Doc. No.

: PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172528'3'-MCD-03-04 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-08 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.com
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

1. Set up Approval(QC-MCN-
1.Set up Approval(QC-MCN-
F01)
1st PC Set up QC Incharge F01)
Chuck 2.Operator Log Book (QC-
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER

8.01 ▼ 22 ± 2.0 kg/cm2 Pressure Gauge 1 2/shift 2.100% Operator Monitoring Readjust the Pressure
Pressure 1 2/shift 3.In Process inspection
MCN-F10)
3.In Process Inspection Report
report(QC-MCN-F02)
(QC-MCN-F02)

1.Set up Approval 1.Set up Approval

Ø 50.8 / 51.2 1st PC Setup QC Incharge
(QC-MCN-F01) / CMM Report Check Tooling & ascertain (QC-MCN-F01) / CMM Report
8.02 Inner Diameter 1 CMM / SPG-74 100% Operator
mm 1 35th PC Inspector
2.In Process Inspection root Cause 2.In Process Inspection
Report(QC-MCN-F02) Report(QC-MCN-F02)

1.Set up Approval
1.Set up Approval
(QC-MCN-F01) / CMM
CMM / Bore (QC-MCN-F01) / CMM
Report
▼ Ø 95.000 / Gauge with Dial 1st PC Setup QC Incharge Report
Check Tooling & ascertain 2.Operator log Book
8.03 Inner Diameter 2 100% Operator 2.100 % Operator Monitoring
TURNING Ist SETUP

• 95.040 mm LC 0.001 MSR-05- 1 10th PC Inspector 3.In Process Inspection

root Cause (QC-MCN-F10)
2 3.In Process Inspection Report
Report(QC-MCN-F02)
(QC-MCN-F02)
4.SPC Analysis
4. SPC Chart
CHUCK

8 8.04 Outer Diameter 3

Ø 110.7 / 111.3
mm
Vernier Caliper 1st PC Set up QC Incharge
Set up Approval
(QC-MCN-F01)
Check tooling & ascertain Set up Approval
root cause (QC-MCN-F01)

Ø 229.00 / Set up Approval Check tooling & ascertain Set up Approval

8.05 Inner Diameter 4 Vernier Caliper 1st PC Set up QC Incharge
232.00 mm (QC-MCN-F01) root cause (QC-MCN-F01)

1.Set up Approval
1.Set up Approval
(QC-MCN-F01)
(QC-MCN-F01)
1st PC Setup QC Incharge 2.Operator log Book
▼ Ø 271.30 / SG-32 with MSP- 2.100 % Operator Monitoring Check Tooling & ascertain
8.06 Outer Diameter 6 •
100% Operator (QC-MCN-F10)
271.40 mm 23 1 20th PC Inspector
3.In Process Inspection Report root Cause
3.In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
4.SPC Analysis
4. SPC Chart

Ø 275.5 / 276.5 Set up Approval Check tooling & ascertain Set up Approval
8.07 Outer Diameter 7 Vernier Caliper 1st PC Set up QC Incharge
mm (QC-MCN-F01) root cause (QC-MCN-F01)

1 of 17
 Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172528'3'-MCD-03-04 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-08 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.com
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

16.50 / 18.00 Set up Approval Check tooling & ascertain Set up Approval
8.08 Depth 9 Depth Vernier 1st PC Set up QC Incharge
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER

mm (QC-MCN-F01) root cause (QC-MCN-F01)

C2 MAX.
Underfill
8.09 10 N/A
Permissible at
One Place

Set up Approval Check tooling & ascertain Set up Approval

8.1 Radius 12 R10.0 mm Radius Gauge 1st PC Set up QC Incharge (QC-MCN-F01) root cause (QC-MCN-F01)
TURNING Ist SETUP

Set up Approval Check tooling & ascertain Set up Approval

8.11 Chamfer 13 1.5 X 45 ͦ Visual 1st PC Set up QC Incharge (QC-MCN-F01) root cause (QC-MCN-F01)
CHUCK

8
Tool Profile / Set up Approval Check tooling & ascertain Set up Approval
8.12 Radius 14 R0.8 mm Visual
1st PC Set up QC Incharge (QC-MCN-F01) root cause (QC-MCN-F01)

8.13 Angle 15 30 ͦ Pattern Controlled

Set up Approval Check tooling & ascertain Set up Approval

8.14 Radius 16 R3.0 mm Radius Gauge 1st PC Set up QC Incharge (QC-MCN-F01) root cause (QC-MCN-F01)

Set up Approval Check tooling & ascertain Set up Approval

8.15 Chamfer 17 0.5 X 45 ͦ Visual 1st PC Set up QC Incharge (QC-MCN-F01) root cause (QC-MCN-F01)

2 of 17
 Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172528'3'-MCD-03-04 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-08 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.com
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

