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This document provides a process flow diagram (PFD) for part number N9092230, a swingarm sub part. The PFD outlines the process steps, equipment used, sources of variation to control, and product and process characteristics achieved at each step. Key steps include tube bending, welding, machining operations, and heat treatment. The supplier is required to control sources of variation and process parameters at each step to achieve all required product characteristics.

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100% found this document useful (1 vote)

510 views132 pages

PPAP Document Submission Checklist

Uploaded by

ఆనంద్ అవధానుల

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as XLS, PDF, TXT or read online on Scribd

List of documents submitted

Part Name : XXXX Plant Location :

PPAP Submission Level : L-3 Part No. & Rev:
Supplier Name :
S No Document Title Applicable S or NA or R
1 List of documents submitted S
2 Design Records
Bill Of Material S
Drawing S
Test Standards S
3 Engineering Change Documents NA
4 Customer Engineering Approval S
5 Design FMEA NA
6 Process Flow Diagram S
Overall Process Flow (for Ass NA
Process Flow Chart (for Feede NA
7 Process FMEA S
8 Dimensional Results S
9 Material Performance Test Results S
10 Initial Process Study S
Summary of Initial Process S
Control Chart S
Pp, Ppk Calculation Sheet S
11 Measurement System Analysis Stu NA / R
MSA for variable characteristi S
MSA for attribute characteristi S
12 Qualified Laboratory Documentati S
13 Control Plan S
14 PSW S
Weight Calculation Sheet S
15 Appearance Approval Report NA / R
16 Bulk Material Requirements Checkl NA
17 Sample Product R
18 Master Sample R
19 List of Checking Aids S
20 Records of Compliance With
Customer-Specific Requirements NA / R

Agreement of Inspection S
List of approved TIER 2 suppliers S
Photographs of the Tools,
Fixtures, Guages & S
Equipments
List of external laboratories (if NA
the services are used)
Process Qualification Records NA / R
Packaging Standard S
Prepared By: Approved By:
Remarks
Approved By:
SUPPLIER NAME

Bill Of Material
SL.NO PART NO DESCRIPTION QTY MATERIALS REMARKS

1 N9092219 TUBE SWINGARM R DISC 1 TUBE 40X25X1.63 THK

2 N9092029 TUBE SWINGARM L DISC 1 TUBE 40X25X1.63 THK

3 N3090689 BOSS RR SWINGING ARM PIVOT 2 ERW FINCUT OR CEW OD CONTROLLED

4 N9092049 BRIDGE SWINGARM 1 TUBE 40X30X2.0THK

5 N9091439 GUSSET BRIDGE 1 SHEET 2 THK

6 N9092039 BRIDGE GUSSET 1 SHEET 2.5 THK

7 N9092059 BRKT RR SHOCK ABS L 1 SHEET 2.5 THK

8 N9092169 BRKT RR SHOCK ABS 1 SHEET 2.5 THK

9 N9091409 REINF SWINGARM R 1 SHEET 2.5 THK

10 M7090699 BRKT.CHAIN CASE MTG FRONT 1 SHEET 2.5 THK

11 0334070 SQWELD NUT M6 2

12 K200230 HEXAGONAL NUT M10 2 STEEL P12

13 M7090059 REINF SWINGARM L 1 SHEET 2.5 THK

14 N9092119 GUIDE CHAINCASE MTG 1 SHEET 1.63 THK

15 N9092209 BRAKE ANCHOR 1

16 N9091889 CLAMP DISC BRAKE HOSE 2 SHEET 1.6 THK

Prepared by: V.SivaKarthikeyan Approved By : Mr.S.S.Reddy

Customer Engineerin
Part Name : xxxx

Supplier Name : xxxx

Specification Actual Observation

Mark up Characteristics
drg sl no description
LSL USL Sample 1 Sample 2

3 3.5 ± 0.1 mm 3.4 3.6 3.82 3.86

6 Φ 30 + 0.3 mm 30.0 30.3 30.43 Not checked

8 8.8 ± 0.2 mm 8.6 9.0 7.89 Not checked

10 Φ 4.5 + 0.2 mm 4.5 4.7 4.73 Not checked

12 42 ± 0.4 mm 41.6 42.4 44.34 Not checked

14 112.1 ± 0.4 mm 111.7 112.5 106.60 Not checked

16 6 ± 0.2 mm 5.8 6.2 6.32 6.34

19 89 ± 0.5 mm 88.5 89.5 92.8 93.67

22 66 ± 0.5 mm 65.5 66.5 67.89 Not checked

24 Φ 9 + 0.3 mm 9.0 9.3 7.19 7.21

26 43.2 ± 0.4 mm 42.8 43.6 44.26 Not checked

27 52.4 ± 0.4 mm 52.0 52.8 57.51 Not checked

Note - Deviations for characteristics with severity 4 and above are not permissible

Prepared by : xxxxx

Checked & Requested by : xxxx

Approved by (RND Designer) : xxxx

Customer Engineering Approval
Part No. & Rev: xxxx

Plant Location: xxxx

Temporary
Nature or
Deviation countermeasu Corrective Target Date
deviation and Effect Severity
from mean re Action for CA
root cause
(Disposition)

o/s 0.26 NA

o/s 0.13

u/s 0.71

o/s 0.03

o/s 1.94

u/s 5.10
From the No effect on Request for Sustain the
o/s 0.14 initial mould function and 1 permanent approval
approval itself assembly deviation dimension
o/s 3.3

o/s 1.39

u/s 1.81

o/s 0.66

o/s 4.71

Date xxxx

Date xxxx
Max permissible
Remarks
Qty for CA

NA
Supplier Name & Address : SUPPLIER NAME Page 01 of 01

PROCESS FLOW DIAGRAM PFD No.: PFD/TVS/N9092230/001

Part Name: SWINGARM SUB Drawing No. N9092230 PFD Initial Date : PFD Rev.no. "00
Part No. XXXXX Issue / Rev.# 27.09.2013 13.09.2016 PFD Rev.Date : 13.09.2017

Process Description Equipment No., Fixture no., Incoming Sources of Variation

Process step / Product Characteristics to be achieved in each Process Characteristics to be controlled to achieve the complete set
(Write as elaborately as Symbol Tool No., and (What operator should check process / operation step
Operation possible This will help you to (See bottom of page Manufacturing Location on part while loading do not include of product characteristics
(Write all characteristics to be
No. identify all potential process for symbols used) (Give process parameters to be controlled (write all 6M + E conditions to be controlled in this column)
failure mode in process FMEA ). here.) achieved: stated,implied and obligatory requirements )
complete details )

1.RM Grade Variation 1.Material Grade : IS 513 1.Man :

2.Dimension variation 2.Dimension As Per Drawing 1.a) Operator Skill Matrix Min.- (L-3) Complete

3.Rust 3.Rust Not Allowed 2.Machine : Nill.

4.Dent mark 4.Dent mark Not Allowed 3.Material :

5.Damage 5.Damage Not Allowed 3.a) Material Grade : IS 513
4.Method :

4.a) MRR Register Entry.(Qty , Weight )

Raw material and child parts
10 Manual 4.b) Receiving inspection Report
Receipt / Inspection
5.Measurement :

5.a) Digital Vernier Caliper, Range 0-300 mm .

5.b) Measurement Tap, Range: 0~5 meter .

6.Material Handling :

6.a) Hand Trolley Condition

7.Environment :
7.a) Iuminous level (800-1000) lux.

1.Material Without Identification 1.Storing in Unspecified Area Not Allowed 1.Man :

2.Damage 2.Damage Not Allowed 1.a) Operator Skill Matrix Min.- (L-3) Compleat
3.Dent mark 3.Scratches Not Allowed 2.Machine : Nill
4.Scratches 3.Material :
3.a) Material Grade : IS 513

4.Method :
Raw material and child parts
20 Manual 4.a) Verification for Min. and Max Stock Qty. Report
Storage
4.a) Visual tactile
5.Measurement : Nill

6.Material Handling :

6.a) Hand Trolley Condition.

7.Environment :
7.a) Iuminous level (400-600) lux.
1.Weld Undercut 1.Excess Welding Not allowed 1.Man :
2.blow holes 2.In completed Welding Not allowed 1.a) Operator Skill Matrix Min.- (L-3) Complete
Fixture No : 3.burn through 3.Burn Through Not allowed 2.Machine :
Aluminum Welding Fixture
SA/U180/A-FIX/WS01 4.Excess Welding 2.a) Wire Diameter = 1.2 mm
5.Incomplete weld 2.b) Machine Capacity =SR(100-350)
3.Material : Nill
4.Method :

Tack welding of Brkt, 30 4.a) Voltage = 20-25 V

30 RR Shock absorber L + Machine Name : 4.b) Current = 130-180 A
TACK WELDING
Hex Nut M10 4.c) Wire feed = 7-12 MPM
M/C
4.d) Gas flow = 15-25 LPM
5.Measurement :
5.d) Digital Height Gauge, Range (0~600 mm)
6.Material Handling :
Manufacturing Location :
6.a) Parts storage in plastic Bins
TVS Line - Welding Shop
7.Environment :
7.a) Iuminous level (400-600) lux.
1.Weld Undercut 1.Front CC Brkt C.D 168 ± 0.80 1.Man :
Fixture No : 2.blow holes 2.Front-Rear CC Brkt C.D 350 ± 0.80 1.a) Operator Skill Matrix Min.- (L-3) Complete
Aluminum Welding Fixture
SA/U180/A-FIX/WS02 3.burn through 3.LH/RH Slot C.D 488 ± 0.80 2.Machine :
4.Excess Welding 4.LH & RH S/Abs Brkt C.D 458.30 ± 1.00 2.a) Wire Diameter = 1.2 mm
5.Incomplete weld 5.Weld Undercut Not allowed 2.b) Machine Capacity =SR(100-350)
6.blow holes Not allowed 3.Material : Nill
STAGE 1 -Robot Welding 7.burn through Not allowed 4.Method :
Of Boss +Swing arm LH & Machine Name :
RH + Brkt RR shock Robo Mig Welding 8.Excess Welding Not allowed 4.a) Voltage = 20-25 V
40
absorber assembly M/C 9.In completed Welding Not allowed
40 4.b) Current = 200-240 A
LH&RH+ Brkt chain case
mtg front assembly + 4.c) Wire feed = 22-26 MPM
Reinforcement swing arm R
4.d) Gas flow = 20-25 LPM
&L
5.Measurement :
5.d) Digital Height Gauge, Range (0~600 mm)
Manufacturing Location : 6.Material Handling :
TVS Line - Welding Shop 6.a) Parts storage in Trolley Condition
7.Environment :
7.a) Iuminous level (400-600) lux.
1.Weld Undercut 1.Rear Width 200 + 2.0 1.Man :
2.blow holes 2.Front width 127 + 0.70 + 0.3 1.a) Operator Skill Matrix Min.- (L-3) Complete
Fixture No : 3.burn through Not allowed
3.Weld Undercut 2.Machine :
SA/U180/A-FIX/WS03
4.Excess Welding 4.blow holes Not allowed 2.a) Wire Diameter = 1.2 mm
5.Incomplete weld 5.burn through Not allowed 2.b) Machine Capacity =SR(100-350)
6.Excess Welding Not allowed 3.Material : Nill

STAGE 2 - Robot Welding Machine Name :

5.Incomplete weld

7.Incomplete weld Not allowed 4.Method :

STAGE 2 - Robot Welding Machine Name : 4.a) Voltage = 20-25 V
Of LH & RH Tube Robo Mig Welding
50
50 assembly + Gusset bridge L M/C 4.b) Current = 200-240 A
+ brige gusset +Bridge
4.c) Wire feed = 22-26 MPM
swing arm
4.d) Gas flow = 20-25 LPM
5.Measurement :
5.d) Digital Height Gauge, Range (0~600 mm)
Manufacturing Location : 6.Material Handling :
TVS Line - Welding Shop 6.a) Parts storage in Trolley Condition
7.Environment :
7.a) Iuminous level (400-600) lux.
1.Boring Thickness under size 1.Bore ID Ф24.00 + 0.02 -01.Man :
2.Boring Line mark 2.Boring Line mark Not allowed 1.a) Operator Skill Matrix Min.- (L-3) Complete
3.Damage 3.Offset Not allowed 2.Machine :
Machine Name : 4.Boring off set 4.Damage Not allowed 2.a) Boring tip = one in 1000 no's
Boring machine
2.b) Clamping pressure =4 bar
3.Material : Nill
4.Method :
60 STAGE 3 - Boss Boring 60
4.a) Spintill RPM= 800
5.Measurement :
5.a) Digital Vernier Caliper, Range 0-300 mm
Manufacturing Location :
6.Material Handling :
TVS Line - Welding Shop
6.a) Parts storage in Trolley Condition
7.Environment :
7.a) Iuminous level (400-600) lux.
1. No Bend in the swing arm tube 1.Rear Width 200 + 2.0 1.Man :
Fixture No : 2.Front width 127 + 0.70 + 0.30 1.a) Operator Skill Matrix Min.- (L-3) Complete
SA/U180/A-FIX/R-04 3.LH Tube C.off 103 + 0.50 2.Machine : Nill
4.RH Tube C.off 97 + 2.0 3.Material : Nill
5.LH S/Abs Brkt C.Off 114.30 ± 1.20 4.Method :
6.RH S/Abs Brkt C.Off 109.30 ± 1.20 4.a) Inspect the pin & bush.
Fixture Name:
7.Symmetry ÷ 0.80 5.Measurement : Nill
Revising Fixture
8.Front CC Brkt C.Off 100 ± 1.00 6.Material Handling :
9.Front-Rear CC Brkt C.Off 10.30 ± 0.50 6.a) Parts storage in Trolley Condition
10.Bridge Tube C.D 125 ± 2.0 7.Environment :
11.Front CC Brkt C.D 34.20 ± 0.50 7.a) Iuminous level (400-600) lux.
70 STAGE 4- Revising 70
12.Rear CC Brkt C.D 40.20 ± 0.50
13.LH & RH S/Abs Brkt C.D 47.50 ± 1.20
14.S.Abs Brkt Perpendicularity ┴ 1.00 mm
15.S.Abs Brkt Parelism Ф 0.5
Manufacturing Location : 16.Rear CC Brkt Perpendicularity ┴ 1.00 mm
TVS Line - Welding Shop
17.Front CC Brkt Perpendicularity ┴ 1.00 mm
18.Front CC Brkt C.D 168 ± 0.80
19.Front-Rear CC Brkt C.D 350 ± 0.80
20.LH/RH Slot C.D 488 ± 0.80
21.LH & RH S/Abs Brkt C.D 458.30 ± 1.00
22.Dent mark Not allowed
1.Undercut 1.Fitting Inner Brkt C.Off 46.50 ± 1.20 1.Man :
Fixture No : 2.blow holes 2.Fitting Inner Brkt C.D 103 ± 2.0 1.a) Operator Skill Matrix Min.- (L-3) Complete
SA/U180/FIX/WS/05 3.burn through 3.Front Clamp disc brake hose CD 166 ± 1.0 2.Machine :
4.Excess Welding 4.Rear Clamp disc brake hose CD 375 ± 1.0 2.a) Wire Diameter = 0.8 mm
5.Front Clamp disc brake hose
5.Incomplete weld C.Off
84 ± 1.0 2.b) Machine Capacity = ARC(100-300)
6.Rear Clamp disc brake hose
C.Off
118 ± 1.0 3.Material : Nill
7.Brake Anchor Height 9.3 ± 0.50 4.Method :
STAGE 5 - Manual Machine Name :
Welding of Stage 3 + Clamp 8.Brake Anchor CD 436 ± 0.5 4.a) Voltage = 20-25
Manual mig
80 Disc brake hose(2 no's) welding 9.Excess Welding Not allowed 4.b) Current = 130-180
+Guide chain mtg + Brake 80 10.In completed Welding Not allowed 4.c) Wire feed = 7-12 MPM
Anchor
11.burn through Not allowed 4.d) Gas flow = 12-25 LPM
5.Measurement :
5.a) Digital Height Gauge, Range (0~600 mm)
Manufacturing Location : 6.Material Handling :
TVS Line - Welding Shop 6.a) Parts storage in Trolley Condition
7.Environment :
7.a) Iuminous level (400-600) lux.
1. No Burn Through 1.Spatter Not allowed 1.Man :
2.Weld on Weld 2.Chisel Mark Not allowed 1.a) Operator Skill Matrix Min.- (L-3) Complete
2.Machine : Nill
3.Material : Nill
4.Method :
90 STAGE 6 -Chipping 90 Manual 4.a) Visual tactile
5.Measurement : Nill
6.Material Handling :
6.a) Parts storage in Trolley Condition
7.Environment :
7.a) Iuminous level (400-600) lux.
1. No Burn Through 1.Weld spatters Not allowed 1.Man :
2.Weld on Weld 2.Undercut Not allowed 1.a) Operator Skill Matrix Min.- (L-3) Complete
3. blow holes Not allowed 2.Machine : Nill
4.Incomplete weld Not allowed 3.Material : Nill
4.Method :
STAGE 7 -Visual
100 100
Manual 4.a) Visual tactile
Inspection
5.Measurement : Nill
6.Material Handling :
6.a) Parts storage in Trolley Condition
7.Environment :
7.a) Iuminous level (400-600) lux.
Moved To Powder coating Ref -- External Powder coating Process flow Diagram

1.Threa missing 1.Threa missing Not allowed 1.Man :

2.Thread washout 2.Thread washout Not allowed 1.a) Operator Skill Matrix Min.- (L-3) Complete
3.Thread damage 3.Thread damage Not allowed 2.Machine :
4. Thread M6,M10 Thread Plug 2.a) Tapping Gun RPM = 200
gauge
2.b) Tapping Frq. = 2000 no's
3.Material : Nill
4.Method :
110 STAGE 8 -Retapping 110 Retapping Gun 4.a) Visual tactile
4.b) Tightening Torque = 35-40 n/m
5.Measurement :
5.a) Thread Plug gauge
6.Material Handling :
6.a) Parts storage in Trolley Condition
7.Environment :

7.a) Iuminous level (400-600) lux.

1. Inserting of Bush Damage 1.Dimension 124+0.7+0.3 1.Man :
2.Parts Missing Not allowed 1.a) Operator Skill Matrix Min.- (L-3) Complete
3.Loose assy Not allowed 2.Machine : Nill
4.Worng part assy Not allowed 3.Material : Nill
4.Method :
STAGE 9- Inserting of Bush
120 To Swing Arm Assy (2- 120
Manual 4.a) Visual tactile
no's)
5.Measurement : Nill
6.Material Handling :
6.a) Parts storage in Trolley Condition
7.Environment :
7.a) Iuminous level (400-600) lux.
1. Inserting of Bush Damage 1.Dimension 124+0.7+0.3 1.Man :
Fixture No : 200+2.0
2.Dimension 1.a) Operator Skill Matrix Min.- (L-3) Complete
SA/U180/A-FIX/R-04
3.Dimension 103+0.5 2.Machine : Nill
4.Dent Not Allowed 3.Material : Nill
5.Damage Not Allowed 4.Method :
Fixture Name:
130 STAGE 10- Revising
130 Revising Fixture 4.a) Visual tactile
5.Measurement : Nill
6.Material Handling :

Manufacturing Location : 6.a) Parts storage in Trolley Condition

TVS Line - Welding Shop 7.Environment :
7.a) Iuminous level (400-600) lux.
1.Inside weld spatter Component should easily All Pins 1.Man :
answer the Final Acc Gauge answering
2.Free from Dust freely 1.a) Operator Skill Matrix Min.- (L-3) Complete
Component should easily All Pins
answer the Final Acc Gauge answering
2.Free from Dust freely
2.Machine : Nill
3.Material : Nill
4.Method :

Final Acceptance Gauge Acc Gauge - 4.a) Gauge Check list

140
Inspection TVS-Gug/0616/U180 4.b) Gauge calibration frequence
5.Measurement : Nill
6.Material Handling :
6.a) Parts storage in Trolley Condition
7.Environment :
7.a) Iuminous level (800-1000) lux.
1.powder coating un coverage 1.Dent Not allowed 1.Man :
2.Powder coating peel off 2.Damage Not allowed 1.a) Inspector Skill Matrix Min.- (L-3) Complete
3.Roughness 3.Part missing Not allowed 2.Machine : Nill
4.powder coating un coverage Not allowed 3.Material : Nill
5.Powder coating peel off Not allowed 4.Method :
4.a) Final Inspection report
4.b) Inspector Training Report
150 Final Visual Inspection Manual
4.c) Operator Self Inspection
4.e) 100% of Visual Inspection
5.Measurement : Nill
6.Material Handling :
6.a) Parts storage in Trolley Condition
7.Environment :
7.a) Iuminous level (800-1000) lux.
1.Unspecified trolley 1.Std Trolley Visual 1.Man :
2.Trolley qty 40-50 no's 1.a) Inspector Skill Matrix Min.- (L-3) Complete
2.Machine : Nill
3.Material : Nill
4.Method :
160
4.a) Operator Self Inspection
160 Loading of Trolley Trolley
4.b) 100% of Visual Inspection
5.Measurement : Nill
6.Material Handling :
6.a) Parts storage in Trolley Condition
7.Environment :
7.a) Iuminous level (800-1000) lux.
1.Dim Variation 1.Dim Variation Not Allowed 1.Man :
2.Dent 2.Dent Not Allowed 1.a) Operator Skill Matrix Min.- (L-3) Complete
3.Damage 3.Damage Not Allowed 2.Machine : Nill
4.Operation Missing 4.Operation Missing Not Allowed 3.Material : Nill
4.Method :
4.a) PDI Inspection report (No :BMW/PDI/NB05140-15/001 )
4.b) Inspector Training Report
170 Dock Audit Manual 4.c) Operator Self Inspection
4.e) 100% of Visual Inspection
5.Measurement :
5.a) Instrument Name : Digital Vernier Caliper(0~300 mm)
6.Material Handling :
6.a) Parts storage in plastic Bins
7.Environment :
7.a) Iuminous level (800-1000) lux.
1.Part No Changed As per the customer schedule 1.Man :
2.Part Name Changed Preplanned transportation 1.a) Operator Skill Matrix Min.- (L-3) Complete
3.Qty Variation 2.Machine : Nill
4.Crack 3.Material : Nill
5.Damage 4.Method :
4.a) Trolley Condition
180 Dispatch to TVS Trolley 4.b) Vehicle Condition
5.Measurement :
5.a) Weight Scale
6.Material Handling :
6.a) Move To dispatch Area using Trolley Condition .

7.Environment :
7.a)Iuminous level (400-600) lux.

Rev.No. Date: Details of Revision Rev. No. Date: Details of Revision

Prepared by : V.Sivakarthikeyan Approved by : Mr.S.S.Reddy

xx xx
Symbols : Operation : x Operation + Inspection : x
Transportation : Storage :
SUPPLIER NAME
Potential Failure Mode and Effects Analysis
(Process FMEA)
System : Vehicle Assy Key Date 27.09.2013 FMEA Number
Drawing No :- XXXXX
Component: SWINGARM FMEA Date 03.07.2016 Page .NO:

Model : TVS - Revision No : - L4 FMEA Rev. No. 0 Prepared by

FMEA Rev. Date 03.07.2017
Core Team :Mr.Velayutham(PED), Mr.SS.Reddy(QAD),Mr.Siva subramani (PRD),Mr.Sivakumar(Purchase),Sivakarthikeyan(QAD)
Process Responsibility : Mr velayutham

Characteristic
Class (Special

Detection (D)
Occurrence

(SxOxD)
Severity
Process No. and Current Process controls - Prevention of

R.P.N.
Process Deliverables / Potential cause(s) / Current Process controls - Detection of Cause and / or

(O)
S.No Description of Potential Failure Mode Potential Effect(s) of Failure Cause and / or Prevention of Failure

)
Requirements Mechanism(s) of Failure Detection of Failure Mode
Operation Mode

Next.Process : Can not be Used for Next Process (S=8) Cause : Verification of Supplier Material
Cause : Verification for Supplier Material Test Certificate (D=8)
Vehicle Mfr. : loss of Test Certificate and 3rd-Party Test Report
1.Material Grade : IS 513 Material Grade Variation 8 1.Supplier Process Failure 2 FM : Receiving 8 128
Secondary function (S=6) End User : FM :
Inspection Report (D=5)
Audible noise vehicle operable (s=4) Nill

Next.Process : Can not be Used for Next Process (S=8) Cause : Incomimg Inspection reportst (D=5)
Vehicle Mfr. : loss of Cause : Incoming inspection Standards Gauge Inspection (D=7)
2.Dimension Dimension Variation 8 1.Poor Supplier end Control 2 5 80
Secondary function (S=6) End User FM : Nill FM :Supplier Inspection Report
: Audible noise vehicle operable (s=4) Visual (D=8)

Next.Process :Rework in Station before Process (S=5)

Vehicle Mfr. : vechicle
Cause : 45 days inventory followed Cause : Verification for ERP Report (D=5)
3.No rust Rust operable but comfort but reduced level (S=5) 5 1.Excess Inventory 2 8 80
FM : Nill FM : Visual Inspection (D=8)
End User : Audible noise vehicle
operable (S=4)

Next.Process : Rework in Station before Process (S=5)

Cause : Manual material handling as per Cause : Receiving Inspection Report (D=5)
Vehicle Mfr. : vechicle
3.No Damage Damage 5 1.Improper handling W.I FM 2 FM :Supplier Inspection Report 8 80
operable but comfort but reduced level (S=5)
: Nill Visual (D=8)
End User : Poor appearance (S=4)

Next.Process :Rework in Station before Process (S=5)

Vehicle Mfr. : vechicle Cause : Verification for Supplier Cause : Receiving Inspection Report (D=5)
5.No Dent mark Dent mark operable but comfort but reduced level (S=5) 5 1.Improper material storage Inspection Report 2 FM :Supplier Inspection Report 8 80
End User : Audible noise vehicle FM : Nill Visual (D=8)
operable (S=4)

Next.Process : Time Delay and out Flow Rej

Raw Material Operator Skill Matrix Min.- 1.Not Done Training Cause : Training Attendance Register Cause : Skill Matrix Report (D=5)
10 Operator Skill Matrix Low Level Completed Vehicle Mfr. : Out Flow rejection 4 2 5 40
Receipt / Inspection (L-3) Complete 2.operator Absent FM : Nill FM : Skill Matrix V.C.S Display (D=8)
End User : N.A

Next.Process : Time Delay Cause :Verification for .Gate entry /Material Receipt Register
1.Qty Variation Cause : Supplier Inspection Report
MRR Register Entry Vehicle Mfr. : N.A 4 1.Supplier Process Failure 2 (D=8) FM : 5 40
2.Weight Variation FM : Nill
End User : N.A ERP Report (D=5)

Next.Process : 1.Problem in Next Process,Part have to be Rework

Cause :Verification for Internal Auditee Report (D=5)
Vehicle Mfr. : N.A Cause : Internal Audit
Receiving inspection Report Wrong Dimension 5 1.Supplier Process Failure 2 FM : Receiving Inspection 5 50
End User : FM : Nill
Report (D=8)
N.A

1.Digital Vernier Caliper, Next.Process : Can not be Used for Next Process (S=8)
Range 0-300 mm . Vehicle Mfr. : Out flow 1.Out of Calibration Cause : M.S.A report Cause :Verification for calibration report (D=5)
Dimension Variation 8 2 5 80
2.Measurement Tap, Range: of not-good Part to Customer End User Equipment Used FM : Nill FM : calibration report (D=8)
0~5 meter . : N.A

Next.Process : Can not be Used for Next Process (S=8) Cause : Suitable trolley Design during Cause :.Verification for Maintenance Report (D=5)
Hand Trolley Condition. 1.Material Damage Vehicle Mfr. : N.A 8 1.Wrong Trolley Condition. NPD (Drawing) 2 FM : Internal 5S'Audite 5 80
Hand Trolley Condition. 1.Material Damage Vehicle Mfr. : N.A 8 1.Wrong Trolley Condition. NPD (Drawing) 2 FM : Internal 5S'Audite 5 80
End User : N.A FM : Nill (D=8)

Next.Process : Can not be Used for Next Process (S=8) Cause :Verification for Check sheet (D=5)
Iuminous level (400-600) Cause : Internal Audit
Inspection no done properly Vehicle Mfr. : N.A 8 1.Wrong Iuminous level 2 FM : Iuminous level Visual 5 80
lux. FM : Nill
End User : N.A Inspection (D=8)

Next.Process : Poor appearance Customer Dissatisfaction (S=5)

Cause : Will Provided 3 C" and 5 S "
Vehicle Mfr. : Cause : Verification for Check Sheet (D=5)
1.Storing in specified Area Storing in Unspecified Area 5 1.Wrong Layout Area Training 2 5 50
N.A FM : Visual Inspection (D=8)
FM : Nill
End User : N.A

Next.Process :Rework in Station before Process (S=5)

Vehicle Mfr. : vechicle Cause : Daily Monitoring Inventory Cause : Verification for Min. and Max Stock Qty. Report (D=5)
2.No Damage Damage operable but comfort but reduced level (S=5) 5 1.Over material Flow Control 2 FM : Visual 5 50
End User : Audible noise vehicle FM : Nill Inspection (D=8)
operable (S=4)

Next.Process :Rework in Station before Process (S=5)

Vehicle Mfr. : vechicle Cause :Daily Monitoring Inventory Cause : Verification for Min. and Max Stock Qty. Report (D=5)
3.No Scratches Scratches operable but comfort but reduced level (S=5) 5 1.Over material Flow Control 2 FM : Visual 5 50
End User : Audible noise vehicle FM : Nill Inspection (D=8)
operable (S=4)

Next.Process : Time Delay and out Flow Rej

Raw Material
20
Storage

Next.Process :Can not be Used for Next Process (S=8) Cause : Verification of Supplier Material
Cause : Verification for Supplier Material Test Certificate (D=8)
Vehicle Mfr. : loss of Test Certificate and 3rd-Party Test Report
Material Grade : IS 513 Material Grade Variation 8 1.Supplier Process Failure 2 FM : Receiving 5 80
Secondary function (S=6) FM :
Inspection Report . (D=5)
End User : Audible noise vehicle operable (s=4) Nill

Next.Process : Time Delay Cause :Inventory Report (D=5)

Verification for Min. and 1.Wrong Min. and Max Stock Cause : ERP Report
1.Qty Variation Vehicle Mfr. : N.A 4 2 FM :Min. and Max Stock Qty Visual Checking 5 40
Max Stock Qty. Report Qty. FM : Nill
End User : N.A (D=8)

Next.Process : Can not be Used for Next Process (S=8)

Cause : Suitable trolley Design during Cause :.Verification for Maintenance Report (D=5)
Vehicle Mfr. : N.A
Hand Trolley Condition. 1.Material Damage 8 1.Wrong Trolley Condition. NPD (Drawing) 2 FM : Internal 5S'Audite 5 80
End
FM : Nill (D=8)
User : N.A

Next.Process : Can not be Used for Next Process (S=8)

Cause :Verification for Check sheet (D=5)
Iuminous level (400-600) Vehicle Mfr. : N.A Cause : Internal Audit
Inspection no done properly 8 1.Wrong Iuminous level 2 FM : Iuminous level Visual 5 80
lux. FM : Nill
Inspection (D=8)
End User : N.A

Next.Process :Rework in Station before Process (S=5) Cause :1. Operation Standard displyed at
Cause : Set-up Verification Report (D=5) Operater Skill
Vehicle Mfr. : Reduce work are
Inadequate operator Skill Matrix Visual Display (D=8) FM : In-process
No Excess Welding Excess Welding weld strength & Aesthetic Not Good (S=5) 5 2.Daily Fixture monitoring check sheet 2 5 50
Process parameter variation Inspection Report.(D=7) 100 % Visual Inspection at
End User : Audible noise vehicle 3.Operator skill matrix
final visual inspection stage (D=8)
operable (S=4) FM : Nill
Next.Process : Rework in Station before Process (S=5)
Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Operater Skill
Vehicle Mfr. : Reduce
Inadequate welder Skill work are Matrix Visual Display (D=8) FM : In-process
No In completed Welding In completed Welding weld strength & Aesthetic Not Good (S=5) 5 2 5 50
3.Operator skill matrix Inspection Report.(D=7) 100 % Visual Inspection at
End User : Audible noise vehicle
FM : Nill final visual inspection stage (D=8)
operable (S=4)

