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MODEL P-90 MAJOR ABC PROCESS QUALITY CONTROL SHEET (I) 69 KM. STONE, DELHI JAIPUR HIGHWAY,
MINOR DHARUHERA (HARYANA)
PART NO. 7500002890(HHML Part No. 18350-KTC-9000 DOC NO. PFC/E38000-10003 REV NO. 02
PART NAME MUFFLER COMPLETE EXHAUST WELDING PROCESS
SOURCE MAJESTIC AUTO LIMITED,LUDHIANA DATE : 22.04.09 PAGE 01 OF 02
30
20 IN PROCESS 25
IN PROCESS PLATE TAIL SPOT
INNER SUB INSPECTION INSPECTION WELDING
ASSY.PLUG PLATE TAIL FITTING
WELDING
IN PROCESS
INSPECTION
35
IN PROCESS 40 45
IN PROCESS
PLUG WELDING INSPECTION CURLING MUFF. STAY MUFFLER
INSPECTION
COMPLETION COMP WELDING
IN PROCESS
INSPECTION
55
50 55 IN PROCESS STAY HOUSE GUIDE
STOPPR MAIN IN PROCESS STOPPER MAIN INSPECTION WELDING
STAND INSPECTION STAND WELDING
NO.PUNCHING
60
STAY MUFFLER COVER,STAY CONTINUE
IN PROCESS B PROTECTOR,HOOK
INSPECTION PROTECTOR WELDING
80 IN PROCESS 85
FINAL
SANDING, INSPECTION INSPECTION
GRINDING TRUING
Important Item
QUALITY CHARACTERISTICS
Trouble Mode
Sequence of
Process
Process Name/Equipment Name(Name of
Supplier)
Detail of
No. Control Item Specified value Inspected by Inspection Method Inspection Frequency Data Form Control item Specified value Inspected by Inspection Method Inspection Frequency Data form
Process/Sketch
00 RECEIPT OF BOP'S
1.PIPE INNER SUB ASSY. RQC GAUGE(T12-81207) SAMPLING F/INS/08
2. PLATE TAIL WELDED RQC GAUGE(T12-81202) SAMPLING F/INS/08
3.STAY MUFFLER RQC GAUGE(T12-81204) SAMPLING F/INS/08
4.STOPPER MAIN STAND RQC GAUGE(T12-81206) SAMPLING F/INS/08
5.STAY HOUSE GUIDE RQC V CALIPER SAMPLING F/INS/08
6.STAY B PROTECTOR RQC GAUGE(T12-81233) SAMPLING F/INS/08
7.HOOK PROTECTOR RQC GAUGE(T12-81221) SAMPLING F/INS/08
8.STAY MUFFLER COVER RQC GAUGE(T12-81228) SAMPLING F/INS/08
9.PIPE DIFFUSER RQC GAUGE(T12-81208) SAMPLING F/INS/08
10.PIPE COMP. EXH RQC GAUGE(T12-81267) SAMPLING F/INS/08
10 BODY & CAP BODY CIR. WELDING/CIR 1 MISMATCH NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 CURENT 120A SUPERVISOR AMMETER EVERY 4 HRS. PATROL INS.SHT.
WELDING SPM(DYNARC) BLOW HOLE/POROSITY NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 VOLTAGE 20 V SUPERVISOR VOLTMETER DO PATROL INS.SHT.
CLAMP MARK NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 GAS FLOW 8 LTR/MIN. SUPERVISOR FLOW METER DO PATROL INS.SHT.
WIRE DIA 1.0 mm SUPERVISOR MICROMETER ONCE IN A SHIFT
WIRE MATL. SUS 308L SUPERVISOR
15 FORMING MAIN MUFFLER BODY 1 DIMN. 75.20.5 mm QC REC GAUGE THRICE A SHIFT F/INMW/01-08 DIE AND PUNCH SUPERVISOR VISUAL EVERY 4 HOURS. PATROL INS. SHT
EXCESSIVE WEAR OUT NOT ALLOWED
FORMING SPM 2 DAMAGE/DEPRESSION MARKS NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-09
DIMN. FROM BODY BIG END TO
TOOL NO.T16-81198 3 198 1.5
mm QC V CALIPER THRICE A SHIFT F/INMW/01-10
FORMING CURVATURE
INNER SUB ASSY. PLUG WELDING DIMN. FROM SEPRATOR BIG END TO
20 1 61.00.5mm QC V CALIPER THRICE A SHIFT F/INMW/01-06 CURRENT 120 A SUPERVISOR AMMETER EVERY 4 HRS. PATROL INS.SHT.
