PPAP/FAI DOCUMENTS CHECK LIST

CUSTOMER NAME : M/S CONTENTIAL ENGINES LTD. SUBMISSION DATE :

PART NAME : Spacer Distribution Pipe DOC No.:

DWG NO/Rev No.: CP4197002 REV. NO.:

MATERIAL: STEEL2172-91/ ALT- STEEL 1912-04 ORG. DATE:

CORE TEAM MEMBER: Mr. Aviral Rajwanshi, Mr. Hariom Sharan,Mr. Kamal,Mr
SUPPLIER: PMT INNOTECH PVT. LTD.
Debender
PROCESS RESP.: Mr. Hariom Sharan PRODUCT: MACHINING COMPONENT
REQUIREMENT
S.NO REQUIREMENT REMARKS
YES/NO/NA
1 CUSTOMER DRAWING YES

2 ENGINEERING CHANGE DOCUMENTS

3 CUSTOMER ENGINEERING APPROVAL

4 DFMEA NA

5 PFD YES

6 PFMEA YES

7 CONTROL PLAN YES

8 MSA STUDY YES

9 DIMENSIONAL ANALYSIS YES

10 MATERIAL TEST CERTIFICATE (MTC) YES

11 INITIAL PROCESS STUDY YES

12 QUALIFIED LABORATORY DOCUMENTS YES

13 AAR NA

14 SAMPLE PRODUCTS YES

15 MASTER SAMPLE YES

16 CHECKING AIDS YES CALIBRATION DATE NA

17 PACKING STANDARD YES PRIMARY PACKING PHOTO NA

18 PSW YES

19 PROCESS SHEET YES

R/NO. REV. DATE REVISION SUMMARY REASON FOR REVISION

Prepared by:- CHECKED BY:- Approved by:

PMT/ENGG/F/030-00 02-01-2021
 Process Flow Diagram

Supplier Name Custome

PMT INNOTECH PVT. LTD.
Opp. – Inderprasth colony (Sec-49) Badkhal – Pali
road M/s. Continental Engines Limi
Bhakri, Faridabad - 121001 (Haryana) INDIA, Plot No.-A88, B
Ph. No.- 0129-2435249, E-mail : - [email protected]

Part name : - SPACER DISTRIBUTION PIPE Part No :

Operation OUTSOUC
Operation Inspection Storage Move Special
Operation Cum Insp. E
S. No Characteristics
Description
(if any)

Receiving of 10
10
Raw Material

Insp. of Raw 11
11
Material

12
Storage of Raw
12
Material,

PRE MACHINING
20
1ST SET UP 20

PRE MACHINING
30
2ND SETUP
30

TURNING 1ST
40
SETUP
40

TURNING 2ND 50
50
SETUP

60 GRINDING
60

70 SIOT MILLING
70

80 DEBURRING 80
 90 PLATING
90

91 Insp. of Plating 91

100 Final Inspection

100

110 Packing 110

111 Storage 111

112 Dispatch
112

Legend
Symbols Activity Definition
When something is done to or by the subject being followed at a
Operation
changed added to or created.
Move When something is moving or being moved from one workspace

Inspection Operation Cum When something is being produce and inspected itself.

OUTSOURCED When Something is being produce outside

Inspection When something is checked or verified to quality or examined for

Storage When something is kept or protected against unauthorised remo

Special Characteristics When something is Special Characteristics them marked.

Prepared By:- Checked By:-

Value added Process
Note : -
Nonvalue added Process
PMT/ENGG/F/004-00:10-JAN-2018
 PFD NO: PFD/ CP4197002

m REV. NO. :- 01
Org. DT. :- 31.03.2015
Customer Name

/s. Continental Engines Limited.

Plot No.-A88, Bhiwadi (Rajasthan) INDIA

CP4197002 REV. NO./DATE :- 03/09-03-2015

Key Product
Key Process Characteristics
Characteristics

Quantity/Weight as per
N/A
challan/Po.

All dimensions to be control

as per PROCESS Sheet N/A
NoCP4197002

Lot wise/Batchwise storage

of Raw Material,FIFO N/A
Board

All dimensions to be control

as per PROCESS Sheet FEED
NoCP4197002

All dimensions to be control

as per PROCESS Sheet FEED
NoCP4197002

All dimensions to be control

as per PROCESS Sheet FEED RPM
NoCP4197002

All dimensions to be control

as per PROCESS Sheet FEED RPM
NoCP4197002

All dimensions to be control

as per PROCESS Sheet N/A
NoCP4197002

All dimensions to be control

as per PROCESS Sheet N/A
NoCP4197002

No damage N/A
 Outsource N/A

All dimensions to be control

as per PROCESS Sheet N/A
No CP4269002

All dimensions to be control

as per PROCESS Sheet As per PDI Inspection. Standard (IS 2500) / Report
NoCP4197002

No damage As per Packing Std. Doc N O- PACK/CP4197002

No damage,No rust As Per FIFO Standardization

No damage, &
deformation during As per Work Instruction
transportation

Definition
o or by the subject being followed at a given work area. Something is being
ed.
g or being moved from one workspace or location to another.

produce and inspected itself.

produce outside

d or verified to quality or examined for information or the act of doing so.

protected against unauthorised removal.

l Characteristics them marked.

