CONTROL PLAN

Prototype Pre-Launch Production Date (Origin) : Date (Review) & Rev No Prepared By Vikas Tiwari
Key Contact/Phone :Mr. Suraj Soni
Contact Number : +918109092470
Control Plan Number : BEL/CP/23578693 / P03 & 23578820 / P03 07.07.2019 17.10.2019 & 01 Approved By Rohit mandkriya

Core Team : Suraj Soni, Selvan T.G., Devendra Patil, Rohit, DS Chandel, SB Chaurasia,
Part No./ Latest change Level 23578693 / P03 & 23578820 / P03 Customer Engineering Approval Date (If Required) :
Shailendra Dubey and Vikas Tiwari

Part Name/Description. : BRACKET,C-SHAPE LH / RH Supplier Plant Approval Date : Customer Quality Approval Date (If Required) :

Supplier Plant : Pithampur Supplier Code :45841 Other Approval Date (If Required) : Other Approval Date (If Required) :

Characteristic Methods
Control Method
Part/ Machine, Special Reaction Plan
Process Name/ Operation Sample
Process Device, Jig, characteristi Evaluation including corrective
description Product/ Process Specification
No. Tools for Mfg. No. Product Process cs Measurement action
Tolerances Error Proofing/
Techniques Size Freq. Detection
Prevention

Check every batch by 3rd

part (if buy by trader) Inward Inspection
1 RAW MATERIAL -------- E34 T.C. VERIFICATION As per RQC sampling plan RQC Section:03
Check by once in a year (if Record
buy by Mill)

2 SHEET THICKNESS -------- 2±0.2 MICRO METER " " Nill " 1. Inform to Supervisor
2. Containtment of RM.
RM reciept and incoming
10 --- 3. Reject and send back
inspection of sheet
3 LENGTH -------- 2500 ±10 MEASURING TAPE " " Nill " to supplier. (or)
4. Scrap

4 WIDTH -------- 1250 ±10 MEASURING TAPE " " Nill "

FREE FROM RUST, DAMAGE &

5 APPEARANCE -------- VISUAL " " Nill "
BURRS

Inprocess Insp.
1 LENGTH -------- 1250 ±5 M.Tape First & last 2nos. Every one hour Nil
Reprot

2 WIDTH -------- 64 ±1 VC First & last 2nos. Every one hour Stopper in M/c "
1. Inform to Supervisor
Shearing 2. Material sorting
20 Shearing 3 THICKNESS -------- 2 ±0.2 MICRO METER First & last 2nos. Every one hour Nil "
Machine 3. Rework if excess size.
4. Reject if undersize
FREE FROM RUST, DAMAGE &
4 APPEARANCE -------- VISUAL First & last 2nos. Every one hour Nil "
BURRS
BLADE
5 CUTTING -------- SHARP VISUAL First & last 2nos. Every one hour Nil "
EDGE
L 66 ±0.5 VC Inprocess Insp.
1 LENGTH x WIDTH -------- First & last 2nos. Every one hour Stopper pin for strip
W 56.7 ±0.5 & 57.72 ±0.5 MICRO METER Reprot

Tool no. -
2 BLANK PROFILE -------- AS PER MASTER SAMPLE Visual First & last 2nos. Every one hour Nil "
80711-017 1. Inform to Supervisor
30 Blanking 2. Material sorting 3.
Tonnage - Rework 4. Scrap
3 APPEARANCE -------- FREE FROM DAMAGE & BURRS Visual 100%-for O Per Lot Nil "
175T

4 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23578693-OS1 Nil "

 Characteristic Methods
Control Method
Part/ Machine, Special Reaction Plan
Process Name/ Operation Sample
Process Device, Jig, characteristi Evaluation including corrective
description Product/ Process Specification
No. Tools for Mfg. No. Product Process cs Measurement action
Tolerances Error Proofing/
Techniques Size Freq. Detection
Prevention

1st flange height - 29.5 ±1 VC/Height Gauge Inprocess Insp.

1 FLANGE HEIGHT -------- First & last 2nos. Every one hour Nil
2nd flange height - 24.5 ±1 [80711-20] Reprot

2 WIDTH -------- 20 ±0.5 VC First & last 2nos. Every one hour Nil "

Tool no. -
3 DISTANCE -------- 53 ±1 VC First & last 2nos. Every one hour Nil " 1. Inform to Supervisor
80711-019
2. Material sorting
40 Forming LH+RH
3. Rework
Tonnage -
4 RADIUS -------- 2XR4 RG First & last 2nos. Every one hour Nil 4. Reject
175T

5 APPEARANCE -------- FREE FROM DAMAGE & BURRS Visual 100%-for O Per Lot Nil "

6 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23578693-OS2 Nil "

Ø12 +0.4/0.0 Inprocess Insp.

1 HOLE DIAMETER -------- VC / CF [80711-20] First & last 2nos. Every one hour Nil
Ø9 +0.4/0.0 Reprot

2 HOLE POSITION -------- 2x 15 ±1 VC / CF [80711-20] First & last 2nos. Every one hour Nil

Tool no. -
3 HOLE POSITION -------- 14.5 +0.0/-0.5 VC / CF [80711-20] First & last 2nos. Every one hour Nil " 1. Inform to Supervisor
80711-018
2. Material sorting
50 Piercing & parting 2 Station
3. Rework
Tonnage -
4 DIM -------- 9.5 +0.0/-0.5 VC / CF [80711-20] First & last 2nos. Every one hour Nil 4. Reject
175T

5 APPEARANCE -------- FREE FROM DAMAGE & BURRS Visual 100%-for O Per Lot Nil "

6 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23578693-OS3 Nil "

Sr no Rev. No. Revision Date Revision Summary

1 1 17.10.2019 Add Dimension : Radius 2xR4, Dim 9.5+0.0/-0.5

Prepared by Vikas Tiwari Approved by - Rohit Mandkriya

LEGEND FOR INSPECTED BY :E-ENGINNER; O - OPERTOR;I - INSPECTOR;L-LINER LEADER; TPG-THREAD PLUG GAUGE;VC-VERNIER
LEGEND FOR CLASS :CC - CRITICAL ; SC - SIGNIFICANT ; A - A CLASS ;P-PLP; B- B CLASS
CALIPER;F.M-FLAT MICROMETER;PM-POINT MICROMETER;M.T;MEASURING TAPE;DVC; DIGITAL VERNIER CALIPER:

Note - After power failure,Machine break down & fixture break down check suspeced part as well as first part of Production batch

Note=* indicate that Nut torque Check by putting bolt/stud in nut & applying mallet on bolt/nut-in that case nut should not detach from part
 CONTROL PLAN
Prototype Pre-Launch Production Date (Origin) : Date (Review) & Rev No Prepared By Vikas Tiwari
Key Contact/Phone :Mr. Suraj Soni
Control Plan Number : BEL/CP/23527824 /P03 Contact Number : +918109092470
07.07.2019 17.10.2019 & 01 Approved By Rohit mandkriya
23527826 / P03
Part No./ Latest change Level : 23527824 / P03 Core Team : Suraj Soni, Selvan T.G., Devendra Patil, Rohit, DS Chandel, SB Chaurasia,
Customer Engineering Approval Date (If Required) :
23527826 / P03 Shailendra Dubey and Vikas Tiwari

Part Name/Description. : BRACKET,BUMPER INTERFACE Supplier Plant Approval Date : Customer Quality Approval Date (If Required) :

Supplier Plant : Pithampur Supplier Code :45841 Other Approval Date (If Required) : Other Approval Date (If Required) :

Characteristic Methods
Machine, Control Method
Part/ Process Name/ Special Reaction Plan including corrective
Device, Jig, Sample
Process No. Operation description characteristics Product/ Process Evaluation Measurement action
Tools for Mfg. No. Product Process
Specification Tolerances Techniques Error Proofing/
Size Freq. Detection
Prevention
Check every batch by 3rd part (if
As per RQC sampling plan RQC buy by trader)
1 RAW MATERIAL -------- BSK46 T.C. VERIFICATION Inward Inspection Record
Section:03 Check by once in a year (if buy by
Mill)
1. Inform to Supervisor
2 SHEET THICKNESS -------- 3 ±0.3 MICRO METER " " Nill "
RM reciept and 2. Containtment of RM.
10 incoming inspection of --- 3. Reject and send back to supplier.
sheet 3 LENGTH -------- 2500 ±10 MEASURING TAPE " " Nill " (or)
4. Scrap
4 WIDTH -------- 1250 ±10 MEASURING TAPE " " Nill "

FREE FROM RUST, DAMAGE &

5 APPEARANCE -------- VISUAL " " Nill "
BURRS

1 LENGTH -------- 1250 ±5 M.Tape First & last 2nos. Every one hour Nil Inprocess Insp. Reprot

2 WIDTH cs 122 ±1 VC First & last 2nos. Every one hour Stopper in M/c "
1. Inform to Supervisor
Shearing 2. Material sorting
20 Shearing 3 THICKNESS -------- 3 ±0.3 MICRO METER First & last 2nos. Every one hour Nil "
Machine 3. Rework if excess size.
4. Reject if undersize
FREE FROM DAMAGE &
4 APPEARANCE -------- VISUAL First & last 2nos. Every one hour Nil "
BURRS

BLADE CUTTING
5 -------- SHARP VISUAL First & last 2nos. Every one hour Nil "
EDGE

1 LENGTH -------- 221±1 VC First & last 2nos. Every one hour Nil Inprocess Insp. Reprot

2 WIDTH -------- 107±1 VC First & last 2nos. Every one hour Stopper in M/c

3 Distance -------- 57±1 VC First & last 2nos. Every one hour Nil

4 Dim -------- 93.17±1 VC First & last 2nos. Every one hour Nil

Tool no. - 5 Dim -------- 2X 30.01 VC First & last 2nos. Every one hour Nil 1. Inform to Supervisor
80711-008 2. Material sorting
30 Blanking
3. Rework
Tonnage- 175T 6 Distance -------- 98.56±1 VC First & last 2nos. Every one hour Stopper in M/c 4. Scrap

7 Radius -------- 2xR14.5 R.G First & last 2nos. Every one hour Stopper in M/c "

8 Radius -------- 2xR5 R.G First & last 2nos. Every one hour Nil

FREE FROM RUST, DAMAGE &

9 APPEARANCE -------- VISUAL 100%-for O Per Lot Nil "
BURRS

10 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23527824-OS1 Guide plate as per blank profile Inprocess Insp. Reprot
 Characteristic Methods
Machine, Control Method
Part/ Process Name/ Special Reaction Plan including corrective
Device, Jig, Sample
Process No. Operation description characteristics Product/ Process Evaluation Measurement action
Tools for Mfg. No. Product Process
Specification Tolerances Techniques Error Proofing/
Size Freq. Detection
Prevention

