ppap for neel metal

PPAP KIT FOR

MTG. BRACKET – 15 LTR AIR TANKPART NO. F1F000914

(ON FVDP VEHICLES)

TO NEEL METAL PRODUCT LIMITED SIDCUL ,PANTNAGAR

FROMTHUKRAL STEEL ENGINEERSTULSI DWAR ,KICCHA ROADU.S.N.

TO NEEL METAL PRODUCT LIMITED SIDCUL ,PANTNAGAR


Thukral Steel EngineersDOCUMENTS INDEX FOR PPAP

PART No.:- F1F00914 #.0 STATUS ON :-

PART NAME:- MIG. BRACKET -15 LTR AIR TANK SUPPLIER :- Thukral Steel Engineers

S. No. REQUIREMENTRequired Available

REMARKSYES NO YES NO

1Part Submission Warrant (PSW) Y Y

2Customer Specification Y Y

3Engineering Change Specification N N

4Design FMEA N N

5Process Flow Diagram Y Y

6Process FMEA Y Y

7Control Plan Y Y

8Pre Dispatch Inspection Report Y Y

9No. of Sample Product N N

10MSA / R &R Y Y

11Chemistry & Mechanical Test Report N N

12Third Party Chemical; LaboratoryTest report Y Y

13Checking Aid List Y Y

14Master Sample Y Y

15Calibration Certificate Y Y

16Calibration History Cards for Instrument Y Y

17Appearance Approval Report N N

18Bulk Material(if any) N N

19Record of Compliance (if any) N N

20Y Y

Reviewed By Approved By

Amit Joshi Prem Thukral

Quality Management System Certificate for ISO 9001-2008

Thukral Steel Engineers PART SUBMISSION WARRANT

Part Name MTG.BRACKET-15 LTR AIR TANK Part Number F1F00914 #.0

Safety and/or Government Regulation Engineering Drawing Change Level

0 Dated 11/5/2013

Additional Engineering Changes Dated

Shown on Drawing Number Purchase Order No. Weight (kg)

Checking Aid Number Engineering Change Level Dated

SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION

Thukral Steel EngineersSupplier Name/Code

Tulsi Dwar , Kiccha road Customer Name/Division Neel Metal Products Limited /SIDCULStreet Address

Buyer/Buyer Code

Rudrapur/U.S.N/ U.K./263153City/District/State/Pin code Application FVDP VEHICLES

Note: Does this part contain any restricted or reportable substances?

Are plastic parts identified with appropriate ISO marking codes?

REASON FOR SUBMISSION

Initial submission Change to Optional Construction or Material

Engineering Change(s) Sub-Supplier or Material Source Change

Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part Processing

Correction of Discrepancy Parts produced at Additional Location

Tooling Inactive > than 1 year Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.

Level 2 - Warrant with product samples and limited supporting data submitted to customer.

Level 3 - Warrant with product samples and complete supporting data submitted to customer.

Level 4 - Warrant and other requirements as defined by customer.

Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.

SUBMISSION RESULTS

The results for dimensional measurements material and functional tests appearance criteria statistical process package

These results meet all drawing and specification requirements: (If "NO" - Explanation Required)

Mold / Cavity / Production ProcessBlanking & shearing - punching - bending - welding - fastning - final inspection - packing

DECLARATION

I affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable

Production Part Approval Process Manual 3rd Edition Requirements. I further warrant these samples were

produced at the production rate of 250 / 12 hours. I have noted any deviations from this declaration below.

EXPLANATION/COMMENTS:

Print Name Prem Thukral Title Business Partner Phone No. 9760047600 Fax No.

Supplier Authorized Signature Date 12/5/2013

FOR CUSTOMER USE ONLY (IF APPLICABLE)

Part Warrant Disposition: Part Functional Approval:

Customer Name Customer Signature Date

Dimensional Materials/Function Appearance

YES NO

Yes No

Yes No

Yes No

Approved RejectedOther

Approved

Waived

A17

Show the code assigned to the manufacturing location on the purchase order

A20

Show the complete address of the location where the product was manufactured

Appearance

Thukral Steel Engineers CUSTOMER SPECIFICATION

PART NAME: MTG. BRACKET-15 LTR AIR TANK PREPARED BY: Amit joshi DATE (ORIGIN): 15-05-2013

PART NO. F1F00914 #.0CORE TEAM: Pryank , Ramu sharma .

