Global Process Flow Diagram

1. Global Process Flow Diagram New Part or New Customer & Part Existing Customer & Part, Order Received & Reviewed Refer to customer Contract, Review, Identify Feasibility Reject Order Raw Materials FMEA 10 Production Planning Accept Process Design PC03b Green Sand Mixing FMEA 40 Receive & Verify Raw Materials FMEA 10 PC05 & 3a Core Shop, Make Cores FMEA 20 PC04 Air Set, Make Cores FMEA 20 PC07 Air Set, Mould Carousel FMEA PC01 Develop Pattern & Core Equipment PC06 HWS, Mould FMEA 50 Trial & ISR PC02 Melting & Casting FMEA 30 & 60 PC06 Assemble HWS Moulds & Cores FMEA 50 PC06b Mechanical testing REJECT Approve for Production Sub Contract Heat Treat as required Verify Test PASS REJECT PC08a Knock out FMEA 70 PC08b Desprue, Shot Blast, Grind, Fettle FMEA 100 Desprue& Shot Blast (product specific)FMEA 90 PC09 Inspect & Despatch FMEA 140 &130 REJECT Inspect FMEA 110 Sub Contract Machining as required Accept FMEA Index WI Index Issue 9 -08/11 Uncontrolled if hard copy.

2. Global Process Flow Diagram Support Processes Management review QP 5.6 Business Planning QP 5. Control of Nonconforming product QP 8.3 Maintenance QP 6.3.1 IT QP 7.5.1 Resource management QP 6.1 Continual improvement QP 8.5.1 Corrective action QP 8.5.2 Document control QP 4.2 Training QP 6.2 Internal Auditing QP 8.2.2 Customer satisfaction QP 8.2.01 Issue 7 -08/11 Uncontrolled if hard copy.