SHYAM ENTERPRISES UNIT-

PROCESS AND PRODUCT AUDIT PLAN FOR CUP-CO

PLANNING
S.No PART NO VS JAN FEB MAR APR
ACTUAL
PLANNING
1 NP 963848
ACTUAL

PLANNING
2 NP934854
ACTUAL

PLANNING
3 NP 488862
ACTUAL

PLANNING
4 NP812794
ACTUAL

PLANNING
5 NP985207
ACTUAL

PREPARED BY: ARGHYA

TERPRISES UNIT-II, JSR

PLAN FOR CUP-CONE FOR THE YEAR OF 2018

MAY JUN JUL AUG SEP OCT NOV DEC

P
27/09/18

P
NO MAT

P
NO MAT

P
2/11/2018

P
14/11/2018

APPROVED BY:
 SHYAM ENT Process & Product Audit Report of Through Hardened Part F. 7.5.2.1
Part No: NP963848 SH/SQF-1/I 57/18 DATE: 27/09/18
UNIT-II
SEQ.NO OPERATION DESCRIPTION PARAMETERS FINDINGS
I Traceability and Loading
1 Visual Components Free From Rust & Damages No abnormality

2 Identification Identification Tag is available No abnormality

3 Batch Quantity Specified quantity as per WI No abnormality

4 Loading Pattern As per WI Back face Down
Remarks : Found Adequate.
II Pre Washing
i) Visually Visually found OK
III THROUGH HARDENING IN SQF-1
1 Gas flow
(i) Endo 8.0 m3/hr 8.0 m3/hr

(ii) LPG 400 LPH 400 LPH

(iii) Nitrogen As per requirement NA

2 Temperature

(i) SQF-1 838° C 839.4°C

3 Carbon Potential for SQF-1

(i) Set Point 0.85% 0.85%

4 Time

(i) Hardening Cycle 45 min 45 min

5 Quenching Process (Through Hardening)

(i) Agitator Speed 750 rpm 754 rpm

(ii) Oil temperature 90 ° c 92° c

(ii) Quality Of Quenching Oil Free from contamination Found ok, verified by tc
(iii) Quenching Delay 30 sec 24 sec
iv) Quenching Time 20 min 20 min

(iv) Dripping Time 10 min 10 min

(v) Hardness of the product in As quench
64-67 hrc 65 hrc
condition
 SHYAM ENT Process & Product Audit Report of Through Hardened Part F. 7.5.2.1
Part No: NP963848 SH/SQF-1/I 57/18 DATE: 27/09/18
UNIT-II
SEQ.NO OPERATION DESCRIPTION PARAMETERS FINDINGS
6 Post Washing
Nozzle Spray Spray from all Nozzles No abnormality

Bath temperature 60 ° c ( +/- 5° c) 63° C

Bath concentration 2.0 ~ 4.0 % 2.80%

Oil skimmer working in oil skimming No abnormality

7 TEMPERING
Temperature 246 248

Time 240 min 240 min

Refer annexure detailed process monitoring observation sheet SH/SQF-1/ J 17/18

Remarks :

VI UNLOADING
1 Visual Components free from damages No damage

2 Visual appearance Free from oily surface and shoot No oil, shoot available

VII METALLURGICAL TESTING

Testing Description Specification Actual

1. Surface hardness In HRC 58-64 HRC 60~61 HRC

2 Center Harndess in HRC 58-64 HRC 59-60 HRC

5 Microstructure RA=10 % max Not observed in visual method

Dispersed Carbide Through out
Carbide Matrix of martensite

Core Ferrite Nil

IGO Nil

FREE FERRITE Nil

NMTP Nil

VIII DIMENSIONAL INSPECTION AFTER HARD TURNING

i) OD 192.00 mm ( +250 - +300 micron ) 192.70 mm

ii) ID 178.98 mm (-450 - -400 micron) 179.45 mm

iii) WIDTH PARALLISM 0.050 mm 0.150 mm

iv) Thickness 46.50 mm 46.93 mm

V) Taper Angle 55° 50'00'' (By Master piece) 55° 50'00''

Surface hardness, center hardness & microstructure are confirm to specification

VIII PACKAGING AND LABELLING

REMARKS

Found satisfactory.

