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APQP DOCUMENTATION INDEX SHEETP
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SE
SDesign goals ( Team and Program need dates ) Design goals ( Timing chart )Product related requirements ( Product Information Data )Team Feasibility Commitment Manufacturing feasibility ( Capacity Planning )Risk assessment sheetCustomer Specific RequirementsSpecial charecteristicsRaw Material requirements
Design FMEAReliability resultsDesign Review(s)Diagnostic guidelinesDesign for Manufacturing and AssemblyDesign Verification Subcontractor APQP StatusEngineering Drawings and SpecificationsProduct error proofing, as appropriateMaterial specification Drawing and Specification changes
Drawings with numbered parametersProcess Flow DiagramProcess F.M.E.AMeasurement Systems AnalysisPre-Lauch Control PlanProduct Tracebility.Work InstructionsPacking SpecificationsProduction Control Plan ( Charecteristic matrix )
Production Trial RunProduction Validation TestingProduction Part Approval ( PPAP with PSW )Preliminary Process Capability StudyDesign verification planProgram need datesProduct quality planning summary and sign offRisk assessment sheet
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Data for Quality,reliability,maintainability and measurability, results of error proofing,methods of rapid detection and feedback of product /process nonconformance
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Data for Quality,reliability,maintainability and measurability, results of error proofing,methods of rapid detection and feedback of product /process nonconformance
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BNR Exports,Bangalore APQP TEAM PLAN
Part description : DRIVE SHAFT Original date : 02.05.09Drawing no : C0713250 Rev no / Date : NILRev no / date :ISSUE -10 / 24-10 - 2008 Page no : 1 of 1Customer : MONOPUMPS Application : PUMP
CROSS FUNCTIONAL / MULTI DISCIPLINARY TEAM
Sl no CFT / MDT MEMBERS DESIGNATION DEPARTMENT CONTACT DETAILS
1 Mr. Rajesh C.E.O [email protected]
Phone no
2 Mr. Ambi Daniel G.M [email protected]
Phone no
3 Mr. Lekshman Divisional Manager [email protected]
Phone no
4 Mr. Neelakantan Consultant [email protected]
Phone no
5 Mr.Shunmuganandam Engineer Design & [email protected]
Phone no
6 Mr.Dinesh Manager [email protected]
Phone no
7 Mr.Lokesh Assistant Manager [email protected]
Phone no
8 Mr.Raghaventhiran Manager [email protected]
Phone no
9 Mr.Prakash Engineer [email protected]
Phone no
10 Mr.Muruganandam Engineer [email protected]
Phone no
11 Ms.Usha Excecutive Trainee [email protected]
Phone no
12 Mr.Muthukumaran Senior Engineer [email protected]
Phone no
13 Mr.Joel Inspector [email protected]
Phone no
14 Mr.Nataraj Foreman Tool [email protected]
Phone no
15 Mr.Prasanna Supervisor [email protected]
Phone no
16 Subramanya Manager [email protected]
Phone noWeekly Conference Call Time
International Day
Participant Code Date
Page 6 of 54
BNR Exports,BangaloreAPQP - TIMING PLAN
25.06.09 Rev. No.: 00
Updated on :
S.No ACTIVITY G/Y/R STATUSPLAN ACTUAL
REMARKSSTART COMPLETE START COMPLETE
Drive Shaft C0713250
STAGE:1 PLAN AND DEFINE PROGRAM
1.1 Customer inputs
1.1.1 Component Drawing G Ambi Daniel 4.05.09 4.05.09 4.05.09 4.05.09
1.2 APQP Team formation G Ambi Daniel 4.05.09 4.05.09 4.05.09 4.05.09
1.3 G 5.05.09 5.05.09 5.05.09 5.05.09
1.4 Team Feasibility Commitment G Rajesh 5.05.09 5.05.09 5.05.09 5.05.09
1.5 Risk analysis G Rajesh 6.05.09 08.05.09 6.05.09 8.05.09
1.6 G Lekshman 8.05.09 8.05.09 8.05.09 8.05.09
1.7 G Ambi Daniel 11.05.09 11.05.09 11.05.09 11.05.09
1.8 G Lokesh / Dinesh 11.05.09 11.05.09 11.05.09 11.05.09
1.9 Design Inputs
1.9.1 Design concept approval G
NOT APPLICABLE1.9.2 G
1.9.3 Drawing release G
STAGE: 2 PROCESS DESIGN AND DEVELOPMENT
2.1 Process Flow Diagram G Dinesh / Lokesh 11.05.09 11.05.09 11.05.09 11.05.09
2.2 Charactertics Matrix G Muthukumar 11.05.09 11.05.09 11.05.09 11.05.09
2.3 Process FMEA G Dinesh / Lokesh 11.05.09 12.05.09 11.05.09 12.05.09
2.4 G Ambi Daniel 11.05.09 11.05.09 11.05.09 11.05.09
2.5
2.5.1 G 11.05.09 11.05.09 11.05.09 11.05.09
2.5.2 Sending enquiry to suppliers G 11.05.09 11.05.09 11.05.09 11.05.09
2.5.3 Supplier Finalisation G 11.05.09 11.05.09 11.05.09 11.05.09
2.5.4 G 11.05.09 11.05.09 11.05.09 11.05.09
2.6 NOT APPLICABLE
2.7 Mistake Proofing R Lokesh / Prakash 11.05.09 11.05.09 11.05.09 11.05.09
2.8 G Lokesh / Prakash 25.06.09 30.08.09 25.06.09 17.08.09
2.90 G 25.06.09 30.08.09 25.06.09 17.08.09
2.10 Pre-launch control Plan G Muthukumaran 13.05.09 13.05.09 13.05.09 13.05.09
2.11 Work Instructions
RESPONS -IBILITY
Prepare Product Information Data
Lekshman/ Shivakumar/ Neelakantan
Customer Specific RequirementsIdentification of Special CharacteristicsIdentification of Gauge and Testing Equipment
3D Modelling & 2D Drawings Preparation
Finalisation of Special characteristicsGage design and developmentFinalisation of Gauge and testing equipment.
Ambi Daniel / Dinesh
Lekshman / SubramanyaLekshman / Subramanya
Procurement of gauge and testing equipment
Dinesh / Muthukumaran
Development of subcontractor Process
Manufacturing process design and development verification
Traceability for product / manufacturing process non conformities
Prasanna / Muthukumaran
Page 7 of 54
BNR Exports,BangaloreAPQP - TIMING PLAN
25.06.09 Rev. No.: 00
Updated on :
S.No ACTIVITY G/Y/R STATUSPLAN ACTUAL
REMARKSSTART COMPLETE START COMPLETE
Drive Shaft C0713250
RESPONS -IBILITY
2.11.1 Work instruction for cutting G Neelakantan 13.05.09 13.05.09 13.05.09 13.05.09
2.11.2 G Neelakantan 13.05.09 13.05.09 13.05.09 13.05.09
2.11.3 G Neelakantan 13.05.09 13.05.09 13.05.09 13.05.09
2.11.4 G Neelakantan 13.05.09 13.05.09 13.05.09 13.05.09
2.11.5 Work Instructions for Packing G Neelakantan 13.05.09 13.05.09 13.05.09 13.05.09
2.12 Packing Specification
2.12.1 G Lekshman 01.08.09 01.08.09 01.08.09 01.08.09
2.12.2 Packaging sign off approval G Lekshman 17.08.09 17.08.09 17.08.09 17.08.09
2.13
2.13.1 Raw material G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
2.13.2 Premachining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
2.13.3 Heat treatment G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
2.13.4 Final machining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
2.13.5 Assembly and Try out G 11.05.09 11.05.09 11.05.09 11.05.09
2.13.6 Inspection and ready for trial G 11.05.09 11.05.09 11.05.09 11.05.09
2.14
2.14.1 Raw material G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
2.14.2 Premachining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
2.14.3 Heat treatment G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
2.14.4 Final machining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
2.14.5 Assembly and Try out G 11.05.09 11.05.09 11.05.09 11.05.09
2.14.6 Inspection and ready for trial G 11.05.09 11.05.09 11.05.09 11.05.09
2.15
2.15.1 Raw material G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
2.15.2 Premachining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
2.15.3 Heat treatment G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
2.15.4 Final machining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
2.15.5 Assembly and Try out G 11.05.09 11.05.09 11.05.09 11.05.09
2.15.6 Inspection and ready for trial G 11.05.09 11.05.09 11.05.09 11.05.09
STAGE : 3 MANUFACTURING PROCESS VALIDATION
3.1 Trial I
3.1.1 Cutting G Prasanna 25.06.09 25.06.09 25.06.09 25.06.09
3.1.2 Premachining G Nataraj 25.06.09 25.06.09 26.06.09 26.06.09
3.1.3 CNC Turning 1st Operation G 11.07.09 11.07.09 11.07.09 11.07.09
3.1.4 CNC Turning 2nd Operation G 16.07.09 16.07.09 16.07.09 16.07.09
3.1.5 CNC Turning 3rd Operation G 21.07.09 21.07.09 21.07.09 21.07.09
3.1.6 CNC Turning 4 th operation 23.07.09 23.07.09 23.07.09 23.07.09
Work instruction for CNC Turning
Work instruction for CNC Milling
Work Instructions for Conventional
Packing Specification preparation
Tool Mfg - Holding fixture CNC turning
Nataraj / Prakash
Prakash / Muthukumar
Tool Manufacturing - Drill jig - 1
Nataraj / Prakash
Prakash / Muthukumar
Tool Manufacturing - Drill jig - 2
Nataraj / Prakash
Prakash / Muthukumar
C.Prakash/ Muruganantham
C.Prakash/ Muruganantham
C.Prakash/ Muruganantham
C.Prakash/ Muruganantham
Page 8 of 54
BNR Exports,BangaloreAPQP - TIMING PLAN
25.06.09 Rev. No.: 00
Updated on :
S.No ACTIVITY G/Y/R STATUSPLAN ACTUAL
REMARKSSTART COMPLETE START COMPLETE
Drive Shaft C0713250
RESPONS -IBILITY
3.1.7 CNC Turning 5 th operation 28.07.09 28.07.09 28.07.09 28.07.09
3.1.6 Cross hole drill and Reaming G Jaganath 28.07.09 28.07.09 28.07.09 28.07.09
3.1.7 CNC Turning 6 th Operation G 29.07.09 29.07.09 29.07.09 29.07.09
3.1.8 Rethreading G Lokesh/Nataraj 30.07.09 30.07.09 30.07.09 30.07.09
3.1.9 Deburring G Lokesh/Nataraj 30.07.09 30.07.09 30.07.09 30.07.09
3.2.0 Final inspection G Muthukumar 31.07.09 31.07.09 31.07.09 31.07.09
3.2.1 Assembly G Lokesh/Nataraj 17.08.09 17.08.09 17.08.09 17.08.09
3.2.2 Cleaning and Packing G Lokesh/Nataraj 17.08.09 17.08.09 17.08.09 17.08.09
3.2.3 Despatch G 19.08.09 19.08.09 19.08.09 19.08.09
STAGE: 4 PPAP DOCUMENTATION
4.2 MSA Study G Muthukumar 13.07.09 13.07.09 2.07.09 02.07.09
4.3 Ppk Study G Muthukumar 17.07.09 22.07.09 17.07.09 22.07.09
4.4 Final inspection G joel karkada 31.07.09 31.07.09 31.07.09 31.07.09
4.5 PPAP Document Preparation G Muthukumar 31.07.09 31.07.09 31.07.09 31.07.09
STAGE : 5 FEEDBACK ASSESMENT AND CORRECTIVE ACTION
5.1 Customer approval of PPAP
5.2 Commence Bulk Production
5.3
5.4 Managemenet Review
LEGEND
S.NO STATUS DESCRIPTION Colour Revision Details: DESCRIPTION
1 G- GREEN - COMPLETED 1 Rev 1 : APQP Timing plan is updated to the Micro Level
2 Y - YELLOW - INPROGRESS 2 Rev 2 : Trial date is revised
3 R - RED - DELAY 3 Rev 3 : Trial date is revised
Team Members Signature
C.Prakash/ Muruganantham
C.Prakash/ Muruganantham
Lekshman and Raghaventhiran
Resolution of quaility, Delivery Issue
BNR Exports,BangaloreTEAM FEASIBILITY COMMITMENT
CUSTOMER MONOPUMPS
DATE 2/5/2009
PART NAME DRIVE SHAFT REV DATE
PART NO C 07 13250 ISSUE 10 DATE 24-10-2008
SL NO CONSIDERATIONS BASIS FOR REVIEW Y / N REMARKS
1
Is product adequately defined
Y
2
Can Engineering Performance Specifications be met as written?
Y
3 Y
4 Y
5
Is there adequate capacity to produce product? Capacity Matrix
Y
6 Y
7 Y
8
Is raw material requirements feasible
Y
9 Y
10
Is there any requirement of special skills Skill Matrix
N
11
Is delivery Requirements Feasible Capacity Matrix
Y
Shiva kumar.B Neelakantan Ambi Daniel
PREPARED BY CHECKED BY APPROVED BY
Our product quality planning team has considered the following questions, not intended to be all-inclusive in performing a feasibility evaluation. The drawings and/or specifications provided have been used as a basis for analyzing the ability to meet all specified requirements. All “NO” answers are supported with attached comments identifying our concerns and/or proposed changes to enable us to meet the specified requirements
Product Drawing, Customer Specific Requirements if any, Contract Review check list
Product Drawing, Customer Specific Requirements if any,Contract Review check list
Can the Product be manufactured with Cpk’s that meet requirements
Customer DrawingSpecial Characteristics ListContract Review Check ListSPC Study Reports
Is SPC used on similar products and when SPC used are the processes in control and Stable ( Cpk’s greater than 1.33)
Customer DrawingSpecial Characteristics ListContract Review Check ListSPC Study Reports
Can the product be manufactured without incurring unusual cost for capital equipment / tooling alternative manufacturing methods
Customer DrawingCustomer Specific requirements if anyContract review check listCapacity MatrixTool and Equipment ListIs Gauges / test equipment are compatible to meet the product
requirementsExisting Control Plan,Gauges and Test Equipment List, MSA Study reports
Approved Supplier ListRaw Material SpecificationsIncoming Inspection Control Plan
Is Equipment, Tooling and Facility requirements compatible to meet the Product Requirements
Existing Control Plan,Process Flow ChartEquipment and Tooling ListCapacity Matrix
BNR Exports
CAPACITY PLANNING
PART NAME DRIVE SHAFT
CUSTOMER MONOPUMPS REV DATE : 24-10-2008
S.NO PROCESS NAME MACHINE NAME
TOTAL CAPACITY FREE CAPACITY REQUIRED CAPACITY
UOM HOURS / MONTH UOM HOURS / MONTH UOM HOURS / MONTH
1 CUTTING 3 machines 1131 Hours 452 AVAILABLE
2 PRE MACHINING 3 lathes 1131 Hours 452 AVAILABLE
3 CNC TURNING 18 Machines 6660 3555 AVAILABLE
4 5 machines 1885 754 AVAILABLE
5 MANUAL ASSEMBLY 2 Work stations 754 301 AVAILABLE
6 CLEANING PACKING 1 Work stations 377 150 AVAILABLE
Note:
Shiva kumar.B Neelakantan Ambi Daniel
PART NO: C 0713250
REV NO : ISSUE 10
CONVENTIONAL DRILLING & REAMING
DATE: 03/05/09
REV DATE : 24-10-2008
REMARKS
Ambi Daniel
Page 12 of 54
Date : 04 / 05 / 09
RISK ASSESSMENT CHECK LIST
BNR Exports Bangalore
CUSTOMER : M/S MONOPUMPS
PRODUCT : DRIVE SHAFT / C 0713250
APPLICATION : PUMP
MEMBERS PRESENT : Rajesh, Daniel, Neelakantan, Lokesh, Dinesh, Raghaventhiran, Prakash, Lekshman, Subramanya and Muruganandam.
DESCRIPTION High High
1 QUALITY HISTORY :-
1.1
1.2 Are there frequent quality rejects at the receiving plant for similar products?
1.3 Was there a recall action due to a similar component or system?
2 SUPPLIER PROFILE :-
2.1 Does it require new material and supply source?
2.2
2.3 How is the supplier’s earlier performance is satisfied in the similar materials?
3 ENGINEERING PROFILE :-
3.1 Is it a new design?
3.2 Are the manufacturing techniques new to us?
3.3
STEP NO.
Does the products application have a high warranty or things gone Wrong on current model or similar models?
Is the product or manufacturing technology new to the supplier and his manufacturing location?
Are similar products subjects to numerous design changes that threaten program timing?
Page 13 of 54
Date : 04 / 05 / 09
RISK ASSESSMENT CHECK LIST
BNR Exports Bangalore
3.4 Is there high product or process complexity?
3.5
4 POTENTIAL – PROFILE :-
4.1
4.2 Volume regularity assurable? Long term contracts possible?
4.3 Can competition follow this easily?
4.4Technological obsolescence possibility is there?
Is the product strategically important due to high visibility or functional performance?
Does it require higher investments for development and regular production? Justifiable?
Page 14 of 54
Date : 04 / 05 / 09
RISK ASSESSMENT CHECK LIST
BNR Exports Bangalore
5 PRODUCT PERFORMANCE VERSUS TARGETS :-
5.1
5.2
5.3 Is the program timing compressed?
5.4 Are the cost targets aggressive?
5.5
NATURE in No.s
HIGH RISK : 0
MEDI RISK : 13
LOW RISK: 7
20
Will the design goals (functional performance) and reliability goals be difficult to achieve?
Will the quality goals (warranty, scrap rates, rework PPM etc.) be difficult to achieve?
Manufacturing productivity targets justifiable and achievable in-line with volume requirements?
