Gate & Globe PDF

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PT. ALFA VALVES INDONESIA

JL. Mercedes No. 324, Wanaherang, Gunung Putri, Bogor - Indonesia
Phone : (62 - 21) 8686 0009 ; Fax : (62 - 21) 8686 0008 Phone : (62 - 21) 8686 0009 ; Fax : (62 - 21) 8686 0008
E-mail : alfavalve@cbn.net.id
PRODUCTION FLOW CHART of GATE & GLOBE VALVES
Document No. :
Revision No. :
AVI-P-FC-002
0
Prepared By : Tunggul H.P
Approved By : S. Martahan Panjaitan pp y
Issued Date : November 14, 2002
Notice
This document and it's content are property of PT. ALFA VALVES INDONESIA. Neither this document nor this its content may
be copied in a whole or in apart thereof or transferred to a third party or used in any other way detrimental to the interest of
PT. ALFA VALVES INDONESIA.
0 2 OF 4
DATE OF ISSUED
PAGE
14-Nov-02
PRODUCTION PROCESS FLOW CHART OF GATE & GLOBE VALVES
ALFA VALVES
DOC NO.
REV.
AVI-P-FC-002
#
-
PROCESS DOCUMENT REMARK
Check for correct content and quantity
Store Personel
materials againts packing list or supplier
supplier D/D / invoice to Alfa. PO.
Discrepancies shall be identifed
START
INCOMING
MATERIAL
PURCASE ORDER VENDOR PACKING LIST
MATERIALS RECEIVE RETURN'S OUTWARD
-
-
-
#
-
-
Materials consumable log book
raised for Indirect Material record
QC inspector
Material Mill Test Reports will be kept
Discrepancies shall be identifed
for remedial action
Material stock status raised
for Direct Material record
by QC Department.
Visual Surface Inspection(MSS-SP 55)
Di i l I ti
DELIVERY MATERIALS CONS. LOG
MATERIALS STOCK
MILL TEST REPORT QC INCOMING
INCOMING MATERIAL
QC
INCOMING
INSPECTION
-
#
#
-
NO
* Face to Face/End to End Dimensions
NCMR ( Non Conforming Material
meeting receive reports & decide
material status
* Wall thickness
Dimensional Inspection
MRB ( Material Review Board)
* Flange Dimensions
* Height, Handwheel
* Etc.
NCMR NC Tag
OK ? NON-CONFORMANCE
YES
-
#
#
-
Sales Order and / or customer delivery
Report )
Production Assembly Operator
Production Work Order shall based on
NC Tag ( Non Conforming Tag )
Store Personel
RAW
MATERIAL
STORAGE
MATERIAL STOCK INVENTORY STOCK
PRODUCTION PRODUCTION WORK
COLLECT KIT
VALVES
#
-
#
NO
Inspect for Quantity and suitability of
Sales Order and / or customer delivery
order
parts
MAT. REQ. / ISSUED
ASSY
REQUEST FOR KIT
COMPLETENESS
PARTS INS.
BEFORE
ASSEMBLY
OK ?
MAT. REQ. / ISSUED
YES
#
-
#
Tack Welding.
NO NO
Bushing is fixed into Bonnet by
MRB
ASSY IN-PROCESS INSTALL
BUSHING,
YOKE SLEEVE
& RETAINING
NUT INTO
BONNET
TRIAL &
NCMR
-
YES
#
YES
NCP : Non-Conformance Procedure
TRIAL &
ERROR
NCP
NCMR
INSTALL EYE
BOLTS INTO
BONNET
A
OK ? OK ?
ASSY IN-PROCESS
