INDO SHELL CAST PRIVATE LTD Doc.

No: Customer format

COIMBATORE PROCESS FLOW CHART
INDIA Rev.No / Date: 04 / 15.05.2019

PRODUCT NAME : CAT SWL INLET MACHINED Date of Origin : 20/03/2018 PFC No: PFC/07/SRD- 01

M/S DANFOSS POWER

PRODUCT NO : 11190722 Drawing Rev : D Customer: SOLUTIONS (US)
COMPANY.

Process Process name / Incoming source of

Location Machine No. Fixture No. Product Characteristics Process Characteristics
No. Operation Description variation Operation
Operation Inspection cum Decision Storage Transit
inspection

1. Quantity mismatch
RAW MATERIAL FROM 1. No of Qty, 1. Loading and Unloading the material,
10 2. Part mix up ISC - I NA NA
FOUNDRY 2. Free from part mixup. 2. Parts counting.
3. Parts damage.

1. Casting defects, 1.Machining allowance

20 RAW MATERIAL INSPECTION 2. Castings Rust, ISC - II NA NA 2. Chemical and Physical As per perdict plan
3. Improper Inspection. requirement

30 RAW MATERIAL STORAGE Part mix up ISC - II NA NA 1.Keep it in separate bins By using fork lifter

RAW MATERIAL
TRANSPORTATION FROM
40
STORAGE AREA TO SURYA
ENGINEERING WORKS
Surya Engineering By using fork lifter
Casting defects NA NA 1.Keep it in separate bins
Works

1. Casting variation, 1.Core hole distance Stock,

PRE MACHINING- 1 Surya Engineering Lathe Machine Feed, Speed, Depth Of Cut, Coolant oil.
50 2. Tool & Insert wear, Chuck 2. Total Thickness stock,
( DATUM "E" FACE - SIDE ) Works ( M/C No : SEW-TC-01 )
3. Hardness of Casting. 3.Flatness.

1. Core hole distance Stock,

PRE MACHINING- 2 1. Casting variation,
Surya Engineering Lathe Machine 2. Total Thickness stock, Feed, Speed, Depth Of Cut, Coolant oil.
60 ( DATUM "E" OPPOSITE FACE - 2. Tool & Insert wear, Chuck
Works ( M/C No : SEW-TC-02 ) 3. Flatness,
SIDE ) 3. Hardness of Casting.
4. Parallelism.

PRE MACHINING INWARD 1.Distance variation As per perdict plan

70 ISC - II NA NA 1.Machining allowance,
INSPECTION 2.Thickness variation

SURFACE GRINDING-1 1.Core hole distance,

1.Distance variation Grinding Machine Feed, Speed, Depth Of Cut, Coolant oil.
80 ( DATUM "E" OPPOSITE FACE - ISC - II Magnetic table 2. Total Thickness stock,
2.Thickness variation ( M/C No : ISC-II-SGM-01 )
SIDE ) 3.Flatness.

SURFACE GRINDING-2
90
( DATUM "E" FACE - SIDE )
1. Total Thickness,
1.Distance variation Grinding Machine Feed, Speed, Depth Of Cut, Coolant oil.
ISC - II Magnetic table 2. Flatness,
2.Thickness variation ( M/C No : ISC-II-SGM-01 )
3. Parallelism.

1.M14x1.5
2.ES / CDS-068-Port
3.4.00MM Drill
1. Tools wear in edge,
4.M8X1.25
( DATUM "E" OPPOSITE FACE - 2. Incorrect tools,
5.12.00mm Drill
SIDE ) 3. Hardness of casting, Horizontal Machining Center
6.9/16-18 UNF Feed, Speed, Depth Of Cut, Coolant oil.
100 SPOT FACING, PORT 4. Tools Blend, ISC - II ( M/C No : ISC-II-MAZAK-HMC- ISC-MS-HIC-722
7. 1 5/16-12UN
FORMING, DRILLING, TAPPING 5. Improper clamping, 03 )
8. OSV PER 155M5833
& CHAMFERING 6. Projection in rest &
9. M8X1.0
clamp area
10.7/16-20UNF
11.1 5/18-12 UN
12.6.00MM Drill

