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Master List of Work Instructions for Engine & Gear Box

Work Instructions for Engine & Gear Box

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Master List of SOP for Engine & Gear Box

SOP for Engine & Gear Box

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 Department - En

Title of Document

Work Instructions for Engine & Gear Box

ons for Engine & Gear Box

ENGINE RIGGING

ENGINE DE- RIGGING

ENGINE TESTING

NUMBER. MARKING M/c,BALL,PLUG & PIN FITMENT/ STAGE -1

TURN TABLE & TOD

PCN & SCREW PLUG FITMENT

BEARING SHELL FITMENT

CRANKSHAFT FITMENT

THRUST BEARING , BEARING SHELL & MB CAP FITMENT

BOLCK UNLOADING TO SHORT BLOCK LINE

CRANKSHAFT SUB ASSEMBLY

LOADING OF BLOCK & OIL PUMP FITMENT

MAIN BEARING CAP BOLT TIGHTNING

CRANKSHAFT TORQUE TO TURN & END PLAY CHECKING

REWORK IN / OUT

BUFFER

CAM SHAFT SUBASSEMBLY- BALL & GEAR FITMENT

FLYHWEEL HSG, FLYWHEEL,TG CASE SUBASSEMBLY

FLYWHEEL HSG SEAL FITMENT

TG CASE SEAL FITMENT

FLYWHEEL HSG & TG CASE SEALENT APPLICATION

FLYWHEEL MARKING

FLYWHEEL HSG UNLOADING

FIP & DRIVE HOUSING ASSEMBLY

VALVE FITMENT (HEAD SUB ASSY)

TURN OVER DEVICE

LOWER VALVE SEAT & VALVE STEM SEAL FITMENT

VALVE SPRING & UPPER VALVE SEAT FITMENT

REPAIR LOOP IN

MANUAL REWORK STATION

2 VALVE LEAK TESTING

4 VALVE LEAK TESTING

CROSS TRANSFER
REPAIR LOOP OUT

UNLOADING OF HEAD- All Models DAMPER SUBASSEMBLY-135LT3,HA57L135, C

FITMENT OF TIMING BACK PLATE,CAMSHAFT & IDLER GEAR FITMENT

FLYWHEEL HOUSING FITMENT

SEAL LEAK CHECKING & FITMENT OF FLYWHEEL & FLYWHEEL BRG,STOPPER FI

ENGINE ORIENTATION CHANGE & BRACKET FITMENT

TG CASE & FIP FITMENT

REWORK OUT

BUFFER

REWORK IN

DAMPER PULLEY & FIP BRACKET FITMENT

PISTON & CONNECTING ROD ASSEMBLY

FITMENT OF PISTON & CONROD & TIGHTNING

SHORT BLOCK TESTING

REWORK IN/OUT

BUFFER

SUMP SEALENT APPLICATION

OIL STARINER & SUMP FITMENT

BUFFER

FIP & COMPRESSOR LUBE PIPE FITMENT

ULOADING OF BLOCK TO LONG BLOCK LINE

UNLOADING OF BLOCK
CYLINDER HEAD & DAMPER PULLEY FITMENT

CYLINDER HEAD BOLT TIGHTENING

FITMENT OF ROCKER SHAFT ASSY AND OIL COOLER

DUMPER NUT FITMENT & TIMING SETTING & THERMOSTAT FITMENT

EXHAUST MANIFOLD & VENT PIPE FITMENT

TURBO MTG. & AIR COMPRESSOR SUB ASSY.

