Doc. No.

: PDC-EPD-F02

Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : 424513119900-MCD-01-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-09 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. BLN Evaluation/ Measurement
Description No. Product Process Specification/ Control Method
r No. Technique
Tolerance Size Freq. & Responsibility
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER CHUCK

1.Setup Approval
1.Setup Approval
(QC-MCN-F01)
Bore gauge with 1stPC Set up QC Incharge (QC-MCN-F01)
Check & Segregate 2.Operator log Book (QC-
ɸ 40.007 / 2.100% Operator Monitoring
9.01 Inner Diameter 1 ▼ Dial LC 0.001 with 100% Operator 3.In Process Inspection
Check tooling & MCN-F10)
39.982 mm 10th PC Inspector ascertain root cause 3.In Process Inspection
MSR-32-1 1 Report (QC-MCN-F02)
Report (QC-MCN-F02)
4.SPC Analysis
4.SPC Chart

1.Setup Approval
1.Setup Approval
(QC-MCN-F01)
1stPC Set up QC Incharge (QC-MCN-F01)
Check & Segregate 2.Operator log Book (QC-
ɸ 68.020 / CMM / SG with 2.100% Operator Monitoring
9.02 Inner Diameter 2 ▼ 100% Operator Check tooling & MCN-F10)
68.050 mm MSP 10th PC Inspector
3.In Process Inspection
ascertain root cause 3.In Process Inspection
1 Report (QC-MCN-F02)
Report (QC-MCN-F02)
4.SPC Analysis
4.SPC Chart
TURNING Ist SETUP

ɸ 115.900 / Set up Approval Check Tooling & Set up Approval

9.03 Outer Diameter 3 Vernier Caliper 1st PC Set up QC Incharge
(QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)
116.100 mm

9
ɸ 122.5 /127.5 Set up Approval Check Tooling & Set up Approval
9.04 Outer Diameter 4 Vernier Caliper 1st PC Set up QC Incharge
(QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)
mm

ɸ 173.5 / 178.5 Set up Approval Check Tooling & Set up Approval

9.05 Outer Diameter 5 Vernier Caliper 1st PC Set up QC Incharge
(QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)
mm

ɸ 233.5 / 238.5 Set up Approval Check Tooling & Set up Approval

9.06 Outer Diameter 6 Vernier Caliper 1st PC Set up QC Incharge
(QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)
mm

1 of 18
 TURNING Ist S

CNC TURNING CENTER WITH 3 JAW

9 Doc. No. : PDC-EPD-F02

Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : 424513119900-MCD-01-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-09 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. BLN Evaluation/ Measurement
Description No. Product Process Specification/ Control Method
r No. Technique
Tolerance Size Freq. & Responsibility

ɸ 271.5 / 276.5 Set up Approval Check Tooling & Set up Approval

9.07 Outer Diameter 7 Vernier Caliper 1st PC Set up QC Incharge
(QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)
mm

1. Set up Approval 1. Set up Approval

ɸ 304.3 / 304.4 1st PC Set up QC Incharge (QC-MCN-F01) Check tooling & (QC-MCN-F01)
NC TURNING CENTER WITH 3 JAW HYDRAULIC POWER

9.08 Outer Diameter 8 Vernier Caliper 1 35th PC Inspector 2. In process Inspection Report ascertain root cause 2.In Process Inspection Report
mm
(QC-MCN-F02) (QC-MCN-F02)

ɸ 339.5 / 340.5 Set up Approval Check Tooling & Set up Approval

9.09 Outer Diameter 9 Vernier Caliper 1st PC Set up QC Incharge
(QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)
mm

Set up Approval Check Tooling & Set up Approval

9.1 Depth 10 5.9 / 6.1 mm Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)
TURNING Ist SETUP

CHUCK

1. Set up Approval 1. Set up Approval

1st PC Set up QC Incharge (QC-MCN-F01) Check tooling & (QC-MCN-F01)
9.11 Depth 11 26.9 / 27.1 mm Depth Vernier
9 1 35th PC Inspector 2. In process Inspection Report
(QC-MCN-F02)
ascertain root cause 2.In Process Inspection Report
(QC-MCN-F02)