Conclusion
 SHYAM ENT Process & Product Audit Report of Through Hardened Part F. 7.5.2.1
Part No: NP963848 SH/SQF-1/I 57/18 DATE: 27/09/18
UNIT-II
SEQ.NO OPERATION DESCRIPTION PARAMETERS FINDINGS
Timken Part NP963848, process audit parameters are found satisfactory

Audited by : Arghya Roy Approved by: Rajib Chatterjee

 SHYAM ENT Process & Product Audit Report of Through Hardened Part F. 7.5.2.1
Part No: NP812794 SH/SQF-2/K-19/18 DATE: 02/11/18
UNIT-II
SEQ.NO OPERATION DESCRIPTION PARAMETERS FINDINGS
I Traceability and Loading
1 Visual Components Free From Rust & Damages No abnormality

2 Identification Identification Tag is available No abnormality

3 Batch Quantity Specified quantity as per WI No abnormality

4 Loading Pattern As per WI /SH/QIS/WI/67 Back face Down
Remarks : Found Adequate.
II Pre Washing
i) Visually Visually found OK
III THROUGH HARDENING IN SQF-1
1 Gas flow
(i) Endo 8.0 m3/hr 8.0 m3/hr

(ii) LPG 400 LPH 400 LPH

(iii) Nitrogen As per requirement NA

2 Temperature

(i) SQF-2 825° C 827.2°C

3 Carbon Potential for SQF-2

(i) Set Point 0.85% 0.85%

4 Time

(i) Hardening Cycle 25 min 28 min

5 Quenching Process (Through Hardening)

(i) Agitator Speed 750 rpm 752 rpm

(ii) Oil temperature 90 ° c 93° c

(ii) Quality Of Quenching Oil Free from contamination Found ok, verified by tc
(iii) Quenching Delay 30 sec 18 sec
iv) Quenching Time 20 min 20 min

(iv) Dripping Time 10 min 10 min

(v) Hardness of the product in As quench
64-67 hrc 66 hrc
condition
 SHYAM ENT Process & Product Audit Report of Through Hardened Part F. 7.5.2.1
Part No: NP812794 SH/SQF-2/K-19/18 DATE: 02/11/18
UNIT-II
SEQ.NO OPERATION DESCRIPTION PARAMETERS FINDINGS
6 Post Washing
Nozzle Spray Spray from all Nozzles No abnormality

Bath temperature 60 ° c ( +/- 5° c) 64° C

Bath concentration 2.0 ~ 4.0 % 2.75%

Oil skimmer working in oil skimming No abnormality

7 TEMPERING
Temperature 246 248

Time 240 min 240 min

Refer annexure detailed process monitoring observation sheet SH/SQF-2/ K-19/18

Remarks :

VI UNLOADING
1 Visual Components free from damages No damage

2 Visual appearance Free from oily surface and shoot No oil, shoot available

VII METALLURGICAL TESTING

Testing Description Specification Actual

1. Surface hardness In HRC 58-64 HRC 60~61 HRC

2 Center Harndess in HRC 58-64 HRC 59-60 HRC

5 Microstructure RA=10 % max Not observed in visual method

Dispersed Carbide Through out
Carbide Matrix of martensite

Core Ferrite Nil

IGO Nil

FREE FERRITE Nil

NMTP Nil

VIII DIMENSIONAL INSPECTION AFTER HARD TURNING

i) OD 140.00 mm ( +300 - +250 micron ) 140.70 mm

ii) ID 132.89 mm (-450 - -400 micron) 132.45 mm

iii) WIDTH PARALLISM 0.050 mm 0.150 mm

iv) Thickness 33.00 mm 33.02 mm

V) Taper Angle 60° 00'00'' (By Master piece) 60° 50'00''

Surface hardness, center hardness & microstructure are confirm to specification

VIII PACKAGING AND LABELLING

REMARKS

Found satisfactory.

