Shanmugha Precision Forging

Control Plan
Proto
Control Plan No:
type. Pre-launch Production Core team: VSR , JB & Prem . Rev No: O1
CP/SPF/ 109
Rev Date: 20.08.2014
ü Plant Approval / date ;18.07.2007 Date (Orig): 18.07.2007
Issue Date: 20.08.2014
Part Name : Other Approval / Date ; NA Customer Engineering Approvel / Date : NA
3 1/4" BORE A-SERIES SIDE-LUG
CAPS
Key Contact Name : V.SUNDARARAJAN / J. BALAJI Customer Quality Approval / Date : NA

Drg / Part No :A02-P02 Key Contact Phone : 91 99949 67805/ 91 99449 44495 Other Approval / Date : NA

Drg. Issue Level : A

Machine, Characteristics Methods
Jigs, Spl Product/ Evaluation Reaction Responsibility
Process Fixtures Chara Process measurement Plan/
Opn.No.
Description Tools for No Product Process c- Specification Technique Sample Size Freq. Control Method Corrective
Class Action
Mfg. Tolerance

Receipt of 1 quantity Weighing Machine

10 Matl. From `1 Every Lot D I
Supplier 2 Gate pass Verfication

1 Rectangle 99.0 ±0.25 X 150.0 ±0.25 Dig.Vernier caliper

2 Length Variable Measuring tape Supplier &
Document
3 Material Raw Aluminium 6061 T6 Supplier supplied test report External Agencies
20 Verfication Every Lot D I
Material Material Test
Report Certificate & GRN
No cracks, blow holes,
4 Surface Visual
Dents Allowed
1 Length 99.0 ±0.25 Dig. Vernier Caliper
2 Thickness 21.1 ±0.25 Dig. Vernier Caliper
Band saw 3 Width 99.0 ±0.25 Dig. Vernier Caliper
Line Inspection
Slug 4 Length 150±0.25 Dig. Vernier Caliper
30 Cutting Cutting 1 25 report /First off & G O&I
Cutting Last off report
Machine 5 Length 296.0 ±0.5 Dig. Vernier Caliper
Genernal Free from Burrs &
6 Visual
Workmanship Damage
1 Width 146.05±0.190 Dig. Height Gauge
2 Distance 25.4±0.190 Dig. Height Gauge
3 Thickness 19.05 ±0.190 Dig. Height Gauge
4 Height 95.25±0.190 Dig. Height Gauge
5 Radius 6.35 ±0.095 Contracer
6 Width 95.25±0.190 Dig. Height Gauge Line Inspection
Shape 7 Radius 6.35 ±0.095 Contracer
40 Milling M/c Milling 1 20 report /First off & F O&I
Milling
8 Radius 2X3.17 ±0.095 Radius Gauge Last off report
9 Radius 4X3.17 ±0.095 Radius Gauge
10 Flatness 0.15MAX 2d with dial
11 All finishes(u.o.s) 3.2 Ra Max Surface Roughness Tester
Genernal Free from Burrs &
12 Visual
Workmanship Damage
1 Length 35.0 ±0.25 Dig. Vernier Caliper
Band saw Line Inspection
Slug 2 Parallelism 0.1 2d with dial
50 Cutting Cutting 1 25 report /First off & F O&I
Cutting Last off report
Machine Genernal Free from Burrs &
3 Visual
Workmanship Damage

FORM NO;QAC;01/R0 Page 1 of 4

 Shanmugha Precision Forging
Control Plan
Proto
Control Plan No:
type. Pre-launch Production Core team: VSR , JB & Prem . Rev No: O1
CP/SPF/ 109
Rev Date: 21.06.2018
ü Plant Approval / date ;18.07.2007 Date (Orig): 18.07.2007
Issue Date: 21.06.2018
Part Name : Other Approval / Date ; NA Customer Engineering Approvel / Date : NA
3 1/4" BORE A-SERIES SIDE-LUG CAPSKey Contact Name : V.SUNDARARAJAN / J. BALAJI Customer Quality Approval / Date : NA
Drg / Part No :A02-P02 Key Contact Phone : 91 99949 67805/ 91 99449 44495 Other Approval / Date : NA

Drg. Issue Level : C

Machine, Characteristics Methods
Spl Reaction
Jigs, Product/ Evaluation Responsibility
Process Chara Plan/
Opn.No. Fixtures Process measurement
Description No Product Process c- Sample Size Freq. Control Method Corrective
Tools for Specification Technique
Class Action
Mfg. Tolerance
1 Bore Depth 23.87 ±0.190 Dig. Vernier Caliper
2 Diameter Ø 82.486 ±0.028 Dig. Blade Micrometer
3 Diameter Ø 86.677±0.047 Dig. Height Gauge
4 Runout w.r.t "A" 0.12 Max Dig. Height Gauge
5 Length 33.0 ±0.25 Dig. Vernier Caliper
6 Distance 2.38 ±0.095 Depth Micrometer
7 Face Gr. Depth 1.409 ±0.047 Dig. Height Gauge
8 Finish on Gr.Face Ra 0.8 Max Surface Roughness Tester
9 ┴ w.r.t "A" 0.07 Max Dig. Height Gauge
10 Gr. Depth 0.22 ±0.095 Contracer
11 Face Gr. Diameter Ø 69.85±0.190 Contracer
12 Length 95.25±0.2 Dig.Vernier Caliper Line Inspection
Jobber, 13 Center Distance 47.434 ±0.047 Dig. Height Gauge report /First off &
60 Turning I Turning 14 Center Line Position Turning 0.12 Max Dig. Height Gauge 1 15 Last off report F O&I
Fixture (*Dimension
15 Flatness 0.12 Max Dig. Height Gauge 1piece/shift)
16 Diameter Ø 18.072 ±0.047 Dig. Vernier Caliper
17 Groove Width 4.8±0.095 Dig. Height Gauge
18 Thickness 1.52 ±0.190 Dig. Height Gauge
19 Finish(2x) Ra 0.8 Max Surface Roughness Tester
20 ID . Gr.Diameter Ø 24.066±0.047 Caliper Gauge
21 Runout w.r.t "A" 0.12 Max Dig. Height Gauge
22 All finishes(u.o.s) 3.2 Ra Max Surface Roughness Tester
23 Internal Corners R0.38 Max Profile Projector
24 External Corners Chmf 0.25 +0.25 /-0.0 Profile Projector
Genernal Free from Burrs &
25 Visual
Workmanship Damage
1 Total Length 31.75 ±0.190 Dig. Vernier Caliper
2 // W.R.T "B" 0.12 Max Dig. Height Gauge
3 // W.R.T "B" 0.07 Max Dig. Height Gauge Line Inspection
Jobber, 4 All finishes(u.o.s) 3.2 Ra Max Surface Roughness Tester report /First off &
70 Turning II Turning 5 Internal Corners Turning R0.38 Max Profile Projector 1 5 Last off report F O&I
Fixture (*Dimension
6 External Corners Chmf 0.25 +0.25 /-0.0 Profile Projector 1piece/shift)