1.Set up Approval
Check Tooling & Set up Approval
9.12 Chamfer 12 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge (QC-MCN-F01)
Ascertain root Cause (QC-MCN-F01)
2. Program Controlled

1. Set up Approval
1. Set up Approval
(QC-MCN-F01)/CMM
Check & Segregate (QC-MCN-F01)/CMM
1st PC Set up QC Incharge Report
9.13 Concentricity 13 ▼ 0.05 w.r.t. 'A' SPG-76 / CMM Check tooling & Report
1 20th PC Inspector 2. In process Inspection
ascertain root cause 2.In Process Inspection
Report (QC-MCN-F02)
Report (QC-MCN-F02)
3.Proces Controlled

2 of 18
 TURNING Ist SE

CNC TURNING CENTER WITH 3 JA

CHUCK
Doc. No. : PDC-EPD-F02

9 Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : 424513119900-MCD-01-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-09 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. BLN Evaluation/ Measurement
Description No. Product Process Specification/ Control Method
r No. Technique
Tolerance Size Freq. & Responsibility

1.Set up Approval
Surface Finish Check tolling & Set up Approval
9.14 Surface Finish 14 3.2 μRa 1st PC Set up QC Incharge (QC-MCN-F01)
Comparator 2.Program Controlled
ascertain root cause (QC-MCN-F01)
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER

1.Set up Approval
Surface Finish Check tolling & Set up Approval
9.15 Surface Finish 15 3.2 μRa 1st PC Set up QC Incharge (QC-MCN-F01)
Comparator 2.Program Controlled
ascertain root cause (QC-MCN-F01)

1.Set up Approval
1.Set up Approval
(QC-MCN-F01)
Surface Finish 1st PC Set up QC Incharge Check tolling & (QC-MCN-F01)
9.16 Surface Finish 16 ▼ 1.6 μRa 2.In Process Inspection
Comparator 1 4 Hours Inspector
Report (QC-MCN-F02)
ascertain root cause 2.In Process Inspection
Report (QC-MCN-F02)
3.Program Controlled

1.Set up Approval
Check Tooling & Set up Approval
TURNING Ist SETUP

9.17 Chamfer 17 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge (QC-MCN-F01)

Ascertain root Cause (QC-MCN-F01)
2. Program Controlled
CHUCK

9 9.18 Depth 18 6.9/7.1 mm Depth Vernier 1st PC Set up QC Incharge

Set up Approval
(QC-MCN-F01)
Check Tooling & Set up Approval
Ascertain root Cause (QC-MCN-F01)

Set up Approval Check Tooling & Set up Approval

9.19 Depth 19 4.9 / 5.1 mm Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)

1.Set up Approval
Surface Finish Check tolling & Set up Approval
9.2 Surface Finish 20 3.2 μRa 1st PC Set up QC Incharge (QC-MCN-F01)
Comparator 2.Program Controlled
ascertain root cause (QC-MCN-F01)

3 of 18
 CNC TURNING CENTER WITH 3 JAW
TURNING Ist SET

CHUCK
Doc. No. : PDC-EPD-F02

9 Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : 424513119900-MCD-01-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-09 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. BLN Evaluation/ Measurement
Description No. Product Process Specification/ Control Method
r No. Technique
Tolerance Size Freq. & Responsibility

1.Set up Approval
1.Set up Approval
(QC-MCN-F01)
Surface Finish 1st PC Set up QC Incharge Check tolling & (QC-MCN-F01)
9.21 Surface Finish 21 ▼ 0.8 μRa 2.In Process Inspection
Comparator 1 4 Hours Inspector
Report (QC-MCN-F02)
ascertain root cause 2.In Process Inspection
Report (QC-MCN-F02)
3.Program Controlled
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER

1.Set up Approval
Surface Finish Check tolling & Set up Approval
9.22 Surface Finish 22 3.2 μRa 1st PC Set up QC Incharge (QC-MCN-F01)
Comparator 2.Program Controlled
ascertain root cause (QC-MCN-F01)

1.Set up Approval
Check Tooling & Set up Approval
9.23 Chamfer 23 2.0 X 45 ̊ VC+Bevel Protractor 1st PC Set up QC Incharge (QC-MCN-F01)
Ascertain root Cause (QC-MCN-F01)
2. Program Controlled

