Doc No.

Kangaro Group Of Company Rev. No

Issue Date
HIGH LEVEL PROCESS FLOW DIAGRAM (Pre Launch) Page No.
Legends Used Operatio n; Ins pectio n; S to rage; M o ve; Ins pectio n->Operatio n; Operatio n->Ins pectio n; Ins pectio n->Operatio n->Ins pectio n; Delay; P o ka Y o ke

[Link] Part Code Part Name Photograph Qty Domain IS Standard 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

Material CRC-DD

1 Staple Guide 1 Heat Treatment

Surface Finish Black Oxide Compound +

Raw Material Raw Material Main Store To Next ops Stamping Bending
Material MC-11 Projection
Welding Cleaning Brazing

2 Front Plate 1 Heat Treatment 350 ~450 HV5

Surface Finish Black Oxide

BOP
BOP Inspection Main Store Blanking
Material CRC-DD
Visual
Spot Welding Mig Welding Mig Welding Grinding Blackening Inspection Main Store
3 Middle 1 Heat Treatment

Surface Finish Black Oxide Compound + Resizing with

Raw Material Raw Material Main Store To Next ops Stamping First Bending U Bending Gauge
Material C-80/ Spring Steel
Spot Welding

4 Tensioner 1 Heat Treatment

Surface Finish Black Oxide Compound +

Raw Material Raw Material Main Store To Next ops Stamping Bending Stress Releiving
Material CRC-DD

5 Middle Holder 1 Heat Treatment C Hard (500~550 HV5)

Surface Finish Black Oxide Compound +

Raw Material Raw Material Main Store To Next ops Stamping U Bending Carburizing CFM
Material CRC-DD

6 Middle Bracket 1 Heat Treatment C Hard (500~550 HV5)

Surface Finish Black Oxide Compound + First Bending

Raw Material Raw Material Main Store To Next ops Stamping Tool U Bending Tool Carburizing CFM
 project:
Operation
Part name:
Description Product characteristics
Material tag
(Identification & Traceability)
Material as per requisition slip
Receiving Of Child
Parts Qty as per Tag and requisition slip
Asthetics
(No Rust, No Dents, No Scratch)

Perpendicularity with respect to Z

Dimension # 3
Front Plate Face should Butt with Staple Guide
Projection Weld Position with respect to Y
Projection Welding Nugget Dimensions
Faces Should remain inside the the Staple Guide

Aesthetics

Hardness

Brazing Area
Brazing

Perpendicularity (BP)
Front Plate Height (BP)

Acid Cleaning

Aesthetics
Buffing

Hardness
Stress Relieving

Perpendicularity with respect to Z (BP)

Surface Grinding
Transfer To Next
Operation

project:
Operation
Part name:
Description Product characteristics
Material tag
(Identification & Traceability)
Material as per requisition slip
Receiving Of Child
Qty as per Tag and requisition slip
Parts
Asthetics
(No Rust, No Dents, No Scratch)

Spot Welding Nugget (Both Sides 2 Spots)

Parallelism with respect to Z
Spot Welding
Dimension # 4

Inner U Size

Middle Resizing
with Gauge

Aesthetics
Buffing

Transfer To Next
Operation

project:
Operation
Part name:
Description Product characteristics
Material tag
(Identification & Traceability)
Material as per requisition slip
Receiving Of Child
Qty as per Tag and requisition slip
Parts
Asthetics
(No Rust, No Dents, No Scratch)

Dimension #2
Both faces should Butt together
Dimension # 4 (On both sides)
Spot Welding
Spot Welding Nugget ( 6 Spots )
Maximum Displacement in Staple Guide Assy
Spot Welding

Transfer To Next
Operation

project:
Operation
Part name:
Description Product characteristics
Material tag
(Identification & Traceability)
Material as per requisition slip
Receiving Of Child
Qty as per Tag and requisition slip
Parts
Asthetics
(No Rust, No Dents, No Scratch)

Welding Bead on Both Sides

Holder Hole Position with respect to Z and Y
Holder Hole Diameter
Hole CD from front plate
Mig Welding
Pin Should Free to move in Hole
Both faces should butt together Staple Assy and Middle Holder
Dimension # 9
Welding Penetration

Mig Welding Welding Tacks on Either Sides

Tacking

Transfer To Next
Operation

project:
Operation
Part name:
Description Product characteristics
Material tag
(Identification & Traceability)
Material as per requisition slip
Receiving Of Child
Qty as per Tag and requisition slip
Parts
Asthetics
(No Rust, No Dents, No Scratch)

Welding Bead length on both sides

Welding Bead on both sides
Dimension # 4
Dimension # 5
Mig Welding Position with respect to Z
Both the faces Middle Bracket and Middle should butt together
Mig Welding

Grind to match the surface (Weld should not come out)

Dimension # 9
Welding Penetration

Aesthetics
Belt Grinding

Aesthetics
Surface Grinding

Blackening

Transfer To Next
Operation
 PHT-150
Staple Guide + Front Plate Assy
Specification

SC

SC

SC

SC

0.1 mm BP SC
0.1 ± 0.05 BP SC
BP SC
0.1 mm BP SC
BP SC
BP SC

No Weld marks on The Top Of

The Surface
36-45 HRC SC

[Link] at inside the both

corner of front plate welded
area BP
2. Brazing should not Visible
from back side of staple guide

0.1|Z BP SC
0.1 ± 0.05 mm BP SC

No Precipitate Marks to be
there on part

36-45 HRC SC

0.1|Z BP SC
 PHT-150
Middle + Tensioner Assy
Specification
SC
SC
SC
SC

2.8 mm BP SC
0.1 mm BP SC
17.85 + 0.1 mm BP SC

11 ± 0.1 mm

No Sharp Edges

PHT-150
Staple Guide Assy + Middle Assy
Specification
SC
SC
SC
SC

1.1 +0.15 -0.05 mm BP SC

BP SC
0.95 +0.05-0.10 mm BP SC
Ø 3.5 mm BP SC
0.05 max BP SC
 PHT-150
Middle Assy + Middle Holder
Specification
SC
SC
SC
SC

10.50 mm BP SC
0.3 mm BP SC
Ø 5.60 -0.00-0.05 BP SC
262.40 mm BP SC
Ø 4 mm BP SC
BP SC
20.20 ± 0.10 mm BP SC
20 % of Min Sheet Thickness ES SC
2 Welding Tacks

PHT-150
Middle Holder Assy + Middle Bracket
Specification
SC
SC
SC
SC

15.0 mm BP SC
12.0 mm BP SC
1.35 -0.00 -0.05 mm BP SC
11 ± 0.05 mm BP SC
0.05 mm BP SC
BP SC
 BP SC
5.6 mm BP SC
20 % of Min Sheet Thickness ES SC
No Extra Welding On the Side
BP
Surfaces

After Grinding Max. 0.1 mm

BP
above Middle Surface
 Operation Cause & Effect Relationship w.r.t Product Characterstic {Projection Welding (F Plate + S Guide)}
Source of Incoming Variation Process Characterstics
# No. Description Char # Product Characterstic
Material Man Machine Method Measurement Mother Nature
10 Receiving Of Child Material tag
Parts Wrong requisition Operator Skill Material Handling Visual Lux Level
(Identification & Traceability)

Material as per requisition slip Wrong Material issued

Qty as per Tag and requisition slip Material Mixup

Asthetics
Rusty/ Dent/ Scratch on material
(No Rust, No Dents, No Scratch)

20 Projection Welding
(Staple Guide + Front
Perpendicularity with respect to Z Front Plate Flatness Operator Skill Machine Condition Fixture Condition Height Gauge Accuracy
Plate )

Staple Guide Flatness Air Pressure

Dimple Height

Dimension # 3 Slot Cut of Staple Guide Operator Skill Electrode Condition Height Gauge Accuracy

Front Plate Blank Over Size

Front Plate Face should Butt with Staple

Burr at Staple Guide Face Fixture Condition
Guide

Burr at Front Plate Face

Position with respect to Y Front Plate Side Slot Over Size Fixture Condition

Air Pressure

Projection Welding Nugget Dimensions Staple Guide Dimple CD Machine Condition Air Pressure Vernier Calliper Accuracy

Current

Heat %

Hold Cycle

Weld Cycle

Off Cycle

Squeeze Cycle

Electrode Condition

Faces Should remain inside the the

Front Plate Side Slot Over Size Fixture Condition
Staple Guide
30 Brazing
(Staple Guide + Front Aesthetics Oil on Part Operator Skill Fixture Condition
Place Sub Assembly)
Hardness O2 + LPG

Quenching Media

Brazing Area(BP) Operator Skill Fixture Condition

Flux

Perpendicularity (BP) NG Child Parts Operator Skill Torch Condition Fixture Condition Height Gauge Accuracy

Gas Flow Regulator

Front Plate Height (BP) NG Child Parts Operator Skill Height Gauge Accuracy

40 Acid Cleaning /
Pickling

50 Buffing
No Precipitate Marks to be there on part Operator Skill Machine Condition Buffing Wheel Condition

60 Stress Relieving
Hardness Oily Material Machine Condition Relieving Temperature Hardness Tester Accuracy

Relieving Time

70 Surface Grinding
Perpendicularity with respect to Z (BP) Operator Skill Machine Condition Grain Size

Wheel Width

Transfer To Next
Operation
1. Stick Bin Tag
2. Handover The
Material
 Kangaro Group of Companies (KGOC) Doc. No
Rev. No
FC/PE/TA-182.6A
01

Process Flow Chart Issue Date

Page No
12 of 25
Part Number 182.6 A Part Rev # 01 Plant Kanin india Type Origin Date 27-11-2021
Part Description Projection Welding (F Plate + S Guide) Section Welding Shop Proto Type Key Date
Project Number PHT-150 Mr. Arvind, Mr. Tariq, Mr. Jaskaran, Mr. [Link], Mr. Pre Launch P Cust App Date
CFT
Project Description Stanely hammer tacker Manpreet, Mr. Gian singh, Production
Legend Used Symbols Operation; Inspection; Storage; M ove; Inspection->Operation; Operation->Inspection; Inspection->Operation->Inspection; Delay; P oka Yoke Characterstic Class CC: Critical, SC: Significant

Operation Characterstics
Machine Used Source of Incoming Variation Symbol
No. Description No. Product Process Class
Wrong requisition 10.01 Material Identification Tag …….

