1.

01
0.88
1.07
1.02
1.11
1.00
1.00
1.11
0.77

tank leak 0
 JOINT_WISE_WELDER
SHIFT INCHARGE C.B. SUDHAKAR

JOINT NAME SLNO: WELDER NAME 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 26 27 28 29 30 31

F/D TACK 1 SATHISH
2 MD IMRAN

R/D TACK 1 NANDAKUMAR

2 ZAFFER

FRAME PIVOT TACK 1 IMRAN

2 SELVAKUMAR

FORK END TACK 1 ZAFFER

2 IMRAN

FORK TACK 1 VISWANATHAN

2 P. RAJAN

FORK PIVOT TACK 1 K. SURESH

2 MATHIVANAN

FORK RUN WELDING 1 SARAVANAN

2 MANIKKARAJ
3 TAMILARASAN
4 MOHANDASS
5 VIMALRAJ

PIVOT RUN WEALDING 1 SARAVANAN

2 MANIKKARAJ
3 SINGRAVEL
4

H/TUBE JOINT 1 VIMALRAJ

2 SARAVANAN
3

S/T & B/T JOINT 1 ASHOK KUMAR

2 TAMILARASAN

S/T , B/T & BB JOINT 1 TAMILARASAN

2 J. ASHOK KUMAR

Page 3
 JOINT_WISE_WELDER
3
4

S/T & T/TUBE JOINT 1 MOHANDASS

2 ULAGANATHAN

B/T & T/TUBE JOINT 1 ULAGANATHAN

2 MANIKKARAJ

C/S & BB JOINT 1 JAYABALU

2

S/T & S//S JOINT 1 UMAPATHY

2 SELVAKUMAR

C/S END JOINT 1 MATHI

2 MANIKKARAJ

PIVOT JOINT 1
2

C/S BRIDGE PLATE JOIN 1 SATHISH

2 VISWANATHAN
3 JAYABALU
4
5
6

S/S PLATE JOINT 1 UMAPATHY

2 MANIKKARAJ
3 JAYABALU
4 VISWANATHAN
5
6

C/S END JOINT 1 MATHIYALAGAN

2 SINGRAVEL
3 VISWANATHAN
4 K. SURESH
5
6

Page 4
 ACCEPTED F O R K ID N O S

Date: Inspected by: Shift Model

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Blow hole
Brake hole drilling wrong position
Brass lump
Bulging
Caving
Column Thread damaged
Dent
Double numbring
Dropout Over filing
Dropout up and down
Dropout wrong assy
End twist
Eyelet damaged in welding
F/column bush Drain hole wrong
F/Column bush line mark
F/Column thread damaged
Fork blade damage
Fork blade up & down
Milling missing
Number not clear
Ovalling mark
Over filing
Pin hole ( Brazing )
Pin hole ( welding )
Pitted
Pivot damaged in polishing
Pivot damaged in welding
Pivot height less
Pivot pitch not ok
Pivot thread damaged
Pivot twist
poor Tack welding
Rolling mark
Thread missing
Turning dia Damaged
Turning length less
Turning length more
Turning OD Under size
Under cut ACCEPTED:

Welding crack REJECTED:

Welding under cut INSECTED:

SlNo Defects Qty Total

1 Acid leakage
2 B/tube line mark
3 BB damage
4 BB thread missing
5 Blow holes
6 Bottom tube bulging
7 Brass lumps
8 Bulging
9 Cable guide cross
10 Cable stopper cross
11 Dent
12 drain hole missing
13 drain hole outer side
14 End damage
15 End welding missing
16 Excess brass
17 File mark
18 Hit mark
19 Lack of brazing
20 line mark
21 number missing
22 Oily surface
23 Out side hole
24 Overlap welding
25 Pin hole
26 Pitted
27 Pivot damage
28 Pivot assembly cross / bend
29 Pivot hole missing / with brass
30 Pivot Pitted
31 Pivot thread spoil
32 Planishing missing
33 poor brazing
34 Poor polishing
35 poor welding
36 poracity
37 Rust
38 S/tube reaming missing
39 Seat Tube bulge
40 Swaging mark
41 Thread damage
42 Top side numbering line mark
43 Tube Bulging
44 Tube line mark
45 Weld missing
46 Welding spatters
47 Welding under cut
48 white powder
49 Yellow mark
 A C C E P T E D S E L F F I N I S H F ORK ID N O S
Date: Inspected by: Shift Model
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
 Defects FORK ID NUMBERS TOTAL

