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Manufacturing Process and Testing Procedure Qualification

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Rahul Maurya
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34 views3 pages

Manufacturing Process and Testing Procedure Qualification

Uploaded by

Rahul Maurya
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Hindustan Engineering Works

264, Bhawanathpur, Trilochan Mahadev, Jaunpur UP 222136


Deals in: - Machining job work “Lathe turning, milling, drilling, shaping and fabrication”
Phone no: - +91 9486274693 Email [email protected] GSTIN
09BFHPM9795R1Z0

Manufacturing Process and Testing Procedure Qualification

1. Objective

The goal of this document is to outline the detailed manufacturing process workflow and the
testing procedure qualification to ensure compliance with quality standards and customer
requirements. This document also highlights the list of measuring and testing equipment
along with the machines utilized in the manufacturing process.

2. Manufacturing Process Workflow

2.1 Raw Material Inspection

 Raw materials are inspected upon receipt for quality and compliance.
 Material Test Certificates (MTCs) are verified against purchase orders.
 Inspections include:
o Dimensional checks.
o Visual inspection for surface defects.
o Chemical and mechanical property verification (outsourced if necessary).

2.2 Pre-Machining Preparation

 Cleaning and deburring of raw materials.


 Marking materials as per job drawings.
 Ensuring the availability of tools and gauges before machining begins.

2.3 Machining Operations

 Machining is performed using:


o Lathe machines for turning and threading.
o Shaper machine for planing and shaping.
o Drill machines for precise hole-making.
 Operations are executed as per the job card and detailed work instructions.

2.4 In-Stage Inspection

 Critical dimensions are checked at defined stages using calibrated instruments.


 Process parameters such as feed rate, speed, and cutting depth are monitored and
recorded.

2.5 Heat Treatment (if applicable)

 Components requiring stress relief or hardness enhancement undergo heat treatment.


 Process parameters such as temperature and duration are recorded.
Hindustan Engineering Works
264, Bhawanathpur, Trilochan Mahadev, Jaunpur UP 222136
Deals in: - Machining job work “Lathe turning, milling, drilling, shaping and fabrication”
Phone no: - +91 9486274693 Email [email protected] GSTIN
09BFHPM9795R1Z0

2.6 Final Machining

 Final machining is performed to achieve specified tolerances and surface finishes.


 Special operations such as threading or grooving are completed at this stage.

2.7 Final Inspection

 Comprehensive inspection includes:


o Dimensional checks using vernier calipers and micrometers.
o Visual inspection for surface finish and defects.
o Non-destructive testing (NDT) such as ultrasonic testing (UT) or magnetic
particle testing (MPT) as needed.

2.8 Packing and Dispatch

 Components are cleaned, marked, and packed securely.


 Dispatch notes and inspection reports are prepared.

3. Testing Procedure Qualification

3.1 Testing Standards

 All tests are performed in compliance with relevant standards.

3.2 Testing Methodologies

1. Dimensional Testing
o Dimensional checks using vernier calipers, micrometers, and depth gauges.
o Cross-referencing dimensions against approved drawings.
2. Mechanical Testing
o Hardness testing using Rockwell or Brinell testers.
o Load tests performed to validate strength.
3. Surface Finish Testing
o Profilometers are used to measure Ra values.
4. Non-Destructive Testing (NDT)
o Magnetic Particle Testing (MPT), Dye Penetrant Testing (DPT), and
Ultrasonic Testing (UT) for internal defect detection.

3.3 Procedure Validation

 Testing procedures are validated by performing trial runs on sample components.


 Validation results are documented in a Testing Procedure Qualification Report
(TPQR).
Hindustan Engineering Works
264, Bhawanathpur, Trilochan Mahadev, Jaunpur UP 222136
Deals in: - Machining job work “Lathe turning, milling, drilling, shaping and fabrication”
Phone no: - +91 9486274693 Email [email protected] GSTIN
09BFHPM9795R1Z0

3.4 Record Keeping

 All test results are recorded and stored for a minimum of 5 years for traceability.

4. List of Measuring and Testing Equipment


Type of Guage Next due
/ Test Make and Range of Year of Calibration
S.NO Equipment Model Least Count Measurement Purchase Calibration Date date
1 Vernier Caliper Somet Inox 1/20 mm 0 - 150 mm 2018 03/12/2024 02/12/2025
2 Vernier Caliper Insize 0.02 mm 0 - 150 mm 2020 03/12/2024 02/12/2025
3 Vernier Caliper Aero Space 0.02 mm 0- 200 mm 2021 03/12/2024 02/12/2025
4 Vernier Caliper Kristeel 0.02 mm 0-200 mm 2021 03/12/2024 02/12/2025
5 Depth Gauge Kristeel 1/2 mm 0 -150 mm 2024 03/12/2024 02/12/2025
Micrometer - 03/12/2024 02/12/2025
6 Outside Kristeel 0.01 mm 0-25 mm 2024
Micrometer - 03/12/2024 02/12/2025
7 Outside Kristeel 0.01 mm 25-50 mm 2024

5. List of Machines
S. No. Description Make Year of MFG Capacity
1 Lathe Machine NAV ASHU 2022 12 feet
2 Lathe Machine NAV ASHU 2023 8 feet
3 Lathe Machine South india 2021 6 feet
4 Lathe Machine 2015 6 feet
5 Welding Machine 4 Local make 2018 400Amp
6 Grinder - 2 - 2018
7 Drill Machine - 2017 2 Inch
Shree Ram
8 Hydraulic Press Ludhiana 2023 150 MT
9 Hydraulic Press Ludhiana 2010 150 MT
10 Hydraulic Press Ludhiana 2015 25 MT
11 Shapper Machine Ludhiana 2015 18 Inch
12 Power Hacksaw Ludhiana 2015 6 Inch

6. Conclusion

The manufacturing and testing procedures outlined in this document ensure that components
are produced and inspected to meet the highest quality standards. The use of calibrated
measuring instruments and well-maintained machinery, along with validated procedures,
guarantees compliance with customer requirements and industry benchmarks.

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