Subject : PPAP Documents

Customer : KAY JAY (TVS MOTOR CO)

Part Name : Needle roller.
Part No. : R1020430
NRB Size : 3X5 BP

NRB Bearings Ltd.

E-40,MIDC Chikalthana,
Aurangabad, INDIA 431 210
 Prep. By : AKG

PPAP Requirements Date : 18.06.2017

Size : 3X5 BP

Req.
Requirement Reference Rev. No. Date Remarks
No.
3X5 BPDrg
1 Design Records of Saleable Product no.131.001.D3
20.12.2005 Attached

Engineering change documents, The Engineering changes has not occurred in the
2
if any Drawing No. : 3X5 BPDrg no.131.001.D3

Customer Engineering approval

3 Not applicable.
if required

4 Design FMEA Not applicable.

5 Process Flow Diagram A/PF1/01 24 15.12.2016 Attached.

6 Process FMEA A/FM/01 24 15.12.2016 Attached.

7 Dimensional results - 01.02.2017 Attached.

8 Material, Performance Test Results 13.07.2016 Attached.

9 Initial Process Capability Study - 01.02.2017 Attached.

10 Measurement System Analysis Study - 01.02.2017 Attached.

11 Qualified Laboratory Documentation 2/8/2014 Standard Room- PL 3.

12 Control Plan A/CP/QC/01 24 15.12.2016 Attached.

13 Part Submission Warrant (PSW) - 18.06.2017 Attached.

14 Appearance Approval Report (AAR) Not Applicable

Bulk Material Requirements Checklist

15 Not Applicable
(for bulk material PPAP only)

16 Sample Product 60000 NOS Nos.

17 Master Sample 2 Nos. Master Samples are retained at NRB.

The Instruments, Gauges and Fixtures list is attached , which are used for
18 Checking Aids Product Measurement.

Records of Compliance with

19 -
Customer-Specific Requirements
 Process Flow
Item : BR,BR60,BSM,BP,BS,TR90(Cutting route) Process Responsibility :
Product:Needle Roller NDL. SOFT & NDL. HARD
Core Team :MDP,MMK,SDS,PRK,CMH,SPS,PSG,NTA,SWRKey Date:1/11/99
Op. Brief Description Incoming Sources of Variation Process Flow Diagram
no.
10 Cutting Wire Coil weight
Wire Dia. Variation
Wire Ovality
Wire Circularity
Wire UTS

20 Hammering LP/LF Difference

and Visual
Lapping a) End bend

30 Heat treatment Microstructure of wire a

130 Q.C.Inspection

70 Grinding / lapping Diameter ( fc & fh )

Bend, circularity, ovality, oily
low CD , mix needle

80 Floor inspection b
110 Polishing Dia allowance for polishing A
/ Washing Visual
a) Grinding mark

120 Visual Mix, damage, grinding mark, C

rust, dust & soft

130 Q.C Inspection

b C

140 Dia grading & Dia range from grinding/ polishing

b d
Length sorting Mix , damage, dirt, dust, rust
( If required) on ndl.
D

150 Stage inspection

A D

160 Packing

170 Finished goods

store
rocess Flow
Process Identification: A/PF/01 Rev. No. 24
Date(Original):30/10/99 Date(Revised): 15.12.2016
Prepared by:PRK Rev by PRK
Product Characteristics Process Charateristics

Length(LP) (IP) Man : Nil

Machine :PM Schedule,Predective
Bend (IP) maintenance
LP/LF Difference (IP) Method:Setup of Cutting Machine
Squareness (IP) Envoirnment: Nil

Visual (FC)
a) End bend
b) Damage mark
c) Roller mark
End form / CD/CR (IP) Man : Nil
fC (IP) Machine :Nil
fH (IP) Method:Soda Water Strength
Length (BP) Envoirnment: Nil
Visual (FC)
a) Rust & Pitting

