AMIE PROJECT ON

“An Analysis of Incoming material Quality control

In Siemens Organization”

The institution of engineers (India)

(ESTABLISHED 1920, INCORPORATED BY ROYAL CHARTER 1935)

8, GOKHALE ROAD KOLKATA-700020

MECHANICAL ENGINEERING

UNDER ESTEEMED GUIDANCE BY PREPARED BY

Mr. Mukesh K. Gupta Ravindra Chandrakant Erabatti

(-----------) Membership No. ST545153-7

1
The Institution of Engineers (India) ST-545153-7
 -

CONTENTS

Topic Page No.

1) Certificate of originality ………………………………………………....3

2) Statement of Project Completion………………………………………...4

3) Acknowledgement………………………………………………………..5

4) Synopsis of project ………………………………………………………8-9

5) Description of Organization and department …………………………...10-13

6) Introduction

I. Background of Quality Control.....................................................15

7) Objective of study ………………………………………………………16-32

8) Detailed methodology of study………………………………………….33-35

9) Statement of the problem………………………………………………...36

10) Flow Chat of incoming inspection …………………………………… 37-38

11) Incoming inspection process flow through SAP…………………………39-40

12) Analysis /Solution /Description & final Result……………………….. 41-44

13) Conclusion ……………………………………………………………….45

14) Scope of Future study…………………………………………………….46

15) Comments from project guide…………………………………………….47

2
The Institution of Engineers (India) ST-545153-7
 .

CERTIFICATE OF ORIGINALITY

I hereby confirm that the text of this project is original and contains no material that has been
required for any degree or diploma in any university or any material previously or written unless
the reference to this material is made.

Yours faithfully Approved by

Mr. Ravindra C.Erabatti Mr. Mukesh K Gupta
(ST -545153-7)

Signature of Student Signature of Guide

Date: ---------------------- Date: ----------
Name: ------------------ Name: ----------------------
Membership no: --------------- Membership no: ----------------------

Address: --------------------------------- Address: --------------------------------

-------------------- --------------------
-------------------- --------------------

3
The Institution of Engineers (India) ST-545153-7
 STATEMENT OF PROJECT COMPLETION

DECLARATION

I, Ravindra Chandrakant Erabatti, declare that the work presented in this dissertation titled
“An Analysis of Incoming material Quality control in Siemens Organization” is an authentic
record of my own work carried out at Siemens Ltd.
I, to the best of my knowledge & honesty certify that the conducted study and the respective

project report is entirely new and original, and has not been submitted by me to any other

institution for fulfilment of a course of study.

Ravindra Chandrakant Erabatti

(ST-545153-7)

Mr. Mukesh K. Gupta

()

4
The Institution of Engineers (India) ST-545153-7
 ACKNOWLEDGEMENT

Firstly I would like to thank Almighty God, for his blessings

I would like to express my heartily thanks and indebtedness to my project guide Mr. Mukesh K.

Gupta for his enormous help and encouragement throughout the course of this project report,

which happens to my role model, has always give me a real example of how a researcher should

work.

I express my soulful gratitude to Mr. Yasir Abidi(Incoming Quality Head), Siemens Ltd. for his

valuable time for helping and encouraging me to perform comprehensive steady by managing

official schedules.

I acknowledge gratefully the help and suggestion of my friends and colleague in sprit of their busy

schedule and huge workload they were always eager to help me with their worm attitude and

technical knowledge.

And most importantly I am thankful to the institute for stimulating and emphasizing students to

perform detailed study which equip us to work in corporate world.

Ravindra Chandrakant Erabatti

(ST-545153-7)

5
The Institution of Engineers (India) ST-545153-7
 The Institution of engineers (India)
(Established in 1920, Incorporated by royal charter 1935)
8 Gokhale Road, Kolkata-700 020

BONAFIDE CERTIFICATE
This is to certify that the project work for “An Analysis of Incoming material
Quality control in Siemens Organization” was done by Mr.Ravindra
Chandrakant Erabatti (ST-545153-7) for the partial fulfilment of the award of
AMIE in Mechanical engineering during the year of 2018-2019under my guidance.
This is a bonafide record of the project done by the above student.

Mr. Mukesh K. Gupta

(M 62711-3)
Project Guide

Place: Mumbai

Date:
6
The Institution of Engineers (India) ST-545153-7
 AMIE PROJECT SYNOPSIS ON

“An Analysis of Incoming material Quality control In Siemens

Organization”

The institution of engineers (India)

(ESTABLISHED 1920, INCORPORATED BY ROYAL CHARTER 1935)

8, GOKHALE ROAD KOLKATA-700020

MECHANICAL ENGINEERING

UNDER ESTEEMED GUIDANCE BY PREPAREDBY

7
The Institution of Engineers (India) ST-545153-7
 SYNOPSIS
1. TITLE OF THE PROJECT:

“ An Analysis of Incoming material Quality control in Siemens

Organization “
2. OBJECTIVE OF THE STUDY:-
In order to understand the incoming quality control, history development ,definition using
sampling plan, quality tool and technique and the standard and standardized quality
management system (QMS) as stated in ISO 9001:20 Research in Siemens company was done in
incoming quality control department .

