CMD Work Instruction

Die Inspection Maintenance Plan
Die Inspection
PM 1/M
Maintenance Plan
Die Maintenance
Month 1 2 3 4 5 6 7 8 9 10 11 12
Plan
Actual
A-CMD-F-7539
Aditya Auto Products & Engg. (I) Pvt. Ltd. WORK INSTRUCTION
Peenya , Bangalore .
ISSUE A DATE OF ISSUE : 2012 01 23 REF . NO : A - CMD - WI - 7527
REVISION :00 DATE OF REVISION : 2012 01 23 PAGE NO : 1 OF 1
TITLE :
Work Instruction for Deciding Periodicity of Preventive Maintenance & Use of Label
The purpose of this maintenance label is to allow die periodic inspection (PM) to be done smoothly, and depending on the
process planning sheet standards and the production plan will be periodically adjusted.
(Inspection Period) Monthly Production

1/M Atleast 10,000
1/2M Atleast 5,000 at most 10,000
1/3M Atleast 1,000 at most 5,000
1/6M Atleast at most 1,000
This periodic inspection is based on the items of the Press Die Ispection Maintenance, Checksheet, and if repair is
necessary, repair will be done each time.
This label A-CMD-F-7539 will be posted on the front of the die so that operators know when the inspection date
Die Inspection 04 05 06
PM 1/M
Maintenance Plan Die Maintenance
Month 1 2 3 4 5 6 7 8 9 10 11 12 2 3
Plan 15 20 18 19 21
Actual 14 22 18 20
1 4 1
Die Maintenance Press Department
After inspection maintenance, fill in

1 the implemented dated in the Changeover die
actual Return Start production
Die
2 According to the die cycle, fill in

the next planned date.
4
Implement inspection based on the 3 Send die to die maintenance after
Press Die Inspection Maintenance Send production before or after planned
Checksheet. Die inspection
PREPARED BY : APPROVED BY :
SIGN & DATE : SIGN & DATE :
Aditya Auto Product & Engg. (I) Pvt. Ltd.
Peenya, Bangalore WORK INSTRUCTION
ISSUE : A DATE OF ISSUE: 2012 01 23 REF.No.A-CMD-WI-7517

REVISION: 00 DATE OF REVISION: 2012 01 23 PAGE No. 1 of 1
TITLE: WORK INSTRUCTION FOR SELF LIFE ITEMS.
1. The following items are classified as SELF LIFE items.
1. Araldite - Customer supplied material.
2. Phenolic moulding compound - like Bakelite Moulding Power, etc.
2.1 The responsibility of controlling the issue of Self-life items rest with the Stores incharge..
2.2 The stores incharge shall follow First In First Out (FIFO) method to handle and issue these
materials.
2.3 The stores incharge shall inform PPC on receipt of Araldite material from customer and PPC
incharge shall arrange for production of the components immediately.
2.4 PPC incharge to ensure that the material is consumed within the validity period.
For Backelite materials / Phenolic Moulding Compounds,

the following procedure shall be followed
3.1 Stores incharge to identify the material received and enter into a Register.
3.2 Stores incharge to identify the material by giving the sl.no for all the materials received
The next batch of material received will contain the sl no. in ascenting chronological order.
3.3 While issuing the material, stores incharge to issue material in the order of sl.no.
3.4 In the absence of manufacuring / expiry date on the bags / container by the supplier,
stores incharge shall specify 6 months as expiry date from the date of receipt and control
phenolic compound through register.
Periodic review of self-life items to be done once in 6 months and any material which is crossed
its self life shall be identified and informed to Divl.Head for further action for both customer
material as well as NTTF IL purchased materials.
REVISION Brief Description of Change Authorised date

FROM TO by
PREPARED BY APPROVED BY
Sign & date Sign & date
Aditya Auto Products & Engg. (I) Pvt. Ltd.

TITLE:
WORK INSTRUCTION FOR PACKING IN COMPONENT MANUFACTURING DIVISION.
1. The packing of products shall be the responsibility of the Despatch Supervior.
2, The packing of components are as per the annexure enclosed.

FROM TO by

TITLE: WORK INSTRUCTION FOR MATERIAL IDENTIFICATION AND STORAGE IN CMD
STORES.
1. The material in the stores shall be arranged as per the location displayed in stores.
2. Materials under inspection and rejected items to be identified seperately and to be

stored as per location.
3. Materials should be identified with stickers or tags or marking seperately identifying customer
and NTTF IL materials.
4 The colour to be used for NTTF IL material is white and black and for customer
supplied materials orange & black
5. Heavy materials to be stored on floor and light materials are to be stored in racks.
6. Sufficient sapce to be maintained inbetween the materials for easy movement of materials.
7. Use safety devices wherever necessary.
8. Self life items are to be identified seperately.

FROM TO by
Aditya Auto Products & Engg (I) Pvt. Ltd.
ISSUE : A DATE OF ISSUE: 2012 01 23 REF.No.N-CMD-WI-7513

TITLE:
WORK INSTRUCTION FOR HOT STAMPING
1. Mount the printing pads on the machine with adjustable screws.

2. Set the temperataure time & foil selection as follows
1. Temperature 180°C - 200°C

2. Time 2 - 4 seconds
3. Foils Knob Holder L & W 20mm For all Mopeds.
Knob W 30mm
Knob L 20mm
3. Adjust the Depth.
4. Adjust the stroke Length for correct orientation of Printing.
5. After heating of pads to the said temperature take 5 samples after printing.
6. Check the printed components with master sample for printing damages & for the position
with the gauge.
7. Keep the printed components neatly in plastic trays.
8. Scrap the rejected components.

