BUREAU OF INDIAN STANDARDS (Southern Regional Office) › qazwsx › oth › 60CM15633.pdfThe Tyre is so made that can be used by mounting and inflating on the appropriate rim. The

BUREAU OF INDIAN STANDARDS (Southern Regional Office) Our Ref: 60/CM 1 6 Dec 2013 Subject: Preparation & Review of Product Manuals for Product Certification This has reference to CMD-I’s circular CMD-1/31 dated 11 Nov 2013 on the above subject. In this connection, the draft Product Manual in respect of IS 15633 allotted to SRO has been prepared. The same is attached herewith for hosting on the BIS Intranet for inviting suggestions and comments for a period of 15 days. The comments may be sent to SRO/ HBO. (H.L. Upendar) DDGS Encl: a/a HITSD BIS HQ E. DEVENDAR Scientist G & Deputy Director General (South) Bureau of Indian Standards Southern Regional Office IV Cross Road, C.I.T. Campus Tharamani, Chennai - 600 113 Email: [email protected] Phone: 044 - 2254 2365 Fax: 044 - 2254 1087

MANUAL FOR AUTOMOTIVE VEHICLESPNEUMATIC TYRES FOR PASSENGER CAR

VEHICLESDIAGONAL AND RADIAL PLY AS PER IS 15633:2005

DOC No.HBO/15633/1 MANUAL Prepared by HBO 26 NOVEMBER 2013

FOR BIS USE ONLY

MANUAL

FOR

AUTOMOTIVE VEHICLES – PNEUMATIC TYRES FOR PASSENGER CAR VEHICLES

– DIAGONAL AND RADIAL PLY

AS PER

IS 15633:2005

FIRST ISSUE

NOVEMBER 2013

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN 9,B.S.Z.MARG

NEW DELHI 110 002




AMENDMENT SHEET

Amendment No. Date of Issue




CONTENTS

I FOREWORD II SECTION - 1 (PRODUCT DESCRIPTION) III SECTION – 2 (RAW MATERIALS/COMPONENTS) IV SECTION – 3 (MANUFACTURING PROCESS) V SECTION – 4 (CERTIFICATION CRITERIA) VI SECTION – 5 (INSPECTION AND TESTING)




I FOREWORD

BIS has published Indian Standards on Automotive Vehicles – Pneumatic Tyres for Passenger Car Vehicles – Diagonal and Radial Ply namely IS 15633:2005. The products were brought under Mandatory BIS Certification effective from Pneumatic Tyres and Tubes for Automotive Vehicles (Quality Control) order, 2009 issued by Ministry of Commerce and Industry (Department of Industrial Policy and promotion) (DIPP) vide S.O. No.2953 (E) dated 19.11.2009. This Q.C. Order shall come into force immediately. The manual of Automotive Vehicles – Pneumatic Tyres for Passenger Car Vehicles – Diagonal and Radial Ply provides guidelines on various aspects related to Certification of Tyres according to IS 15633 along with Scheme of Testing and Inspection (STI). The provisions of this Indian Standards, STI’s and also the various guidelines issued from time to time for certification of Automotive Vehicles – Pneumatic Tyres for Passenger Car Vehicles – Diagonal and Radial Ply is kept in view while preparing this manual. Specific proformae have been included for submission of reports of preliminary, periodic and verification inspections so as to facilitate uniform reporting by all concerned, covering all essential parameters required to be reported as per the relevant ISS, STI. Other proformae for checking plant, process and personnel, etc have also been included. In case of any dispute, the requirements of the Indian Standards and the corresponding STI shall prevail. This document is intended only for internal use by BIS officers and inspection personnel working on behalf of BIS. However, others can draw benefit from the Manual to improve their activities related to certification. Suggestions for any improvement in this Manual may be sent to CMD-III.




II SECTION – 1

PRODUCT DESCRIPTION

1.0 AUTOMOTIVE VEHICLES – PNEUMATIC TYRES FOR PASSENGER CAR VEHICLES – DIAGONAL AND RADIAL PLY Automotive Vehicles – Pneumatic Tyres means Tyres used for Passenger Car Vehicles – Diagonal and Radial Ply for general, dimensional and performance requirements designed for Vehicles in Categories M1, T1 & T2. Tyre: Tyre is an annular, torroidal shaped inflatable envelope made of elastic materials, natural and/or synthetic rubber or a blend thereof, reinforced with a textile/steel cord fabric casing enclosing multi-coil wire beadings. The Tyre is so made that can be used by mounting and inflating on the appropriate rim. The type of Pneumatic Tyres are for normal road use, special use tyre for mixed use (both on and off the road) and restricted speed snow tyre. 1.1. The technical characteristics of the carcass of a tyre are Structure, Diagonal or Bias-ply, Radial, Bead, Cord, Carcass, Tread, Sidewall, Lower Sidewall, Tread Groove, Section Width, Overall Width, Section Height (H), Nominal Aspect Ratio (Ra), Outer Diameter (D), Tyre – size Designation, Nominal Rim Diameter, Rim, Measuring Rim, Test Rim, Chunking, Cord Separation, Ply Separation, Tread Separation, Load Index, Ply Rating, Speed Symbol, Table Load-Capacity Variation with Speed, Theoretical Rim.




