You are on page 1of 690

PT.

BINA USAHA MANDIRI


MIZUSAWA
OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec.
. Jatiuwung - Tangerang, INDONESIA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 80 mm

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

Remark

> Quantity Trial


> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,90 0,05

3,95

> Silicone

2,30 0,05

2,32

> Mangan

Max. 0,40

0,41

> Phospor

Max. 0,03

0,024

> Sulphur

Max. 0,02

0,027

Standard (%)

Actual (%)

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item
> Carbon

2,60 - 3,90

> Silicone

1,60 - 3,00

> Mangan

0,10 - 0,80

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

1522

> Pouring

1400 ~ 1420

1411

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRES
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 Cav
9 Mold

3. INSPECTION
A. Visual Defect (%)
Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

0 Pcs

100%

Remark :
1 pcs dipotong untuk pengecekan shrinkage

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite
> Hardness

Ferrite 70 %
Nodularyti 70 %
HB / HRB

140 ~ 210 HB

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

No
1

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab
Gatting system kurang efektif

Shrinkage

Shrikage

Tindakan Perbaik
Perubahan gatting system

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT
Engineering
Trial Date

SALAH

Tindakan Perbaikan
erubahan gatting system

Pre Launch
Mass Production

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI


MIZUSAWA
OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya
. Kec. Jatiuwung - Tangerang, INDONESIA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 80 mm

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

Remark

10

> Quantity Trial


> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,90 0,05

3,90

> Silicone

2,30 0,05

2,33

> Mangan

Max. 0,40

0,43

> Phospor

Max. 0,03

0,04

> Sulphur

Max. 0,02

0,03

Standard (%)

Actual (%)

> Carbon

2,60 - 3,90

3,78

> Silicone

1,60 - 3,00

3,00

> Mangan

0,10 - 0,80

0,42

> Phospor

Max. 0,08

0,05

> Sulphur

Max. 0,05

0,02

0,025 - 0,090

0,040

Standard ( C )

Actual ( C )

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

1424

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :
Gatting system sebelum perubahan

Sebelum
perubah
an

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 Cav
10 Mold

3. INSPECTION
A. Visual Defect (%)
Item
> Sli

Defect
1

Item

Defect

Remark

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

8 Pcs Total Defect

1 Pcs

Remark :
1 pcs dipotong untuk pengecekan shrinkage

B. Microstructure
Item

Standard

Actual

Ferrite 70 %

70%

Nodularyti 70 %

90%

140 ~ 210 HB

183 - 187 HB

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite
> Hardness

HB / HRB

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Remark

No
1

Gatting system setelah perubahan

Setelah perubahan
Ingate dibuat 2 jalu

ROGRESS

4. ANALISA MASALAH
Masalah

Penyebab
Gatting system kurang efektif

Shrinkage

Shrikage

Tindakan Perbaikan
1 Perubahan gatting system

JUDGEMENT

O N
K G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT
Engineering
Trial Date

Tindakan Perbaikan
n gatting system

Pre Launch
Mass Production

PIC

Waktu

Approved

ord Engineering

Prepared
Process Engineering

PT. BINA USAHA MANDIRI


MIZUSAWA
OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec.
. Jatiuwung - Tangerang, INDONESIA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 50 mm

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,90 0,05

3,95

> Silicone

2,30 0,05

2,32

> Mangan

Max. 0,40

0,41

> Phospor

Max. 0,03

0,024

> Sulphur

Max. 0,02

0,027

Standard (%)

Actual (%)

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item
> Carbon

2,60 - 3,90

> Silicone

1,60 - 3,00

> Mangan

0,10 - 0,80

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

1522

> Pouring

1400 ~ 1420

1411

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 Cav
9 Mold

3. INSPECTION
A. Visual Defect (%)
Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

2 Pcs

Remark :
1 pcs dipotong untuk pengecekan shrinkage

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite
> Hardness

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

No
1

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah
Badlift

Penyebab
Pattern kurang release

Tindakan Perbaikan

Penghalusan pattern pada bagia


terjadi badlift

BadLift

Shrinkage

Gatting system kurang efektif

Shrinkage

Perubahan gatting system

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT
Engineering
Trial Date

14.11.2015

Pre Launch
Mass Production

SALAH
Tindakan Perbaikan

enghalusan pattern pada bagian yang


rjadi badlift

erubahan gatting system

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI


MIZUSAWA
OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung
. - Tangerang, INDONESIA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 50 mm

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

10

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,90 0,05

3,90

> Silicone

2,30 0,05

2,33

> Mangan

Max. 0,40

0,43

> Phospor

Max. 0,03

0,04

> Sulphur

Max. 0,02

0,03

Standard (%)

Actual (%)

> Carbon

2,60 - 3,90

3,78

> Silicone

1,60 - 3,00

3,00

> Mangan

0,10 - 0,80

0,42

> Phospor

Max. 0,08

0,05

> Sulphur

Max. 0,05

0,02

0,025 - 0,090

0,040

Standard ( C )

Actual ( C )

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

1424

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Sebelum perubahan

Sebelum
perubahan

TRIAL PROGRES
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box

2 Cav

Trial Qty

10 Mold

3. INSPECTION
A. Visual Defect (%)
Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :
1 pcs dipotong untuk pengecekan shrinkage

B. Microstructure
Item

Remark

Standard

Actual

Ferrite 70 %

70%

Nodularyti 70 %

90%

140 ~ 210 HB

183 - 187 HB

HB/HRB

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite
> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation
Setelah perubahan

No
1

Setelah perubahan
Ingate dibuat 2 jalu

PROGRESS

4. ANALISA MASALAH
Masalah
Shrinkage

Shrikage

Penyebab
Gatting system kurang efektif

Tindakan Perbaik
1 Perubahan gatting system

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT
Engineering
Trial Date

01.12.2015

Pre Launch
Mass Production

ASALAH

Tindakan Perbaikan
Perubahan gatting system

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI


MIZUSAWA
OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya
. Kec. Jatiuwung - Tangerang, INDONESIA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. Yanmar Diesel Indonesia

Cavity/mould

12

Pcs

Part Name

Pump Body TF 60/120

Weight/pc

0,8

Kg

Part No.

105500-51012

Weight/mould

22

Kg

Material

FCD 50

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

12

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,85 - 3,95

3,90

> Silicone

1,95 0,05

2,18

> Mangan

0,40 - 0,60

0,40

> Phospor

Max. 0,03

0,03

> Sulphur

Max. 0,03

0,01

Standard (%)

Actual (%)

> Carbon

3,20 - 3,90

3,68

> Silicone

2,30 - 2,75

2,83

> Mangan

Max. 0,70

0,40

> Phospor

Max. 0,10

0,03

> Sulphur

Max. 0,03

0,03

> Magnesium

Max. 0,050

0,043

> Cu

0,20 - 0,30

0,27

Standard ( C )

Actual ( C )

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

1422

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

cross joint dengan arah yang berbeda, penyebab kemungkinan terjadinya cross joint diakibatkan oleh

TRIAL PROGRESS
Core Material

Kg

Core Weight/pc

Cav Core Box

Trial Qty

12 Mold

3. INSPECTION
Remark

No
1

Masalah
Sand Inclution

45 %

Bad Mold

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

48

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

71 Pcs Total Defect

59 Pcs

Remark :
Check 130 pcs

BadMold
B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite
> Hardness

Ferrite 70 %

70%

Nodularyti 70 %

90%

140 ~ 210 HB

183 - 187 HB

HB/HRB

Standard

Actual

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Cross Joint

jadinya cross joint diakibatkan oleh mesin


Cavity 1

2 pcs

Cavity 2

8 pcs

Cavity 3

3 pcs

Cavity 4

- pcs

Cavity 5

1 pcs

Cavity 6

2 pcs

Cavity 7

2 pcs

Cavity 8

2 pcs

Cavity 9

4 pcs

Cavity 10

2 pcs

Cavity 11

4 pcs

Cavity 12

6 pcs

GRESS

4. ANALISA MASALAH

Masalah
and Inclution

Penyebab
Pasir terkikis oleh cairan atau
pasir rontok

Tindakan Perbaikan
Pada proses mold harus lebih teliti saat
proses pembersihan

Si
Pasir keropos atau pressure
rendah

menggunakan pressure harus ditinggikan


untuk mencegah pasir keropos

BadMold

paatern terdapat cross joint atau cek cross joint pada pattern dan analisa pad
permasalahan pada mesin molding
mesin molding bermasalah
sehingga pada saat proses
assembling molding menjadi tidak
rata

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT
Engineering
Trial Date

04.12.2015

Pre Launch
Mass Production

Tindakan Perbaikan

mold harus lebih teliti saat


ersihan

n pressure harus ditinggikan


gah pasir keropos

t pada pattern dan analisa pada


n pada mesin molding

PIC

Waktu

Approved

ord Engineering

Prepared
Process Engineering

PT. BINA USAHA MANDIRI


MIZUSAWA
OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec.
. Jatiuwung - Tangerang, INDONESIA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT Panasonic Manufacturing Ind

Cavity/mould

Part Name

PC 2,0 HC

Weight/pc

Part No.

XRKS20MPRZF

Weight/mould

Material

FC 10

Yield

Pcs

4,21
9

Specification

Remark

> Quantity Trial

Moulds

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,70 - 3,95

3,84

> Silicone

2,30 - 2,60

2,38

> Mangan

0,40 Max

0,38

> Phospor

0,03 Max

0,027

> Sulphur

0,03 Max

0,028

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Carbon

3,90 0,05

> Silicone

2,20 0,05

> Mangan

0,40 Max

> Phospor

0,03 Max

> Sulphur

0,02 Max

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item

Standard

Kg
%

1. PATTERN MAKING
Item

Kg

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
1,2 Kg

2 cav
15 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

15 Pcs Total Defect

0 Pcs

100 %

Remark :
1 pcs casting dipotong untuk pengecekan komposisi dan microstructure

B. Microstructure
Item

Standard

Actual

> Graphite type

A& B

Size

4-6

> Matrix : P/F


> Cementite
> Hardness

Remark

Ferrite 70 %
75 - 85 HRB

78 - 81

HB/HRB

Standard

Actual

Remark

11 Kgf mm2

No Test

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Masalah

GRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT
Engineering
Trial Date

17.12.2015

Pre Launch
Mass Production

Tindakan Perbaikan

PIC

Waktu

Approved

ord Engineering

Prepared
Process Engineering

PT. BINA USAHA MANDIRI


MIZUSAWA
OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec.
. Jatiuwung - Tangerang, INDONESIA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 50 mm

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

Remark

> Quantity Trial

Moulds

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

2,60 - 3,90

> Silicone

1,60 - 3,00

> Mangan

0,10 - 0,80

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 cav
10 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT
Engineering
Trial Date

17.12.2015

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI


MIZUSAWA
OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec.
. Jatiuwung - Tangerang, INDONESIA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 80 mm

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

Remark

> Quantity Trial

Moulds

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

2,60 - 3,90

> Silicone

1,60 - 3,00

> Mangan

0,10 - 0,80

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 cav
10 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite
> Hardness

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT
Engineering
Trial Date

17.12.2015

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI


MIZUSAWA
OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung . Tangerang, INDONESIA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT Panasonic Manufacturing Ind

Cavity/mould

Part Name

PC GP 2,0 HC

Weight/pc

Kg

Part No.

XRKS20MPRZF

Weight/mould

Kg

Material

FC 10

Yield

1. PATTERN MAKING
Item

Specification

Remark

> Quantity Trial

Moulds

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,20 0,05

> Mangan

0,40 Max

> Phospor

0,03 Max

> Sulphur

0,02 Max

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,70 - 3,95

> Silicone

2,30 - 2,60

> Mangan

0,40 Max

> Phospor

0,03 Max

> Sulphur

0,03 Max

> Magnesium
> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 cav
30 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

75 ~ 85 HRB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT
Engineering
Trial Date

17.12.2015

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. YANMAR DIESEL INDONESIA

Cavity/mould

Part Name

Balancer Shaft L70V

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FCD 450

Yield

1. PATTERN MAKING
Item

Specification

Remark

> Quantity Trial

Moulds

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,95 0,05

> Silicone

2,15 0,05

> Mangan

Max 0,40

> Phospor

Max 0,03

> Sulphur

Max 0,03

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,6 - 3,90

> Silicone

2,70- 3,00

> Mangan

Max 0,40

> Phospor

Max 0,03

> Sulphur

Max 0,03

> Magnesium

0,030 - 0,050

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item
> Per Mould

Standard

Second/Mould

> Per Ladle


Notes :

Minutes/Ladle

TRIAL PROGRESS
Core Material
Kg

Core Weight/pc

Cav Core Box


Trial Qty

8 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

8 Pcs Total Defect

0 Pcs

Standard

Actual

Remark :

B. Microstructure
Item

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength

Standard

Actual

Remark

Masalah

Elongation

GRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

18.12.2015

Pre Launch
Mass Production

Tindakan Perbaikan

PIC

Waktu

Approved

ord Engineering

Prepared
Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT Panasonic Manufacturing Ind

Cavity/mould

Part Name

PC GP 1,0 HC

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FC 10

Yield

1. PATTERN MAKING
Item

Specification

Remark

> Quantity Trial

Moulds

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,90 0,05

3,95

> Silicone

2,20 0,05

2,22

> Mangan

0,40 Max

0,39

> Phospor

0,03 Max

0,03

> Sulphur

0,02 Max

0,02

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,70 - 3,95

3,95

> Silicone

2,30 - 2,60

2,44

> Mangan

0,40 Max

0,39

> Phospor

0,03 Max

0,02

> Sulphur

0,03 Max

0,03

Standard ( C )

Actual ( C )

Remark

Actual

Remark

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 cav
15 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

75 ~ 85 HRB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

29.12.2015

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 40 mm

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

2,60 - 3,90

> Silicone

1,60 - 3,00

> Mangan

0,10 - 0,80

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 cav
9 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

9 Pcs Total Defect

0 Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

14.12.2015 oke

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 65 mm

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

Cav/Mould

FCD 45

1 Cavity

Yield

1. PATTERN MAKING
Item

Specification

Remark

> Quantity Trial

Moulds

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

2,60 - 3,90

> Silicone

1,60 - 3,00

> Mangan

0,10 - 0,80

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 cav
Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

8 Pcs Total Defect

0 Pcs

Standard

Actual

Remark :

B. Microstructure
Item

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength

Standard

Actual

Remark

Masalah

Yield Strength
Elongation

GRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

14.12.2015

Pre Launch
Mass Production

Tindakan Perbaikan

PIC

Waktu

Approved

ord Engineering

Prepared
Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT Panasonic Manufacturing Ind

Cavity/mould

Part Name

PC GP 2.0 HC

Weight/pc

4,21

Kg

Kg

46,7

Part No.