WITH MUFF.COMPL./WELD ADDA(MAL) BODY END
TOOL NO.T13-81189 2 WELDING SMOOTH QC VISUAL THRICE A SHIFT F/INMW/01-06 VOLTAGE 20 V VOLTMETER
GAS FLOW 8 LTR/MIN. MICROMETER
WIRE DIA 1.0 mm
WIRE MATL. SUS 308L
TOOL NO. MAL-135 INCLINATION OF PLATE TAIL NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06
2 NUGGEST DIA 4.5-4.8 mm QC GAUGE THRICE A SHIFT F/INMW/01-06 SQUEEZE 2-2.3 CONTROL PANEL
3 ANGLE 90O APART QC VISUAL THRICE A SHIFT F/INMW/01-06 WELD 1.4-1.6 CONTROL PANEL
4 NO. OF SPOTS 3 SPOTS QC VISUAL THRICE A SHIFT F/INMW/01-06 HOLD 0.8-1.2 CONTROL PANEL
TOOL NO. MAL-178 3 WALL THK. 40.3 mm QC V.CALIPER THRICE A SHIFT F/INMW/01-06
OVALITY, BULGING,CRACK,FACE
4 NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 UNIFORM CLAMPING ___________ OPERATOR VISUAL
DEFORMATION
50 STOPPER MAIN STAND NO PUNCHING 1 LETTER HEIGHT 5 QC VISUAL THRICE A SHIFT F/INMW/01-06 PNEU PRESSURE 5-6 BARS SUPERVISOR PRESSURE GAUGE EVERY 4 HRS. PATROL INSP. SHT
Classification of trouble modes of completed vehicles (machines) : 1.Fire, 2. Fails to stop, 3. Fails to run, 4. Receives electric shocks, 5. Fails to conform to legal requirements, 6. Outer appearance and commercial value.
PROCESS QUALITY CONTROL SHEET (II)
PART NAME :MUFFLER COMP. EXH. MODEL P-90 DOC.NO:E38000-10003
DHARUHERA
Sequence of Process PART NO. : 7500002890(HHML Part No. 18350-KTC-9000 PAGE-------02--------OF----------02---------
QUALITY CHARACTERISTICS
Important Item
Trouble Mode
CONTROL OF MANUFACTURING CONDITIONS (Equipment, metal
Process Name/Equipment Name(Name of Supplier) mold,fail-safe devices,hydraulic power,voltage, temperature etc.)
TOOL NO. T13-81245 2 BOLT PROJECTION LOOSE NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 VOLTAGE 20 V VOLTMETER
TOOL NO.-T13-81258 2 WELDING PROPERLY WELDED QC VISUAL THRICE A SHIFT F/INMW/01-06 VOLTAGE VOLTMETER
20 V
GAS FLOW 8 LTR/MIN. FLOWMETER
80 WELDING COMPLETION,REPAIR MUFF,COMP.EXH. 1 WELDING PUNCHRED NOT ALLOWED QC VISUAL 100% __________ CURRENT 120 A SUPERVISOR AMMETER EVERY 4 HRS PATROL INS.SHT.
3 WELDING UNCOMPLETE NOT ALLOWED QC VISUAL 100% __________ GAS FLOW 8 LTR/MIN. FLOWMETER
85 SANDING,GRINDING MUFFLER COMP.EXH. 1 SPATTERS NOT ALLOWED QC VISUAL 100% __________ DISC GRINDING DISC SUPERVISOR VISUAL EVERY 4 HRS PATROL INS.SHT.
2 WELDING UNEVEN NOT ALLOWED QC VISUAL 100% __________ GRIT 120 SUPERVISOR VISUAL EVERY 4 HRS PATROL INS.SHT.
TO QUALIFY TRUING
90 TRUING & FINAL INSPECTION MUFFLER COMP.EXH. 1 FITMENT PARAMETERS QC TRUING FIXTURE 100% F/INMW/01-06 THREE PINS IN PROPER WORKING CONDITION SUPERVISOR VISUAL EVERY 4 HRS PATROL INS.SHT.
