Precision Engineering Complex

(PEC)

The Precision Engineering Complex, PIA's youngest division,

was created in 1978 to manufacture products for the
commercial aviation industry. Today, the PEC is a world-class
manufacturing enterprise, powered by state-of-the-art
machinery and technology, and an exceptional team of
engineers and technicians.
The PEC is a reliable supplier to Boeing Commercial Airplane
Group of USA, SNECMA of France, General Electric Aircraft
Engine of USA, Daimler-Benz Aerospace Airbus (formerly
Deutsch Aerospace) of Hamburg, and Fisher Advanced
Composite Components (FACC) of Reid, Austria. The PEC has
earned these contracts through transparent, competitive
bidding, and by adhering to consistent Quality Standards and
on-time delivery. Supplying products for the assembly lines
of global aviation heavyweights has garnered prestige and
international recognition for the PEC and it has emerged as a
truly great corporation.
Amongst the PEC's myriad achievements, was the
manufacture of a series of metallic parts that are used for
attaching overhead stowage compartments with the interiors
of A320/A321 aircraft. These parts were commissioned by
the FACC of Austria in 1993 and the PEC took up the
manufacturing challenge, resulting in many more contracts
over the years.
The unflinching support of PIA's Logistics and Procurement
divisions, over the years, has enabled the PEC to acquire raw
materials from FACC-approved sources in Europe and North
America. This backing has truly helped the PEC to fulfill its
mission of making one-time deliveries to global customers.

PRINTED CIRCUIT BOARD

(PCB)
 PCB Manufacturing:
The PEC is equipped with a modern PCB
manufacturing facility powered by state-of-the-art technology. The PCB
division has the capability of producing 80 square feet of Printed Circuit
Boards in a single shift operation. Customized PCBs can also be produced
according to customer specifications.

TYPES OF PCB:
• Single layer PCB
• Double layer PCB
• Multilayer PCB
• Flexible or ribbon layer PCB

LAYERS OF PCB:
• Top layer
• Bottom layer
• Drill layer

WORK ORDER:
The user can provide the pattern of PCB in four
different ways.
1. Same PCB which user wants.
2. By giving any logic diagram of circuit which has to be implemented
on PCB.
3. By giving any PCB design using CAD software.
4. By providing Photo tool.

MANUFACTURING PROCESS:
Drilling & routing:
 A/c to the required PCB design CNC program in
develop and using CNC machine Up to three PCB’s can be drilled and
routed at the same time.

Through Hole Process:

It is electro less plating.

Yellow Room:
In this room film is laminated on the PCB. Only yellow
light is use in this room in any other light it will be expose from its
connection. An other machine is use to expose the lamination.
After this process a machine is use, this is divided into three sections.
1. Card develops.
2. Card wash (Water is used for washing purpose)
3. Drying the card.

Electro Plating:
In this process either Tin Lead or Copper platting is
use.

Film Stripping:
Potassium Hydroxide is use to remove film from sheet.

Copper Etching:
A liquid (Accu guard) is use for copper etching.

Brightening:
After copper etching an infra red fusing system is use to
melt Tin Lead at 260C due to this process Tin Lead shines.

Gold Plating:
This process is use if it is necessary in some PCBs.

Solder Masking:
A paper type substance called Polyester Mash is use
for solder masking and all other PCB is coated with green ink this is called
Green Ink Mask.
Multilayer PCB:
In multilayer PCB there are several layers use to
combine to form a single PCB. The purpose to make multilayer PCB is to
compact the size of electronic circuit. PEC has made up to 10 layers of
PCB. All the PCBs are combine and melt at 170C after this process
multilayer PCB is complete. In multilayer PCB, PCB drill in the last stage.
PROCESS FOR SINGLE AND DOUBLE SIDED
PCB’s
PROCESS FOR MULTILAYER PCB’s
PCB QUALITY ASSURANCE
Inspection stages during production.
• First article Inspection
• In-process Inspection
• Final Inspection

FIRST ARTICLE INSPECTION:

Inspection of the first piece of
the lot, Process, Batch, Method to ensure its compliance to specification and
customer requirements.

IN-PROCESS INSPECTION:
Stage wise checks to ensure that
the criteria set forth by first article is maintained through out the processing.

FINAL INSPECTION:
Inspection of the finished PCBs to ensure
that the final product is as per specification.
ELECTRICAL MAINTENANCE

CNC Machines
 Computer Numerical Controlling machines are special purpose machines
used to make any mechanical part according to the programming
programmed by a user through computer.

CNC machine consists on the following parts.

• NC
• PLC
• Pneumatic/Hydraulic System
• Measuring System
• Drives

NC:
Numerical controlling consists of electronic and electrical devices.
NC executes according to the programming.

