Quality Control Procedures

All products manufactured by Lucknow Metals adhere to strict quality specifications, including
mechanical properties, chemical compositions, dimensions, surface finishes, and tolerances. These
specifications comply with relevant industry standards, ensuring regulatory and customer requirements
are met. Tolerance limits are established and regularly reviewed using statistical process control (SPC)
methodologies to maintain competitiveness and quality.

3. Project Planning and Design

Every project begins with comprehensive planning and design. Our engineering team develops detailed
drawings and specifications defining each product’s concept, materials, dimensions, tolerances, surface
finish, and safety requirements.

 General Process: Specifications are set to align with quality standards and customer needs.

 For Transformer Tanks: The process includes CAD modeling for form, function, aesthetics, and
weld details, followed by fabrication process simulations to identify clashes or out-of-tolerance
features. A full cost estimate—covering raw materials, labor, machine time, and overhead—is
prepared, and required personal protective equipment (PPE) such as welding helmets,
respirators, and cut-resistant gloves is identified to ensure team safety.

4. Material Procurement and Inspection

All incoming raw materials are rigorously inspected before entering production to ensure they meet
project and quality specifications.

 General Procedures: Supplier certificates and delivery notes are verified, and a 10% sample
undergoes visual and dimensional checks (e.g., thickness, flatness, straightness). Findings are
recorded in the Incoming Inspection Log.

 For Transformer Tanks: Mill test certificates are checked to confirm chemical composition, yield
and tensile strengths, and hardness. Visual inspections identify surface defects like mill scale,
laminations, or rust, and mechanical tests (e.g., tensile strength analysis, hardness testing via
Rockwell, Brinell, or Vickers scales, impact resistance evaluation, and spectrographic testing for
chemical composition) are performed as required.

5. Fabrication Processes

Manufacturing follows standardized operating procedures (SOPs) with defined quality checkpoints to
ensure consistency and adherence to standards.
  General SOPs: Step-by-step instructions and decision criteria guide operators. Key process
parameters (e.g., temperature, pressure, flow rates) are monitored and maintained within limits
using automated control systems and SPC techniques.

 For Transformer Tanks: Specific processes include CNC plasma cutting, pressbrake bending with
dedicated tooling blocks, machining of flange holes, tack-welding assemblies, full-penetration
welding, and surface preparation. Each operation is documented in a process flow chart to
facilitate in-process quality checks.

6. Inspections and Testing

6.1 In-Process Inspection

In-process inspections occur at critical checkpoints throughout fabrication to detect and address issues
early.

 General Checkpoints:

o Post-Cutting: Dimensions verified to ±0.5 mm tolerance.

o Post-Welding: Visual inspection for weld integrity (no cracks or porosity).

o Post-Painting/Coating: Uniform coverage and adhesion tested.

 For Transformer Tanks: Continuous visual checks during welding identify undercut, porosity, or
misalignment. Non-destructive testing (NDT) methods—ultrasonic, radiographic, magnetic
particle, and dye penetrant testing—are employed to detect internal and surface defects.

6.2 Final Inspection and Testing

Completed products undergo comprehensive final inspection to ensure they meet all specifications.

 General Procedures: Dimensional verification against engineering drawings using precision

instruments (e.g., digital calipers, micrometers, CMMs), surface finish assessment (Ra value or
visual standard), and functional tests (e.g., pressure tests for tanks). A Certificate of
Conformance (Form QC-05) is issued upon approval.

 For Transformer Tanks: Laser trackers and coordinate measuring machines (CMMs) verify
squareness, shell straightness, and flange flatness to within ±1 mm. Structural response testing
under simulated loads ensures resilience. Any deviations trigger root-cause analysis and
corrective action.

7. Nonconformance Handling

Items not meeting specifications are managed systematically to maintain quality.

 Procedure: Nonconforming items are tagged with an “NC” label, logged in the Nonconformance
Report (Form QC-07), and reviewed by the QC Manager for rework or scrap decisions. Corrective
actions are tracked in the CAPA Register (Form QA-10).

8. Record Keeping and Documentation

All quality control activities are documented to ensure traceability and compliance.

 Records Maintained: Equipment logs (calibration status, maintenance history), step-by-step

process checklists, material certifications, inspection reports, testing results, calibration
certificates, and non-conformance reports. Each product batch is assigned a unique
identification number.

 Retention Periods: QC forms are retained for a minimum of 3 years; critical records (e.g.,
material certifications, testing results) are maintained for at least 7 years to comply with
industry standards and customer requirements.

 Audits: Quarterly internal audits by the Quality Manager ensure documentation accuracy and
process adherence.

9. Delivery and Site Handling (Where Applicable)

 General Process: A final QC signoff is completed, and packaging methods are assessed to
prevent transit damage (e.g., weight distribution, crane-lift points considered in load plans).

 For Transformer Tanks: Packaging includes skid supports, internal bracing, and corrosion
inhibitors. Upon arrival, the field team oversees unloading, inspects for transit damage, and
performs final assembly steps (e.g., fitting covers or accessory brackets) if needed.