Wba000038000 CP
Wba000038000 CP
: 'IPA/832
                                                                                                                                                                     CONTROL PLAN                                                                                                                                       Date ( Orig. ) :- 2/11/2024
                                                                                                                                                                                                                                                                                                                              Rev.NO 1                                       Rev. Date: 8/8/2024
                         CUSTOMER: Dorman                                                 PART NAME :        Pre pressed wheel hub                DRG.NO:        WBA000038117                             DRG REV NO : 00                         Prototype : ¨       Prelaunch :   þ       Production: o                                                                            AUTONOMOUS           MAINTENANCE (BY OPERATOR)
                                                                                                                                                                                          MACHINE /Device/Tool                               RECORD BY                                             Cycle Time                                                                             Control Document: CLIA Check Sheet
                                                                                                                                  Process Number                Process Name                                                   OPERATORS/
 KEY CONTACT:                                           CORE TEAM- Amit / Vinod/ Hardik / Prakash/Rupesh /                                                                                                                                           INSPECTOR                                                                                              CHECK POINT                                           SPECS                                          FRQE.
            Mr. Amit Singh                              Rohit / Hitesh                                                                                                                                                           SETTER
                                                                                                                                                                                              DB BEPM - 01                                                                                          12 Sec
                                                                                                                                       20                      Bearing Pressing                                                     l                    □
                                Characteristics                                                                                                                           Production                                    QA
                                                                        Special                                                                                                                                                                                                                                                            General cleaning                              M/C cleaning                                                             Daily
                                                                                                                 Evaluation Measurement         Error                      Sample                                    Sample
 S.N.                                                                    Char             Specification                                                                                                                                            Control Method                   Reaction Plan                  Corrective Action
                                                                                                                          System              Proofing
                     Product                           Process           Class
                                                                                                                                                               Size         Frqe.         Resp.    Size              Frqe.          Resp.
  2
        Ø 57 OD RUNOUT OF W.R.T. DATUM
        'B' AND 'D'
                                                                                   0.05 mm Max                 Height Stand
                                                                                                                                                               Every
                                                                                                                                                                Pcs
                                                                                                                                                                       100% Checking               5 Pcs Every shift start Up             £         FPIR Sheet                                                                            Oiling                                        oiling / greasing                                                        Daily
  3
        Ø 68 OD RUNOUT OF W.R.T. DATUM
        'B' AND 'D'
                                                                                   0.05 mm Max                 Height Stand
                                                                                                                                                               Every
                                                                                                                                                                Pcs
                                                                                                                                                                       100% Checking               5 Pcs Every shift start Up             £         FPIR Sheet                                                                            Hydraulic Pressure                            Pressure set between 15-25 kg/cm2                                        Daily
  4
        FLANGE FACE RUNOUT OF W.R.T.
        DATUM 'B' AND 'D'
                                                                                   0.2 mm Max                  Height Stand
                                                                                                                                                               Every
                                                                                                                                                                Pcs
                                                                                                                                                                       100% Checking               5 Pcs Every shift start Up             £         FPIR Sheet                                                                            Oil leakage check                             Stop any oil leakages                                                    Daily
  5
        FLANGE OD RUNOUT OF W.R.T.
        DATUM 'B' AND 'D'
                                                                                   0.2 mm Max                  Height Stand
                                                                                                                                                               Every
                                                                                                                                                                Pcs
                                                                                                                                                                       100% Checking               5 Pcs Every shift start Up             £         FPIR Sheet
  7
        OUTER HUB OD PERPENDICULARITY
        OF W.R.T. DATUM 'D'
                                                                                   0.5 mm Max                  Height Stand
                                                                                                                                                               Every
                                                                                                                                                                Pcs
                                                                                                                                                                       100% Checking               5 Pcs Every shift start Up             £         FPIR Sheet
Internal and External Cleaning of machine Should be clean/ No sludge Every two months
Check all proximity sensors Clean/No damage/No loose Every two months
Check & Clean camera lens Clean glass and lesne with sprit Every two months
Clean all DC valves and Pressure Gauges Clean and no damage Every two months
check oil level in hydro-pneumatic press oil must be in green Every two months
                                                                                                                                                                                                                                                                                                                                           Poka
  1                     -----                     Hydraulic Pressure             35 to 45 kg/cm2               Dial Indicator
                                                                                                                                                               One
                                                                                                                                                               Time
                                                                                                                                                                         Every Day          l         ----            -----                ----   FPIR Sheet
                                                                                                                                                                                                                                                                      If it is not as per Specification
                                                                                                                                                                                                                                                                      Inform Maintenance Team
                                                                                                                                                                                                                                                                                                                                           Yoke
                                                                                                                                                                                                                                                                                                                                           No.