CONCLUSION BY C F T : Moderate risk item if not handled carefully during the process might get converted to high risk item.
ACTION PLANNED :- ( BASED ON HIGH RISK ELEMENTS ) :
Page 15 of 54
Date : 04 / 05 / 09
RISK ASSESSMENT CHECK LIST
CUSTOMER : M/S MONOPUMPS
PRODUCT : DRIVE SHAFT / C 0713250
APPLICATION : PUMP
MEMBERS PRESENT : Rajesh, Daniel, Neelakantan, Lokesh, Dinesh, Raghaventhiran, Prakash, Lekshman, Subramanya and Muruganandam.
Medium Low
√
√
√
√
√
√
√
√
√
Page 16 of 54
Date : 04 / 05 / 09
RISK ASSESSMENT CHECK LIST
√
√
√
√
√
√
Page 17 of 54
Date : 04 / 05 / 09
RISK ASSESSMENT CHECK LIST
√
√
√
√
√
in No.s in %
0 0
13 65
7 35
100
Moderate risk item if not handled carefully during the process might get converted to high risk item.
BNR Exports CUSTOMER SPECIFIC REQUIREMENT SHEETCustomer: Mono Pumps Ltd., UKDate: 22.09.2008
Requirements Originator
1 Allen Bolts assembled in Drive Shafts must be applied with ProductionLocktite on top 50% of the threaded portion and back faceof the bolt head.
1 Nil
1 Part numbers on all Muncher Half Couplings must beengraved on each part. Production
1 All the parts other than Muncher Half Couplings must have the label with Part number pasted on the packed product Logistics
2 Universal Joint assemblies threads must be protected withPlastic caps Logistics
1 Goods are sent by sea freight unless specified in PO or Logisticsa separate communication by customer
2 Wood packaging material must be fumigated before despatchby Freight forwarder Customer
3 Due date in PO is at UK, deduct 6 weeks for shipping Logistics4 Each case must be pasted with a label consisting PO Number Logistics5 Delivery Terms: Incoterms 2000: Ex Works Logistics6 Destination Airport: Manchester, UK
Destination Seaport: Felexstowe, UK Logistics7 Nominated Freight Forwarder: DSV Sea & Air Logistics Logistics
1 Submit GSP certificates for each consignment Logistics
Special Manufacturing /Technical Requirements:
Special Handling Requirements:
Special Marking Requirements:
Special Packaging and Preservation:
Special Delivery Requirements:
Special Documentation Requirements:
Prepared by Reviewed by: Approved by
BNR Exports - Bangalore
SPECIAL CHARACTERISTICS
PART NAME : DRIVE SHAFT PART NO.: C 0713250 Rev / Issue : 10
CUSTOMER M/S MONOPUMPS Family / Group Pump REV DATE: 24.10.2008
S.NO DESCRIPTION SPECIFICATION INSTRUMENT REMARKS
1 1 Outside Diameter 65.00 / 64.98 Micrometer
2 4 Bore Diameter 40.05 / 40.03 Bore gauge / Plug gauge
3 5 Concentricity 0.03 w.r.t. A Dial indicator with stand
4 11 Outside Diameter 69.8 / 69.75 Micrometer
5 13 Bore Diameter 51.13 / 51.08 Bore gauge / Plug gauge
6 46 Bore Diameter 30.03 / 29.99 Bore gauge / Plug gauge
7 52 Bore Diameter 19.12 / 19.09 Bore gauge / Plug gauge
Shiva kumar.B Neelakantan Ambi Daniel
PREPARED BY CHECKED BY APPROVED BY
DRAWING
S.NO
BNR Exports
DOC NO : BNR / PFD / 01
DATE : 11.05.09
REV NO : 0
PART NAME DRIVE SHAFT
CUSTOMER MONOPUMPS
PART NO C 0713250 REVISION LEVEL / DATE - : ISSUE -10 / 24-10 - 2008
PROCESS FLOW MACHINE OUTCOME
--- - - -
- -
Dimensional / Visual deviations CUTTING MANUAL Accepted cut pieces
Dimensional / Visual deviations PRE-MACHINING Conventional lathe BINS
Dimensional / Visual deviations CNC First Operation 108 / 03 BINS
Dimensional / Visual deviations 108 / 04 BINS
Dimensional / Visual deviations PUMA -01 BINS
108 / 01 BINS
108 / 01 BINS
Conventional BINS
Dimensional / Visual deviations PUMA -01 BINS
Rethreading Manual BINS
Visual Defects / Inclusions Deburring Manual BINS
Dimensional / Visual deviations Final inspection BINS
Assembly Manual BINS
Improper Cleaning & Packing Manual BINS and Crates
DESPATCH Manual Wooden Crates
LEGEND
OPERATION INPUT OPERATION CUM INSPECTION
PROCESS FLOW DIAGRAM
INCOMING SOURCE OF VARIATION
OPERATION DESCRIPTION
METHOD OF MOVEMENT IN
STATION
RECEIPT OF RAW MATERIAL
Visual defects Bar Diameter O/S & U/S . Qty -Weight/ Nos / Spec are not matching
RAW MATERIAL INSPECTION
Correct Raw material inward
BAND SAW CUTTING 01 / 02
Accepted premachined components
Accepted components for second operation
CNC Second Operation
Accepted components for Third operation
CNC Third Operation
Accepted components for Fourth operation
Variation in Hole sizes and Positional dimensions / Dimensional / Visual deviations.
CNC Fourth ( First Cross hole ) Operation
Accepted components for CNC Fifth operation.
Variation in Hole sizes and Positional dimensions / Dimensional / Visual deviations.
CNC Fifth ( Second Cross hole ) Operation
Accepted components for Conv drilling & Reaming operation.
Variation in Hole sizes and Positional dimensions / Dimensional / Visual deviations.
Conventional Drilling and Reaming
Accepted components for CNC sixth operation.
CNC sixth ( ID & OD finish ) operation
Accepted components for retapping operation
Gauge not answering / Damages
Accepted components for Deburring operation
Accepted components for Final inspection
Manual / Instruments / Gauges / Visual
Accepted components for Assembly
Non assembly / Mismatch / Damages
Accepted Assemblies for Cleaning ,Packing.
CLEANING & PACKING
O K packed Assemblies to Despatch
Wrong mode of despatch / Improper documentation
Acceptable Assemblies for Customer.
02
01
03
04
05
06
07
08
11
12
13
14
15
14&1516&17
18
09
10
LEGENDINSPECTION OUTPUT
SHEET 1 OF 1
Shiva kumar.B Neelakantan Ambi Daniel
PREPARED BY CHECKED BY APPROVED BY
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
(PFMEA)Part No C O713250 Process Responsibility Mr. Rajesh B.M - C.E.O
Part Name DRIVE SHAFT Key Date 12.05.09
Drg Rev No/ Date Issue 10 24 - 10 - 2008
Mr.Daniel, Neelakantan, Lokesh, Dinesh, Muthukumar, Prakash, Muruganandam and Shivakumar.
Potential failure mode Potential Effect(s) of FailurePrevention
1 & 2
8 6 Educate the suppliers
Diameter U/S Cannot be used Educate the suppliers
Visual Defects 7 4 Educate the suppliers
3 CUTTING
Cutting length O/S
8 5
Cutting length U/S Cannot be used
4.00 Pre- Machining
Dimensions O/S
8
Wrong program / setting
5
wrong tooling
Machine capability
Dimensions U/S
wrong program / setting
wrong tooling
Machine capability
Visual Defects 4
5.00
Dimensions O/S
8
Wrong program / setting
5
wrong tooling
Machine capability
Dimensions U/S
wrong program / setting
wrong tooling
Machine capability
Visual Defects 4
6.00
Dimensions O/S
8
Wrong program / setting
5
wrong tooling
Core Team Members
Process No
Process Function / Requirements
S e v
C L S
Potential Cause(s) / Mechanism of Failure
O C
R
Current Process Control
Raw Material Receiving and
Inspection
Chemical composition,Hardness, Microstructure, Decarb Level, Inclusion Rating & Grain Size-Not meeting the Specifications
Machinibility poor,Surface finish poor,Reduce functional life
Wrong shipment from supplier end
Provide training to operator
Machining difficulties and reduced tool life, Increased Process time
Wrong shipment from supplier end
Wrong shipment from supplier end
Delay in production and Machining difficulties
Wrong shipment / Improper handling from supplier end
Machining difficulties and reduced tool life, Increased Process time
Improper stopper setting / Loading
Operator training / Set up approval
Improper stopper setting / Loading
Operator training / Set up approval
Machining difficulties and reduced tool life, Increased Process time / ID oversize cannot be used.
Work Instructions / Set-Up Approval
Cannot be used / ID undersize Machining difficulties and reduced tool life, Increased Process time
Work Instructions / Set-Up Approval
Delay in production and Machining difficulties / Cannot be used.
Machining and Handling deviations
Handling instructions and visual displays
CNC FIRST OPERATION
Machining difficulties and reduced tool life, Increased Process time / ID oversize cannot be used.
