PROCESS FLOW DIAGRAM

Product ABB Tank Issue Date & Rev : 06.01.2018

Supplier Name TAIKISHA ENGINEERING INDIA PVT LTD Part Name :
Supplier Location Village, Kondapuri, Tal:Shirur, Pune Part No :
DOC NO. -
Legend:
Operation Transport Inspection Delay Storage
Operation or Event
OP Description of Operation or Event Evaluation and Analysis Methods

Specification of grade as per supplier TC & RMQP

Free from wrinkles,scratches, Waveness, Bow, Rust, Dents,
Damages.
10 Receipt of raw material
Qty-as per Invoice
Storage at Cleaned & Identified Area: colour code
Dimensional measurment as per RMQP
Usage date : within expairy limit
10.2 Paint Shade : According to P.O.
Visualy : No damage & leakage
Designation, Diameter of wire as per TEIL FILLER WIRE
10.3 Filler Wire MATRIX-
Batch No According to P.O.
Dimension As per Drawing
10.4 Receipt of machining part/flanges
Protection of sealing surface : Free from dent and scratch
20 Storage Storage at Cleaned & Identified Area

30 Programming dimensions as per DXF File & Drawing

dimensions, profile as per Drawing
laser parameter as per Program
40 Laser/Plasma cutting
Visual = frr from burr, flatness, scale
Identification & Traceacbility : Laser Engraving Part No & Project
Name as per ABB Drawing and BOM

50 Flattening No bow/waviness on laser cut part

as per drawing
60 Chamfering/Beveling/Edge Preparation Manual Operation.

dimensions, profile as per Drawing

70 CNC Bending Free from crack on material, scoring
Bending angles- Bevel Protector

Visual as per ISO 5817

80 Tack weld
dimensions, profile as per Drawing & checking fixtures
Welding As per drawing & Weld plan No.
90 Full welding dimensions as per Drawing & checking fixtures

Free from weld defect.

100 Tank Inside blasting -Conservator Surface roughness Ra Value 3.2-9.6 Ra value /(>50µ)
Sandblasting Sa2.5
110 Masking -Blasting surface masking on metal surface as per WI.

DFT ABB Specification 1ZCH100516

120 Inside primer
Visual Free from dust, No uncover
130 Cleaning Free from dust,metal particles, removal of masking tape

Welding As per drawing & Weld plan No.

140 Full welding dimensions as per Drawing & checking fixtures
Free from weld defect.

150 Weld rework Free from weld defect.

160 Identification Punching Identification no. on part as per ABB specification 1ZCH101237
& Job Card
 Dimensions Before Machining As per drawing
170 Dimensional Inspection
Digital vernier,Measuring tape Laser meter,Inspection Jig.

C.D,Dim and Flatness of maounting pad As per drawing

180 Machining Four PAD-2XCH200810
Dimensional report of supplier
Flatness and C.D,Diagonal As per drawing 2XCH200810-CEE
190 Trimos Inspection and CEF
Dimensional report of Fero Machine.
Child Part fitment with Tank
200 White Assembly
Critical dimension inspection
All RCD dimensions TANK AND COVER and Loose parts RCD
dimension As per drawing
210 Dimension Inspection
Digital vernier,Measuring tape,template, Laser meter,Inspection
Jig.
Welding visual inspection
220 PT Inspection
Oil tight joint as per Work instruction & ABB STD 1ZCH100604

230 Weld line blasting Visual Inspection of welding after Sandblasting on weldline as
per Work instruction
Visual : No weld defect
240 VT Inspection
Qulified VT Level-II Inspector
250 Weld Rework Free from weld defect.
Air pressure at 0.3bar
260 Pneumatic testing
No leakage as per ABB Specification 1ZCH101885
Surface roughness Ra Value 3.2-9.6 Ra value /(>50µ)

blasting profile as per sa2.5

270 Tank Full blasting -Inside and Outside
Protection of sealing surface, threads, ST area as per ABB
drawing.
No oil, greese, rust on blasted surface
DFT & paint specification as per ABB Specification 1ZCH100516
REV_D
Internal White Primer -Tank Inside &
280 cover Bottom side Humidity, surface temp., ambien temp., dew point as per QIC

Masking as per ABB specification.

