Doc No: ME/PFD/42 KIRLOSKAR OIL ENGINES LTD.

, KAGAL

Rev No: 00 PROCESS FLOW DIAGRAM FOR R 810 ENGINE ATPP

Rev Date: 09 June 2015 Dept.: Mfg. Engineering

Crankcase loading, Number punching,

10
Fitment of Gallery plugs, FIP mounting
stud, Liner & Liner protrusion
checking

Tappet insertion, Fitment of Oil spray

nozzle, Bearing Shells, Crankshaft,
20 Thrust washer, M.B cap & End play
checking

Header cooler S/A 30A

Crankcase loading, Fitment of Lube oil

FIP S/A 30B
pump, Delivery tube, header cooler,
30 FIP, FWE Oil seal housing, Bell housing
dowel & Crankshaft dowel, Name
plate fitment
Name plate punching 30C

Belt tension, Shipping plug &

Piston conrod S/A Fitment of Bell housing, Piston conrod 41 Oil draining
40A 40 510 Thermostat plug Fitment/
& Suction tube 0
Thermostat adaptor Fitment

Fitment of Cambush, Camshaft,

Gear casing S/A 42 Fitment of foot Cleaning & Oiling to flywheel,
50A 50 Intermediate gear, Timing gear, Gear 520
0 Housing, Radiator pipe fitment
casing S/A & Front oil seal

Crank Pulley marking 60A 60 Fitment of Crank pulley, Oil sump & 43
Masking of Engines Exhaust side Wiring of
Bumping clearance check 0 530 Engine/Breather pipe fitment

FIP side wiring harness/

Fitment of lub oil pipe & Fuel timing 44 Loading and unloading of
70 540 Air cleaner and flexible pipe
0 Engines
assembly

Cylinder head SA, Fitment of

Intake manifold, Exhaust
manifold, Turbocharger & Fitment of Cylinder head 45 Engine Cleaning 550 Breather Pipe fitment/
80A 80
Thermostat subassembly, Injector fitment 0 Engine Fan fitment

Fitment of Push rod, Rocker arm,

46 Primer Painting Number punching & air cleaner
90 Tappet setting, Fuel filter bracket & 560
0 fitment
Fuel filter

Fitment of Leak off pipe, HP pipes, 47 Final Painting Gear & Starter end side Passing
100 570
rocker cover & Engine unloading 0

Compressor S/A, Alternator Fitment of Oil filter, Starter, Air 48 Demasking of Engine 580 FIP & Flywheel end side Passing
S/A 110A 110 cleaner bracket, Alternator, Oil drain 0
pipe, Diffuser support bracket, CAC
pipe, Compressor & 'V' belt

Skid packing, Wooden packing,

610
120 Leak testing - Fuel, Water & Oil circuit Export packing of Engine

130 Flywheel Fitment & Oil Filling 620 Accessories Packing

310 Engine Testing FG Stock

Symbol Description

Storage

Operation

Flow

Inspection

Decision making

Delay

Prepared by ( TA/TL ) Reviewed By ( TL/GL) Approved By ( GL/UL)

Process Flow Process Noise Factors (4M) Core Process

Man
Machine Method Environment (Process Parameter)

Material ( Indirect) :

Input ( Direct) Intended Output

Process:

OUTPUT
INPUT

Unintended
Output
Process Function & Product Requirements to the product: Impact of changed Product General Process
Characteristics/ Requirements (Interface to Design) Characteristics Requirements

Process function Output per shift-

OEE :
PPE- :
Product Requirement
Process Function & Product Requirements to the product: Impact of changed Product General Process
Characteristics/ Requirements (Interface to Design) Characteristics Requirements

Process function Output per shift-

OEE :
PPE- :
Product Requirement

Example of Parameter Diagram

 Structure Analysis (P2)
1.Process Items
2.Process Steps
System, Subsystem,
Station number and Name of Focus element
Part element or Name of the process
SA 1 SA 2-( Input from PFD)

Component / Part Element: 10

Subsystem: 20

System: 30

40

50
60
110A
Structure Analysis (P2)
2.Process Steps 3.Process Work Element
Station number and Name of Focus element Man,Machine,Material Environment etc.

SA 2-( Input from PFD) SA 3

Man - :
Machine-
Method- :
Material- :
Environment:

Man - :
Machine- :
Method- :
Material- :
Environment:

Man - :
Machine- :
Method-:
Material- :
Environment: