CRITICAL HERO HONDA MOTORS LIMITED,

MODEL P-90 MAJOR ABC PROCESS QUALITY CONTROL SHEET (I) 69 KM. STONE, DELHI JAIPUR HIGHWAY,
MINOR DHARUHERA (HARYANA)
PART NO. 7500002890(HHML Part No. 18350-KTC-9000 DOC NO. PFC/E38000-10003 REV NO. 02
PART NAME MUFFLER COMPLETE EXHAUST WELDING PROCESS
SOURCE MAJESTIC AUTO LIMITED,LUDHIANA DATE : 22.04.09 PAGE 01 OF 02

BASIC FOR PRODUCTION CHANGE PARTS PURCHASED FROM OUTSIDE VENDOR

Approval Test Prodn. Submit Ist
Critical
PROCESS FLOW DIAGRAM S.No. Process & Required checked Piece date S.No. PART No. Part Name Supplier
Description

1 7500002925 PIPE INNER SUB ASSY. THAPAR ENGG.

2 7500002942 PLATE TAIL WELDED MAGNA CORE
00 10 3 7500002915 STAY MUFFLER MAGNA CORE
INSPECTION BODY & CAP 15
RECEIPT OF IN PROCESS 4 7500002915 STOPPER MAIN STAND MAGNA CORE
BODY FORMING MAIN
BOPS INSPECTION 5 7500002954 STAY MUFFLER COVER MAGNA CORE
CIR.WELDING MUFFLER
BODY 6 7500002918 STAY B PROTCTOR MAGNA CORE
7 7500002919 HOOK PROTECTOR MAGNA CORE
8 7500002920 STAY HOUSE GUIDE MAGNA CORE
IN PROCESS
9 7500002896 PIPE DIFFUSER COMP MAGNA CORE
INSPECTION
10 7500002891 PIPE COMPL.EXHAUST THAPAR ENGG.

30
20 IN PROCESS 25
IN PROCESS PLATE TAIL SPOT
INNER SUB INSPECTION INSPECTION WELDING
ASSY.PLUG PLATE TAIL FITTING
WELDING

IN PROCESS
INSPECTION

35
IN PROCESS 40 45
IN PROCESS
PLUG WELDING INSPECTION CURLING MUFF. STAY MUFFLER
INSPECTION
COMPLETION COMP WELDING

IN PROCESS
INSPECTION

55
50 55 IN PROCESS STAY HOUSE GUIDE
STOPPR MAIN IN PROCESS STOPPER MAIN INSPECTION WELDING
STAND INSPECTION STAND WELDING
NO.PUNCHING

60
STAY MUFFLER COVER,STAY CONTINUE
IN PROCESS B PROTECTOR,HOOK
INSPECTION PROTECTOR WELDING

HHML APPROVAL VENDOR APPROVAL

DATE NAME AUTHORISED DATE CHECKED APPROVED
SIGNATORY LOT MARKING BY BY

LOT CODE 22.04.09 ENGG. DEPTT. QA Mr.PRITPAL SINGH

 CRITICAL
HERO HONDA MOTORS LIMITED,
MAJOR
MODEL P-90 ABC PROCESS QUALITY CONTROL SHEET (I) 69 KM. STONE, DELHI JAIPUR HIGHWAY,
DHARUHERA (HARYANA)
MINOR
PART NO. 7500002890(HHML Part No. 18350-KTC-9000 DOC NO. PFC/E38000-10003 REV NO. 02
PART NAME MUFFLER COMPLETE EXHAUST WELDING PROCESS
SOURCE MAJESTIC AUTO LIMITED,LUDHIANA DATE : 22.04.09 PAGE 02 OF 02

BASIC FOR PRODUCTION CHANGE PARTS PURCHASED FROM OUTSIDE VENDOR

Critical Approval Test Prodn. Submit Ist
PROCESS FLOW DIAGRAM S.No. Process & Required checked Piece date S.No. Part No. Part Name Supplier
Description
1 7500002925 PIPE INNER SUB ASSY. THAPAR ENGG.
2 7500002942 PLATE TAIL WELDED MAGNA CORE
70 70 3 7500002915 STAY MUFFLER THAPAR ENGG.
IN PROSESS PIPE COMP IN 75
PIPE 4 7500002915 STOPPER MAIN STAND THAPAR ENGG.
INSPECTION EXHAUST PROCESS WELDING
DIFFUSER 5 7500002954 STAY MUFFLER COVER MAGNA CORE
WELDING INSPECTION COMPLETION &
WELDING 6 7500002918 STAY B PROTCTOR MAGNA CORE
REPAIR
7 7500002919 HOOK PROTECTOR MAGNA CORE
8 7500002920 STAY HOUSE GUIDE MAGNA CORE
IN PROCESS
9 7500002896 PIPE DIFFUSER COMP MAGNA CORE
INSPECTION
10 7500002891 PIPE COMPL.EXHAUST THAPAR ENGG.

