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YA

WA
LK
AR
IN
DU
ST YAWALKAR
RODUCTION
RI PART APPROVAL
INDUSTRIES
ES

INJECTOR CLAMP (FORGED)


200606530014
REV '03'

Greaves Cotton Ltd.


YAWALKAR INDUSTRIES
INDEX PAP
Level 5
Sr no. Description Applicability or non Appl. with reason
1 Part Submission Warrant S Attached.
5th level submission
2 Design records of saleable product Customer drawing received. Attached
-for proprietary comp./details Not applicable
-for all other comp./ details Not applicable

3 Engineering changes documents, if any Not applicable


i.e deviations etc.
4 Customer engg. approval, if required Not Applicable .

5 Design FMEA Not Applicable

6 Process Flow diagram S Attached.

7 Process FMEA S Attached.

8 Layout Inspection report S Attached.

9 Material , performance Test results S Attached.

10 Initial Process study S Attached.


Significant consecutive production run
11 Measurement system Analysis studies S Attached.
( Include stability, linearity, bias, R&R)
12 Qualified laboratory documentation S Attached.

13 Quality Plan S Attached.

14 Control Plan S Attached.


Std format, reaction plan relate with CP
15 (AAR) Appearance Approval Report Not applicable

16 Bulk Material Requirements checklist Not applicable


( for bulk material PPAP only)
17 Sample Product S One sample to be submitted to Customer
Refer sample quantity produced for PPAP
18 Master Sample R One sample to be retained at YAWALKAR INDUSTRIES
Single master sample marked/coloured
19 Checking Aids S Attached.
List of gauges/templates/fixtures etc.
20 Records of compliance with customer-
No specific requirement
specific requirements
S Supplier shall submit to customer
R Supplier shall retain at appropriate location
YI/GCL/INDEX 0094.00.12.06.2014
YAWALKAR INDUSTRIES
Manufacturers of precision engine components, CNC VMC Machining specilists, Manufacturing Engineers
Phone (020) 24220099, 64009299 yawalkar.industries@gmail.com

PART SUBMISSION WARRANT


Part Name - INJECTOR CLAMP (FORGED) Part Number - 200606530014
Safety and or
Govt. Regulation Yes No Engineering Drawing Change Level : 03 Date 12.11.14
Additional Engineering Changes - NA
Shown on Drawing No. N.A. Purchase Order No. Weight - 0.12 kg.
Checking Aid No. Engineering Change Level - - Dated - -

SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION


YAWALKAR INDUSTRIES Dimensional Materials/Functional Appearance
Supplier Name Supplier Code
S-12, PARVATI INDUSTRIAL ESTATE, Customer Name/Division -GREAVES COTTON LTD. (DEU)
Street Address Buyer/Buyer Code - Mr. Devdatta Malvadkar ( Vendor Devp)
PUNE MAHARASHTRA 411009 Application - New D Engine
City State Zip
Note:- Does this part contain any restricted or reportable substance Yes No

Are plastic parts identified with appropriate ISO marking Codes Yes No
REASON FOR SUBMISSION
Initial Submission Change to Optional Construction or Material
Engineering Change(s) Sub Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment or Additional Change in Part Processing
Correction of Discrepancy Parts Produced at Additional Location
Tooling Inactive > than 1 year Other- please specify

REQUESTED SUBMISSION LEVEL (Check one)


Level 1- Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer
Level 2- Warrant with product samples and limited supporting data submitted to customer
Level 3- Warrant with product samples and complete supporting data submitted to customer (Circle)
Level 4- Warrant and other requirements as defined by customer.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Level 5- Warrant with product samples and complete supporting18 data
19 reviewed at supplier's manufacturing location.

SUBMISSION RESULTS
The results for dimensional measurements material and functional tests appearance criteria statistical process package
These results meet all drawing and specification requiremen Yes No (if "No"- Explanation Required)
Mold/Cavity/Production Process _______________________
DECLARATION
I hereby affirm that the samples represented by this warrant are representative of our parts and have been made to the
applicable Production Part Approval Process Manual 3rd Edition Requirement. I further warrant these samples were
produced at the production rate of _500 / 8 hours. I have noted any deviations from this declaration below :

EXPLANATION COMMENTS______________________________________________________________
Name -M Bedi Title - Incharge Dev. Phone No : 020 -24227453 Fax No. 24227453
Supplier Authorized Signature ___________________________________________ Date - 08.02..2015

FOR CUSTOMER USE ONLY ( IF APPLICABLE)

Part Disposition : Approved Rejected Part Functional Approval: Approved


Other_________ Waived

Customer Name - GREAVES COTTON LTD. (DEU) Cust Sign - Mr. Devdatta Malvadkar (Vendor Dev.) Date
YI/GCL/PSW 0094.00.12.06.2014
YAWALKAR INDUSTRIES
PROCESS FLOW DIAGRAM (Pre-launch/ Prototype/ Production)
Customer: GREAVES COTTON LTD. (DEU) Symbols
Part Number: 200606530014 Storage Transportation Operation Inspection
Part Name: INJECTOR CLAMP
Part Rev./Rev Date: 03(12.11.14) PFD No. YI/GCL/PFD 0094.00.12.06.2014
Core Team : KKK

YAWALKAR INDUSTRIES
Process Description
S Type of Machine / Incoming Sources of
(Operation/ Inspection/ Key Product Characteristics
R Facility Variation
Transportation/ Storage)

