spm autocomp systems pvt ltd. india 3 rd november’ 2012
DESCRIPTION
INTRODUCTION. SPM AUTOCOMP SYSTEMS PVT LTD. INDIA 3 rd November’ 2012. CONTENTS. SPM – AN OVERVIEW - Corporate Profile, Vision and Mission, Road Map and Customers List - Plants and their locations - Manufacturing Product Range - PowerPoint PPT PresentationTRANSCRIPT
SPM AUTOCOMP SYSTEMS PVT LTD.
INDIA3rd November’ 2012
INTRODUCTION
CONTENTS
1. SPM – AN OVERVIEW
- Corporate Profile, Vision and Mission, Road Map and Customers List
- Plants and their locations
- Manufacturing Product Range
- Materials and specifications
- Organization Chart – Plant 2 (Ranjangaon)
- Process Design and Engineering Capability
- Facility of Manufacturing and Testing/Inspection Equipment
- Raw Material Sources
- Process/Product Capability – Cp and Cpk
- Mistake Proofing and Error Proofing at manufacturing process
3. MACHINING PROCESS
• Process Flow
• Leak Testing
• Packaging
2. CASTING PROCESS
• Process Flow
• Casting Technology
CONTENTS ….. Continued
CONTENTS
4. DEVELOPMENT PROCESS
• Cross Functional Team/Multi Disciplinary Team
• Project Details
• Project Input – Drawing, CAD Model, customer standards
• Feasibility study – Summary
• Project planning Chart
• Process Design – Casting
• Pattern lay out
• Gating System
• Core Concept
• Molding process
• Quality Planning
• PFD, PFMEA and CP – Foundry and Machining
SPM – AN OVERVIEW
CORPORATE PROFILE
Foundation Established at 2002
Employee 755 person in total 450 persons at Manesar Gurgaon unit305 persons at Ranjangaon Pune unit
Capital Capital : USD 4.27 Mio ( Gurgaon unit) Capital : USD 15.0 Mio ( Pune Unit )
Turnover 2011-12 : USD 36 Mio (w/o BOP USD 23 Mio)
Production Casting & Machining of Automotive components
Certification ISO/TS 16949 & ISO14001
Plants Manesar, Gurgaon (Foundry & Machine Shop) Ranjangaon, Pune ( Foundry & Machine Shop)
VISION & MISSION
VISION
To Achieve Ten percent of the World Market of Cast Exhaust Manifolds by the Year 2015.
MISSION
To exceed customer’s expectations by offering best service, Exhaust Manifolds and Machined Cast components of International Quality at the most competitive prices. To achieve significant continual improvement, reduction in all forms of waste and optimum use of all types of resources under safe working environment.
SPM ROAD MAP TO VISION
74 PPM at Customer End
Internal Rejection control from 15% to 6%
Yield Improvement from 37% to 45%.
Productivity improvement 30%
Organization Stability & DevelopmentOrganization Recruitment
Setting up of Technical Research Center
No. of Product developed – 40 Nos. No. of Product developed –25 Nos.
New Foundry for Exhaust manifold, Turbine Housing & Turbo Manifolds
No. of Customers Built – 7 NosNo. of Customers Built – 5 Nos.
Target Sales: 10% of world market i.e. 3.6 million of Cast Exhaust Manifold
Sales Achieved –US $ 36.21 Million Sales Achieved – US $4.78 Million
2009-152005-092002 - 05
Development
Phase
Consolidation
PhaseGrowth Phase
Customer Basket and Share of Business without BOP
0.66% 1.50% 1.75% 1.80%3.53%
4.51%5.55%
7.25%
9.87%
10.63%
52.94%
Customer Wise sales
Other
BRIDGESTONE TVS INDIA PVT. LTD.
GENERAL MOTORS
JCB INDIA LIMITED
SKH METALS LIMITED PLANT
FIAT INDIA
FORD INDIA
TATA CUMMINS LIMITED
TATA MOTORS LIMITED.
SUZUKI POWERTRAIN INDIA LIMITED
MARUTI UDYOG LTD.
LIST OF CUSTOMERS
Maruti Suzuki India ( Ex Manifold, Maniverter )
Suzuki Power Train ( Ex Manifold, Diff Case, Eng Bkt)
SKH-Magneti Marelli ( Catalytic cones)
Ford Motor Company ( Exhaust Manifolds)
Ford Motor Company Export ( Exhaust Manifolds)
General Motors ( Exhaust Manifolds)
Honda Siel Cars India ( Exhaust Manifold)
Ashok Leyland ( Exhaust Manifolds)
Daimler ( Exhaust Manifolds)
JCB (Exhaust Manifold & Connecting bends)
LIST OF CUSTOMERS Cont…
Tata Motors ( PVBU & CVBU) : Ex Manifold,Steering
Knuckles, Engine mounting Bkts
Tata Cummins : Ex Manifold
Bridgestone TVS India : Engine Mounting Bkt
Fiat India : Exhaust Manifold
Mahindra Navistar : Exhaust Manifolds
Hyundai Motors : Exhaust Manifold
Avtec Ltd : Exhaust Manifold for Daimler engines
Eicher Motors Ltd: Ex Manifold and Ex Bend.