Approved BY:-
CUSTOMER : M/s. Continental Engines Limited PAR

PART NO: CP4197002 SPACER DIS

TEAM MEMBERS: (CFT);- Mr. Aviral Rajwanshi, Mr. Kamal

CL
A
PROCESS FUNCTION PRODUCT POTENTIAL FAILURE
OPN. NO. S POTENTIAL EFFECTS OF FAILURE
REQUIREMENTS CHARACTERISTICS MODE
S

Receiving of Raw (1)Functional Problem at

OP-10 Chemical Composition Composition Wrong
Material customer end

Function and Fitment Problem at

DIM.(82±0.2) DimU/S & O/S
customer end

Function and Fitment Problem at

DIA (Ø12±0.3) Dia U/S & O/S
customer end

OP-20 TRAUB 1st Set up

Function and Fitment Problem at

DIM(41±0.3) Dim U/S & O/S
customer end

Function and Fitment Problem at

2XCHAMFER (0.5x45°) Out of Spec
customer end
 Function and Fitment Problem at
OP-30 TRAUB 2nd Set up DIA (Ø12±0.3) Dia U/S & O/S
customer end

T.LENGTH T.LENGTH Function and Fitment Problem at

(80±0.3) U/S & O/S customer end

2XCHAMFER (1±0.2x45 Function and Fitment Problem at

Out of Spec
ᵒ±1°) customer end

PERPENDICUL- Function and Fitment Problem at

Out of Spec
ARITY(0.2 A) customer end

Function and Fitment Problem at

DIA. Ø14±0.2 Dia U/S & O/S
customer end

OP-40 CNC 1ST Set up

Function and Fitment Problem at

DIA. Ø20.2±0.1 Out of Spec
customer end

Function and Fitment Problem at

RADIUS 1±0.2 Out of Spec
customer end
 Function and Fitment Problem at
DIM.(40±0.2) Dim U/S & O/S
customer end

2XCHAMFER (0.5x45 Function and Fitment Problem at

Out of Spec
ᵒ) customer end

Function and Fitment Problem at

DIM.(80±0.3) Dim U/S & O/S
customer end

2XCHAMFER (1±0.2x45 Function and Fitment Problem at

Out of Spec
ᵒ±1°) customer end

PERPENDICUL- Function and Fitment Problem at

Out of Spec
ARITY(0.2 A) customer end

OP-50 CNC 2nd Set up

Function and Fitment Problem at

DIA. Ø20.2±0.1 Out of Spec
customer end

2XCHAMFER Function and Fitment Problem at

Out of Spec
(0.2±0.1x45 ᵒ±1°) customer end
 Function and Fitment Problem at
RADIUS 1±0.2 Out of Spec
customer end

DIA.
Function and Fitment Problem at
OP-60 GRINDING Ø20+0.075~Ø20+0.095 Dia U/S & O/S
customer end

Function and Fitment Problem at

OP-70 MILLING SLOT DIM.(2±0.2) Dim U/S & O/S
customer end

If burr available fitment problem

OP-80 DEBURRING No burr dent line mark occer . Visual
problem occr

Function Problem at customer

OP-90 Plating Thickness-8-12 um Plating U/S / O/S
end

Assy Failure at customer end part

reject
All defects in parts All defects in parts not
Customer Dis-satisfation and
OP-100 FINAL INSPECTION should be captured captured ( Dim &
Aesthetic problem at customer
( Dim & Visual) Visual)
end

(1) Packing should be as (1) Wrong QTY

per packing STD dispatched to
PACKING ,STORAGE (2) Bin/ customer (1) Line stop at customer
OP-110
& DISPATCH Trolley,corrugated box (2) Wrong Bin/ (2) Customer Dis-satisfation
should be loading Trolley,corrugated box
properly used
 (1) Packing should be as (1) Wrong QTY
per packing STD dispatched to
PACKING ,STORAGE (2) Bin/ customer (1) Line stop at customer
OP-110
& DISPATCH Trolley,corrugated box (2) Wrong Bin/ (2) Customer Dis-satisfation
should be loading Trolley,corrugated box
properly used

Legends for Potential Effects: Legends for Class:-

NP - Effect on next process for severity number
Assy - Effect on internal Assy line 10 , 9 - C (Critical Characteristic)
Cust - Effect on customer assy line 8- S ( Significat Characteristic)
App - Effect on application 8- M (Major Characteristic) Effects on next process

REV.NO. DATE CHANGE/REASON OF CHANGE

PREPARED BY SAAJAN KUMAR CHECKED BY:
PMT/ENGG/F/005-00: 10-JAN-2018
 PMT INNOTECH PVT. LTD.
PROCESS FMEA
PART NAME PART FAMILY

SPACER DISTRIBUTION PIPE

S O
E C
POTENTIAL CAUSE(S) OF CURRENT PROCESS CONTROLS
POTENTIAL EFFECTS OF FAILURE V C
FAILURE PREVENTION

(1) Raw Material TC from Supplier / and

(1). Sub-standard Material
(1)Functional Problem at inspection at our end from Third Party
7 Received from supplier 2
customer end
(2) Mixed at job work
(2) Supplier Audit

(1) Tool Wear Out

(1) Insert change frequency to be decided
(2) Setting not proper
Function and Fitment Problem at (2) Training plan should be made
7 (3) Machine Variation 1
customer end (3) Machine preventive Maintainance
(4) Tool may be broke
should be made

(1) Insert change frequency to be decided

(1) Setting not proper
Function and Fitment Problem at (2) Training plan should be made
7 (2) Machine Variation 2
customer end (3) Machine preventive Maintainance
(3) Tool may be broke
should be made
(4) Wrong Offset

Function and Fitment Problem at (1) Setting not proper (1) Training plan should be made
6 2
customer end (2) Machine Variation (2) Machine preventive Maintainance
(3) Wrong Offset should be made

(1) Insert change frequency to be decided

(1) Setting not proper
Function and Fitment Problem at (2) Training plan should be made
6 (2) Machine Variation 2
customer end (3) Machine preventive Maintainance
(3) Tool may be broke
should be made
 (1) Insert change frequency to be decided
(1) Setting not proper
Function and Fitment Problem at (2) Training plan should be made
7 (2) Machine Variation 2
customer end (3) Machine preventive Maintainance
(3) Tool may be broke
should be made
(4) Wrong Offset

