Vendor name : KRIYA POLYTECH

Venter code :

Part no : 50055011 / 12
Part Name : BOTTOM COVER LH/RH

Drg.Rev.No :

Customer : SMRC

KRIYA POLYTECH
THIRUMALISAI
 KRIYA POLYTECH APQP TIMING PLAN
Customer : SMRC PART NAME : BOTTOM COVER LH/RH PART NO. : 50045011 /12

PLAN
Sl. ACTUAL COMPLETION
ACTIVITIES RESPONSIBILITY Status
No. DATE
START DATE FINISH DATE

Phase I - Plan and Define Program

1 CFT Formation

2 Define Scope

3 Initial Risk Analysis

4 Customer Inputs

5 Customer Product specific requirements

Identification of Product / Process

6
Special characteristics
7 Management Review - Plan define

Phase : II - PRODUCT DESIGN AND DEVELOPMENT

8 Customer drawing

9 Agreement of Inspection

10 Material specification

New equipment, Tooling, Facilities, Gauges / Test

11
equipment plan

12 Team Feasibility Commitment

13 Process Feasibility Review

Management Review - Product Design and
14
Development
Phase : III - PROCESS DESIGN AND DEVELOPMENT

15 Packing standard and Specification

16 Floor Plan Layout

17 Process Flow Chart

18 Process FMEA

19 Prelaunch Control plan

20 Measurement System Anlysis study Plan

21 Preliminary Process Capacbility Study Plan

22 Product and Process Quality Review

Management Review - Process Design and

23
Development

Phase : IV - PRODUCT AND PROCESS VALIDATION

24 Production Trail Run

25 Measurement System Evaluation

26 Preliminary Process Capacbility Study

27 Production Part Approval Process (PPAP)

28 Packaging Evaluation

29 Prodution Control plan

30 Quality Planning Sign off

Phase : V - CUSTOMER FEED BACK

31 TGW & TGR reports

32 Customer Feed back

Remarks :

Prepared By Reviewed By Approved By

Format No:NAP / QAD / 23 Rev.No :00 Rev.Date :01.06.2011

 DOC NO: KPT/DEV/03
REV/DATE:
KRIYA POLYTECH
FORMATION AND SCOPE OF CFT 00/01.04.2013
PAGE: 3 0F 27

Customer: SMRC KPT REF No:

Cust Part No: 50055011/12 Purchase Order No: 0

Description: Bottom Cover LH / RH Date:

The following members are appointed to the cross functional team to execute advanced product quality planning
(APQP) , validation ( Product and process validation ) and take overall production responsibility for this product/
product group.

The team members shall meet as needed and finalise issues. Regarding Non- conformances, CA&PA and
continuous improvement initiavities.

Sl. No. Team Members Role Responsibility

Resource planning & Sub
1 A.Lakshmanan Facilitator supplier selection
Process design
development, Man power
2 A.Malmarugan Team Leader Management

Sample production &

Inspection, Process
validation, ECN
monitoring, CAPA,
3 R.Ilayaraja Team Member Training, Packing
Machine & Mould
4 R.Raja Team Member Maintenance

5 S.Dhandapani Team Member Material procurement

6 R.Vaithiyalingam Team Member Inventory Management

Given below are the target dates for each activity.

Activity Target Date

Product/ Process Development
Product/ Process Validation
PPAP submission
Commence Full Scale Production

Proprietor:

Date :
 SCOPE
Project : BA
Part No :
50055011 / 12

Part Name BOTTOM COVER LH/RH

Drawing Revision
00 dt 22/9/2013
level:
The scope is limited to the following processes.

Processes involved :

1 Injection Moulding

Signature : A.Lakshmanan Signature :

Supplier : Kriya Polytech SMR

Date : Date :
 KRIYA POLYTECH

Analyzed By Checked By Approved By

RISK ANALYSIS CHECK LIST

CUSTOMER : SMRC

PART NAME : BOTTOM COVER LH / RH Date :

PART NO. : 50045011 /12

RISK FACTORS
Sl.
No. DESCRIPTION HIGH MEDIUM LOW REMARKS

Ram materials
1 Raw material availability √
supplied by customer.

2 Identification of New sources √ Nil

We can Manufacture as per existing

3 Manufacturing Feasibility √
process

4 Checking Fixtures / Instruments √ Gauge available

5 New Dies / Moulds / Tools √ Mould Provided by customer

After Long run Approx 5 lakhs shots

6 Tool Life √ tool will wear and tear it will be
afffected the productivity and quality.

Pollution Control
7 √ Saleout the plastic scraps
(Environmental affect)

No Need we can manufacture from

8 New Machine requirement √
existing machine
We can meet the customer
9 Targets for Productivity √ requirements as per existing machine
spare capacity

10 Packaging Methodology √ Existing method only

11 Manufacturing Period √ As per customer requirement.

We can meet the quality targert as per

12 Targets for Quality √
the customer requirements.

13 New / Known process √ Known process only

We can achieve the Cpk as per

14 Cpk Achievement √
customer requirements.

Month volume very low (Approx : 6000

15 Volume of Business √
Nos)

16 Others

Conclusion: This component risk is Low.

Format No: Rev.No :00 Rev. Date :
 CUSTOMER INPUT CHECK LIST

Part No : 50055011 / 12 Project

Part Name : Bottom Cover Drawing Revision Level 00 dt 22/9/2013

Sl. Decription Details Status

1 Enquiry in oral or written and date Email dt

2 Component details

3 Raw Material procurement by :

Customer supplied
Customer ( SMRC ) or by us ( supplier )
4 Samples - Non Tooled up or Tooled up
Single cavity / Multi cavity 2 cavities
Qty and Submission date
5 Documentation to be submitted
along with samples
Process flow diagram
Control Plan
FMEA
Dimension report √
Material Test certificate √
Balloon drawing ( SMRC approved )
Special process details
6 Is reference sample given by the customer No

7 Expected annual requirement 1.5 Lakh

8 Capacity Planning discussed with Customer Yes

9 Internal co-ordination Required

Product development & design

Tool design & development
Manufacturing √
Quality √
Materials √
Marketing √
10 Others :
Customer specific requirements

Signature : Signature :

Supplier : SMRC
Date : Date :
00 dt 22/9/2013
 CUSTOMER PRODUCT SPECIFIC REQUIREMENTS

