WORK INSTRUCTION
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WORK INSTRUCTION TO DRAW SAMPLES FOR TESTING
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Sampling Plan Used For Testing
1.0 Raw Material Testing
1.1 For raw material analysis (Rod/Wire), samples will be drawn by laboratory as per the following
plan.
S. Bars
Test Coils
No. Up to 25 26-50 51-90 Over 90
1 Hardness 2 3 5 8 100%
2* Tensile strength & NA NA NA NA 2
%age Reduction in
area
3 Surface Defects 2 3 5 8 100%
4 Internal cracks, 2 3 5 8 100%
Porosity
5 Microstructure 1 1 1 1 1
6 Inclusion Rating 1 1 1 1 1
7 Grain Size 1 1 1 1 1
8 Decarburization 1 1 1 1 1
9 Chemical 2 3 5 8 100%
Composition
10 Hardenability Test 2 3 5 8 100%
11 Coating Thickness 2 3 5 8 100%
12 Upsetting tests NA NA NA NA 100%
(Ref. ASME B18.18-2017)
Note:
1. Even if one sample is rejected the lot will be rejected.
2. The Samples are supposed to pass all test enlisted.
3. * mark test will be conducted at the time of new vendor evaluation or when any problem is
faced at the time of production.
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WORK INSTRUCTION TO DRAW SAMPLES FOR TESTING
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2.0 In process Inspection
S. Test Test No. of Samples Frequency
No. Stage
1 Forging Under Head Radius Integrity/ Crack 1 Each Setting
2 Rolling Thread Laps 1 Each Setting
3 Hardening Quench Hardness 1 Every 4 Hours
4 Hardening Microstructure 1 1 Per Shift
5. Hardening Decarburization/ Carburization By 1 1 Per Shift
Microscopic Method
6 Hardening Decarburization/ Carburization By 1 1 Per Week
Hardness Method
The above sampling plan has been arrived after years of experience and without any
customer complaint.
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WORK INSTRUCTION TO DRAW SAMPLES FOR TESTING
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3.0 Sampling Plan for checking Tempered and finished Material for various Test
Enlisted
(Ref ASTM F1470-2019)
Sr. Nature of Test Lot Size
No. Up to 1000 1000-5000 5001-250000:
No of Samples No of Samples No of Samples:
Normal Tightened Normal Tightened Normal Tightened
1 HARDNESS 4 8 6 12 8 16
2 MICROHARDNESS 4 8 6 12 8 16
3 TENSILE STRENGTH 2 4 3 6 4 8
(WEDGE / AXIAL)
4 PROOF LOAD (NUT ) 2 4 3 6 4 8
5 PROOF LOAD 1 2 1 2 1 2
(BOLT & SCREW)
6 DISCONTINUTIES 4 8 6 12 8 16
(MACRO ETCH)
7 HYDROGEN 4 8 6 12 8 16
EMBRITTLEMENT
8 DECARBURIZATION 1 2 1 2 1 2
9 SHEAR 2 4 3 6 4 8
10 TORQUE 2 4 3 6 4 8
11 SALT SPRAY 2 4 3 6 4 8
12 COATING 2 4 3 6 4 8
THICKNESS (NON
DESTRUCTIVE)
13 CASE DEPTH 2 4 3 6 4 8
14 METALLOGRAPHY 1 2 1 2 1 2
15 WASHER HARDNESS 2 4 4 8
NOTE:-
1 If one sample is rejected the lot will be rejected. Up to 1000, where sample size exceeds lot size
100% inspection to be applied.
2 The sampling plan for coating thickness has been made based on experience and no customer
complaint has been received. If any customer complaint is received the sampling plan may be
revised.
3 The sample will be checked for parameters 1,8,14 at tempering stage (2,13 if required) and
3,4,5,6,7,7,10,11,12 at final stage for Finished items.
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WORK INSTRUCTION TO DRAW SAMPLES FOR TESTING
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4 Tensile and chemical testings are mandatory at the time of PPAP Stage and in case of any
doubt/ problem. In other cases, a check of hardness and microstructure are considered adequate
for the purpose of clearance of material.
5 If 5 or more consecutive lots are rejected shift to tightened inspection from normal and vice
versa.
6 This sampling plan is applicable if no customer requirement, else sampling plan as per
customer specification will be applicable.