1 Slot Size -------- 2X (31.2x17.2)+0.5/-0 VC First & last 2nos. Every one hour Nil Inprocess Insp. Reprot

2 Distance -------- 38.03±1 VC First & last 2nos. Every one hour Nil

Tool no. - 3 Slot C.D. -------- 99 ±0.5 VC First & last 2nos. Every one hour Stopper in M/c " 1. Inform to Supervisor
Slot piercing & 80711-009 2. Material sorting
40
parting and notching 3. Rework
Tonnage- 175T 4 DIMENTION -------- 10±1 4. Reject

FREE FROM DAMAGE &

5 APPEARANCE -------- VISUAL 100%-for O Per Lot Nil "
BURRS

6 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23527824-OS2 Nil "

1 Flange height -------- 29.5±1 HG / CF (80711-11) First & last 2nos. Every one hour Nil Inprocess Insp. Reprot

2 Distance -------- 30.5±1 HG / CF (80711-11) First & last 2nos. Every one hour Nil "

3 Width -------- 133+1.5/-0.0 HG / CF (80711-11) First & last 2nos. Every one hour Nil "

4 Width sc 175+0.0/-0.5 HG / CF (80711-11) First & last 2nos. Every one hour Stopper in M/c "
Tool No :
1. Inform to Supervisor
80711-010
2. Material sorting
50 Forming LH + RH 5 RADIUS -------- R3 RG First & last 2nos. Every one hour Nil "
3. Rework
4. Reject
Tonnage : 175T
6 DIM -------- 25.84±0.1 HG / CF (80711-11) First & last 2nos. Every one hour Nil "

7 DIM -------- 45±1 HG / CF (80711-11) First & last 2nos. Every one hour Nil "

FREE FROM SCORING

8 APPEARANCE -------- VISUAL 100%-for O Per Lot Nil "
DAMAGE & BURRS

9 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23527824-OS3

Sr no Rev. No. Revision Date `

1 2 17.10.19 Add Dimention : Dim 10±1,Radius 2xR5,Dim45±1 & 25.84±0.1

Prepared by Vikas Tiwari Approved by - Rohit Mandkriya

LEGEND FOR INSPECTED BY :E-ENGINNER; O - OPERTOR;I - INSPECTOR;L-LINER LEADER; TPG-THREAD PLUG GAUGE;VC-VERNIER CALIPER;F.M-FLAT MICROMETER;PM-POINT
LEGEND FOR CLASS :CC - CRITICAL ; SC - SIGNIFICANT ; A - A CLASS ;P-PLP; B- B CLASS
MICROMETER;M.T;MEASURING TAPE;DVC; DIGITAL VERNIER CALIPER:

Note - After power failure,Machine break down & fixture break down check suspeced part as well as first part of Production batch

Note=* indicate that Nut torque Check by putting bolt/stud in nut & applying mallet on bolt/nut-in that case nut should not detach from part
 CONTROL PLAN
Prototype Pre-Launch Production Date (Origin) : Date (Review) & Rev No Prepared By Vikas Tiwari
Key Contact/Phone :Mr. Suraj Soni
Contact Number : +918109092470
Control Plan Number : BEL/CP/23527827 / P03 07.07.2019 17.10.2019 & 01 Approved By Rohit mandkriya

Core Team : Suraj Soni, Selvan T.G., Devendra Patil, Rohit, DS Chandel, SB
Part No./ Latest change Level :23527827 / P03 Customer Engineering Approval Date (If Required) :
Chaurasia, Shailendra Dubey and Vikas Tiwari

Part Name/Description. : BRACKET,MFB INTERFACE, LH/RH Supplier Plant Approval Date : Customer Quality Approval Date (If Required) :

Supplier Plant : Pithampur Supplier Code :45841 Other Approval Date (If Required) : Other Approval Date (If Required) :

Characteristic Methods
Control Method
Part/ Machine, Special Sample
Process Name/ Operation Product/ Process Evaluation Reaction Plan including
Process Device, Jig, characteristic
description No. Product Process Specification Measurement corrective action
No. Tools for Mfg. s Error Proofing/
Tolerances Techniques Size Freq. Detection
Prevention

Check every batch by 3rd part (if

buy by trader)
1 RAW MATERIAL -------- BSK46 T.C. VERIFICATION As per RQC sampling plan RQC Section:03 Inward Inspection Record
Check by once in a year (if buy
by Mill)

2 SHEET THICKNESS -------- 5 ±0.4 MICRO METER " " Nill "
1. Inform to Supervisor
2. Containtment of RM.
RM reciept and incoming
10 --- 3. Reject and send back
inspection of sheet 3 LENGTH -------- 2500 ±10 MEASURING TAPE " " Nill "
to supplier. (or)
4. Scrap
4 WIDTH -------- 1250 ±10 MEASURING TAPE " " Nill "

FREE FROM RUST,

5 APPEARANCE -------- VISUAL " " Nill "
DAMAGE & BURRS

1 LENGTH -------- 1250 ±5 M.Tape First & last 2nos. Every one hour Nil Inprocess Insp. Reprot

2 WIDTH -------- 64 ±1 VC First & last 2nos. Every one hour Stopper in M/c Inprocess Insp. Reprot
1. Inform to Supervisor
Shearing 2. Material sorting
20 Shearing 3 THICKNESS -------- 5 ±0.4 MICRO METER First & last 2nos. Every one hour Nil Inprocess Insp. Reprot
Machine 3. Rework if excess size.
4. Reject if undersize
FREE FROM RUST,
4 APPEARANCE -------- VISUAL First & last 2nos. Every one hour Nil Inprocess Insp. Reprot
DAMAGE & BURRS

5 BLADE CUTTING EDGE -------- SHARP VISUAL First & last 2nos. Every one hour Nil Inprocess Insp. Reprot

L 227 ±1
1 LENGTH x WIDTH -------- VC First & last 2nos. Every one hour Nil Inprocess Insp. Reprot
W 64 ±1

2 SLOT SIZE -------- 2 X (37 X 23) +0.5/-0 VC First & last 2nos. Every one hour Nil "

3 DIMENSION -------- 71.38±1 VC First & last 2nos. Every one hour Nil "

Tool no. - 80711- 4 DIMENSION -------- 2x32 ±0.5 VC First & last 2nos. Every one hour Nil " 1. Inform to Supervisor
012 2. Material sorting
30 Slot piercing & parting
3. Rework
Tonnage- 175T 5 DIMENSION -------- 56.78 ±1 VC First & last 2nos. Every one hour Nil 4. Reject

6 SLOT C.D. -------- 99 ±0.5 VC First & last 2nos. Every one hour Nil "

FREE FROM DAMAGE

7 APPEARANCE -------- Visual 100%-for O Per Lot Nil "
& BURRS

8 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23527827-OS1 Guide plate as per blank profile Inprocess Insp. Reprot
 Characteristic Methods
Control Method
Part/ Machine, Special Sample
Process Name/ Operation Product/ Process Evaluation Reaction Plan including
Process Device, Jig, characteristic
description No. Product Process Specification Measurement corrective action
No. Tools for Mfg. s Error Proofing/
Tolerances Techniques Size Freq. Detection
Prevention

1 FLANGE HEIGHT -------- 30 ±1 (TYP) VC/Height Gauge/CF First & last 2nos. Every one hour Nil Inprocess Insp. Reprot

2 INNER WIDTH -------- 175 +1/-0 VC / CF (80711-14) First & last 2nos. Every one hour Nil "

3 DIMENSION -------- 50.51 ±0.5 VC / CF (80711-14) First & last 2nos. Every one hour Nil "

Tool No. -80711- 4 FLATNESS -------- 0.5 FILLER GAUGE First & last 2nos. Every one hour Nil " 1. Inform to Supervisor
013 2. Material sorting
40 Forming
3. Rework
Tonnage- 175T 5 DIMENSION -------- 35.5±1 VC /HG First & last 2nos. Every one hour Nil " 4. Reject

6 RADIUS -------- 2 x R5 RG First & last 2nos. Every one hour Nil "

FREE FROM DAMAGE

7 APPEARANCE -------- Visual 100%-for O Per Lot Nil "
& BURRS

8 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23527827-OS2 Nil "

Sr no Rev. No. Revision Date Revision Summary

1 01 17.10.2019 Add forming Dimention 35.5±1

Prepared by Vikas Tiwari Approved by - Rohit Mandkriya

LEGEND FOR INSPECTED BY :E-ENGINNER; O - OPERTOR;I - INSPECTOR;L-LINER LEADER; TPG-THREAD PLUG GAUGE;VC-VERNIER CALIPER;F.M-FLAT
LEGEND FOR CLASS :CC - CRITICAL ; SC - SIGNIFICANT ; A - A CLASS ;P-PLP; B- B CLASS
MICROMETER;PM-POINT MICROMETER;M.T;MEASURING TAPE;DVC; DIGITAL VERNIER CALIPER:
Note - After power failure,Machine break down & fixture break down check suspeced part as well as first part of Production batch

Note=* indicate that Nut torque Check by putting bolt/stud in nut & applying mallet on bolt/nut-in that case nut should not detach from part
 CONTROL PLAN
Prototype Pre-Launch Production Date (Origin) : Date (Review) & Rev No Prepared By Vikas Tiwari
Key Contact/Phone :Mr. Suraj Soni
Contact Number : +918109092470
Control Plan Number : BEL/CP/23527833 / P03 07.07.2019 17.10.2019 & 01 Approved By Rohit mandkriya

Core Team : Suraj Soni, Selvan T.G., Devendra Patil, Rohit, DS Chandel, SB
Part No./ Latest change Level :23527833 / P03 Customer Engineering Approval Date (If Required) :
Chaurasia, Shailendra Dubey and Vikas Tiwari

Part Name/Description. : BRACKET,SLEEVE, CIRCULAR Supplier Plant Approval Date : Customer Quality Approval Date (If Required) :

Supplier Plant : Pithampur Supplier Code :45841 Other Approval Date (If Required) : Other Approval Date (If Required) :

Characteristic Methods
Control Method
Part/ Machine, Special
Process Name/ Operation Sample Reaction Plan including
Process Device, Jig, characteristic Product/ Process Evaluation Measurement
description No. Product Process corrective action
No. Tools for Mfg. s Specification Tolerances Techniques Error Proofing/
Size Freq. Detection
Prevention

Check every batch by 3rd part (if

buy by trader)
1 RAW MATERIAL -------- E34 T.C. VERIFICATION As per RQC sampling plan RQC Section:03 Inward Inspection Record
Check by once in a year (if buy
by Mill)

2 SHEET THICKNESS -------- 2 ±0.2 MICRO METER " " Nill " 1. Inform to Supervisor
2. Containtment of RM.
RM reciept and incoming
10 --- 3. Reject and send back
inspection of sheet 3 LENGTH -------- 2500 ±10 MEASURING TAPE " " Nill " to supplier. (or)
4. Scrap

4 WIDTH -------- 1250 ±10 MEASURING TAPE " " Nill "

FREE FROM RUST,

5 APPEARANCE -------- VISUAL " " Nill "
DAMAGE & BURRS

First & last

1 LENGTH -------- 1250 ±5 M.Tape Every one hour Nil Inprocess Insp. Reprot
2nos.

First & last

2 WIDTH cs 76 -0.2/+0 VC Every one hour Stopper in M/c "
2nos.
1. Inform to Supervisor
Shearing First & last 2. Material sorting
20 Shearing THICKNESS -------- 2 ±0.2 MICRO METER Every one hour Nil "
Machine 2nos. 3. Rework if excess size.
4. Reject if undersize
FREE FROM RUST, First & last
APPEARANCE -------- VISUAL Every one hour Nil "
DAMAGE & BURRS 2nos.

