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POLYRUB COOPER STANDARD FTS PVT LTD.

Process Flow chart
Part Name :- HOSE-RAD,INLET PFD No.: PFC/Reno/01 Prepared by: Biswajit

Part No. :- 215016VB0A PFD Date: 06.05.2019 Approved by: Goutam Das

Key Date:- 07.06.19

Core Team :- YP,PJ,VS,PA,MB,CJ,SRB, RK,YK,AC,PK,BDM Revision No.: 0
Revision Date: - --
Operation No.
Incoming Source of Variation Process Flow Diagram Product characteristics Process characteristics
Brief Description
10 a)   Poor planning at supplier End a) Qty. As per Purchase order a) Instruction to store (Storage and
handling)
Receipt of raw Material b)   Contingency plan not available at 10 b) Weighing Scale 
supplier End
c)   Verification not done at the time of
dispatch from supplier End
20 a) Manufacturing process not followed a) Bought out material should meet a) Skill Inspector
at supplier end required specification
Receiving Inspection b) Inspector not qualified for Incoming b) Raw material should meet b) As per Quality Plan
inspection specific requirement
20
c) Self Life
d) Supplier TC

20A a)  Wrong material identification a) Proper labeling a) Skill Operator

Labeling b)  Wrong Expiration date b) Label printing machine
20 A

30 a)   Awareness not given to operator a) FIFO system a) Tag on raw material with visual
identification
b)   Wrong material issued b) Self Life b) Special storage conditions to be
Storage of Material
available with store.
c)   Special storage conditions not 30
followed

40A a) Load cell is not calibrated a) Carbon Weight a) Air pressure

Carbon weighing b) Self Life b) Calibration of Load cell
40A
40B a) Load cell is not calibrated a) Filler Weight a) Air pressure
b) Self life b) Calibration of Load cell
Filler weighing c) Labeling with bar code
40 B

40C a) Load cell is not calibrated a) Chemical Weight a) Air pressure

Chemical Weighing b) Self life b) Calibration of Load cell
40C c) Labeling with bar code

40 D a) Load cell is not calibrated a) Polymer Weight a) Air pressure

Polymer Weighing b) Self life b) Calibration of Load cell
40D c) Labeling with bar code

40E a) Load cell is not calibrated a) Oil Weight a) Air pressure

Oil Weighing b) Calibration of Load cell
c) Labeling with bar code
40E

40F a) Less time given in kneader a) Ingrediant Mix a) Time

Kneader b) More time given in kneader b) No Scrorch in rubber b) Temperature
c) Timer calibration not done c) Calibrated Equipment
d) Temperature controller failure 40F d) Labeling with lot no.
e) Operator miss the ingredient
feeding
40G a) Temperature controller not a) Speed
calibrated
Twin Tapper b) M Temperrature controller failure b) Calibrated equipment
40G
c) Operrator not aware about the c) Temperature
speed requirement
d) Skilled operator
40 H a) Strip sticking to each other a) straight Strip a) Free from contamination
Gear Pump b) Foreigen partical not visualised b) Mesh size
to operator 40H c) Speed of gear pump
c) External contamination
40I a)Non matching of compound a)As per Standard a)Calibration of testing equipement
Lab Testing characteristics with std. b)Skilled operator
b)Wrong testing method 40I
c)Lack of operator awarenerss
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Operation No.
Incoming Source of Variation
Brief Description
45 a) FIFO not maintained
Storage of compound b) AC contrroller not calibrated
c) External contamination
50A a) More friction betn rubber & screw
Extrusion ( Inner layer ) b) Less water circulation
c) Temperature controller failure
d) Heater failure
e) Sensor failure
f) More pr. Of rubber
g) More flow of rubber
h) Les flow of rubber
i) Carbon brush failure
j) Wrong selection of screw trurns
k) Wrong selection of die & Pin
l) More air pressure
m) No. air pressure
n) More RPM
o) Less RPM
50B a) Incorrect stich size
Knitting b) Incorrect bobbin selectrion
c) Knitting head distance incorrect
d) Niddle break
e) Awareness not given to operator
Process Flow Diagram Product characteristics Process characteristics
a) FIFO a) Maturation Temperature
b) Maturation time
c) Calibration of temp. indicator
45
a) Outer diameter a) Screw Temperature
b) Inner diameter b) Cylinder temperature - 1
c) Tube Wall thickness c) Cylinder temperature - 2
e) Hose appearance d) Head temperature
e) Matrix temperature
f) Material temperature
g) Motor current
50A
h) Screw turns
i) Free from contamination
a) Stich size as per specification a) Skil operator
b) Correct yarn b) Feeder
c) Pitch as per specification c) Contamination on yarn
50B
d) No. of bobbin as per
specification

