PPAP Documents

Customer
Kay Jay Forging Ltd.

SH 5228 (N3020120)
 Output Sheet Of PPAP
Part/Size: SH 5228 (WALUJ) Date: 25.05.17
Document/ Rev status
Sr.
Requirement Document Remark
No.
References
Design Records of saleable
1 SH 5228 NA
products
Engineering change
2 Not Applicable NA
documents,if any
CustomerEngineering
3 Not Applicable NA
Approval,if req..
4 Design FMEA Not Applicable NA
6
5 Process Flow Diagrams W/PF/26/01 Attached
25.03.16
65
6 Process FMEA N/FM/26/74 QC
10.05.17
7 Dimensional Results Attached Attached
Material performance test
8 Attached Attached
results
9 Initial process study Attached Attached

Measurement System
10 Attached Attached
Analysis studies
Qualified Laboratory
11 Lab Manual QC
Documentation
4
12 Control Plan W/CP/26/55 Attached
12.11.2016
13 Part Submission Warrant Attached Attached

Appearance Approval
14 Not Applicable NA
Report if applicable
Bulk material requirements
15 Not Applicable NA
checklist (for bulk material
PPAP only)
16 Sample Product Not Applicable NA
Stored at NRB
17 Master sample QC
Waluj
18 Checking Aids Attached Attached
Records of compliance
19 Not Applicable NA
with customer specific
requirements
S :The supplier shall submit to designated customer products approval activity and retain a copy of records or documentation items
at appropriate locations,including manufacturing.
R :The supplier shall retain at appropriate locations,including manufacturing and readily available to the customer representative
upon request.
. :The supplier shall retain at appropriate locations and submit to the customer upon request.

Authorized Signatory
Name K.S.Deore
Designation Manager QA
 Page 3 of 21

Process Flow
Part Name:Crank Pin Process Responsibility : Crank Process Identification :W/PF/26/01 Rev. No.:- 6
Part family : SH5228 Pin Date ( Original ) : 28.01.2007 Date (Revised): 25.03.16
Customer part no: N3020120

Core Team : HJ,AAM,GKB,AKS.KSD,VDS,VSB,YAP,NRG.

Operation Incoming Sources of

Operation Description Process Flow Diagram Product Characteristics Process Characteristics
Number Variation

Raw material inspection

10 - As per RMI plan

Raw Material transport to

15 -
Vendor
Turning & Drilling at vendor
20 - As per Turning control plan

Receipt Inspection (Turned

50 drilled & marking Blanks from - As per Receiving Inspection Plan

Vendor)

70 Heat Treatment Variaition in chemical composition As per Hardening control plan

Man - Skilled operator (1-7), wheel

100 Rough OD grinding OD oversize from turning 1) Outer Dimeter Size
grade(2,5)

Turning Runout more 2) Circularity Machine - Spindle runout > specified

(2,3,5,6,) Excess Vibration more than spec
3) Free from Grinding marks (2,3)

4) Ovality Method - , wheel dressing (1,to7),

dresser(2,5,6,7), track (2,5,6,7) Coolant
( 2) , regulating wheel RPM (3,4,6), Tilt
angle. (3,4,6,7), setting of OD master
5) Taper (1),entry and exit guide(4,7), Center
height (3,4,6)
Environment - surrounding temp.(1)

Prepared By: Reviewed By: Approved by : MMN

 Page 4 of 21

120 Prefinal OD grinding OD oversize from Rough Grd 1) Outer Dimeter Size

Excess ovality 2) Circularity

3) Free from Grinding marks

4) Ovality

5) Taper

Environment - surrounding temp.(1)

air pressure, job hole & wheel centre

1) Sharp edges from turning

123
Cross hole chamfer buffing 1) Removed sharp edges

Raw material Crack 1) Machine should detect Crack (BP) Man - skilled operator

surface crack generated in

Grinding operation
Machine - magnetic filed (1)

Method - Concentratation of fluorecent

124 Crack Detection Solution / powder (1) Ultraviolet light
functioning (1), Currect setting (1),
Condition of electrode (1), Clean MTO/Oil
(1)

Environment - illumination (1)

Dirty component Man: skilled operator(1,2)

1) Hardeness is as per spec
Coolant with component
Machine-
125 Eddy current sorter
Method :
1.Less air pressure for sorter
2.Feeding of component ( touching to
OD oversize from turning 1) OD Size Man - Skilled operator

OD undersize from turning 2) OD Surface Finish

Runout more 3) Circularity Machine - 1.Spindle runout/play

(2,3,5,6,)
4) Cylindricity 2.Vibration (2,3)

150 Finish OD grinding Method - , 1.Wheel dressing frequency

5) Free from Grinding marks (1,to7),2. Dresser (2,5,6,7),3. Track
(2,5,6,7) 4.Coolant % ( 2),
6) Ovality 5Regulating wheel RPM (3,4,6), 6.Tilt
Angle (3,4,6,7), 7.setting of OD master (1),
8.entry guide condition
7) Taper
Environment - High surrounding temp.(1)

Prepared By: Reviewed By: Approved by : MMN

 Page 5 of 21

200 Heavy dirt on component 1) Free from dirt Man - skilled operator (1)

2.Dirt Content below Specified limit. For Limit Size wise Machine- Freq. Of Ultrasonic generator
refer spec sheet (1),
Ultrasonic Cleanning Method : filters (1),clean MTO (1), cycle
time as per spec(1),

