KATARIA INDUSTRIES PVT LTD.

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34-38 & 44, Industrial Estate,RATLAM (M.P) - 457001 INDIA
Prototype Pre-Launch ✘
Productio CONTROL PLAN
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CONTROL PLAN NO:CP-SS BLK-01
Product Name: SPRING STEEL WIRE BLACK
Rev. Date: 01st May,2018
Rev. No.:08
Core Team :- B V Ugale, Sarvesh Origin Date: 20th Jan,2015

Parameters Methods
Part/ Process Tools/ Special
Process Name / Machinery Characteri Reaction Plan
Operation Evaluation
No. used for Mfg. S.No Product Process stics(¥) Product /Process Specifications Measurement Frequency of check Responsibility Control Method
Description
Technique

Shift QC Supervisor/
……. 1 ……. Identification & Traceability ……. Supplier Tag verification Visual Each Coil Wire Rod Yard Hold for Testing
Operator

Receipt,
Tagging & Shift QC Supervisor/ WI-WS-01
10 Un-loading of Grade -wise coloured Tagging WI-PR-10
Crane 2 ……. ……. As per grade-wise colored tagging & polythene Visual Each Coil Wire Rod Yard Hold for Re-testing
Wire Rod & Polythene
Operator

……. 3 ……. Document ……. Verification of Supplier TC Visual Each lot Shift QC Supervisor/ Follow-up with supplier
I/C QC for TC

A Physical Properties

Size (Diameter) 5.50-7.00±0.30 mm Micrometer Min 2 sample per QC Tester /

……. 1 …… ……. Reject
(mm) 8.00-12.00±0.40mm (0-25mm) heat I/C QC

Tensile Strength Tensile Machine

Incoming ……. 2 …… ……. As per grade-wise internal specs (100 KN) Min 2 sample per QC Tester / Reject
Inspection & (Kgs. / mm2) heat I/C QC
20 (200KN) SF-QC-01A,
Testing of
Wire Rod WI-QC-01,
Vernier caliper IT-QC-01A
Min 2 sample per QC Tester /
……. 3 % Reduction Area …… ……. As per grade-wise internal specs (0-150mm) heat I/C QC Reject
Tensile M/c

Deep Etching Test Surface should be free from deep pitting, seams, Min 2 sample per QC Tester
……. 4 …… ……. HCL Acid (Chem.) / Reject
(Macro) chip-off etc heat
I/C QC

SF-QC-17/00 Page 1 of 5
 Parameters Methods
Process
Part/ Name / Tools/ Special
Process Operation Machinery Characteri Evaluation Reaction Plan
No. Description used for Mfg. S.No Product Process stics(¥) Product /Process Specifications Measurement Frequency of check Responsibility Control Method
Technique
B Chemical Composition

As per grade required of IS:4454:P1/ QC Tester

……… 1 % Carbon …… ……. Strohlein Apparatus/ Min 1 sample per heat (Chem.) / Reject
As per customer specific requirement Visually TC verified
I/C QC

As per grade required of IS:4454:P1/ Mobile Spectro/ QC Tester

……. 2 % Manganese …… ……. Min 1 sample per heat (Chem.) / Reject
As per customer specific requirement Visually TC verified I/C QC

As per grade required of IS:4454:P1/ QC Tester

…….. 3 % Silicon …… ……. Wt. Analysis/ Visually Min 1 sample per heat (Chem.) / Reject
As per customer specific requirement TC verified SF-QC-01A,
I/C QC WI-QC-01B,
IT-QC-01A
Incoming As per grade required of IS:4454:P1/ QC Tester
Strohlein Apparatus/
20 Inspection & ……. 4 % Sulphur …… ……. Visually TC verified Min 1 sample per heat (Chem.) / Reject
(Cont.) Testing of Wire As per customer specific requirement I/C QC
Rod
As per grade required of IS:4454:P1/ Wt. Analysis/ Visually Min 1 sample per heat QC Tester
……. 5 % Phosphorus …… ……. (Chem.) / Reject
As per customer specific requirement TC verified
I/C QC