REV. NO: 00

CUSTOMER: NEEL METAL PRODUCTS LIMITED , SIDCUL REV DATE:

S.no Item No. Dim. Type Specification Dimension

Customer Drawing For Reference

1 1 Blank Dim.

Length 710 mm

Width 25 mm

Hole Dim. 5 mm

Hole Location

Hole Dim. 8.5 mm

Hole Location

2 2 Blank Dim.

Length 160 mm

Width 40 mm

Hole Dim. 5 mm ( 9 mm countersunk height )

Hole location

3 3 Blank Dim.

Length 140 mm

Width 35 mm

Hole Dim. 20 mm

Hole location 55 mm(from center line) & 15 mm from outer side

Arc radius 111 mm

4 4 Rivet Standard 10 X5 mm

Dim : 9 ± 0.1 mm ( From Outer Side )

Dim : 57± 0.1 mm ( from center line )

Dim : 56 ± 0.1 mm( from centre line)

4 4 Rivet Standard 10 X5 mm

Thukral Steel Engineers PROCESS FLOW DIAGRAM

PART NAME: MTG. BRACKET-15 LTR AIR TANK PREPARED BY: Amit joshi Process flow chart no: PFD/MTG.BRACKET /00

PART NO. F1F00914 #.0CORE TEAM: Pryank , Ramu sharma . DATE (ORIGIN): 15-05-2013

REV. NO: 00CUSTOMER:NEEL METAL PRODUCTS LIMITED , SIDCUL REV DATE:

OPER NO. DESCRIPTIION EQUIPMENT AND FACILITY

STO

RAG

E

TRAN

SPO

RT

OPE

RATI

ON

INSP

ECTI

ON

DELA

Y

PRODUCT CHARACTERISTICS

10 Material Test Certificate Chemical Composition MS

20 Storage Predefined Location Handeling Inadequate Rack location defined

30 Blanking & Shearing Shear Cutter/Automate Dimensions, Appearance Defined in each item flow chart

40 Punching Dimensions,location Defined in each item flow chart

50 Bending Bending M/c/Manual Dimensions Defined in each item flow chart

60 Welding MMAW Thick,Appearance

70 Rivited Appearance Properly Fit

80 Final Inspection Inspection Room Appearance

100 Dispatch Area

INCOMING SOURCE OF VARIATION O

PERA

TIO

N &

INSP

ECTI

ON

Receiving of Material

CNC Turret Punch Press/Automate

Item 2 &3 ( Thick : 8-10 mm,No Welding Defect )

Fastning & Assembly

Free from burr, and sharp edges and other Weld defect

Dispatch to Customer

Thukral Steel Engineers PROCESS FLOW DIAGRAM

Process flow chart no: PFD/MTG.BRACKET /00DATE (ORIGIN): 15-05-2013REV. NO: 00REV DATE:

Receipt material

Material Movement

Component Movement

Component Movement

Component Movement

Component Movement

Component Movement

Component Movement

Standard Packing

PROCESS CHARACTERISTICS / REMARKS

Thukral Steel Engineers

FMEA NO. : FMEA/MTG. BRACKET/01 CORE TEAM : DATE (ORIG.) : 12/05/2013

PART NAME :MTG. BRACKET- 15 LTR AIR TANK Mr.Pryank, Mr.Ramu Sharma , Mr. Satnam singh REVISION NO. : 00

PART NO. : F1F00914 #.0 REVISION DATE : --

CUSTOMER NAME : NEEL METAL PRODUCT LIMITED,SIDCULPREPARED BY. :Amit Joshi

APPROVED BY : Prem Thukral

PROCESS POTENTIAL POTENTIAL S C POTENTIAL O CURRENT CURRENT D R RECOMMENDED RESPONSBILITY ACTION RESULTS

FUNCTIONS FAILURE EFFECT(S) OF L CAUSE(S)/ PROCESS PROCESS ACTION(S) & TARGET ACTIONS S O D RMODE FAILURE E A MECHANISM(S) C CONTROLS CONTROLS E P COMPLETION TAKEN P