1.Set up Approval
1.Set up Approval
(QC-MCN-F01)
Surface Finish 1st PC Set up QC Incharge Check tooling & ascertain (QC-MCN-F01)
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER

8.16 Surface Finish 18 3.2 μRa 2. In Process Inspection

Tester 1 4 Hour Inspector
3. Process & Program
root cause 2. In Process Inspection Report
(QC-MCN-F02)
Controlled

Surface Finish Set up Approval Check tooling & ascertain Set up Approval
8.17 Surface Finish 19 3.2 - 6.3 μRa 1st PC Set up QC Incharge
Comparator (QC-MCN-F01) root cause (QC-MCN-F01)

12.5 µRa - Surface Finish Set up Approval Check tooling & ascertain Set up Approval
8.18 Surface Finish 20 1st PC Set up QC Incharge
25 μRa Comparator (QC-MCN-F01) root cause (QC-MCN-F01)
TURNING Ist SETUP

Surface Finish Set up Approval Check tooling & ascertain Set up Approval
8.19 Surface Finish 21 3.2 - 6.3 μRa 1st PC Set up QC Incharge
Comparator (QC-MCN-F01) root cause (QC-MCN-F01)
CHUCK

8
Set up Approval Check tooling & ascertain Set up Approval
8.2 Chamfer 22 1.0 X 45 ͦ Visual 1st PC Set up QC Incharge (QC-MCN-F01) root cause (QC-MCN-F01)

Tool Profile / Set up Approval Check tooling & ascertain Set up Approval
8.21 Radius 23 R0.2 / 0.5 mm Visual
1st PC Set up QC Incharge (QC-MCN-F01) root cause (QC-MCN-F01)

Surface Finish Set up Approval Check tooling & ascertain Set up Approval
8.22 Surface Finish 24 3.2 - 6.3 μRa 1st PC Set up QC Incharge
Comparator (QC-MCN-F01) root cause (QC-MCN-F01)

Depth Vernier / Set up Approval Check tooling & ascertain Set up Approval
8.23 Depth 26 4.7 / 6.2 mm Height Gauge
1st PC Set up QC Incharge (QC-MCN-F01) root cause (QC-MCN-F01)

3 of 17
 Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172528'3'-MCD-03-04 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-08 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.com
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

Surface Finish Set up Approval Check tooling & ascertain Set up Approval
8.24 Surface Finish 27 3.2 - 6.3 μRa 1st PC Set up QC Incharge
Comparator (QC-MCN-F01) root cause (QC-MCN-F01)
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER CHUCK

1.Setup Approval 1.Setup Approval

1st PC Setup QC Incharge (QC-MCN-F01) Check Tooling & ascertain (QC-MCN-F01)
8.25 Depth 28 ▼ 12.5 / 12.7 mm Height Gauge 1 35th PC Inspector 2.In Process Inspection root Cause 2.In Process Inspection
Report(QC-MCN-F02) Report(QC-MCN-F02)

1.Setup Approval 1.Setup Approval

1st PC Setup QC Incharge (QC-MCN-F01) Check Tooling & ascertain (QC-MCN-F01)
8.26 Depth 29 ▼ 1.4 / 1.6 mm Depth Vernier 1 50th PC Inspector 2.In Process Inspection root Cause 2.In Process Inspection
Report(QC-MCN-F02) Report(QC-MCN-F02)

1.Setup Approval
1.Setup Approval
TURNING Ist SETUP

(QC-MCN-F01)
1st PC Setup QC Incharge (QC-MCN-F01)
Check Tooling & ascertain 2.Operator Log Book
8.27 Depth 30 6.80 / 7.20 mm Height Gauge 1 20th PCOperator 2.100 % Operator Monitoring
root Cause (QC-MCN-F10)
1 50th PC Inspector 3.In Process Inspection
3.In Process Inspection
Report(QC-MCN-F02)
Report(QC-MCN-F02)

8 18.00 / 19.50 Set up Approval Check tooling & ascertain Set up Approval
8.3 Depth A1 Depth Vernier 1st PC Set up QC Incharge (QC-MCN-F01) root cause (QC-MCN-F01)
mm

Set up Approval Check tooling & ascertain Set up Approval

8.31 Depth A2 6.2 / 7.7 mm Depth Vernier 1st PC Set up QC Incharge (QC-MCN-F01) root cause (QC-MCN-F01)

1.Setup Approval 1.Setup Approval

14.00 / 14.20 1st PC Setup QC Incharge (QC-MCN-F01) Check Tooling & ascertain (QC-MCN-F01)
8.32 Depth A3 ▼ Depth Vernier 1 20th PC Inspector 2.In Process Inspection root Cause 2.In Process Inspection
mm
Report(QC-MCN-F02) Report(QC-MCN-F02)

Set up Approval Check tooling & ascertain Set up Approval

8.28 Depth A4 43.50 mm Depth Vernier 1st PC Set up QC Incharge (QC-MCN-F01) root cause (QC-MCN-F01)

Set up Approval Check tooling & ascertain Set up Approval

8.29 Width A5 70.50 mm Depth Vernier 1st PC Set up QC Incharge (QC-MCN-F01) root cause (QC-MCN-F01)

4 of 17
 Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172528'3'-MCD-03-04 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-08 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.com
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.

