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SPM AUTOCOMP SYSTEMS PVT LTD. INDIA

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

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

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

5 SPM – AN OVERVIEW

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 : USD 36 Mio (w/o BOP USD 23 Mio) Production Casting & Machining of Automotive components Certification ISO/TS & 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 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.

8 SPM ROAD MAP TO VISION 74 PPM at Customer End
Development Phase Consolidation Growth Phase 74 PPM at Customer End Internal Rejection control from 15% to 6% Yield Improvement from 37% to 45%. Productivity improvement 30% Organization Stability & Development Organization 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 Nos No. of Customers Built – 5 Nos. Target Sales: 10% of world market i.e. 3.6 million of Cast Exhaust Manifold Sales Achieved –US $ Million Sales Achieved – US $4.78 Million

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 PLANT LOCATIONS 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) Plant -1 Serving to all domestic customers like MSIL, SPIL, TML, JCB, Honda and Tata-Cummins based in North and Eastern India 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,

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

14 SITE PLAN – Plant 2 Machine Shop Foundry

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

16 Tata Motors – Engine Mounting Bracket Line
Standard Room

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

18 Manufacturing Product Range
Catalytic Inlet Exhaust Manifold Manifold Assembly Mounting Bracket Case Differential Steering Knuckle

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

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. ) AS CAST AS MACHINED EXHAUST MANIFLOD GM 1.3 LTR

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

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

24 METALLURGY GRADE & SPECIFICATION
Specification Grade FCD 450 FCD 450HS SG 500 HTN 550 FCD 500M D-5S Customer Maruti Suzuki Eicher Avtec TATA Suzuki Powertrain AVTEC Chemical Composition %C 2.5 Min 3.2 – 4.40 3.5 2.3 Max %Si -- %Mn 0.4 Max 0.3 0.30 Max 1.0 Max %P - 0.10 Max 0.08 Max 0.050 Max 0.50 Max %S 0.03 Max 0.02 Max 0.015 Max 0.020 Max %Mo %Cr %Mg 0.09 Max 0.025 Min %Cu 0.5 Max %Ni Mechanical Properties 1. Hardness (BHN) 2. Tensile Strength 450 Mpa 45Kg/mm2 500 Mpa 490 N/mm2 550 N/mm2 50 Kg/mm2 Mpa 3.Yield Strength 280 Mpa 38Kg/mm2 290 Mpa 320 Mpa 375 N/mm2 33 Kg/mm2 Mpa 4.Elongation (Min) 10% 7% 8% 5% % Microstructure 1. Nodularity 60% Min 75% 75% Min 80% Min 90% Min 85% Min 2. Nodule Count 70 Min 3. Pearlite 50 % Max Balance 10% Max Ferrite + Pearlite with 2% max Cementite 10% Max** 40% Max 4. Cementite 5% Max 5. Ferrite 50% Min 70% 70% Min 90% Max - Specification after Heat Treatment New Development

25 QMS And EMS CERTIFICATION
ISO/TS And ISO-14001

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) 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

28 FACILITY OF MANUFACTURING & TESTING/INSPECTION EQUUIPMENT
FOUNDRY - PRODUCTION FOUNDRY - QUALITY Sl. Equipment Description Model/Make Nos. 1 Moulding M/c Fritz 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 7 Wedge Breaker 8 Shot Blasting m/c 9 Tumbler Rotary Type 10 Heat Treatment Furnace APS 11 Fettling Facility Sl Equipment Description Make & Model Nos. 1 Spectro Spectro Lab, Germany 2 Microscope Union, Japan 3 Optical Brinell Hardness Tester Fine Testing 4 UTM for Checking GCS Versatile 5 IR Moistur Teller 6 Permeability Meter 7 Test Sieves

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

30 PHASE 1 - PREFILL 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

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

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

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

34 Flask rigidity is of paramount importance in high-pressure molding
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.

