PAGE 1 OF 3

CONTROL PLAN
PROTOTYPE PRE-LAUNCH KEY CONTACT PERSON : BALAJI P (DGM-MFG) DATE (ORIGINAL) : 03.06.2021
x PRODUCTION KEY CONTACT PHONE : 044-27163014 DATE (REVISED) : NIL
CONTROL PLAN NO. : CPN / EM / PAA 819 REVISION : 0 CORE TEAM : QPT CUSTOMER ENGG. APPROVAL / DATE ( If Reqd. ) : NIL
PART NUMBER : PAA 819 REVISION : A SUPPLIER / PLANT APPROVAL / DATE : NIL
CUSTOMER QUALITY APPROVAL / DATE ( IF REQUIRED. ) : NIL
CUSTOMER PART NO.: 545-7489
WHEEL CODE : EAG 349
PART NAME : DW16L x 26 CONSTRUCTION EQUIPMENT WHEEL OTHER APPROVAL DATE (IF REQUIRED) : NIL
SUPPLIER / PLANT : M/s. WIL, SRIPERUMBUDUR SUPPLIER CODE :- PRODUCTION : SPDC ASSEMBLY LINE
MACHINE,DEVICES, JIGS, TOOLS MFG. PROCESS & PRODUCT CHARACTERISTICS POKA YOKE & HUMAN AID CONTROLS

SPECIAL char.class
SAMPLE
OPN. DESCRIPTION OF PRODUCT CONTROL REFERENCE CORRECTIVE
PRODUCT / RESPONSIBILITY REACTION PLAN
NO. OPERATION DESCRIPTION OF PROCESS PRODUCT EVALUATION & METHOD DOCUMENTS CONTROL ACTION PLAN
MACHINE TOOL NUMBER No PROCESS POKA YOKE NO FREQUENCY REACTION PLAN
TOOL PARAMETER CHARACTERISTICS MEASUREMENT METHOD
SPECIFICATION SIZE FREQUENCY
TECHNIQUE

ARRGT EAP 290 LOAD 60 - 100 BAR PRESSURE GAUGE

RIM LOCATOR 1 / EAP 290 CURRENT (I) 170 - 260 A AMMETER

TOP TOOL 2 / EAP 290 VOLTAGE (V) 27 - 32 V VOLTMETER

1 NO DURING SETTING VISUAL SUPERVISOR
CAT MARKING GAS FLOW
3 / EAP 290 15 - 25 Lpm GAS FLOW METER
INSERT (Lpm)

WH.CODE
4 / EAP 290 WIRE DIA (MM) 1.2 mm VERNIER CALIPER
MARKING INSERT

PART NO INSERT 5/ EAP 290 TACK WELD LENGTH 30 mm MIN SCALE / VISUAL

TACK WELD AT REFER:

PRESS DISC 4 PLACES / JOINT WI/EMU/SA/001
(PAD 496) INTO RIM TACK WELD POSITION CIRCUMFERENTIALL VISUAL (Standard Operating
QUARANTINE ,
BASE Y STOP PRODUCTION, Procedure),
300T BARANI PRESS Reflective sensor REWORK IF ANY
(PAR 111) AND TACK (90°APPROX) CORRECT THE F/EMQ/051,
10 & MIG WELDING F/SPDR/EMQ/117 DAILY for valve hole DEFECTIVE
WELD (IN CASE OF SETTING & INFORM WI/EMU/SA/025 (Setup
MACHINE location COMPONENT
LOW INTERFERENCE SUPERVISOR instruction),
PROCESSED
BETWEEN RIM & WI/EMU/SA/020
VALVE HOLE TO BE 5 NOS DURING SETTING
DISC) & MARKING (Parameters List)
INLINE WITH BOLT
HOLES 1 NO 3 TIMES / SHIFT INSPECTION INSPECTOR
VALVE HOLE POSITION (NO RELATION VISUAL REPORT QA
BETWEEN VALVE 1 NO DURING BATCH
HOLE POSITION AND COMPLETION
BOLT HOLES)

AS PER DRG
MARKING VISUAL
PRA 1887
ASSY INSET
DISTANCE FROM
FLANGE FACE TO DISC 191.75 ± 2 mm SCALE
FACE
(AS PER DRGS)
143 / ERG 5 (or) 54 AS PER DRG
RUNNING HUB MARKING VISUAL
/ ERG 207 PRA 1887
BORE LOCATOR 84 / ERG 5 RUNOUT 2.5 mm MAX DIAL INDICATOR
QUARANTINE ,
DURING SETTING
5 NOS REWORK IF ANY
11 / ERG 57 (or) ASSY INSET 3 TIMES / SHIFT INSPECTION INSPECTOR INFORM REFER:
13 INSPECT PEG 1 NO DEFECTIVE
84 / AN 127 DISTANCE FROM DURING BATCH REPORT QA SUPERVISOR F/EMQ/051
1 NO COMPONENT
FLANGE FACE TO DISC 191.75 ± 2 mm SCALE COMPLETION
PROCESSED
FACE
(AS PER DRG)

