PAGE 1/1

Supplier name:-GROWTH ENGINE PVT.LTD

Control Plan No.: 1 STAGE MASS PRODUCTION

SA B C R
ISSUING COMPANY [SUPPLIER] CONFIRMATION DEPARTMENT
Part LOT CONTROL
MODEL P-17
Designation REQUIRED-YES PROCESS QUALITY CONTROL TABLE ( 1 ) GROWTH ENGINE PVT. LTD. SUNBEAM AUTO PVT. LTD.

APPR. BY CONFIRM CREATE APPR. BY CREATE REC. BY

PART NO. 102328300050/102328400050

PARTNAME CASE BOTTOM P-17 DISC LH & RH

Process diagram (Attach the A3-sized sheet for more space, if necessary.)
COMPONENT PARTS SOURCING LIST
PROCESS SEQUENCE
SOURCE
S.NO. PART NO. PART NAME SUPPLIER NAME
10 RECEIVE ALUMINIUM ALLOYS INGOTS HS-1 H & MELTING PURCHASED INHOUSE

1 102328300050/102328400050 ALUMINIUM ALLOYS HS-1 H SUNLAND

NAMO

AKSHAY

20 PREPARATION OF DIE SAMYAK

30 METAL TREATMENT IN H/FURNACE

40 CASTING (GDC)

50 BENDSAW

60 GRINDING

70 FETTLING

80 LEAKAGE TESTING

90 FINAL INSPECTION
++++++++

100 PDIR

110 DESPATCH

Process diagram symbol: In accordance with JIS Z8206 (Compound symbol: Indicate primary job on outside, and secondary job inside.)

○
Executing quality
○ Processing □ Quantity inspection Intersection of flow line
◇ inspection while mainly
executing processing 1

0 06.09.2018 INITIAL ISSUE S.K SINGH S.K SINGH ANUJ SHUKLA

○ Transport ◇ Quality inspection  
Executing quantity
Grouping of processes for inspection while mainly
～ control purpose ◇
□ executing quality   Approve Cofirm Create Cofirm APPR. BY
inspection Date/
▽ Storage ― Sequence of process Month/Year
Description of revision
Creating department [SUPPLIER] Conforming department

S-: Safety Characteristics, A-: Critical Characteristics, B & C-: General characteristic, R-: Regulatry Legal characteristics
0
1
 Page 2 of 18
77 1 2 3 4 5 6 7
COMPANY NAME:- GROWTH ENGINE PVT.LTD.

MODEL NAME P-17

PROCESS QUALITY CONTROL TABLE ( 2 ) PAGE :

PART NAME CASE BOTTOM P-17 DISC LH & RH

PART NO.: 102328300050/102328400050

CRITICAL ITEM PRODUCTION CONDITION CONTROL

F.M :- FAILURE MODE QUALITY CHARACTERISTICS [ EQUIPMENT, METAL MOULD, FAIL SAFE DEVICE, HYDRAULIC POWER, VOLTAGE, TEMPERATURE, etc. ]

S.NO. PROCESS NAME

C.I. - CRITICAL ITEM A RELATED TO FUNCTIONAL / FITMENT s SAFETY CONTROL CONTROL
PERSON CHECK SEHEMATIC
SUMISSION S.NO. CRITICAL ITEM FREQUENCY DATA TYPE
PERSON DATA INCHARGE METHOD DRAWING
F.M C.I S.NO. CONTROL ITEM SPECIFICATION CHECK METHOD FREQUENCY FREQ. OF ITEM VALUE
INCHARGE TYPE
DATA

s 1 Chem. Comp H.S.1 H SUP. Spectometer SAPL Lab T.C

Every lot /
Copper 2.77 - 3.20 Every 3
month

Silicon 6.00 - 7.00

Iron 0.6

Magnesium 0.20 - 0.30

Nickel 0.1

Manganese 0.2
Receive
10 Aluminium Alloy Zinc 0.20 - 0.40
Ingots & Melting

Titanium 0.2

Lead 0.1

Tin 0.1

Chromium 0.1

Aluminium Balance

SUP Hand
Temp. of alloy 760 ±100C Every heat Register 01
OPR Pyrometer

Metal cleaning Metal should be Clean OPR Visual Check Every Heat -

Preparation of Dycote : Water (1:4) By volume &

1 OPR Each time
dycote solution Approx. experince

Free from dycots &

2 Die cleaniness sticky material By OPR Visually Each Shift
Flexible Grinder

heating oFdie &

3 With LPG OPR By experience Each time
core pin

20 Preparation of Die Coating thk. on Approx. (0.15-0.20) mm

4 OPR Visually Each time
Die &core pin by judgement
Each time
cleaning of air Air routes should be
5 OPR Visually during die
routes clean
prev. maint
loading on Bolting of die half in
6 OPR Visually Each time
machine alignment

7 Preheat the Die With LPG OPR By experience Each time

Cleaning of H/ H/F should be free from

1 OPR Visual Every heat -
Furnace dross

GR6512 (300±5 g) per CHECK SHEET

2 Addition of flux SUP By weight Every heat GEPL:PRDC:01
350 Kg Metal Approx..
 Page 3 of 18

Hand
CHECK SHEET
3 Temp. of metal (725 ± 15)o C OPR Pyrometer Every heat GEPL:PRDC:02
/Dip type TC

