Supplier standardised process guide

- Raw material testing

- RM Processing
- Forging

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Forging process control summery as per below

Raw
Material
Yard
Control
Ultrasonic Cutting
Inspection operation
Control control
Forging
Process
Control
MPI Forging Process
Inspection Control
Control
Heat
Treatmen
t Process
Control

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Guideline summery as per below

Under stand
the
Drawing for
Proper Material
Sepcifcatio Purchasing
Tagging to all
ns of
Inspected
Raw
recieved
material
Lot Raw
Material Initial
Metallurgical Guideline Inspection of
Inspection material before
as per control unloading
plan Seperate
for received lot Unloading
of all received
material in material
yard.

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Steel Mill TC

Understand the Drawing

for material
Specifications before
purchasing

Steel Steel Process Cleanliness Insp. Metallurgical Crack & Fracture

requirements details detials Inspections Testings

A.Steel Grade & Gas A.Steel A. Microstructure A.Surface

DWM A.Inclusion
Rej level req. Manufacturing Rating B. Grain size condition
CC / B.Approved Steel Mill Route B. Macro & C. Decarb level B. MPI
PPM List B. Rolling Upset Test D. Hardness Testing
C. Required Bar Input size C. Step
C. Rolling- Reduction E. Jominy req. C.Ultrasonic
For Forging down
Problems D.Spark & spectral Ratio C. Mechanical testing
test
Bank / Theme testing Properties D. Blue
fracture
test
Needs to understand the all metallurgical inspections as per customer
requirements as given above(Steel Mill TC attached for reference.

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Raw Material Yard Contol
Do’s :
7. 100% Spark & spectral
test for RM bars to detect
mix up of grade.

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Raw Material Yard Contol
Do’s :
1. Unload RM in different
areas with
-Heat no.
-Steel grade
-Dia of bar.
2. Tag material as WIP/ OK
after testing.
3. Use ‘FIFO’ Tag/sticker.
4. Paint both end of bar as
per colour code Chart.
5. Paint along length of RM
bar as per chart.
6. Move NOT OK RM to
scrap yard.
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Raw Material Yard Contol
Don’ts :
1. Don’t unload or mix
condition, unbundled
RM.
2. Don’t store Different
grade and
similar/close dia
material.
3. Donot mix different
heat of same
grade/steel mill/ dia
together.
4. Donot store
rejected
‘RM’ with ‘OK’ RM
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Metallurgical Testing of RM
1. Steel grade ( Third party inspection.
2. Jominy test( Third party inspection.
3. Inclusion rating( Third party inspection.
4. Microstructure Inspection
5.Grain Size
6.Hardness
7. Macro
sample
inspectio
n
8. Upset
test
9. 100% or
End piece
of bar
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Metallurgical Testing of RM

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Manufacturing facility with adequate controls

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Cutting Operation
Do
Control
1-Full bar
colour coding
before cutting

2.Check
diameter of
loaded bar
as a 100%
frequency as
per control
plan
Mahindra
Unique CIE Automotive Ltd.
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Cutting Operation DONTs
Control :

1-Bar not coloured fully

2- Checking frequency of diameter of

bar not check as per control plan

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Cutting Operation Control-End piece Segregation
DOs:
1-100% segregation of end piece not
mix in regular cutting bar
2.Scrap the end piece not keep in shop
flower to make conflict

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Cutting Operation Control-End piece
Segrigation DONTs:
1-No poka-yoke system to separate
removal of end piece
2.End piece mix in regular cut bar
pallet.
3.End piece kept on flower

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Cut bar Ready for forging
DOs:
Proper tagging of cut bar pallet
1. RM grade
2. Heat code
3. Bar Size
4. Qty
5. Date, shift & operator codes

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Cut bar Ready for forging
DONTs:
No tag
Cut pallet
Overflow
ing pallet
Similar size bar adjacent to the
pallet.

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Forging Process Control- Pyrometer
DOs:
Pyrometer should be in
Working condition during
forging process

Verify Normal Working of

overheat & Underheat
poka-yoke

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Forging Process Control- Pyrometer
DONTs:
Working of forging press or
hammer, without working of
temperature pyrometer.

Abnormal or non-working of
overheat & Underheat
poka- yoke

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