Technical Review:

Program : Mahindra Oil Pump

Part No.: M0106066
Description: VALVE
Supplier: BHAGWAN PRECISION (P) LTD.
Prepared by: Bhagwat Sharma
Revision Date: 30.10.18
1. General information
 Kick –off: ------- (14.12.2018)
 Off Tool T3 : 10-Feb-2019 (300 Nos)
 PPAP : 10-Sep-2019
 Run @ Rate: 30-Oct-2019
 SOP: Dec-2019

10-Feb-19 Sep-2019 Oct- 2019 Dec 2019

10- June-
18

Volume
 Annual volume 2020 : ~1,60,000
 MCR for Run @ Rate : 1,60,000 X 20% = 1,92,000

Date: Author: 2
1. Drawing

Date: Author: 3
• Part Print
 Part Name: VALVE
 Part Number: M0106066
 Latest Revision Level: NIL Updated date: NIL
 Part weight: 0.019 KG
 Raw Material: SAE 1018 / EN 1A (P)
 Specification number: Dia. 18 mm

CHEMICAL COMPOSITION SAE-1018

%C % Si % Mn % S max % P max % Pb. % Ni % Cr % Mo

0.15/ 0.20 0.10 / 0.20 0.60 / 0.90 0.05 0.04 ---- ---- ---- ----

CHEMICAL COMPOSITION EN1A(P)

%C % Si % Mn % S max % P max % Pb. % Ni % Cr % Mo

0.07/ 0.15 0.10 Max. 0.80 / 1.20 0.20 / 0.30 0.07 ---- ---- ---- ----

• Raw material
 Material Source: M/s Rohit Steels (sunflag Steel Mill)
 Material substitute(If necessary): M/s Rohit Steels (Gerdau-Steel Mill)

Date: Author: 4
2. Process Strategy & Capacity

EN1A
No. of No. of New
In-House / Strategy / No. of Machines No. of Machines Remark
Op No. Description Machines Machines
Supplier s
Concept Required available Considered Planned
10 Blank cutting In-House Band saw 1 1 1 Nil
20 CNC Turning-1st In-House CNC Turn 1 20 1 Nil
30 CNC Turning-2nd In-House CNC Turn 1 20 1 Nil
40 Milling In-House VMC 1 12 1 Nil
50 Heat Treatment In-house SQF M/c 1 2 1 Nil
60 O.D. Grinding In-House CLG 1 8 1 Nil

100 % MPI for crack

70 In-House MPI 1 1 1 Nil
detection

Eddy current
80 In-house Eddy current 1 1 1 Nil
testing

1018
5* Color coding In-House Manual 1 1 1 Nil
10A Blank cutting In-House Band saw 1 1 1 Nil

*In case 1018 the entire bar will be color coded through out the length.

Note:
This slide applies to every different processes.
Example provided, to be modified as per requirement
Date: Author: 5
2. Process Strategy Detail
BHAGWAN PRECISION
ROHTAK
PROCESS CONTROL PLAN
PART NAME PREV. OPERATION OPERATION NAME NEXT OPERATION OPERATION No.

VALVE RAW MATERIAL INSP. BLANKS CUTTING TURNING 1st. 10

PART No. MATERIAL / BAR SIZE LEGENDS REV. No. / DATE : DOCUMENTS No.
M01106066 SAE 1018 / ø18.0 Significant - <SC> , Major- M, Minor - m BP-MA-300/182

WORK INSTRUCTIONS
30.0 ± 0.2

BAR Ø18.0

Ø8.0
2
4
Rev. No./ Approved
Description (Revisions Detail)
Date By

3
15.0 ± 0.20

NOTE : BREAK SHARP CORNERS MAY BE EITHER A CHAMFER OR A RADIUS FROM 0.2mm Min. TO 1.0mm Max.
Dim.
0~6 6 ~ 30 30 ~ 120 120 ~ 315 315 ~ 1000
From to
Tol in
± 0.10 ± 0.20 ± 0.30 ± 0.50 ± 0.80 CLAMPING RESTING LOCATING
mm
Characteristic Methods
Process Specia
Part / Sample
Name Machine Device l Product/process Error Corectiv Reaction
Process Evaluation Measurement Control Resp. Record
Operation Tools For Mfg. No. Product Process Char. Control Proofi e Action Plan
Number Technique Method
Description Class Parameters ng Size Freq.