1. Set up Approval
Set up Check tooling & Set up Approval
TURNING Ist SETUP

9.24 Angle 24 90 º ± 0º20' CMM 1st PC

1/Shift
(QC-MCN-F01)/CMM Report
ascertain root cause (QC-MCN-F01)/CMM Report
2. Program Controlled
CHUCK

9 9.25 Depth 25 14.5 / 14.8 mm Depth Vernier 1st PC Set up QC Incharge

Set up Approval
(QC-MCN-F01)
Check Tooling & Set up Approval
Ascertain root Cause (QC-MCN-F01)

Set up Approval Check Tooling & Set up Approval

9.26 Depth 26 5.1 / 5.3 mm Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)

9.27 Radius 27 R10 mm Visual Pattern Controlled

4 of 18
 CNC TURNING CENTER WITH 3 JAW
TURNING Ist SET

CHUCK
Doc. No. : PDC-EPD-F02

9 Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : 424513119900-MCD-01-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-09 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. BLN Evaluation/ Measurement
Description No. Product Process Specification/ Control Method
r No. Technique
Tolerance Size Freq. & Responsibility

1.Set up Approval
Check Tooling & Set up Approval
9.28 Angle 28 15 º Bevel Protractor 1st PC Set up QC Incharge (QC-MCN-F01)
Ascertain root Cause (QC-MCN-F01)
2. Pattern Controlled
JAW HYDRAULIC POWER CHUCK
CNC TURNING CENTER WITH 3

1.Set up Approval
Check Tooling & Set up Approval
9.29 Radius 29 R2.0 mm Radius Gauge 1st PC Set up QC Incharge (QC-MCN-F01)
Ascertain root Cause (QC-MCN-F01)
2. Process Controlled
TURNING Ist SETUP

Set up Approval Check Tooling & Set up Approval

9.3 Depth A1 98.5 mm Ref. Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)

9
Set up Approval Check Tooling & Set up Approval
9.31 Depth A2 94.5 mm Ref. Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)

Depth Vernier+ Set up Approval Check Tooling & Set up Approval

9.32 Depth A3 29.0 mm Ref. 1st PC Set up QC Incharge
Micrometer (QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.

1 E/DWLNL 25M08 WNMG080416GH UC5115 1 N/A Rough Turning

Tool Control

2 A 25EWLNL M08 WNMG080416GH UC5115 2 N/A Rough Boring

O9901
3 E/DWLNL 25M08 WNMG G080408 GHUC5115 3 N/A Finish Turning

4 A32/A25 EWNL M08 WNMG G080408 GHUC5115 4 N/A Finish Boring

Remarks: The ballooned dimensions 1 & 2 to be checked by the operator 100% and has to be recorded in the log book.

5 of 18
 Doc. No. : PDC-EPD-F02

Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. :424513119900-MCD-02-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-10 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

ɸ 162.00 / Set up Approval Check Tooling & Set up Approval

10.01 Inner Diameter 30 Vernier Caliper 1st PC Set up QC Incharge
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER

162.50 mm (QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)

1.Setup Approval
1.Setup Approval
(QC-MCN-F01)
1stPC Set up QC Incharge (QC-MCN-F01)
Check & Segregate 2.Operator log Book (QC-
ɸ 330.10 / CMM / SG-35-1 with 2.100% Operator Monitoring
10.02 Inner Diameter 31 ▼ 100% Operator Check tooling & MCN-F10)
330.15 mm MSP 10th PC Inspector
3.In Process Inspection
ascertain root cause 3.In Process Inspection
1 Report (QC-MCN-F02)
Report (QC-MCN-F02)
4.SPC Analysis
4.SPC Chart
TURNING Ist SETUP

ɸ 363.700 / Set up Approval Check Tooling & Set up Approval

10.03 Outer Diameter 32 Vernier Caliper 1st PC Set up QC Incharge
(QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)
364.300 mm
CHUCK

10 10.04 Depth 33
26.00 / 26.30 Depth Vernier + 1st PC Set up QC Incharge
1. Set up Approval
(QC-MCN-F01) Check tooling &
1. Set up Approval
(QC-MCN-F01)
mm Micrometer 1 35th PC Inspector 2. In process Inspection Report ascertain root cause 2.In Process Inspection Report
(QC-MCN-F02) (QC-MCN-F02)

