Você está na página 1de 12

LOADING PATTERN

1) VERTICAL COMPONENT ON FIXTURE WITH CLAMPING. 2) CHARGE QTY-130 NOS

FIXTURE
1) HOLDING FIXTURE WITH CLAMPS

CONSUMABLE 1) QUENCHING OIL 2) LPG GAS (PROPANE GAS)

TOOL

(O 76.0 ) (O 42.0 )

GAUGES
1) HARDNESS TESTER

PROCESS PARA METERS


1) CARBURISING GAS TEMPERATURE 900~940C & REDn 840~870C 2) QUENCHING TEMP. 50~150C 94.0

INPUT QUALITY
1) FREE FROM DENTS & DAMAGES.

INPROCESS QUALITY

OUTPUT QUALITY
1) CASE DEPTH 0.4 TO 0.7 mm 2) HARDNESS 81 TO 83 HRA 3) CORE HARDNESS - >= 1000

CHECK POINT BEFORE START OF M/C

WORK INSTRUCTION
CLAMP REST LOCATE

MOD.

NEW DRWING RELESED.

MACHINEFURNACE

ALTERATIONS

APP. 20/11/12 CHK. 20/11/12 DATE SIGN PART NO. SF14053032 OPR. NO. 110

OPERATION SHEET SANJEEV AUTO-PARTS


MANUFACTURERS PVT. LTD. AURANGABAD-431136

OPERATION:- HEAT TREAT MENT DRN. 20/11/12 MATERIAL:- ZFN417-A PART NAME:- LOCKING SLIDE 4475_319_054

1) LOAD COMPONENT ON FIXTURE 2) ENSURE HEIGHT OF CHARGE 3) ENSURE NO CONTACT BETWEEN COMPONENT 4) LOAD THE CHARGE IN FURNACE 5) MONITOR %CP, TIME & TEMPERATURE AS PER HEAT TREATMENT CYCLE. 6) UNLOAD THE CHARGE & INSPECT SAMPLE FOR GIVEN SPECIFICATION. 7) KEEP COMPONENT IN SINGLE POCKET BIN

PD/F08/R0

I = IMPORTANT DIMENSIONS

LOADING PATTERN
NO OF COMPONENT: 1 COMPONENT

FIXTURE
1.GRINDING MANDRILL

CONSUMABLE
10.2 A
Rz2
+0.1

SOLUABLE OIL- 1:20 CONCENTRATION OIL TANK CLEAN FREQUENCY - 6 MONTHS

TOOL 1.GRINDING WHEEL 400 X 50 X 127 TYPE -463-K5 (TH01021001) GAUGES


1. AIR RING GAUGE 50h8 (GA14006042) 2. EXPANDING MANDREL NO. (GA14010046) 3. D.H.G.

49.98 0.005

O 42

^ 0.03 A

PROCESS PARA METERS


1. FEED: 0.2 TO 1.6 MM/ MIN 2. SPEED : 1500-1800RPM

94.0 Rz2.5

I ^ 0.03 A I n 0.03 A

3. CLAMPING PRESSURE : 3-5 BAR 4. FINE FEED : 1 MM/MIN

INPUT QUALITY
1. ENSURE NO DENTS ON RESTING FACE. 2. CHECK BURR ON OD. 3. CHECK ID SIZE OF COMPONENT.

INPROCESS QUALITY 1. COMPONENT SHOULD BE LOBBING FREE. 2. CIRCULARITY SHOULD BE 0.002 MAX.

NOTE : DATUM A IS PCD

OUTPUT QUALITY 1. OD SIZE - 49.98 0.005 I 2. RUNOUT : 0.03 WRT A Rz 2 3. ROUGHNESS 4. RUNOUT : 0.03 WRT A I 5. PERPENDICULARITY : 0.03 WRT A I 6. SURFACE FINISH : Rz2.5
7. DIMN.10.2 +0.1 8. VISUAL : NO PATCH MARK,CHATTER MARK. CHECK POINT BEFORE START O F M/C 1. CHECK COOLANT LEVEL IN TANK. 2. CHECK WHEEL RPM. 3. CHECK FEED.

WORK INSTRUCTION
CLAMP REST LOCATE

MOD.

NEW DRAWING RELESED.

