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Precision Engineering Complex

(PEC)

The Precision Engineering Complex, PIA's youngest division,

was created in 1978 to manufacture products for the

commercial aviation industry. Today, the PEC is a world-class

manufacturing enterprise, powered by state-of-the-art

machinery and technology, and an exceptional team of

engineers and technicians.

The PEC is a reliable supplier to Boeing Commercial Airplane

Group of USA, SNECMA of France, General Electric AircraftEngine of USA, Daimler-Benz Aerospace Airbus (formerly

Deutsch Aerospace) of Hamburg, and Fisher Advanced

Composite Components (FACC) of Reid, Austria. The PEC has

earned these contracts through transparent, competitive

bidding, and by adhering to consistent Quality Standards and

on-time delivery. Supplying products for the assembly lines

of global aviation heavyweights has garnered prestige and

international recognition for the PEC and it has emerged as atruly great corporation.

Amongst the PEC's myriad achievements, was the

manufacture of a series of metallic parts that are used for

attaching overhead stowage compartments with the interiors

of A320/A321 aircraft. These parts were commissioned by

the FACC of Austria in 1993 and the PEC took up the

manufacturing challenge, resulting in many more contracts

over the years.

The unflinching support of PIA's Logistics and Procurement

divisions, over the years, has enabled the PEC to acquire raw

materials from FACC-approved sources in Europe and North

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America. This backing has truly helped the PEC to fulfill its

mission of making one-time deliveries to global customers.

PRINTED CIRCUIT BOARD

(PCB)

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PCB Manufacturing:The PEC is equipped with a modern PCB

manufacturing facility powered by state-of-the-art technology. The PCB

division has the capability of producing 80 square feet of Printed Circuit

Boards in a single shift operation. Customized PCBs can also be produced

according to customer specifications.

TYPES OF PCB:

Single layer PCB

Double layer PCB

Multilayer PCB

Flexible or ribbon layer PCB

LAYERS OF PCB: Top layer

Bottom layer

Drill layer

WORK ORDER:The user can provide the pattern of PCB in four

different ways.

1. Same PCB which user wants.

2. By giving any logic diagram of circuit which has to be implemented

on PCB.

3. By giving any PCB design using CAD software.

4. By providing Photo tool.

MANUFACTURING PROCESS:

Drilling & routing:

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A/c to the required PCB design CNC program in

develop and using CNC machine Up to three PCBs can be drilled and

routed at the same time.

Through Hole Process:It is electro less plating.

Yellow Room:In this room film is laminated on the PCB. Only yellow

light is use in this room in any other light it will be expose from its

connection. An other machine is use to expose the lamination.

After this process a machine is use, this is divided into three sections.

1. Card develops.

2. Card wash (Water is used for washing purpose)

3. Drying the card.

Electro Plating:In this process either Tin Lead or Copper platting is

use.

Film Stripping:Potassium Hydroxide is use to remove film from sheet.

Copper Etching:A liquid (Accu guard) is use for copper etching.

Brightening:After copper etching an infra red fusing system is use to

melt Tin Lead at 260C due to this process Tin Lead shines.

Gold Plating:This process is use if it is necessary in some PCBs.

Solder Masking:A paper type substance called Polyester Mash is use

for solder masking and all other PCB is coated with green ink this is called

Green Ink Mask.

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Multilayer PCB:In multilayer PCB there are several layers use to

combine to form a single PCB. The purpose to make multilayer PCB is to

compact the size of electronic circuit. PEC has made up to 10 layers of

PCB. All the PCBs are combine and melt at 170C after this processmultilayer PCB is complete. In multilayer PCB, PCB drill in the last stage.

PROCESS FOR SINGLE AND DOUBLE SIDED

PCBs

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PROCESS FOR MULTILAYER PCBs

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PCB QUALITY ASSURANCE

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Inspection stages during production.

First article Inspection

In-process Inspection

Final Inspection

FIRST ARTICLE INSPECTION:Inspection of the first piece of

the lot, Process, Batch, Method to ensure its compliance to specification and

customer requirements.

IN-PROCESS INSPECTION:Stage wise checks to ensure that

the criteria set forth by first article is maintained through out the processing.

FINAL INSPECTION:Inspection of the finished PCBs to ensure

that the final product is as per specification.

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ELECTRICAL MAINTENANCE

CNC Machines

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Computer Numerical Controllingmachines are special purpose machines

used to make any mechanical part according to the programming

programmed by a user through computer.

CNC machine consists on the following parts.

NC

PLC

Pneumatic/Hydraulic System

Measuring System

Drives

NC: Numerical controlling consists of electronic and electrical devices.

NC executes according to the programming.