ATB - 0.4% (1.4

Add grain refiner CHECK SHEET
4 Kg±30gm) WT/350KG SUP By weight Every heat
Metal treatment ATB GEPL:PRDC:01
30 Metal Approx.
in H/FURNACE

Addition of Sr -0.11% (400 ±20gms CHECK SHEET

5 SUP By weight Every heat
modifier )/ 350 Kg Metal Approx. GEPL:PRDC:01

Degasing by degasing machine CHECK SHEET

6 OPR 20-24 mins Every heat GEPL:PRDC:02
DN2 Gas

7 Chemical comp. H.S.-1 H SUP Spectrometer SAPL lab T.C

Hand
Pyrometer/ CHECK SHEET
1 Temp. of metal 725±15°C OPR direct dip type
Every heat GEPL:PRDC:02
TC

2 Hyd. Pr 45± 10 Kgf/ Cm-2 OPR Pressure Gauge 24 hrs check sheet

Wire mesh for

1 Casting As per Operating Instruction OPERATOR TIMERS EACH TIME 3 12 X12 mesh/ wire / inch OPR Visually Each lot
filter
Solidification
4 1.5 ~ 2 Min. Sup. TIMERS EACH TIME
Gravity Die Time
40
casting
No visual defect (As per MASTER
2 Visual defect OPERATOR Visually Every shift
sample)

A DIMENSION INSPECTION REPORT AS FOLLOWS :-

A

1 OD 49.0 INSPECTOR VERNIER Every shift

2 OD 39.0- 0.1 INSPECTOR VERNIER Every shift

3 OD 40.0 -0.1 INSPECTOR VERNIER Every shift

4 ID 29.0-0.2 INSPECTOR I.D CALIPER Every shift

5 CORE DEPTH 23.0 -0.5 INSPECTOR DEPTH VERNIER Every shift

CHECK
SHEET
6 CORE DEPTH 253.5- 1.0 INSPECTOR DEPTH VERNIER Every shift
GEPL:QA
C:01

7 WIDTH 23.8=0.2 INSPECTOR VERNIER Every shift

8 F/ Boss DIAØ (RH) 15 -0.50 INSPECTOR VERNIER Every shift

AXLE BOSS
9 43.0±0.20 INSPECTOR VERNIER Every shift
WIDTH

10 CONCENTRICITY 0.5 MAX. INSPECTOR PISTON CALIPER Every shift

FREE FROM BH,NF,SKG,CRACK ,

11 Visual defect INSPECTOR VISUAL Every shift
CATCHING , PIN HOLE
 Page 4 of 18

3000 to 3100 Check sheet

1 Belt belt change OPTR By production
set GEPL:PRDB:01

50 Bendsaw OPR Visually Each piece

Apperance
2 Raiser Removing Once during
Defects SUP Visually
set up

CHECK
SHEET
1 Flash removal No extra material INSPECTOR Visually Each piece
GEPL:
60 Grinding QAG:01

1100-1200 Check sheet

1 Condition of Belt change the belt OPR By production GEPL:PRDG:01
pcs

REGISTER
70 Fettling 1 Extra flash No extra flashes INSPECTOR Visually Each piece
02

REGISTER
1 Free from leakage No leakage OPR Visually Each piece
03
80 Leakage Testing
Pressure
1 Air pressure 6-7 Kgf/cm2 OPR Each piece
gauge

CHECK
SHEET
90 Final Inspection 1 Casting Quality No visual defect as per master sample INSPECTOR Visually Each piece GEPL:QAF:
01

CORE PIN
1 253.50 -1.0 INSPECTOR DEPTH VERNIER 5 piece
DEPTH

OIL SEAL
2 23.0 -0.50 INSPECTOR DEPTH VERNIER 5 piece
FACING

F/ Boss DIAØ
3 15 -0.50 INSPECTOR DIGITAL VERNIER 5 piece
(RH)

4 FACING NO TAPPER CUTTING INSPECTOR HEIGHT GUAGE 5 piece

CHECK DAILY BASIS

SHEET / LAYOUT
100 PDIR 5 DENTS NO DENTS INSPECTOR VISUAL 5 piece
GEPL:PDI PER 6
:01 MONTH

6 NON FILLING NO NON FILLING INSPECTOR VISUAL 5 piece

7 EXTRA FLASH NO FLASH INSPECTOR VISUAL 5 piece

UNDER
8 NO UNDER CUT INSPECTOR VISUAL 5 piece
GRINDING

9 OVER GRINDING NO OVER GROUND INSPECTOR VISUAL 5 piece

Shipment to be made as
1 Safe shippment SUP Visually Each piece
per packing standard
110 Despatch -
350,500,450 SET/PER
2 Packing process OPR Visually Each piece
TROLLY

Insulat Exhaust
Protectio A
ion gas Identificatio Denotes- SAFETY
Complete vehilce's failure TURNING FUNCTION Stopping n CRITICAL
mode classification:-
1 RUNNING FUNCTION IS LOST 2 IS LOST
3 function failure 4 Gaurding function failure 5 functio 6 function 7 control 8 n function PROCESS/PARAMET PROCESS/PARAMETER
n function failure ER
failure S
failure failure
 PAGE 1/1

Supplier name:-GROWTH ENGINE PVT.LTD

Control Plan No.: 1 STAGE MASS PRODUCTION

SA B C R
ISSUING COMPANY [SUPPLIER] CONFIRMATION DEPARTMENT
Part LOT CONTROL
MODEL KWAG
Designation REQUIRED-YES PROCESS QUALITY CONTROL TABLE ( 1 ) GROWTH ENGINE PVT. LTD. SUNBEAM AUTO PVT. LTD.

