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PT. ALFA VALVES I NDONESI A

JL. Mercedes No. 324, Wanaherang, Gunung Putri, Bogor - Indonesia
Phone : (62 - 21) 8686 0009 ; Fax : (62 - 21) 8686 0008
E-mail : alfavalve@cbn.net.id
PRODUCTION GENERAL PROCESS FLOW CHART of VALVES
Document No. : AVI-P-FC-000
0 Revision No. :
Prepared By : Tunggul H.P
S M h P j i A d B : S. Martahan Panjaitan Approved By
This document and it's content are property of PT. ALFA VALVES INDONESIA. Neither this document nor this its content may be
copied in a whole or in apart thereof or transferred to a third party or used in any other way detrimental to the interest of PT.
ALFA VALVES INDONESIA.
Notice
Issued Date : April 08, 2003
PROCESS
0 2 OF 4
DATE OF ISSUED
PAGE
8-Apr-03
PRODUCTION GENERAL PROCESS FLOW CHART OF VALVES
DOCUMENT REMARK
ALFA VALVES
DOC NO.
REV.
AVI-P-FC-000
START
#
-
-
-
Check for correct content and quantity
Store Personel
materials againts packing list or supplier
supplier D/D / invoice to Alfa. PO.
Discrepancies shall be identifed
for remedial action
Material stock status raised
for Direct Material record
START
INCOMING
MATERIAL
PURCASE ORDER VENDOR PACKING LIST
MATERIALS RECEIVE RETURN'S OUTWARD
DELIVERY MATERIALS CONS.
-
#
-
-
Materials consumable log book
raised for Indirect Material record
o ec a e a eco d
by QC Department.
Visual Flange Finish Surface (MSS-SP 6)
Dimensional Inspection
QC inspector
Material Mill Test Reports will be kept
Visual Surface Inspection(MSS-SP 55)
MATERIALS STOCK
MILL TEST REPORT QC INCOMING
INCOMING MATERIAL
-
*
*
Face to Face/End to End Dimensions
Wafer Check : API Std. 594
Butterfly : API Std. 609
Class 800 & 1500, Threaded, Socket
Weld & Buttweld, End-to-End Refer to
Alf V l t d d API 602
Dimensional Inspection
ASME B16.34
For Ball , Gate, Globe, Check & Plug :
ASME B16.10 ; API 6D ;
Wall thickness (API Std.600 or
QC
INCOMING
INSPECTI-
ON
*
*
*
#
Alfa Valves standard as per API 602
Flange Dimensions
meeting receive reports & decide the
MRB ( Material Review Board)
Height, Handwheel, Stem, Bolts, Nuts
Etc.
ASME B16.5 ; ASME B16.47;
MSS SP-44
NCMR NC T
-
-
# Store Personel
NCMR ( Non Conforming Material
material status
Report )
NC Tag ( Non Conforming Tag )
YES
NO
NCMR NC Tag
OK ?
NON-CONFORMANCE
PROCEDURE (NCP)
RAW
MATERIAL
STORAGE
MATERIAL STOCK INVENTORY STOCK
#
-
# Production AssemblyOperator
Sales Order and / or customer delivery
order
Production Assembly Operator
Production Work Order shall based on
PRODUCTION PRODUCTION WORK
MAT. REQ. / ISSUED
COLLECT
KIT VALVES
ASSY
#
-
# Production Assembly Operator
NO
Production Assembly Operator
Inspect for Quantity and suitability of
parts
YES
REQUEST FOR KIT
COMPLETENESS
PARTS INS.
BEFORE
ASSEMBLY
OK ?
MAT. REQ. / ISSUED
A
AVI-P-FC-000
AVI-P-FC-000
0
PRODUCTION GENERAL PROCESS FLOW CHART OF VALVES
ALFA VALVES
DOC NO.
REV.
DATE OF ISSUED
PAGE
8-Apr-03
3 OF 4
#
*
PROCESS DOCUMENT
Work Instructions
REMARK
Production Assembly Operator
Refer to Valves Drawing and Assembling
A
PARTS
ASSEMBLY
ASSY IN-PROCESS
#
#
-
NO NO
YES
YES
MRB
Functional Inspection
J oint Torques Inspection
Production Assembly Operator
OK ?
TRIAL &
ERROR
OK ? NCP
NCMR
ASSEMBLY DAILY
PERFORMANCE
REPORT
VALVE
ASSY
-
#
YES
J oint Torques Inspection
NO NO
MRB
ASSY
INSPECTI-
ON
NCMR
OK ?
