RADHE KRISHNA INDUSTRIES

CONTROL PLAN
ELECTROPLATING (General Purpose Component) PAGE 1/6
Doc No:-

CUSTOMER : ARIHANT VEHICLE MODEL:

PART NO: PART NAME BOLT FLANGE SH 6 X 16 DATE(ORIG):01/03/06

96001-06016-02-00

REVISE DATE : 25.8.2017

CORE TEAM: Mr. Harish Madan, Mr. Mahinder, Mr. V. Raja, Mr. Ashish, Mr. Vishal, Mr. Jai Singh KEY CONTACT: Mr. Vishal DVM (P.E.)

OPERATION Stag
DESCRIPTION e NO. Process Product ERROR
PROCESS CLASS SPECIFICATIONS MEASUREMENT SAMPLE CONTROL INSP.
Characteristics characteristics PROFING
No:
Step No. TECHNIQUES SIZE FREQ. METHOD BY REACTION PLAN Corrective action
Automatic
Temperature Record in Stop the plant inform to
1 _ M 60~70 Thermometer two times per shift temp. W
(Deg Cel) APSI/FM/QA/11 Maintenance dept.,
Control
Lab
Record in Addition / dilution of chemical
2 concentration _ M 40-60g/lit Titration once Twice in a Week - inspect
APSI/FM/QA/11 in tank
or
Density (Deg Record in Addition / dilution of chemical
3 _ M 4-8ºBe Hydrometer One time per day W
Beume) APSI/FM/QA/11 in tank
If sludge is in the tank transfer
Record in the soloution& clean again &
4 cleaning of tank _ M decantation in a non working day visual 100% Monthly - S
APSI/FM/QA/11 confirm the concentration &
10 Soak-Clean 11 Density
5 Dip time (min) - M 9-10 min Timer - - - PLC controlled - -

new bath preparation in a non fully drain & make Record in confirm the concentration &
6 Chemical change _ M 100% after 3 month _ S
working day New Bath APSI/FM/QA/11 Density of bath made
Lab
7 Oil content _ Mn maximum 5% By Calculation weekly _ inspect -
or
Make the level by adding
component should be fully
8 Level of solution - M visual 100% per shift - - W R.O.water. If Any abnormility
immersed
comes Inform to supervisor
if any abnormality Stop the
Temperature Automatic Record in
1 S 60~70°C Thermometer two time per shift W plant inform to Maintenance
(Deg Cel) Control APSI/FM/QA/11
dept.,
Lab
Record in Addition / dilution of chemical
2 concentration S 40-60g/lit Titration once weekly - inspect
APSI/FM/QA/11 in tank
or
Density (Deg Record in Addition / dilution of chemical
3 S 8-12 º Be Hydrometer Once Per day - W
Beume) APSI/FM/QA/111 in tank
If sludge is in the tank transfer
Record in the soloution& clean again &
4 Tank Cleaning S decantation in a non working day visual 100% monthly - S
APSI/FM/QA/11 confirm the concentration &
Density
transfer this solution
new bath preparation in a non Record in confirm the concentration &
5 Chemical change _ S to Stage no:12 then 100% after 3 month - S
working day APSI/FM/QA/11 Density
make fresh bath
20 Anodic clean 19 Cleaning of MS Record in if any abnormality comes
6 S Free From Sludge Visual & manual Once weekly W
plate APSI/FM/QA/111 inform to supervisor
Current monitering record in
7 Current Density S 25-50 ASF By Calculation once per month PLC controlled S ragister or formate once in two
hrs.

8 Time of dip (min) - S 3.0-5.0 min Timer - - - PLC controlled - -

Make the level by adding raw
component should be fully
9 Level of solution - S visual 100% per shift - - W water. If Any abnormility
immersed
The rectifier sholud deliver the Ifcomes Inform
it is greater to supervisor
than 2 min, hold
required D.C. current according to all components in this tank at
10 Rectifier failure S Visual 100% per shift - - W
the entered component and no:of the time of rectifier failure as
pieces If it is greater than 2lot
Suspected min hold,
all components in this tank at
11 Power failure S - - - - - - W
the time of power failure as
Suspected lot
Prepared by: Mr. Deepak APPROVED BY : Mr. V. Raja CUSTOMER APPROVAL:(If Reqd) ISSUE ISSUE DATE :
D BY :
CLASS C- Critical, M - Major, S- Significant, Mn - Minor
LEGEND FOR INSPECTED BY : W - OPERATOR ; I - INSPECTOR ; S - SUPERVISOR ;
 RADHE KRISHNA INDUSTRIES
CONTROL PLAN
ELECTROPLATING (General Purpose Component) PAGE 2/6 Doc No:-
CUSTOMER : ARIHANT VEHICLE MODEL:
PART NO: PART NAME BOLT FLANGE SH 6 X 16 DATE(ORIG):01/03/06
96001-06016-02-00