MACHINEOD GRINDING M/C

1. START WITH HYDRAULIC ON AND GRINDING ON. 2. TAKE JOB FROM BIN AND CHECK DENT FREE JOB. 3. CLEAN THE CARRIER. 4. LOAD THE COMPONENT. 5. PRESS CYCLE START BUTTON. 6. TAKE FINISH COMPONENT AND CHEAK OD SIZE AS PER DRAWING. 7. APPLY THE ANTI RUST OIL . 8. KEEP OK COMPONENT IN SINGLE POCKET BIN. PD/F08/R0

ALTERATIONS

APP. CHK. DRN. DATE SIGN PART NO. SF14053032 OPR. NO. 120

OPERATION SHEET
OPERATION:- OD GRINDING

SANJEEV AUTO-PARTS
MANUFACTURERS PVT. LTD. AURANGABAD-431136

MATERIAL:- ZFN417-A PART NAME:- LOCKING SLIDE 4475_319_054

CONTROL PLAN
X Prototype X Pre-launch Production Key Contact/Phone : 1) Mr.R.V.Vaidya +0240-2244001 +0240-2244002 Core Team : 1) Mr. S.G.Waghmare 2) Mr. D.T.Kawle 3) Mr. J.S.Isargunde Supplier / Plant Approved / date Date (Org) 25.11.2012

32
Date (Rev.) 20.11.2012

Control Plan Number : CP/ FG14000032 Part Number/Latest Change Level Part Name/Description Part Process Number : SF14053032 (4475_319_054) : LOCKING SLIDE : 120

Customer Engineering Approval/Date (If Reqd)

Customer Quality Approval/Date (If Reqd)

Process Name/ Operation Description: OD Grinding Supplier/Plant :- Sanjeev Auto Parts , K96, Waluj, Aurangabad Machine, Device, for Mfg. Characteristics No. Product Process Setting approval Supplier Code: 38709 Special Char. Class I I I I ^ ^ { Other Approval/Date (If Reqd) Methods Product/ Process Specification/ Tolerance As per control plan 49.98 0.005 ARG (GA14006042) 3. Grinding M/C. 4. 5. 6. 7. Roughness Run out Run out Perpendicularity Dimn. 0.4Ra 0.03 0.03 0.03 10.2 +0.1 ARG: - Air Ring Gauge A A A Roughness tester Dial &Between Center. Dial &Between Center. Dial & height gauge Digital height gauge 100% 5 5 5 5 5 Continues Per hour Per hour Per hour Per hour Per hour HIPR HIPR HIPR HIPR HIPR Evaluation/ Measurement Technique ARG & Micrometer ARG & Micrometer 2. Out Side Diameter. Sample Control Method Size Continuous 5 OK jobs 1 Freq. Every Setting Per hour Setting Approval Report HIPR Prod. Supervisor Operator Operator Operator Operator Operator Operator Operator If not ok 1. Stop the production 2. Confirm last hour production 3.Do re setting & inspect 5 comp. Responsibility Other Approval / Date (If Reqd)

Reaction Plan/Correcti ve action

1.

HIPR: - Hourly Inspection & Production Report

: Important dimension

PD/F09/R2

LOADING PATTERN NO. OF COMPONENTS : 1 NOS FIXTURE

CONSUMABLE
ANTI RUST OIL

TOOL

94.0

GAUGES

PROCESS PARA METERS


1) NO EXCESS OIL REMAINS ON COPMPONENT

(O 42.0 ) (O 76.0 )

INPUT QUALITY
1) ENSURE CLEANED COMPONANT FREE FROM RUST & DUST

INPROCESS QUALITY

OUTPUT QUALITY
1) COMPONENT FREE FROM DUST, CHIPS & RUST.

CHECK POINT BEFORE START O F M/C

WORK INSTRUCTION
1) TAKE COMPONENT FROM SINGLE POCKET BIN. 2) PUT ON THE TABLE. 3)INSPECT UNDER MAGNIFY GLASS. 4) SPRAY ANTIRUST OIL ON COMPONENT 5) NO CHIP IN ANTIRUST OIL. ALTERATIONS APP. 20/11/12 CHK. 20/11/12 6)FORWARD TO THE PACKING.

