This slide is useful all stander working procedure

2. PROCESS -STANDARD

3. PROCESS -STANDARD

4. PROCESS -STANDARD

5. PROCESS -STANDARD
TOTAL TIME START TO END PROCESS
IS LEAD TIME
LEAD TIME

7. PROCESS -STANDARD

8. PROCESS -STANDARD

9. PROCESS -STANDARD

10. PROCESS -STANDARD

11. PROCESS -STANDARD

12. PROCESS -STANDARD

13. PROCESS -STANDARD

14. PROCESS -STANDARD

15. PROCESS -STANDARD

16. 1.what is welding:-joining two metal pieces by applying currant
pressure
2.Principle of spot weld working:- resistance spot welding which
contact with metal surface are joined by heating electric current
are passé through the electrode by applying pressure and heat
(welding under constant current and pressure )
3.projection welding or nut ring welding :-some portion of metal
weld to required area by applying heat and pressure
PROCESS -STANDARD

17. NUGGET Description
Generally Nugget checking calculation
NUGGET CHECKING METHOD
D2
D1
D=( D1 + D2 ) / 2
PROCESS -STANDARD

18. Nugget checking procedure
TWO TYPE OF PROCEDURE
DESTRACTIVE TEST
1.PEEL-UP TEST(one
weld part over tilt
and remove)
2.CHISEL
TEST(chisel driven
b/w sheet and
separator)
PROCESS -STANDARD

19. HOW TO SETTING NUGGET DIA IN OPERATION
1.Between 1 to 3 spot performing in only one part 5√t
=5 is standard and T is thickness of material (least count)
A= CLASS (IMPROTENT SPOT)
2.Between 3 to 6 spot performing in only one part 4√t
=4 is standard and T is thickness of material (least count)
B= CLASS (GENERAL SPOT)
3. Above 5 to more spot performing in only one part 3√t
=3 is standard and T is thickness of material (least count)
C= CLASS (GENERAL SPOT)
PROCESS -STANDARD

20. What is weld button or fusion nugget
 Overlapping of small pieces of metal is nugget
Brief procedure of weld nugget
1.After distractive test over lapping metal cut in-between and this piece undergo
for penetration test. the level of cut nugget actual dia =if 5.2mm
2. The weld button dia =if 5.8mm
with the help of graph
3. This graph meeting point is actual nugget 5.68mm
0
1
2
3
4
5
6
7
8
1 2 3
penetration test
weld nugget
PROCESS -STANDARD

21. WHAT IS HENARY TEST
 Afar checking weld button on process in-between 10
minutes once checking nugget is hennary
 Use of this is strength of the weld can conform actually
PROCESS -STANDARD

22. VA/NVA
 VA=VALUE ADDED
 NVA=NON VALUE ADDED
STORE
BOP
RACK LINE
NVA NVA
PROCESS -STANDARD

23. Co2 welding(MIG)or GMAW
 MIG=metal inert gas
 GMAW=gas metal arc welding
MIG welding working principle
Constant current and metal filler
1.Electric current to produced heat
2.Electrode to be fill the joint(copper wire)
3.Shielding gas to be protect the welding from the air
Percentage of shielding gas(std)
Argon=80%
Co2=20%
Usage of more consumption
Argon =75%
Co2=25%

24.  CO2 welding parameter
1 mm
160-240
18-22 V
10-18
LPM
PROCESS -STANDARD

25.  Usage of co2 welding material
Swan neck
Copper and
brass CF=
Contact tip
copper
CF=700no
Nozzle
Copper coated
CF=5000no
Insulator
Copper and
brass CF=5000
Tip holder
CF=5000 no
PROCESS -STANDARD

26. Defects of CO2 welding
Bead miss Weld miss
Bead shift Weld offset
Burn through Burn part or hole edge
Spatter Continues spatter
Double bead One over weld
Blow hole Duo to less gas flow blow
hole
Over flow Welded over area more
then required
Weld miss
Under cut Weld is not completed
Pin hole Duo to less gas flow blow
hole
porosity Uneven welded
PROCESS -STANDARD

27. How to calculate co2 penetration test
5mm
3mm
Calculation
Tp *100
T1
Tp=depth of penetration
T1=Thickness of part(minimum)
Penetration must be above 20mm
PROCESS -STANDARD

