Contoh Trial Progres

PT.
BINA USAHA MANDIRI

MIZUSAWA
OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec.
. Jatiuwung - Tangerang, INDONESIA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
PT TOMOE VALVE BATAM
Cavity/mould
Part Name
BODY 304 YA - 80 mm
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
Remark
> Quantity Trial

> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
A. Furnace Composition
Item
Standard (%)
Actual (%)
> Carbon
3,90 0,05
3,95
> Silicone
2,30 0,05
2,32
> Mangan
Max. 0,40
0,41
> Phospor
Max. 0,03
0,024
> Sulphur
Max. 0,02
0,027
Standard (%)
Actual (%)
Remark
Nama Material
Remark
Nama Material
B. Casting Composition
Item
> Carbon
2,60 - 3,90
> Silicone
1,60 - 3,00
> Mangan
0,10 - 0,80
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
1522
> Pouring
1400 ~ 1420
1411
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRES
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 Cav
9 Mold
3. INSPECTION
A. Visual Defect (%)
Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
0 Pcs
100%
Remark :
1 pcs dipotong untuk pengecekan shrinkage
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
> Hardness
Ferrite 70 %
Nodularyti 70 %
HB / HRB
140 ~ 210 HB
C. Mechanical Properties
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
No
1
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Gatting system kurang efektif
Shrinkage
Shrikage
Tindakan Perbaik
Perubahan gatting system
JUDGEMENT
O
K
N
G
Approved
Spv/Koord Engineering
No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02
TECHNICAL DEPT
Engineering
Trial Date
SALAH
Tindakan Perbaikan
erubahan gatting system
Pre Launch
Mass Production
PIC
Waktu
Approved
Prepared
Process Engineering
PT. BINA USAHA MANDIRI

MIZUSAWA
OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya
. Kec. Jatiuwung - Tangerang, INDONESIA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
PT TOMOE VALVE BATAM
Cavity/mould
Part Name
BODY 304 YA - 80 mm
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
Remark
10
> Quantity Trial

> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,90 0,05
3,90
> Silicone
2,30 0,05
2,33
> Mangan
Max. 0,40
0,43
> Phospor
Max. 0,03
0,04
> Sulphur
Max. 0,02
0,03
Standard (%)
Actual (%)
> Carbon
2,60 - 3,90
3,78
> Silicone
1,60 - 3,00
3,00
> Mangan
0,10 - 0,80
0,42
> Phospor
Max. 0,08
0,05
> Sulphur
Max. 0,05
0,02
0,025 - 0,090
0,040
Standard ( C )
Actual ( C )
Remark
Nama Material
Remark
Nama Material
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
1424
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Gatting system sebelum perubahan
Sebelum
perubah
an
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 Cav
10 Mold
3. INSPECTION
Item
> Sli
Defect
1
Item
Defect
Remark
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
8 Pcs Total Defect
1 Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Ferrite 70 %
70%
Nodularyti 70 %
90%
140 ~ 210 HB
183 - 187 HB
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
> Hardness
HB / HRB
Item
Tensile Strength
Yield Strength
Elongation
Remark
No
1
Gatting system setelah perubahan
Setelah perubahan
Ingate dibuat 2 jalu
ROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Shrinkage
Shrikage
Tindakan Perbaikan
1 Perubahan gatting system
JUDGEMENT
O N
K G
Approved
TECHNICAL DEPT
Engineering
Trial Date
Tindakan Perbaikan
n gatting system
Pre Launch
Mass Production
PIC
Waktu
Approved
ord Engineering
Prepared
Process Engineering

MIZUSAWA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
PT. TOMOE VALVE BATAM
Cavity/mould
Part Name
BODY 304 YA - 50 mm
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,90 0,05
3,95
> Silicone
2,30 0,05
2,32
> Mangan
Max. 0,40
0,41
> Phospor
Max. 0,03
0,024
> Sulphur
Max. 0,02
0,027
Standard (%)
Actual (%)
Remark
Nama Material
Remark
Nama Material
Item
> Carbon
2,60 - 3,90
> Silicone
1,60 - 3,00
> Mangan
0,10 - 0,80
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
1522
> Pouring
1400 ~ 1420
1411
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 Cav
9 Mold
3. INSPECTION
Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
2 Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
> Hardness
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
Item
Tensile Strength
Yield Strength
Elongation
No
1
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Badlift
Penyebab
Pattern kurang release
Tindakan Perbaikan
Penghalusan pattern pada bagia

terjadi badlift
BadLift
Shrinkage
Shrinkage
JUDGEMENT
O
K
N
G
Approved
TECHNICAL DEPT
Engineering
Trial Date
14.11.2015
Pre Launch
Mass Production
SALAH
Tindakan Perbaikan
enghalusan pattern pada bagian yang

rjadi badlift
erubahan gatting system
PIC
Waktu
Approved
Prepared
Process Engineering

MIZUSAWA
OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung
. - Tangerang, INDONESIA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
Cavity/mould
Part Name
BODY 304 YA - 50 mm
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
10
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,90 0,05
3,90
> Silicone
2,30 0,05
2,33
> Mangan
Max. 0,40
0,43
> Phospor
Max. 0,03
0,04
> Sulphur
Max. 0,02
0,03
Standard (%)
Actual (%)
> Carbon
2,60 - 3,90
3,78
> Silicone
1,60 - 3,00
3,00
> Mangan
0,10 - 0,80
0,42
> Phospor
Max. 0,08
0,05
> Sulphur
Max. 0,05
0,02
0,025 - 0,090
0,040
Standard ( C )
Actual ( C )
Remark
Nama Material
Remark
Nama Material
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
1424
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Sebelum perubahan
Sebelum
perubahan
TRIAL PROGRES
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box
2 Cav
Trial Qty
10 Mold
3. INSPECTION
Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Remark
Standard
Actual
Ferrite 70 %
70%
Nodularyti 70 %
90%
140 ~ 210 HB
183 - 187 HB
HB/HRB
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Setelah perubahan
No
1
Setelah perubahan
Ingate dibuat 2 jalu
PROGRESS
4. ANALISA MASALAH
Masalah
Shrinkage
Shrikage
Penyebab
Tindakan Perbaik
1 Perubahan gatting system
JUDGEMENT
O
K
N
G
Approved
TECHNICAL DEPT
Engineering
Trial Date
01.12.2015
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

MIZUSAWA
OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya
. Kec. Jatiuwung - Tangerang, INDONESIA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
PT. Yanmar Diesel Indonesia
Cavity/mould
12
Pcs
Part Name
Pump Body TF 60/120
Weight/pc
0,8
Kg
Part No.
105500-51012
Weight/mould
22
Kg
Material
FCD 50
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
12
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,85 - 3,95
3,90
> Silicone
1,95 0,05
2,18
> Mangan
0,40 - 0,60
0,40
> Phospor
Max. 0,03
0,03
> Sulphur
Max. 0,03
0,01
Standard (%)
Actual (%)
> Carbon
3,20 - 3,90
3,68
> Silicone
2,30 - 2,75
2,83
> Mangan
Max. 0,70
0,40
> Phospor
Max. 0,10
0,03
> Sulphur
Max. 0,03
0,03
> Magnesium
Max. 0,050
0,043
> Cu
0,20 - 0,30
0,27
Standard ( C )
Actual ( C )
Remark
Nama Material
Remark
Nama Material
Item
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
1422
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
cross joint dengan arah yang berbeda, penyebab kemungkinan terjadinya cross joint diakibatkan oleh
TRIAL PROGRESS
Core Material
Kg
Core Weight/pc
Cav Core Box
Trial Qty
12 Mold
3. INSPECTION
Remark
No
1
Masalah
Sand Inclution
45 %
Bad Mold

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
48
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
71 Pcs Total Defect
59 Pcs
Remark :
Check 130 pcs
BadMold
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
> Hardness
Ferrite 70 %
70%
Nodularyti 70 %
90%
140 ~ 210 HB
183 - 187 HB
HB/HRB
Standard
Actual
Remark
Item
Tensile Strength
Yield Strength
Elongation
Cross Joint
jadinya cross joint diakibatkan oleh mesin

Cavity 1
2 pcs
Cavity 2
8 pcs
Cavity 3
3 pcs
Cavity 4
- pcs
Cavity 5
1 pcs
Cavity 6
2 pcs
Cavity 7
2 pcs
Cavity 8
2 pcs
Cavity 9
4 pcs
Cavity 10
2 pcs
Cavity 11
4 pcs
Cavity 12
6 pcs
GRESS
4. ANALISA MASALAH
Masalah
and Inclution
Penyebab
Pasir terkikis oleh cairan atau
pasir rontok
Tindakan Perbaikan
Pada proses mold harus lebih teliti saat
proses pembersihan
Si
Pasir keropos atau pressure
rendah
menggunakan pressure harus ditinggikan

untuk mencegah pasir keropos
BadMold
paatern terdapat cross joint atau cek cross joint pada pattern dan analisa pad
permasalahan pada mesin molding
mesin molding bermasalah
sehingga pada saat proses
assembling molding menjadi tidak
rata
JUDGEMENT
O
K
N
G
Approved
TECHNICAL DEPT
Engineering
Trial Date
04.12.2015
Pre Launch
Mass Production
Tindakan Perbaikan
mold harus lebih teliti saat

ersihan
n pressure harus ditinggikan

gah pasir keropos
t pada pattern dan analisa pada

n pada mesin molding
PIC
Waktu
Approved
ord Engineering
Prepared
Process Engineering

MIZUSAWA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
PT Panasonic Manufacturing Ind
Cavity/mould
Part Name
PC 2,0 HC
Weight/pc
Part No.
XRKS20MPRZF
Weight/mould
Material
FC 10
Yield
Pcs
4,21
9
Specification
Remark
> Quantity Trial
Moulds
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,70 - 3,95
3,84
> Silicone
2,30 - 2,60
2,38
> Mangan
0,40 Max
0,38
> Phospor
0,03 Max
0,027
> Sulphur
0,03 Max
0,028
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Carbon
3,90 0,05
> Silicone
2,20 0,05
> Mangan
0,40 Max
> Phospor
0,03 Max
> Sulphur
0,02 Max
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
Standard
Kg
%
1. PATTERN MAKING
Item
Kg
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
1,2 Kg
2 cav
15 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
15 Pcs Total Defect
0 Pcs
100 %
Remark :
1 pcs casting dipotong untuk pengecekan komposisi dan microstructure
B. Microstructure
Item
Standard
Actual
> Graphite type
A& B
Size
4-6
> Matrix : P/F

> Cementite
> Hardness
Remark
Ferrite 70 %
75 - 85 HRB
78 - 81
HB/HRB
Standard
Actual
Remark
11 Kgf mm2
No Test
Item
Tensile Strength
Yield Strength
Elongation
Masalah
GRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
JUDGEMENT
O
K
N
G
Approved
TECHNICAL DEPT
Engineering
Trial Date
17.12.2015
Pre Launch
Mass Production
Tindakan Perbaikan
PIC
Waktu
Approved
ord Engineering
Prepared
Process Engineering

MIZUSAWA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
Cavity/mould
Part Name
BODY 304 YA - 50 mm
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
Remark
> Quantity Trial
Moulds
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
2,60 - 3,90
> Silicone
1,60 - 3,00
> Mangan
0,10 - 0,80
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 cav
10 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved
TECHNICAL DEPT
Engineering
Trial Date
17.12.2015
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

MIZUSAWA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
Cavity/mould
Part Name
BODY 304 YA - 80 mm
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
Remark
> Quantity Trial
Moulds
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
2,60 - 3,90
> Silicone
1,60 - 3,00
> Mangan
0,10 - 0,80
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 cav
10 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
> Hardness
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved
TECHNICAL DEPT
Engineering
Trial Date
17.12.2015
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

MIZUSAWA
OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung . Tangerang, INDONESIA
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
Cavity/mould
Part Name
PC GP 2,0 HC
Weight/pc
Kg
Part No.
XRKS20MPRZF
Weight/mould
Kg
Material
FC 10
Yield
1. PATTERN MAKING
Item
Specification
Remark
> Quantity Trial
Moulds
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,20 0,05
> Mangan
0,40 Max
> Phospor
0,03 Max
> Sulphur
0,02 Max
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,70 - 3,95
> Silicone
2,30 - 2,60
> Mangan
0,40 Max
> Phospor
0,03 Max
> Sulphur
0,03 Max
> Magnesium
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 cav
30 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
75 ~ 85 HRB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved
TECHNICAL DEPT
Engineering
Trial Date
17.12.2015
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering
PT. BINA USAHA MANDIRI MIZUSAWA

OFFICE/FACTORY : Jl. KH. EZ. Mutaqien Kp. Doyong, Kel. Alam Jaya Kec. Jatiuwung Tangerang, INDONESIA.
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
PT. YANMAR DIESEL INDONESIA
Cavity/mould
Part Name
Balancer Shaft L70V
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FCD 450
Yield
1. PATTERN MAKING
Item
Specification
Remark
> Quantity Trial
Moulds
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,95 0,05
> Silicone
2,15 0,05
> Mangan
Max 0,40
> Phospor
Max 0,03
> Sulphur
Max 0,03
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,6 - 3,90
> Silicone
2,70- 3,00
> Mangan
Max 0,40
> Phospor
Max 0,03
> Sulphur
Max 0,03
> Magnesium
0,030 - 0,050
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
> Per Mould
Standard
Second/Mould
> Per Ladle

Notes :
Minutes/Ladle
TRIAL PROGRESS
Core Material
Kg
Core Weight/pc
Cav Core Box

Trial Qty
8 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
8 Pcs Total Defect
0 Pcs
Standard
Actual
Remark :
B. Microstructure
Item
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Standard
Actual
Remark
Masalah
Elongation
GRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
JUDGEMENT
O
K
N
G
Approved
TECHNICAL DEPT Engineering