APPR. BY CONFIRM CREATE APPR. BY CREATE REC. BY

PART NO. 105628300050/105628400050

PARTNAME CASE BOTTOM KWAG LH & RH DRUM

Process diagram (Attach the A3-sized sheet for more space, if necessary.)
COMPONENT PARTS SOURCING LIST
PROCESS SEQUENCE
SOURCE
S.NO. PART NO. PART NAME SUPPLIER NAME
10 RECEIVE ALUMINIUM ALLOYS INGOTS HS-1 H & MELTING PURCHASED INHOUSE

1 105628300050/105628400050 ALUMINIUM ALLOYS HS-1 H SUNLAND

NAMO

AKSHAY

20 PREPARATION OF DIE SAMYAK

30 METAL TREATMENT IN H/FURNACE

40 CASTING (GDC)

50 BENDSAW

60 GRINDING

70 FETTLING

80 LEAKAGE TESTING

90 FINAL INSPECTION
++++++++

100 PDIR

110 DESPATCH

Process diagram symbol: In accordance with JIS Z8206 (Compound symbol: Indicate primary job on outside, and secondary job inside.)

○
Executing quality
○ Processing □ Quantity inspection Intersection of flow line
◇ inspection while mainly
executing processing

0 06.09.2018 INITIAL ISSUE S.K SINGH S.K SINGH ANUJ SHUKLA

○ Transport ◇ Quality inspection  
Executing quantity
Grouping of processes for inspection while mainly
～ control purpose ◇
□ executing quality   Approve Cofirm Create Cofirm APPR. BY
inspection Date/
▽ Storage ― Sequence of process Month/Year
Description of revision
Creating department [SUPPLIER] Conforming department

S-: Safety Characteristics, A-: Critical Characteristics, B & C-: General characteristic, R-: Regulatry Legal characteristics
0
1
 Page 6 of 18
77 1 2 3 4 5 6 7
COMPANY NAME:- GROWTH ENGINE PVT.LTD.

MODEL NAME KWAG

PROCESS QUALITY CONTROL TABLE ( 2 ) PAGE :

PART NAME CASE BOTTOM KWAG LH & RH DRUM

PART NO.: 105628300050/105628400050

CRITICAL ITEM PRODUCTION CONDITION CONTROL

F.M :- FAILURE MODE QUALITY CHARACTERISTICS [ EQUIPMENT, METAL MOULD, FAIL SAFE DEVICE, HYDRAULIC POWER, VOLTAGE, TEMPERATURE, etc. ]

S.NO. PROCESS NAME

C.I. - CRITICAL ITEM A RELATED TO FUNCTIONAL / FITMENT s SAFETY CONTROL CONTROL
PERSON CHECK SEHEMATIC
SUMISSION S.NO. CRITICAL ITEM FREQUENCY DATA TYPE
PERSON DATA INCHARGE METHOD DRAWING
F.M C.I S.NO. CONTROL ITEM SPECIFICATION CHECK METHOD FREQUENCY FREQ. OF ITEM VALUE
INCHARGE TYPE
DATA

s 1 Chem. Comp H.S.1 H SUP. Spectometer SAPL Lab T.C

Every lot /
Copper 2.77 - 3.20 Every 3
month

Silicon 6.00 - 7.00

Iron 0.6

Magnesium 0.20 - 0.30

Nickel 0.1

Manganese 0.2
Receive
10 Aluminium Alloy Zinc 0.20 - 0.40
Ingots & Melting

Titanium 0.2

Lead 0.1

Tin 0.1

Chromium 0.1

Aluminium Balance

SUP Hand
Temp. of alloy 760 ±100C Every Heat Register 01
OPR Pyrometer

Metal cleaning Metal should be Clean OPR Visual Check Every Heat -

Preparation of Dycote : Water (1:4) By volume &

1 OPR Each time
dycote solution Approx. experince

Free from dycots &

2 Die cleaniness sticky material By OPR Visually Each Shift
Flexible Grinder

heating oFdie &

3 With LPG OPR By experience Each time
core pin

20 Preparation of Die Coating thk. on Approx. (0.15-0.20) mm

4 OPR Visually Each time
Die &core pin by judgement
Each time
cleaning of air Air routes should be
5 OPR Visually during die
routes clean
prev. maint
loading on Bolting of die half in
6 OPR Visually Each time
machine alignment

7 Preheat the Die With LPG OPR By experience Each time

Cleaning of H/ H/F should be free from

1 OPR Visual Every heat -
Furnace dross

GR6512 (300±5 g) per CHECK SHEET

2 Addition of flux SUP By weight Every heat GEPL:PRDC:01
350 Kg Metal Approx..
 Page 7 of 18

Hand
CHECK SHEET
3 Temp. of metal (725 ± 15)o C OPR Pyrometer Every heat GEPL:PRDC:02
/Dip type TC

