Ppap - Q19-W240e 121

PPAP Modules - Index Date: 2.11.
21
Part No & Rev: Q19-W240E121

Part Name: Bearing Cover LSS Process: Machining
Customer Name : ZF Wind Power
Status
Sl no Description Remarks
(A/NA)
1 Design Records NA
2 Authorized Engineering Change (note) Documents NA
3 Engineering Approval / (Concessions if any) NA
4 DFMEA NA
5 PFD A
6 PFMEA A
7 Control Plan A
8 Measurement System Analysis Studies (MSA) A
9 Dimensional Results (Layout Inspection Report) A
10 Records of Material / Performance Tests NA
11 Initial Process Studies (Process Capability) A
12 Process Layout (SOP) A
13 Appearance Approval Report NA
14 Tool Layout A
15 Master Sample NA
16 Checking Aids (with calibration results) A
17 Customer Specific Requirements - Whichever applicable
1) AOI Signed off NA
2) Traceability Marking & record A
3) Packaging Standard A
18 Part Submission Warrant (PSW) A
Comments:
Legend: A-Available, NA-Not Applicable

COMPONENT NAME Bearing Cover LSS REF NO PRD-D-01
DRAWING NUMBER Q19-W240E121 PROCESS FLOW CHART REV NO 0
DRG. REV NO C REV DATE 2.11.21
DRG REV DATE __
CUSTOMER ZF Wind Powers
TEAM MEMBERS Vibinesh , S.P.Balasubramani , Ashokkumar , Prabu
Process Flow Number SBV-PFC-001
Process Flow Rev No & Date 01 / 20.8.22
RAWMATERIA
OPN. & INSP.
INSPECTION
TRANSPORT
OPERATION
INCOMING SOURCES OF PRODUCT
RECEIVING
STORAGE
OPERATION NUMBER DESCRIPTION EQUIPMENT AND FACILITY PROCESS CHARCTERISTICS
VARIATION CHARCTERISTICS
L
Raw material Received From Material defects , Qty
Inward Inspection , Stock verify
10 Supplier/Customer & Incoming DC from Customer Variations, Weight Variation, Stock ,Physical Counting , Inward Inspection
for machining Ref:QA/R/02
Inspection Cutting Tapper
Machine : VTM-1600
Machine ID : VTM-01
VTM-1 st Opn Program Error , Improper OD , ID , Thickness , Drill
Process Parameters , Tool layout , process
20 Jaws : 1,2,3,4 setting , Casting Out , Dia ,Tap
Layout , Work Instructions
Program No : ZF 44 Improper tooling Ref : QA/R/04
Process : Turning , Milling & Drilling
Machine : H Boring -
Machine ID : H Boring - 01
H Boring - 1 Improper setting , Improper Dril Dia, Thread Hole, Process Parameters , Tool layout , process
30 Fixture :
tooling, Handling damage Ref : QA/R/04 Layout , Work Instructions
Q19-W240E121
Process : Drilling & tapping , Angle Holes
Dimensional Results as per

Calibrated Measuring Instruments & Instruments not calibrated ,
40 Final Inspection drawing, Free from rust, dent & Instruments calibrations , Final Inspection
Equipments No sampling Plan
damage
Bins , Separater , Rust prevent Improper packing materials &

50 Packing & Dispatch Free from damages, Oil Apply , Packing Procedure
oils ,Transport Handling
Prepared By / Date : Ashok kumar Approved By / Date ; S.P.Balasubramaniam
S.No Rev No Rev History
1 0 Initial Revision
2 1 Process Combined
Doc No : QA/D/03
QUALITY & CONTROL PLAN
Rev No : 0 Rev Date :
Sample PreLaunch Production
Key contact / Phone Ashok kumar - 9597803696
Part Name / Description Bearing Cover LSS Customer ZF Wind Power

Drawing Number Q19-W240E121 Control Plan No : SBV - CP - 01
Drawing Rev No C Rev date : __ Core Team : Vibinesh , S.P.Balasubramani , Ashokkumar , Prabu
Characteristics Methods
Process name /
Part / proecss Machine, Device, Special Evaluation /
Operation Product / process Reaction plan
number Jigs, Tools for Mfg No Product Process char. Measurement Sample size Sample Frequencey Control method
Description specification / Tolerance
class technique
Quantity as per DC & Physical counting& Stock Ledger & Inward