TAPPET SETTING & AIR COMPRESSOR FITMENT

REWORK OUT

TIMING SETTING ROTARY PUMP

REWORK IN

AIR INTAKE & WATER PUMP &WATER PUMP PULLEY FITMENT

INJECTOR FITMENT

INJECTOR CLAMP NUT , STARTOR MOTOR& EXHAUST ELBOW FITMENT

INJECTOR PIPE CLIP & BOOSTER PIPE & LEAK OFF PIPE

COOLENT ELBOW FITMENT ,ALTERNATOR & BELT TENSION

WATER & OIL WAYS LEAK TESTING

OIL FILLING & HP PIPE TORQUING & CLIP FITMENT

UNLOADING ENGINE

REWORK OUT

BUFFER

REWORK IN

BLOCK & CRANK SHAFT WASHING

CAM SHAFT WASHING

TG CASE / FLYWHEEL / FLYWHEEL HOUSING WASHING

CYLINDER HEAD WASHING

ENGINE DRESSING

ENGINE PAINTING

ENGINE PDI

INJECTOR GRADING

ENGINE REPAIR

NUMBER. MARKING M/c,BALL,PLUG & PIN FITMENT/ STAGE -1

TURN TABLE & TOD

PCN & SCREW PLUG FITMENT

BEARING SHELL FITMENT

CRANKSHAFT FITMENT

THRUST BEARING , BEARING SHELL & MB CAP FITMENT

BOLCK UNLOADING TO SHORT BLOCK LINE

CRANKSHAFT SUB ASSEMBLY

LOADING OF BLOCK & OIL PUMP FITMENT

MAIN BEARING CAP BOLT TIGHTNING

CRANKSHAFT TORQUE TO TURN & END PLAY CHECKING

REWORK IN / OUT

BUFFER

CAM SHAFT SUBASSEMBLY- BALL & GEAR FITMENT

FLYHWEEL HSG, FLYWHEEL,TG CASE SUBASSEMBLY

FLYWHEEL HSG SEAL FITMENT

TG CASE SEAL FITMENT

FLYWHEEL HSG & TG CASE SEALENT APPLICATION

FLYWHEEL MARKING

FLYWHEEL HSG UNLOADING

FIP & DRIVE HOUSING ASSEMBLY

VALVE FITMENT (HEAD SUB ASSY)

TURN OVER DEVICE

LOWER VALVE SEAT & VALVE STEM SEAL FITMENT

VALVE SPRING & UPPER VALVE SEAT FITMENT

REPAIR LOOP IN

MANUAL REWORK STATION

2 VALVE LEAK TESTING

4 VALVE LEAK TESTING

CROSS TRANSFER

REPAIR LOOP OUT

UNLOADING OF HEAD- All Models
DAMPER SUBASSEMBLY-135LT3,HA57L135, CRS
FITMENT OF TIMING BACK PLATE,CAMSHAFT & IDLER GEAR FITMENT

FLYWHEEL HOUSING FITMENT

SEAL LEAK CHECKING & FITMENT OF FLYWHEEL & FLYWHEEL BRG,STOPPER FI

ENGINE ORIENTATION CHANGE & BRACKET FITMENT

TG CASE & FIP FITMENT

REWORK OUT

BUFFER

REWORK IN

DAMPER PULLEY & FIP BRACKET FITMENT

PISTON & CONNECTING ROD ASSEMBLY

FITMENT OF PISTON & CONROD & TIGHTNING

SHORT BLOCK TESTING

REWORK IN/OUT

BUFFER

SUMP SEALENT APPLICATION

OIL STARINER & SUMP FITMENT

BUFFER

FIP & COMPRESSOR LUBE PIPE FITMENT

ULOADING OF BLOCK TO LONG BLOCK LINE

UNLOADING OF BLOCK

CYLINDER HEAD & DAMPER PULLEY FITMENT

CYLINDER HEAD BOLT TIGHTENING

FITMENT OF ROCKER SHAFT ASSY AND OIL COOLER

DUMPER NUT FITMENT & TIMING SETTING & THERMOSTAT FITMENT

EXHAUST MANIFOLD & VENT PIPE FITMENT

TURBO MTG. & AIR COMPRESSOR SUB ASSY.

TAPPET SETTING & AIR COMPRESSOR FITMENT

REWORK OUT

TIMING SETTING ROTARY PUMP

REWORK IN

AIR INTAKE & WATER PUMP &WATER PUMP PULLEY FITMENT

INJECTOR FITMENT

INJECTOR CLAMP NUT , STARTOR MOTOR& EXHAUST ELBOW FITMENT

INJECTOR PIPE CLIP & BOOSTER PIPE & LEAK OFF PIPE

COOLENT ELBOW FITMENT ,ALTERNATOR & BELT TENSION

WATER & OIL WAYS LEAK TESTING

OIL FILLING & HP PIPE TORQUING & CLIP FITMENT

UNLOADING ENGINE

REWORK OUT

BUFFER

REWORK IN

BLOCK & CRANK SHAFT WASHING

CAM SHAFT WASHING

TG CASE / FLYWHEEL / FLYWHEEL HOUSING WASHING

CYLINDER HEAD WASHING

ENGINE DRESSING

ENGINE PAINTING

ENGINE PDI
INJECTOR GRADING

ENGINE REPAIR

COMPONENT WASHING

MAIN CASING SUB ASSY. Heating & Bearing Press

MAIN CASING SUB ASSY( Number Punching & Sub assy)