80 IN PROCESS 85
FINAL
SANDING, INSPECTION INSPECTION
GRINDING TRUING

HHML APPROVAL VENDOR APPROVAL

DATE NAME AUTHORI DATE CHECKED APPROVED
SED LOT MARKING BY BY
SIGNATO
LOT CODE 22.04.09 ENGG. DEPT. QA Mr.PRITPAL SINGH
 PROCESS QUALITY CONTROL SHEET (II)
PART NAME: MUFFLER COMPLETE EXHAUST MODEL P-90 DOC.NO:E38000-10003
DHARUHERA PART NO. : 7500002890(HHML Part No. 18350-KTC-9000 PAGE-------01--------OF----------02---------
CONTROL OF MANUFACTURING CONDITIONS

Important Item
QUALITY CHARACTERISTICS

Trouble Mode
Sequence of
Process
Process Name/Equipment Name(Name of
Supplier)
Detail of
No. Control Item Specified value Inspected by Inspection Method Inspection Frequency Data Form Control item Specified value Inspected by Inspection Method Inspection Frequency Data form
Process/Sketch

00 RECEIPT OF BOP'S
1.PIPE INNER SUB ASSY. RQC GAUGE(T12-81207) SAMPLING F/INS/08
2. PLATE TAIL WELDED RQC GAUGE(T12-81202) SAMPLING F/INS/08
3.STAY MUFFLER RQC GAUGE(T12-81204) SAMPLING F/INS/08
4.STOPPER MAIN STAND RQC GAUGE(T12-81206) SAMPLING F/INS/08
5.STAY HOUSE GUIDE RQC V CALIPER SAMPLING F/INS/08
6.STAY B PROTECTOR RQC GAUGE(T12-81233) SAMPLING F/INS/08
7.HOOK PROTECTOR RQC GAUGE(T12-81221) SAMPLING F/INS/08
8.STAY MUFFLER COVER RQC GAUGE(T12-81228) SAMPLING F/INS/08
9.PIPE DIFFUSER RQC GAUGE(T12-81208) SAMPLING F/INS/08
10.PIPE COMP. EXH RQC GAUGE(T12-81267) SAMPLING F/INS/08

10 BODY & CAP BODY CIR. WELDING/CIR 1 MISMATCH NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 CURENT 120A SUPERVISOR AMMETER EVERY 4 HRS. PATROL INS.SHT.

WELDING SPM(DYNARC) BLOW HOLE/POROSITY NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 VOLTAGE 20 V SUPERVISOR VOLTMETER DO PATROL INS.SHT.
CLAMP MARK NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 GAS FLOW 8 LTR/MIN. SUPERVISOR FLOW METER DO PATROL INS.SHT.
WIRE DIA 1.0 mm SUPERVISOR MICROMETER ONCE IN A SHIFT
WIRE MATL. SUS 308L SUPERVISOR

15 FORMING MAIN MUFFLER BODY 1 DIMN. 75.20.5 mm QC REC GAUGE THRICE A SHIFT F/INMW/01-08 DIE AND PUNCH SUPERVISOR VISUAL EVERY 4 HOURS. PATROL INS. SHT
EXCESSIVE WEAR OUT NOT ALLOWED
FORMING SPM 2 DAMAGE/DEPRESSION MARKS NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-09
DIMN. FROM BODY BIG END TO
TOOL NO.T16-81198 3 198 1.5
mm QC V CALIPER THRICE A SHIFT F/INMW/01-10
FORMING CURVATURE

INNER SUB ASSY. PLUG WELDING DIMN. FROM SEPRATOR BIG END TO
20 1 61.00.5mm QC V CALIPER THRICE A SHIFT F/INMW/01-06 CURRENT 120 A SUPERVISOR AMMETER EVERY 4 HRS. PATROL INS.SHT.
WITH MUFF.COMPL./WELD ADDA(MAL) BODY END

TOOL NO.T13-81189 2 WELDING SMOOTH QC VISUAL THRICE A SHIFT F/INMW/01-06 VOLTAGE 20 V VOLTMETER
GAS FLOW 8 LTR/MIN. MICROMETER
WIRE DIA 1.0 mm
WIRE MATL. SUS 308L

PLATE TAIL WELDED FITTING IN TOOLING ELEMENTS

25 1 BODY END TO TAIL PLATE FACE 160.5mm QC V CALIPER THRICE A SHIFT F/INMW/01-06 NOT ALLOWED SUPERVISOR VISUAL EVERY 4 HRS. PATROL INSP. SHT
MUFFLER COMP. EXCESSIVE WEAR OFF

TOOL NO. MAL-135 INCLINATION OF PLATE TAIL NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06

PLATE TAIL WELDED SPOT WELDING MANUAL

NO BREAKAGE OF
30 WITH MUFF.COMP.SPOT WELDING 1 WELD STRENGTH QC (DESTRUCTIVE ONCE IN SHIFT F/INMW/01-06 SPOT DIA 6.0 mm SUPERVISOR V.C EVERY 4 HRS. PATROL INS.SHT.
WELDED NUGGEST
SPM(SUNRISE) TESTING)

2 NUGGEST DIA 4.5-4.8 mm QC GAUGE THRICE A SHIFT F/INMW/01-06 SQUEEZE 2-2.3 CONTROL PANEL

3 ANGLE 90O APART QC VISUAL THRICE A SHIFT F/INMW/01-06 WELD 1.4-1.6 CONTROL PANEL

4 NO. OF SPOTS 3 SPOTS QC VISUAL THRICE A SHIFT F/INMW/01-06 HOLD 0.8-1.2 CONTROL PANEL

HEAT CONTROL 3-3.3 CONTROL PANEL

VOLT 408V CONTROL PANEL

INNER SUB ASSY. PLUG WELDING

35 1 NO. OF PLUG HOLES 4 NOS. QC VISUAL THRICE A SHIFT F/INMW/01-06 CURRENT 120 A SUPERVISOR AMMETER EVERY 4 HRS. PATROL INS.SHT.
COMPLETION/WELDING ADDA(MAL)
2 WELDING SMOOTH QC VISUAL THRICE A SHIFT F/INMW/01-06 VOLTAGE 20 V VOLTMETER
GAS FLOW 8 LTR/MIN. FLOW METER
WIRE DIA 1.0 mm MICROMETER
WIRE MATL. SUS 308L
40 CURLING MUFF. COMP. 1 DIMN. 70.5 mm QC V.CALIPER THRICE A SHIFT F/INMW/01-06
SPM(MAL) 2 DIMN. 1101.0 mm QC V.CALIPER THRICE A SHIFT F/INMW/01-06