Bush drilling wrong position

Blow hole

Brass lumps

Bulging

Caving

Column line mark

Double numbering

End over filing

End up and down INSPECTED QTY

End wrong assy REJECTED QTY

End damage in welding ACCEPTED QTY

End twist

End twist

Fork blade damage

Fork blade up and down

Number not clear

Ovalling mark

Pendulum gauge notok

pin hole – brazing

Pin hole – welding

Pitted

Pivot damage – polish

pivot damage – welding

Pivot pitch not ok

Pivot plate cross

Pivot thread damage

Poor tack welding

Turning dia under size

Turning height less

Turning height more

Overlap welding

W/o Went hole

Welding overlap

Welding spark damage

Welding under cut

A METALLURGICAL TEST

1 FLATTENING TEST - 1 EVERY LOT PER SUPPLIER

2 DRIFT EXPANSION TEST - 1 PER EVERY LOT PER SUPPLIER

STEEL TUBES
3 TENSILE STRENGTH - 1 TYPE PER EVERY LOT PER SUPPLIER

CHEMICAL COMPOSITION & PROPERITIES - 1/6 MONTH PER EVERY

4 SUPPLIER

5 WELDING PENETRATION TEST - 1 PER 1000 FRAME PER MODEL

FRAME

6 BRAZING TEST 1 PER 1000 FRAMES / MODEL

7 FRAME & FORK B/O SPARK EROSION TEST - 1 PER EVERY LOT PER SUPPLIER
COMPONENT

8 WELDING PENETRATION TEST - 1 PER 1000 FRAME PER MODEL

FORK

9 BRAZING TEST 1 PER 1000 FRAMES / MODEL

B PRODUCT TEST
FATIGUE TEST WITH VERTICAL FORCES ( 1000 N) - EN STD 14764
10 ( CITY & TREKKING )

IMPACT TEST -FALLING MASS ( 22.5 Kg /DROP HT. 180 MM) - EN STD
11 FRAME 14764 ( CITY TREKKING )

FATIGUE TEST WITH PEDALLING FORCES ( 1000 N) - EN STD 14764

12 ( CITY & TREKKING )

13 STATIC BENDING TEST (1000 N) - EN STD 14764 ( CITY & TREKKING )

FRONT FORK BENDING TATIGUE TST ( ± 450 N) - EN STD 14764 ( CITY

14 FORK TREKKING )
 FORK

REARWARD IMPACT TEST MASS ( 22.5 Kg /DROP HT. 180 MM) - EN

15 STD 14764 ( CITY TREKKING )

C PHOSPHATATION

16 FRAME & FORK COATING THICKNESS

D PAINT TEST - MACHINICAL RESISTANCE

17 CROSS HATCH ADHESION REF: STD ISO 2409 AUG.1992

18 DIRECT IMPACT RESISTANCE REF: STD ISO 6272 APR. 1993

19 FRAME & FORK MANDREL BEND REF: STD ISO 1519 OCT. 1981

20 ABRASION RESISTANCE

RESISTANCE TO GRAVELLING REF: STD CT063 DECATHLON TEST-

21 (REFERRING TO SAE J400 DEC. 2001)

