Doc No: WI/OP5/4

WORK INSTRUCTION
Page No: 1 of 2
Issue No.:
GEAR AND SHAFT
Date :

09-01-00005 SC325 CENTER GEAR

Item codes & Description
09-01-01022 SC325 CENTER SPLINE SHAFT

Purpose / Objective This process describes by gear & shaft for spindle rotation

Scope This component converts the gear and shaft.

Responsibility Production in charge/ Operator/quality

All gear manufacturing Machines , material cutting & machining oils,

Equipment, Instrument,
facilities, Accessories,
consumable, required / used.
Factors/parameters allowable
value / criteria.
Recording details
tools of (hob, cutters, grinding wheels, drill & taps, Allen keys, spanners
tool keys, nuts, jaws with chuck ,brushes ,files ) instruments as
(micrometer, vernier, dial indicator & stand ,height gauge, tape, surface
table),( open air ,light ,free places) etc…
Component drawing, Process Card xxxxx
Production Job card, inspection report, bin card

Safety Precautions, Additional

Hand gloves, Mask, shoes ,eye glass, helmet etc.
information.

Step by step procedures - How the work has to be carried out?

Select the raw material as per drawing referents. Before select the raw material refers the item code
1
and color coding for Table 1.1.

2 Machine on and ensure the oil level, coolant level, air pressure and lubrication.

3 Select the tools and measuring instruments as per drawing. With Reference process cord xxxxxx.

Ensure the raw Material as per drawing after loading the machine. Material lording purpose used for
4
crane.
Set the cutting length to the machine as per drawing dimension. After clam the material and set the
5 machine parameters (rpm and federate) after run the machine.

6 Clamping and cutting process follow the below step 6.1 (Fig-1).

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WORK INSTRUCTION
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Issue No.:
GEAR AND SHAFT
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Raw material clamping and cutting method

6.1

Fig-1

Cutting process will be completed. Fist component check and verify the QA inspector as per drawing
7 dimension. And operator also checking the fist component dimension as per drawing then continuously
runs the machine as per production plane.

8 Collect the cutting material on the pine and put the material identification card.

Total cutting material issue the bin card and reties the total stock. After remove the material on the
9
machine then put the location.

Ensure the cutting length and pine card. After move to next process for turning machine. Moving
10
process used by Crane, Forklift, traly.

11 Machine on and ensure the oil level, coolant level, air pressure and lubrication.

First operation wise select the machine jaws, tools and measuring instruments as per drawing. With
12
Reference process cord xxxxxx

Clamp the jaws in the chuck after clamping the raw material. First operation clamping method follow the
13
below step 14.1 (Fig-2).
Step by step create the programs and take the offset after run the machine step by step sequences.
14
First operation sequences follow the below step 15.

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Issue No.:
GEAR AND SHAFT
Date :

14.1

Fig-2

Number of sequences in first operation as per drawing:

♦ Drilling
♦ Outer rough turning
15 ♦ Inner rough turning
♦ Outer finishing
♦ Inner finishing
♦ Canel (v grooving)
16 First component finish and check as per drawing dimensions. After informer the QA inspector.
QA inspection it will be ok. Then collect the first inspection report after continues the production as per
17
production planning. Operator every five component check and writing the inspection report.
Finally first operation finished component inspection by as per drawing tolerance. Verify the QA
18
inspector and send to next operation.
Second operation wise select the machine, jaws, tools and measuring instruments as per drawing.
19
With Reference process cord xxxxxx
Clamp the jaws in the chuck after clamping the raw material. Second operation clamping method follow
20
the below step 21.1 (Fig-3).
Step by step create the programs and take the offset after run the machine step by step sequences.
21
Second operation sequences follow the below step 23.
21.1

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Issue No.:
GEAR AND SHAFT
Date :

Fig-3

Number of sequences in second operation as per drawing:

♦ Outer rough turning

♦ Outer finishing
23

♦ Vertical milling

♦ Horizontal milling

24 First component finish and check as per drawing dimensions. After informer the QA inspector.

QA inspection it will be ok. Then collect the first inspection report after continues the production as per
25
production planning. Operator every five component check and writing the inspection report.

