SOP-QAD-001_Inhouse Calibration

STANDARD OPERATING PROCEDURE

PAGE:

1 of 4

DOCUMENT No:

SOP- QAD-001

PREPARED BY :

HOD-QA In-house Calibration

DOCUMENT REVISION:

D

APPROVED BY

HOD-QA

ISSUED BY :

MR

DATE:

23.09.2013

1. Purpose The purpose of this procedure is to provide general directions for calibration.

2 Scope

This procedure covers calibration of all gauges and inspection fixtures used in INDO MIM.

3 Responsibilities It is the responsibility of the Head of Quality to ensure that this procedure is followed properly. No changes may be made to this instruction without the authorization of the Head of QA.

4 Process 4.1 In-house Calibration

4.1.1 General

Qualified personnel shall perform the calibration of gauges. Minimum Diploma in Mechanical engg with six months experience in the calibration area shall be considered as qualified or in supervision of calibration in charge.

Temperature and humidity of calibration room will be maintained as below

Temp: 22±2° and Humidity 50 ±10%.

Soaking of gauge shall be carried out at calibration room for about half an hour minimum. Visual checking shall be carried out for all kind of damages or any markings over the gauge. For all standard gauges, IS 3455 standard will be referred to decide the wear limits. For all special gauges, respective gauge drawings will be referred to decide the wear limits. For individual pin gauges ±0.005mm is acceptance criteria For parallel blocks, IS : 2949 - 1992 standard will be referred to decide the wear limits For Surface Granite Block , IS: 7327 - 1991 standard will be referred to decide the wear limits

4.1.2 Method of Calibration

4.1.2.1 Plug Gauge, Pin Gauge and Width Gauge

Ensure only calibrated digimatic micrometer / 1-micron plunger dial is used. Ensure that the above digimatic micrometer / micron plunger dial is used only for calibration

purpose. Clean the base of Dial stand Select the suitable size of Slip gauge of “0 " Grade. Ensure proper wringing of Slips (Use Minimum number of slips). Set the slips with only 10-20 micron pressure on the plunger dial. Measurement shall be taken at different places of gauge. Record the observation in calibration report / History card. Compare the measured values against the wear limits for deciding the status.

4.1.2.2 Snap gauges

Use VMS / Bore gauge for calibration. Measurements must be taken at different places of gauge. The actual size of a gap is defined as the perpendicular distance between the gauging surfaces. Record the observation in calibration report / History card. Compare the measured values against the wear limits for deciding the status.

If calibration of gauges

by using plunger dial


PAGE:

2 of 4

DOCUMENT No:

SOP- QAD-001

PREPARED BY :


DOCUMENT REVISION:

D

APPROVED BY

HOD-QA

ISSUED BY :

MR

DATE:

23.09.2013

4.1.2.3 Ring gauges

Use VMS / Bore gauge for calibration. Measurements must be taken at different places of gauge. Record the observation in calibration report / History card. Compare the measured values against the wear limits to decide the status..

4.1.2.4 Receiver Gauges & inspection fixtures (position, pitch, distance, profile gauges, depth gauges etc.)

The receiver gauges shall be calibrated as per the gauge drawings using Height gauge /VMS/ 1-micron plunger dial or appropriate instruments.

In receiver gauges the gauge pins, width gauges, holes & slots shall be calibrated and measurement must be taken at different places of gauges.

Record the observations in calibration report / History card. Compare the measured values against acceptable wear limit and decide the status.

4.1.2.5 Feeler gauge/Thickness gauge

Ensure only calibrated digimatic micrometer / one-micron plunger dial is used. Measurements must be taken at different places of gauge. Up to ± 0.005mm deviation will be allowed from the basic dimension on all feelers. Record the values in calibration / history card and decide the status.

4.1.2.6 Dove tail gauges

The Dove tail gauges shall be calibrated as per the gauge drawing by using calibrated “0” grade slip gauges, dig micrometer & measuring pins.

Select the suitable size of measuring pins & “0” grade slip gauge (given in gauge drawing) for internal dovetail size measurement.