TOOL NO. MAL-178 3 WALL THK. 40.3 mm QC V.CALIPER THRICE A SHIFT F/INMW/01-06
OVALITY, BULGING,CRACK,FACE
4 NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 UNIFORM CLAMPING ___________ OPERATOR VISUAL
DEFORMATION

STAY MUFF.WELDING WITH MUFFLER DIMN. FROM START POSITION OF STAY

45 1 236.71.0mm QC H.GAUGE THRICE A SHIFT F/INMW/01-06 CURRENT 120 A SUPERVISOR AMMETER EVERY 4 HRS. PATROL INS.SHT.
COMP.SPM(MAL) TO CAP BODY END
BLOW HOLES POROSITY,
SPM(MAL) 2 NOT ALLOWED QC VISUAL VOLTAGE 20 V VOLTMETER
PUNTURE,SCRATCHES,DAMAGE
TOOL NO- MAL-208 GAS FLOW 8 LTR/MIN. FLOW METER
WIRE DIA 1.0 mm MICROMETER
WIRE MATL. SUS 308L

50 STOPPER MAIN STAND NO PUNCHING 1 LETTER HEIGHT 5 QC VISUAL THRICE A SHIFT F/INMW/01-06 PNEU PRESSURE 5-6 BARS SUPERVISOR PRESSURE GAUGE EVERY 4 HRS. PATROL INSP. SHT

HYD. PNUM. PRESS 2 CATALYST CODE MI QC VISUAL THRICE A SHIFT F/INMW/01-06

MONTH & YEAR OF

TOOL NO.T13-81275 3 MONTH & YEAR QC VISUAL THRICE A SHIFT F/INMW/01-06 NO PUNCH EXCESSIVE NOT ALLOWED SUPERVISOR VISUAL EVERY 4 HRS. PATROL INSP. SHT
MANUFACTURING

Classification of trouble modes of completed vehicles (machines) : 1.Fire, 2. Fails to stop, 3. Fails to run, 4. Receives electric shocks, 5. Fails to conform to legal requirements, 6. Outer appearance and commercial value.
 PROCESS QUALITY CONTROL SHEET (II)
PART NAME :MUFFLER COMP. EXH. MODEL P-90 DOC.NO:E38000-10003
DHARUHERA
Sequence of Process PART NO. : 7500002890(HHML Part No. 18350-KTC-9000 PAGE-------02--------OF----------02---------

QUALITY CHARACTERISTICS

Important Item
Trouble Mode
CONTROL OF MANUFACTURING CONDITIONS (Equipment, metal
Process Name/Equipment Name(Name of Supplier) mold,fail-safe devices,hydraulic power,voltage, temperature etc.)

Inspected Inspection Detail of

No. Control Item Specified value Inspection Method Inspection Frequency Data Form Control item Specified value Inspected by Inspection Method Data form
by Frequency Process/Sketch

BLOW HOLES POROSITY,

STOPPER MAIN STAND WELDING WITH MUFF.COMP./
55 1 PUNTURE, SCRATCHES, NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 CURRENT 120 A SUPERVISOR AMMETER EVERY 4 HRS. PATROL INS.SHT.
SPM(MAL)
DAMAGE

DIMN. FACE OF STOPPER

TOOL NO. MAL-207 2 MAIN STAND TO CAP BODY 181.51.0 mm QC V.CALIPER THRICE A SHIFT F/INMW/01-06 VOLTAGE VOLTMETER
END 20 V
GAS FLOW 8 LTR/MIN. FLOW METER

WIRE DIA 1.0 mm MICROMETER

WIRE MATL. SUS 308L

BLOW HOLES POROSITY,

60 STAY HOUSE GUIDE WELDING WITH MUFF. ) 1 PUNTURE, SCRATCHES, NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 CURRENT 120 A SUPERVISOR AMMETER EVERY 4 HRS. PATROL INS.SHT.
DAMAGE

TOOL NO. T13-81245 2 BOLT PROJECTION LOOSE NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 VOLTAGE 20 V VOLTMETER

GAS FLOW 8 LTR/MIN. FLOWMETER

WIRE DIA 1.0 mm MICROMETER

WIRE MATL. SUS 308L

BLOW HOLES POROSITY,

STAY MUFF.COVER,STAY 'B' PROTECTOR,HOOK
65 1 PUNTURE, SCRATCHES, NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 CURRENT 120 A SUPERVISOR AMMETER EVERY 4 HRS. PATROL INS.SHT.
PROTECTOR WELDING WITH MUFF.
DAMAGE

TOOL NO.-T13-81258 2 WELDING PROPERLY WELDED QC VISUAL THRICE A SHIFT F/INMW/01-06 VOLTAGE VOLTMETER
20 V
GAS FLOW 8 LTR/MIN. FLOWMETER

WIRE DIA 1.0 mm MICROMETER

WIRE MATL. SUS 308L

BLOW HOLES POROSITY,

PIPE DIFFUSER WELDING WITH MUFF.COMP.EXH./CIR
70 1 PUNTURE, SCRATCHES, NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 VOLTAGE SUPERVISOR VOLTMETER EVERY 4 HRS. PATROL INS.SHT.
WELDING
DAMAGE 20 V
SPM(DYNARC) 2 DIMN. 127.51.0 mm QC V.CALIPER THRICE A SHIFT F/INMW/01-06 CURRENT 120A SUPERVISOR AMMETER EVERY 4 HRS. PATROL INS.SHT.

