TILARA BRASS COMPONENTS

NAME OF SUPPLIER

TILARA BRASS COMPONENTS

ADDRESS
Company Address
PLOT NO. 3895, ROAD NO. W, G.I.D.C., PHASE - 3, DARED
JAMNAGAR

QUALITY MANAGEMENT SYSTEM

ISO 9000 ✘ Yes No ISO/TS 19649 Yes No

DEVELOPMENT PART DETAILS

PART NAME TUBE CONNECTOR (3/4-16 UNF-2A)

PART NUMBER T291187

Drg Rev NUMBER 0

PPAP Event Initial Submission

PPAP Rev No. 00

PPAP Lot Batch No. 123

PPAP Lot Qty. 10

No. of Lots Send 1

 Company Name

PPAP INDEX
Sr. No. Document
1 Part Submission Warrant (PSW)
2 Design Records for product
2.1 Ballon Drawing
3 Process Flow Diagram.
4 Process FMEA
5 Control Plan
6 Measurement System Analysis study
7 Initial Process Study
8 Dimensional Result
9 Material performance test result
Qualified Laboratory Documents
10
(Internal & External Lab Scope)
11 Master Sample
12 Checking Aids
13 List of approved Supplier
14 Packing Standard
Company
Logo
 Part Submission Warrant

Part Name TUBE CONNECTOR (3/4-16 UNF-2A) Part Number T291187

Safety and/or
Government Regulation Yes ✘ No Engineering Drawing Change Level 0 Dated _19/08/2019___

Additional Engineering Changes NIL Dated __________________

Shown on Drawing No. Purchase Order No. By Email Weight(Kg) 0.04 kg

Checking Aid No. AS PER LIST Engineering Change Level Dated

SUPPLIER MANUFACTURING INFORMATION CUSTOMER SUBMITTAL INFORMATION

Supplier Name & Supplier Code Customer Name / Division

Street Address Buyer / Buyer Code

.
City State Zip Country Application .
Are plastic parts identified with appropriate ISO marking codes?
Yes No ✘ N/A
REASON FOR SUBMISSION (Check at list one)
✘
Initial Change to Optional Construction or
Submission
Engineering Material
Sub-Supplier or Material Source
Tooling: Transfer, Replacement, Refurbishment,
Changes(s) Change
Change in Part Processing
or additional
Correction of Parts Produced at Additional
Tooling Inactive > than
Discrepancy Location
Other - please
1 year specify

REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report).
Submitted
Level to customer.
2 - Warrant with product samples and limited supporting data submitted
to customer.
Level 3 - Warrant with product samples and complete supporting data submitted
✘
to customer.
Level 4- Warrant and other requirements as defined by customer.
Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's
manufacturing location.
SUBMISSION RESULTS

dimensional material and functional appearance statistical process

The results for ✘ ✘ ✘
These results meet allmeasurements
drawing and specification requirements: tests No (Ifcriteria
"No" - Explanation package
✘ Yes
Mold/ Cavity / Production Process MACHINING Required)

DECLARATION
I hereby affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable Production
Part Approval Process Manual 4th Edition Requirements. I further warrant these samples were
produced at the production rate of 1200 / 8 hours. I have noted any deviations from this declaration below:

EXPLANATION / COMMENTS:

Supplier Authorized Signature Date 21/ 08/ 2019

Print Name Fax No.
Phone No.
Title E-mail

FOR CUSTOMER USE ONLY (IF APPLICABLE)

Part Warrant Disposition: Approve Rejecte Part Functional Approval :
Approved
d d Other
Waived
Customer Signature Date

Print Name Customer Tracking Number (Optional)

Put the Photo Copy Of Supplier Athorised Signature
 6

11
10

12
 4

5
3 2

17
11

18

19 1
13 14 15 16
 PROCESS FLOW DIAGRAM
Customer: 0 Drg No.: T291187
Part No.: T291187 Drg Rev/Date.: 00
Part Disc.: TUBE CONNECTOR (3/4-16 UNF-2A) Date: _19/08/2019___
Symbols
Desired Outcome / Process
Process # & Incoming Source of Machine(s) /
Manufacturing Location Product Characteristics &
Description Variation Equipment(s) used
characteristics Location

Quantity Variation,
Dimension Variation &
Free bend Dent, Receiving Inspection
Material Chemical
Raw Martial weight, Garde,Material Report,Doccument
and ,mechanical Property Weight Sacle,Digital
Inward & Outsourcing As per Specification No. 31-RIR
variation. Caliper,Micrometer
Inspection C3604, /Challan /MTC
Weight Variation
A/F 19.00±0.2 /Invoice.
physical damage
/Bend/Dent,mark,crack

Speed= 1400 RPM,

Tool Breakage Feed=2000 mm/min.
Operation1
Parting Company Name Tool Wear Cutter Machine Speed /Feed/Tool life Tool grinding everyday &
Wrong tool ,Wrong position tool change after 2000
parts.

