FMT. No.

:- F/PD/05
MODEL CLASS CRITICAL MAJOR MINOR CRITICAL GRADE A B C

Rev. No.:- 00
Part Name Roller (DID-420 AD) PROCESS QUALITY CONTROL SHEET (I)
Part No. 12035-DR-50
Eff. Date :- 01.11.2009
Customer DAIDO INDIA PVT.LTD.
Rev. No. 00
Page : 01 of 03
Rev. Date 24.07.12
BASIC FOR PRODUCTION CHANGE PARTS PURCHASED FROM OUTSIDE VENDOR

PROCESS FLOW DIAGRAM Critical Approval Test Prodn. Submit Ist

S.No. Process & Required checked Piece date S.No. Part No. Part Name Supplier
Description

Prime Source Sunflag

SAE 1018
A Raw Material
7.15~7.20 mm
B C 10 D
A Draw Bench Rohit Steels

10 OP.NO. 10 Forging Rohtas Fastener Pvt. Ltd.

R.M.Incomin R.M. Insp. R.M. Storage Forging Final Insp .

g

Packing &
Dispatch

DAIDO APPROVAL RFL APPROVAL

DATE NAME AUTHORISED SIGNATURE DATE MADE BY CHECKED BY APPROVED BY
LOT MARKING

26.08.17 Mr. Yuvraj Mr. Vikas Mr. Vijay Kumar

LOT CODE
 PROCESS QUALITY CONTROL SHE

PROTOTYPE PRE-LAUNCH PRODUCTION

Customer Part Name Roller (DID-420AD) CORE TEAM Contact No. Signature

Customer Part No. 12035-DR-50 Engg. (Mr. Vikas) +91-9728556410

Drg Rev. No./Date 00/24.07.2012 Q.A. (Mr. Gurumukh) +91-9515233005

Control Plan No. CP-SA-060 Prod. (Mr. Parveen) +91-9215444015

Control Plan Rev. No. 01 Q.A(HT). (Mr. Vijay) +91-9215444016

Sequence of Process

Important Item

QUALITY CHARACTERISTICS
Trouble Mode

Process Name/Equipment
Name(Name of Supplier)

No. Control Item Specified value Inspected by Inspection Method Sample Size

%C 0.15~0.20

%Si 0.30 Max.

Mill T.C., Third
Party & Inhouse
1 Grade : 1018 %Mn 0.0.60~0.90 Lab Engineer 1 Pc.
Spectro Report
Analysis.
%P 0.04 Max.

%S 0.05 Max.

2 Wire Size 7.15~7.20 mm Lab Engineer Micrometer 1 Pc.

Coating Thickness
3 Phosphate Coating 6 Micron Min. Lab Engineer 1 Pc.
Tester
PROTOTYPE PRE-LAUNCH PRODUCTION

Customer Part Name Roller (DID-420AD) CORE TEAM Contact No. Signature

Customer Part No. 12035-DR-50 Engg. (Mr. Vikas) +91-9728556410

Drg Rev. No./Date 00/24.07.2012 Q.A. (Mr. Gurumukh) +91-9515233005

Control Plan No. CP-SA-060 Prod. (Mr. Parveen) +91-9215444015

Control Plan Rev. No. 01 Q.A(HT). (Mr. Vijay) +91-9215444016

Sequence of Process

Important Item

QUALITY CHARACTERISTICS
Trouble Mode

Process Name/Equipment
Name(Name of Supplier)

No. Control Item Specified value Inspected by Inspection Method Sample Size

Scale,scratch, piping,bend,die mark,

4 Should not Present Lab Engineer Visual 1 Pc.
dent,pitting,rust & casting defects.

5 Wire Seam 0.06 mm Max. Lab Engineer Microscope 1 Pc.

Visual/Magnify
6 Macroetch Test C1R1S1~C2R2S2 Lab Engineer 1 Pc.
Glass
Visual/Magnify
7 Upset Test 66% Min. Lab Engineer 2 Pc.
Glass

8 Tensile Strength 38~45 Kg/mm2 Lab Engineer U.T.M 2 Pc.

Incomming
B Inspection of 9 % Elongation 22 Min. Lab Engineer U.T.M 2 Pc.
Raw Material
10 % Reduction in Area 60 Min. Lab Engineer U.T.M 2 Pc.

Rockwel Hardness
11 Surface Hardness Wire Core HRB-7 HRB Max. Lab Engineer 1 Pc.
Tester
Rockwel Hardness
12 Core Hardness Wire 90 HRB Max. Lab Engineer 1 Pc.
Tester
PROTOTYPE PRE-LAUNCH PRODUCTION

Customer Part Name Roller (DID-420AD) CORE TEAM Contact No. Signature

Customer Part No. 12035-DR-50 Engg. (Mr. Vikas) +91-9728556410

Drg Rev. No./Date 00/24.07.2012 Q.A. (Mr. Gurumukh) +91-9515233005

Control Plan No. CP-SA-060 Prod. (Mr. Parveen) +91-9215444015

Control Plan Rev. No. 01 Q.A(HT). (Mr. Vijay) +91-9215444016

Incomming
B Inspection of
Raw Material
Sequence of Process

Important Item

QUALITY CHARACTERISTICS
Trouble Mode

Process Name/Equipment
Name(Name of Supplier)