1 Facing Tool WNMG WNMG 080412 1 N /A Outer Diameter Rough

Tool Control

2 Boring Bar WNMG Dia 32 WNMG 080412 2 N /A Bore Rough

O5281
3 Facing Tool WNMG WNMG 080408 3 N /A Outer Diameter Finish

4 Boring Bar WNMG WNMG 080404 4 N /A Bore Finish

Remarks: The ballooned dimensions 1, 2, 6 to be checked by the operator 100% and has to be recorded in the log book.Chuck Pressure has to be recorded in the log book.
Reviewed on 03/05/2016. Reviewed as per Product Audit Plan on 20/06/2018.

5 of 17
 Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172528'3'-MCD-03-04 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-09 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.c
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. BLN Evaluation/ Measurement
Description No. Product Process Specification/ Control Method
r No. Technique
Tolerance Size Freq. & Responsibility

1. Set up Approval(QC-
1.Set up Approval(QC-MCN-
MCN-F01)
1st PC Set up QC Incharge F01)
Chuck 2.Operator Log Book (QC-
9.01 ▼ 22 ± 2.0 kg/cm2 Pressure Gauge 1 2/shift 2.100% Operator Monitoring Readjust the Pressure
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER CHUCK

Pressure 1 2/shift 3.In Process inspection

MCN-F10)
3.In Process Inspection
report(QC-MCN-F02)
Report (QC-MCN-F02)

1.Setup Approval
1.Setup Approval
(QC-MCN-F01)
1st PC Setup QC Incharge (QC-MCN-F01)
Ø 296.7 / 297.3 Check Tooling & ascertain 2.Operator Log Book
9.02 Outer Diameter 8 Vernier Caliper 1 20th PC Operator 2.100 % Operator Monitoring
mm 1 50th PC Inspector 3.In Process Inspection
root Cause (QC-MCN-F10)
3.In Process Inspection
Report(QC-MCN-F02)
Report(QC-MCN-F02)

12.5 µRa - Surface Finish Set up Approval Check tooling & ascertain root Set up Approval
9.04 Surface Finish 25 1st PC Set up QC Incharge
25 μRa Comparator (QC-MCN-F01) cause (QC-MCN-F01)
TURNING IInd SETUP

1.Setup Approval
1.Setup Approval
(QC-MCN-F01)
1st PC Setup QC Incharge (QC-MCN-F01)
Check Tooling & ascertain 2.Operator Log Book
9.05 Depth 31 ▼ 61.9 / 62.1 mm Depth Vernier 1 20thPC Operator 2.100 % Operator Monitoring
root Cause (QC-MCN-F10)
1 35th PC Inspector 3.In Process Inspection
3.In Process Inspection
Report(QC-MCN-F02)
9 Report(QC-MCN-F02)

1.Setup Approval
1.Setup Approval
(QC-MCN-F01)
1st PC Setup QC Incharge (QC-MCN-F01)
Check Tooling & ascertain 2.Operator Log Book
9.06 Depth 32 ▼ 41.9 / 42.1 mm Depth Vernier 1 20thPC Operator 2.100 % Operator Monitoring
root Cause (QC-MCN-F10)
1 35th PC Inspector 3.In Process Inspection
3.In Process Inspection
Report(QC-MCN-F02)
Report(QC-MCN-F02)

Chamfer Set up Approval Check tooling & ascertain root Set up Approval
9.07 33 7.8 / 8.2 mm Height Gauge 1st PC Set up QC Incharge
Depth (QC-MCN-F01) cause (QC-MCN-F01)

33.70 / 34.30 Set up Approval Check tooling & ascertain root Set up Approval
9.08 Depth 34 Depth Vernier 1st PC Setup QC Incharge
mm (QC-MCN-F01) cause (QC-MCN-F01)

6 of 17
 CNC TURNING CENTER WITH 3 JA
9

TURNING II
Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172528'3'-MCD-03-04 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-09 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.c
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. BLN Evaluation/ Measurement
Description No. Product Process Specification/ Control Method
r No. Technique
Tolerance Size Freq. & Responsibility

Set up Approval Check tooling & ascertain root Set up Approval

9.09 Depth 35 17.3 / 17.8 mm Depth Vernier 1st PC Setup QC Incharge
(QC-MCN-F01) cause (QC-MCN-F01)

1.Setup Approval
1.Setup Approval
(QC-MCN-F01)
1st PC Setup QC Incharge (QC-MCN-F01)
Check Tooling & ascertain 2.Operator Log Book
9.10 Width 36 15.3 / 15.7 mm Micrometer 1 20thPC Operator 2.100 % Operator Monitoring
TURNING CENTER WITH 3 JAW HYDRAULIC POWER CHUCK

root Cause (QC-MCN-F10)

