M VOS 193 c

Customer :

Supplier Name

Part No

Description

Production Part Approval Process

Customer :Supplier name: Part name : OILSEAL

Part No. : VOS 193

List of documents submitted(Tick inside the box)

PPAP manual ref no1 Design record a 1

2 Engineering change documents 2

3 Customer engineering approval 3

4 Design FMEA 4

5 Process flow diagram a 5

6 Process FMEA a 6

7 Dimensional results a 7

8 Material performance test results 8

9 Initial process study a 9

10 Measurement system analysis studies a 10

11 Qualified labarotary documentation 11

12 Control Plan a 12

13 Part submission Warrant a 13

14 Appearance approval report 14

15 Bulk material requirement check list 15

16 Sample product a 16

17 Master Sample 17

18 Checking aids a 18

19 Deviation and action plan -

PPAP rev no.: 0

Submission date: 16.09.10

List of documents submitted(Tick inside the box)

PPAP manual ref no

PPAP History SheetPART NO :VOS 193

SNO PPAP Details of Change SignatureRev .No Date

1 NIL 16.09.10 Initial submission

PREPARED BY : APPROVED BY:

of 29

PROCESS FLOWPart Name / Description : Oil Seal Date (original) : 13.09.2010 Rev No : 00

Drawing / Part no : VOS 193 Revision Date : NIL

Process flow no : BI / PF/ 193 Customer Ref. No : BSE 0300B - WK 30.14(B)

Op. / Brief Desc. Incoming Sources of Variations Process Flow Diagram Product Characteristics Process Characteristics

_

_

Material Grade _

20.Storage of Raw Material Material Grade _

30.Weighing of Mix Ingredients Weight of the Ingredients _

40. Rubber Mixing Rubber Compound Mixing Time.

Customer Ref. No : BSE 0300B - WK 30.14(B)

Core Team : Production / Quality / Marketing (CFT)

10. A. Incoming Inspn. Of Raw Material. (Shell)

1.Wrong Specification Material shipped by supplier 2. Visual defects like Rust , Burr, Bend, cutshell, tool mark, Rust, Dent, OD line mark , Pit mark supplied by the Supplier

1. I.D. : Ø 44.10 ± 0.10 mm 2. P.D. : Ø 35.50 ± 0.15 mm 3. HT. : 6.35 ± 0.10 mm 4. ST :0.91 MATERIAL : CRCS IS 513 - 1994

10. B. Incoming Inspn. Of Raw Material. (Spring)

1.Wrong Specification Material shipped by supplier 2. Visual defects like Bend, Rust , Burr, peel off supplied by the Supplier

1. Spring Length : 103.00 mm 2. Coil Dia : Ø 1.58 mm 3. Wire Dia : Ø 0.30 mm MATERIAL : GI IS 4454 - 2001 PART1

10.C. Incoming Inspection of Chemicals & Raw Rubber

Wrong Specification Material shipped by supplier

1.Wrong Grade Material 2.Wrong Specification/Size Material 3.Defective material

1.Incorrect ingredients weight 2.Incorrect chemical selection. 3.Ingredients missed out 4. Instrument Error.

1. Poor Dispersion 2.Temperature variation of coolant circulation in roll mill.

30

10.A.

10.B.

10.C.

30

20

10.A.

10.B.

10.C.

40

of 29







Variation in Rubber Hardness Hardness : 70 ± 5 shore A _

Specific Gravity variation. 1.20 ~ 1.25 _

Tensile Strength variation. Minimum 12.5 N/mm² _

Elongation variation. Minimum 250 %

60. Extrusion Over Cure of Rubber compound. Blank Shape Extrusion Time

70. Dipping Dipping Chemical Specific Gravity. Process Temperature.

50. Compound testing A)Hardness

50. Compound testing B)Specific Gravity

50. Compound testing C)Tensile Strength

50. Compound testing D) Ultimate Elongation

1) In correct/ Excess bonding layer in shell 2) Rust / Surface defects in shell 3) Process Temperature variation 4) Life time of dipping chemicals

50.A.

50.B.

70

50.A.

50.B.

60

50.C.

50.D.

of 29







80. Rubber Cutting Rubber Blank _1) Incorrect Rubber selection 2) Variation in Rubber weight 3) Weighing Machine Error.

80 80

of 29







90.Moulding _

100. Finishing Apperance _

110. Trimming _

120. Final Inspection _

Visual. _

140. Packing & Labelling Part No & Qty. _

1)Curing Temperature Variation 2) Pressure Variation 3)Time Variation 4) Visual Defects like Short fill , Poor flow, tearing , stripping, Bad mould, Under cure , foreign matter , Bad shell , Bond failure , Dent

1.Appearance. 2.Temperature. 3.Time. 4.Pressure.

1) Uneven Flash removal, Tearing., 2) Poor Finishing 3) Tool bit wear out 1) Trimming Needle wear out 2) Uneven location of seal in Trimming machine 3) Incorrect Trimming / I.D. Dimension variation

1) After trimming , Ensure Id thro ID checking Gauge. ID: 29.00 ± 0.25

1) Dimension Variation 2) Short fill , Poor flow, tearing , stripping, Bad mould, Under cure , foreign matter , Bad shell , Bond failure , Dent .

1) O.D. : 47.78 / 47.93 mm 2) I.D. : 28.75 ± 0.25 mm 3) Height : 8.00 ± 0.20 4) Free from visual defects like Short fill , Poor flow, tearing , stripping, Bad mould, Under cure , foreign matter , Bad shell , Bond failure , Dent .

130. Spring Fitment (Spring with oil seal)

1) Wrong Spring selection 2) spring open out while fitment with seal

1) Quantity Variation 2) Incorrect packing media. 3)Product Mixup

130

70.