No. Control Item Specified value Inspected by Inspection Method Sample Size

13 Microstructure Wire Pearlite+Ferrite Lab Engineer Microscope 1 Pc.

Surface Hardness Rockwel Hardness

14 25 HRC Max. Lab Engineer 1 Pc.
As Quench Tester
Core Hardness Rockwel Hardness
15 25 HRC Max. Lab Engineer 1 Pc.
As Quench Tester
Microstructure
16 Intermediate Products Lab Engineer Microscope 1 Pc.
As Quench

17 Grain Size Above 5 Lab Engineer Microscope 1 Pc.

ABCD Thin 2 Heavy

18 Inclusion Rating Lab Engineer Microscope 1 Pc.
1.5 Max.

19 Wire Decarb(Complete) Nil Lab Engineer Microscope 1 Pc.

20 Wire Decarb(Partial) 0.10 Max.Partial Lab Engineer Microscope 1 Pc.

 FMT. No.:- F/PD/05
Rev. No.:- 00
TROL SHEET (II) 01.11.2009
Page 02 of 03

RFL Drg. No. SA060-F01

RFL Drg Rev. No. 01

RFL Drg Rev. Date 24.08.2017

CP Date (Origin) 30.10.2014

Latest CP Rev. No./Date 01/25.08.2017

CP Prepared By /Date 01 24.08.2017 Taper Note on Length added (ECN No. 1-177)

CP Approved By /Date CP Rev. No. CP Rev. Date CP Rev. Detail

CONTROL OF MANUFACTURING CONDITIONS

(Equipment, metal mold,fail-safe devices,hydraulic power,voltage,
temperature etc.)

Insp. Insp. Detail of

Inspection Frequency Data Form Control item Specified value Inspected by Data form
Method Freq. Process/Sketch

Heatwise

Each Coil

Each Coil
RFL Drg. No. SA060-F01

RFL Drg Rev. No. 01

RFL Drg Rev. Date 24.08.2017

CP Date (Origin) 30.10.2014

Latest CP Rev. No./Date 01/25.08.2017

CP Prepared By /Date 01 24.08.2017 Taper Note on Length added (ECN No. 1-177)

CP Approved By /Date CP Rev. No. CP Rev. Date CP Rev. Detail

CONTROL OF MANUFACTURING CONDITIONS

(Equipment, metal mold,fail-safe devices,hydraulic power,voltage,
temperature etc.)

Insp. Insp. Detail of

Inspection Frequency Data Form Control item Specified value Inspected by Data form
Method Freq. Process/Sketch

Each Coil

Each Coil

Per Heat
(Mill TC / Spectro)

Per Heat
F/LAB/01

Per Heat

Per Heat

Per Heat

Each Coil

Each Coil
RFL Drg. No. SA060-F01

RFL Drg Rev. No. 01

RFL Drg Rev. Date 24.08.2017

CP Date (Origin) 30.10.2014

(Mill TC / Spectro)
Latest CP Rev. No./Date 01/25.08.2017

F/LAB/01
CP Prepared By /Date 01 24.08.2017 Taper Note on Length added (ECN No. 1-177)

CP Approved By /Date CP Rev. No. CP Rev. Date CP Rev. Detail

CONTROL OF MANUFACTURING CONDITIONS

(Equipment, metal mold,fail-safe devices,hydraulic power,voltage,
temperature etc.)

Insp. Insp. Detail of

Inspection Frequency Data Form Control item Specified value Inspected by Data form
Method Freq. Process/Sketch

Per Heat

Each Coil

Each Coil

Per Heat

Per Heat

Per Heat

Per Heat

Per Heat
PROTOTYPE PRE-LAUNCH PRODUCTION

Customer Part Name Roller (DID-420AD)

Customer Part No. 12035-DR-50

Drg Rev. No./Date 00/24.07.2012

Control Plan No. CP-SA-060

Control Plan Rev. No. 01

Important Item
Trouble Mode

Process
Sequence of

Name/Equipm
Process

ent
Name(Name of
Supplier) No. Control Item

1 Outer Dia.
PROTOTYPE PRE-LAUNCH PRODUCTION

Customer Part Name Roller (DID-420AD)

Customer Part No. 12035-DR-50

Drg Rev. No./Date 00/24.07.2012

Control Plan No. CP-SA-060

Control Plan Rev. No. 01

Important Item
Trouble Mode

Process
Sequence of

Name/Equipm
Process

ent
Name(Name of
Supplier) No. Control Item

2 Total Length
PROTOTYPE PRE-LAUNCH PRODUCTION

Customer Part Name Roller (DID-420AD)

Customer Part No. 12035-DR-50

Drg Rev. No./Date 00/24.07.2012

Control Plan No. CP-SA-060

Control Plan Rev. No. 01

Important Item
Trouble Mode

Process
Sequence of

Name/Equipm
Process

ent
Name(Name of
Supplier) No. Control Item

3 Inner Dia.
PROTOTYPE PRE-LAUNCH PRODUCTION

Customer Part Name Roller (DID-420AD)