SUPPLIER : KRIYA POLYTECH

CUSTOMER : SMRC

PART NO : 50055011/12 PART NAME : Bottom Cover LH / RH

DETAILS SL.No ELEMENTS FREQ
CUSTOMER FOCUS & 1 Requirement
Yearly
A CONTINUOUS 2 Expectations
IMPROVEMENT 3 Customer Visit Need based
1 Item
REGULATORY
B
REQUIRMENT
2 Applicable std. Not applicable

Plastic / Foam
1 Packing cover

C EMS
2 Conservation max.possible

2 Transporter Own
1 Colour Black
2 SST(300/144/96) NA
D APPEARANCE QUALITY 3 Painting N/A
4 Powder Coating N/A
5 Passivation N/A
1 Dimensional Every lot
2 Materrial Test Report Every batch
3 Machanicl properties N/A
4 Performance test N/A
E QUALITY
5 Layout inspection Yearly once
6 Customer claim Need based

7 Customer review Yearly

1 Logo SMRC logo
2 Supplier code Identification
traceability in Part
IDENTIFICATION & 3 Customer Part No. and Report
F
TRACEBILITY 4 Batch Code -
Serial no., Code
-
5 details
6 Head code -

G CHANGE CONTROL
1 ECN changes Need based
To preserve from
H PRESERVATION
1 dust No

I PACKING
1 (Purchase) Plastic cover & Bin

J PALLETISING
1 (Purchase) N/A

K REVIEW
1 Review of CSR Need based
We here by agree to comply with above customer specific requirements.
CUSTOMER

DATE :
Prepared By :
IREMENTS

SCOPE and
Review of requirements,
expectations once in a year
depending upon the situation
Shall be made on need basis.
Items and applicable std to be
specified and certified for every
despatch.
use bio degragable material
Maximise use of re-cylable / reusable
material
Conserve resources like power,
Water wood etc in manufacturing /
storage / transportation
To be aware of unit EMS policies
and requiremnet on transportation.

To be ensured as per drawing

requirement

To be reported as per AOI

To be reported as per AOI
To be reported as per AOI
To be reported as per AOI
To be reported as per AOI
To be addressed based on need
Supplier shall review the Quality
performance once in year.

Decodification to be provided to
Customer every year

Purchase will communicate, Supplier

to provide cut-off on introduction
Unless specified the agreed norms
to be followed
Unless specified the agreed norms
to be followed
Elimination of gunny bags, loose
supplies
Customer shall audit supplier on
adherence of CSR based on need
with prior intimation.

SUPPLIER

DATE :
Approved By :
 IDENTIFICATION OF CRITICAL / SIGNIFICANT / PRODUCT /
PROCESS / CUSTOMER FITMENT CHARACTERISTICS
Project
Part No : 50055011 / 12

Part Name : Bottom Cover LH / RH

Drawing Revision Level :

Qty in Qty and

Product /
Sl. Characteristic Specification Ppk frequency
process
study for ongoing

1 Weight Product 50 nos 3 months

Signature : Signature :

Supplier : Kriya Polytech SMRC

Date : Date :

13 of 53 Essae Digitronics Private Limited

 RML / STA / 012 , REV 0

14 of 53 Essae Digitronics Private Limited

 Management Review - Plan and Define Phase

Project Date :

Part No

Drawing
Part Name:
Revision level
1. Completion of Phase : Plan and define

2. Records of Discussion : ( enclosed )

All records are filled up

2a. Concerns / Resolutions If any :

All records are verified with customer and agreed both

Comments by Supplier's authorIsed person :

All records are verified with customer and agreed both

Sign/Date

Signature : Signature :

Supplier : Customer:

Date : Date :
nt Review - Plan and Define Phase
SUPPLIER PAGE 1 / 5

AGREEMENT OF INSPECTION

1) This agreement is applicable to the part(s) mentioned below.

PART NAME:- MODEL :-

PART NO DRG REV LEVEL

2) Important Quality characteristics

The important quality characteristics of the parts mentioned above will be controlled by the vendor and any changes in the inspection
or process will be accordingly modified and managed.

SL.NO Parameters Specification Remarks

1 Apperance Refer Inspection Standard
Material
2 Refer Inspection Standard

3 Dimensions Refer Inspection Standard

4 In-House Rejection Refer Inspection Standard

3) Frequency of Inspection & Test

Vendor to inspect the parts as per the following frequency and submit the report to Supplier Quality of RML

SL.NO Parameters Sampling Frequency Remarks

1 Apperance 100% Every Lot

Material
2 1 Speciman Once in Year

3 Dimensions As per SCQI - 034 Every Lot

4 In-House Rejection 100% Once in month

4) In case of any changes in the process ,Supplier to obtain written approval from Rane SQA .

5) In case of any changes in the above mentioned parameters , Supplier to obtain written approval from Rane SQA prior to the
changes ..

N.Viswanathan

Supplier Rane ( Madras ) Limited

RML / STA / 034 , REV 0
TEAM FEASIBILITY COMMITMENT Page 1 / 3
Date:

Part No PROJECT
Part Name

Drawing Revision Level

The undersigned have met in a special session to review the ability of the design and process to meet key quality and
productivity objectives for the above project. The drawings and / or specifications provided have been used as a
basis for analyzing the ability to meet all specified requirements. All "no" answers are supported with attached comments
identifying our concerns and/or proposed changes to enable us to meet the specified requirements.

YES NO N.A CONSIDERATION

Supplier risk evaluation: (To be done by the Supplier)

YES Is the product adequately defined (application requirements, etc.) to enable feasibility evaluation?

YES Do we have copies of all material specifications, released prints and SCs or CCs?

NA Can Engineering Performance Standards be met as written / do we have copies of all?

YES Can product be manufactured as per the drawing / standards ?

YES Can all the dimensions be measured and metallurgically tested ?

YES Can product be manufactured with Cpk's that meet requirements of SC or CCs?

YES Is there adequate capacity to meet required volumes in 6 production days / week?

YES Does the design allow the use of efficient material handling techniques?

YES Do we understand customer's APQP/ PPAP requirements?

YES Do we understand the packaging requirements?

YES Does our location have experience with this product and manufacturing technology?

Can the product be manufactured without incurring any unusual:

YES * Costs for capital equipment?

YES * Costs for tooling?

NA * Alternative manufacturing methods?

YES * Inspection methods or Testing ?