IS 15633:2005

Indian Standard AUTOMOTIVE VEHICLES – PNUEMATIC TYRES

FOR PASSENGER CAR VEHICLES – DIAGONAL AND RADIAL PLY –

SPECIFICATION (Reaffirmed 2010)

AMENDMENT NO.1 AUGUST 2009 AMENDMENT NO.2 APRIL 2011

(2 Amendments)




1.3 LIST OF INDIAN STANDARDS FOR REFERENCE OF RAW MATERIALS/COMPONENTS AND TEST METHODS

IS No Title 10694 (Part 2):1996 Automotive vehicles – Rims – General requirements:

Part 2 Passenger car vehicle rims (first revision)

1.4 CHECK-LIST FOR SUBMISSION OF AN APPLICATION FOR GRANT OF LICENCE The Section gives the guidelines on actions related to receiving of an application and its processing for grant of licence (GOL). The pre-requisites for GOL shall be as per the requirements published in BIS website, (www.bis.org.in) either for old procedure or for simplified procedure. Application for grant of licence for Automotive Vehicles – Pneumatic Tyres for Passenger Car Vehicles – Diagonal and Radial Ply as per IS 15633:2005 shall be accompanied by the list of documents given in BIS website (www.bis.org.in). An application under simplified procedure shall be accompanied with the original test reports of type approval of family/range of tyres along with test reports from recognised BIS Outside laboratories as per IS 15633:2005 for which GOL has been requested. 1.4.1 RECORDING OF APPLICATION An application with its enclosures shall be scrutinized as per the check-list given in Annex-A to C. Recording shall be done when all pre-requisites have been addressed in the application with supporting documents. 1.4.2 INSPECTION The format for Preliminary Inspection report specific to Tyres shall be as given at Annex-D, in case of the application received under normal procedure.




ANNEX-D CM/PF 201

Sept 1995 BUREAU OF INDIAN STANDARDS

REPORT OF PRELIMINARY INSPECTION

Application No. CM/A- IR No………………… IS: Date of writing IR…………………. Product: 1.GENERAL INFORMATION

(a) Applicant’s Name

(b) Address: (i) Factory :

(ii) Office :

(c ) Date of Inspection:

(d) Situation of factory

(e) Telephone/Fax (i) Factory

(ii) Office

( f ) Management Staff

(g) Person(s) Contacted

1.1 BIS Licences, if any, held by the applicant REMARKS OF REVIEW OFFICER

1.

2.




3.

4.

5.

________________________________________________________________________

Signature:

Review Officer’s Name

& Designation :

Date of Review :

2. RAW MATERIALS

(a) Raw Materials used :

(See Annexure)

_________________________________________________________________________________ Sl. Raw Material Name of With or Without Test Certificate How Received No. Supplier BIS Certification of the supplier Batches/Lots Mark Nature of Package

(b) Arrangements for testing As received

(c ) Details of sampling

(d) Methods of Disposal of Sub-standard raw materials

(e) Record of tests with Proforma of records




3. MANUFACTURE

(a) Type/Grade/Variety being Manufactured at the time of inspection

(b) Description of process from Raw material to finished product Stage ready for dispatch(Also Enclose layout plan of the factory)

(c ) Intermediate points where control is exercised

(d ) Details of records maintained and Controls used

(e ) Method(s) of disposal of sub-standard Products

(f) Units of production

(g) Production per day of per shift

(h) Details of manufacturing machinery ( see proforma PF 305 Annexed)

(i) Technical comments on manufacturing Capabilities and inprocess controls

4. PACKAGING AND MARKING

(a) Nature of Packing

(b) Quantity per package

(c) Marking of article

(d ) Method of marking(printing, Stenciling, embossing, etc.)

(e) Form of Label(s), if any

(f) Batch or Code numbering for identification

(g) In what manner marking differs from the provision in the Indian Standard Specification




5. LABORATORY AND INSPECTION

(a) Details of staff

________________________________________________________________________

Sl. No. Name of Person Qualification Experience

________________________________________________________________________

(b) Competency of testing personnel

(c ) Equipment and other (See proforma PF 306 Annexed)

facilities for complete

testing as per the Indian

Standard Specification

Testing equipments/chemicals

not available

(d ) Accuracy of instruments and

arrangements for calibration

(e) Records maintained in laboratory

for routine tests

Sl. No. Requirement/Characteristics Values

(f) Stage of processing where Laboratory reports are made available (g) Sampling and testing of finished Products




6. SAMPLE

(a) Source of drawal(stock/production)

(b) Size of lot from which sampled

(c ) Type/Grade/Variety and Size of the sample

(d) Details of counter sample left with the firm

(e) Manner of packing, labeling, coding and sealing

(f) How sealed/ Give impression of seal used

(g) Laboratory to which despatched

(h) Test results on a sample tested in the factory

__________________________________________________________________________________

Requirements Value Value Recorded Remarks Tested Obtained by firm __________________________________________________________________________________

(i) Any further information regarding sample drawn

(j) Information regarding to other type/grade/variety applied for

(k) Comments on the testing capabilities

7. OTHER INFORMATION

(a) Main Buyers and selling price

(b) Storage facilities

(c ) Hygienic conditions(in case of

food products give complete note

as per relevant hygienic code)

(d) Discussion with the firm on

(i) STI and marking fee rate

(ii) The manner of putting the Standard Mark

(iii) Manner of manufacture and despatches

without Standard Mark in case of stoppage

of marking




8. INSPECTION/TESTING CHARGES Collected/Not collected(Give

details of collection)

9. CONCLUSIONS,RECOMMENDATIONS

AND POINTS FOR ACTION

Signature:

Inspected by:

No. of Encl.: (Name)

Designation :




1.4.3 The verification by BIS Inspecting Officer shall be reported in the format specific to Tyres and as given at Annex-E, in case of the application received under simplified procedure but not through a Chartered Engineer. 1.4.4 Aspects to be inspected During preliminary inspection/verification visit, for assessing capabilities of the applicant organization, with respect to manufacturing and testing facilities; competence of Quality Assurance Personnel shall be verified.




