Proto type Pre-launch Production Core team: K. Sridhar, N. Sridaran, V. Sridharan, l..Kamalakannan, M.

Karthikeyan,R

- - a Plant Approval / Date:

Part Name: 10.5 cum Other Approval / Date:

Drg. / Part No: A0Y07400PH31 / PH52 Key Contact Name: Mr. S.Sekar - VP

Drg. / Issue Level : # Key Contact Phone : 9940161963

Characteristics

Part / Process Process Name /

M/C Device No.
Number Operation Description
Sl.No Product Process

1 Sheets _

2 Sheet length _

3 Sheet width _

10 Incoming _ 4 Sheet thk _

5 Paint colour _
Part / Process Process Name /
10 Incoming M/C Device
_ No.
Number Operation Description
Sl.No Product Process

6 Paint supply viscosity _

7 Components & Trim items _

_
Shearing Shearing 1 Length x width x thk
_

Blanking Shearing 2 Length x width x thk _

Hole I.D _
Piercing Piercing tool 3
Distance of holes _

_
Nibbling Nibbling machine 4 Nibbling
_
20

_
Web length x flange height
Folding Press brake 5
Holle referance
_
Part / Process Process Name / M/C Device No.
Number Operation Description Web length x flange height
Folding Press brake Sl.No
5 Product Process
Holle referance

Notching Notching tool 7 Length x width _

Corner shearing _
Corner shearing 8 Length x width
tool

1 Floor length _

2 Floor width _

3 _

4 _

5 _

6 _
Floor 'X' member intermediate distance
7 _

8 _

9 _

Floor Assy Assy Fixture

30
 Floor 'X' member intermediate distance

Part / Process Process Name / M/C Device No.

Number Operation Description
Sl.No Product Process

10 _
Floor Assy Assy Fixture
30

11 Floor long member length _

12 Floor long member width _

13 long member front tapper cutting dimension _

14 Rear hinge stiffner from backup plate inner _

15 Rear overhang _

16 Floor long member length _

15 Floor long member width _

16 Side plate to rear hinge center distance _

Reinforcement profile plate length from _

17
back up plate

18 Rear hinge inner center distance _

1 No of child parts _
Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

1 Side board length _

2 Side board width _

Side board assy Assy Fixture 3 Top rail distance _

4 _

5 Centre stiffener intermediate distane _

6 _
40

7 Tarpaulin hook dist. From handle & Top rail _

8 _
Tarpaulin hook distance
9 _

1st ladder pipe dist. from side board bottom _

10

2nd ladder pipe dist. from 1st ladder pipe _

11

12 Handle dist. from front vr. stiffener _

Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

1 Head board lower plate width x height _

2 Head board upper plate width x height _

3 Canopy plate _

Assy Fixture 4 Front 'Y' stiffener inner dist. at top _

50

5 Front 'Y' stiffener inner dist. at bottom _

7 Canopy Stiff. distance _

8 Wheel choke mtg brkt distance _

Tail door sheet width _

2

3 Tail door sheet height _

4 Tail door Horiz. & Vert. column _

Tail door setting & _

Assy Fixture 5 Tail door width
60

welding

Tail door height _

6
Part / Process Process
Tail Name /&
door setting
M/C Device
Assy No.
Fixture

60
Number Operation Description
welding
Sl.No Product Process

7 Tail door 'U' bend _

Tail door plate at bottom sq. tube _

8

1 Sub frame folded channel _

2 Length _

_
3 Cross bearer distance
_

_
Sub frame setting &
Assy Fixture
70

welding
4 Sub frame support plate-5nos. distance _

_
 Sub frame setting &
Assy Fixture

70
Part / Process welding
Process Name / M/C Device No. 4 Sub frame support plate-5nos. distance
Number Operation Description
Sl.No Product Process

5 Sub frame Width _

6 Pivot length _

7 Prop to rear hinge centre distance _

8 Prop mtg brkt distance _

9 Front Body Guide Position _

1 sub assembly _

2 i) Lux level _
Shot blasting
80

Shot blasting
booth
3 ii) Blasting distance _

4 iii ) air pressure _

1 Polyester putty & Sealant application _

2 Emery dressing(Buffing) _

Painting booth &

90

primer Painting
spray gun
Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

Primer paint _
3
Painting booth & i )Paint viscosity
90

primer Painting
spray gun
4 ii) Spraying distance _

5 iii ) Spraying air pressure _

6 Inspection _

1 Body interior length _

2 Body interior width _

3 Body interior height _

Cubing Assy Fixture
4 Front board board angle _

Tail door height from back up plate bottom _

Tail door setting _

Secondry lock brkt setting _

100

_
Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

100

1 Rear cleat plate distance _

2 Middle cleat plate distance _

3 Front cleat plate distance _

Mounting Chassis frame 4 Pivot mtg brkt 2 dist. (LH/RH) _

5 Pivot mtg brkt 1 dist. _

6 Gap b/w Pivot top& bottom brkt _

7 cleat plate hole offset _

Polyester putty & Sealant application (If _

1
any)

2 Emery dressing (Buffing ) _

Painting booth &

110

Final Painting 3 Finish paint i )Paint viscosity _

spray gun

6 Inspection _

7 Coating thickness _
 Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

1 Electrical _

2 Wiring harness routing _

120

PDI - 3 Tipping operation _

4 Mudguard ,suppresor _

5 Reflecting , AL sticker _

1 Body cleaning _

2 Loose components packing _

130

Dispatch Hydra

3 Body loading _

Note1: All Dimension are in mm

Note 2: I - Inspector, O - Operator, C – Captain
Note 3: D – Reject the Lot & Inform Supplier For Necessary action
E – Stop & Segregate
F – Stop & Correct the Process.Raise INCR
G -- Stop & Segregate Move Rework Material for Non Conformance area
H – Hold the lot, Segregate / Reject, Inform Customer
 Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

R – Stop & Replace & Inform Supervisor for necessary action

Note 4 : FOA - First Off Approval , LOA - Last Off Approval , FIR - Final Inspection Report , DIR - Defect Intimation Report, INCR - Internal Non Conforman
Note 5 : During FOA, LOA stage 3 nos should be recorded in Inprocess check Sheet. Check 3 nos during Patrol Inspection and record 1 no in Inprocess ch

Prepared by: V. Sridharan Checked By : N. Sridharan

Date : 30.12.2017
* DIMENSIONS NOT LISTED ARE NOT CHECKED AS THEY ARE BEING CONTROLLED BY THE TOOLS. TOOLS ARE CERTIFIED BY TOOL ROOM / QUALITY .
· IN FINAL INSPECTION ONLY 5 REDINGS RECORDED.
 AUTOMOTIVE COACHES & COMPONENTS LTD

CONTROL PLAN

Control Plan No : QA/CAB/CP/01

kannan, M. Karthikeyan,R. Selvakumar, V.Sundarajan, Mohan Rev No : 03

Date (Orig) : 03.07.2015 Rev Date : 20.12.2017

Customer Engg Approval / Date : Issue Date : 20.12.2017

Customer Quality Approval / Date :

Other Approval / Date :