CLAMP REST LOCATE

MOD.

NEW DRWING RELESED.

MACHINEWASHING M/C

OPERATION SHEET SANJEEV AUTO-PARTS


MANUFACTURERS PVT. LTD. AURANGABAD-431136

OPERATION:DRN. 20/11/12 WASHING & CLEANING DATE SIGN MATERIAL:- ZFN417-A PART NO. SF14053032 PART NAME:- LOCKING SLIDE 4475_319_054 OPR. NO. 130

PD/F08/R0

CONTROL PLAN
X Prototype X Pre-launch Production Key Contact/Phone : 1) Mr.R.V.Vaidya +0240-2244001 +0240-2244002 Core Team : 1) Mr. S.G.Waghmare 2) Mr. D.T.Kawle 3) Mr. J.S.Isargunde Supplier/ Plant Approval/Date Date (Org) 20.11.2012 Date (Rev.) 20.11.2012

32

Control Plan Number : CP/ FG14000032 Part Number/Latest Change Level Part Name/Description Part Process Number Process Name/ Operation Description Supplier/Plant Sanjeev Auto Parts Mfgrs Pvt Ltd., K-96, MIDC, Waluj, Aurangabad. Machine, Device, Mg Books for Mfg. Characteristics Special Char. Class : SF14007032 (4475_319_054) : LOCKING SLIDE : 130 :-WASHING Supplier Code: 38709

Customer Engineering Approval/Date (If Reqd)

Customer Quality Approval/Date (If Reqd)

Other Approval/Date (If Reqd)

Methods Product/ Process Specification/ Tolerance Evaluation/ Measurement Technique Sample Control Method Size 100% Freq. Continuous Per hour Per lot Millipore Report Operator Prod. Supervisor QA Inspector Responsibility

No.

Product

Process

Reaction Plan & corrective action

1 Washing m/c 2

Visual dimension

No Rust, no scale of HT

Visual

5 1

Cleanliness

Max Allowable contaminant=25.948mg

Millipore

If component is not ok then rewash it

PD/F09/R2

BRAKE ALL SHARP EDGES ASK IF IN DOUBT

MARKING LOCATION OPTIONAL

8.00 -0.5 2.0 +1


.8 14 0 25 -0.
DOG.

72.5 +1
20

DIN 5480-W62X1.25X30X48X9h
6.5 +0.2 I

19

SEE DETAIL 'X'


87

' 0

P1 Rz20

'

Rz63

O 59.0 -0.2

0.8 0.4 0.35 0.2


5

y Ch.0.6 x 45
2. 51

9.00 +0.5 MARKED ACC. TO ZFN 2011 X 55.0 -1


R 2. 5

I ^ 0.05 P1

10.50 -0.5 83.50 -0.3 94.0


Rz2.5

-1

CONTACT PATTERN WITH SAMPLE MATING GEAR

30

30 5

^ 0.05 P1 I n 0.05 P1 I
R1.6 -0.2 I CH.1.7 +0.3 X 45

Rz5 C

ALTERNATIVE

0.35 0.2

0.8 0.4

FORGING TOLERANCE ACC. TO EN 10243 DRAFT ANGLE = 6 ( ) SUPPLEMENTRY DIMENSION SPLINE GEAR TEETH TEST DIMENSION OVER ROLLERS ACC. TO DIMENSION INSPECTION REPORT 100% TESTING WITH PROFILE GAUGE
CURVIC COUPLING Z = 6 / Mn = 9.833

## DEVIATION TO 4475_319_043 VER "a" SEE DRAW. MODIFICATION # ALTERNATIVE MATERIAL ACC. TO TABLE 4475_700_072

R0.4 0.2

DETAIL 'X'

RELIEF GROOVE

HEAT TREATMENT CASE HAEDENED ACC TO ZFN 417 I SURFACE HARDNESS : 81 TO 85 HRA. CASE DEPTH : 0.4 TO 0.7 CORE STRENGHT : 1000 N/mm2

SR.NO. SPUR GEAR, BEVEL GEAR TOOTH DATA 1 NO. OF TEETH/ NORMAL MODULE Z = 48 / Mn = 1.25 2 3 4 5 6 7 8 9 PRESSURE ANGLE HELIX ANGLE HAND OF HELIX CENTER DISTANCE IN HOUSING MATING GEAR No/NO. TEETH SETTING DATA ACC TO M NO. OPD DIMENSION(Over Pin2.5) ROOT DIAMETER