Jaguar Land Rover & Toyota (under negotiation)
No. of Plants
3
Locations Plant – 1 : Manesar, Gurgaon (Foundry & Machine Shop)Plant – 2 : Ranjangaon, Pune (Foundry & Machine shop)Plant – 3 : Pithampur, Indore, MP (Sand Making Plant)
Customers @ Plant -1
Serving to all domestic customers like MSIL, SPIL, TML, JCB, Honda and Tata-Cummins based in North and Eastern India
Customers @ Plant - 2
Serving to all domestic customers based in west and south India like TML (PCBU&CVBU), Ford, GM, Fiat, Hyundai, Tata Cummins, Navistar, Daimler and export customers like Ford, Fiat and JCBCustomers under discussion: JLR, Honeywell & Toyota,
PLANT LOCATIONS
OVERVIEW PLANT - 2
MAIN ENTERANCE
Machine Shop Building
Administration Block
Foundry Building
SITE PLAN – Plant 2
Machine Shop
Foundry
Fiat - 1.3 SDE Exhaust Manifold Line
Tata Motors – Steering Knuckle Line
Machining Facility – Plant 2
Tata Motors – Engine Mounting Bracket Line
Standard Room
PRODUCT DETAILS
CORE PRODUCTS :
Exhaust Manifolds
Turbine Housing
Turbo Manifold
STRATEGIC PRODUCTS :
Steering Knuckle
Mounting Brackets
Case Differential
Exhaust ManifoldCatalytic Inlet Manifold Assembly
Mounting Bracket Case Differential Steering Knuckle
Manufacturing Product Range
Exhaust Manifold (Honda)
Split Type Manifold (Mahindra Navistar)
Split Type Manifold (JCB)
Manufacturing Product Range
Ex. Manifold Ford CD (Part no. :BK3Q-9430-CD ) - EXPORT
AS CAST AS MACHINED
Manufacturing Product Range
EXHAUST MANIFLOD GM 1 LTR. (Part no. ) 55569360
EXHAUST MANIFLOD GM 1.3 LTR. 55570416
AS CAST AS MACHINED
EXHAUST MANIFLOD GM B12D 96416307
Manufacturing Product Range
AS CAST AS MACHINED
AS CAST AS MACHINED
Ex. Manifold Hyundai (Part no. : 2851103020)
Manufacturing Product Range
METALLURGY GRADE & SPECIFICATION
Specification
Grade FCD 450 FCD 450HS SG 500 HTN 550 FCD 500M D-5S
CustomerMaruti Suzuki
Eicher AvtecMaruti Suzuki
TATASuzuki
PowertrainAVTEC AVTEC
Chemical Compositi
on
%C 3.4 - 4.20 3.0 - 4.0 2.5 Min 3.4 - 4.20 3.2 – 4.40 3.5 3.2 - 3.50 3.0 - 4.0 2.3 Max
%Si 2.3 - 3.40 2.0 - 3.0 -- 3.5 - 4.30 4.0 - 4.50 4.0 - 4.50 3.8 - 4.40 2.0 - 3.0 4.9 - 5.5
%Mn 0.2 - 0.5 0.1 - 0.6 0.4 Max 0.2 0.5 0.1 - 0.50 0.3 0.30 Max 0.2 - 0.60 1.0 Max
%P - 0.10 Max 0.08 Max -- 0.050 Max 0.50 Max 0.050 Max 0.10 Max 0.08 Max
%S 0.03 Max 0.50 Max 0.02 Max 0.03 Max 0.015 Max 0.015 Max 0.020 Max 0.020 Max 0.02 Max
%Mo -- -- -- -- 1.0 - 1.50 1.0 - 1.50 0.6 - 1.10 -- --
%Cr -- -- -- -- -- -- -- 0.30 Max 1.15 - 2.25
%Mg -- 0.09 Max 0.09 Max -- 0.01 - 0.05 0.01 - 0.05 0.025 Min 0.025 Min 0.02 - 0.06
%Cu -- -- -- -- -- -- -- -- 0.5 Max
%Ni -- -- -- -- -- -- -- -- 34.0 - 37.0
Mechanical
Properties
1. Hardness (BHN) 149 -194 143-217 149-207 161-215 200 - 255 200 - 240 170 - 255 170 - 241 120 - 150
2. Tensile Strength 450 Mpa 45Kg/mm2 450 Mpa 450 Mpa 500 Mpa 490 N/mm2 550 N/mm2 50 Kg/mm2 390 - 470 Mpa
3.Yield Strength 280 Mpa 38Kg/mm2 290 Mpa 280 Mpa 320 Mpa 375 N/mm2 33 Kg/mm2 210 - 260 Mpa
4.Elongation (Min) 10% 10% 10% 7% 7% 8% 5% 5% 15 - 18%
Microstructure
1. Nodularity 60% Min 75% 75% Min 60% Min 80% Min 90% Min 85% Min 90% Min 85% Min
2. Nodule Count 70 Min -- -- 70 Min -- -- -- -- --
3. Pearlite 50 % Max Balance Balance 10% Max Ferrite + Pearlite with 2%
max Cementite
10% Max** 40% Max -- --
4. Cementite -- 5% 5% Max -- -- -- 5% Max 5%
