Ppap 067

(AN ISO/TS 16949:2009 Co.
41/21-21-22, SITE-4, INDL. AREA SAHIBABAD , GHAZIABAD (UP) -201010 PHONE No.0120-2896926,3265914 FAX: 0120-2897522 E-MAIL : splgandhi@ yahoo.com
PRODUCTION PART APPROVAL PROCESS PART NAME: STAY SUCT . HOSE PART NO: 146542 - 833
CUSTOMER M/S .SUBROS LTD.
P P A P INDEX
PART NAME PART No. BRACKET Customer Name S# 01 PSW 02 DESIGN RECORD 03 ECN DOCUMENT 04 CUSTOMER ENGR APPROVAL 05 DESIGN FMEA 06 PFD 07 PROCESS FMEA 08 LAYOUT INSP. 09 MATERIAL TEST REPORT 10 QUALITY LAB. DOCUMENTS 11 INITIAL PROCESS STUDY 12 CONTROL PLAN 13 CHECKING AIDS 14 M.S.A(R&R) 15 BULK MATERIAL REQUIRED LIST 16 SAMPLE 17 MASTER SAMPLE 18 RECORD OF CUSTOMER COMP. 19 CUSTOMER SPECIFIC REQ. 20 QUALITY PLAN 21 WORK INSTRUCTION SHEET DESCRIPTION YES
STAY SUCT. HOSE 146542 - 833 M/S SUBROS LTD.

NO N/R REMARKS
PREPARED BY: KAPIL TOMAR
APPROVED BY: VINOD ARYA
STPL
Part Name : STAY SUCT. HOSE
PART SUBMISSION WARRANT

( F-09-01) Cust. Part Number 146542 - 833 Org. Part Number: 0 Nil Yes Dated Dated No Purchase Order No. Dated
ISSUE REVISION DATE
Shown on Drawng No. Engineering Change Level Additional Engineering Changes Safety and/or Government Regulation Checking Aid No.
Weight (Kg)
STPL/ SUB / CA/ 833 Checking Aid Engineering Change Level
29/06/2013
ORGANIZATION MANUFACTURING INFORMATION
Organization Name & Supplier/ Vendor Code SPECIAL TOOLS PVT. LTD. Street Address 41/20-21-22,Site-4, Inds. Area City Region Postal Code Country Application Shahibabad Ghaziabad 201010 India MATERIALS REPORTING Has Customer-required Substances of concern information been reported?. Submitted by IMDS or other customer format Are Polymeric parts identified with appropriate ISO marking codes? REASON FOR SUBMISSION o Initial Submission o Engineering Change(s) o Tooling Transfer , Reaplacement ,Refurbishment or additional o Correction of Discrepancy o Tooling inactive > than 1 year REQUESTED SUBMISSION LEVEL (Check one) :
CUSTOMER SUBMITTAL INFORMATION SUBROS Customer Name / Division MANESAR Buyer / Buyer Code
o Yes
o No
o Yes
o No
o Change to Optional Construction or Material o Supplier or Material Source Change o Change in Part Processing oParts Product at Additional Location o Other-Please Specify below
o Level 1 - Warrant only (and for designated appearance items, an Apperance Approval Report ) submitted to customer o Level 2 - Warrant with product samples and limited supporting data to customer. o Level 3 - Warrant with product samples and complete supporting data submitted to customer. o Level 4 - Warrant & other requirements as defined by customer o Level 5 - Warrant with product samples and complete supporting data reviewed at organizatio's manufacturing location. SUBMISSION RESULTS The result for dimensional measurements material & functional test and Yes No appearance criteria Statistical process package
The result meet all drawing and spacifaction requirement :
(if "No" - Explanation Required)
Mold / Cavity / Production Process.. DECLARATION I affirm that the samples represented by this warrant are representative of our parts which were made by a procss that meets all Producion Part Approval Process manual 4 th edition Requirements. I further warrant these samples were produced at the production rate of _____ /_____hours. I also certify that documented evidence o such compliance is on file and available for below. I have noted any deviation from this declaration below. EXPLANATION/COMMENTS:. Is each Customer Tool properly tagged and numbered? Organization Authorised Signature. . Print Name : Title SANDEEP SHARMA PLANT HEAD Phone No. : Email o Yes o No Dated 9811556757 FAX No. : oNa
splgandhi@yahoo.com
Part Functional Approval : oApproved oWaived Date Customer Tracking Number (Optional)
For Customer Use only (If Applicable) Part Warrant Disposition : oApproved Customer Signature Print Name
oRejected
oother
:A : 01 : 24-11-2006
0.110
29/06/2013
oN/a
oN/a
Statistical process package
meets all Producion Part rate of _____ /_____hours. n from this declaration below.
PROCESS FLOW DIAGRAM