PAINT TEST - PHYSICAL AND CHEMICAL

E RESISTANCE
MEASUREMENT OF GLOSS OF NON MATALLIC PAINT FILM REF: STD
22 ISO 2813

RESISTANCE OF CHEMICAL PRODUCTS REF: STD ISO 2812 METHOD 2

23 FRAME & FORK &3

24 RESISTANCE TO SWEAT REF: STD NFS 80-772

PAINT TEST - RESISTANCE TO WEATHERING

F CONDITIONS
25 NSS REF: STD ISO 9227 DEC.1190

a) Blistering ( W/O SCARIFICAITON) REF: STD ISO 4628/2 *ASTM D714-87

26 WILL BE USED FOR EVALUATION OF BLISTERING

27 b) Rusting ( W/O SCARIFICATION ) REF: STD ISO 4628/3

c) Blistering ( WITH SCARIFICAITON ) REF: STD ISO 4628/2 **ASTM D714-

28 87 WILL BE USED FOR EVALUATION OF BLISTERING
FRAME & FORK
29 d) Rusting ( WITH SCARIFICAITON ) REF: STD 1SO 4628/3

30 ACCELERATED AGEING TEST REF: STD NFT 30036 ISO 3668

31 a) Gloss measurement NFT 30064

32 b) Cross hatch adhesion test ISO 2409

TEST ON THE STICKERS OF PAINTED FRAME AND

G FORK WHEN THERE IS NO CLEAR COAT ON THE
STICKERS
33 PEEL ADHESION TEST

34 ADHESION OF THE INK

35 NAIL SCRATCH TEST

36 RESISTANCE TO CLEANING COIDITIONS

FRAME & FORK

COMPOSITION OF THE INK REF: STD EN71, ASTM F 963, 16 CFR PART
37 1303

RESISTANCE FO CHEMICAL PRODUCTS REF: STD ISO2836 OCT.1999

39 TEST MEHOD 3.3.1

39 RESISTANCE TO SWEAT REF: STD NFS 80-772

40 RESISTANCE OF UV

TEST ON THE STICKERS OF PAINTED FRAME AND

H FORK AIMED TO BE CLEAR COAT
COMPOSITION OF THE INK REF: STD EN71, ASTM F 963, 16 CFR PART
41 1303

RESISTANCE TO CHEMICAL PRODUCTS REF: STD 2836-OCT.1999

42 TEST METHOD 3.3.1

43 FRAME & FORK RESISTANCE TO SWEAT REF: STD NFS 80-772

44 RESISTANCE OF UV

ABILITY OT BE CLEAR COATED AND RESISTANCE TO TEMPERATURE

45 DURING THE CURING OF CLEAR COAT
 PREVENTIVE MAINTENANCE PLANE FOR TIG WELDING MACHINE
MC NO: SHIFT: DATE:
Supervisor (or) Shift
SLNO PARAMETERS Daily Checks Weekly checks Monthly Checks
incharge sign
POWER
Check the 3 phase availability voltage proper
1
connection/light on panel
2 Check for proper earth connection
3 Check for all leads thight
4 Check for braker on
MACHINE
1 Check for panel fuction
2 Check for cooling fan working
TORCH CONSUMABLES
1 Check for tungsten electrode rod
2 Check for tightening bush thread
3 Check for electrode sheld including o ring
4 Check for Torch body damages
5 Check insulating ring damages
6 Check for Gas Nozzle breakage
7 Housing for tighterning bush/gas lens
8 Check for proper gas flow
9 Damages Physocally to Equipment
10 De dusting
11 Terminal tightness
12 Check for torch cable damage
13 Check for cooling fan working
14 Check for operating knobs damages

MC NO: SHIFT: DATE

Supervisor (or) Shift
SLNO PARAMETERS Daily Checks Weekly checks Monthly Checks
incharge sign

1 Check the 3 phase availability voltage proper

connection/light on panel
2 Check for proper earth connection
3 Check for all leads thight
4 Check for braker on
MACHINE
1 Check for panel fuction
2 Check for cooling fan working
TORCH CONSUMABLES
1 Check for tungsten electrode rod
2 Check for tightening bush thread
3 Check for electrode sheld including 'o' ring
4 Check for Torch body damages
5 Check insulating ring damages
6 Check for Gas Nozzle breakage
7 Housing for tighterning bush/gas lens
8 Check for proper gas flow
9 Damages Physocally to Equipment
10 De dusting
11 Terminal tightness
12 Check for torch cable damage
13 Check for cooling fan working
14 Check for operating knobs damages
 Fork – Defects Reason Name
Welding crack

