PROCESS FLOW DIAGRAM

Part Name :BKT

INTRUCTION FRONT
Process Responsibily ;-ProdProcess Identification
DOOR
REAR
Part No
:0103AW0160N Key Date;1/28/2011
Part Family
Doc No;-TAPL\QA\PFD\0160Date (Origin)
Date (Reviewed)
Core Team :Vijay mankare,Sandeep ,Devraj,Shivkumar,Appa.
Operation
Process
Incoming sources of
Process Flow Diagram
No.
description
variation

10

20

30

RAW
MATERIAL
INWARD
INSP.

1)Incorrect Grade of
Material
2) incorrect Size of Material
3) Surface & edges
4)Wrong Dimension

Storage

No material damage & rusty

Transport to
next work
stastion

No material damage & rusty

SHEARING &
CROSS
SHEARING
1)Material Damage
(BROUGHT
2)Materail Rusty
OUT UNDER 3)Wrong size cutting
TAPL
CONTROL)

Transport to
next work
stastion

No material damage & rusty

BLANKING

1)Blank cut
2)Materail Rusty
3)Wrong size mat.
4)Material dimension not OK
5)Wrong material

Transport to
next work
stastion

No material damage & rusty

40

50

60

FORMING

1)Material Damage due to

low pressure 2)Materail
Rusty
3)Material dimension not OK
4)Wrong material

Transport to
next work
stastion

No material damage & rusty

FLANGE &
RESTICK

1)Material Damage
2)Materail Rusty
3)Wrong size Nut

Transpot to
Final
Inspection

No material damage & rusty

PIERCING

1)burr at hole
2)CD change.
3)hole undersize.

Transpot to
Final
Inspection

No material damage & rusty

70

Final
Inspection

1)WIP Parts.
2)Damage Part.
3)Rusty Part.

80

Packing &
Dispatch

1)Despatch without
PDIR,TC.
2)Non std.Bins.
3)Rusty Part.

Sr no

Rev. No.

Revision
Date

Revision Summary

OW DIAGRAM
Project
PFD Symbol

Prepared By :Sandeep
Approved By : Sandeep
Rev. No.
:0

W201

ID

Characteristics
Product
Process

2)Reqiured size of
material
3)Free from
Burr,rust, pitt
marks, dent
marks, Damages
4)Required
dimension
No part damage
No Rusty

No part damage
No part mixup

1)Proper
mat.handling
2)Anti rust oil or
pickling.
3) Required
dimension

No part damage
No part mixup

1)Supplier TC
2)As per BOQP
3)

For Taging

Dedicated troylleys

As per process
standard

Dedicated troylleys

No excess burr, no
damage, number
of holes, hole
As Per BOQP
under size

No part damage
No part mixup

Dedicated troylleys

Shut height:No excess flange,

25x150
no damage, no
cushion pressure:tool marks
2.0kg/bar

No part damage
No part mixup

Dedicated troylleys

Shut height:No excess flange, 25x150

no damage, no
cushion pressure:tool marks
2.0kg/bar

1)No Part Damage

2) No Part Mixup

No excess burr, no
damage, number Cutting clearance
of holes, hole
, Shut height
under size

1)No Part Damage

2) No Part Mixup

Panel Geometry

1)No damage of
material
For taging
2)Dedicated Bins

As Per BOQP

As per Customer
Approved Bins

on Summary

Reason for Revision

Tapovan Auto Tech Pvt

PROCESS FLOW DIAGRA

CUSTOMER

Cosma International

VEHICLE /
MODEL

M&M 3G FRAM

SUPPLIER
CODE

PART NO.

0203BBC00230N

REV DATE

11/03/2016

PFD.REV.N
O

PART NAME

TRANS INTERFACE
BRKT RH

REV NO

14

PFD.REV.
DATE

DRAWING NAME

TRANS INTERFACE
BRKT RH

ASSLY NO

0203BBC00230N

PFD.ORG.
DATE

DRAWING NO.

0203BBC00230N

ASSLY NAME

TRANS INTERFACE
BRKT RH

PFD KEY
DATE

Operation No.

10

Process
description

Incoming sources of variation

1)Incorrect Grade of Material

Raw Material
2)Thickness U/S or O/S
Receiving Inspection 3)Width U/S or O/S

Storage

No material damage & rusty

Transportation to
next work station

material damage & rusty

1) Ofcut

20

2)Edges Burr
3)Material thickness

Blancking & Piercing

o/s,u/s.
Transportation to
next work station

40

Forming

Transportation to
next work station
50

Trim
Operation on 500T
Press

60

Transportation to
next work station
Part of
Transportation to
next work station
Flange and Restrack