1 .To understand the concept movement of ordered material from incoming to factory
2. To understand concept of acceptance sampling plan of incoming material
3. To understand general characteristics for selection of measuring instrument
4. To study seven basic tool of quality for trouble shooting issue related quality.
5. By using SAP(QM ) application to understand material flow through system.
6. To understand the use of different testing machine and measuring instrument in incoming
quality

3. RATIONALE OF THE STUDY

In order to understand the incoming quality control, history development ,definition using
sampling plan, quality tool and technique and the standard and standardized quality
management system (QMS) as stated in ISO 9001:20 Research in Siemens company was done in
incoming quality control department .This study about measurement in checking the incoming
raw material parts to identify the parts whether in specification or out of specification limit for
this task of measuring any tools and equipment we have been use important for determine that
which tools are suitable for measuring there are some method for summarize for result using
many quality tools such as pareto diagram and cause and effect diagram
Inspection of quality control based on incoming are :
1. Improve the quality of the input material with less variation
2. Greater productivity on the process of checking and transferring to production Section.
3. The way of improve the better supplier relations so that supplier always keep quality
conformance level for the parts incoming time to time

8
The Institution of Engineers (India) ST-545153-7
4. DETAILED METHODOLOGY TO BE USED FOR CARRYING OUT OF THE
STUDY:
1. Interaction with the R&D team to understand test plan &CTC dimension which help during
incoming inspection
2. Collection of data from R &D for preparing control plan,
3. To study vendor test certificate which meet with material specification
4. Queries generation and their solutions
5. Studying ISO /DIN standard, Acceptance sampling plan, and different type of raw material
standard

6. Details study of ISO 9000 QUALITY SYSTEM

7. Details Study of Quality Assurance plan (QAP) & Acceptance sampling Plan with AQL
level

EXPECTED CONTRIBUTION FROM THE STUDY:

1. To understand seven basic tool of quality for trouble shooting issue related quality.

2. To Understand Component test plan, control plan, Acceptance sampling plan, ISO standard,
Report preparation which help to better way carryout inspection
3. To understand SAP (QM) Module which help to maintaining data &fetching data also
understand to process flow in SAP
4. To understand the use of testing equipment, measuring instrument in incoming lab
5. To understand checking fixture which help reduce inspection time and more accuracy
6. To understand 7QC tools which help to trouble shooting problem observed in component

9
The Institution of Engineers (India) ST-545153-7
 DESCRIPTION OF THE WORKING ORGANISATION

Siemens Switchboard plant has established an enviable leadership in the market. This has
been made possible owing to the deep sense of responsibility and the untiring efforts shown
by entire staff of this unit. The switchboard’s factory at Kalwa Works is engaged in the
manufacture of a variety of power transmission equipment which includes high tension
switchboards, OVCB, load break switches, etc. This unit has a well-balanced setup of
administration as well as the shop-floor function, which results in the smooth functioning.
The switchboard products have met and set quality standards that have earned a clear
acceptance on the national as well as international market and as such have emerged as
leaders in a highly competitive environment.

1. THE SWITCHGEAR FACTORY

This plant covers a wide range of equipment concerned with switching &
protection. The product in the switchgear of
Siemens includes high and low tension
precision equipment. The low tension
comprises of contactors, bi-metallic relays,
circuit breakers, fuse, switches, motor control
switches and control switches like push-
buttons, pilot lamps, limit switches, RC fuses,
fuse bases, etc. It also manufactures route
interlocking relays and relay groups for Indian
Railways. The SAP R/3 is introduced in this
plant that increases working efficiency.

10
The Institution of Engineers (India) ST-545153-7
 INCOMING INSPECTION DEPARTMENT
The ability of any organization to react to the needs of customers and service market by timely
introduction of new improved products plays an important role in its success. These new and
improved products should have good Quality and durability for efficient working of the products
and to make a market for the product. Thus regular interaction between production, design and
Quality is very important function, which is performed by the Quality Control (Incoming
Inspection) department. In this department regular inspection of bought out material is carried out
to maintain the Quality standard. There is major contribution of this department in reducing %
rejection of the product. The main aim of this department is to produce the product without any
rejection at the first instant and to satisfy the needs of customer so that company’s status is
maintained.

