210Nm Proto Control Plan - 19-02-24

CONTROL PLAN ( 210Nm Transmission Assembly)
Part Name: 210Nm Transmission Assembly Core Team :JS/SD/PV/ASS/RCP/MR/RP/TD/SS Control Plan format No. FR/APH/ME/03
Part No.: BU0094Z Key date : -- Rev No & Rev date: 01 & 20-04-2024
Rev. Spl
Characteristics No Char Method
Class
Part / Process Name/ Operation Machine/
Process No Description Device/Jigs/Fixtures Reaction Plan
Product/Process Specification Evaluation/ Measurement
No Product Process Class Tolerance Technique Size Frequency Control Method Who
10-20 Disassembly of case and IM plate & Load the components in washing pallet & washing
Pneumatic Gun, Check Mtg. Face of

Socket - A/F 14 mm (TULEX T/m case & Rear Damage free and clean No Dents / Damages on Keep components seperately by
1 work table machined faces Visual All 100% Self check Operator identifying with rejection tag
14 Cover
Ensure no lump presence in Check no presence of Keep components seperately by

case 2 burr, lump No presence Visual All 100% Self check Operator identifying with rejection tag
10
Fixture for locating the IM

Plate 3 Hole Orientation Should align with IM plate hole Visual All 100% Self check Operator align the hole
Pressing Load
Idler shaft not Complete butting with Im Plate Analog pressure gauge
4 completely butt to All 100% Self Check Operator Repress manually and check for butting
IM plate face.( 40-60 Kg/cm2) reading
2 dowels we need By dowel pressing tool & Keep components seperately by

Dowel Preesing 5 press at main No presence Tool Control All 100% Self check Operator
housing hammer identifying with rejection tag
15
Battery Gun,Socket for Adjust the toque 50 ~ 55 NM We need to

bolts tightening 6 value to 50 - 55 Mounting At fixture maintain torque value Torque Wrench All 100% Self check Operator Alling Fixture to tightening by gun
Disassembly of Case and IM

Plate & Load the
components in washing
pallet & washing Washing Pallet for
components Case,Rr.Cover, Total contamination Production
Shift Arm (3 nos.), Front 7 miilipore value 50 mg max. Millipore test afterwashing 1 1/month Central Lab Report Hold all T/m and inform to supervisor
Cover, Gears & Shafts,Hub, level in T/m supervisor
Sleeves.
Dryness of Auto Temp control Check Hot air temp & inform to
Washing machine 8 component 90% Dryness to be maintained Subjective (Visual) 100% 100% arrangement is provided Operator supervisor
Self check / auto indicator

20 9 Washing fluid level As per machine manual Level indicator 1 1/day in the machine Operator Open valve for water filling
10 Nozzle blockage check No nozzle Block Nozzle block check pump 1 1/month self check Maintaince Clean Nozzle
operator
At start of Auto Temperature Stop Washing operation. Inform to

11 Water Temperature 30°C - 60°C Temperature indicator 1 Operator
shift Controller Maint.
Concentration check sheet Lab/

12 Concentration level 4~6% Refractometer and pH meter 1 1/2days attached on the washing Maintainance Add solution./ Inform to supervisor
pH value 8.5~10
m/c operator
30 Kitting tray placement on conveyor
1 of 26
Rev. Spl
Class
All parts presence in kiiting bin

30 Kitting tray placement on Trolley & Kitting Bin 1 Total parts availability without any mix-up Visual All 100% Setup change over sheet Operator Remove bin from assy area & inform
conveyor (30 nos.) Kitting bin to be identified as stores
BLUE color for NALT trans
40- Top gear shaft bearing fitment
Analog pressure gauge 1/day (Start

1 Pressing load 30~40 kg/cm2 reading 1 of A shift) JH CHECK SHEET Operator Inform to supervisor
Brg. fitment in Top Gear Hyd. Press
Shaft Fixture
End position of
Bearing(Not fully Complete butting with Top
2 Gear Shaft face Visual All 100% Self check Operator inform to supervisor
assembled)
Groove should be on bottom

3 Bearing Orientation Visual All 100% POKA YOKE Operator inform to supervisor
side during assy in TGS
40
Visual Inspection and

Snap ring fitment in Top 4 Snap Ring fit Proper insertion of snap ring manual All 100% Commitment mark at same Operator Insert correctly.
Gear Shaft condition
station
Needle Bearing Assembly 5 Grease application Sufficient Grease - 2gm appx. Manual All 100% Self check Operator Apply grease
Needle bearing Keep components seperately by

6 condition No damage in the bearing Visual 1 100% Self check Operator identifying with rejection tag
50 Cluster gear shaft bearing fitment
Once/day
Brg. fitment in Cluster Gear Analog pressure gauge (Start of A
Shaft Hyd. Press M/c 1 Pressing load. 30~40 kg/cm2 reading 1 J H Check Sheet Operator Inform the supervisor
shift)
End position of
Complete butting with cluster
2 Bearing(Not fully Shaft face Visual All 100% Self check Operator Inform the supervisor
Assembled)
50 Groove should be on bottom

Angular ball Bearing side during loading into fixture
3 Visual All 100% Poka Yoke Operator Inform the supervisor
Orientation & Groove should be Top side
after assembly into CGS
Snap ring fitment in Cluster Snap Ring fit Proper insertion of snap ring
Gear Shaft 4 condition and make commitment mark Manual All 100% Self check Operator Inform the supervisor
for snap ring presence
60 Sleeve & Clutch Hub Top 3rd assembly
2 of 26
Rev. Spl
Class
Sleeve & Clutch Hub Top- Manual 1 Movement of Hub & Clutch hub moves freely at By feel of Operator All 100% Self check Operator Reorient & recheck
3rd assembly Sleeve dead load
Big Chamfer of sleeve t-3rd &