(1) Tool Wear Out

(1) Insert change frequency to be decided
(2) Setting not proper
Function and Fitment Problem at (2) Training plan should be made
7 (3) Machine Variation 2
customer end (3) Machine preventive Maintainance
(4) Tool may be broke
should be made
(5) Wrong Offset

(1) Insert change frequency to be decided

(1) Setting not proper
Function and Fitment Problem at (2) Training plan should be made
6 (2) Machine Variation 2
customer end (3) Machine preventive Maintainance
(3) Tool may be broke
should be made

(1) Insert change frequency to be decided

Function and Fitment Problem at (1) Setting not proper (2) Training plan should be made
7 3
customer end (2) Machine Variation (3) Machine preventive Maintainance
should be made

(1) Tool Wear Out

(2) Setting not proper
Function and Fitment Problem at
6 (3) Machine Variation 2 (1) Training plan should be made
customer end
(4) Tool may be broke
(5) Wrong Offset

(1) Tool Wear Out (1) Insert change frequency to be decided

Function and Fitment Problem at (2) Setting not proper (2) Training plan should be made
7 1
customer end (3) Machine Variation (3) Machine preventive Maintainance
(4) Wrong Offset should be made

Function and Fitment Problem at

6 (1) Machine Variation 2 (1) Training plan should be made
customer end
 (1) Tool Wear Out
(1) Insert change frequency to be decided
(2) Setting not proper
Function and Fitment Problem at (2) Training plan should be made
7 (3) Machine Variation 2
customer end (3) Machine preventive Maintainance
(4) Tool may be broke
should be made
(5) Wrong Offset

(1) Insert change frequency to be decided

(1) Setting not proper
Function and Fitment Problem at (2) Training plan should be made
6 (2) Machine Variation 2
customer end (3) Machine preventive Maintainance
(3) Tool may be broke
should be made

(1) Tool Wear Out

(1) Insert change frequency to be decided
(2) Setting not proper
Function and Fitment Problem at (2) Training plan should be made
7 (3) Machine Variation 2
customer end (3) Machine preventive Maintainance
(4) Tool may be broke
should be made
(5) Wrong Offset

(1) Insert change frequency to be decided

(1) Setting not proper
Function and Fitment Problem at (2) Training plan should be made
6 (2) Machine Variation 2
customer end (3) Machine preventive Maintainance
(3) Tool may be broke
should be made

(1) Insert change frequency to be decided

Function and Fitment Problem at (1) Setting not proper (2) Training plan should be made
7 3
customer end (2) Machine Variation (3) Machine preventive Maintainance
should be made

(1) Tool Wear Out (1) Insert change frequency to be decided

Function and Fitment Problem at (2) Setting not proper (2) Training plan should be made
7 1
customer end (3) Machine Variation (3) Machine preventive Maintainance
(4) Wrong Offset should be made

(1) Insert change frequency to be decided

(1) Setting not proper
Function and Fitment Problem at (2) Training plan should be made
6 (2) Machine Variation 2
customer end (3) Machine preventive Maintainance
(3) Tool may be broke
should be made
Function and Fitment Problem at
6 (1) Machine Variation 2 (1) Training plan should be made
customer end

(1) Tool Wear Out

(1) Insert change frequency to be decided
(2) Setting not proper
Function and Fitment Problem at (2) Training plan should be made
6 (3) Machine Variation 2
customer end (3) Machine preventive Maintainance
(4) Tool may be broke
should be made
(5) Wrong Offset

(1) Tool Wear Out

(1) Insert change frequency to be decided
(2) Setting not proper
Function and Fitment Problem at (2) Training plan should be made
7 (3) Machine Variation 2
customer end (3) Machine preventive Maintainance
(4) Tool may be broke
should be made
(5) Wrong Offset

If burr available fitment problem (1) Unskill Manpower

(1) Training provide to operator
occer . Visual 5 (2) WI Not 2
(2) Visual Defects available
problem occr Available

(1) Unskill Manpower

Function Problem at customer (1) Training provide to operator
5 (2) WI Not 2
end (2) Visual Defects available
Available

(1) Training Provide to Inspector about

inspection and how to used instruments
and Gauges and about sampling plan
(2) Instrument and Gauges to be calibrated
as per plan
(1) Instrument and gauge error (3) Sampling plan to be followed
Assy Failure at customer end part (2) Instrument and gauge are
reject not calibrated as per decided
Customer Dis-satisfation and frequency
7 2
Aesthetic problem at customer (3) Untrained Inspector
end Sampling plan not followed
(4) Inspection std/ Visual
AIDS/WI not made

(1) Packing std not made

(2) Untrained associate used in (1) Packing std made as per requirement
(1) Line stop at customer
5 loading 2 (2) Training provided to associate about
(2) Customer Dis-satisfation
packing and loading
 (1) Packing std not made
(2) Untrained associate used in (1) Packing std made as per requirement
(1) Line stop at customer
5 loading 2 (2) Training provided to associate about
(2) Customer Dis-satisfation
packing and loading

A type controls - Controls that Detect the failure mode after it happens
B type control - Controls that Detect the cause when it happens and in- turn prevents
C type control - Controls that prevent the cause
) Effects on next process

ASON OF CHANGE REV.NO. DATE

CHECKED BY:
PVT. LTD.
FMEA
CP4197002
PART FAMILY MODEL DOC. NO.
14.04.2022
DATE (ORIG.)
REV. NO. / DATE 00/---
PROCESS RESPONSIBILITY : DPM(Development)
D R ACTION RESULTS
E P S
CURRENT PRODUCT RECOMMENDED RESP./TARGET
CONTROLS DETECTION T N ACTIONS COMPLETION DATE ACTION TAKEN
E

Incoming Inspection 5 70

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
5 35
2Hrs.
(3)WI should made

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
5 70
2Hrs.
(3)WI should made

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
5 60
2Hrs.
(3)WI should made

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
5 60
2Hrs.
 (1) Set up Approval
(2) Inprocess insp. 2Pcs /
5 70
2Hrs.
(3)WI should made

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
2Hrs. 5 70
(3) WI should made
(4)Training to be Provided

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
5 60
2Hrs.

