Control Plan: FG 260 As Per IS 210: 2009
Control Plan: FG 260 As Per IS 210: 2009
Control Plan: FG 260 As Per IS 210: 2009
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
WI - Sand
1.01 Moisture 2.0% - 4.0% Moisture Tester Remix
Preparation
Bath Sample/
Chemical Refer Grade Chart 1 Heat Readjust
4.01 ▼ Spectro Analysis Lab Testing
Composition QC-CAS-F01 1 Final Sample/ Composition
Heat
Charging
Induction Furnace
1 of 24
Control Plan
Doc. No. : PDC-EPD-F02
Rev. No. : 01 (03/04/2015)
Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
L
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : D10447340A Revision No. (Date) : 01(26/12/2015) Mr. Pradeep Garg MR/ DGM Opr.
Control Plan Number : D10447330A CP-CAS 01-09 Organization / Plant Approval Date : N/A Date (Originated) :26/12/2015 Mr. RS Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : FT3035 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Samdar Singh Manager - Casting
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Induction Furnace
Grade : FG 260 As Per IS 210 : 2009
Characteristics Methods
4 /
Melting and
Part Pouring
Process Name/
Machine, Device, Special
Process Jig, Tools for Char. Evaluation/ Sample Reaction Plan Record
Operation Description BLN Product/ Process/
Number Mfg. No. Product Process Class Measurement Control Method
No. Specification/ Tolerance
Technique Size Freq. & Responsibility
Review Gating
Digital Wall Foundry Shift System in case No need to
4.04 Pouring Time ▼ 15-25 mins Clock
2 2 / day
Supervisor of any adverse record
observations
2 of 24
Control Plan
Doc. No. : PDC-EPD-F02
Rev. No. : 01 (03/04/2015)
Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
L
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : D10447340A Revision No. (Date) : 01(26/12/2015) Mr. Pradeep Garg MR/ DGM Opr.
Control Plan Number : D10447330A CP-CAS 01-09 Organization / Plant Approval Date : N/A Date (Originated) :26/12/2015 Mr. RS Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : FT3035 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Samdar Singh Manager - Casting
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Visual Inspection
7 Grinding Bench Grinder 7.01 Gating & Parting Line No extra material Visual 100% Each Lot Blasting Shop Incharge Rework / Reject
Brinell Hardness
Hardness Testing Refer Grade Chart Testing Machine 3000 As Per Internal Check & Hardness Report
8 Testing 8.02 Hardness Test 1 Lab Testing
M/C ( QC-CAS-F01 ) Kg Load Ǿ 10.00 mm Sample Plan Segregate LAB-CAS-F03
Ball
In Case Of Failure
check counter Check Physical Charging Report
UTM 8.03 Tensile Strength UTM 1 1 Per Shift
sample. If this also Properties PRD-CAS-F01
fails, reject the lot.
Each Batch-
Paint Spray Coating Thicker
9.01 DFT 150-250 microns 1 Blasting Shop Re Coat
Gun Tester
Incharge
WI Painting
9 Painting N/A
(PRD-CAS-WI10)
Each Batch-
9.03 Drying Time 6-8 Hours Watch 100% Blasting Shop Adjust Time
Incharge
3 of 24
Control Plan
Doc. No. : PDC-EPD-F02
Rev. No. : 01 (03/04/2015)
Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
L
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : D10447340A Revision No. (Date) : 01(26/12/2015) Mr. Pradeep Garg MR/ DGM Opr.
Control Plan Number : D10447330A CP-CAS 01-09 Organization / Plant Approval Date : N/A Date (Originated) :26/12/2015 Mr. RS Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : FT3035 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Samdar Singh Manager - Casting
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
4 of 24
Format No. : QC-CAS-F01
Metallurgical Specifications
Type Tensile Strength Yield Strength % Elongation
Grade Standards Microstructure
(C. I / S.G.) (Min.) (Min.) (Min.)
D 4512 Ferrite-Pearilite (Type1) 450 310 - 285 12%
SG SAE J434 Revised FEB2004
D 5506 Pearlitic-Ferrite (Type 1) 550 380 - 350 6%
Note : * Grade Specification in Customer Drawing doesn't stipulate Chemical composition . Composition mentioned is
based upon proprietary experience , Mechanical properties requirement & Customer Drawing.