( F-09-02)
ISSUE REV DATE
: : :
A 0 01-11-01
Part No. Part Name Customer
146542 - 833 STAY SUCTION HOSE M/S SUBROS LTD.
Report No. Date Of Issue Rev. Status 2) BRACKET
S.T.P.L/SUB./PFD 833 10/7/2013 0 3) BOLT
1) STAY SUCT. HOSE
FLOW
S.NO
PROCESS
FLOW
S.NO
PROCESS
FLOW
S.NO
PROCESS
STORAGE INCOMING INSPN. ( R/M) BLANKING + PUNCHING NOTCH BENDING BENDING CHILD PART WELDING
STORAGE INCOMING INSPN. BLANKING
STORAGE INCOMING INSPN.
3A
10 20
2A 2B
30
2C
BENDING
40
50
60 BOLT WELDING
70
POWDER COATING INCOMING INSPECTION FINAL INSPECTION PACKING PRE DISPATCH AUDIT
` `
80
90
100
110
120
DISPATCH
Transfer Storage Inspection Oeration cum Inspection Operation
Prepared By : NEERAJ SHUKLA
Approved By: VINOD ARYA
STPL
Prototype Pre-Launch Production Control plan number : STPL/SUB/CP/833 Product number / Latest change level :: 146542-833
CONTROL PLAN (F-09-04)

Key contact : Vinod Arya Phone Nos: 9560033352
Core Team: Mr.Vinod Arya, AMIT(Q.A).PANKAJ(podn.),Surander(Store),Sachin Kumar(Dispatch)
Page :
Date ( Orig. ): Date(Afact.) : 10/7/2013 10/7/2013
Customer Engineering Approval / Date(if Reqd.) :- Customer Quality Approval/Date (if Reqd.)
Product Name / Description : STAY SUCTION HOSE Supplier / plant: Special Tools Pvt Ltd.
Part Process No. M/c, Device, Jig, Tools for mfg., Customer Information
Supplier / Plant approval Date: Csupplier Code :

Characteristics
Other Approval Date ( if Reqd) : Specs/Char Class
-----
Other Approval Date (if Reqd.) :-----Methods
Process
Product
S. No
Process Name / Opn. Description
Product / Process Specs. Tolerance
Sample Evaluation Meas. Technique Size Freq. Control Method Error Proofing Reaction Plan Corrective Action
1 2 10 Incoming INSPN. 3
MATERIAL THICKNESS Appearance
SPCC - SD 3.20.20 No Burr No Dent No Scratch.
SPPLR. SPECTRO LAB
1Pcs n=5
Per Year PerLot IQIR
MICRO METER Visual
REJECT / STOP
Inform to supplier and quality head / Segregate the material
Power Press 50 - 100Tons Blanking + Punching Tool 1/3
1 THICKNESS 2 HOLE DIA 3 HOLE DIA 4 DIM 5 DIM
3.20.20
MICRO METER
5 Nos
F.M.L
Side Gauges and Stoper Pin
6.50.5 60.5 9.20.5 121 16.21 No Burr No Dant/Scr. No Blank Short
V.C V.C V.C V.C H.G Visual

Q.M.C
provided
20
Blanking +Punching
6 DIM Appearance
REJECT / STOP
Inform to rpoduction and quality head / rectify and tool / segregate the material
Power Press 30-60 Tons 30 Notch Bending

Bending Tool 2/3
1 ANGLE 2 DIM
140 14.31
No Dent/ No Scratch.
PP H.G
5 Nos F.M. L.
Q.M.C
stopper pin and gauges in tool
REJECT / STOP
Power Press 60 -100Tons

Bending Tool 3/3
1 DIM 2 DIM 3 DIM 4 Appearance
25.70.5 81.400.50 27 No Crack No Dent/ No Scratch.
HG HG HG Visual
5 Nos F.M. L.
sttoper pin and gauges in tool
40
Bending
Q.M.C
REJECT / STOP
CHILD BRACKET
1 2 2A Incoming INSPN. 3 MATERIAL THICKNESS Appearance SPCC - SD 1.2t No Burr No Dent No Scratch.
SPPLR. SPECTRO LAB
1Pcs n=5
Per year PerLot IQIR
MICRO METER Visual
REJECT / STOP
STPL

Page :
Product Name / Description : STAY SUCTION HOSE Supplier / plant: Special Tools Pvt Ltd. Power Press 10 - 30 Tons Csupplier Code :
Supplier / Plant approval Date: Other Approval Date ( if Reqd) : 1.2t ----5 Nos
Other Approval Date (if Reqd.) :-----F.M.L
1 THICKNESS 2 APPEARANCE
MICRO METER

Q.M.C
No Burr No Dant/Scr. No Blank Short
VISUAL
2B
Blanking
Blanking.Tool 1/2
provided
REJECT / STOP
Power Press 10 - 30 Tons
1 THICKNESS 2 DIM
1.2t
MM H.G
5 Nos F.M. L.

