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Presentation on theme: "SPM AUTOCOMP SYSTEMS PVT LTD. INDIA SPM AUTOCOMP SYSTEMS PVT LTD. INDIA 3 rd November 2012 INTRODUCTION."— Presentation transcript:


2 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 3. MACHINING PROCESS Process Flow Leak Testing Packaging 2.CASTING PROCESS Process Flow Casting Technology CONTENTS ….. Continued

4 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


6 CORPORATE PROFILE Foundation Established at 2002 Employee 755 person in total 450 persons at Manesar Gurgaon unit 305 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)

7 VISION & MISSION VISION To Achieve Ten percent of the World Market of Cast Exhaust Manifolds by the Year 2015. MISSION To exceed customers 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.

8 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 MillionSales Achieved – US $4.78 Million 2009-152005-092002 - 05 Development Phase Consolidation Phase Growth Phase

9 Customer Basket and Share of Business without BOP

10 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)

11 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)

12 No. of Plants 3 LocationsPlant – 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 JCB Customers under discussion: JLR, Honeywell & Toyota, PLANT LOCATIONS

13 OVERVIEW PLANT - 2 MAIN ENTERANCE Machine Shop Building Administration Block Foundry Building

14 SITE PLAN – Plant 2 Machine Shop Foundry

15 Fiat - 1.3 SDE Exhaust Manifold Line Tata Motors – Steering Knuckle Line Machining Facility – Plant 2

16 Tata Motors – Engine Mounting Bracket Line Standard Room

17 PRODUCT DETAILS CORE PRODUCTS : Exhaust Manifolds Turbine Housing Turbo Manifold STRATEGIC PRODUCTS : Steering Knuckle Mounting Brackets Case Differential

18 Exhaust Manifold Catalytic InletManifold Assembly Mounting BracketCase DifferentialSteering Knuckle Manufacturing Product Range

19 Exhaust Manifold (Honda) Split Type Manifold (Mahindra Navistar) Split Type Manifold (JCB) Manufacturing Product Range

20 Ex. Manifold Ford CD (Part no. :BK3Q-9430-CD ) - EXPORT AS CAST AS MACHINED

21 Manufacturing Product Range EXHAUST MANIFLOD GM 1 LTR. (Part no. ) 55569360 EXHAUST MANIFLOD GM 1.3 LTR. 55570416 AS CAST AS MACHINED

22 EXHAUST MANIFLOD GM B12D 96416307 Manufacturing Product Range AS CAST AS MACHINED

23 AS CASTAS MACHINED Ex. Manifold Hyundai (Part no. : 2851103020) Manufacturing Product Range

24 METALLURGY GRADE & SPECIFICATION Specification GradeFCD 450FCD 450HSSG 500HTN 550FCD 500MD-5S Customer Maruti Suzuki EicherAvtec Maruti Suzuki TATA Suzuki Powertrain AVTEC Chemical Compositi on %C3.4 - 4.203.0 - 4.02.5 Min3.4 - 4.203.2 – 4.403.53.2 - 3.503.0 - 4.02.3 Max %Si2.3 - 3.402.0 - 3.0--3.5 - 4.304.0 - 4.50 3.8 - 4.402.0 - 3.04.9 - 5.5 %Mn0.2 - 0.50.1 - 0.60.4 Max0.2 0.50.1 - 0.500.30.30 Max0.2 - 0.601.0 Max %P-0.10 Max0.08 Max--0.050 Max0.50 Max0.050 Max0.10 Max0.08 Max %S0.03 Max0.50 Max0.02 Max0.03 Max0.015 Max 0.020 Max 0.02 Max %Mo-- 1.0 - 1.50 0.6 - 1.10-- %Cr-- 0.30 Max1.15 - 2.25 %Mg--0.09 Max --0.01 - 0.05 0.025 Min 0.02 - 0.06 %Cu-- 0.5 Max %Ni-- 34.0 - 37.0 Mechanic al Properties 1. Hardness (BHN)149 -194143-217149-207161-215200 - 255200 - 240170 - 255170 - 241120 - 150 2. Tensile Strength450 Mpa45Kg/mm2450 Mpa 500 Mpa490 N/mm2550 N/mm250 Kg/mm2390 - 470 Mpa 3.Yield Strength280 Mpa38Kg/mm2290 Mpa280 Mpa320 Mpa375 N/mm2 33 Kg/mm2210 - 260 Mpa 4.Elongation (Min)10% 7% 8%5% 15 - 18% Microstruc ture 1. Nodularity60% Min75%75% Min60% Min80% Min90% Min85% Min90% Min85% Min 2. Nodule Count70 Min-- 70 Min-- 3. Pearlite50 % MaxBalance 10% Max Ferrite + Pearlite with 2% max Cementite 10% Max**40% Max-- 4. Cementite--5%5% Max-- 5% Max5% 5. Ferrite50% Min70%70% Min90% Min Balance90% Max-- - Specification after Heat Treatment New Development