AVI-P-FC-002
14-Nov-02 AVI-P-FC-002
0 3 OF 4
ALFA VALVES
DOC NO.
REV.
DATE OF ISSUED
PAGE
#
#
MRB
REMARK
NO
PROCESS DOCUMENT
YES
NO
YES
NCMR
A
OK ?
TRIAL &
ERROR
OK ? NCP
ASSY IN PROCESS
#
#
MRB
y p
NO NO
INSTALL
STEM,
GLAND AND
GLAND
FLANGE INTO
BONNET
OK ?
TRIAL &
ERROR
OK ? NCP
ASSY IN-PROCESS
NCMR
#
YES
YES
INSTALL
GLAND
PACKING
AND
EYEBOLT
NUTS INTO
BONNET
ASSY IN-PROCESS
#
#
MRB
NO NO
YES
YES
OK ?
TRIAL &
ERROR
OK ? NCP
INSTALL
HANDWHEEL
(HW) & HW
NUT INTO
BONNET
NCMR
ASSY IN-PROCESS
#
#
-
#
MRB
MRB
Visual & Functional Inspection
MRB
YES
NO NO
NO NO
YES
OK ?
TRIAL &
ERROR
OK ? NCP
BONNET
ASSY
INSPECTION
NCMR
ASSY IN-PROCESS
#
#
-
-
# NO
For Globe valve install Disc Stem Ring
& Disc Washer to connect the Disc into
Stem
MRB NO NO
Sealing surface wear track
YES Production Assembly Operator
YES
MRB NO
OK ?
TRIAL &
ERROR
OK ? NCP
INSTALL
WEDGE/DISC
INTO STEM
OK ?
TRIAL &
OK ?
NCMR
NCMR
ASSY IN-PROCESS
#
YES
YES Production Assembly Operator
OK ?
TRIAL &
ERROR
OK ?
NCP
INSTALL
GASKET
B
NCMR
ASSY IN-PROCESS
AVI-P-FC-002
AVI-P-FC-002
0 4 OF 4
ALFA VALVES
DOC NO.
REV.
DATE OF ISSUED
PAGE
14-Nov-02
#
REMARK PROCESS DOCUMENT
B
BOLTING
BONNET
ASSY INTO
BODY WITH
STUD BOLTS
#
-
-
#
Functional Inspection
J oint torques Inspection
MRB
YES
NO NO
& NUTS
OK ?
TRIAL &
ERROR
OK ? NCP
ASSEMBLY DAILY
PERFORMANCE REPORT
NCMR
VALVE ASSY
INSPECTION
NC Tag
#
-
-
-
-
-
#
Production Testing Operator
MRB
API 598 or API 6D
High-Pressure Closure Test
Shell Test
(Upon Customer's Requirements)
Backseat Test
Low-Pressure Closure Test
NO
VALVE
PRESSURE
TESTING
TESTING DAILY
PERFORMANCE REPORT
NON CONFORMANCE OK ?
NCMR NC Tag
#
#
-
The Plates are mounted in the most
practicable position
Production Painting Operator
Production Packing Operator
YES
INSTALL ID
PLATE
NON-CONFORMANCE
COATING
OK ?
COATING DAILY
PERFORMANCE REPORT
#
-
#
QC Inspector
Production will advise QC that valves
are ready for final Inspection by
Completing a"Request for QC
Inspection Form"
QC Inspector NO
YES
OK ?
FINAL
INSPECTION
NON-CONFORMANCE
REQUEST for QC QC FINAL INSPECTION
QC FINAL INSPECTION
NCMR CORRECTIVE ACTION
#
#
-
-
-
MTR=Material Test Report
QC Inspector
COC=Certificate of Compliance & Test
PTR=Pressure Test Report
Production Packing Operator
PACKAGING
& DESPATCH
DOCUMENTA
TION
SALES ORDER
ALFA PACKING LIST
PACKING LABEL
COC MTR
PTR DVIR
-
#
DVIR=Dimensions & Visual Ins. Report
Store Personel
TION
SHIPMENT
END
SHIPMENT SCHEDULE DELIVERY DOCKET
VALVES STOCK INVENTORY STOCK
WARRANTY VALVES DATA LOG
AVI-P-FC-002

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PT. ALFA VALVES INDONESIA

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