APQP -DR SHFT

58
APQP DOCUMENTATION INDEX SH PHASES Design goals ( Team and Program need dates ) Design goals ( Timing chart ) Product related requirements ( Product Inform Team Feasibility Commitment Manufacturing feasibility ( Capacity Planning Risk assessment sheet Customer Specific Requirements Special charecteristics Raw Material requirements Design FMEA Reliability results Design Review(s) Diagnostic guidelines Design for Manufacturing and Assembly Design Verification Subcontractor APQP Status Engineering Drawings and Specifications Product error proofing, as appropriate Material specification Drawing and Specification changes Drawings with numbered parameters Process Flow Diagram Process F.M.E.A Measurement Systems Analysis Pre-Lauch Control Plan Product Tracebility. Work Instructions Packing Specifications Production Control Plan ( Charecteristic matr Production Trial Run Production Validation Testing Production Part Approval ( PPAP with PSW ) Preliminary Process Capability Study Design verification plan Program need dates Product quality planning summary and sign off Risk assessment sheet I PLAN & DEFINE II PRODUCT DESIGN & DEVELOPMENT III PROCESS DESIGN AND DEVELOPMENT V PRODUCT & PROCESS VALIDATION Data for Quality,reliability,maintainability

Transcript of APQP -DR SHFT

Page 1: APQP -DR SHFT

APQP DOCUMENTATION INDEX SHEETP

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SDesign goals ( Team and Program need dates ) Design goals ( Timing chart )Product related requirements ( Product Information Data )Team Feasibility Commitment Manufacturing feasibility ( Capacity Planning )Risk assessment sheetCustomer Specific RequirementsSpecial charecteristicsRaw Material requirements

Design FMEAReliability resultsDesign Review(s)Diagnostic guidelinesDesign for Manufacturing and AssemblyDesign Verification Subcontractor APQP StatusEngineering Drawings and SpecificationsProduct error proofing, as appropriateMaterial specification Drawing and Specification changes

Drawings with numbered parametersProcess Flow DiagramProcess F.M.E.AMeasurement Systems AnalysisPre-Lauch Control PlanProduct Tracebility.Work InstructionsPacking SpecificationsProduction Control Plan ( Charecteristic matrix )

Production Trial RunProduction Validation TestingProduction Part Approval ( PPAP with PSW )Preliminary Process Capability StudyDesign verification planProgram need datesProduct quality planning summary and sign offRisk assessment sheet

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Data for Quality,reliability,maintainability and measurability, results of error proofing,methods of rapid detection and feedback of product /process nonconformance

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Production Part ApprovalCustomer feed backProduction validation and testingPackaging evaluation.Customer comment formQuality function deployment

IV

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Data for Quality,reliability,maintainability and measurability, results of error proofing,methods of rapid detection and feedback of product /process nonconformance

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BNR Exports,Bangalore APQP TEAM PLAN

Part description : DRIVE SHAFT Original date : 02.05.09Drawing no : C0713250 Rev no / Date : NILRev no / date :ISSUE -10 / 24-10 - 2008 Page no : 1 of 1Customer : MONOPUMPS Application : PUMP

CROSS FUNCTIONAL / MULTI DISCIPLINARY TEAM

Sl no CFT / MDT MEMBERS DESIGNATION DEPARTMENT CONTACT DETAILS

1 Mr. Rajesh C.E.O [email protected]

Phone no

2 Mr. Ambi Daniel G.M [email protected]

Phone no

3 Mr. Lekshman Divisional Manager [email protected]

Phone no

4 Mr. Neelakantan Consultant [email protected]

Phone no

5 Mr.Shunmuganandam Engineer Design & [email protected]

Phone no

6 Mr.Dinesh Manager [email protected]

Phone no

7 Mr.Lokesh Assistant Manager [email protected]

Phone no

8 Mr.Raghaventhiran Manager [email protected]

Phone no

9 Mr.Prakash Engineer [email protected]

Phone no

10 Mr.Muruganandam Engineer [email protected]

Phone no

11 Ms.Usha Excecutive Trainee [email protected]

Phone no

12 Mr.Muthukumaran Senior Engineer [email protected]

Phone no

13 Mr.Joel Inspector [email protected]

Phone no

14 Mr.Nataraj Foreman Tool [email protected]

Phone no

15 Mr.Prasanna Supervisor [email protected]

Phone no

16 Subramanya Manager [email protected]

Phone noWeekly Conference Call Time

International Day

Participant Code Date

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BNR Exports,BangaloreAPQP - TIMING PLAN

25.06.09 Rev. No.: 00

Updated on :

S.No ACTIVITY G/Y/R STATUSPLAN ACTUAL

REMARKSSTART COMPLETE START COMPLETE

Drive Shaft C0713250

STAGE:1 PLAN AND DEFINE PROGRAM

1.1 Customer inputs

1.1.1 Component Drawing G Ambi Daniel 4.05.09 4.05.09 4.05.09 4.05.09

1.2 APQP Team formation G Ambi Daniel 4.05.09 4.05.09 4.05.09 4.05.09

1.3 G 5.05.09 5.05.09 5.05.09 5.05.09

1.4 Team Feasibility Commitment G Rajesh 5.05.09 5.05.09 5.05.09 5.05.09

1.5 Risk analysis G Rajesh 6.05.09 08.05.09 6.05.09 8.05.09

1.6 G Lekshman 8.05.09 8.05.09 8.05.09 8.05.09

1.7 G Ambi Daniel 11.05.09 11.05.09 11.05.09 11.05.09

1.8 G Lokesh / Dinesh 11.05.09 11.05.09 11.05.09 11.05.09

1.9 Design Inputs

1.9.1 Design concept approval G

NOT APPLICABLE1.9.2 G

1.9.3 Drawing release G

STAGE: 2 PROCESS DESIGN AND DEVELOPMENT

2.1 Process Flow Diagram G Dinesh / Lokesh 11.05.09 11.05.09 11.05.09 11.05.09

2.2 Charactertics Matrix G Muthukumar 11.05.09 11.05.09 11.05.09 11.05.09

2.3 Process FMEA G Dinesh / Lokesh 11.05.09 12.05.09 11.05.09 12.05.09

2.4 G Ambi Daniel 11.05.09 11.05.09 11.05.09 11.05.09

2.5

2.5.1 G 11.05.09 11.05.09 11.05.09 11.05.09

2.5.2 Sending enquiry to suppliers G 11.05.09 11.05.09 11.05.09 11.05.09

2.5.3 Supplier Finalisation G 11.05.09 11.05.09 11.05.09 11.05.09

2.5.4 G 11.05.09 11.05.09 11.05.09 11.05.09

2.6 NOT APPLICABLE

2.7 Mistake Proofing R Lokesh / Prakash 11.05.09 11.05.09 11.05.09 11.05.09

2.8 G Lokesh / Prakash 25.06.09 30.08.09 25.06.09 17.08.09

2.90 G 25.06.09 30.08.09 25.06.09 17.08.09

2.10 Pre-launch control Plan G Muthukumaran 13.05.09 13.05.09 13.05.09 13.05.09

2.11 Work Instructions

RESPONS -IBILITY

Prepare Product Information Data

Lekshman/ Shivakumar/ Neelakantan

Customer Specific RequirementsIdentification of Special CharacteristicsIdentification of Gauge and Testing Equipment

3D Modelling & 2D Drawings Preparation

Finalisation of Special characteristicsGage design and developmentFinalisation of Gauge and testing equipment.

Ambi Daniel / Dinesh

Lekshman / SubramanyaLekshman / Subramanya

Procurement of gauge and testing equipment

Dinesh / Muthukumaran

Development of subcontractor Process

Manufacturing process design and development verification

Traceability for product / manufacturing process non conformities

Prasanna / Muthukumaran

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BNR Exports,BangaloreAPQP - TIMING PLAN

25.06.09 Rev. No.: 00

Updated on :

S.No ACTIVITY G/Y/R STATUSPLAN ACTUAL

REMARKSSTART COMPLETE START COMPLETE

Drive Shaft C0713250

RESPONS -IBILITY

2.11.1 Work instruction for cutting G Neelakantan 13.05.09 13.05.09 13.05.09 13.05.09

2.11.2 G Neelakantan 13.05.09 13.05.09 13.05.09 13.05.09

2.11.3 G Neelakantan 13.05.09 13.05.09 13.05.09 13.05.09

2.11.4 G Neelakantan 13.05.09 13.05.09 13.05.09 13.05.09

2.11.5 Work Instructions for Packing G Neelakantan 13.05.09 13.05.09 13.05.09 13.05.09

2.12 Packing Specification

2.12.1 G Lekshman 01.08.09 01.08.09 01.08.09 01.08.09

2.12.2 Packaging sign off approval G Lekshman 17.08.09 17.08.09 17.08.09 17.08.09

2.13

2.13.1 Raw material G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.13.2 Premachining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.13.3 Heat treatment G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.13.4 Final machining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.13.5 Assembly and Try out G 11.05.09 11.05.09 11.05.09 11.05.09

2.13.6 Inspection and ready for trial G 11.05.09 11.05.09 11.05.09 11.05.09

2.14

2.14.1 Raw material G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.14.2 Premachining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.14.3 Heat treatment G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.14.4 Final machining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.14.5 Assembly and Try out G 11.05.09 11.05.09 11.05.09 11.05.09

