MANUFACTURING PROCESS

PRE
PART MOULDING
MOULDING
RECEIVING PROCESS
PROCESS

FINAL INSP.& PRODUCT ASSY.

PACKING TESTING PROCESS

1. THE PROCESS INVOLVED IN MAKING OF A FINISHED GOOD ARE CALLED

MANUFACTURING PROCESS.
2. MANUFACTURING PROCESS CONSISTS OF FOLLOWING PROCESS
 COMPONENT RECEIVING

METAL & ALUMUNIUM PARTS

• RUBBER MASTER BATCHES

RAW MATERIALS AND CHEMICALS

CONSUMABLE ITEMS
 METAL & ALMUNIUM PARTS
1. Parts are received in BOP section
2. BOP is responsible for checking parts for lots.
3. Metal dimensions, datum, threads are checked.
4. Various Suppliers are engaged to check proper supply of metals &
aluminum parts.
5. Some metals need processing while some are directly used.

RUBBER MATERIAL
1. Master batches of rubber rolled in packs of 30Kg & 60 kg are received to store.
2. Master rubber or (A mix rubber) is used for making rubber (B mix) with adding
chemicals to obtain rubber with desired characteristics.
3. Main suppliers of rubber master batches are:
(a). CHENNIA
(b).MADHURAI
4. Rubber is used for milling before its expiry date.
RAW MATERIAL AND CHEMICALS

 Store receives raw materials like

 Chemicals are received in store and are stored at different location

according to their reactive nature and temperature conditions.
 Chemicals are handled with extra caution as they be hazardous &
risk safety and life of all workers
 CONSUMABLE ITEMS

 All items required for writing, documentation and marking purpose

are stored in store, some consumable items are
 PENS
 MARKERS
 REGISTERS
 STICKERS
 FLOOR TAPES
 FILES
 FOLDERS
 NOTEPADS
 CUTTERS
 A4 PAPERS
 Pre Moulding Process

PHOSPHATIN
MIXING & RUBBER
DEGREASING G
MILLING TESTING
TREATMENT

SHOT ADSHEIVE
PREFORMING
BLASTING COATING

1. All the process on a received part/component to make it ready for moulding

process are Pre Moulding Process.
2. Parts are processed and make fit for use.
 DEGREASING PROCESS
 PURPOSE: Remove oil , dirt & dust from part.

DEGREASING TANK

HOT WATER RESIN

WATER RESIN 02
WATER RESIN 01

OVEN
TIME- 180-240 S TIME- 30-60 S TIME- 30-60 S TIME- 180-240 S
TEMP.- 50±5°C TEMP.- -----°C TEMP.- 85±5°C TEMP.- 100±10°C

CYCLE TIME:- 8 minutes.

TANK QUANTITY:- It has 5 tanks ( degreasing, 2 water resin, hot water resin & oven tanks).

BARREL QUANTITY:-It has 2 barrels for loading and unloading of parts

CHEMICAL USED:- Nipakline (Powder & liquid)

CHECK POINTS:- The degreasing parts are tested for their quality with INK test. Ink is poured
on surface of part if ink flows smoothly over surface degreasing Is prefect if ink flows in zig jag
way degreasing needed to be done again.
 DEGREASING PROCESS

SHELF LIFE:- 24 hours

TEMPERATURE:- Degreasing tank has a temperature of 50±5°C.

TANK CLEANING:- 15 Days

PROCESS CHECKING:-The water from tank is added with

phenolpathline and titrated with sulphuric acid, if solution turns pink to
white so that our process is ok.

SULPHURIC ACID(16-19)ml

SOLUTION WILL TURN PINK TO

WHITE

WATER FROM TANK(10)ml

+
PHENOLPATHALINE(4-5)ml
 SHOT BLASTING
• PURPOSE:- To provide roughness and increase bonding in between metal and rubber
surfaces .

CYCLE TIME:- 15 MIN ( GENERAL PARTS)

20 MIN (YP8 PARTS)

MACHINE QUANTITY:- It has 4 machines.

GRIT USED:- G-80(YP8 & HONDA PARTS)

G-16,18( GENERAL PARTS)
AL -60(ALMUNIUM PARTS)

CHECK POINTS:- The parts after shot blasting are send for inspection of roughness.
Roughness tester shows roughness values.

Ra
Rz
 SHOT BLASTING

ROUGHNESS SPEC:- Ra= 2-5.5 µ

Rz= 15-35µ. Aluminum parts
Ra= 3-12µ
Rz=15-75µ Honda parts

TEMPERATURE:- Room temperature.