Customer Part No. 12035-DR-50

Drg Rev. No./Date 00/24.07.2012

Control Plan No. CP-SA-060

Control Plan Rev. No. 01

Important Item
Trouble Mode

Process
Sequence of

Name/Equipm
Process

ent
Name(Name of
Supplier) No. Control Item

Counter (Both
4 Sides)
PROTOTYPE PRE-LAUNCH PRODUCTION

Customer Part Name Roller (DID-420AD)

Customer Part No. 12035-DR-50

Drg Rev. No./Date 00/24.07.2012

Control Plan No. CP-SA-060

Control Plan Rev. No. 01

Important Item
Trouble Mode

Process
Sequence of

Name/Equipm
Process

ent
Name(Name of
Supplier) No. Control Item

Surface
5 Roughness on
Outer Dia.
PROTOTYPE PRE-LAUNCH PRODUCTION

Customer Part Name Roller (DID-420AD)

Customer Part No. 12035-DR-50

Drg Rev. No./Date 00/24.07.2012

Control Plan No. CP-SA-060

Control Plan Rev. No. 01

Important Item
Trouble Mode

Process
Sequence of

Name/Equipm
Process

ent
Name(Name of
Supplier) No. Control Item

Surface
6 Roughness on
Inner Dia.
FORGING
10
PROTOTYPE PRE-LAUNCH PRODUCTION

Customer Part Name Roller (DID-420AD)

Customer Part No. 12035-DR-50

Drg Rev. No./Date 00/24.07.2012

Control Plan No. CP-SA-060

Control Plan Rev. No. 01

Important Item
Trouble Mode

Process
Sequence of

Name/Equipm
Process

ent
Name(Name of
Supplier) No. Control Item
FORGING
10
(14B6S)
Roundness on
7 Outer Dia.
PROTOTYPE PRE-LAUNCH PRODUCTION

Customer Part Name Roller (DID-420AD)

Customer Part No. 12035-DR-50

Drg Rev. No./Date 00/24.07.2012

Control Plan No. CP-SA-060

Control Plan Rev. No. 01

Important Item
Trouble Mode

Process
Sequence of

FORGING
10 Name/Equipm
Process

(14B6S)
ent
Name(Name of
Supplier) No. Control Item

Roundness on
8 Inner Dia.
PROTOTYPE PRE-LAUNCH PRODUCTION

Customer Part Name Roller (DID-420AD)

Customer Part No. 12035-DR-50

Drg Rev. No./Date 00/24.07.2012

Control Plan No. CP-SA-060

Control FORGING
10Plan Rev. No. 01
(14B6S)

Important Item
Trouble Mode

Process
Sequence of

Name/Equipm
Process

ent
Name(Name of
Supplier) No. Control Item

9 Taper on Length
PROTOTYPE PRE-LAUNCH PRODUCTION

Customer Part Name Roller (DID-420AD)

Customer Part No. 12035-DR-50

FORGING
10 No./Date
Drg Rev. 00/24.07.2012
(14B6S)
Control Plan No. CP-SA-060

Control Plan Rev. No. 01

Important Item
Trouble Mode

Process
Sequence of

Name/Equipm
Process

ent
Name(Name of
Supplier) No. Control Item

Concentricity on
10 Inner Dia. W.r.t.
Outer Dia.
PROTOTYPE PRE-LAUNCH PRODUCTION
FORGING
10
(14B6S)
Customer Part Name Roller (DID-420AD)

Customer Part No. 12035-DR-50

Drg Rev. No./Date 00/24.07.2012

Control Plan No. CP-SA-060

Control Plan Rev. No. 01

Important Item
Trouble Mode

Process
Sequence of

Name/Equipm
Process

ent
Name(Name of
Supplier) No. Control Item

Microstructure &
11 Crack
 FORGING
10
(14B6S)

PROTOTYPE PRE-LAUNCH PRODUCTION

Customer Part Name Roller (DID-420AD)

Customer Part No. 12035-DR-50

Drg Rev. No./Date 00/24.07.2012

Control Plan No. CP-SA-060

Control Plan Rev. No. 01

Important Item
Trouble Mode

Process
Sequence of

Name/Equipm
Process

ent
Name(Name of
Supplier) No. Control Item

12 Appearance
 PROCESS QUALITY CONTROL SHEET (III)

RFL Drg. No. SA060

RFL Drg Rev.
CORE TEAM Contact No. Signature 01
No.
RFL Drg Rev.
Engg. (Mr. Vikas) +91-9728556410 24.08.2
Date
Q.A. (Mr.
+91-9515233005 CP Date (Origin) 30.10.2
Gurumukh)
Latest CP Rev.
Prod. (Mr. Parveen+91-9215444015 01/25.08
No./Date
Q.A(HT). (Mr. CP Prepared
+91-9215444016
Vijay) By /Date
CP Approved
By /Date

QUALITY CHARACTERISTICS

Inspection
Specified value Inspected by Inspection Method Sample Size Data Form
Frequency

At the time of
7.72~7.77 QA. Insp. Micrometer 5 Pcs. setting/Tooling
Change &/2Hrs.
 PROCESS QUALITY CONTROL SHEET (III)

