CONTROL PLAN

Supplier/Plant : WELLPRO COMPONENTS PVT.LTD. Control Plan (Original) Date -: 10-08-2023

Prototype Prelaunch Production Key Contact / Phone : RANJIT PISTE DCN.(Document Change Note) NO. :- NA
Part Name/Description : VX-3 Core Team:- RAMESH SHINDE, PRAMOD SID, PRASAD SHINDE, PRATHAMESH KHOT Customer Engineering Approval Date(If Reqd) - NA
Part No/Latest Change Level : 1HC0027482 Customer Name -: HITACHI Customer Quality Approval date(If Reqd) - NA
Casting Drawing NO. -: NA Assly Drawing NO. - :

Characteristics Sample Frequency

Process / Machines, Equipments,

Opr.no. Operation Jigs, Fixtures, Tools, etc Spl Char Class Specification/ Tolerance Evaluation /Measurement Error Proofing Control Method Reaction Plan Corrective Action
Techniques
Description for Mfg. No Product Process Checking Frequency Record Frequency

Control Plan No :- CP/ABB/VX3/7482/10

01 Silicon 6.5 – 7.5 % Chemical analysis 1 NO / BATCH 1 NO / BATCH Spectro report

02 Iron 0.50 % max. Chemical analysis 1 NO / BATCH 1 NO / BATCH Spectro report

MACHINE NAME :-
SPECTRO MACHINE
INGOTS INWARD INSPECTION

03 Copper 0.10 % max. Chemical analysis 1 NO / BATCH 1 NO / BATCH Spectro report

04 Manganese 0.30 % max. Chemical analysis 1 NO / BATCH 1 NO / BATCH Spectro report IF SPECIFICATION IS OUT
OF TOLERANCE REJECT
10 A HOLD THE LOT THE MATERIAL AND
SENT BACK TO THE
05 Magnesium 0.20 – 0.80 % Chemical analysis 1 NO / BATCH 1 NO / BATCH Spectro report SUPPLIER

06 Nickel 0.05 % max. Chemical analysis 1 NO / BATCH 1 NO / BATCH Spectro report

TOOL :- NA
07 Zinc 0.20 % max. Chemical analysis 1 NO / BATCH 1 NO / BATCH Spectro report

08 Tin 0.20 % max. Chemical analysis 1 NO / BATCH 1 NO / BATCH Spectro report

PREPARED BY :- PRASAD SHINDE CHECKED BY :- RANAJIT PISHTE APPROVED BY :- RAMESH SHINDE

Rev No. : 00 Describtion : First release Revision Date [Control Plan] : 10/08/2023 Approved by : Ramesh Shinde
Control Plan No :- CP/ABB/VX3/7482/20
JIG. & FIXTURE NO. :- IF RETURNS ARE NOT
CHARGE PREPERATION

AVAILABLE AS PER
01 FRESH ALLOYS 40 % Of Charge mix Weighing Scale EVERY HEAT EVERY HEAT MELTING LOG SHEET STANDARD CHARGE
LM25 MIX, USE FRESH
20
MACHINE NAME :- 02 RETURNS 60 % Of Charge mix Weighing Scale EVERY HEAT EVERY HEAT MELTING LOG SHEET RESET OR INFORM TO INDTED, DO NOT USE
WEIGHING SCALE SUPERVISOR RETURNS ABOVE 60%

TOOL :-
03

PREPARED BY :- PRASAD SHINDE CHECKED BY :- RANAJIT PISHTE APPROVED BY :- RAMESH SHINDE

Rev No. : 00 Describtion : First release Revision Date [Control Plan] : 10/08/2023 Approved by : Ramesh Shinde
Control Plan No :- CP/ABB/VX3/7482/30
JIG. & FIXTURE -
01 Cleaning of furnace Inside of furnace should be clean. Visual Before Melting NA DAILY MELTING LOG SHEET
RESET OR INFORM TO
SUPERVISOR
MELTING

MACHINE NAME :- NA 02 Addtion of raw AS PER OP. NO 20 Weighing balance Before Melting NA
30 material
TOOL :- Crane,
spanners, allen key, etc 03

PREPARED BY :- PRASAD SHINDE CHECKED BY :- RANAJIT PISHTE APPROVED BY :- RAMESH SHINDE

Rev No. : 00 Describtion : First release Revision Date [Control Plan] : 10/08/2023 Approved by : Ramesh Shinde
Control Plan No :- CP/ABB/VX3/7482/40

