Implementation of ISO Standard for Design of Mechanical Components in an organization

Dr. E.PALANISWAMY1, S.P.VENKATESAN2, G.VELMURUGAN3, M.SAMBATH KUMAR4

2Associate

Excel College of Engineering & Technology, Tamil Nadu, Professor, Mechanical Engineering, Excel College of Engineering & Technology, Tamil Nadu, 3,4Assistant Professor, Excel College of Engineering & Technology, Tamil Nadu Email id: prof.eps@gmail.com, spvens@gmail.com, gvelmurugan06@yahoo.co.in, sambathkumarkm@gmail.com

1Principal,

ABSTRACT: The Purpose of this procedure is to describe the sequence of activities that are to be followed while designing new products and carrying out design changes. This design procedure is applicable to all new products developed in the company and permanent design changes. Each design activity is carried out and documented. KEYWORD: Design, Development, Manager/Asst.Manager, 7.3 DESIGN AND DEVELOPMENT PROCEDURE: 7.3.1 DESIGN AND DEVELOPMENT PLANNING: Decision for New product Development: New Product development decision is made based on the request/Proposal received from the management and sales team .The Proposal can be from Design and Development Department itself. The Proposal from the management is sent to the General Manager of our company via e-mail. Decision is recorded in the proposal itself. After Clearance from the Management to proceed with new product development, required resources for development are identified by Manager and the same is reviewed and approved by General Manager. For each project we determine the stage of design and development In design development planning various activities, responsibility, and target date are indicated XYZ/DD/001 This design plan is reviewed, verified and validated by Manager XYZ/DD/004, XYZ/DD/005& XYZ/DD/006 Decision for improvement on existing Product/Modifications: The Problem in the existing product is identified by the service team and Sales Head and is informed to the General Manager. The root cause for the problems is identified and the changes in the various parameters on the existing Product are derived with the same procedure as on the Decision for the new Product development.

7.3.2 DESIGN AND DEVELOPMENT INPUTS: The inputs of the customers are being provided by the sales and service team through mail, oral discussion and monthly service meetings. Based on the proposal and data collected the design input requirements are finalized by General Manager. The finalized requirements are recorded as design input from XYZ/DD/003. In finalizing this requirements information from the previous design and corrective and preventive action records are also considered. The input covers performance, functional, technical and constructional requirements which are reviewed and approved by Manager.

7.3.3 DESIGN OUTPUT: Design output is in the form of drawing ,Bill of materials reference XYZ/DD/007 & XYZ/DD/008

The drawings provide adequate information on material, grade and other processing requirements. Additionally the drawing also provides dimensional detail and tolerance to facilitate product verification.

The components which are outsourced are verified against the inputs given and then tested as a sample prototype. NOTE: Instruction manual indicates the guideline for proper usage and safety precautions. 7.3.4 REVIEW ON DESIGN AND DEVELOPMENT A review meeting is held by General Manager/Manager with the department heads of production, QC and Purchase to decide the following points. To evaluate whether the design is in accordance with the input. (XYZ/DD/003) Difficulties encountered if any, in manufacturing/outsourcing the components as per required specification.

Difficulty in maintaining, measurements of quality standards as specified details. Details of discussions and conclusions are recorded and maintained by Assistant Manager in the format XYZ/DD/004.If any changes in the design, corrections are made by Manager/Assistant Manager and the components are made as per the revision in design. MAKING OF PROTO TYPE: The components verified and approved by General Manager/Manager are taken for assembly of prototype by production. All the observation and inspection results are recorded in inspection report ad performance in product test report XYZ/DD/009 by Executives.

7.3.5 COLLECTION AND VERIFICATION OF DATA FOR DESIGN AND DEVELOPMENT Manager/Manager collects following additional data in consultation with the sales team and service team. Already existing design available in the market. Referring competitors design ,catalogues and samples if available Any other requirements or special operating conditions required

Any applicable statuary and legal requirements related to the product. Above collected data are verified and reviewed by General Manager/Manager. If there is any variation between the collected data and the requirement of the Sale and Service Team these are resolved by General Manager. The details of discussion and conclusions are recorded as review meeting minutes XYZ/MOM/009 by Assistant Manager. COMPONENT DRAWING PREPARATION Based on finalized design input, design calculations are made and detailed component drawings, assembly drawings, bill of material are prepared by Assistant Manager.