BLADE First & last

-------- SHARP VISUAL Every one hour Nil "
CUTTING EDGE 2nos.

L 70 ±0.5 First & last

1 LENGTH x WIDTH -------- VC Every one hour Stopper pin for strip Inprocess Insp. Reprot
W 37 ±0.5 2nos.

First & last

Tool no. - 2 BLANK PROFILE -------- AS PER MASTER SAMPLE Visual Every one hour Nil " 1. Inform to Supervisor
2nos.
80711-029 2. Material sorting
30 Blanking
3. Rework
FREE FROM DAMAGE &
Tonnage - 175T 3 APPEARANCE -------- Visual 100%-for O Per Lot Nil " 4. Scrap
BURRS

4 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23527833-OS1 Nil "

 Characteristic Methods
Control Method
Part/ Machine, Special
Process Name/ Operation Sample Reaction Plan including
Process Device, Jig, characteristic Product/ Process Evaluation Measurement
description No. Product Process corrective action
No. Tools for Mfg. s Specification Tolerances Techniques Error Proofing/
Size Freq. Detection
Prevention

First & last

1 FLANGE HEIGHT -------- 27 ±1 VC Every one hour Nil "
2nos.
Tool no. - 1. Inform to Supervisor
80711-030 FREE FROM SCORING 2. Material sorting
40 1st Forming 2 APPEARANCE -------- VISUAL 100%-for O Per Lot Nil "
DAMAGE & BURRS 3. Rework
Tonnage - 175T 4. Reject
3 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23527833-OS2 Nil "

25 +0.5/-0
VC /Go-Nogo gauge First & last
1 INNER DiA. -------- 15.5 +0.3/-0 Every one hour Nil "
[80711-32] 2nos.

First & last

Tool no. - 2 DIM -------- 3 ±1 VC Every one hour Nil " 1. Inform to Supervisor
2nos.
80711-031 2. Material sorting
50 2nd & 3rd Forming
3. Rework
FREE FROM SCORING
Tonnage - 175T 3 APPEARANCE -------- VISUAL 100%-for O Per Lot Nil " 4. Reject
DAMAGE & BURRS

4 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23527833-OS3 Nil "

Sr no Rev. No. Revision Date Revision Summary

1 01 17.10.2019 Add Dimention : Dim 3 ±1

Prepared by Vikas Tiwari Approved by - Rohit Mandkriya

LEGEND FOR INSPECTED BY :E-ENGINNER; O - OPERTOR;I - INSPECTOR;L-LINER LEADER; TPG-THREAD PLUG GAUGE;VC-VERNIER CALIPER;F.M-FLAT
LEGEND FOR CLASS :CC - CRITICAL ; SC - SIGNIFICANT ; A - A CLASS ;P-PLP; B- B CLASS
MICROMETER;PM-POINT MICROMETER;M.T;MEASURING TAPE;DVC; DIGITAL VERNIER CALIPER:
Note - After power failure,Machine break down & fixture break down check suspeced part as well as first part of Production batch

Note=* indicate that Nut torque Check by putting bolt/stud in nut & applying mallet on bolt/nut-in that case nut should not detach from part
 CONTROL PLAN
Prototype Pre-Launch Production Date (Origin) : Date (Review) & Rev No Prepared By Vikas Tiwari
Key Contact/Phone :Mr. Suraj Soni
Control Plan Number : BEL/CP/23628030 / P02 Contact Number : +918109092470
07.07.2019 17.10.2019 & 01 Approved By Rohit mandkriya

Core Team : Suraj Soni, Selvan T.G., Devendra Patil, Rohit, DS Chandel,
Part No./ Latest change Level :23628030 / P02 Customer Engineering Approval Date (If Required) :
SB Chaurasia, Shailendra Dubey and Vikas Tiwari

Part Name/Description. : COLLAR,FRONT BRACKET Supplier Plant Approval Date : Customer Quality Approval Date (If Required) :

Supplier Plant : Pithampur Supplier Code :45841 Other Approval Date (If Required) : Other Approval Date (If Required) :
Characteristic Methods
Control Method
Part/ Machine, Special Sample
Process Name/ Operation Product/ Process Evaluation Reaction Plan including
Proces Device, Jig, characteristic
description No. Product Process Specification Measurement Error Proofing/ corrective action
s No. Tools for Mfg. s Size Freq. Detection
Tolerances Techniques Prevention
Check every batch by 3rd part (if
buy by trader)
1 RAW MATERIAL -------- BSK46 T.C. VERIFICATION As per RQC sampling plan RQC Section:03 Inward Inspection Record
Check by once in a year (if buy by
Mill)
1. Inform to Supervisor
2 SHEET THICKNESS -------- 3 ±0.3 MICRO METER " " Nill " 2. Containtment of RM.
RM reciept and incoming
10 --- 3. Reject and send back
inspection of sheet 3 LENGTH -------- 2500 ±10 MEASURING TAPE " " Nill "
to supplier. (or)
4 WIDTH -------- 1250 ±10 MEASURING TAPE " " Nill " 4. Scrap

FREE FROM RUST,

5 APPEARANCE -------- VISUAL " " Nill "
DAMAGE & BURRS

25 +0.4/-0 X 15.3 First & last

1 Inner Diameter -------- VC Every one hour Nil Inprocess Insp. Reprot
+0.2/-0 2nos.
First & last 1. Inform to Supervisor
2 Outer Diameter -------- 47 +1/-0 X 37 +1/-0 VC Every one hour Nil "
2nos. 2. Material sorting
20 Laser cutting Base program
Laser program First & last 3. Rework
Program -------- Screen visual Every one hour Nil "
(Bel/MC1/025) 2nos. 4. Scrap
FREE FROM DAMAGE
3 APPEARANCE -------- Visual 100%-for O Per Lot Nil "
& BURRS
Sr no Rev. No. Revision Date Revision Summary
1 00 07.07.2019
Prepared by Vikas Tiwari Approved by - Rohit Mandkriya
LEGEND FOR CLASS :CC - CRITICAL ; SC - SIGNIFICANT ; A - A CLASS ;P-PLP; B- B CLASS LEGEND FOR INSPECTED BY :E-ENGINNER; O - OPERTOR;I - INSPECTOR;L-LINER LEADER; TPG-THREAD PLUG GAUGE;VC-VERNIER CALIPER;F.M-FLAT
Note - After power failure,Machine break down & fixture break down check suspeced part as well as first part of Production batch
Note=* indicate that Nut torque Check by putting bolt/stud in nut & applying mallet on bolt/nut-in that case nut should not detach from part
 CONTROL PLAN
Date (Review) & Rev
Prototype Pre-Launch Production Date (Origin) : Prepared By Vikas Tiwari
Key Contact/Phone :Mr. Suraj Soni No
Contact Number : +918109092470
Control Plan Number : BEL/CP/23527844 / P04 07.07.2019 17.10.2019 & 01 Approved By Rohit mandkriya

Core Team : Suraj Soni, Selvan T.G., Devendra Patil, Rohit, DS Chandel,
Part No./ Latest change Level :23527844 / P04 Customer Engineering Approval Date (If Required) :
SB Chaurasia, Shailendra Dubey and Vikas Tiwari

Part Name/Description. : BRACKET,INSTEP SECTION Supplier Plant Approval Date : Customer Quality Approval Date (If Required) :

Supplier Plant : Pithampur Supplier Code :45841 Other Approval Date (If Required) : Other Approval Date (If Required) :
Characteristic Methods
Control Method
Part/ Machine, Special Sample Reaction Plan
Process Name/ Operation Product/ Process Evaluation
Proce Device, Jig, characteristi including corrective
description No. Product Process Specification Measurement Error Proofing/
ss No. Tools for Mfg. cs Size Freq. Detection action
Tolerances Techniques Prevention
Check every batch by
M. tap 3rd part (if buy by
As per RQC sampling plan
1 Tube size -------- 60X40XT3XL6000 Vernier caliper trader) Inward Inspection Record
RQC Section:03
Micro meter Check by once in a year
(if buy by Mill) 1. Inform to Supervisor
2. Containtment of RM.
RM reciept and incoming 2 Material properties -------- ERWYS310 T.C. VERIFICATION " " Nil "
10 3. Reject and send back
inspection of sheet
to supplier. (or)
3 Slot C.D. -------- 60 ±0.5 Visual " " Nil " 4. Scrap

FREE FROM
4 APPEARANCE -------- Visual 100%-for O Per Lot Nil "
DAMAGE & BURRS

First & last Every one 1. Inform to Supervisor

1 Length -------- 910 ±2 M.Tap Nil Inprocess Insp. Reprot 2. Containtment of RM.
2nos. hour
20 Cutting 3. Reject and send back
FREE FROM to supplier. (or)
2 APPEARANCE -------- Visual 100%-for O Per Lot Nil "
DAMAGE & BURRS 4. Scrap