First Pcs Inspection

Inspection 1 31.20 ± 0.2
Parting Company Name Dimension Digital caliper Report , Document no.
42-FPIR

Speed= 1400 RPM,

Operation 2
Tool Breakage Feed=2000 mm/min.
Turning,Facing, 1"Automatic Turning
Boring,Threading,C
Company Name Tool Wear
Machine
Speed /Feed/Tool life Tool top grinding
Wrong tool ,Wrong position everyday & tool change
hamfer
after 2000 parts.

16.80 (MIN.),
10.00± 0.2,
11.00 ± 0.2, First Pcs Inspection
Inspection 2 Report , Document no.
Digital calliper, Roughness 16.00 ± 0.2,
Turning,Facing, 5.50 ± 0.3, 42-FPIR
Boring,Threading,C
Company Name Dimension Comperator,Vision 16.00 ± 0.5, In-process Inspection
measuring System 3/4 - 16 UNF-2A, 45°,
hamfer Report, Document
45° ~ 46°, NO.32-IPIR
Flatness 0.01,
R6.3

Speed= 1400 RPM,

Operation 3,
Tool Breakage Feed=2000 mm/min.
Boring,Facing, 3/4" Mannual Turning
Turnig,
Company Name Tool Wear
Machine
Speed /Feed/Tool life Tool top grinding
Wrong tool ,Wrong position everyday & tool change
Chamfer
after 500 parts.

30.20 + 0.3/-0.25,
7.50 ± 0.2,
8.05 ± 0.09, First Pcs Inspection
Inspection 3 Report , Document no.
Digital calliper, Roughness 11.20 ± 0.3,
Boring,Facing, 42-FPIR
Turnig,
Company Name Dimension Comperator,Vision 5.70 ± 0.25,
In-process Inspection
measuring System, 10.90 ± 0.2,
Chamfer Report, Document
0.5, NO.32-IPIR
C 0.3,
45°

Dent , Crack, Missing

Visually Inspection Company Name Damage, Dent Mark Visually Operation, damage, --
Burrs

Dimension mismatch,
Pre-Dispatch Inspection
Dimensional and Visual Digital Vernier , Micrometre, Dent , Crack, Missing
Final inspection Company Name Inspection Gauges Operation, damage,
Report, Document NO.-
33-PDIR
Burrs

Quantity Variation,
Damaged Packing
Packing As per Customer
Packing & Dispatch Company Name Wrong parts dispatch Weighing scale,Stripping
Standard.
Skilled Manpower
Wrong Packing Quantity machine
Wrong Location.

Prepared By

Prepared By: Approved By: Page 10 of 36

 Approved By

Prepared By: Approved By: Page 11 of 36

 PAP Kit (Feb'04)

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Part No. T291187 Rev. 0 FMEA Number: --

Part Name . TUBE CONNECTOR (3/4-16 UNF-2A) Process Responsibility: Prepared by:

Key Date _19/08/2019___ Date (Orig.) _19/08/2019___

Team: Date (Rev.)

C Potential O Current D
Process Potential Potential S l Cause(s)/ c Process e R. Recommended Responsibility Action Results
Process sr. no. Function/ Failure Effect(s) of e a Mechanism(s) c Controls t P. Actions & Target Actions S O D R.
Mode Failure v s of Failure u Prevention Detection e N. Date Taken e c e P.
Requirement s r 'A' type B'/'C' type c v c t N.
Hex Size (19.00 ± 0.02) is Check the Rod dimension along on
6 Wrong Supply Without inspection 2 Supplier Inspection Report 5 60
wrong length
Dimensional, Visual & Material
10 Raw Material Inspection properties are not meeting with
the specified requirement. Change In Material Property 6 Wrong Supply Without inspection 2 Supplier Test Certificate Third Party testing 5 60

Material is accepted with

20 Raw material storage. Quantity Variation Raw Material Storage 6 Weighing 2
challan & TC
Quantity is checked on receipt. 2 24

Set up of Parting tool is

ensured by the Supervisor. In process inspection by the line
30
Operation1
31.20±0.20 will Cause failure in further 5 Incorrect Set up of parting tool,
2 Tool Re-Sharping everyday. inspector after every 2 hour, As per 4 40
Parting operation clamping and setup Inncorrect machine Set up
Also ensure proper handling Control Plan
of parts.

Set up of Turning tool is

Incorrect Set up of Turning tool, tool ensured by the Supervisor. In process inspection by the line
Will cause failure of fitment of
16.08 (MIN.) 4 breakage , or tool blunt, improper tool 4 Tool Re-sharping everyday. inspector after every 2 hour, As per 4 64
pipe
resahrpning frequency Also ensure proper handling Control Plan
of parts.

Set up of Bore tool is ensured

Incorrect Set up of Bore tool, tool by the Supervisor. Tool top In process inspection by the line
Will cause failure of fitment &
10.00 ± 0.2 5 breakage , or tool blunt, improper tool 4 Re-Sharping everyday. Also inspector after every 2 hour, As per 4 80
leakage problem
resahrpning frequency ensure proper handling of Control Plan
parts.