FROM TO by

TITLE:
WORK INSTRUCTION FOR TAMP / PAD PRINTING.
1. Mount the printing pad on bottom face and rubber holder on the top face.
2. Mix the ABS ink (Pad Printing) with 609 reducer in the ratio of 100GMS: 5ML & fill the ink Tray.
3. Place the fixture on the table'
4. Preheat the component with 60 Watts Bulb in the container for minimum 5 seconds.
5. Adjust the depth for correct printing by placing the component on the fixture.
6. Adjust the stroke length.
7. Take sampe impression on the component.
8. Inspect the printed component with master sample for visual damage and with gauge for position.
9. Cure the component in open atmosphere for 24 hours.
10. Rejected components to be scraped.

FROM TO by
ISSUE : A DATE OF ISSUE : 2012 01 23 REF . NO : A - CMD - WI - 7523
REVISION : 00 DATE OF REVISION : 2012 01 23 PAGE NO : 1 OF 1
TITLE : WORK INSTRUCTION FOR POST CURING OF
VALVE BODY 367 COMPONENTS IN POST CURING OVEN
1 Set the Temperature controller TC 061 of preheating oven to 170 ±10°C
2 The VALVE BODY 367 COMPONENTS after compression moulding shall be arranged in trays
in the oven.
3 TIME SWITCH TS 203 CLOCK TIME setting to be ensured. If the time is not ok adjust the time
by using 'CLOCK SETTING' , 'HRS' & 'MIN' knobs.
4 Set the Start time1 in TS 203. Start time1 is when part is placed in the oven first.
5 Set the Duration time1 to 12.00 Hrs in the time switch TS 203
6 Post curing oven to be switched 'ON' and reading noted in POST CURING MONITORING CHART.
7 At every 1Hr interval readings to be noted in POST CURING MONITORING CHART.
8 After the end time is achieved as soon as the Hooter sounds , switch OFF the oven , timer and
unload the parts.
9 Start time2,3&4 & Duration time2,3&4 can be used to load components in 4 different timings based on
the individual loading time
10 When minimum 2 different time setting components are in oven, during hooter sounds switch of the
oven unload only the first loaded components for which Post curing over, reset the Start time2 &
Duration time2 for the second loaded components & then switch 'ON' the oven & proceed with post curing
11 Follow the same procedure for 3rd & 4th loadings.
9 Mark green dot at the ejector pin on the parts for evidence of carrying out the postcuring.
10 The component shall be checked for any defects during post curing and if any
the same to be brought to the notice of the Supervisor / Line Inspector.
11 Pack 80 components with seperators & liners in a box.
12 Move the components for secondary operations.
REVISION DETAILS SIGN & DATE

FROM TO

ANNEXURE FOR FR BODY WELDING COMPONENTS
REF . NO : A - CMD - WI - 7526 PAGE NO : 2 OF 2
ISSUE :A DATE OF ISSUE : 2012 01 23
REVISION : 00 DATE OF REVISION : 2012 01 23
FIXTURE COMPONENT
AIR TEMPERA
Sl.No COMPONENT WELDING WELDING
PRESSURE TURE
THICKNESS THICKNESS
1 FR BODY LHD 120 psi 280 ±10°C 4.0 mm 4.0 mm
2 FR BODY TBI 120 psi 270 ±10°C 4.2 mm 4.6 mm
3 FR BODY 597 80 psi 265 ±10°C 4.0 mm 4.2 mm
4 FR BODY 607 80 psi 265 ±10°C 4.0 mm 4.2 mm
5 FR BODY 680 80 psi 265 ±10°C 4.0 mm 4.2 mm
6 FR BODY 1023 75 psi 265 ±10°C 3.8 mm 4.0 mm
7 FR BODY 1142 75 psi 265 ±10°C 4.0 mm 4.2 mm
8 FR BODY 1537 75 psi 265 ±10°C 4.0 mm 4.2 mm
9 FR BODY 1402 70 psi 270 ±10°C 3.4 mm 3.6 mm
10 FR BODY 1419 70 psi 265 ±10°C 4.0 mm 4.2 mm
11 FR BODY 792 70 psi 265 ±10°C 4.0 mm 4.2 mm
12 FR BODY 711 65 psi 265 ±10°C 4.0 mm 4.2 mm

Aditya Auto Products & Engg (I) Pvt. Ltd. WORK INSTRUCTION
TITLE : WORK INSTRUCTION FOR TOOL SETTING IN
F R BODY WELDING IN BILLOMATIC MACHINE
1 LOAD BOTH THE HALVES OF FIXTURE ON THE MACHINE.
2 ALIGN BOTH HALVES USING DOWEL PINS AND THEN CLAMP THE FIXTURE MANUALLY.
3 BRING THE HEATER PLATE FORWARD AND CLOSE THE FIXTURE TO TOUCH THE HEATER
PLATE AND THEN TIGHTEN THE TOP NUT AVAILABLE ON THE SIDE OF THE CYLINDER TO
FIX THE DISTANCE DURING THE HEATING PERIOD.
4 MANUALLY CLOSE THE FIXTURE AND SET THE WELDING GAP DURING PRESSING PERIOD
AS PER THE ANNEXURE AND THEN TIGHTEN THE NUT WHICH IS DOWN.
5 CHECK AND SET THE AIR LINE PRESSURE AS PER REQUIREMENT= 100psi=7kg/cm2 =7bar
6 RUN ONE COMPONENT IN SEMI MODE AND CHECK FOR WELDING THICKNESS AND DO
THE PRESSURE LEAK TEST, IF OK RUN THE MACHINE.
7 CHECK THE CONDITION OF TEFLON SHEET, REPLACE EVERY 2000 NOS WELDED PARTS