Q.M.C
4.170.5
2C
Bending
Bending Tool 1/2
provided
REJECT / STOP
MIG Welding
1 DIM 2 DIM 3 APPEARANCE
0.40.1 19.70.5
H.G V.C VISUAL
5 Nos F.M. L.
Parameter controler provided

Q.M.C
Inform to rpoduction
50
Child Part Welding
on m/c
REJECT / and quality head / Correct the process / STOP

segregate the material
BOLT M6 X15
1 2 3A Incoming Inspection No Dent No Scratch. MIG Welding THREAD APPEARANCE M6 X 15 No Burr TRG Visual I.Q.I.R n=5 PerLot
REJECT / STOP
1 THREAD 2 APPEARANCE
M6X15 No Crack
TRG Visual
5 Nos F.M. L.
Parameter controler
Q.M.C
Inform to rpoduction
60
Bolt Welding
provided on m/c
REJECT / and quality head / Correct the process / STOP

segregate the material
70
E.D PAINT
OUT SOURCE
1 2 SST THICKNESS APPEARANCE as per standard 20 Min NO BLISTER NO PITTED NO PEEL OFF n=1 n=5 Per Year PerLot IQIR
80
Incoming Inspection
TIME CONTROLER PROVIDED AT OVEN
REJECT / STOP
Inform to Supplier and quality head / Segregate the material
STPL