Pivot damage in polishing

Eyelet damage in welding

Frame – Defects
Thread washout

Pitted

Dent

Fork – Defects Reason Name

Welding crack

Pivot damage in polishing

Eyelet damage in welding

Frame – Defects

Thread washout

Pitted

Dent

Fork – Defects Reason Name

Welding crack

Pivot damage in polishing

Eyelet damage in welding

Frame – Defects

Thread washout

Pitted

Dent

Fork – Defects Reason Name

Welding crack

Pivot damage in polishing

Eyelet damage in welding

Frame – Defects

Thread washout

Pitted

Dent
 AS PER TOLERANCE AS PER TOLERANCE OF
MEASUREMENT
SLNO DESCRIPTION UOM OF DECATHLON DECATHLON (MEDUIM ACTUAL STATUS
TYPE
(LOW RANGE) RANGE)

1 SEAT TUBE SYMMETRY 4.1 VARIABLE TYPE MM 2 1.5 0.4 OK

2 HEAD TUBE POSITION 4.2.1 VARIABLE TYPE MM 3 2 -0.2 OK

3 HEAD TUBE AXIS ORIENTATION 4.2.2 VARIABLE TYPE MM 4 2.5 6.5 NOT OK

4 HEAD TUBE FACE PARALLELISM 4.3 VARIABLE TYPE MM 0.5 0.5 0.5 OK

5 REAR TRIANGLE SYMMETRY 5.1 VARIABLE TYPE MM 2.5 1.5 -0.2 OK

6 TYRE ALIGNMENT ON C/STAY 5.2 VARIABLE TYPE MM 4 3 0.3 OK

7 TYRE ALIGNMENT ON S/STAY 5.3 VARIABLE TYPE MM 4 3 0.3 OK

8 RIM SYMMETRY BET. PIVOT 5.4 VARIABLE TYPE MM 3 2 -0.1 OK

9 S/STAY BRIDGE HOLE SYMMETRY 5.5 VARIABLE TYPE MM 2 2 1.4 OK

10 C/STAY BRIDGE HOLE SYMMETRY 5.6 VARIABLE TYPE MM 2 2 0.3 OK

11 BRAKE PIVOT PARALLELISM 5.7 VARIABLE TYPE DEG. 3O 3O 0,0 OK

12 BRAKE PIVOT PARALLELISM 5.7 VARIABLE TYPE DEG. 3O 3O 2O OK

13 PIVOT HEIGHT VARIABLE TYPE MM 1 OK

14 PIVOT SPRING HOLE ALIGNMENT 5.8 VARIABLE TYPE MM 1 1 0.3 OK

15 HEAD TUBE VERTICAL POSITION 6.1 VARIABLE TYPE MM 3 2 OK OK

16 HEAD TUBE HORIZONTAL POSITION 6.2 VARIABLE TYPE MM 3 2 OK OK

17 HEAD TUBE ANGLE 6.3 VARIABLE TYPE DEG. 2.5 / 0.5 O 0.5 / 1.0 O OK OK

18 TUBES BENDING POSITION VARIABLE TYPE MM OK

19 C/STAY VERTICAL POSITION 6.5 VARIABLE TYPE MM B1- 1, B2-3 B1- 1, B2-2 0.5 OK

20 DROPOUT AXIS POSITION 6.6 VARIABLE TYPE MM 3 2 1.5 OK

 LIST OF Q U A L I F I E D W E L D E R S - STEEL
SLNO EMP. NAME EMP. NO: Shift incharge VALID UP TO

2 ASKAR UK 90002 Surindrababu 09/09/2014

3 BAGREERATHAN.M 90044 Surindrababu 21/4/2014
4 CHIDHAMBAREESHWARAN 62365 Sudhakar 23/11/2014
5 CHITAMBARAM S 90011 Surindrababu 23/11/2014
6 HARIHARAN R 90024 Surindrababu 09/09/14
8 JAIPALU 90010 Sudhakar 09/09/2014
9 KAMESH M 90041 Surindrababu 23/11/2014
10 LAL SHING S 90005 Surindrababu 09/09/2014