Trial Date
18.12.2015
Pre Launch
Mass Production
Tindakan Perbaikan
PIC
Waktu
Approved
ord Engineering
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
Cavity/mould
Part Name
PC GP 1,0 HC
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FC 10
Yield
1. PATTERN MAKING
Item
Specification
Remark
> Quantity Trial
Moulds
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,90 0,05
3,95
> Silicone
2,20 0,05
2,22
> Mangan
0,40 Max
0,39
> Phospor
0,03 Max
0,03
> Sulphur
0,02 Max
0,02
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,70 - 3,95
3,95
> Silicone
2,30 - 2,60
2,44
> Mangan
0,40 Max
0,39
> Phospor
0,03 Max
0,02
> Sulphur
0,03 Max
0,03
Standard ( C )
Actual ( C )
Remark
Actual
Remark
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 cav
15 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
75 ~ 85 HRB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
29.12.2015
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
Cavity/mould
Part Name
BODY 304 YA - 40 mm
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
2,60 - 3,90
> Silicone
1,60 - 3,00
> Mangan
0,10 - 0,80
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 cav
9 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
9 Pcs Total Defect
0 Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
14.12.2015 oke
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
Cavity/mould
Part Name
BODY 304 YA - 65 mm
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
Cav/Mould
FCD 45
1 Cavity
Yield
1. PATTERN MAKING
Item
Specification
Remark
> Quantity Trial
Moulds
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
2,60 - 3,90
> Silicone
1,60 - 3,00
> Mangan
0,10 - 0,80
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 cav
Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
8 Pcs Total Defect
0 Pcs
Standard
Actual
Remark :
B. Microstructure
Item
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Standard
Actual
Remark
Masalah
Yield Strength
Elongation
GRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
JUDGEMENT
O
K
N
G
Approved

Trial Date
14.12.2015
Pre Launch
Mass Production
Tindakan Perbaikan
PIC
Waktu
Approved
ord Engineering
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
PC GP 2.0 HC
Weight/pc
4,21
Kg
Kg
46,7
Part No.
Weight/mould
Material
FC 10
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
38
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,90 0,05
3,95
> Silicone
2,20 0,05
2,22
> Mangan
0,40 Max
0,39
> Phospor
0,03 Max
0,03
> Sulphur
0,02 Max
0,02
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,70 - 3,95
3,95
> Silicone
2,30 - 2,60
2,44
> Mangan
0,40 Max
0,39
> Phospor
0,03 Max
0,02
> Sulphur
0,03 Max
0,03
Standard ( C )
Actual ( C )
Remark
Actual
Remark
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
> Per Mould
Standard
Second/Mould
Pcs
> Per Ladle

Notes :
Minutes/Ladle
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 cav
38 Mold
3. INSPECTION
Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
Remark
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
29 Pcs Total Defect
12 Pcs
Remark :
9 casting yang NG bad core dilakukan proses repair
B. Microstructure
Item
Standard
Actual
> Graphite type
A&B
A&B
Size
4-6
Ferrite 70 %
3%F
> Matrix : P/F

> Cementite
> Hardness
Remark
Nodularyti 70 %
75 - 85 HRB
133 - 135
HB/HRB
Standard
Actual
Remark
Item
Tensile Strength
Yield Strength
No
1
Elongation
PROGRESS
4. ANALISA MASALAH
Masalah
Slag Inclution
Penyebab
Tindakan Perbaikan
Gatting system kurang efektif dan Modifikasi gatting system dibuat

belum menggunakan sedex
JUDGEMENT
O
K
N
G
Approved

Trial Date
29.12.2015
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
odifikasi gatting system dibuatkan slag trap
PIC
Rohyat /
Sujarwo
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
PC GP 2.0 HC
Weight/pc
4,21
Kg
Kg
46,7
Part No.
Weight/mould
Material
FC 10
Yield
Pcs
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
60
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,70 - 3,95
3,90
> Silicone
2,30 - 2,60
2,84
> Mangan
0,40 Max
0,40
> Phospor
0,03 Max
0,03
> Sulphur
0,03 Max
0,02
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Carbon
3,90 0,05
> Silicone
2,20 0,05
> Mangan
0,40 Max
> Phospor
0,03 Max
> Sulphur
0,02 Max
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
> Per Mould
Standard
Second/Mould
> Per Ladle

Notes :
Minutes/Ladle
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 cav
60 Mold
3. INSPECTION
Item
> Sli
Defect
2
Item
Defect
Remark
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
53 Pcs Total Defect
7 Pcs
Standard
Actual
> Graphite type
A& B
A& B
Size
4-6
Ferrite 70 %
3%F
Nodularyti 70 %
Remark :
B. Microstructure
Item
> Matrix : P/F

> Cementite
> Hardness
Remark
79 ~ 84
HB/HRB
Actual
Remark
Item
Tensile Strength
Yield Strength
Standard
No
1
Masalah
Slag Inclution
Elongation
GRESS
ag Inclution
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
Gatting system kurang efektif dan Modifikasi gatting system dibuatkan slag tra
belum menggunakan sedex
JUDGEMENT
O
K
N
G
Approved

Trial Date
5.01.2016
Pre Launch
Mass Production
Tindakan Perbaikan
ting system dibuatkan slag trap
PIC
Rohyat /
Sujarwo
Waktu
Approved
ord Engineering
Prepared
Process Engineering
TRIAL PROGRESS
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs Core Material
Customer
Cavity/mould
Part Name
BODY 304 YA - 80 mm
Weight/pc
3,1
Kg Core Weight/pc
Weight/mould
13,3
Kg Cav
Part No.
Material
FCD 45
Yield
66
Core Box
% Trial Qty
RCS
0,86 Kg
2 cav
8 Mold
1. PATTERN MAKING
Item
3. INSPECTION
Specification
> Quantity Trial
Remark
No

Item
Moulds
Defect
Item
> Released Pattern
OK / NG
> Sli
> CJ
> Hardness Mould
80 ~ 89
> SE
> BL
> Sensor Cope
1 / 2 / 3 / 4
> Si
> BM
> Sensor Drag
1 / 2 / 3 / 4
> SD
> CS
> Diameter Sprue
28 / 30 / 32
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,90 0,05
3,94
> Crush
> Silicone
2,30 0,05
2,25
> SP
> Mangan
Max. 0,40
0,40
> RO
> Phospor
Max. 0,03
0,027
> Carbide
> Sulphur
Max. 0,02
0,026
Total GooD
Item
> Harness Up
Low
> Excentric
> Carbon
2,60 - 3,90
3,70
> Silicone
1,60 - 3,00
3,08
> Mangan
0,10 - 0,80
0,40
> Phospor
Max. 0,08
0,030
> Sulphur
Max. 0,05
0,016
Item
0,025 - 0,090
0,040
> Graphite type
C. Temperature
8 Pcs Total Defect
0 Pcs
Standard
Actual
Remark :
Actual (%)
> Cu
Remark
Low
Standard (%)
> Magnesium
Defect
Remark
Nama Material
B. Microstructure
Size
> Matrix : P/F
Ferrite 70 %
Remark
Ma
Item
Standard ( C )
Actual ( C )
Remark
> Cementite
1500 ~ 1520
> Hardness
> Pouring
1400 ~ 1420
Item
Item
Standard
Actual
Remark
Tensile Strength
> Per Mould
Second/Mould
Yield Strength
> Per Ladle
Minutes/Ladle
Elongation
Notes :
HB/HRB
140 ~ 210 HB
> Tapping
D. Pouring Time
Nodularyti 70 %
Standard
Actual
Remark
ESS

Trial Date
7.01.2016
Pre Launch
Mass Production
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
PIC
Waktu
JUDGEMENT
O
K
N
G
Approved
Prepared
Process Engineering
TRIAL PROGRESS
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs Core Material
Customer
Cavity/mould
Part Name
BODY 304 YA - 50 mm
Weight/pc
2,19
Kg Core Weight/pc
Weight/mould
13,3
Kg Cav
Part No.
Material
FCD 45
Yield
66
Core Box
% Trial Qty
RCS
0,35 Kg
2 cav
8 Mold
1. PATTERN MAKING
Item
3. INSPECTION
Specification
> Quantity Trial
Remark
No

Item
Moulds
Defect
Item
> Released Pattern
OK / NG
> Sli
> CJ
> Hardness Mould
80 ~ 89
> SE
> BL
> Sensor Cope
1 / 2 / 3 / 4
> Si
> BM
> Sensor Drag
1 / 2 / 3 / 4
> SD
> CS
> Diameter Sprue
28 / 30 / 32
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,90 0,05
3,94
> Crush
> Silicone
2,30 0,05
2,25
> SP
> Mangan
Max. 0,40
0,40
> RO
> Phospor
Max. 0,03
0,027
> Carbide
> Sulphur
Max. 0,02
0,026
Total GooD
Item
> Harness Up
Low
> Excentric
> Carbon
2,60 - 3,90
3,70
> Silicone
1,60 - 3,00
3,08
> Mangan
0,10 - 0,80
0,40
> Phospor
Max. 0,08
0,030
> Sulphur
Max. 0,05
0,016
Item
0,025 - 0,090
0,040
> Graphite type
C. Temperature
8 Pcs Total Defect
0 Pcs
Standard
Actual
Remark :
Actual (%)
> Cu
Remark
Low
Standard (%)
> Magnesium
Defect
Remark
Nama Material
B. Microstructure
Size
> Matrix : P/F
Ferrite 70 %
Remark
Ma
Item
Standard ( C )
Actual ( C )
Remark
> Cementite
1500 ~ 1520
> Hardness
> Pouring
1400 ~ 1420
Item
Item
Standard
Actual
Remark
Tensile Strength
> Per Mould
Second/Mould
Yield Strength
> Per Ladle
Minutes/Ladle
Elongation
Notes :
HB/HRB
140 ~ 210 HB
> Tapping
D. Pouring Time
Nodularyti 70 %
Standard
Actual
Remark
ESS

Trial Date
7.01.2016
Pre Launch
Mass Production
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
PIC
Waktu
JUDGEMENT
O
K
N
G
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
12
Pcs
Weight/pc
0,46
Kg
Weight/mould
10,5
Kg
Yield
52,2
Customer
PT. NICE
Cavity/mould
Part Name
Insert Ring 0120
Part No.
Material
FC - 200
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,50 - 3,60
3,52
> Silicone
1,95 - 2,05
1,60
> Mangan
0,50 - 0,60
0,59
> Phospor
Max. 0,03%
0,028
> Sulphur
Max. 0,03%
0,025
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,40 - 3,50
3,51
> Silicone
1,95 - 2,35
1,86
> Mangan
0,5 - 0,7
0,57
> Phospor
Max. 0,03%
0,027
> Sulphur
Max. 0,03%
0,024
Standard ( C )
Actual ( C )
Remark
Standard
Actual
Remark
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
> Pouring
D. Pouring Time
Item
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Hardness Up
Micro :
Hardness and Micro Test

Result Test Hardness : 227 - 241 HB
TRIAL PROGRESS
Core Material
Kg
Core Weight/pc
Cav Core Box

Trial Qty
5 Mold
3. INSPECTION
Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
60
Remark
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
0 Pcs Total Defect
60 Pcs
Standard
Actual
Remark
227 - 241
HB/HRB
Actual
Remark
Remark :
B. Microstructure
Item
> Graphite type
Size
> Matrix : P/F
> Cementite
Ferrite %
Nodularyti %
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
No
1
7 - 241 HB
PROGRESS
4. ANALISA MASALAH
Masalah
Shrinkage pada bagian Ingate
Shrinkage
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
12.01.2016
Pre Launch
Std FC-25 FW NF60

C:
Mass Production
ASALAH
Si :
Tindakan Perbaikan
PIC
Waktu
Mn :
P:
S:
Approved
Prepared
Process Engineering
Std FC-25 FW NF60

3,10 - 3,80%
1,50 - 2,50%
0,40 - 0,80%
Max. 0,01%
Max. 0,01%

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
24
Pcs
Weight/pc
0,18
Kg
Weight/mould
9,32
Kg
46,35
Customer
PT. NICE
Cavity/mould
Part Name
Insert Ring 0130
Part No.
Material
FC - 200
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,50 - 3,60
3,45
> Silicone
1,95 - 2,05
1,60
> Mangan
0,50 - 0,60
0,57
> Phospor
Max. 0,03%
0,028
> Sulphur
Max. 0,03%
0,023
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,40 - 3,50
3,36
> Silicone
1,95 - 2,35
1,85
> Mangan
0,5 - 0,7
0,56
> Phospor
Max. 0,03%
0,025
> Sulphur
Max. 0,03%
0,02
Standard ( C )
Actual ( C )
Remark
Standard
Actual
Remark
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
> Pouring
D. Pouring Time
Item
> Per Mould
Second/Mould
> Per Ladle

Notes :
Minutes/Ladle
Hardness Up

Micro :
TRIAL PROGRESS
Core Material
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 Mold
3. INSPECTION
Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
46
Remark
Masalah
Shrinkage pada bagia
> R Surface
> BH
> MD
> Dim Up
Shrinkage
Low
> SP
No
1
> PH
> Crush
Defect
BadLift pada cavity M
Permukaan kasar
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
0 Pcs Total Defect
48 Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite %
Kasar
Nodularyti %
> Hardness
234 - 241
HB/HRB
Actual
Remark
Item
Tensile Strength
Yield Strength
Standard
Elongation

Micro :
GRESS
4. ANALISA MASALAH
Masalah
hrinkage pada bagian ingate
Shrinkage
adLift pada cavity M
ermukaan kasar
Kasar
Penyebab
Tindakan Perbaikan
JUDGEMENT
O
K
N
G
Approved

Trial Date
Pre Launch
Std FC-25 Ring Pulley

C:
3,00 - 2,70%
Si : 1,40 - 2,60%
Mass Production
Mn : 0,55 - 0,75%
Tindakan Perbaikan
PIC
Waktu
P:
S:
Max. 0,08%
Max. 0,05%
Approved
ord Engineering
Prepared
Process Engineering
25 Ring Pulley
00 - 2,70%
40 - 2,60%
55 - 0,75%
ax. 0,08%
ax. 0,05%

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
PC GP 2.0 HC (Pattern Steel)
Weight/pc
4,21
Part No.
FC 10
Yield
1. PATTERN MAKING
Item
Specification
Remark
> Quantity Trial
Moulds
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,70 - 3,95
3,75
> Silicone
2,30 - 2,60
2,24
> Mangan
0,40 Max
0,37
> Phospor
0,03 Max
0,026
> Sulphur
0,03 Max
0,030
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Carbon
3,90 0,05
> Silicone
2,20 0,05
> Mangan
0,40 Max
> Phospor
0,03 Max
> Sulphur
0,02 Max
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
> Per Mould
Standard
Kg
Kg
Weight/mould
Material
Pcs
Second/Mould
> Per Ladle

Notes :
Minutes/Ladle
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 cav
Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
> Graphite type
A&B
A&B
Size
4-6
Ferrite 70 %
97% P
> Matrix : P/F

> Cementite
> Hardness
Remark
Nodularyti 70 %
75 - 85 HRB
79 - 84
HB/HRB
Standard
Actual
Remark
Item
Tensile Strength
Yield Strength
Elongation
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
JUDGEMENT
O
K
N
G
Approved