MAIN SHAFT SUB ASSY -1

MAIN SHAFT SUB ASSY -2

SYNCHROPACK SUB ASSY Fitment Of Hub & Sleeve)

LAYSHAFT SUB ASSY( Gears Fitment)

INPUT SHAFT SUB ASSY ( Bearing Press & Locking)

INPUT SHAFT COVER SUB ( Oil Seal Press In Input Cover)

FORWARD FORK SUB ASLY

DRESSING ( Clutch Housing & Furnishing)

COUPLING( Assy Of Lay Shaft & Main Shaft & Selector Shaft)

SELECTOR TOWER SUB ASSY

BELL HOUSING SUB ASSY

REVERSE SELECTOR FORK

TESTING

LINKAGE SUB ASSLY

MAIN LINE STAGE -1

MAIN LINE STAGE -2

MAIN LINE STAGE -3

MAIN LINE STAGE -4

MAIN LINE STAGE -5

MAIN LINE STAGE -6

PTO ASSEMBLY

GEAR BOX ASSEMBLY PDI

GEAR BOX REWORK

KITTING OPERATION

WASHING COMPONENTS

SPECIFIC OIL HOLES WASHING AND AIR BLOW

OIL WAYS LEAK TEST

MB CAP TIGHTENING AND NO PUNCHING

SEMI FINISH LINE BORING CAM ,CRANK,IDLER , OP BUSH BORE AND FE &RE D

OP BUSH PRESSING

I FINISH LINE BORING CAM ,CRANK,IDLER , OP BUSH BORE AND FE &RE DOWE

FINISH MILLING FEF.REF OP BORE AND CAM COUNTER BORE

FINISH BORING LINER BORES ,FINISH MILLING HEAD FACE AND DOWELS REA

WASHING AND CRANK BORE DEBURRING

HOLE MILLINGAND REAMING TAPPET HOLES

ROUGH AND FINISH HONING LINER BORES

WASING LINER BORES AND AIR BLOW

LINER BORES GRADE CHECKING AND PUNCHING

MB CAP LOOSIENING
INJECTION FLOOD WASHING

CAM BUSH PRESSING

WELCH PLUGS PRESSING

WATER WAYS LEAK TEST

WASING AND LINER BORES OILING

LINER FITMENT

LINER PRESSING

LINER PROTURSION CHECKING

SPECIFIC OIL HOLES WASHING AND AIR BLOW

OIL WAYS LEAK TEST

MB CAP TIGHTENING AND NO PUNCHING

SEMI FINISH LINE BORING CAM ,CRANK,IDLER , OP BUSH BORE AND FE &RE D

OP BUSH PRESSING

I FINISH LINE BORING CAM ,CRANK,IDLER , OP BUSH BORE AND FE &RE DOWE

FINISH MILLING FEF.REF OP BORE AND CAM COUNTER BORE

FINISH BORING LINER BORES ,FINISH MILLING HEAD FACE AND DOWELS REA

WASHING AND CRANK BORE DEBURRING

HOLE MILLINGAND REAMING TAPPET HOLES

ROUGH AND FINISH HONING LINER BORES

WASING LINER BORES AND AIR BLOW

LINER BORES GRADE CHECKING AND PUNCHING

MB CAP LOOSIENING
INJECTION FLOOD WASHING

CAM BUSH PRESSING

WELCH PLUGS PRESSING

WATER WAYS LEAK TEST

WASING AND LINER BORES OILING

LINER FITMENT

LINER PRESSING

LINER PROTURSION CHECKING

GENERAL PURPOSE MACHINE

FINISH MILL ROCKER FACE,13.4 DOWEL HOLE

S/F MILL COMB. FACE, PARENT BORE

SPECIFIC HOLE WASH

V/S & V/G AIR LEAK TEST

HEAT ON V/S AREA & V/S PRESS

VALVE SEAT PRESSING

VALVE GUIDE PRESSING

FINISH MILL COMB. FACE

FINISH MILL IMF, EMF & INJECTOR BORE

INJECTION FLOOD WASHING

BALL PRESS UNIT

W/P PRESS