Weight/mould

Material

FC 10

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

38

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,90 0,05

3,95

> Silicone

2,20 0,05

2,22

> Mangan

0,40 Max

0,39

> Phospor

0,03 Max

0,03

> Sulphur

0,02 Max

0,02

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,70 - 3,95

3,95

> Silicone

2,30 - 2,60

2,44

> Mangan

0,40 Max

0,39

> Phospor

0,03 Max

0,02

> Sulphur

0,03 Max

0,03

Standard ( C )

Actual ( C )

Remark

Actual

Remark

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item
> Per Mould

Standard

Second/Mould

Pcs

> Per Ladle


Notes :

Minutes/Ladle

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 cav
38 Mold

3. INSPECTION
A. Visual Defect (%)
Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

Remark

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

29 Pcs Total Defect

12 Pcs

Remark :
9 casting yang NG bad core dilakukan proses repair

B. Microstructure
Item

Standard

Actual

> Graphite type

A&B

A&B

Size

4-6

Ferrite 70 %

3%F

> Matrix : P/F


> Cementite
> Hardness

Remark

Nodularyti 70 %
75 - 85 HRB

133 - 135

HB/HRB

Standard

Actual

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength

No
1

Elongation

PROGRESS

4. ANALISA MASALAH
Masalah
Slag Inclution

Penyebab

Tindakan Perbaikan

Gatting system kurang efektif dan Modifikasi gatting system dibuat


belum menggunakan sedex

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

29.12.2015

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

odifikasi gatting system dibuatkan slag trap

PIC
Rohyat /
Sujarwo

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT Panasonic Manufacturing Ind

Cavity/mould

Part Name

PC GP 2.0 HC

Weight/pc

4,21

Kg

Kg

46,7

Part No.

Weight/mould

Material

FC 10

Yield

Pcs

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

60

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,70 - 3,95

3,90

> Silicone

2,30 - 2,60

2,84

> Mangan

0,40 Max

0,40

> Phospor

0,03 Max

0,03

> Sulphur

0,03 Max

0,02

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Carbon

3,90 0,05

> Silicone

2,20 0,05

> Mangan

0,40 Max

> Phospor

0,03 Max

> Sulphur

0,02 Max

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item
> Per Mould

Standard

Second/Mould

> Per Ladle


Notes :

Minutes/Ladle

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 cav
60 Mold

3. INSPECTION
A. Visual Defect (%)
Item
> Sli

Defect
2

Item

Defect

Remark

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

53 Pcs Total Defect

7 Pcs

Standard

Actual

> Graphite type

A& B

A& B

Size

4-6

Ferrite 70 %

3%F

Nodularyti 70 %

Remark :

B. Microstructure
Item

> Matrix : P/F


> Cementite
> Hardness

Remark

79 ~ 84

HB/HRB

Actual

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength

Standard

No
1

Masalah
Slag Inclution

Elongation

GRESS

ag Inclution

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

Gatting system kurang efektif dan Modifikasi gatting system dibuatkan slag tra
belum menggunakan sedex

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

5.01.2016

Pre Launch
Mass Production

Tindakan Perbaikan

ting system dibuatkan slag trap

PIC
Rohyat /
Sujarwo

Waktu

Approved

ord Engineering

Prepared
Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA

TRIAL PROGRESS

OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs Core Material

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 80 mm

Weight/pc

3,1

Kg Core Weight/pc

Weight/mould

13,3

Kg Cav

Part No.
Material

FCD 45

Yield

66

Core Box

% Trial Qty

RCS
0,86 Kg

2 cav
8 Mold

1. PATTERN MAKING
Item

3. INSPECTION

Specification

> Quantity Trial

Remark

No

A. Visual Defect (%)


Item

Moulds

Defect

Item

> Released Pattern

OK / NG

> Sli

> CJ

> Hardness Mould

80 ~ 89

> SE

> BL

> Sensor Cope

1 / 2 / 3 / 4

> Si

> BM

> Sensor Drag

1 / 2 / 3 / 4

> SD

> CS

> Diameter Sprue

28 / 30 / 32

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,90 0,05

3,94

> Crush

> Silicone

2,30 0,05

2,25

> SP

> Mangan

Max. 0,40

0,40

> RO

> Phospor

Max. 0,03

0,027

> Carbide

> Sulphur

Max. 0,02

0,026

Total GooD

B. Casting Composition
Item

> Harness Up
Low
> Excentric

> Carbon

2,60 - 3,90

3,70

> Silicone

1,60 - 3,00

3,08

> Mangan

0,10 - 0,80

0,40

> Phospor

Max. 0,08

0,030

> Sulphur

Max. 0,05

0,016

Item

0,025 - 0,090

0,040

> Graphite type

C. Temperature

8 Pcs Total Defect

0 Pcs

Standard

Actual

Remark :
Actual (%)

> Cu

Remark

Low

Standard (%)

> Magnesium

Defect

Remark

Nama Material

B. Microstructure

Size
> Matrix : P/F

Ferrite 70 %

Remark

Ma

Item

Standard ( C )

Actual ( C )

Remark

> Cementite

1500 ~ 1520

> Hardness

> Pouring

1400 ~ 1420

C. Mechanical Properties

Item

Item
Standard

Actual

Remark

Tensile Strength

> Per Mould

Second/Mould

Yield Strength

> Per Ladle

Minutes/Ladle

Elongation

Notes :

HB/HRB

140 ~ 210 HB

> Tapping

D. Pouring Time

Nodularyti 70 %

Standard

Actual

Remark

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

ESS

TECHNICAL DEPT Engineering


Trial Date

7.01.2016

Pre Launch
Mass Production

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

PIC

Waktu

JUDGEMENT

O
K

N
G

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA

TRIAL PROGRESS

OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs Core Material

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 50 mm

Weight/pc

2,19

Kg Core Weight/pc

Weight/mould

13,3

Kg Cav

Part No.
Material

FCD 45

Yield

66

Core Box

% Trial Qty

RCS
0,35 Kg

2 cav
8 Mold

1. PATTERN MAKING
Item

3. INSPECTION

Specification

> Quantity Trial

Remark

No

A. Visual Defect (%)


Item

Moulds

Defect

Item

> Released Pattern

OK / NG

> Sli

> CJ

> Hardness Mould

80 ~ 89

> SE

> BL

> Sensor Cope

1 / 2 / 3 / 4

> Si

> BM

> Sensor Drag

1 / 2 / 3 / 4

> SD

> CS

> Diameter Sprue

28 / 30 / 32

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,90 0,05

3,94

> Crush

> Silicone

2,30 0,05

2,25

> SP

> Mangan

Max. 0,40

0,40

> RO

> Phospor

Max. 0,03

0,027

> Carbide

> Sulphur

Max. 0,02

0,026

Total GooD

B. Casting Composition
Item

> Harness Up
Low
> Excentric

> Carbon

2,60 - 3,90

3,70

> Silicone

1,60 - 3,00

3,08

> Mangan

0,10 - 0,80

0,40

> Phospor

Max. 0,08

0,030

> Sulphur

Max. 0,05

0,016

Item

0,025 - 0,090

0,040

> Graphite type

C. Temperature

8 Pcs Total Defect

0 Pcs

Standard

Actual

Remark :
Actual (%)

> Cu

Remark

Low

Standard (%)

> Magnesium

Defect

Remark

Nama Material

B. Microstructure

Size
> Matrix : P/F

Ferrite 70 %

Remark

Ma

Item

Standard ( C )

Actual ( C )

Remark

> Cementite

1500 ~ 1520

> Hardness

> Pouring

1400 ~ 1420

C. Mechanical Properties

Item

Item
Standard

Actual

Remark

Tensile Strength

> Per Mould

Second/Mould

Yield Strength

> Per Ladle

Minutes/Ladle

Elongation

Notes :

HB/HRB

140 ~ 210 HB

> Tapping

D. Pouring Time

Nodularyti 70 %

Standard

Actual

Remark

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

ESS

TECHNICAL DEPT Engineering


Trial Date

7.01.2016

Pre Launch
Mass Production

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

PIC

Waktu

JUDGEMENT

O
K

N
G

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

12

Pcs

Weight/pc

0,46

Kg

Weight/mould

10,5

Kg

Yield

52,2

Customer

PT. NICE

Cavity/mould

Part Name

Insert Ring 0120

Part No.
Material

FC - 200

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,50 - 3,60

3,52

> Silicone

1,95 - 2,05

1,60

> Mangan

0,50 - 0,60

0,59

> Phospor

Max. 0,03%

0,028

> Sulphur

Max. 0,03%

0,025

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,40 - 3,50

3,51

> Silicone

1,95 - 2,35

1,86

> Mangan

0,5 - 0,7

0,57

> Phospor

Max. 0,03%

0,027

> Sulphur

Max. 0,03%

0,024

Standard ( C )

Actual ( C )

Remark

Standard

Actual

Remark

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping
> Pouring
D. Pouring Time
Item
> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Hardness Up

Micro :

Hardness and Micro Test


Result Test Hardness : 227 - 241 HB

TRIAL PROGRESS
Core Material

Kg

Core Weight/pc

Cav Core Box


Trial Qty

5 Mold

3. INSPECTION
A. Visual Defect (%)
Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

60

Remark

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

0 Pcs Total Defect

60 Pcs

Standard

Actual

Remark

227 - 241

HB/HRB

Actual

Remark

Remark :

B. Microstructure
Item
> Graphite type
Size
> Matrix : P/F
> Cementite

Ferrite %
Nodularyti %

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

No
1

7 - 241 HB

PROGRESS

4. ANALISA MASALAH
Masalah
Shrinkage pada bagian Ingate

Shrinkage

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

12.01.2016

Pre Launch

Std FC-25 FW NF60


C:

Mass Production

ASALAH

Si :
Tindakan Perbaikan

PIC

Waktu

Mn :
P:
S:

Approved

Prepared

Spv/Koord Engineering

Process Engineering

Std FC-25 FW NF60


3,10 - 3,80%
1,50 - 2,50%
0,40 - 0,80%
Max. 0,01%
Max. 0,01%

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

24

Pcs

Weight/pc

0,18

Kg

Weight/mould

9,32

Kg

46,35

Customer

PT. NICE

Cavity/mould

Part Name

Insert Ring 0130

Part No.
Material

FC - 200

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,50 - 3,60

3,45

> Silicone

1,95 - 2,05

1,60

> Mangan

0,50 - 0,60

0,57

> Phospor

Max. 0,03%

0,028

> Sulphur

Max. 0,03%

0,023

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,40 - 3,50

3,36

> Silicone

1,95 - 2,35

1,85

> Mangan

0,5 - 0,7

0,56

> Phospor

Max. 0,03%

0,025

> Sulphur

Max. 0,03%

0,02

Standard ( C )

Actual ( C )

Remark

Standard

Actual

Remark

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping
> Pouring
D. Pouring Time
Item
> Per Mould

Second/Mould

> Per Ladle


Notes :

Minutes/Ladle

Hardness Up

Hardness and Micro Test


Result Test Hardness : 275 - 322 HB
Micro :

TRIAL PROGRESS
Core Material

Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 Mold

3. INSPECTION
A. Visual Defect (%)
Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

46

Remark

Masalah
Shrinkage pada bagia

> R Surface
> BH

> MD

> Dim Up

Shrinkage
Low

> SP

No
1

> PH

> Crush

Defect

BadLift pada cavity M

Permukaan kasar

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

0 Pcs Total Defect

48 Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite %

Kasar

Nodularyti %

> Hardness

234 - 241

HB/HRB

Actual

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength

Standard

Elongation

Hardness and Micro Test


Result Test Hardness : 234 - 241 HB
Micro :

GRESS

4. ANALISA MASALAH

Masalah
hrinkage pada bagian ingate

Shrinkage

adLift pada cavity M

ermukaan kasar

Kasar

Penyebab

Tindakan Perbaikan

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

Pre Launch

Std FC-25 Ring Pulley


C:
3,00 - 2,70%
Si : 1,40 - 2,60%

Mass Production

Mn : 0,55 - 0,75%
Tindakan Perbaikan

PIC

Waktu

P:
S:

Max. 0,08%
Max. 0,05%

Approved

ord Engineering

Prepared
Process Engineering

25 Ring Pulley
00 - 2,70%
40 - 2,60%

55 - 0,75%

ax. 0,08%
ax. 0,05%

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT Panasonic Manufacturing Ind

Cavity/mould

Part Name

PC GP 2.0 HC (Pattern Steel)

Weight/pc

4,21

Part No.
FC 10

Yield

1. PATTERN MAKING
Item

Specification

Remark

> Quantity Trial

Moulds

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,70 - 3,95

3,75

> Silicone

2,30 - 2,60

2,24

> Mangan

0,40 Max

0,37

> Phospor

0,03 Max

0,026

> Sulphur

0,03 Max

0,030

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Carbon

3,90 0,05

> Silicone

2,20 0,05

> Mangan

0,40 Max

> Phospor

0,03 Max

> Sulphur

0,02 Max

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item
> Per Mould

Standard

Kg
Kg

Weight/mould

Material

Pcs

Second/Mould

> Per Ladle


Notes :

Minutes/Ladle

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 cav
Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

> Graphite type

A&B

A&B

Size

4-6

Ferrite 70 %

97% P

> Matrix : P/F


> Cementite
> Hardness

Remark

Nodularyti 70 %
75 - 85 HRB

79 - 84

HB/HRB

Standard

Actual

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength

Elongation

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

29.12.2015

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT Panasonic Manufacturing Ind

Cavity/mould

Part Name

PC GP 1,0 HC

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FC 10

Yield

1. PATTERN MAKING
Item

Specification

Remark

> Quantity Trial

Moulds

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,70 - 3,95

3,75

> Silicone

2,30 - 2,60

2,24

> Mangan

0,40 Max

0,37

> Phospor

0,03 Max

0,026

> Sulphur

0,03 Max

0,030

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Carbon

3,90 0,05

> Silicone

2,20 0,05

> Mangan

0,40 Max

> Phospor

0,03 Max

> Sulphur

0,02 Max

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

RCS

Core Weight/pc

1,174 Kg

Cav Core Box


Trial Qty

2 cav
Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Size

> Cementite
> Hardness

Remark

A&B

> Graphite type

> Matrix : P/F

Actual

Ferrite 70 %

97% P

Nodularyti 70 %
75 ~ 85 HRB

79 - 84

HB/HRB

Standard

Actual

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

29.12.2015

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. MKM

Cavity/mould

Part Name

DRUM HAND BRAKE TD (Steel)

Weight/pc

Part No.