Set up of facing tool is

Incorrect Set up of Facing tool, tool ensured by the Supervisor. In process inspection by the line
Will cause failure of fitment of
11.00 ± 0.2 5 breakage , or tool blunt, improper tool 4 Tool top Re-Sharping inspector after every 2 hour, As per 4 80
pipe
resahrpning frequency everyday. Also ensure proper Control Plan
handling of parts.

Set up of Turning tool is

Incorrect Set up of Turning tool, tool ensured by the Supervisor. In process inspection by the line
Will cause failure of fitment of
16.00 ± 0.2 4 breakage , or tool blunt, improper tool 5 Tool top Re-Sharping inspector after every 2 hour, As per 4 80
pipe
resahrpning frequency everyday. Also ensure proper Control Plan
handling of parts.

Set up of Turning tool is

Incorrect Set up of Turning tool, tool ensured by the Supervisor. In process inspection by the line
Will cause failure of fitment of
5.50 ± 0.3 4 breakage , or tool blunt, improper tool 5 Tool top Re-Sharping inspector after every 2 hour, As per 3 60
pipe
resahrpning frequency everyday. Also ensure proper Control Plan
handling of parts.
Operation 2
Turning,Facing,
40 Boring,Threading, Set up of Bore tool is ensured
Chamfer Incorrect Set up of Bore tool, tool by the Supervisor. Tool top In process inspection by the line
Will cause failure of fitment of
16.00 ± 0.5 5 breakage , or tool blunt, improper tool 4 Re-Sharping everyday. Also inspector after every 2 hour, As per 3 60
pipe
resahrpning frequency ensure proper handling of Control Plan
parts.

Set up of Threading insert is

Incorrect Threading insert,Threading In process inspection by the line
Will cause failure of fitment & ensured by the
3/4 - 16UNF - 2A 5 UNF-2A insert breakage, Threading insert 5 inspector after every 2 hour, As per 3 75
leakage problem Supervisor.Also ensure proper
blunt, Control Plan
cleaning of collets.

Set up of Bore tool is ensured

Incorrect Set up of Bore tool, tool by the Supervisor. Tool top In process inspection by the line
Will cause failure of fitment of
45° 4 breakage , or tool blunt, improper tool 4 Re-Sharping everyday. Also inspector after every 2 hour, As per 4 64
pipe
resahrpning frequency ensure proper handling of Control Plan
parts.

Set up of Turning tool is

Incorrect Set up of Turning tool, tool ensured by the Supervisor. In process inspection by the line
Will cause failure of fitment of
45°~46° 4 breakage , or tool blunt, improper tool 4 Tool top Re-Sharping inspector after every 2 hour, As per 5 80
pipe
resahrpning frequency everyday. Also ensure proper Control Plan
handling of parts.

Set up of Turning tool is

Incorrect Set up of Turning tool, tool ensured by the Supervisor. In process inspection by the line
Will cause failure of fitment of
Flatness 0.01 4 breakage , or tool blunt, improper tool 3 Tool top Re-Sharping inspector after every 2 hour, As per 4 48
pipe
resahrpning frequency everyday. Also ensure proper Control Plan
handling of parts.

Set up of Turning tool is

Incorrect Set up of Turning tool, tool ensured by the Supervisor. In process inspection by the line
R 6.3 Inappropriate Apperance 3 breakage , or tool blunt, improper tool 4 Tool top Re-Sharping inspector after every 2 hour, As per 5 60
resahrpning frequency everyday. Also ensure proper Control Plan
handling of parts.

Set up of facing tool is

Incorrect Set up of Facing tool, tool ensured by the Supervisor. In process inspection by the line
Will cause failure of fitment of
30.20 + 0.3/-0.25 4 breakage , or tool blunt, improper tool 4 Tool top Re-Sharping inspector after every 2 hour, As per 4 64
pipe
resahrpning frequency everyday. Also ensure proper Control Plan
handling of parts.

Set up of Bore tool is ensured

Incorrect Set up of Bore tool, tool by the Supervisor. Tool top In process inspection by the line
Will cause failure of fitment of
7.50 ± 0.2 5 breakage , or tool blunt, improper tool 4 Re-Sharping everyday. Also inspector after every 2 hour, As per 4 80
pipe
resahrpning frequency ensure proper handling of Control Plan
parts.

Set up of Bore tool is ensured

Incorrect Set up of Bore tool, tool by the Supervisor. Tool top In process inspection by the line
Will cause failure of fitment of
8.05 ± 0.09 5 breakage , or tool blunt, improper tool 5 Re-Sharping everyday. Also inspector after every 2 hour, As per 3 75
pipe
resahrpning frequency ensure proper handling of Control Plan
parts.

Set up of Turning tool is

Incorrect Set up of Turning tool, tool ensured by the Supervisor. In process inspection by the line
Will cause failure of fitment of
11.20 ± 0.3 4 breakage , or tool blunt, improper tool 4 Tool top Re-Sharping inspector after every 2 hour, As per 5 80
pipe
resahrpning frequency everyday. Also ensure proper Control Plan
handling of parts.