Next.Process : Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Operater Skill
Vehicle Mfr. : Reduce weld
Inadequate operator Skill work are Matrix Visual Display (D=8) FM : In-process
No Burn Through Burn Through strength & Aesthetic Not Good (S=5) 5 2 5 50
Process parameter variation 3.Operator skill matrix Inspection Report.(D=7) 100 % Visual Inspection at
End User : Audible noise vehicle operable
FM : Nill final visual inspection stage (D=8)
(S=4)

Next.Process : Time Delay and out Flow Rej

Next.Process :Weld beed low leads to reduce life time

Cause :1. SOP Provided Cause : Set-up Verification Report (D=5)
Vehicle Mfr. :Not 1.Improper std
Wire Diameter = 0.8 mm Wire Dia Variation 4 3.Operator Training 2 FM : In-process Inspection 5 40
applicable End User : Not 2.Untrained welder
FM : Nill Report.(D=7)
applicable

Tack welding of
Brkt, RR Shock Next.Process :Rework in Station before Process (S=5)
30
absorber L + Hex Vehicle Mfr. : vechicle 1.Power sorce Problem Cause : Preventive maint, Process Cause : Set-up Verification Report (D=5) Preventive
Nut M10 Voltage = 20-25V Voltage variation operable but comfort but reduced level (S=5) 5 2. parameter not setted parameter display. 2 Maint.Check sheet (D=5) 5 50
End User : Audible noise vehicle correctly FM : Nill FM : In-process Inspection Report.(D=7)
operable (S=4)
Next.Process :Rework in Station before Process (S=5)
Vehicle Mfr. : vechicle 1.Power sorce Problem Cause : Preventive maint, Process Cause : Set-up Verification Report (D=5) Preventive
Current = 130-180A Current variation operable but comfort but reduced level (S=5) 5 3. parameter not setted parameter display. 2 Maint.Check sheet (D=5) 5 50
End User : Audible noise vehicle correctly FM : Nill FM : In-process Inspection Report.(D=7)
operable (S=4)
Next.Process :Rework in Station before Process (S=5)
Vehicle Mfr. : vechicle 1.Power sorce Problem Cause : Preventive maint, Process Cause : Set-up Verification Report (D=5) Preventive
Wire feed = 7-12 MPM Wire feed variation operable but comfort but reduced level (S=5) 5 4. parameter not setted parameter display. 2 Maint.Check sheet (D=5) 5 50
End User : Audible noise vehicle correctly FM : Nill FM : In-process Inspection Report.(D=7)
operable (S=4)
Next.Process :Rework in Station before Process (S=5)
Vehicle Mfr. : vechicle 1.Power sorce Problem Cause : Preventive maint, Process Cause : Set-up Verification Report (D=5) Preventive
Gas flow = 15-25 LPM Gas flow variation operable but comfort but reduced level (S=5) 5 5. parameter not setted parameter display. 2 Maint.Check sheet (D=5) 5 50
End User : Audible noise vehicle correctly FM : Nill FM : In-process Inspection Report.(D=7)
operable (S=4)

Digital Height Gauge, Next.Process : Can not be Used for Next Process (S=8)
Cause :Verification for calipration report (D=5)
Range (0~600 mm) , Vehicle Mfr. : Out flow 1.Out of Calibration Cause : M.S.A report
1.Dimention Variation 8 2 FM : calipration report Visual 5 80
No : of not-good Part to Customer End User Equipment Used FM : Nill
Inspection (D=8)
HIV/DVC/006 : N.A

Next.Process : Can not be Used for Next Process (S=8) Cause : Suitable plastic Bins Design Cause :.Verification for Maintenance Report (D=5)
1.Wrong Parts storage in
Parts storage in plastic Bins 1.Material Damage Vehicle Mfr. : N.A 8 during NPD (Drawing) 2 FM : Internal 5S'Audite 5 80
plastic Bins
End User : N.A FM : Nill (D=8)

Next.Process : Can not be Used for Next Process (S=8) Cause :Verification for Check sheet (D=5)
Iuminous level (400-600) Cause : Internal Audite
Inspection no done properly Vehicle Mfr. : N.A 8 1.Wrong Iuminous level 2 FM : Iuminous level Visual 5 80
lux. FM : Nill
End User : N.A Inspection (D=8)

1.Front CC Brkt C.D =

168 ± 0.80

Next.Process :Can not be Used for Next Process (S=8) Improper clamping Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Welding Fixture
Vehicle Mfr. : loss of Locating pin Worn out work area Daily Audit Check Sheet (D=5)
Dimension Under Size 8 2 5 80
Secondary function (S=6) End User : Audible Locating stopper worn out 2.Fixture calibration report Operater Skill Matrix Visual Display (D=8)
noise vehicle operable (s=4) Inadequate operator Skill FM : Nill FM : In-process Inspection Report.(D=7)
Next.Process :Can not be Used for Next Process (S=8) Improper clamping Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Welding Fixture
Vehicle Mfr. : loss of Locating pin Worn out work area Daily Audit Check Sheet (D=5)
Dimension Over size 8 2 5 80
Secondary function (S=6) End User : Audible Locating stopper worn out 2.Fixture calibration report Operater Skill Matrix Visual Display (D=8)
noise vehicle operable (s=4) Inadequate operator Skill FM : Nill FM : In-process Inspection Report.(D=7)

2.Front-Rear CC Brkt C.D

= 350 ± 0.80

3.LH/RH Slot C.D =

488 ± 0.80

4.LH & RH S/Abs Brkt C.D

= 458.30 ± 1.00

Next.Process :Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Operater Skill
Vehicle Mfr. : Reduce
Inadequate operator Skill work are Matrix Visual Display (D=8) FM : In-process
5.No weld under cut Weld Under cut weld strength & Aesthetic Not Good (S=5) 5 2 5 50
2.Operator skill matrix Inspection Report.(D=7) 100 % Visual Inspection at
End User : Audible noise vehicle
FM : Nill final visual inspection stage (D=8)
operable (S=4)

Next.Process :Rework in Station before Process (S=5) Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Operater Skill
STAGE 1 -Robot
Vehicle Mfr. : Reduce Nozzle not cleaned properly work are Matrix Visual Display (D=8) Maintanence Check sheet ( D=
Welding Of Boss
6.No Blow Holes Blow Holes weld strength & Aesthetic Not Good (S=5) 5 Inadequate welder Skill 2.Manitanence checksheet 2 5) FM : In-process Inspection Report.(D=7) 5 50
+Swing arm LH &
End User : Audible noise vehicle 3.Operator skill matrix 100 % Visual Inspection at final visual inspection stage
RH + Brkt RR
operable (S=4) FM : Nill (D=8)
shock absorber
40
assembly LH&RH+
Brkt chain case
mtg front assembly
+ Reinforcement Next.Process : Rework in Station before Process (S=5)
Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Operater Skill
swing arm R & L Vehicle Mfr. : Reduce weld
Inadequate operator Skill work are Matrix Visual Display (D=8) FM : In-process
7..No Burn Through Burn Through strength & Aesthetic Not Good (S=5) 5 2 5 50
Process parameter variation 3.Operator skill matrix Inspection Report.(D=7) 100 % Visual Inspection at
End User : Audible noise vehicle operable
FM : Nill final visual inspection stage (D=8)
(S=4)

Next.Process : Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Operater Skill
Vehicle Mfr. : Reduce weld
work are Matrix Visual Display (D=8) FM : In-process
9.No In completed Welding In completed Welding strength & Aesthetic Not Good (S=5) 5 Inadequate welder Skill 2 5 50
3.Operator skill matrix Inspection Report.(D=7) 100 % Visual Inspection at
End User : Audible noise vehicle operable
FM : Nill final visual inspection stage (D=8)
(S=4)
Next.Process : Time Delay and out Flow Rej
Operator Skill Matrix Min.- 1.Not Done Training Cause : Training Attendance Register Cause : Skill Matrix Report (D=5)
Operator Skill Matrix Low Level Completed Vehicle Mfr. : Out Flow rejection 4 2 5 40
(L-3) Complete 2.operator Absent FM : Nill FM : Skill Matrix Visual Display (D=8)
End User : N.A

Next.Process :Weld beed low leads to reduce life time

Cause :1. SOP Provided Cause : Set-up Verification Report (D=5)
Vehicle Mfr. :Not 1.Improper std
Wire Diameter = 1.2 mm Wire Dia Variation 4 3.Operator Training 2 FM : In-process Inspection 5 40
applicable End User : Not 2.Untrained welder
FM : Nill Report.(D=7)
applicable

Next.Process :Rework in Station before Process (S=5)

Vehicle Mfr. : vechicle 1.Power sorce Problem Cause : Preventive maint, Process Cause : Set-up Verification Report (D=5) Preventive
Current = 220-240A Current variation operable but comfort but reduced level (S=5) 5 3. parameter not setted parameter display. 2 Maint.Check sheet (D=5) 5 50
End User : Audible noise vehicle correctly FM : Nill FM : In-process Inspection Report.(D=7)
operable (S=4)

Next.Process :Rework in Station before Process (S=5)

Vehicle Mfr. : vechicle 1.Power sorce Problem Cause : Preventive maint, Process Cause : Set-up Verification Report (D=5) Preventive
Wire feed = 20-26 MPM Wire feed variation operable but comfort but reduced level (S=5) 5 4. parameter not setted parameter display. 2 Maint.Check sheet (D=5) 5 50
End User : Audible noise vehicle correctly FM : Nill FM : In-process Inspection Report.(D=7)
operable (S=4)

Next.Process :Rework in Station before Process (S=5)

Vehicle Mfr. : vechicle 1.Power sorce Problem Cause : Preventive maint, Process Cause : Set-up Verification Report (D=5) Preventive
Gas flow = 20-25 LPM Gas flow variation operable but comfort but reduced level (S=5) 5 5. parameter not setted parameter display. 2 Maint.Check sheet (D=5) 5 50
End User : Audible noise vehicle correctly FM : Nill FM : In-process Inspection Report.(D=7)
operable (S=4)

Next.Process : Can not be Used for Next Process (S=8) Cause : Suitable Trolley Design during Cause :.Verification for Maintenance Report (D=5)
Parts storage in Trolley 1.Wrong Parts storage in
1.Material Damage Vehicle Mfr. : N.A 8 NPD (Drawing) 2 FM : Internal 5S'Audite 5 80
Condition plastic Bins
End User : N.A FM : Nill (D=8)

1.Rear Width =200 + 2.0

2.Front width =
127 + 0.70 + 0.30

Next.Process :Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Operater Skill
Vehicle Mfr. : Reduce
Vehicle Mfr. : Reduce
Inadequate operator Skill work are Matrix Visual Display (D=8) FM : In-process
3.No weld under cut Weld Under cut weld strength & Aesthetic Not Good (S=5) 5 2 5 50
2.Operator skill matrix Inspection Report.(D=7) 100 % Visual Inspection at
End User : Audible noise vehicle
FM : Nill final visual inspection stage (D=8)
operable (S=4)

Next.Process : Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Operater Skill
Vehicle Mfr. : Reduce weld
Inadequate operator Skill work are Matrix Visual Display (D=8) FM : In-process
5..No Burn Through Burn Through strength & Aesthetic Not Good (S=5) 5 2 5 50
Process parameter variation 3.Operator skill matrix Inspection Report.(D=7) 100 % Visual Inspection at
End User : Audible noise vehicle operable
FM : Nill final visual inspection stage (D=8)
(S=4)

STAGE 2 - Robo
Welding of Stage
1-Stage 2+ Bridge Next.Process : Rework in Station before Process (S=5)
50 Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Operater Skill
swingarm + Gusset Vehicle Mfr. : Reduce weld
work are Matrix Visual Display (D=8) FM : In-process
bridge L + Bridge 7.No In completed Welding In completed Welding strength & Aesthetic Not Good (S=5) 5 Inadequate welder Skill
3.Operator skill matrix
2
Inspection Report.(D=7) 100 % Visual Inspection at
5 50
gusset End User : Audible noise vehicle operable
FM : Nill final visual inspection stage (D=8)
(S=4)

Next.Process : Time Delay and out Flow Rej

Next.Process :Weld beed low leads to reduce life time

Next.Process :Rework in Station before Process (S=5)

Vehicle Mfr. : vechicle 1.Power sorce Problem Cause : Preventive maint, Process Cause : Set-up Verification Report (D=5) Preventive
Current = 200-240A Current variation operable but comfort but reduced level (S=5) 5 3. parameter not setted parameter display. 2 Maint.Check sheet (D=5) 5 50
End User : Audible noise vehicle correctly FM : Nill FM : In-process Inspection Report.(D=7)
operable (S=4)

Next.Process :Rework in Station before Process (S=5)

Vehicle Mfr. : vechicle 1.Power sorce Problem Cause : Preventive maint, Process Cause : Set-up Verification Report (D=5) Preventive
Wire feed = 22-26 MPM Wire feed variation operable but comfort but reduced level (S=5) 5 4. parameter not setted parameter display. 2 Maint.Check sheet (D=5) 5 50
End User : Audible noise vehicle correctly FM : Nill FM : In-process Inspection Report.(D=7)
operable (S=4)

Next.Process :Rework in Station before Process (S=5)

Next.Process :Can not be Used for Next Process (S=8) Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Welding Fixture
Vehicle Mfr. : loss of work area Daily Audit Check Sheet (D=5)
Dia Over size 8 Improper setting 2 5 80
Secondary function (S=6) End User : Audible 2.Fixture calibration report Operater Skill Matrix Visual Display (D=8)
noise vehicle operable (s=4) FM : Nill FM : In-process Inspection Report.(D=7)

1.Bore ID =
Ф24.00 + 0.02 -0.10

Next.Process :Can not be Used for Next Process (S=8) Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Welding Fixture
Vehicle Mfr. : loss of work area Daily Audit Check Sheet (D=5)
Dia Under Size 8 Improper setting 2 5 80
Secondary function (S=6) End User : Audible 2.Fixture calibration report Operater Skill Matrix Visual Display (D=8)
noise vehicle operable (s=4) FM : Nill FM : In-process Inspection Report.(D=7)

Next.Process :Rework in Station before Process (S=5) Cause :1. Operation Standard displyed at
Vehicle Mfr. : Reduce work are Cause : Set-up Verification Report (D=5) Tool History
2.No Bore line mark Bore line mark weld strength & Aesthetic Not Good (S=5) 5 Bore insert worn out 2.Tool history card 2 card verified ( D= 5 ) FM : In-process 5 50
End User : Audible noise vehicle Inspection Report.(D=7)
operable (S=4) FM : Nill

Next.Process : Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Operater Skill
Vehicle Mfr. : Reduce
Inadequate Operator Skill work are Matrix Visual Display (D=8) FM : In-process
3.No Bore Offset Bore Offset weld strength & Aesthetic Not Good (S=5) 5 2 5 50
3.Operator skill matrix Inspection Report.(D=7) 100 % Visual Inspection at
End User : Audible noise vehicle
FM : Nill final visual inspection stage (D=8)
operable (S=4)

Next.Process : Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Operater Skill
Vehicle Mfr. : Reduce weld
work are Matrix Visual Display (D=8) FM : In-process
4.No Damage Damage strength & Aesthetic Not Good (S=5) 5 Improper Material handling 2 5 50
3.Operator skill matrix Inspection Report.(D=7) 100 % Visual Inspection at
End User : Audible noise vehicle operable
FM : Nill final visual inspection stage (D=8)
(S=4)

STAGE 3 - Boss Next.Process : Time Delay and out Flow Rej

60 Operator Skill Matrix Min.- 1.Not Done Training Cause : Training Attendance Register Cause : Skill Matrix Report (D=5)
Boring Operator Skill Matrix Low Level Completed Vehicle Mfr. : Out Flow rejection 4 2 5 40
(L-3) Complete 2.operator Absent FM : Nill FM : Skill Matrix Visual Display (D=8)
End User : N.A

Next.Process :Rework in Station before Process (S=5)

Cause :1. Will Provided Operator
Vehicle Mfr. : vechicle Cause : Set-up Verification Report (D=5)
Bore tip frequency per 1000 Training 2.Tool Calibration Will be
Not follow the frequency operable but comfort but reduced level (S=5) 5 1. Punch Wornout 2 FM : In-process Inspection Report. 5 50
nos done before running the Process
End User : Audible noise vehicle (D=7)
FM : Nill
operable (S=4)

Next.Process :Rework in Station before Process (S=5)

Cause : Preventive maint.Air pressure to
Vehicle Mfr. : vechicle Cause : Set-up Verification Report (D=5)
1.Wrong Air pressure be ensured before starting the process
Clamping pressure = 4 bar Air pressure Variation operable but comfort but reduced level (S=5) 5 2 FM : In-process Inspection Report. 5 50
Controle FM
End User : Audible noise vehicle (D=7)
: Nill
operable (S=4)

Next.Process :Rework in Station before Process (S=5)

Vehicle Mfr. : vechicle 1.Power sorce Problem Cause : Preventive maint, Process Cause : Set-up Verification Report (D=5) Preventive
Spindle speed = 800 RPM Speed variation operable but comfort but reduced level (S=5) 5 3. parameter not setted parameter display. 2 Maint.Check sheet (D=5) 5 50
End User : Audible noise vehicle correctly FM : Nill FM : In-process Inspection Report.(D=7)
operable (S=4)

1.Rear Width =200 + 2.0

4.RH Tube C.off =97 + 2.0

Next.Process :Can not be Used for Next Process (S=8) Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Verified gauge
Vehicle Mfr. : loss of Improper Revising work area calibration Report (D=5)
Dimension Over Size 8 2 5 80
Secondary function (S=6) End User : Audible Inadequate operator Skill 2.Gauge Calibration report Operater Skill Matrix Visual Display (D=8)
noise vehicle operable (s=4) FM : Nill FM : In-process Inspection Report.(D=7)
6.RH S/Abs Brkt C.Off
=109.30 ± 1.20
Next.Process :Can not be Used for Next Process (S=8) Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Verified gauge
Vehicle Mfr. : loss of Improper Revising work area calibration Report (D=5)
Dimension Under Size 8 2 5 80
Secondary function (S=6) End User : Audible Inadequate operator Skill 2.Gauge Calibration report Operater Skill Matrix Visual Display (D=8)
noise vehicle operable (s=4) FM : Nill FM : In-process Inspection Report.(D=7)
Next.Process :Can not be Used for Next Process (S=8) Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Verified gauge
Vehicle Mfr. : loss of Improper Revising work area calibration Report (D=5)
Dimension Over Size 8 2 5 80
Secondary function (S=6) End User : Audible Inadequate operator Skill 2.Gauge Calibration report Operater Skill Matrix Visual Display (D=8)
noise vehicle operable (s=4) FM : Nill FM : In-process Inspection Report.(D=7)

7.Symmetry =÷ 0.80

70 Revising
Next.Process :Can not be Used for Next Process (S=8) Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Verified gauge
Vehicle Mfr. : loss of Improper Revising work area calibration Report (D=5)
Dimension Over Size 8 2 5 80
Secondary function (S=6) End User : Audible Inadequate operator Skill 2.Gauge Calibration report Operater Skill Matrix Visual Display (D=8)
noise vehicle operable (s=4) FM : Nill FM : In-process Inspection Report.(D=7)
13.LH & RH S/Abs Brkt
C.D 47.50 ± 1.20
Next.Process :Can not be Used for Next Process (S=8) Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Verified gauge
Vehicle Mfr. : loss of Improper Revising work area calibration Report (D=5)
Dimension Under Size 8 2 5 80
Secondary function (S=6) End User : Audible Inadequate operator Skill 2.Gauge Calibration report Operater Skill Matrix Visual Display (D=8)
noise vehicle operable (s=4) FM : Nill FM : In-process Inspection Report.(D=7)

Next.Process :Can not be Used for Next Process (S=8) Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Verified gauge
Next.Process :Can not be Used for Next Process (S=8) Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Verified gauge
Vehicle Mfr. : loss of Improper Revising work area calibration Report (D=5)
Dimension Over Size 8 2 5 80
Secondary function (S=6) End User : Audible Inadequate operator Skill 2.Gauge Calibration report Operater Skill Matrix Visual Display (D=8)
noise vehicle operable (s=4) FM : Nill FM : In-process Inspection Report.(D=7)
18.Front CC Brkt C.D 168
± 0.80
Next.Process :Can not be Used for Next Process (S=8) Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Verified gauge
Vehicle Mfr. : loss of Improper Revising work area calibration Report (D=5)
Dimension Under Size 8 2 5 80
Secondary function (S=6) End User : Audible Inadequate operator Skill 2.Gauge Calibration report Operater Skill Matrix Visual Display (D=8)
noise vehicle operable (s=4) FM : Nill FM : In-process Inspection Report.(D=7)

Next.Process :Rework in Station before Process (S=5)

Cause :1. Will Provided Operator
Vehicle Mfr. : vechicle Cause : Set-up Verification Report (D=5)
Training 2Operation standard
22.No Dent mark Dent mark operable but comfort but reduced level (S=5) 5 1.Improper material handling 2 FM : In-process Inspection Report. 5 50
display. FM
End User : Audible noise vehicle (D=7)
: Nill
operable (S=4)

Next.Process : Time Delay and out Flow Rej

Next.Process : Can not be Used for Next Process (S=8)

Cause :Verification for calipration report (D=5)
Vehicle Mfr. : Out flow 1.Out of Calibration Cause : M.S.A report
No Inspect the pin & bush. 1.Dimention Variation 8 2 FM : calipration report Visual 5 80
of not-good Part to Customer End User Equipment Used FM : Nill
Inspection (D=8)
: N.A

Next.Process :Can not be Used for Next Process (S=8) Improper clamping Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Welding Fixture
Next.Process :Can not be Used for Next Process (S=8) Improper clamping Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Welding Fixture
Vehicle Mfr. : loss of Locating pin Worn out work area Daily Audit Check Sheet (D=5)
Dimension Over size 8 2 5 80
Secondary function (S=6) End User : Audible Locating stopper worn out 2.Fixture calibration report Operater Skill Matrix Visual Display (D=8)
noise vehicle operable (s=4) Inadequate operator Skill FM : Nill FM : In-process Inspection Report.(D=7)

1.Fitting Inner Brkt C.Off

46.50 ± 1.20

2.Fitting Inner Brkt C.D =

103 ± 2.0

3.Front Clamp disc brake

hose CD = 166 ± 1.0

4.Rear Clamp disc brake

hose CD = 375 ± 1.0

5.Front Clamp disc brake

hose C.Off = 84 ± 1.0

6.Rear Clamp disc brake

hose C.Off = 118 ± 1.0

STAGE 5 - Manual
Welding of Stage 3
+ Clamp Disc brake
80
hose(2 no's) +Guide
chain mtg + Brake Next.Process :Can not be Used for Next Process (S=8) Improper clamping Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Welding Fixture
Anchor Vehicle Mfr. : loss of Locating pin Worn out work area Daily Audit Check Sheet (D=5)
Dimension Over size 8 2 5 80
Secondary function (S=6) End User : Audible Locating stopper worn out 2.Fixture calibration report Operater Skill Matrix Visual Display (D=8)
noise vehicle operable (s=4) Inadequate operator Skill FM : Nill FM : In-process Inspection Report.(D=7)

7.Brake Anchor Height =

9.3 ± 0.50

8.Brake Anchor CD =
436 ± 0.5

Next.Process : Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Operater Skill
Vehicle Mfr. : Reduce
Inadequate welder Skill work are Matrix Visual Display (D=8) FM : In-process
No In completed Welding In completed Welding weld strength & Aesthetic Not Good (S=5) 5 2 5 50
3.Operator skill matrix Inspection Report.(D=7) 100 % Visual Inspection at
End User : Audible noise vehicle
FM : Nill final visual inspection stage (D=8)
operable (S=4)

Next.Process : Rework in Station before Process (S=5)

Next.Process : Time Delay and out Flow Rej

Operator Skill Matrix Min.- 1.Not Done Training Cause : Training Attendance Register Cause : Skill Matrix Report (D=5)
Operator Skill Matrix Low Level Completed Vehicle Mfr. : Out Flow rejection 4 2 5 40
(L-3) Complete 2.operator Absent FM : Nill FM : Skill Matrix Visual Display (D=8)
End User : N.A
Next.Process :Weld beed low leads to reduce life time
Cause :1. SOP Provided Cause : Set-up Verification Report (D=5)
Vehicle Mfr. :Not 1.Improper std
Wire Diameter = 0.8 mm Wire Dia Variation 4 3.Operator Training 2 FM : In-process Inspection 5 40
applicable End User : Not 2.Untrained welder
FM : Nill Report.(D=7)
applicable

Next.Process :Rework in Station before Process (S=5)

Vehicle Mfr. : vechicle 1.Power sorce Problem Cause : Preventive maint, Process Cause : Set-up Verification Report (D=5) Preventive
Voltage = 20-25V Voltage variation operable but comfort but reduced level (S=5) 5 2. parameter not setted parameter display. 2 Maint.Check sheet (D=5) 5 50
End User : Audible noise vehicle correctly FM : Nill FM : In-process Inspection Report.(D=7)
operable (S=4)
Next.Process :Rework in Station before Process (S=5)
Vehicle Mfr. : vechicle 1.Power sorce Problem Cause : Preventive maint, Process Cause : Set-up Verification Report (D=5) Preventive
Current = 130-180A Current variation operable but comfort but reduced level (S=5) 5 3. parameter not setted parameter display. 2 Maint.Check sheet (D=5) 5 50
End User : Audible noise vehicle correctly FM : Nill FM : In-process Inspection Report.(D=7)
operable (S=4)
Next.Process :Rework in Station before Process (S=5)
Vehicle Mfr. : vechicle 1.Power sorce Problem Cause : Preventive maint, Process Cause : Set-up Verification Report (D=5) Preventive
Wire feed = 7-12 MPM Wire feed variation operable but comfort but reduced level (S=5) 5 4. parameter not setted parameter display. 2 Maint.Check sheet (D=5) 5 50
End User : Audible noise vehicle correctly FM : Nill FM : In-process Inspection Report.(D=7)
operable (S=4)
Next.Process :Rework in Station before Process (S=5)
Vehicle Mfr. : vechicle 1.Power sorce Problem Cause : Preventive maint, Process Cause : Set-up Verification Report (D=5) Preventive
Gas flow = 15-25 LPM Gas flow variation operable but comfort but reduced level (S=5) 5 5. parameter not setted parameter display. 2 Maint.Check sheet (D=5) 5 50
End User : Audible noise vehicle correctly FM : Nill FM : In-process Inspection Report.(D=7)
operable (S=4)

Next.Process :Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at
Vehicle Mfr. : Reduce Cause : Set-up Verification Report (D=5) Operater Skill
Inadequate operator Skill work are
No Spatter Spatter weld strength & Aesthetic Not Good (S=5) 5 2 Matrix Visual Display (D=8) FM : 100 % Visual 5 50
Chipping notdone effectively 3.Operator skill matrix
End User : Audible noise vehicle Inspection at final visual inspection stage (D=8)
FM : Nill
operable (S=4)

Next.Process : Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at
Vehicle Mfr. : Reduce Cause : Set-up Verification Report (D=5) Operater Skill
Inadequate Operator Skill work are
No Chisel mark Chisel mark weld strength & Aesthetic Not Good (S=5) 5 2 Matrix Visual Display (D=8) FM : 100 % Visual 5 50
3.Operator skill matrix
End User : Audible noise vehicle Inspection at final visual inspection stage (D=8)
FM : Nill
operable (S=4)

STAGE 6 -
90
Chipping
Next.Process : Time Delay and out Flow Rej
Operator Skill Matrix Min.- 1.Not Done Training Cause : Training Attendance Register Cause : Skill Matrix Report (D=5)
Operator Skill Matrix Low Level Completed Vehicle Mfr. : Out Flow rejection 4 2 5 40
(L-3) Complete 2.operator Absent FM : Nill FM : Skill Matrix Visual Display (D=8)
End User : N.A

Next.Process :Rework in Station before Process (S=5)

Next.Process :Rework in Station before Process (S=5)
Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Operater Skill
Vehicle Mfr. : Reduce
Inadequate operator Skill work are Matrix Visual Display (D=8) FM : In-process
.No weld under cut Weld Under cut weld strength & Aesthetic Not Good (S=5) 5 2 5 50
2.Operator skill matrix Inspection Report.(D=7) 100 % Visual Inspection at
End User : Audible noise vehicle
FM : Nill final visual inspection stage (D=8)
operable (S=4)

Next.Process :Rework in Station before Process (S=5) Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Operater Skill
Vehicle Mfr. : Reduce Nozzle not cleaned properly work are Matrix Visual Display (D=8) Maintanence Check sheet ( D=
No Blow Holes Blow Holes weld strength & Aesthetic Not Good (S=5) 5 Inadequate welder Skill 2.Manitanence checksheet 2 5) FM : In-process Inspection Report.(D=7) 5 50
End User : Audible noise vehicle 3.Operator skill matrix 100 % Visual Inspection at final visual inspection stage
operable (S=4) FM : Nill (D=8)
STAGE 7 -Visual Next.Process : Rework in Station before Process (S=5)
100 Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Operater Skill
Inspection Vehicle Mfr. : Reduce weld
work are Matrix Visual Display (D=8) FM : In-process
No In completed Welding In completed Welding strength & Aesthetic Not Good (S=5) 5 Inadequate welder Skill 2 5 50
3.Operator skill matrix Inspection Report.(D=7) 100 % Visual Inspection at
End User : Audible noise vehicle operable
FM : Nill final visual inspection stage (D=8)
(S=4)
Next.Process : Time Delay and out Flow Rej
Operator Skill Matrix Min.- 1.Not Done Training Cause : Training Attendance Register Cause : Skill Matrix Report (D=5)
Operator Skill Matrix Low Level Completed Vehicle Mfr. : Out Flow rejection 4 2 5 40
(L-3) Complete 2.operator Absent FM : Nill FM : Skill Matrix Visual Display (D=8)
End User : N.A

Moved To Powder coating Ref -- External Powder coating PFMEA

Next.Process :Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at
Vehicle Mfr. : Reduce Cause : Set-up Verification Report (D=5) Operater Skill
Inadequate operator Skill work are
No Thread Missing Thread Missing weld strength & Aesthetic Not Good (S=5) 5 2 Matrix Visual Display (D=8) FM : 100 % Visual 5 50
3.Operator skill matrix
End User : Audible noise vehicle Inspection at final visual inspection stage (D=8)
FM : Nill
operable (S=4)

Next.Process : Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at
Vehicle Mfr. : Reduce Cause : Set-up Verification Report (D=5) Operater Skill
Inadequate Operator Skill work are
No Thread Washout Thread Washout weld strength & Aesthetic Not Good (S=5) 5 2 Matrix Visual Display (D=8) FM : 100 % Visual 5 50
3.Operator skill matrix
End User : Audible noise vehicle Inspection at final visual inspection stage (D=8)
FM : Nill
operable (S=4)

Next.Process : Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at
Vehicle Mfr. : Reduce Cause : Set-up Verification Report (D=5) Operater Skill
Inadequate Operator Skill work are
No Thread Damage Thread Damage weld strength & Aesthetic Not Good (S=5) 5 2 Matrix Visual Display (D=8) FM : 100 % Visual 5 50
3.Operator skill matrix
End User : Audible noise vehicle Inspection at final visual inspection stage (D=8)
FM : Nill
operable (S=4)

Cause :1. Operation Standard displyed at

Next.Process : Can not be Used for Next Process (S=8) Cause : Set-up Verification Report (D=5) Operater Skill
work are
Thread size M6, M10 Thread plug gauge answer NOGO Vehicle Mfr. : N.A 8 improper tapping 2 Matrix Visual Display (D=8) FM : 100 % Visual 5 80
3.Operator skill matrix
End User : N.A Inspection at final visual inspection stage (D=8)
FM : Nill

Next.Process : Time Delay and out Flow Rej

STAGE 8 -
110 Next.Process :Rework in Station before Process (S=5)
Retapping
Vehicle Mfr. : vechicle 1.Power sorce Problem Cause : Preventive maint, Process Cause : Set-up Verification Report (D=5) Preventive
Tapping Gun RPM = 200 Speed variation operable but comfort but reduced level (S=5) 5 3. parameter not setted parameter display. 2 Maint.Check sheet (D=5) 5 50
End User : Audible noise vehicle correctly FM : Nill FM : In-process Inspection Report.(D=7)
operable (S=4)

