CRITICAL HERO HONDA MOTORS LIMITED,

ASSY.PART No:
MODEL KTRJ
750004153
MAJOR AB C PROCESS QUALITY CONTROL SHEET (I) 69 KM. STONE, DELHI JAIPUR HIGHWAY,
MINOR DHARUHERA (HARYANA)

PART NO. 7500004156 DOC NO. REV NO. 01

PART NAME COVER MUFFLER POWDER COATING PROCESS
SOURCE MAJESTIC AUTO LTD. DATE : 07.11.08 PAGE 01 OF 01

BASIC FOR PRODUCTION CHANGE PARTS PURCHASED FROM OUTSIDE VENDOR

Critical Approval Test Prodn. Submit Ist
PROCESS FLOW DIAGRAM S.No. Process & Required checked Piece date S.No. Part No. Part Name Supplier
Description
1 ACCILINE-44 RAJIT PAINTS
2 RUST REMOVER RAJIT PAINTS
1 2 3 3 PHOSODINE RAJIT PAINTS
RAW MATERIAL DEGREASING WATER 4 ACCILIYTE RAJIT PAINTS
LOADING TANK RINSE 5 PP GLOSY POWDER MAHARANI PAINTS

8 7 6 5 4
PASSIVATION WATER PHOSPHATING WATER DE-RUSTING
RINSE RINSE

9 10 11 12 13
DRYER CLEANING POWDER BAKING OVEN UNLOADING
BEFORE POWDER COATING
COATING

14
INSPECTION

HHML APPROVAL VENDOR APPROVAL

DATE NAME AUTHORISED DATE MADE BY CHECKED APPROVED
SIGNATORY LOT MARKING BY BY

LOT CODE 07.11.08 RADHA KRISHNA SAHU

 PROCESS QUALITY CONTROL SHEET (II)
PART NAME :COVER MUFFLER MODEL KTRJ(PART No.7500004153) DOC.NO:
DHARUHERA PART NO. : 7500004156 HHML DRG.No-18300-KTR-8600 PAGE-------01--------OF----------01---------

QUALITY CHARACTERISTICS CONTROL OF MANUFACTURING CONDITIONS

Trouble Mode
Sequence of

(Equipment, metal mold,fail-safe devices,hydraulic power,voltage, temperature etc.)

Process

Process Name/Equipment

`
Name(Name of Supplier)
Inspection
No. Control Item Specified value Inspected by Inspection Method Data Form Control item Specified value Inspected by Inspection Method Inspection Frequency Data form Detail of Process/Sketch
Frequency

RAW MATERIAL GAP BASET EQUAL IN

1 OPERATER VISUAL 100% NO NO. BASKET 4 OPERATOR VISUALLY 100%
LOADING TO BASKET EACH

QTY. /BASKET 24 OPERATOR VISUALLY 100%

NO OIL ON
2 DEGREASING TANK OIL OPERATER VISUAL 100% TANK MS
COMPONENT

SOLUTION LEVEL UPTO MARK OPERATOR VISUAL TWO HOUR

TEMP 70-80 C OPERATOR TEMP. CONTROL 4/SHIFT FORMAT

CONCENTRATION 25-40 ANALYST TITRATION ONCE A DAY FORMAT

DIP TIME 10-15 MIN ENGINEER AUTO SET MONTHLY REGISTER

3 WATER RINSE WATER FLOW 400-450 LITS. OPERATOR VISUAL 100% TANK MS

WATER USED RAW WATER

DISCARD FREQ. CONTINEOUS INCHARGE PAINTING CONTINEOUS

DIP TIME JUST DIP AND OUT ENGINEER AUTO SET MONTHLY REGISTER

4 DE-RUSTING TANK MS

TEMPERATURE 45-50 C OPERATOR TEMP CONTROL 4/SHIFT FORMAT

CONCENTRATION 10-15 ANALYST TITRATION ONCE A DAY FORMAT
DIP TIME 4-7MIN. ENGINEER AUTO SET MONTHLY REGISTER

5 WATER RINSE WATER FLOW 400-450 LITS. OPERATOR VISUAL 100% TANK MS
WATER USED RAW WATER
DISCARD FREQ. CONTINEOUS INCHARGE PAINTING CONTINEOUS
DIP TIME JUST DIP AND OUT ENGINEER AUTO SET MONTHLY REGISTER

6 PHOSPHATING TEMPERATURE 65-75 C OPERATOR TEMP CONTROL 4/SHIFT FORMAT

TANK MS
CONCENTRATION 20-25 ANALYST TITRATION ONCE A DAY FORMAT
DIP TIME 7-10MIN. ENGINEER AUTO SET MONTHLY REGISTER

7 WATER RINSE WATER FLOW 400-450 LITS. OPERATOR VISUAL 100% TANK MS
WATER USED RAW WATER
DISCARD FREQ. CONTINEOUS INCHARGE PAINTING CONTINEOUS

8 PASSIVATION TEMPERATURE 70-90 C OPERATOR TEMP CONTROL 4/SHIFT FORMAT

TANK MS
CONCENTRATION 0.4-0.6 ANALYST TITRATION ONCE A DAY FORMAT
DIP TIME JUST DIP AND OUT ENGINEER AUTO SET MONTHLY REGISTER
 DIP TIME JUST DIP AND OUT ENGINEER AUTO SET MONTHLY REGISTER

9 DRYER TEMPERATURE 70-80 C OPERATOR TEMP CONTROL 4/SHIFT FORMAT

TIME 5 MIN. ENGINEER AUTOSET MONTHLY REGISTER

CLEANING BEFORE
10 DUST _ OPERATOR
POWDER COATING

11 POWDER COATING CURRENT 70-90 KVA OPERATOR MANUALLY CONTINEOUS REGISTER

AIR PRESSURE 1 -2 Kgf / sq.cm. OPERATOR MANUALLY CONTINEOUS REGISTER

12 BAKING OVEN TEMPERATURE 210-220 C OPERATOR TEMP CONTROL 4/SHIFT FORMAT

TIME 10-12 MIN. OPERATOR AUTOSET MONTHLY REGISTER

13 UNLOADING VISUAL ROUGHNESS LOADER VISUAL 100% VERBAL

14 INSPECTION THICKNESS MIN. 50 MICRON INSPECTOR THICKNESS TESTER FORMAT

WITH CROSS MARK &
ADDITION INSPECTOR -do-
CELOTAP
DENTS & SCRATCHES INSPECTOR VISUAL -do-

Classification
Classification
of trouble
of trouble
modesmodes
of completed
of completed
vehicles
vehicles
(machines)
(machines)
: : 1.Fire, 2. Fails to stop, 3. Fails to run, 4. Receives electric shocks, 5. Fails to conform to legal requirements, 6. Outer appearance and commercial value.