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PROCESS DOCUMENT

ITI LIMITED
BANGALORE

SAS/PD/ MCS/01

MACHINE SHOP

ISSUE: 02 DATE :06/04/11

1.0.

PURPOSE: Manufacture Mechanical components, sub-assemblies and assemblies consisting of purchased items and fabricated items.

2.0.

SCOPE: The process document is applicable in fabrication machine shop Department of SAP Division and for the manufacture of mechanical items related to SAP Division, TDP Division and SATCOM Division..

3.0.

PROCESS OBJECTIVES AND TARGETS: 98% of components / piece parts produced should meet the functional requirements. As first time yield.

4.0.

PROCESS OWNER: The Chief of machine shop shall be the process owner. Responsibility / Authority is as per Organization structure SAP/OS/MCS/01 RESOURCE MANAGEMENT: Resources required are: 5.1. Trained / skilled manpower to work on machines and bench area. 5.2. Machines like shearing machines, CNC Turret Punch Press,power presses, Press Brakes, milling machines, power hacksaw, drilling machines, lathe ,hand press etc.. 5.3. Measuring instruments. 5.4. Work saving equipments and tools. 5.5. Safety devices.

5.0

Prepared by Signature: Name :

Chkd./ appd by dept. in-charge SAS DIVISION

Page : 1/9

PROCESS DOCUMENT
ITI LIMITED
BANGALORE

SAS/PD/ MCS/01

MACHINE SHOP

ISSUE: 02 DATE :06/04/11

6.0.

IDENTIFICATIONOF INPUTS (SUPPLIERS)/OUTPUT(CUSTOMERS) INTERNAL INPUT 6.1. Shop orders/Schedule sheet. along with FDN 6.2. Raw material 6.3. Documents, Drawings and layout/process sheet. 6.4. Tryout request (TR). 6.5. S E R (Sample Evaluation Report). OUTPUT 6.7. Delivery Ticket 6.8. Final delivery note (FDN) 6.9 Store return note (SRN). 6.10. S R R O (shop order request note) 6.11. Tool repair card 6.12. Plant repair card. SUPPLIER Production planning

Stores Documentation

Inward goods inspection, Methods. Standards. CUSTOMER(INTERNAL) Inspection /Stores Finishing/Stores. Stores Related departments Tool room Plant maintenance

7.0.

INTERACTIONS: Interactions as per Organization structureSAP/OS/MCS/01

Prepared by Signature: Name :

Chkd./ appd by dept. in-charge

SAS DIVISION
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PROCESS DOCUMENT
ITI LIMITED
BANGALORE

SAS/PD/ MCS/01

MACHINE SHOP

ISSUE: 02 DATE :06/04/11

8.0. 8.1.

PROCESS STEPS / PROCEDURES: Process Steps:


RECEIPT OF SHOP ORDER AND STORE REQUISITION FROM PRODUCTION PLANNING

DRAWAL OF RAW MATERIAL AS PER S R FROM STORES

WORK PLANNING AND DRAWAL OF TOOLS, APPROVED DRAWING / DOCUMENTS

PROCESSING OF RAW MATERIALS RESET

NOT OK

SUBMIT FIRST SAMPLE FOR INSPECTION

OK
BULK PRODUCTION

CONTINUED IN NEXT PAGE

Prepared by Signature: Name :

Chkd./ appd by dept. in-charge SAS DIVISION

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PROCESS DOCUMENT
ITI LIMITED
BANGALORE

SAS/PD/ MCS/01

MACHINE SHOP

ISSUE: 02 DATE :06/04/11

PATROL INSPECTION

OK
BENCH GROUP

OK
INSPECTION

OK
FINISH

ASSEMBLE

FINAL INSPECTION

OK
STORES

NOTE: The above is a typical flow chart, however steps may vary on case to case basis as per process sheets.

Prepared by Signature: Name :

Chkd./ appd by dept. in-charge

SAS DIVISION
Page : 4/9

PROCESS DOCUMENT
ITI LIMITED
BANGALORE

SAS/PD/ MCS/01

MACHINE SHOP

ISSUE: 02 DATE :06/04/11

8.2.

Process Procedure: As per relevant work instructions 8.2.1. Receipt of shop orders and store requisitions and drawal of Raw material / purchased parts from stores. Procedure is defined in work instruction SN/WI/MCS /01. Work planning, drawl of tools and their validation. Procedure is defined in work instructions SN/WI/MCS/02 Process the material as per layout. Procedure is defined in work instruction SN/WI/MCS/04. Offering the finished goods to inspection and delivery to stores. Procedure is defined in work instruction SN/WI/MCS/05. Management of rejected items. Procedure is defined in work instructions SN/WI/MCS/06 Try out of raw material /items purchased / sent by methods department / standards department for manufacturing suitability. Procedure is defined in work instruction SN/WI/MCS/05.

8.2.2. 8.2.3. 8.2.4. 8.2.5. 8.2.6.

9.0.

CONTROL POINTS FOR MONITORING AND MEASUREMENT: Verification for compliance to component drawing /functional requirements at various stages as deemed necessary.

