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* GRE Flange Making Process

* production order should be with unique mould number , Planning should get th

Sr Process Steps Frequency Responsible

1 Mould calibration 6 month QC dept

2 Mould maintenance 1 month or 1000 pieces Production


We have to decide the frequency

3 Mould making Daily morning , after every demould. moulders


4 Pre heating mould

5 Resin Preparation and Checking For Each flange Moulder

6 Fibre Glass For Each Flange Production

7 Moulding For Each Flange Moulder

8 Pre Curing For Each Flange Moulder

8 Flange Demoulding For Each Flange Moulder

9 Post Curing For each flange Moulder


10 squareness For each Flange Grinder person

11 Drilling For Each Flange Drilling Operator

12 OD grinding For each Flange Operator


13 Back Facing

14 QC Check For each Flange QC inspector

15 Business System
Planning + QC acceptance
umber , Planning should get the calibration and maintenance record of the moulds.

Identification Record Machine used

By numbers Should be by Numbers Manual Checking

By numbers Should be by Numbers manual


Some time Outside
Welding

By number NA Manual
oven - For Heating mould at 40 degree

By Batch number Production Order Mixing manual


Mixing Tank
Heating jacket
Weighing Balance
Refractometer
Mixture

By Batch number Production Order Rewinding motor


Weighing Balance e

By Unique identity Production Order Moulding machine


Oven pre Curing

By Number Production Order Oven

By Number Production Order manual


we can Shift it to Machined One

By Number Production Order Post Curing Oven


Need Oven Element
By Number Production Order Grinder 230 mm
Cutting table
Tube Level

By number Production Order Radial Drill machine - 2 no's


CNC drill machine

By Number Production Order OD grinding small With Grinder 230 mm

Lathe Machine 12" and 24 " size


bench grinder

By Unique Identity By Unique Identity numbeThickness gauge


DSC machine - TG value Check

Scanners
PC's
Internet
Tool Used

Vernier
Micrometre

Spanners Set
Allen Keys

Spanners
Temperature Gun

Bucket

Hammer
Spanners
Screw Driver
Bottom Sheet

Trolley
Drill template Different Sizes
Spanners
Thread Rods
Nuts

Spanner
Consumable Used

Welding rods

Mould releasing Agent


high temp gloves LG 806 En338 size 10

Bucket 2 ltr
Stirrer
Resin
hardener

WR 360 X 100
WR 360 X 50
WR 360 X 1300

Label paper
Paint Roller - 150
Paint Roller - 120 mm
MS Roller Día 20 x 75 mm
Rubber Gloves Size
Plastic Gloves Micron and Size
Mask V 20
Goggles
Safety Shoes
Coverall
brush Animal hair
High Temp gloves

High Temp grease


High Temp gloves
Diamond cut-off Wheel 125 mm - 1.8 mm thickness with serration and internal diamond coating.
Diamond cut-off Wheel 180 mm - 1.8 mm thickness with serration and internal diamond coating.

Core Bits different sizes


Wire Brush
Brush to clean
bearing
oil seal

Día 80 X 80 mm drum as per our drawing


With 30-40 grit diamond

Lathe turning Tools - Lath Tool ISO 06LH 2020 K20 Miranda
Insert CARBIDE INSERTS CNMG 120408 TT 1500
Tool for insert PCLNL 3225 M12
Nitrogen Gas
maintenance Items

Nuts
Washers

Preventive maintenance

Gear Box
Heating Element

Winding Shaft

Preventive maintenance
Bobbin roller
Chain

Temp Gun
V belt

Motor
V belt
Bearing
All spares as per list

Water Nipple
PU tube
Drill Adopter
Sleeve
GRE Flange Making process
Mould making

Pre heating mould

Resin Preparation and Checking

Fibre Glass preparation

Moulding process by Rotating machne

Pre Curing - Oven

Flange Demoulding - manual

Post Curing - Oven

squareness by hand grinder

Drilling ( By radial Drill )

OD grinding ( By OD grinder ) CNC machine

Back Facing ( On back Facing machine)

QC Check
* Criticality Analysis - GRE production machines.
Criticality Guidelines
1- Least Critical, work is not going to stop b
2- We have more than one machines or wa
3- Market Standard Available machine, can
4- Market Standard but has lead time more
5- Most Critical. Work will stop and producti
* Limitation - This figures gives manufacturing process view. It docent cover the external factors like environment laws, lega

Sr No Machine Purpose Criticality


1 Welding Machine For mould rectification 3
2 oven - For Heating mould at 40 degree mould heating 2
3 Mixing Tank 4
4 Heating jacket 5
5 Refractometer 2
6 Rewinding motor 3
7 Weighing balance standard 5 kg 1
8 Moulding machine 2
9 Oven pre Curing 2
10 De Moulding machine 2

11 Post Curing Oven 4


12 Grinder 230 mm 2
13 Radial Drill machine - 2 no's 4
14 CNC drill machine ?
15 OD grinding small With Grinder 230 mm 2
16 Lathe Machine 12" and 24 " size 2
17 DSC machine 4
18 Weighing Balance precise on e250 gram 1
18 Scanners 1
19 PC's 1
20 Internet 5
21 Fork Lift 4
22 DG set 3
23 Resin Mixture grinder NEW
24 IPD tank NEW
25 Resin Table and Bath NEW
Critical, work is not going to stop because of this machine
ave more than one machines or ways, so we can use them alternately and will carry the work without affecting output (20% is acceptab
et Standard Available machine, can be arranged in 1 day or can be outsourced
et Standard but has lead time more than 2 days , We have multiple machines but breakdown of 1 machine result in output rates affecti
Critical. Work will stop and production get affected more than a 75%.
l factors like environment laws, legal law changes, safety environment etc.

