Battery Pack Inspection Guide
Battery Pack Inspection Guide
PART NO. : KE242080 PRINT DATE : Dec 12, 2023 UNIT : BATTERY ASSY PLANT :3
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
BTM CELL HOLDER ORIENTATION OF
1 0005 INSERT ASSLY AND INSERTS(BIGGER AS PER TMOS VISUAL 1/Shift
LOADING SIDE IN)
THERMISTOR THERMISTOR
13 0040 PASTING-1,2,3& POSITION ON CELLS 15.0000 38.0000 65.0000 MM SCALE 3/SHIFT
INSERT ASSY
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
THERMISTOR ORIENTATION OF
14 0040 PASTING-1,2,3& CABLE AS PER TMOS VISUAL 3/SHIFT
INSERT ASSY
THERMISTOR PASTING OF
COMPLETE
15 0040 PASTING-1,2,3& THERMISTOR VISUAL 3/SHIFT
INSERT ASSY STICKER -1 ON CELL PASTING
THERMISTOR PASTING OF
COMPLETE
16 0040 PASTING-1,2,3& THERMISTOR VISUAL 3/SHIFT
INSERT ASSY STICKER-2 ON CABLE PASTING
THERMISTOR ORIENTATION OF
20 0040 PASTING-1,2,3& INSERTS( BIGGER VISUAL 1/SHIFT
INSERT ASSY SIDE IN)
THERMISTOR NO OF INSERTS ON
21 0040 PASTING-1,2,3& TOP CELL HOLDER 7.0000 7.0000 7.0000 EA VISUAL 1/SHIFT
INSERT ASSY
THERMISTOR THERMISTOR
23 0050 PASTING-4 & POSITION ON CELLS 15.0000 38.0000 65.0000 MM SCALE 3/SHIFT
ROUTING
THERMISTOR ORIENTATION OF
24 0050 PASTING-4 & CABLE AS PER TMOS VISUAL 3/SHIFT
ROUTING
THERMISTOR PASTING OF
COMPLETE
25 0050 PASTING-4 & THERMISTOR VISUAL 3/SHIFT
ROUTING STICKER -1 ON CELL PASTING
THERMISTOR PASTING OF
COMPLETE
26 0050 PASTING-4 & THERMISTOR VISUAL 3/SHIFT
ROUTING STICKER-2 ON CABLE PASTING
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
THERMISTOR THERMISTOR CABLE
27 0050 PASTING-4 & BLUE NO MISSING VISUAL 3/SHIFT
ROUTING LOCATION(X1,Y4)
THERMISTOR ROUTING OF
28 0050 PASTING-4 & THERMISTOR AS PER TMOS VISUAL 3/SHIFT
ROUTING CABLES
MODULE PRESENCE OF 6
35 0070 TIGHTENING(AUTO SCREWS - M4x60 VISUAL 3/SHIFT
STATION) FLANGE HEAD
MODULE VERIFICATION
36 0070 TIGHTENING(AUTO OFTIGHTENING 1.3000 1.8000 2.3000 NME M TRQ.WREN 3/SHIFT
STATION) TORQUE 6SCREWS
MODULE TIGHTENING
37 0070 TIGHTENING(AUTO SEQUENCE AS PER TMOS WORK-INS 3/SHIFT
STATION)
MODULE NO TRACEABILITY
39 0070 TIGHTENING(AUTO BYPASS IN HMI DISPLAY 3/SHIFT
STATION)
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
INTERCONNECTOR PRESENCE OF 7 no
40 0080 LOADING - TOP DUAL ROW VISUAL 3/SHIFT
INTERCONNECTOR
INTERCONNECTOR NO DAMAGE ON
41 0080 LOADING - TOP INTERCONNECTORS VISUAL 3/SHIFT
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
TOP WELDING-B NO FLASHES
53 0102 NOT ALLOWED VISUAL 3/SHIFT
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
FLIPPING NO DAMAGE ON
66 0110 MODULE VERIFY 3/SHIFT
INTERCONNECTOR PRESENCE OF
69 0120 LOADING - BOTTOM SINGLE ROW 2.0000 2.0000 2.0000 EA VERIFY 1/SHIFT
INTERCONNECTORS
INTERCONNECTOR NO DAMAGE ON
70 0120 LOADING - BOTTOM INTERCONNECTORS VISUAL 3/SHIFT
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
BOTTOM WELDING-B PULLOFF LOAD-
79 0142 SINGLE ROW(+ve&-ve 6.0000 0.0000 0.0000 KF PULL&CHK 1/DAY
LV cells
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
BOTTOM WELDING-C NO PEEL OFF OF
92 0143 INTERCONNECTOR NOT ALLOWED VISUAL 3/SHIFT
BTM CONDITION OF
96 0170 DAMPER,THERMAL DAMPERS NO DAMAGE VISUAL 3/SHIFT
SHEET&BTM SHELL
ASLY
BTM PRESENCE OF FOUR
97 0170 DAMPER,THERMAL DAMPERS ON VISUAL 3/SHIFT
SHEET&BTM SHELL BOTTOM SIDE
ASLY
BTM PRESENCE OF
98 0170 DAMPER,THERMAL BOTTOM SHELL VISUAL 3/SHIFT
SHEET&BTM SHELL
ASLY
BTM SEATING OF BOTTOM
99 0170 DAMPER,THERMAL SHELL ON MODULE NO GAP VISUAL 3/SHIFT
SHEET&BTM SHELL
ASLY
BTM CONDITION OF
100 0170 DAMPER,THERMAL BOTTOM SHELL NO DAMAGE VISUAL 3/SHIFT
SHEET&BTM SHELL
ASLY
RTV DISPENSING CURING TIME
101 0210 INTERLOCK IN DISPLAY 1/SHIFT
HMI-10min
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
TOP SHELL ASSLY TIGHTENING
105 0215 &(TIGHTENING SEQUENCE AS PER TMOS WORK-INS 3/SHIFT