Vernier Caliper Setup /

1 Length M 30.00 ± 0.20 5Pcs. Insp. Yes
L.C. 0.01mm 2 hrs.
Micrometer Setup /

In Case of non confermity Suspected Material, Inform to Producer & Inspector of Q.A. to reset the
2 Bar Dia M 18.0 5Pcs. Insp. Yes
L.C. 0.01mm 2 hrs.
Vernier Caliper Setup /
3 Depth M 15.0 ±0.10 5Pcs. Insp. Yes

For <SC> & Tolerance below than 0.05mm use of Process Control Chart (FM-QA-06) is mandatory.
L.C. 0.01mm 2 hrs.
Vernier Caliper Setup /
4 Dia M 8.0 5Pcs. Insp. Yes
L.C. 0.01mm 2 hrs.

Process Setting Approval Sheet (FM-QA-02)

TRAUB A 25 (COLLET Ø18.00)

Process Inspection Report (FM-PRD-01)

BLANKS CUTTING

Rejection / Rework
During Setting
Collet Ø18.00 pg Visually / Vernier Caliper Setter No

Machine.
10 Setting Approval
During Setting
Parting Tool 3/8x3/8x8" Visually / Vernier Caliper Setter Yes
Setting Approval
During Setting
Drill ø8.00 Visually / Vernier Caliper Setter Yes
Setting Approval
RPM Chart / Gear Chain During Setting
RPM 500 Setter No
System Setting Approval
Feed Chart / Gear Chain During Setting
Feed 32 Pcs./Hr Setter No
System Setting Approval
Special Container / Issue
Cutting Oil Straight Cut Daily Optr. Yes
Slip

Note:
a) Elaborate each Operation in detail, including machine clamping location, resting location, tooling, reference etc.,
b) Use multiple slides as required

Date: Author: 6
2. Process Strategy Detail
BHAGWAN PRECISION
ROHTAK
PROCESS CONTROL PLAN
PART NAME PREV. OPERATION OPERATION NAME NEXT OPERATION OPERATION No.

VALVE BLANKS CUTTING TURNING 1st. TURNING 2nd. 20

PART No. MATERIAL / BAR SIZE LEGENDS REV. No. / DATE : DOCUMENTS No.
M01106066 SAE1018 / ø18.0 Significant - <SC> , Major- M, Minor - m BP-MA-300-182 /020

WORK INSTRUCTIONS
11 4.34 ± 0.05
1.50 ± 0.10 10
12
1.8
0.3 ± 0.10 X 45° 9

Ø14.40 ± 0.050
Ø15.0 ± 0.050

Ø16.20 ± 0.020
6
7 Rev. No./
Description (Revisions Detail)
Approved
Date By

3
90°

R0
2 5

.3
0.45 ± 0.1 X 45°

2.5
1 4
28.5 ± 0.10

NOTE : BREAK SHARP CORNERS MAY BE EITHER A CHAMFER OR A RADIUS FROM 0.2mm Min. TO 1.0mm Max.
Dim.
0~6 6 ~ 30 30 ~ 120 120 ~ 315 315 ~ 1000
From to
Tol in
± 0.10 ± 0.20 ± 0.30 ± 0.50 ± 0.80 CLAMPING RESTING LOCATING
mm
Characteristic Methods
Process
Part / Special Sample
Name Machine Device Product/process Error Corectiv Reaction
Process Char. Evaluation Measurement Control Resp. Record
Operation Tools For Mfg. No. Product Process Control Proofi e Action Plan
Number Class Technique Method
Description Parameters ng Size Freq.

Vernier Caliper Setup /

1 T Length M 28.50±0.10 5Pcs. Insp. Yes
L.C. 0.01mm 2 hrs.
Setup /

In Case of non confermity Suspected Material, Inform to Producer & Inspector of Q.A. to reset the
2 Chamfer M 0.45 ± 0.1 X 45° Profile Projecter 5Pcs. Insp. Yes
2 hrs.
Setup /
3 Angle M 90° Profile Projecter 5Pcs. Insp. Yes

For <SC> & Tolerance below than 0.05mm use of Process Control Chart (FM-QA-06) is mandatory.
2 hrs.
Setup /
4 Roughness M 2.5 Roughness tester 5Pcs. Insp. Yes
2 hrs.
Setup /
5 Radius M 0.3 Profile Projecter 5Pcs. Insp. Yes
2 hrs.
Micrometer Setup /
6 Dia M 16.20 ± 0.020 5Pcs. Insp. Yes
L.C. 0.01mm 2 hrs.
Micrometer Setup /
7 Dia M 14.40 ± 0.050 5Pcs. Insp. Yes
CNCTURNING CENTER (SOFT JAW'S & CHUCK

L.C. 0.01mm 2 hrs.