70. 90

100

110

140

120

CONTROL PLANPrototype Pre-launch Production

Control plan Number : BI / CP/193 Key Contact / Phone : Date (original) : 13.09.2010Revision Date : NILRev No : 00Part Name / Description : Oil Seal Core Team : PRODUCTION ,QUALITY, MARKETING Customer Eng. Approval / Date : N/ADrawing / Part no : VOS 193 Engineering change level : Nil. Customer Quality approval / Date : N/ASupplier Code : Supplier / Plant approval / Date : Other Approval Date ( If required ) : Plant / Location :

Characteristics Methods

Resp.No Product Process Size Frequency Control methods

10.A. Digi Vernier Dimension _ Nil Each lot

10. B. Dimension Nil Each lot

10.C. Material Grade Nil Each lot

20 Material Grade Nil Each lot Store

30 Weight of the ingredients Nil Every Batch

40 Two Roll Mill. Rubber Compound Mixing Time As per Milling procedure. Nil Every Batch

50.A. Hardness _ Hardness : 70 ± 5 shore A Nil Every Batch Testing Records.

50.B. Densimeter. Specificgravity _ 1.20 ~ 1.25 Densimeter Nil Every Batch Testing Records.

50.C. a.Tensile Strength _ Minimum 12.5 N/mm² Nil Testing Records.

50.D. Ultimate Elongation _ Minimum 250 % Nil Testing Records.

Part / Process Numbe

r

Process Name/Operation Description

Machine,Device,Jigs,Tools

for Mfg

Spercial

Char. Class

Reaction Plan /

Corrective action

Product/Process Spercification / tolerance

Evaluation / Measureme

nt Technique

Error Proofi

ng

10. A. Incoming Inspn. Of Raw Material. (Shell)

1. I.D. : Ø 44.10 ± 0.10 mm 2. P.D. : Ø 35.50 ± 0.15 mm 3. HT. : 6.35 ± 0.10 mm 4. ST :0.91 MATERIAL : CRCS IS 513 - 1994

Digimatic Vernier

caliper, Dial Indicator ,

Micrometer.

As Per sampling

PlanIncoming

Inspection ReportReject the RM

Store & QC


Digi Vernier & Scale

1. Spring Length : 103.00 mm 2. Coil Dia : Ø 1.58 mm 3. Wire Dia : Ø 0.30 mm MATERIAL : GI IS 4454 - 2001 PART1

Digimatic Vernier caliper,

Steel Scale.

As per sampling

planIncoming

Inspection ReportReject the RM

Store & QC


Ensure Chemical Grade Number, Weight, Quantity with respect to D.C.

Visual check

Every time

Supplier Test Report

Reject the RM

Store & QC

20.Storage of Raw Material

1.Correct Grade of material 2.Correct specification/size of material

Visual check

Every time

Visual check , stock Record.

Reject the RM

30.Weighing of Mix Ingredients

Weighing Machine

As per mixing weight chart.

Weigh Machine

Read out.Every time

Receipe Check List

Stop & Correct

the process.

Milling Section

40. Rubber Mixing

Visual check

Every time

As per Milling procedure.

Stop & Correct

the process.

Milling Section


Hardness Tester

Hardness Tester

One sample

Stop & Correct

the process.

Lab Assistant


One sample

Stop & Correct

the process.

Lab Assistant

Compound testing C)Tensile Strength

UTM(Universal Testing Machine)


Two Sample

15 days once.

Stop & Correct

the process.

Lab Assistant

Compound testing E) Ultimate Elongation



Two Sample

15 days once.

Stop & Correct

the process.

Lab Assistant






r



for Mfg

Spercial

Char. Class

Reaction Plan /

Corrective action



nt Technique

Error Proofi

ng

60 60. Extrusion Blank Shape. Extrusion Time. Nil Every Batch Visual check

70 70. Dipping Cleaning Chemical Process Temperature. As per Work Instruction Nil Every Day

Cleaning Chemical Process Time As per Work Instruction Nil Every Day _

Drying Section Dryer Drying Temperature As per Work Instruction _ Nil _ Every lot Visual check _

Drying Section Dryer Drying Time As per Work Instruction _ Nil _ Every lot Visual check _

Dipping

Hydrometer

_ As per Work Instruction Hydrometer Nil Every Day Testing Records.

80 Rubber Blank. _ As per Loading Chart Nil Random Every Batch Visual check

90 90.Moulding 90 Appearance Visual Nil Random Every Lift

Temperature 170°c ± 5°c Pyrometer Nil 2 Times Every Shift

Curing Time 3.5 mins Nil Every Lift Every Lift

Pressure. 1500psi - 2000psi Nil Every Lift Every Lift

Oilseal _ Nil Each sizes QC

Extruder & Die

Uniformity of Rubber blank.

Visual check

Every time

Stop & Correct

the process.

Extrusion operator.

Temperature Controller. Thermomet

erSampling

PlanProcess Condition

Record FR/DPC/27a

Stop & Correct

the process.

Dipping Section

Cleaning Process

Timer Controller Time

IndicatorSampling

PlanProcess Condition

Record FR/DPC/27a

Dipping Section

Temperature Controller. Dipping

Section

Timer Controller

Dipping Section

Dipping Solution - Specificgravity.

Sampling Plan

Stop & Correct

the process.

Dipping Section

80. Rubber Cutting

Weighing Machine

Digital Read out of

Weighing Machine.

Stop & Correct

the process.

Rubber Cutting Section.

Hydraulic Press Cavity

& Tools

Part should be free from Short fill , Poor flow, tearing , stripping, Bad moulding, Under cure , foreign matter , Bad shell , Bond failure , Dent

In patrol Inspection

Report.

Stop & Correct

the process.

QC - Patrol

Inspector.

Temperature Controller.


Report.

Stop & Correct

the process.

QC - Patrol

Inspector.

Timer Controller

Time Indicator


Report.

Pressure Gauge

Pressuer Indicator


Report.

Seal Dimension


Digimatic Vernier caliper.

