SPM AUTOCOMP SYSTEMS PVT LTD. INDIA 3 rd November’ 2012

SPM AUTOCOMP SYSTEMS PVT LTD.

INDIA3rd November’ 2012

INTRODUCTION

CONTENTS

1. SPM – AN OVERVIEW

- Corporate Profile, Vision and Mission, Road Map and Customers List

- Plants and their locations

- Manufacturing Product Range

- Materials and specifications

- Organization Chart – Plant 2 (Ranjangaon)

- Process Design and Engineering Capability

- Facility of Manufacturing and Testing/Inspection Equipment

- Raw Material Sources

- Process/Product Capability – Cp and Cpk

- Mistake Proofing and Error Proofing at manufacturing process

3. MACHINING PROCESS

• Process Flow

• Leak Testing

• Packaging

2. CASTING PROCESS

• Process Flow

• Casting Technology

CONTENTS ….. Continued

CONTENTS

4. DEVELOPMENT PROCESS

• Cross Functional Team/Multi Disciplinary Team

• Project Details

• Project Input – Drawing, CAD Model, customer standards

• Feasibility study – Summary

• Project planning Chart

• Process Design – Casting

• Pattern lay out

• Gating System

• Core Concept

• Molding process

• Quality Planning

• PFD, PFMEA and CP – Foundry and Machining

SPM – AN OVERVIEW

CORPORATE PROFILE

Foundation Established at 2002

Employee 755 person in total 450 persons at Manesar Gurgaon unit305 persons at Ranjangaon Pune unit

Capital Capital : USD 4.27 Mio ( Gurgaon unit) Capital : USD 15.0 Mio ( Pune Unit )

Turnover 2011-12 : USD 36 Mio (w/o BOP USD 23 Mio)

Production Casting & Machining of Automotive components

Certification ISO/TS 16949 & ISO14001

Plants Manesar, Gurgaon (Foundry & Machine Shop) Ranjangaon, Pune ( Foundry & Machine Shop)

VISION & MISSION

VISION

To Achieve Ten percent of the World Market of Cast Exhaust Manifolds by the Year 2015.

MISSION

To exceed customer’s expectations by offering best service, Exhaust Manifolds and Machined Cast components of International Quality at the most competitive prices. To achieve significant continual improvement, reduction in all forms of waste and optimum use of all types of resources under safe working environment.

SPM ROAD MAP TO VISION

74 PPM at Customer End

Internal Rejection control from 15% to 6%

Yield Improvement from 37% to 45%.

Productivity improvement 30%

Organization Stability & DevelopmentOrganization Recruitment

Setting up of Technical Research Center

No. of Product developed – 40 Nos. No. of Product developed –25 Nos.

New Foundry for Exhaust manifold, Turbine Housing & Turbo Manifolds

No. of Customers Built – 7 NosNo. of Customers Built – 5 Nos.

Target Sales: 10% of world market i.e. 3.6 million of Cast Exhaust Manifold

Sales Achieved –US $ 36.21 Million Sales Achieved – US $4.78 Million

2009-152005-092002 - 05

Development

Phase

Consolidation

PhaseGrowth Phase

Customer Basket and Share of Business without BOP

0.66% 1.50% 1.75% 1.80%3.53%

4.51%5.55%

7.25%

9.87%

10.63%

52.94%

Customer Wise sales

Other

BRIDGESTONE TVS INDIA PVT. LTD.

GENERAL MOTORS

JCB INDIA LIMITED

SKH METALS LIMITED PLANT

FIAT INDIA

FORD INDIA

TATA CUMMINS LIMITED

TATA MOTORS LIMITED.

SUZUKI POWERTRAIN INDIA LIMITED

MARUTI UDYOG LTD.

LIST OF CUSTOMERS

Maruti Suzuki India ( Ex Manifold, Maniverter )

Suzuki Power Train ( Ex Manifold, Diff Case, Eng Bkt)

SKH-Magneti Marelli ( Catalytic cones)

Ford Motor Company ( Exhaust Manifolds)

Ford Motor Company Export ( Exhaust Manifolds)

General Motors ( Exhaust Manifolds)

Honda Siel Cars India ( Exhaust Manifold)

Ashok Leyland ( Exhaust Manifolds)

Daimler ( Exhaust Manifolds)

JCB (Exhaust Manifold & Connecting bends)

LIST OF CUSTOMERS Cont…

Tata Motors ( PVBU & CVBU) : Ex Manifold,Steering

Knuckles, Engine mounting Bkts

Tata Cummins : Ex Manifold

Bridgestone TVS India : Engine Mounting Bkt

Fiat India : Exhaust Manifold

Mahindra Navistar : Exhaust Manifolds

Hyundai Motors : Exhaust Manifold

Avtec Ltd : Exhaust Manifold for Daimler engines

Eicher Motors Ltd: Ex Manifold and Ex Bend.

