M VOS 193 C

Customer
Supplier Name
Part No
Description
Production
Part
Approval
Process
Customer :
Part name : OILSEAL
Supplier name:
Part No. :
VOS 193
List of documents submitted

(Tick inside the box)
PPAP manual ref no
Design record
Engineering change documents
Customer engineering approval
Design FMEA
Process flow diagram
Process FMEA
Dimensional results
Material performance test results
Initial process study
10
Measurement system analysis studies
10
11
Qualified labarotary documentation
12
Control Plan
12
13
Part submission Warrant
13
14
Appearance approval report
14
15
Bulk material requirement check list
15
16
Sample product
17
Master Sample
18
Checking aids
19
Deviation and action plan
PPAP rev no.:
11
16
17
18
-
Submission date:
16.09.10
PPAP manual ref no
PPAP History Sheet

PART NO :VOS 193
PPAP
SNO
Rev .No
Date
1
NIL
16.09.10
PREPARED BY :
Details of Change
Signature
Initial submission
APPROVED BY:
PROCESS FLOW
Part Name / Description : Oil Seal
Date (original) : 13.09.2010
Drawing / Part no : VOS 193
10. A. Incoming Inspn. Of Raw

Material. (Shell)
10. B. Incoming Inspn. Of Raw

Material. (Spring)
10.C. Incoming Inspection of

Chemicals & Raw Rubber
: 00
Revision Date : NIL
Customer Ref. No : BSE 0300B - WK

30.14(B)
Op. / Brief Desc.
Rev No
Process flow no : BI / PF/ 193

Incoming Sources of Variations
1.Wrong Specification Material
shipped by supplier
2. Visual
defects like Rust , Burr, Bend,
cutshell, tool mark, Rust, Dent, OD
line mark , Pit mark supplied by the
Supplier
shipped by supplier
2. Visual
defects like Bend, Rust , Burr, peel
off supplied by the Supplier
Process Flow Diagram
10.A.
10.B.
Wrong Specification Material

shipped by supplier
10.C.
20.Storage of Raw Material
1.Wrong Grade Material

2.Wrong
Specification/Size Material
3.Defective material
30.Weighing of Mix Ingredients
1.Incorrect ingredients weight

2.Incorrect
chemical selection.
3.Ingredients missed out
4. Instrument
Error.
40. Rubber Mixing
1. Poor Dispersion
2.Temperature variation of
coolant circulation in roll mill.
20
30
40
Core Team : Production / Quality /

Marketing (CFT)
Customer
Product Characteristics
Process Characteristics
1. I.D. : 44.10 0.10 mm

2. P.D. : 35.50
0.15 mm
3. HT. : 6.35 0.10 mm
_
4. ST :0.91
MATERIAL :
CRCS IS 513 - 1994
1. Spring Length : 103.00 mm
2. Coil Dia : 1.58 mm
3.
_
Wire Dia : 0.30 mm
MATERIAL : GI IS 4454 - 2001
PART1
Material Grade
Material Grade
Weight of the Ingredients
Rubber Compound
Mixing Time.
PROCESS FLOW
50. Compound testing

A)Hardness

Variation in Rubber Hardness
50.A.

Marketing (CFT)
Customer
Hardness : 70 5 shore A
1.20 ~ 1.25
Minimum 12.5 N/mm
50.B.

B)Specific Gravity
Specific Gravity variation.

C)Tensile Strength
Tensile Strength variation.

D) Ultimate Elongation
Elongation variation.
60. Extrusion
Over Cure of Rubber compound.
70. Dipping
: 00
Revision Date : NIL

30.14(B)
Op. / Brief Desc.
Rev No
1) In correct/ Excess bonding layer

in shell
2) Rust / Surface
defects in shell
3)
Process Temperature variation
4) Life time of
dipping chemicals
50.C.
50.D.
60
70
Minimum 250 %
Blank Shape
Extrusion Time
Dipping Chemical Specific Gravity.
Process Temperature.
PROCESS FLOW
80. Rubber Cutting
: 00
Revision Date : NIL

30.14(B)
Op. / Brief Desc.
Rev No

1) Incorrect Rubber selection

2) Variation in Rubber
weight
3) Weighing
Machine Error.
80

Marketing (CFT)
Customer
Rubber Blank
PROCESS FLOW
90.Moulding
: 00
Revision Date : NIL

30.14(B)
Op. / Brief Desc.
Rev No

1)Curing Temperature Variation
2) Pressure Variation
3)Time Variation
4) Visual
Defects like Short fill , Poor flow,
tearing , stripping, Bad mould,
Under cure , foreign matter , Bad
shell , Bond failure , Dent
1) Uneven Flash removal, Tearing.,
2) Poor Finishing
3) Tool bit wear
100. Finishing

Marketing (CFT)
Customer
1.Appearance.
70.
90
2.Temperature.
_
3.Time.
4.Pressure.
100
Apperance
1) After trimming , Ensure Id thro ID

checking Gauge. ID: 29.00 0.25
out
110. Trimming
1) Trimming Needle wear out

2) Uneven location of
seal in Trimming machine
3)
Incorrect Trimming / I.D. Dimension
variation
120. Final Inspection
1) Dimension Variation
2) Short fill , Poor
flow, tearing , stripping, Bad mould,
shell , Bond failure , Dent .
130. Spring Fitment (Spring with oil

seal)
1) Wrong Spring selection

2) spring open out
while fitment with seal
140. Packing & Labelling
1) Quantity Variation
2) Incorrect packing
media.
3)Product Mixup
70.
110
1) O.D. : 47.78 / 47.93 mm

2) I.D. :
120
28.75 0.25 mm
3) Height : 8.00
0.20
4) Free
from visual defects like Short fill , Poor
flow, tearing , stripping, Bad mould, Under
cure , foreign matter , Bad shell , Bond
failure , Dent .
130
140
Visual.
Part No & Qty.
CONTROL PLAN
Prototype
Pre-launch
Control plan Number :
BI / CP/193
Production
Key Contact / Phone
Core Team
: PRODUCTION ,QUALITY, MARKETING
Engineering change level
Supplier Code
Supplier / Plant approval / Date

Characteristics
Part /
Process
Machine,Devi
Process
Name/Operati ce,Jigs,Tools
Numbe
on Description
for Mfg
r
10.A.
10. B.
10. A.
Incoming
Inspn. Of Raw
Material.
(Shell)
10. B.
Incoming
Inspn. Of Raw
Material.
(Spring)
Digi Vernier
Digi Vernier
& Scale
No
: 00
Customer Eng. Approval / Date : N/A
: Nil.
Product
Dimension

