1. Press machine Process & parameters....

1. Machine allocation for the NPD Trials, prelaunch , PPAP Run

3. TYPES OF PRESSES -
 MECHANICAL PRESS
A - CRANK PRESS
B - SCREW PRESS
C - KNUCLE JOINT PRESS
D - LINK PRESS
 HYDRAULIC PRESS

4. HPS SHOP
1.1200 Ton
2.1000 Ton
3. 800 Ton
4. 630 Ton
5. 500 Ton
6.360 Ton
SPM SHOP
7.125 Ton
8.110 Ton
9.75 TON
10.63 Ton
11.50 Ton
12.30 Ton
12.10 Ton

5.  Mechanical
power press. A mechanical
power
press shears, punches, forms, metal or
other
materials by means of tools or dies
attached
to slides or rams. Metal working
occurs
by placing stock on a bottom die and
striking
it with a top die.

6. Switch of the main power supply
Switch of the emergency buttons
Use the safety block (Cylinder)
Ensure floor area clean from oil, water
Ensure rotary spotting wheel at bottom
before starting work
Ensure safety rope in working
Ensure all PPE's to be used by all persons as
applicable
Apron
Hand
Gloves
Safety Shoes
Ear Plug

7. 1 ‘S’ SORTING (Seiri)Sorting out required and not required items and
eliminate which are not required
2 ‘S’ Simplify (SEITON) place for everything and everything’s in it place
3 ‘S’ Shine (Seiso)Made workstation neat and clean.
4 ‘S’ Standardization
(Seiketsu)
Constantly maintain the state of cleanliness and
hygiene of our workshop
5 ‘S’ Sustain (Shitsuke)Make a habit of applying the 5’S in the section
and follow workshop rules

9. RAM
CONNETING
ROD
PNUMATIC
PANEL
OPERATING
PANEL
TWO
HAND OPERATING SWITCH
SAFETY
BLOCK

10. SHOPFLOOR
PIT AREA
C
O
L
U
M
N
C
O
L
U
M
N
B E D
CROWN
HYDRAULIC OIL TANK
AIR RECEIVERS
SLIDE
OPERATING PANELAIR SYSTEM PANEL
MAIN ELECTRICAL PANEL
PRESS FOUNDATION
FLYWHEEL
CONNECTING
RODS
1
1
2
3
4
5
6
7
8
LUB OIL TANK
9
10
11
Hydraulic motor
LUB
MOTOR
MAIN
MOTOR
SLIDE
MOTOR
BELT12
1000T PRESS SPECIFICATIONS
Sr No. POINTS SPECIFICATION
1 CAPACITY OF MACHINE 1000 TON
2 MACHINE NO. 5912891
3 NAME OF MACHINE POWER PRESS
4 MAKE YANGLI
5 MODEL NO. JD36-1000-SM
6 YEAR OF MFG. 2012
7 MAIN DRIVE MOTOR (KW/HP) 132KW/175HP
8 SPM 12-16 IDEAL
9 WORKING AIR PRESSURE 4-6 BAR
10 SLIDE STROKE 500MM
11 BOLSTER AREA 2200 x 4000 MM
12 SHUT HEIGHT 1190 MM

11. 1 AIR OPERATED
2 OIL OPERATED
3 SPRING OPERATED
PNEUMATIC DIE CUSHIONS ARE USED FOR OBTAINING BLANK HOLDING
PRESSURE FOR DRAWING, FORMING OR OTHER SPECIAL PRESS WORK.
 DIE CUSHION CONSISTS OF ONE OR MORE PNEUMATIC CYLINDERS , EACH WITH
PISTON, PISTON ROD AND TOP PAD.
WHEN COMPRESSED AIR IS ADMITTED TO THE CYLINDERS, THE CUSHION
MOVES UPWARD POSITION.
DIE CUSHIONS PROVIDE AN INFINITE RANGE OF PRESSURE ADJUSTMENT FOR
VARING SHEET THICKNESS.

