iso 9001:2015 quality management system iso 9001 : 2015...

Quality Management System

EG PP WI 401

ISO 9001 : 2015

Name Signature Date

Prepared By B. Gowri Kumari 01.04.2017

Reviewed By Y. Krishna Rao 01.04.2017

Approved By M V V Vidyasagar 01.04.2017

CONTROL OF CONFIDENTIALITY

The information contained in this document is the property of HBL, No part of this document may be reproduced in any form without the prior permission in writing of MR/DMR of HBL, Power Electronics

Date Status of review

Reviewed On 01.04.2017 Document revised as per ISO9001:2015 standard

Next review 01.04.2020

ISO 9001:2015


Manufacturing Process Instructions-Production


EG PP WI 401

TABLE OF CONTENTS

Sl.No Description Section Page

1 Title Page - -

2 Control Sheet A 01

3 Distribution List B 01

4

Purpose, Scope and

Responsibility 1.0,2.0,3.0 02

5 Manufacturing Process instructions 4.0 01

6 Sequence of operations 5.0 01 - 10

7 Fixing of label & Identification 6.0 11

8 Electrical assembly & instructions 7.0 11

9 Cable preparation & Crimped connections 8.0 & 9.0 12

10 Soldiering connections, 10.0 13

11 SAP procedure 11 14

12 Risk management 12 14

13 Knowledge management 13 14

14 Change management 14 15

15 Training 15 15

Section: A –Control Sheet Date :01.04.2017

Revision : 00 Page 1 of 1


EG PP WI 401

DISTRIBUTION LIST

S.No Copy No Distributed to Location

1 01 In-Charge Manufacturing PE Shop Floor

2 02 I/C QA PE-QA

3 03 Auditor copy ISO Document Centre

Section: B –Distribution list Date :01.04.2017



EG PP WI 401

1.0 Purpose :

The manufacturing process instructions given for mechanical and electrical assembly of

chargers, cell boosters, DCDB and DC-DC converters which ensures that manufactured

products meets all the customer requirements.

2.0 Scope:

The instructions are prepared to cover mechanical and electrical assembly of chargers

3.0 Responsibility & Authority :

In Charge production shall be responsible authorized for implementation and maintaining

activities.

Organization Chart

Section: –1,2 & 3 – Purpose, Scope & Responsibility Date :01.04.2017


DGM (PE - Operations)

(Y. Krishna Rao)

Sr. Manager (PE - Engg)

(BSV Prasad)

Manager (PE - Production)

(B. Gowri)

PPC

(G. Siva Kumar)

Mechanical Assembly

(G. Vijaya Kumar)

Electrical Wiring

(J. Srinivas Goud)

Testing

(K. Manohar)

Manager - (Procurement)

(PNV Lakshman)


EG PP WI 401

Responsibilities & Authorities

Head Production &

Planning

Responsibilities: Accountability of machine & Manpower.

Accountability of Stocks and Material consumption,

Accountability for accidents & incidents within the

department. Responsible for Quality of product and MIS

circulation. Preparing production plans in coordination with

sale and Engineering.

Supervisor Production

Responsibilities: Preparing production schedule based on

plan provided by PPC. Ensuring production flow as per

schedule. Arranging materials from stores required for Job.

Arranging PPEs for

Technician

Responsibilities:

Section: –1,2 & 3 – Purpose, Scope & Responsibility Date :01.04.2017



EG PP WI 401

PROCEDURES AND WORK INSTRUCTIONS

4.0 MANUFACTURING PROCESS INSTRUCTIONS – BATTERY CHARGERS:

4.1 General

Battery Chargers manufacturing consists of

Mechanical assembly

Electrical wiring and

Testing

4.2 Design Documents:

Battery Chargers are manufactured / assembled based on design documents released by Engineering department. The documents include,

Bill Of Materials (BOM) / Work Order

General Arrangement Drawings (GAD)

Internal component Layouts (ICL)

Wiring Drawings

Label Drawings The assembly process shall conform to the documentation and standard manufacturing practices. Quality Control is carried out at various stages of Assembly and conformance to standard manufacturing practices is ensured at every stage.

