I NP UT-P ROCESS-OUTP UT SHEET

P art Operation
Model P art No. P art Name Operation No. Opn. Rev.
Mod. No. Description
3 W heeler 22151106 Brake Drum Cast I ron 4 170 Boring & Facing 01' 04.09.2019
PRO
CESS

CLAMPING

RESTING
 3M - METHOD

3.1 -OPERATION SEQUENCE

SR. N Activity Cycle sequence Time in Sec

1 Open Door 2
Unloading
2 Press foot switch & Unload component 2

3 Clean Jaw & Resting face Cleaning 5

4 Load component & press foot switch 5

5 close door Loading 2

6 Press cycle start 2

7 Machining cycle Machining 42

CYCLE TIME 60
 I NP UT-P ROCESS-OUTP UT SHEET
P art Operation Operation
Model P art No. P art Name Opn. Rev.
Mod. No. No. Description
Boring &
3 W heeler 2.2E+07 Brake Drum Cast Iron 4 170 01' 04.09.201
Facing
OUTP
UT
 OUTPUT CONDITION
SR.N Inspection Responsibil
Parameter Defect No. Specification Measured by Gauge No.
O. frequency ity
1 Inner Dia 44,45,46 52.00 +0.050 Plug Gauge … … … .. 100%
Surface Finish on
2 41 Ra 6.3 Surface Tester … … … .. 1 per Shift Inspector/
dia.52.0 Operator/
3 Inner Dia 52,53 90.0 +1.0 Paddle Gauge … … … .. 1 per 20 CMM
Engineer
54,55,56,
5 Thickness 5.0 ±0.10 Snap Gauge … … … .. 1 per 20
57
Dent, damage, free No Dent, damage,
6 from burr & - Visual … … … .. 100% Operator
burr & patchmark
patchmark
 I NP UT-P ROCESS-OUTP UT SHEET
P art
Model P art No. P art Name Mod. Operation No. Operation Description Opn. Rev.
No.
3 W heeler 22151106 Brake Drum Cast I ron 4 180 Boring & Facing 01' 04.09.201

P ROCESS
 3M - METHOD

3.1 -OPERATION SEQUENCE

SR. N Activity Cycle sequence Time in Sec

1 Open Door 10
Uploading
2 Press foot sw itch & Unload component 10

3 Clean Jaw & Resting face Cleaning 10

4 Load component & press foot sw itch 5

5 Press foot sw itch & Center clamp 5

Loading
6 close door 5

7 Press cycle start 5

8 Machining cycle Machining 42

CY CLE TIME 92
 OUTPUT CONDITION

SR.NO Defect Inspection

Parameter Specification Measured by Gauge No. Responsibility
. No. frequency

1 Inner Dia 59,60 170.00 Paddle Gauge … … … .. 1 per 20

+0.10
2 Depth 68,69 31.00 ±0.20 Flush Pin Gauge … … … .. 1 per 20

Cylinder Bore Inspector/

3 Ovality max. 66 0.10 mm … … … .. 1 per Shift Operator/ CMM
Gauge
TIR Gauge / 1 per 20 / Engineer
4 Total Runout 58 0.06 mm … … … ..
Mahar (Mahr)1 Per
Roundness Shift
5 Face Runout 43 0.10 mm Dial Gauge … … … .. 1 per 20

6 Radius - R1 Radius Gauge … … … .. 1 per 20 Inspector

Surface Finish
7 67 Ra 6.3 Surface Tester … … … .. 1 per Shift Inspector
on dia. 170.0
Dent, No Dent,
8 damage, free - damage, burr Visual … … … .. 100% Operator
from burr & & patchmark
patchmark
 I NP UT-P ROCESS-OUTP UT SHEET
P art
Model P art N o. P art N ame Mod. Operation N o. Operation Descriptio Opn. Rev.

Brake Drum Cast N o.

3 W heeler 2.2E+07 4 190 6 Hole Drilling 01' 04.09.2019
I ron
P ROCESS

LOCATING RESTING
(ID 52.0)
 3M - METHOD

3.1 -OPERATION SEQUENCE

SR. NO. Activity Cycle sequence Time in Sec

2 Unload component . Unloading 5

3 clean Resting face. Cleaning 10

4 Load part on fixture. Loading 5

5 Press cycle start button. 5

8 Machining cycle Machining 32

CYCLE TIME 57
 3.2 PROCESS PARAMETERS

Sr. Defect No. Cutting Insert / Drill Operation Cutting Feed in mm/ min. Make
No. Tool Detail speed in
74,75,76, HSS Drill dia. 13.0 4 Hole Drilling Dia
1 Step Drill 649 192mm/ min. SMITH
81,82 x 11.5 11.50
74,75,76, Counter HSS Drill dia. 9.0 2 Counter Drilling
2 649 192mm/ min. SMITH
81,82 Step Drill x 4.70 x 90º Dia 4.70
 I NP UT-P ROCESS-OUTP UT SHEET
P art Operation
M odel P art N o. P art N ame M od. Operation Descriptio Opn. Rev.
N o.
N o.
3 W heeler 22151106 Brake Drum Cast I ron 4 190 6 H ole Drilling 01' 04.09.2019

OUTP UT
 OUTPUT CONDITION
Inspection Responsibilit
SR.NO. Parameter Defect No. Specification Measured by Gauge No.
frequency y
Dia 11.50+0.2
1 Hole dia. 74,75 Plug gauge … … … .. 1 per 20
x4nos.
Dia 4.7+0.1
2 Hole dia. 81,82 Plug gauge … … … .. 1 per 20
x2nos.

