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PT. ALFA VALVES INDONESIAJL. Mercedes No. 324, Wanaherang, Gunung Putri, Bogor - Indonesia
Phone : (62 - 21) 8686 0009 ; Fax : (62 - 21) 8686 0008 Phone : (62 - 21) 8686 0009 ; Fax : (62 - 21) 8686 0008 E-mail : [email protected]
PRODUCTION FLOW CHART of TRUNNION BALL VALVE
AVI-P-FC-001A
0
:
Revision No. :
Document No.
S. Martahan Panjaitan
Tunggul H.P
Approved By :
Prepared By :
pp y
Issued Date : April 08, 2003
This document and it's content are property of PT. ALFA VALVES INDONESIA. Neither this document nor this its content maybe copied in a whole or in apart thereof or transferred to a third party or used in any other way detrimental to the interest ofPT. ALFA VALVES INDONESIA.
Notice
ALFA VALVES DOC NO.
REV.
AVI-P-FC-001A
0 2 OF 6
DATE OF ISSUED
PAGE
8-Apr-03
PRODUCTION PROCESS FLOW CHART OF TRUNNION BALL VALVE
#-
materials againts packing list or suppliersupplier D/D / invoice to Alfa. PO.Discrepancies shall be identifed
DOCUMENT REMARK
Check for correct content and quantityStore Personel
PROCESS
START
INCOMING MATERIAL
PURCASE ORDER VENDOR PACKING LIST
MATERIALS RECEIVE RETURN'S OUTWARD
-
-
-
#-
- Visual Surface Inspection(MSS-SP 55)Di i l I ti
by QC Department.Material Mill Test Reports will be kept
Discrepancies shall be identifedfor remedial actionMaterial stock status raisedfor Direct Material recordMaterials consumable log bookraised for Indirect Material record
QC inspector
DELIVERY MATERIALS CONS. LOG
MATERIALS STOCK
MILL TEST REPORT QC INCOMING
INCOMING MATERIAL
QC INCOMING
INSPECTION-
#
#-
* Height, Handwheel* Etc.
* Wall thicknessDimensional Inspection
meeting receive reports & decidematerial status
NO
* Face to Face/End to End Dimensions
NCMR ( Non Conforming Material
MRB ( Material Review Board)
* Flange Dimensions
NCMR NC TagOK ? NON-CONFORMANCE
YES
-
#
#-
Production Assembly OperatorProduction Work Order shall based on
Report )NC Tag ( Non Conforming Tag )
Store Personel
Sales Order and / or customer delivery
RAW MATERIAL STORAGE
MATERIAL STOCK INVENTORY STOCK
PRODUCTION PRODUCTION WORK COLLECT KIT VALVES
#-
#
parts
Production Assembly OperatorInspect for Quantity and suitability of
Sales Order and / or customer delivery order
Production Assembly OperatorNO
MAT. REQ. / ISSUED ASSY
REQUEST FOR KIT COMPLETENESS
PARTS INS. BEFORE
ASSEMBLY
OK ? MAT. REQ. / ISSUED
#
# MRB
Production Assembly Operator
NO NO
YES
ASSY IN-PROCESS INSTALL BODY SEAT (1) & CAP SEAT(2) INTO
SEAT RETAINER
TRIAL & NCP NCMROK ? OK ?-
#
NCP : Non-Conformance Procedure
Production Assembly OperatorYES
YES
ERROR NCP NCMR
INSTALL SPRING (WAVE OR COIL) INTO
SEAT RETAINER
A
OK ? OK ?
ASSY IN-PROCESS
AVI-P-FC-001A
ALFA VALVES DOC NO.
REV.
DATE OF ISSUED
PAGE
8-Apr-03AVI-P-FC-001A
0 3 OF 6
PRODUCTION PROCESS FLOW CHART OF TRUNNION BALL VALVE
#
#
MRB
Production Assembly Operator
PROCESS DOCUMENT
YES
YES
REMARK
NO NONCMR
A
OK ? TRIAL & ERROR OK ? NCP
#
#
#
MRB
P d ti A bl O t
Production Assembly OperatorYES
YESYES
NO NO
INSTALL BODY SEAT
RETAINER (1) ASSY INTO
BODY
OK ? TRIAL & ERROR OK ? NCP
ASSY IN-PROCESS
NCMR
#
#
#
Production Assembly Operator
MRBNO NO
YES
YESYES
Production Assembly Operator
INSTALL BODY SEAT
O-RING
OK ? TRIAL & ERROR OK ? NCP
INSTALL
NCMR
ASSY IN-PROCESS
ASSY IN-PROCESS
#
#
MRB
YESProduction Assembly Operator
NO NO
YES
INSTALL BALL INTO
BODY
OK ? TRIAL & ERROR OK ? NCP
INSTALL O-RING
NCMR
ASSY IN PROCESS
ASSY IN-PROCESS
#
#
NO NO
YES
YES
MRB
Production Assembly Operator
RING, BEARING
INTO LOWER STEM
OK ? TRIAL & ERROR OK ? NCP NCMR
#
#
#
NO
YES
YES Production Assembly Operator
Production Assembly Operator
MRBNO
INSTALL LOWER
STEM ASSY INTO BALL
OK ? TRIAL & ERROR OK ? NCP NCMR
ASSY IN-PROCESS
YESINSTALL THRUST
BEARING & THRUST WASHER
INTO LOWER STEM
B
ASSY IN-PROCESS
AVI-P-FC-001A
PRODUCTION PROCESS FLOW CHART OF TRUNNION BALL VALVE
8-Apr-03AVI-P-FC-001A
0 4 OF 6ALFA VALVES DOC NO.
