Presentation on theme: "SPM AUTOCOMP SYSTEMS PVT LTD. INDIA"— Presentation transcript:
1 SPM AUTOCOMP SYSTEMS PVT LTD. INDIA INTRODUCTIONSPM AUTOCOMP SYSTEMS PVT LTD. INDIA3rd 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 PROCESSProcess FlowLeak TestingPackaging
4 CONTENTS 4. DEVELOPMENT PROCESS Cross Functional Team/Multi Disciplinary TeamProject DetailsProject Input – Drawing, CAD Model, customer standardsFeasibility study – SummaryProject planning ChartProcess Design – CastingPattern lay outGating SystemCore ConceptMolding processQuality PlanningPFD, PFMEA and CP – Foundry and Machining
6 CORPORATE PROFILE Foundation Established at 2002 Employee 755 person in total450 persons at Manesar Gurgaon unit305 persons at Ranjangaon Pune unitCapitalCapital : USD 4.27 Mio ( Gurgaon unit)Capital : USD 15.0 Mio ( Pune Unit )Turnover: USD 36 Mio (w/o BOP USD 23 Mio)ProductionCasting & Machining of Automotive componentsCertificationISO/TS & ISO14001PlantsManesar, Gurgaon (Foundry & Machine Shop)Ranjangaon, Pune ( Foundry & Machine Shop)
7 VISION & MISSIONVISIONTo Achieve Ten percent of the World Market of Cast Exhaust Manifolds by the Year 2015.MISSIONTo 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 DevelopmentPhaseConsolidationGrowth Phase74 PPM at Customer EndInternal Rejection control from 15% to 6%Yield Improvement from 37% to 45%.Productivity improvement 30%Organization Stability & DevelopmentOrganization RecruitmentSetting up of Technical Research CenterNo. of Product developed – 40 Nos.No. of Product developed –25 Nos.New Foundry for Exhaust manifold, Turbine Housing & Turbo ManifoldsNo. of Customers Built – 7 NosNo. of Customers Built – 5 Nos.Target Sales: 10% of world market i.e. 3.6 million of Cast Exhaust ManifoldSales Achieved –US $ MillionSales 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 BktsTata Cummins : Ex ManifoldBridgestone TVS India : Engine Mounting BktFiat India : Exhaust ManifoldMahindra Navistar : Exhaust ManifoldsHyundai Motors : Exhaust ManifoldAvtec Ltd : Exhaust Manifold for Daimler enginesEicher 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 -1Serving to all domestic customers like MSIL, SPIL, TML, JCB, Honda and Tata-Cummins based in North and Eastern IndiaPlant - 2Serving 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,
13 OVERVIEW PLANT - 2MAIN ENTERANCEAdministration BlockMachine Shop BuildingFoundry Building
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.PrefillShootSqueeze
30 PHASE 1 - PREFILLPrefill 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 moldOutstanding casting skin quality
31 PHASE 2 - SHOOTExcellent mold surface hardness with homogeneous distribution from mold center to flask edgesDistanceto edge25 mm or LessMold hardness87-92°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 achievedStrictly controlled compression force per mold surface unitMinimum casting mass variationMinimum usage of sand
33 FLASK DESIGNPin / 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 FEATURESFlask cleaning unit (left). Automatic Box Cleaning as compared to Manual Cleaning in the Present LineAutomatic 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 castingDiameter variation is < +/- 0.5 mmMass variation< 0.2 kg on 50 kg casting
37 FACILITY OF MANUFACTURING & TESTING/INSPECTION EQUUIPMENT MACHINE SHOP - PRODUCTIONMACHINE SHOP - QUALITYSl.Equipment DescriptionMake & ModelNos.1HMCMakino/DMG2VMCMakino S33/ DMG73AMS MCV 500S/450S244CNC Milling M/cBFW5CNC Turning MachineLOKESH6Pneumatic Leak Test M/c with Auto MarkingAuto Test10Washing MachineGayatri AutoSl.Equipment DescriptionMake & ModelAccuracyNos.1CMMCarl Jeissmm2Roughness testerMitutuyo09.01 Ra3Milipore TesterMilipore4Weighing MachineAdventureGms5Tool Pre-setterPWB Swiss0.001mm6All Std. instruments like micrometer, height gauges, Lever Dial etc
38 Raw Material Sources S. No. Raw Material Source Remarks 1 Scrap MSIL GECold Rolled mild steel scrap2Graphite(1) Graphite India(2) MPM3FeMoMoly Metals / Ess Ell Mining4FesiRNB Carbide5FeSiMgSnam Alloy6BentoniteAshapura International7LustronMPM8Innoculant9Raw SandAllahabad Sand10Resin Coated sandSPM, Indore
39 Process Capability of Foundry Critical Parameters Process Capability of Existing Product - FoundryProcess Capability of Foundry Critical ParametersS. No.SpecificationCritical ParametersProcess Capabililty Index (Cpk)Jan-12Feb-12Mar-12Apr-12May-12Jun-12Jul-12Aug-1211.65 ~ 2.00 Kg/cm2Green Compressive Strength (GCS)1.361.381.371.421.451.511.52240 ~ 48Compactibility1.351.481.391.341.411.493134 ~ 156Permeability1.531.571.611.581.64