First off (Every setting)

In First-off Approval Record

(FR/FAM/29b)

Stop & Correct

the process.






r



for Mfg

Spercial

Char. Class

Reaction Plan /

Corrective action



nt Technique

Error Proofi

ng

100 100. Finishing Visual As per Work Instruction Nil Random Each lot Visual check

110 110. Trimming ID Dimension I.D. Gauge Nil Each lot

120 Nil Each lot QC

Finishing Motor,

Mandrel & Emery sheet.

Visual check

Stop & Correct

the process.

Finishing Section

Trimming Machine

1) After trimming , Ensure Id thro ID checking Gauge. ID: 29.00 ± 0.25

First off (Every setting)

In First-off Approval Record

(FR/FAT/29a)

Stop & Correct

the process.

Trimming Section

120. Final Inspection

Gauge, Digi.vernier & ID plug

Gauge

1. Visual 2. Dimension.


Digimatic Vernier caliper.

As per Sampling Plan. 2) 100% Visual Inpection.

Final Inspection Report.

Reject the

Material.

PROCESS FMEAPart Name / Description : Oil Seal Drawing / Part no : VOS 193 Date(Orijnal): 13.9.2010 Model Year / Vehicle(s) : FMEA Number : BI / FMEA / 193 Revision Date : NILCustomer Ref. No : BSE 0300B - WK 30.14(B) Core Team : QUALITY,MARKETING & PRODUCTION. (CFT) Rev no : 00

Potential Failure Mode Det Action Taken Action taken S O D RPN

8 2 2 32

8 2 2 32

8 2 5 80

Product reject . 5 2 3 30

8 2 2 32

40. Rubber Mixing 8 2 2 32

Variation in Rubber Hardness 6 2 2 24

Specific Gravity variation. 6 2 2 24

8 2 UTM Test Result 2 32

Elongation Variation 8 2 UTM Test Result 2 32

Process Function \ Requirements

Potential effects of Failure

Sev

PC Clas

sPot. Cause(s) /

Mechanism of FailureOcc

Current Process Control Detection

RPN

Respty and target /

Comp. Date

10. A. Incoming Inspn. of Raw Material. (Shell)

1.Wrong Specification Material shipped by supplier 2. Visual defects like Rust , Burr, Bend, cutshell, tool mark, Rust, Dent, OD line mark , Pit mark supplied by the Supplier

Product reject and return to the

supplier.

Incorrect material supplied by the

supplier.

1)Incoming Inspection with respect to sampling plan. 2) Incoming Inspection Report( Ref : WI/II/01 - Rev-00)


1.Wrong Specification Material shipped by supplier 2. Visual defects like Bend, Rust , Burr, peel off supplied by the Supplier


supplier.


supplier.

1)Incoming Inspection with respect to sampling plan. 2) Incoming Inspection Report( Ref : WI/II/01 - Rev-00)


Wrong Specification Material shipped by supplier


supplier.


supplier.1) As per test certificate


1.Wrong Grade Material 2.Wrong Specification/Size Material 3.Defective material

1) Incorrect Method of stacking raw material. 2) Storekeeper product knowledge / less awareness.,

1) Work instruction displayed 2)Skill Matrix & Training for concern person /operator ( Ref : WI/SI/13 - Rev-00)

30.Weighing of Mix Ingredients

1.Incorrect ingredients weight 2.Incorrect chemical selection. 3. Life time of ingredients 4.Ingredients missed out

Performance get reduced &

Difficult to meet customer

requirement

1.Sequence of material pick - up not

followed.1)Weight Machine

1. Hardness variation 2. Poor Dispersion 3.Temperature variation of coolant circulation in roll mill.

Performance get reduced &

Difficult to meet customer

requirement

1. Inadequate mixing time.

2.Excess mixing time.

1)Harddness testing method 2)visual


Performance get reduced

1. Inadequate mixing time.


Hardness tester Indicator



Sequence of material added not followed.

Densimeter output values/ Testing

results

50. Compound testing C)Tensile Strength

a.Tensile Strength Variation Performance get reduced

1.Inadequate mixing time.


50.Compound testing D) Ultimate Elongation


1.Inadequate mixing time.


PROCESS FMEAPart Name / Description : Oil Seal Drawing / Part no : VOS 193 Date(Orijnal): 13.9.2010 Model Year / Vehicle(s) : FMEA Number : BI / FMEA / 193 Revision Date : NILCustomer Ref. No : BSE 0300B - WK 30.14(B) Core Team : QUALITY,MARKETING & PRODUCTION. (CFT) Rev no : 00

Potential Failure Mode Det Action Taken Action taken S O D RPNProcess Function \ Requirements


Sev

PC Clas

sPot. Cause(s) /

Mechanism of FailureOcc


RPN

Respty and target /

Comp. Date

60. Extrusion Over cure of Rubber compound. 8 2 2 32

70. Dipping 8 2 2 32

80. Rubber Cutting Product Rejection 5 2 2 20

90.Moulding Product Rejection 8 3 2 48

100. Finishing Product Rejection 7 2 Visual 2 28

110. Trimming Product Rejection 8 2 2 32

1. Incorrect Inspection 8 2 2 32

8 2 2 32

6 2

_

2 24

NOTE:A Typer- Detect on failur HIC- High impact characteristics FC-Functional charactisticsB Typer- Detect on failure cauBP- Blue print IP - Inprocess product characteristicsC Typer -Prevent on failure cauES- Engineering spercification

Operable at reduced level of

performance.

1. Not feed the material

continuously. 2.Problem in water circulation.

1) Periodic checking of water circulation. 2) visual1) In correct/ Excess bonding layer in

shell 2) Rust / Surface defects in shell 3) Process Temperature variation 4) Process Time variation. 5)Dipping Procedure Variation. 6)Life time of dipping chemicals.

1) Bond failure 2)Curing process may delay

Process not followed as per Work Instruction.

1)Testing Method 2) Work Instruction Displayed. ( Ref : WI/DI/02 - Rev-00)

1) Incorrect Rubber selection 2) Variation in Rubber weight

Manual cutting of Rubber blank.

