Format No: PES/QF/QA/03

PROCESS FLOW DIAGRAM Rev No: 00

Rev Date: 05.02.2018
Part No.: J105-39600 PFD No.: 33
Part Name: CASE E483 PFD Date of Origin: 18/07/2023
Drawing Rev. No.:TS-32685 PFD Rev. No.: 00
Drawing Rev. Date: 03.12.2013 PFD Rev. Date: 18/07/2023
Symbols

Op. Product characteristics Process Characteristics

Process Decscription Incoming Source of Variation
No. (KPOV) (KPIV)

1. Verification of Quantity as per 1. Skilled store person

invoice 2. Crane or Fork Lift
Receipt of casting material 2. Proper Labeling on Box 3. Work Instruction for receipt
10 -
of material
4. Labels

1. Quantity not as per invoice 1.Verification of material grade with 1. Skilled Inspector
MTC 2. Digital Vernier
2. Pocket Width 8±1.0 3. Raw material quality plan
3. OD 72 ± 1.0 4. Material OK sticker /
3. Visual Insp -Casting should be Reject tag
20 Incoming inspection free from dirt,dust,rusty etc. 5. PPE's
It should be proper fettel & shot 6. Cutter
blasting. 7. Incoming inspection
Ensure the should be free from quality plan
Crack.

1. Storage of material at identified 1. Skilled store person

location 2. Crane or Fork Lift
30 Storage of Incoming material - 2. Storage of material in FIFO order 3. FIFO procedure
with FIFO sticker 4. Wooden Pallet or Other
5. FIFO label
1st Operation - CNC
40 1.Rough Facing 1. Skilled operator
Tool No.-01 - Face Rough
- 2.Free from burr and sharp edge 2. Work instructions
3. Measuring Instrument
1st Operation - CNC 1. ID 29.5 ± 0.5 4. Rejection Bin
Tool No.-02 - ID Rough 2.Free from burr and sharp edge 5. First Piece Report

1st Operation - CNC 1. OD 64.6 ± 1.0

Tool No.-03 - Face Finish 2. ID 90 ± 1.0
3. Depth 5.1 ±0.8
4. Width 10.5 ±0.8
5. Surface Finish Ra3.2
6.Free from burr and sharp edge

1. ID 30 (-0.025/-0.045)
2. Chamfer 1.5 (+0.2/-0.00)
1st Operation - CNC
3. Angle 30°±1°
Tool No.-04 - ID Finish
4. Surface Finish Ra3.2
5. Surface Finish Ra25
5.Free from burr and sharp edge

1st Operation - CNC 1. Groove ID 105 (+0.00/-0.20)

Tool No.-05 - Groove Finish 2. Groove Width 3.5 (+0.25/-0.00)
3. Groove Depth 2.4 ±0.050
4. Radius 0.4 Max
5. Radius 0.4 Max
6. Surface Finish Ra3.2
7. Surface Finish Ra3.2
8. Surface Finish Ra3.2
9. Free from burr and sharp edge

1. ID 54.00 ± 0.5 1. Skilled operator

2nd Operation - CNC 2. Free from burr and sharp edge 2. Work instructions
-
Tool No.-01 ID Rough 3. Measuring Instrument
4. Rejection Bin
1. ID 55 (-0.020/-0.045) 5. First Piece Report
2. Chamfer 1.5 ±0.2
3. Angle 30°±1°
2nd Operation - CNC 4. Surface Finish Ra3.2
Tool No.-02 ID Finish & Face Finish 5. Surface Finish Ra25
6. Total Length 56.4 ±0.1
7. Free from burr and sharp edge

50 1. Groove ID 56.66 ± 0.3

2. Groove Width 1.6 ± 0.1
3. Groove Radius R0.8±0.1
4. Groove Surface Finish Ra25
5. Groove Surface Finish Ra25
6. Surafce Finish Ra12.5
2nd Operation - CNC 7. Distance 24 (+0.10/-0.20)
Tool No.-03 Groove Finish 8. Perpendicularity 0.1 w.r.t.Z
9. Flatness 0.2
10. Concentricity 0.1 w.r.t.Z
11. Roundness 0.015
12. Cylindricity 0.015

1. 4 Spot Face - 23±0.2 1. Skilled operator

2. Surface Finish - Ra6.3 2. Work instructions
1st Operation - VMC Tool 3. 4 Width 9 ± 0.2 3. Measuring Instrument
No.-1- Spot Face 4. Depth 1.5 ± 0.8 4. Rejection Bin
60 -
Tool Name - End Mill 5. Free from burr and sharp edge 5. First Piece Report & In-
Tool Size - ø23.00 mm Process inspection
Part No.: J105-39600 PFD No.: 33
Part Name: CASE E483 PFD Date of Origin: 18/07/2023
Drawing Rev. No.:TS-32685 PFD Rev. No.: 00
Drawing Rev. Date: 03.12.2013 PFD Rev. Date: 18/07/2023
Symbols

Op. Product characteristics Process Characteristics

Process Decscription Incoming Source of Variation
No. (KPOV) (KPIV)

1. 4- Hole ø8.7 ± 0.2

2. Position Coordinate 59.4 ± 0.2
3. Position Coordinate 75.3 ± 0.2
1st Operation - VMC 4. Position Coordinate 21.3 ± 0.2
Tool No.-2- Drilling 5. Position Coordinate 65.6 ± 0.2
- 6. Position Coordinate 10.1 ± 0.2
Tool Name - Drill Tool
Tool Size - ø8.7 mm 7. Position Coordinate 4.8 ± 0.2
8. Position Coordinate 83.2 ± 0.2
9. Free from burr and sharp edge

1. 4 Radius R0.4 Max

1st Operation - VMC 2. Free from burr and sharp edge
Tool No.-3- Radius
-
Tool Name - Radius Tool
Tool Size - ø0.4 Max

1. Free from burr, sharp edges. 1. Skilled worker

2. Free from rust, dust, dirt, crack, 2. Limit samples for defects
proper shot blasting 3. LUX level at inspection
station of 1000 to 1200
70 Deburring -
4. Rejection bin
5. Work Instruction
6. Rough Paper

1. Free from burr 1. Skilled worker

2. Free from dust 2. Limit samples for defects
3. Free from coolent water on part 3. LUX level at inspection
station of 1000 to 1200
80 Air cleaning Improper deburring
4. Rejection bin
5. Work Instruction
6. Air gun
Part No.: J105-39600 PFD No.: 33
Part Name: CASE E483 PFD Date of Origin: 18/07/2023
Drawing Rev. No.:TS-32685 PFD Rev. No.: 00
Drawing Rev. Date: 03.12.2013 PFD Rev. Date: 18/07/2023
Symbols

Op. Product characteristics Process Characteristics

Process Decscription Incoming Source of Variation
No. (KPOV) (KPIV)

1. Free from burr, sharp edges. 1. Skilled Inspector

2. Dimesions as per final quality plan 2. Calibrated Instruments
3.Visual Insp - Casting should be 3. Defect galary for case part
free from dirt,dust,rusty crack etc. 4. Limit samples for defects
It should be proper fetteling & shot 5. LUX level at inspection
blasting. station of 1000 to 1200
90 Final Inspection Improper air cleaning 4. Free from porosity, blow hole, 6. Rejection bin
shrinkage, extra sand & other 7. Work Instruction
casting defects

1. Dimesions as per final quality plan 1. Skilled Inspector

100 Pre-Delivery Inspection Improper final inspection 2. Calibrated Instruments 3.
Work Instruction
1. Free from rust 1. Skilled worker
2. Free from extra oil on part 2. Polybag
110 Oiling PDI not done 3. Oil tank

1. Packing as per packaging 1. Skilled worker

standard 2. Packaging standard
120 Packaging Oiling Not Proper 2. Proper labelling 3. Pet trays, CG box,
3. Proper barcode 4. Packaging Labels
5. Barcode

1. Stoarage of FG at identfied 1. Skilled worker

location 2. FG material handling
130 FG Storage Improper Packaging 2. Stoarage of FG in FIFO order procedure

1. Selecting proper mode of 1. Skilled store person

1. Improper Packaging transport 2. Manual stacker
140 Disptach 2. Packaged quantity not as per 2. Dispatch quantity as per invoice 3. FG Material handling
packaging standard procedure
4. Computer and Printer

Prepared By: Pankaj Bhike

 Manufacturing Location Machine Details
Jig Fixture & gauges
details (Inhouse/ ( M/c make, tonnage, details ( Jig
outsource, supplier name, m/c photo, m/c Photographs Photographs
Number, guage id)
address & photographs) number)

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Inhouse CNC 4 (4.10 ton)/ CNC 7 CNC 4

Pako Engineering Sevices CNC 7 ( 4.10 ton)/ ----
CNC 8 ( 4.10 ton)/
CNC 3 ( 4.10 ton)

CNC 8 CNC 3

Inhouse CNC 4 (4.10 ton)/ CNC 7 CNC 4

Pako Engineering Sevices CNC 7 ( 4.10 ton)/ WITHOUT PART
CNC 8 ( 4.10 ton)/
CNC 3 ( 4.10 ton)

CNC 2nd Set up

CNC 8 CNC 3 Holding Fixture
WITH PART

Inhouse BFW VMC-2 WITHOUT PART

Pako Engineering Sevices VMC-01 (5.90 ton)/
VMC-02 (5.90 ton)/
VMC-03 (4.70 ton)

VMC Holding
Fixture- 01
 Inhouse BFW
Manufacturing
Pako EngineeringLocation
Sevices Machine(5.90
VMC-01 Details
ton)/
Jig Fixture & gauges
details (Inhouse/ ( M/c make,
VMC-02 tonnage,
(5.90 ton)/
VMC-03 (4.70m/c
ton) Photographs details ( Jig Photographs
outsource, supplier name, m/c photo,
Number, guage id)
address & photographs) number)

VMC Holding
Fixture- 01 WITH PART

VMC -1 VMC 3

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 Manufacturing Location Machine Details
Jig Fixture & gauges
details (Inhouse/ ( M/c make, tonnage,
Photographs details ( Jig Photographs
outsource, supplier name, m/c photo, m/c
Number, guage id)
address & photographs) number)

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Approved By: Amit Kothawale