5. Ferrite 50% Min 70% 70% Min 90% Min 90% Min Balance 90% Max --
- Specification after Heat Treatment
New Development
QMS And EMS CERTIFICATION
ISO/TS 16949 And ISO-14001
Organization Chart
Microsoft Excel Worksheet
Design and Engineering Capability
FOUNDRY – ENGINEERING
Design Facilities Simulation Software – ANYCAST UG CAD & CAM - NX 7 Auto Cad In-house Pattern Making Facility Video Image Analyser Spectrometer for chemical analysis
MANUFACTURING - ENGINEERING
VMC (LMW – KODI 40) M1TR with DRO CNC Turning Center Surface Grinder Radial Drilling M/c Hydraulic Fixture for machining Millipore tester for global cleanliness requirement Air decay Leak Testing machines for leak proof casting
FACILITY OF MANUFACTURING & TESTING/INSPECTION EQUUIPMENT
Sl. Equipment Description Model/Make Nos.
1 Moulding M/cFritz Hansberg HPM, 120 boxes/hr
2 Nos.
2 Sand Plant Disa 1 Unit
3 Core Shooter Susha / Span 5 Nos
4 Core Drying oven OSE 1 No
5 Induction Furnace Inductotherm 2 Nos
6 Mould Handling System Fritz Hansberg 1 Unit
7 Wedge Breaker 2 Nos.
8 Shot Blasting m/c Disa 1 No
9 Tumbler Rotary Type 1 No
10 Heat Treatment Furnace APS 1 No
11 Fettling Facility 1 Unit
FOUNDRY - PRODUCTION
SlEquipment Description Make & Model Nos.
1 SpectroSpectro Lab, Germany 1
2 Microscope Union, Japan 1
3Optical Brinell Hardness Tester Fine Testing 1
4UTM for Checking GCS Versatile 1
5 IR Moistur Teller Versatile 1
6 Permeability Meter Versatile 1
7 Test Sieves Versatile 1
FOUNDRY - QUALITY
Based upon a three-phase molding sequence featuring prefill, shoot, and squeeze, the HANSBERG Molding System is a consolidated, foundry-proven mold making technology which ensures the production of castings consistently complying with the strictest quality control requirements.
Based upon a three-phase molding sequence featuring prefill, shoot, and squeeze, the HANSBERG Molding System is a consolidated, foundry-proven mold making technology which ensures the production of castings consistently complying with the strictest quality control requirements.
ShootShoot
SqueezeSqueeze
PrefillPrefill
New Moulding Line Details:
Moulding Process
Prefill ensures that clot-free sand always fill deep pockets and cavities, even when the pattern contour is most intricate,
as is the case with this knuckle arm mold
Outstanding casting skin qualityOutstanding casting skin quality
PHASE 1 - PREFILLPHASE 1 - PREFILL
Shooting is instrumental to achieving high compaction in deep cavities where squeezing
alone can not always reach
Mold hardness87-92°
Excellent mold surface hardness with homogeneous distribution from mold center to flask edges
Excellent mold surface hardness with homogeneous distribution from mold center to flask edges
PHASE 2 - SHOOTPHASE 2 - SHOOT
Distanceto edge
25 mm or Less
Draft Angle 0.5 Deg.
Outstanding mold rigidity is always
achieved Minimum casting mass variationMinimum casting mass variation
Uniform compaction throughout the mold depth
Uniform compaction throughout the mold depth
PHASE 3 - SQUEEZEPHASE 3 - SQUEEZE
Minimum usage of sand Minimum usage of sand
Strictly controlled compression
force per mold surface unit
FLASK DESIGNFLASK DESIGN
Nodular iron flask pair (above). Note the double-wall design combining high rigidity with lightness.
Nodular iron flask pair (above). Note the double-wall design combining high rigidity with lightness.
