Format No. : ENG-FR-24 Rev. No. 00 Date : 01.04.

2011

KALRA OVERSEAS & PRECISION ENGINEERING LTD.

TEAM FEASIBILITY COMMITMENT (FORGING)
CUSTOMER : DATE :

PART NUMBER :

PART NAME :

SAMPLE QUANTITY : SHEET :

Feasibility Considerations

1 Material

Material - Lead Time-

Section - Tentative cost-

2 Heat Treatment :-

Hardness :-
Tensile Strength :-

3 Cut Weight = Gross Weight = Finish Forging Weight =

4 Unit & Capacity Required

Parts /Day -
No. Of days required to complete quantity of - Days / Annume

5 Forging Procedure
Upset / Finisher / Trimming / Piercing

6 Die Block Size Lead Time Tentative Cost

7 Trim Tool Size Lead Time Tentative Cost

8 Piercing Punch size Lead Time Tentative Cost

Total Budget including manufacturing cost

9 Drawing Clarification required If Any

10 Help Required from customer if any (Standard if any / cutting tool / drawing / model )

11 Special Gauges if required Lead Time Tentative Cost

12 Development Lead Time (Tentative)

13 Tentative budget (forging development)

14 Sample Batch Size -

 KALRA OVERSEAS & PRECISION ENGINEERING LTD.
TEAM FEASIBILITY COMMITMENT (FORGING)
CUSTOMER : DATE :

PART NUMBER :

PART NAME :

SAMPLE QUANTITY : SHEET :

YES NO CONSIDERATION
Is product adequately defined (application requirements, etc.) to enable
feasibility evaluation ?
Can Engineering Performance Specifications be met as written ?
Can product be manufactured to tolerances specified on drawing ?
Can product be manufactured with Cpk's that meet requirements ?
Is there adequate capacity to produce product ?
Does the design allow the use of efficient material handling techniques ?
Can the product be manufactured without incurring any unusual;
Costs for capital equipment ?
Costs for tooling ?
Alternative manufacturing methods ?
Is statistical process control required on product ?
Is statistical process control presently used on similar products ?
Where statistical process control is used on similar products;
Are the processes in control and stable ?
Are Cpk's greater then 1.33 ?
Conclusion
Feasible Product can be produced as specified with no revisions.
Feasible Changes recommended ( See attached ).
Not Feasible Design revision required to produce product within the specified requirements.

Sign - off

TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE

(Corporate Mktg Exec.) Works Manager (VPO)

TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE

(Corporate Engg. Exec.) (Manager Forging design & development)

TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE

(Corporate Purchase Manager) (Manager Mfg'g design & development)
Format No. : ENG-FR-24 Rev. No. 00 Date : 01.04.2011

KALRA OVERSEAS & PRECISION ENGINEERING LTD.

TEAM FEASIBILITY COMMITMENT (FORGING)
CUSTOMER : DATE :

PART NUMBER :

PART NAME :

SAMPLE QUANTITY : SHEET :

Feasibility Considerations

1 Material Details :

Material - Lead Time-

Section - Tentative cost-

Cut Weight -

Gross Weight -

Finish Forging Weight -

2 Heat Treatment :

3 Unit & Capacity :

Parts /Day -

No. Of days required to complete quantity of - Days / Annume

4 Forging Process :

5 Die Block Size Lead Time Tentative Cost

6 Trim Tool Size Lead Time Tentative Cost

7 Piercing Punch size Lead Time Tentative Cost

8 Total Budget including manufacturing cost

9 Drawing Clarification required If Any

 KALRA OVERSEAS & PRECISION ENGINEERING LTD.
TEAM FEASIBILITY COMMITMENT (FORGING)
CUSTOMER : DATE :

PART NUMBER :

PART NAME :

SAMPLE QUANTITY : SHEET :

10 Help Required from customer if any (Standard if any / cutting tool / drawing / model )

11 Special Gauges if required Lead Time Tentative Cost

12 Development Lead Time (Tentative)

13 Tentative budget (forging development)

14 Sample Batch Size -

YES NO CONSIDERATION
Is product adequately defined (application requirements, etc.) to enable
feasibility evaluation ?
Can Engineering Performance Specifications be met as written ?
Can product be manufactured to tolerances specified on drawing ?
Can product be manufactured with Cpk's that meet requirements ?
Is there adequate capacity to produce product ?
Does the design allow the use of efficient material handling techniques ?
Can the product be manufactured without incurring any unusual;
Costs for capital equipment ?
Costs for tooling ?
Alternative manufacturing methods ?
Is statistical process control required on product ?
Is statistical process control presently used on similar products ?
Where statistical process control is used on similar products;
Are the processes in control and stable ?
Are Cpk's greater then 1.33 ?
Conclusion
Feasible Product can be produced as specified with no revisions.
Feasible Changes recommended ( See attached ).
Not Feasible Design revision required to produce product within the specified requirements.

Sign - off

TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE

(Corporate Mktg Exec.) Works Manager (VPO)

TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE

(Corporate Engg. Exec.) (Manager Forging design & development)

TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE

(Corporate Purchase Manager) (Manager Mfg'g design & development)
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 15.12.2020
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: NIL, 12.12.2020 REV NO & DATE: NIL, 12.12.2020
CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 01 DATED- 26.11.2020 REV NO & DATE: REV- 01 DATED- 26.11.2020
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 50 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

1 Material Details
Material Section:
30MnVS6 Ø40

Customer Standard (If Any) DIN EN 10267

RMS Existing
IF EXISTING (RMS Ref. No) Specific Order Based Ref. KOPL Part No. NA
Complexity to Purchase Specific Order Based & Min. Heat Size
Lead Time 5 Weeks

2 ESTIMATED WEIGHTS (kgs)

Cut Wt. 0.850
Gross Wt. 0.893
Finish Forging Wt. 0.630
Expected Yield (%) 70.59%

3 Special Characteristics: (Forging) Process/Customer NP :- Next process , SP :- Subsequent process , CE :- Customer End , EU:-End User
SPL.
Balloon .
Description Dimension Tol + Tol - Char. Potential Cause Effect Control mapping
No
Class

NP NIL
Die Inspection
SP
Wall thickness variation after drilling (Weak Report / Hot
* Wrong die profile / Wrong wall at end)
29 Total Height 77.5 0.7 0.4 Inspection
Cam programming Report / Final
CE Part may reject in assembly
inspection Report
EU Part may fail in running
NP NIL
Die Inspection
SP
Wall thickness variation after drilling (Weak Report / Hot
41 Lobe radius R18 0.5 0.5 * Wrong die profile / Wrong wall at end) Inspection
Cam programming
CE Part may reject in assembly Report / Final
inspection Report
EU Part may fail in running
Setting error NP Mismatch out of spec
Die Inspection
Ram play SP NIL Report / Hot
57 Mismatch 0.5 Max - - * May not fit in fixture Inspection
NIL CE Report / Final
Reject post machining
inspection Report
Die locks wear EU NIL

4 Main Production Unit

Forging Unit 1000T
Single / Multiple Single
Est. Qty/Shift (8 hrs) with 80% OEE 1350 Nos
Expected Die Life (Nos/Set) 6000 - 8000 Nos

4a OPR. No. Forging Process Input Purpose Results Expected (Dimension/Ballooning no.) Requirement of Gauges list for process control

20 Cutting Process Sheet / Control Plan Required weight Ensure Weight is whithin specifacation (Ø40x87mm)

40A Edger Process Sheet / Control Plan Descaling & Preform Reduce Scale defect & Improve the Suraface Quality
Vernier Caliper, Pistol Caliper, Outside Caliper,
Ensure Proper Filling in Blocker & Increased the Finisher Die
40B Blocker Process Sheet / Control Plan To generate required volume Radius Gauge, Bevel Protractor, V Block, Right
Life
Ange & Height Gauage
Process Sheet / Control Plan / Forging
40C Finisher Customer Requirements Final product with flash
Drawing
Process Sheet / Control Plan / Forging
50 Trimming Customer Requirements / Excess material removing Free from flash (Dimn +0.4 / -0.4)
Drawing

60 Controlled Cooling Control Plan To achieve the desired hardness Hardness within the specification (220 ~ 260 BHN) Brinell Hardness Tester

4b Heat Treatment Controlled Cooling

Hardness Range 220 ~ 260 BHN
Microstructure Requirements Ferrite & Pearlite structure. Banding is not acceptable.
Tensile Strength 750 - 900 N/mm2

4c OPR. No. Post Forging Operations Input Purpose Results Expected (Dimension/Ballooning no.) Requirement of Gauges list for process control

Flash extension / Body cut within the specification

70 Linishing Control Plan / Forging Drawing Remove trimmed extra flash extension Vernier Caliper
(Dimn +0.4 / -0.4)

Free from scale / surafce finish within the specification (Rz

80 Shot blasting (Rz 100) Control Plan / Forging Drawing Descaling / Desired surafce finish Surafce tester / Master piece / visual inspection
100)
90 Crack Detection MPI & Demagnetize (2 Gauzz) Control Plan / Forging Drawing Crack detection Crack defect inspection intensity meter / visual inspection

Vernier Caliper, Pistol Caliper, Outside Caliper,

100 Final inspections Control Plan / Forging Drawing Visual / Dimensional inpection All parameters within the specifid limit Radius Gauge, Bevel Protractor, V Block, Right
Ange & Height Gauage
110 Preservation & Transportation Control Plan Rust free & movement Ontime & Rust free Trolly / Pallets

4d Die & Tool Material

Die Specification Die Material L B H Qty Wt (kgs) Rate/Kg Value Lead Time (Wks) Specific Gravity
Top Flatener DB6 280 210 125 1 43.27 ₹ 230.00 ₹ 9,952.82 2 7.85
Bot Flatener DB6 280 210 125 1 43.27 ₹ 230.00 ₹ 9,952.82 2 Constant
Top Blocker DB6 280 210 130 1 45.00 ₹ 230.00 ₹ 10,350.93 2 6.17
Bot Blocker DB6 280 210 110 1 38.08 ₹ 230.00 ₹ 8,758.48 2
Top Finisher DB6 280 210 130 1 45.00 ₹ 230.00 ₹ 10,350.93 2
Bot Finisher DB6 280 210 110 1 38.08 ₹ 230.00 ₹ 8,758.48 2
Trim Punch DB6 160 160 90 1 18.09 ₹ 230.00 ₹ 4,159.87 2
Trim Die DB6 260 210 70 1 24.23 ₹ 230.00 ₹ 5,573.58 2