Page :
Product Name / Description : STAY SUCTION HOSE Supplier / plant: Special Tools Pvt Ltd. 1 2 3 4 5 6 7 8 9 90 Final Inspection 10 11 Csupplier Code : THICKNESS DIM DIM DIM ANGLE HOLE DIA DIM DIM THREAD PLATING THICKNESS APPEARANCE
Supplier / Plant approval Date: Other Approval Date ( if Reqd) : 3.20.20 9.20.5 25.70.5 0.4 19.71 6.50.5 81.40.5 16.21 M6 X 15 20 Min NO BLISTER NO PITTED NO PEEL OFF NO CRACK NO DENT NO SCRATCH ----M.M V.C H.G H.G PP V.C H.G H.G TRG THICKNESS TESTER VISUAL n=5 n=5 n=5 n=5 n=2 n=5 Per lot
Other Approval Date (if Reqd.) :-----As per final inspection standard
REJECT / STOP
Inform to Production and quality head / Segregate the material / Stop the dispatch
Manual
Appearance
No Burr No Rusty
Visual
100%
Per Pre dispatch audit Lot
Stop the dispatch
100
Packing
No Scratches No Operation Missing
REJECT / STOP
and segregate the
material
Manual 1 Packing 2 Qty 110 Pre Dispatch AUDIT 3 Leveling 4 Insp. Report Compare with invoice Qty& Packing Slip Qty REJECT / STOP 120 Dispatch As per Costumer Requirement REACTION PLAN
1. REJECT THE LOT AND INFORM THE SUPERVISOR / QAD 2. CORRECT THE PROCESS AND CONTINUE 3. STOP THE PROCESS AND INFORM THE SUPERVISOR 4. ALL REACTION PLAN INVOKES 100 % INSPECTION
Visual
100%
Per Lot Customer Feedback
PROCESS - FMEA
F:09-03 Item : STAY SUCTION HOSE ( 146542 - 833 ) Model Year / Vehicle :
Part/ Proc. No.
ISSUE : A REV. DATE : 00 : 01.11.01
Org. Date Key Date :
10/7/2013 10/7/2013
O C C Current process control prevention Current process control detection D E T
FMEA NO :STPL / SUB/ FMEA/833
Rev '00
Action Results Action Taken S E V O C C D E T R P N
Core Team : SANDEEP SHARMA ( PLANT HEAD),VINOD ARYA, AMIT (Q.A),PANKAJ(Prdn.), Surander Singh(Store)
Process/ Function Requirements
Potential Failure Mode Potential Effects of Failure
S E V
C L A S
Potential Cause of Mechanism of Failure
R P N
Recommended Actions
Responsibility & Target Completion Date
10
1) Wrong PO given to supplier 2) Defective material supplied by supplier 6 3) Incoming inspection failure.
1) issuing RM PO with part R/M 2 STD. 2) Supplier Test Certificate and 2 material received in single heat number 3)Before Start Process Check By Q.C Insp. Or Make Q.M.C
72
Thickness undersize
Life of component less, Wrinkle, Burr etc.
72
72
1) Wrong PO given to supplier 2) Defective material supplied by supplier Thickness oversize Die damaged, Thinning, Crack. 6 3) Incoming inspection failure.
1) issuing RM PO with part R/M 2 STD. 2) Supplier Test Certificate and material received in single heat 2 number 3)Before Start Process Check By Q.C Insp. Or Make Q.M.C compare with master list of R/M & IQIR
72
72
72
INCOMING INSPECTION Width under / over Size
1) Wrong PO given to supplier Difficult for location 4 2) Defective material supplied by supplier 3) Incoming inspection failure. Material preservation is not proper Rusty material supplied by supplier Wrong property Material supplied by Supplier Improper preservation Transportation Problem 1. Die & Punch Wear Out 2. Imroper Clearance in Die.
1) issuing RM PO with part R/M 2 STD. 2) Supplier Test Certificate and 2 material received in single heat number 1) issuing RM PO with part R/M 2 STD. SHEET WIDTH OR THIK.
48
48
48
Part Cracking Problem Damage & Excess oil Appearance poor Physical & Chemical Properties Rust Dent and Deformation Next Operation Part Cracking/ Wrinkle Problem Life of component less Produce rusty parts Appearance poor Crack developed / Tool wear out handling Fitment Problem / Difficult in handling.
5 5 5 5 5 5 7
3 3 3 3
R/M incoming inspection R/M incoming inspection
As Per Standerd & IQIR
6 6 6 6 6 6
90 90 90 90 90 90 84 100% Ins. Befoure Dispatch & Training Provided for Packing Associate
Compare TC with standard R/M incoming inspection IQIR IQIR
3 3 2
Customer Burr
Preventive Maintenance done as 2 per schedule.
3. Missalign in tooling User 4. RM Thckness is Less 5. Raw Material Problem Next Operation Part Location problem. 7 Punch broken. Preventive Maintenance done as per schedule.
Set up approval and patrol inspection.
96 6
QA+Packing /Done on 2/1/13
Raw Material incoming Inspection
84 100% Ins. Befoure Dispatch & Training Provided for Packing Associate
Incomplete Blanking
Customer
Fitment Prob.
Setting Problem
Use Operation Standard.
96
User
Cutting Clearance Problem. Cutting Edge Blunt.
strip size match to die locating area
Next Operation Part Location problem.
Location Problem
Preventive Maintenance done as per schedule. Set up approval and patrol inspection. 6
Blank Misfeed
Customer
Fitment Prob.
Sheet / Blank Undersize.
96
2 Raw Material incoming Inspection
User Next Operation poor strength poor strength 6 6 setting problem die spotting prob raw materal problum 6 8 Punch broken. Setting problem. Wrong cutting clearance. Cutting edge blunt. Next Operation Production Hold Die Broken Customer User
Next Operation Piercing Hole missing Part Location problem. 7
2 2 2
use opration standerd p.m of die raw materal incoming inspaction
20
BLANKING & PIERCING
neck
Customer User
72 6 72
Next Operation Part Location problem. Customer Fitment Prob
2 P.M. of die 2 As Per S.T.P.L Satting Std. P.M. of die P.M. of die 2 Use Operation Standard. 2 Preventive Maintenance of Die. 2 scrap remove/hours
2 P.M. of die
Piercing Hole missing
Set up approval and patrol inspection.1 00% Ins.at Final stage.
5 60 5 80
User
6 7
Setting Problem External Element in the Die Scrap Jammed.