Digital Read out of weigh Machine

1) Visual Defects like Short fill , Poor flow, tearing , stripping, Under cure , foreign matter , Bad shell , Bond failure , Dent, Badmoulding.

1. Hydraulic pressure , Curing Time , Temperature variation (Heater Problem ). 2.Lack of cavity cleaning

Patrol Inspection Record.

1) Uneven Flash removal, Tearing., 2) Poor Finishing

1. Improper Finishing. 2. Incorrect

selection of Tool.

1) Trimming Needle wear out 2) Incorrect Trimming / I.D. Dimension variation

Improper trimming and Improper tool Finishing.

In First-off Approval Record (FR/FAT/29a)

120. Final Inspection

Performance get reduced /

Fitment problem to the End User.

Inadequate Visual Aids and defect

samples.

1) Final Inspection Report 2) 100% Visual Inspection ( Ref :

130. Spring Fitment (Spring with oil seal)

1) Wrong Spring selection 2) spring open out while fitment with seal

Performance get reduced /

Fitment problem to the End User.

Due to carelessness of the operator.

1) I.D. Checking Gauge available.,.

140. Packing & Labelling

1) Quantity Variation 2) Incorrect packing media. 3)Product Mixup

Customer dissatisfaction.

1. Similar Parts placed at near by location or same location. 2. Counting Error.

STATISTICAL PROCESS CONTROL STUDY PART NAME: Oilseal INSTRUMENT: Digi.vernier L.COUNT: 0.01 mm

DATE: 15.09.10 PART NO.: VOS 193 SPEC: 29.00 ± 0.25 MACHINE: Trimming Machine SAMPLE SIZE: 50 PARAMETER: INNER DIAMETER NO.OF DECIMALS: 2DATA COLLECTION: -

S. NO. 1 2 3 4 5 6 7 8 9 10

U.T.L. 41.25SAMPLE D2 A2 D4

1 28.94 29.02 29.08 29.04 29.05 29.02 29.06 29.12 29.02 29.06 1 1.123 2.560 3.270

2 28.96 29.03 29.06 29.04 29.06 29.04 29.05 29.08 29.04 29.04 2 1.128 1.880 3.270

3 28.96 29.02 29.04 29.02 29.04 29.05 29.06 29.10 29.02 29.01

L.T.L. 40.753 1.693 1.020 2.570

4 28.92 29.04 29.06 29.04 29.06 29.03 29.04 29.12 29.05 29.04 4 2.059 0.730 2.230

5 28.94 29.02 29.05 29.05 29.06 29.05 29.04 29.10 29.04 29.05 5 2.326 0.590 2.110CALCULATIONS: -FOR HISTOGRAM

28.96 29.04 29.08 29.05 29.06 29.05 29.06 29.12 29.05 29.06 Xmax.= 29.1200 NO.OF NON CONFORMING PART = 50 NOS.

28.92 29.02 29.04 29.02 29.04 29.02 29.04 29.08 29.02 29.01 Xmin.= 28.9200 RANGE 0.04 0.02 0.04 0.03 0.02 0.03 0.02 0.04 0.03 0.05 R-BAR = 0.03200 NO. OF PARTS ABOVE U.T.L. = 0 NOS. AVG. 28.94 29.03 29.06 29.04 29.05 29.04 29.05 29.10 29.03 29.04 X-BAR = 29.0386 NO. OF PARTS BELOW L.T.L. = 50 NOS. Process Width ( P ) = 0.2000 Specification Width(S) = 0.5000 Index (K)={2 x (D-XBAR) / S}= 47.8456 INTERVAL FREQ. CU. FREQ.

Design Centre ( D ) = 41.0000 Interval = 0.0400 Selecting no. of classes = 5 28.8000 28.8400 0 0 Starting Point = 28.9200 No. of readings= 50.0000 Shift Of 'X-BAR' from 'D' = 11.9614 28.8400 28.8800 0 0

28.8800 28.9200 0 0

28.9200 28.9600 1 1

28.9600 29.0000 4 5

29.0000 29.0400 0 5

29.0400 29.0800 23 28

29.0800 29.1200 18 46

29.1200 29.1600 4 50

29.1600 29.2000 0 50

29.2000 29.2400 0 50

29.2400 29.2800 0 50

29.05748

29.01972

0.0675200000000001

0

0.039952.08600

REMARKS : PROCESS IS EXCELLENT Ppk=Min(PPL,PPU)= -97.71847

XLARGE

XSMALL

U.C.L.XBAR =

L.C.L.XBAR =

U.C.L.RBAR =

L.C.L.RBAR =

Std.Dev."s"=Pp=(S/6s)=

29 29 29 29 29 29 29 29 29 29 29 29

29 29 29 29 29 29 29 29 29 29 29 29

0

5

10

15

20

25 HISTOGRAM

DIMENSION

FREQ

.

1 2 3 4 5 6 7 8 9 100.000.010.020.030.040.050.060.070.08 R- CHART

RANGEU.C.L.L.C.LR-BAR

1 2 3 4 5 6 7 8 9 1028.85

28.90

28.95

29.00

29.05

29.10

29.15 X-CHARTAVG.U.C.L.L.C.L.X-BAR

SAMPLE

VALU

E

Gauge Repeatability & Reproducibility StudyAPPRAISER/ PART VOS 193 AVERAGETRIAL # 1 2 3 4 5 6 7 8 9 101(A) 1 29.02 28.94 29.12 29.08 29.06 29.12 29.02 28.96 29.14 29.04 29.0502 2 29.03 28.95 29.13 29.09 29.07 29.11 29.02 28.97 29.15 29.03 29.0553 3 29.02 28.95 29.13 29.08 29.07 29.11 29.02 28.96 29.15 29.04 29.053 Average 29.023 28.947 29.127 29.083 29.067 29.113 29.020 28.963 29.147 29.037 Xabar = 29.05Range 0.01 0.01 0.01 0.01 0.01 0.01 0.00 0.01 0.01 0.01 Rabar = 0.01

