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CONTROL PLAN
Prototype Prelaunch Production Date(Orig) Date (Rev.)
01-04-2020 27-04-2020
Control Plan Number CP20200804 Revision A
Part Name/Description Drive Post, "A"X"B", "L"m Long, "G" Mils
Part Number - REV 810021-A-B-L-G; 810003-A-B-L-G
Typical Post, "A"X"B", "L"m Long, "G" Mils
Parent-Level Assembly P/N Parent-Level Assy Description

Supplier
Supplier Key Contact/E-mail
Factory Supplier Core Team

Characteristics Methods
Part/ Process Name/ Special Product/Process Evaluation/
Machine, Device, Control
Process Operation No. Product Process Char. Specification/ Measurement Size Freq. Reaction Plan
Jig, Tools, for Mfg. Method
Number Description Class Tolerance Technique

Free of rough/jagged
edges, cracks, roll Visual Continuo 100%
1 Appearance 100% Reject
marks, visual defects Inspection us Inspection

Heat Number,
Material Hold and
100%
2 Mill Certificate Grade/Quantity/Size, 1 Heat Quarantine
Inspection
Certified Mill Material
Signature

Material Chemical Incoming Reject per

ASTM A992,
3 Chemical Comparison Per 1 pc Heat Inspection ASTM A6,
Table 1
Analysis ASTM E350 Record Section 17

Material Tensile Test Per Incoming Reject per

Universal Testing ASTM A992,
4 Mechanical ASTM A6, 2 pc Heat Inspection ASTM A6,
Machine Table 2
Analysis Section 11 Record Section 17

100 Incoming Inspection Incoming Reject per

Charpy V-Notch Brittle
5 * 27J, min. @ 0°C ASTM A673 3 pc Heat Inspection ASTM A6,
Impact Toughness Fracture
Record Section 17
1) Flange
Width/Depth +
Flange/W eb Incoming
Vernier Caliper ANSI Reject
6 Shape Thickness Per Per Lot Inspection
and Micrometer Z1.4, GI 2 AQL 2.5
ASTM A6, Table 2.1 Record
2) Tolerances per
JIS G3192, Table 4

Vernier Calipers Incoming

W eb Off- ANSI Reject
7 JIS G3192, Table 4 with depth gauge Per Lot Inspection
Center Z1.4, GI 2 AQL 2.5
stinger Record

Incoming
Straightness/ Steel wire and ANSI Reject
8 ASTM A6, Table 24 Per Lot Inspection
Camber calibrated shim Z1.4, GI 2 AQL 2.5
Record
Incoming
ASTM A6, Section Tape Measure, ANSI Reject
9 Linear Weight Per Lot Inspection
12.3.3 Scale Z1.4, GI 2 AQL 2.5
Record
Incoming
ANSI Reject
Jig Saw 1 Length As Per Drawing Tape Measure Per Lot Inspection
Z1.4, GI 2 AQL 2.5
Record
End Cut Steel Square, Incoming
ANSI Reject
2 Perpendiculari JIS G3192, Table 4 Calibrated Per Lot Inspection
Z1.4, GI 2 AQL 2.5
ty Precision Shim Record
200 Cutting Reject,
quarantine +
Free from burr,sharp mark
Visual Continuo 100%
3 Appearance edges, rust, undercut,. 100% defective
Inspection us Inspection
parts and
inform
supervisor.
 Characteristics Methods
Part/ Process Name/ Special Product/Process Evaluation/
Machine, Device, Control
Process Operation No. Product Process Char. Specification/ Measurement Size Freq. Reaction Plan
Jig, Tools, for Mfg. Method
Number Description Class Tolerance Technique
Reject,
quarantine +
Free from burr, slot
mark
hole sharp edges, Visual Continuo 100%
1 Appearance 100% defective
rust, undercut, die Inspection us Inspection
parts and
marks, & damage.
inform
supervisor.
Reject,
quarantine +
mark
Quantitiy of Visual Continuo 100%
2 100% defective
Slotted Holes Inspection us Inspection
parts and
inform
supervisor.
Reject,
Set-Up
As Per Drawing quarantine +
Record
(maintain on +ve side 2 pc set-up mark
Slotted Hole
3 to accommodate Vernier Calipers defective
Width Ongoing
HDG thickness) 1 pc per hour parts and
Inspection
inform
Record
supervisor.
Reject,
Set-Up
As Per Drawing quarantine +
Record
(maintain on +ve side 2 pc set-up mark
Slotted Hole
4 to accommodate Vernier Calipers defective
Length Ongoing
HDG thickness) 1 pc per hour parts and
Inspection
inform
Record
supervisor.
Reject,
Set-Up
quarantine +
Record
2 pc set-up mark
Slotted Hole
5 As Per Drawing Vernier Calipers defective
Location Ongoing
1 pc per hour parts and
Inspection
inform
Record
Hydraulic Stamping supervisor.
300 Hole Punching Machine Reject,
Set-Up
(Machine #: ) quarantine +
Record
2 pc set-up mark
Slotted Hole
6 As Per Drawing Vernier Calipers defective
Location Ongoing
1 pc per hour parts and
Inspection
inform
Record
supervisor.
Reject,
Set-Up
quarantine +
Record
2 pc set-up mark
Slotted Hole
7 As Per Drawing Vernier Calipers defective
Location Ongoing
1 pc per hour parts and
Inspection
inform
Record
supervisor.
Reject,
Set-Up
quarantine +
Record
2 pc set-up mark
Slotted Hole
8 As Per Drawing Vernier Calipers defective
Location Ongoing
1 pc per hour parts and
Inspection
inform
Record
supervisor.
Reject,
Set-Up
quarantine +
Record
2 pc set-up mark
As Per Drawing
9 Vernier Calipers defective
Ongoing
1 pc per hour parts and
Inspection
inform
Record
supervisor.
Reject,
Set-Up
quarantine +
Slot Edge -to- Record
2 pc set-up mark
Edge of Flange
10 As Per Drawing Vernier Calipers defective
(Centered) Ongoing
1 pc per hour parts and
Inspection
inform
Record
supervisor.
 Characteristics Methods
Part/ Process Name/ Special Product/Process Evaluation/
Machine, Device, Control
Process Operation No. Product Process Char. Specification/ Measurement Size Freq. Reaction Plan
Jig, Tools, for Mfg. Method
Number Description Class Tolerance Technique
Package/Transport As Per SOP / WI Visual 100% Reject and re-
400 1 Lot QTY Per Lot
to HDG ------------------ Inspection Inspection package

