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10. Synopsis
10.1 Relevance:
10.4 Objective:
1) Establish all Processes from C.I. Casting to Machining for HOUSING -TRANS CASE
COVER FRONT.
2) Prepare all the Document Related to development process. ie (PPAP,APQP,SPC)
3) Design & Manufacturing the All fixture and the Receiving Gauges for the HOUSING -
TRANS CASE COVER FRONT
4) Obtaining cycle time required to executing the all Process.
5) Calculate Production rate per month, which can fulfillment of customer Requirement.
10.5 Methodology:
1. Develop the Casting supplier and getting sample casting from it.
2. Testing the chemical and physical properties which can satisfy the customer requirement
3. Prepare the Production Part Approval Process (PPAP) Document for Casting.
4. Prepare Process sheet and Analysis operation for the Machining
5. Design & Manufacture the Fixture as per Operation.
6. Prepare the tooling list and Gauges Required for Machining & Inspection Purpose.
7. Prepare the Production Part Approval Process (PPAP) Document for Machining
8. Prepare Initial Sampling Inspection Report.
9. Calculate cycle time required to full finish the part.
10. Dispatch all Sample part to the customer.
11. Analysis the Production Capacity During one month.
12. Correct the Procedure If any Defect Occurs at customer End.
10.6Activity chart:
Sr. Aug- Sep- Oct- Nov- Dec- Jan- Feb- Mar- Apr-
No Activity / Month 2018 2018 2018 2018 2018 2019 2019 2019 2019
1 Literature review
Prepare APQP
2
Documents
Process Flow Diagram
3
For all Processes
Casting Sample From
4 the Approved Supplier
& Testing
Prepare PPAP For
5
Casting Process
Prepare Process Sheet
6
For Machining
Fixture Designing &
7 Manufacturing For the
Machining
Machining and
8 Inspection of Sample
part
Prepare PPAP For
9
Machining Process
Dispatch sampled part
10
To Customer
11 Draft of Report
12 Submission of Report
Approximate cost for the Design, Analysis and Manufacturing of product is around
80000 INR.
1. Design lab with different design software’s like Auto Cad, UG,
2. C.I. Casting Suppler.
3. Material Testing Lab.
4. VMC, CNC, CMM machine.
5. Fixture and Cutting Tools.
6. Gauges and Instruments.
Signature of Student
Signature of Guide
10.10 References:
[1] Mats Bagge, Process planning for precision manufacturing, ISSN 1650-1888Copyright ©
Mats Bagge 2014.
[2] Mateja Karničar Šenk, Peter Metlikovič, Matjaž Maletič, Boštjan Gomišček, Development
of New Product/Process Development Procedure for SMEs, Organizacija, Volume 43,DOI:
10.2478/v10051-010-0009-y, Number 2, March-April 2010.
[3] Kapil Mittal, Prabhakar Kaushik , Dinesh Khanduja, Evidence of APQP in quality
improvement: An SMEcase study, ISSN 1750-9653, International Journal of Management
Science and Engineering Management, 7(1): 20-28, 2012.
[4] A.R.Dandekar, G.S.Joshi , A.P.Shrotri, S.B.Khandagale, A Review Of Application Of Some
Product Development Techniques Applied In Engineering Industry, IJRET: International
Journal of Research in Engineering and Technology ,eISSN: 2319-1163 | pISSN: 2321-7308.
[5] Dr.M.Arasu, Development Of Quality Cost System In Cast Iron Foundries, Foundry Journal,
Vol.51, No.6, pp. 36 - 40, July 2005.
[6] Mr. Siddalingswami. S. HiremathDr. S. R. Dulange Advanced Techniques IN Casting
Defects And Rejection Analysis: A Study In An Industry, Novateur Publications, International
Journal Of Innovations In Engineering Research And Technology [IJIERT], ISSN: 2394-
3696,VOLUME 2, ISSUE 9, SEP.-2015.
[7] prof. Ing. Tomáš Elbel, doc. Ing. Jiří Hampl, Diagnostics And Casting Quality Control
,Edition: first, 2013 ,Number of pages: 177.
[8] DaimlerChrysler Corporation, Ford Motor Company, General Motors Corporation
Production part approval process (PPAP) Fourth Edition March 2006. Copyright 2006.
[9] Breaks india, Supplier Quality Assurance Manual (SQAM) Rev 2, 2009.