Manufacturing Instructions Requirements and principles

Transcription

1 May 2016 Manufacturing Instructions Requirements and principles SN ICS Supersedes SN 200-1: Table of contents Page 1 Scope Requirements Principles Country-specific regulations Safety regulations Hazardous materials / environmental protection Basic specifications Inadmissible hazardous materials Admissible hazardous materials Radioactivity Tolerancing principle Reference surface Residual magnetism Marking of components during manufacture Basic specifications WBS number and material number Serial number Batch number Supplier evaluation system Publication form of SN Annex A (for information) - Structure of the WBS number (example)... 4 Referenced technical standards, codes and regulations... 5 Revision of May Scope This company standard specifies requirements and principles for manufacture and supply of mechanical and fluid power system products/materials of SMS group. 2 Requirements The requirements specified in the parts of SN 200 shall be fulfilled if no other requirements are made in drawings, ordering and/or other manufacturing documents. This standard is indicated as binding document in drawing title blocks, contracts and/or ordering documents. If the requirements cannot be fulfilled, consulting with SMS group is necessary. The SN 200 series of standards comprises the following additional parts: SN SN SN SN SN SN SN SN SN Manufacturing Instructions - Blank parts and semi-finished products Manufacturing Instructions - Thermal cutting and bending Manufacturing Instructions - Welding Manufacturing Instructions - Machining Manufacturing Instructions - Assembly and disassembly Manufacturing Instructions - Corrosion protection Manufacturing Instructions - Shipment Manufacturing Instructions - Transport Manufacturing Instructions - Inspection Edited by: SMS group Standards Office SMS group GmbH 2016 "The present document is protected by copyright. Reproduction, distribution and utilization of this document as well as communication of its contents to others are prohibited unless expressly authorized by us. Any violations will be prosecuted under criminal law and will result in an obligation to pay damages. All rights reserved." Number of pages: 5

2 Page 2 3 Principles 3.1 Country-specific regulations The place of use of a machine or a component determines the country-specific regulations to be observed. 3.2 Safety regulations The country-specific safety regulations shall always be observed. For components coming into contact with oxygen, it shall be ensured that they are absolutely clean from any oil and grease. Couplings requiring the introduction of heat (flame) for disconnecting shall not be used on pipe lines carrying flammable fluids. 3.3 Hazardous materials / environmental protection Basic specifications DIN EN stipulates that materials used in products shall not release hazardous substances to a degree exceeding the maximum permissible limit specified for the material in the corresponding European standard or allowed by the national stipulations of the member state to which the product is supplied Inadmissible hazardous materials The following substances, preparations or constituents are absolutely prohibited in products or materials of SMS group: - Asbestos and/or mixed compounds containing asbestos, - Cadmium or chromium (VI) compounds, lead in bonded form, - Solvents remaining in products or materials. In addition, country-specific regulations concerning inadmissible hazardous substances shall be complied with. Other inadmissible hazardous materials are indicated in drawings, ordering and/or other manufacturing documents. When inadmissible hazardous materials or emissions develop in the course of manufacture, e.g. welding emissions, these shall be exhausted at the point at which they emerge. The compliance with this regulation shall be proven in a certificate; see SN Admissible hazardous materials For admissible substances, materials or preparations which are used in the products of SMS group and which are not subject to item 3.3.2, safety data sheets according to the Ordinance on Hazardous Substances in accordance with EC Directive 98/24/EC or the resulting national regulations shall be attached to the supply stating the SMS group purchase order number for identification. If no safety data sheets are available, the manufacturer/supplier shall undertake to enclose with the supply in due time and in a well visible form other environmentally and safety relevant product information to allow proper transport and handling, storage and disposal of the hazardous materials by SMS group or by its customers in line with the regulations Radioactivity All products and materials shall be free of ionising radiation which exceeds the natural characteristic radiation. Ionising radiation is considered to exceed the characteristic radiation when a radiation level is found during an examination which is higher than the level of the ambient radiation. SMS group reserves the right of refusing the acceptance of products/materials found to possess such excess ionising radiation. 3.4 Tolerancing principle Unless otherwise indicated on the drawings, all tolerances on dimensions, shape and location are subject to the principle of independence in accordance with DIN EN ISO All dimensional tolerances of standard tolerance degree IT9 according to DIN EN ISO 286-1: are subject to the envelope requirement E specified in DIN EN ISO : Example: Indication on the drawing 100+0,087 or 100H9 3.5 Reference surface The marking of reference surfaces on drawings as shown in figure 2 is an SMS group specific stipulation. The reference surface is the blank part surface of a component which is relevant for the start of dimensioning. This surface is identified on the drawings by a reference triangle and the reference letter R in a circle and shall be considered in the manufacturing sequence. Reference triangle with reference letter R in a circle Fig. 2 Reference surface