28. QUALITY -MANAGEMENT

29. CONTROL PLAN
PROCESS
NAME
PRODUCT CONTROL CHARACTERISTIC
MANUFACTURING CONDITION
CONTROL
OPN
NO.
CHECK
POINT
SPEC.
RESP
.
INSPEC
TION
TOOL
MEAS
URING
FREQU
ENCY
RECOR
DING
SHEET
SPECI
AL
Char.
Class
Cp/Cp
k less
than
1.33,
then
Action
plan
reqd.
RECORD
ING
FREQUE
NCY
CHE
CK
POI
NT
SPEC. RESP.
METH
OD
MEASURI
NG
FREQUE
NCY
RECOR
DING
SHEET
SPOT
WELDING OF
(83501 &
83505-Rh) (
83601 &
83605-Lh)
90 /
180
Child Part
Position
No gap at mating area
PROD Visual 100%
M
.---
Squeeze
time
7~10
cycles
PROD
SSW
display
panel
once per
shift
PARAMETE
R CHECK
SHEET
As per Master part M
Nugget dia
Weld
Strength
DIA 4 MM MIN PROD Vernier
EVERY 3000
SPOTS
ELECTRODE
CHECK
SHEET
M
Weld
time
6~8
cycles
PROD
SSW
display
panel
once per
shift
Appearan
ce
No Dent
PROD Visual 100%
Mn
Current
(KA)
7.5~8.5
Cycle
PROD
SSW
display
panel
once per
shift
No Spot Burr Mn
No Spatter Mn
Hold time
3~5
cycles
PROD
SSW display
panel
once per
shift
No Weld Crack Mn
No Pin Hole Mn
Pressure
3~3.5
Kg/cm2
PROD
Pressure
Gauge
once per
shift
Weld Position M
Part Bend & Spot Miss M
Electrode
Tip
Dressing
As per
STD
PROD Flat file
Every 500
spots
NO of
spots
RH-10 nos LH-10 nos PROD Visual 100% M
Electrod
e Tip
Allingme
nt
As per
STD
PROD carbon test
Every
3000 spots
ELCTRODE
CHECK
SHEET
QUALITY -MANAGEMENT

30. 7QC TOOS
 Cause and Effect Diagrams(ishikawa, causes and
effect diagram, fish bone, 5w1h)
 Flow Charts
 Check sheets
 Histograms
 Pareto Charts
 Control Charts
 Scatter Diagrams
7 QC tools is reverse engineering method to
find out the actual root cause and counter
measure
QUALITY -MANAGEMENT

31. Cause & Effect Diagrams
Sample
Incorrect
shipping
documents
Manpowe
r
Materials
Methods Machine
Environmen
t Keyboard sticks
Wrong source info
Wrong purchase order
Typos
Source info incorrect
Dyslexic
Transposition
Didn’t follow proc.
Glare on
displayTemp.
No procedure
No communications
No training
Software problem
Corrupt
data
QUALITY -MANAGEMENT

32. Flow charts
Linear
Benefits
 Show what actually happens at
each step in the process
 Show what happens when
non-standard events occur
 Graphically display processes
to identify redundancies and
other wasted effort
How is it done?
 Write the process step inside
each symbol
 Connect the Symbols with
arrows showing the direction
of flow
Toolbox
QUALITY -MANAGEMENT

33. Quality Tool
Sample Linear Flow
1- Fleet Analysis
utilizes data
warehouse reports to
create and distribute
a selection matrix.
2 - Other Groups
compile data as
determined by FRB.
3 - FRB meets to
analyze data.
4 - FRB selects
candidate problems
for additional
investigation.
5 - Action Assignee
performs detail
analysis of failure.
Requests failure
analysis as needed.
6 - Action Assignee
documents
investigation
findings.
7 - Action Assignee
reports investigation
results to FRB.
8 - Fleet Analysis
monitors failed item
to ensure failure has
been corrected.
Still
failing?
9 - FRB Categorize
Failure: Workmanship,
component, material,
maintenance, or
design. Also fleet
wide or RSU.
10 - FRB determines
required corrective
action - i.e. QAM or
supplier corrective
action.
11 - Fleet Analysis
monitors failure to
ensure corrective
action is effective.
Still
failing?
No
Yes
Yes
END
No
Start
Flow charts
Linear
QUALITY -MANAGEMENT

34. Pareto Charts
Weighted Pareto
 Vilfredo pareto state
that 80%of the effects
come from 20% of
effects
0
100
200
300
400
500
600
700
800
900
WeightedCost
Weighted cost 800 208 100 80 42 14 6
Gap Dent Hole Crack Scratch Others Stain
Defect Total Cost
Weighted
cost
Gap 4 200 800
Dent 104 2 208
Hole 20 5 100
Crack 10 8 80
Scratch 42 1 42
Others 14 1 14
Stain 6 1 6
Pareto Charts
QUALITY -MANAGEMENT

