Tata Projects Limited Fabrication & Galvanizing L3 D

OBJECTIVE:

To carry out Fabrication of tower parts as per CS/MQP/IS

To carry out galvanizing of black fabricated material as per CS / MQP / IS
To carry out validation of Galvanizing process twice a year.

PROCESS SUPPLIER, OWNER AND THE CUSTOMER:

Supplier Process owner Customer

Raw Material Stores In

charge/
Production In-charge Despatch In-charge
Production Planning Control
In charge

SCOPE:

Receipt of raw material to handover of Finished material to Despatch

DISPUTE RESOLUTION / ESCALATION

In case of any points of differences arises in implementation of this process it shall be escalated to Head
TMU

REPORTING

Owner of the
Measure Source of data MIS
Measure
Production as per target PPC PPC PPC
Rejection QA QA QA IN-CHARGE
Rework QA QA QA IN-CHARGE
LDO consumption FABRICATION FABRICATION
Plate wastage PPC PPC
Consumable cost STORES STORES
Zinc Consumption STORES /GALVANIZING GALVANIZING
PRODUCTION
LDO Consumption STORES / GALVANIZING GALVANIZING
IN-CHARGE
Acid Consumption STORES / GALVANIZING GALVANIZING
Wire Consumption STORES / GALVANIZING GALVANIZING
Ash Generation GALVANIZING GALVANIZING
Dross Generation GALVANIZING GALVANIZING

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Tata Projects Limited Fabrication & Galvanizing L3 D

ACTIVITIES AND TIMELINES: Fabrication

1. Incharge Fabrication will receive the JC, MIR, and Sketches for Proto & JC, MIR, and Sketches
along with RS for Mass production released by PPC department via -
Job Card – TPL/TMU/PPC/001
MIR – TPL/TMU/PPC/002
RS – TPL/TMU/PPC/003.

2. In charge - Fabrication will make the Daily Production Plan based on Monthly Production Plan using
Shop sketches
JC – TPL/TMU/PPC/001
RS – TPL/TMU/PPC/003.

3. In charge - Fabrication will release the MIR to Raw Material Yard for material issue along with Daily
Production Plan - TPL/TMU/FAB/007

4. Shift In charge - Fabrication will ensure to receive the raw material at respective machines as per
plan.

5. Shift In charge - Fabrication will ensure to process the job as per Daily Production Plan and shop
sketch.

6. Shift In charge - Fabrication will offer the First piece of each item to Shift In charge - QA for
inspection.

7. Shift In charge - QA will inspect the first piece as per sketch and note it down in respective
RS–TPL/TMU/PPC/003

8. Shift In charge - Fabrication will ensure to complete the rout sheet quantity after first piece checking
and necessary actions taken as per rework / rejection (RW / RJ Slip -TPL/TMU/QA/04)

9. Shift In charge - Fabrication will offer the finished black material to Shift In charge - QA for inspection
with Fabrication Inspection Report (TPL/TMU/FAB/03) .

10. Shift In charge-QA will inspect the material as per Fabrication Inspection Report TPL/TMU/FAB/03
RS–TPL/TMU/PPC/003 and Shop sketch.

11. Shift In charge - Fabrication will ensure to take necessary action for rework and rejection and
hand over the accepted material to Galvanizing via Material Transfer Note TPL/TMU/FAB/04 .

12. In case of Proto modification / rejection , rectify / refab the required item as per proto check
sheet and hand over to proto department.

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Tata Projects Limited Fabrication & Galvanizing L3 D

ACTIVITIES AND TIMELINES: Galvanizing

1. Supervisor - Galvanizing will receive the material from Fabrication / Engineering / Vendor. He will
check the material as per Material Transfer note & Rout sheet / Packing list and apply the lime as a
confirmation and record it in Taking Over Register TPL/TMU/Gal/ R-01.

2. In charge - Galva will make the Daily Production Plan based on Monthly Production Plan.

3. Supervisor - Galva will carry out the activity of loading of material on rack for galvanizing of material
as per length and section and record it in Loading Register TPL/TMU/Gal/R-02.

4. Shift In charge - Galva will ensure process parameters of all the process tanks are per
specification mentioned in TPL/TMU/GAL/CH-02 before carrying out the galvanizing process.
(Ref Daily Chemical Report – TPL/TMU/QA-08).

