RESTRICTED (DRAFTIPROVISIONAL) QUALITY ASSURANCE PLAN FOR (CARRIER 4TH PLANETARY GEAR TRAIN(OPN.20,30,60,70) SEMI MACHINED FORGING) DRG.NO.175.40.024-1/SMF (LF NO: 3956401121) No: HVF/T-72C/QAP/40/CARRIER 4TH PLANETARY GEAR TRAIN(OPN.20,30,60,70) SEMI MACHINED FORGING/242198- 00 ISSUE No: 00 DATE: SEP - 2021 QUALITY ASSURANCE (RIG-SUB ASSEMBLY) HEAVY VEHICLES FACTORY AVADI CHENNAI ~ 600 054 Page 1 of 17QUALITY ASSURANCE PLAN (QAP) FOR CARRIER 4TH PLANETARY GEAR TRAIN(OPN.20,30,60,70) SEMI MACHINED FORGING DRG. NO.175.40.024-1/SMF PREPARED BY REVIEWED BY (C.NANDAKUMAR) (V.RAJA) YWMYQA (RIG-SA) WMIQA (RIG-SAIST&CT) APPROVED BY hak (SUBHAM BILWAN) AWMIQA-RIG-(SA) ISSUED BY QUALITY ASSURANCE (RIG- SUB ASSEMBLY) HEAVY VEHICLES FACTORY ‘AVADI CHENNAI ~ 600 054 Page 2 of 17‘CONTENTS PAGE .No. IMPORTANT NOTES. INTRODUCTION AM SCOPE DOCUMENTS: ITEM USED ON LIST OF DRAWINGS: BILL OF MATERIAL, CONDITIONS OF USE/ STORAGE INSTRUCTIONS ‘SAMPLING PLAN VISUAL INSPECTION DIMENSIONAL CHECKS MATERIAL CHECKS, ‘ACCEPTANCE / PERFORMANCE TESTS FITMENT AND PERFORMANCE TEST INTERCHANGEABILITY "7 CALIBRATION CHECKS 18 MARKINGNDENTIFICATION 4 o PRESERVATION CHECK 11 20. PACKING CHECK 1 21 DOCUMENTATION 12 22, REFERENCE 12 23. ANNEXURE-A, 18 24 FIGURE 14-16 26. APPENDIX 7 Page 3 of 17‘IMPORTANT NOTE Note-1 This is only a provisional and wil be amended from tine to time according to the requirement, No addition, deletion and reproduction will be done without permission of The Sr. General Manager, Heavy Vehicles Factory, Avadi, Chennai — 54, Note-2 ‘Any instruction contained in this does not prejudice the terms and conditions of the contract what so ever. In case of any contradiction between the contents ofthis ‘QAP and the elause in the contract, the later wil prevail Note-3 ‘The stores should be manufactured strictly only as per the drawings supplied by the Inspection Authority and not as per the samples, fF any received by the ‘manufacturer for guidance purpose. Note-4 ‘Any amendment issued by the Inspection Authority shall be incorporated in the QAP and the records for the amendments carried out should be maintained as per the Performa at Appendix-A Note-s Th case of any contradiction between the contents of this QAP and drawings issued along withthe contract, the latter wil prevail 2INTRODUCTION 41. This quality plan lays down the ingpection and testing procedure to be carried out “onthe component CARRIER 4TH PLANETARY GEAR TRAIN(OPN.20,30,60,70) SEMI MACHINED FORGING TO DRGNO 175.40.024-4/SMF being procured indigenously. This is prepared, based on the acceptance standards and inspection parameters laid’ down in collaborators documents and on the inspection test standards followed in respect of similar indigenous items, 2. This QAP is the property of Government of India and is able for amendments fas and when required. The Sr. General Manager, Heavy Vehicles Factory, ‘Avadi, Chennai ~ 600 054, is the inspecting Authority for this assembly. Any query carfication on the content ofthis QAP shall be referred to this Factory. ‘Any departure from these instructions is allowed only after written approval ‘rom the above authority. Notwithstanding the tests indicated in this QAP, the inspecting Officer has the right to carry out any test to check conformance to the paper particulars quoted in the Supply Order, which he may consider necessary to satisfy himself about the stores which he has to accept SAM The QAP Is aimed at standardizing the Inspection procedure and acceptance nom for CARRIER 4TH FLANETARY GEAR. TRAIN(OPN.20,30,60,70) SEMI MACHINED FORGING TO ORGNO 175,40.024-11SMF. Page 4 of 17It also aims at giving adequate information fo the manufacturer on the quality requirements so that the required qualiy control methods are established, This is also meant to guide authorized Inspection Officer in his routine inspection and to set out main points to which his attention must be drawn to ensure thatthe accepted siores meet the stipulated standards, 4. SCOPE: ‘This QAP outlines in general terms, the checks and methods to be used during “inspection of | CARRIER’ 4TH PLANETARY — GEAR