11 MANIKARAJ J 90017 Sudhakar 09/09/2014
13 MATHIYAZHAGAN K 90025 Sudhakar 09/9/2014
14 MOHAMMED IMRAN 63394 Sudhakar 23/11/2014
15 NANDAKUMAR S 90030 Surindrababu 9/9/2014
16 PRABAKARAN S 63328 Surindrababu 23/11/2014
18 RAJAN P 90032 Sudhakar 23/11/2014
19 RAJKUMAR.A 62338 Surindrababu 20/4/2014
20 RAMKI.M 62403 Surindrababu 23/11/2014
21 RAZACK QURAISHI M.A 90040 Surindrababu 09/09/14
22 SAMPATH M 90021 Surindrababu 23/11/2014
23 SASIKUMAR.G 62247 Surindrababu 20/4/2014
24 SATHISH .J 90033 Sudhakar 09/09/2014
25 SATHISH KUMAR.K 62383 Sudhakar 09/03/11
26 SINGARAVELU 90022 Sudhakar 04/06/13
27 SIVAKUMAR M 90035 Surindrababu 09/09/14
28 SUGAN RAJ.S 90039 Surindrababu 23/11/2014
29 SUGUMAR M 90031 Sudhakar 09/09/14
30 TAMILARSAN J 90013 Sudhakar 09/9/2014
31 THIYAGARAJAN R 90014 Surindrababu 22/7/2013
32 ULAGANATHAN S 90018 Sudhakar 09/09/2014

33 UMAPATHY K 90008 Sudhakar 04/06/13

34 VARADHARAJA PERUMAL 90028 Sudhakar 23/11/2014

35 VIJAYKANTH.I 62294 Sudhakar 9/3/2014
36 VISWANATHAN S 90034 Sudhakar 23/11/2014
37 SELVA KUMAR R 62468 Sudhakar 22/7/13
38 SANTHOSE Kamaraj 2/12/2015
39 HARI Kamaraj 2/12/2015
40 AMERJITH Kamaraj 2/12/2015
41 KUMAR Kamaraj 2/12/2015
42 MANNU Kamaraj 2/12/2015
43 RAMDULAR Kamaraj 2/12/2015
 FRAME TUBE PREPERATION CELL
DATE

OPERATION DAY NIGHT DAY NIGHT DAY NIGHT

PREPIERCING 1
H/T

PREPIERCING 2

COMPLETED TUBE

PARTING
BOTTOM BRACKET

PIERCING

RAMING

NUMBERING

COMPLETED TUBE

BENDING

PREPIERCING 1
TOP TUBE

PREPIERCING 2

MITRING 1 & H. MITRING

MITRING 2

COMPLETED TUBE

OVALLLING

BENDING
BOTTOM TUBE

PREPIERCING 1

MITRING 1

HOLLOW MITRING

HOLLOW MITRING (III MITRING)

DRILLING

COMPLETED TUBE

PIERCING

MITRING
SEAT TUBE

DRILLING

SLOTTING

DRILLNG 15 MM

COMPLETED TUBE
BRIDGE TUBE

MITRING 1

MITRING 2

DRILLING

COMPLETED TUBE
NO. PRODUCTED
NO. REJECTED
ACCEPTED SETS
TOTAL MAN POWER
 TUBE PREPERATION CELL -FRAME
DATE : MODELS

OPERATION
PROD. REJ. PROD. REJ. PROD. REJ. PROD. REJ. PROD. REJ.
26x15 (L) 26x19 (L) 26x16 (G) 26x19 (G) 26x21 (G)
PREPIERCING 1
TUBE
HEAD

PREPIERCING 2

COMPLETED TUBE
BENDING

PREPIERCING 1
TOP TUBE

PREPIERCING 2

MITRING 1 & H. MITRING

MITRING 2

COMPLETED TUBE
OVALLING / BENDING

PREPIERCING 1
BOTTOM TUBE

PREPIERCING 2

MITRING 1

MITRING 2

MITRING 3

HOLLOW MITRING

BUSH HOLE DRILL

COMPLETED TUBE
PIERCING
SEAT TUBE

MITRING

SLOTTING

PIERCING 1 ( 15 MM )