General - Quantity Verification - 1 no Receipt of every lot
inward inspection inward inspection inspection report
Receiving of 1. If any shortage

part from General Paint Peel off Inward Inspection Free From Paint Peel off Visual 10 nos Every Lot Inward Inspection Report /excess
10 Customer & Inward Area 2. If any Dimesion issue
Inward information to be given
inspection to Customer
General Damage Inward Inspection Free from damage Visual 10 nos Every Lot Inward Inspection Report
General Rust Inward Inspection Free from rust Visual 10 nos Every Lot Inward Inspection Report
Vertical Turning Milling

process Setup approval Report /
1 Bore Diameter Frequency of inspection 780H8 Inside Micrometer 1 Nos 100%
Stage Inspection Report
process control

2 Bore Diameter Frequency of inspection 763.6 Inside Micrometer 1 Nos 100%
process control

3 Bore Diameter Frequency of inspection 774 Inside Micrometer 1 Nos 100%
process control

4 Bore Diameter Frequency of inspection 820 Inside Micrometer 1 Nos 100%
process control

5 Outer Diamter Frequency of inspection 1060H8 Beam Gauge 1 Nos 100%
process control

6 Total Length Frequency of inspection 69 Vernier 1 Nos 100%
process control
7 Face Depth Frequency of inspection 9 Depth Vernier 1 Nos 100%
process control

8 Bore Depth Frequency of inspection 18 Depth Vernier 1 Nos 100%
process control

9 Depth Frequency of inspection 20 Depth Vernier 1 Nos 100%
process control

10 Depth Frequency of inspection 60 Depth Vernier 1 Nos 100%
process control

11 Bore Depth Frequency of inspection 41 Depth Vernier 1 Nos 100%
process control

SURFACE process ROUGHNESS Setup approval Report /
12 Frequency of inspection Ra6.3 1 Nos 100%
Machine : VTM-1600 FINISH TESTER Stage Inspection Report
Machine ID : VTM- process control
01
20 VTM - 1 St Opn
Jaws : Vertical Turning Milling
Program No : SURFACE process ROUGHNESS Setup approval Report /
FINISH TESTER Stage Inspection Report
process control

process control

process control
Vertical Turning Milling Stop the process and

SURFACE process ROUGHNESS Setup approval Report / Adjust.
process control NC parts Will be
Quarentined with Paint
Code
Vertical Turning Milling 1. rework - Yellow
SURFACE process ROUGHNESS Setup approval Report / paint, 2. Material
Stage Inspection Report Rejection - Blue Paint ,
FINISH TESTER
process control 3. Machining rejection -
Red Paint
NC parts Will be
Quarentined with Paint
Code
1. rework - Yellow
paint, 2. Material
Rejection - Blue Paint ,
3. Machining rejection -
Red Paint

process control

19 Chamber Frequency of inspection 2X45 BEVEL 1 Nos 100%
process control

20 17 x Hole Dia Frequency of inspection 22 Bore Dial 1 Nos 100%
process control

21 PCD Frequency of inspection 1120 Vernier 1 Nos 100%
process control

22 Tap Frequency of inspection G1/4 TPG 1 Nos 100%
process control

23 Tap Depth Frequency of inspection 12 Vernier 1 Nos 100%
process control

24 2 x Tap Frequency of inspection M20 TPG 1 Nos 100%
process control
H Boring process
Frequency of inspection Setup approval Report /
25 2 x Tap G3/8 TPG 1 Nos 100%
process control
H Boring process
26 Hole Depth 16 Vernier 1 Nos 100%
process control
H Boring process
27 2 x Hole 30 Vernier 1 Nos 100%
process control
H Boring process
28 Depth 21 Depth Vernier 1 Nos 100%
Machine : H Boring process control
-
Machine ID : H
30 H BORING Boring - 01
Fixture : Q19-
W240E121
Machine : H Boring
-
Machine ID : H
30 H BORING Boring - 01
Fixture : Q19- H Boring process

