D. R.

Steel & Industries

Pvt. Ltd.

Corporate Office : 24, N.S. Road,

4th Floor, R. No. 33, Kolkata - 700 001
Phone : (033) 2243 2863

Works : 17/1/1, K.B. Sarani (Mall Road),

Dum Dum, Kolkata - 700 080, West Bengal
Telefax. : (033) 2559 4853
e-mail: drsteelindia@gmail.com
Website : www.drsteel.in

Work Instructions
AS PER ISO 9001 : 2015 STANDARD

Doc No : DRSIPL-WI
Issue No : 02
Issue Date : 04.12.2017
Revision No : 00
Revision Date : Nil

Approved By Prepared & Issued By

Director - I QMS Coordinator

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WORK INSTRUCTIONS SECTION : NIL

TITLE : CONTENTS REFERENCE : NIL PAGE NO. 01 of 01

LIST OF WORK INSTRUCTIONS

Work Instruction for Safety.......................................................…….……............ WI-714-001

Work Instruction for Welding………………….....…............…............................ WI-851-001

Work Instruction for Drilling………………….....…............…............................. WI-851-002

Work Instruction for Grinding………………….....…............…........................... WI-851-003

Work Instruction for Pressing………………….....…............…........................... WI-851-004

Work Instruction for Shearing.……………….....…............…............................. WI-851-005

Work Instruction for Shaping………………….....…............…............................ WI-851-006

Work Instruction for Packaging………………….....…............…........................ WI-854-001

Work Instruction for Physical Inspection and Dimension Checking.. WI-910-001

Work Instruction for Sampling Plan.......…....……..……………....................... WI-910-002

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Authorization:

These work instructions describes the process instructions for D.R.Steel

covering QMS. It is approved by the Director - I. However these work
instructions are designed, prepared by admin staff / process owner in
consultation with Director - I & II.

Re-servicing, utilization or disclosure to third party (excluding interested

parties) in any form whatsoever is not permitted without written consent
from the Director - I. However this document is available to all applicable
interested parties.

This work instruction manual is a controlled document and updates and

up gradation if any will be automatically issued to the authorized holders.

Distribution:

1. Authorized holders of the Manual are: (Hard copy)

Distribute Controlled Copy

Director - I 1
Director - II 2
Certifying Body 3

2. Authorized holders of the Manual are: (Soft copy)

Works 4 (‘Read only’ type)

Internal Auditor’s 5 (‘Read only’ type)
External Auditor’s 6 (‘Read only’ type)

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To ensure that each copy of the work instruction manual maintains a

complete record of amendments; this amendment page is updated and
revised with each document when revised and with each revision of the
entire manual. The date of the issue/revision will be amended with every
amendment. Amendments of a minor or editorial nature may be
undertaken and incorporated by office staff. Amendments affecting policy
shall only be incorporated with the approval of Director -I.

 Amendment Sheet

Amend. Doc Title Page New Issue / Amended Approved

No No No. Revision No By By
& Date

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1.0 SCOPE : Safety WI-714-001

All activities inside the Plant.

2.0 RESPONSIBILITY :

Production Incharge / Supervisor / Work Force.

3.0 ACTIVITY :

A. Safety
 Ensure absence of naked wire or wire with poor insulation.
 Ensure to provide guards on the belt driven motors and/or to put board
“DANGER-RUNNING BELT” or so near the machines.
 Keep bucket with sand for each major electrical installations / machines.
 Report to respective Supervisor / Production Incharge for any electrical flash.
 Ensure to keep fire extinguisher of reasonable capacity with updated refilling.
 Display safety slogans at different locations.
 Ensure to keep telephone number of all essential service as fire, hospital,
ambulance, police, local doctor, as well as telephone number of Production
Incharge, at the Factory Gate Office and they are suitably displayed.

B. Personnel
 Ensure to wear asbestos gloves while working with hot objects. In all other cases
working gloves are used. Use goggles in welding operation.
 Use safety helmets while working in top.
 Wear shoes, in shop.
 Ensure not to wear loose shirt.
 Ensure personnel to be alert and to avoid taking food in the shop floor.
 Ensure that “FIRST AID BOX” with updated medicine be available in the office.