Revision Date : NILRev No
Customer Quality approval / Date : N/A
Other Approval Date ( If required ) :
Process
Plant / Location :
Methods
Sperc
Reaction
Evaluation /
Error
ial
Plan /
Product/Process
Measureme
Resp.
Proofi
Size
Frequency Control methods Correctiv
Char.
Spercification / tolerance
nt
ng
Class
e action
Technique
1. I.D. : 44.10 0.10
mm
2. P.D. :
Digimatic
35.50 0.15 mm
Vernier
As Per
Incoming
Reject
Store &
3. HT. : 6.35 0.10 mm caliper, Dial Nil sampling Each lot
Inspection Report the RM
QC
Indicator ,
Plan
4. ST :0.91 Micrometer.
MATERIAL
:
1. Spring Length
: 103.00
CRCS IS 513 - 1994
mm
2. Coil Dia :
1.58 mm
3.
Wire Dia : 0.30 mm
Dimension
Digimatic
Vernier
caliper,
Steel Scale.
Nil
As per
sampling
plan
Each lot
Incoming
Inspection Report
Reject
the RM
Store &
QC
Visual
check
Nil
Every
time
Each lot
Supplier Test
Report
Reject
the RM
Store &
QC
Visual
check
Nil
Every
time
Each lot
Visual check ,
stock Record.
Reject
the RM
As per mixing weight

chart.
Weigh
Machine
Read out.
Nil
Every
time
Every Batch
Receipe Check
List
Stop &
Correct
the
process.
Milling
Section
Visual
check
Nil
Every
time
Every Batch
Stop &
Correct
the
process.
Milling
Section
Hardness
Tester
Nil
One
Every Batch Testing Records.
sample
Stop &
Correct
Lab
the
Assistant
process.
MATERIAL : GI IS 4454 2001 PART1

10.C.
10.C. Incoming
Inspection of
Chemicals &
Raw Rubber
Material Grade
20
20.Storage of
Raw Material
Material Grade
30
30.Weighing of
Mix
Ingredients
40
40. Rubber
Mixing
50.A.
50.B.
50.C.
50.D.
Weighing
Machine
Two Roll Mill.
50. Compound
testing
Hardness
Tester
A)Hardness
50. Compound
testing
Densimeter.
B)Specific
Gravity
Compound
testing
UTM(Univers
al Testing
C)Tensile
Machine)
Strength
Compound
testing
UTM(Univers
E) al Testing
Machine)
Ultimate
Elongation
Ensure Chemical Grade

Number, Weight, Quantity
1.Correct Grade of
with respect to D.C.
material
2.Correct
specification/size of
material
Weight of the ingredients
As per Milling
procedure.
Store
Rubber Compound
Mixing Time
As per Milling procedure.
Hardness
Hardness : 70 5 shore A
Specificgravity
1.20 ~ 1.25
Densimeter
Nil
One
Every Batch Testing Records.
sample
Stop &
Correct
Lab
the
Assistant
process.
a.Tensile Strength
Minimum 12.5 N/mm
UTM(Univer
sal Testing
Machine)
Nil
Two
Sample
15 days
once.
Testing Records.
Stop &
Correct
Lab
the
Assistant
process.
Ultimate Elongation
Minimum 250 %
UTM(Univer
sal Testing
Machine)
Nil
Two
Sample
15 days
once.
Testing Records.
Stop &
Correct
Lab
the
Assistant
process.
CONTROL PLAN
Prototype
Pre-launch
BI / CP/193
Production
Key Contact / Phone
Core Team
Supplier Code

Characteristics
Part /
Process
Machine,Devi
Process
Numbe
on Description
for Mfg
r
60
70
60. Extrusion
70. Dipping
Cleaning
Process
Drying Section
Drying Section
No
Extruder &
Die

: Nil.
:
Product

Process
Plant / Location :
Methods
Sperc
Evaluation /
Error
ial
Product/Process
Measureme
Proofi
Size
Frequency
Char.
nt
ng
Class
Technique
Thermomet
er
Nil
Sampling
Every Day
Plan
Stop &
Process Condition
Correct
Record
the
FR/DPC/27a
process.
Dipping
Section
As per Work Instruction
Time
Indicator
Nil
Sampling
Plan
Every Day
Process Condition
Record
FR/DPC/27a
Dipping
Section
Drying Temperature
Nil
Every lot
Visual check
Dipping
Section
Dryer
Drying Time
Nil
Every lot
Visual check
Dipping
Section
Dipping Solution Specificgravity.
Hydrometer
Nil
Sampling
Plan
Every Day
Testing Records.
Stop &
Correct
the
process.
Dipping
Section
Rubber Blank.
As per Loading Chart
Digital Read
out of
Weighing
Machine.
Nil
Random Every Batch
Visual check
Stop &
Correct
the
process.
Rubber
Cutting
Section.
Appearance
Part should be free from

Short fill , Poor flow,
tearing , stripping, Bad
moulding, Under cure ,
foreign matter , Bad
shell , Bond failure , Dent
Visual
Nil
Random
Every Lift
In patrol
Inspection
Report.
Stop &
QC Correct
Patrol
the
Inspector.
process.
Temperature
Controller.
Temperature
170c 5c
Pyrometer
Nil
2 Times
Every Shift
In patrol
Inspection
Report.
Stop &
QC Correct
Patrol
the
Inspector.
process.
Timer
Controller
Curing Time
3.5 mins
Time
Indicator
Nil
Every Lift Every Lift
In patrol
Inspection
Report.
Pressuer
Indicator
Nil
Every Lift Every Lift
In patrol
Inspection
Report.
Digimatic
Vernier
caliper.
Nil
Temperature
Controller.
Timer
Controller
Uniformity of Rubber
blank.
Cleaning Chemical
Process Temperature.
Cleaning Chemical
Process Time
Dryer
Every
time
Dipping
90
80. Rubber
Cutting
90.Moulding
Stop &
Correct Extrusion
the
operator.
process.
Nil
Timer
Controller
Extrusion Time.
Resp.
Visual
check
Temperature
Controller.
Blank Shape.
Reaction
Plan /
Control methods Correctiv
e action
Every Batch
Visual check
Hydrometer
80
: 00
Weighing
Machine
Hydraulic
Press Cavity
& Tools
90
1) O.D. : 47.78 / 47.93

mm
Pressure
Gauge
Pressure.
1500psi
- 2000psi
I.D. : 28.75
0.25 mm
2)
3)
Height : 8.00 0.20
Seal
Dimension
Oilseal
_
4) Free from
visual defects like Short
fill , Poor flow, tearing ,
stripping, Bad mould,
First off
(Every
setting)
Each sizes
In First-off
Approval Record
(FR/FAM/29b)
Stop &
Correct
the
process.
QC
CONTROL PLAN
Prototype
Pre-launch
BI / CP/193
Production
Key Contact / Phone
Core Team
Supplier Code