Man: skilled operator(1,2)

1) Cap OD Undersize 1) Both size cap fitting

Machine- Poka yoke is not working for

2) Cap OD Oversize 2) Cap fitting to a proper depth sensing the cap(2)
215 Cap fitting Method : air pressure(2)
3) Counter ID oversize

4) Counter ID undersize

Input components are with

1) Temp stabilized material Man - Skilled (1),
hign temp
Soaking for temp stabilization Machine - Air conditioner
216
Method - soaking time as per spec. (1)

Environment - surrounding temp (1)

Angular relations are not ok 1) Relation of cross hole w.r.t. inclined should be ok(BP)
2) Depth of Inclined Hole 3) Depth of cross Hole Man - skilled operator (1,2,3)
from drilling operations

Relation checking of cross hole Machine -calibrated fixture (1,2,3)

220
Method - Size of gauging pins (1,2,3)

Environment - Nil

1) Free from Grinding marks , Flat marks, rusty marks Man - skilled (1)

Dirty component 2) Free from Pitting, Free from Chamfer damage Machine- Lamp for visual inspection

Method - method of visual

230 Visual inspection of crank pins 3) Free from crack , free from dent marks

4) Free from dirt Environment - illumination

Temp of component is high 1) Sorting in correct grade Man - skilled operator (1,)

240 Grading Machine- calibration date(1)

Method - master used (1), method of

grading(1),

Environment - surrounding temp (1)

300 Oiling by VCI 418 Method: deeping in oil

Machine -

310 Colour coding Method - Use of proper colour (1)

Environment -

Method : type of box used(2),method of

340 Packing in boxes Correct boxes for each sizes.
packing(1)

350 Pre Dispatch Inspection As per spec Method - As per PDI plan
NA

Method: Move to FG
360 Move to stores - -

Rev.Details are in generic PFD for Crank Pin

Prepared By: Reviewed By: Approved by : MMN

 Page 6 of 21

CONTROL PLAN
Control Plan No.:- W/CP/26/29 Rev. No. :-004
Prototype Prelaunch Production Key Contact / Phone :- Mr. Hemant Jog (0240) 6634501
Date ( Orig. ) :- 17.07..2013 Date ( Rev. ) :- 12.11.2016
Part Family / Drawing no. :- Crankpin-SH 5228 rev a NA3020120 (TVS) Core Team :- HJ, AAM,AKS,KSD,GKB,VDS,NBB Customer Engineering Approval Date (If Req'd) :-
Supplier Plant Approval :- Customer Quality Approval Date (If Req'd) :-
Supplier Plant :- NRB Bearings Ltd. Waluj
Other Approval Date (If Req'd) :- Other Approval Date (If Req'd) :-
Process Name Machine, Characteristics Methods
Part / Special Char.
Process Product/process Evaluation / Measurement Control Method
Operation Tools for Mfg. No. Product Process Recording Sample Frequency Responsibility Reaction Plan Corective Action
Number Class Specification/Tolerance Technique Error Proffing Detection

As per As per Inspection

Raw material As per Inspection plan As per Inspection
10 Manual 1 Inspection plan Y As per Inspection plan Inspection Report Inspector Reject
inspection plan
plan

As per
Inward Inspection As per Inspection plan no. As per Inspection
30 material Manual 1 plan of N/OT/12/5177 T & plan Y As per Inspection plan Each Lot Inspection Report Inspector Reject
inspection Turned N/OT/12/51777 D
blanks of size

As per
Inward Inspection As per Inspection
50 material Manual 1 plan of As per Inspection plan. plan Y As per Inspection plan Each Lot Inspection Report Inspector Reject
inspection drilled blanks
of size
Inward
As per
material As per Inspection plan no. As per Inspection
55 Manual 1 Inspection Y As per Inspection plan Each Lot Inspection Report Inspector Reject
inspection N/OT/12/112 plan
plan
Plug
70 Heat Furnace As per HT control plan As per HT control As per HT control plan As per Heat treatment
1 As per HT control plan Inspector Rework/Reject
Treatment plan controlplan

Prepared by -NBB Reviewed by - AAM Authorised by - KSD

 100 OD Grinding Centerless Page 7 of 21
(Rough) OD Grinder 1 Outer Dia f 26.04 (±0.005) Comparator LC 1.0 µ Y 5 nos. New setting/per shift First-off Operator

Y 5 nos. per hour In process Inspection Operator

5.0 m Operator
2 Ovality Comparator LC 1.0 µ Y 5 nos. New setting/per shift First-off

Y 2 nos. per hour In process Inspection Operator

3 Taper 5.0 µ Comparator LC 1.0 µ Y 5 nos. New setting/per shift First-off Operator
Rework/Reject
Reset the m/c
Y 2 nos. per hour In process Inspection Operator

4 Circularity 5.0 µ on plain OD MMQ30 Y 5 nos. New setting/per shift MMQ30 Graph Operator

Free from damage, burns, dash

First-off
5 Visual marks, deep grd marks ,surface Visual Inspection Y 5 nos. New setting/per shift Operator
crack