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
2Hrs. 4 84
(3) WI should made
(4)Training to be Provided

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
2Hrs. 5 60
(3) WI should made
(4)Training to be Provided

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
2Hrs. 5 35
(3) WI should made
(4)Training to be Provided

(2) Inprocess insp. 2Pcs /

5 60
2Hrs.
(2)Training to be Provided
(1) Set up Approval
(2) Inprocess insp. 2Pcs /
2Hrs. 5 70
(3) WI should made
(4)Training to be Provided

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
5 60
2Hrs.

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
2Hrs. 5 70
(3) WI should made
(4)Training to be Provided

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
5 60
2Hrs.

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
2Hrs. 4 84
(3) WI should made
(4)Training to be Provided

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
2Hrs. 5 35
(3) WI should made
(4)Training to be Provided

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
5 60
2Hrs.
 (2) Inprocess insp. 2Pcs /
5 60
2Hrs.
(2)Training to be Provided

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
2Hrs. 5 60
(3) WI should made
(4)Training to be Provided

(1) Set up Approval

(2) Inprocess insp. 2Pcs /
2Hrs. 5 70
(3) WI should made
(4)Training to be Provided

1) Inprocess insp. 2Pcs /

2Hrs.
5 50
(2)Training to be Provided
to Manpower

1) Inprocess insp. 2Pcs /

2Hrs.
5 50
(2)Training to be Provided
to Manpower

(1) PDI Report each lot

(2) 100% Visual inspection
at final stage
(3) Inspection STD/ Visual
Inspection/WI made and
displayed at final stage
(4) Dock Audit each lot
before dispatch
7 98

(1) WI made and displayed

packing and dispatch area
(2) Part re-verify by
packing incharge and 4 40
dispatch incharge
(3) Dock Audit
 (1) WI made and displayed
packing and dispatch area
(2) Part re-verify by
packing incharge and 4 40
dispatch incharge
(3) Dock Audit

er it happens
appens and in- turn prevents the failure mode

CHANGE
APPROVED BY:
CP4197002

14.04.2022

00/---

ACTION RESULTS
O D R
C E P

C T N
 C/Plan No : - CP/CP4197002
CONTROL PLAN
Rev. No. : - 01
Prototype Pre Launch Production Org. Date : - 31.03.2015
Customer Name : - M/s. Continental Engines Limited. Mr. Hariom Sharan Approval/Sign./Date (If Req.)
Key Contact / Phone: -
Part Description : - SPACER DISTRIBUTION PIPE Mr. Kamal Supplier Plant Customer Engg. Customer Q.A
Part No. : – CP4197002
Core Team: - Mr.Hariom sharan,Mr. Kamal, Mr. Debender
Latest Drg. Change- '03 / Date - 17.07.2015
Characteristics Methods
Process Name / Machine, Sample
Part/ Special Char. Evaluation /
Operation Device, Jig, Product / Process Specification / Reaction Plan
Proc # Product Process Class. Control Method
description Tools For Mfg. Number Tolerance
Measurement Sample Sample
Technique Size Freq.
Verification As per
Receiving of raw No damage & deformation of Each Put Reject Tag & Material Send
10 Manual 1 Quantity & Packaging of Quantity N/A Visual Sampling As Per Instruction
material packing & product. Lot back to supplier.
& Packaging Plan

Supplier Test Each Reject & return the material to

1 Material -------------- N/A En 1A (Without Lead) Supplier TC
certificates Lot supplier with report

Each
2 OD N/A Ø 22±0.2 DVC
Lot

C-0.14% max,Si-0.05% max,

Third Party
Chemical composition Mn-0.9-1.3%,P-0.11% max, S- inspection YEARLY
0.27-0.33% max
Receiving of
11 N/A
Inspection
Third Party
3 Tensile Strength 460-760 N/MM² As per Incoming Reject & return the material to
inspection
Inspection supplier with report
Third Party
4 PROOF STENGTH 370 N/MM² MIN YEARLY
inspection

Third Party
5 Elongation 8% min
inspection

Free from Bend, Damage Rust, Each

6 Appearances -------------- N/A Visual
Pitted, Crack. Lot

Proper storage & preservation,

Storage of Raw Handling Damage of Each
12 Manual 1 Storage N/A which can prevent from physical Visual As per FIFO Standard Segregate/ Restore
Material packaging Lot
deformation and . FIFO followed

1 Dim -------------- 82 ± 0.20 mm Dvc

2 Drill Dia Ø12±0.3 Ppg Per 2Hrs

PRE MACHINING Traub 1st Inprocess Line Report To Incharge

20 3 Dim N/A 41±0.3 DVC 1Pc
SET UP Set-up Inspector Immediately

4 2xChamfer 0.5x45° Contracer Per Shift

Free from Burr, Dent, Rust,

5 Appearances -------------- Visual Per 2Hrs
Crack etc.

1 Dia 12±0.3 Ppg

PRE MACHINING Traub 2nd Inprocess Line Report To Incharge
30 1Pc Per 2Hrs
SET UP Set-up Inspector Immediately
 PRE MACHINING Traub 2nd Inprocess Line Report To Incharge
30 1Pc Per 2Hrs
SET UP Set-up Inspector Immediately
Free from Burr, Dent,
2 Appearances Visual
Damage, Pitted, Crack.