Jaguar Land Rover & Toyota (under negotiation)

No. of Plants

3

Locations Plant – 1 : Manesar, Gurgaon (Foundry & Machine Shop)Plant – 2 : Ranjangaon, Pune (Foundry & Machine shop)Plant – 3 : Pithampur, Indore, MP (Sand Making Plant)

Customers @ Plant -1

Serving to all domestic customers like MSIL, SPIL, TML, JCB, Honda and Tata-Cummins based in North and Eastern India

Customers @ Plant - 2

Serving to all domestic customers based in west and south India like TML (PCBU&CVBU), Ford, GM, Fiat, Hyundai, Tata Cummins, Navistar, Daimler and export customers like Ford, Fiat and JCBCustomers under discussion: JLR, Honeywell & Toyota,

PLANT LOCATIONS

OVERVIEW PLANT - 2

MAIN ENTERANCE

Machine Shop Building

Administration Block

Foundry Building

SITE PLAN – Plant 2

Machine Shop

Foundry

Fiat - 1.3 SDE Exhaust Manifold Line

Tata Motors – Steering Knuckle Line

Machining Facility – Plant 2

Tata Motors – Engine Mounting Bracket Line

Standard Room

PRODUCT DETAILS

CORE PRODUCTS :

Exhaust Manifolds

Turbine Housing

Turbo Manifold

STRATEGIC PRODUCTS :

Steering Knuckle

Mounting Brackets

Case Differential

Exhaust ManifoldCatalytic Inlet Manifold Assembly

Mounting Bracket Case Differential Steering Knuckle

Manufacturing Product Range

http://en.wikipedia.org/wiki/Image:Fiat_logo.jpg

Exhaust Manifold (Honda)

Split Type Manifold (Mahindra Navistar)

Split Type Manifold (JCB)


Ex. Manifold Ford CD (Part no. :BK3Q-9430-CD ) - EXPORT

AS CAST AS MACHINED


EXHAUST MANIFLOD GM 1 LTR. (Part no. ) 55569360

EXHAUST MANIFLOD GM 1.3 LTR. 55570416

AS CAST AS MACHINED

EXHAUST MANIFLOD GM B12D 96416307


AS CAST AS MACHINED

AS CAST AS MACHINED

Ex. Manifold Hyundai (Part no. : 2851103020)


METALLURGY GRADE & SPECIFICATION

Specification

Grade FCD 450 FCD 450HS SG 500 HTN 550 FCD 500M D-5S

CustomerMaruti Suzuki

Eicher AvtecMaruti Suzuki

TATASuzuki

PowertrainAVTEC AVTEC

Chemical Compositi

on

%C 3.4 - 4.20 3.0 - 4.0 2.5 Min 3.4 - 4.20 3.2 – 4.40 3.5 3.2 - 3.50 3.0 - 4.0 2.3 Max

%Si 2.3 - 3.40 2.0 - 3.0 -- 3.5 - 4.30 4.0 - 4.50 4.0 - 4.50 3.8 - 4.40 2.0 - 3.0 4.9 - 5.5

%Mn 0.2 - 0.5 0.1 - 0.6 0.4 Max 0.2 0.5 0.1 - 0.50 0.3 0.30 Max 0.2 - 0.60 1.0 Max

%P - 0.10 Max 0.08 Max -- 0.050 Max 0.50 Max 0.050 Max 0.10 Max 0.08 Max

%S 0.03 Max 0.50 Max 0.02 Max 0.03 Max 0.015 Max 0.015 Max 0.020 Max 0.020 Max 0.02 Max

%Mo -- -- -- -- 1.0 - 1.50 1.0 - 1.50 0.6 - 1.10 -- --

%Cr -- -- -- -- -- -- -- 0.30 Max 1.15 - 2.25

%Mg -- 0.09 Max 0.09 Max -- 0.01 - 0.05 0.01 - 0.05 0.025 Min 0.025 Min 0.02 - 0.06

