promod gajare brembo brake india pvt ltd

8/11/2019 Promod Gajare Brembo Brake India Pvt Ltd

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Pramod Gajare

Brembo Brake India Pvt Ltd Pune

Selection, Control Process Parameters

& Heat Treatment of GDC

02 March 2013

VI National Foundry Conclave Coimbatore

Prospering in New Abnormal


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CUSTOMER EXPECTATIONS and ANSWERS

Achievable through

optimal management with

structured and disciplined

manner

This is possible through

strong Quality

Management System

(QMS)

Quality System is

developed, implemented

and its effectiveness is

improved by adopting

Process Approach


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PROCESS APPROACH

Process : An activity or set of activities using resources, and managed in

order to enable the transformation of inputs into outputs, can be

considered as a process. (Many a time output from one process directly

forms the input to the next process)

Process Approach : Application of a system of processes within an

organization, together with the identification and interactions of these

processes, and their management to produce the desired outcome.

Process approach provides ongoing control over the linkages between

individual processes as well as over the combinations and interactions

The process approach emphasizes the importance of

Understanding and meeting requirements

The need to consider processes in terms of added value (Value addition)Obtaining results of process performance and effectiveness, and

Continual improvement of processes based on objective measurement.


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PROCESS APPROACH contd..

The evolution and analysis of each process has to be done in

disciplined manner; so that the interactions of the processes can beidentified without any ambiguity.

What is input

What output is expected

Who will execute the process (Competence / Skills / Training of the

person)

How to execute the process? ( Methods / Procedures / Work

Instructions )

With what the process is to be executed (Materials, tools,

equipment, consumables etc...)With What Key criteria? ( Measurement / Test / Assessment )

The tool used for this evolution and analysis : Turtle Diagram


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TURTLE DIAGRAM

PROCESSINPUT OUTPUT

With Who ?(Competence /

skills / Training)

With WhatKey Criteria?

(Measurement,

Assessment)

How?(Methods /

Sequence /

Procedures)

With What?(Materials /

Equipments)


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TURTLE DIAGRAM

(Compare consecutive processes for output & input)

PROCESSINPUT OUTPUT

With Who ?

With What

Key Criteria?How?

With What?

PROCESSINPUT OUTPUT

With Who ?

With What

Key Criteria?How?

With What?

PROCESS # 1 PROCESS # 2


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CHECK, INSPECT & CONTROLCheck :

to verify something

Inspect :to look at something carefully in order to check that it is correct or good enough

Control :

the power to make decisions about something and decide what should happen ,

a law, agreement, or method that limits something

the process of checking to make certain that rules or standards are being applied,to make people behave in the way that you want them to behave

to make a machine, system, vehicle, etc.. move or operate in the way that you

want it to

to keep something at the correct level

the ability to stop something from increasing or becoming dangerous,to prevent something from increasing too much or too quickly

to prevent something harmful from spreading or becoming more dangerous


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UNDERSTANDING CUSTOMER REQUIREMENTS

SpecifiedRequirements

Not Stated butnecessary for

specified or intendeduse

Statutory &Regulatory

Requirements

Additionalrequirements

considered necessaryby the organization

CUSTOMERREQUIREMENTS


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FEASIBILITY ANALYSIS

Detailed study & analysis of technical specifications and

test methodsConsider all aspects ( Monthly / yearly volumes, cost,

delivery mode etc...)

Gaps Identification : Comparison with what is

maintained / achieved for running product and what isspecified (expected) for the new product.

Actions for closing the Gaps : to make manufacturing of

new part (casting) feasible

Detailed feasibility Report always helps


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SPECIAL CHARACTERISTICS

These are product characteristics or process parameters

which; if not complied with; may affect safety, conformity to

national/international regulatory standards, fitment,

function, performance, or subsequent processing of product.

Control on process parameters to ensure capability is often

missed out. Some examples of such parameters are

solutionising temperature, quenching delay time, quenching

water temperature , ageing temperature , etc...

