PAGE:

OPERATIONAL CONTROL PLAN NO. 1 / 8

OPERATIONAL CONTROL PLAN MI/QD/OCP-BA/45
Part Name : Brake Pipe Manifold-10 Process No. : BA/045 Process Name : Visual Inspection
Part No. : LPLA-33835-BA Customer Drg. Rev. No. : Material from (Supplier): Cleaning
Customer Drg. No. : LPLA-33835-BA Customer Drg. Rev. Date. : Material To (Customer) : Packing
Machine Name : VMC-01 Note: -

Process Instructions
Containment Instructions( सुरक्षा निर्देश )
2
After complete visual inspection of parts, paste adhesive tape at the holes
face so that it would not contaminate again. विसुअल
इंस्पेक्शन पूरा होने पर, सही पार्ट्स पर, चिपकने वाला टेप लगाएं ताकि ये दुबारा गन्दा न हो पाएं ।
1

Reaction Plan

;fn ihl esa dksb deh (Not as per control Plan) gks rks] lqijokbtj dks lwfpr djsa A fiNyk eky
NkaVs] tgkWa rd lgh ihl feysa A

Edition No. Revision No. Effective Date Checked By Approved By

01 00 16.08.2019
ENGG/F/22, Rev. No.: 00
 OPERATIONAL CONTROL PLAN NO. PAGE: 2 / 8
OPERATIONAL CONTROL PLAN MI/QD/OCP-BA/45
Part Name : Brake Pipe Manifold-10 Process No. : BA/045 Process Name : Visual Inspection
Part No. : LPLA-33835-BA Customer Drg. Rev. No. : Material from (Supplier): Cleaning
Customer Drg. No. : LPLA-33835-BA Customer Drg. Rev. Date. : Material To (Customer) : Packing
2
Machine Name : VMC-01 Note: -

Process Instructions
A External surface(बाहरी सतह) :
Use 10x magnification lense for visual of the parts. विसुअल
1
इंस्पेक्शन के लिए १० x बड़ा करने वाले लेंस का प्रयोग करें ।
Parts should be free from dent, scratches etc at the external surface of the
part, surface finish should be as per Limit Sample. पार्ट की बाहरी
2 सतह पर कोई डेंट, स्क्रै च आदि नहीं होना चाहिए, पार्ट की सरफे स फिनिश लिमिट सैंपल की ग्तारह होनी चाहिए।

Parts should be free from sharp edges, chattering, any machining and
3 material defect etc. पार्ट मैं कोई शार्प एज , चैटरिंग, कोई मशीनिंग डिफे क्ट, मटेरियल डिफे क्ट आदि नहीं होना चाहिए ।
No burr at cross hole
B Internal Cleanliness (अंदर की सफाई) :
Use 10x magnification lense and torch for visual of inside holes of the
1 parts. पार्ट के अंदर वाले होलों के विसअ
ु ल इंस्पेक्शन के लिए १० x बड़ा करने वाले लेंस
और टोर्च का प्रयोग करें ।

Every part shall be Checked for Inside Ø3.20 hole debries, burrs and
2 quality of drilling. प्रत्येक पार्ट को Ø3।२० की अंदर बर्र, चिप्स बरु ादा और ड्रिल की
कवालिटी के लिए अच्छी तरह से चेक किया जायेगा।

Check inside cross hole for burr by torch light under magnifying glass.
3 पार्ट की अंदर क्रोस होल पर बर्र की जांच टोर्च की मदद से 10x लेंस के नीचे
होगी ।

Every batch shall be verified by sectioning part for debries, burrs and
4 quality of drilling. हर लॉट की जांच बर्र, चिप्स बुरादा और ड्रिल की कवालिटी के लिए
पार्ट को काट कर होनी चाहिए।

All hole should be free from debries, burr, swarf etc, i.e. any type of
5 contamination not allowed. सभी होल बर्र, चिप्स , बुरादा, और किसी भी प्रकार की गंदिगी से मुक्त और साफ़ होने
चाहिए । No burr at cross hole
Angle 120 face finish should be as per Limit Sample. No dent, scratches
6 allowed at this face. एंगल १२० डिग्री वाले फे स की फिनिश लिमिट सैंपल की तरह होनी चाहिए। इस फे स पर किसी भी
प्रकार का डेन्ट, स्क्रै चेस आदि नहीं होने चाहिए।