W240E121 29 1 x Tap G3/8 TPG 1 Nos 100%
process control
H Boring process
30 Hole Depth 18 Vernier 1 Nos 100%
process control
H Boring process
31 Depth 54 Vernier 1 Nos 100%
process control
H Boring process
32 Drill depth 65 Vernier 1 Nos 100%
process control
Final Inspection ,
Dimensional Frequency of inspection As per Final inspection
General As per Drawing 1 No 100% Final Inspection report Quarantine
Inspection Control Report
40 Final Inspection Final Inspection
General Visual Inspection inspection process control As per Visual Standard Visual 1 no 100% Final Inspection report Quarantine
Packing 1 _ Packing ,Oil Apply _ Customer Requirement Packing Procedure 100% Every Lot ___ Quarantine
Packing &
50
Despatch
Hold the lot and
Dispatch 2 Quantity _ _ Customer Requirement Physical counting 100% Every Lot Invoice
Recount
Critical Parameters / Special Charecteristics
Prepared By / Date : J.Ashokkumar Approved By / Date : S.P.Balasubramani
S.No Rev no Rev Date
1 0 Initial Revision
2.11.21
Responsibility
Quality Inspector
Quality Inspector
Quality Inspector
Quality Inspector
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Quality Inspector
Quality Inspector
Dispatch Incharge
Dispatch Incharge
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS(PROCESS FMEA)
Part Name Bearing Cover LSS Process Responsibility Ashok kumar
Format number SBV-FMEA-01
Part No Q19-W240E121 Contact No 9597803696
Rev no / date C / -- Key Date 20.8.22 Revision No 0
Core Team Date (Rev) 20.8.22
Resp. Action Results
C
&
Potential S l Potential Cause(s) / O D R Recommend
Potential Effect(s) of Current Process Current Process Target S O D R
Opn no Operation Name Failure e a Mechanism(s) of c e P ed
Failure Controls Prevention Controls Detection Compl Actions e c e P
Mode v s Failure c t N action(s)
-etion Taken v c t N
s
Date
1. counting missing
Quantity Mismatch coustomer commitment not meet 4 2. worker unawerness 5 Manual Counting Supplier DC QTY 4 80
Inward Inspection
1. Improper inspection at
Production plan will affect , customer end. Work instruction , Training to
Visual Defects 4 4 Final Inspection report 5 80
coustomer commitment not meet 2. worker unawerness final inspector
10
Less Stock Next operation unwash or

Stock under size
Size inconsistancy
Inward Inspection 4 Raw material problem 4 Reqiured as per standard Inform to supplier 4 64
Over Stock for next operation.
Stock over size Tool may break due to Excess
Stock
Assemble part enter Freely , Customer Wrong size adjustment, Training given to operator , Tool First piece inspection report
780,774,820 ID over size Line Stoppage , Function Issue , leakage 5 insert weared, 4 Life Monitoring , Calibrated Stage 3 60
may occur wrong seletion of Instruments inspection report
instrument
Wrong size adjustment, Training given to operator , Tool First piece inspection report
780,774,820 ID under Not enter the Assembly Part , Next insert weared,
size operation issue , Figment Issue
5
wrong seletion of
4 Life Monitoring , Calibrated Stage 3 60
Instruments inspection report
instrument
Wrong size adjustment,

Not enter the Assembly Part , Next insert weared, Training given to operator , Tool First piece inspection report
1060 OD over size operation issue , Figment Issue 5 wrong seletion of 4 Life Monitoring , Calibrated Stage 4 80
instrument Instruments inspection report
Assemble part enter Freely , Customer Wrong size adjustment,

Line Stoppage , Function Issue, leakage insert weared, Training given to operator , Tool First piece inspection report
1060 OD under size may occur 5 wrong seletion of 4 Life Monitoring , Calibrated Stage 4 80
instrument Instruments inspection report
VTM
Machine : VTM-
visual inspection
1600 Machine condition not good Ensure machine PM
Machine ID : Improper Surface finish quickly weared in running
Product may fail due to leakage
6 Insrt weared 5 TO follow tool life chart 3 90
parameter changed To follow sop, First piece inspection report
VTM-01 Hourly inspection
report
Jaws :
Program No :
Line Stoppage , Function Issue , leakage insert weared,
Draill Dia 22 over size
may occur
5
wrong seletion of
20,30 Instruments inspection report
instrument
& H Boring
Machine : H
Boring -
Machine ID : H Wrong size adjustment, Training given to operator , Tool First piece inspection report
Boring - 01 Draill Dia 22 under size Not enter the Assembly Part , Next
operation issue , Figment Issue
5 insert weared,
wrong seletion of
instrument
Fixture :
Wrong size adjustment, Training given to operator , Tool First piece inspection report
M20 Tap , G3/8 , G1/4 Not enter the Assembly Part , Next insert weared,
Tap hole tight operation issue , Figment Issue
5
wrong seletion of
instrument
VTM
Machine : VTM-
1600
Machine ID :
VTM-01
Jaws :
Program No :
20,30
& H Boring POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS(PROCESS FMEA)
Machine : H
Part Name Bearing Cover LSS Process Responsibility Ashok kumar
Boring - Format number SBV-FMEA-01
Machine ID : H
Rev no / date C / -- Key Date 20.8.22 Revision No 0
Boring - 01
Fixture : C
&
s Wrong size adjustment,
M20 Tap , G3/8 , G1/4 Not enter the Assembly Part , Next insert weared,
Training given to operator , Tool First piece inspection report Date
Tap hole tight operation issue , Figment Issue
5
wrong seletion of
instrument
VTM
Machine : VTM-
1600
Machine ID :
VTM-01
Jaws :
Program No :
20,30
& H Boring
Machine : H
Boring - POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS(PROCESS FMEA)
Machine ID : H
PartBoring
Name - 01 Bearing Cover LSS Process Responsibility Ashok kumar
Format number SBV-FMEA-01
Fixture
Rev no / date
: C / -- Key Date 20.8.22 Revision No 0
C
&
s
Date
M20 Tap , G3/8 , G1/4 Line Stoppage , Function Issue , leakage insert weared,
Tap hole No go answer may occur
5
wrong seletion of
instrument
Ensure machine PM First piece inspection report