Pin / bushing assembly (right). Each flask is fitted with one round and one elongated bushing. Poka-Yoke: Automated sensors to ensure the dimensional accuracies of pins & bushes.
Pin / bushing assembly (right). Each flask is fitted with one round and one elongated bushing. Poka-Yoke: Automated sensors to ensure the dimensional accuracies of pins & bushes.
Flask rigidity is of paramount importance in high-pressure molding. Wall deformation should not exceed 0.25 mm under a load of 4 kgf/cm2.
Flask rigidity is of paramount importance in high-pressure molding. Wall deformation should not exceed 0.25 mm under a load of 4 kgf/cm2.
SPECIAL FEATURESSPECIAL FEATURES
Automatic sprue cutting unit (right). Online Automatic Sprue Cutting as compared to Manual cutting in Present Line, avoiding variation in pouring cup size
Automatic sprue cutting unit (right). Online Automatic Sprue Cutting as compared to Manual cutting in Present Line, avoiding variation in pouring cup size
Flask cleaning unit (left). Automatic Box Cleaning as compared to Manual Cleaning in the Present Line
Flask cleaning unit (left). Automatic Box Cleaning as compared to Manual Cleaning in the Present Line
Mass variation < 0.2 kg on 50 kg casting
Diameter variation is < +/- 0.5 mm
CASTINGS DIMENSIONAL ACCURACYCASTINGS DIMENSIONAL ACCURACY
Complying with the strictest
quality control requirements:
automotive safety part
casting
MACHINE SHOP - PRODUCTION
Sl. Equipment DescriptionMake & Model
Accuracy Nos.
1 CMM Carl Jeiss0.00001mm 1
2 Roughness tester Mitutuyo09.01
Ra 1
3 Milipore Tester Milipore 1
4 Weighing Machine Adventure0.0001 Gms 1
5 Tool Pre-setterPWB Swiss
0.001mm 1
6
All Std. instruments like micrometer, height gauges, Lever Dial etc Mitutuyo
Sl. Equipment DescriptionMake & Model Nos.
1 HMCMakino/
DMG 2
2 VMCMakino
S33/ DMG 7
3 VMCAMS MCV 500S/450S
24
4 CNC Milling M/c BFW 1
5 CNC Turning Machine LOKESH 1
6Pneumatic Leak Test M/c with Auto Marking Auto Test 10
6 Washing MachineGayatri
Auto 2
MACHINE SHOP - QUALITY
FACILITY OF MANUFACTURING & TESTING/INSPECTION EQUUIPMENT
Raw Material Sources
S. No. Raw Material Source Remarks
1 Scrap (1) MSIL(2) GE
Cold Rolled mild steel scrap
2 Graphite (1) Graphite India(2) MPM
3 FeMo Moly Metals / Ess Ell Mining
4 Fesi RNB Carbide
5 FeSiMg Snam Alloy
6 Bentonite Ashapura International
7 Lustron MPM
8 Innoculant Snam Alloy
9 Raw Sand Allahabad Sand
10 Resin Coated sand SPM, Indore
Process Capability of Existing Product - Foundry
Process Capability of Foundry Critical ParametersS. No. Specification Critical Parameters
Process Capabililty Index (Cpk)
Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12
1 1.65 ~ 2.00 Kg/cm2Green Compressive Strength (GCS) 1.36 1.38 1.36 1.37 1.42 1.45 1.51 1.52
2 40 ~ 48 Compactibility 1.35 1.48 1.39 1.45 1.37 1.34 1.41 1.49
3 134 ~ 156 Permeability 1.42 1.51 1.53 1.49 1.57 1.61 1.58 1.64
Process Capability of Existing Product - Machining
Process Capability of Critical Parameters - MachiningS. No. Specification Component Name Critical Parameters
Process Capabililty Index (Cpk)Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12
1 0.07 mm min. Exhaust Manifold - F8D Flatness 1.38 1.39 1.40 1.39 1.41 1.42 1.44 1.47
2 0.25 mm Max. Exhaust Manifold - 830 Position 1.63 2.09 2.17 2.04 2.25 2.03 1.77 2.06
3 Ra1.6 Max. Case Diff. Surface Finish 4.12 5.13 4.61 3.87 3.19 4.71 5.21 5.27
4 28.0+0.012+0.033 Case Diff. Inner Dia 2.92 3.16 2.61 2.67 2.79 2.82 2.87 3.41
5 57.0+0.002+0.021 Case Diff. Outer Dia 2.48 2.64 2.79 2.93 3.11 3.15 3.17 3.22
6 0.04 mm Max. Case Diff. Run Out 2.11 2.87 2.67 2.91 2.96 2.99 3.06 3.17
Process Capability of Existing Product - Machining
1. Sand Plant• Batch Quantity of Mixer - load cell
• Additives Weighing - load cell
• RTC Compatibility
2. Molding line • Shoot pressure in mold machine
• Squeeze presssure in mold machine
• Air pressure of mold line
3. Core Shop• Higher & low temperature of core box of all machines
• Air pressure of core shooters
• Core oven temperature
List of Poke Yoke
Doc No.: - QAD/F/41 A
Rev No :- 02
Rev. Date : 01.05.2012
OPERATION NO:- OP-20 M/C NO.:-
Description :-Prevention / Detection Stage : To avoid wrong loading three stopper fitted in fixture plate.