III SECTION – 2

RAW MATERIALS/COMPONENTS 2.0. GENERAL The following is the list of important raw materials/components required for manufacture of Automotive Vehicles – Pneumatic Tyres for Passenger Car Vehicles – Diagonal and Radial Ply as per IS 15633:

2.1 RAW MATERIALS/ COMPONENTS Natural Rubber Master Batch Calendar Roll Bead Wire Carbon Black Sulphur Activators Antioxidants Zinc Oxide Silica Lubricants Resins Stearic Acid VP Latex Precipitated Silica RM Sulphur Insoluble Sulphur Process Oil Paraffin Wax Resorcinol Formaldehyde Ammonia Silicon Oil Silicon Emulsion Peptsir Synthetic Rubber Latices Activators Vulcanizing Agents Tyre Cord Solvent




Annexure- II

RAW MATERIAL TEST

RAW MATERIAL CONTROLS – All the incoming raw materials shall be tested and proper records maintained before releasing material for production. Alternatively, the raw material shall be accompanied by the test certificate from the supplier. Recommended list of various raw materials is as given below:

Sl. No. Item Test

1. Natural Rubber a) Visual inspection b) Moisture content c) Ash content d) Dirt content e) Viscosity 2. Synthetic rubber a) Moisture content b) Ash content c) Viscosity d) Compound testing 3. Lattices a) Contents b) Viscosity c) TSC 4. Carbon black a) Moisture contents b) Ash content c) DBP value d) Iodine number e) Sieve residue 5. Activators a) Moisture content b) Sieve residue c) ASSAY d) Ash content e) HCL insoluble f) Acid number 6. Vulcanising agents a) Melting point b) Acetone insolubles c) Specific gravity d) Softening point e) Solubility




7. Process Oil a) Aniline point b) Viscosity c) Specific gravity 8. Tyre cord a) Wrap sheets i) Breaking strength ii) Percentage elongation iii) Twist iv) Moisture content b) Nylon square woven fabric i) Strip and grab strength ii) Adhesion iii) EPI 9. Bead wire a) Breaking strength/ b) Percentage elongation c) Torsion d) Bend test e) Adhesion f) Copper coating 10. Solvent a) Specific gravity b) Distillation range

Note : The list of raw materials are to be tested as per Annex-II and proper records are to be maintained. The list is not exhaustive.

2.2 SAMPLING PLAN The above raw materials shall be checked on each consignment or lots purchased from time to time as given above: (Annex-II)




SECTION – 3

MANUFACTURING PROCESS

3.0 The list of Manufacturing Machinery, description of manufacturing process and infrastructure for production for manufacture of Automotive Vehicles – Pneumatic Tyres for Passenger Car Vehicles – Diagonal and Radial Ply as per IS 15633 has given below:

List of Manufacturing Machinery

S. No Section Description 1 Banbury Banbury 11D-3Nos,F270-1No. 2 Extruder (U-1) Extruders (Unit-1) HFE & CFE 3 Bead Winding Machines 4 Bead Wrapping M/Cs 5 Bead Flipping machines 6 Slitter Machines 7 Banner Cutter 8 Tyre Building machines 9 Chafer folding machines 10

Tyre Building

Splice Jammers 11 Presses 12 Awling Machine 13 Balancing Machines 14

Tyre Curing

Trimming Machines 15 Dip Unit 74” Calendar

Dip/Calendar

36” Calendar (U-1/U-2) Note: Firm has to submit declaration regarding Manufacturing Machinery as per CM/PF 305 along with application.




CM/PF 305

(First Revision) March 1997

DECLARATION REGARDING MANUFACTURING MACHINERY

1. Application No. ____________________________________

2. Licence No. ______________________________________

3. Name/Address _____________________________________

______________________________________

Date Machinery Make Capacity Number Remarks




CM/PF 305

(First Revision)

March 1997

MANUFACTURING MACHINERY DECLARATION

I hereby declare that the machinery of which details are given overleaf is owned by me and are actually installed in the premises*. Sig. of Firm’s Representative _______________ Name _______________ Designation ______________ Date _______________ * I also declare that in case of grant of licence , I will send prior intimation to BIS whenever any machinery is taken out of the premises of the firm due to any reason.

I have checked and found that machinery of which details are given overleaf was available during my inspection. Sig. of BIS I.O. _______________________ Name _______________________ Designation _______________________ Date of verification _________________




3.1 PROCESS DESCRIPTION 3.1.1 INSPECTION/TESTING: Raw materials like Rubber, Latex, Tyre Cords, Bead Wire, Rubber chemicals etc are accepted based on supplier’s test reports & are tested. 3.1.2 MIXING: Rubber, Filler & Rubber chemicals are mixed into a homogenous compound in Banbury and made into sheet from in the mill. 3.1.3 EXTRUSION: Pre-forming of Rubber compound by forcing the materials through a fixed die to obtain a definite profile in extruder. This extrudate is cooled and cut into required length to produce the treads/side wall. 3.1.4 DIPPING: Tyre cord is dipped in Resorcinol Formaldehyde latex solution and stretched in dip unit to produce Dipped Fabric. 3.1.5 CALENDERING: Dipped Fabric is coated with rubber compound on both the sides to the required thickness in calender and cooled to produce Calendered Fabric. 3.1.6 BIAS CUTTING: The Calendered Fabric is cut into required width in Bias Cutter, spliced and rolled into continuous length using cloth liners. 3.1.7 BEAD WINDING: Bead wires are coated with rubber and wound into required diameter in Bead Winding machine. These Beads are subsequently wrapped/flipped with Calandered Fabric to produce flipped/wrapped bead. Apex is applied wherever applicable. 3.1.8 TYRE BUILDING: All the components made by the above process (i.e., cut ply, tread, side wall, bead, etc.) are assembled in Tyre Building machine in the specified sequence to produce green tyre. 3.1.9 TYRE CURING: Green Tyre is vulcanized in tyre curing press under high pressure and temperature. Mould and bladder gives the required shape and pattern to the tyre. 3.1.10 FINAL INSPECTION: The cured tyres are subjected to 100% visual inspection carried out as per IS/STI of 15636. The tyres are then sent to godown for shipment.




3.2 PROCESS CONTROL – The frequency of inspection and parameters shall be according to the approved plant quality audit programme. The areas of manufacturing given in Annexure-III shall be covered in this programme. During each stage, the given parameters and equipment set up shall be controlled, audited and recorded.

