1.After recieving the Monthly Production Plan from the Planning Dept,a Weekly & Daily Production Plan is formed.
2.After discussion with the planning dept,1st the In-House Production capacity is fulfilled & then the rest is given to the sub-contract.
3.Generally,due to high number of orders,final finishing is done In-house & rest by the sub-contractors.
4.Thus the individual components with their BOM is given respectively to the Sub-contractors & In-House machining dept.
5.Also the fluid to be passing through the valve is also specified to the production & design dept.
TYPES OF OPERATIONS
INVOLVED IN MACHINING
1.Turning: Stem,Body,Bellow Collar,Plug,etc.
3.Drilling: Flange Holes,Gland flange holes,Bonnetetc.
4.Spot-Facing: Flange holes in the body,etc.
5.Threading: Stem,Yoke sleeve,Nut & Bolts,etc.
7.Welding: Fillet Welding(between body & cylinder,flanges),Butt-welding(at butt-weld ends),Fusion Welding(between bellows & top/bottom bellow collars),Stellite Welding(at the seat).
8.Lapping: Between wedge & seat-ring,back-seat of the stem.
Procedure & Work Involved In Assembly Of SG Valves
1.The general assembly procedure depends on the production plan.
2.After going through the production plan,Material Requisition Slip is given to store.
3.After recieving materials from the store(via the Material Requisition Slip) internal planning is done.
4.Once materials are recieved from store,a ‘Job Card’ is designed,wherein its is specified that which job will be performed by whom.It consists of
5.Assembly drawings are then given to the respective persons & assembly process begins.
6.Sub-assembly is done first.It consists of
Bellow collar welding,
Bellow testing(pneumatic).If testing fails,it would mean there is a problem with the welding.So re-welding is done,i.e,the welded area is fused & again tested.If testing fails again,then the bellow is rejected.
Bonnet assembly is done.It depends on the design.First seat is lapped for body & checked for any blow-holes.If blow-holes are present then it is lathe machined & again lapped.
Then body & bonnet is assembled by attaching a gasket in between them(which provides sealing between 2 metal parts).
7.Finally after all the parts are assembled,the valve is sent for testing.
8.Then the packing list is created which consists of the following:
Type of Valve
No. Of boxes
Weight of valves
Finally sent to Dispatch Dept.
1.After testing,all the sharp corners & edges are smoothened.
2.Surface of the valves is cleaned & dried with a thinner.
3.After cleaning,the valves are sprayed with 2 coats of metal primer & 2 coats of paint as specified by the customer in the PO.
4.There are some paint colour codification standards though which are as follows:
- Silver colour paint for ‘Thermoshield heat resistant applications upto 600 deg.
- Tata Blue colour paint for Steam applications.
- Yellow Colour for Chlorine applications(esp for Euro-Chloro Design).
5.End connections & serrations are painted with 2 coats of antirust.
6.Then the valaves are kept for drying for around 30 mins.
7.Identification Plates are punched.
8.Finally the valves are inspected again visually.
1.Painted valve should be cleaned & dried.
2.End of valves are protected with end caps.
3.Then the valves are sealed in polythene or bubbled sheets(for exports).
4.Small pouches of silica gel will be placed in each polythene bag to absorb moisture.
5.Sealed valves are placed in wooden boxes with enough packing material to avoid damage during transit.
6.Packing list, including size & quantity will be placed in the box.
7.Address of customer to be stencilled on box as per purchase order.
8.Arrow mark should be indicated on box.
Dispatch Dept in SG
1.Packing List is recieved from the Assembly Dept
2.The Assembly dept also sends the FGR(Finished Goods Receipt) to the Dispatch dept.FGR contains the foll:
Description of Goods,
List of all the customers.
3.After recieving PL & FGR, the goods are physically checked.
4.Then the Packing List to the respective customer is sent via the dispatch dept.
5.Purchase Order(PO) is verified for the mode of payment.
6.The Payment consists of the following details of Taxes also viz.
- VAT(for local sales within Karnataka) of 14%
- CST(Central Sales Tax for Interstate Sales) of 14%
- Export (No tax for overseas export)
- ED (Excise Duty) of 10.3%.
The following exemptions for the above taxes exist:
- If ‘FORM C’ is submitted by the customer,then only a CST of 2% is charged.But constant follow-up from the Sales Dept with the customer is required.
- If Govt Companies(like BARC,etc) give us ‘ED exemption certificate’,then no ED tax is charged.
- If SEZ’s & Export Oriented Unit(EOU) submits FORM 1 to us then no excise Duty is charged.
7.After verification of PO,Dispatch Documents are prepared which contains the foll:
- a) Commercial Documents
- Invoice (which is the actual Bill of the whole package; 4 copies).
- Delivery Challan (which contains the information about the package details like qty,size,etc; 3 copies)
- Packing List (3 copies)
- b) Technical Documents
- Test Certificate
- Release Note
- Warranty Certificate,etc
8.Finally these dispatch documents are sent to the customer via the transporter.
9.Also FGR & Dispatch Documents are maintained in a register to keep a track of the records.