Setup /
8 Dia M 15.0 ± 0.050 Profile Projecter 5Pcs. Insp. Yes

Process Setting Approval Sheet (FM-QA-02)

2 hrs.

Process Inspection Report (FM-PRD-01)

Setup /
9 Chamfer M 0.45 ± 0.1 X 45° Profile Projecter 5Pcs. Insp. Yes
2 hrs.
Vernier Caliper Setup /
10 Length M 1.5 ± 0.10 5Pcs. Insp. Yes

Rejection / Rework
L.C. 0.01mm 2 hrs.
TURNING 1st.

Setup /
11 Length M 4.34 ± 0.05 Profile Projecter 5Pcs. Insp. Yes

Machine.
2 hrs.
Setup /
20 12 Length M 1.8 Profile Projecter 5Pcs. Insp. Yes
2 hrs.

Turning Tool
1 MTJNR 2020 K16 Visually During Setting Setter No
(Rough)
2 Insert TNMG 16 04 04 Visually During Setting Setter Yes

3 RPM 1800~2500 Prog. Display During Setting Setter No

0.18 ~ 0.22
4 Feed Prog. Display During Setting Setter No
mm/rev.
Tool Life Monitoring
5 TCF After --- Pcs. Setter Yes
Sheet (FM-PRD-02)
During Setting
16 Clamping Pressure 15 ~ 18 Kg Pressure Guage Setter Yes
Setting Approval
17 Hyd. Oil Grade 68 At Max. Level Level Gauge Daily Setter Yes
Cutting oil Garde & Clear edge - AA & 4% Every Top Prdn.
18 Special Container Verificati No
concentration Concentration Up Supr.
on of
Oilly, Smelly &
19 Cleaning of Water Visually Every Shift Container Optr. No
Colour Change

Note:
a) Elaborate each Operation in detail, including machine clamping location, resting location, tooling, reference etc.,
b) Use multiple slides as required

Date: Author: 7
2. Process Strategy Detail
BHAGWAN PRECISION
PROCESS CONTROL PLAN
ROHTAK
PART NAME PREV. OPERATION OPERATION NAME NEXT OPERATION OPERATION No.

VALVE TURNING 1st. TURNING 2nd. MILLING 30

PART No. MATERIAL / BAR SIZE LEGENDS REV. No. / DATE : DOCUMENTS No.
M01106066 SAE1018 / ø18.00 Significant - <SC> , Major- M, Minor - m BP-MA-200-182/030

WORK INSTRUCTIONS
1
28.0 ± 0.10
10
A R0
3.0 ± 0.10
1.0 ± 0.10
Ma .6 2
x.

20° ±
3
4

3°
( Ø16.20 )
Rev. No./ Approved
Description (Revisions Detail)
Date By

9 4.0

0.15 A
Ø12.7 ± 0.10
10° 0.65 X 45°
MA 8
X. 5
7
6

vALVE
Dim.
0~6 6 ~ 30 30 ~ 120 120 ~ 315 315 ~ 1000
From to
Tol in
± 0.10 ± 0.20 ± 0.30 ± 0.50 ± 0.80 CLAMPING RESTING LOCATING
mm
Characteristic Methods
Process Specia
Part / Sample
Name Machine Device l Product/process Error Corectiv Reaction
Process Evaluation Measurement Control Resp. Record
Operation Tools For Mfg. No. Product Process Char. Control Proofi e Action Plan
Number Technique Method
Description Class Parameters ng Size Freq.

Vernier Caliper Setup /

1 T Length M 28.0 ±0.15 5Pcs. Insp. Yes
L.C. 0.01mm 2 hrs.

In Case of non confermity Suspected Material, Inform to Producer & Inspector of Q.A. to reset the
Vernier Caliper Setup /
2 Length M 3.0 ±0.10 5Pcs. Insp. Yes
L.C. 0.01mm 2 hrs.

