PROCESS FLOW DIAGRAM

MAGOD FUSION TECHNOLOGIES PVT LTD

Part HMCL-P90-EX-UPSET &
Customer Name: Rane Engine Valve Ltd PFD Competition Date: Contact:
Number: FORGE
Location: Hydrabad Part Name: Engine Valve PFD Revision Date: Contact Phone:
Prepared By: Contact E-mail:

PFD
Opn. No. Description Product Characteristics Process Characterisitcs
Operation Inspect Delay Transport Storage
10 Raw Material Inspection Diameter
Length
Visual Cavity form
Weight
Cavity Depth
No. of item
Cleaning of Incomming
20 Job Free from any oil and dust

30 Load Valve To Trolly No Damage

Avoid mixing with rejected, processed
valve

Laser Cladding on Valve

40 Tip Power
Powder flow
Air Pressure
Water chiller temperature
Stand off
Carrier Gas flow
50 Final Inspection Deposition weight
Overall Length
Blow hole
Edge Melting
Cavity Form

60 Packing Free from Powder partical

Kept valves in customer receive bins

70 Dispatch Ensure correct documentation

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CONTROL PLAN

Magod Fusion Technologies Pvt

Type Prototype Pre-launch Production Key Contact/Phone Date(Orig.) Issue No / DT :

Part Number/Latest Change Level Core Team DS/AJ/RR/AS/SM Customer Engineering Approval/Date(If Reqd.) - Rev No / DT : Nil
Customer Part no :
Customer Part Number/Latest Change Level Supplier/Plant/Approval/Data Magod Fusion Technologies Pvt. Ltd. Customer Quality Approval/Date(If Reqd.) -
Drg No :
Part Name/Description Other Approval/Date(If Reqd.) Other Approval/Date(If Reqd.) -
Supplier/Plant Supplier Code
Operation # Characteristics Methods
Process Name / Operation Machine, Device, Tool for Special Char.
Evaluation Measurement Sample Reaction Plan
Description Mfg. No. Product Process Class Product / Process Specification / Tolerance Control Method
Operation Code Technique Size Freq.
10 Raw material Inspection Vernier Caliper with LC 1 Diameter C R2.50 +/- 0.05 mm Vernier Caliper 5 Per Lot Incomming Inspection Record-OperatorInform and Send Back to customer if found not OK
2 Length (OL) M 72.55 +/- 0.10 mm Vernier Caliper 5 Per Lot Incomming Inspection Record-OperatorInform and Send Back to customer if found not OK
3 Visual Cavity Form Visual 5 Per Lot Incomming Inspection Record-OperatorInform and Send Back to customer if found not OK

Weighing scale with LC 10mg 4 Valve Weight M Weighing scale 5 Per Lot Incomming Inspection Record-OperatorInform and Send Back to customer if found not OK

5 Cavity Depth C 1.75 +/-0.10 mm Vernier Caliper 5 Per Lot Incomming Inspection Record-OperatorInform and Send Back to customer if found not OK
6 No. of Items Match to Customer DC Visual Counting All Full Lot Incomming Inspection Record-OperatorInform Customer about less or more Quantity received

20 Cleaning of Incoming Valve IP 1 Oil / Dust Removal Free from Oil / Dust Visual all full lot Process Route Card- Operator Re - cleaning to be done for if
Cotton Oil layer is not removed properly
Compressed Air

30 Load Valve to Trolly Trolley 1 No Damage Avoid Mixing Separate trolley for un processed valve all full lot Process Route Card- Operator Re - cleaning to be done for if found mix
Valve holding Tray 2 Avoid mixing with cleaned and
un cleaned valve

40 Laser Cladding on Valve Tip Laser System 1 Power 1050 +/- 50 W Actual power display on Laser System 1 2000 Task sheet, FOA -operator If valve melting obseved then set power in specified range
Powder Feeder 2 Powder flow 27 - 29 gms/min Calibration of powder 1 2000 Task sheet, FOA -operator Re calibrate the powder
Compressor 3 Air Pressure 6 - 7 bar Air compressor PLC - - Task sheet, FOA -operator Auto control
Chiller 4 Water chiller temperature 14 - 17 °C Chiller Temperature controller - - Task sheet, FOA -operator Auto control
Stand Off Gauge 5 Stand off 20 +/- 1 mm Stand off Gauge 1 2000 Task sheet, FOA -operator Re set the stand off
Flow meter Carrier Gas Flow 10 lpm +/- 2lpm Flow meter 1 2000 Task sheet, FOA -operator Set flow within specifies range

50 Final Inspection 1 Deposition weight M 0.25 - 0.30 grams Weighing Scale 5 500 Final Inspection Report-Inspector Rework valve if powder not cladded as specified range
2 Overall Length (OL) M 72.4 mm +/- 0.10 mm Vernier Caliper 5 500 Final Inspection Report-Inspector Rework valve if powder not cladded as specified range
3 Blow hole Edge melting PT test 5 500 Final Inspection Report-Inspector Separate valve with Edged melted as reject
4 Porasity Porasity <100 µ PT test 5 500 Final Inspection Report-Inspector Separate valve with blow hole as reject
5 Deposition fusion Free from Bonding UT Test 5 500 Final Inspection Report-Inspector Separate valve with Bonding defect as reject
Defects

60 Packing Customer Specified/Provided 1 Powder partical removal Free from powder particals Visual all full lot Process Route Card- Operator Re - cleaning to be done for if
Kept valves in customer receive bins 2 Avoid Mixing of OK, Reject and Powder layer is not removed properly
Bubble Wrap Rework valves
Shrink Wrap ,,

70 Dispatch Documentation 1 Documentation Ensure correct documentation Enter in dispatch register all full lot Documentation- Incharge/Admin Record in data base
2

NOTE: M= PROCESS MAJOR, C= PROCESS CRITICAL, OL= OVERALL LENGTH, FOA= FIRST OFF APPROVAL