6251 CP

Control Plan
Page No :
Prototype
Pre-Launch
Key Contact : Amit Parikh

Phone No - 0657 - 2371021
Production
Date (Orig.) : 07.06.2014
1 of 11
Date (Rev. 1) :
Control Plan Number : PE / CP / 6251 / 01

Part / Drg. Number / Latest Change Level - 5336251 / 01
Core Team : APP, OPS,BBS,BKR, LPM
Customer Engineering Approval / Date (If Req' d)
Part Name / Description PIPE, AIR TRANSFER.
Supplier / Plant Approval / Date
Customer Quality Approval / Date (If Req' d)
Supplier / Plant Pravin Engineering Pvt.

Ltd.
Other Approval / Date (If Req' d)
Other Approval / Date (If Req. d)
Supplier Code : P0007

Characteristics
Part / Process Name / Machine, No.

Process
Operation
Device, Jig
Number
Description
Tools for
Mfg.
Al. alloy (50016)

received and
storage.
Product
Identification
Supplier
Chemical
Composition
FORMAT NO. PE - F - QS - APQP / CP - 043

REV - 01
Methods
Process
> Verification of
composition %
of elements in
alloy.
Storage
Spl. Char. Product/Process/

Class.
Specification /
Tolerance
Identification colour
Mark given on Ingot.
(W.I. # 3.19)
Approved sources
> As per Cummins

Engg. STD -50016
> different Al. alloy
Evaluation
Measurement
Technique
Visual
Visual
Third Party
Spectro
analysis
Visual
Sample
Recor Resp
ding
Size
Freq.
Y/N
100%
cont.
100%
cont.
Control Method
>Supplier Invoice
>Supplier T.C.
>Batch wise
Raw
Material
verification
Indent
Reaction Plan
> Reject & return

to supplier
> Rework
>
Approved source list

> Reject
> W.I. # 3.19.A
Once Monthly/
Lot
Wise
> Third Party spectro

report
100%
> Stock Register for Al. > Re - arrange &

alloy.
Re-check.
> Different location for
different Al. alloy in raw
material store.
cont.
> Reject &Return

to supplier
NOTE S SUPERVISOR , IINSPECTOR , O OPERATOR
(SIGNATURE)
CONTROL PLAN
Page No :

Part Name / Description
Part / Drg. Number

PIPE, AIR TRANSFER
Prototype
Pre-Launch
Process
Machine,
No.
Name /
Device, Jig Tools
Operation
for Mfg.
Description
Shell Core
Making
5336251
Production
Characteristics
Part /
Process
Number
Date (Orig.) : 07.06.2014
Product
Methods
Process
Spl. Product/Process/
Char. Specification /
Class Tolerance
.
Evaluation
Measurement
Technique
Sample
Recor Resp
ding
Control Method
Reaction Plan
Size
Once
Freq.
per hour
Y/N
Y
> PCS ( F-10)

> W.I #
3.33.A
> Re-set & Re-check
> Visual
100%
Cont.
> Re-Mix & Re-check
> 60 - 70 Sec
> Visual
100%
Cont.
Dry
(moisture free)
> Visual
100%
Cont.
> W.I # 3.33

(for Shell
Core)
> Operators
awareness
> W.I # 3.33.B
(for Shell
Core)
> Operators
awareness
> Visual Sample
> Proper Clean
> Visual
100%
Cont.
> Operators
awareness
> Visual Sample
> Segregate & Reject /

