SHREE SPHEROTECH PVT.LTD.

CONTROL PLAN
Prototype Pre-launch ✘ Production `
Control plan No: SSPL/CP/ CI /10 Key Contact Person/Phone: Mr. Virendra Patil - 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --
Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018
Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SS Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --

CHARACTERISTICS METHODS
SR. PROCESS MACHINE,
SP. SAMPLE
NAME / DEVICE, JIG, PRODUCT /
CHAR. EVALUATION REACTION PLAN
OPERATION TOOLS FOR PROCESS Error CONTROL
NO. DESCRIPTION MFG. NO. PRODUCT PROCESS CLASS. SPECIFICATION / MEASUREMENT METHOD RECORD RESP.
Proofing
TOLERANCE TECHNIQUE SIZE FREQ.

RECEIPT OF RAW MATERIAL & INCOMING RAW

10
MATERIAL INSPECTION AFETR RECIVING OF MATERIAL
10A
AT FOUNDRY GET.

C --
0.5% Max

Si 0.5% Max --
Collect
P 0.15 % Max piece of --
Spectrometer same
S 0.15% Max type --
from lot Per lot
Incoming If Found not ok, Reject
& grind (As per --
Mn 0.2% Min Incoming Raw Asst. Lab material & Inform to
M. S. Scrap for Incomin
Inspection material Incharge, Purchase dept. &
Cr. 0.2% Max spectro g quality --
sample. Register Supplier,
Plan)
Plate Fish/Angle
--
Type Cutting
size 2cm X 2cm Min. --
Visual
Free From Oil,
Rust, Tor Steel, 1 --
Nature Moisture
C 3.5 to 4.3 % --

Si 2.0 to 2.5 % --
Supplier T
If Found not ok, Reject
-- C& Store I/C,
Test Cetificate with Every Incoming material & Inform to
CI Pig Iron Mn 0.4 to 1.0 % 1 Incoming Asst. Lab
every supply. Supply Inspection Purchase dept. &
Inspection Incharge
Supplier,
Register
 Supplier T
If Found not ok, Reject
C& Store I/C,
Test Cetificate with Every Incoming material & Inform to
CI Pig Iron 1 Incoming Asst. Lab
every supply. Supply Inspection Purchase dept. &
Inspection Incharge
-- Supplier,
P 0.15 % Max Register

--
S 0.10 % Max
 Visual Insp.for If Found not ok, Reject
Every Incoming Asst. Lab material & Inform to
CI Boring Scrap rust, oil free & Visual Insp 1 -- No record
Supply Inspection Incharge Purchase dept. &
sutable size
Supplier,
C 3.00-4.00 % --

Si 1.70-2.30 % Inhouse --
Inspection melt -- Supplier T
Mn 0.40 % max Incoming If Found not ok, Reject
100-200Kg of C& Store I/C,
Pipe Scrap Every Inspection material & Inform to
S 0.01 % max Pipe scrap in 1 -- Incoming Asst. Lab
( DI Scrap ) Supply Purchase dept. &
furnace, take Inspection Incharge
P 0.07 % max -- Supplier,
spectro of same & Register
check. --
Cr 0.05 % max
Ti 0.06 % max --

VM 2% Max --

S.% 1.5% Max --

Test Cetificate with Supplier T
every supply, also If Found not ok, Reject
C&
Moisture % 1% Max on actual use. Every -- Incoming Asst. Lab material & Inform to
CPC (If possible check
1 Incoming
Supply Inspection Incharge Purchase dept. &
recovery from Inspection
Supplier,
Ash% 1% Max spectro) -- Register

Fixed C.% By Difference --

--
Moisture 12 % Max Supplier T
Supplier Test If Found not ok, Reject
C&
Maxicarb Cetificate with Every Incoming Asst. Lab material & Inform to
every supply &
1 -- Incoming
(Amcol) VM 15-40 Supply Inspection Incharge Purchase dept. &
inhouse inspection Inspection
Supplier,
--
Register
LOI 30-55
Swelling Value 28-45 --
50 sec to 80 sec.
Gelling Time Supplier Test --
Max
Cetificate with Random
ly
pH Value 8 to 11 every supply & collect --
Supplier T
inhouse small If Found not ok, Reject
Moisture % 8 % Max. -- C&
inspection Qty. Every Incoming Asst. Lab material & Inform to
Bentonite from 4- Supply Incoming
370-500 ml/ gm Inspection Incharge Purchase dept. &
M.B.Value 5 bags -- Inspection
Min Supplier,
mix Register
throughl
y. --
Free from lumps &
Nature contamination. Visual --
Powder form
--
 Random
Volatile Matter % 60 ±10% ly --
collect
5 Max Test Cetificate with small -- Supplier T C
If Found not ok, Reject
Coal Dust/ / Ash Content % Qty. Every Incoming & Incoming Asst. Lab
every supply & from 4- Supply Inspection Inspection Incharge
material & Inform to
Pitch Powder inhouse inspection 5 bags Purchase dept. & Supplier,
Register
By Difference mix --
Random
throughl
Fixed C.% ly
y.
collect
AFS No. 45-65 sand --
from
Moisture % 7 % Max Test Cetificate with
differnt -- Supplier T C
If Found not ok, Reject
Silica Sand every supply &
location Every Incoming & Incoming Asst. Lab
material & Inform to
(Washed) Clay Content 2.0 % Max from Supply -- Inspection Inspection Incharge
inhouse inspection Purchase dept. & Supplier,
received Register
lot &
Sand Distribution Single Pick mix --
throughl
Test Cetificate with y& --
Si = every supply, also on Check
2%max actual use. --
Ca = (If possible check Supplier T C
recovery from If Found not ok, Reject
1.50 - 2.50 % Every Incoming & Incoming Asst. Lab
Innoculant spectro). 100% -- material & Inform to
Al. = Max Supply Inspection Inspection Incharge
Purchase dept. & Supplier,
Register
Ba = 2.5 %max --

Size = 2-6mm Visual --

No.460 Test Cetificate -- If Found not ok, Reject

Supplier T Store I/C,
with every supply Every Incoming material & Inform to
Steel Shots Size No.550 -- C , No Asst. Lab
Supply Inspection Purchase dept. &
Record Incharge
Supplier,
Visual --

PREPARED BY: Mr. Sachin Kumbhar REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
 MARVELOUS VIMERCATI FOUNDRY PVT.LTD.
CONTROL PLAN
Prototype Pre-launch Production ✘ `
Control plan No: MVF/CP/SG / 40 Key Contact Person/Phone: Mr. S.S.Kumbhar 9689899362
Part No./Latest Change Level: All SG Iron Items Core Team VIP, PDJ, SSK
Part Description All SG Iron Items Other Approval / Date (If required ) --
Supplier plant : --- Date (Original) 01.10.10
Supplier code --- Date (Revised) 28.02.11
Prepared by SSK Customer Engg. Approval date if reqd. --
Approved by PDJ Customer Quality Approval date if reqd. Other Approval / Date (If required )