2 Orientation of sleeve oil groves on clutch hub are Visual All 100% Self check Operator Correct the Orientation.
Top 3rd
opposite side.
Insert should not fall out, No

60 Check shift feel of Keep components seperately by
3 Clucth hub & sleeve abnormal blockages, No By feel of Operator All 100% Self check Operator identifying with rejection tag
jamming
Groove should be towards

4 Insert Orientation Clutch Hub Visual All 100% Self check Operator Correct the Orientation.
Opening of Spring insert is

5 Insert spring opening phased 120° Visual All 100% Self check Operator Disassemble & correct
70 Sleeve & Clutch Hub Low-2nd assembly
Sleeve & Clutch Hub Low- Movement of Hub & Clutch hub moves freely at
2nd assembly 1 Sleeve dead load By feel of Operator All 100% Self check Operator Reorient & recheck
Big Chamfer of sleeve L-2nd &

2 Orientation of sleeve 4 groves on clutch hub are on Visual All 100% Self check Operator Correct the Orientation.
same side.
Insert should not fall out, No

Check shift feel of Clutch Keep components seperately by
3 hub & sleeve abnormal blockages in shifting, By feel of Operator All 100% Self check Operator identifying with rejection tag
No jamming
70
Right level of insert Reassemble the right inserts and

4 As per visual AID Visual All 100% Self check Operator
assembly recheck
Groove should be towards

5 Insert Orientation Visual All 100% Self check Operator Correct the Orientation.
Clutch Hub
Opening of Spring insert is

6 Insert spring Orientation phased 120 Visual All 100% Self check Operator Disassemble & correct
80 IM plate Sub Assembly

Freeness of Cluster
IM Plate sub-assy. Manual pressing 1 Snap ring Should rotate freely in groove Hand feel All 100% Self check Operator Inform to supervisor
Freeness of Main
2 shaft brg. Snap ring Should rotate freely in groove Hand feel All 100% Self check Operator Inform to supervisor
3 Bolt M8x20 Visual All 100% Self check Operator Replace with correct bolt
Visual Inspection and

4 Bolt missing M8x20 Visual All 100% Commitment mark Operator Check and Tighten the bolt
80 Torque wrench with light

indication & interlock with
5 Bolt Torque SC 19 ± 4 Nm Torque Wrench All 100% conveyor end stopper using Operator Inform to supervisor
PLC programme.
3 of 26
Rev. Spl
Class
80
Torque Wrench
6 19 ± 2 Nm Torque calibrator 1 1/month Metrology Lab Inform to supervisor
calibration
Interlock Plug
7 assembly No Leakage leak test All 100% Air leak testing Operator Inform to supervisor
90 3rd Gear Assy. in Main shaft

Re-apply oil
Fixture for clamping main Lubrication of needle Apply transmission oil on
3rd Gear Assy. in Main shaft shaft . 1 brg. needle brg. Visual All 100% Self check Operator
Orientation of Gear
2 3rd Main Dog teeth towards top side Visual All 100% Self check Operator Correct the Orientation.
3 3rd Gear Free Should rotate Freely By Feel of Operator All 100% Self check Operator Inform to supervisor
rotation
Fit condition of Block

4 Should move freely By Feel of Operator All 100% Self check Operator Move till block ring is free
Ring
Block ring assembly Presence of Block ring Visual All 100% Self check Operator Disassemble & Correct
90
Orientation of Clutch Chamfer side of sleeve towards

5 Hub Top-3rd Visual All 100% Self check Operator Disassemble & Correct
assembly Top gear side
Once/day
Assembly tools Inner & Condition of Clutch hub
Outer 6 pressing Tool No Burrs in ID / face of Tool Visual 1 (Start of A Visual aid Operator Inform supervisor and Deburr the tool
shift)
Snap ring should enter in

Snap Ring fit snap ring Should not groove in entire periphery and Manual
7 condition rotate All 100% Self check Operator Remove snap ring, Recheck & assemble
should not rotate
8 Snap Ring missing Presence of snap ring Visual All 100% Self check Operator
100-110 1st gear & 2nd gear assembly in main shaft
2nd gear Needle Keep components seperately by

1 bearing condition No damage in the bearing Visual All 100% Self check Operator identifying with rejection tag
Lubrication of needle Apply transmission oil on Keep components seperately by

2 brg. & Block Rings needle brg. & Block Ring Visual All 100% Self check Operator indentifying with NC Tag
Orientation of Gear
3 2nd Main Dog teeth opposite to top side Visual All 100% Self check Operator Correct the Orientation.
4 Missing of 2nd block ring Presence of part Visual All 100% Self check Operator Re Assemble the parts
4 of 26
Rev. Spl
Class
Parallel groove in Clutch hub

5 Orientation of Clutch towards 1st gear side, & Bigger Visual All 100% Self check Operator Disassemble & Replace.
hub Low 2nd
chamfer of sleeve top side.
Condition of
6 components after No Burrs Visual All 100% Self check Operator Inform supervisor
pressing
Once/
Pressing load. Of Collar Analog pressure gauge
7 GLM 30~40 kg/cm2 reading 1 shift(start of JH check sheet Operator Set the press load.
A-Shift)
8 Missing of 1st block ring Presence of part Visual All 100% Self check Operator Re Assemble the parts
Gear 2nd and 1st assembly
100-110 main shaft Orientation of Gear
9 1st Main Dog teeth opposite to top side Visual All 100% Self check Operator Correct the Orientation.
Orientation of First Oil groove of Thrust washer

10 Thrust Washer towards low gear side. Visual All 100% Self check Operator Rework & Replace.
11 Orientation of Snap ring groove of Brg. Visual All 100% POKA YOKE Operator Rework & Replace.
Bearing Towards Low gear side.
Free rotation of 2nd main after

12 Gear 2nd main bearing pressing By feel of Operator All 100% Self check Operator Inform to supervisor
Orientation of
Oil groove of Thrust washer
13 Second Thrust towards Reverse Gear side. Visual All 100% Self check Operator Remove & Replace.
Washer
Analog pressure gauge Once/day.

