Supplier EVERSHINE FINISHER CONTROL PLAN Control Plan No.

CP-01
Customer Lifelong Prototype Pre-Launch Production Date (Orig.) 1/5/2018
Part Number/Latest Change Needle Core Team Mr. Rahul, Mr. Vishesh, Dharmender
Level Date (Rev.)
Part Name/Description Needle Key Contact /Phone No. Rev. 0
PROCESS MACHINE, CHARACTERISTICS METHODS
PART/ SPECIAL
NAME/ DEVICE, JIG, EVALUTION/ SAMPLE
PROCESS CHAR. PRODUCT/ PROCESS CONTROL REACTION
OPERATION TOOLS FOR NO. PRODUCT PROCESS MEASUREMENT
NUMBER CLASS SPECIFICATION/ TOLERANCE SIZE FREQ. METHOD PLAN
DESCRIPTION MFG. TECHNIQUE

Incoming 1 Material ABS BLACK

Verification by raw Direct Provided Inform to
10 Inspection 2 Grade As per issued by customer 100% per lot
material bag. by Customer Customer
(Raw Material ) 3 Make As per issued by customer
4 Color Transparent

Inform the store

Material Identification FIFO date
Storage Of Raw Raw As per store standard & incharge &
20 Manual 1 tags or date entry /FIFO 100% per lot entry / Receiving
Material Material procedure exchange the
system register
raw material

Inform the store

Material Identification
Raw As per store standard & Material Issue incharge &
30 Issue Of Material Manual 1 tags or date entry /FIFO 100% per lot
Material procedure Register exchange the
system
raw material

1 Injection time
2 Cooling Time
3 Holding Time
4 Cycle Time
5 Nozzle Temp.
6 Z1 Temp. As per process
As per store standard & parameter Inform To
7 Z2 Temp. PLC Display Screen 100% 2 hour
procedure Sheet F-QAD- Supervisor
Molding Process & Injection Molding 8 Z3 Temp. 01-05A
40
Inspection Machine 9 Z4 Temp.
10 Injection Pressure
11 Locking Pressure
12 Holding Pressure

Molding Inprocess
1 No molding defects allowed Visual n=3 per FOA / MOA /
defect Inspection 3 pcs Reject/ rework
shift LOA
2 Fitment As Fitment As per mating part
Supplier EVERSHINE FINISHES CONTROL PLAN Control Plan No. CP-01
Customer Lifelong Prototype Pre-Launch Production Date (Orig.) 1/5/2018
Part Number/Latest Change
Needle Core Team Mr. Rahul, Mr. Vishesh, Dharmender
Level Date (Rev.)
Part Name/Description Needle Key Contact /Phone No. Rev.
CHARACTERISTICS METHODS
MACHINE,
PART/ PROCESS NAME/ SPECIAL SAMPLE
DEVICE, JIG, PRODUCT/ PROCESS EVALUTION/
PROCESS OPERATION CHAR. CONTROL
TOOLS FOR NO. PRODUCT PROCESS SPECIFICATION/ MEASUREMENT REACTION PLAN
NUMBER DESCRIPTION CLASS SIZE FREQ. METHOD
MFG. TOLERANCE TECHNIQUE
Checking (Visual) & Material Visual & As per packing
50 Manual 1 As per WI 100% Per Lot Repacking
Packing (Components) Counting/Weighing std.

By Measuring Final
Final Inspection Segregation /
60 Instruments / 1 Molding defect Inspection As per FOA / MOA / LOA Visual 3 pcs Per lot FOA MOA LOA
(PDI) Rework
Checking Aids Process

Material Supply as per customer

70 Dispatch Manual 1 Loading Visual 100% Every Lot
(Components) schedule

Prepared By Approved By Customer Approval (if required)

 CP-01
1/5/2018

REACTION PLAN

Repacking

Segregation /
Rework
 Supplier SRG MOULDINGS PFMEA No. PFMEA/SRG/RB/01
Customer RINDER INDIA (P.) LTD.
PROCESS FAILURE MODE & EFFECTS ANALYSIS Date (Orig.) 1/5/2018
Core Team- Mr. Ravi Ranjan, Mr. Kamal Bhatt, Mr.Ram Mahesh, Mr. Sunil Mourya, Mr.
Part Number 70043-01 Mulayam Rajput Date(Rev.)
2/4/2018
Part Name Tail Lamp Reflector- Key Contact/Phone No.- 0124-4379845 Rev. 1
Action Results

RESPONSIBILITY
REQUIREMENTS

RECOMMENDED
CLASSIFICATION

OCCURRENCE

COMPLETION
DETECTION

OCCURRENCE
& TARGET
SEVERITY
CURRENT CURRENT

DETECTION
ACTION

SEVERITY
PROCESS POTENTIAL POTENTIAL POTENTIAL ACTION

DATE
PROCESS PROCESS
STEP/ FAILURE EFFECT(S) OF CAUSE OF RPN TAKEN &
CONTROLS CONTROLS RPN
FUNCTION MODE FAILURE FAILURE EFFECTIVE
PREVENTION DETECTION
DATE