TRAIN(OPN.20,30,60,70) SEMI MACHINED FORGING TO DRG.NO 175.40.024-1/SMF including the technical requirements of the drawings. The recommended Quality Plan stipulated herein is mandatory and should be stticly adhered to For inspection purpose, only the latest iseue of this QAP will be made ‘applicable and copies of this QAP can be obtained from the issuing authority i.e. The Sr. General Manager, Heavy Vehicles Factory, Avadi, and Chennai Note: i. Tender enquiry (TE) and supply order (S.0) will be issued with QAP stating that inspection willbe done as per QAP. |i In case of TE, itis responsiblity ofthe vendor to obtain the copy of QAP and. give the statement of compliance that vendor will abide by the QAP in case supply order is placed ill In case of S.0, itis the responsible ofthe vendor to obtained copy of QAP and dive the statement of compliance that the vendor will folow QAP. However, GMHIVE reserves the right to revisefupdate the QAP from time to time 5, DOCUMENTS: ) On placement of firm supply order, One set of relevant specification and technical instructions on the subject item can be obtained by the contractor from AHSP through DOOIHVE Any claifcation required on these documents should be obtained from the Inspecting Authority |. The Sr. General Manager, Heavy Vehicles Factory, ‘Avadi, Chennai ~ 600 054. Equivalents to the collaborators specifications and standards will be decided only by the Inspecting Authority and should not be Luniaterally decided, For any change in the specifications, standards or written approval, any alterations in specication can be affected and not otherwise. ©) The process instruction sheets supplied by the collaborators are available with the Authority Holding Sealed Particulars, ie. The Controllerate of Qualty ‘Assurance (Heavy Vehicles), Avadi, Chennai for the referance. The relevant process sheets may be studied at the premises of the AHSP after obtaining necessary permission. The supplier after scrutiny of the concerned process sheets and connected paper particulars should establish the necessary production and inspection facilities, Particulary the inspection test rigs, stands, fitures, template, gauges. etc should be provided as recommended in these process sheets. If process Page 6 of 17 » ¢sheet / Process Book Is not available the detalls particulars/parameters available in the drawings to be sticly adhered. 6.ITEM USED ON: 1) 17540.024-/PL_- CARRIER, 4TH PLANETARY GEAR TRAIN 7. LIST OF DRAWING: DRG. NO NOMENCLATURE | REMARKS ~~} garien ati —| PLANETARY GEAR TRAN (OPN.20,30,60,70) ‘SEMI MACHINED _ |_ “Foran 8. BILL OF MATERIALS: (Individual tems as mentioned in tatle to Para 7) SL [onG. no [NOMENCLATURE | MATERIAL SPECIFICATIONS [ay T ‘CARRIER 4TH | PLANETARY GEAR TRAIN 1 175.40.024- | (py. 20,30,60,70 | STEEL 38XC GOST 4543-71 ‘ISM 7 SEM MACHINED | FORGING Note: VendoriContractor may use approved alternate material if any as specified in drawing/specification. “Also Refer Para 13. 9. CONDITIONS OF USE/STORAGE INSTRUCTIONS ‘This aesemblyitem should be properly packed to proted from transit / handling damage and influence of atmospheric preciptations. In addition, the following parameters should be ensured: (a) The threaded parts if any should be covered with suitable plastic caps to prevent damages. (©) Ifthe item consists of assemblies, each assembly shoule be packed separately. (6) The stores are to be suitably covered for preventing ingress of dust and Dirventry of sunlight / moisture. (@) The packaging slp shall contains (i) Certificate of testing- NABL Certificate. (i) Guarantee! Warranty Certificate, (ii) Service and maintenance instructions. Page 6 of 17(iv) Delivery Slip with Inspector's Acceptance Mark (e) The stores are not permitted to be stored together with ois. Petrol, acids, alkaline and other substances to avoid damage to the metal J’ rubber ‘components 410. SAMPLING PLAN: SI SE] sampting Pian | itor uk | Visual napecton | 100% 05% Gavel napecton evel ae Dimensional 00% | semping, Noma Inspection, ACL 2:8 of IS 2500 (Part-)-2000 i No. for each batch of raw material (ii) | Material inspection | 1.No | orheat treatment lot as required by specifications. (w) | Acceptance test | 100% — (©) | _ Pressure testing Wachining /Fiment7 Performance tial on higher assembly / ‘Tank vay | Wsichangeadiy Test Test standigal vii | Fitures/GaugesiMan | 100% 100 % drelslote | Marking/dentiication | 100% 700% Packingi 2 | poseitn 100% 100%, oy clause Is applicable if mentioned in supply order or project ‘sanction order. ‘A\New (First time supplier ofthis item) supplier should obtain clearance from HVF for buk production which will he issued only after Inspectionfevaluation of pilot samples by HVF. 11. VISUAL INSPECTION [Sampling plan as per Para- 10 ()] ‘The stores are to be visually examined on 100 % of pilot /bulk and same ‘should be free from any defects and all the finishing requirements shall satisfy as indicated in technical conditions of the assembly / component craving, Page 7 of 17The components shall be checked for the folowing and should be free from the defects: ‘+ Defects in construction Cracks/Dents/Scratches Fitment ofall components Presence of foreign particles Moisture and dust Corrosion of metal parts Mechanical imperfections & distortion ‘Any form of deterioration of material and finishing Packing and preservation should be ensured as per drawingsirelevant ‘TY specification (To be ensured on receipt at consignee end) 12, DIMENSIONAL CHECK [Sampling plan as per Para- 10(i)] The dimensions of individual component, sub assembly and major assembly shall be checked and ensured as per respective drawing Dimensional check should be carried out as per samping plan. However, the inspecting authoritytep. may at his discretion, tighten the inspection level and acceptance quality level on the ciltical lems and adapt check point during manufacture 12.4 CARRIER 4TH PLANETARY GEAR TRAIN (OPN.20,30.50,70) SEMI MACHINED FORGING TO DRG.NO-175.40.024-1/SME, 1. All dimensions(Forging and Machining) shall be confirmed as per ‘drawing/specification 2. ‘Surface fiistvRoughness should be confirmed as per drawing and specification. 3. For admissible alternate method for manufacture in dimensions/materiat i any, refer drawinglspecitication. 13) MATERIAL CHECKS [SAMPLING PLAN AS PARA - 10 i)] Material specimen fest bars of the components shall be in conformity as. per the material mentioned in the relevant documertsidrawing. NABL test Feports for all the parameters as per relevant specifications to be submitted, Test samples to be submitted by the vendor to HVF, # required. The material check will be carried out as per sampling plan. *Howerer, if the manufacturer proposes any alternative material at the stage of tender enquiry, the same has to be approved and a written concurrence should be obtained from AHSP through DDOIHVF, before usage of such materials, For each heat codevbatch the test barsftest samples as specified in GOSTIspecification is to be submitted for testing chemical, mechanical and physical properties and other parameters and also the test certificates for the ‘same is fo be submited Page 8 of 1743.4 CARRIER 4TH PLANETARY GEAR TRAIN(OPN.20,30,60,70) SEMI MACHINED FORGING TO ORG.NO-175.40.024-1/SMF ‘) The component should be manufactured from STEEL 38XC GOST wean Chemis proper: apc STEEL 046 GOST 4549-71 ee eS nTENT OF ELEMENTS, - arm e ] 8 [im | a | =e 3a] oo} aso 0 | to to to to 0.035 | 0.935 20 | 0.30 Lofe_| 1% | of | so | Note: For mass fraction of other elements refer GOST 4543-71 ) Mechanical properties: As per STEEL 38XC GOST 454971 Ultimate [Elongation | Relative | Impact point strength, |% reduction | strength | men?” 1 | Nim’ ofsrea % | KCUI (kgfimm!) | (Kgflmm?) | gmniem) oe — Not ess than 735) 930 @ 75 _| _@5) ee 7 | Not PERFORMANCE / ACCEPTANCE TEST: CARRIER 4TH PLANET AR 4. ‘TRAIN (OPN.20,30,60,70) SEMI MACHINED FORGING (OPN NO:020 TURNING) TO DRG.NO.175.40.024.1/SME. 4, Hardness 302-255 BHN, 2. All technical requirements (T-R) points to be corformed as per Process ‘BooK/TD book NoteForging and Machining) ‘Stage wise inspection and process of the component as specified in TD/ Process book J illustration book is to be confirmed by the supplier during ‘manufacturing the components. 