Soman micro accurate

 


 GENERAL GUIDELINES – INSPECTION REQUIREMENTS
ARTICLE NO SMA 9701

00 PREFACE
     
    This Article gives the General Guidelines on
inspection requirements.
    It is designated as Article No SMA 9701

APR
9, 1997
  PREFACE ARTICLE
NO
SMA 9701 00
REV
0

01
MATERIAL IDENTIFICATION

1. All
materials to be offered for identification, prior to check testing
and manufacturing.
2. Stamp
transfer procedures are mandatory for all critical items and same
will be finalized during initial
    inspection visits.
3. Vender to
maintain a raw material identification record as under.

Date
C.T.No.
Material
Specs.
Size
of 
Material
TC
No.
and Date
Results 
Remarks


4. Casting – Initial heats will be witnessed, and the heat will be
identified by strip method if the test bars
    are not integral.

APR
9, 1997
  MATERIAL
IDENTIFICATION
ARTICLE
NO
SMA 9701 01
REV
0

02. MATERIAL INSPECTION

1.0   
General
        
1.1    All material inspection to be at/by, Clients / SMA
approved Laboratories / agencies /
                
personnel’s
        
1.2   
Material Identification / Lab test slip to be sent to laboratory /
agency along with challan.
                
The same to be filled in by SMA during  Material Identification

SOMAN MICRO
ACCURATE
MATERIAL IDENTIFICATION / LAB TESTS SLIP

CLIENT 
PROJECT

VENDOR 
P. O. NO.

CT
NO.
SPECIFICATION
TEST
REQUIRED
ID
STAMPING
     
THIS
SLIP TO BE ATTACHED WITH CHALLAN
FOR SMA

        
1.3    Following Tests are subject to witness
of Soman Micro.
                 
1. Non Destructive Tests.
                 
2. Mechanical Tests.
                 
3. Micro Examination.
        
1.4    General Material inspection requirements are per
clause No. 4.1 & 4.2 for  Ferrous and 
                 
Non Ferrous materials. These Tables are only for information and not to be
applied as is.
                 
Application of component / material is to be considered as prime while
deciding the test
                 
requirements.
                                                                                                                                            
2.0   
Non Destructive Testing.
       
2.1    Non destructive tests are should be in
accordance with the specifications as applicable.

Material
Type
Ultrasonic
Test
Magnetic
Particle
Examination
Liquid
Penetrent
Test
Casting
    ASTM
E 165
Forging
ASTM
A 388
ASTM A 745
ASTM
A 275
ASTM
E 165
Bar
Stock
ASTM
A 435
ASTM A 577
ASTM A 578
  ASTM
E 165


         2.2   
For all critical components, Ultrasonic testing of raw material is
recommended.
         2.3   
In case of doubts, NDT to be carried out at any stage of manufacture.
3.0   
Destructive Testing
        
3.1    All mechanical test methods to meet ASTM
standards.
         3.2   
Chemical tests may be witnessed, if required.
         3.3   
For all types of Stainless steel material, micro test is mandatory,
and same may be waived
                 
in certain cases subject to application.

                                                                                                                                             

4.0   
Tables
4.1 – Test
requirements – Ferrous materials

01. 
Tubes and Pipes  –  Seamless
06. 
Bolting Material
02. 
Tubes and Pipes  –  ERW
07. 
Billets and Forgings.
03. 
Plates, Sheets and Strips.
08. 
Casting.
04. 
Structural Steel.
09. 
Wrought Iron, Cast Iron & Maleable
       Iron Casting. 
05. 
Bars, Rods and Wires.
10. 
Corrosion Resisting and Heat 
       Resisting Steels

N.B. : 0  =  NOT APPLICABLE
         1 
=  APPLICABLE

SR.
NO.
TEST
REQUIRED
MATERIALS
    01 02 03 04 05 06 07 08 09 10

NON
DESTRUCTIVE TEST

01 ULTRASONIC TEST 0 0 1 1 1 0 1 0 0 1
02 MAGNETIC PARTICLE EXAM 0 0 0 0 0 1 1 0 0 1
03 DIE PENETRANT TEST 0 0 0 0 0 0 0 1 1 0
04 EDDY CURRENT TEST 1 0 0 0 0 0 0 0 0 0
05 RADIOGRAPHIC EXAMINATION 0 0 0 0 0 0 0 0 0 0
06 HYDRO TEST 1 1 0 0 0 0 0 0 0 0
07 PNEUMATIC TEST 1 1 0 0 0 0 0 0 0 0
08 DIMENSIONAL CHECKUP 1 1 1 1 1 1 1 1 1 1
09 VISUAL INSPECTION 1 1 1 1 1 1 1 1 1 1