13. 1. THIS MECHANISUM IS USED TO INCREASE OR DECREASE THE SHUT HIEGHT OF THE PRESS AS PER
THE REQUIREMENT OF DIE HEIGHT.PROCEDURE FOR SLIDE ADJUSTMENT TO SET THE DIE ON PRESS

•SET COUNTER BALANCER PRESSURE AS PER DIE WEIGHT CHART
1. START MAIN MOTOR
2. TAKE RAM AT TDC ON INCH MODE
3. TAKE SLIDE ADJUSTMENT AT ON MODE
4. SLIDE ADJUSTMENT SIGNAL WILL GLOWS (GREEN) ON RH PANAL
5. TAKE SLIDE UP OR DOWN AS PER DIE SHUT HT. REQUIREMENT

17. 1. Vernier caliper
Vernier Caliper used for measuring of linear dimensions, like length, Inside dimensions, Outside dimensions, height,
depth…etc.
Types are
1. Vernier Caliper
2. Vernier height gauge
3. Vernier depth gauge
1.Vernier Caliper
a. Simple/Mechanical Vernier caliper
b. Dial Vernier caliper
c. Digital Vernier caliper
1. First Part locate properly & clean the surface of which dimensions are measuring.
2. Check the dimension properly, compare it with std. known value
3. Accuracy of digital V.C is more than simple Vernier

24. Start up check sheet
Set up Approval check sheet
Machine Log Book
Kaizen

25. To find out the abnormality
based on 7 category
identify the abnormality
Does the operator
solve the
abnormality
NoNo YesYes
Put the red tag and
write the description as
per abnormality found
Put the White tag and
write the description
aspen abnormality
found
Record the white tag
description in
abnormality register and
enter countermeasure,
target date ,
responsibility
Record the Red tag
description in
abnormality register
( date of detection ,
detector)

26. JH 0&1
Initial
cleaning
With
meaning
Initial cleaning with meaning ,
finding abnormalities,
SOC (sources of contamination),
Hard to access area (HTA)
JH -2
Countermeasure

Against

abnormality
Countermeasure
against abnormality,
SOC,
HTA, and performing kaizen,
OPL

JH -3
Prepare

tentative
Standard
Prepare
tentative standard to allow
basic
condition to be place &device the
method
of visual control

27. JH -4
General inspection
To understand the functioning of the machine.
To understand Technical systems (hydraulic,
pneumatics, electrical) of the machine
To make the operator machine competent
JH -5
Autonomous
Inspection
To prevent the machine from technical faults and
keep machine condition high
To work according to rules and regulations.
To make the operator process competent
JH -6
Standardization
Standardized the activity which worked previously in
JHstep 1, 2 and 3
JH -7
Autonomous
Management
Records all the machine failures and prepare
corrective action plan.
To make the operator business competent

35. SET UP MATRIX
Doc. No.   QD/PR/02
Rev. No.   00
U-301 Projects PARTS Rev. Date   01.01.2014
Sr. No. Part Name/Part No. Operation
Parameters Unit 
SPM 500T 630T 800T 1000TMachine Bed Size mm
1
REINF D PILLAR UPPER RH/ LH
0101EU300320N/690N
Draw (10)
Required Shut Height On Press mm
- - -
  