Set up Approval Check Tooling & Set up Approval

10.05 Depth 34 96.7 / 96.9 mm Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)

92.550 / 93.050 Set up Approval Check Tooling & Set up Approval

10.06 Depth 35 Depth Vernier 1st PC Set up QC Incharge
mm (QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)

1.Set up Approval
Check tolling & Set up Approval
10.07 Surface Finish 36 3.2 μRa Surface Finish Tester 1st PC Set up QC Incharge (QC-MCN-F01)
ascertain root cause (QC-MCN-F01)
2.Program Controlled

6 of 18
 Doc. No. : PDC-EPD-F02

Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. :424513119900-MCD-02-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-10 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER

1.Set up Approval
Check tolling & Set up Approval
10.08 Surface Finish 37 3.2 μRa Surface Finish Tester 1st PC Set up QC Incharge (QC-MCN-F01)
ascertain root cause (QC-MCN-F01)
2.Program Controlled

1.Set up Approval
Check tolling & Set up Approval
10.09 Groove Radius 38 R0.8 mm MAX. Tool Profile / Visual 1st PC Set up QC Incharge (QC-MCN-F01)
ascertain root cause (QC-MCN-F01)
2.Program Controlled

1. Set up Approval
Check Tooling & Set up Approval
TURNING Ist SETUP

10.10 Chamfer 39 0.5 X 45 º Visual 1st PC Set up QC Incharge (QC-MCN-F01)

Ascertain root Cause (QC-MCN-F01)
2. Process Controlled
CHUCK

1. Set up Approval
10 10.11 Groove Depth 40 0.8 mm Visual 1st PC Set up QC Incharge (QC-MCN-F01)
2. Process Controlled
Check Tooling & Set up Approval
Ascertain root Cause (QC-MCN-F01)

10.12 Angle 41 25 º Visual 1st PC Set up QC Incharge Program Controlled

Set up Approval Check Tooling & Set up Approval

10.13 Depth 42 3.9 / 4.1 mm Depth Vernier 1st PC Set up QC Incharge
(QC-MCN-F01) Ascertain root Cause (QC-MCN-F01)

1.Set up Approval 1.Set up Approval

Check & Segregate
CMM/Height gauge 1st PC Set up QC Incharge (QC-MCN-F01) / CMM (QC-MCN-F01) / CMM
10.14 Flatness 43 ▼ 0.1 mm Check tooling &
with Dial LC 0.001 100% Inspector Report
ascertain root cause
Report
2.Process Controlled 2. On Part

7 of 18
 Doc. No. : PDC-EPD-F02

Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. :424513119900-MCD-02-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-10 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER

10.15 Angle 44 78 ° Pattern Controlled

10.16 Radius 45 R10 mm Visual Pattern Controlled

1.Set up Approval
1.Set up Approval
(QC-MCN-F01)
Surface Finish 1st PC Set up QC Incharge Check tolling & (QC-MCN-F01)
1.6 μRa
TURNING Ist SETUP

10.17 Surface Finish 46 ▼ 2.In Process Inspection

Tester 1 4 Hours Inspector
Report (QC-MCN-F02)
ascertain root cause 2.In Process Inspection
Report (QC-MCN-F02)
3.Program Controlled
CHUCK

1.Set up Approval
10 10.18 Surface Finish 47 3.2 μRa Surface Finish Tester 1st PC Set up QC Incharge (QC-MCN-F01)
2.Program Controlled
Check tolling & Set up Approval
ascertain root cause (QC-MCN-F01)

1. Set up Approval
Check & Segregate Set up Approval
Set up (QC-MCN-F01)/CMM
10.19 Parallelism 48 ▼ 0.05 mm CMM 1st PC 1 / Shift Report
Check tooling & (QC-MCN-F01)/CMM
ascertain root cause Report
2.Proces Controlled

1. Set up Approval
Check & Segregate Set up Approval
Set up (QC-MCN-F01)/CMM
10.20 Concentricity 49 ▼ 0.05 w.r.t. 'A' CMM 1st PC 1 / Shift Report
Check tooling & (QC-MCN-F01)/CMM
ascertain root cause Report
2.Proces Controlled

