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FIXTURE
CONSUMABLE
TOOL
PROCESS PARAMETERS
INPUT QUALITY
INPROCESS QUALITY
OUTPUT QUALITY
CHECK POINT BEFORE START OF M/C
GAUGES
LOADING PATTERN
1) VERTICAL COMPONENT ONFIXTURE WITH CLAMPING.
1) QUENCHING OIL2) LPG GAS (PROPANE GAS)
1) FREE FROM DENTS & DAMAGES.
1) CASE DEPTH - 0.4 TO 0.7 mm2) HARDNESS - 81 TO 83 HRA3) CORE HARDNESS - >= 1000
1) CARBURISING GAS TEMPERATURE900~940C & REDn 840~870C
2) QUENCHING TEMP. 50~150C
1) HARDNESS TESTER
1) HOLDING FIXTURE WITH CLAMPS
2) CHARGE QTY-130 NOS
76.0(O )
94.
0
42.0(O )
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FIXTURE
TOOL
PROCESS PARAMETERS
INPUT QUALITY
INPROCESS QUALITY
OUTPUT QUALITY
CHECK POINT BEFORE START OF M/C
GAUGES
LOADING PATTERN
FIXTURE
CONSUMABLE
TOOL
PROCESS PARAMETERS
INPUT QUALITY
OUTPUT QUALITY
CHECK POINT BEFORE START OF M/C
GAUGES
LOADING PATTERN
NO OF COMPONENT: 1 COMPONENT
SOLUABLE OIL- 1:20 CONCENTRATION
OIL TANK CLEAN FREQUENCY - 6MONTHS
1. AIR RING GAUGE 50h8
1. OD SIZE - 49.98 0.005
1. CHECK COOLANT LEVEL IN TANK.
1. FEED: 0.2 TO 1.6 MM/ MIN
2. SPEED : 1500-1800RPM
3. CLAMPING PRESSURE : 3-5 BAR
4. FINE FEED : 1 MM/MIN
2. RUNOUT : 0.03 WRT A
8. VISUAL : NO PATCH MARK,CHATTERMARK.
2. CHECK WHEEL RPM.
1. ENSURE NO DENTS ON RESTING FACE.
2. CHECK BURR ON OD.
3. CHECK ID SIZE OF COMPONENT.
1. COMPONENT SHOULD BE LOBBINGFREE.
2. CIRCULARITY SHOULD BE 0.002 MAX.
1.GRINDING WHEEL 400 X 50 X 127TYPE -463-K5(TH01021001)
1.GRINDING MANDRILL
3. ROUGHNESS Rz 2
(GA14006042)
I = IMPORTANT DIMENSIONS
I
I
I = IMPORTANT DIMENSIONS
4. RUNOUT : 0.03 WRT A
5. PERPENDICULARITY : 0.03 WRT A6. SURFACE FINISH : Rz2.5
7. DIMN.10.2 +0.1
I
I
2. EXPANDING MANDREL NO.(GA14010046)
3. D.H.G.
^ 0.03 A
Rz2
II
II
49.9
80.0
05
42
O
10.2+0.1
94.0
A
^ 0.03 A
n 0.03 ARz2.5
NOTE : DATUM A IS PCD
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CONTROL PLAN 32
PD/F09/R2
Machine,
Device, forMfg.
CharacteristicsSpecial
Char.Class
Methods
Responsibility
Reaction
Plan/Corrective actionNo. Product Process
Product/ ProcessSpecification/
Tolerance
Evaluation/ Measurement
Technique
SampleControl Method
Size Freq.
Grinding
M/C.
1. - Settingapproval
- As per control plan ARG & Micrometer Continuous5 OK jobs
Every
Setting
Setting Approval
Report
Prod. Supervisor
If not ok 1.
Stop theproduction
2. Confirm
last hour
production
3.Do resetting &
inspect 5
comp.
