MICRO TURNERS

MASTER LIST OF PRODUCTS

SR.
PART NAME PART NO. DRG NO
NO

1 Dowel Dia 8.0 m.m. 39099906 655

2 Dowel Dia 10.0 m.m. 39100006 656
4 Pipe Pin Dia 14.0 m.m. 114609493 1931
5 Rod Shift 31101051 675
6 Shaft Rocker DU101191 638
7 Shaft Gear Fork JD561006 917
8 Bearing Cone DH181023 300
9 Bearing Cone DH181025 298
10 Bearing Race DH181026 299
11 Sprocket 31101035 674
12 Sprocket JZ531002 957
13 Sprocket JD531003 918
14 Crank Sprocket Silent Chain JE531036 2066
15 Sprocket crank shaft
16 Starter Drive Assy. B104D PF621400 2081
17 Sleeve B104D PF511061 2121
18 Axle Rear Wheel PF131235 2044
19 Shaft Swing Arm JA121003 696
20 Assembly Gear Starter Clutch PF621403
Gear Starter Clutch B104D PF621401 2141
Needle Bush JE621403
21 Assembly Kick Shaft B104D PF621002
Kick Shaft B104D PF621003 2145
Gear Kick Pinion B104D PF621004 2146
Sleeve K11 JE621004 2147
Spring Big K11 JE621003 2148
22 Assembly Shaft Kick DU101039
Shaft Kick * DU101045 294
Ratchet ct-100 * 31101038 662
 Gear kick pinion * DU101038 663
Spring Big * 31101041
Spring Small * 31101039
Washer Big * 39099511
Guide Bush * 31101040
23 ASSEMBLY KICK SHAFT JE621000
KICK SHAFT * JE621001 1589
24 Assembly Spindle JA621000
Spindle * JA621001 628
Ratchet XCD * JA621002 629
Pinion XCD * JA621003 630
Washer Small * 39099311
Spring Small * DS101117
Circlip Big * 39073817
Circlip Small * 39240817
Bush Pinion * JB621005
25 Collar Cam Shaft DU101067 640
26 Nut Primary Drive DH101195 641
27 Nut Crank Shaft 52JA0028 908
28 Rocker Arm Exhaust JA511211 632
29 Rocker Arm Intake JA511210 621
30 Collar Sprocket JA551009 713
31 Spacer Crank Shaft JD531004 902
32 Spacer Cam Sprocket JA511216 921
33 Collar Clutch DU101109 639
34 Collar Clutch JA551406 620
35 NUT DF DF181090 637
36 Holder 28101195 658
37 Bushing DD101309 642
38 Bush 1st Driven JZ551205 1199
39 Bolt Cam Pivot DH101392 43
40 Solid Dowel 4.0 m.m. 39099206 643
41 Stud M6 X 35 DD101350 1022
42 Bolt M10 X 16 DD101366 1032
43 Bolt M6 X 106 DD101347 1023
44 Cyl. Bolt M8 X 201 DU101349 1033
45 Bolt M8 X 136 JB511015 937
46 Bolt M8 X 190 JB511011 946
47 Bolt M8 X 195 JA511008 1025
48 Sleeve Spark Plug JB 511018 938
49 Axle Rear Wheel PA131223 1712
50 Shaft Swing Aarm PA122015 1474
51 SLEEVE SWING ARM PIVOT PA111030 1711
52 Axle Rear Wheel JK131201 667
53 Axle Front Wheel JK131023 665
54 Shaft Swing Aarm JK122006 615
55 Axle Rear Wheel DX151016 633
56 Axle Front Wheel PA131002 940
57 Shaft Swing Aarm DS171013 397
58 Axle Rear Wheel JN131211 914
59 Axle Front Wheel JB131017 794
60 Shaft Gear Change JD561202 935
61 Drive assembly JA621406 1226
62 Gear starter clutch JA621410 1227
63 Shaft Gear Change JA561201 936
64 Sleeve Spark Plug JD511004 724
65 SLEEVE SWING Arm DK171006 705
66 Shaft Rocker Arm JD511209 714
67 SHAFT SWING ARM JZ122011 1646
68 Axle Rear Wheel JZ131217 1652
69 Input shaft assy. JZ 551009
70 Output shaft assy. 52JA5502
71 Axle Rear Wheel PA131224 1475
72 Bearing Cone Lower 550AM 02102 1861
73 ASSEMBLY KICK SHAFT PA 621004
74 Axle Rear Wheel PA 131239 1814
75 Axle Rear Wheel DJ151032 248
76 Shaft Swing Aarm JD 122002 884
77 Input shaft assy. PA 52PA0420
SHAFT INPUT T/M 1888
GEAR 2ND DRIVE 1433
GEAR 3RD DRIVE 1434
GEAR 4TH DRIVE D105 1889
78 Output shaft assy. PA 52PA0420
SHAFT OUTPUT TRANSMISSION 1441
GEAR 2ND DRIVEN 1438
GEAR 3RD DRIVEN 1439
GEAR 4 TH DRIVEN 1893
79 Input shaft assy. JE55100
SHAFT INPUT * 1867
GEAR 2ND DRIVE K11 * 1868
GEAR 3RD DRIVE * 1591
GEAR 4TH DRIVE K11 * 1869
GEAR 5TH DRIVE K11 * 1870
80 Output shaft assy.
SHAFT OUTPUT TRANSMISSION * 1872
GEAR 1ST DRIVEN K11 * 1878
GEAR 2ND DRIVEN K11 * 1873
GEAR 3RD DRIVEN K11 * 1592
GEAR 4TH DRIVEN K11 * 1874
GEAR 5TH DRIVEN K11 * 1875
CIRCLIP EXTENSION *
SPLINE WASHER *
WASHER THRUST (13.2 X 26 X 0.5) *
RUBBER O RING *
WASHER 1MM *
BUSH 2ND DRIVEN * 1200
BUSH 1ST DRIVEN * 1199
WASHER 2ND DRIVEN
81 Head Bolt Cover Assy. JE511053
Bolt Spl. Head cover * GF101086 1031
Rubber Mounting * GF101087
Spl. Washer Cover * GF101127
82 Precoated Bolt M6 x 14 DH101639 1258
83 COLLAR BOLT M6X20 SPH. SL.SC UPTO H/T 39167304 1264
84 Precoated Bolt M6 x 28 JM100045 1266
85 Bolt M6 x 30 39107404 1270
86 Bolt M6 x 40 JA541044 1271
87 Bolt M6 x 35 39107504 1272
88 SPH HEX FLANGE BOLT M6 X 25 upto H/T 39195904 1257
89 SPH HEX FLANGE BOLT M6 X 75 upto H/T 39106604 1260
90 M6 X1X 25 HEX COLLAR SC upto H/T 39155304 1261
91 COLLAR BOLT M6X22 upto H/T JA561211 1262
92 FLANGE BOLT M6X25 upto H/T JA581406 1263
93 M6 X1X 10 HEX COLLAR SC upto H/T 39155104/ 59040028 1267
94 SPH HEX FLANGE BOLT M6 X 47 upto H/T 39214704 1274
95 HEX COLLAR BOLT M8X1.25X16 upto H/T 39155604 1678
96 HEX FLANGE SC M8X1.25X14 upto H/T 39194004 1681
97 HEX FLANGE M8X1.25X20 upto H/T 39194604 1682
98 HEX COLLAR SC M8X1.25X60 upto H/T 39231204 1684
99 HEX COLLAR BOLT M10 X 117 upto H/T 39270204 1688
100 SOCKET HEAD CAP SCREW M6 X 18 SPH.SL.SC(H/T) upto H/T DD101318 1690
101 M8 X1.25X 31 HEX FLANGE SCREW upto H/T 59040025 1692
102 HEX COLLAR BOLT M8X22 39102304 1693
103 SET SCREW M6X1.0X16 upto H/T 39199404 1694
104 M6 X1X 25 upto H/T 39074801 1696
105 PAN HEAD BOLT M6 X 14 upto H/T 39070201 1697
106 PAN HEAD BOLT M6 X 30 upto H/T 39075301 1698
107 M6 X1X 18 PAN HEAD SCREW upto H/T 39107801 1699
108 PEN HEAD SCREW M6X1.0X12 upto H/T DH101380 1702
109 COUNTER SHUNK SCREW M6X1.0X14 upto H/T 39169901 1705
110 FLANGE NUT M6X1.0X6 UPTO TAPPING * 39079815 1718
111 FLANGED NUT M8X1.0X7.5 UPTO TAPPING * 59150005 1719
112 FLANGED NUT M10X1.25X10 39272315 1721
113 HEXAGUN NUT M10X1.25 X 8 upto H/T 39070815 1722
114 M5 X0.8X 14 COUNTER SUNK SCREW upto H/T KBCC 0514 1745
115 SOCKET HEAD CAP SCREW M6 X1X 20 upto H/T DD 101340 1748
116 FLANGE BOLT M6X1.25X75 upto H/T JA113404 1957
117 BOLT FLANGE M8X1.25X85 upto H/T 59040018 1958
118 MASHROOM HEAD M5X0.8X10 UPTO THREAD ROLLING 39070501 1959

Prepared By:- Approved By:-

S

CUSTOMER
REMARKS
NAME

Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Endurance
Bajaj
Bajaj
Sensera
Sensera
Sensera
Sensera
Pending to supply
Bajaj
Bajaj
Bajaj
T.S.N.
Bajaj
Assy.
Assy.
Bajaj
Assy.
Assy.
Assy.
Assy.
Bajaj
Assy.
Assy.
Assy.
Assy.
Assy.
Assy.
Assy.
Bajaj
Assy.
Bajaj
Assy.
Assy.
Assy.
Assy.
Assy.
Assy.
Assy.
Assy.
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj No Schd.
Bajaj
Bajaj
Bajaj
Bajaj Model not running
T.S.N. Model not running
T.S.N. Model not running
Bajaj
Bajaj
Neel Auto
Bajaj
Bajaj
Neel Auto/M.M.T./Badve
Bajaj
Bajaj
Badve
Bajaj
Bajaj
Badve
Bajaj
Neel Auto
Bajaj
Badve Model not running
Badve Model not running
Bajaj
Bajaj
Bajaj Model not running
Endurance
Bajaj
Bajaj
Bajaj
Neel Auto
Bajaj
Assy.
Assy.
Assy.
Assy.
Bajaj
Assy.
Assy.
Assy.
Assy.
Bajaj
Assy.
Assy.
Assy.
Assy.
Assy.
Bajaj
Assy.
Assy.
Assy.
Assy.
Assy.
Assy.
Assy.
Assy.
Assy.
Assy.
Assy.

Bajaj/ Assy.
Varroc/ Assy.
Bajaj
Assy.
Assy.
Assy.
Bajaj
Bajaj/Endurance/AEL
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
 Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj
Bajaj

Approved By:-

Format No.F01 - 6302

SPC Monitoring sheet

Drawing Paramet Parameter Checking

S. No. Part Name Model Operation
No er detail Specific Method

Transmisson Gear
Hobing

Gear 2nd MT- Span PROCESS Flange

1 M106 13.69/13.71
Drive 1868 Size Hobing (IPO) micrometer .01

Gear 1st MT- Span PROCESS Flange

2 M106 25.31/25.33
Driven 1878 Size Hobing (IPO) micrometer

Gear 2nd MT- Span PROCESS Flange mic

3 M106 19.10/19.12
Driven 1873 Size Hobing (IPO) meter .01

Gear 3rd MT- Span PROCESS Flange

4 M106 15.22/15.24
Driven 1592 Size Hobing (IPO) micrometer .01

Gear 4th MT- Span PROCESS Flange

5 M106 13.45/13.47
Driven 1874 Size Hobing (IPO) micrometer .01

Gear 5th MT- Span PROCESS Flange

6 M106 21.85/21.87
Driven 1875 Size Hobing (IPO) micrometer .01

Gear 4th MT- Span PROCESS Flange

7 M106 19.34/19.36
Drive 1869 Size Hobing (IPO) micrometer .01

Gear 5th MT- Span PROCESS Flange

8 M106 15.37/15.39
Drive 1870 Size Hobing (IPO) micrometer .01

Gear 3rd MT- Span PROCESS Flange

9 M106 22.00/22.02
Drive 1591 Size Hobing (IPO) micrometer .01

MT- Span PROCESS Flange

10 Shaft Input M106 14.14/14.16
1867 Size Hobing (IPO) micrometer .01

Hobing Parameter:-10
Threading
 MT- Pitch PROCESS Flange
11 Shaft Input M106 13.25/13.29
1867 Dia. Rolling (IPO) micrometer .01

Thread Rolling Machine :-01

Honing
Gear 1st MT- CUST DRAWING Air Plug
12 M106 ID 16.016/16.034
Driven 1878 (Honing) Gauge .001

Gear 2nd MT- CUST DRAWING Air Plug

13 M106 ID 20.000/20.021
Driven 1873 (Honing) Gauge .001

Gear 3rd MT- CUST DRAWING Air Plug

14 M106 ID 17.000/17.018
Driven 1592 (Honing) Gauge .001

Gear 4th MT- CUST DRAWING Air Plug

15 M106 ID 17.016/17.034
Drive 1869 (Honing) Gauge .001

Gear 5th MT- CUST DRAWING Air Plug

16 M106 ID 17.016/17.034
Drive 1870 (Honing) Gauge .001

Honing Parameters:-05
Date

Grinding

MT- CUST DRAWING

17 Shaft Input M106 OD 16.966/16.984 M/c Gauge.001
1867 (Grinding)

MT- CUST DRAWING

18 Shaft Input M106 OD 12.989/13.00 M/c Gauge.001
1867 (Grinding)

Shaft MT- CUST DRAWING

19 M106 OD 16.966/16.984 M/c Gauge.001
Output 1872 (Grinding)

Shaft MT- CUST DRAWING

20 M106 OD 12.989/13.00 M/c Gauge.001
Output 1872 (Grinding)
 Drive
MT- Outer PROCESS (IPO)
21 Assembly 9.980 ±0.005 M/c Gauge.001
1226 Dia Grinding
JA 621406

Shaft kick Outer PROCESS (IPO)

22 MT-294 15.972+0.01 M/c Gauge.001
DU101045 dia Grinding

Shaft kick MT- PROCESS (IPO)

23 12.954+0.01
JE 621001 1589 Grinding
Outer
dia
Shaft kick MT- PROCESS (IPO)
24 15.938+0.01
JE 621001 1589 Grinding

Grinding OD:-08
Final Drawing
25 MT- Stack CUST DRAWING
Shaft Input M106 77.50/77.60
1867 Height

Groove
26 MT- CUST DRAWING
Shaft Input M106 Distanc 23.90/24.00
1867
e
Groove
27 MT- CUST DRAWING
Shaft Input M106 Distanc 55.60/55.70
1867
e

28 Shaft MT- Stack CUST DRAWING

M106 71.30/71.50
Output 1872 Height
Gear
29 Starter MT- Span Flange mic
40.061 +0.07 CUST DRAWING
Clutch 1227 Size meter .01
JA 621410
Drive
30 MT- Span 14.003 / 14.05 CUST DRAWING Flange mic
Assembly
1226 Size meter .01
JA 621406
Drive
31 MT- Span Flange mic
Assembly 15.249 +0.071 CUST DRAWING
1226 Size meter .01
JA 621406
Root
32 Sprocket CUST DRAWING Point
MT-674 Diamete 25.14 ±0.1
CT -100 Micrometer .01
r
 Root
33 Sprocket D CUST DRAWING
MT-957 Diamete 28.95±0.1
-125M
r

Final Drawing Parameter:-09

Date
Gear Starter Clutch & Sprocket CNC Turning
Gear
34 Starter MT- Inner Air Plug
38.445 +0.015 CUST DRAWING
Clutch 1227 Dia Gauge .001
JA 621410
Gear
35 Starter MT- Outer CUST DRAWING Air Plug
49.60 +0.03
Clutch 1227 Dia Gauge .001
JA 621410

36 Sprocket Inner CUST DRAWING Air Plug

MT-674 17.152 / 17.170
CT -100 Dia Gauge .001

37 Sprocket Root CUST DRAWING Comparator

MT-674 0.08 Max
CT -100 Runout stand .01

Sprocket D Inner No Match

38 MT-957 18.462±0.01
-125M Dia Drawing

Sprocket D Root No Match

39 MT-957 0.04 Max
-125M Runout Drawing

CNC Turning ID & OD:-6

1.Sheet should be separate for each model.

2.If SPC done more than one model, then SPC summary should be combined.

3.Level change of any parameter is clearly shown in SPC monitoring sheet and summary sheet.

4.Also send the month wise/model wise parameter level changr (if any)status with action taken in Graphical form
 Month :--1-August -2015
Not Find Runing Machine & No Plan Production
Teeth
Date
1 2 3 4 5 6 7 8 9 10 11 12 13 14

3T 5 5 5

5T 5

4T

3T 5

4T 5

3T 5

4T 5

5 5
 5 5

5 5 5

5 5

1 2 3 4 5 6 7 8 9 10 11 12 13 14
 5

5 5 5 5 5 5 5 5 5 5

7T 5 5 5 5 5 5 5 5

5T

3T

5 5 5 5 5 5 5 5 5 5 5
 1 2 3 4 5 6 7 8 9 10 11 12 13 14

5 5 5 5 5 5 5 5

5 5 5 5 5 5 5

5 5 5 5 5 5 5 5 5 5 5

5 5 5 5 5 5 5 5 5 5 5

sheet.

n taken in Graphical form(PPT).

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

5 5

5 5

5
 5

5 5 5

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
 5 5 5 5

5 5 5 5 5 5 5

5 5 5 5

5 5 5 5 5 5 5
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

5 5 5 5

5 5 5 5

5 5 5 5 5 5 5

5 5 5 5 5 5 5
30 31
30 31
30 31
 Aug.14

S.No Cell Wise Machine Operation Total Qty

Completed No Plan

1 Hobing Parameter 10 0 10

2 Final Drawing Parameter 9 2 7

3 Grinding OD 8 1 7

4 CNC Turning ID & OD 6 4 2

5 Honing Parameters 5
0 5

6 Thread Rolling Machine 1 0 1

Drive Assy JA 621406 (46 Teeth

7 2
&18 Teeth) Hobing Span Size

8 New 1st Driven JH Honing 1

9 New G S C PF Bearing Depth 1

10 Sprocket Soft Hobing Root Dia 1

Total Qty 39

12 10
10 9 4
8
8 6
6
4 2
2 1
0 0
r r
et e et e OD OD
ra m ra m
di ng D
&
P a Pa in I ar
i ng i ng Gr rn i ng i n gP
b w
Ho Dr
a
CT
u
Ho
n
n al CN r
F i Th

J
sy
e As
D riv
 Pa Pa in gI r
Gr Pa
i ng i ng rni
n g
ob aw Tu ni n
H
l Dr C Ho
a CN r
Fin Th

J
sy
e As
D riv
 Sep.

Cell Wise Machine Operation Total Qty

Completed No Plan

Hobing Parameter 10

Final Drawing Parameter 9

Grinding OD 8

CNC Turning ID & OD 6

Honing Parameters 5

Thread Rolling Machine 1

10 5
9 4 4
8
6 3
5
2 2 2
1 1 1 1 1 1
0 0 0 0
r r rs e g a
et e et e OD OD et e i ne Si z ni n pt h Di
a m i ng & m a ch
a n H o De o ot
ar i nd ID a ra M p JH n g R
gP G r i ng gP i ng gS ari i ng
in
urn ni n ol l bin ven Be ob
raw T o R H o D ri P F H
C H
rea
d h) st SC o ft
CN Th Teet w1 G e tS
e k
18 N
Ne
w roc
et h& Sp
Te
46
0 6(
4
21
J A6
ssy
i veA
Dr
 Pa in gI Pa
r M Sp JH in gR
i ng Gr rni
n g ll i ng i ng en ear bin
raw Tu ni n Ro ob ri v F B o
C Ho d h)
H
st
D CP ft H
CN rea eet 1 S t So
Th T Ne
w
wG ke
&1
8
Ne roc
th Sp
6 Tee
6 (4
40
621
JA
sy
e As
D riv
 Aug.15 Oct Aug.16 Nov Aug.17

5
4
3
2
1 1 1
0
h a
ept Di
gD o ot
gR
bin
Ho
S o ft
 g R
bin
ft Ho
So
Aug.17 Dec Aug.18 Jan Aug.19 Feb
Feb
SPC Monitoring sheet
Month
S. No. Part Name Model Dimension
/ Parameter detail
1 Gear 2nd Drive M106 Span Size
2 Span Size
Gear 1st Driven M106
3 ID
4 Span Size
Gear 2nd Driven M106
5 ID
6 ID
Gear 3rd Driven M106
7 Span Size
8 Gear 4th Driven M106 Span Size
9 Gear 5th Driven M106 Span Size
10 ID
Gear 4th Drive M106
11 Span Size
 12 Span Size
Gear 5th Drive M106
13 ID
14 Gear 3rd Drive M106 Span Size
15 Span Size

1
16 Pitch Dia.
17 OD
18 Shaft Input M106 OD
19 Stack Height
20 Groove Distance
21 Groove Distance
22 OD
23 Shaft Output M106 OD
24 Stack Height
25 Inner Dia
Gear Starter Clutch
JA 621410
26 Gear Starter Clutch
Outer Dia
JA 621410
27 Span Size
28 Outer Dia
29 Drive Assembly JA
Span Size
621406
30 Span Size
31 Inner Dia
32 Root Runout
Sprocket CT -100
33 Root Diameter

34 Inner Dia
35 Root Runout
Sprocket D -125M
36 Root Diameter

37 Shaft kick DU101045 Outer dia

38
Shaft kick JE 621001 Outer dia
 Shaft kick JE 621001 Outer dia
39

1.Sheet should be separate for each model.

2.If SPC done more than one model, then SPC summary should be combined.
3.Level change of any parameter is clearly shown in SPC monitoring sheet and summary
4.Also send the month wise/model wise parameter level changr (if any)status with actio
Month April'15 Level Status May'15 Level Status
Dimension
/ Parameter spec. Cp Cpk L0 L1 L2 L3 Cp Cpk L0 L1

13.69/13.71 1.64 1.55 L1 1.66 1.58 L1

25.31/25.33 1.83 1.61 L1 1.53 1.43 L1
16.016/16.034 1.94 1.73 L0 1.9 1.73 L0
19.10/19.12 1.81 1.52 L1 1.91 1.56 L1
20.000/20.021 1.74 1.67 L0 1.86 1.71 L0
17.000/17.018 1.98 1.69 L0 2 1.72 L0
15.22/15.24 1.87 1.55 L1 1.89 1.59 L1
13.45/13.47 1.77 1.56 L1 1.83 1.56 L1
21.85/21.87 1.62 1.57 L1 1.68 1.6 L1
17.016/17.034 2.05 1.83 L0 1.91 1.7 L0
19.34/19.36 1.66 1.58 L1 1.73 1.54 L1
 15.37/15.39 1.73 1.59 L1 1.74 1.55 L1
17.016/17.034 1.83 1.68 L0 1.92 1.57 L1
22.00/22.02 1.73 1.59 L1 1.68 1.51 L1
14.14/14.16 1.68 1.45 L1
13.25/13.29 1.41 1.39 L1
16.966/16.984 2.7 1.94 L0
12.989/13.00 1.77 1.56 L1
77.50/77.60 1.54 1.51 L1
23.90/24.00 1.47 1.41 L1
55.60/55.70 1.43 1.42 L1
16.966/16.984 1.8 1.78 L0
12.989/13.00 1.59 1.52 L1
71.30/71.50 1.71 1.58 L1
38.445 +0.015 2.08 1.69 L0 2.15 1.73 L0
 49.60 +0.03 2.64 1.74 L0 4.01 3.49 L0
40.061 +0.07 1.81 1.53 L1 1.6 1.34 L1
9.980 ±0.005 1.69 1.57 L1 1.69 1.6 L1
14.003 +0.05 1.69 1.46 L1 1.55 1.36 L1
15.249 +0.071 2.12 1.38 L1 2.29 1.51 L1
17.162 ±0.01 1.66 1.54 L1 1.62 1.52 L1

0.08 Max 1.94 1.4 L1 2.82 1.52 L1

25.14 ±0.1 2.28 1.41 L1 2.22 1.4 L1

18.462±0.01 2.15 1.89 L0 1.8 1.7 L0

0.04 Max 2.56 1.75 L0 2.61 1.74 L0

28.95±0.1 1.8 1.73 L0 4.08 3.21 L0

15.972+0.01 1.44 1.4 L1 1.46 1.42 L1

12.954+0.01 1.69 1.44 L1

 15.938+0.01 1.52 1.41 L1

Level summary 12 27 Level summary 9 18

ary should be combined.

SPC monitoring sheet and summary sheet.
evel changr (if any)status with action taken in Graphical form(PPT).
Level Status Jun'15 Level Status July'15 Level Status AUG'15

L2 L3 Cp Cpk L0 L1 L2 L3 Cp Cpk L0 L1 L2 L3 Cp

1.68 1.57 L1 … … … …
1.67 1.53 L1 … … … …
1.93 1.69 L0 … … … …
1.79 1.5 L1 … … … …
1.99 1.85 L0 … … … …
2.05 1.67 L0 … … … …
1.84 1.55 L1 … … … …
1.51 1.41 L1 … … … …
1.66 1.53 L1 … … … …
1.92 1.8 L0 … … … …
1.77 1.63 L1 … … … …
1.51 1.41 L1 … … … …
1.84 1.72 L0 … … … …
1.64 1.44 L1 … … … …
1.53 1.46 L1 … … … …
… … … …
1.95 1.86 L0 … … … …
1.64 1.59 L1 … … … …
1.4 1.38 L1 … … … …
1.56 1.37 L1 … … … …
1.42 1.4 L1 … … … …
1.97 1.9 L0 … … … …
1.36 1.35 L1 … … … …
1.78 1.6 L1 … … … …
1.88 1.71 L0 3.06 3.05 L0 … … … 1.94
4.15 4.07 L0 4.65 4.59 L0 … … … 2.84
1.7 1.42 L1 1.7 1.4 L1 … … 1.47
1.62 1.43 L1 1.85 1.4 L1 … … …
1.55 1.41 L1 … … … …
1.97 1.35 L1 … … … …
3.67 2.71 L0 3.67 3 L0 … … … 2.35
1.94 1.33 L1 2.39 2 L0 … … … 2.82

1.98 1.75 L0 2.35 2.28 L0 … … …

2.87
2.42 2.21 L0 2.35 2.18 L0 … … … …
… … … …

3.88 3.15 L0 3.1 2.57 L0 … … … …

1.35 1.34 L1 1.54 1.34 L1 … … …

… … … …
 … … … …
… … … …
Level summary 13 22 Level summary 7 3 … … …
 Q
AUG'15 Level Status Remark
Cpk L0 L1 L2 L3

… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN
… … … … … NO PLAN

1.78 L0 … … …
2.79 L0 … … …
1.36 L1 … …
… … … … …
… … … … … NO PLAN
… … … … … NO PLAN

2.33 L0 … … …

1.78 L0 … … …

… … …
1.98 L0
… … … … …
… … … … …

… … … … …

… … … … …

… … … … …
… … … … …
… … … … …
… 5 1 … …
 L0 - levels Parameters

Month Aug.14 Sep'14 Oct'14 Dec'14 Jan'15 Feb'15 Mar'15 April'15 May'15 Jun'15 July'15 AUG.15
Total
S.NO Part Name L0
Dimension Dimension Level
/ Parameter / Parameter L0 L0 L0 L0 L0 L0 L0 L0 L0 L0 L0 L0
detail spec.

1 Gear 1st L0 L0 L0 L0 L0 L0 …. L0 L0 L0 …
ID 16.016/16.034 9
Driven
2 Gear 2nd L0 L0 L0 L0 L0 L0 …. L0 L0 L0 ….
ID 20.000/20.021 9
Driven
3 Gear 3rd L0 L0 L0 L0 …. L0 L0 L0 ….
ID 17.000/17.018 … … 7
Driven
4 Gear 4th Drive ID 17.016/17.034 L0 L0 L0 L0 L0 L0 …. L0 L0 L0 …. 9

5 Gear 5th Drive ID 17.016/17.034 L0 L0 L0 L0 L0 L0 … L0 …. L0 …. 8

6 OD 16.966/16.984 L0 L0 L0 L0 L0 L0 … L0 …. L0 …. 8
7 Shaft Input OD 12.989/13.00 …. …. …. L0 L0 L0 …. …. …. …. …. 3
8 OD 16.966/16.984 L0 L0 L0 L0 L0 L0 L0 …. L0 …. 8

9 Drive Assembly L0 L0 …. L0 …. …. …. ….
JA 621406
Outer Dia 9.980 ±0.005 …. …. …. 3

10 Inner Dia 17.162 ±0.01 …. … .,.. L0 L0 …. …. …. …. L0 L0 L0 5

Sprocket CT -
11 Root Diameter 25.14 ±0.1 …. …. …. L0 L0 L0 L0 L0 5
100
12 Root Runout 0.08 Max …. …. ….. ….. ….. ….. …. …. … … L0 L0 2
13 Inner Dia 18.462±0.01 …. …. …. L0 L0 L0 L0 L0 L0 L0 L0 8
14 Sprocket D - L0 L0 L0 L0 L0 L0 …..
Root Runout 0.04 Max …. ….. ….. …. 6
125M
15 Root Diameter 28.95±0.1 …. …. …. L0 L0 L0 L0 L0 L0 L0 7
16 Gear Starter Inner Dia 38.445 +0.015 ….. …. …. …. …. L0 L0 L0 L0 L0 L0 L0 7
Clutch
17 JA 621410 Outer Dia 49.60 +0.03 ….. …. …. ….. …. L0 L0 L0 L0 L0 L0 L0 7

Total L0 6 6 7 14 14 13 5 12 9 13 7 5 111
 Level - L1 (1.67 MINIMUM)
Month Aug'14 Sep'14 Oct'14 Dec'14 Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 July'15 AUG'15
S. Dimension TOTAL
No. Part Name Dimension
/ Parameter detail / Parameter L1 L1 L1 L1 L1 L1 L1 L1 L1 L1 L1 L1 L1
spec.
1 Gear 2nd Drive Span Size 13.69/13.71 L1 L1 L1 L1 L1 L1 …. L1 L1 L1 …. …. 9
2 Gear 1st Driven Span Size 25.31/25.33 L1 L1 L1 L1 L1 L1 …. L1 L1 L1 …. …. 9
3 Gear 2nd Driven Span Size 19.10/19.12 L1 L1 L1 L1 L1 L1 …. L1 L1 L1 …. …. 9
4 ID 17.000/17.018 L1 L1 …. …. …. …. …. …. …. …. …. …. 2
Gear 3rd Driven
5 Span Size 15.22/15.24 …. …. …. …. L1 L1 …. L1 L1 L1 …. …. 5
6 Gear 4th Driven Span Size 13.45/13.47 …. …. …. …. L1 L1 …. L1 L1 L1 …. …. 5
7 Gear 5th Driven Span Size 21.85/21.87 …. …. …. …. L1 L1 …. L1 L1 L1 …. …. 5
8 Gear 4th Drive Span Size 19.34/19.36 …. …. …. …. L1 L1 …. L1 L1 L1 …. …. 5
9 Span Size 15.37/15.39 …. …. …. …. L1 L1 …. L1 L1 L1 …. …. 5
Gear 5th Drive
10 ID 17.016/17.034 …. …. …. …. …. …. …. …. L1 …. …. …. 1
11 Gear 3rd Drive Span Size 22.00/22.02 …. …. …. …. …. L1 …. L1 L1 L1 …. …. 4
12 Span Size 14.14/14.16 L1 L1 L1 L1 L1 L1 …. L1 …. L1 …. …. 8
13 Pitch Dia. 13.25/13.29 L1 L1 L1 L1 L1 L1 …. L1 …. …. …. …. 7
14 OD 12.989/13.00 L1 L1 L1 …. …. …. …. L1 …. L1 …. …. 5
Shaft Input
15 Stack Height 77.50/77.60 L1 L1 L1 L1 L1 L1 …. L1 …. L1 …. …. 8
16 Groove Distance 23.90/24.00 L1 L1 L1 L1 L1 L1 …. L1 …. L1 …. …. 8
17 Groove Distance 55.60/55.70 L1 L1 L1 L1 L1 L1 …. L1 …. L1 …. …. 8
18 OD 12.989/13.00 L1 L1 L1 L1 L1 L1 …. L1 …. L1 …. …. 8
Shaft Output
19 Stack Height 71.30/71.50 L1 L1 L1 L1 L1 L1 …. L1 …. L1 …. …. 8
20 Inner Dia 38.445 +0.015 …. …. …. L1 L1 …. …. …. …. …. …. …. 2
21 Gear Starter Clutch Outer Dia 49.60 +0.03 …. …. …. L1 L1 …. …. …. …. …. …. …. 2
JA 621410
22 Span Size 40.061 +0.07 …. …. …. L1 L1 …. L1 L1 L1 L1 L1 …. 7
23 Outer Dia 9.980 ±0.005 …. …. …. …. …. L1 …. L1 L1 L1 L1 …. 5
24 Drive Assembly JA Span Size 14.003 +0.05 …. …. …. L1 L1 L1 L1 L1 L1 L1 …. …. 7
621406
25 Span Size 15.249 +0.071 …. …. …. L1 L1 L1 L1 L1 L1 L1 …. …. 7
26 Inner Dia 17.162 ±0.01 …. …. …. …. …. L1 L1 L1 L1 …. …. 4
27 Root Runout 0.08 Max …. …. …. L1 L1 L1 L1 L1 L1 L1 …. …. 7
Sprocket CT -100
28 Root Diameter 25.14 ±0.1 …. …. …. …. …. L1 L1 L1 L1 …. …. …. 4

29 Sprocket D -125M Root Diameter 28.95±0.1 …. …. …. …. …. …. L1 …. …. …. …. …. 1

30 Shaft kick …. …. …. L1 L1 L1 L1 L1 L1 L1 L1 L1
Outer dia 15.972+0.01 9
DU101045
31 Shaft kick JE 12.954+0.01 …. …. …. L1 L1 L1 …. L1 …. …. …. …. 4
Outer dia
32 621001 15.938+0.01 …. …. …. L1 L1 L1 …. L1 …. …. …. …. 4
TOTAL LEVEL - L1 12 12 11 19 24 25 8 27 18 22 3 1 182
Month S .No Part Name ProblemName Observation

Problem Qty 1

Input Shaft JE Pitch Dia U/S-.15 Closed

1 1
(13.25/13.29) mm Problem

Pending
Aug-15

0
Problem

Problem Qty 1

Shaft Kick (DU OD U/S-.004 Closed

2 0
101045) micron Problem

Pending
1
Problem
 Pr

0
0.2
0.4
0.6
0.8
1
1.2
ob
lem
Qt
y

1
Cl
os
ed
Pr
ob
Pe lem

1
nd
in
gP
ro
bl
em

0
Pr
ob
lem
Qt
y
1

Cl
os
ed
Pr
ob
Pe lem

0
nd
in
gP
ro
bl
em
1
Level Status Aug.14 Sep.14 Oct.14 Dec.14 Jan.15 Feb.15 Mar.15

Monthly
39 39 39 39 39 39 39
Targat

No Plan 21 21 21 6 1 1 26

Lo 6 6 7 14 14 13 5
L1 12 12 11 19 24 25 8
L2 0 0 0 0 0 0 0

L3 0 0 0 0 0 0 0

45
40 39 39 39 39 39 39 39 39 39

35
30 27
24 25 26
25
20 21 21 21 19

15 14 14 13
12 12 11 12
10 7 8
6 6 5
5 6

0 1 1 0
Aug.14 Sep.14 Oct.14 Dec.14 Jan.15 Feb.15 Mar.15 Apr.15 M
 Apr.15 May.15 Jun.15 Jul.15 AUG.15

39 39 39 39 39

0 12 4 29 33

12 9 13 7 5
27 18 22 3 1
0 0 0 0

0 0 0 0

39 39 39 39 39 39
Monthly Targat

33
Lo
27 29
5 26
22 L1
18
No Plan
12 13
8 9 12
7
5 5
4 3
1
0
Mar.15 Apr.15 May.15 Jun.15 Jul.15 AUG.15
 Process Plating Audit
Month
August.15 Sep.15 Oct.15 Nov.15 Dec.15

S.N0 Nominate W-1 W-2 W-3 W-4 W-1 W-2 W-3 W-4 W-1 W-2 W-3 W-4 W-1 W-2 W-3 W-4 W-1 W-2 W-3 W-4

1 Bajaj

2 Tejpal

3 Tejpal

4 Tejpal

Prepared By:-Tejpal Gangwar Approved By:-

 Rev No :- 00
PROCESS AUDIT CHECK SHEET
Rev Date:- 01.04.15

Name :-Plating Area Audit Date :-13.08.2015

Auditor Name :- Tejpal Gangwar

Process :-Plating
Auditee Name :-Ashish

Sr No Stage Parameter Specification Observation

Rusty No Heavy Rust/Pitted √

1 Input Part Inspection Oily/Greased No Heavy Oily √
Damage No Damage √
Chemical Steelex K20 No Report Growel
Concentration 100 - 120 gm/ltr √
Temp 60-75°C 60°
2 Degreasing
Density 9 - 11 Be 10 Be
Dip Time 10-12 min 10 min
Oil Skeamer Continiously √
Water Flow Continiously √
3 Water Rinse - 1 PH 10 to 12 11.3
Dip Time 10 - 15 Sec 10 sec
Water Flow Continiously √
4 Water Rinse - 2 PH 9 to 11 10
Dip Time 10 - 15 Sec 10 sec
Chemical Gindox 281 No Report Growel
Concentration 150 - 200 gpl √
5 De - Scaling Temperature 60 - 75°C 63°
Density 10 - 13° Be 13° Be
Dip Time 8 - 10 Min 10 min
Water Flow Continiously √
6 Water Rinse - 1 PH 10 to 12 11.5
6 Water Rinse - 1

Dip Time 10 - 15 Sec 10 sec

PH 9 to 11 10.8
7 Water Rinse - 2
Dip Time 10 - 15 Sec 10 sec
Chemical Hydrochloric Acid No Report Growel
Concentration 40 - 50% √
8 Acid Pickle Temp 20 - 35°C - RT RT
Density 9 -12 Be 12 Be
Dip Time 2 - 3 Min 2 min
Water Flow Continiously √
9 Water Rinse - 1 PH 3 to 5 2.4
Dip Time 10 - 15 Sec 10 sec
PH 5 to 6 5.9
10 Water Rinse - 2
Dip Time 10 - 15 Sec 10 sec
Chemical Gindox 114 No Report Growel
Concentration 100 - 120 gm/ltr √
Temp 50~65°C. 63°
11 Anodic Clean
Density 9 - 11° Be 12°
Current Density 15 - 20 Amp/sq feet ×
Dip Time 2 - 4 Min 2 min
Water Flow Continiously √
12 Water Rinse - 1 PH 10 to 12 11.5
Dip Time 10 - 15 Sec 10 sec
PH 9 to 11 11.6
13 Water Rinse - 2
Dip Time 10 - 15 Sec 10 sec
Chemical HCL - Com No Report Growel
Concentration 8 - 10% √
14 Acid Activation Temp 20 - 35°C - RT RT
Density 2 - 3 Be 2 Be
Dip Time 1 - 2 Min 1 min
 Conductivity <25 usec. √
Water Rinse - 1
15
(DM Water)
PH 4 - 6 Min 2.4
Dip Time 10 - 15 Sec 10 sec

Water Rinse - 2 PH 6 to 7 5.7

16
(DM Water) Dip Time 10 - 15 Sec 10 sec
Chemical Caustic Soda No Report Growel
17 Neutralizer Concentration 40 - 50 gpl √
Dip Time 60 Sec 60 sec
Filteration Continiously √
Temperature 18 - 35 °C 35°
10 ~ 15 Amps/sq. ft
Alk Zinc Vat Plating
Current
(150-170 Amp/Load) ×
18 520 Ltr Tank - 1 Half Volatage 5 - 8 Volt 8V
Plating
Dip Time 12 Min 12 min
Zinc Metal 10 - 15gpl √
Sodium Hydroxide 110 - 140 gpl √
Conductivity <25 usec. √
Water Rinse - 1
19
(DM Water)
PH 10 to 12 12.4
Dip Time 20 - 40 Sec 20 sec

Conductivity <25 usec. √

Water Rinse - 2
20
(DM Water) PH 8 to 9 8
Dip Time 10 - 15 Sec 10 sec

Hydrogen Temperature 180 - 210 °C No Confirm

21
Embrillment Dip Time 4 Hrs No Confirm
Chemical Caustic Soda No Report Growel
22 Neutralizer Concentration 30 - 40 gpl √
Dip Time 60 Sec 60 sec
23 Flash Plating P:rocess Time 2 min 2 min
Conductivity <25 usec. √
Water Rinse - 1
24
(DM Water)
 Water Rinse - 1
24
(DM Water)
PH 10 to 12 10
Dip Time 20 - 40 Sec 20 sec
Conductivity <25 usec. √
Water Rinse - 2
25
(DM Water)
PH 8 to 9 8
Dip Time 10 - 15 Sec 10 sec
Chemical Nitric Acid Com. No Report Growel
26 Nitric Dip Concentration 10 - 20 ml/ltr √
Dip Time 5 - 10 Sec 5 sec
Conductivity <25 usec. √
Water Rinse
27
(DM Water)
PH 4 to 6 5.9
Dip Time 10 - 15 Sec 10 sec
Chemical Trichrome 2203 HCB No Report Growel

28
Passivation Concentration 100 - 120 ml/ltr √
(Triv irrd)
PH 1.8 - 2.2 2.1
Dip Time 60 Sec 60 sec
Conductivity <25 usec. √
Water Rinse
29
(DM Water)
PH 3 to 6 5.2
Dip Time 10 - 15 Sec 10 sec
Chemical Zincoseal 605 MWLB No Report Growel

30 Sealent
Concentration 200 - 250 ml/ltr √
PH 9 - 11 9.3
Dip Time 60 Sec 60 sec
Temperature 50 - 70 °C 60°
31 Baking
Cycle Time 10 - 15 Min 10 min
Plating Thickness 8 - 12 µ 8 micron
32 Surface test
NSS Test WR - 168& RR - 480 Hrs √
Process Parameter Daily/Shift Daily
Shade Matching Daily/Shift Daily

Process Data NSS Test Monthly Monthly

33
Recoeding/Monitoring
 Process Data
33
Recoeding/Monitoring Process Re-Validation New Part ×
QC/PC/IPO Should Follow/Update QC
Equipment Calibration Should be Calibrated √
Total NC 19
Auditor Sign:-Tejpal Gangwar
Auditee Name:-Ashish Format No :-
 Rev No :- 00

Rev Date:- 01.04.15

udit Date :-13.08.2015 Audit Date:-21.08.2015

Process :-Plating Process :-Plating

Remarks Observation Remarks

√
√
√
1 No Report Growel 1
Report Available Lab Engg not Presented

77° 1
10 Be
10 min

√
√
8.6 1
10 sec

√
9.3
10 sec
1 No Report Growel 1
Report Available Lab Engg not Presented

67°
12° Be
10 min

√
10.7
 10 sec
10.5
10 sec
1 No Report Growel 1
Report Available Lab Engg not Presented

RT
12 Be
2 min

√
1 4.2
10 sec
6.2 1
10 sec
1 No Report Growel 1
Report Available Lab Engg not Presented

45° 1
1 11° Be

× 1
4 min

√
12
10 sec
1 11.3
10 sec
1 No Report Growel 1
Report Available Lab Engg not Presented

RT
2 Be
1 min
Report Available √ (18)20.08.15 Report Available
1 8.3 1
10 sec
8.1 1
10 sec
1 No Report Growel 1
Report Available Lab Engg not Presented

60 sec

√
38° Chillar Not Ok 1

1 × 1

8V
12 min

√
No Test Growel 1
Report Available √ Report Available
1 11.9
20 sec
Report Available
√ perday not checked
10.5
10 sec
1 180°c
1 4 hrs
1 No Report Growel 1
Report Available Lab Engg not Presented

60 sec
2 min
Report Available √ Report Available
 11.9
20 sec
Report Available √ Report Available
8
10 sec
1 No Report Growel 1
Report Available Lab Engg not Presented

5 sec
Report Available √ Report Available
7.3 1
10 sec
1 No Report Growel 1
Report Available Lab Engg not Presented

2.1
60 sec
Report Available √ Report Available
6
10 sec
1 No Report Growel 1
Report Available √ Report Available
7.3 1
60 sec
58°
10 min
11,9 micron

Report Available √ Report Available

Daily
Daily
Report Available Monthly Report Available
 1 × 1
Control Plan Update QC Control Plan Update
Yearly √ Yearly
23
 VARIABLE CONTROL CHARTS
Company Microturners-v Characteristic Process ID Honing Period n A2 D3 D4 d2

Part Name 1st Driven JH USL Sample Size 50 M / C. No. :-Honing-2 2 1.88 0 3.27 1.13

Part No. LSL Frequency 5 Instrument No. Air plug Gauge 3 1.02 0 2.57 1.69

AVERAGE CHART (X BAR CHART) X.D.B. = Average X.B.= UCL=X.D.B.+A2R.B.= LCL=X.D.B. -A2R.B.= 4 0.73 0 2.28 2.06
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
5
0.58 0 2.11 2.33

ACTION

ON SPECIAL CAUSES

. ANY POINT OUTSIDE OF THE CONTROL LIMITS

. A RUN OF 7 POINTS ALL ABOVE OR ALL BELOW

THE CENTRAL LINE

. A RUN OF 7 POINTS UP OR DOWN

NOTE :- THE PROCESS MUST BE IN CONTROL BEFORE

CAPABILTY CAN BE DETERMINED.

RANGE CHART (R.B.= AVERAGE OF R)= UCLr= D4*R.B.= LCLr=D3*R.B.=

DATE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
TIME 3:45
1 16.021
2 16.023
3 16.021
4 16.02
5 16.024
SUM 80.109 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
AVG. X-BAR 16.0218 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
R (RANGE) 0.004
SIGMA= R.B./d2 Cp =(USL-LSL)/6*SIGMA= Cpu=(USL-X.D.B)/(3*SIGMA=
Process Under Control YES / NO Cpl=(X.D.B.-LSL)/3*SIGMA= Cpk= Min.(Cpu.Cpl)=
NOTE :- List of events occurred during the Study e.g. Material Change / Mould Change / Parameter Setting Change / Operator Change / Measurement Method Change / Change in
Environment Like Temp. Voltage Fluctuation etc.

DATE SHIFT TIME COMMENTS (CHANGE OF DESCERIPTIONS)

10.08.2015 B 3:45 Honing Machine -2 ,Operator's name:-Kranti (Setting Change),Checking Parameter:-ID

ACTION INSTRUCTIONS
Company Microturners-v Characteristic 1.5+.1

Part Name Gear Starter Clutch USL 1.6

Part No. PF 621401 (Bearing) LSL 1.5

1 2 3 4 5 6 7
RANGE CHART (R.B.= AVERAGE OF R)= UCLr= D4*R.B.= LCLr=D3*R.B
 DATE 1 2 3 4 5 6 7
TIME
1
2
3
4
5
SUM 0 0 0 0 0 0 0
AVG. X-BAR 0 0 0 0 0 0 0
R (RANGE) 0
SIGMA= R.B./d2 Cp =(USL-LSL)/6*SIGMA=
Process Under Control YES / NO Cpl=(X.D.B.-LSL)/3*SIGMA=
 VARIABLE CONTROL CHARTS
1.5+.1 Process Depth Bearing Period

1.6 Sample Size 50 M / C. No. :-NRB Presure m/c

1.5 Frequency 5 Instrument No. Height Gauge .01

AVERAGE CHART (X BAR CHART) X.D.B. = Average X.B.= UCL=X

8 9 10 11 12 13 14 15
LCLr=D3*R.B.=
 8 9 10 11 12 13 14 15
3:30 4:00 4:35
1.55 1.52 1.56
1.53 1.54 1.53
1.55 1.57 1.56
1.54 1.54 1.52
1.54 1.56 1.53
7.71 0 7.73 7.7 0 0 0 0
1.542 0 1.546 1.54 0 0 0 0
0.02 0.05 0.04
= Cpu=(USL-X.D.B)/(3*SIGMA=
MA= Cpk= Min.(Cpu.Cpl)=
TROL CHARTS

o. :-NRB Presure m/c

nt No. Height Gauge .01

X.B.= UCL=X.D.B.+A2R.B.= LCL=X.D.B. -A2R.B.=

16 17 18 19 20 21 22 23
 16 17 18 19 20 21 22 23

0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0

=
24 25 26 27 28 29 30 31
24 25 26 27 28 29 30 31

0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
 n A2 D3 D4 d2

2 1.88 0 3.27 1.13

3 1.02 0 2.57 1.69

4 0.73 0 2.28 2.06

5
0.58 0 2.11 2.33

ACTION

ON SPECIAL CAUSES

. ANY POINT OUTSIDE OF THE CONTROL LIMITS

. A RUN OF 7 POINTS ALL ABOVE OR ALL BELOW

THE CENTRAL LINE

. A RUN OF 7 POINTS UP OR DOWN

NOTE :- THE PROCESS MUST BE IN CONTROL BEFORE

CAPABILTY CAN BE DETERMINED.
NOTE :- THE PROCESS MUST BE IN CONTROL BEFORE
CAPABILTY CAN BE DETERMINED.
NOTE :- List of events occurred during the Study e.g. Material Change / Mould Change / Parameter Setting Change / Operato
Environment Like Temp. Voltage Fluctuation etc.

DATE SHIFT TIME COMMENTS (CHANGE OF DESCER

8.08.2015 B 3:30 NRB Presure Machine ,Operator Name;- ,Checking Parameter ;-Depth Bearing in Gear Starter Clutch PF
10.08.2015 B 4:00 NRB Presure Machine ,Operator Name;- ,Checking Parameter ;-Depth Bearing in Gear Starter Clutch PF
11.08.2015 B 4:30 NRB Presure Machine ,Operator Name;- ,Checking Parameter ;-Depth Bearing in Gear Starter Clutch PF

ACTION INSTRUCTIONS
eter Setting Change / Operator Change / Measurement Method Change / Change in

MENTS (CHANGE OF DESCERIPTIONS)

th Bearing in Gear Starter Clutch PF
th Bearing in Gear Starter Clutch PF
th Bearing in Gear Starter Clutch PF
Company Microturners-v Characteristic 14.00/14.03

Part Name Drive Assy USL 14.03

Part No. JA 621406 LSL 14

1 2 3 4 5 6 7
RANGE CHART (R.B.= AVERAGE OF R)= UCLr= D4*R.B.= LCLr=D3

DATE 1 2 3 4 5 6 7
TIME
 1
2
3
4
5
SUM 0 0 0 0 0 0 0
AVG. X-BAR 0 0 0 0 0 0 0
R (RANGE) 0
SIGMA= R.B./d2 Cp =(USL-LSL)/6*SIGMA=
Process Under Control YES / NO Cpl=(X.D.B.-LSL)/3*SIGMA=
 VARIABLE CONTROL CHARTS
14.00/14.03 Process Teeth Cutting Period

14.03 Sample Size 50 M / C. No. :-

14 Frequency 5 Instrument No. Microme

AVERAGE CHART (X BAR CHART) X.D.B. = Average X.B.=

7 8 9 10 11 12 13 14
 LCLr=D3*R.B.=

7 8 9 10 11 12 13 14
2:00 2:00 2:00
 14.02 14.03 14.01
14.01 14.02 14
14.01 14.03 14.01
14.01 14.02 14.01
14.01 14.02 14.02
0 0 0 0 0 70.06 70.12 70.05
0 0 0 0 0 14.012 14.024 14.01
0 0 0 0.01 0.01 0.02
6*SIGMA= Cpu=(USL-X.D.B)/(3*SIGMA=
)/3*SIGMA= Cpk= Min.(Cpu.Cpl)=
RIABLE CONTROL CHARTS
Period

M / C. No. :-

Instrument No. Micrometer .01 (094)

.B. = Average X.B.= UCL=X.D.B.+A2R.B.= LCL=X.D.B. -A2R.B.=

15 16 17 18 19 20 21 22
15 16 17 18 19 20 21 22
2:00
 14.01
14.01
14.01
14.01
14
0 0 70.04 0 0 0 0 0
0 0 14.008 0 0 0 0 0
0.01
-X.D.B)/(3*SIGMA=
n.(Cpu.Cpl)=
22 23 24 25 26 27 28 29
22 23 24 25 26 27 28 29
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
 n A2 D3 D4 d2

2 1.88 0 3.27 1.13

3 1.02 0 2.57 1.69

4 0.73 0 2.28 2.06

30 31
5
0.58 0 2.11 2.33

ACTION

ON SPECIAL CAUSES

. ANY POINT OUTSIDE OF THE CONTROL LIMITS

. A RUN OF 7 POINTS ALL ABOVE OR ALL BELOW

THE CENTRAL LINE

. A RUN OF 7 POINTS UP OR DOWN

NOTE :- THE PROCESS MUST BE IN CONTROL BEFORE

CAPABILTY CAN BE DETERMINED.
 NOTE :- THE PROCESS MUST BE IN CONTROL BEFORE
CAPABILTY CAN BE DETERMINED.

30 31
0 0
0 0
NOTE :- List of events occurred during the Study e.g. Material Change / Mould Change / Parameter Setting Change / Op
Environment Like Temp. Voltage Fluctuation etc.

DATE SHIFT TIME COMMENTS (CHANGE OF DE

12.08.15 A 2:00 Machine Name-Hobing 13,Operator - Naveen , Instrument Micrometer .01,Parameter-Span size ,Part Name :- Drive Assy 46 Te
13.08.2015 A 2:00 Machine Name-Hobing 13,Operator - Naveen , Instrument Micrometer .01,Parameter-Span size ,Part Name :- Drive Assy 46 Te
14.08.2015 A 2:00 Machine Name-Hobing 13,Operator - Naveen , Instrument Micrometer .01,Parameter-Span size ,Part Name :- Drive Assy 46 Te
17.08.2015 A 2:00 Machine Name-Hobing 13,Operator - Naveen , Instrument Micrometer .01,Parameter-Span size ,Part Name :- Drive Assy 46 Te

ACTION INSTRUCTIONS
ge / Parameter Setting Change / Operator Change / Measurement Method Change / Change in

COMMENTS (CHANGE OF DESCERIPTIONS)

1,Parameter-Span size ,Part Name :- Drive Assy 46 Teeth.
1,Parameter-Span size ,Part Name :- Drive Assy 46 Teeth,Instrument ' s No:-M-094
1,Parameter-Span size ,Part Name :- Drive Assy 46 Teeth,Instrument ' s No:-M-094
1,Parameter-Span size ,Part Name :- Drive Assy 46 Teeth,Instrument ' s No:-M-094
Company Microturners-v Characteristic 15.26/15.29

Part Name Drive Assy USL 15.29

Part No. JA 621406 LSL 15.26

1 2 3 4 5 6 7
RANGE CHART (R.B.= AVERAGE OF R)= UCLr= D4*R.B.= LCLr=D3

DATE 1 2 3 4 5 6 7
TIME
 1
2
3
4
5
SUM 0 0 0 0 0 0 0
AVG. X-BAR 0 0 0 0 0 0 0
R (RANGE) 0
SIGMA= R.B./d2 Cp =(USL-LSL)/6*SIGMA=
Process Under Control YES / NO Cpl=(X.D.B.-LSL)/3*SIGMA=
 VARIABLE CONTROL CHARTS
15.26/15.29 Process Teeth Cutting Period

15.29 Sample Size 50 M / C. No. :-Hobing

15.26 Frequency 5 Instrument No. Microme

AVERAGE CHART (X BAR CHART) X.D.B. = Average X.B.=

7 8 9 10 11 12 13 14
 LCLr=D3*R.B.=

7 8 9 10 11 12 13 14
2;15 2:15 2:15
 15.27 15.28 15.28
15.26 15.28 15.27
15.27 15.27 15.26
15.28 15.28 15.27
15.28 15.28 15.28
0 0 0 0 0 76.36 76.39 76.36
0 0 0 0 0 15.272 15.278 15.272
0 0 0 0.02 0.01 0.02
6*SIGMA= Cpu=(USL-X.D.B)/(3*SIGMA=
)/3*SIGMA= Cpk= Min.(Cpu.Cpl)=
RIABLE CONTROL CHARTS
Period

M / C. No. :-Hobing

Instrument No. Micrometer .01 (094)

.B. = Average X.B.= UCL=X.D.B.+A2R.B.= LCL=X.D.B. -A2R.B.=

15 16 17 18 19 20 21 22
15 16 17 18 19 20 21 22
2:15
 15.26
15.27
15.27
15.27
15.27
0 0 76.34 0 0 0 0 0
0 0 15.268 0 0 0 0 0
0.01
-X.D.B)/(3*SIGMA=
n.(Cpu.Cpl)=
22 23 24 25 26 27 28 29
22 23 24 25 26 27 28 29
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
 n A2 D3 D4 d2

2 1.88 0 3.27 1.13

3 1.02 0 2.57 1.69

4 0.73 0 2.28 2.06

30 31
5
0.58 0 2.11 2.33

ACTION

ON SPECIAL CAUSES

. ANY POINT OUTSIDE OF THE CONTROL LIMITS

. A RUN OF 7 POINTS ALL ABOVE OR ALL BELOW

THE CENTRAL LINE

. A RUN OF 7 POINTS UP OR DOWN

NOTE :- THE PROCESS MUST BE IN CONTROL BEFORE

CAPABILTY CAN BE DETERMINED.
 NOTE :- THE PROCESS MUST BE IN CONTROL BEFORE
CAPABILTY CAN BE DETERMINED.

30 31
0 0
0 0
NOTE :- List of events occurred during the Study e.g. Material Change / Mould Change / Parameter Setting Change / Op
Environment Like Temp. Voltage Fluctuation etc.

DATE SHIFT TIME COMMENTS (CHANGE OF DE

12.08.15 A 2:15 Machine Name-Hobing 11,Operator - Naveen , Instrument Micrometer .01,Parameter-Span size ,Part Name :- Drive Assy 18 Te
13.08.2015 A 2:15 Machine Name-Hobing 11,Operator - Naveen , Instrument Micrometer .01,Parameter-Span size ,Part Name :- Drive Assy 18 Te
14.08.2015 A 2:15 Machine Name-Hobing 11,Operator - Naveen , Instrument Micrometer .01,Parameter-Span size ,Part Name :- Drive Assy 18 Te
17.08.2015 A 2:15 Machine Name-Hobing 11,Operator - Naveen , Instrument Micrometer .01,Parameter-Span size ,Part Name :- Drive Assy 18 Te

ACTION INSTRUCTIONS
ge / Parameter Setting Change / Operator Change / Measurement Method Change / Change in

COMMENTS (CHANGE OF DESCERIPTIONS)

1,Parameter-Span size ,Part Name :- Drive Assy 18 Teeth.
1,Parameter-Span size ,Part Name :- Drive Assy 18 Teeth,Instrument No:-M-114
1,Parameter-Span size ,Part Name :- Drive Assy 18 Teeth,Instrument No:-M-114
1,Parameter-Span size ,Part Name :- Drive Assy 18 Teeth,Instrument No:-M-114
Company Microturners-v Characteristic 40.06 / 40.09

Part Name GSC USL 40.09

Part No. JA 621410 LSL 40.06

1 2 3 4 5 6 7
RANGE CHART (R.B.= AVERAGE OF R)= UCLr= D4*R.B.= LCLr=D3*R.B
 DATE 1 2 3 4 5 6 7
TIME
1
2
3
4
5
SUM 0 0 0 0 0 0 0
AVG. X-BAR 0 0 0 0 0 0 0
R (RANGE) 0
SIGMA= R.B./d2 Cp =(USL-LSL)/6*SIGMA=
Process Under Control YES / NO Cpl=(X.D.B.-LSL)/3*SIGMA=
 VARIABLE CONTROL CHARTS
40.06 / 40.09 Process Teeth Cutting Period

40.09 Sample Size 50 M / C. No. :-Hobing

40.06 Frequency 5 Instrument No. Micrometer .01 (09

AVERAGE CHART (X BAR CHART) X.D.B. = Average X.B.= UCL=X

8 9 10 11 12 13 14 15
LCLr=D3*R.B.=
 8 9 10 11 12 13 14 15
10:00 10:00
40.07 40.06
40.07 40.08
40.06 40.06
40.07 40.06
40.07 40.07
0 0 0 0 0 200.34 200.33 0
0 0 0 0 0 40.068 40.066 0
0 0 0 0 0.01 0.02
= Cpu=(USL-X.D.B)/(3*SIGMA=
MA= Cpk= Min.(Cpu.Cpl)=
TROL CHARTS

o. :-Hobing

nt No. Micrometer .01 (094)

X.B.= UCL=X.D.B.+A2R.B.= LCL=X.D.B. -A2R.B.=

16 17 18 19 20 21 22 23
 16 17 18 19 20 21 22 23

0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0

=
24 25 26 27 28 29 30 31
24 25 26 27 28 29 30 31

0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
 n A2 D3 D4 d2

2 1.88 0 3.27 1.13

3 1.02 0 2.57 1.69

4 0.73 0 2.28 2.06

5
0.58 0 2.11 2.33

ACTION

ON SPECIAL CAUSES

. ANY POINT OUTSIDE OF THE CONTROL LIMITS

. A RUN OF 7 POINTS ALL ABOVE OR ALL BELOW

THE CENTRAL LINE

. A RUN OF 7 POINTS UP OR DOWN

NOTE :- THE PROCESS MUST BE IN CONTROL BEFORE

CAPABILTY CAN BE DETERMINED.
NOTE :- THE PROCESS MUST BE IN CONTROL BEFORE
CAPABILTY CAN BE DETERMINED.
NOTE :- List of events occurred during the Study e.g. Material Change / Mould Change / Parameter Setting Change / Operato
Environment Like Temp. Voltage Fluctuation etc.

DATE SHIFT TIME COMMENTS (CHANGE OF DESCER

13.08.15 A 1:15 Machine Name-Hobing 11,Operator - Ashok , Instrument Micrometer .01,Parameter-Span size ,Part Name :- Gear Starter Clutch JA,Ins

ACTION INSTRUCTIONS
eter Setting Change / Operator Change / Measurement Method Change / Change in

MENTS (CHANGE OF DESCERIPTIONS)

size ,Part Name :- Gear Starter Clutch JA,Instrument 's No:M-114.
 Company Characteristic

Part Name USL

Part No. LSL

AVERAGE CHART (X BA

RANGE CHART (R.B.= AVERAGE OF R)= UCLr= D4*R.B.=

 DATE

TIME

3
4

SUM

AVG. X-BAR

R (RANGE)
SIGMA= R.B./d2 Cp =(USL-LSL)/6*SIGMA=

Process Under Control YES / NO Cpl=(X.D.B.-LSL)/3*SIGMA=

 VARIABLE CONTROL CHARTS
Process Period

Sample Size

Frequency Instrument No.

AR CHART) X.D.B. = Average X.B.= UCL=X.D.B.+A2R.B.=

LCLr=D3*R.B.=
Cpu=(USL-X.D.B)/(3*SIGMA=

Cpk= Min.(Cpu.Cpl)=
LCL=X.D.B. -A2R.B.=
n A2 D3 D4 d2

2 1.88 0 3.27 1.13

3 1.02 0 2.57 1.69

4
0.73 0 2.28 2.06

5
0.58 0 2.11 2.33
NOTE :- List of events occurred during the Study e.g. Material Change / Mould Change / Para

DATE SHIFT TIME

ACTION INSTRUCTIONS
hange / Parameter Setting Change / Operator Change / Measurement Method Change / Change in

COMMENTS (CHANGE OF DESCERIPTIONS)

/ Change in Environment Like Temp. Voltage Fluctuation etc.
 TPM Circle No.: Activity KK
MICRO TPM Circle Name: Loss no./
TURNERS, PANT
NAGAR Step
Dept: PROD. Result Area P
Cell No.: Cell Name:Hobbing cell Machine: Process / Stage : Inspe
Kaizen Theme: Idea : We arefound grind of broken area from top sid

To reduce cost of MOT gauge. COUNTERMEASURE:

Problem / Present status:

Carbide broken of MOT gauge during Before:
handling i.e gauge not use for inspection &
gauge scraped

Why- Why Analysis : Results:

WHY - 1 :MOt gauge broken.

WHY - 2 :Due to wrong handling.
WHY - 3 :No any idea scrap cost reduce of
MOT gauge.

Root No any idea scrap cost reduce of

Cause MOT gauge.

Registration no. & Date :

Registered by :
Manager's Sign :
 JH QM PM SHE OT DM E&T
Micro Turners, Pant Nagar

Q - Def. A C D S M Kaizen No.:

Process / Stage : Inspection
Operation : Inspection
broken area from top side

Bench Mark V-block setting time mo

Target Zero
After : KAIZEN Start 21.09.2014
KAIZEN Finish
Team Members:
1. Mr.Tejpal Gangwar
2.Mr.Arvind
3.Mr.Rohit Kumar

Benefits:

KAIZEN SUSTENANCE :
How to do :

What To Do

Scope & Plan for Horizontal Deployment

Target
Sr no Model Responsibility
Date
 o Turners, Pant Nagar

o.:
n : Inspection

V-block setting time more

Zero
21.09.2014

embers:

STENANCE :

rizontal Deployment
Responsibility Status