14 Collar assembly Pressing load. 30~40 kg/cm2 1 (Start of A- J H Check Sheet Operator Set the press load.
reading shift)
Fit condition of Block

15 Should move freely By Feel of Operator All 100% Self check Operator Move till block ring is free
Ring
Freeness of 1st &

16 2nd gear Damage free tool Should rotate Freely By Feel of Operator All 100% Self check Operator Inform to supervisor
120 Matching of TGS & CGS
120 Matching of CGS & TGS Case Pallet Proper Matching of No Dents & Damage Visual All 100% Self check Operator Dismantle T/M
CGS & TGS
130 IM plate & gear train assembly
Snap ring Fit Snap ring enters into groove of

Case Pallet 1 condition IM plate and should not rotate Manual All 100% Self check Operator Tap & Correct
Orientation of Rev Oil groove of Thrust washer

2 main Thrust Washer towards Reverse Gear side. Visual All 100% Self check Operator Correct the assembly
5 of 26
130 IM Plate and Gear Train Assy
Rev. Spl
Class
Fit condition of Block Shoud snap ring seat in bearing

3 Ring Top 3rd groove By Feel of Operator All 100% Self check Operator check and put commitment mark
130 IM Plate and Gear Train Assy

Guide Tool for Main Shaft Opearator
Bore & Guide Tool for CGS 4 Manual assembly by malletting Visual All 100% acknowledgement with Operator Check and reassemble the parts
Bore Commitement mark
5 Freeness of all gears Should rotate Freely By Feel of Operator 1 100% Self check Operator Inform to supervisor
Barcode no. must be

6 clearly visible Barcode no. pasted properly Visual 1 Check 100% Self check Operator Inform to supervisor
matching
140 Sleeve & Clutch Hub Rev-5th assembly
Fixture 1 Movement of Hub & Clutch hub moves freely at By feel of Operator All 100% Self check Operator Orient & recheck
Sleeve dead load
Big Chamfer of sleeve R-5th &

2 Orientation of sleeve 2 groves on clutch hub are on Visual All 100% Self check Operator Correct the Orientation.
Opposite side.
Sleeve & Clutch Hub Rev-5th

140 Long arm side should be
assembly Refer visual aid & inspect
3 Orientation of Insert towards big chamfer end of Visual All 100% 200% Operator Correct the Orientation.
sleeve
Check shift feel of Insert should not fall out, No Keep components seperately by
4 abnormal blockages, No By feel of Operator All 100% Self check Operator
Clucth hub & sleeve jamming indentifying with rejection tag
Insert spring Opening of Spring insert is

5 Visual All 100% Self check Operator Disassemble & correct
assembly phased 120°
150A Gear Reverse Main and rev counter Assy
Gear Reverse Main and rev Needle bearing Keep components seperately by
counter Assy Assembly Pallet 1 condition No damage in the bearing Visual All 100% Self check Operator indentifying with rejection tag
150A Free rotation of 5th

2 gear Should rotate Freely By Feel of Operator All 100% Self check Operator Inform to supervisor
Orientation of Clutch Bigger chamfer of sleeve Rev.

3 Hub 5th towards Rev. gear side. Visual All 100% Self check Operator Remove & Replace.
150B Reverse Idler Gear Assy
Claw part of thrust washer is

Orientation of thrust between I.M. plate rib towards Visual
Reverse Idler Gear Assy. Nut runner 1 washer All 100% Self check Operator Remove & Replace.
IM plate
6 of 26
Rev. Spl
Class
2 Freeness of Rev. gear Should rotate Freely after self By Feel of Operator All 100% Self check Operator Inform to supervisor
lock nut tightening
Torque Transducer in nut Auto control,Display of

3 Self lock nut torque SC 120± 20 Nm runner All 100% tightening status Autocheck Hold & Inform to supervisor
150B
Only 2-3 threads of Nut

Replace with caulked nut and inform
4 Self lock nut Caulking on Nut should engage with shaft idler All 100% Hand feel Operator supervisor
threads
5 Orientation of 2nd Groove towards reverse idler Visual All 100% Self check Operator Correct the Orientation.
Thrust washer
160 Lock washer and Nut Main shaft Assy
Nut runner 1 Orientation of lock Claws opposite to ClutchHub Visual All 100% Self check Operator Correct the Orientation.
washer Rev5th fac
Orientation of lock Chamfer side towards

2 nut ClutchHub Rev5th Visual All 100% Self check Operator Correct the Orientation.
Nut Main shaft Auto control,Display of

Lock washer and Nut Main 3 torque SC 130 ± 10Nm SNR All 100% tightening status Operator Hold & Inform to supervisor
160 shaft Assy
Operator
ensuring the
Lock Washer More than 2 places holding of Self check with 100% crimping process Disassemble & Replace with new
Screw Driver 4 crimping lock washer in nut groove Visual All 100% commitment mark with different washer
provided colour
commitment
mark
170 5th Main gear assy
5th Main gear assy Manual 1 Missing of synchro Part Presence Visual and commitment mark All 100% Self check Operator Check and reassemble the parts
at same station
170
Needle Roller Keep components seperately by
Manual 2 Condition No Roller missing Visual All 100% Self check Operator indentifying with rejection ta
Free rotationof Rev

3 Should rotate Freely By Feel of Operator All 100% Self check Operator Inform to supervisor
gear
wrong model gear (part mix Poka Yoke interlock for 5th Keep components seperately by
4 5th gear assembly up) Pokayoke at station All 100% gear Operator indentifying with rejection tag
180 5th counter gear assy and Bearing assy
5th counter gear assy and Missing of 5th counter