ATB - 0.4% (1.4

Add grain refiner CHECK SHEET
4 Kg±30gm) WT/350KG SUP By weight Every heat
ATB GEPL:PRDC:01
Metal treatment Metal Approx.
30
in H/FURNACE
Addition of Sr -0.11% (400 ±20gms CHECK SHEET
5 SUP By weight Every heat
modifier )/ 350 Kg Metal Approx. GEPL:PRDC:01

Degasing by degasing machine CHECK SHEET

6 OPR 20-24 mins Every heat GEPL:PRDC:02
DN2 Gas

7 Chemical comp. H.S.-1 H SUP Spectrometer SAPL lab T.C

Hand
Pyrometer/ CHECK SHEET
1 Temp. of metal 725±15°C OPR direct dip type
Every heat GEPL:PRDC:02
TC

2 Hyd. Pr 45± 10 Kgf/ Cm-2 OPR Pressure Gauge 24 hrs check sheet

Wire mesh for

1 Casting As per Operating Instruction OPERATOR TIMERS EACH TIME 3 12 X12 mesh/ wire / inch OPR Visually Each pcs
filter
Solidification
4 1.5 ~ 2 Min. Sup. TIMERS EACH TIME
Gravity Die Time
40
casting
No visual defect (As per MASTER
2 Visual defect OPERATOR Visually Every shift
sample)

A DIMENSION INSPECTION REPORT AS FOLLOWS :-

A

1 OD 49.0 ±0.50 INSPECTOR VERNIER Every shift

2 OD 40.0 +0.50 INSPECTOR VERNIER Every shift

3 OD 39.0 +0.50 INSPECTOR VERNIER Every shift

4 ID 28.7 -0.20 INSPECTOR I.D CALIPER Every shift

5 Core Depth 253.50 -1.0 INSPECTOR DEPTH VERNIER Every shift

6 Core Depth 21.50 -0.50 INSPECTOR DEPTH VERNIER Every shift

7 Width (RH) 23.50 ±0.20 INSPECTOR VERNIER Every shift

CHECK
SHEET
GEPL:QA
8 Width (LH) 23.0 +0.20 INSPECTOR VERNIER Every shift C:01

9 Axle Pad Width (LH) 27.0 +0.20 INSPECTOR VERNIER Every shift

D.L Boss Thickness-

10 14.45 +0.20 INSPECTOR VERNIER Every shift
(LH)

11 Axle Boss Width (RH) 46.0 +0.20 INSPECTOR VERNIER Every shift

12 Collar Offset Max.(0.4) INSPECTOR VERNIER Every shift

13 Concentricitty 0.5(Max.) INSPECTOR PISTON CALIPER Every shift

 Page 8 of 18

free from B/H, N/F, CATCHING,

14 Apperance Defects SHRINKAGE, WARPAGE&PIN HOLEetc INSPECTOR Visually Every shift
 Page 9 of 18

3000 to 3100 Check sheet

1 Belt belt change OPTR By production
set GEPL:PRDB:01

50 Bendsaw OPR Visually Each piece

2 Apperance Defects Raiser Removing Once during

SUP Visually
set up

CHECK
SHEET
1 Flash removal No extra material OPR Visually Each piece
GEPL:
60 Grinding QAG:01

1100-1200 Check sheet

1 Condition of Belt change the belt OPR By production
pcs GEPL:PRDG:01

70 Fettling 1 Extra flash No extra flashes OPR Visually Each piece Register 02

1 Free from leakage No leakage OPR Visually Each piece Register 03

80 Leakage Testing
Pressure
1 Air pressure 6-7 Kgf/cm2 OPR Each piece
gauge

CHECK
SHEET
90 Final Inspection 1 Casting Quality No visual defect as per master sample INSPECTOR Visually Each piece GEPL:QAF:
01

CORE PIN
1 253.50 (-1.0) INSPECTOR DEPTH VERNIER 5 piece
DEPTH

OIL SEAL
2 21.50 -0.5 INSPECTOR DEPTH VERNIER 5 piece
FACING

3 FACING NO TAPPER CUTTING INSPECTOR HEIGHT GUAGE 5 piece

4 DENTS NO DENTS INSPECTOR VISUAL 5 piece CHECK DAILY BASIS

SHEET / LAYOUT
100 PDIR
GEPL:PDI PER 6
:01 MONTH
5 NON FILLING NO NON FILLING INSPECTOR VISUAL 5 piece

6 EXTRA FLASH NO FLASH INSPECTOR VISUAL 5 piece

UNDER
7 NO UNDER CUT INSPECTOR VISUAL 5 piece
GRINDING

8 OVER GRINDING NO OVER GROUND INSPECTOR VISUAL 5 piece

Shipment to be made as
1 Safe shippment SUP Visually Each piece
per packing standard
110 Despatch -

2 Packing process 550 SET/PER TROLLY OPR Visually Each piece

Insulat Exhaust
Protectio A
ion gas Identificatio Denotes- SAFETY
Complete vehilce's failure TURNING FUNCTION Stopping n CRITICAL
mode classification:-
1 RUNNING FUNCTION IS LOST 2 IS LOST
3 function failure 4 Gaurding function failure 5 functio 6 function 7 control 8 n function PROCESS/PARAMET PROCESS/PARAMETER
n function failure ER
failure S
failure failure
 PAGE 1/1

Supplier name:-GROWTH ENGINE PVT.LTD

Control Plan No.: 1 STAGE MASS PRODUCTION

SA B C R
ISSUING COMPANY [SUPPLIER] CONFIRMATION DEPARTMENT
Part LOT CONTROL
MODEL P-90
Designation REQUIRED-YES PROCESS QUALITY CONTROL TABLE ( 1 ) GROWTH ENGINE PVT. LTD. SUNBEAM AUTO PVT. LTD.

