CONTROL PLAN FOR SPOT WELDING Page 1 of 3

Prototype Pre-launch Production Key Contact / Phone: Date ( Orig.) 16.8.2016 Date (Rev): 00/27.09.2016

Control Plan
Customer Engineering Approval date (If Require) NA
Number :
CFT :
Part Number Latest Change Level Level Date Customer Quality Approval date (If Require) NA

Part Name 2 1-Apr-16 Organization /Plant Approval /Date Other Approval /Date (If Require) NA

Organization
Organization code Other Approval/ Date (If Req'd)
/Plant

Characteristics Methods
Process Name Special
Part / Process Machine, Device, Tool
Operation Char. Reaction Plan Corrective Action
Number for Mfg. Evaluation Measurement Technique
Description No. Product Process Class. Product / Process Specification/Tolerance Sample Size Freq. Control Method Error Proofing
[ L.C. ]

Detection Prevention
Quarantine the lot
Counter machine & work
1 Material OK in qty -- -- Material OK in qty Material issue slip -- and & reject the
Receipt of child instruction sheet for stores 100 % by operator with no
defective parts
parts from record & 1 no at 2 hr
A Trolley / Manual 100% Each lot Inform to supervisor
press shop to frequency by inspector
assembly line 2 No damage, rust & oil to material -- -- No damage, rust & oil to material Visual with no record Material issue slip --

Check the clamping

Spot Welding at Base Bracket AT + 100 % by operator with no record & Quarantine the lot
CC-25 Visual Inspection as per FPIR & Inprocess Work instruction for operating condition ,fixture
1 Brake Bracket RH + ETC Mounting -- Number of spots 9 nos 1 1 no at 2 hr frequency by inspector EP-MT-001 and & reject the
reference sample Inspection. spot welding machine condition and process
Asssly with record on FPIR defective parts
parameter.

2 Distance -- CC-2 145.5

3 Distance -- CC-2 58.40

Inspection Fixture
5 nos
bmgB-IF-91
4 Distance -- CC-2 70.9 1. Work instruction for spot
First piece to be done for first five
welding robe Check the clamping
Spot Welding at samples,Inprocess inspection to be Quarantine the lot
Base Bracket 5 Distance -- CC-2 12.5 FPIR & Inprocess condition ,fixture
for 5 samples every 2hr and Last and & reject the
MT + Brake Robotic Spot Weld Inspection. 2. Spot welding fixture is condition and process
piece inspection to be done for 5 defective parts
Bracket Machine + Vernier Caliper having provision for proper parameter.
6 Diameter -- -- 12±0.2 (11.8 to 12.2) 5 nos samples
Stage no:-1 G-244 clamping, stopper and
RH+Clutch Spotting fixture
bracket LH + AM1_P54 (2no) location pin provision
Dia 20 mm (No spot in this Zone) at 2 location EP-MT-002
ETC Mounting 7 No spot weld zone (As shown on drg) -- -- as shown in drawing Visual 1
Asssly
Inspection Fixture EP-MT-001
8 Distance -- -- 88.3 5 nos
bmgB-IF-91

Presence Spot weld burr spatter, CC-25 Free from Spot weld burr spatter, rust, pin
9 -- Visually 1 100 % by operator with no record &
rust, crack, pin hole and damage hole, crack and damage
1 no at 2 hr frequency by inspector
with record on F Check the clamping
Quarantine the lot
10 Spot welding Position -- -- As per reference sample 1 FPIR & Inprocess condition ,fixture
bmgB-IF-91 1. Work instruction for spot and & reject the
Inspection. condition and process
welding robe defective parts
CC-25 Vernier parameter.
11 Spot diameter -- 7.5 to 8.5mm
G-244
Once At the start of shift
Presence of all part with correct
11 -- -- As per thickness master list bmg/Ford/RM List
thickness

Spot Welding at Base Bracket MT + 100 % by operator with no record &

Visual Inspection as per
1 Brake Bracket LH+Clutch bracket RH -- -- 7 nos Spot 1 1 no at 2 hr frequency by inspector
reference sample
+ ETC Mounting Asssly with record on FPIR

2 Distance -- CC-2 83.4 5

Inspection Fixture
3 Distance -- CC-2 70.90 bmgB-IF-91 5

4 Distance -- CC-2 41.6

CC-2 Vernier First piece to be done for first five

5 Diameter -- 74±0.2
G-244 samples,Inprocess inspection to be
6 Distance -- CC-2 145.5 for 5 samples every 2hr and Last
piece inspection to be done for 5
8 Distance -- CC-2 58.4 samples
5
Inspection Fixture
9 Distance -- -- 52.6+ 1.0 bmgB-IF-91

10 Distance -- -- 47.7+ 1.0/-0

Spot Welding at
Vernier
Base Bracket 11 Diameter -- -- 12±0.2
G-244
MT + Brake Robotic Spot Weld Check the clamping
Quarantine the lot
Bracket Machine + 12 Distance CC-2 227.8 FPIR & Inprocess Work instruction for operating condition ,fixture
Stage no:-2 and & reject the
LH+Clutch Spotting fixture Inspection. spot welding machine EP-MT-001 condition and process
defective parts
bracket RH + AM2_P54(2 no) 13 Distance CC-2 236.8 parameter.
ETC Mounting
Asssly
14 Distance CC-2 70.0 First piece to be done for first five
samples,Inprocess inspection to be
CC-2 Inspection Fixture
15 Distance 27.0 5 for 5 samples every 2hr and Last
bmgB-IF-91
piece inspection to be done for 5
16 Distance CC-2 27.0 samples

17 Distance CC-2 127.7

18 Distance CC-2 68.6

19 No of spot -- -- 7 no
100 % by operator with no record &
Visually 1 1 no at 2 hr frequency by inspector
Presence Spot weld burr spatter, Free from Spot weld burr spatter, rust, pin
20 -- -- with record on FPIR
rust, crack, pin hole and damage hole, crack and damage

Template
21 Spot welding Position -- -- As per reference sample
bmg-B-IF-90
22 Spot diameter -- -- 8±0.5 Once At the start of shift
Vernier
Presence of all part with correct G-244
23 -- -- As per thickness master list
thickness
Note :- Critical Characteristics : CC ,Special characteristics : SC REV. NO. REV. DATE REVISION DETAILS

PREPARED BY : Yogesh Patil APPROVED BY : Vishwanathe Balprakash

PREPARED BY
APPROVED BY
Q.A.ENGINEER
Q.A.
INCHARGE