                                                                                                                                                                                                                                                                                                                                                                 Poka Yoke Details                         Responsibility                                 Freq
                                                                                                                                                                                                                                                                                                                standard sheet or
  4                     -----                     Load Pick up                        112 mm                   M/c Display
                                                                                                                                                               One
                                                                                                                                                               Time
                                                                                                                                                                         Every Day          l         ----            -----                ----   FPIR Sheet
                                                                                                                                                                                                                                                                      If it is not as per Specification
                                                                                                                                                                                                                                                                      Inform Maintenance Team
                                                                                                                                                                                                                                                                                                                control plan & start the
                                                                                                                                                                                                                                                                                                                cycle & take first piece
                                                                                                                                                                                                                                                                                                                                                                                                 TOOL LIFE MANAGEMENT
                                                                                                                                                                                                                                                                                                                approval from QA
                                                                                                                                                                                                                                                                                                                person then start
  5                     -----                     Stroke End                          115 mm                   M/c Display
                                                                                                                                                               One
                                                                                                                                                               Time
                                                                                                                                                                         Every Day          l         ----            -----                ----   FPIR Sheet
                                                                                                                                                                                                                                                                      If it is not as per Specification
                                                                                                                                                                                                                                                                      Inform Maintenance Team
                                                                                                                                                                                                                                                                                                                production.                                 Tool Parameter                                         Freq.                                         Actions
Note:- Sample checking by operator is not recorded , Record should be kept which is checked by quality supervisor ( Product Parameter) & production supervisor (Process Parameter) only.
Reference Work Instruction For Machine :- Job Set Up - WI/PROD/ASSLY/306 , FPA Approval - WI /PROD/ASSLY/ 102 ,Material Handeling,Storing & Preservation - WI/PROD/GEN/10 ,Safety Work Instruction-WI/PROD/ASSLY/101., CLIR Check sheet - D/MNT/DBBEPM-01 , Reaction Plan Number - RPP/011 Rev no.-00
SPECIAL CHARACTERISTIC & SYMBOL :- Critical Characteristic : CC Significant Characteristic : SC 2 Reference only : # Functional Characteristic : FC Major Characteristic : MC
CUSTOMER : Dorman PART NAME : Pre pressed wheel hub DRG.NO : WBA000038117 DRG REV NO : 00 Prototype : ¨ Prelaunch : þ Production: o AUTONOMOUS MAINTENANCE (BY OPERATOR)
                                                                                                                                                                                                                       MACHINE /Device/Tool                                             RECORD BY                                                Cycle Time                                                           Control Document: CLIA Check Sheet
                                                                                                                                                      Process Number                Process Name
                     KEY CONTACT:                                                                                                                                                                                                                                      OPERATORS/ SETTER              INSPECTOR                                                                                     CHECK POINT                                        SPECS              FRQE.
                                                               CORE TEAM- Amit / Vinod/ Hardik / Prakash/Rupesh / Rohit / Hitesh
                      Mr. Amit Singh                                                                                                                                                                                         Visual Station
                                                                                                                                                           30                 Visual & Dimenstion                                                                            l                           □
                                       Characteristics                                                                                                                                          Production                                                        QA
                                                                             Special                                                                                                             Sample                                                     Sample
                                                                                                                                 Evaluation Measurement             Error
    S.N.                                                                      Char                  Specification                                                                                                                                                                                    Control Method              Reaction Plan                Corrective Action
                                 Product                      Process                                                                     System                  Proofing
                                                                              Class
                                                                                                                                                                                   Size             Frqe.            Resp.     Size                           Frqe.             Resp.