First & last Every one

1 1st Angle -------- 149° ±1° B.P. Nil Inprocess Insp. Reprot
2nos. hour
1. Inform to Supervisor
2. Material sorting
30 1st & 2nd Bending 2 2nd Angle -------- 121° ±1° B.P. " " " "
3. Rework
4. Scrap
FREE FROM
3 APPEARANCE -------- Visual 100%-for O Per Lot Nil "
DAMAGE & BURRS

First & last Every one

1 Length -1 -------- 492 ±1 M. Tap Nil Inprocess Insp. Reprot
2nos. hour
1. Inform to Supervisor
2. Material sorting
40 End taper cutting 2 Length -2 -------- 571 ±1 M. Tap " " " "
3. Rework
4. Scrap
FREE FROM
3 APPEARANCE -------- Visual 100%-for O Per Lot Nil "
DAMAGE & BURRS

2 X (43 +0.4/-0 X First & last Every one

1 Slot size -------- Vernier caliper Nil Inprocess Insp. Reprot
33.3 +0.2/-0) 2nos. hour

2 X (25 +0.4/-0 X 1. Inform to Supervisor

2 Slot size -------- Vernier caliper " " " "
15.3 +0.2/-0) 2. Material sorting
50 Slot cutting
3. Rework
3 Slot C.D. -------- 60 ±0.5 Vernier caliper " " " " 4. Scrap

FREE FROM
4 APPEARANCE -------- Visual 100%-for O Per Lot Nil "
DAMAGE & BURRS
Sr no Rev. No. Revision Date Revision Summary
1 00 07.07.2019
Prepared by Vikas Tiwari Approved by - Rohit Mandkriya
LEGEND FOR CLASS :CC - CRITICAL ; SC - SIGNIFICANT ; A - A CLASS ;P-PLP; B- B CLASS LEGEND FOR INSPECTED BY :E-ENGINNER; O - OPERTOR;I - INSPECTOR;L-LINER LEADER; TPG-THREAD PLUG GAUGE;VC-VERNIER
Note - After power failure,Machine break down & fixture break down check suspeced part as well as first part of Production batch
Note=* indicate that Nut torque Check by putting bolt/stud in nut & applying mallet on bolt/nut-in that case nut should not detach from part
 CONTROL PLAN
Prototype Pre-Launch Production Date (Origin) : Date (Review) & Rev No Prepared By Vikas Tiwari
Key Contact/Phone :Mr. Suraj Soni
Control Plan Number : BEL/CP/23576664 / P04 Contact Number : +918109092470 07.07.2019 17.10.2019 & 01 Approved By Rohit mandkriya

Core Team : Suraj Soni, Selvan T.G., Devendra Patil, Rohit, DS

Part No./ Latest change Level : 23576664 / P04 Customer Engineering Approval Date (If Required) :
Chandel, SB Chaurasia, Shailendra Dubey and Vikas Tiwari

Part Name/Description. : TUBE,CONNECTING Supplier Plant Approval Date : Customer Quality Approval Date (If Required) :

Supplier Plant : Pithampur Supplier Code :45841 Other Approval Date (If Required) : Other Approval Date (If Required) :
Characteristic Methods
Control Method
Part/ Machine, Special Product/ Sample
Process Name/ Evaluation Reaction Plan including
Proces Device, Jig, characteristic Process
Operation description No. Product Process Measurement Error Proofing/ corrective action
s No. Tools for Mfg. s Specification Size Freq. Detection
Techniques Prevention
Tolerances
Check every batch by 3rd part (if
As per RQC sampling plan RQC buy by trader) Inward Inspection
1 RAW MATERIAL -------- YST310 T.C. VERIFICATION
Section:03 Check by once in a year (if buy by Record
Mill)
RM reciept and Hold or reject lot or send
2 TUBE SIZE -------- 38 SQ. X T3 mm VC / Micro meter " " Nill "
10 incoming inspection of --- back to supplier and
sheet 3 LENGTH -------- 5 meter MEASURING TAPE " " Nill " communicate it

FREE FROM
4 APPEARANCE -------- RUST, DAMAGE VISUAL " " Nill "
& BURRS
First & last
1 Length - 1 -------- 540.62 ±1 M. Tap Every one hour Nil Inprocess Insp. Reprot
2nos. Hold The Material for
20 Tapper end cutting 2 Length - 2 -------- 463 ±1 M. Tap " " Nill " any non conformity &
Inform to Supervisor
FREE FROM
5 APPEARANCE -------- Visual 100%-for O Per Lot Nil "
DAMAGE &
Sr no Rev. No. Revision Date Revision Summary
1 00 07.07.2019
Prepared by Vikas Tiwari Approved by - Rohit Mandkriya
LEGEND FOR CLASS :CC - CRITICAL ; SC - SIGNIFICANT ; A - A CLASS ;P-PLP; B- B CLASS LEGEND FOR INSPECTED BY :E-ENGINNER; O - OPERTOR;I - INSPECTOR;L-LINER LEADER; TPG-THREAD PLUG GAUGE;VC-VERNIER CALIPER;F.M-
Note - After power failure,Machine break down & fixture break down check suspeced part as well as first part of Production batch
Note=* indicate that Nut torque Check by putting bolt/stud in nut & applying mallet on bolt/nut-in that case nut should not detach from part
 CONTROL PLAN
Prototype Pre-Launch Production Date (Origin) : Date (Review) & Rev No Prepared By Vikas Tiwari
Key Contact/Phone :Mr. Suraj Soni
Contact Number : +918109092470
Control Plan Number : BEL/CP/23576668 / P03 07.07.2019 17.10.2019 & 01 Approved By Rohit mandkriya

Core Team : Suraj Soni, Selvan T.G., Devendra Patil, Rohit, DS Chandel, SB Chaurasia,
Part No./ Latest change Level : 23576668 / P03 Customer Engineering Approval Date (If Required) :
Shailendra Dubey and Vikas Tiwari

Part Name/Description. : BRACKET,CONNECTING Supplier Plant Approval Date : Customer Quality Approval Date (If Required) :

Supplier Plant : Pithampur Supplier Code :45841 Other Approval Date (If Required) : Other Approval Date (If Required) :

Characteristic Methods
Control Method
Part/ Machine, Special
Process Name/ Operation Sample Reaction Plan including
Proces Device, Jig, characteristic Product/ Process Specification Evaluation
description No. Product Process Measurement corrective action
s No. Tools for Mfg. s Tolerances
Techniques Error Proofing/
Size Freq. Detection
Prevention
Check every batch by 3rd
part (if buy by trader) Inward Inspection
1 RAW MATERIAL -------- BSK46 T.C. VERIFICATION As per RQC sampling plan RQC Section:03
Check by once in a year (if Record
buy by Mill)
1. Inform to Supervisor
2 SHEET THICKNESS -------- 4 ±0.4 MICRO METER " " Nill " 2. Containtment of RM.
RM reciept and incoming
10 --- 3. Reject and send back
inspection of sheet 3 LENGTH -------- 2500 ±10 MEASURING TAPE " " Nill "
to supplier. (or)
4 WIDTH -------- 1250 ±10 MEASURING TAPE " " Nill " 4. Scrap

FREE FROM RUST, DAMAGE &

5 APPEARANCE -------- VISUAL " " Nill "
BURRS

1 LENGTH -------- 1250 ±5 M.Tape First & last 2nos. Every one hour Nil Inprocess Insp. Reprot

2 WIDTH -------- 140 +0/0.5 VC " " Stopper in M/c " 1. Inform to Supervisor
Shearing 3 THICKNESS -------- 4 ±0.4 MICRO METER " " Nil " 2. Material sorting
20 Shearing
Machine 3. Rework if excess size.
FREE FROM RUST, DAMAGE &
4 APPEARANCE -------- VISUAL " " Nil " 4. Reject if undersize
BURRS
5 BLADE CUTTING EDGE -------- SHARP VISUAL " " Nil "
L 130 ±1
VC
1 LENGTH x WIDTH -------- W 135 ±1 " " Stopper pin for strip Inprocess Insp. Reprot
MICRO METER
Tools No T 4 96.19±01
1. Inform to Supervisor
[80711-021] 2 BLANK PROFILE -------- AS PER MASTER SAMPLE Visual " " " " 2. Material sorting
30 Blanking
3. Rework
Tonnage FREE FROM RUST, DAMAGE &
3 APPEARANCE -------- Visual 100%-for O Per Lot Nil " 4. Scrap
175T BURRS

4 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23576668-OS1 Nil "

1) 44 ±1(TYP)
Guide plate as per blank
1 FLANGE HEIGHT -------- 2) 24±1 (TYP) VC/Height Gauge First & last 2nos. Every one hour Inprocess Insp. Reprot
profile
2 INNER WIDTH -------- 60 +1/-0 VC " " " "

3 DISTANCE -------- 121.85 ±1 HG " " " "

Tools No
4 DISTANCE -------- 25.73 ±1 VC " " " " 1. Inform to Supervisor
[80711-022]
2. Material sorting
40 Forming LH+RH
5 DIM -------- 51.8 ±1 VC " " " " 3. Rework
Tonnage
4. Reject
175T 6 RADIUS R50 & 2XR6 RG " " " "
FREE FROM SCORING DAMAGE
7 APPEARANCE -------- VISUAL 100%-for O Per Lot Nil "
& BURRS

8 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23576668-OS2 Nil "

 Characteristic Methods
Control Method
Part/ Machine, Special
Process Name/ Operation Sample Reaction Plan including
Proces Device, Jig, characteristic Product/ Process Specification Evaluation
description No. Product Process Measurement corrective action
s No. Tools for Mfg. s Tolerances
Techniques Error Proofing/
Size Freq. Detection
Prevention

1 HOLE DIAMETER -------- Ø8 +0.4/-0 VC/CF [80711-23] First & last 2nos. Every one hour Nil Inprocess Insp. Reprot

2 HOLE POSITION -------- 36.72±0.5 VC/CF [80711-23] " " " "
Tools No 1. Inform to Supervisor
[80711] HOLE POSITION -------- 30 ±0.5 VC/CF [80711-23] " " " " 2. Material sorting
50 Piercing & parting 2 Station
3. Rework
Tonnage 175T 3 APPEARANCE -------- FREE FROM DAMAGE & BURRS Visual 100%-for O Per Lot Nil " 4. Reject

4 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23576668-OS3 Nil "

Sr no Rev. No. Revision Date Revision Summary

1 01 17.10.2019 Add Dimention : Dim 51.8 ±1 ,Radius R50 & 2XR6, Hole position 36.72 ±0.5