4.3 Mechanical Assembly of Charger Console:

The consoles are procured from approved vendor, meeting customer acceptance norms and the drawings released by Engineering. The operations for mechanical assembly of all parts in the console are described below.

5.0 Sequences of operations are:

5.1 Fixing of Mounting Accessories

5.2 Mounting of Magnetics

5.3 Types of Sub –Assemblies and their mounting

5.4 Fixing of cable troughs

5.5 Fixing of front control switches on the door

Section: – Manufacturing process instructions Date :01.04.2017



EG PP WI 401

5.1 Fixing Of Mounting Accessories

Remove the side and back covers of the console. Fix 'C' channels as per the requirement. 'C' channels are fixed at sides of the console structure using appropriate hardware as per BOM / Work order. The threaded blocks / 8MM nuts are held inside the square slots / holes of the structure. Ensure all hardware is tightened to the optimum with respective tools, as illustrated in below.

MS “L” angles of size as specified in the BOM are to be fixed to the bottom of the structure for mounting the Magnetics. Two “L” angles are required for fixing one set of Transformer and Choke. If the transformer and choke are not fitting in one line dimensionally, Choke will be fixed on another two separate angles. Distance between the two “L” angles should be maintained as per the transformer size and fixed using appropriate hardware, ensuring optimum tightening of fastners.

“L” angle/bracket of size as required as per BOM /ICL /GAD are fixed wherever required. These “L” angles/brackets are fixed to the structure directly with bolts, threaded block / nuts and respective plain & spring washers.

Section: 5– Sequence of operations Date :01.04.2017



EG PP WI 401

5.2 Mounting of Magnetics:

Magnetics, which includes the Power Transformer and Choke, are mounted at the bottom of the console on “L” angles. Magnetics should have clearance on all the sides for free air circulation. Generally, Transformer and Chokes have to be fixed at minimum four points, after drilling matching holes on the “L” supporting angles. For transformer above 300kg weight, six-point fixing should be adopted and use appropriate hardware. Transformer fixing is as shown in Fig. 2b.

The orientation of the transformers and chokes should be such that the terminals are easily accessible from front or rear. Magnetics of heavy weight should be reinforced at the top position, in at least two places to the console frame /supporting channel. The reinforcing is shown in Fig. 2a. Reinforcement is done by connecting “C” channels with one end connected to the transformer top side to nearest vertical frame of the console. The “C” channel cut to appropriate size and fixed to the frame with “L” angles of sizes as required as per BOM, No component should be mounted on the transformer and choke




EG PP WI 401

Operation like drilling, tapping should not be done near the magnetics in order to avoid metallic scrap falling on the magnetics. In unavoidable circumstances of rework magnetics are to be covered to prevent metal scrap falling on them.

5.3 Type of Sub-Assemblies:

Sub – assemblies are of the following types.

a. Sub-assemblies on Mounting Plates. b. Sub-assemblies on Bakelite sheets. c. Sub-assemblies on FRP sheets. d. Sub-assemblies on PCB rack.

5.3.1 Sub-Assemblies on mounting plates:

a. PCB Mounting Plates: The PCB mounting plates are generally of the sizes as per BOM. They are fixed as per the internal component layout. The mounting plate is fixed directly on to the “C” channels by means of appropriate hardware illustrated as below.

b. PCB Sub-Assemblies: All PCB’s are mounted on individual plate of size as per BOM and internal component layout. The mounting holes of the PCB'S corresponding holes of size 3.3mm / 4mm (typical) are drilled on the mounting plate. Nylon PCB'S supports are fixed over this holes with self-fixing M3 screws. Distance between 2 PCB'S should be at least 10mm.




EG PP WI 401

PCB'S are fixed on the self-locking Nylon supports. PCB fixing arrangement shown in below

The fixing of the cards on the mounting plates should be in such a way that the adjustment of variable components such as trim pots is possible.

The RC card & Pulse card should be mounted as close as possible to the rectifier bridge assembly.

c. Component Mounting Plate: The mounting plates are taken as per the BOM. They are generally fixed to the width of the console for easy accessibility. These mounting plates are to be fixed with MS “L” angle/bracket of appropriate sizes the “C” channels as per below picture. The “L” angles are fixed to the mounting plate by appropriate hardware fixed to the tapped holes of “L” angles/Brackets.