2.14.6 Inspection and ready for trial G 11.05.09 11.05.09 11.05.09 11.05.09

2.15

2.15.1 Raw material G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.15.2 Premachining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.15.3 Heat treatment G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.15.4 Final machining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.15.5 Assembly and Try out G 11.05.09 11.05.09 11.05.09 11.05.09

2.15.6 Inspection and ready for trial G 11.05.09 11.05.09 11.05.09 11.05.09

STAGE : 3 MANUFACTURING PROCESS VALIDATION

3.1 Trial I

3.1.1 Cutting G Prasanna 25.06.09 25.06.09 25.06.09 25.06.09

3.1.2 Premachining G Nataraj 25.06.09 25.06.09 26.06.09 26.06.09

3.1.3 CNC Turning 1st Operation G 11.07.09 11.07.09 11.07.09 11.07.09

3.1.4 CNC Turning 2nd Operation G 16.07.09 16.07.09 16.07.09 16.07.09

3.1.5 CNC Turning 3rd Operation G 21.07.09 21.07.09 21.07.09 21.07.09

3.1.6 CNC Turning 4 th operation 23.07.09 23.07.09 23.07.09 23.07.09

Work instruction for CNC Turning

Work instruction for CNC Milling

Work Instructions for Conventional

Packing Specification preparation

Tool Mfg - Holding fixture CNC turning

Nataraj / Prakash

Prakash / Muthukumar

Tool Manufacturing - Drill jig - 1

Nataraj / Prakash

Prakash / Muthukumar

Tool Manufacturing - Drill jig - 2

Nataraj / Prakash

Prakash / Muthukumar

C.Prakash/ Muruganantham

C.Prakash/ Muruganantham

C.Prakash/ Muruganantham

C.Prakash/ Muruganantham

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BNR Exports,BangaloreAPQP - TIMING PLAN

25.06.09 Rev. No.: 00

Updated on :

S.No ACTIVITY G/Y/R STATUSPLAN ACTUAL

REMARKSSTART COMPLETE START COMPLETE

Drive Shaft C0713250

RESPONS -IBILITY

3.1.7 CNC Turning 5 th operation 28.07.09 28.07.09 28.07.09 28.07.09

3.1.6 Cross hole drill and Reaming G Jaganath 28.07.09 28.07.09 28.07.09 28.07.09

3.1.7 CNC Turning 6 th Operation G 29.07.09 29.07.09 29.07.09 29.07.09

3.1.8 Rethreading G Lokesh/Nataraj 30.07.09 30.07.09 30.07.09 30.07.09

3.1.9 Deburring G Lokesh/Nataraj 30.07.09 30.07.09 30.07.09 30.07.09

3.2.0 Final inspection G Muthukumar 31.07.09 31.07.09 31.07.09 31.07.09

3.2.1 Assembly G Lokesh/Nataraj 17.08.09 17.08.09 17.08.09 17.08.09

3.2.2 Cleaning and Packing G Lokesh/Nataraj 17.08.09 17.08.09 17.08.09 17.08.09

3.2.3 Despatch G 19.08.09 19.08.09 19.08.09 19.08.09

STAGE: 4 PPAP DOCUMENTATION

4.2 MSA Study G Muthukumar 13.07.09 13.07.09 2.07.09 02.07.09

4.3 Ppk Study G Muthukumar 17.07.09 22.07.09 17.07.09 22.07.09

4.4 Final inspection G joel karkada 31.07.09 31.07.09 31.07.09 31.07.09

4.5 PPAP Document Preparation G Muthukumar 31.07.09 31.07.09 31.07.09 31.07.09

STAGE : 5 FEEDBACK ASSESMENT AND CORRECTIVE ACTION

5.1 Customer approval of PPAP

5.2 Commence Bulk Production

5.3

5.4 Managemenet Review

LEGEND

S.NO STATUS DESCRIPTION Colour Revision Details: DESCRIPTION

1 G- GREEN - COMPLETED 1 Rev 1 : APQP Timing plan is updated to the Micro Level

2 Y - YELLOW - INPROGRESS 2 Rev 2 : Trial date is revised

3 R - RED - DELAY 3 Rev 3 : Trial date is revised

Team Members Signature

C.Prakash/ Muruganantham

C.Prakash/ Muruganantham

Lekshman and Raghaventhiran

Resolution of quaility, Delivery Issue

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BNR Exports,BangaloreTEAM FEASIBILITY COMMITMENT

CUSTOMER MONOPUMPS

DATE 2/5/2009

PART NAME DRIVE SHAFT REV DATE

PART NO C 07 13250 ISSUE 10 DATE 24-10-2008

SL NO CONSIDERATIONS BASIS FOR REVIEW Y / N REMARKS

1

Is product adequately defined

Y

2

Can Engineering Performance Specifications be met as written?

Y

3 Y

4 Y

5

Is there adequate capacity to produce product? Capacity Matrix

Y

6 Y

7 Y

8

Is raw material requirements feasible

Y

9 Y

10

Is there any requirement of special skills Skill Matrix

N

11

Is delivery Requirements Feasible Capacity Matrix

Y

Shiva kumar.B Neelakantan Ambi Daniel

PREPARED BY CHECKED BY APPROVED BY

Our product quality planning team has considered the following questions, not intended to be all-inclusive in performing a feasibility evaluation. The drawings and/or specifications provided have been used as a basis for analyzing the ability to meet all specified requirements. All “NO” answers are supported with attached comments identifying our concerns and/or proposed changes to enable us to meet the specified requirements

Product Drawing, Customer Specific Requirements if any, Contract Review check list

Product Drawing, Customer Specific Requirements if any,Contract Review check list

Can the Product be manufactured with Cpk’s that meet requirements

Customer DrawingSpecial Characteristics ListContract Review Check ListSPC Study Reports

Is SPC used on similar products and when SPC used are the processes in control and Stable ( Cpk’s greater than 1.33)

Customer DrawingSpecial Characteristics ListContract Review Check ListSPC Study Reports

Can the product be manufactured without incurring unusual cost for capital equipment / tooling alternative manufacturing methods

Customer DrawingCustomer Specific requirements if anyContract review check listCapacity MatrixTool and Equipment ListIs Gauges / test equipment are compatible to meet the product

requirementsExisting Control Plan,Gauges and Test Equipment List, MSA Study reports

Approved Supplier ListRaw Material SpecificationsIncoming Inspection Control Plan

Is Equipment, Tooling and Facility requirements compatible to meet the Product Requirements

Existing Control Plan,Process Flow ChartEquipment and Tooling ListCapacity Matrix

Page 10: APQP -DR SHFT

BNR Exports

CAPACITY PLANNING

PART NAME DRIVE SHAFT

CUSTOMER MONOPUMPS REV DATE : 24-10-2008

S.NO PROCESS NAME MACHINE NAME

TOTAL CAPACITY FREE CAPACITY REQUIRED CAPACITY

UOM HOURS / MONTH UOM HOURS / MONTH UOM HOURS / MONTH

1 CUTTING 3 machines 1131 Hours 452 AVAILABLE

2 PRE MACHINING 3 lathes 1131 Hours 452 AVAILABLE

3 CNC TURNING 18 Machines 6660 3555 AVAILABLE

4 5 machines 1885 754 AVAILABLE

5 MANUAL ASSEMBLY 2 Work stations 754 301 AVAILABLE

6 CLEANING PACKING 1 Work stations 377 150 AVAILABLE

Note:

Shiva kumar.B Neelakantan Ambi Daniel

PART NO: C 0713250

REV NO : ISSUE 10

CONVENTIONAL DRILLING & REAMING

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DATE: 03/05/09

REV DATE : 24-10-2008

REMARKS

Ambi Daniel

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Page 12 of 54

Date : 04 / 05 / 09

RISK ASSESSMENT CHECK LIST

BNR Exports Bangalore

CUSTOMER : M/S MONOPUMPS

PRODUCT : DRIVE SHAFT / C 0713250

APPLICATION : PUMP

MEMBERS PRESENT : Rajesh, Daniel, Neelakantan, Lokesh, Dinesh, Raghaventhiran, Prakash, Lekshman, Subramanya and Muruganandam.

DESCRIPTION High High

1 QUALITY HISTORY :-

1.1

1.2 Are there frequent quality rejects at the receiving plant for similar products?

1.3 Was there a recall action due to a similar component or system?

2 SUPPLIER PROFILE :-

2.1 Does it require new material and supply source?

2.2

2.3 How is the supplier’s earlier performance is satisfied in the similar materials?

3 ENGINEERING PROFILE :-

3.1 Is it a new design?

3.2 Are the manufacturing techniques new to us?

3.3

STEP NO.

Does the products application have a high warranty or things gone Wrong on current model or similar models?

Is the product or manufacturing technology new to the supplier and his manufacturing location?

Are similar products subjects to numerous design changes that threaten program timing?

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Page 13 of 54

Date : 04 / 05 / 09

RISK ASSESSMENT CHECK LIST

BNR Exports Bangalore

3.4 Is there high product or process complexity?

3.5

4 POTENTIAL – PROFILE :-

4.1

4.2 Volume regularity assurable? Long term contracts possible?

4.3 Can competition follow this easily?

4.4Technological obsolescence possibility is there?

Is the product strategically important due to high visibility or functional performance?