5. Supervisor - Galva will carry out the Galvanizing process as per Process Validation Chart / CS /
MQP and Annx-02, 03 , 04 and record it in Furnace Register TPL/TMU/GALV/ R-04.

6. Shift In charge - Galva will verify the zinc coating thickness as per requirement and record it in
Furnace Register TPL/TMU/GALV/ R-04.

7. If the material is OK then shift In charge Galva will proceed further if NOT ok then send it back for
reprocessing.

8. Supervisor - Galva will carryout the unloading / finishing and stacking of material as per rout sheet
quantity. Each item will be provided coloured tag for WIP aging.

9. Shift In charge - Galva will offer the finished material to Shift In charge QA and he will carryout the
inspection as per Route sheet and applicable CS/MQP.

10. Shift In charge - Galva will hand over the OK material to Despatch with Galvanizing Material
Inspection and handing over Report TPL/TMU/GALV-01. A handover tag will be attached with
each item for ease of identification of handed over material.

11. Shift In charge -Galva will ensure to carry out ash collection,drossing ,weighment of ash and dross
and handing over to Stores via Store Return Note.(TPL/TMU/FAB/04).

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Tata Projects Limited Fabrication & Galvanizing L3 D

ACTIVITIES AND TIMELINES: Galvanizing Process Validation

1. Supervisor QA will receive coupon samples for light, medium and heavy section of different
thickness of angles and plates.(Ref :CS-04 / MQP / IS).

2. Supervisor QA will ensure to check the tank parameters for its chemical composition.
(Ref : Process Tank Parameter Chart CH-02)

3. Supervisor Galv will ensure to load the samples on the rack and carry out galvanizing as per
TPL/TMU/Galv/PI/01

4. Shift In charge Galva and Shift In charge QA will check galvanized sample for visual and galvanizing
parameter and note the results.

5. Shift In charge QA will carry out sample testing rack wise for adhesion, zinc coating and preece test
and note down the result.

6. In charge Galva and In charge QA will check the results of all the sample and standardize the
process parameter.

7. In charge Galva and In charge QA will approve the process as capable after standardizing the
process parameters.(TPL/TMU/GALV/F-03)

8. In charge Galva and In charge QA will review the process twice in a year and in between if required
for any special material.

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 Tata Projects Limited Fabrication & Galvanizing

PROCESS FLOWCHART & ACTIVITY: Fabrication

Flow Chart Activity Owner

Start In charge Fabrication will receive the JC, MIR, and

Sketches for Proto & JC, MIR, and Sketches along
with RS for Mass production released by PPC In charge -
department via JC – TPL/TMU/PPC/001 Fabrication
Receive JC, MIR
MIR – TPL/TMU/PPC/002
RS – TPL/TMU/PPC/003

In charge - Fabrication will make the planning of the

production for the day as per priority and plant
Plan Production and capacity with
allocation In charge -
Shop sketches
Fabrication
JC – TPL/TMU/PPC/001
RS–TPL/TMU/PPC/003
Daily Production Plan - TPL/TMU/FAB/007

In charge - Fabrication will release the MIR to Raw In charge -

Release MIR
Material Yard for material issue. Fabrication

Shift In charge - Fabrication will ensure to receive Shift In charge -

Receipt of Material
the raw material at respective machines as per plan. Fabrication

Shift In charge - Fabrication will ensure to process

the job as per plan sequentially as applicable in the
shop sketch.
Process the job Operations like
Cutting (Gas/Machine)
Process the job Shift In charge -
B Stamping (Manual/Machine)
Operations Fabrication
Punching/Drilling (Manual/CNC)
Notching
Heel-Cutting (Gas/Grind/Shaper/CNC)
Bending (Hot/Cold)
Welding

Shift In charge - Fabrication will offer the First piece Shift In charge -
Offer for inspection A
of each item to Shift In charge - QA for inspection Fabrication

Shift In charge - QA will inspect the first piece as

Accepted Rejected
Insp. Status per sketch and note it down in respective Shift In charge - QA
RS–TPL/TMU/PPC/003
Rework

Shift In charge - Fabrication will ensure to complete

Complete the Do necessary Handover the
the rout sheet quantity after first piece checking and Shift In charge -
entire Route Rectifications REJECTED
necessary actions taken as per rework / rejection Fabrication
Sheet Quantity material
(RW / RJ Slip - TPL/TMU/QA/04)