Prepared by Vikas Tiwari Approved by - Rohit Mandkriya

LEGEND FOR INSPECTED BY :E-ENGINNER; O - OPERTOR;I - INSPECTOR;L-LINER LEADER; TPG-THREAD PLUG GAUGE;VC-VERNIER CALIPER;F.M-FLAT
LEGEND FOR CLASS :CC - CRITICAL ; SC - SIGNIFICANT ; A - A CLASS ;P-PLP; B- B CLASS
MICROMETER;PM-POINT MICROMETER;M.T;MEASURING TAPE;DVC; DIGITAL VERNIER CALIPER:
Note - After power failure,Machine break down & fixture break down check suspeced part as well as first part of Production batch

Note=* indicate that Nut torque Check by putting bolt/stud in nut & applying mallet on bolt/nut-in that case nut should not detach from part
 CONTROL PLAN
Prototype Pre-Launch Production Date (Origin) : Date (Review) & Rev No Prepared By Vikas Tiwari
Key Contact/Phone :Mr. Suraj Soni
Control Plan Number : BEL/CP/23578705 / P03 Contact Number : +918109092470 07.07.2019 17.10.2019 & 01 Approved By Rohit mandkriya

Core Team : Suraj Soni, Selvan T.G., Devendra Patil, Rohit, DS Chandel, SB
Part No./ Latest change Level : 23578705 / P03 Customer Engineering Approval Date (If Required) :
Chaurasia, Shailendra Dubey and Vikas Tiwari

Part Name/Description. : BRACKET,TOWER ASSY LH/RH Supplier Plant Approval Date : Customer Quality Approval Date (If Required) :

Supplier Plant : Pithampur Supplier Code :45841 Other Approval Date (If Required) : Other Approval Date (If Required) :

Characteristic Methods
Control Method
Part/ Machine, Special
Process Name/ Operation Sample Reaction Plan including
Proces Device, Jig, characteristic Product/ Process Evaluation
description No. Product Process Specification Measurement corrective action
s No. Tools for Mfg. s Error Proofing/
Tolerances Techniques Size Freq. Detection
Prevention

Check every batch by 3rd part (if

As per RQC sampling plan RQC buy by trader)
1 RAW MATERIAL -------- BSK46 T.C. VERIFICATION Inward Inspection Record
Section:03 Check by once in a year (if buy
by Mill)

2 SHEET THICKNESS -------- 3 ±0.3 MICRO METER " " Nill " 1. Inform to Supervisor
2. Containtment of RM.
RM reciept and incoming
10 --- 3. Reject and send back
inspection of sheet
3 LENGTH -------- 2500 ±10 MEASURING TAPE " " Nill " to supplier. (or)
4. Scrap

4 WIDTH -------- 1250 ±10 MEASURING TAPE " " Nill "

FREE FROM RUST,

5 APPEARANCE -------- VISUAL " " Nill "
DAMAGE & BURRS

1 LENGTH -------- 1250 ±2 M.Tape First & last 2nos. Every one hour Nil Inprocess Insp. Reprot

2 WIDTH -------- 250 ±1 VC First & last 2nos. Every one hour Stopper in M/c "
1. Inform to Supervisor
Shearing 2. Material sorting
20 Shearing 3 THICKNESS -------- 3 ±0.3 MICRO METER First & last 2nos. Every one hour Nil "
Machine 3. Rework if excess size.
4. Reject if undersize
FREE FROM RUST,
4 APPEARANCE -------- VISUAL First & last 2nos. Every one hour Nil "
DAMAGE & BURRS

BLADE
5 -------- SHARP VISUAL First & last 2nos. Every one hour Nil "
CUTTING EDGE

1 LENGTH -------- 217.7 ±1 VC First & last 2nos. Every one hour Nil "

2 WIDTH -------- 250 ±1 VC First & last 2nos. Every one hour Stopper in M/c "

3 Dimension -1 -------- 4 X 47.5 ±1 VC First & last 2nos. Every one hour Nil "

4 Dimension -2 -------- 2 X 62 ±0.5 VC First & last 2nos. Every one hour Nil "

5 Dimension -3 -------- 2 X 79.5 ±1 VC First & last 2nos. Every one hour Nil "
1. Inform to Supervisor
2. Material sorting
Tool no. - 6 Hole Size ------- 10 ±0.5 VC First & last 2nos. Every one hour Nil "
3. Rework
80711-026
30 Piercing & parting 4. Scrap
Tonnage - 175T 7 Hole Size ------- 7.1 ±0.5 VC First & last 2nos. Every one hour Nil "
 1. Inform to Supervisor
Characteristic Methods 2. Material sorting
Tool no. - Control Method
Part/ Machine, Special 3. Rework
Process Name/ Operation 80711-026 Sample Reaction Plan including
Proces
30 Piercing & parting Device, Jig, characteristic Product/ Process Evaluation 4. Scrap
description No. Product Process Specification Measurement corrective action
s No. Tools for Mfg. s Error Proofing/
Tonnage - 175T Tolerances Techniques Size Freq. Detection
Prevention

8 Hole Position ------- 2 X 25.69 ±1 VC First & last 2nos. Every one hour Nil "

9 Hole Position ------- 84.81 ±0.5 VC First & last 2nos. Every one hour Nil "

10 End to hole center ------- 2 X 61.35 ±0.5 HG First & last 2nos. Every one hour Nil "

FREE FROM DAMAGE &

11 APPEARANCE ------- Visual 100%-for O Per Lot Nil "
BURRS

12 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23578705-OS1 Guide plate as per blank profile Inprocess Insp. Reprot

1 Flange height -------- 90 ±1 HG / CF (80711-28) First & last 2nos. Every one hour Nil Inprocess Insp. Reprot

2 Width -------- 51 ±0.5 VC / CF (80711-28) First & last 2nos. Every one hour Nil "

3 Face to hole center -------- 25.5 ±0.7 VC / CF (80711-28) First & last 2nos. Every one hour Nil "
Tool no. - 1. Inform to Supervisor
80711-027 2. Material sorting
50 Forming 4 Radius -------- 2 X R7 RG First & last 2nos. Every one hour Nil "
3. Rework
Tonnage - 175T 4. Scrap
5 Angle -------- 2 x 90 ̊ ±0.5 ̊ BP First & last 2nos. Every one hour Nil "

FREE FROM SCORING

6 APPEARANCE -------- VISUAL 100%-for O Per Lot Nil "
DAMAGE & BURRS

7 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23578705-OS2 Nil "

Sr no Rev. No. Revision Date Revision Summary

1 00 07.07.2019 Add dimension - 2X61.35 ±0.5, 25.5 ±0.7 & 2XR7

Prepared by Vikas Tiwari Approved by - Rohit Mandkriya

LEGEND FOR INSPECTED BY :E-ENGINNER; O - OPERTOR;I - INSPECTOR;L-LINER LEADER; TPG-THREAD PLUG GAUGE;VC-VERNIER CALIPER;F.M-FLAT
LEGEND FOR CLASS :CC - CRITICAL ; SC - SIGNIFICANT ; A - A CLASS ;P-PLP; B- B CLASS
MICROMETER;PM-POINT MICROMETER;M.T;MEASURING TAPE;DVC; DIGITAL VERNIER CALIPER:

Note - After power failure,Machine break down & fixture break down check suspeced part as well as first part of Production batch

Note=* indicate that Nut torque Check by putting bolt/stud in nut & applying mallet on bolt/nut-in that case nut should not detach from part
 CONTROL PLAN
Prototype Pre-Launch Production Date (Origin) : Date (Review) & Rev No Prepared By Vikas Tiwari
Key Contact/Phone :Mr. Suraj Soni
Control Plan Number : BEL/CP/23628039 / P02 Contact Number : +918109092470 07.07.2019 17.10.2019 & 01 Approved By Rohit mandkriya

Core Team : Suraj Soni, Selvan T.G., Devendra Patil, Rohit, DS

Part No./ Latest change Level : 23628039 / P02 Customer Engineering Approval Date (If Required) :
Chandel, SB Chaurasia, Shailendra Dubey and Vikas Tiwari

Part Name/Description. : BRACKET,FRONT BRACKET Supplier Plant Approval Date : Customer Quality Approval Date (If Required) :

Supplier Plant : Pithampur Supplier Code :45841 Other Approval Date (If Required) : Other Approval Date (If Required) :

Characteristic Methods
Control Method
Part/ Machine,
Process Name/ Operation Special Sample Reaction Plan including
Process Device, Jig, Product/ Process Evaluation
description No. Product Process characteristics Specification Measurement corrective action
No. Tools for Mfg. Error Proofing/
Tolerances Techniques Size Freq. Detection
Prevention
Check every batch by 3rd part (if
buy by trader)
1 RAW MATERIAL -------- BSK46 T.C. VERIFICATION As per RQC sampling plan RQC Section:03 Inward Inspection Record
Check by once in a year (if buy by
Mill)

2 SHEET THICKNESS -------- 3 ±0.3 MICRO METER " " Nill "
1. Inform to Supervisor
2. Containtment of RM.
RM reciept and incoming
10 --- 3. Reject and send back
inspection of sheet 3 LENGTH -------- 2500 ±10 MEASURING TAPE " " Nill "
to supplier. (or)
4. Scrap
4 WIDTH -------- 1250 ±10 MEASURING TAPE " " Nill "

FREE FROM RUST,

5 APPEARANCE -------- VISUAL " " Nill "
DAMAGE & BURRS

First & last

1 LENGTH -------- 1250 ±2 M.Tape Every one hour Nil Inprocess Insp. Reprot
2nos.

First & last

2 WIDTH SC 127 ±1 VC Every one hour Stopper in M/c "
2nos.
1. Inform to Supervisor
Shearing First & last 2. Material sorting
20 Shearing 3 THICKNESS -------- 3 ±0.3 MICRO METER Every one hour Nil "
Machine 2nos. 3. Rework if excess size.
4. Reject if undersize
FREE FROM RUST, First & last
4 APPEARANCE -------- VISUAL Every one hour Nil "
DAMAGE & BURRS 2nos.

BLADE First & last

5 -------- SHARP VISUAL Every one hour Nil "
CUTTING EDGE 2nos.

First & last

1 LENGTH -------- 225.42 ±1 VC Every one hour Nil Inprocess Insp. Reprot
2nos.

First & last

2 WIDTH -------- 29±0.5 VC Every one hour Nil "
2nos.

First & last

Tool no. - 3 WIDTH -------- 44 ±0.5 VC Every one hour Stopper in M/c " 1. Inform to Supervisor
2nos.
80711-33 2. Material sorting
30 Blanking
3. Rework if excess size.
First & last
Tonnage - 175T RADIUS -------- 8 X R10 RG Every one hour Niill " 4. Reject if undersize
2nos.

