REPORT ON WORKING OF STANDARD ROOMS

Name : Surender Pal SID NO. : BTCHTQ07090140 Organization: Victora Tool Engineers Pvt. Ltd. Designation: Plant Head

INTRODUCTION TO THE ORGANIZATION:

Victora Tool Engineers Pvt. Ltd. is the flagship company of Rs. 318 Crore group of companies having manufacturing facilities for Original Equipment Manufacturer (OEM). Victora caters need of customers in Sheet Metal, tubular & machined parts/assemblies for automobile industry, Elevator industry, White Good Industry and Telecom Sector. Coupled with rich domain knowledge in design, development and engineering, VTEPL is equipped with world class manufacturing facilities to fully cater the needs of almost all types of industries.

Establishment: Established at : Faridabad Promoter : Mr. G.S. Banga Year of Inception : 1972 Ownership Structure : Private Limited Total No. of Manufacturing Facility : Six Total Area : 118000 Sq. Meter Total No. of Employees : 2200

Details of Units:

S. No

Unit Name Area of Business Certification Year of Establish-ment

1 Victora Tool Engineers Pvt. Ltd. (Unit 1)

Sheet Metal Parts & Assly. for Automotive Ind.

TS 16949:2004 & OHSAS 18001:2007

1972

2 Victora Tool Engineers Pvt. Ltd. (Unit 2)

Sheet Metal Parts & Assly. for Elevator & Telecom Ind. & Press tools

ISO 9001:2008, ISO 14001:2004 & OHSAS 18001:2007

1997

3 Victora Tool Engineers Pvt. Ltd. (Unit 3)

CNC Turned Parts for Automotive Industries

TS 16949 :2004 1988

4 SDL Auto Pvt. Ltd. Sheet Metal Parts & Assemblies for Automobile Seat Frame & Exhaust System.

TS 16949 :2004 1994

5 Victora Auto Parts Pvt Limited (Export Division)

Tubular & Rod Hangers for Automotive Exhaust System

TS 16949:2004 2003

6 Victora Automotive Inc

Sheet Metal & CNC Turned Parts for Exhaust System & Shock Absorbers

TS 16949:2004 2008

Victora has state of the art manufacturing facility including Power Presses, CNC Turning Centers, Resistance Welding, CNC tube & rod bending machines, in-house tool design & manufacturing, in-house standard room etc.

Page 1 of 9

Victora cliental includes name like Maruti Suzuki India Limited, Tenneco Automotive Europe, Eber Spacher, Emcon Technologies, Nissan Motors, TS Techsun India, Schindler India Pvt. Ltd, Ericsson India Pvt. Ltd., L & T, Sona Koyo Steering System, Rane NSK Steering System & many more.

TYPER OF GAUGES / INSTRUMENTS USED: There are mainly three types of Gauges / Instruments used in our standard room.

1. Standard Equipment: a) Measuring Instrument: These are the standard instruments which are commonly used

for dimensional measurement of different parts. For examples Vernier calipers, Micrometer, height gauge etc.

b) Testing Equipment: These are the standard equipment which is used for testing physical & mechanical properties of raw material or parts. For example Ericson Cupping Tester, Universal Testing Machine, Harness Tester, Surface Roughness Tester Etc.

2. Profile Checker / Panel Checker: These are kind of checking aid made specifically for individual parts. This is mainly used for checking profile in automobile body parts. By Panel checker we can collect measuring data at various points in part profile and can take decision after compilation.

3. Receiving Gauges : These are also checking aid made to check specific part or parameter. These gauges are used for attribute kind of measurement and decision are taken as accepted or rejected. With these gauges dimensional measurement is not possible. For examples snap gauges, plug gauge etc.

Page 2 of 9

List of Instrument & Testing Equipment:

S. No

Name of Instrument

Least Count Purpose Remarks

1 Vernier Calipers 0.01 & 0.02mm To measure Linear distance, outer Diameter, inside Diameter & Linear Depth.

2 Micrometer 0.01 & 001mm To Check Outer Size /Diameter

3 Point Micrometer

0.01 mm To check sheet thickness & sheet thinning at different areas.

4 Digital Height Gauge

0.01mm Stationary instrument to check linear distance from one point to another point

5 Bore Gauge 0.01 &

0.001mmTo check inner diameter w.r.t. some standard.

6 Bevel Protectors 5 minutes To check angle of different surface

7 Profile

Projectors X 10 times To see & check

parameter with magnified view.

8 Dial Indicators 0.001 7 0.01mm

Used as accessory with Height Gauge to check the distance preciously.

Page 3 of 9

9 Coordinate Measuring Machine (CMM)

0.005 mm To Check 3 Dimensional Profile of Part, tool, Gauge etc.

10 Radius Gauge 0.5 mm To check Inner & outer radius.

11 Slip Gauge 0.05mm Used as master for

checking linear distance

12 Filler Gauge 0.001mm Used to check small distance/ Gap where one side is closed & vernier caliper can not be used.

13 Surface Plate Used as a master base for measurement

14 Plug Gauge Used to check go & No-go size.

15 Magnetic V-Block

Accessory to hold work piece for measurements

16 Box Angle Plate & Slotted Angle Plate

Accessories to hold work piece for measurements

17 Universal Testing Machine

To check Tensile Strength, Yield Point & elongation of Raw Material or Part

18 Hardness Tester To check Hardness

of Work piece in various scales

19 Cupping Tester To check Draw

ability (elongation) of Raw Material (Steel Sheet up to 3.0 mm)

Page 4 of 9

20 Surface Roughness Tester

To Check Surface finish of various machined surface

21 Paint/ Plating Thickness Tester

To check coating thickness of paint/ Plating

METHOD OF PROCURING AND CONTROLLING GAUGES:

Requirement of Instruments and Standard gauges can be arose due to new product requirement, replacement of faulty / discarded instrument or additional requirement for existing product due to increased volume. Instruments/ testing equipment & Standard gauges are procured based on following selection Criteria:

S. No.

Selection Criteria Deciding Factor for Selection

1 Parameter to be Measured Type of Instrument/ Gauge2 Range of Parameter to be

MeasuredSize of Instrument /Gauge

3 Place of Use Make / Least Count of Instrument / Gauge4 Accuracy / Tolerance of Parameter Least Count of Instrument / Gauge

Based on above criteria, purchase indent is raised by user and approved by Quality Assurance Manager. Sequence of activities is shown below in flow chart:

Input Activity Responsibility

Page 5 of 9

Receiving Gauges & Profile Checkers are made for individual part in house as per concept given by customers & are validated on Co-ordinate Measuring Machine (CMM) w.r.t. design data.FREQUENCY OF CALIBRATION OF GAUGES:

Based on the type of instruments, place of use, frequency of usage, accuracy of instrument frequency of calibration has been decided as below:

S. No.

Instrument Frequency of Calibration

1 Vernier Calipers One Year2 Micrometers One Year3 Bevel Protectors Six Months4 Height Gauge One Year5 Radius & Feeler Gauges Six Month6 Thread Plug & Ring Gauge Three Months7 Dial Indicators Six Months8 Bore Gauge One Year9 Hardness Tester One Year10 Surface Plate Two Years11 Co-ordinate Measuring Machine One Year12 Torque Tester One Year13 Panel Checker & Receiving Six Months

Page 6 of 9

Purchase Indent Approval

Source Selection

QA Requirement

Approved Supplier List

Numbering of Instrument & Entry

in Instrument Master List

QA Manager

Purchase Manager

Price Finalization Purchase Manager

Supplier Quotation

Verification of Instrument on

Receipt

QA ManagerSpecification of Requirement

QA ManagerIdentification Procedure & Master Register

Issue of Instrument at the

Place of Use

QA Manager

Gauge Validation14 Pressure Gauges / Ammeter /

Volt MeterSix Months

Frequency of Calibration & Calibration Plan for whole year is monitored through a format as below:

S. No

Instrument I/D

Instrument Description

Range Least Count

Calibration Frequency

Location Calibration PlanJan Feb March April

As per frequency of calibration, gauges / instruments can be calibrated either in-house calibration lab or from NABL accredited calibration lab.

In our organization calibration or validation are carried out as per below list:

S. No.

Type of Gauge Calibration / Validation Source

Calibration Method

1 Standard Measuring Instrument

Out side Calibration Lab

By using master gauges

2 Standard Gauges Out side Calibration Lab

By Master Instruments

3 Surface Plate On site by Outside Calibratio0n Lab

4 Pressure Gauge / Ammeter / Voltmeter

Outside Calibration Lab With master gauges

5 Panel Checker In-house Validation With CMM using master data

6 Receiving Gauges In-house Validation With CMM using master data

TYPE OF EQUIPMENTS USED AND DESCRIPTION:

Following Instruments are used for calibration.

S. No.

Type of Instruments Used for Calibration

Grade Used for

1 A set of Gauge Blocks (Slip Gauge Box)

0 Grade Vernier Calipers, Height Gauge, Micrometer, Bevel Protector, Box Angle Plate, V-Blocks, Right Angle

2 Caliper Checker ------ Vernier Caliper, Height Gauge3 Sine Bar ------ Bevel Protector4 Master Cylinder ------ Bevel Protector, Box Angle Plate,

V-Blocks, Right Angle5 Single Axis Measuring

Machine------ Dial Indicators, Dial Bore Gauge,

Thread Ring Gauge6 Profile Projector ------ Radius Gauge, Thread Pitch

Gauge7 Dial Indicator ------ Box Angle Plate, V-Blocks, Right

Angle8 Thread Measuring Wire ------ Thread Plug Gauge

Page 7 of 9

9 Digimatic Micrometer ------ Thread Plug Gauge10 Standard Foils ------ Digital Coating Thickness Gauge11 Electronic Level ------ Surface Plate12 Digital Multi meter 4.5 ------ Voltmeter, 13 Digital Clamp Meter ------ Ampere Meter14 Universal Calibrator ------ Ampere Meter15 Digital Pressure Gauge ------ Pressure Gauge16 Digital Torque Tester ------ Torque Driver

LIST OF OUTSIDE CALIBRATION LAB;1. BELZ Calibration Laboratory, Faridabad2. Bag son Calibration Lab New Delhi3. National Physical Laboratory New Delhi4. S.V. Precision Instruments Hyderabad5. Accurate Engineering Co. Pvt. Ltd. Pune6. Sri Ram Institute of Technology New Delhi

METHOD OF CALIBRATION;Following Steps are taken for calibration of gauges & instruments:

1) Based on the instrument’s stability, purpose, degree of usage, environment, past history of equivalent instruments and manufacturer’s recommendations calibration frequencies / interval are decided.

2) As per decided calibration plan & frequencies, gauge / instrument is retrieved from user department before due date of calibration.

3) Gauge / instrument condition is checked for any kind of physical damage or abnormal results.

4) Gauge / Instruments are sent to outside calibration lab with proper identification and acceptance criteria.

5) After calibration gauge / instrument is received back & checked for its results. Results are verified against acceptance criteria and certificates are marked as accepted or rejected. Also reports are verified for instrument used for calibration and its traceability to NABL.Gauge / Instruments are checked for proper identification, calibration date, next due date etc.

6) After entering the calibration status in Gauge History Card. Gauge / instruments are issued back to respective user.

7) In case gauge/ instrument are found out of acceptance criteria, it is withdrawn from use & deleted from master list.

SYSTEM OF MAINTAINING RECORDS OF GAUGES / CALIBRATION:Various formats are used for maintaining records of gauges / calibration. These are:

1. Master List of Variable Gauge / Instruments  DOC.NO.:ML/QA/01

MASTER LIST OF VARIABLE MEASURING INSTRUMENTS REV.NO.:00    EFF.DATE:01/01/01      Page:S.No. CODE No. MAKE SIZE LEAST COUNT ISSUE TO LOCATION

             

2. Master List of Attribute Gauges

Victora Tool Engineers Pvt. Ltd.DOC.NO.:ML/QA/02

MASTER LIST OF ATTRIBUTE GAUGES REV.NO.:00

     EFF.DATE:01/01/01

  Page:

Page 8 of 9

CUSTOMER:          S.No

.CODE

No.DESCRIPTIO

NTYPE OF GAUGES

DRAWING REV. No.

DATE LOCATION

             

3. Calibration Plan & StatusS. No

Instrument I/D

Instrument Description

Range Least Count

Calibration Frequency

Location Calibration PlanJan Feb March April

4. Calibration Standard & History Sheet

 

Doc.No.:CS/QA/i.c.Rev.No.:00Eff.Date:01/01/01

CALIBRATION STANDARD

 

INSTRUMENT CODE   LEAST COUNT LOCATIONDESCRIPTION   RANGE FREQUENCY

S.NOINSPECTIO

N ITEMSPECIFICATIO

NACCEPTANCE CRITERIA

MASTER INSTRUMENT REMARKS

A          

CALIBRATION HISTORY SHEET F/QA/10/00

INSTRUMENT CODE LEAST COUNT LOCATIONDESCRIPTION RANGE FREQUENCYHISTORY SHEET OBSERVATION

RESULTS

NEXT DUE

CALIBRATED BY APPROVE BY

S.N.CALIB.DATE A B C D E F G H I J   DATE  

1                              

Page 9 of 9