QUALITY DOSSIER. We Assure Quality

Transcription

1 UALITY DOSSIER We Assure uality

2 WE ASSURE YOU WE ASSURE YOU WE ASSURE YOU WE ASSURE YOU WE ASSURE WE ASSURE YOU WE ASSURE YOU WE ASSURE WE YOU YOU WE ASSURE YOU WE ASSURE YOU WE ASSURE WE ASSURE YOU WE ASSURE WE ASSURE YOU WE ASSURE YOU WE YOU WE ASSURE YOU YOU YOU YUY O

3 c ompany Profile Yamuna, Global Headquarters of Kirloskar Brothers Limited is among the green buildings in India with LEED Certified Platinum Rating Kirloskar Brothers Limited (KBL) is a leading global fluid management organization. KBL is the largest manufacturer and exporter of Centrifugal Pumps and Valves in India. Established in 1888 and incorporated in 1920, Kirloskar Brothers Limited (KBL) is the flagship company of Kirloskar group in India. The core business of KBL is Industrial Pumps, Engineered Pumps and Projects, Agriculture and Domestic Pumps, Valves, Motors, Hydro turbines and anti Corrosion Products. By virtue of its pronounced competitive edge in terms of skilled engineering manpower, technological strengths and infrastructure, KBL is an internationally acclaimed pump manufacturer. The company s product range comprises of end suction pumps, solid handling pumps, submersible pumps, concrete volute pumps, vertical turbine pumps, canned motor pumps, monobloc pumps. KBL manufactures pumps to meet various national and international standards like IS, BS, DIN, ISO, JIS, API etc. KBL has offices in all continents with satisfied customers worldwide. Our wide-range of fluid engineering equipments finds applications in all sectors, to mention a few are Water, Irrigation, Industry, Power, Building & Construction, Defence, Oil & Gas, Distribution and Customer Sales and Services. We take this opportunity to quickly highlight the key differentiation areas at KBL: AAA Technology-Products are Appropriate, Adaptable and Affordable Excellence in Manufacturing, Design, Development and System Engineering An ISO 9001, ISO and OHSAS company with all manufacturing facilities under one roof, KBL has state-of-the-art machining facilities, ferrous and nonferrous foundries, testing facilities at one of the Asia s largest Hydraulic Research Centre Manpower with excellence in Engineering, Research, Design and Marketing Capabilities to provide Turnkey Fluid Handling Solutions 3 3 Wide pump range - 4 m /hr to m /hr

4 Cast Iron, Spl. / Alloy Steel and Non Ferrous Foundry Agricultural, Domestic, Industrial and Engineered Pumps Packaged Pumping Systems Civil Construction and Piping Motor Total Fluid Management Under One Roof Valves EPC Pump Projects Anti - Corrosion Products uality Philosophy The name Kirloskar is synonymous with quality and dependability in the engineering industry. Pioneering industrial revolution in India, Kirloskar group has contributed immensely in every field of its operation during its 120 year-long journey and holds a place of repute in the industry for its good business values and customer focus. Our Commitment The philosophy of Kirloskar has at its base the idea that all industrial endeavors must positively impact life and society around it. It is a confluence of mind and matter to create and generate such power which can impact human life in a positive way. Our commitments are a part of the imbibed values and ethos we follow to meet our goals and the customers' expectations from us. Our Value System is the backbone of every action. These values are the Foundation of KBL and shall be responsible for its success, growth and widespread reputation in years to come. It is the basis of enhancing our ability to serve customers and to be more competitive. We believe in continuous improvement on the basis of a long term Vision and continual innovation.

5 KBL MISSION we shall be known globally as a reliable, innovative and cost effective solution provider in hydraulic machines and systems. KBL VISION We shall be amongst the first five pump companies in the world, by year 2015 and become the preferred choice of customers as well as employees.

6 C ertifications The ISO certifications of our uality Management System are a reflection of our ongoing efforts towards design process to achieve the highest possible Customer Satisfaction. Besides stringent quality approach KBL also works on continuous improvement of its environmental performance. Primary objectives of this approach are increasing energy efficiency, safe handling of foundry activities, absence of restricted and hazardous media to make our product more sustainable.

7 CERTIFICATIONS Kirloskar Brothers Limited puts high priority on safe working environment. The company meets all safety regulations of concerned markets and goes beyond it to provide safer products. There has been continuous upgradation in product safety with new technology brought in.

8 ssociation with Global Consultants A and EPC Contractors TEIL

9 P roduct Approvals Certificate No. 111b Product quality is continuously upgraded to meet the ever increasing Customer/Market needs. Our products are certified to international standards like CE, FM, UL etc. KBL is in the process of obtaining N-stamp certification.