Visual Free from dust, No uncover
DFT & paint specification as per ABB Specification 1ZCH108857
Humidity, surface temp., ambien temp., mixing ratio, dew point
290 External Primer as per QIC
Masking as per ABB specification.
Visual Free from rundown, uncover, blister, rough finish.
Apply external primer within 16 hours of sandblasting
300 Masking -Blasting surface Masking as per ABB specification & ABB Specification
1ZCH104661
DFT & paint specification as per 1ZCH108857 QIC
1ZCH108858
Gloss & Shade as per QIC
310 Top Coat Painting Visual Free from rundown, uncover, blister, rough finish.
Cross cut adhesion test-sample piece As per 1ZCH104699
store in clean area under closed cabin in dust free enviornment.

320 Rettaping No rust,No dust,No thread damage Go gauge pass

330 Aluminium plate fitment Fitment As per drawing ,SOP

340 Inside Visual Inspection By endoscope camera Free from dust ,spatter
On pallet Stracursl Welded Frame
350 Packing
Packing as per work instruction

Prepared By : Arvind Jadhav Approved By : Sudhir Ambre

 FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)
Project: CKG & BQF Part Name : ABB Tank Start Date: 10/5/2018
Team Leader: Rohit Mathanker Drawing no : AS per Project Drg NO Revision no. 01
Prepared By: Rohit Mathanker Document no.- KI/PFMEA/01 Revision Date: 1/6/2019
Team Members: Sunil Gupta, Ashok tripathi, Mayank Gupta,

Occurrence

Detection
Severity
Revised
Potential Effect(s) of Failure Potential Cause(s) of Current process controls Recommended
No. Process Function Potential Failure Mode RPN Responsibility Completion Date

Occ.
Det.
Sev.

RPN
Failure Action(s)
Customer Effect Inprocess prevent Detect
vender approval & rating Incoming material inspection report & TC
not in size, rusty, wrencle, pitted No effect Delay in production (OTD affected) 5 Vender not approved as per our norms. 3 review 2 30
sheets/Pipe/elbow/ Rod
10 (EN 10025-2 S355J2N,
order acceptance Incoming material inspection report & TC
SS304L, AW5754, AW 6082, chemical & mechanical properties not Application requirement not meet.
Fail during service 5 issue at supplier end. 3 review 2 30
matched Crack during bending

not matched with required specification i.e. vender approval & rating Incoming material inspection report & TC
EN ISO 14341-A- review
G 42 4 M 3Si1, DIN EN ISO 14343-A-G 23 Application requirement not welding defect during weldingproduction
5 Vender not approved as per our norms. 2 2 20
12 L Si meet. delay.
Welding filler wire
chemical & mechanical properties not material requirement mentioned on PO Incoming material inspection report & TC
matched Application requirement not welding defect during welding production Material received without order & order acceptance. review
5 2 2 20
meet. delay. acceptance.

vender approval & rating Incoming material inspection report & TC

Application requirement not review
production delay. 5 Vender not approved as per our norms. 2 2 20
meet.
Shielding
Not matched with wps requirement
gas order acceptance Incoming material inspection report & TC
Application requirement not Material received without order review
production delay. 5 2 2 20
meet. acceptance.

vender approval & rating Incoming material inspection report & TC

OTD affected 5 Vender not approved as per our norms. 3 review 2 30
Wrong shade Delay in production
Paint
Wrong type of paint Self life expired order acceptance Incoming material inspection report & TC
Material received without order review
OTD affected 5 2 2 20
acceptance.

incoming inspection not carried out

Identification is not available on sheet OTD affected Delay in production 7 2 qualified inspector being deployed incoming inspection report. 2 28
inspection propely/un qualified person.