4e ESTIMATED LEAD TIME (WKS) STATUS SUB-TOTAL ₹ 67,857.91

DESIGN & ENGINEERING CW1 TO START GST 18%
MODELLING, DIE & TOOL DRG RELEASE CW2 TO START TOTAL ₹ 80,072.34
DIE MANUFACTURING CW4 TO START EST. MANUFACTURING COST ₹ 48,043.40 60%
TOTAL ESTIMATED TIME (WKS) 6 TOTAL DIE & TOOL MFG COST ₹ 128,115.74

CONTINGENCY
5 Alternate Production Unit
Forging Unit 1600T
Single / Multiple Double (Cut For Two)
Est. Qty/Shift (8 hrs) with 80% OEE 1000x2 Nos
Expected Die Life (Nos/Set) 6000 - 8000x2 Nos

5a OPR. No. Forging Process Input Purpose Results Expected (Dimension/Ballooning no.) Requirement of Gauges list for process control
20 Cutting Process Sheet / Control Plan Required weight Ensure Weight is whithin specifacation
40A Edger Process Sheet / Control Plan Descaling & Preform Reduce Scale defect & Improve the Suraface Quality
Ensure Proper Filling in Blocker & Increased the Finisher Die
40B Blocker Process Sheet / Control Plan To generate required volume
Life Vernier Caliper, Pistol Caliper, Outside Caliper,
Radius Gauge, Bevel Protractor, V Block, Right
Process Sheet / Control Plan / Forging Ange & Height Gauage
40C Finisher Customer Requirements Final product with flash
Drawing

Process Sheet / Control Plan / Forging

50 Trimming Customer Requirements / Excess material removing Free from flash
Drawing
60 Controlled Cooling Control Plan To achieve the desired hardness Hardness within the specification Brinell Hardness Tester
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 15.12.2020
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: NIL, 12.12.2020 REV NO & DATE: NIL, 12.12.2020
CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 01 DATED- 26.11.2020 REV NO & DATE: REV- 01 DATED- 26.11.2020
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 50 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

5b Heat Treatment Controlled Cooling

Hardness Range 220 ~ 260 BHN
Microstructure Requirements Ferrite & Pearlite structure. Banding is not acceptable.
Tensile Strength 750 - 900 N/mm2

5c OPR. No. Post Forging Operations Input Purpose Results Expected (Dimension/Ballooning no.) Requirement of Gauges list for process control
70 Linishing Control Plan / Forging Drawing Remove trimmed extra flash extension Flash extension / Body cut within the specification Vernier Caliper
80 Shot blasting (Rz 100) Control Plan / Forging Drawing Descaling / Desired surafce finish Free from scale / surafce finish within the specification Surafce tester / Master piece / visual inspection
90 Crack Detection MPI & Demagnetize (2 Gauzz) Control Plan / Forging Drawing Crack detection Crack defect inspection intensity meter / visual inspection
Vernier Caliper, Pistol Caliper, Outside Caliper,
100 Final inspections Control Plan / Forging Drawing Visual / Dimensional inpection All parameters within the specifid limit Radius Gauge, Bevel Protractor, V Block, Right
Ange & Height Gauage
110 Preservation & Transportation Control Plan Rust free & movement Ontime & Rust free Trolly / Pallets

4d Die & Tool Material

Die Specification Die Material L B H Qty Wt (kgs) Rate/Kg Value Lead Time (Wks) Specific Gravity
Top Buster DB6 360 190 175 1 0.00 ₹ 230.00 ₹ - 2 7.85
Bot Buster DB6 360 190 120 1 0.00 ₹ 230.00 ₹ - 2 Constant
Top Blocker DB6 360 230 140 1 0.00 ₹ 230.00 ₹ - 2 6.17
Bot Blocker DB6 360 230 165 1 0.00 ₹ 230.00 ₹ - 2
Top Finisher DB6 360 230 140 1 0.00 ₹ 230.00 ₹ - 2
Bot Finisher DB6 360 230 165 1 0.00 ₹ 230.00 ₹ - 2
Trim Punch DB6 160 160 90 1 18.09 ₹ 230.00 ₹ 4,159.87 2
Trim Die DB6 260 210 70 1 24.23 ₹ 230.00 ₹ 5,573.58 2

4e ESTIMATED LEAD TIME (WKS) STATUS SUB-TOTAL ₹ 9,733.45

DESIGN & ENGINEERING 1 TO START GST 18%

MODELLING, DIE & TOOL DRG RELEASE 2 TO START TOTAL ₹ 11,485.47

DIE MANUFACTURING 4 TO START EST. MANUFACTURING COST ₹ 4,594.19 40%

TOTAL ESTIMATED TIME (WKS) 7 TOTAL DIE & TOOL MFG COST ₹ 16,079.66
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 15.12.2020
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: NIL, 12.12.2020 REV NO & DATE: NIL, 12.12.2020
CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 01 DATED- 26.11.2020 REV NO & DATE: REV- 01 DATED- 26.11.2020
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 50 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

6 Special Characteristics (Machining): Process/Customer NP :- Next process , SP :- Subsequent process , CE :- Customer End , EU:-End User

SPL.
Balloon .
Description Dimension Tol + Tol - Char. Potential Cause Effect Control mapping
No
Class

NP Nil

24 Lug bore CD 55.800 0.100 0.100 * Wrong setting/Spacer wearout

SP

CE
Nil

Fitment problem
1) 1/Hours Inspection on
Trimos

EU Nil

NP Nil

32 Barrel OD Ø40.5 0.100 0.100 * Insert Wear, Offset Error

SP

CE
Not locating in fixture

Fitment problem
1)100% Inspection on
Dial comparator gauge

EU Nil

NP Nil

38 Total height 67.730 0.150 0.150 * Lug radius under size/over size
SP

CE
Nil

Fitment problem
1) 1/Hours Inspection on
Trimos /VMM

EU Nil

7 Machined
a OPR. No. Machining Process Input Clamping Resting Orientation Results Expected (Dimension/Ballooning no.) Gauges Tooling & Insert Fixture

1) shotblasted forging & MPI

Foging drawing:-19 ,21,29,41,57,53 & other parameter as per forging Vernier caliper &
205/208 Forging received & Inwad inspection 2) Supplier inward Inspection - - - - -
drawing height gauge
report

Forging
1.EW & SW Mismatch Lobe ID "V"
36. OD 40.6 ± 0.1 (Cp/Cpk) V block
2. lobe Height Variation Loactor & Tail 1) Dial stand & V block CNMG120412
Lobe Width 27. ID 35.2 ± 0.1 Centerlizer
210 CNC #1 - Barrel OD / ID Turning 3.Concentricity of Prism Stock Centre 2) Dial comparator TNMG160408
(Pr 15-18 bar) 32 & 33. R/O - Face & ID wrt C: 0.1 (Cp/Cpk) Pullback chuck
I-Diameter to Support 3) ID bore gauge CCMT06208
33. Symm. 0.1 wrt "A&B" (Cp/Cpk) Center suppourt
O-Diameter (Pr 6-8 Bar)
38. Prism Height Dim: 67.73± 0.1 (Cp/Cpk)
4. R18 ± 0.5 (variation with 0.2

1. Machined 1. Lobe Rough Bore Pos within 0.1 wrt to Barrel OD & Barrel Face SOMT08T306/ V type top clamp
ID Ø 35.2 control within ±0.03. Lobe Top Radius Barrel Face & 2. Lobe Rough Boring Sym within 0.1 wrt to Barrel OD. SPMG07T308XT430 Locator
220 CNC #2 - Rough Lobe Bore & Face Lobe radius 1) Plug gauge
2. Forging Dim Tgt: 67.600 -0.4 (R18) Locate on ID 3. CD 55.80 ± 0.1 CCMT060208\ Specer
3. Lobe Wall Var 0.6 Max. CNMG120408 2 jaw chuck

1. Machined
ID Ø 35.2 control within ±0.03.
20. Lobe Finish Bore Pos within 0.2 wrt to Barrel OD & Face
2. Forging Dim Tgt: 67.600 -0.4 Rest on Barrel
22. Lobe Finish Bore Sym within 0.2 wrt to Barrel OD. 1) Air plug gauge U clamp
3. Lobe Wall Var 0.6 Max. Face Orient using
Clamping on 4. Chamfer Symmetry within 0.2 wrt Barrel OD 2) Dial stand & Height Locator
CNC #3 - Face, Rough / Finish Lobe Through Boring, 4. Centre Ht., Pos & Ø of 1st Retractable CCMT060208
230 Inner Pad using 14. Concentricity 0.1 wrt E (pokayoke - finish through boring) mater Specer
Both Sides Chamfer Side Rough Bore. Locate in Locator in Ø TCMT110204
floating Clamps 24. CD 55.80 ± 0.050 (Cp/Cpk) 3) Chamfer mandrel 2 jaw chuck
5. Lobe Face Distance wrt Barrel 23.14 ± 0.050
12. Ø 24.00 +0.020 / +0.041 (Cp/Cpk) gauge & height master Dimond pin
Barrel OD: Dimn: 53.45± 0.050 ID
21. Roundness Ø 24.00 +0.020 / +0.041 - 0.008 max
6. // Lobe Pad wrt Barrel Face
within 0.20 max

Clamping on 04. Milling symmetry control within 0.1

#4 Lobe Slot Milling & Rest Pad Milling - Material Barrel OD - Rest on Barrel Ø 23.90 ±0.020 15. Pad Milling Height control within 32±0.1 1) Width gauge
1.EW & SW Mismatch TPKN Insert
240 Removal 1.5 MM Chuck & Collet Face - Collet One Side Pin 17. Pad milling parallelism control within 0.1 max 2) Height master & Collet type fixture
2. Inner pad height CCMT060208
(Both Milling - UP Milling) Arrangement Arngmnt Engagement 01. Milling height 69.5 ±0.1 dial stand
(Mech Type) 06. milling width53 ±0.2

248 #5 Hand Deburring - Pad Corner Finished M/ced Part Manual Manual Manual No Sharp Corners Visual - -

#6 Hand Deburring - Finish Bore & Mandrel Checking

248 Finished M/ced Part Manual Manual Manual No Sharp Corners Visual - -
(100%)

250 #7 Washing Deburred Parts Washing M/c Washing M/c Washing M/c Rust Protected Parts Visual - -

260 #8 Visual Checking (Eye Sequence Chart) & Packing Rust Protected Parts Manual Manual Manual Final Product Visual - -

7 Packaging (Internal Part handling)

b Part Handling Process
Box/Trolly/Bins Part Qty per Wt of Empty
OPR. No. Part handling Material description Part Qty/Layer Wt /Part Total Wt of Box/Trolly/Bins
Internal size Box/Trolly/Bins Box/Trolly/Bins
Sr. No. Instruction