01 Treatment TEMEPRATURE DISPLAY ONCE IN HOUR ONCE IN HOUR PROCESS MONITERING CHECK
temperatture 725º ± 5º SHEET

02 Addition of flux & 200gm per 100kg WEINGH SCALE ONCE IN HEAT ONCE IN HEAT MELTING LOG SHEET
removing the dross

03 Degassing Time 14 ~ 16 minute TIMER AUTOMATIC STOP ONCE IN 45 MIN ONCE IN HEAT MELTING LOG SHEET
MACHINE NAME :- AFTER CYCLE
MELTING CUM
HOLDING FURNACE
04 N2 Flow Rate 12 ~ 18 LPM DISPLAY UNIT ONCE IN HEAT ONCE IN HEAT MELTING LOG SHEET

TOOL :- NA
05 N2 Pressure 3 ~ 5 bar PRESSURE DIAL ONCE IN HEAT ONCE IN HEAT MELTING LOG SHEET

Shaft Rotor Speed 300-400 rpm

06 DI VALUE < 2.7 DI MACHINE ONCE IN HEAT ONCE IN HEAT MELTING LOG SHEET

07 Addition of TiB (5:1) 200gm per 100kg WEINGH SCALE ONCE IN HEAT ONCE IN HEAT MELTING LOG SHEET
METAL TREATMENT

40 08 Addition of Sr 200gm per 100kg WEINGH SCALE ONCE IN HEAT ONCE IN HEAT MELTING LOG SHEET RESET OR INFORM TO
SUPERVISOR

09 Silicon 6.5 – 7.5 % Chemical analysis 1 NO /HEAT 1 NO /HEAT Spectro report

10 Iron 0.50 % max. Chemical analysis 1 NO /HEAT 1 NO /HEAT Spectro report

11 Copper 0.10 % max. Chemical analysis 1 NO /HEAT 1 NO /HEAT Spectro report

12 Manganese 0.30 % max. Chemical analysis 1 NO /HEAT 1 NO /HEAT Spectro report

13 Magnesium 0.20 – 0.80 % Chemical analysis 1 NO /HEAT 1 NO /HEAT Spectro report

14 Nickel 0.05 % max. Chemical analysis 1 NO /HEAT 1 NO /HEAT Spectro report

15 Zinc 0.20 % max. Chemical analysis 1 NO /HEAT 1 NO /HEAT Spectro report

16 Tin 0.20 % max. Chemical analysis 1 NO /HEAT 1 NO /HEAT Spectro report

17 Lead 0.05 % max. Chemical analysis 1 NO /HEAT 1 NO /HEAT Spectro report

PREPARED BY :- PRASAD SHINDE CHECKED BY :- RANAJIT PISHTE APPROVED BY :- RAMESH SHINDE

Rev No. : 01 Describtion : Rotor Speed Added. Revision Date [Control Plan] : 23/04/2025 Approved by : Ramesh Shinde
Control Plan No :- CP/ABB/VX3/7482/50

01 Die temperature Min 300°C Temperature Gun ONCE IN HOUR ONCE IN HOUR FIRST OFF & STAGE INSPECTION
REPORT

02 Pouring temperature Temperature Gun ONCE IN HOUR ONCE IN HOUR FIRST OFF & STAGE INSPECTION
730º ± 5ºC REPORT

03 Use of shell cores Core insert in Die Visual 100% ONCE IN HOUR FIRST OFF & STAGE INSPECTION
REPORT
MACHINE NAME :- TILT
GRAVITY MACHIINE
04 Placement of shell cores Sand should not fall in the die while placing the core Visual 100% ONCE IN HOUR FIRST OFF & STAGE INSPECTION
in the die in the die REPORT

05 Tilting Time 12-15 Sec Timer AUTO TILTING AT THE START OF SHIFT AT THE START OF SHIFT FIRST OFF & STAGE INSPECTION
REPORT
TOOL :- NA
06 Solidification Time 120 sec + 10 Sec Timer Buzzer AT THE START OF SHIFT AT THE START OF SHIFT FIRST OFF & STAGE INSPECTION
REPORT

