Quality control. Technical control

Control and sorting of parts

Cleaned, degreased and washed parts and one-piece units of road machines are delivered to the control and sorting section, which is one of the critical sections of the repair enterprise, since the quality and cost of repairing machines largely depend on its accurate and skilled work. If unusable parts, erroneously assigned to the group of suitable ones, get into the assembly, this will inevitably lead to a decrease in the quality of the repair. If the inspector mistakenly assigns good or repairable parts to the group of bad parts, then the number of good or repaired parts will be artificially reduced. During assembly, an additional number of new or refurbished parts will be required, which, in turn, will lead to an increase in the cost of repairing the machine. Details that are not subject to depersonalization for technical or production reasons must be submitted for inspection as a set.

The main purpose of control and sorting (defect detection) is to determine the technical condition of parts and sort them into appropriate groups.

As a result of fault detection, parts must be sorted into four groups and marked with paint of the appropriate color:
1) suitable parts, the dimensions of which lie within the limits acceptable without repair, taking into account their pairing with new parts - the color is white (sometimes for some machines, according to technical conditions - blue);
2) fit parts, the dimensions of which lie within the limits acceptable without repair, taking into account their pairing with parts that were in operation - color green;
3) parts to be repaired - color yellow;
4) unusable parts - red color. Suitable without restoration include parts, damage or wear of the surfaces of which lie within the allowable values ​​that do not prevent further use. These parts are sent to the picking department or to an intermediate warehouse.

Parts requiring repair include parts whose surface damage and wear are at the limit or exceed the permissible limits, and it is impossible to mate them, since they cannot ensure normal operation of the mate until the next overhaul. The technical condition of these parts allows you to repair worn and damaged surfaces. These parts are sent to an intermediate warehouse or to the appropriate workshops for restoration.

Unusable parts include parts whose technical condition does not allow for high-quality repairs. These parts are sent to the scrapyard. It should be noted that the classification of parts as unusable is a conditional matter and largely depends on the degree of equipment of the repair enterprise and the technical feasibility of their restoration. Control and sorting of parts is carried out in accordance with the requirements of technical specifications.

Technical conditions for each type of machine are developed by research institutes or central design bureaus on the basis of research and practical materials on wear, damage to parts and repair methods and are approved by higher organizations (ministries). Specifications are made in the form of separate cards for each part. These cards indicate: the procedure for monitoring and sorting parts; devices and tools for control; types of defects for which the part is rejected; allowed defects; dimensions allowed without repair; ways to fix defects. On each part to be repaired, the controller stamps the number of the technological route.

The results of sorting for each item name are entered in the defect list, the forms of which are intended for units of each item. One defect sheet form is usually filled out for several sets of the unit, for example, for all gearboxes disassembled in a given shift. The troubleshooting list consists of four separate parts. The first, which lists all the parts that have passed the control and sorting, their catalog number and the results of the control, is the main part and is submitted to the production department of the workshop or plant. The second one, which indicates the number of good parts, is delivered together with the parts to the intermediate warehouse of good parts or to the assembly department of the assembly shop. The third, which indicates the number of parts to be repaired, along with the parts goes to the appropriate shops for restoration or to the warehouse of parts awaiting repair. The last, fourth part of the statement, which indicates the number of unusable parts, is handed over together with unusable parts to the scrapyard.

The process of defect detection of parts consists of several sequentially performed methods of control: external inspection, carried out to detect visible damage; detail measurements; physical control methods (magnetic, ultrasonic, luminescent, x-ray, etc.).

To establish the strength characteristics of the base metal and welded joints, mechanical properties are determined. Let's look at some of these methods.

All parts are subjected to an external inspection to identify visible damage: scratches, nicks, cracks, scuffs, surface defects of welded, soldered and riveted joints. External examination is carried out with the naked eye or, if necessary, using a magnifying glass.

Parts are measured to determine the geometric dimensions of parts, deviations from their regular geometric shape (taper, ovality, curvature, torsion), and surface wear. The surfaces of some parts are tested for hardness. Individual parts are checked for elasticity (springs, springs). Measurements are carried out with universal measuring instruments (calipers, depth gauges, caliper gauges, micrometers, indicator inside gauges, probes, radius gauges, etc.), special measuring instruments (threaded gauges, smooth gauges, brackets, templates, etc.), special devices and devices (hardness testers, devices for determining the elasticity of springs, devices for measuring the axial and radial runout of ball bearings, etc.). When choosing measuring instruments, it is necessary to take into account the configuration, dimensions and accuracy class of the controlled part.

To reveal hidden defects in parts (shells, slag inclusions, hairlines, internal cracks, etc.), physical control methods are used: magnetic, luminescent, ultrasonic, x-ray. Parts operating under conditions of alternating loads (connecting rods, crankshafts, etc.) are subjected to such control. Particular care should be taken to control the parts whose work is related to traffic safety (steering arms, pivot pins, etc.).

The magnetic method is based on the fact that when a magnetic flux passes through a controlled part in places where there are surface and internal defects, scattering fluxes occur, which are detected using a magnetic powder or an induction coil. After checking, the part is demagnetized. To control parts by this method, universal magnetic flaw detectors of the types MDV (Fig. 18), M-217, etc. are used. When testing on the flaw detector MDV, the parts are placed on prisms 3. Then they are raised with a foot pedal to the level of the pole pieces of the electromagnet and pressed with handle 5 The contact density of the part with the pole pieces is provided by a clamping mechanism driven by a handle. Electromagnets are turned on and the part is sprinkled with magnetic powder (crocus).

Rice. 18. Universal magnetic flaw detector type MDV

The essence of the ultrasonic method lies in the fact that when ultrasound propagates in details, its vibrational energy is reflected from the interface between two media, for example, air-metal in a crack, or a foreign inclusion-metal in slag inclusions, etc.

The existing types of designs of ultrasonic flaw detectors are based on the shadow or impulse principles of defect detection.

The shadow method is associated with the appearance of a "sound shadow" area behind the defect. Using this method, products of a simple shape and small thickness are controlled with bilateral access. The pulse method is based on the reflection of ultrasonic vibrations from the defect surface. Control by this method is carried out with access to the part from one side. Let us consider as an example the scheme of operation of an ultrasonic flaw detector operating on the basis of the shadow method (Fig. 19). Short electrical pulses from the ultrasonic generator are fed to a piezoelectric emitter, which converts them into ultrasonic vibrations. These vibrations in the form of ultrasonic waves are transmitted to the controlled part. If there is no defect on its surface, then ultrasonic waves reach the piezoelectric receiver. These waves, after being converted into electrical impulses and amplifying them in an amplifier, are recorded by an indicator (Fig. 19, a). If during the movement of the emitter and receiver along the controlled part, a defect is encountered in the path of ultrasonic waves (Fig. 19, b), then the waves sent by the emitter are reflected from the surface of the defect and do not fall on the receiver. A change in the position of the indicator arrow indicates that there is a defect in this part of the part.

The nature of defects and methods of technical control of some typical parts. Typical parts include engine cylinder blocks, crankshafts, gears, ball bearings, splined shafts, connecting rods, etc.

Engine cylinder blocks may have the following defects: cracks and through holes on the surface of the block, thread stripping in the threaded holes, broken studs, scale in the cavity of the water jacket, wear of the cylinders of the block, warping of the upper plane of the block, wear of the holes for the camshaft bushings, wear of the holes for root bearings, etc.

Cracks, through shells, thread stripping, broken studs, scale can be detected by external inspection. Cracks that are not detected by external inspection are detected during a hydraulic leak test of the block.

The diameters of the working surfaces of the liners are measured with an indicator inside gauge in planes parallel and perpendicular to the axis of the crankshaft in a place corresponding to the extreme position of the piston ring when the piston is at top dead center. The amount of wear is determined by the largest diameter. On the basis of the data obtained, it is established under which repair size the working surface of the sleeve should be processed. Holes for main bearings and camshaft bushings are also measured with inside gauges (can be measured with micrometer gauges) in two planes. The amount of wear is determined by the largest diameter. Warping of the upper plane of the block is controlled by a straightedge using a feeler gauge.

Crankshafts may have the following defects: bending, wear of the main and connecting rod journals, thread breaks in the holes, cracks, scuffing on the journals. Thread breaks, cracks, scuffs can be detected by external inspection. The diameters of the main and connecting rod journals of the crankshaft are measured with a micrometer in two belts located 10-12 mm near the fillets in two mutually perpendicular directions: in a plane passing through the axes of the main and corresponding connecting rod journals, and in a plane perpendicular to it. The taper value is defined as the difference between the largest and smallest diameters of the neck, measured in two belts and mutually perpendicular planes. The value of ovality is determined by subtracting from the largest diameter of the neck the smallest, measured in one zone, but in different planes.