Backup Plan
We have near by Company Varadraj for urgent things.
We have many ovens including QC dept air heating oven.
We have one more mixing motor and gear box which we can use as alternative, but needed 3 hrs downtime.
We have to Procure one more to have the alternative with us.
We have pot life standard table method and TG check as a alternatives.
We can Do it manually in case of any failures
we have 4 in total weighing balance.
We have alternative available that is other machines.
We have alternatives available with us.
We have alternatives available with us.

We can make some fixtures like drawer for pre curing oven and convert it to Postcuring.
We have alternatives available with us.
We are facing output issue with one machine so we have asked CNC drill machine.
Coming Soon…
We have options available with grinders.
We have 2 options with us.
We can outsource this activity to our group company or outside here in Pune.
we have one in stock and we can use other method for sample weighing.
We have 4 machines and alternative from PC is available option.
We have many alternatives.
We have 2 ISP Tata and Sify.
We can rent a forklift but there is delay of 3 hrs.
We have 2 X 180 Kva which we can use alternately.
for proper mixing of resin and hardner.
For safe use of IPD.
For safe and effective use.
utput (20% is acceptable) rate of production.

in output rates affecting by more than 50%.

Cost

88750
120000

25000

USD 62700

100000
discuss it with
* Tools and Consumable criticality mapping -

Sr no
1
2
3
4
5
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10
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63
* Tools and Consumable criticality mapping -

Particulars
Vernier
Micrometre
Welding rods
Spanners Sets
Temperature Gun
Nuts of various Size - Check Sizes or need sample
Washers Check Sizes
Mould releasing Agent F57 LNC
high temp gloves LG 806 En338 size 10
Bucket 2 ltr
Stirrer manual
Gear Box - For Resin Mixing tank
Heating Element for Heating jacket
Epoxy Resin
Hardener
WR 360 X 100
WR 360 X 50
WR 360 X 1300
Winding Shaft
Label paper
Chain
Bobbin Roller
3 jaw Chuck 250 mm
Chuck Key Long
Paint Roller - 150
Paint Roller - 120 mm
MS Roller Dia 20 x 75 mm
Rubber Gloves Size
Plastic Gloves Micron and Size
Mask V 20
Mask 414
Goggles
Safety Shoes different Sizes
Coverall Different Sizes
brush Animal hair
Hammer Soft hammer 50 mm
Hemmer black
Hammer soft 75 mm
V belt different sizes - V Belt B880 B 33 and ,B 983LLP/B 37
Post Curing Oven Motor 3 phase, 3 Hp, foot mounted, 1420 rpm , H or F class winding ( IEC 60034-1)
Screw Driver Set
Bottom Sheet for Oven
Trolley for Post Curing Oven
High Temp grease for post curing Oven. Temp up to 200 degree cel.
Diamond cut-off Wheel 125 mm - 1.8 mm thickness with serration and internal diamond coating
Diamond cut-off Wheel 180 mm - 1.8 mm thickness with serration and internal diamond coating
Drill template Different Sizes
Core Bits different sizes
T Thread Rods
Nuts
Wire Brush
Brush to clean
Drill Adopter
bearing 6005 2Z with Oil seal
oil seal U Seal 25-38-7
Diamond Día 80 X 80 mm drum as per our drawing With 30-40 grit diamond
Spanner
Lathe turning Tools - Lath Tool ISO 06LH 2020 K20 Miranda
Insert CARBIDE INSERTS CNMG 120408 TT 1500
Tool for insert PCLNL 3225 M12
Nitrogen Gas
PU Tube
Sleeve for drill machine
Criticality Guidelines
1- Least Critical, work is not going to affect because of this.
2- We have more than one tools or ways, so we can use them alternately and will carry the work
3- Market Standard Available tools, can be arranged in 1 day.
4- Market Standard but has lead time more than 1 Week.
5- Work will stop and production get affected more than a 75%.

Criticality Store Stock Uom


2
2
2
2
4 1 Nos
2
2
3 27.9 kg
2 5 Nos
1 7 Nos
1
4 1 Nos
5 0
4 4400 Kg
5 540 Kg
5 8400 Kg
5 3276 Kg
5 5500 Kg
4 0
?
2
4
3
2
3 70 Nos
3 90 Nos
4
3 22 Nos
3 2750 Nos
2 400
2 265
2 18
2 14
4 70 nos
4 1480 nos
4 2 nos
3 1
3
3
4
1
2
3
3
4 2 nos
4 2 nos
4
4
2
2
2
2
4 2 nos
3
3
4
1
4
4
4
3
1
1
ly and will carry the work without affecting output (20% is acceptable) rate of production.
*Mould Numbers