10.0. MEASUREMENT MECHANISMS AND CONTROL OF MEASURING DEVICES: Calibration of various measuring instruments done by Gauge control department periodically. 11.0. HANDLING AND PEERSERVATION OF PRODUCTS: 11.1 11.2 11.3 Work saver. Trolleys for movement of jobs /items. Suitable packing of sub-assemblies where required.

Prepared by Signature: Name :

Chkd./ appd by dept. in-charge SAS DIVISION

Page : 5/9

PROCESS DOCUMENT
ITI LIMITED
BANGALORE

SAS/PD/ MCS/01

MACHINE SHOP

ISSUE: 02 DATE :06/04/11

12.0. DATA / RECORDS: The various records generated on the are:12.1 Shop order register. 12.2 Store requisition / drawal register. 12.3 Shop order card. 12.4 Final delivery note 12.5 S R R O. 12.6 Delivery ticket 12.7 Delivery ticket register 12.8 Register for delivery of FDNs 12.9 Tryout register. 12.10 Tool repair card 12.11. Plant repair card. 13.0 DATA ANALYSIS AND CONTINUOUS IMPROVEMENT: The data collected on process objectives and targets are collected and analyzed suitable corrective/preventive action is initiated. 14.0 REVIEW The results are obtained as per clause 13 are reviewed periodically for exploring the possibilities of continuous improvement. If required the targets are re-fixed.

15.0. REFERENCE DOCUMENTS:

15.1 Divisional Supplement to Company Quality Manual 15.2 Six Mandatory Procedure.

END OF DOCUMENT.

Prepared by Signature: Name :


FILE NAME:SNPDMCS4..MSW.

Chkd./ appd by dept. in-charge

SAS DIVISION
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PROCESS DOCUMENT
ITI LIMITED
BANGALORE

SAS/PD/ MCS/01

MACHINE SHOP
ORGANISATION CHART

ISSUE: 02 DATE :06/04/11

CMR (FA) SAS

AEE (V)

AEE (J)

AEE (M)

AE-1

AE-2

AE-1

AE-2

AE (CNC)

Prepared by Signature: Name :


FILE NAME:SNPDMCS4..MSW.

Chkd./ appd by dept. in-charge

SAS DIVISION
Page : 7/9

PROCESS DOCUMENT
ITI LIMITED
BANGALORE

SAS/PD/ MCS/01

MACHINE SHOP
HEAD CMR (FA) SAS RESPONSIBILITY Administrative head of the department and responsible for the production, attend meetings pertaining to shop on different issues like raw materials, production, safety, quality etc.
Responsible for Supervision and out put of section under him. Co-ordinate with other sections within Department for smooth flow of work. Responsible for material movement and arranging final finishing operation.

ISSUE: 02 DATE :06/04/11 INTERFACING DEPARTMENTS All departments in SAS division, Planning and connected departments of other divisions.

SECTION Machine Shop Manufacturing

F-6 Cutting, Bench, Power press, CNC Punching, Straightening, Welding, Forming, Drilling, Milling, Turning. Movement F- 6

AEE (V) FA SAS

Inspection, Tool Room, Methods / Process, Documentation, Stores, Plant and related Depts.

AE-1

Inspection, Tool Room, Methods / Process, Documentation, Stores, Plant and related Depts

F-6 Shop Administration

AE-2

Responsible for shop administration, material follow up and stores coordination.

Planning, stores, IED, OS-SAS, P&A, documentation, Methods and related depts.

Prepared by Signature: Name :


FILE NAME:SNPDMCS4..MSW.

Chkd./ appd by dept. in-charge

SAS DIVISION
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PROCESS DOCUMENT
ITI LIMITED
BANGALORE

SAS/PD/ MCS/01

MACHINE SHOP
HEAD AEE (J) FA SAS RESPONSIBILITY
Responsible for day to day administration of the department. coordination with Methods, Tool room, Planning and other shops to carry out production works. To attend the meetings in connection with production, quality ctc. Movement of Material and finished goods. Responsible for Supervision and out put of section under him. Co-ordinate with other sections within the Department for smooth flow of work. Responsible for Shop Administration, Followup and Co-ordination with other Departments. Responsible for managing CNC Punch press section. In charge of
programming and production of

ISSUE: 02 DATE :06/04/11 INTERFACING DEPARTMENTS


All Departments in TDP Division and connected Departments of other Divisions

SECTION
Machine shop (F-11)

F-11Cutting , Power press, Press Brake, Welding Drilling,Milling,Bench.

AE-1

Inspection, Tool Room, Methods / Process, Documentation, Stores, Plant and related Depts Planning, Stores, IED, OS - SAS, Documentation Methods and connected Departments. Planning and Methods of Divisions, Tool Rooms, R & D and related Departments.

F-11 Shop Administration.

AE -2

CNC Punch Press.

AE (CNC)

jobs taken up in the section and coordination with other sections of Machine Shop.

Prepared by Signature: Name :

Chkd./ appd by dept. in-charge

SAS DIVISION
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