1. Set up Approval
Check & Segregate Set up Approval
Set up (QC-MCN-F01)/CMM
10.21 Concentricity 50 ▼ 0.05 w.r.t. 'A' CMM 1st PC 1 / Shift Report
Check tooling & (QC-MCN-F01)/CMM
ascertain root cause Report
2.Proces Controlled

8 of 18
 Doc. No. : PDC-EPD-F02

Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. :424513119900-MCD-02-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-10 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

1.Set up Approval
Height Gauge+Bevel Check Tooling & Set up Approval
10.22 Chamfer 51 2.0 X 45 ̊ 1st PC Set up QC Incharge (QC-MCN-F01)
Protractor 2. Program Controlled
Ascertain root Cause (QC-MCN-F01)

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.
Tool Control

1 EWLNL 2525M08 WNMG 08041G6H UC5115 1 N/A Outer Diameter Finish

2 A40TEWLNLM08 WNMG 080416GH UC5115 2 N/A Bore Finish O9902

3 A40TEWLNLM08 WNMG 080408GH UC5115 3 N/A Bore Finish

Remarks:

9 of 18
 Doc. No. : PDC-EPD-F02

Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. :424513119900-MCD-04-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-11 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

ɸ 11.15 / 11.35 Set up Approval Check tooling & Set up Approval

11.01 Drill Dia 52 Vernier Caliper 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)
mm
DRILLING , TAPPING & TIMING MARK

ɸ 11.970 / Set up Approval Check tooling & Set up Approval

11.02 Drill Dia 53 Vernier Caliper 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)
12.060 mm

17.80 / 18.20 Set up Approval Check tooling & Set up Approval

11.03 Drill Depth 54 Vernier Caliper 1st PC Set up QC Incharge
mm (QC-MCN-F01) ascertain root cause (QC-MCN-F01)
VMC Machine

1.Set up Approval
Check tooling & Set up Approval
11.04 Chamfer 55 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge (QC-MCN-F01)
11 2.Program Controlled
ascertain root cause (QC-MCN-F01)

1.Set up Approval
Check tolling & Set up Approval
11.05 Surface Finish 56 3.2 μRa Surface Finish Tester 1st PC Set up QC Incharge (QC-MCN-F01)
ascertain root cause (QC-MCN-F01)
2.Program Controlled

1.Set up Approval
1.Set up Approval
1st PC (QC-MCN-F01) / CMM
Set up QC Incharge (QC-MCN-F01) / CMM
ɸ 12.80 / 13.20 Report Check Tooling &
11.06 4 Holes 57 ▼ CMM / SPG-69 100% Operator
2.100% Operator monitoring ascertain Root cause
Report
mm 20th PC Inspector 2.In Process Inspection
1 3.InProcess Inspection Report
Report(QC-MCN-F02)
(QC-MCN-F02)

1.Set up Approval
Check tooling & Set up Approval
11.07 Chamfer 58 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge (QC-MCN-F01)
ascertain root cause (QC-MCN-F01)
2.Program Controlled

10 of 18
 Doc. No. : PDC-EPD-F02

Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. :424513119900-MCD-04-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-11 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

1.Set up Approval
Check tolling & Set up Approval
11.08 Surface Finish 59 3.2 μRa Surface Finish Tester 1st PC Set up QC Incharge (QC-MCN-F01)
ascertain root cause (QC-MCN-F01)
2.Program Controlled

1.Set up Approval
1st PC 1.Set up Approval
Set up QC Incharge (QC-MCN-F01) / CMM Report
DRILLING , TAPPING & TIMING MARK

Check Tooling & (QC-MCN-F01) / CMM Report

11.09 2 Holes Thru 60 M10 TPG-14 100% Operator 2.100% Operator monitoring
ascertain Root cause 2.In Process Inspection
1 20th PC Inspector 3.InProcess Inspection Report
Report(QC-MCN-F02)
(QC-MCN-F02)

1.Set up Approval
Set up Check tooling & Set up Approval
11.10 PCD 61 ▼ ɸ 95 ± 0.1 mm CMM 1st PC 1 / Shift
(QC-MCN-F01)/CMM Report
ascertain root cause (QC-MCN-F01)/CMM Report
2.Program Controlled
VMC Machine