Next.Process :Rework in Station before Process (S=5)

Cause :1. Will Provided Operator
Vehicle Mfr. : vechicle Cause : Set-up Verification Report (D=5)
Training 2.Tool Calibration Will be
Tapping Frq. = 2000 no's Not follow the frequency operable but comfort but reduced level (S=5) 5 1. Punch Wornout 2 FM : In-process Inspection Report. 5 50
done before running the Process
End User : Audible noise vehicle (D=7)
FM : Nill
operable (S=4)
Next.Process :Rework in Station before Process (S=5)
Vehicle Mfr. : vechicle 1.Air supply sorce Problem Cause :1. Will Provided Operator Cause : Set-up Verification Report (D=5)
Tightening Torque = 35-40 n Torque Variation high operable but comfort but reduced level (S=5) 5 2. parameter not Training 2 FM : In-process Inspection Report. 5 50
End User : Audible noise vehicle setted correctly FM : Nill (D=7)
operable (S=4)

Next.Process : Can not be Used for Next Process (S=8)

Cause :Verification for calipration report (D=5)
Vehicle Mfr. : Out flow 1.Out of Calibration Cause : M.S.A report
Thread Plug Gauge Thread pitch variation 8 2 FM : calipration report Visual 5 80
of not-good Part to Customer End User Equipment Used FM : Nill
Inspection (D=8)
: N.A

1.Dimension 124+0.7+0.3

Next.Process : Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at
Vehicle Mfr. : Reduce Cause : Set-up Verification Report (D=5) Operater Skill
Inadequate Operator Skill work are
No Part Missing Part Missing weld strength & Aesthetic Not Good (S=5) 5 2 Matrix Visual Display (D=8) FM : 100 % Visual 5 50
3.Operator skill matrix
End User : Audible noise vehicle Inspection at final visual inspection stage (D=8)
FM : Nill
operable (S=4)

Next.Process : Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at
Vehicle Mfr. : Reduce Cause : Set-up Verification Report (D=5) Operater Skill
Inadequate Operator Skill work are
No Loose assy Loose assy weld strength & Aesthetic Not Good (S=5) 5 2 Matrix Visual Display (D=8) FM : 100 % Visual 5 50
STAGE 9- Inserting 3.Operator skill matrix
End User : Audible noise vehicle Inspection at final visual inspection stage (D=8)
120 of Bush To Swing FM : Nill
operable (S=4)
Arm Assy (2-no's)

Next.Process : Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at
Vehicle Mfr. : Reduce Cause : Set-up Verification Report (D=5) Operater Skill
Inadequate Operator Skill work are
No Wrong part assy Wrong Part Assy weld strength & Aesthetic Not Good (S=5) 5 2 Matrix Visual Display (D=8) FM : 100 % Visual 5 50
3.Operator skill matrix
End User : Audible noise vehicle Inspection at final visual inspection stage (D=8)
FM : Nill
operable (S=4)

Next.Process : Time Delay and out Flow Rej

1.Dimension 124+0.7+0.3

1.Dimension 200+2.0

1.Dimension 103+0.5
STAGE 10-
130
Revising Next.Process :Can not be Used for Next Process (S=8) Improper clamping Cause :1. Operation Standard displyed at Cause : Set-up Verification Report (D=5) Welding Fixture
Vehicle Mfr. : loss of Locating pin Worn out work area Daily Audit Check Sheet (D=5)
Dimension Under Size 8 2 5 80
Secondary function (S=6) End User : Audible Locating stopper worn out 2.Fixture calibration report Operater Skill Matrix Visual Display (D=8)
noise vehicle operable (s=4) Inadequate operator Skill FM : Nill FM : In-process Inspection Report.(D=7)

Next.Process : Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at
Vehicle Mfr. : Reduce Cause : Set-up Verification Report (D=5) Operater Skill
Inadequate Operator Skill work are
No Dent Dent weld strength & Aesthetic Not Good (S=5) 5 2 Matrix Visual Display (D=8) FM : 100 % Visual 5 50
3.Operator skill matrix
End User : Audible noise vehicle Inspection at final visual inspection stage (D=8)
FM : Nill
operable (S=4)

Next.Process : Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at
Vehicle Mfr. : Reduce Cause : Set-up Verification Report (D=5) Operater Skill
Inadequate Operator Skill work are
NoDamage Damage weld strength & Aesthetic Not Good (S=5) 5 2 Matrix Visual Display (D=8) FM : 100 % Visual 5 50
3.Operator skill matrix
End User : Audible noise vehicle Inspection at final visual inspection stage (D=8)
FM : Nill
operable (S=4)

Next.Process : Time Delay and out Flow Rej

Cause :1.Gauge allowed the defect

Next.Process :Can not be Used for Next Process (S=8) Improper clamping
component. Cause : Gauge calibration report (D=5)
Component should easily Vehicle Mfr. : loss of Locating pin Worn out
Gauge not Answering 8 2. Operator not trained 2 Operater Skill Matrix Visual Display 5 80
answer the Final Acc Gauge Secondary function (S=6) End User : Audible Locating stopper worn out
3.Gauge inspection skiped (D=8) FM : In-process Inspection Report.(D=7)
noise vehicle operable (s=4) Inadequate operator Skill
FM : Nill

Next.Process : Time Delay and out Flow Rej

Operator Skill Matrix Min.- 1.Not Done Training Cause : Training Attendance Register Cause : Skill Matrix Report (D=5)
Operator Skill Matrix Low Level Completed Vehicle Mfr. : Out Flow rejection 4 2 5 40
(L-3) Complete 2.operator Absent FM : Nill FM : Skill Matrix Visual Display (D=8)
Operator Skill Matrix Low Level Completed Vehicle Mfr. : Out Flow rejection 4 2 5 40
(L-3) Complete 2.operator Absent FM : Nill FM : Skill Matrix Visual Display (D=8)
End User : N.A

Final Acceptance
140
Gauge Inspection
Next.Process : 1.Problem in Next Process,Part have to be Rework Cause:Verification for Internal Auditee Report (D=5)
Gauge calibration Cause : Internal Audit
Wrong Dimension Vehicle Mfr. : N.A 5 1.Wrong Ispection report 2 FM : PDI Inspection 5 50
frequence/Gauge Check list FM : Nill
End User : N.A Visual tactile(D=8)

Next.Process : Rework in Station before Process (S=5)

Cause :1. Operation Standard displyed at
Vehicle Mfr. : Reduce Cause : Set-up Verification Report (D=5) Operater Skill
Inadequate Operator Skill work are
No Powder coating UncoveraPowder Coverage weld strength & Aesthetic Not Good (S=5) 5 2 Matrix Visual Display (D=8) FM : 100 % Visual 5 50
3.Operator skill matrix
End User : Audible noise vehicle Inspection at final visual inspection stage (D=8)
FM : Nill
operable (S=4)

Final Visual
150 Next.Process : Rework in Station before Process (S=5)
Inspection Cause :1. Operation Standard displyed at
Vehicle Mfr. : Reduce Cause : Set-up Verification Report (D=5) Operater Skill
Inadequate Operator Skill work are
No Powder coating peel off Powder coating peel off weld strength & Aesthetic Not Good (S=5) 5 2 Matrix Visual Display (D=8) FM : 100 % Visual 5 50
3.Operator skill matrix
End User : Audible noise vehicle Inspection at final visual inspection stage (D=8)
FM : Nill
operable (S=4)

Next.Process : Time Delay and out Flow Rej

Final Inspection report ,

Next.Process : 1.Problem in Next Process,Part have to be Rework Cause:Verification for Internal Auditee Report (D=5)
Inspector Training Report , Cause : Internal Audit
Wrong Dimension Vehicle Mfr. : N.A 5 1.Wrong Ispection report 2 FM : PDI Visual 5 50
Operator Self Inspection , FM : Nill
End User : N.A tactile(D=8)
100% of Visual Inspection

Next.Process : Can not be Used for Next Process (S=8) Cause :Verification for Check sheet (D=5)
Iuminous level (800-1000) Cause : Internal Audite
Inspection no done properly Vehicle Mfr. : N.A 8 1.Wrong Iuminous level 2 FM : Iuminous level Visual 5 80
lux. FM : Nill
End User : N.A Inspection (D=8)
Cause :1. Operation Standard displyed at
Next.Process : Time Delay and out Flow Rej Cause : Set-up Verification Report (D=5) Operater Skill
Inadequate Operator Skill work are
Standard trolley Trolley changed Vehicle Mfr. : Out Flow rejection 4 2 Matrix Visual Display (D=8) FM : 100 % Visual 5 40
3.Operator skill matrix
End User : N.A Inspection at PDI stage (D=8)
FM : Nill

Cause :1. Operation Standard displyed at

Next.Process : Time Delay and out Flow Rej Cause : Set-up Verification Report (D=5) Operater Skill
Inadequate Operator Skill work are
Trolley Quantity(40-50) Quantity variation Vehicle Mfr. : Out Flow rejection 4 2 Matrix Visual Display (D=8) FM : 100 % Visual 5 40
3.Operator skill matrix
End User : N.A Inspection at PDI stage (D=8)
FM : Nill

160 Loading of Trolley

Next.Process : Time Delay and out Flow Rej
Operator Skill Matrix Min.- 1.Not Done Training Cause : Training Attendance Register Cause : Skill Matrix Report (D=5)
Operator Skill Matrix Low Level Completed Vehicle Mfr. : Out Flow rejection 4 2 5 40
(L-3) Complete 2.operator Absent FM : Nill FM : Skill Matrix Visual Display (D=8)
End User : N.A

Next.Process : Nill
Cause : Will Provided Operator Training
Vehicle Mfr. :Vehicle operable but reduced level of Cause : Operator Self Inspection (D=7)
Specified Dimension Dimension Variation 7 1.Inadequate inspection skill FM 2 7 98
performance (S=7) FM :PDI Inspection Report (D=7)
: Nill
End User : Audible noise vehicle operable (S=4)

Next.Process :Rework in Station before Process (S=5)

Vehicle Mfr. : vechicle Cause : Will Provided Operator Training
Cause : Operator Self Inspection (D=7)
No Dent Dent operable but comfort but reduced level (S=5) 5 1.Inadequate inspection skill FM 2 7 70
FM :PDI Visual Inspection Report (D=8)
End User : Audible noise vehicle : Nill
operable (S=4)

Next.Process : Nill
Cause : Will Provided Operator Training
Vehicle Mfr. :Vehicle operable but reduced level of Cause : Operator Self Inspection (D=7)
No Damage Damage 7 1.Inadequate inspection skill FM 2 7 98
performance (S=7) FM :PDI Visual Inspection Report (D=8)
: Nill
End User : Audible noise vehicle operable (S=4)

Next.Process : Nill Cause : SOP Display in machine Area,

Cause : Operator Self Inspection (D=7)
No Operation Missing Operation Missing Vehicle Mfr. :Customer end Rejection (S=7) 7 1.Inadequate inspection skill Will Provided Operator Training 2 7 98
FM :PDI Visual Inspection Report (D=8)
End User : Nill FM : Nill

170 Dock Audit

Final Inspection report ,

Next.Process : 1.Problem in Next Process,Part have to be Rework Cause:Verification for Internal Auditee Report (D=5)
Inspector Training Report , Cause : Internal Audit
Wrong Dimension Vehicle Mfr. : N.A 5 1.Wrong Ispection report 2 FM : PDI Inspection 5 50
Operator Self Inspection , FM : Nill
End User : N.A Visual tactile(D=8)
100% of Visual Inspection

Next.Process : Can not be Used for Next Process (S=8)

Digital Vernier Caliper, Cause :Verification for M.S.A Report (D=5)
Vehicle Mfr. : Out flow 1.Out of Calibration Cause : calipration report
Range 0-300 mm ,No : 1.Dimention Variation 8 2 FM : calipration report Visual 5 80
of not-good Part to Customer End User Equipment Used FM : Nill
HIV/DVC/006 Inspection (D=8)
: N.A

Next.Process : Can not be Used for Next Process (S=8)

Digital Height Gauge, Cause :Verification for calipration report (D=5)
Vehicle Mfr. : Out flow 1.Out of Calibration Cause : M.S.A report
Range: 0~600 mm, No: 1.Dimention Variation 8 2 FM : calipration report Visual 5 80
of not-good Part to Customer End User Equipment Used FM : Nill
HE/DHG/02 Inspection (D=8)
: N.A
Next.Process : Can not be Used for Next Process (S=8) Cause : Suitable plastic Trolley Design Cause :.Verification for Maintenance Report (D=5)
Parts storage in Trolley 1.Wrong Parts storage in
1.Material Damage Vehicle Mfr. : N.A 8 during NPD (Drawing) 2 FM : Internal 5S'Audite 5 80
condition Trolley
End User : N.A FM : Nill (D=8)

Next.Process : Time Delay and out Flow Rej

As per the customer 1.Not effective production Cause : Hyjunka plan to be trained Cause : Training matrix (D=7)
Not meeting the requirement Vehicle Mfr. : Out Flow rejection 4 2 7 56
schedule planning FM : Nill FM :Plan and target report (D=7)
End User : N.A

Next.Process : Time Delay and out Flow Rej

1.Not effective transport Cause : Will Provided Training Cause : Training matrix (D=7)
Preplanned transportation transportation delay Vehicle Mfr. : Out Flow rejection 4 2 7 56
planning FM : Nill FM :Plan and target report (D=7)
End User : N.A

Next.Process : Time Delay and out Flow Rej

Next.Process : Can not be Used for Next Process (S=8) Cause : Suitable Trolley Design during Cause :.Verification for Maintenance Report (D=5)
Trolley Condition./ Vehicle
1.Material Damage Vehicle Mfr. : N.A 8 1.Wrong Trolley Condition. NPD (Drawing) 2 FM : Internal 5S'Audite 5 80
Condition
End User : N.A FM : Nill (D=8)

Next.Process : Can not be Used for Next Process (S=8)

Cause :Verification for calipration report (D=5)
Weight Scale Calibration Vehicle Mfr. : Out flow 1.Out of Calibration Cause : M.S.A report
1.Weight Variation 8 2 FM : calipration report Visual 5 80
Status (HIV/WG/01) of not-good Part to Customer End User Equipment Used FM : Nill
Inspection (D=8)
: N.A

V.Sivakarthikeyan

Responsibility ACTION RESULTS

(by name) &
Recommended Target R

OCC

DET
Action(s) Completion Date Description of

Key Contact Person / Phone :Mr. Satish Vakundkar Date (Org ): 03.07.16 Revision No : Revision Date :
Control Plan number : CONT/TVS/N9092230/001
CFT Members : Mr.Velayutham, Mr.SS.Reddy,
Part number / Latest Change level : N9092230 Customer Engineering Approval / Date (if Reqd.) :
Mr.Sivakumar, V.Sivakarthikeyan.Mr.G.Manimaran
Part Name/Description : SWING ARM Supplier / Plant Approval / Date Customer Quality Approval / Date (if Reqd.) :

Supplier Plant: HEMA ENGG INDUSTRIES LTD-IV Supplier Code Other Approval / Date(if Reqd.) Other Approval / Date(if Reqd.) Customer information

Characteristics Methods Corrective Action

Special Customer
Part Process Name Product / (to be filled up
Machine Device Charact Specific Evaluation Error Reaction Plan (Also
Process Operation Process Sample only if the specified
jig.Tools for Mfg. No Product Process eristics requireme Measurement proofin Control Method Responsibility see note below )
number Description Specification reaction plan does not
Class nt if any Technique g Size Freq work )
Tolerance
N= 1 If any material discrepancy return back to
Every Batch 1.Verification of Supplier Material Test Certificate BOP _
C= 0 supplier

N= 5 If any material discrepancy return back to

1 Material Grade : IS 513 _ Nill Nill IS 513 Supplier Test Report Nill 6-month once 2. 3rd-Party Test Report BOP _
C= 0 supplier

N= 1 If any material discrepancy return back to

Every Batch 3.Receiving Inspection Report Visual Inspection BOP _
C= 0 supplier

N=5 If any material discrepancy return back to

Every Batch 1.Incomming Inspection report BOP _
C=0 supplier

N=5 If any material discrepancy return back to

2 Dimension _ Nill Nill As Per Drwing Supplier Test Report Nill Every Batch 2.Gauge inspection BOP _
C=0 supplier

N= 1 If any material discrepancy return back to

Every Batch 3.Receiving Inspection Report Visual Inspection BOP _
C= 0 supplier

N= 5 If any material discrepancy return back to

Every Batch 1.Receiving Inspection Report BOP _
C= 0 supplier
2 Damage _ Nill Nill Not Allowed Visual Nill
N= 1 If any material discrepancy return back to
Every Batch 2.Supplier Inspection Report Visual BOP _
C= 0 supplier

N= 5 If any material discrepancy return back to

Every Batch 1.Receiving Inspection Report BOP _
C= 0 supplier
3 Dent mark _ Nill Nill Not Allowed Visual Nill
N= 1 If any material discrepancy return back to
Every Batch 2.Supplier Inspection Report Visual BOP _
C= 0 supplier

N= 1 1.Skill Matrix Report Available Check

Every Month H.R Skill Matrix Evaluation _
C= 0

N= 1
4 _ Operator Skill Matrix Min.- (L-3) Complete Nill Nill Min L-3 Complete Visual Nill Every Month 2.Skill Matrix V.C.S Display Verified. Press Shop In charge Skill Matrix Evaluation _
C= 0

N= 1
Every Month 3. Training Attendance Register Available Check H.R Skill Matrix Evaluation _
C= 0
Raw material and child
N= 1 1.Gate entry /Material Receipt Register If any material discrepancy return back to
10 parts Receipt / Manual Every Batch Store Executive _
C= 0 ( MRR ) supplier
Inspection
MRR Register Entry. As per supplier Digital Weighing N= 1 If any material discrepancy return back to
5 _ Nill Nill Nill Every Batch 2. ERP Report Store Executive _
(Qty , Weight ) invoice Machine C= 0 supplier

N= 1 If any material discrepancy return back to

Every Batch 3.Supplier Inspection Report Store Executive _
C= 0 supplier

N= 1
6 _ Receiving inspection Report Nill Nill As Per Drawing D.V.C /D.H.G Nill Every Lot 1.Verification for Internal Auditee Report M.R If Any Failure Internal Non Conformation _
C= 0

N= 1
Every Year 1. calibration report Lab In charge If Any Failure Re tun Back Laboratory _
Ball Micro Meter C= 0
7 _ Ball Micro Meter, Range: 0~25 mm , Nill Nill As Per Drawing Range 0-25 mm Nill
LC-0.01 mm N= 1
Every 6-Month 2.Verification for M.S.A Report Lab In charge If Any Failure Re tun Back Laboratory _
C= 0

N= 1
Calibration Plan 1. calibration report Lab In charge If Any Failure Re tun Back Laboratory _
Ball Micro Meter C= 0
8.00 _ Measurement Tap, Range: 0~5 meter, Nill Nill As Per Drawing Range 0-25 mm Nill
LC-0.01 mm N= 1
MSA-Contact 2.Verification for M.S.A Report Lab In charge If Any Failure Re tun Back Laboratory _
C= 0

N= 1 1.Verification for Maintenance Report

Every Weeks Maintenance In charge If any Problem Re Auditee _
C= 0

As Per Customer N= 1
9 _ Hand Trolley Condition. Nill Nill Visual Nill Every Day 2.Trolley Visual Inspection Maintenance In charge If any Problem Re Auditee _
Requirement C= 0

N= 1
Every Month 3.Trolley Auditee 5s" Report Maintenance In charge If any Problem Re Auditee _
C= 0

N= 1 1.Verification for Check sheet

Every Day Maintenance In charge If Any Failure Replaced Light _
C= 0

N= 1
10 _ Iuminous level Nill Nill (800-1000) lux. Lux Metter Nill Every Day 2. Iuminous level Visual Inspection Maintenance In charge If Any Failure Replaced Light _
C= 0

N= 1
Every Weeks 3.Internal Auditee Report Maintenance In charge If Any Failure Replaced Light _
C= 0
N=1 1. Will Provided 3 C" and 5 S " Training Report
Every Month Store Executive Follow Min.& Max Qty for storage _
Storage as per C=0
20.01 Storing in specified Area _ Nill Nill inventory ,through Visual Nill
ERP N=1
Every Day 2. Verification for Check Sheet Store Executive Follow Min.& Max Qty for storage _
C=0

N=1
Every Day 1. Daily Monitoring Inventory Control Store Executive Follow Min.& Max Qty for storage _
C=0

N=1 2. Verification for Min. and Max Stock Qty. Report

20.02 Damage _ Nill Nill Not Allowed Visual Nill Every Day Store Executive Follow Min.& Max Qty for storage _
C=0

N=1
Every Batch 3. Visual tactile Store Executive Follow Min.& Max Qty for storage _
C=0

N=1
Every Day 1. Daily Monitoring Inventory Control Store Executive Follow Min.& Max Qty for storage _
C=0

N=1 2. Verification for Min. and Max Stock Qty. Report

20.03 Scratches _ Nill Nill Not Allowed Visual Nill Every Day Store Executive Follow Min.& Max Qty for storage _
C=0

N=1
Every Batch 3. Visual tactile Store Executive Follow Min.& Max Qty for storage _
C=0

N= 1 1.Skill Matrix Report Available Check

Every Month H.R Skill Matrix Evaluation _
C= 0

N= 1
20.04 _ Operator Skill Matrix Min.- (L-3) Complete Nill Nill Min L-3 Complete Visual Nill Every Month 2.Skill Matrix V.C.S Display Verified. Press Shop In charge Skill Matrix Evaluation _
C= 0

N= 1
Every Month 3. Training Attendance Register Available H.R Skill Matrix Evaluation _
C= 0

Raw material and child N= 1 If any material discrepancy return back to

20 Manual Every Batch 1.Verification of Supplier Material Test Certificate BOP _
parts Storage C= 0 supplier

N= 5 If any material discrepancy return back to

20.05 _ Material Grade : IS 513 Nill Nill IS 513 Supplier Test Report Nill 6-month once 2. 3rd-Party Test Report BOP _
C= 0 supplier

N= 1 If any material discrepancy return back to

Every Batch 3.Receiving Inspection Report Visual Inspection BOP _
C= 0 supplier

N= 1 If any material discrepancy return back to

Every Batch 1.ERP Report Store Executive _
C= 0 supplier

As per supplier Digital Weighing N= 1 If any material discrepancy return back to

20.06 _ Verification for Min. and Max Stock Qty. Report Nill Nill Nill Every Day 2.Inventory Report Store Executive _
invoice Machine C= 0 supplier

N= 1 If any material discrepancy return back to

Every Lot 3.Min. and Max Stock Qty Visual Checking Store Executive _
C= 0 supplier

N= 1 1.Verification for Maintenance Report

Every Weeks Maintenance In charge If any Problem Re Auditee _
C= 0

As Per Customer N= 1
20.07 _ Hand Trolley Condition. Nill Nill Visual Nill Every Day 2.Trolley Visual Inspection Maintenance In charge If any Problem Re Auditee _
Requirement C= 0

N= 1
Every Month 3.Internal Auditee 5s" Report Maintenance In charge If any Problem Re Auditee _
C= 0

N= 1 1.Verification for Check sheet

Every Day Maintenance In charge If Any Failure Replaced Light _
C= 0

N= 1
20.08 _ Iuminous level Nill Nill ( 400-600 ) lux. Lux Metter Nill Every Day 2. Iuminous level Visual Inspection Maintenance In charge If Any Failure Replaced Light _
C= 0

N= 1
Every Weeks 3.Internal Auditee Report Maintenance In charge If Any Failure Replaced Light _
C= 0

N=3 Inform to Supervisor Stop & Correct the

Every Shift Start 1.Set-up Verification Quality /Supervisor _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
1 Excess Welding _ Nill Nill Not Allowed Visual Nill 2. In-process Inspection Quality In charge _
C=0 Hours Process
N= 1
Every Month 1.Skill Matrix Report Available H.R Skill Matrix Evaluation _
C= 0
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality /Supervisor _
C=0 Process
Machine No : WMC- N=5 Every One Inform to Supervisor Stop & Correct the
2 In complete welding _ Nill Nill Not Allowed Visual Nill 2. In-process Inspection Quality In charge _
01 C=0 Hours Process
N= 1
Every Month 1.Skill Matrix Report Available H.R Skill Matrix Evaluation _
C= 0
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality /Supervisor _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
3 Burn Through _ Nill Nill Not Allowed Visual Nill 2. In-process Inspection Quality In charge _
C=0 Hours Process
N= 1
Every Month 1.Skill Matrix Report Available H.R Skill Matrix Evaluation _
C= 0
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
4 Wire Dia Nill Nill 1.2 mm DVC Nill 2. In-process Inspection Quality In charge _
C=0 Hours Process
N=1 Inform to Supervisor Stop & Correct the
Every Shift Start 3.SOP Display in Machine Area Available Check Press Shop In charge _
C=0 Process
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
5 Voltage Nill Nill 20-25V DRO Nill 2.In-process Inspection Quality In charge _
C=0 Hours Process
Machine capacity: : N=1 Inform to Supervisor Stop & Correct the
Every Shift Start 3.Tool History Card Available Check Press Shop In charge _
SR(100-350) C=0 Process
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
Tack welding of Brkt, 6 Current Nill Nill 130-180A DRO Nill 2. In-process Inspection Quality In charge _
C=0 Hours Process
30 RR Shock absorber L +
Hex Nut M10 N=1 Maint. In charge / Inform to Supervisor Stop & Correct the
Every Weeks 3.Preventive maint.Check sheet _
C=0 Supervisor Process
N= 1
Every Month 1.Skill Matrix Report Available H.R Skill Matrix Evaluation _
C= 0
N= 1
7 _ Wire feed Nill Nill 7-12 MPM DRO Nill Every Month 2.Skill Matrix V.C.S Display Verified. Press Shop In charge Skill Matrix Evaluation _
C= 0
N= 1
Every Month 3. Training Attendance Register Available Check H.R Skill Matrix Evaluation _
C= 0
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
8 _ Gas Flow Nill Nill 15-25 LPM DRO Nill 2. In-process Inspection Quality In charge _
C=0 Hours Process
N=1 Maint. In charge / Inform to Supervisor Stop & Correct the
Every Weeks 3.Preventive maint.Check sheet _
C=0 Supervisor Process
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
9 _ Operator Skill Matrix Min.- (L-3) Complete Nill Nill Min L-3 Complete Visual Nill 2. In-process Inspection Quality In charge _
C=0 Hours Process
N=1 Start of Each 3.Operator Training Report Available Check
Weld Shop In charge Recheck the Stroke . Readjust if required _
Location : TVS weld C=0 Shift
Shop
Digital Height Gauge N= 1
Every Year 1. calibration report Lab In charge If Any Failure Re tun Back Laboratory _
Range 0- C= 0
10 _ Digital Height Caliper, Range 0-600 mm ,No : HIV/DHG/ Nill Nill As Per Drawing Nill
600 mm N= 1
LC-0.01 mm Every 6-Month 2.Verification for M.S.A Report Lab In charge If Any Failure Re tun Back Laboratory _
C= 0

Start of Each
As Per Customer N= 1
11 _ Parts storage in plastic Bins Nill Nill Visual Nill Shift Start of 1. Pallet Visual Inspection Shop In charge Operator Replaced Pallet _
Req C= 0
work after break

N= 1 1.Verification for Check sheet

Every Day Maintenance In charge If Any Failure Replaced Light _
C= 0
N= 1
12 _ Iuminous level Nill Nill (400-600) lux. Lux Metter Nill Every Day 2. Iuminous level Visual Inspection Maintenance In charge If Any Failure Replaced Light _
C= 0
N= 1
Every Weeks 3.Internal Auditee Report Maintenance In charge If Any Failure Replaced Light _
C= 0
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height Gauge N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
1 Front CC Brkt C.D _ Nill Nill 168 ± 0.80 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.Fixture Calibration Report Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height Gauge N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
1 Front-Rear CC Brkt C.D _ Nill Nill 350 ± 0.80 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.Fixture Calibration Report Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height Gauge N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
3 LH/RH Slot C.D _ Nill Nill 488 ± 0.80 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.Fixture Calibration Report Available Check Weld Shop In charge _
Machine No : C=0 Shift Process
RWMC-01 N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height Gauge N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
4 LH & RH S/Abs Brkt C. _ Nill Nill 458.30 ± 1.00 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.Fixture Calibration Report Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
5 Weld Under cut _ Nill Nill Not Allowed Visual Nill
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
5 Weld Under cut _ Nill Nill Not Allowed Visual Nill

N=1 Start of Each Inform to Supervisor Stop & Correct the

4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
6 Blow Holes _ Nill Nill Not Allowed Visual Nill
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process

7 Burn Through _ Nill Nill Not Allowed Visual Nill N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process

N=1 Start of Each Inform to Supervisor Stop & Correct the

4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process

STAGE 1 -Robot N=3 Every Shift Start Inform to Supervisor Stop & Correct the
Welding Of Boss 1. Set-up Verification Quality In charge _
C=0 Process
+Swing arm LH &
RH + Brkt RR shock N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
absorber assembly C=0 Hours Process
40 8 Excess Welding - Nill Nill Not Allowed Visual Nill
LH&RH+ Brkt chain N=1 Start of Each Inform to Supervisor Stop & Correct the
case mtg front 3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
assembly +
Reinforcement swing N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
arm R & L C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
9 Incopleted Welding - Nill Nill Not Allowed Visual Nill
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process

Machine capacity: : N=3 Inform to Supervisor Stop & Correct the

Every Shift Start 1.Set-up Verification Quality In charge _
SR(100-350) C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
_ Operator Skill Matrix Min.- (L-3) Complete Nill Nill Min L-3 Complete Visual Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Start of Each 3.Operator Training Report Available Check

Weld Shop In charge Recheck the Stroke . Readjust if required _
C=0 Shift
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
10 Wire Dia Nill Nill 1.2 mm DVC Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Inform to Supervisor Stop & Correct the

Every Shift Start 3.SOP Display in Machine Area Available Check Weld Shop In charge _
C=0 Process
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
11 Voltage Nill Nill 20-25V DRO Nill C=0 Hours
2.In-process Inspection Quality In charge
Process
_

N=1 Inform to Supervisor Stop & Correct the

Every Shift Start 3.SOP Display in Machine Area Available Check Weld Shop In charge _
C=0 Process
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
12 Current Nill Nill 200-240A DRO Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Inform to Supervisor Stop & Correct the

Every Weeks 3.SOP Display in Machine Area Available Check Weld Shop In charge _
C=0 Process
N= 1
Every Month 1.Set-up Verification H.R Skill Matrix Evaluation _
C= 0
N= 1
13 _ Wire feed Nill Nill 22-26 MPM DRO Nill C= 0
Every Month 2. In-process Inspection Weld Shop In charge Skill Matrix Evaluation _

N= 1
Every Month 3.SOP Display in Machine Area Available Check H.R Skill Matrix Evaluation _
C= 0
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
14 _ Gas Flow Nill Nill 20-25 LPM Gas Flow meter Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Maint. In charge / Inform to Supervisor Stop & Correct the

Every Weeks 3.SOP Display in Machine Area Available Check _
C=0 Supervisor Process
Digital Height Gauge N= 1
Every Year 1. calibration report Lab In charge If Any Failure Re tun Back Laboratory _
C= 0
Location : TVS _ Digital Height Caliper, Range 0-600 mm ,No : HIV/ Nill Nill As Per Drawing Range 0-600 mm Nill
LC-0.01 N= 1
weld Shop Every 6-Month 2.Verification for M.S.A Report Lab In charge If Any Failure Re tun Back Laboratory _
mm C= 0
16
Start of Each
As Per Customer N= 1
_ Parts storage in Trolley Condition Nill Nill Visual Nill C= 0
Shift Start of 1. Pallet Visual Inspection Weld Shop In charge Replaced Pallet _
Req work after break

N= 1 1.Verification for Check sheet

Every Day Maintenance In charge If Any Failure Replaced Light _
C= 0

17 _ Iuminous level Nill Nill (400-600) lux. Lux Metter Nill

N= 1
17 _ Iuminous level Nill Nill (400-600) lux. Lux Metter Nill C= 0
Every Day 2. Iuminous level Visual Inspection Maintenance In charge If Any Failure Replaced Light _