Bearing assy gear Part Presence Visual All 100% Self check Operator Check and reassemble the parts
7 of 26
180
Rev. Spl
Class
Missing of bearing Part Presence Visual All 100% Self check Operator Check and reassemble the parts
180 Missing of plain washer Part Presence Visual All 100% Self check Operator Check and reassemble the parts
Once/shift
1 Condition of Tool No Burrs in ID / face of Tool Visual 1 (start of A Self check Operator Deburr the tool
shift)
Nut runner 2 Self lock nut torque SC 120 ± 20 Nm SNR All 100% Self check Operator Hold & Inform to supervisor
190-200 Thrust washer selection & thrust ring assy.
Thrust washer Poka yoke inerlock for Inform Supervisor

Thrust washer assembly 1 Part Presence Poka yoke at station All 100% Operator
missing thrust washer presence
Thrust washer selection jig

Thrust washer size (Size, Colour,No of Dots)
Thrust washer selection 1 (after selection ball (7.8, Green ,1) Thickness flush slection gauge All 100% Visual Inspection and Operator Inform Supervisor
gauge to be assembled in (7.9, Green, 2) (8.0, Green ,3) (Gauge No. : G 81350) Commitment mark
main shaft oil hole) (8.1, White ,1) (8.2,
White ,2) (8.3, White ,3)
Thrust washer selection jig

Thrust washer selection & Gauge Calibration (Size 7.8, 7.9, 8.0, 8.1, 8.2, 8.3) Thickness flush slection gauge 1 1/Year Guage Calibration Metrology Lab Inform Supervisor
190-200 thrust ring assy.
Opening of Snap Ring to be at

External plier 7" 2 Orientation of Snap right angles to Thrust Ring Visual All 100% Self Check Operator Correct opening position
ring opening (within 60° band)
3 Fit condition of Snap No Rotation Visual All 100% Self Check Operator Change Snap Ring & Reconfirm
Ring
5th gear assembly Gap between thrust

inspection 4 washer and 5th gear Feeler gauge 0.1~0.29mm Feeler gauge All 100% Gauging Operator Check and inform quality
210 Shift Rod & Arm Assy

sensor with magnet guide
tool. After interlock pin
assembly light indication
displayed & Conveyor end
stopper interlock system
Assembly of using by PLC programme
Interlock pin fitment tool 1 Interlock Pin Apply grease No missing Interlock Pin Visual All 100% Operator Dis-assemble & place the interlock pin
210 Shift Rod & Arm Assy
Assembly of Fork
2 and rods No missing parts Visual All 100% Self Check operator Re Assemble the parts
8 of 26
Rev. Spl
210 Shift Rod & Arm Assy Class
3 split pin pressing face butting of arm Visual All 100% Self check Operator Hold & Inform to Supervisor
220A Detent plate assy

Torque wrench with light
indication displayed &
interlock with conveyor
Ball and Detent No missing of ball and spring as end stopper using PLC
Air Tool& Torquewrench 1 spring well as free entry of ball manual All 100% programme Operator Inform Supervisor
Orientation of Concave side of detent plate

2 upside(Identification TOP to be Visual All 100% Self check Operator Correct orientation
220A Detent plate assy Detent Plate upside).
If leakage found at leak test, assemble

3 Packing assy No packing missing Visual All 100% Self check Operator
the packing with grease
4 Bolt Torque SC Torque = 19±4 Nm Torque Wrench All 100% Self check Operator Hold & Inform to supervisor
Torque Wrench
Torque = 19±4 Nm Torque calibrator 1 1/month Metrology Lab Inform to supervisor
calibration
220B Spring Pin assy
Complete fitment with Installer

Presence of spring to avoid direct hammering on
Pneumatic Hammer 1 Visual All 100% Self check Operator Fit completely
pin Shift arm spcifically Shift Arm
Top Third
220B Spring Pin assy

Operator
Gears shifting and interlock
2 Shifting Check Smooth shifting presence check All 100% acknowledgement with Operator Inform Supervisor
Commitement mark
9 of 26
Rev. Spl
Class
Part
220B/ Process Name/
Spring Pin Operation
assy Machine/
Interlock Plug
3 assembly No Leakage leak test All 100% Air leak testing Operator Inform Supervisor
230 Sealing cap & dowel pin pressing in Case
Sealing cap pressing in Case Press 1 Plug fitment height No Projection from Face; 0 ~ Tool Control All 100% Tool Control TMPC Inform to supervisor
2mm below face
Apply Loctite 262

around plug before Wipe the excess sealant and pass the
No excess sealant Visual All 100% Commitment mark Operator part
fitment
230
Dowel pin assembly Press 2 Pin Orientation Bigger chamfer top side Tool Control All 100% Self check Operator Correct the orientation.
Pin projection from Check Tool condition / inform

3 T/m case face 32 mm Tool Control 1 Tool Control Tool Control TMPC supervisor
235 Insert Assembly in Case
Apply Loctite 638 Self check.

Sealant Presence before Apply sealant and re-fasten as per the
Sealant catridge 1 around plug before assembly of 2 inserts Visual All 100% Retrival of insert itself Operator process
fitment while revesing the tool
Pre tight insert with Air 3-5 bar input air pressure (line Inform Supervisor and correct the
Air tool 2 tool pressure) Visual 1 Once/Day JH Check sheet Operator process parameter
235 Thread Insert assembly

Insert fastening (2 Pokayoke for fastening with Refasten and apply torque as per
Preset Torque Wrench 3 nos) 32 - 40 Nm Tool Control All 100% stopper interlock Operator process
self check and commitment Remove and reject the Case housing
4 Insert projection No Projection from Face Visual All 100% Operator incase of tap depth issue/ Reject Insert
mark at station incase of Insert height issue (O/S)
240 Rear Cover Sub Assembly
Press & Fixture Equipment