35.  What is stress:-some external system of the force acts on a
body it undergo some deformation
 Stain:-single force(system of force)acts on abode it
undergo same deformation this deformation per unit
length is know as strain
 Elasticity:-the property of the certain material return back
to their original position after removing the external force
know as elasticity
 Tensile stress:- the objects is pull two equal and opposite
direction it increases the length is called tensile stress
 Compressive stress :- :- the objects is push two equal
and opposite direction it decrees the length is called
Compressive stress
QUALITY -MANAGEMENT

36. Formulas
Circle:- A=∏*r² A= area ∏ =3.14 r=radius
Circumference:- C=∏*d C= Circumference d=diameter
Rectangle:-A=Length*width
Triangle:-A=hb*b/2 b=base hb=height
Parallelogram:- A=b*h b=base h=height
r²
height
height
base
base
length
width
d

37.  What is a Spot Weld?
 A Spot Weld is a Metal Joining Process requiring no Filler Medium. This
process is based solely on the principle of OHMS LAW where V(voltage) =
I(current) x R(resistance) or I(current) = V(voltage) R(resistance). Most Base
Metals have very low Resistance (micro-ohms). Low Voltage Secondary
Outputs (up to 30 VAC in a Spot Welding Transformer) in conjunction with the
Low Resistance in the Base Material can produce a very High Current (Kilo-
Ampere) Draw through the interface of the stack of two or more metals to be
joined. This high "Welding Current" almost instantly liquifies the metal at the
interface where the electrodes make contact under pressure with the base
materials. When the Welding Current is turned off, the water circulating
through the electrodes, while still under pressure, secures the welded joint.
And this is the basis behind Resistance Welding, also known as Spot Welding

38. What is the advantage of a Spot Weld?
Spot Welding is the quickest and most economical method of joining Wieldable Base Metals.
What is a Welding Control?
By today's standards, A Welding Control is a microprocessor driven Computer that precisely commands
timing functions and Weld Current Intensity
Why is the Force between the Electrodes important?
Proper "Welding Force" decreases Surface Resistance which eliminates Flashing/Expulsion.

39. TPM(Total Productive Maintenance)
 TPM is a system of maintaining and improving the production and quality system through
the machine , equipments, process
 8-pillers in TPM system
1. Autonomous maintenance (Jishu Hozen):-basic maintenance of operator like cleaning of machine,
lubricating, oiling, and tightening of bolt and nut this actives increases the machine and equipments
life
2.Planned maintenance:-periodic maintenance to reduce the break down
3.Quality maintenance:- this is ensuring by quality to detect and prevent error during production
using lean tool such (JIDOKA)and (ANDON)
4.Focused Improvement(Kobetsu Kaizen):-
5.Early Equipment Maintenance:-
6.Educton an Training:-
7.Safety,health &Environment:-
8:-office TPM:-
TPM- MANAGEMENT

40. Six big losses
SIX BIG LOSSES OEE LOSS
CLASSIFICATION
EXAMPLES REMARKS
Machine breakdowns DTL Fan belt breakage, tool
failures, motor
breakdown
Must be clearly defined
so as not confuse with
small stops
Setup loss and minor
adjustments
DTL Product change-over
staff shortage, material
shortage
SMED is used for
reducing the effects of
this loss
Minor stoppages SL Inspection jams,
adjustments, blocked
sensing devices
Very short stop(-
5mins)not requiring
technical intervention
Slow Running SL Poor setting and
alignments
Factors that prevent the
design capacity/speed
from been achieved
Start-up Errors QL Scrap and rework Occur before the process
start in earnest
Production Defects QL Scrap and rework Occur during the
running of the process
DTL=Down Time Loss SL=speed loss QL=Quality loss
TPM- MANAGEMENT

41. Toyota Production System
Goal:-Highest Quality, Lowest cost Shortest Lead Time
JUST IN TIME HIGH QUALITY JIDOKA
Operate with the minimum
resource required to
consistently delivery:
1.Just what is needed
2.In just required amount
3.Just where it is needed
4.Just when it is needed
1.Detect the abnormalities
2.Stop and response
Heijunka Standardised work kaizen
process
Min
in put
Mix
out
put
Muda muri
mura
method
Minimum Lead Time
Stability
TPM- MANAGEMENT