%Cu -- -- -- -- -- -- -- -- 0.5 Max

%Ni -- -- -- -- -- -- -- -- 34.0 - 37.0

Mechanical

Properties

1. Hardness (BHN) 149 -194 143-217 149-207 161-215 200 - 255 200 - 240 170 - 255 170 - 241 120 - 150

2. Tensile Strength 450 Mpa 45Kg/mm2 450 Mpa 450 Mpa 500 Mpa 490 N/mm2 550 N/mm2 50 Kg/mm2 390 - 470 Mpa

3.Yield Strength 280 Mpa 38Kg/mm2 290 Mpa 280 Mpa 320 Mpa 375 N/mm2 33 Kg/mm2 210 - 260 Mpa

4.Elongation (Min) 10% 10% 10% 7% 7% 8% 5% 5% 15 - 18%

Microstructure

1. Nodularity 60% Min 75% 75% Min 60% Min 80% Min 90% Min 85% Min 90% Min 85% Min

2. Nodule Count 70 Min -- -- 70 Min -- -- -- -- --

3. Pearlite 50 % Max Balance Balance 10% Max Ferrite + Pearlite with 2%

max Cementite

10% Max** 40% Max -- --

4. Cementite -- 5% 5% Max -- -- -- 5% Max 5%

5. Ferrite 50% Min 70% 70% Min 90% Min 90% Min Balance 90% Max --

- Specification after Heat Treatment

New Development

QMS And EMS CERTIFICATION

ISO/TS 16949 And ISO-14001

Organization Chart

Microsoft Excel Worksheet

Design and Engineering Capability

FOUNDRY – ENGINEERING

Design Facilities Simulation Software – ANYCAST UG CAD & CAM - NX 7 Auto Cad In-house Pattern Making Facility Video Image Analyser Spectrometer for chemical analysis

MANUFACTURING - ENGINEERING

VMC (LMW – KODI 40) M1TR with DRO CNC Turning Center Surface Grinder Radial Drilling M/c Hydraulic Fixture for machining Millipore tester for global cleanliness requirement Air decay Leak Testing machines for leak proof casting

FACILITY OF MANUFACTURING & TESTING/INSPECTION EQUUIPMENT

Sl. Equipment Description Model/Make Nos.

1 Moulding M/cFritz Hansberg HPM, 120 boxes/hr

2 Nos.

2 Sand Plant Disa 1 Unit

3 Core Shooter Susha / Span 5 Nos

4 Core Drying oven OSE 1 No

5 Induction Furnace Inductotherm 2 Nos

6 Mould Handling System Fritz Hansberg 1 Unit

7 Wedge Breaker 2 Nos.

8 Shot Blasting m/c Disa 1 No

9 Tumbler Rotary Type 1 No

10 Heat Treatment Furnace APS 1 No

11 Fettling Facility 1 Unit

FOUNDRY - PRODUCTION

SlEquipment Description Make & Model Nos.

1 SpectroSpectro Lab, Germany 1

2 Microscope Union, Japan 1

3Optical Brinell Hardness Tester Fine Testing 1

4UTM for Checking GCS Versatile 1

5 IR Moistur Teller Versatile 1

6 Permeability Meter Versatile 1

7 Test Sieves Versatile 1

FOUNDRY - QUALITY

Based upon a three-phase molding sequence featuring prefill, shoot, and squeeze, the HANSBERG Molding System is a consolidated, foundry-proven mold making technology which ensures the production of castings consistently complying with the strictest quality control requirements.

Based upon a three-phase molding sequence featuring prefill, shoot, and squeeze, the HANSBERG Molding System is a consolidated, foundry-proven mold making technology which ensures the production of castings consistently complying with the strictest quality control requirements.

ShootShoot

SqueezeSqueeze

PrefillPrefill

New Moulding Line Details:

Moulding Process

Prefill ensures that clot-free sand always fill deep pockets and cavities, even when the pattern contour is most intricate,

as is the case with this knuckle arm mold

Outstanding casting skin qualityOutstanding casting skin quality

PHASE 1 - PREFILLPHASE 1 - PREFILL

Shooting is instrumental to achieving high compaction in deep cavities where squeezing

alone can not always reach

Mold hardness87-92°

Excellent mold surface hardness with homogeneous distribution from mold center to flask edges

Excellent mold surface hardness with homogeneous distribution from mold center to flask edges

PHASE 2 - SHOOTPHASE 2 - SHOOT

Distanceto edge

25 mm or Less

Draft Angle 0.5 Deg.