50C a) Temperature controller failure a) Moisture free yarn a) Temperature

Hot Air Gun b) Calibration of temperature
50C controller

50D a) More friction betn rubber & screw a) Outer Diameter as per Spec. a) Screw Temperature
Extrusion b) Less water circulation b) Wall thickness as per Spec. b) Cylinder temperature - 1
( Outer Layer ) c) Temperature controller failure c) Correct bonding c) Cylinder temperature - 2
d) Heater failure d) No tool mark on green hose d) Head temperature
e) Sensor failure 50D e) Layser printing on Green hose e) Material temperature
f) More pressure of rubber f) Vacuum pressure
g) Wrrong selection of Die & Cone g) Conveyor speed
h) Vacuum die ID is more than req
i) Pre heating of yarn nor done
j) Less vacuum pressure
k) Die damages
50E a) Temperature controller failure a) Hose cooling a) Temperature
Chiller b) Speed of Belt
50E

50F a) Wrong setting in panel board a) Length a) Frree from contamination

Green hose cutting b) Green hose cutting blade 50F
wareout

50G a) Sharp edge on wooden pallet a) Maturation time a) Free from contamination
Green hose storage b) FIFO not followed
50G

50H a)Non matching of product. a)As per Standard a)Calibration of testing equipement
Lab Testing characteristics with std. b)Skilled operator
50H
b)Wrong testing method
c)Lack of operator awarenerss

60A a) Lack of operator awarenerss a) Pre heating a) Skill Operator

Hose insertion & loading b) Mandrel Mix up b) No yarn coming out b) Ok releasing agent application
60A
on mandrel c) Thread is coming out from Brush
brush c) Releasing agent application
d) Verifrication of mandrel

60B a) Improper working og Inlet a) No inner line mark on hose a) Time

Vulcunization & outlet valve b) Inner diameter b) Temperature
b) Improper working of timer c) Hose length c) Stem pressure
c) Dent mark on mandrel
60B
d) Contamination on mandrel
e) Less maturation time for green
Hose
f) Ply in mandrrel mounting rack
g) Cap shifted below the making level
level
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Operation No.
Incoming Source of Variation Process Flow Diagram Product characteristics Process characteristics
Brief Description
60C a) Mandrel touches to each other a) Hose should not damages a) Part Mix up
Hose removal from in vulcunization 60C
mandrel b) Operator not aware about the
hose removal process
70 a) Improper setting of time a) Clean hose a) Time
Washing b) Improper working of inlet & b) Temperature
Outlet valve c) Clean water
c) Water changing frequency not d) Free from contaminatrion
define 70 e) Water PH
d) Machine running in manual
mode
e) Uncleaned bins use for storage
f) Open bins

90 a) Improper lighting a) Parts as per drawing/Fixture a) Proper lighting

90
Verification b) Wrong inspection tools b) Calibrated testing and measuring
c) Wrong specification used instrument
c) Use of inspection standard
d) Instrument not calibrated d) Eye sight checking
e) Eye sight
100 a) Vibration in printing base a) Pad printing distance from a) Pressure
Pad printing b) Vibration in priting fixture 100 end of the hose b) Presence of pad printing
c) Wrong fixture setting b) Pad printing logo As per drg
d) Wrong plate used for priting c) Correct pad printing position
e) Wrong pad priting ink ratio
110B a) Hose marking not done properly a) Length a) Mesh protector insertion tool
Assembly of Mesh b) Glue bottol jam b) Presence of mesh protector
Protector with hose c) Operator miss the sequence of 110B c) Posirtion
operation d) Glue quantity

110 F a) T - assembly not covered in fixture a) T connector Orientation a) Calibration of profile gauge
Assembly of b) T connector Position
110F
T - connector with hose b) Operator not followed the
sequence of operation

120 a) Change in parameter setting a) No single bubble allowed a) Time

Leakage testing b) Fluctuation in pneumatic line b) Pressure
120
c) Insidde damages in hose c) Free from contamination
d) Unclean bins
e) Unclean basins

130
Screen Printing a) Wrong Part Number
a) Wrong Setting 130 a) Printing Verification

150 a) Improper lighting a) Parts as per drawing/Fixture a) Proper lighting

Final Inspection b) Wrong inspection tools b) Calibrated testing and measuring
instrument
c) Wrong specification used c) Use of inspection standard
150
d) Instrument not calibrated d) Eye sight checking
e) Eye sight
160 a) Packaging spec. not follow a) Qty as per Standard a) Skill operator
Packaging & Labeling b) requirement not clear b) Correct part packaging b) Correct ASN punching
c) Manually bar code taken c) Correct labeling c) Packaging box should be dry
160 d) Bar code label as per Std d) Pallets with fumigation

170 a) Wrong address putted on invoice a) Part should not damages during a) Work instruction/customer wise
Shipping copy
b) Improper planning transportation
b) Shipment on time packing instructions.
b)  Document Audit

c) Correct shipping address c)  Calibrated balance used

& location d)  Different colored bins for
conforming, non-conforming.
170 e) Computerized schedule tracking
f)  Document Audit
g) Material handling equipment to be
used
Change Summary
Sr. No. Date Rev. No. Reason for Change Remark
1 07.06.2019 0 Initial Release