  DESTRUCTIVE TEST

11 CHEMICAL 1 1 1 1 1 1 1 1 1 1
12 MICRO EXAM (CASTING
& S.S.)
1 1 1 1 1 1 1 1 1 1
13 MICRO EXAM 1 0 0 0 0 0 0 0 0 0
14 IGC (STAINLESS STEEL) 1 1 1 0 0 1 0 0 0 0
15 TENSION TEST 1 1 1 1 1 1 1 1 1 1
16 YIELD STRENGTH 1 1 1 1 1 1 1 1 1 1
17 ELONGATION 1 1 1 1 1 1 1 1 1 1
18 REDUCTION OF AREA 1 1 1 1 0 1 0 0 0 0
19 BEND TEST 0 0 1 1 0 0 0 0 0 1
20 CHARPY IMPACT TEST 0 0 1 1 0 0 0 0 0 0
21 FLATNESS TEST 1 1 0 0 0 0 0 0 0 0
22 FLARRING TEST 1 1 0 0 0 0 0 0 0 0
23 HARDNESS TEST 0 0 1 1 1 1 1 1 1 1

4.2 – Test requirements – Non Ferrous materials

01. 
Tubes and Pipes  –  Seamless
06. 
02. 
07. 
Billets and Forgings.
03. 
Plates, Sheets and Strips.
08. 
Casting.
04. 
Structural Steel.
09. 
— 
05. 
Bars, Rods and Wires.
10. 

N.B. :
0  =  NOT APPLICABLE
         1 
=  APPLICABLE

SR.
NO.
TEST
REQUIRED
MATERIALS
    01 02 03 04 05 06 07 08 09 10

NON
DESTRUCTIVE TEST

01 ULTRASONIC TEST 0 1 1 1 1 0
02 MAGNETIC PARTICLE EXAM 0 0 0 0 1 0
03 DIE PENETRANT TEST 0 0 0 0 0 1
04 EDDY CURRENT TEST 1 0 0 0 0 0
05 RADIOGRAPHIC
EXAMINATION
0 0 0 0 0 0
06 HYDRO TEST 1 0 0 0 0 0
07 PNEUMATIC TEST 1 0 0 0 0 0
08 DIMENSIONAL CHECKUP 1 1 1 1 1 1
09 VISUAL INSPECTION 1 1 1 1 1 1

DESTRUCTIVE TEST

11 CHEMICAL 1 1 1 1 1 1
12 MICRO EXAM (CASTING
& S.S.)
0 0 0 0 1 1
13 MICRO EXAM 1 0 0 0 0 0
14
15 TENSION TEST 1 1 1 1 1 1
16 YIELD STRENGTH 1 1 1 1 1 1
17 ELONGATION 1 1 1 1 1 1
18 REDUCTION OF AREA 1 1 1 0 0 0
19 BEND TEST 0 1 1 0 0 0
20 CHARPY IMPACT TEST 0 1 1 0 0 0
21 FLATNESS TEST 1 0 0 0 0 0
22 FLARRING TEST 1 0 0 0 0 0
23 HARDNESS TEST 0 1 1 1 1 1
                                                                                                                                            
  
APR
9, 1997
  MATERIAL
INSPECTION
ARTICLE
NO
SMA9701 02
REV
0

03.   HEAT
TREATMENT

1.Heat Treatment shouldbeas per clients specification / drawings.

2. All casting and forgings to be heat treated per cod. Time Temperature
charts essential.

3. Time Temperature charts essential, wherever heat treatment cycle is
specified.

4. Hardness check – Initially 100% with three reading on each
quantity.

5. Calibration certificates of thermocouples, pyrometers and Hardness
Testing machines along with 
    master reference blocks are to be offered for
verification

APR
9, 1997
  HEAT
TREATMENT
ARTICLE
NO
SMA9701 03
REV
0

04.   DIMENSIONAL INSPECTION

1. Use of calibrated
instruments for dimensional inspection is appreciated.

2. Shop calibration of instruments is acceptable, if method of
calibration is scientific.

3. Tolerances – wherever not specified on the drawing IS 2102 medium
is applicable with prior 
    consent of client.

4. Vendor should have all necessary facilities required for
dimensional inspection.

5. The characteristics, which are not possible to check after removing
the component from the 
    machine, such characteristics to be offered on
machine or qualifying gauges to be made.