All threaded hole finish should be ar per Limit Sample, no chattering and flat
7 thread allowed. सभी थ्रेड होलों की फिनिश लिमिट सैंपल की अनुसार होनी चाहिए, चैटरिंग,और फ्लै ट थ्रेड नहीं चलेगी ।

8 Millipore test should be conducted from external lab for every lot. हर लॉट No Debries allowed in
का सफाई टेस्ट(Millipore test) किसी बाहरी लैब से होना चाहिए। thread & holes
Edition No. Revision No. Effective Date Checked By Approved By
01 00 16.08.2019
ENGG/F/22, Rev. No.: 00
 PAGE:
OPERATIONAL CONTROL PLAN NO. 3 / 8
OPERATIONAL CONTROL PLAN MI/QD/OCP-AA/45
Part Name : Brake Pipe Manifold-10 Process No. : AA/045 Process Name : Visual Inspection
Part No. : LPLA-33835-AA Customer Drg. Rev. No. : Material from (Supplier): Cleaning
Customer Drg. No. : LPLA-33835-AA Customer Drg. Rev. Date. : Material To (Customer) : Packing
Machine Name : Note: -
2 Process Instructions
A External surface(बाहरी सतह) :
Use 10x magnification lense for visual of the parts. विसुअल
1
इंस्पेक्शन के लिए १० x बड़ा करने वाले लेंस का प्रयोग करें ।
Parts should be free from dent, scratches etc at the external surface of the
part, surface finish should be as per Limit Sample. पार्ट की बाहरी
2 सतह पर कोई डेंट, स्क्रै च आदि नहीं होना चाहिए, पार्ट की सरफे स फिनिश लिमिट सैंपल की ग्तारह होनी चाहिए।

Parts should be free from sharp edges, chattering, any machining and
3 material defect etc. पार्ट मैं कोई शार्प एज , चैटरिंग, कोई मशीनिंग डिफे क्ट, मटेरियल डिफे क्ट आदि नहीं होना चाहिए ।

B Internal Cleanliness (अंदर की सफाई) :

Use 10x magnification lense and torch for visual of inside holes of the
1 parts. पार्ट के अंदर वाले होलों के विसुअल इंस्पेक्शन के लिए १० x बड़ा करने वाले लेंस
और टोर्च का प्रयोग करें ।

All threaded hole should be free from debries, burr, swarf etc, i.e. any type of
2 contamination not allowed. सभी होल बर्र, चिप्स , बुरादा, और किसी भी प्रकार की गंदिगी से मुक्त और साफ़ होने
चाहिए ।

Every part shall be Checked for Inside Ø3.20 hole debries, burrs and
3 quality of drilling. प्रत्येक पार्ट को Ø3।२० की अंदर बर्र, चिप्स बरु ादा और ड्रिल की
कवालिटी के लिए अच्छी तरह से चेक किया जायेगा।
Check inside joint hole for burr by torch light under magnifying glass. पार्ट No Burrs allowed in inside
4
की अंदर जोड़ों होल पर बर्र की जांच टोर्च की मदद से 10x लेंस के नीचे होगी । Ø3.20 holes
No Scratches & Dents
Every batch shall be verified by sectioning part for debries, burrs and No Debries allowed in allowed in 120° face
thread & holes
5 quality of drilling. हर लॉट की जांच बर्र, चिप्स बुरादा और ड्रिल की कवालिटी के लिए
पार्ट को काट कर होनी चाहिए।
Angle 120 face finish should be as per Limit Sample. No dent, scratches
6 allowed at this face. एंगल १२० डिग्री वाले फे स की फिनिश लिमिट सैंपल की तरह होनी चाहिए। इस फे स पर किसी भी
प्रकार का डेन्ट, स्क्रै चेस आदि नहीं होने चाहिए।

All threaded hole finish should be ar per Limit Sample, no chattering and flat
7 thread allowed. सभी थ्रेड होलों की फिनिश लिमिट सैंपल की अनुसार होनी चाहिए, चैटरिंग,और फ्लै ट थ्रेड नहीं चलेगी ।

8 Millipore test should be conducted from external lab for every lot. हर लॉट
का सफाई टेस्ट(Millipore test) किसी बाहरी लैब से होना चाहिए।
Edition No. Revision No. Effective Date Checked By Approved By
01 02 11.01.2020
ENGG/F/22, Rev. No.: 00 PAGE: 4 / 8
 PAGE:
OPERATIONAL CONTROL PLAN NO. 5 / 8
OPERATIONAL CONTROL PLAN MI/QD/OCP-AA/45
Part Name : Brake Pipe Manifold-10 Process No. : AA/045 Process Name : Visual Inspection
Part No. : LPLA-33835-AA Customer Drg. Rev. No. : Material from (Supplier): Cleaning
Customer Drg. No. : LPLA-33835-AA Customer Drg. Rev. Date. : Material To (Customer) : Packing
Machine Name : VMC-01 Note: -