For <SC> & Tolerance below than 0.05mm use of Process Control Chart (FM-QA-06) is mandatory.
Setup /
3 Chamfer M 1.0 ± 0.10 Contracar 5Pcs. Insp. Yes
2 hrs.
Contracar / Profile Setup /
4 Angle M 20° 3' 5Pcs. Insp. Yes
Projecter 2 hrs.
Setup /
5 Concentricity M ø0.15 Wat. A V Block With Dial Stand 5Pcs. Insp. Yes
2 hrs.
Vernier Caliper Setup /
6 Dia M 12.7±0.10 5Pcs. Insp. Yes
L.C. 0.01mm 2 hrs.
CNCTURNING CENTER (SOFT JAW'S & CHUCK

Setup /
7 Chamfer M 0.65 X 45° Profile Projecter 5Pcs. Insp. Yes
2 hrs.

Process Setting Approval Sheet (FM-QA-02)

Contracar / Profile Setup /

Process Inspection Report (FM-PRD-01)

8 Angle M 10° Max 5Pcs. Insp. Yes
Projecter 2 hrs.
Setup /
9 Roughness M 4.0 Roughness Tester 5Pcs. Insp. Yes
2 hrs.

Rejection / Rework
TURNING 2nd.

Machine.
30

Turning Tool
1 MTJNR 2020 K16 Visually During Setting Setter No
(Rough)
2 Insert TNMG 16 04 04 Visually During Setting Setter Yes

3 RPM 1800~2500 Prog. Display During Setting Setter No

0.18 ~ 0.22
4 Feed Prog. Display During Setting Setter No
mm/rev.
Tool Life Monitoring
5 TCF After --- Pcs. Setter Yes
Sheet (FM-PRD-02)
During Setting
6 Clamping Pressure 15 ~ 18 Kg Pressure Guage Setter Yes
Setting Approval
7 Hyd. Oil Grade 68 At Max. Level Level Gauge Daily Setter Yes
Cutting oil Garde & Clear edge - AA & 4% Every Top Prdn.
8 Special Container Verificati No
concentration Concentration Up Supr.
on of
Oilly, Smelly &
9 Cleaning of Water Visually Every Shift Container Optr. No
Colour Change

Note:
a) Elaborate each Operation in detail, including machine clamping location, resting location, tooling, reference etc.,
b) Use multiple slides as required

Date: Author: 8
2. Process Strategy Detail
BHAGWAN PRECISION
PROCESS CONTROL PLAN
ROHTAK
PART NAME PREV. OPERATION OPERATION NAME NEXT OPERATION OPERATION No.

VALVE TURNING 2nd. MILLING HEAT TREATMENT 40

PART No. MATERIAL / BAR SIZE LEGENDS REV. No. / DATE : DOCUMENTS No.
M01106066 SAE1018 / ø18.00 Significant - <SC> , Major- M, Minor - m BP-MA-200-182/040

WORK INSTRUCTIONS

3.0 ± 0.10

(Ø16.20 ± 0.020 )
2

Rev. No./ Approved

Description (Revisions Detail)
Date By

0.5 ± 0.07
( 28.0 ± 0.10 )

vALVE
Dim.
0~6 6 ~ 30 30 ~ 120 120 ~ 315 315 ~ 1000
From to
Tol in
± 0.10 ± 0.20 ± 0.30 ± 0.50 ± 0.80 CLAMPING RESTING LOCATING
mm
Characteristic Methods
Process Specia
Part / Sample
Name Machine Device l Product/process Error Corectiv Reaction
Process Evaluation Measurement Control Resp. Record
Operation Tools For Mfg. No. Product Process Char. Control Proofi e Action Plan
Number Technique Method
Description Class Parameters ng Size Freq.

Vernier Caliper Setup /

In Case of non confermity Suspected Material, Inform to Producer & Inspector of Q.A. to reset the
1 Depth M 0.5 ± 0.07 5Pcs. Insp. Yes
L.C. 0.01mm 2 hrs.
Vernier Caliper Setup /
2 Width M 3.0 ± 0.10 5Pcs. Insp. Yes

For <SC> & Tolerance below than 0.05mm use of Process Control Chart (FM-QA-06) is mandatory.
L.C. 0.01mm 2 hrs.