JIG
DEEP CUT, SCRATCH, BLOW
TOOL NO.-T13-81209 2 NOT ALLOWED QC VISUAL 100% F/INMW/01-06 TAIL PLATE PIN IN PROPER WORKING CONDITION SUPERVISOR VISUAL EVERY 4 HRS PATROL INS.SHT.
HOLE, PUNCTURE, SPATTER
CLAMPING CYL IN PROPER WORKING CONDITION SUPERVISOR VISUAL EVERY 4 HRS PATROL INS.SHT.
Classification of trouble modes of completed vehicles (machines) : 1.Fire, 2. Fails to stop, 3. Fails to run, 4. Receives electric shocks, 5. Fails to conform to legal requirements, 6. Outer appearance and commercial value.
CRITICAL
HERO HONDA MOTORS LIMITED,
MODEL KWAG MAJOR ABC PROCESS QUALITY CONTROL SHEET (I) 69 KM. STONE, DELHI JAIPUR HIGHWAY, DHARUHERA (HARYANA)
MINOR
PART NO. 75000004196(HHML Part No. 18350-KWA-9400) DOC NO. PFC/E38000-10001 REV NO. 0
PART NAME COVER-A MUFFLER WELDING PROCESS
SOURCE MAJESTIC AUTO LTD.LDH. DATE : 24.07.09 PAGE 01 OF 01
IN PROCESS
INSPECTION
30
20 IN PROCESS
ROLLING INSPECTION TIG WELDING
IN PROCESS
INSPECTION
40
50
IN PROCESS
FORMING
TAB CUTTING INSPECTION
IN PROCESS
INSPECTION
Important Item
Trouble Mode
QUALITY CHARACTERISTICS
Sequence of
Process
Process Name/Equipment
Name(Name of Supplier) Inspected Inspection
No. Control Item Specified value Inspection Method Data Form Control item Specified value Inspected by Inspection Method Inspection Frequency Data form Detail of Process/Sketch
by Frequency
RAW MATERIAL/POSCO
00 STEEL(KOREA)
0 MATERIAL SPECIFICATION SUS 409L RQC LAB SAMPLING F/INS/08
COIL(ID 500,OD
SUS 409L 1 LENGTH RQC TAPE SAMPLING F/INS/08
950,Wt.500Kg.)
BLANKING/MECHANICAL
10 PRESS 75 TON
1 PROFILE MASTER PC QC VISUAL THRICE A SHIFT F/INMW/01-06
ROLLING/ROLLER NO.
20 (MAL-208/51)
1 EDGE GAP 1-1.5 mm(MAX.) QC VISUAL EVERY 2 HRS. F/INMW/01-06 ROLLERS WEAR OUT NOT ALLOWED SUPERVISOR VISUAL EVERY 4 HOURS PATROL INSP. SHEET
HAMMER
TIG WELDING/TIG NO
30 WELDING JAW(MAL-387)
1 WELDING STRENGTH
BREAKAGE/CRACK
QC (DESTRUCTIVE THRICE A SHIFT F/INMW/01-06 CURRENT. 200-260 A SUPERVISOR AMMETER EVERY 4 HRS PATROL INSP. SHEET
TESTING)
WELDING PUNCHED/BLOW
2 NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 VOLTAGE. 15-20 V QC VOLTMETER
HOLES
3 BURNING NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 GAS. FLOW 6 LTR/MIN. QC FLOW METER
Classification of trouble modes of completed vehicles (machines) : 1.Fire, 2. Fails to stop, 3. Fails to run, 4. Receives electric shocks, 5. Fails to conform to legal requirements, 6. Outer appearance and commercial value.
PROCESS QUALITY CONTROL SHEET (II)
PART NAME :COVER-A MUFFLER MODEL KWAG DOC.NO: E38000-10001
DHARUHERA 75000004196(HHML Part No. 18350-KWA-9400) PAGE-------02--------OF----------02---------
CONTROL OF MANUFACTURING CONDITIONS
Important Item
Trouble Mode
QUALITY CHARACTERISTICS
Sequence of
Process
Process Name/Equipment
Name(Name of Supplier)
Inspected Inspection Detail of
No. Control Item Specified value Inspection Method Inspection Frequency Data Form Control item Specified value Inspected by Inspection Method Data form
by Frequency Process/Sketch
40 TAB CUTTING 1 UNDER CUTS NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06
HEAVY BURR
DIE & PUNCH NOT PATROL INSP.
