AB Silencer Muffler Weld Machine

Weld process description ( Flange & Tube welding to muffler )

Process is semi automatic. The flange and tube sub assembly and the
muffler is loaded into the weld machine, on to spring loaded cones.
The guard door is closed and the start button held down.
The muffler parts are rotated on the cones and the mig weld is applied
through the weld gun mounted on a moving frame.
The cones are rotated by use of an electric motor, belt and pulley system.

Weld controls. Amps, Wire Feed are located on the front of the machine
The weld head is adjustable through the use of locking pins for different
muffler systems.
 AB Silencer Receiving Inspection Report
Part no xyz234 Part Name Sub Tube

a
c

b f d

Dimension Standard ( mm ) Equipment Result ( mm ) Judgment

a 200 +/- 5 Vernier Caliper 201 OK
b ( I/D ) 75 +/- 1 Vernier Caliper 74 OK
c 3 +/- 0,2 Vernier Caliper 3.1 OK
d 3 +/- 0,2 Vernier Caliper 3.1 OK
e 3 +/- 0,2 Vernier Caliper 3.1 OK
f 3 +/- 0,2 Vernier Caliper 3.1 OK

Inspector James Bond Date 1-Nov-04

AB Silencer Receiving Inspection Report

Part no xyz234 Part Name Sub Tube

a
c

b f d

Dimension Standard ( mm ) Equipment Result ( mm ) Judgment

a 200 +/- 5 Vernier Caliper 202 OK
b ( I/D ) 75 +/- 1 Vernier Caliper 76 OK
c 3 +/- 0,2 Vernier Caliper 2.8 OK
d 3 +/- 0,2 Vernier Caliper 2.8 OK
e 3 +/- 0,2 Vernier Caliper 2.8 OK
f 3 +/- 0,2 Vernier Caliper 2.8 OK
Inspector P Charles Date 12-Dec-04
 AB Silencer work Instruction
Process Flange assy Issue Date 1-Jan-01
Sequence Sequence Illustration
1 Place Flange on Jig
2 Place Pipe on Jig Pipe
3 Weld full 360 degree
4 Check weld
5 Place OK parts into WIP Rack Flange
6 Rework parts if required.
Jig

weld
Safety point Watch out for hot welds 360
Wear Weld mask and protective clothing

AB Silencer work Instruction

Process Muffler Inspection Issue Date 1-Jan-01
Sequence Sequence Illustration
1 Rotate Muffler through 360 degrees
2 Check for weld condition and splatter

Note If parts are No Good or require rework complete

reject check sheet and place parts in Rework Rack.

Safety point Watch out for hot welds

 AB Silencer Muffler Cell

AUTO
Muffler Rack Weld Machine
W
IP
Ra
ck
Flange &
Tube
Flange and Rack
Tube
welding Inspection
station Table
(Manual
weld) Scrap Bin

Scrap Bin Finished

ASSY
Rack

Gang way
 Photograph Initial Analysis

Location a Full weld

Location b Partial weld
Location c No Weld
a

Comment
Muffler has partial weld. The weld is OK in Places.
The weld in only about 180 degrees ( Half way) around the Muffler joint
This is easy to detect and should have been found and stopped at final
inspection.

Who Sean O'Dea Q MGR

Date 16-Jan-05
 AB Material Company Certificate of Conformance

Product ID Part No xyz 234

Product Name 75 mm steel Tube

Manufacturer Tube Cube company

Batch OCT200401

This material conforms to all applicable ISO material standards and

specifications

Received 11/4/2004 OK NOK

AB Material Company Certificate of Conformance

Product ID Part No xyz 234

Product Name 75 mm steel Tube

Manufacturer Tube Cube company

Batch NOV200406

This material conforms to all applicable ISO material standards and

specifications

Received 11/28/2004 OK NOK

Part No xyz 12943 Date 4-Nov
Part Name

Batch QTY Reworked Scraped

30 II I

60 IIII II III

30 II I

Part No xyz 12943 Date 4-Dec

Part Name

Batch QTY Reworked Scraped

30 II I

30 IIII IIII I II

30 IIII IIII I
Picture.
72,9 to 73,3 mm

Date. 31 Jan 2005 Comment

General condition is very poor, signs of weld spatter on shaft
and heavy impact damage, knocks are visible.
Dimensional inspection of jig difficult due to condition but shaft
diameter is not even and ranges from 72,9 to 73,3 mm
Completed By. S Man
 Flange
1

Pipe weld
2 3

Muffler weld Assy

4 5

Storage Inspection Process

Number Inspection Method Frequency Standard

1 Dimension check 1 off each batch To drawing

2 Dimension check 1 off each batch

1 off each batch
1 off each batch

3 Visual Weld 100% To Master Part

4 NA NA NA

5 Visual Weld 100% To Master Part

 15-Jan-05

Abnormal noise

1. Problem Description

The test Staff at reported a problem with 1 off problem of an

abnormal noise coming from the engine area at final test.
Initial analysis indicated that the abnormal noise is coming from the muffler
within the exhaust system, with the muffler only having a partial weld.

Attached Photograph shows partial weld

area.

Partial weld this area

Note: 8D will be issued for this problem.
 AB Silencer Muffler Training matrix
Muffler Inspection

Fork Lift
Parts Inspection
Flange
Welding
Muffler welding
WHO

F Flinstone

J Park

K Turk

J Bond

P Charles

Not work work

work Train Others
Trained unsupervised unsupervised
Supervised not to takt to takt