Set up of Turning tool is

Operation 3, Incorrect Set up of Turning tool, tool ensured by the Supervisor. In process inspection by the line
Will cause failure of fitment of
Boring,Facing, 5.70 ± 0.25 3 breakage , or tool blunt, improper tool 4 Tool top Re-Sharping inspector after every 2 hour, As per 4 48
50 pipe
Turnig, resahrpning frequency everyday. Also ensure proper Control Plan
Chamfer handling of parts.

Set up of Boring tool is

ensured by the
Incorrect Bore tool, Bore tool In process inspection by the line
Will cause failure of fitment of Supervisor.Resharpening of
10.90 ± 0.2 5 breakage, bore tool blunt,improper 5 inspector after every 2 hour, As per 3 75
pipe tool after every 8 hours. Also
tool resharping frequency Control Plan
ensure proper cleaning of
collets.

Set up of Boring tool is

ensured by the
Incorrect Bore tool, Bore tool In process inspection by the line
Will cause failure of fitment of Supervisor.Resharpening of
0.5 1 breakage, bore tool blunt,improper 5 inspector after every 2 hour, As per 3 15
pipe tool after every 8 hours. Also
tool resharping frequency Control Plan
ensure proper cleaning of
collets.

Set up of Turning tool is

Incorrect Set up of Turning tool, tool ensured by the Supervisor. In process inspection by the line
Will cause failure of fitment of
C 0.3 2 breakage , or tool blunt, improper tool 4 Tool top Re-Sharping inspector after every 2 hour, As per 4 32
pipe
resahrpning frequency everyday. Also ensure proper Control Plan
handling of parts.

Prepared By: Page 12 of 36 Approved By:

 PAP Kit (Feb'04)
Set up of Boring tool is
ensured by the
Incorrect Bore tool, Bore tool In process inspection by the line
Will cause failure of fitment of Supervisor.Resharpening of
45° 1 breakage, bore tool blunt,improper 5 inspector after every 2 hour, As per 3 15
pipe tool after every 8 hours. Also
tool resharping frequency Control Plan
ensure proper cleaning of
collets.

Impropriate Appearance of
Dent, Damage, crack, Surface Cross check sampling of inspected
60 Visual Checking
flaws
product, Damage piece 5 Visual check miss out 2 Training to Visual Inspector
material
4 40
dispatch to customer

Defective components will be Control plan for each part with

selection of wrong instrument / usage In process inspection by the line
70 Final inspection Variation in Measurement noticed. passed & defect free 5 2 inspection instruments inspector after every 1 hour.
6 60
of non calibrated instrument
components will be rejected. described in it.

component should be
component not packed properly
damages,Less / more component should be packed Weight will be cross checking at
80 Packing / Despatch Quantity less / more than the 5 Improper Weighing / counting 2 6 60
component will reach customer perfectly without any exposure despatch PERSON
invoice
end
Prepared By
Approved By

Prepared By: Page 13 of 36 Approved By:

 Compny Logo

Initial Pre Launch Production CONTROL PLAN

Key Contact/Phone : Phone NO. : DATE (Org) : _19/08/2019___ DATE (Rev) :
Part Code : T291187 Core Team : Customer Engineering Approval Date(If Reqd)
Part Name/Description : TUBE CONNECTOR (3/4-16 UNF-2A) Supplier/Plant Approval Date Customer Quality Approval date(If Reqd)
Supplier/Plant : Other approvalDate(If Reqd) Other Approval Date(If Reqd)
Supplier Code :
Characteristics / Parameters Methods
Part/ Process Name/ Sample
Machine, Device, Jigs, Spl. Product Evaluation
Process Operation Reaction Plan
Tools for Mfg. No. Parameter Characteristics Char. Class / Process Specification/ Measurements Current Process Controls
Number Description Size Freq
Tolerance. Technique

If found any deviation,

As Per purchase Raw Matrial Inspection inform to purchase
10.1 Hex Size Order -- 19.00 ± 0.02 Digital Caliper 5 pcs. Per.Lot Report, Document NO. 31- department and ask for
RIR replacement with
correct material.

10 Raw Matrial --
Inspection
If found any deviation,
Raw Matrial Test Certificate As per supplier Test inform to purchase
10.2 Grade Supplied by Supplier. -- C3604 certificate 1 pcs. Per.Lot Thired Party test Certificate department and ask for
replacement with
correct material.

If found any deviation,

As per inform to purchase
Raw Matrial Raw Matrial As Per purchase purchase department and ask for
20 Storage Weight Scale 20.1 weight Order -- Raw Matrial weight Weight Scale Per.Lot Reciving Challan
order replacement with
correct material.

First Piece Inspection If found any deviation,

30 Machine Parting Machine 30.1 Total Length As per Drawing -- 31.20±0.20 Digital Caliper 5 pcs. Per.Lot Report Doc.No - 42FIR reject the material and
Set up - 1 ask for correct setting to
production dept.