Genernal Free from Burrs &

7 Visual
Workmanship Damage
1 Drill Ø (4x) 10.35±0.04 Plain plug gauge
2 Center Distance 70.104 SQ.±0.190 Dig. Height Gauge
3 Center Distance(2X) 35.052 ±0.095 Dig. Height Gauge
4 Distance 47.434 ±0.047 Dig. Height Gauge
Line Inspection
FORM NO;QAC;01/R0 Page 2 of 4 report /First off &
 5 Center Distance(2X) 35.052 ±0.095 Dig. Height Gauge Line Inspection
report /First off &
Drilling 4- 6 Center Distance 70.104 SQ.±0.190 Dig. Height Gauge
80 VMC Drilling 1 5 Last off report(* F O&I
Holes 7 All finishes(u.o.s) 3.2 Ra Max Surface Roughness Tester dimension
8 Internal Corners R0.38 Max Profile Projector 1piece / shift)

9 External Corners Chmf 0.25 +0.25 /-0.0 Profile Projector

Genernal Free from Burrs &
10 Visual
Workmanship Damage

FORM NO;QAC;01/R0 Page 3 of 4

 Shanmugha Precision Forging

Control Plan
Proto
Control Plan No:
type. Pre-launch Production Core team: VSR , JB & Prem . Rev No: O1
CP/SPF/ 109
Rev Date: 20.08.2014
ü Plant Approval / date ;18.07.2007 Date (Orig): 18.07.2007
Issue Date: 20.08.2014
Part Name : Other Approval / Date ; NA Customer Engineering Approvel / Date : NA
3 1/4" BORE A-SERIES SIDE-LUG
CAPS
Key Contact Name : V.SUNDARARAJAN / J. BALAJI Customer Quality Approval / Date : NA
Drg / Part No :A02-P02 Key Contact Phone : 91 99949 67805/ 91 99449 44495 Other Approval / Date : NA
Drg. Issue Level : A
Machine, Characteristics Methods
Spl Reaction
Jigs, Product/ Evaluation Responsibility
Process Chara Plan/
Opn.No. Fixtures Process measurement
Description No Product Process c- Sample Size Freq. Control Method Corrective
Tools for Class Specification Technique Action
Mfg. Tolerance
1 Drill Ø (2x) 14.262±0.04 Plain plug gauge
2 ┴ w.r.t "A" 0.12 Max Dig. Height Gauge
3 Distance 16.662 ±0.095 Dig. Height Gauge
4 Center Distance 120.65±0.095 Dig. Height Gauge Line Inspection
Drilling - 2 5 Distance 60.325 ±0.095 Dig. Height Gauge report/First off &
90 VMC Drilling 1 10 F O&I
Holes last off report
6 All finishes(u.o.s) 3.2 Ra Max Surface Roughness Tester
(1piece /shift)
7 Internal Corners R0.38 Max Profile Projector
8 External Corners Chmf 0.25 +0.25 /-0.0 Profile Projector
Genernal Free from Burrs &
9 Visual
Workmanship Damage
Free from Burrs &
100 Deburring Manual 1 Deburring Manual Visual 1 25 F O&I
Damage

Final As Per Final Final inspection

110 1 As Per FIP / NUMATICS /109 R I
Inspection Inspection Plan Report

Note 1 : All Dimensions are in mm

Note 2 : I - Inspector O - Operator S - Setter
Note 3 : D - Reject the lot & Inform Supplier for necessary action through Report
.............. E1 to E8 - Stop & Segregate
.............. F - Stop & Correct the process.
.............. G - Stop & Segregate Move Material to Non Conformance area
.............. H - Hold the Lot , Segregete / Reject , Inform Customer
……………….R - Stop & Replace & Inform to the Supervisor for necessary action
Note 4 : A - Customer designated special characters
A - SPF designated special charcters
* DIMENSIONS NOT LISTED ARE NOT CHECKED AS THEY ARE BEING CONTROLED BY THE TOOLS ARE CERTIFIED BY TOOL ROOM / QUALITY
* SUPPLIER PRODUCT INSPECTED AND RANGE RECORDED.
ECN.89 CP/REV1
Prepared by : Checked by: Approved by:
Date: Date: Date:

FORM NO;QAC;01/R0 Page 4 of 4