FREE FROM
4 APPEARANCE -------- VISUAL 100%-for O Per Lot Nil "
DAMAGE & BURRS

5 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23628039-OS1 Guide plate as per blank profile Inprocess Insp. Reprot

First & last

1 Flange height -------- 2 X 84.5 ±1 HG Every one hour Nil Inprocess Insp. Reprot
2nos.

First & last

2 WIDTH sc 62 +1/-0 VC Every one hour Stopper in M/c "
2nos.

First & last

Tool no. - 3 RADIUS -------- 2XR5 RG Every one hour Nill " 1. Inform to Supervisor
2nos.
80711-35 2. Material sorting
40 Forming
3. Rework
First & last
Tonnage - 175T 4 ANGLE -------- 2 x 90 ̊+1/-0 ̊ BP Every one hour Nill " 4. Reject
2nos.
 Characteristic Methods
ToolMachine,
no. - Control Method 1. Inform to Supervisor
Part/
Process Name/ Operation 80711-35 Special Sample 2.Reaction
MaterialPlan including
sorting
Process
40 Forming description Device, Jig, Product/ Process Evaluation
No. Product Process characteristics Specification Measurement corrective action
3. Rework
No. Tools for Mfg. Error Proofing/
Tonnage - 175T Tolerances Techniques Size Freq. Detection 4. Reject
Prevention
FREE FROM
5 APPEARANCE -------- SCORING DAMAGE VISUAL 100%-for O Per Lot Nil "
& BURRS

6 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23628039-OS2 Nil "

First & last

1 Hole Diameter -------- 10 ±0.5 VC / CF (80711-36) Every one hour Nil Inprocess Insp. Reprot
2nos.

First & last

2 Hole Position -------- 34.0+1/-0.5 VC / CF (80711-36) Every one hour Nil "
2nos.
Tool no. - 1. Inform to Supervisor
80711-34 First & last 2. Material sorting
50 Piercing 3 Hole Position -------- 14.5 ±0.5 VC / CF (80711-36) Every one hour Nil "
2nos. 3. Rework
Tonnage - 175T 4. Reject
FREE FROM
4 APPEARANCE -------- VISUAL 100%-for O Per Lot Nil "
DAMAGE & BURRS

5 SHUT HEIGHT ------- AS PER PRESS SHOP OS 23628039-OS3 Nil Inprocess Insp. Reprot

Sr no Rev. No. Revision Date Revision Summary

1 00 17.10.2019 Add Dimention : Dim 34 ±1/-0.5

Prepared by Vikas Tiwari Approved by - Rohit Mandkriya

LEGEND FOR INSPECTED BY :E-ENGINNER; O - OPERTOR;I - INSPECTOR;L-LINER LEADER; TPG-THREAD PLUG GAUGE;VC-VERNIER CALIPER;F.M-FLAT
LEGEND FOR CLASS :CC - CRITICAL ; SC - SIGNIFICANT ; A - A CLASS ;P-PLP; B- B CLASS
MICROMETER;PM-POINT MICROMETER;M.T;MEASURING TAPE;DVC; DIGITAL VERNIER CALIPER:
Note - After power failure,Machine break down & fixture break down check suspeced part as well as first part of Production batch

Note=* indicate that Nut torque Check by putting bolt/stud in nut & applying mallet on bolt/nut-in that case nut should not detach from part
Process Manual Belmaks Metal (India) Ltd. Unit 1 & 2 Section : 17

Process Code: NPD Control Plan Revision : 01

Prototype Pre-launch Production Suraj Soni, Selvan T.G., Devendra Patil, Rohit Mandkriya, DS Control Plan No. : CP/Volvo / 23576633-
Core Team Rev. No. : 01
Chandel, SB Chaurasia, Shailendra Dubey and Vikas Tiwari 90_P05/00

Part Name FRONT SUPPORT INSTEP ASSY RH-MED Plant Approval Date : Original Date : 30.06.2016 Rev. Date : 14.12.2016

23576633_P05
Part No. Other Approval Date : Customer Engineering Approval / Date (if Req'd):
23576690_P05

Drawing No. 78537849_05 Key Contact Name : Praffulla Shringi Customer Quality / Approval / Date (if Req'd):

MODEL /
P9218 Key Contact No. : 8827392481 Other Approval/Date (if Req'd) :
PROJECT

Customer : VOLVO

Part No. & Ver. : 82653796_P07, 82653800_P07 Part Name : BRACKET, CONNECTING
Drawing No. & Rev. : --- Part Status : Child Part
Characteristics Methods
Specia
Part/ Process Name/ Machine,Device Sample
l Responsibilit
Process Operation , Jig., Tools for Product /process Evaluation Reaction Plan
Char. y
Number Description Mfg. No Product Process Specification / Measurement Control Method
Class Size Freq.
Tolerance Technique

Check every batch by

3rd part (if buy by
1 Raw material BSK 46 T.C.Verification Once Every Lot trader)
Check by once in a year 1. Inform to
(if buy by Mill) Supervisor
2. Containtment
INCOMING OF of RM.
10 RQC inspector
RAW MATERIAL 2 Sheet thickness 3±0.3 Micro meter As RQC sampling plan Incoming ins report 3. Reject and
send back to
supplier. (or)
3 Length 2500±5 M.Tape " " "
4. Scrap

4 Width 1250±2 M.Tape " " "

Free from
5 Appearance Visual 100% Continuous "
damage,burrs
As per Inprocess Inprocess Inspection 1. Inform to
1 Length 1250±1.0 M.Tape
sampling plan report Supervisor
2. Material
2 Width 110±0.5 VC " " "
sorting Inprocess
Shearing 3. Rework if Inspector
20 SHEARING 3 Thickness 3±0.3 Micro meter " " "
machine excess size.
Free from 4. Reject if
4 Appearance Visual 100% Continuous " undersize
damage,burrs
Blade
5 Sharp Visual 1 Start of shift -- -- Shift incharge
cutting edge
 As per Inprocess Inprocess Inspection
1 Length 109±0.5 VC
sampling plan report

2 Width-1 49±0.5 VC " " "

1. Inform to
3 Width -2 42.5±0.5 VC " " " Supervisor
2. Material
sorting Inprocess
4 Hole Dia 2-Ø9+0.5 VC " " "
3. Rework if Inspector
BLANKING & excess size.
30 400TEC 5 Hole CD 44±0.5 VC " " " 4. Reject if
PIERCING
undersize
Hole Position
6 30±0.5 VC " " "
from edge

7 End to Hole CD 12±0.5 VC " " "

Free from
8 Appearance 100% Continuous " " Shift incharge
damage,burrs
Ref Die Height Data Steel Rule / Inform HOD QA Shift incharge,
9 Shut Height Setting / Shift OS
sheet Measuring tape / Reject Operators
As per Inprocess Inprocess Inspection
1 Width 75 +1.0 VC
sampling plan report 1. Inform to
Hole Position Supervisor
2 15.17±0.5 VC " " "
from edge 2. Material
sorting Inprocess
3 Flange height 20±1 VC " " "
3. Rework if Inspector
40 FORMING 400TEC
excess size.
4 Flange height 19.6±1 VC " " " 4. Reject if
undersize
5 Appearance Free from tool mark Visual 100% Continuous "

Ref Die Height Data Steel Rule / Inform HOD QA Shift incharge,
6 Shut Height Setting / Shift OS
sheet Measuring tape / Reject Operators

Part No. & Ver. : 82642118_P09, 82644202_P08 Part Name : BRACKET,STEP SUPP LH

Drawing No. & Rev. : --- Part Status : Child Part

Check every batch by
3rd part (if buy by
Inform HOD QA
1 Raw material BSK 46 T.C.Verification Once Every Lot trader)
/ Reject
Check by once in a year
(if buy by Mill)
2 Sheet thickness 3±0.3 Micro meter As RQC sampling plan Incoming insp. report 1. Inform to
INCOMING OF
10 Supervisor RQC inspector
RAW MATERIAL
2. Material
3 Length 2500±5.0 M.Tape " " "
sorting
3. Rework if
4 Width 1250±2.0 M.Tape " " " excess size.
Free from 4. Reject if
5 Appearance Visual 100% Continuous " undersize
damage,burrs
As per Inprocess Inprocess Inspection 1. Inform to
1 Length 430 ±0.5 HG
sampling plan report Supervisor
2. Material
2 Width 270 ±0.5 VC " " "
sorting Inprocess
Shearing 3. Rework if Inspector
20 SHEARING 3 Thickness 3±0.3 Micro meter " " "
machine excess size.
Free from 4. Reject if
4 Appearance Visual 100% Continuous " undersize
damage,burrs
Blade
5 Sharp Visual 1 Start of shift -- -- Shift incharge
cutting edge
 As per Inprocess Inprocess Inspection Inform HOD QA Inprocess
1 Dimensions As per sample part Visual
sampling plan report / Reject Inspector
Free from
30 PIERCING PS 175T 2 Appearance 100% Continuous " " Shift incharge
damage,burrs
Ref Die Height Data Steel Rule / Inform HOD QA Shift incharge,
3 Shut Height Setting / Shift OS
sheet Measuring tape / Reject Operators
As per Inprocess Inprocess Inspection Inform HOD QA Inprocess
1 Dimension As per sample part Visual
sampling plan report / Reject Inspector
40 BLANK CUTTING PS 200TY
Free from
2 Appearance 100% Continuous " " Shift incharge
damage,burrs
As per Inprocess Inprocess Inspection Inform HOD QA
1 Flange height 5±0.5 VC
sampling plan report / Reject Inprocess
50 1st FLANGE PS 400TF
Free from tool Inspector
2 Free from tool mark Visual 100% Continuous " "
mark
As per Inprocess Inprocess Inspection Inform HOD QA
1 Flange height 30 ±1 VC
sampling plan report / Reject
As per Inprocess Inprocess Inspection Inform HOD QA Inprocess
60 2nd FLANGE PS 400TF 2 Flange height 8±0.5 VC
sampling plan report / Reject Inspector
Free from tool
3 Free from tool mark Visual 100% Continuous " "
mark
As per Inprocess Inprocess Inspection Inform HOD QA
1 Slot size (15x30) ±0.5 VC
sampling plan report / Reject

2 Hole Dia. 2-Ø9±0.5 VC " " " "

Inprocess
70 PIERCING PS 300T
Inspector
3 Hole C.D. 236±0.5 VC " " " "