GAS FLOW 8 LTR/MIN. FLOWMETER

WIRE DIA 1.0 mm MICROMETER

WIRE MATL. SUS 308L

BLOW HOLES POROSITY,

PIPE COMP.EXH. WELDING WITH
75 1 PUNTURE, SCRATCHES, NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 CURRENT 120 A SUPERVISOR AMMETER EVERY 4 HRS. PATROL INS.SHT.
MUFF.COMP.EXH./CIR. WELDING SPM(DYNARC)
DAMAGE

SPM (DYNARC) VOLTAGE 20V VOLTMETER

GAS FLOW 8 LTR/MIN. FLOWMETER

WIRE DIA 1.0 mm MICROMETER

WIRE MATL. SUS 308L

80 WELDING COMPLETION,REPAIR MUFF,COMP.EXH. 1 WELDING PUNCHRED NOT ALLOWED QC VISUAL 100% __________ CURRENT 120 A SUPERVISOR AMMETER EVERY 4 HRS PATROL INS.SHT.

2 WELDING UNEVEN NOT ALLOWED QC VISUAL 100% __________ VOLTAGE 20 V VOLTMETER

3 WELDING UNCOMPLETE NOT ALLOWED QC VISUAL 100% __________ GAS FLOW 8 LTR/MIN. FLOWMETER

WIRE DIA 1.0 mm MICRO METER

WIRE MATL. SUS 308L

85 SANDING,GRINDING MUFFLER COMP.EXH. 1 SPATTERS NOT ALLOWED QC VISUAL 100% __________ DISC GRINDING DISC SUPERVISOR VISUAL EVERY 4 HRS PATROL INS.SHT.

2 WELDING UNEVEN NOT ALLOWED QC VISUAL 100% __________ GRIT 120 SUPERVISOR VISUAL EVERY 4 HRS PATROL INS.SHT.

TO QUALIFY TRUING
90 TRUING & FINAL INSPECTION MUFFLER COMP.EXH. 1 FITMENT PARAMETERS QC TRUING FIXTURE 100% F/INMW/01-06 THREE PINS IN PROPER WORKING CONDITION SUPERVISOR VISUAL EVERY 4 HRS PATROL INS.SHT.
JIG
DEEP CUT, SCRATCH, BLOW
TOOL NO.-T13-81209 2 NOT ALLOWED QC VISUAL 100% F/INMW/01-06 TAIL PLATE PIN IN PROPER WORKING CONDITION SUPERVISOR VISUAL EVERY 4 HRS PATROL INS.SHT.
HOLE, PUNCTURE, SPATTER
CLAMPING CYL IN PROPER WORKING CONDITION SUPERVISOR VISUAL EVERY 4 HRS PATROL INS.SHT.

Classification of trouble modes of completed vehicles (machines) : 1.Fire, 2. Fails to stop, 3. Fails to run, 4. Receives electric shocks, 5. Fails to conform to legal requirements, 6. Outer appearance and commercial value.
 CRITICAL
HERO HONDA MOTORS LIMITED,
MODEL KWAG MAJOR ABC PROCESS QUALITY CONTROL SHEET (I) 69 KM. STONE, DELHI JAIPUR HIGHWAY, DHARUHERA (HARYANA)
MINOR

PART NO. 75000004196(HHML Part No. 18350-KWA-9400) DOC NO. PFC/E38000-10001 REV NO. 0
PART NAME COVER-A MUFFLER WELDING PROCESS
SOURCE MAJESTIC AUTO LTD.LDH. DATE : 24.07.09 PAGE 01 OF 01

BASIC FOR PRODUCTION CHANGE PARTS PURCHASED FROM OUTSIDE VENDOR

Critical Approval Test Prodn. Submit Ist
PROCESS FLOW DIAGRAM S.No. Process & Required checked Piece date S.No. Part No. Part Name Supplier
Description
1 75OOOO29O8OO BODY NIPPON STEEL
SS 409L SHT.
00 10
INSPECTION
RECEIPT OF RAW BLANKING
MATERIAL

IN PROCESS
INSPECTION

30
20 IN PROCESS
ROLLING INSPECTION TIG WELDING

IN PROCESS
INSPECTION

40
50
IN PROCESS
FORMING
TAB CUTTING INSPECTION

IN PROCESS
INSPECTION

HHML APPROVAL VENDOR APPROVAL

DATE NAME AUTHORISED DATE MADE BY CHECKED APPROVED
SIGNATORY LOT MARKING BY BY

LOT CODE 24.07.09 ENGG. DEPTT. QA PRITPAL SINGH

 PROCESS QUALITY CONTROL SHEET (II)
PART NAME :COVER-A MUFFLER MODEL KWAG DOC.NO: E38000-10001
DHARUHERA 75000004196(HHML Part No. 18350-KWA-9400) PAGE-------01--------OF----------01---------
CONTROL OF MANUFACTURING CONDITIONS

Important Item
Trouble Mode
QUALITY CHARACTERISTICS
Sequence of
Process

Process Name/Equipment
Name(Name of Supplier) Inspected Inspection
No. Control Item Specified value Inspection Method Data Form Control item Specified value Inspected by Inspection Method Inspection Frequency Data form Detail of Process/Sketch
by Frequency

RAW MATERIAL/POSCO
00 STEEL(KOREA)
0 MATERIAL SPECIFICATION SUS 409L RQC LAB SAMPLING F/INS/08

COIL(ID 500,OD
SUS 409L 1 LENGTH RQC TAPE SAMPLING F/INS/08
950,Wt.500Kg.)