Hand Tool 1 Oil seal depth 2±0.3 mm Tool Control 1 NA Tool Control control inform to supervisor
2 oil seal presence Absolute presence visual All 100% Self check operator Check and resassemble the parts
End position of Dust

3 cover Complete butting with case visual All 100% Self check operator inform to supervisor
Oil seal Orientation Oil seal opening face to be Keep components seperately by
240 Rear Cover Sub Assy. 4 and Condition towards top visual All 100% POKA YOKE operator indentifying with rejection tag
Once/day
Analog pressure gauge
Pressing load. 60~90 kg/cm2 reading 1 (Start of A J H Check Sheet Operator Inform the supervisor
shift)
Manual fitment of Drain plug

Drain Plug & 'O' ring and Surface on rear cover free Manual
5 assy All 100% Self check operator inform to supervisor
from detns and damages
10 of 26
240 Rear Cover Sub Assy.

Rev. Spl
Class
6 Parts fitment Drain Plug, O'ring fitted visual All 100% Self check operator Fit parts
250 Front Cover Sub assembly
Oil seal opening face to be Keep components seperately by

1 Oil seal Orientation. towards top Visual All 100% POKA YOKE Operator indentifying with rejection tag
Apply oil on oil seal seating

2 Lubrication area visual All 100% Manual Operator Apply oil before pressing
Once/shift
3 Air Pressure Line Pressure - 4~6 bar Manometer reading. 1 (start of A Self check Operator Set the press load.
250 Front Cover Sub assembly shift)
Once/day
4 Pressing load. 60~90 kg/cm2 Analog pressure gauge 1 (Start of A J H Check Sheet Operator Inform the supervisor
reading shift)
11 of 26
Rev. Spl
250 Front Cover Sub assembly Class
Bellivelle washer Presence of part with concave

5 assembly assembly orientation visual All 100% Self check Operator Check and reassemble the parts
260 T/M Case - Gear Train assy
Presence of rear Check and install the gasket as per

1 Absolute presence Visual All 100% Commitment mark Operator
cover gasket process
2 Condition of paper No damages in gasket Visual All 100% Self check Operator Change the gasket
gasket
Orientation of paper
3 gasket As per the Operation std Visual All 100% Self check Operator Change the orientation
Opearator
Gears shifting and interlock
Hoist with hanger , for 4 Shifting Check Smooth shifting presence check All 100% acknowledgement with Operator Inform Supervisor
lifting gear train & Guide Commitement mark
260 T/M Case - Gear Train assy pins for location and gasket
assy,snap ring fitment
Visual and comitment mark
Opearator
5 Snap ring fit Insert the snap ring fully in the All 100% acknowledgement with Operator Insert fully.
condition groove. Commitement mark
6 Free rotation of Top Free rotation By hand rotation to Top Gear All 100% Self check Operator Inform to supervisor
Gear shaft shaft
Condition of Case
7 and Cover during No Damages in Case and Cover Visual All 100% Self check Operator Inform to supervisor
assembly
270 Front cover assy

Once/shift
Condition of Protective By hand rotation to Top Gear (start of A Self check
Front cover assy Oil seal protecting sleeve 1 sleeve No Dents, Damages, Burrs shaft 1 Operator Inform to supervisor
shift)
270
2 Packing assy No Damages in Case and Cover Visual All 100% Self check Operator At leak testing, assemble the packing
280 Speedo Drive Gear assy
Condition of bearing Once/shift

Speedo Drive Gear assy Hand tool 1 pressing Tool No Burrs in ID / face of Tool Visual 1 (start of A Self check Operator Deburr the tool
shift)
Snap Ring Fit Direction to be offset with

Plier External 7" 2 Visual All 100% Self check Operator Correct
condition respect to Key groove
3 Brg. Fit condition To Touch Snap Ring face Visual All 100% Self check Operator Correct
280
12 of 26
Rev. Spl
Class
Pokayoke and Self check at

speedo drive gear Pokayoke at station /speedo assembly station and
4 missing drive gear presence of speedo gear meter at testing All 100% additional rotational check Operator Hold & Inform Supervisor
in speedo bush station
280
Commitment mark made

parts wood ruff No Front / Back movement of
Point reinforced on 5 Speedo gear Fit key,spacer to be Speedo Gear+ Ensure presence By Feel of Operator All 100% on mainshaft to ensure the Operator Hold & Inform Supervisor
02.08.12 condition assembled of wood ruff Key. presense of woodruf key
during assembly
Pokayoke with stopper

interlock and Operator
6 Snap Ring missing Presence of snapring Pokayoke at station All 100% acknowledgement with Operator fit the snapring
Commitement mark
290 Shim Selection and Front Cover tighteninig
Shim Inspection in CGS Rotate to Settle the Integrated in machine

Front TRB 1 bearing Rotataion at 50rpm Min program All 100% Machine programming Autocheck Correct and Re-process
Inspect the depth from

Machine programming
joint face of main 1. Depth at actuals Integrated in machine (Monitoring of depth value Autocheck
2 housing to bearing face 2. Load at 500kgs program All 100% Correct and Re-process
at load condition in HMI)
Shim Selection for CGS Front
290 TRB
and Front Cover Tightening Inspect the depth from
Shim Inspection in Front Joint face of front cover Integrated in machine Machine programming
cover bearing seating 3 to Bearing seating 1. Depth at actuals program All 100% (Monitoring of depth value Autocheck Correct and Re-process
in HMI)
location
Depth calculation and Operator picks indicated

1. Shim selection as per the Integrated in machine
Shim selection 4 right shim selection as gap finding program All 100% shim and installs in front operator Correct and Re-process
per the gap finding cover
Front cover tightening 5 Front cover bolt SC 25 ± 3 Nm MNR All 100% Auto control,Display of Autocheck Hold & Inform to supervisor
torque (6 nos) tightening status
300-310 Case & Clutch housing bolt tightening
Position of Selector
8 Spindle MNR 1 Switch Correct visual All 100% Self check operator Correct
Missing of spring washer self check and commitment