1 TOTAL LENGTH -------------- N/A 80±0.3 Dvc Per 2Hrs

2 2X CHAMFER -------------- N/A 1±0.2X45 ᵒ±1° Contracer Per Shift

3 PERPENDICULARITY N/A 0.2 A H.G Per 2Hrs

4 ID Ø14±0.2 Dvc Per 2Hrs

OD,
ID,FACING,CCHA CNC-1st Set Inprocess Line Report To Incharge
40 5 OD Ø20.2±0.1 Dvc 1Pc Per 2Hrs
MFER ,RADIUS up Inspector Immediately
(BOTH SIDES)
6 Radius R1 ±0.2 Contracer Per Shift

7 Dim 40±0.2 HG Per 2Hrs

8 2XChamfer 0.5X45° Contracer Per Shift

Free from Burr, Dent, Rust,

9 Appearances -------------- Visual Per 2Hrs
Crack etc.

1 TOTAL LENGTH -------------- N/A 80±0.3 Dvc Per 2Hrs

2 2x CHAMFER -------------- N/A 1±0.2x45 ᵒ±1° Contracer Per Shift

3 PERPENDICULARITY N/A 0.2 A H.G Per 2Hrs

OD,
ID,FACING,CCHA CNC-2nd Set Inprocess Line Report To Incharge
50 4 OD Ø20.2±0.1 Dvc 1Pc Per 2Hrs
MFER ,RADIUS up Inspector Immediately
(BOTH SIDES)
5 2XChamfer 0.2±0.1X45°±1° Contracer Per Shift

6 2xRadius R1 ±0.2 Contracer Per Shift

Free from Burr, Dent, Rust,

7 Appearances -------------- Visual Per 2Hrs
Crack etc.
1 OD Ø20+0.075~Ø20+0.095 ARG

2 Surface Finish Rz32 RT Inprocess Line Report To Incharge

60 GRINDING 1 Nos Per Hr
Inspector Immediately
Free from Burn, Dent,
3 Appearance -------------- Visual
Damage, Pitted, Crack.
1 Slot 2±0.2 Slip Gauge
Inprocess Line Report To Incharge
70 MILLING SLOT Free from Burn, Dent, 1 Pc Per 2Hrs
2 Appearance -------------- Visual Inspector Immediately
Damage, Pitted, Crack.
1 DIM 2±0.2 Slip Gauge
Free from Dent, Inprocess Line Report To Incharge
80 DEBURRING 1 Pc Per 2Hrs
2 Appearance -------------- Crack,Scratch,White Visual Inspector Immediately
Patches.

ANTI-RUST TREATMENT
Y2000- STD121-0004
Color-Bright Passivation
1 PLATING Time Until Basis Metal Supplier Test
Corrosion Appears-1.5 Report Inprocess Line Report To Incharge
Weeks(252 Hrs Min) Inspector Immediately
90 PLATING Outsourced

2 COLOUR BRIGHT PASSIVATION

 Inprocess Line Report To Incharge
Inspector Immediately
90 PLATING Outsourced

3 PLATING THICKNESS 8-12 um DFT METER

Free from Burn, Dent, Inprocess Line Report To Incharge

4 APPEARANCE Visual 1 Pc Per 2Hrs
Damage, Pitted, Crack. Inspector Immediately

ANTI-RUST TREATMENT
Y2000- STD121-0004
Color-Bright Passivation
1 PLATING Time Until Basis Metal Supplier Test
Corrosion Appears-1.5 Report
Weeks(252 Hrs Min)
As Per Sampling Report To Incharge
91 INSPECTION OF PLATING Incoming Inspector
Plan IS2500 Immediately

2 COLOUR BRIGHT PASSIVATION

3 PLATING THICKNESS 8-12 um DFT METER

Free from Burn, Dent,

4 APPEARANCE Visual
Damage, Pitted, Crack.

1 TOTAL LENGTH -------------- N/A 80±0.5 DVC

2 ID -------------- N/A Ø14±0.3 DVC/PPG

∅20+0.120/+0.080
3 OD -------------- ARG
As Per Sampling Report To Incharge
100 FINAL INSPECTION Final Inspector
Plan IS2500 Immediately
4 PLATING THICKNESS 8-12 MICRON DFT METER

5 DIM 2±0.2 Slip Gauge

Free from Dent,

6 Appearance -------------- Crack,Scratch,White Visual
Patch,Rust etc.

110 PACKING
Month & Year Code Shold Be Each Report To Incharge
VISUAL 1 N/A Visual 100%
111 STORAGE Available Lot Immediately

112 Dispatch
PREPARED BY:- CHECKED BY:- APPROVED BY:-
PMT/ENGG/F/006-00:10-JAN-2018
 .PMT INNOTECH PVT. LTD
GAGE R&R(V
Part Number Gage Name Appraiser A