DIMENSIONAL MEASUREMENTS
     1      FLANGE OD                                           -----                  Ø 131.0 ± 0.2                         Job Specific Gauge                               Every Pcs        100% Checking                         5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     2      FLANGE BOLT PCD                                     -----                  Ø 112.0 ± 0.2                         PCD Gauge                                        Every Pcs        100% Checking                         5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     3      FLANGE BOLT SIZE                                    -----                  5-M14x1.5-6H                          Thread Ring Gauge                                Every Pcs        100% Checking                         5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     4      FLANGE 1 Hole Size                                  -----                  M6 X 1-6H                             Thread Ring Gauge                                Every Pcs        100% Checking                         5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     7      FLANGE STEP OD 3                                    -----                  Ø 56.20 ±0.20                         Vernier Caliper                                         -                 -                 -            5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     8
            FLANGE TOP FACE TO OUTER HUB BOTTOM
            FACE DISTANCE
                                                                -----           2      38.90 ± 0.3                           Height stand with dial indicator                      5 Pcs
                                                                                                                                                                                             FPA Every shift start
                                                                                                                                                                                                     up                l              5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     11
            OUTER HUB HOLE PCD
                                                                -----                  Ø 107.0 ± 0.2                         PCD Gauge                                        Every Pcs        100% Checking                         5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     12     OUTER HUB 4 HOLE SIZE                               -----                  4-M12x1.5-6H                          Thread Ring Gauge                                       -                 -                 -            5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR                                                                                                                          N.A
     13     FLANGE TOP SIDE STEP BORE                           -----                  Ø 38.5 ± 0.2                          Form Tracer                                             -                 -                 -            5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     14     FLANGE STEP BORE ANGLE                              -----                  38 °                                  Form Tracer                                             -                 -                 -            3 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     15
            OUTER HUB FLANGE TO BEARING TOP FACE
            DISTANCE
                                                                -----                  17.0 ± 0.2                            Height Gauge                                     Every Pcs        100% Checking                         5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     16     OUTER HUB FLANGE WIDTH                              -----                  12.50 ± 0.2                           Vernier Caliper                                  Every Pcs        100% Checking                         5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     17     FLANGE WIDTH AT BOLT FITMENT AREA                   -----                  10.80 ± 0.2                           Vernier Caliper                                  Every Pcs        100% Checking                         5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     18     FLANGE FACE STEP DIST.                              -----                  5.3 ± 0.2                             Height gauge                                            -                 -                 -            5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     19     RETAINING RING INSIDE DIA                           -----                  30.0 ± 0.2                            Vernier Caliper                                         -                 -                 -            5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
                                                                                                                                                                                                                                                                                     □
                                                                                                                                                                                                                                                                                                                       2.Put not ok material in red bin
     22     FLANGE FACE DIST.-2 FROM BOTTOM FACE                -----                  5.4 ± 0.2                             Height Gauge                                            -                 -                 -            5 pcs      FPA every shift start up                                 FPIR         & record defectwise qty. in daily
                                                                                                                                                                                                                                                                                                                       report & inform to QA person..
     23     FLANGE FACE DIST.-3 FROM BOTTOM FACE                -----                  41.7 ± 0.2                            Form Tracer                                             -                 -                 -            3 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     24     OUTER HUB FACE TO FLANGE FACE DISTANCE              -----                  1.90 ± 0.2                            Form Tracer                                             -                 -                 -            3 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     25     PCD                                                 -----                  116.0 ± 0.3                           PCD Gauge                                        Every Pcs        100% Checking                         5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     26     Flange Step distance                                -----                  10 ± 0.2                              Form Tracer                                             -                 -                 -            3 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
     27     Flange Cornear Rad                                  -----                  R 1.5                                 Form Tracer                                             -                 -                 -            3 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR                                                                                              Control Document: Preventive Maintenance Check Sheet
     28     Cornear Rad                                         -----                  R3                                    Form Tracer                                             -                 -                 -            3 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR                                                                                      CHECK POINT                                        SPECS              FRQE.