MC-862229

Weight/mould

Material

FC 250

Yield

Pcs

6,8

Kg
Kg
%

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

13

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,10 - 3,80

3,56

> Silicone

1,50 - 2,50

2,16

> Mangan

0,40 - 0,90

0,52

> Phospor

Max. 0,10

0,03

> Sulphur

Max. 0,10

0,04

Max. 0,30

0,30

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

Kg

Core Weight/pc

Cav Core Box

Trial Qty

13 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item
> Sli

Defect
1

Item

> BL

> Si

> BM

> SD

> CS
2

Remark

> CJ

> SE

> BC

Defect

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

21 Pcs Total Defect

5 Pcs

Standard

Actual

A (B+D Max.10%)

4-6

Ferrite 2%

2%

Remark :

B. Microstructure
Item
> Graphite type
Size
> Matrix : P/F
> Cementite
> Hardness

Remark

Nodularyti 70 %
187 - 241 HB

192 - 197

HB/HRB

Standard

Actual

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Masalah

GRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

29.12.2015

Pre Launch
Mass Production

Tindakan Perbaikan

PIC

Waktu

Approved

ord Engineering

Prepared
Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT Panasonic Manufacturing Ind

Cavity/mould

Part Name

PC GP-20HCN1 (Pattern Steel)

Weight/pc

4,21

Part No.

13,42

Weight/mould

Material

FC 10

Yield

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,70 - 3,95

3,71

> Silicone

2,30 - 2,60

2,51

> Mangan

0,40 Max

0,40

> Phospor

0,03 Max

0,028

> Sulphur

0,03 Max

0,027

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Carbon

3,90 0,05

> Silicone

2,20 0,05

> Mangan

0,40 Max

> Phospor

0,03 Max

> Sulphur

0,02 Max

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Kg
Kg
%

1. PATTERN MAKING
Item

Pcs

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 cav
3 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

> Graphite type

A&B

Size

4-6

Pearlite Ferrite

97% P

> Matrix : P/F


> Cementite
> Hardness

Remark

Nodularyti 70 %
75 - 85 HRB

83 - 85

HB/HRB

Standard

Actual

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT Panasonic Manufacturing Ind

Cavity/mould

Part Name

PC GP-10HCN1 (Pattern Steel)

Weight/pc

Part No.

2
3,7
12,4

Weight/mould

Material

FC 10

Pcs

Yield

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,70 - 3,95

3,75

> Silicone

2,30 - 2,60

2,24

> Mangan

0,40 Max

0,37

> Phospor

0,03 Max

0,026

> Sulphur

0,03 Max

0,030

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Carbon

3,90 0,05

> Silicone

2,20 0,05

> Mangan

0,40 Max

> Phospor

0,03 Max

> Sulphur

0,02 Max

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1540

> Pouring

1420 - 1440

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Kg
%

1. PATTERN MAKING
Item

Kg

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 cav
5 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

10 Pcs

Remark :

B. Microstructure
Item

Standard

Actual

> Graphite type

A&B

Size

4-6

Pearlite Ferrite

97% P

> Matrix : P/F


> Cementite

Nodularyti 70 %
90 - 95 HRB

> Hardness

Remark

79 - 84

HB/HRB

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. EBARA

Cavity/mould

Part Name

Casing Cover 5 FSH-MN

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FC-200

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
B. Casting Composition
Item
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

Kg

Core Weight/pc

Cav Core Box


Trial Qty

5 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

10 Pcs

Remark :

B. Microstructure
Item

Standard

> Graphite type

A&B

Size

4-6

> Matrix : P/F


> Cementite

Actual

Remark

Pearlite Ferrite
Nodularyti 70 %
HB/HRB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

29.12.2015

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT Panasonic Manufacturing Ind

Cavity/mould

Part Name

PC GP-10HCN1 (Pattern Steel)

Weight/pc

Part No.

RKS10CPRZF

Weight/mould

Material

FC 10

Yield

Pcs
3,7

12,4

Specification

Remark

> Quantity Trial

Moulds

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,20 0,05

> Mangan

0,40 Max

> Phospor

0,03 Max

> Sulphur

0,02 Max

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

NG

> Carbon

3,70 - 3,95

3,97

> Silicone

2,30 - 2,60

2,48

> Mangan

0,40 Max

0,38

> Phospor

0,03 Max

0,020

> Sulphur

0,03 Max

0,060

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1540

> Pouring

1420 - 1440

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Kg
%

1. PATTERN MAKING
Item

Kg

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 cav
Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

10 Pcs

Remark :

B. Microstructure
Item

Standard

Actual

> Graphite type

A&B

Size

4-6

Pearlite Ferrite

97% P

> Matrix : P/F


> Cementite

Nodularyti 70 %
90 - 95 HRB

> Hardness

Remark

79 - 80

HB/HRB

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

01.02.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. MKM

Cavity/mould

Part Name

DRUM HAND BRAKE TD (Steel)

Weight/pc

Part No.

MC-862229

Weight/mould

Material

FC 250

Yield

Pcs

6,8

Kg
Kg
%

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

25

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,50

> Silicone

1,60

> Mangan

0,58

> Phospor

0,031

> Sulphur

0,020

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

Actual (%)

> Carbon

3,10 - 3,80

3,50

> Silicone

1,50 - 2,50

1,85

> Mangan

0,40 - 0,90

0,58

> Phospor

Max. 0,10

0,032

> Sulphur

Max. 0,10

0,028

Max. 0,30

0,31

Standard ( C )

Actual ( C )

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

1421

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

Kg

Core Weight/pc

Cav Core Box

Trial Qty

25 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item
> Sli

Defect
1

Item

Defect

Remark

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

47 Pcs Total Defect

3 Pcs

Standard

Actual

Remark

187 - 241 HB

187 - 197

HB/HRB

Standard

Actual

Remark

Remark :
TRIAL N40

B. Microstructure
Item
> Graphite type
Size
> Matrix : P/F
> Cementite
> Hardness

A (B+D Max.10%)
4-6

Ferrite 2%
Nodularyti 70 %

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

03.2.2015

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

12

Pcs

Weight/pc

0,46

Kg

Weight/mould

10,5

Kg

Yield

52,2

Customer

PT. NICE

Cavity/mould

Part Name

Insert Ring 0120

Part No.
Material

FC - 200

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,50 - 3,60

3,80

> Silicone

1,95 - 2,05

2,01

> Mangan

0,50 - 0,60

0,39

> Phospor

Max. 0,03%

0,025

> Sulphur

Max. 0,03%

0,029

Standard (%)

Actual (%)

> Carbon

3,40 - 3,50

3,75

> Silicone

1,95 - 2,35

2,31

> Mangan

0,5 - 0,7

0,38

> Phospor

Max. 0,03%

0,025

> Sulphur

Max. 0,03%

0,029

Standard ( C )

Actual ( C )

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item

Remark

> Tapping
> Pouring

1420

D. Pouring Time
Item

Standard

Actual

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

Kg

Core Weight/pc

Cav Core Box


Trial Qty

5 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

60 Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

171-187

HB/HRB

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite %
Nodularyti %

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

06.2.2016

Pre Launch

Std FC-25 FW NF60


C:

Mass Production

ASALAH

Si :
Tindakan Perbaikan

PIC

Waktu

Mn :
P:
S:

Approved

Prepared

Spv/Koord Engineering

Process Engineering

Std FC-25 FW NF60


3,10 - 3,80%
1,50 - 2,50%
0,40 - 0,80%
Max. 0,01%
Max. 0,01%

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

24

Pcs

Weight/pc

0,18

Kg

Weight/mould

9,32

Kg

46,35

Customer

PT. NICE

Cavity/mould

Part Name

Insert Ring 0130

Part No.
Material

FC - 200

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,50 - 3,60

3,80

> Silicone

1,95 - 2,05

2,01

> Mangan

0,50 - 0,60

0,39

> Phospor

Max. 0,03%

0,025

> Sulphur

Max. 0,03%

0,029

Standard (%)

Actual (%)

> Carbon

3,40 - 3,50

3,75

> Silicone

1,95 - 2,35

2,31

> Mangan

0,5 - 0,7

0,38

> Phospor

Max. 0,03%

0,025

> Sulphur

Max. 0,03%

0,029

Standard ( C )

Actual ( C )

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item

Remark

> Tapping
> Pouring

1420

D. Pouring Time
Item

Standard

Actual

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

Kg

Core Weight/pc

Cav Core Box


Trial Qty

5 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

117 Pcs Total Defect

Pcs

Remark :
BL : Cavity A = 1pcs, Cavity M = 2 pcs

B. Microstructure
Item

Standard

Actual

Remark

171-187

HB/HRB

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite %
Nodularyti %

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

06.2.2016

Pre Launch

Std FC-25 FW NF60


C:

Mass Production

ASALAH

Si :
Tindakan Perbaikan

PIC

Waktu

Mn :
P:
S:

Approved

Prepared

Spv/Koord Engineering

Process Engineering

Std FC-25 FW NF60


3,10 - 3,80%
1,50 - 2,50%
0,40 - 0,80%
Max. 0,01%
Max. 0,01%

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. NIKKO CAHAYA ELECTRIC

Cavity/mould

Part Name

Front Bracket 1551

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FCD-450

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,80 - 3,90

3,92

> Silicone

2,15 0,05

2,38

> Mangan

Max. 0,40

0,41

> Phospor

Max. 0,03

0,027

> Sulphur

Max. 0,03

0,035

Standard (%)

Actual (%)

> Carbon

3,60 - 3,80

3,75

> Silicone

2,70 - 3,00

3,10

> Mangan

Max.0,40

0,41

> Phospor

Max. 0,03

0,027

> Sulphur

Max. 0,03

0,012

0,030 - 0,050

0,046

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Magnesium

0,15

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

Remark

> Tapping
> Pouring

1420

D. Pouring Time
Item
> Per Mould

Standard

Actual

Remark
Second/Mould

> Per Ladle


Notes :

Minutes/Ladle

TRIAL PROGRESS
Core Material

Kg

Core Weight/pc

Cav Core Box


Trial Qty

3 Mold

3. INSPECTION
A. Visual Defect (%)
Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

Remark

No
1

Masalah
Broken Casting

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

4 Pcs Total Defect

5 Pcs

Remark :

Tidak ada
rongga susut

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite %
Nodularyti %
HB/HRB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength

Standard

Actual

Remark

Elongation

GRESS

4. ANALISA MASALAH

Masalah
oken Casting

Tidak ada
rongga susut

Penyebab

Tindakan Perbaikan

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

Pre Launch

Std FC-25 FW NF60


C:
3,10 - 3,80%

Mass Production

Tindakan Perbaikan

PIC

Waktu

Si :

1,50 - 2,50%

Mn :
P:
S:

0,40 - 0,80%
Max. 0,01%
Max. 0,01%

Approved

ord Engineering

Prepared
Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. YANMAR DIESEL INDONESIA

Cavity/mould

Pcs

Part Name

Fly Wheel NF 60

Weight/pc

18

Kg

Weight/mould

27,3

Kg

Part No.
Material

FC - 250

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,45 0,05

3,43

> Silicone

1,55 0,05

1,57

> Mangan

0,60 0,05

0,54

> Phospor

Max. 0,03

0,030

> Sulphur

Max. 0,03

0,014

Standard (%)

Actual (%)

> Carbon

3,10 - 3,80

3,42

> Silicone

1,50 - 2,50

1,84

> Mangan

0,40 - 0,80

0,54

> Phospor

Max. 0,10

0,030

> Sulphur

Max. 0,10

0,016

Standard ( C )

Actual ( C )

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item

Remark

> Tapping
> Pouring

1403

D. Pouring Time
Item
> Per Mould

Standard

Actual

Remark
Second/Mould

> Per Ladle


Notes :

Minutes/Ladle

TRIAL PROGRESS
Core Material

Kg

Core Weight/pc

Cav Core Box


Trial Qty

9 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

9 Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite %
Nodularyti %
HB/HRB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength

Standard

Actual

Remark

Masalah

Elongation

GRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

10.2.2016

Pre Launch

Std FC-25 FW NF60


C:
3,10 - 3,80%

Mass Production

Tindakan Perbaikan

PIC

Waktu

Si :

1,50 - 2,50%

Mn :
P:
S:

0,40 - 0,80%
Max. 0,01%
Max. 0,01%

Approved

ord Engineering

Prepared
Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA

TRIAL PROGRESS

OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs Core Material

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 40 mm

Weight/pc

1,67

Kg Core Weight/pc

Weight/mould

9,67

Kg Cav

Yield

55,9

Part No.
Material

FCD 45

Core Box

% Trial Qty

RCS
0,19 Kg

2 cav
11 Mold

1. PATTERN MAKING
Item

3. INSPECTION

Specification

> Quantity Trial

Remark

11

No

A. Visual Defect (%)


Item

Moulds

Defect

Item

> Released Pattern

OK / NG

> Sli

> CJ

> Hardness Mould

80 ~ 89

> SE

> BL

> Sensor Cope

1 / 2 / 3 / 4

> Si

> BM

> Sensor Drag

1 / 2 / 3 / 4

> SD

> CS

> Diameter Sprue

28 / 30 / 32

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,90 0,05

3,94

> Crush

> Silicone

2,30 0,05

2,25

> SP

> Mangan

Max. 0,40

0,40

> RO

> Phospor

Max. 0,03

0,027

> Carbide

> Sulphur

Max. 0,02

0,026

Total GooD

B. Casting Composition
Item

> Harness Up
Low
> Excentric

> Carbon

2,60 - 3,90

3,70

> Silicone

1,60 - 3,00

3,08

> Mangan

0,10 - 0,80

0,40

> Phospor

Max. 0,08

0,030

> Sulphur

Max. 0,05

0,016

Item

0,025 - 0,090

0,040

> Graphite type

C. Temperature

11 Pcs Total Defect

0 Pcs

Standard

Actual

Remark :
Actual (%)

> Cu

Remark

Low

Standard (%)

> Magnesium

Defect

Remark

Nama Material

B. Microstructure

Size
> Matrix : P/F

Ferrite 70 %

Remark

Ma

Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

> Cementite

C. Mechanical Properties

D. Pouring Time
Item

Item
Standard

Actual

HB/HRB

140 ~ 210 HB

> Hardness
1444

Nodularyti 70 %

Remark

Standard

Actual

Tensile Strength

> Per Mould

Second/Mould

Yield Strength

> Per Ladle

Minutes/Ladle

Elongation

Notes :

Sebelum perbaikan

Setelah perbaikan

Riser utuh tidak kempot

c/j 1mm

c/j 0 mm

Riser utuh / tidak


efektif

Tidak ada rongga


susut

Remark

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

ESS

TECHNICAL DEPT Engineering


Trial Date

Pre Launch
Mass Production

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

PIC

Waktu

JUDGEMENT

O
K

N
G

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA

TRIAL PROGRESS

OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs Core Material

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 65mm

Weight/pc

2,82

Kg Core Weight/pc

Weight/mould

9,67

Kg Cav

Yield

55,9

Part No.
Material

FCD 45

Core Box

% Trial Qty

RCS
0,50 Kg

2 cav
11 Mold

1. PATTERN MAKING
Item

3. INSPECTION

Specification

> Quantity Trial

Remark

11

No

A. Visual Defect (%)


Item

Moulds

Defect

Item

> Released Pattern

OK / NG

> Sli

> CJ

> Hardness Mould

80 ~ 89

> SE

> BL

> Sensor Cope

1 / 2 / 3 / 4

> Si

> BM

> Sensor Drag

1 / 2 / 3 / 4

> SD

> CS

> Diameter Sprue

28 / 30 / 32

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,90 0,05

3,94

> Crush

> Silicone

2,30 0,05

2,25

> SP

> Mangan

Max. 0,40

0,40

> RO

> Phospor

Max. 0,03

0,027

> Carbide

> Sulphur

Max. 0,02

0,026

Total GooD

B. Casting Composition
Item

> Harness Up
Low
> Excentric

> Carbon

2,60 - 3,90

3,70

> Silicone

1,60 - 3,00

3,08

> Mangan

0,10 - 0,80

0,40

> Phospor

Max. 0,08

0,030

> Sulphur

Max. 0,05

0,016

Item

0,025 - 0,090

0,040

> Graphite type

C. Temperature

11 Pcs Total Defect

0 Pcs

Standard

Actual

Remark :
Actual (%)

> Cu

Remark

Low

Standard (%)

> Magnesium

Defect

Remark

Nama Material

B. Microstructure

Size
> Matrix : P/F

Ferrite 70 %

Remark

Ma

Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

> Cementite

C. Mechanical Properties

D. Pouring Time
Item

Item
Standard

Actual

Remark

Standard

Tensile Strength

> Per Mould

Second/Mould

Yield Strength

> Per Ladle

Minutes/Ladle

Elongation

Notes :

Sebelum Improve

Riser tidak berfungsi dengan baik

Setelah Improve

Sedikit menyusut

Riser utuh / tidak


efektif

HB/HRB

140 ~ 210 HB

> Hardness
1444

Nodularyti 70 %

Keropos pada
bagian Ingate

Tidak ada
keropos pada
bagian Ingate

Actual

Remark

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

ESS

TECHNICAL DEPT Engineering


Trial Date

Pre Launch
Mass Production

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

PIC

Waktu

JUDGEMENT

O
K

N
G

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 65mm

Weight/pc

2,82

Kg

Weight/mould

9,67

Kg

Yield

55,9

Part No.
Material

FCD 45

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

20

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,90 0,05

3,95

> Silicone

2,30 0,05

2,28

> Mangan

Max. 0,40

0,38

> Phospor

Max. 0,03

0,029

> Sulphur

Max. 0,02

0,029

Standard (%)

Actual (%)

> Carbon

2,60 - 3,90

3,63

> Silicone

1,60 - 3,00

3,01

> Mangan

0,10 - 0,80

0,36

> Phospor

Max. 0,08

0,033

> Sulphur

Max. 0,05

0,013

0,025 - 0,090

0,045

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Magnesium

0,15

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,50 Kg

2 cav
20 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

18

Remark

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

2 Pcs Total Defect

18 Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

22.2.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Weight/pc

1,67

Kg

Weight/mould

9,67

Kg

Yield

55,9

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 65mm

Part No.
Material

FCD 45

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

20

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,90 0,05

3,95

> Silicone

2,30 0,05

2,28

> Mangan

Max. 0,40

0,38

> Phospor

Max. 0,03

0,029

> Sulphur

Max. 0,02

0,029

Standard (%)

Actual (%)

> Carbon

2,60 - 3,90

3,63

> Silicone

1,60 - 3,00

3,01

> Mangan

0,10 - 0,80

0,36

> Phospor

Max. 0,08

0,033

> Sulphur

Max. 0,05

0,013

0,025 - 0,090

0,045

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Magnesium

0,15

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,19 Kg

2 cav
11 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

20 Pcs Total Defect

0 Pcs

Standard

Actual

Remark :

B. Microstructure
Item

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

22.2.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Weight/pc

2,82

Kg

Weight/mould

9,67

Kg

Yield

55,9

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 65mm

Part No.
Material

FCD 45

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

20

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,90 0,05

3,95

> Silicone

2,30 0,05

2,34

> Mangan

Max. 0,40

0,37

> Phospor

Max. 0,03

0,032

> Sulphur

Max. 0,02

0,021

Standard (%)

Actual (%)

> Carbon

3,60 - 3,90

3,74

> Silicone

2,70 - 3,00

3,14

> Mangan

Max.0,04

0,39

> Phospor

Max. 0,08

0,03

> Sulphur

Max. 0,05

0,015

0,025 - 0,090

0,050

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Magnesium

0,155

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

1423

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Casting yang terdapat Srk pada mold ke : 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,13

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,19 Kg

2 cav
20 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

12

Remark

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

0 Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

24.02.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 50 mm

Weight/pc

2,19

Kg

Weight/mould

13,3

Kg

66

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

20

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,90 0,05

3,95

> Silicone

2,30 0,05

2,34

> Mangan

Max. 0,40

0,37

> Phospor

Max. 0,03

0,032

> Sulphur

Max. 0,02

0,021

Standard (%)

Actual (%)

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item
> Carbon

3,74

> Silicone

2,70 - 3,00

3,14

> Mangan

Max.0,04

0,39

> Phospor

Max. 0,08

0,03

> Sulphur

Max. 0,05

0,015

0,025 - 0,090

0,050

> Magnesium

0,155

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

1423

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,35 Kg

2 cav
20 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

8 Pcs Total Defect

0 Pcs

Standard

Actual

Remark :

B. Microstructure
Item

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

24.02.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Weight/pc

3,1

Kg

Weight/mould

13,3

Kg

66

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 80 mm

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

20

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,90 0,05

3,95

> Silicone

2,30 0,05

2,34

> Mangan

Max. 0,40

0,37

> Phospor

Max. 0,03

0,032

> Sulphur

Max. 0,02

0,021

Standard (%)

Actual (%)

> Carbon

3,60 - 3,90

3,74

> Silicone

2,70 - 3,00

3,14

> Mangan

Max.0,04

0,39

> Phospor

Max. 0,08

0,03

> Sulphur

Max. 0,05

0,015

0,025 - 0,090

0,050

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Magnesium

0,155

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

1423

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Casting yang terdapat Srk pada mold ke : 8, dan 10

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,86 Kg

2 cav
20 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

Remark

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

0 Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

24.02.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 50 mm

Weight/pc

2,19

Kg

Weight/mould

13,3

Kg

66

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

10

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

2,60 - 3,90

> Silicone

1,60 - 3,00

> Mangan

0,10 - 0,80

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

1423

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,35 Kg

2 cav
10 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

8 Pcs Total Defect

0 Pcs

Standard

Actual

Remark :

B. Microstructure
Item

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

26.02.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Weight/pc

3,1

Kg

Weight/mould

13,3

Kg

66

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 80 mm

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

10

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,60 - 3,90

> Silicone

2,70 - 3,00

> Mangan

Max.0,04

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,86 Kg

2 cav
10 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

0 Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

26.02.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Weight/pc

1,67

Kg

Weight/mould

9,67

Kg

Yield

55,9

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 65mm

Part No.
Material

FCD 45

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

10

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,60 - 3,90

> Silicone

2,70 - 3,00

> Mangan

Max.0,04

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1430

1423

Standard

Actual

Remark

D. Pouring Time
Item
> Per Mould
> Per Ladle
Notes :

10 - 13

Remark
Second/Mould
Minutes/Ladle

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,19 Kg

2 cav
10 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

0 Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

26.02.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. EBARA

Cavity/mould

Part Name

Casing Cover 10 FSJ-P

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FC-200

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,35 0,05

> Silicone

1,85 0,05

> Mangan

0,50 - 0,70

> Phospor

Max. 0,03

> Sulphur

Max. 0,03

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,30 - 3,70

> Silicone

1,40 - 2.60

> Mangan

0,40 - 0,80

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium
> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item
> Per Mould

Standard

Second/Mould

> Per Ladle


Notes :

Minutes/Ladle

TRIAL PROGRESS
Core Material

Kg

Core Weight/pc

Cav Core Box


Trial Qty

Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

10 Pcs

Remark :

B. Microstructure
Item

Standard

> Graphite type

A&B

Size

4-6

> Matrix : P/F


> Cementite
> Hardness

Actual

Remark

Pearlite Ferrite
Nodularyti 70 %
Max. 223

HB/HRB

Standard

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength

Elongation

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. Yanmar Diesel Indonesia

Cavity/mould

Part Name

Balancer Shaft L 48/40 A

Weight/pc

Kg

Part No.

114350 - 28012

Weight/mould

Kg

Material

FCD - 450

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

20

> Released Pattern

Moulds

OK / NG

> Hardness Mould


> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,80 - 3,90

> Silicone

2,15 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,03

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,60 - 3,90

> Silicone

2,70 - 3,00

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,03

> Magnesium

0,030 - 0,050

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1530 10

> Pouring

1410 10

1434

Standard

Actual

Remark

D. Pouring Time
Item
> Per Mould

7-9

Remark
Second/Mould

> Per Ladle


Notes :

Minutes/Ladle

Core Material

Core Weight/pc

Cav Core Box

Trial Qty

20 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

20 Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

> Graphite type

A&B

Size

4-6

> Matrix : P/F


> Cementite
> Hardness

Actual

Remark

Ferrite 70 %
Nodularyti 80 %
143 - 217

HB/HRB

Standard

Remark

C. Mechanical Properties
Item
Tensile Strength

46 Kgf/mm2

Yield Strength

30 Kgf/mm2

Elongation

10 %

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. Yanmar Diesel Indonesia

Cavity/mould

Pcs

Part Name

Weight/pc

Kg

Part No.