5 Burn Through _ Nill Nill Not Allowed Visual Nill N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process

N=1 Start of Each Inform to Supervisor Stop & Correct the

4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process

N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
6 Excess Welding - Nill Nill Not Allowed Visual Nill
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process
STAGE 2 - Robot
Welding Of LH & RH N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
Tube assembly + C=0 Process
50
Gusset bridge L + N=5 Every One Inform to Supervisor Stop & Correct the
brige gusset +Bridge 2. In-process Inspection Quality In charge _
C=0 Hours Process
swing arm 7 In completed Welding - Nill Nill Not Allowed Visual Nill
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
Machine capacity: : 4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process
SR(100-350)
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
13 _ Operator Skill Matrix Min.- (L-3) Complete Nill Nill Min L-3 Complete Visual Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Start of Each 3.Operator Training Report Available Check

Weld Shop In charge Recheck the Stroke . Readjust if required _
C=0 Shift
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
8 Wire Dia Nill Nill 1.2 mm DVC Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Inform to Supervisor Stop & Correct the

Every Shift Start 3.SOP Display in Machine Area Available Check Weld Shop In charge _
C=0 Process
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
9 Voltage Nill Nill 20-25V DRO Nill C=0 Hours
2.In-process Inspection Quality In charge
Process
_
9 Voltage Nill Nill 20-25V DRO Nill

N=1 Inform to Supervisor Stop & Correct the

Every Shift Start 3.SOP Display in Machine Area Available Check Weld Shop In charge _
C=0 Process
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
10 Current Nill Nill 200-240A DRO Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Inform to Supervisor Stop & Correct the

Every Weeks 3.SOP Display in Machine Area Available Check Weld Shop In charge _
C=0 Process
N= 1
Every Month 1.Set-up Verification H.R Skill Matrix Evaluation _
C= 0
N= 1
11 _ Wire feed Nill Nill 22-26 MPM DRO Nill C= 0
Every Month 2. In-process Inspection Weld Shop In charge Skill Matrix Evaluation _

N= 1
Every Month 3.SOP Display in Machine Area Available Check H.R Skill Matrix Evaluation _
C= 0
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
12 _ Gas Flow Nill Nill 20-25 LPM Gas Flow meter Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Maint. In charge / Inform to Supervisor Stop & Correct the

Every Weeks 3.SOP Display in Machine Area Available Check _
C=0 Supervisor Process
Digital Height Gauge N= 1
Every Year 1. calibration report Lab In charge If Any Failure Re tun Back Laboratory _
C= 0
Location : TVS _ Digital Height Caliper, Range 0-600 mm ,No : HIV/ Nill Nill As Per Drawing Range 0-600 mm Nill
LC-0.01 N= 1
weld Shop Every 6-Month 2.Verification for M.S.A Report Lab In charge If Any Failure Re tun Back Laboratory _
mm C= 0
14
Start of Each
As Per Customer N= 1
_ Parts storage in Trolley Condition Nill Nill Visual Nill C= 0
Shift Start of 1. Pallet Visual Inspection Weld Shop In charge Replaced Pallet _
Req work after break

N= 1 1.Verification for Check sheet

Every Day Maintenance In charge If Any Failure Replaced Light _
C= 0
N= 1
15 _ Iuminous level Nill Nill (400-600) lux. Lux Metter Nill C= 0
Every Day 2. Iuminous level Visual Inspection Maintenance In charge If Any Failure Replaced Light _

N=1 Inform to Supervisor Stop & Correct the

Every Shift Start 3.SOP Display in Machine Area Available Check Shop In charge _
C=0 Process
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
Manufacturing C=0 Process
Location : TVS N=5 Every One Inform to Supervisor Stop & Correct the
Line - Welding 6 Clamping pressure Nill Nill 4 bar Pressure gauge Nill C=0 Hours
2.In-process Inspection Quality In charge
Process
_
Shop
Manufacturing
Location : TVS
Line - Welding 6 Clamping pressure Nill Nill 4 bar Pressure gauge Nill
Shop
N=1 Inform to Supervisor Stop & Correct the
Every Shift Start 3.SOP Display in Machine Area Available Check Shop In charge _
C=0 Process
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
7 Spindle Speed Nill Nill 800 Tacho meter Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Inform to Supervisor Stop & Correct the

Every Weeks 3.SOP Display in Machine Area Available Check Shop In charge _
C=0 Process
Digital Height Gauge N= 1
Every Year 1. calibration report Lab In charge If Any Failure Re tun Back Laboratory _
C= 0
_ Digital Height Caliper, Range 0-600 mm ,No : HIV/ Nill Nill As Per Drawing Range 0-600 mm Nill
LC-0.01 N= 1
Every 6-Month 2.Verification for M.S.A Report Lab In charge If Any Failure Re tun Back Laboratory _
mm C= 0
9
Start of Each
As Per Customer N= 1
_ Parts storage in Trolley Condition Nill Nill Visual Nill C= 0
Shift Start of 1. Pallet Visual Inspection Shop In charge Replaced Pallet _
Req work after break

N= 1 1.Verification for Check sheet

Every Day Maintenance In charge If Any Failure Replaced Light _
C= 0
N= 1
10 _ Iuminous level Nill Nill (400-600) lux. Lux Metter Nill C= 0
Every Day 2. Iuminous level Visual Inspection Maintenance In charge If Any Failure Replaced Light _

N= 1
Every Weeks 3.Internal Auditee Report Maintenance In charge If Any Failure Replaced Light _
C= 0
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height Gauge N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
1 Rear Width _ Nill Nill 200 + 2.0 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.Fixture Calibration Report Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height Gauge N=5 Every One Inform to Supervisor Stop & Correct the
Fixture No : 2. In-process Inspection Quality In charge _
C=0 Hours Process
SA/U180/A- 2 Front width _ Nill Nill 127 + 0.70 + 0.30 Range 0-600 mm Nill
FIX/R-04 LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height Gauge N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
3 LH Tube C.off _ Nill Nill 103 + 0.50 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height Gauge N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
4 RH Tube C.off _ Nill Nill 97 + 2.0 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height Gauge N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
5 LH S/Abs Brkt C.Off _ Nill Nill 114.30 ± 1.20 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height Gauge N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
6 RH S/Abs Brkt C.Off _ Nill Nill 109.30 ± 1.20 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height Gauge N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
7 Symmetry _ Nill Nill ÷ 0.80 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
Fixture Name: 4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
Revising
Fixture N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height N=5 Every One Inform to Supervisor Stop & Correct the
Gauge 2. In-process Inspection Quality In charge _
C=0 Hours Process
8 Front CC Brkt C.Off _ Nill Nill 100 ± 1.00 Range 0-600 mm Nill
LC-0.01
Fixture Name:
Revising
Fixture

Digital Height
Gauge
8 Front CC Brkt C.Off _ Nill Nill 100 ± 1.00 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height N=5 Every One Inform to Supervisor Stop & Correct the
Gauge 2. In-process Inspection Quality In charge _
Front-Rear CC Brkt C=0 Hours Process
9 _ Nill Nill 10.30 ± 0.50 Range 0-600 mm Nill
C.Off N=1 Start of Each Inform to Supervisor Stop & Correct the
LC-0.01 3.Preventive maintanence Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height N=5 Every One Inform to Supervisor Stop & Correct the
Gauge 2. In-process Inspection Quality In charge _
C=0 Hours Process
10 Bridge Tube C.D _ Nill Nill 125 ± 2.0 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height N=5 Every One Inform to Supervisor Stop & Correct the
Gauge 2. In-process Inspection Quality In charge _
C=0 Hours Process
11 Front CC Brkt C.D _ Nill Nill 34.20 ± 0.50 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height N=5 Every One Inform to Supervisor Stop & Correct the
Gauge 2. In-process Inspection Quality In charge _
C=0 Hours Process
12 Rear CC Brkt C.D _ Nill Nill 40.20 ± 0.50 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height N=5 Every One Inform to Supervisor Stop & Correct the
Gauge 2. In-process Inspection Quality In charge _
LH & RH S/Abs Brkt C=0 Hours Process
13 _ Nill Nill 47.50 ± 1.20 Range 0-600 mm Nill
C.D N=1 Start of Each Inform to Supervisor Stop & Correct the
LC-0.01 3.Preventive maintanence Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process

70 STAGE 4- Revising N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
S.Abs Brkt C=0 Hours Process
14 _ Nill Nill ┴ 1.00 mm Fero Nill
Perpendicularity N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
15 S.Abs Brkt Parelism _ Nill Nill Ф 0.5 Fero Nill
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
Rear CC Brkt C=0 Hours Process
16 _ Nill Nill ┴ 1.00 mm Fero Nill
Perpendicularity N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
Front CC Brkt C=0 Hours Process
17 _ Nill Nill ┴ 1.00 mm Fero Nill
Perpendicularity N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height N=5 Every One Inform to Supervisor Stop & Correct the
Gauge 2. In-process Inspection Quality In charge _
C=0 Hours Process
18 Front CC Brkt C.D _ Nill Nill 168 ± 0.80 Range 0-600 mm Nill
LC-0.01
mm
Digital Height
Gauge
18 Front CC Brkt C.D _ Nill Nill 168 ± 0.80 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height N=5 Every One Inform to Supervisor Stop & Correct the
Gauge 2. In-process Inspection Quality In charge _
Front-Rear CC Brkt C=0 Hours Process
19 _ Nill Nill 350 ± 0.80 Range 0-600 mm Nill
C.D N=1 Start of Each Inform to Supervisor Stop & Correct the
LC-0.01 3.Preventive maintanence Shop In charge _
Manufacturing mm C=0 Shift Process
Location : TVS N=1 Start of Each Inform to Supervisor Stop & Correct the
Line - Welding 4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
Shop
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height N=5 Every One Inform to Supervisor Stop & Correct the
Gauge 2. In-process Inspection Quality In charge _
C=0 Hours Process
20 LH/RH Slot C.D _ Nill Nill 488 ± 0.80 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height N=5 Every One Inform to Supervisor Stop & Correct the
Gauge 2. In-process Inspection Quality In charge _
LH & RH S/Abs Brkt C=0 Hours Process
21 _ Nill Nill 458.30 ± 1.00 Range 0-600 mm Nill
C.D N=1 Start of Each Inform to Supervisor Stop & Correct the
LC-0.01 3.Preventive maintanence Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
22 Dent mark _ Nill Nill Not Allowed Visual Nill
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Preventive maintanence Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Shop In charge _
C=0 Shift Process
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
_ Operator Skill Matrix Min.- (L-3) Complete Nill Nill Min L-3 Complete Visual Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Start of Each 3.Operator Training Report Available Check

Shop In charge Recheck the Stroke . Readjust if required _
C=0 Shift
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
5 Boring tip chage frequency Nill Nill 1000 nos once Tool history card Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Inform to Supervisor Stop & Correct the

Every Shift Start 3.SOP Display in Machine Area Available Check Shop In charge _
C=0 Process
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
7 Spindle Speed Nill Nill 800 Tacho meter Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Inform to Supervisor Stop & Correct the

Every Weeks 3.SOP Display in Machine Area Available Check Shop In charge _
C=0 Process
Digital Height Gauge N= 1
Every Year 1. calibration report Lab In charge If Any Failure Re tun Back Laboratory _
C= 0
_ Digital Height Caliper, Range 0-600 mm ,No : HIV/ Nill Nill As Per Drawing Range 0-600 mm Nill
LC-0.01 N= 1
Every 6-Month 2.Verification for M.S.A Report Lab In charge If Any Failure Re tun Back Laboratory _
mm C= 0
9
Start of Each
As Per Customer N= 1
_ Parts storage in Trolley condition Nill Nill Visual Nill C= 0
Shift Start of 1. Pallet Visual Inspection Shop In charge Replaced Pallet _
Req work after break

N= 1 1.Verification for Check sheet

Fixture No : N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
Front Clamp disc brake C=0 Hours Process
5 _ Nill Nill 84 ± 1.0 Visual Nill
SA/U180/FIX/WS/0 hose C.Off N=1 Start of Each Inform to Supervisor Stop & Correct the
5 3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
Front Clamp disc brake C=0 Hours Process
6 _ Nill Nill 118 ± 1.0 Visual Nill
hose C.Off N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
7 Brake Anchor Height _ Nill Nill 9.3 ± 0.50 Visual Nill
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
8 Brake Anchor CD _ Nill Nill 436 ± 0.5 Visual Nill
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
9 Blow Holes _ Nill Nill Not Allowed Visual Nill
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
STAGE 5 - Manual C=0 Shift Process
Welding of Stage 3 + N=3 Every Shift Start Inform to Supervisor Stop & Correct the
Clamp Disc brake 1. Set-up Verification Quality In charge _
80 C=0 Process
hose(2 no's) +Guide
chain mtg + Brake N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
Anchor C=0 Hours Process

10 Excess Welding - Nill Nill Not Allowed Visual Nill N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process

N=1 Start of Each Inform to Supervisor Stop & Correct the

4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process

N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
6 In completed Welding - Nill Nill Not Allowed Visual Nill
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
7 burn through - Nill Nill Not Allowed Visual Nill
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process
Machine Name :
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
Manual mig C=0 Process
welding N=5 Every One Inform to Supervisor Stop & Correct the
13 _ Operator Skill Matrix Min.- (L-3) Complete Nill Nill Min L-3 Complete Visual Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Start of Each 3.Operator Training Report Available Check

Weld Shop In charge Recheck the Stroke . Readjust if required _
C=0 Shift
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
8 Wire Dia Nill Nill 0.8 mm DVC Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Inform to Supervisor Stop & Correct the

Every Shift Start 3.SOP Display in Machine Area Available Check Weld Shop In charge _
C=0 Process
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
9 Voltage Nill Nill 20-25V DRO Nill C=0 Hours
2.In-process Inspection Quality In charge
Process
_

N=1 Inform to Supervisor Stop & Correct the

Every Shift Start 3.SOP Display in Machine Area Available Check Weld Shop In charge _
C=0 Process
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
10 Current Nill Nill 130-180A DRO Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Inform to Supervisor Stop & Correct the

Every Weeks 3.SOP Display in Machine Area Available Check Weld Shop In charge _
C=0 Process
N= 1
Every Month 1.Set-up Verification H.R Skill Matrix Evaluation _
C= 0
N= 1
11 _ Wire feed Nill Nill 7-12 MPM DRO Nill C= 0
Every Month 2. In-process Inspection Weld Shop In charge Skill Matrix Evaluation _

N= 1
Every Month 3.SOP Display in Machine Area Available Check H.R Skill Matrix Evaluation _
C= 0
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
12 _ Gas Flow Nill Nill 12-25 LPM Gas Flow meter Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Maint. In charge / Inform to Supervisor Stop & Correct the

Every Weeks 3.SOP Display in Machine Area Available Check _
C=0 Supervisor Process
Digital Height Gauge N= 1
Every Year 1. calibration report Lab In charge If Any Failure Re tun Back Laboratory _
C= 0
Location : TVS _ Digital Height Caliper, Range 0-600 mm ,No : HIV/ Nill Nill As Per Drawing Range 0-600 mm Nill
LC-0.01 N= 1
weld Shop Every 6-Month 2.Verification for M.S.A Report Lab In charge If Any Failure Re tun Back Laboratory _
mm C= 0
14
Start of Each
As Per Customer N= 1
_ Parts storage in Trolley Condition Nill Nill Visual Nill C= 0
Shift Start of 1. Pallet Visual Inspection Weld Shop In charge Replaced Pallet _
Req work after break

N= 1 1.Verification for Check sheet

N=1 Start of Each 3.Operator Training Report Available Check

Weld Shop In charge Recheck the Stroke . Readjust if required _
C=0 Shift
Start of Each
As Per Customer N= 1
4 _ Parts storage in Trolley Condition Nill Nill Visual Nill C= 0
Shift Start of 1. Pallet Visual Inspection Weld Shop In charge Replaced Pallet _
Req work after break

N= 1 1.Verification for Check sheet

Every Day Maintenance In charge If Any Failure Replaced Light _
C= 0
N= 1
5 _ Iuminous level Nill Nill (400-600) lux. Lux Metter Nill C= 0
Every Day 2. Iuminous level Visual Inspection Maintenance In charge If Any Failure Replaced Light _

N=1 Start of Each 3.Operator Training Report Available Check

Weld Shop In charge Recheck the Stroke . Readjust if required _
C=0 Shift

Start of Each
As Per Customer N= 1
6 _ Parts storage in Trolley Condition Nill Nill Visual Nill C= 0
Shift Start of 1. Pallet Visual Inspection Weld Shop In charge Replaced Pallet _
Req work after break

N= 1 1.Verification for Check sheet

Every Day Maintenance In charge If Any Failure Replaced Light _
C= 0
N= 1
7 _ Iuminous level Nill Nill (400-600) lux. Lux Metter Nill C= 0
Every Day 2. Iuminous level Visual Inspection Maintenance In charge If Any Failure Replaced Light _

N= 1
Every Weeks 3.Internal Auditee Report Maintenance In charge If Any Failure Replaced Light _
C= 0

Move to Poweder Coading ---- External Powder coating Controll Plan

N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
1 Threa missing _ Nill Nill Not Allowed Visual Nill
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
2 Thread washout _ Nill Nill Not Allowed Visual Nill
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
3 Thread damage _ Nill Nill Not Allowed Visual Nill
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
3 Thread damage _ Nill Nill Not Allowed Visual Nill

N=1 Start of Each Inform to Supervisor Stop & Correct the

4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
4 Thread M6,M10 _ Nill Nill M6,M10 Thread Plug gauge Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Start of Each Inform to Supervisor Stop & Correct the

3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
5 _ Operator Skill Matrix Min.- (L-3) Complete Nill Nill Min L-3 Complete Visual Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Start of Each 3.Operator Training Report Available Check

Weld Shop In charge Recheck the Stroke . Readjust if required _
C=0 Shift
N=3 Inform to Supervisor Stop & Correct the
Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
110 STAGE 8 -Retapping MANUAL
N=5 Every One Inform to Supervisor Stop & Correct the
6 _ Tapping Gun RPM Nill Nill 200 Tacho meter Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Inform to Supervisor Stop & Correct the

Every Weeks 3.SOP Display in Machine Area Available Check Shop In charge _
C=0 Process
N=3
Every Shift Start 1.Set-up Verification Quality In charge
C=0
N=5 Every One
2.In-process Inspection Quality In charge
C=0 Hours
7 _ Tapping Frq Nill Nill 2000 no's Visual Nill

N=1 Maint. In charge /

Every Weeks 3.Preventive maint.Check sheet Replaced Pallet _
C=0 Supervisor

N=3
Every Shift Start 1.Set-up Verification Quality In charge
C=0

N=5 Every One

8 _ Tightening Torque = 35-40 n/m Nill Nill 35-40 n/m Torque Meter Nill
C=0 Hours
2.In-process Inspection Quality In charge

N=1
Every Weeks 3.Operator Training Report Available Check H.R Replaced Pallet _
C=0

N= 1
Every Year 1. calibration report Lab In charge If Any Failure Re tun Back Laboratory
C= 0

_ Thread Plug gauge Nill Nill As Per Drawing Thread Plug gauge Nill

N= 1
Every 6-Month 2.Verification for M.S.A Report Lab In charge If Any Failure Re tun Back Laboratory
C= 0

Start of Each
As Per Customer N= 1 Press Shop In charge
_ Parts storage in Trolley Condition Nill Nill Visual Nill
C= 0
Shift Start of 1. plastic Bins Visual Inspection
Operator
Replaced plastic Bins
Req work after break

N= 1 1.Verification for Check sheet

N= 1
Every Weeks 3.Internal Auditee Report Maintenance In charge If Any Failure Replaced Light _
C= 0

Move to Poweder Coading ---- External Powder coating Controll Plan

N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height Gauge N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
1 Dimension _ Nill Nill 124+0.7+0.3 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.Fixture Calibration Report Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height Gauge N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
2 Dimension Nill Nill 200+2.0 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.Fixture Calibration Report Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
Digital Height Gauge N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
3 Dimension _ Nill Nill 103+0.5 Range 0-600 mm Nill
LC-0.01 N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
mm C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process
9 Dent _ Nill Nill Not Allowed Visual Nill
130 STAGE 10- Revising N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2. In-process Inspection Quality In charge _
C=0 Hours Process

10 Damage - Nill Nill Not Allowed Visual Nill N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Operator Training Report Available Check Weld Shop In charge _
C=0 Shift Process

Manual N=1 Start of Each Inform to Supervisor Stop & Correct the
4.SOP Display in machine Area Available Check Weld Shop In charge _
C=0 Shift Process

N=3 Inform to Supervisor Stop & Correct the

Every Shift Start 1.Set-up Verification Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
13 _ Operator Skill Matrix Min.- (L-3) Complete Nill Nill Min L-3 Complete Visual Nill C=0 Hours
2. In-process Inspection Quality In charge
Process
_

N=1 Start of Each 3.Operator Training Report Available Check

Weld Shop In charge Recheck the Stroke . Readjust if required _
C=0 Shift

Start of Each
As Per Customer N= 1
_ Parts storage in Trolley Condition Nill Nill Visual Nill C= 0
Shift Start of 1. Pallet Visual Inspection Weld Shop In charge Replaced Pallet _
Req work after break

N= 1 1.Verification for Check sheet

N= 1
Every Weeks 3.Internal Auditee Report Maintenance In charge If Any Failure Replaced Light _
C= 0
N=3 Inform to Supervisor Stop & Correct the
Every Setting 1.Operator Self Inspection Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
90.14 Dent _ Nill Nill Not Allowed Visual Nill 2.100% Visual Inspection Report Quality In charge _
C=0 Hours Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Inspector Training Report Available Check Press Shop In charge _
C=0 Shift Process
N=3 Inform to Supervisor Stop & Correct the
Every Setting 1.Operator Self Inspection Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
90.15 Damage _ Nill Nill Not Allowed Visual Nill 2.100% Visual Inspection Report Quality In charge _
C=0 Hours Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Inspector Training Report Available Check Press Shop In charge _
C=0 Shift Process
N=3 Inform to Supervisor Stop & Correct the
Every Setting 1.Operator Self Inspection Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
90.15 Part Missing _ Nill Nill Not Allowed Visual Nill 2.100% Visual Inspection Report Quality In charge _
C=0 Hours Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Inspector Training Report Available Check Press Shop In charge _
C=0 Shift Process
N=3 Inform to Supervisor Stop & Correct the
Every Setting 1.Operator Self Inspection Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
90.15 Powder coating uncoverage _ Nill Nill Not Allowed Visual Nill 2.100% Visual Inspection Report Quality In charge _
C=0 Hours Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Inspector Training Report Available Check Press Shop In charge _
C=0 Shift Process
N=3 Inform to Supervisor Stop & Correct the
150 Final Visual inspection Every Setting 1.Operator Self Inspection Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
90.15 Powder coating peel off _ Nill Nill Not Allowed Visual Nill 2.100% Visual Inspection Report Quality In charge _
C=0 Hours Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Inspector Training Report Available Check Press Shop In charge _
C=0 Shift Process
N= 1
Every Month 1.Skill Matrix Report Available H.R Skill Matrix Evaluation _
C= 0
N= 1
90.16 _ Operator Skill Matrix Min.- (L-3) Complete Nill Nill Min L-3 Complete Visual Nill Every Month 2.Skill Matrix V.C.S Display Verified. Press Shop In charge Skill Matrix Evaluation _
C= 0
N= 1
Every Month 3. Training Attendance Register Available Check H.R Skill Matrix Evaluation _
C= 0

Final Inspection report , Inspector Training Report , N=1

90.17 _ Nill Nill As Per Drawing D.V.C /D.H.G Nill Every Lot 1.Verification for Internal Auditee Report M.R If Any Failure Internal Non Conformation
Operator Self Inspection , 100% of Visual Inspection C=0

Digital Vernier Caliper, N= 1

Every Year 1. calibration report Lab In charge If Any Failure Re tun Back Laboratory _
Digital Vernier Caliper, Range 0-300 mm ,No : Range 0-300 C= 0
90.18 _ Nill Nill As Per Drawing Nill
HIV/DVC/006 mm LC-0.01 N= 1
mm Every 6-Month 2.Verification for M.S.A Report Lab In charge If Any Failure Re tun Back Laboratory _
C= 0

Start of Each
As Per Customer N= 1 Press Shop In charge
90.19 _ Parts storage in trolley condition Nill Nill Visual Nill Shift Start of 1. plastic Bins Visual Inspection Replaced plastic Bins _
Req C= 0 Operator
work after break

N= 1 1.Verification for Check sheet

Every Day Maintenance In charge If Any Failure Replaced Light _
C= 0
N= 1
90.2 _ Iuminous level (800-1000) lux. Nill Nill (800-1000) lux. Lux Metter Nill Every Day 2. Iuminous level Visual Inspection Maintenance In charge If Any Failure Replaced Light _
C= 0
90.2 _ Iuminous level (800-1000) lux. Nill Nill (800-1000) lux. Lux Metter Nill

N= 1
Every Weeks 3.Internal Auditee Report Maintenance In charge If Any Failure Replaced Light _
C= 0
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=1 Start of Each 3.Operator Training Report Available Check
1 Standard Trolley - Nill Nill std Visual Nill C=0 Shift
Weld Shop In charge Recheck the Stroke . Readjust if required _

N=1 Start of Each Inform to Supervisor Stop & Correct the

3.Trolley Check list Weld Shop In charge _
C=0 Shift Process
N=3 Every Shift Start Inform to Supervisor Stop & Correct the
1. Set-up Verification Quality In charge _
C=0 Process
N=1 Start of Each 3.Operator Training Report Available Check
2 Trolley Quantity (40-50) - Nill Nill 40-50 Visual Nill C=0 Shift
Weld Shop In charge Recheck the Stroke . Readjust if required _

N=1 Start of Each Inform to Supervisor Stop & Correct the

3.Trolley Check list Weld Shop In charge _
C=0 Shift Process
N= 1
Every Month 1.Skill Matrix Report Available H.R Skill Matrix Evaluation _
C= 0
160 Loading of Trolley N= 1
3 _ Operator Skill Matrix Min.- (L-3) Complete Nill Nill Min L-3 Complete Visual Nill
C= 0
Every Month 2.Skill Matrix V.C.S Display Verified. Press Shop In charge Skill Matrix Evaluation _

N= 1
Every Month 3. Training Attendance Register Available Check H.R Skill Matrix Evaluation _
C= 0

N=1
4 _ Operator Self Inspection , 100% of Visual Inspection Nill Nill As Per Drawing D.V.C /D.H.G Nill
C=0
Every Lot 1.Verification for Internal Auditee Report M.R If Any Failure Internal Non Conformation

Start of Each
As Per Customer N= 1 Press Shop In charge
5 _ Parts storage in trolley condition Nill Nill
Req
Visual Nill
C= 0
Shift Start of 1. plastic Bins Visual Inspection
Operator
Replaced plastic Bins _
work after break
N= 1 1.Verification for Check sheet
Every Day Maintenance In charge If Any Failure Replaced Light _
C= 0

6 _ Iuminous level (800-1000) lux. Nill Nill (800-1000) lux. Lux Metter Nill N= 1
Every Day 2. Iuminous level Visual Inspection Maintenance In charge If Any Failure Replaced Light _
C= 0
N= 1
Every Weeks 3.Internal Auditee Report Maintenance In charge If Any Failure Replaced Light _
C= 0
N=3 Inform to Supervisor Stop & Correct the
Every Setting 1.Operator Self Inspection Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
1.00 Specified Dimension _ Nill Nill As per Drawing DHG Nill 2.100% Visual Inspection Report Quality In charge _
C=0 Hours Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Inspector Training Report Available Check Press Shop In charge _
C=0 Shift Process
N=3 Inform to Supervisor Stop & Correct the
Every Setting 1.Operator Self Inspection Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
2.00 Dent _ Nill Nill Not Allowed Visual Nill 2.100% Visual Inspection Report Quality In charge _
C=0 Hours Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Inspector Training Report Available Check Press Shop In charge _
C=0 Shift Process
N=3 Inform to Supervisor Stop & Correct the
Every Setting 1.Operator Self Inspection Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
3.00 Damage _ Nill Nill Not Allowed Visual Nill 2.100% Visual Inspection Report Quality In charge _
C=0 Hours Process
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Inspector Training Report Available Check Press Shop In charge _
C=0 Shift Process
N=3 Inform to Supervisor Stop & Correct the
Every Setting 1.Operator Self Inspection Quality In charge _
C=0 Process
N=5 Every One Inform to Supervisor Stop & Correct the
4.00 OperationMissing _ Nill Nill Not Allowed Visual Nill 2.100% Visual Inspection Report Quality In charge _
C=0 Hours Process
170 Dock audit
N=1 Start of Each Inform to Supervisor Stop & Correct the
3.Inspector Training Report Available Check Press Shop In charge _
C=0 Shift Process
N= 1
Every Month 1.Skill Matrix Report Available H.R Skill Matrix Evaluation _
C= 0
N= 1
5 _ Operator Skill Matrix Min.- (L-3) Complete Nill Nill Min L-3 Complete Visual Nill Every Month 2.Skill Matrix V.C.S Display Verified. Press Shop In charge Skill Matrix Evaluation _
C= 0
N= 1
Every Month 3. Training Attendance Register Available Check H.R Skill Matrix Evaluation _
C= 0

Final Inspection report , Inspector Training Report , N=1

6 _ Nill Nill As Per Drawing D.V.C /D.H.G Nill Every Lot 1.Verification for Internal Auditee Report M.R If Any Failure Internal Non Conformation
Operator Self Inspection , 100% of Visual Inspection C=0

Digital Vernier Caliper, N= 1

Every Year 1. calibration report Lab In charge If Any Failure Re tun Back Laboratory _
Digital Vernier Caliper, Range 0-300 mm ,No : Range 0-300 C= 0
7 _ Nill Nill As Per Drawing Nill
HIV/DVC/006 mm LC-0.01 N= 1
mm Every 6-Month 2.Verification for M.S.A Report Lab In charge If Any Failure Re tun Back Laboratory _
C= 0

Suitable plastic Start of Each

N= 1 Press Shop In charge
8 _ Parts storage in trolley condition Nill Nill Trolley Design Visual Nill Shift Start of 1. TrolleyVisual Inspection Replaced Trolley _
C= 0 Operator
during NPD work after break

N= 1 1.Verification for Check sheet

Every Day Maintenance In charge If Any Failure Replaced Light _
C= 0
N= 1
9 _ Iuminous level (800-1000) lux. Nill Nill (800-1000) lux. Lux Metter Nill Every Day 2. Iuminous level Visual Inspection Maintenance In charge If Any Failure Replaced Light _
C= 0
N= 1
Every Weeks 3.Internal Auditee Report Maintenance In charge If Any Failure Replaced Light _
C= 0

As per Customer As Per Customer N =1

1 _ Nill Nill Visual Nill Every lot Packing Std. Store In charge _ _
Schedule Standard C=0

Preplanned As Per Customer N =1

2 Nill Nill Visual Nill Every lot Packing Std. Store In charge _ _
Transportation Standard C=0
N= 1 1.Skill Matrix Report Available Check
Every Month H.R Skill Matrix Evaluation _
C= 0

N= 1
3 _ Operator Skill Matrix Min.- (L-3) Complete Nill Nill Min L-3 Complete Visual Nill
C= 0
Every Month 2.Skill Matrix V.C.S Display Verified. Press Shop In charge Skill Matrix Evaluation _

N= 1
Every Month 3. Training Attendance Register Available Check H.R Skill Matrix Evaluation _
C= 0
180 Move to Dispatch Area Manual
As Per Customer N= 1
4 _ Trolley Condition / Vehicle Condition Nill Nill Visual Nill Every lot As Per hema Invoice Qty Dispatch - In charge _ _
Schedule C= 0

Display In Actual N= 1 Check In Calibration Report Replace the

5 _ Weight Scale Nill Nill
Weight
Weight Scale Nill
C= 0
one year Calibration Report Store In charge
m/c
_

N= 1 1.Verification for Check sheet

Every Day Maintenance In charge If Any Failure Replaced Light _
C= 0

N= 1
6 _ Iuminous level (800-1000) lux. Nill Nill (800-1000) lux. Lux Metter Nill
C= 0
Every Day 2. Iuminous level Visual Inspection Maintenance In charge If Any Failure Replaced Light _

N= 1
Every Weeks 3.Internal Auditee Report Maintenance In charge If Any Failure Replaced Light _
C= 0

6
N = No. of samples to be checked,
C = No. of defectives permitted in the samples checked.
5 1.Set up Approval - * Start of shift,
2.Set up Approval - # Start up After Lunch Break )
4

3
Note: Reaction Plan: Whenever the Process Parameters or Product Characteristics are found non-conforming, quarantine the pieces produced after,the last product characteristic check, identify with Yellow Co lour label and re-inspect 100%.
Remove Non-conforming products and identify with Red,Color Tag. Make entry in Production Log Book and inform Chargehand and Supervisor.
2

1
PREPARED BY : V.SIVAKARTHIKEYAN APPROVED BY : MR.Velayutham DATE:04.08.2016
S.No. DESCRIPTION OF REVISION CARRIED OUT DATE Prepared Approved
LAYOUT INSPECTION REPORT

DATE:
PART NO: DESCRIPTION: Latest issue 25.07.2016

XXXXXX SWINGARM COMP INSPECTOR NAME:

ENCL NO. Thyagaraja

INSPECTIO
SL. N METHOD ACTUAL OBSERVED
SPECIFICA TOLERAN Deviation Deviation
PARAMETER LSL USL
(-) (+)
REMARKS
NO. TION CE / TOOL /
1 2 3 4 5
INSTRU

I APPERANCE INSPECTION PARAMETERS

1 Holes inside painting Not allowed Visual No Holes inside painting OK

2 Weld unde cut Not allowed Visual No Weld unde cut OK

3 Crack Not allowed Visual No Crack OK

4 Weld spatter Not allowed Visual No Weld spatter OK

5 Weld blow holes Not allowed Visual No Weld blow holes OK

6 Thread damage Not allowed Visual No Thread damage OK

7 Burs and Rust Not allowed Visual No Burs and Rust OK

8 Powder coater un coverege Not allowed Visual No Powder coater un coverege OK

II DIMENSIONAL INSPECTION PARAMETERS:

CENTER DISTANCE LH 488 ± 0.8 487.2 488.8 FARO 487.87 487.92 488.01 487.54 48 439.2 0 Not OK
1
CENTER DISTANCE RH 488 ± 0.8 487.2 488.8 FARO 487.84 487.81 487.23 488.14 487.43 0 0 OK

2 PARALLALISM //│ 0.8│A-B 0.8 0.8 0 0.8 FARO 0.53 0.68 0.75 0.79 0.44 0 0 OK

3 DIMENSION 103 ±2 101 105 FARO 102.94 102.71 102.67 102.71 102.84 0 0 OK

4 CENTER DISTANCE 168 ± 0.8 167.2 168.8 FARO 167.9 167.89 168.65 168.19 167.67 0 0 OK

CENTER DISTANCE LH 458.3 ±1 457.3 459.3 FARO 457.1 456.96 457.27 457.57 456.94 0.36 0 Not OK
5
CENTER DISTANCE RH 458.3 ±1 457.3 459.3 FARO 457.55 458.07 457.01 458.84 457.33 0.29 0 Not OK

6 CENTER DISTANCE 350 ± 0.8 349.2 350.8 FARO 350.03 350.16 349.78 349.34 350.32 0 0 OK

7 CENTER DISTANCE 34.2 ± 0.5 33.7 34.7 FARO 34.12 34.44 34.25 33.83 33.99 0 0 OK

CENTER DISTANCE LH 47.5 ± 1.2 46.3 48.7 FARO 47.06 47.59 47.64 47.76 47.02 0 0 OK
8
CENTER DISTANCE RH 47.5 ± 1.2 46.3 48.7 FARO 46.6 46.98 47.27 46.91 46.31 0 0 OK

9 SLOT WIDTH 15.5 ± 0.5 15 16 DVC 15.63 15.62 15.69 15.64 15.67 0 0 OK

10 SYMMETRY 0.8 C 0.8 0.8 0 0.8 FARO 0.99 1.01 0.12 0.98 0.12 0 0.21 Not OK

11 CENTER DISTANCE 40.2 ± 0.5 39.7 40.7 FARO 40.02 40.16 40.05 39.84 40.03 0 0 OK

12 SLOT WIDTH 19.3 ± 0.5 18.8 19.8 DVC 19.59 19.56 19.54 19.58 19.53 0 0 OK

13 SLOT RADIUS 10.55 +0.8 10.55 11.35 FARO 10.64 10.69 10.57 10.68 10.61 0 0 OK

14 SLOT RADIUS 7.75 +0.8 7.75 8.55 FARO 7.81 7.79 7.84 7.79 7.82 0 0 OK

15 DIMENSION 100 ±1 99 101 FARO 101.23 100.79 100.19 101.43 101.22 0 0.43 Not OK

16a PERPENDICULARITY 1/A 1 1 0 1 FARO 0.93 0.45 0.73 0.64 0.82 0 0 OK

16a DIMENSION 46.5 ± 1.2 45.3 47.7 FARO 48.39 46.42 47.72 47.4 48.03 0 0.69 Not OK

17 DIMENSION 125 ±2 123 127 FARO 124.71 124.77 124.67 124.64 124.35 0 0 OK

18 RUN OUT 1 1 0 1 DHG 0.68 0.84 0.73 0.81 0.75 0 0 OK

19 ANGLE 45 ±1 44 46 FARO 45.23 44.83 44.73 45.34 44.86 0 0 OK

20 DIMENSION 41 ± 0.2 40.8 41.2 DVC 41.04 41.03 41.08 41.05 41.03 0 0 OK

21 CONCENTRICITY 0.1 0.1 0 0.1 FARO 0.13 0.31 0.25 0.32 0.28 0 0.22 Not OK

22 FRONT BUSH WIDTH 127 +0.7/+0.3 127.3 127.7 FARO 126.61 126.83 126.65 126.93 127.11 0.69 0 Not OK

23 CYLINDERCITY 0.1 0.1 0 0.1 FARO 0.09 0.13 0.11 0.08 0.12 0 0.03 Not OK

Page 68 of 132
INSPECTIO
SL. N METHOD ACTUAL OBSERVED
SPECIFICA TOLERAN Deviation Deviation
PARAMETER LSL USL REMARKS
NO. TION CE / TOOL / (-) (+)
1 2 3 4 5
INSTRU

+0.02 /
24 BORE DIA 24 23.9 24.02 FARO 23.98 24.01 23.99 23.98 23.98 0 0 OK
-0.1

25 RUN OUT 1 1 0 1 DHG 0.77 0.85 0.81 0.74 0.83 0 0 OK

26 DIMENSION 166 ±1 165 167 FARO 165.38 165.42 164.93 165.58 165.26 0.07 0 Not OK

27 DIMENSION 290 ± 3.2 286.8 293.2 FARO 291.06 290.89 291.23 291.46 291.12 0 0 OK

28 DIMENSION 375 ±1 374 376 FARO 373.82 374.58 373.26 374.82 374.49 0.74 0 Not OK

29 DIMENSION 436 ± 0.5 435.5 436.5 FARO 436.06 436.03 434.97 434.71 435.25 0.79 0 Not OK

30 DIMENSION 76.3 +1.2 75.1 77.5 FARO 78.47 78.12 78.32 77.89 78.42 0 0.97 Not OK

31 BKT SHCK ABS PERPENDICULARITY RH 1/A 1 1 0 1 FARO 0.98 0.4 0.79 0.98 0.96 0 0 OK

32 DIMENSION 9.3 ± 0.5 8.8 9.8 FARO 9.94 9.82 10.17 9.99 9.93 0 0.37 Not OK

33 SWING ARM PERPENDICULARITY RH 1/A 1 1 0 1 FARO 1.67 0.49 1.33 1.23 1.38 0 0.67 Not OK

34 REAR WIDTH 200 +2 200 202 FARO 201.66 201.39 200.75 202.38 201.58 0 0.38 Not OK

35 REAR WIDTH CENTER OFFSET 103 +0.5 103 103.5 FARO 103.81 104.85 102.65 104.28 104.18 0.35 1.35 Not OK

36 DIMENSION 10.3 ± 0.5 9.8 10.8 FARO 10.73 10.79 9.96 10.8 9.86 0 0 OK

37 SWING ARM PERPENDICULARITY LH 1/A 1 1 0 1 FARO 0.27 0.44 0.74 0.54 0.26 0 0 OK

38 BKT SHCK ABS PERPENDICULARITY LH 1/A 1 1 0 1 FARO 0.98 0.41 0.76 0.25 0.71 0 0 OK

BKT CHAIN CASE BKT FRONT

39 PERPENDICULARITY 1/A 1 1 0 1 FARO 0.96 0.98 0.55 0.66 0.63 0 0 OK

40 DIMENSION LH 114.3 ± 1.20 113.1 115.5 FARO 116.88 116.22 114.21 115.1 116.98 0 1.48 Not OK

41 DIMENSION RH 109.3 ± 1.20 108.1 110.5 FARO 110.3 109.52 112.37 110.73 110.15 0 1.87 Not OK

42 SHOCK ABS BKT PARALLALISM //│ 0.5│A-B 0.5 0.5 0 0.5 FARO 0.71 0.25 0.49 0.35 0.68 0 0.21 Not OK

43 DIMENSION 84 ±1 83 85 FARO 82.71 82.57 83.78 85.46 83.72 0.43 0.46 Not OK

44 DIMENSION 118 ±1 117 119 FARO 117.19 116.13 117.62 119.35 117.64 0.87 0.35 Not OK

45 DIMENSION 8 ± 0.5 7.5 8.5 FARO 8.13 8.21 8.29 8.22 8.31 0 0 OK

46 PARALLALISM //│ 0.3│E 0.3 0.3 0 0.3 FARO 0.45 0.51 0.38 0.42 0.36 0 0.21 Not OK

47 DIMENSION 1.5 ± 0.4 1.1 1.9 FARO 1.15 1.23 1.12 1.17 1.13 0 0 OK

+0.7/
48 FRONT BUSH WIDTH 124 124.3 124.7 FARO 124.65 124.56 124.67 124.61 124.58 0 0 OK
+0.3

Inspected by: Thyagaraja Approved by: S.S. REDDY

Page 69 of 132
Summary of Initial Process Studies
Part Name: Part No. & Rev:

Supplier Name: Plant Location:

Sr Special Characteristics Variable / ** Special Control

Class Specs
No. description Attribute exercised

1 Diameter 37.9 -0.20 Variable SPC

** Special controls that are required to be exercised for the

* Target Ppk / Cpk (applicable for
Special Characteristics (in the order of preference) :-

1 Prevention pokayoke Type of Special Characteristics

2 Detection pokayoke Safety / Regulatory (Severity - 9 & 10)

3 Detection pokayoke in the subsequent station/s Fit / Finish - Critical (Severity - 7 & 8)

4 SPC (eg. X bar R charts) Fit / Finish - Major (Severity - 5 & 6)

5 100% inspection

Prepared by Checked by Approved by

Date Date Date
ocess Studies

* Target Actual
Remarks
Ppk / Cpk Ppk / Cpk

1.33 1.83/1.65

et Ppk / Cpk (applicable for variable Special Characteristics)

Non Geometrical
Geometrical Dimensions
Dimensions
1.67 1.33

1.67 1.33

1.33 1.00
Supplier Name & Address: VARIABLE GAUGE REPEATABILITY & REPRODUCIBILITY REPORT
M/S TVS MOTOR COMPANY LTD
Make entries only in green colour boxes. Other boxes protected.
Department : WELD SHOP
Location Code : DATE: 10.03.2016
Part No. : XXXXXXX Requirements:
Part Name, Dimension : SWING ARM No. of Samples = 10
Specification & Tolerance : 40.2±0.5 No. of Appraisers = 3
Gauge No. : No. of Trials = 3
Gauge Description : DIGITAL HEIGHT GAUGE

Appraiser Code <-------------------------------------------------- P A R T S ------------------------------------------------------>

Trial No. TOTAL AVERAGE
& Name 1 2 3 4 5 6 7 8 9 10

1 40.34 40.15 40.24 40.35 40.18 40.11 40.26 40.20 40.42 40.46 402.71 40.27
Mr. Venkatesh 2 40.32 40.16 40.23 40.36 40.17 40.11 40.25 40.21 40.41 40.45 402.67 40.27
3 40.32 40.17 40.23 40.35 40.19 40.12 40.24 40.21 40.41 40.45 402.69 40.27
Avg X1 40.33 40.16 40.23 40.35 40.18 40.11 40.25 40.21 40.41 40.45 402.69 40.27
Range R1 0.02 0.02 0.01 0.01 0.02 0.01 0.02 0.01 0.01 0.01 0.14 0.01

1 40.35 40.16 40.22 40.36 40.17 40.10 40.24 40.19 40.41 40.45 402.65 40.27
Mr. Basha 2 40.34 40.16 40.24 40.36 40.18 40.11 40.25 40.19 40.41 40.45 402.69 40.27
3 40.34 40.15 40.23 40.35 40.18 40.12 40.25 40.20 40.42 40.47 402.71 40.27
Avg X2 40.34 40.16 40.23 40.36 40.18 40.11 40.25 40.19 40.41 40.46 402.68 40.27
Range R2 0.01 0.01 0.02 0.01 0.01 0.02 0.01 0.01 0.01 0.02 0.13 0.01

1 40.32 40.15 40.23 40.36 40.16 40.09 40.25 40.20 40.40 40.28 402.44 40.24
Mr.Thyagaraja 2 40.33 40.16 40.24 40.35 40.17 40.11 40.25 40.21 40.42 40.25 402.49 40.25
3 40.34 40.17 40.22 40.37 40.15 40.12 40.26 40.21 40.41 40.21 402.46 40.25
Avg X3 40.33 40.16 40.23 40.36 40.16 40.11 40.25 40.21 40.41 40.25 402.46 40.25
Range R3 0.02 0.02 0.02 0.02 0.02 0.03 0.01 0.01 0.02 0.07 0.24 0.02

Part Average Xp 40.33 40.16 40.21 40.36 40.17 40.11 40.25 40.20 40.41 40.39 402.61 40.26
Range of Part Avg. 0.30
MEASUREMENT UNIT ANALYSIS % OF TOTAL VARIATION

Repeatability (EV) : R- x K1 0.0518 K1 (for 3 trials): 3.05 % EV = 10.45 %

Reproducibility (AV) : 0.0605 K2 (for 3 appraisers) : 2.70 % AV = 12.19 %

Repeatability & Reproducibility (R&R) : 0.0797 % R&R= 16.06 %

Part Variation (PV) (Rp x K3) : 0.4896 K3 (for 10 parts) : 1.62 % PV = 98.70 %

Total Variation (TV) : 0.4960 NDC: 9

CONCLUSION : Accepted Rejected Conditionally accepted CONDITION FOR ACCEPTANCE:

Enter letter b in appopriate box b Accepted

Acceptance Criteria: Gauge R&R value upto 15 % is accepted. Gauge R&R Value above 30 % is rejected, and requires re-study after the deficiencies are corrected.
Gauge R&R value above 15 % but below 30 % may be acceptable, provided the No. of Data Categories (NDC) is atleast 3, depending upon the risks
involved and considering the cost of repairs / replacement; however, the measurement system shall not be used for checking special characteristics.

PERFORMED BY: Mohan APPROVED BY: SS Reddy

SUPPLIER NAME
Data Sheet for R&R (Attribute type) Study
Gauge Number : H/RE/U180SA/N95227150/AG/00 Date :

Gauge Description : ACC GAUGE

Part No : N9092230 Part Name
Location : Hema Engineering Industries Limited Location :
Assessor A : Assessor B : Assessor C :
Parts TRIAL 1 TRIAL 2 TRIAL 1 TRIAL 2 TRIAL 1
G / NG G / NG G / NG G / NG G / NG
1 G G G G G
2 G G G G G
3 G G G G G
4 G G G G G
5 G G G G G
6 NG NG NG NG NG
7 G G G G G
8 G G G G G
9 G G G G G
10 NG NG NG NG NG
11 G G G G G
12 G G G G G
13 G G G G G
14 G G G G G
15 G G G G G
16 G G G G G
17 G G G G G
18 G G G G G
19 G G G G G
20 G G G G G
21 G G G G G
22 NG NG NG NG NG
23 G G G G G
24 G G G G G
25 G G G G G
26 NG NG NG NG NG
27 G G G G G
28 G G G G G
29 G G G G G
30 G G G G G
31 G G G G G
32 G G G G G
33 G G G G G
34 G G G G G
35 G G G G G
36 G G G G G
37 G G G G G
38 G G G G G
39 G G G G G
40 G G G G G
41 G G G G G
42 G G G G G
43 NG NG NG NG NG
44 G G G G G
45 G G G G G
46 G G G G G
47 G G G G G
48 G G G G G
49 G G G G G
50 G G G G G
Total no. of
Type 1 Errors 4 4 4
Total no. of
Type 2 Errors _ _ _

Acceptance Criteria - Type 1 Error (Rejecting a good part) - not more than 3% for each appraiser
Type 2 Error (Accepting a bad part) - Zero for each appraiser

For results not meeting the acceptance criteria - Retrain the assessors and re-do the R&R study
Before measurement ensure the following conditions :
I 1. Select the components from different batch / Lot / Shift
2. Ensure the following mix of good & bad parts -
Good parts - 35 nos (including 8 marginally good parts - close to USL / LSL)
Bad parts - 15 nos (Including 8 marginally bad parts - close to USL / LSL)
II 1.Don't change the place of the component.
2.Don't change the method
3.Don't change the gauge.
Name of Assessor - A Name of Assessor - B Name of Assessor - C
Suganth Manickam Abhilash
AME
bute type) Study
14.04.2016

SWING ARM

Hosur
Assessor C : Original Part
TRIAL 2 Dimension Remarks
G / NG and Status
G G
G G
G G
G G
G G
NG NG
G G
G G
G G
NG NG
G G
G G
G G
G G
G G
G G
G G
G G
G G
G G
G G
NG NG
G G
G G
G G
NG NG
G G
G G
G G
G G
G G
G G
G G
G G
G G
G G
G G
G G
G G
G G
G G
G G
NG NG
G G
G G
G G
G G
G G
G G
G G
G - GOOD
4 4
_ _ NG - NOT GOOD

3% for each appraiser

the R&R study

to USL / LSL)
USL / LSL)

Checked by : Approved by :
Venkatesan.R Venkatesan.R
Product Weight Details

Part Name : XXXX

Supplier Name : XXXX

Weight in Grams
Part Sr No.
(upto 4 decimels)

Total

PSW Average Weight

Prepared by

Checked by

Approved by
ht Details

Part No. & Rev : XXXX

Plant Location : XXXX

Remarks

Date : xxxx

Date : xxxxx

Date : xxxxx
SUPPLIER NAME
PART NAME : Swing Arm Sub Assy
PART NO : XXXXX
Equipment
S. NO DESCRIPTION CALIBRATION FREQ.
capacity
1 DHG 0~600 mm 12.11.2015 ~ 11.11.2016
DIGITAL VERNIER
2 0~300 mm 12.11.2015 ~ 11.11.2016
CALIPER
3 BEVEL 0~360° 12.11.2015 ~ 11.11.2016
EXTERNAL
4 0~25 mm 12.11.2015 ~ 11.11.2016
MICROMETER
FINAL ACCEPTANCE
5 STD Once per year
GAUGE

Riyaz Mubarak .M Thirumal.M Manimaran .G

Prepared By Checked By Approved By

ATTACH GAUGE PHOTOGRAPH

Supplier Name & Address: Page No. of
PROCESS FLOW DIAGRAM PFD No.: PFD / BC/SB

Part Name: SWING ARM U180 Drawing No. N9092230 PFD Initial Date: PFD Rev. No. 1

Part No. N9092230 Issue/Rev.# L4'd" PFD Rev. Date: 14.05.2016

Process Process Description Symbol Equipment No., Incoming Product Process Characteristics
Step / Fixture No., Tool No., Sources of Characteristics to be to be controlled to
Operation and Manufacturing Variation achieved in each achieve the complete set
No. Location process/operation step of product
characteristics

Dimension
RECEIVING
variation, bend, Free from Rust, excess 1)Recieving inspection as
10 MATERIAL Manual
twist, rust, dent, oil, dent, weld defects per RIP -
INSPECTION
crack, da,mage

20
Excess oil, dust, Improper loading not
20 LOADING MANUAL 1)Use of Dedicated jigs
grease allowed

1) Spray pressure (0.8 to

1.2 KG/ CM2)
30 2) Temperature of heat
Component to be exchangers (50 to 65 deg)
PRE TREATMENT -
Powder coating setup Excess oil, dust, completely free from oil, 3) No contamination of
30 KNOCK OF
Location: HEIL-4 grease grease contamination, bath solution (continiously
DEGREASING [KOD]
dust etc running of Oil skimmer)
4) Chemical concentration
(5-10ML/ Liter) 5) Process
time 60 Sec

1) Spray pressure (0.8 to

40 1.2 KG/ CM2)
2) Temperature of heat
Component to be exchangers (50 to 65 deg)
DEGREASING Powder coating setup Excess oil, dust, completely free from oil, 3) No contamination of
40
STAGE-1 (ADA) Location: HEIL-4 grease grease contamination, bath solution (continiously
dust etc running of Oil skimmer)
4) Chemical concentration
(5-10ML/ Liter) 5) Process
time 60 Sec

1) Spray pressure (0.8 to

1.2 KG/ CM2)
50 2) Temperature of heat
Component to be exchangers (50 to 65 deg)
DEGREASING Powder coating setup Excess oil, dust, completely free from oil, 3) No contamination of
50
STAGE-2 Location: HEIL-4 grease grease contamination, bath solution (continiously
dust etc running of Oil skimmer)
4) Chemical concentration
(5-10ML/ Liter) 5) Process
time 60 Sec

1) No contamination (1.5-2
60 ML Max/Liter)
Alkaline solution Cleaning of alkaline 2) Pressure (0.8 -1.2KG/
SPRAY,RISER &
60 WATER RINSE-1
NOZZLE
on the part to be Solution on CM2)
cleaning component 3) process time 60 Sec
4) frequency of cleaning
Bath (Once in a week)

1) No contamination (1.5-2
ML Max/Liter)
70 Alkaline solution Cleaning of alkaline 2) Pressure (0.8 -1.2KG/
SPRAY,RISER &
70 WATER RINSE-2
NOZZLE
on the part to be Solution on CM2)
3) process time 60 Sec
NOZZLE
cleaning component 3) process time 60 Sec
4) frequency of cleaning
Bath (Once in a week)

1) CHEMICAL
CONCENTRATION (6-
80 No Water 9ML/Liter)
SURFACE SPRAY,RISER & Proper activation of the 2) PH LEVEL (8.0-9.5)
80
ACTIVATION NOZZLE
brakeup on the surface. 3) SPRY PRESSURE
Parts to be found (0.8-1.2 KG/
CM2),4)PROCESS TIME
60 Sec

90 1) CONCENTRATION (18-22ML/
Liter) GRANODINE 952 A/E
2) FREE ACID
CONCENTRATION (0.8-1.2ML)
Parts Should be Complete phosphating 3) TONER VALUE GRANO
SPRAY,RISER &
90 PHOSPHATING
NOZZLE
Completly of the parts, no TONER 130 (2-4ML)
operation skip 4) TEMPERATURE (48-52 Dec)
surface active 5) PRESSURE (0.8-1.2 KG/CM2)
6) TIME (180 Sec)
7) FREQUENCY OF CLEANING
(Once in a week)

1) PH LEVEL in DM Water
100 Complete rinsing of the (6.5-7.2)
Proper and 2) ACIDITY LEVEL (1.5-
SPRAY,RISER & components, no
100 DM RINSE I Uniform 2.0ML Max/ Liter)
NOZZLE checmical sludge on the 3) PROCESS TIME (60 sec)
Phospating coating
Part 4) FREQUENCY OF
CLEANING (once in a week)

1) PH LEVEL in DM Water
110 Complete rinsing of the (6.5-7.2)
Proper and 2) ACIDITY LEVEL (1.5-
SPRAY,RISER & components, no
110 DM RINSE II Uniform 2.0ML Max/ Liter)
NOZZLE checmical sludge on the 3) PROCESS TIME (60 sec)
Phospating coating
Part 4) FREQUENCY OF
CLEANING (once in a week)

1) PH LEVEL in DM Water
120 (6.5-7.2)
Proper and Complete rinsing of the 2) ACIDITY LEVEL (1.5-
SPRAY,RISER &
120 DM RINSE III Uniform components, No Yellow 2.0ML Max/ Liter)
NOZZLE 3) PROCESS TIME (60 sec)
Phospating coating stains on the Part
4) FREQUENCY OF
CLEANING (once in a week)

130 No phospating Complete rinsing of the

SPRAY,RISER & 1) DM water conductivity
130 DM MIST
NOZZLE
sludge and components,With Fresh
(Less than 30 Microns)
yellow stains DM Water

Parts to be
Uniform 1)Oven Temperature 150
140 Parts to be Dry from
140 DRY OFF OVEN OVEN phospating Rinse water
+ 10 deg 2) Process
coating to be Time 15 Min
done.

Silicon mask to be TYPE OF MASK: SILICON

BASED [SPECIFIED MASK
AIR BLOW & AIR VALVE WITH Parts free from provide where ever
150 150 TO BE USED FOR THE
MASKING TRIGGER wet necessary as per Part COMPONENTS WHERE
DWG (If necessary) EVER REQUIRED]

1)MIXING RATIO [VIRGIN

POWDER Vs
RECOVERY POWDER] :
160 Uniform Powder Free from uncoverage, 80:20
160 POWDER COATING Spray Booth & Gun
Coating dust, over flow. 2) FLOW RATE : 250 -
350 gms/min
3) Air Presure (0.2 - 0.5
KG/cm2)

If Parts Found with

DEMASKING & Free from 1) One Skilled inspector
170 VISUAL INSPECTION Powder Un cover should
INSPECTION Coating Un cover be removed as per skill matrix

1)Oven Temperature 240

Parts should be
1)Oven Temperature 240
Parts should be
180 POWDER CURING 180 OVEN Proper curing of Parts + 10 deg
uniform coated 2) Process Time 35 Min

Components to be
1) Skilled Operator
After curing the unloaded in dedicated
2) Use of Dedicated
UNLOADING & ` trolleys and free from
190
FINAL INSPECTION 190
Manual Components to Uncover, Dust, Over
Trollys
be cooled naturlly 3) DFT (dry film thick) Min
flow, pin hole, oozeout
45 Microns
etc.,

Components Components to be 1) Trained Operator for

Revising and Final Acc Gauge No -
200 should be free from answer freely to the Answering to final acc
acc gauge inspection HEIL-4
coating defect. Gauge gauge

Final Visual Powdercoating Powdercoating

210 1) Lux level 800-1000
210 Inspection & Manual Uncoverage, Uncoverage, peeloff,
Spray touchup peeloff, rundown rundown not allowed

1)Product Check DFT min

45 Microns
Check all Product 2)Salt spary test Min 500
Dust free Parts
Parameters including hrs
220 Layout Inspection Manual free from Asthetic
Powder coating 3)Hot water test 1 hr in 70
problems
TSES083 deg DM water
4)Adhesion test No Peel
off in 3M scotch tape

Qty as per the

Dent damage, crack, 1)Dedicated Trolly (80
available trolley
230 Packing 230 Manual cut, improper loading not Nos)
Loading in
allowed 2) No damaged trollyes
specified trollies

Mismatch qty as Record the data and

Dent, damage, tag
per ensure defect free parts &
240 Doc audit Manual missing, improper trolley
invoice,necessary Check samples through
not allowed
reports Attribute gauges.

Trolley capacity : 80 nos

Not as per
250 Dispatch to TVS Trolley Ontime delivery as per As per customer plan
customer plan
customer schedule

Revision History
Rev. No. Date: Details of Revision

Prepared by: Reviewed by: Approved by:

Riyaz Mubarak .M Shashidhar. MR Manimaran .G

Transportation
Symbols: Operation :- 10 Operation + Inspection :- 10 Storage Inspection :-
Potential Failure mode and effects Analysis
(Process FMEA)

System Drawing No. N9092230

Sub System
Component SWING ARM U180 Revision No. L4 ''d" Design/Process Responsibility : Mr.G Manimaran FMEA Number : H/T/PFMEA/BC
Model Year/ Vehicle(s) : Page :
Core Team : Mr.Satish Vakundkar ,Mr.G Manimaran, Mr.Gireesh krishnan, Mr.SS.Reddy, Key Date: 14.05.2016 Rev: 1 Prepared by : Sivakumar
Mr. Sivakumar, Mr.Prabhakar FMEA Date: 14.05.2016 Rev Date: - 14.05.2016 -

Item / Process Potential Failure Mode Potential Effect(s) of Failure Potential cause(s) / Current Design Controls / Current Process Current Design Controls / Current Process Recommended Action(s) Responsibility Action Results

Occurrence
Process Function Requirement / Deliverable Mechanism(s) of Failure controls - Prevention for Causes and / or for controls - Detection for Causes and / or for & Target Actions Taken

Detection
Occurrence
Detection
Severity
Failure Modes Failure Modes / Effects Completion

Class

Severity
RPN
Date

RPN
Operation no. 10 Cause: Inspection Report
Cause: Proper Training to operator SUPPLIER AUDIT DONE AND AWARENESS
1.RUST Free 1.RUST PROBLEM IN SUBSEQUENT IF THE PROBLEM CONTINUES DO
1. IMPROPER INSPECTION BOP QUALITY GIVEN TO THE SUPPLIER ABOUT THE

48
6

4
RECEIVING MATERIAL 2.No EXCESS OIL, DIRT 2.EXCESS OIL, DIRT OPERATIONS AUDIT AT SUPPLIER END
INSPECTION FM :Nil ISSUES
FM/EFCT:
Cause: SKILL MATRIX IMPLIMENT EMPLOYEE TRIANING
1. LOADING OF RUSTY OR Cause: OPERATOR TO BE EDUCATED
1. NO PEEL OFF AFTER POWDER 1. PEEL OFF AFTER POWDER CUSTOMER DISSATISFACTION / PROPER TRAINING GIVEN TO THE
EXCESS OILY SURFACED SUPERVISOR

40
4

5
COATING COATING AESTHETIC ISSUES OPERATOR REGARDING THE PROCESS
COMPONENTS FM :Nil
FM/EFCT: VISUAL

Cause: VISUAL IMPLIMENT EMPLOYEE TRIANING

Cause: DEDICATED JIGS FOR PARTICULAR
Operation no. 20 2.DENT & DAMAGES NOT 1. IMPROPER / DAMAGED JIGS. COMPONENTS PROPER TRAINING GIVEN TO THE
2. DENT & DAMAGES AESTHETIC ISSUES SUPERVISOR

50
5

5
ALLOWED USING JIGS OF OTHER PARTS OPERATOR REGARDING THE PROCESS
FM :Nil
LOADING FM/EFCT:

Cause: VISUAL
Cause: OPERATOR TO BE EDUCATED &
1.IMPLIMENT EMPLOYEE TRAINING
3.NO UNCOVERAGE AFTER 3. UNCOVERAGE AFTER POOR CORROSION RESISTANCE LEADS 1. LOADING OF COMPONENTS DECOATING OF JIGS TO BE DONE 1.EMPLOYEE TRAINING IMPLEMENTED
2. JIG BURNING SCHEDULE TO BE SUPERVISOR

48
6

4
POWDER COATING POWDER COATING TO RUST FORMATION IN FIELD IN DAMAGED JIGS 2. JIG BURNING DONE AS PER SCHEDULE
ADHERED
FM :Nil
FM/EFCT:

Cause: VISUAL
Cause: PROPER SPRAY PRESSURE [0.8 - 1.2
Kg/Cm2] PRESSURE GAUGE CALIBRATION TO
1. IMPROPER CLEANING OPERATOR

30
8

5
BE DONE & ADHERE CHECK LIST PRESSURE GAUGE CALLIBRATION DONE
FM :Nil AS PER SCHEDULE AND REPORT
FM/EFCT: MAINTAINED
Cause: MAINTAIN THE CONCENTRATION BY Cause: ANALYSIS REPORT
2. LOW CHEMICAL ANALYSING AT LAB LAB IN
CHECK ONCE IN SHIFT & RECORD

48
5

4
CONCENTRATION CHARGE INSPECTION DONE AND RECORD
FM :Nil FM/EFCT: MAINTAINED AS SCHEDULED
Cause: VISUAL
Cause: HEAT EXCHANGERS CLEANING TO
3. VARIATION IN TEMPERATURE
1.COMPLETE CLEANING BE DONE PREVENTIVE MAINTENANCE PREVENTIVE MAINTAINANCE DONE AS PER
Operation no. 30 1. COATING PEEL OFF LEADS TO RUST FORMATION DUE TO HEAT EXCHANGERS OPERATOR

30
6

5
2.NO EXCESS OIL SCHEDULE TO BE ADHERE SCHEDULE
PROBLEMS
FM :Nil
FM/EFCT:

Cause: ANALYSING AT SUPPLIER END & Cause: ANALYSIS REPORT

PRE TREATMENT - KNOCK OF 4. BATH SOLUTION FRESH PREPERATION CONFIRM WITH TEST REPORT & LAB IN

30
5

5
DEGREASING [KOD] CONTAMINATION USING PURE CHEMICALS CHARGE PERFORMING THE REQUIRED TEST AND
FM :Nil FM/EFCT: MAINTAINING THE REPORT
Cause: VISUAL
Cause: PREVENTIVE MAINTAINENCE TO BE
DONE PREVENTIVE MAINTENANCE PREVENTIVE MAINTAINANCE DONE AS PER
5. EQUIPMENT BREAK DOWN OPERATOR

30
8

5
SCHEDULE TO BE ADHERE SCHEDULE
FM :Nil
FM/EFCT:

ROUGH SURFACE AESTHETIC Cause: VISUAL

Cause: PREVENTINE MAINTAINENCE TO BE
PROBLEM
1. IMPURITIES IN BATH DONE TO REMOVE DUST PARTICALS PREVENTIVE MAINTENANCE PREVENTIVE MAINTAINANCE DONE AS PER
2. NO DUST 2. DUST & OPERATOR

40
5

4
SOLUTION SCHEDULE TO BE ADHERE SCHEDULE
COATING SPOT PEEL OFF LEADS TO
FM :Nil
SPOT RUST FM/EFCT:

Cause: VISUAL
Cause: PROPER SPRAY PRESSURE [0.8 - 1.2
Kg/Cm2] PRESSURE GAUGE CALIBRATION TO
1. IMPROPER CLEANING OPERATOR

24
8

4
BE DONE & ADHERE CHECK LIST
FM :Nil GAUGE CALIBRATED AND REPORTS
FM/EFCT: MAINTAINED
Cause: MAINTAIN THE CONCENTRATION BY Cause: ANALYSIS REPORT
2. LOW CHEMICAL ANALYSING AT LAB LAB IN
CHECK ONCE IN SHIFT & RECORD

30
5

5
CONCENTRATION CHARGE INSPECTION DONE AND RECORD
FM :Nil FM/EFCT: MAINTAINED AS SCHEDULED
Cause: VISUAL
Cause: HEAT EXCHANGERS CLEANING TO
3. VARIATION IN TEMPERATURE
BE DONE PREVENTIVE MAINTENANCE PREVENTIVE MAINTAINANCE DONE AS PER
1. NO COATING PEEL OFF COATING PEEL OFF LEADS TO RUST FORMATION DUE TO HEAT EXCHANGERS OPERATOR

60
6

5
Operation no. 40 SCHEDULE TO BE ADHERE SCHEDULE
PROBLEMS
FM :Nil
FM/EFCT:

Cause: ANALYSING AT SUPPLIER END & Cause: ANALYSIS REPORT

4. BATH SOLUTION FRESH PREPERATION CONFIRM WITH TEST REPORT & LAB IN

30
DEGREASING STAGE-1 (ADA)

5
CONTAMINATION USING PURE CHEMICALS CHARGE PERFORMING THE REQUIRED TEST AND
FM :Nil FM/EFCT: MAINTAINING THE REPORT
Cause: VISUAL
Cause: PREVENTIVE MAINTAINENCE TO BE
DONE PREVENTIVE MAINTENANCE PREVENTIVE MAINTAINANCE DONE AS PER
5. EQUIPMENT BREAK DOWN OPERATOR

30
8

5
SCHEDULE TO BE ADHERE SCHEDULE
FM :Nil
FM/EFCT:

Cause: VISUAL
Cause: PREVENTINE MAINTAINENCE TO BE
ROUGH SURFACE AESTHETIC
1. IMPURITIES IN BATH DONE TO REMOVE DUST PARTICALS PREVENTIVE MAINTENANCE PREVENTIVE MAINTAINANCE DONE AS PER
2. NO DUST DUST PROBLEM & COATING SPOT PEEL OFF OPERATOR

40
5

4
SOLUTION SCHEDULE TO BE ADHERE SCHEDULE
LEADS TO SPOT RUST
FM :Nil
FM/EFCT:

Cause: VISUAL
Cause: PROPER SPRAY PRESSURE [0.8 - 1.2
Kg/Cm2] PRESSURE GAUGE CALIBRATION TO
1. IMPROPER CLEANING OPERATOR

24
8

30
5

30
6

5
Operation no.50 SCHEDULE TO BE ADHERE SCHEDULE
PROBLEMS
FM :Nil
FM/EFCT:

Cause: ANALYSING AT SUPPLIER END & Cause: ANALYSIS REPORT

4. BATH SOLUTION FRESH PREPERATION CONFIRM WITH TEST REPORT & LAB IN
60

30
DEGREASING STAGE-2
5

5
CONTAMINATION USING PURE CHEMICALS CHARGE PERFORMING THE REQUIRED TEST AND
FM :Nil FM/EFCT: MAINTAINING THE REPORT
DEGREASING STAGE-2

Cause: VISUAL
Cause: PREVENTIVE MAINTAINENCE TO BE
DONE PREVENTIVE MAINTENANCE PREVENTIVE MAINTAINANCE DONE AS PER
5. EQUIPMENT BREAK DOWN OPERATOR

30
8

5
SCHEDULE TO BE ADHERE SCHEDULE
FM :Nil
FM/EFCT:

Cause: VISUAL
Cause: PREVENTINE MAINTAINENCE TO BE
ROUGH SURFACE AESTHETIC
1. IMPURITIES IN BATH DONE TO REMOVE DUST PARTICALS PREVENTIVE MAINTENANCE PREVENTIVE

120
2. NO DUST DUST PROBLEM & COATING SPOT PEEL OFF OPERATOR

40
5

4
SOLUTION SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
LEADS TO SPOT RUST
FM :Nil
FM/EFCT:

Cause: PROPER SPRAY PRESSURE AS PER Cause: VISUAL

NORMS PRESSURE GAUGE CALIBRATION
1. IMPROPER CLEANING OPERATOR

24
8

4
DONE & CHECK LIST ADHERED GAUGE CALIBRATED AND REPORTS
FM :Nil FM/EFCT: MAINTAINED
Cause: MAINTAIN THE CONCENTRATION BY
Cause: ANALYSIS REPORT
ANALYSING AT LAB & OVER FLOW OF
2. HIGH CONCENTRATION LAB IN
SOLUTION CONTINOUSLY CHECK ONCE IN SHIFT & RECORD

30
5

5
LEVEL CHARGE
Operation no.60 FM/EFCT: INSPECTION DONE AND RECORD
1. NO COATING PEEL OFF COATING PEEL OFF LEADS TO RUST FORMATION FM :Nil MAINTAINED AS SCHEDULED

2
Cause: PREVENTIVE MAINTAINENCE TO BE Cause: VISUAL
DONE PREVENTIVE MAINTENANCE PREVENTIVE
3. POOR BATH MAINTANENCE OPERATOR

60
8

5
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
FM :Nil FM/EFCT:
WATER RINSE I Cause: MONITORING THE PH FOR EVERY Cause: ANALYSIS REPORT
SERVICING OF WATER PLANT FOR
SHIFT LAB IN
4. PH ABOVE THE NORMS EVERY 1 YEAR & CHECK THE PH OF SERVICING MADE AS SCHEDULED

30
5

5
CHARGE
SOLUTION EVERY SHIFT & RECORD
FM :Nil FM/EFCT:
Cause: PREVENTIVE MAINTAINENCE TO BE Cause: VISUAL
ROUGH SURFACE AESTHETIC
1. IMPURITIES IN BATH DONE TO REMOVE DUST PARTICALS PREVENTIVE MAINTENANCE PREVENTIVE
2. NO DUST DUST PROBLEM & COATING SPOT PEEL OFF OPERATOR

32
4

4
SOLUTION SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
LEADS TO SPOT RUST
FM :Nil FM/EFCT:
Cause: PROPER SPRAY PRESSURE AS PER Cause: VISUAL
NORMS PRESSURE GAUGE CALIBRATION
1. IMPROPER CLEANING OPERATOR

24
8

30
Operation no.70

5
LEVEL CHARGE
FM/EFCT: INSPECTION DONE AND RECORD
1. NO COATING PEEL OFF COATING PEEL OFF LEADS TO RUST FORMATION FM :Nil MAINTAINED AS SCHEDULED

2
Cause: PREVENTIVE MAINTAINENCE TO BE Cause: VISUAL
DONE PREVENTIVE MAINTENANCE PREVENTIVE
3. POOR BATH MAINTANENCE OPERATOR

60
8

5
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
FM :Nil FM/EFCT:
Cause: MONITORING THE PH FOR EVERY Cause: ANALYSIS REPORT
WATER RINSE II SERVICING OF WATER PLANT FOR
SHIFT LAB IN
4. PH ABOVE THE NORMS EVERY 1 YEAR & CHECK THE PH OF SERVICING MADE AS SCHEDULED

30
5

32
4

4
SOLUTION SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
LEADS TO SPOT RUST
FM :Nil FM/EFCT:
Operation no.80 Cause: PREVENTIVE MAINTAINENCE TO BE Cause: VISUAL
DONE PREVENTIVE MAINTENANCE PREVENTIVE
1. POOR BATH MAINTANENCE OPERATOR

24
8

4
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
FM :Nil FM/EFCT:
Cause: PREVENTIVE MAINTAINENCE TO BE Cause: VISUAL
ACTIVATION 2. IMPURITIES IN BATH DONE TO REMOVE DUST PARTICALS PREVENTIVE MAINTENANCE PREVENTIVE
OPERATOR

60
8

5
SOLUTION SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
FM :Nil FM/EFCT:
1. NO COATING PEEL OFF COATING PEEL OFF 1. LEADS TO RUST FORMATION
6

2
Cause: PREVENTIVE MAINTAINENCE TO BE Cause: VISUAL
DONE PREVENTIVE MAINTENANCE PREVENTIVE
3. EQUIPMENT BREAK DOWN OPERATOR

60
8

5
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
FM :Nil FM/EFCT:
Cause: MAINTAIN THE CONCENTRATION BY Cause: ANALYSIS REPORT
4. LOW CHEMICAL ANALYSING AT LAB
CHECK ONCE IN SHIFT & RECORD LAB

30
5

5
CONCENTRATION INSPECTION DONE AND RECORD
FM :Nil FM/EFCT: MAINTAINED AS SCHEDULED
Operation no.90 Cause: MAINTAIN THE CONCENTRATION BY Cause: ANALYSIS REPORT
1. LOW CHEMICAL ANALYSING AT LAB
CHECK ONCE IN SHIFT & RECORD LAB

24
5

4
CONCENTRATION INSPECTION DONE AND RECORD
FM :Nil FM/EFCT: MAINTAINED AS SCHEDULED
Cause: HEAT EXCHANGERS CLEANING TO Cause: VISUAL
2. VRIATION IN TEMPERATURE
BE DONE PREVENTIVE MAINTENANCE PREVENTIVE
DUE TO HEAT EXCHANGERS OPERATOR

60
8

5
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
PROBLEMS
FM :Nil FM/EFCT:
1. NO COATING PEEL OFF COATING PEEL OFF LEADS TO RUST FORMATION
6

2
Cause: ANALYSING AT SUPPLIER END & Cause: ANALYSIS REPORT
PHOSPHATING 3. BATH SOLUTION FRESH PREPERATION CONFIRM WITH TEST REPORT &
LAB

30
5

5
CONTAMINATION USING PURE CHEMICALS PERFORMING THE REQUIRED TEST AND
FM :Nil FM/EFCT: MAINTAINING THE REPORT
Cause: PREVENTIVE MAINTAINENCE TO BE Cause: VISUAL
DONE PREVENTIVE MAINTENANCE PREVENTIVE
4. EQUIPMENT BREAK DOWN OPERATOR

30
5

5
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
FM :Nil FM/EFCT:
Cause: PREVENTIVE MAINTAINENCE TO BE Cause:
DONE PREVENTIVE MAINTENANCE PREVENTIVE
2. NO YELLOW RUST YELLOW RUST LEADS TO RUST FORMATION 1. CONVEYOR BREAK DOWN OPERATOR

40
4

5
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
FM :Nil FM/EFCT:

Cause: MAINTAIN THE CONCENTRATION BY

Cause: ANALYSIS REPORT
1. LOW CHEMICAL ANALYSING AT LAB & MAINTAIN THE
3. SPECIFIED COATING POOR CORROSION RESISTANCE LEADS
LOW COATING THICKNESS CONCENTRATION OR LOW PRESSURE CHECK ONCE IN SHIFT & RECORD LAB

28
7

4
THICKNESS TO RUST FORMATION IN FIELD
SPRAY PRESSURE INSPECTION DONE AND RECORD
FM/EFCT:
FM :Nil MAINTAINED AS SCHEDULED
Cause: PRENENTINE MAINTAINENCE TO BE Cause: VISUAL
ROUGH SURFACE AESTHETIC
1. IMPURITIES IN BATH DONE TO REMOVE DUST PARTICALS PREVENTIVE MAINTENANCE PREVENTIVE

120
4. NO DUST DUST PROBLEM & COATING SPOT PEEL OFF OPERATOR

50
5

5
SOLUTION SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
LEADS TO SPOT RUST
FM :Nil FM/EFCT:
Cause: PROPER SPRAY PRESSURE AS PER Cause: VISUAL
1. IMPROPER SURFECE
NORMS PRESSURE GAUGE CALIBRATION
CLEANING AFTER OPERATOR
DONE & CHECK LIST ADHERED GAUGE CALIBRATED AND REPORTS
ROUGH SURFACE AESTHETIC PHOSPHATING
FM :Nil FM/EFCT: MAINTAINED
1. NO BLISTERS BLISTERS PROBLEM & COATING SPOT PEEL OFF

25
5

5
LEADS TO SPOT RUST Cause: PRENENTINE MAINTAINENCE TO BE Cause: VISUAL
DONE TO REMOVE DUST PARTICALS PREVENTIVE MAINTENANCE PREVENTIVE
2. POOR BATH MAINTANENCE OPERATOR
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
Operation no.100 FM :Nil FM/EFCT:
Cause: PREVENTIVE MAINTAINENCE TO BE Cause: VISUAL
DONE PREVENTIVE MAINTENANCE PREVENTIVE
1. CONVEYOR BREAK DOWN OPERATOR
96

48
8

4
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
FM :Nil FM/EFCT:

DM RINSE I
DM RINSE I Cause: MAINTAIN THE CONCENTRATION BY Cause: ANALYSIS REPORT
ANALYSING AT LAB
2. NO YELLOW RUST YELLOW RUST LEADS TO RUST FORMATION 2. CONCENTRATION HIGH CHECK ONCE IN SHIFT & RECORD LAB

30
6

5
INSPECTION DONE AND RECORD
FM :Nil FM/EFCT: MAINTAINED AS SCHEDULED
Cause: CHECK THE CONDUCTIVITY ONCE IN Cause: CONDUCTIVITY METER SERVICING OF WATER PLANT FOR
3. CONDUCTIVITY OF DM A SHIFT EVERY 1 YEAR & CHECK THE
LAB SERVICING MADE AS SCHEDULED

24
4

4
WATER ABOVE THE NORMS CONDUCTIVITY OF SOLUTION EVERY
FM :Nil FM/EFCT: SHIFT & RECORD
Cause: PROPER SPRAY PRESSURE AS PER Cause: VISUAL
1. IMPROPER SURFECE
NORMS PRESSURE GAUGE CALIBRATION
CLEANING AFTER OPERATOR
DONE & CHECK LIST ADHERED GAUGE CALIBRATED AND REPORTS
ROUGH SURFACE AESTHETIC PHOSPHATING
FM :Nil FM/EFCT: MAINTAINED
1. NO BLISTERS BLISTERS PROBLEM & COATING SPOT PEEL OFF

30
5

6
LEADS TO SPOT RUST Cause: PRENENTINE MAINTAINENCE TO BE Cause: VISUAL
DONE TO REMOVE DUST PARTICALS PREVENTIVE MAINTENANCE PREVENTIVE
2. POOR BATH MAINTANENCE OPERATOR
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
Operation no.110 FM :Nil FM/EFCT:
Cause: PREVENTIVE MAINTAINENCE TO BE Cause: VISUAL
DONE PREVENTIVE MAINTENANCE PREVENTIVE
1. CONVEYOR BREAK DOWN OPERATOR

60
8

5
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
FM :Nil FM/EFCT:

DM RINSE II Cause: MAINTAIN THE CONCENTRATION BY Cause: ANALYSIS REPORT

ANALYSING AT LAB LAB IN
2. NO YELLOW RUST YELLOW RUST LEADS TO RUST FORMATION 2. CONCENTRATION HIGH CHECK ONCE IN SHIFT & RECORD

30
6

5
CHARGE INSPECTION DONE AND RECORD
FM :Nil FM/EFCT: MAINTAINED AS SCHEDULED
Cause: CHECK THE CONDUCTIVITY ONCE IN Cause: CONDUCTIVITY METER SERVICING OF WATER PLANT FOR
3. CONDUCTIVITY OF DM A SHIFT EVERY 1 YEAR & CHECK THE LAB IN
SERVICING MADE AS SCHEDULED

24
4

4
WATER ABOVE THE NORMS CONDUCTIVITY OF SOLUTION EVERY CHARGE
FM :Nil FM/EFCT: SHIFT & RECORD
Cause: PROPER SPRAY PRESSURE AS PER Cause: VISUAL
1. IMPROPER SURFECE
NORMS PRESSURE GAUGE CALIBRATION
CLEANING AFTER OPERATOR
DONE & CHECK LIST ADHERED GAUGE CALIBRATED AND REPORTS
ROUGH SURFACE AESTHETIC PHOSPHATING
FM :Nil FM/EFCT: MAINTAINED
1. NO BLISTERS BLISTERS PROBLEM & COATING SPOT PEEL OFF

30
5

6
LEADS TO SPOT RUST Cause: PRENENTINE MAINTAINENCE TO BE Cause: VISUAL
DONE TO REMOVE DUST PARTICALS PREVENTIVE MAINTENANCE PREVENTIVE
2. POOR BATH MAINTANENCE OPERATOR
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
Operation no.120 FM :Nil FM/EFCT:
Cause: PREVENTIVE MAINTAINENCE TO BE Cause: VISUAL
DONE PREVENTIVE MAINTENANCE PREVENTIVE
1. CONVEYOR BREAK DOWN OPERATOR

96
8
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
FM :Nil FM/EFCT:

DM RINSE III Cause: MAINTAIN THE CONCENTRATION BY Cause: ANALYSIS REPORT

ANALYSING AT LAB LAB IN
2. NO YELLOW RUST YELLOW RUST LEADS TO RUST FORMATION 2. CONCENTRATION HIGH CHECK ONCE IN SHIFT & RECORD

60
6

48
4
WATER ABOVE THE NORMS CONDUCTIVITY OF SOLUTION EVERY CHARGE
FM :Nil FM/EFCT: SHIFT & RECORD
Cause: PROPER SPRAY PRESSURE AS PER Cause: VISUAL
1. IMPROPER SURFECE
NORMS PRESSURE GAUGE CALIBRATION
CLEANING AFTER OPERATOR
DONE & CHECK LIST ADHERED GAUGE CALIBRATED AND REPORTS
ROUGH SURFACE AESTHETIC PHOSPHATING
FM :Nil FM/EFCT: MAINTAINED
1. NO BLISTERS BLISTERS PROBLEM & COATING SPOT PEEL OFF

30
5

6
LEADS TO SPOT RUST Cause: PRENENTINE MAINTAINENCE TO BE Cause: VISUAL
DONE TO REMOVE DUST PARTICALS PREVENTIVE MAINTENANCE PREVENTIVE
2. POOR BATH MAINTANENCE OPERATOR
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
Operation no.130 FM :Nil FM/EFCT:
Cause: PREVENTIVE MAINTAINENCE TO BE Cause: VISUAL
DONE PREVENTIVE MAINTENANCE PREVENTIVE
1. CONVEYOR BREAK DOWN OPERATOR

96
8
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
FM :Nil FM/EFCT:

DM MIST Cause: MAINTAIN THE CONCENTRATION BY Cause: ANALYSIS REPORT

ANALYSING AT LAB LAB IN
2. NO YELLOW RUST YELLOW RUST LEADS TO RUST FORMATION 2. CONCENTRATION HIGH CHECK ONCE IN SHIFT & RECORD

60
6

48
4
WATER ABOVE THE NORMS CONDUCTIVITY OF SOLUTION EVERY CHARGE
FM :Nil FM/EFCT: SHIFT & RECORD
Cause: PREVENTIVE MAINTAINENCE TO BE Cause: DIGITAL THERMO METER DISPLAY
1. LOW AIR TEMPERATURE
DONE PREVENTIVE MAINTENANCE PREVENTIVE
1.NO OOZE OUT, BLISTERS OOZE OUT, BLISTERS IMPROPER DRYING OF COMPONENT (BLOWERS & EXHUAST OPERATOR

48
6

8
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
Operation no.140 PROBLEMS)
FM :Nil FM/EFCT:

WATER DRY OFF OVEN Cause: OVEN CLEANING TO BE DONE Cause: VISUAL
ROUGH SURFACE AESTHETIC
1. IMPROPER CLEANING OF EVERY WEEK
2. NO DUST / ROUGHNESS DUST / ROUGHNESS PROBLEM & COATING SPOT PEEL OFF SCHEDULE TO BE ADHERED OPERATOR CLEANING DONE AS SCHEDULED

40
5

8
OVEN
LEADS TO SPOT RUST
FM :Nil FM/EFCT:
Cause: SKILL MATRIX
Cause: OPERATOR TO BE EDUCATED
1. OPERATION SKIPPED BY
1. NO OPERATION SKIP OPERATION SKIP OOZE OUT IMPLIMENT EMPLOYEE TRIANING SUPERVISOR SUITABLE TRAINING GIVEN TO OPERATOR

40
4

5
OPERATOR
Operation no.150 FM :Nil
FM/EFCT:

AIR BLOW & MASKING Cause: OPERATOR TO BE EDUCATED Cause: VISUAL CHECKING
1. PROBLEM AT CUSTOMER
2. NO OPERATION SKIP OPERATION SKIP PAINT DEPOSITION ON FITMENT AREAS IMPLIMENT EMPLOYEE TRIANING SUPERVISOR SUITABLE TRAINING GIVEN TO OPERATOR

15
5

3
END
FM :Nil FM/EFCT:
Cause: CONFIRM WITH SUPPLIER TEST Cause: SUPPLIER TEST REPORT
1. NO PEEL OFF AFTER POWDER 1. USING OF DFECTIVE REPORTS FOR EVERY LOT TC IS MUST, AWARENESS GIVEN TO SUPPLIER AND TC
PEEL OFF LEADS TO RUST FORMATION LAB

24
6

4
COATING POWDERS WHICH ARE EXPIRY SUPPLIER HAS INFORME MAINTAINED BATCHWISE
FM :Nil FM/EFCT:

Cause: SET UP THE PRESSURE & FLOW Cause: VISUAL BEFORE STARTING THE PROCESS
1. EXCESS PRESSURE / FLOW RATE IN CIRCUTE AS PER SPECIFICATION PRESURE FLOW RATE HAVE TO BE
2. NO WAVINESS WAVINESS AESTHETIC PROBLEM LIMITATIONS MARKED IN THE CIRCUIT SUPERVISOR

32
4

8
RATE ENSURED 100% BY OPERATOR/
FM :Nil FM/EFCT: SUPERVISOR
Operation no.160

Cause: PRENENTINE MAINTAINENCE TO BE

Cause: VISUAL
DONE TO CLEAN THE CIRCUTE LINE &
1. IMPROPER ELECTROSTATIC CLEANING TO BE TO BEFORE LINE
NEEDLE OF GUN OPERATOR
FORCE STRAT EVERY SHIFT
POWDER COATING 3. NO UNCOVERAGE AFTER POOR CORROSION RESISTANCE LEADS FM/EFCT: PREVENTIVE MAINTAINANCE SCHEDULE
UNCOVERAGE FM :Nil

48
6

8
POWDER COATING TO RUST FORMATION IN FIELD TO BE ADHERED
Cause: PREVENTIVE MAINTAINENCE TO BE Cause: VISUAL
1. LOW FLOW RATE & DONE
SCHEDULE TO BE ADHERE OPERATOR
PRESSURE
FM :Nil FM/EFCT:

Cause: OPERATION TO BE DONE AT

Cause: VISUAL
ROUGH SURFACE AESTHETIC CLOSED AREA BY CLOSING THE POWDER
1. CONTAMINATED POWDER OR BOOTH AREA TO BE CLOSED & BOOTH AREA TO BE MAINTAINED
4. NO DUST / ROUGHNESS DUST / ROUGHNESS PROBLEM & COATING SPOT PEEL OFF SPRAY BOOTH 96 OPERATOR

48
6

8
DUSTY OPERATION ZONE MAINTAIN PROPER 5S PROPERLY AND HAVE TO BE ENSURED
LEADS TO SPOT RUST
FM/EFCT:
FM :Nil
Cause: SKILL MATRIX
Cause: OPERATOR TO BE EDUCATED
1. OPERATION SKIPPED BY MONITORING THE TRAINED EMPLOYEE
1. NO WAVINESS WAVINESS AESTHETIC PROBLEM EMPLOYEE TRIANING IMPLIMENTED SUPERVISOR

32
4

8
OPERATOR FREQUENTLY
FM :Nil
FM/EFCT: VISUAL
Operation no.170 Cause: SKILL MATRIX
Cause: OPERATOR TO BE EDUCATED
POOR CORROSION RESISTANCE LEADS 1. OPERATION SKIPPED BY MONITORING THE TRAINED EMPLOYEE
2. NO UNCOVERAGE UNCOVERAGE EMPLOYEE TRIANING IMPLIMENTED SUPERVISOR

48
6

8
TO RUST FORMATION IN FIELD OPERATOR FREQUENTLY
FM :Nil
DEMASKING & INSPECTION FM/EFCT: VISUAL
Cause: SKILL MATRIX
ROUGH SURFACE AESTHETIC Cause: OPERATOR TO BE EDUCATED
1. OPERATION SKIPPED BY MONITORING THE TRAINED EMPLOYEE
3. NO DUST / ROUGHNESS DUST / RUOGHNESS PROBLEM & COATING SPOT PEEL OFF EMPLOYEE TRIANING IMPLIMENTED SUPERVISOR

48
6

8
OPERATOR FREQUENTLY
LEADS TO SPOT RUST FM :Nil
FM/EFCT: VISUAL
Cause: PREVENTIVE MAINTAINENCE TO BE Cause: DIGITAL THERMO METER
1. LOW AIR TEMPERATURE
DONE PREVENTIVE MAINTENANCE PREVENTIVE
(BLOWERS & EXHUAST OPERATOR
SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
PROPLEMS)
FM :Nil FM/EFCT:
1. NO COATING PEEL OFF COATING PEEL OFF LEADS TO RUST FORMATION

48
6

8
Operation no.180 Cause: SET UP THE SPEED AS PER Cause: VISUAL
CONVEYOR SPEED FINALISED AND
2. DEVIATION IN CONVEYOR SPECIFICATION FIX THE CONVEYOR SPEED IN
SUPERVISOR INCLUDED IN THE CONTROL PANNEL,THE
SPEED CONTROL PANNEL
SAME HAVE TO BE MONITORED
OVEN CURING FM :Nil FM/EFCT:
Cause: OVEN CLEANING TO BE DONE Cause: VISUAL
ROUGH SURFACE AESTHETIC
1. IMPROPER CLEANING OF EVERY WEEK SCHEDULE ADHERENCE TO BE ACHIEVED
2. NO DUST / ROUGHNESS DUST / RUOGHNESS PROBLEM & COATING SPOT PEEL OFF SCHEDULE TO BE ADHERE OPERATOR

48
6

8
OVEN AND MONITORED
LEADS TO SPOT RUST
FM :Nil FM/EFCT:

Cause: SKILL MATRIX

Cause: ON JOB TRAINING TO OPERATOR
REQUIRED TRAINING GIVEN TO THE
1. UNSKILLED OPERATOR TRAINING TO BE GIVEN SUPERVISOR

48
6

8
OPERATOR AND MONITORED REGULARLY
POOR CORROSION RESISTANCE LEADS FM :Nil
FM/EFCT:
1. NO UNCOVERAGE UNCOVERAGE TO RUST FORMATION IN FIELD /

96
6

8
AESTHETIC PROBLEM
Cause: SKILL MATRIX
Cause: ON JOB TRAINING TO OPERATOR
2. IMPROPER FLOW RATE AND SUITABLE TRAINING GIVEN TO OPERATOR
TRAINING TO BE GIVEN SUPERVISOR

48
6

8
VOLTAGE AND MONITORED
FM :Nil
FM/EFCT:
Cause: SKILL MATRIX
Cause: ON JOB TRAINING TO OPERATOR
SUITABLE TRAINING GIVEN TO OPERATOR
1. UNSKILLED OPERATOR TRAINING TO BE GIVEN SUPERVISOR

48
6

8
AND MONITORED
FM :Nil
AESTHETIC PROBLEM / CUSTOMER FM/EFCT:
2. OVER FLOW NOT ALLOWED OVER FLOW

96
6

8
DISSATISFACTION Cause: SKILL MATRIX
Cause: ON JOB TRAINING TO OPERATOR
2. IMPROPER FLOW RATE AND SUITABLE TRAINING GIVEN TO OPERATOR
TRAINING TO BE GIVEN SUPERVISOR

48
6

8
VOLTAGE AND MONITORED
FM :Nil
FM/EFCT:
Cause: SPRAY AND OVEN TO BE CLOSED Cause: VISUAL
1. ATMOSPHERIC DUST / OVEN PROPERLY TO PREVENT DUST ENTRY SUITABLE TRAINING GIVEN TO OPERATOR
TRAINING TO BE GIVEN SUPERVISOR

40
8

5
DUST AND MONITORED
AESTHETIC PROBLEM / CUSTOMER FM :Nil FM/EFCT:
3. NO DUST / ROUGHNESS DUST

80
8

5
DISSATISFACTION Cause: INCOMIN INSPECTION OF POWDER Cause: LAB REPORTS
Operation no.190 PROPER COMMUNICATION TO THE
1. INCOMING POWDER AT LAB LAB IN FREQUENT MONITORING OF THE
SUPPLIER REGARDING THE POWDER

40
8

5
PROBLEM CHARGE SUPPLIER AS WELL AS LAB REPORTS
STANDARD AND REQUIREMENT
FM :Nil FM/EFCT:

Cause: DRY OFF OVEN- POKA YOKE FOR Cause: AUTOMATIC LINE STOPPAGE IF
TEMPERATURE CONTROL ENSURING TEMPERATURE DECREASES
AESTHETIC PROBLEM / CUSTOMER 1. IMPROPER DRYING OF PREVENTIVE MAINTENANCE PREVENTIVE
4. NO OOSEOUT OOSEOUT PROPER DRYING OPERATOR

54
6

0
DISSATISFACTION COMPONENTS SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
FM :Nil FM/EFCT:

Cause: DRY OFF OVEN- POKA YOKE FOR Cause: AUTOMATIC LINE STOPPAGE IF
UNLOADING & FINAL 1. IMPROPER PRE TREATMENT TEMPERATURE CONTROL ENSURING TEMPERATURE DECREASES
INSPECTION AESTHETIC PROBLEM / CUSTOMER PREVENTIVE MAINTENANCE PREVENTIVE
5. NO BLISTERS BLISTERS AND IMPROPER DRYING OF PROPER DRYING OPERATOR

16
4

0
DISSATISFACTION SCHEDULE TO BE ADHERE MAINTENANCE SCHEDULE IMPLEMENTED
COMPONENTS
FM :Nil FM/EFCT:

Cause: VISUAL CHECKING FOR RUSTY Cause: VISUAL CHECKING

1. COMPONENT RUST,
AESTHETIC PROBLEM / CUSTOMER COMPONENTS BEFORE LOADING SUITABLE TRAINING GIVEN TO OPERATOR
6. NO PIN HOLE PIN HOLE MOISTURE CONTENT IN AIR, TRAINING TO BE GIVEN SUPERVISOR

80
5

0
DISSATISFACTION AND MONITORED
MORE DFT
FM :Nil FM/EFCT:
Cause: DEGREASING OF THE COMPONENTS Cause: PROPER DEGREASING
AESTHETIC PROBLEM / CUSTOMER TO BE ENSURED SUITABLE TRAINING GIVEN TO OPERATOR
7. NO OIL PATCH OIL PATCH 1. IMPROPER CLEANING TRAINING TO BE GIVEN SUPERVISOR

36
6

0
DISSATISFACTION AND MONITORED
FM :Nil FM/EFCT:
Cause: POKA YOKE PROVIDED IN CURING Cause: VISUAL
AESTHETIC PROBLEM / CUSTOMER 1. LOW BAKING AND POWDER OVEN SUITABLE TRAINING GIVEN TO OPERATOR
8. NO DULL FINISH DULL FINISH TRAINING TO BE GIVEN SUPERVISOR

96
6

0
DISSATISFACTION QUALITY AND MONITORED
FM :Nil FM/EFCT:
Cause: OPERATOR TRAINING, INCOMING Cause: VISUAL
9. ORANGE PEEL OFF NOT AESTHETIC PROBLEM / CUSTOMER 1. UNSKILLED OPERATOR, LOW CHECKING OF POWDER SUITABLE TRAINING GIVEN TO OPERATOR
ORANGE PEEL TRAINING TO BE GIVEN SUPERVISOR

96
6

0
ALLOWED DISSATISFACTION POWDER QUALITY AND MONITORED
FM :Nil FM/EFCT:
Cause: VISUAL
Cause: POKA YOKE PROVIDED IN JIGS
AESTHETIC PROBLEM / CUSTOMER 1. DAMAGED JIGS, MANUAL SUITABLE TRAINING GIVEN TO OPERATOR
10. NO SCRATCH SCRATCH TRAINING TO BE GIVEN SUPERVISOR

80
5

0
DISSATISFACTION MISHANDLING AND MONITORED
FM :Nil
FM/EFCT:
Cause: Gauge calibration Interact with the Cause: 100% Gauge inspection
1.Gauge allowed the defect Customer ONCE IN THREE MONTHS CALIBRATION PLAN SCHEDULE TO BE
Inspector - QA

0
component CALIBRATION PLAN ADHERED
Operation no.200 A .Customer dissatisfaction FM :Nil FM/EFCT:
1. ANSWERING TO ACC GAUGE Gauge not Answering B. Not able to assemble in vehicle

54
6

6
FINAL ACC GAUGE INSPECTION C. NC Product. Cause: SKILL MATRIX
Cause: On the job Training
SUITABLE TRAINING GIVEN TO OPERATOR
2. Operator not trained TRAINING TO BE GIVEN SUPERVISOR
AND MONITORED
FM :Nil
FM/EFCT:
Cause: VISUAL
Operation no.210 1. NO Cause: Internal monitoring
Dents, damages, scratches, SUITABLE TRAINING GIVEN TO OPERATOR
DENT,DAMAGE,SCRATCHES,MISPL Problem in subsequent operation 1. Mishandling TRAINING TO BE GIVEN SUPERVISOR

80
5

0
misplace AND MONITORED
MOVE TO ASSEMBLY AREA ACE FM :Nil
FM/EFCT:
Operation no.220 Cause: Skill matrix to be prepared & evaluated Cause: 100% Gauge inspection
NO OPERATION SKIP/EXCESS for the inspector. ONCE IN THREE MONTHS CALIBRATION PLAN SCHEDULE TO BE
Operation skip / excess spraying Poor appearance- Customer dissatisfactioN 1. Inadequate inspector skill Inspector - QA

60
5

0
FINAL VISUAL INSPECTION AND SPRAYING CALIBRATION PLAN ADHERED
SPRAY TOUCH UP FM :Nil FM/EFCT:
Cause: Monthly layout Inspection Schedule
Operation no.230 Cause:
A&B 2.Customer dissatisfaction ONCE IN THREE MONTHS LAYOUT LAY OUT INSPECTION PLAN SCHEDULE TO
NO DIMENSION VARIATION Dimension variation & Out of spec 1. Process variation Inspector - QA

72
6

0
c.Nil INSPECTION PLAN BE ADHERED
LAYOUT INSPECTION FM :Nil
FM/EFCT:
Operation no.240 Cause: Dedicated Trolley Visual Inspection
A. Nil Cause:
NO SCRATCHES , LINE MARK,DENT SUITABLE TRAINING GIVEN TO OPERATOR
Scratches, line mark, Dent, damage B.customer dissatisfaction Operator not Trained TRAINING TO BE GIVEN SUPERVISOR

60
5

0
DAMAGE AND MONITORED
C.Nc Product FM :Nil
PACKING FM/EFCT:
Operation no.260 A. Nil Cause: Sample inspection
Cause:
B.Miss match Comp, defect comp send to
QTY AS PER INVOICE Qty Missing As per Invoice 1. Inadequate inspector skill TRAINING TO BE GIVEN QC- engineer Tra8ning to be given

20
4

5
Customer
FM :Nil
DOC AUDIT C.Nil FM/EFCT:
Cause: 100% VISUAL
Cause: Skill matrix to be prepared
A. Nil SUITABLE TRAINING GIVEN TO OPERATOR
144
1. PROPER PACKING Improper packing 1. Unskilled worker AS PER SCHEDULE SUPERVISOR

48
6

8
B 1.Customer dissatisfaction c.Nil AND MONITORED
FM :Nil
FM/EFCT:
Operation no.260
Cause: Material handling to be done as per work
Cause: Internal audit
A. Nil instruction SUITABLE TRAINING GIVEN TO OPERATOR
2. PROPER TROLLEY Improper trolley 2. Improper trolley or bin used AS PER SCHEDULE SUPERVISOR

30
6

5
B 1.Customer dissatisfaction c.Nil AND MONITORED
FM/EFCT:
FM :Nil
DESPATCH TO TVS
Cause: Material handling to be done as per work Cause: Internal audit
A. Nil instruction SUITABLE TRAINING GIVEN TO OPERATOR
3.PREPLANNED TRANSPORTATION Transportation defects 3. Improper trolley or bin used AS PER SCHEDULE SUPERVISOR

25
5

5
B 1.Customer dissatisfaction c.Nil AND MONITORED
FM :Nil FM/EFCT:
Revision Record
Date Rev. No. Revision Details Sign
CONTROL PLAN
Prototype Pre - launch Production
Date ( Org.): Revision No. Revision date
Key Contact person / Phone : Mr.Gireesh Krishnan (AGM)
1 14.05.2016
Control Plan Number :
26.03.2016
Part Number / Latest Change CFT Members: Satish vakundkar, Gireesh Krishnan, Manimaran, Customer Engineering Approval / Date ( if
N9092230 Prabakar,Reddy,
Level : Reqd.)
Supplier / Plant Approval / Date Customer Quality Approval / Date
Part Name / Description : SWING ARM ASSY U180 (if required)

Supplier Supplier Code: Other Approval / Date ( if Reqd.)

Hema Engineering Industries Ltd- Unit IV 20748 Customer information
/ Plant : Other Approval / Date ( if Reqd. )
Part Process Name Machine, Jigs, Characteristics Special Customer Methods Corrective action
Charact- (to be filled up
Process Operation Fixture, Tools specific Product / Process Evaluation / Error Sample Control Method Responsibility Reaction Plan (Also only if the specified
eristics
Number Description for Mfg No Process Product Class requirement Specification Measurement proofing see note below). Reaction Plan does
Size Frequency not work).
if any Tolerance Technique

FREE FROM RUST, DENT, DAMAGE, EVERY

10.01 COMPONENTS - - Nil VISUAL Nil ONCE VISUAL OPERATOR -
EXCESS OIL, DIRT BATCH

Ridoline 1352 BA, Fixodine 50CF,

Granodine 95 2E, Granotonner 130, Supplier test report cross ANY DEVIATION
PRE TREATMENT AND AS PER EVERY
10.02 CHEMICAL Nil Granodine 95 2A, Granostarter ANALYSIS AT LAB Nil ONCE verification & incominge lab CHEMIST OBSERVED- INFORM TO
RECEIVING MATERIAL PHOSPHATING TSES 083 BATCH
10 Manual 16,Granostarter 16 (Shelf life 12 Inspection Report SUPERVISOR
INSPECTION months)

PP [Pure polyster] - Glossy black, Matt

Supplier test report cross ANY DEVIATION
AS PER black, Silver, Yellow shades and Nylon EVERY
10.03 POWDER APPLICATION ON COMPONENTS Nil ANALYSIS AT LAB Nil ONCE verification & incominge lab CHEMIST OBSERVED- INFORM TO
TSES 083 Black. BATCH
Inspection Report SUPERVISOR
(Shelf life 6 months)

ANY DEVIATION
EVERY
20.01 Conveyor Chain CONVEYOR SPEED - Nil 1.2 m/min CONTROL BOARD DISPLAY Nil TWICE CONTROL PANEL OPERATOR OBSERVED- INFORM TO
SHIFT
Conveyor SUPERVISOR
DIFFERENT JIG NOT TO
20.02 JIGS As Per Jig Matrix MA Nil 50 KGS As Per Jig Matrix Nil - - Jig Matrix Displayed OPERATOR
BE USED
EVERY
20.04 HOOK TO HOLD THE COMPONENT - Nil 300MM PITCH VISUAL Nil ONCE VISUAL OPERATOR
BATCH
20 LOADING HOOK
TWO
20.05 HOOK TO HOLD THE COMPONENT - Nil No bend & damage VISUAL Nil ONCE VISUAL OPERATOR
HOURS
NO BEND ,NO HEAVY
NO DEVIATION, COMPONENT TO BE EVERY DAMAGED JIGS TO BE
Jigs 20.06 DEPOSITED POWDER, NO TO HOLD THE COMPONENT - Nil VISUAL Nil ONCE VISUAL OPERATOR
HOLD CORRECTLY BATCH MOVED TO REWORK
DAMAGE
IMPROPER LOADING, DENT, EVERY WORK INSTRUCTION TO BE SEND BACK TO
COMPONENT 20.07 - - Nil NOT ALLOWED VISUAL Nil ONCE SUPERVISOR
DAMAGE,RUST,EXCESS OIL, BATCH DISPLAYED SUPPLIER
30.01 TYPE OF WATER USED PREPARING SOLUTION Ma Nil RAW WATER - Nil - - _ - _
30.02 RAW WATER PH LEVEL - Nil 6. - 8 PH METER/PH PAPER Nil ONCE SHIFT ANALYSIS REPORT CHEMIST INFORM TO SUPPLIER
IN TWO FILL WITH FRESH RAW
BATH SOLUTION
30.03 WATER LEVEL - Mi Nil 1500LTRS VISUAL Nil ONCE HOURS
VISUAL OPERATOR
WATER
- 1500Ltrs
CHEMICALS: RIDOLINE 1352
BA ( M/S HENKEL ADDITION AS PER LAB
30.04
CHEMBOND SURFACE
CONCENTRATION Ma Nil 05 -10 ml TITRATION AT LAB Nil THRICE PER SHIFT ANALYSIS REPORT CHEMIST RECOMMENDATION
TECHNOLOGIS LTD)
CONTROL PANEL/ TWO CLEAN THE HEAT
BURNER 30.05 DIESEL TEMPERATURE - Nil 50-65 DEG. Nil ONCE CHECK THE HEAT EQUIPMENT OPERATOR
EQUIPMENT
THERMOMETER HOURS
ANY DEVIATION INFORM
PRE TREATMENT - PRESSURE GAUGE 30.06 - PRESSURE - Nil 0.8 - 1.2 Kg/Sq Cm PRESSURE GAUGE Nil TWICE IN A SHIFT PRESSURE GUAGES PROVIDED OPERATOR PMD
30 KNOCK OUT
AUTO MOVEMENT OF ANY DEVIATION INFORM
DEGREASING [KOD] CONVEYOR 30.07 - PROCESS TIME - Nil 60 SEC. Nil TWICE IN A SHIFT READ IN CONTROL PANEL OPERATOR
PMD
CONVEYOR
ANY DEVIATION INFORM
SKIMMER 30.08 - OIL SKIMMER - Nil CONTINUOUS RUNNING VISUAL Nil TWICE IN A SHIFT VISUAL OPERATOR SUPERVISOR
SOLUTION SHOULD BE FREE FROM PREVENTIVE MAINTENANCE ANY DEVIATION INFORM
TANK 30.09 TANK CLEANING OF TANK Ma Nil
SLUDGE
MANUAL Nil ONCE PER WEEK SCHEDULE
OPERATOR SUPERVISOR

FLAT FAN
BALL
ANY DEVIATION INFORM
SPRAY NOZZLE 30.10 SPRAY NOZZEL TYPE - JOINT- Nil 48 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE IN A SHIFT MANUALLY OPERATOR SUPERVISOR
P.P [10
LPM]
IN A PREVENTIVE MAINTENANCE ANY DEVIATION INFORM
RISERS 30.11 RISERS - - Nil 8 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE SCHEDULE
SUPERVISOR SUPERVISOR
MONTH
40.01 TYPE OF WATER USED PREPARING SOLUTION Ma Nil RAW WATER - Nil - - _ - _
40.02 RAW WATER PH LEVEL Nil 6. - 8 PH METER/PH PAPER Nil ONCE SHIFT ANALYSIS REPORT CHEMIST INFORM TO SUPPLIER
PER TWO FILL WITH FRESH RAW
40.03 WATER LEVEL - Mi Nil 1500 LTRS VISUAL Nil ONCE HOURS
VISUAL OPERATOR
WATER
BATH SOLUTION - 1500Ltrs
CHEMICALS: RIDOLINE 1352
BA ( M/S HENKEL ADDITION AS PER LAB
40.04
CHEMBOND SURFACE
- Ma Nil 25-30 ml TITRATION AT LAB Nil THRICE PER SHIFT ANALYSIS REPORT CHEMIST RECOMMENDATION
TECHNOLOGIS LTD)
CONTROL PANEL/ TWO CLEAN THE HEAT
BURNER 40.05 DIESEL TEMPERATURE - Nil 55 - 60 DEG. Nil ONCE CHECK THE HEAT EQUIPMENT OPERATOR
EQUIPMENT
THERMOMETER HOURS
ANY DEVIATION INFORM
40 DEGREASING STAGE - 1 PRESSURE GAUGE 40.06 - PRESSURE - Nil 0.8 - 1.2 Kg/Sq Cm PRESSURE GAUGE Nil TWICE IN A SHIFT PRESSURE GUAGES PROVIDED OPERATOR PMD
AUTO MOVEMENT OF ANY DEVIATION INFORM
CONVEYOR 40.07 - PROCESS TIME - Nil 60 SEC. Nil TWICE IN A SHIFT READ IN CONTROL PANEL OPERATOR
CONVEYOR PMD
SOLUTION SHOULD BE FREE FROM PREVENTIVE MAINTENANCE ANY DEVIATION INFORM
TANK 40.08 TANK CLEANING OF TANK Ma Nil
SLUDGE
MANUAL Nil ONCE PER WEEK SCHEDULE OPERATOR SUPERVISOR

FLAT FAN
BALL
ANY DEVIATION INFORM
SPRAY NOZZLE 40.09 SPRAY NOZZEL TYPE - JOINT- Nil 48 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE IN A SHIFT MANUALLY OPERATOR SUPERVISOR
P.P [10
LPM]
IN TWO PREVENTIVE MAINTENANCE ANY DEVIATION INFORM
RISERS 40.10 RISERS - - Nil 8 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE SCHEDULE
SUPERVISOR SUPERVISOR
MONTHS
50.01 TYPE OF WATER USED - Ma Nil RAW WATER - Nil - - _ - _
50.02 RAW WATER PH LEVEL Nil 6. - 8 PH METER/PH PAPER Nil ONCE SHIFT ANALYSIS REPORT CHEMIST INFORM TO SUPPLIER
PER TWO FILL WITH FRESH RAW
50.03 WATER LEVEL - Mi Nil 3000 LTRS VISUAL Nil ONCE HOURS VISUAL OPERATOR
WATER
BATH SOLUTION - 3000 Ltrs
CHEMICALS: RIDOLINE 1352
BA ( M/S HENKEL ADDITION AS PER LAB
50.04
CHEMBOND SURFACE
- Ma Nil 20-25 ml TITRATION AT LAB Nil THRICE PER SHIFT ANALYSIS REPORT CHEMIST RECOMMENDATION
TECHNOLOGIS LTD)
CONTROL PANEL/ TWO CLEAN THE HEAT
BURNER 50.05 DIESEL TEMPERATURE - Nil 50-55 DEG. THERMOMETER
Nil ONCE
HOURS
CHECK THE HEAT EQUIPMENT OPERATOR
EQUIPMENT
ANY DEVIATION INFORM
50 DEGREASING STAGE - 2 SPRAY PUMPS 50.06 - PRESSURE - Nil 0.8 - 1.2 Kg/Sq Cm PRESSURE GAUGE Nil TWICE IN A SHIFT PRESSURE GUAGES PROVIDED OPERATOR PMD
AUTO MOVEMENT OF ANY DEVIATION INFORM
CONVEYOR 50.07 - PROCESS TIME - Nil 180 SEC. CONVEYOR
Nil TWICE READ IN CONTROL PANEL OPERATOR
PMD
SOLUTION SHOULD BE FREE FROM PREVENTIVE MAINTENANCE ANY DEVIATION INFORM
TANK 50.08 TANK CLEANING OF TANK Ma Nil
SLUDGE
MANUAL Nil ONCE PER WEEK SCHEDULE OPERATOR SUPERVISOR

FLAT FAN
BALL
ANY DEVIATION INFORM
SPRAY NOZZLE 50.09 SPRAY NOZZEL TYPE - JOINT- Nil 120 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE IN A SHIFT MANUALLY OPERATOR SUPERVISOR
P.P [10
LPM]
IN TWO PREVENTIVE MAINTENANCE ANY DEVIATION INFORM
RISERS 50.10 RISERS - - Nil 20 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE SCHEDULE
SUPERVISOR SUPERVISOR
MONTHS
60.01 TYPE OF WATER USED - Ma Nil RAW WATER - Nil - - _ - _
60.02 RAW WATER PH LEVEL Nil 6. - 8 PH METER/PH PAPER Nil ONCE SHIFT ANALYSIS REPORT CHEMIST INFORM TO SUPPLIER
PER TWO FILL WITH FRESH RAW
BATH SOLUTION - 1500 Ltrs 60.03 WATER LEVEL - Mi Nil 1500 LTRS VISUAL Nil ONCE HOURS VISUAL OPERATOR
WATER
CONTINUOUS OVER FLOW
ANALYSIS REPORT FROM
60.04 WATER CONCENTRATION OF CHEMICAL Ma Nil 2ML MAXIMUM TITRATION AT LAB Nil THRICE PER SHIFT
LAB
CHEMIST & FRESH RAW WATER
ADDITION
PRESSURE GUAGES ANY DEVIATION
SPRAY PUMPS 60.05 - PRESSURE - Nil 0.8 - 1.2 Kg/Sq Cm PRESSURE GAUGE Nil TWICE IN A SHIFT
PROVIDED
OPERATOR
INFORM PMD
AUTO MOVEMENT OF ANY DEVIATION
CONVEYOR 60.06 - PROCESS TIME - Nil 60 SEC. Nil TWICE IN A SHIFT READ IN CONTROL PANEL OPERATOR
CONVEYOR INFORM PMD
60 WATER RINSE 1
TWO ANY DEVIATION
60.07 OVER FLOW - Nil CONTINUOUS RUNNING VISUAL Nil ONCE CHECK LIST OPERATOR
HOURS INFORM SUPERVISOR
SOLUTION SHOULD BE FREE FROM EVERY PREVENTIVE MAINTENANCE ANY DEVIATION
60.08 - FREQUENCY OF CLEANING Mi Nil VISUAL Nil ONCE OPERATOR
SLUDGE WEEK SCHEDULE INFORM SUPERVISOR
FLAT FAN
BALL
ANY DEVIATION INFORM
SPRAY NOZZLE 60.09 SPRAY NOZZEL TYPE - JOINT- Nil 48 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE IN A SHIFT MANUALLY OPERATOR SUPERVISOR
P.P [10
LPM]
IN THREE PREVENTIVE MAINTENANCE ANY DEVIATION INFORM
RISERS 60.10 RISERS - - Nil 8 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE SCHEDULE
SUPERVISOR SUPERVISOR
MONTHS
70.01 TYPE OF WATER USED - Ma Nil RAW WATER - Nil - - _ - _
70.02 RAW WATER PH LEVEL Nil 6. - 8 PH METER/PH PAPER Nil ONCE SHIFT ANALYSIS REPORT CHEMIST INFORM TO SUPPLIER
PER TWO FILL WITH FRESH RAW
BATH SOLUTION - 1500 Ltrs 70.03 WATER LEVEL - Mi Nil 1500 LTRS VISUAL Nil ONCE HOURS VISUAL OPERATOR
WATER
CONTINUOUS OVER FLOW
ANALYSIS REPORT FROM
70.04 WATER CONCENTRATION OF CHEMICAL Ma Nil 1~ 1.5 ML MAXIMUM TITRATION AT LAB Nil THRICE PER SHIFT
LAB
CHEMIST & FRESH RAW WATER
ADDITION
PRESSURE GUAGES ANY DEVIATION
SPRAY PUMPS 70.05 - PRESSURE - Nil 0.8 - 1.2 Kg/Sq Cm VISUAL Nil TWICE IN A SHIFT
PROVIDED
OPERATOR
INFORM PMD
AUTO MOVEMENT OF ANY DEVIATION
CONVEYOR 70.06 - PROCESS TIME - Nil 60 SEC. Nil TWICE IN A SHIFT READ IN CONTROL PANEL OPERATOR
CONVEYOR INFORM PMD

70 WATER RINSE 2 Cascadadi

ng to TWO ANY DEVIATION
70.07 OVER FLOW Nil CONTINUOUS RUNNING VISUAL Nil ONCE CHECK LIST OPERATOR
Water HOURS INFORM SUPERVISOR
Rinse I
SOLUTION SHOULD BE FREE FROM EVERY PREVENTIVE MAINTENANCE ANY DEVIATION
70.08 - FREQUENCY OF CLEANING Mi Nil VISUAL Nil ONCE OPERATOR
SLUDGE WEEK SCHEDULE INFORM SUPERVISOR
FLAT FAN
BALL
ANY DEVIATION INFORM
SPRAY NOZZLE 70.09 SPRAY NOZZEL TYPE - JOINT- Nil 48 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE IN A SHIFT MANUALLY OPERATOR SUPERVISOR
P.P [10
LPM]
IN THREE PREVENTIVE MAINTENANCE ANY DEVIATION INFORM
RISERS 70.10 RISERS - - Nil 8 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE SCHEDULE
SUPERVISOR
MONTHS SUPERVISOR

80.01 TYPE OF WATER USED - Ma Nil DM [DE MINERALISED] WATER - Nil - - _ - _

80.02 DM WATER PH LEVEL Nil 6.5 - 7.5 PH METER/PH PAPER Nil THRISE SHIFT ANALYSIS REPORT CHEMIST INFORM TO SUPPLIER
PER TWO FILL WITH FRESH DM
80.03 WATER LEVEL - Mi Nil 1500LTRS VISUAL Nil ONCE HOURS VISUAL OPERATOR
WATER
BATH SOLUTION - 1500Ltrs CHEMICALS [FIXODINE 50CF
( M/S HENKEL CHEMBOND ADDITION AS PER LAB
80.04
SURFACE TECHNOLOGIS
CONCENTRATION - Nil 6 - 9ML TITRATION AT LAB Nil THRICE PER SHIFT ANALYSIS REPORT CHEMIST RECOMMENDATION
LTD)]
ANY DEVIATION
80.05 Bath PH LEVEL - Nil 8.0 - 9.5 ANALYSIS AT LAB Nil THRICE IN A SHIFT - OPERATOR
INFORM SUPERVISOR
PRESSURE GUAGES ANY DEVIATION
80 ACTIVATION SPRAY PUMPS 80.06 PRESSURE Nil 0.8 - 1.2 Kg/Sq Cm VISUAL Nil TWICE IN A SHIFT OPERATOR
PROVIDED INFORM PMD
AUTO MOVEMENT OF ANY DEVIATION
CONVEYOR 80.07 PROCESS TIME Nil 60 SEC. Nil TWICE IN A SHIFT READ IN CONTROL PANEL OPERATOR
CONVEYOR INFORM PMD
SOLUTION SHOULD BE FREE FROM EVERY PREVENTIVE MAINTENANCE ANY DEVIATION
80.08 TANK FREQUENCY OF CLEANING - Nil VISUAL Nil ONCE OPERATOR
SLUDGE WEEK SCHEDULE INFORM SUPERVISOR
FLAT FAN
BALL
ANY DEVIATION INFORM
SPRAY NOZZLE 80.09 SPRAY NOZZEL TYPE - JOINT- Nil 48 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE IN A SHIFT MANUALLY OPERATOR SUPERVISOR
P.P [10
LPM]
IN THREE PREVENTIVE MAINTENANCE ANY DEVIATION INFORM
RISERS 80.10 RISERS - - Nil 8 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE SCHEDULE
SUPERVISOR
MONTHS SUPERVISOR

90.01 TYPE OF WATER USED - Ma Nil DM [DE MINERALISED] WATER - Nil - - _ - _

90.02 DM WATER PH LEVEL Nil 6.5 - 7.5 PH METER/PH PAPER Nil TWICE SHIFT ANALYSIS REPORT CHEMIST INFORM TO SUPPLIER
PER TWO FILL WITH FRESH DM
90.03 WATER LEVEL - Mi Nil 3500LTRS VISUAL Nil ONCE HOURS
VISUAL OPERATOR
WATER
CHEMICALS GRANODINE
952 A/E ( M/S HENKEL ADDITION AS PER LAB
BATH SOLUTION - 3500Ltrs
90.04
CHEMBOND SURFACE
CONCENTRATION - Nil 18 - 22ML TITRATION AT LAB Nil THRICE PER SHIFT ANALYSIS REPORT CHEMIST RECOMMENDATION
TECHNOLOGIS LTD)
CONTINUOUS OVER FLOW
ANALYSIS REPORT FROM CHEMIST &
90.05 - FREE ACID - Nil 0.8 TO 1.2ML TITRATION AT LAB Nil THRICE PER SHIFT
LAB OPERATOR
& FRESH DM WATER
ADDITION
TONER VALUE [GRANO
TONER 130 ( M/S HENKEL ADDITION AS PER LAB ANY DEVIATION
90.06 TONER VALUE Nil 2 - 4ML ANALYSIS AT LAB Nil THRICE PER SHIFT OPERATOR
CHEMBOND SURFACE RECOMMENDATION INFORM SUPERVISOR
TECHNOLOGIS LTD)]
CONTROL PANNEL/ TWO CHECK THE HEAT PREVENTIVE
BURNER 90.07 DIESEL TEMP. - Nil 48 - 520C THERMOMETER
Nil ONCE
HOURS EQUIPMENT
OPERATOR
MAINTANENCE
90 PHOSPHATING
PRESSURE GUAGES ANY DEVIATION
SPRAY PUMPS 90.08 - PRESSURE - Nil 0.8 - 1.2 Kg/Sq Cm VISUAL Nil TWICE PER SHIFT
PROVIDED
OPERATOR
INFORM PMD
AUTO MOVEMENT OF TWICE IN A ANY DEVIATION
CONVEYOR 90.09 - TIME - Nil 180 SEC. CONVEYOR
Nil
SHIFT
READ IN CONTROL PANEL OPERATOR
INFORM PMD
TWO ANY DEVIATION
90.10 - DOSING - Nil CONTINUOUS RUNNING VISUAL Nil ONCE
HOURS
MANUALLY OPERATOR
INFORM PMD
SOLUTION SHOULD BE FREE FROM EVERY PREVENTIVE MAINTENANCE ANY DEVIATION
90.11 TANK FREQUENCY OF CLEANING - Nil VISUAL Nil 100% OPERATOR
SLUDGE WEEK SCHEDULE INFORM SUPERVISOR
FLAT FAN
BALL
ANY DEVIATION INFORM
SPRAY NOZZLE 90.12 SPRAY NOZZEL TYPE - JOINT- Nil 132 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE IN A SHIFT MANUALLY OPERATOR SUPERVISOR
P.P [10
LPM]
IN A PREVENTIVE MAINTENANCE ANY DEVIATION INFORM
RISERS 90.13 RISERS - - Nil 22 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE SCHEDULE
SUPERVISOR SUPERVISOR
MONTH
100.01 TYPE OF WATER USED - Ma Nil DM [DE MINERALISED] WATER - Nil - - _ _ -
TWO
100.02 DM WATER PH LEVEL Nil 6.5 - 7.5 PH METER/PH PAPER Nil ONCE
HOURS
ANALYSIS REPORT CHEMIST INFORM TO SUPPLIER

BATH SOLUTION - 1500Ltrs PER TWO FILL WITH FRESH DM

100.03 WATER LEVEL - Mi Nil 1500LTRS VISUAL Nil ONCE HOURS VISUAL OPERATOR
WATER
CONTINUOUS OVER FLOW
ANALYSIS REPORT FROM CHEMIST &
100.04 - ACIDITY - Nil 2ML MAXIMUM ANALYSIS AT LAB Nil THRICE IN A SHIFT
LAB OPERATOR
& FRESH DM WATER
ADDITION
ADDITION OF FRESH DM ANY DEVIATION
100.05 CHEMICALS P LEVEL
H - Nil 5.5 ~ 6.2 ANALYSIS AT LAB Nil THRICE IN A SHIFT
WATER
OPERATOR
INFORM SUPERVISOR
TWICE IN A PRESSURE GUAGES ANY DEVIATION
SPRAY PUMPS 100.06 - PRESSURE - Nil 0.8 - 1.2 Kg/Sq Cm VISUAL Nil 100%
SHIFT PROVIDED
OPERATOR
INFORM PMD
100 DM RINSE I AUTO MOVEMENT OF TWICE IN A ANY DEVIATION
CONVEYOR 100.07 - PROCESS TIME - Nil 60 SEC. CONVEYOR
Nil
SHIFT
READ IN CONTROL PANEL OPERATOR
INFORM PMD
TWO ANY DEVIATION
100.08 OVER FLOW - Nil CONTINUOUS RUNNING VISUAL Nil ONCE
HOURS
CHECK LIST OPERATOR
INFORM SUPERVISOR
SOLUTION SHOULD BE FREE FROM EVERY PREVENTIVE MAINTENANCE ANY DEVIATION
100.09 - FREQUENCY OF CLEANING - Nil VISUAL Nil 100% OPERATOR
SLUDGE WEEK SCHEDULE INFORM SUPERVISOR
FLAT FAN
BALL
ANY DEVIATION INFORM
SPRAY NOZZLE 100.10 SPRAY NOZZEL TYPE - JOINT- Nil 48 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE IN A SHIFT MANUALLY OPERATOR SUPERVISOR
P.P [10
LPM]
PREVENTIVE MAINTENANCE ANY DEVIATION INFORM
RISERS 100.11 RISERS - - Nil 8 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE IN 3 MONTH SCHEDULE
SUPERVISOR SUPERVISOR
110.01 TYPE OF WATER USED - Ma Nil DM [DE MINERALISED] WATER - Nil - - _ - _
TWO
110.02 DM WATER PH LEVEL Nil 6.5 - 7.5 PH METER/PH PAPER Nil ONCE
HOURS
ANALYSIS REPORT CHEMIST INFORM TO SUPPLIER

