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Casting CP

This document is a control plan for casting a flywheel assembly. It outlines the key contact people, part details, processes, characteristics to be evaluated, measurement techniques, sample sizes and frequencies, control methods, and reaction plans. The processes covered include sand preparation, mould making, and casting. Characteristics such as moisture content, permeability, green compressive strength, mould hardness, and chemical composition are evaluated. Methods such as moisture testing, permeability meters, GCS machines, hardness testing, and spectroscopy are used. Non-conforming test results trigger corrective actions like sand remixing, mould rework, or composition readjustment to ensure process and product specification compliance.

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Suraj Rawat
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© © All Rights Reserved
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Download as XLSX, PDF, TXT or read online on Scribd
3K views2 pages

Casting CP

This document is a control plan for casting a flywheel assembly. It outlines the key contact people, part details, processes, characteristics to be evaluated, measurement techniques, sample sizes and frequencies, control methods, and reaction plans. The processes covered include sand preparation, mould making, and casting. Characteristics such as moisture content, permeability, green compressive strength, mould hardness, and chemical composition are evaluated. Methods such as moisture testing, permeability meters, GCS machines, hardness testing, and spectroscopy are used. Non-conforming test results trigger corrective actions like sand remixing, mould rework, or composition readjustment to ensure process and product specification compliance.

Uploaded by

Suraj Rawat
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLSX, PDF, TXT or read online on Scribd
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Control Plan

Doc. No. : PDC-EPD-F02


Rev. No. : 01 (03/04/2015)
Casting Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : 424513119900 Revision No. (Date):00(07/05/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-01-08 Organization / Plant Approval Date : N/A Date (Originated) : N/A Mr. RS Shekhawat Engg. Drawing [email protected]
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Samadar Singh Manager - Casting

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N/A Mr. Sanju Das Engineer - Lab

Grade : FG 260 as per IS 210:2009


Characteristics Methods
Machine,
Part / Special
Process Name/ Device, Jig,
Process Char. Evaluation/ Sample Reaction Plan Record
Operation Description Tools for BLN Product/ Process/
Number No. Product Process Class Measurement Control Method
Mfg. No. Specification/ Tolerance
Technique Size Freq. & Responsibility

WI - Sand
1.01 Moisture 2.0% - 4.0% Moisture Tester Remix
Preparation

Permeability - Permeability WI - Sand


1.02 Minimum 50 Remix
Facing Sand Meter Preparation
Sand Each Batch- Lab
1 Sand Preparation 1
Mixer Technician
Permeability - Permeability WI - Sand
1.03 Minimum 60 Remix Sand Testing
Backing Sand Meter Preparation
Report

Minimum 0.40 kg/ WI - Sand


1.04 GCS GCS machine Remix
Cm2 Preparation

100 %
Each Batch-
Moulding
Machines

Mould Hardness - Mould Checking &


2 Mould Making 2.01 Min. 65 5 Foundary Shift WI - Moulding
Machine Moulding Hardness tester Break Mould if
Supervisior
not OK

FG 260
Chemical Spectro Readjust
3.01 ▼ Refer Grade Chart 1 Every Heat Lab Technician
Composition Analysis Composition
(QC-CAS-F01)

Operator
Tapping Temperature
3.02 ▼ 1350 ˚ C - 1450˚ C 1 Each Heat Monitoring & Lab Reheat
Temperature Indicator
Induction Furnace

Technician
Charging
Report
Melting and Operator
3 Pouring 1300 – 1400° C Temperature
Pouring 3.03 ▼ 1 Each Heat Monitoring & Lab Reheat
Temperature Indicator
Engg.

Review
Gating
Process Foundry Shift System in
3.04 Pouring Time ▼ Max. 2 mins. 2 2 Per day
Control Supervisior case of any
adverse No need to
observations record
60-75 Mins.
KO Knock Out Refer Knock out Time Foundry Shift Segregate &
4 Knock Out 4.01 Stop Watch 2 2 Per day
Machine Time sheet Supervisior Check
( PRD-CAS-F03 )

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Control Plan
Doc. No. : PDC-EPD-F02
Rev. No. : 01 (03/04/2015)
Casting Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : 424513119900 Revision No. (Date):00(07/05/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-01-08 Organization / Plant Approval Date : N/A Date (Originated) : N/A Mr. RS Shekhawat Engg. Drawing [email protected]
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Samadar Singh Manager - Casting

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N/A Mr. Sanju Das Engineer - Lab

Grade : FG 260 as per IS 210:2009


Characteristics Methods
Machine,
Part / Special
Process Name/ Device, Jig,
Process Char. Evaluation/ Sample Reaction Plan Record
Operation Description Tools for BLN Product/ Process/
Number No. Product Process Class Measurement Control Method
Mfg. No. Specification/ Tolerance
Technique Size Freq. & Responsibility

Blow Holes, Cold Shut,


Shrinkage, Broken
Edges, Crushes, Pin
Blasting Rework /
5 Blasting 5.01 No Visual Defects Holes, Penetration, Visual 100% Each Lot Visual Inspection
Machine Poor Finish, Gas Reject
Casting
Holes, Burrs, Porosity, Analysis
Finns, Report

Visual Inspection
Grinding Gating & Parting Rework /
6 Grinding Machine 6.01 No extra material Visual 100% Each Lot Blasting Shop
Line Reject
Incharge

Micro Test the Cut


Microstructure 1 No Heat- Lab
Testing 7.01 Microstructure Test 1 Lab Testing Section Reject Micro Report
Test Technician
M/C heat if NOT OK

FG 260
7 Testing Refer Grade Chart Brinell Hardness
Hardness
( QC-CAS-F01 ) Testing Machine As Per Internal Check & Hardness
Testing 7.02 Hardness Test 3000 Kg Load Ǿ 1 Lab Testing
M/C Plan Segregate Report
10.00 mm Ball

In Case Of Failure
check counter Check UTM Testing
UTM 7.03 Tensile Strength UTM 1 Shift
sample. If this also Properties Report
fails, reject lot.

Paint Each Batch-


QD Casting Sealer Coating Thicker
Spray 8.01 150-250 microns 1 Blasting Shop Re Coat N/A
Matt Black Tester
Gun Incharge
WI Painting
8 Painting
(PRD-CAS-WI10)
Each Batch-
8.02 Drying Time 3-4 Hours Watch 100% Blasting Shop Adjust Time N/A
Incharge

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