ACTIVITIES:
 Allocation of daily GRN among inspector to carry out Routine Inspection
 To make inspection plan and control plan for routine material
 Communication to vendor if deviations reported in componanants
 Releasing GRNs through SAP with usage decision code
 To make Rejection note in SAP and send rejected material to vendor
 To follow up with Vendor for CAPA against Non-conformance report
 Send the gauges and instruments for recalibration after specific period of time.
 Ordering and maintaining necessary inspection instruments, special gauges and tool
 To Make Monthly KPI with the help of database tool.
 To keep the record of No. of GRNs received per day and No. of GRNs cleared per day &
displays this information graphically on board.
 As supervisor of the Quality department should inspire and motivate the inspector and guide
them to have a better Quality aspect.
 To maintain 5S and Safety principle in Quality lab

11
The Institution of Engineers (India) ST-545153-7
 LIST OF ACTIVITIES TO BE CARRIED OUT TO COMPLETE THE
PROJECT:

A. Guidance from project guide…………………………………………………………4 days

B. Preparation of synopsis ………………………………………………………………2 days
C. Collection of reference texts and data ………………………………………………10 days
D. Study about the selected topic ………………………………………………………15 days
E. Preparation of the project ……………………………………………………………10 days

Fig : Graphical Presentation of activities

PLACES/LABS/EQUIPMENTS AND PLANNING ARRANGEMENT:

1. Visit to R&D Centre

2. Visit to Quality incoming lab as well as third party lab

3. Software Use:-Inspection database software, Microsoft access,Arco_Cad (for CMM machine),

M tool

12
The Institution of Engineers (India) ST-545153-7
PROBLEMS ENVISAGED IN CARRYING OUT THE PROJECT:

Nil

Prepared by Approved by

Mr. Ravindra C.Erabatti Mr. Mukesh K Gupta

( ST 545153-7 )

13
The Institution of Engineers (India) ST-545153-7
 PROJECT REPORT

14
The Institution of Engineers (India) ST-545153-7
 INTRODUCTION
Background of Quality Control

Generally, the quality control normally competition among the companies in order to control and
produce the products in the best condition. The goal of the best quality control is customer
satisfaction. Besides, quality is important for giving customer expectations and needs. Quality
control is a management function whereby control of the quality of raw materials, assemblies,
produced materiel, components, services related to production, and management, production, and
inspection processes is exercised for the purpose of preventing undetected production of
defective material or the rendering of faulty services.

As a general rule, if defects are eliminated or minimized through quality control, the cost of
production due to waste will decrease. It is simply common sense that when products which
deviate from the intended standard are made, they must either be repaired or discarded and this
would obviously incur extra costs. If it is possible to turn out goods that will fulfill the standard,
naturally costs will decrease in addition to improved customers' satisfaction. It is therefore
appropriate to clearly define first what quality control is before we identify the need for quality
control. The most common notion of quality control is the checking or inspection of the product
to ensure its conformance to specifications.

The concepts of quality control have undergone changes in evolutionary process of refinement
and application. Like quality, they have many definitions. One useful definition for quality
control is that helps to put the preceding discussion on standards and measurements into an
action mode as follows:

“Quality control is the regulatory process through which we measure actual quality
Performance, compare it with standards, and act on the difference.”

The Japanese Industrial Standards defined quality control as:

Quality Control is a system comprising all the means used in the economically
Manufacturing of products or services that meet the quality requirements of the
Buyer.
Quality control should therefore encompass the activities of Prevention, Detection and
Correction of product defects that could cause customers' dissatisfaction. The key point in
quality control is therefore the faithful conformance of the product specifications or standard.
Product defects or deviations from specifications can result from any or combination of some of
the following:
i. Poor product design
ii. Defective raw material
iii. Inadequate, inappropriate machines and tools
iv. Inappropriate environment
v. Human errors

15
The Institution of Engineers (India) ST-545153-7
 1. TITLE OF THE PROJECT

“ An Analysis of Incoming material Quality control in

Siemens Organization “
2. OBJECTIVE OF THE STUDY
In order to understand the incoming quality control, history development, definition using
sampling plan, quality tool and technique and the standard and standardized quality management
system (QMS) as stated in ISO 9001:20 Research in Siemens company was done in incoming
quality control department .

