CONTROL PLAN

Prototype Prelaunch Production Key Contact / Phone : Date (Orig.) Date (rev)

Control Plan Number: SEPL/CP/B-029 Rev: 001 Mr.Lokesh.V 91-8861002709 29.03.2016 11.01.2018 (00)
Part Number /Rev No : Core Team : Mr.Ashwath, Mr.Lokesh, Mr.Abhay, Mr.Partha, Mr.K.B. Nagaraj, Mr.Sumeshlal, Customer Engineering Approval / Date (if Req'd.)
X0614A18 Mr.Shankar, Mr.Naveen ----
Part Name / Description & Model Prepared By : Customer Quality Approval / Date (if Req'd.)
KNUCKLE BRACKET Sowmya shree.N
Customer 's name Supplier Code Other Approval / Date (if Req'd.) Other Approval / Date (if Req'd.)
TTIA ---- ----
Material Specification / Norms : ---
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Characteristics Methods Sample

Machine, Sl
Part / Process Name /Operation Device, Jig, Sp.
No /
Process
Description Tools, Drg Char. Product / Process Evaluation /Measurement Reaction Plan
Number Product Process Size Freq. Control Method Responsibility
For Mfg. No Specification/ Technique

1 Material Grade SPH 270C-OD Supplier Test Certificate Feedback to supplier

Inward
Raw material Receipt 100% Every lot Raw Material PC through
10 2 Weight as per Invioce Weighing machine Registor/GRN

1 Material Grade SPH 270C-OD Supplier Test Certificate

2 Thickness 2.3±0.1mm Micrometer HBM-001 L.C 0.01

Feedback to supplier
through Quality
Incoming /Receiving Inspection Inspection 3 Strip Width 212+0/-0.5 DVC HB-D-001-LC-0.01 Problem Report
20 Receiving QC Inspector
(RAW MATERIAL) Table 4 Strip Length 590±0.5 Measuring Tape L.C 1.0 5 nos Every lot inspection Report
(F-Q027) (If it is not
as per standard)
No scratch, Burr, dent, crack,
5 Appearance - rust, damage, bend / Visual
waviness...etc.

Store the raw material

Stored in a neat area with
30 Storage Storage Rack 1 specification wise / customer Storage
Proper identification
Visual 100% Every Lot Receiving register Raw Material PC
wise in separate Rack

250 Ton, 1 Shut height 350 ± 0.5 mm Visual

Every Set - Press Part Quality Tool setter Stop the Production
D Class Every Lot
Up Check Sheet &Operator and reset the process.
machine 2 Press parameters As per Die change Data Sheet Visual

3 Thickness 2.3±0.1mm Micrometer HBM-001 L.C 0.01

Blanking and Piercing
40
(Progressive Tool) 4 Miss Blank Not Allowed Visual Stop the Production
Inspection
Quality Check and Inform to TL &
Table and 3 Nos Every Lot QC Inspector
5 Burr Not Allowed Visual Sheet Take Immediate
Micrometer
Action
No scratch, Burr, dent, crack,
6 Appearance - rust, damage, bend / Visual
waviness...etc.

250 Ton, 1 Shut height 350 ± 0.5 mm Visual

Every Set - Press Part Quality Tool setter Stop the Production
D Class Every Lot
Up Check Sheet &Operator and reset the process.
machine 2 Press parameters As per Die change Data Sheet Visual

50 1st Flanging
3 Flange Variation Not Allowed Visual Stop the Production
Inspection Quality Check and Inform to TL &
3 Nos Every Lot QC Inspector
Table No scratch, Burr, dent, crack, Sheet Take Immediate
4 Appearance - rust, damage, bend / Visual Action
waviness...etc.

250 Ton, 1 Shut height 350 ± 0.5 mm Visual

Every Set - Press Part Quality Tool setter Stop the Production
D Class Every Lot
Up Check Sheet &Operator and reset the process.
machine 2 Press parameters As per Die change Data Sheet Visual

3 Flange Variation Not Allowed Visual

60 2nd Flanging
Stop the Production
Inspection 4 Crack Not Allowed Visual Quality Check and Inform to TL &
3 Nos Every Lot QC Inspector
Table Sheet Take Immediate
No scratch, Burr, dent, crack, Action
5 Appearance - rust, damage, bend / Visual
waviness...etc.

