Raw Material Control

1. Raw Material Control Q: How do you control the chemical composition of raw materials? A: We ensure chemical composition by sourcing high-quality raw materials and verifying with internal spectrometer testing. We also require certificates from suppliers and perform spot checks. 2. Knock-Out Process Q: Do you have a knock-out procedure? A: Yes. We allow the casting to cool sufficiently before knocking out the mold to avoid defects. This is part of our standard post-casting procedure. 8. Traceability Q: How do you ensure material traceability? A: All products are marked with heat number and batch number. We maintain a full traceability record from raw material to finished casting (see Annex 7.1). 10. Inspection and Testing Q: Do you have an inspection and test plan? A: Yes, please refer to our ITP document in the annex. It includes dimensional check, visual inspection, and optional NDT before machining. 11. Rejection Ratio Q: What is your internal and customer rejection ratio? A: Internal rejection rate is about 25%, and customer rejection is around 10%, mainly from earlier batches. This has improved with tighter QC. 5. Heat Treatment Q: Do you perform heat treatment in-house? A: No. We outsource heat treatment to qualified subcontractors who operate certified furnaces. All processes follow our internal SOP and customer specifications, including temperature control, holding time, and cooling method. We monitor each batch and keep full records. 2. Yield Ratio (Updated) Q: What is your typical yield ratio in the foundry? A: Our typical yield ratio ranges from 1.3 to 2.0, depending on the product complexity and casting design. We continuously improve gating and riser systems to reduce metal waste and increase efficiency. Terjemahan: Yield ratio kami berkisar antara 1,3 sampai 2,0, tergantung kompleksitas produk dan desain sistem cor. Kami terus menyempurnakan desain gating dan riser untuk mengurangi pemborosan logam dan meningkatkan efisiensi. Q: What is your company’s standard criteria to judge welding quality? A: We rarely perform welding because our internal policy does not allow compromise on surface defects. If a casting shows significant surface defects, we believe it reflects internal quality as well — and we reject and remelt the part instead of repairing. This approach ensures consistent casting integrity and minimizes risk in the field. 10. Non-Conformity Control Q (EN): Do you keep records of non-conformance reports (NCR)? A (EN): Yes. We log and analyze all NCRs especially for valve products. Terjemahan: Tanya: Apakah Anda mencatat laporan ketidaksesuaian produk (NCR)? Jawab: Ya. Semua NCR kami catat dan analisa, khususnya untuk produk valve. 4. Welding (With Strong Stance) Q: What is your company’s standard criteria to judge welding quality? A: We rarely perform welding because our internal policy does not allow compromise on surface defects. If a casting shows significant surface defects, we believe it reflects internal quality as well — and we reject and remelt the part instead of repairing. This approach ensures consistent casting integrity and minimizes risk in the field. Terjemahan: Kami jarang melakukan pengelasan karena kebijakan internal kami tidak mengizinkan kompromi terhadap cacat permukaan. Jika suatu produk cor menunjukkan cacat di permukaan, kami anggap itu mencerminkan kualitas internal juga — sehingga produk langsung kami tolak dan lebur ulang, bukan diperbaiki. Pendekatan ini menjamin kualitas coran yang konsisten dan mengurangi risiko di lapangan.