WORK INSTRUCTION
A - CMD - WI - 7526
URE MANUALLY.
OUCH THE HEATER

F THE CYLINDER TO
PRESSING PERIOD
0psi=7kg/cm2 =7bar
CKNESS AND DO
S WELDED PARTS
TITLE : WORK INSTRUCTION FOR POST CURING OF
COVER SOLENOID COMPONENTS IN PREHEATING OVEN
1 Preheating Oven shall be switched ON at 100°C ± 10°C .
2 The COVER SOLENOID COMPONENTS after deflashing shall be arranged in trays.
3 TIME SWITCH TS 200's START TIME setting to be ensured.
4 TIME SWITCH TS 200's DURATION TIME setting 3.00 Hrs to be ensured.
5 TIME SWITCH TS 200's CLOCK TIME setting to be ensured.
6 This can be set by using 'SET' , 'HRS' & 'MIN' knobs.
7 Preheating oven switched ON and readings noted in POST CURING MONITORING CHART.
8 At every Hr interval readings to be noted in POST CURING MONITORING CHART.
9 As soon as the Hooter sounds , switch OFF the oven , timer and open the door of oven.
10 Remove all trays with components from oven.
11 Pack and move the components for despatch section.

WORK INSTRUCTION
A - CMD - WI - 7525
ged in trays.
TORING CHART.
RING CHART.
e door of oven.
TITLE : WORK INSTRUCTION FOR CHANGE OF
MATERIAL IN PELLETTISING PROCESS

SL.NO ACTIVITY RESPONSIBILITY REF. DOCUMENT
COMPLETE ALL THE RAW MATERIAL IN
1 OPERATOR PRODUCTION PLAN
THE HOPPER
MOVE THE COMPLETED PELLET BINS & HOURLY

2 OPERATOR
STORE IN THE RACK MONITORING CARD
3 CLEAN THE HOPPER THROUGHLY OPERATOR -
SEAL THE UNFINISHED RAWMATERIAL BAG &

4 OPERATOR -
IDENTIFY
CHANGE THE REQUIRED INSERT FOR NEXT HOURLY

5 OPERATOR
CHANGE MATERIAL MONITORING CARD
SET THE MACHINE AS PER WORK

6 OPERATOR -
INSTRUCTION
7 SET UP APPROVAL OPERATOR -
NOT OK
OK
HOURLY
RUN THE PROCESS OPERATOR
MONITORING CARD
REVISION DETAILS SIGN&DATE

FROM TO

NTTF INDUSTRIES LIMITED
ISSUE : A DATE OF ISSUE: 2012 01 23 REF.No. A-CMD-WI-7521

TITLE: WORK INSTRUCTION FOR POST CURING OF
VALVE BODY 107 & 148 COMPONENTS IN PREHEATING OVEN
1. Set temperature cntroller TC 061 of preheating oven to 90 +/- 10*C
2. The VALVE BODY COMPONENT after compression moulding shall be arranged in trays
in the oven
3. TIME SWITCH TS 200 CLOCK TIME setting to be ensured. If the time is not ok adjust
the time by using "SET", 'HRS', & 'MIN' knobs.
4. Set the start time in TS 200. Start time is when part is placed in the oven.
5. Set the Duration time to 20.00 Hrs in the time switch TS 200.
6. Preheating oven to be switched ON and reading noted in

POST CURING MONITORING CHART.
7. At every 5 hrs inverval readings to be noted in POST CURING MONITORING CHART
8. After the end time is achieved as soon as the Hooter sounds, switch OFF the oven,
timer and unload the parts.
9. Mark yellow dot at the ejector pin on the parts for evidence of carrying out the postcuring.
10, The component shall be checked for any defects during post curing and the same to be
brought to the notice of the Supervisor / Line Inspector.
11 Pack 80 components with seperators & liners in a box.
12. Move the components for secondary operations.

FROM TO by
Aditya Auto Products & Engg. (I) Pvt. Ltd. WORK
Peenya, Bangalore INSTRUCTION

WORK INSTRUCTION FOR PHOSPHATING (LUBRICATION BONELITE) PLATING &
TITLE:
CORBORISING / TEMPERING (CASE HARDENING)
B. THICKNESS:
Check the thickness of the co-processedcoupons for the batch thickness acceptance
by using Gadet. Only if the thickness value falls within the specified limits, the
batch must be accepted and sent to stores to despatch to customers.

FROM TO by
ISSUE A DATE OF ISSUE: 2012 01 23 REF.No. A-CMD-WI-7501

REVISI 00 DATE OF REVISION: 2012 01 23 PAGE No. 6 of 7
TITLE:
7. ACID TIN PLATING
a. Place the components in the acid tin plating batch and start mechanical agitation
of the components.
b. Give the mount of calculted amount of D.C. voltage / Current and carry out the
plating process.
c. Through-out the plating process, the agitation must be carried out uniformly.
d. Take out the components on completion of the plating and subject them for
water rinsing.
8 Two stage cold water rinising
On completion of the plating process the components must be rinsed in the two stage cold
running water to remove all the traces of acids from the surface of the components.
9. Drying
On completion of water rinsing, the components are subjected to drying in the centrifugal
drier. Put the components in the drier and run it for 3 minutes. The wetness on the
components will be removed completely.
10. Inspection
a. Visual
After the post plating process is complete, the components shall be check for visual
defects like dull plating, patching, blisters, burnt deposits and non plating area and
only which are free from the said defects shall be accepted.

FROM TO by

TITLE:
4. Two stage coild running water Rinse
After the completion of alkaline soak cleaning components should be well rinsed in the
two stage cold running water to removed the traces of alkaline contents from the
components. Now the components are ready for scid bright dipping.
CHECK NOTE
No. oil should float on the surface of the cold running water.
5. Acid bright dipping

a. Immerse the soak cleaned components in the acid bright dipping tank for 20 seconds
with mechanical movements of co: components.
b. The batch should be operated at ambient temperature.

