Sai Links (India) Pvt.

Ltd; L-213, MIDC, Ahmednagar

Export Control Classification #REF!

Other restrictions #REF!
PROCESS FLOW DIAGRAM
PART NUMBER: 488-492 Rev B PFD/32/03 Rev Date: 01.01.2023. PREPARED BY: Avinash
PART / FAMILY DESCRIPTION: Handle, Machining of DATE: 01.03.2020

TRANSFORMATION STEP
LIFT (mechanical / other)

CLASSIFICATION
OTHER (SPECIFY)
ADMINISTRATION

LOAD / INSTALL

FABRICATION /
INTERACTION
PACKAGING

REWORK
INSPECT
CONTROL

STORE
MOVE
PRODUCT KC PROCESS KC
METHODS
OPERATION
OPERATION STEP DESCRIPTION

Receive material
10. Receive
stores. Identify tag,
Material from 10 Nil Nil F/24, F/34
WI/GEN/04,
Stores
WI/QA/02
Draw tools as per F/24, F/10, F/34,
20. Drilling
20 WI/PRD/29, Nil Nil Process Drawing
Ø4.927
WI/QA/02 Op. 20
Deburr sharp
25. Deburring 25 Nil Nil F/24, F/34
edges., WI/QA/02
30. Final Final Inspection,
30 Nil Nil F/24, F/16, F/34
Inspection WI/QA/02
40. Packing / Pack & forward to
Forwarding 40 stores, WI/QA/02 Nil Nil F/24, F/34
To Stores
Shipment,
50. Shipment 50 Nil Nil F/24, F/34
WI/QA/02
Copyright @ SAE International. This material is provided by SAE "AS IS" and may be reproduced, used and modified under the condition that the user
hereby holds SAE harmless from user's manipulation of the forms and indemnifies SAE from any and all claims or damages caused by use, modification or Rev -
applications thereof.

Prepared By: Avinash Approved By: Director L / 15 / 00

Export Control Classification
Other restrictions

Process
Prototype - Pre-Launch -

Key Contact Core Team

PROCESS
OPERATION STEP
DESCRIPTION
Copyright @ SAE International. This material is provided by SAE "AS IS" and may be reprod
indemnifies SAE from any and all
 PROCESS FLOW DIAGRAM

Pre-Launch - Production -

INPUTS CLASSIFICATION
 SAE "AS IS" and may be reproduced, used and modified under the condition that the user hereby holds SAE harmle
demnifies SAE from any and all claims or damages caused by use, modification or applications thereof.
 #REF!
#REF!

CESS FLOW DIAGRAM

OUTPUTS CONTROLS
condition that the user hereby holds SAE harmless from user's manipulation of the forms and
modification or applications thereof.
 Date (Orig.)

Date (Rev.)

Customer Approval Date

MISTAKE PROOFING REMARKS

Rev -
 Sai Links (India) Pvt. Ltd; 10 of 16
L-213,
Export MIDC,
Control Ahmednagar
Classification #REF!
Other restrictions #REF!

Process Failure Mode and Effects Analysis (PFMEA)

Prototype - Pre-Launch- Production - Key Contact / Phone Avinash 01.03.2020
Date (Orig.) Date (Rev.): 01.01.2023.

Customer Approval
Part Number: 488-492 Rev B PFMEA/32/03 Core Team Avinash, Siddhesh Joshi
Date
NA

Current Process Action Results

Classification
Responsibility

Occurrence

Occurrence
Severity
Process

Detection

Detection
Actions Taken

Severity
Potential Failure Potential Effect(s) of Failure Potential Cause(s) of & Target
Operation Step Function/ Requirements Prevention Detection RPN Recommended Action RP
Mode Failure Completion
Description Controls Controls Completion N
Date
Date

Separate stores for

1. NEXT OPRN - Machining will not be as per specification. material identification
Material not as 2. ASSEMBLY - No assembly as per specification .
8 Tag not done properly All material should be 3 2 48
and 100% visual
per specification 3. TESTING - Fail in testing. or Tag found missing. Tagged properly.
4. END USER - Will not reach upto end user . inspection before
10. Receive Receive Receive machining.
material 10 material from material from
from stores stores stores.
1. NEXT OPRN - Machining will not be as per specification. Training to all operators
Damage or dent 2. ASSEMBLY - No assembly as per specification .
8 Miss handling Material should be 3 Separate bins or tray 5 120 and inspectors for On going Immediate 7 2 2 28
on material 3. TESTING - Fail in testing. handle carefully should be provided process
4. END USER - Will not reach upto end user . handling of product.

