Subject : CONTROL PLAN REV NO : 00

Prototype Pre-Lauch Production Key Contact / Phone : 020 - 27474447 / 8 Date: 07.05.10
Part Number / Latest Change level : 90006623 ' a ' 29.05.09 CoreTeam:Mr.P.P.Sehmbey,Mr Deepak ,Mr.Sahota, Mrs. A. S. Kad Customer Engineering Approval/Date( if Reqd.)
Part Name : SWAY BAR Supplier/Plant Approval/Date : Customer Quality Approval/Date (If Req'd.)
Supplier/Plant: Mansons Suspension PVT.LTD. Other Approval/Date (If Req'd.) : Other Approval/Date (If Req'd.)
Part / Characteristics Spec Methods
Process Name / Machine, Device,
Process Char. Product / Process Evaluation Error Sample Reaction plan
Operation Description Jig, Tools for Mfg. No. Product Process Control Method
Number Class specification / Measurement Proofing Size Freq.
1 1 REJECT
10 RAW MATERIAL CHEMICAL ANALYSIS CC % C 0.47 to 0.55 QUALITATIVE
Heat Month VARIFICATION WITH
COMPOSITION
Code SUPPLIER TC AND
RECEIVING & INSPECTION [ 51 CrMoV4] % Mn 0.70 to 1.00 ANALYSIS
SPECIFICATION BY
CHECKING FROM
20 TO CONFIRM % Si 0.15 to 0.35
OUTSIDE LAB.
METALLURGICAL % S 0.02 to 0.040

PROPERTIES %P 0.040 max.

% Cr 0.90 to 1.20

% Mo 0.15 to 0.25

%V 0.15 max

% Al 0.02 to 0.06
2 INCLUSION RATING A [ 2.5 ] B [ 2.0 ] MICROSCOPE 1
C [ 2.0 ] D [ 2.0 ] THIN
Heat Month VARIFICATION WITH
A [ 0 .5 ] THICK Code
IS 4163 - J.K. CHART
3 GRAINSIZE 5 - 8 ASTM MICROSCOPE SAME AS CHEMICAL
ANALYSIS
4 MICROSTRUCTURE FERRITE + PEARLITE MICROSCOPE
same as above
5 HARDNESS 240 BHN MAX. 10 HEAT REWORK LESS REJECT
AS PER WORK
BRINELL HARDNESS
TESTER INSTRUCTION

6 LENGTH MEASURING TAPE 10 LOT AS PER CONTROL REJECT

PLAN
7 STRAIGHTNESS VISUALLY 100% REWORK
FREE FROM FLAWS,
8 SURFACE DEFECTS LAPS,SEAMS, PEELING VISUALLY
MARKS, CRACKS, RUST
ETC.

30 CUTTING TO SIZE Double piller cutting m/c 1 DIA 56 - 0.13 MM VERNIER CALIPER 5 Nos. Hr REJECT

1 ST PIECE APPR. &

Stopper
2 LENGTH 1548 +/- 1 MM MEASURING TAPE 5 Nos. Hr INPROCESS ADJUST & RESET
Setting
INSPECTION
 Part / Characteristics Spec Methods
Process Name / Machine, Device, Product / Process Evaluation
Process Char. Error Sample Reaction plan
Operation Description Jig, Tools for Mfg. No. Product Process specification / Measurement Control Method
Number Class Proofing Size Freq.
Tolerance Technique
USE OF
TEMP. OF END OF Continuous ADJUST OIL FLOW BY
40 HEATING Oil fired heating furnace 1 TEMPERATURE 900-1100 Deg. Cel THERMOCOUPLE THERMOCOUPLE &
BAR monitoring OPERATOR
RECORD SHEET

TIME 1 - 2 Mins. STOP WATCH

Size
FORGING OF ONE END & POWER PRESS, FIRST OFF APPROVAL RESETTING OR
50 1 WIDTH / FORGED OD CC 68.1 +/- 2.5 MM VERNIER CALIPER Specific 5 Nos. Hr
ANNEALING Forging die, lime powder RECORDED CHANGE OF DIE
Die