Y 2 nos. per hour In process Inspection Operator

A Grinding wheel & At every wheel

As per setup chart Verify wheel sticker Y 1 Nos. First off Inspection Operator Reject the wheel
Regulating wheel change
B spec/
Reg & size (For
grd Wheel
Manual counting/signal Redress the wheel if
dressing As defined in W.I./Set up plan N ---- After defined freq. Inprocess Inspection Operator
on screen rqurired
(for 1,2,3,4)
C Tilt angle of Reg.
As per setup chart Match the marking Y One Each setting First off inspection Operator Reset the m/c
Wheel (for 1,4)
D RPM of Regulating
As per set up plan RPM indicator Y One Each setting First off inspection Operator Reset the m/c
wheel
E (for 1,2,4)
Center height
As per set up plan Vernier Height gauge Y One Each setting First off inspection Operator Reset the m/c
( for 2,4)
F Spindle runout Regualting wheel :- <15µ Adjust the play from
Dial gauge Y 1 Nos. Every wheel change Machine log book Operator
(for 2,4,5) Grinding wheel :- < 20µ maint
G Cut setting Visual & feeling( On
As per work instrucion N new setting Every new setting --- Operator Reset /dress the wheel
( for 3,5) slide setting dial)
H Lower track
Free from over wear Visual N One Each setting --- Operator Change the track
(for 1,2,4,5)
I Should not overwear, align the
Entry and exit guides
entry of pin from guides with reg Visual, hand feel N One Each setting ---- Operator Change the guides
(for 3,5)
wheel
J
Dressers ( Reg & grd Every week/wheel
Dresser point should be sharp Visual/ Finger feeling N one Record in log book Operator Change the diamond
wheel) (for 1,2,4,5) change
K Coolant should not over dirt MIN :50 LPM Rework/Reject
Coolant ( for 1,2,5) Y Every shift First Off Operator
,changing freq 4 month 3~4% Reset the m/c
L Coolant Flow , Coolant %
Setting of OD Master Correct size OD Master as per pass Calibration identification Change the master if
N --- After every setting Operator
(for 1) on BR Gauge opn master required inform to QC
As per Set-up Plan / Work
At the start of each
Set Up Parameters instruction of Y — First-off Operator Reset the m/c
lot
Machine
Safety Instruction :- 1.Ensure upper guard is fitted 2.Don't put finger /hand inside during cycle 3.Use nose mask/ear muff whenever reqd .

Prepared by -NBB Reviewed by - AAM Authorised by - KSD

 120 OD Grinding( Centerless Page 8 of 21
Prefinal) Centerless Magnetic
New setting/per
grinding m/c 1 Outer Dia f 26.020 (±0.003) comparator LC 1µ Y 5 nos. First-off Operator saparator
shift
provided on T-4

New V belt
Y 5 nos. per hour In process Inspection Operator
conveyor provided
Interlinking of
New setting/per First-off
2 Ovality 3.0 µ /comparator LC 1µ Y 5 nos. Operator Prefinal & Buffing
shift Rework/Reject
Reset the m/c .
Comparator LC 1 µ Y 2 nos. per hour In process Inspection Operator
3.0 µ,
Circularity New setting/per First-off/ roundness
3 No regular waviness , chatter Roundness Tester Y 5 nos. Operator
Naer centre shift graph
form
4 Taper 2.0 µ comparator LC 1µ Y 2 nos. New setting/per First-off/ cylindricity Operator
shift graph
Free from damage, burns, dash
New setting/per First-off
5 Visual marks, deep grd marks ,surface Visual Inspection Y 5 nos. Operator
shift
crack
N 2 nos. After every 0.5 hour In process Inspection Operator
A Grinding wheel & At every wheel
As per setup chart Verify wheel sticker Y 1 Nos. First off Inspection Operator Reject the wheel
Regulating wheel change
B spec/
Reg & size (For
grd Wheel
Manual counting/signal Redress the wheel if
dressing As defined in W.I./Set up plan N ---- After defined freq. Inprocess Inspection Operator
on screen rqurired
(for 1,2,3,4)
C Tilt angle of Reg.
As per setup chart Match the marking Y One Each setting First off inspection Operator Reset the m/c
Wheel (for 1,4)
D RPM of Regulating
As per set up plan RPM indicator Y One Each setting First off inspection Operator Reset the m/c
wheel
E (for 1,2,4)
Center height
As per set up plan Vernier Height gauge Y One Each setting First off inspection Operator Reset the m/c
( for 2,4)
F Spindle runout Regualting wheel :- <15µ Adjust the play from
Dial gauge Y 1 Nos. Every wheel change Machine log book Operator
(for 2,4,5) Grinding wheel :- < 20µ maint
G Cut setting Visual & feeling( On
As per work instrucion N Every new setting Every new setting --- Operator Reset /dress the wheel
( for 3,5) slide setting dial)
H Lower track
Free from over wear Visual N One Each setting --- Operator Change the track
(for 1,2,4,5)
I Entry and exit guides Should not overwear, align the Visual, hand feel N One Each setting ---- Operator Change the guides
J (for 3,5) entry of should
Coolant pin from
notguides with reg
over dirt
MIN :50 LPM Rework/Reject
Coolant ( for 1,2,5) ,changing freq 4 month Y Every shift First Off Operator
3~4% Reset the m/c
Coolant Flow , Coolant %
K Dressers ( Reg & grd one Operator
Dresser point should be sharp Visual/ Finger feeling N Every week Record in log book Change the diamond
wheel) (for 1,2,4,5)
L
Setting of OD Master Correct size OD Master as per pass Calibration identification Change the master if
N --- After every setting Operator
(for 1) on BR Gauge opn master required inform to QC