Characteristics
Part /
Process
Machine,Devi
Process
Numbe
on Description
for Mfg
r
100
100. Finishing
Finishing
Motor,
Mandrel &
Emery sheet.
110
110. Trimming
Trimming
Machine
120
120. Final
Inspection
Gauge,
Digi.vernier
& ID plug
Gauge
No
Product
Visual

: Nil.
:

Process
Plant / Location :
Methods
Sperc
Evaluation /
Error
ial
Product/Process
Measureme
Proofi
Size
Frequency
Char.
nt
ng
Class
Technique
ID Dimension
: 00
Visual
check
1) After trimming ,
Ensure Id thro ID checking I.D. Gauge
1)
O.D. :ID:
47.78
/ 47.93
Gauge.
29.00
0.25
mm
2)
I.D. : 28.75 0.25 mm
3)
Height : 8.00 0.20
1. Visual
2. Dimension.
4) Free from
visual defects like Short
fill , Poor flow, tearing ,
stripping, Bad mould,
Under cure , foreign
matter , Bad shell , Bond
failure , Dent .
Reaction
Plan /
Control methods Correctiv
e action
Resp.
Nil
Random
Each lot
Visual check
Stop &
Correct Finishing
the
Section
process.
Nil
First off
(Every
setting)
Each lot
In First-off
Approval Record
(FR/FAT/29a)
Stop &
Correct Trimming
the
Section
process.
Each lot
Final Inspection
Report.
Reject
the
Material.
As per
Sampling
Digimatic
Vernier
caliper.
Nil
Plan.
2) 100%
Visual
Inpection
.
QC
PROCESS FMEA
Date(Orijnal): 13.9.2010
Model Year / Vehicle(s) :
FMEA Number : BI / FMEA / 193
Revision Date : NIL
Customer Ref. No : BSE 0300B - WK 30.14(B)
Core Team
Rev no : 00
Process Function \
Requirements
Potential Failure Mode
PC
Potential effects Se
Pot. Cause(s) /
Oc
Clas
of Failure
v
Mechanism of Failure c
s
Incorrect material
supplied by the
supplier.
32
Incorrect material
supplied by the
supplier.
1)Incoming
Inspection with
respect to sampling
plan.
2
2) Incoming
Inspection
Report( Ref :
WI/II/01 - Rev-00)
32
Incorrect material
supplied by the
supplier.
80
Product reject .
1) Incorrect Method
of stacking raw
material.
2)
Storekeeper product
knowledge / less
awareness.,
30
Performance get
reduced &
Difficult to meet
customer
requirement
1.Sequence of
1)Weight Machine
material pick - up not 2
followed.
32
Performance get
reduced &
Difficult to meet
customer
requirement
1. Inadequate mixing
1)Harddness testing
time.
2 method
2
2.Excess mixing
2)visual
time.
32
Performance get
reduced
1. Inadequate mixing
time.
2
2.Excess mixing
time.
Hardness tester
Indicator
24
Performance get
reduced
Sequence of material
2
added not followed.
Densimeter output
values/ Testing
results
24
a.Tensile Strength Variation
Performance get
reduced
1.Inadequate mixing
time.
2.Excess mixing time.
UTM Test Result
32
Elongation Variation
Performance get
reduced
1.Inadequate mixing
time.
2.Excess mixing time.
UTM Test Result
32
10. A. Incoming
Inspn. of Raw
Material. (Shell)
10. B. Incoming
Inspn. Of Raw
Material. (Spring)

shipped by supplier
Product reject
2. Visual
and return to the
defects like Bend, Rust , Burr, peel
supplier.
off supplied by the Supplier
20.Storage of Raw
Material
30.Weighing of Mix
Ingredients
40. Rubber Mixing
50. Compound
testing
A)Hardness
Wrong Specification Material

shipped by supplier

2.Wrong
Specification/Size Material
3.Defective material
1.Incorrect ingredients weight
2.Incorrect
chemical selection.
3. Life time of ingredients
4.Ingredients missed out
1. Hardness variation
2. Poor Dispersion
3.Temperature
variation of coolant circulation in
roll mill.
Variation in Rubber Hardness
50. Compound
testing
Specific Gravity variation.
B)Specific Gravity
C)Tensile Strength
50.Compound testing
D)
Ultimate Elongation
Respty and
Current Process
RP
target /
Det
Action Taken
Action taken
Control Detection
N
Comp.
Date
1)Incoming
Inspection with
respect to sampling
plan.
2
2) Incoming
Inspection
Report( Ref :
WI/II/01 - Rev-00)

shipped by supplier
2. Visual
Product reject
defects like Rust , Burr, Bend,
and return to the
cutshell, tool mark, Rust, Dent, OD
supplier.
line mark , Pit mark supplied by
the Supplier
10.C. Incoming
Inspection of
Chemicals & Raw
Rubber
: QUALITY,MARKETING & PRODUCTION. (CFT)
Product reject
and return to the
supplier.
1) As per test
certificate
1) Work instruction
displayed
2)Skill Matrix &
2 Training for
concern person
/operator ( Ref :
WI/SI/13 - Rev-00)
O D RPN
PROCESS FMEA
Date(Orijnal): 13.9.2010
FMEA Number : BI / FMEA / 193
Revision Date : NIL
Customer Ref. No : BSE 0300B - WK 30.14(B)
Core Team
Rev no : 00
Process Function \
Requirements
60. Extrusion
70. Dipping
Over cure of Rubber compound.
: QUALITY,MARKETING & PRODUCTION. (CFT)
Respty and
Current Process
RP
target /
Det
Action Taken
Action taken
Control Detection
N
Comp.
Date
PC
Potential effects Se
Pot. Cause(s) /
Oc
Clas
of Failure
v
Mechanism of Failure c
s
Operable at
reduced level of
performance.
1) In correct/ Excess bonding layer in

shell
2) Rust / Surface
defects in shell
3) Process
Temperature variation
1) Bond failure
2)Curing process
4) Process Time variation.
may delay
1. Not feed the

material continuously.
8
2
2.Problem in water
circulation.
1) Periodic checking
of water circulation.
2
2)
visual
32
1)Testing Method
2) Work
2 Instruction Displayed.
( Ref : WI/DI/02
- Rev-00)
32
Digital Read out of

weigh Machine
20
Product Rejection 8
1. Hydraulic
Patrol Inspection
pressure , Curing
Record.
Time , Temperature
3
variation (Heater
Problem ).
2.Lack
of cavity cleaning
48
Product Rejection 7
1. Improper Finishing.
2. Incorrect 2
selection of Tool.
Visual
28
In First-off Approval
Record (FR/FAT/29a)
32
32
32
24
Process not followed as

per Work Instruction.
5)Dipping Procedure Variation.