4(B) 1 29.02 28.94 29.12 29.08 29.06 29.12 29.02 28.96 29.14 29.04 29.050

5 2 29.02 28.93 29.13 29.07 29.06 29.11 29.03 28.97 29.14 29.03 29.049

6 3 29.03 28.94 29.13 29.08 29.07 29.11 29.02 28.96 29.15 29.04 29.053

Average 29.023 28.937 29.127 29.077 29.063 29.113 29.023 28.963 29.143 29.037 Xbbar = 29.0507

7 Range 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 Rbbar = 0.010

7 (C) 1 29.02 28.94 29.12 29.09 29.06 29.12 29.02 28.96 29.14 29.04 29.051

78 2 29.02 28.93 29.12 29.08 29.06 29.12 29.03 28.96 29.14 29.04 29.050

9 3 29.03 28.94 29.13 29.08 29.07 29.11 29.02 28.97 29.15 29.05 29.055

Average 29.023 28.937 29.123 29.083 29.063 29.117 29.023 28.963 29.143 29.043 Xcbar = 29.0520

Range 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 Rcbar = 0.010

16 Part Xdbar = 29.0518

Average(Xp) 29.023 28.940 29.126 29.081 29.064 29.114 29.022 28.963 29.144 29.039 Rp= 0.2

17 [Ra = 0.009 ]+[Rb= 0.010 ] + [Rc= 0.010 } / {# OF APPRAISERS =3] = Rdbar = 0.01

18 [MAX X= 29.0527 ]-[MIN X= 29.0507 0.0020

19 [ R = 0.010 UCLr = 0.0249

20 [ R = 0.010 LCLr = 0.000NOTE:- * D4=3.27 for 2 trials and 2.58 for 3trials, D3= 0 for up to 7 trials Uclr represents the limit of UCLx = 29.0617 indvidual R's. Circle those that are beyond this limit. Identify the cause and correct. Repeat LCLx = 29.0419 these readings using the same appraiser and unit as originally used or discard values and re-average and recompute R and the limiting value from the remaining observations. APPRAISER ( a ) ---- P.PAGIYA LAKSHMIAPPRAISER ( b ) ---- M.VIGNESHAPPRAISER ( c ) ---- A.SARAVANAN

ANALYSIS OF R(bar) CHART :

No. of Points outside UCLr = 0

% of Points outside UCLr = 0 %

As the Range chart is in control, so we can proceed forthe Average chart (Xbar).

ANALYSIS OF X(bar) CHART :

No. of Points outside UCLx = 15No. of Points outside LCLx = 14Total Points outside UCL & LCL = 29

% of Points outside UCLx & LCLx = 96.7

As this % is greater than 50% , the Measurement system is adequate to detect part to part variation

] XDIFF

]x[D4*=2.58] = UCLR

]x[D3*=0.00] = LCLR

a a a a a b b b b b b C C C C28.800

28.850

28.900

28.950

29.000

29.050

29.100

29.150

29.200

X(BAR) CHART

UCLx

LCLx

X(bar)

0 5 10 15 20 25 30 350.000

0.005

0.010

0.015

0.020

0.025

0.030

RANGE CHART

UCLr

LCLr

R(bar)

MEASUREMENT SYSTEM ANALYSIS

Part Name- OILSEAL Gage Name: VERNIER Date - 13.09.2010Identification No.:- 561311009

Specs. - 41.00 ± 0.25From data sheet :Rdbar = 0.010 0.0020 Rp = 0.204

Measurement Unit Analysis % Total Variation (TV)

Repeatability - Equipment Variation (EV).= 8.84 %

.= 0.006 Trials K12 0.88623 0.5908

Reproducibility - Appraiser Variation (AV)100[AV/TV]

.= 1.6 %.= 0.0010

n=number of parts Appraisers 2 3r=number of trials K2 0.7071 0.5231Repeatability & Reproducibility (R&R)

R & R = .= 8.99 %

.= 0.006 Parts K32 0.7071

Part Variation (PV) 3 0.52314 0.4467

.= 0.064 5 0.4030 .= 99.6 %6 0.37427 0.35348 0.3375

Total Variation (TV) 9 0.3249 ndc = 1.41(PV/R&R) TV = 10 0.3146 .= 12.6 ~ 13

.= 0.065

Note:-

Under 10% error - the measurement system is acceptable.10% to 30% error - may be acceptable based upon importance of application, cost of gauge,cost of repairs,etc.Over 30% error - measurement system needs improvement. Make every effort to identify the problems and have them corrected.

(Refer MSA Manual - Third Edition)

Characteristics:- ID

XDIEFFbar =

% EV = 100 [EV/TV] EV = Rdbar x K1

% AV = AV = [(XDIEFF x K2)2 - (EV2/nr)]

% R&R = 100[R&R/TV](EV2+AV2)

PV=Rp x K3 % PV = 100[PV/TV]

(R&R2+PV2)

1. All calculations are based upon predicting 5.15 sigma (99%of the area under the normal distribution curve).

2. AV- If a negative value is calculated under the square root sign, AV defaults to zero(0).

3. Guidelines for acceptance of gage repeatability and reproducibility (%R&R) are.

4. ndc is truncated to the integer & ought to be greater than or equal to 5.