Spring washer assembly 2 (14nos) Presence of parts visual All 100% mark at final station operator Check and reassemble the parts
300-310 Case & Clutch housing bolt

tightening
Case bolts torque (8
8 Spindle MNR 3 nos) SC 30 ~ 46 Nm Torque wrench / MNR All 100% Self check Autocheck Hold & Inform to supervisor
Ensure Assembly of
Spring Clip (Spring Clip (Spring Plate) to be in
4 correct direction visual All 100% Self check operator Correct the direction
Plate)
13 of 26
Rev. Spl
Class
320 Q box Sub-assy
Apply Loctite 262 Loctite 262 sealant to be

Manual 1 around bush and Oil seal Manual All 100% Self check. Operator Check and re-apply the sealant
before fitment applied
Bush Pressfitment till

Press fixture-1 2 Bush Press fitment shouldering Manual All 100% Self check. Operator Check and Re-Press
320 Bush, Sealing cup and Oil

seal fitment in Qbox
Press fixture-2 3 Sealing cup fitment Sealing cup pressfitment Manual All 100% Self check. Operator Check and Re-Press
Press fixture-2 4 Oil seal fitment Oil seal pressfitment Manual All 100% Self check. Operator Check and Re-Press
Assemble 5th/Rev Assemble 5th/Rev spring,

Manual 5 spring, Spring sheet Spring sheet A, Spring sheet B Manual All 100% Self check. Operator Check and Re-Assemble
A, Spring sheet B as per SOP
5th/Rev spring, Spring Assemble washer

sheet A, Spring sheet B, Assemble washer with spring,
330 washer with spring, Internal Manual 6 with spring, Internal Internal shift as per SOP Manual All 100% Self check. Operator Check and Re-Assemble
shift
shift, shifter shaft in Qbox
Assemble shifter Assemble shifter shaft as per Ensure Angle between

Manual 7 internal shift and Shifter shaft All 100% Self check. Operator Check and Re-Assemble
shaft SOP at 180° apart
4mm Pin Pressfitment in Pressfitment of 4mm pin in Check Pin is pressfitted till the
330A Qbox shifter shaft Fixture-3 8 4mm Pin presfitment shifter shaft end All 100% Self check. Operator Check and Re-press
M-Seal application in Apply M-seal in 4mm pin to Ensure M-Seal is properly

9 4mm pin avoid leakage applied All 100% Self check. Operator Check and re-apply the M-Seal
Shims,Linkage Assemble 1 to 3shims Max to Ensure gap to be maintained

10 assembly maintain the gap of 0.1/0.2mm 0.1/0.2mm with feeler gauge All 100% Self check. Operator Check and re-assemble
M-Seal application, Shim
assy, Linkage assy, Nut
340 fastening with washer in
Qbox
Fasten nut with Ensure Manual hand tight
11 spring washer 6-8 Nm with wrench All 100% Self check. Operator Check and re-assemble
Ensure Selection and Selection distance: 215-221mm

12 shifting distance Shifting distance: 199-205mm Vernier caliper All 100% Self check. Operator Check and re-assemble
350 Speedo bush assembly
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Rev. Spl
Class
Speedo Bush Assy (Oil seal Oil seal opening face to be Keep components seperately by
fitment) 1 Oil seal Orientation. towards top Visual All 100% Self check Operator indentifying with rejection tag
350
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Rev. Spl
Class
Fixture Wire mesh part should be Keep components seperately by

Hand tool 1 Orientation of filter down side. Visual All 100% Self check Operator indentifying with rejection tag
350
Speedo Bush Assy (Filter

fitment) Limit set in Load values of
2 Parts fitment O' ring All 100% Self check Operator Fit O'ring
Pressing
Keep components seperately by

3 speedo bush thread Thread size M22 X 1.5 Visual All 100% Self check Operator indentifying with rejection tag
360 Speedo Pinion assy

Air Tool,Feed back Torque indication & interlock with
wrench 1 Bolt Torque SC 19 ± 4Nm Torque Wrench All 100% conveyor end stopper using Operator Inform to supervisor
PLC programme.
Assembly of speedo No malleting during assembly

Socket Size - A/F 12 (Should be adjusted by using Visual / Feeling All 100% Self check Operator Inform to supervisor
bush in Rear Cover yoke for fitment)
360 Speedo Pinion assy
Torque Wrench
2 calibration 19 ± 2 Nm Torque calibrator 1 1/Month Metrology Lab Inform to supervisor
Lubrication Apply multi purpose grease Visual All 100% Self check Operator Apply Grease.
Speedo pinion Should be free when mainshaft Feel of the operator All 100% Self check Operator Remove & replace.
rotation is rotated with yoke
370 Support clutch fork assy

indication displayed &
Support Clutch Fork interlock with conveyor
Support clutch fork assy Feed back torque wrench 1 Torque SC 40 ± 10 Nm Torque Wrench All 100% end stopper using PLC operator Inform to supervisor
programme
370
Operator
Missing of plain & spring
2 washer Presence of washers Visual All 100% acknowledgement with operator Inform to supervisor
Commitement mark
Torque Wrench
3 calibration 40 ± 4 Nm Torque calibrator 1 1/Month Metrology Lab Inform to supervisor
380 Filler plug assembly
16 of 26
Rev. Spl
Class

Filler plug assy and indication displayed &
Torque Wrench 1 Filler Plug Torque SC 40 ± 10 Nm Torque Wrench All 100% interlock with conveyor Operator Inform to supervisor
end stopper using PLC
programme
380 Filler plug assembly Socket Size - A/F 24 mm 2 Filler Plug Torque 40 ± 10 Nm
3 Torque Wrench 40 ± 5 Nm Torque calibrator 1 1/month Metrology Lab Inform to supervisor

calibration
390 Rev. Lamp Switch Assy
Copper Washer assembly 1 Missing of washer Part Presence Visual All 100% Self check Operator Check and reassemble the parts

