Quality Control Process Chart (Machining)

Key Contact: a
SCL- Padi
Production Engineering QUALITY CONTROL PROCESS CHART (MACHINING) MMR / AAR / TR PROTOTYPE / PRE-LAUNCH / PRODUCTION
Part No / Rev. No: Part Description: Cell Description: Customer:ROTEX INDIA Sheet No:
Cell No: FM115/01
A056N643 /D Manifold Doser Fluid (MX) AFSOV Machining cell (CUMMINS) 1 OF 7
PROCESS PARAMETERS QUALITY CHARACTERISTICS
Tool Control Control
Opn. Machine / Operation Control Items (Causes) Controlling Method Control Items Controlling Method
Layout / instruction( instruction
No Description
No. Check Tool of Reaction Check Tool of (Reaction
Factor (4M) Parameter Class Specification Check method Person Parameter Drg. No. Class Specification Check method Person
frequency Control plan) frequency Control plan)
10 Receive Casting As Per casting drawing Sample Visual 100% Operator C1 & C2
Presence of traceability
Shift code At start of Operator Legiblity of Day Code & Final
15 Method Presence of Punch tool Visual C1 & C2 (Part No.& Day code & Visual 100% C1 & C2
Marking shift Inspector Year code punch inspector
Year - Sl No.)
As per partno ; No parting

At start of Operator Casting projection in
Layout & position Visual C1 & C2 line,projection,sharp Visual 100% Operator C1 & C2
shift Inspector Resting place (R1)
A042P955 edges/flash
Location & orientation hole This area needs to be

Visual Pressure At start of Operator
Air Pressure 5 ± 1 bar C1 & C2 as cast face (OP20 setup 1 ensured for "free burr Visual 100% Operator C1 & C2
gauge shift Inspector
LHS & RHS) projections"
At start of Operator Flush Pin Gauge 1 / hr/Loc Operator

20 VMC Method Spindle speed & Feed Prog no ; O0955 Visual LCD Display C1 & C2 Milling height 14 31.0±0.25 C1&C2
shift Inspector SCFG 4631 2/Shift/loc Inspector
At start of Operator
Milliing, drilling, tapping, Clamping Pressure 25±2 bar Pr.gauge C1 & C2 Plug Gauge
shift Inspector 1 / hr/Loc Operator
Diameter - 2 Places 66,70 6S ø8.6 ±0.3 SCFG 4605 C1&C2
At start of Operator 2/Shift/loc Inspector
Jack support pressure 30±2 bar Pr.gauge C1 & C2 Vernier
Two component loading shift Inspector
At start of Operator 1 / Day

Air pressure 5±1 bar Pr.gauge C1 & C2 Parallelism 13 0.2 Wrt A CMM Inspector C1&C2
shift Inspector / location
1/hour /Loc
At start of Operator Reciver gauge
Machine Hydraulic oil Oil level oil level indicator C1 & C2 63 0.2 Wrt AB 2/Shift / Loc Inspector C1&C2
shift Inspector Position CMM
1/ Day /
50,51,52,53,9
At start of Operator 27 , 9 +0.1 / -0.3, 3.14 1.60, 1 / Day
Lubrication oil Oil level oil level indicator C1 & C2 Distance (7 places) 5,96,98,99, CMM Inspector C1&C2
shift Inspector 0.5, 3.57±0.25, 81.9, / location
100,83
16,29,103,105
At start of Operator 1 / Day
Coolant oil Oil level oil level indicator C1 & C2 Flatness (9 Places ) ,102,101,142, 0.1 CMM Inspector C1&C2
shift Inspector / location
97,40
1 / Day
Perpendicularity 66,69 0.3 CMM Inspector C1&C2
/ location
core Plug 1 / hr/Loc Operator
Coolant concentration 5~7% Refractrometer 1 / day Inspector C1 & C2 M8 Core hole size M8 * 1 6H C1&C2
65 gauge 2/Shift/loc Inspector
Screw Plug 1 / hr/Loc Operator
M8 Thread Size M8 * 1 6H C1&C2
65 gauge 2/Shift/loc Inspector
2 / Shift
M8 Core hole Depth 9 ± 0.2 Vernier Inspector C1&C2
/ location
2 / Shift
M8 Thread Depth 64 4 min SPG + Vernier Inspector C1&C2
/ location
Snap Gauge 1 / hr/Loc Operator
Groove Inner diameter 61 6S ø13.5±0.05 C1&C2
SCFG 4606 2/Shift/loc Inspector
NOTE : 1. Operations & Gauges common to both setup (LHS & RHS) parts. Concentricity 62 0.5 wrt M
Concentricity
Gauge
1 / hr/Loc Operator
C1&C2
2. Gauge checking frequency common for both LHS & RHS parts. SCFG 4626
2/Shift/loc Inspector
Plug Gauge 1 / hr/Loc Operator