208 Steel Bin (Raw part) 800x800x700 - 2000 nos 591g 100kg 1300kg 1 Parts should be clean & oiling,Parts should be Identified (Tag)

210 Sing line flow - - - - - - - -

220 Sing line flow - - - - - - - -

230 Sing line flow - - - - - - - -

240 Sing line flow - - - - - - - -

250 Sing line flow - - - - - - - -

Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 15.12.2020
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: NIL, 12.12.2020 REV NO & DATE: NIL, 12.12.2020
CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 01 DATED- 26.11.2020 REV NO & DATE: REV- 01 DATED- 26.11.2020
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 50 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

7 Packaging (Final Dispatch)

b Packing Process
Part Qty per
Sr No. Packing Material description size Part Qty/Layer Wt /Part Wt of Empty Box Total Wt of Box
Box
Sr. No. Instruction

Wooden box & L1160 xW790 x

1 286 2002 0.441KG 48KG 931kg 1 Part should be wash in waching machine
corrgeted box H720MM
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 15.12.2020
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: NIL, 12.12.2020 REV NO & DATE: NIL, 12.12.2020
CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 01 DATED- 26.11.2020 REV NO & DATE: REV- 01 DATED- 26.11.2020
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 50 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

8 Out sources Operations/Process (Preturning/Heat Treatment/Ind. Hardening/Coating ).

a Process: Heat Treatment b Process:

Description: Plug, Sleeve Description:
Preferred Source: Unitherm Preferred Source:
Lead Time (Weeks) 3-4 days Lead Time (Weeks)
Quantity (Nos/Set) 1set Quantity (Nos/Set)
Target Cost : ₹ 58.00 Per Kg Target Cost : ₹ -

c Process: d Process:
Description: Description:
Preferred Source: Preferred Source:
Lead Time (Weeks) Lead Time (Weeks)
Quantity (Nos/Set) Quantity (Nos/Set)
Target Cost : ₹ - Target Cost : ₹ -

9 Special Jig / Fixtures TOTAL COST JIGS & FIXTURES ₹ 80,000.00

Process: Top Tooling CNC #3 + Locator + Locator Pin + Top Top Tooling CNC #2 + Locator + Top Clamp +
a b Process:
Clamp Spacer
Purpose Part Holding Purpose Part Holding
Preferred Source: Rahil Engineering Preferred Source: Rahil Engineering
Lead Time (Weeks) 2 Lead Time (Weeks) 2
Quantity (Nos/Set) 1set Quantity (Nos/Set) 1set
Target Cost : ₹ 15,000.00 Target Cost : ₹ 15,000.00

Process: Top Tooling #4 + Collet Type Chuck (Mech) + Locator

c d Process:
Pin (To be finalized with Rahil)

Purpose Lug & Pad Milling Purpose

Preferred Source: Rahil Engineering Preferred Source:
Lead Time (Weeks) 2 Lead Time (Weeks)
Quantity (Nos/Set) 1set Quantity (Nos/Set)
Target Cost : ₹ 50,000.00 Target Cost : ₹ -

10 Special Cutting Tools TOTAL COST CUTTING TOOLS ₹ 30,000.00

a Description CNC #3 Carbide Special Boring Bar b Process:

Purpose Lobe Finish Bore & Champfer Purpose

Preferred Source: V D Tools Preferred Source:

Lead Time (Weeks) 2 Lead Time (Weeks)
Quantity (Nos/Set) 1 Quantity (Nos/Set)
Target Cost : ₹ 18,000.00 Target Cost : ₹ -

c Process: #4 Milling Cutter (Combiation Type) d Process:

Purpose Pad & Slot Milling Purpose
Preferred Source: Pioneer Tools, Shirwal Preferred Source:
Lead Time (Weeks) 1 Lead Time (Weeks)
Quantity (Nos/Set) 1 Quantity (Nos/Set)
Target Cost : ₹ 12,000.00 Target Cost : ₹ -

11 GAUGES (AS REQUIRED)

Description Dimension Tol + Tol - QTY Lead Time Wks (Tentative) Budget Rs. (Tentative) TOTAL COSTS GAUGES

Barrel ID Bore gauge 35.6 0.1 0.1 1 2 ₹ 6,000.00

Barrel OD Comparator with

40.5 0.1 0.1 1 2 ₹ 6,000.00
master
₹ 32,400.00
Prism: Barrel OD - Special
67.73 0.2 0.2 1 2 ₹ 6,000.00
Height Gauge

Height Master 53.45 0.1 0.1 1 2 ₹ 1,200.00

Height Master 66.4 0.1 0.1 1 2 ₹ 12,000.00

Height Master (Pad) 32 0.1 0.1 1 2 ₹ 1,200.00

₹ -
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 15.12.2020
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: NIL, 12.12.2020 REV NO & DATE: NIL, 12.12.2020
CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 01 DATED- 26.11.2020 REV NO & DATE: REV- 01 DATED- 26.11.2020
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 50 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

12 DRAWING CLARIFICATION (IF REQUIRED) (CSR/STD)

Description Dimension Tol + Tol - Reason/Remarks Justification

13 HELP REQUIRED FROM CUSTOMER (IF ANY) - STD'S, CUTTING TOOLS, DRAWINGS, MODEL, ETC.
Subject Reason Justification

Development Lead Time Weeks 3wks

14
(Tentative) 3wks
Timing Chart Release Date - After TDO release

15 PPAP Submission Qty (Nos) - As Forged 50

PPAP Submission Qty (Nos) - As Machined 20
PPAP Submission Level with date - L3 After TDO release

16 Overall (Tentative) Budget (forging development including dies & Manufacturing Cost) :
No of Shift (Budgeted) 3
Cost / hour - Shift ₹ 30,000.00
Total Cost of Development Time (Forging) ₹ 90,000.00
No of Shift (Budgeted) Inhouse 6
Cost / hour - Shift ₹ 4,000.00
Total Cost of Development Time (Machining) ₹ 24,000.00
Cost Dies, Tooling, Calibration Tools, Gauges, Fixtures etc. ₹ 142,400.00
Total Cost of Development (excluding outsourcing) ₹ 256,400.00

12 CONSIDERATIONS Remarks
Is product adequately defined (application requirements, etc.) to enable feasibility evaluation ? þ
Can Engineering Performance Specifications be met as written ? þ Subject to Drg Clarifications

Can product be manufactured to tolerances specified on drawing ? þ Subject to Drg Clarifications

Can product be manufactured with Cpk's that meet requirements ? þ

Is there adequate capacity to produce product ? þ
Does the design allow the use of efficient material handling techniques ? þ
Can the product be manufactured without incurring any unusual;
Knuckle Joint Coining, Hot Padding, Milling May need to
# Costs for Capital Equipment ? þ shift to VMC as contingency (Fixture-Chuck & End Mill
Available)
# Costs for Tooling ? þ
# Alternative Manufacturing Methods ? x Considered

Is statistical process control required on product ? þ

Is statistical process control presently used on similar products ? x
Where statistical process control is used on similar products;
# Are the processes in control and stable ? x Cp/Cpk - yes, Pp, Ppk - No

# Are Cpk's greater then 1.33 ? x

Conclusion
Product can be produced as specified with no revisions. Feasible þ
Changes recommended ( See attached ). Feasible x
Design Revision required to produce product within the specified requirements. Drg Clari…. x

Sign - off Date 15.12.2020

TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE

Raunaq Kalra Mktg D Nawadkar Operations
TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE
J Swami Engineering CTO Dilip Jawade Engineering
TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE
Ganesh Revgade Forge Design Kartik Hota Engineering M/C
TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE
Pandurang Deokate Purchase D Nayak Production
TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE
Rajesh Pawar Quality HOD B Kumbhar MQA

Rev. Description Date Rev. Description Date

Nil RFQ 15.12.2020 A As per customer drawing Index 03 10.06.2021
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 10.06.2021
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: NIL, 07.06.2021 REV NO & DATE: NIL, 07.06.2021
CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 03 DATED- 28.04.2021 REV NO & DATE: REV- 03 DATED- 28.04.2021
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 198 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

1 Material Details
Material Section:
30MnVS6 Ø40

Customer Standard (If Any) DIN EN 10267

RMS Existing
IF EXISTING (RMS Ref. No) Specific Order Based Ref. KOPL Part No. NA
Complexity to Purchase Specific Order Based & Min. Heat Size
Lead Time 5 Weeks

2 PPAP WEIGHTS (kgs)

Cut Wt. 0.720
Gross Wt. 0.756
Finish Forging Wt. 0.560
Expected Yield (%) 74.07%

3 Special Characteristics: (Forging) Process/Customer NP :- Next process , SP :- Subsequent process , CE :- Customer End , EU:-End User
SPL.
Balloon . No Description Dimension Tol + Tol - Char. Potential Cause Effect Control mapping
Class

NP NIL
Die Inspection
SP
Wall thickness variation after drilling (Weak Report / Hot
29 Total Height 77.5 0.7 0.4 * Wrong die profile / Wrong wall at end) Inspection
Cam programming
CE Part may reject in assembly Report / Final
inspection Report
EU Part may fail in running
NP NIL
Die Inspection
SP
Wall thickness variation after drilling (Weak Report / Hot
39 Lobe radius R18 0.5 0.5 * Wrong die profile / Wrong wall at end) Inspection
Cam programming
CE Part may reject in assembly Report / Final
inspection Report
EU Part may fail in running
Setting error NP Mismatch out of spec
Die Inspection
Ram play SP NIL Report / Hot
59 Mismatch 0.5 Max - - * May not fit in fixture Inspection
NIL CE
Reject post machining Report / Final
inspection Report
Die locks wear EU NIL

4 Main Production Unit

Forging Unit 1000T
Single / Multiple Single
Est. Qty/Shift (8 hrs) with 80% OEE 1350 Nos
Expected Die Life (Nos/Set) 6000 - 8000 Nos

4a OPR. No. Forging Process Input Purpose Results Expected (Dimension/Ballooning no.) Requirement of Gauges list for process control

20 Cutting Process Sheet / Control Plan Required weight Ensure Weight is whithin specifacation

40A Edger Process Sheet / Control Plan Descaling & Preform Reduce Scale defect & Improve the Suraface Quality
Vernier Caliper, Pistol Caliper, Outside Caliper,
Ensure Proper Filling in Blocker & Increased the Finisher
40B Blocker Process Sheet / Control Plan To generate required volume Radius Gauge, Bevel Protractor, V Block, Right
Die Life
Ange & Height Gauage
Process Sheet / Control Plan / Forging
40C Finisher Customer Requirements Final product with flash
Drawing
Process Sheet / Control Plan / Forging
50 Trimming Customer Requirements / Excess material removing Free from flash
Drawing