Finally operation finished component inspection by as per drawing tolerance. And check the visual
26
inspection.

27 Finish component show on the below step 27.10 (Fig -4, Fig-5).

27.1

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Fig-4 Fig-5

27 Finish component move to final inspection for QA section. Inspection is ok put approval pine card.

28 Finally ok components send to the store.

29 Clean the machine and prefer the next component plane.

Table: 1.1

S. Raw material diameter Raw material length

Material grade Color code
No. (mm) (mm)

1 As per drawing As per grade As per drawing As per drawing

Step by step procedures – GEAR HOBING (TOOTH CUTTING)

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Issue No.:
GEAR AND SHAFT
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Receipt to issue the gear blank as per drawing referents.

1

2 Machine on and ensure the spin oil level, cutting oil level, air pressure, lubrication, scrap and chips.

Select the tools and measuring instruments as per drawing. With Reference process cord xxxxxx.
3
(ex: tools: hob, gearing gears, fixtures, spanners and allenkey / flange mice, vernier, dial with stand etc)
As per process suitable machining setting us preplanned and ensured.
4
(Ex: gearing, hob mounting, fixture mounting, stopper setting, fixture and job dialing etc.)
Check the job run out, after clamp us job properly, and Set the cutting depth as per machine standard
5 dimension (rpm and federate)., after then run the machine

6 Clamping and cutting process follow the below step 6.1 (Fig-1).

Gear blank clamping and tooth cutting method

6.1

Fig-1
Cutting process will be completed. Fist component check and verify the QA inspector as per drawing
7 dimension. And operator also checking the fist component dimension as per drawing then continuously
runs the machine as per production plane.

8 Ensure the process and completed gear material on the bines and put the material identification card.

9 Inspection completed After then moves to next step process, Moving process used by Forklift, trolley

10 .

Step by step procedures – GEAR SHAPER (TOOTH CUTTING)

Receipt to issue the gear blank as per drawing referents.
1

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WORK INSTRUCTION
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Issue No.:
GEAR AND SHAFT
Date :

Machine on and ensure the spin oil level, cutting oil level, air pressure,
2
lubrication, scrap and chips.
Select the tools and measuring instruments as per drawing. With Reference process cord xxxxxx.
3
(ex: tools: hob, gearing gears, fixtures, spanners and allenkey / flange mice, vernier, dial with stand etc)
As per process suitable machining setting us preplanned and ensured.
4
(Ex: gearing, cutter mounting, fixture mounting, stopper setting, fixture and job dialing etc.)
Check the job run out, after clamp us job properly, and Set the cutting depth as per machine standard
5 dimension (rpm and federate)., after then run the machine

6 Clamping and cutting process follow the below step 6.1 (Fig-1).

Gear blank clamping and tooth cutting method

6.1

Fig-1
Cutting process will be completed. Fist component check and verify the QA inspector as per drawing
7 dimension. And operator also checking the fist component dimension as per drawing then continuously
runs the machine as per production plane.

8 Ensure the process and completed gear material on the bines and put the material identification card..

9 Inspection completed After then moves to next step process, Moving process used by Forklift, trolley

Step by step procedures – SPLINE MILLING

Receipt to issue the gear blank as per drawing referents.
1

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WORK INSTRUCTION
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Issue No.:
GEAR AND SHAFT
Date :

2 Machine on and ensure the spin oil level, cutting oil level, air pressure, lubrication, scrap and chips.

Select the tools and measuring instruments as per drawing. With Reference process cord xxxxxx.
3
(ex: tools: hob, gearing gears, fixtures, spanners and allenkey / flange mice, vernier, dial with stand etc)
As per process suitable machining setting us preplanned and ensured.
4
(Ex: gearing, cutter mounting, fixture mounting, stopper setting, fixture and job dialing etc.)
Check the job run out, after clamp us job properly, and Set the cutting depth as per machine standard
5 dimension (rpm and federate)., after then run the machine

6 Clamping and cutting process follow the below step 6.1 (Fig-1).

Gear blank clamping and spline milling method

6.1

Fig-1

Milling process will be completed. Fist component check and verify the QA inspector as per drawing
7 dimension. And operator also checking the fist component dimension as per drawing then continuously
runs the machine as per production plane.