Groove width 6S 3.0 ±0.2 C1&C2
59 SCFG 4603 2/Shift/loc Inspector
Flush pin Gauge 1 / hr/Loc Operator
Groove Depth 60 6S 4.0 ±0.2 C1&C2
Vernier Inspector C1&C2
Radius (2 Places ) 58,55 R 0.5
1/week & Every

Chamfer Depth 1.0 ±0.2, Contour tracer Inspector C1&C2
54, tool change
Chamfer Angle 56,68,114, 0.5X45°, 45°
Surface finish 57 Ra1.6 Surfcoder 2 / Day Inspector C1&C2

6S / location
9
1 / hr/Loc Operator
Core dia M10X1 CPG C1&C2
1 / hr/Loc Operator
Thread Size M10X1 SPG C1&C2
2 / Shift
Thread depth 10 min SPG + Vernier Inspector C1&C2
/ location
Drill Depth 10 20.6 ± 0.2

Flush Pin Gauge 1 / hr/Loc Operator
C1&C2
Ø16 + 0.4 Plug Gauge 1 / hr/Loc Operator
Diameter 133 C1&C2
CHECK METHOD TOOL OF CONTROL CONTROL INSTRUCTION Document No:
Process Parameters: Quality Characteristics: Operator: C1 - Stop, Quarantine Prepared : PE Production Quality QCPC FM115/01
- Check sheet
Method of check - type of instrument Gauge No / Description of gauge / Inspector: C2 - Stop, Quarantine, 100%
- Setup Checked:
Untoleranced process parameters Type of instrument inspection and inform to Supervisor Rev.No: Date:
- Control chart
± 10% Variation allowed - Error Proofing Approved:
CRITICAL MAJOR Supervisor: C3 - Rework & C4 - Reject 6
20.10.2020
F/PED/05-M; Rev No:2; Dated:26.11.2012
Key Contact: a
SCL- Padi
Production Engineering QUALITY CONTROL PROCESS CHART (MACHINING) MMR / AAR / TR PROTOTYPE /PRE-LAUNCH / PRODUCTION
Cell No: FM115/01
Machine / Tool Control Control
Opn. Control Items (Causes) Controlling Method Control Items Controlling Method
Operation Layout instruction instruction
No
Description / No. Factor Check Tool of (Reaction Check Tool of (Reaction
Parameter Class Specification Check method Person Parameter Drg. No. Class Specification Check method Person
(4M) frequency Control plan) frequency Control plan)
Angle Every tool Inspector C1&C2
3 118°±2° Contour tracer
change
M10 Thread size 144,156,20 M10X1 - 6H C1&C2
gauge 2/Shift/loc Inspector

