CHECKPOINTS
S.No. Item
Lever Comp, Brake Pedal
1 (Child part of Collapsible Brake Pedal)
- Lever, Brake Pedal No.1
- Lever, Brake Pedal No.2
2 Spring
3 Pedal Comp, Brake
4 Pedal Assy, Brake
5 Boss, Brake Pedal
Concern Points
To check % breakage surf in Lever, Brake Pedal No.1 (Boss mating area)
To check % breakage surf in Lever, Brake Pedal No.2 (Booster pin area)
Rivet Drawing Load checking methodology & other checkpoints/ control
Lever operating range - criteria/how to check for smooth movement of Lever
2 without limits of looseness
Lever operating range - 224° (example) - how to check & frequency of
checking (100% check/ sampling based)- TBD
Clearance b/w Lever1 & 2 (0.3mm max )- how to maintain & checking
method/inspection frequency
How to maintain shaft length 21.5 (+0.2) during welding and its checking
method
at Comp Level
Burr direction in Lever 1 / Lever 2 & its effect on clearance of 0.3mm / lever
rotation operating range.
Press tonnage/RM/Material of Punch/ Coating on Punch/ Die Clearance
* How inspection of lever 2
dimension is being done
* Maintenance schedule
* Inspection frequency
How to control grease application on spring
Check to control spring back action in Arm during Pressing & Robotic Welding
PY for child part miss e.g. E-Ring, Washer, Bush, Spring (EOL)
Requirement to check disengagement load b/w Lever 2 & Boss
Surface Roughness- how to maintain & check
Control to be implemented
*To control Fracture area 20% .
*Shaving process to be used.
*Impact of fine blanking process to be shared by vendor.
* To be checked in UTM. Frequency: First per lot (TBD)
* To be discussed in Tech review - Height of riveting and diameter to be
finalized with supplier by doing actual testing for confirmation of drawing
load. Gauge checking: F,M,L (TBD)
(may change based on development requirements, above is bare min)
* To be discussed in Tech review -100 % feeling check -Training to operator
(may change based on development requirements, above is bare min)
* To be discussed in Tech review -Measurement method & frequency to be
confirmed by supplier.
* Check using filler gauge. First 3 months - 100% check (TBD)
* Inspection frequency after 3 months: first, middle & last (TBD)
(may change based on development requirements, above is bare min)
* Fixture to be made in welding for dimension control.
Fixture concept to be shared by vendor in tech review.
(Robotic Welding concept to be shared)
* Inspection frequency: first, middle & last (TBD)
(may change based on development requirements, above is bare min)
* To be discussed in Tech review -Burr direction to be finalized with supplier
based on trials.
Following Information to be provided by vendor :
* Press tonnage of leve1 & 2:
* RM of die:
* Material of punch:
* Coating (any other surface treatment) on punch :
* Die clearance:
* Inspection Method: Plug gauge
* To be discussed in Tech review - Maintenance schedule
* Inspection frequency - FML/Lot (TBD)
* To be discussed in Tech review - Insertion of lever 2 into boss to be
controlled in axial direction only. Introduction of poka yoke. Vendor to share
concept.
(may change based on development requirements, above is bare min)
* To be discussed in Tech review - To be shared by vendor
* To be discussed in Tech review -To be shared by vendor
* To be discussed in Tech review - Pick up Poka yoke for E ring, bush, washer
(Sensor based).
* To be discussed in Tech review -Pressing of E-ring using special JIG so as to
ensure position. Sensor based control to ensure correct fitment position. To
be finalized with supplier in detail.
* To be discussed in Tech review - To be shared by vendor
* To be discussed in Tech review - To be shared by vendor