Does it require higher investments for development and regular production? Justifiable?

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Page 14 of 54

Date : 04 / 05 / 09

RISK ASSESSMENT CHECK LIST

BNR Exports Bangalore

5 PRODUCT PERFORMANCE VERSUS TARGETS :-

5.1

5.2

5.3 Is the program timing compressed?

5.4 Are the cost targets aggressive?

5.5

NATURE in No.s

HIGH RISK : 0

MEDI RISK : 13

LOW RISK: 7

20

Will the design goals (functional performance) and reliability goals be difficult to achieve?

Will the quality goals (warranty, scrap rates, rework PPM etc.) be difficult to achieve?

Manufacturing productivity targets justifiable and achievable in-line with volume requirements?

CONCLUSION BY C F T : Moderate risk item if not handled carefully during the process might get converted to high risk item.

ACTION PLANNED :- ( BASED ON HIGH RISK ELEMENTS ) :

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Page 15 of 54

Date : 04 / 05 / 09

RISK ASSESSMENT CHECK LIST

CUSTOMER : M/S MONOPUMPS

PRODUCT : DRIVE SHAFT / C 0713250

APPLICATION : PUMP

MEMBERS PRESENT : Rajesh, Daniel, Neelakantan, Lokesh, Dinesh, Raghaventhiran, Prakash, Lekshman, Subramanya and Muruganandam.

Medium Low

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Page 16 of 54

Date : 04 / 05 / 09

RISK ASSESSMENT CHECK LIST

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Page 17 of 54

Date : 04 / 05 / 09

RISK ASSESSMENT CHECK LIST

in No.s in %

0 0

13 65

7 35

100

Moderate risk item if not handled carefully during the process might get converted to high risk item.

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BNR Exports CUSTOMER SPECIFIC REQUIREMENT SHEETCustomer: Mono Pumps Ltd., UKDate: 22.09.2008

Requirements Originator

1 Allen Bolts assembled in Drive Shafts must be applied with ProductionLocktite on top 50% of the threaded portion and back faceof the bolt head.

1 Nil

1 Part numbers on all Muncher Half Couplings must beengraved on each part. Production

1 All the parts other than Muncher Half Couplings must have the label with Part number pasted on the packed product Logistics

2 Universal Joint assemblies threads must be protected withPlastic caps Logistics

1 Goods are sent by sea freight unless specified in PO or Logisticsa separate communication by customer

2 Wood packaging material must be fumigated before despatchby Freight forwarder Customer

3 Due date in PO is at UK, deduct 6 weeks for shipping Logistics4 Each case must be pasted with a label consisting PO Number Logistics5 Delivery Terms: Incoterms 2000: Ex Works Logistics6 Destination Airport: Manchester, UK

Destination Seaport: Felexstowe, UK Logistics7 Nominated Freight Forwarder: DSV Sea & Air Logistics Logistics

1 Submit GSP certificates for each consignment Logistics

Special Manufacturing /Technical Requirements:

Special Handling Requirements:

Special Marking Requirements:

Special Packaging and Preservation:

Special Delivery Requirements:

Special Documentation Requirements:

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Prepared by Reviewed by: Approved by

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BNR Exports - Bangalore

SPECIAL CHARACTERISTICS

PART NAME : DRIVE SHAFT PART NO.: C 0713250 Rev / Issue : 10

CUSTOMER M/S MONOPUMPS Family / Group Pump REV DATE: 24.10.2008

S.NO DESCRIPTION SPECIFICATION INSTRUMENT REMARKS

1 1 Outside Diameter 65.00 / 64.98 Micrometer

2 4 Bore Diameter 40.05 / 40.03 Bore gauge / Plug gauge

3 5 Concentricity 0.03 w.r.t. A Dial indicator with stand

4 11 Outside Diameter 69.8 / 69.75 Micrometer

5 13 Bore Diameter 51.13 / 51.08 Bore gauge / Plug gauge

6 46 Bore Diameter 30.03 / 29.99 Bore gauge / Plug gauge

7 52 Bore Diameter 19.12 / 19.09 Bore gauge / Plug gauge

Shiva kumar.B Neelakantan Ambi Daniel

PREPARED BY CHECKED BY APPROVED BY

DRAWING

S.NO

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BNR Exports

DOC NO : BNR / PFD / 01

DATE : 11.05.09

REV NO : 0

PART NAME DRIVE SHAFT

CUSTOMER MONOPUMPS

PART NO C 0713250 REVISION LEVEL / DATE - : ISSUE -10 / 24-10 - 2008

PROCESS FLOW MACHINE OUTCOME

--- - - -

- -

Dimensional / Visual deviations CUTTING MANUAL Accepted cut pieces

Dimensional / Visual deviations PRE-MACHINING Conventional lathe BINS

Dimensional / Visual deviations CNC First Operation 108 / 03 BINS

Dimensional / Visual deviations 108 / 04 BINS

Dimensional / Visual deviations PUMA -01 BINS

108 / 01 BINS

108 / 01 BINS

Conventional BINS

Dimensional / Visual deviations PUMA -01 BINS

Rethreading Manual BINS

Visual Defects / Inclusions Deburring Manual BINS

Dimensional / Visual deviations Final inspection BINS

Assembly Manual BINS

Improper Cleaning & Packing Manual BINS and Crates

DESPATCH Manual Wooden Crates

LEGEND

OPERATION INPUT OPERATION CUM INSPECTION

PROCESS FLOW DIAGRAM

INCOMING SOURCE OF VARIATION

OPERATION DESCRIPTION

METHOD OF MOVEMENT IN

STATION

RECEIPT OF RAW MATERIAL

Visual defects Bar Diameter O/S & U/S . Qty -Weight/ Nos / Spec are not matching

RAW MATERIAL INSPECTION

Correct Raw material inward

BAND SAW CUTTING 01 / 02

Accepted premachined components

Accepted components for second operation

CNC Second Operation

Accepted components for Third operation

CNC Third Operation

Accepted components for Fourth operation

Variation in Hole sizes and Positional dimensions / Dimensional / Visual deviations.

CNC Fourth ( First Cross hole ) Operation

Accepted components for CNC Fifth operation.

Variation in Hole sizes and Positional dimensions / Dimensional / Visual deviations.

CNC Fifth ( Second Cross hole ) Operation

Accepted components for Conv drilling & Reaming operation.

Variation in Hole sizes and Positional dimensions / Dimensional / Visual deviations.

Conventional Drilling and Reaming

Accepted components for CNC sixth operation.

CNC sixth ( ID & OD finish ) operation

Accepted components for retapping operation

Gauge not answering / Damages

Accepted components for Deburring operation

Accepted components for Final inspection

Manual / Instruments / Gauges / Visual

Accepted components for Assembly

Non assembly / Mismatch / Damages

Accepted Assemblies for Cleaning ,Packing.

CLEANING & PACKING

O K packed Assemblies to Despatch

Wrong mode of despatch / Improper documentation

Acceptable Assemblies for Customer.

02

01

03

04

05

06

07

08

11

12

13

14

15

14&1516&17

18

09

10

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LEGENDINSPECTION OUTPUT

SHEET 1 OF 1

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Shiva kumar.B Neelakantan Ambi Daniel

PREPARED BY CHECKED BY APPROVED BY

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POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PFMEA)Part No C O713250 Process Responsibility Mr. Rajesh B.M - C.E.O

Part Name DRIVE SHAFT Key Date 12.05.09

Drg Rev No/ Date Issue 10 24 - 10 - 2008

Mr.Daniel, Neelakantan, Lokesh, Dinesh, Muthukumar, Prakash, Muruganandam and Shivakumar.

Potential failure mode Potential Effect(s) of FailurePrevention

1 & 2

8 6 Educate the suppliers

Diameter U/S Cannot be used Educate the suppliers

Visual Defects 7 4 Educate the suppliers

3 CUTTING

Cutting length O/S

8 5

Cutting length U/S Cannot be used

4.00 Pre- Machining

Dimensions O/S

8

Wrong program / setting

5

wrong tooling

Machine capability

Dimensions U/S

wrong program / setting

wrong tooling

Machine capability

Visual Defects 4

5.00

Dimensions O/S

8

Wrong program / setting

5

wrong tooling

Machine capability

Dimensions U/S

wrong program / setting

wrong tooling

Machine capability

Visual Defects 4

6.00

Dimensions O/S

8

Wrong program / setting

5

wrong tooling

Core Team Members

Process No

Process Function / Requirements

S e v

C L S

Potential Cause(s) / Mechanism of Failure

O C

R

Current Process Control

Raw Material Receiving and

Inspection

Chemical composition,Hardness, Microstructure, Decarb Level, Inclusion Rating & Grain Size-Not meeting the Specifications

Machinibility poor,Surface finish poor,Reduce functional life

Wrong shipment from supplier end

Provide training to operator

Machining difficulties and reduced tool life, Increased Process time

Wrong shipment from supplier end

Wrong shipment from supplier end

Delay in production and Machining difficulties

Wrong shipment / Improper handling from supplier end

Machining difficulties and reduced tool life, Increased Process time

Improper stopper setting / Loading

Operator training / Set up approval

Improper stopper setting / Loading

Operator training / Set up approval

Machining difficulties and reduced tool life, Increased Process time / ID oversize cannot be used.