CP4197002 MICROMETER Amit

Part Name Gage Number GAGE RANGE Appraiser B

SPACER DISTRIBUTION PIPE MM-01 0-25 Sunil

Characteristic Specification Gage Type L.C. Appraiser C

20 (0.12/0.08) 20.08 20.12 Variable 0.001 Bippin

Trials Parts Appraisers

3 10 3

APPRAISER/ PART

TRIAL # 1 2 3 4 5 6 7 8 9

A 1 20.102 20.098 20.099 20.102 20.102 20.101 20.102 20.103 20.102

2 20.102 20.098 20.099 20.101 20.102 20.101 20.102 20.103 20.102

3 20.102 20.098 20.099 20.102 20.102 20.101 20.101 20.102 20.102

AVE 20.102 20.098 20.099 20.102 20.102 20.101 20.102 20.103 20.102

R 0.000 0.000 0.000 0.001 0.000 0.000 0.001 0.001 0.000

B 1 20.101 20.102 20.102 20.102 20.098 20.099 20.102 20.102 20.101

2 20.100 20.101 20.101 20.102 20.098 20.099 20.102 20.102 20.101

3 20.100 20.101 20.102 20.102 20.098 20.099 20.101 20.102 20.101

AVE 20.100 20.101 20.102 20.102 20.098 20.099 20.102 20.102 20.101

R 0.001 0.001 0.001 0.000 0.000 0.000 0.001 0.000 0.000

C 1 20.102 20.102 20.102 20.098 20.102 20.098 20.100 20.102 20.102

2 20.103 20.102 20.102 20.098 20.102 20.099 20.099 20.102 20.102

3 20.102 20.103 20.102 20.098 20.101 20.098 20.099 20.102 20.102

AVE 20.102 20.102 20.102 20.098 20.102 20.098 20.099 20.102 20.102

R 0.001 0.001 0.000 0.000 0.001 0.001 0.001 0.000 0.000

PART

AVE ( Xp ) 20.10 20.10 20.10 20.10 20.10 20.10 20.10 20.10 20.10

(ra + rb + rc) / (# OF APPRAISERS) =

(Max x - Min x) =

R x D4* =
 R x D3* =

PREPARED BY : CHECKED BY
 Format No. PMT/ENGG/F/00

GE R&R(VARIABLE)
Rev No. 00
Date 10.01.2018
Reviewed Quality Head
Approval Quality Head

Appraiser A Part Number Gage Name Appraiser A

Amit CP4197002 MICROMETER Amit

Appraiser B Part Name Gage Number GAGE RANGE Appraiser B

SPACER DISTRIBUTION
Sunil MM-01 0-25 Sunil
PIPE
Appraiser C Characteristic Specification GAGE TYPE L.C. Appraiser C

Bippin 20 (0.12/0.08) 20.08 20.12 Variable 0.001 Bippin

Date Performed Characteristic Classification Trials Parts Appraisers

31.03.2015 3 10 3

AVERAGE Measurement Unit Analysis % Tolerance (To

10 Repeatability - Equipment Variation (EV)
20.098 20.101 EV = R x K1 Trials K1 % EV
20.098 20.101 = 0.000 x 0.5908 2 0.8862
20.098 20.101 = 0.000 3 0.5908
20.098 xa= 20.101 Reproducibility - Appraiser Variation (AV)
0.000 ra= 0.000 AV = {(xDIFF x K2)2 - (EV2/nr)}1/2 % AV
20.102 20.101 = {(0.000 x 0.5231)^2 - (0.000 ^2/(10 x 3))}^1/2
20.102 20.101 = 0.000 Appraisers 2 3
20.102 20.101 K2 0.7071 0.5231 n = number of parts
20.102 xb= 20.101 Repeatability & Reproducibility (R & R) r = number of trials
0.000 rb= 0.000 R&R = {(EV2 + AV2)}1/2 Parts K3
20.101 20.101 = {(0.000^2 + 0.000^2)}^1/2 2 0.7071 % R&R
20.101 20.101 = 0.000 3 0.5231
20.101 20.101 Part Variation (PV) 4 0.4467
20.101 xc= 20.101 PV = RP x K3 5 0.4030 Gage System O
0.000 rc= 0.001 = 0.003 x 0.3146 6 0.3742
X= 20.101 = 0.00 7 0.3534 % PV
20.10 Rp= 0.0028 Total Variation 8 0.3375
R= 0.0004 TV = TOLERANCE / 6 9 0.3249
xDIFF= 0.000 = 6.700 10 0.3146 ndc

UCLR= 0.001
 LCLR= 0.000

ED BY APPROVED BY:
 PMT/ENGG/F/008
00
10.01.2018
Quality Head
Quality Head

Appraiser A

Amit
Appraiser B

Sunil

Appraiser C

Bippin
Appraisers Date Performed

3 31.03.2015

% Tolerance (Tol)

= 100 (EV/TV)

= 0.00353

= 100 (AV/TV)

= 100(0.000/6.700)

= 0.00

n = number of parts

r = number of trials

= 100 (R&R/TV)

= 100(0.000/6.700)

= 0.004
Gage System OK

= 100 (PV/TV)

= 100(0.001/6.700)

= 0.01

= 5.17
 QA - Inspection Standard / Report
Customer/Supplier’s Name : - M/s. Continental Engines Limited. Date : - 31.03.2015
Part Name : - SPACER DISTRIBUTION PIPE Lot Qty. : - 05 nos.
Part No : - CP4197002 Sample Qty.-05 NOS.
Bill / Invoice No. / Date : - VARIABLES QTY.
Your's P.O. No.:
S.
Observation
Parameter Specification Insp. Method
1 2
No
A Appearance Report
Free from dent,
A1 Appearance damage, and Visual OK OK
sharp edges

B Dimensional Report
B1 DIM 2±0.2 DVC 2.02 2.03

B2 OD Ø20 (+0.12/0.08) MIC. 20.11 20.101

B3 ROUGHNESS 3.2 RT OK OK
B4 PERPENDICULARITY 0.2 A H.G 0.12 0.13
B5 TOTAL LENGTH 80±0.5 DVC 80.02 80.04
B6 2x CHAMFER 1±0.2x45° H.G 1.1 1.2
B7 PERPENDICULARITY 0.2 A H.G 0.12 0.13
B8 ID Ø14±0.3 DVC 14.1 14.2
B9 2x RADIUS 1±0.2 CONTRACER 1.15 1.2
EN1A WITHOUT
B10 Material Third Test certificates
LEAD

C-0.14% max,Si-
0.05% max, Mn-
B11 Chemical composition 0.9-1.3%,P-0.11% Third Test certificates
max, S-0.27-
0.33% max