Conclusion
 SHYAM ENT Process & Product Audit Report of Through Hardened Part F. 7.5.2.1
Part No: NP812794 SH/SQF-2/K-19/18 DATE: 02/11/18
UNIT-II
SEQ.NO OPERATION DESCRIPTION PARAMETERS FINDINGS
Timken Part NP812794, process audit parameters are found satisfactory

Audited by : Arghya Roy Approved by: Rajib Chatterjee

 SHYAM ENT Process & Product Audit Report of Through Hardened Part F. 7.5.2.1
Part No: NP985207 SH/SQF-2/K-81/18 DATE: 14/11/18
UNIT-II
SEQ.NO OPERATION DESCRIPTION PARAMETERS FINDINGS
I Traceability and Loading
1 Visual Components Free From Rust & Damages No abnormality

2 Identification Identification Tag is available No abnormality

3 Batch Quantity Specified quantity as per WI No abnormality

4 Loading Pattern As per WI /SH/QIS/WI/67 Back face Down
Remarks : Found Adequate.
II Pre Washing
i) Visually Visually found OK
III THROUGH HARDENING IN SQF-1
1 Gas flow
(i) Endo 8.0 m3/hr 8.0 m3/hr

(ii) LPG 400 LPH 400 LPH

(iii) Nitrogen As per requirement NA

2 Temperature

(i) SQF-2 825° C 826.9°C

3 Carbon Potential for SQF-2

(i) Set Point 0.85% 0.85%

4 Time

(i) Hardening Cycle 25 min 26 min

5 Quenching Process (Through Hardening)

(i) Agitator Speed 750 rpm 748 rpm

(ii) Oil temperature 90 ° c 92.7° c

(ii) Quality Of Quenching Oil Free from contamination Found ok, verified by tc
(iii) Quenching Delay 30 sec 22 sec
iv) Quenching Time 20 min 20 min

(iv) Dripping Time 10 min 10 min

(v) Hardness of the product in As quench
64-67 hrc 65-66 hrc
condition
 SHYAM ENT Process & Product Audit Report of Through Hardened Part F. 7.5.2.1
Part No: NP985207 SH/SQF-2/K-81/18 DATE: 14/11/18
UNIT-II
SEQ.NO OPERATION DESCRIPTION PARAMETERS FINDINGS
6 Post Washing
Nozzle Spray Spray from all Nozzles No abnormality

Bath temperature 60 ° c ( +/- 5° c) 63.8° C

Bath concentration 2.0 ~ 4.0 % 3.20%

Oil skimmer working in oil skimming No abnormality

7 TEMPERING
Temperature 246 247.5

Time 240 min 240 min

Refer annexure detailed process monitoring observation sheet SH/SQF-2/ K-81/18

Remarks :

VI UNLOADING
1 Visual Components free from damages No damage

2 Visual appearance Free from oily surface and shoot No oil, shoot available

VII METALLURGICAL TESTING

Testing Description Specification Actual

1. Surface hardness In HRC 58-64 HRC 60~61 HRC

2 Center Harndess in HRC 58-64 HRC 59-60 HRC

5 Microstructure RA=10 % max Not observed in visual method

Dispersed Carbide Through out
Carbide Matrix of martensite

Core Ferrite Nil

IGO Nil

FREE FERRITE Nil

NMTP Nil

VIII DIMENSIONAL INSPECTION AFTER HARD TURNING

i) OD 165.00 mm ( +300 - +250 micron ) 165.70 mm

ii) ID 152.69 mm (-450 - -400 micron) 152.35 mm

iii) WIDTH PARALLISM 0.050 mm 0.050 mm

iv) Thickness 33.54 mm ( +350 - +300 micron ) 33.52 mm

V) Taper Angle 50° 42'00'' (By Master piece) 50° 42'00''

Surface hardness, center hardness & microstructure are confirm to specification

VIII PACKAGING AND LABELLING

REMARKS

Found satisfactory.

Conclusion
 SHYAM ENT Process & Product Audit Report of Through Hardened Part F. 7.5.2.1
Part No: NP985207 SH/SQF-2/K-81/18 DATE: 14/11/18
UNIT-II
SEQ.NO OPERATION DESCRIPTION PARAMETERS FINDINGS
Timken Part NP985207, process audit parameters are found satisfactory

Audited by : Arghya Roy Approved by: Rajib Chatterjee