Rev. Lamp Switch indication displayed &
390 Rev. Lamp Switch Assy 2 Torque SC 35 ± 5 Nm Torque Wrench All 100% interlock with conveyor Operator Inform to supervisor
Feed back torque wrench programme
socket size A/F 24 Rev. Lamp Switch
3 35 ± 5 Nm
Torque
Torque Wrench
4 35 ± 2.5 Nm Torque calibrator 1 1/month% Metrology Lab Inform to supervisor
calibration
400 Q. Box Assy
Paking of Q-box with gasket
and grease 1 Missing of operation No missing Visual All 100% Self check Operator Check and reassemble the parts
Plain & Spring washer 2 Missing of washers Part Presence Visual All 100% Self check Operator Check and reassemble the parts
assembly
Wire clamp (clip harness)

assembly 3 Missing of operation No missing Visual All 100% Self check Operator Check and reassemble the part
400 Q. Box Assy

2 Bolts & 2 indication displayed &
4 studsTorque SC 25 ± 3 Nm Torque wrench All 100% operator Hold & Inform to superviso
interlock with conveyor
5 Condition of Q Box No Dents, damages, scratches Visual All 100% Self check Operator Replace / Correct Q Box
etc.
Air Tool& Torquewrench
6 Weld portion in Q Box Assy No blowholes All 100% Self check Operator Replace Q Box
7 Q Box Pin Should project out All 100% Self check Operator Replace Q Box
410A Selection Brkt. Assy.
Spring washer assembly 1 Missing of washer Part Presence Visual All 100% Self check operator Check and reassemble the parts
Air Tool 2 2 Bolts Tightening Complete butting with face Visual All 100% Self check operator Hold & Inform to supervisor
410A Selection Brkt. Assy.
Torque Wrench 1 M8 bolt torque SC 24 ± 4Nm Torque Wrench 1 Once /Week Torque Audit Quality inspector Inform to supervisor
410B Shift Brkt. Assy.
17 of 26
Rev. Spl
Class
Spring washer assembly 1 Missing of washer Part Presence Visual All 100% Self check operator Check and reassemble the parts
Self Check &

Air Tool 2 2 Bolts Tightening Complete butting with face Visual All 100% acknowledgment with Operator Hold & Inform to supervisor
commitment mark,
410B Shift Brkt. Assy.
420 Sub assembly of clutch release bearing
Orientation of
1 release bearing and As per quality standard Visual All 100% Self Check Equipment Hold & Inform to supervisor
shift block
2 Pressing pressure 3-5 bar Visual 1 1/shift Daily check sheet Operator Inform supervisor and rectify the issue
420 Sub assembly of clutch Press & fixture

release bearing
Stop the line and check the parts

Inspect bearing
3 visually As per visual AID Visual All 100% Self Check operator produced in the particular batch and
inform supervisor
Stop the line and check the parts

Face runout variation Variable gauge for faceout
4 after pressing 0.05mm Max inspection 5 1/shift Log book operator produced in the particular batch and
inform supervisor
430 Air Leak Testing
1.Test pressure: -0.2 ~
0.5 Pa 2.test pressure Leakage Rate < 40 Pa in 10 Air Leak Tester also apply soa Record the leak value in Check for Leak from various Joints &
430 Air Leak Testing Air Leak Tester 1 Air Leak Test time: 20sec 3.test p solution at sealing joints to All 100% operator
seconds of test know the leakage area Log note Inform Supervisor
stabilisation :8 sec
4.test Detection : 10 sec
Use neutral soap solution / inform
Soap Solution PH Neutal (Labolene) Visual on packaging All 100% Self check Operator supervisor
Ensure No leakage from No leakage Soap Solution All 100% Self check Operator Replace defective part
Q Box Side
440-Dust Cover, Fork shift & release bearing assy
Grease on support Sphere
Manual 1 Grease Presence surface visual All 100% Self check. Operator Apply Grease.
Dust Cover & Fork shift assy 2 Orientation of Dust Direction as per Shift fork Visual All 100% Self check. Operator Remove & replace.
Cover Groove
Dust Cover Condition No Damages Visual All 100% Self check. Operator Remove & replace.
440
3 Missing of operation Part Presence Visual All 100% Self check. Operator Check and reassemble the parts
Assembly of release bearing
with spring
18 of 26
Rev. Spl
Class
440 Product/Process Specification Evaluation/ Measurement
Assembly of release bearing

with spring
Grease application in
4 shift block Apply grease in shift block Visual All 100% Self check. Operator Apply Grease.
Assembly of bracket return Missing of spring

spring 5 assembly Part Presence Visual All 100% Self check. Operator Check and reassemble the parts
450 - Production testing
Correct timer setting & Inform to

Equipment 1 Oil filling Oil Qty. 1.55 ± 0.05 litr Machine All 100% Equipment control Operator supervisor
No Abnormal noises and Input Record in log note and

EOL testing 2 Noise check in all gears Speed 2000rpm and Ouput By operator's feel All 100% Auto data acquistion Operator Identify with Rejection Tag
torque 25Nm integrated
EOL testing Bearing noise No abnormal noises By operator's feel All 100% Record in log book Operator Identify with Rejection Tag
Record in log note and

EOL testing 3 Shiftability check Smooth sliding of the gears Feel of the operator All 100% Auto data acquistion Operator Identify with Rejection Tag
integrated
Cracks/Damages / No crack or breakage on the

