• Dies and Tools are prepared for production by Die-Shop is inspected critically. Sample plaster cast also taken and laid out for dimension to suit drawings. Necessary corrections are done till the sample cast and cavity depths and templates fitting assured by inspection. Dies and Tools release notes are prepared to load the dies and tools for production.
• When the Dies are loaded on hammer, the first sample is tried out. The same is critically inspected for dimensions, matching, forging defects, etc. If any variation observed, the same is rectified. Unless sample forging obtained is acceptable stage, production of forging is not started.
• When the samples are found satisfactory, hot control inspector allows the forging production. He assures the quality during the production after every 15 minutes. Dimensional report also prepared during the production. One number after every one hour of production till the die run production is over. Forge Shop Supervisor is responsible for the quality of the forging.
• Forged components are inspected 100% visually. Green inspection report is also prepared for the lot and accepted forging is issued for flash grinding.
• After grinding, the green forging is issued to heat treatment department for normalising or hardening and tempering. First sample lot is heat-treated, grain structure, hardness, etc. checked. Once the sample lot found acceptable, batch lot is heat-treated. Normalised parts are checked for hardness 15%. For hardened parts first quenched, hardness verified then proceeded for tempering. Heat Treatment cycles are followed as required for different parts. 100% hardness is checked on the hardened and tempered parts. Hard or soft parts are separately kept in bins for reprocessing. Accepted forging (heat treated is issued for shot blasting)
• Shot blasting operation attended on all heat-treated accepted forging to make the components scale free. The Shot Blasted components are visually inspected if properly shot blasted or not. If not, they are shot blasted again. Visual and dimensional inspections are carried out then after.
• Segregation is done during the visual inspection of the shot blasted parts for forging defects. Dimensional inspection of the lot is also carried out for important dimensions. Necessary grinding work of minor nature is attended. Quality Assurance confirms the quality of the lot, dimensionally and visually. Grain structure, hardness, BHN, spark or spectral tests are also done.
• If required, crack detection is also carried out on partial lot or 100% to detect the crack on magnaflux inspection machine. Care is taken that not a single part is having surface defects in general and crack or lap in particular.
• Coining, Qualifying, Gauging, Colour (priming), etc., also attended as per specifications.
Quality assurance accepts the lot after careful inspection then the components are released for dispatch. Dimensional report of samples taken at random from the lot being dispatched and metallurgical test certificate also being prepared for the same lot.
Records of production and quality control inspection are prepared at every state of production, processing and quality assurance.
We are ISO 9001-2000 Company certified by QMI Canada. We got our certification in Dec-2003.