40 Process Capability of Critical Parameters - Machining Process Capability of Existing Product - MachiningProcess Capability of Critical Parameters - MachiningS. No.SpecificationComponent NameCritical ParametersProcess Capabililty Index (Cpk)Jan-12Feb-12Mar-12Apr-12May-12Jun-12Jul-12Aug-1210.07 mm min.Exhaust Manifold - F8DFlatness1.381.391.401.411.421.441.4720.25 mm Max.Exhaust Manifold - 830Position1.632.092.172.042.252.031.772.063Ra1.6 Max.Case Diff.Surface Finish126.96.36.1993.873.194.715.215.274Inner Dia2.923.162.612.672.792.822.873.415Outer Dia2.482.642.9188.8.131.52.2260.04 mm Max.Run Out2.112.912.962.993.06
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 cellAdditives Weighing - load cellRTC Compatibility2. Molding lineShoot pressure in mold machineSqueeze presssure in mold machineAir pressure of mold line3. Core ShopHigher & low temperature of core box of all machinesAir pressure of core shootersCore oven temperature
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 TechnologyThe 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 TechnologyIn 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 TechnologyCores 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 TechnologyThe 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) 1Molding ProcessHigh pressure molding – HorizontalBox size 900*700*2252No of cavities in pattern Match plate4 ~ 8 (depends on geometry)3Core process- Hot baked shell sand process4No of cores required for the casting~ 4 (depends on geometry)5Melting processMedium frequency Inductionfurnace - electric6De-coring process- Mechanical vibrator7Shot blasting process- Stage shot blasting using cast iron shot8Casting finishing- Manual fettling grinders
56 Casting Product Process Details Sand PreparationCore Making & Core TrimmingMould Closing & ClampingMeltingMagnesium TreatmentPouringLab Clearance for CastingPrimary InspectionKnocking & HaulingShot blastingFinal Inspection (Foundry Stage)Re-shot BlastingFettlingReady for MachiningMoldingDrying & Insp.Core SettingLab ClearanceInoculation
57 PROCESS FLOW - CASTING Final Inspection Raw material Sand Preparation Engine QCPROCESS FLOW - CASTINGRaw materialSand PreparationCore MakingCore TrimmingMetallurgical InspPouringMeltingMouldingShot blastingFettlingRe Shot blastingFinal Inspection
58 CORE MAKING PROCSS Core box cleaning Applying parting agent Checking of temperatureAir pressure settingSetting of cycle timeVerification of sand levelLoose pc. installationVerification of air pressure
59 CORE MAKING PROCSS Start of machine in auto mode Cleaning of sand on core box areaCore removal from core boxSeparation of loose pc.Ingate cuttingCleaning by aluminum stripRecordingCore 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 dressingInspection of core for over baked and under bakedGraphite Pasting where requiredVisual inspection of coreStorage of coreChecking of finishing and profile of core
61 MOULDING PROCESS Check the Cope pattern before loading Check the Drag pattern before loadingLift the pattern for loadingClean the bolster by using Compressed AirPut heat / date code on patternTighten the allen bolt of drag pattern by allen key with cross directionTighten the allen bolt of cope pattern by allen key with cross directionMount the pattern with properly matching of dowel pins
62 MOULDING PROCESS Set the molding machine parameter Clean the pattern Spray mold releasing agentCheck the outcome cope mold qualitySet and Check the mold for any sand crushing after core settingCheck the core before settingMake venting on cope mold at specified locationCheck 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 moldMold ready for pouring
64 Addition of turning Chips in Furnace MELTING PROCESSWeighing of ScrapPutting in empty binEmpty FurnaceWeighing of graphite on weighing scale.Addition of re-melt in FurnaceAddition of turning Chips in FurnaceAddition Scrap in furnaceAddition of graphite in furnace
65 Addition of Ferro Alloys in Furnace MELTING PROCESSAddition of e re-melt in Furnace (if required)Addition of Ferro Alloys in FurnaceAddition of Ferrogen in half filled FurnaceAddition of re-melt in Furnace (If required)Preparation of Coin SampleChecking of temperature in FurnaceRemoval The slag from FurnaceSpreading 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 compositionWeight the FeSiMgAdd FeSiMg in treatment ladle by using funnel.Put steel punch over FeSiMg in treatment ladle by using funnelMake zero weight of treatment ladleTap the melt in treatment LadleCheck the weight of melt