Hardness (ES) Man :Qualified operators

Microstructure (ES) Machine : PM Schedule,Predective maint.
Method: LPG Flow rate
Hardening temp.
Tempering temp.
Soaking time before quenching(SHF)
Cycle time before quenching(TRR)
Endo Gas Flow rate
Envoirnment: Nil

Hardness, Man : Nil

Length Machine :Nil
Method: Nil
Envoirnment: Nil

Diameter (IP) Man : Nil

Concave, convex, ovality, taper Rev 14Machine :PM
circularity (BP) Schedule,Predective maintenance added
Visual ( FC) Method: Setup of OD Grinding M/c
( Free from grinding, Damage, Envoirnment: Nil
Groove mark etc. )
Surface finish (BP)
( Ra for lapping )

Diameter Man : Nil

Machine :Nil
Method: Nil
 Envoirnment: Nil

Diameter (BP) Man : Nil

Visual (FC) Machine :Nil
a)Free from grinding mark Method:Soda Water Strength
b) Free from dirt, dust, rust Envoirnment: Nil
End relief (BP)

Visual (FC) Man : Trained operators

Free from mix ndls. Machine :Nil
grinding mark, rust, dirt, dust & soft Method: Visual plates
Free from Damage mark, pitting Envoirnment: Nil

Diameter, ccv, cvx, ovality Man : Nil

cir., cyl., surface finish, taper, Machine :Nil
Method: Nil
Squareness, Crowning ( if reqd.) Envoirnment: Nil
Visual Inspection
Free from mix ndls.
damage, grinding mark, rust, dirt,
dust, pitted & soft Needles

Dia.group in required Class. Man : Nil

Length Machine :Nil
Method: Setup of Dia. Grading M/c
Envoirnment: Room temperature.

Diameter Man : Nil

Machine :Nil
Method: Nil
Envoirnment: Nil

Correct Identification Man : Nil

Correct qty. Machine :Nil
Method: Weighing Scale
Envoirnment: Nil

Size and Quantity matching with Man : Nil

Invoice Machine :Nil
Method: Nil
Envoirnment: Nil
 Inspection Report
Size : 3X5 BP Description :

Customer Part No.: R1020430 Customer Name :

Work Order No.: 17S0438 Lot / Order Qty.:

Sr. Samp Observation

Parameter Specification
No. Qty. 1 2 3

1 Outer Diameter 2.990 /3.000 mm 5 2.997 2.998 2.997

2 Length 4.80 / 5.00 mm 5 4.92 4.94 4.90

3 Radius 0.10 /0.50 mm 5 0.25 0.32 0.29

5 Circularity 1.0 m 5 0.42 0.44 0.64

6 Ra on O.D 0.10 m 5 0.05 0.06 0.05

7 Hardness 58 /66 HRc 5 62 61 62

Conforms to SAE 52100 ( Raw material test ce

8 Chem.Composition As per SAE 52100
attached.) 6171F

REMARKS: Accepted.

DISPOSITION CHECKED BY

ACCEPTED REJECTED
BPW
√
T/FO/10/004
 Date : 01.02.2017

Report No. : 01

Description : Needle Roller

Customer Name : KAY JAY (TVS MOTOR CO)

Lot / Order Qty.: 1

Observation
Remarks
4 5

2.999 2.998 ok

4.92 4.91 ok

0.35 0.37 ok

0.61 0.74 ok

0.06 0.04 ok

63 62 ok

100 ( Raw material test certificate

ached.) 6171F

APPROVED BY

PRK
 Prep. By. : AKG
Initial Process Study Report
Date:- 01.02.2017

Customer KAY JAY

(TVS MOTOR Customer Part No:- R1020430 NRB Size:- 3X5 BP
Name :- CO)