Outstanding mold rigidity is always

achieved Minimum casting mass variationMinimum casting mass variation

Uniform compaction throughout the mold depth

Uniform compaction throughout the mold depth

PHASE 3 - SQUEEZEPHASE 3 - SQUEEZE

Minimum usage of sand Minimum usage of sand

Strictly controlled compression

force per mold surface unit

FLASK DESIGNFLASK DESIGN

Nodular iron flask pair (above). Note the double-wall design combining high rigidity with lightness.

Nodular iron flask pair (above). Note the double-wall design combining high rigidity with lightness.

Pin / bushing assembly (right). Each flask is fitted with one round and one elongated bushing. Poka-Yoke: Automated sensors to ensure the dimensional accuracies of pins & bushes.

Pin / bushing assembly (right). Each flask is fitted with one round and one elongated bushing. Poka-Yoke: Automated sensors to ensure the dimensional accuracies of pins & bushes.

Flask rigidity is of paramount importance in high-pressure molding. Wall deformation should not exceed 0.25 mm under a load of 4 kgf/cm2.

Flask rigidity is of paramount importance in high-pressure molding. Wall deformation should not exceed 0.25 mm under a load of 4 kgf/cm2.

SPECIAL FEATURESSPECIAL FEATURES

Automatic sprue cutting unit (right). Online Automatic Sprue Cutting as compared to Manual cutting in Present Line, avoiding variation in pouring cup size

Automatic sprue cutting unit (right). Online Automatic Sprue Cutting as compared to Manual cutting in Present Line, avoiding variation in pouring cup size

Flask cleaning unit (left). Automatic Box Cleaning as compared to Manual Cleaning in the Present Line

Flask cleaning unit (left). Automatic Box Cleaning as compared to Manual Cleaning in the Present Line

Mass variation < 0.2 kg on 50 kg casting

Diameter variation is < +/- 0.5 mm

CASTINGS DIMENSIONAL ACCURACYCASTINGS DIMENSIONAL ACCURACY

Complying with the strictest

quality control requirements:

automotive safety part

casting

MACHINE SHOP - PRODUCTION

Sl. Equipment DescriptionMake & Model

Accuracy Nos.

1 CMM Carl Jeiss0.00001mm 1

2 Roughness tester Mitutuyo09.01

Ra 1

3 Milipore Tester Milipore 1

4 Weighing Machine Adventure0.0001 Gms 1

5 Tool Pre-setterPWB Swiss

0.001mm 1

6

All Std. instruments like micrometer, height gauges, Lever Dial etc Mitutuyo

Sl. Equipment DescriptionMake & Model Nos.

1 HMCMakino/

DMG 2

2 VMCMakino

S33/ DMG 7

3 VMCAMS MCV 500S/450S

24

4 CNC Milling M/c BFW 1

5 CNC Turning Machine LOKESH 1

6Pneumatic Leak Test M/c with Auto Marking Auto Test 10

6 Washing MachineGayatri

Auto 2

MACHINE SHOP - QUALITY

FACILITY OF MANUFACTURING & TESTING/INSPECTION EQUUIPMENT

Raw Material Sources

S. No. Raw Material Source Remarks

1 Scrap (1) MSIL(2) GE

Cold Rolled mild steel scrap

2 Graphite (1) Graphite India(2) MPM

3 FeMo Moly Metals / Ess Ell Mining

4 Fesi RNB Carbide

5 FeSiMg Snam Alloy

6 Bentonite Ashapura International

7 Lustron MPM

8 Innoculant Snam Alloy

9 Raw Sand Allahabad Sand

10 Resin Coated sand SPM, Indore

Process Capability of Existing Product - Foundry

Process Capability of Foundry Critical ParametersS. No. Specification Critical Parameters

Process Capabililty Index (Cpk)

Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12

1 1.65 ~ 2.00 Kg/cm2Green Compressive Strength (GCS) 1.36 1.38 1.36 1.37 1.42 1.45 1.51 1.52

2 40 ~ 48 Compactibility 1.35 1.48 1.39 1.45 1.37 1.34 1.41 1.49

3 134 ~ 156 Permeability 1.42 1.51 1.53 1.49 1.57 1.61 1.58 1.64

Process Capability of Existing Product - Machining

Process Capability of Critical Parameters - MachiningS. No. Specification Component Name Critical Parameters

Process Capabililty Index (Cpk)Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12

1 0.07 mm min. Exhaust Manifold - F8D Flatness 1.38 1.39 1.40 1.39 1.41 1.42 1.44 1.47