Rework
> Visual
100%
Cont.
> Visual Sample.
> Check die mounting

> Die handed
over to maintenance
> Ganesh Shell

Core PE/M/72
> Die Temp.
L.H.S 330 30C > Temp. Controller

R.H.S 330 30C
> Shell Core Die

> Brush
> Knife
> Zirkote Coat

Solution
> Zirkote : water

1 : 1.5
> Curing Time
> Resin Coated

Sand
> Parting line clean
> Re-adjust & Re-check
> Pre-heat in sunlight or

under 60 Watt bulb for
moisture free
> Parting line

mismatch
(no extra sand

particle)
> No Mismatch
> Core Baking
> Proper Baking
> Visual
100%
Cont.
> Visual Sample.
> Segregate & Reject
> Inside Core
> No Solid Core
> Visual
100%
Cont.
> Visual Sample.
> Remove the extra

sand from inside the
core
> Outside Surface

of core
> Proper Coated
> Visual
100%
Cont.
> Visual Sample.
> Re-coat / Core

Repairing
10
> Damage
> No Damage
> Visual
100%
Cont.

REV - 01
O / I > PCS ( F-10)
(SIGNATURE)
CONTROL PLAN
Page No :

Part / Drg. Number

PIPE, AIR TRANSFER
Prototype
Pre-Launch
5336251
Production
Characteristics
Part /
Process
Number
Process
Machine, Device, No.
Name /
Jig Tools for Mfg.
Operation
Description
Melting of Al. > Melting Furnace

alloy
(Electric)
> Crucible
Product
Process
> Holding Furnace

Temp.
> Molten Metal
Methods
Class Tolerance

REV - 01
Evaluation
Measurement
Technique
Sample
Recor Resp
ding
Control Method
Reaction Plan
Size
Freq.
Y/N
> 950 C (Approx.)
> Temp. Controller
100%
Cont.
> Tempreture
Controler
> Re-Set &

Re-check
> 650 + 50C
> Temp. Indicator
Once
melt wise
> W.I # 3.41

(for Melting Furnace)
> Re-adjust &

Re-check
> Weight
Once
melt wise
> W.I # 3.41

(for Melting Furnace)
> Re-purified
100%
Cont.
> Different Bins for

different alloy
(colour code)
> Reject & Scrap
> Dipping Ladle
Date (Orig.) : 07.06.2014
-0
> Purification of metal

with Al. Cover flux
> 500 gm / 100 Kg

Molten Al.
> To avoid Mix-up of

different Al. alloy
> Melt same Al alloy > Visual
( S I G NAT U R E )
CONTROL PLAN
Page No :

Part / Drg. Number

PIPE, AIR TRANSFER
Prototype
Pre-Launch
5336251
Production
Characteristics
Part /
Process
Number
Process
Machine, Device, No.
Name /
Jig Tools for Mfg.
Operation
Description
Preparation > Holding

of Al. alloy Furnace (Electric)
Date (Orig.) : 07.06.2014
Product
Process
Methods
Class Tolerance
.
Evaluation
Measurement
Technique
Sample
Record Resp
ing
Size
Freq.
Y/N
Control Method
Reaction Plan
> Holding Furnace

Temp.
> 705 15C
> Temp. Controller
100%
Cont.
> Tempreture
Controler
> Re-Set &

Re-check
> Crucible
> Molten Metal Temp
> 625 15C
> Temp. Indicator

Calibrated
Once
per hour
> PCS ( F-08)
> Re-adjust &

Re-check
> Chemical Lab

Equipment
> Degassing with Tablet
> 2 Tab / 100 Kg of

Molten Al.
> Weight (Pc)

1 Tab = 50 gm
Once
melt wise
> W.I # 3.2.A

> Re-Degassing
(for Molten (1 tab if required)
metal)
> Purification of metal

with Al. Cover flux
> 200 gm / 100 Kg

of Molten Al.
> Weight (Pot)

1 Pot = 200 gm
Once
melt wise
> W.I # 3.2.A

> Re-purified
(for Molten
metal)
> Grain refiner

Al. Innoculent
Tablet
> Tensile Strength
> Hardness Test
> 1 Tab / 100 Kg of

Molten Al.
> Weight (Pc)