M10 core hole Size 144,156,135,20 M10X1 - 6H C1&C2
2 / Shift
/ location
2 / Shift
M10 Drill depth 145 20.60±0.2 CPG + Vernier Inspector C1&C2
/ location
1 / hr/Loc Operator
Diameter 1 ø5.6±0.05 Air Plug gauge C1&C2
ø3 hole Depth 8 30.6±0.2 Flush pin gauge
1 / hr/Loc Operator
SCFG 4622 C1&C2
Drill Depth 140 40.0 ±0.2
C1&C2

Diameter 5,143,49 ø3.0±0.2 C1&C2
Flush pin gauge
1 / hr/Loc Operator
6 34.3±0.2 SCFG 4757 C1&C2


M10 core hole Size 144,156,135,20 M10X1 - 6H C1&C2
2 / Shift
/ location

Pre-Drill Depth 19 12.5±0.2 C1&C2

Diameter 149 ø3.0±0.2 C1&C2

Depth 150 48.0±0.2 C1&C2
0.6wrt FAD Receiver gauge 1 / hr/Loc
Operator
Inter position 153,147,17 0.6wrt EAH SCFG 4630 2/Shift/loc C1&C2
Inspector
0.6wrt JDA CMM 1/Day/Loc
M10 O'Ring Port intersection dia
121 11.10 +0.1 CMM 1/Day/loc Inspector C1&C2
(3Places)
Every tool
M10 O'Ring Port chamfer Angle 122 12 ± 1° Contour Tracer Inspector C1&C2
change
Flush pin gauge 1 / hr/Loc Operator
C1&C2
Depth 124 1.60 +0.4 SCFG 4756, 2/Shift/loc Inspector
Method of check - type of instrument Gauge No / Description of gauge / - Check sheet Inspector: C2 - Stop, Quarantine, 100%
Untoleranced process parameters Type of instrument inspection and inform to Supervisor Checked:
- Setup Rev.No: Date:
± 10% Variation allowed CRITICAL MAJOR - Control chart Supervisor: C3 - Rework & C4 - Reject Approved: 6
20.10.2020
- Error Proofing
Key Contact:
a
SCL- Padi
Cell No: FM115/01
A056N643 / D Manifold Doser Fluid (MX) AFSOV Machining cell (CUMMINS) 3 OF 7
Machine / Tool Control
Opn. Control Items (Causes) Controlling Method Control Control Items Controlling Method
Operation Layout / instruction
No instruction(Re
Description No. Factor Check Tool of Check Tool of (Reaction
Parameter Class Specification Check method Person action plan) Parameter Drg. No. Class Specification Check method Person
(4M) frequency Control frequency Control plan)
Plug gauge 1 / hr/Loc Operator
Diameter 44 Ø14.8 ± 0.1 C1&C2
Plug gauge 1 / hr/Loc Operator
Depth 46 2.2 ± 0.1 C1&C2
Chamfer Depth 47 2X 0.5 Contour tracer

2/week, Every
Inspector C1&C2
As per prog no At start of Operator tool change
30 VMC Method Spindle speed & Feed Visual LCD Display C1 & C2 Chamfer Angle 45 2X 45° Contour tracer
; O0955 shift Inspector
Milliing, drilling, At start of Operator 1 / hr/Loc Operator
Clamping Pressure 25±2 bar Pr.gauge C1 & C2 Diameter 48 ø6.0 -0.1 -0.07 Air plug gauge C1&C2
tapping, shift Inspector 2/Shift/loc Inspector
Two component At start of Operator Plug Gauge 1 / hr/Loc Operator
Jack Pressure 30 ± 2bar Pr.gauge C1 & C2 Depth 38 13.3±0.05 C1&C2
loading shift Inspector SCFG 4612 2/Shift/loc Inspector
(LH Loading & RH At start of Operator Plug Gauge 1 / hr/Loc Operator
Air pressure 5±1 bar Pr.gauge C1 & C2 Diameter 3 ± 0.2 C1&C2
Loading) shift Inspector SCFG 4603 2/Shift/loc Inspector
1 / hr/Loc Operator
Drill depth Thru in M8 core hole Visual C1&C2
At start of Operator core Plug 1 / hr/Loc Operator