70

Operation on 400T
Press
Transportation to
next work station

material damage & rusty

1)Free From
Burr,Dent,Damages,Tool mark
Scrap Mark,Thining
3)OK Dimensions

Dent and Damage

1)Hole Missing in privious Op.
2) Free
From Burr
3) Hole U/S,O/S
4)Dim.Not Ok
material damage & rusty
1)Selection of M/C
2)Free From Burr
material damage & rusty
1)Free From Burr
2)Dim.Not Ok
3) Free From Damaged
material damage & rusty

PFD Symbol

80

Cam Piercing
Operation
on 300T Press
Transportation to
next work station

90

Pierc ing
Operation on
300T Press
Transportation to
next work station

90

100

Sr. No
1
2
PREPARED BY :

material damage & rusty

1)Hole Missing in privious Op.
2) Free
From Burr
3) Hole U/S,O/S
4)Dim.Not Ok
material damage & rusty

Measuring and
Restrack
Operation on
400T Press

1)Free From Burr

2)Dim.Not Ok
3) Free From Damaged

Transportation to
next work station

material damage & rusty

Final Inspection

1)Burr
2)Dent and Damage
3)Hole pull up/down
4)Crack,scoring,wrinkle,folding,wav
iness
5)Dimensions

Transportation to
Packing & Dispatch

110

1) Free From Crack,Thinning in

previous operation
2)Dim.Not Ok
3) Scoring or
Damaged

Packaging &
Dispatch
Rev. No.
1
2

Dent and Damage

No material damage & rusty

Revision Date
25.07.2015
15-10-2015
Shakil

Inner Width Dim.82.3 +1/+1.5

ped as customer requirement.
Strip size width change by cus

Auto Tech Pvt.Ltd.

ESS FLOW DIAGRAM

100100

DOC. NO.

TAT/PFD/30-40N

00

PROCESS RESPONSIBILITY :

Tapovan Auto Tech Pvt.Ltd.

NA

Core Team - Sanjay Alone,Shakil,,Zahir Abbas,Devraj,B.mule,S.Hingane

14/10/14

Inspection
Operation cum
Inspection

14/10/14

Transportation

Storage
Packing and
Dispatch

Delay

Characteristics

PFD Symbol

Product

Process

1)Thickness-3.20.15 mm(check
before loading to Shearing
operation)
2)Material Free From Rust,Pitted Etc.

1)Material TC
2)RMQPFE410 Std.
3)Packing
4)Loading and Unloading method

No part damage
No Rusty
No part damage
No part mix-up
1) Thickness - -3.20.15 mm
2)OD-165 0.25
3) ID - 70 0.25
4)FreeDent,Damage,Rusty,Bur
No part damage
No part mix-up
1)No Burr,Dent,Dmaged
2)No Ofcut
3)Ok Dimensions

1) Tagging
2)Dedicated floor space

No Dent and Damage

Single piece manually

1)Machine- 500T
3)Shut Height-845 1 mm
2)M/C Selection
3)Punch Radius &
Gauging
Single piece manually

1) No Hole Miss
2) No Burr
3) No Hole U/S,O/S
4)Dim.Should be OK
No part damage
No part mix-up
1)No Burr,Dent,Dmaged
No part damage
No part mix-up
1)No Burr
2)No Crack
3)Dim.Shoud be OK.
No part damage
No part mix-up

1)Machine-shearing machine
2)Stopper length.
3)Sharpern Blade
Single piece manually
1)Machine-600T
2)Shut Height-8081 mm
M/C Selection
Inproper Gauging

3)Wrong
4)

Selection of M/C
Single piece manually
1)Machine-400T
2)Shut Height-535 1 mm
3)M/C Selection
4)Punch Radius &
Gauging
Single piece manually

1)No Scoring or Damaged

2)No Crack
3)Dim.Shoud be OK.
No part damage
No part mix-up
1) No Hole Miss
2) No Burr
3) No Hole U/S,O/S
4)Dim.Should be OK
No part damage
No part mix-up
1)No Burr
2)No Crack

1)Machine-300T
2)Shut Height-500 1 mm
3)M/C Selection
4)Punch Radius &
Gauging
Single piece manually
1)Machine- 300T
2)M/C Selection
3)Punch Radius & Gauging
Single piece manually
1)M/C Selection
2)Punch Radius & Gauging

3)Dim.Shoud be OK.
No part damage
No part mix-up

Single piece manually

1)No of hole-7 nos In 30N& 9 nos.In

40N
2)No Crack
3)Scoring As per ref sample
4)No Folding
1)Calibrated Instrument
5)Dent ,Damage, Rusty,black
2)Sampling frequency
patches,tool marks& Scrap marks-As
per ref sample
6)No Burr.
7)Hole Pull Up & down

No Dent and Damage

1)No part damage
No Rusty
2)Dispatched as per define
packaging std.

Dedicated packing box

1) Tagging
2)Dedicated floor space

Revision Summary
ner Width Dim.82.3 +1/+1.5 delete from contol plan because parts are produced without restrike
ed as customer requirement.
rip size width change by customer Cosma Before 295mm After 290mm
APPROVED BY : Shakil