First Pcs Inspection Report , If found any deviation,

Document no. 42-FPIR,In- reject the material and
40.1 Step Length As per Drawing -- 16.08 (MIN.) Digital Caliper 5 pcs. Per.Lot process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

First Pcs Inspection Report , If found any deviation,

Document no. 42-FPIR,In- reject the material and
40.2 Diameter As per Drawing -- 10 ± 0.2 Digital Caliper 5 pcs. Per.Lot process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

First Pcs Inspection Report , If found any deviation,

Document no. 42-FPIR,In- reject the material and
40.3 Diameter As per Drawing -- 11 ± 0.2 Digital Caliper 5 pcs. Per.Lot process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

First Pcs Inspection Report , If found any deviation,

Document no. 42-FPIR,In- reject the material and
40.4 Diameter As per Drawing -- 16 ± 0.2 Digital Caliper 5 pcs. Per.Lot process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

Prepared by: Approved By: 14 of 14

 First Pcs Inspection Report , If found any deviation,
40.5 Step Length As per Drawing -- 5.5 ± 0.3 Digital Caliper 5 pcs. Per.Lot Document no. 42-FPIR,In- reject the material and
process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

Machine 1/2" Automatic Turning First Pcs Inspection Report , If found any deviation,
40 Set up - 2 Machine Document no. 42-FPIR,In- reject the material and
40.6 Hole Depth As per Drawing -- 16 ± 0.5 Digital Caliper 5 pcs. Per.Lot process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

First Pcs Inspection Report , If found any deviation,

40.7 Thread As per Drawing -- 3/4 - 16UNF - 2A Thread Gauge 5 pcs. Per.Lot Document no. 42-FPIR,In- reject the material and
process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

First Pcs Inspection Report , If found any deviation,

40.8 Chamfer As per Drawing -- 45° Vision Measuring 5 pcs. Per.Lot Document no. 42-FPIR,In- reject the material and
System process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

First Pcs Inspection Report , If found any deviation,

40.9 Chamfer As per Drawing -- 45°~46° Vision Measuring 5 pcs. Every 2 Hour Document no. 42-FPIR,In- reject the material and
System process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

First Pcs Inspection Report , If found any deviation,

40.10 Flatness As per Drawing -- 0.01 Vision Measuring 5 pcs. Every 2 Hour Document no. 42-FPIR,In- reject the material and
System process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

First Pcs Inspection Report , If found any deviation,

Roughness Document no. 42-FPIR,In- reject the material and
40.11 Radius As per Drawing -- R 6.3 Comperator 5 pcs. Every 2 Hour process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

First Pcs Inspection Report , If found any deviation,

Document no. 42-FPIR,In- reject the material and
50.1 Total Length As per Drawing -- 30.2 + 0.3/-0.25 Digital caliper 5 pcs. Every 2 Hour process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

Prepared by: Approved By: 15 of 15

 First Pcs Inspection Report , If found any deviation,
50.2 Diameter As per Drawing -- 7.5 ± 0.2 Digital caliper 5 pcs. Every 2 Hour Document no. 42-FPIR,In- reject the material and
process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

First Pcs Inspection Report , If found any deviation,

50.3 Bore Diameter As per Drawing -- 8.05 ± 0.09 Pin Gauge 5 pcs. Every 2 Hour Document no. 42-FPIR,In- reject the material and
process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

First Pcs Inspection Report , If found any deviation,

Document no. 42-FPIR,In- reject the material and
50.4 Diameter As per Drawing -- 11.2 ± 0.3 Digital caliper 5 pcs. Every 2 Hour process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

First Pcs Inspection Report , If found any deviation,

Document no. 42-FPIR,In- reject the material and
50.5 Step Length As per Drawing -- 5.7 ± 0.25 Digital caliper 5 pcs. Every 2 Hour process Inspection Report, ask for correct setting to
Machine Set 3/4" Manual Turning Document NO.32-IPIR production dept.
50 up-3 Machine

First Pcs Inspection Report , If found any deviation,

Document no. 42-FPIR,In- reject the material and
50.6 Hole Depth As per Drawing -- 10.9 ± 0.2 Digital caliper 5 pcs. Every 2 Hour process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

First Pcs Inspection Report , If found any deviation,

Vision Measuring Document no. 42-FPIR,In- reject the material and
50.7 Chamfer length As per Drawing -- 0.5 System 5 pcs. Every 2 Hour process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

First Pcs Inspection Report , If found any deviation,

Vision Measuring Document no. 42-FPIR,In- reject the material and
50.8 Chamfer As per Drawing -- C 0.3 System 5 pcs. Every 2 Hour process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

First Pcs Inspection Report , If found any deviation,

Vision Measuring Document no. 42-FPIR,In- reject the material and
50.9 Chamfer As per Drawing -- 45° System 5 pcs. Every 2 Hour process Inspection Report, ask for correct setting to
Document NO.32-IPIR production dept.

Dent, Damage, If found any deviation,

60 Visual Checking -- 60.1 crack, Surface -- -- -- Eye Whole Lot -- -- reject the material and
flaws ask to packing dept.