RECEIPT OF RAW
10 --- --- ---
MATERIAL

DIAMETER
RAW MATERIAL
20 WORK BENCH VARIATION, MATERIAL DIA 36 mm En-8 BLACK BAR STOCK
INSPECTION
COMPOSITION

FORGING + HEAT
30 TREATMENT+ 0.3 T HAMMER --- 201 - 255 BHN HARDNESS
SHORTBLASTING

DIA 8.5 DRILLING AND DIA 9.00


40 DRILLING 1ST SET UP DRILLING MACHINE ---
REAMING, R 20 PROFILE CUTTER

50 DRILLING 2ND SET UP DRILLING MACHINE --- TAPER DRILLING 5 DEG

SLOTS 22.2+0.1.
VERT. MILLING CH. 4 x 45 DEG
60 MILLING ---
MACHINE DIMN 13.5
DIST 34

Page 4 of 39
YAWALKAR INDUSTRIES
Process Description
S Type of Machine / Incoming Sources of
(Operation/ Inspection/ Key Product Characteristics
R Facility Variation
Transportation/ Storage)

R 30 AND R 50
70 GRINDING SURFACE GRINDER ---
DIST 7.37

DEBURRING AND BURR FREE COMPONENT, QTY OF


80 WORK BENCH ---
INSPECTION COMPONENTS

AS PER YI/GCL/PDIR
90 PDI WORK BENCH ---
0094.00.12.06.2014

PACKAGING AND
100 STORES --- FREE FROM OIL & DUST AND QTY
DISPATCH
PREPARED BY APPROVED BY

Page 5 of 39
AR INDUSTRIES
M (Pre-launch/ Prototype/ Production)
Symbols
Operation & Delay
Inspection together

Key Control Characteristics

---

METALLURGICAL TEST REPORT OF RAW MATERIAL PER LOT,


CHECK MATERIAL COMPOSITION

DIA 18, OVERLALL LENGTH 60, DIST 10, HEIGHT 9.1, WIDTH 34,
WIDTH 18

DIGITAL VERNIER, PROFILE GAUGE

DIGITAL VERNIER AND HEIGHT GAUGE

DIGITAL VERNIER AND HEIGHT GAUGE

Page 6 of 39
Key Control Characteristics

RADIUS GAUGE AND HEIGHT GAUGE

1. DEBURRING ALL OVER AND CLEANING 2.


VISUAL INSPECTION AND QTY CHECK

AS PER PDI REPORT

VISUAL INSPECTION AND PDI REPORT

Page 7 of 39
YAWALKAR INDUSTRIES
POTENTIAL FAILURE MODE & EFFECTS ANALYSIS (PROCESS FMEA)
Customer: GREAVES COTTON LTD. (DEU)
Part No.: 200606530014 Process Responsibility: YAWALKAR INDUSTRIES
Part Name: INJECTOR CLAMP Prepared by: MD MANDHARE, RB NEVE
Part Rev/Rev. Dt: 03 (12/11/2014) Key date: 18.12.2014

ITEM/ POTENTIAL POTENTIAL SEV POTENTIAL OC CURRENT DE RPN


FUNCTION/ FAILURE MODE EFFECTS OF CAUSES/ PROCESS
OPERATION FAILURE MECHANISMS CONTROL
OF FAILURE Preventive Detective

1. Proper protection of Raw 1. Application of Rust


Humidity in air,
Material Getting Rusty No Effect 6 2 Material and oiling remover and Oiling 1 12
seasonal variation
2. FEFO for Raw Material 2. Visual Inspection.
10, 20, 30
Receipt,
Inspection and
Storage of Forging 1. Incoming material
1. Work instruction
Metallurgical Variation of Material Wrong material testing
No Effect 3 2 2.On job training to 2 12
Composition received 2. Metallugical
operator
inspection of every lot

Part Rejection,
ID Æ9 O/S 3 2 2 12
Replacement

ID Æ9 U/S Rework, Replacement 3 2 2 12


1. Insert wear
40. 1. Work instruction
Part Rejection, 2. Wrong offset
Drilling R 20 O/S 3 2 2. Tool change 100% Inspection 2 12
Replacement 3. Wrong Speed &
1st Setup frequency/30P
Feed
R20 U/S Rework, Replacement 3 2 2 12

FINISH > Rz12.5 Functional Failure 3 2 2 12

Part Rejection, 1. Insert wear


Taper 5 Deg O/S 3 2 1. Work instruction 2 12
50. Replacement 2. Wrong offset
2. Tool change 100% Inspection
Drilling 2nd Setup Assy Fitment tight, 3. Wrong Speed &
Taper 5 Deg U/S 3 3 frequency/30P 3 27
Rework Feed

Page 8 of 39
YAWALKAR INDUSTRIES
POTENTIAL FAILURE MODE & EFFECTS ANALYSIS (PROCESS FMEA)
Customer: GREAVES COTTON LTD. (DEU)
Part No.: 200606530014 Process Responsibility: YAWALKAR INDUSTRIES
Part Name: INJECTOR CLAMP Prepared by: MD MANDHARE, RB NEVE
Part Rev/Rev. Dt: 03 (12/11/2014) Key date: 18.12.2014