CHARACTERISTICS METHODS
SR. MACHINE,
PROCESS NAME SP.
DEVICE, JIG, PRODUCT / SAMPLE CONTROL METHOD
/ OPERATION CHAR. EVALUATION
TOOLS FOR PROCESS
DESCRIPTION NO. PRODUCT PROCESS CLASS. MEASUREMENT
NO. MFG. SPECIFICATION
TECHNIQUE SIZE FREQ. RECORD RESP.
/ TOLERANCE

40 Sand preparation Sand Mixer Sand preparation Green sand

Additions
1 Bentonite 0.5 to 1.5 % Weighing 1 Per Green Mixer Operetor,
Hour Sand Line Inspector,
2 Coal Bond 0.5 % Max. Weighing
Testing Shift
Silica 10 % Max. Weighing Record Supervisor, QA
3
(Fresh)Sand Sheet Incharge,
4 Return Sand 90% Min. by Timer(Range 0 to MVF/QA/F/
60Sec.LC-1 Sec) 01
5 Mulling time 120-135 Sec by Timer(Range 0 to
180Sec.LC-6 Sec)
As per by Timer(Range 0 to
6 Water 30Sec.LC-0.6Sec)
Requirement
Sand Inspection sand testing Green Sand
Equipment
80 to 150 NO. Measurment of 1 sample Green Line Inspector,
1 Permeability Permeabillity of per Sand Shift
sand by Tester Hour Testing Supervisor, QA
Record Incharge,
Compression 1000 to 1600 Measurment of Sheet
2
Strength gm/sq.cm. compression
<SC> 2.8 to 3.5 % strength of sand
Measurment of MVF/QA/F/01
by Strangth
moisute by M/C
3 Moisture
moisture tester

38 TO 50 mm Measurment of
4 Compactibiity Compactibiity of
sand by scale
 MARVELOUS VIMERCATI FOUNDRY PVT.LTD.
CONTROL PLAN
Prototype Pre-launch Production ✘ `
Control plan No: MVF/CP/SG / 40 Key Contact Person/Phone: Mr. S.S.Kumbhar 9689899362
Part No./Latest Change Level: All SG Iron Items Core Team VIP, PDJ, SSK
Part Description All SG Iron Items Other Approval / Date (If required ) --
Supplier plant : --- Date (Original) 01.10.10
Supplier code --- Date (Revised) 28.02.11
Prepared by SSK Customer Engg. Approval date if reqd. --
Approved by PDJ Customer Quality Approval date if reqd. Other Approval / Date (If required )

CHARACTERISTICS METHODS
SR. MACHINE,
PROCESS NAME SP.
DEVICE, JIG, PRODUCT / SAMPLE CONTROL METHOD
/ OPERATION CHAR. EVALUATION
TOOLS FOR PROCESS
DESCRIPTION NO. PRODUCT PROCESS CLASS. MEASUREMENT
NO. MFG. SPECIFICATION
TECHNIQUE SIZE FREQ. RECORD RESP.
/ TOLERANCE

10-16% Washing of sand 1 Weekly Sand Lab Inspector,

5 Total Clay to find out total Testing QA Incharge,
Clay by Washer Work sheet
MVF/QA/F/
8-11 % Determine Active
02
Clay by
6 Active Clay volumetric
method by MB
Test instrument.
3-5 % Subtraction of
7 Dead Clay Ative Clay from
Total clay
2-4 % Weight Analysis
8 VM
of sand by
3-6% burning
Weight Analysis
9 LOI of sand by
burning
60-80% Measurment of
10 AFS No. verious grain size
by seives
PREPARED BY: APPROVED BY

Revision Record:
Date Rev. No Existing Changed to Reason of change

28.02.2011 1 Nil Tolerances for Mulling time defined Suggestion during Internal Audit
 REACTION PLAN

Mulling Time and Raw

material addition
changes as per the sand
properties changes and
required

If not within the Range,

Reject the sand & Refer
Annexure A
 REACTION PLAN

If not within the Range

Refer Annexure A &
Adjest the Bentonite ,
water, coal compound
and fresh sand

Addition of req. AFS

sand
 SHREE SPHEROTECH PVT.LTD.
CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/CP/ CI /20 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --
Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018
Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --

CHARACTERISTICS METHODS
SR. MACHINE,
PROCESS NAME SP.
DEVICE, JIG, PRODUCT / SAMPLE
/ OPERATION CHAR. EVALUATION REACTION PLAN
TOOLS FOR PROCESS Error CONTROL
DESCRIPTION NO. PRODUCT PROCESS CLASS. MEASUREMENT RECORD RESP.
NO. MFG. SPECIFICATION / Proofing METHOD
TOLERANCE TECHNIQUE SIZE FREQ.

No.damage,
Damage, Crack, crack , Loose, Pattern
loose Getting , thick or excess 1stl y Verification
Pattern Maker, If Found Damage,
Riser, Runner, used wear plate, When Inprocess Record
1 Visual Inspection 1 -- Molding Rework, refit the
wear plate, Parting adquate Parting Molding Inspection Register
Supervisor Pattern
Line, Vent, core Line, Provision of Started -SSPL-PS-
print vents, proper R-01
core prints

Match Plate
2 Ø25mmX5" Snap guage --
PATTERN & -Round Pin
CORE BOX
Match Plate -Flat
20 EQUIPMENT 3 Ø21mmX5" Snap guage --
Pin
VERIFICATION /
INSPECTION Match Plate- Ø25mmXØ32mmX
4 25mm
Snap guage -- Pattern
Round Pin
1stly Verification Pattern Maker, If Found damage or
Closing -Round When Inprocess Record
5 Ø25mmX13" Snap guage 1 -- Molding wareout, replace the
Pin Molding Inspection Register
Supervisor bush & pins.
Started SSPL-PS-R-
6 Closing -Flat Pin Ø21mmX13" Snap guage -- 01

Molding Box Ø25mmXØ30mmX

7 25mm
Plug guage --
-Round Bush
Molding Box -Flat Ø21mmXØ32mmX
8 25mm Plug guage --
Bush

PREPARED BY: Mr. Sachin Kumbhar REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
 SHREE SPHEROTECH PVT.LTD.

CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/CP/ CI /30 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --
Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018
Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --

CHARACTERISTICS METHODS
SR. MACHINE,
PROCESS NAME SP.
DEVICE, JIG, SAMPLE
/ OPERATION CHAR. PRODUCT / EVALUATION REACTION PLAN
TOOLS FOR PROCESS Error CONTROL
DESCRIPTION NO. PRODUCT PROCESS CLASS. MEASUREMENT RECORD RESP.
NO. MFG. SPECIFICATION / Proofing METHOD
TOLERANCE TECHNIQUE SIZE FREQ.

