PPAP CHECK LIST

Supplier Name: J.P.ENTERPRISES Supplier Code: 500014 Location :-LUMAX IND Ltd. PANTNAGER
Submission Level
S.No. Requirements
Level 1 Level 2 Level 3 Level 4 Level 5 AVAILABILITY Y/N
1 Design Records of Saleable Product R S S * R N
- for Proprietary Components / Details R R R * R N
- for all other Components / Details R S S * R N
2 Engineering Change Documents, if any R S S * R N

3 Customer Engineering Approval, if required R R S * R N

4 Design FMEA R R S * R N
5 Process Flow Diagram R R S * R Y
6 Process FMEA R R S * R Y
7 Dimensional Results R S S * R N
8A Material Test Results # R S S * R Y
8B Performance Test Results R S S * R Y
9 Initial Process Study R R S * R N
10 Measurement System Analysis Study R R S * R N
11 Qualified Laboratory Documentation R S S * R N
12 Control Plan R R S * R Y
13 Part Submission Warrant (PSW) S S S S S Y
Appearance Approval Report (AAR)
14 S S S S N
if applicable *
Bulk Material Requirements Checklist
15 R R R * R N
(for bulk material PPAP only)
16 Sample Product (Qty. as asked by Cust) R S S * R Y
17 Master Sample (02 sets) R R R * R N
18 Checking Aids R R R * R Y
Records of Compliance
19 With Customer-Specific R R S * R N
Requirements
LEGENDS R = Retain REMARKS: - A copy of PPAP & master samples shall be retained with supplier
S = Submit to Customer - for Plastic material, Test Certificate from Supplier or Photograph of bag giving Name and Batch Code details shall be provided
* = Submit to Customer on request
JP/QC/017 REV:00 DATE: 12/06/18
 PART SUBMISSION WARRANT

Part Name STUD PIN COMP H/L YG4 Part Number 16007237

Safety and/or
Government Regulation Yes No Engineering Drawing Change Level Dated

Additional Engineering Changes ---- Dated 12/07/2018

Shown on Drawing No. ………. Purchase Order No. Weight 12 gram

Checking Aid No. Engineering Change Level Dated

SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION

Dimensional Materials / Functional Appearance

M/S. J.P.Enterprises 500014
Supplier Name Supplier Code
Customer Name / Division LUMAX INDUSTRIES LTD.
PANT NAGER
Street Address
Buyer / Buyer Code RAJESH CHANDEL
Khasra No.236 Gali No.1 Basai Enclave Part 3 Gurugram (H.R)
Application H/L Market
City/State/Postal Code

REASON FOR SUBMISSION

Initial Submission Change to Optional Construction or Material
Engineering Change(s) Sub-Supplier or Material Source Change
Tooling; Transfer, Replacement, Refurbishment, or additional Change in Part Processing
Correction of Discrepancy Parts Produced at Additional Location

Other - please specify

REQUESTED SUBMISSION LEVEL (Check One )

Level 1 -- Warrant, Appearance Approval Report (for designated appearance items only).

Level 2 -- Warrant, Parts, Drawing, Inspection Results, Laboratory and Functional Results, Appearance Approval Report

Level 3 -- At Customer Location -- Warrant, Parts, Drawings, Inspection Results, Laboratory and Functional Results
Appearance Approval Report, Process Capability Results, Capability Study, Process Control Plan, Gauge
Study FMEA.

Level 4 -- Per Level 3, but without parts.

Level 5 -- At Supplier Location -- Warrant, Parts, Drawings, Inspection Results, Laboratory and Functional Results
Appearance Approval Report, Process Capability Results, Capability Study, Process Control Plan, Gauge
Study FMEA.

SUBMISSION RESULTS

The results for dimensional measurement material and functional tests appearance criteria statistical process
package. These results meet all drawing and specification requirements : Yes No (If "No" -- Explanation Required ).