60 Controlled Cooling Control Plan To achieve the desired hardness Hardness within the specification Brinell Hardness Tester

4b Heat Treatment Controlled Cooling

Hardness Range 220 ~ 260 BHN
Microstructure Requirements Ferrite & Pearlite structure. Banding is not acceptable.
Tensile Strength 750 - 900 N/mm2

4c OPR. No. Post Forging Operations Input Purpose Results Expected (Dimension/Ballooning no.) Requirement of Gauges list for process control
70 Linishing Control Plan / Forging Drawing Remove trimmed extra flash extension Flash extension / Body cut within the specification Vernier Caliper

80 Shot blasting (Rz 100) Control Plan / Forging Drawing Descaling / Desired surafce finish Free from scale / surafce finish within the specification Surafce tester / Master piece / visual inspection

90 Crack Detection MPI & Demagnetize (2 Gauzz) Control Plan / Forging Drawing Crack detection Crack defect inspection intensity meter / visual inspection

Vernier Caliper, Pistol Caliper, Outside Caliper,

100 Final inspections Control Plan / Forging Drawing Visual / Dimensional inpection All parameters within the specifid limit Radius Gauge, Bevel Protractor, V Block, Right
Ange & Height Gauage
110 Preservation & Transportation Control Plan Rust free & movement Ontime & Rust free Trolly / Pallets

4d Die & Tool Material

Die Specification Die Material L B H Qty Wt (kgs) Rate/Kg Value Lead Time (Wks) Specific Gravity
Top Flatener DB6 280 210 125 1 43.27 ₹ 230.00 ₹ 9,952.82 2 7.85
Bot Flatener DB6 280 210 125 1 43.27 ₹ 230.00 ₹ 9,952.82 2 Constant
Top Blocker DB6 280 210 130 1 45.00 ₹ 230.00 ₹ 10,350.93 2 6.17
Bot Blocker DB6 280 210 110 1 38.08 ₹ 230.00 ₹ 8,758.48 2
Top Finisher DB6 280 210 130 1 45.00 ₹ 230.00 ₹ 10,350.93 2
Bot Finisher DB6 280 210 110 1 38.08 ₹ 230.00 ₹ 8,758.48 2
Trim Punch DB6 160 160 90 1 18.09 ₹ 230.00 ₹ 4,159.87 2
Trim Die DB6 260 210 70 1 24.23 ₹ 230.00 ₹ 5,573.58 2

4e ESTIMATED LEAD TIME (WKS) STATUS SUB-TOTAL ₹ 67,857.91

DESIGN & ENGINEERING CW1 TO START GST 18%
MODELLING, DIE & TOOL DRG RELEASE CW2 TO START TOTAL ₹ 80,072.34
DIE MANUFACTURING CW4 TO START EST. MANUFACTURING COST ₹ 48,043.40 60%
TOTAL ESTIMATED TIME (WKS) 6 TOTAL DIE & TOOL MFG COST ₹ 128,115.74

CONTINGENCY
5 Alternate Production Unit
Forging Unit 1600T
Single / Multiple Double (Cut For Two)
Est. Qty/Shift (8 hrs) with 80% OEE 1000x2 Nos
Expected Die Life (Nos/Set) 6000 - 8000x2 Nos

5a OPR. No. Forging Process Input Purpose Results Expected (Dimension/Ballooning no.) Requirement of Gauges list for process control
20 Cutting Process Sheet / Control Plan Required weight Ensure Weight is whithin specifacation
40A Edger Process Sheet / Control Plan Descaling & Preform Reduce Scale defect & Improve the Suraface Quality
Ensure Proper Filling in Blocker & Increased the Finisher
40B Blocker Process Sheet / Control Plan To generate required volume
Die Life Vernier Caliper, Pistol Caliper, Outside Caliper,
Radius Gauge, Bevel Protractor, V Block, Right
Process Sheet / Control Plan / Forging Ange & Height Gauage
40C Finisher Customer Requirements Final product with flash
Drawing

Process Sheet / Control Plan / Forging

50 Trimming Customer Requirements / Excess material removing Free from flash
Drawing
60 Controlled Cooling Control Plan To achieve the desired hardness Hardness within the specification Brinell Hardness Tester
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 10.06.2021
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: NIL, 07.06.2021 REV NO & DATE: NIL, 07.06.2021
CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 03 DATED- 28.04.2021 REV NO & DATE: REV- 03 DATED- 28.04.2021
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 198 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

5b Heat Treatment Controlled Cooling

Hardness Range 220 ~ 260 BHN
Microstructure Requirements Ferrite & Pearlite structure. Banding is not acceptable.
Tensile Strength 750 - 900 N/mm2

5c OPR. No. Post Forging Operations Input Purpose Results Expected (Dimension/Ballooning no.) Requirement of Gauges list for process control
70 Linishing Control Plan / Forging Drawing Remove trimmed extra flash extension Flash extension / Body cut within the specification Vernier Caliper
80 Shot blasting (Rz 100) Control Plan / Forging Drawing Descaling / Desired surafce finish Free from scale / surafce finish within the specification Surafce tester / Master piece / visual inspection
90 Crack Detection MPI & Demagnetize (2 Gauzz) Control Plan / Forging Drawing Crack detection Crack defect inspection intensity meter / visual inspection
Vernier Caliper, Pistol Caliper, Outside Caliper,
100 Final inspections Control Plan / Forging Drawing Visual / Dimensional inpection All parameters within the specifid limit Radius Gauge, Bevel Protractor, V Block, Right
Ange & Height Gauage
110 Preservation & Transportation Control Plan Rust free & movement Ontime & Rust free Trolly / Pallets

4d Die & Tool Material

Die Specification Die Material L B H Qty Wt (kgs) Rate/Kg Value Lead Time (Wks) Specific Gravity
Top Buster DB6 360 190 175 1 0.00 ₹ 230.00 ₹ - 2 7.85
Bot Buster DB6 360 190 120 1 0.00 ₹ 230.00 ₹ - 2 Constant
Top Blocker DB6 360 230 140 1 0.00 ₹ 230.00 ₹ - 2 6.17
Bot Blocker DB6 360 230 165 1 0.00 ₹ 230.00 ₹ - 2
Top Finisher DB6 360 230 140 1 0.00 ₹ 230.00 ₹ - 2
Bot Finisher DB6 360 230 165 1 0.00 ₹ 230.00 ₹ - 2
Trim Punch DB6 160 160 90 1 18.09 ₹ 230.00 ₹ 4,159.87 2
Trim Die DB6 260 210 70 1 24.23 ₹ 230.00 ₹ 5,573.58 2

4e ESTIMATED LEAD TIME (WKS) STATUS SUB-TOTAL ₹ 9,733.45

DESIGN & ENGINEERING 1 TO START GST 18%

MODELLING, DIE & TOOL DRG RELEASE 2 TO START TOTAL ₹ 11,485.47

DIE MANUFACTURING 4 TO START EST. MANUFACTURING COST ₹ 4,594.19 40%

TOTAL ESTIMATED TIME (WKS) 7 TOTAL DIE & TOOL MFG COST ₹ 16,079.66
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 10.06.2021
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: NIL, 07.06.2021 REV NO & DATE: NIL, 07.06.2021
CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 03 DATED- 28.04.2021 REV NO & DATE: REV- 03 DATED- 28.04.2021
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 198 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

6 Special Characteristics (Machining): Process/Customer NP :- Next process , SP :- Subsequent process , CE :- Customer End , EU:-End User

SPL.
Balloon . No Description Dimension Tol + Tol - Char. Potential Cause Effect Control mapping
Class

NP Nil

*
1) one tool use for both
SP Nil lug chamfer in one setup
5 Symmetry of Lug face & lug bore
0.1max. - - Worng offset/Worng tool selection 2) SOP
chamfer base on Barrel OD
CE Fitment problem 3) Symm. SPL gauge
with height gauge
EU Nil

NP Nil

* SP Nil 1) one tool use for both

11 lug finish in one setup
Both lug concentricity 0.1max - - Wrong setting
2) SOP
CE Fitment problem 3) Mandrel

EU Nil

NP Nil

13 Lug bore Ø24F7

0.02
0.041
- * Insert Wear, Offset Error
SP

CE
Nil

Fitment problem
1) 100% inspection in
APG

EU Nil

NP Nil

17 Parallelism Base on Barrel face 0.1max - - * Part not rest properly/Part fully not
clamp
SP

CE
Nil

Fitment problem
1) 100% inspection in
Dial stand

EU Nil

NP Nil

*
SP Nil
19 1) 100% inspection in
Pad height 32.000 0.100 0.100 Insert Wear, Offset Error
Dial stand
CE Fitment problem

EU Nil

NP Nil

21 Lug bore Ø24F7

0.02
0.041
- * Insert Wear, Offset Error
SP

CE
Nil

Fitment problem
1) 100% inspection in
APG

EU Nil

NP Nil

23 Lug bore position Base on barrel OD

& Face
0.2max - - * Lug bore CD & Symeentry not ok
SP

CE
Nil

Fitment problem
1) 1/Hours Inspection on
Trimos

EU Nil

NP Nil

26 Lug bore CD 55.800 0.100 0.100 * Wrong setting/Spacer wearout

SP

CE
Nil

Fitment problem
1) 1/Hours Inspection on
Trimos

EU Nil

NP Nil

32 Barrel ID runout base on Barrel OD 0.1max - - * Wrong setting/Chuck runout

SP

CE
Nil

Fitment problem
1) 1/Hours Inspection on
Trimos

EU Nil

NP Nil

33 Barrel face runout base on Barrel OD 0.1max - - * Wrong setting/Chuck runout

SP

CE
Nil

Fitment problem
1) 1/Hours Inspection on
Trimos

EU Nil

NP Nil

36 Barrel OD Ø40.5 0.100 0.100 * Insert Wear, Offset Error

SP

CE
Not locating in fixture

Fitment problem
1)100% Inspection on
Dial comparator gauge

EU Nil

NP Nil

38 Concentricity 0.1max - - * Wrong setting/Chuck runout

SP

CE
Nil

Fitment problem
1) 1/Hours Inspection on
Dial stand & SPL fixture

EU Nil

NP Nil

41 Total height 67.730 0.150 0.150 * Lug radius under size/over size
SP

CE
Nil

Fitment problem
1) 1/Hours Inspection on
Trimos /VMM

EU Nil
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 10.06.2021
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: NIL, 07.06.2021 REV NO & DATE: NIL, 07.06.2021
CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 03 DATED- 28.04.2021 REV NO & DATE: REV- 03 DATED- 28.04.2021
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 198 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