Trial Date
29.12.2015
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
Cavity/mould
Part Name
PC GP 1,0 HC
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FC 10
Yield
1. PATTERN MAKING
Item
Specification
Remark
> Quantity Trial
Moulds
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,70 - 3,95
3,75
> Silicone
2,30 - 2,60
2,24
> Mangan
0,40 Max
0,37
> Phospor
0,03 Max
0,026
> Sulphur
0,03 Max
0,030
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Carbon
3,90 0,05
> Silicone
2,20 0,05
> Mangan
0,40 Max
> Phospor
0,03 Max
> Sulphur
0,02 Max
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
RCS
Core Weight/pc
1,174 Kg
Cav Core Box

Trial Qty
2 cav
Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Size
> Cementite
> Hardness
Remark
A&B
> Graphite type
> Matrix : P/F
Actual
Ferrite 70 %
97% P
Nodularyti 70 %
75 ~ 85 HRB
79 - 84
HB/HRB
Standard
Actual
Remark
Item
Tensile Strength
Yield Strength
Elongation
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
29.12.2015
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
PT. MKM
Cavity/mould
Part Name
DRUM HAND BRAKE TD (Steel)
Weight/pc
Part No.
MC-862229
Weight/mould
Material
FC 250
Yield
Pcs
6,8
Kg
Kg
%
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
13
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,10 - 3,80
3,56
> Silicone
1,50 - 2,50
2,16
> Mangan
0,40 - 0,90
0,52
> Phospor
Max. 0,10
0,03
> Sulphur
Max. 0,10
0,04
Max. 0,30
0,30
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Kg
Core Weight/pc
Cav Core Box
Trial Qty
13 Mold
3. INSPECTION
No

Item
> Sli
Defect
1
Item
> BL
> Si
> BM
> SD
> CS
2
Remark
> CJ
> SE
> BC
Defect
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
21 Pcs Total Defect
5 Pcs
Standard
Actual
A (B+D Max.10%)
4-6
Ferrite 2%
2%
Remark :
B. Microstructure
Item
> Graphite type
Size
> Matrix : P/F
> Cementite
> Hardness
Remark
Nodularyti 70 %
187 - 241 HB
192 - 197
HB/HRB
Standard
Actual
Remark
Item
Tensile Strength
Yield Strength
Elongation
Masalah
GRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
JUDGEMENT
O
K
N
G
Approved

Trial Date
29.12.2015
Pre Launch
Mass Production
Tindakan Perbaikan
PIC
Waktu
Approved
ord Engineering
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
PC GP-20HCN1 (Pattern Steel)
Weight/pc
4,21
Part No.
13,42
Weight/mould
Material
FC 10
Yield
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,70 - 3,95
3,71
> Silicone
2,30 - 2,60
2,51
> Mangan
0,40 Max
0,40
> Phospor
0,03 Max
0,028
> Sulphur
0,03 Max
0,027
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Carbon
3,90 0,05
> Silicone
2,20 0,05
> Mangan
0,40 Max
> Phospor
0,03 Max
> Sulphur
0,02 Max
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Kg
Kg
%
1. PATTERN MAKING
Item
Pcs
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 cav
3 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
> Graphite type
A&B
Size
4-6
Pearlite Ferrite
97% P
> Matrix : P/F

> Cementite
> Hardness
Remark
Nodularyti 70 %
75 - 85 HRB
83 - 85
HB/HRB
Standard
Actual
Remark
Item
Tensile Strength
Yield Strength
Elongation
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
Weight/pc
Part No.
2
3,7
12,4
Weight/mould
Material
FC 10
Pcs
Yield
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,70 - 3,95
3,75
> Silicone
2,30 - 2,60
2,24
> Mangan
0,40 Max
0,37
> Phospor
0,03 Max
0,026
> Sulphur
0,03 Max
0,030
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Carbon
3,90 0,05
> Silicone
2,20 0,05
> Mangan
0,40 Max
> Phospor
0,03 Max
> Sulphur
0,02 Max
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1540
> Pouring
1420 - 1440
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Kg
%
1. PATTERN MAKING
Item
Kg
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 cav
5 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
10 Pcs
Remark :
B. Microstructure
Item
Standard
Actual
> Graphite type
A&B
Size
4-6
Pearlite Ferrite
97% P
> Matrix : P/F

> Cementite
Nodularyti 70 %
90 - 95 HRB
> Hardness
Remark
79 - 84
HB/HRB
Item
Tensile Strength
Yield Strength
Elongation
Standard
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
PT. EBARA
Cavity/mould
Part Name
Casing Cover 5 FSH-MN
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FC-200
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
Item
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Kg
Core Weight/pc
Cav Core Box

Trial Qty
5 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
10 Pcs
Remark :
B. Microstructure
Item
Standard
> Graphite type
A&B
Size
4-6
> Matrix : P/F

> Cementite
Actual
Remark
Pearlite Ferrite
Nodularyti 70 %
HB/HRB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
29.12.2015
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
Weight/pc
Part No.
RKS10CPRZF
Weight/mould
Material
FC 10
Yield
Pcs
3,7
12,4
Specification
Remark
> Quantity Trial
Moulds
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,20 0,05
> Mangan
0,40 Max
> Phospor
0,03 Max
> Sulphur
0,02 Max
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
NG
> Carbon
3,70 - 3,95
3,97
> Silicone
2,30 - 2,60
2,48
> Mangan
0,40 Max
0,38
> Phospor
0,03 Max
0,020
> Sulphur
0,03 Max
0,060
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1540
> Pouring
1420 - 1440
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Kg
%
1. PATTERN MAKING
Item
Kg
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 cav
Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
10 Pcs
Remark :
B. Microstructure
Item
Standard
Actual
> Graphite type
A&B
Size
4-6
Pearlite Ferrite
97% P
> Matrix : P/F

> Cementite
Nodularyti 70 %
90 - 95 HRB
> Hardness
Remark
79 - 80
HB/HRB
Item
Tensile Strength
Yield Strength
Elongation
Standard
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
01.02.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
PT. MKM
Cavity/mould
Part Name
DRUM HAND BRAKE TD (Steel)
Weight/pc
Part No.
MC-862229
Weight/mould
Material
FC 250
Yield
Pcs
6,8
Kg
Kg
%
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
25
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,50
> Silicone
1,60
> Mangan
0,58
> Phospor
0,031
> Sulphur
0,020
Remark
Nama Material
Remark
Nama Material
Item
Standard (%)
Actual (%)
> Carbon
3,10 - 3,80
3,50
> Silicone
1,50 - 2,50
1,85
> Mangan
0,40 - 0,90
0,58
> Phospor
Max. 0,10
0,032
> Sulphur
Max. 0,10
0,028
Max. 0,30
0,31
Standard ( C )
Actual ( C )
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
1421
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Kg
Core Weight/pc
Cav Core Box
Trial Qty
25 Mold
3. INSPECTION
No

Item
> Sli
Defect
1
Item
Defect
Remark
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
47 Pcs Total Defect
3 Pcs
Standard
Actual
Remark
187 - 241 HB
187 - 197
HB/HRB
Standard
Actual
Remark
Remark :
TRIAL N40
B. Microstructure
Item
> Graphite type
Size
> Matrix : P/F
> Cementite
> Hardness
A (B+D Max.10%)
4-6
Ferrite 2%
Nodularyti 70 %
Item
Tensile Strength
Yield Strength
Elongation
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
03.2.2015
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
12
Pcs
Weight/pc
0,46
Kg
Weight/mould
10,5
Kg
Yield
52,2
Customer
PT. NICE
Cavity/mould
Part Name
Insert Ring 0120
Part No.
Material
FC - 200
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,50 - 3,60
3,80
> Silicone
1,95 - 2,05
2,01
> Mangan
0,50 - 0,60
0,39
> Phospor
Max. 0,03%
0,025
> Sulphur
Max. 0,03%
0,029
Standard (%)
Actual (%)
> Carbon
3,40 - 3,50
3,75
> Silicone
1,95 - 2,35
2,31
> Mangan
0,5 - 0,7
0,38
> Phospor
Max. 0,03%
0,025
> Sulphur
Max. 0,03%
0,029
Standard ( C )
Actual ( C )
Remark
Nama Material
Remark
Nama Material
Item
> Magnesium
> Cu
C. Temperature
Item
Remark
> Tapping
> Pouring
1420
D. Pouring Time
Item
Standard
Actual
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Kg
Core Weight/pc
Cav Core Box

Trial Qty
5 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
60 Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
171-187
HB/HRB
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite %
Nodularyti %
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
06.2.2016
Pre Launch
Std FC-25 FW NF60

C:
Mass Production
ASALAH
Si :
Tindakan Perbaikan
PIC
Waktu
Mn :
P:
S:
Approved
Prepared
Process Engineering
Std FC-25 FW NF60

3,10 - 3,80%
1,50 - 2,50%
0,40 - 0,80%
Max. 0,01%
Max. 0,01%

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
24
Pcs
Weight/pc
0,18
Kg
Weight/mould
9,32
Kg
46,35
Customer
PT. NICE
Cavity/mould
Part Name
Insert Ring 0130
Part No.
Material
FC - 200
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,50 - 3,60
3,80
> Silicone
1,95 - 2,05
2,01
> Mangan
0,50 - 0,60
0,39
> Phospor
Max. 0,03%
0,025
> Sulphur
Max. 0,03%
0,029
Standard (%)
Actual (%)
> Carbon
3,40 - 3,50
3,75
> Silicone
1,95 - 2,35
2,31
> Mangan
0,5 - 0,7
0,38
> Phospor
Max. 0,03%
0,025
> Sulphur
Max. 0,03%
0,029
Standard ( C )
Actual ( C )
Remark
Nama Material
Remark
Nama Material
Item
> Magnesium
> Cu
C. Temperature
Item
Remark
> Tapping
> Pouring
1420
D. Pouring Time
Item
Standard
Actual
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Kg
Core Weight/pc
Cav Core Box

Trial Qty
5 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
117 Pcs Total Defect
Pcs
Remark :
BL : Cavity A = 1pcs, Cavity M = 2 pcs
B. Microstructure
Item
Standard
Actual
Remark
171-187
HB/HRB
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite %
Nodularyti %
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
06.2.2016
Pre Launch
Std FC-25 FW NF60

C:
Mass Production
ASALAH
Si :
Tindakan Perbaikan
PIC
Waktu
Mn :
P:
S:
Approved
Prepared
Process Engineering
Std FC-25 FW NF60

3,10 - 3,80%
1,50 - 2,50%
0,40 - 0,80%
Max. 0,01%
Max. 0,01%

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
PT. NIKKO CAHAYA ELECTRIC
Cavity/mould
Part Name
Front Bracket 1551
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FCD-450
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,80 - 3,90
3,92
> Silicone
2,15 0,05
2,38
> Mangan
Max. 0,40
0,41
> Phospor
Max. 0,03
0,027
> Sulphur
Max. 0,03
0,035
Standard (%)
Actual (%)
> Carbon
3,60 - 3,80
3,75
> Silicone
2,70 - 3,00
3,10
> Mangan
Max.0,40
0,41
> Phospor
Max. 0,03
0,027
> Sulphur
Max. 0,03
0,012
0,030 - 0,050
0,046
Remark
Nama Material
Remark
Nama Material
Item
> Magnesium
0,15
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
Remark
> Tapping
> Pouring
1420
D. Pouring Time
Item
> Per Mould
Standard
Actual
Remark
Second/Mould
> Per Ladle

Notes :
Minutes/Ladle
TRIAL PROGRESS
Core Material
Kg
Core Weight/pc
Cav Core Box

Trial Qty
3 Mold
3. INSPECTION
Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
Remark
No
1
Masalah
Broken Casting
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
4 Pcs Total Defect
5 Pcs
Remark :
Tidak ada
rongga susut
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite %
Nodularyti %
HB/HRB
> Hardness
Item
Tensile Strength
Yield Strength
Standard
Actual
Remark
Elongation
GRESS
4. ANALISA MASALAH
Masalah
oken Casting
Tidak ada
rongga susut
Penyebab
Tindakan Perbaikan
JUDGEMENT
O
K
N
G
Approved

Trial Date
Pre Launch
Std FC-25 FW NF60

C:
3,10 - 3,80%
Mass Production
Tindakan Perbaikan
PIC
Waktu
Si :
1,50 - 2,50%
Mn :
P:
S:
0,40 - 0,80%
Max. 0,01%
Max. 0,01%
Approved
ord Engineering
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
PT. YANMAR DIESEL INDONESIA
Cavity/mould
Pcs
Part Name
Fly Wheel NF 60
Weight/pc
18
Kg
Weight/mould
27,3
Kg
Part No.
Material
FC - 250
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,45 0,05
3,43
> Silicone
1,55 0,05
1,57
> Mangan
0,60 0,05
0,54
> Phospor
Max. 0,03
0,030
> Sulphur
Max. 0,03
0,014
Standard (%)
Actual (%)
> Carbon
3,10 - 3,80
3,42
> Silicone
1,50 - 2,50
1,84
> Mangan
0,40 - 0,80
0,54
> Phospor
Max. 0,10
0,030
> Sulphur
Max. 0,10
0,016
Standard ( C )
Actual ( C )
Remark
Nama Material
Remark
Nama Material
Item
> Magnesium
> Cu
C. Temperature
Item
Remark
> Tapping
> Pouring
1403
D. Pouring Time
Item
> Per Mould
Standard
Actual
Remark
Second/Mould
> Per Ladle

Notes :
Minutes/Ladle
TRIAL PROGRESS
Core Material
Kg
Core Weight/pc
Cav Core Box

Trial Qty
9 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
9 Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite %
Nodularyti %
HB/HRB
> Hardness
Item
Tensile Strength
Yield Strength
Standard
Actual
Remark
Masalah
Elongation
GRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
JUDGEMENT
O
K
N
G
Approved

Trial Date
10.2.2016
Pre Launch
Std FC-25 FW NF60

C:
3,10 - 3,80%
Mass Production
Tindakan Perbaikan
PIC
Waktu
Si :
1,50 - 2,50%
Mn :
P:
S:
0,40 - 0,80%
Max. 0,01%
Max. 0,01%
Approved
ord Engineering
Prepared
Process Engineering
TRIAL PROGRESS
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs Core Material
Customer
Cavity/mould
Part Name
BODY 304 YA - 40 mm
Weight/pc
1,67
Kg Core Weight/pc
Weight/mould
9,67
Kg Cav
Yield
55,9
Part No.
Material
FCD 45
Core Box
% Trial Qty
RCS
0,19 Kg
2 cav
11 Mold
1. PATTERN MAKING
Item
3. INSPECTION
Specification
> Quantity Trial
Remark
11
No