1 .To understand the concept movement of ordered material from incoming to factory
2. To understand concept of acceptance sampling plan of incoming material
3. To understand general characteristics for selection of measuring instrument
4. To study seven basic tool of quality for trouble shooting issue related quality.
5. By using Sap application to understand material flow through system.
6. To understand the use of different testing machine and measuring instrument in incoming
quality
2.1 Movement of Ordered Material:
It is very essential to know that how material is processed from factory gate to shop
floor via inspection department. When the loaded truck comes at factory gate the security
stamps on Challan brought along with the truck and truck enters in the factory. Then this
truck comes at LRD – Load Receiving Department of respective unit. Then the material is
unloaded from vehicle in to container depending upon size and quality of the material they
are kept either in shaper box – a small container or a cage box – a large container. The small
things like washer, nuts etc. are kept in rack provided for this purpose. While doing this
counting or weighing of material as per Challan is done. After counting material is shifted in
empty location.
Then GRN – GOOD’S RECEIPT NOTE is prepared. According to location a tag is
fixed on the container. This tag will contain following information –GRN – No. Date,
Containers, Location, Quantity, Month etc. Then the GRNS are forwarded to group leader.
Group leader will record the GRNS and marks some of them as urgent which are required
urgently. Then he distributes it to the quality inspectors. Then the quality inspectors will
inspect the material considering various aspects and decision is taken whether the material
is accepted or rejected.
Now if the material is accepted then it will shift to the stores. Then it will supply on
the shop floor as per requirement. The GRNS of such material will offer to enter in SAP
system. This will be ‘Okayed’ in computerized SAP system by authorized person. The GRNS
16
The Institution of Engineers (India) ST-545153-7
are released in system means material moved out from incoming inspection department and
it is under stores department. In case of rejection, the material is shifted to Rejection Area
provided separately for this purpose.
A caged room is provided to avoid accidentally mixing of rejected material with
accepted material. The GRNS of such rejected material is also offered to SAP system.
Authorized person will enter these in system as Rejected only. The Rejection Challan of such
GRNS are made. The rejection record is maintained with respective data to eliminate the
cause of rejection.

MATERIAL MOVEMENT AFTER COMING IN THE FACTORY

LOAD RECEIVING DEPARTMENT (LRD)

UNLOADING AT INCOMING DEPT.

DEPENDING
ON THE SIZE
OF GOODS
SCHAFFER

CAGE BOX BOX

TAG ATTACHED AFTER COUNTING

GOODS RECEIPT
NOTE (GRN) OF THE
MATERIAL IS
PREPARED IN SAP

GRN FORWARDED TO QUALITY

PERSON FOR INDSPECTION OF THE
MATERIAL

SENT TO YES NO
RETURNED
STORES OR TO THE
LINE AFTER TO ACCEPT VENDOR
ACCEPTING THE MATERIAL SORTED
OR NOT

17
The Institution of Engineers (India) ST-545153-7
2.2 Sampling plan
A key element of acceptance sampling is the sampling plan. Sampling plans specify the lot size,
the sample size, the number of samples to be taken, and the acceptance/rejection criteria. A
variety plans can be used. Some plans call for selection of a single sample, and others call for
two or more samples, depending on the nature of the plan. The plan used is Single Sampling Plan
and as shown in Table 2.1.

In the single plan, one random sample is drawn from each lot, and every item in the sample is
examined and classified as either “good” or “defective.” If any sample contains more than a
specified number of defectives, c, that lot is rejected.

Table 2.1: Sample Table of Single Sampling Plan

2.3 General characteristics for selection of measuring instrument

 Accuracy: The degree of agreement of the measured dimension with its true
magnitude.

 Amplification: The ratio of measuring instrument output to the input dimension; it is
also called magnification.

 Calibration: The adjustment or setting of a measuring instrument to give readings
that are accurate within a reference standard.

 Drift: An instrument’s capability to maintain its calibration over time; also called
stability.

18
The Institution of Engineers (India) ST-545153-7
  Linearity: The accuracy of the readings of a tool over its full working range.

 Magnification: The ratio of measuring instrument output to the input dimension; also
called amplification.
 Precision: Degree to which a measuring instrument gives repeated measurement of
the same standard.

 Repeat accuracy: The same as accuracy, but repeated many times.

 Resolution: the smallest dimension that can be read on an instrument.

 Rule of 10 (gage maker’s rule): An instrument or gage should be ten times more
accurate than the dimensional tolerances of the part being measured. A factor of 4 is
known as the mil standard rule.

 Sensitivity: Smallest difference in a dimension that an instrument can distinguish or

detect.

 The speed of response: How rapidly a measuring instrument indicates a

measurement, particularly when some parts are measured in rapid succession.

 Stability: An instrument’s capability to maintain its calibration over time; also called
drift

2.5 Seven Basic Tools of Quality

X

The Seven Basic Tools of Quality (also known as 7 QC Tools) originated in Japan when the
country was undergoing major quality revolution and had become a mandatory topic as part of
Japanese’s industrial training program. These tools which comprised of simple graphical and
statistical techniques were helpful in solving critical quality related issues. These tools were
often referred as Seven Basics Tools of Quality because these tools could be implemented by
any person with very basic training in statistics and were simple to apply to solve quality-related
complex issues.
.