ITEM/ POTENTIAL POTENTIAL SEV POTENTIAL OC CURRENT DE RPN


FUNCTION/ FAILURE MODE EFFECTS OF CAUSES/ PROCESS
OPERATION FAILURE MECHANISMS CONTROL
OF FAILURE Preventive Detective
Part Rejection,
Slot W 22.2 O/S 3 2 2 12
Replacement

Slot W 22.2 U/S Rework, Replacement 3 3 3 27

Part Rejection,
Dist 13.5 U/S 3 2 1. Work instruction 2 12
60. Replacement 1. Insert wear
2. Tool change 100% Inspection
Milling 2. wrong offset
frequency/30P
Dist 13.5 O/S Rework, Replacement 3 3 3 27

Part Rejection,
Dist 34 U/S 3 2 2 12
Replacement

Dist 34 O/S Rework, Replacement 2 2 2 8

Page 9 of 39
YAWALKAR INDUSTRIES
POTENTIAL FAILURE MODE & EFFECTS ANALYSIS (PROCESS FMEA)
Customer: GREAVES COTTON LTD. (DEU)
Part No.: 200606530014 Process Responsibility: YAWALKAR INDUSTRIES
Part Name: INJECTOR CLAMP Prepared by: MD MANDHARE, RB NEVE
Part Rev/Rev. Dt: 03 (12/11/2014) Key date: 18.12.2014

ITEM/ POTENTIAL POTENTIAL SEV POTENTIAL OC CURRENT DE RPN


FUNCTION/ FAILURE MODE EFFECTS OF CAUSES/ PROCESS
OPERATION FAILURE MECHANISMS CONTROL
OF FAILURE Preventive Detective

Part Rejection,
R 30 O/S 4 3 3 36
Replacement

R 30 U/S Rework, Replacement 4 3 3 36

Part Rejection, 1. Work instruction


70. R 50 U/S 4 1. Insert wear 3 3 36
Replacement 2. Tool change 100% Inspection
Grinding 2. wrong offset
frequency/30P

R 50 O/S Rework, Replacement 4 3 3 36

Part Rejection,
Dist 7.37 U/S 4 4 4 64
Replacement

Dist 7.37 O/S Rework, Replacement 4 4 4 64

80,90, 100,
Customer Complaint. Qty Quantity short & Bad Ensure good quality of
PDI , Packaging 4 operator mistake 2 Visual Inspection 2 16
mismatch. Packing packing material
and Dispatch

Page 10 of 39
PFMEA # YI/GCL/PFMEA 0094.00.12.06.2014
Core Team: RBN, KKK
FMEA date (Orig): 12.01.2015
FMEA date (Rev) --
RECOMMENDED RESPONSIBILIT
ACTION RESULTS
ACTION
ACTION
S O D RPN
TAKEN

NONE

NONE

NONE

NONE

NONE

NONE

NONE

NONE

Drill resharpening not


Operator
correct

Page 11 of 39
PFMEA # YI/GCL/PFMEA 0094.00.12.06.2014
Core Team: RBN, KKK
FMEA date (Orig): 12.01.2015
FMEA date (Rev) --
RECOMMENDED RESPONSIBILIT
ACTION RESULTS
ACTION
ACTION
S O D RPN
TAKEN

NONE

Cutter Resharpening as
per tool replacement Operator
frequency

NONE

Cutter Resharpening as
per tool replacement Operator
frequency

NONE

NONE

Page 12 of 39
PFMEA # YI/GCL/PFMEA 0094.00.12.06.2014
Core Team: RBN, KKK
FMEA date (Orig): 12.01.2015
FMEA date (Rev) --
RECOMMENDED RESPONSIBILIT
ACTION RESULTS
ACTION
ACTION
S O D RPN
TAKEN
Cutter Resharpening as
per tool replacement Operator
frequency
Cutter Resharpening as
per tool replacement Operator
frequency
Cutter Resharpening as
per tool replacement Operator
frequency
Cutter Resharpening as
per tool replacement Operator
frequency
Wrong Inspection or
Operator
setting
Wrong Inspection or
Operator
setting

NONE

Page 13 of 39
YAWALKAR INDUSTRIES
LAYOUT INSPECTION REPORT
CUSTOMER: GREAVES COTTON LTD. (DEU)

PART NAME : INJECTOR CLAMP - FORGED Part No.: 200606530014 Part Rev./Rev Dt.: 03 (12/11/2014)

Sr. Obsevations
Dimension Gauge/Instrument
No 1 2 3 4 5 REMARK
1 Dia 9.0 Digital Vernier Calliper 9.02 9.02 9.02 9.02 9.02