50.000 h8 61.750 h11 FIT SIZE

= 30

= 0

= = ------a= a= 4461_353_056 / Z = 48 4461_351_061/ Z = 6 0041 072 569 0042 710 009 64.578/64.507 59.250

0.000 -0.039 0.000 -0.190

50.000 49.961 61.750 61.560

ALLOWNCE MAXIMUM LIMITS

SANJEEV AUTO PARTS MFRS. PVT. LTD.


MATERIAL & HEAT TREATMENT :- ZFN417-A

d = 60.0

80.00 +0.5

da = 61.75 h11

df = 59.25 -0.68

O 70.00 -0.5

O 63.00 -0.5

O 76.00 -0.5

O 50.00 h8

O 42.0 +0.4

O 38.5 +0.4

I
20/11/12 20/11/12 20/11/12

PART NAME :-

LOCKING SLIDE

PRPD BY CHKD BY APPD BY

MOD.

20/11/12 NEW DRAWING RELEASED. CHANGES DATE

PART. NO. :-

FG14000032

S.P.A. J.S.I. R.V.V.


F

4475_319_054_DES001 MOD NO. CUST. REF. NO./MOD. NO.:-

DATE

PD/F15/R2

CONTROL PLAN
X Prototype X Pre-launch Production Key Contact/Phone : 1) Mr.R.V.Vaidya +0240-2244001 +0240-2244002 Core Team : 1) Mr. S.G.Waghmare 2) Mr. D.T.Kawle 3) Mr. J.S.Isargunde Supplier / Plant Approved / date Date (Org) 20.11.2012 Date (Rev.) 20.11.2012

32

Control Plan Number : CP/ FG14000032 Part Number/Latest Change Level Part Name/Description Part Process Number Process Name/ Operation Description Supplier/Plant Sanjeev Auto Mfrs Pvt.Ltd. K-96 ,MIDC,Waluj,Aurangabad Characteristics Machine, Device, for Mfg. No. 1. 2 3. 4. 5. 6. 7. 8. Manual 9. 10. 11. 12. 13. 14. 15. 16. Dimension Runout Perpendicularity Surface finish Radius Dimension Dimension Total length I I I ^ Product OD diameter Diameter Diameter Diameter Diameter OD Runout Internal diameter ID Chamfer Process Special Char. Class I I ^ : SF14007032 (4475_319_054) : LOCKING SLIDE : 140 page : 1/4

Customer Engineering Approval/Date (If Reqd)

Customer Quality Approval/Date (If Reqd)

: VISUAL DIMENSION INSPACTION Supplier Code: 38709 Other Approval/Date (If Reqd) Other Approval / Date (If Reqd)

Methods Product/ Process Specification/ Tolerance 76.0 -0.5 70.0 -0.5 63.0 -0.5 59.0 -0.2 50.0 h8 0.05 42.0 +0.4 Ch.0.6 x 45 10.50 -0.5 0.05 0.05 Rz 2.5/ Rz5 R2.5 -1.0 55 .0 -1 83.50 -0.3 94.0 P1 P1 P1 Evaluation/ Measurement Technique Digital Vernier caliper Digital Vernier caliper Digital Vernier caliper Digital Vernier caliper ARG Dial & mandrill Digital Vernier caliper Bevel protector & height gauge Digital Vernier caliper Dial & mandrill Dial & V-Block Surface finish tester Radius gauge Vernier caliper Digital height gauge Digital height gauge Sample Control Method Size Freq. PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector If not OK reject the lot.& inform to supervisor Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Responsibility Reaction Plan & corrective action

I-Important dimension, APG Air Plug Gauge


PD/F09/R2

CONTROL PLAN
X Prototype X Pre-launch Production Key Contact/Phone : 1) Mr.R.V.Vaidya +0240-2244001 +0240-2244002 Core Team : 1) Mr. S.G.Waghmare 2) Mr. D.T.Kawle 3) Mr. J.S.Isargunde Supplier / Plant Approved / date Date (Org) 25.11.2012