Work Instructions / Set-Up Approval
Cannot be used / ID undersize Machining difficulties and reduced tool life, Increased Process time
Work Instructions / Set-Up Approval
Delay in production and Machining difficulties / Cannot be used.
Machining and Handling deviations
Handling instructions and visual displays
CNC SECOND OPERATION
Machining difficulties and reduced tool life, Increased Process time / ID oversize cannot be used.
Work Instructions / Set-Up Approval
6.00
Dimensions O/S
8Machine capability
5
Dimensions U/S
wrong program / setting
wrong tooling
Machine capability
OD - 69.80 /69.75 oversize
8
***
5
OD - 69.80 /69.75 under rsize
Bore dia - 51.08 /51.13 oversize
***Bore dia - 51.08 /51.13 undersize
Visual Defects 8 4
7.00
Dimensions O/S
8
Wrong program / setting
5
wrong tooling
Machine capability
Dimensions U/S
wrong program / setting
wrong tooling
Machine capability
Visual Defects 4
8.00
Dimensions O/S
8
Wrong program / setting
5
wrong tooling
Machine capability
Dimensions U/S
wrong program / setting
wrong tooling
Machine capability
Hole dia - 30.03 /29.99 oversize
8 *** 5
Hole dia - 30.03 /29.99 under size
Visual Defects 8 4
9.00
Dimensions O/S
8
Wrong program / setting
5
wrong tooling
Machine capability
Dimensions U/S
wrong program / setting
wrong tooling
Machine capability
Hole dia - 19.12 / 19.09 oversize
8 *** 5
Hole dia - 19.12 / 19.09 undersize
Visual Defects 8 4
10.00
Hole dia O/S
8
Wrong program / setting
5
wrong tooling
Machine capability
Hole dia U/S
wrong program / setting
wrong tooling
Machine capability
Dimensions O/S
Wrong program / setting
wrong tooling
Machine capability
Dimensions U/S
wrong program / setting
wrong tooling
Machine capability
Visual Defects 4
11.00
Dimensions O/S
8
Wrong program / setting
5
wrong tooling
Machine capability
Dimensions U/S
wrong program / setting
wrong tooling
Machine capability
CNC SECOND OPERATION
Machining difficulties and reduced tool life, Increased Process time / ID oversize cannot be used.
Work Instructions / Set-Up Approval
Cannot be used / ID undersize Machining difficulties and reduced tool life, Increased Process time
Work Instructions / Set-Up Approval
Machining difficulties and reduced tool life, Increased Process time. / Fitment problem at customer end Wrong program / setting
/ Tooling / Machine capability
Work Instructions / Set-Up Approval / PPk / CPk studiesCannot be used / Fitment problem at
customer end.
Cannot be used / Fitment problem at customer end. Wrong program / setting
/ Tooling / Machine capability
Work Instructions / Set-Up Approval / PPk / CPk studiesMachining difficulties and reduced
tool life, Increased Process time. / Fitment problem at customer end
Delay in production and Machining difficulties / Cannot be used.
Machining and Handling deviations
Handling instructions and visual displays
CNC THIRD OPERATION
Machining difficulties and reduced tool life, Increased Process time / ID / Groove width oversize cannot be used.
Work Instructions / Set-Up Approval
Cannot be used / ID / Groove width undersize Machining difficulties and reduced tool life, Increased Process time
Work Instructions / Set-Up Approval
Delay in production and Machining difficulties / Cannot be used.
Machining and Handling deviations
Handling instructions and visual displays
CNC FOURTH OPERATION
Machining difficulties and reduced tool life, Increased Process time / ID / Groove width oversize cannot be used.
Work Instructions / Set-Up Approval
Cannot be used / ID / Groove width undersize Machining difficulties and reduced tool life, Increased Process time
Work Instructions / Set-Up Approval
Cannot be used / Fitment problem at customer end. Wrong program / setting
/ Tooling / Machine capability
Work Instructions / Set-Up Approval / PPk / CPk studies
Machining difficulties and reduced tool life, Increased Process time. / Fitment problem at customer end
Delay in production and Machining difficulties / Cannot be used.
Machining and Handling deviations
Handling instructions and visual displays
CNC FIFTH OPERATION
Machining difficulties and reduced tool life, Increased Process time / ID / Groove width oversize cannot be used.
Work Instructions / Set-Up Approval
Cannot be used / ID / Groove width undersize Machining difficulties and reduced tool life, Increased Process time
Work Instructions / Set-Up Approval
Cannot be used / Fitment problem at customer end. Wrong program / setting
/ Tooling / Machine capability
Work Instructions / Set-Up Approval / PPk / CPk studies
Machining difficulties and reduced tool life, Increased Process time. / Fitment problem at customer end
Delay in production and Machining difficulties / Cannot be used.
Machining and Handling deviations
Handling instructions and visual displays
CROSS HOLE DRILLING AND
REAMING (CONV)
Cannot be used / Fitment problem at customer end
Work Instructions / Set-Up Approval
Machining difficulties and reduced tool life, Increased Process time
Work Instructions / Set-Up Approval
Cannot be used / Fitment problem at customer end
Work Instructions / Set-Up Approval
Cannot be used / Fitment problem at customer end
Work Instructions / Set-Up Approval
Delay in production and Machining difficulties / Cannot be used.
Machining and Handling deviations
Handling instructions and visual displays
CNC SIXTH OPERATION
Machining difficulties and reduced tool life, Increased Process time / ID oversize cannot be used.
Work Instructions / Set-Up Approval
Cannot be used / ID undersize Machining difficulties and reduced tool life, Increased Process time
Work Instructions / Set-Up Approval
11.00
OD - 64.98 / 65.00 oversize
8
***
5
OD - 64.98 / 65.00 under rsize
Bore dia - 40.05 / 40.03 oversize
***Bore dia - 40.05 / 40.03 undersize
***
Visual Defects 4
12.00 8
Skill / Knowledge
5
wrong tooling
wrong gauges
Skill / Knowledge
wrong tooling
wrong gauges
Visual Defects 4
13 Deburring 85
Visual Defects 4
14 Final Inspection 8 4
Visual Defects
15 ASSEBLY
Non assembly
8Improper instructions 3
Mismatch
Visual Defects 4
16 & 17
Improper cleaning
8 Improper instructions 3
Visual controls
Improper packing work instructions
Imprper handling
wrong quantity
wrong packing materials
mix up of bad parts Packing instruction
18 Despatch
wrong mode of transport
8 2wrong destination
Improper documentation
CNC SIXTH OPERATION
Machining difficulties and reduced tool life, Increased Process time. / Fitment problem at customer end Wrong program / setting
/ Tooling / Machine capability
Work Instructions / Set-Up Approval / PPk / CPk studiesCannot be used / Fitment problem at
customer end.
Cannot be used / Fitment problem at customer end. Wrong program / setting
/ Tooling / Machine capability
Work Instructions / Set-Up Approval / PPk / CPk studiesMachining difficulties and reduced
tool life, Increased Process time. / Fitment problem at customer end
Concentricity 0.03 wrt A (Reference)
Cannot be used / Fitment problem at customer end.
wrong program / setting / Tooling / Machine capability / skill level
Work Instructions / Set-Up Approval / PPk / CPk studies
Delay in production and Machining difficulties / Cannot be used.
Machining and Handling deviations
Handling instructions and visual displays
RE - THREADING OPERATION
Thread gauge not answering ie GO and NO GO both ends not entering
Machining difficulties and reduced tool life, Increased Process time./ Fitment problem at customer end.
Work Instructions / Set-Up Approval
Thread gauge both ends ie GO and NO GO are entering.
Cannot be used / Fitment problem at customer end
Work Instructions / Set-Up Approval
Delay in production and Machining difficulties / Cannot be used.
Machining and Handling deviations
Handling instructions and visual displays
Presence of unwanted burrs / Sharp Projections on Corners, Mating surfaces, Edges,
Cannot be used / Fitment problem at customer end / Delay in process time.
Unskilled labour / wrong Toolings
Training and Visual aids to educate employees
Delay in production and Machining difficulties / Cannot be used.
Machining and Handling deviations
Handling instructions and visual displays
Wrong method of inspection Cannot be used / Fitment problem
at customer end / Customer dissatisfaction.
Improper instructions / semi skilled inspectors / wrong selection / usage of instruments / Gauges
Educate the inspectors and systematic hourly inspection .
Dimensional / Visual deviations not detected / detected allowed without authorization.
Delay in production and Machining difficulties / Cannot be used.
Machining and Handling deviations
Handling instructions and visual displays
Cannot be used / Fitment problem at customer end / Customer dissatisfaction.
Educate the inspectors and systematic hourly inspection .Delay in production and Machining
difficulties / Cannot be used.Machining and Handling deviations
Handling instructions and visual displays
CLEANING and PACKING
Bad / Damaged parts Cannot be used / Fitment problem at customer end / Customer dissatisfaction / Complaint.
Customer requirement copy desplayed
Bad / Damaged parts Cannot be used / Fitment problem at customer end / Customer dissatisfaction / Complaint.