Material Mixup 10.02 Material Quantity …….

Receiving of Child Parts

10 Manual Rusty/ Dent/ Scratch on material 10.03 Aesthetics …….

20 Projection Welding Projection Welding

(Staple Guide + Front Machine Front Plate Flatness 20.01 Perpendicularity with respect to Z(BP) SC
Plate ) (PW-04)
Staple Guide Flatness 20.02 Dimension # 3(BP) SC

Dimple Height 20.03 Front Plate Face should Butt with Staple Guide(BP) SC

Slot Cut of Staple Guide 20.04 Position with respect to Y(BP) SC

Front Plate Blank Over Size 20.05 Projection Welding Nugget Dimensions(BP) SC

Burr at Staple Guide Face 20.06 Faces Should remain inside the the Staple Guide(BP) SC

Burr at Front Plate Face 20.07 Operator Skill

Front Plate Side Slot Over Size 20.08 Machine Condition

Staple Guide Dimple CD 20.09 Fixture Condition

20.10 Air Pressure

20.11 Electrode Condition

20.12 Current

20.13 Heat %

20.14 Hold Cycle

20.15 Weld Cycle

20.16 Off Cycle

20.17 Squeeze Cycle

20.18 Height Gauge Accuracy

20.19 Vernier Calliper Accuracy

30 Brazing Torch + Filler Distance Between Staple Guide and

(Staple Guide + Front Metal(Brass) 30.01 Aesthetics
Front Plate
Place Sub Assembly)
30.02 Hardness sc

30.03 Brazing Area(BP)

30.04 Perpendicularity (BP) sc

30.05 Front Plate Height (BP) sc

30.06 Operator Skill

30.07 Fixture Condition

30.08 O2 + LPG

30.09 Flux

30.10 Quenching Media

30.11 Filler material

40 Acid Cleaning / Pickling Manual Follow Acid Cleaning Process from Blackening PFC

Buffing Wheel Condition 50.01 Aesthetics

Cylindrical Buffing
50 Buffing 50.02 Buffing Wheel Type
Machine

Parts with Oil 60.01 Hardness SC

60.02 Stress Relieving Temperature
60 Stress Relieving Heating Furnace
60.03 Stress Relieving Time

Parts with Dust and Oil 70.01 Perpendicularity with respect to Z (BP) SC
Surface Grinder + 70.02 Grain Size
70 Surface Grinding
Vice
 Surface Grinder +
70 Surface Grinding
Vice 70.03 Grinding Wheel Width

13 of 25

Revision History
Rev. No. Rev Date Revision Details Revised By Verified By Approved By
 Kangaro Group of Companies (KGOC) Doc. No
Rev. No
PF/PE/TA-182.6A
01

Process Failure Mode And Effect Analysis Issue Date

Page No
1/8/2021

Part Number 182.6 A Part Rev # 01 Plant Kanin india Type Origin Date 27-11-2021 14 of 25
Part Description Projection Welding (F Plate + S Guide) Section Welding Shop Proto Type Key Date
Project Number PHT-150 Mr. Arvind, Mr. Tariq, Mr. Jaskaran, Mr. [Link], Mr. Manpreet, Mr. Gian Pre Launch ### Cust App Date
CFT singh,
Project Description Stanely hammer tacker Production

Action Priority
Potential Current Process Current Process

Occurrence
Operation Action Results

Detection
Potential Causes Controls Controls Resp. &
Potential Recommended

Class

RPN
Requirement Failure Mode Effect(s) of Severity Actions Target
Failure Mechanism of Date
No Function Failure Prevention Detection Action Taken Sev Occ Det AP
20 Projection Perpendicularity Perpendicularity
Welding with respect to More
(Staple Z(BP) 1. Operator Skill
Guide + Evaluation (Type B)' 1. Manpower Skill Matrix
Front Plate ) Next Process: Monitoring Manpower Skill Matrix
8 Operator Skill No Control 10 6 480 H HR/ Prod. 8 3 5
100 % Reject [Link] Piece approval 2. Manpower Change and Change Point System
and Patrol Inspection Matrix
(Type B)

1. Preventive
Maintenance of Machine
Subsequent as per Schedule
Predictive Maintenance
Process : 1 Machine Condition No Control 10 (Type B) 6 480 H Maint. Predictive Maintenance 8 4 6
of Machine
NA 2. First Pueve Approval
and Patrol Inspection
(Type B)

8 SC
Preventive Maintenance Predictive maintenance
Customer (Plant): Predictive Maintenance
8 Fixture Condition No Control 10 of Fixture as per plan 6 480 H of Fixture to be Tool Room 8 4 6
100 % Reject as per Decided frequency
(Type B) implemented

1. Autocut air Pressure

End User :
Regulator to fix in
Loss of Primary Air Pressure Regulator Machine Set up Approval Regulator Installation at
8 Air Pressure 7 6 336 H Pneumatic Line. Maint. 8 3 6
Function (Type A) (Type B) place along with Andon
2. Andon to fix if
pressure change

Safety &
Daily Calibration with Scheduled Calibration
Regulatory: Height Gauge
1 Master 2 plan 6 96 M
No Discemible Accuracy
(Type A) (Type B)
effect

1. Operator Skill
Evaluation (Type B)' 1. Manpower Skill Matrix
Next Process: Monitoring Manpower Skill Matrix
8 Operator Skill No Control 10 6 480 H HR/ Prod. 8 3 5
100 % Reject [Link] Piece approval 2. Manpower Change and Change Point System
and Patrol Inspection Matrix
(Type B)

1. Preventive
Maintenance of Fixture
as per Plan
(Type B)
Subsequent 50 Strokes Dressing 2. First Piece Approval
Electrode and Patrol Inspection
Process : 1 Alarm 2 6 96 M
Condition (Type B)
NA (Type A)

Dimension More 8 SC

Daily Calibration with Scheduled Calibration

Customer (Plant): Height Gauge
8 Master 2 plan 6 96 M
100 % Reject Accuracy
(Type A) (Type B)

End User :
8
100 % Reject

Dimension # 3(BP) Safety &

Regulatory:
1
No Discemible
effect

1. Operator Skill
Evaluation (Type B)' 1. Manpower Skill Matrix
Next Process: Monitoring Manpower Skill Matrix
8 Operator Skill No Control 10 6 480 H HR/ Prod. 8 3 5
100 % Reject [Link] Piece approval 2. Manpower Change and Change Point System
and Patrol Inspection Matrix
(Type B)

1. Preventive
Subsequent 50 Strokes Dressing Maintenance of Fixture
Electrode as per Plan
Process : 1 Alarm 2 6 96 M
Condition (Type B)
NA (Type A)
2. First Piece Approval
and Patrol Inspection
Dimension Less 8 SC
Daily Calibration with Scheduled Calibration
Customer (Plant): Height Gauge
8 Master 2 plan 6 96 M
100 % Reject Accuracy
(Type A) (Type B)

End User :
Loss of Primary
8
Function

Safety &
Regulatory:
1
No Discemible
effect

Preventive Maintenance Predictive maintenance

Next Process: Predictive Maintenance
8 Fixture Condition No Control 10 of Fixture as per plan 6 480 H of Fixture to be Tool Room 8 4 6
100 % Reject as per Decided frequency
(Type B) implemented

Subsequent
Process : 1
NA
Front Plate Face
should Butt with No Butt 8 SC
Staple Guide(BP) Customer (Plant):
8
100 % Reject

End User :
Loss of Primary
8
Function

Safety &
Regulatory:
1
No Discemible
effect

Preventive Maintenance Predictive maintenance

Next Process: Predictive Maintenance
8 Fixture Condition No Control 10 of Fixture as per plan 6 480 H of Fixture to be Tool Room 8 4 6
100 % Reject as per Decided frequency
(Type B) implemented