Format No. : QC-CAS-F01
In-House Specification (Casting) - Grade Issue No. : 04 (20/05/2015)
Chart Rev. No. : 03 (20/05/2015)
Description Product Parameters Specifications Process Parameters Specifications
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
L
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : D10447340A-MCD-01-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-10 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
1.Set up Approval
1.Set up Approval
1st PC Setup QC Incharge (QC-MCN-F01)
(QC-MCN-F01)
Chuck 2/Shift Operator 2.Operator log book
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER
10.01 ▼ 22 ± 2.0 kg/cm2 Dial Indicator 1 2.100% Operator Monitoring Readjust the Pressure
Pressure 2/Shift Inspector
3.In Process Inspection
(QC-MCN-F10)
1 3.In Process Inspection
report (QC-MCN-F02)
report (QC-MCN-F02)
1.Set up Approval(QC-MCN-
Surface Check Tooling & Set up Approval(QC-MCN-
10.03 Surface Finish 22 ▼ 1.6μRa 1st PC Set up QC Incharge F01)
TURNING IST SETUP
1.Set up Approval(QC-MCN-
Tool Profile Check Tooling & Set up Approval(QC-MCN-
10.05 Radius 24 R0.5 mm MAX. 1st PC Set up QC Incharge F01)
/ Visual 2.Program Controlled
ascertain root Cause F01)
7 of 24
Doc. No. : PDC-EPD-F02
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
L
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : D10447340A-MCD-01-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-10 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
33
1.Set up Approval(QC-MCN- 1.Set up Approval(QC-MCN-
1st PC Set up QC Incharge F01) / CMM Report Check Tooling & F01) / CMM Report
10.12 Depth ▼ 8.85 / 9.15 mm Depth Vernier
1 20th PC Inspector 2.In Process Inspection ascertain root Cause 2.In Process Inspection
CHUCK
10
10.13 Angle 35 45 ̊ Pattern Controlled
1.Set up Approval(QC-MCN-
Check Tooling & Set up Approval(QC-MCN-
10.14 Chamfer 36 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge F01)
ascertain root Cause F01)
2. Program Controlled
1.Set up Approval(QC-MCN-
Surface Check Tooling & Set up Approval(QC-MCN-
10.16 Surface Finish 44 1.6μRa 1st PC Set up QC Incharge F01)
Comparator 2.Program Controlled
ascertain root Cause F01)
8 of 24
Doc. No. : PDC-EPD-F02
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
L
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : D10447340A-MCD-01-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-10 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
1.Set up Approval(QC-MCN-
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER CHUCK
1.Set up Approval(QC-MCN-
F01)
Bore gauge with 1st PC F01)
Set up QC Incharge Check & Segregate 2. Operator Log Book (QC-
Ø 39.965 / 2.100% Operator Monitoring
10.17 Inner Diameter 45 ▼ Dial LC 0.001 100% Operator
3.In Process Inspection
Check tooling & MCN-F10)
39.990 mm 10th PC Inspector ascertain root cause 3.In Process Inspection
With MSR 32-1 1 Report (QC-MCN-F02)
Report (QC-MCN-F02)
4.SPC Analysis
4.SPC Chart
1.Set up Approval(QC-MCN-
1.Set up Approval(QC-MCN-
F01)
Bore gauge with 1st PC F01)
Set up QC Incharge Check & Segregate 2. Operator Log Book (QC-
Ø 100.000 / 2.100% Operator Monitoring
10.18 Inner Diameter 46 ▼ Dial LC 0.001 100% Operator
3.In Process Inspection
Check tooling & MCN-F10)
100.054 mm 10th PC Inspector ascertain root cause 3.In Process Inspection
With MSR 31-1 1 Report (QC-MCN-F02)
Report (QC-MCN-F02)
4.SPC Analysis
4.SPC Chart
Ø 217.5 / 222.5
10.20 Outer Diameter 48 As Cast Pattern Controlled
mm
10
Check & Segregate