PIERCING 2 ( 6 MM )

COMPLETED TUBE
SWAGING

CUTTING

DOOMING

MILLING
CHAIN STAY

DRILLING

OVALLING

DIMPLING

BENDING

PLANISHING – RH SIDE

HOLLOW MITRING

COMPLETED TUBE
SWAGING

CUTTING

DOOMING

MILLING
SEAT STAY

DRILLING

BENDING – SINGLE

PAIR WELDING

PAIR BENDING

PLANISHING – RH SIDE

PAIR MITRING

COMPLETED TUBE
PATING

PIERCING
BB

REAMING

NUMBERING

COMPLETED TUBE
DATE Process
13/5/08 to 15/5/08 champ bmx carrier fixing

20/5/08 AXN dx fixture f/d fixture modified for Flash

20/5/08 Alu III prepared

24/9/08 TD-3377/03 , TD-3377/00 nylon block fixed to avoid damage the alu c/s , s/s while milling

18/9/2008 CHAIRMAN AWARD WON THROUGH ACCURATE14

22/10/08 Stand for S/t plug gauge mounting at reaming area for Decathlon

01/11/08 Cable stopper local source developed (M/s BPM inds.) for Decathlon

Additional drain hole drilling fixture f/b & S/s

New gauge to check the orientation of Mitring wrt spring plate for both frame and fork pivot

Spare tools
1TTDPT342
1TTDPT339
1TTDPT340
1TTDPT344
1TTDPT346
1TTDPT345
1TTDFX504
1TTDPT347
1TTDOT099
1TTDMD273
1TTDPT348

23/12/2008 Frame 26 x 17” Proto samle made - Handed over to Mr. Karuppiah

Fork milling master setting piece (SGA )

08/12/08 Head tube vent hole process changed from drilling to piercing

30/12/08 MD AWARD TOP RANK

23/1/2009 Seat tube vent hole process changed from drilling to piercing

28/1/2009 Scooter gauge modified to cover entire dropout for scootering

25/1/2009 Fork blade & end Tack welding fixture

28/1/2009 Fine adjustment provided in hydralic press

Drilling fixture modification'

03/03/09 Fork blade & end Tack welding fixture

 C/stay bridge plate pair welding wrong direction

current fixture

Modified fixture

Seperate fixture for k20” c/stay pair mitring

24” s/stay bridge tube mitring fixture modification

Tube washing

Seperate fixture for k24” c/stay pair mitring

Gauge safety

BB piercing

04/06/10 New BB reamer trail

BB reaming machine “V” block change to avoid the coaxial defects

20th jun Head tube reamer and Bb reamer new source M/s 5 star carbide form tools introduced

9th aug BB threading check modified to suite local tap instead of imported saving is Rs.

20th aug Fork filing elimination productivity increased by 20%

C/stay, S/stay, F/blade Milling productivity improvement TD 3377/00 TD 3377/01

Fork blade end Indexing brazing

7th Sep Sticker paper for ctn reduced from 2 nos to 1 no. Saving is Rs.0.60

BB numbering 0 deleted
BB reaming eleminated

12-Nov Alloy bottom bracket 44.45 establishment

Supplier identificaiton and trail made
V block for machine
Bom correction
 qty
904

TD 3363/00 Bending tool CJ

TD 3360/00 Oval ling tool - Hyd press RAKI
TD 3361/00 300R Bending tool - Hyd press RAKI
TD 3374/00 Cranking tool - 25/1/2009 PER
TD 3379/00 98R bending tool TAN
TD 3376/00 1000R Pair bending tool - hyd press STAR
TD 3365/00 FD welding fix PENIEL
TD 3380/00 Oval ling tool PER
TD 3366/00 FB bending tool HAR
TD 3367/00 Mitring die VIG
TD 2807/02 Fork bending TAN
19/11/2009

Pitch – 50
 TI CYCLES OF INDIA
DEVATION NOTE

Specified Welding Proposed Welding Requested Approved Authorised

Date Welder Name Reason
joint joint By By By