2. Firm shall submit the inspaction process detalls/reports to HVF. 3. If requiredi/applicable HVF shal witnessiverify stage wise inspectioniprocess detaile during manufacturing ofthe components, 4, The component may be subject to endurance test, When fited in higher assembly as specified in process ilustration! TD bcok 14.1 PERFORMANCE / ACCEPTANCE TEST: CARRIER 4TH PLANETARY GEAR ‘TRAIN (OPN.20,30,60,70) SEMI MACHINED FORGING (OPN NO-030 TURNING) TO DRG.NO.175,40.024-1/SME, 1. Hardness. 302 -255 BHN, 2, Run out of A & B should not exceed 0.1 mm w.rt 6153, 14.2 PERFORMANCE / ACCEPTANCE TEST: CARRIER 4TH PLANETARY GEAR "TRAIN (OPN.20,30,60,70) SEMI MACHINED FORGING (OPN NO-060 DRILLING) TO DRG.NO.175.40.024-1/SME. Page 9 of 17 For olfier properties refer GOST 4543-771, Hardness 302.255 BHN, 2. Difference of dimension ‘a’ should be within 2.5 mm. 14.3 PERFORMANCE / ACCEPTANCE TEST: CARRIER 4TH PLANETARY GEAR ‘TRAIN (OPN.20,30,60,70) SEMI MACHINED FORGING (OPN NO:070 ‘SLOT MILLING TO DRG.NO.175,40.024-1/SMF. 1. Hardness 302 255 BHN, 2. Difference of dimension ‘a’ should be within 2.5 mm, 3. Shit of axis of reference Dia. 60 mm to Dia. 250 mm should be within 2.5, Note: The Forging Manufacturers are requited to folow the instructions strictly so far as supply of forgings. ‘All billetsfolooms should be used for manufacturing forgings melt wise. The forgings made from particular mould should be clearly marked to avoid mix up with those melts from other melts ) Whi dispatching forgings clear indication of melt should be given in I Note ‘and preferably forgings of each met should be separately dispatched Copies of all test certificates of chemistry, grain size, nctusion, microstructure ‘and physical properties ete, as obtained from stoel suaplies should be along With the test certificates of forgings as carried out at the premises of forging suppliers The forging supplied should satisly the requires chemical and physical properties, microstructure, grain size, inclusions rating, hardenablity etc. €) After normalizing or hardening & tempering, as the case may be, the firms shall check the microstructure as specified in drawing/specifiation/GOST and satisty themselves forts correctness before dispatch of forgings. ) In case of normalized forgings, it has been observed that sometimes microstructure is having banded structure and diffcuties are experienced in broaching the components, hence banded structure wil not be accepted and firms are advised to ensure proper microstructure free from banding before dispatch of the forgings. 16) ELTMENT / MACHINING AND PERFORMANCE TEST: ‘2, Pilot samples should be checked for fitmenlmachining tials and Performance test to ascertain the efficacy of the system under different ‘operating conditons by fiting in higher assembly and repeating it for {nctional checks, wherever required. . The item shall posses appropriate material for mschining as indicated in the drawing and should be supplied in such a way that the components to suit in machinefitures!sigs etc to carry out machining . The component should be free from any defects after machining in tral and should be in line with the parameters as specified in the GOSTi¢rawing and Specification. 4d. The component should be clean, free from distortion, cracks and other harmful defects Page 10 of 17 3)fe. The component shall be well dressed and feted and shall be readily machinable, Preservation coating is to be done afer heat treetment as called for in the specification. 16) INTERCHANGEABILITY: 17) CALIBRATION CHECKS (TEST STANDS/JIGS/FIXTUERSIGAUGES/NSTRUMENTS): ‘The supplier / Contractor should have suitable Instruments, Test Stand, jigs, fixture, mandrels and gauges to cary out ualty checks, to ensure Conformance of components/assembly as per drawirg and Specification TR. points. The supplier / contractor should submit calibration reports for instrumentsfixtures/gauges/mancrels etc, which are used during process of inspection activites. 