Appropriate Statistical tools with correct measurement

system or suitable automation is expected for controlling the

manufacturing process parameters.


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TOOLS FOR PROCESS CONTROL

Optimum management of the manufacturing processes by

controlling all the special characteristics of process and the

productthrough following methodologies, tools, and

techniques.

Fool proofing /Mistake proofing

Automatic sequencing

Automatic detection and isolation

Control by variables

Control by attributes

This is applicable at all stages of manufacturing process; right

from receipt of ingots till the dispatch of the castings.


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ALARMS, INTERLOCKS AND AUTOMATIONAlarm for non-operation

Alarm for premature operation

Alarm for malfunctionAlarms to remind about repetitive/ Scheduled activity

Interlock for Sequence

Interlock for subsequent operations.

Periodic check for proper functioning of the Alarms and interlocks is MUST.

Automation reduces human effort and fatigue substantially and removes any chanceof human error

Automation respects time, therefore, higher productivity is expected

Automation obeys logical sequencing, hence enables repetitive actions

Automation, due to its timer discipline, ensures consistency and therefore constantquality!

Areas of Automation

Chemical Analysis of Melt

Temperature control of Melt , Die, Heat Treatment furnace

Metal Pouring

Fettling


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PROCESS DESIGNSolely dependent on the technological competency of the

supplier.

The logical and systematic handling and monitoring of variousstages of design is important

Use of mathematical calculations always help to understand the

pros and cons of the concepts used.

All elements of the process must be addressed ( Time to reachsoaking temperature, Quenching delay time )

Consider all possible abuses, their effects and counter actions

(e.g. misuses, manipulations, mishandlings, misapplications,

mistreatments)

Make use of Gaps Identified during feasibility analysis & the

proposed actions for closing the gaps.


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PROCESS FLOW, FMEA, CONTROL PLANS AND

WORK INSTRUCTIONSBackbone of manufacturing process: extreme precaution has to be taken while

making and updating these documents.

Unambiguous definition of (a) Incoming source of variation, (b) special characteristics

of product and manufacturing process in the process flow.

FMEA : Identify ways in which a product / process can fail to meet critical customer

requirements and actions for avoiding the same. The past historical data about

Things gone wrong, things gone right (TGW-TGR)helps to make this task easy.

Control plan must be made available before performing the initial trials cycles. At

this stage the status of control plan isPre-Launchcontrol plan. The control plan

shall be finalized after the trial cycles are completed successfully.

Work instructions serve the expected purpose only when those are simple & easy to

understand. The pictures of accepted and not accepted working practices as well as

of the parts add value to them. The work instructions must be written in a language

which the operators can read and understand.


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SIMULATION STUDYThis tool helps to great extent to find out the potential failures.

Sometimes corrections in the mould are either very costly or not possible,

which can be avoided by using simulation study.Reduces the substantial work of doing the actual trials, checking the

samples, doing analysis and then doing corrections in the mould.

Few iterations of the simulation study and the changes in the design based

on the results of simulation , helps to have a good design output.

Simulation studies must be incorporated in the design program atappropriate intervals.

Consider all aspects during giving inputs for simulation study. (e.g. Minimum

and Maximum limits for : metal temperature, important elements of the

alloy etc..)

Extract maximum possible outputs from simulation. (e.g. Mould filling

pattern, solidification pattern, fill time, trapped oxides, hot spots, air

pockets, areas of shrinkage, porosity, micro-porosity , mould temperature)


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TRIAL CYCLES (INITIAL TRIALS)The trial cycles should be performed to understand following;

adequacy of the process and mould to meet the Quality and productivity

requirements of the part.effectiveness of equipments used for manufacturing , inspection , testing

and material handling

effectiveness of Pokayoke (mistake proofing) provided

effectiveness of training of all involved personnel

effectiveness of controls for traceability

limits of Aesthetic appearance

inputs for revising the Process Flow, FMEA , control plan and work

instructions

Do not forget to document the results, actions identified, and actions

taken for each trial cycle.