1120 PCD Not Assemble part not answer, Customer end Machine condition not good
maintained Figment issue
5
Setting error
5 TO follow tool life chart Stage 3 75
To follow sop, inspection report
Improper process
All drawing Dimensional inspection as
Product may fail during use 7 parameters / Insuffcient 3 Training provided 4 84
dimensions per quality plan
stock
40 FINAL INSPECTION +
vibration , line mark,
Customer Requirement not met 7 Improper Handling 3 Training provided 100% visual inspection 4 84
visual apearence
Quanitity Mismatch Customer Requirement not met 7 Improper Palletizsation 3 Work instruction 100% visual inspection 4 84
50 Packing & Dispatch Part Mixup Customer Requirement not met 7 Improper indentification 3 Work instruction 100% visual inspection 4 84
Rust Prevent Oil /

Parts may become rust at Customer Inadequate Trainning /
Moisture Observent 7 3 Work instruction 100% visual inspection 4 84
end Incorrect Work Instructions
not provided
Note : If RPN Number Exceeds 100 , Corrective Action Will be taken
REC. NO : QAD - R06
Final Inspection Report DATE

REV. NO
:
: 01
PAGE : 1 of 1
Customer : ZF WIND POWER Part name : COVER Part number & Rev no :Q19-W240E121 Page:
Operation : Machining Total Qty: 01 Inspected Qty: 01 Invoice no: Date: 2.11.2021
Tolerance Part No
Cus. B.no Description Specification Sp.ch Measuring Remarks
method
Min Max 1
Inside
1 Bore Diameter 780H8 780 780.125 780.060
Micrometer
Inside
2 Bore Diameter 763.6 - - 763.800
Micrometer
Inside
3 Bore Diameter 774 774 774.13 773.100
Micrometer
Inside
4 Bore Diameter 820 820 821.00 820.100
Micrometer
5 1059.835 1060.00 1059.95/1059.

Outer Diamter 1060H8 Beam Gauge
98
6 Total Length 69 - - Vernier 69.000
7 Face Depth 9 8.8 9.00 Depth Vernier 8.900
8 Bore Depth 18 17.9 18.10 Depth Vernier 18.000
9 Depth 20 16.8 17.20 Depth Vernier 20.070
10 Depth 60 58.5 61.50 Depth Vernier 60.400
11 Bore Depth 41 40 41.00 Depth Vernier 40.500
ROUGHNESS
12 SURFACE FINISH Ra6.3 - - OK
TESTER
ROUGHNESS
TESTER
ROUGHNESS
TESTER
ROUGHNESS
TESTER
ROUGHNESS
TESTER
ROUGHNESS
TESTER
ROUGHNESS
TESTER
Ensure by
19 Chamber 2X45 - - OK
program
20 17 x Hole Dia 22 - - Bore Dial 22.05/22.12
21 PCD 1120 - - Vernier 1120.100
22 Tap G1/4 - - TPG OK
23 Tap Depth 12 - - Vernier 14.100
24 2 x Tap M20 - - TPG OK

