HOSE ASSEMBLY ASSURANCE MANUAL

REV.                    QUALITY ASSURANCE                 SIGNATURE

OF                                     QAS

                                          PRODUCTION                           SIGNATURE

                                           PRODS     

APPROVED BY          ENGINEERING MGR.              SIGNATURE

COPY TO                                                   UNIT

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1. GOAL
2. APPLICATION FIELD
3. ABBREVIATIONS
4. RESPONSABILITIES
5. CONTENTS OF HOSE ASSEMBLY ASSURANCE MANUAL

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Phase 1                        Hose Type
Phase 2                       Cut Length/Interaxle Length
Phase 3                       Out Side Skive
Phase 4                        Inside Skive
Phase 5                        Inside/Outside Skive Control
Phase 6                        1^st Fitting/2^nd Fitting
Phase 7                        Orientation
Phase 8                        Crimping Diameter and Crimping Diameter Control
Phases 9                      Manufacturing Date Marking
Phase 10                      Proof Test (if requested)
Phase 11                      Hose Flushing (if requested)
Phase 12                     Capping (if requested)

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SHEETS OF REFERENCE

1. MANUFACTURING AND CONTROL SHEET
2. INTERNAL ORDER
3. INTERAXLE LEGTH INERPRETATION
4. FITTING ORIENTATION
5. CRIMPING DIAMETER CHART
6. INSTRUCTIONS P32/FP110
7. HOSE FLUSHING – REGOLATION MACHINE CHART
8. PROOF TEST REPORT

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1.0 GOAL
Hose Assembly Assurance Manual defines assembly process in order to garantee and assure that all operation of assembly productions are made following requirements requested by Customer Specifications e by Manuli Specifications.
2.0 APPLICATION FIELD
Work and control phases described in this Manual are applicable only to the activity of Hose Assembly production.
Each assembly phase is numbered with reference to Manufacturing and Control Sheet
3.0 ABBREVIATIONS
STOS              :           STORE SUPERVISOR
PROD             :           PRODUCTION
PRODS           :           PRODUCTIONE SUPERVISOR
QAS                :           QUALITY ASSURANCE SUPERVISOR
NC                  :           NON CONFORM PRODUCT
MF/C               :           MANUFACTURING AND CONTROL SHEET
4.0 RESPONSABILITY
PRODS

• Issue MF/C with reference to internal order and give to production.
• Operate swaging machine. At this operation, PRODS has to assure on every hose assembly that they are made following MF/C.

PROD

• Has the responsibility to assembly and to control along the manufacturing process following what is written in SF/C.

QAS

• Operate test pressure machine and report test result.
• Issue NON CONFORM PRODUCT SHEET of NC

PHASE 1                                       HOSE TYPE

OPERATIONS	MACHINE	SHEET OF REFERENCE
Take from the storage the type of hose with the same code indicated on MF/C
Write the hose lot# on M/FC
Attention: to facilitate traceability of hose assembly, the type of hose used to manufacture a single lot of hose assembly must possibly be of the same lot

PHASE 2                      CUT LENGTH / INTERAXLE LENGTH

OPERATIONS	MACHINE	SHEET OF REFERENCE
Cut length is indicated in MF/C. If it is not specified, operate as follow: n     consider interaxle length “L” of assembly indicated in MF/C; n     subtract from the measure of interaxle length “L”  the sum of fittings length “x”, considering the measure from the abutting end of rubber hose to the fitting interaxle n     subtract to the result obtained the extension obtained  during the crimping phase (5mm for braided hose and 8mm for spiralled hose)	L             x
Set the hose cut measure	steel ruler
Attention: cut must be perpendicular to the hose		cut section YES NO
Switch on the machine and wait until the number of cycles is stable.	cutting machine
Rule downward speed of blade (knife) depending on type of hose to be cut. A wrong regulation of downward speed can break the blade. For spiralled hose : minimum speed for all other types : normal speed.	cutting machine
Speed can be regulated with the handle on the left of cutting machine.  Turning the handle anticlockwise speed increases and viceversa.	cutting machine	Front side handle
Control cut rubber hose length and writ it on MF/C.	Steel ruler

PHASE 3                                                    OUTSIDE SKIVE

OPERATION	MACHINE	SHEET OF REFERENCE
Take the pin guide of the same diameter of hose to be skived (see marking on the pin).
Set the pin as the skive length indicated on MF/C measuring with caliper the distance between the abutting  of pin and the knife.	Skive machine
Set the phase inverter to wheel the mandrel to anticlockwise
Switch the skive machine with the foot -switcher
Insert the hose in the mandrel to skive.
Skive depth must unwrap rubber to void damage till metallic reinforce is visible.
Be careful not to leave rubber dross, shavings on the hose.
Attention: skive has to be done just on hose with metallic reinforce.