Machine Hydraulic oil Oil level oil level indicator C1 & C2 M14 x 1 Core hole size 41 M14x1 - 6H C1&C2
shift Inspector gauge 2/Shift/loc Inspector
At start of Operator Screw Plug 1 / hr/Loc Operator
Lubrication oil Oil level oil level indicator C1 & C2 M14 x 1 Thread size 28 M14x1.5 - 6H C1&C2
shift Inspector gauge 2/Shift/loc Inspector
At start of Operator Flush Pin Gauge 1 / hr/Loc Operator
Coolant oil Oil level oil level indicator C1 & C2 M14 x 1 Core hole depth 39 9.3+0.1 C1&C2
shift Inspector SCFG 4611 2/Shift/loc Inspector
Coolant concentration 5~7% Refractrometer 1 / day Inspector C1 & C2 M14 x 1 Thread Depth 42 7 min SPG + Vernier Inspector C1&C2
Ring Gauge 1 / hr/Loc Operator

Groove ID 31 ø19.8 ± 0.1 C1&C2
Groove width 32 2.05 ± 0.05 C1&C2
Groove Depth 35 1.2 - 0.15 C1&C2
Radius 33 R 0.2 Contour tracer
0.6 wrt DBA

0.2 wrt AB
Position 67,63,43,25
0.6 wrt HBA Receiver Gauge 1 / hr/Loc
0.6 wrt GBA Operator
SCFG 4760 2/Shift/loc C1&C2
NOTE : 1. Operations & Gauges common to both setup (LHS & RHS) parts. 23.57±0.25
CMM 1/day/Location
Inspector
92, 93, 94, 37.43 ± 0.25
2. Gauge checking frequency common for both LHS & RHS parts. Milling Height
104 36.07 ± 0.25
52.30 ± 0.3
M14 O'Ring Port 2/week, Every
22,23 45°, 15°±1° Contour tracer Inspector C1&C2
chamfer Angle tool change
M14 O'Ring Port
24 15.80 +0.1 CMM
intersection dia
M4 X 0.7 Thread size Screw Plug 1 / hr/Loc Operator
80 M4 X 0.7 - 6H C1&C2
(2 places) gauge 2/Shift/loc Inspector
M4 X 0.7 Drill size core Plug 1 / hr/Loc Operator
M4 X 0.7 - 6H C1&C2
(2 places) gauge 2/Shift/loc Inspector
M4X0.7 Thread Depth
81 8-8.5 mm SPG + Vernier
(2 places)
M4X0.7 core hole depth
Through Visual
(2 places)
Diameter 79 Ø3.1 ± 0.2 C1&C2
Depth 78 2.2 ±0.1 C1&C2
Position Inter Position
1 / hr/Loc Operator
Position 82,73 Ø0.30 wrt HK Gauge C1&C2
Ø0.35 wrk HL SCFG 4652

- Check sheet
Method of check - type of instrument Gauge No / Description of gauge / Inspector: C2 - Stop, Quarantine, 100% Checked:
- Setup
- Control chart
± 10% Variation allowed CRITICAL MAJOR Supervisor: C3 - Rework & C4 - Reject Approved: 6
- Error Proofing 20.10.2020
Key Contact: a
SCL- Padi
Cell No: FM115/01
Machine / Tool Control Items (Causes) Controlling Method Control Control Items Controlling Method Control
Opn.
Operation Layout instruction instruction
No
Description / No. Factor Check Tool of (Reaction Check Tool of (Reaction
Parameter Class Specification Check method Person Parameter Drg. No. Class Specification Check method Person
(4M) frequency Control plan) frequency Control plan)
0.6 wrt HBA, 0.6

