cycle time

8 hour shift capacity for HAVC Asseambly

s.no Dept process

Number of cycles

1 2 3 4 5 6 7 8 9 10 Avarage

1

HAV

C

stage -2119 121 120 119 121 123 122 124 124 125 121.8

2stage -3

124 124 123 124 123 125 125 123 123 124 123.8

3stage -4

120 120 121 120 121 122 122 121 121 121 120.9

4stage -5

116 116 118 117 118 118 117 119 117 118 117.4

5stage -6

122 120 122 120 121 122 120 121 120 120 120.8

120.9

6stage -1

121 121 120 119 120 119 119 120 119 120 119.8

7stage-2

120 121 120 119 120 120 119 120 121 120 120.0

8stage-3

119 118 118 119 118 119 120 119 120 119 118.9

119.6

9stage -1

109 108 110 111 109 108 110 110 108 109 109.2

10stage-2

108 110 109 110 110 109 110 109 110 108 109.3

110.0

11 Blower Assystage -1

120 122 119 119 120 119 118 119 120 120 119.6

120

12

fille

r nec

k

Gsl F/C59 60 61 60 59 60 60 60 61 60 60

DSL F/C73 72 71 72 73 73 72 73 71 72 72.2

Hose lower38 36 37 38 36 37 38 37 38 38 37.3

cooling module

fan &shroud

fille

r nec

k

Bracket Assy10 11 10 9 10 11 11 11 11 11 10.5

240

240

262

241

240

480

399

772

8 hour capacity

APPEARANCE INSTRUCTION SHEETPREPARED CHECKED APPROVED

DATE PART NAME MATERIAL

REV NO PART NUMBER COLOUR

SNO CHECK POINTS CHECKING METHOD

DOOWON AUTOMOTIVE SYSTEM INDIA PVT.LTD

NO part name Moulding defect

1

FAN(φ378)