YES Is statistical process control presently used on similar products?

Where statistical process control is used on similar products:

YES * Are the processes in control and stable?

YES * Are Cpk's greater than 1.33?

Customer High Risk Evaluation : (to be filled by Customer's STA/ Materials)

* Is it an existing supplier / existing manufacturing location for customer's parts ?

* Did the supplier's historic launch performance meet Customer's expectations?

* Is this a carry over part and has a back up ?

Low Risk Product can be produced as specified with no revisions.

Low Risk Additional information or clarification required (see attached)
High Risk High risk part for the program

PPAP level concurred : 1 2 3 4 5

Head - Product Design Head - Process Design Head - Manufacturing

(Supplier) (Supplier) (Supplier)

Head - Quality Head - Materials Head - Marketing

(Supplier) (Supplier) (Supplier)
 Head - STA - Rane Head - Materials - Rane

Manufacturability and Measurability Page 2 / 3

Date: 27.04.09

Part No 31 14 062 9 0 PROJECT

Part Name SPRING ASPL/RML/04

Drawing Revision Level 2

Manufacturability Measurability
sl Dimension Characteristic Remarks
YES / NO YES / NO

1 2.6±0.02 mm Wire Diameter YES YES Outsource

As per IS 7906 Part II -

2 14.9±0.5 mm Outside Diameter YES YES
1975
As per IS 7906 Part II -
3 22.8±0.3 mm Outside Diameter YES YES
1975 Closer

4 1.5 No of Active Coils YES YES Compensation dim

5 3 Total No of Coils YES YES Compensation dim

6 13.34 mm (ref) Free Height YES YES Compensation dim

7 Right Hand Direcion of Wind YES YES

Squared &
8 End YES YES
Ground Parallel
As per IS 7906 Part II -
9 33.2±3.32 kgf Load at 8.3 mm Ht. YES YES
1975

10 6.58 kgf/mm (ref) Spring Rate YES YES Ref dim

Grade 3 IS
11 Material Specification YES YES Outsource
4454 Part I

Jothimurugan.P R.Jayaraman

Head - Product Design Head - Process Design Head - Manufacturing

(Supplier) (Supplier) (Supplier)

Jothimurugan.P N.Viswanathan T.R.Samy

Head - Quality Head - Materials Head - Marketing

(Supplier) (Supplier) (Supplier)

Head - STA - Rane Head - Materials - Rane

RML / STA / 020 , REV 0

 Manufacturability and Measurability Page 3 / 3

Date:

Part No PROJECT

Part Name

Drawing Revision Level

Manufacturability Measurability
sl Dimension Characteristic Remarks
YES / NO YES / NO

Head - Product Design Head - Process Design Head - Manufacturing

(Supplier) (Supplier) (Supplier)

Head - Quality Head - Materials Head - Marketing

(Supplier) (Supplier) (Supplier)

Head - STA - Rane Head - Materials - Rane

RML / STA / 020 , REV 0
 PFR No: 74
KRIYA POLYTECH PROCESS FEASIBILITY REVIEW Date : 21.11.2013
File :
Drawing Number : 50055011/12 Rev. No: 00 Supplier Name: M/S KRIYA POLYTECH
Description : Bottom Cover LH / RH Date : 22/09/2013 Address : 182, SIDCO Industrial Estate,
Product : ECN No: Thirumalisai Chennai
600124
No. of safety characterisitcs <1> in the part :
Anticipated process
Process capability maintained capability based on
Sl no. Safety characterisitics <1> Manufacturing process identifed Similar part manufactured Target process capability- Cpk Production Capacity Cost Error Proofing Feasibility
in the simialr part similar part
manufactured
1 - Moulding "O" Ring Cpk >= 1.33 Cpk >= 1.67 Cpk >=1.67 3000/month Rs 1.92 / piece R/M Weighing process Yes

Customer requirement:
Actual cost: 1..90/piece Yes
1000 / month

Given Process Achievable Process Measuring Type/ Feasibility

S.No Features Specification Criticality Operation Proposed Machine Remarks
Tolerance Band Tolerance Band Instrument (Yes/No)

Detail

1 Inner Diameter 23.47 ± 0.24 Moulding Compression molding M/C 0.24 mm 0.48 mm Tapper Plug Gauge Yes

2 Thickness (A) 2.62 ± 0.08 Moulding Compression molding M/C 0.08 mm 0.16 mm Dial thickness gauge Yes

3 Thickness (R) 2.62 ± 0.08 Moulding Compression molding M/C 0.08 mm 0.16 mm Dial thickness gauge Yes

4 Hardness 65/75 IRHD Moulding Compression molding M/C 10 IRHD 10 IRHD Micro Hardness Tester Yes

5 Packing standard Polythene cover Packing 2500/bag Yes

For SMRC use only * If "No",indiate reasons

General Comments:

Submitted by: Reviewed by: Approved by:

Date : Date : Date :
 DOC NO: KPT/DEV/03
REV/DATE:
NEW EQUIPMENT, TOOLING AND TEST EQUIPMENT PLAN 00/01.04.2013
KRIYA POLYTECH PAGE: 9 0F 27

Part No: Drg Rev No:

Part Name: Rev Date:
Customer:

Sl.No. Opn No. Description Type of Tool No.of Cavity Remarks

1 30 Moulding Plastic injection Moulding 2 Supplied by customer

 DOC NO: KPT/DEV/03
REV/DATE: 00/01.04.2013
GAUGE / TESTING EQUIPMENT REQUIREMENTS PAGE: 8
KRIYA POLYTECH 0F 27

Part No: Drg Rev No:

Part Name: Rev Date:
Customer:

Type of
Sl.No. Opn No. Characteristic Specification Qty Required Remarks
Gauge/Instrument
 APQP TIMING PLAN
PART NAME / COVER & NOZZLE
Customer : HANIL AUTOMOTIVE PART NO. : 86150-4N900
DESCRIPTION : ASSY COWL TOP RHD

PLAN ACTUAL
Sl.
ACTIVITIES RESPONSIBILITY REMARKS
No. START FINISH
START DATE FINISH DATE
DATE DATE

1 Collection of inputs & review for adequacy 15.03.11 19.03.11 MGR-Marketing

2 Feasibility Review & Risk analysis 20.03.11 31.03.11 MGR-Marketing

Identification of Product / Process

3 01.04.11 07.04.11 Mgr-QA
Special characteristics

Preparation of Process Input Form (Quality goals,

4 08.04.11 14.04.11 Mgr-QA
Targets for Productivity, Cost, etc.)