32
Date (Rev.) 20.11.2012

Control Plan Number : CP/ FG14000032 Part Number/Latest Change Level Part Name/Description Part Process Number Process Name/ Operation Description Supplier/Plant Sanjeev Auto Mfrs Pvt.Ltd. K-96 ,MIDC,Waluj,Aurangabad Characteristics Machine, Device, for Mfg. No. 17. 18. 19. 20. 21. 22. 23. 24. Manually 25. 26. 27 28. 29. 30. 31. 32. Surface finish DIN 5480 Dimension Angle Marking Dimension Dimension Dimension I Product Dimension Radius Internal diameter Diameter Diameter OD Internal length Surface finish Process Special Char. Class : SF14007032 (4475_319_054) : LOCKING SLIDE : 140 page : 2/4

Customer Engineering Approval/Date (If Reqd)

Customer Quality Approval/Date (If Reqd)

: VISUAL DIMENSION INSPACTION Supplier Code: 38709 Other Approval/Date (If Reqd) Other Approval / Date (If Reqd)

Methods Product/ Process Specification/ Tolerance 9.00 +0.5 R2.5 -1 38.5 +0.4 59.25 -0.68 60 61.75 (h11) 80.0 +0.5 Rz63 Rz20 W62X1.25x30x48x9h 6.5 +0.2 87 19 020 4475_319_054 72.5 +1 8.00 -0.5 2 +1 Evaluation/ Measurement Technique Digital height gauge Radius gauge Digital Vernier caliper Digital Vernier caliper TTi m/c Digital Vernier caliper Digital height gauge Surface tester Surface tester Visual Digital height gauge CMM Visual Digital height gauge Vernier caliper DHG. Sample Control Method Size Freq. PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector If not OK reject the lot.& put in red bin inform to supervisor Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Responsibility Reaction Plan & corrective action

I-Important dimension, APG Air Plug Gauge


PD/F09/R2

CONTROL PLAN
X Prototype X Pre-launch Production Key Contact/Phone : 1) Mr.R.V.Vaidya +0240-2244001 +0240-2244002 Core Team : 1) Mr. S.G.Waghmare 2) Mr. D.T.Kawle 3) Mr. J.S.Isargunde Supplier / Plant Approved / date Date (Org) 25.11.2012

32
Date (Rev.) 20.11.2012

Control Plan Number : CP/ FG14000032 Part Number/Latest Change Level Part Name/Description Part Process Number Process Name/ Operation Description Supplier/Plant Sanjeev Auto Mfrs Pvt.Ltd. K-96 ,MIDC,Waluj,Aurangabad Characteristics Machine, Device, for Mfg. No. 33. 34. 35. Product Dimension Chamfer Radius Process Special Char. Class I : SF14007032 (4475_319_054) : LOCKING SLIDE : 140 page : 3/4

Customer Engineering Approval/Date (If Reqd)

Customer Quality Approval/Date (If Reqd)

: VISUAL DIMENSION INSPACTION Supplier Code: 38709 Other Approval/Date (If Reqd) Other Approval / Date (If Reqd)

Methods Product/ Process Specification/ Tolerance 14.8 -0.25 Ch.1.7 X 45 1.6 -0.2 Evaluation/ Measurement Technique Vernier caliper Contrasor Contrasor Sample Control Method Size Freq. PDI Report PDI Report PDI Report QA Inspector QA Inspector QA Inspector Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Responsibility Reaction Plan & corrective action

Detail X (RELIEF GROOVE)


36. 37. 38. 39. Manually 40. 41. 42. 43. 44. 45. 46.. 47. Angle Dimension Radius No. of teeth /module Pressure angle No. of teeth /module Surface hardness Case depth 30 5 0.35 0.2 R0.4 0.2 48 / mn 1.25 30 6 / mn = 9.833 81 to 83 0.4 to 0.7 Vernier caliper Digital Vernier caliper Profile projector Counting & TTi m/c TTi m/c Counting Hardness tester Microscope Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) PDI Report PDI Report PDI Report PDI Report PDI Report PDI Report H.T. Report H.T. Report QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector Dimension Angle Dimension Dimension 0.8 0.4 30 5 0.8 0.4 0.35 0.2 Digital Vernier caliper Profile projector Digital Vernier caliper Digital Vernier caliper Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) PDI Report PDI Report PDI Report PDI Report QA Inspector QA Inspector QA Inspector QA Inspector If not OK reject the lot.& put in red bin inform to supervisor