REVISE DATE : 25.8.2017

CORE TEAM: Mr. Harish Madan, Mr. Mahinder, Mr. V. Raja, Mr. Ashish, Mr. Vishal, Mr. Jai Singh KEY CONTACT: Mr. Vishal DVM (P.E.)

PROCESS Product CLASSPECIFICATIONS MEASUREMENT SAMPLE INSP.

OPERATION Process ERROR
DESCRIPTION Stage NO. Characteristics
characteristi
PROFING CONTROL CORRECTIVE
Step No. no. cs TECHNIQUES SIZE FREQ. METHOD BY REACTION PLAN ACTION
1 water flow S water should over flow visual 100% Per Shift _ Visual W if water overflow not there inform to Supervisor
2 Level of solution - S component should be fully immersed visual 100% per shift - - W If Any abnormility comes Inform to supervisor
30 Water Rinse 1 14
Record in
3 Tank Cleaning S fully drain & filled with fresh water Once weekly - APSI/FM/QA/1 W If tank is not clean, again reclean the tank
1
4 water flow S water should over flow visual 100% Per Shift _ Visual W if water overflow not there inform to Supervisor

40 Water Rinse 2 15 5 Level of solution - S component should be fully immersed visual 100% per shift - - W If Any abnormility comes Inform to supervisor
Record in
6 Tank Cleaning S fully drain & filled with fresh water Once weekly - APSI/FM/QA/1 W If tank is not clean, again reclean the tank
1
Record in
1 Density (Deg Beume) M 10~15º Be Hydrometer once per day APSI/FM/QA/1 W Addition / dilution of chemical in tank
1
Record in Lab
2 concentration M 20-30 % Titration once Twice in a week APSI/FM/QA/1 inspect if there is abnormality Stop the plant inform to Supervisor
1 or
Record in
If sludge is in the tank transfer the soloution & clean again &
3 Tank Cleaning M decantation in a non working day visual 100% monthly - APSI/FM/QA/1 S
confirm the concentration & Density
1
Record in
new bath preparation in a non working
50 Acid Pickling 16 4 Chemical change free from rust M fully drain & make New Bath 100% after 3 month - APSI/FM/QA/1 S confirm the concentration & Density
day
1
5 Dip time (min) M 1 to 2 min Timer - - - PLC controlled - -

Make up the level by adding R.O water. If Any abnormility comes

6 Level of solution M component should be fully immersed visual 100% per shift - - W
Inform to supervisor
If it is greater than 2 min hold in this tank, take out all
7 Power failure M - - - - - - W
components in this tank as with out platin
1 water flow S water should over flow visual 100% Per Shift _ Visual W if water overflow not there inform to Supervisor

60 Water Rinse 1 17 2 Level of solution - S component should be fully immersed visual 100% per shift - - W If Any abnormility comes Inform to supervisor
Record in
3 Tank Cleaning S fully drain & filled with fresh water Once weekly - APSI/FM/QA/1 W If tank is not clean, again reclean the tank
1
1 water flow S water should over flow visual 100% Per Shift _ Visual W if water overflow not there inform to Supervisor