RPM (End Mill

2000~2500 Program Display During Setup Insp. Yes
3.0mm)

Feed (End Mill) 600~1000 Program Display During Setup Insp. Yes

Operato
Tool Life (End Mill) 800 Pcs. Program Display During Setup Yes
r
Setter/
Clamping Pressure 18 ~ 22 Kg/cm2 Pressure Guage During Setup No

Process Setting Approval Sheet (FM-QA-02)

Operato

Process Inspection Report (FM-PRD-01)

r
Hyd. Oil In Green Zone Level Gauge Daily Setter No

Cutting oil Every

3-5% Refractrometer Daily Setter\ Yes
MILLING MACHINE

Rejection / Rework
concentration Top Up
Oily, Smelly & Colour Every Verification Operato
Cleaning of Water Visually No

Machine.
of
MILLING

Change Shift r
Container
30

Note:
a) Elaborate each Operation in detail, including machine clamping location, resting location, tooling, reference etc.,
b) Use multiple slides as required

Date: Author: 9
2. Process Strategy Detail
BHAGWAN PRECISION
ROHTAK
PROCESS CONTROL PLAN
PART NAME PREV. OPERATION OPERATION NAME NEXT OPERATION OPERATION No.

VALVE MILLING HEAT-TREATMENT GRINDING 50

PART No. MATERIAL / BAR SIZE LEGENDS REV. No. / DATE : DOCUMENTS No.
M01106066 SAE 1018 / ø18.00 Significant - <SC> , Major- M, Minor - m BP-MA-200-182/050

WORK INSTRUCTIONS

1)

( Ø16.20 )
( 28.0 )

NOTE :-
HEAT TREATMENT : CARBURIZING
HARDNESS : HV 500 ± 300
HARDNESS DEPTH : 0.3 ~ 0.55

NOTE : BREAK SHARP CORNERS MAY BE EITHER A CHAMFER OR A RADIUS FROM 0.2mm Min. TO 1.0mm Max.
For Open Dimension Please refer Bhagwan Precision Standard - A
CLAMPING RESTING LOCATING

Characteristic Methods
Process
Part / Sample
Name Machine Device Special Corective Reaction
Process Product/process Evaluation Measurement Error Resp. Record
Operation Tools For Mfg. No. Product Process Char. Class Control Method Action Plan
Number Control Parameters Technique Proofing
Description Size Freq.

Rockwell Hardness
1 Surface Hardness 500 ~ 300 HV1 10 Pcs. Lot Insp. Yes

Inspection
Tester

Report ()
Process
Microvicker Hardness
2 Case Depth 030 ~ 0.55 mm 2 Pcs. Lot Insp. Yes
Tester
Fine Tempered Evaluation Measurement
3 Microstructure 2 Pcs. Lot Insp. Yes
Martensite+(10 % Technique
Incoming Inspection

incomin

materia
Damage on No Damage on

Regist
1 Visually 100% Per lot Insp./ oper. Yes

er
g
surface surface

l
2 Rust No Rust allowed Visually 100% Per lot Insp./ oper. Yes
3 Dia 16.07 / 16.010 Digital Micrometer 100% Per lot Insp./ oper. Yes
Storage
Wi for material handling visual
No rust , damage &
1 Improper storage Visually Lotwise Every Lot inspection for every batch Insp No
dent allowed
inspection tag
2 Improper storage Batch Treceabilty Visually Lotwise Every Lot Route card Insp Yes
Charge Preparation
100% Check Ht Log Book/ Process sheet (F05-
1 Loding Quantity 200 ± 10Kg Wt. Machine Lotwise oper. Yes
Every Lot 5302)
As per work 100% Check Wi for Loding Pattern visual
2 Loding Pattern Visually Lotwise oper. No
instruction Every Lot inspection for every batch
Fixture / Basket As per work 100% Check Wi for fixture / basket visual
3 Visually Lotwise oper. No
Design Ng instruction Every Lot inspection for every batch
Pre Washing
HT log book/process sheet (F05-
1 Jogging (Temp) 70⁰C ±10⁰C Digital Display Lotwise Setting
5302)
Insp Yes

HT log book/process sheet (F05-

2 Jogging (Time) 20 Min By Alarm Lotwise Setting Insp Yes
5302)
3 Jogging(Alkali %) 3% to 5% Refatrometer Daily Daily Daily check sheet Insp Yes
HT log book/process sheet (F05-
4 Spary (Temp) 70⁰C ±10⁰C Digital Display Lotwise Setting Insp Yes