1 Tab = 50 gm
Once
melt wise
> As per Cummins

Engg. STD -50016
> Tensile Testing

Machine
Model:TKG-50KN
>
Hardness
Two
Batch
wise
> W.I # 3.2.A

> Re-Degassing
(for Molten (1 tab if required)
metal)
> Mechanical
> Reject &Return to
properties
supplier
Log. Book
(Degasser Tablet)
> Dipping Ladle

REV - 01
Mechanical
properties.
( S I G NAT U R E )
CONTROL PLAN
Page No :

PIPE, AIR TRANSFER
Prototype
Pre-Launch
5336251
Production
Characteristics
Part /
Process
Number
Process
Machine,
No.
Name /
Device, Jig
Operation Tools for Mfg.
Description
Gravity Die
Casting
> Gravity Die

>
Holding
furnace
> Spoon
>
Tong
> Spray
Gun
>
Hard / Soft
Brush
Date (Orig.) : 07.06.2014
Part / Drg. Number
Product
Methods
Process
Char. Specification / Tolerance
Class.
Evaluation
Measurement
Technique
Sample
Recor Resp
ding
Control Method
Reaction Plan
Size
Freq.
Y/N
> Molten Metal

Temp.
> 625 15C
>Temp. Indicator
Once
per
hour
> PCS ( F-08)
> Re-adjust &

Re-check
> Preparation of
Die coat
> French chalk powder :

water : sodium silicate
10 :15 :
0.50
> Uniformity in Die Coat
Coating
> Weight
Once
Shift
> W.I # 3.3
> Shake well before use
> Visual
100%
cont.
(for Die Coating)
> Die Coat Spray
> Die Temp.
> 175 25C
> Temp. Indicator
Once
Start
> Pouring
> Un-interupted
> Same Speed
> Same Distance
> Visual
100%
cont.
> Solidification Time
> When runner / riser

solidify
(End of liquid form)
> Visual
100%
cont.
> Operator
Awareness
> Timely Die Open
> 4.5 0.76 (W.Thick)
> Q.I.E
1st Pc
Shift
O/I
> F.P.A. (F-15)
> Reject / Take the deviation
Dimn. Parameter
( F.P.A)
> W.I # 3.3
> Re-coating &

Re-check
(for Die Coating)

> W.I # 3.5
> Die Pre Heat
(for
G.D.C. )
> Control Pouring
> Operator
Awareness
> 45.0 0.76 (I.D)

> 67.7 0.76 (I.D)
> 76.7 0.76 (O.D)
> Grain structure
> Fine
> Fracture Test
1 Pc
25 Pcs
> PCS ( F-08)
> Crack / Blow Hole
> No Crack / Blow Hole
> Visual
100%
cont.
> PCS ( F-08)
10 > Surface finish
> Smooth & No "V" Notch

at parting line (inside)
> Visual
100%
cont.
> Visual Sample
> Rectify & Recheck

(Change die coat & donot
use improper parting line
clean shell core)
11 > Product
Identification
> Should Exit
> Visual
100%
cont.
> Visual Sample
> Rectify & Recheck (Clean

the die coat layer stick in
engraving no. by pointed
pin)
> After approval from
customer part identification
will engrave

REV - 01
(SIGNATURE)
CONTROL PLAN
Page No: 6

PIPE, AIR TRANSFER
Prototype
Pre-Launch
Part / Drg. Number
Date (Orig.) : 07.06.2014

5336251
Production
Characteristics
Part /
Process
Number
Process
Name /
Operation
Description
Cutting of
Runner /
Riser
Machine,
Device, Jig
Tools for
Mfg.
No.
Product
Methods
Process
Spl.
Product/Process/
Char. Specification / Tolerance
Class.
Evaluation
Measurement
Technique
Sample
Size
Fettling
>Bandsaw
Cutting M/c
> Cutting
Blade
> Flat File

>Round File
>Vice
> Vibration &

Sharpness of
cutting blade
Freq.
Control Method
> Cutting blade

10 TPI
> Visual
100%
cont
> W.I # 3.8 for

Cutting M/C
> Visual
100%
cont.
> Visual Sample
100%
cont.
> W. I # 3.9
(for fettling)
>visual
sample
-do-
> Component
> Free fronm Runner /

Riser
Parting Line
Free from Burrs.

