BRASS COPPER & ALLOY (I) LTD.

Gujarat,
India Process Control Plan ( ) PROTOTYPE, ( ) PRELAUNCH, (√ )PRODUCTION Date :-20//09/24

Control Plan Number Key contact/phone DOC.Number/ Revision

16 Suryakant Patil / 9637106063 QAD/FR/CP/01 Rev. 01
Part Number /Latest change leval Core Team Customer Engineering Approval / Date (If Req 'd)
1400752502/01 Vikesh,Pratik, Shreyansh NA
Part Name/Description Supplier/Plant Approval /Date Customer Quality Approval / Date (If Req 'd)
TUBULAR RING TRML M8 Sn (CSA- 50.0) Motherson NA
Supplier/ Plant Supplier Code Other Approval/ Date (if Req 'd) Other Approval/ Date (if Req 'd)
COPPER PLANT - 2 601493
Product / Process Characteristics Control Methods/Measurement
Process Machine,
Part/Process Name / Device, Jig, Ref Doc. Number/ Specification Evaluation/Me Remarks
Characteristic Key Sample size & Reaction Plan
Number Operation Tools for Specification No & asurement Control Method (Special Process)
Description Manufacturing Description Dim Frequency
Dimensions Instrument

Hardness Testing
Copper Tube Grade, Hardness ETP grade, Min 90 HV5 (HD), machine-02,
-- 1 pc./Batch.
& Conductivity . Min 97% I.A.C.S. Conductivity meter-
Raw Material PO, Supplier TC 02
Raw Material
[As per RM Specification If NOK, reject & return
OP-10 Inward / incoming - RM Inspection Report
QAD/CH/02 & quality to the supplier
inspection I.D. = 10.0
plan (QAD-QP-01) (RM) ] I.D., 10.0 mm Digital Vernier
mm(± 3%)
O.D. , 14.0 mm Calliper-15, Min. 5 pcs./Batch.
O.D. = 14.0
Length 8' or 10' Measuring Tape-01
mm(± 3%)

Storage of Define location for raw

OP-20 Manually - Location FIFO - Visual - Material size identified
Raw material material

Tube cutting Cutting Machine

1st pcs Setup

As per quality plan (QAD-QP-01) Vernier Caliper -
Setting Dim. of tube cutting length L = 55 mm (± 1.0 mm) - 1st pcs of setting
(Lug)/ Cutting length chart 15
Approval
If any problem, stop
the m/c immediately &
Inprocess As per quality plan (QAD-QP-01) Vernier Caliper - Insprocess Inspection
Dim. of tube cutting length L = 55 mm (± 1.0 mm) - Min. 5 pcs./2 hrs inform to production
OP-30 Inspection Cutting Machine (Lug)/ Cutting length chart 15 Report.
supervisor and
Setting work instruction
supervisor will be
rectify the tool / Die.
Last pcs As per quality plan (QAD-QP-01) Vernier Caliper - Last 1 pcs after
Dim. of tube cutting length L = 55 mm (± 1.0 mm) -
Approval (Lug)/ Cutting length chart 15 production

Tube
Chamfering machine
Champhering
1st pcs Setup
As per quality plan (QAD-QP-01) Dim. of tube Champhering Beval protector-
Setting 60° (± 5°) - 1st pcs of setting
(Lug) angle 01 If any problem, stop
Approval
the m/c immediately &
Insprocess Inspection
Inprocess Chamfering As per quality plan (QAD-QP-01) Dim. of tube Champhering Beval protector- inform to production
OP-40 60° (± 5°) - Min. 5 pcs./2 hrs Report.
Inspection machine (Lug) angle 01 supervisor and
Setting work instruction
supervisor will be
rectify the tool / Die.
Last pcs As per quality plan (QAD-QP-01) Dim. of tube Champhering Beval protector- Last 1 pcs after
60° (± 5°) -
Approval (Lug) angle 01 production

Dropping Dropping
 I.D., 8.8 mm (± 0.24 mm)
Vernier Calliper-
As per dropping size chart O.D. , 13.0 mm (± 0.39 mm) -
15
Dropping Length 19 mm (± 0.57 mm)