42.  Heijunka(KANBAN POST)
 Lead time or manufacturing lead time:-total time required to manufacturing the item
including order preparation time queue time, setup time, run time, move time,
inspection time, it time from SFG- FG time
 Lean:-continuous removal of waste from manufacturing process (muda)
TPM- MANAGEMENT

43. JIT SYSTEM
 JIT:-just in time
 This system is use full for inventory control
 Advantage
 1,elimination war house storage
 2.less money an raw material because enough to make the production
JIT:-just in time
PUSH -UP PULL-UP
Storage send No storage hand to
mouth customer
Ts company Haccp
company
TPM- MANAGEMENT

44. JIDOKA and Andon
Jidoka
Jidoka is manufacturing high quality products(poka-yoka)
If equipment malfunction or defective produces the part the affected machine
automatically stop
This is related to machine organ from Toyota productive system
Andon
This andon system is an manufacturing term referring to a system to notify
management ,maintenance and other worker of the quality or process problem
Through audio alarms text or other display
TPM- MANAGEMENT

45. OEE=Overall Equipment Efficiency
OEE= Availability *performance*quality
1.Planned production=shift length- breaks
=510-50
=460minuts
2.operating time=planned production time-brake down time
=460-87
=373
3.Good pieces= total pieces-rejected pieces
=19271-423
=18848
4.Part per minutes(ideal run rate)=total production/production time(in minutes)
TPM- MANAGEMENT

46. Availability=operating time/planned production time
=373/460
=0.8109*100
=81.09 %
Performances =total pieces/operating time/ideal run rate(part per minutes)
=19271/373/60
=0.8611*100
=86.108 %
Quality =good pieces/total pieces
= 18848/19271
=0.978*100
=97.804%
 OEE= Availability *performance*quality
 =0.8109*0.8611*0.9780
 =0.6829*100
 OEE= (68.29%)
TPM- MANAGEMENT

47. Losses
 Speed loss:-small break down like power loss, abnormality safety of man or
part meeting, others
 Fix loss:-time. Meeting.5s.jig Line Start up Tea Time 1 Lunch Time Tea Time 2
Tea + Snacks (If overtime) Total Fixed Loss
 Variable loss;- Manpower Issue Machine Problem Material Issue Fixture
Issues Others
 Quality loss :- Start-up Errors -Occur before the process start in earnest
 Down Time Loss:- Machine breakdowns
TPM- MANAGEMENT

48. TPM- MANAGEMENT

49. TPM- MANAGEMENT

50. 7 types of fuguai
FUGUAI/Abnormality/inconvenient
TPM- MANAGEMENT

51. 7 Types of Accidents in industries
 A –Type:- Actuator -Using wrong tool and wrong method in machine
 B- Type:-Big –standing under machine, die
 C- Type:-Car-hitting into the fork lift
 D-Type:-Drop-walking in shop floor duo to oil or hazardous
 E-Type:-unsafe working method
 F-Type:-Hot object touch naked hand
 G-Type:-Gillette –cut injury with sharp objects

52. Production Part Approval Process (PPAP)
1. Design Records
2. Authorized Engineering Change Documents
3. Customer Engineering Approval, if required
4. Design Failure Modes and Effects Analysis (DFMEA) applied in special
situations
5. Process Flow Diagram
6. Process Failure Modes and Effects Analysis (PFMEA)
7. Control Plan
8. Measurement Systems Analysis (MSA)
9. Dimensional Results
10. Records of Material / Performance Test Results
11. Initial Process Studies
12. Qualified Laboratory Documentation
13. Appearance Approval Report (AAR)
14. Sample Production Parts
15. Master Sample
16. Checking Aids
17. Customer-Specific Requirements
18. Part Submission Warrant (PSW) – NCR calls this the “Production Warrant”
Supplier shall submit
these 12 items and
retain a copy of records
at appropriate locations
QUALITY -MANAGEMENT

53. IATF-16949 CORE TOOLS
International automotive taskforce
 APQP- Advance product quality planning
 PPAP-Production part approval process
 MSA- Measurement Systems Analysis
 SPC-Statistical process control
 FMEA-Failure Modes and Effects

54.  Ppap is developed by AIAG(automotive industries action group)in 1993 with
input from the big 3-Ford chrysler & gm
latest version of PPAP AIAG 4th edition effective June 1-2006
Purpose of PPAP
Yes we are understand the customer requirement (production & quality)
5-level of PPAP submitting required
MASTER SAMPLE
Physical sample:- this sample doesn't change long period of time
Analytical sample record:-this sample change over every time