S OF FAILURE PREVENTION DETECTION DATE NV S C T N

10 WRONG Material 8 C 1 SUPPLIER 1 8

20 STORAGE Material Mixup 8 1 CHECKLIST 3 48

30

Length over size 7 SETTING DISTURB 1 LOCK PROVIDED 3 75

Length Under Size. 7 SETTING DISTURB 1 LOCK PROVIDED 3 75

40 PUNCHING

Improper Location 6 SETTING DISTURB 2 LOCK PROVIDED 2 56

Hole undersize 6 TOOL WORN OUT 2 2 56

Hole Oversize 3 TOOL WORN OUT 2 2 56

Burr 4 1 1 56

50 BENDING

Length under size 5 SETTING DISTURB 2 LOCK PROVIDED 3 50

Length over size . 5 SETTING DISTURB 2 LOCK PROVIDED 3 50

60 WELDING

UNDER & CRACKS 5 2 6 50

5 3 6 50

5 2 6 50

70 5 5 6 50

90 PACKING Job get damaged 4 2 TRAINING 7 60

LEGENDS: S = SEVERITY O = OCCURRENCE, D = DETECTION, RPN = RISK PRIORITY NUMBER,

O AND S:(1) LOW-(10) HIGH, D=1~10 (10=REMOTE POSSIBILITY OF DETECTION)

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

PROCESS PFMEA

Opern No.

REQUIREMENTS

RECEIVING OF MATERIAL

Material being rejected

WRONG MATERIAL USED AT SUPPLIER END.

MTC, DIMENSIONAL AND VISUAL CHECK.

Material at Improper Location

DESIRE LOCATION NOT AVAILABLE

SEPARATE AREA DEFINED FOR EVERY MATERIAL.

BLANKING & SHEARING

MATING PART NOT FIT PROPERLY

SET UP APP &100% INSP

PROBLEM AT CUSTOMER END

APP &100% INSP


APP &100% INSP


SET TOOL CHANGE FREQUENCY

APP &100% INSP


SET TOOL CHANGE FREQUENCY

APP &100% INSP


IMPROPER CLEARENCE

SET TOOL OR DIE CHANGE FREQUENCY

APP &100% INSP





IMPROPER STRENGTH

UNSKILLED WELDER

WEDER TRANING PROVIDED

APP &100% INSP

POROSITY & TRAPED SLAG

IMPROPER STRENGTH

AIR/HYDROGEN ENTRAPMENT & IMPROPER FLUX USED

PROPER SHIELDING & FLUX USED

APP &100% INSP

IMPROPER PENITRATION

IMPROPER STRENGTH

POWER/HEAT INPUT TO LOW

PROPER POWER/HEAT INPUT PROVIDED

APP &100% INSP

Fastning & Assembly

IMPROPER FASTNING


IMPROPER HOLDING IN FIXTURE

CARE WHILE FIXTURING THE PART

APP &100% INSP

DAMAGE COPONENT REACH TO THE CUSTOMER END.

IMPROPER PACKING METHOD

VISUAL INSPECTION

Thukral Steel EngineersCONTROL PLAN

Prototype Production Core Team :- Date ( Orig) : 12/5/2013

Control Plan Number : CP/MTG.BRACKET/01 Name Deptt. Sign. Revision No. : 0

Part Name : MTG. BRACKET -15LTR AIR TANK Amit Joshi Quality Revision Date : --

Part No. F1F00914 #.0 Pryank Process Prepared By : Amit Joshi

Customer Name : Neel Metal Product Ltd. Ramu Sharma Process Approved By : Prem Thukral

Part/ Process Machine, Characteristic Spl. Methods

Process Name/ Device, Item no Product Process Char. Product/process Evaluation/ Sample Control Reaction

no. Operation Tool, Jig Class Specification/ Measurement Method Plan

Description For Mfg. Tolerance Technique Size Freq.