DECLARATION
I affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable customer
drawing and specifications and are made from specified materials on regular production tooling with no operations other than the regular
production process. I have noted any deviations from this declaration below :

EXPLANATION / COMMENTS

Print Name PAWAN KUMAR PATHAK Title M.D Phone No. 9873564673

Supplier Authorized Signature (SPOC) Date

FOR CUSTOMER USE ONLY

Approved Rejected Other

Part Disposition
Customer Name Customer Signature Date

REV:00 Date- 12/06/2018

 PROCESS FLOW DIAGRAM
PART NO. 16007237
PART NAME STUD PIN COMP H/L YG4 SUPPLIER NAME: M/s. J.P. Enterprises SUPPLIER CODE: 500014
MODEL PRELIMINARY
PRODUCTION KAPIL KUMAR Mr.Pawan Pathak MR.AKASH CONFIRMATION DEPARTMENT
ISSUED BY NAME & SIGN. OF SQR NAME & SIGN. OF SPOC PRODUCTION ENGINEERING
COMPONENTS PARTS SOURCING LIST
S.NO. DRG. NO. PART NAME MATERIAL SOURCE SUB-SUPPLIER NAME
10 RM Incoming & Inspection
BOP IN
1 STUD KNOB PP LAMBA POLYMERS

20
RM Storage

30
Moulding & Inspection

30 Cutting & Deflashing

40

50
Final Inspection

60 Packing

70 Storage
& Despatch

PROCESSING QUALITY INSPECTION

MOVE OPERATION CUM INSP. Kapil kumar Mr. Jaipal
STORAGE /
PROCESS ORDER CHANGE DESCRIPTION CHANGE ISSUE NO. ISSUE DATE ISSUED BY APPROVED BY
DISPATCH LEVEL
JP/QC/017 REV:00

-161-
 SUPPLIER NAME M/s. J.P.Enterprises APPROVED BY (SPOC) CHECKED BY (SQR) PREPARED BY
LUMAX INDUSTRIES PANTNAGAR
SUPPLIER CODE 500014 PAWAN PATHAK KAPIL
PART NAME STUD PIN COMP H/L YG4 PERSON IN CHARGE PAWAN PATHAK DRAWING NO. REVISION NO.:-
PART NO 16007237 CORE TEAM Mr.Jaipal,Mr.Akash,Mr.Kapil,Mr.Pramod REVISION DATE:- ……..
//PROTOTTPE //PRELAUNCH// PRODUCTION// :
CONTROL CHARACTERISTIC (PART/PRODUCT PARAMETERS) MANUFACTURING CONDITION CONTROL (PROCESS PARAMETERS)

Cp/Cpk RESULT
MEASURING RECORDING SPECIAL (is result < 1.33, RECORD MEASURING RECORDING
PROCESS NAME OPN NO. CHECK POINT SPEC. RESP. INSPECTION TOOL CHECK POINT SPEC. RESP. CHECK METHOD ILLUSTRATION
FREQUENCY SHEET CHAR. CLASS then action plan FREQ. FREQ. SHEET
reqd.)

- Bags should not Damaged,

-Grade should be clearly visible
- Manufacturing Date & Expiry Date
Receiving & Inspection Appearance should be mentioned on Bags & Visual
10 Clearly visible. Quality Engineer Each Lot
of RM
Chemical Bags should not in wet
Condition.
material PP H11 (MA) MTC MTC FILE
Raw Material should be kept at own
location
Each raw material location should be
Storage of RM 20 Appearance Quantity Supervisor Store WEIGHT M/C Each Lot srote register
identified.
Raw Material should be stored on
Dry condition.
Mould Alignment
DVC Mould Setting should be OK on Inj. Visual
Moulding M/C
Dia. 31.50±0.30mm DVC Hydraulic Pressure 1000 ± 50 Kg Pr. Gauge
Thread ID 5.0±0.10mm DVC Heater- 4 PLCS 1000 W ( All Heater ) Visual
Moulding 30 Flap thick. 3.0±0.10mm DVC Temp.(Z1) 130 ± 10 °C Engr.-Production Every Set-up Yes INJ. MOULDING MACHINE
Engineer-Quality 2 Times/Shift-QA Engr.
Lock Dim (small) 4.0±0.10mm DVC Temp.(Z2) 130 ± 10 °C
Lock Dim (Big) 6.0±0.10mm DVC Temp.(Z3) 130 ± 10 °C
Temp. Gauge
Dim. 5.30±0.10mm
Dim. 13.0±0.20mm
Dia 21.0±0.20mm DVC Temp.(Z4) 130 ± 10 °C
- Pieces should be deflashed on
Operator / 100% By Operator
Cutting & Deflashing 40 Appearance Marked Line
Engineer-Quality
Visual
2 Times/Shift-QA Engr.
NA
- No Deep Cut

