CIRCLIPS TECHNOLOGIE PVT. LTD.

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 A. Product Knowledge :-
 Types Of Products :
Circlips / Retaining Rings:

External Circlip- For Shafts Internal Circlip- For Bore

External Circlip- VA Type Internal Circlip- VB Type

External Circlip- K Type Internal Circlip- K Type

Crescent Ring- C Type “E” Clips

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 Snap Rings:

Snap rings- For Shafts Snap rings- For Shafts & Bores

Push- On Fix / Grip:

Grip Rings Toothed Clips

Heavy Duty Push – On Fix

Special Wire Rings:

Special Wire Rings –For Shafts

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 Support Washers:

Support Washers Shims

Washers:

Disc Springs Washer Wave Spring washer

Dowel Pins :

Spiral Dowel Pins Roll Pins / Dowel Pins

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  Application :-

 Agri Machines  Bearings  Pumps

 Automobiles  Gear Boxes  Generators

 Aerospace Motors  Turbo Chargers

 Earthmovers  Textile Machines  Engines

 Railways  Heavy Vehicles  Pharma Equipments

Trailers Diesel Sets Electronic Appliances

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  Special Characteristics :-

Special Characteristics of product Includes 2 types & they are symbolically

represented such as –

1. Critical Characteristics
2. Significant Characteristics

Special Characteristics includes – Inside Die (ID), Outside Die (OD),Thickness & Hardness.
It affects at customer assembly- Product characteristic or process parameter which
can affect safety or Regulatory compliance, fit, function, performance or
subsequent processing of product.
Minor Characteristics includes – Width, Lug Width, Lug Hole, Gap etc.

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 B. Process Knowledge :-

The products are made from Wire as well as from Sheet. The process as per that is given below.

WIRE SHEET
Flattening Sheet Slitting
Coiling
Stress Relieving
Coil Cutting

Profile Cutting
Hole Punching
Coining
Austempering
Press Tempering
Vibro Cleaning
Phosphating
Final Inspection
Oiling & Packing
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 Process flow for “Wire”:-

1. Flattening :-
Flattening is the initial setting process. Thickness & Width of
the product is maintain here as per IS Standard as well as Drawings.

Mandrel

2. Coiling :-
After flattening, Coils are made on coiling machine. Mandrel is
Used for that purpose. Outside/Inside Die of the product is
maintain here. Also burrs, rust & cracks observed here.

3. Stress Relieving :-
After that coils are send for removing undue stress in stress relieving furnace. They are stress relieved at specific
temperature & soaking time. After that they are cool down at room temperature.

4.Coil Cutting:-
After stress relieving, coil cutting is done on power press.
Coils are get separated from one another.
Straight cuts , Angles, burrs , rust, sharp edges etc. observed here.

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5. Profile Cutting :-
After coil cutting , profile cutting to be done. In this process , profile
(Shape) is given to circlip. Outside/Inside Dia, Width, Lug Width is
observed here.

6. Hole Punching:-
After that hole punching is done on lug of the circlip. Dimension of the
lug hole is maintain here.

7. Coining:-
If any type of Ovalilty observed in the pre process then coining is
done for removing ovality. As well as thickness also maintain here.

8. Austempering :-
After that material send for austempering in austempering
furnace for maintaining hardness. Temperature is maintain in
Zone- 1, Zone- 2 , Zone – 3 , & Zone – 4.
Material is pass through a belt called “ Continuous Mesh Belt ”
 Austempering is heat treatment that is applied to ferrous metals, most notably steel and ductile
iron. In steel it produces a bainite microstructure whereas in cast irons it produces a structure of
acicular ferrite and high carbon, stabilized austenite known as ausferrite. It is primarily used to improve
mechanical properties or reduce / eliminate distortion. Austempering is defined by both the process
and the resultant microstructure. Typical austempering process parameters applied to an unsuitable
material will not result in the formation of bainite or ausferrite and thus the final product will not be
called austempered. Both Microstructures may also be produced via other methods. For example, they
may be produced as-cast or air cooled with the proper alloy content. These materials are also not
referred to as austempered.

9. Press Tempering :-
After that material is send in Tempering Furnace for maintaining Hardness as per requirement.
In this temperature is maintain through temperature Controller & soaking time also monitor
Tempering is a process of heat treating, which is used to increase the toughness of iron-based
alloys. Tempering is usually performed after hardening, to reduce some of the excess hardness , and is
done by heating the metal to some temperature below the critical point for a certain period of time,
then allowing it to cool in still air. The exact temperature determines the amount of hardness removed,
and depends on both the specific composition of the alloy and on the desired properties in the finished
product. For instance, very hard tools are often tempered at low temperatures, while springs are
tempered to much higher temperatures. In glass, tempering is performed by heating the glass and then
quickly cooling the surface, increasing the toughness.
10. Vibro Cleaning :-
Vibro cleaning / deburring is done for removing burrs, Sharp edges & rust
on the product. “Ceramic Stones” are used for that.

11. Phosphating:-
Phosphate coatings are used on Steel parts for corrosion resistance, lubricity, or as a foundation for
subsequent coatings or painting.
It serves as a conversion coating in which a dilute solution of phosphoric acid and phosphate salts
is applied via spraying or immersion and chemically reacts with the surface of the part being coated to
form a layer of insoluble, crystalline phosphates. Phosphate conversion coatings can also be used
on Aluminum, Zinc, Condominium, Silver and Tin.
The main types of phosphate coatings are manganese, Iron and zinc. Manganese phosphates are
used both for corrosion resistance and lubricity and are applied only by immersion. Iron phosphates are
typically used as a base for further coatings or painting and are applied by immersion or by spraying.
Zinc phosphates are used for corrosion resistance (phosphate and oil), a lubricant base layer, and as a
paint/coating base and can also be applied by immersion or spraying

12. Final Inspection :-

Inspection of the product is done here as per customer specification as well as IS Standard on sampling
basis.

13. Oiling & Packing :-

Oiling & Packing of product is done here. Polythene bags are used for packing.
Instrument Handling & Knowledge :
A) Dial Vernier Caliper :-
Dial Vernier is used for measuring Outside Dia, Inside Dia, Width
Lug width, Lug hole etc.

1.Dry and clean the protective 2. Loosen the beam lock

sticker of the dial caliper with of the dial caliper.
clean cloth (or soaked with
cleaning oil)

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 3. Dry and clean all the measuring surfaces of the four jaws of the caliper with clean cloth
(or soaked with cleaning oil)

4.Then fully close the dial caliper

5.Open the lower jaws of the dial caliper on the
to check whether the needle points
outside parts of the item by sliding the movable
to 0 or not. If it points to 0, then you
jaws of the dial caliper
can begin to take a measurement.

6.Firstly, insert the internal jaws of the dial caliper into

the hole .
Secondly, open the internal jaws up to fit the hole
perfectly

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 B) Outside Micrometer :
Micrometer is used for measuring Thickness.

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 1.Place the object between the anvil and
spindle.

2.Turn the ratchet until the spindle

meets object.

3. Spin ratchet until you hear 3 clicks.

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 4. Verify both the anvil and spindle are touching
the object evenly.

5. Set the thimble lock while the micrometer

is still on the object.

6. Remove the micrometer from the

object once it's been locked.

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 C.NC Parts Handling :-

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 D. Abnormal Situation :-
Tool/Machine Breakdown (More Than 3 Hours)

Instrument Failure- Gauge Out Of Calibration

Poka Yoke failure

Continuous Non Conformance In The Product

Sub parts Mix Up

New Defect In Product.

Fallen parts on the floor

Generator Set Failure more then 10 mins

Accident Happens With Operator During Production activity

Note : If any abnormal situation creates then follow abnormal situation handling procedure.

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Abnomal Situation Handling Procedure :
Control Plan :
E. Types Of Defects In Product :-

Rusty Hole Out Hole Out

Burr Dent Mark

Cut Piece
DEFECT MATRIX :-
Rework Matrix :
CIRCLIPS TECHNOLOGIE PVT. LTD.
Plot No. 235, GIDC, Umargam – 396 171.

Rework Matrix
Defect Rework Not Rework
Burr Observed Yes -
Thickness Undersize - Yes
Thickness Oversize Yes -
ID Undersize Yes
ID Oversize Yes
OD Undersize Yes
OD Oversize Yes
Gap Oversize - Yes
Gap Undersize Yes
Dent Mark - Yes
Out Cutting Yes
Hole Out Yes
Hole Undersize - Yes
Hole OverSize - Yes
Prepared By: Shital P. Approved By.: Mr. A.Kazi.

Version No.: 2.00 Issue Date:01.02.2012 Format No.:CTPL/PROD/19

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ROUTE CARD :
Front View Back View

REWORK TAG :
 Rework Work Instruction :
CIRCLIPS TECHNOLOGIE PVT. LTD.
Plot No. 235, GIDC, Umbergaon – 396 171.

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Prepared By : Shital P. Checked By : Mr. A. Kazi. Approved By : Mr. Arvind D.

Version No. : 2.00 Issue Date : 01.02.2012 Format No. :CTPL/WI/RWK

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 F. Awareness About 5 S :-

5S ROAD MAP

DISCIPLINE 5S-SHITSUKE

STANDARDIZATION 4S-SEIKETSU

CLEANLINESS
3S-SEISO

SYSTEMATIC
ARRANGEMENT 2S-SEITON

SORTING 1S-SEIRI

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Guidelines For It’s Implementation :-
1S-SEIRI-
Segregate Unwanted & Wanted Material Then keep the
unwanted Material Separately with Red Tag.
Decide The Disposition Method Of Unwanted Material.

2S-SEITON-
After Segregation Only Wanted Material Will Remain At Work
Place.Prepare The Systematic Layout Of Zone.
Keep The items At Designated Place Only.

3S- SEISO-
Clean The Work Place Regularly On Decided Frequency.

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4S- SEIKETSU-
Prepare The Standards For Everything.
Standard For Cleaning, Standard For Keeping The Items.

5S-SHITSUKE-
Follow The Standards.
Always Do The 1S,2S,3S,4S Activities On Decided
Intervals.
Maintain The Discipline.

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 G. Awareness About Safety :-
Operator must be aware about safety measures. For that following safety measures are
implemented at production area.

Safety concerns taken care through provision of Apron , Safety shoes ,

Goggles, Hand gloves ,First Aid box , Fire extinguisher, Helmets , Training for
usage of fire extinguisher.
In case of high level noise levels , ear muffs are provided to operators.

In case of dust , masks are provided to operators.

Hazardous items are identified by “Caution” sign.

Safety awareness is ensured to plant personnel through training , safety

posters , fire extinguisher , work instructions addressing safety aspects.

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 Thank You…….

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