Implementation Date : 27/05/2012
Sketch / Photo (Before) :
Poke - Yoke Identification & Implementation Sheet
PART NAME:-EXHAUST MANIFOLD
Mistake Proofing / Error Proofing detail
Sketch / Photo (After) :
Mistake Observed / Anticipated : Wrong loading problem.
PART NO.:- CUSTMER NAME:- HYUNDAI
STOPPER 3 NOS.
Poke Yoke Implementation
Doc No.: - QAD/F/41 A
Rev No :- 02
Rev. Date : 01.05.2012
OPERATION NO:- OP-30 M/C NO.:-
Sketch / Photo (After) :
Poke - Yoke Identification & Implementation Sheet
PART NAME:-EXHAUST MANIFOLD PART NO.:- CUSTMER NAME:- HYUNDAI
Mistake Observed / Anticipated : Wrong loading problem.
Sketch / Photo (Before) :
Mistake Proofing / Error Proofing detail Description :-Prevention / Detection Stage :To avoid wrong loading three stopper fitted in fixture plate.
Implementation Date : 27/05/2012
STOPPER 3 NOS.
Poke Yoke Implementation
Doc No.: - QAD/F/41 A
Rev No :- 02
Rev. Date : 01.05.2012
OPERATION NO:- OP-40 M/C NO:-
Sketch / Photo (After) :
Poke - Yoke Identification & Implementation Sheet
PART NAME:-EXHAUST MANIFOLD PART NO.:- CUSTMER NAME:- HYUNDAI
Mistake Observed / Anticipated : Wrong loading problem.
Sketch / Photo (Before) :
Mistake Proofing / Error Proofing detail Description :-Prevention / Detection Stage : To avoid wrong loadingthree stopper fitted in fixture plate.
Implementation Date : 27/05/2012
STOPPER 3 NOS.
Poke Yoke Implementation
Doc No.: - QAD/F/41 A
Rev No :- 02
Rev. Date : 01.05.2012
OPERATION NO:- OP-50 M/C NO.:-
Sketch / Photo (After) :
Poke - Yoke Identification & Implementation Sheet
PART NAME:-EXHAUST MANIFOLD PART NO.:- CUSTMER NAME:- HYUNDAI
Mistake Observed / Anticipated : Wrong loading problem.
Sketch / Photo (Before) :
Mistake Proofing / Error Proofing detail Description :-Prevention / Detection Stage :To avoid wrong loadingthree stopper fitted in fixture plate.
Implementation Date : 27/05/2012
STOPPER 3 NOS.
Poke Yoke Implementation
Poke Yoke Implementation
Quality
Cost
DeliveryFocus Area
Development
In Process Inspection Process Improvement
Productivity Value Engineering
On time
Design Capability First Time Right
SPM – THE COMPLETE SOLUTION
CASTING TECHNOLOGY
&PROCESS
HIGH PRESSURE MOLDING PROCESS
We, at SPM have opted for High pressure molding process with green sand having a composition of Silica sand with 98% minimum silica content, sodium based Bentonite for better swelling and binding property, Lustrous carbon for providing a reducing atmosphere in the mold cavity. Water is added to get the optimum properties in the sand mix like compactibility, green compressive strength, Loss on ignition, dry strength, and also better collapsibility for easy separation of casting from sand at the time of knock out. This sand is reusable by remixing small quantities of Bentonite and other additives for replenishing the lost properties due to molten liquid metal casting process.
Casting Technology
The molds for any casting component are normally made in two halves, i.e. drag half and cope half and the core for creating the inner surface of the casting component is made separately with a different process. For making both mold halves we make pattern which is mounted on match plates with respect to the center lines of the guide pins and bushes to suit to the molding machine which we are using. The pattern mounted on the match plate is incorporated with running system with in-gates for the uniform filling of liquid metal in the cavity.
Casting Technology
In the molding process we create an outer surface of the component which we intend to manufacture and after making the mold we place the shell cores in the sand mould and this makes the internal cavities of the casting component.