1. Autocut air Pressure

Subsequent Regulator to fix in
Air Pressure Regulator Machine Set up Approval Regulator Installation at
Process : 1 Air Pressure 7 6 336 H Pneumatic Line. Maint. 8 3 6
(Type A) (Type B) place along with Andon
NA 2. Andon to fix if
Position with pressure change
Position Shift 8 SC
respect to Y(BP)

Customer (Plant):
8
100 % Reject

End User :
Loss of Primary
8
Function

Safety &
Regulatory:
1
No Discemible
effect

1. Preventive
Maintenance of Machine
as per Schedule
Next Process: Predictive Maintenance
4 Machine Condition No Control 10 (Type B) 6 0 H Maint. Predictive Maintenance 8 4 6
100 % Rework of Machine
2. First Pueve Approval
and Patrol Inspection
(Type B)

1. Autocut air Pressure

Subsequent Regulator to fix in
Air Pressure Regulator Machine Set up Approval Regulator Installation at
Process : 1 Air Pressure 7 6 336 H Pneumatic Line. Maint. 8 3 6
(Type A) (Type B) place along with Andon
NA 2. Andon to fix if
pressure change

First Piece Approval and

Customer (Plant): Panel Digital Controls
8 Current 2 Patrol Inspection 6 96 M
100 % Reject (Type A)
(Type B)

End User :
First Piece Approval and
Loss of Primary Panel Digital Controls
8 Heat % 2 Patrol Inspection 6 96 M
Function (Type A)
(Type B)

Projection Safety &

First Piece Approval and
Welding Nugget Nugget Less Regulatory: 8 SC Hold Cycle Panel Digital Controls
1 2 Patrol Inspection 6 96 M
Dimensions(BP) No Discemible (Type A)
(Type B)
effect

First Piece Approval and

Panel Digital Controls
Weld Cycle 2 Patrol Inspection 6 96 M
(Type A)
(Type B)

First Piece Approval and

Panel Digital Controls
Off Cycle 2 Patrol Inspection 6 96 M
(Type A)
(Type B)

First Piece Approval and

Panel Digital Controls
Squeeze Cycle 2 Patrol Inspection 6 96 M
(Type A)
(Type B)

1. Preventive
Maintenance of Fixture
as per Plan
(Type B)
50 Strokes Dressing 2. First Piece Approval
Electrode and Patrol Inspection
Alarm 2 6 96 M
Condition (Type B)
(Type A)

Daily Calibration with Scheduled Calibration

Vernier Calliper
Master 2 plan 6 96 M
Accuracy
(Type A) (Type B)

Preventive Maintenance Predictive maintenance

Next Process: Predictive Maintenance
8 Fixture Condition No Control 10 of Fixture as per plan 6 480 H of Fixture to be Tool Room 8 4 6
100 % Reject as per Decided frequency
(Type B) implemented

Subsequent
Process : 1
NA
Faces Should
remain inside the
Faces not Inside 8 SC
the Staple
Guide(BP)
Customer (Plant):
8
100 % Reject

End User :
Loss of Primary
8
Function

Safety &
Regulatory:
1
No Discemible
effect
30 Brazing Aesthetics Degraded Function 1. Operator Skill
(Staple : Evaluation/ Matrix
Guide + Aesthetically Part 1. Manpower Skill Matrix
Record Sheet (Type B)'
Front Place not good due to Next Process: Monitoring
Sub over brazing 2. Manpower Change
No Discemible 1 Operator Skill No Control 10 [Link] Training 6 420 H HR/ Prod.
Assembly) Sheet
Effect (Type B)
3. Frequently Manpower 15 of 25
[Link] Sample
Training
(Type B)

Subsequent
Process :
Preventive Maintenance Predictive maintenance
Production may
7 Fixture Condition No Control 10 of Fixture as per plan 6 420 H of Fixture to be Tool Room
has to be sorted
(Type B) implemented
and less than
100% Scrap

7
Customer (Plant):
Sorting, Line
5
Shutdown for 1
hour

End User :
Very objectionable
4
appearence

Safety &
Regulatory:
1
No Discemible
effect

Hardness Degraded Function 1. Operator Skill

: Evaluation/ Matrix
Becomes Brittle 1. Manpower Skill Matrix
Record Sheet (Type B)'
Monitoring
Next Process:
2. Manpower Change
No Discemible 1 Operator Skill No Control 10 [Link] Training 6 480 H HR/ Prod.
Sheet
Effect (Type B)
3. Frequently Manpower
[Link] Sample
Training
(Type B)

Subsequent 1. First Piece Approval

Process : 8 Quenching Media No Control 10 and Patrol Inspection 6 480 H Prod
100 % Scrap (Type B)

8 sc
1. First Piece Approval
Customer (Plant): Flow Gauges at Cylinder
5 O2 + LPG No Control 10 and Patrol Inspection 6 480 H Prod
Line Shut Down to Set and Calibrate
(Type B)

End User :
Loss of Primary
8
Function

Safety &
Regulatory:
1
No Discemible
effect

Brazing Area(BP) Degraded Function 1. Operator Skill

: Evaluation/ Matrix
Brazing not done 1. Manpower Skill Matrix
Record Sheet (Type B)'
Monitoring
Next Process:
2. Manpower Change
No Discemible 1 Operator Skill No Control 10 [Link] Training 6 420 H HR/ Prod.
Sheet
Effect (Type B)
3. Frequently Manpower
[Link] Sample
Training
(Type B)

Subsequent
Preventive Maintenance Predictive maintenance
Process :
5 Fixture Condition No Control 10 of Fixture as per plan 6 420 H of Fixture to be Tool Room
Less than 100%
(Type B) implemented
rework

7
Customer (Plant):
6 Flux No Control 10 No Control 10 700 H Prod
Line Shut Down

End User :
Degradation of 7
primary Function

Safety &
Regulatory:
1
No Discemible
effect

No Function : 1. Operator Skill

Brazing not done Evaluation/ Matrix
on required area 1. Manpower Skill Matrix
Record Sheet (Type B)'
Monitoring
Next Process:
2. Manpower Change
No Discemible 1 Operator Skill No Control 10 [Link] Training 6 480 H HR/ Prod.
Sheet
Effect (Type B)
3. Frequently Manpower
[Link] Sample
Training
(Type B)

Subsequent Preventive Maintenance Predictive maintenance

Process : 8 Fixture Condition No Control 10 of Fixture as per plan 6 480 H of Fixture to be Tool Room
100% Reject (Type B) implemented

8
Customer (Plant):
6 Flux No Control 10 No Control 10 800 H Prod
Line Shut Down

End User :
Loss of primary 8
Function

Safety &
Regulatory:
1
No Discemible
effect

Perpendicularity Perpendicularity
(BP) More
1. Operator Skill
Evaluation (Type B)' 1. Manpower Skill Matrix
Next Process:
Monitoring Manpower Skill Matrix
No Discemible 1 Operator Skill No Control 10 6 480 H HR/ Prod. 8 3 5
[Link] Piece approval 2. Manpower Change and Change Point System
Effect
and Patrol Inspection Matrix
(Type B)

1. Preventive
Maintenance of Machine
Subsequent as per Schedule
Predictive Maintenance
Process : 1 Torch Condition No Control 10 (Type B) 6 480 H Maint. Predictive Maintenance 8 4 6
of Machine
100 % Reject 2. First Pueve Approval
and Patrol Inspection
(Type B)

8 sc
Preventive Maintenance Predictive maintenance
Customer (Plant): Predictive Maintenance
8 Fixture Condition No Control 10 of Fixture as per plan 6 480 H of Fixture to be Tool Room 8 4 6
100 % Reject as per Decided frequency
(Type B) implemented

End User :
Timely Planned
Loss of Primary Gas Pressure Regulator Machine Set up Approval Regulator Installation at
8 Gas Flow Regulator 7 6 336 H Calibration of Gauges Maint. 8 3 6
Function (Type A) (Type B) place
and Regulators

Safety &
Daily Calibration with Scheduled Calibration
Regulatory: Height Gauge
1 Master 2 plan 6 96 M
No Discemible Accuracy
(Type A) (Type B)
effect

Front Plate Height Height More

(BP)

Next Process: Daily Calibration with Scheduled Calibration

Height Gauge
No Discemible 1 Master 2 plan 6 96 M
Accuracy
Effect (Type A) (Type B)

Subsequent
Process : 8
100 % Scrap

8 sc
Customer (Plant):
8
100 % Reject

End User :
Loss of Primary
8
Function

Safety &
Regulatory:
1
No Discemible
effect

50 Buffing Aesthetics Precipitate Marks

on part
1. Operator Skill
Evaluation (Type B)'
Next Process:
No Discemible 1 Operator Skill No Control 10 6 180 M
[Link] Piece approval
Effect
and Patrol Inspection
(Type B)
50 Buffing Aesthetics Precipitate Marks
on part

1. Preventive
Maintenance of Machine
Subsequent
as per Schedule
Process : Predictive Maintenance
Triggers Minor
3 Machine Condition No Control 10 (Type B) 6 180 M
of Machine
Maint. Predictive Maintenance 3 4 6 16 of 25
2. First Pueve Approval
reaction plan
and Patrol Inspection
(Type B)