6)Life time of dipping chemicals.
80. Rubber Cutting
1) Incorrect Rubber selection

2) Variation in Rubber Product Rejection 5
weight
90.Moulding
1) Visual Defects like Short fill ,

Poor flow, tearing , stripping,
shell , Bond failure , Dent,
Badmoulding.
1) Uneven Flash removal, Tearing.,
100. Finishing
2) Poor Finishing
Manual cutting of
Rubber blank.
1) Trimming Needle wear out

Product Rejection
Improper trimming and

Improper tool Finishing.
1. Incorrect Inspection
Performance get
reduced /
Fitment problem
to the End User.
Inadequate Visual
Aids and defect
samples.
130. Spring Fitment

(Spring with oil seal)
1) Wrong Spring selection

2) spring open out
while fitment with seal
Performance get
reduced /
Fitment problem
to the End User.
Due to carelessness
of the operator.
140. Packing &

Labelling
1) Quantity Variation
2) Incorrect packing
media.
3)Product Mixup
110. Trimming
120. Final Inspection
2) Incorrect
Trimming / I.D. Dimension variation
NOTE:
A Typer- Detect on failur HIC- High impact characteristics
B Typer- Detect on failure causBP- Blue print
C Typer -Prevent on failure cau ES- Engineering spercification
Customer
dissatisfaction.
1)
2 Final Inspection
Report
2) 100% Visual
Inspection
( Ref :
WI/FII/07 - Rev-00)
1) I.D. Checking
2 Gauge available.,.
1. Similar Parts
placed at near by
location or same
2
location.
2. Counting
_
Error.
FC-Functional charactistics
IP - Inprocess product characteristics
O D RPN
STATISTICAL PROCESS CONTROL STUDY

PART NAME:
Oilseal
INSTRUMENT:
Digi.vernier
L.COUNT:
0.01 mm
PART NO.:
VOS 193
SPEC:
29.00 0.25
MACHINE:
Trimming Machine
PARAMETER:
INNER DIAMETER
NO.OF DECIMALS:
SAMPLE SIZE:
50
DATA COLLECTION: S. NO.
1
2
10
28.94
29.02
29.08
29.04
29.05
29.02
29.06
29.12
29.02
29.06
28.96
29.03
29.06
29.04
29.06
29.04
29.05
29.08
29.04
28.96
29.02
29.04
29.02
29.04
29.05
29.06
29.10
29.02
28.92
29.04
29.06
29.04
29.06
29.03
29.04
29.12
29.05
29.04
28.94
29.02
29.05
29.05
29.06
29.05
29.04
29.10
29.04
29.05
DATE:
15.09.10
SAMPLE
D2
A2
D4
1.123
2.560
3.270
29.04
1.128
1.880
3.270
29.01
1.693
1.020
2.570
2.059
0.730
2.230
2.326
0.590
2.110
U.T.L.
41.25
L.T.L.
40.75
CALCULATIONS: FOR HISTOGRAM

XLARGE
28.96
29.04
29.08
29.05
29.06
29.05
29.06
29.12
29.05
29.06
Xmax.=
29.1200
XSMALL
28.92
29.02
29.04
29.02
29.04
29.02
29.04
29.08
29.02
29.01
Xmin.=
28.9200
NO.OF NON CONFORMING PART =
50 NOS.
RANGE
0.04
0.02
0.04
0.03
0.02
0.03
0.02
0.04
0.03
0.05
R-BAR =
0.03200
NO. OF PARTS ABOVE U.T.L. =
0 NOS.
AVG.
28.94
29.03
29.06
29.04
29.05
29.04
29.05
29.10
29.03
29.04
X-BAR =
29.0386
NO. OF PARTS BELOW L.T.L. =
50 NOS.
Process Width ( P ) = 0.2000
Specification Width(S) =
0.5000
Index (K)={2 x (D-XBAR) / S}=
47.8456
Design Centre ( D ) = 41.0000
Interval =
0.0400
Selecting no. of classes =
28.8000
Starting Point =
No. of readings=
50.0000
Shift Of 'X-BAR' from 'D' =
11.9614
28.8400
28.9200
FREQ.
VALUE
HISTOGRAM
25
20
X-CHART
29.15
29.1
29.05
29
28.95
15
28.9
28.85
10
29.2800
29.2400
29.2000
29.1600
29.1200
29.0800
29.0400
29.0000
28.9600
28.9200
28.8800
28.8400
28.8000
28.8400
28.8800
28.9200
28.9600
29.0000
29.0400
29.0800
29.1200
29.1600
29.2000
29.2400
DIMENSION
REMARKS :
PROCESS IS EXCELLENT
INTERVAL
5 SAMPLE
6
7
0.08
0.07
0.06
0.05
0.04
0.03
0.02
0.01
0
10
A
V
G
.
U
.
C
.
L
.
L
.
C
.
L
.
R- CHART
R
A
N
G
E
U
.
C
.
L
.
10
FREQ.
CU. FREQ.
28.8400
28.8800
28.8800
28.9200
28.9200
28.9600
28.9600
29.0000
29.0000
29.0400
29.0400
29.0800
23
28
29.0800
29.1200
18
46
29.1200
29.1600
50
29.1600
29.2000
50
29.2000
29.2400
50
29.2400
29.2800
50
U.C.L.XBAR =
29.05748
L.C.L.XBAR =
29.01972
U.C.L.RBAR =
0.0675200000000001
L.C.L.RBAR =
Std.Dev."s"=
0.03995
Pp=(S/6s)=
2.08600
Ppk=Min(PPL,PPU)=
-97.71847
Gauge Repeatability & Reproducibility Study