Cushion Pin height above the bolster bed. mm  
Cushion Pressure kg/cm2  
Cushion Pressure Mpa  
Cushion Pin Size(DiaxLength) mm  
No. of cushion pin required Nos  
Cushion hole dia. mm  
Riser Spcification (LenghthXWidthXHeight) mm  
No. of Riser required Nos  
Packing Specification(LengthXWidthXHeight) mm  
No. of packing required Nos  
Trim, Cam trim , Cam Pier &
Pierce
(20)
Required Shut Height On Press mm
- -
779.60±0.50
-
887.7±0.50
Packing Specification(LengthXWidthXHeight) mm Not Applicable Not Applicable
No. of packing required Nos Not Applicable Not Applicable
Packing Specification(LengthXWidthXHeight) mm Not Applicable 3100 X 1800 X 110
No. of packing required Nos Not Applicable 1
Flanging & Restrike
(30)
Required Shut Height On Press mm
-
780.0±0.50
- -
885.2±0.50
Packing Specification(LengthXWidthXHeight) mm Not Applicable Not Applicable
No. of packing required Nos Not Applicable Not Applicable
Packing Specification(LengthXWidthXHeight) mm Not Applicable 3100 X 1800 X 110
No. of packing required Nos Not Applicable 1
Cam Trim, Cam Part off & Cam
pierce
(40)
Required Shut Height On Press mm
-
780.0±0.50 781.40±0.50
- -
Packing Specification(LengthXWidthXHeight) mm Not Applicable Not Applicable
No. of packing required Nos Not Applicable Not Applicable
Packing Specification(LengthXWidthXHeight) mm Not Applicable Not Applicable
No. of packing required Nos Not Applicable Not Applicable

36. 2
PNL EXTN RR BODY SIDE OUTER RH/ LH
0101EU300310N/670N
Draw
(10)
Required Shut Height On Press mm
- - -
875.90±0.50 883.60±0.50
Cushion Pin height above the bolster bed. mm 150.00±0.50 130.00±0.50
Cushion Pressure kg/cm2 2.0 -2.5 2.00
Cushion Pressure Mpa Not Applicable Not Applicable
Cushion Pin Size(DiaxLength) mm 38.5X545 38.5X545
No. of cushion pin required Nos 15 15
Cushion hole dia. mm 40+5.00/-0.5 40+5.00/-0.5
Riser Spcification (LenghthXWidthXHeight) mm Not Applicable Not Applicable
No. of Riser required Nos Not Applicable Not Applicable
Packing Specification(LengthXWidthXHeight) mm 3100 X 1800 X 110 3100 X 1800 X 110
No. of packing required Nos 1 1
Trim & Pierce
(20)
Required Shut Height On Press mm
- - -
878.6±0.50 886.10±0.50
Packing Specification(LengthXWidthXHeight) mm Not Applicable Not Applicable
No. of packing required Nos Not Applicable Not Applicable
Packing Specification(LengthXWidthXHeight) mm 3100 X 1800 X 110 3100 X 1800 X 110
No. of packing required Nos 1 1
Flanging
(30)
Required Shut Height On Press mm
-
780.0±0.50 778.20±0.50 877.60±0.50
-
Packing Specification(LengthXWidthXHeight) mm Not Applicable Not Applicable Not Applicable
No. of packing required Nos Not Applicable Not Applicable Not Applicable
Packing Specification(LengthXWidthXHeight) mm Not Applicable Not Applicable 3100 X 1800 X 110
No. of packing required Nos Not Applicable Not Applicable 1
Pierce, Part off, Cam Pierce,
Cam Trim & Flanging
(40)
Required Shut Height On Press mm
-
780.0±0.50 780.50±0.50 877.0±0.50 888.90±0.50
Packing Specification(LengthXWidthXHeight) mm Not Applicable Not Applicable Not Applicable Not Applicable
No. of packing required Nos Not Applicable Not Applicable Not Applicable Not Applicable
Packing Specification(LengthXWidthXHeight) mm Not Applicable Not Applicable 3100 X 1800 X 110 3100 X 1800 X 110
No. of packing required Nos Not Applicable Not Applicable 1 1