Casting Technology
Cores are set in the drag mould with respect to the core prints. In the cope mould, adequate venting is provided. Both the halves are cleaned with compressed air for any foreign particles adhering to the cavity surfaces. Then the cope half is closed on top of the drag half with the help of guide pins and bushes to avoid mismatch in the casting component. These molds are being filled with molten metal with specified chemistry and metal temperature, which helps in filling the entire mold cavities irrespective of the casting thickness variation.
Casting Technology
The poured molds are allowed to cool on the molding line for a minimum of 45 minutes and then the castings are separated from the molds, cleaned for adhering sand particles by shot blasting, separated from the gating system with the help of breaker units and then the extra flashes, if any, are removed from the casting with the help of fettling equipments. Then the casting components are machined to remove the extra material provided as machining allowance to make the casting components suitable for assembling on other parts.
Casting Technology
1 Molding Process -High pressure molding – Horizontal Box size 900*700*225
2 No of cavities in pattern Match plate
- 4 ~ 8 (depends on geometry)
3 Core process - Hot baked shell sand process
4 No of cores required for the casting
- 1 ~ 4 (depends on geometry)
5 Melting process -Medium frequency Induction furnace - electric
6 De-coring process - Mechanical vibrator
7 Shot blasting process - Stage shot blasting using cast iron shot
8 Casting finishing - Manual fettling grinders
Casting Process (Basics)
Sand Preparation
Core Making & Core Trimming
Mould Closing & Clamping
Melting
Magnesium Treatment
Pouring
Lab Clearance for Casting
Primary Inspection
Knocking & Hauling
Shot blasting
Final Inspection (Foundry Stage)
Re-shot BlastingFettling
Ready for Machining
Molding
Drying & Insp.
Core Setting
Lab Clearance
Inoculation
Casting Product Process Details
Raw material
PROCESS FLOW - CASTING
Sand Preparation
Core Making Core Trimming
Moulding
Final Inspection
Melting Pouring Metallurgical
Insp
Re Shot blasting Fettling Shot blasting
Engine QC 29.08.12
CORE MAKING PROCSS
Core box cleaning Applying parting agent
Checking of temperature
Air pressure setting
Loose pc. installationVerification of sand level
Setting of cycle timeVerification of air
pressure
Start of machine in auto mode
Cleaning of sand on core box area
Core removal from core box
Separation of loose pc.
Cleaning by aluminum strip
Ingate cuttingRecording Core Storage
CORE MAKING PROCSS
Core ready for inspection, trimming
and dressing
Remove all parting lines and fins from
core surface.
Remove all projection & ingates from core surface.
Inspection of core for over baked and under
baked
Visual inspection of core
Graphite Pasting where required
Storage of core Checking of finishing and profile of core
CORE TRIMMING AND DRESSING
MOULDING PROCESS
Check the Cope pattern before
loading
Check the Drag pattern before
loading
Lift the pattern for loading
Clean the bolster by using Compressed
Air
Mount the pattern with properly
matching of dowel pins
Tighten the allen bolt of cope pattern by
allen key with cross direction
Put heat / date code on pattern
Tighten the allen bolt of drag pattern by
allen key with cross direction
Clean the pattern Set the molding machine parameter
Spray mold releasing agent
Check the outcome cope mold quality
Set and Check the mold for any sand crushing after core
setting
Make venting on cope mold at specified
location
Check the outcome drag mold quality
Check the core before setting
MOULDING PROCESS
Left the mold to go for closing station
Left the mold to go for closing station
Write box no of Particular heat and customer name on
top of the mold
Mold ready for pouring
MOULDING PROCESS
Weighing of Scrap Putting in empty bin
Empty Furnace Weighing of graphite on weighing scale.
Addition of graphite in furnace
Addition Scrap in furnace
Addition of turning Chips in Furnace
Addition of re-melt in Furnace
MELTING PROCESS
Addition of Ferrogen in half filled Furnace
Addition of e re-melt in Furnace (if required)
Addition of re-melt in Furnace (If required)
Addition of Ferro Alloys in Furnace
Spreading of Slax-30 at melt in Furnace
Removal The slag from Furnace
Checking of temperature in Furnace
Preparation of Coin Sample
MELTING PROCESS
Put the Coin Sample in water for cooling
Send the sample to lab for testing chemical composition
Put steel punch over FeSiMg in treatment ladle
by using funnel
Weight the FeSiMg Add FeSiMg in treatment ladle by
using funnel.
Make zero weight of treatment ladle
Tap the melt in treatment Ladle
Check the weight of melt
MELTING PROCESS
Transfer of melt in pouring ladle & add the inoculant in stream
Checking of temperature in pouring ladle before pouring
Removal of slag from the pouring ladle before pouring
Taking of metal from pouring ladle for coin sample.