Based on the results of measurements, the amount of wear is set (taking into account the amount of scuffing, ovality and taper on the necks) and then it is determined under which repair size the crankshaft journals should be machined. The bending of the shaft is controlled by an indicator along the middle neck, setting it with extreme main necks on prisms.

Gears (gears) may have defects: tooth wear, chipping, dents, cracks or microcracks on the surfaces of the teeth. Tooth wear in thickness is controlled by a caliper gauge, tangential and optical gear gauges, and templates. Measurements are taken along the chord of the initial circle at three teeth located at an angle of 120° relative to each other in two sections. Chipping, dents, cracks or microcracks on tooth surfaces can be detected by visual inspection using a 10x loupe.

Ball bearings can have defects: metal chips or cracks on the rings, chipping or peeling of the rolling surface, damage to the cages, discoloration on the rings, increased axial and radial clearances.

Axial and radial clearances are controlled on a special device (Fig. 20). Other defects can be detected by external examination using a 10x magnifying glass.

Splined shafts can have the following main defects: shaft curvature, wear of bearing places and wear of splines in width. The curvature of the shaft is checked in the centers of the machine or fixture along the unworn part of the splines with a dial indicator. The wear values ​​of the bearing seats and the wear of the splines in width can be determined using measurements with micrometers or calipers.

Rice. 20. Determining clearance in ball bearings:
a-device for determining the values ​​of the radial clearance; b-device for determining the values ​​of the axial clearance; c - checking the axial clearance without a device

Connecting rods may have defects: bending, twisting, wear of the hole of the upper head of the connecting rod. Bending and twisting are checked on a special device. The amount of wear of the hole of the upper head of the connecting rod is determined by measuring the diameter of the hole with an indicator inside gauge.

Rice. 21. Table for flaw detection of hardware

Organization of workplaces. When controlling and sorting, jobs are organized in the control and sorting department of the dismantling shop. It is advisable to specialize workplaces for groups of parts of certain names. For example, a workplace for flaw detection of hardware (bolts, nuts, washers, etc.) parts of gearboxes, engines, etc. Specialization of workplaces allows better use of equipment, fixtures and tools, facilitates the work of inspectors, which ultimately increases labor productivity and improves the quality of defect detection of parts. A table or workbench is installed at the workplace. Table covers are divided into zones: for parts awaiting inspection; for flaw detection of parts; for sorting parts into suitable, unusable, requiring repair; for technical documentation. To control large parts at the workplace, platforms with calibration plates are provided. The workplace must be equipped with all necessary devices, devices, tools for control. Flaw detectors, centers and other devices are installed separately on stand tables. Cabinets and racks are installed in the workplace to store control devices and tools. For the accumulation and transportation of parts, it is necessary to provide a special container. As vehicles, electric cars with a lifting platform or forklifts are used. To lift large and heavy parts, the workplace is equipped with lifting equipment.

To Category: - Repair of road machines

Volatile control is control at a random time, appointed by the head of the Quality Control Department (BTK).

The basis for conducting a flying control should be:

• information about failures in operation (STP 131-026-001);

• information on repeated deviations from the requirements of the design documentation

(STP 131-021-009);

• the need for expert evaluation of the product, operation;

The need for QCD employees to fulfill their official duties for the prevention of marriage;

• inconsistency of the production culture of the site with the production culture map (STP 131-006-015);
• information from the UGMetr about the non-compliance of measuring instruments with the requirements for them (STP 131-029-014).

Volatile control is carried out by QCD employees throughout the entire chain of product manufacturing, incl. and on the backlog of finished parts in warehouses and other workshops. If necessary, the head of the BTC (OTC) may involve specialists from technological services.

During flying control, the following is carried out:

• verification of compliance with the requirements of the technological process;
• verification of compliance with the requirements of the design documentation;
• extraordinary test;
• verification of the impact on the quality of products of measuring instruments that do not meet the requirements for them.

Based on the results of the volatile control, an act of volatile control is drawn up.

The act of flying control with conclusions and recommendations is sent to the head of the workshop for drawing up measures and taking measures to eliminate inconsistencies, incl. on the use of products tested by measuring instruments that have deviations.

The head of the inspected workshop sends one copy of the measures to the Quality Control Department for monitoring execution. Responsibility for organizing the elimination of inconsistencies lies with the head of the shop.

Note - Carrying out a flying control should not in all cases end with the execution of an act. The controller exercising volatile control in the course of performing his official duties may confine himself to verbal information to the contractor, production and control foremen, write a remark in the marriage prevention journal, draw up a marriage certificate (STP 131-021-009).

3.5. Operational control procedure

Operational control is the control of a product or process during the execution or after the completion of a technological operation, embedded in the process control chart.

Interoperational control is the control of the product after the completion of the technological operation (operations) by one performer before transferring the product to another performer.

In order to prevent non-compliance of manufactured products, the Quality Control Department carries out operational control in accordance with the requirements of the technical process.

At the request of the QCD controller, the performer must present the product, measuring instruments with certificates of validity, technological process, equipment. It is strictly forbidden to allow for further processing products that are not presented by the quality control department for interoperational control, provided for by the technological process.

If the above requirements are not met, the head of the BTC suspends acceptance until action is taken and informs the head of the Quality Control Department.

After the acceptance of products at interoperational control is completed, the controller closes the individual order for payment and stamps the batch of products (tag) with a triangular brand (stamp).

In case of non-compliance with the requirements of the manufacturing technology, the QCD inspector must familiarize the foreman with the corresponding entry in the marriage prevention log against signature and immediately demand, and the foreman must comply with the requirement to stop work and sort out the stock of products manufactured after the previous control check. The controller must report this to the head of the BTC or the shift supervisor.

In case of non-compliance with the requirements of the manufacturing technology, the contractor must store the non-conforming products separately from the good ones and, at the end of the shift, hand over the non-conforming products to the inspector of the reject isolator in accordance with STP 131-021-009.

3.6. The procedure for presenting products for acceptance control

Acceptance control is the control of products, based on the results of which a decision is made about their suitability for further use.

The controller checks the products for their compliance with the requirements of ND, TD and samples - standards (STP 131-031-127).

Products are presented for acceptance control by the quality control department by the contractor or foreman (foreman). Installation, movement of products at control posts (control plates) is carried out by the worker himself.

Along with the products are presented:

• delivery note (form PG - 63, annex 7 ), signed by the site foreman in three copies (for IZ in four copies). When moving products between workshops and factories without presenting a price, it is allowed to use a delivery note (form PG - 65). Upon receipt of spare parts for sale, the delivery note is issued in the form PG-63, ( annex 7 ) in five copies, in the manner prescribed in STP 131-250-004;
• normative documentation, technical documentation (if necessary);
• technological passport (STP 131-031-126) - if the product is certified.

Notes:

1. Delivery-acceptance invoices are allowed to be drawn up through carbon paper (except for signatures and stamps). At the same time, copies must be legible: clear, easily identifiable and recoverable, and signatures and stamps must be affixed to each copy.
2. When products move between plants, the entry for loaded containers in the delivery note is made in accordance with STP 131-020-002.
3. Passportized assembly units and their tests are presented individually with a technological passport.
4. Complete machines and units are presented individually with a technological passport and a bearer note (Appendix 8). For the organization of pre-sale preparation of tractors, a bearer note is drawn up in the form of Appendix 9.
5. In some cases, by decision of the head of the BTK (OTK), for the period of working out the technology for manufacturing parts (assembly units), a bearer note is issued for any technological operation.

The products presented by the contractor are registered by the controller in the register of the products presented, while the column “Name of the part or assembly unit” is filled in if necessary.

The product accepted by the quality control department without comments is considered to be delivered from the first presentation. The controller puts on the product (tag) the mark of suitability in accordance with the technological process.

Note - In the event that the contractor presents separately suitable products and products that have deviations from the requirements of the documentation, indicating deviations, a return from the first presentation is not issued. In this case, a decision on parts with deviations is drawn up in accordance with the established procedure in accordance with STP 131-021-009, and the products are placed in a reject isolation ward until the said decision is approved.

Upon presentation of the product and execution of the delivery-acceptance invoice for the master of the supplier's workshops (the contractor - in the case of presentation of finished products by the contractor) and the consumer, the columns are filled in: "Shop-delivery", "Warehouse-recipient", "Handed over", "Accepted". Columns "No. p / p", "Name of products", "Unit of measurement", "Per shift", "Quantity" (accepted products in numbers and words), is filled in by the employee of the PDB of the supplier's workshop and indicates the number, date of the decision, if the product made according to the decision (material grade in case of replacement).

