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Operaction STD - Forging

The document outlines the quality plan for welding operations on stay rods. It specifies 5 key characteristics to be inspected including ball diameter, concentricity, welding, total length, and appearance. The sampling plan, inspection methods, frequency of inspection, control methods and reaction plans are defined for each characteristic. The quality plan aims to ensure stay rods meet specifications through inspection and rework of non-conforming parts.

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akaman614
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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31 views12 pages

Operaction STD - Forging

The document outlines the quality plan for welding operations on stay rods. It specifies 5 key characteristics to be inspected including ball diameter, concentricity, welding, total length, and appearance. The sampling plan, inspection methods, frequency of inspection, control methods and reaction plans are defined for each characteristic. The quality plan aims to ensure stay rods meet specifications through inspection and rework of non-conforming parts.

Uploaded by

akaman614
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLSX, PDF, TXT or read online on Scribd
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VULCON COLD FORGE PVT.LTD DOC. NO.

: POPQ/F/01

REV. NO/DT.:
PART OPERATION QUALITY PLAN
ISSUE DATE : 01.05.2022

DESCRIPTION :- STAY ROD J1D


PART NO. 021RVM2598-03LABX MATERIAL : SAE-1018HHB
CUSTOMER : SANDHAR POPQ NO POQP 021RVM2598-03LABX / 02
MODEL OPERATION NO. :- / 02 (WELDING)
SKETCH :-

S CONTROL
No. CHARACTERISTIC CTQ SPECIFICATION INSPECTION METHOD SAMPLING PLAN FREQUENCY METHOD REACTION PLAN
RESPONSIBILITY

REWORK &
1 Ball Dia 17.44±0.07 MM 5pcs 2Hrs P.I/Q.C.I REJECT

REWORK &
2 Concetricity 0.20IA DG 1pcs 4Hrs P.I/Q.C.I REJECT
REWORK &
3 Welding Visual 10pcs 2Hrs P.I/Q.C.I REJECT
Projection Welding
REWORK &
4 Total Length 300.0±0.5 HG/DV 5pcs 2Hrs P.I/Q.C.I REJECT
REWORK &
5 Apperance Visual 10pcs 2Hrs P.I/Q.C.I REJECT
no dents,pitted etc

LEGEANDS
P.I. = PATROL INSPECTION , S.I. = MM = MICRO METER , P.G = PIN GUAGE
SET UP INSPECTION DMM = DIGITAL MICRO METER
DVC = DIGITAL VERNIER CALIPER , VC = VERNIER VMM = VISION MEASURING MACHINE ,PP = PROJECTOR PROFILE
CALIPER H.G = HEIGHT GAUGE , T.R.G = THREAD RING GAUGE
O.S.I. = OPERATOR SELF INSPECTION Q.C.I. = Q.C. PART OPERATION QUALITY PLAN NUMBER :- POPQ /PARTS
INSPECTOR OPR = OPERATOR NAME/OPERATION NO

REV. NO. REV. DATE PREPARED BY APPROVED BY

NEW FORMATE IMPLEMENT , POPQ /F/01 , ISSSUE DATE, 01.05.2022 ,REV NO 00


VULCON COLD FORGE PVT.LTD DOC. NO. : POPQ/F/01

REV. NO/DT.:
PART OPERATION QUALITY PLAN
ISSUE DATE : 01.05.2022

DESCRIPTION :- STAY ROD ABHF


PART NO. MATERIAL : SAE-1018HB
CUSTOMER : SANDHAR POPQ NO POQP / 02
MODEL OPERATION NO. :- / 02 (WELDING)
SKETCH :-

S CONTROL
No. CHARACTERISTIC CTQ SPECIFICATION INSPECTION METHOD SAMPLING PLAN FREQUENCY METHOD REACTION PLAN
RESPONSIBILITY

