ASSY PART NAME :- STOPPER BRKT ASSY

ASSY PART NO :-
MODEL :- BRIO
V.CODE ----

Supplier Name & Address :- M/S AGRO ENGINEERING WORKS PLOT NO. 22, SEC-7, IMT MANESAR

Customer Name & Address :- M/s, BRIDGSTONE INDIA AUTOMOTIVE PARTS PVT. LTD.
CHILD PART NAME :- STOPPER BRKT
CHILD PART NO :- 1L0081-13
PCS PAGE NO. 2
PFD PAGE NO. 1
FMEA PAGE NO. 3
Change Level No.:- 00
Mr. RAJNEESH CHOUHAN +91-9911122451
Mr. RAM LAL
CORE TEAM Mr. PIYUSH
Mr. BRIJNEESH SHARMA
Mr. RAHUL SHARMA
DOC SHORT NAME MB
 ASSY. STOPPER BRKT ASSY
PART NAME
INDL. STOPPER BRKT
ASSY. 1L0081-13
PART NO.
INDL. 1LD081-13 (1 )

SL. NO. PROCESS DESCRIPTION PROCESS MACHINE CONTR

AP

GAS
STAGE 1 :
MIG WELDING OF STOPPER ROBOTIC MIG WELDING WEL
10
BKT (1) & BRACKET (2) 350 AMP
THK = 3.2 MM

WELD
 10
BKT (1) & BRACKET (2) 350 AMP
THK = 3.2 MM

STITC

WELD

R- PATROL INSPECTION
LEGENDS AM-AUTOMATIC MEASUREMENT
FOR W-OPERATOR
CONTROL P-PROCESS APPROVAL
IN CHARGE I-INSPECTOR
D-DIE SETTER R
 ASSY. STOPPER BRKT ASSY
PART NAME
INDL. STOPPER BRKT
ASSY. 1L0081-13
PART NO.
INDL. 1LD081-13 (1 )

SL. NO. PROCESS DESCRIPTION PROCESS MACHINE CONTR

20 CHIPPING MANUAL LY STATION SPATTER SHO

BURR AND SCORING MA

30 DEBURRING MANUAL LY STATION
EDGE

AP
40 INSPECTION MANUAL INSPECTION
F

F
 50 FINAL INSPECTION MANUAL INSPECTION AP

60 PACKING & DISPATCH

R- PATROL INSPECTION
LEGENDS AM-AUTOMATIC MEASUREMENT
FOR W-OPERATOR
CONTROL P-PROCESS APPROVAL
IN CHARGE I-INSPECTOR
D-DIE SETTER R

F/DEV/09
 PROCESS CONTROL STANDARD

CONTROL PARAMETER STANDARD SPEC.

NO SPATTER, NO BLOW HOLE, NO UNDER CUT,

APPEARANCE WELDING MISS, UNEVEN WELDING, NO INSIDE
WELDING

CURRENT 180 ~ 220 A

VOLTAGE 18 ~ 21 V

GAS FLOW RATE 12~ 20 LPM

WELDING SPEED 45.0 CM/MIN

WIRE DIA Ø 1.2 mm

20% OF SHEET THICKNESS AND THROAT

WELD PENETRATION LENGTH 70% OF SHEET THICKNESS AND LEG
LENGTH EQUAL TO MIN. SHEET THICKNESS
STITCH OUT LENGTH 10~12mm

WELDING LENGTH 30.0 MM MIN.

REV. NO./DT. DESCRIPTION

 PROCESS CONTROL STANDARD

CONTROL PARAMETER STANDARD SPEC.

SPATTER SHOULD NOT BE THERE SPATTER SHOULD BE NOT

AND SCORING MARK SHOULD NOT BE THERE ON

BURR AND SCORING MARK SHOULD NOT BE THE
EDGES OF THE PART

NO SPATTER, NO BLOW HOLE, NO UNDER CUT,

APPEARANCE
WELDING MISS, UNEVEN WELDING

CD 149± 0.5

CD 178.8± 0.2
CD 77.5± 0.5

CD 40.7± 0.5

CD 12.4± 0.5

CD 18.1± 0.3

CD 3.3± 0.2

CD 14.5± 0.3

DIM 80± 0.5

DIM 41± 0.5

SLOT 15.2±0.2 *14.0± 0.2

SLOT 15±0.2 *13.2± 0.2

DIA Ø 12.5+0.2 mm
FLATNESS 0.25 MAX

FLATNESS 0.3 MAX

FLATNESS 0.25 MAX

DIM 105.2

DIM 175.8

DIM 165

DIM 90.3

DIM 55.4

DIM 59.5±0.5

DIM 21.5

DIM 105.5± 0.4

 DIM 23.4

DIM 39.2

NO PAINT FLOW MARKS, AIR BUBBLE, BLUSTER,

APPEARANCE
LESS COATING THICKNESS ETC

SHOULD BE AS PER CUSTOMER STANDARD

REV. NO./DT. DESCRIPTION

 VENDOR
V.CODE
NDARD
MODEL

CONTROL
CONTROL SPEC INSPECTION METHOD
INCHARGE

NO SPATTER, NO BLOW HOLE, NO UNDER CUT,

WELDING MISS, UNEVEN WELDING, NO INSIDE VISUAL
WELDING

180 ~ 220 A

18 ~ 21 V
CONTROL PANEL
12~ 20 LPM

45.0 CM/MIN I

Ø 1.2 mm MICROMETER / STANDARD

20% OF SHEET THICKNESS AND THROAT

LENGTH 70% OF SHEET THICKNESS AND LEG WELD ANALYSER
LENGTH EQUAL TO MIN. SHEET THICKNESS
 I

10~12mm FLAT SCALE

30.0 MM MIN. VERNIER / TEMPLATE

DATE

ESCRIPTION APPD. BY.