CHECK NOTE
a. No. dull / tarnished surface should be seen on the components after washing in
cold running water.
b. No. oil should float on the acid bright dipping bath.
6. Two stage cold running water rinse:
After the completionof acid bright dipping, components should be well washed, rinsed in
cold running water to remove the traces of acids from the surface of the components.
CHECK NOTE:
No. oil should float on the surface of the cold running water

FROM TO by

TITLE:
CHECK NOTE:
There should be no oil or grease traces on the cleaned components.
2 Dry in open air

After taking out the components from the solvent cleaning tank, hang the components in the
components hanging area for 10 minutes.
Check note:
There should be no solvent visible after drying.
3. Alkaline soak cleaning:
a. Soak the components in the alkaline soak cleaning tank for 5 minues.
b. Maintaining the temperature at +/- 5 C
c. Wash in two stage coid running water.
CHECK NOTE
.
a.. No oil traces / droplete should be seen on the components after the
components are washed in the cold running water.
b. No. oil should float on the alkaline cleaning bath.

FROM TO by

TITLE:
Solution required Temp. Time

a. Degreasing castic sode + metal 60 to 70*C 5-10 min
b. Water rinsing Running water Room Temp. imme
Hydrochloric acid
c Cleaning Room Temp. 2-3 min
1/4 ltr + 11 ltr water
d. Water rinsing Runner water Room Temp. imme
e. Desolution rimsing Water + sodium cynaide Room Temp. imme

5 - 10%
f. Zinc plating Rectified 8 - 18 AMP - 35 - 40*C 20 min
400V current.
g. Water rinsing Runner water Room Temp. imme
Liquid chromate + water

h. Passivation Room Temp. 2 -3 minu
10 ml for 1 ltr of water
I. Water rinsing Runner water Room Temp. imme
j. Drying Dryier 60 - 70 *C 20 min
k. Inspection Visual & for thickness for
plating
TIN PLATING : Process of treatment is as shown:
1. Solvent Cleaning
a. The solvent cleaning is to be carried out at ambient temperature
b. Take the required quantity of wired components for solvent cleaning. Immerse the
components in the solvent cleaning bath and shake them for 5 minutes.
c. Cleaning take out the components from the solvent cleaning tank and allow them
to dry in open air.
d. Now the solvent cleaning is completed.

FROM TO by

TITLE:
Approval Sib-Contractors will be issued Work Instruction to carry out special proess as per our
requirements. The same will be verified and approved with change. If required. By Divi.Head
1. Process Qualification : By conducting trial
2 Procedure to carryout : As per Work Instruction

the process
3 Monitoring the Process : By Sub contractors
Phosphating (Lubrication, Bondelite) : Applicable to M S Plates

1. Put 50 to 100 pcs of Plates in the basket / jig.
2. Basket / jig is rolled in solution of bath
3 After setting time the basket is moved to another bath
4. Process treatment is shown below:
a.. Degreasing : Alkaline degreasing in heated tank
Temp. 80 - 100C Time: 10-15 minutes.
b. Rinsing : In running water
c. Derusting : Hydrochloric acid 33% commercial acid
in PVC Tank. Time: 10 - 15 minutes
d Rinising : In running water
e Phosphating : Phoscoat - "c" (Zinc) liquid concentration 5 to 6% for one liter water.
Add 50 - 60 ML phoscoat liquid. Time : 15 - 25 Minutes.
Temperature : 70 - 90 Degree Centigrade
f. Rinising : In running water
g. Passivation : Dichromate (seal phos) concentration one liter for 10 ml of mater

h. Rinising 1 to 2 Minutes
PLATING : Zinc Plating : Applicable to M.S. Plate
1. Put 5 to 6 Kgs of components to the basket.

2. Basket is rolled/agitate in the bath
3. After setting time, the basket is moved to another bath.
4. Process of treatment is as shown

FROM TO by
WORK INSTRUCTION
Peenya, Bangalore

TITLE:
CARBORISING / TEMPERING (CASE HARDENING)

REQUIRED CASE DEPTH : 0.15 - 0.25 MM AT 550 HV 0.5
CORE HARDNESS : 380-450 HV 10
SL.No. OPERATION DES. FURNANCE MEDIA CONTROL PARAMETER
1 Wiring / Loading By Manual using One over other vertically
16-18 Gauge wire Temperature: 89 +/-10*C
2 Carborising In cyanide salt bath Time : 30 - 60 min. from loading
time. Cyanide: 10 -12%
3 Austenising In cyanide salt bath Directly from
Carburising temp.
4 Quenching salt / oil quench Temp.4-70 deg.c. for oil
150 - 180 deg for salt quench.
Quench Time min.10 min
5 Inspection Rock well m/c Qty: 10 Nos

with 60 Kg. Load /HV min 78 HRA / 650 HV
Temp: 170 +/- 10 deg.
6 tempering In forced air circulation
Time: 2 HRS Min.
furnace / salt bath
7 Inspection 630-700 HV2/78-81 HRA,

I.. Surface Hardness By HV / HRA QTY 30 Nos per heat.
ii. Case depth BY HV 015-020 mm at 550 HV 0.5
iii. Core hardness BY HV QTY:1 No./heat 380-450 HV 10
QTY: 1 N0./HEAT

FROM TO by
Peenya, Bangalore
ISSUE : A DATE OF ISSUE : 2012 01 23 REF . NO : A-CMD-WI-7519

TITLE : FLOW CHART FOR MATERIAL CHANGE FROM A TO B IN INJECTION MOULDING MACHINE
SL NO ACTIVITY RESP ACTIVITY RES
ACCEPTED - MOVE THE

