STANDARD OPERATING PROCEDURE - COMPANY NAME

COMPONENT NAME:

COMPONENT NO:

I. MACHINE :CHECKS/METHODS

III. OPERATION (INTERNAL GRINDING)

CNC GRINDING M/C: 560.01(CNC INTERNAL GRINDING)

A) BEFORE START OF PRODUCTION

A) OPERATING METHODS
WHAT TO DO !
1. Check coolant level at the start of shift visually. 2.
Check Oil level in the chiller unit at the start of shift.
It should be within level marked on level indicator.
1. Inspection of received Component
3.Check movement of clamping jaws.

5. Declamping the components.

If point falls in yellow zone or on the

border of gren and yellow zone

if the point falls in red zone.

Open the door manually, hold component with hand,operate

the declamp switch by hand to declamp component.

Proper clamping avoids

accident/improves required
quality parameters.

GAUGE

GAUGE No.

Hard jaws

To run the machine

automatically

Quill

Diamond dresser

Declamping will make the

component ready for removal
from the machine.

PIN DIA 7 mm

Setting Ring for air gauge

Air plug gauge

free.

Plug gauge dia

31.05 +0.021/-0.000

Setting ring dia 31.05

RECORD

10

Master gear

INSPECTION FREQUENCY

Cell member will continue the operation

Cell member will check the earlier machine parts,machined after the last
checked part. If all these falls either in green or yellow zone,he will set
the machine and continue the operation.
If any of the earlier parts checked is found to be outside
specification,the cell member will approach process engineer or process
engineer for advice.

TOOL NO.

1
1set

As per part programme NO. O 1200

PROCESS MONITORING CHART

VII. MACHINE SETTING PROCEDURE

1.Run dresser touch programme (O 0212), job touch programme (O 0312) in auto cycle and machine will store the values automatically.
2. Clean
component gears M3.5 with cloth for proper resting of clamping and dialing pins.
3.Set
the coolant nozzles in the component bore.
4.Put correction in wear offset 02, keep the machine in single block mode and run the programme no. O 1200
5. Check size and give correction in wear offset 02.
6.Check taper
and readjust strokes.
7.After getting
the taper ok,run the machine in auto mode (prog. no. O 1200) and maintain required bore size .
8. Grind new component and ensure all quality parameters.
9. Get the component checked from quality assurance department and receive setting ok slip.

Cell member will take one more reading.If next point falls in green
zone,he will continue the operation.
If the next point falls in yellow/red zone,cell
member will reset the machine.

QTY

C Plot X-bar, R-chart

No. of readings
2
1
1
1
2
1
1
1

TOOL DESCRIPTION

Grdg. Wheel 40x28x12.7

S.NO.

Ensure wheel guard covered the wheel, remove the component

correct position avoids
and pins with hand for self inspection and after inspecting put accident. Placing component
in proper bin keeps it dent
it into the proper material bin.

BORE DIAMETER 31.05 +0.021/+0.00

Time Schedule For Readings to Be Taken In Shift For Pre Control Chart
Shift A
Shift B
Time
Time
6:30am
2:30pm
7:30am
3:30pm
8:30am
4:30pm
9:30am
5:30pm
10:30am
6:30pm
11:30am
7:30pm
12:30pm
8:30pm
1:30pm
9:30pm
ii) Actions to be taken by cell members:-

V. TOOLING DETAILS

B) PRODUCT CHECK :

i)The cell member will measure the concerned parameters as per frequency defined under SOP and plot it on a computer.

If this point fall in green zone

Cleaned teeth and face

deliver controlled composite
error .

Removal after wheel guard in

6. Removal of components from machine and

replacement in bin/ trolley

SPECIFICATION

Pick up the component,check for any hard projected material

on face of bigger diameter and check that component is free
from oil/scaling.

1.Check the component on machine, put correction in R-parameters if size is under and
rework the component.
2. Place the component in rejection area after marking with RED paint, if
component with projected size is over than the specified limits.
material and scaling can
3. Contact shop supervisor, if problem persists.
cause excess composite error
4.Contact maintenance/ tool control cell in case of machine or tool related
problem.
WHY TO DO !

Close machine door by hand, press cycle start switch on

control board.

II. TOOL :CHECKS/METHODS

B) DURING PRODUCTION
1.Check proper flow of coolant to avoid glazing of
grinding wheels and to get required finish/size.
2.During self inspection, if the readings going at
extreme limit of the size, put correction in wear offset
02.
3.Keep watch during dressing and change the dresser
if abnormal dressing noise is heard or size variation
observed.
4.Must ensure time to time the setting of air gauges
with masters.

HOW TO DO !