Position 43, 116, CMM 1/ Day / Loc Inspector C1&C2
wrt SBA
71,72,77,84,85 18, 36, 24.8, 16±0.2,
Distance (10 places) ,86,87,88,89, 15, 10.5, 17.9, 21, CMM 1/ Day / Loc Inspector C1&C2
90, 68.18±0.25, 51.9,
Height 104 64.10±0.3 CMM 1/ Day / Loc Inspector C1&C2
Every tool
Chamfer Angle 118 0.8X45° Contour tracer Inspector C1&C2
change
126,127,128,
53.4, 9.9, 22,
Distance (8 places) 132,134,148, CMM 1/ Day / Loc Inspector C1&C2
37.2±0.4,27, 8.8, 8,
152,157,
M14 x 1.5 Core hole size 28 M14x1.5 - 6H C1&C2
M14 x 1.5 Thread size 28 M14x1.5 - 6H C1&C2
M14 x 1.5 Core hole depth 27 14.0 ±0.2 C1&C2
M14 x 1.5 Thread Depth 30 10.5 min SPG + Vernier 2/Shift/loc Inspector C1&C2

Diameter 73 Ø7.5 ± 0.2 C1&C2
Vernier 1 / hr/Loc Operator

Depth 74 25.5 C1&C2

M14 x 1 Core hole size 41 M14x1 - 6H C1&C2
M14 x 1 Thread size 28 M14x1- 6H C1&C2
M14 x 1 Core hole depth 39 9.3+0.1 C1&C2
M14 x 1 Thread Depth 42 7 min SPG + Vernier 2/Shift/loc Inspector C1&C2
Ring Gauge 1 / hr/Loc Operator

Groove ID 31 ø19.8 ± 0.1 C1&C2
Groove width 32 2.05 ± 0.05 C1&C2
Groove Depth 35 1.2 - 0.15 C1&C2
Every tool
Radius 33 R 0.2 Contour tracer Inspector C1&C2
change
1 / hr/Loc Operator
Diameter 137 ø8 (-0.1/-0.07) Air Plug gauge C1&C2

Depth of Ø8 48 13.3±0.05 C1&C2

Diameter 136 Ø4±0.2 C1&C2
Thru in M10 core 1 / hr/Loc Operator

Depth of Ø4 136 Through C1&C2
hole inside 2/Shift/loc Inspector
Process Parameters: Quality Characteristics: - Check sheet Operator: C1 - Stop, Quarantine Production Quality
Prepared : PE QCPC FM115/01
- Setup
Checked:
Untoleranced process parameters Type of instrument - Control chart inspection and inform to Supervisor Rev.No: Date:
- Error Proofing Approved:
± 10% Variation allowed CRITICAL MAJOR Supervisor: C3 - Rework & C4 - Reject 6 20.10.2020
Key Contact:
a
SCL- Padi
Cell No: FM115/01
Opn. Machine / Operation Control Items (Causes) Controlling Method Control Control Items Controlling Method Control
Tool Layout / No. instruction instruction
No Description
Check (Reaction Check Tool of (Reaction
Factor (4M) Parameter Class Specification Check method Tool of Control Person Parameter Drg. No. Class Specification Check method Person
frequency plan) frequency Control plan)

144,156,13 core Plug 1 / hr/Loc Operator

M10 core hole Size M10X1 - 6H C1&C2
5,20 gauge 2/Shift/loc Inspector
1 / hr/Loc Operator
M10 Thread Depth 125 10 min SPG + Vernier C1&C2

Pre-Drill Depth 19 12.5±0.2 C1&C2
1 / hr/Loc Operator
Diameter Ø6.0 ± 0.2 Plug gauge C1&C2
1 / hr/Loc Operator
Drill depth Through Visual C1&C2

Spot face Dia Ø16 +0.4/-0.0 C1&C2
1 / hr/Loc Operator
Spot Face depth 0.5 max Flush pin gauge C1&C2

Depth 124 1.60 +0.4 C1&C2
SCFG 4756, 2/Shift/loc Inspector
M10 O'Ring Port chamfer Every tool