10 S upplier uality Supplier quality standard specifies management system requirements for use in the supplier shop and to assure quality and continues improvement in supplier s performance. KBL follows a standard process to develop the necessary competence and to meet the specific quality requirements of KBL products at suppliers end. Supplier uality Management Assessment Training Performance monitoring Statistical process control Process upgradation Poka Yoke Value engineering MS certification Manufacturing excellence ( 5S, Kaizen, etc.) uality Planning Careful planning of manufacturing process and the definition of required checks at hold points are laid down in document 'uality Assurance Plan'. These uality Assurance plans are documents to be strictly adhered to. uality Control Incoming inspection guarantees that only material and procured components meeting the strict requirements are used. To make sure that only material of impeccable quality are passed on, nonconforming parts are conspicuously marked 'rejected'. Final inspection is the conclusive testing instrument to ensure that only conforming components are dispatched and this is documented in inspection documents. It is the responsibility of in-process inspection to check the execution and correct measurements between the individual manufacturing steps. uality Inspection Inspection activities are carried out by trained quality professionals. Most advanced technologies are used for non-destructive material tests on components. The inspection is supervised by trained NDT professionals. NDT Testing TEST ACTIVITIES Radiography Testing Liquid Penetration Testing Magnetic Particle Testing Ultrasonic Testing Helium Leak Testing REFERENCE CODES USED ASME SEC III-,NB, NC, ND ASME SEC V ASME SEC VIII ASME SEC IX ASTM B16.34*

11 uality Inspection Non Destructive Testing Ultrasonic Testing Liquid Penetrant Testing Magnetic Particle Testing Helium Leak Testing Radiography Testing

12 Destructive Testing Facilities Destructive material tests on samples give additional proof of material quality. Material tests and metallographic examinations are conducted in our own laboratories or in state-accredited testing institutes. These tests are carried out and evaluated exclusively by trained and authorized personnel. The test results are forwarded to the customers in the form of quality certificates. List of Destructive Testing Machines Name of Instrument Universal Testing Machine Hardness Testing Machine (BHN) Hardness Testing Machine (Rockwell) Hardness Testing Machine (Digital) Impact Testing Machine Calibration of Equipment The measuring instruments used for geometrical checks like gauges templates and other measuring instruments are subject to a strict, regular and documented calibration process. For this KBL has well equipped gauge and instrument rooms covering a wide range of calibrated instruments to ensure product quality.

13 Balancing Machines We have world class balancing machines of Schenk make with a capacity upto 5 tonnes and rotor diameter of 2.5 m with a resolution of 0.1 gm. Seven machines are available in horizontal and vertical arrangements. These machines cover a wide range of sizes and accuracies. Hydro Testing

14 Testing Facility One of the largest Hydraulic Research Center's (HRC) in Asia testing for pumps at duty condition up to 5000 kv 3 and discharge up to m /hr Closed circuit NPSH testing capabilities Computerized data acquisition system Sump model study facility Hydraulic Reserc h Center Conceptualized and built under the guidance and supervision of British Hydraulic Research Association Testing at 50 Hz and 60 Hz frequency covering all global supply voltages (3.3 kv /6.6 kv /11 kv /13.2 kv) Test Facility Capabilities SR. NO. PARAMETER 1 2 TEST LOOP NO Flow, m /hr Head, m Power Supply 3 Ph 50 Hz 11 kv (HT) kw 6.6 kv (HT) kw 3.3 kv (HT) kw 6.6 kv (HT) kw 3.3 kv (HT) kw 440 V (LT) kw 4 Crane Facility 10/50 Tonne (crane hook height 18.5 m) 10 Tonne (crane hook height 12 m) 15 Tonne (crane hook height 18.5 m) 2 Tonne (crane hook height 4 m)

15 S pecial Process For achieving world class quality levels, special manufacturing and testing facilities have been established as follows Seamless pattern manufacturing State- of- the art painting and paint quality inspection facilities Investment casting Well equipped metrology lab Heat treatment facilities CED coating Coordinate measuring machine Specialized test facility for fire fighting pump sets Repli-casting Seamless Pattern Manufacturing Facility Paint Shop Facility Surface preparation before painting. Surface as per SSPC-SP-grades. Painting is carried out in enclosed paint booths. We can offer painting for different paint schemes in Epoxy and PU categories. We are experienced in meeting the specification requirements of global EPC contractors and customers like Bechtel, Alstom, Shell etc. Adhesion Test as per ASTM 3359 Dry Film Test (DFT) as per SSPC-PA-2 Holiday Test as per ASTM D

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