work instruction - loading-tamil

WORK INSTRUCTION FOR

INSPECTION OF RAW MATERIAL

WORK INSTRUCTION FOR INSPECTION OF RAW MATERIAL

PREPARED BY: APPROVED BY:

Scope :

Applicable to Plastic Raw Materials

Responsibility:

Stores Assistant \ store keeper

Description :

1. Check the quantity of the inward items as per the purchase

order.

2. Take the sample size as 5 bags for lot on a randam basis

3. For all raw materials check the material Name ( if applicable)

4. Check whether the items are free from physical damages

5. For raw materials which have specific values ( mentioned in

the P.O) check the specification

6. Record the status of inspection in the GRN

7. If any rejection (Product NC) is found during this inward it

will be handled as per QSP\ 04

The below table may be used for reference to Handle the

Inward Inspection

Parameter to Inspect Specification Measuring Techinique Sampling Size

Material Name \

Quantity \ Free

From Damage

As per P.OVisual Inspection \

Weighing Machine 5 Bags \ Lot


RAW MATERIAL RECEIPT ,STORAGE &

HANDLING

WORK INSTRUCTION FOR RAW MATERIAL RECEIPT ,

STORAGE & HANDLING


Raw Material Receipt

The Raw material received from supplier should be checked For the following

1. Quantity as per the Invoice \ D.C

2. The Raw Material mentioned in the Invoice \ D.C and the raw

material received

3. Packing condition , There should not be any tear and the

material should not spill from the bags

4. The bags should not be damp

Incase of discrepancies, talk to the Supplier and take necessary action immediately

STORAGE

1. The raw materials should be kept in the pallet allocated for the

material

2. The distance between one material and the other should be

atleastone foot

3. The raw material name should be clearly displayed

4. The raw material register should be updated immediately

HANDLING

1. The raw material required for production should be taken from the

stores only after entering in the raw material register.

2. Once the bag is opened and the material is taken, the bag shouild be

closed

3. Never keep the bags with raw material in OPEN CONDITION


MOULD LOADING

WORK INSTRUCTION FOR MOULD LOADING

Nkhy;L Vw;Wtjw;fhd nray;Kiw tpsf;fk;


Scope :

Applicable to Injection moulding section

Responsibility:

Operators \ Trainee \ Supervisor \ Engineer

Description :

1. Check the Mould Properly with all auxillary system is available like locating

ring,lifting bar, Eye bolt ,cooling Nipples & verify the Mould check list.Nkhy;il Vw;Wtjw;f;F Kd; Nkhy;L nrf; yp];by; cs;s midj;Jk; (NyhNfl;bq;rpq;> ypg;bq; ghu;> I Nghy;l;& ypq; ypg;gpy;) cs;sjh vd cWjp nra;J nfhs;sTk;.

2. Select Ejector rod & fix to the related Holes Nkhy;bw;F jFe;j Vn[f;lu; uhL vLj;J nk\pdpy; jFe;j ,lj;jpy; nghUj;jTk;.

3. Confirm machine platen is sufficiently open and hydraulic

ejector is in fully back positionnk\pdpd; gpNsl;bid Nkhy;Lf;F Vw;wthW jpwe;J nfhs;sTk; kw;Wk; Il;uhypf; Vn[f;lu; KOtJk; gpd;Gwkhf ,Uf;FkhW cWjp nra;J nfhs;sTk;.

4. Lift the mould using the crane by means of Eyebolt & chain/RopeNkhy;il I Nghy;l;> Nuhg; kw;Wk; fpNudpd; cjtpAld; J}f;fTk;.

5. Locate the mould in the fixed platen of the machine guiding

the locating ring.Nkhy;il nk\pdpd; gpf;];L gpNsl;ldpy; NyhNfl;bq;upq; cjtpAld; nghUj;jNtz;Lk;.