2 THICKNESS CC 38 +/- 0.5 MM VERNIER CALIPER 5 Nos. Hr AS ABOVE AS ABOVE

USE OF
TEMP. OF END OF Continuous ADJUST OIL FLOW BY
60 HEATING Oil fired heating furnace 1 TEMPERATURE 900-1100 Deg. Cel THERMOCOUPLE THERMOCOUPLE &
BAR monitoring OPERATOR
RECORD SHEET

TIME 1 - 2 Mins. STOP WATCH

Size
FORGING OF SECOND POWER PRESS, FIRST OFF APPROVAL RESETTING OR
70 1 WIDTH CC 68.1 +/- 2.5 MM VERNIER CALIPER Specific 5 Nos. Hr
END & ANNEALING Forging die, lime powder RECORDED CHANGE OF DIE
Die

2 THICKNESS CC 38 +/- 0.5 MM VERNIER CALIPER 5 Nos. Hr AS ABOVE AS ABOVE

GRINDING THROUGH
80 PEDSTRAL GRINDING 1 LENGTH 1580 +/- 1 MM FIXURE 100% TRAINED OPERATOR RESETTING OF FIXURE
ROUGH EDGES.
DRILLING & 1 ST PIECE APPR. &
Drill machine, Drill bit,
90 CHAMPHERING FIRST 1 HOLE DIA 47.6 +/- 0.13 MM PLUG GAUGE 5 Nos. Hr INPROCESS CHANGE OF DRILL
Champher Drill
HOLE INSPECTION
1 ST PIECE APPR. &
2 WALL THICKNESS 10.25 +/- 0.2 MM VERNIER CALIPER 5 Nos. Hr INPROCESS CHANGE OF DRILL
INSPECTION
DRILLING & CHANGE OF DRILL,
95 CHAMPHERING SECOND 1 HOLE DIA 47.6 +/- 0.13 MM PLUG GAUGE 5 Nos. Hr SAME AS ABOVE RESETTING OF
HOLE FIXTURE
1 ST PIECE APPR. &
2 WALL THICKNESS 10.25 +/- 0.2 MM VERNIER CALIPER 5 Nos. Hr INPROCESS CHANGE OF DRILL
INSPECTION

3 CD CC 1512 +/- 1 MM FIXTURE 100%

LATHE MACHINE, INPROCESS

100 TURNING & GRINDING 1 DIA CC 44.5 - 0.13 MM VERNIER CALIPER 5 Nos. Hr
GRINDING MACHINE INSPECTION

WALKING BEAM USE OF

Continuous ADJUST OIL FLOW BY
110 HEATING HARDENING 1 UNIFORM HEATING TEMPERATURE 850 +/- 10 Deg. C THERMOCOUPLE THERMOCOUPLE &
monitoring OPERATOR
FURNANCE RECORD SHEET
MEASUREMENT RESET IF REQUIRED BY
TIME 27 - 30 MINS 1 Day RECORD SHEET
WATCH SUPERVISIOR
Part
BENDING TOOL, FIRST OFF
120 BENDING & QUENCHING 1 CD MAJOR 642.1 +/- 3.2 MM MEASURING TAPE Specific 5 Nos. Hr RESETTING OF TOOL
QUENCHING OIL RECORDED
Fixture
2 HEIGHT MAJOR 400.1 +/- 6.4 MM HEIGHT GAUGE 5 Nos. Hr