2. Out Side Diameter. - I 49.98 0.005 ARG & Micrometer 1 Per hour HIPR OperatorARG (GA14006042) 100% Continues - Operator
3. Roughness - - 0.4Ra Roughness tester 5 Per hour HIPR Operator4. Run out
- I ^ 0.03 ADial &Between Center. 5 Per hour HIPR Operator
5. Run out- I ^ 0.03 A
Dial &Between Center. 5 Per hour HIPR Operator
6. Perpendicularity - I { 0.03 A Dial & height gauge 5 Per hour HIPR Operator7. Dimn. - - 10.2 +0.1 Digital height gauge 5 Per hour HIPR Operator
HIPR: - Hourly Inspection & Production Report : Important dimension ARG: - Air Ring Gauge
X Prototype X Pre-launch Production
Control Plan Number : CP/ FG14000032
Key Contact/Phone : 1) Mr.R.V.Vaidya
+0240-2244001+0240-2244002
Date (Org) 25.11.2012 Date (Rev.) 20.11.2012
Part Number/Latest Change Level : SF14053032 (4475_319_054) Core Team : 1) Mr. S.G.Waghmare
2) Mr. D.T.Kawle
3) Mr. J.S.Isargunde
Customer Engineering Approval/Date (If Reqd)
Part Name/Description : LOCKING SLIDE
Part Process Number : 120 Supplier / Plant Approved / date Customer Quality Approval/Date (If Reqd)
Process Name/ Operation Description: OD Grinding
Supplier/Plant :- Sanjeev Auto Parts , K96, Waluj,Aurangabad
Supplier Code:38709
Other Approval/Date (If Reqd) Other Approval / Date (If Reqd)
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76.0(O )
94.0
42.0(O )
FIXTURE
CONSUMABLE
TOOL
PROCESS PARAMETERS
INPUT QUALITY
INPROCESS QUALITY
OUTPUT QUALITY
CHECK POINT BEFORE START OF M/C
WORK INSTRUCTION
GAUGES
LOADING PATTERN
NO. OF COMPONENTS : 1 NOS
ANTI RUST OIL
1) NO EXCESS OIL REMAINS ONCOPMPONENT
1) COMPONENT FREE FROM DUST,CHIPS & RUST.
1) TAKE COMPONENT FROM SINGLE
1) ENSURE CLEANED COMPONANTFREE FROM RUST & DUST
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CONTROL PLAN 32
PD/F09/R2
X Prototype X Pre-launch Production
Control Plan Number : CP/ FG14000032
Key Contact/Phone : 1) Mr.R.V.Vaidya
+0240-2244001+0240-2244002
Date (Org) 20.11.2012 Date (Rev.) 20.11.2012
Part Number/Latest Change Level : SF14007032 (4475_319_054) Core Team : 1) Mr. S.G.Waghmare
2) Mr. D.T.Kawle
3) Mr. J.S.Isargunde
Customer Engineering Approval/Date (If Reqd)
Part Name/Description : LOCKING SLIDE
Part Process Number : 130 Supplier/ Plant Approval/Date Customer Quality Approval/Date (If Reqd)
Process Name/ Operation Description :-WASHING
Supplier/Plant
Sanjeev Auto Parts Mfgrs Pvt Ltd.,
K-96, MIDC, Waluj, Aurangabad.
Supplier Code:
38709
Other Approval/Date (If Reqd)
Machine,
Device, MgBooks for
Mfg.
CharacteristicsSpecial
Char.
Class
Methods
Responsibility
Reaction
Plan &corrective
actionNo. Product ProcessProduct/ Process
Specification/ Tolerance
Evaluation/
Measurement
Technique
Sample
Control MethodSize Freq.
Washing
m/c
1 Visual dimension - - No Rust, no scale of HT Visual
100% Continuous
-
OperatorIf
component
is not okthen rewash
it
5 Per hourProd.
Supervisor
2 Cleanliness - -Max Allowable
contaminant=25.948mg Millipore 1 Per lot Millipore Report QA Inspector
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SANJEEV AUTO PARTS MFRS. PVT. LTD.
MATERIAL & HEAT TREATMENT :-
PART NAME :- PRPD BY
CHKD BY
APPD BY
MOD NO. DATEMOD. CHANGES
BRAKE ALL SHARP EDGES ASK IF IN DOUBT
PART. NO. :-
CUST. REF. NO./MOD. NO.:-
PD/F15/R2
DATE
38.
5
+0.4
OO
76.
00
-0.
5
2.0+1
10.50-0.5
70.
00
-0.
5
O
63.
00
-0.
5
O
59.0
-0.
2
O
50.0
0
O
h8
42.
0
+0.4
O
61.
75
da=
h11
94.0
83.50-0.3
55.0-1
9.00+0.5
80.00+0.5
8.00-0.572.5+1
6.5+0.2
87
19'
020'
R2.5
-1
R2.5
-1
^ 0.05 P1
n 0.05 P1
14.80
-0.25
Ch.0.6 x 45
SEE DETAIL 'X'
P1
^ 0.05 P1
R1.6 -0.2
Rz63
DOG.
16
60.0
d
=59.
25
-0.
68
df=
MARKING LOCATION OPTIONAL
CONTACT PATTERN WITHSAMPLE MATING GEAR
MARKED ACC.TO ZFN 2011 X
ALTERNATIVERz5C
Rz2.5CH.1.7 +0.3 X 45
0.
35
0.
2
30
5
0.
8
0.4
0.350.2
0.80.4
30
5
R0.4 0.2
DETAIL 'X'
RELIEF GROOVE
S.P.A.J.S.I.
R.V.V.