2 WIDTH 247-0.5 mm RQC TAPE SAMPLING F/INS/08

3 THK. 1.20.08mm RQC MICROMETER SAMPLING F/INS/08

4 C% 0.030 MAX RQC LAB SAMPLING F/INS/08

5 Mn% 1.00 MAX RQC LAB SAMPLING F/INS/08

6 Si% 1.00 MAX RQC LAB SAMPLING F/INS/08

7 P% 0.04 MAX RQC LAB SAMPLING F/INS/08

8 S% 0.030 MAX RQC LAB SAMPLING F/INS/08

9 Cr.% 10.50 ~11.75 RQC LAB SAMPLING F/INS/08

10 N% 0.030 MAX RQC LAB SAMPLING F/INS/08

13 Ti% 10 X (C+N)~0.75 RQC LAB SAMPLING F/INS/08

15 TENSILE STRENGTH(Mpa) 360 MIN RQC LAB SAMPLING F/INS/08

16 HARDNESS(Hv) 170 MAX RQC LAB SAMPLING F/INS/08

BLANKING/MECHANICAL
10 PRESS 75 TON
1 PROFILE MASTER PC QC VISUAL THRICE A SHIFT F/INMW/01-06

DIE & PUNCH WEAR

TOOL NO.T16-81337 2 HEAVY BURR NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 NOT ALLOWED SUPERVISOR VISUAL EVERY 4 HOURS PATROL INSP. SHEET
OFF

3 RUST NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06

4 SCRATCHES NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06

5 DAMAGE NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06

ROLLING/ROLLER NO.
20 (MAL-208/51)
1 EDGE GAP 1-1.5 mm(MAX.) QC VISUAL EVERY 2 HRS. F/INMW/01-06 ROLLERS WEAR OUT NOT ALLOWED SUPERVISOR VISUAL EVERY 4 HOURS PATROL INSP. SHEET

OPERATOR / 100% / 2-3 TIMES

2 EDGE OVER LAPPING NOT ALLOWED QC VISUAL EVERY 2 HRS. F/INMW/01-06 PLACING LOCATION EXACT LOCATION VISUAL PATROL INSP. SHEET
SUPERVISOR PER SHIFT

HAMMER
TIG WELDING/TIG NO
30 WELDING JAW(MAL-387)
1 WELDING STRENGTH
BREAKAGE/CRACK
QC (DESTRUCTIVE THRICE A SHIFT F/INMW/01-06 CURRENT. 200-260 A SUPERVISOR AMMETER EVERY 4 HRS PATROL INSP. SHEET
TESTING)
WELDING PUNCHED/BLOW
2 NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 VOLTAGE. 15-20 V QC VOLTMETER
HOLES

3 BURNING NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 GAS. FLOW 6 LTR/MIN. QC FLOW METER

4 WELDING FINISH SMOOTH QC VISUAL THRICE A SHIFT F/INMW/01-06 ELECTRODE 3MM. QC

Classification of trouble modes of completed vehicles (machines) : 1.Fire, 2. Fails to stop, 3. Fails to run, 4. Receives electric shocks, 5. Fails to conform to legal requirements, 6. Outer appearance and commercial value.
 PROCESS QUALITY CONTROL SHEET (II)
PART NAME :COVER-A MUFFLER MODEL KWAG DOC.NO: E38000-10001
DHARUHERA 75000004196(HHML Part No. 18350-KWA-9400) PAGE-------02--------OF----------02---------
CONTROL OF MANUFACTURING CONDITIONS

Important Item
Trouble Mode
QUALITY CHARACTERISTICS
Sequence of
Process

Process Name/Equipment
Name(Name of Supplier)
Inspected Inspection Detail of
No. Control Item Specified value Inspection Method Inspection Frequency Data Form Control item Specified value Inspected by Inspection Method Data form
by Frequency Process/Sketch

40 TAB CUTTING 1 UNDER CUTS NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06

HEAVY BURR
DIE & PUNCH NOT PATROL INSP.
TOOL NO. MAL-313 2 PROJECTION NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 SUPERVISOR VISUAL EVERY 4 HRS
WEAR OFF ALLOWED SHEET
DAMAGE

3 TAB HEIGHT BELOW 1 mm QC VISUAL THRICE A SHIFT F/INMW/01-06

FORMNG(FORMING TOOLING
V.CALIPER/PLUG NOT PATROL INSP.
50 TOOL) 1 DIA 31.8+0.5/+0.2 QC THRICE A SHIFT F/INMW/01-06 ELEMENTS SUPERVISOR VISUAL EVERY 4 HRS
GAUGE ALLOWED SHEET
TOOL NO.-189 WEAR OFF

Classification
Classification
of trouble
of trouble
modesmodes
of completed
of completed
vehicles
vehicles
(machines)
(machines)
: 1.Fire,: 1.Fire,
2. Fails2.toFails
stop,to3.stop,
Fails3.toFails
run, to
4. run,
Receives
4. Receives
electricelectric
shocks,shocks,
5. Fails5.toFails
conform
to conform
to legaltorequirements,
legal requirements,
6. Outer
6. appearance
Outer appearance
and commercial
and commercial
value. value.
 CRITICAL
MODEL KWAG MAJOR ABC PROCESS QUALITY CON
MINOR
PART NO. 75000004197(HHML Part No. 18350-KWA-9400)
PART NAME COVER-A MUFFLER WELDING PROCE
SOURCE MAJESTIC AUTO LTD.LDH.