Annexure III

Area Parameters to be controlled 1. Compounding Ingredient weights. 2. Mixing Time/Temperature or Energy, sequence 3. Dip Preparation Ingredient weights, time,

temperature sequence 4. Dipping Temperature, stretch/tension, speed/time, width. 5. Extrusion Stock identification, temperature, width, dimensions. 6. Calendering Stock/fabric identification, temperature, width, gauge. 7. Bead making Stock/wire identification, diameters, No. of strands, No. of turns. 8. Stock preparation Stock identification, width, angle. 9. Tyre building Component identification, sequence. 10. Tyre curing Time, temperature/pressure, sequence. 11. Final Inspection : Every tyre shall be visually inspected for defects and appearance. 12. In process Testing In process materials shall be tested as given below: a) COMPOUND Final batch Sp, Gravity Rapid Modulus Rheometer Test Physical Properties




Area Parameters to be controlled b) DIP SOLUTION Final Total solids pH value c) DIPPED FABRIC Tyre Cord warp sheet Breaking strength % Elongation Adhesion & Dip pick up Sq. Woven nylon fabric E.P.I. Strength Adhesion and dip pick up d) CALENDERED FABRIC Tyre cord warp sheet E.P.I. Gauge Sq. Metre weight Sq. woven fabric Gauge Sq. Metre weight




SECTION – 4

CERTIFICATION CRITERIA

4.1Application for type approval to be submitted by the manufacturers shall meet the test requirements when tested as per schedule given in Table 1 of each family of tyres before submission of application.

Type Test Schedule (Table 1)

Sl. No. Tests Tyre 1 Tyre 2 Tyre 3 Tyre 4

(1) (2) (3) (4) (5) (6) i) Tyre marking √ - - - ii) Tyre Dimensions √ - - - iii) Tread wear indicator √ - - - iv) Tyres strength test √ - - - v) Endurance test - √ - - vi) Load/speed performance

test - - √ -

vii) Bead Unseating Resistance Test for tubeless Tyres

- - - √

4.1.1 The application for type approval shall contain atleast the technical information as specified in 4.1.2.

4.1.2 INFORMATION TO BE SUBMITTED FOR TYPE APPROVAL OF TYRES

Manufacturer’s name and address Telephone No.: FAX No.: E-mail Address: Contact Person; Tyre-size designation; Trade-name or mark; Category of use (normal/special/snow); Structure: diagonal (bias ply/bias belted)/radial; Speed Category Load Index of the tyre/maximum load carrying capacity (kg) Whether the tyre is to be used with or without an inner tube; Whether the tyre is normal or reinforced; Ply rating no. of tyres for (for code designated tyres) Overall section width (mm); Overall diameter (mm) Rim on which tyre can be mounted; Measuring rim and test rim;




Inflation pressure (bar) Inflation pressure corresponding to maximum load carrying capacity Test and measurement pressures

Factor X referred in 3.31 in case of theoretical (imaginary) rim, if applicable; Maximum speed permitted by the tyre manufacturer and the load carrying capacity

allowed for that maximum speed applicable only for tyres identified by means of letter code “V” within the size designation and suitable for speeds over 240 km/h or for tyres identified by means of letter code “Z” within the size designation and suitable for speeds over 270 km/h;

Intended for use on (type of vehicle); Numbers and height of tread wear indicator; Type of tread pattern (Lug or rib); and Drawing or photograph in triplicate identifying tyre tread pattern side wall marking

and relevant dimensions of inflated tyre mounted on the measuring rim. 4.1.2. CRITICAL TEST REQUIREMENTS The following tests shall be carried out as per IS 15633 a. Tyre dimensions i) Section width of tyre ii) Tyre outer diameter b. Load/Speed performance test c. . Endurance Test d. Bead Unseating Resistance Test for Tubeless Tyres d. Tread wear indicators e. Tyres strength 4.2. SCHEME OF TESTING AND INSPECTION Scheme of testing and inspection as per IS 15633:2005 Automotive Vehicles – Pneumatic Tyres for Passenger Car Vehicles – Diagonal and Radial Ply, presently the Doc: STI/15633/3, February 2012 for Pneumatic Tyres for Passenger Car Vehicles as per IS 15633:2005 is in operation for both domestic and foreign manufacturers.




SCHEME OF TESTING AND INSPECTION

Doc: STI/15633/3, February 2012

SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF

AUTOMOTIVE VEHICLES – PNUEMATIC TYRES FOR PASSENGER CAR VEHICLES – DIAGONAL AND RADIAL PLY

ACCORDING TO IS 15633:2005

(Copy enclosed)




4.3 MARKING FEE RATES The rate of marking fee for Certification of Automotive Vehicles – Pneumatic Tyres for Passenger Car Vehicles – Diagonal and Radial Ply as per IS 15633 has given below: Minimum Marking Fee: Rs. 2,46,000/- for Large Scale manufacturing units and Rs. 2,09,000/- for Small Scale manufacturing units During an operative period of one year Unit Rate: Rs. 2.00 for first 1,00,000 units; Rs. 1.50 for next 1,00,000 units and Rs. 1.35 for the remaining units (Unit=One Tyre) Note: This marking fee as per CMD Circular ref: CMD-3/16:15633 dated 26.09.2012 4.4 GROUPING GUIDELINES There are no grouping guidelines available for grant of licence/inclusion of new varieties of Automotive Vehicles – Pneumatic Tyres for Passenger Car Vehicles – Diagonal and Radial Ply as per IS 15633:2012. However, type approval for each family/range of tyres shall be tested at Outside Laboratory for grant/inclusion of varieties. 4.5 SAMPLE SIZE For conformity of production test minimum 4 no’s of samples of each family/range shall be drawn for testing as given in the Table 3

Conformity of Production Tests/Acceptance Tests (Table 3)

Sl. No. Tests Tyre 1 Tyre 2 Tyre 3 Tyre 4

(1) (2) (3) (4) (5) (6) i) Tyre marking √ - - - ii) Tyre Dimensions √ - - - iii) Tread wear indicator √ - - - iv) Tyres strength test √ - - - v) Endurance test - √ - - vi) Load/speed performance

test - - √ -

vii) Bead Unseating Resistance Test for tubeless Tyres

- - - √

After carrying out the above test all the samples shall be disposed off.