As per grade required of IS:4454:P1/ Mobile Spectro/ QC Tester

……. 6 %Copper …… ……. Min 1 sample per heat (Chem.) / Reject
As per customer specific requirement Visually TC verified I/C QC
……. 7 Micro-Stucture …… ……. Fine Pearlite Optical Microscope Min. 1 Sample per heat Metallurgical Engineer Reject
……. 8 Partial Decarb …… ……. Max. 1.0% of wire rod dia Optical Microscope Min. 1 Sample per heat Metallurgical Engineer Reject
WI-QC-20
……. 9 Grain Size …… ……. 7 - 8 ASTM Optical Microscope Min. 1 Sample per heat Metallurgical Engineer WI-QC-21 Reject
Inclusion As per purchase specs. WI-QC-22
……. 10 (A to D) …… ……. Thick - 1.0 Max. Optical Microscope Min. 1 Sample per heat Metallurgical Engineer Reject
(Above 8.00mm ) Thin - 1.5 Max.
Batch Pickling Baths Batch Pickling

1 ……….. % age Conc ……. 4 to 20% Volumetric Analysis Min.Once in a shift QC Tester (Chem.) / Discard/Addition
I/C QC

2 ……….. %age Fe ……. 12 % Max. Volumetric Analysis Min.Once in a shift QC Tester (Chem.) / Discard/Addition
I/C QC
HCL Acid Bath
Batch Pickling Dip time ……. 40 Minutes Poka Yoke System Min.Once in a shift QC Tester (Chem.) WI-BP-01, Memo to Elect. for
30 (Surface if 4% =< %HCL Conc. < 10% WI-BP-02, rectification
Preparation) SF-CL-01,
3 ……….. Dip time ……. 30 Minutes Poka Yoke System Min.Once in a shift QC Tester (Chem.) WI-QC-03, Memo to Elect. for
if 10% =< %HCL Conc. < 15% SF-BP-05 rectification
Dip time Memo to Elect. for
if 15% =< %HCL Conc. < 20% ……. 20 Minutes Poka Yoke System Min.Once in a shift QC Tester (Chem.) rectification
4 ……….. Removal of scale ……. Grey Colour Visual Each Coil Pickling Operator Re-pickle
Water Rinsing QC Tester (Chem.) /
(Pre-Rinsing) 5 ……….. Ph ……. 2 Min. Ph paper Min.Once in a shift I/C QC Discard

Water Washing 6 ……….. Ph ……. Continue spray washing of surface water till pH value Poka Yoke System Each coil Pickling Supervisor Memo to Maint. For
(Post Rinsing) of outlet spray water reaches 7 Min. Pickling Operator rectification

SF-QC-17/00 Page 2 of 5
 Parameters Methods
Process
Part/ Name / Tools/ Special
Process Operation Machinery Characteri Evaluation Reaction Plan
No. Description used for Mfg. S.No Product Process stics(¥) Product /Process Specifications Measurement Frequency of check Responsibility Control Method
Technique

Coating Baths Pre-Coating Process

Pointage
7 ……….. (TA) ……. 10-25 Volumetric Analysis Min. Once in a shift QC Tester Addition/Maintain
8 ……….. Accelerator ……. Should be blue color Starch Iodide Paper Min. Once in a shift QC Tester Adjust/Re-set
9 ……….. Temp. ……. Temp. Indicator/ QC Tester Adjust/Re-set
75 - 900C Thermometer
Min. Once in a shift
Phosphate Baths Dip time Memo to Elect. for
if 10 =< pointage(TA). < 15 ……. 35 Minutes Poka Yoke System Min. Once in a shift QC Tester (Chem.) rectification