2 0.25 mm Max. Exhaust Manifold - 830 Position 1.63 2.09 2.17 2.04 2.25 2.03 1.77 2.06

3 Ra1.6 Max. Case Diff. Surface Finish 4.12 5.13 4.61 3.87 3.19 4.71 5.21 5.27

4 28.0+0.012+0.033 Case Diff. Inner Dia 2.92 3.16 2.61 2.67 2.79 2.82 2.87 3.41

5 57.0+0.002+0.021 Case Diff. Outer Dia 2.48 2.64 2.79 2.93 3.11 3.15 3.17 3.22

6 0.04 mm Max. Case Diff. Run Out 2.11 2.87 2.67 2.91 2.96 2.99 3.06 3.17

Process Capability of Existing Product - Machining

1. Sand Plant• Batch Quantity of Mixer - load cell

• Additives Weighing - load cell

• RTC Compatibility

2. Molding line • Shoot pressure in mold machine

• Squeeze presssure in mold machine

• Air pressure of mold line

3. Core Shop• Higher & low temperature of core box of all machines

• Air pressure of core shooters

• Core oven temperature

List of Poke Yoke

Doc No.: - QAD/F/41 A

Rev No :- 02

Rev. Date : 01.05.2012

OPERATION NO:- OP-20 M/C NO.:-

Description :-Prevention / Detection Stage : To avoid wrong loading three stopper fitted in fixture plate.

Implementation Date : 27/05/2012

Sketch / Photo (Before) :

Poke - Yoke Identification & Implementation Sheet

PART NAME:-EXHAUST MANIFOLD

Mistake Proofing / Error Proofing detail

Sketch / Photo (After) :

Mistake Observed / Anticipated : Wrong loading problem.

PART NO.:- CUSTMER NAME:- HYUNDAI

STOPPER 3 NOS.

Poke Yoke Implementation


Rev No :- 02

Rev. Date : 01.05.2012




PART NAME:-EXHAUST MANIFOLD PART NO.:- CUSTMER NAME:- HYUNDAI



Mistake Proofing / Error Proofing detail Description :-Prevention / Detection Stage :To avoid wrong loading three stopper fitted in fixture plate.


STOPPER 3 NOS.



Rev No :- 02

Rev. Date : 01.05.2012

OPERATION NO:- OP-40 M/C NO:-






Mistake Proofing / Error Proofing detail Description :-Prevention / Detection Stage : To avoid wrong loadingthree stopper fitted in fixture plate.


STOPPER 3 NOS.



Rev No :- 02

Rev. Date : 01.05.2012







Mistake Proofing / Error Proofing detail Description :-Prevention / Detection Stage :To avoid wrong loadingthree stopper fitted in fixture plate.


STOPPER 3 NOS.



Quality

Cost

DeliveryFocus Area

Development

In Process Inspection Process Improvement

Productivity Value Engineering

On time

Design Capability First Time Right

SPM – THE COMPLETE SOLUTION

CASTING TECHNOLOGY

&PROCESS

HIGH PRESSURE MOLDING PROCESS

We, at SPM have opted for High pressure molding process with green sand having a composition of Silica sand with 98% minimum silica content, sodium based Bentonite for better swelling and binding property, Lustrous carbon for providing a reducing atmosphere in the mold cavity. Water is added to get the optimum properties in the sand mix like compactibility, green compressive strength, Loss on ignition, dry strength, and also better collapsibility for easy separation of casting from sand at the time of knock out. This sand is reusable by remixing small quantities of Bentonite and other additives for replenishing the lost properties due to molten liquid metal casting process.

Casting Technology

The molds for any casting component are normally made in two halves, i.e. drag half and cope half and the core for creating the inner surface of the casting component is made separately with a different process. For making both mold halves we make pattern which is mounted on match plates with respect to the center lines of the guide pins and bushes to suit to the molding machine which we are using. The pattern mounted on the match plate is incorporated with running system with in-gates for the uniform filling of liquid metal in the cavity.

Casting Technology

In the molding process we create an outer surface of the component which we intend to manufacture and after making the mold we place the shell cores in the sand mould and this makes the internal cavities of the casting component.

Casting Technology

Cores are set in the drag mould with respect to the core prints. In the cope mould, adequate venting is provided. Both the halves are cleaned with compressed air for any foreign particles adhering to the cavity surfaces. Then the cope half is closed on top of the drag half with the help of guide pins and bushes to avoid mismatch in the casting component. These molds are being filled with molten metal with specified chemistry and metal temperature, which helps in filling the entire mold cavities irrespective of the casting thickness variation.