4 End to Hole 2-(14.5±0.5) HG " " " "

As per Inprocess Inprocess Inspection Inform HOD QA

1 Flange height 10.5 ±1 VC
sampling plan report / Reject Inprocess
80 3rd FLANGE PS 300T
Free from tool Inspector
2 Free from tool mark Visual 100% Continuous " "
mark
As per Inprocess Inprocess Inspection Inform HOD QA
1 Slot size (6x56)±0.5 VC
sampling plan report / Reject
Inprocess
90 PIERCING PS 300T 2 Slot size (6x26)±0.5 VC " " " "
Inspector

3 Slot Position 16 ±1 HG " " " "

Part No. & Ver. : 23576658_P03, 23527825_P03 Part Name : BRACKET,TRIM PANEL SUPPOR

Drawing No. & Rev. : ---- Part Status : Child Part

Check every batch by
3rd part (if buy by
Inform HOD QA
1 Raw material BSK 46 T.C.Verification Once Every Lot trader)
/ Reject
Check by once in a year
(if buy by Mill)

INCOMING OF 2 Sheet thickness 3±0.3 Micro meter As RQC sampling plan Incoming ins report "
10 RQC inspector
RAW MATERIAL
3 Length 2500±5.0 M.Tape " " " "

4 Width 1250±2.0 M.Tape " " " "

Free from
5 Appearance Visual 100% Continuous " "
damage,burrs
 As per Inprocess Inprocess Inspection Inform HOD QA
1 Length 1250±2.0 M.Tape
sampling plan report / Reject
Inprocess
2 Width 598±0.5 M.Tape " " " "
Shearing Inspector
20 SHEARING
machine Free from
3 Appearance Visual 100% Continuous " "
damage,burrs
Blade
4 Sharp Visual 1 Start of shift -- --
cutting edge
As per Inprocess Inprocess Inspection Inform HOD QA
1 Dim. 52 ±0.5 VC
sampling plan report / Reject Inprocess
As per Inprocess Inprocess Inspection Inform HOD QA Inspector
2 Hole size 2- Ø8 ±0.5 VC
sampling plan report / Reject
30 BLANKING & PIE PS 200T-400T
As per profile
3 Dimension Visual " " " "
template
Free from
4 Appearance 100% Continuous " " Shift incharge
damage,burrs
As per Inprocess Inprocess Inspection Inform HOD QA
1 Dim. 52 ±0.5 VC
sampling plan report / Reject Inprocess
As per Inprocess Inprocess Inspection Inform HOD QA Inspector
2 Dim. 40 ±0.5 VC
sampling plan report / Reject
40 NOTCHING PS 200T-400T
As per profile
3 Dimension Visual " " " "
template
Free from
4 Appearance 100% Continuous " " Shift incharge
damage,burrs
As per Inprocess Inprocess Inspection Inform HOD QA
1 Flange height 63 ±1 HG
sampling plan report / Reject
As per Inprocess Inprocess Inspection Inform HOD QA
2 Hole position 30±.5 HG
sampling plan report / Reject
Inprocess
50 1st FORMING PS 600T 3 Emboss depth 6.7±.5 HG " " " "
Inspector

4 Hole position 197.5±1 HG " " " "

Free from tool

5 Free from tool mark Visual 100% Continuous " "
mark
3 x (11.5 +0.3/-0 x As per Inprocess Inprocess Inspection Inform HOD QA
1 Slot VC
15.5 +0.3/-0) sampling plan report / Reject

2 Hole dia (2 nos) 9±0.3 VC " " " "

3 CD 99.75±0.5 VC " " " "

Inprocess
60 CAM PIERCING PS 400T 4 CD 109.4±0.5 VC " " " "
Inspector

5 Hole edge dis 22±0.5 VC " " " "

6 Hole edge dis 13.9±0.5 VC " " " "

7 Hole edge dis 14±0.5 VC " " " "

 As per Inprocess Inprocess Inspection Inform HOD QA
1 Flange height 15 ±0.5 HG
sampling plan report / Reject
Inprocess
70 2nd FORMING PS 400T 2 Width 58 ±0.5 HG " " " "
Inspector
Free from tool
3 Free from tool mark Visual 100% Continuous " "
mark
As per Inprocess Inprocess Inspection Inform HOD QA
1 Hole C.D. 378 ±0.5 HG
sampling plan report / Reject

2 Height 130.5 ±1 HG " " " "

3 Height 152.2 ±.5 HG " " " "

Inprocess
80 RESTRIKE PS 400T
Hole dis from Inspector
4 52.22 ±.5 HG " " " "
edge
Hole dis from
5 117.2 ±.5 HG " " " "
edge
Free from tool
6 Free from tool mark Visual 100% Continuous " "
mark

Part No. & Ver. : 82654642 & P06 Part Name : Bracket, Tube Mounting RH

Drawing No. & Rev. : --- Part Status : Child Part

Check every batch by
Inform HOD QA
1 Raw material Fe410 T.C.Verification Once Every Lot 3rd part (if buy by
/ Reject
trader)
2 Thickness 3 ±0.3 Micro meter As RQC sampling plan Incoming ins report "

BOP AND 3 Length 39 -0.5 VC " " " "

10 INCOMING RQC inspector
INSPECTION 4 Width 37 +0.5 VC " " " "

5 Height 23 +0.5 VC " " " "

Free from Free from

6 Visual 100% Continuous " "
damage,burrs damage,burrs
Manual (Buffing Burr & Scratches not Inform HOD QA
20 DEBURRING 1 Appearance Visual 100% Continuous -- Shift incharge
Wheel Grit-120) allowed / Reject

PREPARED BY : ROHIT MANDKRIYA APPROVED BY: PRAFULLA SHRINGI

AMMENDMENT RECORD
REV
SL.NO DATE PROCESS NO Reason For Revision APPROVED BY
NO
 CONTROL PLAN
Date
Prototype Pre-Launch Production Date (Origin) : (Review) & Prepared By Vikas Tiwari
Key Contact/Phone :Mr. Suraj Soni
Rev No
Contact Number : +918109092470
Control Plan Number : BEL/CP/23576633-90/ P05 07.07.2019 19.05.20 & 01 Approved By Rohit mandkriya

Core Team : Suraj Soni, Selvan T.G., Devendra Patil, Rohit Mandkriya,
Part No./ Latest change Level : 23576633/ 90_P05 Customer Engineering Approval Date (If Required) :
DS Chandel, SB Chaurasia, Shailendra Dubey and Vikas Tiwari

Part Name/Description. : FRONT SUPPORT INSTEP ASSY LH/RH Supplier Plant Approval Date : Customer Quality Approval Date (If Required) :

Supplier Plant : Pithampur Supplier Code :45841 Other Approval Date (If Required) : Other Approval Date (If Required) :

