Quality Department

SONALIKA STANDARD PRE DELIVERY INSPECTION PROCEDURE

PDCA cycle

n Quality Assurance

n Quality Control

n Operational Considerations

n Quality Assessment

Unit Outline

Quality Control procedures

n Quality Control procedures should also cover: Instrument calibration, Participation in interlaboratory-comparison programs, Computational checks, Periodic review of procedures, specifications and operating

records, Observation of operations and evaluation of quality control

data,

INSTRUMENTS USED IN COMPANY• Vernier calliper• Micrometer• Depth gauge• Feeler gauge• Bore Gauge• Callipers • Dial Indicator• Slip Gauges• Angle plate• Talysurf surface roughness

tester

Slip Gauge

Vernier Calliper

Micrometer

The scale can be read directly to 0.01mm, as shown above, but may also be estimated to 0.001mm when the lines are nearly coincident because the line thickness is 1/5 of the spacing between them

Dial Gauge

• Dial gauge or dial indicators are used for checking flatness of surfaces and parallelism of bar and rods.

• They are also used for testing the machine tools and linear dimensions of jobs.

• The dial is divided into 100 equal divisions, each division represents a spindle movement of 0.01mm.

Vernier Depth Gauge

Least count is 0.02

Measures the height and depth of work piece or components

Feeler Gauge

• Made with hardened alloy steel.

• It is used to measure the gap in a part.

Slip Gauges

• It is a rectangular block made with hardened steel, and is also known as gauge block.

• The rectangular blocks are 9mm*30mm in size upto 10mm length.

• The process of blocks adhere is called wringing.

Angle plate

• An angle gauge is a hardened steel block approx 75mm long 16mm wide.

• It is largely used in various industries for clamping and holding work in vertical position.

Bore GaugeA dial or vernier bore gauge measures a bore directly.The gauge has three symmetrical anvils that protrude from the gauge body that are connected to the dial or micrometer mechanism.As the knob is rotated it moves the anvils in or out with respect to the measurements. The knob usually has a slipping mechanism to take the feel out of the device and increase reliability between measurements. Its least count is 0.01mm

Callipers (outside)• Used to measure

external size of an object• Made of high carbon

steel • Carbon is maximum

upto 2.0 (Acc to Fe-C Diagram)

Callipers (Inside)• Used to measure

internal size if object• The upper calliper is

manually adjusted and the lower one contains adjusting screw

Talysurf surface roughness tester

PROJECT WORK• BRAKE PEDAL LOCK NOT WORKING• REAR COVER MOUNTING COVER LOOSE• WATER SEPARATOR BANJO LEAKAGE• LEAKAGE FROM THE HYDRAULIC DELIVERY PIPE

ADOPTER• BRAKE SWITCH SPRING MOUNTING MISSING• REAR FENDER LIGHT MOUNTING SURFACE ON REAR

FENDER FOUND UNEVEN RESULTING GAP B/W REAR FENDER LIGHT & FENDER

Problem: Brake pedal lock not working

Root Cause: • One pedal offset after welding.• Due to arrangement of handling. Action taken: • Inspection of welding from supplier end.• Proper handling starts.

Problem: Water separator Banjo leakage.

Root Cause: Water separator Banjo Torque found less. It is basically operator fault.• Required torque: 22-27 Nm• Observed torque: 11-13 Nm

Action taken:Banjo retightened at defined torque• Spot facing starts at HMS ( Heavy

machine shop)

Problem: Leakage from hydraulic delivery pipe adopter.

• Root Cause: Metallic chips found in O ring groove resting area, due to chips O ring damaged and resulting leakage from adopter face.• Action taken: Washing starts

inside the company.

Problem: Brake switch spring mounting missing problem.

• Root Cause: Hole not drilled by operator from supplier end.

• Action taken: Split pin to be fitted from supplier end before dispatched.

Problem: Rear fender light mounting surface on rear fender found uneven in Baagban DI-30 resulting after tightening, gap observed between fender and fender light.Fender surface uneven

• Root Cause: : Rear fender light mounting surface on rear fender is uneven

• Action taken: Inspection starts from supplier end.

Problem: Rear cover mounting bolt loose.

Root Cause:• Extra casting near mounting area due to less approach for

tightening nut on stud.• Mounting hole shifted toward the fillet area, seems to be core

shifted

Action taken:• Spot facing starts at HMS ( Heavy machine shop)

THANK

YOU