8 Ensure the process and completed gear material on the bines and put the material identification card..

9 Inspection completed After then moves to next step process, Moving process used by Forklift, trolley

10 .

Step by step procedures – SPLINE BROACHING

Receipt to issue the gear blank as per drawing referents.
1

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WORK INSTRUCTION
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Issue No.:
GEAR AND SHAFT
Date :

2 Machine on and ensure the spin oil level, cutting oil level, air pressure, lubrication, scrap and chips.

Select the tools and measuring instruments as per drawing. With Reference process cord xxxxxx.
3
(ex: broach, fixtures, spanners and allenkey / vernier, dial with stand etc)
As per process suitable machining setting us preplanned and ensured.
4
(Ex: broaching tool mounting, fixture mounting, stopper setting, fixture and job dialing etc.)
Check the job run out, after clamp us job properly, and Set the cutting depth as per machine standard
5 dimension (rpm and federate)., after then run the machine

6 Clamping and cutting process follow the below step 6.1 (Fig-1) & (Fig-2)

Gear blank clamping and broaching method

6.1

Fig-1 Fig-2

Broaching process will be completed. Fist component check and verify the QA inspector as per drawing
7 dimension. And operator also checking the fist component dimension as per drawing then continuously
runs the machine as per production plane.

8 Ensure the process and completed gear material on the bines and put the material identification card.

9 Inspection completed After then moves to next step process, Moving process used by Forklift, trolley

10 .

Step by step procedures – KEYWAY SLOTTING

Receipt to issue the gear blank as per drawing referents.

1

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WORK INSTRUCTION
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Issue No.:
GEAR AND SHAFT
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2 Machine on and ensure the spin oil level, cutting oil level, air pressure, lubrication, scrap and chips.

Select the tools and measuring instruments as per drawing. With Reference process cord xxxxxx.
3
(ex: slotting tool, fixtures, spanners and allenkey / vernier, dial with stand etc)
As per process suitable machining setting us preplanned and ensured.
4
(Ex: slotting tool mounting, fixture mounting, stopper setting, fixture and job dialing etc.)
Check the job run out, after clamp us job properly, and Set the cutting depth as per machine standard
5 dimension (rpm and federate)., after then run the machine

6 Clamping and cutting process follow the below step 6.1 (Fig-1)

Gear blank clamping and keyway slotting method

6.1

Fig-1
Slotting process will be completed. Fist component check and verify the QA inspector as per drawing
7 dimension. And operator also checking the fist component dimension as per drawing then continuously
runs the machine as per production plane.

8 Ensure the process and completed gear material on the bines and put the material identification card.

9 Inspection completed After then moves to next step process, Moving process used by Forklift, trolley

Step by step procedures – TOOTH ROUNDING

Receipt to issue the gear blank as per drawing referents.

1

2 Machine on and ensure the spin oil level, cutting oil level, air pressure, lubrication, scrap and chips.

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 Doc No: WI/OP5/4
WORK INSTRUCTION
Page No: 11 of 2
Issue No.:
GEAR AND SHAFT
Date :

Select the tools and measuring instruments as per drawing. With Reference process cord xxxxxx.
3
(ex: cutting tool, fixtures, spanners and allenkey / vernier, dial with stand etc)
As per process suitable machining setting us preplanned and ensured.
4
(Ex: tool mounting, fixture mounting, stopper setting, fixture and job dialing etc.)
Check the job run out, after clamp us job properly, and Set the cutting depth as per machine standard
5 dimension (rpm and federate)., after then run the machine

6 Clamping and cutting process follow the below step 6.1 (Fig-1)

Gear blank clamping and tooth rounding method

6.1

Fig-1

Tooth rounding process will be completed. Fist component check and verify the QA inspector as per
7 drawing dimension. And operator also checking the fist component dimension as per drawing then
continuously runs the machine as per production plane.

