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Kultur Dokumente
Page No :
Prototype
Pre-Launch
Production
1 of 11
Date (Rev. 1) :
Product
Identification
Supplier
Chemical
Composition
Methods
Process
> Verification of
composition %
of elements in
alloy.
Storage
Identification colour
Mark given on Ingot.
(W.I. # 3.19)
Approved sources
Evaluation
Measurement
Technique
Visual
Visual
Third Party
Spectro
analysis
Visual
Sample
Recor Resp
ding
Size
Freq.
Y/N
100%
cont.
100%
cont.
Control Method
>Supplier Invoice
>Supplier T.C.
>Batch wise
Raw
Material
verification
Indent
Reaction Plan
Once Monthly/
Lot
Wise
100%
cont.
(SIGNATURE)
CONTROL PLAN
Page No :
Prototype
Pre-Launch
Process
Machine,
No.
Name /
Device, Jig Tools
Operation
for Mfg.
Description
Shell Core
Making
5336251
Production
Characteristics
Part /
Process
Number
Product
Methods
Process
Spl. Product/Process/
Char. Specification /
Class Tolerance
.
Evaluation
Measurement
Technique
Sample
Recor Resp
ding
Control Method
Reaction Plan
Size
Once
Freq.
per hour
Y/N
Y
> Visual
100%
Cont.
> 60 - 70 Sec
> Visual
100%
Cont.
Dry
(moisture free)
> Visual
100%
Cont.
> Visual
100%
Cont.
> Operators
awareness
> Visual Sample
> Visual
100%
Cont.
> Visual
100%
Cont.
> Visual
100%
Cont.
> Visual
100%
Cont.
10
> Damage
> No Damage
> Visual
100%
Cont.
(SIGNATURE)
CONTROL PLAN
Page No :
Prototype
Pre-Launch
5336251
Production
Characteristics
Part /
Process
Number
Process
Machine, Device, No.
Name /
Jig Tools for Mfg.
Operation
Description
> Crucible
Product
Process
Methods
Spl. Product/Process/
Char. Specification /
Class Tolerance
Evaluation
Measurement
Technique
Sample
Recor Resp
ding
Control Method
Reaction Plan
Size
Freq.
Y/N
100%
Cont.
> Tempreture
Controler
Once
melt wise
> Weight
Once
melt wise
> Re-purified
100%
Cont.
-0
( S I G NAT U R E )
CONTROL PLAN
Page No :
Prototype
Pre-Launch
5336251
Production
Characteristics
Part /
Process
Number
Process
Machine, Device, No.
Name /
Jig Tools for Mfg.
Operation
Description
Product
Process
Methods
Spl. Product/Process/
Char. Specification /
Class Tolerance
.
Evaluation
Measurement
Technique
Sample
Record Resp
ing
Size
Freq.
Y/N
Control Method
Reaction Plan
100%
Cont.
> Tempreture
Controler
> Crucible
Once
per hour
Once
melt wise
Once
melt wise
Once
melt wise
Two
Batch
wise
(Degasser Tablet)
> Dipping Ladle
Mechanical
properties.
( S I G NAT U R E )
CONTROL PLAN
Page No :
Pre-Launch
5336251
Production
Characteristics
Part /
Process
Number
Process
Machine,
No.
Name /
Device, Jig
Operation Tools for Mfg.
Description
Gravity Die
Casting
Product
Methods
Process
Spl. Product/Process/
Char. Specification / Tolerance
Class.
Evaluation
Measurement
Technique
Sample
Recor Resp
ding
Control Method
Reaction Plan
Size
Freq.
Y/N
>Temp. Indicator
Once
per
hour
> Preparation of
Die coat
> Weight
Once
Shift
> Visual
100%
cont.
Once
Start
> Pouring
> Un-interupted
> Same Speed
> Same Distance
> Visual
100%
cont.
> Visual
100%
cont.
> Operator
Awareness
> Q.I.E
1st Pc
Shift
O/I
Dimn. Parameter
( F.P.A)
> Fine
1 Pc
25 Pcs
> Visual
100%
cont.
> Visual
100%
cont.
11 > Product
Identification
> Visual
100%
cont.
(SIGNATURE)
CONTROL PLAN
Page No: 6
Pre-Launch
Production
Characteristics
Part /
Process
Number
Process
Name /
Operation
Description
Cutting of
Runner /
Riser
Machine,
Device, Jig
Tools for
Mfg.
No.
Product
Methods
Process
Spl.
Product/Process/
Char. Specification / Tolerance
Class.
Evaluation
Measurement
Technique
Sample
Size
Fettling
>Bandsaw
Cutting M/c
> Cutting
Blade
Freq.
Control Method
> Visual
100%
cont
> Visual
100%
cont.
100%
cont.
> W. I # 3.9
(for fettling)
>visual
sample
-do-
> Component
Parting Line
Visual
Reaction Plan
Y/N
Segregate &
Reject / Rework
Sharp edge
Smooth
Visual
100%
cont.
Unwanted
Projection
Visual
100%
cont.
- do-
-do-
Inside surface
Visual
100%
cont.
- do-
Recor Resp
ding
-do-
(SIGNATURE)
CONTROL PLAN
Page No: 7
Pre-Launch
Production
Machine,
Device, Jig
Tools for
Mfg.
