Page 1 of 1

ALPHA SYSTEMS
PROCESS FLOW CHART
Name of the Customer ATHER ENERGY Symbols Doc Ref A / 16/07/2014

Part Name / Description: HSRP BRACKET

Operation &
Storage Delay
Inspection
Part Number 340A0011349

Supplier's approving
Mr.Ganesh Mallya
Authority / Date:
Operation Inspection Transportation

Supplier Code:

Mr.Ganesh Mallya, Mr.Shiva kumar,

Core Team: Mr.Sukumar , Mr.Doreswamy,Mr PFD Date 14.06.2019 Rev. No 0 Rev Date
Sathish,Mr Sanjeev,Mr Nadaf

Process Symbols
Description
Process (Operation/ Type of Machine / Incoming Sources of
Key Product Characteristics Key Process Characteristics
step Inspection/ Facility Variation
Transportation/
Storage)

a) Improper Rolling process from R/M

Supplier or Improper packing.
'b) Personnel training for material
handling.
Raw Material a) Check R/M Thickness , c) Verification of the TC with the R/M
Variation in Thickness ,
0 Inward & Manual
Width & Grade
b) Check R/M width spec.
Inspection c) Check R/M Properties. d) Record the lot traceability.
e) Visual appearance Not Ok (I,e
Dent, Damage Line marks, Pit
marks,Rust & other defects)

a) Store the material proper condition

RAW a) Proper Storage with & to be protected from the
1. Variation in Thickness ,
1 MATERIAL Trolley
Width & Grade
Identification. atmosphere
STORAGE b) Follow FIFO System. b) Improper storage location

a)Machine capacity low.

Shearing maching 1.Width under size, a) Miss Blanking.
b)wrong size selection.
2 SHEARING M/c No : 2.Width over size,3.Burr b) Dimensional variation.
c)wrong process setting.
01 4.Specfied Thicnes c) Excess burr.
d) No periodic M/c maintenance.

a) Machine capacity low

Power Press 63T / 1) Strip width ,
BLANKING& Dimensional variation b) wrong tool selection
3 100T 2) Total Length ,3.Edge
PIERCING Excess Burr c) wrong process setting
Burr
d) No periodic tool maintenance.

a) Machine capacity low

Power Press 1) Blank Length
Dimensional variation b) wrong tool selection
4 FORMING 63TON 2 )Edge burr,3.Hole
Excess Burr c) wrong process setting
diameter, 4.CD
d) No periodic tool maintenance

1.Check the CED Coating

1. Forming Dimn,2.Visul
5 CED COATING Out source defects 3.CD Variation
Thickness 2.Appearence 1.Verification the Supplier Test reports
Inspection

Tool mark , damage , scoring

VISUAL 1.Visual defects
Manual mark , piericing burr , piercing
INSPECTION 2.Coating defects
CD , Plating defect
a) Un skilled inspector
6 b) No final inspection plan
c) wrong gauge inspection method
1) Dimensions as per Drawing.
FINAL Dimension and Visual
Manual 2) Part should be fit for
INSPECTION defects
function,aesthetic & reliability.

a)Parts packed in Non-

standard bins b)Quantity
1.As per the customer packing aWork instructon control plan
PACKING Manual mismatch ,
std. b)Personnel training
c) Wrong label on the
bins/Packing
7

a)No wrong shipment

No damage boxes. No
b)Qty. as per Schedule
DISPATCH By Vehicle identification tag on bins / Work instructon & Check sheet.
c)Correct label & traceability for
Box
part identity.

Prepared By: Shivakumar N Approved By: Mr Ganesh mallya