3
Customer (Plant): First Piece Approval and
Buffing Wheel
Triggers Minor 3 No Control 10 Patrol Inspection 6 180 M
Condition
reaction plan (Type B )

End User :
Moderately
3
objectionalble

Safety &
Regulatory:
1
No Discemible
effect

60 Stress Hardness Hardness More

Relieving
1. Preventive
Maintenance of Machine
Next Process: as per Schedule
Predictive Maintenance
No Discemible 1 Machine Condition No Control 10 (Type B) 6 480 H Maint. Predictive Maintenance 8 4 6
of Machine
Effect 2. First Pueve Approval
and Patrol Inspection
(Type B)

Subsequent
Process :
First Piece Approval and
100 % of the Relieving Panel Digital Controls
6 2 Patrol Inspection 6 96 M
Production may Temperature (Type A)
(Type B)
Have to be
reworked

8 SC
First Piece Approval and
Customer (Plant): Panel Digital Controls
8 Relieving Time 2 Patrol Inspection 6 96 M
100 % Reject (Type A)
(Type B)

End User :
Daily Calibration with Scheduled Calibration
Loss of Primary Hardness Tester
8 Master 2 plan 6 96 M
Function Accuracy
(Type A) (Type B)

Safety &
Regulatory:
1
No Discemible
effect

Hardness Less
1. Preventive
Maintenance of Machine
Next Process: as per Schedule
Predictive Maintenance
No Discemible 1 Machine Condition No Control 10 (Type B) 6 420 H Maint. Predictive Maintenance 8 4 6
of Machine
Effect 2. First Pueve Approval
and Patrol Inspection
(Type B)

Subsequent
Process :
First Piece Approval and
100 % of the Relieving Panel Digital Controls
6 2 Patrol Inspection 6 84 M
Production may Temperature (Type A)
(Type B)
Have to be
reworked

7 SC
First Piece Approval and
Customer (Plant): Panel Digital Controls
6 Relieving Time 2 Patrol Inspection 6 84 M
100 % Rework (Type A)
(Type B)

End User :
Daily Calibration with Scheduled Calibration
Degradation of Hardness Tester
7 Master 2 plan 6 84 M
Primary Function Accuracy
(Type A) (Type B)

Safety &
Regulatory:
1
No Discemible
effect

70 Surface Perpendicularity Perpendicularity

Grinding with respect to Z More
(BP) 1. Operator Skill
Evaluation (Type B)'
Next Process:
No Discemible 1 Operator Skill No Control 10 6 480 H
[Link] Piece approval
Effect
and Patrol Inspection
(Type B)

1. Preventive
Maintenance of Machine
Subsequent as per Schedule
Predictive Maintenance
Process : 8 Machine Condition No Control 10 (Type B) 6 480 H Maint. Predictive Maintenance 8 4 6
of Machine
100 % Reject 2. First Pueve Approval
and Patrol Inspection
(Type B)

8 SC
Mentioned on Wheel First Piece Approval and
Customer (Plant):
8 Grain Size and Work Instruction 4 Patrol Inspection 6 192 M
100 % Reject
(Type B) (Type B)

End User :
Mentioned on Wheel First Piece Approval and
Loss of Primary
8 Wheel Width and Work Instruction 4 Patrol Inspection 6 192 M
Function
(Type B) (Type B)

Safety &
Regulatory:
1
No Discemible
effect

Revision History
Rev. No. Revision Date Revision Details Revised By Verified By Approved By
01 25-2-2022 Operation 50,60,70 Added Mr. Jaskaran Mr. Aditya Mr. Tariq
 Kangaro Group of Companies (KGOC) Doc. No
Rev. No
CP/PE/TA-182.6A
01

Control Plan Issue Date

Page No
Part Number 182.6 A Part Rev # 01 Plant Kanin india Type Origin Date 27-11-2021 17 of 25
Part Description Projection Welding (F Plate + S Guide) Section Welding Shop Proto Type Key Date
Project Number PHT-150 Mr. Arvind, Mr. Tariq, Mr. Jaskaran, Mr. [Link], Mr. Manpreet, Mr. Pre Launch P Cust App Date
CFT
Project Description Stanely hammer tacker Gian singh, Production
Characteristic Class: CC-Critical ; SC- Significant
Operation/Process Characteristics Method
Equipment Product/Process Sample Size Reaction Plan
Measuring Control

Class
No Description No Product Process Specifications & Data Recording Responsibility
Method Size Freq Method
Tolerance
20 Projection Projection
Welding Welding Machine FPA
(Staple Guide + (PW-04) 2 (Start of Quality Inspector
Front Plate ) Shift)

Inform Production Supervisor and

First Piece
20.01 Perpendicularity with … SC 0.1 mm Height Gauge 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
respect to Z(BP) (Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.02 Dimension # 3(BP) … SC 0.1 ± 0.05 mm Height Gauge 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
(Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

Front Plate Face should First Piece
20.03 … SC Front Face should Butt Visual 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Butt with Staple Approval and
together (Once/Shift) control of Non conforming
Guide(BP) Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.04 Position with respect to … SC 0.1 mm Height Gauge 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
Y(BP) (Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.05 Projection Welding … SC 3.5 mm Vernier Calliper 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
Nugget Dimensions(BP) (Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

Faces Should remain First Piece
20.06 … SC Faces Should remain Visual 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
inside the the Staple Approval and
inside Staple Guide (Once/Shift) control of Non conforming
Guide(BP) Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

1. Operator Skill
Evaluation (Type
B)'
Inform Production Supervisor ,Train
20.07 … Operator Skill Level 3 / Level 4 Operator Skill 1 As per Plan FORMAT Prod Supervisor the operator and Evaluate the
Matrix [Link] Piece
Performance as per Freezed system
approval and
Patrol Inspection
(Type B)

1. Preventive
Maintenance of
Machine as per
Inform Production Supervisor and
1. No Parameters FPA Schedule Machine Condition
20.08 Machine Condition Fluctuation Visual/Tactical 1 (Start of (Type B) check sheet Quality Inspector Quality Person follow " Process for
control of Non conforming
2. No Loose Parts Shift) 2. First Pueve FORMAT
products"
Approval and
Patrol Inspection
(Type B)

Welding fixture
Preventive Stop & ^Inform Production
[Link] Wear / Tear, Fixture & Tool
20.09 Fixture Condition Visual & tactical start of production Maintenance of Quality Inspector Supervisor and Quality Person
Spatter on the fixture inspection check
Fixture as per plan follow " Process for control of Non
2. sheet
(Type B) conforming products"

Process Control Inform Production Supervisor and

FPA
20.10 Air Pressure 2.2 Kgf Digital Panel 2 Machine Set up Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Approval (Type B) FM/QA/05 control of Non conforming
Shift)
products"

1. Preventive
Maintenance of
Inspect the Instrument, If able to
Fixture as per Plan
Electrode Dressing calibrate then Dispatch for
20.11 Electrode Condition Flat from Tip Visual/Tactical 1 Every 50 (Type B) Quality Assurance calibration , otherwise discard the
Check sheet
(No Buljing) Strokes 2. First Piece
FORMAT Instrument from master list and
Approval and
scrap
Patrol Inspection
(Type B)

First Piece Process Control Inform Production Supervisor and

FPA
20.12 Current 2.1 KA Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Process Control Inform Production Supervisor and

FPA
20.13 Heat % 65% Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Process Control Inform Production Supervisor and

FPA
20.14 Hold Cycle 10 Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Process Control Inform Production Supervisor and

FPA
20.15 Weld Cycle 4 Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Process Control Inform Production Supervisor and

FPA
20.16 Off Cycle 10 Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Process Control Inform Production Supervisor and

FPA
20.17 Squeeze Cycle 88 Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

Inspect the Instrument, If able to

Scheduled calibrate then Dispatch for
20.18 Height Gauge Accuracy ……. Calibration As Per Plan Calibration Plan FORMAT Quality Assurance calibration , otherwise discard the
(Type B ) Instrument from master list and
scrap
Inspect the Instrument, If able to
Scheduled calibrate then Dispatch for
20.19 Vernier Calliper Accuracy ……. Calibration As Per Plan Calibration Plan FORMAT Quality Assurance calibration , otherwise discard the
(Type B ) Instrument from master list and
scrap
 30 Brazing Torch + Filler FPA
(Staple Guide + Metal(Brass) 2 (Start of Quality Inspector
Front Place Sub Shift) First Piece
Assembly) Approval and FM/QA/05
Patrol Inspection Stop & ^Inform Production
No Weld marks on The 2 Patrol Quality Inspector Supervisor and Quality Person
30.01 Aesthetics- Visual (Once/Shift)
Top Of The Surface follow " Process for control of Non 18 of 25
conforming products"

100% Self Inspection N operator

FPA
2 First Piece Quality Inspector
(Start of Stop & ^Inform Production
Approval
Vicker hardness Shift) Supervisor and Quality Person
30.02 Hardness sc 36-45 HRC FM/QA/05
testing m/C follow " Process for control of Non
Patrol conforming products" "
2 Patrol Inspection Quality Inspector
(Once/Shift)