Ensure proper wringing of slips are (use minimum no of slips). Use dig-micrometer and suitable size of measuring pins (given in gauge drawing) for External size

measurement. Measurements must be taken at different places of gauge. Record the observation in calibration / History card. Compare the measured values against the wear limits to decide the status. Magnetic Parallel Blocks

4.1.2.7 The parallel blocks shall be calibrated by using VMS Measurement must be taken on entire plane by minimum 10 points Recall for the flatness of the face & Perpendicularity as well Measured values will be taken and monitored in the gage life monitor/ calibration history card IS : 2949 - 1992 standard will be referred to decide the wear limits

4.1.2.8 Granite Surface Plate

The surface plate shall be calibrated by using VMS / Digital height gage Measurement must be taken on entire plane by min 20 points Recall for the flatness of the face & Perpendicularity as well IS: 7327 - 1991 standard will be referred to decide the wear limits


PAGE:

3 of 4

DOCUMENT No:

SOP- QAD-001

PREPARED BY :


DOCUMENT REVISION:

D

APPROVED BY

HOD-QA

ISSUED BY :

MR

DATE:

23.09.2013

5 Environmental Instructions

Cotton waste used for cleaning gauges should be disposed in designated bin. Ensure there is no oil spillages while calibration. Switch off the power in standards room when not in use.

6 Health & Safety Instructions Ensure sufficient lighting in the area of calibration. Use gloves while handling instruments / gauges to prevent cuts or injuries due to sharp edges. While handling receiver gauges ensure there is no slippages. Always wear safety shoes while calibration. Wash with soap and water after calibration. If Isopropyl alcohol is spills on eye, immediately flush the eyes with water for at least 15 mins. Cold water

may be used.

7 Documents Reference Control of MME - PRO-QAD-004 Master list of instrument and gauges - MSL-009 and MSL-010 Gauge drawings

8. Records Reference

Gauge calibration / history card - FORM-QAD-007

ANNEXURE - 1

STANDARDS ROOM – SCOPE

SI. No.

Test / calibration carried out

Competency Required Equipment used Method

Standards reference

1. Plug gauges

ITI/Diploma with Min. six months experience in the calibration of all type of instruments &gauges, and measurement

Dig micrometer / 1mic plunger dial /

‘0’gradeslip gauge

As per above procedure

IS 3455

2. Width gauges


Dig micrometer / 1 mic plunger dial /

‘0’ grade slip gauge As per above WI IS 3455

3. Receiver gauge


VMS / Micrometer / Plunger dial / slip gauge / Ht.Gauge

As per drawings As per gauge

drawing

4. Snap gauge / Bridge

gauge

ITI/Diploma with Min. six months experience in the calibration of all type of instruments &gauges

VMS / Bore gauge As per above

WI IS 3455


PAGE:

4 of 4

DOCUMENT No:

SOP- QAD-001

PREPARED BY :


DOCUMENT REVISION:

D

APPROVED BY

HOD-QA

ISSUED BY :

MR

DATE:

23.09.2013

5. Depth gauge ITI/Diploma with Min. six months experience in the calibration of all type of instruments &gauges

Digital micrometer / Ht.gauge

As per above WI

IS 3455

8. Dovetail gauge ITI/Diploma with Min. six months experience in the calibration of all type of instruments &gauges

Digital micrometer / ‘0’ grade slips with

measuring pin.

As per above WI

As per gauge drawing

9. Plain Ring gauge ITI/Diploma with Min. six months experience in the calibration of all type of instruments &gauges

VMS, Bore gauge As per above WI IS 3455

10 Pin Gauges ITI/Diploma with Min. six months experience in the calibration of all type of instruments &gauges

Dig Micrometer As per above WI ±0.005mm

11 Product Dimensional

inspection


As per control plan/FIP/WI

As per the control plan

As per control plan/Part Drawing

12 Parallel Blocks & V

blocks


VMS As per above

Instruction IS : 2949 -

1992

13 Granite Surface

Plates


VMS As per above

instruction IS: 7327 -

1991

ANNEXURE – 2

SI. No. Instrument Instrument Code

#. Range Units Least Count

1 Digimatic micrometer

IMM-MIC-08 0-25mm mm/inch 0.001mm

2 Digimatic Height master

IMM-HMG-01 0-600mm mm/inch 0.001

3 Dial Height gauge

IMM-HMG-02 0-300mm mm 0.01mm

4

Video measuring system

IMM-VMS-01 300X200X200mm mm/inch 0.001

9. Revision details

Rev level Description of change

A First Release

B Modified to address EHS requirement

C Room temp 22+/- 2 deg revised

D Included the parallel blocks and granite surface plates, Competency added in Annexure -1 , Master list of master equipments added in Annexure-2