70 Water Rinse 2 18 2 Level of solution - S component should be fully immersed visual 100% per shift - - W If Any abnormility comes Inform to supervisor
Record in
3 Tank Cleaning S fully drain & filled with fresh water Once weekly - APSI/FM/QA/1 W If tank is not clean, again reclean the tank
1
Record in
Automatic
1 Temperature (Deg Cel) S 60~70°C Thermometer two time per shift APSI/FM/QA/1 W if any abnormality Stop the plant inform to Maintenance dept.,
Control
1
Record in Lab
2 concentration S 40-60g/lit Titration once Twice in a week - APSI/FM/QA/1 inspect Addition / dilution of chemical in tank
1 or
Record in
3 Density (Deg Beume) S 8-12 º Be Hydrometer Once Per day - APSI/FM/QA/1 W Addition / dilution of chemical in tank
1
Record in
If sludge is in the tank transfer the soloution& clean again &
4 Tank Cleaning S decantation in a non working day visual 100% monthly - APSI/FM/QA/1 S
confirm the concentration & Density
1
Record in
new bath preparation in a non working transfer this solution to Stage no:12
5 Chemical change _ S 100% after 3 month - APSI/FM/QA/1 S confirm the concentration & Density
day then make fresh bath
1
80 Anodic clean 19 Record in
6 Cleaning of MS plate S Free From Sludge Visual & manual Once weekly APSI/FM/QA/1 W if any abnormality comes inform to supervisor
1
7 Current Density S 25-50 ASF By Calculation once per month PLC controlled S Current monitering record in ragister or formate once in two hrs.

8 Time of dip (min) - S 3.0-5.0 min Timer - - - PLC controlled - -

Make the level by adding raw water. If Any abnormility comes

9 Level of solution - S component should be fully immersed visual 100% per shift - - W
Inform to supervisor
The rectifier sholud deliver the required
If it is greater than 2 min, hold all components in this tank at the
10 Rectifier failure S D.C. current according to the entered Visual 100% per shift - - W
time of rectifier failure as Suspected lot
component and no:of pieces
If it is greater than 2 min hold, all components in this tank at the
11 Power failure S - - - - - - W
time of power failure as Suspected lot

Prepared by: Mr. Deepak APPROVED BY : Mr. V. Raja CUSTOMER APPROVAL:(If Reqd) ISSUE ISSUE DATE :
D BY :
CLASS C- Critical, M - Major, S- Significant, Mn - Minor
LEGEND FOR INSPECTED BY : W - OPERATOR ; I - INSPECTOR ; S - SUPERVISOR ;
 RADHE KRISHNA INDUSTRIES
CONTROL PLAN
ELECTROPLATING (General Purpose Component) PAGE 3/6 Doc No:-
CUSTOMER : ARIHANT VEHICLE MODEL:
PART NO: PART NAME BOLT FLANGE SH 6 X 16 DATE(ORIG):01/03/06
96001-06016-02-00
REVISE DATE : 25.8.2017
CORE TEAM: Mr. Harish Madan, Mr. Mahinder, Mr. V. Raja, Mr. Ashish, Mr. Vishal, Mr. Jai Singh KEY CONTACT: Mr. Vishal DVM (P.E.)
PROCESS Product MEASUREMENT SAMPLE ERROR CONTROL INSP.
OPERATION Process
DESCRIPTIO Stage NO. Characteristics characteri CLASS SPECIFICATIONS PROFIN CORRECTI
Step No. N no. stics TECHNIQUES SIZE FREQ. G METHOD BY REACTION PLAN VE ACTION
1 water flow S water should over flow visual 100% Per Shift _ Visual W if water overflow not there inform to Supervisor
component should be fully
90 Water Rinse 1 20 2 Level of solution - S visual 100% per shift - - W If Any abnormility comes Inform to supervisor
immersed
fully drain & filled with Record in
3 Tank Cleaning S Once Weekly - APSI/FM/QA/11
W If tank is not clean, again reclean the tank
fresh water
1 water flow S water should over flow visual 100% Per Shift _ Visual W if water overflow not there inform to Supervisor
component should be fully
100 Water Rinse 2 21 2 Level of solution - S visual 100% per shift - - W If Any abnormility comes Inform to supervisor
immersed
fully drain & filled with Record in
3 Tank Cleaning S Once Weekly - APSI/FM/QA/11
W If tank is not clean, again reclean the tank
fresh water
Density (Deg Record in
1 M 10~15º Be Hydrometer once per day _ APSI/FM/QA/11
W Addition / dilution of chemical in tank
Beume)
Record in
2 concentration M 20-30% Titration once Twice in a week _ APSI/FM/QA/11
Lab inspector Addition / dilution of chemical in tank
Record in If sludge is in the tank transfer the soloution& clean again & confirm the
3 Tank Cleaning M No sludge in chemical Decantation once Twice in a month _ APSI/FM/QA/11
S
concentration & Density
new bath preparation in a non fully drain & make New Record in
110 Acid Activation 22 4 Chemical change M 100% after 3 month - APSI/FM/QA/11
S confirm the concentration & Density
working day Bath