1 TAKE 5 COMPONENTS FROM MOULD TO RACK
RUNNING MOULD FOR LIR
REJECTED - MOVE THE MOULD
TO TOOL MAINT FOR
2 REMOVE THE BALANCE MATL:A RECTIFICATION
FROM THE HOPPER & TO BE KEPT IN
THE SAME BAG (ie MATERIAL & GRADE)
AND TO BE SEALED.
3 CLEAN THE HOPPER USING

COMPRESSED AIR / COTTON WASTE
SAME COLOUR : PURGE THE MATL: A

4 TO REMOVE THE MATERIAL FORM USING PP MATL & PURGE PP
BARREL INCREASE SHOT WT, INJECTION MATL USING MATL B
SPEED TO MAX. LEVEL AND ZONAL
TEMPERATURE ( 250 - 260°C)
DIFFERENT COLOUR: DO THE PURGIN
ACTIVITY AS IN SAME COLOUR & RE
NOZZLE, SHUT OFF VALVE
CLEAN & FIT BACK
5 TAKE 15 SHOTS OR TILL THE
CONTAMINATION / BLOCK DOTS OR
ELEMINATED FORM THE NEXT LOADED
MOUILD IN MATL.B &SCRAP THE COMPT.
6 TAKE FRESH SHOTS FULLY FILLED NO

SHORT MOULD.PART Wt. SHOULD BE
RECORDED IN FIR
7 IF FIR OK
CONTINUE PRODUCTION
LEGEND :-
OPERATOR MATERIAL MOVEMENT TOOL SETTER SUPERVISOR
FIR -FIRST OFF INSPN. REPORTLIR - LAST OFF INSP MATL: A - RUNNING MAMATL:B- NEXT LOAD MATERIAL

HARI BHARGO PEENYA WORK INSTRUCTION
REV : 00 DATE OF REV : 2014 01 23 PAGE : 1 OF 2
TITLE: STANDARD PRESS TOOL SETTING PROCEDURES FOR PRESS TOOLS.

FOR CONVENTIONAL PRESSESS, FINE BLANKING MACHINES & FOR
DIE CUSHION.
1. Wipe Mlc. Bed, bottom face of ram, top and bottom of tool and parallel block if used.
2. Check alignment of all slug-clearance openings in all lower die members with
corresponding openings in bed and parallel block.
3. Set stroke length as per tonnage requirement.
4. Bring ram down by hand to its lowest point and inserts shank of upper shoe in ram.
5. Adjust ram to shut height of tool.
6. Place clamps or bolts in position for securing lower shoe. But do not tighten bolts,
7. Tighten ram bolts to hold shank or Top plate in contact with ram
8. Tighten all bolts or clamps to secure bottom plate, tighten opposite rather than adjacent
bolts or clamps to equalize pressure.
9. Adjust ram so that the shortest punch will enter die a minimum distance to ensure
travel of slugs (or blanks) below the straight. Tighten ram adjustment screws.
10. Raise ram, lubricate all cutting edges and moveing parts, lubricate pillar and bushes.
11. Try out die by hand by inching for uniform punch and die clearance with plastic sheet /
paper instead of stock material.
PREPARED BY: APPROVED BY:
SIGN & DATE: SIGN & DATE



DIE CUSHION.
12. Cut a small number of stampings, Inspect for cut bands, burrs and
dimensional and other standards.
13. Install and adjust safety devices.
14. Check and tighten all bolts holding Mlc. Bed, once in a week.
For presses using pnematic die cushions the following procedure shall be followed:
a) Place 4 pins/Rods on the die cushion bolster holes.
b) Ensure the Pins/ Rods are on the same bed height, this can be adjusted with
die cushion valve.
c) Atleast 9.5mm are pre travel shall be allowed on the drawings before the tool on th work.
d) Clamp the tool on the machine.
e) Start with low pressure and increase the pressure gradually as required.
f) Cushion should not be operated in excess of its reted capacity.
Procedure for Fine Blanking Tool setting:
Before setting the tooling on the fine blanking the required shut height between the tool
platten must be roughly adjusted, the shut height distances vary with the type of table in use
(fixed - moving - combine). The upper table can beadjusted through a distance of 80mm.

WORK INSTRUCTION
Peenya, Bangalore


DIE CUSHION.
1) Place the required adoptor ring & pressure pads in the fine blank press.
2) Set the tool on top lower press table & lightly clamp the die set down.
3) Raise the ram to top dead centre (TDC) using the ausillar ram motor & temporary clamp
the die set to the upper table.
4) Raise the ram to bottom dead centre (BDC) & guide the material to be blanked between
the punch & die.
5) Again raise the ram the auxillary motor & clamp the material firmly in the tool.
6) Firmly clamp both halves of the die set to the upper & lower table respectively.
7) Using either single stroke or impulse stroke run the machine & lower the upper table
accordingly until the component is just blanked from the strip.
In order to adjust the shut height, one of the two buttons table up or table down must be pressed,
the height set can be read often the scale set above the safety guard.

WORK INSTRUCTION
Peenya , Bangalore.
ISSUE: A DATE OF ISSUE : 2012 01 23 REF . NO : A-CMD-WI-7509
REV : 00 DATE OF REVISION : 2012 01 23 PAGE NO : 1 OF 2

TITLE WORK INSTRUCTION IN CASE OF STOPPAGE OF MACHINE
INJECTION MOULDING :
Following instructions are to be followed by all moulding operators in case of
unplanned stoppage such as power failure etc.,
IF POWER FAILURE IS 15 to 60 MINUTES DURATION

---- Do not operate the machine
---- Put ON the heating
---- Wait till temperature reaches the processing limits
---- Purge out material which was in the barrel
---- Check for all parameters
---- Produce 5 components & Compare with reference sample
---- If Okay continue the production
---- If not inform the supervisor for further action
IF POWER FAILURE IS EXCEEDING 60 MINUTES

---- Carry out the sequence of operations mentioned above by maintaining barrel
temperature 15 to 20 Degree more than the processing temperature.