30 MOULD SAND Sand Mixer Sand

PREPARATION Testing
Themocuple at record proper distribute return
Return Sand Per Inprocess Molding
45°C Max. return sand 1 - sheet - sand in Sand storage
Temp. Hour Inspction Supervisor,
hopper SSPL- hopper
PROD-F-
03
Sand preparation Green sand
Additions
1 -------------------> Bentonite 0.5 to 1.5 % Weighing Scale 1 Per -- Mixer Operetor, Mulling Time and Raw
Hour Molding material addition
2 -------------------> Coal Bond 0.5 % Max. Weighing Scale -- Supervisor, changes as per the sand
Green Foundry properties changes and
Silica 10 % Max. Sand
3 -------------------> Weighing Scale -- Manager required
(Fresh)Sand Testing
90% Min. Inprocess
4 -------------------> Return Sand Timer -- Record
Inspction
Sheet
120-135 Sec SSPL/QA/
5 -------------------> Mulling time Timer -- F/26
As per
6 -------------------> Water Requirement Timer --

30A SAND TESTING sand testing Green Sand

Equipment
130 to 230 NO. Permeabillity 1 sample Green Molding If not within the Range,
1 Permeability --
Tester per Sand Supervisor, Reject the sand & Refer
Compression 1100 to 1500 GCS Strangth Hour Testing Annexure A
2 -- Inprocess Record
Strength gm/sq.cm. M/C
Inspction Sheet -
3 Moisture <SC> 2.8 to 3.5 % moisture tester -- SSPL-
PROD-F-
03
 SHREE SPHEROTECH PVT.LTD.

CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/CP/ CI /30 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --
Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018
Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --
30A SAND TESTING sand testing
CHARACTERISTICS METHODS
Equipment
SR. MACHINE, 1 sample Green Molding If not within the Range,
PROCESS NAME SP. per Sand Supervisor, Reject the sand & Refer
DEVICE, JIG, SAMPLE
/ OPERATION CHAR. PRODUCT / EVALUATION Hour Testing REACTION
Annexure PLAN
A
TOOLS FOR PROCESS Error CONTROL
DESCRIPTION NO. PRODUCT PROCESS CLASS. MEASUREMENT RECORD
Record RESP.
NO. MFG. SPECIFICATION / Proofing Inprocess
METHOD
TOLERANCE TECHNIQUE SIZE FREQ. Inspction Sheet -
SSPL-
Compactibiity PROD-F-
4 Compactibiity 35 TO 45 mm -- 03
scale
Clay Washer & 1 sample Sand Lab Inspector, If not within the Range
5 Total Clay 10-14% --
Weighing Scale per Day Testing QA Refer Annexure A &
7-10 % MB Test Work sheet Incharge,Found Adjest the Bentonite ,
6 Active Clay -- - ry manager water, coal compound
instrument.
SSPL/QA/ and fresh sand
3-7 % Subtraction of F/26
7 Dead Clay Ative Clay from -- Inprocess
Total clay Inspction
8 VM 3-6 % Muffle furnace --

9 LOI 3-6% Muffle furnace --

50-75% Test seives Addition of req. AFS
10 AFS No. --
sand

PREPARED BY: Mr. Sachin Kumbhar REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
 SSPL/CP/CI/30
SHREE SPHEROTECH REV.00
PVT.LTD. DATE:21.05.2015

Annexure A
Property Limit Observation Action Plan
1.50-75 AFS caI Fresh Sand sa^ND Addition
10 % poxaa vaaZivaNao
kmaI 2. Coal Compound Addition 300 gms p`maaNao
Total Clay 10-14 % vaaZIvaNao Fine Tuning krNao.
Blowing caalau krNao. sa^ND caa ipk
14 % poxaa baGauna jyaa AFS vartI Peak Value kamaI
jaast Aaho %yaa AFS caI sa^ND Addition caalua
k$na Fine Tuning krNao.
1.Bentonite Addition 500 gm nao vaaZvauna prt
Report caok krNao, ,yaaogya nasalyaasa prt
7.0 % poxaa 500gm Bentonite Addition krNao.
kmaI 2. Fresh Sand Addition kmaI krNao,(Permiability
Active Clay 7.0 -10.0 % yaaogya yaot Asaola tr)

Bentonite Addition 500 gm nao kmaI krNao va

10.0 % poxaa
Report caok krNao, yaaogya nasalyaasa prt
jaast
500gm Bentonite Addition kmaI krNao.
1.Coal Compound Addition 200 gm nao
3.00% poxaa
vaaZvauna Fine Tunning krNao,.Blowing
kmaI
caalau Asalyaasa baMd krNao.
Dead Clay 3.00-7.00 %
Coal Compound Addition 200 gm nao kmaI k$na
7.00 % poxaa
Fine Tunning krNao,.Blowing caalau k$na Fines
jaast
baahor kaZNao
3.00% poxaa 1.Fresh Sand Addition- Permeability yaoagya
kmaI zovat vaaZvaNao.
VM 3.00-6.00 %
6.00 % poxaa 1.Fresh Sand Addition- Permeability yaoagya
jaast zovat kmaI krNao. 28-38 Sec

1. Coal Compound Addition 200 gm Per Mixer nao

3.00% poxaa vaaZvauna Fine Tunning krNao,.
kmaI
2.Fresh Sand Addition 5 Kg/ Mixer kmaI krNao.
LOI 3.00-6.00 %
1. Coal Compound Addition 200 gm Per Mixer kmaI
6.00% poxaa k$na Fine Tunning krNao,.
jaast
2.Fresh Sand Addition 5 Kg/ Mixer vaaZivaNao.
50 poxaa 1.65-70 AFS caI Fresh Sand Addition caalau
kmaI krNao.
AFS No. 50-75 75 poxaa 1. Blowng caalau krNao.
jaast 2. 50-75 AFS caI Fresh Sand Addition caalau
krNao.