APPRAISER/
TRIAL #
1(A)
1
2
2
3
3
Average
Range
1
29.02
29.03
29.02
29.023
0.01
2
28.94
28.95
28.95
28.947
0.01
PART
3
29.12
29.13
29.13
29.127
0.01
4
29.08
29.09
29.08
29.083
0.01
VOS 193
5
29.06
29.07
29.07
29.067
0.01
6
29.12
29.11
29.11
29.113
0.01
7
29.02
29.02
29.02
29.020
0.00
8
28.96
28.97
28.96
28.963
0.01
9
29.14
29.15
29.15
29.147
0.01
AVERAGE
10
29.050
29.04
29.055
29.03
29.053
29.04
29.037 Xabar = 29.05
0.01 Rabar = 0.01
4(B)
29.02
28.94
29.12
29.08
29.06
29.12
29.02
28.96
29.14
29.04
29.050
29.02
28.93
29.13
29.07
29.06
29.11
29.03
28.97
29.14
29.03
29.049
29.053
29.03
28.94
29.13
29.08
29.07
29.11
29.02
28.96
29.15
29.04
Average
29.023
28.937
29.127
29.077
29.063
29.113
29.023
28.963
29.143
29.037 Xbbar = 29.0507
7 Range
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.01
Rbbar = 0.010
7 (C)
29.02
28.94
29.12
29.09
29.06
29.12
29.02
28.96
29.14
29.04
29.051
78
29.02
28.93
29.12
29.08
29.06
29.12
29.03
28.96
29.14
29.04
29.050
29.03
28.94
29.13
29.08
29.07
29.11
29.02
28.97
29.15
29.05
29.055
Average
29.023
28.937
29.123
29.083
29.063
29.117
29.023
28.963
29.143
29.043 Xcbar = 29.0520
Range
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.01
16 Part
Xdbar = 29.0518
Average(Xp)
17
29.023
[Ra =
18 [MAX X=
19
Rcbar = 0.010
28.940
29.126
0.009 ]+[Rb=
29.0527 ]-[MIN X=
[R=
29.081
0.010 ] + [Rc=
29.064
29.114
29.022
28.963
29.144
29.039
0.010 } / {# OF APPRAISERS =3] =
Rp= 0.2
Rdbar = 0.01
29.0507 ] XDIFF
0.0020
0.010 ]x[D4*=2.58] = UCLR
20
[R=
0.010 ]x[D3*=0.00] = LCLR
NOTE:- * D4=3.27 for 2 trials and 2.58 for 3trials, D3= 0 for up to 7 trials Uclr represents the limit of
indvidual R's. Circle those that are beyond this limit. Identify the cause and correct. Repeat
these readings using the same appraiser and unit as originally used or discard values and
re-average and recompute R and the limiting value from the remaining observations.
APPRAISER ( a ) ---P.PAGIYA LAKSHMI
APPRAISER ( b ) ---M.VIGNESH
APPRAISER ( c ) ---A.SARAVANAN
UCLr =
0.0249
LCLr =
UCLx =
LCLx =
0.000
29.0617
29.0419
ANALYSIS OF R(bar) CHART :

RANGE CHART
No. of Points outside UCLr = 0
0.030
0.025
% of Points outside UCLr =
0.020
UCLr
0.015
LCLr
0 %
R(bar)
0.010
As the Range chart is in control, so we can proceed for

the Average chart (Xbar).
0.005
0.000
0
10
15
20
25
30
35
ANALYSIS OF X(bar) CHART :
X(BAR) CHART
29.200
29.150
29.100
29.050
29.000
28.950
28.900
28.850
28.800
UCLx
LCLx
X(bar
)
No. of Points outside UCLx =

No. of Points outside LCLx =
Total Points outside UCL & LCL =
15
14
29
% of Points outside UCLx & LCLx =
96.7
As this % is greater than 50% , the Measurement

system is adequate to detect part to part variation
MEASUREMENT SYSTEM ANALYSIS

Part Name- OILSEAL
Gage Name:
VERNIER
Characteristics:- ID
Identification No.:- 561311009
Specs. 41.00 0.25
From data sheet :Rdbar = 0.010
XDIEFFbar =
0.0020
Measurement Unit Analysis
Repeatability - Equipment Variation (EV)
EV = Rdbar x K1
.= 0.006
Trials
2
3
Reproducibility - Appraiser Variation (AV)
Date - 13.09.2010
Rp = 0.204
% Total Variation (TV)
% EV = 100 [EV/TV]
.= 8.84 %
K1
0.8862
0.5908
% AV = 100[AV/TV]
AV = [(XDIEFF x K2) - (EV /nr)]

2
.=
.= 0.0010
n=number of parts
Appraisers
r=number of trials
K2
Repeatability & Reproducibility (R&R)
R&R=
2
0.7071
3
0.5231
% R&R = 100[R&R/TV]
.= 8.99 %
(EV2+AV2)
.= 0.006
Part Variation (PV)

PV=Rp x K3
.= 0.064
Total Variation (TV)

TV =
(R&R2+PV2)
1.6 %
Parts
2
3
4
5
6
7
8
9
10
K3
0.7071
0.5231
0.4467
0.4030
0.3742
0.3534
0.3375
0.3249
0.3146
% PV = 100[PV/TV]
.= 99.6 %
ndc = 1.41(PV/R&R)
.= 12.6
~
13
.= 0.065
Note:1. All calculations are based upon predicting 5.15 sigma (99%of the area under the normal distribution curve).
2. AV- If a negative value is calculated under the square root sign, AV defaults to zero(0).
3. Guidelines for acceptance of gage repeatability and reproducibility (%R&R) are.
Under 10% error - the measurement system is acceptable.
10% to 30% error - may be acceptable based upon importance of application, cost of gauge,cost of repairs,etc.
Over 30% error - measurement system needs improvement. Make every effort to identify the problems and
have them corrected.
4. ndc is truncated to the integer & ought to be greater than or equal to 5.
(Refer MSA Manual - Third Edition)
Suppliers Name
List of checking Aids
Date: 13.09.10
Part No.:VOS 193
Customer :
Part namOILSEAL
Rev. No.: 0
Sl.
Characteristic /
Gauge / Instrument
No
Description
Description
OUTER DIAMETER
INNER DIAMETER
HEIGHT
SPRING LENGTH
PREPARED BY :
DIGITAL VERNIER
CALIPER
Plug Gauge
DIAL INDICATOR /
DIGITAL VERNIER
CALIPER
STEEL SCALE
Least Count
Gauge
Availabile
Calibration
Drg.
of gauge /
frequency/agency
Rev. No.
Instrument
0.01 mm 561311009
6Months
BI / PG / 151
BI / DI / 01 /
0.01 mm
1.0 mm
1Year
QA
1Year & 6Months
561311009
BSS 01
1Year
APPROVED BY:
frequency/agency
TO
INSPECTION REPORT
Date:
Description: Oil Seal
Customer Ref: BSE 0300B - WK 30.14(B)
Our Ref: VOS 193
Dimension: 48*30*8
Hardness: 70 +/- 5 Shore A
Sample size:
Qty:
DIMENSIONAL INSPECTION
Sl.NO Description Method
Of
Checking
1)
2)
3)
4)
Outer Dia Digi.Vernier
Inner Dia
Gauge
(with spring)
Height
Digi.Vernier
Specification
Max
Min
mm
mm
47.93
29.00
8.20
47.78
28.50
7.80
Observation
mm
47.89
47.84
47.82
47.81
47.85
47.91
47.92
47.86
47.88
47.82
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
7.94
8.06
7.92
8.00
8.04
8.04
8.08
7.98
8.04
8.08
OK
OK
OK
OK
OK
Visual
Conclusion:
Accepted Rejected Con.Accept
Inspected By:
in
Approved By:
Part Submission Warrant

Part Name
Cust. Part Num
Shown on Drawing No.
Org. Part Numb
Engineering Change Level
Dated
---
Additional Engineering Changes