Coin Sample cooling
Pouring of metal in Mould
Offer sample for testing
MELTING PROCESS
KNOCK OUT AND SHOT BLASTING
Taking out incoming bunches from knockout
Removal of bunches from hoist to floor
Arranging of all bunches as per item / heat no. wise
Heat no. identification
Knock out of casting with wedge breakerLoading of separated
casting into shot blasting hanger
Putting the hanger inside the machine
Closing of door
Machine operation in auto mode
Casting taking out after shot blasting
Offer the casting for Primary Inspection
KNOCK OUT AND SHOT BLASTING
FETTLING PROCESS
Component for FettlingChipping Pedestal Grinding Straight Cutter
Grinding
Pneumatic hand grinding
Re-shot blasting Grinding through air tool
Component for Inspection
CASTING INSPECTION PROCESS
Casting Inspection Ok Component for Machining
MACHINING PROCESS
Layout of Machine Shop
PROJECT BASICS ( Machining)
1 Machining Process VMC
2 Post machining de-burring
Manual
3 Post machining leak testing
Automatic test cycle using dry air process
4 On line and patrol inspection
Standard and special gauges, Carl Zeiss 3D Co-ordinate measuring machine
5 Part washing Auto cycle part washing m/c
6 Anti-rust treatment Using antirust oil and VCI bag protection
7 Packing Corrugated box with partition
Face Milling &Drilling Spot Facing Boss Milling& M6
Tapping
Face Milling ø 114.0
M18 Tapping
Packing
Date code Numbering Leak Testing
Final Fixture Inspection
Oiling Washing Final Inspection
Engine QC 29.08.12
MACHINE SHOP PROCESS FLOW
Leak testing machine detail
Leakage Machine
Specification :- Pressure : 103 KPa- Allowable Limit : 100 cc/min.
Packaging
Proposed Packaging• Individual component packing in VCI
bag.• Corrugated box
FORD CD EXPORT PACKAGING Example
DEVELOPMENT PROCESS
CFT/MDT Team
S. No.
Name of the Person
Department Designation Job Responsibility
1 P K Banerjee Engineering JMD Chief Co-ordinator of Project
2 Jayarama Pradhan
Corporate Quality, Engg. And Customer Support
General Manager
Final Approval of the Project
3 Rajan Nair Process Development - Casting
Chief Technical Officer
Development of the casting process
4 Poonam Wangnoo
Quality Senior Manager
Analysis of the product and process capability
5 Anil Shinde Machine Engg. Senior Manger Development of the Machining process
6 N S Jina Process Engg. – Machine shop
Manager Development of Tooling – Machine shop
Sl No
Parameter Measuring method
Sample
Control methodSize Freq.
01Green Compressive Strength (GCS)
Universal Strength M/c 1 Every Hour Sand Testing Report
02 Moisture IR Moisture Dryer 1 Every Hour Sand Testing Report
03 Permeability Permeability 1 Every Hour Sand Testing Report
04 Compactability Scale 1 Every Hour Sand Testing Report
05 Active Clay Methylene Blue Test 1 Every Shift Sand Testing Report
06 Total Clay Clay Washer 1 Once / Week Sand Testing Report
07 Mold Hardness Mould Hardness Tester 1 Every Hour Check Sheet
08Tapping / Ladle Release Temperature
Pyrometer 1 Every LaddleDaily Melting, Pouring & Analysis Report.
09 Weight of Additions Weighing Scale 1 Every TreatmentDaily Melting, Pouring & Analysis Report.
10Time control after Treatment to final Pouring
Hooter 1 Every Treatment ----
11Chemical Composition (Furnace Metal)
Coin Sample + Spectro Meter
1 Every HeatDaily Melting, Pouring & Analysis Report, Spectra Report
Final Quality Check (Quality Planning)
Sl No
Parameter Measuring method
Sample
Control methodSize Freq.
12Chemical Composition (After Mg Treatment)
Coin Sample + Spectro Meter
1 Every TreatmentDaily Melting, Pouring & Analysis Report, Spectro Report
13 Nodularity Microscope 1 Every TreatmentDaily Melting, pouring & Analysis Report
14 Microstructure Microscope 1 Every TreatmentDaily Melting, pouring & Analysis Report
15 Hardness Brinel Hardness Tester 1 Every TreatmentDaily Melting, pouring & Analysis Report
16 Elongation Universal Testing M/c 1Once Per Prod. Lot (Continuous Heat)
Mechanical Test Report
17 Tensile Strength Universal Testing M/c 1Once Per Prod. Lot (Continuous Heat)
Mechanical Test Report
18 Yield Strength Universal Testing M/c 1Once Per Prod. Lot (Continuous Heat)
Mechanical Test Report
19 Wall ThicknessCut Section + Vernier Caliper / Pistol Caliper
1 Every 500 CastingWall Thickness Insp. Report
20Casting Surface Defects like Shrinkage, Blow Holes etc.