19
The Institution of Engineers (India) ST-545153-7
  Cause and Effect Diagram (Ishikawa Diagram / Fishbone Diagram): The cause and
effect diagram gives a graphical arrangement to the potential causes of a problem
(effect). This arrangement helps both with brainstorming and with understanding areas of
opportunity

 Control Chart: Control charts are fairly sophisticated run charts that add in limits of
statistical variation. This helps teams separate normal fluctuations built into a system
from special causes that spike the output.

 Pareto Chart: A Pareto Chart takes advantage of the 80/20 rule to visually show the
categories with the largest impact on a problem.

20
The Institution of Engineers (India) ST-545153-7
 Scatter Diagram: A scatter diagram shows the relationship between two factors. The
visual nature of the chart makes patterns jump out

21
The Institution of Engineers (India) ST-545153-7
 Histogram: A histogram is a type of bar chart that shows data in equal ‘buckets.’ This let
the user see the distribution of data.

 Check Sheet: Check sheets provide a way to collect and tally data. The individual
collecting data simply makes a mark in the appropriate box as a data event is tallied.
Check sheets are commonly set up as a grid, allowing for two factors to be recorded at
once (i.e. type of defect across the top and work station it was identified on in the vertical
column.)

22
The Institution of Engineers (India) ST-545153-7
  Flow Chart: A flow chart is a visual representation of the path an entity takes through a
process. This ‘entity’ could be a person, product or information.

23
The Institution of Engineers (India) ST-545153-7
2.6 APPLICATION OF SAP IN INCOMING INSPECTION DEPARTMENT
Introduction of SAP
SAP (Systems, Applications & Products in data processing) is one of the widely used ERP
(enterprise resource planning) software packages in the computer industry. It was founded by SAP
AG in 1972. Its latest package Shakti 9 was introduced in Nov. 1998. Siemens uses the advanced
developed version of SAP called 4.0 with lot of features in it.

Its Applications
SAP being a ERP software (enterprise resource planning) finds applications in every
field of company .This sap software is common throughout the company & accessible by every
person given the authority to use the software .SAP covers various areas of company interest
shown as below In fig 5.1
 PRODUCTION PLANNIG.
 ACCOUNTING.
 HUMAN RESOURCE PLANNING.
 MARKETING.
 DESIGNING (For creating a BOM of a assembly or subassembly)
 FINANCE.
 LOGISTICS.
 CREATING & MAINTAING A PURCHASE ORDER.
 INVENTORY.

24
The Institution of Engineers (India) ST-545153-7
These are the major areas covered by SAP.

List of SAP
applications

Role Of SAP In Quality Incoming Inspection Department

Quality incoming inspection department depends heavily on SAP for various
purposes .It is connected to finance, marketing, and production planning activities through
SAP. This helps them in create & plan out their activities accordingly. Some of the activities
carried out by department on SAP are as follow:

Material Planning & Creating Purchase order

Accordingly purchase order is created in SAP & sent to vendor. This information is
shared by Finance department to make payments. A record of such orders is automatically
maintained.

Checking Stock Overview

SAP enables department to know the quantity of material available in factory
As the material enters the company a GRN (Goods Receipt Note) is produced in SAP .This
GRN enters the material details in SAP system as regards the Quantity, cost, vendor name,

25
The Institution of Engineers (India) ST-545153-7
vendor code etc. SAP also helps in knowing the location of the material in store & incoming.
This is as shown in the fig 5.2

Item no & Description

Store location &

max usage

Fig 2.2

Posting GRN
T
GRN (GOODS RECEIPT NOTE) is posted through SAP .GRN contains the GRN no.,
quantity, sample size, year, and inspector number, vendor name, vendor code number,
purchase order number, inspection lot number.

Fig 2.3
GRN NO. ACCEPTED
QUANTITY
26
The Institution of Engineers (India) ST-545153-7
When the material’s inspection gets over, then the inspectors put stamp on GRN.

Blue stamp if all the quantity is accepted and red stamp if it gets rejected. Afterwards all GRN are
collected and then it is released with the help of SAP. Excel sheet is prepared in which GRN no.
accepted quantity, remark is there with file name as GPMdate.xls.Refer fig 2.3. This file is then
posted through SAP. Posting means now the material can be further be used in line. Refer fig 2.4

Upload
file
name

Fig 2.4

Bill of Material (Part List)

We can get bill of material which is also called as part lit through SAP.

We just have to put our plant number (9e62), part PTD number of ten digits to get bill of material.
In bill of material we have sub parts name, drawing number, their ammendments, their revised
version number and part belongs to which type of circuit breaker is also mentioned.

Releasing of Material

Releasing of material can we done by putting inspection lot number in QA02>QUALITIY

INSPECTION>INSPECTION LOT>PROSESSING>CHANGE.