Ø 277.5 / 282.5 Set up Approval(QC-MCN- Set up Approval(QC-MCN-
10.21 Inner Diameter 49 Vernier Caliper 1st PC Set up QC Incharge
F01)
Check Tooling &
F01)
mm Ascertain root cause
1.Set up Approval(QC-MCN-
1.Set up Approval(QC-MCN-
1st PC F01)
Set up QC Incharge F01) Check & Segregate
Ø 313.5 / 313.6 SG - 27 - 1&2 with 2. Operator Log Book (QC-
10.22 Outer Diameter 50 100% Operator 2.100% Operator Monitoring Check tooling &
mm MSP-25 20th PC Inspector 3.In Process Inspection Report ascertain root cause
MCN-F10)
1 3.In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
9 of 24
Doc. No. : PDC-EPD-F02
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
L
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : D10447340A-MCD-01-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-10 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
1 20th PC Inspector 2.In Process Inspection ascertain root Cause 2.In Process Inspection
Report (QC-MCN-F02) Report (QC-MCN-F02)
1.Set up Approval(QC-MCN-
Check Tooling & Set up Approval(QC-MCN-
10.27 Chamfer Angle 60 15 ̊ Bevel Protector 1st PC Set up QC Incharge F01)
ascertain root Cause F01)
10 2.Program Controlled
1.Set up Approval(QC-MCN-
Check Tooling & Set up Approval(QC-MCN-
10.28 Chamfer Depth 61 1.4 / 1.6 mm Height Gauge 1st PC Set up QC Incharge F01)
ascertain root Cause F01)
2.Program Controlled
Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.
Remarks: The ballooned dimension 45 , 46 & 50 to be checked by the operator 100% and has to be recorded in the log book.
Reviwed on 14/05/2016.
10 of 24
Doc. No. : PDC-EPD-F02
Production Drawing No. : D10447340A-MCD-02-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-11 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
1.Set up Approval
1.Set up Approval
(QC-MCN-F01)
(QC-MCN-F01)
Chuck 2.Operator log book
11.01 ▼ 22 ± 2.0 kg/cm2 Dial Indicator 1 2/Shift 2.100% Operator Monitoring Readjust the Pressure
Pressure 3.In Process Inspection
(QC-MCN-F10)
3.In Process Inspection
report (QC-MCN-F02)
report (QC-MCN-F02)
1.Set up Approval(QC-MCN-
Check Tooling & Set up Approval(QC-MCN-
11.06 Chamfer 27 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge F01)
ascertain root cause F01)
2.Program Controlled
11 of 24
Doc. No. : PDC-EPD-F02
Production Drawing No. : D10447340A-MCD-02-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-11 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
1.Set up Approval(QC-MCN-
Check Tooling & Set up Approval(QC-MCN-
11.11 Chamfer 40 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge F01)
ascertain root cause F01)
2.Program Controlled
1.Set up Approval(QC-MCN-
1.Set up Approval(QC-MCN-
TURNING IInd SETUP
F01)
1st PC F01)
Set up QC Incharge 2.Operator Log Book (QC-
Ø 328.10 / MSP - 21 with SG- 2.100% Operator Monitoring Check Tooling &
11.13 Inner Diameter 42 ▼ 100% Operator MCN-F10)
328.20 mm 35-1&2 20th PC Inspector
3.In Process Inspection ascertain root cause
3.In Process Inspection
1 Report (QC-MCN-F02)
Report (QC-MCN-F02)
4.SPC Analysis
4.SPC Chart
1.Set up Approval(QC-MCN-
Ø 159.5 / 160.5 Check Tooling & Set up Approval(QC-MCN-
11.15 Inner Diameter 53A Inside Caliper 1st PC Set up QC Incharge F01)
ascertain root cause F01)
mm 2.Program Controlled
12 of 24
Doc. No. : PDC-EPD-F02
Production Drawing No. : D10447340A-MCD-02-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-11 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
D10342920
11.23 Punch 69 Visual N/A On Part
FG-260
Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.
Tool Control
Remarks: The ballooned dimension 42 to be checked by the operator 100% and has to be recorded in the log book.
Reviwed on 14/05/2016.
13 of 24
Doc. No. : PDC-EPD-F02
Production Drawing No. : D10447340A-MCD-03-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-12 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
1.Set up Approval(QC-MCN-
1.Set up Approval(QC-MCN-
Receiver Gauge- 1st PC Set up QC Incharge F01) Check & Segregate
F01)
12.01 Angle 1 90 ̊ ± 15 ' 100% Operator 2.100% Operator Monitoring Check tooling &
05 1 35th PC Inspector 3.In-Process Inspection Report ascertain root cause
2.In-Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
1.Set up Approval(QC-MCN-
Set up Check tooling & Set up Approval(QC-MCN-F01)
12.02 Angle 2 35 ̊± 0 ̊30 ' CMM 1st PC 1 / Shift
F01) / CMM Report
ascertain root cause / CMM Report
2.Program Controlled
Crank , Timing , Clutch & Side Drilling
1. Set up Approval(QC-MCN-
1st PC 1.Set up Approval(QC-MCN-
Set up QC Incharge F01)/CMM Report
Angle CMM / Receiving Check tooling & F01)/CMM Report
12.03 3 30 ̊± 0 ̊30 ' 100% Operator 2. 100% Operator Monitoring
(12 Holes) Gauge-05 1 35th PC Inspector 3. In Process Inspection Report
ascertain root cause 2.In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
VMC MACHINE
1.Set up Approval(QC-MCN-
Set up Check tooling & Set up Approval(QC-MCN-F01)
12.04 Center Distance 3A 67.2 mm CMM 1st PC 1 / Shift
F01) / CMM Report
ascertain root cause / CMM Report
2.Program Controlled
12
1.Set up Approval(QC-MCN-
Set up Check tooling & Set up Approval(QC-MCN-F01)
12.05 Center Distance 3B 84.9 mm CMM 1st PC 1 / Shift
F01) / CMM Report
ascertain root cause / CMM Report
2.Program Controlled
1. Set up Approval(QC-MCN-
1.Set up Approval(QC-MCN-
CMM / Receiving 1st PC Set up QC Incharge F01)/CMM Report
Check tooling & F01)/CMM Report
12.07 Angle 5 55 ̊ ± 0̊ 20' 100% Operator 2. 100% Operator Monitoring
Gauge - 12 1 35th PC Inspector 3. In Process Inspection Report
ascertain root cause 2.In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
14 of 24
Crank , Timing , Clutch
VMC MAC
12 Doc. No. : PDC-EPD-F02
Production Drawing No. : D10447340A-MCD-03-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-12 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
1. Set up Approval(QC-MCN-
1st PC 1.Set up Approval(QC-MCN-
Set up QC Incharge F01)/CMM Report
CMM / Receiving Check tooling & F01)/CMM Report
12.09 Angle 6 60 ̊ ± 0̊ 20' 100% Operator 2. 100% Operator Monitoring
Gauge - 12 1 35th PC Inspector 3. In Process Inspection Report
ascertain root cause 2.In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
1.Set up Approval(QC-MCN-
Set up / Check tooling & Set up Approval(QC-MCN-F01)
12.10 Center Distance 7 88.9 mm CMM 1st PC
1 / Shift
F01) / CMM Report
ascertain root cause / CMM Report
2.Program Controlled
Crank , Timing , Clutch & Side Drilling
1.Set up Approval(QC-MCN-
Set up / Check tooling & Set up Approval(QC-MCN-F01)
12.11 Center Distance 8 88.9 mm CMM 1st PC
1 / Shift
F01) / CMM Report
ascertain root cause / CMM Report
2.Program Controlled
1. Set up Approval(QC-MCN-
VMC Machine
1. Set up Approval(QC-MCN-
1st PC 1.Set up Approval(QC-MCN-
CMM / Receiving Set up QC Incharge F01)/CMM Report
Check tooling & F01)/CMM Report
12.13 Angle 10 60 ̊ ± 0̊ 20'
Gauge - 12
100% Operator 2. 100% Operator Monitoring
ascertain root cause 2.In Process Inspection Report
1 35th PC Inspector 3. In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
1.Set up Approval(QC-MCN-
1.Set up Approval(QC-MCN-
F01)
1st PC Set up QC Incharge Check tooling & F01)
12.14 2 Holes 11 Ø 6.8 / 7.2 mm Vernier Caliper 1 35th PC Inspector
2.In Process Inspection
ascertain root cause 2.In Process Inspection Report
Report(QC-MCN-F02)
(QC-MCN-F02)
3.Program Controlled
15 of 24
VMC Machine
Crank , Timing , Clutch &
Doc. No. : PDC-EPD-F02
Production Drawing No. : D10447340A-MCD-03-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-12 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
1. Set up Approval(QC-MCN-
CMM / 1st PC 1.Set up Approval(QC-MCN-
Set up QC Incharge F01)/CMM Report
Check tooling & F01)/CMM Report
12.15 Center Distance 12 ▼ 35.7 / 36.3 mm Receiving Gauge 100% Operator 2. 100% Operator Monitoring
ascertain root cause 2.In Process Inspection Report
- 12 1 35th PC Inspector 3. In Process Inspection
(QC-MCN-F02)
Report (QC-MCN-F02)
1. Set up Approval(QC-MCN-
1.Set up Approval(QC-MCN-
CMM / Receiving 1st PC Set up QC Incharge F01)/CMM Report
Check tooling & F01)/CMM Report
12.16 Angle 13 60 ̊ ± 0̊ 20' 100% Operator 2. 100% Operator Monitoring
Gauge - 12 1 35th PC Inspector 3. In Process Inspection Report
ascertain root cause 2.In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
1.Set up Approval(QC-MCN-
Set up Check tooling & Set up Approval(QC-MCN-F01)
12.17 Angle 14 35 ̊± 0 ̊30 ' CMM 1st PC 1 / Shift
F01) / CMM Report
ascertain root cause / CMM Report
2.Program Controlled
Crank , Timing , Clutch & Side Drilling
1.Set up Approval(QC-MCN-
Set up Check tooling & Set up Approval(QC-MCN-F01)
12.18 Center Distance 14A 121.2 mm CMM 1st PC 1 / Shift
F01) / CMM Report
ascertain root cause / CMM Report
2.Program Controlled
VMC MACHINE
1.Set up Approval(QC-MCN-
Set up Check tooling & Set up Approval(QC-MCN-F01)
12.19 Center Distance 14B 131.9 mm CMM 1st PC 1 / Shift
F01) / CMM Report
ascertain root cause / CMM Report
2.Program Controlled
12 1. Set up Approval(QC-MCN-
1.Set up Approval(QC-MCN-
1st PC Set up QC Incharge F01)
12 Holes Check tooling & F01)
12.20 M8 X 1.25 TPG - 09 100% Operator 2. 100% Operator Monitoring
Equlispaced 1 35th PC Inspector 3. In Process Inspection Report
ascertain root cause 2.In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
1. Set up Approval(QC-MCN-
15 CMM / 1st PC Set up QC Incharge F01)/CMM Report
1.Set up Approval(QC-MCN-
Check tooling & F01)/CMM Report
12.21 PCD ▼ Ø 312.0 mm Receiving 100% Operator 2. 100% Operator Monitoring
ascertain root cause 2.In Process Inspection Report
Gauge-05 1 35th PC Inspector 3. In Process Inspection
(QC-MCN-F02)
Report (QC-MCN-F02)
16 of 24
Crank , Timing , Clutch & Side
VMC MACHINE
Doc. No. : PDC-EPD-F02
12
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
L
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : D10447340A-MCD-03-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-12 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
15
1.Set up Approval(QC-MCN-
Set up Check tooling & Set up Approval(QC-MCN-
12.22 True Position ▼ Ø 0.2 CMM 1st PC 1 / Shift
F01) / CMM Report
ascertain root cause F01) / CMM Report
2.Process Controlled
8°
Timing to be 10.0 mm high
12.23 15A 0.3 mm deep Visual 100% N/A On part
Punched & Green color
mark
1. Set up Approval(QC-MCN-
1st PC 1.Set up Approval(QC-MCN-
Set up QC Incharge F01)/CMM Report
Ø 12.8 / 13.2 Check tooling & F01)/CMM Report
12.25 6 Holes
mm
CMM / SPG - 69 100% Operator 2. 100% Operator Monitoring
ascertain root cause 2.In Process Inspection Report
1 35th PC Inspector 3. In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
Crank , Timing , Clutch & Side Drilling
1. Set up Approval(QC-MCN-
16 1st PC Set up QC Incharge F01)/CMM Report
1.Set up Approval(QC-MCN-
Ø 71.8 / 72.2 CMM / Receiving Check tooling & F01)/CMM Report
12.26 PCD
mm Gauge - 12
100% Operator 2. 100% Operator Monitoring
ascertain root cause 2.In Process Inspection Report
1 35th PC Inspector 3. In Process Inspection Report
VMC MACHINE
(QC-MCN-F02)
(QC-MCN-F02)
1.Set up Approval(QC-MCN-
12 12.27 True Position ▼ Ø 0.4 w.r.t.'A" CMM 1st PC
Set up
1 / Shift
F01) / CMM Report
Check tooling &
ascertain root cause
Set up Approval(QC-MCN-
F01) / CMM Report
2.Process Controlled
1. Set up Approval(QC-MCN-
1st PC 1.Set up Approval(QC-MCN-
Ø 5.80 / 6.20 Set up QC Incharge F01)/CMM Report
Check tooling & F01)/CMM Report
12.28 2 Holes CMM / SPG-66 100% Operator 2. 100% Operator Monitoring
ascertain root cause 2.In Process Inspection Report
mm 1 35th PC Inspector 3. In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
21
17 of 24
Crank , Timing , Clutch & Side Drilli
Doc. No. : PDC-EPD-F02
VMC MACHINE
Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
L
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : D10447340A-MCD-03-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
12
Control Plan Number:D10447330A CP-12 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
1.Set up Approval(QC-MCN-
Check tooling &
12.30 Chamfer 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge F01)
ascertain root cause
Set up Approval(QC-MCN-F01)
2.Program Controlled
1. Set up Approval(QC-MCN-
Check tooling &
12.31 Drill Depth 62 40.0 mm Vernier Caliper 1st PC Set up QC Incharge F01)
ascertain root cause
Set up Approval(QC-MCN-F01)
2. Program Controlled
1. Set up Approval(QC-MCN-
1.Set up Approval(QC-MCN-
F01)
Std Bolt with 1st PC Set up QC Incharge Check tooling & F01)
12.32
Crank , Timing , Clutch & Side Drilling
1.Set up Approval(QC-MCN-
Ø 0.013 Set up Check tooling & Set up Approval(QC-MCN-
12.33 True Position 70 ▼ CMM 1st PC F01) / CMM Report
w.r.t.'A" 1 / Shift
2.Process Controlled
ascertain root cause F01) / CMM Report
12
1. Set up Approval(QC-MCN-
1st PC 1.Set up Approval(QC-MCN-
Set up QC Incharge F01)/CMM Report
Ø 13.032 / Check tooling & F01)/CMM Report
12.34 Dowel Diameter 71 ▼ CMM / SPG - 70 100% Operator 2. 100% Operator Monitoring
13.059 mm 1 10th PC Inspector 3. In Process Inspection
ascertain root cause 2.In Process Inspection Report
(QC-MCN-F02)
Report (QC-MCN-F02)
18 of 24
Crank , Timing , Clutch & Side Drilling
Doc. No. : PDC-EPD-F02
VMC MACHINE
Production Drawing No. : D10447340A-MCD-03-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-12 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
12
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
1.Set up Approval(QC-MCN-
Surface F01) Check tooling & Set up Approval(QC-MCN-
12.35 Surface Finish 72 ▼ 1.6 μRa 1st PC Set up QC Incharge
Comparator 2. Program & Process ascertain root cause F01)
Controlled
1.Set up Approval(QC-MCN-
Check tooling &
12.36 Chamfer 73 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge F01)
ascertain root cause
Set up Approval(QC-MCN-F01)
2.Program Controlled
19 of 24
Doc. No. : PDC-EPD-F02
Production Drawing No. : D10447340A-MCD-03-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-12 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.