I-Important dimension, APG Air Plug Gauge


PD/F09/R2

CONTROL PLAN
X Prototype X Pre-launch Production Key Contact/Phone : 1) Mr.R.V.Vaidya +0240-2244001 +0240-2244002 Core Team : 1) Mr. S.G.Waghmare 2) Mr. D.T.Kawle 3) Mr. J.S.Isargunde Supplier / Plant Approved / date Date (Org) 25.11.2012 Date (Rev.) 20.11.2012

32

Control Plan Number

: CP/ FG14000032
: SF14007032 (4475_319_054) : LOCKING SLIDE : 140 page : 4/4

Part Number/Latest Change Level Part Name/Description Part Process Number Process Name/ Operation Description Supplier/Plant

Customer Engineering Approval/Date (If Reqd)

Customer Quality Approval/Date (If Reqd)

: VISUAL DIMENSION INSPACTION Supplier Code: 38709 Other Approval/Date (If Reqd) Other Approval / Date (If Reqd)

Sanjeev Auto Mfrs Pvt.Ltd. K-96 ,MIDC,Waluj,Aurangabad Characteristics Machine, Device, for Mfg. No. 48. 49. Manually 50. 51. 52. Product Core strength Root diameter DOP. Material Visual

Methods Process Special Char. Class Product/ Process Specification/ Tolerance 1000 N/mm 59.250 Vernier caliper Spline ring gauge GO /NOGO Chemical analysis Visually Evaluation/ Measurement Technique Sample Control Method Size Freq. H.T. Report PDI Report PDI Report PDI Report PDI Report QA Inspector QA Inspector QA Inspector QA Inspector QA Inspector If not OK reject the lot.& put in red bin inform to supervisor Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Sampling plan SSP (N) Responsibility Reaction Plan & corrective action

64.578/64.507
ZFN417-A No. teeth dent & damage

PD/F09/R2

CONTROL PLAN
X Prototype X Pre-launch Production Key Contact/Phone : 1) Mr.R.V.Vaidya +0240-2244001 +0240-2244002 Core Team : 1) Mr. S.G.Waghmare 2) Mr. D.T.Kawle 3) Mr. J.S.Isargunde Supplier/ Plant Approval/Date: Date (Org) 25.11.2012 Date (Rev.)

32

Control Plan Number : CP/ FG14000032 Part Number/Latest Change Level Part Name/Description Part Process Number Process Name/ Operation Description Supplier/Plant Sanjeev Auto Parts Mfrs Pvt. Ltd., K-96, MIDC, Waluj, Aurangabad Machine, Device, for Mfg. Characteristics No. Product Process : SF14007032 (4475_319_054) : LOCKING SLIDE : 150 : Packing & Forwarding Supplier Code: 360450

Customer Engineering Approval/Date (If Reqd)

Customer Quality Approval/Date (If Reqd):

Other Approval/Date (If Reqd):

Special Char. Class

Methods Product/ Process Specification/ Tolerance Evaluation/ Measurement Technique Sample Control Method Size Freq. If not OK, put in red bin. Responsibility Reaction Plan & Corrective action

Manual

Packing & forwarding

Packing in Bin

Visual counting

100%

Continues

Physical Verification

Dispatch officer

PD/F09/R2

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS [PROCESS FMEA] POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS [PROCESS FMEA]
Component : Locking slide Model Year / Vehicle(s) : Core Team : ANK/RBK/RVV/PMP/SGW/HMS/JSI/Mrs.VSK Drawing No:- 4475_319_054 Drg. Rev. F Revision Date :Process Responsibility : Mr. R.B.K. Key Date : 29/12/2012 FMEA Date :29/12/2012 FMEA No. : 01 Rev. No. : Rev. Date : Page No. : 1/1 Prepare By : JSI Responsibility & Target Complition Date

Class

OCC

RPN

Opration Sr. No.

Item Function

Requrement.