Loose Tool clamping. Ensure tightening of 2 Set Up approval 5 60

tool
1. NEXT OPRN - Machining will not be as per
specification.
U/S 2. ASSEMBLY - No assembly as per specification . 6 Tool Wear Tool Change 2 Stage inspection 4 48
3. TESTING - Fail in testing.
4. END USER - Will not reach upto end user .

Incorrect cutting Check Control Plan 2 Set Up approval 4 48

parameter
2 X BS .270
Loose Tool clamping. Ensure tightening of 2 Set Up approval 5 50
tool
1. NEXT OPRN - Machining will not be as per
specification.
O/S 2. ASSEMBLY - No assembly as per specification . 5 Tool Wear Tool Change 2 Stage inspection 4 40
3. TESTING - Fail in testing.
4. END USER - Will not reach upto end user .

Incorrect cutting Check Control Plan 2 Set Up approval 4 40

parameter
20. Drilling 20 Drilling
Ø4.927
Loose Tool clamping. Ensure tightening of 2 Set Up approval 5 60
tool
1. NEXT OPRN - Machining will not be as per
specification.
U/S 2. ASSEMBLY - No assembly as per specification . 6 Tool Wear Tool Change 2 Stage inspection 4 48
3. TESTING - Fail in testing.
4. END USER - Will not reach upto end user .

Incorrect cutting Check Control Plan 2 Set Up approval 4 48

parameter
2X BS 1.325
Loose Tool clamping. Ensure tightening of 2 Set Up approval 5 50
tool
1. NEXT OPRN - Machining will not be as per
specification.
O/S 2. ASSEMBLY - No assembly as per specification . 5 Tool Wear Tool Change 2 Stage inspection 4 40
3. TESTING - Fail in testing.
4. END USER - Will not reach upto end user .

Incorrect cutting Check Control Plan 2 Set Up approval 4 40

parameter

Prepared By: Avinash Approved By: Director L / 16 / 00

 Sai Links (India) Pvt. Ltd; 11 of 16

Loose Tool clamping. Ensure tightening of

L-213, MIDC, Ahmednagar
2 Set Up approval 5 80
tool

Instead of Drill Dia.

1. NEXT OPRN - Machining will not be as per 5.00mm, Use of Drill
specification. Dia. 4.50mm & Special
U/S 2. ASSEMBLY - No assembly as per specification . 8 Tool Wear Tool Change 5 Stage inspection 4 160 Reamer Dia. 4.97mm. Avinash & Avinash & 7 2 2 28
3. TESTING - Fail in testing. 15.01.2021 28.01.2021
4. END USER - Will not reach upto end user . 100% Inspection for 1st
Three Lots by Operator
- GO & NOGO Gage

Incorrect cutting Check Control Plan 2 Set Up approval 4 64

parameter
2X .194- .200 Thru

Loose Tool clamping. Ensure tightening of 2 Set Up approval 5 70

tool

Instead of Drill Dia.

5.00mm, Use of Drill
1. NEXT OPRN - Machining will not be as per Dia. 4.50mm & Special
O/S
specification.
7 Tool Wear Tool Change 5 Stage inspection 4 140 Reamer Dia. 4.97mm. Avinash & Avinash & 7 2 2 28
20. Drilling 2. ASSEMBLY - No assembly as per specification . 15.01.2021 28.01.2021
20 Drilling 3. TESTING - Fail in testing. 100% Inspection for 1st
Ø4.927 4. END USER - Will not reach upto end user . Three Lots by Operator
- GO & NOGO Gage.

Incorrect cutting Check Control Plan 2 Set Up approval 4 56

parameter

Position Loose Tool clamping. Ensure tightening of 2 Set Up approval 4 64

tool
1. NEXT OPRN - Machining will not be as per
specification.
U/S 2. ASSEMBLY - No assembly as per specification . 8 Tool Wear Tool Change 2 Stage inspection 3 48
3. TESTING - Fail in testing.
4. END USER - Will not reach upto end user .

