TMT M1CS Actuator Pre-ship MeetingAvasarala Technologies Limited

Bangalore, India

September 13th, 2013

Pre-Ship Meeting

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Objectives– Review status of contract deliverables

Assembled and tested actuators – Review inspection reports

Manufacturing report – Requirements for production ready drawings and

documentation

Production cost estimate– Discuss TMT’s supplier qualification process– Concerns with ATL’s performance

Review status of contract deliverables

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Agenda– Contract Deliverables

Review piece part fabrication inspection reports and assembly process

– Comparison between ATL and third party inspections (TMT Leads)

ATL’s manufacturing report (ATL Leads)

ATL’s production cost estimate (ATL Leads)

Pre-Ship Meeting

Agenda– Supplier Qualification

Summarize TMT supplier qualification process (TMT Leads)

Concerns with ATL’s performance (TMT Leads)– Raw material procurement, certification and substitutions

– Casting

– Workmanship

– Assembly

– Manufacturing statistics, for example the number of re-works and re-makes,etc (ATL Leads)

– Final Test

– Schedule

– Miscellaneous

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Pre-Ship Meeting

Agenda– Next Steps – Any other business

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Contract Deliverables

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Contract Deliverables 1

Comparison between ATL and third party inspections

Actuator Dimension Deviation List ATL_TUV.xls

prod_proto_parts_inventory_comments (1).xlsx

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Contract Deliverables 2

The threaded end of the part 140-3 Flexure Rod SSA Connect was not manufactured properly. This is easily detected visually and yet it passed two inspections. Please make the remaining 8 pieces available for inspection today.

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Contract Deliverables 3

ATL’s manufacturing report (ATL Leads)– Production Schedule?

Manufacturing Report for actuator from ATL

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Contract Deliverables 3

ATL’s production cost estimate (ATL Leads)

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Sl.No DescriptionActual Cost

RsWastage / Rejections

Handling Charges

Finance Cost

Over Head Cost

ProfitTotal

Overheads

Total Rs

1 Material 19,093 6% 2% 7.5% 7.5% 10% 33% 25,394 2 Manufacturing 89,320 6% 7.5% 7.5% 10% 31% 117,009 3 BOP 186,235 2% 2% 7.5% 7.5% 10% 29% 240,243 4 Assembly 12,500 0% 0% 7.5% 7.5% 10% 25% 15,625 5 Inspection 3,000 0% 0% 7.5% 7.5% 10% 25% 3,750

6Documentation / Inspection Reports/History Docket

2,000 0% 0% 7.5% 7.5% 10% 25% 2,500

7 Final Testing 3,000 0% 0% 7.5% 7.5% 10% 25% 3,750

8Export packing and Transporation charges up to IIA, Bangalore

1,500 0% 0% 7.5% 7.5% 10% 25% 1,875

Total/No 316,648 410,146

Notes

1 The prices are based on the current material Rates

2 Dollar Prices taken are Rs.65/US$

3 Labour Index as per the Labour Bureau - Index No 235 with the base year as 2001

4 As per the Contrcat clause no 5.8 This is the non-Binding estimate of cost of manufacturing

6 Propre Increase has to be given on the above estimates taking in to account material cost, labour Index & Exhange rate variations since the time of order will be more than one year from now & the above estimates are current estimates

Supplier Qualification

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Supplier Qualification 1

Summarize TMT supplier qualification process (TMT Leads)– TMT.PMO.MGT.10.011.DRF02.pdf

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Supplier Qualification 2

Raw material procurement, certification and substitutions– Deviations of P-III actuator occurred during manufacturing.xls

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Supplier Qualification 3

Casting– T slot found to be difficult to cast. Taper in the T section, because of

draft provided to remove the core after pouring the material. Suggestion by ATL: Large taper to release the core after pouring. Rectangular or circular shape will be more easier than "T " slot for production.  

– Surface texture is .poor. See following pictures.

– Secondary treatment (Chromate conversion) is of poor quality

– Manufacturing error: Extra hole found near hole of Ø 8.15. The extra hole measures Ø 5.39 and is deep up to T-Slot in # 101-1.

– Re-use of serial numbers is a poor practice. Duplication of number in 101-1.

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Supplier Qualification 4

Casting– Sand casting according to drawing-Gravity die casting suggested by

ATL and accepted by TMT. Is there any other casting technique which will improve surface texture?

– Material A356 T6 according to drawing. ATL used A356 T61. This was informed to ITCC/TMT post facto and TMT accepted the change.

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Supplier Qualification 5

Supplier Qualification 6

Supplier Qualification 7

Supplier Qualification 8

Supplier Qualification 9

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Supplier Qualification 10

Workmanship and handling.– Often poor resulting in dings, divots and scratches. See

following pictures.

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Supplier Qualification 11

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Supplier Qualification 12

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Supplier Qualification 13

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Supplier Qualification 14

Assembly Errors– First two assembled actuators (Refer to following photos)

The offloader arms were installed upside down

Both offload flexures were installed in an inconsistent orientation

Do not place a fastener in the end of the upper arm.

The insert at the top of the Upper Connect Block must be flush or below the machined surface.

– Most fasteners were not adequately tightened, and in particular, the 4-bar linkage could move laterally

– C flexures were not always properly installed and aligned.– Encoder scale was improperly handled (fingerprints).– Voice coil magnet and coil not always properly aligned.

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Supplier Qualification 15

Assembly Errors– When tightening the fastener into the output shaft of the Ultramotion actuators,

react the torque using a wrench on the flat at the actuator output shaft as note in the plan to prevent damage to the internal anti-rotation mechanism.  The Ultramotion actuators seem to have a lot of rotary play.  

This may have damaged the linear actuator on actuator no. 5.– Wrong fastener used in attachment of linear actuator to end block.. M6 used

instead of 8-32. TMT traced error to ATL assembly procedure. (see page 3 and page 32).

This error damaged one of the first two delivered actuators to the point that the re-tapping will be necessary.

– TMT never received an assembly procedure checklist and inspection report. Indicates poor QA during the assembly procedure.

– TMT suggests that QA is involved throughout the assembly process and through pack and ship.

– Photographs should be taken after inspection of each piece part and assembly and delivered as part of the inspection documentation.

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Supplier Qualification 16

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Supplier Qualification 17

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Supplier Qualification 18

Manufacturing statistics– TMT would like ATL to provide manufacturing statistics on

pieces that required re-work and those that required to be re-made.

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Supplier Qualification 19

Final Testing– TMT took responsibility for acceptance testing of the actuators

for this round of prototypes. During production TMT requires the supplier to take responsibility for acceptance testing. Does ATL have any concerns or issues with this approach?

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Supplier Qualification 20

ScheduleSchedule of activities conducted by ATL for PIII actuators.xls

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Supplier Qualification 21

Miscellaneous– Manufacturing report is deficient in a number of areas. Primary

weakness is the lack of proposed manufacturing and assembly techniques for the production actuators based on the experience gained building the prototypes.

– Manufacturing report does not include a listing of the fabrication process and machines used for each piece part.

– Material substitution were made without requesting prior approval from TMT.

– Manufacturing report did not include a schedule for production.

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Next Steps

Actuator production timeline.

Next Steps– TMT will provide ATL a summary performance report with a request

for a response from ATL.– Future TMT qualification survey at ATL.

Any other business

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