6. All operations should be done in Mould set up mode.midj;J nray;ghLfisAk; nrl;bq; Nkhby; nra;aTk;.

7. Close the moving side platen slowely till touch the mould%tpq; irL bNsl;lid nkJthf Nkhy;il njhLk;tiu FNsh]; nra;aTk;.

8. Ensure the mould position and level is correct by touching

injection nozzle.Nkhy;L NyhNfl;bq; nra;jJ rupahf cs;sjh vd;gij ,d;n[f;\d; eh\piyitj;J rupghu;j;J nfhs;sTk;.


MOULD LOADING

WORK INSTRUCTION FOR MOULD LOADING


9. After confirming the mould setup, Actuate the lockingNkhy;L NyhNfl;bq; nra;j gpwF> nk\pdpy; Nkhy;bw;F Vw;wthW yhf;fpq; nfhLf;fTk;.

10. Clamp the mould using clamps, spacers, washer, bolts, allen keys,

Spanners & pipes];Ngru;> thru;> Myd; Nghy;l;> Myd; fP> ];ghdu;]; & igg; cjtpAld; Nkhy;il nghUj;j Ntz;Lk;.

11. Remove lifiting bar & locking plates from the mould Nkhy;bypUe;J ypg;bq; ghu; kw;Wk; yhf;fpq; gpNsl;il fow;w Ntz;Lk;.

12. Open the mould slowlly and check inside surface first by cleaningNkhy;il nkJthf Xgd; nra;J NkYk; Nkhy;il Rj;jk; nra;Jcl;Gwk; ed;whf cs;sjh vd rupghu;f;fTk;.

13. Fix the ejector strokes depends upon the mould constructionNkhy;bw;F Vw;wthW Vn[f;lu; ];l;Nuhf; nrl; nra;aTk;.

14. Connect the inlet and outlet of the water lines to the mould,d;yl; kw;Wk; MTl;yl; thl;lu; iyid Nkhy;by; ,izf;fTk;.

15. Provide normal \ Chiller \ MTC as applicableNjitf;Nfw;g ehu;ky; / rpy;yu; / vk; b rp nfhLf;f Ntz;Lk;.


MOULD UNLOADING

WORK INSTRUCTION FOR MOULD UNLOADINGNkhy;L ,wf;Ftjw;fhd nray;Kiw tpsf;fk;.


Scope :


Responsibility:


Description :

1. Clean the mould & apply rust preventive spray to the core and cavity Nkhy;il Jilj;J Jug;gbf;fhky; ,Ug;gjw;Fupa ];gpNuia Nfhu; kw;Wk; Nftpl;b irby; mbf;fTk;.

2. Remove water line and clean the water channels with

blowing air.thl;lu; iyd;fis Row;wp thl;lu; Nrdypy; GNshapq; Vu; %yk; fpsPd; nra;a Ntz;Lk;.

3. Ensure that hydraulic ejector (M/Cs) is in backwardIl;uhypf; vn[f;rd; KOtJk; gpd;Gwkhf ,Uf;FkhW cWjp nra;J nfhs;sTk;.

4. Using the safety mode, close the mould slowelynk\pdpy; Nrg;l;b Nkhby; itj;J Nkhy;il nkJthf FNsh]; nra;aTk;.

5. Fix the lifting bar \ locking plate to the mouldNkhy;by; ypg;bq; ghu; kw;Wk; yhf;fpq; gpNsl;il ,izf;fTk;.

6. Suspend the mould with crane by menas of eyebolt & chainNkhy;il I Nghy;l; kw;Wk; ];by;Nuhg; %yk; fpNudpy; gpbf;fTk;.

7. Remove all the clamps from the platens.Midj;J fpshk;GfisAk; gpNsl;ldpy; ,Ue;J fow;wTk;.

8. Open the platen slowely till is required to lift the mould

from machine gpNsl;lid nkJthf Xg;gd; nra;J Nkhy;il nk\pdpy; ,Ue;J ntspNa vLf;fTk;.