25 2 x Tap G3/8 - - TPG OK
26 Hole Depth 16 - - Vernier 18.200
27 2 x Hole 30 - - Vernier 30.100
28 Depth 21 - - Depth Vernier 21.500
29 1 x Tap G3/8 - - TPG OK
30 Hole Depth 18 - - Vernier 19.400
31 Depth 54 53.5 54.50 Vernier 54.200
32 Drill depth 65 - - Vernier 65.100
33 Visual Inspection - - OK
Free from burr, dent mark, damage, line mark,drill oval, clamping mark, etc., Visual - -
Accepted Qty 1
Deviation Qty - Remarks:
Rejection Qty -
J.Ashokkumar S.P.Balasubramanyam
Inspected by Approved by
Reference SBV-CA-001
SBV CHECKING AIDS
Rev. status / Date 0 / 20.8.22
Customer : ZF Wind Power Date of origin 20.8.2022
Drawing No : Q19-W240E121 Part Name / Description: Bearing Cover LSS
Calibration
Sl.No. Chresteristics Specification Range Least Count Remark
frequency
1 BEAM GAUGE 1060H8 UP TO 1500 365
2 Inside Micrometer 780H8 50-1500 0.01 365
3 Vernier 69 0-300 0.01 365
4 Depth Vernier 21 0-300 0.01 365
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Prepared by : Ashok kumar Approved by : S.P.Balasubramaniam Page: 01 of 01
Note: Checking aids can include fxtures, Gauges, Models, Templates, Mylars to the product being submitted.
Part Submission Warrant
Part Name Bearing Cover LSS Cust. Part Number

Shown on Drawing No. Q19-W240E121 Org. Part Number Q19-W240E121
Engineering Change Level C Dated __
Additional Engineering Changes __ Dated __
Safety and / or Government Regulation Yes ✘ No Purchase Order No. Weight (kg)
Checking Aid No. SBV-CA-001 Checking Aid Engineering Change Level 0 Dated 20.8.22
ORGANIZATION MANUFACTURING INFORMATION CUSTOMER SUBMITAL INFORMATION

SBV Engineering Works ZF Wind Power
Organization Name & Supplier / Vendor Code Customer Name / Division

Bettatha puram Pudur , Karamadai (Po)
Street Address Buyer / Buyer Code
Coimbatore
City Region Postal Code Country Application
REASON FOR SUBMISSION (Check at least one )

✘ Initial submission Change to Optional Construction or Material
Engineering Change(s) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part Processing
Correction of Discrepancy Parts produced at Additional Location
Tooling Inactive > than 1 year Other - please specify below
REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.
Level 2 - Warrant with product samples and limited supporting data submitted to customer.
✘ Level 3 - Warrant with product samples and complete supporting data submitted to customer.
Level 4 - Warrant and other requirements as defined by customer.
Level 5 - Warrant with product samples and complete supporting data reviewed at organization's manufacturing location.
SUBMISSION RESULTS
The results for ✘ dimensional measurements material and functional tests appearance criteria statistical process package
These results meet all design record requirements: ✘ YES NO (If "NO" - Explanation Required)
Mold / Cavity / Production Process Machining
DECLARATION
I affirm that the samples represented by this warrant are representative of our parts, which were by a process that meets all Production Part Approval Process
Manual 4th Edition Requirements. I further affirm that these samples were produced at the production rate of 1300 Nos / 8 hours.I also certify that documented
evidence of such complince is on file and available for review. I have noted any deviations from thisdeclaration below.
EXPLANATION/COMMENTS:
Is each Customer Tool properly tagged and numbered? YES NO ✘ n/a

Organization Authorized Signature Date : 20.8.22
Print Name S.P.Balasubra maniam Phone No. FAX No.
Title Plant Head E-Mail : sbvengg2015@gmail.com
FOR CUSTOMER USE ONLY (IF APPLICABLE)
Part Warrant Disposition: Approved Rejected Other
Customer Signature Date
Print Name Customer Tracking Number (optional )

Ref No.: SBV - PL - 01
SBV PROCESS LAYOUT
Rev No 0 Date 20.8.22
VTM-1 st Opn
COMPONENT NAME Bearing Cover LSS OPERATION NAME
DRAWING NO Q19-W240E121 PROGRAM NO / REV NO ZF 44
DRAWING REV NO C FIXTURE NAME / NO -
DRAWING REV DATE - PROCESS EQUIPMENT / MACHINE VTM
OPERATION NO 20 CUSTOMER ZF Wind Power
Orientation Component in Clamping condition

Setting Procedure
Pin
1. Air Clean the Chuck
2. Jaws Setting
3. Leg Setting , Turning & Facing
Operating Procedure
1. Job Loading
2. Job Runout & Face out correction
3. Job Clamping and start the process
4. After Roughing , Part should be loose clamped for

finishing
5. Provide Top clamp before drilling
6. Before Declamping , Check all the parameters
Clamping jaws
Clamping Jaws
Rev no Rev Date REV DESCRIPTION IF Any Problem, Follw Paint Code
0 20.8.22 Process Layout Initiated Rework Yellow
Material Rejection Blue