TRIAL &
ERROR
OK ? NCP
#
-
-
-
-
-
#
Shell Test
NO
API 598 or API 6D
MRB
(Upon Customer's Requirements)
Low-Pressure Closure Test
Production Testing Operator
High-Pressure Closure Test
Backseat ( if any)
YES
VALVE
PRESSURE
TESTING
TESTING DAILY
PERFORMANCE
REPORT
#
NO
Production Painting Operator
YES
NON-CONFORMANCE
PROCEDURE (NCP)
OK ?
NCMR NC Tag
COATING
COATING DAILY
PERFORMANCE
REPORT
#
-
-
#
-
Inspection Form"
Production Packing Operator
Production will advise QC that valves
practicable position
Completing a"Request for QC
are ready for final Inspection by
QC Inspector
The Plates are mounted in the most
INSTALL ID
PLATE
FINAL
INSPECT-
ION
REQUEST for QC QC FINAL INSPECTION
QC FINAL INSPECTION
#
NO
QC Inspector
Inspection Form
OK ?
NON-CONFORMANCE
PROCEDURE (NCP)
NCMR CORRECTIVE ACTION
B
AVI-P-FC-000
PRODUCTION PROCESS FLOW CHART OF FLOATING BALL VALVE
ALFA VALVES
DOC NO.
REV.
DATE OF ISSUED
PAGE 0 4 OF 5
8-Apr-03 AVI-P-FC-001
#
PROCESS DOCUMENT
Production Assembly Operator
REMARK
B
BOLTING
CAP ASSY
INTO BODY
ASSY WITH
STUDBOLTS
#
Production Assembly Operator
STUD BOLTS
& NUTS
INSTALL
STOPPER &
SNAP RING
INTO LEVER
ASSY IN-PROCESS
#
#
-
NO NO
YES
YES
Production Assembly Operator
For Gear Operator Ball Valves, Install
Bevel Gear Operator Assembly into
Valve Body.
MRB
OK ?
TRIAL &
ERROR
OK ? NCP
INSTALL
LEVER ASSY
INTO BODY
NCMR
ASSY IN-PROCESS
#
#
-
NO
YES
Head Bolts.
MRB
For Gear Operator Ball Valves,
NO
into Body Mounting Pad with Hex
Bolting Bevel Gear Operator Assy
Production Assembly Operator
OK ?
TRIAL &
ERROR
OK ? NCP
BOLTING
LEVER WITH
SET SCREW
NCMR
ASSY IN-PROCESS
#
#
-
-
MRB
NO NO
YES
J oint torques Inspection
Production Assembly Operator
Functional Inspection
OK ?
TRIAL &
ERROR
OK ? NCP
NCMR
ASSEMBLY DAILY
PERFORMANCE REPORT VALVE ASSY
INSPECTION
#
#
-
-
-
YES
API 598 API 6D
Low-Pressure Closure Test
High-Pressure Closure Test
Production Testing Operator
NO
Shell Test
NO
MRB
OK ?
TRIAL &
ERROR
OK ? NCP
VALVE
PRESSURE
TESTING
TESTING DAILY
PERFORMANCE REPORT
NCMR
-
#
YES
NO
API 598 or API 6D
(Upon Customer's Requirements)
MRB
C
NON-CONFORMANCE OK ?
NCMR NC Tag
AVI-P-FC-001
AVI-P-FC-000
0 4 OF 4
PRODUCTION GENERAL PROCESS FLOW CHART OF VALVES
ALFA VALVES
DOC NO.
REV.
DATE OF ISSUED
PAGE
8-Apr-03
#
REMARK PROCESS DOCUMENT
Production Packing Operator
B
PACKAGING
& DESPATCH
SALES ORDER
ALFA PACKING LIST
PACKING LABEL
#
-
-
-
-
-
-
COC=Certificate of Compliance & Test
MTR=Material Test Report
DVIR=Dimensions & Visual Ins. Report
QC Inspector
MDR=Manufacturing Data Record
PTR=Pressure Test Report
(if i d b t )
PCR=Protective Coating Report
DOCUMENT
ATION
ALFA PACKING LIST
COC MTR
PTR DVIR
WARRANTY VALVES DATA LOG
# Store Personel
(if required by customers)
SHIPMENT
END
SHIPMENT SCHEDULE DELIVERY DOCKET
VALVES STOCK INVENTORY STOCK
END
AVI-P-FC-000