67 MELTING PROCESSChecking of temperature in pouring ladle before pouringPouring of metal in MouldRemoval of slag from the pouring ladle before pouringTransfer of melt in pouring ladle & add the inoculant in streamCoin Sample coolingTaking 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 knockoutRemoval of bunches from hoist to floorArranging of all bunches as per item / heat no. wiseHeat no. identificationKnock out of casting with wedge breakerClosing of doorPutting the hanger inside the machineLoading of separated casting into shot blasting hanger
69 KNOCK OUT AND SHOT BLASTING Machine operation in auto modeCasting taking out after shot blastingOffer the casting for Primary Inspection
70 FETTLING PROCESS Chipping Pedestal Grinding Straight Cutter Grinding Component for FettlingComponent for InspectionRe-shot blastingGrinding through air toolPneumatic hand grinding
71 CASTING INSPECTION PROCESS Ok Component for Machining
74 PROJECT BASICS ( Machining) 1Machining ProcessVMC2Post machining de-burringManual3Post machining leak testingAutomatic test cycle using dry air process4On line and patrol inspectionStandard and special gauges, Carl Zeiss 3D Co-ordinate measuring machine5Part washingAuto cycle part washing m/c6Anti-rust treatmentUsing antirust oil and VCI bag protection7PackingCorrugated box with partition
80 CFT/MDT Team S. No. Name of the Person Department Designation Job Responsibility1P K BanerjeeEngineeringJMDChief Co-ordinator of Project2Jayarama PradhanCorporate Quality, Engg. And Customer SupportGeneral ManagerFinal Approval of the Project3Rajan NairProcess Development - CastingChief Technical OfficerDevelopment of the casting process4Poonam WangnooQualitySenior ManagerAnalysis of the product and process capability5Anil ShindeMachine Engg.Senior MangerDevelopment of the Machining process6N S JinaProcess Engg. – Machine shopManagerDevelopment of Tooling – Machine shop
81 Final Quality Check (Quality Planning) Sl NoParameterMeasuring methodSampleControl methodSizeFreq.01Green Compressive Strength (GCS)Universal Strength M/c1Every HourSand Testing Report02MoistureIR Moisture Dryer03Permeability04CompactabilityScale05Active ClayMethylene Blue TestEvery Shift06Total ClayClay WasherOnce / Week07Mold HardnessMould Hardness TesterCheck Sheet08Tapping / Ladle Release TemperaturePyrometerEvery LaddleDaily Melting, Pouring & Analysis Report.09Weight of AdditionsWeighing ScaleEvery Treatment10Time control after Treatment to final PouringHooter----11Chemical Composition (Furnace Metal)Coin Sample + Spectro MeterEvery HeatDaily Melting, Pouring & Analysis Report, Spectra Report
92 Pattern Layout Concept a) Gating System Design & AnalysisSpureCasting and Core WeightCasting Weight(Single Cavity)4.6KgGating Weight15.50 KgRisers Weight_Total casting weight (4 cavity)18.56 KgNo of Core02 Nos.Total Core Weight2.0 KgIn GateCastingCore_2Core_1Runner bar
93 Gating System design and Analysis G4D3-9430-DA1 Exhaust Manifold a) Gating System DesignG4D DA1 Exhaust ManifoldSpureIn GateCasting Weight(Single Cavity)4.808KgGating Weight15.50 KgRisers Weight_Total Castings Weight (4 cavity)KgNo of Core02 NosTotal Core Weight2.25 KgCastingCore_2Core_1Runner bar
94 Gating System design and Analysis b) Data InputMaterials and ConditionsCasting MaterialSi MoMould MaterialGreen SandCore MaterialShell SandPouring Temperature1440cMold Temperature25 CLiquidus / Solidus (Castings)1172℃ / 1135℃Gating DesignSpureRunner BarIn gateChemical Composition of Material (IDM 5381)CSiMnCuSPMoMg3.4 Max.0.6Max-0.02Max0.08Max
95 Concept for Core – Shell Core Main CoreASSEMBLY CORE BOXEjecting pin mounting plateMounting PlateEjecting pinCore box _ Bush HalfCore box _ Pin HalfCore
96 Concept for Core – Shell Core Main CoreTrimmed CoreCore 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 – CA1PFMEA – Foundry – CA1CP – Foundry – CA1
99 PFD, PFMEA & Control Plan of CA1 – Machine shop PFD – Machine shop – CA1PFMEA – Machine-shop – CA1CP – Machine shop – CA1
100 PFD, PFMEA & Control Plan of DA1 - Foundry PFD – Foundry – DA1PFMEA – Foundry – DA1CP – Foundry – DA1
101 PFD, PFMEA & Control Plan of DA1 – Machine shop PFD – Machine shop – DA1PFMEA – Machine-shop – DA1CP – Machine shop – DA1