C. Environment
 Ensure to have clean drinking water and that reservoirs are cleaned periodically.
 Ensure to have suitable illumination and ventilation in all areas of the plant.
 All toilets to be cleaned daily and ensure that workmen to maintain cleanliness to
toilets.
 Shop floor to be cleaned regularly for sharp objects, remnant of oil, rubber pad,
grease, etc.
 Ensure to clean the shop floor every week with detergent or suitable materials.
 Workmen to ensure throwing all scrap wastes, as jute, cotton waste, etc. in
appropriate boxes.

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1.0 SCOPE : Welding WI-851-001

All manufacturing / welding items.

2.0 RESPONSIBILITY :

Welder

3.0 ACTIVITY :

STORAGE AND HANDLING OF ELECTRODES

1. Keep Electrodes in their original packets or cartons in a dry and well-ventilated

place.
2. Return the unused Electrodes to the storage so that they are not exposed to
inheated and damp working area when they can regin moisture.

PREPARATION OF JOINT FACES

1. If preparation or cutting of the material is necessary, do it by shearing, chipping,

grinding, machining, thermal cutting or thermal gouging.
2. Clean of all oil or grease and scale or rust.

PROTECTION FROM THE WEATHER

1. See that the surfaces to be welded are dry.

2. Take necessary precaution to protect outdoor welding areas during rainy season.

INTER- RUN CLEANING

1. Clean thoroughly to remove particles of slag, spalters etc after each run of weld
bead.
2. Remove visible defects, such as cracks, cavities and other deposition faults if any
before depositing subsequent run of weld.

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WELD PROFILE

1. In the welded condition, the welds face to be grounded off of the surface of the
parent metal.
2. Dress off where a flush surface is required.

QUALITY OF WELDS

1. See that welded joint shall be free from defects that would impair the genuine
service performance of the construction.

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WELDING PROCEDURE SPECIFICATION (WPS) AS PER IS : 9595

BASE METALS
SPEC / TYPE/ GRADE – IS : 2062 Fe 410 WA
BASE METAL THICKNESS – 16 MM
THICKNESS RANGE - MIN. 5 MM, MAX. 32 MM
GROVE :- “V” FILLET – N/A

JOINTS

JOINTS DESIGN : SINGLE – ‘V’ , BACKING : NIL

JOINT DETAILS :

POSITIONS

POSITION OF GROVE : IG

WELDING PROGRESSION : DOWN HAND FLAT.

FILLER METALS

SFA : 5.1 AWS NO. : E7018

F NO : 2 A NO : 1

FILLER METERIAL SIZE -  3.15 MM &  4.0 MM OF ESAB.

PER HEAT : N/A

POST WELD HEAT TREAMENT : N/A

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ELECTRICAL CHARACTERISTICS
CURRENT : DC. AMPS RANGE : 100-160. POLARITY : EP. VOLTS : 22-25

TECHNIQUE

1. ROOT PASS - WEAVE

2. OTHER PASSES - WAVE
3. INTERPASS CLEANING : BY CHIPPING & GRINDING.
4. PASS : MULTIPASS.
5.
WELD PROCESS FILLER METAL CURRENT VOLT TRAVEL SPEED
LAYERS CLASS DIA (MM.) AMP. RANG (MM/MIN)
E
ROOT RUN MMAW E7018 3.15 90-140 22.24 100-120
SUBSEQVELT MMAW E7018 4.0 120-160 22.25 110-130
LAYERS
BACK RUN MMAW E7018 3.15 80-140 22.24 100-120
FINAL RUN MMAW E7018 4.0 120-160 22.25 110-130

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PROCEDURE QUALIFICATION RECORD (PQR)

WELDING PROCESS : MMAW TYPE : MANUAL

BASE METALS

GRADE : IS: 2062 Fe410 WA To IS: 2062 Fe410 WA

TEST COUPON SIZE : 16 X 150 X 540 MM (2 NOS.)

JOINT DETAILS :

POSITION - I G

WELDING PROGRESSION : DOWN HAND

FILLER METAL SIZE :  3.15 mm &  4.0 mm.