In Case of non confermity Suspected Material, Inform to Producer & Inspector of Q.A. to reset the Machine.
5302)
HT log book/process sheet (F05-
5 Spary (Time) 20 Min By Alarm Lotwise Setting Insp Yes
5302)
6 Spary (Alkali %) 3% to 5% Refatrometer Daily Daily Daily check sheet Insp Yes
HT log book/process sheet (F05-
7 Dry (Temp) 90⁰C ±10⁰C Digital Display Lotwise Setting
5302)
Insp Yes

HT log book/process sheet (F05-

8 Dry (Time) 20 Min By Alarm Lotwise Setting Insp Yes
5302)
Pre Heating
During Setting HT log book/process sheet (F05-
1 Temp. 450⁰C ±10⁰C Digital Display Insp Yes
Setting Approval 5302)
During Setting HT log book/process sheet (F05-
2 Time 60 ± 5 Min By Alarm Insp Yes
Setting Approval 5302)
Carburizing & Hardening
870⁰C ±5⁰C

book/pr
recordi

recordi
1 Carburizing (Temp) Digital Display Lotwise Setting Insp Yes

HT log
Graph
SCAD

ocess

5302)
sheet
(F05-
ng

ng
A
2 Time 45 ± 5 Min By Alarm Lotwise Setting Insp Yes
3 CP % 0.95 ± 0.05% CP Control Lotwise Setting Insp Yes
HEAT TREATMENT

Rejection / Rework
Diffusion

recording

recording

book/pro
±5⁰C

SCADA
1 Temperature 860⁰C Digital Display Lotwise Setting Insp Yes

HT log
Graph

5302)
sheet
(F05-
cess
SQF

2 Time 15 ± 5 Min By Alarm Lotwise Setting Insp Yes

50
3 CP % 0.85 ± 0.05% CP Control Lotwise Setting Insp Yes

Hardening

book/proces

(F05-5302)
1 Temperature 830⁰C ±5⁰C Digital Display Lotwise Setting Insp Yes

recording

recording
SCADA

s sheet
HT log
Graph
2 Time 20 ± 5 Min By Alarm Lotwise Setting Insp Yes
3 CP % 0.80 ± 0.05% CP Control Lotwise Setting Insp Yes

Oil Temp.

book/proce
1 Oil Temp.(°C) 110⁰C ±5⁰C Digital Display Lotwise Setting

recording

recording
Insp Yes

ss sheet
SCADA

HT log
Graph

5302)
(F05-
Agitator Speed Durning
2 100 ± 10 RPM Digital Display Lotwise Setting Insp Yes
quenching
3 Agitator Speed 450 ± 10 RPM Digital Display Lotwise Setting Insp Yes

book/pr
4 LPG 3 LPM Max. Flow Meter Lotwise Setting Insp Yes

HT log

ocess

5302)
sheet
(F05-
5 AIR 1 LPM Max. Flow Meter Lotwise Setting Insp Yes
6 AMMONIA 6 LPM Max. Flow Meter Lotwise Setting Insp Yes
Post Washing
HT log book/process sheet (F05-
1 Jogging (Temp) 70⁰C ±10⁰C Digital Display Lotwise Setting
5302)
Insp Yes

HT log book/process sheet (F05-

2 Jogging (Time) 20 Min By Alarm Lotwise Setting Insp Yes
5302)
3 Jogging(Alkali %) 3% to 5% Refatrometer Daily Daily Daily check sheet Insp Yes
HT log book/process sheet (F05-
4 Spary (Temp) 70⁰C ±10⁰C Digital Display Lotwise Setting
5302)
Insp Yes

HT log book/process sheet (F05-

5 Spary (Time) 20 Min By Alarm Lotwise Setting Insp Yes
5302)
6 Spary (Alkali %) 3% to 5% Refatrometer Daily Daily Daily check sheet Insp Yes
HT log book/process sheet (F05-
7 Dry (Temp) 90⁰C ±10⁰C Digital Display Lotwise Setting
5302)
Insp Yes