istics Methods

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

_ Against Specified grade TC _ _ 1

_ As per PO Measuring tape _ _ 1

_ As per PO Measuring tape _ _ 1

_ As per PO Micrometer _ _ 1

_ Paint shade Master sample _ _ 1

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

_ 45±10 secs B4 Cup _ _ 1

_ As per IPS Measuring tape/Micrometer/vernier _ _ 1

_ As specified in drawing Measuring tape _ _ 1

_ No shearing burr Visual _ _ 1

_ As specified in drawing Measuring tape _ _ 1

_ As specified in drawing Vernier _ _ 1

_ As specified in drawing Measuring tape _ _ 1

_ As specified in drawing Template _ _ 1

_ No cutting burr Visual _ _ 1

_ As specified in drawing Measuring tape _ _ 1

_ No crack in bend line Visual _ _ 1

_ Squre / angle Visual _ _ 1

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

_ No tool mark Visual _ _ 1

_ As specified in drawing Measuring tape _ _ 1

_ As specified in drawing Measuring tape _ _ 1

_ 3368mm Measuring tape _ _ 1

_ 2328mm Measuring tape _ _ 1

_ 295mm Measuring tape _ _ 1

_ 722mm Measuring tape _ _ 1

_ 1150mm Measuring tape _ _ 1

_ 1566mm Measuring tape _ _ 1

_ 1983mm Measuring tape _ _ 1

_ 2400mm Measuring tape _ _ 1

_ 2831mm Measuring tape _ _ 1

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

_ 3262mm Measuring tape _ _ 1

_ 3420mm Measuring tape _ _ 1

_ 846mm Measuring tape _ _ 1

_ 17 mm \ 16° Measuring tape _ _ 1

_ 5 mm Measuring tape _ _ 1

_ 335 ± 1mm Measuring tape _ _ 1

_ 4365mm Measuring tape _ _ 1

_ 846mm Measuring tape _ _ 1

_ 1551 ± 1mm Measuring tape _ _ 1

_ 1150 mm Measuring tape _ _ 1

_ Measuring tape _ _ 1

_ 07 Nos. Measuring tape _ _ 1

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

_ 3827mm Measuring tape _ _ 1

_ 1479mm Measuring tape _ _ 1

_ 24mm Measuring tape _ _ 1

_ 619mm Measuring tape _ _ 1

_ 1816mm Measuring tape _ _ 1

_ 3010mm Measuring tape _ _ 1

_ 260 x 145mm TYP Measuring tape _ _ 1

_ 1060mm Measuring tape _ _ 1

_ 1210mm Measuring tape _ _ 1

_ 300mm Measuring tape _ _ 1

_ 400mm Measuring tape _ _ 1

_ 775mm Measuring tape _ _ 1

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

_ 2328 x 1500 x 4 mm Measuring tape _ _ All

_ 2328 x 356 x 4 mm Measuring tape _ _ All

_ 2328 x 279mm Measuring tape _ _ All

_ 270mm Measuring tape _ _ All

_ 686mm Measuring tape _ _ All

_ 740mm Measuring tape _ _ All

_ 175 x 233mm Visual _ _ All

_ 2236mm Measuring tape _ _ All

_ 1150mm Measuring tape _ _ All

_ 80 x 80 x 4mm thk 80 x 80 _ _
vernier & micro meter All
x 6mm thk

_ 2396mm Measuring tape _ _ All

_ 1310mm Measuring tape _ _ All

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

_ 1198 x 50mm Measuring tape _ _ All

_ 10mm Measuring tape _ _ All

_ 200 x 85 X5mm Measuring tape _ _ All

_ 3777mm Measuring tape _ _ All

_ 1112mm Measuring tape _ _ All

_ 1917mm Measuring tape _ _ All

_ 2627mm Measuring tape _ _ All

_ 3507mm Measuring tape _ _ All

_ 406mm Measuring tape _ _ All

_ 395mm Measuring tape _ _ All

_ 610mm Measuring tape _ _ All

_ 1160mm Measuring tape _ _ All

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

_ 1000mm Measuring tape _ _ All

_ 864 mm Measuring tape _ _ All

_ 3498 ±2 mm Measuring tape _ _ All

_ 166 x 125mm Measuring tape _ _ All

_ 490 x 96mm Measuring tape _ _ All

_ 1090 x 120 mm Measuring tape _ _ All

_ G 18 grid RA gauge _ _ All

_ 800 lux Lux meter _ _ 1

_ 1 feet Visual _ _ All

_ 6 bar Pr. Gauge _ _ All

_ Grinding marks, Hammer mark _ _

Visual All
putty & Joint sealant application

_ 180 Grade/320Grade Visual _ _ All

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

_ 20 - 22 sec Stop watch _ _ All

_ 9 to 12 inch Visual _ _ All

_ 30 to 50 PSI Pr. Gauge _ _ All

_ With out Paint defect Visual _ _ All

_ 3610mm Measuring tape _ _ All

_ 2328 mm Measuring tape _ _ All

_ 1288 mm Measuring tape _ _ All

_ 70° Measuring tape _ _ All

_ 47 mm Measuring tape _ _ All

_ No offset visual _ _ All

_ Measuring tape _ _ All

_ Measuring tape _ _ All

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

_ 165mm Measuring tape _ _ All

_ 1672mm Measuring tape _ _ All

_ 2415mm Measuring tape _ _ All

_ 2957 / 3142 mm Measuring tape _ _ All

_ 3607mm Inclinometer _ _ All

_ 5mm Inclinometer _ _ All

_ Mtg pin Poke yoke _ _ All

_ Grinding marks, Hammer mark _ _

Visual All
putty & Joint sealant application

_ 320 Grade Visual _ _ All

_ 20 - 22 sec Stop watch _ _ All

_ With out Paint defect Visual _ _ All

_ 60 - 80 microns Coating thickness gauge _ _ All

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

_ All electrical items should work Electrical test _ _ All

_ As per ESK Visual _ _ All

_ Free movement Power pack _ _ All

_ Full tight Spanner _ _ All

_ As per ESK Visual _ _ All

_ No dust Visual _ _ All

_ Covered by polythene cover Visual _ _ All

_ As per TPH _ _ All

 Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

Internal Non Conformance Report , IIR - Incoming Inspection Report

cord 1 no in Inprocess check Sheet.

: N. Sridharan
Rev Date : 20.12.2017

Issue Date : 20.12.2017

Methods

Reaction Plan / Corrective

Freq. Control Method Resp.
Action

Per lot

Per lot

Per lot

Per lot Incoming inp. Checklist D I

Per lot
 Incoming inp. Checklist D I
Reaction Plan / Corrective
Freq. Control Method Resp.
Action

Per lot

Per lot

per hour

per hour

per hour

per hour I

per hour

per hour

First off/Inprocess insp.

per hour
report

per hour

per hour

per hour
 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

per hour

per hour

per hour

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

First off/Inprocess insp.

report
 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

1no/Shift
First off/Inprocess insp.
report
1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift
 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

First off/Inprocess insp.

1no/Shift
report

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift
 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

1no/Shift

1no/Shift

1no/Shift

First off/Inprocess insp.

1no/Shift
report

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

First off/Inprocess insp.

1no/Shift
report

1no/Shift
 First off/Inprocess insp.
report Reaction Plan / Corrective
Freq. Control Method Resp.
Action

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift
First off/Inprocess insp.
report
1no/Shift

1no/Shift
 First off/Inprocess insp.
report
Reaction Plan / Corrective
Freq. Control Method Resp.
Action

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

100%

100%
Inspection Check list
100%

100%

1no/Shift

1no/Shift

Inspection Check list

 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

1no/Shift
Inspection Check list
1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

First off/Inprocess insp.

1no/Shift
report
 Reaction Plan / Corrective
Freq. Control Method Resp.
Action
First off/Inprocess insp.
report

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

1no/Shift

100%

100%

100% Inspection Check list

100%

100%
 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

100%

100%

100% Final insp. Checklist

100%

100%

100% visual

100% Packing list

100% As per TPH

 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

Approved By. N. Sridharan