EG PP WI 401

The components are mounted on a mounting plate as per the internal Component layout. Generally, Contactors, Relays, Shunts, closed type Fuses, MCBs, MCCB's, power sockets etc. are mounted as per below picture. If any special requirements are needed, the mounting plates size to be considered accordingly

Length of the screws should be chosen as required for firm fixing of the contactor with appropriate hardware.

The contactor's are mounted in such a way that they are fixed vertical to the charger as shown in below picture.

While mounting MCCB'S at least 10mm clearance should be available at the terminal ends and 15mm on the sides

All components are mounted as per the mounting holes of the respective components.

Fuses should be grouped in such a way that all AC fuses are on the left side and DC fuses on the right side of the mounting plate.

All fuses are mounted along with the length are mounted such that they will be vertical in the charger




EG PP WI 401

5.3.2 Sub-Assemblies on Bakelite Sheet:

a. Capacitor Bank Assembly: The Capacitor bank sub – assembly is done on 6mm Bakelite Sheet. This sub – assembly is fixed nearest to the choke using “C” channels as per BOM,GAD,ICL and use appropriate hardware The capacitor assembly is fixed in such a way that the vent hole of the capacitor is on the topside for every capacitor.

Filter capacitors as per the quantity specified in BOM are mounted on 6mm Bakelite sheet of suitable size considering the number of capacitors & space available. Capacitor clamps are used for mounting the capacitors. Capacitor clamps are of 4 sizes/ based on the capacitor Bakelite sheets are drilled at suitable places for fixing these clamps. M4 X 15 appropriate CSK screws will be used for fixing, with appropriate washer to the Bakelite sheet. The procedure is as follows.

Clamping the capacitors with the capacitor clamp.

Clamp to be tightened by M4 screws such that it grips the capacitor firmly.

Mounting of capacitors on pre-drilled holes on Bakelite sheet with appropriate fasteners.

The following precautions have to be taken:

The screw heads should be least 2mm inside the bottom surface of the Bakelite sheet. This is to avoid shortening with the “C” channel contact after mounting.




EG PP WI 401

b. Inter Connections of Capacitors: Capacitors are mounted and inter

connected using aluminum / copper bus bar of suitable size. Individual capacitors are inter connected in serial, & separate for positive (Red) and negative (Black) terminals with identification of heat shrinkable sleeve. Holes are drilled on the bus bars considering the pitch between the terminals & the screw size. The bus bars are fixed on to the terminals using screws provided on the capacitor.

c. Semi-Conductor Fuse Assembly: The Semiconductor /HRC fuses as specified in the BOM'S are mounted on FRP sheet. The fuses are to be fixed near to the Bridge Module. The fuses are mounted straight, such that they are vertical /feasibility of space to the charger. The fuse terminals are fixed to the FRP sheet using appropriate hardware.

5.3.3 Sub-Assemblies on FRP sheet : ( Rectifier Module Heat Sink Assembly)

a. Heat Sink Assembly: Heat sinks are assembled on FRP sheet normally as per BOM/ICL/GAD of appropriate size as required The FRP sheets are mounting along width of the console at rear side of the structure using 'L' brackets with appropriate hardware Also on 'L' Brackets using appropriate hardware The semiconductor fuses are mounted on the FRP sheets near to the Bridge modules (Refer above picture)




EG PP WI 401

b. Mounting of Device on Heat Sink: The type of heat sink is specified in BOM. The extruded heat sink surface on which the device is mounted is cleaned with fine buffing to smoothen the surface. Appropriate tapping is done on the heat sink to mount the device. Heat sink compound is applied on the stud portion of the device and fixed to the heat sink. Typical mounting of device on to the heat sink is shown in below picture The device will be tightened with correct torque as mentioned in manufacturer catalogue.