WATER WAYS OIL WAYS LEAK TEST

JOINT FACE REAR FACE MACHINING

TOP BOTTOM & FILLER ELBOW FACE MACHINING

GENERAL PURPOSE MACHINE

FINISH MILL ROCKER FACE& PROCESS DOWEL HOLE

S/F MILL COMB. FACE, PARENT BORE

SPECIFIC HOLE WASHING

V/S & V/G AIR LEAK TEST

HEAT ON V/S AREA

VALVE SEAT PRESSING

VALVE GUIDE PRESSING

VALVE SEAT & VALVE GUIDE MACHINING ,COM. FACE MILLING

FINISH MILL IMF, EMF & INJECTOR BORE

INJECTION FLOOD WASHING

STEEL BALL & WELSCH PLUG PRESSING

WELSCH PLUG PRESSING

WATER WAYS OIL WAYS LLEAK TEST

DEBURRING

HELICOIL FITMENT

FINAL INSPECTION

GENERAL PURPOSE MACHINE

FINISH MILL ROCKER FACE,PROCESS DOWEL HOLE

S/F MILL COMB. FACE, PARENT BORE

SPECIFIC HOLE WASHING

V/S & V/G AIR LEAK TEST

HEATING ON V/S AREA

VALVE SEAT PRESSING

VALVE GUIDE PRESSING

VALVE SEAT & VALVE GUIDE MACHINING ,FINISH MILL COMB. FACE

FINISH MILL IMF, EMF, INJECTOR BORE& INJECTOR FIXING HOLE MACHINING

INJECTION FLOOD WASHING

STEEL BALL & WELSCH PLUG PRESSING

WELSCH PLUG PRESSING

WATER WAYS OIL WAYS LEAK TESTING

FACING, CENTERING & REAR END OD TURNING

STRAIGHTENING

ROUGH TURNING OF ALL JOURNALS & FINISH TURNING OF FIRST JOURNAL

FINISH TURNING OFJOURNALS DIAMETERS, FINISH GROOVING & OIL GROOVI

KEYWAY MILLING

MILLING OF CAMS LOBES

GUN DRILLING

CROSS OIL HOLE DRILLING FE TAPPING, RE REAMING

HIGH PRESSURE WASHING - LONG OIL HOLE

INDUCTION HARDENING OF CAMS & JOURNALS

TEMPERING
STRAIGHTENING

RE-CENTRING,OIL HOLE DRILLING ON REAR END

GRINDING OF JOURNAL DIA & FRONT END DIA / THRUST FACE

GRINDING OF INLET & EXHAUST CAM LOBES

DEBURR CAM LOBES

CRACK DETECTION

INTERMEDIATE WASHING

INSPECTION ON ACCURATE

CAM LOBE LAPPING

PARKERISING

JOURNAL DIAMETER LAPPING

FINAL WASHING, OILING & FINAL INSPECTION

SPECIFIC OIL HOLES WASHING AND AIR BLOW

OIL WAYS LEAK TEST

MB CAP TIGHTENING AND NO PUNCHING

SEMI FINISH LINE BORING CAM ,CRANK,IDLER , OP BUSH BORE AND FE &RE D

OP BUSH PRESSING

I FINISH LINE BORING CAM ,CRANK,IDLER , OP BUSH BORE AND FE &RE DOWE

FINISH MILLING FEF.REF OP BORE AND CAM COUNTER BORE

FINISH BORING LINER BORES ,FINISH MILLING HEAD FACE AND DOWELS REA

WASHING AND CRANK BORE DEBURRING

HOLE MILLINGAND REAMING TAPPET HOLES

ROUGH AND FINISH HONING LINER BORES

WASING LINER BORES AND AIR BLOW

LINER BORES GRADE CHECKING AND PUNCHING

MB CAP LOOSIENING

INJECTION FLOOD WASHING

CAM BUSH PRESSING

WELCH PLUGS PRESSING

WATER WAYS LEAK TEST

WASING AND LINER BORES OILING

LINER FITMENT

LINER PRESSING

LINER PROTURSION CHECKING

GENERAL PURPOSE MACHINE