FPA
2 First Piece Quality Inspector
(Start of
Approval
Shift)
[Link] at inside the FM/QA/05
both corner of front Stop & ^Inform Production
30.03 plate welded area Visual 2 Patrol Patrol Inspection Quality Inspector Supervisor and Quality Person
Brazing Area (Once/Shift) follow " Process for control of Non
2. Brazing should not
Visible from back side conforming products"
of staple guide

100% Self Inspection & N operator

Work instruction

FPA
2 First Piece Quality Inspector
(Start of
Approval Stop & ^Inform Production
Shift)
30.04 Perpendicularity … sc 0.1|Z Height Gauge FM/QA/05 Supervisor and Quality Person
follow " Process for control of Non
Patrol conforming products"
2 Patrol Inspection Quality Inspector
(Once/Shift)

FPA
2 First Piece Quality Inspector
(Start of
Approval Stop & ^Inform Production
Shift)
30.05 Front plate height … sc 0.1 ± 0.05 mm Height Gauge FM/QA/05 Supervisor and Quality Person
follow " Process for control of Non
Patrol conforming products"
2 Patrol Inspection Quality Inspector
(Once/Shift)

1. Operator Skill
Evaluation (Type
B)'
Inform Production Supervisor ,Train
30.06 Operator Skill Level 3 / Level 4 Operator Skill .----- N Prod Supervisor the operator and Evaluate the
Matrix [Link] Piece
Performance as per Freezed system
approval and
Patrol Inspection
(Type B)

Stop & ^Inform Production

Process Control
30.07 O2 +LPG Visual start of production Setup verification Quality Inspector Supervisor and Quality Person
Flame color Large blue Check Sheet
follow " Process for control of Non
conforming products"

Process Control
30.09 Flux Borax Visual start of production Setup verification Check Sheet Quality Inspector

Stop & ^Inform Production

Process Control
30.10 Quencing media Visual start of production Setup verification Quality Inspector Supervisor and Quality Person
Water Check Sheet
follow " Process for control of Non
conforming products"
Process Control
30.11 Filler material Brass Visual start of production Setup verification Quality Inspector
Check Sheet
Dia1.6 (tag)

40 Acid Cleaning / Manual Follow Acid Cleaning Process from Blackening Control Plan
Pickling

Process Control
50.01 Aesthetics No Precipitate Marks Visual start of production Setup verification Check Sheet Quality Inspector
to be there on part Stop & ^Inform Production
50 Buffing Cylindrical Buffing Supervisor and Quality Person
Machine follow " Process for control of Non
conforming products"

50.02 Buffing Wheel Type Visual start of production Setup verification Process Control Quality Inspector
Cloth Buffing Wheel Check Sheet

FPA
2 First Piece Quality Inspector
(Start of Stop & ^Inform Production
Approval
Vicker hardness Shift) Supervisor and Quality Person
60.01 Hardness sc 36-45 HRC FM/QA/05
testing m/C follow " Process for control of Non
Patrol conforming products" "
2 Patrol Inspection Quality Inspector
(Once/Shift)
60 Stress Relieving Heating Furnace
60.02 Stress Relieving Furnace Display start of production Setup verification Process Control Quality Inspector
Temperature 250°C Check Sheet Stop & ^Inform Production
Supervisor and Quality Person
follow " Process for control of Non
Process Control conforming products"
60.03 Stress Relieving Time 30min Furnace Timer start of production Setup verification Quality Inspector
Check Sheet

FPA
2 First Piece Quality Inspector
(Start of
Approval Stop & ^Inform Production
Shift)
70.01 Perpendicularity with … sc 0.1|Z Height Gauge FM/QA/05 Supervisor and Quality Person
respect to Z (BP) follow " Process for control of Non
Patrol conforming products"
2 Patrol Inspection Quality Inspector
(Once/Shift)

70 Surface Grinding Surface Grinder +

Vice
70.02 Grain Size Mentioned on start of production Setup verification Process Control Quality Inspector
120 mm Wheel & Work instruction Check Sheet
Stop & ^Inform Production
Supervisor and Quality Person
follow " Process for control of Non
Process Control conforming products"
70.03 Grinding Wheel Width Mentioned on start of production Setup verification Quality Inspector
13 mm Check Sheet
Wheel & Work instruction

CD - Centre
Disannce "@ " marked F- Critical
UTS - Ultimate HV - Vicker Hardness (Unit of TDS - Total RG-Receiving gauge
(Hole to pH - measurement of acidity or dimension to be for Function MTS :Material
^Abbreviation Hole, Hole
Tensile Strength DVC-DigitaL
alkanity, measurement of hydrogen
Hardness given by the Test Dissolve Solids SP-Standard Pin
observe nd A: Critical
VMS: Vision
Technical " * "Parameter to be
used to
(Stress at which Vernier Calliper
ion concenteration of a solution
known as Vicker Pyramid (any mineral, salt, PG-Plug gauge
update after for
Measuring System
Specification validate in Production lot
material Breaks Number) metal) HG- Height Guge
Functional validation in trials Assembly
Edge)

Revision History
Rev. No. Revision Date Revision Details Revised By Verified By Approved By
01 25-2-2022 Added operation 60 & 70 Mr. Jaskaran Mr. Aditya Mr. Tariq
 Kangaro Group of Companies (KGOC) Doc. No CP/PE/TA-182.11A
Rev. No 01

Control Plan Issue Date

Page No
Part Number 182.11 A Part Rev # 01 Plant Kanin india Type Origin Date 27-11-2021 19 of 25
Part Description Spot Welding (Middle + Tensioner) Section Welding Shop Proto Type Key Date
Project Number PHT-150 Mr. Arvind, Mr. Tariq, Mr. Jaskaran, Mr. [Link], Mr. Manpreet, Mr. Gian Pre Launch P Cust App Date
CFT
Project Description Stanely hammer tacker singh, Production
Characteristic Class: CC-Critical ; SC- Significant
Operation/Process Characteristics Method
Equipment Product/Process Sample Size Reaction Plan
Measuring Control

Class
No Description No Product Process Specifications & Data Recording Responsibility
Method Size Freq Method
Tolerance
20 Spot Welding Projection Weld
(Middle + Machine FPA
Tensioner) (PW-04) 2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

Patrol First Piece
20.01 Spot Welding Nugget … SC Ø 2.8 mm Vernier Calliper 2 FM/QA/05 Quality Inspector Quality Person follow " Process for
(Once/Shift) Approval and
(Both Sides 2 Spots)(BP) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.02 Parallelism with respect … SC 0.1 mm Height Gauge 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
to Z(BP) (Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.03 Dimension # 4(BP) … SC 17.85 + 0.1 mm Height Gauge 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
(Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

1. Operator Skill
Evaluation (Type
B)'
Inform Production Supervisor ,Train
20.04 …. Operator Skill Level 3 / Level 4 Operator Skill 1 As per Plan FORMAT Prod Supervisor the operator and Evaluate the
Matrix [Link] Piece
Performance as per Freezed system
approval and
Patrol Inspection
(Type B)

1. Preventive
Maintenance of
Machine as per
Inform Production Supervisor and
1. No Parameters FPA Schedule Machine Condition
20.05 Machine Condition Fluctuation Visual/Tactical 1 (Start of (Type B) check sheet Quality Inspector Quality Person follow " Process for
control of Non conforming
2. No Loose Parts Shift) 2. First Pueve FORMAT
products"
Approval and
Patrol Inspection
(Type B)

Process Control Inform Production Supervisor and

FPA
20.06 Air Pressure 2.08 Bar Digital Panel 2 Machine Set up Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Approval (Type B) FM/QA/05 control of Non conforming
Shift)
products"

First Piece Process Control Inform Production Supervisor and

FPA
20.07 Current 1.8 KA Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Process Control Inform Production Supervisor and

FPA
20.08 Heat % 45% Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Process Control Inform Production Supervisor and

FPA
20.09 Hold Cycle 10 Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Process Control Inform Production Supervisor and

FPA
20.10 Weld Cycle 5 Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"
 1. Preventive
Maintenance of
Machine as per
Process Control Inform Production Supervisor and
FPA Schedule
20.11 Off Cycle 10 Digital Panel 2 Check Sheet Quality Inspector Quality Person follow " Process for
(Start of (Type B) 20 of 25
FM/QA/05 control of Non conforming
Shift) 2. First Pueve
products"
Approval and
Patrol Inspection
(Type B)

First Piece Process Control Inform Production Supervisor and

FPA
20.12 Squeeze Cycle 130 Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

Preventive Inform Production Supervisor and

1. No Parameters FPA Machine Condition
20.13 Fixture Condition Visual/Tactical 1 Maintenance of Quality Inspector Quality Person follow " Process for
Fluctuation (Start of check sheet
Fixture as per plan control of Non conforming
2. No Loose Parts Shift) FORMAT
(Type B) products"