SECTION – 5

INSPECTION & TESTING

5.1 The list of test equipments is to be prepared/provided by CL. However, the following test equipment/facilities is required for testing Automotive Vehicles – Pneumatic Tyres for Passenger Car Vehicles – Diagonal and Radial Ply as per IS 15633:2005.

Test Equipment Declaration Sl No

Test Equipment/Chemicals & identification Numbers where applicable

Least count & Range (where applicable)

Valid Calibration (where required) Yes/No

Tests used in with clause reference

1 Plunger tester machine ID no:PT-TW 005 Load 1 kg &

0-1000 kgf Tyre Strength


0-5000 kgf Tyre Strength


0-10,000 kgf Tyre Strength

4 VMI Plunger Tyre test Machine ID no: PT-TW 009

Load 1 daN & 0-1000 daN

Tyre Strength

Measuring Instruments 5 Pie tape 300-600mm 6 Pie tape 600-900mm 7 Pie tape 900-1200mm 8 Measuring tape 1 mm &

0-3.0 m

9 Digital Vernier Calliper 0.01mm & 0-200mm

10 Digital depth gauge 0-25mm 11 Dial Pressure Gauge-ODIN 0-160PSI 12 Digital Pressure Gauge-KELLER 0 to 30kg/cm2

Dimensional measurements

Note: Firm has to submit declaration regarding Test Equipment/Facilities as per CM/PF 306 along with application.




CM/PF 306 (Second revision)

May 2001 DECLARATION REGARDING TEST EQUIPMENT

No entry to be crossed

1. Application No. ____________ 2. Licence No. ______________

3. Name /Address __________________

Sl. No. & Date

Test Equipment/Chemicals and Identification Numbers (Where applicable)

Least Count & Range (Where applicable)

Valid Calibration (Where required) Yes/No

Tests Used in with Clause Reference

Remarks (Indicate number of Equipment)




CM/PF 306 (Second revision)

May 2001

TEST EQUIPMENT DECLARATION

I hereby declare that the test equipments of which details are given overleaf are owned by me and are actually installed in the premises.

I also declare that in case of grant of licence, I will send intimation to BIS whenever any equipment is taken out of the premises of the firm due to any reason.

Signature of firm’s

Representative

_____________________

Name _________________________

Designation________________________

Date ___________________________

I have checked and found that the test equipment of which details are given overleaf were available during my inspection.

Sig. of BIS I.O. _____________________

Name _________________________

Designation________________________

Date of verification _________________




5.2 STATUS OF TEST FACILITIES There are no test facilities available in BIS labs for testing Automotive Vehicles – Pneumatic Tyres for Passenger Car Vehicles – Diagonal and Radial Ply as per IS 15633:2005. However, the following is the list of Outside recognised laboratories:

List of Outside Recognized Laboratories

Sl No.

Name of the Recognized Laboratory Lab Code Testing Charges Remarks

1 Indian Rubber Manufacturers Research Association, 16/V, 254/1B Wagle Industrial Estate, Thane (West)-400604 Maharashtra Contact : Dr.K.Thavamani, Director & Sh.K.Rajkumar,QM Tel : 022-25811348, 23910 Fax : 022-25823910

7119305 Rs. 95500/- for Tubeless and Rs. 89000/- for tube type

included w.e.f. 15.03.2010

2 Gujarat Test House Plot No.292, Road No.4, GIDC Kathwada Ahmedabad-382430 Gujarat Contact : Shri A.N. Barua, CEO Tel : 09825063601 Fax : 079-22168817

7109836 Rs. 59,000/-( With tube); Rs. 61,000/-(Tube less)

Included w.e.f.07-Feb-2013

3 Automotive Research Association Of India,(ARAI) S.No.102, Vetal Hill, Off Paud Road, Kothrud, Pune-411038 Maharashtra Contact : Shri A.V. Mannikar Tel : 020-3023 1100/1350 Fax : 020-30231104

7106935 Rs. 123,360/-

4 Central Institute Of Road Transport, (CIRT) Pune Nasik Road Bhosari Pune-411026 Maharashtra Contact : Shri N.R.Kachare, Sc E & Head ED-1 Tel : 09822744918, Fax : 020-67345407

7105101 Rs.110600/- for All Load Index and speed L to Y [10% discount to BIS]

'Second Load / Speed performance Test(Cl.4.2.2)' will be sub-contracted to M/s IRMRA, Thane




5 International Centre for Automotive Technology Plot No.26, Sector-3, HSIDC, IMT Manesar Gurgaon-122050 Haryana Contact : Mr. Dinesh Tyagi, Director Tel : 0124-4586100,4586111 Fax : 0124-2290005

8123734 Rs.86,000/- FOR TESTING OF PNEUMATIC TYRES(TUBELESS)AS PER IS:15633

Included w.e.f. 18-July-2013

5.3 PROCEDURE FOR GRANT OF LICENCE Grant of Licence shall be granted based on type approval Independent testing basis. 5.4 TEST TO BE CARRIED OUT IN FACTORY

a. During Preliminary/Verification/Surveillance inspection, all possible tests shall be carried out in the factory. A sample shall also be drawn for independent testing for which the testing charges shall be borne by BIS. b. No market samples shall be drawn due to its high cost.




CM/PF 251 July 1995

BUREAU OF INDIAN STANDARDS REPORT OF PERIODIC INSPECTION/LOT INSPECTION

(Put √ mark on the appropriate nature of inspection)

(. .. . . . . . . . . . . . inspection since the grant of licence/Renewal)

CM/L - IR No.. . . . . . . . ..

Valid upto: Date of writng IR . . . . . . .