MEASUREMENT RESET IF REQUIRED BY

QUENCHING TIME 4 MINUTES MINIMUM 1 Day
WATCH SUPERVISIOR
QUENCHING OIL RESET IF REQUIRED BY
45 - 80 Deg Cel. THERMOCOUPLE 1 Day
TEMPERATURE SUPERVISIOR
CheckTemp.Ensure
1 HARDNESS MAJOR 52 - 58 HRC ROCKWELL H.T. 1 Hr RECORD SHEET
Quenching Delay
 Part / Characteristics Spec Methods
Process Name / Machine, Device, Product / Process Evaluation
Process Char. Error Sample Reaction plan
Operation Description Jig, Tools for Mfg. No. Product Process specification / Measurement Control Method
Number Class Proofing Size Freq.
Tolerance Technique
Oil Fired Contineous CONTINUOUS ADJUST OIL FLOW BY
130 TEMPERING TEMPERATURE 410 +/- 10.C THERMOCOUPLE RECORD SHEET
Tempering Furnace MONITORING OPERATOR

TIME 3.5 TO 4.5 Hrs. P.D.T.

BRINELL HARDNESS
1 HARDNESS CC 40 - 50 HRC 3 PALLET X bar R barCHART HARD - REWORK / SOFT- REJECT
TESTER

MAGNAFLUX CRACK LONGITUDINALLY &

140 CRACK DETECTION
DETECTION MACHINE
1 CRACK DETECTION
TRANSVERSE
VISUALLY 100% RECORD SHEET REJECT

CONCENTRATION 0.2 TO 0.5 DIV ( 0.75

OF GMS/LTR OF MAGNETIC ON THE FLASK DAILY
FLUORESCENT MEDIUM PARTICLES )

CURRENT 1200 - 1400 AMPS. AMMETER

INSPECTION FIXURE
HYDRUALIC PRESS, Rectification modify,
150 PROFILE CHECKING 1 CD CC 642.1 +/- 3.2 MM OR MEASURING 100%
FITMENT FIXTURE, BENDING TOOL
TAPE
MEASURING TAPE,
HEIGHT GAUGE 2 HEIGHT CC 400.1 +/- 6.4 MM HEIGHT GAUGE

SHOT PEENING CONFIRM PLACEMENT OF

160 SHOT PEENING 1 COVERAGE MINIMUM 90 % VISUAL 100% BARS
MACHINE
SHOT GRADE INTENSITY OR ARC RESETTING FOR
2 HEIGHT
0.40 TO 0.50 ALMEN GAUGE 1 WEEK RECORDED
S 270-330 CURRENT & TIME

CURRENT 22 - 25 Amps AMMETETR CONTINEOUS ADDITION OF SHOTS

PEENING TIME 3 - 5 MINS. TIMER CONTINEOUS RESET IF REQUIRED.

170 POWDER COATING ELECTRASTATIC GUN 1 FILM THICKNESS 50 MICRONS MIN DFT METER 5 LOT RECORD SHEET

SPRAYING & BAKING TEMPERATURE 240 +/- 10Deg. C THERMOCOUPLE 1 Hr RECORD SHEET
BAKING OVEN , JIGS,
EPOXY POLYSTER
BAKING TIME 25 MINUTES P.D.T.
POWDER , SG
SATINBLACK, MAKE MODIFYBAKING
BERGER 2 PENCIL HARDNESS 3H 3H PENCIL 5 LOT
TREATMENT
PREDESPATCH REJECT & CORRECTIVE
190 FINAL INSPECTION 1 BAR DIA 44.5 +/- 0.13 MM VERNIER CALIPER 10 NO. LOT
INSPECTION REPORT ACTION
2 C.D. 642.1 +/- 3.2 MM MEASURING TAPE 10 NO. LOT as above

3 HEIGHT 400.1 +/- 6.4 MM HEIGHT GAUGE 10 NO. LOT as above

4 HOLE DIA 47.6 +/- 0.13 MM VERNIER CALIPER 10 NO. LOT as above

5 FORGED OD 68.1 +/- 2.5 MM VERNIER CALIPER 10 NO. LOT as above

6 FORGED THK. 10.25 +/- 0.2 MM VERNIER CALIPER 10 NO. LOT as above

7 DIM 860.7 +/- 3.2 MM VERNIER CALIPER 10 NO. LOT as above