Doc. No.

: PDC-EPD-F02

Control Plan 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. : D10414420A Revision No. (Date): 01(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410A CP-CAS 01-09 Organization / Plant Approval Date : N/A Date (Originated) : 03/10/2015 Mr. RS Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 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. Sandeep Das Lab Technician

Grade : FG 260 As Per IS 210 : 2009

Special Char. Class

Characteristics Methods
Machine,
Part /
Process Name/ Device, Jig,
Process Evaluation/ Sample Reaction Plan Record
Operation Description Tools for BLN Product/ Process/
Number No. Product Process Measurement Control Method
Mfg. No. Specification/ Tolerance
Technique Size Freq. & Responsibility

WI - Sand
1.01 Moisture 2.0% - 4.0% Moisture Tester Remix
Preparation

Permeability- Facing Permeability WI - Sand

1.02 Minimum 50 Remix
Sand Meter Preparation
Sand Each Batch- Lab
1 Sand Preparation 1
Mixer Technician
Permeability - Backing Permeability WI - Sand Sand Testing
1.03 Minimum 60 Remix
Sand Meter Preparation
Report

Minimum 0.40 kg/ WI - Sand

1.04 GCS GCS machine Remix
Cm2 Preparation

Each Batch- 100 % Checking

Moulding Mould Hardness - Mould Hardness
2 Mould Making Machine 2.01
Machine Moulding
70-95 tester
5 Foundry Shift WI - Moulding & Break Mould
Supervisor if not OK

Each Batch- 100 % Checking

Core Hardness
3 Core Making Manual 3.01 Core Hardness Min. 40 tester
5 Foundry Shift WI - Core Making & Break Core if
Supervisor not OK

FG 260
Chemical Readjust
4.01 ▼ Refer Grade Chart Spectro Analysis 1 Every Heat Lab Technician Composition
Composition QC-CAS-F01

Tapping Operator Charging

Temperature
Induction Furnace

4.02 Temperature ▼ 1350 ˚ C - 1450˚ C 1 Each Heat Monitoring & Lab Reheat Report
Indicator
Technician

4
Melting and Operator
Pouring Pouring 1300 ˚ C -1400° C Temperature
4.03 ▼ 1 Each Heat Monitoring & Lab Reheat
Temperature Indicator
Engg.

Review Gating
Foundry Shift System in case No need to
4.04 Pouring Time ▼ 15-25 mins Stop Watch 2 2 / day
Supervisor of any adverse record
observations

1 of 21
 Doc. No. : PDC-EPD-F02

Control Plan 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. : D10414420A Revision No. (Date): 01(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410A CP-CAS 01-09 Organization / Plant Approval Date : N/A Date (Originated) : 03/10/2015 Mr. RS Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 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. Sandeep Das Lab Technician

Grade : FG 260 As Per IS 210 : 2009

Special Char. Class

Characteristics Methods
Machine,
Part /
Process Name/ Device, Jig,
Process Evaluation/ Sample Reaction Plan Record
Operation Description Tools for BLN Product/ Process/
Number No. Product Process Measurement Control Method
Mfg. No. Specification/ Tolerance
Technique Size Freq. & Responsibility

60-75 Mins.
KO Knock Out Refer Knock out Time Information Foundry Shift Segregate &
5 Knock Out 5.01 2 2 / day Charging Report
Machine Time sheet Table Supervisor Check
( PRD-CAS-F03 )

Blow Holes, Cold Shut,

Shrinkage, Broken
Blasting Edges, Crushes, Pin
6 Blasting 6.01 No Visual Defects Visual 100% Each Lot Visual Inspection Rework / Reject
Machine Holes, Penetration,
Poor Finish, Gas Holes, Casting Analysis
Burrs, Porosity, Finns. Report

Grinding Visual Inspection

7 Grinding Machine 7.01 Gating & Parting Line No extra material Visual 100% Each Lot Blasting Shop Incharge Rework / Reject

Micro Test the Cut

Microstructure 1 No Heat- Lab
Testing 8.01 Microstructure Test 1 Lab Testing Section Reject Micro Report
M/C Test Technician
heat if NOT OK

Hardness
FG260 Brinell Hardness
8 Testing Refer Grade Chart Testing Machine 3000 As Per Internal Check &
Testing 8.02 Hardness Test 1 Lab Testing Hardness Report
M/C ( QC-CAS-F01 ) Kg Load Ǿ 10.00 mm Plan Segregate
Ball

In Case Of Failure
check counter UTM Testing
UTM 8.03 Tensile Strength UTM 1 Shift sample. If this also
Check Properties
Report
fails, reject lot.