Manual 4 Breakages check aasembled T/M Visual All 100% Register Operator Attach Rejection Tag
450 Production testing Rev Lamp Switch Record in log note and
No Fuse / Earth / Short. Rev Check the rev. Shifting and Identify with
EOL testing 5 (Special Switch used) Lamp Should Glow Lamp All 100% Auto data acquistion Operator Rejection Tag in case of shifting issue
Functioning integrated
No damage and thread

ensure any damage,malfunctionung &
EOL testing 6 speedo meter sensor washout in speedometer Visual All 100% self check Operator thread washout in sensor connector
sensor connetor
speedo meter at testing on Record in log note and

Speedo Gear
EOL testing 7 Presence Speedometer should Work Cluster meter (Dash Board All 100% operator commitment Operator Identify with Rejection Tag
added) mark
Manual 8 No missing / incomplete assy. Visual All 100% Self check Operator Identify with Rejection Tag
Transmission model Proper sequence to be

EOL testing 9 and serial no etching followed All 100% Auto Equipment conro Inform maintenance
19 of 26
450 Production testing

Rev. Spl
Class
Validation of EOL for EOL to detect the neutral QA Opeartor &

EOL Validation neutral running running Funtional test 1 1/month EOL Validation report Equipment conrol Re-Validate with NG Part
detection
460 Final Assembly after testing
Oil drained from the Oil to be drained from the By removing the draining self check and commitment
Manual 1 T/M drain plug adapter All 100% mark at final station operator Drain the oil
Socket - A/F 24 Torque

Wrench 2 Drain plug Torque SC 40 ± 10 Nm Torque Wrench All 100% POKA YOKE operator Inform to supervisor

Operation indication displayed &
Torque Wrench 3 completion for drain 40 ± 10 Nm Torque Wrench All 100% interlock with conveyor operator Inform to supervisor
plug torque end stopper using PLC
programme
torque wrench
Torque Wrench 4 calibration 40±-5 Nm Torque calibrator 1 1/month Metrology Lab Inform to supervisor
Sealant application in air Loctite 242 sealant to be

Manual (Breather plug) 5 breather applied Manual All 100% Self check. Operator Check and re-apply the sealant
460 Final Assembly after testing

Air Breather should be butt to Self check. And make
Manual 6 Butting area rear cover face Visual All 100% Commitment mark Operator Remove & replace.
Manual 7 Dummy cap fittment Caps to be placed on Rear Visual All 100% PDI Register operator Replace the cap
cover and speedo bush
8 Visual All 100% Self check Operator In Case of any problem inform
supervisor
Operator
Manual 9 Presence of Fornt cover Presence of parts Visual. All 100% acknowledgement with Operator Identify with Rejection Tag
snap ring and thrust ring (Visual Aid 021)
Commitement mark
Operator
Presence model and
Manual 10 serial no etching mark Presence of punch mark Visual All 100% acknowledgement with Operator Identify with Rejection Tag
Commitement mark
470 - Pre Dispatch Inspection
20 of 26
Rev. Spl
Class
As per PDI
Pre Dispatch Inspection Manual 1 Checksheet As per check sheet As per check shee All 100% PDI Check Sheet PDI operator Inform to supervisor
470
Dispatch 2 OK T/M OK T/M to be despatched Visual on T/M with OK PDI All 100% Operator Inform to supervisor
Rev No Date Description
1 18.06.20 New document release for Proto Assembly
2 19.02.2024 Op 160 (Lock Washer crimpping) updated due to Field Compalint
21 of 26
Rev. Spl
Class
22 of 26

210Nm Proto Control Plan - 19-02-24

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CONTROL PLAN ( 210Nm Transmission Assembly)

Pneumatic Gun, Check Mtg. Face of

Ensure no lump presence in Check no presence of Keep components seperately by

Fixture for locating the IM

2 dowels we need By dowel pressing tool & Keep components seperately by

Battery Gun,Socket for Adjust the toque 50 ~ 55 NM We need to

Disassembly of Case and IM

Self check / auto indicator

At start of Auto Temperature Stop Washing operation. Inform to

Concentration check sheet Lab/

30 Kitting tray placement on conveyor

All parts presence in kiiting bin

40- Top gear shaft bearing fitment

Analog pressure gauge 1/day (Start

Groove should be on bottom

Visual Inspection and

Needle bearing Keep components seperately by

50 Cluster gear shaft bearing fitment

50 Groove should be on bottom

60 Sleeve & Clutch Hub Top 3rd assembly

Big Chamfer of sleeve t-3rd &

Insert should not fall out, No

Groove should be towards

Opening of Spring insert is

70 Sleeve & Clutch Hub Low-2nd assembly

Big Chamfer of sleeve L-2nd &

Insert should not fall out, No

Right level of insert Reassemble the right inserts and

Groove should be towards

Opening of Spring insert is

80 IM plate Sub Assembly

Visual Inspection and

80 Torque wrench with light

90 3rd Gear Assy. in Main shaft

Fit condition of Block

Orientation of Clutch Chamfer side of sleeve towards

Snap ring should enter in

100-110 1st gear & 2nd gear assembly in main shaft

2nd gear Needle Keep components seperately by

Lubrication of needle Apply transmission oil on Keep components seperately by

Parallel groove in Clutch hub

Orientation of First Oil groove of Thrust washer

Free rotation of 2nd main after

Analog pressure gauge Once/day.

Fit condition of Block

Freeness of 1st &

120 Matching of TGS & CGS

130 IM plate & gear train assembly

Snap ring Fit Snap ring enters into groove of

Orientation of Rev Oil groove of Thrust washer

Fit condition of Block Shoud snap ring seat in bearing

130 IM Plate and Gear Train Assy

Barcode no. must be

140 Sleeve & Clutch Hub Rev-5th assembly

Big Chamfer of sleeve R-5th &

Sleeve & Clutch Hub Rev-5th

Insert spring Opening of Spring insert is

150A Gear Reverse Main and rev counter Assy

150A Free rotation of 5th