35 SPECIAL FEATURES Flask cleaning unit (left). Automatic Box Cleaning as compared to Manual Cleaning in the Present Line Automatic sprue cutting unit (right). Online Automatic Sprue Cutting as compared to Manual cutting in Present Line, avoiding variation in pouring cup size

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

37 FACILITY OF MANUFACTURING & TESTING/INSPECTION EQUUIPMENT
MACHINE SHOP - PRODUCTION MACHINE SHOP - QUALITY Sl. Equipment Description Make & Model Nos. 1 HMC Makino/DMG 2 VMC Makino S33/ DMG 7 3 AMS MCV 500S/450S 24 4 CNC Milling M/c BFW 5 CNC Turning Machine LOKESH 6 Pneumatic Leak Test M/c with Auto Marking Auto Test 10 Washing Machine Gayatri Auto Sl. Equipment Description Make & Model Accuracy Nos. 1 CMM Carl Jeiss mm 2 Roughness tester Mitutuyo 09.01 Ra 3 Milipore Tester Milipore 4 Weighing Machine Adventure Gms 5 Tool Pre-setter PWB Swiss 0.001mm 6 All Std. instruments like micrometer, height gauges, Lever Dial etc

38 Raw Material Sources S. No. Raw Material Source Remarks 1 Scrap MSIL
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 9 Raw Sand Allahabad Sand 10 Resin Coated sand SPM, Indore

39 Process Capability of Foundry Critical Parameters
Process Capability of Existing Product - Foundry Process Capability of Foundry Critical Parameters S. 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/cm2 Green Compressive Strength (GCS) 1.36 1.38 1.37 1.42 1.45 1.51 1.52 2 40 ~ 48 Compactibility 1.35 1.48 1.39 1.34 1.41 1.49 3 134 ~ 156 Permeability 1.53 1.57 1.61 1.58 1.64

40 Process Capability of Critical Parameters - Machining
Process Capability of Existing Product - Machining Process Capability of Critical Parameters - Machining S. 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 1.41 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 Inner Dia 2.92 3.16 2.61 2.67 2.79 2.82 2.87 3.41 5 Outer Dia 2.48 2.64 2.93 3.11 3.15 3.17 3.22 6 0.04 mm Max. Run Out 2.11 2.91 2.96 2.99 3.06

41 Process Capability of Existing Product - Machining

42 List of Poke Yoke 1. Sand Plant 2. Molding line 3. Core Shop
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

43 Poke Yoke Implementation

44 Poke Yoke Implementation

45 Poke Yoke Implementation

46 Poke Yoke Implementation

47 Poke Yoke Implementation

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

49 CASTING TECHNOLOGY &PROCESS

50 Casting Technology 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.

51 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.

52 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.

53 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.

54 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.

55 Casting Process (Basics)
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 ~ 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

56 Casting Product Process Details
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

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

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

59 CORE MAKING PROCSS Start of machine in auto mode
Cleaning of sand on core box area Core removal from core box Separation of loose pc. Ingate cutting Cleaning by aluminum strip Recording Core Storage

60 CORE TRIMMING AND DRESSING
Remove all parting lines and fins from core surface. Remove all projection & ingates from core surface. Core ready for inspection, trimming and dressing Inspection of core for over baked and under baked Graphite Pasting where required Visual inspection of core Storage of core Checking of finishing and profile of core

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 Put heat / date code on pattern Tighten the allen bolt of drag pattern by allen key with cross direction Tighten the allen bolt of cope pattern by allen key with cross direction Mount the pattern with properly matching of dowel pins

62 MOULDING PROCESS Set the molding machine parameter Clean the pattern
Spray mold releasing agent Check the outcome cope mold quality Set and Check the mold for any sand crushing after core setting Check the core before setting Make venting on cope mold at specified location Check the outcome drag mold quality

63 MOULDING PROCESS 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

64 Addition of turning Chips in Furnace
MELTING PROCESS Weighing of Scrap Putting in empty bin Empty Furnace Weighing of graphite on weighing scale. Addition of re-melt in Furnace Addition of turning Chips in Furnace Addition Scrap in furnace Addition of graphite in furnace

65 Addition of Ferro Alloys in Furnace
MELTING PROCESS Addition of e re-melt in Furnace (if required) Addition of Ferro Alloys in Furnace Addition of Ferrogen in half filled Furnace Addition of re-melt in Furnace (If required) Preparation of Coin Sample Checking of temperature in Furnace Removal The slag from Furnace Spreading of Slax-30 at melt in Furnace

66 MELTING PROCESS Put the Coin Sample in water for cooling
Send the sample to lab for testing chemical composition Weight the FeSiMg Add FeSiMg in treatment ladle by using funnel. Put steel punch over FeSiMg in treatment ladle by using funnel Make zero weight of treatment ladle Tap the melt in treatment Ladle Check the weight of melt