1st pcs Setup

As per work instruction of dropping Oil pressure 150 kg/cm2 Pressure gauge 1st pcs of setting
Setting Approval
If any problem, stop
Insprocess Inspection the m/c immediately &
Vernier Calliper- Report. inform to production
OP-50 Dropping machine As per conrol plan Strock length 90.5 mm -
15 / Scale Setting work instruction supervisor and
supervisor will be
I.D., 8.8 mm (± 0.24 mm) rectify the tool / Die.
Inprocess Vernier Calliper -
As per dropping size chart O.D. , 13.0 mm (± 0.39 mm) - Min. 5 pcs./2 hrs
Inspection 15
Dropping Length 19 mm (± 0.57 mm)

I.D., 8.8 mm (± 0.24 mm)

Last pcs Vernier Calliper - Last 1 pcs after
As per dropping size chart O.D. , 13.0 mm (± 0.39 mm) -
Approval 15 production
Dropping Length 19 mm (± 0.57 mm)

Forging Power Press 30 Ton

Palm Width=18.0 Barrel
Drawing No. HEX/CSA 50/23 [As mm(±1.0mm), Palm Thick =
Palm width, Palm length = Vernier Calliper-
per quality plan (QAD-QP-01) 4.0 mm (±0.3mm)& 1st pcs of setting
Thickness & Barrel length 16.0 mm 15
(Lug)] Barrel length = 16.0 mm (min)
1st pcs Setup (min.)
Setting Approval
Vernier Callipe / If any problem, stop
As per control plan Strock length 105.0 mm - 1st pcs of setting
scale the m/c immediately &
Insprocess Inspection
inform to production
OP-60 Power Press 30 Ton Report.
Palm Width=18.0 Barrel supervisor and
Drawing No. HEX/CSA 50/23 [As Setting work instruction
Inprocess Palm width, Palm mm(±1.0mm), Palm Thick = length = Vernier Calliper- supervisor will be
per quality plan (QAD-QP-01) 4.0 mm (±0.3mm)& Min. 5 pcs./2 hrs rectify the tool / Die.
Inspection Thickness & Barrel length 16.0 mm 15
(Lug)] Barrel length = 16.0 mm (min) (min.)
Palm Width=18.0 Barrel
Drawing No. HEX/CSA 50/23 [As mm(±1.0mm), Palm Thick =
Last pcs Palm width, Palm length = Vernier Calliper- Last 1 pcs after
per quality plan (QAD-QP-01) 4.0 mm (±0.3mm)&
Approval Thickness & Barrel length 16.0 mm 15 production
(Lug)] Barrel length = 16.0 mm (min) (min.)
Arc cutting &
Power Press 20 Ton
Holling
Palm Length = 23.6 mm (±1.0
mm) & Total length = 46.8 mm (±
1.4 mm)
Palm Length & Total length Stud hole = 8.4 mm(+0.2 / -0.0mm) Stud
1st pcs Setup Drawing No. HEX/CSA 50/23[As
Stud hole, Hole = Vernier Calliper-
Setting per quality plan (QAD-QP-01) X 12.0mm(± 0.10mm) 1st pcs of setting
Front distance, 8.4 X 15
Approval (Lug)] Front Dist =11.8 mm(± 0.4mm),
Back distance 12.0
Back Dist =11.8 mm,
Hole centre to barrel distance =
35.0mm( ± 1.0mm)