1 35th PC Inspector 3.In Process Inspection
3.In Process Inspection
Report(QC-MCN-F02)
Report(QC-MCN-F02)

Surface Finish Set up Approval Check tooling & ascertain root Set up Approval
9.11 Surface Finish 37 3.2 - 6.3 μRa 1st PC Set up QC Incharge
Comparator (QC-MCN-F01) cause (QC-MCN-F01)

Surface Finish Set up Approval Check tooling & ascertain root Set up Approval
9.12 Surface Finish 38 3.2 - 6.3 μRa 1st PC Set up QC Incharge
Comparator (QC-MCN-F01) cause (QC-MCN-F01)
TURNING IInd SETUP

Check tooling & ascertain root

9.13 Groove Depth 39 0.0 -1.0 mm Visual 1st PC Setup QC Incharge Program Controlled
cause
N/A

0.07 TIR
9 9.14 Parallelism 40 ▼
MAX. with
CMM / Height
Gauge with Dial LC
1st PC Setup /
1 / Shift
1.Set up Approval
(QC-MCN-F01) /
1.Set up Approval
Check Tooling & ascertain (QC-MCN-F01) /
Ref. 'C' on Ø 100% Inspector CMM Report
root cause CMM Report
0.001 2. On Part
225 mm

12.5 µRa - Surface Finish Set up Approval Check tooling & ascertain root Set up Approval
9.15 Surface Finish 41 1st PC Set up QC Incharge
25 μRa Comparator (QC-MCN-F01) cause (QC-MCN-F01)

12.5 µRa - Surface Finish Set up Approval Check tooling & ascertain root Set up Approval
9.16 Surface Finish 43 1st PC Set up QC Incharge
25 μRa Comparator (QC-MCN-F01) cause (QC-MCN-F01)

7 of 17
 CNC TURNING CENTER WITH 3 JAW HYD
TURNING IInd SET
Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
9 Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172528'3'-MCD-03-04 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-09 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.c
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. BLN Evaluation/ Measurement
Description No. Product Process Specification/ Control Method
r No. Technique
Tolerance Size Freq. & Responsibility

1.Set up Approval 1.Set up Approval

1st PC Set up QC Incharge (QC-MCN-F01) Check tooling & ascertain root (QC-MCN-F01)
9.17 Surface Finish 45 3.2 - 6.3 μRa Surface Finish Tester
1 4 Hour Inspector 2. In Process Inspection cause 2. In Process Inspection Report
3. Process & Program Controlled (QC-MCN-F02)

Ø 117.7 / 118.3 Set up Approval Check tooling & ascertain root Set up Approval
9.18 Inner Diameter 46 Inside Caliper 1st PC Set up QC Incharge
mm (QC-MCN-F01) cause (QC-MCN-F01)

Ø 135.5 / 136.5 Set up Approval Check tooling & ascertain root Set up Approval
9.19 Inner Diameter 47 Inside Caliper 1st PC Set up QC Incharge
mm (QC-MCN-F01) cause (QC-MCN-F01)
ING CENTER WITH 3 JAW HYDRAULIC POWER CHUCK

Ø 149.0 / 151.0 Set up Approval Check tooling & ascertain root Set up Approval
9.20 Inner Diameter 48 Vernier Caliper 1st PC Set up QC Incharge
mm (QC-MCN-F01) cause (QC-MCN-F01)

Ø 229.5 / 230.5
9.21 Groove Inner Dia 49 Visual 1st PC Program Controlled
mm

1.Setup Approval
1.Setup Approval
TURNING IInd SETUP

(QC-MCN-F01)
Ø 234.5 / 235.5 1st PC Setup QC Incharge Check Tooling & ascertain (QC-MCN-F01)
9.22 Inner Diameter 50 Vernier Caliper 2.100 % Operator Monitoring
mm 1 35th PC Inspector
3.In Process Inspection
root Cause 3.In Process Inspection
Report(QC-MCN-F02)
Report(QC-MCN-F02)

9 9.23 Outer Diameter 51

Ø 290.5 / 291.5
Vernier Caliper 1st PC Set up QC Incharge
Set up Approval Check tooling & ascertain root Set up Approval
mm (QC-MCN-F01) cause (QC-MCN-F01)

Set up Approval Check tooling & ascertain root Set up Approval

9.24 Radius 53 R3.00 mm Radius Gauge 1st PC Setup QC Incharge
(QC-MCN-F01) cause (QC-MCN-F01)

8 of 17
 CNC TURNING CENTER WITH 3 JAW HYDRAULIC
Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)

TURNING IInd SETUP

Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172528'3'-MCD-03-04 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-09 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.c
9
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. BLN Evaluation/ Measurement
Description No. Product Process Specification/ Control Method
r No. Technique
Tolerance Size Freq. & Responsibility