Smooth & parting line
should not be mismatch
Visual
Reaction Plan
Y/N
> Re joint & Re grinding
> Segregate & Reject / Rework
Segregate &
Reject / Rework
Sharp edge
Smooth
Visual
100%
cont.
Unwanted
Projection
Remove & Smooth
Visual
100%
cont.
- do-
-do-
Inside surface
Smooth & Free from

sand / Foreign particles
Visual
100%
cont.
- do-
> Segregate & Reject / Rework

(Rectity the mismatch component
by filling or buffing)

REV - 01
Recor Resp
ding
-do-
(SIGNATURE)
CONTROL PLAN
Page No: 7

PIPE, AIR TRANSFER
Prototype
Part / Drg. Number
Date (Orig.) : 07.06.2014

5336251
Pre-Launch
Production
Machine,
Device, Jig
Tools for
Mfg.
No.
Product
Size
Freq.
Y/N
Hot Cure Water

Temp.
90 C 5 c
Temp. Controller
Each
cycle
> Daily Check List

(For V.I)
> Re-set & Re-check
Vacuum pressure
at Auto Clave
-760 mm of Hg
Pressure Gauge
Each
cycle
> Daily Check List

(For V.I)
> Rectify & Re-check
Cycle Time
> Dry 30 min.

> Dry wet 60 min.
> Hot water 30
min.
Timer / Watch
Each
cycle
Porosity seal
Leak Proof Test
100%
cont.
> Record for V.I

> L.P.T
> Reject the Leakage components
Air Pressure
> Pressure
Gauge
100%
cont.
> Re - Set &
Re-check
> Timer
100%
cont.
> Calibration of
Gauge
> W.I.# 3.14
for LPT
> W.I # 3.14 for LPT
> Re - Set &
Re-check
100%
cont.
LPT Record
Characteristics
Part /
Process
Number
Process
Name /
Operation
Description
Vacuum
> V.I (IMP)
Impregnation PLANT
Leak Proof
Test
Leak Proof
Vacuum
impregnated
component
-
Methods
Process
Class. Tolerance
1 Kg / cm
Evaluation
Measurement
Technique
Sample
Recor Resp
ding
Test fixture
> Holding time =
1min
PE/FIX/LPT/3
2
2

REV - 01
Leak Proof
Dipping in water
No Leakage
Visual
(Air Bubble)
Control Method
> W.I # 3.13 for V.I
Reaction Plan
> Re-set & Re-check
> Leakage Components move to

VI.
(SIGNATURE)
CONTROL PLAN
Page No : 8

PIPE, AIR TRANSFER
Prototype
Pre-Launch
Part / Drg. Number
Production
Characteristics
Part / Process Name Machine, Device,

Process
/ Operation
Jig Tools for Mfg.
Number
Description
10
CNC Machining > CNC M/c

PE/ M/82
>
Machining Fixture
PE/
FIX/LM-34
> Facing Insert
> Grooving Insert
> Parting Tool
>Chamfering
Insert
REV - 01
Methods
No.
Product
Clamping of
component in
Fixture
> Tight Fitting in

fixture
>Tool change
frequency
> After tool blunt
Date (Orig.) : 07.06.2014

5336251
Process
Class. Tolerance
> Facing Insert
> 8000
> Grooving Insert
> 9000
> Parting Tool
> 9000
> M/c Parameter
RPM
Feed
> Facing Insert
900
0.15
> Chamfering
900
0.15
> Grooving Insert
900
0.04
> Parting Tool
900
0.04
Evaluation
Measurement
Technique
Visual
> CRT screen
> Diameter
> Diameter
> Position
> Diameter
> Position
> Width
> Depth
> Height
> Width
> Flatness
> Center Height
> 155.8 1.02
> Chamfer
> 0.5 0.2 x 45
> Height Gauge

(Trimos)
> Profile Projector
> Chamfer
> 0.5 0.2 x 45
> Profile Projector
Sample
Reco Resp Control Method

rding
Size
Freq.
Y/N
100%
cont.
> Rectify & Re-check

> Notify
the Production Supervisor
Tool issue
register
> Replace against Quality

Issue
100%
> Programming > Lock the Program
> PCS (F-11)

> PDS
>
Cpk (major)
> 54.0 0.10
> Digital Caliper
1 Pc
25Pcs
O/I
> 56.0 0.25
> Digital Caliper
1 Pc
25Pcs
O/I
> C.M.M
1 Pc
set up
> Digital Caliper
1 Pc
25Pcs
O/I
> C.M.M
1 Pc
set up
> 3.22 0.1
> Digital Caliper
1 Pc
25Pcs
O/I
> 2.0 0.08
> C.M.M
1 Pc
set up
> 2.33 0.13
> Profile Projector
> 3.65 0.05
> Profile Projector
>
> C.M.M
1 Pc
25Pcs
O/I
1 Pc
set up
> 65.85 0.15
/ 0.10
Reaction Plan
> Segregate & Reject.
(SIGNATURE)
CONTROL PLAN
Page No :

PIPE, AIR TRANSFER
Prototype
Pre-Launch
Part / Drg. Number

5336251
Production
Characteristics
Part /
Process
Number
Process
Name /
Operation
Description
11
Deburing
12
High
Pressure
Cleaning
Machine,
Device, Jig
Tools for Mfg.
> Flat file
High Pressure
Cleaning
Machine
No.
Product
Methods
Process
Spl.
Char.
Class.
Product/Process/
Specification /
Tolerance
Evaluation
Measurement
Technique
Size
Freq.
Y/N
> Free from burrs &

sharp edge.
Visual
100%
cont.
> Temperture
Controller
100%
cont.
100%
> Facing
surface
> Solvent
Temp.
> 55 C 5 C
> Compressed
air pressure
> 5 to 6 bars
> Free from burrs,

dust, dust oily
surface
> Component
Cleaning
09
Date (Orig.) : 07.06.2014
> Visual
Sample
Record Resp
ing
Control Method
Reaction Plan
Rectify & Re-check
> Daily Checklist

(for H.P.C)
> Re-set & Re-check
> Daily Checklist

(for H.P.C)
> Re-adjust & Re-check
cont.
> Millipore Test
> Re - clean & Re - check
REV - 01
( S I G NAT U R E )
n Plan
Re-check
check
Re-check
Re - check
CONTROL PLAN
Page No :

PIPE, AIR TRANSFER
Prototype
Pre-Launch
Part / Drg. Number

5336251
Production
Characteristics
Part / Process Name /

Process
Operation
Number
Description
13
Final Inspection /
Pre Dispatch
Inspection
No.
> Diameter
> Diameter
> Width
REV - 01
Product
Methods
Machine,
Device, Jig
Tools for Mfg.
10
Date (Orig.) : 07.06.2014
Process
Spl.
Char.
Class.
Product/Process/
Specification /
Tolerance
Evaluation
Measurement
Technique
> 54.0 0.10
> Digital Caliper
> 65.85 0.15
> Digital Caliper
> 3.22 0.1
> Digital Caliper
> Depth
> 2.0 0.08
> C.M.M
> Flatness
>
> C.M.M
> Diameter
> 76.70 0.76
> Vernier Caliper
> Center Height
> 155.8 1.02
> Height Gauge

(Trimos)
Inner Surface
> Smooth
> Free from
sand particles
Outer Surface
/ 0.10
> Smooth
> Free from
burrs / Sharp edge
& Casting defect.
Sample
Reco Resp
rding
Size
Freq.
Y/N
As per Sampling
Plan
Lot
Visual
100%
Visual
100%
Control
Method
Reaction Plan
> PDI Report > Stop Dispatch

(F
>Segregate & Rework /
- 6)
Reject
>
Quality Plan
CATEGORY-I
(F - 37)
> For
Immediate Despatch
> Log Book
F.I. OK
For Final
component will
move
Inspection
with PDI report.
(log - 4)
> CATEGORY- II
> For Inventory
F.I. OK
component will
move
to strorage area & the PDI
report will be made
before dispatch.

