Apqp - DR SHFT

APQP DOCUMENTATION INDEX SHEET
Design goals ( Team and Program need dates )
I PLAN & DEFINE

Design goals ( Timing chart )
Product related requirements ( Product Information Data )
Team Feasibility Commitment
Manufacturing feasibility ( Capacity Planning )
Risk assessment sheet
Customer Specific Requirements
Special charecteristics
Raw Material requirements
Design FMEA
Reliability results
II PRODUCT DESIGN &
Design Review(s)
DEVELOPMENT
Diagnostic guidelines
Design for Manufacturing and Assembly
Design Verification
Subcontractor APQP Status
Engineering Drawings and Specifications
Product error proofing, as appropriate
Material specification
Drawing and Specification changes
PHASES
Drawings with numbered parameters

III PROCESS DESIGN AND
Process Flow Diagram

DEVELOPMENT
Process F.M.E.A
Measurement Systems Analysis
Pre-Lauch Control Plan
Product Tracebility.
Work Instructions
Packing Specifications
Production Control Plan ( Charecteristic matrix )
Production Trial Run

Production Validation Testing
IV PRODUCT & PROCESS
Production Part Approval ( PPAP with PSW )

Preliminary Process Capability Study
VALIDATION
Design verification plan

Program need dates
Product quality planning summary and sign off
Risk assessment sheet
Data for Quality,reliability,maintainability and measurability, results
of error proofing,methods of rapid detection and feedback of
product /process nonconformance
VALIDATI
IV PRODUCT &
Data for Quality,reliability,maintainability and measurability, results
of error proofing,methods of rapid detection and feedback of
product /process nonconformance
Production Part Approval

ASSESSMENT &
CORRECTIVE
V FEEDBACK
Customer feed back
ACTION Production validation and testing
Packaging evaluation.
Customer comment form
Quality function deployment
APPLCBLTY
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
APQP TEAM PLAN
BNR Exports,Bangalore
Part description : DRIVE SHAFT Original date : 02.05.09
Drawing no : C0713250 Rev no / Date : NIL
Rev no / date :ISSUE -10 / 24-10 - 2008 Page no : 1 of 1
Customer : MONOPUMPS Application : PUMP
CROSS FUNCTIONAL / MULTI DISCIPLINARY TEAM
Sl no CFT / MDT MEMBERS DESIGNATION DEPARTMENT CONTACT DETAILS

rajesh@bnr-group.com
1 Mr. Rajesh C.E.O Operations
Phone no
daniel@bnr-group.com
2 Mr. Ambi Daniel G.M Technical
Phone no
lekshman@bnr-group.com
3 Mr. Lekshman Divisional Manager PLP
Phone no
neel_vish@rediffmail.com
4 Mr. Neelakantan Consultant Systems
Phone no
Manufacturing@bnr-group.com
5 Mr.Shunmuganandam Engineer Design & Estimation
Phone no
quality@bnr-group.com
6 Mr.Dinesh Manager Quality
Phone no
Production@bnr-group.com
7 Mr.Lokesh Assistant Manager Production
Phone no
stores@bnr-group.com
8 Mr.Raghaventhiran Manager Stores
Phone no
9 Mr.Prakash Engineer Production
Phone no
10 Mr.Muruganandam Engineer C.N.C
Phone no
11 Ms.Usha Excecutive Trainee Production
Phone no
12 Mr.Muthukumaran Senior Engineer Quality
Phone no
13 Mr.Joel Inspector Quality
Phone no
Manufacturing@bnr-group.com
14 Mr.Nataraj Foreman Tool Room
Phone no
15 Mr.Prasanna Supervisor Production
Phone no
Purchase@bnr-group.com
16 Subramanya Manager Purchase
Phone no
Weekly Conference Call Time
International Day
Participant Code Date

Page 6 of 60
25.06.09 Rev. No.: 00

APQP - TIMING PLAN
BNR Exports,Bangalore Updated on :
RESPONS PLAN ACTUAL

S.No ACTIVITY G/Y/R STATUS REMARKS
-IBILITY START COMPLETE START COMPLETE
Drive Shaft C0713250

STAGE:1 PLAN AND DEFINE PROGRAM
1.1 Customer inputs
1.1.1 Component Drawing G Ambi Daniel 4.05.09 4.05.09 4.05.09 4.05.09
1.2 APQP Team formation G Ambi Daniel 4.05.09 4.05.09 4.05.09 4.05.09
Lekshman/
Prepare Product Information
1.3 G Shivakumar/ 5.05.09 5.05.09 5.05.09 5.05.09
Data
Neelakantan
1.4 Team Feasibility Commitment G Rajesh 5.05.09 5.05.09 5.05.09 5.05.09
1.5 Risk analysis G Rajesh 6.05.09 08.05.09 6.05.09 8.05.09

Customer Specific
1.6 G Lekshman 8.05.09 8.05.09 8.05.09 8.05.09
Requirements
Identification of Special
1.7 G Ambi Daniel 11.05.09 11.05.09 11.05.09 11.05.09
Characteristics
Identification of Gauge and
1.8 G Lokesh / Dinesh 11.05.09 11.05.09 11.05.09 11.05.09
Testing Equipment
1.9 Design Inputs
1.9.1 Design concept approval G
3D Modelling & 2D Drawings

1.9.2 G NOT APPLICABLE
Preparation
1.9.3 Drawing release G
STAGE: 2 PROCESS DESIGN AND DEVELOPMENT
2.1 Process Flow Diagram G Dinesh / Lokesh 11.05.09 11.05.09 11.05.09 11.05.09
2.2 Charactertics Matrix G Muthukumar 11.05.09 11.05.09 11.05.09 11.05.09
2.3 Process FMEA G Dinesh / Lokesh 11.05.09 12.05.09 11.05.09 12.05.09

Finalisation of Special
2.4 G Ambi Daniel 11.05.09 11.05.09 11.05.09 11.05.09
characteristics
2.5 Gage design and development
Finalisation of Gauge and Ambi Daniel /
2.5.1 G 11.05.09 11.05.09 11.05.09 11.05.09
testing equipment. Dinesh
Lekshman /
2.5.2 Sending enquiry to suppliers G 11.05.09 11.05.09 11.05.09 11.05.09
Subramanya
Lekshman /
2.5.3 Supplier Finalisation G 11.05.09 11.05.09 11.05.09 11.05.09
Subramanya
Dinesh /
Procurement of gauge and
2.5.4 G Muthukumaran 11.05.09 11.05.09 11.05.09 11.05.09
testing equipment
Development of subcontractor
2.6 NOT APPLICABLE
Process
2.7 Mistake Proofing R Lokesh / Prakash 11.05.09 11.05.09 11.05.09 11.05.09
Manufacturing process design

2.8 G Lokesh / Prakash 25.06.09 30.08.09 25.06.09 17.08.09
and development verification
Traceability for product /

Prasanna /
2.90 manufacturing process non G 25.06.09 30.08.09 25.06.09 17.08.09
Muthukumaran
conformities
2.10 Pre-launch control Plan G Muthukumaran 13.05.09 13.05.09 13.05.09 13.05.09
2.11 Work Instructions

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APQP - TIMING PLAN
RESPONS PLAN ACTUAL

2.11.1 Work instruction for cutting G Neelakantan 13.05.09 13.05.09 13.05.09 13.05.09
Work instruction for CNC
2.11.2 G Neelakantan 13.05.09 13.05.09 13.05.09 13.05.09
Turning
Work instruction for CNC
2.11.3 G Neelakantan 13.05.09 13.05.09 13.05.09 13.05.09
Milling
Work Instructions for
2.11.4 G Neelakantan 13.05.09 13.05.09 13.05.09 13.05.09
Conventional
2.11.5 Work Instructions for Packing G Neelakantan 13.05.09 13.05.09 13.05.09 13.05.09
2.12 Packing Specification