7 Machined
a OPR. No. Machining Process Input Clamping Resting Orientation Results Expected (Dimension/Ballooning no.) Gauges Tooling & Insert Fixture

1) shotblasted forging & MPI

Foging drawing:-16 ,18,29,39,49,59 & other parameter as per Vernier caliper &
205/208 Forging received & Inwad inspection 2) Supplier inward Inspection - - - - -
forging drawing height gauge
report

Forging
27. Sym of cone 70 deg (m/c'ed Rz 10): 0.2 wrt A, B
1.EW & SW Mismatch Lobe ID "V"
36. OD 40.50 ± 0.1 (Cp/Cpk) V block
2. lobe Height Variation Loactor & Tail 1) Dial stand & V block CNMG120412
Lobe Width 31. ID 35.60 ± 0.1 Centerlizer
210 CNC #1 - Barrel OD / ID Turning 3.Concentricity of Prism Stock Centre 2) Dial comparator TNMG160408
(Pr 15-18 bar) 32 & 33. R/O - Face & ID wrt C: 0.1 (Cp/Cpk) Pullback chuck
I-Diameter to Support 3) ID bore gauge CCMT06208
38. Concentricity 0.1 wrt "F" (Cp/Cpk) Center suppourt
O-Diameter (Pr 6-8 Bar)
41. Prism Height Dim: 67.73± 0.1 (Cp/Cpk)
4. R18 ± 0.5 (variation with 0.2

1. Machined 1. Lobe Rough Bore Pos within 0.1 wrt to Barrel OD & Barrel Face SOMT08T306/ V type top clamp
ID Ø 35.6 control within ±0.03. Lobe Top Radius Barrel Face & 2. Lobe Rough Boring Sym within 0.1 wrt to Barrel OD. SPMG07T308XT430 Locator
220 CNC #2 - Rough Lobe Bore & Face Lobe radius 1) Plug gauge
2. Forging Dim Tgt: 67.600 -0.4 (R18) Locate on ID 3. CD 55.80 ± 0.1 CCMT060208\ Specer
3. Lobe Wall Var 0.6 Max. 4. Lobe Face Distance wrt Barrel OD: Dimn: 53.45± 0.050 CNMG120408 2 jaw chuck

1. Machined
ID Ø 35.6 control within ±0.03. 23. Lobe Finish Bore Pos within 0.2 wrt to Barrel OD & Face
2. Forging Dim Tgt: 67.600 -0.4 Rest on Barrel 1. Lobe Finish Bore Sym within 0.1 wrt to Barrel OD.
1) Air plug gauge U clamp
3. Lobe Wall Var 0.6 Max. Face Orient using 05. Chamfer Symmetry within 0.1 wrt Barrel OD
Clamping on 2) Dial stand & Height Locator
CNC #3 - Face, Rough / Finish Lobe Through Boring, 4. Centre Ht., Pos & Ø of 1st Retractable 05. Lobe Face Sym within 0.070 wrt Barrel OD CCMT060208
230 Inner Pad using mater Specer
Both Sides Chamfer Side Rough Bore. Locate in Locator in Ø 11. Concentricity 0.1 wrt E (pokayoke - finish through boring) TCMT110204
floating Clamps 3) Chamfer mandrel 2 jaw chuck
5. Lobe Face Distance wrt Barrel 23.14 ± 0.050 26. CD 55.80 ± 0.050 (Cp/Cpk)
gauge & height master Dimond pin
Barrel OD: Dimn: 53.45± 0.050 ID 13. Ø 24.00 +0.020 / +0.041 (Cp/Cpk)
6. // Lobe Pad wrt Barrel Face 24. Roundness Ø 24.00 +0.020 / +0.041 - 0.008 max
within 0.20 max

Clamping on 04. Milling symmetry control within 0.1

#4 Lobe Slot Milling & Rest Pad Milling - Material Barrel OD - Rest on Barrel Ø 23.90 ±0.020 19. Pad Milling Height control within 32±0.1 1) Width gauge
1.EW & SW Mismatch TPKN Insert
240 Removal 1.5 MM Chuck & Collet Face - Collet One Side Pin 17. Pad milling parallelism control within 0.1 max 2) Height master & Collet type fixture
2. Inner pad height CCMT060208
(Both Milling - UP Milling) Arrangement Arngmnt Engagement 01. Milling height 69.5 ±0.1 dial stand
(Mech Type) 08. milling width53 ±0.2

248 #5 Hand Deburring - Pad Corner Finished M/ced Part Manual Manual Manual No Sharp Corners Visual - -

#6 Hand Deburring - Finish Bore & Mandrel Checking

248 Finished M/ced Part Manual Manual Manual No Sharp Corners Visual - -
(100%)

250 #7 Washing Deburred Parts Washing M/c Washing M/c Washing M/c Rust Protected Parts Visual - -

260 #8 Visual Checking (Eye Sequence Chart) & Packing Rust Protected Parts Manual Manual Manual Final Product Visual - -

7 Packaging (Internal Part handling)

b Part Handling Process
Box/Trolly/Bins Part Qty per Wt of Empty
OPR. No. Part handling Material description Part Qty/Layer Wt /Part Total Wt of Box/Trolly/Bins
Internal size Box/Trolly/Bins Box/Trolly/Bins
Sr. No. Instruction

208 Steel Bin (Raw part) 800x800x700 - 2000 nos 591g 100kg 1300kg 1 Parts should be clean & oiling,Parts should be Identified (Tag)

210 Sing line flow - - - - - - - -

220 Sing line flow - - - - - - - -

230 Sing line flow - - - - - - - -

240 Sing line flow - - - - - - - -

250 Sing line flow - - - - - - - -

7 Packaging (Final Dispatch)

b Packing Process
Part Qty per
Sr No. Packing Material description size Part Qty/Layer Wt /Part Wt of Empty Box Total Wt of Box
Box
Sr. No. Instruction

Wooden box & L1160 xW790 x

1 286 2002 0.441KG 48KG 931kg 1 Part should be wash in waching machine
corrgeted box H720MM
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 10.06.2021
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: NIL, 07.06.2021 REV NO & DATE: NIL, 07.06.2021
CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 03 DATED- 28.04.2021 REV NO & DATE: REV- 03 DATED- 28.04.2021
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 198 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

8 Out sources Operations/Process (Preturning/Heat Treatment/Ind. Hardening/Coating ).

a Process: Heat Treatment b Process:

Description: Plug, Sleeve Description:
Preferred Source: Unitherm Preferred Source:
Lead Time (Weeks) 3-4 days Lead Time (Weeks)
Quantity (Nos/Set) 1set Quantity (Nos/Set)
Target Cost : ₹ 58.00 Per Kg Target Cost : ₹ -

c Process: d Process:
Description: Description:
Preferred Source: Preferred Source:
Lead Time (Weeks) Lead Time (Weeks)
Quantity (Nos/Set) Quantity (Nos/Set)
Target Cost : ₹ - Target Cost : ₹ -

9 Special Jig / Fixtures TOTAL COST JIGS & FIXTURES ₹ 80,000.00

Process: Top Tooling CNC #3 + Locator + Locator Pin + Top Top Tooling CNC #2 + Locator + Top Clamp +
a b Process:
Clamp Spacer
Purpose Part Holding Purpose Part Holding
Preferred Source: Rahil Engineering Preferred Source: Rahil Engineering
Lead Time (Weeks) 2 Lead Time (Weeks) 2
Quantity (Nos/Set) 1set Quantity (Nos/Set) 1set
Target Cost : ₹ 15,000.00 Target Cost : ₹ 15,000.00

Process: Top Tooling #4 + Collet Type Chuck (Mech) + Locator

c d Process:
Pin (To be finalized with Rahil)

Purpose Lug & Pad Milling Purpose

Preferred Source: Rahil Engineering Preferred Source:
Lead Time (Weeks) 2 Lead Time (Weeks)
Quantity (Nos/Set) 1set Quantity (Nos/Set)
Target Cost : ₹ 50,000.00 Target Cost : ₹ -

10 Special Cutting Tools TOTAL COST CUTTING TOOLS ₹ 30,000.00

a Description CNC #3 Carbide Special Boring Bar b Process:

Purpose Lobe Finish Bore & Champfer Purpose

Preferred Source: V D Tools Preferred Source:

Lead Time (Weeks) 2 Lead Time (Weeks)
Quantity (Nos/Set) 1 Quantity (Nos/Set)
Target Cost : ₹ 18,000.00 Target Cost : ₹ -

c Process: #4 Milling Cutter (Combiation Type) d Process:

Purpose Pad & Slot Milling Purpose
Preferred Source: Pioneer Tools, Shirwal Preferred Source:
Lead Time (Weeks) 1 Lead Time (Weeks)
Quantity (Nos/Set) 1 Quantity (Nos/Set)
Target Cost : ₹ 12,000.00 Target Cost : ₹ -

11 GAUGES (AS REQUIRED)

Description Dimension Tol + Tol - QTY Lead Time Wks (Tentative) Budget Rs. (Tentative) TOTAL COSTS GAUGES

Barrel ID Bore gauge 35.6 0.1 0.1 1 2 ₹ 6,000.00

Barrel OD Comparator with

40.5 0.1 0.1 1 2 ₹ 6,000.00
master
₹ 32,400.00
Prism: Barrel OD - Special
67.73 0.2 0.2 1 2 ₹ 6,000.00
Height Gauge

Height Master 53.45 0.1 0.1 1 2 ₹ 1,200.00

Height Master 66.4 0.1 0.1 1 2 ₹ 12,000.00

Height Master (Pad) 32 0.1 0.1 1 2 ₹ 1,200.00

₹ -
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 10.06.2021
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: NIL, 07.06.2021 REV NO & DATE: NIL, 07.06.2021
CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 03 DATED- 28.04.2021 REV NO & DATE: REV- 03 DATED- 28.04.2021
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 198 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

12 DRAWING CLARIFICATION (IF REQUIRED) (CSR/STD)

Description Dimension Tol + Tol - Reason/Remarks Justification

Symmetry of Chamfer Dimension Considering fixture locating clearances, offset parameters in CNC
0.200 max Similar to existing part SC0926/03 (Customer No ……...936)
65.000±0.2 Set Up 3

Considering fixture locating clearances, offset parameters in CNC

Symmetry of Dimension 66.400±0.2 0.200 max One Side Lobe facing done in Set up 2, 2nd Lobe facing done on Set Up 3
Set Up 3

