Process Flow Chart

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.
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.
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

REV- 01
5) Parting line clean
Visual Sample displayed on the

Shop floor.
> Visual Sample displayed on the
Shop floor.
6) Parting line mismatch

Shop floor.
7) Core Baking

Shop floor.
8) Inside Core

Shop floor.
9) Outside Surface of Core

Shop floor.
10) Damage
> PCS (F-10)
>
(SIGNATURE)
PROCESS
INSPECTION
STORAGE TRANSPORT
PROCESS FLOW CHART

PAGE : 3
PART NAME
Oper. No.
: 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
> Al. Innoculent Tablet
> 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
5336251
> Mechanical properties
CONTD. TO NEXT PAGE

REV- 01
(SIGNATURE)
PROCESS
PROCESS FLOW CHART

PAGE : 4
PART NAME
: PIPE,
AIR TRANSFER
5336251
DATE (Org.)
: 12.05.2014
Spl.
Char.
Class
Control Method
Characteristics
Oper.
No.
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.
> Solidification Time
> 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
(SIGNATURE)
REV- 01
PROCESS
PROCESS FLOW CHART

PAGE : 5
PART NAME
:PIPE,
AIR TRANSFER
DATE (Org.)
: 12.05.2014
Characteristics
Oper.
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
Fetting
PE/WI/3.9
Fetting Area
> Parting line
>W.I. # 3.9 (for fetting )

> Visual Sample
displayed on the Shop floor
> Sharp edge

> Visual Sample
> Unwanted Projection

> Visual Sample
> Inside surface

> Visual Sample
> 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

REV- 01
(SIGNATURE)
PROCESS
PROCESS FLOW CHART

PAGE : 6
PART NAME
: PIPE,
AIR TRANSFER
DATE (Org.) : 12.05.2014
Characteristics
Oper.
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
> 54.0 0.10 (Diameter)

> 56.0 0.25 (Diameter)
> Clamping of
component in fixture
> 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 45 (Chamfer)
> 0.5 0.2 x 45 (Chamfer)

REV- 01
(SIGNATURE)
PROCESS
INSPECTION
STORAGE TRANSPORT
PROCESS FLOW CHART

PAGE : 7
PART NAME
: PIPE,
AIR TRANSFER
5336251
DATE (Org.)
: 12.05.2014
Characteristics
Oper.
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

REV- 01
PROCESS
INSPECTION
STORAGE TRANSPORT
(SIGNATURE)
PROCESS FLOW CHART

PAGE : 8
PART NAME
: PIPE,
AIR TRANSFER
5336251
DATE (Org.)
: 12.05.2014
Characteristics
Oper.
No.
13
Final Inspection/
Pre Dispatch Insp.
Work
Instruction
Reference
Number
> PE/ WI/3.17
Location
> Final Insp. area
Fixture / Die
Reference
Number
Product
Process
> Diameter 54.0 0.10
> Diameter 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 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

REV- 01
(SIGNATURE)
PROCESS
PROCESS FLOW CHART

PAGE : 9
PART NAME
: PIPE, AIR TRANSFER
DATE (Org.)
: 12.05.2014
Characteristics
Oper.
No.
14
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

Process Flow Chart

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PROCESS FLOW CHART

(PRESSURE/ GRAVITY DIE CAST COMPONENT)

DATE (Org.) : 12.05.2014

Al. alloy5016 Receipt

> PE/ WI/ 3.18

Raw Material Store

1) Identification (Colour code)

> Supplier Invoice

> Approved source list

> Third Party Spectro

CONTD. TO NEXT PAGE

> Different location

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

INSPECTION STORAGE TRANSPORT