     29     SPLINE PARAMETER                                    -----                  As per Drawing                        GO No Go gauge                                   Every Pcs        100% Checking                         5 pcs      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR
N.A
     1                       Burning Mark                       -----                    Should be free from Visual Defect                 Visually                                  -         100 % Inspection        l              5 Pc.      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR                                                                                                               TOOL LIFE MANAGEMENT
     2                             Rusty                        -----                    Should be free from Visual Defect                 Visually                                  -         100 % Inspection        l              5 Pc.      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR                                                                                      Tool Parameter                                      Freq.             Actions
     3                             Dents                        -----                    Should be free from Visual Defect                 Visually                                  -         100 % Inspection        l              5 Pc.      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR                                                                      N.A
     4                       Sharp corner                       -----                    Should be free from Visual Defect                 Visually                                  -         100 % Inspection        l              5 Pc.      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR                                                                      N.A
     5                         Scratches                        -----                    Should be free from Visual Defect                 Visually                                  -         100 % Inspection        l              5 Pc.      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR                                                                      N.A
     6                             Crack                        -----                    Should be free from Visual Defect                 Visually                                  -         100 % Inspection        l              5 Pc.      FPA every shift start up
                                                                                                                                                                                                                                                                                     □                    FPIR                                                                      N.A
N.A
N.A
N.A
Note:- Sample checking by operator is not recorded , Record should be kept which is checked by quality supervisor ( Product Parameter) & production supervisor (Process Parameter) only.
Reference Work Instruction For Machine :- Job Set Up - WI/PROD/ASSLY/123 , FPA Approval - WI /PROD/ASSLY/ 102 ,Material Handeling,Storing & Preservation - WI/PROD/GEN/10 ,Safety Work Instruction-WI/PROD/ASSLY/101.
SPECIAL CHARACTERISTIC & SYMBOL :- Critical Characteristic : CC Significant Characteristic : SC 2 Reference only : # Functional Characteristic : FC Major Characteristic : MC
                                                                                                                                                                       MACHINE /Device/Tool                            RECORD BY                                 Cycle Time                                                 Control Document: CLIA Check Sheet
                                                                                                               Process Number                   Process Name                                              OPERATORS/
        KEY CONTACT:               CORE TEAM- Amit / Vinod/ Hardik / Prakash/Rupesh /                                                                                                                                        INSPECTOR                                                                        CHECK POINT                               SPECS                      FRQE.
         Mr. Amit singh            Rohit / Hitesh                                                                                                                                                           SETTER
                                                                                                                                                                          DB MRK 05 / 06
                                                                                                                       40                            Marking                                                   l                 □
                      Characteristics                                                                                                                     Production                                QA
                                                                                                                                                                                                                                                                                                    General cleaning                     M/C cleaning                               Daily
                                                       Special                                 Evaluation Measurement           Error                      Sample                                 Sample
S.N.                                                                      Specification                                                                                                                                    Control Method            Reaction Plan              Corrective Action
                                                      Char Class                                        System                Proofing
            Product                Process
                                                                                                                                               Size            Frqe.   Resp.    Size            Frqe.          Resp.                                                                                M/C all panel fan                    Panel fan should be ON                     Daily
DIMENSIONAL MEASUREMENTS
  1    Marking                          -----
                                                                    As per Given
                                                                    Details in DRG.
                                                                                              As per Marking Guide Line                         -
                                                                                                                                                       100% Checking
                                                                                                                                                        by Operator      l       5 pcs
                                                                                                                                                                                         FPA Every shift
                                                                                                                                                                                         start up                 □                FPIR
                                                                                                                                                                         l                                        □
                                                                      Font size should be                                                                                                FPA Every shift                                    nature of defect, stop the     (document          Internal and External Cleaning of
  2           Font                      -----                                                      Visual Inspection                            -              100%              5 Pc.                                             FPIR     production                     results in                                           Should be clean/ No sludge      3 Month
                                                                       as per guide line                                                                                                 start up                                                                                             machine
                                                                                                                                                                                                                                            2.Put not ok material in red Corrective action
                                                                                                                                                                                                                                            bin & record defectwise qty. forrmat)
  3          visible                    -----
                                                                      'Marking should be
                                                                            visible
                                                                                                   Visual Inspection                            -              100%      l      5 Pc.
                                                                                                                                                                                         FPA Every shift
                                                                                                                                                                                         start up                 □                FPIR     in daily report & inform to QA
                                                                                                                                                                                                                                            person..
                                                                                                                                                                                                                                                                                              Machine Guard and cover           No damage/No loose              3 Month
  5       Scratchiest                   -----
                                                                     Should be free from
                                                                      Scratchiest Mark
                                                                                                   Visual Inspection                            -              100%      l      5 Pc.