10 AllC MS Per lot Per Lot

Sheet Thickness 2mm, 5 mm, 3 mm Micro Meter n=6 Per Lot

20 Storage Storage Area All Racks Quantity AS per Challan 100% Lot W.I. for Storage Inform Head Store

30

Blanking & Shearing 1 DimensionDim : 709 - 711mm Vernier Caliper n=7 Per Hour

Dim : 26 - 24 mm Vernier Caliper n=7 Per Hour IIR

Blanking & Shearing 2 DimensionVernier Caliper n=7 Per Hour

Vernier Caliper n=7 Per Hour IIR

Blanking & Shearing 3 Dimension

Dim : 140 - 141mm Vernier Caliper n=7 Per Hour

Vernier Caliper n=7 Per Hour

Standard Sample n=7 Per Hour IIR

40 Punching

1

DimensionDia : 5 - 5.1 mm Vernier Caliper n=7 Every 2 hr IIR

Dia : 8.5 - 8.6 mm Vernier Caliper n=7 Every 2 hr IIR

Location

Vernier Caliper n=7 Every 2 hr IIR


2

Dimension Vernier Caliper n=2 Every 2 hr IIR

Location



3

Dimension Dia : 20 - 21 mm Vernier Caliper

LocationVernier Caliper n=7 Every 2 hr IIR


50 Bending

Bending m/c1

Diameter Standard Sample n=7 Every 2 hr IIR

Dimension Standard Sample n=2 Every 2 hr IIR

2 Dimension Standard Sample

60 Welding MMAW Dimension 17 - 0.15 mm Vernier Caliper n=7 Every 2 hr IIR

70 Fastning & Assembly Reviting m/c Diameter 11 - 12 mm, 5 mm Vernier Caliper n=7 Every 2 hr IIR

Dimension Vernier Caliper n=7 Every 2 hr IIR

80 Final Inspection Inspection Room All Appearance Visual n=100% Every Lot No Recording

90 Packing Packaging Area Quantity 250 Pcs Every Lot

Receiving of Material

Material Test Certificate

Chemical Composition


Raw Material Register

Raw Material Register

Bending m/c /Shear cutter

Dim : 160± 1 mm

Dim : 40± 1 mm

Dim : 35 ± 1 mm

R : 111± 0.1 mm

CNC Turret Punch Press/Automate

Inform Production & Quality Head

Dim : 9 ± 0.1 mm ( From Outer Side )

Dim : 57± 0.1 mm ( from center line )

Dia : 5± 0.1 mm

Dim : 9.5± 0.1 mm (counter sunk height)

Dim : 56 ± 0.1 mm(from centre line)

Dim : 15 ± 1 mm ( From outer side )

Dim : 55 ± 1 mm (From Center Line)

R : 2.5± 0.1 mm


R : 8± 0.1 mm

R : 105± 0.1 mm


Inform Production & Quality Head 1.5± 0.1 mm , 5± 0.1 mm

Free from burr , sharp edges and other Weld Defect

Inform Quality Head


Pre-Launch

Thukral Steel EngineersCONTROL PLAN

Prototype Production Core Team :- Date ( Orig) : 12/5/2013

Control Plan Number : CP/MTG.BRACKET/01 Name Deptt. Sign. Revision No. : 0

Part Name : MTG. BRACKET -15LTR AIR TANK Amit Joshi Quality Revision Date : --

Part No. F1F00914 #.0 Pryank Process Prepared By : Amit Joshi

Customer Name : Neel Metal Product Ltd. Ramu Sharma Process Approved By : Prem Thukral

Part/ Process Machine, Characteristic Spl. Methods

Process Name/ Device, Item no Product Process Char. Product/process Evaluation/ Sample Control Reaction

no. Operation Tool, Jig Class Specification/ Measurement Method Plan

Description For Mfg. Tolerance Technique Size Freq.