1.18.00MM Drill
2.20.00MM Drill
1. Tools wear in edge,
3. M10X1.5-6H
2. Incorrect tools,
( DATUM "E" FACE - SIDE ) 4. 5.00MM Drill
3. Hardness of casting, Horizontal Machining Center
SPOT FACING, PORT 5.4.00MM Drill Feed, Speed, Depth Of Cut, Coolant oil.
110 4. Tools Blend, ISC - II ( M/C No : ISC-II-MAZAK-HMC- ISC-MS-HIC-722
FORMING, DRILLING, TAPPING 6.12.00MM Drill
5. Improper clamping, 03 )
& CHAMFERING 7.8.75 Reamer
6. Projection in rest &
8.IES- 0111-8SAE
clamp area
9. 6 SAE9/16-18 UNF
10. ES-1345
Page 1 of 2
 INDO SHELL CAST PRIVATE LTD Doc. No: Customer format
COIMBATORE PROCESS FLOW CHART
INDIA Rev.No / Date: 04 / 15.05.2019

PRODUCT NAME : CAT SWL INLET MACHINED Date of Origin : 20/03/2018 PFC No: PFC/07/SRD- 01

M/S DANFOSS POWER

PRODUCT NO : 11190722 Drawing Rev : D Customer: SOLUTIONS (US)
COMPANY.

Process Process name / Incoming source of

Location Machine No. Fixture No. Product Characteristics Process Characteristics
No. Operation Description variation Operation
Operation Inspection cum Decision Storage Transit
inspection

1.Dimension variation 1. Loading and Unloading the material,

120 DEBURRING ISC - II NA NA 1.Smooth edges,and corners As per Work
2. Parts Instruction
counting.
2.Operation missing

1). Improper visible for lettering Lettering punch,

Engraving Machine Letters visibility, Letters
130 PART ENGRAVING 2). Hardness of casting ISC - II NA As per Work Instruction
( M/C No : ISC-II-ENGR-01 ) Distance.
3) Engraving tool wear in edge, ( ISC-II-TS-MS-ENGR- WI - 35 / 00)

Endoscopy Machine As per Work Instruction

140 ENDOSCOPY INSPECTION 1.Casting defects ISC - II NA Core merge clear
( M/C No : ISC-II-ESM-01 ) ( ISC-TS-MR- LRO-D15 )

Dimension variation and As per Final Quality Plan

150 FINAL INSPECTION ISC - II NA NA As per inspection report
operation missing

1.Dust particles Ultrasonic Machine As per Work Instruction

160 ULTRASONIC CLEANING ISC - II NA 1.Contaminants clear
2.Rust ( M/C No : ISC-II-USM-01 ) ( ISC-II-WI-SRDAN-01 )

170 MILLIPORE TESTING 1.Dust particles ISC - II MC-01 NA 1.Contaminants clear As per Work Instruction

1.Rust As per Packing Specification

180 RUST PREVENTIVE OILING ISC - II NA NA As per Work Instruction
2.Dust particles ( ISC-TS-QCD-PS-D04.52 )

Qty mismatch and packing box As per Packing Specification

190 PACKING ISC - II NA NA As per Work Instruction
size variation ( ISC-TS-QCD-PS-D04.52 )

Documentation and wrong As per Packing Specification

200 DESPATCH ISC - II NA NA As per Work Instruction
packing slip ( ISC-TS-QCD-PS-D04.52 )

Revision Details

Rev No Rev Date Revision Description

0 20.03.2018 New Release

1 15.11.2018 Reviewed and updated Customer Drawing revision changed ( Rev No---> "B" from Rev No---> "P5" ).

2 07.03.2019 Reviewed and updated Customer Drawing revision changed ( Rev No---> "C" from Rev No---> "B" ).

3 10.04.2019 Reviewed and updated Customer Drawing revision changed ( Rev No---> "D" from Rev No---> "C" ).

4 15.05.2019 Reviewed and updated remove internal 'K' parameters. ( PFC no change )
PREPARED BY: GANESAN.O APPROVED BY : S.SELVAM ISSUED BY : S.SELVAM

DATE:: 15.05.2019 DATE:: 15.05.2019 DATE:: 15.05.2019

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