APPR. BY CONFIRM CREATE APPR. BY CREATE REC. BY

PART NO. 103028300050/103028400050

PARTNAME CASE BOTTOM P-90 LH & RH

Process diagram (Attach the A3-sized sheet for more space, if necessary.)
COMPONENT PARTS SOURCING LIST
PROCESS SEQUENCE
SOURCE
S.NO. PART NO. PART NAME SUPPLIER NAME
10 RECEIVE ALUMINIUM ALLOYS INGOTS HS-1 H & MELTING PURCHASED INHOUSE

1 103028300050/103028400050 ALUMINIUM ALLOYS HS-1 H SUNLAND

NAMO

AKSHAY

20 PREPARATION OF DIE SAMYAK

30 METAL TREATMENT IN H/FURNACE

40 CASTING (GDC)

50 BENDSAW

60 GRINDING

70 FETTLING

80 LEAKAGE TESTING

90 FINAL INSPECTION
++++++++

100 PDIR

110 DESPATCH

Process diagram symbol: In accordance with JIS Z8206 (Compound symbol: Indicate primary job on outside, and secondary job inside.)

○
Executing quality
○ Processing □ Quantity inspection Intersection of flow line
◇ inspection while mainly
executing processing

0 06.09.2018 INITIAL ISSUE S.K SINGH S.K SINGH ANUJ SHUKLA

○ Transport ◇ Quality inspection  
Executing quantity
Grouping of processes for inspection while mainly
～ control purpose ◇
□ executing quality   Approve Cofirm Create Cofirm APPR. BY
inspection Date/
▽ Storage ― Sequence of process Month/Year
Description of revision
Creating department [SUPPLIER] Conforming department

S-: Safety Characteristics, A-: Critical Characteristics, B & C-: General characteristic, R-: Regulatry Legal characteristics
0
1
 Page 11 of 18
77 1 2 3 4 5 6 7
COMPANY NAME:- GROWTH ENGINE PVT.LTD.

MODEL NAME P-90

PROCESS QUALITY CONTROL TABLE ( 2 ) PAGE :

PART NAME CASE BOTTOM P-90 LH & RH

PART NO.: 103028300050/103028400050

CRITICAL ITEM PRODUCTION CONDITION CONTROL

F.M :- FAILURE MODE QUALITY CHARACTERISTICS [ EQUIPMENT, METAL MOULD, FAIL SAFE DEVICE, HYDRAULIC POWER, VOLTAGE, TEMPERATURE, etc. ]

S.NO. PROCESS NAME

C.I. - CRITICAL ITEM A RELATED TO FUNCTIONAL / FITMENT s SAFETY CONTROL CONTROL
PERSON CHECK SEHEMATIC
SUMISSION S.NO. CRITICAL ITEM FREQUENCY DATA TYPE
PERSON DATA INCHARGE METHOD DRAWING
F.M C.I S.NO. CONTROL ITEM SPECIFICATION CHECK METHOD FREQUENCY FREQ. OF ITEM VALUE
INCHARGE TYPE
DATA

s 1 Chem. Comp H.S.1 H SUP. Spectometer SAPL Lab T.C

Every lot /
Copper 2.77 - 3.20 Every 3
month

Silicon 6.00 - 7.00

Iron 0.6

Magnesium 0.20 - 0.30

Nickel 0.1

Manganese 0.2
Receive
10 Aluminium Alloy Zinc 0.20 - 0.40
Ingots & Melting

Titanium 0.2

Lead 0.1

Tin 0.1

Chromium 0.1

Aluminium Balance

SUP Hand
Temp. of alloy 760 ±100C Every heat Register 01
OPR Pyrometer

Metal cleaning Metal should be Clean OPR Visual Check Every heat -

Preparation of Dycote : Water (1:4) By volume &

1 OPR Each time
dycote solution Approx. experince

Free from dycots &

2 Die cleaniness sticky material By OPR Visually Each Shift
Flexible Grinder

heating oFdie &

3 With LPG OPR By experience Each time
core pin

20 Preparation of Die Coating thk. on Approx. (0.15-0.20) mm

4 OPR Visually Each time
Die &core pin by judgement
Each time
cleaning of air Air routes should be
5 OPR Visually during die
routes clean
prev. maint
loading on Bolting of die half in
6 OPR Visually Each time
machine alignment

7 Preheat the Die With LPG OPR By experience Each time

Cleaning of H/ H/F should be free from

1 OPR Visual Every heat -
Furnace dross

GR6512 (300±5 g) per CHECK SHEET

2 Addition of flux SUP By weight Every heat GEPL:PRDC:01
350 Kg Metal Approx..
 Page 12 of 18

Hand
CHECK SHEET
3 Temp. of metal (725 ± 15)o C OPR Pyrometer Every HEAT GEPL:PRDC:02
/Dip type TC