Item
Moulds
Defect
Item
> Released Pattern
OK / NG
> Sli
> CJ
> Hardness Mould
80 ~ 89
> SE
> BL
> Sensor Cope
1 / 2 / 3 / 4
> Si
> BM
> Sensor Drag
1 / 2 / 3 / 4
> SD
> CS
> Diameter Sprue
28 / 30 / 32
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,90 0,05
3,94
> Crush
> Silicone
2,30 0,05
2,25
> SP
> Mangan
Max. 0,40
0,40
> RO
> Phospor
Max. 0,03
0,027
> Carbide
> Sulphur
Max. 0,02
0,026
Total GooD
Item
> Harness Up
Low
> Excentric
> Carbon
2,60 - 3,90
3,70
> Silicone
1,60 - 3,00
3,08
> Mangan
0,10 - 0,80
0,40
> Phospor
Max. 0,08
0,030
> Sulphur
Max. 0,05
0,016
Item
0,025 - 0,090
0,040
> Graphite type
C. Temperature
11 Pcs Total Defect
0 Pcs
Standard
Actual
Remark :
Actual (%)
> Cu
Remark
Low
Standard (%)
> Magnesium
Defect
Remark
Nama Material
B. Microstructure
Size
> Matrix : P/F
Ferrite 70 %
Remark
Ma
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
> Cementite
D. Pouring Time
Item
Item
Standard
Actual
HB/HRB
140 ~ 210 HB
> Hardness
1444
Nodularyti 70 %
Remark
Standard
Actual
Tensile Strength
> Per Mould
Second/Mould
Yield Strength
> Per Ladle
Minutes/Ladle
Elongation
Notes :
Sebelum perbaikan
Setelah perbaikan
Riser utuh tidak kempot
c/j 1mm
c/j 0 mm
Riser utuh / tidak

efektif
Tidak ada rongga

susut
Remark
ESS

Trial Date
Pre Launch
Mass Production
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
PIC
Waktu
JUDGEMENT
O
K
N
G
Approved
Prepared
Process Engineering
TRIAL PROGRESS
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs Core Material
Customer
Cavity/mould
Part Name
BODY 304 YA - 65mm
Weight/pc
2,82
Kg Core Weight/pc
Weight/mould
9,67
Kg Cav
Yield
55,9
Part No.
Material
FCD 45
Core Box
% Trial Qty
RCS
0,50 Kg
2 cav
11 Mold
1. PATTERN MAKING
Item
3. INSPECTION
Specification
> Quantity Trial
Remark
11
No

Item
Moulds
Defect
Item
> Released Pattern
OK / NG
> Sli
> CJ
> Hardness Mould
80 ~ 89
> SE
> BL
> Sensor Cope
1 / 2 / 3 / 4
> Si
> BM
> Sensor Drag
1 / 2 / 3 / 4
> SD
> CS
> Diameter Sprue
28 / 30 / 32
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,90 0,05
3,94
> Crush
> Silicone
2,30 0,05
2,25
> SP
> Mangan
Max. 0,40
0,40
> RO
> Phospor
Max. 0,03
0,027
> Carbide
> Sulphur
Max. 0,02
0,026
Total GooD
Item
> Harness Up
Low
> Excentric
> Carbon
2,60 - 3,90
3,70
> Silicone
1,60 - 3,00
3,08
> Mangan
0,10 - 0,80
0,40
> Phospor
Max. 0,08
0,030
> Sulphur
Max. 0,05
0,016
Item
0,025 - 0,090
0,040
> Graphite type
C. Temperature
11 Pcs Total Defect
0 Pcs
Standard
Actual
Remark :
Actual (%)
> Cu
Remark
Low
Standard (%)
> Magnesium
Defect
Remark
Nama Material
B. Microstructure
Size
> Matrix : P/F
Ferrite 70 %
Remark
Ma
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
> Cementite
D. Pouring Time
Item
Item
Standard
Actual
Remark
Standard
Tensile Strength
> Per Mould
Second/Mould
Yield Strength
> Per Ladle
Minutes/Ladle
Elongation
Notes :
Sebelum Improve
Riser tidak berfungsi dengan baik
Setelah Improve
Sedikit menyusut
Riser utuh / tidak

efektif
HB/HRB
140 ~ 210 HB
> Hardness
1444
Nodularyti 70 %
Keropos pada
bagian Ingate
Tidak ada
keropos pada
bagian Ingate
Actual
Remark
ESS

Trial Date
Pre Launch
Mass Production
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
PIC
Waktu
JUDGEMENT
O
K
N
G
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
Cavity/mould
Part Name
BODY 304 YA - 65mm
Weight/pc
2,82
Kg
Weight/mould
9,67
Kg
Yield
55,9
Part No.
Material
FCD 45
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
20
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,90 0,05
3,95
> Silicone
2,30 0,05
2,28
> Mangan
Max. 0,40
0,38
> Phospor
Max. 0,03
0,029
> Sulphur
Max. 0,02
0,029
Standard (%)
Actual (%)
> Carbon
2,60 - 3,90
3,63
> Silicone
1,60 - 3,00
3,01
> Mangan
0,10 - 0,80
0,36
> Phospor
Max. 0,08
0,033
> Sulphur
Max. 0,05
0,013
0,025 - 0,090
0,045
Remark
Nama Material
Remark
Nama Material
Item
> Magnesium
0,15
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,50 Kg
2 cav
20 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
18
Remark
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
2 Pcs Total Defect
18 Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
22.2.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Weight/pc
1,67
Kg
Weight/mould
9,67
Kg
Yield
55,9
Customer
Cavity/mould
Part Name
BODY 304 YA - 65mm
Part No.
Material
FCD 45
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
20
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,90 0,05
3,95
> Silicone
2,30 0,05
2,28
> Mangan
Max. 0,40
0,38
> Phospor
Max. 0,03
0,029
> Sulphur
Max. 0,02
0,029
Standard (%)
Actual (%)
> Carbon
2,60 - 3,90
3,63
> Silicone
1,60 - 3,00
3,01
> Mangan
0,10 - 0,80
0,36
> Phospor
Max. 0,08
0,033
> Sulphur
Max. 0,05
0,013
0,025 - 0,090
0,045
Remark
Nama Material
Remark
Nama Material
Item
> Magnesium
0,15
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,19 Kg
2 cav
11 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
20 Pcs Total Defect
0 Pcs
Standard
Actual
Remark :
B. Microstructure
Item
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
22.2.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Weight/pc
2,82
Kg
Weight/mould
9,67
Kg
Yield
55,9
Customer
Cavity/mould
Part Name
BODY 304 YA - 65mm
Part No.
Material
FCD 45
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
20
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,90 0,05
3,95
> Silicone
2,30 0,05
2,34
> Mangan
Max. 0,40
0,37
> Phospor
Max. 0,03
0,032
> Sulphur
Max. 0,02
0,021
Standard (%)
Actual (%)
> Carbon
3,60 - 3,90
3,74
> Silicone
2,70 - 3,00
3,14
> Mangan
Max.0,04
0,39
> Phospor
Max. 0,08
0,03
> Sulphur
Max. 0,05
0,015
0,025 - 0,090
0,050
Remark
Nama Material
Remark
Nama Material
Item
> Magnesium
0,155
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
1423
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Casting yang terdapat Srk pada mold ke : 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,13
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,19 Kg
2 cav
20 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
12
Remark
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
0 Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
24.02.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
Cavity/mould
Part Name
BODY 304 YA - 50 mm
Weight/pc
2,19
Kg
Weight/mould
13,3
Kg
66
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
20
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,90 0,05
3,95
> Silicone
2,30 0,05
2,34
> Mangan
Max. 0,40
0,37
> Phospor
Max. 0,03
0,032
> Sulphur
Max. 0,02
0,021
Standard (%)
Actual (%)
Remark
Nama Material
Remark
Nama Material
Item
> Carbon
3,74
> Silicone
2,70 - 3,00
3,14
> Mangan
Max.0,04
0,39
> Phospor
Max. 0,08
0,03
> Sulphur
Max. 0,05
0,015
0,025 - 0,090
0,050
> Magnesium
0,155
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
1423
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,35 Kg
2 cav
20 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
8 Pcs Total Defect
0 Pcs
Standard
Actual
Remark :
B. Microstructure
Item
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
24.02.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Weight/pc
3,1
Kg
Weight/mould
13,3
Kg
66
Customer
Cavity/mould
Part Name
BODY 304 YA - 80 mm
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
20
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,90 0,05
3,95
> Silicone
2,30 0,05
2,34
> Mangan
Max. 0,40
0,37
> Phospor
Max. 0,03
0,032
> Sulphur
Max. 0,02
0,021
Standard (%)
Actual (%)
> Carbon
3,60 - 3,90
3,74
> Silicone
2,70 - 3,00
3,14
> Mangan
Max.0,04
0,39
> Phospor
Max. 0,08
0,03
> Sulphur
Max. 0,05
0,015
0,025 - 0,090
0,050
Remark
Nama Material
Remark
Nama Material
Item
> Magnesium
0,155
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
1423
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Casting yang terdapat Srk pada mold ke : 8, dan 10
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,86 Kg
2 cav
20 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
Remark
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
0 Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
24.02.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
Cavity/mould
Part Name
BODY 304 YA - 50 mm
Weight/pc
2,19
Kg
Weight/mould
13,3
Kg
66
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
10
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
2,60 - 3,90
> Silicone
1,60 - 3,00
> Mangan
0,10 - 0,80
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
1423
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,35 Kg
2 cav
10 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
8 Pcs Total Defect
0 Pcs
Standard
Actual
Remark :
B. Microstructure
Item
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
26.02.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Weight/pc
3,1
Kg
Weight/mould
13,3
Kg
66
Customer
Cavity/mould
Part Name
BODY 304 YA - 80 mm
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
10
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,60 - 3,90
> Silicone
2,70 - 3,00
> Mangan
Max.0,04
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,86 Kg
2 cav
10 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
0 Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
26.02.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Weight/pc
1,67
Kg
Weight/mould
9,67
Kg
Yield
55,9
Customer
Cavity/mould
Part Name
BODY 304 YA - 65mm
Part No.
Material
FCD 45
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
10
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,60 - 3,90
> Silicone
2,70 - 3,00
> Mangan
Max.0,04
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1430
1423
Standard
Actual
Remark
D. Pouring Time
Item
> Per Mould
> Per Ladle
Notes :
10 - 13
Remark
Second/Mould
Minutes/Ladle
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,19 Kg
2 cav
10 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
0 Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
26.02.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
PT. EBARA
Cavity/mould
Part Name
Casing Cover 10 FSJ-P
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FC-200
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,35 0,05
> Silicone
1,85 0,05
> Mangan
0,50 - 0,70
> Phospor
Max. 0,03
> Sulphur
Max. 0,03
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,30 - 3,70
> Silicone
1,40 - 2.60
> Mangan
0,40 - 0,80
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
> Per Mould
Standard
Second/Mould
> Per Ladle

Notes :
Minutes/Ladle
TRIAL PROGRESS
Core Material
Kg
Core Weight/pc
Cav Core Box

Trial Qty
Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
10 Pcs
Remark :
B. Microstructure
Item
Standard
> Graphite type
A&B
Size
4-6
> Matrix : P/F

> Cementite
> Hardness
Actual
Remark
Pearlite Ferrite
Nodularyti 70 %
Max. 223
HB/HRB
Standard
Remark
Item
Tensile Strength
Yield Strength
Elongation
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
JUDGEMENT
O
K
N
G
Approved

Trial Date
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
Cavity/mould
Part Name
Balancer Shaft L 48/40 A
Weight/pc
Kg
Part No.
114350 - 28012
Weight/mould
Kg
Material
FCD - 450
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
20
> Released Pattern
Moulds
OK / NG
> Hardness Mould

> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,80 - 3,90
> Silicone
2,15 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,03
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,60 - 3,90
> Silicone
2,70 - 3,00
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,03
> Magnesium
0,030 - 0,050
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1530 10
> Pouring
1410 10
1434
Standard
Actual
Remark
D. Pouring Time
Item
> Per Mould
7-9
Remark
Second/Mould
> Per Ladle

Notes :
Minutes/Ladle
Core Material
Core Weight/pc
Cav Core Box
Trial Qty
20 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
20 Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
> Graphite type
A&B
Size
4-6
> Matrix : P/F

> Cementite
> Hardness
Actual
Remark
Ferrite 70 %
Nodularyti 80 %
143 - 217
HB/HRB
Standard
Remark
Item
Tensile Strength
46 Kgf/mm2
Yield Strength
30 Kgf/mm2
Elongation
10 %
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
JUDGEMENT
O
K
N
G
Approved

Trial Date
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Pcs
Part Name
Weight/pc
Kg
Part No.
Weight/mould
Kg
Material
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
30
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
Item
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1530 10
> Pouring
1410 10
D. Pouring Time
Item
> Per Mould
> Per Ladle
Notes :
Standard
7-9
Second/Mould
Minutes/Ladle
TRIAL PROGRESS
Core Material
Kg
Cav Core Box
Trial Qty
30 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
Defect
Remark
> Si
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
> Graphite type
A&B
Size
4-6
> Matrix : P/F

> Cementite
> Hardness
Actual
Remark
Ferrite 70 %
Nodularyti 80 %
143 - 217
HB/HRB
Standard
Remark
Item
Tensile Strength
46 Kgf/mm2
Yield Strength
30 Kgf/mm2
Elongation
10 %
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
Cavity/mould
Part Name
Balancer Wheight
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FC-200
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
10
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,50 - 3,60
> Silicone
1,50 - 1,60
> Mangan
0,50 - 0,60
> Phospor
Max. 0,05
> Sulphur
Max. 0,06
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,10 - 3,80
> Silicone
1,50 - 2,50
> Mangan
0,40 - 0,60
> Phospor
Max. 0,10
> Sulphur
Max. 0,10
> Magnesium
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1510 10
> Pouring
1410 10
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
> Per Mould
> Per Ladle
Notes :
Standard
5-7
Second/Mould
Minutes/Ladle
TRIAL PROGRESS
Core Material
Kg
Cav Core Box
Trial Qty
10 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
Defect
Remark
> Si
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
8 Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
> Graphite type
A&B
Size
4-6
> Matrix : P/F

> Cementite
> Hardness
Actual
Remark
Ferrite 70 %
Nodularyti 80 %
187 - 241
HB/HRB
Standard
Remark
Item
Tensile Strength
46 Kgf/mm2
Yield Strength
30 Kgf/mm2
Elongation
10 %
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
7.3.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
Cavity/mould
Part Name
Cyl. Rear Cover
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FC-200
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
10
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
Item
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1510 10
> Pouring
1410 10
D. Pouring Time
Item
> Per Mould
> Per Ladle
Notes :
Standard
5-7
Second/Mould
Minutes/Ladle
TRIAL PROGRESS
Core Material
Kg
Cav Core Box
Trial Qty
10 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
Defect
Remark
> Si
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
8 Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
> Graphite type
A&B
Size
4-6
> Matrix : P/F

> Cementite
> Hardness
Actual
Remark
Ferrite 70 %
Nodularyti 80 %
187 - 241
HB/HRB
Standard
Remark
Item
Tensile Strength
46 Kgf/mm2
Yield Strength
30 Kgf/mm2
Elongation
10 %
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
9.3.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Weight/pc
3,1
Kg
Weight/mould
27,4
Kg
45,25
Customer
Cavity/mould
Part Name
BODY 304 YA - 80 mm
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,60 - 3,90
> Silicone
2,70 - 3,00
> Mangan
Max.0,04
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,86 Kg
2 cav
2 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
0 Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
15.03.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Weight/pc
3,1
Kg
Weight/mould
13,3
Kg
66
Customer
Cavity/mould
Part Name
BODY 304 YA - 80 mm
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
10
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,60 - 3,90
> Silicone
2,70 - 3,00
> Mangan
Max.0,04
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,86 Kg
2 cav
10 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
0 Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
15.03.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
Cavity/mould
Part Name
BODY 304 YA - 50 mm
Weight/pc
2,19
Kg
Weight/mould
13,3
Kg
66
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
10
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
2,60 - 3,90
> Silicone
1,60 - 3,00
> Mangan
0,10 - 0,80
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
1423
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,35 Kg
2 cav
10 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
Defect
Remark
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
8 Pcs Total Defect
0 Pcs
Standard
Actual
Remark :
B. Microstructure
Item
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
26.02.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
BODY 304 YA - 40 mm
Weight/pc
Part No.
Weight/mould
Material
FCD 45
Yield
1,67
Kg
26,36
Kg
50,6
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,90 0,05
3,93
> Silicone
2,30 0,05
2,60
> Mangan
Max. 0,40
0,40
> Phospor
Max. 0,03
0,022
> Sulphur
Max. 0,02
0,016
Standard (%)
Actual (%)
> Carbon
3,60 - 3,90
3,70
> Silicone
2,70 - 3,00
3,23
> Mangan
Max.0,04
0,40
> Phospor
Max. 0,08
0,027
> Sulphur
Max. 0,05
0,009
0,025 - 0,090
0,043
Remark
Nama Material
Remark
Nama Material
Item
> Magnesium
0,131
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Pcs
TRIAL PROGRESS
Core Material
RCS
0,19 Kg
Core Weight/pc
Cav Core Box
2 cav
Trial Qty
3 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
9 Pcs
Remark :
2 pcs solid, core nya kurang 2 pcs
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
22.03.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
BODY 304 YA - 65 mm
Weight/pc
Part No.
Material
FCD 45
6
2,82
Kg
Weight/mould
33,92
Kg
Yield
49,88
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,90 0,05
3,93
> Silicone
2,30 0,05
2,60
> Mangan
Max. 0,40
0,40
> Phospor
Max. 0,03
0,022
> Sulphur
Max. 0,02
0,016
Standard (%)
Actual (%)
> Carbon
3,60 - 3,90
3,70
> Silicone
2,70 - 3,00
3,23
> Mangan
Max.0,04
0,40
> Phospor
Max. 0,08
0,027
> Sulphur
Max. 0,05
0,009
0,025 - 0,090
0,043
Remark
Nama Material
Remark
Nama Material
Item
> Magnesium
0,131
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Pcs
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,50 Kg
2 cav
3 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
8 Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
22.03.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
BODY 304 YA - 50 mm
Weight/pc
Part No.
Weight/mould
Material
FCD 45
Yield
2,19
Kg
27,14
Kg
48,4
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,90 0,05
3,93
> Silicone
2,30 0,05
2,60
> Mangan
Max. 0,40
0,40
> Phospor
Max. 0,03
0,022
> Sulphur
Max. 0,02
0,016
Standard (%)
Actual (%)
> Carbon
3,60 - 3,90
3,70
> Silicone
2,70 - 3,00
3,23
> Mangan
Max.0,04
0,40
> Phospor
Max. 0,08
0,027
> Sulphur
Max. 0,05
0,009
0,025 - 0,090
0,043
Remark
Nama Material
Remark
Nama Material
Item
> Magnesium
0,131
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Pcs
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,35 Kg
2 cav
3 Mold
3. INSPECTION
No

Item
> Sli
Defect
Item
Defect
Remark
> CJ
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
8 Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
24.03.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
BODY 304 YA - 40 mm
Weight/pc
Part No.
Weight/mould
Material
FCD 45
Yield
1,67
Kg
26,36
Kg
50,6
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
10
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,60 - 3,90
> Silicone
2,70 - 3,00
> Mangan
Max.0,04
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Pcs
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,19 Kg
2 cav
10 Mold
3. INSPECTION
No

Item
> Sli
Defect
1
> SE
Item
Defect
Remark
18
> CJ
> BL
> Si
> SD
> BM
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
58 Pcs Total Defect
21 Pcs
Standard
Actual
Remark :
B. Microstructure
Item
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
04.04.2016
6404
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
BODY 304 YA - 50 mm
Weight/pc
Part No.
Weight/mould
Material
FCD 45
Yield
2,19
Kg
27,14
Kg
48,4
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,60 - 3,90
> Silicone
2,70 - 3,00
> Mangan
Max.0,04
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Pcs
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,35 Kg
2 cav
4 Mold
3. INSPECTION
No

Item
Defect
Item
Remark
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
06.04.2016
6406
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
BODY 304 YA - 65 mm
Weight/pc
Part No.
Material
FCD 45
6
2,82
Kg
Weight/mould
33,92
Kg
Yield
49,88
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,60 - 3,90
> Silicone
2,70 - 3,00
> Mangan
Max.0,04
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
1425
> Pouring
1400 ~ 1420
Remark
D. Pouring Time
Item
Standard
Actual
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Pcs
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,50 Kg
2 cav
3 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
Remark
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
13 Pcs Total Defect
5 Pcs
Standard
Actual
Remark :
B. Microstructure
Item
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
06.04.2016
6406
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Weight/pc
3,1
Kg
Weight/mould
27,4
Kg
45,25
Customer
Cavity/mould
Part Name
BODY 304 YA - 80 mm
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
14
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,60 - 3,90
> Silicone
2,70 - 3,00
> Mangan
Max.0,04
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
1425
> Pouring
1400 ~ 1420
Remark
D. Pouring Time
Item
Standard
Actual
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,86 Kg
2 cav
14 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> SD
Defect
Remark
> BM
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
56 Pcs Total Defect
11 Pcs
Standard
Actual
Remark :
B. Microstructure
Item
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
06.04.2016
6406
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
BODY 304 YA - 50 mm
Weight/pc
Part No.
Weight/mould
Material
FCD 45
Yield
2,19
Kg
27,14
Kg
48,4
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
20
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,60 - 3,90
> Silicone
2,70 - 3,00
> Mangan
Max.0,04
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
1413
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,35 Kg
2 cav
20 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
Remark
14
12
> BC
> Core
> Srk
10
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
82 Pcs Total Defect
38 Pcs
Standard
Actual
Remark :
B. Microstructure
Item
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
15.04.2016
6415
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
BODY 304 YA - 65 mm
Weight/pc
Part No.
Material
FCD 45
6
2,82
Kg
Weight/mould
33,92
Kg
Yield
49,88
1. PATTERN MAKING
Item
Specification
Remark
> Quantity Trial
Moulds
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,60 - 3,90
> Silicone
2,70 - 3,00
> Mangan
Max.0,04
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
1425
> Pouring
1400 ~ 1420
Remark
D. Pouring Time
Item
Standard
Actual
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Pcs
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,50 Kg
2 cav
Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
13 Pcs Total Defect
5 Pcs
Standard
Actual
Ferrite 70 %
80%
Nodularyti 70 %
90%
140 ~ 210 HB
198
HB/HRB
Standard
Actual
Remark
Remark :
B. Microstructure
Item
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
12.04.2016
6412
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Weight/pc
3,1
Kg
Weight/mould
27,4
Kg
45,25
Customer
Cavity/mould
Part Name
BODY 304 YA - 80 mm
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,60 - 3,90
> Silicone
2,70 - 3,00
> Mangan
Max.0,04
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
1405
> Pouring
1400 ~ 1420
Remark
D. Pouring Time
Item
Standard
Actual
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,86 Kg
2 cav
9 Mold
3. INSPECTION
Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
1`
Remark
10
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
25 Pcs Total Defect
11 Pcs
Standard
Actual
Remark :
B. Microstructure
Item
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
No
1
PROGRESS
4. ANALISA MASALAH
Masalah
Shrinkage
Penyebab
Tindakan Perbaik
1. Modifikasi riser untuk bagia
bagian ekor dengan penamba
15mm pada semua riser
penambahan
tinggi 15mm
JUDGEMENT
O
K
N
G
Approved

Trial Date
11.04.2016
6411
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
Modifikasi riser untuk bagian leher dan
agian ekor dengan penambahan tinggi
penambahan
tinggi 15mm
penambahan
tinggi 15mm
Perubahan ukuran
ingate
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
BODY 304 YA - 65 mm
Weight/pc
Part No.
Material
FCD 45
6
2,82
Kg
Weight/mould
33,92
Kg
Yield
49,88
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,90 0,05
3,95
> Silicone
2,30 0,05
2,25
> Mangan
Max. 0,40
0,40
> Phospor
Max. 0,03
0,025
> Sulphur
Max. 0,02
0,028
Standard (%)
Actual (%)
> Carbon
3,60 - 3,90
3,74
> Silicone
2,70 - 3,00
3,05
> Mangan
Max.0,04
0,40
> Phospor
Max. 0,08
0,025
> Sulphur
Max. 0,05
0,009
0,025 - 0,090
0,039
Remark
Nama Material
Remark
Nama Material
Item
> Magnesium
0,17
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
1434
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Pcs
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,50 Kg
2 cav
9 Mold
3. INSPECTION
Item
Defect
Item
Remark
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
49 Pcs Total Defect
4 Pcs
Remark :
Final Inspect : 49 pcs, OK : 38 pcs, NG : 11 pcs, 7 skg, 4 c/j
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
No
1
> Sli
> Crush
Defect
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
1. Mesin molding tidak stabil
(melintir)
Tindakan Perbaik
1. Preventif maintenance
Cross joint
2. Riser tidak efektif (tidak

berfungsi)
2. Modifikasi riser : penamb

pada riser.
Perubahan pada ingate
Skg pada
bagian ekor
Skg pada
bagian leher
(after
Finishing)
JUDGEMENT
O
K
N
G
Approved

Trial Date
28.04.2016
6428
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
Preventif maintenance
Modifikasi riser : penambahan tinggi

ada riser.
Perubahan pada ingate
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
PT. EBARA
Cavity/mould
Part Name
BEARING HOUSING 335
Weight/pc
Kg
Part No.
Weight/mould
Kg
Material
Yield
1. PATTERN MAKING
Item
Specification
Remark
> Quantity Trial
Moulds
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
Item
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
cav
Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
28.04.2016
6428
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Weight/pc
3,1
Kg
Weight/mould
27,4
Kg
45,25
Customer
Cavity/mould
Part Name
BODY 304 YA - 80 mm
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
10
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,90 0,05
> Silicone
2,30 0,05
> Mangan
Max. 0,40
> Phospor
Max. 0,03
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,60 - 3,90
> Silicone
2,70 - 3,00
> Mangan
Max.0,04
> Phospor
Max. 0,08
> Sulphur
Max. 0,05
> Magnesium
0,025 - 0,090
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
1432
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,86 Kg
2 cav
10 Mold
3. INSPECTION
Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> SD
Defect
Remark
> BM
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
35 Pcs Total Defect
5 Pcs
Standard
Actual
80 %
90,6 %
Remark :
B. Microstructure
Item
> Graphite type
Remark
Size
> Matrix : P/F
> Cementite
> Hardness
Ferrite 70 %
Nodularyti 70 %
140 ~ 210 HB
163
HB/HRB
Standard
Actual
Remark
Item
Tensile Strength
Yield Strength
Elongation
No
1
PROGRESS
4. ANALISA MASALAH
Masalah
Shrinkage
Penyebab
Riser tidak efektif
Tindakan Perbaik
1. Modifikasi riser untuk bagia
bagian ekor dengan penamba
penambahan ting
riser bagian
leher15mm
penambahan tin
riser bagian e
15mm
2. Trial casting
JUDGEMENT
O
K
N
G
Approved

Trial Date
02.05.2016
6502
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
Modifikasi riser untuk bagian leher dan
agian ekor dengan penambahan tinggi
PIC
Sujarwo
Waktu
02-4-2016
Faqih
02-4-2016
penambahan tinggi
riser bagian
leher15mm
penambahan tinggi
riser bagian ekor
15mm
Trial casting
Qty : 10 mold / 1 ladel
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
PT. EBARA
Cavity/mould
Part Name
CONNECTOR 80LL
Weight/pc
6,56
Kg
Weight/mould
17,4
Kg
Part No.
Material
FC-200
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,55
> Silicone
1,53
> Mangan
0,51
> Phospor
0,034
> Sulphur
0,019
Remark
Nama Material
Remark
Nama Material
Item
Standard (%)
Actual (%)
> Carbon
3.00 ~ 3.70 %
3,49
> Silicone
1.40 ~ 2.60 %
1,84
> Mangan
0.40 ~ 0.80 %
0,64
> Phospor
Max. 0,08 %
0,034
> Sulphur
Max. 0,05 %
0,017
Standard ( C )
Actual ( C )
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
1429
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
FURAN
Kg
Core Weight/pc
Cav Core Box

