RESPONSIBLE SECTION Doc No;- F21CS01

PROCESS FLOW DIAGRAM

MODEL KWPG DATE;- 6/6/2013
JAYASHREE POLYMERS.P.LTD
APPR. BY CHK BY PREPARED BY
PART NO. 18293-KVT-9000 SHEET 1/1
SRINIVASABABU SWAMINATHAN VINOTH
PARTNAME RUBBER PKG PROTECTOR

PROCESS FLOW CHART

CONDITION OF COMPLETE PARTS

NG
B- 10 Receipt of Master Scrap C- 10 Compression S.NO. PART NO. PART NAME QUANTITY MAKER NAME

Yard Moulding
Batch From Pune
1 GHA/ACM
JPPL-UNIT-1
NG OK 2 CHEMICALS
Return to B- 20 Master Batch
Supplier Inspection C- 20 Deflashing

OK

B-30 Storage of Master

Batch
C- 30 Post Curing

B- 40 Master Batch NG
Mixing Kneader
D- 10 Final inspection (PDI)

OK
B- 40(A) Final Batch
Mixing Mixing Mill
D- 20 Packing & Dispatch

B-50 Final Batch Testing

B-60 Sheet Cutting

FLOW CHART SYMBOLS [ COMBINATIONS OF SYMBOLS CAN BE USED TO SHOW MULTIPLE OPERATION PROCESSES ]

PROCESSING QUANTITY CHECK CROSS PART OF FLOW LINE MAINLY AS PROCESSING PARTS AND DOING INSPECTION

TRANSFER QUALITY CHECK CONTROL DIVISION OF FLOW CHART MAINLY AS INSPECTING QUALITY AND DOING Q'TY INSPECTION
0 31.5.2016 INITIAL RELEASE CHECKED MFG

STORAGE FLOW CHART No. DATE REVISION DETAIL MANUFACTURING APPROVAL

 PROCESS QUALITY CONTROL SHEET ( II )
SUPPLIER CODE 4J18 APPROVED BY CHECKED BY PREPARED BY
CUSTOMER INDO AUTOTECH LTD.
REVISION DATE 17.06.13
PART NAME RUBBER PKG PROTECTOR PERSON INCHARGE MANIKANDARAJA REVISION NO. 00
(Srinivasababu,Swami,Rajesh,Siva,Manivannan,Vinoth, SRINIVASABABU SWAMINATHAN VINOTH
PART NO. 18293-KVT-9000 CORE TEAM Selva,Suresh,Natraj,Mahendren,Moorthy)
// PROTOTYPE // PRE LAUNCH // PRODUCTION //
Cp/Cpk
CONTROL CHARACTERISTICS MANUFACTURING CONDITION CONTROL
results( If
SPEC Cp/Cpk
OPN. IAL Results RECORDING
PROCESS NAME INSPECTION RECORDING MEASURING REMARKS
NO. No. CHECK POINT SPEC. RESP. MEASURING FREQUENCY Char. observed less FREQUENCY No. CHECK POINT SPEC. RESP. CHECK METHOD RECORDING SHEET
TOOL SHEET Class than 1.33, FREQUENCY
then Action
plan Recd.)
Inward register
1 Master Batch GHA/ACM Visual
F20ST01
Receiving of Master
B-10 Store Staff Each lot
batch from Pune
Weighing balance Store Register
2 Weight As Per PO & Invoice no.
JPPL-Stores F20ST02

Mfg.Date,Batch No.Packing
1 Appearance condition and free from Visual
contamination
MASTER BATCH
Master Batch Master Batch Grade & Batch
B-20 2 GHA/ACM Lab Inspector Visual Each lot TEST REPORT
Inspection No.
F09MX22

Specific Gravity
3 Specific Gravity 1.28 ± 0.04
Balance

FIFO Color Coading system (As per

1 FIFO Each lot
W15ST02)

Storage of Master Storage Should Be Covered From

B-30 2 Storage Condition Store Staff Visual Per Day -------
Batch Dust & Other Particle

6 month from date of mfg.As per the

3 Shelf of Life Work instruction Per Day
W15ST07

1 Master Batch With Material Grade GHA/ACM As per Formula card

Final Batch Mixing Formula card
B-40 Store Staff Every Batch
(Kneader) F03MX03
Electronic Weighing
2 Chemicals As per formula card
Balance M/C

1 Time(Batch Warming) 8 mins

Time(Add curing
2 10 mins
agents mixing mill) Timer Formula card/F03MX03
Fianl batch mixing- Fine mixing(Mixing
B-40(A) 3 4 mins Mixing Operator Every Batch
(Mixing mill) mill)
4 Sheet Out 3 min
Mixing Roller
5 30 ± 5 Pyrometer
Temperature
1 Hardness 70 ± 5 °A Shore oA Durometer Each Batch
2 Tensile Strength in (Mpa) 90 - 250 Tensile Testing M/c once in 10 Batches
3 % Elongation at Break 100 - 300 Tensile Testing M/c once in 10 Batches
Rheo meter MH (Max Torque
4 50.99 - 71.65
for Hardness) Lab test report
Final batch testing B-50 Lab Inspector
5 ML (Min Torque for Flow) 10.76 - 19.05 F07QA05
TC90 (For end time of Rheo M/c Every Batch
6 3.80 - 6.23
Curing)