Visual 100% ---- Daily Inspection Report
Final Quality Check (Quality Planning)
Core shopPattern shop
Pattern & Coreshop In charge
Quality Meeting
Daily & Monthly
Foundry Quality
CONTINUOUS QUALITY IMPROVEMENTS
Moulding shop
Melting Fettling
Machine shopQuality
M.D.
Moulding shop incharge
Melting shop incharge
Fettling shop incharge
Conclusion
Thank You
• EXHAUST MANIFOLD G4D3-9430-CA1Adobe Acrobat
Document
Adobe Acrobat Document
• EXHAUST MANIFOLD G4D3-9430-DA1
Adobe Acrobat Document
Adobe Acrobat Document
Project Input - Drawings
Project Details
S. No.
Name of the Project
Part Name Part Number Customer Shared Volume
1 AJ - 200 Exhaust Manifold
G4D3-9430-CA (N/S)
FY14/15 - 2094FY15/16 - 49061FY16/17 - 192299FY17/18 - 218726FY18/19 - 225605FY19/20 - 231074FY20/21 - 235392FY21/22 - 235392FY22/23 - 235392
2 AJ - 200 Exhaust Manifold
G4D3-9430-DA (E/W)
Project Input – CAD Model
North / SouthMid / Low Spec
East / WestMid Spec Only
Feasibility Clarification – Summary
Microsoft Excel Worksheet
Project Planning Chart
Adobe Acrobat Document
Cope Side Match Plate
Pattern Layout Concept
Drag Side Match Plate
Drag PatternCope Pattern
Pattern Concept
Pattern Layout Concept
a) Gating System Design & AnalysisCasting and Core Weight
Casting Weight(Single Cavity)
4.6Kg
Gating Weight 15.50 Kg
Risers Weight _
Total casting weight (4 cavity)
18.56 Kg
No of Core 02 Nos.
Total Core Weight 2.0 Kg
SpureIn Gate
Casting
Core_2
Core_1
Runner bar
Pattern Layout Concept
a) Gating System Design Spure
In Gate
Casting
Core_2
Core_1
Runner bar
Casting Weight(Single Cavity)
4.808Kg
Gating Weight 15.50
Kg
Risers Weight _
Total Castings Weight (4 cavity)
19.232 Kg
No of Core 02 Nos
Total Core Weight 2.25 Kg
G4D3-9430-DA1Exhaust Manifold
Gating System design and Analysis
Casting Material Si Mo
Mould Material Green Sand
Core Material Shell Sand
Pouring Temperature 1440c
Mold Temperature 25 C
Liquidus / Solidus (Castings) 1172℃ / 1135℃
Gating Design
Materials and Conditions
C Si Mn Cu S P Mo Mg
3.4 Max.
3.75-4.5
0.6Max -
0.02Max
0.08Max
0.4-0.6
-
Chemical Composition of Material (IDM 5381)
b) Data Input
Spure
Runner Bar
In gate
Gating System design and Analysis
Concept for Core – Shell Core
Main Core ASSEMBLY CORE BOX
Ejecting pin mounting plate
Mounting Plate Mounting
Plate
Ejecting pin mounting plate
Ejecting pin
Ejecting pin
Core box _ Bush Half
Core box _ Pin Half
Core
Concept for Core – Shell Core
Main Core
Core Trimming area(pink line )
Trimmed Core
After dipping Core
Actual Core Photographs and Assembly
Core_1 Core_2
core_1&2 Assemble
PFD, PFMEA & Control Plan of CA1 - Foundry
Microsoft Excel 97-2003 Worksheet
Microsoft Excel 97-2003 Worksheet
Microsoft Excel 97-2003 Worksheet
PFD – Foundry – CA1 PFMEA – Foundry – CA1 CP – Foundry – CA1
PFD, PFMEA & Control Plan of CA1 – Machine
shop
PFD – Machine shop – CA1 PFMEA – Machine-shop – CA1 CP – Machine shop – CA1
Microsoft Excel 97-2003 Worksheet
Microsoft Excel 97-2003 Worksheet
Microsoft Excel 97-2003 Worksheet
PFD, PFMEA & Control Plan of DA1 - Foundry
PFD – Foundry – DA1 PFMEA – Foundry – DA1 CP – Foundry – DA1
Microsoft Excel 97-2003 Worksheet
Microsoft Excel 97-2003 Worksheet
Microsoft Excel 97-2003 Worksheet
PFD, PFMEA & Control Plan of DA1 – Machine shop
PFD – Machine shop – DA1 PFMEA – Machine-shop – DA1 CP – Machine shop – DA1
Microsoft Excel 97-2003 Worksheet
Microsoft Excel 97-2003 Worksheet
Microsoft Excel 97-2003 Worksheet