Shelf life:- 8 hours.

 PHOSPHATING TREATMENT
• PURPOSE: Prevent parts from rust & improve bonding of metal and rubber.

DEGREASIN DEGREASIN Water Rinse Water Rinse Water Rinse Phosphating

G 01 G 02 01 02 03

6-10 min. 6-10 min. 30-60 Sec. 30-60 Sec. 30-60 Sec. 180 Sec.

50±5°C 50±5°C -- -- -- 78° - 82°C

Oven Oven Hot water Water Rinse Water Rinse Water Rinse
02 01 Rinse 06 05 04

30-60 Sec.
5-6 min. 5-6 min. 30-60 Sec. 30-60 Sec. 30-60 Sec.
--
110±5°C 110±5°C -- -- --

(LAYOUT)
 PHOSPHATING TREATMENT

CYCLE TIME:- minutes.

TANK QUANTITY:- It has 11 tanks ( 2 degreasing, 3 water resin, phosphate tank,3 water resin ,
hot water resin & oven tanks).

TANK VOLUME :-1850 LITERS

CHEMICAL USED:- BSM

BSR,AXCLATOR

CHECK POINTS:- 1.No dust or rust present on surface

2. No dent or damage to surface

QUALITY POINTS:- The quality check for phosphating is weight variation analysis of
processed parts to parts dipped in chemical to remove coating of phosphate.

coating weight = weight of part after coating- weight after dipping in chemical
area of part
The standard coating weight is 2-5Gr/m²
 PHOSPHATING TREATMENT

Chemical for coating check:- The solution consists of 5% chromium oxide 95% DM
water heated at 78-82°c.

Process check:- The chemical of phosphate tank is titrated with Sodium Thiosulphate
with added (0.5-1) grms of Sodium Carbonate and (1-2)grms of Potassium Carbonate
and HCL (20)ml. The solution will turn from red/brown to white.

SODIUM THIOSULPHATE(5-7)ml

SOLUTION WILL TURN BROWN TO

WHITE
WATER FROM TANK(10)ml
+
SODIUM CARBONATE (0.5-
1)grm
+
POTASSIUM CARBONATE(1-
2)grm
+
 PHOSPHATING TREATMENT

SHELF LIFE:- 24 hours

TEMPERATURE:- Phosphate tank has a temperature of 78-82°C.

PART CHECKING FREQUENCY:- First part approval in every shift.

 ADHESIVE COATING
• PURPOSE: Improve bonding of metal and rubber & increase life of part.

CYCLE TIME:- minutes.

PROCESS:- 1. After phosphate treatment the material is oven on temp 70±5°c.

2.Primary coating
3.Oven for secondary coating on temp 70±5°c.
4.Secondary coating
5.Oven on temp 70±5°c.

CHEMICAL USED:-Chemlok 205( primary coating)

Chemlok 6220&6108 (Secondary coating)
Toulene (additive)

CHECK POINTS:- 1.No dirt or dust present on surface

2.No dent or damage to surface
3. Proper phosphate coating
 ADHESIVE COATING

QUALITY CHECK:- The quality check for coating is done with coating thickness tester &
viscosity tester. Viscosity of chemical is checked

The viscosity spec is :- 9-12 sec (Primary & Secondary Coating).

PART CHECKING FREQUENCY:- First part approval in every shift.

COATING SPEC:- Primary coating:- 7-20 microns

Secondary coating:- 17-40 microns

COATING RATIO:- Primary coating:- 2:1:1 (Chemlok:MIBK:Toluene)

Secondary coating:- 1:1 (Chemlok:MIBK)

OVEN TEMPERATURE:- Primary coating 70±5°c ( 5 minutes)

Secondary coating 70±5°c ( 5 minutes)

Shelf life:- Primary coating:- 96 hours

Secondary coating:- 24 hours
 MIXING & MILLING
• PURPOSE: To Prepare final rubber bathes for Moulding as per requirement .

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 MIXING & MILLING

PROCESS:- 1. Master batches received from Chennai & Maduria are stored in store section.
2.Sample from Master bath is sent to R&T lab for rubber checks.
3.Rubber is loaded in automatic chemical mixing machine which add chemicals like
SMS & powder chemicals according to recipe received from Chennai plant .
4.After mixing rubber the rubber is milled and coole
5.Oven on temp 70±5°c.