Separate area used for MS & SS

SS & MS machining parts mixed up OTD affected wrong part may be used 5 No identification on parts 2 Manget used for confirmation 2 20
Grades. .
20 Storage

Welding defect/Joint che. Mech, Storage of filler wire separate with DB

Filler wire No effect Inappropriate wire may be used. 7 2 Grade mentioned on box 2 28
property may affected. and CE mark with identification.

Paint defect (storage in high temp.) Product fail during application Painting defect 6 storage condition for paint not followed, 3 RH & temp. maintained. Procedure and parameter recording 1 18

component cutting drawing is not as cutting drawing validate by design In coming inspection by qualified
Dimension is not as per drawing OTD affected Delay in production 8 2 2 32
per requirement. team person
Plasma cutting
1.Validation of process/ Operator
Poor cutting quality In coming inspection by qualified
OTD affected Fiment problem, rework 7 wrong parameter used by opararetor 2 /programmer 2 28
hole oblong.,taper cutting person
2.Monitoring the process
 TAIKISHA ENGINEERING INDIA PVT. LTD
PROCESS FLOW CHART
PFD.NO.:- TEI/ABB/GN/PFD-1 Rev-01 Date -06.01.2018 Manufacturing Process
Supplier: TAIKISHA ENGG INDIA PVT. LTD Supp. Code:
Address: Gat no 321,323 Kondhapuri.
Part Name : ABB TANK MOD.NO. : NIL DATE:- 02-01-2017

Part No. N/A

Core Team :
KAILAS,PANKAJ,ARVIND, TAMBE, SUDHIR, BOMBE, CHALKE, SHIRSAT
PROCESS PRODUCT PROCESS
PROCESS DESCRIPTION
NO. CHARACTERISTS CHARACTERISTICS
1. As per inspection QAP & RMQP
10 Receipt Inspection of Raw material 2. As per Standerd referance & Customer N/A
specification

1. Identification. & raw material

20 Storage n/a
preservation

1. Hole Size, Nos. of Holes Lense Cutting speed Cutting Gas Focus
2. Length, Width, Cutting edges. Laser Power Cutting Pressure
30 Laser cutting
3. Bow after laser cutting. Piercing Time Nozzle Dia. Nozzle Dist.
4. Thickness of cut blank. UT Test material use.

1. Flatness (0.5 to 1mm ) depending upon

1. Roller setting considering thickness of material to be
40 Flatenning thickmess
flatened.
2. Free from Scratches,

1. Bending Height, width & Angle

2. Hole Position, Radius & Angle
1. Required Tonnage, Pressure
3. Crack, Dent, Damage & Die
50 Bending 2. Back Gauge Position.
4.Punch Mark
3. Appropriate Die & Punch
5.Opposite bend

60 Chamfering/Beveling/Edge Preparation as per drawing Manual Operation.

70 Do tack welding & full welding to 2 air tanks Welding as per drawing as per WELD PLAN
 NDT STOP : Do VT inspection of welds before VT inspection CPC2 CT3 100% weld length ISSUE REPORT for this VT special inspection
80 closing the air boxes and horizontal stiffer (U VT PT Report QA-8.3-F01-00
hidden
frame) on bottom tank

Inside Primer for the Tank parts (like as per specification given in inside primer painting
90 DFT & Masking as per specification
conservator) those wil come into contact of oil [1ZCH100515/1ZCH100516]

process parameter record

100 Dimensional Inspection All dimension as per drawing
Report QA-8.2.4-F01

110 Full welding Welding as per drawing WELD PLAN

120 Final Dimensional Inspection -TANK All dimension as per drawing ensure that measuring instruments are calibrated.

By identification Number punch on define area.

