Facilities and Capabilities
Casting
Casting includes the following parts:
Cast iron melting furnace
Cast iron melting in a temperature of 1400°C.
Bronze melting furnace
Melting and inoculation of raw materials at a temperature of 11500°C.
Molding and core making
Molding and core making are performed through the models manufactured by industrial sands. Thanks to modern and updated technology used in the factory, the percentage of wastes and defects of casting have decreased to a great extent and speed of production and quality has noticeably increased accordingly.
Casting
Casting is performed after confirmation by laboratory director at a specific temperature.
Machining and Shot blast
Machining
Machining and cutting all parts are performed by full-automatic and semi-automatic lathe machines under the supervision of highly experienced quality control engineers and technicians by instrumentations. Using the said equipment, human errors are noticeably decreased and such errors can be regarded as equal to zero.
Shot blast
This stage of the production process is to achieve a high level of smoothness and free from sand, ... which itself has 2 different stages:
1.Soil cleaning
Cleaning the surface sands stuck to the surface of the part.
2.Polishing
In order to achieve the maximum smoothness on the surface and omission of the entire sands stuck in the pores of the part.
Quality control
All stages of production are performed under the supervision of quality control manager by considering the updated and world standards so that no defective part will be transferred from one stage to another and eventually the output product is completely intact by meeting the standard and desirable quality. Inspections performed comprise the following items:
1.Primary vision control
The cast part, after being cooled and primary sand cleaning, is reviewed with respect to physical defects (misrun, hot/cold crack, gas/contractive hole and the ones. If the respective part is sound and safe, it will be transferred to the next stage. However, in case probable defect of any sort is found, the said part will be transferred to storage for raw materials so that it will be re-melted and returned to production cycle once again.
2.Secondary Vision Control
After machining, the parts are examined with respect to visible defects such as blow hole, flack and crack and the ones. If the said pars are sound and safe, they will be transferred to the next stage. However, in case probable defect of any sort is found, the said part will be transferred to storage for raw materials so that it will be re-melted and returned to the production cycle accordingly.
3.Control of dimensions
Control of dimensions of part after machining is performed by using instrumentation and calibration by QC manager.
Laboratory
All of these tests are conducted by metallurgical engineers. The results are registered and recorded so that final product enjoys the alloy that exactly meets the respective standard and order placed by customers. This section consists of four parts:
1.Metallographic Laboratory
Study of cast iron samples in terms of microscopic structure and basic copper samples to specify the percentage of phase.
2.Quantometer Laboratory
Study of cast parts in terms of analysis (percentage of ingredient elements).
3.Polymer Laboratory (MFI Device)
Study of polymeric samples in terms of measurement of melt index.
4.Pressure Test
Measurement of mechanical strength of cast and polymeric valves.
Hydrostatic Test
This test is conducted by devices with calibrated gauge. Due to the great importance attached to this test, each device should have a specific person in charge. After conduction the said test, defective parts are transferred to wastes part and the results are registered, analyzed and recorded. This test consists of two different phases:
1.Leakage Test
The valve is tested at open state according to the updated standard.
2.Sealing/Functional Test
The valve is tested at closed state according to the updated standard.
Hacking the serial number
At this stage, a specific serial number is etched on all produced valves. The said serial number comprises figures and letters that indicate the • name of valve, • type of alloy, • production date and numerator. All of these numbers are registered and recorded in archive and website of the company accordingly. Moreover, the said number provides the possibility of tracking for both the company and consumer as well.
Packaging and Storage
At this part, in order to prevent impact on gear of valves during storage process, the said valves are packed in cartons and the cartons are sheared.
Administrative Automation System
At Kar o Andisheh Noavar Company, in order to prevent waste of time and to accelerate receipt, production and submission of orders, an administrative automation system is used so that the factory and the head office are linked in an integrated form and also it provides control of system function for senior managers of the company accordingly. This causes that all stages until an order is submitted to the customer can be tracked.