1. a) Licensee

IS

Product

Size/Grade/Variety

b) Other license(s) held CM/L . . . . .. . . . . IS Product

2. Special inspection charges, if applicable How realized/ Cheque/Draft

Not realized Details

3. Date of inspection

4. Person(s) contacted

5. Previous inspection

a) Date b) Conducted by

c) Conclusions and recommendations

d) Despatch details of last 2 samples

------------------------------------------------------------------------------------------------------------

Sl. No. Date of drawl Date of dispatch Test Result: Pass/Fail

of sample of sample if available

-----------------------------------------------------------------------------------------------------------

1.

2.




-----------------------------------------------------------------------------------------------------------

6. ACTION ON ADVICE RENDERED IN PREVIOUS INSPECTION OR OTHERWISE

ASKED FOR WHILE GRANTING LICENCE /RENEWAL OF THE LICENCE

________________________________________________________________________

REMARKS OF THE REVIEWING OFFICER (ON IRS, TRS , GENERAL ETC)

______________________________________________________________________________________

7. changes since previous inspection:

a) Technical

b) Administrative

8. Description of the Article(s) being manufactured

at the time of inspection

9. Raw Materials:

a) Name of major ones Supplied by

b) Does the firm test the major raw materials or does it

depend on the Test Certificate from supplier ?

c) In either case note the maximum and minimum values of principal requirements

Sl. No. Requirements Variation in Test Values

1.

2.

3.

4.

d) Disposal of the sub standard raw materials

10. Production and supply since last inspection (details of completed month to be furnished)




Month Quantity

a) Quantity produced

b) Quantity marked

c) Quantity unmarked and manner of disposal

d) Reasons for not marking

e) Parties supplied to (Give complete address):

11. Storing, Packing and marking of BIS certified material

a) Material held in stock

b) Condition of storing

c) Packing and marking on packages

d) At what stage marking is done (After or before test results are known)

e) Any change in the marking procedure from approved one

12. Production control

(As observed from text and other relevant materials)

a) How is control system being operated? Satisfactorily/Not satisfactorily

b) Variation in test result for principal requirements (append test results , if necessary

or if requires by the Instruction sheet for the standard)

Sl. No. Requirement Variation in Test Values




c) Are the test records being maintained

satisfactorily vis-à-vis the STI for the

product licenced ?

d) What is the percentage of rejection, their

reasons and manner of disposal?

(Indicate batches disposed)

f) Whether the failure is due to inherent cause(s) or chance cause(s) ?

13 Testing in factory

a) Description of the sample: Batch/ C.U. Date of Requirement Value Recorded Remarks

Tested Manufacturing Tested Obtained Value

b) Are the instruments used calibrated periodically ? Instruments Date of Remarks

Calibrated Calibration

c) Are the instruments reasonably

accurate ?

d) Any addition to the existing testing

equipments

e) Any comments on testing, testing

equipment, testing personnel etc

14. Samples for Independent Tests

a) Sl. No. Description Batch/C.U. No. Date of Mfg.

Type/Grade/Size/Variety




b) From where sampled (Stock or production

line ) ?

c) Test record of the batch from which

sample is drawn

Sl. No. Requirement Recorded Test Value

d) Give details of packing, labeling, coding,

etc of the sample

e) How sealed ? Give impression of the seal used

f) Samples brought in or left with the firm for

despatch to BIS or outside testing lab ?

g) Details of the counter sample left with the firm

and the manner of packing, labeling, coding,

sealing etc and also give impression of the seal

h) Any further information

15. Food Articles

(Indicate the hygienic conditions maintained

in the factory surroundings, in the plant ,

equipment, personal hygiene, general

remarks etc.)

16. Conclusions and Recommendations

a) Has the scheme operated satisfactorily for Satisfactory/ Unsatisfactory

the period since last inspection ?

b) If operated unsatisfactory, give reasons

c) Assessment of the operation of the scheme

based on the present vis-à-vis past

performance




d) Any discussion with the form on any point

of interest, such as manufacturing difficulties,

in-process control, testing procedure or any

difficulty/irregularities observed in the operation

e) Any action to be taken including suspension

f) Any other observation/comments for better

appraisal of the report

Signature:

No. of Encl.: Inspected by:

(Name)

Designation:

Station: Date:

5.5 RAW MATERIAL SAMPLES No Raw material samples testing is required during the inspection.

STI/15633/3,Februrary 2012

Page 1 of 11

SCHEME OF TESTING AND INSPECTION

FOR CERTIFICATION OF AUTOMOTIVE VEHICLES – PNEUMATIC TYRES

FOR PASSENGER CAR VECHICLES – DIAGONAL AND RADIAL P LY ACCORDING TO IS 15633:2005

1. LABORATORY – A laboratory shall be maintained which shall be suitably equipped and staffed where different tests given in the specification shall be carried out in accordance with the methods given in the specification.

2. TEST RECORDS - All records of tests, inspection and calibration shall be kept in suitable forms approved by the Bureau.

2.1 All testing apparatus/measuring instruments shall be periodically checked and calibrated and records of such checks/calibration shall be maintained.

2.2 Copies of any records and other connected papers that may be required by the Bureau shall be made available at any time on request.

3. QUALITY CONTROL – It is recommended that, as far as possible, Statistical Quality Control (SQC) methods may be used for controlling the quality of the product during production as envisaged in this Scheme [See IS 397 (Part I) to IS 397 (Part 4)].

3.1 In addition, effort should be made to gradually introduce a Quality Management System in accordance with IS/ISO 9001.

4. STANDARD MARK – The Standard Mark, as given in Column (1) of the First Schedule of the licence, shall be embossed on each tyre, provided always that each tyre to which this mark is thus applied conforms to every requirement of the specification.

4.1 OTHER MARKING - In addition the information given in Annex I shall be marked on each tyre.

5. LEVELS OF CONTROL - The tests, as indicated in Table 1 attached and at the levels of control specified therein, shall be carried out on the whole production of the factory which is covered by this scheme and appropriate records and charts maintained in accordance with paragraph 2.0 above. All the production which conforms to the Indian Standards and covered by the licence shall be marked with certification mark of the Bureau.

5.1 Only those finished product which meet all the requirements of the specification shall be considered fit to be covered under the BIS certification Marks Scheme.