For materials like Acetal & PVC increase the temperature only by 5 to 10 Degree
above the processing temperature.
STOPPAGE OF MACHINE BEFORE LUNCH BREAK OR DUE TO ANY OTHER REASON
---- Stop the Material feeding to the barrel
---- Empty the barrel by producing the components or by purging out the material if any
---- Compare last component with Reference sample, If Okay keep the components
in accepted bin or else reject it
---- Close the mould in Mould setting mode
---- Switch OFF the motor
---- Keep the heating in ON condition
STARTING OF MACHINE AFTER LUNCH BREAK OR DUE TO ANY OTHER REASON
---- Switch ON the motor
---- Check for all parameters
---- Open material feeding and purge out material for 2 to 3 Shots
---- Apply Mould release agent if necessary
---- Produce 5 samples & compare with Reference sample, If Okay continue production
If not inform the supervisor for further action
REVISION BRIEF DESCRIPTION OF CHANGE AUTHORISED / DATE

From To

WORK INSTRUCTION
Peenya , Bangalore.
ISSUE: A DATE OF ISSUE : 2012 01 23 REF . NO : A-CMD-WI-7509
REV : 00 DATE OF REVISION : 2012 01 23 PAGE NO : 2 OF 2
TITLE WORK INSTRUCTION IN CASE OF STOPPAGE OF MACHINE
COMPRESSION MOULDING :
In case of Power failure
---- Wait till the processing temperature is achieved

---- Eject the component / Material in the mould
---- Proceed with production
STOPPAGE OF MACHINE BEFORE LUNCH BREAK OR DUE TO ANY OTHER REASON
---- Clean the core & cavity thoroughly by blowing air
---- Compare last component with Reference sample, If Okay keep the components
in accepted bin or else reject it
---- Close the mould in Mould setting mode
---- Switch OFF the motor
---- Keep the heating in ON condition
---- Switch OFF the Preheater
STARTING OF MACHINE AFTER LUNCH BREAK OR DUE TO ANY OTHER REASON
---- Switch ON the Motor & Preheater
---- Check for all parameters & Mould condition
---- Clean the core & cavity thoroughly by blowing air
---- Apply Mould release agent if necessary
---- Produce 5 samples & compare with Reference sample, If Okay continue production
If not inform the supervisor for further action
REVISION BRIEF DESCRIPTION OF CHANGE AUTHORISED / DATE

From To


REVISION: 00 DATE OF REVISION: 2012 01 23 PAGE No. 1 OF 1
TITLE: WORK INSTRUCTION FOR OPERATION & FIXTURE SETTING ON BELLOMATIC
WELDING MACHINE I & II
1 Load the fixture on the two halves of mounting plate and align with two dowel pins..
2. Place the Teflon sheet on the heating plate
3. Set the temperature , timers & heating in the panel board as per the process
control chart. .
4. Ensure the system pressure for 80 psi. If the system pressure is below 80 psi, then stop
the production.
5. Load components to be welded in holding fixture. .
6. Refer Process Control Chart for usage (if any) of floats.
7. Switch on the machine.
8. Ensure the air pressure is between 5&7 Kg/cm2 before starting
8. Once set parameters established, take 5 samples & get set-up approval from QAD.
9. After acceptance proceed production else inform supervisor for further action.
10. Close the glass door while heating and welding.

FROM TO by

REVISION: 00 DATE OF REVISION: 2012 01 23 PAGE No.1 OF 1
TITLE:
WORK INSTRUCTION FOR PELLETISING OPERATIONAL SEQUENCE
1 Clean the machine before starting.
Change the inserts (letter) as per Work Instruction A-CMD-WI-7508 (Pellettising weight
2 details)
3 Adjust the limit switch "4" for required weight as per display chart.
Pour the specified grade of material as per A-CMD-WI-7508 in the hopper, material flow
4
will be on gravity.
Take few samples of pellets and weigh the pellet for the weight (If required, adjust the limit
5
switch 4) .
6 Ensure the system pressure for 40 to 60 kg/sq.cm
7 Keep the pellets in a tray, close the bins.
8 Continue the production in auto cycle.
9 Check frequenltly for pellet weight.

FROM TO by

REVISION: 00 DATE OF REVISION: 2012 01 23 PAGE No.1 OF 1
TITLE: WORK INSTRUCTION FOR TOOL SETTING FOR
COMPRESSION MOULDING
1 The Coupler shall be mounted on the plunger of the machine..
2. The adopter shall be mounted on the mould if required.

3. The moulding tool with the adopter shall be mounted on the loading device of the machine in
closed condition.
4. Push the mould inside in such a way that Adopter & Coupler aligns.
5. Asbestos sheet for insulation shall be provided between the bed of machine and mould and
the ram of the machine and mould.
6. Switch LS 20 shall be adjusted for plunger movement.
7. Ram shall be closed.
8. The mould shall be clamped and tightened.
9. Heater connections shall be given to the mould and put ON as per Operation Standard
10. Opening adjustment, slow down, ejection, mould safety, locking tonnage and breathing
stroke shall be adjusted using LS1,LS2,LS2A,LS3,LS4 & LS 4A.
11. Transfer speed shall be adjusted for transfer movement of the plunger.
12. Transfer pressure shall be adjusted depending upon the weight of the compnent and flow of the
material for transfer moulds.
13. Locking tonnage shall be given using pre moulding force setting and locking force setting
with their respective limit switches.
14 Curing period shall be adjusted depending upon the component.