New equipment, Tooling, Facilities, Gauges / Test

5 15.04.11 03.05.11 Mgr-QA
equipment plan

6 Team feasibility commitments 04.05.11 11.05.11 Mgr-QA

7 Floor Plan Review 12.05.11 17.05.11 Mgr-QA

17 Preparation of Process Flow diagram 18.05.11 31.05.11 Mgr-QA

18 Pre-launch Control Plan 18.05.11 31.05.11 Mgr-QA

19 Process FMEA 18.05.11 31.05.11 Mgr-QA

8 Measurement System Analysis Plan 18.05.11 31.05.11 Mgr-QA

9 Statistical Process Control Plan 18.05.11 31.05.11 Mgr-QA

14 Packaging Standards / Instructions 01.06.11 09.06.11 Mgr-QA

10 Trial run - I 10.06.11 30.06.11 Mgr-QA

16 Peformance Testing 10.06.11 20.07.11 Mgr-QA

ECN changes
17 ECN Changes 20.07.11 15.09.11 HANIL done by
cutomer

18 Trial Run - II 16.09.11 30.09.11 Mgr-QA

19 MSA Study 16.09.11 30.09.11 Mgr-QA

20 SPC Study 16.09.11 30.09.11 Mgr-QA

21 Characteristic Matrix 16.09.11 30.09.11 Mgr-QA

22 Work Instructions (WI) 16.09.11 30.09.11 Mgr-QA

23 Prodution Control plan 16.09.11 30.09.11 Mgr-QA

24 Packaging Evalution 16.09.11 30.09.11 Mgr-QA

25 ISAR Documents & Sample submission 16.09.11 30.09.11 Mgr-QA

26 Quality Planning Sign off 01.10.11 01.10.11 Mgr-QA

27 TGW & TGR reports 15.12.11 30.12.11 Mgr-QA

Remarks :

Prepared By Reviewed By Approved By

Format No:NPTL / QAD / 23 Rev.No :00 Rev.Date :02.02.08

 FLOOR PLAN LAYOUT DATE :
L/U Point
INJECTION MOULDING

M/C IM-09-550 T A
M/C IM-10-350 T

M/C IM-08-550 T B
EB Pannel WORK
& DG TABLE

M/C IM-06 -650 T

M/C IM-07-850 T

M/C IM-05-1100T

M/C IM-04-1100T

M/C IM-03-1600T
Room

M/C IM-02-2000T

M/C IM-01-2500T
TOOL ROOM

TOILET

G MNT NC AREA
A
N
G GANG WAY
W
AY
CANTEEN

OFFICE WIP STORAGE FG STORAGE

EMPTY TROLLEY STORAGE
AREA

RECEPTION
QA LAB
GANG WAY

FINAL INSPECTION
RG AREA RM STORES FG
STORAGE
CHECKER FIRE WALL DESPATCH PDI AREA
AREA INSPECTION AREA

Indicates flow of product

IN / OUT
 IN / OUT
Prepared by : Approved by :
 Management Review - Product Design and Development Phase

Project BA Date :

Part No 50055011 / 12

Part Name: Bottom Cover LH / RH Drawing Revision level

1. Completion of Phase : Process Design and Development

2. Records of Discussion : ( enclosed )

2a. Concerns / Resolutions If any :

All records are verified few points will be claried with customer

Comments by Supplier's authorIsed person :

All records are verified few points will be claried with customer
A.Lakshmanan /
Signature / Date

Signature : A.Lakshmanan Signature :

Supplier : Kriya Polytech SMRC

Date : Date :
ew - Product Design and Development Phase

records are verified few points will be claried with customer

records are verified few points will be claried with customer

 PACKAGING AGREEMENT
CUSTOMER NAME SMRC VENDOR SMR

SUPPLIER NAME KPT Prepared Checked Approved SQA PURCHASE STORE

Sivakum
DATE OF AGREEMENT 02.08.2013 NAME ar
R.Ilayaraja A.Malmarugan
NAME
BOTTOM COVER
PART NAME LH/RH
SIGN SIGN

PART NUMBER 50045011/12

MODEL BA ORVM PACKING FLOW PHOTOGRAPH

STAGE - 1 STAGE -2

BIN COLOUR BLUE

QTY PER BIN(or) BOX & A. 200 Nos per Poly cover PHOTOGRAPH
QTY PER POLY COVER B. 800 Nos per Bin PHOTOGRAPH (BIN (or) BOX WITH
(EMPTY BIN or BOX) LINERS - APPLICABLE FOR
EMPTY BIN (or) BOX - ASTHETIC PARTS ONLY)
WEIGHT
2.1 kgm
WEIGHT OF BIN ((or) BOX
WITH PARTS
5.5 kgm

LENGTH 600

BIN (or) BOX SIZE WIDTH 400

HEIGHT 220
STAGE -3
LENGTH 475

POLY COVER SIZE WIDTH 310

THICKNESS *
PHOTOGRAPH
NOTE : ( PART STACKING METHOD)
1. CLEANING OF BIN IS MANDATORY BEFORE STARTING OF
PACKING .
2. NO OVER FLOW OF PARTS IN BIN.
3. PERIODIC MAINTANCE TO BE CARRIED OUT FOR ALL THE
RECYCLE BINS

REVISION HISTORY SMR COMMENTS

REV.NO / DATE DETAILS
00 / 02.08.2013 INTIAL RELEASE
Format No: QA-F-60, Rev No/ Date:01 / 02.04.09
 PROCESS FLOW DIAGRAM
KRIYA POLYTECH
Changeover Key Inspection Key Part # 50045011/12
P=Product A=Automatic Product: BOTTOM COVER LH/RH Customer Part # 50045011/12
T=Tooling M=Manual Date: 24.06.2013 Customer SMR
S=Software V=Visual Prepared By: R.ILAYARAJA Rev No. & Date 00 & 24.06.2013
D=Dunnage Q=Quality Audit Approved By: CFT (L.SURESH, A.MALMARUGAN, R.ILAYARAJA, S.DHANDAPANI, PFD No. PFD/ SMR /BA/ 002
L=Label Symbol Instructions GOKUL, VENKATESH, SIVAKUMAR & RAJA )