Improper work instructions
work instructions for despatch
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS BNR - FMEA - 01
(PFMEA) Prepared by Shiva kumar.B
Date (Orig.) 12.05.09
Date (Rev.) NIL
NIL
Mr.Daniel, Neelakantan, Lokesh, Dinesh, Muthukumar, Prakash, Muruganandam and Shivakumar.
Actions Results
Detection
2 96Inward Inspection
Inward Inspection
Inward Inspection 2 56
Hourly inspection
2 80
Hourly inspection
2
80
Hourly inspection 64
2 80
Self inspection report 2 64
2 80
FMEA Number
Rev No
Current Process Control D
E T
R P
N
Recom- mended Action(s)
Responsi-bility &
Target DateActions Taken
S E V
O C R
D E T
R P N
Verification of test certificate with external lab
Setup approval and hourly inspection
Setup approval and hourly inspection report
Setup approval and hourly inspection
Setup approval and hourly inspection
Setup approval and hourly inspection
2 80
2 80
Hourly inspection 2 64
2
80
Hourly inspection 64
2 80
2 80
Hourly inspection 2 64
2 80
2 80
Hourly inspection 2 64
2
80
Hourly inspection 64
2 80
Setup approval and hourly inspection
Setup approval and hourly inspection
Setup approval ,hourly inspection and Control chart.
Setup approval ,hourly inspection and Control chart.
Setup approval and hourly inspection
Setup approval and hourly inspection
Setup approval and hourly inspection
Setup approval and hourly inspection
Setup approval ,hourly inspection and Control chart.
Setup approval and hourly inspection
Setup approval and hourly inspection
Setup approval ,hourly inspection and Control chart.
Setup approval and hourly inspection
Setup approval and hourly inspection
Setup approval and hourly inspection
Setup approval and hourly inspection
Setup approval and hourly inspection
Setup approval and hourly inspection
2
80
Hourly inspection 64
280
Hourly inspection 64
Hourly inspection 280
64
Final inspection 2 64
Hourly inspection3 72
2 64
2 48
2 32
Setup approval ,hourly inspection and Control chart.
Setup approval ,hourly inspection and Control chart.
Setup approval ,hourly inspection and Control chart.
Gauge checking / Hourly inspection
Gauge checking / Hourly inspection
Check list for cleaning and packing
Check list for despatch
GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEETVARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
C071 3250 MICROMETER JOEL
Part Name Gage Number Appraiser B
DRIVE SHAFT 120302 MUTHU
Characteristic Gage Type Appraiser C
OUTER DIAMETER BALARAM
Characteristic Classification Trials Parts Appraisers Date Performed
2 10 3 02.07.09
Measurement Unit Analysis % Total Variation (TV) Repeatability - Equipment Variation (EV)
EV = Trials K1 % EV = 100 (EV/TV)
= 0.001 x 0.8862 2 0.8862 = 100(0.001/0.006)
= 0.001 3 0.5908 = 18.34
Reproducibility - Appraiser Variation (AV)
AV = % AV = 100 (AV/TV)
= {(0.002 x 0.5231)^2 - (0.001 ^2/(10 x 2))}^1/2 = 100(0.001/0.006)
= 0.001 Appraisers 2 3 = 11.46
0.7071 0.5231 n = number of parts
Repeatability & Reproducibility (R & R) r = number of trials
R & R = Parts
= {(0.001^2 + 0.001^2)}^1/2 2 0.7071 % R&R = 100 (R&R/TV)
= 0.001 3 0.5231 = 100(0.001/0.006)
Part Variation (PV) 4 0.4467 = 21.62
PV = 5 0.4030 Gage system may be acceptable
= 0.020 x 0.3146 6 0.3742
= 0.0063 7 0.3534 % PV = 100 (PV/TV)
Total Variation (TV) 8 0.3375 = 100(0.006/0.000)
TV = 9 0.3249 = 97.63
= {(0.001^2 + 0.006^2)}^1/2 10 0.3146 ndc = 1.41(PV/GRR)
= 0.0064 = 6
All calculations are based upon predicting 5.15 sigma (99.0% of the area under the normal distribution curve).
of operators (g) which is assumed to be greater than 15.AV - If a negative value is calculated under the square root sign, the appraiser variation (AV) defaults to zero (0).
R x K1
{(xDIFF x K2)2 - (EV2/nr)}1/2
K2
{(EV2 + AV2)}1/2 K3
RP x K3
{(R&R2 + PV2)}1/2
K1 is 5.15/d2, where d2 is dependent on the number of trials (m) and the number if parts times the number
K2 is 5.15/d2, where d2 is dependent on the number of operators (m) and (g) is 1, since there is only one range calculation.
K2 is 5.15/d2, where d2 is dependent on the number of parts (m) and (g) is 1, since there is only one range calculation.
d2 is obtained from Table D3, "Quality Control and Industrial Statistics", A.J. Duncan.
PART APPRAISER AVERAGE CHARTDEPT. OPERATION DATE CONTROL LIMITS CALCULATED ENGINEERING SPECIFATION PART NO.
QA OD TURNINGMACHINE NO. DATES OF STUDY CHARACTERISTIC SAMPLE SIZE FREQUENCY PART NAME
LT 25/1 02.07.09 OUTER DIAMETER 10 DRIVE SHAFTNUMBER OF APPRAISERS APPRAISER A APPRAISER B APPRAISER C
3 JOEL MUTHU BALARAM
43.3236 UCL = 109.8042 LCL = -23.1571 AVERAGES (X BAR CHART)
64.98600 UCL = 167.33895 LCL = 0.0000 RANGES (R CHART)
NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
DATE/TIME
R 1 64.980 64.990 64.990 64.980 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.980 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000
2 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.990 64.980 64.990 64.980 64.980 64.980 64.980 64.980 65.000
3 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
4
S 5
SUM 129.960 129.980 129.980 129.970 129.960 129.960 129.980 129.960 129.960 130.000 129.960 129.980 129.980 129.980 129.960 129.960 129.980 129.960 129.960 130.000 129.960 129.970 129.970 129.980 129.960 129.960 129.970 129.960 129.960 130.000
X 43.320 43.327 43.327 43.323 43.320 43.320 43.327 43.320 43.320 43.333 43.320 43.327 43.327 43.327 43.320 43.320 43.327 43.320 43.320 43.333 43.320 43.323 43.323 43.327 43.320 43.320 43.323 43.320 43.320 43.333
R 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000
** = POINT OUT OF CONTROL
x =
r =
EAD ING
SUM NUM
HIGH- LOW
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
-40.000
-20.000
0.000
20.000
40.000
60.000
80.000
100.000
120.000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
0.0000
20.0000
40.0000
60.0000
80.0000
100.0000
120.0000
140.0000
160.0000
180.0000
BNR Exports,Bangalore CONTROL PLAN
PROTOTYPE PRE-LAUNCH PRODUCTION
PART NUMBER/LATEST CHANGE LEVEL : C071 3250 / 10 ( OLD NO 12013906 )
PART NAME / DESCRIPTION : DRIVE SHAFT SUPPLIER/PLANT APPROVAL/DATE :
UNIT SUPPLIER CODE OTHER APPROVAL/ DATE (IF REQD.)
PROCESS NAME/OPERATION CHARACTERISTICS
METHODS
NO PRODUCT PROCESS
1 Receipt of raw material 1 weighment Inward Inspection * Kgs / Tons
2 Receiving Inspection 1 Visual *
2 Diameter ** 75.0 mm
3 Material ** As per order (SS316,410)
3 Cutting Bandsaw M/C 1 Length Sawing * 263+0.5
4 Pre machining Lathe M/C 1 OD Machining * 72+0.5
2 Inner Dia * 38-0.2
3 Bore depth * 99.0-0.10
4 Bore depth * 128.0 -0.10
5 Inner Dia * 24.50 +0.10
6 Inner Dia * 25.0 ± 0.10
7 Bore depth * 81.50-0.10
8 Inner dia * 50.0-0.10
9 Inner depth * 57.0-0.10
5 CNC 1st Operation CNC Turnning M/C 1 OD Machining ** 65.3+0.20
Facing,Turning, Drilling, Turning insert 2 Length ** 196.0±0.10
Boring, Chamfering , WNMG 080408 T603 3 Chamfer (Od stock ) **
Step boring WNMG 080404 T603 4 Corner radius ** R 1.6
Boring insert 5 Angle *
CCMT 09T304 T603 6 Bore dia ** 39.7-0.05
7 Bore length ** 101.0±0.10
8 Chamfer ( Id stock ) ** 2.3x 30º
9 Step bore dia ** 26.0±0.1
10 Bore length ** 130.0±0.10
6 CNC 2nd Operation CNC Turnning M/C 1 OD Machining ** 69.76 / 69.79
Facing, boring,step boring Turning insert 2 Perpendicularity ** 0.07 wrt B
Chamfering,Threading WNMG 080408 T603 3 Concentricity ** 0.07 wrt A
WNMG 080404 T603 4 Total length ** 260.0±0.1
Boring insert 5 Bore dia ** 51.09 / 51.12
CCMT 09T304 T603 6 Bore depth ** 58±0.10
TT 1500 7 Bore dia ** 37.0±0.10
8 Bore depth ** 83±0.10
9 Thread u/c dia * 26.0 ±0.25
10 u/c depth * 6.0 ±0.25
11 Perpendicularity ** 0.07 wrt B
12 Concentricity ** 0.07 wrt A
13 Thread size ( Entry tap ) ** M24x40.0
7 CNC 3rd Operation CNC Turnning M/C 1 Step dia ** 61.02-61.08
Grooving 2 Concentricity ** 0.07 wrt A
3 Step length ** 3.920 / 3.980
4 Corner radius in OD & ID ** (2x) R2
5 Corner radius ** R1
6 Groove dia ** 56.02 / 56.08
7 Concentricity ** 0.07 wrt A
8 Groove length ** 8.02 / 8.08
KEY CONTACT/PHONE : (080) 7833420
CORE TEAM : Mr.Rajesh, Daniel, Neelakantan, Lokesh, Dinesh, Muthukumar, Prakash, Muruganandam and Shivakumar.