37. 3
REINF PNL SIDE TO HD LMP PNL RH/LH
0102FU300020N/ 010N
Draw ( common die for Rh &
LH )
(10)
Required Shut Height On Press mm
- -
768.20±0.50 868.40±0.50 874.50±0.50
Cushion Pin height above the bolster bed. mm 150.00±0.50 160.00±0.50 160.00±0.50
Cushion Pressure kg/cm2 2.0 -2.5 2.0 -2.5 2
Cushion Pressure Mpa Not Applicable Not Applicable Not Applicable
Cushion Pin Size(DiaxLength) mm 38.5X545 38.5X545 38.5X545
No. of cushion pin required Nos 19 19 19
Cushion hole dia. mm 40+5.00/-0.5 40+5.00/-0.5 40+5.00/-0.5
Riser Spcification (LenghthXWidthXHeight) mm Not Applicable Not Applicable Not Applicable
No. of Riser required Nos Not Applicable Not Applicable Not Applicable
Packing Specification(LengthXWidthXHeight) mm 3100 X 1800 X 110 3100 X 1800 X 110 3100 X 1800 X 110
No. of packing required Nos 1 1 1
Trim & Flange Down (2
STAGE)
(20)
Required Shut Height On Press mm
- -
846.80±0.50 942.70±0.50 853.0±0.50
Packing Specification(LengthXWidthXHeight) mm Not Applicable Not Applicable Not Applicable
No. of packing required Nos Not Applicable Not Applicable Not Applicable
Packing Specification(LengthXWidthXHeight) mm Not Applicable 3100 X 1800 X 110 3100 X 1800 X 110
No. of packing required Nos Not Applicable 1 1
Trim , Pierce & Cam Flanging
(30)
Required Shut Height On Press mm
- -
778.2±0.50 945.10±0.50
-
Packing Specification(LengthXWidthXHeight) mm Not Applicable Not Applicable
No. of packing required Nos Not Applicable Not Applicable
Packing Specification(LengthXWidthXHeight) mm Not Applicable 3100 X 1800 X 110
No. of packing required Nos Not Applicable 1

38. 4
CROSS MBR PNL FRONT BOTTOM
0102AU300230N
Draw (10)
Required Shut Height On Press mm
- - - -
872.8 ± 0.50
Cushion Pin height above the bolster bed. mm 140.00±0.50
Cushion Pressure kg/cm2 2.0 -3.0
Cushion Pressure Mpa Not Applicable
Cushion Pin Size(DiaxLength) mm 38.5X545
No. of cushion pin required Nos 26
Cushion hole dia. mm 40+5.00/-0.5
Riser Spcification (LenghthXWidthXHeight) mm Not Applicable
No. of Riser required Nos Not Applicable
Packing Specification(LengthXWidthXHeight) mm 3100 X 1800 X 110
No. of packing required Nos
1
Trim & Pierce (2 STAGE)
(20)
Required Shut Height On Press mm
- -
770.8±0.50 864.4 ± 0.50 878.3 ± 0.50
Packing Specification(LengthXWidthXHeight) mm Not Applicable Not Applicable Not Applicable
No. of packing required Nos Not Applicable Not Applicable Not Applicable
Packing Specification(LengthXWidthXHeight) mm Not Applicable 3100 X 1800 X 1103100 X 1800 X 110
No. of packing required Nos Not Applicable
1 1
 
Note:- 1) Process parameters shown below will be the same for all the operations.
Air Pressure of air feed (Kg/cm2) 5.00 - 7.00 Counter Balance Pressure (Kg/cm2)3.50 - 4.50 Air Pressure of Clutch (Kg/cm2)5.00 - 6.00
 
Air Pressure of air feed (MPA) 0.50 - 0.70 Counter Balance Pressure (MPA)0.35 - 0.45 Air Pressure of Clutch (MPA)0.50 - 0.60
Rule:-
1) Start Production only after verification of the setup checksheet by Production Supervisor/ Engineer.
2) All the machine parameters should be set in a specified value during checksheet verification if not in specified limit, set the parameter as per adjustment instruction.
3) Production Supervisor/ Engineer will correct the abnormality immediately and allow operator to run the machine.
4) FREQUENCY:1)AT THE START OF EVERY SHIFT 2)TOOL BREAK DOWN/ REMOVED 3) MACHINE BREAK DOWN/ABNORMAL CONDITION
PREPARED BY:- APPROVED BY:-
Rev No.: Rev Date Revision Summary Reason for Revision
        