122 12 ± 1° Contour Tracer Inspector C1&C2
Angle change
Receiver gauge
1 / hr/Loc Operator
Position 153 0.6wrt TBA SCFG 4630 C1&C2
CMM
1 / hr/Loc Operator
Diameter 117 6s Ø12 +0.043 Air Plug Gauge C1&C2
Flush pin gauge

1 / hr/Loc Operator
Depth 115 6s 11.5 - 0.2 SCFG 4618 , C1&C2
Vernier
Every tool
Chamfer depth 120 2+ 0.5 Contracer Inspector C1&C2
change
Every tool
Chamfer angle 119 15° Contracer Inspector C1&C2
change
Run out 107 0.1 wrt P CMM 1/Day/Loc Inspector C1&C2
Gap gauge 1 / hr/Loc Operator

Outer Diameter 106 6s ø 20 ± 0.1 C1&C2

Diameter 111 ø 16 - 0.2 C1&C2

Width 108 2 ± 0.1 C1&C2

Depth 109 8 Min C1&C2
Every tool
Radius 110 R0.5-.15 Contour Tracer Inspector C1&C2
change
Gauge pin should pass

7,11 1.75 min through Visual check 100% Operator C1&C2
through
2 / Shift /
Inspector C1&C2
location
Presence of single dot mark 100%

Operator C1&C2
Difference between two on LH Loading and double
Visual
component loading dot mark on RH loading 2 / Shift /
Inspector C1&C2
machinedcomponent location
Provide interlock between

Presence of shift code
marking machine and Op20 Visual 100% Pokayoke
marking
VMC .
Tool life Tool life programIntroduced Visual 100% Pokayoke
Operation missing Power cut program Visual 100% Pokayoke
Introduced tool breakage

Tool Breakage sensor Visual 100% Pokayoke

- Check sheet
- Setup
Checked:
- Control chart Approved:
± 10% Variation allowed CRITICAL MAJOR Supervisor: C3 - Rework & C4 - Reject 6 20.10.2020
- Error Proofing F/PED/05-M; Rev No:2; Dated:26.11.2012
Key Contact: a
SCL- Padi
Cell No: FM115/01
Opn. Machine / Operation Tool Layout Control Items (Causes) Controlling Method Control Control Items Controlling Method Control
No Description / No. instruction instruction
Check Tool of (Reaction Check Tool of (Reaction
Deburring & Air Once at the Operator
40 Men Skill of operator Skill matrix C1
cleaning start of shift Inspector
Washing Machine / Once at the Operator 100% Operator

50 Machine Air pressure 5 ± 1 bar Visual display C1 Free from burrs No burr allowed Visual check C1 & C2
Washing start of shift Inspector 1 / shift Inspector
Once at the Operator

Water temperature 50°- 60° degrees Visual display C1
start of shift Inspector
Once at the Operator No coolant should 100% Operator

Water pressure Min 5 bar Visual display C1 Free from coolant Visual check C1 & C2
start of shift Inspector be present 1 / shift Inspector

Washing time 120 sec Visual display C1
Level indicator in Once at the Operator White rust not 100% Operator
Water level Visual C1 Free from white rust Visual check C1 & C2
tank start of shift Inspector allowed 1 / shift Inspector