Set up Approval Check tooling & ascertain root Set up Approval

9.25 Radius 54 R3.00 mm Radius Gauge 1st PC Setup QC Incharge
(QC-MCN-F01) cause (QC-MCN-F01)

12.5 µRa - Surface Finish Set up Approval Check tooling & ascertain root Set up Approval
9.26 Surface Finish 55 1st PC Set up QC Incharge
25 μRa Comparator (QC-MCN-F01) cause (QC-MCN-F01)

12.5 µRa - Surface Finish Set up Approval Check tooling & ascertain root Set up Approval
9.27 Surface Finish 56 1st PC Set up QC Incharge
25 μRa Comparator (QC-MCN-F01) cause (QC-MCN-F01)
WITH 3 JAW HYDRAULIC
CNC TURNING CENTER
TURNING IInd SETUP

POWER CHUCK

9 9.28 Angle 57 2.00 ͦ Visual Program Controlled

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.

1 Facing Tool WNMG WNMG 080408 1 N /A Outer Diameter Finish

Tool Control

2 Boring Bar DNMG DNMG 150612 2 N /A Bore Finish

O5282
3 Boring Bar VCMT VCMT TR2000 1.2 3 N /A Groove

4 Boring Bar WNMG WNMG 080408 4 N /A Bore Finish

Remarks: The ballooned dimensions 8, 31, 32, 36 & 50 to be checked by the operator and has to be recorded in the log book.Chuck Pressure has to be recorded in the log book.
Reviewed on 03/05/2016. Reviewed as per Product Audit Plan on 20/06/2018.

9 of 17
 Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172528'3'-MCD-02-04 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-10 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.com
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

Setup Approval Check tooling & ascertain root Setup Approval

10.01 Ream Depth 42 9.80 / 10.20 mm Vernier Caliper 1st PC Setup QC Incharge
(QC-MCN-F01) Cause (QC-MCN-F01)

Setup Approval Check tooling & ascertain root Setup Approval

10.02 Drill Depth 44 13.80 /14.20 mm Vernier Caliper 1st PC Setup QC Incharge
(QC-MCN-F01) Cause (QC-MCN-F01)

Set up Approval Check tooling & ascertain root Set up Approval

10.03 Chamfer 52 0.5 x 45° Visual 1st PC Setup QC Incharge
(QC-MCN-F01) cause (QC-MCN-F01)

1.Set up Approval
DRILLING , TAPPING

1st PC (QC-MCN-F01) / CMM 1.Set up Approval (QC-

Set up QC Incharge
62.70 / 62.80 Report Check tooling & ascertain MCN-F01) / CMM Report
10.04 Center Distance 67 ▼ CMM / RG 19 100% Operator
mm 20th PC Inspector
2.100% Opertor Monitoring root cause 2.In Process Inspection
1 3.In Process Inspection Report (QC-MCN-F02)
VMC Machine

Report (QC-MCN-F02)

1.Set up Approval
10 108.64 / 108.74
1st PC Set up QC Incharge
(QC-MCN-F01) / CMM
Report Check tooling & ascertain
1.Set up Approval (QC-
MCN-F01) / CMM Report
10.04 Center Distance 68 ▼ CMM / RG 19 100% Operator
mm 20th PC Inspector
2.100% Opertor Monitoring root cause 2.In Process Inspection
1 3.In Process Inspection Report (QC-MCN-F02)
Report (QC-MCN-F02)
1.Set up Approval
1st PC (QC-MCN-F01) / CMM 1.Set up Approval (QC-
Set up QC Incharge
108.64 / 108.74 Report Check tooling & ascertain MCN-F01) / CMM Report
10.05 Center Distance 69 ▼ CMM / RG 19 100% Operator
mm 20th PC Inspector
2.100% Opertor Monitoring root cause 2.In Process Inspection
1 3.In Process Inspection Report (QC-MCN-F02)
Report (QC-MCN-F02)

1.Set up Approval
1st PC (QC-MCN-F01) / CMM 1.Set up Approval (QC-MCN-
Set up QC Incharge
Report Check tooling & ascertain root F01) / CMM Report
10.06 Center Distance 70 (134.7) mm CMM / RG 19 100% Operator
2.100% Opertor Monitoring cause 2.In Process Inspection Report
1 20th PC Inspector
3.In Process Inspection Report (QC-MCN-F02)
(QC-MCN-F02)

1.Set up Approval
1st PC (QC-MCN-F01) / CMM 1.Set up Approval (QC-
Set up QC Incharge
Report Check tooling & ascertain MCN-F01) / CMM Report
10.07 Center Distance 71 ▼ 62.7 / 62.8 mm CMM / RG 19 100% Operator
2.100% Opertor Monitoring root cause 2.In Process Inspection
1 20th PC Inspector
3.In Process Inspection Report (QC-MCN-F02)
Report (QC-MCN-F02)