Packing Specification
2.12.1 G Lekshman 01.08.09 01.08.09 01.08.09 01.08.09
preparation
2.12.2 Packaging sign off approval G Lekshman 17.08.09 17.08.09 17.08.09 17.08.09
Tool Mfg - Holding fixture
2.13
CNC turning
2.13.1 Raw material G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
2.13.2 Premachining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
2.13.3 Heat treatment G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
2.13.4 Final machining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09
Nataraj /
2.13.5 Assembly and Try out G 11.05.09 11.05.09 11.05.09 11.05.09
Prakash
Prakash /
2.13.6 Inspection and ready for trial G 11.05.09 11.05.09 11.05.09 11.05.09
Muthukumar
Tool Manufacturing - Drill jig

2.14
-1
Nataraj /
Prakash
Prakash /
Muthukumar
Tool Manufacturing - Drill jig
2.15
-2
Nataraj /
Prakash
Prakash /
Muthukumar
STAGE : 3 MANUFACTURING PROCESS VALIDATION
3.1 Trial I
3.1.1 Cutting G Prasanna 25.06.09 25.06.09 25.06.09 25.06.09

C.Prakash/
3.1.3 CNC Turning 1st Operation G 11.07.09 11.07.09 11.07.09 11.07.09
Muruganantham
C.Prakash/
3.1.4 CNC Turning 2nd Operation G 16.07.09 16.07.09 16.07.09 16.07.09
Muruganantham
C.Prakash/
3.1.5 CNC Turning 3rd Operation G 21.07.09 21.07.09 21.07.09 21.07.09
Muruganantham
C.Prakash/
3.1.6 CNC Turning 4 th operation 23.07.09 23.07.09 23.07.09 23.07.09
Muruganantham
Page 8 of 60
25.06.09 Rev. No.: 00

APQP - TIMING PLAN
RESPONS PLAN ACTUAL

C.Prakash/
3.1.7 CNC Turning 5 th operation 28.07.09 28.07.09 28.07.09 28.07.09
Muruganantham
3.1.6 Cross hole drill and Reaming G Jaganath 28.07.09 28.07.09 28.07.09 28.07.09
C.Prakash/
3.1.7 CNC Turning 6 th Operation G 29.07.09 29.07.09 29.07.09 29.07.09
Muruganantham
3.1.8 Rethreading G Lokesh/Nataraj 30.07.09 30.07.09 30.07.09 30.07.09
3.1.9 Deburring G Lokesh/Nataraj 30.07.09 30.07.09 30.07.09 30.07.09
3.2.0 Final inspection G Muthukumar 31.07.09 31.07.09 31.07.09 31.07.09
3.2.1 Assembly G Lokesh/Nataraj 17.08.09 17.08.09 17.08.09 17.08.09
3.2.2 Cleaning and Packing G Lokesh/Nataraj 17.08.09 17.08.09 17.08.09 17.08.09

Lekshman and
3.2.3 Despatch G 19.08.09 19.08.09 19.08.09 19.08.09
Raghaventhiran
STAGE: 4 PPAP DOCUMENTATION
4.2 MSA Study G Muthukumar 13.07.09 13.07.09 2.07.09 02.07.09
4.3 Ppk Study G Muthukumar 17.07.09 22.07.09 17.07.09 22.07.09
4.4 Final inspection G joel karkada 31.07.09 31.07.09 31.07.09 31.07.09
4.5 PPAP Document Preparation G Muthukumar 31.07.09 31.07.09 31.07.09 31.07.09
STAGE : 5 FEEDBACK ASSESMENT AND CORRECTIVE ACTION
5.1 Customer approval of PPAP
5.2 Commence Bulk Production

Resolution of quaility, Delivery
5.3
Issue
5.4 Managemenet Review
LEGEND
S.NO STATUS DESCRIPTION Colour Revision Details: DESCRIPTION
1 G- GREEN - COMPLETED 1 Rev 1 : APQP Timing plan is updated to the Micro Level
2 Y - YELLOW - INPROGRESS 2 Rev 2 : Trial date is revised
3 R - RED - DELAY 3 Rev 3 : Trial date is revised
Team Members Signature

CUSTOMER MONOPUMPS
TEAM FEASIBILITY COMMITMENT
BNR Exports,Bangalore DATE 2/5/2009
PART NAME DRIVE SHAFT REV DATE
PART NO C 07 13250 ISSUE 10 DATE 24-10-2008

Our product quality planning team has considered the following questions, not intended to be all-inclusive in performing a feasibility evaluation. The drawings and/or
specifications provided have been used as a basis for analyzing the ability to meet all specified requirements. All “NO” answers are supported with attached comments
identifying our concerns and/or proposed changes to enable us to meet the specified requirements
SL NO CONSIDERATIONS BASIS FOR REVIEW Y/N REMARKS
Is product adequately defined Product Drawing, Customer Specific

Requirements if any, Contract Review
1 check list Y
Can Engineering Performance Specifications be met as written? Product Drawing, Customer Specific
Requirements if any,
2 Contract Review check list Y
Can the Product be manufactured with Cpk’s that meet Customer Drawing
requirements Special Characteristics List
3 Contract Review Check List Y
SPC Study Reports
Is SPC used on similar products and when SPC used are the Customer Drawing
processes in control and Stable ( Cpk’s greater than 1.33) Special Characteristics List
4 Contract Review Check List Y
SPC Study Reports
Is there adequate capacity to produce product? Capacity Matrix
5 Y
Can the product be manufactured without incurring unusual cost Customer Drawing
for capital equipment / tooling alternative manufacturing methods Customer Specific requirements if any
6 Contract review check list Y
Capacity Matrix
Is Gauges / test equipment are compatible to meet the product Tool andControl
Existing Equipment
Plan,List
requirements Bill of material
Gauges and Test Equipment List, MSA
7 Study reports Y
Is raw material requirements feasible Approved Supplier List

Raw Material Specifications
8 Incoming Inspection Control Plan Y
Is Equipment, Tooling and Facility requirements compatible to Existing Control Plan,

meet the Product Requirements Process Flow Chart
9 Equipment and Tooling List Y
Capacity Matrix
Is there any requirement of special skills Skill Matrix
10 N
Is delivery Requirements Feasible Capacity Matrix

11 Y
Shiva kumar.B Neelakantan Ambi Daniel
PREPARED BY CHECKED BY APPROVED BY

CAPACITY PLANNING
BNR Exports
PART NAME DRIVE SHAFT PART NO: C 0713250
CUSTOMER MONOPUMPS REV NO : ISSUE 10 REV DATE : 24-10-2008
TOTAL CAPACITY FREE CAPACITY REQUIRED CAPACITY

S.NO PROCESS NAME MACHINE NAME
UOM HOURS / MONTH UOM HOURS / MONTH UOM HOURS / MONTH
1 CUTTING 3 machines 1131 Hours 452 AVAILABLE
2 PRE MACHINING 3 lathes 1131 Hours 452 AVAILABLE
3 CNC TURNING 18 Machines 6660 3555 AVAILABLE
CONVENTIONAL
4 DRILLING & 5 machines 1885 754 AVAILABLE
REAMING
5 MANUAL ASSEMBLY 2 Work stations 754 301 AVAILABLE
6 CLEANING PACKING 1 Work stations 377 150 AVAILABLE
Note:

DATE: 03/05/09
0-2008
REMARKS
mbi Daniel
Page 13 of 60
Date : 04 / 05 / 09
RISK ASSESSMENT CHECK LIST
BNR Exports Bangalore
CUSTOMER : M/S MONOPUMPS