Nozzles unblocked Visual C1
start of shift Inspector 1 / Day Dock Audit
Cleanliness (CES 16599) 250 * 125 μm Millipore C1 & C2
/ location Inspector
Water pH value 7 to 9 pH level indicator 1/day Inspector C2
TDS value <300 microns TDS meter 1/day Inspector
Water change frequency 3/Days Visual 2/week Inspector
Filter change frequency 1/Month Visual 1/week Inspector
Filter cleaning frequency 1/week Visual 2/week Inspector
Refer QCPC-A64/01
60 Impregnation
( CES 18307 )
No Leak
Leak test rig / Wet leak testing:
70 Method Air pressure 5±1 bar Visual pr. Gauge (Identified by punch Visual 100% Operator C1 & C2
Leak testing Allowable leak
mark)
Clamping pressure 5±1 bar Visual pr. Gauge Operator C1 1 / shift Inspector C1 & C2
Once at the
start of shift
Testing pressure Min 10 bar Visual pr. Gauge Inspector C2
Leak test machine
has feedback for 3
Air and fuel supplied hole
Testing time 80 sec Stop watch separate ports Visual 100% Pokayoke
blockage problem
displayed in the
machine.
Water change frequency 3/Days Visual 3/day Inspector C2
Washing Machine / Once at the Operator 100%

80 Machine Air pressure 5 ± 1 bar Visual display Free from burrs No burr allowed Visual check
Washing start of shift Inspector 1 / shift
Once at the Operator No coolant should 100%

Water temperature 50°- 60° degrees Visual display C1 Free from coolant Visual check Operator C1 & C2
start of shift Inspector be present 1 / shift
Once at the Operator White rust not 100%

Water pressure Min 25 bar Visual display C2 Free from white rust Visual check Inspector C1 & C2
start of shift Inspector allowed 1 / shift

Washing time 120 sec Visual display
Level indicator in Once at the Operator

Water level Visual
tank start of shift Inspector
Once at the Operator 2 / Day Dock Audit

Nozzles unblocked Visual Cleanliness (CES 16599) 250 * 125 μm Millipore C1 & C2
start of shift Inspector / location Inspector
Water pH value 7 to 9 pH level indicator 1/day Inspector
TDS value <300 microns TDS meter 1/day Inspector
Water change frequency 3/Days Visual 2/week Inspector
Filter change frequency 1/Month Visual 1/week Inspector
Filter cleaning frequency 1/week Visual 2/week Inspector
Process Parameters: Quality Characteristics: Operator: C1 - Stop, Quarantine

- Check sheet Prepared : PE Production Quality Document No:
Method of check - type of instrument Gauge No / Description of gauge / - Setup Inspector: C2 - Stop, Quarantine, 100% QCPC FM115/01
Checked:
± 10% Variation allowed CRITICAL MAJOR - Error Proofing Supervisor: C3 - Rework & C4 - Reject Approved: 6 20.10.2020
Key Contact:
SCL- Padi
Production Engineering QUALITY CONTROL PROCESS CHART (MACHINING) MMR / AAR / TR
a
PROTOTYPE / PRE-LAUNCH / PRODUCTION
Cell No: FM115/01
Opn. Machine / Operation Tool Layout Control Items (Causes) Controlling Method Control Control Items Controlling Method Control
No Description / No. instruction instruction
Check Tool of (Reaction Check Tool of (Reaction
90 Air Cleaning Machine Air cleaning temperature 50°- 60° degrees Visual display C1 & C2 Free from water partical Not allowed Visual check 100% Operator C1 & C2
Air cleaning pressure 5 ± 1 bar Visual pr.gauge C1 & C2
Aircleaning time 60 sec Stop watch C1 & C2 1 / shift Inspector C1 & C2
Once at the Operator Moisture content/White
100 Dryer / Heating Machine Dryer temperature 50°- 60° degrees Visual display C1 & C2 Not allowed Visual check 100% Operator C1 & C2
start of shift Inspector rust
Air Pressure 5 ± 1 bar Visual pr.gauge C1 & C2
Dryer time 60 sec Stop watch C1 & C2 1 / shift Inspector C1 & C2
Free from visual defects As per Final
Once at the Final
110 Final Inspection Men Operator skill Skill matrix Supervisor C1 like shrinkage, Dents, inspection STD Visual 100% C1
Unfill, Drag marks, etc
Method Intensity of light 750 Lux min Lux meter 1 / Month Supervisor C1
Blowhole STD 330-0007