- No Flashes, No Crack, No Deep

Appearance Visual
Cut, No Short Moulding etc.
Finish Black DVC
Dia. 31.50±0.30mm DVC
Thread ID 5.0±0.10mm DVC
Flap thick. 3.0±0.10mm DVC As Per
Final Inspection 50 Lock Dim (small) 4.0±0.10mm Engineer- QA DVC As Per Inspection Plan PDIR Inspection
Lock Dim (Big) 6.0±0.10mm DVC Plan
Dim. 5.30±0.10mm DVC
Dim. 13.0±0.20mm DVC
Dia 21.0±0.20mm DVC
Stud length 49.0±030mm DVC
Thread Dia. 4.8±0.10mm DVC
Total part weight 12 gram Weighing M/C
- No Flashes, No Crack, No Deep 100% By Operator
Appearance Visual
Cut, No Short Moulding. 2 Times/Shift-QA Engr.
Operator /
Packing 60
Engineer-Quality
100% By Operator
Quantity 500 parts per polybag/polyBag Visual
2 Times/Shift-QA Engr.

Each Parts should be kept at own 100% By Operator

Appearance Supervisor Store Visual
location 2 Times/Shift-QA Engr.

Quantity should be verified by

Storage of Finished 100% By Operator
70 Quantity Despatch Supervisor before Supervisor Despatch Counting
Goods and Despatch 2 Times/Shift-QA Engr.
Despatch.

100% By Operator
Packing Packing of Part should be OK Supervisor Despatch Visual
2 Times/Shift-QA Engr.

JP/QC/017 REV:00 Date:12/06/2018

-165-
 Dt. Of Origin & Rev.
CHECKING AIDS LIST Dt. Of Rev.
Doc. No.
Supplier Name:- JP ENTERPRISES
Supplier Code:-- 500014 Checking Aids No.
Part Name:- STUD PIN COMP H/L YG4 Change Level.
Part No:- 16007237 Date : 12/7/2018
Change Level:- -----
PREPARED BY : APPROVED BY :
Guages / Instruments / Calibration Freq. Least count Calibration Date MSA
A INSTRUMENTS Test equipments no. YES/NO/NR
1 Dial Vernier Caliper VC/JP/01 0-200mm 0.02MM 22/06/2017 YES

2 Digital Vernier Caliper DVC/JP/02 0-150MM 0.01MM 22/06/2017 YES

SIGN.(VENDOR) : kapil kumar

J.P. ENTERPRISES PRE DISPATCH IPSPECTION REPORT

Customer name = Lumax Ind.Ltd. Date 12/7/2018

Part No. 16007237 invoice no

Part Name = STUD PIN COMP H/L YG4 Qty. 05 nos

SPECIFICATION
S.NO PARAMETER
& TOLERANCE 1 2 3 4 5 OK / NOT REMARKS

Should be free from burr

dent thread damage,short
1 Appearance mould,shrinkage,breakage OK OK OK OK OK ok
etc.

2 Finish Black OK OK OK OK OK ok

3 Dia. 31.50±0.30mm ok
31.52 31.54 31.54 31.56 31.53

4 Thread ID 5.0±0.10mm ok
4.97 4.98 4.95 4.96 4.98
5 Flap thick. 3.0±0.10mm 2.94 2.96 2.98 2.97 2.94 ok
6 Lock Dim (small) 4.0±0.10mm 4.02 4.02 4.06 4.08 4.05 ok
7 Lock Dim (Big) 6.0±0.10mm 6.02 6.08 6.03 6.04 6.02 ok
8 Dim. 5.30±0.10mm 5.34 5.36 5.31 5.36 5.32 ok
9 Dim. 13.0±0.20mm 12.95 12.91 12.96 12.97 12.95 ok
10 Dia 21.0±0.20mm 21.02 21.06 21.04 21.03 21.07 ok
11 Stud length 49.0±030mm 49.12 49.16 49.18 49.15 49.15 ok
12 Thread Dia. 4.8±0.10mm 4.75 4.76 4.74 4.75 4.76 ok