RFL Drg. No. SA060

RFL Drg Rev.
CORE TEAM Contact No. Signature 01
No.
RFL Drg Rev.
Engg. (Mr. Vikas) +91-9728556410 24.08.2
Date
Q.A. (Mr.
+91-9515233005 CP Date (Origin) 30.10.2
Gurumukh)
Latest CP Rev.
Prod. (Mr. Parveen+91-9215444015 01/25.08
No./Date
Q.A(HT). (Mr. CP Prepared
+91-9215444016
Vijay) By /Date
CP Approved
By /Date

QUALITY CHARACTERISTICS

Inspection
Specified value Inspected by Inspection Method Sample Size Data Form
Frequency

At the time of
6.02~6.28 QA. Insp. Micrometer 5 Pcs. setting/Tooling
Change &/2Hrs.
 PROCESS QUALITY CONTROL SHEET (III)

RFL Drg. No. SA060

RFL Drg Rev.
CORE TEAM Contact No. Signature 01
No.
RFL Drg Rev.
Engg. (Mr. Vikas) +91-9728556410 24.08.2
Date
Q.A. (Mr.
+91-9515233005 CP Date (Origin) 30.10.2
Gurumukh)
Latest CP Rev.
Prod. (Mr. Parveen+91-9215444015 01/25.08
No./Date
Q.A(HT). (Mr. CP Prepared
+91-9215444016
Vijay) By /Date
CP Approved
By /Date

QUALITY CHARACTERISTICS

Inspection
Specified value Inspected by Inspection Method Sample Size Data Form
Frequency

At the time of
5.69~5.77 QA. Insp. PPG 5 Pcs. setting/Tooling
Change &/Hrs.

le.
 PROCESS QUALITY CONTROL SHEET (III)

RFL Drg. No. SA060

RFL Drg Rev.
CORE TEAM Contact No. Signature 01
No.
RFL Drg Rev.
Engg. (Mr. Vikas) +91-9728556410 24.08.2
Date
Q.A. (Mr.
+91-9515233005 CP Date (Origin) 30.10.2
Gurumukh)
Latest CP Rev.
Prod. (Mr. Parveen+91-9215444015 01/25.08
No./Date
Q.A(HT). (Mr. CP Prepared
+91-9215444016
Vijay) By /Date
CP Approved
By /Date

QUALITY CHARACTERISTICS

Inspection
Specified value Inspected by Inspection Method Sample Size Data Form
Frequency

ver applicable.
At the time of
setting/Tooling
0.30 x 45° QA. Insp. Pro. Proj. 2 Pcs.
Change &Once Per
Shift
 PROCESS QUALITY CONTROL SHEET (III)

RFL Drg. No. SA060

RFL Drg Rev.
CORE TEAM Contact No. Signature 01
No.
RFL Drg Rev.
Engg. (Mr. Vikas) +91-9728556410 24.08.2
Date
Q.A. (Mr.
+91-9515233005 CP Date (Origin) 30.10.2
Gurumukh)
Latest CP Rev.
Prod. (Mr. Parveen+91-9215444015 01/25.08
No./Date
Q.A(HT). (Mr. CP Prepared
+91-9215444016
Vijay) By /Date
CP Approved
By /Date

QUALITY CHARACTERISTICS

ation wherever applicable.

Inspection
Specified value Inspected by Inspection Method Sample Size Data Form
Frequency

Surface Roughness

F/QA/03)
Ra 1.6 QA. Insp. 5 Pcs.
Tester

A/02)
At the time of
setting/Tooling
Change & once per
 PROCESS QUALITY CONTROL SHEET (III)

RFL Drg. No. SA060

RFL Drg Rev.
CORE TEAM Contact No. Signature 01
No.
RFL Drg Rev.
Engg. (Mr. Vikas) +91-9728556410 24.08.2
Date
Q.A. (Mr.
+91-9515233005 CP Date (Origin) 30.10.2
Gurumukh)
Latest CP Rev.
Prod. (Mr. Parveen+91-9215444015 01/25.08
No./Date
Q.A(HT). (Mr. CP Prepared
+91-9215444016
Vijay) By /Date

e of observation wherever applicable.

CP Approved
By /Date

QUALITY CHARACTERISTICS

ion Report(F/QA/03)
Inspection

al Reprt(F/QA/02)
Specified value Inspected by Inspection Method Sample Size At the time of Data Form
Frequency
setting/Tooling
Change & once per
Surface Roughness shift
Ra 0.8 QA. Insp. 5 Pcs.
Tester
 PROCESS QUALITY CONTROL SHEET (III)

RFL Drg. No. SA060

RFL Drg Rev.
CORE TEAM Contact No. Signature 01
No.
RFL Drg Rev.
Engg. (Mr. Vikas) +91-9728556410 24.08.2
Date
Q.A. (Mr.
+91-9515233005 CP Date (Origin) 30.10.2

Max. range of observation wherever applicable.

Gurumukh)
Latest CP Rev.
Prod. (Mr. Parveen+91-9215444015 01/25.08
No./Date
Q.A(HT). (Mr. CP Prepared
+91-9215444016
Vijay) By /Date
CP Approved

cess Inspection Report(F/QA/03)

By /Date

ting Approval Reprt(F/QA/02)

QUALITY CHARACTERISTICS

Inspection
Specified value Inspected by Inspection Method Sample Size Data Form
Frequency

15 Micron Max. QA. Insp. Roundness Tester 5 Pcs.

Once Per Week

(Out Side)
 PROCESS QUALITY CONTROL SHEET (III)

RFL Drg. No. SA060

RFL Drg Rev.

tion Min. & Max. range of observation wherever applicable.