9. Place the mould in its positionNkhy;il mjw;Fupa ,lj;jpy; itf;fTk;.

10. Clean the machine areank\pid Rw;wp Jilf;f Ntz;Lk;


HOPPER CLEANING & BARREL

CLEANING PROCEDURE

WORK INSTRUCTION FOR HOPPER CLEANING


Scope :


Responsibility:


Description :

1. Empty the present material from the hopper

2. clean the mesh , magnet and hopper inside

3. Ensure that no foreign material or colour granules present

in the hopper

4. Keep the Hopper Lid closed always after cleaning and after

loading the material

5. Hopper cleaning should be carried out while processing

and different material and master batch



CLEANING PROCEDURE

WORK INSTRUCTION FOR BARREL CLEANING


FOR THE SAME MATERIAL WITH DIFFERENT COLOUR

1. Purge all the material in the barrel in small size

2. Load the required material to the feed throat of the barrel

and purge with High Back Pressure and High screw speed

3.Purging tobe done till the required colour is achived

FOR USING DIFFERENT MATERIAL

1. Purge all the material in the barrel in small size

2. Then use natural colour PP granuales to purge till the

original colour of PP comes.

3. Set the required temperature for the material tobe

processed

4. Load the required material into the hopper

5. Wait till the set temperature is reached

6. Purge the material till the required colour is achieved



CLEANING PROCEDURE

WORK INSTRUCTION FOR BARREL CLEANING


Scope :


Responsibility:


Description :

1. Fill the throat of the injection barrel with the material tobe

purged

2. Set the temperature of Barrel to the melting temperature of

the resin

3. Set the machine to manual mode

4. Adjust the plasticising stroke to the maximum limit of the

machine

5. Press the screw retracting button till the screw retracts to the maximum limit

6. Purge the material in small size till screw position reaches

to zero mm.


Scope :


Responsibility:


Description :

1. Oil level,oil temperature are within specified limits of the machineMapy; nyty;> Mapy; temp k; nk\pdpw;F Vw;w msT (30 c) cs;sjh vd ghuf;fTk;.

2. Machine, hopper and barrel are cleaned as per the requirementNjitf;F Vw;whw; Nghy; nk\pd;p fhg;gu; kw;Wk; / Nguy; Rj;jk; nra;a Ntz;Lk;.

3. The mould is loaded as per mould loading instructionNkhy;il Nkhy;L Nyhbq; nray; Kiw tpsf;fj;jpy; Fwpg;gpl;Ls;s gb Vw;wNtz;Lk;.

4. The material is pre dried (if required) and free from

contamination and is loaded to the hoppernkl;bupaYf;F Njitg;gl;lhy; preheat nra;J J}R ,y;;yhky; Hopper I nfhl;l Ntz;Lk;.

5. The hopper is closedHopper - I %l Ntz;Lk;

6. The MTC or Cooling water line is connected to the mould

as per requirement (with out Leakage) Mould cooling water line (or) M.T.C. line. - I mjw;F jFe;jhw;Nghy;; nrhUf Ntz;Lk;. (ntspapy; rpe;jhky;)

WORK INSTRUCTION FOR MACHINE STARTUPnk\pid Jtf;Ftjw;fhd nray;Kiw tpsf;fk;.


MACHINE START UP


MACHINE START UP

WORK INSTRUCTION FOR MACHINE STARTUPnk\pid Jtf;Ftjw;fhd nray;Kiw tpsf;fk;.


7. Set the Processing parameters for the machine using the

standard process parameter for the component and wait

till the temperature are reached to the set levelM/C - y; standard process parameter - I gad;gLj;jp process setting nra;a Ntz;Lk; gpwF me;j component - f;Fupa temp milAk; tiu fhj;jpUf;f Ntz;Lk;

8. Switch on to safety mode in the machine and close the

moving platen till it reaches 0.0 mm (This can be seen in

the mould closing page of the machineRtpl;ir Md; nra;J nrl;bq; nkhby; itj;J %tpq; gpNsl;lid 0-0 mmtUk; tiu close nra;aTk; (,ij PLC - y; mould closing page - y; ghu;f;fTk;)

9. Switch on to manual mode , set the mould closing &

Opening speed according to the mouldnk\pid manual nrl;bq;fpy; itj;J> mould closing & opening speed Nkhy;bw;F Vw;wthW nrl; nra;aTk;.