8 Ensure the process and completed gear material on the bines and put the material identification card.

9 Inspection completed After then moves to next step process, Moving process used by Forklift, trolley

10 .

Step by step procedures – DEBARRING

Receipt to issue the gear blank as per drawing referents.

1

2 Machine on and ensure the spin oil level, cutting oil level, air pressure, lubrication, scrap and chips.

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Issue No.:
GEAR AND SHAFT
Date :

Select the tools and measuring instruments as per drawing. With Reference process cord xxxxxx.
3
(ex: wheel, fixtures, spanners and allenkey / dial with stand etc)
As per process suitable machining setting us preplanned and ensured.
4
(Ex: wheel mounting, fixture mounting, stopper setting, fixture and job dialing etc.)
Check the job run out, after clamp us job properly, and Set the cutting depth as per machine standard
5 dimension (rpm and federate)., after then run the machine

6 Clamping and cutting process follow the below step 6.1 (Fig-1)

Gear blank clamping and tooth debarring method

6.1

Fig-1

Tooth debarring process will be completed. Fist component check and verify the QA inspector as per
7 drawing dimension. And operator also checking the fist component dimension as per drawing then
continuously runs the machine as per production plane.

8 Ensure the process and completed gear material on the bines and put the material identification card.

9 Inspection completed After then moves to next step process, Moving process used by Forklift, trolley

10 .

Step by step procedures – HEAT TREATMENT

Receipt to issue the gear blank as per drawing referents.

1

2 This process Send to out of source within D.C reference (job work)

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3 Clamping and heat process follow the below step 3.1 (Fig-1)

blank clamping and heat treatment method

3.1

Fig-1
Job work supplier as maintained as gear material required standard tolerance as
Process: case Hardening
HRC-56 TO 60
4
Case depth: 1.2 to 1.5
Bend removing : 0.04 to 0.08

5 Received the process completed gear material on the bines and put the material identification card.

6 Inspection completed After then moves to next step process, Moving process used by Forklift, trolley

Step by step procedures – HARD TURNING & GRINDING

Receipt to issue the gear blank as per drawing referents.

1
Machine on and ensure the spin oil level, coolant oil & water level, air pressure, lubrication, dust and
2
chips.

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Issue No.:
GEAR AND SHAFT
Date :

Select the tools and measuring instruments as per drawing. With Reference process cord xxxxxx.
3 (ex: wheel, hard inserts, boring & facing bars, fixtures, spanners and allenkey / bore gauge, mice’s,
dial with stand etc)
As per process suitable machining setting us preplanned and ensured.
4 (Ex: wheel mounting, fixture mounting, stopper setting, jaws with chuck mounting, programming edit,
required tool arrangement, fixture and job dialing etc.)
Check the job run out, after clamp us job properly, edit on programming and Set the cutting depth as
5 per machine standard dimension (rpm and federate)., after then run the machine

6 Clamping and cutting process follow the below step 6.1 (Fig-1) (Fig-2)

Gear blank clamping and I.D grinding method

6.1

Hard turning Hard grinding

Fig-1 Fig-2

Hard turning process will be completed. First component check and verify the QA inspector as per
7 drawing dimension. And operator also checking the fist component dimension as per drawing then
continuously runs the machine as per production plane.

8 Ensure the process and completed gear material on the bines and put the material identification card.

9 Inspection completed After then moves to next step process, Moving process used by Forklift, trolley

Step by step procedures – CYLINDRICAL GRINDING

Receipt to issue the gear blank as per drawing referents.