10 of 17
 Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172528'3'-MCD-02-04 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-10 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.com
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

1.Set up Approval
1st PC (QC-MCN-F01) / CMM 1.Set up Approval (QC-
Set up QC Incharge
125.45 / 125.55 Report Check tooling & ascertain MCN-F01) / CMM Report
10.08 Center Distance 72 ▼ CMM / RG 19 100% Operator
mm 20th PC Inspector
2.100% Opertor Monitoring root cause 2.In Process Inspection
1 3.In Process Inspection Report (QC-MCN-F02)
Report (QC-MCN-F02)

1.Set up Approval
1st PC (QC-MCN-F01) / CMM 1.Set up Approval (QC-MCN-
Set up QC Incharge
CMM / Receiving Report Check tooling & ascertain root F01) / CMM Report
10.09 PCD 73 Ø 74.00 mm 100% Operator
Gauge-13 50th PC Inspector
2.100% Opertor Monitoring cause 2.In Process Inspection Report
1 3.In Process Inspection Report (QC-MCN-F02)
(QC-MCN-F02)
DRILLING , TAPPING

Check tooling & ascertain root

10.10 Radius 74 R120.0 mm Visual 100% Program Controlled
cause
N/A
VMC Machine

1.Set up Approval
1st PC (QC-MCN-F01) / CMM 1.Set up Approval (QC-
Set up QC Incharge
CMM / Receiving Report Check tooling & ascertain MCN-F01) / CMM Report
10.11 PCD 75 ▼ Ø 251.00 mm 100%
10 Gauge-19
1
Operator
50th PC Inspector
2.100% Opertor Monitoring
3.In Process Inspection
root cause 2.In Process Inspection
Report (QC-MCN-F02)
Report (QC-MCN-F02)

Set up Approval Set up Approval

Setup Check Tooling & ascertain
10.12 Angle 76 13.50 ͦ CMM 1st PC 1/Shift
(QC-MCN-F01) /
Root Cause
(QC-MCN-F01) /
CMM Report CMM Report

Set up Approval Set up Approval

Setup Check Tooling & ascertain
10.13 Angle 77 73 ͦ30'± 10' CMM 1st PC 1/Shift
(QC-MCN-F01) /
Root Cause
(QC-MCN-F01) /
CMM Report CMM Report

10.14 Angle 78 120 ͦ Visual Program Controlled

10.15 Angle 79 120 ͦ Visual Program Controlled

11 of 17
 Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172528'3'-MCD-02-04 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-10 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.com
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

1.Set up Approval
1st PC (QC-MCN-F01) / CMM 1.Set up Approval (QC-MCN-
Set up QC Incharge
Report Check tooling & ascertain root F01)
10.16 Drill Dia Ø 13.5 mm SPG-73 100% Operator
2.100% Opertor Monitoring cause 2.In Process Inspection Report
1 50th PC Inspector
3.In Process Inspection Report (QC-MCN-F02)
(QC-MCN-F02)
80

Set up Approval Set up Approval

Setup Check Tooling & ascertain
10.17 8 Holes Equally Spaced CMM 1st PC 1/Shift
(QC-MCN-F01) /
Root Cause
(QC-MCN-F01) /
CMM Report CMM Report

1.Set up Approval
1st PC (QC-MCN-F01) / CMM 1.Set up Approval (QC-MCN-
Set up QC Incharge
Report Check tooling & ascertain root F01)
10.18 Tap M8 X 1.25 TPG-09 100% Operator
2.100% Opertor Monitoring cause 2.In Process Inspection Report
1 50th PC Inspector
3.In Process Inspection Report (QC-MCN-F02)
(QC-MCN-F02)
DRILLING , TAPPING

1.Setup Approval
Std bolt with Vernier Check tooling & ascertain root Set up Approval
VMC Machine

10.19 Tap Depth 16.00 mm Min. 1st PC Setup QC Incharge (QC-MCN-F01)

Caliper 2.Program Controlled
cause (QC-MCN-F01)

10 10.20 6 Tapped Holes

81
Equally Spaced CMM 1st PC
Setup
Set up Approval
(QC-MCN-F01) /
Check Tooling & ascertain
Set up Approval
(QC-MCN-F01) /
1/Shift Root Cause
CMM Report CMM Report

1. Set Up Approval (QC-

1. Set Up Approval
1st PC Set Up QC Incharge Check Tooling & ascertain MCN-F01)
Drill Depth 20.00 mm Min. Vernier Caliper 2. In Process Inspection
1 4 Hour Inspector
3. Program Controlled
Root Cause 2. Inj Process Inspection
Report (QC-MCN-F02)

1.Setup Approval
Vernier Caliper / Check tooling & ascertain root Set up Approval
Chamfer Dia. 8.5 X 90° 1st PC Setup QC Incharge (QC-MCN-F01)
CMM 2.Program Controlled
cause (QC-MCN-F01)

