QUALITY CONTROL SHOP

It is Systematic control of those variables encountered in manufacturing process, which, affect the excellence of the product. Such variable result from the application of material, men, machine & manufacturing conditions only when these variables are regulated to the extent that they do not detract unit is main shop of ICML. In necessarily from the excellent of the ring-ring process as reflected in the quality of the finished product, can the control of quality be said to exist. Generally, inspection, which is the process of sorting good from bad, is the process of sorting good from bad, is considered as a form of quality control. But quality control and inspect-ion are different. Conceptually, a Q.C. aim of prevention of defects at the very source relies on effective held back system and corrective action procedure. Acceptance of material after subjecting them to in section at inward goods store is inspection concept. Q.C.concept is to take early step to ensure that the material to be supplied is going to be manufactured to the plant's requirements. So as to ultimately eliminate the in ward goods inspection. Discovering that the components produced are not as per required dimensional specifications due to wrong tool or improper settling after the production is over is inspection concept. To prevent the issue of a wrong tool and to have a set up approval procedure prior to starting continuous production and keeping a simple check during production, are Q.C. concepts.

Q.C. uses inspection as a valuable tool. In quality control programmed inspection data are effectively used to take prompt corrective actions to arrest the incidence of occurrence of the same or similar defects in future defects in the job on hand to plan the prevention of.

OBJECTIVES OF Q.C.: Following are main objectives: Evaluation of quality standards of incoming material, product in actual manufacture, & have out going product. Judging the complicity of the process to the established standard & taking suitable action when deviations are noted. Evaluation of optimum quality obtainable under given conditions. To improve quality &productivity by process control & experimentation. Developing procedures for good vendor relations. Developing quality consciousness both within & outside the organization.

QUALITY CHARACTERISTICS: Following are main quality characteristics for components used in ICML. 1) A dimension is a characteristic. A chemical properties is a characteristic 2) A senso

3) ry property is a characteristic. All these characteristics contribute towards the quality of the product. So we can say that appearance of product is quality characteristic ices of the product. Similarly performance, length of life, dependability, reliability, durability, maintainability,

fed, sounded. All characteristics are like a building block that goes in to the construction of say, an arch, which may be considered to be quality.

FACTS OF QUALITY: The quality characteristics can be grouped in to following categories in Somalia ICML.

1) Quality of design 2) Quality of conformance 3) Availability 4) Customer service 1) QUALITY OF DESIGN: The design must meet all the requirements of the customers. The designer has to take into account the question of appearance, reliability, maintainability of the products. The designer should aim at the design, fulfills all the qualities or almost all qualities desired by the customers.

2) QUALITY OF CONFORMANCE: The degree or extent to which a product actually conforms to in accordance with the specification &drawing is called the quality of conformance. 3) AVAILABILITY: This includes such characteristics as reliability, maintainability &length of life. All these indicate as to what extent the product will be available for use. Reliability of the product may be taken as the extent to which it can give continuous service. 4) CUSTOMER SERVICE: This indicates the extent to which the customer can get assistance from the manufacture or keep the product in continuous use. This service is an after sale function.

METHODS OF QUALITY CHECKING : (1) (2) (3) (4) (5) (6) (7) (8) (9) APPEARANCE DIMENSIONS WEIGHT FITMENT FUNCTION/PERFORMANCE MATERIAL/MECHANICAL PROP. PROCESS CHEMICAL COMPOSITION WELD STRENGTH

1. APPEARANCE: It is the first step of the checking the appearance of the component means how the component looks like. Whether its surface is smooth. Whether its edges are sharp or not? Its welding, its surface treatment and its machining. Means its physical structure.

2. DIMENSIONS: It is the most important step of the quality testing of the various components. The dimensioning means the checking of the dimensions of the component, whether these are correct or not? The dimensioning is done by certain components like the VERNIER CALLIPER,

MICROMETER, BEVEL PROTECTOR, HEIGHT GUAGE, etc. These dimensions are checked with respect to the dimensions given in the drawings i.e. the required dimensions. By these measuring equipments the measurement of the dimensions of the component becomes very easy.

3. WEIGHT: The weight of the component is also necessary to it gives the correct idea of the material required to manufacture the component. The weight of

the component is measured by weighing machine. This machine can measure the weight from 500 g to 50000g. Procedure is very easy just place the component on the dashboard. There is a digital screen, which shows the reading of the weight in numbers.

4. FITMENT: Fitment means fitting of the component actually in the vehicle. The component of the vehicle checked whether it is get fitted on the vehicle or not. If the vehicle is get fitted then the component get accepted, if the component is not get fitted then it is rejected. So the acceptation or rejection of the component is also based on the fitment of the component.