1. Preventive
Maintenance of
Inspect the Instrument, If able to
Fixture as per Plan
Electrode Dressing calibrate then Dispatch for
20.14 Electrode Condition Flat from Tip Visual/Tactical 1 Every 50 (Type B) Quality Assurance calibration , otherwise discard the
Check sheet
(No Buljing) Strokes 2. First Piece
FORMAT Instrument from master list and
Approval and
scrap
Patrol Inspection
(Type B)

Inspect the Instrument, If able to

Schedule calibrate then Dispatch for
20.15 Vernier Calliper Accuracy ……. Calibration As Per Plan Calibration Plan FORMAT Quality Assurance calibration , otherwise discard the
(Type B ) Instrument from master list and
scrap

Inspect the Instrument, If able to

Schedule calibrate then Dispatch for
20.16 Height Gauge Accuracy ……. Calibration As Per Plan Calibration Plan FORMAT Quality Assurance calibration , otherwise discard the
(Type B ) Instrument from master list and
scrap

30 Middle Resizing Manual + Resizing

with Gauge Gauge
Quality Inspector

Inform Production Supervisor and

First Piece
30.01 Inner U Size … 11 ± 0.1 mm Plug Gauge 100% Approval and FM/QA/05 Quality Inspector Quality Person follow " Process for
control of Non conforming
Patrol Inspection
products"

operator

1. Operator Skill
Evaluation (Type
B)'
Inform Production Supervisor ,Train
30.02 Operator Awareness Level 3 / Level 4 Operator Skill 1 As per Plan FORMAT Prod Supervisor the operator and Evaluate the
Matrix [Link] Piece
Performance as per Freezed system
approval and
Patrol Inspection
(Type B)

Process Control
40.01 Aesthetics No Sharp Edges Visual/ Feel start of production Setup verification Check Sheet Quality Inspector
Stop & ^Inform Production
40 Buffing Cylindrical Buffing Supervisor and Quality Person
Machine follow " Process for control of Non
conforming products"

40.02 Buffing Wheel Type Visual start of production Setup verification Process Control Quality Inspector
Cloth Buffing Wheel Check Sheet

Revision History
Rev. No. Revision Date Revision Details Revised By Verified By Approved By
01 25-2-2022 Added Operation 30 Mr. Jaskaran Mr. Aditya Mr. Tariq

Kangaro Group of Companies (KGOC) Doc. No

Rev. No
CP/PE/TA-182.3A
00

Control Plan Issue Date

Page No
1/8/2021

Part Number 182.3A Part Rev # 00 Plant Kanin india Type Origin Date 15-11-2021
Part Description Spot Weld (Middle + Staple Guide Assy Section Welding Shop Proto Type Key Date
Project Number PHT-150 Mr. Arvind, Mr. Tariq, Mr. Jaskaran, Mr. [Link], Mr. Manpreet, Mr. Gian Pre Launch P Cust App Date
CFT
Project Description Stanely hammer tacker singh, Production
Characteristic Class: CC-Critical ; SC- Significant
Operation/Process Characteristics Method
Equipment Product/Process Sample Size Reaction Plan
Measuring Control
Class

No Description No Product Process Specifications & Data Recording Responsibility

Method Size Freq Method
Tolerance
20 Spot Welding Projection Weld
(Staple Guide + (PW-03) FPA
Middle Assy) 2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

Patrol First Piece
20.01 Dimension #2(BP) … SC 1.1 +0.15 -0.05 mm Height Gauge 2 Approval and FM/QA/05 Quality Inspector Quality Person follow " Process for
(Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.02 Both faces should Butt … SC Faces should butt Visual 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
together (BP) (Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.03 Dimension # 4 (On both … SC 0.95 +0.05-0.10 mm Height Gauge 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
sides)(BP) (Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.04 Spot Welding Nugget ( 6 … SC Ø 3.5 mm Vernier Calliper 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
Spots )(BP) (Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.05 Maximum Displacement … SC 0.05 max Height Gauge 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
in Staple Guide Assy(BP) (Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)
 1. Operator Skill
Evaluation (Type
B)'
Inform Production Supervisor ,Train
20.06 … Operator Skill Level 3 / Level 4 Operator Skill 1 As per Plan FORMAT Prod Supervisor the operator and Evaluate the
Matrix [Link] Piece
Performance as per Freezed system 21 of 25
approval and
Patrol Inspection
(Type B)

1. Preventive
Maintenance of
Machine as per
Inform Production Supervisor and
1. No Parameters FPA Schedule Machine Condition
20.07 Machine Condition Fluctuation Visual/Tactical 1 (Start of (Type B) check sheet Quality Inspector Quality Person follow " Process for
control of Non conforming
2. No Loose Parts Shift) 2. First Pueve FORMAT
products"
Approval and
Patrol Inspection
(Type B)

1. Preventive
Maintenance of
Inspect the Instrument, If able to
Fixture as per Plan
Electrode Dressing calibrate then Dispatch for
20.08 Electrode Condition Flat from Tip Visual/Tactical 1 Every 50 (Type B) Quality Assurance calibration , otherwise discard the
Check sheet
(No Buljing) Strokes 2. First Piece
FORMAT Instrument from master list and
Approval and
scrap
Patrol Inspection
(Type B)

Welding fixture
Preventive Stop & ^Inform Production
[Link] Wear / Tear, Fixture & Tool
20.09 Fixture Condition Visual & tactical start of production Maintenance of Quality Inspector Supervisor and Quality Person
Spatter on the fixture inspection check
Fixture as per plan follow " Process for control of Non
2. sheet
(Type B) conforming products"

Inspect the Instrument, If able to

calibrate then Dispatch for
20.10 Height Gauge Accuracy ……. Calibration 1 As per plan FORMAT Quality Assurance calibration , otherwise discard the
Instrument from master list and
scrap

Inspect the Instrument, If able to

Schedule calibrate then Dispatch for
20.11 Vernier Calliper Accuracy ……. Calibration As Per Plan Calibration Plan FORMAT Quality Assurance calibration , otherwise discard the
(Type B ) Instrument from master list and
scrap

Process Control Inform Production Supervisor and

FPA
20.12 Air Pressure 2.08 Bar Digital Panel 2 Machine Set up Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Approval (Type B) FM/QA/05 control of Non conforming
Shift)
products"

First Piece Process Control Inform Production Supervisor and

FPA
20.13 Current 2.2 KA Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Process Control Inform Production Supervisor and

FPA
20.14 Heat % 54% Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Process Control Inform Production Supervisor and

FPA
20.15 Hold Cycle 10 Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Process Control Inform Production Supervisor and

FPA
20.16 Weld Cycle 9 Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Process Control Inform Production Supervisor and

FPA
20.17 Off Cycle 10 Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Process Control Inform Production Supervisor and

FPA
20.18 Squeeze Cycle 62 Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

CD - Centre
Disannce "@ " marked F- Critical
UTS - Ultimate HV - Vicker Hardness (Unit of TDS - Total RG-Receiving gauge
(Hole to pH - measurement of acidity or dimension to be for Function MTS :Material
^Abbreviation Hole, Hole
Tensile Strength DVC-DigitaL
alkanity, measurement of hydrogen
Hardness given by the Test Dissolve Solids SP-Standard Pin
observe nd A: Critical
VMS: Vision
Technical " * "Parameter to be
used to
(Stress at which Vernier Calliper
ion concenteration of a solution
known as Vicker Pyramid (any mineral, salt, PG-Plug gauge
update after for
Measuring System
Specification validate in Production lot
material Breaks Number) metal) HG- Height Guge
Functional validation in trials Assembly
Edge)

Revision History
Rev. No. Revision Date Revision Details Revised By Verified By Approved By
Mr. Jaskaran Mr. Aditya Mr. Tariq

Kangaro Group of Companies (KGOC) Doc. No

Rev. No
CP/PE/TA-182.4A
01

Control Plan Issue Date

Page No
Part Number 182.4A Part Rev # 01 Plant Kanin india Type Origin Date 27-11-2021
Part Description Mig Welding (Middle + Middle Holder) Section Welding Shop Proto Type Key Date
Project Number PHT-150 Mr. Arvind, Mr. Tariq, Mr. Jaskaran, Mr. [Link], Mr. Manpreet, Mr. Gian Pre Launch P Cust App Date
CFT
Project Description Stanely hammer tacker singh, Production
Characteristic Class: CC-Critical ; SC- Significant
Operation/Process Characteristics Method
Equipment Product/Process Sample Size Reaction Plan
Measuring Control
Class

No Description No Product Process Specifications & Data Recording Responsibility

Method Size Freq Method
Tolerance
20 Mig Welding Mig Welding
(Middle Assy + Machine FPA
Middle Holder) 2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

Patrol First Piece
20.01 Welding Bead on Both … SC 10.50 mm Thread + Ruler 2 FM/QA/05 Quality Inspector Quality Person follow " Process for
(Once/Shift) Approval and
Sides (BP) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.02 Holder Hole Position with … SC 0.3 mm Height Gauge 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
respect to Z and Y(BP) (Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.03 Holder Hole … SC Ø 5.60 -0.00-0.05 Vernier Calliper/ 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
Diameter(BP) Plug Gauge (Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.04 Hole CD from front plate … SC 262.40 mm Height Gauge FM/QA/05 Quality Person follow " Process for
Approval and
(BP) control of Non conforming
 Inform Production Supervisor and
First Piece
20.04 Hole CD from front plate … SC 262.40 mm Height Gauge 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
(BP) (Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator 22 of 25
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.05 Pin Should Free to move … SC Free Roation of Pin Plug Gauge 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
in Hole(BP) (Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