27
The Institution of Engineers (India) ST-545153-7
Sometimes posting, single material does not lead to release the material. Therefore we have to
release it separately by putting inspection lot number, total sample quantity, inspector number and
then posting it in two parts separately.

2.7 Introduction of testing machine and measuring instrument use in incoming

quality

1. Testing machine 2. Measuring instrument

1. Digital Vernier caliper 1.Brinell hardness

2. Vickers hardness 2. Micrometer

3. Rockwell hardness 3.Bevel protector

4. Height Gauge 4.Thread plug gauge

5. Surface measuring machine 5.Ring gauge

6. Radius gauge

TESTING MACHINE

Brinell hardness testing machine

The Brinell hardness testing machine is used to determine Brinell hardness, is defined in ASTM
E10. Most commonly it is used to test materials that have a structure that is too coarse or that have
a surface that is too rough to be tested using another test method, e.g., castings and forgings. Brinell
testing often use a very high test load (3000 kgf) and a 10mm diameter indenter so that the resulting
indentation averages out most surface and sub-surface inconsistencies

28
The Institution of Engineers (India) ST-545153-7
Rockwell hardness Testing machine

The Rockwell hardness testing machine is used to determine Rockwell hardness, is defined in
ASTM E1 Most commonly it is used toall metals, except in condition where the test metal structure
or surface conditions would introduce too much variations; where the indentations would be too
large for the application; or where the sample size or sample shape prohibits its use.

Vickers hardness Testing machine

The Vickers hardness test method, also referred to as a micro hardness test method, is mostly
used for small parts, thin sections, or case depth work. The Vickers method is based on an optical
measurement system. The Microhardness test procedure, ASTM E-384, specifies a range of light
loads using a diamond indenter to make an indentation which is measured and converted to a
hardness value

29
The Institution of Engineers (India) ST-545153-7
MEASURING INSTRUMENTS

Digital Vernier

The Digital Caliper (sometimes incorrectly called the Digital Vernier Caliper) is a precision
instrument that can be used to measure internal and external distances extremely accurately. The
example shown below is a digital caliper as the distances/measurements, are read from a LCD
display.

Micrometer

The micrometre consist of a semi-circular frame having a cylindrical extension, the barrel (sleeve),
at its right end and a hardened anvil at the other end. The bore of the barrel (sleeve) is threaded
and a spindle screws into the bore. The spindle carries a graduated thimble which turns at one with
it.

30
The Institution of Engineers (India) ST-545153-7
Bevel Protector

Bevel Protractors are the Angular measuring devices. Vernier Bevel protractor is the simplest
angular measuring device which is having a Vernier Scale(Similar principle as the Vernier
Calliper) along with the acute angle attachment.

Thread plug gauge (GO and NO-GO):

A thread plug gauge is used to check acceptance of a “nut” – i.e. an internally threaded
part. For small threaded parts, the gauge will be double ended, with one end carrying the GO gauge
and the other end, the NO-GO. For large parts, the two may be separate pieces. A thread plug
gauge is designed to check the correctness of the pitch diameter (to the given pitch / TPI).

31
The Institution of Engineers (India) ST-545153-7
Solid Thread Ring Gauge (GO and NO-GO):

A solid thread ring gauge is used to check acceptance of a “screw” – i.e. externally threaded
part. The GO and NO-GO rings are normally separate pieces. A thread ring gauge is designed to
check the correctness of the pitch diameter (to the given pitch / TPI).

Radius Gauge

A radius gauge, also known as a fillet gauge, is a tool used to measure the radius of an
object. Radius gauges require a bright light behind the object to be measured. The Gauge is placed
against the edge to be checked and any light leakage between the blade and edge indicates a
mismatch that requires correction.

32
The Institution of Engineers (India) ST-545153-7
 3. METHODOLOGY OF THE STUDY

Following are the Tool and Quality document which helps in analysis of incoming inspection

 Incoming database software

 M-Tool –To generate nonconformance report (NCR)

 ISO 9000 QUALITY SYSTEM

 Quality Assurance plan (QAP) &control plan

 Acceptance sampling plan

Incoming database software

Inspector used to database software for recording inspection Result ,in which help
to tracking inspection status. Also supervisor easily get data for creating monthly
supplier performance.

33
The Institution of Engineers (India) ST-545153-7
M-Tool –To generate nonconformance report (NCR)

M-tool software used to Generate Non conformity report against supplier A non-conformance
report, is a construction-related document that addresses specification deviation or work that fails
to meet quality standards. The report is used to as part of quality control processes by detailing the
problem, how it occurred, and how to prevent it from happening again. An NCR also is used in
determining a resolution with a customer and documenting any corrective changes made.