F
LOCKING SLIDE
FG14000032
4475_319_054_DES001
20/11/12
20/11/12
20/11/12
ZFN417-A
NEW DRAWING RELEASED.20/11/12F
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
## DEVIATION TO 4475_319_043 VER "a"
SEE DRAW. MODIFICATION
# ALTERNATIVE MATERIAL ACC. TO TABLE 4475_700_072
Rz20
DIN 5480-W62X1.25X30X48X9h
y
HEAT TREATMENT
CASE HAEDENED ACC TO ZFN 417
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 CURVIC COUPLING
1 NO. OF TEETH/ NORMAL MODULE Z = 48 / Mn = 1.25 Z = 6 / Mn = 9.833
2 PRESSURE ANGLE = 30 = 03 HELIX ANGLE = =
4 HAND OF HELIX ---- ----
5 CENTER DISTANCE IN HOUSING a = a =
6 MATING GEAR No/NO. TEETH 4461_353_056 / Z = 48 4461_351_061/ Z = 6
7 SETTING DATA ACC TO M NO. 0041 072 569 0042 710 009
8 OPD DIMENSION(Over Pin2.5) 64.578/64.507
9 ROOT DIAMETER 59.250
I
I
I
I
I
I
I
I
I
0.000 50.000
-0.039 49.961
0.000 61.750
-0.190 61.560
MAXIMUM LIMITS
50.000 h8
61.750 h11
FIT SIZE ALLOWNCE
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CONTROL PLAN 32
PD/F09/R2
X Prototype X Pre-launch Production
Control Plan Number : CP/ FG14000032
Key Contact/Phone : 1) Mr.R.V.Vaidya+0240-2244001
+0240-2244002
Date (Org) 25.11.2012 Date (Rev.) 20.11.2012
Part Number/Latest Change Level : SF14007032 (4475_319_054) Core Team : 1) Mr. S.G.Waghmare
2) Mr. D.T.Kawle
3) Mr. J.S.Isargunde
Customer Engineering Approval/Date (If Reqd)
Part Name/Description : LOCKING SLIDE
Part Process Number : 140 page : 4/4 Supplier / Plant Approved / date Customer Quality Approval/Date (If Reqd)
Process Name/ Operation Description : VISUAL DIMENSION INSPACTION
Supplier/PlantSanjeev Auto Mfrs Pvt.Ltd.
K-96 ,MIDC,Waluj,Aurangabad
Supplier Code:38709
Other Approval/Date (If Reqd) Other Approval / Date (If Reqd)
Machine,
Device, forMfg.
CharacteristicsSpecial
Char.Class
Methods
Responsibility
Reaction Plan
& correctiveactionNo. Product Process
Product/ ProcessSpecification/ Tolerance
Evaluation/ MeasurementTechnique
SampleControl Method
Size Freq.
Manually
48. Core strength - - 1000 N/mm Sampling plan SSP (N) H.T. Report QA Inspector
If not OK rejectthe lot.& put in
red bin informto supervisor
49. Root diameter - - 59.250 Vernier caliper Sampling plan SSP (N) PDI Report QA Inspector
50. DOP. - - 64.578/64.507 Spline ring gauge GO /NOGO Sampling plan SSP (N) PDI Report QA Inspector
51. Material - - ZFN417-A Chemical analysis Sampling plan SSP (N) PDI Report QA Inspector
52. Visual - - No. teeth dent & damage Visually Sampling plan SSP (N) PDI Report QA Inspector
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CONTROL PLAN 32
PD/F09/R2
X Prototype X Pre-launch Production
Control Plan Number : CP/ FG14000032
Key Contact/Phone : 1) Mr.R.V.Vaidya+0240-2244001
+0240-2244002
Date (Org) 25.11.2012 Date (Rev.)
Part Number/Latest Change Level : SF14007032 (4475_319_054)
Part Name/Description : LOCKING SLIDE
Core Team : 1) Mr. S.G.Waghmare
2) Mr. D.T.Kawle3) Mr. J.S.Isargunde
Customer Engineering Approval/Date (If Reqd)
Part Process Number : 150
Process Name/ Operation Description : Packing & Forwarding
Supplier/ Plant Approval/Date: Customer Quality Approval/Date (If Reqd):
Supplier/Plant
Sanjeev Auto Parts Mfrs Pvt. Ltd.,
K-96, MIDC, Waluj, Aurangabad
Supplier Code:
360450
Other Approval/Date (If Reqd):
Characteristics Methods
SampleMachine,
Device, forMfg. No. Product Process
SpecialChar.Class
Product/ ProcessSpecification/ Tolerance
Evaluation/
MeasurementTechnique Size Freq.
Control MethodResponsibility
Reaction Plan &
Corrective action
Manual 1 Packing & forwarding - - Packing in Bin Visual counting 100% Continues Physical Verification Dispatch officerIf not OK, put in
red bin.
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