130 Identification no. Product identification visual with sr.no.
1ZCH101237

remove weld sppater & shabby weld

140 Sandering No sander mark on surface
1ZCH100604

No blow holes,spatter,shaby welding,excess welding

150 Visual inspection Welding as per drawing,free from spatters ISO5817 level C / 1ZCH100604
VT PT Report QA-8.3F01-00

160 Penetrent Test No porosity n/a

Pneumatic test at 0.3 bar ,Rework if leakage found &

reinspect.
170 Leakage test ( tank+cover, pipings) Pressure test -no leakage
1ZCH101885 / Leak test inspection report-PR-8.3-01
Work instruction -WI –PROD/MS01/12

Check by water drop test

180 Degreasing No rust and oil on part
Work instruction -MFG-07
 Avoid rust & pitting &Ra 3.2 to 6.3 value as per
1ZCH100515
No rust on material
Sandblasting Work instruction -QA/MS01/04
190 Surface preperation [Sandblasting] roughness, surface profile, as per
record form 1ZCH107892
specification.
Check by water drop test Indicate procedure reference
Maintaing DFT as per 1ZCH100516

Maintaing DFT as per 1ZCH100515/1ZCH100516/

1ZCH100517/1ZCH108911
200 Primer painting Inside & outside No peel-off,uncover
Internal painting Work instruction -MFG-01
record parameters in 1ZCH107918 & 1ZCH108858

No peel -off,uncover shall be there.Cross cut

210 Final Painting adhesion,Gloss of top paint,DFT as per ABB as per QIC
STD
220 Aluminium plate fitment with sikaflex Clean surface, use of adhesive tape, as per Specification
230 Leakage test for Aluminiun Cover leakage of air not less than 10%. input pressure = 0.1bar
No peel -off,uncover,Cross cut Painting Inspection record 1ZCH108912
240 Final INSPECTION (Dimension & painting) adhesion,Gloss of top paint,DFT as per ABB Report QA-8.2.4-F01
STD COC 3.1 certificate
250 Retapping Go gauge pass easily, No go not pass N/A
Check of cleanliness (indide tank pipe,
260 Cleaning (Dust/particle removal) No dust/particles
boxes,..)
As per packing standered provide by
270 Packing No damage due to transport
customer

PREPARED BY : Mr. Arvind APPROVED BY-C M Tambe

Revision Status/Date Revision History

Added Process 40,60,220 and 230
Rev 01/16.01.2018
Made Flow Chart Generic
 DOC .NO.-PFD/GN-01

TRANSPORTATIN STORAGE

OPN & INSP.TOGETHER INSPECTION

OPERATION DELAY

INCOMING PARTS

SYMBOL
ACTION TAKEN
DOC STATUS
 1 Receipt of raw material
2 Paint
3 Filler Wire
4 Receipt of machining part/flanges
5 Storage
6 Programming
7 Laser/Plasma cutting
8 Flattening
9 CNC Bending
10 Cleaning
11 Tack weld
12 Full welding
13 Tank Inside blasting -Conservator
14 Masking -Blasting surface
15 Inside primer
16 Cleaning
17 Full welding
18 Weld rework
19 Identification Punching
20 Dimensional Inspection
21 Machining Four PAD-2XCH200810
22 Trimos Inspection
23 White Assembly
24 Dimension Inspection
25 PT Inspection
26 Weld line blasting
27 VT Inspection
28 Weld Rework
29 Leakage testing
30 Tank Full blasting -Inside and Outside
31 Internal White Primer -Tank Inside & cover Bottom side
32 External Primer
33 Masking -Blasting surface
34 Top Coat Painting
35 Rettaping
36 Aluminium plate fitment
37 Inside Visual Inspection
38 Packing
Receipt Inspection of Raw material
Storage
Laser cutting
Flatenning
Bending
Chamfering/Beveling/Edge Preparation
Do tack welding & full welding to 2 air tanks
NDT STOP : Do VT inspection of welds before closing the air boxes and horizontal stiffer (U frame) on bottom tank
Inside Primer for the Tank parts (like conservator) those wil come into contact of oil
Dimensional Inspection
Full welding
Final Dimensional Inspection -TANK
Identification no.
Sandering
Visual inspection
Penetrent Test
Leakage test ( tank+cover, pipings)
Degreasing
Surface preperation [Sandblasting]
Primer painting Inside & outside
Final Painting
Aluminium plate fitment with sikaflex
Leakage test for Aluminiun Cover
Final INSPECTION (Dimension & painting)
Retapping
Cleaning (Dust/particle removal)
Packing