250 Ton, 1 Shut height 350 ± 0.5 mm Visual

Every Set - Press Part Quality Tool setter Stop the Production
D Class Every Lot
Up Check Sheet &Operator and reset the process.
machine 2 Press parameters As per Die change Data Sheet Visual

3 Flange Variation Not Allowed Visual

70 1st Cam Restrike
Stop the Production
Inspection 4 Crack Not Allowed Visual Quality Check and Inform to TL &
3 Nos Every Lot QC Inspector
Table Sheet Take Immediate
No scratch, Burr, dent, crack, Action
5 Appearance - rust, damage, bend / Visual
waviness...etc.
 CONTROL PLAN
Prototype Prelaunch Production Key Contact / Phone : Date (Orig.) Date (rev)

Control Plan Number: SEPL/CP/B-029 Rev: 001 Mr.Lokesh.V 91-8861002709 29.03.2016 11.01.2018 (00)
Part Number /Rev No : Core Team : Mr.Ashwath, Mr.Lokesh, Mr.Abhay, Mr.Partha, Mr.K.B. Nagaraj, Mr.Sumeshlal, Customer Engineering Approval / Date (if Req'd.)
X0614A18 Mr.Shankar, Mr.Naveen ----
Part Name / Description & Model Prepared By : Customer Quality Approval / Date (if Req'd.)
KNUCKLE BRACKET Sowmya shree.N
Customer 's name Supplier Code Other Approval / Date (if Req'd.) Other Approval / Date (if Req'd.)
TTIA ---- ----
Material Specification / Norms : ---
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Characteristics Methods Sample

Machine, Sl
Part / Process Name /Operation Device, Jig, Sp.
No /
Process
Description Tools, Drg Char. Product / Process Evaluation /Measurement Reaction Plan
Number Product Process Size Freq. Control Method Responsibility
For Mfg. No Specification/ Technique

250 Ton, 1 Shut height 350 ± 0.5 mm Visual Every Lot

Press Part Quality Tool setter Stop the Production
D Class
Use ofLumina Coated As per Die design & Die Coating Every 50000 Check Sheet &Operator and reset the process.
machine 2 Visual
Forming Die change Data Sheet Verfication Strokes

80 2nd Cam Restrike 3 Flange Variation Not Allowed Visual

Stop the Production
Inspection Quality Check and Inform to TL &
4 Crack Not Allowed Visual 3 Nos Every Lot QC Inspector
Table Sheet Take Immediate
No scratch, Burr, dent, crack, Action
5 Appearance - rust, damage, bend / Visual
waviness...etc.
 CONTROL PLAN
Prototype Prelaunch Production Key Contact / Phone : Date (Orig.) Date (rev)

Control Plan Number: SEPL/CP/B-029 Rev: 001 Mr.Lokesh.V 91-8861002709 29.03.2016 11.01.2018 (00)
Part Number /Rev No : Core Team : Mr.Ashwath, Mr.Lokesh, Mr.Abhay, Mr.Partha, Mr.K.B. Nagaraj, Mr.Sumeshlal, Customer Engineering Approval / Date (if Req'd.)
X0614A18 Mr.Shankar, Mr.Naveen ----
Part Name / Description & Model Prepared By : Customer Quality Approval / Date (if Req'd.)
KNUCKLE BRACKET Sowmya shree.N
Customer 's name Supplier Code Other Approval / Date (if Req'd.) Other Approval / Date (if Req'd.)
TTIA ---- ----
Material Specification / Norms : ---
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Characteristics Methods Sample

Machine, Sl
Part / Process Name /Operation Device, Jig, Sp.
No /
Process
Description Tools, Drg Char. Product / Process Evaluation /Measurement Reaction Plan
Number Product Process Size Freq. Control Method Responsibility
For Mfg. No Specification/ Technique

250 Ton, 1 Shut height 350 ± 0.5 mm Visual

Every Set - Press Part Quality Tool setter Stop the Production
D Class Every Lot
Up Check Sheet &Operator and reset the process.
machine 2 Press parameters As per Die change Data Sheet Visual

3 Wall Thickness NG Not Allowed Visual

4 Hole Shift Not Allowed Visual

90 Cam Piercing
Stop the Production
Inspection 5 Hole Burr Not Allowed Visual Quality Check and Inform to TL &
3 Nos Every Lot QC Inspector
Table Sheet Take Immediate
6 Hole Miss Not Allowed Visual Action