1
Machine on and ensure the spin oil level, coolant oil & water level, air pressure, lubrication, dust and
2
chips.
Select the tools and measuring instruments as per drawing. With Reference process cord xxxxxx.
3
(ex: wheel, fixtures, spanners and allenkey / mice’s, dial with stand etc)
4 As per process suitable machining setting us preplanned and ensured.
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Page No: 15 of 2
Issue No.:
GEAR AND SHAFT
Date :

(Ex: wheel mounting, fixture mounting, stopper setting, jaws with chuck and centers mounting,
programming edit, required tool arrangement, fixture and job dialing etc.)
Check the job run out, after clamp us job properly, edit on programming and Set the cutting depth as
5 per machine standard dimension (rpm and federate)., after then run the machine

6 Clamping and cutting process follow the below step 6.1 (Fig-1)

Gear shaft clamping and O.D grinding method

6.1

Fig-1

O.D grinding process will be completed. Fist component check and verify the QA inspector as per
7 drawing dimension. And operator also checking the fist component dimension as per drawing then
continuously runs the machine as per production plane.

8 Ensure the process and completed gear material on the bines and put the material identification card.

9 Inspection completed After then moves to next step process, Moving process used by Forklift, trolley

10 .

Step by step procedures – SPLINE GRINDING

Receipt to issue the gear blank as per drawing reference.

1
Machine on and ensure the spin oil level, coolant oil & water level, air pressure, lubrication, dust and
2
chips.
Select the tools and measuring instruments as per drawing. With Reference process cord xxxxxx.
3
(ex: wheel, fixtures, spanners and allenkey / mice’s, dial with stand etc)
4 As per process suitable machining setting us preplanned and ensured.

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WORK INSTRUCTION
Page No: 16 of 2
Issue No.:
GEAR AND SHAFT
Date :

(Ex: wheel mounting, fixture mounting, stopper setting, jaws with chuck and centers mounting,
programming edit, required tool arrangement, fixture and job dialing etc.)
Check the job run out, after clamp us job properly, edit on programming and Set the cutting depth as
5 per machine standard dimension (rpm and federate)., after then run the machine

6 Clamping and cutting process follow the below step 6.1 (Fig-1)

Gear shaft clamping and SPLINE grinding method

6.1

Fig-6.1
SPLINE grinding process will be completed. Fist component check and verify the QA inspector as per
7 drawing dimension. And operator also checking the fist component dimension as per drawing then
continuously runs the machine as per production plane.

8 Ensure the process and completed gear material on the bines and put the material identification card.

9 Inspection completed After then moves to next step process, Moving process used by Forklift, trolley

Step by step procedures – GEAR GRINDING

Receipt to issue the gear blank as per drawing reference.

1
Machine on and ensure the spin oil level, coolant oil & water level, air pressure, lubrication, dust and
2
chips.
Select the tools and measuring instruments as per drawing. With Reference process cord xxxxxx.
3
(ex: wheel, fixtures, spanners and allenkey / mice’s, dial with stand etc)
As per process suitable machining setting us preplanned and ensured.
4 (Ex: wheel mounting, fixture mounting, stopper setting, jaws with chuck and centers mounting,
programming edit, required tool arrangement, fixture and job dialing etc.)
5 Check the job run out, after clamp us job properly, edit on programming and Set the cutting depth as
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WORK INSTRUCTION
Page No: 17 of 2
Issue No.:
GEAR AND SHAFT
Date :

per machine standard dimension (rpm and federate)., after then run the machine

6 Clamping and cutting process follow the below step 6.1 (Fig-1)

Gear blank clamping and gear grinding method

6.1

Fig-6.1

Gear grinding process will be completed. Fist component check and verify the QA inspector as per
7 drawing dimension. And operator also checking the fist component dimension as per drawing then
continuously runs the machine as per production plane.

8 Ensure the process and completed gear material on the bines and put the material identification card.

9 Inspection completed After then moves to next step process, Moving process used by Forklift, trolley

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