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TRACEABILITYTraceability is the series of links that exists between a part and data

recorded previously during its development, manufacturing, and control

processes.

Enables all links necessary to identify causes of possible product variations

during a well-defined time frame.

Immediately provides the data necessary to analyze and resolve problems

and to isolate the defective products.

Enables appropriate, timely, and less costly action to be taken to resolveproblems arising at customer end or in the market.

Enables that the quantity, sorting or reworking of recalled products to be

limited

Enables identification of the responsibilities in a clear and unmistakable

mannerMust cover the entire development stages and manufacturing stages which

are related to the critical characteristics of the process, special

characteristics of the part, and any other characteristic specified by

customer.


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ALLOY

Controlled specifications for some elements view of further processing. ( e.g. Fe,

Mg, Zn etc...).

Your own Standard for the Alloy ( Aluminum gradePrimary / secondary,

Chemistry, Appearance , Heat No. Identification, Fracture Test , Test certificate, Lot

size etc...)

Quality agreement with Alloy Supplier

Test Facility to check the Chemical composition (Spectrometer with Master standard

samples)

Clear cut SOP (Standard Operating procedure ) for inspection and acceptance of the

Alloy.

Explicit Inspection Check Sheet for inspection of the Alloy received.

Alloy wise separate storage location for ingots ; to prevent mix up.

FIFO (First in , first Out) at all the stages.

Separate location for foundry returns from each type of Alloy

Traceability (Documented & Physical) during issue of the material


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MELTINGBest Control : Separate melting furnace for each alloy.

In case above is not viable (Less volumes, use of many alloys); use of dedicated

crucibles with distinct identification on the crucibles.

Identification of dedicated melting furnaces with colour same as colour code of the

particular alloy.

Controls to keep the charge Dry and free from oil and grease

Protection of flux from moisture pick up

Operator friendly definition of charge ratio (e.g. 200 /220 Kg. ingot and 80 /100 Kg.

foundry returns)

Physical weighing of the ingots, foundry returns and flux

Definition of melting sequence . (e.g. charging of scrap, melting of scrap, flux

addition, charging of ingots, melting of ingots, flux addition, rabble, dross removal )

Definition of the Maximum metal temperature (e.g. 750 Deg Max), tapping Temp.

High temperature alarm to avoid Over heating of the alloy

Coating and preheating for melt handling tools.

Traceability : Date, Furnace number, shift, Operator, Melt No, weight of ingots ,

weight of foundry returns, weights of flux, time duration, Max. temp. & Temp at

tapping etc...


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METAL TRANSFERTransfer ladles of appropriate capacity

Dedicated transfer ladles for each alloy

Identification of dedicated transfer ladles with colour same as colour code of theparticular alloy.

Distinct location for keeping ladles meant for different alloys

Definition of Preheating of ladles (e.g. Type of Burner/ Jig, heating time,

measurement/judgment criteria etc...)

Definition of crucible cleaning (e.g. Time interval, judgment criteria, type of flux

etc...)

Mechanism to ensure transfer to specific holding furnace when more than one alloys

are used . ( e.g. Line layout, route card etc...)

Filtering of molten metal at the time of pouring to holding furnace

Skilled operator : takes care of turbulence and thereby, oxide movement into melt

Traceability : Date, shift, Operator, Melting Furnace number, Holding furnace

number, Melt No, time of transfer, weight of metal transferred.


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METAL TREATMENTTreatment in holding furnace is the BEST CONTROL

Definition of temperature ,sequence, time and amount of the agents (e.g.

refinement, degassing, modification, )

Physical weighing of refiners (e.g. AlTiB) and modifiers (e.g. AlSr)

Definition of degassing parameters (Rotor speed, gas Flow, Pressure, Time etc...)