Work Instructions / Set-Up Approval

Cannot be used / ID undersize Machining difficulties and reduced tool life, Increased Process time

Work Instructions / Set-Up Approval

Delay in production and Machining difficulties / Cannot be used.

Machining and Handling deviations

Handling instructions and visual displays

CNC FIRST OPERATION

Machining difficulties and reduced tool life, Increased Process time / ID oversize cannot be used.

Work Instructions / Set-Up Approval

Cannot be used / ID undersize Machining difficulties and reduced tool life, Increased Process time

Work Instructions / Set-Up Approval

Delay in production and Machining difficulties / Cannot be used.

Machining and Handling deviations

Handling instructions and visual displays

CNC SECOND OPERATION

Machining difficulties and reduced tool life, Increased Process time / ID oversize cannot be used.

Work Instructions / Set-Up Approval

Page 27: APQP -DR SHFT

6.00

Dimensions O/S

8Machine capability

5

Dimensions U/S

wrong program / setting

wrong tooling

Machine capability

OD - 69.80 /69.75 oversize

8

***

5

OD - 69.80 /69.75 under rsize

Bore dia - 51.08 /51.13 oversize

***Bore dia - 51.08 /51.13 undersize

Visual Defects 8 4

7.00

Dimensions O/S

8

Wrong program / setting

5

wrong tooling

Machine capability

Dimensions U/S

wrong program / setting

wrong tooling

Machine capability

Visual Defects 4

8.00

Dimensions O/S

8

Wrong program / setting

5

wrong tooling

Machine capability

Dimensions U/S

wrong program / setting

wrong tooling

Machine capability

Hole dia - 30.03 /29.99 oversize

8 *** 5

Hole dia - 30.03 /29.99 under size

Visual Defects 8 4

9.00

Dimensions O/S

8

Wrong program / setting

5

wrong tooling

Machine capability

Dimensions U/S

wrong program / setting

wrong tooling

Machine capability

Hole dia - 19.12 / 19.09 oversize

8 *** 5

Hole dia - 19.12 / 19.09 undersize

Visual Defects 8 4

10.00

Hole dia O/S

8

Wrong program / setting

5

wrong tooling

Machine capability

Hole dia U/S

wrong program / setting

wrong tooling

Machine capability

Dimensions O/S

Wrong program / setting

wrong tooling

Machine capability

Dimensions U/S

wrong program / setting

wrong tooling

Machine capability

Visual Defects 4

11.00

Dimensions O/S

8

Wrong program / setting

5

wrong tooling

Machine capability

Dimensions U/S

wrong program / setting

wrong tooling

Machine capability

CNC SECOND OPERATION

Machining difficulties and reduced tool life, Increased Process time / ID oversize cannot be used.

Work Instructions / Set-Up Approval

Cannot be used / ID undersize Machining difficulties and reduced tool life, Increased Process time

Work Instructions / Set-Up Approval

Machining difficulties and reduced tool life, Increased Process time. / Fitment problem at customer end Wrong program / setting

/ Tooling / Machine capability

Work Instructions / Set-Up Approval / PPk / CPk studiesCannot be used / Fitment problem at

customer end.

Cannot be used / Fitment problem at customer end. Wrong program / setting

/ Tooling / Machine capability

Work Instructions / Set-Up Approval / PPk / CPk studiesMachining difficulties and reduced

tool life, Increased Process time. / Fitment problem at customer end

Delay in production and Machining difficulties / Cannot be used.

Machining and Handling deviations

Handling instructions and visual displays

CNC THIRD OPERATION

Machining difficulties and reduced tool life, Increased Process time / ID / Groove width oversize cannot be used.

Work Instructions / Set-Up Approval

Cannot be used / ID / Groove width undersize Machining difficulties and reduced tool life, Increased Process time

Work Instructions / Set-Up Approval

Delay in production and Machining difficulties / Cannot be used.

Machining and Handling deviations

Handling instructions and visual displays

CNC FOURTH OPERATION

Machining difficulties and reduced tool life, Increased Process time / ID / Groove width oversize cannot be used.

Work Instructions / Set-Up Approval

Cannot be used / ID / Groove width undersize Machining difficulties and reduced tool life, Increased Process time

Work Instructions / Set-Up Approval

Cannot be used / Fitment problem at customer end. Wrong program / setting

/ Tooling / Machine capability

Work Instructions / Set-Up Approval / PPk / CPk studies

Machining difficulties and reduced tool life, Increased Process time. / Fitment problem at customer end

Delay in production and Machining difficulties / Cannot be used.

Machining and Handling deviations

Handling instructions and visual displays

CNC FIFTH OPERATION

Machining difficulties and reduced tool life, Increased Process time / ID / Groove width oversize cannot be used.

Work Instructions / Set-Up Approval

Cannot be used / ID / Groove width undersize Machining difficulties and reduced tool life, Increased Process time

Work Instructions / Set-Up Approval

Cannot be used / Fitment problem at customer end. Wrong program / setting

/ Tooling / Machine capability

Work Instructions / Set-Up Approval / PPk / CPk studies

Machining difficulties and reduced tool life, Increased Process time. / Fitment problem at customer end

Delay in production and Machining difficulties / Cannot be used.

Machining and Handling deviations

Handling instructions and visual displays

CROSS HOLE DRILLING AND

REAMING (CONV)

Cannot be used / Fitment problem at customer end

Work Instructions / Set-Up Approval

Machining difficulties and reduced tool life, Increased Process time

Work Instructions / Set-Up Approval

Cannot be used / Fitment problem at customer end

Work Instructions / Set-Up Approval

Cannot be used / Fitment problem at customer end

Work Instructions / Set-Up Approval

Delay in production and Machining difficulties / Cannot be used.

Machining and Handling deviations

Handling instructions and visual displays

CNC SIXTH OPERATION

Machining difficulties and reduced tool life, Increased Process time / ID oversize cannot be used.

Work Instructions / Set-Up Approval

Cannot be used / ID undersize Machining difficulties and reduced tool life, Increased Process time

Work Instructions / Set-Up Approval

Page 28: APQP -DR SHFT

11.00

OD - 64.98 / 65.00 oversize

8

***

5

OD - 64.98 / 65.00 under rsize

Bore dia - 40.05 / 40.03 oversize

***Bore dia - 40.05 / 40.03 undersize

***

Visual Defects 4

12.00 8

Skill / Knowledge

5

wrong tooling

wrong gauges

Skill / Knowledge

wrong tooling

wrong gauges

Visual Defects 4

13 Deburring 85

Visual Defects 4

14 Final Inspection 8 4

Visual Defects

15 ASSEBLY

Non assembly

8Improper instructions 3

Mismatch

Visual Defects 4

16 & 17

Improper cleaning

8 Improper instructions 3

Visual controls

Improper packing work instructions

Imprper handling

wrong quantity

wrong packing materials

mix up of bad parts Packing instruction

18 Despatch

wrong mode of transport

8 2wrong destination

Improper documentation

CNC SIXTH OPERATION

Machining difficulties and reduced tool life, Increased Process time. / Fitment problem at customer end Wrong program / setting

/ Tooling / Machine capability

Work Instructions / Set-Up Approval / PPk / CPk studiesCannot be used / Fitment problem at

customer end.

Cannot be used / Fitment problem at customer end. Wrong program / setting

/ Tooling / Machine capability

Work Instructions / Set-Up Approval / PPk / CPk studiesMachining difficulties and reduced

tool life, Increased Process time. / Fitment problem at customer end

Concentricity 0.03 wrt A (Reference)

Cannot be used / Fitment problem at customer end.

wrong program / setting / Tooling / Machine capability / skill level

Work Instructions / Set-Up Approval / PPk / CPk studies

Delay in production and Machining difficulties / Cannot be used.

Machining and Handling deviations

Handling instructions and visual displays

RE - THREADING OPERATION

Thread gauge not answering ie GO and NO GO both ends not entering

Machining difficulties and reduced tool life, Increased Process time./ Fitment problem at customer end.

Work Instructions / Set-Up Approval

Thread gauge both ends ie GO and NO GO are entering.

Cannot be used / Fitment problem at customer end

Work Instructions / Set-Up Approval

Delay in production and Machining difficulties / Cannot be used.

Machining and Handling deviations

Handling instructions and visual displays

Presence of unwanted burrs / Sharp Projections on Corners, Mating surfaces, Edges,

Cannot be used / Fitment problem at customer end / Delay in process time.

Unskilled labour / wrong Toolings

Training and Visual aids to educate employees

Delay in production and Machining difficulties / Cannot be used.

Machining and Handling deviations

Handling instructions and visual displays

Wrong method of inspection Cannot be used / Fitment problem

at customer end / Customer dissatisfaction.

Improper instructions / semi skilled inspectors / wrong selection / usage of instruments / Gauges

Educate the inspectors and systematic hourly inspection .

Dimensional / Visual deviations not detected / detected allowed without authorization.

Delay in production and Machining difficulties / Cannot be used.

Machining and Handling deviations

Handling instructions and visual displays

Cannot be used / Fitment problem at customer end / Customer dissatisfaction.

Educate the inspectors and systematic hourly inspection .Delay in production and Machining

difficulties / Cannot be used.Machining and Handling deviations

Handling instructions and visual displays

CLEANING and PACKING

Bad / Damaged parts Cannot be used / Fitment problem at customer end / Customer dissatisfaction / Complaint.