Following point included in Non Conformance Report (NCR)

 What is the main reason for the NCR or what went wrong
 Why the work doesn't meet specs
 What can be done to prevent the problem from happening again
 Explanation of corrective action taken/to be taken
 Key players involved in the NCR and specs affected under the NCR

34
The Institution of Engineers (India) ST-545153-7
ISO 9000 Quality System

 It enables to identify and plan tasks and other method of performance in order to yield the right
results.
 It provides the means for identifying and resolving problems and preventing their recurrence,
thereby improving conformance.
 It enables staff to control their own operations thereby fire fighting and freeing managers from
constant intervention in the business operations. This will help to create quality awareness and
job satisfaction among employees.
 It provides means for document links the company’s experience. This can serve as a basis for
training staff and thus improving their performance.
 It provides data that can be used to determine the performance level of operating processes and
products and to effect improvements.
 It generates objectives evidence to demonstrate the quality of products and effectiveness of
systems and thus to build confidence among customers.

Quality Assurance plan

A quality assurance plan is a document, constructed by the project team, meant to ensure the
final products are of the utmost quality. A quality assurance plan contains a set of documented
activities meant to ensure that customers are satisfied with the goods or services a company
provides.

Quality Control Plan

The Control Plan is a document that describes the actions (measurements,

inspections, quality checks or monitoring of process parameters) required at each phase of
a process to assure the process outputs will conform to pre-determined requirements.

Acceptance Sampling

In acceptance sampling is more focused to this project with inspection and measuring of the
incoming raw material before going through the production. Acceptance sampling is a form of
inspection that is applied to lots or batches of items either before or after a process instead of
during the process. In this case, the lots represent incoming purchased items from suppliers of
the factory. The purpose of acceptance sampling is to decide whether a lot satisfies
predetermined standards. All inspections important in this incoming department that satisfy
standards are passed or accepted while those do not are rejected.

35
The Institution of Engineers (India) ST-545153-7
 4.STATEMENT OF THE PROBLEM
First, quality of the incoming quality control on raw materials in any industry has played an
important role. All industries have their responsibilities on managing their quality on raw
materials in order to make sure that this output products can be produced. Company not only has
to provide cost effective product but also quality in incoming materials, which satisfy the further
processing line and good output.

The measurements should be broadly classified as follows:

1. To measure the characteristics of an individual article for the purpose of determine whether or

not the piece conforms to the specifications.

2. To measure the characteristics of the pieces in a sample taken at random from a lot.

3. To measure and choose the supplier giving most problem for incoming material.

4. To measure supplier performance by supplier audit

5.To measure material characteristics with calibrated tool

6.To identified and measure critical to quality dimension with the help of R&D

7.For New Development Part, Plan must be Know before proceeding inspection

8. Correct stock posting to be done in SAP to help correct inventory of material in Warehouse

9. To be Carried out inspection with the help of Control Plan document must.

10.To maintain Temperature of Lab which is necessary for machine performance

11 Fixture must validated with set of frequency because period of time there is chances fixture

wear out

36
The Institution of Engineers (India) ST-545153-7
 5. Flow Chart of Inspection

37
The Institution of Engineers (India) ST-545153-7
Description of Flow Chart
Supplier:-The raw material is coming from suppliers related.

Incoming Material:-In Incoming Quality Control

Department, the raw material for
Cover Top and Chassis Main received.

Incoming Inspection:-IQC will check on dimension, and

Visual for incoming parts.

The condition of product checked.

If Accept If Reject:

Proceed to warehouse and 1 Obtain the Material

Production line used Rejection Report for the
Rejection due to visual and
Dimension defects
.
2. Identify most problem of
Rejection before send back to
Supplier

38
The Institution of Engineers (India) ST-545153-7
 6. Incoming Inspection process flow through SAP
Process Objective

This deals with the creation and processing of Inspection Lots in TRF for Incoming
Material. Inspection lot can be used for the following process:

 Describe the Quality Inspection Parameters of Material.

 Calculation of Sample size for inspection.
 Describe quality specification for material.
 To record and calculate the results during inspection.
 To record usage decision on material.
 To place the material to appropriate stock and location.

In an Inspection lot, TRF QA can capture the results and defects of material received with the
help of Inspection lot system status progress of inspection activity can be monitored.

a. General Requirements

 Inspect vendor goods upon receipt (Goods Receipt Note).