5 Dip time (min) M 10-20 seconds Timer - - - PLC controlled - -

6 Power failure
7 Level of solution
If it is greater than 2 min hold in this tank, take out all components in
M - - - - - W
this tank as with out plating
component should be fully
M visual 100% per shift - - W If Any abnormility comes Inform to supervisor
immersed

1 Water flow S water should over flow visual 100% Per Shift _ Visual W if water overflow not there inform to Supervisor
component should be fully Make up the levl by adding D.M.water. If Any abnormility comes Inform
2 Level of solution - S visual 100% per shift - - W
120 Water Rinse 23 immersed to supervisor
fully drain & filled with Record in
3 Tank Cleaning S Once Weekly - W If tank is not clean, again reclean the tank
fresh water APSI/FM/QA/11

Temperature in four hours per Record in

1 C 50-60 ° C Thermometer once APSI/FM/QA/11
W if any abnormality comes inform to supervisor
(Deg Cel) shift
Density (Deg Record in
2 C 20-25ºBe Hydrometer once per day APSI/FM/QA/11
W Addition / dilution of chemical in tank
Baume)
four Record in
3 pH C 3.8-4.2 pH meter per shift APSI/FM/QA/11
W if any abnormality comes inform to supervisor
times
C Ni metal 60- 70 gpl Analysis
Nickel
C 175-225 gpl By Calculation Record in Addition / dilution of chemical in tank when the value approaches min or
4 Concentration sulphate once Twice in a week Lab inspector
APSI/FM/QA/11 max. value
Nickel
C 45-55 gpl Analysis
chloride
C Boric acid 40-50 gpl Analysis
5 Current density M 20-25 ASF By Calculation once per month PLC control S Current monitering record in ragister or formate once in two hrs.

6 Filtration S Max pressure=1.0-2.0 Kg/cm2 Pressure gauge Once two days - W if any abnormality comes inform to supervisor and maintenance dept.,
7 air agitation M Regular Visual 100% per shift _ W if any abnormality comes inform to supervisor and maintenance dept.,
Nickel metal in
8 M should be up to working level Manual once per day _ W if any abnormality comes inform to supervisor and DPM[Plating]
baskets

Semi Bright 31/32/3 9 Auto dosing volume of chemical Record in

130 M set value=200-400 ml/1000Ah Once per shift APSI/FM/QA/11
W if any abnormality comes inform to supervisor and DPM[Plating]
Nickel 3 chemical collected in a stroke
Tank Cleaning No sludge in the anode basket,
Record in
10 and anode bag M no holes in the bag and look for Visual Once monthly APSI/FM/QA/11
W if any abnormality comes inform to supervisor and DPM[Plating]
cleaning any basket damage
11 Dip time (min) M 10-15 min Timer - - - PLC controlled - -
component should be fully Make the level by adding D.M.water. If Any abnormility comes Inform to
12 Level of solution M visual 100% per shift - - W
immersed supervisor
Conductivity should be less than
13 D.m water quality M Conductivity meter Once per shift - - W If Any abnormility comes Inform to supervisor
10 µSiemens/cm
The rectifier sholud deliver the
required D.C. current according If it is greater than 2 min, hold all components in this tank at the time of
14 Rectifier failure M Visual 100% per shift - - W
to the entered component and rectifier failure as Suspected lot
no:of pieces
If it is greater than 2 min, hold all components in this tank at the time of
15 Power failure M - - - - - - W
power failure as Suspected lot
16 Mn Copper( 10 ppm) Analysis Ones monthly - - Lab inspector -
17 Impurities Mn Iron( 50ppm) Analysis Ones monthly - - Lab inspector -
18 Mn Chrome( 30 ppm) Analysis Ones monthly - - Lab inspector -
Transporter
If transporter fail , treat this material as NG part & hold for 72
19 failure due to M relay should not loose By touching once per day - w
hrs ,passed the part after 100% file test.
relay loose
Prepared by: Mr. Deepak APPROVED BY : Mr. V. Raja CUSTOMER APPROVAL:(If Reqd) ISSUED BY : ISSUE DATE :
CLASS C- Critical, M - Major, S- Significant, Mn - Minor
LEGEND FOR INSPECTED BY : W - OPERATOR ; I - INSPECTOR ; S - SUPERVISOR ;
 RADHE KRISHNA INDUSTRIES
CONTROL PLAN
Doc No:-
ELECTROPLATING (General Purpose Component) PAGE 4/6