No scratch, Burr, dent, crack,

7 Appearance - rust, damage, bend / Visual
waviness...etc.
 CONTROL PLAN
Prototype Prelaunch Production Key Contact / Phone : Date (Orig.) Date (rev)

Control Plan Number: SEPL/CP/B-029 Rev: 001 Mr.Lokesh.V 91-8861002709 29.03.2016 11.01.2018 (00)
Part Number /Rev No : Core Team : Mr.Ashwath, Mr.Lokesh, Mr.Abhay, Mr.Partha, Mr.K.B. Nagaraj, Mr.Sumeshlal, Customer Engineering Approval / Date (if Req'd.)
X0614A18 Mr.Shankar, Mr.Naveen ----
Part Name / Description & Model Prepared By : Customer Quality Approval / Date (if Req'd.)
KNUCKLE BRACKET Sowmya shree.N
Customer 's name Supplier Code Other Approval / Date (if Req'd.) Other Approval / Date (if Req'd.)
TTIA ---- ----
Material Specification / Norms : ---
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Characteristics Methods Sample

Machine, Sl
Part / Process Name /Operation Device, Jig, Sp.
No /
Process
Description Tools, Drg Char. Product / Process Evaluation /Measurement Reaction Plan
Number Product Process Size Freq. Control Method Responsibility
For Mfg. No Specification/ Technique

1 Shut height 350 ± 0.5 mm Visual Stop the production

250 Ton,
and Inform to TL &
D Class 3 Nos NA NA QC Inspector
As per Die change Data Sheet Take Immediate
machine 2 Press parameters Visual
(Q3- PDPO71) Action

3 OUTER BKT SURFACE ZERO SET DVC HB-D-001-LC-0.01

4 DEVIATION 0.3Max Checking fixture S -TT-014

5 HOLE LOCATION OFF CENTER PIN SET DVC HB-D-001-LC-0.01

6 HOLE DIAMETER 7X12±0.2 Checking fixture S -TT-014

7 HOLE DIAMETER 7X12±0.2 Checking fixture S -TT-014

8 HOLE OFFSET 0.5MAx Checking fixture S -TT-014

9 OUTLINE (4Places) 3+1.5/-0 Checking fixture S -TT-014

10 HOLE DIAMETER :Ø9±0.2 Checking fixture S -TT-014

11 INNER WIDTH (2 Places) 33.6±0.4 Checking fixture S -TT-014

Inspection
100 Line Inspection/Quality Table and 12 DEVIATION 0.5MAX Checking fixture S -TT-014 First part record
Conformation DVC & Stop the production
should be
Checking INNER DIAMETER FML(First,Middle, and Inform to TL &
13 Ø44.6 -45.1 PLUG GAUGE -HB-P-001 3 Nos maintained in QC Inspector
Fixture (2 Places) Last) Take Immediate
Sample Data Sheet
Taper scale Action
(F-Q051)
PLUG WALL THICKNESS -OPEN
14 22.0+0.9/-0 Checking fixture S -TT-014
GAUGE SIDE
WALL THICKNESS -
15 22.0+0.9/-0 Checking fixture S -TT-014
CLOSED SIDE

16 FLANGE (4 Places) 7.5+1.5/-0 DVC HB-D-001-LC-0.01

17 NOTCH WIDTH 55.3 +/-0.4 Checking fixture S -TT-014

FLATNESS -NUT WELD

18 0.3Max DVC HB-D-001-LC-0.01
SURFACE
FLATNESS -SPOT WELD
19 0.5MAx Checking fixture S -TT-014
SURFACE

20 Thickness 2.3 ± 0.17mm Micrometer HB -M-001

Burr, Scrach, Rust,

21 Not Allowed Visual
Deformation, Fractue.

Inspection Check as per Visual Work Stop the Despatch

110 Visual Inspection Table
1 Appearance
Instruction
Visual 100% Every lot NA QC
and Inform to TL

Stop packing & storing

Correct bin qty with Correct Bin qty with , inform to supervisor
120 Storage Storage Rack 1
identification, No part mix-up identification
Visual 100% Every lot NA PC
& take necessary
action
 CONTROL PLAN
Prototype Prelaunch Production Key Contact / Phone : Date (Orig.) Date (rev)