 Inspect goods that have been externally processed when they are returned in goods
receipt.

b. Creation of Lot

 Inspection lot is generated in the background as soon as the TRF MM department has
created the goods receipt of material against Purchase Order. Inspection lot generated is
of Origin 01 and controlled through Quality Management View of the Material Master.

c. Processing of Inspection Lot

 Inspection lot can be processed in following steps:

d. Result and Defect Recording

 Results can be recorded for inspection lot by using transaction code: QA32 or QA51N by
TRF QA for all MIC's assigned to lot. In case defects are noticed then Defect
Notification can be raised for individual characteristics or Lot.

e. Valuation of Characteristics

 Each Characteristic can be evaluated on the basis of specification value or characteristics

attribute of TRF

f. Closing Valuated Characteristic

 Characteristic need to be closed after valuation mark status of lot as closed after
recording and no further result recording is possible afterward.
39
The Institution of Engineers (India) ST-545153-7
g. Usage Decision and Stock Posting

 After goods receipt document, material remains in Quality Restricted Stock. Usage
decision to be taken by TRF QA user and entered for lot based on results recorded during
inspection and accordingly material stock will be moved from Quality (Restricted) stock
to:

 Unrestricted stock for accepted materials.

 Blocked stock for rejected materials.

40
The Institution of Engineers (India) ST-545153-7
 7. ANALYSIS/SOLUTION/DESCRIPTION & FINAL RESULTS:
Introduction of Checking Fixture

・Checking fixture is one name of inspection tooling. It is a scale to measure complicated shape

parts. It is an order made Item. To be used as a correct scale, three important characteristics are

required & construction of its specific area is pre-decided. Shape of scale to be correct

・The area named gauge that represents the actual shape of part to be checked is precisely

machined. Moreover, it is confirmed with a high precision measuring machine.

Shape of scale must not change

・Base that supports the gauge is made of strong construction.

Positioning between scales & checking item must not change

・To fix checking item, precisely made pin or clamps are provided.

PROBLEMS OBSREVED IN QUALITY INCOMING INSPECTION DEPARTMENT:

 Lot of time invested by inspector for measurement maximum dimension &same is

important for product Quality
 Inspection of Some Critical parts ( functional point of view ) is not possible to check 100%
 There is chances of manual error in inspection which might be rejection of component
 Due to some machine limitations(from Available in lab) some dimensions is not able to
check

FIXTURE DESIGN FUNDAMENTALS

Fixture design consists of a number of distinct activities: fixture planning, fixture layout
design, fixture element design, tool body design, etc. Fixture design deals with the establishment
of the basic fixture concepts:

FIXTURE LAYOUT

Fixture layout is an embodiment of the concepts in the form of a spatial Configuration of

the fixture. Generation of fixture layout is to represent the fixture concepts in a physical form. The
following outputs are included in the fixture layout:
41
The Institution of Engineers (India) ST-545153-7
  Positions of locators
 Positions of clamps.
 Positions of supports, if any.
 Type of locators.
 Type of clamps.
 Type of supports.
 Clamping forces and sequence.

Various Aspects of Fixture Design

Following Fixture made in Siemens Organization after analysis of product functionality and same
is difficulty in inspection also

42
The Institution of Engineers (India) ST-545153-7
 Material Description:-Gear Wheel (Drawing) .

Checking Fixture i

Checking Fixture

43
The Institution of Engineers (India) ST-545153-7
Material Description:-Latch Switch Off (Drawing)

Checking Fixture

44
The Institution of Engineers (India) ST-545153-7
 CONCLUSION
 Incoming Quality Control is playing major role to maintaining overall product quality
Also customer satisfaction towards quality

 Inspection processes is detecting internal defects also which might be not detected during
assembly but it will affect after some period of time with usability of product

 Due to incoming Quality Control ,Extra Rework Cost(ECR) on production line will get
minimized

 Vendor Supply performance regular monitored by incoming quality control which help to
take appropriate action on nonconformity

 With help of SAP (QM),With proper way to Material Movement of Released GRN, from
Incoming to Stores which help to maintain correct inventory level

 With the help of 7QC Tools, easily or better way to analysis of failure or deviations
components.

45
The Institution of Engineers (India) ST-545153-7
 SCOPE FOR FUTURE STUDY
 Integration of Bluetooth on measuring instrument which transmit direct measurement reading
to inspection report in PC

 Portable testing machine now days are coming which help to carry out inspection at shop floor
easily if required

 Inspection Report preparation of components to be carried out by with TAB , Eliminate manual
paper work

 With help of CAD file (IGS file ,step file ,Dxf file ) ,CMM inspection is carried out in future with
more precisely also required time of inspection is less compare to manual programming

 Two & three machine feature will be come in one separate machine.

46
The Institution of Engineers (India) ST-545153-7
 COMMENTS OF THE PROJECT GUIDE

The project report covers the most aspects of “An Analysis of Incoming material Quality control
In Siemens Organization” which is helpful in understanding Quality control of incoming
materials is one of the important consideration for improving the quality performance and
customer satisfaction of Siemens Ltd Company.

The suggestion and observation mentioned in this project is considered as a helpful guide line for
future reference with similar scope by the senior management and technical staff related to the
incoming material quality control Activities.

----------------- END OF REPORT ---------------

47
The Institution of Engineers (India) ST-545153-7