After branding the good products, protecting them with plugs according to the technical process and placing them in a container, the controller completes the delivery note: puts down a number corresponding to the serial number in the register of the presented products, signs, assuring his signature with a clear stamp.

At the request of the contract (agreement) for the finished product, the technical control service issues a certificate.

The delivery note is the primary document for accounting for the movement of products in production units and must be submitted to the PDO of the supplier and consumer, the third copy of the invoice is sent to the TsOI PDU.

Notes:

1. If the product is manufactured according to decision, then on the delivery note there should be a corresponding note indicating the number of those. decisions and from what date.
2. Delivery-acceptance invoices that are not issued in accordance with clauses 6.7 and 2.6 are not subject to acceptance. Corrections in the acceptance invoices are not allowed. Delivery-acceptance invoice at the TsOI PDU according to STP 131-020-001.

If a product is detected that does not meet the requirements of ND and TD, the controller stops further acceptance of the batch of products, makes a record of the return of products indicating the defects found in the log book of the presented products, to indicate the discrepancy, it requires the execution of a presentation note and attaches a defective statement (when accepting finished units and cars). The inspector signs the bearer note (defective statement - if any), puts down a stamp and returns the entire batch to the contractor for sorting, correction, sorting, informs the foreman of the site (workshop) about the return of the products.

QCD employees are strictly prohibited from sorting.

The foreman of the site (workshop) must monitor the progress of sorting the returned products.

To determine the cause of the defect and take measures to eliminate and prevent it, the production foreman, if necessary, invites the controller and the technologist. Isolation of nonconforming products in accordance with STP 131-021-009.

The discrepancy between the returned products must be eliminated by the contractor during the shift. In some cases, with the permission of the head of the Quality Control Department, the period may be extended up to five days. The second presentation is made by the foreman of the section (shop) on a bearer note, signed by the head (deputy head) of the shop. On the back of the bearer note, the measures to eliminate and prevent the identified defects, the culprit and the measures taken against him should be indicated.

The third presentation can be made by the head of the shop only after the written permission of the plant director.

If the contractor has not eliminated the discrepancy within the specified period, the controller draws up a marriage certificate in accordance with STP 131-021-009.

The BTK of the shop determines for each section (if necessary) and for the shop as a whole the percentage of product delivery from the first, second and third presentation per month for compiling a report (STP 131-021-024) and assessing the quality of work of performers (STP 131-021-006 ). Accounting and storage of bearer notes is carried out by BTK. Bearer notes are kept in BTK for a month.

It is strictly forbidden to dismantle the assembly units accepted by the quality control department, as well as to install products in the absence of quality control hallmarks and accompanying documentation certifying the quality.

A product made by a performer with a personal brand is considered as handed over from the first presentation. In case of return from consumer shops, products are not taken into account from the 1st presentation.

The procedure for submitting for testing in accordance with the instructions and methods for testing products.

3.7. Nonconformity Prevention

In order to prevent inconsistencies at any stage of the product life cycle, the director of technological audit and his deputies, the heads of technical control services (QCD, BTK, BKKP) can issue an order to the guilty unit (service).

In special cases, at the discretion of the management of the technological audit service, the spine of the "Prescription" is sent to the bureau for product quality and standards management (BUKS) for control.

After disassembly, the degreased, washed, cleaned parts are sent to the control and sorting area. The control and sorting of car parts is one of the basic and responsible sections of the repair enterprise. This section is subordinate to the technical control department of the plant, which makes it possible to control the work of the dismantling department.

Almost all parts of disassembled units are sent to the control and sorting area. Only devices of the power supply system and electrical equipment, body parts, springs, radiators, fuel tanks, as well as frames are inspected and sorted directly in the departments where they are repaired.

The main purpose of the control is to determine the technical condition of the parts and sort them into the appropriate groups: good, bad and requiring restoration.

Specifications for control-sorting are developed on the basis of research and practical materials on wear and damage to parts and methods for their restoration and are approved by a higher organization (ministry).

Specifications are drawn up in the form of separate cards, which indicate possible defects in the part, methods for their detection, the necessary tools and devices for the production of control, and in some cases - special equipment. The maps also indicate data on the amount of allowable wear, the dimensions of parts suitable for use without restoration, suitable for restoration, and the maximum dimensions of parts at which they should be rejected. At the same time, they give instructions on the permissible deviations from the correct geometric shape of parts: ovality, taper, curvature, etc.

Not only the quality of repair M, but also the technical and economic performance of the enterprise depends on the organization of work on the control and sorting of parts.

In the event that unusable parts, erroneously assigned to the group of suitable ones, fall into the assembly of units, this will inevitably lead to a decrease in the quality of the repair. If the inspector mistakenly assigns parts that are good or require restoration to the group of bad parts, then the number of good parts will be artificially reduced. Additional new parts will be required, and this in turn will lead to an increase in the cost of repairs. Control operations to determine the amount of wear and serviceability of parts are carried out by external inspection and with the help of devices and tools.

An external inspection establishes the general technical condition of the part and reveals external defects - cracks, dents, holes, scuffs, etc.

With the help of tools, the geometric dimensions of the part and its deviations from the correct geometric shape (curvature, ovality, torsion) are determined.

Hidden defects of the part are revealed with special devices and fixtures: structural changes in the material (loss of spring elasticity), shells, hairline, internal cracks, etc.

It is especially necessary to control hidden defects in critical parts of a car operating under conditions of alternating loads. These include crankshafts, connecting rods, piston pins, valves. Great attention should be paid to the identification of hidden defects in parts whose work is related to traffic safety.

With the help of special installations, the water jacket of the block and the cylinder head are also checked for tightness.

The control of parts usually begins with their external inspection. In this case, simple and binocular loupes are used.

Magnetic flaw detectors are used to detect hidden defects and cracks. Magnetic flaw detection is characterized by sufficiently high accuracy, simple equipment, and requires little time for testing.

The essence of the method of magnetic flaw detection is as follows: if a magnetic flux is passed through the controlled part, then if there are cracks in it, its magnetic permeability will be unequal, as a result of which the magnitude and direction of the magnetic flux will change. A local scattering flux appears, and magnetic poles appear at the crack boundaries. After removing the external magnetizing field, these poles establish their own magnetic field over the defect. By registering this local magnetic field, we thereby detect a defect.

Among the various methods for registering a local magnetic field, the most widely used method is the magnetic powder method, which makes it possible to control parts of various shapes and sizes. A ferromagnetic powder is applied to the magnetized part - usually calcined iron oxide (crocus) - or poured over with a special suspension - a liquid (kerosene or transformer oil), in which a fine powder of iron oxide is in suspension. The ratio of the volumes of powder and liquids in suspensions is 1:30; 1:50.

Parts can be coated with slurry by dipping them into the slurry vessel for 1-2 min. At the same time, magnetic powder particles in the form of veins settle in places of the local magnetic field, clearly outlining the location of the defect, which is then easy to determine when examining the part.

Heat-treated parts made of alloy steels are coated with a suspension after they have been magnetized. In this case, the magnetic field in the places of defects arises due to residual magnetism. To detect surface cracks, as well as to control parts with low hardness, suspension coating is carried out at the moment when the parts are under the action of a magnetic field.

To detect defects in the transverse direction (transverse cracks), it is extremely important to perform longitudinal magnetization, and in order to identify longitudinal or oblique defects, it is extremely important to magnetize the part circularly.

Combined magnetization (longitudinal and circular) is also possible, ĸᴏᴛᴏᴩᴏᴇ makes it possible to detect defects in any direction in one magnetization step.

Longitudinal magnetization can be carried out in the field of an electromagnet and in the field of a solenoid, and circular magnetization can be carried out by passing a direct or alternating current of high strength through a part or through a metal rod passed through a hollow part, for example, a piston pin.

After checking by magnetic flaw detection methods, the parts must be demagnetized. Demagnetization of parts is carried out on the same device on which they were magnetized, or with a special device - a demagnetizer. The quality of demagnetization is checked using a special device or by dusting the part with steel powder. A completely demagnetized part does not attract powder.

With the help of magnetic flaw detection, only parts made of ferromagnetic materials (steel, cast iron) can be inspected. For the control of parts made of non-ferrous metals, this method is unsuitable.

In recent years, a fluorescent method has been used to detect cracks. The essence of the method of fluorescent flaw detection is as follows. Parts to be controlled are immersed in a bath of fluorescent liquid for 10-15 min or a fluorescent liquid is applied to the surface of the part with a brush. Possessing good wettability, this liquid penetrates into the cracks in the parts and lingers there. After 10-15 min the fluorescent liquid is washed off for several seconds from the surface of the parts with a jet of cold water at a pressure of about 2 atm; then the parts are dried with heated compressed air.