Paint Each Batch-

Coating Thicker
Spray 9.01 DFT 150-250 microns 1 Blasting Shop Re Coat
Tester
Gun Incharge
WI Painting
9 Painting N/A
(PRD-CAS-WI10)
Each Batch-
9.02 Drying Time 6-8 Hours Watch 100% Blasting Shop Adjust Time
Incharge

2 of 21
 Doc. No. : PDC-EPD-F02

Control Plan 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD-01-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410A CP-10 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

[Link] up Approval
Check & Segregate Set up Approval
(QC-MCN-F01)/CMM
10.01 Runout 0.1 w.r.t.'A' CMM 1st PC
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER

Set up QC Incharge Check tooling & (QC-MCN-F01) / CMM

Report
ascertain root cause Report
2. Process Controlled

29 ▼
[Link] up Approval
Check & Segregate Set up Approval
(QC-MCN-F01)/CMM
10.02 Concentricity 0.1 w.r.t.'A' CMM 1st PC Set up QC Incharge
Report
Check tooling & (QC-MCN-F01) / CMM
ascertain root cause Report
2. Process Controlled

[Link] up Approval Check & Segregate

Set up Approval
10.03 Surface Finish 44 3.2 μRa Surface Comparator 1st PC Set up QC Incharge (QC-MCN-F01) Check tooling &
(QC-MCN-F01)
2. Process Controlled ascertain root cause
TURNING Ist SETUP

[Link] up Approval [Link] up Approval

Check & Segregate
Set up QC Incharge (QC-MCN-F01) (QC-MCN-F01)
10.04 Depth 46 15.5 / 15.9 mm Depth Vernier 1st PC 35th PC Inspector [Link] Process Inspection Report
Check tooling &
[Link] Process Inspection Report
CHUCK

ascertain root cause

(QC-MCN-F02) (QC-MCN-F02)

10
[Link] up Approval
Check & Segregate Set up Approval
(QC-MCN-F01)/CMM
10.05 Perpendicularity 0.05 w.r.t.'A' CMM 1st PC Set up QC Incharge
Report
Check tooling & (QC-MCN-F01) / CMM
ascertain root cause Report
2. Process Controlled

46A ▼
[Link] up Approval
Check & Segregate Set up Approval
(QC-MCN-F01)/CMM
10.06 Flatness 0.5 CMM 1st PC Set up QC Incharge
Report
Check tooling & (QC-MCN-F01) / CMM
ascertain root cause Report
2. Process Controlled

Set up Approval Check tooling & Set up Approval

10.07 Depth 47 24.5 / 24.9 mm Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)

[Link] up Approval [Link] up Approval

Check & Segregate
Set up QC Incharge (QC-MCN-F01) (QC-MCN-F01)
10.08 Depth 48 ▼ 9.00 / 9.15 mm Depth Micrometer 1st PC 35th PC Inspector [Link] Process Inspection
Check tooling &
[Link] Process Inspection
ascertain root cause
Report (QC-MCN-F02) Report (QC-MCN-F02)

3 of 21
 Doc. No. : PDC-EPD-F02

Control Plan 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD-01-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410A CP-10 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER CHUCK

Set up Approval Check tooling & as Set up Approval

10.09 Chamfer 54 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge (QC-MCN-F01) certain root cause (QC-MCN-F01)

[Link] up Approval
Tool Profile / Check tooling & Set up Approval
10.1 Radius 55 R0.6-0.8 mm 1st PC Set up QC Incharge (QC-MCN-F01)
Visual [Link] Controlled
ascertain root cause (QC-MCN-F01)

[Link] up Approval Check & Segregate

Set up Approval
10.11 Surface Finish 55A 3.2 μRa Surface Comparator 1st PC Set up QC Incharge (QC-MCN-F01) Check tooling &
(QC-MCN-F01)
2. Process Controlled ascertain root cause
TURNING Ist SETUP

ɸ 335.5 / 340.5 Set up Approval Check tooling & as Set up Approval

10.12 Outer Diameter 56 Vernier Caliper 1st PC Set up QC Incharge (QC-MCN-F01) certain root cause (QC-MCN-F01)
mm

10 [Link] up Approval
[Link] up Approval
(QC-MCN-F01)
1st PC (QC-MCN-F01)
Set up QC Incharge Check & Segregate [Link] log book
Ø 313.45 / SG-27-1,2 with 2.100% Operator Monitoring
10.13 Outer Diameter 57 ▼ 100% Operator Check tooling & (QC-MCN-F10)
313.55 mm MSP-25 20th PC Inspector
[Link] Process Inspection
ascertain root cause [Link] Process Inspection
1 report (QC-MCN-F02)
report (QC-MCN-F02)
[Link] Analysis
[Link] Chart

[Link] up Approval
[Link] up Approval
Flat bottom Bore (QC-MCN-F01)
1st PC (QC-MCN-F01)
Set up QC Incharge Check & Segregate [Link] log book
Ø 100.00 / gauge with Dial LC 2.100% Operator Monitoring
10.14 Inner Diameter 60 ▼ 100% Operator Check tooling & (QC-MCN-F10)
100.054 mm 0.001 With MSR 31- 10th PC Inspector
[Link] Process Inspection
ascertain root cause [Link] Process Inspection
1 report (QC-MCN-F02)
1 report (QC-MCN-F02)
[Link] Analysis
[Link] Chart

[Link] up Approval
[Link] up Approval
(QC-MCN-F01)
1st PC (QC-MCN-F01)
Set up QC Incharge Check & Segregate [Link] log book
Ø 39.965 / APR -10 -1&2 with 2.100% Operator Monitoring
10.15 Inner Diameter 61 ▼ 100% Operator Check tooling & (QC-MCN-F10)
39.990 mm APG 10th PC Inspector
[Link] Process Inspection
ascertain root cause [Link] Process Inspection
1 report (QC-MCN-F02)
report (QC-MCN-F02)
[Link] Analysis
[Link] Chart