CORE TEAM Contact No. Signature 01
No.
RFL Drg Rev.
Engg. (Mr. Vikas) +91-9728556410 24.08.2
Date
Q.A. (Mr.
+91-9515233005 CP Date (Origin) 30.10.2
Gurumukh)
Latest CP Rev.

In Process Inspection Report(F/QA/03)

Prod. (Mr. Parveen+91-9215444015 01/25.08
No./Date

Setting Approval Reprt(F/QA/02)

Q.A(HT). (Mr. CP Prepared
+91-9215444016
Vijay) By /Date
CP Approved
By /Date

QUALITY CHARACTERISTICS

Inspection
Specified value Inspected by Inspection Method Sample Size Data Form
Frequency
Once Per Week
(Out Side)

12 Micron Max. QA. Insp. Roundness Tester 5 Pcs.

 PROCESS QUALITY CONTROL SHEET (III)

Note:- Mention Min. & Max. range of observation wherever applicable.

RFL Drg. No. SA060
RFL Drg Rev.
CORE TEAM Contact No. Signature 01
No.

In Process Inspection Report(F/QA/03)

RFL Drg Rev.
Engg. (Mr. Vikas) +91-9728556410 24.08.2

Setting Approval Reprt(F/QA/02)

Date
Q.A. (Mr.
+91-9515233005 CP Date (Origin) 30.10.2
Gurumukh)
Latest CP Rev.
Prod. (Mr. Parveen+91-9215444015 01/25.08
No./Date
Q.A(HT). (Mr. CP Prepared
+91-9215444016
Vijay) By /Date
CP Approved
By /Date

QUALITY CHARACTERISTICS

Inspection
Specified value Inspected by Inspection Method Sample Size Data Form
Frequency

At the time of
0.15 Max. QA. Insp. Puppy dial 5 Pcs. setting/Tooling
Change &/Hr.
 Note:- Mention Min. & Max. range of observation wherever applicab
PROCESS QUALITY CONTROL SHEET (III)

In Process Inspection Report(F/QA/03)

Setting Approval Reprt(F/QA/02)
RFL Drg. No. SA060
RFL Drg Rev.
CORE TEAM Contact No. Signature 01
No.
RFL Drg Rev.
Engg. (Mr. Vikas) +91-9728556410 24.08.2
Date
Q.A. (Mr.
+91-9515233005 CP Date (Origin) 30.10.2
Gurumukh)
Latest CP Rev.
Prod. (Mr. Parveen+91-9215444015 01/25.08
No./Date
Q.A(HT). (Mr. CP Prepared
+91-9215444016
Vijay) By /Date
CP Approved
By /Date

QUALITY CHARACTERISTICS

Inspection
Specified value Inspected by Inspection Method Sample Size Data Form
Frequency

At the time of
0.10 Max. QA. Insp. PPG & Puppy Dial 5 Pcs. setting/Tooling
Change &/Hr.
 Note:- Mention Min. & Max. range of observation where
In Process Inspection Report(F/QA/03)
Setting Approval Reprt(F/QA/02)
PROCESS QUALITY CONTROL SHEET (III)

RFL Drg. No. SA060

RFL Drg Rev.
CORE TEAM Contact No. Signature 01
No.
RFL Drg Rev.
Engg. (Mr. Vikas) +91-9728556410 24.08.2
Date
Q.A. (Mr.
+91-9515233005 CP Date (Origin) 30.10.2
Gurumukh)
Latest CP Rev.
Prod. (Mr. Parveen+91-9215444015 01/25.08
No./Date
Q.A(HT). (Mr. CP Prepared
+91-9215444016
Vijay) By /Date
CP Approved
By /Date

QUALITY CHARACTERISTICS

Inspection
Specified value Inspected by Inspection Method Sample Size Data Form
Frequency
Uniform Pearlite &
Ferrite Matrix &
At the time of
Crack not more than Microscope/Micro Hv
QA. Insp. 5 Pcs. setting/Tooling
0.20 mm Tester
Change &/4Hrs.
 In Process Inspection Report(
Note:- Mention Min. & Max. range of observ
Setting Approval Reprt(F/
PROCESS QUALITY CONTROL SHEET (III)

RFL Drg. No. SA060

RFL Drg Rev.
CORE TEAM Contact No. Signature 01
No.
RFL Drg Rev.
Engg. (Mr. Vikas) +91-9728556410 24.08.2
Date
Q.A. (Mr.
+91-9515233005 CP Date (Origin) 30.10.2
Gurumukh)
Latest CP Rev.
Prod. (Mr. Parveen+91-9215444015 01/25.08
No./Date
Q.A(HT). (Mr. CP Prepared
+91-9215444016
Vijay) By /Date
CP Approved
By /Date