Availability of final Once at the
Method As per standard Visual Supervisor C1 for machined surfaces
inspection standard start of shift
(Zone2 Grade B)
120 Packing Method VCI cover thickness / Size Packing box free from damages Visual
Packing box Final

Seperator ply / Sleeve ply Visual 1/Lot Operator C1 VCI Cover Presence Visual 100% C1
standard Inspector
Pallet Inspector Separators 3ply Visual
Clearance in the packing

Packing box Less clearance Visual
slot
Process Parameters: Quality Characteristics: Operator: C1 - Stop, Quarantine

- Check sheet Prepared : PE Production Quality Document No:
- Setup
Method of check - type of instrument Gauge No / Description of gauge / Inspector: C2 - Stop, Quarantine, 100% QCPC FM115/01
Checked:
± 10% Variation allowed CRITICAL MAJOR - Error Proofing Supervisor: C3 - Rework & C4 - Reject Approved: 6 20.10.2020

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Key Contact: a

As per partno ; No parting

Location & orientation hole This area needs to be

At start of Operator Flush Pin Gauge 1 / hr/Loc Operator

At start of Operator 1 / Day

Plug Gauge 1 / hr/Loc Operator

1/week & Every

Chamfer Angle 56,68,114, 0.5X45°, 45°

Surface finish 57 Ra1.6 Surfcoder 2 / Day Inspector C1&C2

Drill Depth 10 20.6 ± 0.2

core Plug 1 / hr/Loc Operator

Plug Gauge 1 / hr/Loc Operator

Screw Plug 1 / hr/Loc Operator

core Plug 1 / hr/Loc Operator

Flush pin Gauge 1 / hr/Loc Operator

Plug Gauge 1 / hr/Loc Operator

Flush pin Gauge 1 / hr/Loc Operator

Chamfer Depth 47 2X 0.5 Contour tracer

At start of Operator core Plug 1 / hr/Loc Operator

Ring Gauge 1 / hr/Loc Operator

Radius 33 R 0.2 Contour tracer

0.6 wrt DBA

CHECK METHOD TOOL OF CONTROL CONTROL INSTRUCTION Document No:

0.6 wrt HBA, 0.6

Height 104 64.10±0.3 CMM 1/ Day / Loc Inspector C1&C2

Plug Gauge 1 / hr/Loc Operator

Vernier 1 / hr/Loc Operator

core Plug 1 / hr/Loc Operator

M14 x 1 Thread Depth 42 7 min SPG + Vernier 2/Shift/loc Inspector C1&C2

Ring Gauge 1 / hr/Loc Operator

Flush pin Gauge 1 / hr/Loc Operator

Plug Gauge 1 / hr/Loc Operator

Thru in M10 core 1 / hr/Loc Operator

Screw Plug 1 / hr/Loc Operator

144,156,13 core Plug 1 / hr/Loc Operator

Flush pin Gauge 1 / hr/Loc Operator

Plug Gauge 1 / hr/Loc Operator

Flush pin gauge 1 / hr/Loc Operator

M10 O'Ring Port chamfer Every tool

Flush pin gauge

Run out 107 0.1 wrt P CMM 1/Day/Loc Inspector C1&C2

Gap gauge 1 / hr/Loc Operator

Gap gauge 1 / hr/Loc Operator

Gap gauge 1 / hr/Loc Operator

Gap gauge 1 / hr/Loc Operator

Gauge pin should pass

Presence of single dot mark 100%

Provide interlock between

Tool life Tool life programIntroduced Visual 100% Pokayoke

Operation missing Power cut program Visual 100% Pokayoke

Introduced tool breakage

CHECK METHOD TOOL OF CONTROL CONTROL INSTRUCTION Document No:

Washing Machine / Once at the Operator 100% Operator

Once at the Operator

Once at the Operator No coolant should 100% Operator

Once at the Operator

Once at the Operator

TDS value <300 microns TDS meter 1/day Inspector