-
( S I G NAT U R E )
CONTROL PLAN
Page No : 11
PIPE, AIR TRANSFER
Prototype
Pre-Launch
Part / Drg. Number
Production
Characteristics
Part /
Process
Number
14
Process
Name /
Operation
Description
Packaging
Machine,
Device, Jig
Tools for Mfg.
> Packing slip

> Cartoon
Methods
No.
Product
Process
Spl.
Char.
Class.
Product/Process/
Specification /
Tolerance
Evaluation Measurement
Technique
Barcode Label 2D
Matrix Barcode
sticker
2D Matrix Barcode
Sticker
as per
cummins Engg. Std
No 18287
Visual
Size
100%
Freq.
cont.
Y/N
N
> Height
20
> Vernier Height Gauge
100%
cont.
> Center Distance
100%
cont.
> Height
75
100%
cont.
> Center Distance
20
100%
cont.
As per packaging
Standard of
component.
Visual
100%
cont.
> Brown Tape
15
16
Storage
Dispatch
Date (Orig.) : 07.06.2014

5336251
Sample
Record Resp
ing
Control Method
Reaction Plan
> Re- Label &

Re - check
> Repack &

Re - check
> Ware House
Tagging
Visual
100% Lot wise
> Presence of 100% > Re - tagging &

Tagging
Re - check
> Ware House
As per Invoice
Visual
100%
> PDI Report

> Packing
slip
>
Dock Audit
cont.
REV - 01
( SIGNATURE)
> Stop the Dispatch

6251 CP

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Control Plan

Key Contact : Amit Parikh

Date (Orig.) : 07.06.2014

Control Plan Number : PE / CP / 6251 / 01

Core Team : APP, OPS,BBS,BKR, LPM

Customer Engineering Approval / Date (If Req' d)

Part Name / Description PIPE, AIR TRANSFER.

Supplier / Plant Approval / Date

Customer Quality Approval / Date (If Req' d)

Supplier / Plant Pravin Engineering Pvt.

Other Approval / Date (If Req' d)

Other Approval / Date (If Req. d)

Supplier Code : P0007

Part / Process Name / Machine, No.

Al. alloy (50016)

FORMAT NO. PE - F - QS - APQP / CP - 043

Spl. Char. Product/Process/

> As per Cummins

> different Al. alloy

> Reject & return

Approved source list

> Third Party spectro

> Stock Register for Al. > Re - arrange &

> Reject &Return

NOTE S SUPERVISOR , IINSPECTOR , O OPERATOR

Control Plan Number : PE / CP / 6251 / 02

Part / Drg. Number

Date (Orig.) : 07.06.2014

> PCS ( F-10)

> Re-set & Re-check

> Re-Mix & Re-check

> W.I # 3.33

> Proper Clean

> Segregate & Reject /

> Visual Sample.

> Check die mounting

> Ganesh Shell

> Die Temp.

L.H.S 330 30C > Temp. Controller

> Shell Core Die

> Zirkote Coat

> Zirkote : water

> Curing Time

> Resin Coated

> Parting line clean

> Re-adjust & Re-check

> Pre-heat in sunlight or

> Parting line

(no extra sand

> Core Baking

> Proper Baking

> Visual Sample.

> Segregate & Reject

> Inside Core

> No Solid Core

> Visual Sample.

> Remove the extra

> Outside Surface

> Proper Coated

> Visual Sample.

> Re-coat / Core

FORMAT NO. PE - F - QS - APQP / CP - 043

O / I > PCS ( F-10)