15 Raw material / Pellets shall be preheated if required as per the following matrix.
1 KW 2.5 KW
Compression Moulding 90 to 120 Seconds 60 to 90 Seconds
Transfer Moulding 120 to 150 Seconds 90 to 120 Seconds
16. Preheated pellets shall be put into the Pots/Cavities in the mould.
17 The operator shall check for any defects during production and report the same to the
Line Inspector / Supervisor.
FROM TO by

TITLE: WORK INSTRUCTION FOR TOOL SETTING IN
INJECTION MOULDING MACHINES (SP SERIES)
1 The Moulding Tool shall be mounted on the machine in closed condition by means of
Tie bars and eye bolt.
2. The mould shall be clamped & tightened and adopter and coupler shall
be used wherever applicable.
3. Water cooling and hot water connections shall be made depending upon the type
of raw material.
4 Setting of the mould shall be done and checked for travelling, opening, closing and Ejections
These shall be set by their respective controls.
5. Barrel setting: Barrel plunger shall be aligned to the centre of the sprue bush of the mould
after cavity locking tonnage.
6. Material Pre-heating: As per Operation Standard.
7. Barrel cleaning : As per Work instruction A-CMD-WI-7519
8. Barrel Heating: Barrel heating shall be done according to the material used and
temperatures to be maintained at the different zones of the barrel shall be as per
the Operation Standard..
9. Shot Weight shall be as specified in the Operation Standard.
10 Injection period & Injection Pressure shall be as specified in the Operation Standard.
11 Cooling period shall be as per the Operation Standard.
12. The operator shall check for any defects of the component and of the machine setting during
production and report for the same to the Supervisor / Line inspector.
13. The mould shall be unloaded and kept back in Mould Rack after production (duly oiled)

FROM TO by

TITLE: WORK INSTRUCTION FOR TOOL SETTING IN
INJECTION MOULDING MACHINES (FR SERIES)
1 The Moulding tool shall be mounted on the machine in closed condition by means of
Tie bar and eye bolt.
2. The mould shall be clamped & tightened and adopters and couplers shall be used
wherever applicable.
3. Water cooling and hot water connections shall be made depending upon the type
of raw material used.
4 Setting of the mould shall be done and checked for travelling, opening, closing and Ejections
These shall be set by their respective controls.
5. Barrel setting is automatic, when the mould is locked.
6. Material Pre-heating: As per Operation Standard.
7. Barrel cleaning : As per Work instruction A-CMD-WI-7519
8. Barrel Heating: Barrel heating shall be done according to the material used and
temperatures to be maintained at the different zones of the barrel shall be as per
the Operation Standard.
9. Shot Weight shall be as specified in the Operation Standard.
10 Injection period & Injection Pressure shall be as specified in the Operation Standard.
11 Cooling period shall be as per the Operation Standard.
12. The operator shall check for any defects of the component and of the machine setting during
production and report for the same to the Supervisor / Line inspector.
13. The mould shall be unloaded and kept back in mould rack after production (duly oiled)

FROM TO by

TITLE : WORK INSTRUCTION FOR TOOL SETTING IN D110 MACHINE
1 The moulding tool shall be mounted on the machine in closed condition by means of
Tie bar and bolts
2 The mould to be aligned by using Adopter & Coupler .
3 Cooling / Hot water connections shall be made depending upon the type of
mould ( Refer Operation Standard )
4 Setting of the mould shall be done by checking for all parameters like Open & Close,
Ejection travelling, Injection , etc., & The same will be SAVED in the system
During repeated loadings RECALL the stored datas from the system and proceed.
5 Material preheating : As per Operation Standard
6 Barrel Cleaning : As per Work Instruction N-CMD-WI-7519
7 Barrel Heating : Barrel heating shall be done according to the material used and
temperatures to be maintained at different zones of the barrel shall be as per Process
Control Chart / Operation Standard.
8 Shot weight shall be as specified in Operation Standard
9 Injection period & Injection pressure shall be adjusted depending upon the weight of the
component and raw material used, as per Operation Standard
10 The operator shall check for any defects of the components and the machine setting
during production and report for the same to the Supervisor / Line inspector.
11 The mould shall be unloaded and kept in Mould rack after production ( Duly applying Anti
corrosion wax coating spray).
REVISION DETAILS SIGN & DATE

FROM TO
K INSTRUCTION
A - CMD - WI - 7520
MACHINE
by means of
pen & Close,
per Process
weight of the
hine setting
y applying Anti
SIGN & DATE

Peenya, Bangalore
TITLE : WORK INSTRUCTION FOR PELLET DISPLAY CHART

NO OF
MATERIA PELLETS
L ID ON PER WEIGHT OF
SL .NO COMPONENT CUSTOMER MATERIAL COLOUR PELLETS SHOT EACH PELLET
1 AUMA HOUSING 1NO1NC PAD THD 311 BLACK I 1 35 ± 2
2 AUMA HOUSING 2NO2NC PAD THD 311 BLACK I 1 25 ± 2
3 INSULATION WASHER ABB THD 311 BLACK I 1 20 ± 2
4 VALVE BODY 107 BIL CN 3918 BLACK X 8 58 ± 1
7 COVER SOLENOID DENSO THD 111 BLACK U 3 56 ± 2
8 COMP. MOULDED PULLEY SUESSEN THD 311 BLACK I 6 62 ± 2
9 CONNECTION BLOCK ABB THD 311 BLACK I 1 30 ± 2
10 CONTACT BASE EML PAD THD 111 BLACK U 1 48 ± 2
NOTE 1. DIAMETER OF PELLET - 48 mm
2. LENGTH OF THE PELLET WILL BE VARIED TO SUIT THE WEIGHT OF THE PELLET
SIGN & DATE SIGN & DATE

