locking slide part2

7/27/2019 Locking Slide Part2

1/12

FIXTURE

CONSUMABLE

TOOL

PROCESS PARAMETERS

INPUT QUALITY

INPROCESS QUALITY

OUTPUT QUALITY

CHECK POINT BEFORE START OF M/C

GAUGES

LOADING PATTERN

1) VERTICAL COMPONENT ONFIXTURE WITH CLAMPING.

1) QUENCHING OIL2) LPG GAS (PROPANE GAS)

1) FREE FROM DENTS & DAMAGES.

1) CASE DEPTH - 0.4 TO 0.7 mm2) HARDNESS - 81 TO 83 HRA3) CORE HARDNESS - >= 1000

1) CARBURISING GAS TEMPERATURE900~940C & REDn 840~870C

2) QUENCHING TEMP. 50~150C

1) HARDNESS TESTER

1) HOLDING FIXTURE WITH CLAMPS

2) CHARGE QTY-130 NOS

76.0(O )

94.

0

42.0(O )


2/12

FIXTURE

TOOL

PROCESS PARAMETERS

INPUT QUALITY

INPROCESS QUALITY

OUTPUT QUALITY


GAUGES

LOADING PATTERN

FIXTURE

CONSUMABLE

TOOL

PROCESS PARAMETERS

INPUT QUALITY

OUTPUT QUALITY


GAUGES

LOADING PATTERN

NO OF COMPONENT: 1 COMPONENT

SOLUABLE OIL- 1:20 CONCENTRATION

OIL TANK CLEAN FREQUENCY - 6MONTHS

1. AIR RING GAUGE 50h8

1. OD SIZE - 49.98 0.005

1. CHECK COOLANT LEVEL IN TANK.

1. FEED: 0.2 TO 1.6 MM/ MIN

2. SPEED : 1500-1800RPM

3. CLAMPING PRESSURE : 3-5 BAR

4. FINE FEED : 1 MM/MIN

2. RUNOUT : 0.03 WRT A

8. VISUAL : NO PATCH MARK,CHATTERMARK.

2. CHECK WHEEL RPM.

1. ENSURE NO DENTS ON RESTING FACE.

2. CHECK BURR ON OD.

3. CHECK ID SIZE OF COMPONENT.

1. COMPONENT SHOULD BE LOBBINGFREE.

2. CIRCULARITY SHOULD BE 0.002 MAX.

1.GRINDING WHEEL 400 X 50 X 127TYPE -463-K5(TH01021001)

1.GRINDING MANDRILL

3. ROUGHNESS Rz 2

(GA14006042)

I = IMPORTANT DIMENSIONS

I

I

I = IMPORTANT DIMENSIONS

4. RUNOUT : 0.03 WRT A

5. PERPENDICULARITY : 0.03 WRT A6. SURFACE FINISH : Rz2.5

7. DIMN.10.2 +0.1

I

I

2. EXPANDING MANDREL NO.(GA14010046)

3. D.H.G.

^ 0.03 A

Rz2

II

II

49.9

80.0

05

42

O

10.2+0.1

94.0

A

^ 0.03 A

n 0.03 ARz2.5

NOTE : DATUM A IS PCD


3/12

CONTROL PLAN 32

PD/F09/R2

Machine,

Device, forMfg.

CharacteristicsSpecial

Char.Class

Methods

Responsibility

Reaction

Plan/Corrective actionNo. Product Process

Product/ ProcessSpecification/

Tolerance

Evaluation/ Measurement

Technique

SampleControl Method

Size Freq.

Grinding

M/C.

1. - Settingapproval

- As per control plan ARG & Micrometer Continuous5 OK jobs

Every

Setting

Setting Approval

Report

Prod. Supervisor

If not ok 1.

Stop theproduction

2. Confirm

last hour

production

3.Do resetting &

inspect 5

comp.

2. Out Side Diameter. - I 49.98 0.005 ARG & Micrometer 1 Per hour HIPR OperatorARG (GA14006042) 100% Continues - Operator

3. Roughness - - 0.4Ra Roughness tester 5 Per hour HIPR Operator4. Run out

- I ^ 0.03 ADial &Between Center. 5 Per hour HIPR Operator

5. Run out- I ^ 0.03 A

Dial &Between Center. 5 Per hour HIPR Operator

6. Perpendicularity - I { 0.03 A Dial & height gauge 5 Per hour HIPR Operator7. Dimn. - - 10.2 +0.1 Digital height gauge 5 Per hour HIPR Operator

HIPR: - Hourly Inspection & Production Report : Important dimension ARG: - Air Ring Gauge