PLC: Programmable Logic Controller is divided into three parts.

1.Main Processor

2.Communication Module

3.I/O Devices

Pneumatic System:Pneumatic System uses air to perform certain tasks.

Hydraulic System:Hydraulic System uses liquid to perform certain

tasks.

Measuring Systems:Normally two measuring systems are used.

1. Linear Scale

2. Rotary Scale

Drives:Drives are of two types

1. AC Drives

2. DC Drives

AC Drives:

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AC Drives are controlled through frequency.

DC Drives:

DC Drives are controlled through armature voltage and field

current.

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QUALITY CONTROL

QUALITY POLICY OF PEC

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Precision Engineering Complex is committed to be a leader and

innovator in providing products and other diverse engineering

discipline for both domestic and global market place.

It is their policy to achieve customer satisfaction by ensuringthat supplies and service adhere to contractual specifications and

also meet or exceed their needs and expectation.

Continual improvement will be achieved through adoption of

quality system, which provides a structure for setting of quality

objectives, active participation, organized education and training

of all personnel.

Q/A SYSTEM REQUIREMENTS

Adaptation to international standard/Spec

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Quality policy

Q/A organization

Evaluation selection & approval of sources for procurement if materials.

Purchases control & receiving inspection

Manufacturing/Process control system

Establishment of standard labs for calibration of instruments and citification

of materials.

Inspection & testing system.

Non conformance control and corrective action.

Internal audits for product, stores, documents and Q/A system.

Product identification & traceability.

Control an inspection stamps

Defect analysis, capabilities reports (Quality Data Analysis).

Certification & approval of special process and personnel (NDT, Plasma,

Welding, Plating etc).

Training & motivation of staff for quality concept & awareness.

Continuous improvement.

Maintenance of quality records.

Documented quality system (QAM).

INSPECTION PROCEDURE

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DOCUMENTS

IS PROCEDURE REVIEWED AND APPROVED BY Q.A?IS PROCEDURE FILLIWED?

IS PROCEDURE FOLLOWED?

VISUAL INSPECTION

NICKS

CONTAMINATION

SCRATCH

BURR

CORROSION

COLD SHUNT

MAR

PAROSITY LACK OF WELD PENETRATION

DENTS

DISCOLORATION

CRAK

SURFACE ROUGHNESS

DAMAGE THREAD

INCLUSION

MICRO SPATTEP

GEOMATRIC FEATURE INSPECTION

CONCENTRICITY

SQUARENESS

ROUNDNESS

SYMMETRY

DISTO

DIMENSIONAL INSPECTION

F.A INSPECTION INPROCESS INSPECTION, SPC & PRECOMTROL TECHNIQUES

FINAL INSPECTION 100% MIL-STD-105D LEVEL-11

PDCA Cycle

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INSPECTION AND MEASUREMENT

PROCESS INPUT: Inspection procedure NC control procedure

quality plan.

PROSESS OUTPUT: a) Detection of confirming & non confirming parts.

b) Defect analysis report.

RESPONSIBILITY: I/C quality assurance (Mech)

PROCEDURE: QA-PR-8.0-01

CUSTOMER: P& PC machine shop.

PROCESS METRICS: a) Inspection report

b) NCR form, CAR & PAR Forms

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ELECTRICALASSEMBLY

CAPABILITIES OF ELECTRICAL ASSEMBLY

SHOP

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Indigenous development of sophisticated electronic system.

To prepare circuits/drawings and specifications through reverse

engineering.

To develop assembly and testing procedures.

Stuffing if all type of PCBs and fabrication of harnesses.

Complete assembly of electrical/electronics system.

System functional test and acceptance of PEC made system.

To design special test equipment for qualification and acceptance of

PEC made system.

To initiate modification on any in use system as per the requirement

of local customer.

To undertake repair of sophisticated electrical/electronic system even

without schematic diagrams.

CONCLUSION:

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The Precision Engineering Complex (PEC) at PIA manufactures

high precision parts for the aerospace industry and a number of

other industries.

The PEC is an integrated facility that houses major engineeringdisciplines under one roof, including investment casting,

conventional and CNC machining, Optics, PCB, Electrical,

Electronics and Composites. Multi-disciplinary teamwork enables

intelligent decision making and high quality output in all phases

of product development and manufacturing.

Across the globe, PEC products take to the skies every day. The

PEC is a supplier to USA and Europe and serves companies such

as General Electric, Airbus Industries and Boeing. Services runthe gamut from simple machining jobs to complex shaping using

high precision CNC controlled equipment. The team is

experienced in cutting large varieties of basic and exotic

materials including hard steels, aluminum alloys, and the

machining of a wide range of castings, forging and extrusions.