7 TS2 (For Start time of Curing) 1.19 - 2.11

Weighing
Mill report
Sheet Cutting B-60 1 Slug Wt.in Sheet Cutting M/C 2.9 gm/cavity Mixing Operator Balance/Specfication
F03MX09
Chart L10TR02
PRODUCT PARAMETERS AS PER PROCESS CHART PROCESS CHARACTERISTICS
1 DIAMETER 19±0.4 VC/PP 1 Compound name GHA / ACM

2 DIMENSION 10.5±0.3 VC/PP First Piece Approval / Every Setting First piece approval 2 Cure Time 4 Mins

3 DIAMETER 13.5-0.2 VC/PP and Every mould cleaning sheet (F09QA02/1) 3 Temperature 170 ± 5°C

4 DIAMETER 9.5-0.2 VC/PP 4 Hydraulic pressure 190 ± 10 Kg/Cm2

Compression Qc inspector Visual Thrice in a shift prodn log/F16PR08
C-10 5 Bumping 0-8 times
moulding QC Inspector
6 Loading Weight/Cavity 2.9 gms/cavity
Patrol inspection
free from moulding defects, air Report
5 Visual Visual Every 4 hrs Once
blisters, crack,under fill, etc. 7 Total cavity 144 nos
(F09QA02/2)
Mould Preventive Development
8 20-25 K Shots As per Planing sheet Every 3 month Check sheet F13TR07
Maintenance incharge
 PROCESS QUALITY CONTROL SHEET ( II )
SUPPLIER CODE 4J18 APPROVED BY CHECKED BY PREPARED BY
CUSTOMER INDO AUTOTECH LTD.
REVISION DATE 17.06.13
PART NAME RUBBER PKG PROTECTOR PERSON INCHARGE MANIKANDARAJA REVISION NO. 00
(Srinivasababu,Swami,Rajesh,Siva,Manivannan,Vinoth, SRINIVASABABU SWAMINATHAN VINOTH
PART NO. 18293-KVT-9000 CORE TEAM Selva,Suresh,Natraj,Mahendren,Moorthy)
// PROTOTYPE // PRE LAUNCH // PRODUCTION //
Cp/Cpk
CONTROL CHARACTERISTICS MANUFACTURING CONDITION CONTROL
results( If
SPEC Cp/Cpk
OPN. IAL Results RECORDING
PROCESS NAME INSPECTION RECORDING MEASURING REMARKS
NO. No. CHECK POINT SPEC. RESP. MEASURING FREQUENCY Char. observed less FREQUENCY No. CHECK POINT SPEC. RESP. CHECK METHOD RECORDING SHEET
TOOL SHEET Class than 1.33, FREQUENCY
then Action
plan Recd.)
Dust /dirt / loose flash & Cut Mark Route Card
Deflashing C-20 1 Free from flash Deflashing Operator Visual Each Part
not permissible F16PR25

1 Post Curing Time 4 hrs Timer

Post Curing C-30 1 Appearance Under Cure / Over Cure Oven operator Visual Each Lot ---- Oven Operator Each lot Oven Register F10PR02
2 Temperature 170 ± 5 Temp indicator
Visual & Dimensions inspection as per VDA

1 DIAMETER 19±0.4 Inspector DVC/PP 5 pcs/lot

2 DIMENSION 10.5±0.3 Inspector DVC/PP 5 pcs/lot

3 DIAMETER 13.5-0.2 Inspector DVC/PP 5 pcs/lot

4 DIAMETER 9.5-0.2 Inspector DVC/PP 5 pcs/lot

Final Inspection(PDI) D-10 5 DIMENSION 5±0.2 Inspector DVC/PP 5 pcs/lot

PDI Report
(FO7QA06)
6 DIMENSION 2±0.2 Inspector DVC/PP 5 pcs/lot

7 DIMENSION 3.5±0.2 Inspector DVC/PP 5 pcs/lot

8 Material GHA/ACM Inspector MTC Once / 6 months

Part Profile Should be As Per

9 Part Profile Inspector Visual 100%
Drawing

10 Appearance No visual defects allowed Inspector Visual 100%

Special characteristics

1 Packing Condition As per Packing Standard Packing Supervisor Visual Each lot
As per Dispatch
Packing & Dispatch D-20 2 Identification Part No./Part Name & Qty. Packing Supervisor Visual Each lot
check sheet
3 PDI Report With Sign. PDIR Packing Supervisor Visual Each lot