QUALITY CHARACTERISTICS

Inspection
Specified value Inspected by Inspection Method Sample Size Data Form
Frequency
Burr,Dent,Chips,Cra
cks,Detrimental
At the time of
Seams,Pits,Folds,
QA. Insp./Operator Visual 10 Pcs. setting/Tooling
Laps,Scale & Scale
Change &/Hr.
Pockets etc. are not
allowed
 FMT. No.:- F/PD/05
Rev. No.:- 00
01.11.2009
Page 03 of 03
0-F01

01

8.2017

0.2014

08.2017

01 24.08.2017 Taper Note on Length added (ECN No. 1-177)

CP Rev. No. CP Rev. Date CP Rev. Detail

CONTROL OF MANUFACTURING CONDITIONS
(Equipment, metal mold,fail-safe devices,hydraulic power,voltage,
temperature etc.)
Inspection Inspection Detail of
Control item Specified value Inspected by Data form
Method Frequency Process/Sketch

Speed control F/QA/02

Speed 140 Pcs/Minute Sup./Op. Per Shift
Switch F/QA/03
 FMT. No.:- F/PD/05
Rev. No.:- 00
01.11.2009
Page 03 of 03
0-F01

01

8.2017

0.2014

08.2017

01 24.08.2017 Taper Note on Length added (ECN No. 1-177)

CP Rev. No. CP Rev. Date CP Rev. Detail

CONTROL OF MANUFACTURING CONDITIONS
(Equipment, metal mold,fail-safe devices,hydraulic power,voltage,
temperature etc.)
Inspection Inspection Detail of
Control item Specified value Inspected by Data form
Method Frequency Process/Sketch

Air Pressure 3 ~ 6 Kg/cm2 Sup./Op. Pressure Gauge Per Shift F/MNT/10

 FMT. No.:- F/PD/05
Rev. No.:- 00
01.11.2009
Page 03 of 03
0-F01

01

8.2017

0.2014

08.2017

01 24.08.2017 Taper Note on Length added (ECN No. 1-177)

CP Rev. No. CP Rev. Date CP Rev. Detail

CONTROL OF MANUFACTURING CONDITIONS
(Equipment, metal mold,fail-safe devices,hydraulic power,voltage,
temperature etc.)
Inspection Inspection Detail of
Control item Specified value Inspected by Data form
Method Frequency Process/Sketch
 FMT. No.:- F/PD/05
Rev. No.:- 00
01.11.2009
Page 03 of 03
0-F01

01

8.2017

0.2014

08.2017

01 24.08.2017 Taper Note on Length added (ECN No. 1-177)

CP Rev. No. CP Rev. Date CP Rev. Detail

CONTROL OF MANUFACTURING CONDITIONS
(Equipment, metal mold,fail-safe devices,hydraulic power,voltage,
temperature etc.)
Inspection Inspection Detail of
Control item Specified value Inspected by Data form
Method Frequency Process/Sketch
 FMT. No.:- F/PD/05
Rev. No.:- 00
01.11.2009
Page 03 of 03
0-F01

01

8.2017

0.2014

08.2017

01 24.08.2017 Taper Note on Length added (ECN No. 1-177)

CP Rev. No. CP Rev. Date CP Rev. Detail

CONTROL OF MANUFACTURING CONDITIONS
(Equipment, metal mold,fail-safe devices,hydraulic power,voltage,
temperature etc.)
Inspection Inspection Detail of
Control item Specified value Inspected by Data form
Method Frequency Process/Sketch
 FMT. No.:- F/PD/05
Rev. No.:- 00
01.11.2009
Page 03 of 03
0-F01

01

8.2017

0.2014

08.2017

01 24.08.2017 Taper Note on Length added (ECN No. 1-177)

CP Rev. No. CP Rev. Date CP Rev. Detail

CONTROL OF MANUFACTURING CONDITIONS
(Equipment, metal mold,fail-safe devices,hydraulic power,voltage,
temperature etc.)
Inspection Inspection Detail of
Control item Specified value Inspected by Data form
Method Frequency Process/Sketch
 FMT. No.:- F/PD/05
Rev. No.:- 00
01.11.2009
Page 03 of 03
0-F01

01

8.2017

0.2014

08.2017

01 24.08.2017 Taper Note on Length added (ECN No. 1-177)

CP Rev. No. CP Rev. Date CP Rev. Detail

CONTROL OF MANUFACTURING CONDITIONS
(Equipment, metal mold,fail-safe devices,hydraulic power,voltage,
temperature etc.)
Inspection Inspection Detail of
Control item Specified value Inspected by Data form
Method Frequency Process/Sketch
 FMT. No.:- F/PD/05
Rev. No.:- 00
01.11.2009
Page 03 of 03
0-F01

01

8.2017

0.2014

08.2017

01 24.08.2017 Taper Note on Length added (ECN No. 1-177)

CP Rev. No. CP Rev. Date CP Rev. Detail

CONTROL OF MANUFACTURING CONDITIONS
(Equipment, metal mold,fail-safe devices,hydraulic power,voltage,
temperature etc.)
Inspection Inspection Detail of
Control item Specified value Inspected by Data form
Method Frequency Process/Sketch
 FMT. No.:- F/PD/05
Rev. No.:- 00
01.11.2009
Page 03 of 03
0-F01

01

8.2017

0.2014

08.2017

01 24.08.2017 Taper Note on Length added (ECN No. 1-177)