CUSTOMER : ARIHANT VEHICLE MODEL:

BOLT FLANGE SH 6 X 16
PART NO: PART NAME DATE(ORIG):01/03/06
96001-06016-02-00
REVISE DATE : 25.8.2017
CORE TEAM: Mr. Harish Madan, Mr. Mahinder, Mr. V. Raja, Mr. Ashish, Mr. Vishal, Mr. Jai Singh KEY CONTACT: Mr. Vishal DVM (P.E.)
ERROR
PROFING
PROCESS OPERATION Product MEASUREMENT SAMPLE CONTROL INSP.
NO. Process Characteristics characteristic CLASS SPECIFICATIONS
CORRECTIVE
s
Step No. DESCRIPTION Stage no. TECHNIQUES SIZE FREQ. METHOD BY REACTION PLAN REACTION
Record in
if any abnormality comes inform to
1 Temperature (Deg Cel) C 50-60 °C Thermometer twice per shift APSI/FM/QA/1 W supervisor
1

Record in
2 Density (Deg Baume) C 19-23 °Be Hydrometer once per day APSI/FM/QA/1 W Addition / dilution of chemical in tank
1

Record in
if any abnormality comes inform to
3 pH C 2.5-3.0 pH meter four times per shift APSI/FM/QA/1 W supervisor
1
C Nickel metal 60-70 gpl Analysis
Record in
Twice in a
4 Concentration in gpl C nickel chloride 65-75 gpl Analysis once APSI/FM/QA/1 Lab inspector Addition / dilution of chemical in tank
week
1
C Boric acid 40-50 gpl Analysis
Current monitering record in ragister
5 Current density C 18-22 ASF By Calculation once per month PLC control S or formate once in two hrs.

if any abnormality comes inform to

6 Filtration S Max pressure=1.0-2.0 Kg/cm2 Pressure gauge Once per two day - W supervisor and maintenance dept.,

if any abnormality comes inform to

7 air agitation M Regular Visual 100% per shift _ W supervisor and maintenance dept.,
if any abnormality comes inform to
8 Nickel metal in baskets M should be up to working level Manual once per day _ W supervisor and DPM[Plating]
140 Tri Nickel 30 volume of chemical Record in
if any abnormality comes inform to
9 Auto dosing chemical C set value=100-200 ml/1000Ah collected in a Once per shift APSI/FM/QA/1 W supervisor and DPM[Plating]
stroke 1
No sludge in the anode
Record in
Tank Cleaning and anode bag basket, no holes in the bag if any abnormality comes inform to
10 M Nil Once monthly - APSI/FM/QA/1 W supervisor and DPM[Plating]
cleaning and look for any basket
1
damage

11 Dip time (min) C 2.5-3.5 min Timer - - - PLC controlled - -

make the level by adding D.M.water. If

component should be fully
12 Level of solution C visual 100% per shift - - W Any abnormility comes Inform to
immersed supervisor
Conductivity should be less If Any abnormility comes Inform to
13 D.m water quality M Conductivity meter Once per shift - - W supervisor
The than 10 µSiemens/cm
rectifier sholud deliver the
If it is greater than 2 min, hold all
required D.C. current
14 Rectifier failure C Visual 100% per shift - - W components in this tank at the time of
according to the entered
component and no:of pieces Ifrectifier failurethan
it is greater as Suspected
2 min hold,lot
all
15 Power failure C - - - - - W components in this tank at the time of
power failure as Suspected lot
16 Mn Copper( 10 ppm) Analysis Ones monthly - Lab inspector