2 Dia 12.1 Digital Vernier Calliper 12.10 12.10 12.10 12.10 12.10

3 Dist 13.5 Digital Height Gauge 13.50 13.45 13.50 13.50 13.50

4 Dist 3.5 Digital Height Gauge 3.45 3.45 3.45 3.48 3.47

5 Height 23.1 Digital Height Gauge 23.20 23.00 23.00 23.10 23.00

6 Dist 7.37±0.1 Digital Height Gauge 7.39 7.4 7.4 7.42 7.35

7 Dist 22.2+0.1 Digital Vernier Calliper 22.2 22.3 22.3 22.2 22.2

8 R20 Radius Radius Gauge OK OK OK OK OK

9 R50 Radius Radius Gauge OK OK OK OK OK

10 R30 Radius Radius Gauge OK OK OK OK OK

11 FINISH Rz16 Surface comparator OK OK OK OK OK

12 FINISH Rz25 Surface comparator OK OK OK OK OK

13 FINISH Rz12.5 Surface comparator OK OK OK OK OK

14 Dimn 18 Digital Vernier 18.1 18.2 18.2 18.2 18.2

15 Dimn 10 Digital Vernier 10.20 10.20 10.20 10.20 10.20

16 Dimn 34 Digital Vernier 34.20 34.10 34.10 34.10 34.10

17 CH 4 X 45 Deg Digital Height Gauge 4.10 4.00 4.10 4.10 4.10

18 Dia 18 Digital Vernier 18.30 18.20 18.40 18.30 18.30

19 Dist 34 Digital Vernier 34.50 34.50 34.50 34.50 34.50

20 Dist 24 Dial Gauge Setup 24.50 24.40 24.40 24.40 24.50

21 L 58 Digital Vernier 58.10 58.20 58.20 58.20 58.20

22 R5 Radius Gauge OK OK OK OK OK

23 Height 14 Digital Height Gauge 14.10 14.20 14.10 14.10 14.10

24 Height 17.5 Digital Height Gauge 17.60 17.60 17.50 17.60 17.60

25 Height 14 Digital Vernier 14.10 14.20 14.20 14.20 14.20

26 R 0.5 TYP Qualified in Milling Cutter OK OK OK OK OK

27 R 15 TYP Qualified in Milling Cutter OK OK OK OK OK

28 15 Deg TYP Qualified in Forging OK OK OK OK OK

29 R 10 TYP Qualified in Forging OK OK OK OK OK

30 R 9 TYP Qualified in Forging OK OK OK OK OK

31 R 4 TYP Qualified in Forging OK OK OK OK OK

32 Hardness 201-255 BHN Harness Tester 250 BHN 250 BHN 245 BHN 250 BHN 245 BHN

33 Visual OK OK OK OK OK

Checked By & Date:

Page 14 of 39 YI/GCL/LIR 0094.00.12.06.2014


YAWALKAR INDUSTRIES
Quality Plan
Part Name : INJECTOR CLAMP - FORGED QP No. : YI/GCL/QP 0094.00.12.0

Part No. : 200606530014 QP Rev. No. : 00

Rev. No./Rev. Dt. : 03 (12/11/2014) QP Date (Orignal) : 12/01/2015

Dwg. Rev.Date : N.A. QP Date (Rev): ----

Specification
Critical
S.No. Parameter Method L.C
parameter
Lower limit Upper limit

A Visual Inspection

Free from burr, Dent,


1 Damages , Sharp edges , Visual Visual NA NA
blow holes , & rust

B Dimensions

1 Dia 9.0 9.100 9.200 Digital Vernier Calliper 0.01 NA

2 Dia 12.1 12.100 12.300 Digital Vernier Calliper 0.01 NA

3 Dist 13.5 13.300 13.700 Digital Height Gauge 0.01 NA

4 Dist 3.5 3.400 3.600 Digital Height Gauge 0.01 NA

5 Height 23.1 22.900 23.300 Digital Height Gauge 0.01 NA

6 Dist 7.37±0.1 7.270 7.470 Digital Height Gauge 0.01 NA

7 Dist 22.2+0.1 22.200 22.300 Digital Vernier Calliper 0.01 NA

8 R20 Radius --- --- Radius Gauge --- NA

9 R50 Radius --- --- Radius Gauge --- NA

10 R30 Radius --- --- Radius Gauge --- C

11 FINISH Rz16 --- --- Surface comparator --- NA

12 FINISH Rz25 --- --- Surface comparator --- C

13 FINISH Rz12.5 --- --- Surface comparator --- NA

14 Hardness 201.000 255.000 Hardness Tester --- NA


Prepared by : R B Neve Approve
KAR INDUSTRIES
Quality Plan
QP No. : YI/GCL/QP 0094.00.12.06.2014

QP Rev. No. : 00

QP Date (Orignal) : 12/01/2015

QP Date (Rev): ----

Frequency Responsibility Reaction plan

100%

1P/Hr

1P/Hr

1P/Hr

1P/Hr
If components
Quality Inspector

1P/Hr found ok, send it


to Customer. If
100% components
found defective,
reject qty &
100%
Inform to
production
100%

100%

100%

100%

100%

100%

1P/Forging Lot
Approved by : K K KOHLI
YAWALKAR INDUSTRIES
CONTROL PLAN ENGINEERING CHANGE DOCUMENTS
PROTOTYPE PRE-LAUNCH PRODUCTION
ATTACHED
Control Plan Number CP Rev No Key Contact/Phone Date (Orig.) Date (Rev.)
YI/GCL/CP 0094.12.06.2014 03 R B Neve (9881494915) 1/12/2015
Part Number/ Part Rev./Rev Date: Core Team Customer Engineering Approval/Date (If Req'd.)
200606530014 / 03 (12/11/2014) M D Mandhare NA
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)
INJECTOR YOKE 12/18/2014
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
YAWALKAR INDUSTRIES
Characteristic Methods Control Method
Description of Machine tool/ Prod /Proc Measurement Sample
Opn # M/C # Product Process Special Char Record Responsibility Reaction plan
operation Fixture Spec/Tol technique Size/Freq