CP Rev. No. CP Rev. Date CP Rev. Detail

CONTROL OF MANUFACTURING CONDITIONS
(Equipment, metal mold,fail-safe devices,hydraulic power,voltage,
temperature etc.)
Inspection Inspection Detail of
Control item Specified value Inspected by Data form
Method Frequency Process/Sketch
 FMT. No.:- F/PD/05
Rev. No.:- 00
01.11.2009
Page 03 of 03
0-F01

01

8.2017

0.2014

08.2017

01 24.08.2017 Taper Note on Length added (ECN No. 1-177)

CP Rev. No. CP Rev. Date CP Rev. Detail

CONTROL OF MANUFACTURING CONDITIONS
(Equipment, metal mold,fail-safe devices,hydraulic power,voltage,
temperature etc.)
Inspection Inspection Detail of
Control item Specified value Inspected by Data form
Method Frequency Process/Sketch
 FMT. No.:- F/PD/05
Rev. No.:- 00
01.11.2009
Page 03 of 03
0-F01

01

8.2017

0.2014

08.2017

01 24.08.2017 Taper Note on Length added (ECN No. 1-177)

CP Rev. No. CP Rev. Date CP Rev. Detail

CONTROL OF MANUFACTURING CONDITIONS
(Equipment, metal mold,fail-safe devices,hydraulic power,voltage,
temperature etc.)
Inspection Inspection Detail of
Control item Specified value Inspected by Data form
Method Frequency Process/Sketch
 FMT. No.:- F/PD/05
Rev. No.:- 00
01.11.2009
Page 03 of 03
0-F01

01

8.2017

0.2014

08.2017

01 24.08.2017 Taper Note on Length added (ECN No. 1-177)

CP Rev. No. CP Rev. Date CP Rev. Detail

CONTROL OF MANUFACTURING CONDITIONS
(Equipment, metal mold,fail-safe devices,hydraulic power,voltage,
temperature etc.)
Inspection Inspection Detail of
Control item Specified value Inspected by Data form
Method Frequency Process/Sketch
Part No: 95801-10095-00 Part Name.: Bolt Flange 10x95

Drg. No.: R0346-F01 Rev. No.: 00

Lot No.: Heat No.:

Sr. No. Parameters Specification Inspection Method

A Speed 140 Pcs/Minute Speed control Switch

B Air Pressure 3 ~ 6 Kg/cm2 Pressure Gauge

1 Length 95.00±0.50 Vernier

2 Head Height with Collar 9.20 Max. Vernier

3 TRD Length 27.50~28.50 Vernier

4 TRD 9.08~9.11 Micrometer

5 Hex Across Flat 13.78~13.98 Micrometer

6 Shank Dia. 9.76~9.96 Micrometer

7 Collar Dia 18.50±0.40 Micrometer

8 Collar Thickness 1.60±0.20 Micrometer

9 Hex Across Corner 15.5 Min. Vernier

10 Hex Length 6.90 Min. Vernier

11 Head Resses Dia 12.00 ~ Vernier

12 Head Resses Depth 1.50 ~ Vernier

Part No: 95801-10095-00 Part Name.: Bolt Flange 10x95

Drg. No.: R0346-F01 Rev. No.: 00

Lot No.: Heat No.:

Sr. No. Parameters Specification Inspection Method

13 Pointing Dia 7.30~7.60 Vernier

14 Flange Angle 10° Max Prof. Proj.

15 Angle(Across Flat) 30° Prof. Proj.

16 Transition Dia. 11.20 Max. Prof. Proj.

17 Pointing Angle 20°~25° Prof. Proj.

18 Pointing Length 1.74 Ref. Prof. Proj.

19 Under Head Radius R0.42~R0.58 Prof. Proj.

PDF
20 Stamp Visual
8.8
21 Shank Angle 15° Prof. Proj.

22 Radius under hex 1.30 Max. Prof. Proj.

23 Straightness 0.20 TIR Max. Dial or V-Block

24 Conc. On A/F w.r.t. Body 0.40 TIR Max. Dial or V-Block

Conc,on Collar Dia wrt

25 0.40 TIR Max. Dial or V-Block
Shank Dia

26 Runout of Bearing Face 0.15 TIR Max. Puppy Dial or V-Block

 Burr,Dent,Chips,Cracks,Detr
imental Seams,Pits,Folds,
27 Appearance Visual
Laps,Scale or Scale Pockets
etc. are not allowed

Disposition

Inspected By:
 ROHTAS FASTENERS (P) LTD.

IN-PROCESS INSPECTION REPORT

Machine No.:

Operation Name: Fo

Operator Name:

Sample Size Inspection Freq.

Once Per Shift

Once Per Shift

5 Pcs. Tooling Change or/2Hrs.

5 Pcs. Tooling Change or/2Hrs.

5 Pcs. Tooling Change or/2Hrs.

5 Pcs. Tooling Change or/2Hrs.

5 Pcs. Tooling Change or/2Hrs.

5 Pcs. Tooling Change or/2Hrs.

5 Pcs. Tooling Change or/2Hrs.

5 Pcs. Tooling Change or/2Hrs.

5 Pcs. Tooling Change or/2Hrs.

5 Pcs. Tooling Change or/2Hrs.

5 Pcs. Tooling Change or/2Hrs.

5 Pcs. Tooling Change or/2Hrs.

 ROHTAS FASTENERS (P) LTD.