PHASE 4                                                              INSIDE SKIVE

OPERATIONS	MACHINE	SHEET OF REFERENCE
Spiralled hose must be skived inside.
Take the guide pin of the same diameter of the hose to be skived (see marking on the pin).
Set the ghiera as the skive length indicated on MF/C measuring the distance between the ghiera abutting and the knife.	Skive machine
Set the phase inverter to wheel the mandrel to clockwise
Switch the skive machine with the foot -switcher
Insert the hose in the mandrel to skive.
Skive depth must unwrap rubber to void damage till metallic reinforce is visible.
Be careful not to leave rubber droll, shavings inside the hose.

PHASE 5                                           INSIDE/OUTSIDE SKIVE CONTROL

OPERATIONS	MACHINE	SHEET OF REFERENCE
Control the skive length with caliper as indicated in MF/C.	Caliper
Operator must also consult with skiving chart for the skive length in order to prevent too long/to short skive.		Skiving Chart
If skive is out of the range, put the assembly hose in a NC area, QAS to fill the Non Conformity product sheet.		Non Conformity Product Sheet

PHASES 6                                1^ST FITTING / 2^ND FITTING

OPERATIONS	MACHINE	SHEET OF REFERENCE
Fittings are stored boxes identified with the product code which recorded in stock cards and/or computer.
Take fittings indicated on MF/C of the same box.
Put in the fittings to the hoses as indicated on MF/C.

PHASE 7                                           ORIENTATION

OPERATIONS	MACHINE	SHEET OF REFERENCE
Block fittings in the vice.	Vice
Turn manually the other fitting, following the chart enclosed, till the value indicated on MF/C is visible on goniometer	Goniometer

PHASES 8                          MANUFACTURING DATE MARKING

OPERATIONS	MACHINE	SHEET OF REFERENCE
Use electric pen to mark date-month-year on the ferrule of the assembly hose.   Example : 30/12/43	Electric Pen

PHASES 9                   CRIMPING DIAMETER AND CRIMPING DIAMETER  CONTROL

OPERATIONS	MACHINE	SHEET OF REFERENCE
The crimping diameter is indicated on MF/C.
Consult crimping diameter chart to choose the set of dies required for the crimping diameter requested.	P32/FP 110	Crimping Diameter Chart
Be sure the machine is turned off.
Put in the correct dies. Make sure that all dies are completely sit on the master dies.
Operator must also consult with the crimping diameter chart in order to prevent the out of range of crimping diameter.		Crimping Diameter Chart
Switch the machine on.	P32/FP 110	Instructions P32/FP110
Set the right crimping diameter with the diameter setting device.	“	Instructions P32/FP110
Push the press button to crimp the hose.	“	Instructions P32/FP110
Control the crimping diameter with caliper. Operator must measure the crimping diameter in every change of diameter setting
If crimping diameter is out of range, put the assembly hose in a NC area, QAS to fill the Non Conformity Product Sheet.		Non Conformity Product Sheet

PHASE 10                                         PROOF TEST (IF REQUESTED)

OPERATIONS	MACHINE	SHEET OF REFERENCE
Supply the bench with connections conform to hose to be tested.	Pressure bench	Customer Specifications
Switch on the bench and the computer.
Select or create the recipe. Remember that the proof pressure is double the working pressure written on the rubber hose.
Close the door and start the bench.
When cycle is finished write results on MF/C.
Print the report if requested by the Customer.
If there is leakage along the rubber or on the fittings, put the assembly hose in a NC area, QAS to fill the Non Conformity Product Sheet.		Non Conformity Product Sheet

PHASE 11                               HOSE FLUSHING (IF REQUESTED)

OPERATIONS	MACHINE	SHEET OF REFERENCE
THE USE OF GLOVES IN THIS PHASE IS COMPULSORY
Control oil level with dipstick. If oil is under the half fill it up with oil.	Dipstick
Prepare the machine according to the hoses diameter, following the machine chart for the time and number of pumps	FMX 150	MOD. MOT06
Screw hoses on the rack in the correct way, being careful with long hoses, with wide bend radius (it is sufficient to screw two turns)
Push the two buttons on the sides of the bench. Door closes and automatically cycle works.	Front side       buttons
Door opens automatically, unscrew the hoses and put them on the rack to drip.
Attention: fluid used in this phase is oil for spark erosion (BP/HP-0 FINA IT/11-004 FINA PARAPUR/1013) and pollution grade to specifics NAS 1638 is checked monthly in an outside laboratory. According to the analysis results: if the value of fluid is less or equal to 8 NAS can be used till the following month; if it is more or equal to 9 NAS must be changed by TEQ.

PHASE 12                                                  CAPPING (IF REQUESTED)

OPERATIONS	MACHINE	SHEET OF REFERENCE
Take caps according to hose type and diameter.
Cap fittings when hoses are completely dry (if flushed).

NOTE
The handling of hoses from the cutting phase to the fitting assembly/crimping one and from the latter and the flushing phase, has to be done by racks which can garantee outside hose cleanliness and prevent abrasions due to trailing along the floor.

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