 VENDOR
V.CODE
NDARD
MODEL

CONTROL
CONTROL SPEC INSPECTION METHOD
INCHARGE

HOULD BE NOT THERE VISUAL W

ULD NOT BE THERE ON EDGES OF THE PART VISUAL W

NO SPATTER, NO BLOW HOLE, NO UNDER CUT,

VISUAL
WELDING MISS, UNEVEN WELDING

149± 0.5 RECEIVING GAUGE

178.8± 0.2 RECEIVING GAUGE

 77.5± 0.5 RECEIVING GAUGE

40.7± 0.5 RECEIVING GAUGE

12.4± 0.5 RECEIVING GAUGE

18.1± 0.3 RECEIVING GAUGE

3.3± 0.2 RECEIVING GAUGE

14.5± 0.3 RECEIVING GAUGE

80± 0.5 RECEIVING GAUGE

41± 0.5 RECEIVING GAUGE

15.2±0.2 *14.0± 0.2 RECEIVING GAUGE

15±0.2 *13.2± 0.2 RECEIVING GAUGE I

Ø 12.5+0.2 mm RECEIVING GAUGE

0.25 MAX RECEIVING GAUGE

0.3 MAX RECEIVING GAUGE

0.25 MAX RECEIVING GAUGE

105.2 RECEIVING GAUGE

175.8 RECEIVING GAUGE

165 RECEIVING GAUGE

90.3 RECEIVING GAUGE

55.4 RECEIVING GAUGE

59.5±0.5 RECEIVING GAUGE

21.5 RECEIVING GAUGE

105.5± 0.4 RECEIVING GAUGE

 23.4 RECEIVING GAUGE

39.2 RECEIVING GAUGE

NO PAINT FLOW MARKS, AIR BUBBLE, BLUSTER,

VISUAL I
LESS COATING THICKNESS ETC

R STANDARD W

DATE

ESCRIPTION APPD. BY.

 AGRO ENGINEERING WORKS REV. NO.
---- 0
BRIO PAGE NO.
1/1
SAMPLING SCHEME
RECORDING YES/NO REMARKS
FREQUENCY

n=1
FOA/LOA and n=1
INCASE OF ANY
YES
ABNORMALITY i.e
POWER BREAKDOWN
ETC.

AS PER SIS N 4403

 NO

n=1
YES
FOA/LOA

PREPARED BY. APPD. BY

VENDOR

MSIL
 AGRO ENGINEERING WORKS REV. NO.
---- 0
BRIO PAGE NO.
4/1
SAMPLING SCHEME
RECORDING YES/NO REMARKS
FREQUENCY

100% NO

100% NO
100% NO
 100% NO

100% NO

PREPARED BY. APPD. BY

VENDOR

MSIL
 AGRO ENGINEERING WORKS
BILL OF MATERIAL

PROTOTYPE PRELAUNCH PRODUCTION

Heat Treatment
ASSY Part Child Part Raw Material Raw Material Raw Material
Sub child part Child Part no. Source Qty / Assy Source REMARK
Name/Part no. Name Specification Processed Source
(If Applicable)

STOPPER BRKT ------- 1LD081-13 (1) IN HOUSE SAPH440-P SAPH440-P 1 Nos. M/s TATA STEEL …… ……

STOPPER BRKT
ASSY (1L0081-13)

BRKT ------- 1LD081-13 (2) IN HOUSE SAPH440-P SAPH440-P 1 Nos. M/s TATA STEEL …… ……

PREPARED BY:- APPROVED BY:-

MODEL BRIO AGRO ENGINEERING WORKS (UNIT-II) RESPONSIBLE SECTION.
FORMAT NO : FE /DE/019/ 00

APPROVED CHECKED PREPARED

PART. No 1L0081-13
BY BY BY

PART.NAME STOPPER BRKT ASSY PROCESS FLOW DIAGRAM NARPAL

YADAV
R K DUBEY
AMAN
SAINI
Page: 01 of 01

PROCESS FLOW CHART REV. 01

STOPPER BRKT 1LD081-13 (1) BRKT 1LD081-13 (2) CONDITION OF COMPLETE PARTS
(10)RAW MATERIAL
(10)RAW MATERIAL ARRANGEMENT CLASSIFICATION

No PART.No PART.NAME REMARKS

INHOUSE BOP RAW MATERIAL SOURCE
(20) BLANKING +
PUNCHING

(20) BLANKING + 1 1LD081-13 (1) RING(1) M/s TATA STEEL

PUNCHING

(30) FORMING 1 M/s TATA STEEL

2 1LD081-13 (2) STOPPER (2)

(30) PUNCHING

(40) FORMING 2

(50) FORMING 3 (40) BENDING

(60) RE-STRIKE

(70) PUNCHING

(10 ) MIG WELDING OF STOPPER BRKT + BRKTBRKT NO. 1 + BRKT NO. 2

(20)CHIPPING

(30) Deburring

(40) GAUGING
.

(50)FINAL INSPECTION

`
(60)PACKING & DISPATCH

FLOW CHART SYMBOL :-

PROCESS QUANTITY CHECK CROSS PARTOF FLOW LINE MAINLY AS PROCESSING PARTS AND DOING INSPECTION

MAINLY AS INSPECTING QUALITY AND DOING Q'TY

STORE QUALITY CHECK SUPPLIER PART
INSPECTION
REVISION DETAIL - 01

CHECKED. MFG.
LOADING/UNLOADING FLOW CHART TRANSPORTATION CONNECTOR 1- NOTCHING OPERATION ADDITION FOR BURR
No DATE: 20/3/201 DIRECTION CHANGE MANUFACTURING. APPROVAL