4 of 21
 Doc. No. : PDC-EPD-F02

Control Plan 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD-01-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410A CP-10 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

[Link] up Approval
[Link] up Approval
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER CHUCK

(QC-MCN-F01) Check & Segregate

1st PC Set up QC Incharge (QC-MCN-F01)
10.16 Surface Finish 62 ▼ 1.6 μRa Surface Comparator [Link] Process Inspection Check tooling &
1 4 Hours Inspector
Report (QC-MCN-F02) ascertain root cause
[Link] Process Inspection
Report (QC-MCN-F02)
[Link] Controlled

[Link] up Approval
Check & Segregate Set up Approval
Set up (QC-MCN-F01) / CMM
10.17 Concentricity 63 ▼ 0.5 w.r.t.'A' CMM 1st PC 1 / Shift Report
Check tooling & (QC-MCN-F01) / CMM
ascertain root cause Report
2. Process Controlled

[Link] up Approval Check & Segregate

Set up Approval
10.18 Angle 65 45 ̊ Bevel Protractor 1st PC Set up QC Incharge (QC-MCN-F01) Check tooling &
(QC-MCN-F01)
[Link] Controlled ascertain root cause

Vendor
TURNING Ist SETUP

Identification Code:13434 Set Up Approval (QC-MCN- Set Up Approval (QC-MCN-

10.19 A1 Visual 1st PC Set up QC Incharge Check & Segregate.
Marked Heat Code: F01) F01)
YYMMDD

10 10.2 Depth A2 10.0 mm Ref. Depth Vernier 1st PC Set up QC Incharge

Set up Approval
(QC-MCN-F01)
Check tooling &
ascertain root cause
Set up Approval
(QC-MCN-F01)

Set up Approval Check tooling & Set up Approval

10.21 Depth A3 21.3 mm Ref. Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)

Set up Approval Check tooling & Set up Approval

10.22 Depth A4 32.0 mm Ref. Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)

Set up Approval Check tooling & Set up Approval

10.23 Depth A5 108.6 mm Ref. Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)

5 of 21
 TURNING Ist

CNC TURNING CENTER WITH 3 JA

10
Doc. No. : PDC-EPD-F02

Control Plan 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD-01-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410A CP-10 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

Hardness Testing
10.24 Hardness A6 180-230 HB 100% Set up QC Incharge Check & Segregate. On Part
Machine

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.

1 E/DWLNL 25M08 WNMG080416GH UC5115 1 N/A Rough Turning

Tool Control

2 A 25EWLNL M08 WNMG080416GH UC5115 2 N/A Rough Boring

3 E/DWLNL 25M08 WNMG G080408 GHUC5115 3 N/A Finish Turning

4 A32/A25 EWNL M08 WNMG G080408 GHUC5115 4 N/A Finish Boring

Remarks: The ballooned dimensions 57, 60 & 61 to be checked by the operator 100% and has to be recorded in the log book.

6 of 21
 Doc. No. : PDC-EPD-F02

Control Plan 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD-02-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410 CP-11 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER CHUCK

[Link] up Approval
Vernier Caliper + Check tooling & Set up Approval
11.01 Chamfer 23 3.0 X 45 ̊ 1st PC Set up QC Incharge (QC-MCN-F01)
Bevel protractor [Link] Controlled
ascertain root cause (QC-MCN-F01)

Set up Approval Check tooling & Set up Approval

11.02 Chamfer 24 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge (QC-MCN-F01) ascertain root cause (QC-MCN-F01)

[Link] up Approval
Check & Segregate Set up Approval
Set up (QC-MCN-F01) / CMM
11.03 Concentricity 25 ▼ ɸ 0.1 w.r.t. 'A' CMM 1st PC 1 / Shift Report
Check tooling & (QC-MCN-F01) / CMM
ascertain root cause Report
2. Process Controlled
TURNING 2nd SETUP

[Link] up Approval
Tool Profile / Check tooling & Set up Approval
11.04 Radius 26 R01.0mm MAX. 1st PC Set up QC Incharge (QC-MCN-F01)
Visual [Link] Controlled
ascertain root cause (QC-MCN-F01)

Set up Approval Check tooling & Set up Approval

11 11.05 Chamfer 28 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge (QC-MCN-F01) ascertain root cause (QC-MCN-F01)

[Link] up Approval
Tool Profile / Check tooling & Set up Approval
11.06 Radius 30 R1.0 mm 1st PC Set up QC Incharge (QC-MCN-F01)
Visual [Link] Controlled
ascertain root cause (QC-MCN-F01)

[Link] up Approval Check & Segregate

Surface Finish Set up Approval
11.07 Surface Finish 31 3.2 μRa 1st PC Set up QC Incharge (QC-MCN-F01) Check tooling &
Comparator 2. Process Controlled ascertain root cause
(QC-MCN-F01)