Safety and/or Government Regulation
Yes
Checking Aid No.
---
Dated
Purchase Order No.
No
Weight (kg)
N/A
Checking Aid Engineering Change Level
ORGANISATION MANUFACTURING INFORMATION
Dated
N/A
CUSTOMER SUBMITTAL INFORMATION

Customer Name/Division
Street Address
Buyer/Buyer Code
Region
Postal Code
Country
Application
Has Customer-required Substances of Concern information been reported?
RUBBER MOULDING
Yes
No
n/a
Yes
No
n/a
Submitted by IMDS or other customer format :
Are polymeric parts identified with appropriate ISO marking codes?
REASON FOR SUBMISSION ( Check at least one )
Initial submission
Change to Optional Construction or Material
Engineering Change (s)
Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional
Change in Part Processing
Correction of Discrepancy
Parts produced at Additional Location
Tooling Inactive > than 1 year
Other - please specify below
REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.
Level 2 - Warrant with product samples and limited supporting data submitted to customer.
Level 3 - Warrant with product samples and complete supporting data submitted to customer.
Level 4 - Warrant and other requirements as defined by customer.
Level 5 - Warrant with product samples and complete supporting data reviewed at organisation's manufacturing location.
SUBMISSION RESULTS
The results for
dimensional measurements
These results meet all design record requirements:
material and functional tests
YES
NO
appearance criteria
statistical process package
(If "NO" - Explanation Required)
Mold / Cavity / Production Process

DECLARATION
I affirm that the samples represented by this warrant are representative of our parts which where made by a process that meets all production part
Approval Process Manual 4th Edition Requirements. I further affirm that these samples were produced at the production rate of _2800 / __8___ hours.
I also certify that documented evidence of such compliance is on file and available for review. I have noted any deviations from this declaration below.
EXPLANATION/COMMENTS:
Is each Customer Tool properly tagged and numbered?
Yes
No
n/a
Organisation Authorised Signature
Date
Print Name:
Phone No.
FAX No.
E-mail
Title
FOR CUSTOMER USE ONLY (IF APPLICABLE)

PPAP Warrant Disposition:
Customer Signature
Print Name
Feb
Approved
Rejected
Other
Date
Customer Tracking Number ( Optional )
PROCESS FLOW
Part Name
: " INSERT "
Rev No
Part Number : SI/RF/MECH : 1469
Date origin : 03.01.08
Revision Date :
Process Sheet : 01
Process flow no : GAJ 01
Department
Op. / Brief Desc.
1.Wrong Specification Material shipped

by supplier
2.Rusted/Pitted Material supplied by
10. Incoming Inspn. Of Raw Material. the Supplier
( Material - IS 513 Grade 'DD' )
3.Incorrect Thickness supplied by
the supplier
4. Wrong report
attache
20.Storage of Raw Material

2.Wrong Specification/Size
Material
3.Rust/Pit mark
observed material
:TOOLROOM.
1.Correct Specification of RM
10
2.Rust/Pit mark free material

3.Correct Report with every
consignment
1.Correct Grade of material
20
2.Correct
specification/size of material
3.Rust prevention of material
2.Width:70.0 0.50
30.Strip Shearing of sheets
1.Inspector training for intrepretation

of report.
2.Operator knowledge on Rust/ Pit
mark material identification,while
unloading the material
1.Moisture/Acid content in Storage

Area
2.Application of Rust
prevention on the material surface
2.Operator knowledge on identifying /
storage of Raw Material
3.Material Handling methodology /
Equipment 4.Duration of storage
1.Length:12503.0
1.Incorrect Size (Thickness,Width &

Length) of Material
2.Wrong
Grade Raw Material
30
3.Thick ness: 0.60

4.Appearance:Free from
burr, bend,twist,tool mark&cut blank.
1.Operator knowledge on Parameter

setting on shearing machine
2.Operator knowledge on identifying
the correct Raw Material to be fed
3.Cleanliness and condition of
Shearing machine
4.Capacity of the machine
1.Outer dia-1: 54.00 0.20

40
40. Shell forming & Piercing
Forming locator is offset to punch

profile.
50.Facing
Carriage stopper length variation &

tool performance.
50
60.Deburring
Improper butting & belt grinder

m/cbelt performance
60
2.Outer dia-2: 48.000.20
Forming locator symmetrical to punch

profile.
1.Height Face:7.80 0.10

0.10
4.Height:7.800.20
3.Thickness: 0.60 Maintain stopper distance&tool bit

performance.
5.Appearance:Free
2.Appearance:freefrom
from
Free from burr
burr,tol
mark,bend,twist&crack
tool
mark,bend,crack&twist.
Proper butting&maintainbelt grinding

M/C belt performance.
PROCESS FLOW
Part Name
: " INSERT "
Rev No
Date origin : 03.01.08
Revision Date :
Process Sheet : 01
Process flow no : GAJ 01
Department
Op. / Brief Desc.
:TOOLROOM.
1.Operator skill
70
70. Patrol Inspection
80.Storage after pressing (in Bins) in

station / Inventroy Area
1.Accept Good Part

2.Reject Bad Part
1.Thick
1.No Pit ness:0.600.10
mark/Rust on parts
1.Parts with Pitmark/Rust

2.Damaged Parts
3.Parts with out proper
identification
80
2.No Damages
2.Material
on parts
specification:IS:513
GRADE"DD"
3.Correct identification with
complete details
3.Outer dia-1: 54.00 0.20
4.Outer dia-2: 48.000.20
90
90. 100% Visual Final Inspection
2.Operator
knowledge on disposition
methodology
3.Operator vision Capability
4.Lighting in Inspection Area
1.Operator knowledge on stacking
methodology of parts in Bin
2.Bin cleanliness
3.Selection of storage
Bins
4.Quantity stacked
5.Duration of storage of
P
1.Operator skill
6.Appearance:
2.Operator
Free from burr,bend,cutting taper,rust,blow knowledge on disposition
holes&scratches.
methodology
3.Operator vision Capability
4.Operator
knowledge on keeping the material
with identification
1.Quantity in Pack
100
100.Packaging & Labelling
2.Correct selection of Packing media

3.Attach correct Standard Label
110.Despatch to customer
1.Wrong Label / Part
110
Correct shipment of Part / Invoice / DC
1.Operator knowledge on Pack

Quantity / Stacking method
PROCESS FMEA
Part Name
: " INSERT "
FMEA No
Date(Orig )
Rev no :
Prepared by :
Core Team
Process Function \
Requirements
PC
Potential effects
Sev Clas
of Failure
s
: 3.01.08
: TOOLROOM,QUALITY,MARKETING&PRODUCTION.
Pot. Cause(s) /
Mechanism of Failure
10. Incoming Inspn. Of