1.Set up Approval
1st PC 1.Set up Approval
Set up QC Incharge (QC-MCN-F01) / CMM Report
Check Tooling & (QC-MCN-F01) / CMM Report
11.11 12 Tapped Holes 62 M8 X 1.25 TPG-09 100% Operator 2.100% Operator monitoring
11 1 20th PC Inspector 3.InProcess Inspection Report
ascertain Root cause 2.In Process Inspection
Report(QC-MCN-F02)
(QC-MCN-F02)

Set up Approval Check tooling & Set up Approval

11.12 Drill Depth 63 20.0 mm Vernier Caliper 1st PC Set up QC Incharge
(QC-MCN-F01) ascertain root cause (QC-MCN-F01)

1.Set up Approval
1.Set up Approval
(QC-MCN-F01)
Std Bolt with Vernier 1st PC Set up QC Incharge Check tooling & (QC-MCN-F01)
11.13 Tap Depth 64 15.0 mm 2. In Process Inspection
Caliper 1 35th PC Inspector
Report(QC-MCN-F02)
ascertain root cause 2. In Process Inspection
Report(QC-MCN-F02)
2.Program Controlled

11 of 18
 VMC Machi
DRILLING , TAPPING &
Doc. No. : PDC-EPD-F02
11 Control Plan Rev. No. : 01 (03/04/2015)
Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. :424513119900-MCD-04-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-11 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

1.Set up Approval
1.Set up Approval
1st PC (QC-MCN-F01) / CMM
Set up QC Incharge (QC-MCN-F01) / CMM
CMM / Receiving Report Check Tooling &
11.14 PCD 65 ▼ ɸ 312 ± 0.1 mm 100% Operator Report
Gauge-05 35th PC Inspector
2.100% Operator monitoring ascertain Root cause
2.In Process Inspection
1 3.InProcess Inspection Report
Report(QC-MCN-F02)
(QC-MCN-F02)

1.Set up Approval
1.Set up Approval
1st PC (QC-MCN-F01) / CMM
Set up QC Incharge (QC-MCN-F01) / CMM
CMM / Receiving Report Check Tooling &
11.15 True Position 66 ▼ ɸ 0.03 w.r.t.A 100% Operator Report
Gauge-05 35th PC Inspector
2.100% Operator monitoring ascertain Root cause
2.In Process Inspection
1
DRILLING , TAPPING & TIMING MARK

3.InProcess Inspection Report

Report(QC-MCN-F02)
(QC-MCN-F02)

1.Set up Approval
1st PC 1.Set up Approval
Set up QC Incharge (QC-MCN-F01) / CMM Report
CMM / Receiving Check Tooling & (QC-MCN-F01) / CMM Report
11.16 Angle 67 30º 100% Operator 2.100% Operator monitoring
Gauge-05 35th PC Inspector 3.InProcess Inspection Report
ascertain Root cause 2.In Process Inspection
1 Report(QC-MCN-F02)
(QC-MCN-F02)
VMC Machine

1.Set up Approval
Set up Check tooling & Set up Approval
11.17 Angle 68 90 ° CMM 1st PC 1 / Shift
(QC-MCN-F01)/CMM Report
ascertain root cause (QC-MCN-F01)/CMM Report
2.Program Controlled
11

1.Set up Approval
Set up Check tooling & Set up Approval
11.18 Angle 69 90 ° CMM 1st PC 1 / Shift
(QC-MCN-F01)/CMM Report
ascertain root cause (QC-MCN-F01)/CMM Report
2.Program Controlled

1.Set up Approval
Set up Check tooling & Set up Approval
11.19 Angle 70 15° CMM 1st PC 1 / Shift
(QC-MCN-F01)/CMM Report
ascertain root cause (QC-MCN-F01)/CMM Report
2.Program Controlled

12 of 18
 DRILLING , TAPPING & TIM

VMC Machine
Doc. No. : PDC-EPD-F02

Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)

11
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. :424513119900-MCD-04-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-11 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

1.Set up Approval
Set up Check tooling & Set up Approval
11.20 Angle 71 15° CMM 1st PC 1 / Shift
(QC-MCN-F01)/CMM Report
ascertain root cause (QC-MCN-F01)/CMM Report
2.Program Controlled

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.