IN-PROCESS INSPECTION REPORT

Machine No.:

Operation Name: Fo

Operator Name:

Sample Size Inspection Freq.

5 Pcs. Tooling Change or/2Hrs.

2 Pcs. Tooling Change or /Once Per Shift

2 Pcs. Tooling Change or /Once Per Shift

2 Pcs. Tooling Change or /Once Per Shift

2 Pcs. Tooling Change or /Once Per Shift

2 Pcs. Tooling Change or /Once Per Shift

2 Pcs. Tooling Change or /Once Per Shift

10 Pcs. Tooling Change or /Hrs.

2 Pcs. Tooling Change or /Once Per Shift

2 Pcs. Tooling Change or /Once Per Shift

5 Pcs. Tooling Change or /Hrs.

5 Pcs. Tooling Change or /Hrs.

5 Pcs. Tooling Change or /Hrs.

5 Pcs. Tooling Change or /Hrs.

10 Pcs. Tooling Change or /Hrs.

Accepted
 FMT No. :
Rev. No. :
Eff. Date:
Page

Date & Shift: Total Rejection:

Forging Material Grade: Detail of Rejection

QA Person Name:

Observations
 FMT No. :
Rev. No. :
Eff. Date:
Page

Date & Shift: Total Rejection:

Forging Material Grade: Detail of Rejection

QA Person Name:

Observations
Under Deviation :- Rejected :- X

Approved By:
 F/QA/03
01
25.09.2017
01 of 02

Total Rejection:
Detail of Rejection

Judgement
 F/QA/03
01
25.09.2017
02 of 02

Total Rejection:
Detail of Rejection

Judgement
 Rejected :- X

Approved By:
 ROHTAS FASTENERS (P) LTD.

SETTING APPROVAL REPORT

Part No: 95801-10095-00 Part Name.:Bolt Flange 10x95 Machine No.:
Drg. No.:R0346-F01 Rev. No.: 00 Operation Name: Forging
Lot No.: Heat No.: Operator Name:
Setting Done Time: Setting Time:

Sr. Inspection Observa

Parameters Specification
No. Method 1 2
1 Length 95.00±0.50 Vernier

2 Head Height with Collar 9.20 Max. Vernier

3 TRD Length 27.50~28.50 Vernier

4 TRD 9.08~9.11 Micrometer

5 Hex Across Flat 13.78~13.98 Micrometer

6 Shank Dia. 9.76~9.96 Micrometer

7 Collar Dia 18.50±0.40 Micrometer

8 Collar Thickness 1.60±0.20 Micrometer

9 Hex Across Corner 15.5 Min. Vernier

10 Hex Length 6.90 Min. Vernier

11 Head Resses Dia 12.00 ~ Vernier

12 Head Resses Depth 1.50 ~ Vernier

13 Pointing Dia 7.30~7.60 Vernier

14 Flange Angle 10° Max Prof. Proj.

15 Angle(Across Flat) 30° Prof. Proj.

16 Transition Dia. 11.20 Max. Prof. Proj.

17 Pointing Angle 20°~25° Prof. Proj.

18 Pointing Length 1.74 Ref. Prof. Proj.

 19 Under Head Radius R0.42~R0.58 Prof. Proj.

PDF
20 Stamp Visual
8.8

21 Shank Angle 15° Prof. Proj.

22 Radius under hex 1.30 Max. Prof. Proj.

23 Straightness 0.20 TIR Max. Dial & V-Block

24 Conc. On A/F w.r.t. Body 0.40 TIR Max. Dial & V-Block

Conc,on Collar Dia wrt

25 0.40 TIR Max. Dial & V-Block
Shank Dia

Puppy Dial & V-

26 Runout of Bearing Face 0.15 TIR Max.
Block

Burr,Dent,Chips,Cracks,De
trimental
Seams,Pits,Folds,
27 Appearance Visual
Laps,Scale & Scale
Pockets etc. are not
allowed
Remarks :

Inspected By: Approved By:

 FMT No. : F/QA/02
LTD. Rev. No. : 01
Eff. Date: 25.09.2017
PORT Page 01 of 01
Date & Shift:
Material Grade:
Inspector Name:
Setting Done By:
Observations
3 4 5 Judgement
 Disposition

Accepted
Under
Deviation
Rejected X
Approved By:
 PRODUCTION
Efficiency(%) MACHINE SETTINGS
WORKER M/C NO. SETTING ADJUST APPROVAL

MACHINE 1

OVERALL 2

HIGH EFFICIENCY OPERATORS 4

SR.
NAME % 5
NO.

1 6

2 7

3 8

LOW EFFICIENCY OPERATORS 10

SR.
NAME % 11
NO.

1 12

2 13

3 14

4 15

MATERIAL HOLD LOSSES

M/C. No. DUE TO %
PART NO OPERATOR

QTY. NO MATERIAL

REASON NO PLAN

OPERATOR M/C UNDER BREAKDOWN

UCTION
MACHINE SETTINGS
TOTAL

LOSSES
%