Trial Qty
cav
5 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
19.5.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Weight/pc
7,9
Kg
Weight/mould
18,1
Kg
Customer
PT. EBARA
Cavity/mould
Part Name
CONNECTOR 100LL
Part No.
Material
FC-200
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,55
> Silicone
1,53
> Mangan
0,51
> Phospor
0,034
> Sulphur
0,019
Remark
Nama Material
Remark
Nama Material
Item
Standard (%)
Actual (%)
> Carbon
3.00 ~ 3.70 %
3,49
> Silicone
1.40 ~ 2.60 %
1,84
> Mangan
0.40 ~ 0.80 %
0,64
> Phospor
Max. 0,08 %
0,034
> Sulphur
Max. 0,05 %
0,017
Standard ( C )
Actual ( C )
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
1429
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
FURAN
0,86 Kg
Core Weight/pc
Cav Core Box

Trial Qty
cav
5 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
19.5.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering
TRIAL PROGRESS
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
20
Customer
PT. GARUDA METAL UTAMA
Cavity/mould
Part Name
GEAR WHEEL 1692
Weight/pc
Part No.
24052
Weight/mould
10
Material
FCD-450
Yield
40
0,205
Pcs Core Material
RCS
Kg Core Weight/pc
0,334 Kg
Kg Cav
2 cav
Core Box
% Trial Qty
5 Mold
1. PATTERN MAKING
Item
3. INSPECTION
Specification
> Quantity Trial
Remark

Item
Moulds
Defect
> Released Pattern
OK / NG
> Sli
> Hardness Mould
80 ~ 89
> SE
> BL
> Sensor Cope
1 / 2 / 3 / 4
> Si
> BM
> Sensor Drag
1 / 2 / 3 / 4
> SD
> CS
> Diameter Sprue
28 / 30 / 32
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
2. M E L T I N G
Item
Remark
Nama Material
Item
Standard (%)
Actual (%)
> Carbon
3,85 - 3,90
3,90
> Crush
> Silicone
2,40 - 2,50
2,11
> SP
> Mangan
Max. 0,35
0,37
> RO
> Phospor
Max. 0,1
0,028
> Carbide
> Sulphur
Max. 0,02
0,015
Total GooD
Item
No
1
Ma
Badlift
Slag Inclution
Hardness Up
> CJ
3
> Harness Up
Low
> Excentric
96 Pcs Total Defect
4 Pcs
Standard
Actual
Ferrite 70 %
70%
Remark :
Actual (%)
> Carbon
3,50 - 4,20
3,73
> Silicone
3,00 - 3,30
2,86
> Mangan
Max. 0,8
0,38
> Phospor
Max. 0,1
0,030
> Sulphur
Max. 0,02
0,007
Item
> Magnesium
0,02 - 0,06
0,044
> Graphite type
C. Temperature
Remark
Low
Standard (%)
> Cu
Defect
Remark
Nama Material
NG
B. Microstructure
Size
> Matrix : P/F
Remark
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
> Cementite
> Hardness
1421
Item
Standard
Actual
Remark
Tensile Strength
> Per Mould
Second/Mould
Yield Strength
> Per Ladle
Minutes/Ladle
Elongation
Notes :
90%
180 ~ 220 HB
192 - 197
HB/HRB
Standard
Actual
Remark
D. Pouring Time
Item
Nodularyti 75 %
ESS

Trial Date
13.5.2016
LOT : D5G
Pre Launch
Mass Production
4. ANALISA MASALAH
Masalah
Penyebab
1. Pattern kurang release
Tindakan Perbaikan
1. Penghalusan pattern pada bagian yang
terjadi badlift
Badlift pada cavity

nomor 15
on
Sli
p
TEST 1
192 - 197 HB
1. Terdapat komposisi yang tidak 1. Komposisi metal harus sesuai standar

masuk standar yaitu Silikon (Si),
Standar 3,00 - 3,30 aktualnya
2,86 (NG)
PIC
Waktu
TEST 2
234 - 247 HB
TEST 3
241 - 270 HB
JUDGEMENT
O
K
N
G
Approved
Prepared
Process Engineering
TRIAL PROGRESS
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
pcs Core Material
Customer
PT. EBARA
Cavity/mould
Part Name
BEARING HOUSING 225-1
Weight/pc
5,3
Kg Core Weight/pc
Weight/mould
17,7
Kg Cav
Yield
59,8
Part No.
Material
FC-150
Core Box
% Trial Qty
RCS
Kg
cav
15 Mold
1. PATTERN MAKING
Item
3. INSPECTION
Specification
> Quantity Trial
Remark
15

Item
Moulds
Defect
Item
OK / NG
> Sli
> CJ
> Hardness Mould
80 ~ 89
> SE
> BL
> Sensor Cope
1 / 2 / 3 / 4
> Si
> Sensor Drag
1 / 2 / 3 / 4
> SD
> CS
> Diameter Sprue
28 / 30 / 32
> BC
> Core
> Srk
> R Surface
> PH
> BH
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,75 0,05
4,09
> Crush
> Silicone
2,15 0,05
2,00
> SP
> Mangan
Max. 0,40
0,38
> RO
> Phospor
Max. 0,03
0,034
> Carbide
> Sulphur
Max. 0,03
0,023
Total GooD
Item
Actual (%)
> Carbon
3,50 - 3,70
3,79
> Silicone
2,20 - 2,40
2,39
> Mangan
Max. 0,40
0,35
> Phospor
Max. 0,03
0,033
> Sulphur
Max. 0,03
0,021
> Cu
C. Temperature
Sand Inclution
Cross Joint
> BM
13
Badlift
> Dim Up
Low
> Harness Up
Low
> Excentric
2 Pcs Total Defect
28 Pcs
93 % NG
Standard
Actual
Remark
Remark :
Standard (%)
> Magnesium
> MD
Remark
Ma
> Released Pattern
Defect
No
1
Remark
Nama Material
B. Microstructure
Item
> Graphite type
Size
> Matrix : P/F
A
4-6
Ferrite 90 %
Item
Standard ( C )
> Tapping
1540 10
> Pouring
1440 10
Actual ( C )
Remark
> Cementite
> Hardness
1424
Item
Standard
Actual
Remark
175 - 179
HB/HRB
Standard
Actual
Remark
Tensile Strength
> Per Mould
Second/Mould
Yield Strength
> Per Ladle
Minutes/Ladle
Elongation
Notes :
174 ~ 233 HB
D. Pouring Time
Item
Nodularyti 70 %
Mold Demage
ESS

Trial Date
18.5.2016
K5G
Pre Launch
Mass Production
4. ANALISA MASALAH
Masalah
Badlift di cavity 1
dan 2 area cope dan
drag
ion
Sand drop
Penyebab
Tindakan Perbaikan
Pengecekan permukaan pattern pada area
Pattern kurang release yang terjadi badlift
PIC
Waktu
ge
JUDGEMENT
O
K
N
G
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Pcs
Cavity/mould
Part Name
FLY WHEEL NF60
Part No.
Material
FC-250
Weight/pc
Kg
Weight/mould
Kg
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
15
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,45 0,05
3,53
> Silicone
1,55 0,05
1,56
> Mangan
0,60 0,05
0,60
> Phospor
Max. 0,03
0,035
> Sulphur
Max. 0,03
0,023
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,10 - 3,80
3,54
> Silicone
1,50 - 2,50
1,75
> Mangan
0,40 - 0,80
0,60
> Phospor
Max. 0,10
0,035
> Sulphur
Max. 0,10
0,022
Standard ( C )
Actual ( C )
Remark
Actual
Remark
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Kg
Core Weight/pc
Cav Core Box

Trial Qty
9 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
Remark
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
8 Pcs Total Defect
1 Pcs
Standard
Actual
Remark :
B. Microstructure
Item
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
18.5.2016
K5G
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
20
Pcs
Customer
Cavity/mould
Part Name
GEAR WHEEL 1692
Weight/pc
Part No.
24052
Weight/mould
10
Kg
Material
FCD-450
Yield
40
0,205
1. PATTERN MAKING
Item
Specification
Remark
> Quantity Trial
Moulds
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,85 - 3,90
3,95
> Silicone
2,40 - 2,50
2,25
> Mangan
Max. 0,35
0,38
> Phospor
Max. 0,1
0,025
> Sulphur
Max. 0,02
0,022
Standard (%)
Actual (%)
> Carbon
3,50 - 4,20
3,73
> Silicone
3,00 - 3,30
3,13
> Mangan
Max. 0,8
0,40
> Phospor
Max. 0,1
0,025
> Sulphur
Max. 0,02
0,004
> Magnesium
0,02 - 0,06
0,035
Remark
Nama Material
Remark
Nama Material
Item
0,11
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Kg
TRIAL PROGRESS
Core Material
RCS
Core Weight/pc
0,334 Kg
Cav Core Box
2 cav
Trial Qty
5 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 75 %
HB/HRB
180 ~ 220 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
TEST 1
192 - 197 HB
TEST 2
234 - 247 HB
TEST 3
241 - 270 HB
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
25.5.2015
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
18
Pcs
Customer
Cavity/mould
Part Name
GEAR WHEEL 0500
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FCD-450
Yield
40
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,85 - 3,90
3,95
> Silicone
2,40 - 2,50
2,25
> Mangan
Max. 0,35
0,38
> Phospor
Max. 0,1
0,025
> Sulphur
Max. 0,02
0,022
Standard (%)
Actual (%)
> Carbon
3,50 - 4,20
3,73
> Silicone
3,00 - 3,30
3,13
> Mangan
Max. 0,8
0,40
> Phospor
Max. 0,1
0,025
> Sulphur
Max. 0,02
0,004
> Magnesium
0,02 - 0,06
0,035
Remark
Nama Material
Remark
Nama Material
Item
0,11
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 cav
Mold
3. INSPECTION
Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 75 %
HB/HRB
180 ~ 220 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
No
1
PROGRESS
4. ANALISA MASALAH
Masalah
Dimensi masih over
Penyebab
Tindakan Perbaik
act.
std. 7,5 (act. 8,2)
JUDGEMENT
O
K
N
G
Approved

Trial Date
25.5.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
20
Pcs
Customer
Cavity/mould
Part Name
GEAR WHEEL 1692
Weight/pc
Part No.
24052
Weight/mould
10
Kg
Material
FCD-450
Yield
40
0,205
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
11
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,85 - 3,90
3,95
> Silicone
2,40 - 2,50
2,24
> Mangan
Max. 0,35
0,38
> Phospor
Max. 0,1
0,029
> Sulphur
Max. 0,02
0,020
Standard (%)
Actual (%)
> Carbon
3,50 - 4,20
3,74
> Silicone
3,00 - 3,30
3,37
> Mangan
Max. 0,8
0,39
> Phospor
Max. 0,1
0,021
> Sulphur
Max. 0,02
0,004
> Magnesium
0,02 - 0,06
0,048
Remark
Nama Material
Remark
Nama Material
Item
NG
0,087
> Cu
C. Temperature
Item
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
1399
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Kg
TRIAL PROGRESS
Core Material
RCS
Core Weight/pc
0,334 Kg
Cav Core Box
2 cav
Trial Qty
11 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Remark
Standard
Actual
Ferrite 50 %
75%
Nodularyti 75 %
95%
180 ~ 220 HB
227 - 256
HB/HRB
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
TEST 1
192 - 197 HB
TEST 2
234 - 247 HB
TEST 3
241 - 270 HB
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
27.5.2015
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
18
Pcs
Customer
Cavity/mould
Part Name
GEAR WHEEL 0500
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FCD-450
Yield
40
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,50 - 4,20
3,73%
> Silicone
3,00 - 3,30
3,39%
> Mangan
Max. 0,8
0,39%
> Phospor
Max. 0,1
0,03%
> Sulphur
Max. 0,02
0,008%
> Magnesium
0,02 - 0,06
0,049%
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Carbon
3,85 - 3,90
> Silicone
2,40 - 2,50
> Mangan
Max. 0,35
> Phospor
Max. 0,1
> Sulphur
Max. 0,02
Item
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
> Per Mould
Standard
Second/Mould
> Per Ladle

Notes :
Minutes/Ladle
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
2 cav
5 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Remark
Standard
Actual
Ferrite 50 %
75%
Nodularyti 75 %
95%
190 ~ 220 HB
197 - 233
HB/HRB
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
> Hardness
Item
Tensile Strength
Yield Strength
Masalah
Elongation
GRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
JUDGEMENT
O
K
N
G
Approved

Trial Date
25.5.2016
Pre Launch
Mass Production
Tindakan Perbaikan
PIC
Waktu
Approved
ord Engineering
Prepared
Process Engineering
TRIAL PROGRESS
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
20
Cavity/mould
0,205
Part Name
GEAR WHEEL 1692
Weight/pc
Part No.
24052
Weight/mould
10
Material
FCD-450
Yield
40
Pcs Core Material
RCS
Kg Core Weight/pc
0,334 Kg
Kg Cav
2 cav
Core Box
% Trial Qty
5 Mold
1. PATTERN MAKING
Item
3. INSPECTION
Specification
> Quantity Trial
Remark
No

Item
Moulds
Defect
> Released Pattern
OK / NG
> Sli
> Hardness Mould
80 ~ 89
> SE
> Sensor Cope
1 / 2 / 3 / 4
> Si
> Sensor Drag
1 / 2 / 3 / 4
> SD
> CS
> Diameter Sprue
28 / 30 / 32
> BC
> Core
2. M E L T I N G
Remark
Nama Material
10
3,39
> Crush
> Silicone
2,40 - 2,50
2,35
> SP
> Mangan
Max. 0,35
0,34
> RO
> Phospor
Max. 0,1
0,029
> Carbide
> Sulphur
Max. 0,02
0,022
Total GooD
> Harness Up
Low
> Excentric
58 Pcs Total Defect
42 Pcs
42 %
Remark :
Mold Up = Cav 1 : 5, Cav 2 : 4, Cav 5 : 2, Cav 6 : 2, Cav 8 : 4, Cav 13 : 4, Cav 14 : 2, Cav 17 : 1, Cav
19 : 1
Actual (%)
> Carbon
3,50 - 4,20
3,75
> Silicone
3,00 - 3,30
3,29
> Mangan
Max. 0,8
0,35
> Phospor
Max. 0,1
0,030
> Sulphur
Max. 0,02
0,013
Item
> Magnesium
0,02 - 0,06
0,049
> Graphite type
C. Temperature
25
Low
Standard (%)
> Cu
> R Surface
> Dim Up
3,85 - 3,90
Nama Material
> MD
> Carbon
Remark
> BM
> BH
Actual (%)
Item
Remark
> CJ
> PH
Standard (%)
Defect
> BL
> Srk
Item
Item
B. Microstructure
Standard
Actual
Ferrite 50 %
10%
Size
> Matrix : P/F
Remark
Ma
Item
Standard ( C )
Actual ( C )
Remark
> Cementite
> Tapping
1500 ~ 1520
> Hardness
> Pouring
1400 ~ 1420
D. Pouring Time
Item
Item
Standard
Actual
Remark
Tensile Strength
> Per Mould
Second/Mould
Yield Strength
> Per Ladle
Minutes/Ladle
Elongation
Notes :
Nodularyti 75 %
95%
190 ~ 220 HB
192 - 209
HB/HRB
Standard
Actual
Remark
ESS