Punch broken.
Stoppage of Line
6 72 6 84 6 84
84
PROCESS - FMEA
Part/ Proc. No.
ISSUE : A REV. DATE : 00 : 01.11.01
10/7/2013 10/7/2013
Rev '00
S E V
C L A S
R P N
Recommended Actions
Customer User
Fitment Prob -
Setting problem. 7 Wrong cutting clearance. Cutting edge blunt.
2 As Per S.T.P.L Satting Std. 2 P.M. of die 2 P.M. of die
84
Next Operation Part Location problem. Incomplete Profile. Customer User Fitment Prob. -
8 8
Location Problem Sheet / Blank Undersize.
Preventive Maintenance done as per schedule.
96
100% Ins. Befoure Dispatch & Training QA+Packing Provided for Packing /Done on 2/1/13 Associate
Next Operation Production Hold Die Broken Customer User Stoppage of Line
6 7
Setting Problem External Element in the Die Scrap Jammed.
2 Use Operation Standard. 2 Preventive Maintenance of Die. 2 scrap remove/hours Set up approval and patrol inspection.
6 72 6 84 6 84
Next Operation fitment prob CRACK Customer User poor strength poor strength
7 7
Setting Problem die spotting prob Raw material problem
2 Use Operation Standard. 2 P.M.Of Die customer supplied material
6 84 6 84
Next Operation neck Customer User poor strength 7 7
setting problum die spotting prob Raw material problum 2 2
Use Operation Standard. P.M.Of Die Raw Material incoming Inspection Set up approval and patrol inspection. 6 84 6 84
Next Operation
material deposited on readius
P.Mof die Set up approval and patrol inspection.
30
NOTCH BENDING
Scratch
Customer
poor strength & fittment problem
raw material prob
2 customer supplied material
6 96
100% Ins. Befoure Dispatch & Training Provided for Packing Associate
User
Next Operation pert location is not possibal in next opration 6
setting problam
use opration standerd Set up approval and patrol inspection. P.M of die
Incomplete profile customar user
72
fitment porob
die probnlum
Next Operation Production Hold Die Broken Customer User Next Operation fitment prob CRACK Customer User poor strength poor strength Stoppage of Line
6 7
Setting Problem External Element in the Die
2 Use Operation Standard. 2 Preventive Maintenance of Die.
6 72 6 84
7 7
Setting Problem die spotting prob Raw material problem
2 Use Operation Standard. 2 P.M.Of Die customer supplied material Set up approval and patrol inspection.
6 84 6 84
Next Operation Customer neck User poor strength 7 7
Use Operation Standard. Set up approval and patrol Raw Material incoming Inspection inspection. P.M.Of Die 6 84 6 84
Next Operation
P.Mof die Set up approval and patrol inspection. 100% Ins. Befoure Dispatch & Training Provided for Packing Associate
40
BENDING
Scratch
Customer
raw material prob
6 96
User Next Operation pert location is not possibal in next opration 6 setting problam 2 use opration standerd Set up approval and patrol inspection. die probnlum 2 P.M of die 6 7 Setting Problem External Element in the Die 2 Use Operation Standard. 2 Preventive Maintenance of Die. 6 72 6 84
72
fitment porob
Next Operation Production Hold Die Broken Customer User Stoppage of Line
2A
1) Wrong PO given to supplier
1) issuing RM PO with part R/M 2 STD.
72
Thickness undersize
PROCESS - FMEA
Part/ Proc. No.
ISSUE : A REV. DATE : 00 : 01.11.01
10/7/2013 10/7/2013
Rev '00
S E V
C L A S
R P N
Recommended Actions
2A
Thickness undersize
2) Defective material supplied by supplier 6 3) Incoming inspection failure.
2) Supplier Test Certificate and 2 material received in single heat number 3)Before Start Process Check By Q.C Insp. Or Make Q.M.C
72
72
1) Wrong PO given to supplier 2) Defective material supplied by supplier Thickness oversize Die damaged, Thinning, Crack. 6 3) Incoming inspection failure. INCOMING INSPECTION CHILD BRAKET Width under / over Size Difficult for location 4
1) issuing RM PO with part R/M 2 STD. 2) Supplier Test Certificate and material received in single heat 2 number 3)Before Start Process Check By Q.C Insp. Or Make Q.M.C compare with master list of R/M & IQIR
72
72
72
1) Wrong PO given to supplier 2) Defective material supplied by supplier 3) Incoming inspection failure. Material preservation is not proper Rusty material supplied by supplier Wrong property Material supplied by Supplier Improper preservation Transportation Problem 1. Die & Punch Wear Out 2. Imroper Clearance in Die.
1) issuing RM PO with part R/M 2 STD. 2) Supplier Test Certificate and 2 material received in single heat number 1) issuing RM PO with part R/M 2 STD. SHEET WIDTH OR THIK.
48
48
48
Part Cracking Problem Damage & Excess oil Appearance poor Physical & Chemical Properties Rust Dent and Deformation Part Cracking/ Wrinkle Problem Life of component less Produce rusty parts Appearance poor Crack developed / Tool Next Operation wear out handling Fitment Problem / Difficult in handling.
