thomas bus sop

**MPI#’s- Manufacturing Process Instruction (Product use product# . Equipment-01-XXXX, Process 02-XXXX, General 03-XXXX) TIP-Test/Inspection Procedure, PPI-Product Packaging Procedure, WI-Work Instruction (Non-Production), Cal-Calibration Procedure)

Document Flow: Originator/Revisor>> Dept. Head (orig.)>> Quality/Eng./Mfg (Opt.)>Doc. Control (Control/Distribution) C:\Users\jkalac\Documents\JULIAN\Thomas Bus\Thomas Bus SOP.doc MCC-108 Rev.2 July 02, 2008 QUALITY, MFG &ENG. AUTHORIZATION REQUIRED FOR: MPI, PPI, TIP. QUALITY AUTHORIZATION REQUIRED FOR: WI’S HAVING QUALITY/ENVIROMENAL COMPONENT. QUALITY AUTHORIZATION: CALIBRATION PROCEDURES

PROCESS INSTRUCTIONS Page

1 of 8

(* ) MPI-12-12XX ( ) TIP-# [ Testing: Electrical, Crimping, Mech/Dim, Pressure] ( ) PPI-# ( ) WI-# (Non-Prod) ( )CAL-# R e v . 1

TITLE: 12-127041E Thomas Bus Defroster Assembly instruction CUSTOMER: Thomas Bus APPLICABLE P/N: 12-12XX

Approvals Originator Department Quality Eng. NR Mfg. Other NR Revision Reviser Date Description of Change Department Engineering Production Quality Engineering 0 Julian K. Feb. 27/2012 Initial release Name Julian Kalac Ajit Wason Boris Sukovski Julian Kalac

Signature Date Feb. 27/2012: Feb. 27/2012 Date: Feb. 27/2012 Date: Feb. 27/2012 Date:

Written [Originator] Approval [Dept Head./Designate] Approval [Dept Head./Designate] Approval [Dept Head./Designate]

1.0 Purpose: 2.0 Scope:

To define basic principles of assembly for 12-120XX family of units.

This document provides information about the process assembly for 12-120XX family of units.

3.0 Responsibility/Authority 4.0 Documentation/Training Material

Production/Manufacturing 1. TIP-0063-Leak Test Procedure

2. WI-0241-Torque Specification

STATION 1 Small Part Sub-Assembly (Foam pre-cutting, Motor-Valve-Pre-Assy -MVPA )

STATION 2 (Filter & Heater-Case assembly )

STATION 3 (Blower-Heater Assembly)

STATION 4 (Motor-Valve installation)

STATION 5 (Wire Harness installation)

STATION 6 (Leak/Electrical Testing, Labeling, Final Inspection and Packaging)

12-12701E unit shown

Refer to product drawing for

detailed information.




2 of 8


SMALL PART STATION 1-Foam Pre-Cutting & Motor Valve Assembly

Refer to the Defroster Assembly Drawing 12-12701E

Hose Clamps Item 12 Motor Valve Item 11

Blower Insulation Foam Item 33

Hoses Item 14 & 15

Blower Assy Item 1




3 of 8


5.0 Operating Instruction: Dept: Assembly Customer: Thomas Bus STATION 1 (subassembly, Foam Pre-Cutting, Motor Valve Assembly)

STATION 2-Heater & Filter Case Assembly


Filter & Grill Assy Item 3 & 6

Wing Nuts & Snap Fasteners

Item 30 & 31

Heater Coil Assy Item 2



4 of 8


STATION 3-Blower-Heater Assembly

M5 X 20 Screws Item 28 Blower Assembled onto heater

Blower Cover Item 4


Document Flow: O riginator/Revisor>> Dept. Head (orig.)>> Quality/Eng./Mfg (Opt.)>Doc. Control (Control/Distribution) C:\Users\jkalac\Documents\JULIAN\Thomas Bus\Thomas Bus SOP.doc MCC-108 Rev.2 July 02, 2008 QUALITY, MFG &ENG. AUTHORIZATION REQUIRED FOR: MPI, PPI, TIP. QUALITY AUTHORIZATION REQUIRED FOR: WI’S HAVING QUALITY/ENVIROMENAL COMPONENT. QUALITY AUTHORIZATION: CALIBRATION PROCEDURES