        
Format No : QF/PR/14 Rev. No:00 Rev. Date:01.01.2014

40. Start up check sheet
Set up check sheet
First piece inspection report
In process inspection report
Production log book
Rejection approval note
Poka yoke check sheet

45. NC MANAGEMENT PROCEDURE
 NC HANDLING
Doc. No.
QD/ASSY/01
Rev. No.
03
Rev. Date
01.01.2018
S r . N o .
1
2
3
For mat No: QF/ A S S Y / 18 R ev. No: 0 2 R ev. Dat e: 0 1. 0 1. 2 0 18
R e v . N o . R e v . D a t e R e v is io n S u mma r y R e a s o n F o r R e v is io n
01 24.09.2014
1) Timel ine for ea ch a cti vi ty is defi ned.
2) Reference forma t no/ Document No. i s added.
3) Ins tead of Putti ng ta g on pa rts, ma rki ng the defects by marker, da te,shift a nd
rea son for defect a dded.
1) To ha ve a clea r understa nding of the acti viti es when to do.
2) To unders ta nd which docume nt or forma t to be refe r.
3) To a void mi spl acing of ta g,( For identi fi ca ti on a nd tracebility of the pa rts)
02 04.12.2014 Concern Feedback me chanis m a dde d.
It wa s not defi ned in the Flow Cha rt wha t shoul d be the a cti on if found a defect
generated a t other sta ti on
03 01.01.2018
Defecti ve Pa rt rework criteria changed with incluiding repai r & Da ily DWM gra ph
updati on for rework & rejecti on acti vity a re added
It is cha nged dependi ng upon the modifi ed proce dure with montoring da ily rework &
rejecti on sta tus
TRACK Components Ltd, Pune
NON CONFORMANCE HANDLING FLOW CHART
Purpose :- Handling of NC Parts Produced and detected at Source
Scope :- For all Component(s) and Assembly(s).
P r e p a r e d B y N a me & S ig n : - A p p r o v e d B y N a me & S ig n : -
Defect detected at final inspectionstation
Move the part to Yellow bin.
Put the ok mark on the part with underinspection
tagging, send the part in next station & update the
Update the summery of Daily defect
No(nahI)
Rework / Reapair authorised
Fill therework/repair& re-insepection record (irvak-/
Yes(ha)
Resp:Line Operator
No(nahI)
Defect detected at work station or and abnormal
Resp:Qua lity Inspector
Update the stage wise defect monitoring
Resp:Quality Inspector
Resp:Line Operator
Inform to Production engineer and update
Update the Concernin Concern Feedbak Resp:Quality Inspector
Kept the part in the rework station and
Resp:Line Operator
Rework / Repair authorised
Do the rework/repair as perRework / Repair authorised
Give the part to Inspection station for Rework / Repair authorised
Do the Re-inspection of partFinal & In-process Inspector
Yes(ha)
Writethe "Reject " On the part and also put
the Reject tag on the part and put in red bin
Final Inspector
Final Inspector & Rework/Repair
Update the Rejection approval Sheet (paT-
Dispose the scrap in scrap yard by verifying
Line Supervisor
Final Inspector
Update theRework graph every day LineEngineer
Update theRejection graph every day with LineEngineer
Markthe defect on part, date, shift and machine no. on Markthe defect on part, date, shift as defined. (paT-
Isthe part Reworkable/Repairable,
Isthe part reworked / repaired
Rework / Reapair authorised
Final & In-process Inspector
Update the summery of Daily defect Monitoring
LineEngineer
Final & In-process Inspector