Cone 70 Degrees // 0.200 max wrt A & B // 0.200 max Should be Symmetry of Cone 70 Deg as 0.200 max wrt A & B NA

13 HELP REQUIRED FROM CUSTOMER (IF ANY) - STD'S, CUTTING TOOLS, DRAWINGS, MODEL, ETC.
Subject Reason Justification

Height 67.73 ± 0.15, Gauge Drawings Awaited Measurement in Production Lines To harmonize measurement between Customer & KOPL

Development Lead Time Weeks 3wks

14
(Tentative) 3wks
Timing Chart Release Date 6/10/2021

15 PPAP Submission Qty (Nos) - As Forged 250

PPAP Submission Qty (Nos) - As Machined 200
PPAP Submission Level with date 7/19/2021 L3

16 Overall (Tentative) Budget (forging development including dies & Manufacturing Cost) :
No of Shift (Budgeted) 3
Cost / hour - Shift ₹ 30,000.00
Total Cost of Development Time (Forging) ₹ 90,000.00
No of Shift (Budgeted) Inhouse 6
Cost / hour - Shift ₹ 4,000.00
Total Cost of Development Time (Machining) ₹ 24,000.00
Cost Dies, Tooling, Calibration Tools, Gauges, Fixtures etc. ₹ 142,400.00
Total Cost of Development (excluding outsourcing) ₹ 256,400.00

12 CONSIDERATIONS Remarks
Is product adequately defined (application requirements, etc.) to enable feasibility evaluation ? þ
Can Engineering Performance Specifications be met as written ? þ Subject to Drg Clarifications

Can product be manufactured to tolerances specified on drawing ? þ Subject to Drg Clarifications

Can product be manufactured with Cpk's that meet requirements ? þ

Is there adequate capacity to produce product ? þ
Does the design allow the use of efficient material handling techniques ? þ
Can the product be manufactured without incurring any unusual;
Knuckle Joint Coining, Hot Padding, Milling May need to
# Costs for Capital Equipment ? þ shift to VMC as contingency (Fixture-Chuck & End Mill
Available)
# Costs for Tooling ? þ
# Alternative Manufacturing Methods ? x Considered

Is statistical process control required on product ? þ

Is statistical process control presently used on similar products ? x
Where statistical process control is used on similar products;
# Are the processes in control and stable ? x Cp/Cpk - yes, Pp, Ppk - No

# Are Cpk's greater then 1.33 ? x

Conclusion
Product can be produced as specified with no revisions. Feasible þ
Changes recommended ( See attached ). Feasible x
Design Revision required to produce product within the specified requirements. Drg Clari…. x

Sign - off Date 10.06.2021

TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE

Raunaq Kalra Mktg D Nawadkar Operations
TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE
J Swami Engineering CTO Dilip Jawade Engineering
TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE
Ganesh Revgade Forge Design Kartik Hota Engineering M/C
TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE
Pandurang Deokate Purchase D Nayak Production
TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE
Rajesh Pawar Quality HOD B Kumbhar MQA

Rev. Description Date Rev. Description Date

Nil RFQ 16.12.2020 A As per customer drawing Index 03 10.06.2021
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 10.01.2022
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: A, 10.01.2022 REV NO & DATE: E, 03.03.2023

CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 0A DATED- 17.01.2022 REV NO & DATE: REV- 0A DATED- 17.01.2022
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 990 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

1 Material Details
Material Section:

30MnVS6 Ø40

Customer Standard (If Any) DIN EN 10267

RMS Existing

IF EXISTING (RMS Ref. No) Specific Order Based Ref. KOPL Part No. NA
Complexity to Purchase Specific Order Based & Min. Heat Size

Lead Time 5 Weeks

2 PPAP WEIGHTS (kgs)

Cut Wt. Cut For 2 1.640
Gross Wt. Cut For 2 1.722
Finish Forging Wt. Cut For 2 1.120
Expected Yield (%) 65.04%

3 Special Characteristics: (Forging) Process/Customer NP :- Next process , SP :- Subsequent process , CE :- Customer End , EU:-End User
SPL.
Balloon .
Description Dimension Tol + Tol - Char. Potential Cause Effect Control mapping
No
Class

NP NIL
Die Inspection
SP
Wall thickness variation after drilling (Weak Report / Hot
* Wrong die profile / Wrong wall at end)
27 Total Height 77.5 1.0 0.0 Inspection
Cam programming
CE Part may reject in assembly Report / Final
inspection Report
EU Part may fail in running
NP NIL
Die Inspection
SP
Wall thickness variation after drilling (Weak Report / Hot
* Wrong die profile / Wrong wall at end)
37 Lobe radius R18 0.5 0.5 Inspection
Cam programming
CE Part may reject in assembly Report / Final
inspection Report
EU Part may fail in running
Setting error NP Mismatch out of spec
Die Inspection
Ram play SP NIL Report / Hot
59 Mismatch 0.3 Max - - * May not fit in fixture Inspection
NIL CE Report / Final
Reject post machining
inspection Report
Die locks wear EU NIL

4 Main Production Unit

Forging Unit 1600T
Single / Multiple Double
Est. Qty/Shift (8 hrs) with 80% OEE 1000x2 Nos
Expected Die Life (Nos/Set) 6000 - 8000x2 Nos

4a OPR. No. Forging Process Input Purpose Results Expected (Dimension/Ballooning no.) Requirement of Gauges list for process control

20 Cutting Process Sheet / Control Plan Required weight Ensure Weight is whithin specifacation(Ø40x 166.5)

40A Edger Process Sheet / Control Plan Descaling & Preform Reduce Scale defect & Improve the Suraface Quality
Vernier Caliper, Pistol Caliper, Outside Caliper,
Ensure Proper Filling in Blocker & Increased the Finisher
40B Blocker Process Sheet / Control Plan To generate required volume Radius Gauge, Bevel Protractor, V Block, Right
Die Life
Ange & Height Gauage
Process Sheet / Control Plan / Forging
40C Finisher Customer Requirements Final product with flash
Drawing
Process Sheet / Control Plan / Forging
50 Trimming Customer Requirements / Excess material removing Free from flash
Drawing

60 Controlled Cooling Control Plan To achieve the desired hardness Hardness within the specification Brinell Hardness Tester

4b Heat Treatment Controlled Cooling

Hardness Range 220 ~ 260 BHN
Microstructure Requirements Ferrite & Pearlite structure. Banding is not acceptable.
Tensile Strength 750 - 900 N/mm2

4c OPR. No. Post Forging Operations Input Purpose Results Expected (Dimension/Ballooning no.) Requirement of Gauges list for process control
70 Linishing Control Plan / Forging Drawing Remove trimmed extra flash extension Flash extension / Body cut within the specification Vernier Caliper

80 Shot blasting (Rz 100) Control Plan / Forging Drawing Descaling / Desired surafce finish Free from scale / surafce finish within the specification Surafce tester / Master piece / visual inspection

90 Crack Detection MPI & Demagnetize (2 Gauzz) Control Plan / Forging Drawing Crack detection Crack defect inspection intensity meter / visual inspection

Vernier Caliper, Pistol Caliper, Outside Caliper,

100 Final inspections Control Plan / Forging Drawing Visual / Dimensional inpection All parameters within the specifid limit Radius Gauge, Bevel Protractor, V Block, Right
Ange & Height Gauage
110 Preservation & Transportation Control Plan Rust free & movement Ontime & Rust free Trolly / Pallets

4d Die & Tool Material

Die Specification Die Material L B H Qty Wt (kgs) Rate/Kg Value Lead Time (Wks)
Specific Gravity
Top Flatener DB6 280 210 125 1 43.27 ₹ 230.00 ₹ 9,952.82 2 7.85
Bot Flatener DB6 280 210 125 1 43.27 ₹ 230.00 ₹ 9,952.82 2 Constant
Top Blocker DB6 280 210 130 1 45.00 ₹ 230.00 ₹ 10,350.93 2 6.17
Bot Blocker DB6 280 210 110 1 38.08 ₹ 230.00 ₹ 8,758.48 2
Top Finisher DB6 280 210 130 1 45.00 ₹ 230.00 ₹ 10,350.93 2
Bot Finisher DB6 280 210 110 1 38.08 ₹ 230.00 ₹ 8,758.48 2
Trim Punch DB6 160 160 90 1 18.09 ₹ 230.00 ₹ 4,159.87 2
Trim Die DB6 260 210 70 1 24.23 ₹ 230.00 ₹ 5,573.58 2

4e ESTIMATED LEAD TIME (WKS) STATUS SUB-TOTAL ₹ 67,857.91

DESIGN & ENGINEERING CW1 TO START GST 18%
MODELLING, DIE & TOOL DRG RELEASE CW2 TO START TOTAL ₹ 80,072.34
DIE MANUFACTURING CW4 TO START EST. MANUFACTURING COST ₹ 48,043.40 60%
TOTAL ESTIMATED TIME (WKS) 6 TOTAL DIE & TOOL MFG COST ₹ 128,115.74

CONTINGENCY
5 Alternate Production Unit
Forging Unit 1600T
Single / Multiple Double (Cut For Two)
Est. Qty/Shift (8 hrs) with 80% OEE 1000x2 Nos
Expected Die Life (Nos/Set) 6000 - 8000x2 Nos

5a OPR. No. Forging Process Input Purpose Results Expected (Dimension/Ballooning no.) Requirement of Gauges list for process control
20 Cutting Process Sheet / Control Plan Required weight Ensure Weight is whithin specifacation
40A Edger Process Sheet / Control Plan Descaling & Preform Reduce Scale defect & Improve the Suraface Quality
Ensure Proper Filling in Blocker & Increased the Finisher
40B Blocker Process Sheet / Control Plan To generate required volume
Die Life Vernier Caliper, Pistol Caliper, Outside Caliper,
Radius Gauge, Bevel Protractor, V Block, Right
Process Sheet / Control Plan / Forging Ange & Height Gauage
40C Finisher Customer Requirements Final product with flash
Drawing

Process Sheet / Control Plan / Forging

50 Trimming Customer Requirements / Excess material removing Free from flash
Drawing
60 Controlled Cooling Control Plan To achieve the desired hardness Hardness within the specification Brinell Hardness Tester
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 10.01.2022
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: A, 10.01.2022 REV NO & DATE: E, 03.03.2023

CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 0A DATED- 17.01.2022 REV NO & DATE: REV- 0A DATED- 17.01.2022
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 990 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