Incorrect cutting Check Control Plan 2 Set Up approval 3 48

parameter
[⊕I
Φ.014IAIBIC]
IΦ .008IA Loose Tool clamping. Ensure tightening of 2 Set Up approval 4 56
tool
1. NEXT OPRN - Machining will not be as per
specification.
O/S 2. ASSEMBLY - No assembly as per specification . 7 Tool Wear Tool Change 2 Stage inspection 3 42
3. TESTING - Fail in testing.
4. END USER - Will not reach upto end user .
Incorrect cutting Check Control Plan 2 Set Up approval 3 42
parameter
1. NEXT OPRN - No effect on machining dimension.
25. 25 Deburring No sharp edges Poor
2. ASSEMBLY - No effect on assembly .
3 Mis handling Material should be 2 Separate bins or tray 3 18
3. TESTING - No effect on Testing.
Deburring 4. END USER - Will not reach upto end user . handle carefully should be provided
5. Accident - Chance of cut to body.

Per print &

30. Final
Document
1. NEXT OPRN - ASSEMBLY - Assembly will not affect.
7 Typo Error Make document with 4 Verification by Quality 2 56
30 Final Inspection Control Plan TESTING - Will not carried out.
Inspection inprocess Inspection Head
CP/32 3. END USER - NO OTD at customer end

Training to operators
Packing Packing Damage 1. NEXT OPRN - END USER - Will not reach upto end
9 Not use of specified As per customer 3 Stage Inspection 4 108 and inspector for visual On going Immediate 9 3 3 81
user . packing material requirement inspection for damage process
40. Packing / Packing and and protective packing
Forwarding To 40 forwarding to
Stores stores

Storage FOD 1. NEXT OPRN - END USER - Will not reach upto end
8 Not packed to seal pack the box 3 Stage inspection 3 72
user . prevent dust

Prepared By: Avinash Approved By: Director L / 16 / 00

 Sai Links (India) Pvt. Ltd; 12 of 16
L-213, MIDC, Ahmednagar 1. NEXT OPRN - will not meet drawing specification.
Protective packing with
Send material to
Ship Material Damage
2. ASSEMBLY - Assembly will affect due to short fall of
8 Mis handling Material should be 3 4 96
50. Shipment 50 component.. corrugated box packed
stores handle carefully
3. TESTING - Will not carried out. in wooden box
4. END USER - NO OTD at customer end

Copyright @ SAE International. This material is provided by SAE "AS IS" and may be reproduced, used and modified under the condition that the user hereby holds SAE harmless from user's manipulation of the forms and indemnifies SAE from any and all claims or damages
Rev -
caused by use, modification or applications thereof.

Prepared By: Avinash Approved By: Director L / 16 / 00

 Sai Links (India) pvt. Ltd;
13 of 16
L-213, MIDC, Ahmednanagar

Control Plan No.: CP/32 #REF!

#REF!

Control Plan
Key Contact / Mr. Avinash Date (Orig.): 01.04.2013 Rev A Date (Rev.) 01.01.2023. Rev E
Prototype - Pre-Launch- Production - Phone
Core Team Avinash, Siddhesh Joshi Customer Approval Date: NA
Part Number: 488-492 Rev B

Part Name / Description: Handle, Machining of

Operation Step Process Function / Machine, Device, Characteristics Methods

Classification
Description Jig, Tools For Mfg. Requirements Evaluation / Measurement Technique Sample
Reaction Plan
# Product Process Control Method

Size Freq

10. Receive Material 10 Receive material from Appearance Free from damage, FOD and dent Visual / Tag 100% Each Lot F/24, F/34, WI/QA/02, Communication with Supplier
from Stores stores WI/GEN/04
F/24, F/10, F/34, WI/PRD/29,
7 2X .270 Height Gage Per Hour Stop Production, Communicate with
SAI/D-01 / 02 BS 1 pc. WI/QA/02, Process Drawing
Production Head & Quality Head
Op. 20
SAI/ 2X 1.325 Height Gage Per Hour "
HANDLEDRILL/01
8 BS 1 pc. "
100% by
Drill Dia. 4.50mm Go Gage & NoGO Gage Operator
Each Lot " "
9 Dia. 2X .194 - .200 Thru
20. Drilling Ø4.927 20 Drilling Reamer Dia. Gage Pin - 4.95 to 5.03mm 1 Pc. by
Per Hour "
4.97mm Inspector "
[⊕I Φ.014IAIBIC] Calculation Per Hour "
10 Position
IΦ .008IA
1 pc. "