17 Impurities Mn Iron( 50ppm) Analysis Ones monthly - Lab inspector

18 Mn Chrome( 30 ppm) Analysis Ones monthly - Lab inspector

If transporter fail , treat this material as
Transporter failure due to relay
19 M relay should not loose By touching once per day - w NG part & hold for 72 hrs ,passed the
loose part after 100% file test.
Record in
if any abnormality comes inform to
1 Temperature (Deg Cel) C 50-60 °C Thermometer twice per shift APSI/FM/QA/1 W supervisor
1
Record in
2 Density (Deg Baume) C 20-25º Be Hydrometer once per day APSI/FM/QA/1 W Addition / dilution of chemical in tank
1
Record in
if any abnormality comes inform to
3 pH C 4.6-5.1 pH meter four times per shift APSI/FM/QA/1 W supervisor
1
C Nickel metal 60 -70 gpl Analysis
Nickel
C 175 - 225 gpl By calculation Record in
sulphate Twice in a
150 Bright Nickel 28/29 4 Concentration in gpl once APSI/FM/QA/1 I Addition / dilution of chemical in tank
week
C Nickel chloride 45 -55 gpl Analysis 1

C Boric acid 40 - 50 gpl Analysis

Current monitering record in ragister
5 Current density C 20-25 ASF By Calculation once per month PLC control S or formate
if any abnormality comes inform to
6 Filtration S Max pressure=1.0-2.0 Kg/cm2 Pressure gauge Once per two day - W supervisor and maintenance dept.,
if any abnormality comes inform to
7 air agitation M Regular Visual 100% per shift - W supervisor and maintenance dept.,

Prepared by: Mr. Deepak APPROVED BY : Mr. V. Raja CUSTOMER APPROVAL:(If Reqd) ISSUED BY : ISSUE DATE :

CLASS C- Critical, M - Major, S- Significant, Mn - Minor

LEGEND FOR INSPECTED BY : W - OPERATOR ; I - INSPECTOR ; S - SUPERVISOR ;

 RADHE KRISHNA INDUSTRIES
CONTROL PLAN
ELECTROPLATING (General Purpose Component) PAGE 5/6 Doc No:-
CUSTOMER : ARIHANT VEHICLE MODEL:
BOLT FLANGE SH 6 X 16

PART NO: 96001-06016-02-00 PART NAME DATE(ORIG):01/03/06

REVISE DATE : 25.8.2017

CORE TEAM: Mr. Harish Madan, Mr. Mahinder, Mr. V. Raja, Mr. Ashish, Mr. Vishal, Mr. Jai Singh KEY CONTACT: Mr. Vishal DVM (P.E.)

OPERATION
PROCESS DESCRIPTIO Stag Product MEASUREMENT SAMPLE ERROR CONTROL INSP.
NO. Process Characteristics CLASS SPECIFICATIONS CORRECTIVE ACTION
Step No. N e no. characteristics TECHNIQUES SIZE FREQ. PROFING METHOD BY REACTION PLAN

8 Nickel metal in baskets C should be up to working level Manual once per day _ W if any abnormality comes inform to supervisor and DPM[Plating]

volume of chemical Record in

9 Auto dosing chemical C set value=200-400 ml/1000Ah Once per shift W if any abnormality comes inform to supervisor and DPM[Plating]
collected in a stroke APSI/FM/QA/11

Tank Cleaning and anode No sludge in the anode basket, no holes in the bag Record in
10 M Nil Once monthly W if any abnormality comes inform to supervisor and DPM[Plating]
bag cleaning and look for any basket damage APSI/FM/QA/11

11 Dip time (min) C 10-15 min Timer - - - PLC controlled - -

Make the level of bath by adding the solution of Nickel drag out.If
12 Level of solution C component should be fully immersed visual 100% per shift - - W
Any abnormility comes Inform to supervisor

13 D.m water quality M Conductivity should be less than 10 µSiemens/cm Conductivity meter Once per shift - - W If Any abnormility comes Inform to supervisor

The rectifier sholud deliver the required D.C. current

If it is greater than 2 min, hold all components in this tank at the
14 Rectifier failure C according to the entered component and no:of Visual 100% per shift - - W
time of rectifier failure as Suspected lot
pieces

If it is greater than 2 min hold, all components in this tank at the

15 Power failure C - - - - - - W
time of power failure as Suspected lot
Lab
16 Mn Copper( 10 ppm) Analysis Ones monthly - - -
inspector
Lab
17 Impurities Mn Iron( 50ppm) Analysis Ones monthly - - -
inspector
Lab
18 Mn Chrome( 30 ppm) Analysis Ones monthly - - -
inspector
Transporter failure due to If transporter fail , treat this material as NG part & hold for 72
19 M relay should not loose By touching once per day - - w
relay loose hrs ,passed the part after 100% file test.

