1. 34 critical materials identified
2. 24 materials going into liquid metal.
3. 10 other materials – consumables

• The 2 major inputs (Metal Scrap & Sand) are checked upon reciept at point of entry before unloading.
• The other 32 materials are all inspected after receiving.
• All materials are used only after obtaining clearance from the Laboratory.

1. Chemistry of liquid metal checked by spectrometer - cleared by chemical lab.
2. Tapping temperature checked by immersion pyrometer- cleared by chemical lab
3. Additions of nodulariser & inoculant done- by chemical lab.
4. First box pouring temperature checked in every ladle.
5. Count down timer set at 540 sec used to avoid fading & low temp.
6. Micro coupon poured on last box checked for nodularity & clearance given for the heat.
7. Chill depth checked for grey iron for machinability.
8. Mould filling time checked

• Properties checked every hour: Green compressive strength, gss, compactability, moisture, permeability.
• Properties checked every shift: Loss on ignition, active clay, total clay, dead clay.
• Additional checks are carried out when item being produced is changed.

1. Mould hardness on C-scale is checked every hour (run chart maintained) and for the first mould every item.
2. Set up sample verification is done for first mould of every item for the day.
3. Core setting checking gauges are used for every mould.

1. Resin additions are audit checked.
2. Scratch hardness testing is done on initial run.
3. Viscosity of core wash is checked.
4. Gauging of cores wherever required is performed.
5. Visual inspection of all cores

• There is a defined inspection plan for every item
• Annual layout inspection plan is made & followed
• Hardness checking done for 100% of critical components of pearlitic - ferritic grade nodular iron.
• Dock audit done for every product atleast once in a month.
• Non destructive testing is also performed:
  • Crack detection using permanent yoke magnet.
  • Ultrasonic checking for detection of sub-surface defects