Casting Technology

The poured molds are allowed to cool on the molding line for a minimum of 45 minutes and then the castings are separated from the molds, cleaned for adhering sand particles by shot blasting, separated from the gating system with the help of breaker units and then the extra flashes, if any, are removed from the casting with the help of fettling equipments. Then the casting components are machined to remove the extra material provided as machining allowance to make the casting components suitable for assembling on other parts.

Casting Technology

1 Molding Process -High pressure molding – Horizontal Box size 900*700*225

2 No of cavities in pattern Match plate

- 4 ~ 8 (depends on geometry)

3 Core process - Hot baked shell sand process

4 No of cores required for the casting

- 1 ~ 4 (depends on geometry)

5 Melting process -Medium frequency Induction furnace - electric

6 De-coring process - Mechanical vibrator

7 Shot blasting process - Stage shot blasting using cast iron shot

8 Casting finishing - Manual fettling grinders

Casting Process (Basics)

Sand Preparation

Core Making & Core Trimming

Mould Closing & Clamping

Melting

Magnesium Treatment

Pouring

Lab Clearance for Casting

Primary Inspection

Knocking & Hauling

Shot blasting

Final Inspection (Foundry Stage)

Re-shot BlastingFettling

Ready for Machining

Molding

Drying & Insp.

Core Setting

Lab Clearance

Inoculation

Casting Product Process Details

Raw material

PROCESS FLOW - CASTING

Sand Preparation

Core Making Core Trimming

Moulding

Final Inspection

Melting Pouring Metallurgical

Insp

Re Shot blasting Fettling Shot blasting

Engine QC 29.08.12

CORE MAKING PROCSS

Core box cleaning Applying parting agent

Checking of temperature

Air pressure setting

Loose pc. installationVerification of sand level

Setting of cycle timeVerification of air

pressure

Start of machine in auto mode

Cleaning of sand on core box area

Core removal from core box

Separation of loose pc.

Cleaning by aluminum strip

Ingate cuttingRecording Core Storage

CORE MAKING PROCSS

Core ready for inspection, trimming

and dressing

Remove all parting lines and fins from

core surface.

Remove all projection & ingates from core surface.

Inspection of core for over baked and under

baked

Visual inspection of core

Graphite Pasting where required

Storage of core Checking of finishing and profile of core

CORE TRIMMING AND DRESSING

MOULDING PROCESS

Check the Cope pattern before

loading

Check the Drag pattern before

loading

Lift the pattern for loading

Clean the bolster by using Compressed

Air

Mount the pattern with properly

matching of dowel pins

Tighten the allen bolt of cope pattern by

allen key with cross direction

Put heat / date code on pattern

Tighten the allen bolt of drag pattern by

allen key with cross direction

Clean the pattern Set the molding machine parameter

Spray mold releasing agent

Check the outcome cope mold quality

Set and Check the mold for any sand crushing after core

setting

Make venting on cope mold at specified

location

Check the outcome drag mold quality

Check the core before setting

MOULDING PROCESS

Left the mold to go for closing station

Left the mold to go for closing station

Write box no of Particular heat and customer name on

top of the mold

Mold ready for pouring

MOULDING PROCESS

Weighing of Scrap Putting in empty bin

Empty Furnace Weighing of graphite on weighing scale.

Addition of graphite in furnace

Addition Scrap in furnace

Addition of turning Chips in Furnace

Addition of re-melt in Furnace

MELTING PROCESS

Addition of Ferrogen in half filled Furnace

Addition of e re-melt in Furnace (if required)

Addition of re-melt in Furnace (If required)

Addition of Ferro Alloys in Furnace

Spreading of Slax-30 at melt in Furnace

Removal The slag from Furnace

Checking of temperature in Furnace

Preparation of Coin Sample

MELTING PROCESS

Put the Coin Sample in water for cooling

Send the sample to lab for testing chemical composition

Put steel punch over FeSiMg in treatment ladle

by using funnel

Weight the FeSiMg Add FeSiMg in treatment ladle by

using funnel.

Make zero weight of treatment ladle

Tap the melt in treatment Ladle

Check the weight of melt

MELTING PROCESS

Transfer of melt in pouring ladle & add the inoculant in stream

Checking of temperature in pouring ladle before pouring

Removal of slag from the pouring ladle before pouring

Taking of metal from pouring ladle for coin sample.