ATB - 0.4% (1.4

Add grain refiner CHECK SHEET
4 Kg±30gm) WT/350KG SUP By weight Every heat
ATB GEPL:PRDC:01
Metal treatment Metal Approx.
30
in H/FURNACE
Addition of Sr -0.11% (400 ±20gms CHECK SHEET
5 SUP By weight Every heat
modifier )/ 350 Kg Metal Approx. GEPL:PRDC:01

Degasing by degasing machine CHECK SHEET

6 OPR 20-24 mins Every heat GEPL:PRDC:02
DN2 Gas

7 Chemical comp. H.S.-1 H SUP Spectrometer SAPL lab T.C

Hand
Pyrometer/ CHECK SHEET
1 Temp. of metal 725±15°C OPR direct dip type
Every heat GEPL:PRDC:02
TC

2 Hyd. Pr 45± 10 Kgf/ Cm-2 OPR Pressure Gauge 24 hrs check sheet

Wire mesh for

1 Casting As per Operating Instruction OPERATOR TIMERS EACH TIME 3 12 X12 mesh/ wire / inch OPR Visually Each lot
filter
Solidification
4 1.5 ~ 2 Min. Sup. TIMERS EACH TIME
Gravity Die Time
40
casting
No visual defect (As per MASTER
2 Visual defect OPERATOR Visually Every shift
sample)

A DIMENSION INSPECTION REPORT AS FOLLOWS :-

A

1 OD 49 ± .5 INSPECTOR VERNIER Every shift

2 OD 39.0+0.5 INSPECTOR VERNIER Every shift

3 OD 40.0+0.5 INSPECTOR VERNIER Every shift

4 ID 28.7-0.2 INSPECTOR I.D CALIPER Every shift

5 CORE DEPTH 21.5 -0.5 INSPECTOR DEPTH VERNIER Every shift

6 CORE DEPTH 253.5- 1.0 INSPECTOR DEPTH VERNIER Every shift

CHECK
SHEET
7 WIDTH RH 23.5+0.5 INSPECTOR VERNIER Every shift
GEPL:QA
C:01

8 WIDTH LH 23.0+0.5 INSPECTOR VERNIER Every shift

9 Axle Pad Width (LH) 27.0 +0.20 INSPECTOR VERNIER Every shift

AXLE BOSS
10 46.0+0.20 INSPECTOR VERNIER Every shift
WIDTH RH

DRUM LOCATOR
11 14.5-14.8 INSPECTOR VERNIER Every shift
SIZE

12 CONCENTRICITY 0.5 MAX. INSPECTOR PISTON CAILIPER Every shift

FREE FROM BH,NF,SKG,CRACK ,

13 Apperance Defect INSPECTOR VISUAL Every shift
CATCHING , PIN HOLE
 Page 13 of 18

3000 to 3100 Check sheet

1 Belt belt change OPTR By production
set GEPL:PRDB:01

50 Bendsaw OPR Visually Each piece

Apperance
2
Defects
Raiser Removing Once during
SUP Visually
set up

CHECK
SHEET
1 Flash removal No extra material OPR Visually Each piece
GEPL:
60 Grinding QAG:01

1100-1200 Check sheet

1 Condition of Belt change the belt OPR By production
pcs GEPL:PRDG:01

70 Fettling 1 Extra flash No extra flashes OPR Visually Each piece Register 02

1 Free from leakage No leakage OPR Visually Each piece Register 03

80 Leakage Testing
Pressure
1 Air pressure 6-7 Kgf/cm2 OPR Each piece
gauge

CHECK
SHEET
90 Final Inspection 1 Casting Quality No visual defect as per master sample INSPECTOR Visually Each piece GEPL:QAF:
01

CORE PIN
1 253.50 (-1.0) INSPECTOR DEPTH VERNIER 5 piece
DEPTH

OIL SEAL
2 21.50 -0.5 INSPECTOR DEPTH VERNIER 5 piece
FACING

3 FACING NO TAPPER CUTTING INSPECTOR HEIGHT GUAGE 5 piece

4 DENTS NO DENTS INSPECTOR VISUAL 5 piece

CHECK DAILY BASIS
SHEET / LAYOUT
100 PDIR
GEPL:PDI PER 6
:01 MONTH
5 NON FILLING NO NON FILLING INSPECTOR VISUAL 5 piece

6 EXTRA FLASH NO FLASH INSPECTOR VISUAL 5 piece

UNDER
7 NO UNDER CUT INSPECTOR VISUAL 5 piece
GRINDING

8 OVER GRINDING NO OVER GROUND INSPECTOR VISUAL 5 piece

Shipment to be made as
1 Safe shippment SUP Visually Each piece
per packing standard
110 Despatch -

2 Packing process 550 SET/PER TROLLY OPR Visually Each piece

Insulat Exhaust
Protectio A
ion gas Identificatio Denotes- SAFETY
Complete vehilce's failure TURNING FUNCTION Stopping n CRITICAL
mode classification:-
1 RUNNING FUNCTION IS LOST 2 IS LOST
3 function failure 4 Gaurding function failure 5 functio 6 function 7 control 8 n function PROCESS/PARAMET PROCESS/PARAMETER
n function ER
failure
failure S
failure failure
 PAGE 1/1

Supplier name:-GROWTH ENGINE PVT.LTD

Control Plan No.: 1 STAGE MASS PRODUCTION

SA B C R
ISSUING COMPANY [SUPPLIER] CONFIRMATION DEPARTMENT
Part LOT CONTROL
MODEL KTEA
Designation REQUIRED-YES PROCESS QUALITY CONTROL TABLE ( 1 ) GROWTH ENGINE PVT. LTD. SUNBEAM AUTO PVT. LTD.