48) MARKING | IDENTIFICATION, Marking of the items is to be carried out as called for in the relevant drawing, drawing/T R points. Inscription if any on the components is to be cartied out as called for in the drawing/T.R points. Unless otherwise specified in the drawing! specication, ‘marking should not be carried out over the components, For traceability, marking of part No,, Manufacturer name, supply order No, Serial NoJOity, batch No. and manufacture date & year are to be carried out Suitable method can be adopted, provided that the above parameters re legible and considering the parameters mentioned in the drawing and specification 19) PRESERVATION CHECK 4) Preservative coatings are to be stricty adhered to as called for in the drawing. However, equivalent BIS Standards can also be followed, subject to the thickness of the coatinglpreservative is maintained as per the ‘drawingispecitication. ) Other preservations as necessary to prevent damages due to moisture and dust during process, storage and transit are to be carried out. Conventional Methods can also be resorted to 20) PACKING CHECK Components / Assemblies are to be packed separately to avoid ‘damages during transit/ handling of the same. Part No, and NO. of sets are to be marked on the packing, Packing and preservation should be ensured as per drawings/relevant ‘TY specification (To be ensured on receipt at consignee end) Page 11 of 17,Finished products shall be wrapped / packed using black and opaque polyethylene sheet or bags. 21) DOCUMENTATION Firm has to maintain al the documents as per QAP with respect to the SINo.to have traceability, Vendor has to submit Bill of materials, Material test reports, Class‘ Endurance test reports (wherever specified in drawing/TY spectication/QAP) and Complete PIR (pre-inspection reportat the time of offering the item for inspection. HVF will commence inspection only after scrutiny of these documents. ‘The testingfinspection responsibilty to test all the parameters as per QAP and. drawing specifications as mentioned in Annexure -A (enclosed), Pre ingpection reports (PIR) of firm ke, 1. Chemical analysis, 2.Mechanical properties, 3. Pre-forming process. 4. Coating certification (wherever applicable), 5. Calibration reports of instruments and 6. 100% Dimensional inspection reports. 7. Hardness checks, 8. Certificates for Macrolmicro structure (as applicable), 10. Fracture test (as applicable) ‘and other relevant test reports for acceptance of ie Forging, etc, 22) REFERENCE: 2) Drawing No: 175.40.024-1/SMF ») Material spectication as per drawing STEEL 38XC GOST 4543-71 ©) Gost 44-71 Page 120117ANNEXURE:# su | car “ASSEMBLY? TESTS! STANDARDS TOBE INSPECTION Ro, | carecory | gi SStencLy imgpection | STANRRERe MGiremin | ,SESPONSIBLTY | Rewanns : iu) | Pe Mepecten eons | Fnnastoposiceae | Apert wena “oom ie ee ety |e [meme 2] SE) Fenormaenar "Friant propre he” | Rar GH Bure oT TOO BW S| enateral (BOM) SOM 95 per QAP r v R vendor. Geral canosion 8 2 S] | mamas | Teta [ww | ow | Seiten i pay on 4 35) | Hears cece Hearne e fw] a | sim 5 eg Machining Wal | SERISTSpSrere e |e | Seber Zz “ah 6 RO} Dimonsionat checks | Dimensions as per the e wir R Phat Slo} “Sone ‘Ses 7 | EIS] | aninereacestity | wesingrtaoutiry | Renros? Porte e [ov |e | Rue a : psennton tp vasont fat on? Parero 198 | Contmioane ra | re ce tna sen | Or cate v | ow [mas rove wb by fer. Incase of no cmplance InGOst spect essing 3 Page 13 of 1728 | fg.) § ee r Ww ab y ! a » i WS me i Fl CARRIER 4TH PLANETARY GEAR _TRAIN(OPN.20.30,60,70) SEM! wy |ACHINED FORGINGIOPN No:020 TURNING) TO ORG.NO.175.40.024-1/SMF ia | ———_____1 1522 ome FIG, CARRIER _4TH_PLANETARY GEAR TRAIN(OPN.20,30,60,70)_SEM! MAGHINED FORGING(OPN No:030 TURNING) TO DRG.NO.175.40.024-1/SME Page 14 0f 17& | LG 4 HOLES- 92805 (]oe@/ale IN(OPN,20,30,60,70)_SEMI FIG. _CARRIER_4TH PLANETARY _GEAR_TI MACHINED FORGING(OPN No:060 ORILLING) TO ORG.NO.175.40.024-1/SMF Page 15 0f 17308, FIG. CARRIER 4TH PLANETARY GEAR _TRAIN(OPN.20,30.60,70)_SEM MAGHINED FORGING(OPN No:070 SLOT MILLING) TO ORG.NO.175.40.024- SME Page 16 of 17APPENDIX ‘AV RECORD OF AMENDMENTS SI. | Amendment No. & Amended by | Date of | Initial No date Insertion Page 17 of 17,