Drying and slight heating of the part contribute to the release of the fluorescent liquid from the crack to the surface of the part and its spreading along the edges of the cracks. For better detection of cracks, the surface of the dried part is powdered with fine dry powder of silica gel (SiO 2) and kept in air for 5-30 min. Excess powder is removed by shaking or blowing. Dry microporous silica gel powder further draws the fluorescent liquid out of the cracks. Powder impregnated with liquid, adhering to the edges of cracks, when irradiated with ultraviolet rays, begins to glow with a bright yellow-green light.

The following mixture is used as a fluorescent liquid: light transformer oil (vaseline oil, velosite, etc.) - 0.25 l, kerosene - 0.5 l, gasoline - 0.25 l and dye - defectol of green-golden color in the form of a powder: - 0.25 ᴦ. The mixture is kept until the powder is completely dissolved.

The source of ultraviolet rays are mercury-quartz lamps, the light of which is passed through a special light filter.

The fluorescent method can detect deep cracks (luminous in the form of wide bands), as well as thin and microscopic cracks (luminous in the form of thin lines). Noteworthy is ultrasonic flaw detection. Various types of ultrasonic flaw detectors are known. The method is based on the fact that during the propagation of elastic vibrations, the interface between two media (air - metal) causes reflection of vibrational energy. After an external examination and detection of hidden defects, the geometric dimensions of the parts are checked. Parts are usually measured in places of greatest wear. To determine the place of measurement of parts, it is extremely important to know the nature of their wear.

Consider the nature of the wear of some parts. During operation of the engine, the working surface of the cylinders wears out unevenly. In length, it wears out on a cone, with the greatest wear observed in the upper part of the cylinder, at a distance of approximately 10 mm from the top of the cylinder block. In a plane perpendicular to the axis, the cylinder wears out into an oval. The largest axis of the oval lies in a plane perpendicular to the axis of the crankshaft.

The wear of the cylinders on the cone is explained by the following reasons.

1. The gases formed during the combustion of fuel exert pressure on the piston rings, as a result of which the specific pressure of the latter on the cylinder wall sharply increases. The upper compression ring exerts a particularly high specific pressure (about 30 kg / cm 2), due to which the lubricant is squeezed out between the outer surface of the piston ring and the surface of the cylinder and a semi-dry friction is created.

2. As a result of the loose fit of the piston rings to the cylinder walls, gases breaking through the leaks during compression and combustion of the working mixture blow off the oil film, worsening the lubrication conditions for the rubbing surfaces of the rings and the cylinder.

3. The high temperature that occurs during the combustion of the working mixture leads to a sharp decrease in the viscosity of the oil, which reduces the strength of the oil film.

4. Reducing the speed of the piston, and hence the piston rings, in the upper part of the cylinder when the direction of piston movement changes also contributes to increased wear of the cylinders in the upper part.

5. The upper part of the cylinder walls in contact with hot gases is corroded.

Increased cylinder wear is also facilitated by the low temperature of the cylinder, caused by a violation of the thermal regime of the engine, as well as frequent stops and starts of the engine, especially in winter.

The wear of the cylinder on the oval occurs as a result of the following reasons:

a) uneven deformation of the piston when it is heated during engine operation;

b) irregular shape of the cross section of the cylinder as a result of uneven deformation of its walls during heating;

c) piston pressure on the cylinder wall under the action of a lateral normal force, which is one of the components of the gas pressure force on the piston.

The connecting rod journals of the crankshafts of engines wear out more than the main ones. This is due to the more difficult operating conditions of the connecting rod journals.

The necks wear out on a cone and on an oval. Wear on the cone is explained by elastic deformations of the crankshaft during its operation, and wear on the oval is due to the action of gas pressure forces and inertial forces acting in the same plane passing through the axis of the cylinders. The smallest axis of the oval is in the plane of the location of the cheeks of the crankshaft.

Camshaft journals wear on the oval as a result of the forces generated by valve lift acting on the camshaft in one direction.

At the splined shafts of gearboxes, as well as at the splined tips of the cardan shafts, wear of the splines along the width occurs. The surface of the front side of the spline wears in the direction of rotation of the shaft. This is due to the fact that this surface transmits force during the operation of a gear (spline) connection.

When measuring cylinder diameters, an indicator caliper is usually used. It is extremely important to measure the cylinders at the top, in a place corresponding to the extreme position of the upper piston ring, where wear is greatest.

Measurements are made in two mutually perpendicular directions: parallel to the axis of the crankshaft and perpendicular to it.

The amount of wear is determined by the largest diameter.

The measurement results are recorded in a special passport. On the basis of the data obtained, it is established under which repair size the cylinders of the block should be processed and whether it needs to be lined.

The pistons of engines entering the overhaul are not controlled, since all of them must be replaced with new ones (they have wear that exceeds the allowable).

Piston pins are measured with micrometers or special brackets. In the same way, the diameters of the valve stems and pushers are measured.

The camshaft is checked with a bending indicator. When installing it, it is extremely important to pay attention to the serviceability of the center holes. In a similar way, bending checks are made for crankshafts, axle shafts, gearbox shafts, etc. Valve springs are controlled in length and for elasticity. The suitability of a spring is judged by the magnitude of the force, which is extremely important for compressing it to a certain length.

Measurement of the diameters of the main and connecting rod journals of the crankshaft is carried out with a micrometer. The necks should be measured in two belts located near the fillets in two mutually perpendicular directions: in a plane passing through the axes of the main and corresponding connecting rod journals, and in a plane perpendicular to it. The measurement results are recorded in the passport. As with the control of engine cylinders, these data serve as the basis for determining under which repair size the crankshaft journals should be machined.

At connecting rods, the diameters of the holes of the upper and lower heads are measured. Measurements are made by indicator calipers. The hole of the lower head for the liners is measured in two mutually perpendicular directions: along the axis of the connecting rod and perpendicular to it.

The wear of the gear teeth in terms of thickness is determined by a caliper gauge or special templates. The gear teeth wear out unevenly, therefore, during the control, it is extremely important to measure at least three teeth, mutually located approximately at an angle of 120 o.

For bevel gears, the thickness of the teeth is measured at the end, in the place of the largest module.

The warping of the plane of contact between the block head and the cylinder block is checked on the control plate using a feeler gauge.

At repair plants, to increase the productivity of inspectors, save expensive universal measuring tools, improve the quality of control (eliminate errors in measuring dimensions), scaleless rigid measuring tools are used: plugs, brackets and templates.

Control measuring tools for all parts subject to control are selected in sets based on technical specifications for control-sorting. These tools are recommended to have sets for parts of various units and assemblies: engine, gearbox, steering, etc. The presence of kits greatly facilitates the control process.

The water jackets of the head and cylinder block are checked for tightness, which must be broken (cracks, shells on the walls).

The tightness test is carried out on special stands with water under pressure 4 kg1cm 2 within 2 min. On such stands, not only cylinder blocks are usually tested, but also block heads, ᴛ.ᴇ. they are universal.

The controller must pay attention to the fact that the parts that are not subject to depersonalization for production reasons are delivered as a set.

Based on the external inspection of the parts and the measurements made, in accordance with the technical specifications for the control-sorting, the controller determines which group it is extremely important to attribute this or that part to.

Details based on their condition are sorted into three groups:

1. Suitable, allowed for further operation without restoration.

2. Subject to restoration, the wear and tear of which are eliminated by the methods of restoration mastered at this enterprise, or at another repair enterprise where these parts are restored in the order of cooperation, if it is economically feasible.

3. Worthless parts that cannot be restored due to their condition, wear or damage, as well as those restoration of which under these conditions is not economically feasible.

In order not to confuse parts of different groups under production conditions, they are marked with paint of a certain color. For example, fit - green, requiring restoration - yellow or white, unusable - red.

When inspecting parts, you have to deal with a wide variety of types of wear and damage to parts. The existing specifications for the control and sorting of parts provide for more than 50% of all control operations by the method of external inspection. For this reason, inspectors must be technically competent, qualified, able to give a correct assessment of the condition of any part, correctly determine which group it should be assigned to. This is an important condition for ensuring high-quality and cost-effective repairs. For parts of the first group, i.e., fully fit and within the limits of permissible wear, the technical specifications are stable due to the extreme importance of ensuring the obligatory interchangeability of parts when assembling components and assemblies and the required quality of repair. For details of the second and third groups, ᴛ.ᴇ. recoverable and unusable, technical conditions should be considered as guiding material, since the definition of "parts unsuitable for restoration" is conditional and depends on the degree of equipment of the repair enterprise and the methods of restoration of parts mastered by it. In the latter case, the specifications for control-sorting must be adjusted. All changes made to the technical specifications are subject to approval by a higher organization (ministry).

Sort results for each part name are included in the defect list.

Troubleshooting sheets are prepared for all units and nodes M. One form of the sheet is usually filled out for several sets of a given unit or node, for example, for all engines disassembled in a given shift.

In the defect list, the number of good parts of each name to be restored, and unusable - rejected parts, is put down.

The list is divided into four separate parts. The first, which lists all the parts that have passed control, their catalog number and control results, is the main one.

The second, which indicates the number of good parts, enters the acquisition site along with these parts and serves as the basis for their accounting.

The third, which indicates the number of parts requiring restoration, together with the parts enters the warehouse of parts awaiting restoration, and serves as the basis for their accounting.

The last, fourth part of the statement, which indicates the number of unusable parts, is rented together with the latter to the scrap metal warehouse.

Troubleshooting sheets are not only accounting and reporting documents, but also technical documents, on the basis of statistical processing of which it is possible to determine the replacement ratios and recovery ratios of parts.

Part replacement ratio- this is the ratio of the number of unusable parts to the number of all parts of a given name in the lot.

The replacement and restoration coefficients serve as initial data in the design of repair enterprises, and are also used to calculate the production activities of existing enterprises and make it possible to find out the repair enterprise's need for new parts (to replace rejected ones).

On the basis of these data, applications are made for new parts coming from outside, and the scope of work for the manufacture of parts at this enterprise is also established. With the help of recovery factors, you can determine the amount of work to restore parts.

Since all the parts coming from the disassembly pass through the inspection and sorting area, the defect lists make it possible to control the work of the dismantling department (the number of parts and the quality of the disassembly).

Parts rejected during the inspection are necessarily sent to the scrap metal warehouse. It is necessary to exclude the possibility of getting these parts into the assembly.

From the group of rejected parts, some enterprises single out parts that are used as blanks for the manufacture of other parts.

After checking for each part to be restored, the defector, based on a combination of defects, assigns a technological route.

The technological route is the sequence of elimination of a certain complex of defects. The route is marked on the part with a number or letter P, if it is a rare route.

Detail control - concept and types. Classification and features of the category "Control of parts" 2017, 2018.

The criterion for the control of manufactured products is the compliance of products with the requirements of design documentation and technical documentation.

Responsibility

The head of the quality service is responsible for organizing product quality control.

Responsibility for the implementation of activities under this procedure lies with the heads of departments.

The head of the occupational health and safety department is responsible for organizing the medical examination of the controllers' vision.

Procedure for carrying out activities

Control of the "first part"

The control of the "first part" is carried out in the press shop, in the plastics processing shop, in the assembly shops in the following cases:

At the beginning of the shift;

When installing again or after repairing a die or mold;

When changing the batch of material;

When changing a worker;

When starting the assembly line.

The “first part” is presented to the inspector for control by the workers. In the assembly shop, the “first part” is the assembly unit. The controller controls the manufactured "first part" in accordance with the requirements of the TD. The acceptance results are recorded with the entry “good” in the column “Control of the first part” of the journal “Registration of results of control (tests)” (Appendix A) and in the accompanying documentation in accordance with PSK 7530 (Identification and traceability of products).

For negative results:

The controller isolates the "first part" in accordance with CPM 8300 (Control of nonconforming products);

The adjuster adjusts the equipment until a good part is received. If he

cannot resolve the discrepancy on his own, he informs the production foreman for a decision.

The "first part" is stored at the workplace and presented with the manufactured batch for control.

When changing the tooling, the control of the “last part” is carried out, which is stored with the tooling until the next start in production.

Flying production control

Volatile control is carried out by QCD representatives at least once a

week, as well as additionally due to production needs. The business need may be:

Excess losses from the marriage of the controlled part;

Notification of the consumer about the rejection of products.

During its implementation, it is controlled:

Compliance with the requirements of CD, TD, PSK, RI;

The state of marriage zones;

Identification of material and products;

conditions and terms of storage of products in warehouses and production sites;

Compliance with the FIFO method, etc.

The task for "flying control" is drawn up by the QCD (BTK) in the form (Appendix B). In case of detection of conditions that can lead to a deterioration in product quality, the head of the BTK shop issues a "Warning of non-compliance" (Appendix B) in 2 copies. One copy is sent to the head of the department, a copy to the head of the QCD. On the basis of the "Warning of non-compliance", the head of the QCD has the right to stop the acceptance of products by notifying the head of the quality service. The head of the division has the right to stop production at any stage, as well as shipment with immediate notification of the production director.

Interoperational control

Interoperational control is carried out by Quality Control Department based on the requirements of technological processes at least once a week. The results are drawn up in accordance with Appendix B. Actions with nonconforming products identified as a result of the control are carried out in accordance with PSK 8300. Accompanying documentation is drawn up in accordance with PSK 7530.

Control of the operation by the performer

The worker in the process of work must comply with the requirements of RI and TD. If the operation being performed complies with the requirements of the TD, the worker draws up an accompanying label and (or) a route sheet in accordance with PSK 7530. If non-conforming products are detected, the worker is obliged to inform the production foreman and identify it in accordance with PSK 7530.

Final product control

Presentation of products for control is carried out in batches during the shift, but no later than 30 minutes before the end of the shift. The presentation is made at the control posts of the QCD and sites for the final acceptance of products in accordance with the approved layout of the workshop. The contours of the site are marked with white or yellow lines and the tabular "Finished products".

Products for control are presented with accompanying documentation drawn up in accordance with PSK 7530. In assembly shops with a conveyor system, it is allowed to carry out final control during a shift, piece by piece, in accordance with the requirements of RI and TD.

When accepting products, the inspector is prohibited from using the measuring tool of the worker.

The organization of the workplaces of QCD inspectors, equipping it with the necessary measuring instruments, testing equipment and documentation is carried out by the head of the workshop - the manufacturer of the products presented for control.

QCD inspectors are prohibited from accepting products:

In the absence of cleanliness and order in the workplace of the production worker;

Manufactured using faulty and non-certified measuring instruments;

Without presenting the "first part" (in the workshops in accordance with clause 4.3.1.1).

The results of product acceptance are recorded in the journal (Appendix A) and in the accompanying documentation in accordance with PSK 7530. The quality of products in the assembly shops is confirmed by the stamp of the Quality Control Department in the places provided for by the TD for the products. QCD inspectors in the workshops that carry out packaging are prohibited from pre-stamping packing lists (passports). If an NP is detected, further actions are taken in accordance with PSK 8300.

Products that are not accepted by the QCD at the first presentation are sorted (or disposed of) by the manufacturer's workshop and presented again within three days. Re-submission is carried out by the production foreman with the provision of an act on the analysis and elimination of defects (Appendix D). The presentation of products according to the "Permission Card" is repeated, while the act is not issued. The number of the act or the “Permission Card” is entered by the QCD controller in the column

"Controller" of the magazine (Appendix A) marked "repeatedly".

The percentage of change from the 1st presentation is calculated weekly by the heads of the BTK in one of two options (according to the number of batches or products presented) according to the formula:

K is the number of rejected batches (products); S - the number of initially presented batches (products). The quality engineer of the OAKP weekly (monthly) analyzes the “Product delivery from the 1st presentation” by the shops on the basis of a certificate provided by the heads of the BTC.

Abbreviations

CI- qualification tests

PSI- acceptance tests

PI- periodic tests

TI- type tests

CDP- chief technologist department

WGC- chief designer department

Ogmeter- department of chief metrologist

PEO- planning and Economic Department

KU- commercial management

PZ- customer representation

LCI- laboratory of control tests

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the USSR

INDUSTRY STANDARD

INDUSTRY PRODUCT QUALITY MANAGEMENT SYSTEM.

PRODUCT QUALITY MANAGEMENT SYSTEM AT INDUSTRIAL SERIAL ENTERPRISE, ASSOCIATION.

ORGANIZATION OF DEFECT-FREE MANUFACTURING OF PRODUCTS AND DELIVERY OF ITS TO QCD AND THE CUSTOMER FROM THE FIRST PRESENTATION. MAIN PROVISIONS

OST 1.41725-78

Official edition

UDC 658 „562-014

0TRA0L E80Y STANDARD

INDUSTRY QUALITY MANAGEMENT SYSTEM

products, ost 1.41725-78

PRODUCT QUALITY MANAGEMENT SYSTEM AT INDUSTRIAL SERIAL ENTERPRISES, ASSOCIATION. Introduced for the first time

ORGANIZATION OF DEFECT-FREE MANUFACTURING OF PRODUCTS AND DELIVERY OF ITS TO QCD AND THE CUSTOMER FROM THE FIRST

FOREWORD” MAIN PROVISIONS.

By order of the Ministry, the deadline for the introduction is set

This standard establishes the procedure for organizing defect-free manufacturing of products in the workshops of the main and auxiliary production of enterprises in the industry.

The standard applies to all serial enterprises, production associations and main departments of the Ministry.

Official edition

Reprint prohibited

OST I.41725-78 Page YU

3. ORDER OF SUBMISSION AND ARRIVAL MADE

PRODUCTS

3.1. Presentation of WGC (VTK) products

3.1.1. Only finished and good products or individual operations should be presented to the technical control department. (R

Definition n Good product w-^G08T--GU102 d 71‘. by GO&!

3.1.2. The presentation of products for control of the VTK should be carried out with a set of necessary technical and accompanying documentation (working drawings, route and operational maps, technological passports, work orders and assembly tasks, test cards

3.1.3. The worker - performer C (hereinafter referred to as the performer) before presenting the products of the VTK must check the compliance of its technical documentation and present the products to the production foreman.

3.1.4. The production foreman, before issuing a work order, a route map, a technological passport, must personally verify the quality of the manufactured products.

3.1.6. Presentation of VTK products, critical units of shmon-

the same is produced according to the pre-yielding notice of the standard form, Qeutitywuf-eutJd tfra. yp-etf l pi/l Tut/ IP

(-Appendix -I-). The list is also -iadezdyg-aggregates and -montages-oet. diaetoya - technical department - code

3.2. Manufacture and control of the "first part".

3.2.1. The list of names of parts, assemblies manufactured in batches, according to which the first part is accepted, is established by VTK.

3.2.2. The contractor is obliged to present the "first part" (assembly) from the batch to the production foreman and the VTK employee with the appropriate execution of the check (branding the part, setting the stamp in the work order, etc.).

OST 1.41725-78 ^tr.ts

3.2.3. With a team method of work, the control of the first details can be transferred to the responsibility of the team leaders.

3.2.4. If the "first part" is rejected by the production foreman or VTK employee, then the contractor is obliged to manufacture a new part

3.2 "5" The accepted "first part" is stored at the workplace during the manufacturing period of the entire batch, and then presented to the production foreman and VTK employee with the entire batch.

3.3. Presentation of products for acceptance to the representative of the customer.

3.3.1. Presentation of products is carried out according to a bearer notice, by the head of the VTK. The form of the bearer notice is agreed upon by the manufacturer with the representative of the customer.

3.3.2. The representative of the customer with a bearer notice must be presented with all the necessary regulatory and technical documentation.

3.3.3. A bearer notice upon delivery of products to the representative of the customer in batches is issued for the entire batch.

Product numbers, if any, are entered in the bearer notice,

3.3.4. The list of operations, installations, products submitted for acceptance to the customer's representative is determined by the customer's representative in agreement with the management of the enterprise.

3.3.5. Special arrangements for presenting to the customer's representative the finished and accepted products by GTK must be determined by the current state, industry and in-plant regulatory and technical documentation (NTD), as well as the documentation of the customer's representative.

3.4. Acceptance of products by VTK employees.

3.4.1. The batches of parts or assemblies presented to the VTK during acceptance or operational control are checked for all parameters stipulated by the norm! documentation and drawings.

3*4.2. Products are accepted from the first presentation in the absence of comments from the VTK employees on quality. For the accepted products, the VTK employee draws up all the necessary documentation.

3.4.3, Products ^ manufactured by the contractor in accordance with the requirements of the drawing "but having defects, are accepted from the first presentation in the following cases:

If, in accordance with the technological process, the products must be subjected to specialized control of the VTK using special means not provided for in the technology for the contractor;

In case of high-quality manufacturing by the performer of the entire batch of parts or assemblies and the discovery during the acceptance process of hidden defects "that cannot be determined visually or with the tool he has;

In the event that the worker (manufacturing foreman) reveals an admitted marriage and presents it for control separately from the good product.

3.4.4. For rejected products, a marriage certificate is drawn up indicating in it the nature of the marriage, the reason and the culprit.

3.5. Acceptance of manufactured products by a representative of the customer.

3.5.1. Acceptance of finished products, individual units and assemblies, individual technological operations by a representative of the customer is carried out in accordance with the regulations for representative offices at serial and experimental industrial enterprises.

3.5.2. Acceptance, testing of equipment and individual units before

with the procedure and conditions for acceptance set forth in GOST B 20.57.302/76^^

the supplier of the customer (acceptance and execution of documentation) is carried out.

Jjj ivh regulatory and technical documentation.

3.5.3. The submitted products are accepted by the customer's representative from the first presentation if they comply with the technical specifications, requirements of the drawing and other regulatory documentation for the product.

OCT I.41725-78 Page 13

3.5.4. The representative of the customer for all accepted products draws up the acceptance and accompanying documentation attached to the products.

3.6. Deviation from the acceptance of products by an employee of the VTK and a representative of the customer.

3.6.1. Products ^ presented to the VTK or the representative of the customer ", may be rejected from acceptance in the following cases:

Inconsistencies in parts, assemblies, installation! requirements of technical documentation and control sample (standard);

Failure to present the first part, assembly by the contractor and the lack of acceptance by the production foreman and EGC employee;

Incompleteness of the presented parts and assemblies, incorrect execution of the accompanying documentation by the contractor and the production foreman;

The presence of foreign objects in products, assemblies, assemblies;

The presence of dirt, chips, traces of conservation on parts or bridles,

3.6.2. A batch of parts or assemblies deviates from acceptance by the VTK employee upon detection of the first defect. The VTK employee returns unchecked parts from the batch to the production foreman for rechecking and preparing them for re-submission. VTK draws up a marriage certificate for the rejected part. The reason and the culprit of the marriage is indicated by the production foreman in accordance with the documentation in force in the industry for recording and analyzing defects in production.

3.6.3. The finished product presented to the employee of the VTK or the representative of the customer according to the bearer notice, or individual technological operations, are rejected from acceptance if repeated defects are detected. In this case, the inspection of products is terminated and they are returned to production for preparation for re-presentation.

OST 1.41725~?8 Page. fourteen

3.6.4. The installations of systems, the unit and the product as a whole, submitted for control by the VTK and the customer’s representative, upon acceptance of which do not use the method of objective (measuring) control, are subjected to a full inspection in accordance with the technical documentation. Not detected defect*, in all cases* a list of comments is compiled

standard form -(Appendix 2-~h, n/wwftu f

3.6.5. The remarks of BTK and the customer, which are not directly related to the quality of the presented product, are not grounds for product rejection.

3.7. Re-presentation of BTK products and the customer's representative.

3*7.1. Products "rejected earlier from the acceptance of the BTK and present the customer" after the elimination of comments on the quality of the products are presented again.

3.7.2. Re-presentation of products to the BTK employee is carried out according to the bearer notice of the repeated presentation of Shridsnwe-

yuengzeobns2Q purezdesh,.$ Iobtmne

Myu 3>, signed by ^ chief U ^ ё1ёGA similarly presented-purchased-

eog/meStfaesCJ) SHOMSH H

schya to the representative of the customer peg promoted - notification re-rzzo esr w-elRL Rper / rs / lTiYa (sign. L £> & 8 4s- JV- fOi -77.J

ah ^ ray phenomena ^ podayyeenshre ^ achshshnik--BTK and little chokha r

3.7.3. The administration of the shop, when re-presenting the products of the VTK and the representative of the customer, is obliged to indicate in the presentation notice about the measures taken to eliminate the comments and to recheck the rejected products.

Zt7t4t-41 in the subsequent rejection of the preliminary acceptance of the eye, the third time is presented to the main counter (or deputy) ne » f HfHHTffjmHTftlt. puomu^zvetyashphlyutshipptmtu by the head of ppltgrilttttd

3.7.5. In the case of detection.defects-and the third presentation, Bdrapee-o further presentation and use of products is decided by the ru" hover dem -enterprises jointly about the chief controller, and upon acceptance

iadadedia predrtyatyai “in-the-lem of the customer-oovmeozdyu with the senior representative

we will see you warily.

3.8. Preparation of documentation for the acceptance of VTK products,

3.8.1. Registration of documentation for the accepted products by the VTK employee is carried out in accordance with clause 3.6.2. of this standard,

3.8.2. An employee of the VTK makes a note in work orders for piecework performers and route maps for time-based performers from which presentation the products were handed over.

3.8.3. In technological passports and test cards for accepted products, the VTK employee puts his signature and stamp.

3.8.4 * Products made by a worker with a personal brand are considered as handed over from the first presentation and are issued in a working outfit with his stamp and signature of the master.

