Doc No: BFPL/NPD/F/04,

CONTROL PLAN Rev No: 00

Rev Date: 01-Apr-2023
Origin Date : 01-Apr-2023

Proto type Pre Launch Production Date (Orgi) Date (Rev) Rev
Key Contact Anoop Urs - 9738786972
Control Plan no CP/KBI/DMRC/TD17071B09 17.04.2024 17.04.2024 0

Part no TD17071B09 Mr. Utsav Agarwal (Marketing)

Customer Engg.Approval Date NA
Mr.Anoop Urs (NPD Manager)
Part Name / Description Mr.Madhusudhan & Ghanesh (Production)
Mr.Venkat Karthick (Quality Manager)
Mr.Umesh.A.S (Quality)
Core Team Mr.Purshottama & Kanthraj (Quality)
Mr.Kumar K v (QMS & NPD) Rev No / Rev Date R1 / 03.05.2024
BOTTOM BRACKET MACHINED Mr. Suresh Dominic (Maintenance)
Mr.Chandan (Design)
Mr.Manoj (NPD Engineer)

Organization / Plant
PROJECT DMRC Other Approval Date (If Req) NA
Knorr Bremse India Pvt.Ltd
Characterstic Method
Machine,Device,Jig,
Process Number Process Name/ Operation Description No Spl Char Class Sample Least count Control Method Resp Reaction Plan
Tools for Jig Product Evaluation Measurement Technique
Process Product/Process Specification/ Tolerance
(Gauge No. if Applicable) Size Freq.

1. Raw material as per specification

1.PO 1.Conformance to material test certificate.
2.Quantity verify against P.O & Invoice
Raw materials Received from Jindal 2.Invoice 2. Batch. No & quantity. 100% Supplier Control
10.0 NA 10.1 3. Free from transit damage (Visual) ..... Confirm from RM Certificate Every Lot ..... Purchase D
3.Unloading 3.No damage (packing in good condition) JAL/ CP/ E102127
JAL/PFD/BFPL
4.MTC
4. Reciept of MTC

20.1 Chemical composition ..... © 6060-T66 Confirm from RM/NABL Certificate 1 No's Every Lot ..... D

20.2 Mechanical Properties ..... ⊕ T66 Confirm from RM/NABL Certificate 1 No's Every Lot ..... D

1. Surface Table
BFPL/QA/F/06
2.Feeler Gauges
20.0 RM Inspection 20.3 Profile Dimension ..... ⊕ Thickness As per Drawing Digital Vernier caliper 1 No's Every Lot 0.01mm RM Inspection Prodn & Quality D/G
3. Vernier Calipers
register
4. Dial Indicator

20.4 Linear and Angular Dimensions … ⊕ Dimensions As per Drawing Instruments and Equipments 100% As per sampling plan - F/G/R

Visual Free from Dents, damages & As per sampling plan

20.5 Appearance ..... ..... Every Lot … G
scratches

BFPL/QA/F/08 In
30.0 Cutting Classic magic 30.1 Length … ..... 846.6mm ±0.5mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection Prodn & Quality F/G/R
register

BFPL/QA/F/08 In
40.1 Tapping Hole dia … ..... 4.2 ±0.1 mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

BFPL/QA/F/08 In
40.2 Pitch (3X) … ..... 15±0.2mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

BFPL/QA/F/08 In
40.3 Distance … ..... 400.8±0.5mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

1st setting Drilling

BFPL/QA/F/08 In
40.4 Diameter (2x) … ..... 6.5 ±0.2mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

BFPL/QA/F/08 In
40.5 Distance … ..... 200 ±0.5 mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

BFPL/QA/F/08 In
40.6 Distance … ..... 200 ±0.5 mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register
 Doc No: BFPL/NPD/F/04,

CONTROL PLAN Rev No: 00

Rev Date: 01-Apr-2023
Origin Date : 01-Apr-2023

Proto type Pre Launch Production Date (Orgi) Date (Rev) Rev
Key Contact Anoop Urs - 9738786972
Control Plan no CP/KBI/DMRC/TD17071B09 17.04.2024 17.04.2024 0

Part no TD17071B09 Mr. Utsav Agarwal (Marketing)