07 Wall thickness 23 ±0.5 Vernier AT THE START OF AT THE START OF FIRST OFF & STAGE INSPECTION
SETUP SETUP REPORT

08 OD Ø 148 ± 0.20 Vernier ONCE IN HOUR ONCE IN HOUR FIRST OFF & STAGE INSPECTION
REPORT

09 OD Ø 105 ± 0.20 Vernier ONCE IN HOUR ONCE IN HOUR FIRST OFF & STAGE INSPECTION
REPORT
DIE CASTING

50 RESET OR INFORM TO
SUPERVISOR
12 Total Height 224±1

13 Width 40±0.5

14 Width 30±0.5

15 Distance 80±0.5

16 Ribs at pad Visuali ok Visual 100% ONCE IN HOUR FIRST OFF & STAGE INSPECTION
REPORT

17 Calender punch as per month Visual 100% ONCE IN HOUR FIRST OFF & STAGE INSPECTION
REPORT

18 Ejection Pin mark 0.50 projection or depression -- ONCE IN HOUR ONCE IN HOUR FIRST OFF & STAGE INSPECTION
REPORT

20 Visual Defects Unfill,cold shut,ejector pin marks, sand --- 100% ONCE IN HOUR FIRST OFF & STAGE INSPECTION
removal,warpage,blow hole, shrinkage,crack REPORT

W23J31B
21 Heat code punch Visual 100% ONCE IN HOUR FIRST OFF & STAGE INSPECTION
(W-WELLPRO,23- YEAR CODE,J-MONTH CODE,31 - REPORT
DATE CODE,B- SHIFT)

PREPARED BY :- PRASAD SHINDE CHECKED BY :- RANAJIT PISHTE APPROVED BY :- RAMESH SHINDE

Rev No. : 00 Describtion : First release Revision Date [Control Plan] : 10/08/2023 Approved by : Ramesh Shinde
 Supplier/Plant : WELLPRO
Prototype Prelaunch Production Key Contact / Phone : RA
Part Name/Description : VX-3 Core Team:- RAMESH SHI
Part No/Latest Change Level : 1HC0027482 Customer Name -: HITACH
Casting Drawing NO. -: NA Assly Drawing NO. - :

Characteristics

Process / Operation Machines, Equipments, Jigs,

Opr.no.
Description Fixtures, Tools, etc for Mfg.
No Product Process

Control Plan No :- CP/ABB/VX3/7482/10

Gun
01
Placement
MACHINE NAME :- Decoring
DECORING

Gun
10 Visual
02
Defects

TOOL :- NA 03

PREPARED BY :- PRASAD SHINDE

Rev No. : 00 Describtion : First release

Control Plan No :- CP/ABB/VX3/7482/20

No under
01 cut / no
over cut
MACHINE NAME :- Cutting
DEGATING

m/c, blade, etc…

20 02
 DEGATIN
20

TOOL :- NA 03

PREPARED BY :- PRASAD SHINDE

Rev No. : 00 Describtion : First release

Control Plan No :- CP/ABB/VX3/7482/30
FETTLING

MACHINE NAME :- Grinding No gate

30 01
m/c, belt, file, etc… projections

PREPARED BY :- PRASAD SHINDE

Rev No. : 00 Describtion : First release

Control Plan No :- CP/ABB/VX3/7482/40

01 Shots size
MACHINE NAME :- Shot
SHOT BLASTING

Blasting Machine
40 02 Cycle time

Uniform
TOOL :- NA 03 Casting
surface finish

PREPARED BY :- PRASAD SHINDE

Rev No. : 00 Describtion : First release

Control Plan No :- CP/ABB/VX3/7482/50
INSPECTION
CASTING

VISUAL
50 MACHINE NAME :- NA 01
DEFECTS

PREPARED BY :- PRASAD SHINDE

Rev No. : 00 Describtion : First release

Control Plan No :- CP/ABB/VX3/7482/20
 CONTROL PLAN
ier/Plant : WELLPRO COMPONENTS PVT.LTD.
ontact / Phone : RANJIT PISTE
Team:- RAMESH SHINDE, PRAMOD SID, PRASAD SHINDE, PRATHAMESH KHOT
omer Name -: HITACHI
Drawing NO. - :

Spl Char Specification/ Evaluation /Measurement Error

Class Tolerance Techniques Proofing

At the riser of
Decoring Gun
Part

No Sand In Part Visual

CHECKED BY :- RANAJIT PISHTE

Revision Date [Control Plan] : 10/08/20

As per master
Visual
sample
CHECKED BY :- RANAJIT PISHTE

Revision Date [Control Plan] : 10/08/20

As per master
Visual
sample

CHECKED BY :- RANAJIT PISHTE

Revision Date [Control Plan] : 10/08/20

Shot Size
Party Test Report
0.40mm

2.00 Minute PLC Controller

Visually
Visual
accepted

CHECKED BY :- RANAJIT PISHTE

Revision Date [Control Plan] : 10/08/20

as per
Visual
accepatance

CHECKED BY :- RANAJIT PISHTE

Revision Date [Control Plan] : 10/08/20

 Control Plan (Original) Date -: 10-08-2023
DCN.(Document Change Note) NO. :- NA
Customer Engineering Approval Date(If Reqd) - NA
Customer Quality Approval date(If Reqd) - NA