TOOL NO. MAL-313 2 PROJECTION NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 SUPERVISOR VISUAL EVERY 4 HRS
WEAR OFF ALLOWED SHEET
DAMAGE
FORMNG(FORMING TOOLING
V.CALIPER/PLUG NOT PATROL INSP.
50 TOOL) 1 DIA 31.8+0.5/+0.2 QC THRICE A SHIFT F/INMW/01-06 ELEMENTS SUPERVISOR VISUAL EVERY 4 HRS
GAUGE ALLOWED SHEET
TOOL NO.-189 WEAR OFF
Classification
Classification
of trouble
of trouble
modesmodes
of completed
of completed
vehicles
vehicles
(machines)
(machines)
: 1.Fire,: 1.Fire,
2. Fails2.toFails
stop,to3.stop,
Fails3.toFails
run, to
4. run,
Receives
4. Receives
electricelectric
shocks,shocks,
5. Fails5.toFails
conform
to conform
to legaltorequirements,
legal requirements,
6. Outer
6. appearance
Outer appearance
and commercial
and commercial
value. value.
CRITICAL
MODEL KWAG MAJOR ABC PROCESS QUALITY CON
MINOR
PART NO. 75000004197(HHML Part No. 18350-KWA-9400)
PART NAME COVER-A MUFFLER WELDING PROCE
SOURCE MAJESTIC AUTO LTD.LDH.
00 10
INSPECTION
RECEIPT OF RAW LENGTH
MATERIAL CUTTING
(TUBE)
IN PROCESS 20 IN PROCESS
INSPECTION PIERCING INSPECTION
30
IN PROCESS
FORMING INSPECTION
HHML APPROVAL
DATE NAME AUTHORISED
SIGNATORY LOT MARKING
LOT CODE
HERO HONDA MOTORS LIMITED,
S QUALITY CONTROL SHEET (I) 69 KM. STONE, D
DHARUHERA (HARYANA)
DOC NO. PFC/E38000-10001
WELDING PROCESS
DATE : 24.07.09
OCESS
ECTION
VENDOR APPRO
DATE MADE BY
PAGE 01 OF 01
Important Item
QUALITY CHARACTERISTICS
Trouble Mode
Sequence of
Process
Process Name/Equipment
Name(Name of Supplier)
No. Control Item Specified value Inspected by
COIL(ID 500,OD
SUS 409L 1 LENGTH RQC
950,Wt.500Kg.)
TENSILE
15 STRENGTH(Mpa 360 MIN RQC
)
BLANKING/MECHANICAL
10 PRESS 75 TON
1 PROFILE MASTER PC QC
ROLLING/ROLLER NO.
20 (MAL-208/51)
1 EDGE GAP 1-1.5 mm(MAX.) QC
EDGE OVER
2 NOT ALLOWED QC
LAPPING
WELDING
2 PUNCHED/BLO NOT ALLOWED QC
W HOLES
WELDING
4 SMOOTH QC
FINISH
Classification of trouble modes of completed vehicles (machines) : 1.Fire, 2. Fails to stop, 3. Fails to run, 4. Receives electric shocks,
UALITY CONTROL SHEET(II)
MODEL KWAG DOC.NO: E38000-10001
PAGE-------01--------OF----------01--------
CONTROL OF MANUFACTURING CONDITIONS
CHARACTERISTICS
DIE &
NOT SUPERVIS EVERY 4
VISUAL THRICE A SHIFT F/INMW/01-06 PUNCH VISUAL PATROL INSP. SHEET
ALLOWED OR HOURS
WEAR OFF
HAMMER
(DESTRUC
THRICE A SHIFT F/INMW/01-06 CURRENT. 200-260 A SUPERVISOR AMMETER EVERY 4 HRS
PATROL INSP. SHEET
TIVE
TESTING)
. Receives electric shocks, 5. Fails to conform to legal requirements, 6. Outer appearance and commercial value.