REWORK &
1 Ball Dia 17.44±0.07 MM 5pcs 2Hrs P.I/Q.C.I REJECT

REWORK &
2 Concetricity 0.20IA DG 1pcs 4Hrs P.I/Q.C.I REJECT
REWORK &
3 Welding Visual 10pcs 2Hrs P.I/Q.C.I REJECT
Projection Welding
REWORK &
4 Total Length 211±0.5 HG/DV 5pcs 2Hrs P.I/Q.C.I REJECT
REWORK &
5 Apperance Visual 10pcs 2Hrs P.I/Q.C.I REJECT
no dents,pitted etc

LEGEANDS
P.I. = PATROL INSPECTION , S.I. = MM = MICRO METER , P.G = PIN GUAGE
SET UP INSPECTION DMM = DIGITAL MICRO METER
DVC = DIGITAL VERNIER CALIPER , VC = VERNIER VMM = VISION MEASURING MACHINE ,PP = PROJECTOR PROFILE
CALIPER H.G = HEIGHT GAUGE , T.R.G = THREAD RING GAUGE
O.S.I. = OPERATOR SELF INSPECTION Q.C.I. = Q.C. PART OPERATION QUALITY PLAN NUMBER :- POPQ /PARTS
INSPECTOR OPR = OPERATOR NAME/OPERATION NO

REV. NO. REV. DATE PREPARED BY APPROVED BY

NEW FORMATE IMPLEMENT , POPQ /F/01 , ISSSUE DATE, 01.05.2022 ,REV NO 00


VULCON COLD FORGE PVT.LTD DOC. NO. : POPQ/F/01

REV. NO/DT.:
PART OPERATION QUALITY PLAN
ISSUE DATE : 01.05.2022

DESCRIPTION :- PIN MAIN STEP BAAR


PART NO. /50603-AK-0000 MATERIAL : SAE-10B21
CUSTOMER : SANDHAR POPQ NO POQP /50603-AK-0000 / 20
MODEL OPERATION NO. :- / 20 (forging )
SKETCH :-

S CONTROL
No. CHARACTERISTIC CTQ SPECIFICATION INSPECTION METHOD SAMPLING PLAN FREQUENCY METHOD REACTION PLAN
RESPONSIBILITY

NO
BURRS,CHIPS,DE VISUAL REWORK &
8 APPEARANCE 10 PCS Every 2 hours P.I/Q.C.I REJECT
NTS,PITED,ETC

LEGEANDS
P.I. = PATROL INSPECTION , S.I. = MM = MICRO METER , P.G = PIN GUAGE
SET UP INSPECTION DMM = DIGITAL MICRO METER
DVC = DIGITAL VERNIER CALIPER , VC = VERNIER VMM = VISION MEASURING MACHINE ,PP = PROJECTOR PROFILE
CALIPER H.G = HEIGHT GAUGE , T.R.G = THREAD RING GAUGE
O.S.I. = OPERATOR SELF INSPECTION Q.C.I. = Q.C. PART OPERATION QUALITY PLAN NUMBER :- POPQ /PARTS
INSPECTOR OPR = OPERATOR NAME/OPERATION NO

REV. NO. REV. DATE PREPARED BY APPROVED BY

NEW FORMATE IMPLEMENT , POPQ /F/01 , ISSSUE DATE, 01.05.2022 ,REV NO 00


VULCON COLD FORGE PVT.LTD DOC. NO. : POPQ/F/01

REV. NO/DT.:
PART OPERATION QUALITY PLAN
ISSUE DATE : 01.05.2022

DESCRIPTION :- PIN MAIN STEP BAAR


PART NO. /50603-AK-0000 MATERIAL : SAE-10B21
CUSTOMER : SANDHAR POPQ NO POQP /50603-AK-0000 / 20
MODEL OPERATION NO. :- / 20 (forging )
SKETCH :-

S CONTROL
No. CHARACTERISTIC CTQ SPECIFICATION INSPECTION METHOD SAMPLING PLAN FREQUENCY METHOD REACTION PLAN
RESPONSIBILITY