APPR. BY CONFIRM CREATE APPR. BY CREATE REC. BY

PART NO. 18102830050/181028400050

PARTNAME CASE BOTTOM KTEA LH & RH DRUM

Process diagram (Attach the A3-sized sheet for more space, if necessary.)
COMPONENT PARTS SOURCING LIST
PROCESS SEQUENCE
SOURCE
S.NO. PART NO. PART NAME SUPPLIER NAME
10 RECEIVE ALUMINIUM ALLOYS INGOTS HS-1 H & MELTING PURCHASED INHOUSE

1 18102830050/181028400050 ALUMINIUM ALLOYS HS-1 H SUNLAND

NAMO

AKSHAY

20 PREPARATION OF DIE SAMYAK

30 METAL TREATMENT IN H/FURNACE

40 CASTING (GDC)

50 BENDSAW

60 GRINDING

70 FETTLING

80 LEAKAGE TESTING

90 FINAL INSPECTION
++++++++

100 PDIR

110 DESPATCH

Process diagram symbol: In accordance with JIS Z8206 (Compound symbol: Indicate primary job on outside, and secondary job inside.)

○
Executing quality
○ Processing □ Quantity inspection Intersection of flow line
◇ inspection while mainly
executing processing

0 06.09.2018 INITIAL ISSUE S.K SINGH S.K SINGH ANUJ SHUKLA

○ Transport ◇ Quality inspection  
Executing quantity
Grouping of processes for inspection while mainly
～ control purpose ◇
□ executing quality   Approve Cofirm Create Cofirm APPR. BY
inspection Date/
▽ Storage ― Sequence of process Month/Year
Description of revision
Creating department [SUPPLIER] Conforming department

S-: Safety Characteristics, A-: Critical Characteristics, B & C-: General characteristic, R-: Regulatry Legal characteristics
0
1
 Page 15 of 18
77 1 2 3 4 5 6 7
COMPANY NAME:- GROWTH ENGINE PVT.LTD.

MODEL NAME KTEA

PROCESS QUALITY CONTROL TABLE ( 2 ) PAGE :

PART NAME CASE BOTTOM KTEA LH & RH DRUM

PART NO.: 18102830050/181028400050

CRITICAL ITEM PRODUCTION CONDITION CONTROL

F.M :- FAILURE MODE QUALITY CHARACTERISTICS [ EQUIPMENT, METAL MOULD, FAIL SAFE DEVICE, HYDRAULIC POWER, VOLTAGE, TEMPERATURE, etc. ]

S.NO. PROCESS NAME

C.I. - CRITICAL ITEM A RELATED TO FUNCTIONAL / FITMENT s SAFETY CONTROL CONTROL
PERSON CHECK SEHEMATIC
SUMISSION S.NO. CRITICAL ITEM FREQUENCY DATA TYPE
PERSON DATA INCHARGE METHOD DRAWING
F.M C.I S.NO. CONTROL ITEM SPECIFICATION CHECK METHOD FREQUENCY FREQ. OF ITEM VALUE
INCHARGE TYPE
DATA

s 1 Chem. Comp H.S.1 H SUP. Spectometer SAPL Lab T.C

Every lot /
Copper 2.77 - 3.20 Every 3
month

Silicon 6.00 - 7.00

Iron 0.6

Magnesium 0.20 - 0.30

Nickel 0.1

Manganese 0.2
Receive
10 Aluminium Alloy Zinc 0.20 - 0.40
Ingots & Melting

Titanium 0.2

Lead 0.1

Tin 0.1

Chromium 0.1

Aluminium Balance

SUP Hand
Temp. of alloy 760 ±100C Every Heat Register 01
OPR Pyrometer

Metal cleaning Metal should be Clean OPR Visual Check Every Heat -

Preparation of Dycote : Water (1:4) By volume &

1 OPR Each time
dycote solution Approx. experince

Free from dycots &

2 Die cleaniness sticky material By OPR Visually Each Shift
Flexible Grinder

heating oFdie &

3 With LPG OPR By experience Each time
core pin

20 Preparation of Die Coating thk. on Approx. (0.15-0.20) mm

4 OPR Visually Each time
Die &core pin by judgement
Each time
cleaning of air Air routes should be
5 OPR Visually during die
routes clean
prev. maint
loading on Bolting of die half in
6 OPR Visually Each time
machine alignment

7 Preheat the Die With LPG OPR By experience Each time

Cleaning of H/ H/F should be free from

1 OPR Visual Every heat -
Furnace dross

GR6512 (300±5 g) per CHECK SHEET

2 Addition of flux SUP By weight Every heat GEPL:PRDC:01
350 Kg Metal Approx..

Metal treatment
30
in H/FURNACE
 Page 16 of 18

Hand
CHECK SHEET
3 Temp. of metal (725 ± 15)o C OPR Pyrometer Every heat GEPL:PRDC:02
/Dip type TC

ATB - 0.4% (1.4

Add grain refiner CHECK SHEET
4 Kg±30gm) WT/350KG SUP By weight Every heat
ATB GEPL:PRDC:01
Metal treatment Metal Approx.
30
in H/FURNACE
Addition of Sr -0.11% (400 ±20gms CHECK SHEET
5 SUP By weight Every heat GEPL:PRDC:01
modifier )/ 350 Kg Metal Approx.