Set up Approval Check tooling & Set up Approval

11.08 Depth 32 28.8 / 29.2 mm Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)

7 of 21
 TURNING 2nd

CNC TURNING CENTER WITH 3 JA

11
Doc. No. : PDC-EPD-F02

Control Plan 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD-02-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410 CP-11 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

Set up Approval Check tooling & Set up Approval

11.09 Depth 33 33.0 mm Ref. Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)

Set up Approval Check tooling & Set up Approval

11.10 Chamfer 34 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER

(QC-MCN-F01) ascertain root cause (QC-MCN-F01)

ɸ 149.5 / 150.5 Set up Approval Check tooling & Set up Approval

11.11 Inner Diameter 35 Inside Caliper 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)
mm

ɸ 165.5 / 164.5 Set up Approval Check tooling & Set up Approval

11.12 Inner Diameter 36 Vernier Caliper 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)
mm
TURNING 2nd SETUP

[Link] up Approval
[Link] up Approval
(QC-MCN-F01)
1st PC (QC-MCN-F01)
ɸ 328.2 / 328.3 Set up QC Incharge Check & Segregate [Link] log book
2.100% Operator Monitoring
11.13 Inner Diameter 37 ▼ SPG-80-1 100% Operator
[Link] Process Inspection
Check tooling & (QC-MCN-F10)
mm
CHUCK

1 20th PC Inspector ascertain root cause [Link] Process Inspection

report (QC-MCN-F02)
report (QC-MCN-F02)
[Link] Analysis
11 [Link] Chart

ɸ 344.5 / 349.5 Set up Approval Check tooling & Set up Approval

11.14 Inner Diameter 38 Vernier Caliper 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)
mm

ɸ 387.5 / 392.5 Set up Approval Check tooling & Set up Approval

11.15 Inner Diameter 39 Vernier Caliper 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)
mm

[Link] up Approval
Check & Segregate Set up Approval
Set up (QC-MCN-F01) / CMM
11.16 Perpendicularity 40A ▼ 0.05 w.r.t.'A' CMM 1st PC 1 / Shift Report
Check tooling & (QC-MCN-F01) / CMM
ascertain root cause Report
2. Process Controlled

8 of 21
 CNC TURNING CENTER WITH 3 JA
TURNING 2nd S

CHUCK
11 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD-02-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410 CP-11 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

[Link] up Approval
Tool Profile / Check tooling & Set up Approval
11.17 Radius 41 R5.0 mm 1st PC Set up QC Incharge (QC-MCN-F01)
Visual [Link] Controlled
ascertain root cause (QC-MCN-F01)
TURNING CENTER WITH 3 JAW HYDRAULIC POWER CHUCK

[Link] up Approval Check & Segregate

Set up Approval
11.18 Surface Finish 42 6.3 μRa Visual 1st PC Set up QC Incharge (QC-MCN-F01) Check tooling &
(QC-MCN-F01)
2. Process Controlled ascertain root cause

[Link] up Approval Check & Segregate

Set up Approval
11.19 Surface Finish 43 3.2 μRa Surface Finish Tester 1st PC Set up QC Incharge (QC-MCN-F01) Check tooling &
(QC-MCN-F01)
2. Process Controlled ascertain root cause

Set up Approval Check tooling & Set up Approval

11.20 Depth 50 49.5 / 50.0 mm Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)
TURNING 2nd SETUP

Set up Approval Check tooling & Set up Approval

11.21 Depth 51 56.0 mm Ref. Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)

11 11.22 Depth 52 98.0 mm Ref. Depth Vernier 1st PC Set up QC Incharge

Set up Approval
(QC-MCN-F01)
Check tooling &
ascertain root cause
Set up Approval
(QC-MCN-F01)

CMM / Height [Link] up Approval [Link] up Approval

Check & Segregate
1st PC Set up QC Incharge (QC-MCN-F01) / CMM (QC-MCN-F01) / CMM
11.23 Flatness 53 ▼ 0.1 mm Gauge with Dial LC Check tooling &
100% Inspector Report
ascertain root cause
Report
0.010 2. Process Controlled 2. On Part

[Link] up Approval [Link] up Approval

1st PC Set up QC Incharge (QC-MCN-F01) Check tooling & (QC-MCN-F01)
11.24 Depth A7 ▼ 19.8 / 20.2 mm SPG-75
1 35th PC Inspector [Link] Process Inspection ascertain root cause [Link] Process Inspection
Report (QC-MCN-F02) Report (QC-MCN-F02)

9 of 21
 TURNING 2nd SETUP

CNC TURNING CENTER WITH 3 JAW HYDR

Doc. No. : PDC-EPD-F02

Control Plan 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
11
Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD-02-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410 CP-11 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

Set up Approval Check tooling & Set up Approval

11.25 Depth A8 ▼ 29.75 mm Ref. Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)

Set up Approval Check tooling & Set up Approval

11.26 Depth A9 107.08 mm Ref. Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.
Tool Control

1 EWLNL 2525M08 WNMG 080416GH UC5115 1 N/A Outer Diameter Finish

2 A40TEWLNLM08 WNMG 080416GH UC5115 2 N/A Bore Finish

3 A40TEWLNLM08 WNMG 080408GH UC5115 3 N/A Bore Finish

Remarks: The ballooned dimensions 37 to be checked by the operator 100% and has to be recorded in the log book.