A Shift In charge - Fabrication will offer the finished

Offer the Finished Receipt of material
black material to Shift In charge - QA for inspection Shift In charge -
material for D against rejection
inspection with Fabrication Inspection Report Fabrication
slip
(TPL/TMU/FAB/03)

C B

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 Tata Projects Limited Fabrication & Galvanizing

PROCESS FLOWCHART & ACTIVITY: Fabrication

Flow Chart Activity Owner

C
Rejected
Accepted
Shift In charge - QA will inspect the material as per
Inspection Status Shift In charge -
Fabrication Inspection Report TPL/TMU/FAB/03 ,
QA
RS–TPL/TMU/PPC/003 and Shop sketch.

Rework

Shift In charge - Fabrication will ensure to take

Handover to Handover the necessary action for rework and rejection and hand Shift In charge -
Galvanizing / Do necessary over the accepted material to Galvanizing via Fabrication
REJECTED
Engineering Rectifications Material Transfer Note TPL/TMU/FAB/04
material

D
Receipt of
B material

End

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 Tata Projects Limited Fabrication & Galvanizing

PROCESS FLOWCHART & ACTIVITY : Galvanizing of Black Fabricated Material

Flow Chart Activity Owner

Start

Supervisor - Galvanizing will receive the material from

Receive material from Fabrication / Engineering / Vendor. He will check the
Supervisor -
Fabrication/ material as per Materia Transfer note & Rout sheet /
Galvanizing
Engineering/Vendor Packing list and apply the lime as a confirmation and record
it in Taking Over Register TPL/TMU/Gal/ R-01

In charge - Galva will make the Daily Production Plan based

Plan the production In charge - Galva.
on Monthly Production Plan.

Supervisor - Galva will carry out the activity of loading of

material on rack for galvanizing of material as per length and Supervisor -
Load the rack
section and record it in Loading Register TPL/TMU/Gal/R- Galvanizing.
02

Shift In charge - Galva will ensure process parameters of all

the process tanks are per specification mentioned in
Ensure all tank parameters TPL/TMU/GAL/CH-02 before carrying out the galvanizing
Shift In charge -
within specification Galva.
process. (Ref Daily Chemical Report –
TPL/TMU/QA-08).

Supervisor - Galva will carry out the Galvanizing process as

Galvanize the Material per Process Validation Chart / CS / MQP and Annx-02, 03 Supervisor -
, 04 and record it in Furnace Register TPL/TMU/GALV/ R- Galvanizing.
04

Not Shift In charge - Galva will verify the zinc coating thickness
Zinc coating Ok with Alcometer as per requirement and record it in Furnace Shift In charge -
thickness Register TPL/TMU/GALV/ R-04. Galva.
If NOT ok then send it back for reprocessing.
Ok

Unload the rack and Supervisor - Galva will carryout the unloading / finishing and
Supervisor -
stacking of material as per rout sheet quantity. Each item
finish the material. Galvanizing
will be provided coloured tag for WIP aging.

Not
Ok Shift In charge - Galva will offer the finished material to Shift Shift In charge
Inspection
In charge QA and he will carryout the inspection as per (Galva ) /
status Route sheet and applicable CS/MQP Shift In charge (QA)

Ok

Shift In charge - Galva will hand over the OK material to

Hand over the Despatch with Galvanizing Material Inspection and
material to dispatch Shift In charge -
handing over Report TPL/TMU/GALV-01. A handover tag
Galva.
will be attached with each item for ease of identification of
handed over material.

Carry out Shift In charge -Galva will ensure to carry out ash
collection,drossing ,weighment of ash and dross and Shift In charge -
ash collection &
handing over to Stores with Store Return Note. Galva.
Drossing
(TPL/TMU/FAB/04).

End

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 Tata Projects Limited Fabrication & Galvanizing

PROCESS FLOWCHART & ACTIVITY: Process Validation of Galvanizing

Flow Chart Activity Owner

Start

Supervisor QA will receive coupon samples for light,

Receive coupon
medium and heavy section of different thickness of Supervisor (QA)
samples
angles and plates.(Ref :CS-04 / MQP / IS)

Supervisor QA will ensure to check the tank

Ensure correctness of parameters for its chemical composition.
Supervisor (QA)
tank parameters (Ref : Process Tank Parameter Chart CH-02
Daily chemical Report TPL/TMU/QA-08)

Load coupon samples Supervisor Galv will ensure to load the samples on the Supervisor -
on the rack rack and carry out galvanizing as per Galva/PI/01 Galvanizing.