26 Organization Chart

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

28 FACILITY OF MANUFACTURING & TESTING/INSPECTION EQUUIPMENT Sl.Equipment DescriptionModel/MakeNos. 1Moulding M/c Fritz Hansberg HPM, 120 boxes/hr 2 Nos. 2Sand PlantDisa1 Unit 3Core ShooterSusha / Span5 Nos 4Core Drying ovenOSE1 No 5Induction FurnaceInductotherm2 Nos 6Mould Handling SystemFritz Hansberg1 Unit 7Wedge Breaker 2 Nos. 8Shot Blasting m/cDisa1 No 9TumblerRotary Type1 No 10Heat Treatment FurnaceAPS1 No 11Fettling Facility 1 Unit FOUNDRY - PRODUCTION Sl Equipment DescriptionMake & ModelNos. 1Spectro Spectro Lab, Germany1 2MicroscopeUnion, Japan1 3 Optical Brinell Hardness TesterFine Testing1 4 UTM for Checking GCSVersatile1 5IR Moistur TellerVersatile1 6Permeability MeterVersatile1 7Test SievesVersatile1 FOUNDRY - QUALITY

29 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. Shoot Squeeze Prefill New Moulding Line Details: Moulding Process

30 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 quality PHASE 1 - PREFILL

31 Shooting is instrumental to achieving high compaction in deep cavities where squeezing alone can not always reach Mold hardness 87-92° Excellent mold surface hardness with homogeneous distribution from mold center to flask edges PHASE 2 - SHOOT Distance to edge 25 mm or Less Draft Angle 0.5 Deg.

32 Outstanding mold rigidity is always achieved Minimum casting mass variation Uniform compaction throughout the mold depth PHASE 3 - SQUEEZE Minimum usage of sand Strictly controlled compression force per mold surface unit

33 FLASK DESIGN 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.

34 Flask rigidity is of paramount importance in high- pressure molding. Wall deformation should not exceed 0.25 mm under a load of 4 kg f /cm 2.

35 SPECIAL FEATURES 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

36 Mass variation < 0.2 kg on 50 kg casting Diameter variation is < +/- 0.5 mm CASTINGS DIMENSIONAL ACCURACY Complying with the strictest quality control requirements: automotive safety part casting

37 MACHINE SHOP - PRODUCTION Sl.Equipment Description Make & Model Accura cyNos. 1CMMCarl Jeiss 0.00001 mm1 2Roughness testerMitutuyo 09.01 Ra1 3Milipore TesterMilipore 1 4Weighing MachineAdventure 0.0001 Gms1 5Tool Pre-setter PWB Swiss 0.001m m1 6 All Std. instruments like micrometer, height gauges, Lever Dial etcMitutuyo Sl.Equipment Description Make & ModelNos. 1HMC Makino/DM G2 2VMC Makino S33/ DMG7 3VMC AMS MCV 500S/450S 24 4CNC Milling M/cBFW1 5CNC Turning MachineLOKESH1 6 Pneumatic Leak Test M/c with Auto MarkingAuto Test10 6Washing Machine Gayatri Auto2 MACHINE SHOP - QUALITY FACILITY OF MANUFACTURING & TESTING/INSPECTION EQUUIPMENT

38 Raw Material Sources S. No.Raw MaterialSourceRemarks 1Scrap(1)MSIL (2) GE Cold Rolled mild steel scrap 2Graphite(1) Graphite India (2) MPM 3FeMoMoly Metals / Ess Ell Mining 4FesiRNB Carbide 5FeSiMgSnam Alloy 6BentoniteAshapura International 7LustronMPM 8InnoculantSnam Alloy 9Raw SandAllahabad Sand 10Resin Coated sandSPM, Indore

39 Process Capability of Existing Product - Foundry Process Capability of Foundry Critical Parameters S. No.SpecificationCritical Parameters Process Capabililty Index (Cpk) Jan-12Feb-12Mar-12Apr-12May-12Jun-12Jul-12Aug-12 11.65 ~ 2.00 Kg/cm2 Green Compressive Strength (GCS)1.361.381.361.371.421.451.511.52 240 ~ 48Compactibility1.351.481.391.451.371.341.411.49 3134 ~ 156Permeability1.421.511.531.491.571.611.581.64