10 of 21
 Doc. No. : PDC-EPD-F02

Control Plan 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD--03-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410 CP-12 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

[Link] up Approval(QC-MCN-
[Link] up Approval(QC-MCN-
1st PC Set up QC Incharge F01)/CMM Report Check & Segregate
CMM / Receiver F01)/CMM Report
12.01 Angle 1 90 ̊ ± 15 '
Gauge-05
100% Operator 2.100% Operator Monitoring Check tooling &
[Link]-Process Inspection Report
1 35th PC Inspector [Link]-Process Inspection Report ascertain root cause
(QC-MCN-F02)
(QC-MCN-F02)
DRILLING, TAPPING & TIMING MARK

[Link] up Approval(QC-MCN-
Set up / Check tooling & Set up Approval(QC-MCN-
12.02 Dimension 2 67.0 mm CMM 1st PC
1 / Shift
F01) / CMM Report
ascertain root cause F01) / CMM Report
[Link] Controlled

[Link] up Approval(QC-MCN-
Set up / Check tooling & Set up Approval(QC-MCN-
12.03 Dimension 3 84.9 mm CMM 1st PC
1 / Shift
F01) / CMM Report
ascertain root cause F01) / CMM Report
[Link] Controlled
VMC Machine

[Link] up Approval(QC-MCN-
Set up / Check tooling & Set up Approval(QC-MCN-
12.04 Angle 4 ▼ 35 ° ± 30' CMM 1st PC
1 / Shift
F01) / CMM Report
ascertain root cause F01) / CMM Report
[Link] Controlled

12
[Link] up Approval(QC-MCN-
[Link] up Approval(QC-MCN-
1st PC Set up QC Incharge F01)/CMM Report Check & Segregate
CMM / Receiver F01)/CMM Report
12.05 Angle 5 55 ̊ ± 0 ̊30 '
Gauge-12
100% Operator 2.100% Operator Monitoring Check tooling &
[Link]-Process Inspection Report
1 35th PC Inspector [Link]-Process Inspection Report ascertain root cause
(QC-MCN-F02)
(QC-MCN-F02)

[Link] up Approval(QC-MCN-
R135.2 / 135.5 Set up / Check tooling & Set up Approval(QC-MCN-
12.06 Radius 6 ▼
mm
CMM 1st PC
1 / Shift
F01) / CMM Report
ascertain root cause F01) / CMM Report
[Link] Controlled

[Link] up Approval(QC-MCN-
Set up / Check tooling & Set up Approval(QC-MCN-
12.07 Radius 7 ▼ R148 ± 0.2 mm CMM 1st PC
1 / Shift
F01) / CMM Report
ascertain root cause F01) / CMM Report
[Link] Controlled

11 of 21
 VMC Ma
DRILLING, TAPPING
12
Doc. No. : PDC-EPD-F02

Control Plan 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD--03-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410 CP-12 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

[Link] up Approval(QC-MCN-
Set up / Check tooling & Set up Approval(QC-MCN-
12.08 Dimension 8 121.2 mm CMM 1st PC
1 / Shift
F01) / CMM Report
ascertain root cause F01) / CMM Report
[Link] Controlled

[Link] up Approval(QC-MCN-
Set up / Check tooling & Set up Approval(QC-MCN-
12.09 Dimension 9 131.9 mm CMM 1st PC
1 / Shift
F01) / CMM Report
ascertain root cause F01) / CMM Report
[Link] Controlled
DRILLING, TAPPING & TIMING MARK

[Link] up Approval(QC-MCN-
[Link] up Approval(QC-MCN-
1st PC Set up QC Incharge F01)/CMM Report Check & Segregate
CMM / Receiver F01)/CMM Report
12.10 Angle 10 65 ̊± 20'
Gauge-12
100% Operator 2.100% Operator Monitoring Check tooling &
[Link]-Process Inspection Report
1 35th PC Inspector [Link]-Process Inspection Report ascertain root cause
(QC-MCN-F02)
(QC-MCN-F02)

[Link] up Approval(QC-MCN-
[Link] up Approval(QC-MCN-
1st PC Set up QC Incharge F01)/CMM Report Check & Segregate
CMM / Receiver F01)/CMM Report
12.11 Angle 11 60 ̊ ± 0 ̊30 '
Gauge-12
100% Operator 2.100% Operator Monitoring Check tooling &
[Link]-Process Inspection Report
VMC Machine

1 35th PC Inspector [Link]-Process Inspection Report ascertain root cause

(QC-MCN-F02)
(QC-MCN-F02)

12 [Link] up Approval(QC-MCN-
[Link] up Approval(QC-MCN-
1st PC Set up QC Incharge F01)/CMM Report Check & Segregate
CMM / Receiver F01)/CMM Report
12.12 Angle 12 60 ̊ ± 0 ̊30 '
Gauge-12
100% Operator 2.100% Operator Monitoring Check tooling &
[Link]-Process Inspection Report
1 35th PC Inspector [Link]-Process Inspection Report ascertain root cause
(QC-MCN-F02)
(QC-MCN-F02)