SUPPLIER PLANT : BNR EXPORTS
PART PROCESS NO
MACHINE,JIG DEVICE, TOOLS FOR
MANUFACTURING
SPECIAL CHAR CLASS
PRODUCT /PROCESS SPECIFICATION/
TOLERANCE
No crack,damages and pit marks
3.3x10o
45o
9 Step length ** 48.0±0.1
10 Groove dia ** 65.10 / 65.25
11 Concentricity ** 0.07 wrt A
12 Groove width ** 3.75/3.85
13 Corner radius ** (2X) R1
14 Outside Corner radius ** R0.1 / R0.2
15 Angle * (2x) 0-5º
16 Step length ** 56.16 / 56.22
17 Groove dia ** 67.58 / 67.84
18 Concentricity ** 0.07 wrt A
19 Groovewidth ** 2.65 / 2.71
20 Surface finish ** Ra 1.6
8 CNC 4 TH OPERATION CNC Turnning M/C 1 Hole dia Drilling & Boring *** 29.99 / 30.03
First cross hole HSS Ø28.0 2 Ref. Length ** 27.90 / 28.1
CCMT 09T304 T603 3 Hole position ** 0.20 wrt A C
9 CNC 5 TH OPERATION CNC Turnning M/C 1 Hole dia Drilling & Boring *** 19.09 / 19.12
Secondt cross hole HSS Ø18.5 2 Ref. Length ** 27.90 / 28.1
CCMT 09T304 T603 3 Hole position ** 0.20 wrt A C
10 Conventional 3 C / Hole dia 2 Drilling ** 14.22 / 14.29
4 Ref length ** 38±0.10
5 Hole position ** 0.07 wrt A
11 CNC 6th Operation CNC Turning M/C 1 OD Turning *** 64.985 / 64.995
2 OD Length * 196.0 ± 0.15
3 ID Boring *** 40.03 / 40.05
4 ID Depth * 101.0 ± 0.15
5 Concentricity *** 0.02 wrt A
6 Surface finish ** Ra 0.8
12 Rethreading Hand 1 Thread size Tapping ** M24
Tap to M20 Tap M24 2 Thread length 40
13 Deburring Manual 1 Visual **
14 Final Inspection 1 OD Inspection *** 64.98 / 65.0
2 Chamfer **
3 Corner radius ** R 1.6
4 ID *** 40.03-40.05
5 Concentricity ** 0.03 wrt A
6 Surface finish ** Ra 0.8
7 Bore length ** 101.0±0.25
8 ID Chamfer ** 2 x 30º
9 Step bore dia ** 26.0±0.25
10 Bore length ** 130±0.25
11 OD ** 69.75 / 69.80
12 Total length ** 260.0±0.25
13 Bore dia *** 51.08 / 51.13
14 Bore depth ** 58±0.25
15 Bore dia ** 37±0.25
16 Bore depth ** 83±0.25
17 Thread u/c dia * 26.0 ±0.25
18 u/c depth * 6.0 ±0.25
19 Perpendicularity ** 0.1 wrt B
20 Concentricty ** 0.1 wrt A
21 Step dia ** 61.00 / 61.10
22 Corner radius ** (2x) R2
23 Corner radius ** R1
24 Groove dia ** 56.00 / 56.10
25 Groove length Inspection ** 8.00 / 8.10
Cross Hole Drilling & Reaming
Parts to be free from burrs,sharp corners,dents
and damages
3.0x10o
26 Step length ** 3.90 / 4.00
27 Step length ** 48.0±0.25
28 Groove dia ** 65.05 / 65.30
29 Groove width ** 3.7-3.9
30 Corner radius (2X) ** R1
31 Out corner radius (2X) * R0.1 / R0.2
32 Angle (2x) * 0-5º
33 Step length ** 56.14 / 56.24
34 Groove dia ** 67.56 / 67.86
35 Groovewidth ** 2.63-2.73
36 Step length ** 196±0.25
37 Chamfer * 45º
38 Concentricity ** 0.1 wrt A
39 Concentricity ** 0.1 wrt A
40 Concentricity ** 0.1 wrt A
41 Concentricity ** 0.1 wrt A
42 Concentricity ** 0.1 wrt A
43 Perpendicularity ** 0.1 wrt B
44 Surface finish ** Ra 1.6
45 Thread size ** M24
46 Hole dia ** 29.99 / 30.03
47 Ref. Length ** 27.80 / 28.20
48 Hole position ** 0.2 wrt A,C
49 Hole dia ** 14.20-14.31
50 Hole position ** 0.1 wrt A
51 Hole Ref Ht ** 38±0.25
52 Hole dia ** 19.09 / 19.12
53 Hole position ** 0.2 wrt A,C
54 Ref length * 27.80 / 28.20
15 Allen bolt assembly Manuel 1 Fixing of bolt with locktite **
2 5910 ** locktite under the bolt
16 Cleaning 1 Clean the Component with White waste
17 Packing 1 Pack the componant with bubble sheet
18 Despatch
NOTE:' MINOR, ''MAJOR, '''CRITICAL, 100%INSPECTION TO BE DONE, SPC TO BE DONE FOR > 50 NOS and for TOLERANCE of < 0.05 , PC=PROGRAME CONTROL, PP=PROFILE PROJECTOR..MH-Micro Height, HG-Vernier height gauge
REPRESENTATIONS: F= FINISH, S.I.R = SELF INSPECTION REPORT,
EVALUATION USING CMM IS DONE 1NO./4hr.
SETTING APPROVAL = New setting, Change of Tool, Collet, Jaws, Speed, Feed or any other change in Process / Setup -----VISUAL: Rust, Cracks, Pitting, Bend, Dents, Burrs & Damages are not allowed
QUARANTINE: Apart from rejected batches, batches produced / received should be kept separate till decision on the batch is taken. Ex. Batch produced between tool changes, batch received from supplier etc
Prepared by
Checked by
Approved by REV
Proper alignment of bolt & apply Sealant under the bolt
head
CONTROL PLAN
DATE(ORG): DATE(REV):
CUSTOMER ENGEERING APPROVAL/DATE
SUPPLIER/PLANT APPROVAL/DATE : CUSTOMER QUALITY APPROVAL / DATE
OTHER APPROVAL/ DATE (IF REQD.) CONTROL PLAN ISSUE NO: 01
METHODS
RECORDSAMPLECONTROL MATHOD REACTION PLAN
SIZE FREQ
Weighing scale
Every lot
DC / INVOICE GRIR
Naked eye
Micrometer
Exturnal lab
Vernier caliper 100% Every lot Self inspection report Reset the blade Self inspection report
Micrometer
2 Nos 1 hr Self inspection report Reset the tool Self inspection report
Bore gauge
Vernier caliper
Vernier caliper
Bore gauge
Bore gauge
Vernier caliper
Bore gauge
Vernier caliper
Micro meter
2 Nos 1 hr Self inspection report Self inspection report
Vernier caliper
Profile projector
Radius gauge
Profile projector
Bore dial gauge
Depth Vernier
Profile projector
Bore dial gauge
Depth vernier
Micro meter
1 Nos 1hr Self inspection report Self inspection report
Dial with stand/CMM
Dial with stand
Vernier caliper
Bore dial gauge
Depth vernier
Bore dial gauge
Depth vernier
Plug gauge
Vernier caliper
Dial with stand/CMM
Dial with stand
Thread plug gauge
Micrometer
Dial with stand
Profile projector
PP/Radius gauge
PP/Radius gauge
Blade micrometer
Dial with stand
Depth Micrometer / PP
(080) 7833420 24.12.06
CORE TEAM : Mr.Rajesh, Daniel, Neelakantan, Lokesh, Dinesh, Muthukumar, Prakash, Muruganandam and Shivakumar.