10 ……….. Dip time ……. 30 Minutes Poka Yoke System Min. Once in a shift QC Tester (Chem.) Memo to Elect. for
if 15 =< pointage(TA). < 20 rectification
Dip time ……. 25 Minutes Poka Yoke System Min. Once in a shift QC Tester (Chem.) Memo to Elect. for
if 20 =< pointage(TA). =< 25 rectification
Water Washing 11 ……….. Ph ……. Continue spray washing of surface water till pH value Poka Yoke System Each coil Pickling Supervisor Memo to Elect. for
(Post Rinsing) of outlet spray water reaches 7 Min. Pickling Operator rectification
WI-BP-01,
Pre-Coating WI-BP-02, Addition/
40 12 ……….. %age Conc. ……. 10-20% Volumetric Analysis Min. Once in a shift QC Tester
Process SF-CL-01, Maintain
13 ……….. Temp. ……. 85 -1000C Temp. Indicator/ Min. Once in a shift QC Tester WI-QC-03, Adjust/Re-set
Thermometer SF-BP-05
Borax Bath
Dip time ……. 02 Minute Poka Yoke System Min. Once in a shift QC Tester (Chem.) Memo to Elect. for
if10% =< %Borax Conc. < 15% rectification
14 ………..
Dip time ……. 01 Minute Poka Yoke System Min. Once in a shift QC Tester (Chem.) Memo to Elect. for
if15% =< %Borax Conc. =< 20% rectification

15 ……….. Strength ……. 7-12 Volumetric Analysis Min. Once in a shift QC Tester
Addition/
(gm/ltr) Maintain
Temp. Indicator/
16 ……….. Temp. ……. 60 -800C
Thermometer
Min. Once in a shift QC Tester Adjust/Re-set
Lime Bath
Dip time Memo to Elect. for
if7% =< %Lime Conc. < 10% ……. 02 Minute Poka Yoke System Min. Once in a shift QC Tester (Chem.) rectification
17 ………..
Dip time ……. 01 Minute Poka Yoke System Min. Once in a shift QC Tester (Chem.) Memo to Elect. for
if10% =< %Lime Conc. =< 12% rectification
Wire Drawing
Shift Opr/
1 ……… Start-up Checklist ……. As defined in WI-PR-09 Visual Once in a shift
Shift Sup. SF-PR-11 Reject
Micrometer Shift Opr/
2 ……… Die Schedule ……. As defined in WI-PR-05
(0-25mm)
Once in day
Process Control Insp. SF-QC-15 Get correct die schedule
Set-up Approval (Process Sample Memo)
Diameter, As per grade required of IS:4454:P1 or Micrometer SF-QC-49,
Tensile Strength Tensile M/c Min. 1 sample Shift QC Tester PC-103/107
1 ……… ……. as per Customer specs or as per internal process Reject
Torsion, Torsion M/c per shift /Shift Prod. Supervisor
Finish %RA sheet Vernier Caliper
50 Drawing Wire Drawing
M/c
Process Regular Inspection by Production Supervisor
1 Size (Diameter) ……… ……. As per daily program Micrometer After every 2 Hrs. Shift Supervisor Reject
(mm) (0-25mm)
Smooth
2 Surface Finish ……… ……. (As displayed in positive sample) Visual After every 2 Hrs. Shift Supervisor Reject
SF-PR-07
AD = 70mm Max. (FG)
3 Cast of wire ……… ……. CD = Minimum of Diameter Measuring Tape After every 2 Hrs. Shift Supervisor Reject
of finish drum
Note: AD= Axial Displacement, CD= Casting Diameter

SF-QC-17/00 Page 3 of 5
 Parameters Methods
Process
Part/ Name / Tools/ Special
Process Operation Machinery Characteri Evaluation Reaction Plan
No. Description used for Mfg. S.No Product Process stics(¥) Product /Process Specifications Measurement Frequency of check Responsibility Control Method
Technique

Regular Inspection by Process Control Team

1 ……… Temp. for Die and Drum ……. Water temp. in die box =40 °C Max. Temperature Gun Once in a shift Process Control Memo to Maintenance
Cooling Drum temperature =60 °C Max. Inspector
Prod. Supr./
Type & Condition of Lubricant 1st 2 dies boxes -TR-41B, Changed the lubricant as
2 ……… used in die boxes ……. Balance dies boxes-2267 Visual Once in a shift Process Control requirement
Inspector

3 ……… Proper Accumulation of wire ……. Wire should be accumulated on drums as per Visual Once in a shift Process Control Re-set rings
on drum instruction and should not jam on the drum Inspector

4 ……… Speed ……. As per planned programme / Display on screen/

Once in a shift Process Control Give Memo to Electrical
As per process sheet Speed indicators Inspector Maint.

