Control Plan No.

: 01
CONTROL PLAN Format No.: PPTL/CP/PD/01
Proto Type: Pre-launch: Production: ✘ 28/08/2013
Date (Org.) : --
Core Team : Sonal Jain, Rakesh Pandey, Pramod Rawat,
Uday Pratap Singh Revision Date: 12/10/2013 Date (Review) : 01 08/01/2014
Part Name / Description : Applicable for all tubes
Customer Engineering Approval Date (If Req'd.) : --- N/A
Supplier / Plant Approval Date : --- 28/08/2013 Customer Quality Approval Date ( If Req'd.) : --- N/A
Supplier / Plant / Site : Prem Prakash Tubes Ltd., Pithampur
Supplier Code : Trader Other Approval Date ( If Req'd.) : --- N/A

Characteristics Method
Process
Part Machine, Device, Special
Name, Product / Evaluation Sampling
Process jigs, tools for No. Chara. Responsibili Re-action Plan
Operation Product Process Process Measurement Control Method
No. Manufacturing Class ty
Description Spec. / Tole. Techniques Size Freq

Dimensions As per IS : 10748 1 coil

1 Width +10 mm Measuring Tape 1 coil

2 Thickness +/- 0.08 mm Micrometer 3 coil

Chemical Composition As per 10748 1 coil

1 Carbon As per IS 1 coil

Raw
2 Manganese As per IS 1 coil
material Receiving
Inspection 3 Sulphur As per IS
Chemical
1 coil
Lab Inspection record Reject the material and
(Chemical & analysis Incharge send back to supplier
Mechanical 4 Phosphorus As per IS 1 coil
testing)
Physical Properties 1 coil

1 Yst As per IS UTM 1 coil

2 T-S As per IS UTM 1 coil

3 E% As per IS UTM 1 coil

4 Bend Test As per IS 1 coil No Record

Identify & Keep Separately for

As per Slitting Measuring Tape, Quality
1 Width
Chart Vernier
2 Coil
Inspector
Inspection record recovery/rework. Use for
recovery.

Identify & Keep Separately for

As per Slitting Quality recovery/rework. Use for
2 Thickness
Chart
Micrometer 3 Coil
Inspector
Inspection record
recovery.If recovery not
10 Slitting Slitting Machine possible reject it.

Rework. Check cutter

3 Burr No Burr Visual 2 setup Operator No Record tolrance and sharpness and
correct it if required.
 10 Slitting Slitting Machine Characteristics Method
Process
Part Machine, Device, Special
Name, Product / Evaluation Sampling
Process jigs, tools for No. Chara. Responsibili Re-action Plan
Operation Product Process Process Measurement Control Method
No. Manufacturing Class ty
Description Spec. / Tole. Techniques Size Freq

4 Spacer size As per m/c shaft Vernier Once start up Operator No Record Do required setting

1 OD * As per IS chart Vernier 1 1 Hr.

Quality
Inspector
Inspection record
Identify & Keep Seperately.
Rework/recovery.

Quality Identify & Keep Seperately.

2 Thickness As per IS chart Micrometer 1 1 Hr.
Inspector
Inspection record
Rework/recovery.

Quality Identify & Keep Seperately.

3 Length As per IS chart measuring tape 1 1 Hr.
Inspector
Inspection record
Rework/recovery.

Quality Identify & Keep Seperately.

4 Stamping As per IS chart Visual 100%
Inspector
Inspection record
Rework/recovery.

Tube Mill
5 Weld strength * No visual Cracks
Bend/Flattening
Test
100%
Quality
Inspector
Inspection record
Identify & Keep Seperately.
Reject/reweld if possible.
20 Tube Mill
Rolling Quality Identify & Keep Seperately.
6 pin hole No pin hole Hydrotesting m/c ongoing
Inspector
No Record
Reject/reweld if possible.

Visual/Surface Quality
7 finish
Roll Setting As per standard Visual ongoing
Inspector
Inspection record Identify & Keep Seperately.