FINISH MILL ROCKER FACE,PROCESS DOWEL HOLE

S/F MILL COMB. FACE, PARENT BORE

SPECIFIC HOLE WASHING

V/S & V/G AIR LEAK TEST

HEATING ON V/S AREA

VALVE SEAT PRESSING

VALVE GUIDE PRESSING

VALVE SEAT & VALVE GUIDE MACHINING ,FINISH MILL COMB. FACE

FINISH MILL IMF, EMF, INJECTOR BORE& INJECTOR FIXING HOLE MACHINING
INJECTION FLOOD WASHING

STEEL BALL & WELSCH PLUG PRESSING

WELSCH PLUG PRESSING

WATER WAYS OIL WAYS LEAK TESTING

NUMBER PUNCHING - CAMSHAFT

MILL HF & SF AND DRILL, REAM & CHAMFER DOWEL HOLES

R MILL BEARING CAP WIDTH & R BORE LINER BORE FOR CLEARANCE

R & SF MILL FRONT FACE & REAR FACE

ROUGH LINER BORE & ROUGH COUNTER BORE TO DEPTH

ROUGH MILL CRANK HALF ROUND BORE

MILL BRG NOTCHES ON HALF ROUND BORE & MILL SIDES OF BRG REGISTER F

FINISH MILL SUMP FACE

ROUGH BORE CAM BORE

DRILL LONG OIL GALLERY HOLE & DRILL OIL HOLE FROM FRONT END TO DEPT

DRILL ø7 DOUBLE ANGLE WATER HOLES ON HEAD FACE

R & SF OC FACE & BOSSES, R & SF IP FACE & BOSSES AND SLOT MILL AT IP FA

SF OC FACE & BOSSES, C'BORE RECESS HOLES, CORE DRILL & REAM WP HOLE

DRILL VARIOUS HOLES ON OC FACE & IP FACE

R BORE IDLER BORE, R/SF/C'BORE/CHAMFER CAM BORES AND DRILL REAM & T

R BORE OP BORE AND DRILL & TAP VARIOUS LEFT OUT HOLES ON F/E, R/E & O

DRILL/HOLEMILL BEARING MOUNTING HOLES & DRILL SUMP FIXING HOLES

TAP BRD CAP & SUMP FIXING HOLES

DRILL BOLT HOLE ON HD FACE & AIR BLOW

DR & TAP VARIOUS HOLES ON HD FACE AND SPOT FACE DIP STICK

DR/CH/REAM/SPOT FACE IP FACE & DR WATER HOLE ON HEAD FACE

DRILL ø5 WATER HOLES INBETWEEN BARREL

DRILL & CHAMFER VARIOUS HOLES ON FRONT & REAR END

TAP VARIOUS MTG HOLES IN F/E & R/E

GENERAL PURPOSE WASHING

SPOT FACE, DRILL, HOLE MILL & REAM ANG DIP STICK HOLE ON IP FACE

DRILL STRAIGHT WATER HOLES ON HEAD FACE

DRILL & C'BORE ø4.3 WATER HOLE ON HEAD FACE & DRILL ø16 DOUBLE ANGL

DRILL ø4 WATER HOLE ON HEAD FACE & DRILL ø5 WATER HOLE IN IDLER

DRILL & C'BORE TAPPET HOLES

DRILL ø8 HOLE FROM CRANK BORE TO OIL GALLERY & DRILL ø18 STRAIGHT OI

DR ø8-1ST CR & DR, TAPPING, SF AND TAP TG 1/2" HOLE

DR,S'F & TAP INCL HOLE SUMP ON IP FACE & DR ø14 ANG HOLE ON SUMP FAC

MILL PCN SEAT FACE & DR/TAP VARIOUS HOLES AT SUMP FACE

S'FINISH FINISH & BROACH BRG TO WIDTH

GENERAL PURPOSE WASHING

ROCKER & COMBUSTION FACE ROUGH MILLING

ROCKER FACE SEMI FINISH MILLING

COMBUSTION FACE SEMI FINISH MILLING

PROCESS DOWEL HOLES & FRONT FACE ROUGH

IMF & EMF MILLING

BOLT HOLE DRILLING

PUSH ROD HOLE DRILLING

IMF WP & M8 TAPPING

ANGULAR WATER HOLE ON EMF