Free of deformation, Visual Continuo 100%

Receipt of Material 1 Appearance 100% Reject
dents, and damage Inspection us Inspection

grade of zinc
containing 0.5 to 1.4
% lead, a minimum
Zinc Ingot Reject and
of 98.5 % zinc, with As per Test
2 Chemical ASTM E536 Per Lot return to sub-
controlled impurity SOP / WI Certificate
Composition supplier
levels, as specified in
Zinc Ingot Table 1 of ASTM
B6.

Zinc metal shall be

reasonably free of Visual
Zinc Ingot Continuo 100%
3 surfacecorrosion and Inspection Per 100% Reject
Appearance us Inspection
adhering foreign ASTM B6
matter
# of Parts per SOP / Stop
Visual 100%
4 Quantity WI Lot set-up production
Inspection Inspection
------------------ and rectify
Sufficient gap
Stop
Part-to-Part between adjacent Visual 100%
5 Lot set-up production
Clearance parts per ASTM Inspection Inspection
and rectify
A385 Section 5
Stop
Hanging Jig Visual 100%
6 Orientation 45 deg tilted Lot set-up production
Inspection Inspection
and rectify

Flow without undue

Stop
resistance into, over, Visual 100%
Hot-Dip Galvanizing 7 Drainage Lot set-up production
through, and out of the Inspection Inspection
and rectify
fabricated article

As per SOP / WI (1.0 HDG Stop

Specific As per Shift
8 to 1.4) Hydrometer Inspection production
Gravity SOP / WI Start
----------------- Record and rectify
As per SOP / WI HDG Stop
NaOH Volumetric As per Shift
9 (10-15kg/100L) Inspection production
Concentration Analysis SOP / WI Start
----------------- Record and rectify
As per SOP / WI HDG Stop
As per Shift
10 pH (1-2 pH) pH Scale Inspection production
SOP / WI Start
------------------ Record and rectify
100%
Degreasing Tank Per dip Inspection
(Tank #: ) As per SOP / WI Stop
Temperature As per ---- ----
11 (85° - 90°C) Thermometer production
of Tank SOP / WI Shift HDG
---------------------- and rectify
Start Inspection
Record
100%
Per dip Inspection
Stop
Submersion As per SOP / WI As per ---- ----
12 Timer production
Time ---------------------- SOP / WI Shift HDG
and rectify
Start Inspection
Record
HDG Stop
As per SOP / WI As per Shift
13 pH pH Scale Inspection production
---------------------- SOP / WI Start
Record and rectify
100%
Rinsing Tank
Per dip Inspection
(Tank #: Stop
Temperature As per SOP / WI As per ---- ----
14 Thermometer production
of Tank ---------------------- SOP / WI Shift HDG
and rectify
) Start Inspection
Record
 Characteristics Methods
Part/ Process Name/ Special Product/Process Evaluation/
Machine, Device, Control
Process Operation No. Product Process Char. Specification/ Measurement Size Freq. Reaction Plan
Jig, Tools, for Mfg. Method
Number Description Class Tolerance Technique
As per SOP / WI
(1.1 to 1.3) HDG Stop
Specific As per Shift
15 -------------------- Hydrometer Inspection production
Gravity SOP / WI Start
Record and rectify