Trial Date
2.6.2016
26C
Pre Launch
Mass Production
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
PIC
Waktu
JUDGEMENT
O
K
N
G
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Customer
PT. EBARA
Cavity/mould
Part Name
CONNECTOR 80 LM
Weight/pc
Kg
Weight/mould
Kg
Part No.
Material
FC-200
Yield
1. PATTERN MAKING
Item
Specification
Remark
> Quantity Trial
Moulds
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
Item
> Carbon
3.00 ~ 3.70 %
> Silicone
1.40 ~ 2.60 %
> Mangan
0.40 ~ 0.80 %
> Phospor
Max. 0,08 %
> Sulphur
Max. 0,05 %
> Magnesium
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
FURAN
Kg
Core Weight/pc
Cav Core Box

Trial Qty
cav
Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
BODY 304 YA - 50 mm
Weight/pc
Part No.
Weight/mould
Material
FCD 45
Yield
Cav
2,19
Kg
27,14
Kg
48,4
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,90 0,05
3,94
> Silicone
2,30 0,05
2,14
> Mangan
Max. 0,40
0,38
> Phospor
Max. 0,03
0,025
> Sulphur
Max. 0,02
0,019
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,60 - 3,90
3,71
> Silicone
2,70 - 3,00
2,84
> Mangan
Max.0,04
0,39
> Phospor
Max. 0,08
0,025
> Sulphur
Max. 0,05
0,005
0,025 - 0,090
0,035
Standard ( C )
Actual ( C )
Remark
Actual
Remark
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
> Per Mould
Standard
Second/Mould
> Per Ladle

Notes :
Minutes/Ladle
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,35 Kg
2 cav
9 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Standard
Actual
Remark
Masalah
Elongation
GRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
JUDGEMENT
O
K
N
G
Approved

Trial Date
16.6.2016 LOT 6616
Pre Launch
Mass Production
Tindakan Perbaikan
PIC
Waktu
Approved
ord Engineering
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
BODY 304 YA - 65 mm
Weight/pc
Part No.
Material
FCD 45
6
2,82
Kg
Weight/mould
33,92
Kg
Yield
49,88
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,90 0,05
3,94
> Silicone
2,30 0,05
2,14
> Mangan
Max. 0,40
0,38
> Phospor
Max. 0,03
0,025
> Sulphur
Max. 0,02
0,019
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,60 - 3,90
3,71
> Silicone
2,70 - 3,00
2,84
> Mangan
Max.0,04
0,39
> Phospor
Max. 0,08
0,025
> Sulphur
Max. 0,05
0,005
0,025 - 0,090
0,035
Standard ( C )
Actual ( C )
Remark
Actual
Remark
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Pcs
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,50 Kg
2 cav
8 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
O
K
N
G
Approved

Trial Date
16.6.2016 LOT 6616
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Pcs
Weight/pc
3,1
Kg
Weight/mould
27,4
Kg
45,25
Customer
Cavity/mould
Part Name
BODY 304 YA - 80 mm
Part No.
Material
FCD 45
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
30
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,90 0,05
3,94
> Silicone
2,30 0,05
2,14
> Mangan
Max. 0,40
0,38
> Phospor
Max. 0,03
0,025
> Sulphur
Max. 0,02
0,019
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,60 - 3,90
3,71
> Silicone
2,70 - 3,00
2,84
> Mangan
Max.0,04
0,39
> Phospor
Max. 0,08
0,025
> Sulphur
Max. 0,05
0,005
0,025 - 0,090
0,035
Standard ( C )
Actual ( C )
Remark
Actual
Remark
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Core Weight/pc
Cav Core Box

Trial Qty
RCS
0,86 Kg
2 cav
30 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
> Graphite type
Standard
Actual
Remark
80 %
Size
> Matrix : P/F
> Cementite
Ferrite 70 %
Nodularyti 70 %
HB/HRB
140 ~ 210 HB
> Hardness
Item
Standard
Tensile Strength
Yield Strength
Elongation
280
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
16.6.2016 LOT 6616
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering
TRIAL PROGRESS
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
BODY 304 YA - 40 mm
Weight/pc
Part No.
8
1,67
26,36
Weight/mould
Material
FCD 45
Yield
50,6
Pcs Core Material

Kg Core Weight/pc
Kg Cav
Core Box
% Trial Qty
RCS
0,19 Kg
2 cav
11 Mold
1. PATTERN MAKING
Item
3. INSPECTION
Specification
> Quantity Trial
Remark
11
Moulds
No

Item
dipuring 10 mold
Defect
Item
> Released Pattern
OK / NG
> Sli
> CJ
> Hardness Mould
80 ~ 89
> SE
> BL
> Sensor Cope
1 / 2 / 3 / 4
> Si
> BM
> Sensor Drag
1 / 2 / 3 / 4
> SD
> CS
> Diameter Sprue
28 / 30 / 32
> BC
2. M E L T I N G
Item
Remark
Nama Material
> R Surface
> PH
> BH
> MD
> Dim Up
Actual (%)
> Carbon
3,90 0,05
3,80
> Crush
> Silicone
2,30 0,05
2,10
> SP
> Mangan
Max. 0,40
0,35
> RO
> Phospor
Max. 0,03
0,022
> Carbide
> Sulphur
Max. 0,02
0,014
Total GooD
Item
Low
> Harness Up
Low
> Excentric
Standard (%)
Actual (%)
Remark
3,60 - 3,90
3,69
> Silicone
2,70 - 3,00
2,89
OK
> Mangan
Max.0,04
0,37
OK
> Phospor
Max. 0,08
0,027
OK
> Sulphur
Max. 0,05
0,006
OK
Item
0,025 - 0,090
0,043
OK
> Graphite type
C. Temperature
1 Pcs
Standard
Actual
Ferrite 70 %
80%
1,25 %
Nama Material
> Carbon
> Cu
79 Pcs Total Defect
Remark :
OK
> Magnesium
Remark
> Core
> Srk
Standard (%)
Defect
B. Microstructure
Size
> Matrix : P/F
Remark
Ma
Item
Standard ( C )
Actual ( C )
Remark
> Cementite
> Tapping
1500 ~ 1520
1510
> Hardness
> Pouring
1400 ~ 1420
1421
D. Pouring Time
Item
Item
Standard
Actual
Remark
Tensile Strength
> Per Mould
Second/Mould
Yield Strength
> Per Ladle
Minutes/Ladle
Elongation
Notes :
Nodularyti 70 %
90%
140 ~ 210 HB
198
HB/HRB
Standard
Actual
Remark
ESS

Trial Date
17.06.2016
LOT 6617
Pre Launch
Mass Production
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
PIC
Waktu
JUDGEMENT
O
K
N
G
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
20
Pcs
Customer
Cavity/mould
Part Name
GEAR WHEEL 1692
Weight/pc
Part No.
24052
Weight/mould
10
Kg
Material
FCD-450
Yield
40
0,205
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,85 - 3,90
3,95
> Silicone
2,40 - 2,50
2,32
> Mangan
Max. 0,35
0,36
> Phospor
Max. 0,1
0,027
> Sulphur
Max. 0,02
0,023
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,50 - 4,20
3,75
> Silicone
3,00 - 3,30
3,21
> Mangan
Max. 0,8
0,38
> Phospor
Max. 0,1
0,029
> Sulphur
Max. 0,02
0,014
> Magnesium
0,02 - 0,06
0,045
Standard ( C )
Actual ( C )
Remark
Actual
Remark
Item
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Kg
TRIAL PROGRESS
Core Material
RCS
Core Weight/pc
0,334 Kg
Cav Core Box
2 cav
Trial Qty
8 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Remark
Standard
Actual
Ferrite 50 %
10%
Nodularyti 75 %
95%
190 ~ 220 HB
192 - 209
HB/HRB
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
20.6.2016
LOT
N6G
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering
TRIAL PROGRESS
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
PT. EBARA
Cavity/mould
Part Name
CONNECTOR 80LL
Weight/pc
Part No.
2
6,56
24
Weight/mould
Material
FC-200
Yield
54,6
Pcs Core Material
FURAN
Kg Core Weight/pc
Kg Cav
Core Box
% Trial Qty
0,71 Kg
cav
3 Mold
1. PATTERN MAKING
Item
3. INSPECTION
Specification
> Quantity Trial
Remark
No

Item
Moulds
Defect
Item
> Released Pattern
OK / NG
> Sli
> CJ
> Hardness Mould
80 ~ 89
> SE
> BL
> Sensor Cope
1 / 2 / 3 / 4
> Si
> BM
> Sensor Drag
1 / 2 / 3 / 4
> SD
> CS
> Diameter Sprue
28 / 30 / 32
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,35 0,05
3,80
> Crush
> Silicone
1,95 0,05
2,15
> SP
> Mangan
0,40 - 0,50
0,39
> RO
> Phospor
Max. 0,03
0,023
> Carbide
> Sulphur
Max. 0,03
0,024
Total GooD
Item
Actual (%)
> Carbon
3.00 ~ 3.70 %
3,79
> Silicone
1.40 ~ 2.60 %
2,45
> Mangan
0.40 ~ 0.80 %
0,40
> Phospor
Max. 0,08 %
0,022
> Sulphur
Max. 0,05 %
0,018
> Cu
C. Temperature
Remark
Low
> Harness Up
Low
> Excentric
6 Pcs Total Defect
0 Pcs
Standard
Actual
4-6
Ferrite 70 %
2%
Remark :
Standard (%)
> Magnesium
Defect
Remark
Nama Material
B. Microstructure
Item
> Graphite type
Size
> Matrix : P/F
Remark
Ma
Item
Standard ( C )
Actual ( C )
Remark
> Cementite
> Tapping
1500 ~ 1520
1514
> Hardness
> Pouring
1400 10
1409
D. Pouring Time
Nodularyti 70 %
Item
Item
Standard
Actual
Remark
Tensile Strength
> Per Mould
Second/Mould
Yield Strength
> Per Ladle
Minutes/Ladle
Elongation
Notes :
MOLDING
COPE
DRAG
CASTING
Max. 223 HB
159 - 166
HB/HRB
Standard
Actual
Remark
ESS

Trial Date
22.6.2016 LOT
P6G
Pre Launch
Mass Production
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
PIC
Waktu
JUDGEMENT
O
K
N
G
Approved
Prepared
Process Engineering
TRIAL PROGRESS
Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
PT. EBARA
Cavity/mould
Part Name
CONNECTOR 100LL
Weight/pc
Part No.
Material
FC-200
2
7,91
Weight/mould
26
Yield
60
Pcs Core Material
FURAN
Kg Core Weight/pc
Kg Cav
Core Box
% Trial Qty
0,86 Kg
cav
3 Mold
1. PATTERN MAKING
Item
3. INSPECTION
Specification
> Quantity Trial
Remark
No

Item
Moulds
Defect
Item
> Released Pattern
OK / NG
> Sli
> CJ
> Hardness Mould
80 ~ 89
> SE
> BL
> Sensor Cope
1 / 2 / 3 / 4
> Si
> BM
> Sensor Drag
1 / 2 / 3 / 4
> SD
> CS
> Diameter Sprue
28 / 30 / 32
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,35 0,05
3,80
> Crush
> Silicone
1,95 0,05
2,15
> SP
> Mangan
0,40 - 0,50
0,39
> RO
> Phospor
Max. 0,03
0,023
> Carbide
> Sulphur
Max. 0,03
0,024
Total GooD
Item
Actual (%)
> Carbon
3.00 ~ 3.70 %
3,79
> Silicone
1.40 ~ 2.60 %
2,45
> Mangan
0.40 ~ 0.80 %
0,40
> Phospor
Max. 0,08 %
0,022
> Sulphur
Max. 0,05 %
0,018
> Cu
C. Temperature
Remark
Low
> Harness Up
Low
> Excentric
6 Pcs Total Defect
0 Pcs
Standard
Actual
> Graphite type
A-B
Size
4-6
Ferrite 70 %
2%
Remark :
Standard (%)
> Magnesium
Defect
Remark
Nama Material
B. Microstructure
Item
> Matrix : P/F
Remark
Ma
Item
Standard ( C )
Actual ( C )
Remark
> Cementite
> Tapping
1500 ~ 1520
1514
> Hardness
> Pouring
1400 10
1409
D. Pouring Time
Item
Item
Standard
Actual
Remark
Tensile Strength
> Per Mould
Second/Mould
Yield Strength
> Per Ladle
Minutes/Ladle
Elongation
Notes :
CASTING
MOLD
COPE
DRAG
Nodularyti 70 %
Max. 223 HB
159 - 166
HB/HRB
Standard
Actual
Remark
ESS

Trial Date
22.6.2016 LOT
P6G
Pre Launch
Mass Production
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
PIC
Waktu
JUDGEMENT
O
K
N
G
Approved
Prepared

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
PT. EBARA
Cavity/mould
Part Name
CONNECTOR 80 LM
Weight/pc
Part No.
Material
FC-200
2
6,03
Kg
Weight/mould
20
Kg
Yield
60
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,35 0,05
3,80
> Silicone
1,95 0,05
2,15
> Mangan
0,40 - 0,50
0,39
> Phospor
Max. 0,03
0,023
> Sulphur
Max. 0,03
0,024
Remark
Nama Material
Remark
Nama Material
Item
Standard (%)
Actual (%)
> Carbon
3.00 ~ 3.70 %
3,79
> Silicone
1.40 ~ 2.60 %
2,45
> Mangan
0.40 ~ 0.80 %
0,40
> Phospor
Max. 0,08 %
0,022
> Sulphur
Max. 0,05 %
0,018
Standard ( C )
Actual ( C )
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 10
1409
Standard
Actual
Remark
D. Pouring Time
Item
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Pcs
MOLDING
COPE
DRAG
TRIAL PROGRESS
Core Material
FURAN
Kg
Core Weight/pc
Cav Core Box

Trial Qty
cav
3 Mold
3. INSPECTION
Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
> Graphite type
A-B
Size
4-6
Ferrite 70 %
2%
> Matrix : P/F

