STANDARD OPERATING / QUALITY ASSURANCE PLAN

Drawings are carefully studied along with Design and functional requirement. Deviations and modifications are consulted and got approved. We wish to acquaint you with our procedure as it stands today and are constantly modifying as we go from assignment to assignment. We are sure, a perusal on following shall generate, a sense of confidence in our capacity.

Depending on the nature, type of product, assignment the relevant section of following total procedure shall be applicable

VC VISUAL CHECK

100 % Visual Checking is done for Raw Materials, Castings, Forging and any intermediate processing carried out at vendor e.g. Sand, Shot Blasting, Painting or Rubber Lagging etc.

RM RAW MATERIAL

All Raw Materials procured shall be as per agreed Specification & Tested for required tests
Material shall be identified as per identification code e.g. X Y 000
where X : Heat no. or lab tkt no.
Y : Our code no
000 : Component Sr no
Material identification-cum lab test slips shall be sent along with our challan to testing laboratories
Log book of above identification code shall be maintained as per following format Date I c no Material size & spec T c no Result Remark

MI MATERIAL INSPECTION

All specified and those not specified but required tests are carried out.

MIDT DESTRUCTIVE TEST

Chemical analysis
Physical tests are witnessed by SI/TPIA/Client
Micro/IGC test in case of stainless steel are witnessed by SII/TPIA/CLIENT

MINDT NON DESTRUCTIVE TEST

Magnetic Particle examination as per ASTM A 275
Hardness test according to scale agreed
Ultrasonic test as per ASTM A 388 / A 577 / A 475 as applicable be taken
NDT may be repeated on request at any stage of inspection

HT HEAT TREATMENT

Heat treatment as per specification shall be carried out and hardness recorded in the scale specified or its equivalent
Heat chart / Cycles are furnished wherever possible
Annealing shall be done for all forging and castings
Stress Relieving shall be done for welded structures

DI DIMENSIONAL CHECK

Tolerance Inspection
                  SI   VC   CLIENT   TPIA
0.050
0.030         100%     100% or random sample option
0.010
0.005
0.0005       100%     100%
Dimensional inspection record is maintained
Characteristic such as are more convenient are checked on machine otherwise gauges are provided
General inspection stage - Inspection blank - Inspection after drilling - Inspection after drilling / reaming
Any other mutually agreed between TPIA / CLIENT

ST SURFACE TREATMENTS

Surface Treatment such as Zinc Plating, Chromium Plating, Blackodizing, Painting, Rubber Lagging etc. are checked before and after for assessing thickness
Scratch test
Adhesive Tape test
Thickness test
Charpy test

W WELDING

Welding is carried out as per specification
Welding rods tested before use
Welding & repair procedure established
Welder qualification test conducted or only pre qualified welders are used
LPT test is carried out.
100% Radiography or as agreed between SI/TPIA/Client is carried out on weld area

SDB STATIC & DYNAMIC BALANCING

Rotating components depending upon their speed of rotation are balanced statically or dynamically. Residual imbalance as specified is achieved.

PC PROCESS CONTROL

A layout preparation, diagonal checking transfer of holes among mating components is part of our culture and people are trained accordingly
Jigs / Fixtures wherever necessary are designed and design discussed with Client / TPIA. Tolerances on Jigs / Fixtures are 1/10th of those on actual component. Initial components produced are thoroughly checked
Wherever quantity is large Gauges are manufactured to check critical dimensions. Holes are on GO / NO GO Gauges./ threads are checked with standard Thread Gauges.

BOI BOUGHT OUT ITEMS-IMPORTED-INDIGENEOUS

Components such as Belt, Motor, Gear Box, Chain, Coupling, Bearing are procured from reputed manufacturers only.
Critical components are imported
Manufacturer’s certificates are obtained and the same are passed on to Client/TPIA

A ASSEMBLY

All components are assembled to verify various fittings, matching expected.
Running trails wherever possible are taken without load.
In case the entire assembly is not possible mockup assembly is made & trails taken on these.

DR DOCUMENTATION / RECORD

All vendor / locations for special processes shall be intimated to Client / TPIA
Material test certificates related to respective components
Heat treatment reports / charts of specific components
Layout inspection reports of Jigs / Fixtures and Gauges
Stage wise dimensional inspection reports.
Final approved general arrangement drawing / detail drawings / as built drawings.



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