Sr. No. Part Name Parameter Pp Ppk Result

1 Needle roller. Length. 2.66 2.28 OK

Fixture: NA. Dial Micrometer 0-25 Work Order No:- Least Count 0.01mm

Length. Upper spec. 5.000

Collected &
Characteristic: 17S0438 Reported by:
sgn
Lower spec. 4.800

Enter the data from the row below (Enter 5 data in one row - Sample size - 5) Avg Range
Group-1 4.92 4.90 4.91 4.93 4.93 4.92 0.03

Group-2 4.94 4.94 4.90 4.92 4.90 4.92 0.04

Group-3 4.90 4.91 4.93 4.91 4.93 4.92 0.03

Group-4 4.94 4.90 4.92 4.90 4.92 4.92 0.04

Group-5 4.90 4.91 4.93 4.91 4.93 4.92 0.03

Group-6 4.94 4.90 4.92 4.90 4.92 4.92 0.04

Group-7 4.94 4.90 4.92 4.90 4.90 4.91 0.04

Group-8 4.91 4.93 4.91 4.93 4.91 4.92 0.02

Group-9 4.90 4.92 4.90 4.92 4.90 4.91 0.02

Group-10 4.91 4.93 4.91 4.93 4.92 4.92 0.02

Group-11 4.90 4.92 4.90 4.92 4.91 4.91 0.02

Group-12 4.94 4.90 4.92 4.90 4.90 4.91 0.04

Group-13 4.91 4.93 4.91 4.93 4.90 4.92 0.03

Group-14 4.90 4.92 4.90 4.92 4.91 4.91 0.02

Group-15 4.91 4.93 4.91 4.93 4.90 4.92 0.03

Group-16 4.90 4.92 4.90 4.92 4.92 4.91 0.02

Group-17 4.90 4.92 4.90 4.92 4.90 4.91 0.02

Group-18 4.91 4.93 4.91 4.93 4.92 4.92 0.02

Group-19 4.90 4.92 4.90 4.92 4.91 4.91 0.02

Group-20 4.90 4.92 4.90 4.92 4.91 4.91 0.02

Group-21 4.91 4.93 4.91 4.93 4.91 4.92 0.02

Group-22 4.94 4.90 4.92 4.90 4.90 4.91 0.04

Group-23 4.91 4.93 4.91 4.93 4.92 4.92 0.02

Group-24 4.90 4.92 4.90 4.92 4.91 4.91 0.02

Group-25 4.91 4.93 4.91 4.93 4.90 4.92 0.03

Pp = 2.66 Max Reading = 4.940

Ppk = 2.28 Min Reading = 4.900 Approved By:-PRK

Sigma 0.0125 Total Samp 125

3 Sigma 0.0376 Subgr Samp 5
6 Sigma 0.0752
X - Avg. 4.91
 4 44
Prep By : AKG
Measurement System Analysis
Studies Report (Variable) Date : 01.02.2017