1 Solid Carbide Drill Ø 11.2 mm 1 N/A

2 Solid Carbide Drill Ø 12.8 mm 2 N/A

3 SCLHM Ø 13.01 mm 3 N/A Crank Drilling O0907

Tool Control

4 High Speed Steel machine tap M10 4 N/A

5 Solid Carbide Lunge Reamer Ø 13.04 mm 5 N/A

6 Solid Carbide Drill Ø 8.10 mm 6 N/A

7 Solid Carbide Drill Ø 8.5 mm 7 N/A

Clutch Drilling & Tapping O0908
8 High Speed Steel machine tap M8 X 1.25 8 N/A

9 Chamfer Tool Ø 20.0 mm 9 N/A

Remarks:

13 of 18
 Doc. No. : PDC-EPD-F02

Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. :424513119900-MCD-03-04/04-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-12 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Evaluation/ Sample Reaction Plan Record
Numbe Jig, Tools for Mfg.
Description No. Product BLN No. Process Specification/ Measurement Control Method
r
Tolerance Technique Size Freq. & Responsibility

Timing Mark
12.01 Height
72 15.0 mm Visual Program Controlled On Part
DRILLING , TAPPING & TIMING MARK

12.02 Dimension 73 5.0 mm Visual Program Controlled On Part

Timing Mark
12.03 Position Angle
74 10 ° 12° 14° Visual Program Controlled On Part
VMC Machine

Timing Mark
12.04 Depth
75 0.4 mm Visual Program Controlled On Part

11

Timing Mark
12.05 Angle
76 90 ° Visual Program Controlled On Part

1.Set up Approval
1st PC 1.Set up Approval
Set up QC Incharge (QC-MCN-F01) / CMM Report
Check Tooling & (QC-MCN-F01) / CMM Report
12.06 Tap 77 M12 X2 TPG-27 100% Operator 2.100% Operator monitoring
ascertain Root cause 2.In Process Inspection
1 35th PC Inspector 3.InProcess Inspection Report
Report(QC-MCN-F02)
(QC-MCN-F02)

1.Set up Approval
1.Set up Approval
(QC-MCN-F01)
1st PC Set up QC Incharge Check tooling & (QC-MCN-F01)
12.07 Drill Depth 78 22.0 mm Vernier Caliper 1 35th PC Inspector
2. In Process Inspection
ascertain root cause 2. In Process Inspection
Report(QC-MCN-F02)
Report(QC-MCN-F02)
2.Program Controlled

14 of 18
 Doc. No. : PDC-EPD-F02

Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. :424513119900-MCD-03-04/04-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-12 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Evaluation/ Sample Reaction Plan Record
Numbe Jig, Tools for Mfg.
Description No. Product BLN No. Process Specification/ Measurement Control Method
r
Tolerance Technique Size Freq. & Responsibility
DRILLING , TAPPING
& TIMING MARK

1.Set up Approval
1.Set up Approval
VMC Machine

(QC-MCN-F01)
Std Bolt with 1st PC Set up QC Incharge Check tooling & (QC-MCN-F01)
12.08 Tap Depth 79 18.0 mm 1
2. In Process Inspection
Vernier Caliper 35th PC Inspector
Report(QC-MCN-F02)
ascertain root cause 2. In Process Inspection
Report(QC-MCN-F02)
2.Program Controlled
11

34.90 / 35.10
12.09 Dimension 80 Vernier Caliper Process Controlled
mm

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.
Tool Control

1 Solid Carbide Drill ɸ 10.3 mm 1 N/A Side Drill

2 High Speed Steel machine tap M12 2 N/A Tap

O0909
3 Chamfer Tool ɸ 15 mm 3 N/A Chamfer

4 Timing Mark Tool 4 N/A

Remarks:

15 of 18
 Doc. No. : PDC-EPD-F02

Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. : 424513119900 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-13 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

Chamfered Side
Industrial Heating oven & Hydraulic Press

of Ring Gear To be on Top 100% Operator Check &

13.01 Visual 100% Operator N/A
Teethe (not Side Monitoring Segregate
Ballooned)
Ring Gear Heating & Fitment

Gap Between
Filler Gauge of 100% Operator Check &
13.02 Shoulder & Face 6 0.25 mm Max 100% Operator N/A
of Gear 0.25 mm Monitoring Segregate