Space between Based upon tube

8 rolls dia
Visual 1 set up Operator No Record Reset

9 Voltage * 360 - 440 volts voltmeter once start up Operator Inspection record Reset

10 Ferrite rod setting Below contact Visual 1 set up Operator No Record Reset

Welding Roll As per

11 profile Requirement
Std gauge 1 set up Operator No Record Reset

Uniform
In appropriate
1 Varnish
Distribution of Visual 1 set up Operator No Record Reset
varnish
Varnish
30 (As per Varnish Machine As per
requirement) 2 Die Size
Requirement
Visual 1 set up Operator No Record Reset

Varnish Quality
3 temprature
50-60 °C Thermameter ongoing
Inspector
No Record Reset

Measurement Quality
1 Length As per IS
Tape
100%
Inspector
No Record Do rework/use for recovery

2 no burr Visually ok Visually 100% Operator No Record Do Rework

3 Damages Visually ok Visually 100% operator No Record Do rework

40 End Facing End facing machine

Clamping As per
4 pressure Requirement
Visually Once setup Operator No Record Resetting
 Characteristics Method
Process
Part Machine, Device, Special
40
Process EndName,
Facing Endjigs,
facing machine
tools for No. Chara. Product / Evaluation Sampling
Responsibili Re-action Plan
Operation Product Process Process Measurement Control Method
No. Manufacturing Class ty
Description Spec. / Tole. Techniques Size Freq

As per
5 Machine speed
Requirement
Gear system Once setup operator No Record Resetting

As per
6 Feed
Requirement
ongoing Operator No Record Resetting

Identify & Keep Seperately.

As per IS
1 No leakages
Specification
visual 100% Inspection record Check if rework/recovery
possible.
Hydrotestin
g Hydrotesting Process
50 machine As per IS supervisor
(As per 2 Water pressure
Specification
pressure gage 1 Set up No Record Reset
requirement)

Clamping As per
3 pressure Requirement
visual 1 Set up No Record Reset

Acid Pickling

Acid During
Water and HCL Inspection
1 Concentration
Content(100- Counting Once replacemen
record
Adjust conc.
120gm/ltr.) t

Acid tank, Water tank 2 Pickling Time 4 to 7 Min. Clock Every lot No Record Adjust timing
& Flux tank
Sp. Gravity 1.5- Inspection
3 Flux Gravity
1.2
Hydrometer 1 lot
record
Adjust

Outer surface 100% visual

4 Surface
should be clean
Visually
inspection
No Record Rework

Drying
Dryer
Temperature
1 Temp. 60 -80 °C
Meter
Every lot No Record Adjust

Zinc Platting
Galvanizing Process
60 (As per Supervisor
requirement) Rework . If rework not
1 Uniformity IS : 4736 Lab testing 1 Hr. Inspection record
possible reject

2 Adhesion IS : 4736 Hammer test 1 Hr. Inspection record Rework

No Zn inside
3 bore
internal die 100% No Record Rework
Zinc Bath

Platting Chemical One time during

4 Grade
Zn Lab testing
Replacing Zn
No Record

Temperature
5 Temp. 430- 450 °C
Meter
Every lot No Record
Adjust
 Zinc Bath

Characteristics Method
Process
Part Machine, Device, Special
Name, Product / Evaluation Sampling
Process jigs, tools for No. Chara. Responsibili Re-action Plan
Operation Product Process Process Measurement Control Method
No. Manufacturing Class ty
Description Spec. / Tole. Techniques Size Freq
Adjust
6 Platting Time 30 sec Clock Every lot No Record

Ext unit,quenching Quenching tank Temperature

tank 1 temperature
50-60 °C
Meter
Every lot No Record

Check while
1 Tool Angle Protactor
replacement
Operator No Record Change the tool

Threading
Quality
2 Length of thread As per IS Vernier 1 Hr.
Inspector
inspection Report Do rework/use for recovery

Threading
Quality
3 Depth of thread As per IS Pitch gauge 1 Hr.
Inspector
inspection Report Do rework/use for recovery
Threading
70 (As per Threading Machine
Threading
requirement) Quality
4 Pitch As per IS Pitch gauge 1 Hr.
Inspector
inspection Report Rework/reject

Threading
Quality
5 No. of threads As per IS Counting 1 Hr.
Inspector
inspection Report Rework/reject

Threading
Major Dia. Go/No go ring Quality
6 As per IS
gauge
1 Hr.
Inspector
inspection Report Rework/reject

As per customer
1 Total Qty
requirement
Counting

Process
80 Packing - 100%
Supervisor
PDI Recheck complete lot

As per customer
2 Total Weight
requirement
Weight scale

Prepared By :- Mr. Sonal Jain Approved By :- Mr. Pramod Rawat

QC Engineer QC Manager