Punch Position Check Tooling &

12.13 Radius
12A R140.0 mm Visual 100% Program Controlled
ascertain root cause
N/A

Check Tooling &

12.14 Punch Position 12B Equal Distance Visual 100% Program Controlled
ascertain root cause
N/A

12 of 21
 VMC Machi
DRILLING, TAPPING &
Doc. No. : PDC-EPD-F02
12 Control Plan 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD--03-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410 CP-12 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

Punch Height 8.0 mm Check Tooling &

12.15 DEG_8 PS DC
12C
Deep 0.2 mm
Visual 100% Operator Monitoring
ascertain root cause
On part

[Link] up Approval(QC-MCN-
[Link] up Approval(QC-MCN-
1st PC Set up QC Incharge F01)/CMM Report Check & Segregate
CMM / Receiver F01)/CMM Report
12.16 Angle 13 60 ̊ ± 0 ̊30 '
Gauge-12
100% Operator 2.100% Operator Monitoring Check tooling &
[Link]-Process Inspection Report
1 35th PC Inspector [Link]-Process Inspection Report ascertain root cause
(QC-MCN-F02)
(QC-MCN-F02)
DRILLING, TAPPING & TIMING MARK

[Link] up Approval(QC-MCN-
[Link] up Approval(QC-MCN-
1st PC Set up QC Incharge F01)/CMM Report Check & Segregate
CMM / Receiver F01)/CMM Report
12.17 Center Distance 14 ▼ 36.0 ± 0.3 mm
Gauge-12
100% Operator 2.100% Operator Monitoring Check tooling &
[Link]-Process Inspection
1 35th PC Inspector [Link]-Process Inspection ascertain root cause
Report (QC-MCN-F02)
Report (QC-MCN-F02)

[Link] up Approval(QC-MCN-
F01)/CMM Report [Link] up Approval(QC-MCN-
1st PC Set up QC Incharge Check & Segregate
CMM / Receiver 2.100% Operator Monitoring F01)/CMM Report
12.18 Angle 15 60 ̊ ± 0 ̊30 '
Gauge-05
100% Operator
[Link]-Process Inspection Report
Check tooling &
[Link]-Process Inspection Report
VMC Machine

1 35th PC Inspector ascertain root cause

(QC-MCN-F02) (QC-MCN-F02)
[Link] Controlled

12 [Link] Up Approval (QC-

Check Tooling & Set up Approval
12.19 Radius 16 R179.0 mm Visual 1st PC Set up QC Incharge MCN-F01)
ascertain root cause (QC-MCN-F01)
2. Process Controlled

Timing Mark 8̊
12.20 Angle to be 17 10 mm High Visual 100% N/A On Part
Punched 0.3 mm Deep

[Link] up Approval(QC-MCN-
[Link] up Approval(QC-MCN-
1st PC Set up QC Incharge F01)
Check tooling & F01)
12.21 12 Tapped Holes M8 X 1.25 TPG - 09 100% Operator 2.100% Operator Monitoring
ascertain root cause [Link]-Process Inspection
1 35th PC Inspector [Link]-Process Inspection
Report (QC-MCN-F02)
Report (QC-MCN-F02)

13 of 21
 VMC Machi
DRILLING, TAPPING &
Doc. No. : PDC-EPD-F02
12 Control Plan 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD--03-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410 CP-12 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

[Link] up Approval(QC-MCN-
[Link] up Approval(QC-MCN-
1st PC Set up QC Incharge F01)/CMM Report Check & Segregate
18 Ø 312.0 ± 0.1 CMM / Receiver F01)/CMM Report
12.22 PCD ▼
mm Gauge-05
100% Operator 2.100% Operator Monitoring Check tooling &
[Link]-Process Inspection
1 35th PC Inspector [Link]-Process Inspection ascertain root cause
Report (QC-MCN-F02)
Report (QC-MCN-F02)

[Link] up Approval
Check & Segregate Set up Approval
Set up (QC-MCN-F01) / CMM
12.23 True Position Ø 0.2 CMM 1st PC
1 / Shift Report
Check tooling & (QC-MCN-F01) / CMM
ascertain root cause Report
[Link] Controlled
DRILLING, TAPPING & TIMING MARK

[Link] up Approval(QC-MCN-
[Link] up Approval(QC-MCN-
1st PC Set up QC Incharge F01)/CMM Report Check & Segregate
Ø 12.8 / 13.02 F01)/CMM Report
12.24 6 Holes
mm
CMM / SPG - 69 100% Operator 2.100% Operator Monitoring Check tooling &
[Link]-Process Inspection Report
1 35th PC Inspector [Link]-Process Inspection Report ascertain root cause
(QC-MCN-F02)
(QC-MCN-F02)

[Link] up Approval(QC-MCN-
[Link] up Approval(QC-MCN-
19 1st PC Set up QC Incharge F01)/CMM Report Check & Segregate
CMM / Receiver F01)/CMM Report
12.25 PCD ▼ Ø 72 ± 0.2
Gauge-12
100% Operator 2.100% Operator Monitoring Check tooling &
[Link]-Process Inspection
VMC Machine