Page 2 of 11

5.2 RAW MATERIAL CONTROLS – All the incoming raw materials shall be tested and proper records maintained before releasing material for production. Alternatively, the raw material shall be accompanied by the test certificate of the supplier. Recommended list of various raw materials is given in Annexure II.

5.3 PROCESS CONTROL – The frequency of inspection and parameters shall be according to the approved plant quality audit programme. The areas of manufacturing given in Annex III shall be covered in this programme. During each stage, the given parameters and equipment set up shall be controlled, audited and recorded.

5.4 TYPE APPROVAL/TYPE TEST : For type approval/type test, the procedure stipulated under clause 6 and Table 19 of IS 15633 shall be followed for each family of Tyres before permission is granted for covering the tyres under BIS Certification Marks Scheme. The procedure as given in cl. 6.2.3 to 6.2.5 of IS 15633 shall be followed when there are changes in the technical specification of already approved tyres or for extension of type approval.

5.5 CONFORMITY OF PRODUCTION TEST/ACCEPTANCE TEST : During operation of licence, the procedure stipulated under Clause 7.1 to 7.4 and Table 20 of IS 15633 shall be followed for conformity of production test/acceptance test.

6.0 REJECTIONS – A separate record shall be maintained giving information relating to the rejection of the production not conforming to the requirements of the specification and the method of its disposal. Such material shall in no circumstances be stored together with that conforming to the specification.

7.0 SAMPLES – The licensee shall supply, free of charge, the samples required in accordance with the Bureau of Indian Standards (Certification) Regulations, 1988, as subsequently amended, from the factory or godowns. The Bureau shall pay for the samples taken by it from the open market.

8.0 REPLACEMENT – Whenever a complaint is received soon after the goods with Standard Marks have been purchased and used, and if there is adequate evidence that the goods have not been misused, defective goods or their components are replaced or repaired free of cost by the licensee in case the complaint is proved to be genuine and the warranty period (where applicable) has not expired. The final authority to judge the conformity of the product to the Indian Standard shall be with the Bureau. The firm shall have own complaint investigation system as per IS/ISO 10002.

8.1 In the event of any damages caused by the goods bearing the Standard Mark, or claim being filed by the consumers against BIS Standard Mark and not “conforming to” the relevant Indian Standard, entire liability arising out of such non conforming product shall be of licensee and BIS shall not in any way be responsible in such cases.


Page 3 of 11

9.0 STOP MARKING – The marking of the product shall be stopped under intimation to the Bureau if, at any time, there is some difficulty in maintaining the conformity of their product to the specification, or the testing equipment goes out of order. The marking may be resumed as soon as the defects are removed under intimation to Bureau. 9.1 The marking of the product shall be stopped immediately if directed to do so by Bureau for any reason. The marking may then be resumed only after permission by the Bureau. The information regarding resumption of markings shall also be sent to the Bureau.

10.0 PRODUCTION DATA – The licensee shall send to BIS as per the enclosed proforma-1 to be authenticated by a Chartered Accountant statement of quantity produced, marked and exported by him and the trade value thereof at the end of each operative year of the licence.

Table 1…


Page 4 of 11

IS 15633:2005

AUTOMOTIVE VEHICLES – PNEUMATIC TYRES For Passenger Car vehicles (Diagonal and Radial Ply )

TABLE 1 LEVELS OF CONTROL (Para 5 of the Scheme of Testing and Inspection)

TEST DETAILS LEVELS OF CONTROL

Test Methods Cl. Requirement Clause Reference

No. of Samples

Frequency Remarks

4.1 Tyre Dimensions Annex B&C Table 7 to 12

IS 15633: 2005

1 Once in three months for each variety

4.2 Load/Speed Performance test

Annex D Table 13

-do- 1 Once in three months

4.3 Endurance Test Annex E Table 14


4.4 Bead Unseating Resistance Test for tubeless tyres

Annex F Table 15

& 16


4.5 Tread wear indicators

4.5.1 to 4.5.3.

-do- 1 Once in three months for each variety

4.6 Tyre Strength Test (PlungerTest)

Annex G Table 17

& 18


1. In case of failure in any requirement, the marking shall be suspended, reasons for failure investigated and corrective actions taken. Double the no. of samples indicated shall then be tested and marking & original frequency restored only if, both samples pass. 2) Samples may be drawn and tested as per clause 4.2, 4.3, 4.4 & 4.6 in such a way that all varieties of tyres manufactures are covered once in two years.

5 Marking 5 Annex H

and J

-do- Each Tyre

6 Type Approval/ Type Test

6.1 to 6.2.5

Table 19 Annex K.

-do- one Each family of Tyre

At the time of initial approval or whenever there is any change in already approved family of tyres.

Note- Definition of ‘Variety’-The tyre defined uniquely by tyre size designation, structure, speed category, load index, ply rating and category of use. For example 5.65-12, Bias-ply, 60 H, 4 PR, Normal & 5.65-12, Bias-ply, 60 H, 6 PR, Normal are two different varieties of tyres.

Annexure - I….


Page 5 of 11

Annexure - I

MARKINGS - (Cl.5 of IS 15633:2005)

5.1 Tyre shall be permanently and legibly marked on both the sides of their sidewalls in the case of symmetrical tyre and at least on the outer sidewall in the case of asymmetrical tyre shall bear following markings :

a) Make (manufacturer’s name) or trade name shall be placed at least on one

side wall. b) Tyre size designation given in 3.17 c) An indication of the structure as follows :

1) On diagonal (bias-ply) tyres: no marking or character ‘_’, or the letter ‘D’

placed in front of the rim-diameter marking 2) On radial-ply tyres: the letter ‘R’ placed in front of the rim-diameter

marking and, optionally, the word ‘RADIAL’ 3) On bias – belted tyres, the letter ‘B’ placed in front of the rim-diameter

marking, and in addition the word ‘BIAS-BELTED’ 4) On radial – ply tyres suitable for speeds higher than 240 km/h the letter ‘R’,

placed in front of the rim diameter marking, may be replaced with ‘ZR’. d) The speed-category symbol (or symbols),

i) An indication of the tyre’s nominal speed category in the form of the

symbol given in 3.28 ii) Tyres suitable for speeds in excess of 300 km/h must be marked with the

service description (load index and speed symbol) corresponding to the performance up to 300 km/h.