1.Set up Approval
1st PC (QC-MCN-F01) / CMM 1.Set up Approval (QC-
Set up QC Incharge
3 Holes Ø 5.974 / 5.988 SPG-72 / Receiving Report Check tooling & ascertain MCN-F01)
10.21 82 ▼ 100% Operator
Drill Dia mm Gauge- 19 20th PC Inspector
2.100% Opertor Monitoring root cause 2.In Process Inspection
1 3.In Process Inspection Report (QC-MCN-F02)
Report (QC-MCN-F02)

10.22 Radius 83 R5.00 mm As Cast

12 of 17
 Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172528'3'-MCD-02-04 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-10 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.com
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

10.23 Radius 84 R5.00 mm As Cast

10.24 Width 85 (2) mm Visual Program Controlled

10.25 Radius 86 R5.00 mm As Cast

DRILLING , TAPPING

VMC Machine

1.Set up Approval
Check tooling & ascertain root Set up Approval
10.26 Radius 87 R18.00 mm Receiving Gauge-19 1st PC Set up QC Incharge (QC-MCN-F01)
cause (QC-MCN-F01)
2.Process Controlled

10
1.Setup Approval
43.00 / 47.00 Check tooling & ascertain root Set up Approval
10.27 Dimension 88 Vernier Caliper 1st PC Setup QC Incharge (QC-MCN-F01)
mm 2.Pattern Controlled
cause (QC-MCN-F01)

1.Setup Approval
18.50 / 21.50 Check tooling & ascertain root Set up Approval
10.28 Dimension 89 Vernier Caliper 1st PC Setup QC Incharge (QC-MCN-F01)
mm 2.Pattern Controlled
cause (QC-MCN-F01)

10.29 Angle 90 15 ͦ Pattern Controlled N/A

1.Setup Approval
Height Gauge with Check tooling & ascertain root Set up Approval
10.30 Depth 91 6.80 / 9.20 mm 1st PC Setup QC Incharge (QC-MCN-F01)
Scribber 2.Pattern Controlled
cause (QC-MCN-F01)

1.Set up Approval
VMC Machine
DRILLING ,

1st PC (QC-MCN-F01) / CMM 1.Set up Approval (QC-MCN-

Set up QC Incharge
Report Check tooling & ascertain root F01)
TAPPING

10.31 Depth 92 16.80/19.20 mm SPG-65 100% Operator

2.100% Opertor Monitoring cause 2.In Process Inspection Report
1 50th PC Inspector
3.In Process Inspection Report (QC-MCN-F02)
(QC-MCN-F02)
10

10.32 Depth 93 62.00 mm Checked after IInd Setup

13 of 17
 Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172528'3'-MCD-02-04 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-10 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.com
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.

1 Solid Carbide Drill Ø 6.6 mm 1 N/A Clutch Drill

2 Solid Carbide Drill Ø 13.7 mm 2 N/A Crank Hole

3 Solid Carbide Drill Ø 5.7 mm 3 N/A Dowel Drill

Tool Control

4 High Speed Steel Chamfer Tool Ø 22.0 mm 4 N/A Chamfer

O5289
5 Reamer Ø 5.974 mm 5 N/A Dowel Reamer

6 High Speed Steel Tap M8 X 1.25 6 N/A Tapping

7 Spot Face tool Ø 27.5 mm 7 N/A Spot face

8 High Speed Steel Ø 6.8 mm 8 N/A Dimple Depth

Remarks: Reviewed on 03/05/2016. Reviewed as per Product Audit Plan on 20/06/2018.

14 of 17
 Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172529 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-11 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.com
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

1.Set up Approval
Chamfered Side 2.Work Instructions Set up Approval-Ring
To be on Top 1st PC Setup QC-Engg
11.01 of Ring Gear
Side
Visual
100% Operator
(PRD-MCN-WI11) Check & Segregate Fittment
Teeth 3.100% Operator (QC-MCN-F17)
Induction Heater & Hydraulic Press

Monitoring
Ring Gear Heating & Fittment

Ring Gear 1.Set up Approval Set up Approval-Ring

140 °C - 150 ° Temperature 1st PC Setup QC-Engg Readjust the
11.02 Heating ▼ 2.100% Operator Fittment
Temp. C Indicator 100% Operator Monitoring temperature
(QC-MCN-F17)

1.Set up Approval Set up Approval-Ring

Ring Pressing Pressure Dial 1st PC Setup QC-Engg Re-Press & Re-adjust
11 11.03 Load
▼ 100Kgf/cm2
Indicator 100% Operator
2.100% Operator
the Pressure
Fittment
Monitoring (QC-MCN-F17)

Ring Pressing 1.Set up Approval Set up Approval-Ring

1st PC Setup QC-Engg
11.04 Holding ▼ Min. 10 Sec. Digital Wall Clock
100% Operator
2.100% Operator Re-press Fittment
Dwell Time Monitoring (QC-MCN-F17)

Gap Between 1.Set up Approval Set up Approval-Ring

Filler Gauge of 1st PC Setup QC-Engg
11.05 Shoulder & Face ▼ 0.10 mm Max 2.100% Operator Check & Segregate Fittment
of Gear 0.100 mm 100% Operator Monitoring (QC-MCN-F17)

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.
Tool Control

Remarks: Reviewed on 03/05/2016. Reviewed as per Product Audit Plan on 20/06/2018.