Acid Content As per SOP / WI HDG Stop

Volumetric As per Shift
16 (HCL or (100-150 g/L) Inspection production
Analysis SOP / WI Start
H2SO4) -------------------- Record and rectify
As per SOP / WI
HDG
(100 to 120 g/L, Volumetric As per Shift Discard
17 Iron Content Inspection
MAX) Analysis SOP / WI Start solution
Record
-------------------
Pickling Tank
(Tank #: 100%
Per dip Inspection
Stop
Submersion As per SOP / WI As per ---- ----
) 18 Timer production
Time ---------------------- SOP / WI Shift HDG
and rectify
Start Inspection
Record
100%
Per dip Inspection
Stop
Temperature As per SOP / WI As per ---- ----
19 Thermometer production
of Tank ---------------------- SOP / WI Shift HDG
and rectify
Start Inspection
Record
HDG Stop
As per SOP / WI As per Shift
20 pH pH Scale Inspection production
---------------------- SOP / WI Start
Record and rectify
100%
Rinsing Tank
Per dip Inspection
(Tank #: Stop
Temperature As per SOP / WI As per ---- ----
21 Thermometer production
500 of Tank ---------------------- SOP / WI Shift HDG
and rectify
) Start Inspection
Record
Hot-Dip Galvanizing As per SOP / WI
HDG Stop
Specific (1.1 to 1.3) As per Shift
22 Hydrometer Inspection production
Gravity -------------------- SOP / WI Start
Record and rectify

Zinc
As per SOP / WI HDG Stop
Aluminum Volumetric As per Shift
23 (200-400 g/L) Inspection production
Chloride Analysis SOP / WI Start
------------------- Record and rectify
Content
As per SOP / WI HDG Stop
Volumetric As per Shift
24 Iron Content (0 to 50 g/L) Inspection production
Analysis SOP / WI Start
--------------------- Record and rectify
As per SOP / WI HDG Stop
As per Shift
Fluxing Tank 25 pH (3.5 to 4.5) pH Scale Inspection production
SOP / WI Start
(Tank #: -------------------- Record and rectify
100%
Per dip Inspection
) As per SOP / WI Stop
Temperature As per ---- ----
26 (30° - 80°C) Thermometer production
of Tank SOP / WI Shift HDG
------------------ and rectify
Start Inspection
Record
100%
Per dip Inspection
Stop
Submersion As per SOP / WI As per ---- ----
27 Timer production
Time ---------------------- SOP / WI Shift HDG
and rectify
Start Inspection
Record
As per SOP / WI
100%
(80° - 150°C)
Per dip Inspection
Temperature Stop
As per ---- ----
Oven Drying 28 & * ASTM A143 to avoid Thermometer production
SOP / WI Shift HDG
Time hydrogen and rectify
Start Inspection
embrittlement
Record
 Characteristics Methods
Part/ Process Name/ Special Product/Process Evaluation/
Machine, Device, Control
Process Operation No. Product Process Char. Specification/ Measurement Size Freq. Reaction Plan
Jig, Tools, for Mfg. Method
Number Description Class Tolerance Technique
100%
Per dip Inspection
As per SOP Stop
Temperature As per ---- ----
29 (440° - 460°C) Thermometer production
of Bath SOP / WI Shift HDG
------------ and rectify
Start Inspection
Record
HDG Stop
98.0%, min per Volumetric As per Every 2
30 Molten Zinc Inspection production
ASTM A123M Analysis SOP / WI weeks
Record and rectify
Removal of
Stop
contaminents As per SOP / WI Visual Continou 100%
31 Visual production
on zinc bath ---------------------- Inspection s Inspection
and rectify
surface
100%
Per
Inspection
Zinc Bath As per SOP / WI Batch Stop
Immersion As per ----
(Tank #: 32 ----------------- Timer ---- production
Rate SOP / WI HDG
Shift and rectify
Inspection
Start
) Record
100%
Per dip Inspection
Stop
Submersion As per SOP / WI As per ---- ----
33 Timer production
time ---------------------- SOP / WI Shift HDG
and rectify
Start Inspection
Record
100%
Per
Inspection
Batch Stop
Withdrawal As per SOP / WI As per ----
34 Timer ---- production
Rate ---------------------- SOP / WI HDG
Shift and rectify
Inspection
Start
Hot-Dip Galvanizing Record
100%
Per dip Inspection
As per SOP / WI Stop
Quenching As per ---- ----
36 Temperature ----------------- Thermometer production
(Tank #: SOP / WI Shift HDG
and rectify
Start Inspection
Record
)
As per SOP / WI HDG Stop
As per Shift
37 pH * (2.5 to 4.0) pH scale Inspection production
SOP / WI Start
------------------- Record and rectify
As per SOP / WI
Sodium HDG Stop
(0.2 mass [wt] %) Volumetric As per Shift
38 Dichromate * Inspection production
ASTM A767 Analysis SOP / WI Start
Concentration Record and rectify