Weight/mould

Kg

Material

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

30

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
B. Casting Composition
Item
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
> Magnesium
> Cu
C. Temperature
Item
> Tapping

1530 10

> Pouring

1410 10

D. Pouring Time
Item
> Per Mould
> Per Ladle
Notes :

Standard
7-9

Second/Mould
Minutes/Ladle

TRIAL PROGRESS
Core Material

Kg

Cav Core Box

Trial Qty

30 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

Defect

Remark

> Si
> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

> Graphite type

A&B

Size

4-6

> Matrix : P/F


> Cementite
> Hardness

Actual

Remark

Ferrite 70 %
Nodularyti 80 %
143 - 217

HB/HRB

Standard

Remark

C. Mechanical Properties
Item
Tensile Strength

46 Kgf/mm2

Yield Strength

30 Kgf/mm2

Elongation

10 %

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. Yanmar Diesel Indonesia

Cavity/mould

Part Name

Balancer Wheight

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FC-200

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

10

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,50 - 3,60

> Silicone

1,50 - 1,60

> Mangan

0,50 - 0,60

> Phospor

Max. 0,05

> Sulphur

Max. 0,06

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,10 - 3,80

> Silicone

1,50 - 2,50

> Mangan

0,40 - 0,60

> Phospor

Max. 0,10

> Sulphur

Max. 0,10

> Magnesium
> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1510 10

> Pouring

1410 10

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item
> Per Mould
> Per Ladle
Notes :

Standard
5-7

Second/Mould
Minutes/Ladle

TRIAL PROGRESS
Core Material

Kg

Cav Core Box

Trial Qty

10 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

Defect

Remark

> Si
> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

8 Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

> Graphite type

A&B

Size

4-6

> Matrix : P/F


> Cementite
> Hardness

Actual

Remark

Ferrite 70 %
Nodularyti 80 %
187 - 241

HB/HRB

Standard

Remark

C. Mechanical Properties
Item
Tensile Strength

46 Kgf/mm2

Yield Strength

30 Kgf/mm2

Elongation

10 %

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

7.3.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. Yanmar Diesel Indonesia

Cavity/mould

Part Name

Cyl. Rear Cover

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FC-200

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

10

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
B. Casting Composition
Item
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
> Magnesium
> Cu
C. Temperature
Item
> Tapping

1510 10

> Pouring

1410 10

D. Pouring Time
Item
> Per Mould
> Per Ladle
Notes :

Standard
5-7

Second/Mould
Minutes/Ladle

TRIAL PROGRESS
Core Material

Kg

Cav Core Box

Trial Qty

10 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

Defect

Remark

> Si
> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

8 Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

> Graphite type

A&B

Size

4-6

> Matrix : P/F


> Cementite
> Hardness

Actual

Remark

Ferrite 70 %
Nodularyti 80 %
187 - 241

HB/HRB

Standard

Remark

C. Mechanical Properties
Item
Tensile Strength

46 Kgf/mm2

Yield Strength

30 Kgf/mm2

Elongation

10 %

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

9.3.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Weight/pc

3,1

Kg

Weight/mould

27,4

Kg

45,25

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 80 mm

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,60 - 3,90

> Silicone

2,70 - 3,00

> Mangan

Max.0,04

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,86 Kg

2 cav
2 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

0 Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

15.03.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Weight/pc

3,1

Kg

Weight/mould

13,3

Kg

66

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 80 mm

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

10

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,60 - 3,90

> Silicone

2,70 - 3,00

> Mangan

Max.0,04

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,86 Kg

2 cav
10 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

0 Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

15.03.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 50 mm

Weight/pc

2,19

Kg

Weight/mould

13,3

Kg

66

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

10

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

2,60 - 3,90

> Silicone

1,60 - 3,00

> Mangan

0,10 - 0,80

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

1423

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,35 Kg

2 cav
10 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

Defect

Remark

> CS
> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

8 Pcs Total Defect

0 Pcs

Standard

Actual

Remark :

B. Microstructure
Item

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

26.02.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 40 mm

Weight/pc

Part No.

Weight/mould

Material

FCD 45

Yield

1,67

Kg

26,36

Kg

50,6

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,90 0,05

3,93

> Silicone

2,30 0,05

2,60

> Mangan

Max. 0,40

0,40

> Phospor

Max. 0,03

0,022

> Sulphur

Max. 0,02

0,016

Standard (%)

Actual (%)

> Carbon

3,60 - 3,90

3,70

> Silicone

2,70 - 3,00

3,23

> Mangan

Max.0,04

0,40

> Phospor

Max. 0,08

0,027

> Sulphur

Max. 0,05

0,009

0,025 - 0,090

0,043

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Magnesium

0,131

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Pcs

TRIAL PROGRESS
Core Material

RCS
0,19 Kg

Core Weight/pc

Cav Core Box

2 cav

Trial Qty

3 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

9 Pcs

Remark :
2 pcs solid, core nya kurang 2 pcs

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

22.03.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 65 mm

Weight/pc

Part No.
Material

FCD 45

6
2,82

Kg

Weight/mould

33,92

Kg

Yield

49,88

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,90 0,05

3,93

> Silicone

2,30 0,05

2,60

> Mangan

Max. 0,40

0,40

> Phospor

Max. 0,03

0,022

> Sulphur

Max. 0,02

0,016

Standard (%)

Actual (%)

> Carbon

3,60 - 3,90

3,70

> Silicone

2,70 - 3,00

3,23

> Mangan

Max.0,04

0,40

> Phospor

Max. 0,08

0,027

> Sulphur

Max. 0,05

0,009

0,025 - 0,090

0,043

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Magnesium

0,131

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Pcs

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,50 Kg

2 cav
3 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

8 Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

22.03.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 50 mm

Weight/pc

Part No.

Weight/mould

Material

FCD 45

Yield

2,19

Kg

27,14

Kg

48,4

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,90 0,05

3,93

> Silicone

2,30 0,05

2,60

> Mangan

Max. 0,40

0,40

> Phospor

Max. 0,03

0,022

> Sulphur

Max. 0,02

0,016

Standard (%)

Actual (%)

> Carbon

3,60 - 3,90

3,70

> Silicone

2,70 - 3,00

3,23

> Mangan

Max.0,04

0,40

> Phospor

Max. 0,08

0,027

> Sulphur

Max. 0,05

0,009

0,025 - 0,090

0,043

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Magnesium

0,131

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Pcs

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,35 Kg

2 cav
3 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item
> Sli

Defect

Item

Defect

Remark

> CJ
> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

8 Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

24.03.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 40 mm

Weight/pc

Part No.

Weight/mould

Material

FCD 45

Yield

1,67

Kg

26,36

Kg

50,6

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

10

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,60 - 3,90

> Silicone

2,70 - 3,00

> Mangan

Max.0,04

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Pcs

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,19 Kg

2 cav
10 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item
> Sli

Defect
1

> SE

Item

Defect

Remark

18

> CJ
> BL

> Si

> SD

> BM
> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

58 Pcs Total Defect

21 Pcs

Standard

Actual

Remark :

B. Microstructure
Item

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

04.04.2016

6404

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 50 mm

Weight/pc

Part No.

Weight/mould

Material

FCD 45

Yield

2,19

Kg

27,14

Kg

48,4

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,60 - 3,90

> Silicone

2,70 - 3,00

> Mangan

Max.0,04

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Pcs

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,35 Kg

2 cav
4 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

Remark

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

06.04.2016

6406

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 65 mm

Weight/pc

Part No.
Material

FCD 45

6
2,82

Kg

Weight/mould

33,92

Kg

Yield

49,88

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,60 - 3,90

> Silicone

2,70 - 3,00

> Mangan

Max.0,04

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

1425

> Pouring

1400 ~ 1420

Remark

D. Pouring Time
Item

Standard

Actual

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Pcs

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,50 Kg

2 cav
3 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

Remark

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

13 Pcs Total Defect

5 Pcs

Standard

Actual

Remark :

B. Microstructure
Item

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

06.04.2016

6406

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Weight/pc

3,1

Kg

Weight/mould

27,4

Kg

45,25

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 80 mm

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

14

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,60 - 3,90

> Silicone

2,70 - 3,00

> Mangan

Max.0,04

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

1425

> Pouring

1400 ~ 1420

Remark

D. Pouring Time
Item

Standard

Actual

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,86 Kg

2 cav
14 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> SD

Defect

Remark

> BM
> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

56 Pcs Total Defect

11 Pcs

Standard

Actual

Remark :

B. Microstructure
Item

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

06.04.2016

6406

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 50 mm

Weight/pc

Part No.

Weight/mould

Material

FCD 45

Yield

2,19

Kg

27,14

Kg

48,4

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

20

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,60 - 3,90

> Silicone

2,70 - 3,00

> Mangan

Max.0,04

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

1413

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,35 Kg

2 cav
20 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

Remark

14

12

> BC

> Core

> Srk

10

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

82 Pcs Total Defect

38 Pcs

Standard

Actual

Remark :

B. Microstructure
Item

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

15.04.2016

6415

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 65 mm

Weight/pc

Part No.
Material

FCD 45

6
2,82

Kg

Weight/mould

33,92

Kg

Yield

49,88

1. PATTERN MAKING
Item

Specification

Remark

> Quantity Trial

Moulds

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,60 - 3,90

> Silicone

2,70 - 3,00

> Mangan

Max.0,04

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

1425

> Pouring

1400 ~ 1420

Remark

D. Pouring Time
Item

Standard

Actual

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Pcs

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,50 Kg

2 cav
Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

13 Pcs Total Defect

5 Pcs

Standard

Actual

Ferrite 70 %

80%

Nodularyti 70 %

90%

140 ~ 210 HB

198

HB/HRB

Standard

Actual

Remark

Remark :

B. Microstructure
Item

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite
> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

12.04.2016

6412

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Weight/pc

3,1

Kg

Weight/mould

27,4

Kg

45,25

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 80 mm

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,60 - 3,90

> Silicone

2,70 - 3,00

> Mangan

Max.0,04

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

1405

> Pouring

1400 ~ 1420

Remark

D. Pouring Time
Item

Standard

Actual

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,86 Kg

2 cav
9 Mold

3. INSPECTION
A. Visual Defect (%)
Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

1`

Remark

10

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

25 Pcs Total Defect

11 Pcs

Standard

Actual

Remark :

B. Microstructure
Item

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

No
1

PROGRESS

4. ANALISA MASALAH
Masalah
Shrinkage

Penyebab

Tindakan Perbaik
1. Modifikasi riser untuk bagia
bagian ekor dengan penamba
15mm pada semua riser

penambahan
tinggi 15mm

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

11.04.2016

6411

Pre Launch
Mass Production

ASALAH

Tindakan Perbaikan
Modifikasi riser untuk bagian leher dan
agian ekor dengan penambahan tinggi
5mm pada semua riser

penambahan
tinggi 15mm

penambahan
tinggi 15mm

Perubahan ukuran
ingate

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 65 mm

Weight/pc

Part No.
Material

FCD 45

6
2,82

Kg

Weight/mould

33,92

Kg

Yield

49,88

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,90 0,05

3,95

> Silicone

2,30 0,05

2,25

> Mangan

Max. 0,40

0,40

> Phospor

Max. 0,03

0,025

> Sulphur

Max. 0,02

0,028

Standard (%)

Actual (%)

> Carbon

3,60 - 3,90

3,74

> Silicone

2,70 - 3,00

3,05

> Mangan

Max.0,04

0,40

> Phospor

Max. 0,08

0,025

> Sulphur

Max. 0,05

0,009

0,025 - 0,090

0,039

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Magnesium

0,17

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

1434

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Pcs

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,50 Kg

2 cav
9 Mold

3. INSPECTION
A. Visual Defect (%)
Item

Defect

Item

Remark

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

49 Pcs Total Defect

4 Pcs

Remark :
Final Inspect : 49 pcs, OK : 38 pcs, NG : 11 pcs, 7 skg, 4 c/j

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

No
1

> Sli

> Crush

Defect

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab
1. Mesin molding tidak stabil
(melintir)

Tindakan Perbaik
1. Preventif maintenance

Cross joint

2. Riser tidak efektif (tidak


berfungsi)

2. Modifikasi riser : penamb


pada riser.
Perubahan pada ingate

Skg pada
bagian ekor

Skg pada
bagian leher
(after
Finishing)

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

28.04.2016

6428

Pre Launch

Mass Production

ASALAH
Tindakan Perbaikan
Preventif maintenance

Modifikasi riser : penambahan tinggi


ada riser.
Perubahan pada ingate

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. EBARA

Cavity/mould

Part Name

BEARING HOUSING 335

Weight/pc

Kg

Part No.

Weight/mould

Kg

Material

Yield

1. PATTERN MAKING
Item

Specification

Remark

> Quantity Trial

Moulds

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
B. Casting Composition
Item
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

cav
Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

28.04.2016

6428

Pre Launch

Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Weight/pc

3,1

Kg

Weight/mould

27,4

Kg

45,25

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 80 mm

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

10

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,90 0,05

> Silicone

2,30 0,05

> Mangan

Max. 0,40

> Phospor

Max. 0,03

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,60 - 3,90

> Silicone

2,70 - 3,00

> Mangan

Max.0,04

> Phospor

Max. 0,08

> Sulphur

Max. 0,05

> Magnesium

0,025 - 0,090

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

1432

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,86 Kg

2 cav
10 Mold

3. INSPECTION
A. Visual Defect (%)
Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> SD

Defect

Remark

> BM
> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

35 Pcs Total Defect

5 Pcs

Standard

Actual

80 %

90,6 %

Remark :

B. Microstructure
Item
> Graphite type

Remark

Size
> Matrix : P/F
> Cementite
> Hardness

Ferrite 70 %
Nodularyti 70 %
140 ~ 210 HB

163

HB/HRB

Standard

Actual

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

No
1

PROGRESS

4. ANALISA MASALAH
Masalah
Shrinkage

Penyebab
Riser tidak efektif

Tindakan Perbaik
1. Modifikasi riser untuk bagia
bagian ekor dengan penamba
15mm pada semua riser

penambahan ting
riser bagian
leher15mm

penambahan tin
riser bagian e
15mm

2. Trial casting

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

02.05.2016

6502

Pre Launch
Mass Production

ASALAH

Tindakan Perbaikan
Modifikasi riser untuk bagian leher dan
agian ekor dengan penambahan tinggi
5mm pada semua riser

PIC
Sujarwo

Waktu
02-4-2016

Faqih

02-4-2016

penambahan tinggi
riser bagian
leher15mm
penambahan tinggi
riser bagian ekor
15mm

Trial casting
Qty : 10 mold / 1 ladel

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. EBARA

Cavity/mould

Part Name

CONNECTOR 80LL

Weight/pc

6,56

Kg

Weight/mould

17,4

Kg

Part No.
Material

FC-200

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,55

> Silicone

1,53

> Mangan

0,51

> Phospor

0,034

> Sulphur

0,019

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

Actual (%)

> Carbon

3.00 ~ 3.70 %

3,49

> Silicone

1.40 ~ 2.60 %

1,84

> Mangan

0.40 ~ 0.80 %

0,64

> Phospor

Max. 0,08 %

0,034

> Sulphur

Max. 0,05 %

0,017

Standard ( C )

Actual ( C )

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

1429

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

FURAN
Kg

Core Weight/pc

Cav Core Box


Trial Qty

cav
5 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

19.5.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Weight/pc

7,9

Kg

Weight/mould

18,1

Kg

Customer

PT. EBARA

Cavity/mould

Part Name

CONNECTOR 100LL

Part No.
Material

FC-200

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,55

> Silicone

1,53

> Mangan

0,51

> Phospor

0,034

> Sulphur

0,019

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

Actual (%)

> Carbon

3.00 ~ 3.70 %

3,49

> Silicone

1.40 ~ 2.60 %

1,84

> Mangan

0.40 ~ 0.80 %

0,64

> Phospor

Max. 0,08 %

0,034

> Sulphur

Max. 0,05 %

0,017

Standard ( C )

Actual ( C )

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

1429

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

FURAN
0,86 Kg

Core Weight/pc

Cav Core Box


Trial Qty

cav
5 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

19.5.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA

TRIAL PROGRESS

OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

20

Customer

PT. GARUDA METAL UTAMA

Cavity/mould

Part Name

GEAR WHEEL 1692

Weight/pc

Part No.