Potential Failure Mode

Potential Effect(s) or Failure

Potential Cause(s) / Mechanism(s) or Failure

Current process control Prevention

Current process control Detection

Recommended Action(s)

Action Taken

10

Raw material

ZF7B 64 X 97.7

Improper material grade Total length O/s Total length U/S

Possibility of loss of primary function Tool life detoriets in machining Patch mark during machining Poor Surface finish in next opration /low performance core hardness low & tool life detorate in Roughing Tool life detorietsin CNC turning Patch mark during CNC turning Tool life detorietsin CNC turning Patch mark during CNC turning Tool life detorietsin CNC turning Effect on subsicuent operation. Tool life detorietsin CNC turning Patch mark during CNC turning Effect on subsiqent operation , more stock has to remove. patchmark occurs during grinding operation. Chip formation on tooth profile & major dia oversize in Hobbing opration /Poor tooth formation Flank underfilling & major dia undersize/Poor tooth formation,notches occures Effect on subsiqent operation , more stock has to remove. Low level of performance. Effect on subsiqent operation on gear od fitment not possible. Effect on subsiqent operation , low per formance. Effect on subsiqent operation on gear od fitment not possible.tool life detorate Effect on subsiqent operation , low per formance. Effect on subsiqent operation , teeth variation In gear cutting OD cut.

8 4 7

Material mix up Cutting stroke Excess Cutting stroke less low furnace Temp./ Lot release from furnace before Normalising required time / soaking time less High furnace Temp./lot put in furnace more then required time/ soking time more Tool wear out Setting Not ok Tool wear out Setting Not ok Tool wear out Tool wear out Tool wear out Setting Not ok Tool wear out.

1 2 2

Colour coading for bar from supplier setting Checklist setting Checklist Temp. controller & soking time alram provided Temp. controller & soking time alram provided Tool life monitoring setting approval report Tool life monitoring setting approval report Tool life monitoring Tool life monitoring Tool life monitoring setting approval report Tool life monitoring

Sampling inspection for chemical composition Inprocess inspection as per control plan Inprocess inspection as per control plan

8 5 5

64 40 70

20

Bar cutting 64 X 97.7

Below Range 30 Normalising 170-210 BHN Over Range 80 0.1 80 0.1 64 0.1 40 Roughing 64 0.1 74 0.1 74 0.1 82 0.1 82 0.1 50.25 +0.03 50.25 +0.03 61.650.05 OD O/S OD U/S OD O/S OD U/S Dimn. O/S Dimn. U/S OD O/S OD U/S OD O/S OD U/S Hobbing Dia.O/S.

5 Check samples in every lot and Maintain inprocess monitering sheet 5 HIPR HIPR HIPR HIPR HIPR HIPR HIPR HIPR HIPR/Setting approval report 6 5 5 5 5 5 5 5 5

50

5 4 7 4 7 4 7 4 7

2 2 2 2 2 2 2 2 2

50 40 70 40 70 40 70 40 70

4 7

I
Setting Not ok,offset given by operator not ok Setting Not ok,wronge offset given by operator Setting Not ok / builtup edge on tool tip Tool wear out. Setting Not ok Setting Not ok Setting Not ok Setting Not ok

2 2 Setting approval,Training to operator HIPR/Setting approval report HIPR/Setting approval report 2 Setting approval,Training to operator Setting Approval Report / Coolant flow set on tool tip Tool life monitoring Setting Approval Report Setting Approval Report/Tool life monitoring Setting Approval Report Setting Approval Report/Tool life monitoring Setting Approval Report Inpection by between center.. Setting Approval Report Tool life monitoring Setting approval,Training to operator Tool life monitoring Inspection By Width Gauge Setting Approval Report Setting Approval Report Setting Approval Report Setting Approval Report Setting Approval Report Setting Approval Report Setting Approval Report Setting Approval Report Setting Approval Report Setting Approval Report Tool life monitoring Setting Approval ReportHIPR Material flow as per PFD only trainning to the operator / Setting approval report HIPR/Setting approval report

48 84

84

61.650.05 58.9 +0.05 58.9 +0.05 38.7 +0.05 50 CNC Turning 38.7 +0.05 40.250.05 40.250.05