PROCESS FLOW DIAGRAM

00 10
INSPECTION
RECEIPT OF RAW LENGTH
MATERIAL CUTTING
(TUBE)

IN PROCESS 20 IN PROCESS
INSPECTION PIERCING INSPECTION

30
IN PROCESS
FORMING INSPECTION
 HHML APPROVAL
DATE NAME AUTHORISED
SIGNATORY LOT MARKING

LOT CODE
 HERO HONDA MOTORS LIMITED,
S QUALITY CONTROL SHEET (I) 69 KM. STONE, D
DHARUHERA (HARYANA)
DOC NO. PFC/E38000-10001
WELDING PROCESS
DATE : 24.07.09

BASIC FOR PRODUCTION CHANGE PARTS PURCHASED FROM OU

Critical Approval Test Prodn. Submit Ist
S.No. Process & Required checked Piece date S.No. Part No.
Description
1 75OOOO4197OO

OCESS
ECTION
 VENDOR APPRO
DATE MADE BY

24.07.09 ENGG. DEPTT.

ITED,
69 KM. STONE, DELHI JAIPUR HIGHWAY,
DHARUHERA (HARYANA)
REV NO. 0

PAGE 01 OF 01

TS PURCHASED FROM OUTSIDE VENDOR

Part Name Supplier

BODY NIPPON STEEL

SS 409L SHT.
 VENDOR APPROVAL
MADE BY CHECKED APPROVED
BY BY

ENGG. DEPTT. QA PRITPAL SINGH

 PROCESS QUALITY CON
PART NAME : COVER-B MUFFLER
DHARUHERA 75000004196(HHML Part No. 18350-KWA-9400)

Important Item
QUALITY CHARACTERISTICS

Trouble Mode
Sequence of
Process

Process Name/Equipment
Name(Name of Supplier)
No. Control Item Specified value Inspected by

RAW MATERIAL/POSCO MATERIAL

00 STEEL(KOREA)
0
SPECIFICATION
SUS 409L RQC

COIL(ID 500,OD
SUS 409L 1 LENGTH RQC
950,Wt.500Kg.)

2 WIDTH 247-0.5 mm RQC

3 THK. 1.20.08mm RQC

4 C% 0.030 MAX RQC

5 Mn% 1.00 MAX RQC
6 Si% 1.00 MAX RQC
7 P% 0.04 MAX RQC
8 S% 0.030 MAX RQC

9 Cr.% 10.50 ~11.75 RQC

10 N% 0.030 MAX RQC

13 Ti% 10 X (C+N)~0.75 RQC

TENSILE
15 STRENGTH(Mpa 360 MIN RQC
)

16 HARDNESS(Hv) 170 MAX RQC

BLANKING/MECHANICAL
10 PRESS 75 TON
1 PROFILE MASTER PC QC

TOOL NO.T16-81337 2 HEAVY BURR NOT ALLOWED QC

3 RUST NOT ALLOWED QC

4 SCRATCHES NOT ALLOWED QC

5 DAMAGE NOT ALLOWED QC

ROLLING/ROLLER NO.
20 (MAL-208/51)
1 EDGE GAP 1-1.5 mm(MAX.) QC
 EDGE OVER
2 NOT ALLOWED QC
LAPPING

TIG WELDING/TIG WELDING NO

30 WELDING JAW(MAL-387)
1
STRENGTH BREAKAGE/CRACK
QC

WELDING
2 PUNCHED/BLO NOT ALLOWED QC
W HOLES

3 BURNING NOT ALLOWED QC

WELDING
4 SMOOTH QC
FINISH
Classification of trouble modes of completed vehicles (machines) : 1.Fire, 2. Fails to stop, 3. Fails to run, 4. Receives electric shocks,
UALITY CONTROL SHEET(II)
MODEL KWAG DOC.NO: E38000-10001
PAGE-------01--------OF----------01--------
CONTROL OF MANUFACTURING CONDITIONS
CHARACTERISTICS

Inspection Inspection Specified Inspection Inspection

Data Form Control item Inspected by Data form
Method Frequency value Method Frequency

LAB SAMPLING F/INS/08

TAPE SAMPLING F/INS/08

TAPE SAMPLING F/INS/08

MICROMET
SAMPLING F/INS/08
ER
LAB SAMPLING F/INS/08
LAB SAMPLING F/INS/08
LAB SAMPLING F/INS/08
LAB SAMPLING F/INS/08
LAB SAMPLING F/INS/08

LAB SAMPLING F/INS/08

LAB SAMPLING F/INS/08

LAB SAMPLING F/INS/08

LAB SAMPLING F/INS/08

LAB SAMPLING F/INS/08

VISUAL THRICE A SHIFT F/INMW/01-06

DIE &
NOT SUPERVIS EVERY 4
VISUAL THRICE A SHIFT F/INMW/01-06 PUNCH VISUAL PATROL INSP. SHEET
ALLOWED OR HOURS
WEAR OFF

VISUAL THRICE A SHIFT F/INMW/01-06

VISUAL THRICE A SHIFT F/INMW/01-06

VISUAL THRICE A SHIFT F/INMW/01-06

ROLLERS NOT SUPERVISO EVERY 4

VISUAL EVERY 2 HRS. F/INMW/01-06 VISUAL PATROL INSP. SHEET
WEAR OUT ALLOWED R HOURS
 OPERATOR /
100% / 2-3
PLACING EXACT
VISUAL EVERY 2 HRS. F/INMW/01-06 VISUAL TIMES PER
PATROL INSP. SHEET
LOCATION LOCATION SUPERVISO
SHIFT
R