Suppliers Name

List of checking Aids Date: 13.09.10

Part No.:VOS 193 Customer :

Part namOILSEAL

Rev. No.: 0Sl. Characteristic / Gauge / Instrument Gauge Availabile Calibration No Description Description Least Count Drg. of gauge / frequency/agency

Rev. No. Instrument1 OUTER DIAMETER 0.01 mm 561311009 6Months

2 INNER DIAMETER Plug Gauge BI / PG / 151 1Year

3 HEIGHT 0.01 mm QA 1Year & 6Months

4 SPRING LENGTH STEEL SCALE 1.0 mm BSS 01 1Year

PREPARED BY : APPROVED BY:

DIGITAL VERNIER CALIPER

DIAL INDICATOR / DIGITAL VERNIER

CALIPER

BI / DI / 01 /

561311009

frequency/agency

TO Date: Description: Oil Seal

Our Ref: VOS 193Dimension: 48*30*8Hardness: 70 +/- 5 Shore ASample size: Qty:

DIMENSIONAL INSPECTION

Sl.NO Description Method Specification Observation in mmOf Max Min

Checking mm mm 1 2 3 4 5

1) Outer Dia Digi.Vernier 47.93 47.78 47.89 47.84 47.82 47.81 47.85

47.91 47.92 47.86 47.88 47.82

2) Inner Dia Gauge 29.00 28.50 ok ok ok ok ok(with spring)

ok ok ok ok ok

3) Height Digi.Vernier 8.20 7.80 7.94 8.06 7.92 8.00 8.04

8.04 8.08 7.98 8.04 8.08

OK OK OK OK OK4) Visual

Conclusion:Accepted Rejected Con.Accept

P

Inspected By: Approved By:

INSPECTION REPORTCustomer Ref: BSE 0300B - WK 30.14(B)

Feb2009 CFG-1001

Part Submission Warrant

Part Name Cust. Part Num

Shown on Drawing No. Org. Part Numb

Engineering Change Level Dated

Additional Engineering Changes --- Dated ---

Safety and/or Government Regulation Purchase Order No. Weight (kg)

Checking Aid No. Checking Aid Engineering Change Level N/A Dated N/AORGANISATION MANUFACTURING INFORMATION CUSTOMER SUBMITTAL INFORMATION

Customer Name/Division

Street Address Buyer/Buyer Code

\ Region Postal Code Country Application RUBBER MOULDING

Has Customer-required Substances of Concern information been reported?

Submitted by IMDS or other customer format :

Are polymeric parts identified with appropriate ISO marking codes?REASON FOR SUBMISSION ( Check at least one )

Initial submission Change to Optional Construction or MaterialEngineering Change (s) Sub-Supplier or Material Source ChangeTooling: Transfer, Replacement, Refurbishment, or additional Change in Part ProcessingCorrection of Discrepancy Parts produced at Additional LocationTooling Inactive > than 1 year Other - please specify below

REQUESTED SUBMISSION LEVEL (Check one)Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.Level 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 organisation's manufacturing location.

SUBMISSION RESULTSThe results for dimensional measurements material and functional tests appearance criteria statistical process packageThese results meet all design record requirements: (If "NO" - Explanation Required)Mold / Cavity / Production ProcessDECLARATIONI affirm that the samples represented by this warrant are representative of our parts which where made by a process that meets all production part

I also certify that documented evidence of such compliance is on file and available for review. I have noted any deviations from this declaration below.EXPLANATION/COMMENTS:

Is each Customer Tool properly tagged and numbered?

Organisation Authorised Signature Date

Print Name: Phone No. FAX No.

Title E-mail

FOR CUSTOMER USE ONLY (IF APPLICABLE)PPAP Warrant Disposition:

Customer Signature DatePrint Name Customer Tracking Number ( Optional )

Approval Process Manual 4th Edition Requirements. I further affirm that these samples were produced at the production rate of _2800 / __8___ hours.

YES NO

Approved Rejected Other

Yes No

Yes No n/a

Yes No n/a

Yes No n/a

E4

Engineering released finished end item part name

N4

Engineering released finished end item part number

N5

Engineering released finished end item part number

G6

Enter the checking aid engineering change level

N6

Enter the checking aid engineering change level date

G7

List all authorized engineering changes not yet incorporated on the drawing but which are incorporated in the part

R8

Enter the actual weight in kilograms to four decimal places

E10

Enter the checking aid number, if one is used for dimensional inspection

N15

Enter the buyer's name and code

N17

Enter the model year, vehicle name, or engine, transmission, etc.

C24

Number of product sample(s) and submission of master sample(s) for layout to be confirmed by receiving plant.

I31

Submission Level required by Dura de Mexico.

G46

IMDS ID number obtained from IMDS website: www.mdsystem.com

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PROCESS FLOW

Part Name : " INSERT " Rev No :

Part Number : SI/RF/MECH : 1469 Date origin : 03.01.08 Revision Date :

Process Sheet : 01 Process flow no : GAJ 01 Department :TOOLROOM.



30.Strip Shearing of sheets

40. Shell forming & Piercing

50.Facing

60.Deburring Free from burr

10. Incoming Inspn. Of Raw Material. ( Material - IS 513 Grade 'DD' )

1.Wrong Specification Material shipped by supplier 2.Rusted/Pitted Material supplied by the Supplier 3.Incorrect Thickness supplied by the supplier 4. Wrong report attache

1.Correct Specification of RM 2.Rust/Pit mark free material 3.Correct Report with every consignment

1.Inspector training for intrepretation of report. 2.Operator knowledge on Rust/ Pit mark material identification,while unloading the material

1.Wrong Grade Material 2.Wrong Specification/Size Material 3.Rust/Pit mark observed material

1.Correct Grade of material 2.Correct specification/size of material 3.Rust prevention of material

1.Moisture/Acid content in Storage Area 2.Application of Rust prevention on the material surface 2.Operator knowledge on identifying / storage of Raw Material 3.Material Handling methodology / Equipment 4.Duration of storage

1.Incorrect Size (Thickness,Width & Length) of Material 2.Wrong Grade Raw Material

1.Length:1250±3.0 2.Width:70.0 ±0.50 3.Thick ness: 0.60 4.Appearance:Free from burr, bend,twist,tool mark&cut blank.

1.Operator knowledge on Parameter setting on shearing machine 2.Operator knowledge on identifying the correct Raw Material to be fed

3.Cleanliness and condition of Shearing machine 4.Capacity of the machine

Forming locator is offset to punch profile.