TITLE : WORK INSTRUCTION FOR PELLET (WEIGHT) DISPLAY CHART

SL .NO COMPONENT MATERIAL COLOUR CUSTOMER SHOT WEIGHT SYMBOL
1 BODY TOP & BOTTOM THD 311 BLACK GECAIL 175 - 185 Gms I
2 AUMA HOUSING 1NO1NC THD 311 BLACK PAD 35 - 40 Gms I
3 AUMA HOUSING 2NO2NC THD 311 BLACK PAD 25 - 35 Gms I
4 INSULATION WASHER THD 311 BLACK ABB 20 - 25 Gms I
5 VALVE BODY 107 CN 3918 BLACK BIL 220 - 230 Gms X
8 COVER SOLENOID THD 111 BLACK DENSO 150 - 170 Gms U
9 COMP. MOULDED PULLEY THD 311 BLACK SUESSEN 320 - 330 Gms I
10 CONNECTION BLOCK THD 311 BLACK ABB 30 - 40 Gms I
11 CONTACT BASE EML THD 111 BLACK PAD 40 - 50 Gms U
NOTE 1. DIAMETER OF PELLET - 48 mm
2. LENGTH OF THE PELLET WILL BE VARIED TO SUIT THE WEIGHT OF THE PELLET

Aditya Auto Products & Engg. (I) Pvt. Ltd

TITLE : WORK INSTRUCTION FOR PELLET IDENTIFICATION

SL.NO MATERIAL IDENTIFICATION ON PELLETS
1 TX 311
A
2 T H D 111
U
3 T H D 311
I
4 C N 3918
X
5 TX 315T
S
6 OTHERS
K
7
N
8
D

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Die Inspection Maintenance Plan

(Inspection Period) Monthly Production

Die Maintenance Press Department

After inspection maintenance, fill in

2 According to the die cycle, fill in

ISSUE : A DATE OF ISSUE: 2012 01 23 REF.No.A-CMD-WI-7517

TITLE: WORK INSTRUCTION FOR SELF LIFE ITEMS.

1. The following items are classified as SELF LIFE items.

1. Araldite - Customer supplied material.

2. Phenolic moulding compound - like Bakelite Moulding Power, etc.

For Backelite materials / Phenolic Moulding Compounds,

REVISION Brief Description of Change Authorised date

ISSUE : A DATE OF ISSUE: 2012 01 23 REF.No.A-CMD-WI-7516

1. The packing of products shall be the responsibility of the Despatch Supervior.

2, The packing of components are as per the annexure enclosed.

REVISION Brief Description of Change Authorised date

ISSUE : A DATE OF ISSUE: 2006 01 25 REF.No.A-CMD-WI-7515

2. Materials under inspection and rejected items to be identified seperately and to be

7. Use safety devices wherever necessary.

8. Self life items are to be identified seperately.

REVISION Brief Description of Change Authorised date

ISSUE : A DATE OF ISSUE: 2012 01 23 REF.No.N-CMD-WI-7513

1. Mount the printing pads on the machine with adjustable screws.

1. Temperature 180°C - 200°C

3. Adjust the Depth.

4. Adjust the stroke Length for correct orientation of Printing.

7. Keep the printed components neatly in plastic trays.

8. Scrap the rejected components.

REVISION Brief Description of Change Authorised date

ISSUE : A DATE OF ISSUE: 2012 01 23 REF.No.A-CMD-WI-7512

3. Place the fixture on the table'

6. Adjust the stroke length.

7. Take sampe impression on the component.

9. Cure the component in open atmosphere for 24 hours.

10. Rejected components to be scraped.

REVISION Brief Description of Change Authorised date

ISSUE : A DATE OF ISSUE : 2012 01 23 REF . NO : A - CMD - WI - 7523

REVISION : 00 DATE OF REVISION : 2012 01 23 PAGE NO : 1 OF 1

TITLE : WORK INSTRUCTION FOR POST CURING OF

VALVE BODY 367 COMPONENTS IN POST CURING OVEN

1 Set the Temperature controller TC 061 of preheating oven to 170 ±10°C

7 At every 1Hr interval readings to be noted in POST CURING MONITORING CHART.

11 Pack 80 components with seperators & liners in a box.

12 Move the components for secondary operations.

REVISION DETAILS SIGN & DATE

SIGN & DATE : SIGN & DATE :

1 FR BODY LHD 120 psi 280 ±10°C 4.0 mm 4.0 mm

2 FR BODY TBI 120 psi 270 ±10°C 4.2 mm 4.6 mm

3 FR BODY 597 80 psi 265 ±10°C 4.0 mm 4.2 mm

4 FR BODY 607 80 psi 265 ±10°C 4.0 mm 4.2 mm

5 FR BODY 680 80 psi 265 ±10°C 4.0 mm 4.2 mm

6 FR BODY 1023 75 psi 265 ±10°C 3.8 mm 4.0 mm

7 FR BODY 1142 75 psi 265 ±10°C 4.0 mm 4.2 mm

8 FR BODY 1537 75 psi 265 ±10°C 4.0 mm 4.2 mm

9 FR BODY 1402 70 psi 270 ±10°C 3.4 mm 3.6 mm

10 FR BODY 1419 70 psi 265 ±10°C 4.0 mm 4.2 mm

11 FR BODY 792 70 psi 265 ±10°C 4.0 mm 4.2 mm

12 FR BODY 711 65 psi 265 ±10°C 4.0 mm 4.2 mm

SIGN & DATE : SIGN & DATE :