24052

Weight/mould

10

Material

FCD-450

Yield

40

0,205

Pcs Core Material

RCS

Kg Core Weight/pc

0,334 Kg

Kg Cav

2 cav

Core Box

% Trial Qty

5 Mold

1. PATTERN MAKING
Item

3. INSPECTION

Specification

> Quantity Trial

Remark

A. Visual Defect (%)


Item

Moulds

Defect

> Released Pattern

OK / NG

> Sli

> Hardness Mould

80 ~ 89

> SE

> BL

> Sensor Cope

1 / 2 / 3 / 4

> Si

> BM

> Sensor Drag

1 / 2 / 3 / 4

> SD

> CS

> Diameter Sprue

28 / 30 / 32

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

2. M E L T I N G
A. Furnace Composition
Item

Remark

Nama Material

Item

Standard (%)

Actual (%)

> Carbon

3,85 - 3,90

3,90

> Crush

> Silicone

2,40 - 2,50

2,11

> SP

> Mangan

Max. 0,35

0,37

> RO

> Phospor

Max. 0,1

0,028

> Carbide

> Sulphur

Max. 0,02

0,015

Total GooD

B. Casting Composition
Item

No
1

Ma
Badlift

Slag Inclution

Hardness Up

> CJ
3

> Harness Up
Low
> Excentric

96 Pcs Total Defect

4 Pcs

Standard

Actual

Ferrite 70 %

70%

Remark :
Actual (%)

> Carbon

3,50 - 4,20

3,73

> Silicone

3,00 - 3,30

2,86

> Mangan

Max. 0,8

0,38

> Phospor

Max. 0,1

0,030

> Sulphur

Max. 0,02

0,007

Item

> Magnesium

0,02 - 0,06

0,044

> Graphite type

C. Temperature

Remark

Low

Standard (%)

> Cu

Defect

Remark

Nama Material

NG

B. Microstructure

Size
> Matrix : P/F

Remark

Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

> Cementite
> Hardness

1421

Item
Standard

Actual

Remark

Tensile Strength

> Per Mould

Second/Mould

Yield Strength

> Per Ladle

Minutes/Ladle

Elongation

Notes :

90%

180 ~ 220 HB

192 - 197

HB/HRB

Standard

Actual

Remark

C. Mechanical Properties

D. Pouring Time
Item

Nodularyti 75 %

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

ESS

TECHNICAL DEPT Engineering


Trial Date

13.5.2016

LOT : D5G

Pre Launch
Mass Production

4. ANALISA MASALAH
Masalah

Penyebab
1. Pattern kurang release

Tindakan Perbaikan
1. Penghalusan pattern pada bagian yang
terjadi badlift

Badlift pada cavity


nomor 15

on

Sli
p

TEST 1
192 - 197 HB

1. Terdapat komposisi yang tidak 1. Komposisi metal harus sesuai standar


masuk standar yaitu Silikon (Si),
Standar 3,00 - 3,30 aktualnya
2,86 (NG)

PIC

Waktu

TEST 2
234 - 247 HB

TEST 3
241 - 270 HB

JUDGEMENT

O
K

N
G

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA

TRIAL PROGRESS

OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

pcs Core Material

Customer

PT. EBARA

Cavity/mould

Part Name

BEARING HOUSING 225-1

Weight/pc

5,3

Kg Core Weight/pc

Weight/mould

17,7

Kg Cav

Yield

59,8

Part No.
Material

FC-150

Core Box

% Trial Qty

RCS
Kg

cav
15 Mold

1. PATTERN MAKING
Item

3. INSPECTION

Specification

> Quantity Trial

Remark

15

A. Visual Defect (%)


Item

Moulds

Defect

Item

OK / NG

> Sli

> CJ

> Hardness Mould

80 ~ 89

> SE

> BL

> Sensor Cope

1 / 2 / 3 / 4

> Si

> Sensor Drag

1 / 2 / 3 / 4

> SD

> CS

> Diameter Sprue

28 / 30 / 32

> BC

> Core

> Srk

> R Surface

> PH

> BH

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,75 0,05

4,09

> Crush

> Silicone

2,15 0,05

2,00

> SP

> Mangan

Max. 0,40

0,38

> RO

> Phospor

Max. 0,03

0,034

> Carbide

> Sulphur

Max. 0,03

0,023

Total GooD

B. Casting Composition
Item

Actual (%)

> Carbon

3,50 - 3,70

3,79

> Silicone

2,20 - 2,40

2,39

> Mangan

Max. 0,40

0,35

> Phospor

Max. 0,03

0,033

> Sulphur

Max. 0,03

0,021

> Cu
C. Temperature

Sand Inclution

Cross Joint

> BM

13

Badlift

> Dim Up
Low
> Harness Up
Low
> Excentric

2 Pcs Total Defect

28 Pcs

93 % NG

Standard

Actual

Remark

Remark :
Standard (%)

> Magnesium

> MD

Remark

Ma

> Released Pattern

Defect

No
1

Remark

Nama Material

B. Microstructure
Item
> Graphite type
Size
> Matrix : P/F

A
4-6

Ferrite 90 %

Item

Standard ( C )

> Tapping

1540 10

> Pouring

1440 10

Actual ( C )

Remark

> Cementite
> Hardness

1424

Item
Standard

Actual

Remark

175 - 179

HB/HRB

Standard

Actual

Remark

Tensile Strength

> Per Mould

Second/Mould

Yield Strength

> Per Ladle

Minutes/Ladle

Elongation

Notes :

174 ~ 233 HB

C. Mechanical Properties

D. Pouring Time
Item

Nodularyti 70 %

Mold Demage

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

ESS

TECHNICAL DEPT Engineering


Trial Date

18.5.2016

K5G

Pre Launch
Mass Production

4. ANALISA MASALAH
Masalah

Badlift di cavity 1
dan 2 area cope dan
drag

ion

Sand drop

Penyebab

Tindakan Perbaikan
Pengecekan permukaan pattern pada area
Pattern kurang release yang terjadi badlift

PIC

Waktu

ge

JUDGEMENT

O
K

N
G

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

Pcs

Cavity/mould

Part Name

FLY WHEEL NF60

Part No.
Material

FC-250

Weight/pc

Kg

Weight/mould

Kg

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

15

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,45 0,05

3,53

> Silicone

1,55 0,05

1,56

> Mangan

0,60 0,05

0,60

> Phospor

Max. 0,03

0,035

> Sulphur

Max. 0,03

0,023

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,10 - 3,80

3,54

> Silicone

1,50 - 2,50

1,75

> Mangan

0,40 - 0,80

0,60

> Phospor

Max. 0,10

0,035

> Sulphur

Max. 0,10

0,022

Standard ( C )

Actual ( C )

Remark

Actual

Remark

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

Kg

Core Weight/pc

Cav Core Box


Trial Qty

9 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

Remark

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

8 Pcs Total Defect

1 Pcs

Standard

Actual

Remark :

B. Microstructure
Item

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

18.5.2016

K5G

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

20

Pcs

Customer

PT. GARUDA METAL UTAMA

Cavity/mould

Part Name

GEAR WHEEL 1692

Weight/pc

Part No.

24052

Weight/mould

10

Kg

Material

FCD-450

Yield

40

0,205

1. PATTERN MAKING
Item

Specification

Remark

> Quantity Trial

Moulds

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,85 - 3,90

3,95

> Silicone

2,40 - 2,50

2,25

> Mangan

Max. 0,35

0,38

> Phospor

Max. 0,1

0,025

> Sulphur

Max. 0,02

0,022

Standard (%)

Actual (%)

> Carbon

3,50 - 4,20

3,73

> Silicone

3,00 - 3,30

3,13

> Mangan

Max. 0,8

0,40

> Phospor

Max. 0,1

0,025

> Sulphur

Max. 0,02

0,004

> Magnesium

0,02 - 0,06

0,035

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

0,11

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Kg

TRIAL PROGRESS
Core Material

RCS

Core Weight/pc

0,334 Kg

Cav Core Box

2 cav

Trial Qty

5 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 75 %
HB/HRB

180 ~ 220 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

TEST 1
192 - 197 HB

TEST 2
234 - 247 HB

TEST 3
241 - 270 HB

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

25.5.2015

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

18

Pcs

Customer

PT. GARUDA METAL UTAMA

Cavity/mould

Part Name

GEAR WHEEL 0500

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FCD-450

Yield

40

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,85 - 3,90

3,95

> Silicone

2,40 - 2,50

2,25

> Mangan

Max. 0,35

0,38

> Phospor

Max. 0,1

0,025

> Sulphur

Max. 0,02

0,022

Standard (%)

Actual (%)

> Carbon

3,50 - 4,20

3,73

> Silicone

3,00 - 3,30

3,13

> Mangan

Max. 0,8

0,40

> Phospor

Max. 0,1

0,025

> Sulphur

Max. 0,02

0,004

> Magnesium

0,02 - 0,06

0,035

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

0,11

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 cav
Mold

3. INSPECTION
A. Visual Defect (%)
Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 75 %
HB/HRB

180 ~ 220 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

No
1

PROGRESS

4. ANALISA MASALAH
Masalah
Dimensi masih over

Penyebab

Tindakan Perbaik

act.

std. 7,5 (act. 8,2)

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

25.5.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

20

Pcs

Customer

PT. GARUDA METAL UTAMA

Cavity/mould

Part Name

GEAR WHEEL 1692

Weight/pc

Part No.

24052

Weight/mould

10

Kg

Material

FCD-450

Yield

40

0,205

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

11

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,85 - 3,90

3,95

> Silicone

2,40 - 2,50

2,24

> Mangan

Max. 0,35

0,38

> Phospor

Max. 0,1

0,029

> Sulphur

Max. 0,02

0,020

Standard (%)

Actual (%)

> Carbon

3,50 - 4,20

3,74

> Silicone

3,00 - 3,30

3,37

> Mangan

Max. 0,8

0,39

> Phospor

Max. 0,1

0,021

> Sulphur

Max. 0,02

0,004

> Magnesium

0,02 - 0,06

0,048

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

NG

0,087

> Cu
C. Temperature
Item

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

1399

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Kg

TRIAL PROGRESS
Core Material

RCS

Core Weight/pc

0,334 Kg

Cav Core Box

2 cav

Trial Qty

11 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Remark

Standard

Actual

Ferrite 50 %

75%

Nodularyti 75 %

95%

180 ~ 220 HB

227 - 256

HB/HRB

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite
> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

TEST 1
192 - 197 HB

TEST 2
234 - 247 HB

TEST 3
241 - 270 HB

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

27.5.2015

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

18

Pcs

Customer

PT. GARUDA METAL UTAMA

Cavity/mould

Part Name

GEAR WHEEL 0500

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FCD-450

Yield

40

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,50 - 4,20

3,73%

> Silicone

3,00 - 3,30

3,39%

> Mangan

Max. 0,8

0,39%

> Phospor

Max. 0,1

0,03%

> Sulphur

Max. 0,02

0,008%

> Magnesium

0,02 - 0,06

0,049%

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Carbon

3,85 - 3,90

> Silicone

2,40 - 2,50

> Mangan

Max. 0,35

> Phospor

Max. 0,1

> Sulphur

Max. 0,02

B. Casting Composition
Item

> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item
> Per Mould

Standard

Second/Mould

> Per Ladle


Notes :

Minutes/Ladle

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

2 cav
5 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Remark

Standard

Actual

Ferrite 50 %

75%

Nodularyti 75 %

95%

190 ~ 220 HB

197 - 233

HB/HRB

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite
> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength

Masalah

Elongation

GRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

25.5.2016

Pre Launch
Mass Production

Tindakan Perbaikan

PIC

Waktu

Approved

ord Engineering

Prepared
Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA

TRIAL PROGRESS

OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. GARUDA METAL UTAMA

20

Cavity/mould

0,205

Part Name

GEAR WHEEL 1692

Weight/pc

Part No.

24052

Weight/mould

10

Material

FCD-450

Yield

40

Pcs Core Material

RCS

Kg Core Weight/pc

0,334 Kg

Kg Cav

2 cav

Core Box

% Trial Qty

5 Mold

1. PATTERN MAKING
Item

3. INSPECTION

Specification

> Quantity Trial

Remark

No

A. Visual Defect (%)


Item

Moulds

Defect

> Released Pattern

OK / NG

> Sli

> Hardness Mould

80 ~ 89

> SE

> Sensor Cope

1 / 2 / 3 / 4

> Si

> Sensor Drag

1 / 2 / 3 / 4

> SD

> CS

> Diameter Sprue

28 / 30 / 32

> BC

> Core

2. M E L T I N G
Remark

Nama Material

10

3,39

> Crush

> Silicone

2,40 - 2,50

2,35

> SP

> Mangan

Max. 0,35

0,34

> RO

> Phospor

Max. 0,1

0,029

> Carbide

> Sulphur

Max. 0,02

0,022

Total GooD

> Harness Up
Low
> Excentric

58 Pcs Total Defect

42 Pcs

42 %

Remark :
Mold Up = Cav 1 : 5, Cav 2 : 4, Cav 5 : 2, Cav 6 : 2, Cav 8 : 4, Cav 13 : 4, Cav 14 : 2, Cav 17 : 1, Cav
19 : 1

Actual (%)

> Carbon

3,50 - 4,20

3,75

> Silicone

3,00 - 3,30

3,29

> Mangan

Max. 0,8

0,35

> Phospor

Max. 0,1

0,030

> Sulphur

Max. 0,02

0,013

Item

> Magnesium

0,02 - 0,06

0,049

> Graphite type

C. Temperature

25

Low

Standard (%)

> Cu

> R Surface

> Dim Up

3,85 - 3,90

Nama Material

> MD

> Carbon

Remark

> BM

> BH

Actual (%)

Item

Remark

> CJ

> PH
Standard (%)

B. Casting Composition

Defect

> BL

> Srk

A. Furnace Composition
Item

Item

B. Microstructure
Standard

Actual

Ferrite 50 %

10%

Size
> Matrix : P/F

Remark

Ma

Item

Standard ( C )

Actual ( C )

Remark

> Cementite

> Tapping

1500 ~ 1520

> Hardness

> Pouring

1400 ~ 1420

C. Mechanical Properties

D. Pouring Time
Item

Item
Standard

Actual

Remark

Tensile Strength

> Per Mould

Second/Mould

Yield Strength

> Per Ladle

Minutes/Ladle

Elongation

Notes :

Nodularyti 75 %

95%

190 ~ 220 HB

192 - 209

HB/HRB

Standard

Actual

Remark

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

ESS

TECHNICAL DEPT Engineering


Trial Date

2.6.2016

26C

Pre Launch
Mass Production

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

PIC

Waktu

JUDGEMENT

O
K

N
G

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Customer

PT. EBARA

Cavity/mould

Part Name

CONNECTOR 80 LM

Weight/pc

Kg

Weight/mould

Kg

Part No.
Material

FC-200

Yield

1. PATTERN MAKING
Item

Specification

Remark

> Quantity Trial

Moulds

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
B. Casting Composition
Item
> Carbon

3.00 ~ 3.70 %

> Silicone

1.40 ~ 2.60 %

> Mangan

0.40 ~ 0.80 %

> Phospor

Max. 0,08 %

> Sulphur

Max. 0,05 %

> Magnesium
> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

FURAN
Kg

Core Weight/pc

Cav Core Box


Trial Qty

cav
Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 50 mm

Weight/pc

Part No.