6. Other than joint inspection, vendors dimensional inspection report
mandatory, prior to
     Soman Micro inspection.

7. Normal stages for dimensional check.
    1.   Blank inspection.
    2.   Inspection after drilling /
slotting.
    3.   Inspection after thread cutting.
    4.   If inspection at any other stage is
found necessary, depending on the process layout of the
          component, then
same will be finalized during initial inspection visits.

8. De-burring is must before dimensional inspection

APR
9, 1997
  DIMENSIONAL
INSPECTION
ARTICLE
NO
SMA9701 04
REV
0

05.   VISUAL INSPECTION
1. All castings and
forgings to be shot blasted before visual inspection

2. Visual inspection
100%.

3. De-burring, fettling is must before visual inspection.

                                                                                                                                             

APR
9, 1997
  VISUAL
INSPECTION
ARTICLE
NO
SMA9701 05
REV
0

06.   METALISING AND SURFACE TREATMENT

1. Metalising
should be as per drawing/specifications.

2. Metalising will be
witnessed at initial stages.

3. Check testing of metalising material is at discretion of 
Client/Soman Micro.

4. Chrome plating                            
Liquid CUSo4
                                    
                
Thickness inspection

5. Blackodising                               
0.5% Oxalic acid spot test.

6. Parcolubrication / Phosphating    
 Scratch
test .
                                                     
Visual inspection in sunlight


7.
Painting
                                      
Mechanical
cleaning inspection prior to painting 
                     
                                
Adhesive tape test.
                                                     
Thickness inspection

8. Wire metalising                           
Chemical of bond material

                                       
              
Chemical of metalising material.

9.Plasma coating                           
Load test on sample if specified in
drawing/specification,
 
                                           
          
Dimensions, Thickness
 

 


                                          

APR
9, 1997
  METALISING
AND SURFACE TREATMENT
ARTICLE
NO
SMA9701 06
REV
0

07.   WELDING

1. All
welding procedures and welder�s performance shall be qualified.

2. Weld procedure qualification records and welder performance,
certified by any other third party,
    may be acceptable.

3. Weld
Repairs
.
  
3.1
 
No
weld repairs are acceptable unless written permission fromClient
/ Soman Micro.
  

3.2
Acceptance of weld repairs are subject to approval of
repair weld procedures,
         by Client/

Soman Micro
.
   3.3 Extent of defect shall be established by mechanically
removing the defect and 
        
carrying
liquid penetrent test.
   3.4 Defect
shall be welded by approved procedure & welder. Final NDT, as
        
agreed shall be carried out.
   3.5 Record
of all weld repairs to be maintained.

APR
9, 1997
  WELDING ARTICLE
NO
SMA9701 07
REV
0

08. BALANCING

1. Balancing
should as per drawing/specifications.

2. Balancing will be witnessed 100% by Soman Micro at initial stages and
then at random as required

APR
9, 1997
  BALANCING ARTICLE
NO
SMA9701 08
REV
0

09. PROCESS CONTROL

1. All
holes should be jig located.

2.Following to be
considered as process controlled characteristics and initially to be
checked 
   100% and then at random as required.
   
1.
Characteristics
controlled by jigs/Fixtures.
    2.Heat treatment cycles.

3. Vendor may have to
precisely control or machine, certain open dimensions, to
achieve, 
    required precision on other dimension.

                                                                                                                                         

APR
9, 1997
  PROCESS
CONTROL
ARTICLE
NO
SMA9701 09
REV
0

10. STATISTICAL QUALITY CONTROL

1. For
mass production items SQC to be carried out.

2. 
Vendor to implement
SPC.

3. The SQC to
be carried out in accordance with.

           MIL 105 D
(ABC Standard)
           Normal
Inspection
           Single
Sampling
           Level –
Depending on the criticality of the characteristics.

4. SQC
will be carried out for process controlled characteristics.

APR
9, 1997
  STATISTICAL
QUALITY CONTROL
ARTICLE
NO
SMA9701 10
REV
0

11. ASSEMBLY FITMENT AND FUNCTIONAL ASSESSMENT

1. All
assemblies will be shop assembled prior to dispatch

2. The aspects not
checked during routine inspection will be verified
during assembly
    fitment and
interchangeability inspection.