PRODUCT : DRIVE SHAFT / C 0713250
APPLICATION : PUMP
MEMBERS PRESENT : Rajesh, Daniel, Neelakantan, Lokesh, Dinesh, Raghaventhiran, Prakash, Lekshman, Subramanya and Murugana
STEP NO. DESCRIPTION High High
1 QUALITY HISTORY :-
1.1 Does the products application have a high warranty or things gone Wrong on
current model or similar models?
1.2 Are there frequent quality rejects at the receiving plant for similar products?
1.3 Was there a recall action due to a similar component or system?
2 SUPPLIER PROFILE :-
2.1 Does it require new material and supply source?
2.2 Is the product or manufacturing technology new to the supplier and his
manufacturing location?
2.3 How is the supplier’s earlier performance is satisfied in the similar materials?
3 ENGINEERING PROFILE :-
3.1 Is it a new design?
3.2 Are the manufacturing techniques new to us?
3.3 Are similar products subjects to numerous design changes that threaten program
timing?
Page 14 of 60
Date : 04 / 05 / 09
3.4 Is there high product or process complexity?
3.5 Is the product strategically important due to high visibility or functional

performance?
4 POTENTIAL – PROFILE :-
4.1 Does it require higher investments for development and regular production?
Justifiable?
4.2 Volume regularity assurable? Long term contracts possible?
4.3 Can competition follow this easily?
4.4
Technological obsolescence possibility is there?
Page 15 of 60
Date : 04 / 05 / 09
5 PRODUCT PERFORMANCE VERSUS TARGETS :-
5.1 Will the design goals (functional performance) and reliability goals be difficult to
achieve?
5.2 Will the quality goals (warranty, scrap rates, rework PPM etc.) be difficult to
achieve?
5.3 Is the program timing compressed?
5.4 Are the cost targets aggressive?
5.5 Manufacturing productivity targets justifiable and achievable in-line with volume
requirements?
NATURE in No.s
HIGH RISK : 0
MEDI RISK : 13
LOW RISK: 7
20
CONCLUSION BY C F T : Moderate risk item if not handled carefully during the process might get
ACTION PLANNED :- ( BASED ON HIGH RISK ELEMENTS ) :

Page 16 of 60
Date : 04 / 05 / 09
SSMENT CHECK LIST
nthiran, Prakash, Lekshman, Subramanya and Muruganandam.

Medium Low
√
Page 17 of 60
Date : 04 / 05 / 09
SSMENT CHECK LIST
√
Page 18 of 60
Date : 04 / 05 / 09
SSMENT CHECK LIST
in No.s in %
0 0
13 65
7 35
100
dled carefully during the process might get converted to high risk item.
BNR Exports CUSTOMER SPECIFIC REQUIREMENT SHEET
Customer: Mono Pumps Ltd., UK
Date: 22.09.2008
Requirements Originator
Special Manufacturing /Technical Requirements:

1 Allen Bolts assembled in Drive Shafts must be applied with Production
Locktite on top 50% of the threaded portion and back face
of the bolt head.
Special Handling Requirements:

1 Nil
Special Marking Requirements:

1 Part numbers on all Muncher Half Couplings must be
engraved on each part. Production
Special Packaging and Preservation:

1 All the parts other than Muncher Half Couplings must have the
label with Part number pasted on the packed product Logistics
2 Universal Joint assemblies threads must be protected with
Plastic caps Logistics
Special Delivery Requirements:

1 Goods are sent by sea freight unless specified in PO or Logistics
a separate communication by customer
2 Wood packaging material must be fumigated before despatch
by Freight forwarder Customer
3 Due date in PO is at UK, deduct 6 weeks for shipping Logistics
4 Each case must be pasted with a label consisting PO Number Logistics
5 Delivery Terms: Incoterms 2000: Ex Works Logistics
6 Destination Airport: Manchester, UK
Destination Seaport: Felexstowe, UK Logistics
7 Nominated Freight Forwarder: DSV Sea & Air Logistics Logistics
Special Documentation Requirements:

1 Submit GSP certificates for each consignment Logistics
Prepared by Reviewed by: Approved by
SPECIAL CHARACTERISTICS
BNR Exports - Bangalore
PART NAME : DRIVE SHAFT PART NO.: C 0713250 Rev / Issue : 10
CUSTOMER M/S MONOPUMPS Family / Group Pump REV DATE: 24.10.2008
DRAWI
S.NO NG DESCRIPTION SPECIFICATION INSTRUMENT REMARKS
S.NO
1 1 Outside Diameter 65.00 / 64.98 Micrometer
2 4 Bore Diameter 40.05 / 40.03 Bore gauge / Plug gauge
3 5 Concentricity 0.03 w.r.t. A Dial indicator with stand
4 11 Outside Diameter 69.8 / 69.75 Micrometer

DOC NO : BNR / PFD / 01
PROCESS FLOW DIAGRAM DATE : 11.05.09
BNR Exports REV NO : 0
PART NAME DRIVE SHAFT
CUSTOMER MONOPUMPS
PART NO C 0713250 REVISION LEVEL / DATE - : ISSUE -10 / 24-10 - 2008
METHOD OF
INCOMING SOURCE OF OPERATION
PROCESS FLOW MACHINE MOVEMENT IN OUTCOME
VARIATION DESCRIPTION
STATION
RECEIPT OF RAW
--- - - -
01 MATERIAL
Visual defects
Bar Diameter O/S & U/S . 02 RAW MATERIAL Correct Raw material
- -
Qty -Weight/ Nos / INSPECTION inward
Spec are not matching
03 BAND SAW CUTTING

Dimensional / Visual deviations CUTTING MANUAL Accepted cut pieces
01 / 02
04 Accepted premachined
Dimensional / Visual deviations PRE-MACHINING Conventional lathe BINS
components
05 Accepted components for

Dimensional / Visual deviations CNC First Operation 108 / 03 BINS
second operation
06 CNC Second Accepted components for

Dimensional / Visual deviations 108 / 04 BINS
Operation Third operation
07 CNC Third Accepted components for

Dimensional / Visual deviations PUMA -01 BINS
Operation Fourth operation
Variation in Hole sizes and CNC Fourth ( First

Positional dimensions / Cross hole ) 108 / 01 BINS
CNC Fifth operation.
Dimensional / Visual deviations. Operation
Variation in Hole sizes and CNC Fifth ( Second Accepted components for
Positional dimensions / 09 Cross hole ) 108 / 01 BINS Conv drilling & Reaming
Dimensional / Visual deviations. Operation operation.
Variation in Hole sizes and

10 Conventional Drilling Accepted components for
Positional dimensions / Conventional BINS
and Reaming CNC sixth operation.
Dimensional / Visual deviations.
11 CNC sixth ( ID & OD Accepted components for

Dimensional / Visual deviations PUMA -01 BINS
finish ) operation retapping operation

Gauge not answering / Damages Rethreading Manual BINS
Deburring operation

Visual Defects / Inclusions Deburring Manual BINS
Final inspection
14 Manual / Instruments / Accepted components for

Dimensional / Visual deviations Final inspection BINS
Gauges / Visual Assembly
Non assembly / Mismatch / 15 Accepted Assemblies for

Assembly Manual BINS
Damages Cleaning ,Packing.
CLEANING & O K packed Assemblies to

Improper Cleaning & Packing Manual BINS and Crates
14&15
16&17 PACKING Despatch
18
Wrong mode of despatch / Acceptable Assemblies for
DESPATCH Manual Wooden Crates
Improper documentation Customer.
OPERATION INPUT OPERATION CUM INSPECTION
LEGEND
LEGEND
INSPECTION OUTPUT
SHEET 1 OF 1

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
(PFMEA)
Part No C O713250 Process Responsibility Mr. Rajesh B.M - C.E.O
Part Name DRIVE SHAFT Key Date 12.05.09
Drg Rev No/ Date Issue 10 24 - 10 - 2008
Core Team Members Mr.Daniel, Neelakantan, Lokesh, Dinesh, Muthukumar, Prakash, Muruganandam and Shivakumar.
Current Process Control