Palm Length = 23.6 mm (±1.0

mm) & Total length = 46.8 mm (±
1.4 mm)
Palm Length & Total length Stud hole = 8.4 mm(+0.2 / -0.0mm) Stud If any problem, stop
Drawing No. HEX/CSA 50/23[As
Inprocess Stud hole, Hole = Vernier Calliper- the m/c immediately &
per quality plan (QAD-QP-01) X 12.0mm(± 0.10mm) Min. 5 pcs./2 hrs Insprocess Inspection
Inspection Front distance, 8.4 X 15 inform to production
OP-70 Power Press 20 Ton (Lug)] Front Dist =11.8 mm(± 0.4mm), Report.
Back distance 12.0 supervisor and
Back Dist =11.8 mm, Setting work instruction
supervisor will be
Hole centre to barrel distance =
rectify the tool / Die.
35.0mm( ± 1.0mm)
 Palm Length = 23.6 mm (±1.0
mm) & Total length = 46.8 mm (±
1.4 mm)
Palm Length & Total length Stud hole = 8.4 mm(+0.2 / -0.0mm) Stud
Drawing No. HEX/CSA 50/23[As
Last pcs Stud hole, Hole = Vernier Calliper- Last 1 pcs after
per quality plan (QAD-QP-01) X 12.0mm(± 0.10mm)
Approval Front distance, 8.4 X 15 production
(Lug)] Front Dist =11.8 mm(± 0.4mm),
Back distance 12.0
Back Dist =11.8 mm,
Hole centre to barrel distance =
35.0mm( ± 1.0mm)

Deburring Deburring Machine

Setting As per quality plan (QAD-QP-01) If any problem, stop

Deburring time frequency 30 Min - Visual check Time monitoring the m/c immediately &
Approval (Lug) Insprocess Inspection
inform to production
OP-80 Vibro Machine Report.
supervisor and
Setting work instruction
Inprocess As per quality plan (QAD-QP-01) Visual after completion of supervisor will be
Free from sharp edeges & burr - Visual check Min. 5 pcs./30 Min
Inspection (Lug) process rectify the tool / Die.

Inspection
Manually Drawing No. HEX/CSA 50/23 [As Vernier Caliper- If NOK, segregate
Before Tin Min.5 pcs./ Befor plating
OP-90 /Inspecion per quality plan (QAD-QP-01) Dims. of formed terminal All dims as per dwg - 15 /Visual production parts &
Plating Batch. Inspection Report.
instruments (Lug)] check. rework or reject.
process

Plating thickness Min.5 pcs./

Drawing No. HEX/CSA 50/23, Tin plating thickness 6 microns (min) -
Tin Plating Plating thickness tester Batch. After plating Inspection If NOK, rework the
OP-100 Cust Drg [As per quality plan (QAD-
process tester Report defective batch
QP-01) (Lug)] Min.5 pcs./
Visual No blackness, no peel off - Visual check
Batch.
free from dent, burr, crack & Visual
Drawing No. HEX/CSA 50/23 [As Visual defects - Visual check Record of summary
tin plating visual defects inspection (100 Rework or reject NOK
OP-110 Final Inspection -- per quality plan (QAD-QP-01)
Vernier Caliper Min.5 pcs./ Finish Goods parts
(Lug)] All dims. of the terminal All dimensions -
/Visual check. Batch. Inspection Report.

Manually / Weighing If NOK material will be

OP-120 Packing Packing Standard Qty. pack As per packing standard - Visual check 100% / batch DPR
& Packing machines repacking

Storage of If any problem

No packing damage
OP-130 Manually - Appearance - Visual check 100% / batch FG Stock inform to store
finish good in & no over qty. loading
store incharge

If any problem
inform to store
Inspection of incharge / packing/ If
Batch code should not be old Dispatch
plating material Manually - Plated material shelf life - Visual check All / lot batch code is old
more than six month Details.
shelf life more than 6 month
OP-140 then send for
replatting

If any problem
Dispatch to Dispatch
Manually - Material As per MSSL / HEX schedule - Visual check All / lot inform to store
customer Details.
incharge / packing

Note : 1) Any material which is under suspicion for Quality parameter ( During setting change,M/C breakdown, shift changeover ) is kept with separate tag and bin and is 100 % inspected before dispatch.

Sr.No. NAME TITLE CONTACT No. E- MAIL ADDRESS

1 Swapnil Kini Assistant General Manager - Quality 9324792904 swapnil@hexworldwide.com

2 Suryakant patil Manager - Quality 9637106063 managerquality@hexworldwide.com
3 Shreyansh Bhusara Assistant Manager - Quality 7574934458 qad@hexworldwide.com
4 Dharmesh Bhoya Quality engineer 9898271488 qad@hexworldwide.com