|
The company has a fully equipped quality control department to assess
the quality of all incoming raw materials from various suppliers. They
undergo stringent quality control inspection according to the laid down
specification before they are cleared for production.
To carryout all these, our QC department is equipped with adequate
testing facilities.
A brief description of the procedure that is being followed for
inspection of incoming raw materials, in process inspection and finished
product inspection is appended below.
1.0.
Incoming Raw Materials
1.1. Steel Electrode quality wire rods as per IS : 2879 received from TISCO / SAIL
are delivered to the wire drawers premises located at Ambattur. The
samples of rod coils with corresponding coil numbers are given to QC Lab
for testing with heat numbers. The QC chemist records the details in the
M.S-ROD / Wire Analysis Register. A numerical number in a serial manner
is given (to denote the batch no) based on the number of consignments in
a calendar year by respective wire drawers.
1.2. QC chemist arranges for testing as per inspection plan and records the
test results viz: spark, etching, chemistry in M.S. Rod / Wire analysis
register. The results are informed to the respective wire drawers.
1.3. Only approved coils are taken up for drawing operation and in case of
any rejection, the wire drawer is notified and such coil is delivered
back to factory with its Weight Certificate by the wire drawer and the
rejected coil number is verified by QC chemist. The rejected coil is
then kept in a separate place and returned to the supplier.
1.4. The drawn wires in the form of coils are received in the goods receiving
area with batch nos, coils & weight where the physical dimension and
weight are checked by the Stores lncharge. They are then sent to QC lab
by a memo for tests. The identification tags bearing the batch number
and other details are tied to each coil.
1.5. The wires are then checked forepart, etching and chemistry and the test
results are recorded in the wire test register.
1.6. The results are communicated and "|PASSED'' stamp is given on the
respective tags of each coil.
1.7. Only passed drawn wires are issued for wire cutting operation.
1.8. The wires are straightened, cut to required length and stacked in pallet
with proper identification and other details.
2.0 Powder Raw Materials & Silicates
2.1 On receipt of materials. stores informs QC Lab through a memo.
2.2. QC chemist preserves the memo, records the details in the Raw Materials
register and issues identification tags to the powder material, under
inspection.
2.3. Sampling and testing are done as per inspection plan and verified
against respective raw material specification.
2.4. Test results are recorded in the Raw Material Analysis Register.
2.5. Test results are then communicated to store and the (Under Inspection)
identification tag will be stuck with a PASSED STICKERS (Green in Colour)
2.6. In case of silicates, passed stickers are stuck on the drums.
2.7. In case of rejection, such bags / drums will be kept separately for
further action with a ''Rejected / Tag / sticker'' (Red in Colour)
Reference Documents
1. Inspection plan (raw materials & steel)
2. Raw material specifications
3. Testing procedures
4. Is : 2879 (1975)
Records
1. M.S. Rod Wire Analysis Register
2. Raw Material Analysis Register
3. Suppliers Test Certificate
Tags
1. Raw Material Under Inspection Card (White)
2. Wire Cut Length (White)
3. M. S. Wire Tags (Green)
4. Green Sticker for “Passed”
5. Red Sticker for “Rejected”
6. Yellow Card for “Held up”
3.0 Inprocess Inspection
3.1. Dry mixing is done as per formulation under the strict supervision
of Quality Control supervision after mixing oversees unloading in bags with
correct weight and puts an identification tag on each bag indicating the
batch numbering date of mixing.
3.2. Wet mixing is done under the direct supervision of production
supervisor who ensures the correct quantity addition of silicates as per the
requirements assuring the quality of the paste.
3.3. The details are recorded in paste mixing register.
3.4. He further oversees the following and records in the concentricity
test registers as per the inspection plan during production (QC / DISP/O3).
|
1.Electrode Diameter |
2. Electrode Length |
|
3. Brush end |
4. Concentricity of the coating |
|
5. Striking end condition |
6. General surface condition |
3.5. The electrodes after production are kept in trays which are
stacked in trolleys one over the other with proper identification tags.
3.6. They are then kept for air drying over night for 6o13 types and 48
to 72 Hours for 7018 types and then lodged in to the drying / or baking oven
as the case may be depending on nature of electrodes.
3.7. The packing supervisor is responsible for drying and baking
operation as per the parameters displayed.
3.8. All the drying / baking details are recorded in the oven / Baking
register.
3.9. He also oversees the packing operation where he ensures the
following as per parameters displayed.
1. Batch number & Date and other infestations.
2. Number of pieces per carton
3. Number of Cartons per box
4. Shrink wrapping of carton / Boxes
3.10. Before he starts packing, he also ensures he coating moisture of
the electrodes by testing in the QC Lab. If found OK, he will proceed with
the packing.
Records
1. Paste Mixing Register
2. Concentricity-rest Register
3. Drying / Baking Register
Tags
Electrode Batch Number & Date Identification Tag (White)
Reference Documents
1. QC Display for drymixing
2. QC Display for wet mixing
3. QC Display for inprocess production parameters
4. QC Display for drying and baking
5. QC Display for standard method of packing
4.0. Finished Products Inspection
4.1 . The finished electrodes are subjected to the following tests
before they are finally despatched to the customers.
(a) Welding performance tests in various positions for which the electrode
is recommended for each batch.
(b) Coating moisture test for each batch.
(c) All weld metal chemistry
(d) All weld mechanical properties (All weld Tensile / impact)
(e) Metal recovery test where it is claimed
(f) Diffusible H2 test for LH electrodes
4.2. The test welder is responsible for all the above activities and
does everything as per the Inspection plan displayed given as annexure.
4.3. All the results are verified against declared values of the product
specification and recorded.
Reference Documents
1. QC Display for current / Amperes
2. QC Display for frequency of tests
3. Product specification brochures
Records
1. Welding performance reports
2. All weld metal chemical / mechanical Register
3. Daily moisture test register.
Top
|
Conventional