X Prototype X Pre-launch Production

Control Plan Number : CP/ FG14000032

Key Contact/Phone : 1) Mr.R.V.Vaidya

+0240-2244001+0240-2244002

Date (Org) 25.11.2012 Date (Rev.) 20.11.2012

Part Number/Latest Change Level : SF14053032 (4475_319_054) Core Team : 1) Mr. S.G.Waghmare

2) Mr. D.T.Kawle

3) Mr. J.S.Isargunde

Customer Engineering Approval/Date (If Reqd)

Part Name/Description : LOCKING SLIDE

Part Process Number : 120 Supplier / Plant Approved / date Customer Quality Approval/Date (If Reqd)

Process Name/ Operation Description: OD Grinding

Supplier/Plant :- Sanjeev Auto Parts , K96, Waluj,Aurangabad

Supplier Code:38709

Other Approval/Date (If Reqd) Other Approval / Date (If Reqd)


4/12

76.0(O )

94.0

42.0(O )

FIXTURE

CONSUMABLE

TOOL

PROCESS PARAMETERS

INPUT QUALITY

INPROCESS QUALITY

OUTPUT QUALITY


WORK INSTRUCTION

GAUGES

LOADING PATTERN

NO. OF COMPONENTS : 1 NOS

ANTI RUST OIL

1) NO EXCESS OIL REMAINS ONCOPMPONENT

1) COMPONENT FREE FROM DUST,CHIPS & RUST.

1) TAKE COMPONENT FROM SINGLE

1) ENSURE CLEANED COMPONANTFREE FROM RUST & DUST


5/12

CONTROL PLAN 32

PD/F09/R2



Key Contact/Phone : 1) Mr.R.V.Vaidya

+0240-2244001+0240-2244002

Date (Org) 20.11.2012 Date (Rev.) 20.11.2012


2) Mr. D.T.Kawle




Part Process Number : 130 Supplier/ Plant Approval/Date Customer Quality Approval/Date (If Reqd)

Process Name/ Operation Description :-WASHING

Supplier/Plant

Sanjeev Auto Parts Mfgrs Pvt Ltd.,

K-96, MIDC, Waluj, Aurangabad.

Supplier Code:

38709

Other Approval/Date (If Reqd)

Machine,

Device, MgBooks for

Mfg.


Char.

Class

Methods

Responsibility

Reaction

Plan &corrective

actionNo. Product ProcessProduct/ Process

Specification/ Tolerance

Evaluation/

Measurement

Technique

Sample

Control MethodSize Freq.

Washing

m/c

1 Visual dimension - - No Rust, no scale of HT Visual

100% Continuous

-

OperatorIf

component

is not okthen rewash

it

5 Per hourProd.

Supervisor

2 Cleanliness - -Max Allowable

contaminant=25.948mg Millipore 1 Per lot Millipore Report QA Inspector


6/12

SANJEEV AUTO PARTS MFRS. PVT. LTD.

MATERIAL & HEAT TREATMENT :-

PART NAME :- PRPD BY

CHKD BY

APPD BY

MOD NO. DATEMOD. CHANGES

BRAKE ALL SHARP EDGES ASK IF IN DOUBT

PART. NO. :-

CUST. REF. NO./MOD. NO.:-

PD/F15/R2

DATE

38.

5

+0.4

OO

76.

00

-0.

5

2.0+1

10.50-0.5

70.

00

-0.

5

O

63.

00

-0.

5

O

59.0

-0.

2

O

50.0

0

O

h8

42.

0

+0.4

O

61.

75

da=

h11

94.0

83.50-0.3

55.0-1

9.00+0.5

80.00+0.5

8.00-0.572.5+1

6.5+0.2

87

19'

020'

R2.5

-1

R2.5

-1

^ 0.05 P1

n 0.05 P1

14.80

-0.25

Ch.0.6 x 45

SEE DETAIL 'X'

P1

^ 0.05 P1

R1.6 -0.2

Rz63

DOG.

16

60.0

d

=59.

25

-0.

68

df=

MARKING LOCATION OPTIONAL

CONTACT PATTERN WITHSAMPLE MATING GEAR

MARKED ACC.TO ZFN 2011 X

ALTERNATIVERz5C

Rz2.5CH.1.7 +0.3 X 45

0.

35

0.

2

30

5

0.

8

0.4

0.350.2

0.80.4

30

5

R0.4 0.2

DETAIL 'X'

RELIEF GROOVE

S.P.A.J.S.I.

R.V.V.

F

LOCKING SLIDE

FG14000032

4475_319_054_DES001

20/11/12

20/11/12

20/11/12

ZFN417-A

NEW DRAWING RELEASED.20/11/12F

FORGING TOLERANCE ACC. TO EN 10243

DRAFT ANGLE = 6

( ) SUPPLEMENTRY DIMENSION

SPLINE GEAR TEETH

TEST DIMENSION OVER ROLLERS ACC.