10. Now the machine is ready for operation,g;nghOJ cw;gj;jpia Jtf;Ftjw;F nk\pd; jahuhf cs;sJ.

11. Set the machine counter to Zero M/c - y; counter - I Zero nrl; nra;aTk;

12. Start the production ,Once the components are made as

per the requirements get the production clearance from

Quality & continue the production. cw;gj;jpia Jtf;fTk;> juk; tha;e;j cw;gj;jp Jtq;fpaTld; juf;fl;Lg;ghl;blk; Production clearance ngw;wTld;> cw;gj;jpia njhluTk;.


MACHINE STOPPAGE

WORK INSTRUCTION FOR MACHINE STOPPAGE


Scope :


Responsibility:


Description :

1. Close the Hopper

2. Run the machine till Hopper material is empty

3. Take out the injection unit back

4. Remove the material from hopper

5. Clean the hopper with Air or Cloth

6. Purge out the remaining Hopper material in Small Size

7. Use PP or PS granules and do further purging to ensure no

traces of PA, PC,POM & PBT resin is left out in the barrel

which will affects the barrel.

8. Disconnect the mould water circulating lines

9. Unload the mould as per the Mould Unloading procedure

WORK INSTRUCTION FOR PRE DESPATCH AUDIT

AND DESPATCH PROCEDURE


1. All components before despatch should be inspected for the compliance of all

the parameters as per control plan followed by us.nghUl;fs; mDg;Gtjw;F Kd;G juf;fl;LghL jpl;lj;jpd;fPo; mjw;Fupa fUtpfis nfhz;L Ma;T nra;j gpd;G mDg;gLfpwJ.

2. The sampling of components should be made as per our sampling plannghUl;fs; sampling plan mbg;gilapy; gupNrhjpf;fg;gl;LfpwJ.

3. Packing slips should be pasted to the bins giving all the details like

componenet name, Qty, Customer name , colour , date , etcjahupj;j nghUl;fs; mlq;fpa Bin apd; Nkw;gFjpapy; mjDila ngau;> vz;zpf;if thbf;ifahsu; ngau;> epwk;> Njjp kw;Wk; gpw tpguq;fs; xl;lg;gl;bUf;Fk;.

4. Incase if the parameter are not complying with the requirements,

inform customer about the same and arrange to get deviation for

the lot if required most urgentmtrufhyj;jpy; nghUl;fs; gupkhdj;jpy; VjhtJ Fiw ,Ug;gpd; mij thbf;ifahsu;fSf;F njuptpj;J Fwpg;gpl;l vz;zpf;iff;F mDkjp ngw;W mDg;gLfpwJ.

5. Inform invoicing supersvisor for making the Invoice by filling Despatch RequisitionmDg;Gk; nghUl;fspd; tpguj;ij tpiyg;gl;bay; Nkw;ghu;itahsUf;F gl;bay; ,lg;gLfpwJ.

6. Send the material to the customer along with the Invoicethbf;ifahsu;fSf;F nghUl;fs; cld; tpiyg;gl;bay; mDg;gLfpwJ.

7. If the material is being send through the transporter, ensure that the transporters

Lorry Receipt is completely filled and keep necessary copies with us for future

reference and followupnghUl;fis thfdj;jpy; mDg;Gk; nghOJ thfdk; kw;Wk; nghUl;fspd; tpguk; gw;wpa efy; G+u;j;jp nra;ag;gl;L Nfhg;gpy;p itf;fg;gLfpwJ.