40 Process Capability of Existing Product - Machining Process Capability of Critical Parameters - Machining S. No.SpecificationComponent NameCritical Parameters Process Capabililty Index (Cpk) Jan-12Feb-12Mar-12Apr-12May-12Jun-12Jul-12Aug-12 10.07 mm min.Exhaust Manifold - F8DFlatness1.381.391.401.391.411.421.441.47 20.25 mm Max.Exhaust Manifold - 830Position1.632. 3Ra1.6 Max.Case Diff.Surface Finish4.125.134.613.873.194.715.215.27 428.0+0.012+0.033Case Diff.Inner Dia2.923.162.612.672.792.822.873.41 557.0+0.002+0.021Case Diff.Outer Dia2.482.642.792.933. 60.04 mm Max.Case Diff.Run Out2.112.872.672.912.962.993.063.17

41 Process Capability of Existing Product - Machining

42 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

43 Poke Yoke Implementation





48 Quality Cost Delivery Focus Area Development In Process Inspection Process Improvement Productivity Value Engineering On time Design Capability First Time Right SPM – THE COMPLETE SOLUTION


50 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

51 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

52 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

53 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

54 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

55 1Molding Process-High pressure molding – Horizontal Box size 900*700*225 2No of cavities in pattern Match plate -4 ~ 8 (depends on geometry) 3Core process- Hot baked shell sand process 4No of cores required for the casting - 1 ~ 4 (depends on geometry) 5Melting process-Medium frequency Induction furnace - electric 6De-coring process- Mechanical vibrator 7Shot blasting process- Stage shot blasting using cast iron shot 8Casting finishing- Manual fettling grinders Casting Process (Basics)

56 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 Blasting Fettling Ready for Machining Molding Drying & Insp. Core Setting Lab Clearance Inoculation Casting Product Process Details

57 Raw material PROCESS FLOW - CASTING Sand Preparation Core Making Core Trimming Moulding Final Inspection MeltingPouring Metallurgical Insp Re Shot blasting Fettling Shot blasting Engine QC 29.08.12

58 CORE MAKING PROCSS Core box cleaning Applying parting agent Checking of temperature Air pressure setting Loose pc. installation Verification of sand level Setting of cycle time Verification of air pressure

59 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 cutting Recording Core Storage CORE MAKING PROCSS

60 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

61 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

62 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

63 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

64 Weighing of ScrapPutting 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

65 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

66 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

67 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

68 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 breaker Loading of separated casting into shot blasting hanger Putting the hanger inside the machine Closing of door

69 Machine operation in auto mode Casting taking out after shot blasting Offer the casting for Primary Inspection KNOCK OUT AND SHOT BLASTING

70 FETTLING PROCESS Component for Fettling ChippingPedestal Grinding Straight Cutter Grinding Pneumatic hand grinding Re-shot blasting Grinding through air tool Component for Inspection

71 CASTING INSPECTION PROCESS Casting Inspection Ok Component for Machining


73 Layout of Machine Shop

74 PROJECT BASICS ( Machining) 1Machining ProcessVMC 2Post machining de- burring Manual 3Post machining leak testing Automatic test cycle using dry air process 4On line and patrol inspection Standard and special gauges, Carl Zeiss 3D Co-ordinate measuring machine 5Part washingAuto cycle part washing m/c 6Anti-rust treatmentUsing antirust oil and VCI bag protection 7PackingCorrugated box with partition

75 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

76 Leak testing machine detail Leakage Machine Specification : - Pressure : 103 KPa - Allowable Limit : 100 cc/min.

77 Packaging Proposed Packaging Individual component packing in VCI bag. Corrugated box



80 CFT/MDT Team S. No. Name of the Person DepartmentDesignationJob Responsibility 1P K BanerjeeEngineeringJMDChief Co-ordinator of Project 2Jayarama PradhanCorporate Quality, Engg. And Customer Support General ManagerFinal Approval of the Project 3Rajan NairProcess Development - Casting Chief Technical Officer Development of the casting process 4Poonam WangnooQualitySenior ManagerAnalysis of the product and process capability 5Anil ShindeMachine Engg.Senior MangerDevelopment of the Machining process 6N S JinaProcess Engg. – Machine shop ManagerDevelopment of Tooling – Machine shop

81 Sl No ParameterMeasuring method Sample Control method SizeFreq. 01 Green Compressive Strength (GCS) Universal Strength M/c1Every HourSand Testing Report 02MoistureIR Moisture Dryer1Every HourSand Testing Report 03Permeability 1Every HourSand Testing Report 04CompactabilityScale1Every HourSand Testing Report 05Active ClayMethylene Blue Test1 Every ShiftSand Testing Report 06Total ClayClay Washer1 Once / WeekSand Testing Report 07Mold HardnessMould Hardness Tester1 Every HourCheck Sheet 08 Tapping / Ladle Release Temperature Pyrometer1 Every Laddle Daily Melting, Pouring & Analysis Report. 09Weight of AdditionsWeighing Scale1Every Treatment Daily Melting, Pouring & Analysis Report. 10 Time control after Treatment to final Pouring Hooter1Every Treatment ---- 11 Chemical Composition (Furnace Metal) Coin Sample + Spectro Meter 1Every Heat Daily Melting, Pouring & Analysis Report, Spectra Report Final Quality Check (Quality Planning)