                                                                                                                                                                                         FPA Every shift
                                                                                                                                                                                         start up                 □                FPIR                                                             All contactor/relay/MCB/Drive
                                                                                                                                                                                                                                                                                                                                         No loose/No Damage/No loose
                                                                                                                                                                                                                                                                                                                                         connection
                                                                                                                                                                                                                                                                                                                                                                               3 Month
Check & Clean Panel Exhaust fan Clean and no damage 3 Month
                                                                                                                                                                                                                                                                                                    Poka
  1           -----          Speed                                   45 TO 55                 Visually
                                                                                                                                               One
                                                                                                                                               Time
                                                                                                                                                         Every Day       l        ----           -----             ----   FPIR
                                                                                                                                                                                                                                            If it is not as per Specification
                                                                                                                                                                                                                                            Inform Maintenance Team
                                                                                                                                                                                                                                                                                                    Yoke
                                                                                                                                                                                                                                                                                                    No.
                                                                                                                                                                                                                                                                                                                   Poka Yoke Details             Responsibility             Freq
production.
N.A
Note:- Sample checking by operator is not recorded , Record should be kept which is checked by quality supervisor ( Product Parameter) & production supervisor (Process Parameter) only.
Reference Work Instruction For Machine :- Job Set Up - WI/PROD/ASSLY/142 , FPA Approval - WI /PROD/GRD / 33,Material Handling,Storing&Preservation-WI/PROD/GEN/10,Positive Recall Material & Rejection Suspected Material-WI/PROD/GRD/42,Saefty Work Instruction-WI/PROD/GRD/08.,CLIA Check sheet - D/MNT/MRK04
CUSTOMER : Dorman PART NAME : Pre pressed wheel hub DRG.NO : WBA000038117 DRG REV NO : 00 Prototype : ¨ Prelaunch : þ Production: o AUTONOMOUS MAINTENANCE (BY OPERATOR)
                                                                                                                                                                                  MACHINE /Device/Tool                             RECORD BY                                         Cycle Time                                                 Control Document: CLIA Check Sheet
                                                                                                                           Process Number                   Process Name                                                OPERATORS/
KEY CONTACT:                            Mr. CORE TEAM- Amit / Vinod/ Hardik / Prakash/Rupesh /                                                                                                                                            INSPECTOR                                                                                CHECK POINT                             SPECS                FRQE.
        Amit Singh                          Rohit / Hitesh                                                                                                                                                                SETTER
                                                                                                                                                                                          Manually
                                                                                                                                   60                      Oiling & Packing                                                l                   □
                         Characteristics                                                                                                                             Production                                    QA
DIMENSIONAL MEASUREMENTS
  1    Oiling                              -----
                                                                              'part must be
                                                                              protect with oil
                                                                                                         Visually                                     Every Pcs      Every pcs      l          -               -                   -          Visually                                                                                       MAINTENANCE (BY Maintenance Dept.)
VISUAL CHECKS
                                                                                                                                                                                                                                                                                                                            Poka
  1             -----          Oiling Media Type             Anticorit - 03 WC                           Display on CAN
                                                                                                                                                           One
                                                                                                                                                           Time
                                                                                                                                                                    Every Day       l         ----           -----             ----    FPIR
                                                                                                                                                                                                                                                          If it is not as per Specification
                                                                                                                                                                                                                                                          Change It.
                                                                                                                                                                                                                                                                                                                            Yoke
                                                                                                                                                                                                                                                                                                                            No.
                                                                                                                                                                                                                                                                                                                                        Poka Yoke Details            Responsibility      Freq
N.A
Notes : Within 12 angle head bolt and inside hexagonal bolt , We will supply as loose condition in a box.
Reference Work Instruction For Machine :- Job Set Up - WI/PROD/ASSLY/43 , FPA Approval - WI /PROD/ASSLY/ 102 , Gauss Meter with Comparison Work Instruction - WI/QA/CAL/47,Material Handeling,Storing & Preservation - WI/PROD/GEN/10 ,Safety Work Instruction-WI/PROD/ASSLY/101.
5/30/2024 1 Proto to Prelaunch Transfer All Operation Jignesh Ramavat Pawan Jangir Amit Singh
NOTE: