REPORT ON WORKING OF STANDARD ROOMS

Name : Surender Pal Organization: Victora Tool Engineers Pvt. Ltd. SID NO. : BTCHTQ07090140 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 Promoter Year of Inception Ownership Structure Total No. of Manufacturing Facility Total Area Total No. of Employees : Faridabad : Mr. G.S. Banga : 1972 : Private Limited : Six : 118000 Sq. Meter : 2200

Details of Units:
S. No 1 2 Unit Name Victora Tool Engineers Pvt. Ltd. (Unit 1) Victora Tool Engineers Pvt. Ltd. (Unit 2) Victora Tool Engineers Pvt. Ltd. (Unit 3) SDL Auto Pvt. Ltd. Area of Business Sheet Metal Parts & Assly. for Automotive Ind. Sheet Metal Parts & Assly. for Elevator & Telecom Ind. & Press tools CNC Turned Parts for Automotive Industries Sheet Metal Parts & Assemblies for Automobile Seat Frame & Exhaust System. Certification TS 16949:2004 & OHSAS 18001:2007 ISO 9001:2008, ISO 14001:2004 & OHSAS 18001:2007 TS 16949 :2004 TS 16949 :2004 Year of Establishment 1972 1997

3 4

1988 1994

Victora Auto Parts Pvt Limited (Export Division) Victora Automotive Inc

Tubular & Rod Hangers for Automotive Exhaust System Sheet Metal & CNC Turned Parts for Exhaust System & Shock Absorbers

TS 16949:2004

2003

TS 16949:2004

2008

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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.
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

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measurement is not possible. For examples snap gauges, plug gauge etc.

List of Instrument & Testing Equipment:

S. Name of No Instrument
1 Vernier Calipers

Least Count
0.01 & 0.02mm

Purpose
To measure Linear distance, outer Diameter, inside Diameter & Linear Depth. To Check Outer Size /Diameter To check sheet thickness & sheet thinning at different areas. Stationary instrument to check linear distance from one point to another point To check inner diameter w.r.t. some standard. To check angle of different surface

Remarks

2 3

Micrometer Point Micrometer

0.01 & 001mm 0.01 mm

Digital Height Gauge

0.01mm

5 6

Bore Gauge Bevel Protectors

0.01 & 0.001mm 5 minutes

Profile Projectors

X 10 times

To see & check parameter with magnified view.

Dial Indicators

0.001 7 0.01mm

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

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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 Used to check small distance/ Gap where one side is closed & vernier caliper can not be used. Used as a master base for measurement

12

Filler Gauge

0.001mm

13

Surface Plate

14 15 16 17

Plug Gauge Magnetic VBlock Box Angle Plate & Slotted Angle Plate Universal Testing Machine

Used to check go & No-go size. Accessory to hold work piece for measurements Accessories to hold work piece for measurements To check Tensile Strength, Yield Point & elongation of Raw Material or Part To check Hardness of Work piece in various scales

18

Hardness Tester

19

Cupping Tester

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

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20

Surface Roughness Tester Paint/ Plating Thickness Tester

To Check Surface finish of various machined surface To check coating thickness of paint/ Plating

21

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.
1 2 3 4

Selection Criteria
Parameter to be Measured Range of Parameter to be Measured Place of Use Accuracy / Tolerance of Parameter

Deciding Factor for Selection

Type of Instrument/ Gauge Size of Instrument /Gauge Make / Least Count of Instrument / Gauge 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

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QA Requirement

Purchase Indent Approval

QA Manager

Approved Supplier List

Source Selection

Purchase Manager

Supplier Quotation

Price Finalization

Purchase Manager

Specification of Requirement

Verification of Instrument on Receipt

QA Manager

Identification Procedure & Master Register

Numbering of Instrument & Entry in Instrument Master List

QA Manager

Issue of Instrument at the Place of Use

QA Manager

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.
1 2 3 4 5 6 7 8 9 10 11 12 13

Instrument
Vernier Calipers Micrometers Bevel Protectors Height Gauge Radius & Feeler Gauges Thread Plug & Ring Gauge Dial Indicators Bore Gauge Hardness Tester Surface Plate Co-ordinate Measuring Machine Torque Tester Panel Checker & Receiving

Frequency of Calibration
One Year One Year Six Months One Year Six Month Three Months Six Months One Year One Year Two Years One Year One Year Six Months