Coin Sample cooling

Pouring of metal in Mould

Offer sample for testing

MELTING PROCESS

KNOCK OUT AND SHOT BLASTING

Taking out incoming bunches from knockout

Removal of bunches from hoist to floor

Arranging of all bunches as per item / heat no. wise

Heat no. identification

Knock out of casting with wedge breakerLoading of separated

casting into shot blasting hanger

Putting the hanger inside the machine

Closing of door

Machine operation in auto mode

Casting taking out after shot blasting

Offer the casting for Primary Inspection

KNOCK OUT AND SHOT BLASTING

FETTLING PROCESS

Component for FettlingChipping Pedestal Grinding Straight Cutter

Grinding

Pneumatic hand grinding

Re-shot blasting Grinding through air tool

Component for Inspection

CASTING INSPECTION PROCESS

Casting Inspection Ok Component for Machining

MACHINING PROCESS

Layout of Machine Shop

PROJECT BASICS ( Machining)

1 Machining Process VMC

2 Post machining de-burring

Manual

3 Post machining leak testing

Automatic test cycle using dry air process

4 On line and patrol inspection

Standard and special gauges, Carl Zeiss 3D Co-ordinate measuring machine

5 Part washing Auto cycle part washing m/c

6 Anti-rust treatment Using antirust oil and VCI bag protection

7 Packing Corrugated box with partition

Face Milling &Drilling Spot Facing Boss Milling& M6

Tapping

Face Milling ø 114.0

M18 Tapping

Packing

Date code Numbering Leak Testing

Final Fixture Inspection

Oiling Washing Final Inspection

Engine QC 29.08.12

MACHINE SHOP PROCESS FLOW

Leak testing machine detail

Leakage Machine

Specification :- Pressure : 103 KPa- Allowable Limit : 100 cc/min.

Packaging

Proposed Packaging• Individual component packing in VCI

bag.• Corrugated box

FORD CD EXPORT PACKAGING Example

DEVELOPMENT PROCESS

CFT/MDT Team

S. No.

Name of the Person

Department Designation Job Responsibility

1 P K Banerjee Engineering JMD Chief Co-ordinator of Project

2 Jayarama Pradhan

Corporate Quality, Engg. And Customer Support

General Manager

Final Approval of the Project

3 Rajan Nair Process Development - Casting

Chief Technical Officer

Development of the casting process

4 Poonam Wangnoo

Quality Senior Manager

Analysis of the product and process capability

5 Anil Shinde Machine Engg. Senior Manger Development of the Machining process

6 N S Jina Process Engg. – Machine shop

Manager Development of Tooling – Machine shop

Sl No

Parameter Measuring method

Sample

Control methodSize Freq.

01Green Compressive Strength (GCS)

Universal Strength M/c 1 Every Hour Sand Testing Report

02 Moisture IR Moisture Dryer 1 Every Hour Sand Testing Report

03 Permeability Permeability 1 Every Hour Sand Testing Report

04 Compactability Scale 1 Every Hour Sand Testing Report

05 Active Clay Methylene Blue Test 1 Every Shift Sand Testing Report

06 Total Clay Clay Washer 1 Once / Week Sand Testing Report

07 Mold Hardness Mould Hardness Tester 1 Every Hour Check Sheet

08Tapping / Ladle Release Temperature

Pyrometer 1 Every LaddleDaily Melting, Pouring & Analysis Report.

09 Weight of Additions Weighing Scale 1 Every TreatmentDaily Melting, Pouring & Analysis Report.

10Time control after Treatment to final Pouring

Hooter 1 Every Treatment ----

11Chemical Composition (Furnace Metal)

Coin Sample + Spectro Meter

1 Every HeatDaily Melting, Pouring & Analysis Report, Spectra Report

Final Quality Check (Quality Planning)

Sl No

Parameter Measuring method

Sample

Control methodSize Freq.

12Chemical Composition (After Mg Treatment)

Coin Sample + Spectro Meter

1 Every TreatmentDaily Melting, Pouring & Analysis Report, Spectro Report

13 Nodularity Microscope 1 Every TreatmentDaily Melting, pouring & Analysis Report

14 Microstructure Microscope 1 Every TreatmentDaily Melting, pouring & Analysis Report

15 Hardness Brinel Hardness Tester 1 Every TreatmentDaily Melting, pouring & Analysis Report

16 Elongation Universal Testing M/c 1Once Per Prod. Lot (Continuous Heat)

Mechanical Test Report

17 Tensile Strength Universal Testing M/c 1Once Per Prod. Lot (Continuous Heat)


18 Yield Strength Universal Testing M/c 1Once Per Prod. Lot (Continuous Heat)


19 Wall ThicknessCut Section + Vernier Caliper / Pistol Caliper

1 Every 500 CastingWall Thickness Insp. Report

20Casting Surface Defects like Shrinkage, Blow Holes etc.