Customer Engg.Approval Date NA
Mr.Anoop Urs (NPD Manager)
Part Name / Description Mr.Madhusudhan & Ghanesh (Production)
Mr.Venkat Karthick (Quality Manager)
Mr.Umesh.A.S (Quality)
Core Team Mr.Purshottama & Kanthraj (Quality)
Mr.Kumar K v (QMS & NPD) Rev No / Rev Date R1 / 03.05.2024
BOTTOM BRACKET MACHINED Mr. Suresh Dominic (Maintenance)
Mr.Chandan (Design)
Mr.Manoj (NPD Engineer)

Organization / Plant
PROJECT DMRC Other Approval Date (If Req) NA
Knorr Bremse India Pvt.Ltd
Characterstic Method
Machine,Device,Jig,
Process Number Process Name/ Operation Description No Spl Char Class Sample Least count Control Method Resp Reaction Plan
Tools for Jig Product Evaluation Measurement Technique
Process Product/Process Specification/ Tolerance
(Gauge No. if Applicable) Size Freq.

BFPL/QA/F/08 In
40.7 Distance … ..... 3.60 ±0.2mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

BFPL/QA/F/08 In
Distance (3.60) mm
40.8 … ..... Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
(Reference Dimesnion)
register

BFPL/QA/F/08 In
40.9 Distance … ..... 25 ±0.2mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

Prodn & Quality

BFPL/QA/F/08 In
40.10 Distance … ..... 25 ±0.2mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

BFPL/QA/F/08 In
40.11 Distance … ..... 839.4±0.3mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

BFPL/QA/F/08 In
40.12 Diameter (3x) … ..... 9 ±0.2mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

40.0 Comet

BFPL/QA/F/08 In
40.13 Distance … ..... 14.50 ±0.3mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

BFPL/QA/F/08 In
40.14 Distance … ..... 22.8 ±0.5mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

BFPL/QA/F/08 In
40.16 Distance … ..... (25) mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

2nd Setting
Milling

BFPL/QA/F/08 In
40.17 Distance … ..... (22.80) mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

BFPL/QA/F/08 In
40.18 Distance … ..... 400.50 ± 0.50 mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

BFPL/QA/F/08 In
40.19 Distance … ..... 400.50 ± 0.50 mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

BFPL/QA/F/08 In
40.20 Distance … ..... 8 ± 0.20 mm Digital Vernier caliper 100% As per sampling plan 0.01 mm process Inspection F/G/R
register
 Doc No: BFPL/NPD/F/04,

CONTROL PLAN Rev No: 00

Rev Date: 01-Apr-2023
Origin Date : 01-Apr-2023

Proto type Pre Launch Production Date (Orgi) Date (Rev) Rev
Key Contact Anoop Urs - 9738786972
Control Plan no CP/KBI/DMRC/TD17071B09 17.04.2024 17.04.2024 0

Part no TD17071B09 Mr. Utsav Agarwal (Marketing)

Customer Engg.Approval Date NA
Mr.Anoop Urs (NPD Manager)
Part Name / Description Mr.Madhusudhan & Ghanesh (Production)
Mr.Venkat Karthick (Quality Manager)
Mr.Umesh.A.S (Quality)
Core Team Mr.Purshottama & Kanthraj (Quality)
Mr.Kumar K v (QMS & NPD) Rev No / Rev Date R1 / 03.05.2024
BOTTOM BRACKET MACHINED Mr. Suresh Dominic (Maintenance)
Mr.Chandan (Design)
Mr.Manoj (NPD Engineer)

Organization / Plant
PROJECT DMRC Other Approval Date (If Req) NA
Knorr Bremse India Pvt.Ltd
Characterstic Method
Machine,Device,Jig,
Process Number Process Name/ Operation Description No Spl Char Class Sample Least count Control Method Resp Reaction Plan
Tools for Jig Product Evaluation Measurement Technique
Process Product/Process Specification/ Tolerance
(Gauge No. if Applicable) Size Freq.

BFPL/QA/F/08 In
40.21 Distance … ..... 7 ± 0.20 mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

BFPL/QA/F/08 In
40.22 Distance … ..... 7 ± 0.20 mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

Prodn & Quality

BFPL/QA/F/08 In
40.23 Distance … ..... 10.50 ± 0.20 mm Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
register

BFPL/QA/F/08 In
Distance (1.50) mm
40.24 … ..... Digital Vernier caliper 100% As per sampling plan 0.01mm process Inspection F/G/R
(Reference Dimesnion)
register

BFPL/QA/F/08 In
Distance (25) mm 100%
40.25 … ..... Digital Vernier caliper As per sampling plan 0.01mm process Inspection F/G/R
(Reference Dimesnion)
register
 Doc No: BFPL/NPD/F/04,