Raw Material.
( Material - IS 513 Grade
'DD' )
1.Wrong Specification
Cust- Difficult to
Material shipped by
meet production
supplier
shedule
2.Rusted/Pitted
Material supplied by the
Supplier
3.Incorrect
Thickness supplied by
the supplier
Delivery not checked

asper invoice while
unloading
20.Storage of Raw
Material
1.Wrong Grade
Cust- Difficult to
Material4. Wrong report meet production
attache 2.Wrong
shedule
Specification/Size
Material
3.Rust/Pit mark
observed material
Wrong receipt from

supplier
Wrong disposition of RM
30.Strip Shearing of
sheets
1.Incorrect Size
(Thickness,Width &
Length) of Material
Cust- Silver
streaks
Operator knowledge on
idnetifying / storage of
RM
1.Material handling
methodology/Equipment
2.Duration of
RM storage
Supplier compounding /
formulation error /
process error
Occ
Current Process
Control
Prevention
Current Process
Control Detection
De
Rec.
RPN
t
Actions
1.Operator
training
Training to operators
1.Operator
training
WI for RM handling
PM of
trollys as per
schedule
A.Visual inspection 7
RM inventroy
after pressing of the
monitoring against
part
selflife
49
21
49
2.Wrong
Grade Raw Material
3.Cleanliness and
condition of Shearing
machine
4.Capacity of the
machine
1.Forming tool
2 Frequency &
2.Machine,method &
training.
operator.
WI for cleaning of
De-humidifier
WI
for cleaning of RM
feeding area
Proper locator
40. Shell forming &

Piercing
Forming locator is offset Product reject.

to punch profile.
50.Facing
Height u/s&o/s.
Product reject.
2.Facing tool,lathe
method
3 Frequency &
training.
60.Deburring
Burr
Product
reject&rework.
& operator.
1.Belt grinding
m/c belt
performance.
3 Frequency &
training.
Revision Date :
Process Responsibility:TOOLROOM
1 1.Propper
7
RM verification
incoming
against P.O.while
inspection of raw offlaoding
material.
Visual
2.Inspector
Inspection of RM
training
Verification of
Rust/Pit mark on the
surface by random
check
1 1.Material
RM verification
3
size&Grade
during incoming
specifications
stage
provided on
Training for
Rmstorage room. Inspectors
1 Two
sides&opposite
sides stopper
provided.
: GAJ 01
40
Detail work
instruction given in
pcp
45
Maintain belt
performance
54
Respty and
target /
Comp. Date
Actio
n
S O D
taken
RPN
PROCESS FMEA
Part Name
: " INSERT "
FMEA No
Date(Orig )
Rev no :
Prepared by :
Core Team
Process Function \
Requirements
PC
Potential effects
Sev Clas
of Failure
s
5
70..First & Patrol

Inspection
80..Storage after
moulding in Bins in
station / Inventory Area
90. 100% Visual Final

Inspection
Parts with scratches

Damaged Parts
Accept bad Part
Difficult to meet
customer
schedule
Difficult to meet
customer
schedule
100.Packaging &
Labelling
110.Despatch to
customer
Wrong label / Part
Customer
dissatisfied
: 3.01.08
: TOOLROOM,QUALITY,MARKETING&PRODUCTION.
Pot. Cause(s) /
Mechanism of Failure
1.Operator skill
2.Operator
methodology
3.Operator
vision capability
Lighting
in Inspection
4.Operator
knowledge of
Area
Rejection methodology
stacking methodology of
parts in Bins
1.Bin cleanliness
2.Selection of
storage Bins
3.Quantity stacked
4.Duration of
storage of Parts
1.Operator skill
2.Operator
methodology
3.Operator
vision capability
4.Operator knowledge of
Rejection methodology
Current Process
Control
Prevention
Current Process
Control Detection
De
Rec.
RPN
t
Actions
Training to operators 3
45
Proper lighting near

the machine
42
Training to store
personnel
3 100%Visual &
Trainign to operators 4
Gauge check up / Inspectors
in final
inspection.
60
1.Operator knowledge on
Pack Quantity / Stacking
method
48
Stores personnel skill
Training to store
personnel
36
A Typer- Detect on failure HIC- High impact characteristics
FC-Functional charactistics
B Typer- Detect on failure cause BP- Blue print
IP - Inprocess product characteristics
Revision Date :
Process Responsibility:TOOLROOM
NOTE:
C Typer -Prevent on failure causeES- Engineering spercification
Occ
: GAJ 01
Respty and
target /
Comp. Date
Actio
n
S O D
taken
RPN
CONTROL PLAN
Prototyper
Pre-launch
Production
Control plan Number : SI/RF/Mech:1469
Key Contact / Phone
: Mr.M..MURUGAVEL
Part Name
Core Team
: TOOLROOM,QUALITY,MARKETTING&PRODUCTION.
: " INSERT "

Supplier Code
57372
Part /
Process
Machine,De
Process
Name/Operatio vice,Jigs,Tool
Numbe
n Description
s for Mfg
r
10
10. Incoming
Inspn. Of Raw
Material.
( Material IS 513 Grade
'DD' )
09344006009 , 09345202505
10.01 1.Correct Specification of

RM
2.Rust/Pit mark free

material
Revision Date :
Characteristics
Product
Rev No
:A
No
Date(Orig.):05.01.08
Process
1.Inspector training for
interpretation of replort
2.Operator knowledge
on repacking methodology
after inspcetion
3.Operator
skill to use measuring
instruments/ gauges
Sperci
al
Char.
Class
Plant / Location :Bright, Pondicherry
Methods
Product/Process
IS513GRADE:DD
Evaluation / Error
Measurement Proofin
Technique
g
Supplier test Nil
certificate
Size
Frequenc
y
As per Each lot

samplin
g plan
Control methods
Reaction
Plan /
Corrective
action
Resp.
Visual inspection on Reject the MAT & QA

raw material.
RM
Check as per
invoice while
unloading
Length:25003.0
20
20.Storage of
RM
Grade
of material
20.01 1.Correct
3.Correct
Report
with Moisture content in storage
area
every consignment
2.Correct
specification/size of
20.02 1.Length:12503.0
material
identifying / storage of RM
20.03
30
30.Strip
Shearing of
sheets
Shearing
machine
30.01
3.Rust
2.Width:70.0
prevention of 0.50
material
Material handling
methodology / Equipment
Duration of storage
1.Maintain stopper distance
55.00 mm
2.Operator
knowledge on identifying the
correct RM to be fed
40
40. Shell
forming &
Piercing
4.Appearance:Free from
burr, bend,twist,tool
Power
40.01 1.Outer dia-1: 54.00
mark&cut blank.
press&formi
0.20
ng&Piercing
tool
Visual check Nil
Every
time
Each lot
width:12503.0
Correct
identification
1.Length:12503.0
Alloted location
Length:25003.0
WI for material handling
Thick&
Equipment
As per FIFO
ness : 0.600.10
2.Width:70.0
0.50
Training to
Store
personnel
Training to
Store
personnel
Nil
one
time
Training Record
HR
Nil
one
time
As per
training
calender
As per
training
calender
Skill Record
Training Record
HR
Measuring
tape
Vernier
Micrometer.
Nil
Each
tray
Every
time
IN-process ins rep
Every
time
whenever Machine capacity

colour
record
changes
Nil
5 Nos
F.O.S.
IN-process ins rep
everyhou
r
Stop
&correct
Vernier
Nil
Micrometer.
Visual check
5 Nos
Once in
hour
IN-process ins rep
Stop
&correct
PRD
5 Nos
Once in
hour
IN-process ins rep
Stop
&correct
PRD
width:12503.0
PRD
Skill Record
Stop
&correct
PRD
3.Thick ness:
3.Thick ness: 0.60

