5.

1 Quality Control Tools:

1. Pareto Chart

2. Histogram

3. Flow Diagram

4. Check Sheet

5. Scatter Diagram

6. Control Chart

7. Cause and effect Diagram

Calibration Wing:

• There is a separate department under Quality Control and Assurance known as

Calibration.
• Here, There is first article inspection where there is check for defects Infront of the
client. The model is made as per the Drawings provided by the client.
• Only first 5 products of the produced batch is checked for defects.

CMM:

• This bears the final inspection procedures in the quality department.

• Here there is Dimensional check of the product as per the Engineering drawing
provided by the client. Followed by this there is there is Visual Check.
• There is use of instruments such as Vernier Callipers, Plane Gauge.
• Minute amount of defect is permitted such as in the case of a Hole, a defect of
0.01mm in its diameter is permitted.
Rolls-Royce Engine Department:

• There are 3 types of parts involved in a Rolls-Royce Engine namely Major, Minor and
Sub-minor Parts.
• This department at TATA Sikrosky deals with only Sub-minor Parts.
• Titanium is used in the construction of these sub-minor parts.
• Manufacturing Processes involved are Turning, Milling, Multi-axel turn Milling, Wire
cut and VTL.
• Turning is based on 2-axis and 3-axis where the milling is based on 3-axis and 5-axis.
Turn mill is of 5 and 7 Axes where the part is stationary and the machine moves
around the part.
• There is Water jet cutting in x, y and z direction.

Part Inspection:

• It is based on CMM in RR Engine department.

• There are primarily 4 types namely Manual Inspection, Human Visual Inspection,
CMM and OMM which is basically combination of CMM and Profile Projection.
• There is also Accuracy and Shadow check involved.
• Talysurl has a tracing accuracy of 4nm.
• There is Laser QC method present along with Manual Checking with Updated
software using which only flat plates can be tested.

NDT- NON Destructive Testing:

• Primarily divided into 2 divisions dealing with Fluorescent Particle Inspection and
Magnetic Particle Inspection respectively.
• The Fluorescent Particle Inspection is divided into two types namely Immersion
Dipping and electro-static lining.
• In Immersion Dipping, which is water based in used on Large Parts where they are
hanged and coat is sprayed on them. It involves wash and dry mechanism.
• In Electro static lining, which is oil based and is used for small particles to dip in, it
involves a pre-wash and then in emulsifier. When the oil gets away, it is water
washed and dried for 30 minutes in temperatures of 60-70 degrees.
• Once these respective processes are done, they are placed under UV light to see
illuminating fluorescent and the defects are detected.
• The Magnetic Particle Inspection is classified into 2 types namely Head shock and
Coil shock methods.
• In head shock method, the particle is inserted between material and oil is sent using
a sprayer. Electricity is passed and the Particle is removed. Oil gets deposited on the
cracks due to action of current and hence crack visualisation is done.
• The current has to be maintained as per constrain or else the part burns out. The
particle is demagnetised before removing ensuring all the current is drawn out of the
Particle.
• In coil shock method, Magnetic and Electric fields are generated in perpendicular
directions using which the cracks are visualised in circular direction.
• The Magnetic method cannot be used to find defects in materials like Aluminium or
Brass as they are not magnetic in nature.