4. PERFORMANCE INDICATORS OF THE SYSTEM OF DEFECT-FREE MANUFACTURING OF PRODUCTS.

4.1. Characteristics of indicators.

4.1.1. Evaluation of the work of production units (shops) at the enterprises of the industry should be carried out according to two types of indicators:

The indicator of the delivery of products to the VTK and the customer from the first presentation. The indicator characterizes the quality of production for the month; - a complex indicator of the quality of labor (hereinafter referred to as the coefficient of labor quality). The indicator characterizes in aggregate the quality of labor for the month of production, technical and support personnel working in the shop.

4.1.2. Delivery of products to the NTC and the customer from the first presentation

and labor quality factor are reporting for each production shop and VTK.

4.1.3. Indicators (clause 4.1.1.) should be used in evaluating the work of shops under the conditions of socialist competition and in the distribution of bonuses. The indicators for the enterprise as a whole are taken into account in

OST 1.41725-78

main departments together with other performance indicators of the enterprise.

4.1.4. Indicators (clause 4.1.1.) can be determined by a block of the same type of workshops (preparation-stamping, metalwork-assembly and others).

4L.5. The methodology for determining and accounting for the indicator of product delivery to the customer's representative from the first presentation is determined by additional regulatory and technical documentation approved by the Ministry and agreed with the customer's management.

6. The indicator of the delivery of products to the VTK and the representative for kalik

from the first presentation is determined by the formula as a percentage:

T about. - T open.

D S ---- * (I I

where: T about. - the labor intensity of work for the month, performed by the performer, team, accounting * or the total labor intensity of work in the volume of gross output according to the price for the month.

Т otk.- labor-intensive ^ work for the product, rejected by the employee of the VTK or the representative / customer, respectively, according to the executors of the divisions. \ / ®

4.1.7. Indicator, characters! the number of cases of deviations or the percentage of products rejected by the STC and the customer's representative is operational, supplementing / the indicator of delivery of products to the STC and the customer's representative from the first / presentation. The indicator is used when discussing cases of deviation from product acceptance at operational meetings on quality with the heads of the workshop and with the head of the enterprise.

The indicator is determined by the formula:

Where: Noth/ number of notifications submitted for products, off*|en-

OCT I.41725-78 Page 17

BTU or customer's changer.

Instant $gkoyauchVo submitted notices for products ^ submitted ^ BTC go to the representative of the customer for the day, week, month.

4 * 1 * 8, The indicator characterizing and the number of cases of product deviations "is not ^ reporting and cannot be ^ / used when determining the coefficient of labor quality in the workshop,

4L.9. The coefficient of labor quality for tse ^ y is determined by the form

Where: I - the maximum value of the labor quality coefficient,

m - the number of specified factors (all comments) on the quality of work /

ss - size / reduction for one remark of a certain I

view (fakchbra))

the number of comments of one type I (factor) per month, the procedure for calculating indicators.

4.2.1> h Calculation of the indicator of delivery of BTK products from the first presentation for individual performers and for teams, sections, workshops ^ will be carried out by the Information and Computing Center (ICC).

4.2.2. The calculation of the indicator is carried out in parallel with the salary once a month

4.2.3. The main or source documents for calculating indicators are:

work orders for piecework performers^

established production facilities

(D

mi masters and workers^BTK;

Information on the labor intensity of rejected works for performers working on a time basis during the final control (Appendix 4).

4.2 ^ 4 ". Information on the labor intensity of rejected works is compiled by an employee of the Labor and Wage Bureau (BTiz) of the workshop on the basis of

your statements of rejected works * (Appendix 5

2.5. The list of rejected works determines their list and the list of specific ^ culprits of marriage or defect. For finished products consisting of ready-made, assemblies made by various performers, the deviation is issued \ for those performers through whose fault the defects were made.

4.2.6. A list of rejected works for the workshop should be compiled by the VTK and submitted to the BTiZ on a weekly basis. The deadlines for the submission of the last statements to the BTiZ are consistent with the deadlines for the submission of payment documents (work orders)

4.2.7 # Information / delivery of VTK products from the first presentation by individual performers, sections, workshops, SHSho are drawn up in the input of summary tabulagrams * (Recommended Appendix 6.) The tabulagram contains the amount of the monthly salary of each worker, the amount of the bonus accrued to him for the delivery of products, from the first / presentation. An example of calculating the rate of delivery of BTKKhr products for the first presentation by an individual performer and a workshop is given in Appendix 7.

4.3. The procedure for determining the coefficient of labor quality by workshops.

4.3.1. The labor quality coefficient "K w f" is determined separately by the technical bureau of the QCD:

on the production shop;

According to the technical / control bureau, VTK.

4.3.2. The calculation of the coefficient (Formula 3) is based on

analysis of data on deviations in the work of the workshop and the EJ obtained from:

Reporting information about the work of the shop and VTK for the current period; accounting information of the ITC in terms of delivery of VTK products from the first

presentation, about the losses of the workshop from marriage;

Accounting information about non-fulfillment of measures, non-introduced structural changes, issued sheets for eliminating defects

information of the maintenance and repair department (ERD) about the unfulfilled improvements on the products on the basis of complaints; other information, at / ityva-

\ ^ received \ in the technical bureau of the OTC. when calculating „Kk.t.

3.3. Information about deviations in work according to its content corresponds to the factors set forth in appendices 8.9. All / factors are divided into typical groups and each factor is assigned shis |

4.3.4. ^The size of the decrease in the quality factor / ore is the same for all enterprises. They are established / based on the statistics of the applied sizes of the decrease in the labor quality factor in enterprises.

4.3.5. The size of the bottom "K k. t>" according to the break is differentiated by

groups of workshops and should be a multiple of the average level of scrap for each group. aggregate and defense, workshops - / marriage 0.5 percent "To k. t." reduced by AP.\ / ®

4.3.6. The chief controller ^ the head of the OUK, if necessary, is allowed to introduce additional factors of "punitive measures" and forms of encouragement that are taken into account / according to the conditions of social competition.

4.3.7. Further addition and refinement of the reduction dimensions

"Kg t" according to the factors was produced by the main departments

Ministries in agreement on management, quality and reliability.

4.3.8. The calculation of the quality factor of the corpse is carried out according to

the table for calculating the coefficient of labor quality in shops for the reporting month (Appendix 10).

4.3.9. An employee of the Technical Bureau of the Quality Control Department for each code \factors and each workshop enters / into the table the amount of reduction "Kg ^",

4.3.10. The total size of the decrease in the indicator and the actual impression*

tel by workshop or technical control bureau are given in

the final column of the calculation table.

OCT I.41726-78 Page 2

I. GENERAL PROVISIONS

1.1. The organization of defect-free manufacturing of products and its delivery to the Quality Control Department and the customer from the first presentation at serial enterprises is the main part of the product quality management system in the association and at the enterprises of the industry.

1.2. The standard was developed in accordance with and in the development of OST I.00201-76 and quality management systems operating in the industry.

1.3. Defect-free manufacturing of products is understood as the system of work of performers and maintenance engineering and technical personnel of the workshop, which ensures the manufacture and delivery of products to the technical control bureau (VTK) and the customer without defects from the first presentation.

1.4. Defect-free manufacturing of products in production and auxiliary shops is ensured by a complex of organizational, production, technical and ideological measures with high consciousness and responsibility of the performers and employees of the enterprise.

1.5. Responsible persons for the quality of products manufactured by the workshop ^ should be:

The worker as a direct executor;

Production foreman as technical manager of the production site;

The head of the shop and his deputies as senior technical and administrative heads of the shop.

1.6. For the quality of products accepted by the VTK and handed over to the consumer shops, along with the employees of the technical control bureau, direct executors, production foremen, and the head of the shop should be responsible.

1.7. Responsibility for compliance with the technological discipline

4v3.II. The calculation table ^ KlTv,s for the shops of the VTK is printed in three copies, signed by the engineer) performing the calculation, controlled by the head T.B. OTK and signed by the chief controller and head of the OUK.

4.3.12. Two copies of the calculation - "K. "^ Sent to the SUK for

accounting and submission to the OTiZ ichkomishzhzh "on summing up the results of the socialist competition between the workers and auxiliary shops of the enterprise. ®

4.3.13. A high / low level of work of shops in terms of the labor quality coefficient "is set by the Ltshs enterprise, for example: the ZHV coefficient characterizes the good work of the shops, the shop can be presented for awarding a place to it under the conditions of social competition; a coefficient of 0.5 and below reflects the unsatisfactory work of the shop^

4.4. Planning the labor quality factor for workshops and BS workshops

4.4.1% Planning of the labor quality coefficient "K pl>" leads

Quality Management Department (Bureau)*

4.4.2. The labor quality index is planned for the quarter ana-%

it is logical to plan the manufacture of products of the main production. Century vate l - ^ d "corresponds to the arithmetic mean ottatism for the past quarter. The arithmetic mean coefficient of labor quality in the past quarter ^ ^ ^ - is determined by: ®

OCT 1.41725-78 Page 3

us, for the performance of work in accordance with the approved technical process and for the admitted marriage in work (definition of marriage in accordance with GOST I7I02-7I) is assigned to the direct executors, foremen, production foremen, shop managers; control is carried out by BTK and the technological bureau of the shop.