3. Functional assessment at client�s site after dispatch.

APR
9, 1997
  ASSEMBLY
FITMENT AND FUNCTIONAL ASSESSMENT
ARTICLE
NO
SMA9701 11
REV
0

12. JIGS AND FIXTURES

1. Vendor
to submit drawings of Jigs and Fixtures for approval to Client/
Soman
Micro.

2. Tolerances-10%
that of component tolerance or per Indian Standard.

3. Jigs and
Fixtures will be qualified by
Soman
Micro
as mentioned.
    3.1  Dimensional
inspection of Jigs and Fixtures.
    3.2  Machining
of 5 nos. from the Jigs and Fixtures.
    3.3  Inspection
of same components by instruments.
    3.4  Hard
punching on Jigs/Fixtures.
    3.5  Clearance
for mass production

4.Jigs and Fixtures to
be identified by hard punching, the component drawing No.
    List of
characteristics, controlled by that particular jig or fixture to be
submitted.

5. Jigs,
Fixture reference must justify the drawing reference.

6. Jigs to be drilled on NC/CNC/Jig boring machine

APR
9, 1997
  JIGS
AND FIXTURES
ARTICLE
NO
SMA9701 12
REV
0

13. GAUGES

1.Vendor
to submit drawings of gauges for approval to Client/
Soman
Micro.

2. Tolerances-
   10% that of component tolerance or per IS 3455.

3. Gauges will be qualified by Soman
Micro
as mentioned.

   

3.1  Dimensional
inspection of gauges.
   
3.2  Inspection
of 5 nos. of components by gauge.
    3.3  Inspection
of same components by instruments.
    3.4 
Acceptance of gauge to use in production.

4. Specified
characteristics to be hard punched on gauges.
 

5. Tapped holes will be checked by standard thread gauges.

6. Holes, Elliptical, holes, slots will be checked by go-nogo pin
gauges.

APR
9, 1997
  GAUGES ARTICLE
NO
SMA9701 13
REV
0

14. HARDWARE AND BOUGHTOUTS

1. Hardware should be good
quality and of reputed manufacturer, including all hardware
specified  
    commercially.

2. A qualified thread profile may be used to verify the hardware and
its fitment eg. A tapped hole
    in a plate, a nut etc.

3. Such thread profile to be pre-qualified by go – no go gauge.

4. ASTM Std & Machinery Handbook will be used as a reference for
hardware / bought outs, unless
    otherwise specified.

APR
9, 1997
  HARDWARE
AND BOUGHTOUTS
ARTICLE
NO
SMA9701 14
REV
0

15. DESIGN CHANGES AND NON CONFORMITY

1. For any change in
clients design, DCR to be raised by manufacturer.

2. Written approval prior to manufacture / procurement, from Client / Soman
Micro
on such 
     DCR is mandatory.

3. If any Non conformity produced during any stage of manufacture NCR
to be raised by 
    manufacturer.

4. Acceptance of such Non-conformity either as is, with rework, with
modification, is at
    discretion of Client/Soman
Micro

5. Written Acceptance on such Non conformity from Client / Soman
Micro
is
mandatory prior to 
     proceed for next stage of manufacture.

APR
9, 1997
 

DESIGN CHANGES
AND NON CONFIRMATIVE

ARTICLE
NO
SMA9701 15
REV
0

16. RECORDS AND DOCUMENTS 

1. All inspection records
to be maintained per clients drawings.

2. All characteristics to be numbered on drawings.

3. Vendor to ensure that all specifications, drawings or any other technical
documents are 
    available with him before starting the process of
manufacture.

4. Vendor to make available following documents during inspection /
visits.
     4.1  Clients P.O. copy.
     4.2  Client specifications and drawings.
     4.3  Stage wise inspection reports.

5. It is recommended to have one file for one purchase order’s
documents.

APR
9, 1997
  RECORDS
AND DOCUMENTS 
ARTICLE
NO
SMA9701 16
REV
0

17. FINAL DOCUMENTATION

1. Following to be
submitted as final documentation.
    1.1  Design change record along with as built
drawings – if  same is accepted by Client/Soman
Micro

    1.2  Material test certificates – Defining
components.
    1.3  Heat treatment record.
    1.4  Jigs/Fixtures/Gauges inspection reports.
    1.5  Stage wise and dimensional inspection
record.
    1.6  Non conformity reports – Item wise and with
quantity. Summary sheet necessary
APR
9, 1997
  FINAL
DOCUMENTATION
ARTICLE
NO
SMA9701 17
REV
0

18. SUBMISSIONS

1. Vendor to submit during our first visit.
     1.1  Manufacturing bar chart.
     1.2  Quality plan with stages of
inspection.
     1.3  Process lay out for individual
component.
     1.4  List of sub vendors with address
and other details.
     
2. Vendor to identify following personnels.
     2.1  Planning Personnel.
     2.2  Q.C. Personnel.
     2.3  Overall Incharge. 

APR
9, 1997
  SUBMISSIONS ARTICLE
NO
SMA9701 18
REV
0