(KPC, QCI)
Changeover
Store/Get

Contain
Rework
Inspect

(KCC,
Operation Description Significant Product Characteristics Significant Process Characteristics
Scrap/

QCC)
Move

Class

Class
Op-
Fab

Seq (Outputs) (Inputs)

M

Raw Material Receiving ( Material- ASA, 1. No damage of Raw Material bag after
WR 9310 SAMSUNG) receiving
2.No Foreign particles in RM bags
Raw Material Move to stores
10 M
Raw Material Inspection ( Material- ASA, As per Incoming Inspection
WR 9310 SAMSUNG) (Apperenance & Moisture testing)
Rejected material sent back to
supplier/Scrapped
Raw material storage No Dust Contamination Store under shelter, FIFO Followed
20
Issue to production - (bags)
Pre drying of polymer As per Predrying Standard (DOC NO.:
30 No moisture
W/PRDN/01)
Injection moulding ( Job Set up approval & Standard Process Sheet
As per CP/ SMR / BA / 002, Part
40.1 Line production ) SC as per SMP (Date/Rev no.:
weight
21.06.2013 /00)
M Online inspection (First O.K./Last O.Kand
40.2 & As per CP/ SMR / BA / 002
Hourly Inspection)
40.3
Suspect material rejected/Scrapped
100% Visual inspection As per AIS/QAD/KPT/BA/ 002
50
WIP product storage FIFO
M Final Inspection As per CP/ SMR / BA / 002
60
Suspect material rejected/Scrapped
70 Packing & Labeling As per packing standard 800 Nos per Bin
80 Dispatch to Customer
AMENDMENT DETAILS
REV NO. REV DATE REASON FOR REVISION REMARKS
 PROCESS FAILURE MODE AND EFFECT ANALYSIS
Chennai

Customer Name : M/S SMRC Process Responsibility : A.Malmarugan PFMEA Number : PFMEA/SMRC/BA/002

Part Number : 50045011/12 Key Date : 24.06.2013 Prepared By : R.ILAYARAJA

Part Name : BOTTOM COVER LH/RH ISSUE NO./ DT: 00 / 24.06.2013 PFMEA Date(Orig) : 24.06.2013

Model Year(s)/Vehicle(s) :- BA PFMEA Date(Rev) :

CORE TEAM : (L.SURESH, A.MALMARUGAN, R.ILAYARAJA, S.DHANDAPANI, R.RAJA & )

O Current Process Controls Action Results

c
c D
C
Potential u e Responsibilit
S l Recommended
Proce Process Function / Potential Failure Cause's)/ r t y & Target
e a RPN
ss No. Requirements Mode Mechanism's) r e Completion S O D R
v s Action's) Actions
Next operation Customer End customer of Failure e Prevention Detection c Date e c e P
s Taken
n t v c t N
c
e

10 Incomming inspection

1. identification Incoming material register &

1. Wrong material wrong
problem Visual inspection of raw verification of supplier test
10.1 In coming inspection 2. Damaged packing --- Dissatisfaction 4 --- despatch ,improper 2 4 32
2. loss material certificate for every lot by
packing.
of material comparing with spec

20 Raw material storage

1. Wrong place storage 1. material cannot Identification problem Incoming material register &
proper location & identification
2.old find easily verification of supplier test
20.1 Raw material storage --- Dissatisfaction 7 --- 2 FIFO 6 84
material not taken 2. material process certificate for every lot by
followed
FIFO followed affect & degrade comparing with spec

30 Pre-heating

High pre heating

1. Poor appearance temperature Process monitoring sheet-pre
30.1 Pre-heating Degrade material ---- Dissatisfaction 6 --- 3 Pre heating work instruction 5 90
2.Blow holes Low pre heating heating temperature
temperature

40 Injection moulding

1.Standard parameter setting Visual & Dimension

2.Process inspection on first pc. Set-up,
7 --- High injection speed 3 parameter patrol & 100% online 4 84
3. adherance to SPP with re- inspection Verify of parameter
setting and setting limit spec - frist pc. & monitoring
 O Current Process Controls Action Results
c
c D
C
Potential u e Responsibilit
S l Recommended
Proce Process Function / Potential Failure Cause's)/ r t y & Target
e a RPN
ss No. Requirements Mode Mechanism's) r e Completion S O D R
v s Action's) Actions
Next operation Customer End customer of Failure e Prevention Detection c Date e c e P
s Taken
n t v c t N
c
e

1.Standard parameter setting Visual & Dimension

2.Process inspection on first pc. Set-up,
7 --- Less injection speed 3 parameter patrol & 100% online 4 84
Possibility of 3. adherance to SPP with re- inspection Verify of parameter
1. Fitment issue loosing setting and setting limit spec - frist pc. & monitoring
2.appearance issue primary
Short Fill & flow mark Dissatisfaction
3.Dimension functional
variation requirement of 1.Standard parameter setting Visual & Dimension
the product. 2.Process inspection on first pc. Set-up,
7 --- Less nozzle temp 3 parameter patrol & 100% online 4 84
3. adherance to SPP with re- inspection Verify of parameter
setting and setting limit spec - frist pc. & monitoring

1.Standard parameter setting Visual & Dimension

2.Process inspection on first pc. Set-up,
7 --- Shot size less 3 parameter patrol & 100% online 4 84
3. adherance to SPP with re- inspection Verify of parameter
setting and setting limit spec - frist pc. & monitoring

1.Standard parameter setting Visual & Dimension

2.Process inspection on first pc. Set-up,
7 --- High shot size 3 parameter patrol & 100% online 4 84
Possibility of 3. adherance to SPP with re- inspection Verify of parameter
1. Fitment issue loosing setting and setting limit spec - frist pc. & monitoring
2.appearance issue primary
Flash Dissatisfaction
3.Dimension functional
variation requirement of 1.Standard parameter setting Visual & Dimension
40.1 Injection moulding the product. 2.Process inspection on first pc. Set-up,
High injecction
7 --- 3 parameter patrol & 100% online 4 84
pressure
3. adherance to SPP with re- inspection Verify of parameter
setting and setting limit spec - frist pc. & monitoring

Possibility of
1.Standard parameter setting Visual & Dimension
loosing
2.Process inspection on first pc. Set-up,
1.appearance issue primary
Sliver sticks Dissatisfaction 7 --- High barrel temp 3 parameter patrol & 100% online 4 84
functional
3. adherance to SPP with re- inspection Verify of parameter
requirement of
setting and setting limit spec - frist pc. & monitoring
the product.