1.8. Responsibility for the quality of the current technological documentation, as well as for the timely introduction of changes into it, should be borne by the technologists and the head of the technological bureau of the workshop.

1.9. Responsibility for organizing the work of the BTK, fulfilling all the requirements of the OST in the control of product quality, performing the functions of accounting and responsibility for indicators of defect-free labor should be assigned to the chief controller of the enterprise.

1.10. The provision of BTK and the customer's representative with the necessary regulatory and technical documentation related to the system of defect-free manufacturing of products should be assigned to the technical and production services of the shop.

2. ORGANIZATIONAL BASES OF DEFECT-FREE MANUFACTURING OF PRODUCTS.

2L. The organization of work on defect-free manufacturing of products should be determined by this standard and the standards of enterprises developed in accordance with it (STP) and other regulatory and technical documentation.

2.2. The system of defect-free manufacturing of products provides for organizational, technical and educational measures aimed at solving the following main issues:

Structural and technological refinement of new products launched into mass production;

Development of serial technological processes;

Improving the organization of production processes

OCT 1.41725-78 Page 4

leniya products;

Improving the organization and methods of product quality control;

Organization of certification of performers and their transfer to self-control;

Development of action plans to improve product quality;

Educating performers of consciousness and responsibility for product quality;

Moral and material encouragement of performers for defect-free production of products.

2.3. Structural and technological refinement of new products, as well as the development and implementation of serial technological processes for new products in the process of launching them into mass production, is carried out in accordance with the adopted system at the enterprises of the industry and the current regulatory and technical documentation.

2.3.1. One of the stages of work to improve the design and quality of individual parts and assemblies in the manufacture of the first staged products is the organized design study of drawings.

and documentation in production workshops, taking into account the proposals of working performers, production foremen, engineering and technical workers. All proposals to refine the design (drawings) of parts and assemblies should be immediately considered by the leading designers of the serial design department with decision-making.

2.3.2. The development of serial technological processes for a new product should provide for the use and application of standard technological processes, unified and standardized tooling elements, standard control operations, automated and mechanized controls for mass parts and other means,

providing reliable quality control results.

2.4. Improving the organization of production processes for the manufacture of products provides for:

Organization and maintenance of individual production processes of processing, assembly, welding, in-line production of products and other processes ^ Use of visual aids (posters) in the work for performing individual technological operations or labor methods;

Organization of scheduled preventive maintenance of workplaces and equipping them with standard and specialized equipment;

Organization of work on technical training and advanced training of performers at special targeted courses with training

their work on the system of defect-free manufacturing of products;

Organization of systematic inspections to maintain a culture of work and cleanliness of workplaces by workshop and general plant commissions,

2.4.1. The organization of production and work culture that meet the requirements of the production process at sites and workplaces should exclude the possibility of contamination of the units, the ingress of foreign objects, industrial waste and damage to manufactured products.

2.5. Improving the organization and methods of product quality control provides for:

Quality control of individual parts, assemblies and elements of complex systems according to control samples (standards);

Acceptance of the first parts, assemblies, assemblies and assemblies of newly mastered products (after their acceptance by the production foreman and BTK employee) by a special commission consisting of shop specialists. Acceptance is formalized by a special act;

Consideration of technical and organizational issues that arise in production and upon acceptance of products by permanent integrated commissions for quality (G1DKK) of the workshop and enterprise. PDKK work system

OST 1.41725-78 Page. 6

determined by the normative documentation of the Ministry;

Organization of annual inspections by BTC employees and public commissions and maintaining the quality level of products in all production shops for compliance with their regulatory and technical documentation and delivery conditions;

Monitoring the implementation of schedules for checking technological equipment, equipment * the state of control and testing stations and measuring instruments; provision of workplaces with control and measuring means;

Organization of periodic "flying inspections" of product quality, checking the status of technical documentation by the employees of the BTC and IT.R of the shop according to pre-drawn plans.

VpOgfycif JjQtMusty

2.6. The organization of the certification of performers and their transfer to self-control provides for:

SftoPvuG checks)

Organization of certification of performers for their performance of responsible technological operations through the workshop qualification commission

oroZersts zRvfm? f

this. The certification system should provide for the procedure in which the performer is deprived of the certificate and the right to work on this operation in cases of repeated violations of the technological process and the manufacture of defective products. The list of responsible operations is approved by the order for the workshop;

The procedure for issuing personal brands to performers with a certificate for the right to self-control of manufactured products or individual operations without presenting the BTK. Personal brands and certificates should be issued to performers who are excellent in production, delivering products for a long time from the first presentation. The certificate issued to the performer must indicate the types of work or the list of operations assigned to him. The quality of the work of the performer should be checked periodically by flying control of the BTK or the inspection team of the Quality Control Department, Issuing

OCT I 41725-78 Page 7

personal stigma and deprivation of the performer of a personal stigma for serious omissions in the work is established by the current regulatory documentation,

2.7, Development of action plans to improve product quality provides for:

Improving the design of parts, assemblies of serial products based on the results of cyclic, strength and life tests;

Technological use of:?: means of ensuring product quality (hardening processes, electrospark, ultrasonic processing methods and others ^ the use of non-destructive testing tools and other objective methods;

Elimination of the causes of marriage and defects in products in production based on a technical analysis of each case of the nature of the marriage;

Elimination of the causes of damage to finished parts and assemblies during their installation, storage and transportation, through the use of special and universal organizational equipment and mechanization;

Increasing the percentage of delivery of products to BTK and the customer's representative from the first presentation through the development and implementation of organizational forms and the active implementation of a system for defect-free manufacturing of products;

Elimination of cases of return of products from consumer workshops by increasing the demands on the performers and employees of the workshop and BTK services;

Organization of an active method of monitoring the implementation of measures to improve the quality * of products and mechanized accounting of their implementation;

Implementation of activities and decisions taken at meetings of the "day of quality" with the head of the enterprise or the head of the shop.

2.7.1. The action plans being developed are divided into one-

rative, requiring immediate implementation in production ^ and long-term - quarter » year.

2.7.2. The development of action plans should be carried out using the records of the VTK about deviations in product quality, information from consumer workshops about cases of return of defective products

and product defects identified in operation;

2.7.3. The procedure for developing action plans is determined by the regulatory documentation in force at the enterprise.

2.8. Raising consciousness and responsibility for product quality among performers provides for:

Formation in each performer of the consciousness of personal responsibility for his work and the work of the section "of the shop;

Bringing to the attention of all shop workers about the results of the work of the unit on the quality of products;

Display and promotion of the best achievements and methods of work of production leaders;

Organization of meetings (conversations) with leading designers and representatives of operating organizations (customer) to get acquainted with malfunctions and shortcomings in the operation of individual units or components and products.

2.9. Moral and material encouragement of performers for defect-free production of products.

2.9.1. The moral encouragement of performers for defect-free work is an important incentive to improve quality, instill a sense of responsibility and professional pride in their work. Forms of moral encouragement should be varied and determined depending on the degree of merits of the performers and the nature of their contribution to the overall task of improving product quality, the main of which are:

OCT I.41725-78 Page nine

Rewarding with the badge "Excellent worker of socialist competition 5 'or an honorary diploma of the Ministry;

Awarding with the badge "Excellent worker of quality" of the Ministry;

Rewarding with the badge "Excellent worker of quality" of the plant;

Rewarding with the diploma "Excellent worker of quality" of the plant;

Information about the titles awarded, awards, performance achieved by individual performers through the factory seal, general factory and shop honor boards, public meetings, etc.

Presentation of benefits for the right to receive living space and vouchers to health resorts.

2.9.2. Material incentives (bonuses) for performers, engineering and technical workers (1TP) and employees for defect-free manufacturing of products are used in combination with quantitative indicators of the implementation of the plan by production units.

2.9.3. The system should objectively take into account the results of the work of both individual performers and the team as a whole.

2.9 "4. The conditions for determining the amount of premiums are"

For piece workers and time workers - high-quality implementation of the technological process and delivery of products from the first presentation;

Engineering and technical workers of the shop - high indicators of the quality of labor (the quality factor is the absence of rough steam -

nii-delivery of products to the representative of the customer; ®

VTK employees (controllers) - high-quality performance of control functions, the absence of cases of missing defects and returning products to consumer shops;

For engineering and technical workers of the BTK workshop - the fulfillment of the quality indicators of the work of the BTK (labor quality factor), the absence of product deviations by the customer's representative.