PREPARED BY: Mr. Sachin Kumbhar REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
 SSPL/CP/CI/30
SHREE SPHEROTECH REV.00
PVT.LTD. DATE:21.05.2015

Annexure A
Property Limit Observation Action Plan
1.Fresh Sand addition (50-55 AFS)caI 5Kg/ Mixer
k$na Permeability caok kravaI va prt fine
130 poxaa tunning kravao.
kmaI 2.Coal Compound Addition 300 gm kmaI k$na
Permeability caok kravaI va prt fine tunning
Permeability 130-230 kravao.
1.Fresh Sand addition (50-55 AFS)caI 5Kg/ Mixer
kmaI k$na Permeability caok kravaI va prt fine
230% poxaa tunning kravao.
jaast 2.Coal Compound Addition 300 gm vaaZvauna
Permeability caok kravaI va prt fine tunning
2.8% poxaa kravao.
1 laITr paNaI vaaZvaavao.
Moisture 2.8-4.0 % kmaI
4.0% poxaa
1 laITr paNaI kmaI kravao.
jaast
1.Bentonite Addition 500 gm nao vaaZvaNao.
1000% poxaa 2.Mixing Time 20 Sec. nao vaaZvaNao.
Green kmaI
3.Fresh Sand addition Permeability iktI yaoto to
Compression 1000-1400 %
baGauna kmaI krNao.
Strength
1400% poxaa 1.Bentonite Addition 500 gm nao vaaZvaNao.
jaast 2.Mixing Time 20 Sec. nao kmaI krNao.
1.Moisture % caok k$na 3.2% pya-Mt Adjust
35% poxaa kravao
2.Fresh Sand addition Permeability iktI yaoto to
kmaI
Compatibility 35- 50 % baGauna kmaI krNao.
50% poxaa 1. Fresh Sand addition Permeability iktI yaoto to
jaast baGauna 5 Kg / Mixer vaaZvaNao.
1. Pnumatic Rammer vaaprNao.
80 poxaa
2.Squeeze time 1 sec. nao vaaZvaNao.
kmaI
3. Jolt time 1 sec. nao vaaZvaNao.
Mold Hardness 80-95
1. Pnumatic Rammer vaap$ nayao.
95 poxaa
jaast 2.Squeeze time 1 sec. nao kmaI krNao.
3. Jolt time 1 sec. nao kmaI krNao.

PREPARED BY: Mr. Sachin Kumbhar REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
 SHREE SPHEROTECH PVT.LTD.
CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/CP/ CI /40 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --
Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018
Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --
CHARACTERISTICS METHODS
PROCESS SP.
SR. MACHINE,
NAME / CHA PRODUCT / SAMPLE
DEVICE, JIG, EVALUATION REACTION
OPERATION R. PROCESS Error
TOOLS FOR NO. PRODUCT PROCESS MEASUREMENT
CONTROL
RECORD RESP. PLAN
DESCRIPTIO CLAS SPEC'N/ Proofing METHOD
NO. MFG. TECHNIQUE
N S. TOLERANCE SIZE FREQ.

40 Moulding Moulding Heat No & Process Sheet

Per for molding If Not Found
machine Date Code As per method 1st piece SSPL/PRD/F- Molding
( Jolt 1 on Casting Visually 1 Heat -- Inform to Q.A.
Card approval 02 Supervisor
squeeze Load for that Batch
machine)
Mould Process Sheet If Found rough
85 to 95 no. for molding
2 hardness mold surface,
Horizontal 5 time SSPL/PRD/F-
Mould hardness Per 1st piece 02 Molding sand Fall & less
<SC> and per --
tester Shift approval Supervisor, mold Hardness
75 to 85 no. Item
Reject the mold
Vertical
& Return Sand in
Damage, Visual muller, check
3 Crack, loose Inspection No.damage, sand properties
Per Inprocess Molding & take app.
Sand, crack , Loose Visually 100% --
Shift inspection Verification Supervisor Action
venting sand etc.

Ingate Must be uniform Inprocess Molding

4 Painting Visually 1 1 Repaint
and continuous inspection supervisor
Air 5.5 to 8 Kg/sq Air pressure 1st piece Process Molding Inform to
5 First Piece -- Supervisor . Stop
Pressure cm2 gauge approval Sheet for Supervisor
molding molding & correct
Jolting & Inform to
the pressure
squeze SSPL/PRD/ Supervisor . Stop
1st piece F-02 Molding
6 Time 3 Second Timer 1 Per Set molding & correct
approval Supervisor the Jolting Time

Placing of No Record Rejet the Mold.

Filter Molding
Ceramic Filter &
7 Visually 1 1 Supervisor,
Shell Filter
Molder
PREPARED BY: Mr. Sachin Kumbhar REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
 SHREE SPHEROTECH PVT.LTD.

CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/CP/ CI /50 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --

Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018

Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,M Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --
CHARACTERISTICS METHODS
SP.
SR. PROCESS MACHINE,
CHAR PRODUCT / SAMPLE
NAME / DEVICE, JIG, EVALUATION
. REACTION PLAN
OPERATION TOOLS FOR PROCESS Error CONTROL
NO. PRODUCT PROCESS CLAS MEASUREMENT RECORD RESP.
NO. DESCRIPTION MFG. SPEC'N/ Proofing METHOD
S. TECHNIQUE SIZE FREQ.
TOLERANCE

Scratch Core Hardness Verification , Core shop

PREPARE 1 55 Min 5 nos. per lot --
Hardness tester Core Supervisor
CORE
Outside Incoming Inspection If Found Defected Reject the
50 (OUTSIDE
Source Damage, inspection Register Core
SOURCE)
2 Finish, Defect Free Visually -- SSPL/CS/F-
Shell Core Baking Color 01

PREPARED BY: Mr. Sachin Kumbhar REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
 SHREE SPHEROTECH PVT.LTD.

CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/CP/ CI /60 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --
Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018
Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,M Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --
CHARACTERISTICS METHODS
SP.
SR. PROCESS MACHINE,
CHAR PRODUCT / SAMPLE
NAME / DEVICE, JIG, EVALUATION
. PROCESS Error CONTROL REACTION PLAN
OPERATION TOOLS FOR
NO. PRODUCT PROCESS CLAS MEASUREMENT RECORD RESP.
NO. DESCRIPTION MFG. SPEC'N/ Proofing METHOD
S. TECHNIQUE SIZE FREQ.
TOLERANCE

As per process
1 Core Setting Visual 1 1 -- Verfication
card
Inprocess Molding If Found no proper Setting &
60 Core Setting Manually
inspection Supervisor sand fall Reject the mold.
Venting
2 As on pattern Visual 1 1 -- No Record
Location

PREPARED BY: Mr. Sachin Kumbhar REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
 SHREE SPHEROTECH PVT.LTD.

CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/CP/ CI /70 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --
Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018
Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,M Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --
CHARACTERISTICS METHODS
SP.
SR. PROCESS MACHINE,
CHAR PRODUCT / SAMPLE
NAME / DEVICE, JIG, EVALUATION Error
. PROCESS REACTION PLAN
OPERATION TOOLS FOR NO. PRODUCT PROCESS CLAS MEASUREMENT Proofin
CONTROL
RECORD RESP.
NO. DESCRIPTION MFG. SPEC'N/ METHOD
S. TECHNIQUE SIZE FREQ. g
TOLERANCE

70 Mold Closing : Manually

Verification, Molding
Clamping & Filter 1 Clamping Tight Clamping Visually 1 1 -- Tighten
No Record Supervisor
Placement
If required as
Filter Inprocess Verification, Molding
2 per process Visually 1 1 -- Place filter
Placing Inspection No Record Supervisor
card

Mold No Mold Verification, Molding If mold Crush Observed Reject

3 Visually 1 1 --
Crushing Crushing No Record Supervisor the Mold.

PREPARED BY: Mr. Sachin Kumbhar REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
 SHREE SPHEROTECH PVT.LTD.

CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/CP/ CI /80 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --
Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018
Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SS Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --
CHARACTERISTICS METHODS
SR. PROCESS MACHINE,
SP.
NAME / DEVICE, JIG, PRODUCT / CONT REACTION
CHAR. EVALUATION SAMPLE Error
OPERATION TOOLS FOR PROCESS ROL PLAN
NO. PRODUCT PROCESS CLASS. MEASUREMEN Proofi RECORD RESP.
NO. DESCRIPTION MFG. SPECIFICATION / METH
T TECHNIQUE SIZE FREQ ng OD
TOLERANCE .
80 CHARGE Induction 1 Pig Iron As per Annex B weighing scale 1 Per -- Inproc Productio Melting CRCA,
PREPARATION Furnace (% of Charge Mix Heat ess n log Supervisor, Shellcoke or
2 M.S Scrap 10-20% of Pig Iron, MS inspe sheet graphite,Fesi
Scrap. & R.R. is ction SSPL/PR , FeMn.,
Returns / on Avalability of D/F-01 Copper will
3 10-30%
Boring Certain be adjust
Material)Refer until you get
4 R.R Balance annexure B requd.
Chemistry on
5 DI Scrap 20-30% ferrolab/
Spectro.
As Per Process
6 C.P.C ( Carbon)
Requirment
As Per Process
7 Ferro Silicon
Requirment
Ferro As Per Process
8
Manganese Requirment
As Per Process
9 Copper
Requirment

PREPARED BY: Mr. Sachin Kumbhar REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
 SSPL/CP/CI/ 80

SHREE SPHEROTECH PVT.LTD. REV.00

DATE: 21.05.2015

Annexure B
Contingency Plan for Charge Mix
Sr. No. Situation Our Action

If Pig Iron(CI & SG) not available in 1.Add more amount of MS steel for cast iron & CRCA
1
totally or some amount scrap for Sg Iron to adjest the charge in kg.

2.Add more amount of CPC for Cast Iron % shell coke for
SG Iron to adjest the C%

3.Add more amount of FeSi to adjest the Si.%

4.Add more runner riser to makeup the charge in Kg.

PREPARED BY: Mr. Sachin

REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
Kumbhar
 SHREE SPHEROTECH PVT.LTD.

CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/CP/ CI /90 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --
Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018
Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --
CHARACTERISTICS METHODS
SR. PROCESS
MACHINE, SP.
NAME / EVALUATION SAMPLE Error CONTRO REACTION
DEVICE, JIG, CHAR. PRODUCT / PROCESS
OPERATION NO. PRODUCT PROCESS MEASUREMENT
L
Proofin METHO RECORD RESP. PLAN
TOOLS FOR MFG. CLASS. SPECIFICATION /
NO. DESCRIPTION TOLERANCE TECHNIQUE SIZE FREQ. g D

90 Melting Induction
Molten Metal Bath Composition Production
Furnace Inprocess
Per log sheet Melting
1 Inspectio
1 Carbon 3.20 To 3.30 % Heat n SSPL/PRD Supervisor ( To reduce C
Ferro lab machine -- /F-01 %,Si %, Mn%
2 Silicon 1.70 To 1.80 % add CRCA ) or
( To increase C
1 Carbon 3.20 To 3.30 % % , Si % , Mn
2 Silicon 1.70 To 1.80 % add
Recarboriser
3 Manganese 0.60 To 90 % Inproce Graphite &
Per ss Spectro Melting FeSi & FeMn )
4 Sulphur 0.2% Max Spectrometer 1 --
Heat Inspecti Report Supervisor The qty should
on not exceed
5 Phosporous 0.2% Max specified %)
6 Copper 0.2% Max
7 Cromium 0.10 To 0.20 %

Inproces Production Correct the

Temp. of Per s log sheet Melting
8 <SC> 1500 - 1520°C Temp. pyrometer 1 -- Inspecti SSPL/PRD Supervisor temp. & then
Molten metal. Heat
on start the pouring
/F-01

PREPARED BY: Mr. Sachin Kumbhar REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
 SHREE SPHEROTECH PVT.LTD.

CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/CP/ CI /100 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --
Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018
Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.S Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --
CHARACTERISTICS METHODS
SR.
PROCESS MACHINE,
SP.
NAME / DEVICE, JIG, PRODUCT / EVALUATION SAMPLE
CHAR. Error REACTION PLAN
OPERATION TOOLS FOR NO. PRODUCT PROCESS
PROCESS
MEASUREMENT CONTROL
RECORD RESP.
CLASS. SPECIFICATION / Proofing METHOD
DESCRIPTION MFG. TECHNIQUE
NO. TOLERANCE SIZE FREQ.

100 Inoculation & 250 Kg Pouring

Pouring laddle Weighing scale Inprocess
1 Innoculation 0.3% 1 Per Laddle --
Inspection
(done at stores)

Production
1 st box Log sheet & If temp. is high then ,
Measurment of Metal
2 pooring 1420°C 1 Per Heat -- Process correct the temp. &
Temp. by Pyrometer Melting then start the pouring
Temp Sheet for
Supervisor
molding
Inprocess SSPL/PRD/
Inspection F-02

last Box If temp. is low then ,

Measurment of Metal retreat the laddle &
3 pooring 1380°C 1 Per Heat --
pour back into the
Temp. by Pyrometer
Temp furnace

Per Laddle
Preparation
of Spectro As per metal Grade As per metal Grade Inprocess Spectro
Spectrometer 1 Chemistry
sample specification specification Inspection report
speciman

PREPARED BY: Mr. Sachin Kumbhar REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
 SHREE SPHEROTECH PVT.LTD.

CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/CP/ CI /110 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --
Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018
Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.S Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --
CHARACTERISTICS METHODS
SR. PROCESS
MACHINE,
NAME / SP. SAMPLE
DEVICE, JIG, PRODUCT / CONTR
OPERATION CHAR. EVALUATION Error REACTION PLAN
TOOLS FOR PROCESS OL
DESCRIPTIO NO. PRODUCT PROCESS CLASS. MEASUREMENT Proofin RECORD RESP.
MFG. SPECIFICATIO METHO
NO. N TECHNIQUE SIZE FREQ. g D
N / TOLERANCE

110 If boxes knock-out

before the time
Measurment of
45 Minutes after Melting specified then
1 Cooling Time Time on countdown 1 1 -- No Record
pouring supervisor segregate through
timer.
hardness & chilling
effect.
Inprocs
Poured Mold If knock-out cycle is
Knock-out 10 to 15 sec on Personal judgment s
cooling & Melting insufficient for sand
Machine 2 Knockout Time knockout by expiriance 1 1 -- Inspect No Record
Knockout supervisor loosening , then
machine persons ion
repeat the cycle.

