) Curing Time > Operator awareness

> W.I. # 3.33.B (for Span Core m/c)

-5) Parting line clean

-6) Parting line mismatch

-7) Core Baking

-8) Inside Core

-9) Outside Surface of Core

-CONTD. TO NEXT PAGE 10) Damage - > PCS (F-10)

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

(SIGNATURE)

REV- 01

PROCESS

INSPECTION STORAGE TRANSPORT

PART NAME :

PIPE, AIR TRANSFER

PART / DRG. NUMBER :

5336251

Oper.

No.

Work

Instruction

Reference

Number

Fixture / Die

Reference

Number

Spl.

Char

Class

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

4) Resin Coated

Sand > Operator awareness > Visual Sample displayed on the Shop floor.

> Visual Sample displayed on the Shop floor.

Shell Core

Making

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PROCESS FLOW CHART

PAGE : 3

DATE (Org.) : 12.05.2014

Oper. No.

Location

Product

Process

Control Method

3 - > Holding Furnance Temp. - > Temperatrure Controller

PE/WI/3.1

_-

- > Molten Metal - > W.I. # 3.41 (for Melting Furnace)

PE/WI/3.2 - - > W.I. # 3.41 (for Melting Furnace)

-

-4 GDC area - > Holding Furnance Temp. - > Temperatrure Controller

- > Molten Metal Temp. - > PCS (F-08)

PE/WI/3.2 - > Degassing with Tablet - > W.I # 3.2.A (For Molten metal)

> Al. Cover Flux - > W.I # 3.2.A (For Molten metal)

PE/WI/3.22 - > Al. Innoculent Tablet - > W.I # 3.2.A (For Molten metal)

PE/WI/3.23 > Mechanical properties - > Mechanical properties log book

CONTD. TO NEXT PAGE

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

(SIGNATURE)

REV- 01

PROCESS

INSPECTION STORAGE TRANSPORT

PART NAME :

PIPE, AIR TRANSFER

PART / DRG. NUMBER :

5336251

Operation

Description

Work

Instruction

Reference

Number

Fixture / Die

Reference

Number

Spl. Char

Class

Melting Furnace (Electric)

> Purification of metal with Al. cover flux.

> To avoid Mix-up of

different Al. alloy > Different Bins for different alloy. (colour code)

> Tensile Stength > Hardness Test

Melting of

Al. alloy

Preparation of Al.

alloy

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PROCESS FLOW CHART

PAGE : 4

DATE (Org.) : 12.05.2014

Characteristics

Control Method

Operation Description

Location

Product

Process

5 G.D.C Die. - > Molten metal temp. - > PCS (F-08)

-

> Preparation of Die coat > W.I. # 3.3 (For Die Coating)

> 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

> Dimn Parameter - > F.P.A (F-15)

> Grain structure _- _{> PCS (F-08)}

> Crack / Blow Hole - > PCS (F-08)

> Surface finish

-> Product Identification

-CONTD. TO NEXT PAGE

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

(SIGNATURE)

REV- 01

PROCESS

INSPECTION STORAGE TRANSPORT

PART NAME :

PIPE, AIR TRANSFER

PART / DRG. NUMBER :

5336251

Oper.

No.

Work

Instruction

Reference

Number

Fixture / Die

Reference

Number

Spl.

Char.

Class

G.D.C Area ( Holding Furnance)

> Visual Sample displayed on the Shop floor

Gravity

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.

PROCESS FLOW CHART

PAGE : 5

DATE (Org.) : 12.05.2014

Characteristics

Operation Description

Location

Product

Process

Control Method

6 PE/WI/3.8 > PE/ M / 49 Cutting fixture > Cutting blade 10 TPI > Vibration & - > Work Insruction for Bandsaw cutting sharpness of cutting

blade

> Components free from - - > Visual Sample Displayed Runner / Riser

-7 PE/WI/3.9 Fetting Area - > Parting line -

-- > Sharp edge -

-- > Unwanted Projection -

-- > Inside surface -

-8

> PE / WI / 3.13 V.I. Plant - > Porosity sealed of component.

-> Cycle Time > L.P.T

CONTD. TO NEXT PAGE

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

(SIGNATURE)

REV- 01

PROCESS

INSPECTION STORAGE TRANSPORT

PART NAME :

PIPE, AIR TRANSFER

PART / DRG. NUMBER :

5336251

Oper.

No.

Work

Instruction

Reference

Number

Fixture / Die

Reference

Number

Spl.

Char.

Class

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

> Hot Water temp. > Vacuum Pressure at Auto clave

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

Fetting

Cutting of Runner/ Riser

Vacuum Impregnation

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.

PROCESS FLOW CHART

PAGE : 6

DATE (Org.) : 12.05.2014

Characteristics

Operation Description

Location

Product

Process

Control Method

9

> PE/FIX/LPT/32 - > Air Pressure

-> Leak Proof > Dipping in water - > LPT Record

10

> PE / WI / 3.11 > PE/M/82/60 > PE/FIX/LM-34

> RPM & FEED of m/c

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

(SIGNATURE)

REV- 01

PROCESS

INSPECTION

STORAGE TRANSPORT

PART NAME :

PIPE, AIR TRANSFER

PART / DRG. NUMBER :

5336251

Oper.

No.

Work

Instruction

Reference

Number

Fixture / Die

Reference

Number

Spl.

Char.

Class

Leak Proof Test

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

> Ф 54.0 ± 0.10 (Diameter) > Clamping of component in fixture > PCS (F-11) > PDS > Cpk (major) > Ф 56.0 ± 0.25 (Diameter) > Tool change frequency > Ф 65.85 ± 0.15 (Diameter) > 3.22 ± 0.10 (Width) > 2.0 ± 0.08 (Depth) > 2.33 ± 0.13 (Height) > 3.65 ± 0.05 (Width)

Leak proof test

Machining

(C.N.C)

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PROCESS FLOW CHART

PAGE : 7

DATE (Org.) : 12.05.2014

Characteristics

Operation Description

Location

Product

Process

Control Method

11

> PE/WI/3.11 > Drilling m/c - > Facing surface - -

-12 PE/WI/3.12 - - - > Millipore Test

> Filtration

-> Solvent Temp. - > Daily Check list (For H.P.C) - > 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)

PART NAME :

PIPE, AIR TRANSFER

PART / DRG. NUMBER :

5336251

Oper.

No.

Work

Instruction

Reference

Number

Fixture / Die

Reference

Number

Spl.

Char.

Class

High Pressure Cleaning M/c > Component Cleaning (free from burrs, dust oil particles) > Compressed air pressure

High Pressure

Cleaning

Deburring

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PROCESS FLOW CHART

PAGE : 8

DATE (Org.) : 12.05.2014

Characteristics

Control Method

Operation Description

Location

Product

Process

13 > PE/ WI/3.17 > Final Insp. area - - > PDI Report (F-6)

- - > Quality Plan (F-37) > Width 3.22 ± 0.10 -> Depth 2.0 ± 0.08 -> / 0.10 (Flatness) -- -- --

-CONTD. TO NEXT PAGE

-

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

REV- 01

(SIGNATURE)

PROCESS

INSPECTION STORAGE TRANSPORT

PART NAME :

PIPE, AIR TRANSFER

PART / DRG. NUMBER :

5336251

Oper.

No.

Work

Instruction

Reference

Number

Fixture / Die

Reference

Number

Spl.

Char.

Class

> Diameter Ф 54.0 ± 0.10 > Diameter Ф 65.85 ± 0.15

> 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)

Final Inspection/

Pre Dispatch Insp.

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PROCESS FLOW CHART

PAGE : 9 DATE (Org.) : 12.05.2014

Characteristics

Control Method Operation Description Location Product Process

14 > PE/ WI/ 3.18 Packaging area - - -

-15 > PE/ WI/ 3.18 Ware - House - - - > Presence of 100% Tagging

16 > PE/ WI/ 3.18 Ware - House - - -

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

REV- 01 (SIGNATURE)

PROCESS INSPECTION STORAGE TRANSPORT PART NAME :

PIPE, AIR TRANSFER

PART / DRG. NUMBER :

5336251

Oper. No. Work Instruction Reference Number Fixture / Die Reference Number Spl. Char. Class.

> Labeling with bar code sticker

> Tagging for Material Identification > PDI Report > Packing slip > Dock Audit Packaging Storage Dispatch

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