Pre-Launch

100 Dispatch Dispatch Area

Inform Head Dispatch

THUKRAL STEEL ENGINEERS

PRE DISPATCH INSP. REPORT DOC NO: TSE/7.5/F05/R0

RUDRAPUR ISSUE NO.:-00

ISSUE ON:-18/03/2013

JOB NO : REFERENCE W.I/INSPECTION STD. NO.CUSTOMER NAME : NEEL METAL PRODUCT LIMITED PART NO . F1F00914

DISCRIPTION : MTG. BRACKET - 15 LTR AIR TANK

ON FVDP VEHICLES

DATE :OBSERVATION /SAMPLE

REMARKS

S.N. INSP. ITEM DESCRIPTION SPECIFICATION 1 2 3 4

1Dimension Micro Meter 2,5,3 2,5,3 2,5,3 2,5,3

2 Dimension Dim 709 -711 mm Vernier Caliper 710 711 710 710

3 Dimension Dim : 26 - 24 mm Vernier Caliper 25 25 25 26

4 Dimension Vernier Caliper 160 160 161 159




8 Dimension Standard Sample 111 111 112 111

9 Dimension Dia : 5 - 5.1 mm Vernier Caliper 5 5 5 5

10 Dimension Dia : 8.5 - 8.6 mm Vernier Caliper 8.5 8.5 8.5 8.5




14 Dimension Vernier Caliper 9.5 9.5 9.5 9.6


16 Dimension Dia : 20 - 21 mm Vernier Caliper 20 20 21 20.5

17

Dimension Vernier Caliper 15 15 15 15


19 Dimension Standard Sample 2.5 2.5 2.5 2.5



22 Dimension 17 - 15 mm Vernier Caliper 17 17 15 16

23 Dimension 5 x 10 mm Vernier Caliper 5x10 5x10 5x10 5x10

24 Appereance Visual ok ok ok ok ok

DISPOSITION

ACCEPTED

REJECTED

2mm, 5 mm, 3 mm

Dim : 160± 1 mm

Dim : 40± 1 mm

Dim : 140 - 141mm

Dim : 35 ± 1 mm

R : 111± 1 mm

Dim : 9 ± 0.1 mm

Dim : 57± 0.1 mm

Dia : 5± 0.1 mm


Dim : 112± 0.1 mm(from centre line)

Dim : 15 ± 1 mm ( From outer side )


R : 2.5± 0.1 mm

R : 8± 0.1 mm

R : 105± 0.1 mm


ACCEPTED …………………………………. UNDER DEVIATION

CHECKED BY. APPROVED BY. DATE

Thukral Steel EngineersR&R STUDY REPORT - VARIABLES

Part No. F1F00914 #.0 IMTE No. Date 15/05/2013Part Name MTG. BRACKET- 15 LTR AIR TANK IMTE Description Appraisers NS/AK/ABCharacteristic DIAMETER Range 2 MMSpecification Least Count 0.01 MMNo. Of Trials 3 No. Of Samples 10 No. Of Appraisers 3

App.Trial Sample Average

1 2 3 4 5 6 7 8 9 10

A1 217 217 217 217 217 218 218 218 218 2182 218 218 218 218 217 217 217 217 217 2173 218 217 217 217 217 217 217 217 217 217

Average 217.6667 217.333 217.333 217.333 217 217.333 217.333 217.333 217.333 217.3333 217.33333

Range 1 1 1 1 0 1 1 1 1 1 0.9

B1 218 218 218 217 217 217 217 217 217 2172 218 217 217 217 217 217 217 217 217 2173 218 217 217 217 217 218 218 218 218 218

Average 218 217.333 217.333 217 217 217.333 217.333 217.333 217.333 217.3333 217.33333

Range 0 1 1 0 0 1 1 1 1 1 0.7

C1 217 217 217 217 217 217 217 217 217 2172 217 217 217 217 217 217 217 217 217 2173 217 217 217 217 217 217 217 217 217 217

Average217 217 217 217 217 217 217 217 217 217 217

Range 0 0 0 0 0 0 0 0 0 0 0

217.5556 217.222 217.222 217.111 217 217.222 217.222 217.222 217.222 217.2222Xdbar 217.22222Rp 0.5555556