If knock-out cycle is
Sand
Sand free Melting insufficient for sand
3 adhering to Visually 1 1 -- No Record
Casting supervisor loosening , then
Castings
repeat the cycle.

PREPARED BY: Mr. Sachin Kumbhar REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
 SHREE SPHEROTECH PVT.LTD.

CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/CP/ CI /120 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --
Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018
Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --
CHARACTERISTICS METHODS
SR. PROCESS MACHINE, SAMPLE
SP. PRODUCT /
NAME / DEVICE, JIG, EVALUATION Error CONT
CHAR. PROCESS REACTION PLAN
OPERATION TOOLS FOR NO. PRODUCT PROCESS MEASUREMENT Proofi ROL
NO. DESCRIPTION MFG.
CLASS. SPECIFICATION / FREQ METH RECORD RESP.
TECHNIQUE SIZE ng OD
TOLERANCE .

120 Shot blasting Shot blasting 1 Stage Time - 5

Mashine Shot blasting to 7 Min. Fettling & Job
1 Timer 1 1 -- No Record
Time 2 Stage Time - 2 Inspector
to 4 Min. If the casting
Sand cleaning is not
2 adhering to Sand free Casting Visually 1 1 -- proper , then repeat
Inproc No Record
Castings the cycle. If the
ess
problem remains for
Inspe
Daily more than I week,
Verify the casting ction
Inspection change the S/B time
cleaning , free from
Report & after process re-
Foundry foundry defects Fettling & Job
3 Visually 1 1 -- Rejection validation.
Defects like sand drop , Inspector
Report
cold shut , shift ,
SSPL/QA/
crack etc.
F-04
incom
Incoming
ing Fettling & Reject If Not Found
4 Shot Size S 550 Visual 100% - --
Inspe
Inspection
Lab.Asst. As Per Std
Register
ction

PREPARED BY: Mr. Sachin Kumbhar REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
 SHREE SPHEROTECH PVT.LTD.

CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/CP/ CI /130 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --
Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018
Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SS Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --
CHARACTERISTICS METHODS
SR.
PROCESS MACHINE, PRODUCT /
SP. SAMPLE
NAME / DEVICE, JIG, PROCESS EVALUATION Error CONTRO
CHAR. REACTION PLAN
OPERATION TOOLS FOR NO. PRODUCT PROCESS L
CLASS. SPECIFICATIO MEASUREMENT Proofin METHO RECORD RESP.
DESCRIPTION MFG. N/ TECHNIQUE g
NO. SIZE FREQ. D
TOLERANCE
130 Fettling Grinders, No extra metal /
Cutters 1 Extra Metal Visually 1 1 -- Rework the casting
fins
Excess Visual
No Excess Inproce
2 Felling / Visually 1 1 -- Inspection Reject
Felling / Grinding ss
Grinding cum QA Inspecter
Inspecti
Free from Rejection
on
foundry defects Report
Foundry
3 like sand drop , Visually 1 1 -- Reject
Defects
cold shut , shift ,
crack etc.

PREPARED BY: Mr. Sachin Kumbhar REVIEWED BY : Mr. Ameya Patil APPROVED BY : Mr. Virendra Patil
 SHREE SPHEROTECH PVT.LTD.

CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/CP/ CI /140 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --
Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018
Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SS Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --
CHARACTERISTICS METHODS
SR. MACHINE, SAMPLE
PROCESS NAME / SP. PRODUCT /
DEVICE, EVALUATION
OPERATION CHAR. PROCESS Error REACTION PLAN
JIG, TOOLS NO. PRODUCT PROCESS
CONTROL
DESCRIPTION CLASS. SPECIFICATION / MEASUREMENT Proofing METHOD RECORD RESP.
NO. FOR MFG. TECHNIQUE SIZE FREQ.
TOLERANCE

140 Final inspection

Chemistry 1 C.% 3.00-3.70 %
2 Si.% 1.70-2.30 % Spectro report If chemistry is not found as per
3 Mn.% 0.60-0.90 % in Soft Copy Process Card then check the
Inprocess and TC (May Melting
4 S.% 0.15 % Max Spectrometer 1 per heat -- Inspection not contain Supervisors
microstructure, hardness & tensile, if
5 P.% 0.15 % Max heatwise these are found ok then accept the
observations) Lot.
6 Cu.% 0.20 % Max
7 Cr. % 0.20-0.45 %
8 Flake Size 4-6 mm
Microstructure
Flakes Report in Soft If micro for Grapite Type & Size , And
9 Min.350 Ferrite and perlite % not as specified
Count Microscope with Inprocess Copy and TC
Microstructure 90% Min 1 per lot -- (May not Lab Assit. then check the hardness & tensile, if
10 Pearlite % Image Analyser Inspection contain these are found ok then accept the
heatwise Lot.
11 Ferrite % 10% Max observations)
12 Carbide % 5% Max

Casting
If hardness found low or high then check
Brinel Hardness Inprocess Hardness
Hardness 13 Hardness Hardness Testing 217 to 257 BHN 1 per Heat -- Job Inspector the tensile & also Check 100 % Hardness
Testing Inspection Testing of that Heat. Sort & send or Reject.
Report

In every 4
Week If this If tensile found low of 1st test bar
Tensile 241 Mpa UTM Machine grade Inprocess Outside lab
Tensile Strength 14 1 poured in
--
Inspection Lab Assit. then check 2nd test bar,if both test
Strength (External Lab) reports
these found foulty then reject
weeks.
 Verify the castings
for free from foundry
defects like sand Visual
drop , cold shut , Inspection
Visual Foundry Free from Inprocess
17 Visual Inspection shift , crack, Visual 1 1 -- cum Job Inspector Reject the Casting.
Defects Defects Inspection
Shrinkage, Blow Rejection
Holes etc. Report

Visual
Inspection if Found Defected Castings Rework
Well Dressed & Inprocess
18 Fettling Visual Inspection Visual 1 1 --- cum Job Inspector (For under fettling only) or Reject the
Fettled Inspection
Rejection Casting.
Report

Free from Colour coading for Inprocess Visual If found Defected Castings mixing,
19 Visual Inspection Visual 1 1 --- Job Inspector
Mixing casting Inspection Inspection sagrigate & make colour coading.

Total Cast
30 Vernier Calper 5 per Lot --- Job Inspector Reject or Rework the Batch,
Height
Cast Dist 3 Vernier Calper 5 per Lot --- Casting Job Inspector Reject or Rework the Batch,
Dimensional
Cast Profile R 19 Radius fillet 5 per Lot --- Job Inspector Reject or Rework the Batch,
Inprocess Inspection
Dimensions 20 Pad Profile R 12.0 Radius fillet 5 per Lot --- Report Job Inspector Reject or Rework the Batch,
Inspection
Dim. 88.0 +-0.8 Vernier Calper 5 per Lot --- Job Inspector Reject or Rework the Batch,
Dim. 91.5 +-0.8 Vernier Calper 5 per Lot --- Job Inspector Reject or Rework the Batch,
Eaton Logo Visual Inspection Visual 1 1 ---

Non Distructive Radiographi Inprocess Visual If Found Defected, Re design gatting

21 Radiographic testing Level II Gamma Ray IR 192 1 Year --- Job Inspector
testing c testing Inspection Inspection system, or process.

Inprocess Visual If Found Defected, Re design gatting

Distructive testing 22 Cut Section Visual Inspection Defect free Cutting Machine 1 6 Month --- Job Inspector
Inspection Inspection system, or process.

200000
Third
Non Distructive Casting Lay Measuring Nos Lay out If Found Defected cummunicate to
23 As per Drawings As per Drawings 1 --- Party Assit.QA Inch.
testing out Instruments Produced report customer
Inspection
/ Cavity

Casting Reject or Rework the Batch, If

Dimensions As Per
As Per Dimensional Inprocess Dimensional Dimensions not in specification and
(Only if Customer 24 Dimensional 5 Lot --
Inspection Job Inspector
Quality Plan Inspection rectify the pattern by customer
Requirement( Quality Plan
Report approval.

PREPARED BY: Sachin Kumbhar REVIEWED BY : Ameya Patil APPROVED BY : Virendra Patil
 `

Micro & hardness Location

 SHREE SPHEROTECH PVT.LTD.

CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/CP/ CI /150 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 5001460-001 Rev. - L / 09 Feb 09 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description END CAP Casting Other Approval / Date (If required ) --
Material Grade VS 2-1-3-2 (FG 260) Date (Original) 23.03.2018
Supplier plant : --- Rev. No/ date 00 / 23.03.2018
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SS Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --
CHARACTERISTICS METHODS
SR. MACHINE, SAMPLE
PROCESS NAME / SP. PRODUCT /
DEVICE, EVALUATION
OPERATION CHAR. PROCESS Error REACTION PLAN
JIG, TOOLS NO. PRODUCT PROCESS
CONTROL
DESCRIPTION CLASS. SPECIFICATION / MEASUREMENT Proofing METHOD RECORD RESP.
NO. FOR MFG. TECHNIQUE SIZE FREQ.
TOLERANCE

150 Verify the castings

for free from foundry Visual
defects like sand Inspection
Free from drop , cold shut , Inprocess
1 Visual Inspection shift , crack,
Visual 1 1 -- cum Job Inspector Reject the Casting.
Defects Inspection
Shrinkage, Blow Rejection
Holes etc. Report

Visual
Inspection if Found Defected Castings Rework
Dispatch -- Well Dressed & Inprocess
2 Fettling Visual Inspection Visual 1 1 --- cum Job Inspector (For under fettling only) or Reject the
Fettled Inspection
Rejection Casting.
Report

Free from Colour coading for Inprocess Visual If found Defected Castings mixing,
3 Visual Inspection Visual 1 1 --- Job Inspector
Mixing casting Inspection Inspection sagrigate & make colour coading.

Properly Stacked If found not stacked or not packed in

Stacked Inprocess Visual
4 Visual Inspection or packed in Visual 1 1 --- Job Inspector polythene bag then hold the auto
Casting Inspection Inspection
polythene gony pack it & then release the auto.

PREPARED BY: Sachin Kumbhar REVIEWED BY : Ameya Patil APPROVED BY : Virendra Patil
 SHREE SPHEROTECH PVT.LTD.

CONTROL PLAN
Prototype Pre-launch ✘ Production
Control plan No: SSPL/M-CP/BG-Cover-4301607/10 Key Contact Person/Phone: Mr. Virendra Patil 9970966333
Part No./Latest Change Level: 4301607/ E / 06.09.2006 Core Team Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SSK
Part Description Bearing Cover, C Shaft Other Approval / Date (If required ) --
Material Grade SAE G 3000 Grey Iron (FG 260) Date (Original) 05.07.2017
Supplier plant : --- Rev. No/ date 00 / 05.07.2017
Supplier code --- Customer Engg. Approval date if reqd. --
Prepared by Mr.VSP, Mr.ABP,Mr.Vhanugare,Mr.SS Customer Quality Approval date if reqd. --
Reviewed by Mr.Vhanugare Other Approval / Date (If required ) --
CHARACTERISTICS METHODS
SR. MACHINE, SAMPLE
PROCESS NAME / SP. PRODUCT /
DEVICE, EVALUATION
OPERATION CHAR. PROCESS Error REACTION PLAN
JIG, TOOLS NO. PRODUCT PROCESS
CONTROL
DESCRIPTION CLASS. SPECIFICATION / MEASUREMENT Proofing METHOD RECORD RESP.
NO. FOR MFG. TECHNIQUE SIZE FREQ.
TOLERANCE

INCOMING QUANTITY AS INCOMING

10
INSPECTION
MANUAL 1 QUANTITY
PER CHALLAN
COUNTING 100% 100% -- INSP RECORD
Store I/C 1.INFORM TO SUPERVISOR
Inprocess
Inspection
NO VISUAL VISUAL INCOMING
DEFECTS INSPECTION
100% 100% -- INSP RECORD
Inspector 2. REPORT TO FOUNDRY

INPROCES
VERNIER S IN-PROCESS OPERATOR &
20 FINISH TURNING CNC 1 BORE BORE ∅93.73 1 1 IN 5 -- INSPECTIO INSP RECORD INSPECTOR
CALIPER
N

INPROCES
BORING S IN-PROCESS OPERATOR &
2 DEPTH DEPTH 7.39 / 7.14 DEPTH VERNIER 1 1 IN 5 -- INSPECTIO INSP RECORD INSPECTOR
BAR
N

INPROCES
VERNIER S IN-PROCESS OPERATOR &
3 WIDTH WIDTH 12.70 1 1 IN 5 -- INSPECTIO INSP RECORD INSPECTOR
CALIPER
N

INPROCES
CHAMFER VERNIER S IN-PROCESS OPERATOR &
4 CHAMFER 1 1 IN 15 -- INSPECTIO INSP RECORD INSPECTOR 1. STOP THE PROCESS.
0.8X45° CALIPER
N 2. INFORM TO SUPERVISOR
INPROCES 3. CHECK LAST 5 FOR
FLATNESS < S IN-PROCESS OPERATOR & VARIATION.
5 FLATNESS FILLER GAUGE 1 1 IN 5 -- INSPECTIO INSP RECORD INSPECTOR
0.051 4. RESET THE PROCESS.
N
5. CHECK THE JOB IF OK,
INPROCES CONTINUE, IF NOT, THEN
PARALLELI PARALLELISM < S IN-PROCESS OPERATOR &
REPEAT 4 & 5
6 CMM 1 1 IN 25 -- INSPECTIO INSP RECORD INSPECTOR
SM 0.051
N
 5. CHECK THE JOB IF OK,
CONTINUE, IF NOT, THEN
REPEAT 4 & 5