5 of 8


STATION 4-Motor Valve Installation

Clamp screw tighten 35 inLbs

and validate with torque

Place clamp 1” away from fitting

bead then tighten screw to 35 inLbs



Motor Valve Assembly

Use P-80 Lubricant/Sealant when

assembling hoses onto fittings.

Hose # 16 & Clamps

OUT

Tighten all screws to specification

(WI-0241) and put Green Torque

sealant when finished

1” IN




6 of 8


STATION 5- Wire Harness Installation

Mount the wire Harness using 4-40

screws & nuts (4 screws and 4 nuts)

Outside view of Case

Inside view of Case




7 of 8


STATION 6- TEST, FINAL INSPECTION, COVER ASSEMBLY & PACKING

Leak Test as per Test Procedure TIP-0063

Test at 50 Psi for 5 min

Check for any damaged coils and

straighten them with a comb

Pack as Per Packing Procedure MCCWI-005 next page:

Hook up fittings for

test like below using 1”

end fittings




8 of 8





9 of 8


PACKAGING COILS USE BOX 1-2” BIGGER THEN COIL(S)

USE COMPRESSED PAPER TO PROTECT COPPER MATERIAL

FULLY COVER FIN MATERIAL WITH CONTINUOUS CARBOARD

PACKAGING HVAC UNITS USE BOX AT LEAST 1-2” BIGGER THEN

UNIT

USE COMPRESSED PAPER TO PROTECT COPPER MATERIAL/ BLOCK/HEATER VALVES

USE CARBOARD AROUND UNIT

EXTRA PROTECTION IS NEEDED WHEN COVER EXTENDS BEYOND CASING

**UNIT IN BOX SHOULD NOT MOVE AFTER GOOD PACKAGING** !!

Extra cardboards

3.1 HAZARDOUS GOODS SHIPPING: Identified by markings or labels as per Hazardous shipping protocol. 3.2 GENERAL PACKAGING: Large assemblies (i.e bus/rail) will require a wood crate for shipment. Blowers,

small assemblies and purchased parts should use a combination of cardboard and paper to protect as above. 3.3 COMPLETE THE PACKAGING: Ensure labels are on boxes to show I.D.

4.0 HEALTH & SAFETY REQUIRMENTS : N/A

5.0 QUALITY REQUIREMENT Q.A will perform In-process audits of packaging to ensure material is packaged to prevent transit damage.

Q.A will check for labels, identification and any customer requirements as part of its inspections. Production Lead Hands will check all shipments 100% to ensure compliance to shipping protocol Shipping will ensure all labels and markings are placed on the boxes as per customer request. Q.A will perform a pre-shipment drop test as per ISTA standard when required.

6.0 RESPONSIBILITIES 6.1 Production Lead Hand/Assemblers must ensure packaging provides enough protection to

prevent movement and damage. If they have any concerns, they should notify the Production Supervisor or Quality Assurance. QA is responsible for auditing the packaging function. Shipping personal must ensure material packaged from their location provides enough protection to prevent damage. All markings required are defined on the label and via any

other special shipping instructions. Packaging shall be stamped to identify shipper and/or initialed.

7.0 REFERENCE DOCUMENTS 7.1 WI-0701Shipping procedure for MCC product 7.3 ISTA-International Safe Transit Association Document QOP-07 Inspection and Test Status

thomas bus sop

Engineering

quality authorization

process assembly

product drawing

leak test procedure

pressure ppi

designate approval dept

blowerheater assembly

control controldistribution