Hobbing Dia.U/S. OD O/S OD. U/S. ID O/S ID O/S ID O/S ID U/S

7 4 7 4 7

2 2 2 2 2

6 HIPR/Setting approval report HIPR/Setting approval report HIPR/Setting approval report HIPR/Setting approval report HIPR/Setting approval report 5 HIPR/Setting approval report HIPR/ Setting approval HIPR. HIPR/Setting approval report HIPR/Setting approval report HIPR/ Setting approval HIPR/ Setting approval HIPR/ Setting approval HIPR/ Setting approval HIPR/ Setting approval HIPR/ Setting approval HIPR/ Setting approval HIPR/ Setting approval Ist piece setup approval & in process inspection report/HIPR Ist piece setup approval & in process inspection report/HIPR 100% inspection bySpline ring gauge 100% inspection bySpline ring gauge Ist piece setup approval / 100% visual inspection with PIN & DHG /HIPR 100% visual inspection before HT 100% visual inspection before HT 5 5 5 6 6 5 5 5 5 6 6

84 40 70 48 84

7 7 5 6 4 7 7 8 Setting Not ok Center dimn.not ok Setting Not ok. Component out clamed by operator. Tool wear out.

2 2 2 2 2 2 2 2

70 70 50 60 48 84 70 80

runout 0.03

Runout not ok

Oversize 7.80.05 Undersize Undersize 7.80.05 Oversize Excess No. of teeth (6T) less Oversize 70 VMC MILLING 293'14" Undersize Oversize 6.6+0.05 Undersize Root diameter O/s Root Dia 59.250 (-0.6) Root diameter U/s 90 Hobbing - (48T) DOP 64.510/64.540 No step 0.03 120 Identification marking Part No heat code wrong punching 130 Heat treatment OD U/S OD O/S 160 OD Grinding 49.980.005 Taper excess OD Runout Should be free from rust, dust Corrosion during Transport, etc. Should be free from rust, dust Application of rust oil more etc. DOP size.O/S DOP size.U/S step at root PCD R/O not ok punch missing

Effect on subsiqent operation , more stock has to remove. patchmark occurs during grinding operation. loose fitment of mating part Assly not done Assembly not possible Assembly not possible Assembly not possible Play occurs & noise in assembly Fitment not possible Play occurs & noise in assembly Fitment problem in assembly Excess back lash in engine assembly Fitment problem in assembly Play in assembly Step at root side of Shaft /Noise occures in assembly Engine noise Material cant be identify material cant be identify with respect to the batch size

Setting Not ok,offset given by operator not ok Tool wear out. Std width insert not avilable (Doubble Plung) mismatch of PCD mismatch of PCD OD O/S OD U/S mismatch of PCD

8 8 8 7 8 7 7 7 6 7 6 7 4 4 I

1 1 2 2 2 2 2 2 2 2 2 2 1 1

5 5 6 6 6 6 5 5 6 6 8 6 8 8

40 40 96 84 96 84 70 70 72 84 96 84 32 32 0 0 0 0 0 0 0 0 0 0

I
mismatch of PCD Setting Not ok Setting Not ok Setting Not ok Setting Not ok Tool blunt Setting Not ok Material movement not as per PFD Unskilled Operator/ Setting not ok Seprate HT PFMEA Attached

Bearing loose fitment Assembly not possible Poor performance in assembly Excess OD Runout loss of Primary Funtion Oilyness more

7 8 7 7 4 2

Setting Not ok I Setting Not ok wrong offset given Setting Not Ok Setting not oK, Each OD seprate Setup Component not deep in oil Insuuficient time given for oil removing from component

2 2 2 2 3 2 2

Setting Approval Report Setting Approval Report operator traing Setting Approval Report Setting Approval Report Rust preventing paper is use to avoid rust with 100% Deeping in antirust oil Rust preventing paper is use to avoid rust

100 % inspection by ARG 100 % inspection by ARG 100 % inspection by ARG 100 % inspection by ARG inspection with DHG /HIPR

6 6 6 6 6 8 8

84 96 96 84 126 64 32 All OD Grinding in One setup R.V.Vaidya Dt.29/10/2012 all OD Grinding Taken on Hi-life CNC machine 7 1 6 42

100% inspection 100% inspection

260

Packing

RPN

DET

SEV

Occ

Sev

Det