PROCESS FLOW DIAGRAM
Process Name :
Process Method : NICKEL BARREL
Op No. Op. / Breif Desc Incoming source of variations Process Flow Diagram Product Characteristics Process Characteristics
10 Raw material Wrong material receipt Surface to be free from Rack 3C Storage
Receiving
Material Mix up a) Oil Material FIFO Follow up
Rust b) Greese
Excess Oil c) Rust
d) Scales
15 Vibro Cleaning Excess material Loading -- Surface to be free from Oil, Grease,
Rust
Heavy Rust in the component
Heavy Oil in the component
30 Water Rinsing - 1 HCL on the Surface of the Surface to be free from Hcl Tap Water
component
Water Level
50 Acid Pickiling Excess material Loading Surface to be free from rust HCL Commercial grade
Heavy Welding Scales 0.5% inhbitor
60 Water Rinsing - 1 HCL on the Surface of the Surface to be free from Hcl Tap Water
component
Water Level
90 Zinc Nickel plating Excess load Surface of the component Time
Cathode failure deposited with zinc metal Temperature
Anode hooking failure Metal
Current
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PROCESS FLOW DIAGRAM
Process Name :
Process Method : NICKEL BARREL
Op No. Op. / Breif Desc Incoming source of variations Process Flow Diagram Product Characteristics Process Characteristics
10
100 Raw
Watermaterial
Rinsing - 1 Wrong materialwith
Heavy Alkinity receipt
scales Surface to be free from Rack 3C Storage
DM Water Level
Alkalinity
120 Bright dip Excess water carry over Surface free from alkinity Nitric Acid
and
Concentration of Nitric ready for chromate bonding. Water level
130 Water Rinsing - 1 Carry over of Bright dip Surface to be ready for DM Water Level
Chromate bonding
140 Passivation Excess load in a basket Surface to be covered with pH Value
Chromate film
150 Water Rinsing - 1 Passivation Carry Over Surface to be free from DM Water Level
excess
chromate
160 Water Rinsing - 2 -- Surface to be free from DM Water Level
excess
chromate
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PROCESS FLOW DIAGRAM
Process Name :
Process Method : NICKEL BARREL
Op No. Op. / Breif Desc Incoming source of variations Process Flow Diagram Product Characteristics Process Characteristics
10 Raw material Wrong material receipt Surface to be free from Rack 3C Storage
170 Top Coat -- Surface to be protected by Concentration 2 to 3% by
lacquer for better salt spray Volume
180 Drying Dryer heater Failure Surface to be free from Temperature
wet condition Time
190 Final Inspection Plating Mix up Passivation change Instrument calibration
Material Mix up Blister / Pell off / Jig Mark Inspector Training
Wet Condition Un coverage / Stain
Low thickness Less Zinc deposition
200 Storage & Plating Mix up Despatch Tags Rack 3C Storage
Despatch
Material Mix up Material FIFO Follow up
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