Receipt of Raw DIA 36 mm En-8 BAR


10 --- --- --- --- Ø 36 --- --- --- --- ---
Material STOCK

Material TC
Chemical %C - 0.4 to 0.5
Raw Material DIA 36 mm En-8 BAR analysis - Third %Mn - 0.6 to 0.9
20 --- --- --- --- Ø 36 Each Lot Supervisor Ratain for 90 days
Testing STOCK party material %Si - 0.4 Max
Testing report %S - 0.045 Max
%P - 0.045 Max

1. Stop the
production &
First Piece Approval imform to
PHSW Report, Supervisor
30 Forging 0.3 T Hammer L 70 mm --- --- ± 1.0 Digital Vernier Each Lot Supervisor Ratain for 90 days
01 Hardness 201 to 255
BHN 2. Check the
privious
component for OK
ID Æ9 --- --- ± 0.100 Plug Gauge 100% Supervisor piece

3. Identify and
Drilling 1st Set First Piece Approval keep the
40 Drill Tap Center C 04 R 20 --- C --- Radius Gauge 100% Supervisor
up Report component in
rejected/ rework
Surface area
FINISH Rz12.5 --- --- --- 1P/Hr Supervisor
comparator
4. Correct the
setting & take the
fIrst piece
approval

5. Tool change
Page 19 of 39
Frequency/30P
YAWALKAR INDUSTRIES
CONTROL PLAN ENGINEERING CHANGE DOCUMENTS
PROTOTYPE PRE-LAUNCH PRODUCTION
ATTACHED
Control Plan Number CP Rev No Key Contact/Phone Date (Orig.) Date (Rev.)
YI/GCL/CP 0094.12.06.2014 03 R B Neve (9881494915) 1/12/2015
Part Number/ Part Rev./Rev Date: Core Team Customer Engineering Approval/Date (If Req'd.)
200606530014 / 03 (12/11/2014) M D Mandhare NA
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)
INJECTOR YOKE 12/18/2014
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
YAWALKAR INDUSTRIES
Characteristic Methods Control Method
Description of Machine tool/ Prod /Proc Measurement Sample 1. Stop the
Opn # M/C # Product Process Special Char Record Responsibility production
Reaction&plan
operation Fixture Spec/Tol technique Size/Freq
imform to
Drilling 2nd Set First Piece Approval Supervisor
50 Drill Tap Center C 04 ID 12.1 (Taper 5 Deg) --- --- ± 0.100 Digital Vernier 100% Supervisor
up Report
2. Check the
privious
Slot W 22.2 --- --- + 0.100 Digital Vernier 100% Supervisor component for OK
piece

3. Identify and
Dist 13.5 --- --- ± 0.200 Digital Vernier 100% Supervisor keep the
First Piece Approval component in
60 Milling Milling rejected/ rework
Report
area
Dist 34 --- --- ± 0.200 Digital Vernier 100% Supervisor
4. Correct the
setting & take the
Digital Height fIrst piece
Ch 4 X 45 Deg --- --- ± 0.100 1P/Hr Supervisor
Gauge approval

5. Tool change
Frequency/30P

Page 20 of 39
YAWALKAR INDUSTRIES
CONTROL PLAN ENGINEERING CHANGE DOCUMENTS
PROTOTYPE PRE-LAUNCH PRODUCTION
ATTACHED
Control Plan Number CP Rev No Key Contact/Phone Date (Orig.) Date (Rev.)
YI/GCL/CP 0094.12.06.2014 03 R B Neve (9881494915) 1/12/2015
Part Number/ Part Rev./Rev Date: Core Team Customer Engineering Approval/Date (If Req'd.)
200606530014 / 03 (12/11/2014) M D Mandhare NA
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)
INJECTOR YOKE 12/18/2014
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
YAWALKAR INDUSTRIES
Characteristic Methods Control Method
Description of Machine tool/ Prod /Proc Measurement Sample 1. Stop the
Opn # M/C # Product Process Special Char Record Responsibility Reaction plan
operation Fixture Spec/Tol technique Size/Freq production &
imform to
Supervisor
R 30 --- --- --- Radius Gauge 100% Supervisor
2. Check the
privious
Surface component for OK
Rz 16 --- --- --- 1P/Hr Supervisor
comparator piece

3. Identify and
Surface First Piece Approval
70 Grinding R 50 --- --- --- Radius Gauge 100% Supervisor keep the
Grinder Report
component in
rejected/ rework
Surface area
Rz 25 --- --- --- 1P/Hr Supervisor
comparator
4. Correct the
setting & take the
Digital Height fIrst piece
Dist 7.37 --- --- ± 0.100 100% Supervisor
Gauge approval

5. Tool change
Deburring and As per YI/GCL/PDIR Quality Give back for
Frequency/30P
80 --- --- --- --- --- --- Visual 100%
cleaning all over 0094.00.12.06.2014 Supervisor Deburring

Quarantine &
Visual and As per YI/GCL/PDIR Quality
90 PDI --- --- Final Inspection --- --- --- 10 per lot Check Qty &
Digital Vernier 0094.00.12.06.2014 Supervisor
status on Box.
Quarantine &
Packing & Standard Neat , Clean
100 Tixo tape --- Pack Box Packing Visual Continual PDIR and Sticker Supervisor Check Qty &
Dispatch Packing Packing
status on Box.