13 Total part weight 12 gram OK OK OK OK OK ok

prep.by appd.by
 J.P. ENTERPRISES
PROCESS FMEA
Process Failure Mode And Effects Analysis
Part Name . STUD PIN COMP H/L YG4 Rev. No.
(Process FMEA)
FMEA Number:
Part No. 16007237 Process Responsibility: Mr.Pawan Pathak Prepared by: Mr.Kapil
Model Year(s)/Vehicle(s) Key Date : 6/12/2018 Rev No.
Mr.Jaipal,Mr.Akash,Mr.Kapil,Mr
Team: Customer Lumax Ind. Ltd. Rev. Date
.Pramod
Detail Before Change Detail After Change Change
S.No. Drg.Rev.No. Drg.Rev.Date Change Sugg.By Status
Ammendment Detail Sugg. To

Process Potential Current Process

Potential Recommen Responsibil
Part/ Function/ Potential Cause(s)/ Actions
Effects Severity Class Controls Controls R.P.N ded ity & Target Severity Occurrence Detection R.P.N
process No. Requirement Failure Mode Mechanism(s) Occurrence Detection Taken
of Failure Prevention Detection Actions Date
s of Failure
packing condition Verfication
not good Check the done by store
Raw material
Problem at next packing person at the
damaged due to
operation.
5 Condition
1 time of
7 35
Receiving of transpotation
Raw Material , visually unloading the
as per customer raw material
Requirment(TP Improper
E 80) Identification Stock Material
Problem at next Regester to be Identiification
Material Mixup
operation.
5 mainton after
1 checked by
7 35
Identification store incharge

10 RAW Not Porper Inspection Std. Supplier test

Raw material not Problem at next
MATERIAL as per standard operation. 8 checked at made for raw 1 report checked 7 56
INSPECTION Supplier end material for every lot

Material
Stock
NOT PROPER Identiification
NOT PROPER Not Maintion FIFO Regester to be
STORAGE IDENTIFICATION. system 4 STORAGE OF
mainton after
2 checked by 7 56
RAW MATERIAL STORE
Identification
KEEPER

Location defined Material issue

ISSUE OF Wrong Material Delay production / Matterial not on
RAW MATRIAL Issue Production not run 7 designated location
on display board 2 slip 6 84
material wise (NPI/STR/F/02)

PRE- MACHNE SET

Control Plan, ,
UP APPROVAL
HAETING OF Silver Mark On PROCESS
20 RAW The Component
Poor appearance 4 LOW TEMP.
PRAMETER, 3 AT A 5 60
FREQUENCYOF
MATERIAL work instruction
EVERY SHIFT

SETUP
MOULD APPROVAL &
CONDITION INPROCESS
INJECTION TIME SHORT MOULDING CHART INSPECTION
LESS /SHRINKAGE 7 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 70
SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR

SETUP
MOULD APPROVAL &
CONDITION INPROCESS
INJECTION TIME CHART INSPECTION
OVER
EXTRA FLASHES 5 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 50
SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR
 SETUP
MOULD APPROVAL &
CONDITION INPROCESS
COOLING TIME CHART INSPECTION
LESS
SHRINKAGE 7 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 70
SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR

SETUP
MOULD APPROVAL &
CONDITION INPROCESS
FITMENT
COOLING TIME CHART INSPECTION
OVER
PROBLEM AT 7 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 70
CUSTOMER END
SETTING DONE VISUAL
BY SETTER INSPECTION BY
MOULDING OPERATOR
PROCESS &
30 COOLING OF
PARTS/
INSPECTION SETUP
MOULD APPROVAL &
CONDITION INPROCESS
PART NOT FILLING CHART INSPECTION
HOLD TIME LESS
PROPERLY 7 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 70
SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR

SETUP
MOULD APPROVAL &
CONDITION INPROCESS
HOLD TIME CHART INSPECTION
OVER
NO EFFECT 7 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 70
SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR

SETUP
MOULD APPROVAL &
CONDITION INPROCESS
SHORT MOULDING
CHART INSPECTION
HEAT-1 LESS /SHRINKAGE/ 7 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 70
MOISTURE
SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR

SETUP
MOULD APPROVAL &
CONDITION INPROCESS
FLOW
CHART INSPECTION
HEAT-1 OVER MARK/MATERIAL 7 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 70
BURN
SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR

30 MOULDING
PROCESS & SETUP
COOLING OF MOULD APPROVAL &
PARTS/ CONDITION INPROCESS
MATERIAL NOT CHART INSPECTION
INSPECTION HEAT-2 LESS
FLOW IN BARREL 7 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 70
SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR

SETUP
MOULD APPROVAL &
CONDITION INPROCESS
CHART INSPECTION
HEAT-2 OVER MATERIAL BURN 7 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 70
SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR
 SETUP
MOULD APPROVAL &
CONDITION INPROCESS
MATERIAL NOT CHART INSPECTION
HEAT-3 LESS FLOW IN BARREL 7 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 70
SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR

SETUP
MOULD APPROVAL &
CONDITION INPROCESS
CHART INSPECTION
HEAT-3 OVER MATERIAL BURN 7 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 70
SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR

SETUP
MOULD APPROVAL &
CONDITION INPROCESS
MATERIAL NOT CHART INSPECTION
HEAT-4 LESS FLOW IN BARREL 7 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 70
SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR

SETUP
MOULD APPROVAL &
CONDITION INPROCESS
CHART INSPECTION
HEAT-4 OVER MATERIAL BURN 7 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 70
SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR

SETUP
MOULD APPROVAL &
INJ CONDITION INPROCESS
SHORT MOULDING CHART INSPECTION
PRESSURE /SHRINKAGE 7 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 70
LESS SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR

SETUP
MOULD APPROVAL &
INJ CONDITION INPROCESS
CHART INSPECTION
PRESSURE EXTRA FLASHES 5 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 50
OVER SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR

SETUP
MOULD APPROVAL &
CONDITION INPROCESS
INJ SPEED CHART INSPECTION
LESS
SHRINKAGE 7 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 70
SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR

SETUP
MOULD APPROVAL &
CONDITION INPROCESS
INJ SPEED CHART INSPECTION
OVER
EXTRA FLASHES 5 SETTING NOT OK
FOLLOW & 2 2HRS. & 100% 5 50
SETTING DONE VISUAL
BY SETTER INSPECTION BY
OPERATOR
 TO TRAINED 100% VISUAL
GATE POOR REJECTED BY NOT PROPERLY
40 CUTTING APPERANCE CUSTOMER 4 BUFFING/CUTTING
THE 3 CHECK BY 7 84
OPERATOR OPERATOR
TO TRAINED 100% VISUAL
POOR REJECTED BY NOT PROPERLY
50 DEFLESHING APPERANCE CUSTOMER 4 BUFFING/CUTTING
THE 3 CHECK BY 7 84
OPERATOR OPERATOR
NOT PROPERLY TO TRAINED 100% VISUAL
FINAL POOR REJECTED BY
60 INSPECTION APPERANCE CUSTOMER 4 INSPECTION BY THE 3 CHECK BY 7 84
OPERATOR OPERATOR OPERATOR

Packing Std.
Packing Qty. Customer not Packing Std. not
5 to be 2 4 40
More & Less. accepted followed
followed
Packing/Stackin Operator
Damaging of Customer not As per work
5 g not 2 cum packer 4 40
product accepted instruction.
70 Packing homogeneous check and
sign the
TO packing slip
2.WRONG PROVIDE
Customer not NO LABLING
PACKING 7 THE 2 4 56
accepted STD.
SLIP LABLING
STD.

PDI Report
Inspection Fitment
Material skip at Inspection as per
80 P.D.I notdone as problem at 4 2 6 48
pdi as per FIS sampling
per standard Customer end
plan

Despatch to Despatch
Despatch not Despatch
Customer not be regester
90 DESPATCH as per 6 regester not 2 4 48
accepted monitoring follow on
sehedule follow
daily. daily

Minor Critical Outsource

Parameter Parameter Process
Legends:
Prepared By: Approved By:

JP/QC/017
.