EVALUATION / MEASUREMENT TECH
As per sampling
plan
Reject and send back to supplierSupplier inspection
reportReceving inspection
report
Reset the insert check the speed and feed
Reset the insert check the speed and feed
Profile projector
1 Nos 1hr Self inspection report Self inspection report
Micrometer
Dial with stand
Profile projector
Profile projector
Profile projector
Profile projector
Profile projector
1 Nos 1 hr Self inspection report Self inspection report
Blade micrometer
Dial with stand
Profile projector
Roughness tester
Bore dial gauge
1 Nos 1 hr Self inspection report Self inspection reportMicro height /Vernier caliper
Dial with stand
Bore dial gauge
1 Nos 1 hr Self inspection report Self inspection reportMicro height /Vernier caliper
Dial with stand
Plug gauge
4 Nos 1 hr Self inspection report Self inspection report
Vernier caliper
Height gauge with Dial
Micrometer
Vernier caliper
Plug gauge/Bore gauge
Vernier caliper
Height gauge with dial
Roughness tester
Thread plug gauge100% Every lot Self inspection report Change the tap Self inspection report
Venier caliper
Visul 100% Every lot
Micrometer
Every lot Final inspection report Final inspection report
Profile projector
Radius gauge / PP
Bore dial gauge
Dial with stand
Roughness tester
Venier caliper
PC
Bore dial gauge
Depth vernier
Micro meter
Vernier caliper
Bore dial gauge
Vernier caliper
Bore dial gauge
Depth vernier
Plug gauge
Vernier caliper
Dial with stand / CMM
Dial with stand
Micrometer/Vernier caliper
PP/Radius gauge
PP/Radius gauge
Blade micrometer
Depth Micrometer
Every lot Final inspection report Final inspection report
Reset the insert check the speed and feed
Reset the insert check the speed and feeds
Reset the insert check the speed and feeds
Reset the insert check the speed and feeds
Reset the reaming tool and reset the drill bit
As per sampling
plan
Reject and segregate the lot
As per sampling
plan
Reject and segregate the lot
Profile projector
Every lot Final inspection report Final inspection report
Profile projector
Blade micrometer
Slip gauge/PP
PP/Radius gauge
PP
PP
Profile projector
Blade micrometer
Profile projector
Venier caliper
Profile projector
Dial with stand
Dial with stand
Dial with stand
Dial with stand
Dial with stand
Dial with stand
Roughness tester
Thread plug gauge
Plug gauge
Micro-hite / Vernier caliper
Dial with stand
Plug gauge
Dial with stand
Vernier caliper
Plug gauge
Dial with stand
Micro-height / Vernier caliper
Visual
Visual 100% Every Batch
Visual 100% Every Batch
NOTE:' MINOR, ''MAJOR, '''CRITICAL, 100%INSPECTION TO BE DONE, SPC TO BE DONE FOR > 50 NOS and for TOLERANCE of < 0.05 , PC=PROGRAME CONTROL, PP=PROFILE PROJECTOR..MH-Micro Height, HG-Vernier height gauge
REPRESENTATIONS: F= FINISH, S.I.R = SELF INSPECTION REPORT,
EVALUATION USING CMM IS DONE 1NO./4hr.
SETTING APPROVAL = New setting, Change of Tool, Collet, Jaws, Speed, Feed or any other change in Process / Setup -----VISUAL: Rust, Cracks, Pitting, Bend, Dents, Burrs & Damages are not allowed
QUARANTINE: Apart from rejected batches, batches produced / received should be kept separate till decision on the batch is taken. Ex. Batch produced between tool changes, batch received from supplier etc
CONTROL PLAN NO:
BNR /CP/186
SIGN /DATE REV No. 1 Page:5/5
As per sampling
plan
Reject and segregate the lot
BNR Exports
DATE:
Rev No: 0
CUSTOMER MONOPUMPS
PART NO C 0713250
PART NAME DRIVE SHAFT
WORK PROCESS CODIFICATION DESCRIPTION CODIFICATION
GRIR - 382
W.O. No 320
W.O. No 320
W.O. No 320
W.O. No 320
W.O. No 320
W.O. No 320
XXX / YYY / ZZZ 1 / 5 To 2 / 5 / BNRE /1344
Note:
COMPONENT NO DURING PROCESS: COPY
XXX / YYY / ZZZ
Invoice No
No of boxes in the Consignment
BOX NO.
W O XXX
RUNNING SERIAL NUMBER
WORK ORDER
Shiva kumar.B Neelakantan Ambi Daniel
PREPARED BY CHECKED BY APPROVED BY
TRACEABILITY FOR PRODUCT / MANUFACTURING PROCESS
Receive Heat No / Batch no / Lot No. from raw material supplier
WORK ORDER NUMBER AT BNR :
RAW MATERIAL FROM . SUPPLIER
CUTTING
C.N.C. OPERATIONS
CONVENTIONAL OPERATIONS
FINAL INSPECTION
ASSEMBLY
CLEANING & PACKING
DESPATCH
WORK INSTRUCTION FOR CUTTING OPERATION
Issue No:01 Date:15-06-05 Rev No:00 Date:15-06-05 OPERATION: CUTTING OPERATION
1) Receive the cutting slip from planning/production dept. 2) Clean the machine job holding area with brush and coolant. 3) Check the size of the raw material. 4) Set for required length as mentioned in cutting slip. 5) Clamp the job and start the m/c. 6) Adjust the feed with the adjustment lever. 7) Check the cut material for length, taper etc. 8) Arrange the cut parts in the bin, and identify with identification tag.
WORK INSTRUCTION FOR CNC TURNING OPERATION
Issue No:01 Date:15-06-05 Rev No:00 Date:15-06-05 OPERATION: CNC Turning
1) Study and understand the drawing dimensions, tolerances properly. If in doubt clarify 2) Check the route card correctly updated and duly signed. 3) Use proper tools, fixtures with respect to drawing 4) Ensure all related formats are existing 5) Ensure proper clamping of components in chuck, minimum holding length as per standard. 6) Set the machine for the required program and verify the program for all tool offset and availability of tool parameters and sequence as per job. 7) Get first piece approval as per drawing from QC personnel 8) Check and record the dimensions in the self-inspection report format at regular intervals 9) Use calibrated instruments/gauges for measuring purpose 10) Keep the instruments at respective place after use 11) Check the life of the tool by checking the finish and change insert whenever required 12) All sharp corners to be removed with 0.050mm radius and include this in the programme 13) Clean the your Machine after use and keep your m/c surrounding clean
PREPARED BY PREPARED BY APPROVED BY
WORK INSTRUCTION FOR CNC TURNING OPERATION
Issue No:01 Date:15-06-05 Rev No:00 Date:15-06-05 OPERATION: CNC Turning
1) Study and understand the drawing dimensions, tolerances properly. If in doubt clarify 2) Check the route card correctly updated and duly signed. 3) Use proper tools, fixtures with respect to drawing 4) Ensure all related formats are existing 5) Ensure proper clamping of components in chuck, minimum holding length as per standard. 6) Set the machine for the required program and verify the program for all tool offset and availability of tool parameters and sequence as per job. 7) Get first piece approval as per drawing from QC personnel 8) Check and record the dimensions in the self-inspection report format at regular intervals 9) Use calibrated instruments/gauges for measuring purpose 10) Keep the instruments at respective place after use 11) Check the life of the tool by checking the finish and change insert whenever required 12) All sharp corners to be removed with 0.050mm radius and include this in the programme 13) Clean the your Machine after use and keep your m/c surrounding clean
PREPARED BY PREPARED BY APPROVED BY
WORK INSTRUCTION FOR DRILLING OPERATIONS
Issue No:01 ` Date:15-06-05Rev No:00 Date:15-06-05
OPERATION: DRILLING OPERATION1) Study and understand the drawing dimensions, tolerances properly. If in doubt clarify
2) Check the route card/ job card/ control plans are provided as per latest issue no.
3) Use proper drills, fixtures with respect to drawing.
4) Get first piece approval as per drawing from QC personnel
5) Check and record the dimensions in the self-inspection report format at regular intervals
6) Use calibrated instruments/gauges for measuring purpose
7) Keep the instruments at respective place after use
8) Drill to be grind properly whenever required.
9) Deburring to be carried out after drilling operation.
10) Ensure all the drills/taping operations completed.
11) Ensure no parts are missed for the required operations.
12) Use tag systems for identification.
13) Arrange the parts in all the stags. 14) Clean the Machine after use and keep your m/c surrounding clean.
WORK INSTRUCTION FOR DEBURRING
OPERATIONS Issue No:01 Date:15-06-05 Rev No:00 Date:15-06-05
OPERATION: DEBURRING
1). Study the drawing requirements and root card process 2). Identify the requirements of the deburring process 3). Identify the required tools for deburring operation 4). Use rubber sheet over the table 5). Use plastic bins for arranging the parts 6). Break corners by ±0.2mm wherever specification not given 7). Blow air after deburring operation 8). Arrange the parts and identify the parts with suitable tag.