e) The inscription ‘M+S’ or ‘M.S’ or ‘M&S’ in the case of snow tyre. f) The load index given in Annex A or maximum load carrying capacity and ply

rating (if applicable). g) Maximum permissible tyre pressure in kPa or bar or kg/cm2 or any combination of

this units. h) The word ‘TUBELESS’ if the tyre is designed for use without an inner tube,

J) Manufacturer’s Code (May be placed on one side wall) k) week and year code (code only in the form of ‘2504’ which indicates 25th

week of year 2004) or month and year code of manufacturer (code only in the form of MAR 04’ which indicates march month of year 2004);

m) In the case of tyres which can be regrooved, symbol ‘U’ at least 20 mm in

diameter, or the work ‘REGROOVABLE’, moulded on the sidewall. 5.2 Example of Tyre size designation given in Annex ‘H


Page 6 of 11

5.3 Tread wear indicators marking shall be provided at minimum six/four (as

applicable) places along the circumference to give indication to the user for location of tread wear indicator.

5.4 The markings given in 5.1 shall be moulded into or on the tyres. These shall be

clearly legible and situated in the lower area of the tyre on at least one of its side walls, except for the inscription given in 5.1.The layout for tyre markings given in Annex ‘J’.

ANNEXURE II……..


Page 7 of 11

ANNEXURE II

RAW MATERIAL TEST (See Clause 5.2)

Sl. No. Item Test

1. Natural rubber a) Visual inspection

b) Moisture content c) Ash content d) Dirt content e) Viscosity

2. Synthetic rubber a) Moisture content

b) Ash content c) Viscosity d) Compound testing

3. Lattices a) contents

b) Viscosity c) TSC

4. Carbon black a) Moisture contents

b) Ash content c) DBP value d) Iodine number e) Sieve residue

5. Activators a) Moisture content

b) Sieve residue c) ASSAY d) Ash content e) HCL insoluble f) Acid number

6. Vulcanising agents a) Melting point

b) Acetone insolubles c) Specific gravity d) Softening point e) Solubility


Page 8 of 11

Sl. No. Item Test

7. Process oil a) Aniline point b) Viscosity 8.

Tyre cord

c)

a)

Specific gravity

Warp sheets i) Breaking

strength ii) Percentage

elongation iii) Twist iv) Moisture

content

b) Nylon square woven fabric i) Strip and grab

strength

ii) Adhesion iii) EPI

9.

Bead wire

a) b) c) d) e) f)

Breaking strength/ Percentage elongation Torsion Bend test Adhesion Copper coating

10.

Solvent

a) b)

Specific gravity Distillation range

Note : The list of raw materials to be tested and proper records maintained (See clause 5.2). The list is not exhaustive.

ANNEXURE III…..


Page 9 of 11

1.

Area

Compounding

ANNEXURE III Parameters to be controlled

Ingredient weights.

2.

Mixing

Time/Temperature or Energy, sequence

3.

Dip Preparation Ingredient weights, time,

temperature sequence 4.

Dipping

Temperature, stretch/tension, speed/time, width. 5.

Extrusion

Stock identification, temperature, width, dimensions. 6.

Calendering

Stock/fabric identification, temperature, width, gauge. 7.

Bead making

Stock/wire identification, diameters, No. of strands, No. of

turns. 8.

Stock preparation

Stock identification, width, angle.

9.

Tyre building

Component identification, sequence.

10.

Tyre curing Time, temperature/pressure,

sequence. 11.

Final Inspection :

Every tyre shall be visually inspected for defects and appearance.

12.

In process Testing

In process materials shall be tested as given below :

a) COMPOUND

Final batch

Sp, Gravity Rapid Modulus Rheometer Test

Physical Properties


Page 10 of 11

b)

Area

DIP SOLUTION

Parameters to be controlled

Final

Total solids PH value

c)

DIPPED FABRIC

Tyre Cord warp sheet

Breaking strength % Elongation Adhesion & Dip pick up

Sq. woven nylon fabric

E.P.I. Strength Adhesion and dip pick up

d)

CALENDERED FABRIC

Tyre cord warp sheet

E.P.I. Gauge Sq. metre weight

Sq. woven fabric

Gauge Sq. Metre weight

Proforma 1….


Page 11 of 11

Proforma - 1

PROFORMA FOR OBTAINING PRODUCTION DETAILS

Period covered

Name of Licensee

CM/L No.

Name of Articles (s) IS No.

Grade/Type/Size/Variety/Class/Rating

1.1 Brand/Trade/Name(s) of BIS Certification Marked Products

2.0 Total production of the articles(s)

Licensed for certification marking

2.1 Total production of the article(s)

Conforming to Indian Standard

3.0 Production covered with BIS Certification Mark and its

Value

a) Quantity b) Value (Rs.)

3.1 Brand Name used on production covered under BIS Certification Mark

3.2 Calculation of marking fee on unit-rate basis; Marking Fee per unit

a) Unit

b) Quantity covered with BIS Certification Mark

c) Marking fee rounded off in whole rupees as obtained by applying unit rates given in (a) on quantity given in (b)

Note: Incase a clause is not applicable, suitable remarks may be given against it.

4.0 Quantity not covered with BIS Certification Mark. If any, and the reasons for such non-coverage

4.1 Brand Name under with non certified goods were sold

5.0 Quantity Exported with BIS Standard Mark and its value

5.1 Brand Name under which BIS Certified goods are exported

6.0 Authentication by Chartered Accountant

Documents

BUREAU OF INDIAN STANDARDS (Southern Regional Office) › qazwsx › oth › 60CM15633.pdfThe Tyre is so made that can be used by mounting and inflating on the appropriate rim. The