Process Instructions
Containment Instructions( सुरक्षा निर्देश )
2
After complete visual inspection of parts, paste adhesive tape at the holes
face so that it would not contaminate again. विसुअल
इंस्पेक्शन पूरा होने पर, सही पार्ट्स पर, चिपकने वाला टेप लगाएं ताकि ये दुबारा गन्दा न हो पाएं ।
1

Reaction Plan
;fn ihl esa dksb deh (Not as per control Plan) gks rks] lqijokbtj dks lwfpr djsa A fiNyk eky
NkaVs] tgkWa rd lgh ihl feysa A

Edition No. Revision No. Effective Date Checked By Approved By

01 00 16.08.2019
ENGG/F/22, Rev. No.: 00
 PAGE: 6 / 8
OPERATIONAL CONTROL PLAN NO.
OPERATIONAL CONTROL PLAN MI/QD/OCP-AA/30
Part Name : Brake Pipe Manifold-10 Process No. : AA/030 Process Name : Drilling & Tapping(VMC)
Part No. : LPLA-33835-AA Customer Drg. Rev. No. : Material from (Supplier): Parting
Customer Drg. No. : LPLA-33835-AA Customer Drg. Rev. Date. : Material To (Customer) : Deburing
Machine Name : VMC-01 Note: -

77°
73°
6

27.28
26.78

General:
No Sharp Edges 19
General Finish 3.2Ra
22
M10x1-6H 15
15.20
2 10.70
10.30 1 14.80 13
0.1 A

175.25 12 0.13 A
14
Rz16

4.75
9.75
9 9.25 7
Ø9.15
8.92
Ø3.28

3
60.70 10 3.12
122°
60.30 50.25 7.00Min 118°
17°
13° 16
4 49.75
4.258
11
3.75

18 0.10 A 21
22 Chamfer 0.50±0.25x45°

5th Set UP
Edition No. Revision No. Effective Date Checked By Approved By
01 00 16.08.2019
ENGG/F/22, Rev. No.: 00
 PAGE: 7/8
5 Inspection Instructions OPERATIONAL CONTROL PLAN NO.MI/QD/OCP-AA/30
* Least Count
Specification (In mm Sample Size / Freq.
Sr. Evaluation Method Unless
Parameter (In mm Unless Otherwise Specified) QCC Control method Responsibility Recording
No. (MMD No.)
Otherwise In-process ATC Type
Specified) Setup
Mean Range Size Freq. Tool Insert Offset Jaws / Fixture

Product Parameters

Thread Plug gauge √ 1Pc /2Hr √ √ √ Process Inspection Report & Setting approval report Inspector YES
1 Inside Thread M10 x 1.0 -6H
Every 10th Part Operator No
Thread Plug gauge

DVC 0.01 √ 1Pc /2Hr √ √ √ Process Inspection Report & Setting approval report Inspector YES
2 Dimension 10,50 10.30 ~ 10.70
Every Part Operator No
Receiver Gauge

DVC 0.01 √ 1Pc /2Hr √ √ √ Process Inspection Report & Setting approval report Inspector YES
3 Dimension 60,50 60.30 ~ 60.70
Every Part Operator No
Receiver Gauge

4 Dimension 50.00 50.30 ~49.70 DVC 0.01 1Pc /2Hr √ √ √ Process Inspection Report & Setting approval report Inspector YES

5 Dimension 27.03 27.28 ~ 26.78 DVC 0.01 √ 1Pc /2Hr √ √ √ Process Inspection Report & Setting approval report Inspector YES

6 Angle 75° 77° ~ 73° Profile Projector 1Pc Set up √ √ √ Process Inspection Report & Setting approval report Inspector YES

DVC 0.01 √ 1Pc /2Hr √ √ √ Process Inspection Report & Setting approval report Inspector YES
7 Minor Diameter (2Nos) Ø9.00 Ø9.15 ~ 8.92 SC
Plug Gauge
Every 10th Part Operator No

TPG+DVC 0.01 √ 2Pc /2Hr √ √ √ Process Inspection Report & Setting approval report
8 Thread depth 7.00Min. SC
TPG+DVC
Every 10th Part