AWS NO. : E 7018 , SPEC. No. : S.1

TECHNIQUE

TRAVEL SPEED 100 - 120 MM/ MIN

BEAD WEAVE
PASS MULPTPASS
INTERPASS CLEANING GRINDING & CHIPPING
BACK GOUGING GRINDING
PREHEAT N/A
POSTWELD HEAT TREATMENT N/A

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ELECTRICAL CHARACTERISTICS

POLARITY - EP, AMPS : 90 - 160 , VOLTS : 22 – 25.

VISUAL EXAM. - SATISFACTORY

WELD PROCESS FILLER METAL CURRENT VOLT TRAVEL

LAYERS RANGE SPEED
ROOT RUN MMAW E7018 / 3.15 90 – 140 22 100 – 110
INTER PASS MMAW E7018 / 4.0 120 – 160 25 110 – 120
BACK RUN MMAW E7018 / 3.15 90 – 140 22 100 – 110
FINAL RUN MMAW E7018 / 4.0 120 - 160 25 110 - 120

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WELDER QUALIFICATION RECORD (WQR)

WELDER NAME :

WELDING PROCESS :
WPS NO. :
MATERIAL WELDED :

JOINT DETAILS :

JOINT DESIGN : SINGLE V

BACKING : NIL
BACKING MATERIAL : NA

SIZE OF PLATES :

WELDING POSITION - IG
WELDING PROGRESSION - DOWN HAND

REPORTS

1. VISUAL -

2. PHYSICAL TEST -

3. ROOT & FACE -

BEND TEST
4. ULTRASONIC TEST -

WE CERTIFY THAT THE STATEMENTS IN THIS RECORD ARE CORRECT AND THAT
THE TEST COUPONS WERE PREPARED, WELDED AND TESTED IN ACCORDANCE
WITH REQUIREMENTS.

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Drilling WI-851-002
1.0 SCOPE :

All drilling machines.

2.0 RESPONSIBILITY :

Operators

3.0 ACTIVITY :

3.0.1 Check the machine for cleanliness and electrical and mechanical system for
smooth operation.
3.0.2 Check the necessary drilling jigs and drill bits required as per the nature of the
job.
3.0.3 Do proper marking on the material.
3.0.4 Fix the job in the proper position. If required the chuck and tools may be
changed.
3.0.5 Select and fix the required drill bit in position. Fix up and adjust the tools, as
required including centering.
3.0.6 Check the proper positioning of the material and check the drilling position.
3.0.7 Start the operation and slowly do the drilling at desired speed.
3.0.8 Once the operation is done, remove the material / proceed next drilling.
3.0.9 At the end of the work, clean the machine properly.

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Grinding WI-851-003
1.0 SCOPE :

All grinding machines.

2.0 RESPONSIBILITY :

Operators

3.0 ACTIVITY :

3.0.1 Check the machine for cleanliness and electrical and mechanical system for
smooth operation.
3.0.2 Check the dressing of the grinding wheel.
3.0.3 Hold the job / tools in the proper position. If required use gloves for holding.
3.0.4 Start the operation and slowly complete the job. For portable grinder hold the
machine with rubber gloves only.
3.0.5 Use guards on wheel and goggles for protection of eyes.
3.0.6 Fix the job properly during fettling / grinding operation.
3.0.7 At the end of the work , clean the machine properly.

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Pressing WI-851-004
1.0 SCOPE :

All pressing machines.

2.0 RESPONSIBILITY :

Operators

3.0 ACTIVITY :

3.0.1 Check the machine thoroughly.

3.0.2 Fixed die (male / female) on the holder.
3.0.3 Set the proper depth of cut which is depending up the amount of material is to be
removed.
3.0.4 After the operation open the die & keep it proper place.
3.0.5 At the end of the work, clean the machine properly.

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Shearing WI-851-005
1.0 SCOPE :

All Shearing machines jobs.

2.0 RESPONSIBILITY :

Operators

3.0 ACTIVITY :

3.0.1 Check the machine for cleanliness.

3.0.2 Check the position of the blade.
3.0.3 Marking & Fix the job in the proper position.
3.0.4 Cut the materials slowly. Check the material against the drawing provided for
time to time.
3.0.5 Once the operation is done rejected materials are kept in proper position.
3.0.6 At the end of work clean the machine properly.