Manufacturing: Stop
Material grade Wrong Grade shipment and additional Wrong Material Receiving
as required Material sort and rework due to supply by supplier Inspection report
affected material.
Operation 10:
Incoming
Proper Inspection Of
Incoming Manufacturing: Line 5 Un Skilled 2 5 50
inspection as per Wrong Inspection Inspection Std. Raw Material &
Inspection shutdown Inspector
Standard BOP
(RM & BOP)
Inspection Wrong Incoming
Manufacturing: Wrong
Report / Test Inspection Un Calibrated Document & Data
material supply to
Certificate by Report / Test Instrument Control
production
Supplier Certificate

Manufacturing: Wrong
Material location Material location Untrained Man- Guidelines for new Identification on
material supply to
identified Not Identified power comers Bags
production

1. Inadequate
1.Inventory normal
Stack height Improper Stacking Manufacturing: Mix-up space 2.Stacking
Operation 20 defined set Identification
of Raw Material of material height not
& 30: 2.Stacking Height
standardize
4 2 5 40
R/M storage Manufacturing: 1.No syatem
& Issue Of FIFO system FIFO system not Improper tracebility in defined Work Instruction
Raw Material followed Identification
followed next operation 2.Unskilled For FIFO
personnel

1.Lack of
Manufacturing: Wrong
Specified Wrong Material knowledge Guidelines for new
part produce and Line Training
material issued Issued 2.Unidentified comers
shutdown
material

Temp. & time less

than specified in Raw Material
Material Pre-
End user: Customer line work instruction for Pre-heating
Heating Standard
shutdown material pre- Inspection
Operation 40: Manufacturing: Stop heating
No Silver stricks, Silver stricks, Gas
production and
Gas Mark, Voids Mark, Voids & 3 2 In-Process 3 30
Raw Material additional sort and Process setting Process data
& Poor Shining Poor Shining Inspection
Pre-Heating rework due to affected error standard
material. Method
Temp. Controller Daily machine
Calibration of
not functioning checking
Temp. Controller
properly method
Class Legends: 9-10: Critical, 7-8:Major, 4-6:Significant, 1-3: Minor
PREPARED BY APPROVED BY
SRGM/ENG/F-12; Rev.01, Rev. Date : 1.08.2018 Page 1 of 3
 Supplier SRG MOULDINGS PFMEA No. PFMEA/SRG/RB/01
PROCESS FAILURE MODE & EFFECTS ANALYSIS
Customer RINDER INDIA (P.) LTD. Date (Orig.) 1/5/2018
Core Team- Mr. Ravi Ranjan, Mr. Kamal Bhatt, Mr.Ram Mahesh, Mr. Sunil Mourya, Mr. Mulayam Rajput
Part Number 70043-01 Date(Rev.) 2/4/2018
Part Name Tail Lamp Reflector- Key Contact/Phone No.- 0124-4379845 Rev. 1
Action Results

RESPONSIBILITY
REQUIREMENTS

RECOMMENDED
CLASSIFICATION

OCCURRENCE

COMPLETION
DETECTION

OCCURRENCE
& TARGET
SEVERITY
CURRENT

DETECTION
ACTION

SEVERITY
PROCESS POTENTIAL CURRENT PROCESS ACTION

DATE
POTENTIAL EFFECT(S) OF POTENTIAL CAUSE OF PROCESS
STEP/ FAILURE CONTROLS RPN TAKEN &
FAILURE FAILURE CONTROLS RPN
FUNCTION MODE PREVENTION EFFECTIV
DETECTION
E DATE

End User: Unable to Fitment.Customer

line shutdown Decrease in injection speed , Process data & Inprocess In-Process Inspection
Manufacturing and Assembly: Line presure & barrel temp. inspection standard Method
shutdown and additional sort and rework

MAJOR
due to affected material.
No short
Short Moulding 6 2 5 60
moulding
Temp. Controller & pressure
Calibration of pressure Daily machine
gauge not functioning
gauge & temp. controller checking method
properly

Decrease in Injection
Process data & Inprocess In-Process Inspection
pressure, Injection time &
inspection standard Method
End User: Asthetic problem. coolong time

MAJOR
Manufacturing and Assembly: Line
No sink marks Sink Mark 5 2 5 50
shutdown and additional sort and rework
due to affected material.
Pressure gauge not Calibration of pressure Daily machine
functioning properly gauge & temp. controller checking method

In-Process Inspection
Increase in injection Process data & Inprocess
Method & Statistical
pressure & barrel temp. inspection standard
Process Control
Operation 50:
End User: Tight fitment with the
Moulding assembly part.
MAJOR