5. FUNCTIONAL PERFORMANCE: The functional performance of the component is measured after the fitment of the component. So to make fitting of the component it is very necessary that it will get fitted in the vehicle. Functional performance means how well the component is functioning in the vehicle. In it the functional processes of the component are checked, like the stresses produced in it, its fatigue strength and its reliability etc.

6. MATERIAL/ MECHANICAL PROP: The material of the component should be able to absorb the stress produced in that component. The mechanical proportions means the is the material is reliable to be used to manufacture the component. Is it looks good by appearance or not. The material may be brittle or hard or tensile as required.

7. PROCESS: In this step of the quality control of the components the processes of the components are checked. For making a certain component there are certain processes by which a component should go through. These

processes are made in serial wise and the component should follow these processes in serial wise. If the serial wise processes, which are required to make it, make a component only then that component can be made exactly that which is required. These processes can be checked only at the production work i.e. where the component is manufactured. So in case of our industry the processes can only be checked on the vendor side where the product is manufactured. The processes can be the drilling, punching, tapering, lathing, heat treatment, machining etc.

8. CHEMICAL COMPOSITIONS: -

There are the standard materials, which can be used to make a certain component. For a specific component there is specific material, by only which, that component is manufactured. For the certain component, the material is selected as its requirements like the stresses produced in the component, its working climate, working conditions, working time etc. So it is very necessary to make the component with the required and reliable material. Material checking is done by the certain equipments and requires lots of research. In the I.T.L. the material checking is not done, but the samples of the components are sent to the other companies for the inspection purpose.

9. WELDING CHECKING: Welding checking is also an important process in the quality testing of the different components. Welding checking means checking of the

strength of the welding. The components are made of different parts, which are welded with each other to make the suitable and complete.

ASSEMBLY SHOP

ASSEMBLY SHOP
As the name suggest in this shop assy of all the components of vehicle is done . For assy of various parts ,there are different lines used. These are: Trim 1 Trim-2 Chassis line Final line

Trim 1:After the paint shop the shell is passed to Trim-1 then the shell is properly checked and if the shell is ok then assy of different parts is completed as logo ,door fitment, glass fitment.

Trim 2:After the completion trim-1 operation the shell is then passed to trim2. When shell passed to Trim-2 then shell is again checked and then different Fitments of Trim-2 are completed. When both trim-1&2 operations completed then shell is passed to Final line.

TRIM-2

Chassis line:This is a conventional chassis used for staff cars, radio vehicles, and other specialized types and consisting of two parallel side members and various cross members and brackets. The engine is fitted at the front, and the

wheels are sprung independently by two coil springs with double-action, hydraulic shock absorbers. The spare wheels are carried one on each side of the chassis on stub axles to prevent bellying when traveling over rough ground. In the chassis line passes chassis to final line. There are so many parts are attached to chassis as differential ,brakes,tyres , fuel tank , steering mechanism, suspension system, engine assembly.

Final line:When the shell is completed from trim-1&2 at the same time chassis required for the Fitment operations of the final line. such as fitment of seat, stereo systemetc.

PROCESS FLOW ASSEMBLY SHOP:-

ASSEMBLY SHOP- FLOW CHART:-

PAINT SHOP

TRIM-I

TRIM-II

FINAL LINE

WHEEL ALIGNEMENT

CHASSIS LINE

BRAKE ROLLER TEST

SHOWER TEST

FINAL AUDIT

ROAD TEST

OBJECTIVE:To Produce World Class Vehicles with Best Quality which Include Quality ManagementPrinciples,Latest Manufacturing Techniques, TotalTeamInvolvement, Value Analysis &Time Management.

PRODUCT:S.N 1 2 3 4 5 Model Winner Xciter DLX Seating Capacity 9-Seater 8-Seater & 8-Seater 9-Seater

Royale (CRDFi)8-Seater INSPIRE UNDER R& D

Colours : White,Golden,Silver,Blue,WineRed,Black

SPECIFICATIONS OF MUV RHINO:PARAMETER Overall length Overall width Overall Height Wheel base Track: front SPECIFICATIONS 4440 mm 1645 mm 1885 mm 2541 mm 1360 mm

Rear

1373 mm

SPECIFICATIONS:Max. Speed Min. turning radius Final drive ratio Engine: Type Valve Train Engine displacement Bore x Stroke 136 km/hr in 5th Gear 5.6 mtr. 4.88 Water Cooled,4 Cyl. In Line T/C & I/C Diesel. SOHC 1995 cc 84 mm X 90 mm

SPECIFICATIONS: Air filter Fuel filter Clutch: Type Tyre size Rim size Fuel Tank capacity Maximum Torque Compression Ratio Maximum Power Dry Type Dual Primary & Secondary Single plate, Dry type, cable operated. 205/65 R15 5.5 J x 15 50 Litres 15.5 kg-m / 2500 rpm 21:1 75 ps / 4200 rpm