Sr. Instrument / Calibration R&R

Parameter Code No. Least Count Linearity (µ) % Result
No. Gauge Type Freq. %

Column
1 Diameter BC-03 12 months 0.0002 mm _ 9.82 OK
Comparator

2 Micrometer Length M-175 6 months 0.01 mm _ 9.16 OK

Approved
Prepared By: AKG PRK
By:
 GAUGE REPEATABILITY AND REPRODUCIBILITY STUDY

Part Name = 3X5 BP Gauge Name = Column Comparator

Characteristic = Diameter Gauge No.= BC-03
Specification Min = 2.990 mm Gauge Type = Variable
Specification Max = 3.000 mm L. C.= 0.0002 mm
Tolerance = 0.010 mm Date = 01.02.2017
Appraiser A = L.J.WAGH B = S.M.DESAI C = A.R.PAWAR
PART
Appraiser /
Average
Trial # 1 2 3 4 5 6 7 8 9 10
1. A 1 2.9960 2.9958 2.9954 2.9952 2.9953 2.9956 2.9952 2.9950 2.9950 2.9954 2.995
2. 2 2.9960 2.9958 2.9954 2.9952 2.9953 2.9956 2.9952 2.9950 2.9950 2.9954 2.995 T
K
4
2
3
3. 3 2.9958 2.9958 2.9952 2.9952 2.9953 2.9956 2.9952 2.9950 2.9950 2.9954 2.995 r1.
5i
0
4. Average 2.9959 2.9958 2.9953 2.9952 2.9953 2.9956 2.9952 2.9950 2.9950 2.9954 Xa bar = 2.995 a
6
5
5. Range 0.0002 0.0000 0.0002 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 Ra bar = 0.000 l
s
6. B 1 2.9958 2.9958 2.9954 2.9952 2.9954 2.9956 2.9952 2.9952 2.9950 2.9954 2.995
7. 2 2.9960 2.9958 2.9954 2.9952 2.9954 2.9956 2.9952 2.9950 2.9950 2.9954 2.995
%
E
8. 3 2.9958 2.9958 2.9952 2.9952 2.9954 2.9956 2.9952 2.9950 2.9950 2.9954 2.995
V
9. Average 2.9959 2.9958 2.9953 2.9952 2.9954 2.9956 2.9952 2.9951 2.9950 2.9954 Xb bar = 2.995
%
10. Range 0.0002 0.0000 0.0002 0.0000 0.0000 0.0000 0.0000 0.0002 0.0000 0.0000 Rb bar = 0.000 A
A
2.9960 2.9958 2.9954 2.9952 2.9954 2.9956 2.9952 2.9950 2.9950 2.9954 2.995 3V
2
A =
11. C 1
p V
12. 2 2.9958 2.9958 2.9954 2.9952 2.9954 2.9956 2.9952 2.9950 2.9950 2.9954 2.995 K
p=
13. 3 2.9958 2.9958 2.9952 2.9952 2.9954 2.9956 2.9952 2.9950 2.9950 2.9954 2.995 r2%
a1=
14. Average 2.9959 2.9958 2.9953 2.9952 2.9954 2.9956 2.9952 2.9950 2.9950 2.9954 Xc bar = 2.995 R
i0
15. Range 0.0002 0.0000 0.0002 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 Rc bar = 0.000 s&0
eR&
16. Part X dbar = 2.995 [
2.99589 2.99580 2.99533 2.99520 2.99537 2.99560 2.99520 2.99502 2.99500 2.99540 r1
%
s0
E
Average Rp = 0.001 P R
P[
V
17.R dbar = [ Ra bar + Rb bar + Rc bar] / [ # of Appraisers ] = R dbar = 0.000 V0 V
=
/([
8
T
18.X bar DIFF = [ Max Xbar ] - [ Min Xbar ] = X bar Diff = 0.000 A
=
V
V
D
19. UCLR = [ R dbar ] x [ D4 = 3.27 for 2 trials & 2.58 for 3 trials ] = UCLR = 0.000 =
1
]/
=I0 T
20. LCLR = 0 (For less than 7 trials) LCLR = 0.000 T
V
0
F

Measurement Unit Analysis % of Total Variation 1[V R

F

Repeatability - Equipment Variation (EV)

0](R p
0& x
E
EV = R dbar x K1 Trial K1 % EV = 100 ( EV / Total Variation )
[V R
x2
= 0.0000 2 0.8862 = 9.81 %
P/= K
3 0.5908
VT K
2
Reproducibility - Appraiser Variation (AV) /V +
)3
AV = [ (X bar DIFF x K2)2 - ( EV2 / n x r)] % AV = 100 ( AV / Total Variation ) T2]
= 0.0000 Appraisers 2 3 = 0.51 % V=
K2 0.7071 0.5231
](
A
R
-
(n = Number of parts, r = Number of trials) V
&
Repeatability & Reproducibility ( R & R ) 1
2
R
R & R = ( EV2 + AV2 ) % R & R = 100 ( R & R / Total Variation ) 0
)(2
=
0
= 0.0000 = 9.82 % =
E
Parts K3 [
+
V
Part Variation ( PV ) 2 0.7071 _
2
PV = Rp x K3 3 0.5231 % PV = 100 ( PV / Total Variation )
_
1
/_
= 0.0003 4 0.4467 = 99.52 % =0 (n
/_
5 0.4030 0
P
r_
Total Variation ( TV ) 6 0.3742 Number of Distinct Categories (ndc) 1[V )_
7 0.3534 0]_ 2
]x
TV = (R & R2 + PV2 ) 8 0.3375 ndc = 1.41 * ( PV / R & R ) 0_ )
= 0.0003 9 0.3249 = 14 [= _
=
10 0.3146 _/_
Conclusion :- __ _
The Measurement system is Acceptable / Not Acceptable for measuring Critical / Gauge R & R % _
1
_
Major / Minor characteristic. /]0
Criteria :- 1) If % GRR is 0 - 10%, Acceptable for Critical, Major & Minor characteristic. _0 =
2) If % GRR is 10 - 30%, Acceptable for Major & Minor characteristic only.
3) If % GRR is > 30%, Not Acceptable for all characteristic. 9.82 _[
]_ (
4) If ndc is > or = 5, then it is acceptable. _
Approved by:PRK _
Decision : Gauge Acceptable
T/FO/11/04
P for Critical, Major & Minor characteristic. =
_/=
[=
_
(_
_
_
_
2
_
]_
(_
_
_
_
=_ +
_
=
_
x
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__ %
__ _
__ 2
_
__
__
2
)
__ +
2

__ )
% _
%
_
-
n
_
_
=
(2
=
)
N
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u
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m
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%
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P
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a
=
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=
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 GAUGE REPEATABILITY AND REPRODUCIBILITY STUDY

Part Name = 3X5 BP Gauge Name = Micrometer

Characteristic = Length Gauge No.= M-175
Specification Min = 4.80 mm Gauge Type = Variable
Specification Max = 5.00 mm L. C.= 0.010 MM
Tolerance = 0.200 mm Date = 01.02.2017
Appraiser A = L.J.WAGH B = S.M.DESAI C = A.R.PAWAR
PART
Appraiser /
Average
Trial # 1 2 3 4 5 6 7 8 9 10
1. A 1 4.85 4.84 4.84 4.89 4.86 4.89 4.88 4.86 4.85 4.84 4.860
2. 2 4.85 4.84 4.84 4.89 4.86 4.89 4.88 4.86 4.85 4.84 4.860 T
K
4
2
3
3. 3 4.85 4.84 4.84 4.89 4.86 4.89 4.88 4.86 4.85 4.84 4.860 r1.
5i
0
4. Average 4.85 4.84 4.84 4.89 4.86 4.89 4.88 4.86 4.85 4.84 Xa bar = 4.860 a
6
5
5. Range 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Ra bar = 0.000 l
s
6. B 1 4.84 4.85 4.89 4.84 4.86 4.89 4.89 4.86 4.85 4.84 4.861
7. 2 4.84 4.85 4.89 4.84 4.86 23.80 4.89 4.86 4.85 4.84 6.752
%
E
8. 3 4.84 4.85 4.89 4.84 4.86 4.89 4.89 4.86 4.85 4.84 4.861
V
9. Average 4.84 4.85 4.89 4.84 4.86 11.19 4.89 4.86 4.85 4.84 Xb bar = 5.491
%
10. Range 0.00 0.00 0.00 0.00 0.00 18.91 0.00 0.00 0.00 0.00 Rb bar = 1.891 A
A
4.89 4.84 4.89 4.84 4.85 4.85 4.85 4.86 4.85 4.84 4.856 2=
A
3 V
pV
11. C 1
12. 2 4.89 4.84 4.89 4.84 4.85 4.85 4.85 4.86 4.85 4.84 4.856 K
p=
2
13. 3 4.89 4.84 4.89 4.84 4.85 4.85 4.85 4.86 4.85 4.84 4.856 r%
a=1
14. Average 4.89 4.84 4.89 4.84 4.85 4.85 4.85 4.86 4.85 4.84 Xc bar = 4.856 R
i0
15. Range 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Rc bar = 0.000 s&0
e&R
[
16. Part X dbar = 5.069
4.86 4.84 4.87 4.86 4.86 6.98 4.87 4.86 4.85 4.84 r1
% E
Average Rp = 2.138 P0
s R
P
[
V
VV0
=
17.R dbar = [ Ra bar + Rb bar + Rc bar] / [ # of Appraisers ] = R dbar = 0.630 (
[/
8
T
18.X bar DIFF = [ Max Xbar ] - [ Min Xbar ] = X bar Diff = 0.635 A
=
V
V
D
19. UCLR = [ R dbar ] x [ D4 = 3.27 for 2 trials & 2.58 for 3 trials ] = UCLR = 1.622 ]=
1
/T
=0 I
20. LCLR = 0 (For less than 7 trials) LCLR = 0.000 T
V
0
F