Process & Dia./ Dim. Over Manufacturing and Assembly: Line Temp. Controller & pressure
Inspection 4 Calibration of pressure 2 Daily machine 5 40
Size shutdown and additional sort and rework gauge not functioning
due to affected material. gauge & temp. controller checking method
properly

Dimension oversize due to Preventive Maintenance Daily mould checking

mould NG of mould method

Dia./ Dim. as per

specification
Decrease in injection
In-Process Inspection
pressure & barrel temp. & Process data & Inprocess
Method & Statistical
Decrease in coolong time. inspection standard
Process Control
Mould problems

End User: Loose fitment with the

assembly part.
MAJOR

Dia./Dim. Under Manufacturing and Assembly: Line

4 2 6 48
Size shutdown and additional sort and rework Temp. Controller & pressure Calibration of temp.
due to affected material. Daily machine
gauge not functioning controller, timer &
checking method
properly pressure gauge.

Dimension undersize due to Mould Preventive Daily mould checking

mould NG Mainttenance method

Class Legends: 9-10: Critical, 7-8:Major, 4-6:Significant, 1-3: Minor

PREPARED BY APPROVED BY
SRGM/ENG/F-12; Rev.01, Rev. Date : 1.08.2018
 Supplier SRG MOULDINGS PFMEA No. PFMEA/SRG/RB/01
PROCESS FAILURE MODE & EFFECTS ANALYSIS
Customer RINDER INDIA (P.) LTD. Date (Orig.) 1/5/2018
Core Team- Mr. Ravi Ranjan, Mr. Kamal Bhatt, Mr.Ram Mahesh, Mr. Sunil Mourya, Mr. Mulayam
Part Number 70043-01 Rajput Date(Rev.)
2/4/2018

Part Name Tail Lamp Reflector- Key Contact/Phone No.- 0124-4379845 Rev. 1
Action Results

RESPONSIBILITY
CLASSIFICATION

RECOMMENDED
REQUIREMENTS
PROCESS STEP/

OCCURRENCE

COMPLETION
DETECTION

OCCURRENCE
& TARGET
SEVERITY
FUNCTION

CURRENT CURRENT

DETECTION
ACTION

SEVERITY
POTENTIAL POTENTIAL POTENTIAL ACTION

DATE
PROCESS PROCESS
FAILURE EFFECT(S) OF CAUSE OF RPN TAKEN &
CONTROLS CONTROLS RPN
MODE FAILURE FAILURE EFFECTIV
PREVENTION DETECTION
E DATE

End User: Unable to

fit with assembly
part.
1- Un sharp edge of
Manufacturing and 1- WI for deflashing
knife / cutter Visual Inspection
No flashes Flashes Assembly: Line 2- Training for new
2- Untrainned Method
shutdown and comers
deflasher
additional sort and
rework due to
affected material.
Operation 60:
3 3 4 36
Deflashing
End User: Unable to
fit with assembly
part.
Manufacturing and
Training for new Visual Inspection
No deep cut Deep cut Assembly: Line Untrainned deflasher
comers Method
shutdown and
additional sort and
rework due to
affected material.

End User: Unable to

Proper Wrong fit with assembly Packing std. not Visual Inspection
Packing standard & WI
Inspection Inspection part.Customer line followed Method
shutdown
Less or
End User: Customer Packing std. not Visual Inspection
Fixed quantity Excess Packing standard & WI
line shutdown 5 followed 2 Method 4 40
Operation 70: quantity

Checking End User: Unable to 1. Unskilled packing

Mixing of 1. Training for new
(Visual) & fit with assembly person Visual Inspection
Same material different comers
Packing part.Customer line 2. Unproper Method
component 2. Proper Identification
shutdown Identification

End User: Unable to

Packing Packing is not fit with assembly Packing std. not Visual Inspection
1 5 Packing standard & WI 2 4 40
appropriate appropriate part.Customer line followed Method
shutdown
1- Training for new
Operation 80: End User: Unable to Visual Inspection
MAJOR

1- Unskilled inspector comers

fit with assembly Method & Pre
Proper PDI Wrong PDI 5 2- Error in measuring 2- Calibration of 2 6 60
Final part.Customer line dispatch
instrument instrument used at
Inspection shutdown inspection
final end
End User: Wrong
Operation 90:
FIFO system FIFO system
component. Identification of bins & Visual Inspection
5 WI for bins and trolleys 2 3 30
followed not followed
Customer line box not done properly Method
Dispatch
shutdown
Class Legends: 9-10: Critical, 7-8:Major, 4-6:Significant, 1-3: Minor
PREPARED BY APPROVED BY
SRGM/ENG/F-12; Rev.01, Rev. Date : 1.08.2018 Page 3 of 3