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REPORT OF SHEET METAL AND

MANUFACTURING PROCESS

PREPARED BY:
ARI WIBOWO NUGROHO
SESA 391637
I. Introduction

1.1 Fabrication
When used as an industrial term, applies to the building of machines, structures and
other equipment, by cutting, shaping and assembling components made from raw
materials. Small businesses that specialize in metal are called fab shop.

Fabrication comprises or overlaps with various metalworking specialties:

 Fabrication shops and machine shops have overlapping capabilities, but fabrication
shops generally concentrate on the metal preparation aspects (such as sawing tubing to
length or bending sheet metal or plate), welding, and assembly, whereas machine shops
are more concerned with the machining of parts on machine tools. Firms that
encompass both are also common.
 The products produced by welders, which are often referred to as weldments, are an
example of fabrication.
 Similarly, millwrights originally specialized in setting up grain mills and saw mills, but
they may be called upon for a broad range of fabrication work.
 Ironworkers, also known as steel erectors, also engage in fabrication. Often the
fabrications for structural work begin as prefabricated segments in a fab shop.

1.2 Metal fabrication


Metal fabrication is a value added process that involves the construction of
machines and structures from various raw materials. A fab shop will bid on a job,
usually based on the engineering drawings, and if awarded the contract will build the
product.
Fabrication shops are employed by self. Typical projects include; loose parts,
structural frames and heavy equipment.
Metalworking is the process of working with metals to create individual parts,
assemblies, or large scale structures. The term covers a wide range of work from large
ships and bridges to precise engine parts and delicate jewellery. It therefore includes a
correspondingly wide range of skills, processes, and tools.

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Metalworking is a science, art, hobby, industry and trade. Its historical roots span
cultures, civilizations, and millennia. Metalworking has evolved from the discovery of
smelting various ores, producing malleable and ductile metal useful for tools and
adornments. Modern metalworking processes, though diverse and specialized, can be
categorized as forming, cutting or joining processes. Today's machine shop includes a
number of machine tools capable of creating a precise, useful work piece.

1.3 Engineering
The fabricator may employ or contract out steel detailers to prepare shop
drawings, if not provided by the customer, which the fabricating shop will use for
manufacturing. Manufacturing engineers will program CNC machines as needed.

II. Organisational Chart

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2.1 Responsibility and Authority

2.1.1 CEO

A) Reports to the Board of Directors

B) Responsible for:
 Overall management of the company
 Laying down quality policy and objectives
 Carrying our management reviews
 Approval of product & process, Design & quality.
 Ensuring the compliance to the quality management system of the company
 Review and approval of quality management system documents
 Finance management
 Approval for purchase of raw materials, consumables and spares
 Review and authorizing all agreement / contract (customer / suppliers)
 Overall responsibility for new products and projects
 Defining responsibility and authority of functions who are expected to take the
independent decision
 Review of orders received from customers
 Review of nonconforming products as a member of review meeting

2.1.2 TECHNICAL MANAGER

A) Reports to Chief Executive Officer

B) Responsible for:
 Overall activities of the day to day production operations
 Planning and review of production against plan
 Process design and development
 Identification of training needs of functions reporting to him
 Preparation of work instruction for production activities
 Initiation of corrective action with regard to in process / final stages of production
 Maintaining customer satisfaction and taking suitable corrective action
 Implementing the corrective actions for the customer complaints in coordination with
CEO

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 Initiating the corrective action against the customer complaint in coordination with
CEO
 Proposal of corrective action and verification of effectiveness of
 corrective actions
 Monitoring customer satisfaction and taking suitable corrective actions
 Ensure safe working practice
 Drawing control in related to distribution and revision and over all maintenance
 Control of customer supplied products / documents
 Has the authority to stop production, to correct the quality problems.

2.1.3 PURCHASE STORE IN CHARGE

A) Reports to CEO

B) Responsible for:
 Preparation of purchase order / Arranging for purchase of Raw Materials, spares and
consumables
 Supplier evaluation and maintenance of approved suppliers list follow up with suppliers
 Maintenance of minimum stock level
 Stock register and material identification
 Preservation of materials identification
 Preservation of materials stores

2.1.4 SUPERVISOR-PRODUCTION

A) Reports to technical manager

B) Responsible for:
 Production , quality as per planning
 Man, Materials, Methods, Machineries Management
 Monitoring House Keeping
 Ensure safe working practice
 Maintenance of records related to production & quality
 Identification of training needs of functions reporting to him
 Has the authority to stop production, to correct the quality problems

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2.1.5 CLIENTS
Schneider Transformer Cibitung

2.1.6. QUALITY CONTROL

Process input Mode of output Process Measures

1.Quality plan/Work Instruction 1. Inspection report 1. Number of customer


complaints, Related to quality of
2.Drawings/Specifications 2. Non conformance report
the product.
3.Incoming Raw material specification 3. Corrective action report
2. Customer rejection percentage
4. Measuring devices

5. Inspection skill

6. In formations/feedback from the


customer with regard to quality of the
product.

7. Inspection status

2.1.7 INCOMING STAGE:


A. On action on receipt of raw materials from suppliers/processed products from the
service providers are inspected as per incoming/process/product wise quality
B. The raw materials/production operations are accepted based on the test
certificates/inspection reports wherever required as applicable received from the
suppliers/service providers.
C. The quality supplied and accepted criteria is ensured against P.O/job order as applicable
and the same is updated in the material inward inspection report/service provider’s
register

The non-conformance identified during this inspection, are handled as in continual


improvement process.

2.1.8 IN PROCESS AND FINAL STAGE


A. In process and final inspection are carried out as per the process and final inspection
quality plan. The inspection results are recorded in inspection reports.
B. Final inspection/Testing are done on the finished 100% Qty of the product as per the
final inspection quality plan

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C. Final inspection/Testing results are recorded in the Final /stage inspection report.
D. If result are not meeting accepted criteria/tolerance during in process /final stage ,then
non-conforming product control process is implemented as per the process module-
continual improvement process
E. Inspection status is identified on the components through tag/board/respective
location/paint mark identification.

2.1.9 SUPERVISOR-QUALITY CONTROL

A) Reports to technical manager

B) Responsible for:
 Overall quality control and assurance
 Maintenance of records related to incoming materials, in process materials and final
stage productions inspection reports including dimensional inspection
 Calibration of inspection and testing equipment / instruments
 Identification of training needs of functions reporting to him
 Has the authority to stop production, to correct the quality problems.

3. MACHINARY LIST

NO MACHINE NAME CAPACITY


1 SHEARING 4MM*2500MM
2 BENDING 3MM*2500MM
3 BENDING 4MM*3100MM
4 PUNCH 6MM*2500*1250MM
5 WELDING 300 A

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