13
Ring Gear 220°C - 235° 100% Operator Readjust the
13.03 Heating Digital Thermostat 100% Operator N/A
Temp C Monitoring temperature

Ring Gear
100% Operator
13.04 Heating 20-30 mins Watch 100% Operator N/A N/A
Time Monitoring

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.
Tool Control

Remarks:

16 of 18
 Doc. No. : PDC-EPD-F02

Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. :424513119900-MCD-03-04 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number : 424513119900 CP-14 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Dharam Singh Engineer -CMM

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

Ø 14.00 mm Tool Controlled

Dynamic Balancing Machine

Check tooling & Set Up Approval- DB

14.01 Drill Diameter Vernier Caliper 1st PC Set Up- DB Supervisor & WI
ascertain root cause (QC-MCN-F07)
MAX. (PRD-MCN-WI06)
Dynamic Balancing

13.00 mm Stopper Controlled & WI Measure & Readjust Set Up Approval- DB

14.02 Drill Depth Vernier Caliper 1st PC Set Up- DB Supervisor
Max. (PRD-MCN-WI06) the size of stopper (QC-MCN-F07)
14 81

1.Set Up Approval cum In

1.Set Up Approval cum In
Process Inspection Report -
Process Inspection Report -
Balancing Dynamic 1st PC Set Up- DB Supervisor Dynamic Balancing
Dynamic Balancing
14.04 30 g-cm 100% Operator Check & Segregate (QC-MCN-F07)
Value Balancing Machine 1 20th PC Inspector
(QC-MCN-F07)
2. Operator Log Book (QC-
2. Operator Log Book (QC-
MCN-F11)
MCN-F11)
3. On Part

Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.

1 Drill Ø 14.00 - 18.00 mm 1 N/A Side Drill

Tool Control

Remarks: Ballooned Dimension 81 to be Checked by Operator 100% & has to be recorded in Operator Log Book.

17 of 18
 Doc. No. : PDC-EPD-F02

Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details

Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO

Production Drawing No. :424513119900 Revision No. (Date): 00(2806/2015) Mr. Himanshu Duniwal PC

Control Plan Number :424513119900 CP-15,16 & 17 Organization / Plant Approval Date : N/A Date (Originated) : N / A Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : 424513119900 Other Approval / Date (if Reqd.) :N/A Customer Engineering Approval /Date (if Reqd.) : N / A Mr. Arjun Yadav Manager - M/C Shop

Part Name / Description : Flywheel Assembly Organization / Supplier Code : Customer Quality Approval / Date (if Reqd.) : N / A Mr. Babulal Jangid Packing Supervisor

Special Char. Class

Characteristics Methods
Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. Evaluation/ Measurement
Description No. Product BLN No. Process Specification/ Control Method
r Technique
Tolerance Size Freq. & Responsibility

100 % Sorting for

Pre-dispatch AS PER PDI
15
Inspection
15.01 AS PER PDI Report
Report
AS PER PDI Report AS PER PDI Report In - Process Control Deviated PDI Report
Parameters

Surface of the part

should be dry and
16.01 Cleaning of parts
free from the Rust
Visual 100% Each Batch Re-cleaning
& Chips

Light Film of oil to Surface shall only

16.02 be applied with a coated with RPO Visual 100% Each Batch Re-Oiling
Oiling Area & Packaging Area

soaked cloth but no Excess Oil

Oiling & Packaging

16.03 Part Identification No Mixing Visual 100% Each Batch 100 % Sorting -
PKG-PDS-WI01, PKG-
PDS-WI02, Drg No.
424513119900
16
PKG-01-01
16.04 Box Type
As per Packaging
Visual 100% Each Batch & Monitoring by -
Specification Sheet Supervisor

Quantity Per As per Packaging

16.05
Box Specification Sheet Visual 100% Each Batch Daily Packing Report
Repacking

As per Packaging
16.06 Labeling
Specification Sheet Visual 100% Each Batch -

Other Packaging As per Packaging

16.07
Material Specification Sheet
Visual 100% Each Batch -

Customer Name, As per Dispatch DES-PDS-WI01 and TAG

17 Dispatch 17.01 Visual Examination 100% Each Dispatch Re-Checking Dispatch Documents
Quantity, Date….. Schedule & Label on Box

18 of 18