INJECTOR BORE & ANGULAR WATER HOLES

SPRINF SEAT & VALVE GUIDE

WPON ROCKER FACE

VALVE SEAT ROUGH

Washing Machine

MILL HF & SF AND DRILL, REAM & CHAMFER DOWEL HOLES

R MILL BEARING CAP WIDTH & R BORE LINER BORE FOR CLEARANCE

R & SF MILL FRONT FACE & REAR FACE

ROUGH LINER BORE & ROUGH COUNTER BORE TO DEPTH

ROUGH MILL CRANK HALF ROUND BORE

MILL BRG NOTCHES ON HALF ROUND BORE & MILL SIDES OF BRG REGISTER F

FINISH MILL SUMP FACE

ROUGH BORE CAM BORE

DRILL LONG OIL GALLERY HOLE & DRILL OIL HOLE FROM FRONT END TO DEPT

DRILL ø7 DOUBLE ANGLE WATER HOLES ON HEAD FACE

R & SF OC FACE & BOSSES, R & SF IP FACE & BOSSES AND SLOT MILL AT IP FA

SF OC FACE & BOSSES, C'BORE RECESS HOLES, CORE DRILL & REAM WP HOLE
DRILL VARIOUS HOLES ON OC FACE & IP FACE

R BORE IDLER BORE, R/SF/C'BORE/CHAMFER CAM BORES AND DRILL REAM & T

R BORE OP BORE AND DRILL & TAP VARIOUS LEFT OUT HOLES ON F/E, R/E & O

DRILL/HOLEMILL BEARING MOUNTING HOLES & DRILL SUMP FIXING HOLES

TAP BRD CAP & SUMP FIXING HOLES

DRILL BOLT HOLE ON HD FACE & AIR BLOW

DR & TAP VARIOUS HOLES ON HD FACE AND SPOT FACE DIP STICK

DR/CH/REAM/SPOT FACE IP FACE & DR WATER HOLE ON HEAD FACE

DRILL ø5 WATER HOLES INBETWEEN BARREL

DRILL & CHAMFER VARIOUS HOLES ON FRONT & REAR END

TAP VARIOUS MTG HOLES IN F/E & R/E

GENERAL PURPOSE WASHING

SPOT FACE, DRILL, HOLE MILL & REAM ANG DIP STICK HOLE ON IP FACE

DRILL STRAIGHT WATER HOLES ON HEAD FACE

DRILL & C'BORE ø4.3 WATER HOLE ON HEAD FACE & DRILL ø16 DOUBLE ANGL

DRILL ø4 WATER HOLE ON HEAD FACE & DRILL ø5 WATER HOLE IN IDLER

DRILL & C'BORE TAPPET HOLES

DRILL ø8 HOLE FROM CRANK BORE TO OIL GALLERY & DRILL ø18 STRAIGHT OI

DR ø8-1ST CR & DR, TAPPING, SF AND TAP TG 1/2" HOLE

DR,S'F & TAP INCL HOLE SUMP ON IP FACE & DR ø14 ANG HOLE ON SUMP FAC

MILL PCN SEAT FACE & DR/TAP VARIOUS HOLES AT SUMP FACE

S'FINISH FINISH & BROACH BRG TO WIDTH

 GENERAL PURPOSE WASHING

SOP for Engine & Gear Box

e & Gear Box

TOOL CHANGE PROCEDURE

COMPONENT LOADING & UNLOADING PROCEDURE- OPN 90

COMPONENT LOADING & UNLOADING PROCEDURE- OPN 20 & 30

REWORK & REJECTION COMPOMENT HANDLING PROCEDURE

REWORK INSTRUCTION SHEET

OP 70/80 MAZAK TOOL CHANGE PROCEDURE

OP 60- TOOL SETTING PROCEDURE OF CRANK, CAM, & REAMER

OP 70 MAZAK
REWORK PROCEDURE OF OIL PUMP CASE BORE DEPTH
OP 80-LINER BORE REWORK

OP 110-LINER BORE REWORK

OP 60 M/C RESTORATION AFTER POWER CUT

OP 60-REWORK PROCEDURE FOR OP BORE

OP-60 IDLER BORE REWORK

SET UP CHANGE PROCEDURE

SERIAL NUMBER PUNCHING PROCEDURE

REWORK PROCEDURE(BORE UNDER SIZE)