Lift the component, declamp jaws, locate component in

jaws,insert three pins one by one between component teeth
and each jaw, butt the face of component with the faces of
jaws,clamp jaws over pins by operating clamp switch.

B) DURING PRODUCTION
3. Component clamping
1.Ensure sufficient flow of coolant on the cutting zone.
2.Check
any abnormal sound from machine.
3.Ensure
proper clamping of component to avoid accident during
grinding cycle.
4.Ensure dialing
over pin with in 0.01 mm
4. Grinding cycle

A) BEFORE START OF PRODUCTION

1.Check the cutting points of diamond dresser visually.
2.Dress
the grinding wheel one time automatically in prgramme
no.O 1002.
3.Ensure
dressing amount of 0.02 mm.
4.Check
grinding wheels for minimum diameter.
5.keep the
inspection tooling neat and clean and put on table near
machine.
6.Check
the HF spindle rpm (18000)

IV. IN CASE OF ABNORMALITY.REACTION PLAN

A

pick up the cloth, remove dust/chips/any loose material from

both gear teeth and resting face of bigger diameter.

2. Cleaning of component

SOP NO. 123

VIII. TOOL SETTING PROCEDURE

VI. SAFETY INSTRUCTIONS

1. Donot run the machine in auto mode while door is open.
2 Wear personal protective equipment.
3. Keep the area coolant free near machine to avoid the accident due to
slippage.
4. Ensure the normal sound and noise level of machine.
5. Ensure the sufficient lux level near machine .
6. Cutting feed override should not be more than 100%
A. First Aid Measures For coolant

Eye Contact

Rinse thoroughly with water ( use an eyewash atleast for 15 min.). If the
Irritation persists then Consult the Doctor.

Skin Contact

Wash Off with water and mild soap thoroughly.

Do not induce vomitting consult the doctor.

Ingestion
1. Select the grinding wheel (sr. no. 1) ,hard jaws (sr. no. 2), diamond dresser (sr. no. 4),
Not applicable as the concentrate is not volatile.
Inhalation
and grinding quill (sr. no. 3) as mentioned in the tooling detail.
B.
Actions
In
Case
of
Fire
Type of Fire Extinguisher
2. Select the inspection tooling (sr. no. 6 to 11) as mentioned in the tooling detail.
Operate emergency Switch and Switch off main supply
Oil Fire = Foam Type
3. Get the all tooling issued from Tool crib .
Remove flammable material if lying nearby
Electrical Fire = Dry Powder & CO2 type
4. Clean the grinding quill thoroughly, tight in spindle, tight wheel on spindle.
Inform the supervisor or dial "200" or raise the alarm
Paper, Rubber, Wood Fire = Water type
5.Mount the jaws and bore with grinding wheel to accomodate diameter over pins.
Operate near by portable fire extinguisher
Gas Fire = CO2 Type
6. Mount the
Note: Don't use water & Foam type fire Extinguisher in case of electrical fire
dresser in dressing steady and tight it with allen key.
IX. GENERAL INSTRUCTIONS
7.Dress the new wheel in prog. no. 1102 till the removal of outness.

1. Select the grinding wheel (sr. no. 1) ,hard jaws (sr. no. 2), diamond dresser (sr. no. 4),
and grinding quill (sr. no. 3) as mentioned in the tooling detail.
2. Select the inspection tooling (sr. no. 6 to 11) as mentioned in the tooling detail.
3. Get the all tooling issued from Tool crib .
4. Clean the grinding quill thoroughly, tight in spindle, tight wheel on spindle.
5.Mount the jaws and bore with grinding wheel to accomodate diameter over pins.
6. Mount the
dresser in dressing steady and tight it with allen key.
7.Dress the new wheel in prog. no. 1102 till the removal of outness.
1. Keep the machine neat and clean.
2. Check the air presure in air gauges to avoid rejection.
3. Record readings as per inspection frequency at III(B).

If the cell member suspects any

abnormality in the process.

Cell member will check the parts in between the checking frequency that
is specified by SOP.He will record this point and take action as specified
above as required
Revision History

DATE

10.12.2009

CHANGE LOCATION

CHANGE

FORMAT CHANGED

Revision History
APPD BY

DATE

CHANGE LOCATION

CHANGE

APPD BY.

COMPONENT DETAILS
OPN. NO.

182

MATERIAL

20Mn Cr5

<SC>
Sheet
Date (Origin)

15.03.2010

RECORD IN PMC
RAW MATERIAL

10.10.2010

Plot X-bar, R-chart

F/398727

Significant Characterestic
Critical Characterestics
01 OF 01
1/7/2007

Revision no.

Revision date

10.10.2010

Prepared By

G S Toor
Ajay Gupta

Approved By