c. Terminal Assembly: The FRP sheets are used for mounting the Bolted type

terminals. In general, all terminals should be at the lower portion of the charger or as per the customer requirement at height as specified in general arrangement drawing. The terminals used are as per the BOM'S. Appropriate holes need to be drilled on the FRP sheets for mounting the terminals maintaining a minimum gap of 40mm. Three nuts are used on each bolt to facilitate connection of customer cables. Terminal numbers stickers are fixed as per wiring diagram for easy identification. Clip on terminals are to be mounted on to the D- Rail or Omega rail for MCB




EG PP WI 401

5.3.4 Sub-Assemblies on PCB Rack: PCB rack assembly consists of the following accessories.

PCB rack

PCB Guide

Mother board (PCB)

PCB Cards (3no.s)

The rack is assembled with the above accessories. The assembly is as per below picture

5.4 Fixing of cable troughs : Cable troughs are used for routing of the wires and are fixed to the door, control panel, side frame and mounting plates. Generally, PVC cable troughs used as per BOM/ICL/GAD selected as per the charger. The cable troughs cut to the required size are fixed to the vertical at sides of the structure directly by drilling through the trough with suitable bolts and nuts. The troughs fixed on to the C-Channels are fixed with appropriate hardware inserted inside the C-Channel. For fixing of troughs on the mounting plates, required size holes are to be drilled on the mounting plate and troughs and fixed. The pitch between the fixings should be minimum of 250mm.




EG PP WI 401

5.5 Fixing Of Control Components: Front control components assembly is exactly as per the general arrangement drawing issued by Engineering Department and all these components mounted directly on front Door of the charger.

Generally, the control components consists of meters, Potentiometer, Push button switches, LED Lights, LED display card, engraved labels for identify the Components etc., Generally engraved labels are fixed at appropriate places on the front door using Aluminum Rivets. The label should be placed about 10mm below the component and in general it should be in-line with the labels provided for adjacent components. Cable troughs of appropriate sizes as per BOM are fixed to the front door on the charger in side horizontally and vertically for routing the cables to give connections to the control components on the door. The troughs are to be fixed to the studs/stiffeners provided inside the door. If the numbers of cables coming to the door components are less, these to be bunched with spiral and tied to the studs provided on the door or stuck to the door using adhesive-backed cable tie mounts. Labels should be riveted on the front door before fixing of components, in order to avoid damages to components, especially meters.




EG PP WI 401

6.0 Fixing of Label & Identification :

All components in a charger including PCB’S are identified by labels/stickers. In general, stickers are used as per the reference given in the wiring diagram. The labels are fixed just below the component or side of the component for easy identification.

The following are the aluminum-anodized/Typoliate engraved labels which are to be fixed on the charger:

Charger rating/type label mounted on top of the front door.

Serial number plate fixed to the front door at bottom.

HBL logo fixed on top-right corner of the front door.

All the engraved labels are riveted using Aluminum rivets size M2.4 x 6.4mm as per the

GAD released by Engineering

7.0 Electrical wiring & Instructions:

Charger wiring is done as per respective wiring diagram released by Engineering. The cable routing is decided on the basis of internal component layout.

The Engineering document specifies.

The type and size of cable / wire to be used.

Ferrule no’s for identification of termination.

In general, 1100V grade PVC multi-strand flexible copper cables are used and the PCB wiring is done with 0.5/0.75-sq.mm cable of standard make. For control wiring 2.5-sq.mm cables is used. For power wiring, the cable size depends on the charger rating.

Section: 6&7– Fixing of label & Identification, Electrical wiring Date :01.04.2017



EG PP WI 401

WIRING INSTRUCTIONS:

PCB and control wiring should be run through cable troughs.

Wire bunches should be run vertically/horizontally.

No joints in wiring are acceptable. The cables are routed through troughs and bunched. As per the length required

between the two ends of termination, cable length is cut. While crimping the ends, it is

ensured that sufficient additional wire length is available for cable harnessing and

routing the exact terminal point. Additional wire length of cable bunch is provided for

stress relief and for rework. This additional length should not be more 50 to 60mm .

8.0 Cable Preparation & Crimped Connections:

Cable are taken as per BOM, ICL, GAD etc and prepared as per required length and those ends are prepared for connection by crimping or soldering. For crimped connection the cable insulation is stripped as per the size of terminal lug to be used. The length of the insulation to be stripped to be typically 3mm more than the length of the lug barrel. Wire has to be stripped by adjusting the stripper/sleeve remover as per the cable conductor diameter. Care to be taken while stripping the insulation so that, there is no damage or cut of the conductor.