Both faces should butt First Piece
20.06 … SC Faces should butt Visual 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
together Staple Assy and Approval and
together (Once/Shift) control of Non conforming
Middle Holder(BP) Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
1 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.07 Dimension # 9(BP) … SC 20.20 ± 0.10 mm Vernier Calliper .. Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
(Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
… (Every 15 operator
minutes)

1. Operator Skill
Evaluation (Type
B)'
Inform Production Supervisor ,Train
20.09 … Operator Skill Level 3 / Level 4 Operator Skill 1 As per Plan FORMAT Prod Supervisor the operator and Evaluate the
Matrix [Link] Piece
Performance as per Freezed system
approval and
Patrol Inspection
(Type B)

1. Preventive
Maintenance of
Machine as per
Inform Production Supervisor and
1. No Parameters FPA Schedule Machine Condition
20.10 … Mig Welding Set Visual/Tactical 1 Quality Inspector Quality Person follow " Process for
Fluctuation (Start of (Type B) check sheet
Condition control of Non conforming
2. No Loose Parts Shift) 2. First Pueve FORMAT
products"
Approval and
Patrol Inspection
(Type B)

1. Preventive
Maintenance of
Torch as per
Inform Production Supervisor and
FPA Schedule
20.11 … Torch Condition [Link] Spatter Inside the Visual 2 Quality Inspector Quality Person follow " Process for
(Start of (Type B)
Nozzle control of Non conforming
Shift) 2. First Piece
products"
Approval and
Patrol Inspection Process Control
(Type B) Check Sheet
FM/QA/05

Preventive Inform Production Supervisor and

1. No Parameters FPA Machine Condition
20.12 … Fixture Conditon Visual/Tactical 1 Maintenance of Quality Inspector Quality Person follow " Process for
Fluctuation (Start of check sheet
Fixture as per plan control of Non conforming
2. No Loose Parts Shift) FORMAT
(Type B) products"

1. Preventive
Maintenance as
per Schedule Inform Production Supervisor and
FPA Machine Condition
20.13 … Wire Feed Rate To be smooth without 1 (Type B) Quality Inspector Quality Person follow " Process for
(Start of check sheet
Interuption 2. First Piece control of Non conforming
Shift) FORMAT
Approval and products"
Patrol Inspection
(Type B)

First Piece Process Control Inform Production Supervisor and

FPA
20.14 … Current 123 ~125 A Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Process Control Inform Production Supervisor and

FPA
20.15 … Voltage 21 V Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Inform Production Supervisor and

FPA
20.16 … Welding Angle 2 Approval and Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection control of Non conforming
Shift)
(Type B) products"
Process Control
Check Sheet
FM/QA/05

First Piece Inform Production Supervisor and

FPA
20.17 … Gap B/w Part and Torch 2 Approval and Quality Inspector Quality Person follow " Process for
(Start of Process Control
Patrol Inspection control of Non conforming
Shift) Check Sheet
(Type B) products"
FM/QA/05

Preventive Inform Production Supervisor and

FPA Fixture Condition
20.18 … Guiding Pin Condition 1. No Wear /Defects Visual/Tactical 1 Maintenance of Quality Inspector Quality Person follow " Process for
(Start of check sheet
Fixture as per plan control of Non conforming
Shift) FORMAT
(Type B) products"

Inspect the Instrument, If able to

Scheduled calibrate then Dispatch for
20.19 … Plug Gauge Accuracy ……. Calibration As per plan Calibration plan FORMAT Quality Assurance calibration , otherwise discard the
(Type B) Instrument from master list and
scrap

Inspect the Instrument, If able to

Scheduled calibrate then Dispatch for
20.20 … Vernier Calliper Accuracy ……. Calibration As per plan Calibration plan FORMAT Quality Assurance calibration , otherwise discard the
(Type B) Instrument from master list and
scrap

Inspect the Instrument, If able to

Scheduled calibrate then Dispatch for
20.21 … Microscope Accuracy ……. Calibration As per plan Calibration plan FORMAT Quality Assurance calibration , otherwise discard the
(Type B) Instrument from master list and
scrap

First Piece Inform Production Supervisor and

FPA
20.22 … Gas Flow rate Analog Pressure 2 Approval and Quality Inspector Quality Person follow " Process for
15- 20 ft3/ hr(C02) (Start of Process Control
Gauge Patrol Inspection control of Non conforming
Shift) Check Sheet
(Type B) products"
FM/QA/05

30 Mig Welding Mig Welding

Tacking Machine FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

Patrol First Piece
30.01 Welding Tacks on Either … 2 Welding Tacks Visual 2 FM/QA/05 Quality Inspector Quality Person follow " Process for
(Once/Shift) Approval and
Sides control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

1. Operator Skill
Evaluation (Type
B)'
Inform Production Supervisor ,Train
30.02 … Operator Skill Level 3 / Level 4 Operator Skill 1 As per Plan FORMAT Prod Supervisor the operator and Evaluate the
Matrix [Link] Piece
Performance as per Freezed system
approval and
Patrol Inspection
(Type B)
 1. Preventive
Maintenance of
Machine as per
Inform Production Supervisor and
1. No Parameters FPA Schedule Machine Condition
30.03 … Mig Welding Set
Fluctuation Visual/Tactical 1 (Start of (Type B) check sheet Quality Inspector Quality Person follow " Process for 23 of 25
Condition control of Non conforming
2. No Loose Parts Shift) 2. First Pueve FORMAT
products"
Approval and
Patrol Inspection
(Type B)

Preventive Inform Production Supervisor and

FPA
30.04 … Torch Condition [Link] Spatter Inside the Visual 2 Maintenance of Quality Inspector Quality Person follow " Process for
(Start of
Nozzle Fixture as per plan control of Non conforming
Shift)
(Type B) products"
Process Control
Check Sheet
FM/QA/05

Inform Production Supervisor and

FPA Scheduled Machine Condition
30.05 … Wire Feed Rate To be smooth without 1 Quality Inspector Quality Person follow " Process for
(Start of Calibration plan check sheet
Interuption control of Non conforming
Shift) (Type B) FORMAT
products"

First Piece Process Control Inform Production Supervisor and

FPA
30.06 … Current 96 A Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Process Control Inform Production Supervisor and

FPA
30.07 … Voltage 20.8 V Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Inform Production Supervisor and

FPA
30.08 … Gas Flow rate Analog Pressure 2 Approval and Quality Inspector Quality Person follow " Process for
15- 20 ft3/ hr(C02) (Start of Process Control
Gauge Patrol Inspection control of Non conforming
Shift) Check Sheet
(Type B) products"
FM/QA/05

CD - Centre
Disannce "@ " marked F- Critical
UTS - Ultimate HV - Vicker Hardness (Unit of TDS - Total RG-Receiving gauge
(Hole to pH - measurement of acidity or dimension to be for Function MTS :Material
^Abbreviation Hole, Hole
Tensile Strength DVC-DigitaL
alkanity, measurement of hydrogen
Hardness given by the Test Dissolve Solids SP-Standard Pin
observe nd A: Critical
VMS: Vision
Technical " * "Parameter to be
used to
(Stress at which Vernier Calliper
ion concenteration of a solution
known as Vicker Pyramid (any mineral, salt, PG-Plug gauge
update after for
Measuring System
Specification validate in Production lot
material Breaks Number) metal) HG- Height Guge
Functional validation in trials Assembly
Edge)

Revision History
Rev. No. Revision Date Revision Details Revised By Verified By Approved By
01 25-2-2022 Added Operation no. 30 Mr. Jaskaran Mr. Aditya Mr. Tariq

Kangaro Group of Companies (KGOC) Doc. No

Rev. No
CP/PE/TA-182.2A
01

Control Plan Issue Date

Page No
Part Number 182.2A Part Rev # 01 Plant Kanin india Type Origin Date 27-11-2021
Part Description Mig Welding (Middle + Middle Bracket) Section Welding Shop Proto Type Key Date
Project Number PHT-150 Mr. Arvind, Mr. Tariq, Mr. Jaskaran, Mr. [Link], Mr. Manpreet, Mr. Gian Pre Launch P Cust App Date
CFT
Project Description Stanely hammer tacker singh, Production
Characteristic Class: CC-Critical ; SC- Significant
Operation/Process Characteristics Method
Equipment Product/Process Sample Size Reaction Plan
Measuring Control
Class

No Description No Product Process Specifications & Data Recording Responsibility

Method Size Freq Method
Tolerance
20 Mig Welding Mig Welding
(Middle Assy + Machine FPA
Middle Bracket) 2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