E38000-10001
--01--------OF----------01--------
Detail of
Process/Sketch
IN PROCESS
INSPECTION
30
20 IN PROCESS
STAMPING INSPECTION PIERCING
IN PROCESS
INSPECTION
40
IN PROCESS 50
ROLLING
INSPECTION TIG WELDING
IN PROCESS
INSPECTION
60
IN PROCESS
TAB CUTTING INSPECTION
Important Item
QUALITY CHARACTERISTICS
Trouble Mode
Sequence of
Process power,voltage, temperature etc.)
Process Name/Equipment
Name(Name of Supplier)
Inspected
No. Control Item Specified value Inspection Method Inspection Frequency Data Form Control item Specified value Inspected by Inspection Method Inspection Frequency Data form Detail of Process/Sketch
by
TENSILE
13 360 MIN RQC LAB SAMPLING F/INS/08
STRENGTH(Mpa)
PROFILE/STRAIGHTNESS
10 BLANKING 1
OF EDGES
AS PER MASTER PC QC VISUAL EVERY 2 HRS. F/INMW/01-06 PUNCH /DIE PROFILE SHOULD CORRECT SUPERVISOR VISUAL ONCE A WEEK PATROL INSP.
20 LOGO STAMPING 1 HEIGHT OF LETTERS 11 MM QC V CALIPER THRICE A SHIFT F/INMW/01-06 PNEUMATIC PRESSURE 6 BAR QC GAUGE TWICE A SHIFT PATROL INSP.
HYD. PNEU.PRESS 40T 2 LETTER DEPTH 0.3 MM QC VISUAL THRICE A SHIFT F/INMW/01-06 HOLD TIME 2 SECONDS OPERATOR CONTROL PANEL TWICE A SHIFT PATROL INSP.
TOOL NO. T16-81199 2 HOLE DIA 6.0 MM QC VISUAL THRICE A SHIFT F/INMW/01-06
PUNCH DIE
3 HEAVY BURR NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 NOT ALLOWED SUPERVISOR VISUAL EVERY 4 HRS. PATROL INSP.
EXCESSIVE WEAR OFF
Classification of trouble modes of completed vehicles (machines) : 1.Fire, 2. Fails to stop, 3. Fails to run, 4. Receives electric shocks, 5. Fails to conform to legal requirements, 6. Outer appearance and commercial value.
PROCESS QUALITY CONTROL SHEET (II)
PART NAME : BODY MODEL P-90 DOC.NO: E38000-10002
Process Name/Equipment
Name(Name of Supplier)
Inspected
No. Control Item Specified value Inspection Method Inspection Frequency Data Form Control item Specified value Inspected by Inspection Method Inspection Frequency Data form Detail of Process/Sketch
by
40 ROLLING(ROLLING SPM) 1 EDGE GAP 1.5-2.0 mm(APPROX.) QC V CALLIPER THRICE A SHIFT F/INMW/01-07 ROLLERS WEAR OUT NOT ALLOWED SUPERVISOR VISUAL EVERY 4 HRS. PATROL INSP.
50 TIG WELDING 1 SMALL END DIA 62.7 0.7 mm QC V CALIPER THRICE A SHIFT F/INMW/01-06 CURRENT 180-240 A SUPERVISOR AMMETER EVERY 4 HRS PATROL INSP.
HAMMER
3 WELDING STRENGTH NO BREAKAGE/ CARACK QC (DESTRUCTIVE THRICE A SHIFT F/INMW/01-06 GAS. (ARGON) FLOW 6 LTR/ MIN. SUPERVISOR FLOW METER EVERY 4 HRS INSP.SHEET
TESTING)
WELDING
4 PUNCHERED/BLOW NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06 ELECTRODE DIA 3 MM SUPERVISOR VISUAL 1-2 TIMES/SHIFT PATROL INSP.
HOLE
6 WELDING FINISH SMOOTH QC VISUAL THRICE A SHIFT F/INMW/01-06 EDGE GAP. NOT ALLOWED SUPERVISOR VISUAL 3-4TIMES/SHIFT PATROL INSP.
60 TAB CUTTTING 1 UNDER CUTS NOT ALLOWED QC VISUAL THRICE A SHIFT F/INMW/01-06
Classification of trouble modes of completed vehicles (machines) : 1.Fire, 2. Fails to stop, 3. Fails to run, 4. Receives electric shocks, 5. Fails to conform to legal requirements, 6. Outer appearance and commercial value.