5b Heat Treatment Controlled Cooling
Hardness Range 220 ~ 260 BHN
Microstructure Requirements Ferrite & Pearlite structure. Banding is not acceptable.
Tensile Strength 750 - 900 N/mm2

5c OPR. No. Post Forging Operations Input Purpose Results Expected (Dimension/Ballooning no.) Requirement of Gauges list for process control
70 Linishing Control Plan / Forging Drawing Remove trimmed extra flash extension Flash extension / Body cut within the specification Vernier Caliper
80 Shot blasting (Rz 100) Control Plan / Forging Drawing Descaling / Desired surafce finish Free from scale / surafce finish within the specification Surafce tester / Master piece / visual inspection
90 Crack Detection MPI & Demagnetize (2 Gauzz) Control Plan / Forging Drawing Crack detection Crack defect inspection intensity meter / visual inspection
Vernier Caliper, Pistol Caliper, Outside Caliper,
100 Final inspections Control Plan / Forging Drawing Visual / Dimensional inpection All parameters within the specifid limit Radius Gauge, Bevel Protractor, V Block, Right
Ange & Height Gauage
110 Preservation & Transportation Control Plan Rust free & movement Ontime & Rust free Trolly / Pallets

4d Die & Tool Material

Die Specification Die Material L B H Qty Wt (kgs) Rate/Kg Value Lead Time (Wks) Specific Gravity
Top Buster DB6 360 190 175 1 0.00 ₹ 230.00 ₹ - 2 7.85
Bot Buster DB6 360 190 120 1 0.00 ₹ 230.00 ₹ - 2 Constant
Top Blocker DB6 360 230 140 1 0.00 ₹ 230.00 ₹ - 2 6.17
Bot Blocker DB6 360 230 165 1 0.00 ₹ 230.00 ₹ - 2
Top Finisher DB6 360 230 140 1 0.00 ₹ 230.00 ₹ - 2
Bot Finisher DB6 360 230 165 1 0.00 ₹ 230.00 ₹ - 2
Trim Punch DB6 160 160 90 1 18.09 ₹ 230.00 ### 2
Trim Die DB6 260 210 70 1 24.23 ₹ 230.00 ### 2

4e ESTIMATED LEAD TIME (WKS) STATUS SUB-TOTAL ###

DESIGN & ENGINEERING 1 TO START GST 18%

Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 10.01.2022
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: A, 10.01.2022 REV NO & DATE: E, 03.03.2023

CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 0A DATED- 17.01.2022 REV NO & DATE: REV- 0A DATED- 17.01.2022
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 990 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

MODELLING, DIE & TOOL DRG RELEASE 2 TO START TOTAL ###

DIE MANUFACTURING 4 TO START EST. MANUFACTURING COST ### 40%

TOTAL ESTIMATED TIME (WKS) 7 TOTAL DIE & TOOL MFG COST ###

₹ - ₹ - 0 0.00
₹ - ₹ - 0 0.00
₹ - ₹ - 0
₹ - ₹ - 0
₹ - ₹ - 0
₹ - ₹ - 0
₹ - ₹ - 0
₹ - ₹ - 0
₹ - ₹ - 0
₹ - ₹ - 0
₹ - ₹ - 0

5e ESTIMATED LEAD TIME (WKS) STATUS SUB-TOTAL ₹ -

DESIGN & ENGINEERING 1 WIP GST 18%

MODELLING, DIE & TOOL DRG RELEASE 1 WIP TOTAL ₹ -

DIE MANUFACTURING 2 TO START EST. MANUFACTURING COST ₹ - 30%

TOTAL ESTIMATED TIME (WKS) 4 TOTAL DIE & TOOL MFG COST ₹ -

6 Special Characteristics (Machining): Process/Customer NP :- Next process , SP :- Subsequent process , CE :- Customer End , EU:-End User

SPL.
Balloon .
Description Dimension Tol + Tol - Char. Potential Cause Effect Control mapping
No
Class
NP Nil

*
1) one tool use for both
SP Nil lug chamfer in one setup
6 Symmetry of Lug face & lug bore
0.2max. - - Worng offset/Worng tool selection 2) SOP
chamfer base on Barrel OD
CE Fitment problem 3) Symm. SPL gauge
with height gauge
EU Nil

NP Nil

* SP Nil 1) one tool use for both

12 lug finish in one setup
Both lug concentricity 0.1max - - Wrong setting
2) SOP
CE Fitment problem 3) Mandrel
EU Nil

NP Nil

14 Lug bore Ø24F7

0.02
0.041
- * Insert Wear, Offset Error
SP

CE
Nil

Fitment problem
1) 100% inspection in
APG

EU Nil

NP Nil

18 Parallelism Base on Barrel face 0.1max - - * Part not rest properly/Part fully not
clamp
SP

CE
Nil

Fitment problem
1) 100% inspection in
Dial stand

EU Nil

NP Nil

*
SP Nil
20 1) 100% inspection in
Pad height 32.000 0.100 0.100 Insert Wear, Offset Error
Dial stand
CE Fitment problem

EU Nil

NP Nil

22 Lug bore Ø24F7

0.02
0.041
- * Insert Wear, Offset Error
SP

CE
Nil

Fitment problem
1) 100% inspection in
APG

EU Nil

NP Nil

24 Lug bore position Base on barrel OD

& Face
0.2max - - * Lug bore CD & Symeentry not ok
SP

CE
Nil

Fitment problem
1) 1/Hours Inspection on
Trimos

EU Nil

NP Nil

27 Lug bore CD 55.800 0.100 0.100 * Wrong setting/Spacer wearout

SP

CE
Nil

Fitment problem
1) 1/Hours Inspection on
Trimos

EU Nil

NP Nil

35 Barrel ID runout base on Barrel OD 0.1max - - * Wrong setting/Chuck runout

SP

CE
Nil

Fitment problem
1) 1/Hours Inspection on
Trimos

EU Nil

NP Nil

36 Barrel face runout base on Barrel OD 0.1max - - * Wrong setting/Chuck runout

SP

CE
Nil

Fitment problem
1) 1/Hours Inspection on
Trimos

EU Nil

NP Nil

36 Barrel OD Ø40.5 0.100 0.100 * Insert Wear, Offset Error

SP

CE
Not locating in fixture

Fitment problem
1)100% Inspection on
Dial comparator gauge

EU Nil

NP Nil

38 Symm. 0.2max - - * Wrong setting/Chuck runout

SP

CE
Nil

Fitment problem
1) 1/Hours Inspection on
Dial stand & SPL fixture

EU Nil

NP Nil

44 Total height 67.730 0.150 0.150 * Lug radius under size/over size
SP

CE
Nil

Fitment problem
1) 1/Hours Inspection on
Trimos /VMM

EU Nil
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 10.01.2022
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: A, 10.01.2022 REV NO & DATE: E, 03.03.2023

CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 0A DATED- 17.01.2022 REV NO & DATE: REV- 0A DATED- 17.01.2022
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 990 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

7 Machined
a OPR. No. Machining Process Input Clamping Resting Orientation Results Expected (Dimension/Ballooning no.) Gauges Tooling & Insert Fixture

1) shotblasted forging & MPI

Foging drawing:-16 ,18,29,39,49,59 & other parameter as Vernier caliper &
205/208 Forging received & Inwad inspection 2) Supplier inward Inspection - - - - -
per forging drawing height gauge
report

Forging
27. Sym of Barrel dia 0.2 wrt A, B
1.EW & SW Mismatch Lobe ID "V"
36. OD 40.50 ± 0.1 (Cp/Cpk) V block
2. lobe Height Variation Loactor & Tail 1) Dial stand & V block CNMG120412
Lobe Width 31. ID 35.60 ± 0.1 Centerlizer
210 CNC #1 - Barrel OD / ID Turning 3.Concentricity of Prism Stock Centre 2) Dial comparator TNMG160408
(Pr 15-18 bar) 32 & 33. R/O - Face & ID wrt C: 0.1 (Cp/Cpk) Pullback chuck
I-Diameter to Support 3) ID bore gauge CCMT06208
28. Sym of cone 70 deg (m/c'ed Rz 10): 0.8 wrt A, B Center suppourt
O-Diameter (Pr 6-8 Bar)
41. Prism Height Dim: 67.73± 0.1 (Cp/Cpk)
4. R18 ± 0.5 (variation with 0.2

1. Lobe Rough Bore Pos within 0.1 wrt to Barrel OD &

1. Machined SOMT08T306/ V type top clamp
Barrel Face
ID Ø 35.6 control within ±0.03. Lobe Top Radius Barrel Face & SPMG07T308XT430 Locator
220 CNC #2 - Rough Lobe Bore & Face Lobe radius 2. Lobe Rough Boring Sym within 0.1 wrt to Barrel OD. 1) Plug gauge
2. Forging Dim Tgt: 67.600 -0.4 (R18) Locate on ID CCMT060208\ Specer
3. CD 55.80 ± 0.1
3. Lobe Wall Var 0.6 Max. CNMG120408 2 jaw chuck
4. Lobe Face Distance wrt Barrel OD: Dimn: 53.45± 0.050

1. Machined 24. Lobe Finish Bore Pos within 0.2 wrt to Barrel OD &
ID Ø 35.6 control within ±0.03. Face
2. Forging Dim Tgt: 67.600 -0.4 Rest on Barrel 1. Lobe Finish Bore Sym within 0.1 wrt to Barrel OD.
1) Air plug gauge U clamp
3. Lobe Wall Var 0.6 Max. Face Orient using 06. Chamfer Symmetry within 0.2 wrt Barrel OD
Clamping on 2) Dial stand & Height Locator
CNC #3 - Face, Rough / Finish Lobe Through Boring, 4. Centre Ht., Pos & Ø of 1st Retractable 06. Lobe Face Sym within 0.2 wrt Barrel OD CCMT060208
230 Inner Pad using mater Specer
Both Sides Chamfer Side Rough Bore. Locate in Locator in Ø 12. Concentricity 0.1 wrt E (pokayoke - finish through TCMT110204
floating Clamps 3) Chamfer mandrel 2 jaw chuck
5. Lobe Face Distance wrt Barrel 23.14 ± 0.050 boring)
gauge & height master Dimond pin
Barrel OD: Dimn: 53.45± 0.050 ID 27. CD 55.80 ± 0.050 (Cp/Cpk)
6. // Lobe Pad wrt Barrel Face 14. Ø 24.00 +0.020 / +0.041 (Cp/Cpk)
within 0.20 max 25. Roundness Ø 24.00 +0.020 / +0.041 - 0.008 max