ARRGT. AN 567 WIRE DIA 4 mm VERNIER CALIPER 1 NO DURING SETTING

BORE LOCATOR 8 / EAW 129 WFS (IPM) 49 - 53 WIRE FEED METER OPERATOR
OPERATOR / TECHNICIAN REFER:
VOLTAGE (V) 27 - 30 VOLTMETER CHECK SHEET WI/EMU/SA/002
1 NO EVERY HOUR
(Standard Operating
TIME (SEC) 160 - 170 TIMER Procedure),
BEVEL HEAD & STEEL WI/EMU/SA/003 1.Tabel timer cut
DRIFT (MM) 25 ± 10 STOP PRODUCTION, QUARANTINE ,
RULE (Welding Parameter off. 2.Torch
PRIMO DISC ▼ CORRECT THE REWORK IF ANY
20 SAW DISC WELD List), WI/EMU/SA/027 F/SPDR/EMQ/117 DAILY forward and doen
WELDER SETTING & INFORM COMPONENT
STICKOUT (MM) 25 - 35 STEEL RULE (Operator Check position limit cut
OPERATOR SUPERVISOR FOUND DEFECTIVE
1 NO DURING SETTING OPERATOR / SUPERVISOR Sheet), off
TORCH ANGLE CHECK SHEET
0° ± 2° BEVEL HEAD WI/EMU/SA/028 (Setup
(DEG)
approval check sheet),
TABLE ANGLE WI/EMU/SA/023 (Setup
35°± 2° BEVEL HEAD
(DEG) instruction)
LEG SIZE 6 mm
LAB TEST 1 NO DURING SETTING LAB REPORT SUPERVISOR
PENETRATION 1.5 mm
CLAMPING
60 - 80 Psi
PRESSURE STOP PRODUCTION REFER: QUARANTINE ,
PRESSURE GAUGE 1 NO DURING SETTING VISUAL SUPERVISOR
SERIAL NUMBER TELESYS MARKING MARKING CORRECT THE WI/EMU/SA/004 REWORK IF ANY
30 10 - 25 Psi
MARKING MACHINE PRESSURE SETTING & INFORM (Standard Operating COMPONENT
UNIQUE SL.NO & INSPECTION INSPECTOR SUPERVISOR Procedure) FOUND DEFECTIVE
MARKING DETAILS VISUAL 100% CONTINUOUS
DATE REPORT QA
 PAGE 2 OF 3

CONTROL PLAN
PROTOTYPE PRE-LAUNCH KEY CONTACT PERSON : BALAJI P (DGM-MFG) DATE (ORIGINAL) : 03.06.2021
x PRODUCTION KEY CONTACT PHONE : 044-27163014 DATE (REVISED) : NIL
CONTROL PLAN NO. : CPN / EM / PAA 819 REVISION : 0 CORE TEAM : QPT CUSTOMER ENGG. APPROVAL / DATE ( If Reqd. ) : NIL
PART NUMBER : PAA 819 REVISION : A SUPPLIER / PLANT APPROVAL / DATE : NIL
CUSTOMER QUALITY APPROVAL / DATE ( IF REQUIRED. ) : NIL
CUSTOMER PART NO.: 545-7489
WHEEL CODE : EAG 349
PART NAME : DW16L x 26 CONSTRUCTION EQUIPMENT WHEEL OTHER APPROVAL DATE (IF REQUIRED) : NIL
SUPPLIER / PLANT : M/s. WIL, SRIPERUMBUDUR SUPPLIER CODE :- PRODUCTION : SPDC ASSEMBLY LINE
MACHINE,DEVICES, JIGS, TOOLS MFG. PROCESS & PRODUCT CHARACTERISTICS POKA YOKE & HUMAN AID CONTROLS

SPECIAL char.class
SAMPLE
OPN. DESCRIPTION OF PRODUCT CONTROL REFERENCE CORRECTIVE
PRODUCT / RESPONSIBILITY REACTION PLAN
NO. OPERATION DESCRIPTION OF PROCESS PRODUCT EVALUATION & METHOD DOCUMENTS CONTROL ACTION PLAN
MACHINE TOOL NUMBER No PROCESS POKA YOKE NO FREQUENCY REACTION PLAN
TOOL PARAMETER CHARACTERISTICS MEASUREMENT METHOD
SPECIFICATION SIZE FREQUENCY
TECHNIQUE