3 Counter 70,71 Dia 9 x 90° +0.1 Vernier Caliper … … … .. 1 per 20

Inspector/
Counter Operator/
4 - 2.70 ±0.20 Flush pin Gauge … … … .. 1 per 20 CMM
depth
Engineer
Angle
5 betw een 90 °±0.30' Relation Gauge … … … .. 1 per 20
twAngle
o drill
6 betw een 45 °±0.30' Relation Gauge … … … .. 1 per 20
drill Dia
7 PCD 77,78,79 Dia 70.0±0.10 Relation Gauge … … … .. 1 per 20
Dent, No Dent,
8 damage, - Visual … … … .. 100% Operator
damage, burr
free from
 I NP UT-P ROCESS-OUTP UT SHEET
P art Operation
Model P art No. P art Name Mod. Operation Descriptio Opn. Rev.
No.
No.
3 W heeler ######## Brake Drum Cast I ron 4 200 2 Hole Drill Tap 01' 04.09.2019

OUTP UT
 OUTPUT CONDITION

SR.N Paramete Inspection

Defect No. Specification Measured by Gauge No. Responsibility
O. r frequency
Ø5.00±0.1- 2
1 Hole dia. Plug gauge … … … .. 1 per 20
Hole
M6 x 1.0 mm - 2 Thread Plug Inspector/ Operator/
2 Tapping … … … .. 1 per 20
Hole gauge CMM Engineer
Relation 1 per
3 PCD Ø 66.0±0.1 … … … ..
Gauge/ CMM 20/ 1/ Shift
Dent,
damage, No Dent,
4 Visual … … … .. 100% Operator
free from damage, burr
burr
 I NP UT-P ROCESS-OUTP UT SHEET
P art
Model P art No. P art Name Mod. Operation No. Operation Descripti Opn. R
No.
Face Grooving
3 W heeler 2.2E+07 Brake Drum Cast I ron 4 210 01' 04.0
& Chamfering
P ROCESS

CLAMPING

RESTING
LOCATING(ID
 3M - METHOD

3.1 -OPERATION SEQUENCE

SR. NO Activity Cycle sequence Time in Sec

2 Press foot switch & Unload component Unloading 5

3 Clean Locator & Resting face . Cleaning 10

4 Load component with clamp plate. 10

5 Press foot switch for Center clamping. Loading 10

7 Press cycle start 10

8 Machining cycle Machining 90

CYCLE TIME 135

 3.2 PROCESS PARAMETERS
Sr. Defect Cutting Cutting Feed in
Tool Detail Operation speed in Make
No. No. Tool mm/ min.
m/ min.
1 85,89 Brazed Tool BRZ TOOL ISO7 RH 2516 5.5MM Grooving 80 R.P.M 24 mm/min. ASHOK
2 85,89 Brazed Tool BRZ TOOL ISO 2 LH 2020 45˚ K 20 Chamfering 182.0 x 45 Deg 80 R.P.M 24 mm/min. ASHOK

3 85,89 Brazed Tool BRZ TOOL CHAMFER BT45X8X60 R/H Chamfering 0.5 x 45 Deg 80 R.P.M 24 mm/min. ASHOK

3.3 PROCESS CONDITION

METH Hydraulic clamping pressure in Pressure M/ c

91 15-25 kg / cm2 Daily JH
OD Kg/ cm2 gauge operator

TOOLI Cleanliness of part resting & Finish & clean By hand / M/ c

………… Daily JH
NG clamping surfaces Resting Face visual operator
 I NP UT-P ROCESS-OUTP UT SHEET
P art
Model P art No. P art Name Mod. Operation No. Operation Description Opn. Rev.
No.
Face Grooving &
3 W heeler 22151106 Brake Drum Cast I ron 4 210 01' 04.09.2019
Chamfering
OUTP UT
 OUTPUT CONDITION
SR.N Inspection Responsibilit
Parameter Defect No. Specification Measured by Gauge No.
O. frequency y
Dia 202.0 ±
1 Groove ID Paddle Gauge … … … .. 1 per 20
0.20
Dia 192.0 ±
2 Groove OD Paddle Gauge … … … .. 1 per 20
0.20

3 Depth 14.0±0.2 Flush pin Gauge … … … .. 1 per 20

Inspector/
Operator
4 Radius R 0.5 Visual … … … .. Every tool change.

Chamfer
5 182.0 +1.0 Vernier Caliper … … … .. 1 per 20
dia.
Groove
6 Chamfer 0.5x45' Visual … … … .. 1 per 20
dia.
Bevel Protector/ Std.
7 Angle 45°±30' … … … .. 2 Per Shift Operator
Template
Dent, damage, No Dent,
8 free from burr damage, burr & Visual … … … .. 100%
& patchmark patchmark