CONTROL PLAN Rev No: 00

Rev Date: 01-Apr-2023
Origin Date : 01-Apr-2023

Proto type Pre Launch Production Date (Orgi) Date (Rev) Rev
Key Contact Anoop Urs - 9738786972
Control Plan no CP/KBI/DMRC/TD17071B09 17.04.2024 17.04.2024 0

Part no TD17071B09 Mr. Utsav Agarwal (Marketing)

Customer Engg.Approval Date NA
Mr.Anoop Urs (NPD Manager)
Part Name / Description Mr.Madhusudhan & Ghanesh (Production)
Mr.Venkat Karthick (Quality Manager)
Mr.Umesh.A.S (Quality)
Core Team Mr.Purshottama & Kanthraj (Quality)
Mr.Kumar K v (QMS & NPD) Rev No / Rev Date R1 / 03.05.2024
BOTTOM BRACKET MACHINED Mr. Suresh Dominic (Maintenance)
Mr.Chandan (Design)
Mr.Manoj (NPD Engineer)

Organization / Plant
PROJECT DMRC Other Approval Date (If Req) NA
Knorr Bremse India Pvt.Ltd
Characterstic Method
Machine,Device,Jig,
Process Number Process Name/ Operation Description No Spl Char Class Sample Least count Control Method Resp Reaction Plan
Tools for Jig Product Evaluation Measurement Technique
Process Product/Process Specification/ Tolerance
(Gauge No. if Applicable) Size Freq.

BFPL/QA/F/08 In
50.0 Tapping Tapping Machine 50.1 Tapping … ..... M4 TPG 100% As per sampling plan ..... process Inspection Prodn & Quality F/G/R
register

De-burring & cleaning Handing Concerns Leads to Non Confirming Not accepted 100%
60.0 Manual 60.1 Visual ..... Visual inspection As per sampling plan ..... Prodn & Quality F/G/R
Parts

70.1 Anodizing … ..... As per DIN 17611 TC 100% As per sampling plan ..... MTC F/G/R

70.2 Thickness … ..... 20µm+10 µm TC 100% As per sampling plan ..... MTC Prodn & Quality F/G/R

70.0 Anodizing

70.3 Colour … Natural TC 100% As per sampling plan ..... MTC F/G/R

Free From Dents, Damages, Scratches, Tearing Free From Dents, Damages, Scratches, BFPL/QA/F/09 Final
70.4 Appearance … Tearing marks, Blisters and Bubbles. Visual inspection 100% As per sampling plan ..... Quality F/G/R
marks, Blisters and Bubbles. Inspection register

Ø 4.9 DIN8140 Tap the hole

BFPL/QA/F/08 In
Helicoil Inserting EG M4 (4x) Clean the Surface As per Drawing
80.0 80.1 Threading & Insertion of Helicoil ..... Visual inspection 100% - As per sampling plan - process Inspection Prodn & Quality F/G/R
Helicoil Insert Insertion of Helicoil
register
Helicoil Thread Break off the Helicoil tab
Installation plier

BFPL/QA/F/09
90.0 Final Inspection 1. Anodizing defects, As per Drawing 100%
Dimensions 90.1 As per Drawing … Manual 100% ..... Final Inspection Quality F/G/R
2. Difference in color shade
register

1.Pack the components as per packing standard.

100.1 Open cover with bubble sheet 2.Delivery schedule & Qty as per PO. … Overall Part Visual 100% 100% ..... F

100.0 Packing Standard

Packing & Labelling Bubble sheet Despatch
BFPL / NPD/F/ 07

100.2 Damages Parts damage during the Transit. … Not accepted Visual 100% 100% ..... F

110 Dispatch Dispatch as per schedule against PO - Not accepted 100% Packing Standard
..... 110.1 … Visual inspection Every Lot ..... Despatch F
BFPL / NPD/F/ 07

Amendment History
Note:-
Rev no Description of change Effect Date

00 New Released 17.04.2024 D- Reject the lot & Inform supplier for necessary corrective action
Note :- 100% Inspection parameter carried by operator
01 Dimesnion Added 03.05.2024 F - Stop & Correct the process

R - Stop / Replace / Inform supervisor for necessary action

SP - As per sampling plan G – Stop / Seggregate

⊕ - Special Process

Prepared By: Mr. Manoj Checked By: Mr. Kumar K.V Approved By (Process Owner):Mr. Aoop Urs