Visual 100% ---- Daily Inspection Report

Final Quality Check (Quality Planning)

Core shopPattern shop

Pattern & Coreshop In charge

Quality Meeting

Daily & Monthly

Foundry Quality

CONTINUOUS QUALITY IMPROVEMENTS

Moulding shop

Melting Fettling

Machine shopQuality

M.D.

Moulding shop incharge

Melting shop incharge

Fettling shop incharge

Conclusion

Thank You

• EXHAUST MANIFOLD G4D3-9430-CA1Adobe Acrobat

Document

Adobe Acrobat Document

• EXHAUST MANIFOLD G4D3-9430-DA1



Project Input - Drawings

Project Details

S. No.

Name of the Project

Part Name Part Number Customer Shared Volume

1 AJ - 200 Exhaust Manifold

G4D3-9430-CA (N/S)

FY14/15 - 2094FY15/16 - 49061FY16/17 - 192299FY17/18 - 218726FY18/19 - 225605FY19/20 - 231074FY20/21 - 235392FY21/22 - 235392FY22/23 - 235392

2 AJ - 200 Exhaust Manifold

G4D3-9430-DA (E/W)

Project Input – CAD Model

North / SouthMid / Low Spec

East / WestMid Spec Only

Feasibility Clarification – Summary

Microsoft Excel Worksheet

Project Planning Chart


Cope Side Match Plate

Pattern Layout Concept

Drag Side Match Plate

Drag PatternCope Pattern

Pattern Concept


a) Gating System Design & AnalysisCasting and Core Weight

Casting Weight(Single Cavity)

4.6Kg

Gating Weight 15.50 Kg

Risers Weight _

Total casting weight (4 cavity)

18.56 Kg

No of Core 02 Nos.

Total Core Weight 2.0 Kg

SpureIn Gate

Casting

Core_2

Core_1

Runner bar


a) Gating System Design Spure

In Gate

Casting

Core_2

Core_1

Runner bar

Casting Weight(Single Cavity)

4.808Kg

Gating Weight 15.50

Kg

Risers Weight _

Total Castings Weight (4 cavity)

19.232 Kg

No of Core 02 Nos

Total Core Weight 2.25 Kg

G4D3-9430-DA1Exhaust Manifold

Gating System design and Analysis

Casting Material Si Mo

Mould Material Green Sand

Core Material Shell Sand

Pouring Temperature 1440c

Mold Temperature 25 C

Liquidus / Solidus (Castings) 1172℃ / 1135℃

Gating Design

Materials and Conditions

C Si Mn Cu S P Mo Mg

3.4 Max.

3.75-4.5

0.6Max -

0.02Max

0.08Max

0.4-0.6

-

Chemical Composition of Material (IDM 5381)

b) Data Input

Spure

Runner Bar

In gate

Gating System design and Analysis

Concept for Core – Shell Core

Main Core ASSEMBLY CORE BOX

Ejecting pin mounting plate

Mounting Plate Mounting

Plate

Ejecting pin mounting plate

Ejecting pin

Ejecting pin

Core box _ Bush Half

Core box _ Pin Half

Core

Concept for Core – Shell Core

Main Core

Core Trimming area(pink line )

Trimmed Core

After dipping Core

Actual Core Photographs and Assembly

Core_1 Core_2

core_1&2 Assemble

PFD, PFMEA & Control Plan of CA1 - Foundry

Microsoft Excel 97-2003 Worksheet



PFD – Foundry – CA1 PFMEA – Foundry – CA1 CP – Foundry – CA1

PFD, PFMEA & Control Plan of CA1 – Machine

shop

PFD – Machine shop – CA1 PFMEA – Machine-shop – CA1 CP – Machine shop – CA1




PFD, PFMEA & Control Plan of DA1 - Foundry

PFD – Foundry – DA1 PFMEA – Foundry – DA1 CP – Foundry – DA1




PFD, PFMEA & Control Plan of DA1 – Machine shop

PFD – Machine shop – DA1 PFMEA – Machine-shop – DA1 CP – Machine shop – DA1




Documents

SPM AUTOCOMP SYSTEMS PVT LTD. INDIA 3 rd November’ 2012