Weight/mould

Material

FCD 45

Yield

Cav

2,19

Kg

27,14

Kg

48,4

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,90 0,05

3,94

> Silicone

2,30 0,05

2,14

> Mangan

Max. 0,40

0,38

> Phospor

Max. 0,03

0,025

> Sulphur

Max. 0,02

0,019

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,60 - 3,90

3,71

> Silicone

2,70 - 3,00

2,84

> Mangan

Max.0,04

0,39

> Phospor

Max. 0,08

0,025

> Sulphur

Max. 0,05

0,005

0,025 - 0,090

0,035

Standard ( C )

Actual ( C )

Remark

Actual

Remark

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item
> Per Mould

Standard

Second/Mould

> Per Ladle


Notes :

Minutes/Ladle

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,35 Kg

2 cav
9 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength

Standard

Actual

Remark

Masalah

Elongation

GRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

16.6.2016 LOT 6616

Pre Launch
Mass Production

Tindakan Perbaikan

PIC

Waktu

Approved

ord Engineering

Prepared
Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 65 mm

Weight/pc

Part No.
Material

FCD 45

6
2,82

Kg

Weight/mould

33,92

Kg

Yield

49,88

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,90 0,05

3,94

> Silicone

2,30 0,05

2,14

> Mangan

Max. 0,40

0,38

> Phospor

Max. 0,03

0,025

> Sulphur

Max. 0,02

0,019

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,60 - 3,90

3,71

> Silicone

2,70 - 3,00

2,84

> Mangan

Max.0,04

0,39

> Phospor

Max. 0,08

0,025

> Sulphur

Max. 0,05

0,005

0,025 - 0,090

0,035

Standard ( C )

Actual ( C )

Remark

Actual

Remark

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Pcs

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,50 Kg

2 cav
8 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

16.6.2016 LOT 6616

Pre Launch

Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Pcs

Weight/pc

3,1

Kg

Weight/mould

27,4

Kg

45,25

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 80 mm

Part No.
Material

FCD 45

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

30

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,90 0,05

3,94

> Silicone

2,30 0,05

2,14

> Mangan

Max. 0,40

0,38

> Phospor

Max. 0,03

0,025

> Sulphur

Max. 0,02

0,019

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,60 - 3,90

3,71

> Silicone

2,70 - 3,00

2,84

> Mangan

Max.0,04

0,39

> Phospor

Max. 0,08

0,025

> Sulphur

Max. 0,05

0,005

0,025 - 0,090

0,035

Standard ( C )

Actual ( C )

Remark

Actual

Remark

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material
Core Weight/pc

Cav Core Box


Trial Qty

RCS
0,86 Kg

2 cav
30 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item
> Graphite type

Standard

Actual

Remark

80 %

Size
> Matrix : P/F
> Cementite

Ferrite 70 %
Nodularyti 70 %
HB/HRB

140 ~ 210 HB

> Hardness
C. Mechanical Properties
Item

Standard

Tensile Strength
Yield Strength
Elongation

280

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

16.6.2016 LOT 6616

Pre Launch

Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA

TRIAL PROGRESS

OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. TOMOE VALVE BATAM

Cavity/mould

Part Name

BODY 304 YA - 40 mm

Weight/pc

Part No.

8
1,67
26,36

Weight/mould

Material

FCD 45

Yield

50,6

Pcs Core Material


Kg Core Weight/pc
Kg Cav

Core Box

% Trial Qty

RCS
0,19 Kg

2 cav
11 Mold

1. PATTERN MAKING
Item

3. INSPECTION

Specification

> Quantity Trial

Remark

11

Moulds

No

A. Visual Defect (%)


Item

dipuring 10 mold

Defect

Item

> Released Pattern

OK / NG

> Sli

> CJ

> Hardness Mould

80 ~ 89

> SE

> BL

> Sensor Cope

1 / 2 / 3 / 4

> Si

> BM

> Sensor Drag

1 / 2 / 3 / 4

> SD

> CS

> Diameter Sprue

28 / 30 / 32

> BC

2. M E L T I N G
A. Furnace Composition
Item

Remark

Nama Material

> R Surface

> PH

> BH

> MD

> Dim Up

Actual (%)

> Carbon

3,90 0,05

3,80

> Crush

> Silicone

2,30 0,05

2,10

> SP

> Mangan

Max. 0,40

0,35

> RO

> Phospor

Max. 0,03

0,022

> Carbide

> Sulphur

Max. 0,02

0,014

Total GooD

B. Casting Composition
Item

Low
> Harness Up
Low
> Excentric

Standard (%)

Actual (%)

Remark

3,60 - 3,90

3,69

> Silicone

2,70 - 3,00

2,89

OK

> Mangan

Max.0,04

0,37

OK

> Phospor

Max. 0,08

0,027

OK

> Sulphur

Max. 0,05

0,006

OK

Item

0,025 - 0,090

0,043

OK

> Graphite type

C. Temperature

1 Pcs

Standard

Actual

Ferrite 70 %

80%

1,25 %

Nama Material

> Carbon

> Cu

79 Pcs Total Defect

Remark :
OK

> Magnesium

Remark

> Core

> Srk

Standard (%)

Defect

B. Microstructure

Size
> Matrix : P/F

Remark

Ma

Item

Standard ( C )

Actual ( C )

Remark

> Cementite

> Tapping

1500 ~ 1520

1510

> Hardness

> Pouring

1400 ~ 1420

1421

C. Mechanical Properties

D. Pouring Time
Item

Item
Standard

Actual

Remark

Tensile Strength

> Per Mould

Second/Mould

Yield Strength

> Per Ladle

Minutes/Ladle

Elongation

Notes :

Nodularyti 70 %

90%

140 ~ 210 HB

198

HB/HRB

Standard

Actual

Remark

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

ESS

TECHNICAL DEPT Engineering


Trial Date

17.06.2016

LOT 6617

Pre Launch

Mass Production

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

PIC

Waktu

JUDGEMENT

O
K

N
G

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

20

Pcs

Customer

PT. GARUDA METAL UTAMA

Cavity/mould

Part Name

GEAR WHEEL 1692

Weight/pc

Part No.

24052

Weight/mould

10

Kg

Material

FCD-450

Yield

40

0,205

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,85 - 3,90

3,95

> Silicone

2,40 - 2,50

2,32

> Mangan

Max. 0,35

0,36

> Phospor

Max. 0,1

0,027

> Sulphur

Max. 0,02

0,023

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,50 - 4,20

3,75

> Silicone

3,00 - 3,30

3,21

> Mangan

Max. 0,8

0,38

> Phospor

Max. 0,1

0,029

> Sulphur

Max. 0,02

0,014

> Magnesium

0,02 - 0,06

0,045

Standard ( C )

Actual ( C )

Remark

Actual

Remark

B. Casting Composition
Item

> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Kg

TRIAL PROGRESS
Core Material

RCS

Core Weight/pc

0,334 Kg

Cav Core Box

2 cav

Trial Qty

8 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Remark

Standard

Actual

Ferrite 50 %

10%

Nodularyti 75 %

95%

190 ~ 220 HB

192 - 209

HB/HRB

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite
> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

20.6.2016

LOT

N6G

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA

TRIAL PROGRESS

OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. EBARA

Cavity/mould

Part Name

CONNECTOR 80LL

Weight/pc

Part No.

2
6,56
24

Weight/mould

Material

FC-200

Yield

54,6

Pcs Core Material

FURAN

Kg Core Weight/pc
Kg Cav

Core Box

% Trial Qty

0,71 Kg

cav
3 Mold

1. PATTERN MAKING
Item

3. INSPECTION

Specification

> Quantity Trial

Remark

No

A. Visual Defect (%)


Item

Moulds

Defect

Item

> Released Pattern

OK / NG

> Sli

> CJ

> Hardness Mould

80 ~ 89

> SE

> BL

> Sensor Cope

1 / 2 / 3 / 4

> Si

> BM

> Sensor Drag

1 / 2 / 3 / 4

> SD

> CS

> Diameter Sprue

28 / 30 / 32

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,35 0,05

3,80

> Crush

> Silicone

1,95 0,05

2,15

> SP

> Mangan

0,40 - 0,50

0,39

> RO

> Phospor

Max. 0,03

0,023

> Carbide

> Sulphur

Max. 0,03

0,024

Total GooD

B. Casting Composition
Item

Actual (%)

> Carbon

3.00 ~ 3.70 %

3,79

> Silicone

1.40 ~ 2.60 %

2,45

> Mangan

0.40 ~ 0.80 %

0,40

> Phospor

Max. 0,08 %

0,022

> Sulphur

Max. 0,05 %

0,018

> Cu
C. Temperature

Remark

Low
> Harness Up
Low
> Excentric

6 Pcs Total Defect

0 Pcs

Standard

Actual

4-6

Ferrite 70 %

2%

Remark :
Standard (%)

> Magnesium

Defect

Remark

Nama Material

B. Microstructure
Item
> Graphite type
Size
> Matrix : P/F

Remark

Ma

Item

Standard ( C )

Actual ( C )

Remark

> Cementite

> Tapping

1500 ~ 1520

1514

> Hardness

> Pouring

1400 10

1409

C. Mechanical Properties

D. Pouring Time

Nodularyti 70 %

Item

Item

Standard

Actual

Remark

Tensile Strength

> Per Mould

Second/Mould

Yield Strength

> Per Ladle

Minutes/Ladle

Elongation

Notes :

MOLDING
COPE

DRAG
CASTING

Max. 223 HB

159 - 166

HB/HRB

Standard

Actual

Remark

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

ESS

TECHNICAL DEPT Engineering


Trial Date

22.6.2016 LOT

P6G

Pre Launch
Mass Production

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

PIC

Waktu

JUDGEMENT

O
K

N
G

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA

TRIAL PROGRESS

OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. EBARA

Cavity/mould

Part Name

CONNECTOR 100LL

Weight/pc

Part No.
Material

FC-200

2
7,91

Weight/mould

26

Yield

60

Pcs Core Material

FURAN

Kg Core Weight/pc
Kg Cav

Core Box

% Trial Qty

0,86 Kg

cav
3 Mold

1. PATTERN MAKING
Item

3. INSPECTION

Specification

> Quantity Trial

Remark

No

A. Visual Defect (%)


Item

Moulds

Defect

Item

> Released Pattern

OK / NG

> Sli

> CJ

> Hardness Mould

80 ~ 89

> SE

> BL

> Sensor Cope

1 / 2 / 3 / 4

> Si

> BM

> Sensor Drag

1 / 2 / 3 / 4

> SD

> CS

> Diameter Sprue

28 / 30 / 32

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,35 0,05

3,80

> Crush

> Silicone

1,95 0,05

2,15

> SP

> Mangan

0,40 - 0,50

0,39

> RO

> Phospor

Max. 0,03

0,023

> Carbide

> Sulphur

Max. 0,03

0,024

Total GooD

B. Casting Composition
Item

Actual (%)

> Carbon

3.00 ~ 3.70 %

3,79

> Silicone

1.40 ~ 2.60 %

2,45

> Mangan

0.40 ~ 0.80 %

0,40

> Phospor

Max. 0,08 %

0,022

> Sulphur

Max. 0,05 %

0,018

> Cu
C. Temperature

Remark

Low
> Harness Up
Low
> Excentric

6 Pcs Total Defect

0 Pcs

Standard

Actual

> Graphite type

A-B

Size

4-6

Ferrite 70 %

2%

Remark :
Standard (%)

> Magnesium

Defect

Remark

Nama Material

B. Microstructure
Item

> Matrix : P/F

Remark

Ma

Item

Standard ( C )

Actual ( C )

Remark

> Cementite

> Tapping

1500 ~ 1520

1514

> Hardness

> Pouring

1400 10

1409

C. Mechanical Properties

D. Pouring Time

Item

Item

Standard

Actual

Remark

Tensile Strength

> Per Mould

Second/Mould

Yield Strength

> Per Ladle

Minutes/Ladle

Elongation

Notes :