Sampling Plan Used For Vendor and Final Inspection
Draw Samples as per the following Sampling Inspection System*
AQL SAMPLING INSPECTION PLAN FOR THREADED FASTENERS
1. General Dimensional/Visual/Duds
ISO 2859-1 (1999) / IS: 2500 Part I, 2000 (R2017) - General Inspection Level-I, Dimensional &
Std. Room S-2, Profile Projector related parameter S-1
(Refer Table I)
SINGLE SAMPLING PLAN
NOTE: -- FOR MAJOR AND MINOR DEFECTS REFER APPENDIX--A
The description of the sampling plan is given as following:
For visual and Attribute parameters = General inspection level - I
For Dimensional & standard Room parameters = Special inspection level –II
For Profile Projector related Parameters = Level - III
LOT SIZE VISUAL AND ATTRIBUTE DIMENSIONAL AND DIMENSION RELATED
PARAMETERS LEVEL – I GEOMETRICAL TO PROFILE
(PROCESS OPERATION PARAMETERS LEVEL II PROJECTOR LEVEL III
PARAMETERS) LEVEL II (PREVIOUS
OPERATION PARAMETERS)
SAMPLE ACCEPTANC SAMPLE ACCEPTANCE SAMPLE ACCEPTANCE
SIZE E SIZE SIZE
26~90 5 0 3 0 3 0
91~150 8 0 3 0 3 0
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151~280 13 0 5 0 3 0
281~500 20 0 5 0 3 0
501~1200 32 0 5 0 5 0
1201~3200 50 0 8 0 5 0
3200~ 80 0 13 0 5 0
• ABOVELot size upto 25 Nos. needs 100% inspection.
• During initial production control, 100% Visual Inspection and double of normal sampling
plan for dimensional parameters.
• Rework lot must be 100% Visual inspection and double of normal sampling plan for
dimensional parameters.
APPENDIX A
CLASSIFICATION OF DEFECTS
Sl. Type of Fasteners Major Defects Minor Defects
No.
1. Hexagon socket head Width across flats Thread length
cap screws thread pitch diameter Screw length, shank diameter
( IS : 2269-2006) Thread major diameter Height of head
(ISO 4762:2004) fillet radius Concentricity
Depth of socket End of screws
Perpendicularity of head
of shank
2. Grub screws do Do
( socket head )
(IS:2388-1963)
3. Precision and Thread major diameter Thread pitch diameter undersize
semi precision Thread pitch diameter o/s Thread length
hexagon bolts and Bolt length,
screws Width of across flat Shank diameter, height
(IS:1364-2002) neck diameter
ISO-4014-1999) end of screw
perpendicularity of head
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To shank
4. Hexagon bolts and do do
screws (IS:2389-1968)
5. Hexagon bolts do do
(IS:3138-1966)
6. Knurled thumb Thread major diameter Head diameter, slot width
screws Thread pitch diameter slot depth, thread pitch
(IS:3726-1966) screw length, thread
oversize length, knurling pitch
end of screw , head thickness
diameter undersize
perpendicularity of head
to shank
7. Precision and Width across flats Thread pitch diameter oversize
semi-precision thread pitch undersize thread minor diameter oversize
hexagon nuts thread minor diameter
(IS-1364-1967) undersize thickness
(ISO-4032-1986)
8. Slotted and castle Width across flats Thickness width of slot
nuts thread pitch undersize slot head diameter
(IS:2232-1967) thread minor diameter thread pitch diameter oversize
undersize thread minor diameter oversize
9. Hexagon nuts Width across flats Thread pitch diameter
(IS:3138-1966) thread pitch undersize oversize, thread minor
thread minor diameter diameter oversize,
undersize Thickness
10. Knurled nuts thread pitch undersize Knurled diameter
(IS:3460-1966) thread minor diameter Knurling pitch, thickness,
undersize thread pitch diameter oversize
thread minor
diameter oversize
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11. Studs Thread major diameter All other dimensional
(IS:1862-1967) thread pitch characterstics Diameter oversize
12 12 Corner Screw Thread major diameter Thread pitch diameter undersize
ASME B18.2.1 Thread pitch diameter o/s Thread length
Width of across flat Bolt length,
neck diameter Shank diameter, height
end of screw
perpendicularity of head
To shank
Nick Marks
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DOCUMENT CHANGE HISTORY:
ISSUE/[Link]. EFFECTIVE DATE NATURE OF AMENDMENT PAGE
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WORK INSTRUCTION TO DRAW SAMPLES FOR TESTING
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VERIFIED & ISSUED &
PREPARED BY:
APPROVED BY: S.M.E. / CONTROLLED BY: M.R.
DEPTT. HEAD
FUNC. HEAD
ISSUE/REV. NO. : 01/03 ISSUE/REVISION DATE :27.02.2020
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