Process Flow Chart [PDF]

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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



CONTD. TO NEXT PAGE



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



CONTD. TO NEXT PAGE



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



CONTD. TO NEXT PAGE



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