Page 21 of 39
YAWALKAR INDUSTRIES
PRE-DELIVERY INSPECTION REPORT

GREAVES COTTON LTD. (DEU) Challan No. DATE: Lot Qty:

PART NAME : INJECTOR CLAMP Part No. 200606530014 Rev./Rev Dt: 03 (12/11/2014) Sample Qty: 10/Lo

Sr. Obsevations
Dimention Measuring Aid
No 1 2 3 4 5 6 7 8
1 Dia 9.0 Digital Vernier Calliper 9.01 9.00 9.00 9.01 9.01 9.01 9.01 9.00

2 Dia 12.1 Digital Vernier Calliper 12.2 12.1 12.2 12.2 12.1 12.1 12.1 12.1

3 Dist 13.5 Digital Height Gauge 13.4 13.5 13.4 13.4 13.4 13.4 13.5 13.5

4 Dist 3.5 Digital Height Gauge 3.5 3.4 3.4 3.4 3.5 3.4 3.5 3.4

5 Height 23.1 Digital Height Gauge 23.1 23.1 23.1 23.2 23.2 23.2 23.1 23.2

6 Dist 7.37±0.1 Digital Height Gauge 7.40 7.41 7.41 7.41 7.41 7.41 7.41 7.41

7 Dist 22.2+0.1 Digital Vernier Calliper 22.2 22.3 22.2 22.2 22.2 22.2 22.3 22.3

8 R20 Radius Radius Gauge OK OK OK OK OK OK OK OK

9 R50 Radius Radius Gauge OK OK OK OK OK OK OK OK

10 R30 Radius Radius Gauge OK OK OK OK OK OK OK OK

11 Hardness 201 to 255 BHN Hardness Tester 250 250 245 245 250 245 245 250

Visual - Free from burr, Dent, Damages


12 , Sharp edges , blow holes , & rust
Visual OK OK OK OK OK OK OK OK

Remark :-

YI/GCL/PDIR N0014.00.07.05.2014
Page 22 of 39
YAWALKAR INDUSTRIES
PRE-DELIVERY INSPECTION REPORT

GREAVES COTTON LTD. (DEU) Challan No. DATE: Lot Qty:

PART NAME : INJECTOR CLAMP Part No. 200606530014 Rev./Rev Dt: 03 (12/11/2014) Sample Qty: 10/Lo

Sr. Obsevations
Dimention Measuring Aid
No 1 2 3 4 5 6 7 8

Checked By & Date:

YI/GCL/PDIR N0014.00.07.05.2014
Page 23 of 39
mple Qty: 10/Lot

9 10
9.00 9.00

12.1 12.1

13.5 13.5

3.5 3.5

23.2 23.2

7.40 7.40

22.3 22.2

OK OK

OK OK

OK OK

250 250

OK OK

YI/GCL/PDIR N0014.00.07.05.2014
Page 24 of 39
mple Qty: 10/Lot

9 10

YI/GCL/PDIR N0014.00.07.05.2014
Page 25 of 39
YAWALKAR INDUSTRIES
List of CTQs
PART NAME : INJECTOR CLAMP FORGED Part No. 200606530014

Sr.
Dimention Measurement Method
No
1 Dist 13.5 Height Gauge

2 Dist 7.37±0.1 Height Gauge

3 Dist 22.2+0.1 Vernier


4 R20 Radius Radius Gauge
5 R50 Radius Radius Gauge
Packing Standard

YAWALKAR
INDUSTRIES PACKING STANDARD
PART NAME:- CUSTOMER NAME & CODE:- PROJECT/MODEL Doc. No:
INJECTOR CLAMP FORGED GREAVES COTTON LTD NEW D ENGINE 012-1415-06
PART NO/REV NO:- CUSTOMER PART NO(IF ANY):- Issue Date:
200606530014 15-02-2015
Packing mode (  ) A Special trolley D General purpose plastic bin / trolley

Returnable (Y/N) B General purpose trolley E Carton box G Polythene bag


N C Special plastic bin F Wooden box H Others
In case of other Give Detail:-

Part weight Part dimension ( mm ) Supplier Identification on


0.13 g
(single) Length Width Height packing:
STICKER WITH PART NO., DC NO.
Packing mode weight AND QTY
-- -- --
( Unladen/Empity ) Technical details
Packing mode weight Packing mode dimension ( mm ) Carton box
(Laden/Filled) Length Width Height
Packing capacity No. of Piece 50 PER BOX
-- -- --

Note : 1) Mass production supplies to be done as per the approved packing


2) If any discrepancy observed while parts receiving,Q.A / Stores has the authority to reject / send
back the material.
Revision No. Reason for Revision Person In charge

Prepared By: Approved by: Date:

Page 27
Packing Standard

ARD
Doc. No:
012-1415-06
Issue Date:
15-02-2015

upplier Identification on
packing:
KER WITH PART NO., DC NO.
AND QTY

Technical details
Carton box

50 PER BOX

Date

Page 28
YAWALKAR INDUSTRIES
BIAS STUDY REPORT

Instrument Name : Digital Vernier Date 5/8/2013

I.D. No. : DV / 01 / 01 Reference Standard 10.000

Min. Tolerance 0.001

Sr No. Reading

1 10.001

2 10.001

3 9.998

4 10.001

5 9.998

6 9.998

7 10.001

8 10.002

9 10.001

10 10.002

Average 10.000

Bias = Observed Value - Reference Value

Bias = 0.000

% Bias = 0

Result : Since % Bias less than 10 % . It is acceptable


YI/GCL/BSR 0094.00.12.06.2014
R 0094.00.12.06.2014
YAWALKAR INDUSTRIES
LINEARITY STUDY REPORT

Instrument Name Digital Vernier Date 1/12/2015


ID No. DV / 01 / 01 Min. Tol. 0.001
L.C 0.001 mm
Part 1 2 3 4 5
Ref Value 25.002 50.000 75.001 100.005 125.000
1 25.005 50.001 75.001 100.009 125.001
T
2 24.995 49.995 74.998 100.002 124.979
3 24.989 49.993 75.001 100.003 125.000
R
4 24.983 49.989 74.998 100.000 124.989
5 25.089 50.005 74.998 100.003 125.000
I
6 25.008 49.987 75.001 100.000 124.987
7 25.012 50.006 75.001 100.007 125.000
A
8 24.997 49.994 75.001 99.997 125.001
9 25.005 50.010 75.001 100.020 124.988
L
10 25.003 50.005 75.010 99.989 125.000
11 25.007 50.020 74.980 99.986 124.997
S
12 25.001 49.996 75.010 99.991 125.000
Part Average 25.008 50.000 75.000 100.001 124.995

Ref Value ( x ) 25.00 50.00 75.00 100.01 125.00


Bias ( y ) 0.01 0.00 0.00 0.00 0.00
Range 0.11 0.03 0.03 0.03 0.02
Sigma ( x ) 375.008
Sigma (x2) 34376.250 625.10 2500.00 5625.15 10001.00 15625.00
(Sigma x)2/n 28126.200
Sigma ( x/n ) 75.002
Sigma ( xy) -0.971 0.15 0.00 -0.08 -0.44 -0.60
Sigma ( y ) -0.004
Sigma (y2) 0.000 0.00 0.00 0.00 0.00 0.00
(Sigma y)2/n 0.000
Sigma (y/n) -0.001
Slope a = -0.0001
Intercept b = 0.007
R2 0.900
Bias = b + a*x 0.0043 0.0017168 -0.000867 -0.00345 -0.00603316
|slope|*process
Linearity = 0.0000
Variation
100(Linearity /
% Linearity = 0.01 or| Slope | * 100
(process Variation
Goodness Factor
0.900 Less than 1 % , then accepted
R2

Linearity Plot
1
0.
07
0.
04
0. Bias ( y )
01
0.
2
.0
-0
5
.0
-0

YI/GCL/LSR 0014.00.12.06.2014
YAWALKAR INDUSTRIES
GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET GAGE REPEATABILITY AND REPRODUC
VARIABLE DATA RESULTS VARIABLE DATA RESU
Part Number Gage Name Appraiser A Part Number Gage Name
201203550094 DIGITAL VERNIER 201203550094 DIGITAL VERNIER
Part Name Gage Number Appraiser B Part Name Gage Number
DIPSTICK SLEEVE DV/ 01 /01 DIPSTICK SLEEVE DV/ 01 /01
Characteristic Specification Gage Type Appraiser C Characteristic Gage Type
A/F 16.966 16.984 A/F
Characteristic Classification Trials Parts Appraisers Date Performed Characteristic Classification Trials Parts
3 10 3 14/06/2014 3 10

APPRAISER/ PART AVERAGE Measurement Unit Analysis


TRIAL # 1 2 3 4 5 6 7 8 9 10 Repeatability - Equipment Variation (EV)
1. A 1 16.975 16.975 16.975 16.976 16.976 16.975 16.975 16.975 16.976 16.975 16.975 EV = R x K1 Trials
2 2 16.975 16.975 16.975 16.976 16.976 16.975 16.975 16.975 16.976 16.975 16.975 = 0.000 x 3.05 2
3 3 16.975 16.975 16.975 16.976 16.976 16.975 16.975 16.975 16.976 16.975 16.975 = 0.000 3
4 xa=
AVE 16.975 16.975 16.975 16.976 16.976 16.975 16.975 16.975 16.976 16.975 16.975 Reproducibility - Appraiser Variation (AV)
5 R 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 ra= 0.000 AV = {(xDIFF x K2)2 - (EV2/nr)}1/2
6. B 1 16.975 16.975 16.975 16.975 16.975 16.975 16.975 16.976 16.975 16.975 16.975 = {(0.000 x 2.7)^2 - (0.000 ^2/(10 x 3))}^1/2
7 2 16.975 16.975 16.975 16.975 16.975 16.975 16.975 16.976 16.975 16.975 16.975 = 0.001 Appraisers 2
8 3 16.975 16.975 16.975 16.975 16.975 16.975 16.975 16.976 16.975 16.975 16.975 K2 3.65
9 AVE 16.975 16.975 16.975 16.975 16.975 16.975 16.975 16.976 16.975 16.975 xb= 16.975 Repeatability & Reproducibility (R & R)
10 R 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 rb= 0.000 R&R = {(EV2 + AV2)}1/2 Parts
11. C 1 16.975 16.975 16.975 16.975 16.975 16.975 16.976 16.975 16.975 16.975 16.975 = {(0.000^2 + 0.001^2)}^1/2 2
12 2 16.975 16.975 16.975 16.975 16.975 16.975 16.976 16.975 16.975 16.975 16.975 = 0.001 3
13 3 16.975 16.975 16.975 16.975 16.975 16.975 16.976 16.975 16.975 16.975 16.975 Part Variation (PV) 4
14 xc=
AVE 16.975 16.975 16.975 16.975 16.975 16.975 16.976 16.975 16.975 16.975 16.975 PV = RP x K3 5
15 R 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 rc= 0.000 = 0.000 x 1.62 6
16. PART X= 16.975 = 0.001 7
AVE ( Xp ) 16.975 16.975 16.975 16.975 16.975 16.975 16.975 16.975 16.975 16.975 Rp= 0.000 Tolerance 8
17 (ra + rb + rc) / (# OF APPRAISERS) = R= 0.000 Tol = Upper - Lower 9
18 (Max x - Min x) = xDIFF= 0.000 = 16.984 - 16.966 10
19 R x D4* = UCLR= 0.000 = 0.018
20 R x D3* = LCLR= 0.000
All calculations are based upon predicting 5.15 sigma (99.0% of the area under the normal
* D4 =3.27 for 2 trials and 2.58 for 3 trials; D3 = 0 for up to 7 trials. UCLR represents the limit of individual R's. Circle those that are K1 is 5.15/d2, where d2 is dependent on the number of trials (m) and the number if parts tim
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or dis- assumed to be greater than 15.
card values and re-average and recompute R and the limiting value from the remaining observations. AV - If a negative value is calculated under the square root sign, the appraiser variation (AV
K2 is 5.15/d2, where d2 is dependent on the number of operators (m) and (g) is 1, since ther
Notes: K2 is 5.15/d2, where d2 is dependent on the number of parts (m) and (g) is 1, since there is
d2 is obtained from Table D3, "Quality Control and Industrial Statistics", A.J. Duncan.