Customer requirement copy desplayed

Bad / Damaged parts Cannot be used / Fitment problem at customer end / Customer dissatisfaction / Complaint.

Improper work instructions

work instructions for despatch

Page 29: APQP -DR SHFT

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS BNR - FMEA - 01

(PFMEA) Prepared by Shiva kumar.B

Date (Orig.) 12.05.09

Date (Rev.) NIL

NIL

Mr.Daniel, Neelakantan, Lokesh, Dinesh, Muthukumar, Prakash, Muruganandam and Shivakumar.

Actions Results

Detection

2 96Inward Inspection

Inward Inspection

Inward Inspection 2 56

Hourly inspection

2 80

Hourly inspection

2

80

Hourly inspection 64

2 80

Self inspection report 2 64

2 80

FMEA Number

Rev No

Current Process Control D

E T

R P

N

Recom- mended Action(s)

Responsi-bility &

Target DateActions Taken

S E V

O C R

D E T

R P N

Verification of test certificate with external lab

Setup approval and hourly inspection

Setup approval and hourly inspection report

Setup approval and hourly inspection

Setup approval and hourly inspection

Setup approval and hourly inspection

Page 30: APQP -DR SHFT

2 80

2 80

Hourly inspection 2 64

2

80

Hourly inspection 64

2 80

2 80

Hourly inspection 2 64

2 80

2 80

Hourly inspection 2 64

2

80

Hourly inspection 64

2 80

Setup approval and hourly inspection

Setup approval and hourly inspection

Setup approval ,hourly inspection and Control chart.

Setup approval ,hourly inspection and Control chart.

Setup approval and hourly inspection

Setup approval and hourly inspection

Setup approval and hourly inspection

Setup approval and hourly inspection

Setup approval ,hourly inspection and Control chart.

Setup approval and hourly inspection

Setup approval and hourly inspection

Setup approval ,hourly inspection and Control chart.

Setup approval and hourly inspection

Setup approval and hourly inspection

Setup approval and hourly inspection

Setup approval and hourly inspection

Setup approval and hourly inspection

Setup approval and hourly inspection

Page 31: APQP -DR SHFT

2

80

Hourly inspection 64

280

Hourly inspection 64

Hourly inspection 280

64

Final inspection 2 64

Hourly inspection3 72

2 64

2 48

2 32

Setup approval ,hourly inspection and Control chart.

Setup approval ,hourly inspection and Control chart.

Setup approval ,hourly inspection and Control chart.

Gauge checking / Hourly inspection

Gauge checking / Hourly inspection

Check list for cleaning and packing

Check list for despatch

Page 32: APQP -DR SHFT

GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEETVARIABLE DATA RESULTS

Part Number Gage Name Appraiser A

C071 3250 MICROMETER JOEL

Part Name Gage Number Appraiser B

DRIVE SHAFT 120302 MUTHU

Characteristic Gage Type Appraiser C

OUTER DIAMETER BALARAM

Characteristic Classification Trials Parts Appraisers Date Performed

2 10 3 02.07.09

Measurement Unit Analysis % Total Variation (TV) Repeatability - Equipment Variation (EV)

EV = Trials K1 % EV = 100 (EV/TV)

= 0.001 x 0.8862 2 0.8862 = 100(0.001/0.006)

= 0.001 3 0.5908 = 18.34

Reproducibility - Appraiser Variation (AV)

AV = % AV = 100 (AV/TV)

= {(0.002 x 0.5231)^2 - (0.001 ^2/(10 x 2))}^1/2 = 100(0.001/0.006)

= 0.001 Appraisers 2 3 = 11.46

0.7071 0.5231 n = number of parts

Repeatability & Reproducibility (R & R) r = number of trials

R & R = Parts

= {(0.001^2 + 0.001^2)}^1/2 2 0.7071 % R&R = 100 (R&R/TV)

= 0.001 3 0.5231 = 100(0.001/0.006)

Part Variation (PV) 4 0.4467 = 21.62

PV = 5 0.4030 Gage system may be acceptable

= 0.020 x 0.3146 6 0.3742

= 0.0063 7 0.3534 % PV = 100 (PV/TV)

Total Variation (TV) 8 0.3375 = 100(0.006/0.000)

TV = 9 0.3249 = 97.63

= {(0.001^2 + 0.006^2)}^1/2 10 0.3146 ndc = 1.41(PV/GRR)

= 0.0064 = 6

All calculations are based upon predicting 5.15 sigma (99.0% of the area under the normal distribution curve).

of operators (g) which is assumed to be greater than 15.AV - If a negative value is calculated under the square root sign, the appraiser variation (AV) defaults to zero (0).

R x K1

{(xDIFF x K2)2 - (EV2/nr)}1/2

K2

{(EV2 + AV2)}1/2 K3

RP x K3

{(R&R2 + PV2)}1/2

K1 is 5.15/d2, where d2 is dependent on the number of trials (m) and the number if parts times the number

K2 is 5.15/d2, where d2 is dependent on the number of operators (m) and (g) is 1, since there is only one range calculation.

K2 is 5.15/d2, where d2 is dependent on the number of parts (m) and (g) is 1, since there is only one range calculation.

d2 is obtained from Table D3, "Quality Control and Industrial Statistics", A.J. Duncan.

Page 33: APQP -DR SHFT

PART APPRAISER AVERAGE CHARTDEPT. OPERATION DATE CONTROL LIMITS CALCULATED ENGINEERING SPECIFATION PART NO.

QA OD TURNINGMACHINE NO. DATES OF STUDY CHARACTERISTIC SAMPLE SIZE FREQUENCY PART NAME

LT 25/1 02.07.09 OUTER DIAMETER 10 DRIVE SHAFTNUMBER OF APPRAISERS APPRAISER A APPRAISER B APPRAISER C

3 JOEL MUTHU BALARAM

43.3236 UCL = 109.8042 LCL = -23.1571 AVERAGES (X BAR CHART)

64.98600 UCL = 167.33895 LCL = 0.0000 RANGES (R CHART)

NUMBER 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 26 27 28 29 30

DATE/TIME

R 1 64.980 64.990 64.990 64.980 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.980 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000

2 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.990 64.980 64.990 64.980 64.980 64.980 64.980 64.980 65.000

3 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

4

S 5

SUM 129.960 129.980 129.980 129.970 129.960 129.960 129.980 129.960 129.960 130.000 129.960 129.980 129.980 129.980 129.960 129.960 129.980 129.960 129.960 130.000 129.960 129.970 129.970 129.980 129.960 129.960 129.970 129.960 129.960 130.000

X 43.320 43.327 43.327 43.323 43.320 43.320 43.327 43.320 43.320 43.333 43.320 43.327 43.327 43.327 43.320 43.320 43.327 43.320 43.320 43.333 43.320 43.323 43.323 43.327 43.320 43.320 43.323 43.320 43.320 43.333

R 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000

** = POINT OUT OF CONTROL

x =

r =

EAD ING

SUM NUM

HIGH- LOW

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 26 27 28 29 30

-40.000

-20.000

0.000

20.000

40.000

60.000

80.000

100.000

120.000

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 26 27 28 29 30

0.0000

20.0000

40.0000

60.0000

80.0000

100.0000

120.0000

140.0000

160.0000

180.0000

Page 34: APQP -DR SHFT

BNR Exports,Bangalore CONTROL PLAN

PROTOTYPE PRE-LAUNCH PRODUCTION

PART NUMBER/LATEST CHANGE LEVEL : C071 3250 / 10 ( OLD NO 12013906 )

PART NAME / DESCRIPTION : DRIVE SHAFT SUPPLIER/PLANT APPROVAL/DATE :

UNIT SUPPLIER CODE OTHER APPROVAL/ DATE (IF REQD.)

PROCESS NAME/OPERATION CHARACTERISTICS

METHODS

NO PRODUCT PROCESS

1 Receipt of raw material 1 weighment Inward Inspection * Kgs / Tons

2 Receiving Inspection 1 Visual *

2 Diameter ** 75.0 mm

3 Material ** As per order (SS316,410)

3 Cutting Bandsaw M/C 1 Length Sawing * 263+0.5

4 Pre machining Lathe M/C 1 OD Machining * 72+0.5

2 Inner Dia * 38-0.2

3 Bore depth * 99.0-0.10

4 Bore depth * 128.0 -0.10

5 Inner Dia * 24.50 +0.10

6 Inner Dia * 25.0 ± 0.10

7 Bore depth * 81.50-0.10

8 Inner dia * 50.0-0.10

9 Inner depth * 57.0-0.10

5 CNC 1st Operation CNC Turnning M/C 1 OD Machining ** 65.3+0.20

Facing,Turning, Drilling, Turning insert 2 Length ** 196.0±0.10

Boring, Chamfering , WNMG 080408 T603 3 Chamfer (Od stock ) **

Step boring WNMG 080404 T603 4 Corner radius ** R 1.6

Boring insert 5 Angle *

CCMT 09T304 T603 6 Bore dia ** 39.7-0.05

7 Bore length ** 101.0±0.10

8 Chamfer ( Id stock ) ** 2.3x 30º

9 Step bore dia ** 26.0±0.1

10 Bore length ** 130.0±0.10

6 CNC 2nd Operation CNC Turnning M/C 1 OD Machining ** 69.76 / 69.79

Facing, boring,step boring Turning insert 2 Perpendicularity ** 0.07 wrt B

Chamfering,Threading WNMG 080408 T603 3 Concentricity ** 0.07 wrt A

WNMG 080404 T603 4 Total length ** 260.0±0.1

Boring insert 5 Bore dia ** 51.09 / 51.12

CCMT 09T304 T603 6 Bore depth ** 58±0.10

TT 1500 7 Bore dia ** 37.0±0.10

8 Bore depth ** 83±0.10

9 Thread u/c dia * 26.0 ±0.25

10 u/c depth * 6.0 ±0.25

11 Perpendicularity ** 0.07 wrt B

12 Concentricity ** 0.07 wrt A

13 Thread size ( Entry tap ) ** M24x40.0

7 CNC 3rd Operation CNC Turnning M/C 1 Step dia ** 61.02-61.08

Grooving 2 Concentricity ** 0.07 wrt A

3 Step length ** 3.920 / 3.980

4 Corner radius in OD & ID ** (2x) R2

5 Corner radius ** R1

6 Groove dia ** 56.02 / 56.08

7 Concentricity ** 0.07 wrt A

8 Groove length ** 8.02 / 8.08

KEY CONTACT/PHONE : (080) 7833420

CORE TEAM : Mr.Rajesh, Daniel, Neelakantan, Lokesh, Dinesh, Muthukumar, Prakash, Muruganandam and Shivakumar.