Appearance Free from damage, porosity and dent Visual 100% Each Lot " "

Spindle Speed 2651 RPM or 2600 RPM On 4th Pulley 1 Pc. Per Shift F/10, F/34, WI/PRD/29 "

25. Deburring 25 Deburring Appearance No sharp Edges, dent and porosity after Visual 100% Each Lot F/24, F/34 Stop Production, Communicate with
Drilling Production Head & Quality Head

B Appearance FOD Visual 100% Each Lot F/24, F/16, F/34, WI/QA/02 Communicate with Quality Head

A Appearance Damage / Dent Visual 100% " " "

C Material Heat Number Certificate from Supplier 100% Each Lot " "

1 Document Anodize Anodize per MIL-A-8625, Type II, Class 1 Certificate from Supplier 100% " " "

Paint indicated areas and surfaces according

to Parker Specification P1119 or TT-P-1757
2 Document Type 1 Primer and TT-E-489 class B Enamel Certificate from Supplier 100% " " "
color per FED-STD-595 chip color # 11136
(Red)

Paint Indicated areas according to Parker

Specification P1119, or Per TT-P-1757, Type
3 Document I Primer and TT-E-489, Class B Enamel, Certificate from Supplier 100% " " "
Color per FED-STD-595 Chip Color No.
13655 (Yellow)

30. Final Inspection 30 Final Inspection Indicated Areas may be painted Red or
4 Document Yellow per Note 3 or 4 with Transition Visual 100% " " "
between colors at any point in these areas.

5 Document Over Spray of Paint per Notes 3 and 4 Visual 100% " " "
permissible on indicated surfaces.

6 Document No paint or overspray per Notes 3 and 4 Visual 100% " " "
permissible on indicated surface.

7 BS 2X .270 Height Gage Sampling Plan " " "

8 BS 2X 1.325 Height Gage " " " "

9 2X .194 - .200 Thru Gage Pin and / or GO Gage & NOGO " " "
Dia. Gage 100%

10 Position [⊕I Φ.014IAIBIC] Calculation Sampling Plan " " "

IΦ .008IA

11 Dim. 2X 1.32 - 1.52 Vernier Caliper " " " "

12 Dim. .010 - .080 Vernier Caliper " " " "

Dimensions are in mm , Dimensions in [ ….] are in Inches Checked By:Avinash L / 03 / 00

Prepared By: Avinash Approved By: Director
 Sai Links (India) pvt. Ltd;
14 of 16
L-213, MIDC, Ahmednanagar

Appearance FOD Free Visual 100% Each Lot F/24, F/34, WI/QA02 Stop Packing, Communicate with
Production Head & QC Head
40. Packing / Forwarding 40 Packing Appearance Damage / Dent Free Visual 100% Each Lot " "
To Stores

Appearance Duplex Box - Damage & FOD free Visual Sampling Plan Each Lot " "

50. Shipment 50 Shipment Appearance Free from damage, porosity and dent Visual 100% Each Lot F/24, F/34, WI/QA02 Stop Packing. Communicate with
Production Head & Quality Head
Copyright @ SAE International. This material is provided by SAE "AS IS" and may be reproduced, used and modified under the condition that the user hereby holds SAE harmless from user's manipulation of the forms and indemnifies SAE from any and all claims or damages caused by use,
modification or applications thereof. Rev -

Dimensions are in mm , Dimensions in [ ….] are in Inches Checked By:Avinash L / 03 / 00

Prepared By: Avinash Approved By: Director
Sai Links (India) pvt. Ltd;
15 of 16
L-213, MIDC, Ahmednanagar

Control Method - Proposed Drop Down List

Error / Mistake Proofing
Variable Control Charts
Run Charts with Non-Statistical Limits
PreControl Charts
Life / Useage Control
Attribute Control Charts
Visual Process Check and Checklist

First Piece Check

Test Piece evaluation

Dimensions are in mm , Dimensions in [ ….] are in Inches Checked By:Avinash L / 03 / 00

Prepared By: Avinash Approved By: Director
 AS13004 - Process Risk Identification, Assessment, Mitigtion and Prevention

Description of change Alignment to AS13004 revision Template revision

Original issue Rev - Rev -