Should be
Recovering the Nickel free from
1 M 2-8º Be Hydrometer once per day W Level make up of Bright Nickel bath to be done by the Drag out.
solution from the component Nickel
solution
Nickel drag
160 27 Make the level of bath by adding D.M.water.If Any abnormility
out 2 Level of solution M component should be fully immersed visual 100% per shift - - W
comes Inform to supervisor
3 D.m water quality M Conductivity should be less than 10 µSiemens/cm Conductivity meter Once per shift - - W If Any abnormility comes Inform to supervisor
Record in
4 Tank Cleaning M No sludgeat the bottom of tank Nil Once Twice in amonth W if any abnormality comes inform to supervisor and DPM[Plating]
APSI/FM/QA/11
1 water flow S water should over flow visual 100% Per Shift _ Visual W if water overflow not there inform to Supervisor

170 Water Rinse 1 25 2 Level of solution - S component should be fully immersed visual 100% per shift - - W If Any abnormility comes Inform to supervisor

fully drain & filled with Record in

3 Tank Cleaning S Once weekly - W If tank is not clean, again reclean the tank
fresh water APSI/FM/QA/11

1 water flow S water should over flow visual 100% Per Shift _ Visual W if water overflow not there inform to Supervisor

180 Water Rinse 2 24 2 Level of solution - S component should be fully immersed visual 100% per shift - - W If Any abnormility comes Inform to supervisor

fully drain & filled with Record in

3 Tank Cleaning S Once weekly - W If tank is not clean, again reclean the tank
fresh water APSI/FM/QA/11
Record in
1 Temperature (Deg Cel) S 40-50 °C Thermometer twice per shift W if any abnormality comes inform to supervisor
APSI/FM/QA/11
Record in
2 Density (Deg Baume) M 18-22º Be Hydrometer once per day W Addition / dilution of chemical in tank
APSI/FM/QA/11

S Chromic acid 200 - 250 gpl Record in Lab

3 Concentration Analysis once Twice in week Addition / dilution of chemical in tank
APSI/FM/QA/11 inspector
S sulphate 1.0 - 2.0 gpl
4 Current density S 90-130 ASF By Calculation once per month PLC control S Current monitering record in ragister or formate once in two hrs.
Record in
5 Cleaning of anodes M Properly clean Visual Once per week S if any abnormality comes inform to DPM Plating
APSI/FM/QA/11
Tank Cleaning and sludge Half yearly in non working Record in
6 M No sludge in the tank Visual Once S if any abnormality comes inform to DPM[Plating]
removal day APSI/FM/QA/11
Make the level of bath by adding the solution of Chrome drag out i
Bright
7 Level of solution M component should be fully immersed visual 100% per shift - - W
190 9 Solution.If Any abnormility comes Inform to supervisor
Chrome

8 D.m water quality M Conductivity should be less than 10 µSiemens/cm Conductivity meter Once per shift - - W If Any abnormility comes Inform to supervisor

The rectifier sholud deliver the required D.C. current

If it is greater than 2 min, hold all components in this tank at the
9 Rectifier failure M according to the entered component and no:of Visual 100% per shift - - W
time of rectifier failure as Suspected lot
pieces

If it is greater than 2 min hold, all components in this tank at the

10 Power failure M - - - - - - W
time of power failure as Suspected lot
11 Dip time (min) M 1 to 3 min Timer - - - PLC controlled - -
12 Iron mn monthly
total Impurities gm/ltr ( 12.5 ) Analysis
13 Copper mn monthly
14 Chloride M Max.25 ppm Analysis monthly
Chocolate colour film over
15 M visual - - - - if any abnormality comes inform to DPM[Plating]
anode

Prepared by: Mr. Deepak APPROVED BY : Mr. V. Raja CUSTOMER APPROVAL:(If Reqd) ISSUED BY : ISSUE DATE :

CLASS C- Critical, M - Major, S- Significant, Mn - Minor

LEGEND FOR INSPECTED BY : W - OPERATOR ; I - INSPECTOR ; S - SUPERVISOR ;
 RADHE KRISHNA INDUSTRIES
CONTROL PLAN
ELECTROPLATING (General Purpose Component) PAGE 6/6 Doc No:-

CUSTOMER : ARIHANT VEHICLE MODEL:

BOLT FLANGE SH 6 X 16
PART NO: PART NAME DATE(ORIG):01/03/06
96001-06016-02-00
REVISE DATE : 25.8.2017
CORE TEAM: Mr. Harish Madan, Mr. Mahinder, Mr. V. Raja, Mr. Ashish, Mr. Vishal, Mr. Jai Singh KEY CONTACT: Mr. Vishal DVM (P.E.)