Defined criteria for setting degassing parameters with reference to the seasonal

changes in atmosphere ( e.g. Rainy season, winter, summer etc...)

Measurement of the Relative Humidity on daily basis is always helpful

Automation in degassing (e.g. rotary degassing with programmable settings)

Purity of the Nitrogen gas.(e.g. Ultra High Purity Nitrogen)

Checking of chemical composition after treatment for every melt

Testing of density / density index for every melt


Traceability : Date, Furnace number, shift, Operator, Melt No, weights refiners and

modifiers, time of addition of refiners, and modifiers, Degassing start time, degassing

end time, degassing temperature, gas flow (LPM), Flux used, Chemical composition,

Density/ density index before degassing , Density/ density index after degassing etc...


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DIE MAINTENANCE & DIE COAT APPLICATION

Check sheet for maintenance instructions together with time cycle (frequency)

Being a crucial activity, skilled & trained operator

Check the last casting of the previous run meticulously

Strip or clean coating properly (Use of Glass Bids Blasting Machine)

Open and clean each and every vent plug and gas venting tubes

ENSURE ALL THE VENTS AND TUBES WERE PLACED AT THEIR LOCATIONS

Repair/polish the profiles that showed drag marks/rubbing in the previous run

Preparation of the die coat as required. Use of measuring jars to ensure requisite

amount of water & die coat is used.

Use of a sieve (strainer) to ensure only fine particles of die coat to pass through.

Do not forget to close the lid of the can of supplier tightly. This ensures prevention

of dust particles mixing with the solution.

Check the functioning of the spray gun BEFORE transferring the freshly prepared die

coat into it

Stir the prepared coating solution well before transfer to the gun.

Do not forget to close the lid of the storage can. This ensures prevention of dust

particles mixing with the solution.


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DIE MAINTENANCE & DIE COAT APPLICATION

contdPre-heating the die to required temperature. Use of profile burners to ensure that

there is no concentration of heat due to flame direction.

Do not forget to check the die temperature before spraying the die coat. (Infra-red

digital thermometer is very convenient to measure die temperature)

Spray the die as per desired thickness on the given slide.

CONDUCT DRY RUN TRIAL AFTER ASSEMBLY AND GET SATISFIED

When the Die coat mixture is to be used during the production, vigorous stirring

must precede transfer to gun. Thin particle size of the coating ensures superb

surface finish of the casting. Use of mechanical stirrer is Practically Best Solution

Traceability : Die history card indicating part number, die No, Operator who

performed maintenance, No of castings produced, observations on the last shot,

details of work carried out & parts replaced etc..


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DIE CASTING

Control mechanism for updating the traceability code (when specified )

Interlock to avoid use of wrong programme in case of automatic die operation

Metal Temperature : Control through immersion type thermocouple & temperature

controller (e.g. Thyristor or PID controller )

Interlock for High/Low metal temperature to stop machine operation

Die pre-heating : Use of profile burners to ensure that there is no concentration of

heat due to flame direction.

Interlock for Minimum die temperature to stop machine operation.

Skilled operator : controlled & consistent pouring rate (e.g. 250 grams per second)

Provision of support point /pivot point on the die to facilitate easy pouring

Auto ladling is the BEST CONTROL

Control to protect sand cores from moisture pick up

Protection of flux from moisture pick up


Definition for maximum time for melt holding and repeating the degassing

Audio alarm for repeating the degassing after specified time is lapsed


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DIE CASTING contd

Arrangement to avoid damages to the casting (e.g. Trolley with separators to keep

the shots)

Explicit method / control for physical separation and disposition of initial shots. (e.g.

Cage with lock & key arrangement and a pigeon hole to drop the rejected shots in

the cage)

Definition of inspection parameters, frequency & use of inspection check sheet.

Do not forget to define HOT INSPECTIONfor visual parameters which includes

inspection of feeders, risers etc..

Identification on the shots for respective Melt Number (E.g. Label, Route card etc.)