30.02
IS513GRADE:DD
3.Cleanliness and condition of

Shearing machine
4.Capacity of the
machine
Forming locator symmetrical
to punch profile.
0.60
Thick
ness : 0.600.10
Visual check Nil
4.Appearance:Free
from burr, bend,twist,tool
mark&cut
blank.54.00 0.20 1.Vernier
1.Outer
dia-1:
PRD
2.Outer
2.Outer dia-2: 48.000.20
50
60
50.Facing
60.Deburring
Center lathe 50.01 1.Height Face:7.80 0.10
Belt grinder 60.01 Free from burr

M/C
3.Thickness:
0.60 0.10
dia-2: 48.000.20
Propper cariage stopper
distance.
Maintain belt performance
Free from burr

3.Thickness: 0.60 0.10
4.Height:7.800.10
4.Height:7.800.10
2.Appearance:free from tool
2.Appearance:free from tool

2.micro
meter.
Visual check Nil
CONTROL PLAN
Prototyper
Pre-launch
Production
Control plan Number : SI/RF/Mech:1469
Key Contact / Phone
: Mr.M..MURUGAVEL
Part Name
Core Team
: TOOLROOM,QUALITY,MARKETTING&PRODUCTION.
: " INSERT "

Supplier Code
57372
Part /
Process
Machine,De
Process
Name/Operatio vice,Jigs,Tool
Numbe
n Description
s for Mfg
r
70
80
90
70.First part &

Patrol
Inspection
80.Storage
after Pressing
in Bins in
station /
Inventory Area
90. 100%
Visual Final
Inspection
09344006009 , 09345202505
Characteristics
70.01 1.Accept Good Part

2.Reject Bad Part
2.Material
GRADE"DD"
6.Appearance: Free from

burr,bend,cutting
taper,rust,blow
holes&scratches.
Revision Date :
2.Operator
knowledge
on disposition
Lighting in Inspection
Area
methodology
2.Material
GRADE"DD"
Proper lighting in Inspection
area
rejection methodology
1.Operator skill
2.Operator
methodology
Plant / Location :Bright, Pondicherry
Methods
1.Operator skill
stacking methodology of parts
in Bins
3.Operator vision capability
80.02 4.Outer dia-2: 48.000.20 Bin Cleanliness
Selection of storage Bins
Quantity stacked
Duration of storage of parts
90.01
Sperci
al
Char.
Class
Product/Process
1.Thick ness:0.600.10
As per sample
Process
3.Outer dia-1: 54.00

80.01 Scratch
0.20
Damage
Warpage
Product
1.Thick ness:0.600.10
Rev No
:A
No
Date(Orig.):05.01.08
Training
to operator
3.Outer dia-1:
54.00 0.20
4.Outer
Evaluation / Error
Measurement Proofin
Technique
g
Visual check Nil
5.Height Face:7.80
6.Appearance: Free from
burr,bend,cutting
taper,rust,blow
holes&scratches.
Frequenc
y
3 shots Initial
Once in 2
hrs
Control methods
First Part Approval
Resp.
Reject the QA
part
Patrol Inspection
Visual check Nil
One
time
Per shift
QA
Nil
One
time
As per
Training Record
schedule
Skill Record
HR
Visual check Nil
One
time
Every
shift
STR
Vernier
Nil
Micrometer.
Visual check
100%
Each lot
F.I.R.
Visual check Nil
100%
Each lot
Visual Inspection
STR
Training to store
personnel
STR
dia-2: 48.000.20
0.10
Size
Reaction
Plan /
Corrective
action
Reject the QA
part
3.Operator vision
capability
100
100.Packaging
& Labelling
100
Quantity in dunnage
Correct selection of
dunnage
Correct standard label
110
110.Despatch
to customer
110
Correct shipment of Part /

Invoice / DC
1.Operator knowledge on Pack

Quantity / Stacking method
rejection methodology
As per packaging standard

M VOS 193 C

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M VOS 193 C

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Formati disponibili

Customer

Part name : OILSEAL

List of documents submitted

Engineering change documents

Customer engineering approval

Process flow diagram

Material performance test results

Initial process study

Measurement system analysis studies

Qualified labarotary documentation

Part submission Warrant

Appearance approval report

Bulk material requirement check list

Deviation and action plan

PPAP rev no.:

PPAP manual ref no

PPAP History Sheet

Date (original) : 13.09.2010

Drawing / Part no : VOS 193

10. A. Incoming Inspn. Of Raw

10. B. Incoming Inspn. Of Raw

10.C. Incoming Inspection of

Revision Date : NIL

Customer Ref. No : BSE 0300B - WK

Process flow no : BI / PF/ 193

Process Flow Diagram

Wrong Specification Material

20.Storage of Raw Material

1.Wrong Grade Material

30.Weighing of Mix Ingredients

1.Incorrect ingredients weight

40. Rubber Mixing

Core Team : Production / Quality /

1. I.D. : 44.10 0.10 mm

Weight of the Ingredients

Date (original) : 13.09.2010

Drawing / Part no : VOS 193

50. Compound testing

Process flow no : BI / PF/ 193

Variation in Rubber Hardness

Process Flow Diagram

Core Team : Production / Quality /

Minimum 12.5 N/mm

50. Compound testing

Specific Gravity variation.

50. Compound testing

Tensile Strength variation.

50. Compound testing

Over Cure of Rubber compound.

Revision Date : NIL

Customer Ref. No : BSE 0300B - WK

1) In correct/ Excess bonding layer

Dipping Chemical Specific Gravity.

Date (original) : 13.09.2010

Drawing / Part no : VOS 193

80. Rubber Cutting

Revision Date : NIL

Customer Ref. No : BSE 0300B - WK

Process flow no : BI / PF/ 193

1) Incorrect Rubber selection

Process Flow Diagram

Core Team : Production / Quality /

Date (original) : 13.09.2010