PROCESS Product MEASUREMENT SAMPLE CONTROL INSP. CORRECTIVE

OPERATION NO. Process Characteristics CLASS SPECIFICATIONS ERROR PROFING
characteristics ACTION
Step No. DESCRIPTION TECHNIQUES SIZE FREQ. METHOD BY REACTION PLAN
Record in
1 Tank Cleaning and sludge removal Mn No sludge in the tank Visual Once per six month _ W if any abnormality comes inform to DPM[Plating]
APSI/FM/QA/11
Recovering the Chrome plating Should be free from
2 Mn Density = 1-2º°Be Hydrometer once per day W Level make up of Drag out I to be done by the this Drag out II solution
200 Chrome drag out 7 solution from the component Chrome plating solution
Make the level of bath by adding D.M.water.If Any abnormility comes
3 Level of solution Mn component should be fully immersed visual 100% per shift - - W
Inform to supervisor
Conductivity should be less than 10
4 D.m water quality Mn Conductivity meter Once per shift - - W If Any abnormility comes Inform to supervisor
µSiemens/cm
1 water flow S water should over flow visual 100% Per Shift _ Visual W if water overflow not there inform to Supervisor
210 Water Rinse 1 5 2 Level of solution S S component should be fully immersed visual 100% per shift - - W If Any abnormility comes Inform to supervisor
fully drain & filled with fresh Record in
3 Tank Cleaning S Once Weekly - W If tank is not clean, again reclean the tank
water APSI/FM/QA/11
1 water flow S water should over flow visual 100% Per Shift _ Visual W if water overflow not there inform to Supervisor
220 Water Rinse 2 4 2 Level of solution - S component should be fully immersed visual 100% per shift - - W If Any abnormility comes Inform to supervisor
fully drain & filled with fresh Record in
3 Tank Cleaning S Once Weekly - W If tank is not clean, again reclean the tank
water APSI/FM/QA/11
230 Drier 2 1 Temperature (Deg Cel) Mn 70-80°C Thermometer _ _ Automatic Control _ inform to maintenance dept.,
Record in
240 Unloading 1 1 - component Surface M must be free from dent, scratchs Visual 100% Each unloading W If Any abnormility comes Inform to QA & supervisor
APSI/FM/QA/11
should wear cotton gloves, gently lifting the
1 handling by incompetent person - M Visual 100% per shift - Skill matrix S
component with out hitting
must be free from dent, scratchs, and Record in
2 - Visual M Visual 100% each shift - I Inform to prod. Incharge & QA
plating deffects APSI/FM/QA/11
minimum 10 Record in Lab
Total plating thickness = 15µ min Electrophysik per day In case of abnormality inform to Prod.incharge and QA
Parts/day APSI/FM/QA/11 inspector

3 - Thickness M
Record in Lab
Total Ni plating thickness =15µ min Smart STEP test Machine once one part/daily In case of abnormality inform to Prod.incharge and QA
APSI/FM/QA/11 inspector
250 Inspection
Chamber temp 49 ± 2º C Digital display - once in 8 h Automatic control
Digital display - once in 8
Humidifier temp 65 ± 2º C Automatic control
hours collected
volume of solution
precipitation rate 1-2ml/80cm2/h in the measuring jar - once in cut piece of a Two components per - Record in Lab
4 CASS life = 16 hours M 8 hours Inform to prod. Incharge & QA
pH of collected solution 3.1-3.3 at 25ºC by pH meter - once in 8 hours component month - APSI/FM/QA/11 inspector
by hydrometer-once after
Specific gravity. 1.0255-1.04 at 25ºC -
preparing new solution
- Visual-once in 8 hours -

Prepared by: Mr. Deepak APPROVED BY : Mr. V. Raja CUSTOMER APPROVAL:(If Reqd) ISSUED BY : ISSUE DATE :

CLASS C- Critical, M - Major, S- Significant, Mn - Minor

LEGEND FOR INSPECTED BY : W - OPERATOR ; I - INSPECTOR ; S - SUPERVISOR ;