O
S
Process Process Function / C L Potential Cause(s) / C
Potential failure mode Potential Effect(s) of Failure e
No Requirements S Mechanism of Failure Prevention
v
R
Machinibility poor,Surface finish Wrong shipment from Provide training to

poor,Reduce functional life supplier end operator
Chemical composition,Hardness,
Microstructure, Decarb Level,
Inclusion Rating & Grain Size-Not
meeting the Specifications Machining difficulties and reduced Wrong shipment from
8 6 Educate the suppliers
Raw Material tool life, Increased Process time supplier end
1&2 Receiving and
Inspection
Wrong shipment from
Diameter U/S Cannot be used Educate the suppliers
supplier end
Wrong shipment /
Delay in production and Machining
Visual Defects 7 Improper handling from 4 Educate the suppliers
difficulties
supplier end
Machining difficulties and reduced Improper stopper setting Operator training / Set
Cutting length O/S
tool life, Increased Process time / Loading up approval
3 CUTTING 8 5
Improper stopper Operator training / Set
Cutting length U/S Cannot be used
setting / Loading up approval
Wrong program / setting

Machining difficulties and reduced
Work Instructions /
Dimensions O/S tool life, Increased Process time / wrong tooling
Set-Up Approval
ID oversize cannot be used.
Machine capability
5
wrong program / setting
Cannot be used / ID undersize
4.00 Pre- Machining 8 Work Instructions /
Dimensions U/S Machining difficulties and reduced wrong tooling
Set-Up Approval
tool life, Increased Process time
Machine capability
Delay in production and Machining Machining and Handling Handling instructions

Visual Defects 4
difficulties / Cannot be used. deviations and visual displays

Work Instructions /
Set-Up Approval
Machine capability
5
CNC FIRST Cannot be used / ID undersize
5.00 8 Work Instructions /
OPERATION Dimensions U/S Machining difficulties and reduced wrong tooling
Set-Up Approval
Machine capability

Visual Defects 4

Work Instructions /
Set-Up Approval
8 5
CNC SECOND
6.00
OPERATION
Work Instructions /
Dimensions O/S tool life, Increased Process time /
Set-Up Approval
Machine capability
8 5
Work Instructions /
Set-Up Approval
Machine capability
OD - 69.80 /69.75 oversize tool life, Increased Process time. /
Fitment problem at customer end Wrong program / setting Work Instructions /
CNC SECOND
6.00
OPERATION *** / Tooling / Machine Set-Up Approval /
Cannot be used / Fitment problem at capability PPk / CPk studies
OD - 69.80 /69.75 under rsize
customer end.
8 5
Cannot be used / Fitment problem at
Bore dia - 51.08 /51.13 oversize
customer end. Wrong program / setting Work Instructions /
Machining difficulties and reduced *** / Tooling / Machine Set-Up Approval /
capability PPk / CPk studies
Bore dia - 51.08 /51.13 undersize tool life, Increased Process time. /
Fitment problem at customer end

Visual Defects 8 4
Machining difficulties and reduced Wrong program / setting

tool life, Increased Process time / Work Instructions /
Dimensions O/S wrong tooling
ID / Groove width oversize cannot Set-Up Approval
be used. Machine capability
5
Cannot be used / ID / Groove wrong program / setting
CNC THIRD
7.00 width undersize Machining 8 Work Instructions /
OPERATION Dimensions U/S wrong tooling
difficulties and reduced tool life, Set-Up Approval
Increased Process time Machine capability

Visual Defects 4

8 5
width undersize Machining Work Instructions /
Dimensions U/S wrong tooling
CNC FOURTH Increased Process time Machine capability
8.00
OPERATION
Hole dia - 30.03 /29.99 oversize
Machining difficulties and reduced 8 *** / Tooling / Machine 5 Set-Up Approval /
Hole dia - 30.03 /29.99 under size tool life, Increased Process time. / capability PPk / CPk studies

Visual Defects 8 4

8 5
width undersize Machining Work Instructions /
CNC FIFTH Increased Process time Machine capability
9.00
OPERATION
Hole dia - 19.12 / 19.09 oversize
Machining difficulties and reduced 8 *** / Tooling / Machine 5 Set-Up Approval /
Hole dia - 19.12 / 19.09 undersize tool life, Increased Process time. / capability PPk / CPk studies

Visual Defects 8 4

Cannot be used / Fitment problem Work Instructions /
Hole dia O/S wrong tooling
at customer end Set-Up Approval
Machine capability
Machining difficulties and reduced Work Instructions /
Hole dia U/S wrong tooling
tool life, Increased Process time Set-Up Approval
Machine capability
5
CROSS HOLE Wrong program / setting
10.00 DRILLING AND Cannot be used / Fitment problem 8 Work Instructions /
REAMING (CONV) at customer end Set-Up Approval
Machine capability
Cannot be used / Fitment problem Work Instructions /
at customer end Set-Up Approval
Machine capability
Visual Defects 4

Work Instructions /
Set-Up Approval
Machine capability
8 5
Work Instructions /
Set-Up Approval
Machine capability
OD - 64.98 / 65.00 oversize tool life, Increased Process time. /
Fitment problem at customer end Wrong program / setting Work Instructions /
11.00
CNC SIXTH *** / Tooling / Machine Set-Up Approval /
OPERATION Cannot be used / Fitment problem at capability PPk / CPk studies
OD - 64.98 / 65.00 under rsize
customer end.
Cannot be used / Fitment problem at 5

Bore dia - 40.05 / 40.03 oversize
8 *** / Tooling / Machine Set-Up Approval /
capability PPk / CPk studies
Bore dia - 40.05 / 40.03 undersize tool life, Increased Process time. /
wrong program /
Work Instructions /
Cannot be used / Fitment problem at setting / Tooling /
Concentricity 0.03 wrt A (Reference)
customer end. *** Machine capability / skill
Set-Up Approval /
PPk / CPk studies
level
Visual Defects 4
Machining difficulties and reduced Skill / Knowledge

Thread gauge not answering ie GO Work Instructions /
tool life, Increased Process time./ wrong tooling
and NO GO both ends not entering Set-Up Approval
Fitment problem at customer end. wrong gauges
5
RE - THREADING Skill / Knowledge
12.00 8
OPERATION Thread gauge both ends ie GO Cannot be used / Fitment problem Work Instructions /
wrong tooling
and NO GO are entering. at customer end Set-Up Approval
wrong gauges
Visual Defects 4
Presence of unwanted burrs / Sharp Cannot be used / Fitment problem at Training and Visual
Unskilled labour / wrong
Projections on Corners, Mating customer end / Delay in process 5 aids to educate
Toolings
13 Deburring surfaces, Edges, time. 8 employees
Visual Defects 4
Wrong method of inspection
Improper instructions / Educate the
Cannot be used / Fitment problem
Dimensional / Visual deviations not semi skilled inspectors / inspectors and
at customer end / Customer
detected / detected allowed without wrong selection / usage systematic hourly
14 Final Inspection dissatisfaction. 8 4
authorization. of instruments / Gauges inspection .
Visual Defects
difficulties / Cannot be used. deviations and visual
Educate the displays
Non assembly Cannot be used / Fitment problem
inspectors and
at customer end / Customer Improper instructions 3
Mismatch systematic hourly
15 ASSEBLY dissatisfaction. 8
Delay in production and Machining Machining and Handling inspection .
Handling instructions
Visual Defects 4
Improper cleaning Visual controls
Improper packing work instructions

Bad / Damaged parts Cannot be
CLEANING and Imprper handling used / Fitment problem at customer Customer requirement
16 & 17 8 Improper instructions 3
PACKING wrong quantity end / Customer dissatisfaction / copy desplayed
Complaint.
wrong packing materials
mix up of bad parts Packing instruction
wrong mode of transport

Bad / Damaged parts Cannot be
used / Fitment problem at customer Improper work work instructions for
18 Despatch wrong destination 8 2
end / Customer dissatisfaction / instructions despatch
Complaint.
Improper documentation
FMEA Number BNR - FMEA - 01
Prepared by Shiva kumar.B
Date (Orig.) 12.05.09
Date (Rev.) NIL
Rev No NIL
s Control
D Actions Results
R
E Recom- Responsi-
P
T mended bility & Target Actions S E O C D E R P
Detection Action(s) Date
N Taken V R T N
Verification of test
certificate with
external lab
Inward Inspection 2 96
Inward Inspection
Inward Inspection 2 56
Hourly inspection
2 80
Hourly inspection
Setup approval and

hourly inspection
80
Setup approval and
hourly inspection 2
report
Hourly inspection 64
Setup approval and

hourly inspection
2 80
Setup approval and

hourly inspection
Self inspection report 2 64
Setup approval and

hourly inspection
2 80
Setup approval and
hourly inspection
2 80
Setup approval and

hourly inspection
Setup approval ,hourly

inspection and Control
chart.
2 80

chart.
Hourly inspection 2 64
Setup approval and

hourly inspection
80
Setup approval and 2

hourly inspection
Setup approval and

hourly inspection
2 80
Setup approval and

hourly inspection

inspection and Control 2 80
chart.
Setup approval and

hourly inspection
2 80
Setup approval and

hourly inspection

inspection and Control 2 80
chart.
Setup approval and

hourly inspection
Setup approval and

hourly inspection
80
Setup approval and 2
hourly inspection
Setup approval and

hourly inspection
Setup approval and

hourly inspection
2 80
Setup approval and

hourly inspection
chart.
80
inspection and Control 2
chart.

chart.
Gauge checking /
Hourly inspection
80
2
Gauge checking /
Hourly inspection
80
Hourly inspection 2
64
Final inspection 2 64
3 72
Hourly inspection
2 64
Check list for cleaning

2 48
and packing
Check list for despatch 2 32

GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
C071 3250 MICROMETER JOEL
Part Name Gage Number Appraiser B
DRIVE SHAFT 120302 MUTHU
Characteristic Gage Type Appraiser C
OUTER DIAMETER BALARAM
Characteristic Classification Trials Parts Appraisers Date Performed
2 10 3 02.07.09
Measurement Unit Analysis % Total Variation (TV)

Repeatability - Equipment Variation (EV)
EV = R x K1 Trials K1 % EV = 100 (EV/TV)
= 0.001 x 0.8862 2 0.89 = 100(0.001/0.006)
= 0.001 3 0.59 = 18.34
Reproducibility - Appraiser Variation (AV)
AV = {(xDIFF x K2)2 - (EV2/nr)}1/2 % AV = 100 (AV/TV)
= {(0.002 x 0.5231)^2 - (0.001 ^2/(10 x 2))}^1/2 = 100(0.001/0.006)
= 0.001 Appraisers 2 3 = 11.46
K2 0.71 0.5231 n = number of parts
Repeatability & Reproducibility (R & R) r = number of trials
R&R = {(EV2 + AV2)}1/2 Parts K3
= {(0.001^2 + 0.001^2)}^1/2 2 0.7071 % R&R = 100 (R&R/TV)

= 0.001 3 0.5231 = 100(0.001/0.006)
Part Variation (PV) 4 0.4467 = 21.62
PV = RP x K3 5 0.4030 Gage system may be acceptable
= 0.020 x 0.3146 6 0.3742
= 0.0063 7 0.3534 % PV = 100 (PV/TV)
Total Variation (TV) 8 0.3375 = 100(0.006/0.000)
TV = {(R&R2 + PV2)}1/2 9 0.3249 = 97.63
= {(0.001^2 + 0.006^2)}^1/2 10 0.3146 ndc = 1.41(PV/GRR)
= 0.0064 = 6
All calculations are based upon predicting 5.15 sigma (99.0% of the area under the normal distribution curve).
K1 is 5.15/d2, where d2 is dependent on the number of trials (m) and the number if parts times the number
of operators (g) which is assumed to be greater than 15.
AV - If a negative value is calculated under the square root sign, the appraiser variation (AV) defaults to zero (0).
K2 is 5.15/d2, where d2 is dependent on the number of operators (m) and (g) is 1, since there is only one range calculation.
K2 is 5.15/d2, where d2 is dependent on the number of parts (m) and (g) is 1, since there is only one range calculation.
d2 is obtained from Table D3, "Quality Control and Industrial Statistics", A.J. Duncan.
PART APPRAISER AVERAGE CHART
DEPT. OPERATION DATE CONTROL LIMITS CALCULATED ENGINEERING SPECIFATION PART NO.
QA OD TURNING
MACHINE NO. DATES OF STUDY CHARACTERISTIC SAMPLE SIZE FREQUENCY PART NAME
LT 25/1 02.07.09 OUTER DIAMETER 10 DRIVE SHAFT
NUMBER OF APPRAISERS APPRAISER A APPRAISER B APPRAISER C
3 JOEL MUTHU BALARAM
x= 43.3236 UCL = 109.8042 LCL = -23.1571 AVERAGES (X BAR CHART)
120.000
100.000
80.000
60.000
40.000
20.000
0.000
-20.000
-40.000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
r= 64.98600 UCL = 167.33895 LCL = 0.0000 RANGES (R CHART)
180.0000
160.0000
140.0000
120.0000
100.0000
80.0000
60.0000
40.0000
20.0000
0.0000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
DATE/TIME
R 1 64.980 64.990 64.990 64.980 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.980 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000
E
2 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.990 64.980 64.990 64.980 64.980 64.980 64.980 64.980 65.000
A
D
3 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
I
N
4
G
S 5
SUM 129.960 129.980 129.980 129.970 129.960 129.960 129.980 129.960 129.960 130.000 129.960 129.980 129.980 129.980 129.960 129.960 129.980 129.960 129.960 130.000 129.960 129.970 129.970 129.980 129.960 129.960 129.970 129.960 129.960 130.000
SUM
X 43.320 43.327 43.327 43.323 43.320 43.320 43.327 43.320 43.320 43.333 43.320 43.327 43.327 43.327 43.320 43.320 43.327 43.320 43.320 43.333 43.320 43.323 43.323 43.327 43.320 43.320 43.323 43.320 43.320 43.333
NUM
HIGH-
R 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000 64.980 64.990 64.990 64.990 64.980 64.980 64.990 64.980 64.980 65.000
LOW
** = POINT OUT OF CONTROL

BNR Exports,Bangalore CONTROL PL
PROTOTYPE PRE-LAUNCH PRODUCTION KEY CONTACT/PHONE : (080) 7833420
CORE TEAM : Mr.Rajesh, Daniel, Neelakantan, Lokesh, Di

PART NUMBER/LATEST CHANGE LEVEL : C071 3250 / 10 ( OLD NO 12013906 ) Prakash, Muruganandam and Shivakumar.
PART NAME / DESCRIPTION : DRIVE SHAFT SUPPLIER/PLANT APPROVAL/DATE :
SUPPLIER PLANT : BNR EXPORTS UNIT SUPPLIER CODE OTHER APPROVAL/ DATE (IF REQD.)
MACHINE,JIG DEVICE, CHARACTERISTICS SPECIAL

PART
PROCESS NAME/OPERATION TOOLS FOR CHAR PRODUCT /PROCESS
PROCESS NO
MANUFACTURING CLASS SPECIFICATION/
NO PRODUCT PROCESS TOLERANCE
1 Receipt of raw material 1 weighment Inward Inspection * Kgs / Tons

No crack,damages and pit
2 Receiving Inspection 1 Visual *
marks
2 Diameter ** 75.0 mm
3 Material ** As per order (SS316,410)
3 Cutting Bandsaw M/C 1 Length Sawing * 263+0.5

4 Pre machining Lathe M/C 1 OD Machining * 72+0.5
2 Inner Dia * 38-0.2

3 Bore depth * 99.0-0.10
4 Bore depth * 128.0 -0.10

5 Inner Dia * 24.50 +0.10
6 Inner Dia * 25.0 ± 0.10

7 Bore depth * 81.50-0.10
8 Inner dia * 50.0-0.10
9 Inner depth * 57.0-0.10

5 CNC 1st Operation CNC Turnning M/C 1 OD Machining ** 65.3+0.20
Facing,Turning, Drilling, Turning insert 2 Length ** 196.0±0.10
Boring, Chamfering , WNMG 080408 T603 3 Chamfer (Od stock ) ** 3.3x10o
Step boring WNMG 080404 T603 4 Corner radius ** R 1.6
Boring insert 5 Angle * 45o

CCMT 09T304 T603 6 Bore dia ** 39.7-0.05
7 Bore length ** 101.0±0.10
8 Chamfer ( Id stock ) ** 2.3x 30º
9 Step bore dia ** 26.0±0.1
10 Bore length ** 130.0±0.10
6 CNC 2nd Operation CNC Turnning M/C 1 OD Machining ** 69.76 / 69.79

Facing, boring,step boring Turning insert 2 Perpendicularity ** 0.07 wrt B
Chamfering,Threading WNMG 080408 T603 3 Concentricity ** 0.07 wrt A
WNMG 080404 T603 4 Total length ** 260.0±0.1

Boring insert 5 Bore dia ** 51.09 / 51.12
CCMT 09T304 T603 6 Bore depth ** 58±0.10

TT 1500 7 Bore dia ** 37.0±0.10
8 Bore depth ** 83±0.10
9 Thread u/c dia * 26.0 ±0.25

10 u/c depth * 6.0 ±0.25
11 Perpendicularity ** 0.07 wrt B

12 Concentricity ** 0.07 wrt A
13 Thread size ( Entry tap ) ** M24x40.0
7 CNC 3rd Operation CNC Turnning M/C 1 Step dia ** 61.02-61.08

Grooving 2 Concentricity ** 0.07 wrt A
3 Step length ** 3.920 / 3.980

4 Corner radius in OD & ID ** (2x) R2
5 Corner radius ** R1
6 Groove dia ** 56.02 / 56.08
8 Groove length ** 8.02 / 8.08

9 Step length ** 48.0±0.1
10 Groove dia ** 65.10 / 65.25

12 Groove width ** 3.75/3.85

13 Corner radius ** (2X) R1
14 Outside Corner radius ** R0.1 / R0.2
15 Angle * (2x) 0-5º

16 Step length ** 56.16 / 56.22
17 Groove dia ** 67.58 / 67.84

19 Groovewidth ** 2.65 / 2.71
20 Surface finish ** Ra 1.6

8 CNC 4 TH OPERATION CNC Turnning M/C 1 Hole dia Drilling & Boring *** 29.99 / 30.03
First cross hole HSS Ø28.0 2 Ref. Length ** 27.90 / 28.1

CCMT 09T304 T603 3 Hole position ** 0.20 wrt A C
9 CNC 5 TH OPERATION CNC Turnning M/C 1 Hole dia Drilling & Boring *** 19.09 / 19.12
Secondt cross hole HSS Ø18.5 2 Ref. Length ** 27.90 / 28.1

CCMT 09T304 T603 3 Hole position ** 0.20 wrt A C
10 Cross Hole Drilling & Conventional 3 C / Hole dia 2 Drilling ** 14.22 / 14.29
Reaming 4 Ref length ** 38±0.10
5 Hole position ** 0.07 wrt A

11 CNC 6th Operation CNC Turning M/C 1 OD Turning *** 64.985 / 64.995
2 OD Length * 196.0 ± 0.15

3 ID Boring *** 40.03 / 40.05
4 ID Depth * 101.0 ± 0.15
5 Concentricity *** 0.02 wrt A

12 Rethreading Hand 1 Thread size Tapping ** M24

Tap to M20 Tap M24 2 Thread length 40
Parts to be free from
13 Deburring Manual 1 Visual ** burrs,sharp corners,dents
and damages
14 Final Inspection 1 OD Inspection *** 64.98 / 65.0
2 Chamfer ** 3.0x10o
3 Corner radius ** R 1.6
4 ID *** 40.03-40.05

7 Bore length ** 101.0±0.25

8 ID Chamfer ** 2 x 30º
9 Step bore dia ** 26.0±0.25
10 Bore length ** 130±0.25

11 OD ** 69.75 / 69.80
12 Total length ** 260.0±0.25

13 Bore dia *** 51.08 / 51.13
14 Bore depth ** 58±0.25
15 Bore dia ** 37±0.25

16 Bore depth ** 83±0.25
17 Thread u/c dia * 26.0 ±0.25

18 u/c depth * 6.0 ±0.25
20 Concentricty ** 0.1 wrt A

21 Step dia ** 61.00 / 61.10
22 Corner radius ** (2x) R2

23 Corner radius ** R1
24 Groove dia ** 56.00 / 56.10
25 Groove length Inspection ** 8.00 / 8.10

26 Step length ** 3.90 / 4.00
27 Step length ** 48.0±0.25

28 Groove dia ** 65.05 / 65.30
29 Groove width ** 3.7-3.9

30 Corner radius (2X) ** R1
31 Out corner radius (2X) * R0.1 / R0.2
32 Angle (2x) * 0-5º

33 Step length ** 56.14 / 56.24
34 Groove dia ** 67.56 / 67.86

35 Groovewidth ** 2.63-2.73
36 Step length ** 196±0.25
37 Chamfer * 45º



45 Thread size ** M24
46 Hole dia ** 29.99 / 30.03

47 Ref. Length ** 27.80 / 28.20
48 Hole position ** 0.2 wrt A,C

49 Hole dia ** 14.20-14.31
50 Hole position ** 0.1 wrt A
51 Hole Ref Ht ** 38±0.25

52 Hole dia ** 19.09 / 19.12
53 Hole position ** 0.2 wrt A,C
54 Ref length * 27.80 / 28.20
Proper alignment of bolt &
15 Allen bolt assembly Manuel 1 Fixing of bolt with locktite ** apply Sealant under the bolt
head
2 5910 ** locktite under the bolt
16 Cleaning 1 Clean the Component with White waste
17 Packing 1 Pack the componant with bubble sheet
18 Despatch
NOTE:' MINOR, ''MAJOR, '''CRITICAL, 100%INSPECTION TO BE DONE, SPC TO BE DONE FOR > 50 NOS and for TOLERANCE of < 0.05 , PC=PROGRAME CONTROL, PP=PROFILE PRO
REPRESENTATIONS: F= FINISH, S.I.R = SELF INSPECTION REPORT,
EVALUATION USING CMM IS DONE 1NO./4hr.
SETTING APPROVAL = New setting, Change of Tool, Collet, Jaws, Speed, Feed or any other change in Process / Setup -----VISUAL: Rust, Cracks, Pitting, Bend, Dents, Burrs & Damages are not allow
QUARANTINE: Apart from rejected batches, batches produced / received should be kept separate till decision on the batch is taken. Ex. Batch produced between tool changes, batch received from supp
Prepared by
Checked by
Approved by REV
ONTROL PLAN
3420 DATE(ORG): 24.12.06 DATE(REV):
lakantan, Lokesh, Dinesh, Muthukumar,

CUSTOMER ENGEERING APPROVAL/DATE
mar.
: CUSTOMER QUALITY APPROVAL / DATE
.) CONTROL PLAN ISSUE NO: 01
METHODS
SAMPLE RECORD
EVALUATION / MEASUREMENT
CONTROL MATHOD REACTION PLAN
TECH
SIZE FREQ
Weighing scale DC / INVOICE GRIR
Naked eye As per