HAMMER
(DESTRUC
THRICE A SHIFT F/INMW/01-06 CURRENT. 200-260 A SUPERVISOR AMMETER EVERY 4 HRS
PATROL INSP. SHEET
TIVE
TESTING)

VISUAL THRICE A SHIFT F/INMW/01-06 VOLTAGE. 15-20 V QC VOLTMETER

VISUAL THRICE A SHIFT F/INMW/01-06 GAS. FLOW QC FLOW METER

6 LTR/MIN.

VISUAL THRICE A SHIFT F/INMW/01-06 ELECTRODE 3MM. QC

. Receives electric shocks, 5. Fails to conform to legal requirements, 6. Outer appearance and commercial value.
 E38000-10001
--01--------OF----------01--------

Detail of
Process/Sketch

TROL INSP. SHEET

TROL INSP. SHEET

TROL INSP. SHEET

TROL INSP. SHEET

 CRITICAL HERO HONDA MOTORS LIMITED,
MODEL KWAG MAJOR ABC PROCESS QUALITY CONTROL SHEET (I) 69 KM. STONE, DELHI JAIPUR HIGHWAY, DHARUHERA
MINOR (HARYANA)
PART NO. 7500004188(HHML Part No. 18310-KWA-9400) DOC NO. PFC/E38000-10002 REV NO. 0
PART NAME BODY-A WELDING PROCESS
SOURCE MAJESTIC AUTO LTD.LDH. DATE : 25.07.09 PAGE 01 OF 01

BASIC FOR PRODUCTION CHANGE PARTS PURCHASED FROM OUTSIDE VENDOR

Critical Approval Test Prodn. Submit Ist
PROCESS FLOW DIAGRAM S.No. Process & Required checked Piece date S.No. Part No. Part Name Supplier
Description
1 750,000,290,700 BODY NIPPON STEEL
SS 409L SHT.
00 10
INSPECTION
RECEIPT OF BLANKING
RAW MATERIAL

IN PROCESS
INSPECTION

30
20 IN PROCESS
STAMPING INSPECTION PIERCING

IN PROCESS
INSPECTION

40
IN PROCESS 50
ROLLING
INSPECTION TIG WELDING

IN PROCESS
INSPECTION

60
IN PROCESS
TAB CUTTING INSPECTION

HHML APPROVAL VENDOR APPROVAL

DATE NAME AUTHORISED DATE MADE BY CHECKED APPROVED
SIGNATORY LOT MARKING BY BY

LOT CODE 25.07.09 ENGG.DEPTT. QA Mr.PRITPAL SINGH

 PROCESS QUALITY CONTROL SHEET (II)
PART NAME : BODY-A MODEL KWAG DOC.NO: E38000-10002

DHARUHERA 75000004188(HHML Part No. 18310-KWA-9400) PAGE-------01--------OF----------02---------

CONTROL OF MANUFACTURING CONDITIONS
(Equipment, metal mold,fail-safe devices,hydraulic

Important Item
QUALITY CHARACTERISTICS

Trouble Mode
Sequence of
Process power,voltage, temperature etc.)
Process Name/Equipment
Name(Name of Supplier)
Inspected
No. Control Item Specified value Inspection Method Inspection Frequency Data Form Control item Specified value Inspected by Inspection Method Inspection Frequency Data form Detail of Process/Sketch
by

RAW MATERIAL/POSCO MATERIAL

00 1 SUS 409L RQC LAB SAMPLING F/INS/08
STEEL(KOREA) SPECIFICATION

SUS 409L 2 LENGTH 2080+2 mm RQC TAPE SAMPLING F/INS/08

3 WIDTH 628-0..5 mm RQC TAPE SAMPLING F/INS/08

4 THK. 1.00.08mm RQC MICROMETER SAMPLING F/INS/08

5 C% 0.03 MAX RQC LAB SAMPLING F/INS/08

6 Mn% 1.00 MAX RQC LAB SAMPLING F/INS/08

7 Si% 1.00 MAX RQC LAB SAMPLING F/INS/08

8 P% 0.040 MAX RQC LAB SAMPLING F/INS/08

9 S% 0.030 MAX RQC LAB SAMPLING F/INS/08

10 Cr.% 10.50~11.75 RQC LAB SAMPLING F/INS/08

11 N% 0.030 MAX RQC LAB SAMPLING F/INS/08

12 Ti% 10 x (C+N)~0.75 RQC LAB SAMPLING F/INS/08

TENSILE
13 360 MIN RQC LAB SAMPLING F/INS/08
STRENGTH(Mpa)

14 HARDNESS(Hv) 170 MAX RQC LAB SAMPLING F/INS/08

CUT ANGLE FOR SHEET BEVEL

15 5.787O RQC SAMPLING F/INS/08
LENGTH 2080 PROTECTOR

PROFILE/STRAIGHTNESS
10 BLANKING 1
OF EDGES
AS PER MASTER PC QC VISUAL EVERY 2 HRS. F/INMW/01-06 PUNCH /DIE PROFILE SHOULD CORRECT SUPERVISOR VISUAL ONCE A WEEK PATROL INSP.