Clamping on 05. Milling symmetry control within 0.2

#4 Lobe Slot Milling & Rest Pad Milling - Material Barrel OD - Rest on Barrel Ø 23.90 ±0.020 20. Pad Milling Height control within 32±0.1 1) Width gauge
1.EW & SW Mismatch TPKN Insert
240 Removal 1.5 MM Chuck & Collet Face - Collet One Side Pin 18. Pad milling parallelism control within 0.1 max 2) Height master & Collet type fixture
2. Inner pad height CCMT060208
(Both Milling - UP Milling) Arrangement Arngmnt Engagement 01. Milling height 69.5 ±0.1 dial stand
(Mech Type) 09. milling width53 ±0.2

248 #5 Hand Deburring - Pad Corner Finished M/ced Part Manual Manual Manual No Sharp Corners Visual - -

#6 Hand Deburring - Finish Bore & Mandrel Checking

248 Finished M/ced Part Manual Manual Manual No Sharp Corners Visual - -
(100%)

250 #7 Washing Deburred Parts Washing M/c Washing M/c Washing M/c Rust Protected Parts Visual - -

260 #8 Visual Checking (Eye Sequence Chart) & Packing Rust Protected Parts Manual Manual Manual Final Product Visual - -

7 Packaging (Internal Part handling)

b Part Handling Process
Box/Trolly/Bins Part Qty per Wt of Empty Total Wt of
OPR. No. Part handling Material description Part Qty/Layer Wt /Part
Internal size Box/Trolly/Bins Box/Trolly/Bins Box/Trolly/Bins
Sr. No. Instruction

208 Steel Bin (Raw part) 800x800x700 - 2000 nos 591g 100kg 1300kg 1 Parts should be clean & oiling,Parts should be Identified (Tag)

210 Sing line flow - - - - - - - -

220 Sing line flow - - - - - - - -

230 Sing line flow - - - - - - - -

240 Sing line flow - - - - - - - -

250 Sing line flow - - - - - - - -

7 Packaging (Final Dispatch)

b Packing Process
Part Qty per
Sr No. Packing Material description size Part Qty/Layer Wt /Part Wt of Empty Box Total Wt of Box
Box
Sr. No. Instruction

Wooden box & L1160 xW790 x

1 286 2002 0.441KG 48KG 931kg 1 Part should be wash in waching machine
corrgeted box H720MM
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 10.01.2022
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: A, 10.01.2022 REV NO & DATE: E, 03.03.2023

CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 0A DATED- 17.01.2022 REV NO & DATE: REV- 0A DATED- 17.01.2022
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 990 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

8 Out sources Operations/Process (Preturning/Heat Treatment/Ind. Hardening/Coating ).

a Process: Heat Treatment b Process:

Description: Plug, Sleeve Description:
Preferred Source: Unitherm Preferred Source:
Lead Time (Weeks) 3-4 days Lead Time (Weeks)
Quantity (Nos/Set) 1set Quantity (Nos/Set)
Target Cost : ₹ 58.00 Per Kg Target Cost : ₹ -

c Process: d Process:
Description: Description:
Preferred Source: Preferred Source:
Lead Time (Weeks) Lead Time (Weeks)
Quantity (Nos/Set) Quantity (Nos/Set)
Target Cost : ₹ - Target Cost : ₹ -

9 Special Jig / Fixtures TOTAL COST JIGS & FIXTURES ₹ 80,000.00

Process: Top Tooling CNC #3 + Locator + Locator Pin + Top Top Tooling CNC #2 + Locator + Top Clamp +
a b Process:
Clamp Spacer
Purpose Part Holding Purpose Part Holding
Preferred Source: Rahil Engineering Preferred Source: Rahil Engineering
Lead Time (Weeks) 2 Lead Time (Weeks) 2
Quantity (Nos/Set) 1set Quantity (Nos/Set) 1set
Target Cost : ₹ 15,000.00 Target Cost : ₹ 15,000.00

Process: Top Tooling #4 + Collet Type Chuck (Mech) + Locator

c d Process:
Pin (To be finalized with Rahil)

Purpose Lug & Pad Milling Purpose

Preferred Source: Rahil Engineering Preferred Source:
Lead Time (Weeks) 2 Lead Time (Weeks)
Quantity (Nos/Set) 1set Quantity (Nos/Set)
Target Cost : ₹ 50,000.00 Target Cost : ₹ -

10 Special Cutting Tools TOTAL COST CUTTING TOOLS ₹ 30,000.00

a Description CNC #3 Carbide Special Boring Bar b Process:

Purpose Lobe Finish Bore & Champfer Purpose

Preferred Source: V D Tools Preferred Source:

Lead Time (Weeks) 2 Lead Time (Weeks)
Quantity (Nos/Set) 1 Quantity (Nos/Set)
Target Cost : ₹ 18,000.00 Target Cost : ₹ -

c Process: #4 Milling Cutter (Combiation Type) d Process:

Purpose Pad & Slot Milling Purpose
Preferred Source: Pioneer Tools, Shirwal Preferred Source:
Lead Time (Weeks) 1 Lead Time (Weeks)
Quantity (Nos/Set) 1 Quantity (Nos/Set)
Target Cost : ₹ 12,000.00 Target Cost : ₹ -

11 GAUGES (AS REQUIRED)

Description Dimension Tol + Tol - QTY Lead Time Wks (Tentative) Budget Rs. (Tentative) TOTAL COSTS GAUGES

Barrel ID Bore gauge 35.6 0.1 0.1 1 2 ₹ 6,000.00

Barrel OD Comparator with

40.5 0.1 0.1 1 2 ₹ 6,000.00
master
₹ 32,400.00
Prism: Barrel OD - Special
67.73 0.2 0.2 1 2 ₹ 6,000.00
Height Gauge

Height Master 53.45 0.1 0.1 1 2 ₹ 1,200.00

Height Master 66.4 0.1 0.1 1 2 ₹ 12,000.00

Height Master (Pad) 32 0.1 0.1 1 2 ₹ 1,200.00

₹ -
Format No. : ENG-FR-24 Rev. No. 01 Date : 01.05.2019
KALRA OVERSEAS & PRECISION ENGINEERING LTD.
#VALUE!
TEAM FEASIBILITY & APQP COMMITMENT Date: 10.01.2022
CUSTOMER : A 264

KO PART NO: SC0926/03-F CLAR WE GW KO PART NO: SC0926/03-M CLAR WE GW

REV NO & DATE: A, 10.01.2022 REV NO & DATE: E, 03.03.2023

CUSTOMER PART NO: 105-010429 CLAR WE GW CUSTOMER PART NO: 105-010429 CLAR WE GW
REV NO & DATE: REV- 0A DATED- 17.01.2022 REV NO & DATE: REV- 0A DATED- 17.01.2022
PART NAME : Yoke raw part

SAMPLE / PPAP QUANTITY: 990 Nos

SUPPLY CONDITION: MACHINED

Annual Qty. 40,000/Months

12 DRAWING CLARIFICATION (IF REQUIRED) (CSR/STD)

Description Dimension Tol + Tol - Reason/Remarks Justification

Symmetry of Chamfer Dimension Considering fixture locating clearances, offset

0.200 max Similar to existing part SC0926/03 (Customer No ……...936)
65.000±0.2 parameters in CNC Set Up 3

d
Considering fixture locating clearances, offset

se
Symmetry of Dimension 66.400±0.2 0.200 max One Side Lobe facing done in Set up 2, 2nd Lobe facing done on Set Up 3
parameters in CNC Set Up 3

lo
C
Should be Symmetry of Cone 70 Deg as 0.200 max wrt
Cone 70 Degrees // 0.200 max wrt A & B // 0.200 max NA
A&B

13 HELP REQUIRED FROM CUSTOMER (IF ANY) - STD'S, CUTTING TOOLS, DRAWINGS, MODEL, ETC.
Subject Reason Justification

n
Height 67.73 ± 0.15, Gauge Drawings Awaited Measurement in Production Lines To harmonize measurement between Customer & KOPL

pe
O
Development Lead Time Weeks 3wks
14
(Tentative) 3wks
Timing Chart Release Date 6/10/2021

15 PPAP Submission Qty (Nos) - As Forged 1000

PPAP Submission Qty (Nos) - As Machined 990
PPAP Submission Level with date 18.01.2022 L3 ECN PPAP

16 Overall (Tentative) Budget (forging development including dies & Manufacturing Cost) :
No of Shift (Budgeted) 3
Cost / hour - Shift ₹ 30,000.00
Total Cost of Development Time (Forging) ₹ 90,000.00
No of Shift (Budgeted) Inhouse 6
Cost / hour - Shift ₹ 4,000.00
Total Cost of Development Time (Machining) ₹ 24,000.00
Cost Dies, Tooling, Calibration Tools, Gauges, Fixtures etc. ₹ 142,400.00
Total Cost of Development (excluding outsourcing) ₹ 256,400.00

12 CONSIDERATIONS Remarks
Is product adequately defined (application requirements, etc.) to enable feasibility evaluation ? þ
Can Engineering Performance Specifications be met as written ? þ Subject to Drg Clarifications

Can product be manufactured to tolerances specified on drawing ? þ Subject to Drg Clarifications

Can product be manufactured with Cpk's that meet requirements ? þ

Is there adequate capacity to produce product ? þ
Does the design allow the use of efficient material handling techniques ? þ
Can the product be manufactured without incurring any unusual;
Knuckle Joint Coining, Hot Padding, Milling May need to
# Costs for Capital Equipment ? þ shift to VMC as contingency (Fixture-Chuck & End Mill
Available)
# Costs for Tooling ? þ
# Alternative Manufacturing Methods ? x Considered

Is statistical process control required on product ? þ

Is statistical process control presently used on similar products ? x
Where statistical process control is used on similar products;
# Are the processes in control and stable ? x Cp/Cpk - yes, Pp, Ppk - No

# Are Cpk's greater then 1.33 ? x

Conclusion
Product can be produced as specified with no revisions. Feasible þ
Changes recommended ( See attached ). Feasible x
Design Revision required to produce product within the specified requirements. Drg Clari…. x

Sign - off Date 10.01.2022

TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE

Raunaq Kalra Mktg D Nawadkar Operations
TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE
J Swami Engineering CTO Dilip Jawade Engineering
TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE
Ganesh Revgade Forge Design Kartik Hota Engineering M/C
TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE
Pandurang Deokate Purchase D Nayak Production
TEAM MEMBER / TITLE / DATE TEAM MEMBER / TITLE / DATE
Rajesh Pawar Quality HOD B Kumbhar MQA

Rev. Description Date Rev. Description Date

Nil RFQ 16.12.2020 A As per customer drawing Index 03 10.06.2021
B As per customer drawing Index 0A 10.01.2022