> Cementite
> Hardness
Remark
Nodularyti 70 %
Max. 223 HB
159 - 166
HB/HRB
Standard
Actual
Remark
Item
Tensile Strength
Yield Strength
Elongation
No
1
CASTING
PROGRESS
4. ANALISA MASALAH
Masalah
bagian diameter joint nya tidak
sama pada di satu sisi
Penyebab
Diameter pada
parting line joint
nya sama
bagian diameter (yang

dibentuk oleh core) di
parting line nya tidak
sama
Tindakan Perbaik
Analisa pada dimensi core da
core box
JUDGEMENT
O
K
N
G
Approved

Trial Date
22.6.2016 LOT
P6G
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
nalisa pada dimensi core dan perbaikan
ore box
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
pcs
Customer
PT. EBARA
Cavity/mould
Part Name
BEARING HOUSING 245
Weight/pc
18,5
Kg
Weight/mould
24,5
Kg
Part No.
Material
FC-150
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,75 0,05
3,80
> Silicone
2,15 0,05
2,08
> Mangan
Max. 0,40
0,38
> Phospor
Max. 0,03
0,022
> Sulphur
Max. 0,03
0,018
Standard (%)
Actual (%)
> Carbon
3,50 - 3,70
3,70
> Silicone
2,20 - 2,40
2,40
> Mangan
Max. 0,40
0,38
> Phospor
Max. 0,03
0,023
> Sulphur
Max. 0,03
0,018
Standard ( C )
Actual ( C )
Remark
Nama Material
Remark
Nama Material
Item
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1520 - 1540
> Pouring
1400 10
1408
Standard
Actual
Remark
D. Pouring Time
Item
> Per Mould
Remark
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Molding
COPE
DRAG
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box

Trial Qty
cav
2 Mold
3. INSPECTION
Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
> SP
Defect
Remark
> RO
Low
> Excentric
Total GooD
1 Pcs Total Defect
1 Pcs
50 % NG
Standard
Actual
Remark
4-6
Ferrite 90 %
97% P
Remark :
B. Microstructure
Item
> Graphite type
Size
> Matrix : P/F
> Cementite
> Hardness
Nodularyti 70 %
174 ~ 233 HB
153 - 162
HB/HRB
Standard
Actual
Remark
Item
Tensile Strength
Yield Strength
Masalah
Low
> Harness Up
> Carbide
No
1
Crush
Elongation
Pemasangan Core
GRESS
4. ANALISA MASALAH
Masalah
Badlift dibagian
diameter
Penyebab
Penyebab diakibatkan
pattern keropos/bolong
Tindakan Perbaikan
Tambal pattern
JUDGEMENT
O
K
N
G
Approved

Trial Date
22.6.2016
LOT
P5G
Pre Launch
Mass Production
Tindakan Perbaikan
PIC
Sujarwo
Waktu
28.6.2016
Approved
ord Engineering
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
20
Pcs
Customer
Cavity/mould
Part Name
GEAR WHEEL 1692
Weight/pc
Part No.
24052
Weight/mould
10
Kg
Material
FCD-450
Yield
40
0,205
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3,50 - 4,20
3.43%
> Silicone
3,00 - 3,30
1.87%
> Mangan
Max. 0,8
0.54%
> Phospor
Max. 0,1
0.027%
> Sulphur
Max. 0,02
0.018%
> Magnesium
0,02 - 0,06
> Carbon
3,85 - 3,90
> Silicone
2,40 - 2,50
> Mangan
Max. 0,35
> Phospor
Max. 0,1
> Sulphur
Max. 0,02
Item
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
> Per Mould
Standard
Second/Mould
Kg
> Per Ladle

Notes :
Minutes/Ladle
TRIAL PROGRESS
Core Material
RCS
Core Weight/pc
0,334 Kg
Cav Core Box
2 cav
Trial Qty
8 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
> Graphite type
A-B
Size
4-6
> Matrix : P/F

> Cementite
Actual
Ferrite 50 %
Nodularyti 75 %
HB/HRB
190 ~ 220 HB
> Hardness
Remark
Item
Tensile Strength
Yield Strength
Standard
Actual
Remark
Masalah
Elongation
GRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
JUDGEMENT
O
K
N
G
Approved

Trial Date
28.6.2016
LOT
U6G
Pre Launch
Mass Production
Tindakan Perbaikan
PIC
Waktu
Approved
ord Engineering
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Cavity/mould
Part Name
GEAR WHEEL 0500
Weight/pc
Part No.
18
0,260
FCD-450
Yield
40
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,85 - 3,90
> Silicone
2,40 - 2,50
> Mangan
Max. 0,35
> Phospor
Max. 0,1
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,50 - 4,20
> Silicone
3,00 - 3,30
> Mangan
Max. 0,8
> Phospor
Max. 0,1
> Sulphur
Max. 0,02
> Magnesium
0,02 - 0,06
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Kg
Kg
Weight/mould
Material
Pcs
TRIAL PROGRESS
Core Material
RCS
Core Weight/pc
0,443 Kg
Cav Core Box

Trial Qty
cav
3 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 50 %
Nodularyti 75 %
HB/HRB
190 ~ 220 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
28.6.2016
LOT
U6G
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
Pcs
Cavity/mould
Part Name
END NUT 55/85
Part No.
Material
FC-250
Weight/pc
Kg
Weight/mould
Kg
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
Item
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
Kg
Core Weight/pc
Cav Core Box

Trial Qty
cav
5 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
Actual
Remark
> Graphite type

Size
> Matrix : P/F
> Cementite
Ferrite 50 %
Nodularyti 75 %
HB/HRB
190 ~ 220 HB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
14.7.2016
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
20
Pcs
Customer
Cavity/mould
Part Name
GEAR WHEEL 1692
Weight/pc
Part No.
24052
Weight/mould
10
Kg
Material
FCD-450
Yield
40
0,205
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,85 - 3,90
> Silicone
2,40 - 2,50
> Mangan
Max. 0,35
> Phospor
Max. 0,1
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,50 - 4,20
> Silicone
3,00 - 3,30
> Mangan
Max. 0,8
> Phospor
Max. 0,1
> Sulphur
Max. 0,02
> Magnesium
0,02 - 0,06
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Kg
TRIAL PROGRESS
Core Material
RCS
Core Weight/pc
0,334 Kg
Cav Core Box
2 cav
Trial Qty
5 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
> Graphite type
A-B
Size
4-6
> Matrix : P/F

> Cementite
Actual
Ferrite 50 %
Nodularyti 75 %
HB/HRB
190 ~ 227 HB
> Hardness
Remark
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
19.7.2016
LOT
L7G
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
STARTING HANDLE 55/155
Pcs
Cavity/mould
Part Name
Weight/pc
Kg
Part No.
Weight/mould
Kg
Material
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
> Carbon
3,85 - 3,90
> Silicone
2,40 - 2,50
> Mangan
Max. 0,35
> Phospor
Max. 0,1
> Sulphur
Max. 0,02
Actual (%)
Remark
Nama Material
Actual (%)
Remark
Nama Material
Item
Standard (%)
> Carbon
3,50 - 4,20
> Silicone
3,00 - 3,30
> Mangan
Max. 0,8
> Phospor
Max. 0,1
> Sulphur
Max. 0,02
> Magnesium
0,02 - 0,06
> Cu
C. Temperature
Item
Standard ( C )
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
Actual ( C )
Remark
Actual
Remark
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box
cav
Trial Qty
Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
> Graphite type
A-B
Size
4-6
> Matrix : P/F

> Cementite
Actual
Ferrite 50 %
Nodularyti 75 %
HB/HRB
190 ~ 227 HB
> Hardness
Remark
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
19.7.2016
LOT
L7G
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
STARTING HANDLE 55/155
Pcs
Cavity/mould
Part Name
Weight/pc
Kg
Part No.
Weight/mould
Kg
Material
FCD - 450
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
> Carbon
3.20 - 3.90 %
3.75%
> Silicone
2.30 - 3.30%
3.07%
> Mangan
MAX. 0,70 %
0.40%
> Phospor
Max. 0,03%
0.025%
> Sulphur
Max. 0,05 %
0.004%
> Magnesium
Max. 0,09%
0.047%
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Carbon
3,85 - 3,90
> Silicone
2,40 - 2,50
> Mangan
Max. 0,35
> Phospor
Max. 0,1
> Sulphur
Max. 0,02
Item
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
> Per Mould
Standard
Second/Mould
> Per Ladle

Notes :
Minutes/Ladle
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box
cav
Trial Qty
Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
> Graphite type
A-B
Size
4-6
> Matrix : P/F

> Cementite
Actual
Ferrite 50 %
Nodularyti 75 %
HB/HRB
190 ~ 227 HB
> Hardness
Remark
Item
Tensile Strength
Yield Strength
Standard
Actual
Remark
Masalah
Elongation
GRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaikan
JUDGEMENT
O
K
N
G
Approved

Trial Date
19.7.2016
LOT
L7G
Pre Launch
Mass Production
Tindakan Perbaikan
PIC
Waktu
Approved
ord Engineering
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
Customer
PUMP CASING 125 JBC
Cavity/mould
Pcs
Part Name
Weight/pc
Kg
Part No.
Weight/mould
Kg
Material
Yield
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
Remark
Nama Material
Standard (%)
Actual (%)
Remark
Nama Material
Standard ( C )
Actual ( C )
Remark
Actual
Remark
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
Item
> Carbon
> Silicone
> Mangan
> Phospor
> Sulphur
> Magnesium
> Cu
C. Temperature
Item
> Tapping
1500 ~ 1520
> Pouring
1400 ~ 1420
D. Pouring Time
Item
Standard
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
TRIAL PROGRESS
Core Material
RCS
Kg
Core Weight/pc
Cav Core Box
cav
Trial Qty
Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
> Graphite type
A-B
Size
4-6
> Matrix : P/F
Actual
Remark
Ferrite 50 %
> Cementite
HB/HRB
> Hardness
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
19.7.2016
LOT
L7G
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Phone : (62-21) 590-2488, 590-2489 Fax. (62-21) 590-0627
20
Pcs
Customer
Cavity/mould
Part Name
GEAR WHEEL 1692
Weight/pc
Part No.
24052
Weight/mould
10
Kg
Material
FCD-450
Yield
40
0,205
1. PATTERN MAKING
Item
Specification
> Quantity Trial
Remark
38
> Released Pattern
OK / NG
> Hardness Mould
80 ~ 89
Moulds
> Sensor Cope
1 / 2 / 3 / 4
> Sensor Drag
1 / 2 / 3 / 4
> Diameter Sprue
28 / 30 / 32
2. M E L T I N G
Item
Standard (%)
Actual (%)
> Carbon
3,85 - 3,90
3,90
> Silicone
2,40 - 2,50
2,20
> Mangan
Max. 0,35
0,36
> Phospor
Max. 0,1
0,029
> Sulphur
Max. 0,02
0,021
Standard (%)
Actual (%)
> Carbon
3,50 - 4,20
3,70
> Silicone
3,00 - 3,30
3,60
> Mangan
Max. 0,8
0,38
> Phospor
Max. 0,1
0,317
> Sulphur
Max. 0,02
0,007
> Magnesium
0,02 - 0,06
0,049
Standard ( C )
Actual ( C )
> Tapping
1500 ~ 1520
1409
> Pouring
1400 ~ 1420
Remark
Nama Material
Remark
Nama Material
Item
> Cu
C. Temperature
Item
Remark
D. Pouring Time
Item
Standard
Actual
Remark
> Per Mould
Second/Mould
> Per Ladle
Minutes/Ladle
Notes :
Kg
TRIAL PROGRESS
Core Material
RCS
Core Weight/pc
0,334 Kg
Cav Core Box
2 cav
Trial Qty
38 Mold
3. INSPECTION
No

Item
Defect
Item
> Sli
> CJ
> SE
> BL
> Si
> BM
> SD
> CS
> BC
> Core
> Srk
> R Surface
> PH
> BH
> MD
> Dim Up
> Crush
Defect
Remark
Low
> SP
> Harness Up
> RO
Low
> Carbide
> Excentric
Total GooD
Pcs Total Defect
Pcs
Remark :
B. Microstructure
Item
Standard
> Graphite type
A-B
Size
4-6
> Matrix : P/F

> Cementite
Actual
Ferrite 50 %
Nodularyti 75 %
HB/HRB
190 ~ 227 HB
> Hardness
Remark
Item
Tensile Strength
Yield Strength
Elongation
Standard
Actual
Remark
PROGRESS
4. ANALISA MASALAH
Masalah
Penyebab
Tindakan Perbaik
JUDGEMENT
O
K
N
G
Approved

Trial Date
19.7.2016
LOT
L7G
Pre Launch
Mass Production
ASALAH
Tindakan Perbaikan
PIC
Waktu
Approved
Prepared
Process Engineering

Contoh Trial Progres

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PT.

BINA USAHA MANDIRI

PT TOMOE VALVE BATAM

> Quantity Trial

> Hardness Mould

> Sensor Cope

> Sensor Drag

> Diameter Sprue

> Per Mould

> Per Ladle

Cav Core Box

Pcs Total Defect

> Graphite type

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

PT. BINA USAHA MANDIRI

PT TOMOE VALVE BATAM

> Quantity Trial

> Hardness Mould

> Sensor Cope

> Sensor Drag

> Diameter Sprue

> Per Mould

> Per Ladle

Cav Core Box

8 Pcs Total Defect

> Graphite type

Gatting system setelah perubahan

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

PT. BINA USAHA MANDIRI

PT. TOMOE VALVE BATAM

> Quantity Trial

> Released Pattern

> Hardness Mould

> Sensor Cope

> Sensor Drag

> Diameter Sprue

> Per Mould

> Per Ladle

Cav Core Box

Pcs Total Defect

> Graphite type

Penghalusan pattern pada bagia

Gatting system kurang efektif

Perubahan gatting system

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

enghalusan pattern pada bagian yang

erubahan gatting system

PT. BINA USAHA MANDIRI

PT. TOMOE VALVE BATAM

> Quantity Trial

> Released Pattern

> Hardness Mould

> Sensor Cope

> Sensor Drag

> Diameter Sprue

> Per Mould

> Per Ladle

Cav Core Box

Pcs Total Defect

> Graphite type

No.Dokumen : BM/PR-02/TECH-RC/02 Rev : 02

PT. BINA USAHA MANDIRI

PT. Yanmar Diesel Indonesia

Pump Body TF 60/120