Patrol First Piece
20.01 Welding Bead length on … SC 12 mm DVC and Visual … FM/QA/05 Quality Inspector Quality Person follow " Process for
(Once/Shift) Approval and
both sides(BP) control of Non conforming
Patrol Inspection
products"

Self
… (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.02 Welding Bead on both … SC Welding Bead to be Visual 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
sides(BP) there on Both Sides (Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.03 Dimension # 4(BP) … SC 1.35 -0.00 -0.05 mm Height Gauge 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
(Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
.. (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.04 Dimension # 5(BP) … SC 11 ± 0.05 mm Height Gauge 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
(Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
… (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.05 Position with respect to … SC 0.05 mm Height Gauge 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
Z(BP) (Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
… (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

Both the faces Middle First Piece
20.06 … SC Faces should butt Visual 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Bracket and Middle Approval and
together (Once/Shift) control of Non conforming
should butt together(BP) Patrol Inspection
products"

Self
2 (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

Grind to match the First Piece
20.07 … SC 0.2 max above middle Height Gauge 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
surface (Weld should not Approval and
(Once/Shift) control of Non conforming
come out)(BP) Patrol Inspection
products"

Self
… (Every 15 operator
minutes)

FPA
2 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.08 Dimension # 9(BP) … SC 5.6 mm Height Gauge 2 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
(Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
… (Every 15 operator
minutes)

FPA
1 (Start of Quality Inspector
Shift)

Inform Production Supervisor and

First Piece
20.09 Welding Penetration(ES) … SC 20 % ~40 % of Minimum Microscope FM/QA/05 Quality Person follow " Process for
Approval and
Sheet Thickness control of Non conforming
Patrol Inspection
 Inform Production Supervisor and
First Piece
20.09 Welding Penetration(ES) … SC 20 % ~40 % of Minimum Microscope 1 Patrol FM/QA/05 Quality Inspector Quality Person follow " Process for
Approval and
Sheet Thickness (Once/Shift) control of Non conforming
Patrol Inspection
products"

Self
… (Every 15 operator 24 of 25
minutes)

First Piece
Inform Production Supervisor ,Train
20.10 … Operator Skill Level 3 / Level 4 Operator Skill 1 As per Plan Approval and FORMAT Prod Supervisor the operator and Evaluate the
Matrix Patrol Inspection
Performance as per Freezed system
(Type B)

First Piece Inform Production Supervisor and

1. No Parameters FPA Machine Condition
20.11 … Mig Welding Set Visual/Tactical 1 Approval and Quality Inspector Quality Person follow " Process for
Fluctuation (Start of check sheet
Condition Patrol Inspection control of Non conforming
2. No Loose Parts Shift) FORMAT
(Type B) products"

First Piece Inform Production Supervisor and

FPA
20.12 … Torch Condition [Link] Spatter Inside the Visual 2 Approval and Quality Inspector Quality Person follow " Process for
(Start of
Nozzle Patrol Inspection control of Non conforming
Shift)
(Type B) products"
Process Control
Check Sheet
FM/QA/05

Welding fixture
Preventive Stop & ^Inform Production
[Link] Wear / Tear, Fixture & Tool
20.13 … Fixture Conditon Visual & tactical start of production Maintenance of Quality Inspector Supervisor and Quality Person
Spatter on the fixture inspection check
Fixture as per plan follow " Process for control of Non
2. sheet
(Type B) conforming products"

First Piece Inform Production Supervisor and

FPA Machine Condition
20.14 … Wire Feed Rate To be smooth without 1 Approval and Quality Inspector Quality Person follow " Process for
(Start of check sheet
Interuption Patrol Inspection control of Non conforming
Shift) FORMAT
(Type B) products"

Process Control Inform Production Supervisor and

FPA Scheduled
20.15 … Current 100~105 Amp Digital Panel 2 Check Sheet Quality Inspector Quality Person follow " Process for
(Start of Calibration plan
FM/QA/05 control of Non conforming
Shift) (Type B)
products"

First Piece Process Control Inform Production Supervisor and

FPA
20.16 … Voltage 22 V Digital Panel 2 Approval and Check Sheet Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection FM/QA/05 control of Non conforming
Shift)
(Type B) products"

First Piece Inform Production Supervisor and

FPA
20.17 … Welding Angle 2 Approval and Quality Inspector Quality Person follow " Process for
(Start of
Patrol Inspection control of Non conforming
Shift)
(Type B) products"
Process Control
Check Sheet
FM/QA/05

First Piece Inform Production Supervisor and

FPA
20.18 … Gap B/w Part and Torch 2 Approval and Quality Inspector Quality Person follow " Process for
(Start of Process Control
Patrol Inspection control of Non conforming
Shift) Check Sheet
(Type B) products"
FM/QA/05

First Piece Inform Production Supervisor and

FPA Fixture Condition
20.19 … Guiding Pin Condition 1. No Wear /Defects Visual/Tactical 1 Condition and Quality Inspector Quality Person follow " Process for
(Start of check sheet
Patrol Inspection control of Non conforming
Shift) FORMAT
(Type B) products"

Inspect the Instrument, If able to

Scheduled calibrate then Dispatch for
20.20 … Plug Gauge Accuracy ……. Calibration As per plan Calibration plan FORMAT Quality Assurance calibration , otherwise discard the
(Type B) Instrument from master list and
scrap

Inspect the Instrument, If able to

Scheduled calibrate then Dispatch for
20.21 … Height Gauge Accuracy ……. Calibration As per plan Calibration plan FORMAT Quality Assurance calibration , otherwise discard the
(Type B) Instrument from master list and
scrap

Inspect the Instrument, If able to

First Piece
calibrate then Dispatch for
20.22 … Grinding Belt Condition Not to be Weared Visual Start of Lot Approval and FORMAT Quality Assurance calibration , otherwise discard the
Patrol Inspection
Instrument from master list and
(Type B )
scrap

First Piece Inform Production Supervisor and

FPA
20.23 … Grinding Belt Grit 120 Grit No Belt Grit No 2 Approval and Quality Inspector Quality Person follow " Process for
(Start of Process Control
Number Patrol Inspection control of Non conforming
Shift) Check Sheet
(Type B) products"
FM/QA/05

Inspect the Instrument, If able to

Scheduled calibrate then Dispatch for
20.24 Microscope Accuracy ……. Calibration As per plan Calibration plan FORMAT Quality Assurance calibration , otherwise discard the
(Type B) Instrument from master list and
scrap

First Piece Inform Production Supervisor and

FPA
20.25 Gas Flow rate Analog Pressure 2 Approval and Quality Inspector Quality Person follow " Process for
15- 20 ft3/ hr(C02) (Start of Process Control
Gauge Patrol Inspection control of Non conforming
Shift) Check Sheet
(Type B) products"
FM/QA/05

30 Belt Grinding Belt Grinder

First Piece Inform Production Supervisor and

FPA
30.01 Aesthetics … No Extra Welding On the Visual 2 Approval and N Quality Assurance Quality Person follow " Process for
(Start of
Side Surfaces Patrol Inspection control of Non conforming
Shift)
(Type -B) products"

Inform Production Supervisor and

FPA First Piece
30.02 Belt Grit Number 120 Grit Number Visual written on 2 N Quality Assurance Quality Person follow " Process for
(Start of Approval and
Belt control of Non conforming
Shift) Patrol Inspection
products"

FPA
2 First Piece Quality Inspector
(Start of
Approval Stop & ^Inform Production
After Grinding Max. 0.1 Shift)
40.01 Aesthetics … Visual FM/QA/05 Supervisor and Quality Person
mm above Middle
follow " Process for control of Non
Surface Self conforming products"
2 (Every 15 Patrol Inspection Operator
minutes)
40 Surface Grinding Surface Grinder +
Vice

40.02 Grain Size Mentioned on start of production Setup verification Process Control Quality Inspector
120 mm Wheel & Work instruction Check Sheet Stop & ^Inform Production
Supervisor and Quality Person
follow " Process for control of Non
Mentioned on Setup verification Process Control conforming products"
40.03 Grinding Wheel Width 13 mm start of production Quality Inspector
Wheel & Work instruction Check Sheet

50 Blackening Manual As Per Blackening Control Plan

 CD - Centre
Disannce "@ " marked F- Critical
UTS - Ultimate HV - Vicker Hardness (Unit of TDS - Total RG-Receiving gauge
(Hole to pH - measurement of acidity or dimension to be for Function MTS :Material
^Abbreviation Hole, Hole
Tensile Strength DVC-DigitaL
alkanity, measurement of hydrogen
Hardness given by the Test Dissolve Solids SP-Standard Pin
observe nd A: Critical
VMS: Vision
Technical " * "Parameter to be 25 of 25
used to
(Stress at which Vernier Calliper
ion concenteration of a solution
known as Vicker Pyramid (any mineral, salt, PG-Plug gauge
update after for
Measuring System
Specification validate in Production lot
material Breaks Number) metal) HG- Height Guge
Functional validation in trials Assembly
Edge)

Revision History
Rev. No. Revision Date Revision Details Revised By Verified By Approved By
01 22-5-2022 Added operation No. 40 Mr. Jaskaran Mr. Aditya Mr. Tariq