SPECIFICATIONS:Battery Alternator V AMP Brake: Front wheel Rear wheel Steering system: Manual Rack & Pinion Ventilated Disc Drum 12 V, 65 amp-hr 12 V, 75 amp

SPECIFICATIONS:Suspension: Front Rear Shock absorber Antiroll bar Power Independent wishbone with double

Semi elliptical leaf spring Hydraulic, double telescoping type acting

V type, Provided in front only Hydraulically assisted Rack and Pinion

MACHINES & EQUIPMENTS: SINGLE SLAT CONVEYOR:- TRIM- I &TRIM -II DOUBLE SLAT CONVEYOR :- FINAL LINE

SINGLE SLAT CONVEYOR:-CHASSIS BODY TRANSFER/CHASSIS TRANSFER SYSTEM FLUID FILLING MACHINES:- FINAL LINE CHASSIS INVERSION SYSTEM HYDRAULIC PRESS WHEEL ALIGNMENT MACHINE ROLLER-BRAKE TESTER WHEEL BALANCER SHOWER TEST BOOTH

AWARENESS PROGRAM IN ASSEMBLY SHOP: 5S & HOUSEKEEPING. MATERIAL HANDLING & STORAGE. HANDLING DEFECTS DENT,CHIP & SCRATCHES . PROCESS CONTROL SHEET. STAGEWISE WORK OWNERSHIP. PRECAUTIONS TO AVOID ACCIDENT

SAFETY PRECAUTIONS:
USE SAFETY SHOES. USE HELMETS WHERE NECESSARY. ALWAYS AVOID OIL SPILLAGE. ALWAYS COVER BELT BUCKLE,WRIST WATCH,RING WHILE WORKING ON LINE TO AVOID DENT-PAINT SCRATCHES. FOLLOW THE TEST TRACK RULES WHILE VEHICLE DRIVE TEST. USE MASK WHILE DOING PAINT SPRAY. PUT HAZARDOUS WASTE IN PROPER BIN. SWITCH OFF THE M/C AFTER USE.

DOS & DONTS: DO NOT DRIVE VEHICLE WITHOUT AUTHORIZATION. KEEP VEHICLE CLEAN. DONT SIT IDLE IN VEHICLE. DO 5S DAILY IN YOUR AREA. KEEP TOOLS PROPERLY AFTER USE. DO MAINTENECE & CALIBRATION OF TOOLS IN TIME. DO ALWAYS PAINT MARK AT TORQUING FOR CONFIRMATION.

QUALITY CHECKING ASSEMBLY SHOP:In process Inspection: QP-1 at Trim-I QP-2 at Trim-II QP-3 at Chassis QP-4 at Final

POINTS

IN

QUALITY PROCESS AT TRIM-1:Visual Inspection of Following :

Wiring Harness Fitment & Routing Front wind shield & Back Glass (No Damage, Scratch, Gap etc) Door Glass fitment & movement Inside Grommets, Insulation A/C fitment. Dash Board & Head liner Fitment

QUALITY PROCESS AT TRIM-2:Visual Inspection of Following: Head Lamp & Tail Lamp fitment Door Trims Fitment Seat Belts & Torque Pillar Trims Fitment Control Panel Fitment

QUALITY PROCESS AT CHASSIS LINE:Visual Inspection of Following: Oil Levels: E/G, RR Axle, Gear Box Torque of Prime Important Joints Fitment of Major components Engine, RR Axle, Propeller shaft, Leaf springs, Control Arm, Shock absorbers, Fuel Tank etc.

QUALITY PROCESS AT FINAL LINE:Visual Inspection of Following: Oil Level i.e. Brake oil, Power steering Seats fitment Locking & Unlocking Torque of shell & chassis mtg A/C cooling & Function Electrical function of vehicle Body Gap & offset checking

Road Testing: -

ICML vehicles that will roll out of the assembly line will be subjected to very stringent torture tests to withstand highly demanding road conditions prevalent in the country. Custom-built to international standards, the test track has sine wave, rumbles, rough road, corrugated pot holes, stone paved roads, gradient, water wading zone, under body inspection ramp and smooth road for long distance driving at different speeds. Testing on these different simulated road conditions for acceleration & braking, ride & handling, gradient test, body squeak noise & rattling test, under body inspection & leakage will make the end-product highly road worthy.

Road Tests of The Vehicle for the Following:

Rough Road test Grumblers, Sine Wave & rumble strips : for Shockers, Body squeak noise, loose parts & rattling noise etc Smoke test Gradient : For Vehicle Pick Up & Parking Brake efficiency Water Wading: To check water entry from bottom Normal Test Track: For Acc. Test, Brake test, Vehicle Pulling, Steering wheel wobbling etc. Under Body Ramp : For Leakage Testing