5 5 5 5 5 5 7
3 3 3 3
R/M incoming inspection R/M incoming inspection
As Per Standerd & IQIR
6 6 6 6 6 6
90 90 90 90 90 90 84 100% Ins. Befoure Dispatch & Training Provided for Packing Associate
Compare TC with standard R/M incoming inspection IQIR IQIR
3 3 2
Customer Burr
Preventive Maintenance done as 2 per schedule.
3. Missalign in tooling User 4. RM Thckness is Less 5. Raw Material Problem Next Operation Part Location problem. 7 Punch broken. Preventive Maintenance done as per schedule.
96 6
Raw Material incoming Inspection
Incomplete Blanking
Customer
Fitment Prob.
Setting Problem
Use Operation Standard.
96
User
Cutting Clearance Problem. Cutting Edge Blunt.
strip size match to die locating area
2B
BLANKING
Next Operation Part Location problem.
Location Problem
Preventive Maintenance done as per schedule. Set up approval and patrol inspection.
Blank Misfeed
Customer
Fitment Prob.
Sheet / Blank Undersize.
96
User Next Operation neck Customer User Next Operation Part Location problem. Customer Fitment Prob 6 8 poor strength poor strength 6 6 setting problem die spotting prob raw materal problum Punch broken. Setting problem. Wrong cutting clearance. Cutting edge blunt. Next Operation Production Hold Die Broken Customer User Next Operation fitment prob CRACK Customer poor strength 7 7 Stoppage of Line 6 7 Setting Problem External Element in the Die Scrap Jammed. Setting Problem die spotting prob 2 2 2 use opration standerd p.m of die raw materal incoming inspaction Set up approval and patrol inspection.1 00% Ins.at Final stage. 5 60 5 80 72 6 72
2 P.M. of die 2 As Per S.T.P.L Satting Std. P.M. of die P.M. of die 2 Use Operation Standard. 2 Preventive Maintenance of Die. 2 scrap remove/hours 2 Use Operation Standard. 2 P.M.Of Die
User
6 72 6 84 6 84 6 84
6 84
PROCESS - FMEA
Part/ Proc. No.
ISSUE : A REV. : 00 DATE : 01.11.01
10/7/2013 10/7/2013
O C C Current process control prevention Current D E T
Rev '00
S E V
C L A S
R P N
Recommended Actions
CRACK User poor strength
Raw material problem customer supplied material
Set up control approval and detection patrol inspection.
process
Next Operation Customer neck User poor strength 7 7
Use Operation Standard. Set up approval and patrol Raw Material incoming Inspection inspection. P.M.Of Die 6 84 6 84
Next Operation
P.Mof die Set up approval and patrol inspection. 100% Ins. Befoure Dispatch & Training Provided for Packing Associate
2C
BENDING
Scratch
Customer
raw material prob
6 96
User Next Operation pert location is not possibal in next opration 6 setting problam 2 use opration standerd Set up approval and patrol inspection. die probnlum 2 P.M of die 6 7 Setting Problem External Element in the Die 2 Use Operation Standard. 2 Preventive Maintenance of Die. 6 72 6 84
72
fitment porob
Next Operation Production Hold Die Broken Customer User Location not correct Stoppage of Line
Fitment Problem
Fixture was not ok
2 set the fixture calibration frequency
QMC
70
50
CHILD PART Dimension N.G WELDING
Fitment Problem
Fixture was not ok
QMC
70
3A
INCOMING INSPECTION BOLT M6 X 15
Thread Profile N.G
Fitment problem
Improper handling
2 Inform to supplier
IQIR
72
Dimension N.G
Fitment problem
Fixture was not ok
QMC
48
60
BOLT WELDING
Location not correct
Fitment problem
Fixture was not ok
QMC
56
Std did not give Wrong passivation Next Operation Wrong Appearance to supplier 6 Less Coating thickness Process fault at plating Customer Less life of part supplier
2 1. Customers Quality Standard provide IQIR 2 1. Reject material & return to supplier IQIR
72
70
E.D PAINT
72
80
INCOMING INSPECTION E.D PAINT
N.G Piece pass to the Customer O.K Piece got rejected Customer
customer dissatisfaction
Inspector error
2 Training provided
IQIR
96
less material for final dispatch
inspector errror
2 Training provided
IQIR
96
90
FINAL INSP 1.Inspection Fitment Problem 8 2 Insp. Std Given
Inspection Report ( final) 100% gauging with marking Pre Dispatch Insp.
80
Missing
as per Control plan Defined location for each product Fitment Problem 8 Material Mix 2
100
PACKING Wrong part packing Poor/loose packing Packing Less/Over Qty Material without stripping Customer Dissatisfied Damage during transportation 7 Improper Handling 2 Handling as per std Pre Dispatch Insp. 6 84 96 DOCK Audit as per plan
140
PREDISPATCH Insp.
Abnormility against standard
Customer Dissatisfied
Improper handling
Customer feed back
84
PROCESS - FMEA
Part/ Proc. No.
ISSUE : A REV. : 00 DATE : 01.11.01
10/7/2013 10/7/2013
Rev '00
Process/ Function
S E V
C L A S
R P N
Recommended Actions
140
PRERequirements DISPATCH Insp.
Abnormility against standard
Improper handling
Customer feed back
84
120
DISPATCH
AS per customer Requirement
CHECKING AIDS LIST