SUPPLIER PLANT : BNR EXPORTS

PART PROCESS NO

MACHINE,JIG DEVICE, TOOLS FOR

MANUFACTURING

SPECIAL CHAR CLASS

PRODUCT /PROCESS SPECIFICATION/

TOLERANCE

No crack,damages and pit marks

3.3x10o

45o

Page 35: APQP -DR SHFT

9 Step length ** 48.0±0.1

10 Groove dia ** 65.10 / 65.25

11 Concentricity ** 0.07 wrt A

12 Groove width ** 3.75/3.85

13 Corner radius ** (2X) R1

14 Outside Corner radius ** R0.1 / R0.2

15 Angle * (2x) 0-5º

16 Step length ** 56.16 / 56.22

17 Groove dia ** 67.58 / 67.84

18 Concentricity ** 0.07 wrt A

19 Groovewidth ** 2.65 / 2.71

20 Surface finish ** Ra 1.6

8 CNC 4 TH OPERATION CNC Turnning M/C 1 Hole dia Drilling & Boring *** 29.99 / 30.03

First cross hole HSS Ø28.0 2 Ref. Length ** 27.90 / 28.1

CCMT 09T304 T603 3 Hole position ** 0.20 wrt A C

9 CNC 5 TH OPERATION CNC Turnning M/C 1 Hole dia Drilling & Boring *** 19.09 / 19.12

Secondt cross hole HSS Ø18.5 2 Ref. Length ** 27.90 / 28.1

CCMT 09T304 T603 3 Hole position ** 0.20 wrt A C

10 Conventional 3 C / Hole dia 2 Drilling ** 14.22 / 14.29

4 Ref length ** 38±0.10

5 Hole position ** 0.07 wrt A

11 CNC 6th Operation CNC Turning M/C 1 OD Turning *** 64.985 / 64.995

2 OD Length * 196.0 ± 0.15

3 ID Boring *** 40.03 / 40.05

4 ID Depth * 101.0 ± 0.15

5 Concentricity *** 0.02 wrt A

6 Surface finish ** Ra 0.8

12 Rethreading Hand 1 Thread size Tapping ** M24

Tap to M20 Tap M24 2 Thread length 40

13 Deburring Manual 1 Visual **

14 Final Inspection 1 OD Inspection *** 64.98 / 65.0

2 Chamfer **

3 Corner radius ** R 1.6

4 ID *** 40.03-40.05

5 Concentricity ** 0.03 wrt A

6 Surface finish ** Ra 0.8

7 Bore length ** 101.0±0.25

8 ID Chamfer ** 2 x 30º

9 Step bore dia ** 26.0±0.25

10 Bore length ** 130±0.25

11 OD ** 69.75 / 69.80

12 Total length ** 260.0±0.25

13 Bore dia *** 51.08 / 51.13

14 Bore depth ** 58±0.25

15 Bore dia ** 37±0.25

16 Bore depth ** 83±0.25

17 Thread u/c dia * 26.0 ±0.25

18 u/c depth * 6.0 ±0.25

19 Perpendicularity ** 0.1 wrt B

20 Concentricty ** 0.1 wrt A

21 Step dia ** 61.00 / 61.10

22 Corner radius ** (2x) R2

23 Corner radius ** R1

24 Groove dia ** 56.00 / 56.10

25 Groove length Inspection ** 8.00 / 8.10

Cross Hole Drilling & Reaming

Parts to be free from burrs,sharp corners,dents

and damages

3.0x10o

Page 36: APQP -DR SHFT

26 Step length ** 3.90 / 4.00

27 Step length ** 48.0±0.25

28 Groove dia ** 65.05 / 65.30

29 Groove width ** 3.7-3.9

30 Corner radius (2X) ** R1

31 Out corner radius (2X) * R0.1 / R0.2

32 Angle (2x) * 0-5º

33 Step length ** 56.14 / 56.24

34 Groove dia ** 67.56 / 67.86

35 Groovewidth ** 2.63-2.73

36 Step length ** 196±0.25

37 Chamfer * 45º

38 Concentricity ** 0.1 wrt A

39 Concentricity ** 0.1 wrt A

40 Concentricity ** 0.1 wrt A

41 Concentricity ** 0.1 wrt A

42 Concentricity ** 0.1 wrt A

43 Perpendicularity ** 0.1 wrt B

44 Surface finish ** Ra 1.6

45 Thread size ** M24

46 Hole dia ** 29.99 / 30.03

47 Ref. Length ** 27.80 / 28.20

48 Hole position ** 0.2 wrt A,C

49 Hole dia ** 14.20-14.31

50 Hole position ** 0.1 wrt A

51 Hole Ref Ht ** 38±0.25

52 Hole dia ** 19.09 / 19.12

53 Hole position ** 0.2 wrt A,C

54 Ref length * 27.80 / 28.20

15 Allen bolt assembly Manuel 1 Fixing of bolt with locktite **

2 5910 ** locktite under the bolt

16 Cleaning 1 Clean the Component with White waste

17 Packing 1 Pack the componant with bubble sheet

18 Despatch

NOTE:' MINOR, ''MAJOR, '''CRITICAL, 100%INSPECTION TO BE DONE, SPC TO BE DONE FOR > 50 NOS and for TOLERANCE of < 0.05 , PC=PROGRAME CONTROL, PP=PROFILE PROJECTOR..MH-Micro Height, HG-Vernier height gauge

REPRESENTATIONS: F= FINISH, S.I.R = SELF INSPECTION REPORT,

EVALUATION USING CMM IS DONE 1NO./4hr.

SETTING APPROVAL = New setting, Change of Tool, Collet, Jaws, Speed, Feed or any other change in Process / Setup -----VISUAL: Rust, Cracks, Pitting, Bend, Dents, Burrs & Damages are not allowed

QUARANTINE: Apart from rejected batches, batches produced / received should be kept separate till decision on the batch is taken. Ex. Batch produced between tool changes, batch received from supplier etc

Prepared by

Checked by

Approved by REV

Proper alignment of bolt & apply Sealant under the bolt

head

Page 37: APQP -DR SHFT

CONTROL PLAN

DATE(ORG): DATE(REV):

CUSTOMER ENGEERING APPROVAL/DATE

SUPPLIER/PLANT APPROVAL/DATE : CUSTOMER QUALITY APPROVAL / DATE

OTHER APPROVAL/ DATE (IF REQD.) CONTROL PLAN ISSUE NO: 01

METHODS

RECORDSAMPLECONTROL MATHOD REACTION PLAN

SIZE FREQ

Weighing scale

Every lot

DC / INVOICE GRIR

Naked eye

Micrometer

Exturnal lab

Vernier caliper 100% Every lot Self inspection report Reset the blade Self inspection report

Micrometer

2 Nos 1 hr Self inspection report Reset the tool Self inspection report

Bore gauge

Vernier caliper

Vernier caliper

Bore gauge

Bore gauge

Vernier caliper

Bore gauge

Vernier caliper

Micro meter

2 Nos 1 hr Self inspection report Self inspection report

Vernier caliper

Profile projector

Radius gauge

Profile projector

Bore dial gauge

Depth Vernier

Profile projector

Bore dial gauge

Depth vernier

Micro meter

1 Nos 1hr Self inspection report Self inspection report

Dial with stand/CMM

Dial with stand

Vernier caliper

Bore dial gauge

Depth vernier

Bore dial gauge

Depth vernier

Plug gauge

Vernier caliper

Dial with stand/CMM

Dial with stand

Thread plug gauge

Micrometer

Dial with stand

Profile projector

PP/Radius gauge

PP/Radius gauge

Blade micrometer

Dial with stand

Depth Micrometer / PP

(080) 7833420 24.12.06

CORE TEAM : Mr.Rajesh, Daniel, Neelakantan, Lokesh, Dinesh, Muthukumar, Prakash, Muruganandam and Shivakumar.