Terminations in general, should not exceed two connections on a closed type of terminal. Multiple terminations are terminated separately on insulator with a bolt nut fixing and in turn a single cable of required size should be run to the end terminal.

Cable markers / ferrule size is inserted on the cable as per the identification No. for cables of cross section up to 6sq.mm. For insulation, cables are provided with black sleeves. These sleeves are inserted into the cable end before crimping.

AC and DC cable routing and bunches are provided separately in chargers and dressing of spiral has to be done neatly and perfectly.

Section: 8– Cable preparation & Crimped connections Date :01.04.2017



EG PP WI 401

9.0 Crimping Procedure:

Crimping is done using the proper crimping tool as per cable cross section area. After

selecting suitable lug, stripped end of cable has to be inserted in the lug. Crimping of lug on

to the cable is done with the tool after making sure that cable strands are pushed totally

into the lug to the extend barrel edge. Sleeves are insulated on the stripped Lugs. Dual

crimping is done for cables up to 50sq.mm and triple crimping is done for cables above

50sq.mm.

10.0 Soldering Connections:

Soldered connections are employed for connection to be PCB’s, relays, Potentiometer, Euro Connectors, Buzzer, Window Box, Relimate connector and resistor Board. The soldering is done with a soldering iron and its tips should be properly grounded and cleaned. The process of soldering is as follows:

Cable preparation

Soldering The insulation of wire has to be removed to the required length by wire stripper/ sleeve remover of correct size. Care should be taken to make sure that wires of the exposed strands are tinned with solder iron and self-cored flux solder wire

Section: 9&10– Crimping & Soldering Date :01.04.2017



EG PP WI 401

11.0 SAP Procedure :

After receiving material from Stores, Good Issued to be made as per Work order and completion of Job order Goods Receipt will be made and stock will posted to commercial department to make In-voice.

12.0 Risk Management:

Risk and Opportunity Management: (Clause No.6.1. of ISO 9001: 2015)

The Risks pertaining to Production area have been identified and necessary mitigation

actions are planned as detailed in Risk Register.

The Risk associated with production shall be monitored and reviewed

as per the Risk Monitoring & Review Report

The Risks shall be reviewed as per periodicity indicated in Risk Review Plan

Risks associated with production are being addressed to:

* Give assurance that the QMS can achieve its intended result(s).

* Enhance desirable effects.

* Prevent or reduce undesired effects.

* Achieve improvements.

Mitigation actions shall be carried out as planed and the effectiveness of these actions will also be evaluated.

13.0 Knowledge Management:

Knowledge is an intangible / inalienable asset of an organization.

Organization shall deal the knowledge management in the form of

Organized data / facts, Documents / booklets, brochures, manuals

procedures, practices, work instructions, skills and expertise of

employees, Design change notes, Customer complaint report, Corrective

and Preventive action reports, Customer audit reports etc.,

If knowledge constantly expands, changes and if not appropriately

managed can decay and damage the organization. Knowledge can be

managed and made to work for the benefit of the organization. In-fact it

is essential to manage the body of organization knowledge for the long-

time survival and sustaining the effectiveness of the organization.

Production dept would record the best practice in a register for the new comers to share the knowledge.

Section: 11,12 & 13 – SAP, Risk & Knowledge management Date :01.04.2017



EG PP WI 401

14.0 Change Management:

Change Management process is the process of requesting, determining attainability, Planning, implementing and evaluation of changes to a system. It has two main goals: supporting the processing of changes and enabling traceability of changes,

Change management affect the Production activities:

When customer changes his requirement (parameters, lead time, inspection agency and specification) due to this OTD will get effected.

Change in product design will affect the process time which in turn effect the production and dispatch schedule

15.0 Training:

To improve employee skill, various training program shall be identified for employee working in production and appropriate training shall be given to the concerned as per the Training plan .Performance shall be monitored, if required retraining shall be conducted

Section: 14 & 15 – Change Management & Training Date :01.04.2017