Sample Frequency

Control
Reaction Plan Corrective Action
Method
Checking Frequency Record Frequency

100% NA NA

RESET OR
100% NA NA INFORM TO
SUPERVISOR

APPROVED BY :- RAMESH SHINDE

Revision Date [Control Plan] : 10/08/2023 Approved by : Ramesh Shinde

100% NA NA

Inform to
Tool room
supervisor
 Inform to
Tool room
supervisor

APPROVED BY :- RAMESH SHINDE

Revision Date [Control Plan] : 10/08/2023 Approved by : Ramesh Shinde

Inform to
100% NA NA Tool room
supervisor

APPROVED BY :- RAMESH SHINDE

Revision Date [Control Plan] : 10/08/2023 Approved by : Ramesh Shinde

Inform to
Tool room
supervisor

APPROVED BY :- RAMESH SHINDE

Revision Date [Control Plan] : 10/08/2023 Approved by : Ramesh Shinde

Inform to
100% NA Tool room
supervisor

APPROVED BY :- RAMESH SHINDE

Revision Date [Control Plan] : 10/08/2023 Approved by : Ramesh Shinde

 FIRST OFF , LAST OFF & STAGE INSPECTION REPORT
PART NAME-: VX-3 OPR NAME-: FOUNDRY STAGE Operator Name-: Date -
STI NO/ REV.NO.-: STI/ABB/VX3/748/FDY
PART NO./ Rev.No.-: 1HC0027482 OPR NO.-: Machine No..-: Shift -
Actual Dimensions
Sample Frequency
Time Quality
Product & person
Sr. Parameter & Inspection special
process verification
No. Specification Method char. Job No.
Parameter Checking Record
readings

Frequency Frequency FIRST OFF LAST OFF

ONCE IN ONCE IN
01 Die temperature Min 300°C Temperature Gun
HOUR HOUR

ONCE IN ONCE IN
02 Pouring temperature 730º ± 5ºC Temperature Gun
HOUR HOUR

ONCE IN
03 Use of shell cores Core insert in Die Visual 100%
HOUR
Sand should not fall
Placement of shell in the die while ONCE IN
04 Visual 100%
cores in the die placing the core in HOUR
the die AT THE AT THE
05 Tilting Time 12-15 Sec Timer START OF START OF
SHIFT SHIFT
AT THE AT THE
06 Solidification Time 120 sec + 10 Sec Timer START OF START OF
SHIFT SHIFT
AT THE AT THE
07 Wall thickness 23 ±0.5 Vernier START OF START OF
SETUP SETUP
ONCE IN ONCE IN
08 OD Ø 148 ± 0.20 Vernier
HOUR HOUR

ONCE IN ONCE IN
09 OD Ø 105 ± 0.20 Vernier
HOUR HOUR

ONCE IN ONCE IN
10 width 13.0 ± 0.8 Vernier
HOUR HOUR

ONCE IN ONCE IN
11 width 13 ± 0.80 Vernier
HOUR HOUR

12 Total Height 224±1 0 0 0

13 Width 40±0.5 0 0 0

14 Width 30±0.5 0 0 0

15 Distance 80±0.5 0 0 0

ONCE IN
16 Ribs at pad Visuali ok Visual 1
HOUR

ONCE IN
17 Calender punch as per month Visual 1
HOUR

0.50 projection or ONCE IN ONCE IN

18 Ejection Pin mark Unfill,cold --
depression HOUR HOUR
shut,ejector pin
marks, sand ONCE IN
20 Visual Defects --- 1
removal,warpage,blo HOUR
w hole,
W23J31B
shrinkage,crack
(W-WELLPRO,23-
YEAR CODE,J- ONCE IN
21 Heat code punch Visual 1
MONTH CODE,31 - HOUR
DATE CODE,B-
SHIFT)

Corrective Action -
Reaction Plan - Reset or Inform to the Suervisior.
Inspected By-: Approved By-:
QCA-F-14, Rev. No. 00