Possibility of 1.Standard parameter setting Visual & Dimension

1.High barrel temp
loosing primary 2.Process inspection on first pc. Set-up,
1. Fitment issue 2. low holding
Dim. Variation functional Dissatisfaction 7 --- 3 parameter patrol & 100% online 3 63
requirement of pressure
3. adherance to SPP with re- inspection Verify of parameter
the product. 3. low holding time
setting and setting limit spec - frist pc. & monitoring

1.Standard parameter setting Visual & Dimension

2.Process inspection on first pc. Set-up,
Less injection
7 --- 3 parameter patrol & 100% online 4 84
pressure
Possibility of 3. adherance to SPP with re- inspection Verify of parameter
1. Fitment issue loosing setting and setting limit spec - frist pc. & monitoring
2.appearance issue primary
Sink mark Dissatisfaction
3.Dimension functional
variation requirement of 1.Standard parameter setting Visual & Dimension
the product. 2.Process inspection on first pc. Set-up,
6 --- Hold on pressure less 4 parameter patrol & 100% online 4 84
3. adherance to SPP with re- inspection Verify of parameter
setting and setting limit spec - frist pc. & monitoring

First/ Last & Inprocess Inspection

1.Missing of moulding defects. Poor Skill in defects

Possibility of 1.Standard parameter setting
2.Part Weight Less / high Shot size less 2.Process 1. Visual inspection
loosing primary
40.2 & First off & Patrol Part rejected for moulding 2.Dimension inspection
functional Dissatisfaction 7 SC High injection speed 2 parameter 6 84
40.3 inspection defect
requirement of the 3.Process monitoring
3.Fitment Problem & dim 3. adherance to SPP with re- 4.Control chart
product. Shot size less
variation setting and setting limit spec
Less Cooling Time
 O Current Process Controls Action Results
c
c D
C
Potential u e Responsibilit
S l Recommended
Proce Process Function / Potential Failure Cause's)/ r t y & Target
e a RPN
ss No. Requirements Mode Mechanism's) r e Completion S O D R
v s Action's) Actions
Next operation Customer End customer of Failure e Prevention Detection c Date e c e P
s Taken
n t v c t N
c
e

50 100% visual Inspection

Improper gate
under Cut gate point Lack of apperance Possibility of 5 --- 3 Trimming method control Work instruction 5 75
removing
loosing
100% Visual primary
50.1 Dissatisfaction
inspection functional
requirement of
the product. Improper gate
gate point projection Lack of apperance. 5 --- 3 Trimming method control Work instruction 5 75
removing

60 Final Inspection

Possibility of
1.Seperate rejection area
Final Inspection Flashes loosing 1. Moulding defects
providing
Requirements short fill colour Fitment problem primary mixup
60.1 Dissatisfaction 7 --- 3 2.Components identification Final Inspection Report 4 84
free from moulding change, weld line, lack of apperarance functional 2. Poor inprocess
3.Material process
defects silver streaks requirement of inspection
control
the product.

70 Packing & Labeling

Shortage at
Wrong Qty. Possibility of 6 --- Packing std display 1 Packing standard Knowledge Final inspection Report 5 30
customer end
loosing
primary
70.1 Packing & Labeling Dissatisfaction
functional
Wrong part fitment requirement of
Material process Packing standard & Work Final inspection Report &
Parts mix up problem at customer the product. 6 1 5 30
follow up Instruction provided Visual Inspection Report
end

80 Despatch To Customer

Shortage at No Packing Standard Parts storage with

Wrong part. Possibility of 6 --- 2 Daily despatch register 5 60
customer end & Work instruction identification lable
loosing
primary
80.1 Transport to despatch functional , Dissatisfaction
fitment &
Appearance of
Shortage at the product. No Packing Standard Parts storage with
Worng label & packing 6 --- 2 Daily despatch register 5 60
customer end & Work instruction identification lable

REV
REV DATE SEQUENCE OPERATION AFFECTED AMENDMENT SUMMARY REASON FOR CHANGE
NO.
 CHENNAI
CONTROL PLAN
Control Plan Category Key Contact Name Date (Orig) Date (Rev)

Prototype Pre-Launch Production A.LAKSHMANAN 24.06.2013

Control Plan Number MODEL Key Contact Phone Customer Engineering Approval (If Req'd) Approval Date
CP/SMRC/BA 002 BA 9841035325
Part Number ECN Level: Supplier Code Customer Quality Approval (If Req'd) Approval Date
50045011/12 A / 15.06.2013 K0093
Part Name / Description Raw Material : Core team Members
BOTTOM COVER LH/RH ASA Core Team : L.SURESH, A.MALMARUGAN, R.ILAYARAJA, S.DHANDAPANI, M.DURALIVELU & A.ANANDRAJ
Characteristics Methods

Machine,
Process Name / Operation Special Evaluation /
Part / Proc # Device, Jig, No. Product / Process Specification / Sample Control Method Reaction Plan
description Tools For Mfg. Product Process Char. Measurement Sample Freq. Resp.
Tolerance Size
Class. Technique

Incoming Inspection
Verification of material name, grade name, Size by all Incoming material inspection
10. (Material- ASA , WR 9310 1 Appearance Visual Every batch QA-Engr. Reaction Plan QA - 12
color, Batch no.,and packing condition bags register
Source - Samsung )

Follow the FIFO Systems, Moisture Visual / Temp. & QA-Engr / Temp. & Humidity
20. RM Storage 1 - Every Batch Reaction Plan QA - 12
control Humidity Indicator Store Keeper Monitroing / FIFO Board
Pre heating
Auto / Moisture Predrying Monitoring cum
30 R.M Pre-heating 1 Temp & Time 80-90 degree, 2 hr Temp Controller . Every Bag Production Reaction Plan QA - 12
Predryer reduction inspection report

All process
40.1 Injection moulding IMM - 75 T-3 1 As Per Approved Process Sheets CDC Panel Nil Once in 4 Hrs Quality Process monitoring sheet Reaction Plan QA - 12
parameters

1 No damages & scratches

2 Finish should be as per sample

No moulding defects like shortfill, silver

3 streaks, patch marks, excess flash,
burnmark, weld line and flow lines.
Appearance Visual

4 No cut mark

5 No Gate point projection

MonthTracebility &
First shot / Last shot 6 3 Nos / Every loading / First /Last off inspection
40.2 Date- Shift code should presence Quality Reaction Plan QA - 12
Inspection Cavity Unloading report
Rib
7 thickness 2.0+0.20/-0.10 Vernier
Section A
Rib
8 thickness 2.0+0.20/-0.10 Vernier
Section B

9 Thickness 2.0 ± 0.10 Vernier

Proper fitment Visual with Manual

10 Fitment with Manual Housing housing

11 weight SC 4.3 ± 0.3 Gms Weighing balance

 CHENNAI
CONTROL PLAN
Control Plan Category Key Contact Name Date (Orig) Date (Rev)

Prototype Pre-Launch Production A.LAKSHMANAN 24.06.2013

Control Plan Number MODEL Key Contact Phone Customer Engineering Approval (If Req'd) Approval Date
CP/SMRC/BA 002 BA 9841035325
Part Number ECN Level: Supplier Code Customer Quality Approval (If Req'd) Approval Date
50045011/12 A / 15.06.2013 K0093
Part Name / Description Raw Material : Core team Members
BOTTOM COVER LH/RH ASA Core Team : L.SURESH, A.MALMARUGAN, R.ILAYARAJA, S.DHANDAPANI, M.DURALIVELU & A.ANANDRAJ
Characteristics Methods

Machine,
Process Name / Operation Special Evaluation /
Part / Proc # Device, Jig, No. Product / Process Specification / Sample Control Method Reaction Plan
description Tools For Mfg. Product Process Char. Measurement Sample Freq. Resp.
Tolerance Size
Class. Technique

1 No damages & scratches

2 Finish should be as per sample

No moulding defects like shortfill, silver

3 streaks, patch marks, excess flash,
burnmark, weld line and flow lines.
40.3 Patrol / Hourly Inspection Appearance Visual

4 No cut mark

5 No Gate point projection

MonthTracebility &
6 Inprocess inspection report /
Date- Shift code should presence
1 No / cavity Every 1 hour Quality X & R Chart (control chart - Reaction Plan QA - 12
Rib SC Only)
7 thickness 2.0+0.20/-0.10 Vernier
Section A
Rib
8 thickness 2.0+0.20/-0.10 Vernier
Section B

9 Thickness 2.0 ± 0.10 Vernier

Proper fitment
10 Fitment with Manual Housing Visual with Manual
housing

11 weight SC 4.3 ± 0.3 Gms Weighing balance

No excess flash, damage and other As per Apperance Instruction

50.1 100% Visual inspection 1 Appearance Visual 100 % All shots Production Reaction Plan QA - 12
moulding defects Sheet
 CHENNAI
CONTROL PLAN
Control Plan Category Key Contact Name Date (Orig) Date (Rev)

Prototype Pre-Launch Production A.LAKSHMANAN 24.06.2013

Control Plan Number MODEL Key Contact Phone Customer Engineering Approval (If Req'd) Approval Date
CP/SMRC/BA 002 BA 9841035325
Part Number ECN Level: Supplier Code Customer Quality Approval (If Req'd) Approval Date
50045011/12 A / 15.06.2013 K0093
Part Name / Description Raw Material : Core team Members
BOTTOM COVER LH/RH ASA Core Team : L.SURESH, A.MALMARUGAN, R.ILAYARAJA, S.DHANDAPANI, M.DURALIVELU & A.ANANDRAJ
Characteristics Methods

Machine,
Process Name / Operation Special Evaluation /
Part / Proc # Device, Jig, No. Product / Process Specification / Sample Control Method Reaction Plan
description Tools For Mfg. Product Process Char. Measurement Sample Freq. Resp.
Tolerance Size
Class. Technique

1 No damages & scratches

2 Finish should be as per sample

No moulding defects like shortfill, silver

3 streaks, patch marks, excess flash,
burnmark, weld line and flow lines.
Appearance Visual

4 No cut mark

5 No Gate point projection

MonthTracebility &
6
Date- Shift code should presence
As per
60 Final Inspection sampling Every lot Quality Final inspection / PDI Report Reaction Plan QA - 12
Rib plan
7 thickness 2.0+0.20/-0.10 Vernier
Section A
Rib
8 thickness 2.0+0.20/-0.10 Vernier
Section B

9 Thickness 2.0 ± 0.10 Vernier

Proper fitment
10 Fitment with Manual Housing Visual with Manual
housing

11 weight SC 4.3 ± 0.3 Gms Weighing balance

A.200 Nos per Poly cover

70 Packing & Labeling 1 Method /Qty Machine counting - Every supply Quality Packing standard Reaction Plan QA - 12
B. 800 Nos per Bin

Transport to A.200 Nos per Poly cover

80 Despatch Vehicle Visual 100% Every supply Quality Packing standard Reaction Plan QA - 12
Customer B. 800 Nos per Bin

AMENDMENT DETAILS

REV NO. REV DATE REASON FOR REVISION REMARKS

 MEASUREMENT SYSTEM ANALYSIS PLAN DATE :

BOTTOM COVER
CUSTOMER : SMRC PART NO. / REV. : 50045011 / 12 PART NAME :
LH / RH

INSTRUMENT / GAUGE MSA PLAN DATE

SL.NO. CODE NO LC
DESCRIPTION PLAN DATE ACTUAL COMPLETION DATE

Prepared By Reviewed By Approved By

Format No:NAP / QAD / 28 Rev.No.Date:00 Issued on:01.06.2011

 STATISTICAL PROCESS CONTROL PLAN
CUSTOMER : SMRC PART NO./REV : 40045011 / 12

DATE: PART NAME : BOTTOM COVER LH / RH PREPARED BY :