WORK INSTRUCTION FOR PRE DESPATCH AUDIT &

DESPATCH PROCEDUREnghUl;fs; mDg;Gtjw;F Kd;G gpd;gw;w Ntz;ba topKiwfs;

WORK INSTRUCTION FOR IDENTIFICATION

AND TRACEABILITY PROCEDURE


AT RECEIPT STAGE

All the inward items should be kept in an idendified area,Based on GRN Status , Vendor

Product card (Accepted, Rejected, Waiting for Inspection ) shall be put and disposition

of the items shall be taken accordingly.cs;tUk; nghUl;fs; midj;Jk; milahsk; kw;Wk; xg;Gjy; ngw;w gpd;G mjw;Fupa ,lj;jpy; itf;fg;gLk;.

AT INPROCESS STAGE

During Inprocess stage all the items shall be accompany with the Production slip giving

the details of operations done and the operations tobe donejahupg;G Kw;W ngw;w epiyapy; mjDila epiyia gw;wpa tpguq;fs; xl;lg;gLk;.

AT FINAL STAGE

After pre despatch Inspection the packing slips should be pasted to the bins giving all the

details like component name, Qty, Customer name,Colour, date etc.,jahupj;j nghUl;fs; Ma;T nra;j gpd;G> nghUl;fs; mlq;fpa Bin - apd; Nkw;gFjpapy; nghUl;fspd; ngau;> vz;zpf;if> thbf;ifahsu; ngau;> epwk; kw;w tpguq;fs; xl;lg;gl;bUf;Fk;.

USEAGE OF STATUS CARD

The production slip shall accompany the item if the items is accepted and can proceed for

further operations.

nghUl;fs; xg;Gjy; ngw;w gpd;G> mL;;j;j epiyf;F mDg;gg;gLfpwJ.

The Hold card shall accompany the items of their if their disposition is not decided or they

have to be reworked and they will be kept in the non conformance area.

jahupg;gpy; juf;FiwT fhuzkhf epWj;jp itf;fg;gl;l nghUl;fs; rupgLj;jNth my;yJ Nkw;nfhz;L KbT nra;tjw;fhf cWjp nra;ag;glhj ,lj;jpw;F khw;wp itf;fg;gLk;.

The rejected card shall accompany the items, which are not acceptable for further

processing or despatch and shall be kept separately in an identified area or sent for granulation.

juf;Fiwthd nghUl;fSf;F jdp milahs ml;il xl;lg;gl;L miuf;Fk; ,lj;jpw;F mDg;gLfpwJ.

WORK INSTRUCTION FOR IDENDIFICATION & TRACEABILITY milahskpLjy;> gpd;njhlUjy; gw;wpa Ntiy topKiwfs;.


MATERIAL PRE HEATING


WORK INSTRUCTION FOR MATERIAL PRE HEATING

Scope :

Applicable to Injection moulding & Plastic Raw

material section

Responsibility:


INSTRUCTION:

1. Idendify the material tobe used

2. Take the material from the bag

3. Weigh the material and put in the trey

4. Put the oven in OFF condition, before opening the door

5. Set the temperature as recommended in the instruction sheet

and also time duration

6. Switch on the motor after closing the door

7. Switch on the heater also

8. Temperature will be set as given bellow

ABS

NYLON 6,66

POM

PTFE (TEFLON)

PC

PBT

PMMA

80- 90 C

95 -110 C

75 - 85 C

70 - 80 C

100 -120 C

100 -120 C

90 - 100 C

2 TO 3

2 TO 3

2 TO 3

1.5 TO 2.5

3 TO 4

2 TO 3

2 TO 3

MATERIAL PREDRYING TEMP ( DEG CENT) DURATION ( HRS)


FILL HOSE ASSEMBLY

WORK INSTRUCTION FOR FILL HOSE ASSY (NEW FAUCET)


Scope :

Applicable to Fill hose Assy section

Responsibility:

Operators \ Trainee \ Supervisor

Description :

1. Dipping of Fill Hose in Hot bath at both ends

2. Inserting Cup & Coupler Faucet at one end of Fill hose

and L Connector M/C End on other side of Fill Hose

3. Crimping of Cup Fitted Fill Hose at Both ends

4. Pull of force checking 50 kg (With stand) (S)

5. Pressure Checking 10 Bar (With stand) (S)

6. 100% Leak Testing

7. Cleaning of Fill hose for water after leak testing

8. Assembly of Adaptor Faucet Sub assy with

Coupler Faucet (fitted at one end of the Hose)

9. Final Inspecion

10. Packing and Despatch


FILL HOSE ASSEMBLY

WORK INSTRUCTION FOR FILL HOSE ASSY (NEW FAUCET)

Shree

Mother

Group


DOC NO: SMG \ P \ WI \ 02

REV NO : 01

DATE : 10.03.07

PAGE : 1 OF 2

Scope :

Applicable to Fill hose Assy section

Responsibility:

Operators \ Trainee \ Supervisor

Description :

1. Dipping of Fill Hose in Hot bath at both ends

2. Inserting Cup & Coupler Faucet at one end of Fill hose

and L Connector M/C End on other side of Fill Hose

3. Crimping of Cup Fitted Fill Hose at Both ends

4. Pull of force checking 50 kg (With stand) (S)

5. Pressure Checking 10 Bar (With stand) (S)

6. 100% Leak Testing

7. Cleaning of Fill hose for water after leak testing

8. Assembly of Adaptor Faucet Sub assy with

Coupler Faucet (fitted at one end of the Hose)

9. Final Inspecion

10. Packing and Despatch


ADAPTOR FAUCET SUB ASSY

WORK INSTRUCTION CHANDINI SUB ASSY

Shree

Mother

Group


DOC NO: SMG \ P \ WI \ 02

REV NO : 01

DATE : 10.03.07

PAGE : 1 OF 2

Scope :

Applicable to Fill Hose assy section

Responsibility:


Description :

1.


MACHINE STOPPAGE



Scope :


Responsibility:


Description :

1. Close the Hopper












MACHINE STOPPAGE


nk\pid epWj;Jtjw;fhd nray;Kiw tpsf;fk ;.


Scope :


Responsibility:


Description :

1. Close the HopperHopper - I %lTk;.

2. Run the machine till Hopper material is emptynkl;bupay; midj;Jk; fhypahFk; tiu cw;gj;jpia njhluTk;.

3. Take out the injection unit backM/c - d; ,d;n[f;\d; Adpl;il ntspNa vLf;fTk;.

4. Remove the material from hopperfhg;gupypUe;J nkl;bupaiy ,wf;fTk;.

5. Clean the hopper with Air or Clothfhg;giu mKj;jfhw;W my;yJ Jilg;ghd; cjtpAld; Rj;jk; nra;aTk;.

6. Purge out the remaining Hopper material in Small Sizefhg;gupYs;s nkl;bupaiy rpwpa mstpyhd Purging - fhf vLf;fTk;.



which will affects the barrel.PA, PC, POM & PBT kw;Wk; ,ju Engeering MaterialcgNahfg;gLj;jpapUe;jhy; PP my;yJ PS nkl;bupaiy cgNahfpj;J Nkw;$upa nkl;bupay; vJTk; Nguypy; ,y;yhjthW gu;[pq; nra;a Ntz;Lk;.

8. Disconnect the mould water circulating linesNkhy;by; ,izf;fg;lLs;s Water Line - fis fow;wNtz;Lk;.

9. Unload the mould as per the Mould Unloading procedureNkhy;il Nkhy;L ,wf;Ftjw;fhd nray; Kiw tpsf;fj;jpy; Fwpg;gpl;Ls;s gb ,wf;fTk;.


MACHINE STOPPAGE


Scope :

Responsibility:


Description :

1. Close the Hopper











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