0.333333Rdbar = 0.533333 Rdbar = Average of RbarUCLR = Rdbar * D4 = 1.376 D4 = 3.27 For 2 Trials & 2.58 For 3 TrialsLCLR = Rdbar * D3 = 0 D3 = 0 for 1 to 7 trials

Measurement Unit Analysis % Total VariationRepeatablity : Equipment Variation (EV)

EV = Rdbar X K1 Trials K1 % EV = 100 [ EV / TV ] = 0.533333 X 3.05 2 4.56 = 217.86 % = 0.0061 3 3.05

Reproducibility : Appraiser Variation (AV)

AV = App K2 % AV = 100 [ AV / TV ]= 0.0005 2 3.65 = 17.86 %

3 2.7Repeatablity & Reproducibility (R&R)

R&R % R&R = 100 [ R&R / TV ]= 0.0061 Parts K3 = 218.59 %

2 3.65Part Variation (PV) 3 2.7

PV =Rp X K3 4 2.3 % PV = 100 [ PV / TV ] = 0.0288 5 2.08 = 1028.57 %

6 1.93Total Variation (TV) 7 1.82

TV 8 1.74 No. of distinct catagories (ndc) = 1.41* (PV / R&R)0.0028 9 1.67 = 6.6348

10 1.62 = 5

Result ACCEPTABLE

Prepared By Amit Joshi Approved By Prem Thukral

217±1MM

XBarA

RBarA

XBarA

RBarA

XBarA

RBarA

Part Average

Xbardiff= Xbardiff = Max Xbar - Min Xbar

√(Xbardiff X K2)2 - (EV2 / nr)

√(EV2 + AV2 )

√(R&R2 + PV2 )

Prepared By Approved By Anish Bagga

Of item no 1

Of item no 2

Of item no. 3

Thukral Steel Engineers

CUSTOMER NAME : NEEL METAL PRODUCT LIMITED SUPPLIER NAME: Thukral Steel Engineers

PART NUMBER: F1F00914 #.0 SUPPLIER CODE :

PART DESCRIPTION: PART NAME :MTG. BRACKET- 15 LTR AIR TANK

CUSTOMER APPROVAL/DATE :

S.NO. DIMENSION / CHARACTERISTICS MEASURING INSTRUMENT ID NO. RANGE / L.C.

1 Dim 2mm, 5 mm, 3 mm DIMENSION Micro Meter 0.01MM

2 Dim : 709 - 711mm DIMENSION Vernier Caliper 0-25 / 0.01MM

3 Dim : 26 - 24 mm DIMENSION Vernier Caliper 0-25 / 0.01MM

4 DIMENSION Vernier Caliper 0-25 / 0.01MM


6 Dim : 140 - 141mm DIMENSION Vernier Caliper 0-25 / 0.01MM


8 DIMENSION Standard Sample

9 Dia : 5 - 5.1 mm DIMENSION Vernier Caliper 0-25 / 0.01MM

10 Dia : 8.5 - 8.6 mm DIMENSION Vernier Caliper 0-25 / 0.01MM






16 Dia : 20 - 21 mm DIMENSION Vernier Caliper 0-25 / 0.01MM

17 Dim : 15 ± 1 mm ( From outer side ) DIMENSION Vernier Caliper 0-25 / 0.01MM





22 17 - 0.15 mm DIMENSION Vernier Caliper 0-25 / 0.01MM

23 5 x 10mm DIMENSION Vernier Caliper 0-25 / 0.01MM

25 Visual Visual

26 50 Pcs Pcs Pcs

Date: 15/05/2013 Prepared by : AMIT JOSHI Approved by : PREM THUKRAL

CHECKING AIDS Format no. PPI/CA/ MTG.BRACKET/00

Dim : 160± 1 mm

Dim : 40± 1 mm

Dim : 35 ± 1 mm

R : 111± 0.1 mm

Dim : 9 ± 0.1 mm

Dim : 57± 0.1 mm

Dia : 5± 0.1 mm


Dim : 112± 0.1 mm(from centre line)


R : 2.5± 0.1 mm

R : 8± 0.1 mm

R : 105± 0.1 mm


ppap for neel metal

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