PRODUCT / PROCESS SPECIFICATION / PLAN ACTUAL DATE

TYPE OF CHART
SL.NO. SYMBOL INSTRUMENT REMARKS
CHARACTERISTICS TOLERANCE , mm TO BE USED DATE OF COMPLETION

Prepared By Reviewed By Approved By

Format No:NAP/QAD/29 Rev.No.:00 Rev.Date:01.06.2011

RODUCT AND PROCESS QUALITY REVIEW
Date: 27.04.09

Part No 50055011 /12 PROJECT BA

Part Name Bottom cover LH / RH

Drawing Revision Level 0

YES NO N.A CONSIDERATION

To be done by the Supplier

YES SOP

YES Process specification

YES Calibration of Inspection measuring and test equipment

YES Raw material testing facility / identify approved external egency

YES Process Flow

YES Control Plan

YES FMEA

YES Process Qualification

YES Sampling norm and frequency

YES Preservation and packaging

YES Process capability study - Variable / Attribute , Study Quantity

NO Poka yoke for customer fitment characteristics in similar parts

YES Learnings from rejections of similar parts

YES Measurability of all characteristics

YES Statistical process control presently used on similar parts

YES Are the processes in control and stable for similar parts

YES Is the Cpk greater than 1.33 in similar parts

Signature : LA.Lakshmanan Signature :

Supplier : Kriya Polytech SMRC

Date : Date :

RML / STA / 022 , REV 0

 Prepared by Checked by Approved by
KRIYA POLYTECH

CUSTOMER : SMRC PART NO. : 50045011 / 12

PREPARED BY :
DATE : PART NAME : BOTTOM COVER LH / RH

DIMENSION SPECIFICATION/ OPERATION NUMBER

DESCRIPTION
NO. TOLERANCE 10 20 30 40 50 60 70 80 90 100 110 120

1 Appearance Free from short fill XD

Free from sink mark XD

Free from white mark XD

Free from silver streaks XD

Free from hole flash XD

Free from weld line XD

Free from Pin Mark XD

Free from warpage XD

Free from Flash, Burr & Crack XD

Free from color variation XD

Free from Under Cut XF

Upper 294 ± 2 gms

2 Product Weight XD
Lower 117± 2 gms
Free from child part missing
3 Assembly Upper - Nut Spring 2 Nos X
Lower - Screw 2 Nos

Free from Screw and Clip inter change X

4 Fitment As per checker workstandard XD

Description of occurance

X = Created L = Location C - Clamp D- Process Setting Parameter E - Push F- Cutting Knife

Format No:NAP/QAD/31 Rev.No.:00 Rev..Date: 01.06.2011
G- Alignment H- Cap Protection I - Loading of Mesh

Format No:NAP/QAD/31 Rev.No.:00 Rev..Date: 01.06.2011

 Management Review - Process Design and Development Phase

Project BA Date :

Part No 50055011 /12

Part Name: Bottom Cover LH / RH Drawing Revision level

1. Completion of Phase : Process Design and Development

2. Records of Discussion : ( enclosed )

2a. Concerns / Resolutions If any :

All records are verified few points will be claried with customer

Comments by Supplier's authorIsed person :

All records are verified few points will be claried with customer
A.Lakshmanan /
Signature / Date

Signature : A.Lakshmanan Signature :

Supplier : Kriya Polytech SMRC

Date : Date :

RML / STA / 031 , REV 0

ew - Process Design and Development Phase

records are verified few points will be claried with customer

records are verified few points will be claried with customer

RML / STA / 031 , REV 0

 DOC NO: KPT/DEV/03

KRIYA POLYTECH
PRODUCTION TRIAL RUN REV/DATE: 00/01.04.2013

PAGE: 21 0F 27

Part No: Drg Rev No:

Part Name: Rev Date:

Customer:

Machine
Opn No. Description capacity/Shif Input Output Accepted Qty Rejected Qty Remarks
t

30 Moulding 5 kg 500 480 20 short mould

40 Trimming 480 480 470 10 cut marks

Production Capacity/Shift: 500 / shift Customer requirement/month 6,000

Production Capacity / day: 1500 / day

Production Capacity / month 39000 Production Manager:

 QUALITY PLANNING SIGN -OFF

PART NAME: BOTTOM COVER LH / RH PART NO/REV: BOTTOM COVER LH / RH DATE:

CUSTOMER : SMRC MANUFACTURING PLANT : KRIYA POLYTECH, THIRUMALISAI

1. PRELIMINARY PROCESS CAPABILITY STUDY QUANTITY

REQUIRED ACCEPTABLE PENDING*

Ppk - SPECIAL CHARACTERISTICS 1 1 --

2. CONTROL PLAN APPROVAL (If Required) Approved: YES/NO Date Approved :

3. INITIAL PRODUCTION SAMPLES QUANTITY

CHARACTERISTIC CATEGORY CHARACTERISTICS
SAMPLES PER SAMPLE ACCEPTABLE PENDING*
DIMENSIONAL 5 4 4 --
VISUAL 5 12 10 2
LABORATORY 1 2 2 --
PERFORMANCE NA --

4. GAUGE AND TEST EQUIPMENT QUANTITY

MEASUREMENT SYSTEM ANALYSIS REQUIRED ACCEPTABLE PENDING*
3 3 -
SPECIAL CHARACTERISTIC 1 1

5. PROCESS MONITORING QUANTITY

REQUIRED ACCEPTABLE PENDING*

PROCESS MONITORING INSTRUCTIONS 2 2 -

PROCESS SHEETS 1 1 -
VISUAL AIDS 2 2 -

6. PACKAGING / SHIPPING QUANTITY

REQUIRED ACCEPTABLE PENDING*

PACKAGING APPROVAL 1 1 -
SHIPPING TRIALS

7. SIGN-OFF

Format No:NAP/QAD/36 Rev No : 00/01.06.2011

* REQUIRES PREPARATION OF AN ACTION PLAN TO TRACK PROGRESS

Format No:NAP/QAD/36 Rev No : 00/01.06.2011

 Management Review - Product and Process Validation Phase

Project Date :

Part No

Part Name: Drawing Revision level :

1. Completion of Phase : Product and Process Validation

2. Records of Discussion : ( enclosed )

2a. Concerns / Resolutions If any :

Comments by Supplier's authorIsed person :

Signature / Date

Signature : Signature :

Supplier : KRIYA POLYTECH SMRC

Date : Date :

RML / STA / 035 , REV 0

 KRIYA POLYTECH THINGS GONE RIGHT / THINGS GONE WRONG REPORTS

CUSTOMER : SMRC PART NO./REV. 50045011 / 12

DATE : PART NAME :BOTTOM COVER LH / RH

THINGS GONE WRONG

FAILURE DETAILS POSSIBLE REASONS COUNTER MEASURE ACTION STATUS

THINGS GONE RIGHT

Format No:NPTL/QAD/37 Rev : 00 / 01.04.08

Format No:NPTL/QAD/37 Rev : 00 / 01.04.08