55. CONTROL PLAN
3-TYPES
1. Proto Type:-A Prototype Control Plan is a description of the dimensional
measurements material and performance tests that will occur during manufacture of
the prototype part.
2. Prelaunch:- is a description of the product/ process controls, dimensional
measurements, material and performance tests that occur after prototype and before full
production. ... The production control plan is a logical evolution of the pre-
production control plan
3. Production:- The Control plan is the description of all Product and Process control
operations implemented in the production process.
Appearance Approval Report:- after assemble the vehicle
the part is appear that company only supply the this
report

56. Statistical Process Control
 Statistical Process Control (SPC) is an industry-
standard methodology for measuring and controlling
quality during the manufacturing process. Quality
data in the form of Product or Process measurements
are obtained in real-time during manufacturing
 Cp - process capability
 Cpk -process capability indices
 , commonly referred to as process capability indices,
are used to define the ability of a process to produce a
product that meets requirements. ... Specifications are
normally defined in terms of nominal (+/-) tolerances
or ranges (low to high.

57. Cp - process capability
3σ3σ
σ=Sigma is standard
deviation
CP=USL-LSL
6σ
CP=30-20
32-18
CP=10
14
Cp=0.71
CP<less 1 since process is not
capable
it should be more then 1 process
capable
Cp only use for to knowing process and
center of design

58. Cpk -process capability Index(indices)
CPK=Min= 30-28 ,28-20
35-28 28-21
= 2/7 , 8/7
USL=0.285 (less then< 1) not capable
LSL= 1.142(greater then>1) capable
Since both should be greater then= 1
process is capable
Either one of ratio
(USL OR LSR) is less then 1
then Process is not
capable
Cpk use for any situation of part shifting towards its tolerance

59. What is 1.33 in cpk?
Calculation of a Cpk is a performance metric to show process control. It doesn't
incorporate western electric rules. Also Cpk1.33 means 64 defects per million and
your process is running at 4 sigma.

60. PRESS SHOP
What is press?
Press is machine which converting raw material in finish goods(it is a machine by
which we can do cutting or non cutting process by applying force without
removing chip on metallic or non metallic sheet)
Like
1.drow:- stroke create profile
2.trim:-stroke create cutting necessary edge
3.Piercing:-stroke create hole
4.Flang bending:-stroke make bending
5.Part off:-double cavity die make two part like RH & LH
6.hamming:-stroke made edge bend
7.Blanking:-stroke give necessary shape and size

61. TYPES OF PRESS MACHINE
1.MANUAL PRESS
Foot press
Arbor press
Fly press
Toggle press
2.POWER PRESS
Crank press
Eccentric press
Cam press
Screw press
Rack & pinion press
*HYDRAULIC PRESS
*PNEUMATIC PRESS

62. PRESS SIZE
Mechanical Hydraulic
capacity to 6000 tons capacity to 50000 tons

63. PRESS SHOP PARAMETERS
 Air pressure:-3.5 kg/cm2
 Shut height:-650min 1050mix our company BDC
760mm
 Cushion pressure:-6kg/cm2
 SMED:-Single-Minute Exchange of Dies (less then 10 minutes)
If SMED is more then 10 minutes it should be count in (“TPM-6 BIG
LOSS ‘DOWN TIME LOSS” DTL)

64.  SPM:-stroke per minutes
egg:- total stroke/total time use
SPM:- 3600/425
SPM:-8.47
GSPM:-gross stroke per minutes(without loss of time)
GSPM:- 3600/460
egg:- total stroke/total time use
GSPM:-7.82
SPM is always greater then GSPM

65. DEFECTS OF PRESS PART
DEFECTS ROOT CAUSE COUNTER MEASURE
DENT
1,die peek mark
2,die cleaning not done
3,part handling
4,Die sharp edges touch
5,part movement one place to anther
1,required die PM
2,die cleaning required as per schedule
WRINKLE
Low cushion pressure below as per
standard it create wrinkle in draw
6kg/cm2
Shut height more or less then std
Set as per std
THINING
Area of bending or forming or
more cushion pressure create
thinking in part
Shut height more or less then std
Set as per std
CRAKE
More cushion pressure create
crake
Shut height more or less then std
Set as per std
BURR, PIERCING HOLE NOT
OPEN, SHIFT
Punch worn out shift
Shut height more or less then std
Set as per std

66. Defects Measuring Instrument of Press part