B12 Tensile Strength 460-760 N/MM² Third Test certificates

B13 PROOF STENGTH 370 N/MM² MIN Third Test certificates
B14 Elongation 8% min Third Test certificates
ANTI-RUST
TREATMENT
B15 Third Test certificates
Y2000- STD121-
0004
Color-Bright
B16 Third Test certificates
Passivation
Surface Treatment
Time Until Basis
Metal Corrosion
B17 Appears-1.5 Third Test certificates
Weeks(252 Hrs
Min)
 Final Judgement

Action Taken

Prepared By Checked By
PMT/ENGG/F/02-00-10 JAN 2018
 Report No.: -
ard / Report Sample Insp.
Pilot Insp.
31.03.2015 Final Insp.
: - 05 nos. PRD Insp.
Sample Qty.-05 NOS. Layout Insp.
ATTRIBUTES QTY. Other

Observation
Judgement
3 4 5

OK OK OK OK

2.01 2.02 2.01 OK

20.101 20.101 20.11 OK

OK OK OK OK
0.12 0.1 0.12 OK
80.03 80.03 80.04 OK
1.15 1.11 1.2 OK
0.12 0.1 0.12 OK
14.15 14.2 14.1 OK
1.01 1.13 1.1 OK

est certificates OK

est certificates OK

est certificates OK
est certificates OK
est certificates OK

est certificates OK

est certificates OK

est certificates OK
Accepted OK OK
Rejected
Accepted as Deviation
seggregate
Sent to Vendor

Approved By
 STATISTICAL PROCES
PART NAME: SPACER DISTRIBUTION PIPE INSTRUMENT: MICROMETER
PART NO & MODEL.: CP4197002 SPECIFIC: 20.000
SAMPLE SIZE: 50 NOS OPERATION: CNC SET UP
DATA COLLECTION: -
Sr.NO. 1 2 3 4 5 6 7
1 20.11 20.11 20.09 20.09 20.09 20.09 20.10
2 20.10 20.10 20.10 20.09 20.09 20.09 20.11
3 20.09 20.11 20.09 20.09 20.09 20.09 20.10
4 20.11 20.11 20.11 20.09 20.09 20.09 20.11
5 20.10 20.10 20.09 20.09 20.09 20.09 20.10

CALCULATIONS: -
FOR HISTOGRAM
XLARGE 20.1100 20.1100 20.1100 20.0900 20.0900 20.0900 20.1100
XSMALL 20.0900 20.1000 20.0900 20.0900 20.0900 20.0900 20.1010
RANGE 0.0200 0.0100 0.0200 0.0000 0.0000 0.0000 0.0090
AVG. 20.1020 20.1060 20.0960 20.0900 20.0900 20.0900 20.1046
Process Width ( P ) = 0.0200 Specification Width(S) =
Design Centre ( D ) = 20.1000 Interval =
Starting Point = 20.0900 No. of readings=

U.C.L. 20.1017414 20.1017414 HISTOGRAM

20.1017414 20.1017414 20.1017414 20.1017414 20.1017414
20
L.C.L. 20.0975 20.0975 20.0975 20.0975 20.0975 20.0975 20.0975
18
U.C.L. 0.0146 0.0146 0.0146 0.0146 0.0146 0.0146 0.0146
16
L.C.L. 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
14
X-BAR
12
20.0996 20.0996 20.0996 20.0996 20.0996 20.0996 20.0996
R-BAR
10
0.0086 0.0086 0.0086 0.0086 0.0086 0.0086 0.0086
8

0
6.964 6.972 6.98 6.988 6.996 7.004 7.012 7.02 7.028 7.036 7.044 7.052
6.956 6.964 6.972 6.98 6.988 6.996 7.004 7.012 7.02 7.028 7.036 7.044

REMARKS: - PROCESS IS EXCELLENT

PREPARED BY : SAAJAN KUMAR CHECKED BY-
 Doc No.

PROCESS CONTROL STUDY

Rev No.
Date
Reviewed
Approval

MICROMETER L.COUNT: 0.001 SUPPLIER PMT INNOTECH PVT. LTD

0.080 - -0.120 MACHINE: CNC OPERATOR Sunil
CNC SET UP NO.OF DECIMALS: 3 D.C. NO.

8 9 10 SAMPLE d2
20.10 20.11 20.10 1 --
20.11 20.10 20.11 2 1.128
20.11 20.10 20.11 U.S.L. 20.0800 3 1.693
20.10 20.11 20.10 4 2.059
20.11 20.10 20.11 5 2.326
6 2.534
7 2.704
8 2.847
9 2.97
L.S.L. 20.1200 10 3.078
11 3.173
12 3.258
13 3.336

20.1100 20.1100 20.1100 Xmax.= 20.1100 NO.OF NON CONFORMING PART =

20.1010 20.1010 20.1010 Xmin.= 20.0900
0.0090 0.0090 0.0090 R - BAR = 0.00860 NO. OF PARTS ABOVE U.S.L. =
20.1064 20.1046 20.1064 X - BAR = 20.0996 NO. OF PARTS BELOW L.S.L. =
0.0401 Index (K)={2 x (D-XBAR) / S}= 0.0200 INTERVAL
0.0040 Selecting no. of classes = 5 20.0780 20.0820
50.0000 Shift Of 'X-BAR' from 'D' = 0.0004 20.0820 20.0860
20.0860 20.0900
7.015
X- CHART
20.1017414
7.01
20.1017414 20.1017 20.0900 20.0940
7.005
20.0975
7
20.0975 20.0975 20.0940 20.0980
0.0146
6.995
6.99
0.0146 0.0146 AVG.
20.0980 20.1020
0.0000
6.985
6.98
0.0000 0.0000 Row 30

L.C.L.
20.1020 20.1060
20.0996
6.975 20.0996 20.0996 Row 34 20.1060 20.1100
6.97
0.0086 1 20.0086
3 4 0.0086
5 6 7 8 9 10 20.1100 20.1140
20.1140 20.1180
20.1180 20.1220
0.045 R - CHART
0.04 20.1220 20.1260
0.035
0.03 U.C.L.XBAR =
0.025 RANG

0.02
E
U.C.L.
L.C.L.XBAR =
.052
0.015
.044
0.01
L.C.L.
U.C.L.RBAR =
R-BAR
0.005 L.C.L.RBAR =
0
1 2 3 4 5 6 7 8 9 10 Std.Dev."s"=
Cp=(S/6s)=

CESS IS EXCELLENT Cpk={1-K}xCp)=

APPROVED BY :
Doc No. PMT/ENGG/F/010
Rev No. 00
Date 10.01.18
Reviewed Quality Head
Approval Quality Head

PMT INNOTECH PVT. LTD.