15 of 17
 Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172528'3'-MCD-01-04 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-12 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.com
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code :8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

Ø 250.0 ± 0.5 Stopper Controlled & WI Seek Clarification from Set Up Approval- DB
12.01 PCD 05 Vernier Caliper 1st PC Set Up- DB Supervisor
(PRD-MCN-WI06) Next higher authority (QC-MCN-F07)
mm

Ø 12.70 mm Tool Controlled

Check tooling & ascertain Set Up Approval- DB
12.02 Drill Diameter Vernier Caliper 1st PC Set Up- DB Supervisor & WI
root cause (QC-MCN-F07)
MAX. (PRD-MCN-WI06)
Dynamic Balancing Machine
Dynamic Balancing

Stopper Controlled & WI Measure & Readjust the Set Up Approval- DB

12.03 Drill Depth 22.00 mm Max. Vernier Caliper 1st PC Set Up- DB Supervisor
(PRD-MCN-WI06) size of stopper (QC-MCN-F07)
58

12

Center
20.00 mm WI Seek Clarification from Set Up Approval- DB
12.04 Distance / Wall Vernier Caliper 1st PC Set Up- DB Supervisor
(PRD-MCN-WI06) Next higher authority (QC-MCN-F07)
MIN.
Thickness
894172529"1"ASY-01-01

1.Set Up Approval cum In

1.Set Up Approval Cum In
As per drg. No.

Process Inspection Report -

process Inspection Report-
Dynamic Balancing 1st PC Set Up-DB Supervisor
Dynamic Balancing Check & Segregate the Dynamic Balancing
12.05 Balancing Value 20 g-cm 100% Operator
Material
(QC-MCN-F07)
Machine 1 20th PC Inspector
(QC-MCN-F07)
2.Operator Log Book (QC-
2.100% Operator Monitoring
MCN-F11)
3.Process Controlled
3. On Part
Control

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.
Tool

1 Drill Ø 12.5 mm 1 N/A Drilling N/A

Remarks: Reviewed on 03/05/2016. Reviewed as per Product Audit Plan on 20/06/2018.

16 of 17
 Doc. No. : PDC-EPD-F02
Control Plan Rev. No. : 00 (01/09/2019)
Issue No. : 02 (01/09/2019)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : 894172529 Revision No. (Date): 03(11/05/2016) Mr. Himanshu Duniwal Manager QA & QMS
Control Plan Number : 894172528 CP-13, 14 & 15 Organization / Plant Approval Date : Date (Originated) : 01/01/2014 Mr. R.S. Shekhawat Manager NPD mail@garimacastings.com
Part Number / Model No : 894172529 Other Approval / Date (if Reqd.) : Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop
Part Name / Description : GMI Flywheel Organization / Supplier Code : 8131 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Vineet Upadhyay Engineer QA & QMS

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

Pre-dispatch AS PER PDI 100 % Sorting for PDI Report

13 13.01 AS PER PDI Report
Report AS PER PDI Report AS PER PDI Report In - Process Control
Inspection Deviated Parameters (QC-PDS-F01)

Surface of the part

should be dry and
14.01 Cleaning of parts
free from the Rust Visual 100% Each Batch Re-cleaning
& Chips

Light Film of oil to Surface shall only

14.02 be applied with a coated with RPO Visual 100% Each Batch Re-Oiling
soaked cloth but no Excess Oil
Oiling Area & Packaging Area
Oiling & Packaging

14.03 Part Identification No Mixing Visual 100% Each Batch 100 % Sorting -
PKG-PDS-WI01, PKG-
PDS-WI02, Drg No.
894172529
14
PKG-01-01
14.04 Box Type
As per Packaging
Visual 100% Each Batch & Monitoring by -
Specification Sheet Supervisor

Quantity Per As per Packaging

14.05
Box Specification Sheet Visual 100% Each Batch Daily Packing Report
Repacking

As per Packaging
14.06 Labeling
Specification Sheet
Visual 100% Each Batch -

Other Packaging As per Packaging

14.07
Material Specification Sheet Visual 100% Each Batch -

Customer Name, As per Dispatch DES-PDS-WI01 and TAG

15 Dispatch 15.01 Visual Examination 100% Each Dispatch Re-Checking Dispatch Documents
Quantity, Date….. Schedule & Label on Box

Remarks:Reviewed on 03/05/2016. Reviewed as per Product Audit Plan on 20/06/2018.

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