Reject and send back
sampling Every lot Supplier inspection Receving inspection
Micrometer to supplier
plan report report
Exturnal lab
Vernier caliper 100% Every lot Self inspection report Reset the blade Self inspection report
Micrometer
Bore gauge
Vernier caliper
Vernier caliper
Bore gauge 2 Nos 1 hr Self inspection report Reset the tool Self inspection report
Bore gauge
Vernier caliper
Bore gauge
Vernier caliper
Micro meter
Vernier caliper
Profile projector
Radius gauge
Profile projector Reset the insert check

2 Nos 1 hr Self inspection report Self inspection report
Bore dial gauge the speed and feed
Depth Vernier
Profile projector
Bore dial gauge
Depth vernier
Micro meter
Dial with stand/CMM
Dial with stand
Vernier caliper
Bore dial gauge
Depth vernier
Bore dial gauge
Depth vernier
Plug gauge
Vernier caliper
Dial with stand/CMM

Dial with stand
Thread plug gauge
Micrometer Reset the insert check

1 Nos 1hr Self inspection report Self inspection report
Dial with stand the speed and feed
Profile projector
PP/Radius gauge
PP/Radius gauge
Blade micrometer
Dial with stand
Depth Micrometer / PP
Profile projector
Micrometer
Dial with stand
Profile projector
Profile projector
Profile projector
Profile projector
Profile projector
Blade micrometer
Reset the insert check
Dial with stand 1 Nos 1 hr Self inspection report Self inspection report
the speed and feeds
Profile projector
Roughness tester
Bore dial gauge
Micro height /Vernier caliper 1 Nos 1 hr Self inspection report Self inspection report
the speed and feeds
Dial with stand
Bore dial gauge

Micro height /Vernier caliper 1 Nos 1 hr Self inspection report Self inspection report
the speed and feeds
Dial with stand
Plug gauge
Vernier caliper
Height gauge with Dial

Micrometer
Reset the reaming tool
Vernier caliper 4 Nos 1 hr Self inspection report Self inspection report
and reset the drill bit
Plug gauge/Bore gauge
Vernier caliper
Height gauge with dial

Roughness tester
Thread plug gauge

100% Every lot Self inspection report Change the tap Self inspection report
Venier caliper
Visul 100% Every lot

Micrometer
Profile projector
Radius gauge / PP
Bore dial gauge
Dial with stand

Roughness tester
Venier caliper
PC
Bore dial gauge
Depth vernier
Micro meter
Vernier caliper As per

Reject and segregate
sampling Every lot Final inspection report Final inspection report
Bore dial gauge the lot
plan
Vernier caliper
Bore dial gauge

Depth vernier
Plug gauge
Vernier caliper
Dial with stand / CMM
Dial with stand

Micrometer/Vernier caliper
PP/Radius gauge
PP/Radius gauge
Blade micrometer
Depth Micrometer
Profile projector
Profile projector
Blade micrometer
Slip gauge/PP
PP/Radius gauge
PP
PP
Profile projector
Blade micrometer
Profile projector
Venier caliper
Profile projector
Dial with stand
Dial with stand As per

Reject and segregate
sampling Every lot Final inspection report Final inspection report
Dial with stand the lot
plan
Dial with stand
Dial with stand

Dial with stand
Roughness tester
Thread plug gauge
Plug gauge
Micro-hite / Vernier caliper
Dial with stand

Plug gauge
Dial with stand
Vernier caliper
Plug gauge
Dial with stand
Micro-height / Vernier caliper
Visual
Visual 100% Every Batch

Visual 100% Every Batch
L, PP=PROFILE PROJECTOR..MH-Micro Height, HG-Vernier height gauge
amages are not allowed
ch received from supplier etc
CONTROL PLAN NO:
BNR /CP/186
SIGN /DATE REV No. 1 Page:5/5

DATE:
TRACEABILITY FOR PRODUCT /
MANUFACTURING PROCESS Rev No: 0
BNR Exports
CUSTOMER MONOPUMPS
PART NO C 0713250
PART NAME DRIVE SHAFT
WORK PROCESS CODIFICATION DESCRIPTION CODIFICATION
RAW MATERIAL FROM Receive Heat No / Batch no / Lot

. SUPPLIER GRIR - 382
No. from raw material supplier
CUTTING
W.O. No 320
C.N.C. OPERATIONS
W.O. No 320
CONVENTIONAL
W.O. No 320
OPERATIONS
FINAL INSPECTION
W.O. No 320
ASSEMBLY
W.O. No 320
CLEANING & PACKING

W.O. No 320
DESPATCH
XXX / YYY / ZZZ 1 / 5 To 2 / 5 / BNRE /1344
Note:
COMPONENT NO DURING PROCESS: COPY
XXX / YYY / ZZZ

Invoice No
No of boxes in the Consignment
BOX NO.
WORK ORDER NUMBER AT BNR :
W O XXX
RUNNING SERIAL NUMBER
WORK ORDER

WORKINSTRUCTIO
Issue No:01
Rev No:00
OPERATION: WORK
CUTTING INSTRUC
PREPARED BY OPERATION
OPERATION
1) Receive the cutting slip from planning/p
Issue No:01
2) Clean the machine job holding area w
Rev No:00
OPERATION: CNC Turning

WORK INSTRUCTION FOR DRILLING
1) Study and understand the drawing

OPERATIONS
PREPARED BY
Issue No:01 ` Date:15-06-05
Rev No:00 Date:15-06-05
OPERATION: DRILLING OPERATION

1) Study and understand the drawing dimensions, tolerances properly. If in doubt clarify
clarify
2) Check the route card/ job card/ control plans are provided as per latest issue no.
3) Use proper drills, fixtures with respect to drawing.
4) Get first piece approval as per drawing from QC personnel
5) Check and record the dimensions in the self-inspection report format at regular
intervals
6) Use calibrated instruments/gauges for measuring purpose
7) Keep the instruments at respective place after use
2) Check the route card correctly up

8) Drill to be grind properly whenever required.
9) Deburring to be carried out after drilling operation.
10) Ensure all the drills/taping operations completed.
11) Ensure no parts are missed for the required operations.
12) Use tag systems for identification.
13) Arrange the parts in all the stags.
14) Clean the Machine after use and keep your m/c surrounding clean.
3) Use proper tools, fixtures with re

PREPARED BY
WORK INS
Issue No:01
Rev No:00
OPERATION: DEBURRING
WORK INSTRU
OPERATION S
Issue No:01
Rev No:00
OPERATION: DRILLING OPERATION

1) Ensure parts are accepted
P R EP A R ED BY by QC
BNR Exports PACKING SPECIFICATIONS
Customer: Mono Pumps Ltd., UK
Date: 22.09.2008
Requirements Originator
Special Packaging and Preservation:

1 All the parts other than Muncher Half Couplings must have the
label with Part number pasted on the packed product Logistics
2 Universal Joint assemblies threads must be protected with
Plastic caps Logistics
Delivery Requirements:
1 Wood packaging material must be fumigated before despatch
by Freight forwarder Customer
2 Each case must be pasted with a label consisting PO Number Logistics
3 Delivery Terms: Incoterms 2000: Ex Works Logistics
Documentation Requirements:
1 Submit GSP certificates for each consignment Logistics
Prepared by Checked by Approved by

CRITICAL CHARECTERISTIC MATRIX PLAN DATE
PART NAME DRIVE SHAFT PART NO C 0713250 ISSUE 10 / 24-10-08 CUSTOMER MONO PUMPS
PROCESS NO
PARAMETER SPECIFICATION
SL NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1
OUT SIDE DIAMETER Φ 65 / 64.98 X
2
BORE DIAMETER Φ 40.03 / 40.03 X
3
CONCENTRICITY 0.03 with respect to A X
4
5
6
OUT SIDE DIAMETER Φ 69.75 / 69.80 X
7
PPK1
Sl.No. Date Readings Supplier : BNR Exports