5 ……… Condition of Killing roller ……. Killing rollers cleaned & Visual Once in a shift Process Control Clean & Change with
Finish not to be jammed Inspector WI-PR-01, new one
Drawing Wire Drawing WI-PR-06,
50 Condition of existing rotating Process Control Give Memo to
Process M/c 6 ……… ……. Should be in working condition Visual Once in a shift SF-QC-13,
(Cont.) die Inspector Elec/Mech. Maint.
SF-QC-15,
PC-103/107
7 ……… Condition of existing rotating ……. Should be in working condition Visual Once in a shift Process Control Give Memo to
lubricant agitator Inspector Elec/Mech. Maint.

Condition of drums, guide

Process Control Change the problematic
8 ……… pulleys & rollers (any deep ……. Free from deep grooves with proper alignment Visual Once in a shift Inspector part
grooves)
Process Control Tight die nut or
9 ……… Water leakage at outlet of dies ……. No water leakage allowed Visual Once in a shift
Inspector reset of die

Verification of locking tie rod Should be locking tie rod and cut out of bend Process Control Inform to concern
10 on finish coil & cut their ……… ……. Visual Once in a shift
bend portion portion from end of coil Inspector supervisor

SF-QC-17/00 Page 4 of 5
 Parameters Methods
Process
Part/ Name / Tools/ Special
Process Operation Machinery Characteri Evaluation Reaction Plan
No. Description used for Mfg. S.No Product Process stics(¥) Product /Process Specifications Measurement Frequency of check Responsibility Control Method
Technique

Size (Diameter) As per grade required of IS:4454:P1/ Micrometer

……… 1 …….. ……. As per customer specific requirement/ Each Coil QC Tester Reject
& tolerance (mm) As per internal process sheet (0-25mm)

Tensile Strength As per grade required of IS:4454:P1/

……… 2 …….. ……. As per customer specific requirement/ Tensile M/c Each Coil QC Tester Reject
(Kg/mm²) As per internal process sheet

As per grade required of IS:4454:P1/

……… 3 Torsion …….. ……. As per customer specific requirement/ Torsion M/c Each Coil QC Tester Reject
As per internal process sheet

As per IS:4454:Part 1 or
Final %RA Min 1 sample per 10 WI-QC-01,
……… 4 (If applicable) …….. ……. as per Customer specs or as per internal process Vernier Caliper coils QC Tester Reject
60 Inspection sheet SF-QC-03A,
and Testing PC-103/107

Wrapping As per grade required of IS:4454:P1/

……… 5 …….. ……. As per customer specific requirement/ Torsion M/c 1 sample per 10 coils QC Tester Reject
(If required) As per internal process sheet

Deep Etching Test Surface should be free from deep pitting & seams Both end of 1 coil per QC Tester
……. 6 …… ……. HCL Acid Reject
(Macro) etc lot (Chem.)

As per IS:4454:Part 1 or Min. 1 Sample per

……. 7 Partial Decarb …… ……. as per Customer specs or as per internal process Optical Microscope heat Metallurgical Engineer Reject
sheet

8 Surface Finish ……… ……. Smooth Visual Each Coil Shift Supervisor Reject
(As displayed in positive sample)

Oiling Dip …….. 1 ………. Dip time ……. Just one dip till bubbles stopped Visual Each Coil Shift Supervisor Reject

70 SF-PK-01

Oil Drain Out …….. 2 ………. Drain out time ……. 12 Hours Min. Visual Each Coil Shift Supervisor Reject

Packing & Polythene WI-PK-01

80 …….. 1 ………. Packing ……. Visual Each Coil Packing Supervisor Reject
Storage & HDPE PC-103/107

Material Test Certificate

(M/c No. required), QC Shift Incharge/ SF-QC-19 Arrange and send to
…….. 1 ………. Documents ……. Supplier /Mill T.C.(if required), Visual Each lot
Despatch Supervisor SF-DS-02 customer
Third Party Lab T.C.(if required),
90 PDI & PDI report (if required)
Despatch

Despatch Supervisor /
Crane 2 ………. Despatch ……. As per despatch program Visual Each lot WI-DS-01 Hold
Clerk

SF-QC-17/00 Page 5 of 5