CONTINGENC
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
SHELL TIGHTENING TIGHTENING TORQUE
118 0221 (AUTO STATION) IN CONTROLLER 3.7000 4.2000 4.7000 NME DISPLAY 3/SHIFT
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
BOTTOM COVER TIGHTENING
131 0230 TIGHTENING(AUTO SEQUENCE -16 AS PER TMOS WORK-INS 3/SHIFT
STATION) SCREWS
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
PCB LOADING THERMISTOR CABLE
144 0260 (TIGHTENING ROUTING ASPER AS PER TMOS CHECK 3/SHIFT
CONTINGENCY) COLORCODE
PCB PRESENCE OF 15
146 0270 TIGHTENING(AUTO SCREWS - M4x12SP 15 SCREWS VISUAL 3/SHIFT
STATION)
PCB VERIFICATION
147 0270 TIGHTENING(AUTO OFTIGHTENING 1.3000 1.8000 2.3000 NME M TRQ.WREN 3/SHIFT
STATION) TORQUE15SCREWS
PCB TIGHTENING
148 0270 TIGHTENING(AUTO SEQUENCE -15 AS PER TMOS WORK-INS 3/SHIFT
STATION) SCREWS
PCB NO TRACEABILITY
149 0270 TIGHTENING(AUTO BYPASS IN HMI DISPLAY 3/SHIFT
STATION)
INSERT&FUSE PRESENCE OF
150 0280 TIGHTENING & COVER HOUSING 15 NOS VISUAL 3/SHIFT
THERMISTOR PLUG CAP
INSERT&FUSE VERIFICATION
152 0280 TIGHTENING & OFTIGHTENING 3.0000 3.5000 4.0000 NME C TRQ.WREN 3/SHIFT
THERMISTOR PLUG TORQUE 2SCREWS
INSERT&FUSE TIGHTENING
155 0280 TIGHTENING & SEQUENCE - 2 NOS AS PER TMOS WORK-INS 3/SHIFT
THERMISTOR PLUG
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
+VE & -VE TERMINAL VERIFICATION OF
157 0290 TIGHTENING & +VE 2 SCREWS TT 2.2000 2.7000 3.2000 NME C TRQ.WREN 3/SHIFT
CORDSET
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
TOP COVER GASKET SEATING
PROPER
170 0310 TIGHTENING (AUTO CONDITION ON VISUAL 3/SHIFT
STATION) TOPCOVER SEATING
THERMALPAD VISIBILITY OF
180 0340 PASTING&LASERMAR MARKING VISUAL 3/SHIFT
K ON TOPCOVER
THERMALPAD CORRECT
181 0340 PASTING&LASERMAR NUMBERING AS PER VISUAL 3/SHIFT
K ON TOPCOVER DRG
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
THERMALPAD COMPLETE MARKING
183 0340 PASTING&LASERMAR VISUAL 3/SHIFT
K ON TOPCOVER
THERMALPAD PASTING OF
184 0340 PASTING&LASERMAR THERMAL PAD VISUAL
K ON TOPCOVER
CHAGORI PRESENCE OF
194 0370 TIGHTENING CONTROLLER BMS VISUAL 3/SHIFT
CHAGORI PRESENCE OF
195 0370 TIGHTENING CLAMP CORDSET VISUAL 3/SHIFT
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
CHAGORI PRESENCE OF
196 0370 TIGHTENING SCREWS - M3x8 VISUAL 3/SHIFT
CHAGORI VERIFICATION
197 0370 TIGHTENING OFTIGHTENING 0.4000 0.6000 0.8000 NME C TRQ.WREN 3/SHIFT
TORQUE 4SCREWS
CHAGORI TIGHTENING
198 0370 TIGHTENING SEQUENCE WORK-INS 3/SHIFT
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
RTV APPLICATION SEALANT ON +VE
209 0390 TERMINAL- 2 CHECK 3/SHIFT
SCREWS
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
HRD & EOL - NO FLAG ERROR
222 0430 CAPACITY TESTING DISPLAY 3/SHIFT IN T
ST-1(40CH)
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
HRD & EOL - RATED CAPACITY OF
235 0432 CAPACITY TESTING PACK @ 1C 15.8000 0.0000 0.0000 A/H C DISPLAY 3/SHIFT IN T
ST-3(40CH)
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
HRD & EOL - RATED ENERGY OF
248 0434 CAPACITY TESTING PACK @ 1C 0.8000 0.0000 0.9000 KWH C DISPLAY 3/SHIFT IN T
ST-5(40CH)
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
HRD & EOL - DISCHARGE
261 0437 CAPACITY TESTING OPERATING 10.0000- 0.0000 55.0000 °C S DISPLAY 3/SHIFT IN T
ST-8(40CH) TEMPERATURE
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
HRD & EOL - NO FLAG ERROR
274 0439 CAPACITY TESTING DISPLAY 3/SHIFT IN T
ST-10(40CH
PART NAME : BATTERY PACK ASSY MODEL: UP.467F CELL / LINE NAME : LINE-2
OBSERVATION
Quantitative
Specification 1 2 3 1 2 3 1 2 3
S. Op. Operation Qualitative Spl. Check
Parameters UOM Frequency Result
No No.
No. Desc. Desc. Char Method Date / Shift
L T U
HRD & EOL - NO FLAG ERROR
287 0441 CAPACITY TESTING DISPLAY 3/SHIFT IN T
ST-12(12CH