PER TWO FILL WITH FRESH DM

110.03 WATER LEVEL - Mi Nil 1500LTRS VISUAL Nil ONCE HOURS VISUAL OPERATOR
WATER
BATH SOLUTION - 1500 Ltrs
CONTINUOUS OVER FLOW
ANALYSIS REPORT FROM CHEMIST &
110.04 - ACIDITY - Nil 1 ~ 1.5 ML MAXIMUM ANALYSIS AT LAB Nil THRICE IN A SHIFT
LAB OPERATOR
& FRESH DM WATER
ADDITION
ADDITION OF FRESH DM ANY DEVIATION
110.05 CHEMICALS PH LEVEL - Nil 6.5~7.2 ANALYSIS AT LAB Nil THRICE IN A SHIFT
WATER
OPERATOR
INFORM SUPERVISOR
PRESSURE GUAGES ANY DEVIATION
SPRAY PUMPS 110.06 - PRESSURE - Nil 0.8 - 1.2 Kg/Sq Cm VISUAL Nil TWICE PER SHIFT
PROVIDED
OPERATOR
INFORM PMD
AUTO MOVEMENT OF ANY DEVIATION
110 DM RINSE II CONVEYOR 110.07 - PROCESS TIME - Nil 60 SEC. CONVEYOR
Nil TWICE PER SHIFT READ IN CONTROL PANEL OPERATOR
INFORM PMD
Cascadadi
TWO ANY DEVIATION
110.08 OVER FLOW ng to DM Nil CONTINUOUS RUNNING VISUAL Nil ONCE
HOURS
CHECK LIST OPERATOR
INFORM SUPERVISOR
Rinse I
SOLUTION SHOULD BE FREE FROM EVERY PREVENTIVE MAINTENANCE ANY DEVIATION
110.09 TANK FREQUENCY OF CLEANING - Nil VISUAL Nil ONCE OPERATOR
SLUDGE WEEK SCHEDULE INFORM SUPERVISOR
FLAT FAN
BALL
ANY DEVIATION INFORM
SPRAY NOZZLE 110.10 SPRAY NOZZEL TYPE - JOINT- Nil 48 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE IN A SHIFT MANUALLY OPERATOR SUPERVISOR
P.P [10
LPM]
PREVENTIVE MAINTENANCE ANY DEVIATION INFORM
RISERS 110.11 RISERS - - Nil 8 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE IN 3 MONTH SCHEDULE
SUPERVISOR SUPERVISOR
120.01 TYPE OF WATER USED - Ma Nil DM [DE MINERALISED] WATER - Nil - - _ - _
TWO
120.02 DM WATER PH LEVEL Nil 6.5 - 7.5 PH METER/PH PAPER Nil ONCE
HOURS
ANALYSIS REPORT CHEMIST INFORM TO SUPPLIER

PER TWO FILL WITH FRESH DM

120.03 WATER LEVEL - Mi Nil 1500LTRS VISUAL Nil ONCE HOURS VISUAL OPERATOR
WATER
BATH SOLUTION - 1500 Ltrs
CONTINUOUS OVER FLOW
ANALYSIS REPORT FROM CHEMIST &
120.04 - ACIDITY - Nil 0.5 ~ 1.0 ML MAXIMUM ANALYSIS AT LAB Nil THRICE IN A SHIFT
LAB OPERATOR
& FRESH DM WATER
ADDITION
ADDITION OF FRESH DM ANY DEVIATION
120.05 CHEMICALS P LEVEL
H - Nil 6.5~7.2 ANALYSIS AT LAB Nil THRICE IN A SHIFT
WATER
OPERATOR
INFORM SUPERVISOR
PRESSURE GUAGES ANY DEVIATION
120 DM RINSE III
SPRAY PUMPS 120.06 - PRESSURE - Nil 0.8 - 1.2 Kg/Sq Cm VISUAL Nil TWICE PER SHIFT
PROVIDED
OPERATOR
INFORM PMD
AUTO MOVEMENT OF ANY DEVIATION
CONVEYOR 120.07 - PROCESS TIME - Nil 60 SEC. CONVEYOR
Nil TWICE PER SHIFT READ IN CONTROL PANEL OPERATOR
INFORM PMD
SOLUTION SHOULD BE FREE FROM EVERY PREVENTIVE MAINTENANCE ANY DEVIATION
120.08 TANK FREQUENCY OF CLEANING - Nil VISUAL Nil ONCE OPERATOR
SLUDGE WEEK SCHEDULE INFORM SUPERVISOR
FLAT FAN
BALL
ANY DEVIATION INFORM
SPRAY NOZZLE 120.09 SPRAY NOZZEL TYPE - JOINT- Nil 48 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE IN A SHIFT MANUALLY OPERATOR SUPERVISOR
P.P [10
LPM]
PREVENTIVE MAINTENANCE ANY DEVIATION INFORM
RISERS 120.10 RISERS - - Nil 8 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE IN 3 MONTH SCHEDULE
SUPERVISOR SUPERVISOR
DEGENERATION OF DM OPERATOR / ANY DEVIATION
DIRECT PIPE LINE 130.01 DM WATER CONDUCTIVITY - Nil < 30 MS CONDUCTIVITY METER Nil THRISE PER SHIFT
PLANT SUPERVISOR INFORM SUPERVISOR
TWO
130.02 DM WATER PH LEVEL - Nil 6.5 - 7.5 PH METER/PH PAPER Nil ONCE
HOURS
ANALYSIS REPORT CHEMIST INFORM TO SUPPLIER

FLAT FAN
130 DM MIST BALL
ANY DEVIATION
SPRAY NOZZLE 130.03 SPRAY NOZZEL TYPE - JOINT- Nil 8 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE IN A SHIFT MANUALLY OPERATOR
INFORM SUPERVISOR
P.P [1
LPM]
PREVENTIVE MAINTENANCE ANY DEVIATION INFORM
RISERS 130.04 RISERS - - Nil 2 NOS FREE FROM BLOCKAGE VISUAL Nil ONCE IN 3 MONTH SCHEDULE
SUPERVISOR SUPERVISOR
INFORM ANY
BURNER 140.01 DIESEL OVEN TEMPERATURE - Nil 150±10 ° C CONTROL PANNEL Nil ONCE
IN TWO
HOURS
CHECK LIST OPERATOR DEVIATION TO
SUPERVISOR
EVERY PREVENTIVE MAINTENANCE CLEANING EVERY
BLOWER & EXHAUST 140.02 HOT AIR AIR CIRCULATION - Nil TO BE RUN CONTINUOSLY VISUAL Nil ONCE PMD
WEEK SCHEDULE WEEK
140 WATER DRY OFF OVEN
TWICE IN A ANY DEVIATION
CONVEYOR 140.03 PROCESS TIME - Nil 15 MIN. READ IN CONTROL BOARD Nil 100%
SHIFT
READ IN CONTROL PANEL OPERATOR
INFORM SUPERVISOR
EVERY PREVENTIVE MAINTENANCE CLEAN / REPLACE NEW
FILTER 140.04 FILTER DUST COLLECTION - Nil NOT ALLOWED VISUAL Nil ONCE SUPERVISOR
WEEK SCHEDULE FILTER
FREE FROM PRE TREATMENT EVERY ANY DEVIATION
150.01 PHOSPATING PARTS - Nil VISUAL Nil 100% VISUAL OPERATOR
DEFECTS BATCH INFORM SUPERVISOR
COMPLETELY DRY FROM WATER / IN TWO ANY DEVIATION
150.02 COMPONENTS OIL FREE AIR BLOWER - Nil VISUAL Nil ONCE VISUAL OPERATOR
CHEMICAL HOURS INFORM SUPERVISOR

150 AIR BLOW & MASKING MANUAL PHOSPATING BATH

ANALYSIS REPORT FROM
150.03 COATING THICKNESS Nil 2.00 to 2.80 Gms/M Sq WEIGHING SCALE Nil ONCE SHIFT CHEMIST PARAMETERS TO BE
LAB
CHECKED
SILICON BASED [SPECIFIED MASK TO
VCS DISPLAYED AS PER ANY PROBLEM
150.04 TYPE OF MASK AS PER MATRIX - Nil BE USED FOR THE COMPONENTS VISUAL Nil - - OPERATOR
MATRIX CONTACT SUPERVISOR
WHERE EVER REQUIRED]
INFORM ANY
EVERY VCS DISPLAYED AS PER
160.01 PART AS PER MATRIX - Nil AS PER CUSTOMER DRAWING VISUAL Nil 3 Nos SUPERVISOR DEVIATION
BATCH MATRIX
SUPERVISOR
PURE POLYSTER (M/S MARPOL PVT 1 No / IF FOUND NOT OK,
EVERY REFER SUPPLIER TEST
160.02 TYPE OF POWDER - Nil LTD) NYLON(M/S MAHARANI PAINTS SUPPLIER TEST CERTIFICATE Nil Supplier SUPERVISOR SEND BACK TO
BATCH CERTIFICATE
LTD) Panel SUPPLIER

POWDER ANY DEVIATION TO BE

EVERY
160.03 FINISH (COLOUR) - Nil AS PER CUSTOMER REQUIREMENT VISUAL Nil ONCE LIST TO BE DISPLAYED SUPERVISOR INFORMED TO
BATCH
SUPERVISOR
DURING
INFORM ANY
MIXING RATIO [VIRGIN POWDER ADDITION WORK INSTRUCTION TO BE
160.04 RECOVERY POWDER
Vs RECOVERY POWDER]
- Nil 80 : 20 WEIGHING SCALE Nil ONCE
OF NEW DISPLAYED
OPERATOR DEVIATION
SUPERVISOR
POWDER
IN TWO ADJUST THE PRESSURE IN ANY PROBLEM
160.05 FLUIDISING PRESSURE - Nil 5 - 10 PSI (0.2 - 0.5Kg Sq Cm CHECK LIST Nil ONCE
HOURS MONITOR
OPERATOR
CONTACT SUPERVISOR
160 POWDER COATING POWDER
IN TWO ADJUST THE FLOW METER ANY PROBLEM
GUN MONITOR 160.06 FLOW RATE - Nil 250 - 350 gms/min CHECK LIST Nil ONCE
HOURS IN MONITOR
OPERATOR
CONTACT SUPERVISOR
IN TWO ADJUST VOLTAGE IN ANY PROBLEM
160.07 SPRAY GUN VOLTAGE - Nil 70 - 100 KVA Nil ONCE
HOURS MONITOR
OPERATOR
CONTACT SUPERVISOR
IN TWO ANY PROBLEM
160.08 AIR PRESSURE - Nil 0.2 - 0.5kg/sq cm CHECK LIST Nil ONCE
HOURS
ADJUST PRESSURE OPERATOR
CONTACT SUPERVISOR
PROPER CLEANING TO BE
FOR EVERY
ENSURED BEFORE ANY PROBLEM
BOOTH 160.09 BOOTH CONDITION - - Nil FREE FROM DUST VISUAL Nil 100% COLOR OPERATOR
CHANGING THE COLOR CONTACT SUPERVISOR
CHANGE
SHADE
PREVENTIVE MAINTENANCE ANY DEVIATION
FILTERS 160.10 CARTRIDGE FILTER FILTRATION - Nil BELOW 5 MICRONS WILL BE FILTERED VISUAL Nil - - PMD
SCHEDULE REPLACE NEW ONE
EVERY PREVENTIVE MAINTENANCE ANY DEVIATION
CATRIDGE FILTER 160.11 FILTRATION - Nil NO CHOKE VISUAL Nil 100% SUPERVISOR
WEEK SCHEDULE REPLACE NEW ONE
EMASKING & EVERY ANY DEFECT -
170 170.1 COATED PARTS - Nil FREE FROM UNCOVERAGE & DUST VISUAL Nil 100% VCS TO BE DISPLAYED OPERATOR
INSPECTION BATCH REWORK
THERMOGRAPH STUDY
IN TWO NOTE DOWN TEMP. AT CHEMIST &
180.01 DIESEL OVEN TEMPERATURE FOR - Nil SET TEMPERTURE 240±10° C) CONTROL BOARD DISPLAY Nil ONCE ONCE IN A MONTH OR
HOURS CONTROL BOARD SUPERVISOR
BURNER HEAT PAPER
Travelling teparature Record Glossy - Nil EMT 180 Per 15MIN
0/
TTR Equipment Nil IN A CHEMIST & To Be Ensure proper Hot
180.02 TTR ONCE LAB TEST REPORT
Travelling teparature Record Matt - Nil EMT 2000/Per 10MIN TTR Equipment Nil MONTH SUPERVISOR Air circulation
EVERY PREVENTIVE MAINTENANCE BURNER CLEANING
180 POWDER CURING BLOWER 180.03 HOT AIR AIR CIRCULATION - Nil TO BE RUN CONTINUOSLY VISUAL Nil 100% PMD
WEEK SCHEDULE EVERY WEEK
EVERY PREVENTIVE MAINTENANCE ANY DEVIATION
EXHAUST 180.04 - Nil TO BE RUN CONTINUOSLY VISUAL Nil 100% PMD
WEEK SCHEDULE INFORM SUPERVISOR
IN TWO ANY DEVIATION
CONVEYOR 180.05 PROCESS TIME - Nil 35 MIN. READ IN CONTROL BOARD Nil ONCE READ IN CONTROL PANEL OPERATOR
HOURS INFORM SUPERVISOR
PREVENTIVE MAINTENANCE ANY DEVIATION
FILTERS 180.06 CARTRIDGE FILTER FILTRATION - Nil BELOW 5 MICRONS WILL BE FILTERED VISUAL Nil - - PMD
SCHEDULE REPLACE NEW ONE
INSPECTED PARTS TO BE UNLOADED IN TWO ANY DEVIATION
TROLLY 190.01 POWDER COATED PARTS UNLOADING - Nil VISUAL Nil ONCE - OPERATOR
IN DEDICATED TROLLEY HOURS INFORM SUPERVISOR
FREE FROM
UNCOVERAGE,OVERFLOW, DUST,
OOSEOUT,BLISTER, EVERY OPERATOR /
190.02 APPEARENECE - Nil VISUAL Nil 100% VISUAL ANY DEFECT REWORK
PINHOLE,OILPATCH,DULL BATCH SUPERVISOR
SCRATCHES , ORANGEPEEL, PAINT
RUN DOWN.
1Panel/
Batch EVERY ANY DEVIATION
LAB TEST REPORT CHEMIST
&1Part/Shif BATCH INFORM SUPPLIER
45 MICRONS MINIMUM NYLON t/Model
ELCOMETER 190.03 - COATING THICKNESS - Nil THICKNESS GAUGE Nil
BLACK- MINM 140 MICRONS
5No's/Part
EVERY ANY DEVIATION
No/Model/S LAB TEST REPORT CHEMIST INFORM SUPERVISOR
BATCH
hift
1 No /
95% for PP Black, Max 3% for PP Matt, EVERY ANY DEVIATION
GLOSSO METER 190.04 GLOSS VALUE Nil GLOSSO METER Nil Supplier LAB TEST REPORT CHEMIST INFORM SUPPLIER
@ 600 BATCH
Panel
1 No /
EVERY ANY DEVIATION
Supplier LAB TEST REPORT CHEMIST INFORM SUPPLIER
BATCH
BIRLA 3M-600 SCOTCH NO RUST,PEEL OFF, CRACK, BLISTER, Panel
190.05 - ADHESION TEST - Nil CROSS HATCH TAPE TEST Nil
TAPE CHALKING SHALL BE OBSERVED PER
ANY DEVIATION
1NO MODEL / LAB TEST REPORT CHEMIST
INFORM SUPERVISOR
SHIFT
SHOULD NOT SHOW OF BLISTERS, 1 No /
EVERY ANY DEVIATION
CORROSION SPOTS ,PEEL OFF, Supplier LAB TEST REPORT CHEMIST INFORM SUPPLIER
NEUTRAL SALT SPRAY TEST BATCH
COLOUR FADING AND ANY OTHER Panel
SALT SPRAY CHAMBER 190.06 - CORROSION RESISTANCE TEST Nil WITH CROSS MARK. FERROUS Nil
HARMFULL DEFECT.CREEP SHALL BE PER
PARTS 500 HOUR MINIMUM. ANY DEVIATION
NOT MORE THAN 3MM ON EACH SIDE ONCE MODEL / LAB TEST REPORT CHEMIST
OF THE CROSS MARK. INFORM SUPERVISOR
MONTH
1 No /
THERMAL TEST. COMPONENT EVERY ANY DEVIATION
Supplier LAB TEST REPORT CHEMIST INFORM SUPPLIER
NO BLISTERS OR PEEL OFF SHOULD IS TO BE KEPT IN DM WATER BATCH
Panel
HOT WATER CHAMBER 190.07 - HOT WATER RESISTANCE TEST Nil BE NOTICED AT THE END OF AT A TEMP. OF 70±5° C FOR 1 Nil
UNLOADING & FINAL ADHESION TEST HOUR. DO ADHESION TEST PER
190 ANY DEVIATION
INSPECTION AFTER ONE HOUR 1NO MODEL / LAB TEST REPORT CHEMIST INFORM SUPERVISOR
SHIFT
1 No /
EVERY ANY DEVIATION
Supplier LAB TEST REPORT CHEMIST INFORM SUPPLIER
NO SIGNS OF BLISTER, CORROSION KEEP THE COMPONENT FOR BATCH
Panel
OR LOSS OF ADHESION ON THE 240 HOURS AT 40° C AND 98%
HUMIDITY CHAMBER 190.08 - HUMIDITY TEST Nil Nil PER
POWDER COATED SURFACE AFTER ±1% RH IN HUMIDITY
THE TEST. CHAMBER. MODEL / ANY DEVIATION
1NO LAB TEST REPORT CHEMIST INFORM SUPERVISOR
ONCE IN 3
MONTH
PLACE ONE DROP OF 0.1%
NO SIGNS OF BLISTER, CORROSION OF SULPHURIC ACID ON 1 No /
EVERY ANY DEVIATION
190.09 - ACID RESISTANCE TEST - Nil SPOTS, PEEL OFF AND COLOUR THE COATING AND LEAVE IT Nil Supplier LAB TEST REPORT CHEMIST
BATCH INFORM SUPPLIER
CHANGE FOR 24 HOURS AT ROOM Panel
TEMPERATURE

THE COMPONENT TO BE
EXPOSED FOR 500 HOURS
DURING AND AFTER THE TEST
IN WEATHEROMETER AND
THERE SHOULD BE NO BLISTER ,
ASSESSED AS PER TEST
ACCELERATED WEATHERING PEEL OFF , FADING, 5 BATCH AS PER SUPPLIER TEST SEND THE POWDER
WEATHEROMETER 190.10 - - Nil CYCLE GIVEN BELOW. TEST Nil ONCE CHEMIST
TEST CHALKING , .MAXIMUM ONCE REPORT RETURN TO SUPPLIER
CYCLE, 4 HOURS
PERMISSABLE LOSS BY GLOSSY
CONDENSATE AT 45 DEG. 4
AFTER THE TEST : 20%
HOURS UV RADIATION AT
50 DEG
1 No /
HARDNESS TEST : USE 2H EVERY ANY DEVIATION
Supplier LAB TEST REPORT CHEMIST
PENCIL AT 45° ANGLE TO BATCH INFORM SUPPLIER
Panel
2H PENCIL 190.11 TYPE OF PENCEIL USED EFFECTIVE SURFACE AND - Nil 2H PENCIL SCRATCH TEST Nil
SPEED OF 3MM/SEC APPLYING PER INFORM ANY
MAX PRESSURE TO PENCIL ONCE MODEL / LAB TEST REPORT CHEMIST DEVIATION TO
DAY SUPERVISOR
NO PEEL OFF THE POWDER TEST PIECE OF 20X20 CM 1 No /
FLEXIBILITY EVERY SUPPLIER TEST PANEL
190.12 - - Nil COATING AT THE END OF MANUAL SHOULD BE BENT UPTO Nil Supplier CHEMIST -
TEST BATCH WITH CERTIFICATE
BEND [CONICAL] TEST 2MM Panel
Note: All Dimension are in mm unless otherwise specified.
LEGENDS FOR CONTROL IN CHARGE LEGENDS FOR SPECIAL CHARACTERISTIC CLASS
S PATROL INSPECTOR C - CRITICAL D.H.G. Digital Height Gauge P.G.G.- Plug Gap Gauge
O OPERATOR Ma - MAJOR D.V.C. Vernier Caliper R.G. - Receiver Gauge
FFP FIRST FIVE PARTS Mi - MINOR LFP LAST FIVE PARTS P.G. - Plug Gauge
5 N = No. of samples to be checked, C = No. of defectives permitted
4 Note: Reaction Plan: Whenever the Process Parameters or Product Characteristics are found non-conforming, quarantine the pieces produced after
3 the last product characteristic check, identify with Yellow Colour label and re-inspect 100%. Remove Non-conforming products and identify with Red
2 Colour Tag. Make entry in Production Log Book and inform Team Leader / Charge-hand and Supervisor.
1 Customer Drawing number changed from G4300280 C1 to G4300289 L4 14.05.2016
0 Control plan updated as per AVB audit requirement 26.03.2016 PREPARED BY: APPROVED BY: Date:
Sl. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved Riyaz Mubarak .M Manimaran .G 27/02/2016
Part description Part Number Rev No & date
XXXXXXX XXXXX XXXXX
SlNo Quality
characteristic Spl Char Class Cpk Target UOM
description

I Appearance

1 Flow mark Visual

2 Short fill Visual

Flash at Ejector
3 pins & parting line
Visual

4 Sink Mark Visual

5 Pin mark Visual

6 Strain mark Visual

7 Weld Line Visual

8 Warpage Visual
Damage on
9 textured area
Visual

10 Burn mark Visual

11 Hole blockage Visual

12 Streak Visual

13 Deepcut Visual

14 Degating Visual
Lock Rib bend
15 /Crack
Visual

16 Scoring mark Visual

17 Colour Visual
Wrong direction
29 assy (Mud flap)
Visual
30 Assy part miss Visual
31 Finish (Mud Flap) Visual
II Material
1 PP-3 SJS 1012 Bag

2 MFI (PP 3) grams/10 min

Ash content (PP

3 % Talc filled
3)

4 PP-13 C080MA Bag

5 MFI (PP13 ) grams/10 min

6 U Black Source Bag

III Reliability & Performance.
Material to
1 withstand UV Hours
resistance
IV Dimensional
1 63.8 ± 0.5 mm mm
10+0.3 mm,
10+0.3 mm to be attribute ( OK/Not
2 confirmed in OK)
panel checker
V Other General Requirements

VI Submission of Reports to TVSM SCHEDULE

# Report Type Contents in report
1 RM TC Supplier report
2 Lay out inspectio Inspection report
VII Specific Requirement

General Remarks :

TVSM Part Specific Inspe

# Revision Details
1 Initial review

Person responsible
Name :
Designation :
Sign & Date :
Notes -
Quality characteristic description: Dimension or parameter to be inspected

Spl Char Class : Parameter realted

Safety to -
/Regulatory Critical Fit /Function

Specification : Acceptance criteria

Cpk Targets : Type of Special Characteristics
Safety / Regulatory (Severity - 9 & 10)
Fit / Finish - Critical (Severity - 7 & 8)
Fit / Finish - Major (Severity - 5 & 6)

Means of Inspection : Inspection instrument, equipment, jigs, fixtures, etc. used for inspection
Stage of control : Stage at which inspection is carried out at diffent stages of processes (e.g.In
Frequency at Supplier end : Frequency of inspection carried out at supplier end - To be filled b
Inspection method can be added as separate annexure (if reqd)
TVSM Part Specific Inspection Plan ( Agreement of Inspection )
Sup . Drawing Sup Drg Rev
Model Supplier Name Supplier Code
No No. & Date
XXXX NA NA XXXX XXXX

Stage of
Specification Tolerance Means of Inspection Frequency at Supplier end
control

Sample Size
In process online
Not Allowed Visual 5 nos
inspection
In process online
Not Allowed Visual 5 nos
inspection
In process online
Not Allowed Visual 5 nos
inspection
As per AAR In process online
Not Allowed Visual 5 nos
sample inspection
In process online
Not Allowed Visual 5 nos
inspection
In process online
Not Allowed Visual 5 nos
inspection
As per AAR In process online
Not Allowed Visual 5 nos
sample inspection
In process online
Not Allowed Visual 5 nos
inspection
In process online
Not Allowed Visual 5 nos
inspection
In process online
Not Allowed Visual 5 nos
inspection
In process online
Not Allowed Visual 5 nos
inspection
In process online
Not Allowed Visual 5 nos
inspection
In process online
Not Allowed Visual 5 nos
inspection
Uneven surface In process online
Visual 5 nos
not allowed inspection
In process online
Not Acceptable Visual 5 nos
inspection
In process online
Not Acceptable Visual 5 nos
inspection
In process online
Delta E Less than 1.0 Spectrometer 5 nos
inspection
Not acceptable Visual Final inspection 100%
Not acceptable Visual Final inspection 100%
Enmould Visual Final inspection 100%
As per TSMS M/s Basel Test
Incoming Every lot
9745 certificate
Every 6th Lot
11 ±2.0 MFI testing machine inspection @ 6th Lot
incoming
Every 6th Lot
20 ±2.0 Muffle furnace inspection @ 6th Lot
incoming
As per TSMS M/s Reliance
Incoming Every lot
9745 Test certificate
Every 6th Lot
9 ±1.0. MFI testing machine inspection @ 6th Lot
incoming
M/s Konkan
Konkan Incoming Every lot
Test certificate

up to 1500 hrs Min 1500 Hrs UV Chamber Off line 1 Sheet

63.8 ± 0.5 Vernier FI 1 part

Answering Panel Checker Data sheet 3 nos

s in report Frequency Format

6 months Supplier TC
6 months TVSM format

TVSM Part Specific Inspection Plan latest as on :

Revision Details Revised by
Initial review

For Supplier For TVS- M

tion Major Fit /Function

Geometrical
l Characteristics Non Geometrical Dimensions
Dimensions
1.67 1.33
1.67 1.33
1.33 1

xtures, etc. used for inspection with a specific instruction on reference plane,location and other inspection related instructions. -
ent stages of processes (e.g.In-process inspection , Final inspection ,Pre-despatch inspection, etc.). - To be filled by supplier
at supplier end - To be filled by Supplier
ent of Inspection )
Supplier Code Plant Location
XXXX XXX

quency at Supplier end Remarks:

Sample
Frequency
Every lot

Every lot

Every lot
Every lot
Every lot
Every lot

SAP triggering lot

Every lot

SAP triggering lot

Every lot

Once in year

1 per shift Control chart

Once in production
Onerun
production call one lot

Reporting Method
Through mail

Revised by Date

For TVS- M
spection related instructions. - To be filled by supplier
c.). - To be filled by supplier
Agreement Of Inspection
Supplier name and plant location : XXXX
Part no : XXXX Rev no. / date : XXXX Part name : XXXX Model : XXX
Submission for : Alternate source

# Aspects TVS-M requirements

A Incoming control at supplier end

1.Inspection Standard and reports for the same
Availablity of Child Part Inspection 2.Supplier shall ensure deployment of special
A1 standard and its relavnt reports including characteristics and its control .
Cpk 3.PPAP approval of child parts
4.Lay out inspection Plan and its adherence

B In process control at supplier end

Availablity of approved control plan by TVSM shall audit the process as per approved control
B1
TVSM plan

C Outgoing control at supplier end

Adherence to agreed frequency of testing and report
C1 Layout inspection & functional testing
submission to TVSM. (Refer Annexure)
Shall be performed by supplier and reports shall be
C2 Pre-delivery inspection
updated thorugh On line inspection report updation.
C3 Master samples, Limit samples Validation to be carried out
Check list to be prepared and agreed with the supplier.
C4 Dock Audit
This includes packaging & transportation requirements
D General requirements
1.Lot rejection : Zero lot rejection (Direct on-line)
2.Line rejection -100 PPM
D1 PPM - Target 100 PPM 3.Warranty - 100 PPM,
4.Reliability / Durability as per TVS-M
requirements.
Warranty agreement(if applicable) - for Shall be made exclusively by supplier and signed off by
D2
properietary parts . TVSM
Change management
a) Initial Submission
b) Engineering Changes(ECN) -
Design / Process
c) Tooling - Transfer
, Replacement , Refurbishment or
additional d) 1.Follow PPAP notification route : Notification shall be
Tooling inactive > 1 Year informed in advance & get approval from TVS-M .
D3 e) Change to optional design /
Material f) Sub 2.Change details shall be notified through "Change
contractor / Raw Material source Request Form" .
change
g) Parts produced at additional location
h) Layout Change
i) Offloading to sub-
contractors . j)
Subcontractors to in-house
PART SPECIFIC INSPECTION
E REFER ANNEXURE
STANDARD
Important note : Ensuring adherence to Agreement Of Inspection shall not absolve the supplier of t

The contents of check list for agreement of inspectiion acknowledged & accepted .
Person responsible For Supplier
Name :
Designation :
Sign & Date :
ment Of Inspection and Testing

Supplier Report formats

Inspection / Audit Report submission
Agreement for submission
frequency at supplier end frequency to TVS-M
(Yes / No) to TVS-M

Once in 6 months Not Applicale NO NA

Pokayoke audit - Daily /

weekly
Other special controls audit -
To be retained at supplier end YES Supplier Format
as per approved control plan

As Per AOI As Per AOI YES Supplier Format

updation in
Every lot updation in website YES Tradewithtvs.com
Every 3 months To be retained at supplier end YES
To be agreed with the supplier To be retained at supplier end YES

Indiviual Quality
----- ----- YES rating map
monitoring

Not Applicable Not Applicable NO NA

Before approval & Before approval & Mail
implementation implementation
YES communication

bsolve the supplier of the responsibility of conformity to all TVS-M requirements.

For TVS- M
Remarks
COMPONENT SUPPLY CHAIN CHART (CSCC)

Part description Part Number Rev No & date Model Sup Drg Rev No. & Date

Guidelines:
1. Sub supplier of Parts/Rawmaterials/sub processes/ special processes like Plating,Heat treatment,etc to be covered in CSCC
2. Parent - Child Relationship, graphical representation to be shown.
3. To be included in PPAP submission as customer specific requirement
4. To be amended and approved as part of Change Control Management System ( In case Change in Supply chain)
5.As per Supplier Manual for Rawmaterial, Special Processes,etc., - TVSM approved sources to be used.

Supplier Feature
Product Structure

Tier 1 Tier 2 ………….N

Supplier
Name

Rev No Date Revision Details

Signature
and Prepared By

Designation
CHAIN CHART (CSCC)

Sup Drg Rev No. & Date Supplier Name Supplier Code Plant Location

tment,etc to be covered in CSCC

nge in Supply chain)

o be used.

Supplier Feature
Manufacturing Plant Tier 2 …. N

Location

Tier 2 …N
Approved by Tier 2 …N
QMS
TVSM Refer Certification Tier 2 …N
Guideline 5
Tier 2 …N ( ISO-TS QMS
PPAP Status ( 16949 / ISO Certification
Plant Name Country State. City (Yes/No) Yes/No/NA) 9001) Validity

Revised by
Approved By

Quality Head / Production Head/Unit Head

Photographs of Fixtures,Tools, Gauges and Tes
Part Name XXXXX

Supplier Name XXXXX

Description (pl specify the details of the
Sl. No Photograph
facilities)

Core Side- Fender Front Rear

1
(K6222000)

Cavity Side - Fender Front Rear

2
(K6222000)

3 Core Side- Mudflap (K6222230)

4 Cavity Side - Mudflap (K6222230)

Hole mounting Gauge (Gauge

5
No:6300267)

Hole mounting Gauge with part (Gauge

6
No:6300267)

Name Signed by
Prepared by

Checked by

Approved by
auges and Testing facility
Part No. & Rev : xxxxxx

Plant Location : xxxxx

Remarks

Single Cavity

2 cavity

Assembly ( Fender Front Rear + Mud Flap)

Signed date
Date 13.01.2016

Date 13.01.2016

Date 13.01.2016
SUPPLIER LOGO PACKAGING DATA SHEET

Part Number xxxx

Supplier Code xxxx

Address xxxxx

Phone No.

Packing Details
Packing Type Primary

Material Crates (Green)

Specification 560x450x315 mm

Quantity Packed 16 nos / Crate

Packing Snapshots

Returnable Method

Non-returnable

Prepared by
Packing Number :

Rev (orgin) :

Description :

Name :

E-mail ID :

Contact Person :

king Details
Secondary

2 Ply carton sheet & Foam sheet

610x410 mm & 325 x 225 mm

1 no & 16 nos

Approved by

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