3 Page Residual magnetism The residual magnetism of all parts at the time of delivery shall not exceed 800 A/m. Parts transported with lifting magnets and/or checked for surface defects with full-wave direct-current testers shall be demagnetised. The residual magnetism shall always be examined with an appropriate field intensity meter. The examination shall be proven and certified if so requested by SMS group. 3.7 Marking of components during manufacture Basic specifications Components of in-house and external manufacture shall be marked by the manufacturing shops/departments as specified in the sections and The marking is required to ensure that materials can be found and traced back, and assigned to working papers and quality documents WBS number and material number Parts passed to the manufacturing shop via the incoming goods or material provision department shall be marked with the full WBS number using a wiping-proof white or yellow tube colour marker. When the marking will be removed by further processing, the responsible employee is obliged to apply the marking in another accessible place before the existing marking is removed. Annex A (for information) shows the structure of a WBS number (example for SMS group) Serial number Parts which require marking are given a 6-digit serial number by the SMS group purchasing department. In in-house manufacture, this number is passed on in the working papers, in external manufacture, it is indicated in the ordering documents. For parts which require marking, the necessity of marking is indicated on the drawings and in ordering documents and working papers. A serial number assigned to every component one time ensures that this part can be traced back through all manufacturing processes. The serial number shall be indicated in all quality documents Stamping of the serial number The supplier of the raw material shall stamp the serial number on the material in the place indicated on the drawing using stamping figures of at least 10 mm in height. Stamping shall be applied in such a way that the number is not removed by subsequent processes like annealing or shot-blasting and remains fully legible. The stamped serial number shall be marked by drawing a coloured frame around it using a tube colour marker Re-stamping of the serial number If the serial number is removed or becomes illegible because of processing steps during production (machining, welding, assembling etc.), the employee charged with the processing step shall ensure maintenance of the serial number by re-stamping it in the same or in a different place Finish-stamping of the serial number When manufacture of the component requiring marking has been completed, the serial number shall be finish-stamped in the place specified on the drawing using stamping figures of at least 10 mm in height. In in-house manufacture, finish-stamping shall be carried out by the manufacturing shop, in external manufacture, by the supplier Batch number Stamping of the batch number for specific examination When specific examination is required, the batch number shall be stamped in the place indicated on the drawing using stamping figures of at least 10 mm in height. Stamping shall be applied in such a way that the number is not removed by subsequent processes like annealing or shot-blasting and remains fully legible. The stamped batch number shall be marked by drawing a coloured frame around it using a tube colour marker Re-stamping of the batch number for specific examination If the batch number is removed or becomes illegible because of processing steps during production (machining, welding, assembling etc.), the employee charged with the processing step shall ensure maintenance of the serial number by re-stamping it in the same or in a different place. 3.8 Supplier evaluation system The correctness and completeness of all supplies and services are recorded by SMS group in a supplier evaluation system. This evaluation includes quality, price, faithfulness to deadlines and completeness of the pertaining documents, test records and certificates. 3.9 Publication form of SN 200 The standards of the SN 200 Manufacturing Instructions series are available in the language versions required for manufacture and delivery and is published on the SMS group Intranet and on the Internet in the supplier portal of SMS group.

4 Page 4 Annex A (for information) Structure of the WBS number (example) The WBS (work breakdown structure) element in SAP defines a supply or service to be effected or rendered within the scope of a project. Figure A.1 shows the structure of the WBS number in an example for SMS group. SAP-Einführung bei SMS Demag Die neue Projektnummer - GB Warm/Kalt A Klassifizierung des Projekts Zählnummer für Projekte Anlagentyp Zählnummer für Anlagentyp Gliederungsebene 1 Gliederungsebene 2 Gliederungsebene 3 Produkteinheit Beispiele: A = Anlagenprojekt I = Innenprojekt E = Ersatzteilprojekt für MASTEEL 46 =CSP- Anlage Gliederungsebene 1 01 Einlaufbereich 02 Fertigstraße Gliederungsebene 2 01 Gerüst F1 02 Gerüst F2 Produkteinheit 5350 Schlingenheber Stand: SAP Einführungsteam Fig. A.1 Example of a WBS number of the Hot/Cold Mills Division 14

5 Page 5 Referenced technical standards, codes and regulations DIN EN DIN EN ISO 8015 SN SN SN SN SN SN SN SN SN /24/EC Directive Steel castings for structural uses Technical drawings - Fundamental tolerancing principle Manufacturing Instructions - Blank parts and semi-finished products Manufacturing Instructions - Thermal cutting and bending Manufacturing Instructions - Welding Manufacturing Instructions - Machining Manufacturing Instructions - Assembling and disassembling Manufacturing Instructions - Corrosion protection Manufacturing Instructions - Shipping Manufacturing Instructions - Transport Manufacturing Instructions - Inspection Protection of the health and safety of workers from the risks related to chemical agents at work Revision of May 2016 Editorial revision. Title changed into Requirements and principles. Table of contents added. Load suspending devices removed. Section 1 Scope revised. Section 2 Normative references revised and renamed into requirements Section 3.1 Newly added. Section 3.2 Section 2 newly added from SN 200-6: Section Basic specifications newly added. Section Inadmissible hazardous materials like lead altered to lead in bonded form. Section 3.4 Tolerancing principle adapted to DIN EN ISO Section 3.5 Adding of... blank part surface is the start of dimensioning. Section 3.7 Marking newly added from SN 200-8: Section Section Section 3.9 Removing of the sentence: The stamped serial number shall be marked with a frame using a tube marker, stamping size increased from 8 mm to 10 mm. Newly added. Publication in bound form removed and hint to publications on the Internet.