1.Outer dia-1:Ø 54.00 ± 0.20 2.Outer dia-2: ø48.00±0.20

Forming locator symmetrical to punch profile.

Carriage stopper length variation & tool performance.

1.Height Face:7.80 ± 0.10

Maintain stopper distance&tool bit performance.

Improper butting & belt grinder m/cbelt performance

Proper butting&maintainbelt grinding M/C belt performance.

10

30

20

40

50

60

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PROCESS FLOW

Part Name : " INSERT " Rev No :

Part Number : SI/RF/MECH : 1469 Date origin : 03.01.08 Revision Date :

Process Sheet : 01 Process flow no : GAJ 01 Department :TOOLROOM.


70. Patrol Inspection

4.Lighting in Inspection Area

90. 100% Visual Final Inspection

100.Packaging & Labelling

110.Despatch to customer 1.Wrong Label / Part Correct shipment of Part / Invoice / DC

1.Accept Good Part 2.Reject Bad Part

1.Operator skill 2.Operator knowledge on disposition methodology 3.Operator vision Capability

80.Storage after pressing (in Bins) in station / Inventroy Area

1.Parts with Pitmark/Rust 2.Damaged Parts 3.Parts with out proper identification

1.No Pit mark/Rust on parts 2.No Damages on parts 3.Correct identification with complete details

1.Operator knowledge on stacking methodology of parts in Bin 2.Bin cleanliness 3.Selection of storage Bins 4.Quantity stacked 5.Duration of storage of P

1.Thick ness:0.60±0.10 2.Material specification:IS:513 GRADE"DD" 3.Outer dia-1:Ø 54.00 ± 0.20 4.Outer dia-2: ø48.00±0.20 5.Height Face:7.80 ± 0.10 6.Appearance: Free from burr,bend,cutting taper,rust,blow holes&scratches.

1.Operator skill 2.Operator knowledge on disposition methodology 3.Operator vision Capability 4.Operator knowledge on keeping the material with identification

1.Quantity in Pack 2.Correct selection of Packing media 3.Attach correct Standard Label

1.Operator knowledge on Pack Quantity / Stacking method

110

70

90

80

100

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PROCESS FMEA

Part Name : " INSERT " Part Number : SI/RF/MECH : 1469 FMEA No : GAJ 01

Model Year / Vehicle(s) : Date(Orig ) : 3.01.08 Revision Date :

Prepared by : Core Team : TOOLROOM,QUALITY,MARKETING&PRODUCTION. Process Responsibility:TOOLROOM

Potential Failure Mode Sev Occ RPN S O D RPN

7 1 7 49

7 1 3 21

7 1 7 49

Product reject. 5 2 Proper locator 4 40

50.Facing Height u/s&o/s. Product reject. 5 3 3 45

60.Deburring Burr 6 3 3 54

Rev no :



PC Clas

sPot. Cause(s) /

Mechanism of FailureCurrent Process

Control Prevention


Det

Rec. Actions

Respty and target /

Comp. Date

Action

taken10. Incoming Inspn. Of Raw Material. ( Material - IS 513 Grade 'DD' )

1.Wrong Specification Material shipped by supplier 2.Rusted/Pitted Material supplied by the Supplier 3.Incorrect Thickness supplied by the supplier

Cust- Difficult to meet production shedule

Delivery not checked asper invoice while unloading

1.Propper incoming inspection of raw material. 2.Inspector training

RM verification against P.O.while offlaoding Visual Inspection of RM Verification of Rust/Pit mark on the surface by random check 20.Storage of Raw

Material1.Wrong Grade Material 2.Wrong Specification/Size Material 3.Rust/Pit mark

Cust- Difficult to meet production shedule

Wrong receipt from supplier Wrong disposition of RM

1.Material size&Grade specifications provided on Rmstorage room.

RM verification during incoming stage Training for Inspectors

Operator knowledge on idnetifying / storage of RM

1.Operator training

Training to operators

1.Material handling methodology/Equipment 2.Duration of RM storage

1.Operator training

WI for RM handling PM of trollys as per schedule 30.Strip Shearing of

sheets1.Incorrect Size (Thickness,Width & Length) of Material 2.Wrong Grade Raw Material

Cust- Silver streaks

Supplier compounding / formulation error / process error

Two sides&opposite sides stopper provided.

A.Visual inspection after pressing of the part


WI for cleaning of De-humidifier WI for cleaning of RM feeding area


Forming locator is offset to punch profile.

1.Forming tool 2.Machine,method & operator.

Frequency & training.

2.Facing tool,lathe method & operator.


Detail work instruction given in pcp

Product reject&rework.

1.Belt grinding m/c belt performance.


Maintain belt performance

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PROCESS FMEA

Part Name : " INSERT " Part Number : SI/RF/MECH : 1469 FMEA No : GAJ 01

Model Year / Vehicle(s) : Date(Orig ) : 3.01.08 Revision Date :

Prepared by : Core Team : TOOLROOM,QUALITY,MARKETING&PRODUCTION. Process Responsibility:TOOLROOM

Potential Failure Mode Sev Occ RPN S O D RPN

Rev no :



PC Clas

sPot. Cause(s) /

Mechanism of FailureCurrent Process

Control Prevention


Det

Rec. Actions

Respty and target /

Comp. Date

Action

taken5 3 3 45

7 2 3 42

5 3 4 60

4 3 4 48

Wrong label / Part 6 Stores personnel skill 2 3 36

NOTE:A Typer- Detect on failure HIC- High impact characteristics FC-Functional charactisticsB Typer- Detect on failure causeBP- Blue print IP - Inprocess product characteristics

C Typer -Prevent on failure caus ES- Engineering spercification

70..First & Patrol Inspection

1.Operator skill 2.Operator knowledge on disposition methodology 3.Operator vision capability


Lighting in Inspection Area

Proper lighting near the machine

80..Storage after moulding in Bins in station / Inventory Area

Parts with scratches Damaged Parts

Difficult to meet customer schedule

Operator knowledge on stacking methodology of parts in Bins


1.Bin cleanliness 2.Selection of storage Bins 3.Quantity stacked 4.Duration of storage of Parts

Training to store personnel


Accept bad Part

Difficult to meet customer schedule

1.Operator skill 2.Operator knowledge on disposition methodology 3.Operator vision capability 4.Operator knowledge of Rejection methodology

100%Visual & Gauge check up in final inspection.