Degasing by degasing machine CHECK SHEET

6 OPR 18-22 mins Every heat
DN2 Gas GEPL:PRDC:02

7 Chemical comp. H.S.-1 H SUP Spectrometer SAPL lab T.C

Hand
Pyrometer/ CHECK SHEET
1 Temp. of metal 725±15°C OPR direct dip type
Every heat GEPL:PRDC:02
TC

2 Hyd. Pr 45± 10 Kgf/ Cm-2 OPR Pressure Gauge 24 hrs check sheet

Wire mesh for

1 Casting As per Operating Instruction OPERATOR TIMERS EACH TIME 3 12 X12 mesh/ wire / inch OPR Visually Each pcs
filter
Solidification
4 1.5 ~ 2 Min. Sup. TIMERS EACH TIME
Gravity Die Time
40
casting
No visual defect (As per MASTER
2 Visual defect OPERATOR Visually Every shift
sample)

A DIMENSION INSPECTION REPORT AS FOLLOWS :-

A

1 OD 49.0 INSPECTOR VERNIER Every shift

2 OD 39.5 +0.50 INSPECTOR VERNIER Every shift

3 ID 40.0 INSPECTOR I.D CALIPER Every shift

4 Oil Seal ID (Draft) 39.0 INSPECTOR I.D CALIPER Every shift

5 ID 29.0 INSPECTOR I.D CALIPER Every shift

6 Core Depth 26.0 INSPECTOR DEPTH VERNIER Every shift

7 Core Depth 289 -0.30 INSPECTOR DEPTH VERNIER Every shift

8 Width - RH 25.50 +0.30 INSPECTOR VERNIER Every shift

CHECK
Width - LH 25.0 SHEET
9 INSPECTOR VERNIER Every shift
GEPL:QA
C:01

D.L Boss (T/B)

10 Thickness(LH) 14.60 +0.20 INSPECTOR VERNIER Every shift

11 Axle Boss Width-(RH) 39.50 ±0.30 INSPECTOR VERNIER Every shift

12 Axle Boss Width-(LH) 36.5 INSPECTOR VERNIER Every shift

13 F.BOSS WIDTH 12.0 12.0 INSPECTOR VERNIER Every shift

14 F.BOSS WIDTH 14.0 14.0 INSPECTOR VERNIER Every shift

15 Collar Offset Max.(0.3) INSPECTOR VERNIER Every shift

16 Concentricity 0.5(Max.) INSPECTOR PISTON CAILIPER Every shift

 Page 17 of 18

free from B/H, N/F, CATCHING,SHRINKEGE,

17 Apperance Defects INSPECTOR Visually Every shift
WARPAGE &PINHOLE etc
 Page 18 of 18

3000 to 3100 Check sheet

1 Belt belt change OPTR By production
set GEPL:PRDB:01

50 Bendsaw OPR Visually Each piece

Apperance
2 Raiser Removing Once during
Defects SUP Visually
set up

CHECK
SHEET
1 Flash removal No extra material OPR Visually Each piece
GEPL:
60 Grinding QAG:01
1100-1200 Check sheet
1 Condition of Belt change the belt OPR By production
pcs GEPL:PRDG:01

70 Fettling 1 Extra flash No extra flashes OPR Visually Each piece Register 02

1 Free from leakage No leakage OPR Visually Each piece Register 03

80 Leakage Testing
Pressure
1 Air pressure 6-7 Kgf/cm2 OPR Each piece
gauge

CHECK
SHEET
90 Final Inspection 1 Casting Quality No visual defect as per master sample INSPECTOR Visually Each piece GEPL:QAF:
01

CORE PIN
1 289-0.30 INSPECTOR DEPTH VERNIER 5 piece
DEPTH

OIL SEAL
2 26 INSPECTOR DEPTH VERNIER 5 piece
FACING

3 FACING NO TAPPER CUTTING INSPECTOR HEIGHT GUAGE 5 piece

4 DENTS NO DENTS INSPECTOR VISUAL 5 piece

CHECK DAILY BASIS
SHEET / LAYOUT
100 PDIR
GEPL:PDI PER 6
:01 MONTH
5 NON FILLING NO NON FILLING INSPECTOR VISUAL 5 piece

6 EXTRA FLASH NO FLASH INSPECTOR VISUAL 5 piece

UNDER
7 NO UNDER CUT INSPECTOR VISUAL 5 piece
GRINDING

8 OVER GRINDING NO OVER GROUND INSPECTOR VISUAL 5 piece

Shipment to be made as
1 Safe shippment SUP Visually Each piece
per packing standard
110 Despatch -
550,500,400 SET/PER
2 Packing process OPR Visually Each piece
TROLLY

Insulat Exhaust
Protectio A
ion gas Identificatio Denotes- SAFETY
Complete vehilce's failure TURNING FUNCTION Stopping n CRITICAL
mode classification:-
1 RUNNING FUNCTION IS LOST 2 IS LOST
3 function failure 4 Gaurding function failure 5 functio 6 function 7 control 8 n function PROCESS/PARAMET PROCESS/PARAMETER
n function ER
failure
failure S
failure failure