Measurement Unit Analysis % of Total Variation 1[V R

F

0R ](p
Repeatability - Equipment Variation (EV)
0E x&
EV = R dbar x K1 Trial K1 % EV = 100 ( EV / Total Variation )
= 0.3724 2 0.8862 = 9.84 %
[R xV
P= K
2
/
3 0.5908
VT K
2
Reproducibility - Appraiser Variation (AV) /+ )3
V
AV = [ (X bar DIFF x K2)2 - ( EV2 / n x r)] % AV = 100 ( AV / Total Variation ) T]2
= 0.3253 Appraisers 2 3 = 0.52 % V=
K2 0.7071 0.5231
](
A
R
-
(n = Number of parts, r = Number of trials) V
&
Repeatability & Reproducibility ( R & R ) 1
2
R
R & R = ( EV2 + AV2 ) % R & R = 100 ( R & R / Total Variation ) 0
)(2
=
0
= 0.4945 = 9.16 % =
E
Parts K3 [
+
V
Part Variation ( PV ) 2 0.7071 _
2
_
PV = Rp x K3 3 0.5231 % PV = 100 ( PV / Total Variation ) 1
/
_
= 0.6725 4 0.4467 = 99.54 % =0 (n
_
/0
5 0.4030 P
r
_
Total Variation ( TV ) 6 0.3742 Number of Distinct Categories (ndc) 1[V )_
7 0.3534 02_ ]x]
TV = (R & R2 + PV2 ) 8 0.3375 ndc = 1.41 * ( PV / R & R ) 0_ )
= 0.8348 9 0.3249 = 14 [= _
10 0.3146 _/= _
Conclusion :- __ _
The Measurement system is Acceptable / Not Acceptable for measuring Critical / Gauge R & R % _
1
_
Major / Minor characteristic. /0 ]
Criteria :- 1) If % GRR is 0 - 10%, Acceptable for Critical, Major & Minor characteristic. _0 =
2) If % GRR is 10 - 30%, Acceptable for Major & Minor characteristic only.
3) If % GRR is > 30%, Not Acceptable for all characteristic. 9.16 _[
](_
4) If ndc is > or = 5, then it is acceptable. _
Approved by:PRK _
Decision : Gauge Acceptable
T/FO/11/04
P for Critical, Major & Minor characteristic. =
_/=
[=
_
(_
_
_
_
2
_
]_
(_
_
_
_
=+ _
_
=
_
x
_
__ %
__ _
_2_ _
__
__
2
)
__ +
2

_)_
% _
%
_
-
n
_
_
=
2
(
=
)
N
_
u
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m
_
2
b
/
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e
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r=
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_
o
)%
f]

P
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=
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