Prepared by: Approved By: 16 of 16

 Digital
Caliper,Gauge, as per Pre-Dispatch Inspection If found any deviation,
70 Final inspection -- 70.1 All Dimension -- -- -- VMS,Roughness Qaulity Plan Per.Lot Report,Document NO. 33- reject the material and
PDIR ask to production dept.
Comperator

component not
packed properly
If found any deviation,
80 Packing / Despatch Weighing scale, Stripping 80.1 Quantity less / -- -- -- Weight Scale -- -- AS per Packing Standard reject the material and
machine more than the ask to packing dept.
invoice

Prepared BY

Approved By

Prepared by: Approved By: 17 of 17

 Supplier's
documentation may
be substituted
GAUGE REPEATABILITY AND REPRODUCIBILITY DATAifSHEET
it has
the same functionality
VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
T291187 NAME Digital Caliper Sharukh
Part Name Gage Number Appraiser B
TUBE CONNECTOR (3/4-16 UNF-2A) VR-10 Amrish
Characteristic Specification Gage Type Appraiser C
Total Length 29.95 30.5 Measuring Instrument Ravi
Characteristic Classification Trials Parts Appraisers Date Performed
3 10 3

APPRAISER/ PART AVERAGE

TRIAL # 1 2 3 4 5 6 7 8 9 10
1. A 1 30.08 30.05 30.06 30.05 30.01 30.06 30.08 30.5 30.1 30.12 30.111
2 2 30.08 30.06 30.06 30.05 30.02 30.06 30.08 30.5 30.1 30.12 30.113
3 3 30.08 30.05 30.06 30.05 30.01 30.06 30.08 30.5 30.11 30.12 30.112
4 AVE 30.08 30.0533 30.06 30.05 30.0133 30.06 30.08 30.5 30.1033 30.12 Xa  30.112
5 Range 0 0.01 0 0 0.01 0 0 0 0.01 0 Ra  0.003
6. B 1 30.08 30.05 30.06 30.05 30.01 30.06 30.08 30.5 30.1 30.12 30.111
7 2 30.08 30.05 30.06 30.05 30.01 30.05 30.08 30.5 30.1 30.12 30.11
8 3 30.08 30.05 30.06 30.05 30.01 30.06 30.08 30.5 30.1 30.11 30.11
9 AVE 30.08 30.05 30.06 30.05 30.01 30.0567 30.08 30.5 30.1 30.1167 X b  30.110333
10 Range 0 0 0 0 0 0.01 0 0 0 0.01 R b  0.002
11. C 1 30.08 30.05 30.06 30.05 30.01 30.06 30.08 30.5 30.1 30.12 30.111
12 2 30.08 30.05 30.06 30.05 30.01 30.06 30.08 30.49 30.1 30.11 30.109
13 3 30.08 30.06 30.06 30.05 30.01 30.06 30.08 30.5 30.1 30.12 30.112
14 AVE 30.08 30.0533 30.06 30.05 30.01 30.06 30.08 30.4967 30.1 30.1167 X c  30.110667
15 Range 0 0.01 0 0 0 0 0 0.01 0 0.01 R c  0.003
16. PART X 30.111
Rp 
AVE ( Xp ) 30.08 30.0522 30.06 30.05 30.0111 30.0589 30.08 30.4989 30.1011 30.1178 0.4877778
17 R a  Rb  Rc  # OF APPRAISERS  R 0.0026667
18 (Max x - Min x) = X DIFF 0.0016667

19 R  D4 UCLR= 0.00688
20 R  D3 LCLR= 0

* D4 =3.27 for 2 trials and 2.58 for 3 trials; D3 = 0 for up to 7 trials. UCLR represents the limit of individual R's. Circle those that are
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or dis-
card values and re-average and recompute R and the limiting value from the remaining observations.

Gauge R&R 18 of 36
Notes:

Gauge R&R 19 of 36
 Range Chart Sharukh
Amrish
0.012 Ravi

0.01
0.008
Range 0.006
0.004
0.002
0
1 2 3 4 5 6 7 8 9 10

PART

Gauge R&R 20 of 36
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
T291187 NAME Digital Caliper Sharukh
Part Name Gage Number Appraiser B
TUBE CONNECTOR (3/4-16 UNF-2A) VR-10 Amrish
Characteristic Gage Type Appraiser C
Total Length Measuring Instrument Ravi
Characteristic Classification Trials Parts Appraisers Date Performed
3 10 3

Measurement Unit Analysis % Tolerance (Tol)