DIE & PUNCH WEAR

POWER PRESS 200T 2 HEAVY BURR NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 NOT ALLOWED SUPERVISOR VISUAL EVERY 4 HRS. PATROL INSP.
OFF

CLEANINESS OF BOTH SURFACE SHOULD AFTER THE

OPERATOR/
TOOL NO T16-102626 3 SCRATCHES NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 PUNCH AND DIE NOT CONTAIN FOREIGN VISUAL INCIDENT/ 2
SUPERVISOR
SURFACE ELEMENTS TIMES PER SHIFT

4 RUST NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06

5 DAMAGE NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06

20 LOGO STAMPING 1 HEIGHT OF LETTERS 11 MM QC V CALIPER THRICE A SHIFT F/INMW/01-06 PNEUMATIC PRESSURE 6 BAR QC GAUGE TWICE A SHIFT PATROL INSP.

HYD. PNEU.PRESS 40T 2 LETTER DEPTH 0.3 MM QC VISUAL THRICE A SHIFT F/INMW/01-06 HOLD TIME 2 SECONDS OPERATOR CONTROL PANEL TWICE A SHIFT PATROL INSP.

DIMN. FROM BIGGER END

TOOL NO T16-81205 3 28 MM QC V CALIPER THRICE A SHIFT F/INMW/01-16 CYCLE TIME OPERATOR OPERATOR CONTROL PANEL TWICE A SHIFT PATROL INSP.
OF SHEET

30 PIERCING 1 HOLE POSITION MASTER PC. QC VISUAL THRICE A SHIFT F/INMW/01-06

TOOL NO. T16-81199 2 HOLE DIA 6.0 MM QC VISUAL THRICE A SHIFT F/INMW/01-06

PUNCH DIE
3 HEAVY BURR NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 NOT ALLOWED SUPERVISOR VISUAL EVERY 4 HRS. PATROL INSP.
EXCESSIVE WEAR OFF

4 SCRATCHES NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06

5 DAMAGES NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06

6 NO OF HOLES 11 NOS. QC VISUAL THRICE A SHIFT F/INMW/01-06

Classification of trouble modes of completed vehicles (machines) : 1.Fire, 2. Fails to stop, 3. Fails to run, 4. Receives electric shocks, 5. Fails to conform to legal requirements, 6. Outer appearance and commercial value.
 PROCESS QUALITY CONTROL SHEET (II)
PART NAME : BODY MODEL P-90 DOC.NO: E38000-10002

DHARUHERA 75000002908(HHML Part No. 18310-KTC-9000) PAGE-------02--------OF----------02---------

Important Item QUALITY CHARACTERISTICS CONTROL OF MANUFACTURING CONDITIONS

Trouble Mode
Sequence of
Process

Process Name/Equipment
Name(Name of Supplier)
Inspected
No. Control Item Specified value Inspection Method Inspection Frequency Data Form Control item Specified value Inspected by Inspection Method Inspection Frequency Data form Detail of Process/Sketch
by

40 ROLLING(ROLLING SPM) 1 EDGE GAP 1.5-2.0 mm(APPROX.) QC V CALLIPER THRICE A SHIFT F/INMW/01-07 ROLLERS WEAR OUT NOT ALLOWED SUPERVISOR VISUAL EVERY 4 HRS. PATROL INSP.

100% / 2-3 TIMES PER

TOOL NO.T13-8126 2 EDGE OVER LAPPING NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 PLACING LOCATION EXACT LOCATION OPERATOR/SUPERVISOR VISUAL
SHIFT
PATROL INSP.

50 TIG WELDING 1 SMALL END DIA 62.7 0.7 mm QC V CALIPER THRICE A SHIFT F/INMW/01-06 CURRENT 180-240 A SUPERVISOR AMMETER EVERY 4 HRS PATROL INSP.

(TIG WELDING SPM)

2 BIGGER END DIA 101.8+1.0 mm QC V CALIPER THRICE A SHIFT F/INMW/01-06 VOLTAGE 15-20 V SUPERVISOR VOLTMETER EVERY 4 HRS INSP.SHEET
TOOL NO.

HAMMER
3 WELDING STRENGTH NO BREAKAGE/ CARACK QC (DESTRUCTIVE THRICE A SHIFT F/INMW/01-06 GAS. (ARGON) FLOW 6 LTR/ MIN. SUPERVISOR FLOW METER EVERY 4 HRS INSP.SHEET
TESTING)

WELDING
4 PUNCHERED/BLOW NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 ELECTRODE DIA 3 MM SUPERVISOR VISUAL 1-2 TIMES/SHIFT PATROL INSP.
HOLE

100% / 2-3 TIMES PER

5 BURNING NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 PLACING LOCATION EXACT LOCATION OPERATOR/SUPERVISOR VISUAL PATROL INSP.
SHIFT

6 WELDING FINISH SMOOTH QC VISUAL THRICE A SHIFT F/INMW/01-06 EDGE GAP. NOT ALLOWED SUPERVISOR VISUAL 3-4TIMES/SHIFT PATROL INSP.

60 TAB CUTTTING 1 UNDER CUTS NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06

HEAVY BURR PUNCH DIE

TOOL NO. MAL-190 2 PROJECTION NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 EXCESSIVE WEAR NOT ALLOWED SUPERVISOR VISUAL EVERY 4 HRS. PATROL INSP.
DAMAGE OFF

3 TAB HEIGHT BELOW 1.0 MM QC VISUAL THRICE A SHIFT F/INMW/01-06

Classification of trouble modes of completed vehicles (machines) : 1.Fire, 2. Fails to stop, 3. Fails to run, 4. Receives electric shocks, 5. Fails to conform to legal requirements, 6. Outer appearance and commercial value.