YI/GCL/G R&R N0014.00.07.05.2014


EPRODUCIBILITY DATA SHEET
ATA RESULTS
Appraiser A
RNIER
Appraiser B

Appraiser C

Appraisers Date Performed


10 3 6/14/2014

% Tolerance (Tol)

K1 % EV = 100 (EV/Tol)
4.56 = 100(0.000/0.018)
3.05 = 0.00

% AV = 100 (AV/Tol)
= 100(0.001/0.018)
3 = 3.00
2.70 n = number of parts
r = number of trials
K3
3.65 % R&R = 100 (R&R/Tol)
2.70 = 100(0.001/0.018)
2.30 = 3.00
2.08 Gage system O.K
1.93
1.82 % PV = 100 (PV/Tol)
1.74 = 100(0.001/0.018)
1.67 = 3.00
1.62

under the normal distribution curve).


umber if parts times the number of operators (g) which is

aiser variation (AV) defaults to zero (0).


(g) is 1, since there is only one range calculation.
s 1, since there is only one range calculation.
J. Duncan.
CONTROL CHART ( Process Capability Study )
CUSTOMER GREAVES COTTON LTD. (DEU) Date :- 12.01.2015 Instrument No: DV/01/01
Machine GRINDING Study conducted by :- Neve Instrument Name: Digital Vernier
Characteristics: OD LC: 0.001mm
LSL: 7.270 YI/GCL/Cp-Cpk 0094.00.12.06.2014 Range: 0- 150 mm
USL: 7.470 Part no 200606530014
Specs 7.37±0.1 Die no ---

Time 1 2 3 4 5 6 7 8 9 10
R 1
E
7.450 7.390 7.390 7.390 7.390 7.390 7.390 7.390 7.390 7.430
A 2 7.390 7.390 7.390 7.390 7.390 7.390 7.390 7.390 7.390 7.430
D
I
3 7.410 7.410 7.410 7.410 7.410 7.410 7.410 7.410 7.410 7.430
N 4 7.440 7.410 7.410 7.410 7.410 7.410 7.410 7.410 7.410 7.390
G
S 5 7.430 7.410 7.410 7.410 7.410 7.410 7.410 7.410 7.410 7.390

X 7.424 7.402 7.402 7.402 7.402 7.402 7.402 7.402 7.402 7.414
Range 0.060 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.040

Xbar 7.405
Rbar 0.026

X-UCL 7.470 Cp/Cpk Calculation Note :- Process is capable if Cpk is greater than 1.33
X-LCL 7.270 Sigma= 0.01116
Cp= 2.99
R-UCL 0.003 Cpk= 1.93
R-LCL 0.000

7.500

7.450
X Chart UCL

7.400

7.350

7.300

7.250

7.200

7.150
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

0.070

0.060
R Chart
0.050 UCL LCL R bar

0.040

0.030

0.020

0.010

0.000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
YAWALKAR INDUSTRIES

Part No.: 200606530014 Part Name: INJECTOR CLAMP Rev./Rev Dt.: 03 (12/11/2014)

CHECKING AIDS M/C NO. Qty CALIBRATION FREQUENCY PER YEAR

1 DIGITAL VERNIER DV/01/01 -- 1 2

2 PLOG GAUGE DIA 9.0 FX/GCL/0094/01 --- 1 2

3 RADIUS GAUGE R 20 FX/GCL/0094/02 --- 1 2

4 RADIUS GAUGE R 30 FX/GCL/0094/03 --- 1 2

5 RADIUS GAUGE R 50 FX/GCL/0094/04 --- 1 2

SURFACE ROUGHNESS
6 --- -- 1 ---
COMPARATOR

PREPARED BY R. B. NEVE

CHECKED BY M. D. MANDHARE DATE

YI/GCL/CA 0094.00.12.06.2014