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14

Gauge Validation Pressure Gauges / Ammeter / Volt Meter

Six 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 Jan Calibration Plan 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. 1 2 3 4 5 6 Type of Gauge Standard Measuring Instrument Standard Gauges Surface Plate Pressure Gauge / Ammeter / Voltmeter Panel Checker Receiving Gauges Calibration / Validation Source Out side Calibration Lab Out side Calibration Lab On site by Outside Calibratio0n Lab Outside Calibration Lab In-house Validation In-house Validation Calibration Method By using master gauges By Master Instruments

With master gauges With CMM using master data With CMM using master data

TYPE OF EQUIPMENTS USED AND DESCRIPTION:

Following Instruments are used for calibration.

S. No.
1 2 3 4 5 6 7 8

Type of Instruments Used for Calibration

A set of Gauge Blocks (Slip Gauge Box) Caliper Checker Sine Bar Master Cylinder Single Axis Measuring Machine Profile Projector Dial Indicator Thread Measuring Wire

Grade
0 Grade ------------------------------------

Used for
Vernier Calipers, Height Gauge, Micrometer, Bevel Protector, Box Angle Plate, V-Blocks, Right Angle Vernier Caliper, Height Gauge Bevel Protector Bevel Protector, Box Angle Plate, V-Blocks, Right Angle Dial Indicators, Dial Bore Gauge, Thread Ring Gauge Radius Gauge, Thread Pitch Gauge Box Angle Plate, V-Blocks, Right Angle Thread Plug Gauge

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9 10 11 12 13 14 15 16

Digimatic Micrometer Standard Foils Electronic Level Digital Multi meter 4.5 Digital Clamp Meter Universal Calibrator Digital Pressure Gauge Digital Torque Tester

-----------------------------------------

Thread Plug Gauge Digital Coating Thickness Gauge Surface Plate Voltmeter, Ampere Meter Ampere Meter Pressure Gauge Torque Driver

LIST OF OUTSIDE CALIBRATION LAB;

1. BELZ Calibration Laboratory, Faridabad 2. Bag son Calibration Lab New Delhi 3. National Physical Laboratory New Delhi 4. S.V. Precision Instruments Hyderabad 5. Accurate Engineering Co. Pvt. Ltd. Pune 6. Sri Ram Institute of Technology New Delhi

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

1) Based on the instruments stability, purpose, degree of usage, environment, past history
2) 3) of equivalent instruments and manufacturers recommendations calibration frequencies / interval are decided. As per decided calibration plan & frequencies, gauge / instrument is retrieved from user department before due date of calibration. Gauge / instrument condition is checked for any kind of physical damage or abnormal results. Gauge / Instruments are sent to outside calibration lab with proper identification and acceptance criteria. 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. After entering the calibration status in Gauge History Card. Gauge / instruments are issued back to respective user. In case gauge/ instrument are found out of acceptance criteria, it is withdrawn from use & deleted from master list.

4)
5)

6) 7)

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. MASTER LIST OF ATTRIBUTE GAUGES
DOC.NO.:ML/QA/02 REV.NO.:00 EFF.DATE:01/01/01

Page:

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CUSTOMER: S.No CODE . No.

DESCRIPTIO N

TYPE OF GAUGES

DRAWING REV. No.

DAT E

LOCATION

3. Calibration Plan & Status

S. No Instrument I/D Instrument Description Range Least Count Calibration Frequency Location Jan Calibration Plan Feb March April

4. Calibration Standard & History Sheet

Doc.No.:CS/QA/i.c.

Rev.No.:00 Eff.Date:01/01/01

CALIBRATION STANDARD
INSTRUMENT CODE DESCRIPTION
S.NO INSPECTIO N ITEM

LEAST COUNT RANGE

SPECIFICATIO N ACCEPTANC E CRITERIA

LOCATION FREQUENCY MASTER INSTRUMENT

REMARKS

CALIBRATION HISTORY SHEET

INSTRUMENT CODE DESCRIPTION
HISTORY SHEET CALIB.DA S.N. TE 1

F/QA/10/ 00

LEAST COUNT RANGE

OBSERVATION

LOCATION FREQUENCY RESU LTS NEXT DUE DATE CALIBRA TED BY APPROVE BY

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