HT log book/process sheet (F05-

8 Dry (Time) 20 Min By Alarm Lotwise Setting Insp Yes
5302)
As quench Surface hardness
As quench Surface Microvicker Hardness HT log book/process sheet (F05-
1 750-850 HV1 5 Pcs. Every Lot Insp Yes
hardness Tester 5302)
Tempering
1 Tempering (Temp) 170⁰C ±5⁰C Digital Display Lotwise Setting HT log book/process sheet (F05- Insp Yes
2 Tempering (Time) 90 ± 5 Min By Alarm Lotwise Setting 5302) Insp Yes
Micro Structure
1 - Uniform Martensite MicroScope 2 pcs Every Lot Engg. Yes
Retained Austenite- Metallurgical Test Report / HT log
2 - MicroScope 2 pcs Every Lot Engg. Yes
Microstructure <10% book/process sheet (F05-5302)
3 - Bainite & Ferrite MicroScope 2 pcs Every Lot Engg. Yes
4 - Internal oxidation MicroScope 2 pcs Every Lot Metallurgical Test Report Engg. Yes
Microvicker Hardness
5 Hardness - 700 - 800 HV1 10 pcs Lot Engg. Yes
Tester Metallurgical Test Report / HT log
Microvicker Hardness book/process sheet (F05-5302)
6 Total Case Depth - 0.22 ~ 0.32 mm 2 pcs Lot Engg. Yes
Tester
Charge unloading
Unloading WI & Training to
No dent damage
1 Visually - Visually 1 Every Lot Operators, Superviser check Insp No
allowed

Note:
a) Elaborate each Operation in detail, including machine clamping location, resting location, tooling, reference etc.,
b) Use multiple slides as required

Date: Author: 10
2. Process Strategy Detail
BHAGWAN PRECISION
ROHTAK
PROCESS CONTROL PLAN
PART NAME PREV. OPERATION OPERATION NAME NEXT OPERATION OPERATION No.

VALVE HEAT TREATMENT O.D. GRINDING FINAL INSP. 60

PART No. MATERIAL / BAR SIZE LEGENDS REV. No. / DATE : DOCUMENTS No.
M01106066 SAE 1018 / ø18.0 Significant - <SC> , Major- M, Minor - m BP-MA-200- 182

WORK INSTRUCTIONS
Rz
2 3.2 1)

Ø15.935 / 15.955
1

(28.0)

NOTE : BREAK SHARP CORNERS MAY BE EITHER A CHAMFER OR A RADIUS FROM 0.2mm Min. TO
1.0mm Max.
For Open Dimension Please refer Bhagwan Precision Standard - A CLAMPING RESTING LOCATING

Characteristic Methods
Process Specia
Part / Machine Erro Sample
Name l Product/process Corectiv Reaction
Process Device Tools Evaluation Measurement r Control Resp. Record
Operation Char. e Action Plan
Number For Mfg. No. Product Process Control
Technique Proo Method
Description Class Parameters Size Freq.
fing

For <SC> & Tolerance below than 0.05mm use of Process Control Chart (FM-QA-06) is mandatory.
Air Ring Gauge / D.
1 Dia M 15.935 / 15.955 5 Pcs. 1 Hr. Insp. Yes

In Case of non confermity Suspected Material, Inform to Producer & Inspector of

Micrometer
CENTER LESS GRINDER (GRINDING WHEEL , CONTROL WHEEL & RESTING

2 S. Finish M Rz 3.2 Roughness Tester 2 Pcs. Setup Insp. Yes

Process Setting Approval Sheet (FM-QA-02)

Grinding Wheel During Setting

Process Inspection Report (FM-PRD-01)

14"x6"x4" Vernier Caliper Setter No
Spec. Setting Approval
Control Wheel During Setting

Q.A. to reset the Machine.

9"x3"x4" Vernier Caliper Setter No
Spec. Setting Approval

Rejection / Rework
During Setting
RPM of G. Wheel 1200 Tachometer Setter Yes
O.D. GRINDING

Setting Approval
RPM of Control During Setting
PLATE)

40 ~ 45 Digital Display Setter Yes

Wheel Setting Approval
60
Dressing Freq. of During Setting
2800 ~ 3200 Pcs. Production Record Setter Yes
Control Wheel Setting Approval
Dressing Freq. of During Setting
200 ~ 300 Pcs. Production Record Setter Yes
Grinding Wheel Setting Approval
During Setting
Feed Manually Production Record Insp. No
Setting Approval
During Setting
C.T. 10 Sec. per Cut Auto Cycle Insp. Yes
Setting Approval
Resting Plate During Setting
30° Profile Projector Setter Yes
Angle Setting Approval
Cutting Oil Grade & Castrol A-46 & Special Container & Every Verificati
Setter No
Concentration 2.5~3% Refatrometer Top up on of
Cleaning of Water Oily, Smell, Colour Every In
Visually Optr. No
Tank Change Shift Process