Trainign to operators / Inspectors




110.Despatch to customer

Customer dissatisfied


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CONTROL PLANPrototyper Pre-launch Production

Control plan Number : SI/RF/Mech:1469 Date(Orig.):05.01.08 Rev No : Revision Date :Part Name : " INSERT " Core Team : TOOLROOM,QUALITY,MARKETTING&PRODUCTION. Customer Eng. Approval / Date : N/APart Number : SI/RF/MECH : 1469 Engineering change level : A Customer Quality approval / Date : N/ASupplier Code : 57372 Supplier / Plant approval / Date : Other Approval Date ( If required ) : Plant / Location :Bright, Pondicherry


Resp.No Product Process Size Control methods

10 10.01 Nil Each lot MAT & QA

20 20.01 Visual check Nil Each lot PRD

20.02 Nil HR

20.03 Nil HR

30 30.01 Nil IN-process ins rep PRD

30.02

Visual check Nil PRD

40 40.01 Nil 5 Nos IN-process ins rep

50 50.Facing Center lathe 50.01 Nil 5 Nos IN-process ins rep PRD

60 60.Deburring 60.01 Free from burr Maintain belt performance Free from burr Visual check Nil 5 Nos IN-process ins rep PRD

Key Contact / Phone : Mr.M..MURUGAVEL 09344006009 , 09345202505

Part / Proces

s Numbe

r


Machine,Device,Jigs,Too

ls for Mfg

Spercial

Char. Class

Reaction Plan /

Corrective actionProduct/Process

Spercification / toleranceEvaluation /

Measurement Technique

Error Proofin

gFrequenc

y

10. Incoming Inspn. Of Raw Material. ( Material - IS 513 Grade 'DD' )

1.Correct Specification of RM 2.Rust/Pit mark free material

1.Inspector training for interpretation of replort 2.Operator knowledge on repacking methodology after inspcetion 3.Operator skill to use measuring instruments/ gauges

IS513GRADE:DD Length:2500±3.0

Supplier test certificate

As per sampling plan

Visual inspection on raw material. Check as per invoice while unloading

Reject the RM

20.Storage of RM

1.Correct Grade of material 2.Correct

Moisture content in storage area

IS513GRADE:DD

Every time

Operator knowledge on identifying / storage of RM

Correct identification Alloted location

Training to Store personnel

one time

As per training calender

Training Record Skill RecordMaterial handling

methodology / Equipment Duration of storage

WI for material handling & Equipment As per FIFO

Training to Store personnel

one time

As per training calender

Training Record Skill Record

30.Strip Shearing of sheets

Shearing machine


1.Maintain stopper distance 55.00 mm 2.Operator knowledge on identifying the correct RM to be fed


Measuring tape Vernier Micrometer.

Each tray

Every time

Stop &correct


Every time

whenever colour changes

Machine capacity record


Power press&forming&Piercing tool


Forming locator symmetrical to punch profile.


1.Vernier

F.O.S. everyhour

Stop &correct


Propper cariage stopper distance.


Vernier Micrometer. Visual check

Once in hour

Stop &correct

Belt grinder M/C

Once in hour

Stop &correct

of 29

CONTROL PLANPrototyper Pre-launch Production

Control plan Number : SI/RF/Mech:1469 Date(Orig.):05.01.08 Rev No : Revision Date :Part Name : " INSERT " Core Team : TOOLROOM,QUALITY,MARKETTING&PRODUCTION. Customer Eng. Approval / Date : N/APart Number : SI/RF/MECH : 1469 Engineering change level : A Customer Quality approval / Date : N/ASupplier Code : 57372 Supplier / Plant approval / Date : Other Approval Date ( If required ) : Plant / Location :Bright, Pondicherry


Resp.No Product Process Size Control methods

Key Contact / Phone : Mr.M..MURUGAVEL 09344006009 , 09345202505

Part / Proces

s Numbe

r


Machine,Device,Jigs,Too

ls for Mfg

Spercial

Char. Class

Reaction Plan /

Corrective actionProduct/Process

Spercification / toleranceEvaluation /

Measurement Technique

Error Proofin

gFrequenc

y

70 70.01 As per sample Visual check Nil 3 shots QA

Lighting in Inspection Area Visual check Nil Per shift QA

80 80.01 Training to operator Nil HR

80.02 Visual check Nil STR

90 90.01 Nil 100% Each lot F.I.R. QA

100 100 As per packaging standard Visual check Nil 100% Each lot Visual Inspection STR

110 110 STR

70.First part & Patrol Inspection

1.Accept Good Part 2.Reject Bad Part

1.Operator skill 2.Operator

Initial Once in 2 hrs

First Part Approval Patrol Inspection

Reject the part

Proper lighting in Inspection area

One time

80.Storage after Pressing in Bins in station /

Scratch Damage Warpage

Operator knowledge on stacking methodology of parts in Bins

One time

As per schedule

Training Record Skill Record

Bin Cleanliness Selection of storage Bins Quantity stacked Duration of storage of parts

One time

Every shift



1.Operator skill 2.Operator knowledge on disposition methodology 3.Operator vision capability


Vernier Micrometer. Visual check

Reject the part


Quantity in dunnage Correct selection of dunnage Correct standard label


110.Despatch to customer

Correct shipment of Part / Invoice / DC


M VOS 193 c

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Transcript of M VOS 193 c