( For Gauges, Instruments & Testing Equipments)
Date( Orig ) :
10/7/2013
Checking Aid No.: STPL/ SUB./CA /833 Date:10/07/2013
Customer Name: Name of the Part:

Sr No
M/S SUBROS LTD STAY SUCTION HOSE

GAUGE/INSTURMENTS/TEST EQUIPMENTS NO.
Customer Code: Part No: 146542 - 833

CALIBRATION FREQ. LEAST COUNT MSA YES/NO/NR
GAUGES/INSTRUMENTS
A 1 2 3
INSTRUMENTS Micro Meter Digital Vernier Caliper Digital Height Gauge STPL/MM/02 STPL/DVC//01 STPL/DHG/01 One Year One Year One Year 0.01 mm 0.01 mm 0.01 mm
GAUGES
TESTING EQUIPMENTS
MASTER SAMPLES
PREPARED BY : AMIT DHIMAN
APPROVED BY: VINOD ARYA
SPECIAL
FINAL INSPECTION STANDARD

(F-21-03)A
DOC.No :- STPL/ SUB/ FIS/833 REV :- 00
DATE :- 10/07/13
PART NAME :- STAY SUCT. HOSE PART No:- 146542 - 833 CUSTOMER :- M/S SUBROS LTD.
Special char./class
SL. NO.
INSPECTION ITEM
SEPECIFIED
INSPECTION METHOD / USED TOOLS
FREQUENCY
RESPONSIBILITY
(A) 1
APPEARANCE APPEARANCE Dent , Burr, Scratch, Rust Not allowed Coating defect,color mismatch,blister peel off not visiable VISUAL
100% 100%
PACKING ASSOCIATE PACKING ASSOCIATE
2 (B) 1 2 3 4 5 6 7 8 9 10 11 12 13 14
APPEARANCE (COATING) DIMENSIONS

THICKNESS DIM DIM DIM ANGLE HOLE DIA DIM DIM THREAD PLATING THICKNESS APPEARANCE
VISUAL
3.20.20 9.20.5 25.70.5 0.4 19.71 6.50.5 81.40.5 16.21 M6 X 15 20 Min NO BLISTER NO PITTED NO PEEL OFF NO CRACK NO DENT NO SCRATCH
M.M V.C H.G H.G PP V.C H.G H.G TRG THICKNESS TESTER VISUAL
AS PER S. PLAN AS PER S. PLAN AS PER S. PLAN AS PER S. PLAN AS PER S. PLAN AS PER S. PLAN AS PER S. PLAN AS PER S. PLAN AS PER S. PLAN AS PER S. PLAN
Q.C.Inspector Q.C.Inspector Q.C.Inspector Q.C.Inspector Q.C.Inspector Q.C.Inspector Q.C.Inspector Q.C.Inspector Q.C.Inspector Q.C.Inspector Q.C.Inspector PACKING ASSOCIATE PACKING ASSOCIATE PACKING ASSOCIATE PACKING ASSOCIATE PACKING ASSOCIATE
100% 100% 100% 100% 100% 100%
(c) MATERIAL 1 2 3 Grade