Shift In charge Galva and Shift In charge QA will Shift In charge

Note the results of check galvanized sample for visual and galvanizing Galva and Shift In
galvanized samples parameter and note the results. charge QA

Shift In charge QA will carry out sample testing rack

Test one piece rack Supervisor -
wise for adhesion, zinc coating and preece test and
wise Galvanizing
note down the result.

Not
Ok If not found OK then shall change the parameters and
Supervisor -
Result again follow the points above till uniform results are
Galvanizing
obtained
Ok

In charge Galva and In charge QA will check the

Standardize the Supervisor -
results of all the sample and if found OK shall
process parameter Galvanizing
standardize the process parameter.

In charge Galva and In charge QA will approve the Shift In charge

Approve the process process as capable after standardizing the process (Galva ) /
parameters. Shift In charge (QA)

In charge Galva and In charge QA will review the Shift In charge

Review the process twice
process twice in a year and in between if required for (Galva ) /
in a year
any special material. (TPL/TMU/GALV/F-03) Shift In charge (QA)

End

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 Tata Projects Limited Fabrication & Galvanizing

LIST OF DOCUMENTS / FORMATS REQUIRED:

- JC – TPL/TMU/PPC/001

- MIR – TPL/TMU/PPC/002

- RS – TPL/TMU/PPC/003

- Shop sketches

- Material Transfer Note TPL/TMU/FAB/04

- Fabrication Inspection Report TPL/TMU/FAB/3

- Steel Return Note TPL/TMU/FAB-006

- Daily Production Plan TPL/TMU/FAB-007

- Taking Over Register TPL/TMU/Gal/ R-01

- Loading Register TPL/TMU/Gal/R-02

- TPL/TMU/GAL/CH-02

- Daily Chemical Report – TPL/TMU/QA-08

- Process Validation Chart

- CS / MQP

- Annx-02, 03 , 04

- Furnace Register TPL/TMU/GALV/ R-04

- Galvanizing Material Inspection and handing over Report TPL/TMU/GALV-01

- Store Return Note

- Daily Prodcution planning - fab

- Daily Prodcution planning - Gal

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 Tata Projects Limited Fabrication & Galvanizing

SIPOC Table and Measures:

What is being measured? Review

Supplier What is the Customer
What is Who is the
Who is the EPM output of EPM
being customer of Efficiency Effectiveness
supplier? Process the Process
supplied? the output? Frequency Forum
No. process? No.
Measure Target Frequency Measure Target Frequency

Production
as per Dept.
Planning Galvanized Despatch In- Production as
JC - - objective/ Monthly
Control/ RMS Material charge per target
KRA
In charge

as per Dept.
MIR - Rejection objective/ Monthly
KRA
as per Dept.
RS/Sketch Rework objective/ Monthly
KRA
as per Dept.
LDO
objective/ Monthly
consumption
KRA
as per Dept.
Plate wastage objective/ Monthly
KRA
as per Dept.
Consumable
objective/ Monthly
cost
KRA

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 Tata Projects Limited Fabrication & Galvanizing

SIPOC Table and Measures:

What is being measured? Review

Supplier What is the Customer
What is Who is the
Who is the EPM output of EPM
being customer of Efficiency Effectiveness
supplier? Process the Process
supplied? the output? Frequency Forum
No. process? No.
Measure Target Frequency Measure Target Frequency

as per Dept.
Black Galvanized Zinc
Fabrication PPC objective/ Monthly
Material Material Consumption
KRA
as per Dept.
LDO
objective/ Monthly
Consumption
KRA
as per Dept.
Acid
objective/ Monthly
Consumption
KRA
as per Dept.
Wire
objective/ Monthly
Consumption
KRA
as per Dept.
Ash
objective/ Monthly
Generation
KRA
as per Dept.
Dross
objective/ Monthly
Generation
KRA
Process
Twice a
Validation
year
Report

Process No: 07.01.05/R1 Ver date: 22.12.18 Page no.: 11 of 11