EVALUATION / MEASUREMENT TECH

As per sampling

plan

Reject and send back to supplierSupplier inspection

reportReceving inspection

report

Reset the insert check the speed and feed

Reset the insert check the speed and feed

Page 38: APQP -DR SHFT

Profile projector

1 Nos 1hr Self inspection report Self inspection report

Micrometer

Dial with stand

Profile projector

Profile projector

Profile projector

Profile projector

Profile projector

1 Nos 1 hr Self inspection report Self inspection report

Blade micrometer

Dial with stand

Profile projector

Roughness tester

Bore dial gauge

1 Nos 1 hr Self inspection report Self inspection reportMicro height /Vernier caliper

Dial with stand

Bore dial gauge

1 Nos 1 hr Self inspection report Self inspection reportMicro height /Vernier caliper

Dial with stand

Plug gauge

4 Nos 1 hr Self inspection report Self inspection report

Vernier caliper

Height gauge with Dial

Micrometer

Vernier caliper

Plug gauge/Bore gauge

Vernier caliper

Height gauge with dial

Roughness tester

Thread plug gauge100% Every lot Self inspection report Change the tap Self inspection report

Venier caliper

Visul 100% Every lot

Micrometer

Every lot Final inspection report Final inspection report

Profile projector

Radius gauge / PP

Bore dial gauge

Dial with stand

Roughness tester

Venier caliper

PC

Bore dial gauge

Depth vernier

Micro meter

Vernier caliper

Bore dial gauge

Vernier caliper

Bore dial gauge

Depth vernier

Plug gauge

Vernier caliper

Dial with stand / CMM

Dial with stand

Micrometer/Vernier caliper

PP/Radius gauge

PP/Radius gauge

Blade micrometer

Depth Micrometer

Every lot Final inspection report Final inspection report

Reset the insert check the speed and feed

Reset the insert check the speed and feeds

Reset the insert check the speed and feeds

Reset the insert check the speed and feeds

Reset the reaming tool and reset the drill bit

As per sampling

plan

Reject and segregate the lot

As per sampling

plan

Reject and segregate the lot

Page 39: APQP -DR SHFT

Profile projector

Every lot Final inspection report Final inspection report

Profile projector

Blade micrometer

Slip gauge/PP

PP/Radius gauge

PP

PP

Profile projector

Blade micrometer

Profile projector

Venier caliper

Profile projector

Dial with stand

Dial with stand

Dial with stand

Dial with stand

Dial with stand

Dial with stand

Roughness tester

Thread plug gauge

Plug gauge

Micro-hite / Vernier caliper

Dial with stand

Plug gauge

Dial with stand

Vernier caliper

Plug gauge

Dial with stand

Micro-height / Vernier caliper

Visual

Visual 100% Every Batch

Visual 100% Every Batch

NOTE:' MINOR, ''MAJOR, '''CRITICAL, 100%INSPECTION TO BE DONE, SPC TO BE DONE FOR > 50 NOS and for TOLERANCE of < 0.05 , PC=PROGRAME CONTROL, PP=PROFILE PROJECTOR..MH-Micro Height, HG-Vernier height gauge

REPRESENTATIONS: F= FINISH, S.I.R = SELF INSPECTION REPORT,

EVALUATION USING CMM IS DONE 1NO./4hr.

SETTING APPROVAL = New setting, Change of Tool, Collet, Jaws, Speed, Feed or any other change in Process / Setup -----VISUAL: Rust, Cracks, Pitting, Bend, Dents, Burrs & Damages are not allowed

QUARANTINE: Apart from rejected batches, batches produced / received should be kept separate till decision on the batch is taken. Ex. Batch produced between tool changes, batch received from supplier etc

CONTROL PLAN NO:

BNR /CP/186

SIGN /DATE REV No. 1 Page:5/5

As per sampling

plan

Reject and segregate the lot

Page 40: APQP -DR SHFT

BNR Exports

DATE:

Rev No: 0

CUSTOMER MONOPUMPS

PART NO C 0713250

PART NAME DRIVE SHAFT

WORK PROCESS CODIFICATION DESCRIPTION CODIFICATION

GRIR - 382

W.O. No 320

W.O. No 320

W.O. No 320

W.O. No 320

W.O. No 320

W.O. No 320

XXX / YYY / ZZZ 1 / 5 To 2 / 5 / BNRE /1344

Note:

COMPONENT NO DURING PROCESS: COPY

XXX / YYY / ZZZ

Invoice No

No of boxes in the Consignment

BOX NO.

W O XXX

RUNNING SERIAL NUMBER

WORK ORDER

Shiva kumar.B Neelakantan Ambi Daniel

PREPARED BY CHECKED BY APPROVED BY

TRACEABILITY FOR PRODUCT / MANUFACTURING PROCESS

Receive Heat No / Batch no / Lot No. from raw material supplier

WORK ORDER NUMBER AT BNR :

RAW MATERIAL FROM . SUPPLIER

CUTTING

C.N.C. OPERATIONS

CONVENTIONAL OPERATIONS

FINAL INSPECTION

ASSEMBLY

CLEANING & PACKING

DESPATCH

Page 41: APQP -DR SHFT

WORK INSTRUCTION FOR CUTTING OPERATION

Issue No:01 Date:15-06-05 Rev No:00 Date:15-06-05 OPERATION: CUTTING OPERATION

1) Receive the cutting slip from planning/production dept. 2) Clean the machine job holding area with brush and coolant. 3) Check the size of the raw material. 4) Set for required length as mentioned in cutting slip. 5) Clamp the job and start the m/c. 6) Adjust the feed with the adjustment lever. 7) Check the cut material for length, taper etc. 8) Arrange the cut parts in the bin, and identify with identification tag.

WORK INSTRUCTION FOR CNC TURNING OPERATION

Issue No:01 Date:15-06-05 Rev No:00 Date:15-06-05 OPERATION: CNC Turning

1) Study and understand the drawing dimensions, tolerances properly. If in doubt clarify 2) Check the route card correctly updated and duly signed. 3) Use proper tools, fixtures with respect to drawing 4) Ensure all related formats are existing 5) Ensure proper clamping of components in chuck, minimum holding length as per standard. 6) Set the machine for the required program and verify the program for all tool offset and availability of tool parameters and sequence as per job. 7) Get first piece approval as per drawing from QC personnel 8) Check and record the dimensions in the self-inspection report format at regular intervals 9) Use calibrated instruments/gauges for measuring purpose 10) Keep the instruments at respective place after use 11) Check the life of the tool by checking the finish and change insert whenever required 12) All sharp corners to be removed with 0.050mm radius and include this in the programme 13) Clean the your Machine after use and keep your m/c surrounding clean

PREPARED BY PREPARED BY APPROVED BY

Page 42: APQP -DR SHFT

WORK INSTRUCTION FOR CNC TURNING OPERATION

Issue No:01 Date:15-06-05 Rev No:00 Date:15-06-05 OPERATION: CNC Turning

1) Study and understand the drawing dimensions, tolerances properly. If in doubt clarify 2) Check the route card correctly updated and duly signed. 3) Use proper tools, fixtures with respect to drawing 4) Ensure all related formats are existing 5) Ensure proper clamping of components in chuck, minimum holding length as per standard. 6) Set the machine for the required program and verify the program for all tool offset and availability of tool parameters and sequence as per job. 7) Get first piece approval as per drawing from QC personnel 8) Check and record the dimensions in the self-inspection report format at regular intervals 9) Use calibrated instruments/gauges for measuring purpose 10) Keep the instruments at respective place after use 11) Check the life of the tool by checking the finish and change insert whenever required 12) All sharp corners to be removed with 0.050mm radius and include this in the programme 13) Clean the your Machine after use and keep your m/c surrounding clean

PREPARED BY PREPARED BY APPROVED BY

WORK INSTRUCTION FOR DRILLING OPERATIONS

Issue No:01 ` Date:15-06-05Rev No:00 Date:15-06-05

OPERATION: DRILLING OPERATION1) Study and understand the drawing dimensions, tolerances properly. If in doubt clarify

2) Check the route card/ job card/ control plans are provided as per latest issue no.

3) Use proper drills, fixtures with respect to drawing.

4) Get first piece approval as per drawing from QC personnel

5) Check and record the dimensions in the self-inspection report format at regular intervals

6) Use calibrated instruments/gauges for measuring purpose

7) Keep the instruments at respective place after use

8) Drill to be grind properly whenever required.

9) Deburring to be carried out after drilling operation.

10) Ensure all the drills/taping operations completed.

11) Ensure no parts are missed for the required operations.

12) Use tag systems for identification.

13) Arrange the parts in all the stags. 14) Clean the Machine after use and keep your m/c surrounding clean.

Page 43: APQP -DR SHFT

WORK INSTRUCTION FOR DEBURRING

OPERATIONS Issue No:01 Date:15-06-05 Rev No:00 Date:15-06-05

OPERATION: DEBURRING

1). Study the drawing requirements and root card process 2). Identify the requirements of the deburring process 3). Identify the required tools for deburring operation 4). Use rubber sheet over the table 5). Use plastic bins for arranging the parts 6). Break corners by ±0.2mm wherever specification not given 7). Blow air after deburring operation 8). Arrange the parts and identify the parts with suitable tag.