No.
Product
Size
Freq.
Y/N
90 C 5 c
Temp. Controller
Each
cycle
Vacuum pressure
at Auto Clave
-760 mm of Hg
Pressure Gauge
Each
cycle
Cycle Time
Timer / Watch
Each
cycle
Porosity seal
100%
cont.
Air Pressure
> Pressure
Gauge
100%
cont.
Re-check
> Timer
100%
cont.
> Calibration of
Gauge
> W.I.# 3.14
for LPT
> W.I # 3.14 for LPT
Re-check
100%
cont.
LPT Record
Characteristics
Part /
Process
Number
Process
Name /
Operation
Description
Vacuum
> V.I (IMP)
Impregnation PLANT
Leak Proof
Test
Leak Proof
Vacuum
impregnated
component
-
Methods
Process
Spl. Product/Process/
Char. Specification /
Class. Tolerance
1 Kg / cm
Evaluation
Measurement
Technique
Sample
Recor Resp
ding
Test fixture
> Holding time =
1min
PE/FIX/LPT/3
2
2
Leak Proof
Dipping in water
No Leakage
Visual
(Air Bubble)
Control Method
Reaction Plan
(SIGNATURE)
CONTROL PLAN
Page No : 8
Pre-Launch
Production
Characteristics
10
REV - 01
Methods
No.
Product
Clamping of
component in
Fixture
>Tool change
frequency
Process
Spl. Product/Process/
Char. Specification /
Class. Tolerance
> 8000
> 9000
> 9000
RPM
Feed
900
0.15
> Chamfering
900
0.15
900
0.04
900
0.04
Evaluation
Measurement
Technique
Visual
> Diameter
> Diameter
> Position
> Diameter
> Position
> Width
> Depth
> Height
> Width
> Flatness
> Chamfer
> Chamfer
Sample
Size
Freq.
Y/N
100%
cont.
Tool issue
register
100%
1 Pc
25Pcs
O/I
1 Pc
25Pcs
O/I
> C.M.M
1 Pc
set up
1 Pc
25Pcs
O/I
> C.M.M
1 Pc
set up
1 Pc
25Pcs
O/I
> C.M.M
1 Pc
set up
>
> C.M.M
1 Pc
25Pcs
O/I
1 Pc
set up
/ 0.10
Reaction Plan
(SIGNATURE)
CONTROL PLAN
Page No :
Pre-Launch
Production
Characteristics
Part /
Process
Number
Process
Name /
Operation
Description
11
Deburing
12
High
Pressure
Cleaning
Machine,
Device, Jig
Tools for Mfg.
> Flat file
High Pressure
Cleaning
Machine
No.
Product
Methods
Process
Spl.
Char.
Class.
Product/Process/
Specification /
Tolerance
Evaluation
Measurement
Technique
Size
Freq.
Y/N
Visual
100%
cont.
> Temperture
Controller
100%
cont.
100%
> Facing
surface
> Solvent
Temp.
> 55 C 5 C
> Compressed
air pressure
> 5 to 6 bars
> Component
Cleaning
09
> Visual
Sample
Record Resp
ing
Control Method
Reaction Plan
cont.
REV - 01
( S I G NAT U R E )
n Plan
Re-check
check
Re-check
Re - check
CONTROL PLAN
Page No :
Pre-Launch
Production
Characteristics
Final Inspection /
Pre Dispatch
Inspection
No.
> Diameter
> Diameter
> Width
REV - 01
Product
Methods
Machine,
Device, Jig
Tools for Mfg.
10
Process
Spl.
Char.
Class.
Product/Process/
Specification /
Tolerance
Evaluation
Measurement
Technique
> Depth
> C.M.M
> Flatness
>
> C.M.M
> Diameter
Inner Surface
> Smooth
> Free from
sand particles
Outer Surface
/ 0.10
> Smooth
> Free from
burrs / Sharp edge
& Casting defect.
Sample
Reco Resp
rding
Size
Freq.
Y/N
As per Sampling
Plan
Lot
Visual
100%
Visual
100%
Control
Method
Reaction Plan
( S I G NAT U R E )
CONTROL PLAN
Control Plan Number : PE / CP / 6251 / 11
Page No : 11
Part Name / Description
PIPE, AIR TRANSFER
Prototype
Pre-Launch
Production
Characteristics
Part /
Process
Number
14
Process
Name /
Operation
Description
Packaging
Machine,
Device, Jig
Tools for Mfg.
Methods
No.
Product
Process
Spl.
Char.
Class.
Product/Process/
Specification /
Tolerance
Evaluation Measurement
Technique
Barcode Label 2D
Matrix Barcode
sticker
2D Matrix Barcode
Sticker
as per
cummins Engg. Std
No 18287
Visual
Size
100%
Freq.
cont.
Y/N
N
> Height
20
100%
cont.
100%
cont.
> Height
75
100%
cont.
20
100%
cont.
As per packaging
Standard of
component.
Visual
100%
cont.
15
16
Storage
Dispatch
Sample
Record Resp
ing
Control Method
Reaction Plan
Tagging
Visual
As per Invoice
Visual
100%
cont.
REV - 01
( SIGNATURE)