OPERATION: DRILLING OPERATION
1) Ensure parts are accepted by QC personal 2) Arrange appropriate corrugated boxes and other required packing materials. 3) Ensure all deburring operation done at all sharp corners. 4) Ensure parts are free from defects, like deep marks, cracks & surface treatments of good finish, Ensure there is no unfetteled lumps in case of castings. 5) Ensure no thread damages, missing of threads in case of parts required threading. 6) Ensure there is no missing operation as per drawing, check the plug gauge 100% before packing, if parts are surface treated. 7) Clean the parts with kerosene/TCI oil as required. 8) Apply rest preventive oil to all the parts. (As applicable) 9) Pack each part on a polythene sheets, tube & air bubble sheets as required, and enough stuffing to be given as instructed. 10) Arrange parts in polythene sheet and pack it. 11) Place the polythene packs in corrugated box. 12) Place the corrugated boxes in to the wooden box, covering by thick polythene cover. 13) Enclose inspection report, material test certificate & packing slip in to the corrugated box. 14) Seal the wooden box by sealing wire with sealing lead & write the packing slip No. on wooden box by permanent marker. 14) Stamp address of consignee & exporter on sealing lead.
WORK INSTRUCTION FOR PACKING OPERATIONS
Issue No:01 ` Date:15-06-05 Rev No:00 Date:15-06-05
PREPARED BY PREPARED BY APPROVED BY
PREPARED BY PREPARED BY APPROVED BY
WORK INSTRUCTION FOR DRILLING OPERATIONS
Issue No:01 ` Date:15-06-05Rev No:00 Date:15-06-05
OPERATION: DRILLING OPERATION1) Study and understand the drawing dimensions, tolerances properly. If in doubt clarify
2) Check the route card/ job card/ control plans are provided as per latest issue no.
3) Use proper drills, fixtures with respect to drawing.
4) Get first piece approval as per drawing from QC personnel
5) Check and record the dimensions in the self-inspection report format at regular intervals
6) Use calibrated instruments/gauges for measuring purpose
7) Keep the instruments at respective place after use
8) Drill to be grind properly whenever required.
9) Deburring to be carried out after drilling operation.
10) Ensure all the drills/taping operations completed.
11) Ensure no parts are missed for the required operations.
12) Use tag systems for identification.
13) Arrange the parts in all the stags. 14) Clean the Machine after use and keep your m/c surrounding clean.
OPERATION: DRILLING OPERATION
1) Ensure parts are accepted by QC personal 2) Arrange appropriate corrugated boxes and other required packing materials. 3) Ensure all deburring operation done at all sharp corners. 4) Ensure parts are free from defects, like deep marks, cracks & surface treatments of good finish, Ensure there is no unfetteled lumps in case of castings. 5) Ensure no thread damages, missing of threads in case of parts required threading. 6) Ensure there is no missing operation as per drawing, check the plug gauge 100% before packing, if parts are surface treated. 7) Clean the parts with kerosene/TCI oil as required. 8) Apply rest preventive oil to all the parts. (As applicable) 9) Pack each part on a polythene sheets, tube & air bubble sheets as required, and enough stuffing to be given as instructed. 10) Arrange parts in polythene sheet and pack it. 11) Place the polythene packs in corrugated box. 12) Place the corrugated boxes in to the wooden box, covering by thick polythene cover. 13) Enclose inspection report, material test certificate & packing slip in to the corrugated box. 14) Seal the wooden box by sealing wire with sealing lead & write the packing slip No. on wooden box by permanent marker. 14) Stamp address of consignee & exporter on sealing lead.
WORK INSTRUCTION FOR PACKING OPERATIONS
Issue No:01 ` Date:15-06-05 Rev No:00 Date:15-06-05
PREPARED BY PREPARED BY APPROVED BY
BNR Exports PACKING SPECIFICATIONSCustomer: Mono Pumps Ltd., UKDate: 22.09.2008
Requirements Originator
1 All the parts other than Muncher Half Couplings must have the label with Part number pasted on the packed product Logistics
2 Universal Joint assemblies threads must be protected withPlastic caps Logistics
1 Wood packaging material must be fumigated before despatchby Freight forwarder Customer
2 Each case must be pasted with a label consisting PO Number Logistics3 Delivery Terms: Incoterms 2000: Ex Works Logistics
1 Submit GSP certificates for each consignment Logistics
Prepared by Checked by Approved by
Special Packaging and Preservation:
Delivery Requirements:
Documentation Requirements:
CRITICAL CHARECTERISTIC MATRIX PLAN DATEPART NAME DRIVE SHAFT PART NO C 0713250 ISSUE 10 / 24-10-08 CUSTOMER MONO PUMPS
SL NOPARAMETER SPECIFICATION
PROCESS NO
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1OUT SIDE DIAMETER F 65 / 64.98 X
2BORE DIAMETER F 40.03 / 40.03 X
3CONCENTRICITY X
4BORE DIAMETER F 51.08 / 51.13 X
5BORE DIAMETER F 29.99 / 30.03 X
6OUT SIDE DIAMETER F 69.75 / 69.80 X
7BORE DIAMETER F 19.09 / 19.12 X
0.03 with respect to A
PPK1
Page 48
Sl.No. Date Readings Supplier : BNR Exports
1 84.99 Place : BANGALORE
2 84.983 84.99 Ref. No: 1
4 84.99 Period : 21.08.09
5 84.996 84.99 Part No. : C091 32507 84.99 Part Name : Drive Shaft
8 84.99 Parameter : Outer Diameter
9 84.9910 84.99 USL : 85
11 84.99 LSL : 84.98
12 84.9813 84.99 Operation No. : CNC 4th
14 84.99 Operation desc. : OD & ID Finish
15 84.9916 84.99 Instrument used : Micrometer
17 84.99 Least count : 0.01
18 84.9919 84.9920 84.9921 84.9922 84.9923 84.9924 84.9925 84.9926 84.9927 84.9928 84.9929 84.9930 84.9931 84.9932 84.9933 84.9934 84.9935 84.9936
37
38
39
40
41
42
43
44
PPK1
Page 49
45
46
47
48
49
505152535455565758596061626364656667686970717273747576777879808182838485868788899091929394959697
PPK1
Page 50
9899
100
BNR Exports Process Cpk Study ReportCustomer : Ref. No.
MONO PUMPS 1
Supplier: BNR Exports PERIOD ( Month ):
21.08.09Part No.: C091 3250 Part Name : DRIVE SHAFTParameter Specification Tolerance
OUTER DIAMETER USL 85 LSL 84.98 0.02Operation No: CNC 4th Opn. Description OD & ID Finish
Instrument Used MICROMETER Least Count : 0.01CAPABLE PROCESS OBSERVED
Cp > = 1.66 CAPABLE Cp = 1.42
Cpk > = 1.33 Cpk = 1.33n = 35
No. of Class : 3Observed beyond Specification : Target Nominal :
0.00% 84.99
Estimated beyond Specification : Average (X) 84.9890.00% Process Std. Dev. (Sigma):
0.0024Remarks : Name
Sign & Date
84.97
84.97
84.98
84.98
84.99
84.99
85.00
85.00
85.01
85.01
85.02
85.02
85.03
85.03
85.04
0
5
10
15
20
25
30
35
HISTOGRAM
Dimension
Frequency
PPK3
Page 52
Tolerance : 0.02
Target Nominal : 84.99 Min.value No.of width mid cumulative84.98 -0.015 84.965 84.9675 0
No. of reading : 35 84.98 -0.01 84.97 84.9725 084.98 -0.005 84.975 84.9775 0
Average : 84.98943 84.98 0 84.98 84.9825 284.98 0.005 84.985 84.9875 2
Std. dev. (Sigma) : 0.002355 84.98 0.01 84.99 84.9925 3584.98 0.015 84.995 84.9975 35
Cp value : 1.415403 84.98 0.02 85 85.0025 35Cpk value : 1.334523 84.98 0.025 85.005 85.0075 35
84.98 0.03 85.01 85.0125 35No. of class : 3 84.98 0.035 85.015 85.0175 35
84.98 0.04 85.02 85.0225 35Maximum value : 84.99 84.98 0.045 85.025 85.0275 35Minimum value : 84.98 84.98 0.05 85.03 85.0325 35
84.98 0.055 85.035 85.0375 35Range : 0.01 84.98 0.06 85.04 85.0425 35Class width : 0.005 84.98 0.065 85.045 85.0475 35
84.98 0.07 85.05 85.0525 35Observed beyond 84.98 0.075 85.055 85.0575 35Specification: 0 84.98 0.08 85.06 85.0625 35
84.98 0.085 85.065Estimated beyond zl zu phil phu est percentageSpecification -4.00357 4.488851 3.12E-05 0.9999964 2.762E-05 0.002761647
TARGET NOMINAL 2:if LSL=0: 0
if USL = ~: 0
Cpk value 2:if LSL=0: 0
if USL=~: 0
Cp = ----
PPK3
Page 53
sum of X =X bar =
PPK3
Page 54
frequency0020
3300000000000000
-35