Chemical Properties Physical Properties
SPHC-SD
T.C
PER LOT
Q.C.Inspector
Prepared By :-
KAPIL TOMAR
Approved By :-
Vinod Arya
ISSUE : A REV : 00 DATE :29.09.11
UB/ FIS/833
REMARKS
Vinod Arya
SOURCE LIST
MODEL: PART NAME: STAY SUCT. HOSE PART NO: 146542 - 833 SUBROS PART NO:146542 - 833 Level 1 Parts S# Part Name Part No. Source S# Part Name Part No. Source S# Part Name Part No. Source Level 2 Parts S# Part Name Part No. Source Level 3 Parts Material Spec.
Prepared By : Checked By : Approved By :
STAY SUCT HOSE
146542 833
STPL
STAY SUCT. HOSE (POWDER COATING)
146542 833
POWDER COATING (PTC)
STAY SUCT. HOSE
IN HOUSE
RAW MATERIAL
146542 833 146542 833 146542 833
BHUSHAN STEEL
SPHC-SD
BRACKET BOLT 647850 3010
IN HOUSE OUT SOURSE
RAW MATERIAL RAW MATERIAL
BHUSHAN STEEL
SPCC-SD SS- 41B
PRIME TECH
Ved prakash Vinod Arya Sandeep Sharma
Remarks
PACKING WORK INSTRUCTION

VENDOR NAME
PART NAME : STAY SUCT HOSE PART NO. :146542 - 833
SUPPLIER : M/s STPL QTY. PER BIN :
Purpose :To ensure the proper packing as per the instruction given below:-
EMPTY BOX
BIN WITH PART
BIN READY TO DISPATCH
BIN WITH NAM
Quantity Details:Per Packet qty: Per BIN qty: nos. nos.
BIN Details:BIN SIZE : 500X300X200 inch
Weight Details:Part Weight : 0.110 kg BIN Weight : Gross Wt. : 1.5 kg kg
PREPARED BY
CHECKED BY
APPROVED BY Supplier
DOC. NO ISSUE NO. DATE PAGE A 10/02/2012 1 OF 1
WITH PARTS IN IT.
BIN WITH NAME ON IT

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(AN ISO/TS 16949:2009 Co.

CUSTOMER M/S .SUBROS LTD.

STAY SUCT. HOSE 146542 - 833 M/S SUBROS LTD.

PREPARED BY: KAPIL TOMAR

APPROVED BY: VINOD ARYA

PART SUBMISSION WARRANT

ISSUE REVISION DATE

STPL/ SUB / CA/ 833 Checking Aid Engineering Change Level

ORGANIZATION MANUFACTURING INFORMATION

The result meet all drawing and spacifaction requirement :

(if "No" - Explanation Required)

Statistical process package

PROCESS FLOW DIAGRAM

ISSUE REV DATE

Part No. Part Name Customer

146542 - 833 STAY SUCTION HOSE M/S SUBROS LTD.

Report No. Date Of Issue Rev. Status 2) BRACKET

S.T.P.L/SUB./PFD 833 10/7/2013 0 3) BOLT

1) STAY SUCT. HOSE

STORAGE INCOMING INSPN. BLANKING

STORAGE INCOMING INSPN.

Transfer Storage Inspection Oeration cum Inspection Operation

Prepared By : NEERAJ SHUKLA

Approved By: VINOD ARYA

CONTROL PLAN (F-09-04)

Supplier / Plant approval Date: Csupplier Code :

Other Approval Date ( if Reqd) : Specs/Char Class

Other Approval Date (if Reqd.) :-----Methods

Process Name / Opn. Description

Product / Process Specs. Tolerance

MATERIAL THICKNESS Appearance

SPCC - SD 3.20.20 No Burr No Dent No Scratch.

SPPLR. SPECTRO LAB

Per Year PerLot IQIR

MICRO METER Visual

Inform to supplier and quality head / Segregate the material

Power Press 50 - 100Tons Blanking + Punching Tool 1/3

1 THICKNESS 2 HOLE DIA 3 HOLE DIA 4 DIM 5 DIM

Side Gauges and Stoper Pin

6.50.5 60.5 9.20.5 121 16.21 No Burr No Dant/Scr. No Blank Short

V.C V.C V.C V.C H.G Visual

Power Press 30-60 Tons 30 Notch Bending

stopper pin and gauges in tool

Power Press 60 -100Tons

1 DIM 2 DIM 3 DIM 4 Appearance

25.70.5 81.400.50 27 No Crack No Dent/ No Scratch.

sttoper pin and gauges in tool

Per year PerLot IQIR

MICRO METER Visual

Inform to supplier and quality head / Segregate the material

CONTROL PLAN (F-09-04)

Other Approval Date (if Reqd.) :-----F.M.L

Side Gauges and Stoper Pin

No Burr No Dant/Scr. No Blank Short

Power Press 10 - 30 Tons

Side Gauges and Stoper Pin

Bending Tool 1/2

1 DIM 2 DIM 3 APPEARANCE

H.G V.C VISUAL

Parameter controler provided

Child Part Welding

REJECT / and quality head / Correct the process / STOP

Inform to supplier and quality head / Segregate the material