1 35th PC Inspector [Link]-Process Inspection ascertain root cause

Report (QC-MCN-F02)
Report (QC-MCN-F02)

12 [Link] up Approval
Check & Segregate Set up Approval
Set up (QC-MCN-F01) / CMM
12.26 True Position Ø 0.4 CMM 1st PC
1 / Shift Report
Check tooling & (QC-MCN-F01) / CMM
ascertain root cause Report
[Link] Controlled

[Link] up Approval(QC-MCN-
[Link] up Approval(QC-MCN-
1st PC Set up QC Incharge F01) Check & Segregate
F01)
12.27 2 Holes Ø 6.00 mm SPG - 66 100% Operator 2.100% Operator Monitoring Check tooling &
[Link]-Process Inspection Report
1 35th PC Inspector [Link]-Process Inspection Report ascertain root cause
(QC-MCN-F02)
(QC-MCN-F02)

20

14 of 21
 DRILLING, TAPPING & TIMIN
Doc. No. : PDC-EPD-F02

Control Plan

VMC Machine
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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

12
Production Drawing No. : D10414420A-MCD--03-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410 CP-12 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

[Link] up Approval(QC-MCN- [Link] up Approval(QC-MCN-

20 1st PC Set up QC Incharge F01) Check tooling & F01)
12.28 Drill Depth 25.0 mm Vernier Caliper 1 35th PC Inspector [Link]-Process Inspection Report ascertain root cause [Link]-Process Inspection Report
(QC-MCN-F02) (QC-MCN-F02)

1. Set up Approval(QC-MCN-
Check tooling & Set up Approval(QC-MCN-
12.29 Chamfer 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-
Check tooling & Set up Approval(QC-MCN-
12.30 Chamfer 40 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge F01)
ascertain root cause F01)
2. Program Controlled
DRILLING, TAPPING & TIMING MARK

[Link] up Approval(QC-MCN-
STD Bolt with 1st PC Set up QC-Incharge F01) Check Tooling & Set up Approval(QC-MCN-
12.31 Tap Depth 66 25.0 mm
Vernier Caliper 1 35th PC Inspector [Link]-Process Inspection Report ascertain root cause F01)
(QC-MCN-F02)

1. Set up Approval(QC-MCN- [Link] up Approval(QC-MCN-

1st PC Setup QC Incharge 35th PC F01) Check Tooling & F01)
12.32 Drill Depth 67 28.0 mm Vernier caliper 1 Inspector [Link]-Process Inspection Report ascertain root cause 2. In-Process Inspection Report
(QC-MCN-F02) (QC-MCN-F02)
VMC Machine

[Link] up Approval(QC-MCN-
[Link] up Approval(QC-MCN-
1st PC Set up QC Incharge F01)/CMM Report Check & Segregate
Ø 13.032 /
12 12.33 Dowel Diameter 68 ▼
13.059 mm
CMM / SPG - 70 100%
1
Operator
35th PC Inspector
2.100% Operator Monitoring
[Link]-Process Inspection Report
Check tooling &
ascertain root cause
F01)/CMM Report
[Link]-Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)

Ø 0.013 Set up Set up Approval(QC-MCN- Check tooling & Set up Approval(QC-MCN-

12.34 True Position 69 ▼
w.r.t.'A'
CMM 1st PC
1 / Shift F01) / CMM Report ascertain root cause F01) / CMM Report

[Link] up Approval(QC-MCN-
Check tooling & Set up Approval(QC-MCN-
12.35 Surface Finish 70 ▼ 1.6 μRa Surface Comparator 1st PC Set up QC Incharge F01)
ascertain root cause F01)
[Link] Controlled

15 of 21
 VMC Machine
DRILLING, TAPPING & TI
Doc. No. : PDC-EPD-F02

Control Plan Rev. No. : 01 (03/04/2015)

12
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept.
Issue No. : 04 (03/04/2015)
Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD--03-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414410 CP-12 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

1. Set up Approval(QC-MCN-
Check tooling & Set up Approval(QC-MCN-
12.36 Chamfer 71 1.0 X 45 ̊ Visual 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.

1 Solid Carbide Drill Ø 13.2 mm 1 N/A

2 Solid Carbide Drill Ø 12.8 mm 2 N/A

3 SCLHM Ø 13.01 mm 3 N/A

Tool Control

Crank Drilling & Timing

4 Solid Carbide Lunge Reamer Ø 13.04 mm 4 N/A

5 High Speed Steel Drill Ø 10.0 mm 5 N/A

6 Solid Carbide Drill Ø 6.00 mm 6 N/A

8 Solid Carbide Drill Ø 6.6 mm 8 N/A

Clutch Drilling & Tapping
9 High Speed Steel machine tap M8 X 1.25 9 N/A
Remarks:

16 of 21
 Doc. No. : PDC-EPD-F02

Control Plan 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD-04-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414420 CP-13 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility
Column / Pillar Drill Machine 1"

164.5 / 165.5
13.01 Dimension 58 Fixture Controlled
mm
Side Drilling

Set up Approval Check Tooling & Set up Approval

13.02 2 Holes 69 Ø 8.00 mm Vernier Caliper 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)

13

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.