67 MELTING PROCESS Checking of temperature in pouring ladle before pouring Pouring of metal in Mould Removal of slag from the pouring ladle before pouring Transfer of melt in pouring ladle & add the inoculant in stream Coin Sample cooling Taking of metal from pouring ladle for coin sample. Offer sample for testing

68 KNOCK OUT AND SHOT BLASTING Putting the hanger inside the machine
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 Closing of door Putting the hanger inside the machine Loading of separated casting into shot blasting hanger

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

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

71 CASTING INSPECTION PROCESS Ok Component for Machining

72 MACHINING PROCESS

73 Layout of Machine Shop

74 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

75 MACHINE SHOP PROCESS FLOW
Engine QC MACHINE SHOP PROCESS FLOW Face Milling &Drilling Spot Facing Boss Milling& M6 Tapping Face Milling ø 114.0 Final Fixture Inspection Leak Testing Date code Numbering M18 Tapping Oiling Packing Final Inspection Washing

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

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

78 FORD CD EXPORT PACKAGING Example

79 DEVELOPMENT PROCESS

80 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

81 Final Quality Check (Quality Planning)
Sl No Parameter Measuring method Sample Control method Size Freq. 01 Green Compressive Strength (GCS) Universal Strength M/c 1 Every Hour Sand Testing Report 02 Moisture IR Moisture Dryer 03 Permeability 04 Compactability Scale 05 Active Clay Methylene Blue Test Every Shift 06 Total Clay Clay Washer Once / Week 07 Mold Hardness Mould Hardness Tester Check Sheet 08 Tapping / Ladle Release Temperature Pyrometer Every Laddle Daily Melting, Pouring & Analysis Report. 09 Weight of Additions Weighing Scale Every Treatment 10 Time control after Treatment to final Pouring Hooter ---- 11 Chemical Composition (Furnace Metal) Coin Sample + Spectro Meter Every Heat Daily Melting, Pouring & Analysis Report, Spectra Report

82 Final Quality Check (Quality Planning)
Sl No Parameter Measuring method Sample Control method Size Freq. 12 Chemical Composition (After Mg Treatment) Coin Sample + Spectro Meter 1 Every Treatment Daily Melting, Pouring & Analysis Report, Spectro Report 13 Nodularity Microscope Daily Melting, pouring & Analysis Report 14 Microstructure 15 Hardness Brinel Hardness Tester 16 Elongation Universal Testing M/c Once Per Prod. Lot (Continuous Heat) Mechanical Test Report 17 Tensile Strength 18 Yield Strength 19 Wall Thickness Cut Section + Vernier Caliper / Pistol Caliper Every 500 Casting Wall Thickness Insp. Report 20 Casting Surface Defects like Shrinkage, Blow Holes etc. Visual 100% ---- Daily Inspection Report

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

84 Conclusion Thank You

85 Project Input - Drawings
EXHAUST MANIFOLD G4D CA1 EXHAUST MANIFOLD G4D DA1

86 Project Details S. No. Name of the Project Part Name Part Number
Customer Shared Volume 1 AJ - 200 Exhaust Manifold G4D CA (N/S) FY14/ FY15/ FY16/ FY17/ FY18/ FY19/ FY20/ FY21/ FY22/ 2 G4D 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 Pattern Layout Concept
Cope Side Match Plate Drag Side Match Plate

91 Pattern Layout Concept
Pattern Concept Cope Pattern Drag Pattern

92 Pattern Layout Concept
a) Gating System Design & Analysis Spure Casting 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 In Gate Casting Core_2 Core_1 Runner bar

93 Gating System design and Analysis G4D3-9430-DA1 Exhaust Manifold
a) Gating System Design G4D DA1 Exhaust Manifold Spure In Gate Casting Weight (Single Cavity)‏ 4.808Kg Gating Weight 15.50 Kg Risers Weight _ Total Castings Weight (4 cavity) Kg No of Core 02 Nos Total Core Weight 2.25 Kg Casting Core_2 Core_1 Runner bar

94 Gating System design and Analysis
b) Data Input Materials and Conditions 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 Spure Runner Bar In gate Chemical Composition of Material (IDM 5381) C Si Mn Cu S P Mo Mg 3.4 Max. 0.6Max - 0.02Max 0.08Max

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

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

97 Actual Core Photographs and Assembly
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 – CA1 CP – 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 – DA1 CP – Machine shop – DA1


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