Safety Instruction :-1.Use handgloves , goggle while doing coolant change/ dust cleaning 2.While operating machine use air muff & if reqd nose masks

Prepared by -NBB Reviewed by - AAM Authorised by - KSD

 123 Cross Hole Chamfer Page 9 of 21
Buffing Buffing m/c
Cross Hole
air pressure, job Buffed Sharp edges of Cross
chamfer Rework/ reject/ Reset
1 hole & wheel centre Hole Chamfer perthometer concept y 2 nos Each lot at start first off inspection Operator
Buffing both the machine
Smooth Merging of chamfer
sides

Safety Instruction :-1. Use air muff 2. While changing stansol 60 apply KERODEX CREAM to the hands , Use handgloves while handling stansol 60
124 Crack Crack
detection Detector Reject the cracked pins As
1 Surface Cracks Free from surface cracks Visual Y 100% Each Lot On line/MPI status Record Shift Engineer / operator per Reaction plan WI of
Crack Detection

Setting of KAT Value,

Crack sample& ASTM piece
Ampere , % of Powder As per Set-up Plan / Work instruction of
should show cracks N — Each lot at start First-off Inspection Shift Engineer / operator Reset the m/c
in MPI Oil, Level of MPI Crack Detector
prominently
Oil

Visual N 2 nos every hour inprocess inspection Operator

125 Eddy current eddy
Hardenss Hardenss sorter coil Summery saved
Hardness current summery saved in Shift Engineer /
1 within 60~64 Hardenss in the range of 60~64 & display in the y 100% in computer/ Recheck / reject
sorting sorting computer operator
HRC Ellispe LOG Book
machine
Safety Instruction :-1.Use handgloves , goggle while doing coolant change/ dust cleaning 2.While operating machine use air muff & if reqd nose masks

Prepared by -NBB Reviewed by - AAM Authorised by - KSD

 Page 10 of 21

150 OD grinding Centerless Produce Lower

26.0( +0.004 / -0.002) mm
(Final) Grinding m/c group saparately
((+0.004/+0.002) -white
1 Outer Dia Air gauge LC 0.2 µ Y 5 nos New setting/per shift First-off Operator in Batch. & Don’t
(+0.002/0.0000 - blue (+0.000/-
produce excess
0.002) Yellow
against plan.

Y 5 nos. per hour In process Inspection Operator

First-off/ roundness
2 Circularity 2.0 µ, Roundness Tester Y 5 nos. New setting/per shift Operator
graph
2µ First-off
3 Cylindricity Roundness Tester Y 2 nos. New setting/per shift Operator
Rework/Reject
4 Ovality 2.0 µ Air gauge LC 0.2 µ / Y 5 nos. New setting/per shift First-off Operator
Reset the m/c
5 Surface finish .1 Ra Roughness Tester Y 5 nos. New setting/per shift First-off Operator

6 Taper 1.5 µ Air gauge LC 0.2 µ / Y 5 nos. New setting/per shift First-off Operator

BR Gauge comparator Y 2 nos. per hour In process Inspection Operator

Free from damage, grd burns,

7 Visual chatters, deep scraches, Dash Visual Inspection Y 5 nos. New setting/per shift First-off Operator
marks

Y 2 nos per hour In process Inspection Operator

A Grinding wheels ( At every wheel first Off inspection ,
As per setup chart Verify wheel sticker Y 1 Nos. Operator Reject the wheel
for 1,2,4,5) change machine log book
B
wheel dressing ( for
After 1000~1500 nos. ----- N --- After defined life ---- Operator Redress the wheel
1,2,4,5)
C Grinding wheel
Dresser should not be overwear,
dresser Visual N one per months Machine log book Operator Chanage the diamond
ovality within 10µ
( for 2,3,4)
D Reg wheel Spindle
runout Runout < 0.0025 mm Dial gauge Y once Per month Machine log book Maint change the wheel
( for 2,4,5)
E
Tilt angle of Reg.
As per setup chart Match the marking Y One Each setting First off inspection Operator Reset the m/c
Wheel (for 1,2,4,5)

F RPM of Regulating
wheel As per set up plan RPM indicator Y One Each setting First off inspection Operator Reset the m/c
(for 1,2,4)
G
Center height (for
As per set up plan Vernier Height gauge Y One Each setting First off inspection Operator Reset the m/c
2,4)

Grd wheel spindle

within 1.5µ visual
vibration
H
lower track ( for
Free from over wear Visual N One Each setting --- Operator Change the track
2,3,4,5)

I
entry and exit guides should align with regulating wheel Change the
Visual N One Each setting --- Operator
(for 5,3) axis, should not overwear guides/reset

J Coolant should not over dirt

MIN :50 LPM Rework/Reject
Coolant ( for 1,2,5) ,changing freq 1 month Y Every shift First Off Operator
3~4% Reset the m/c
Coolant Flow , Coolant %
J
setting of OD Master Correct size calibrated OD Master & stickers & colour on Change the master if
Visual N New set up New setting Operator
( for 1) ring master required inform to QC

K
Master should be in running coolant at gauge setting &
Master temp. Temp gauge N online ---- Operator Inform to mainteance
of machine & clean check

Visual N 2 nos every hour inprocess inspection Operator

Safety Instruction :-1.Use handgloves , goggle while doing coolant change/ dust cleaning 2.While operating machine use air muff & if reqd nose masks

Prepared by -NBB Reviewed by - AAM Authorised by - KSD

 1 Page 11 of 21
On line
Free from dust/dirt, dents Visual N 100% Each Lot Operator
Reclean Pins
Dust/Dirt
One ( Average of 50 nos Daily Once Daily Dirt content
Dirt content less than 0.8 mg/pin Millipore Y ( Of Ultrasonic / reclean
) register
Final oiled )
Ultra sonic genetors LED should glow as per cycle of
Visual N once every shift on line Operator Rest the machine
Ultrasonic should be on tank
Washing
200 Washing Conditions of filters cleaning of filters Visual N One Every month cleaning record Operator Clean the filters
Machine (
new)
Replenishing / changing of STANSOL60change
STANSOL 60 Visual One Every month Operator change the Stansol 60
STANSOL60 record

Display of machine Reject/rework the pins

Cycle time As per set up chart N 100% Each Lot On line Operator
control Reclean Pins

Safety Instruction :-1. Use air muff 2. While changing STANSOL 60 aaply KERODEX CREAM to the hands , Use handgloves while handling STANSOL60
Cap fitting after
Cap fitting Dial gauge L C 0.01 + Rework/Reject Modifided Punch
ultrasonic Cap Depth Min 5.0 mm Y 5 nos Each lot at Start First off operator
Press Comparato Reset the m/c to be use for cap
washing work instruction fitting

215 Visul 5 nos. After every 4 hour

presence of
Cap should be present N Each Piece --- operator Reset the m/c
cap
Air Pressure
5 ~ 6 bar Pressure Gauge N

1
Temperature Soaking for 45 min. in A/C Room of
stabilized Temperature Y 100% Each Lot Operator Set room temterature
material 18 to 22º C
Soaking for
216 Temperature A/C Room In Time Register
Stabilization Temp of surrounding 18 to 22 deg Temp gauge N 100% On line Operator Rest the machine

soaking time as per spec. 45 min Wall clock Y 100% On line Operator Re soak the pins

220 Oil-hole poka Yoka

passage Fixture Cross hole should open at central
Cross hole Work Instruction of Hole relation
checking 1 hole Okay clearnce of cycle N 100% Each Piece On line Operator Rework
depth passage checking gauge

Prepared by -NBB Reviewed by - AAM Authorised by - KSD

 230 Visual Manual Free from visual defects Page 12 of 21
(ie. Nail feeling scratch marks,Rust
Free from , pitting , dents & grinding marks,
1 Work Instruction Visual Inspection N 100% Each Piece On line Operator Rework/Reject
visual defects soot , Burr in the holes, no damage
on face near face hole, chamfer,
Lamp for visual cap presence
Visual , depthbeofclean
glass should cap is full ) Visual N One Daily On line Operator Clean the glass
Method of Visual As per Work instruction Visual N One Online On line Operator Do as per sequence
Sufficient illumination should be
Illumination of lights Visual N One Online On line Operator Get start the light
there
240 Grading ofOD Manual
26.0( +0.004 / -0.002) mm
((+0.004/+0.002) -white
1 Outer Dia Air gauge LC 0.2 µ N 100% Each Piece On line Operator Rework/Reject
(+0.002/0.0000 - blue (+0.000/-
0.002) Yellow

Safety Instruction :-1. Use air muff 2. While changing stansol 60 apply KERODEX CREAM to the hands , Use handgloves while handling stansol 60

Washing By VCI Washing On line Add/ Change washing

300 Dust/Dirt Free from Dust/ Dirt Visual N 100% Each Piece Operator
418 Machine media

Manual Manual
310 Colur Code Colur Code. Work Instruction Colur coding is leagible 100% Each Piece On line Operator Rework/Reject
1 n
Packing Manual Ensure the VCI
Paper Sizes 100
1 Quantity 50 nos per Box Visual N 100% Each Piece On line Operator Recount/ Repack x130 for Specific
As per grading / Customer
340 colour coding chart, HMSI/TVS
Packing standard
Crank Pin Name, WO No, Grade,
2 Labling Packing Date, customer part Visual N 100% EACH BOX On line Operator Re Lable
name :-N3020120
350 Pre-dispatch Manual 1 Refer PDI Plan NA NA NA NA NA NA NA NA NA NA NA
inspection

Rev no Date Corrective Action

1 7.2.14 L.H.& Green grade removed

2 03.05.2016 Magnetic saparator provided on T-4 ,New V belt conveyor on T4 , Interlinking. /soaking temp 18 to 22°C

3 28.09.16 Modifided Punch used & / Ensure the VCI Paper Sizes 100 x130 for Specific Customer HMSI/TVS
4 12.11.2016 Lower group produc in Batch & Don’t produce excess against plan.

Prepared by -NBB Reviewed by - AAM Authorised by - KSD

 INSPECTION REP.NO. SH-5228-1

REPORT DATE 22.02.2017

SIZE SH 5228 DESCRIPTION Crank Pin

PARTY CODE - PARTY'S NAME TVS Motors
PART'S PART NO. N3020120 REFERENCE -
WORK ORDER NO. 617092519 LOT / ORD.QTY 5

SR SAMPLE OBSERVATION
PARAMETER SPECIFICATION REMARKS
NO. QTY 1 2 3 4 5

Free from burr,flawdust,rust,

1 Visual Free from burr,flawdust,rust, damages. OK
damages.

2 Length 42.00 ( - 0.10 / - 0.30 ) mm 5 41.78 41.79 41.81 41.82 41.79 OK

3 Drill Diameter 12.00 12.00 ( ± 0.10 ) mm 5 12.02 12.01 12.03 11.98 11.99 OK

4 Drill Diameter 16.00 16.00 ( - 0.05 ~ - 0.15 ) mm 5 15.88 15.87 15.88 15.87 15.87 OK

5 16.00mm Drill Depth 10.00 ( +0.5 / + 1.0 ) mm 5 OK BY DEPTH GAUGE OK

6 16.00mm hole chamfer length 0.6 ~ 1.00 mm 1 0.89 OK

7 Radius R 0.5 mm 1 0.45 OK

8 16.00mm hole chamfer Angle 15° ~ 30° 1 20°23'29" OK

Cross hole Dia. 3.00 mm Detail

9 Cross hole Diameter 3.00 mm Ø 3.00 (±0.10) mm 5 OK BY GO-NOGO GAUGE OK

10 Cross hole Distance 21 mm 21.00 ( ± 0.25 ) mm 5 21.13 21.15 21.14 21.16 21.16 OK

11 Cross hole Chamfer &angle 0.2 ~ 0.4 X 45º 1 1.0 X 45°29'33" OK

Free from burr & sharp edges,

12 Visual no surface cracks such as deep 5 No burr & sharp edges (buffing done) OK
maching mark,cracks.

Face hole Dia 5.00 Detail

13 Face hole Diameter 5.00 mm 5.00 ( ± 0.10) mm 5 OK BY GO-NOGO GAUGE OK

14 Face hole Drill depth 3.5 ( 0 / +0.5 ) mm 5 OK BY DEPTH GAUGE OK

15 Face hole Distance 8.00 mm 8.00 ( ± 0.1 ) mm 5 7.92 7.96 7.98 7.96 7.92 OK

16 Relation angle 90°(+/-2°) 5 89°36'28" 89°29'36" 89°26'38" 89°22'14" 90°26'33" OK

17 Face hole Chamfer & Angle 0.5 ( 0 / +0.2 ) X 45º 1 0.52 X 45°29'38" OK

Inclined hole Dia 5.0 mm. Detail

18 Inclined hole Dia Ø 5.00 ( 0 / +0.2 ) mm 5 OK BY GO-NOGO GAUGE OK

19 Inclined hole angle 39° ( ±1° ) 5 39°23'38" 39°57'32" 39°26'17" 38°26'38" 39°20'39" OK

20 Hole depth 39.5 mm 5 OK BY DEPTH GAUGE OK

21 Dimple angle 78° ( ± 3° ) 1 76°51'34" OK

22 Dimple distance from face 6.5 ( ± 0.15 ) mm 5 6.53 6.58 6.54 6.53 6.48 OK
End Profile

23 OD Chamfer Length 1.25 mm Max 5 1.24 1.25 1.23 1.24 1.24 OK

24 Crowning Length 0.5 mm 5 0.52 0.51 0.54 0.53 0.51 OK

REMARKS: PURPOSE
TVSM Part no: N3020120 PRE-DESP INSP.

SAMPLE SUBMISSION

INVESTIGATION

SAMPLE APPROVAL

SAMPLE STUDY

LOT ACCEPTANCE

DISPOSITION CHECKED BY APPROVED BY

Rejected Accepted YAP KSD

 25 Chamfer length from face 1.00 ( ± 0.20 ) mm 5 0.98 1.03 1.02 0.95 0.98 OK
26 Radius R 1.5 ~ 2.00 mm 5 1.96 1.85 1.86 1.91 1.84 OK
Diameter 26.00 (-
27
0.002/+0.004)
28 Grade 1 YELLOW ( -0.002 ~ + 0.000 ) mm - - - - - -
29 Grade 2 BLUE ( +0.00 ~ + 0.002 ) mm - - - - - -
30 Grade 3 WHITE ( +0.002 ~ + 0.004 ) mm 5 26.0024 26.0026 26.0022 26.0024 26.0022 OK

31 Surface Finish on OD 0.10 µ Ra 5 0.058 0.063 0.058 0.044 0.069 OK

32 Circularity 2.00 µ Max. 5 0.86 0.74 0.88 0.95 0.79 OK

33 Cylindricity 2.00 µ Max. 5 1.26 1.35 1.28 1.02 1.43 OK

NRB SH 5228 month & Year
34 Marking 5 NRB SH 5228 month & Year Code. OK
Code.
35 Cap Fit depth of Plug 5.00 min 5 5.24 5.26 5.28 5.12 5.23 OK
Cap Details OK

36 Cap OD 16.00 (+0.15 ~ +0.22) mm 5 16.18 16.17 16.16 16.17 16.18 OK

37 Cap Width 5.00 (+/-0.5) mm 5 5.03 5.06 5.07 5.05 5.06 OK

38 Cap Thickness 1 (+/-0.1) mm 5 1.02 1.03 1.04 1.02 1.03 OK

39 Radius 40mm 5 39.99 39.96 39.98 40.02 40.03 OK

40 Plug material CRCA 'D' with Zn plated 5 CRCA 'D' with Zn plated OK

41 Material - Crank Pin SCM 420 HV - SCM 420 HV OK

42 Face hole to inclined hole angle 180° +/-2° 5 178°05'01" 178°23'23" 178°04'53" 178°35'33" 179°12'06" OK
Heat treatment- Pin
Carburising,Quenching,
43 Heat treatment 5 Carburising,Quenching, tempering all over. OK
tempering all over.
44 Surface Hardness 60 to 64 HRC 1 63 63 62 63 63 OK

45 Core Hardness 34 to 44 HRC 1 42 HRC OK

46 Effective case depth HV0.3, 550 (1.20 ~ 1.60) mm 1 1.45 mm OK

47 Visual Enssure oil hole connectiovity 1 OK OK

48 Cust. Part no Enssure oil hole connectiovity 1 N3020120 OK

REMARKS:- OK PURPOSE
Grade Dia. Qty PRE-DESP INSP.

Grade 1 YELLOW ( -0.002 ~ + 0.000 ) SAMPLE SUBMISSION

Grade 2 BLUE ( +0.00 ~ + 0.002 ) INVESTIGATION

Grade 3 WHITE ( +0.002 ~ + 0.004 ) 5 SAMPLE APPROVAL

SAMPLE STUDY

Total 5 LOT ACCEPTANCE

DISPOSITION CHECKED BY APPROVED BY

ACCEPTED Accepted YAP KSD

 2
31
15
13
34 23
32 14
19
33 26 24
30 27
17 25
29 18 22

28 21 12
43 11
35 5
9
44
8
45 6 10
42 9
46 4
1
3
47
7
20
16

48
41

40
 39 38
36

37

40
 NRB BEARINGS LIMITED ( SPC -variable_Bi-Lateral Tolerance) ( Rbar/d2)

PLANT SHIFT DEPT. MACH. NO. PART NAME / NO. OPERATION CHARACTERISTIC SAMPLE SIZE FREQUENCY UNITS OPERATOR DATE

Waluj 1 Crank Pin Modler-1 SH 5228 final Grinding OD Reading 125 Intervel µm MBN 21.04.17

DATA
USL 4.000 LSL -2.000 35
Goal
S.No. 1 2 3 4 5 Actual
1 1.2 1.6 1.2 1.4 1.6 30

2 0.8 1 1.2 1.4 1.2

25
3 2.2 2.8 2.6 2.4 2.2
4 0.2 0.6 0.8 0.4 0.6 20

5 1.4 1.2 1 1.2 1.4

6 1.6 1.8 1.2 1.6 1.6 15

7 1.6 1 1.2 0.6 1.2

10
8 1.6 1.2 1.4 1.2 1.8
9 1.4 1.4 1.8 2.2 1.6 5

10 2.4 2.6 2.8 2 2

11 1.6 1.8 1.6 1.4 2.4 0
-0.63 -0.41 -0.19 0.03 0.25 0.47 0.69 0.91 1.12 1.34 1.56 1.78 2.00 2.22 2.44 2.66 2.88 3.10 3.32 3.54 3.75
12 1.8 1.4 1.2 1.4 2.6
13 1.2 1.2 1.4 1.8 1.6
14 1.2 1.4 1.2 2.2 2 X - Chart R - Chart
15 1.6 1.2 1.8 1.6 1.8
5
1.6
16 2.2 2.8 2.2 2.2 2.2
4
17 1.6 1 1.2 0.6 1.2 1.4

18 1.2 1.2 1.4 0.8 1 3

1.2

19 2.2 2.8 2.2 2.2 2.2 2

1
20 1.6 1.2 1.2 1.2 1.4 1
0.8
21 1.4 1.2 1 1.2 1.4
0
0.6
22 1.6 1.8 1.2 1.2 1.6 1 3 5 7 9 11 13 15 17 19 21 23 25

-1
23 1.8 1.4 1.2 1 1.2 0.4

24 1.6 1.2 1.4 1.2 1.8 -2

0.2

25 2.2 2.8 2.6 2.4 2.2 -3

0
26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

27
28 X = Avg x USL = X+A2R LSL = X-A2R R = Avg r USL = D4R LSL = D3R

29 Mean
Proc. Capability s= 0.295 6s = 1.772 Cp = 3.39 Cpk = 2.75 1.000 Mean Actual 1.563
Spec.
30
Remarks :ok
YAP KSD
Checked By Approved By
 Part Submission Warrant

Part Name:. Crank Pin Cust. Part Number.: N3020120 ( SH 5228 )

Shown on Drawing No.: SH 5228 Org. Part Number.:
Engineering Drawing Change Level a Dated 07.02.2014
Additional Engineering Changes Dated
Safety and / or Government Regulation Yes No Purchase Order No. Weight (Kg) 0.1300 Kg
Government Regulation Yes No
Checking Aid No. Attached Checking Aid Engineering Change Level Dated
ORGANIZATION MANUFACTURING INFORMATION CUSTOMER SUBMITTAL INFORMATION
NRB BEARINGS LTD.
Supplier Name. & Supplier / Vendor Code Customer Name /Division KayJay Forging Pvt.Ltd
E-72 MIDC WALUJ
Street/Address Buyer/Buyer Code.
Aurngabad Maharashtra India
City Region Postal Code Country Application CON ROD ASSLY.
MATERIAL REPORTING
Has customer - required Substances of concern information been reported? Yes No
Submitted by IMDS or other customer format: Yes

Are polymetric parts identified with appropriate ISO marking codes ? Yes No N/A
REASON FOR SUBMISSION
P Initial Submission Change to Optional Construction or Material
Engineering Change (s) Sub-Suplier or Material Source Change
Toolings : Transfer ,Replacement,Refurbishment, or additional Change in Part Processing
Correction of Discrepancy Parts Produced at Additional Location
Tooling inactive > than 1 Year Other - Please specify

REQUESTED SUBMISSION LEVEL (Check One)

Level 1 - Warrant only ( and for designated appearance items,an Appearance Approval Report ) submitted to customer

Level 2 - Warrant with product samples and limited supporting data submitted to customer

P Level 3 - Warrant with product samples and complete supporting data submitted to customer

Level 4 - Warrant and other requirements as defined by customer

Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location

SUBMISSION RESULTS
The results for P dimensional measurements, P material and functional tests, appearance criteria P
statistical process package
These results meet all design record requirements: Yes No (If "No" - Explanation Required)
Mold / Cavity / Production Process
DECLARATION
I affirm that the samples represented by this warrant are representative of our parts, which have made by a process that meets all Production Part
Approval Process Manual 4 th Edition Requirements. I further affirm that these samples were produced as the rate of 100 No. / hours.
I also certify that documented evidence of such compliance is on file and available for review. I have noted any deviations from this declaration below.
EXPLANATION / COMMENTS:
Is each Customer Tool properly tagged and numbered ? Yes No N/A
Organization Authorised Signature Date 27.05.17
Print Name K.S.Deore Phone No. 240- 6634517 Fax No.
Title Manager QA Email

FOR CUSTOMER USE ONLY (IF APPLICABLE)

Part Warrant Disposition Approved Rejected Other
Customer Signature Date.
Print Name : Customer Tracking Number (Optional)
C/FO/02/018/2
 Measurement system Report for Crank Pin SH 5228
Date: 27.05.17
Sr. R&R Next Planned
Meaurement system Date of Last MSA Bias Linearity Stability Location of record
No. Attribute Variable date

Measurement System for variable

1 Diameter checking with Air Ring gauge LC 0.0002 mm Aug - 16 NA 8.48% OK OK NA NRB QA Pl8 Waluj Aug - 17
2 Vernier Caliper for diameter checking Sep - 16 NA 9.98% OK OK NA NRB QA Pl8 Waluj Sept-17
3 Roundness Tester MMQ 30 Oct - 16 NA NA OK OK NA NRB QA Pl8 Waluj Oct - 17
4 Spinn Comparator LC 0.01 mm Oct - 16 NA 9.52% OK OK NA NRB QA Pl8 Waluj Oct - 17
Measurement System for attribute
1 Hole Depth with Go-Nogo gauge Jan - 16 OK NA NA NA NA NRB QA Pl8 Waluj Sept-17
2 Scratch Mark Sep - 16 OK NA NA NA NA NRB QA Pl8 Waluj Sept-17
3 Profile projector for end profile Oct - 16 OK NA NA NA NA NRB QA Pl8 Waluj Oct - 17
4 Drill diameter checking with Go-Nogo Gauge Jan - 16 OK NA NA NA NA NRB QA Pl8 Waluj Sept-17
5 Drill blunt marks Sep - 16 OK NA NA NA NA NRB QA Pl8 Waluj Sept-17
6 Unclean in turning Sep - 16 OK NA NA NA NA NRB QA Pl8 Waluj Sept-17
7 Eccentric chmafer on drilling Sep - 16 OK NA NA NA NA NRB QA Pl8 Waluj Sept-17
8 Grinding chatter marks Sep - 16 OK NA NA NA NA NRB QA Pl8 Waluj Sept-17
9 Rust on Pin Sep - 16 OK NA NA NA NA NRB QA Pl8 Waluj Sept-17
10 Pit marks on Pin Sep - 16 OK NA NA NA NA NRB QA Pl8 Waluj Sept-17
11 Dust on Pins Sep - 16 OK NA NA NA NA NRB QA Pl8 Waluj Sept-17
 List of checking Aids used for SH 5228
Date:27.05.17
Sr. Checking Calibration Calibration Due
ID No. Least Count Characteristic Checked
No. Aid/Instrument Frequency Date
1 Digital Vernier Caliper 0.01 mm 12 Months Rod diameter, Pin
DVC-23 Diameter at Turning, Drill
Locations Dec-017
2 Profile Projector NA 12 Months Corner Profile (end
BATY PP-2 profile), Aug-017
3 Comparator LC MM-23 0.0005 mm 12 Months Diameter checking
0.0005 mm Dec-017
4 Air Ring Gauge NA 3 Months Diameter checking
ARGSH5248/2
July-017
5 Setting plug Gauge NA 4 Months Diameter checking
ARSPSH5248/7
Jun-017
6 Width Comparator LC 0.01 mm 12 Months Length
WF-20
0.01 mm Oct-018
7 Perthometer RT-01 NA 12 Months Surface finish checking
Sep-017
8 Formtester MMQ 30 FT-01 0.001 µm 12 Months Roundness
Sep-017
9 Talyrond Hobson FT-02 0.01 µm 12 Months Cylindricity
May-018
10 Cross hole plug gauge NA 12 month Cross hole dia
72827/1
May-018
11 Relation gauge NA 12 Month Face hole relation wrt
SH5228R-1
cross hole Dec-017