4 Solid Carbide Lunge Reamer Ø 13.04 mm 4 N/A Crank Drilling & Timing
Tool Control
20 of 24
Doc. No. : PDC-EPD-F02
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
L
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : D10447340A-MCD-03-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-13 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
1. Set up Approval(QC-MCN-
1st PC 1.Set up Approval(QC-MCN-
Set up QC Incharge F01)
12 Holes Check tooling & F01)
13.01 M8 X 1.25 TPG - 09 100% Operator 2. 100% Operator Monitoring
Equlispaced 1 35th PC Inspector 3. In Process Inspection Report
ascertain root cause 2.In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
DRILL MACHINE
15
TAPPING
1. Set up Approval(QC-MCN-
1st PC 1.Set up Approval(QC-MCN-
Set up QC Incharge F01)
13 13.02 True Position ▼ Ø 0.2 CMM / RG 05 100% Operator
35th PC Inspector
2. 100% Operator Monitoring
3. In Process Inspection
Check tooling &
ascertain root cause
F01)
2.In Process Inspection Report
1 (QC-MCN-F02)
Report (QC-MCN-F02)
1. Set up Approval(QC-MCN-
1.Set up Approval(QC-MCN-
Std Bolt with F01)
1st PC Set up QC Incharge Check tooling & F01)
13.03 Tap Depth 63 Min. 35.0 mm 1
2. Program Controlled
Vernier Caliper 35th PC Inspector
3. In Process Inspection Report
ascertain root cause 2.In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
Control
Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.
Tool
21 of 24
Doc. No. : PDC-EPD-F02
Production * Drawing No. : D10447330A Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-14 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
1.Set up Approval
Chamfered Side of Ring 2.Work Instructions (PRD- Set up Approval-Ring
1st PC Setup QC-Engg Check &
14.01 Gear Teeth (not To be on Top Side Visual MCN-WI11) Fittment
100% Operator Segregate
Induction Heater & Hydraulic Press
Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.
Tool Control
22 of 24
Doc. No. : PDC-EPD-F02
Production * Drawing No. : D10447340A-MCD-04-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-15 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. RS Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer - CMM
Measure &
Dyanamic Balancing
14 Set Up- DB WI
Seek Clarification
Set Up Approval- DB
15.03 Center Distance 30.0 mm Vernier Caliper 1 Supervisior (PRD-MCN-WI06)
from Next higher
(QC-MCN-F07)
authority
2 {Ref. Drg No.
D10447330A}
Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.
Remarks: The ballooned dimension 2 to be checked by the operator 100% and has to be recorded in the log book.
Reviwed on 14/05/2016.
23 of 24
Doc. No. : PDC-EPD-F02
Prototype * Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
L
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production * Drawing No. : D10447340A-MCD-01-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-16,17 & 18 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. RS Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Babulal Jangid Supervisor-Packing
Characteristics Methods
Machine,
Part / Special
Process Name/ Operation Device, Jig,
Process Char. Sample Reaction Plan Record
Description Tools for BLN Product/ Process/ Evaluation/ Measurement
Number No. Product Process Class Control Method
Mfg. No. Specification/ Tolerance Technique
Size Freq.
-
Light Film of oil to be Surface shall only
17.02 applied with a soaked coated with RPO but Visual 100% Each Batch Re-Oiling
cloth no Excess Oil
Oiling Area & Packaging Area
17.03 Part Identification No Mixing Visual 100% Each Batch 100 % Sorting -
PKG-PDS-WI01,
PKG-PDS-WI02, Drg
As per Packaging No. D10447330A
16 Oiling & Packaging 17.04 Box Type Visual 100% Each Batch -
Specification Sheet PKG-01-01
& Monitoring by
Supervisor
Repacking
As per Packaging
17.06 Labelling Visual 100% Each Batch -
Specification Sheet
Remarks:Reviwed on 14/05/2016.
24 of 24