Height gauge+Pin 0.01 √ 1Pc /2Hr √ √ √ Process Inspection Report & Setting approval report Inspector YES
9 Dimension 9.50 9.75 ~ 9.25 SC
Every 10th Part Operator No
Flush Pin Gauge

Plug Gauge √ 1Pc /2Hr √ √ √ Process Inspection Report & Setting approval report Inspector YES
10 Insider Diameter Ø3.20 Ø3.28 ~ 3.12
Plug Gauge Every 10th Part Operator No

Profile projector (Cut piece) & /Set Up

11 Angle 120° 122° ~ 118° SC
Blue matching
√ 1Pc & /2Hr
√ √ √ Process Inspection Report & Setting approval report Inspector YES

SC Denotes significant Characteristics Denotes Major Characteristics Denotes Minor Characteristics

LEGEND: I/P - Inprocess ATC :At Tool Change Indicates Rev No. no.
Edition No. Revision No. Effective Date Checked By Approved By
01 00 16.08.2019
ENGG/F/22, Rev. No.: 00
 PAGE: 8/8
Inspection Instructions OPERATIONAL CONTROL PLAN NO.MI/QD/OCP-AA/30

Specification * Least Count Sample Size / Freq.

(In mm
Sr. (In mm Unless Otherwise Specified) Evaluation Method Unless In-process ATC Type
Parameter QCC Otherwise Control method Responsibility Recording
No. (MMD No.) Specified) Setup
Mean Range Size Freq. Tool Insert Offset Jaws / Fixture

5 Product Parameters
Surface roughness /set up
12 Finish Rz16 SC
tester
√ 1Pc &/alarm
√ √ √ Process Inspection Report & Setting approval report Inspector YES

Spl. . TPG(M12) 1Pc /2Hr √ √ √ Process Inspection Report & Setting approval report Inspector YES
13 Run out 0.10 w.r.t. A
Every 10th Part Operator No
Spl. . TPG(M12)

Spl. . TPG(M12) √ 1Pc /2Hr √ √ √ Process Inspection Report & Setting approval report Inspector YES
14 Concentricity 0.13 w.r.t. A
Every 10th Part Operator No
Spl. . TPG(M12)

Height gauge+Pin 0.01 √ 1Pc /2Hr √ √ √ Process Inspection Report & Setting approval report Inspector YES
15 Drilling Depth (1No.) 15.00 15.20 ~ 14.80
Every 10th Part Operator No
Flush Pin Gauge

Profile Projector (Cut Pc) & Set up &

16 Angle 15° 17° ~ 13° SC 1Pc √ √ √ Process Inspection Report & Setting approval report Inspector YES
Receiver Gauge /shift

17 Dimension 5.00 5.25 ~ 4.75 DVC(Cut Pc) 1Pc /Set up √ √ √ Process Inspection Report & Setting approval report Inspector YES

18 Dimension 4.00 4.25 ~ 3.75 DVC(Cut Pc) √ 1Pc /Set up √ √ √ Process Inspection Report & Setting approval report Inspector YES

Sharp edges,Internal No Sharp edges, Visual (Magnifying

19 1Pc /2Hr √ √ √ Process Inspection Report & Setting approval report Inspector YES
burrs Internal burrs glass & torch)

20 Chamfer 0.50±0.25 x 45° Profile projector (Cut piece) &

√ 1Pc
/Set Up
√ √ √ Process Inspection Report & Setting approval report Inspector YES
(Chamfer Dia 10±0.25(M10) DVC & 2Hr

21 Concentricity 0.10 w.r.t. A Spl. . TPG(M12 & M10) 1Pc /2Hr √ √ √ Process Inspection Report & Setting approval report Inspector YES

Surface roughness
22 General Finish Ra 3.2 Max tester
√ 2Pc /Shift √ √ √ Process Inspection Report & Setting approval report Inspector YES

Process Parameters
Sr.No
Parameter Specification Evaluation Method Size Frequency Control method Responsibility Recording
.

A Lube oil Level Upto Min. Level Mark Level Meter Once / Day at the start of morning Shift Check List Operator YES

SC Denotes significant Characteristics Denotes Major Characteristics Denotes Minor Characteristics

LEGEND: I/P - Inprocess ATC :At Tool Change Indicates Rev No. no.

Edition No. Revision No. Effective Date Checked By Approved By

01 00 16.08.2019