1 Drill Ø 8.0 mm 1 N/A Side Drilling

Tool Control

Remarks:

17 of 21
 Doc. No. : PDC-EPD-F02

Control Plan 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414410A Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414420 CP-14 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility
Industrial Heating oven & Hydraulic Press

Chamfered Side of To be on Top 100% Operator Check &

14.01 Ring Gear Teethe Visual 100% Operator N/A
(not Ballooned) Side Monitoring Segregate
Ring Gear Heating & Fitment

Gap Between
0.254 mm Filler Gauge of 100% Operator Check &
14.02 Shoulder & Face 2 100% Operator N/A
of Gear Max 0.25 mm Monitoring Segregate

Ring Gear 100% Operator Readjust the

14 14.03 14 Heating Temp
Max. 350°C Digital Thermostat 100% Operator
Monitoring temperature
N/A

Ring Gear 100% Operator

14.04 30-40 mins Stop Watch 100% Operator Reheat N/A
Heating Time Monitoring

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.
Tool Control

Remarks:

18 of 21
 Doc. No. : PDC-EPD-F02

Control Plan 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD-03-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414420A CP-15 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

Ø 10.00 mm Tool Controlled

Check tooling & Set Up Approval- DB
15.01 Drill Diameter Vernier Caliper 1st PC Set Up- DB Supervisor & WI
ascertain root cause (QC-MCN-F07)
MAX. (PRD-MCN-WI06)

15.00 mm Stopper Controlled & WI Measure & Readjust Set Up Approval- DB

15.02 Drill Depth Vernier Caliper 1st PC Set Up- DB Supervisor
Dynamic Balancing Machine

Max. (PRD-MCN-WI06) the size of stopper (QC-MCN-F07)

Dynamic Balancing

13

WI Measure & Readjust

15.03 Dimension 46.0 / 46.5 Vernier Caliper 1st PC Set Up- DB Supervisor
(PRD-MCN-WI06) the Dimension
-
15

Seek Clarification
30.0 mm WI Set Up Approval- DB
15.04 Center Distance Vernier Caliper 1st PC Set Up- DB Supervisor from Next higher
Apart (PRD-MCN-WI06)
authority
(QC-MCN-F07)
14 {Ref. Drg No.

[Link] Up Approval cum In

D10414410A}

[Link] Up Approval cum In

Process Inspection Report -
1st PC Set Up-DB Supervisor Process Inspection Report -
Dynamic Dynamic Balancing
Dynamic Balancing
15.05 Balancing Value 20 g-cm 100% Operator Check & Segregate (QC-MCN-F07)
Balancing Machine 1 20th PC Inspector
(QC-MCN-F07)
[Link] Log Book (QC-
2.100%Operator Monitoring
MCN-F11)
3. Process Controlled
3. On Part

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.
Tool Control

1 Drill 14.00-18.00 mm 1 N/A Drill

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 Doc. No. : PDC-EPD-F02

Control Plan 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414420A-MCD-03-04 Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414420A CP-15 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

Remarks: The ballooned dimension 14 to be checked by the operator 100% and has to be recorded in the log book.

20 of 21
 Doc. No. : PDC-EPD-F02

Control Plan 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

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : D10414410A Revision No. (Date): 00(03/10/2015) Mr. Himanshu Duniwal PC

Control Plan Number : D10414420A CP-16, 17 & 18 Organization / Plant Approval Date : N / A Date (Originated) : 03/10/2015 Mr. R.S. Shekhawat Engg. Drawing mail@[Link]
Part Number / Model No : EURO 4550 DC Other Approval / Date (if Reqd.) : N /A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N / A Mr. Babulal Jangid Supervisor-Packing

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

100 % Sorting for

Pre-dispatch AS PER PDI PDI Report
16 16.01 AS PER PDI Report AS PER PDI Report AS PER PDI Report In - Process Control Deviated
Inspection Report (QC-PDS-F01)
Parameters

Surface of the part

should be dry and
17.01 Cleaning of parts
free from the Rust
Visual 100% Each Batch Re-cleaning
& Chips

Light Film of oil to Surface shall only

17.02 be applied with a coated with RPO Visual 100% Each Batch Re-Oiling
soaked cloth but no Excess Oil
Oiling Area & Packaging Area
Oiling & Packaging

17.03 Part Identification No Mixing Visual 100% Each Batch 100 % Sorting -
PKG-PDS-WI01, PKG-
PDS-WI02, Drg No.
D10414410A
16
PKG-01-01
17.04 Box Type
As per Packaging
Visual 100% Each Batch & Monitoring by -
Specification Sheet Supervisor

Quantity Per As per Packaging

17.05
Box Specification Sheet Visual 100% Each Batch Daily Packing Report
Repacking

As per Packaging
17.06 Labeling
Specification Sheet Visual 100% Each Batch -

Other Packaging As per Packaging

17.07
Material Specification Sheet
Visual 100% Each Batch -

Customer Name, As per Dispatch DES-PDS-WI01 and TAG

18 Dispatch 18.01 Visual Examination 100% Each Dispatch Re-Checking Dispatch Documents
Quantity, Date….. Schedule & Label on Box

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