PLC:
Programmable Logic Controller is divided into three parts.
1. Main Processor
2. Communication Module
3. I/O Devices

Pneumatic System:
Pneumatic System uses air to perform certain tasks.
Hydraulic System:
Hydraulic System uses liquid to perform certain
tasks.

Measuring Systems:
Normally two measuring systems are used.
1. Linear Scale
2. Rotary Scale

Drives:
Drives are of two types
1. AC Drives
2. DC Drives

AC Drives:
 AC Drives are controlled through frequency.

DC Drives:
DC Drives are controlled through armature voltage and field
current.
QUALITY CONTROL

QUALITY POLICY OF PEC

Precision Engineering Complex is committed to be a leader and
innovator in providing products and other diverse engineering
discipline for both domestic and global market place.

It is their policy to achieve customer satisfaction by ensuring

that supplies and service adhere to contractual specifications and
also meet or exceed their needs and expectation.

Continual improvement will be achieved through adoption of

quality system, which provides a structure for setting of quality
objectives, active participation, organized education and training
of all personnel.

Q/A SYSTEM REQUIREMENTS

• Adaptation to international standard/Spec
• Quality policy

• Q/A organization

• Evaluation selection & approval of sources for procurement if materials.

• Purchases control & receiving inspection

• Manufacturing/Process control system

• Establishment of standard labs for calibration of instruments and citification

of materials.

• Inspection & testing system.

• Non conformance control and corrective action.

• Internal audits for product, stores, documents and Q/A system.

• Product identification & traceability.

• Control an inspection stamps

• Defect analysis, capabilities reports (Quality Data Analysis).

• Certification & approval of special process and personnel (NDT, Plasma,

Welding, Plating etc).

• Training & motivation of staff for quality concept & awareness.

• Continuous improvement.

• Maintenance of quality records.

• Documented quality system (QAM).

INSPECTION PROCEDURE
 DOCUMENTS
IS PROCEDURE REVIEWED AND APPROVED BY Q.A?
IS PROCEDURE FILLIWED?
IS PROCEDURE FOLLOWED?

VISUAL INSPECTION
• NICKS
• CONTAMINATION
• SCRATCH
• BURR
• CORROSION
• COLD SHUNT
• MAR
• PAROSITY
• LACK OF WELD PENETRATION
• DENTS
• DISCOLORATION
• CRAK
• SURFACE ROUGHNESS
• DAMAGE THREAD
• INCLUSION
• MICRO SPATTEP

GEOMATRIC FEATURE INSPECTION

• CONCENTRICITY
• SQUARENESS
• ROUNDNESS
• SYMMETRY
• DISTO

DIMENSIONAL INSPECTION
• F.A INSPECTION
• INPROCESS INSPECTION, SPC & PRECOMTROL TECHNIQUES
• FINAL INSPECTION 100% MIL-STD-105D LEVEL-11

PDCA Cycle
 INSPECTION AND MEASUREMENT

PROCESS INPUT: Inspection procedure NC control procedure

quality plan.

PROSESS OUTPUT: a) Detection of confirming & non confirming parts.

b) Defect analysis report.

RESPONSIBILITY: I/C quality assurance (Mech)

PROCEDURE: QA-PR-8.0-01

CUSTOMER: P& PC machine shop.

PROCESS METRICS: a) Inspection report

b) NCR form, CAR & PAR Forms
 ELECTRICAL ASSEMBLY

CAPABILITIES OF ELECTRICAL ASSEMBLY

SHOP
 • Indigenous development of sophisticated electronic system.

• To prepare circuits/drawings and specifications through reverse

engineering.

• To develop assembly and testing procedures.

• Stuffing if all type of PCB’s and fabrication of harnesses.

• Complete assembly of electrical/electronics system.

• System functional test and acceptance of PEC made system.

• To design special test equipment for qualification and acceptance of

PEC made system.

• To initiate modification on any in use system as per the requirement

of local customer.

• To undertake repair of sophisticated electrical/electronic system even

without schematic diagrams.

CONCLUSION:
The Precision Engineering Complex (PEC) at PIA manufactures
high precision parts for the aerospace industry and a number of
other industries.
The PEC is an integrated facility that houses major engineering
disciplines under one roof, including investment casting,
conventional and CNC machining, Optics, PCB, Electrical,
Electronics and Composites. Multi-disciplinary teamwork enables
intelligent decision making and high quality output in all phases
of product development and manufacturing.
Across the globe, PEC products take to the skies every day. The
PEC is a supplier to USA and Europe and serves companies such
as General Electric, Airbus Industries and Boeing. Services run
the gamut from simple machining jobs to complex shaping using
high precision CNC controlled equipment. The team is
experienced in cutting large varieties of basic and exotic
materials including hard steels, aluminum alloys, and the
machining of a wide range of castings, forging and extrusions.