OPERATION: DRILLING OPERATION

1) Ensure parts are accepted by QC personal 2) Arrange appropriate corrugated boxes and other required packing materials. 3) Ensure all deburring operation done at all sharp corners. 4) Ensure parts are free from defects, like deep marks, cracks & surface treatments of good finish, Ensure there is no unfetteled lumps in case of castings. 5) Ensure no thread damages, missing of threads in case of parts required threading. 6) Ensure there is no missing operation as per drawing, check the plug gauge 100% before packing, if parts are surface treated. 7) Clean the parts with kerosene/TCI oil as required. 8) Apply rest preventive oil to all the parts. (As applicable) 9) Pack each part on a polythene sheets, tube & air bubble sheets as required, and enough stuffing to be given as instructed. 10) Arrange parts in polythene sheet and pack it. 11) Place the polythene packs in corrugated box. 12) Place the corrugated boxes in to the wooden box, covering by thick polythene cover. 13) Enclose inspection report, material test certificate & packing slip in to the corrugated box. 14) Seal the wooden box by sealing wire with sealing lead & write the packing slip No. on wooden box by permanent marker. 14) Stamp address of consignee & exporter on sealing lead.

WORK INSTRUCTION FOR PACKING OPERATIONS

Issue No:01 ` Date:15-06-05 Rev No:00 Date:15-06-05

PREPARED BY PREPARED BY APPROVED BY

PREPARED BY PREPARED BY APPROVED BY

WORK INSTRUCTION FOR DRILLING OPERATIONS

Issue No:01 ` Date:15-06-05Rev No:00 Date:15-06-05

OPERATION: DRILLING OPERATION1) Study and understand the drawing dimensions, tolerances properly. If in doubt clarify

2) Check the route card/ job card/ control plans are provided as per latest issue no.

3) Use proper drills, fixtures with respect to drawing.

4) Get first piece approval as per drawing from QC personnel

5) Check and record the dimensions in the self-inspection report format at regular intervals

6) Use calibrated instruments/gauges for measuring purpose

7) Keep the instruments at respective place after use

8) Drill to be grind properly whenever required.

9) Deburring to be carried out after drilling operation.

10) Ensure all the drills/taping operations completed.

11) Ensure no parts are missed for the required operations.

12) Use tag systems for identification.

13) Arrange the parts in all the stags. 14) Clean the Machine after use and keep your m/c surrounding clean.

Page 44: APQP -DR SHFT

OPERATION: DRILLING OPERATION

1) Ensure parts are accepted by QC personal 2) Arrange appropriate corrugated boxes and other required packing materials. 3) Ensure all deburring operation done at all sharp corners. 4) Ensure parts are free from defects, like deep marks, cracks & surface treatments of good finish, Ensure there is no unfetteled lumps in case of castings. 5) Ensure no thread damages, missing of threads in case of parts required threading. 6) Ensure there is no missing operation as per drawing, check the plug gauge 100% before packing, if parts are surface treated. 7) Clean the parts with kerosene/TCI oil as required. 8) Apply rest preventive oil to all the parts. (As applicable) 9) Pack each part on a polythene sheets, tube & air bubble sheets as required, and enough stuffing to be given as instructed. 10) Arrange parts in polythene sheet and pack it. 11) Place the polythene packs in corrugated box. 12) Place the corrugated boxes in to the wooden box, covering by thick polythene cover. 13) Enclose inspection report, material test certificate & packing slip in to the corrugated box. 14) Seal the wooden box by sealing wire with sealing lead & write the packing slip No. on wooden box by permanent marker. 14) Stamp address of consignee & exporter on sealing lead.

WORK INSTRUCTION FOR PACKING OPERATIONS

Issue No:01 ` Date:15-06-05 Rev No:00 Date:15-06-05

PREPARED BY PREPARED BY APPROVED BY

Page 45: APQP -DR SHFT

BNR Exports PACKING SPECIFICATIONSCustomer: Mono Pumps Ltd., UKDate: 22.09.2008

Requirements Originator

1 All the parts other than Muncher Half Couplings must have the label with Part number pasted on the packed product Logistics

2 Universal Joint assemblies threads must be protected withPlastic caps Logistics

1 Wood packaging material must be fumigated before despatchby Freight forwarder Customer

2 Each case must be pasted with a label consisting PO Number Logistics3 Delivery Terms: Incoterms 2000: Ex Works Logistics

1 Submit GSP certificates for each consignment Logistics

Prepared by Checked by Approved by

Special Packaging and Preservation:

Delivery Requirements:

Documentation Requirements:

Page 46: APQP -DR SHFT

CRITICAL CHARECTERISTIC MATRIX PLAN DATEPART NAME DRIVE SHAFT PART NO C 0713250 ISSUE 10 / 24-10-08 CUSTOMER MONO PUMPS

SL NOPARAMETER SPECIFICATION

PROCESS NO

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

1OUT SIDE DIAMETER F 65 / 64.98 X

2BORE DIAMETER F 40.03 / 40.03 X

3CONCENTRICITY X

4BORE DIAMETER F 51.08 / 51.13 X

5BORE DIAMETER F 29.99 / 30.03 X

6OUT SIDE DIAMETER F 69.75 / 69.80 X

7BORE DIAMETER F 19.09 / 19.12 X

0.03 with respect to A

Page 47: APQP -DR SHFT
Page 48: APQP -DR SHFT

PPK1

Page 48

Sl.No. Date Readings Supplier : BNR Exports

1 84.99 Place : BANGALORE

2 84.983 84.99 Ref. No: 1

4 84.99 Period : 21.08.09

5 84.996 84.99 Part No. : C091 32507 84.99 Part Name : Drive Shaft

8 84.99 Parameter : Outer Diameter

9 84.9910 84.99 USL : 85

11 84.99 LSL : 84.98

12 84.9813 84.99 Operation No. : CNC 4th

14 84.99 Operation desc. : OD & ID Finish

15 84.9916 84.99 Instrument used : Micrometer

17 84.99 Least count : 0.01

18 84.9919 84.9920 84.9921 84.9922 84.9923 84.9924 84.9925 84.9926 84.9927 84.9928 84.9929 84.9930 84.9931 84.9932 84.9933 84.9934 84.9935 84.9936

37

38

39

40

41

42

43

44

Page 49: APQP -DR SHFT

PPK1

Page 49

45

46

47

48

49

505152535455565758596061626364656667686970717273747576777879808182838485868788899091929394959697

Page 50: APQP -DR SHFT

PPK1

Page 50

9899

100

Page 51: APQP -DR SHFT

BNR Exports Process Cpk Study ReportCustomer : Ref. No.

MONO PUMPS 1

Supplier: BNR Exports PERIOD ( Month ):

21.08.09Part No.: C091 3250 Part Name : DRIVE SHAFTParameter Specification Tolerance

OUTER DIAMETER USL 85 LSL 84.98 0.02Operation No: CNC 4th Opn. Description OD & ID Finish

Instrument Used MICROMETER Least Count : 0.01CAPABLE PROCESS OBSERVED

Cp > = 1.66 CAPABLE Cp = 1.42

Cpk > = 1.33 Cpk = 1.33n = 35

No. of Class : 3Observed beyond Specification : Target Nominal :

0.00% 84.99

Estimated beyond Specification : Average (X) 84.9890.00% Process Std. Dev. (Sigma):

0.0024Remarks : Name

Sign & Date

84.97

84.97

84.98

84.98

84.99

84.99

85.00

85.00

85.01

85.01

85.02

85.02

85.03

85.03

85.04

0

5

10

15

20

25

30

35

HISTOGRAM

Dimension

Frequency

Page 52: APQP -DR SHFT

PPK3

Page 52

Tolerance : 0.02

Target Nominal : 84.99 Min.value No.of width mid cumulative84.98 -0.015 84.965 84.9675 0

No. of reading : 35 84.98 -0.01 84.97 84.9725 084.98 -0.005 84.975 84.9775 0

Average : 84.98943 84.98 0 84.98 84.9825 284.98 0.005 84.985 84.9875 2

Std. dev. (Sigma) : 0.002355 84.98 0.01 84.99 84.9925 3584.98 0.015 84.995 84.9975 35

Cp value : 1.415403 84.98 0.02 85 85.0025 35Cpk value : 1.334523 84.98 0.025 85.005 85.0075 35

84.98 0.03 85.01 85.0125 35No. of class : 3 84.98 0.035 85.015 85.0175 35

84.98 0.04 85.02 85.0225 35Maximum value : 84.99 84.98 0.045 85.025 85.0275 35Minimum value : 84.98 84.98 0.05 85.03 85.0325 35

84.98 0.055 85.035 85.0375 35Range : 0.01 84.98 0.06 85.04 85.0425 35Class width : 0.005 84.98 0.065 85.045 85.0475 35

84.98 0.07 85.05 85.0525 35Observed beyond 84.98 0.075 85.055 85.0575 35Specification: 0 84.98 0.08 85.06 85.0625 35

84.98 0.085 85.065Estimated beyond zl zu phil phu est percentageSpecification -4.00357 4.488851 3.12E-05 0.9999964 2.762E-05 0.002761647

TARGET NOMINAL 2:if LSL=0: 0

if USL = ~: 0

Cpk value 2:if LSL=0: 0

if USL=~: 0

Cp = ----

Page 53: APQP -DR SHFT

PPK3

Page 53

sum of X =X bar =

Page 54: APQP -DR SHFT

PPK3

Page 54

frequency0020

3300000000000000

-35