2

SHROUD11

Havc case12

1

CASE-LOWER spray mark , short mould ,Warpage ,flash

2

CASE-INTAKE

short mould , weld line , burn mark , warpage, insert ofset

short mould , weld line , burn mark , warpage,

spray mark , short mould ,Warpage ,lock broken ,flash



1

DUCT-SHOWER, LH

2

DUCT-SHOWER, RH

3

IMPELLER

1

DOOR-INTAKE spray mark , short mould , burn mark ,flash

2

DOOR-MIX



spray mark , short mould ,Warpage ,lock broken ,flash, Run out

spray mark , short mould , burn mark ,flash, rib damage


3 DOOR-VENT

4 DOOR-DEF

5 DOOR-FOOT

6 COVER-EVAP. COREspray mark , short mould ,flash, rib damage

7 COVER-HTR PIPEspray mark , short mould ,flash, rib damage

1 LEVER-SUB DEFspray mark , short mould ,flash, rib damage

2 LEVER-SUB VENTspray mark , short mould ,flash, rib damage

3 LEVER-SUB FOOTspray mark , short mould ,flash, rib damage

4 LEVER-MODE MAIN (M)spray mark , short mould ,flash, rib damage

5 LEVER-MIX MAIN (M)spray mark , short mould ,flash, rib damage

6 CLIP-EVA. FLANGEspray mark , short mould ,flash, rib damage

7 LEVER-SUB DEFspray mark , short mould ,flash, rib damage

8 LEVER-SUB VENTspray mark , short mould ,flash, rib damage

9 LEVER-SUB FOOTspray mark , short mould ,flash, rib damage





13 LEVER-MIX DOORspray mark , short mould ,flash, rib damage

14 CLIP-HTR PIPEspray mark , short mould ,flash, rib damage

15 COVER-FILTERspray mark , short mould ,flash, rib damage

16 HOSE COOL BOX spray mark , short mould ,flash, rib damage


Injection moulding cappacity plan for Augest-09

NO M/C PART NAME PART NUMBER MATERIAL

1

850#1

A/C FAN(φ378) F42023 - 0400 5% 0.365 60 2 120 2640 1848 5.7 10500

19.2 422.6 26.42 SHROUD F47053 - 0920 5% 0.61 65 2 111 2437 1706 6.2 105003

N-A/C FAN(φ340) F42023 - 0320 5% 0.315 60 2 120 2640 1848 0.8 1500

4 SHROUD F47053 - 0930 5% PP-GF30% 0.424 65 2 111 2437 1706 0.9 15001

850#2

LHD

A/CON

D S LC/BOX

10%

PP-T20%

2.505 100 1 36 792 554 10.8

6000 18.9 416.7 26.0

2 NON C/BOX

3G S L

C/BOX

4 NON C/BOX

5NON-A/C

D S L

6 G S L

7

RHD

A/CON

D S LC/BOX

10% 2.485 100 1 36 792 554 8.1 4500

8 NON C/BOX

9G S L

C/BOX

10 NON C/BOX

11NON-A/C

D S L

12 G S L

1

850#3

LHD CASE-LOWER H40893 - 3720 15% 0.305 60 2 120 2640 1848 3.2 6000

20.3 445.8 27.9

2 CASE-INTAKE B40893 - 3740 / 375 15% 0.555 65 1 55 1218 853 7.0 60003

RHD CASE-LOWER H40893 - 3810 15% 0.293 60 2 120 2640 1848 2.4 4500

4 CASE-INTAKE B40893 - 3830 / 384 15% 0.55 65 1 55 1218 853 5.3 4500

1

550

LHD

DUCT-SHOWER, LH H41223 - 0800 15% 0.115 60 1 60 1320 4.56000

2 DUCT-SHOWER, RH H41223 - 0791 15% 0.105 6000

3 IMPELLER B43232 - 0100 0% PP-T10%(N) 0.122 70 4 206 4526 3168 1.3 6000

8.0 175.0 10.9

4

RHD

DUCT-SHOWER, LH H41223 - 0840 15% PP-T20%

0.1 60 1 60 1320 3.44500

5 DUCT-SHOWER, RH H41223 - 0850 15% 0.115 4500

6 IMPELLER B43232 - 0070 0% PP-10%(B) 0.123 70 4 206 4526 3168 1.4 4500

1

450

LHD

DOOR-INTAKE H41243 - 2010 10%

PP-T40% (N)

0.7 55 2 131 2880 2016 3.0 6000

2 DOOR-MIX H41243 - 1970 10% 0.109 70 4 206 4526 3168 1.9 6000

18.8 412.5 25.8

3 DOOR-VENT H41243 - 2000 10% 0.105 70 4 206 4526 3168 1.9 6000

4 DOOR-DEF H41243 - 1990 10% 0.093 70 4 206 4526 3168 3.3 10500

5 DOOR-FOOT H41243 - 1980 10% 0.115 70 4 206 4526 3168 3.3 10500

6 COVER-EVAP. CORE H40853 - 1930 15%

PP-T20%

0.04 58 4 248 5462 3823 1.6 6000

7 COVER-HTR PIPE H40853 - 1920 15% 0.029 58 4 248 5462 3823 1.6 6000

8

RHD

COVER-EVAP. CORE B41243 - 2100 15% 0.029 58 4 248 5462 3823 1.2 4500

9 COVER-HTR PIPE H41243 - 2040 15% 0.04 58 4 248 5462 3823 1.2 4500

Resycle using

persentagepart weight

cycle time

Active cavity

Hourly target

per day 22hrs

22 hr 70% efficiency

requierddays

monthly plan

Required days

Required man hour

As per 16 hrs a day

PA66-GF17%+M21

H40893 - 3680 / 3700

H40893 - 3770 / 3790


10

450

RHD DOOR INTAKE H41243 - 2050 15% PP-T40% (B)

0.074 55 2 131 2880 2016 2.2 4500

18.8 412.5 25.8

11 DOOR-MIX H40583 - 1960 15% 0.105 70 4 206 4526 3168 1.4 4500

12 DOOR-VENT H40583 - 1950 15% 0.107 70 4 206 4526 3168 1.4 4500

13.7 301.1 18.8

1

220

LHD

LEVER-SUB DEF H44423 - 3880 15% PP-T30% (N)

0.01 40 4 360 7920 5544 1.1 6000

2 LEVER-SUB VENT H44423 - 3860 15% 0.006 40 4 360 7920 5544 1.9 10600

3 LEVER-SUB FOOT H44423 - 3870 15% 0.009 38 4 379 8337 5836 1.8 10600

4 LEVER-MODE MAIN (M) H44423 - 3900 10% POM (N)

0.033 50 2 144 3168 2218 2.7 6000

5 LEVER-MIX MAIN (M) H44423 - 3920 10% 0.016 50 2 144 3168 2218 2.7 6000

6 CLIP-EVA. FLANGE H40883 - 2140 15% PP-T20% 0.011 38 4 379 8337 5836 1.0 6000

7

RHD

LEVER-SUB DEF H44423 - 3990 15% PP-T30% (B)