Machining
Red
Rejection
Diviation White
PREPARED BY:J. Ashok kumar APPROVED BY: S.P.Balasubramaniam

Ref No.: SBV-TL-01
SBV TOOL LAYOUT
Rev No 0 Date 20.8.22
Part Name Bearing Cover LSS OPERATION NAME Turning
DRAWING NO Q19-W240E121 PROGRAM NO / REV NO ZF - 44
DRAWING REV NO C FIXTURE NAME / NO -
DRAWING REV DATE - PROCESS EQUIPMENT / MACHINE VTM
OPERATION NO 20 CUSTOMER ZF Wind Power
Tool Length Projection
S No Oprn-Description Cutting Tool/Insert Tool Holder Accessories Speed RPM Feed Tool Life Remarks
(H-offset) Length
1 Turning PCLNR BD50
70 0.3
2 Turning BORING BAR BD50
100 0.3
3 Turning PCLNR BD50
100 0.2
4 Turning VPMT BD50
60 0.2
5 Turning 50.00 FACE MILL BD50 1500 900
6 Turning 22 UDRILL BD50 1000 100
7 Turning 17.5UDRILL BD50 1000 100
8 Turning 11.8 HSS DRILL BD50 700 70
9 Turning M20TAP BD50 80
10 Turning G1/4 TAP BD50 80
11 Turning CHAMBER TOOL BD50 1000 100
Prepared By/Date Approved By/Date

STATISTICAL PROCESS CONTROL STUDY
Doc No : QA/R/27
Rev : 0 -20.8.22
PART NAME: Bearing Cover LSS INSTRUMENT: ID Mic L.COUNT: 0.001

Customer ZF Wind Power
PART NO.: Q19-W240E121 SPECIFIC: 780H8 MACHINE: VTL 01
SAMPLE SIZE: 20 OPERATION: Turning NO.OF DECIMALS: SPC No SPC-001 SPC Date 20.8.22
DATA COLLECTION: - ALL DIMENSIONS ARE IN INCHES / MM
SNO. 1 2 3 4 5 6 7 8 9 10 SAMPLE D2 A2 D4
1 780.080 780.080 780.060 780.080 780.080 780.080 780.070 780.080 780.060 780.080 U.T.L. 780.1250 1 1.123 2.560 3.270
2 780.070 780.090 780.060 780.080 780.090 780.090 780.070 780.080 780.080 780.070 2 1.128 1.880 3.270
3 3 1.693 1.020 2.570
4 L.T.L. 780.0000 4 2.059 0.730 2.230
5 5 2.326 0.590 2.110
CALCULATIONS: -
FOR HISTOGRAM
XLARGE 780.08 780.09 780.06 780.08 780.09 780.09 780.07 780.08 780.08 780.08 Xmax.= 780.090
NO.OF NON CONFORMING PART = 0 NOS.
XSMALL 780.07 780.08 780.06 780.08 780.08 780.08 780.07 780.08 780.06 780.07 Xmin.= 780.060
RANGE 0.01 0.01 0 0 0.01 0.01 0 0.00 0.02 0.01 2= 0.007 NO. OF PARTS ABOVE U.T.L. = 0 NOS.
AVG. 780.075 780.085 780.06 780.08 780.085 780.085 780.07 780.08 780.07 780.075 8= 780.077 NO. OF PARTS BELOW L.T.L. = 0 NOS.
Process Width ( P ) = 0.0301 Specification Width(S) = 0.1250 Index (K)={2 x (D-8) / S}= 0.2241 INTERVAL FREQ. CU. FREQ.
Design Centre ( D ) = 780.0625 Interval = 0.006100 Selecting no. of classes = 5 779.0356 779.0417 0 0
Starting Point = 779.0600 No. of readings= 20.0000 Shift Of '8' from 'D' = 0.014000 779.0417 779.0478 0 0
8 - CHART 779.0478 779.0539 0 0

HISTOGRAM 780.09
U.C.L. 780.08063 780.08063 780.0806 780.0806 780.0806 780.0806 780.0806 780.0806
900.0000
780.085
780.0806 780.0806 779.0539 779.0600 0 0
L.C.L. 780.0724 780.0724 780.0724 780.0724 780.0724 780.0724 780.0724 780.0724
780.08
780.0724 780.0724 779.0600 779.0661 0 0
VALUE
800.0000 780.075
U.C.L. 0.0148 0.0148 0.0148 0.0148 0.0148 0.0148 0.0148 0.0148
780.07 0.0148 0.0148 AVG. 779.0661 779.0722 0 0
U.C.L
700.0000 780.065 .
L.C.L. 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