REV.
DATE OF ISSUED
PAGE
#
#
NO NO
PROCESS DOCUMENT
YES
YES
REMARK
Production Assembly Operator
MRB
NCMR
B
OK ? TRIAL & ERROR OK ? NCP
#
#
YES
YES
Production Assembly Operator
Production Assembly Operator
BOLTING LOWER
COVER INTO BODY WITH
STUD BOLTS & NUTS
ASSY IN-PROCESS
INSTALL BEARING,
ASSY IN-PROCESS
#NO NO
YESYES
MRB
,THRUST
WASHER & O-RING INTO UPPER STEM
OK ? TRIAL & ERROR OK ? NCP NCMR
#
#
#YES
Production Assembly Operator
NO NO
YESProduction Assembly Operator
MRB
INSTALL UPPER STEM
ASSY INTO BALL
OK ? TRIAL & ERROR OK ? NCP
NCMR
ASSY IN-PROCESS
#
#
Production Assembly OperatorYES
YES
NO NOMRB
BOLTING GLAND ASSY INTO BODY WITH HEX
HEAD BOLTS
OK ? TRIAL & ERROR OK ? NCP NCMR
ASSY IN-PROCESS
#
# MRBNO
YES
NO
YES
Production Assembly OperatorINSTALL
SEAT O-RING INTO CAP
OK ? TRIAL & ERROR OK ? NCP NCMR
ASSY IN-PROCESS
#YES Production Assembly OperatorINSTALL
GASKET & O-RING
BETWEEN BODY AND
CAP
C
ASSY IN-PROCESS
AVI-P-FC-001A
ALFA VALVES DOC NO.
REV.
DATE OF ISSUED
PAGE0
8-Apr-03AVI-P-FC-001A
5 OF 6
PRODUCTION PROCESS FLOW CHART OF TRUNNION BALL VALVE
#
PROCESS DOCUMENT REMARK
Production Assembly Operator
C
BOLTING CAP ASSY INTO BODY ASSY WITH
# Production Assembly Operator
ASSY WITH STUD BOLTS
& NUTS
INSTALL SEALANT
FITTING INTO BODY & CAP
ASSY IN-PROCESS
#
#
NO NO
YESYES
MRB
Production Assembly Operator
OK ? TRIAL & ERROR OK ? NCP
INSTALL DRAIN PLUG INTO BODY
NCMR
ASSY IN-PROCESS
#
#
MRB
YES
NONO
YES
Production Assembly Operator
OK ? TRIAL & ERROR OK ? NCP
INSTALL STEM KEY INTO STEM
NCMR
ASSY IN-PROCESS
#
#-
MRBNO
Production Assembly OperatorFor Lever Operator Ball Valves to
NO
Install Lever into Ball Valve :YES
OK ? TRIAL & ERROR OK ? NCP NCMR
BOLTING GEAR
OPERATOR
ASSY IN-PROCESS
#-
Production Assembly Operator Functional Inspection
* Install Stopper & Snap ring into Lever* Install Lever Assy into Body* Bolting Lever with Set Screw
ASSEMBLY DAILY PERFORMANCE REPORTVALVE ASSY
INSPECTION
OPERATOR ASSY INTO
VALVE MOUNTING PAD WITH HEX HEAD
BOLTS
-
#
YES
NO
Joint torques Inspection
NOMRB
YES
OK ? TRIAL & ERROR
OK ? NCP
D
INSPECTION
NCMR
AVI-P-FC-001A
ALFA VALVES DOC NO.
REV.
DATE OF ISSUED
PAGE
8-Apr-03AVI-P-FC-001A
0 6 OF 6
PRODUCTION PROCESS FLOW CHART OF TRUNNION BALL VALVE
#--
REMARKPROCESS DOCUMENT
Production Testing OperatorShell TestLow-Pressure Closure TestHigh-Pressure Closure Test
D
VALVE PRESSURE
TESTING DAILY PERFORMANCE REPORT
--
#
#
API 598 or API 6D(Upon Customer's Requirements)
YES
NOMRB
Production Painting Operator
High-Pressure Closure Test
COATINGCOATING DAILY
PERFORMANCE REPORT
TESTING
NON-CONFORMANCE OK ? NCMR NC Tag
#-
#-
The Plates are mounted in the mostpracticable position
Production Packing Operator
QC InspectorProduction will advise QC that valves
INSTALL ID PLATE
COATING
FINAL
PERFORMANCE REPORT
REQUEST for QC QC FINAL INSPECTION
#
#
are ready for final Inspection byCompleting a"Request for QC Inspection Form"
NO
YES
Production Packing Operator
QC Inspector
OK ?
FINAL INSPECTION
NON-CONFORMANCE
QC FINAL INSPECTION
NCMR CORRECTIVE ACTION
#
#---
MTR=Material Test Report
DVIR=Dimensions & Visual Ins Report
QC Inspector
PTR=Pressure Test Report
COC=Certificate of Compliance & Test
Production Packing Operator
PACKAGING & DESPATCH
DOCUMENTATION
SALES ORDER
ALFA PACKING LIST
PACKING LABEL
COC MTR
PTR DVIR
-
# Store Personel
DVIR=Dimensions & Visual Ins. Report
SHIPMENT
SHIPMENT SCHEDULE DELIVERY DOCKET
VALVES STOCK INVENTORY STOCK
WARRANTY VALVES DATA LOG
END
AVI-P-FC-001A