Sulphuric Acid As per SOP / WI HDG Stop

Volumetric As per Shift
39 Concentration * (0.2%) Inspection production
Analysis SOP / WI Start
ASTM A767 Record and rectify
Passivation 100%
(Tank #: Per dip Inspection
As per SOP / WI Stop
Temperature As per ---- ----
40 * (32°C - 65°C) Thermometer production
) of Tank SOP / WI Shift HDG
----------------- and rectify
Start Inspection
Record
100%
Per dip Inspection
As per SOP / WI Stop
Submersion As per ---- ----
41 * (20s, Min.) Timer production
Time SOP / WI Shift HDG
----------------- and rectify
Start Inspection
Record

Magnetic
As per ASTM A123, Final Coating As per ASTM
Coating Thickness Gage Per ASTM
1 Section 6.1 Per dip Inspection A123, Section
Thickness per ASTM A123
(Multi-Specimen) Report 8.2.5
B8.2/E376

Final Coating As per ASTM

As per ASTM A123, Per ASTM
2 Finish Visual Per dip Inspection A123, Section
Section 6.2 A123
Report 8.2.5
HDG Final Final Coating As per ASTM
600 As per ASTM A123, Per ASTM
Inspection Inspection A123, Section
3 Appearance Visual Per dip
Section 6.4 A123
Report 8.2.5
As per ASTM Final Coating As per ASTM
As per ASTM, Per ASTM
4 Adherence A123, Section Per dip Inspection A123, Section
Section 6.5 A123
8.3 Report 8.2.5
Chromate Presence of dark Final Coating
Section 6.3 of Re-passivate
5 Coating * deposit or black 1 samples Per shift Inspection
ASTM B201 and re-test
Presence stain Report
 Characteristics Methods
Part/ Process Name/ Special Product/Process Evaluation/
Machine, Device, Control
Process Operation No. Product Process Char. Specification/ Measurement Size Freq. Reaction Plan
Jig, Tools, for Mfg. Method
Number Description Class Tolerance Technique
FTC Part Marking Continou 100%
700 Part Marking Ink-Jet/Stenciling 1 Marking Visual 100% Remediate
Requiements s Continuous
Holes free of excess Visual Continou 100%
1 Appearance 100% Remediate
zinc Inspection s Continuous
Reject AQL
Final
2.5; 100%
Slotted Hole ANSI Dimensional
2 As Per Drawing Vernier Calipers Per Lot Sorting;
Width Z1.4, GI 2 Inspection
Implement
Report
CAPA
Reject AQL
Final
2.5; 100%
Slotted Hole ANSI Dimensional
3 As Per Drawing Vernier Calipers Per Lot Sorting;
Length Z1.4, GI 2 Inspection
Implement
Report
CAPA
Reject AQL
Final
2.5; 100%
Slotted Hole ANSI Dimensional
4 As Per Drawing Vernier Calipers Per Lot Sorting;
Location Z1.4, GI 2 Inspection
Implement
Report
CAPA
Reject AQL
Final
2.5; 100%
Slotted Hole ANSI Dimensional
5 As Per Drawing Vernier Calipers Per Lot Sorting;
Location Z1.4, GI 2 Inspection
Implement
Dimensional Final Report
800 CAPA
Inspection
Reject AQL
Final
2.5; 100%
Slotted Hole ANSI Dimensional
6 As Per Drawing Vernier Calipers Per Lot Sorting;
Location Z1.4, GI 2 Inspection
Implement
Report
CAPA
Reject AQL
Final
2.5; 100%
Slotted Hole ANSI Dimensional
7 As Per Drawing Vernier Calipers Per Lot Sorting;
Location Z1.4, GI 2 Inspection
Implement
Report
CAPA
Reject AQL
Final
2.5; 100%
Slotted Hole ANSI Dimensional
8 As Per Drawing Vernier Calipers Per Lot Sorting;
Location Z1.4, GI 2 Inspection
Implement
Report
CAPA
Reject AQL
Final
2.5; 100%
Slotted Hole ANSI Dimensional
9 As Per Drawing Vernier Calipers Per Lot Sorting;
Location Z1.4, GI 2 Inspection
Implement
Report
CAPA
As per FTC approved
packaging proposal Checklist /
900 Packaging/Shipment 1 Packaging Visual 1 Per Lot Repackage
Photographs

Per Documents
Document Hold the
1000 1 Documents All documents As per FTC protocol Visual 100% Shipmen uploading in
submission Shipment
t Box