REWORK PROCEDURE (TAPPING)

COMPONENT LOADING & UNLOADING PROCEDURE- OPN 100

JOB SETUP CHANGE PROCEDURE OPN 100

JOB SETUP CHANGE PROCEDURE LEAKTESTING OP140 & WELCH PLUG PRESSI

TOOL SETTING PROCEDURE FOR ZOLLER ROOM SHOP-08

HONING TOOL SETTING PROCEDURE

FLOW CHART OF TOOL SETTING ON ZOLLER MACHINE

TOOL CHANGE PROCEDURE AT HONING

COMPONENT INSPECTION ON ACCURATE MACHINE (Opn-190)

FIFO FOR FINISH GOODS- Finish Machining

DO'S & DON’T'S FOR OPERATION NO. 190

INDUCTION HARDENING

CHEMICAL TITRATION / POITAGE CHECKING - PHOSPHATING PLANT-CAMSHAF

FINAL INSPECTION CHECK POINT SHEET

TOOL SETTING PROCEDURE FOR CENTER DRILL FRONT AND REAR END

TOOL SETTING PROCEDURE FOR MLLLING CUTTER FOR CAM LOBE

TOOL SETTING PROCEDURE FOR RH AND LH MILLING CUTTER

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

SET UP CHANGE PROCEDUREDURING MODEL CHANGE FROM H6 TO H4 AT OPE

HARDNESS CHECKING- ROCKWELL HARDNESS TESTER

HARDNESS CHECKING-MACRO VICKERS HARDNESS TESTER

COMPONENT CODIFICATION NUMBER

CONE CLEANING HMC MACHINE

MODEL (SET UP CHANGE )

MACHINE SAFE RUNNING AFTER PROGRAM CURRUPT

SOP FOR CMM INSPECTION

TOOL CHANGE IN AH50 MACHINE

TOOL CHANGE IN AH60 MACHINE

TOOL CHANGE IN AH70 MACHINE

PROCEDURE FOR REJECTION HANDLING

PROCEDURE FOR SWITCHING THE ZOLLER MACHINE ON-OFF

PROCEDURE FOR PRESETTING THE MILLING CUTTER ON ZOLLER MACHINE

PROCEDURE FOR TOOL LIFE MONITORING , AVAILABILITY OF PRESET TOOL & D

PROCEDURE FOR PRESETTING THE TOOL ON ZOLLER ROOM.

PROCEDURE FOR TOOL PRESETTING ON HAIMER MACHINE

PROCEDURE FOR PRESETTINGTHE MILLING CUTTER ON DIALING FIXTURE

PROCEDURE FOR ZOLLER MACHINE CALIBRATION

CUTTER CHANGE IN AB 30 MACHINE

TOOL LIFE RESETTING ON MAZAK

TOOL LIFE RESETTING ON BFW

CUTTER CHANGE IN AB 10 MACHINE

MACHINING COMPONENT AFTER POWER FAILURE

RECEIPT OF NEW TOOLS

CUTTER CHANGE IN AB 70 MACHINE

REGRINDING OF TOOLS

TOOL LIFE RESET In AH 100

TOOL LIFE RESET In AH 110

TOOLING INVENTORY MANAGEMENT

TOOL CHANGE ON CNC MACHINE

REWORK ON SPARKONIX MACHINE - SEMI FINISH HEAD

TAP RETRACT PROCEDURE IN MAZAK HMC

TOOL BREAKAGE REWORK

SOP FOR TRAINING OF NEW JOINED PERSON

TOOL CHANGE IN AH10,20,30 MACHINE

HOW TO OPERATE AB 10 MACHINE

CHECKING PROCEDURE FOR PERIODIC INSPECTION OF JIGS & FIXTURES

MACHINING COMPONENT AFTER SURFACE FINISH NG

REWORK ON SPARKONIX MACHINE - SEMI FINISH BLOCK

HOW TO START THE MAZAK MACHINE IN FANUC

QUILL HEIGHT SETTING IN AH10,AH20,AH30,AH50 MACHINE

SOP FOR JH ACTIVITY

OPERATION AH30 SHIFTING PROCEDURE IN AH 10 IN CASE OF MACHINE BREA

PROCEDURE FOR ARBOR MOUNTING IN MACHINE

MACHINE OPERATING PROCEDURE IN CASE OF COMPONENT STUCK IN CYCLE A

REWORK FOR GEAR NOISE

REWORK FOR TAPPET NOISE

REWORK FOR VALVE HAMMERING

REWORK FOR OIL & WATER MIX

REWORK FOR SMOKE HIGH

REWORK FOR OIL PRESSURE LOW

JOB SET UP PROCEDURE- Engine

RACI (RESPONSIBILITY, AUTHORITY, CONSULT, INFORM) CHART FOR DOCUME

FIFO FOR AGGREGATES DISPATCH

MANUFACTURING QUALITY MATURITY INDEX MQMI

REVIEW MECHANISM OF PREDICTIVE MAINTENANCE

ENSURING NRB & CIRCLIP BY PIKA PIKA
SENSOR
MAIN SHAFT
ENSURING STAGE
NRB -01
& CIRCLIP BY PIKA PIKA SENCOR
MAIN SHAFT STAGE -02
MODEL SELECTION FOR GEAR BOX TESTING

MODEL WISE CLUTCH HOUSING DESCRIPTION

LINKAGE SETTING & GB LOADING ON CONVEYORS

DRESSING & STUDS FITMENTS

CLUTCH HOUSING FITMENT

JOB SET UP PROCEDURE-Gear Box

CHECKING PROCEDURE FOR PERIODIC INSPECTION OF JIGS & FIXTURES

AMT GEAR BOX TESTING PROCEDURE

 01.03.14

Document No. Rev.no. Rev. Date

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P/EB/M/V/008 1 10.07.12

P/EB/M/V/009 1 10.07.12

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P/EB/M/V/012 1 10.07.12

P/EB/M/V/013 1 10.07.12

P/EB/M/V/014 1 10.07.12

P/EB/M/V/015 1 10.07.12

P/EB/M/V/016 1 10.07.12

P/EB/M/V/017 1 10.07.12

P/EB/M/V/018 1 10.07.12

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P/EB/M/V/021 2 10.10.12

P/EB/M/V/022 1 10.07.12

P/EB/M/V/023 2 10.10.12

P/EB/M/V/024 2 02.09.13

P/EB/M/V/025 2 02.09.13

P/EB/M/V/026 0 15.08.12
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P/EB/M/V/028 0 10.10.12

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P/EB/M/V/030 0 10.10.12

P/EB/M/V/031 0 10.10.12

P/EB/M/V/032 0 10.10.12

P/EB/M/V/033 0 01.11.12

P/EB/M/V/034 1 01.01.13

P/EB/M/V/035 0 1.12.12

P/EB/M/V/036 0 11.12.12

P/EB/M/V/037 0 11.08.13

P/EB/M/V/038 0 11.08.13

P/EB/M/V/039 0 11.08.13

P/EB/M/V/040 0 22.11.13

P/EB/M/V/041 0 23.11.13

P/EB/M/V/042 0 04.03.14

P/EA/M/V/001 1 10.07.12

P/EA/M/V/002 1 10.07.12

P/EA/M/V/003 1 10.07.12

P/EA/M/V/004 1 10.07.12

P/EA/M/V/005 1 10.07.12

P/EA/M/V/006 1 10.07.12
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P/EA/M/V/008 0 05.05.13

P/EA/M/V/009 0 15.05.13

P/EA/M/V/010 0 17.12.13

P/EA/M/V/011 0 01.02.14

P/EG/M/V/001 2 27.10.12

P/EG/M/V/002 1 10.07.12

P/EG/M/V/003 2 20.02.13

P/EG/M/V/004 5 27.07.13

P/EG/M/V/005 1 10.07.12

P/EG/M/V/006 1 10.07.12

P/EG/M/V/007 1 10.07.12

P/EG/M/V/008 0 10.10.12

P/EG/M/V/009 0 15.01.13

P/EG/M/V/010 0 27.07.13