Characteristic Methods
Control Method
Part/ Machine, Special Sample Reaction Plan
Process Name/ Operation Product/ Process Evaluation
Process Device, Jig, charact Error including corrective
description No. Product Process Specification Measurement
No. Tools for Mfg. eristics Size Freq. Proofing / Detection action
Tolerances Techniques
Prevention
In-process
M8X1.25 square weld Torque weld 45Nm Every one
Projection Welding 1 -------- Torque meter 1st & last 2nos. Nill inspection
nuts MIN hour
report
For LH 2 Squeez time -------- 22-26 Panel reading " " " "
3 Weld current -------- 5.4-9.4 Panel reading " " " " 1. Inform to Supervisor
1) PN 82642118 Projection &
4 Weld time -------- 8-12 Panel reading " " " " 2. Material sorting
10 2) PN 961614, M8X1.25 mig welding
5 Cooling time -------- 3-7 Panel reading " " " " 3. Rework if acceptable
machine
6 Hold time -------- 0-4 Panel reading " " " " 4. Scrap if not acceptable
For RH
7 Off time -------- 0-4 Panel reading " " " "
1) PN 82644202
8 Air pressure -------- 2-4 BAR GAUGE " " " "
2) PN 961614, M8X1.25
Free from burns
9 Appearance -------- Visual 100% for O Per lot " "
and weld defects
In-process
M8X1.25square weld Torque weld 45Nm Every one
Projection Welding 1 -------- Torque meter 1st & last 2nos. Nill inspection
nuts MIN hour
report
For LH 2 Squeez time -------- 22-26 Panel reading " " " "
3 Weld current -------- 5.4-9.4 Panel reading " " " " 1. Inform to Supervisor
1) PN 82653796 Projection &
4 Weld time -------- 8-12 Panel reading " " " " 2. Material sorting
20 2) PN 961614, M8X1.25 mig welding
5 Cooling time -------- 3-7 Panel reading " " " " 3. Rework if acceptable
machine
6 Hold time -------- 0-4 Panel reading " " " " 4. Scrap if not acceptable
For RH
7 Off time -------- 0-4 Panel reading " " " "
1) PN 82653800
8 Air pressure -------- 2-4 BAR GAUGE " " " "
2) PN 961614, M8X1.25
Free from burns
9 Appearance -------- Visual 100% for O Per lot " "
and weld defects
In-process
M6X1 square weld Torque weld 45Nm Every one
Projection Welding 1 -------- Torque meter 1st & last 2nos. Nill inspection
nuts MIN hour
report
2 Squeez time -------- 22-26 Panel reading " " " "
3 Weld current -------- 5.4-9.4 Panel reading " " " " 1. Inform to Supervisor
Projection & 4 Weld time -------- 8-12 Panel reading " " " " 2. Material sorting
30 Common for LH/RH mig welding 5 Cooling time -------- 3-7 Panel reading " " " "
3. Rework if acceptable
1) PN 23578705 machine 6 Hold time -------- 0-4 Panel reading " " " "
4. Scrap if not acceptable
2) PN 961613, M6X1 7 Off time -------- 0-4 Panel reading " " " "
Pressure
8 Air pressure -------- 2-4 BAR " " " "
gauge(Visual)
Free from burns
9 Appearance -------- Visual 100% for O Per lot " "
and weld defects
 Characteristic Methods
Control Method
Part/ Machine, Special Sample Reaction Plan
Process Name/ Operation Product/ Process Evaluation
Process Device, Jig, charact Error including corrective
description No. Product Process Specification Measurement
No. Tools for Mfg. eristics Size Freq. Proofing / Detection action
Tolerances Techniques
Prevention
In-process
As per reference Every one
Sub Assy. (ST10) 1 Weld length -------- Visual 1st & last 2nos. Nill inspection
smaple hour
report
2 Current -------- ~100 - 120 Voltage " " " " 1. Inform to Supervisor
3 Wire Dia -------- 0.8 mm Vernier Caliper " " " " 2. Material sorting
Welding fixture Pressure 3. Re-setting machine
40 4 Air pressure -------- 04-06 Bar " " " "
Common for LH/RH & machine gauge(Visual) parameter
1) OP30 5 Voltage -------- 18-22 Max Voltmeter " " " " 4. Rework if acceptable
2) PN 23628039 6 Gass Flow -------- 10-15 LPM Visual " " " " 5. Scrap if not acceptable
7 Type of Gas -------- Argon Co2 Visual(Display) " " " "
Free from burns
8 Appearance -------- Visual 100% for O Per lot " "
and weld defects
In-process
As per reference Every one
Sub Assy. (ST10) 1 Weld length -------- Visual 1st & last 2nos. Nill inspection
smaple hour
report
2 Hole C.D. -------- 378±2 M. Tap " " " "
3 Distance (Height) -------- 217.4±1 Height gauge " " " "
4 Distance (Height) -------- 22.8±1 Height gauge " " " "
5 Dimension -------- 161±1 Height gauge " " " "
6 Surface to hole center -------- 33.5±1 Height gauge " " " "
1. Inform to Supervisor
For LH 7 Surface to hole center -------- 93.5±1 Height gauge " " " " 2. Material sorting
1) PN 23576658 Welding fixture 8 Hole position -------- 119±1 Height gauge " " " " 3. Re-setting machine
50
2) OP10, OP20 & OP40 & machine 9 Distance (width) -------- 51±0.5 Vernier Caliper " " " " parameter
10 Distance (Height) -------- 104.6±1 Vernier Caliper " " " " 4. Rework if acceptable
For RH 11 Distance (Height) -------- 14±1 Height gauge " " " " 5. Scrap if not acceptable
1) PN 23527825 12 Current -------- ~100 - 120 Voltage " " " "
2) OP10, OP20 & OP40 13 Wire Dia -------- 0.8 mm Vernier Caliper " " " "
Pressure
14 Air pressure -------- 04-06 Bar " " " "
gauge(Visual)
15 Voltage -------- 18-22 Max Voltmeter " " " "
16 Gass Flow -------- 10-15 LPM Visual " " " "
17 Type of Gas -------- Argon Co2 Visual(Display) " " " "
Free from burns
18 Appearance -------- Visual 100% for O Per lot " "
and weld defects
In-process
As per reference Every one
Sub Assy. (ST20) 1 Weld length -------- Visual 1st & last 2nos. Nill inspection
smaple hour
report
2 Current -------- ~100 - 120 Voltage " " " " 1. Inform to Supervisor
3 Wire Dia -------- 0.8 mm Vernier Caliper " " " " 2. Material sorting
Welding fixture Pressure 3. Re-setting machine
60 4 Air pressure -------- 04-06 Bar " " " "
Common for LH / RH & machine gauge(Visual) parameter
1) PN 23576664 5 Voltage -------- 18-22 Max Voltmeter " " " " 4. Rework if acceptable
2) PN 23576668 6 Gass Flow -------- 10-15 LPM Visual " " " " 5. Scrap if not acceptable
7 Type of Gas -------- Argon Co2 Visual(Display) " " " "
Free from burns
8 Appearance -------- Visual 100% for O Per lot " "
and weld defects
 Characteristic Methods
Control Method
Part/ Machine, Special Sample Reaction Plan
Process Name/ Operation Product/ Process Evaluation
Process Device, Jig, charact Error including corrective
description No. Product Process Specification Measurement
No. Tools for Mfg. eristics Size Freq. Proofing / Detection action
Tolerances Techniques
Prevention
In-process
As per reference Every one
Sub Assy. (ST20) - sleeve sub assy. 1 Weld length -------- Visual 1st & last 2nos. Nill inspection
smaple hour
report
2 Current -------- ~100 - 120 Voltage " " " " 1. Inform to Supervisor
3 Wire Dia -------- 0.8 mm Vernier Caliper " " " " 2. Material sorting
Welding fixture Pressure 3. Re-setting machine
70 4 Air pressure -------- 04-06 Bar " " " "
Common for LH / RH & machine gauge(Visual) parameter
1) PN 23628030 5 Voltage -------- 18-22 Max Voltmeter " " " " 4. Rework if acceptable
2) PN 23527833 6 Gass Flow -------- 10-15 LPM Visual " " " " 5. Scrap if not acceptable
7 Type of Gas -------- Argon Co2 Visual(Display) " " " "
Free from burns
8 Appearance -------- Visual 100% for O Per lot " "
and weld defects
In-process
As per reference Every one
Sub Assy. (ST20) 1 Weld length -------- Visual 1st & last 2nos. Nill inspection
smaple hour
report
2 Hole C.D. -------- 26.3±1 Vernier Caliper " " " "
3 Distance (Height) -------- 420±1 Height gauge " " " " 1. Inform to Supervisor
12 Current -------- ~100 - 120 Voltage " " " " 2. Material sorting
Welding fixture 13 Wire Dia -------- 0.8 mm Vernier Caliper " " " " 3. Re-setting machine
80
Common for LH / RH & machine Pressure parameter
14 Air pressure -------- 04-06 Bar " " " "
1) PN 23527844 gauge(Visual) 4. Rework if acceptable
2) OP60 & OP70 15 Voltage -------- 18-22 Max Voltmeter " " " " 5. Scrap if not acceptable
16 Gass Flow -------- 10-15 LPM Visual " " " "
17 Type of Gas -------- Argon Co2 Visual(Display) " " " "
Free from burns
18 Appearance -------- Visual 100% for O Per lot " "
and weld defects
In-process
As per reference Every one
Sub Assy. (ST30) 1 Weld length -------- Visual 1st & last 2nos. Nill inspection
smaple hour
report
2 Distance (width) -------- 45±1 Vernier Caliper " " " "
3 Distance (Height) -------- 37±1 Height gauge " " " "
4 Distance (Height) -------- 15+0/-1 Height gauge " " " "
5 Hole position -------- 45±1 Height gauge " " " " 1. Inform to Supervisor
Common for LH/RH 6 Hole position -------- 29.5±1 Height gauge " " " " 2. Material sorting
1) PN 23527827-LH/RH Trim edge to slot
Welding fixture 7 -------- 47.5±1 Height gauge " " " " 3. Re-setting machine
90 center
2) PN 23527824-LH & machine parameter
8 Current -------- ~100 - 120 Voltage " " " "
3) PN 82654642-LH/RH 4. Rework if acceptable
9 Wire Dia -------- 0.8 mm Vernier Caliper " " " "
4) PN 23628039-LH/RH 5. Scrap if not acceptable
Pressure
5) PN 23527826-LH 10 Air pressure -------- 04-06 Bar " " " "
gauge(Visual)
11 Voltage -------- 18-22 Max Voltmeter " " " "
12 Gass Flow -------- 10-15 LPM Visual " " " "
13 Type of Gas -------- Argon Co2 Visual(Display) " " " "
Free from burns
14 Appearance -------- Visual 100% for O Per lot " "
and weld defects
 Characteristic Methods
Control Method
Part/ Machine, Special Sample Reaction Plan
Process Name/ Operation Product/ Process Evaluation
Process Device, Jig, charact Error including corrective
description No. Product Process Specification Measurement
No. Tools for Mfg. eristics Size Freq. Proofing / Detection action
Tolerances Techniques
Prevention
In-process
As per reference Every one
Sub Assy. (ST40) 1 Weld length -------- Visual 1st & last 2nos. Nill inspection
smaple hour
report
X - direction at bucket
2 -------- 0 ±7 Foot scale " " " "
side
Y - direction at bucket
3 -------- 0 ±7 Foot scale " " " " 1. Inform to Supervisor
side
Z - direction at bucket 2. Material sorting
For LH Welding fixture 4 -------- 0 ±10 Taper scale " " " " 3. Re-setting machine
100 side
1) OP50, OP80, OP90 & machine 8 Current -------- ~100 - 120 Voltage " " " " parameter
9 Wire Dia -------- 0.8 mm Vernier Caliper " " " " 4. Rework if acceptable
For RH Pressure 5. Scrap if not acceptable
10 Air pressure -------- 04-06 Bar " " " "
1) OP50,OP80,OP90 gauge(Visual)
11 Voltage -------- 18-22 Max Voltmeter " " " "
12 Gass Flow -------- 10-15 LPM Visual " " " "
13 Type of Gas -------- Argon Co2 Visual(Display) " " " "
Free from burns
14 Appearance -------- Visual 100% for O Per lot " "
and weld defects

Inspection before dispatch to Part should be as per Inspection check Before Layout
1 -------- IMTE 5 X Part "
phorotech / Badve checksheet sheet dispatch inspection

X - direction at bucket
2 -------- 0 ±7 Foot scale 100% for O Per lot " 1. Inform to Supervisor
side 100% datum
Y - direction at bucket 2. Material sorting
110 Manual 3 -------- 0 ±7 Foot scale " " " gauge
side 3. Rework or duberring
qualification
Z - direction at bucket 4. Reject
4 -------- 0 ±10 Taper scale " " "
side
Free from carbon
5 Shot-blasting -------- SOP All quantity " " 100% Visual
and impurity
6 RPO -------- Free from rust Visual All quantity " " "
Colour should be
TR21533606
Volvo approved
120 Surface treatment
source
1 (POWDER TOP COAT Refer Tier - 2 PPAP documents
OVER ED PAINTING-
BLACK COLOR)

1 Box size
130 Packing & dispatch to Volvo Fork lift As per Volvo packing standard
2 No. of part per box

Sr no Rev. No. Revision Date Revision Summary

1 1 19.05.2020 Part version number changed from P03 to P05

Prepared by Vikas Tiwari Approved by - Rohit Mandkriya
LEGEND FOR INSPECTED BY :E-ENGINNER; O - OPERTOR;I - INSPECTOR;L-LINER LEADER; TPG-
LEGEND FOR CLASS :CC - CRITICAL ; SC - SIGNIFICANT ; A - A CLASS ;P-PLP; B- B CLASS THREAD PLUG GAUGE;VC-VERNIER CALIPER;F.M-FLAT MICROMETER;PM-POINT
MICROMETER;M.T;MEASURING TAPE;DVC; DIGITAL VERNIER CALIPER:
Note - After power failure,Machine break down & fixture break down check suspeced part as well as first part of Production batch
Note=* indicate that Nut torque Check by putting bolt/stud in nut & applying mallet on bolt/nut-in that case nut should not detach from part