CASTING
MOLD

COPE

DRAG

Nodularyti 70 %
Max. 223 HB

159 - 166

HB/HRB

Standard

Actual

Remark

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

ESS

TECHNICAL DEPT Engineering


Trial Date

22.6.2016 LOT

P6G

Pre Launch
Mass Production

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

PIC

Waktu

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

Prepared

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. EBARA

Cavity/mould

Part Name

CONNECTOR 80 LM

Weight/pc

Part No.
Material

FC-200

2
6,03

Kg

Weight/mould

20

Kg

Yield

60

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,35 0,05

3,80

> Silicone

1,95 0,05

2,15

> Mangan

0,40 - 0,50

0,39

> Phospor

Max. 0,03

0,023

> Sulphur

Max. 0,03

0,024

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

Actual (%)

> Carbon

3.00 ~ 3.70 %

3,79

> Silicone

1.40 ~ 2.60 %

2,45

> Mangan

0.40 ~ 0.80 %

0,40

> Phospor

Max. 0,08 %

0,022

> Sulphur

Max. 0,05 %

0,018

Standard ( C )

Actual ( C )

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 10

1409

Standard

Actual

Remark

D. Pouring Time
Item

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Pcs

MOLDING

COPE

DRAG

TRIAL PROGRESS
Core Material

FURAN
Kg

Core Weight/pc

Cav Core Box


Trial Qty

cav
3 Mold

3. INSPECTION
A. Visual Defect (%)
Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

> Graphite type

A-B

Size

4-6

Ferrite 70 %

2%

> Matrix : P/F


> Cementite
> Hardness

Remark

Nodularyti 70 %
Max. 223 HB

159 - 166

HB/HRB

Standard

Actual

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

No
1

CASTING

PROGRESS

4. ANALISA MASALAH
Masalah
bagian diameter joint nya tidak
sama pada di satu sisi

Penyebab

Diameter pada
parting line joint
nya sama

bagian diameter (yang


dibentuk oleh core) di
parting line nya tidak
sama

Tindakan Perbaik
Analisa pada dimensi core da
core box

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

22.6.2016 LOT

P6G

Pre Launch
Mass Production

ASALAH

Tindakan Perbaikan
nalisa pada dimensi core dan perbaikan
ore box

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

pcs

Customer

PT. EBARA

Cavity/mould

Part Name

BEARING HOUSING 245

Weight/pc

18,5

Kg

Weight/mould

24,5

Kg

Part No.
Material

FC-150

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,75 0,05

3,80

> Silicone

2,15 0,05

2,08

> Mangan

Max. 0,40

0,38

> Phospor

Max. 0,03

0,022

> Sulphur

Max. 0,03

0,018

Standard (%)

Actual (%)

> Carbon

3,50 - 3,70

3,70

> Silicone

2,20 - 2,40

2,40

> Mangan

Max. 0,40

0,38

> Phospor

Max. 0,03

0,023

> Sulphur

Max. 0,03

0,018

Standard ( C )

Actual ( C )

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Magnesium
> Cu
C. Temperature
Item
> Tapping

1520 - 1540

> Pouring

1400 10

1408

Standard

Actual

Remark

D. Pouring Time
Item
> Per Mould

Remark
Second/Mould

> Per Ladle

Minutes/Ladle

Notes :
Molding

COPE

DRAG

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box


Trial Qty

cav
2 Mold

3. INSPECTION
A. Visual Defect (%)
Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

> SP

Defect

Remark

> RO

Low
> Excentric

Total GooD

1 Pcs Total Defect

1 Pcs

50 % NG

Standard

Actual

Remark

4-6

Ferrite 90 %

97% P

Remark :

B. Microstructure
Item
> Graphite type
Size
> Matrix : P/F
> Cementite
> Hardness

Nodularyti 70 %
174 ~ 233 HB

153 - 162

HB/HRB

Standard

Actual

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength

Masalah

Low
> Harness Up

> Carbide

No
1

Crush

Elongation

Pemasangan Core

GRESS

4. ANALISA MASALAH
Masalah

Badlift dibagian
diameter

Penyebab

Penyebab diakibatkan
pattern keropos/bolong

Tindakan Perbaikan
Tambal pattern

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

22.6.2016

LOT

P5G

Pre Launch
Mass Production

Tindakan Perbaikan

PIC
Sujarwo

Waktu
28.6.2016

Approved

ord Engineering

Prepared
Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

20

Pcs

Customer

PT. GARUDA METAL UTAMA

Cavity/mould

Part Name

GEAR WHEEL 1692

Weight/pc

Part No.

24052

Weight/mould

10

Kg

Material

FCD-450

Yield

40

0,205

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3,50 - 4,20

3.43%

> Silicone

3,00 - 3,30

1.87%

> Mangan

Max. 0,8

0.54%

> Phospor

Max. 0,1

0.027%

> Sulphur

Max. 0,02

0.018%

> Magnesium

0,02 - 0,06

> Carbon

3,85 - 3,90

> Silicone

2,40 - 2,50

> Mangan

Max. 0,35

> Phospor

Max. 0,1

> Sulphur

Max. 0,02

B. Casting Composition
Item

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item
> Per Mould

Standard

Second/Mould

Kg

> Per Ladle


Notes :

Minutes/Ladle

TRIAL PROGRESS
Core Material

RCS

Core Weight/pc

0,334 Kg

Cav Core Box

2 cav

Trial Qty

8 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

> Graphite type

A-B

Size

4-6

> Matrix : P/F


> Cementite

Actual

Ferrite 50 %
Nodularyti 75 %
HB/HRB

190 ~ 220 HB

> Hardness

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength

Standard

Actual

Remark

Masalah

Elongation

GRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

28.6.2016

LOT

U6G

Pre Launch
Mass Production

Tindakan Perbaikan

PIC

Waktu

Approved

ord Engineering

Prepared
Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PT. GARUDA METAL UTAMA

Cavity/mould

Part Name

GEAR WHEEL 0500

Weight/pc

Part No.

18
0,260

FCD-450

Yield

40

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,85 - 3,90

> Silicone

2,40 - 2,50

> Mangan

Max. 0,35

> Phospor

Max. 0,1

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,50 - 4,20

> Silicone

3,00 - 3,30

> Mangan

Max. 0,8

> Phospor

Max. 0,1

> Sulphur

Max. 0,02

> Magnesium

0,02 - 0,06

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Kg
Kg

Weight/mould

Material

Pcs

TRIAL PROGRESS
Core Material

RCS

Core Weight/pc

0,443 Kg

Cav Core Box


Trial Qty

cav
3 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 50 %
Nodularyti 75 %
HB/HRB

190 ~ 220 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

28.6.2016

LOT

U6G

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

Pcs

Cavity/mould

Part Name

END NUT 55/85

Part No.
Material

FC-250

Weight/pc

Kg

Weight/mould

Kg

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
B. Casting Composition
Item
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material
Kg

Core Weight/pc

Cav Core Box


Trial Qty

cav
5 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

Actual

Remark

> Graphite type


Size
> Matrix : P/F
> Cementite

Ferrite 50 %
Nodularyti 75 %
HB/HRB

190 ~ 220 HB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

14.7.2016

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

20

Pcs

Customer

PT. GARUDA METAL UTAMA

Cavity/mould

Part Name

GEAR WHEEL 1692

Weight/pc

Part No.

24052

Weight/mould

10

Kg

Material

FCD-450

Yield

40

0,205

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,85 - 3,90

> Silicone

2,40 - 2,50

> Mangan

Max. 0,35

> Phospor

Max. 0,1

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,50 - 4,20

> Silicone

3,00 - 3,30

> Mangan

Max. 0,8

> Phospor

Max. 0,1

> Sulphur

Max. 0,02

> Magnesium

0,02 - 0,06

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Kg

TRIAL PROGRESS
Core Material

RCS

Core Weight/pc

0,334 Kg

Cav Core Box

2 cav

Trial Qty

5 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

> Graphite type

A-B

Size

4-6

> Matrix : P/F


> Cementite

Actual

Ferrite 50 %
Nodularyti 75 %
HB/HRB

190 ~ 227 HB

> Hardness

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

19.7.2016

LOT

L7G

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

STARTING HANDLE 55/155

Pcs

Cavity/mould

Part Name

Weight/pc

Kg

Part No.

Weight/mould

Kg

Material

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

> Carbon

3,85 - 3,90

> Silicone

2,40 - 2,50

> Mangan

Max. 0,35

> Phospor

Max. 0,1

> Sulphur

Max. 0,02

Actual (%)

Remark

Nama Material

Actual (%)

Remark

Nama Material

B. Casting Composition
Item

Standard (%)

> Carbon

3,50 - 4,20

> Silicone

3,00 - 3,30

> Mangan

Max. 0,8

> Phospor

Max. 0,1

> Sulphur

Max. 0,02

> Magnesium

0,02 - 0,06

> Cu
C. Temperature
Item

Standard ( C )

> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

Actual ( C )

Remark

Actual

Remark

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box

cav

Trial Qty

Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

> Graphite type

A-B

Size

4-6

> Matrix : P/F


> Cementite

Actual

Ferrite 50 %
Nodularyti 75 %
HB/HRB

190 ~ 227 HB

> Hardness

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

19.7.2016

LOT

L7G

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

STARTING HANDLE 55/155

Pcs

Cavity/mould

Part Name

Weight/pc

Kg

Part No.

Weight/mould

Kg

Material

FCD - 450

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

> Carbon

3.20 - 3.90 %

3.75%

> Silicone

2.30 - 3.30%

3.07%

> Mangan

MAX. 0,70 %

0.40%

> Phospor

Max. 0,03%

0.025%

> Sulphur

Max. 0,05 %

0.004%

> Magnesium

Max. 0,09%

0.047%

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Carbon

3,85 - 3,90

> Silicone

2,40 - 2,50

> Mangan

Max. 0,35

> Phospor

Max. 0,1

> Sulphur

Max. 0,02

B. Casting Composition
Item

> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item
> Per Mould

Standard

Second/Mould

> Per Ladle


Notes :

Minutes/Ladle

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box

cav

Trial Qty

Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

> Graphite type

A-B

Size

4-6

> Matrix : P/F


> Cementite

Actual

Ferrite 50 %
Nodularyti 75 %
HB/HRB

190 ~ 227 HB

> Hardness

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength

Standard

Actual

Remark

Masalah

Elongation

GRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaikan

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

19.7.2016

LOT

L7G

Pre Launch
Mass Production

Tindakan Perbaikan

PIC

Waktu

Approved

ord Engineering

Prepared
Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

Customer

PUMP CASING 125 JBC

Cavity/mould

Pcs

Part Name

Weight/pc

Kg

Part No.

Weight/mould

Kg

Material

Yield

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

Remark

Nama Material

Standard (%)

Actual (%)

Remark

Nama Material

Standard ( C )

Actual ( C )

Remark

Actual

Remark

> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
B. Casting Composition
Item
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
> Magnesium
> Cu
C. Temperature
Item
> Tapping

1500 ~ 1520

> Pouring

1400 ~ 1420

D. Pouring Time
Item

Standard

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

TRIAL PROGRESS
Core Material

RCS
Kg

Core Weight/pc

Cav Core Box

cav

Trial Qty

Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

> Graphite type

A-B

Size

4-6

> Matrix : P/F

Actual

Remark

Ferrite 50 %

> Cementite
HB/HRB

> Hardness
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

19.7.2016

LOT

L7G

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering

PT. BINA USAHA MANDIRI MIZUSAWA


OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627

20

Pcs

Customer

PT. GARUDA METAL UTAMA

Cavity/mould

Part Name

GEAR WHEEL 1692

Weight/pc

Part No.

24052

Weight/mould

10

Kg

Material

FCD-450

Yield

40

0,205

1. PATTERN MAKING
Item

Specification

> Quantity Trial

Remark

38

> Released Pattern

OK / NG

> Hardness Mould

80 ~ 89

Moulds

> Sensor Cope

1 / 2 / 3 / 4

> Sensor Drag

1 / 2 / 3 / 4

> Diameter Sprue

28 / 30 / 32

2. M E L T I N G
A. Furnace Composition
Item

Standard (%)

Actual (%)

> Carbon

3,85 - 3,90

3,90

> Silicone

2,40 - 2,50

2,20

> Mangan

Max. 0,35

0,36

> Phospor

Max. 0,1

0,029

> Sulphur

Max. 0,02

0,021

Standard (%)

Actual (%)

> Carbon

3,50 - 4,20

3,70

> Silicone

3,00 - 3,30

3,60

> Mangan

Max. 0,8

0,38

> Phospor

Max. 0,1

0,317

> Sulphur

Max. 0,02

0,007

> Magnesium

0,02 - 0,06

0,049

Standard ( C )

Actual ( C )

> Tapping

1500 ~ 1520

1409

> Pouring

1400 ~ 1420

Remark

Nama Material

Remark

Nama Material

B. Casting Composition
Item

> Cu
C. Temperature
Item

Remark

D. Pouring Time
Item

Standard

Actual

Remark

> Per Mould

Second/Mould

> Per Ladle

Minutes/Ladle

Notes :

Kg

TRIAL PROGRESS
Core Material

RCS

Core Weight/pc

0,334 Kg

Cav Core Box

2 cav

Trial Qty

38 Mold

3. INSPECTION
No

A. Visual Defect (%)


Item

Defect

Item

> Sli

> CJ

> SE

> BL

> Si

> BM

> SD

> CS

> BC

> Core

> Srk

> R Surface

> PH

> BH

> MD

> Dim Up

> Crush

Defect

Remark

Low

> SP

> Harness Up

> RO

Low

> Carbide

> Excentric

Total GooD

Pcs Total Defect

Pcs

Remark :

B. Microstructure
Item

Standard

> Graphite type

A-B

Size

4-6

> Matrix : P/F


> Cementite

Actual

Ferrite 50 %
Nodularyti 75 %
HB/HRB

190 ~ 227 HB

> Hardness

Remark

C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation

Standard

Actual

Remark

PROGRESS

4. ANALISA MASALAH
Masalah

Penyebab

Tindakan Perbaik

JUDGEMENT

O
K

N
G

Approved
Spv/Koord Engineering

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

TECHNICAL DEPT Engineering


Trial Date

19.7.2016

LOT

L7G

Pre Launch
Mass Production

ASALAH
Tindakan Perbaikan

PIC

Waktu

Approved

Prepared

Spv/Koord Engineering

Process Engineering