0.01 40 4 360 7920 5544 0.8 4500

8 LEVER-SUB VENT H44423 - 3980 15% 0.006 40 4 360 7920 5544 0.8 4500

9 LEVER-SUB FOOT H44423 - 4000 15% 0.0085 40 4 360 7920 5544 0.8 4500

10

170

LEVER-MODE MAIN (M) H44423 - 3900 10% POM (B)

0.03 50 2 144 3168 2218 2.0 4500

11 LEVER-MIX MAIN (M) H44423 - 4030 10% 0.0155 50 2 144 3168 2218 2.0 4500

7.7 169.8 10.6

12 CLIP-EVA. FLANGE H40883 - 2150 15% PP-T20% 0.011 38 4 379 8337 5836 0.8 4500

13

ALL

LEVER-MIX DOOR H44423 - 3890 15% PP-T30%(N) 0.002 40 4 360 7920 5544 1.9 10500

14 CLIP-HTR PIPE H40883 - 1560 15% PP-T20%

0.0055 38 4 379 8337 5836 1.8 10500

15 COVER-FILTER H40853 - 1910 15% 0.0295 40 4 360 7920 5544 1.9 10500

16 HOSE COOL BOX H48473 - 0010 15% 0.011 45 4 320 7040 4928 2.1 10500

5946 4919 34464554 722 694

200



REV NO PART NUMBER COLOURinspection process


1 short mould & flash in rip area By visual

2 short mould & burn mark By visual

3 weld line and short mould By visual


5 burn mark & warpage By visual

REMARK:

1. After check the all check points 'OK" means put the marking and date and shift

2

1

3

4

5

INSPECTION

ok

not ok

REJ

scrap

packing

isolation





1 short mould & flash in rip area visual

2 short mould & burn mark visual

3 weld line and short mould visual


5 burn mark & warpage visual

REMARK:

1. After check the all check points 'OK" means put the marking writing the date &shift operator code

3

INSPECTION

ok

not ok

REJ

scrap

packing

isolation






2 short mould & burn mark, weld line By visual

3 metal insert position checking By visual

4 weld line and short mould , silver steaks By visual

REMARK:


3

INSPECTION

ok

not ok

REJ

scrap

packing

isolation

1

2

3

4






2 short mould & warpage By visual



REMARK:

1. After check the all check points 'OK" means put the marking and write a date and shift

INSPECTION

ok

not ok

REJ

scrap

packing

isolation

1

2

3

4


DATE PART NAME Lower case LH/RH MATERIAL PP+T20 %

REV NO PART NUMBER H40893-3720/3810 COLOUR blackinspection process



2 short mould & warpage By visual

3 war page ,short mould By visual

4 rip catching mark, short mould By visual

5 silver streaks , short moul By visual

REMARK:


INSPECTION

ok

not ok

REJ

scrap

packing

isolation

4

1

2

3

5


DATE 20.07.09 PART NAME shower duct LH/RH MATERIAL PP+T20 %

REV NO 0 PART NUMBER COLOUR Blackinspection process



2 short mould & flash visual

3 weld line and short mould , locking checking visual

4 weld line and short mould , flash visual

5 bubles, silver streeks visual

REMARK:

1. After check the all check points 'OK" means put the marking and writing the date & shift operator code

H41223-0790/0800/0810/0820

INSPECTION

ok

not ok

REJ

scrap

packing

isolation

1

2 3

4

5


DATE PART NAME Impeller LH/RH

MATERIALPP+T10%

REV NO0

PART NUMBERB43232-0070/0100

COLOURBlack/natural

inspection process


1 short mould visual



4 over all checking a Run out problem visual

5 check the Rip's short fill visual

chek carefully with out struss and tight during packing

REMARK:

1. After check the all check points 'OK" means put the marking

INSPECTION

ok

not ok

REJ

scrap

packing

isolation

1


DATE PART NAME Door vent LH/RH MATERIAL PP+T40%

REV NO PART NUMBER H41243-2000/2050 COLOUR Black/naturalinspection process





4 check deformation(Bend) visual

REMARK:

1. After check the all check points 'OK" means put the marking in locating area

INSPECTION

ok

not ok

REJ

scrap

packing

isolation

1

2

3

4


DATE PART NAME Door DEFF MATERIAL PP+T40%

REV NO PART NUMBER H41243-1990 COLOUR naturalinspection process




3 check the deformation(Bend) visual

REMARK:


INSPECTION

ok

not ok

REJ

scrap

packing

isolation

1 2

3


DATE PART NAME DOOR-INTAKE LH/RH MATERIAL PP+T40%

REV NO PART NUMBER B41243-2010/2000 COLOURnatural

inspection process





REMARK:

1. After check the all check points 'OK" means put the marking writing the date &shift operator code

INSPECTION

ok

not ok

REJ

scrap

packing

isolation

2 1

3


DATE PART NAME DOOR-MIX LH/RH MATERIAL PP+T40%

REV NO PART NUMBER H41243-1970/2040 COLOURnatural

inspection process




3 check the deformation(Bend) visual


visual

REMARK:


INSPECTION

ok

not ok

REJ

scrap

packing

isolation

1

2

3

4


DATE PART NAME COVER-HTR PIPE LH/RH MATERIAL PP+T20 %

REV NO PART NUMBER H40583-1950/1920 COLOUR Blackinspection process


1 short mould & flash in Hole Area visual


3 weld line and short mould in lock area visual

4 weld line and short mould in lock area visual

REMARK:


INSPECTION

ok

not ok

REJ

scrap

packing

isolation12

3

4


DATE PART NAME COVER-EVAP. CORE LH/RH MATERIAL PP+T20 %

REV NO PART NUMBER H40853-1930/1960 COLOUR Black

inspection process


1 short mould & flash in Hole area visual


3 weld line and short mould & Rib dameage visual

4 Flash and short mould visual

5 short ,Flash & warpage visual

REMARK:


INSPECTION

ok

not ok

REJ

scrap

packing

isolation

1

3

4

2

5


DATE PART NAME LEVER-SUB VENT LH/RH MATERIAL PP+T30 %

REV NO PART NUMBER H44423-3860/3980 COLOUR Black

inspection process




3 weld line , gate point projection & Rib dameage visual

4 Flash and short mould , silver streeks visual

REMARK:


INSPECTION

ok

not ok

REJ

scrap

packing

isolation

1

2

3

4


DATE PART NAME LEVER-SUB Food LH/RH MATERIAL PP+T30 %

REV NO PART NUMBER H44423-4000/3880 COLOUR Black/Natureal

inspection process





4 Flash and Rib short mould , silver streeks visual

REMARK:


INSPECTION

ok

not ok

REJ

scrap

packing

isolation

1

2

3

4


DATE PART NAME CLIP-EVA. LH/RH MATERIAL PP+T20 %


inspection process





4 Flash and Rib short mould , silver streeks visual

REMARK:


INSPECTION

ok

not ok

REJ

scrap

packing

isolation12

3


DATE PART NAME MATERIAL pom(F20-03)


inspection process


1 short mould & Flash visual


3 short mould & flow line visual

4 silver streeks , flow mark visual

REMARK:


LEVER-MODE MAIN (M)

INSPECTION

ok

not ok

REJ

scrap

packing

isolation

1

2

3

4


DATE PART NAME MATERIAL pom(F20-03)


inspection process


1 short mould & Flash, lock gape checking visual

2 visual

3 short mould & flow line visual

4 short mould visual

5 silver streeks , flow mark visual

REMARK:


LEVER-MIX MAIN (M)

weld line , gate point projection & Rib dameage, mounting hole checking

INSPECTION

ok

not ok

REJ

scrap

packing

isolation1

2

34

5


DATE PART NAME CLIP-HTR PIPE MATERIAL PP+T20%

REV NO PART NUMBER H40883-0670 COLOUR Black

inspection process


1 short mould & Flash, Hole. gape checking visual

2 short fill blow hole visual

3 short fill blow hole visual

4

5

REMARK:


INSPECTION

ok

not ok

REJ

scrap

packing

isolation

12 3

c

400


DATE PART NAME COVER-FILTER MATERIAL PP+T20%


inspection process


1 short mould & Flash, lock area checking visual

2 short mould checking visual

3 short mould & flow line , silver streeks visual

REMARK:


INSPECTION

ok

not ok

REJ

scrap

packing

isolation

1 2

3


DATE PART NAME HOSE COOL BOX MATERIAL PP+T20%


inspection process


1 short mould & Flash, lock area checking visual

2 short mould & flow line , silver streeks visual

REMARK:


INSPECTION

ok

not ok

REJ

scrap

packing

isolation

12

cycle time

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