1 84.99 Place : BANGALORE
2 84.98
3 84.99 Ref. No: 1
4 84.99 Period : 21.08.09
5 84.99
6 84.99 Part No. : C091 3250
7 84.99 Part Name : Drive Shaft
8 84.99 Parameter : Outer Diameter
9 84.99
10 84.99 USL : 85
11 84.99 LSL : 84.98
12 84.98
13 84.99 Operation No. : CNC 4th
14 84.99 Operation desc. : OD & ID Finish
15 84.99
16 84.99 Instrument used : Micrometer
17 84.99 Least count : 0.01
18 84.99
19 84.99
20 84.99
21 84.99
22 84.99
23 84.99
24 84.99
25 84.99
26 84.99
27 84.99
28 84.99
29 84.99
30 84.99
31 84.99
32 84.99
33 84.99
34 84.99
35 84.99
36
37
38
39
40
41
42
43
44
Page 53
PPK1
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
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68
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79
80
81
82
83
84
85
86
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Page 54
PPK1
98
99
100
Page 55
BNR Exports Process Cpk Study Report
Customer : Ref. No.
MONO PUMPS 1
Supplier: BNR Exports PERIOD ( Month ):

21.08.09
Part No.: C091 3250 Part Name : DRIVE SHAFT
Parameter Specification Tolerance
OUTER DIAMETER USL 85 LSL 84.98 0.02
Operation No: CNC 4th Opn. Description OD & ID Finish
Instrument Used MICROMETER Least Count : 0.01
CAPABLE PROCESS OBSERVED
Cp > = 1.66 CAPABLE Cp = 1.42
Cpk > = 1.33 Cpk = 1.33
n = 35
HISTOGRAM
35
30
25
20
Frequency
15
10
0
84.97
84.97
84.98
84.98
84.99
84.99
85
85
85.01
85.02
85.02
85.03
85.04
85.01
85.03
Dimension
No. of Class : 3
Observed beyond Specification : Target Nominal :
0.00% 84.99
Estimated beyond Specification : Average (X) 84.989
0.00% Process Std. Dev. (Sigma):
0.0024
Remarks : Name
Sign & Date

PPK3
Tolerance : 0.02
Target Nominal : 84.99 Min.value No.of width mid cumulative

84.98 -0.01 84.97 84.97 0
No. of reading : 35 84.98 -0.01 84.97 84.97 0
84.98 0 84.98 84.98 0
Average : 84.99 84.98 0 84.98 84.98 2
84.98 0 84.99 84.99 2
Std. dev. (Sigma) : 0 84.98 0.01 84.99 84.99 35
84.98 0.01 85 85 35
Cp value : 1.42 84.98 0.02 85 85 35
Cpk value : 1.33 84.98 0.02 85.01 85.01 35
84.98 0.03 85.01 85.01 35
No. of class : 3 84.98 0.03 85.02 85.02 35
84.98 0.04 85.02 85.02 35
Maximum value : 84.99 84.98 0.04 85.03 85.03 35
Minimum value : 84.98 84.98 0.05 85.03 85.03 35
84.98 0.05 85.04 85.04 35
Range : 0.01 84.98 0.06 85.04 85.04 35
Class width : 0 84.98 0.06 85.05 85.05 35
84.98 0.07 85.05 85.05 35
Observed beyond 84.98 0.07 85.06 85.06 35
Specification: Err:508 84.98 0.08 85.06 85.06 35
84.98 0.08 85.07
Estimated beyond zl zu phil phu est percentage
Specification -4 4.49 0 1 0 0
TARGET NOMINAL 2:
if LSL=0: 0
if USL = ~: FALSE
Cpk value 2:
if LSL=0: 0
if USL=~: FALSE
Cp = ----
Page 57
PPK3
sum of X =
X bar =
Page 58
PPK3
frequency
0
0
2
0
33
0
0
0
0
0
0
0
0
0
0
0
0
0
0
-35
Page 59
PPK3
Page 60

Apqp - DR SHFT

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APQP DOCUMENTATION INDEX SHEET

Design goals ( Team and Program need dates )

I PLAN & DEFINE

Drawings with numbered parameters

Process Flow Diagram

Production Trial Run

Production Part Approval ( PPAP with PSW )

Design verification plan

Production Part Approval

Sl no CFT / MDT MEMBERS DESIGNATION DEPARTMENT CONTACT DETAILS

Participant Code Date

25.06.09 Rev. No.: 00

RESPONS PLAN ACTUAL

Drive Shaft C0713250

1.1.1 Component Drawing G Ambi Daniel 4.05.09 4.05.09 4.05.09 4.05.09

1.5 Risk analysis G Rajesh 6.05.09 08.05.09 6.05.09 8.05.09

1.9.1 Design concept approval G

3D Modelling & 2D Drawings

1.9.3 Drawing release G

STAGE: 2 PROCESS DESIGN AND DEVELOPMENT

2.2 Charactertics Matrix G Muthukumar 11.05.09 11.05.09 11.05.09 11.05.09

2.3 Process FMEA G Dinesh / Lokesh 11.05.09 12.05.09 11.05.09 12.05.09

Manufacturing process design

Traceability for product /

2.10 Pre-launch control Plan G Muthukumaran 13.05.09 13.05.09 13.05.09 13.05.09

2.11 Work Instructions

25.06.09 Rev. No.: 00

RESPONS PLAN ACTUAL

Drive Shaft C0713250

2.12 Packing Specification

2.13.2 Premachining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.13.3 Heat treatment G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.13.4 Final machining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

Tool Manufacturing - Drill jig

2.14.1 Raw material G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.14.2 Premachining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.14.3 Heat treatment G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.14.4 Final machining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.15.1 Raw material G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.15.2 Premachining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.15.3 Heat treatment G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

2.15.4 Final machining G Nataraj 11.05.09 11.05.09 11.05.09 11.05.09

STAGE : 3 MANUFACTURING PROCESS VALIDATION

3.1.1 Cutting G Prasanna 25.06.09 25.06.09 25.06.09 25.06.09

3.1.2 Premachining G Nataraj 25.06.09 25.06.09 26.06.09 26.06.09

25.06.09 Rev. No.: 00

RESPONS PLAN ACTUAL

Drive Shaft C0713250

3.1.9 Deburring G Lokesh/Nataraj 30.07.09 30.07.09 30.07.09 30.07.09

3.2.0 Final inspection G Muthukumar 31.07.09 31.07.09 31.07.09 31.07.09

3.2.1 Assembly G Lokesh/Nataraj 17.08.09 17.08.09 17.08.09 17.08.09

3.2.2 Cleaning and Packing G Lokesh/Nataraj 17.08.09 17.08.09 17.08.09 17.08.09

STAGE: 4 PPAP DOCUMENTATION

4.2 MSA Study G Muthukumar 13.07.09 13.07.09 2.07.09 02.07.09

4.3 Ppk Study G Muthukumar 17.07.09 22.07.09 17.07.09 22.07.09

4.4 Final inspection G joel karkada 31.07.09 31.07.09 31.07.09 31.07.09

4.5 PPAP Document Preparation G Muthukumar 31.07.09 31.07.09 31.07.09 31.07.09

STAGE : 5 FEEDBACK ASSESMENT AND CORRECTIVE ACTION

5.1 Customer approval of PPAP

5.2 Commence Bulk Production

2 Y - YELLOW - INPROGRESS 2 Rev 2 : Trial date is revised

3 R - RED - DELAY 3 Rev 3 : Trial date is revised

Team Members Signature