Definition of casting of the test bars

Traceability : Date, Furnace number, shift, Operator, Melt No, Die temperature,

Metal temperature, Production start time & end time for each & every melt, No of

initial shots scrapped, Degassing start time, degassing end time, Density/ densityindex after second degassing,, No of castings produced, No of castings rejected &

reasons of rejection

Periodic Calibration of the thermocouples and the temperature controllers


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GATE CUTTING AND FETTLINGMostly neglected for controls in many industries

Ensure Line start approval with check sheet to confirm condition & availability of

the respective tools at each station.In-process inspection helps to reduce operator error as well as rework and

rejection.

Melt wise Movement of the shots with identification to ensure traceability

Human oriented activity ; hence possibility of errors. Use of gate cutting machines

and fixtures help to reduce the errors.

Explicit and distinct definition of activities to be done, tools to be used ,

methods/ sequence to be followed and acceptance limits

Visual Aids with Dos and Don'ts always help

Provision of separate bins/pallets for input and output at each station to avoid

mix-up, missing operation .

Low cost Automation helps to get consistency and productivity

Use of Robotics is an emerging trend

Timely and systematic maintenance of the dies and discipline during die casting

reduces the fettling work.

Traceability : Melt No, Operator, Qty rejected & reasons


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HEAT TREATMENT

Suitable Furnace : Capacity (volume & weight of charge, temperature range),

capability (temperature range & uniformity).

Definition of complete Heat treatment cycle (Time and temperatures for

Solutionising , quenching and ageing with allowable tolerances)

Explicit and distinct definition of Reaction plan in case time and/or temperature

exceeds the specified limits

Temperature control mechanism to suit the tolerance on temperature (e.g. PID

controller)

Position & number of control thermocouples (depends on furnace type & capacity)

Temperature recording graphs for each thermocouple

High temperature alarm and interlock

Interlock/alarm for working of air circulating fan

Control on time temperature cycle through PLC or micro processer.

Definition & control of charge (e.g. Loading pattern, Qty of castings per layer, No. of

layers, No. of Test bars & their position etc..)


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HEAT TREATMENT contd

Definition and control of tank water level in quenching tank

Definition and control for decanting used water & filling fresh water

Definition of quenching water temperature & control mechanism (e.g. 40 Deg. Max,

temperature indicator , addition of fresh water etc..)

Controls for effective quenching (e.g. quenching delay time, water agitation,

minimum time for charge in the water etc..)

Verification and certification of the graph for correctness & completeness of the

cycle for each batch

Inspection & Checks : Hardness, Microstructure , physical properties

Traceability : Date, Furnace number, shift, Operator, HT Batch No. No. of castings

loaded and their Melt Nos, Loading time, Soaking start time, Soaking end time,

Soaking temperatures at every hour, Quenching delay time, Water temperature

before quenching, Hardness Microstructure, physical properties etc..Periodic Calibration of the thermocouples and the temperature controllers

Periodic validation for the temperature uniformity inside the furnace


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FINAL INSPECTION, PACKING AND DISPATCHDistinct & explicit definition of inspection check sheets confirming to agreement

with customer.

Mechanism with check sheet to ensure that all the testing / inspection related to

previous operations is completed and results are in acceptable limits (e.g. Physical

tests, micrographic inspection etc..)

Quantitative and qualitative results recording for acceptance , rejection and rework

Definition of packing standard with pictures for primary and secondary packing,

sequence , Qty, Dos and Don'ts, labeling, etc..

Consider use of Silica Gel or similar means for protection of castings from gettingaffected by humidity.

Mechanism to monitor preservation and traceability of the left out pieces after the

packing.

Mechanism for periodical control to check the preservation condition of the

available stockInterlock at Invoice preparation stage for availability of respective documents and

confirmation of correct packing is the Best Control.

Traceability : Part Name & No. Inspector name, Packing operator name, Melt No &

Qty, No of boxes, Qty per box, Customer Name, Invoice No & date etc


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