780.06
0.0000 0.0000 L.C.L
.
779.0722 779.0783 0 0
X-
X-BAR 780.0765 780.0765 780.0765 780.0765 780.0765 780.0765 780.0765 780.0765

780.055
780.0765 780.0765 779.0783 779.0844 0 0
BAR
600.0000
780.05
R-BAR 0.0070 0.0070 0.0070 0.0070 0.0070 0.0070 0.0070 0.0070
780.045 0.0070 0.0070 779.0844 779.0905 0 0
QTY
500.0000
1 2 3 4 5 6 7 8 9 10
SAMPLE 779.0905 779.0966 0 0
400.0000
2 - CHART 779.0966 779.1027 0 0
0.025
300.0000 MINIMUM DECIMAL VALUE M4 VALUE 779.1027 779.1088 0 0
0.02
1.0000 0 U.C.L.8 ={8+A2x2} 780.08063
200.0000
0.015
0.1000 1 RANGE
L.C.L.8 ={8-A2x2} 780.07237
U.C.L.
100.0000
0.01 0.0100 2 L.C.L. U.C.L.2 ={2 x D4} 0.0147700000000106
R-BAR
0.0000 0.005 0.0010 3 L.C.L.2 ={2 x D3} 0

1 2 3 4 5 6 7 8 9 10 11
0
0.0001 4 Std.Dev."σ"= 0.00933
DIMENSION 1 2 3 4 5 6 7 8 9 10
Cp=(S/6σ)= 2.23230
Cpk={1-K}xCp)= 1.732
REMARKS: - PROCESS IS EXCELLENT
AUD. BY Ashokkumar
Update the Data Only in the Yellow Shaded Cell.
GAUGE REPEATABLITY & REPRODUCIBLITY STUDY

Instrument Name : ID Mic Range : 50-1500MM Part No. : 1 Parameter : ID Report No. : 1
Instrument No. : SBV-IMM-01 Least Count : 0.0100 Part Name : shaft Specification : 780.0H8 Date : 20.8.22
###
Appraiser A : ANBU MEASUREMENT UNIT ANALYSIS % PROCESS VARIATION
TRIAL
1 2 3 4 5 6 7 8 9 10 AVERAGE REPEATABILITY-EQUIPMENT VARIATION (EV) ###
1 780.070 780.080 780.080 780.070 780.080 780.070 780.080 780.080 780.080 780.070 Trial K1 %EV = (EV/TV)*100
2 780.070 780.080 780.080 780.070 780.080 780.070 780.080 780.080 780.080 780.070 2 0.8862
3 780.070 780.080 780.080 780.070 780.080 780.070 780.080 780.080 780.080 780.070 EV = R*K1 = 0.000 3 0.5908 = 6.24
Average 780.070 780.080 780.080 780.070 780.080 780.070 780.080 780.080 780.080 780.070 Xa 780.076 Actual 3 0.5908 ###
Range 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 Ra 0.000 REPRODUCIBILITY-APPRAISER VARIATION %AV = (AV/TV)*100
Operator K2 ###
Appraiser B : PRABHU AV = [(Xdiff*K2)2-(EV2/nr)] 2 0.7071 = 5.405
1 780.070 780.080 780.080 780.070 780.080 780.070 780.080 780.080 780.080 780.070 AV = 0.000 3 0.5231 n=no. of parts
2 780.070 780.080 780.080 780.070 780.080 780.070 780.080 780.080 780.080 780.070 Actual 3 0.5231 r=no. of trials
3 780.070 780.080 780.080 780.070 780.080 780.070 780.080 780.080 780.080 780.080
REPEATABILITY & REPRODUCIBILITY
Average 780.070 780.080 780.080 780.070 780.080 780.070 780.080 780.080 780.080 780.073 Xb 780.076 %R&R = (R&R/TV)*100
Range 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.010 Rb 0.001 ###
R&R = (EV2 + AV2) = 8.25
Appraiser C : SENTHIL R&R = 0.000 ###
1 780.070 780.080 780.080 780.070 780.080 780.070 780.080 780.080 780.080 780.070
PART VARIATION (PV)
2 780.070 780.080 780.080 780.070 780.080 780.070 780.080 780.080 780.080 780.070 % PV= 100(PV/TV)
3 780.070 780.080 780.080 780.070 780.080 780.070 780.080 780.080 780.080 780.070 PV = Rp*K3 = 0.003 = 99.66
Average 780.070 780.080 780.080 780.070 780.080 780.070 780.080 780.080 780.080 780.070 Xc 780.076 TOTAL VARIATION (TV) ###
Range 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 Rc 0.000 TV = (R&R2 + PV2) ndc = 1.41 (PV/GRR) ###
Number of distinct categories
Part Avg. Xp 780.070 780.080 780.080 780.070 780.080 780.070 780.080 780.080 780.080 780.071 Rp= 0.010 TV = 0.003 17.02
ndc = or Greater than 5
Part K3
% EV 6.24
2 0.7071
R = (Ra+Rb+Rc)/#OF OPR = 0.000 3 0.5231
% AV 5.40
X Diff =_(Max X - Min X) = 0.000 4 0.4467
No. of trials A2 D3 D4
UCL R = _(R*D4) = 0.001 5 0.4030
% R&R 8.25
LCL R = (R*D3) = 0.000 2 1.880 0 3.267 6 0.3742
X(D.BAR) = 780.08 UCL X BAR = 780.08 3 1.020 0 2.575 7 0.3534
% PV 99.66
LCL X BAR = 780.08 8 0.3375
NOTE: Graph Scale should be adjusted manually and verify the source data. 9 0.3249
10 0.3146
APPRISER - A APPRISER - B APPRISER - C Actual 10 0.3146
1000.000 1000.000 1000.000
800.000 800.000 800.000 REAMRKS
600.000 600.000 600.000
400.000 400.000 400.000 OK NOT OK IMPROVEMENT REQUIRED
200.000 200.000 200.000 OK
0.000 0.000 0.000
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Acceptable, if the R&R % is < 10% & ndc < 5
Conditionally acceptable, if R&R % is between 10 - 30%
Not accepatable if R&R% is > 30%
0.02 0.02 0.02
0.01 0.01 Study Performed by :

0.01
Verified by :
0.00 0.00 0.00
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 Approved by :
Doc No : QA/R/28 Rev No - 00 Dec 03-2021

Ppap - Q19-W240e 121

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PPAP Modules - Index Date: 2.11.

Part No & Rev: Q19-W240E121

Legend: A-Available, NA-Not Applicable

Process Flow Rev No & Date 01 / 20.8.22

Process : Drilling & tapping , Angle Holes

Dimensional Results as per

Bins , Separater , Rust prevent Improper packing materials &

Prepared By / Date : Ashok kumar Approved By / Date ; S.P.Balasubramaniam

S.No Rev No Rev History

Part Name / Description Bearing Cover LSS Customer ZF Wind Power

Quantity as per DC & Physical counting& Stock Ledger & Inward

Receiving of 1. If any shortage

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling Stop the process and

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Vertical Turning Milling

Fixture : Q19- H Boring process

40 Final Inspection Final Inspection

Critical Parameters / Special Charecteristics

Prepared By / Date : J.Ashokkumar Approved By / Date : S.P.Balasubramani

S.No Rev no Rev Date

Less Stock Next operation unwash or

Wrong size adjustment,

Assemble part enter Freely , Customer Wrong size adjustment,

Ensure machine PM First piece inspection report

Rust Prevent Oil /

Final Inspection Report DATE

5 1059.835 1060.00 1059.95/1059.

6 Total Length 69 - - Vernier 69.000

7 Face Depth 9 8.8 9.00 Depth Vernier 8.900

8 Bore Depth 18 17.9 18.10 Depth Vernier 18.000

9 Depth 20 16.8 17.20 Depth Vernier 20.070

10 Depth 60 58.5 61.50 Depth Vernier 60.400

11 Bore Depth 41 40 41.00 Depth Vernier 40.500

20 17 x Hole Dia 22 - - Bore Dial 22.05/22.12

21 PCD 1120 - - Vernier 1120.100

22 Tap G1/4 - - TPG OK

23 Tap Depth 12 - - Vernier 14.100

24 2 x Tap M20 - - TPG OK

26 Hole Depth 16 - - Vernier 18.200

27 2 x Hole 30 - - Vernier 30.100

28 Depth 21 - - Depth Vernier 21.500

29 1 x Tap G3/8 - - TPG OK

30 Hole Depth 18 - - Vernier 19.400

31 Depth 54 53.5 54.50 Vernier 54.200

32 Drill depth 65 - - Vernier 65.100