82 Sl No ParameterMeasuring method Sample Control method SizeFreq. 12 Chemical Composition (After Mg Treatment) Coin Sample + Spectro Meter 1Every Treatment Daily Melting, Pouring & Analysis Report, Spectro Report 13NodularityMicroscope1Every Treatment Daily Melting, pouring & Analysis Report 14MicrostructureMicroscope1Every Treatment Daily Melting, pouring & Analysis Report 15HardnessBrinel Hardness Tester1Every Treatment Daily Melting, pouring & Analysis Report 16ElongationUniversal Testing M/c1 Once Per Prod. Lot (Continuous Heat) Mechanical Test Report 17Tensile StrengthUniversal Testing M/c1 Once Per Prod. Lot (Continuous Heat) Mechanical Test Report 18Yield StrengthUniversal Testing M/c1 Once Per Prod. Lot (Continuous Heat) Mechanical Test Report 19Wall Thickness Cut Section + Vernier Caliper / Pistol Caliper 1Every 500 Casting Wall Thickness Insp. Report 20 Casting Surface Defects like Shrinkage, Blow Holes etc. Visual100%----Daily Inspection Report Final Quality Check (Quality Planning)

83 Core shop Pattern shop Pattern & Core shop In charge Quality Meeting Daily & Monthly Foundry Quality CONTINUOUS QUALITY IMPROVEMENTS MouldingshopMeltingFettling Machine shop Quality M.D. Moulding shop incharge incharge Melting shop incharge incharge Fettling shop incharge incharge

84 Conclusion Thank You

85 EXHAUST MANIFOLD G4D3-9430-CA1 EXHAUST MANIFOLD G4D3-9430-DA1 Project Input - Drawings

86 Project Details S. No. Name of the Project Part NamePart NumberCustomer Shared Volume 1AJ - 200Exhaust Manifold G4D3-9430-CA (N/S) FY14/15 - 2094 FY15/16 - 49061 FY16/17 - 192299 FY17/18 - 218726 FY18/19 - 225605 FY19/20 - 231074 FY20/21 - 235392 FY21/22 - 235392 FY22/23 - 235392 2AJ - 200Exhaust Manifold G4D3-9430-DA (E/W)

87 Project Input – CAD Model North / South Mid / Low Spec East / West Mid Spec Only

88 Feasibility Clarification – Summary

89 Project Planning Chart

90 Cope Side Match Plate Pattern Layout Concept Drag Side Match Plate

91 Drag PatternCope Pattern Pattern Concept Pattern Layout Concept

92 a) Gating System Design & Analysis Casting and Core Weight Casting Weight (Single Cavity) 4.6Kg Gating Weight15.50 Kg Risers Weight_ Total casting weight (4 cavity) 18.56 Kg No of Core02 Nos. Total Core Weight2.0 Kg Spure In Gate Casting Core_2 Core_1 Runner bar Pattern Layout Concept

93 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-DA1 Exhaust Manifold Gating System design and Analysis

94 Casting Material Si Mo Mould Material Green Sand Core Material Shell Sand Pouring Temperature 1440 c Mold Temperature 25 C Liquidus / Solidus (Castings) 1172 / 1135 Gating Design Materials and Conditions CSiMnCu SPMoMg 3.4 Max. 3.75- 4.5 0.6Max - 0.02 Max 0.08 Max 0.4- 0.6 - Chemical Composition of Material (IDM 5381) b) Data Input Spure Runner Bar In gate Gating System design and Analysis

95 Concept for Core – Shell Core Main Core ASSEMBLY CORE BOX Ejecting pin mounting plate Mounting Plate Ejecting pin mounting plate Ejecting pin Core box _ Bush Half Core box _ Pin Half Core

96 Concept for Core – Shell Core Main Core Core Trimming area(pink line ) Trimmed Core After dipping Core

97 Actual Core Photographs and Assembly Core_1Core_2 core_1&2 Assemble

98 PFD, PFMEA & Control Plan of CA1 - Foundry PFD – Foundry – CA1 PFMEA – Foundry – CA1 CP – Foundry – CA1

99 PFD, PFMEA & Control Plan of CA1 – Machine shop PFD – Machine shop – CA1 PFMEA – Machine-shop – CA1CP – Machine shop – CA1

100 PFD, PFMEA & Control Plan of DA1 - Foundry PFD – Foundry – DA1 PFMEA – Foundry – DA1 CP – Foundry – DA1

101 PFD, PFMEA & Control Plan of DA1 – Machine shop PFD – Machine shop – DA1 PFMEA – Machine-shop – DA1CP – Machine shop – DA1


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