Control Plan Number: SEPL/CP/B-029 Rev: 001 Mr.Lokesh.V 91-8861002709 29.03.2016 11.01.2018 (00)
Part Number /Rev No : Core Team : Mr.Ashwath, Mr.Lokesh, Mr.Abhay, Mr.Partha, Mr.K.B. Nagaraj, Mr.Sumeshlal, Customer Engineering Approval / Date (if Req'd.)
X0614A18 Mr.Shankar, Mr.Naveen ----
Part Name / Description & Model Prepared By : Customer Quality Approval / Date (if Req'd.)
KNUCKLE BRACKET Sowmya shree.N
Customer 's name Supplier Code Other Approval / Date (if Req'd.) Other Approval / Date (if Req'd.)
TTIA ---- ----
Material Specification / Norms : ---
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Characteristics Methods Sample

Machine, Sl
Part / Process Name /Operation Device, Jig, Sp.
No /
Process
Description Tools, Drg Char. Product / Process Evaluation /Measurement Reaction Plan
Number Product Process Size Freq. Control Method Responsibility
For Mfg. No Specification/ Technique

3 OUTER BKT SURFACE ZERO SET Checking fixture S -TT-014

4 DEVIATION 0.3Max Checking fixture S -TT-014

5 HOLE LOCATION OFF CENTER PIN SET Checking fixture S -TT-014

6 HOLE DIAMETER 7X12±0.2 DVC HB-D-001-LC-0.01

7 HOLE DIAMETER 7X12±0.2 DVC HB-D-001-LC-0.01

5
8 HOLE OFFSET 0.5MAx Checking fixture S -TT-014 nos
9 OUTLINE (4Places) 3+1.5/-0 Checking fixture S -TT-014

10 HOLE DIAMETER :Ø9±0.2 DVC HB-D-001-LC-0.01

Inspection 11 INNER WIDTH (2 Places) 33.6±0.4 DVC HB-D-001-LC-0.01

Table and
DVC & 12 DEVIATION 0.5MAX DVC HB-D-001-LC-0.01 Stop the Despatch
Checking and Inform to TL &
130 Final Inspection Fixture 13
INNER DIAMETER
Ø44.6 -45.1 PLUG GAUGE 100% Every Dispatch Sample Data Sheet
QC Inspector
Take Immediate
(2 Places)
Taper scale Action
PLUG WALL THICKNESS -OPEN
14 22.0+0.9/-0 DVC HB-D-001-LC-0.01
GAUGE SIDE
WALL THICKNESS -
15 22.0+0.9/-0 DVC HB-D-001-LC-0.01
CLOSED SIDE
16 FLANGE (4 Places) 7.5+1.5/-0 DVC HB-D-001-LC-0.01
5
17 NOTCH WIDTH 55.3 +/-0.4 DVC HB-D-001-LC-0.01 nos
FLATNESS -NUT WELD
18 0.3Max DVC HB-D-001-LC-0.01
SURFACE
FLATNESS -SPOT WELD
19 0.5MAx DHG H-H-001L.C 0.01
SURFACE
20 Thickness 2.3 ± 0.17mm Micrometer HB -M-001

Burr, Scrach, Rust,

21 Not Allowed Visual 100%
Deformation, Fractue.

Check Customer kanban mis Stop despatch & take

Not Allowed Visual 100% Each lot NA
match immidiate action

140 Packing & Dispatch Correct qty as per the PC

Fork lift,
invoice, part mix-up, Correct qty,No part mix-up and Stop Despatch and
Transport 1 Visual 100% Each lot Invoice
Transportation No Transportation damage. inform to Superiors
Vehicle.
damage.

Note :
1) Die Allignment Monitoring System.
2) Blank Stopper Wearout Conformation.
3) Punch Maintaince & Offal removal Provision. These points Will be Monitored in Die
Preventive Maintaince Check sheet

REVISION RECORD
SL.NO Rev Date Rev Details REV NO
1 29.03.2016 INITIAL RELEASE 00

2 1/4/2018 Dia 44.60/45.10 Plug gauge added 1

and 100% inspection added

Prepared By: Sowmya shree.N 3 1/4/2018 Forming Die with Coating added Approved By: Lokesh.V