Note:
a) Elaborate each Operation in detail, including machine clamping location, resting location, tooling, reference etc.,
b) Use multiple slides as required

Date: Author: 11
3. Print review / correlation

Note:
a)Use quoted print for the review this need to be ballooned for all dimension
b)Either add an xls attachment or imagine to review dimension by dimension, clarify how will be measure and
how this will be correlated with customer (MPT) incoming inspection method

Date: Author: 12
Final Inspection plan

BPPL PRE DISPATCH INSPECTION REPORT Doc. No.- FM-QA-05

Rev.No./Date- 00
Issue date - 01.12.2017

SUPPLIER NAME : BHAGWAN PRECISION (P)

CUSTOMER NAME : MAGNA LOT QTY.: DATE : 05.06.2018
LTD

I R NO. INV. NO. PART NAME : VALVE PART NO. : M0106066

MEASUREMENT RESULT (OBSEVATION)

INSPECTION SAMPLE
S.NO. DIMENSION SPECIFICATION REMARKS
METHOD SIZE
1 2 3 4 5

1 T .LENGTH 28 ± 0.3 D.V.C 5

2 CHAMFER 0.5 ± 0.1 X 45° P.P. 5

3 I.D ø12.7 ± 0.15 P.P.G./D.V.C 5

4 GROOVE DIA ø15 ± 0.1 P.P. 5

5 O.D ø16 -0.04/-0.07 D.M.M 5

6 COUNTER 1 ± 0.2 CONTOUR TESTER 5

7 CONCENTRICITY ø0.20/A H.G+DIAL 5

8 COUNTER ANGLE 20° ± 5° CONTOUR TESTER 5

9 ROUGHNESS Rz 6.3 R.TESTER 5

10 LENGTH 4.5 P.P 5

11 CHAMFER 0.3 ± 0.15 X 45° P.P. 5

12 DIA ø14.5 -0.2 M.M 5

13 MILLING DEPTH 0.5 D.V.C 5

14 MILLING WIDTH 3 D.V.C 5

15 RADIUS R0.3 P.P 5

16 LENGTH 1.5 ± 0.15 H.G 5

17 ROUGHNESS Rz 6.3 R.TESTER 5

18 THICKNESS 3 ± 0.2 D.V.C 5

CONTOUR TESTER
19 ANGLE 10° MAX 1
/ CUT SECTION

20 ROUGHNESS Rz 25 R.TESTER 5

21 ANGLE 90° P.P 5

22 WIDTH 1.5 P.P 5

CONTOUR TESTER
23 RADIUS R0.6 MAX 1
/ CUT SECTION
CARBURIZING HARDNESS HV
HEAT
24 500 ± 400 , CASE DEPTH 0.1 T.C 1
TREATMENT +0.4 MM

JIS G 4804 SUM24L / EN

25 MATERIAL 10087-1 0718
T.C 1

TO BE FREE FROM BURRS

26 VISUALLY APP. AND SHARP EDGES
VISUALLY 5

PREPARED BY: APPROVED BY :

Date: Author: 13
4. MSA (Gauge concept)

Note:
a) Based on the key features on the print supplier needs to be defined and present tentative gauge strategy for
HIC, KPC, PTC or other dimensions that were selected as critical over the design concept development .
b) Tabulate Gauge / measurement concept & availability status for parameters (as above).

Date: Author: 14
5. Core documents initial review

All critical characteristics defined in drawing or that are <0.05 mm are to be

monitored with control chart.

Note:
a)At this stage objective is to have preliminary documents, with examples for similar application to show how
supplier is planning to control critical features.

Date: Author: 15
6. Lessons Learned
Input the less learn about similar part or same part, both Supplier and MPT.

Date: Author: 16
7. Open issues & Exceptions
• Open Issues, exceptions and comments
• Millipore value required 0.001 g should be relaxed to 0.005g max.
(without RPO) and will be only achieved after ultrasonic cleaning.
• Particles sizes could not be checked as the facility is not available.
• Cut off value and load for checking the E.C.D.
• Material of EN1A (P) to be given optional .
• 100% inspection for all sc characteristics will be carried out in final
inspection except Surface finish, dimension 3.0 .
• For the inspection of dimension 3±0.2 will be checked with pin
inserted in diameter Ø12.7 with sharp edge and the dimension will be
checked from face.
• Since CMM facility is not available so the parts to be checked as per
AOI agreement.

Date: Author: 17