TO DIMENSION INSPECTION REPORT

100% TESTING WITH PROFILE GAUGE

## DEVIATION TO 4475_319_043 VER "a"

SEE DRAW. MODIFICATION

# ALTERNATIVE MATERIAL ACC. TO TABLE 4475_700_072

Rz20

DIN 5480-W62X1.25X30X48X9h

y

HEAT TREATMENT

CASE HAEDENED ACC TO ZFN 417

SURFACE HARDNESS : 81 TO 85 HRA.

CASE DEPTH : 0.4 TO 0.7

CORE STRENGHT : 1000 N/mm2

SR.NO. SPUR GEAR, BEVEL GEAR TOOTH DATA CURVIC COUPLING

1 NO. OF TEETH/ NORMAL MODULE Z = 48 / Mn = 1.25 Z = 6 / Mn = 9.833

2 PRESSURE ANGLE = 30 = 03 HELIX ANGLE = =

4 HAND OF HELIX ---- ----

5 CENTER DISTANCE IN HOUSING a = a =

6 MATING GEAR No/NO. TEETH 4461_353_056 / Z = 48 4461_351_061/ Z = 6

7 SETTING DATA ACC TO M NO. 0041 072 569 0042 710 009

8 OPD DIMENSION(Over Pin2.5) 64.578/64.507

9 ROOT DIAMETER 59.250

I

I

I

I

I

I

I

I

I

0.000 50.000

-0.039 49.961

0.000 61.750

-0.190 61.560

MAXIMUM LIMITS

50.000 h8

61.750 h11

FIT SIZE ALLOWNCE


7/12


8/12


9/12


10/12

CONTROL PLAN 32

PD/F09/R2



Key Contact/Phone : 1) Mr.R.V.Vaidya+0240-2244001

+0240-2244002

Date (Org) 25.11.2012 Date (Rev.) 20.11.2012


2) Mr. D.T.Kawle




Part Process Number : 140 page : 4/4 Supplier / Plant Approved / date Customer Quality Approval/Date (If Reqd)

Process Name/ Operation Description : VISUAL DIMENSION INSPACTION

Supplier/PlantSanjeev Auto Mfrs Pvt.Ltd.

K-96 ,MIDC,Waluj,Aurangabad

Supplier Code:38709

Other Approval/Date (If Reqd) Other Approval / Date (If Reqd)

Machine,

Device, forMfg.


Char.Class

Methods

Responsibility

Reaction Plan

& correctiveactionNo. Product Process

Product/ ProcessSpecification/ Tolerance

Evaluation/ MeasurementTechnique

SampleControl Method

Size Freq.

Manually

48. Core strength - - 1000 N/mm Sampling plan SSP (N) H.T. Report QA Inspector

If not OK rejectthe lot.& put in

red bin informto supervisor

49. Root diameter - - 59.250 Vernier caliper Sampling plan SSP (N) PDI Report QA Inspector

50. DOP. - - 64.578/64.507 Spline ring gauge GO /NOGO Sampling plan SSP (N) PDI Report QA Inspector

51. Material - - ZFN417-A Chemical analysis Sampling plan SSP (N) PDI Report QA Inspector

52. Visual - - No. teeth dent & damage Visually Sampling plan SSP (N) PDI Report QA Inspector


11/12

CONTROL PLAN 32

PD/F09/R2



Key Contact/Phone : 1) Mr.R.V.Vaidya+0240-2244001

+0240-2244002

Date (Org) 25.11.2012 Date (Rev.)

Part Number/Latest Change Level : SF14007032 (4475_319_054)


Core Team : 1) Mr. S.G.Waghmare

2) Mr. D.T.Kawle3) Mr. J.S.Isargunde


Part Process Number : 150

Process Name/ Operation Description : Packing & Forwarding

Supplier/ Plant Approval/Date: Customer Quality Approval/Date (If Reqd):

Supplier/Plant

Sanjeev Auto Parts Mfrs Pvt. Ltd.,

K-96, MIDC, Waluj, Aurangabad

Supplier Code:

360450

Other Approval/Date (If Reqd):

Characteristics Methods

SampleMachine,

Device, forMfg. No. Product Process

SpecialChar.Class

Product/ ProcessSpecification/ Tolerance

Evaluation/

MeasurementTechnique Size Freq.

Control MethodResponsibility

Reaction Plan &

Corrective action

Manual 1 Packing & forwarding - - Packing in Bin Visual counting 100% Continues Physical Verification Dispatch officerIf not OK, put in

red bin.


12/12

locking slide part2

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