INPROCES
S IN-PROCESS OPERATOR &
7 POSITION POSITION < 1.02 CMM 1 1 IN 50 -- INSPECTIO INSP RECORD INSPECTOR
N

FEED AS PER PQS VISUAL 1ST 1 /SHIFT EDIT

8 PC LOCK IN-PROCESS OPERATOR &
INSP RECORD INSPECTOR

SPEED AS PER PQS VISUAL 1ST 1 /SHIFT EDIT

9 PC LOCK IN-PROCESS OPERATOR &
INSP RECORD INSPECTOR

30 4 HOLE DRILLING INPROCES

& REAMING HOLE ∅10.43 / S IN-PROCESS OPERATOR &
VMC 1 HOLE PLUG GAUGE 1 1 IN 5 -- INSPECTIO INSP RECORD INSPECTOR
10.24
N

INPROCES
VMC RECEIVING S IN-PROCESS OPERATOR &
2 POSITION POSITION < 0.2 1 1 IN 5 -- INSPECTIO INSP RECORD INSPECTOR 1. STOP THE PROCESS.
FIXTURE GAUGE
N 2. INFORM TO SUPERVISOR
INPROCES 3. CHECK LAST 5 FOR
DRILL RECEIVING S IN-PROCESS OPERATOR & VARIATION.
3 PCD PCD ∅121.23 1 1 IN 5 --
∅10.00 GAUGE INSPECTIO INSP RECORD INSPECTOR 4. RESET THE PROCESS.
N
5. CHECK THE JOB IF OK,
EDIT CONTINUE, IF NOT, THEN
REAMER 1ST LOCK IN-PROCESS OPERATOR &
REPEAT 4 & 5
4 FEED AS PER PQS VISUAL 1 /SHIFT
∅10.30 PC INSP RECORD INSPECTOR

EDIT
1ST LOCK IN-PROCESS OPERATOR &
5 SPEED AS PER PQS VISUAL 1 /SHIFT INSP RECORD INSPECTOR
PC

MARK PER TES-

MARKING 002-2. -4 OR -7
40 MARKING 1 MARKING VISUAL 100% 100%
MACHINE WITH PART
NUMBER. 1. STOP THE PROCESS.
PLANT/VENDOR 2. INFORM TO SUPERVISOR
IDENTIFICATION 3. CHECK LAST 5 FOR VARIATION.
4. RESET THE PROCESS.
AND DATE CODE. 5. CHECK THE JOB IF OK, CONTINUE, IF
RAISED METAL NOT, THEN REPEAT 4 & 5
NOT PERMITTED
 INPROCES
FINAL VERNIER S IN-PROCESS OPERATOR &
50 MANUAL 1 BORE BORE ∅93.73 5 5 / LOT INSPECTIO INSP RECORD INSPECTOR
1. STOP THE PROCESS.
INSPECTION CALIPER
N

INPROCES
S IN-PROCESS OPERATOR &
2 DEPTH DEPTH 7.39 / 7.14 DEPTH VERNIER 5 5 / LOT INSPECTIO INSP RECORD INSPECTOR
2. INFORM TO SUPERVISOR
N

INPROCES
VERNIER S IN-PROCESS OPERATOR &
3 WIDTH WIDTH 12.70 5 5 / LOT INSPECTIO INSP RECORD INSPECTOR
3. CHECK 100% FOR VARIATION.
CALIPER
N

INPROCES
CHAMFER S IN-PROCESS OPERATOR &
4 CHAMFER DEPTH VERNIER 5 5 / LOT INSPECTIO INSP RECORD INSPECTOR
4. SEGREGATE THE LOT.
0.8X45°
N

INPROCES
FLATNESS < S IN-PROCESS OPERATOR &
5 FLATNESS FILLER GAUGE 5 5 / LOT INSPECTIO INSP RECORD INSPECTOR
5. DESPATCH OK LOT ONLY.
0.051
N

INPROCES
PARALLELI PARALLELISM < S IN-PROCESS OPERATOR &
6 CMM 5 5 / LOT INSPECTIO INSP RECORD INSPECTOR
SM 0.051
N

INPROCES
S IN-PROCESS OPERATOR &
7 POSITION POSITION < 1.02 CMM 5 5 / LOT INSPECTIO INSP RECORD INSPECTOR
N

INPROCES
HOLE ∅10.43 / S IN-PROCESS OPERATOR &
8 HOLE PLUG GAUGE 5 5 / LOT INSPECTIO INSP RECORD INSPECTOR
10.24
N

INPROCES
RECEIVING S IN-PROCESS OPERATOR &
9 POSITION POSITION < 0.2 5 5 / LOT INSPECTIO INSP RECORD INSPECTOR
GAUGE
N

INPROCES
RECEIVING S IN-PROCESS OPERATOR &
10 PCD PCD ∅121.23 5 5 / LOT INSPECTIO INSP RECORD INSPECTOR
GAUGE
N

MARKING MARKING & INPROCES

S IN-PROCESS OPERATOR &
11 & VISUAL VISUAL VISUAL 100% 100% INSPECTIO INSP RECORD INSPECTOR
DEFECTS DEFECTS N

APPLY RUST 1. STOP THE PROCESS.

RUST PREVENTIVE INPROCES
2. INFORM TO SUPERVISOR
NO DRY S OPERATOR &
60A OILING PREVENTIV 1 OIL AT ALL VISUAL 100% 100% INSPECTIO
NO RECORD
INSPECTOR
3. CHECK 100% FOR VARIATION.
SURFACE 4. SEGREGATE THE LOT.
E OIL MACHINED N
5. DESPATCH OK LOT ONLY.
SURFACE.

BRUSH 2
60B PACKING
1. STOP THE PROCESS.
DESPATCH OK INPROCES
2. INFORM TO SUPERVISOR
DESPATCH S OPERATOR &
LOT AS PER COUNTING 100% 100% INSPECTIO
CHALLEN
INSPECTOR
3. CHECK 100% FOR VARIATION.
QUANTITY 4. SEGREGATE THE LOT.
CHALLEN N
5. DESPATCH OK LOT ONLY.

PREPARED BY: Sunil Durge REVIEWED BY : Ameya Patil APPROVED BY : Virendra Patil