ARRGT & PART CN 1667 (OR) CN

LOAD 60 - 100 BAR
LIST 3174 S-5
PRESSURE GAUGE 1 NO DURING SETTING VISUAL SUPERVISOR
56 (OR) 57 / CN REFER: QUARANTINE ,
TOP TOOL
PLANISH NAVE 600 T BARANI 1667 INFORM WI/EMU/SA/007 REWORK IF ANY
40
(IF REQD). PRESS 28 (OR) 74 / CN 0.75 mm UPTO DIA SUPERVISOR (Standard Operating COMPONENT
BOTTOM TOOL FLATNESS
1667 390 mm MIN INSPECTOR Procedure) FOUND DEFECTIVE
CMM 1 NO DURING SETTING CMM REPORT
QA

6 / BON 148 BORE

143 / ERG 5 (or) 54
RUNNING HUB BORE DIA Ø281+1.0/-0.0 mm GAUGE (OR) 5 NOS FIRST OFF
/ ERG 207
MICROMETER

ASSY INSET DISTANCE

BORE LOCATOR 84 / ERG 5
FROM FLANGE FACE TO
191.75 ± 2 mm SCALE 100% CONTINUOUS
DISC FACE
(AS PER DRG)
11 / ERG 57 (or)
B / H PEG
84 / AN 127
107 / CMN 531 PLUG
BORE GAUGE 6 / BON 148 BOLT HOLE DIA Ø22+1.0/-0.0 mm
GAUGE

BH PLUG GAUGE 107 / CMN 531

NO.OF BOLT HOLES 10 Nos VISUAL
5 NOS FIRST OFF

VALVE HOLE TO BE 3 NOS PATROL

QUARANTINE ,
REFER:
INLINE WITH BOLT INSPECTION INSPECTOR INFORM REWORK IF ANY
43 FINAL INSPECT 1 NO LAST OFF WI/EMU/SA/015,
HOLES REPORT QA SUPERVISOR COMPONENT
F/EMQ/051
VALVE HOLE POSITION (NO RELATION VISUAL FOUND DEFECTIVE
BETWEEN VALVE
HOLE POSITION AND
BOLT HOLES)

FLATNESS 0.75 mm

B / H PCD Ø335 mm
B / H POSITION w.r.t CMM 1 NO DURING SETTING
0.3 mm MAX
BORE AND NAVE
ANGLE INBETWEEN
36°
TWO BOLT HOLES

TYRE SEAT RUNOUT

& WOBBLE AT BOTH
3.5 mm MAX DIAL INDICATOR 100% CONTINUOUS
VISUAL & MOUNTING
SIDES

DURING SETTING REFER:

5 NOS.
F/EMQ/051, QUARANTINE ,
FREE FROM
DP TESTING FOR SURFACE WELD 3 TIMES / SHIFT INSPECTION INFORM WI/EMU/SA/038 REWORK IF ANY
53 SURFACE WELD DYE PENETRANT TEST 1 NO. INSPECTOR QA
DISC WELD DEFECTS REPORT SUPERVISOR (SOP), COMPONENT
DEFECTS
DURING BATCH WI/MFG/EMA/Q-029 FOUND DEFECTIVE
1 NO.
COMPLETION (WI)

DRESS BUTT JOINT QUARANTINE ,

AND TILTING STATION, FREE FROM INFORM REFER: REWORK IF ANY
60 VISUAL AESTHETICS VISUAL 100% CONTINUOUS VISUAL OPERATOR
CIRCUMFERENTIAL SANDER PROJECTION SUPERVISOR WI/EMU/SA/011 (WI) COMPONENT
WELDING OVER LAP FOUND DEFECTIVE
 PAGE 3 OF 3

CONTROL PLAN
PROTOTYPE PRE-LAUNCH KEY CONTACT PERSON : BALAJI P (DGM-MFG) DATE (ORIGINAL) : 03.06.2021
x PRODUCTION KEY CONTACT PHONE : 044-27163014 DATE (REVISED) : NIL
CONTROL PLAN NO. : CPN / EM / PAA 819 REVISION : 0 CORE TEAM : QPT CUSTOMER ENGG. APPROVAL / DATE ( If Reqd. ) : NIL
PART NUMBER : PAA 819 REVISION : A SUPPLIER / PLANT APPROVAL / DATE : NIL
CUSTOMER QUALITY APPROVAL / DATE ( IF REQUIRED. ) : NIL
CUSTOMER PART NO.: 545-7489
WHEEL CODE : EAG 349
PART NAME : DW16L x 26 CONSTRUCTION EQUIPMENT WHEEL OTHER APPROVAL DATE (IF REQUIRED) : NIL
SUPPLIER / PLANT : M/s. WIL, SRIPERUMBUDUR SUPPLIER CODE :- PRODUCTION : SPDC ASSEMBLY LINE
MACHINE,DEVICES, JIGS, TOOLS MFG. PROCESS & PRODUCT CHARACTERISTICS POKA YOKE & HUMAN AID CONTROLS

SPECIAL char.class
SAMPLE
OPN. DESCRIPTION OF PRODUCT CONTROL REFERENCE CORRECTIVE
PRODUCT / RESPONSIBILITY REACTION PLAN
NO. OPERATION DESCRIPTION OF PROCESS PRODUCT EVALUATION & METHOD DOCUMENTS CONTROL ACTION PLAN
MACHINE TOOL NUMBER No PROCESS POKA YOKE NO FREQUENCY REACTION PLAN
TOOL PARAMETER CHARACTERISTICS MEASUREMENT METHOD
SPECIFICATION SIZE FREQUENCY
TECHNIQUE

FIXTURE EAW 184 CURRENT (I) 170 - 260 A AMMETER

VOLTAGE (V) 27 - 32 V VOLTMETER

1 NO DURING SETTING VISUAL OPERATOR
GAS FLOW
15 - 25 Lpm GAS FLOW METER
(Lpm)

WIRE DIA (MM) 1.2 mm VERNIER CALIPER REFER:

WI/EMU/SA/006
POSITION AND FREE FROM VISUAL QUARANTINE ,
AESTHETIC VISUAL (SOP),
WELD VALVE GUARD DEFECTS INFORM REWORK IF ANY
70 MIG WELDER WI/EMU/SA/017
(PWO 525) INLINE SUPERVISOR COMPONENT
VALVE GUARD FILLET (Tooling Instruction),
WITH VALVE HOLE 4 mm FILLET GAUGE FOUND DEFECTIVE
SIZE WI/EMU/SA/020
(Parameter list)
NO OF STITCH WELDS 2 Nos VISUAL LAYOUT
100% CONTINUOUS INSPECTOR EMQA
INSPECTION
VALVE GUARD TO
VALVE GUARD BE INLINE WITH
VISUAL
POSITION VALVE HOLE & BOLT
HOLE

QUARANTINE ,
FREE FROM VISUAL INFORM REWORK IF ANY
73 INSPECT VISUAL AESTHETICS VISUAL 100% CONTINUOUS VISUAL INSPECTOR EMQA
DEFECTS SUPERVISOR COMPONENT
FOUND DEFECTIVE

SHOT BLAST
15 MIN TIMER
TIME
CURRENT 18-22 A AMMETER

QUARANTINE ,
REFER: JIG POSITION
SHOTBLASTING / SHOT BLASTING OPERATOR / REWORK IF ANY
80 1 NO DURING SETTING VISUAL WI/EMU/EMF/019 F/SPDR/EMQ/117 DAILY LIMIT TO START
PICKLING & OILING M/C SUPERVISOR COMPONENT
WI/EMU/EMF/020 SHOTS FLOW
S 230 SHOTS 150 kg/shift WEIGHTER FOUND DEFECTIVE

FREE FROM
DRESS SHARP EDGE, QUARANTINE ,
PROJECTION, DENT
DENT MARK, CUT INFORM REWORK IF ANY
90 VISUAL AESTHETICS MARK, SHARP EDGE, VISUAL 100% CONTINUOUS VISUAL OPERATOR
MARK & OTHER SUPERVISOR COMPONENT
CUT MARK & OTHER
DEFECTS FOUND DEFECTIVE
VISUAL DEFECTS

FREE FROM RUST &

DUST, ROLL MARKS, QUARANTINE ,
SCALE MARKS, INFORM REWORK IF ANY
93 INSPECT VISUAL AESTHETICS VISUAL 100% CONTINUOUS VISUAL INSPECTOR EMQA
SPATTERS AND SUPERVISOR COMPONENT
OTHER VISUAL FOUND DEFECTIVE
DEFECTS
PRE-TREAT AND QUARANTINE ,
100 PAINT AS PER REWORK IF ANY
REFER: CPN/PP/001 , 002
COMP.DRG COMPONENT
110 TOP COAT FOUND DEFECTIVE
VISUAL INSPECTION QUARANTINE ,
113, 120
& PACKING REWORK IF ANY
125 STORE
DISTRIBUTION LOCATION : QPT
CC ▼ Critical characterstics SCRAP DETAILS ENTRY-F/EMQ/046
SC @ Special Characterstics FOR NC HANDLING REFER : WI/MFG/EMA/Q-040
NOTE : INSPECTION CARRIED OUT 3 Times / Shift → FIRST / MIDDLE / LAST OF THE SHIFT
0 03.06.2021 INITIAL RELEASE
REV. REVISION
REVISION HISTORY
NO. DATE
REVIEWED AND APPROVED FELIX PRASAD SAMPATH GIRI BALAMURUGAN DURAI
BY : R&D TDN MFG QAD