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Shaping WI-851-006
1.0 SCOPE :

All Shaping machines jobs.

2.0 RESPONSIBILITY :

Operators

3.0 ACTIVITY :

3.0.1 Check the machine for cleanliness and electrical and mechanical
system for smooth operation.

3.0.2 Check the measuring instruments and cutting tools required for the work.
3.0.3 Fix the job in the proper position. If required the holding chuck and tools may be
changed.

3.0.4 Fix up and adjust the tools, as required including centering.

3.0.5 Start the operation and slowly do the machining jobs. Check the material against
the drawing provided for time to time.
3.0.6 Once the operation is done rejected materials are kept in proper position &
remove the jobs.
3.0.7 At the end of work clean the machine properly.

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Packaging WI-854-001
1.0 SCOPE :

All Finished Goods

2.0 RESPONSIBILITY :

Production Incharge

3.0 ACTIVITY :

All finished goods are kept in zone wise as and when required and marked
with Company Name , Date of Manufacturing , Drg No, Serial No. and proper
destination etc.

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Physical Inspection and Dimension Checking WI-910-001

1.0 SCOPE :

All Finished products

2.0 RESPONSIBILITY :

Quality Control Incharge

3.0 ACTIVITY :

3.0.1 Check all the critical dimensions as mentioned in the drawing of the product
and note whether they are within the tolerance limit as follows.
3.0.2 Put serial No. on every prominent component, if required.
3.0.3 Select the appropriate measuring instrument including gauge or vernier.
3.0.4 Note the dimensions observed against the required value with specific tolerance
permitted as per the specifications or drawings provided.
3.0.5 Segregate the unacceptable components for corrective action.
3.0.6 Keep proper record of the inspected and accepted materials for next
processing.

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Sampling Plan WI-910-002

1.0 SCOPE :

All Incoming / Process / Finished products.

2.0 RESPONSIBILITY :

Quality Control Incharge

3.0 ACTIVITY :

3.0.1 Sampling : After visual overview of lot, samples shall be drawn from the lot in a
random manner. Sampling shall be as per IS : 2500 Part 1 General Inspection
level II single sampling plan normal inspection table to AQL 2.5 unless any other
sampling plan has been specified. Quality control person shall make himself
thoroughly familiar with the concepts of normal inspection, tightened inspection
and reduced inspection.

Lot or Batch No Sample Acceptance Rejection

Size No No
2 to 8 Max 5 0 1
9 to 15 5 0 1
16 to 25 5 0 1
26 to 50 5 0 1
51 to 90 20 1 2
91 to 150 20 1 2
151 to 280 32 2 3
281 to 500 50 3 4
501 to 1200 80 5 6
1201 to 3200 125 7 8
3201 to 10000 200 10 11
10001 to 35000 315 14 15
35001 to 150000 500 21 22
150001 to 500000 500 21 22
500001 to over 500 21 22

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3.0.2 The samples selected according to the table are for non-destructive tests only.
For destructive tests like chemical composition, tensile strength, impact strength
etc. one sample from each heat/cast should be selected. In case heat or cast
cannot be identified then two/three samples (based on lot size) should be
selected from the lot. Consult top management if lot is low value.

3.0.3 Two Stage sampling: When material is offered packed in cartons, boxes, bags,
bundles etc, two stage sampling will have to be adopted. First select the number
of packages and then select the individual pieces from the sampled packages. For
example, if there are 48 packages containing 30 pieces each (total 1440 pieces),
then number of packages sampled will be 5 and number of pieces will be 125
pieces equally divided from 5 packages. Acceptance and rejection numbers in
this case will be 7 and 8.

3.0.4 Inspect and test each sample against the specified acceptance criteria.

3.0.5 Accept the lot if the no. of defective pieces is equal or less than the corresponding
acceptance no, and reject the entire lot if the no. of defective equals or excess the
corresponding rejection no.

3.0.6 Maintain record in the prescribed form.

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