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  • Stage Wise Control

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    thulasi sanjeevi
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    The document outlines the processes and quality control steps for manufacturing hardened steel components. It lists 10 key production steps including pre-washing, preheating, activation, hardening, and tempering. For each step it specifies operating parameters, evaluation methods, sampling procedures, and responsibilities for process control and non-conformance response. The goal is to achieve the proper surface hardness, core hardness, and appearance through strict adherence to testing protocols and adjustment of machine settings as needed.

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    The document outlines the processes and quality control steps for manufacturing hardened steel components. It lists 10 key production steps including pre-washing, preheating, activation, hardening, and tempering. For each step it specifies operating parameters, evaluation methods, sampling procedures, and responsibilities for process control and non-conformance response. The goal is to achieve the proper surface hardness, core hardness, and appearance through strict adherence to testing protocols and adjustment of machine settings as needed.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    13 views2 pages

    Stage Wise Control

    Uploaded by

    thulasi sanjeevi
    The document outlines the processes and quality control steps for manufacturing hardened steel components. It lists 10 key production steps including pre-washing, preheating, activation, hardening, and tempering. For each step it specifies operating parameters, evaluation methods, sampling procedures, and responsibilities for process control and non-conformance response. The goal is to achieve the proper surface hardness, core hardness, and appearance through strict adherence to testing protocols and adjustment of machine settings as needed.

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    © All Rights Reserved
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    of 2

    Characteristic Method

    Process Machine, Control Method REF PHOTOS


    Process Name/ Device, Special
    Product/ Process Evaluation Sample Responsibility Reaction Plan
    No. Operation Jig,Tools chara.
    desc. for Mfg. No. Product Process Specification Measurement
    Tolerances Techniques Size Freq. Detection Main Controller Over Temp Controller

    Ferro Clean Tempr.


    Temp Temp. Controller
    : 60-75◦C

    Washing Prodn.Sup. Adjust Temp and Timer


    Time Jog Time :10-15' Timer

    Full Batch Every Batch PLC

    50 Pre Washing Washing M/C


    Time Spray Time : 10-15' Timer

    Time Dryer Time : 10-15' Timer

    Top-up Ferro Clean


    concentration Bath % 2% - 4% Refractometer 2-3 Drops Weekly Twice PLC Quality In charge
    Solution

    Temp: 450ºC ± 10ºC Temp controller

    Stress
    Preheating
    60 Preheating Relieving & Full Batch Every Batch PLC Prodn.Sup. Adjust Temp and Time
    Furnace
    Oil Burning

    Time: 60' ±10' Timer

    Activation:

    Prodn.
    Temp:880ºC ±10ºC Temp controller 1 Reading Every 10'-30'
    Supervisor

    Direct Prodn.
    70 SQF- 01 1 Activation Time:46' ±10' PLC 1 Reading Every 10'-30'
    Hardening Supervisor
    Adjust Time,Temp & Gas
    PLC
    Flows

    Prodn.
    CP:0.25 % ± 0.05% CP controller 1 Reading Every 10'-30'
    Supervisor
    Quench delay - 45 Sec max Tempering Delay Between Quenching And Tempering Process 4 Hrs Max

    Ferro Clean Temp:60°-


    Temp Temp.Controller
    75°C
    Full Batch Every Batch Calibrated Instrument Prodn.Sup. Adjust Temp and Timer
    Time Jog Time: 10-15' Timer
    Time Spray Time:10-15' Timer
    Post
    80 Washing M/C
    Washing

    Bath % 2% - 4% Refractometer 2-3 Drops Weekly Twice Calibrated Instrument Quality In charge Top-up Alkaline Base Oil

    As Quench Testing Rockwell Hardness


    90 Surface Hardness 40-45 HRC 5 Nos Random Per Batch Calibrated Instrument Calibrated Instrument Prodn.Sup. Quarantine the Batch.
    Inspection Equipment Tester

    Tempering
    100 Tempering Furnace Temp & Time Temp: 450ºC ±10ºC Temp Controller 100% Every Batch Calibrated Instrument Prodn.Sup. Adjust Temp and time.
    (TF1/TF2)

    Time:90'± 10' Timer

    Rockwell Hardness
    Surface Hardness 25- 30 HRC 13 Nos Random Per Batch Rockwell Hardness Rockwell Hardness
    Tester

    Rockwell Hardness
    Core Hardness 25- 30 HRC 1 No's Random Per Batch Rockwell Hardness Rockwell Hardness
    Tester

    Free from scaling &


    Visual Eyesight 100% Per Batch Eyesight
    Final Testing black patches Quality In charge
    110 Quarantine the Batch.
    Inspection Equipment Engineer

    Fine Tempered
    Case Micro structure Microscope 1 No. Per Batch Microscope Microscope
    Martensite

    Fine Tempered
    Core Micro structure Microscope 1 No. Per Batch Microscope Microscope
    Martensite

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