RP:BOSCH:PFD:20

Part Name : Bearing Pedestal Lagerbock

Dated Originated:
Part No. : F01 C010 100

Manufacturing
Process :
Injection Moulding
PROCESS FLOW DIAGRAM Rev. No. & Dated :
11 & 25.05.2018
Page : 1 of 1
Customer : Bosch

Prelaunch or Radiant Plant :

Production
SEQUENCE OF PROCESSES REMARK
OPERATION WITH
STORAGE OPERATION INSPECTION
INSPECTION
TRANSPORTATION INCOMING SOURCE OF PROCESS PRODUCT
PROCESS NUMBER PROCESS DETAILS
VARIATION CHARACTERSTICS CHARACTERSTICS

Raw material bag in wet condition , Sealed Raw material bag Dry Raw Material bag

Raw material bag tear out Raw material Weight Raw material quantity

10 Receipt of Raw material Less Raw material quantity Raw material Bag numbers Raw material bag quantity

Wrong material (Grade) Raw material grade as per invoice Raw material type

Raw material Batch Test report not

Raw material Test Certificate Raw material type
available

Raw material bag in wet condition , Sealed Raw material bag Dry raw material bag

Open bag / tear bag / unsealed No contamination Dust free raw material

Open bag / tear bag / unsealed Raw Material Moisture content % Dust free raw material

20 Inspection of raw material Raw Material properties not ok Raw material Test certificate Correct Raw material

Moisture Analyser faulty Calibration Dry Raw material

Unskilled Inspector Training Dry Raw material

Inspection environment inadequate Inspection Ambient temperature Dry Raw material

Material mixup Material defined location FIFO Raw material traceability

Improper store ambient Store Temperature and Humidity Saftey of Raw material Bag
30 Storage of raw material
Improper Raw material stock Minimum saftey stock Raw material inventory

Improper Raw material stacking Material Stacking Height Raw material Placement

Wrong raw material issue Part wise raw material Identification Raw material Grade

40 Issue of raw material Improper Raw material quantity Raw material Weight Raw material quantity

Improper identification of Issued

Raw material Batch number Raw material traceability
Raw material

Raw material Improper residence

Preheating timer Dry Raw material
time in oven

Improper working of oven timer Timer Calibration Dry Raw material

Improper Raw material preaheating

Heater with thermocouple Dry Raw material
in oven

Preheating of raw material

50
 Improper working of oven heater Thermocouple Calibration Dry Raw material

Improper Raw material preaheating

Raw material level in hopper drier Dry Raw material
Preheating of raw material in hooper
50
Improper working of hooper heater
Heater thermocouple calibration Dry Raw material
drier

Raw material Improper residence Raw material level sensor in hopper

Dry Raw material
time in hooper drier drier

Raw material level sensor

Raw material level sesnor faulty Dry Raw material
calibration hopper drier

Raw material Improper residence

Preheating timer Dry Raw material
time in hooper drier

Improper working of Hooper drier

Timer Calibration Dry Raw material
timer

Improper Injection and Holding

Pressure gauge Part Weight /Dimensions
Pressure

Improper Injection and Holding

Machine nozzle orifice dia Part Weight / Dimensions
Pressure

Improper Injection & Holding time PLC Timer Part Weight / Dimensions

Improper Cooling time PLC Timer Part Weight / Dimensions

Improper Raw material melt

Barrel Heater with Thermocouple Part Weight / Dimensions
temperature

Injection Moulding Improper Raw material melt

60 Hot runner tempaerature controller Part Weight / Dimensions
temperature

Improper mold temperature Mould temperature controller Part Weight / Dimensions

Improper coolant flow Flow control valve Part Weight / Dimensions

Cooling channel block Water battery Part Weight / Dimensions

Cooling connection identification on

Improper Mold cooling connection Part Weight / Dimensions
mold

Unskilled Operator Operator Training Visual / All dimension as per ICL

Incorrect checking , testing Calibration of checking , testing

Visual / All dimension as per ICL
instrument / Gauge instrument / Gauge

Unskilled Inspector Inspector Training Visual / All dimension as per ICL

Measuring instrument selection /

70 In process inspection Agreement of Inspection Visual / All dimension as per ICL
Method not right

Part inadequate quantity checked Agreement of Inspection Visual / All dimension as per ICL

Inspection environment inadequate Inspection Ambient temperature Visual / All dimension as per ICL

Wrong water used for conditioning DM water grade Weight % Increase

Improper level of DM water Defined level of DM water Weight % Increase

parts Inadequate conditioning Defined quantity of parts Weight % Increase

Conditioning of Molded parts

80 Improper conditioning Time Define Time Weight % Increase
with Distilled water

Improper temperature DM water Temperature Weight % Increase

Dirty water Water changing frequency Weight % Increase / Visual ok

Unskilled opeartor Training Weight % Increae

 Unskilled opeartor Training Weight % Increae

Dry Parts , No Contamination, Part

Improper Drying time Define Time
weight

Dry Parts , No Contamination, Part

Inadequate Part Drying Define Part quanitity
weight

Dry Parts , No Contamination, Part

90 Drying of conditioned parts Improper Air flow Air flow rate
weight

Dry Parts , No Contamination, Part

Improper air temperature Blower Heater
weight

Dry Parts , No Contamination, Part

Improper Blower Heater Heater thermocouple calibration
weight

Improper part quantity Packaging standard Part Quantity

Improper Part Placement in Boxes

Packaging standard Part Packing
or Bins

Wrong size /Type Boxes or Bins

Identification on Boxes or Bins Boxes or Bins
used

Weak boxes wrt total parts weight Packaging validation Boxes or Bins
Packing & Labelling of
90
components
Dirty boxes /Bins Bin cleaning frequency Clean boxes and Bins

Damaged boxes or bins Boxes inspection Standard boxes or bins

labelling as per defined

Impropoer Labelling labelling
standard
Packing , labelling No damage ,No
Unskilled opeartor Training dust

Finished Products mixup Products defined location FIFO Finshed Product traceability

Improper store ambient Store Temperature and Humidity Saftey of Finished product
100 Storage of finish products
Improper Finished Product stock Minimum saftey stock Finished Product inventory

Improper Finished Product stacking Material Stacking Height Finished Product Placement

Incorrect checking , testing Calibration of checking , testing

Visual / All dimension as per ICL
instrument / Gauge instrument / Gauge

Unskilled Inspector Inspector Training Visual / All dimension as per ICL

Measuring instrument selection /

110 Pre-Dispatch Inspection Agreement of Inspection Visual / All dimension as per ICL
Method not right

Part inadequate quantity checked Agreement of Inspection Visual / All dimension as per ICL

Inspection environment inadequate Inspection Ambient temperature Visual / All dimension as per ICL

Improper loading of material Material loading Method OK Parts supply

Wrong Dispatch quantity Dispatch Instruction Right quantitiy

120 Dispatch to customer Wrong Invoice As per PO / Dispatch schedule Right quantitiy

Wrong transport medium As per defined transport agreement No damage

Wrong material dispatch Loader Training Correct material dispatch

Prepared By: Approved By:

 Revison status
Rev No Date Change History Change by Approved by
0

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