PART NAME TEAM MEMBERS DOC NO MMPL/FD/SOP/03

STANDARD OPERATING PROCEDURE All FORD Disc

PART NO Name Designation
ISSUE NO 0
PROCESS NO : PROCESS NAME : Compax Industrial B M Landur Core Shop I/C
Core Making Machine
Systems Pvt Ltd Vinayak Patil Supervisor
REV NO/ DATE 15-02-2017
Asif Supervisor
30,40 and 50 Core Making CUSTOMER FORD INDIA
MMPL Shridhar Howale Quality Inspector SHEET NO 01 of 01
Operating Procedure For Core Sand Preperation Control Limits For Process Paramters
1 ) First take clean washed sand exactly 100 ± 5 Kg. in to the sand mixer, the sand which is taken should be dry. After taking
Sr. No Parameter Control Limit
Sand Core sand start the sand mixer.
Core Core
Preperation Making Scratch Dressing 2 ) Now start to add Part A & Part B between 800 to 1200 ml into the mixer. While mixing put Part A first & then Part B. Add
In Mixer Hardness 1 Washed Sand Qty 100 ± 5 Kg
Part A & B very slowely into the mixer. If required add the vening powder as per the requirement.
3 ) After adding the part A & B into the sand, mix it for 3 to 7 min & then turn off the mixer.
2 Part A 800 to 1200 ml
4) Now, take out the mixed sand in a bucket & add it into the hopper of Cold Box Core Machine. Use the sand before 40 min
3 Part B 800 to 1200 ml
after producing it.
Operating Procedure For Core making, Painting & Finishing 4 Anti- Veining Powder 5 Kg

1 ) First check the Amine gas level into the tank & also check the air pressure which should be minimum 6 Kg/cm2. 5 Mixing Time 5 to 7 Min

2) Now take the core box whose cores are to be produced & check it is as per the startup check sheet. If it Ok then mount
this core box on the core box machine trolley. 6 Low Perghing Pressure 1 to 5 Kg/cm2
Ok Core
Core Core Core Mount On 3 ) As per the part set the cycle time & start the cycle.
Painting Finishing 7 High Perghing Pressure 2 to 6 Kg/cm2
Baking Trolly
4 ) After the cycle is started the corebox will go to the sand shooting station & sand will be shotted into the core box. After
shotting the corebox will move to the next station were gasing will be done. 8 Amine Time 1 to 6 Sec

5 ) After gassing the corebox will come to the next station, were the core will removed from core box. When the core box
reaches to the core removing station the top half of core box will lift up automatically, after that remove the core by hitting 9 Shooting Time 0.05 to 1.00 Sec
plastic hammer at the end of core box.
6 ) When core is removed from bottom half of core box, clean the corebox by air pressure & then close the corebox & then
10 LPP Time 1 to 6 Sec
start the next cycle.
7 ) After core production, Check the core scratch hardness which should be minimum 60 (Once in a shift & for part HPP Time 2 to 8 Sec
11
changeover). After that take that core to remove the extra flashes by using the dressing fixtures. After dressing make a mark
8 ) After core dressing, paint the core by dipping it into the paint booth. Check the paint viscosity on hourly basis & control it Amine Temp 80 to 140 ⁰ C
12
within 15 ± 3 SEC.
13 Paint Viscosity 15 ± 3 Sec
9 ) After core painting put that core into oven for baking.After core baking again inspect the core & do the finishing of core.
10 ) After core finishing, put the Ok cores on trolley. On trolley put the core production date & also the total core qty present 1) For Oven 1 & 3 : - 200 ± 20 ⁰ C
14 Baking Temp
in one trolley. 2) For Oven 2 : - 180 ± 20 ⁰ C
1) Oven 1 : - 51 Minutes , 2) Oven 2 : - 45 Minutes,
15 Baking Time
3) Oven 3: - 22 Minutes
SAFETY:

Control Limits For Product Paramters

Sr. No Parameter Control Limit
1 Core Scartch Hardness 60 Min
2 Gas Evaluation Before Painting 15 CC/Gm Max
3 Gas Evaluation After Painting 20 CC/Gm Max
Helmet Goggle Shoes

Mask

REACTION PLAN
1 ) If the core box is damage or crack then, don’t take the core box for production give it for rework or repair.
2 ) If the Amine gas level is, below the required level, then stop the production. Fill the amine tank & then rechek the level.
3 ) If the paint viscosity is more add the water as per the requirement & if it is less & then add the paint.
4 ) If the core scratch hardness is not as per the requriement then, make the necessary additions & bring it into the required
spec.

Do Don't
1 ) Use the sand for core production which is free from foreign material, such as dust, durt, soil & stone etc. 1 ) Don't use the sand which is having foregin materials in it.

2 ) Before using the core box for production, check it as per the startup checksheet. 2 ) Without checking the corebox as per the startup checksheet, don’t use it for production.

3 ) Check the Amine level & air pressure before starting the production. 3 ) Don't start the production without checking the Amine level & air pressure.

4 ) After core production, do the core dressing operation for every core produced. 4 ) Don't miss the core dressing operation.

5 ) After core dressing make a mark on core by chalk, to identify OK core. 5 ) Don't forget to make a mark on dressing OK core.

6 ) Check the Core Scratch hardness once in a shift & also for change over part. 6 ) Don’t Continue the core production without checking the core hardness for 1st piece sample.

7 ) Paint the core properly & ensure all the main part is main part is painted. 7 ) Don't use the core for porduction which are not painted.

8 ) Keep the painted core properly into the oven. 8 ) Don't damage the core while putting in oven.
WORK CONTENT 9 ) Do the final inspection of core after core baking & then place the core on trolleys. 9 ) Don't miss the final inspection of core after the core baking operation. Don't keep the OK core on ground floor.
REVIEWED BY APPROVED BY
LEGEND : Kg - KiloGram, Gm - Grams, % - Percentage, Min - Minutes, ⁰ C - Degree Celcius, Sec - Seconds, Cm - Centimeter, ml - mililiter