DATE- 12-Apr-22
QTY. 50

A2 D4
-- --
1.880 3.267
1.023 2.575
0.729 2.282
0.577 2.114
0.483 2.004
0.419 1.924
0.373 1.864
0.337 1.816
0.308 1.777
0.285 1.744
0.266 1.717
0.249 1.693

100 NOS.

50 NOS.
50 NOS.
FREQ. CU. FREQ.
0 0
0 0
0 0
19 19
0 19
0 19
15 34
0 34
16 50
0 50
0 50
0 50
20.10174
20.09746
0.0145597999999998
0
0.00370
1.80770
1.77160
 Format No.:-PMT/ENGG/F/017
PMT INNOTECH PVT. LTD.
Rev. No.:- 01

List Of Checking Aids Eff. Date :- 10.01.2018

CUSTOMER NAME - M/s. Continental Engines Limited. Org. Date:- 10.02.2023

PART NAME - SPACER DISTRIBUTION PIPE

PART DRG. NO. - CP4197002

DRG. REV. STATUS. - 03 / Date - 09.03.2015

Material EN1A

MSA Study
S. No Instruments / Gauge Ident. No. Range L.C. Calibration Date Calibration Due Date
YES/NO

1 DVC 0-200MM 0.01 MM

2 HEIGHT GAUGE 0-300 MM 0.01 MM

3 MICROMETER 0-25 MM 0.001 MM

4 ROUGHNESS TESTER

5 CONTRACER

10

Prepared by :- Saajan Kumar Checked by:- Approved by :-

 DOC. No- PACK/CP4197001
PACKING STANDARD
Effect Date:- 31.03.2015

Part Name :-SPACER DISTRIBUTION PIPE Part No. :- CP4197002

Customer :- M/s. Continental Engines Limited.

(A) Primary Packing-

QTY. PACKING DESCRIPTION REMARKS

06 Nos. Plastic Polytheen Bag 6 X 10 Inch

(B) Final Packing -

QTY. PACKING DESCRIPTION REMARKS

10 Packet Corogated Box Size - 12X9X6 Inch. 5 Ply.
ILLUSTRATION :-

200 NOS.Carton Inner

(C) Packing Evaluation

S.NO. Criteria Decision Date

1 Identification: - With Packing Slip
 3 Appearance:- (Instruxtion Paste) Handle with Care

4 Strength :- N/A X
5 Tranportation: - . By Road

Symbol :-

PREPARED BY:- CHECKED BY:- APPROVED BY:-

Format No-PMT/STR/F/009-00:10 JAN 2018

 PMT INNOTECH PVT. LTD.
PART SUBMISSION WARRANT

Part Name: Spacer Distribution Pipe Part Number CP4197002

Safety and/or
Government Regulation Yes ✘ No Engineering Drawing Change Level 03 Dated17.07.2015

Additional Engineering Changes N/A Dated N/A

Shown on Drawing No. CP4197002 Purchase Order No. CS22-23-00443 Weight(kg) 0.097

Checking Aid No. F/017 Engineering Change Level 03 Dated 17.07.2015

SUBMISSION INFORMATION
SUPPLIER MANUFACTURING INFORMATION
Supplier Name & Supplier Code: PMT INNOTECH PVT LTD/0182
✘ Dimensional ✘ Materials / Functional ✘ Appearance
Opp. – Inderprasth colony (Sec-49) Badkhal – Pali road
Bhakri, Faridabad - 121005 (Haryana) INDIA, Customer Name / Division M/S Continental Engines Ltd.
Street Address

Buyer / Buyer Code D.K.Verma/039

Faridabad Haryana 121005 Application Engine Assembly

City State Zip

Note: Does this part contain any restricted or reportable substances Yes ✘ No
Are plastic parts identified with appropriate ISO marking codes Yes ✘ No

REASON FOR SUBMISSION

✘ Initial Submission Change to Optional Construction or Material
Engineering Changes(s) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or
additional Change in Part Processing
Correction of
Tooling Inactive>than
Discrepancy Parts Produced at Additional Location
Other - please
1 year 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 & 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 material and appearance statistical process
✘ ✘ ✘
measurements
These results meet all drawing requirements: functional tests Nocriteria (If "No" - package
Explanation
✘ Yes
Mold Cavity / Production Process Machining Required)

DECLARATION
I hereby affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable
Production Part Approval Process Manual 4Th Edition Requirements. I further warrant these samples were
Produced at the production rate of 250 Parts /8 hours. I have noted any deviations from this declaration below.
EXPLANATION / COMMENTS:

Print Name Mr. Aviral Rajwanshi Title Plant Head Phone No. 8826686658 FAX No. N/A
Supplier Authorised Signature Date 5/22/2022

FOR CUSTOMER USE ONLY (IF APPLICABLE)

Part Warrant Disposition Part Functional Approval

Approved Rejected Approved
Other Other
Customer Name Customer Signature Date

Format No.:- PMT/ENGG/F/016-00/10 Jan 2018

Appearance

Material