For an outsourced component the inputs are explained in detail in design Input ref XYZ/DD/003 ORDERING COMPONENTS/TOOLS: Finalized component drawing for development are issued with a seal as DEVELOPMENT DRAWINGto production /purchase department for Procurement /manufacture of components. On receipt of sample component, verifications of the developed components are carried out by QC and the report is received. Manager/Assistant Manager after reviewing the inspection report clears the components for further processing.

7.3.5 DESIGN VERIFICATION: Based on prototype trial run results, drawings and test results are checked by Manager/Assistant Manager/Executives to ensure that all input requirements are met.

If design input requirements are not met, modifications are made by Manager/Assistant Manager until the design input is achieved. Design verification is carried out by one of the following methods: I. By performing alternate calculations II. Comparing new design with other similar proven design III. By carrying tests and trials IV. By reviewing drawing and other specification V. Design verification details are recorded by Assistant Manager in the format XYZ /DD/005 RELEASE OF DRAWING/SPECIFICATION FOR MANUFACTURING OF PILOT LOT:

If design verification is satisfactory drawings, bill of material and specification are released for pilot lot Production. PILOT LOT PRODUCTION:

After receipt of drawing a pilot batch, of 2 Nos is assembled by the production and verification results are maintained by QC/Production. Pilot lot products are released to market and field trials are verified. An interface meeting is held by General Manager with production, QC, Marketing regarding pilot lot production and design input verification.

7.3.6 DESIGN AND DEVELOPMENT VALIDATION: Design validation is done by General Manager, Manager, Service Head, Sales Head and the results are recorded in Design validation format XYZ /DD/006 The final design are reviewed and the results are recorded in the format XYZ /DD/004 Design validation is done by Manager/Executives by visiting the field and the results are recorded in the design validation form XYZ /DD/006 for the machine.

7.3.7 CONTROL OF DESIGN AND DEVELOPMENT CHANGES: Design and development changes are identified and records are maintained depending on the progress. Receiving information for design change: Design change is carried out for any one of the following reasons: I. Design change for improvements in performance for improvements in functional or aesthetics aspects and in line with

latest material change identified by D&D. II. Based on field or service reports III. Suggestions from other user departments for changes IV. Based on Design validation results Review of implementation requirements Based on the information for change , Manager reviews the change Requisitions In the review if it is found the change is not necessary the concerned Department is informed by Manager

If the change is found necessary, a further review is made with the concerned user departments and details of review are recorded in Review/interface meeting by Assistant Manager Review by D&D and clearance: Implication of design change reviewed by Assistant Manager and details are conveyed to General Manager/Manager for his approval. I. Change in component specification /drawing. Interface with QC and Production: An Interface/review meeting is held with Heads of QC and production departments regarding the design change plan.

The details of discussion are recorded in interface/review meeting XYZ /MOM/009 and maintained by Assistant Manager. Design change verification: The verification of results of trial testing before design change is made by Manager/Executives so that the required results are achieved by changes made. If results are not satisfactory further trials and verification are completed. change is made and maintained by Assistant Manager in the format design

A verification record for design verification XYZ /DD/005 Design change review:

An interface review meeting is held by General Manager with QC, Production, Sales and service to discuss feedback on the design change made. The details of discussion made are recorded in review/interface meeting XYZ /DD/004 and maintained by Assistant Manager Approval of Design change: If the trial run of component/Product with design changes is satisfactory. The implementation sequence is finalized by General Manager and concerned HODs. Then finally cleared details are recorded in design change noted. The revision statuses are issued with CONTROLLED seal after withdrawing the old drawings from user departments. Implementation of design change:

Once results of verification of design change is satisfactory, Implementation of the design change is planned and carried out after considering the following details, which are recorded by Assistant. Manager in design change note- and approved by Manager. The details of change and implementation are communicated to all concerned through design change note XYZ /DD/006. 6.0 Reference: Planning Stage. Ref Doc No. XYZ/DD/001. Key Responsible Person. Ref Doc. No. XYZ/DD/002. Design Input Ref Doc No. XYZ/DD/003. Design Review. Ref Doc No. XYZ/DD/004. Design Verification Report. Ref Doc No. XYZ/DD/005 Design Validation / Change. Report Ref Doc No. XYZ/DD/006. Engineering Drawings. Ref Doc No. XYZ/DD/007 Engineering Bill of Materials. Ref Doc No. XYZ/DD/008. Test Records. Ref Doc No. XYZ/DD/ 009. Document History. Ref Doc No. XYZ/DD/010. Version Control History Record. Ref Doc No. XYZ/DD/011. Development Indent Form. Ref Doc No. XYZ /DD/012. Minutes of Meeting. Ref Doc No. XYZ A/MOM/009.