Repeatability - Equipment Variation (EV) Repeatability to Tolerance Index
EV = Trials K1 % EV = 100 [EV*6.0/Tol]
R  K1
= 0.0027 x 0.5908 2 0.8862 = 100(0.002*6.0/0.550)
= 0.0015754667 3 0.5908 = 1.72
Reproducibility - Appraiser Variation (AV) Reproducibility to Tolerance Index
AV = X DIFF  K2   EV
2
2
nr  % AV = 100 [AV*6.0/Tol]
= SQRT[(0.002 x 0.5231)^2 - (0.002 ^2/(10 x 3)] = 100(0.001*6.0/0.550)
= 0.0008230169 Appraisers 2 3 = 0.90
n = number of parts K2 0.7071 0.5231 Precision to Tolerance Index (P/T Ratio)
r = number of trials % P/T = 100 [GRR*6.0/Tol]
Repeatability & Reproducibility (GRR) = 100(0.002*6.0/0.550)
2 2
GRR = EV  AV Parts K3 = 1.94
= SQRT[0.0016^2 + 0.0008^2] 2 0.7071 Gage system can be acceptable
= 0.0017774848 3 0.5231 Part Variation to Tolerance Index
Part Variation (PV) 4 0.4467 % PV = 100 [PV*6.0/Tol]
PV = Rp  K3 5 0.403 = 100(0.153*6.0/0.550)
= 0.4878 x 0.3146 6 0.3742 = 167.41
= 0.1534548889 7 0.3534
Total Variation (TV) 8 0.3375 % Total Variation (TV)
2 2
TV = GRR  PV 9 0.3249 Measurement Capability Index (%GRR)
= SQRT[0.0018^2+0.1535^2] 10 0.3146 %GRR = 100 [GRR/TV]
= 0.1534651829 = 100(0.002/0.153)
Tolerance = 1.16
Tol = (Upper - Lower) Gage system can be acceptable
= (30.5000 - 29.9500) Number of Distinct Categories
= 0.55 ndc = 1.41(PV/GRR)
All % Tolerance calculations are based upon predicting 6.0 sigma (99.73% of the area under the normal distribution curve). = 121

Gauge R&R 21 of 36
For information on the theory and constants used in the form see MSA Reference Manual, Fourth edition (AIAG) Gage system can be acceptable

Gauge R&R 22 of 36
 Company Name

Kappa Report
Appraiser A Appraiser B Appraiser C
Part # Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Reference LSL USL
1 1 1 1 1 1 1 1 1 1 1
2 1 1 1 1 1 1 1 1 1 1 1. Enter Spec Limits Above
3 1 1 1 0 1 1 1 1 1 1 2. Have 3 appraisers accept/reject
4 1 1 1 1 1 1 1 1 1 1 3. Enter pass/fail in columns B-J
5 1 1 1 1 1 1 1 1 1 1 4. Enter Reference value in colum
6 1 1 1 1 1 1 1 1 1 1 5. Evaluate effectiveness columns
7 0 0 0 0 0 0 0 0 0 0
8 1 1 1 1 1 1 1 1 1 1
9 1 1 1 1 1 1 1 1 1 1
10 1 0 1 1 1 1 1 1 1 1
11 1 1 1 1 1 1 1 1 1 1
12 1 1 1 1 1 1 1 1 1 1
13 1 0 1 1 1 0 1 1 1 1
14 1 1 1 1 1 1 1 1 1 0
15 1 1 1 1 1 1 1 1 1 1
16 1 1 1 1 1 1 1 1 1 1
17 1 1 1 1 1 1 1 0 1 1
18 1 1 1 1 1 1 1 1 1 1
19 1 1 1 1 1 1 1 1 1 1
20 1 1 1 1 1 1 1 1 1 1
0 = Fail
1 = Pass

Crosstabulation Crosstabulation Miss

B Total REF Total Effectiveness Rate
A 0 1 A 0 1 A 92% 8%
0 3 2 5 0 3 3 6 B 92% 8%
1 2 53 53 1 2 52 52 C 93% 7%
Total 5 55 60 Total 5 55 60 System 92% 8%

C Total REF Total Effectiveness

B 0 1 B 0 1 Acceptable >= 90%
0 3 1 4 0 3 3 6 Marginal >=80%
1 2 54 56 1 2 52 54 Unacceptable <80%
Total 5 55 60 Total 5 55 60

A Total REF Total

C 0 1 C 0 1
0 3 2 5 0 3 3 6
1 1 54 55 1 1 53 54
Total 4 56 60 Total 4 56 60
 Company Logo

%R&R Gray zone

0.00000
er Spec Limits Above
e 3 appraisers accept/reject 10+ parts
er pass/fail in columns B-J
er Reference value in column L
luate effectiveness columns AJ-AV
 Company Name
Company Logo

Statistical Process Control

Project : Date : 8/21/2019 Specification
Process / Product : TUBE CONNECTOR (3/4-16 UNF-2A) Characteristic : CTQ Min Nominal Max
Operation : Hole 8.05 8.05 8.14

Data Std Deviation (s) : 0.009 Capability (Cp) : 1.64

Part Actual Mean (m) : 8.106 Capability Index - (Cpk) : 1.24
1 8.1000 Upper Control Limit (UCL) : 8.133
2 8.1100 Lower Control Limit (LCL) : 8.079
3 8.1200 PROCESS IS CAPABLE
4 8.1000
5 8.0900
6 8.1000 Control Chart
7 8.1100 8.1400
8 8.1000
9 8.1100 8.1300
10 8.1000
8.1200
11 8.0900
12 8.1000 8.1100
13 8.1100
14 8.1000 8.1000
15 8.1200
8.0900
16 8.1100
17 8.1000 8.0800
18 8.1000
19 8.1200 8.0700
20 8.1200
8.0600
21 8.1100
22 8.1100 8.0500
23 8.1000 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
24 8.1000
25 8.1200 Actual Mean UCL LCL USL LSL
Put The Inspection report In excel Formate
Put The Photo Copy Of Matrial Test Certificate
 QU ALIF IED LABORAT OR Y
FOR T EST ING & CALIB RATION

App roved Ag enci es Fo r

Sr. No. Testing/Calibration/Purchase Equipment Used NABL Accreditation
Testing An d Cal ibra tion

1 Gujarat Government Calibration Weighing Scale --

Shree Venkatesh
2 Calibration Micrometer NABL Cert. No. C-0153
Engineering Works

Shree Venkatesh
3 Calibration Digital Caliper NABL Cert. No. C-0153
Engineering Works

4
Shree Venkatesh Calibration Thread Plug gauge NABL Cert. No. C-0153
Engineering Works

Shree Venkatesh
5 Calibration Pin Gauge NABL Cert. No. C-0153
Engineering Works

6 Sipcon Instrument Industries Calibration Vision Measuring System --

Prepared By

Approved By
 Company Name

Master Sample

Prepared By
Approved By
me Company Logo

mple
 CHECKING AIDS
PART NAME TUBE CONNECTOR (3/4-16 UNF-2A)
PART NO :- T291187
Rev.No 0 Rev. Dt. NA
INSTRUMENT Next Calibration INSTRUMENT LEAST Calibration
SR NO INSTRUMENT NAME Calibration date RANGE
IDENTIFICATION NO. Due date SR. NO. COUNT agency

WS-03 Gujarat
1 Weighing Scale 6/17/2019 6/16/2020 171096854 500kg 0.05
Government

Shree Venkatesh
2 Micrometer MMTR-01 12/17/2018 12/17/2019 S-2660 0-25mm 0.01
Engineering Works

Shree Venkatesh
3 Digital Caliper VR-10 12/17/2018 12/17/2019 14386254 0-150mm 0.1
Engineering Works

Shree Venkatesh
4 Thread Plug Gauge GR-01,NGR-02 6/5/2019 6/4/2020 -- - -
Engineering Works

Shree Venkatesh
5 Pin Gauge -- - -
Engineering Works

Sipcon Instrument
6 Vision Measuring System VMS-01 12/17/2018 12/16/2019 2495 0.05-150mm 0.05
Industries
PREPARED BY CHECKED BY APPROVED BY
DATE DATE 21/08/2019 DATE
 List of Approved Suppliers
(Raw Material & Outsourced operations)
Part NO. : T291187 Part Description: TUBE CONNECTOR (3/4-16 UNF-2A)
Sr. Name & Address of Raw Material Suppliers Supplies
1

Prepared By
Approved By
 Company Name

Packing Standard
PACKING STANDARD DATE:-21/08/2019
REVISION DATE OF CHANGE CONTENTS APPROVAL
1) 1) 1) 1)
1) Name of Supplier
2) 2) 2) 2)
3) 3) 3) 3)
2) Part Number TUBE CONNECTOR (3/4-16 UNF-2A)
PHOTOGRAPH (INDIVIDUAL PART) PHOTOGRAPH WHEN DULY PACKED
3) Part Description T291187

Nature of parts supplied

4)
(kindly tick the appropriate)
MACHINING PART
Unit of Measure
5) (kindly tick the Nos
appropriate)

6) Method of Packing Plastic Bag

Shelf Life of Item(If any)
7) Nil
(Pl.specify the period.)
INSTRUCTIONS TO BE FOLLOWED
8) Weight of each Component
1 PACKING STANDARD WILL BE REVISED DURING PRODUCTION ORDER
2 STAPLE PINS ARE NOT ALLOWED DURING PACKING OF THE MATERIAL..
9) Quantity / plastic Bag 10
3 LOT CONTROL TAGS SHOULD BE CLEARLY VISIBLE INSIDE THE EVERY PLASTIC BAG..
Thickness of Plastic Bags 4 DATE, PART NO & INVOICE NO. SHOULD BE CLEARLY MENTIONED ON THE BOX.

10)
(Thickness of plastic bags
0.05 Micron
5 NO EXCESSIVE TAPING ON THE BOX SHOULD BE THERE.
should be as per the weight of 6 BOX WIGHT SHOULD NOT EXCEED FROM 20 KGS.
total quantity)
7 DO NOT STACK BOXES IN THE VEHICLE.
8 COMPONENTS.
11) Size of Plastic Bag 9 QUALITY OF CORRUGATED BOXES SHOULD BE THREE PLY ONLY.
10 ENSURE THERE SHOULD NOT BE ANY DUST, FOREIGN PARTICLES IN THE BAG & BOX
Supplier Approval
Department Purchase QA Store
 Accepted/Not
Accepted

Prepared By Approved By Sign.

 Company Logo

APPROVAL

DULY PACKED

ER
AL..
RY PLASTIC BAG..
ON THE BOX.

THE BAG & BOX

Signed Copy to
Store