REWORK &
1 HEAD DIA 9±0.2 MM = MICRO METER 5 PCS Every 2 hours P.I/Q.C.I REJECT

HEAD REWORK &


2 2±0.1 DV 5 PCS Every 2 hours P.I/Q.C.I REJECT
THICKNESS
REWORK &
DIM DV 5 PCS Every 2 hours P.I/Q.C.I REJECT
32.75±0.25
REWORK &
4 DIA MM 5 PCS Every 2 hours P.I/Q.C.I REJECT
6±0.10
REWORK &
5 CHAMFER PP/VMM 1 PCS Every 4 hours P.I/Q.C.I REJECT
C0.5X45°
REWORK &
6 RADIOUS VMM/PP 1 PCS Every 4 hours P.I/Q.C.I REJECT
R0.5± 0.2
REWORK &
7 RADIOUS VVM/PP 1 PCS Every 4 hours P.I/Q.C.I REJECT
R0.25 Max
NO
BURRS,CHIPS,DE VISUAL REWORK &
8 APPEARANCE 10 PCS Every 2 hours P.I/Q.C.I REJECT
NTS,PITED,ETC

LEGEANDS
P.I. = PATROL INSPECTION , S.I. = MM = MICRO METER , P.G = PIN GUAGE
SET UP INSPECTION DMM = DIGITAL MICRO METER
DVC = DIGITAL VERNIER CALIPER , VC = VERNIER VMM = VISION MEASURING MACHINE ,PP = PROJECTOR PROFILE
CALIPER H.G = HEIGHT GAUGE , T.R.G = THREAD RING GAUGE
O.S.I. = OPERATOR SELF INSPECTION Q.C.I. = Q.C. PART OPERATION QUALITY PLAN NUMBER :- POPQ /PARTS
INSPECTOR OPR = OPERATOR NAME/OPERATION NO

REV. NO. REV. DATE PREPARED BY APPROVED BY

NEW FORMATE IMPLEMENT , POPQ /F/01 , ISSSUE DATE, 01.05.2022 ,REV NO 00


VULCON COLD FORGE PVT.LTD DOC. NO. : POPQ/F/01

REV. NO/DT.:
PART OPERATION QUALITY PLAN ISSUE DATE : 01.05.2022
DESCRIPTION :- M4 Screw Pan Head

PART NO. /1005100 MATERIAL : SAE-1010


CUSTOMER : Sandhar POPQ NO POQP /1005100 / 20

MODEL OPERATION NO. :- / 20 (forging )


SKETCH :-

CONTROL
S CHARACTERISTIC CTQ SPECIFICATION INSPECTION METHOD SAMPLING PLAN FREQUENCY METHOD
No. RESPONSIBI REACTION PLAN
LITY
1 HEAD Dia 7.80±0.15 DV 5 PCS Every 2 hours P.I/Q.C.I REWORK & REJECT

P.I/Q.C.I REWORK &


2 HeadThicknes 3.0± 0.08 DV 5PCS Every 2 hours REJECT
3 Length 12.00± 0.20 DV 5PCS Every 2 hours P.I/Q.C.I REWORK & REJECT

4 T.R.D.(M5x0.8) 3.45~3.52 MM 5PCS Every 2 hours P.I/Q.C.I REWORK & REJECT

5 Punch Size PG 5PCS Every 2 hours P.I/Q.C.I REWORK & REJECT


M4 Sandard
6 Radius 0.5 Ref. PG 1PCS Every 4 hours P.I/Q.C.I REWORK & REJECT

7 Radius 0.3 Max. PG 1PCS Every 4 hours P.I/Q.C.I REWORK & REJECT
No
8 APPERANCE Burr,Chips,Dents,Pitted,etc. Visual 10PCS Every 2 hours P.I/Q.C.I REWORK & REJECT

LEGEANDS
P.I. = PATROL INSPECTION , S.I. = SET UP MM = MICRO METER , P.G = PIN GUAGE
INSPECTION DMM = DIGITAL MICRO METER
DVC = DIGITAL VERNIER CALIPER , VC = VERNIER VMM = VISION MEASURING MACHINE ,PP = PROJECTOR PROFILE
CALIPER H.G = HEIGHT GAUGE , T.R.G = THREAD RING GAUGE
O.S.I. = OPERATOR SELF INSPECTION Q.C.I. = Q.C. INSPECTOR PART OPERATION QUALITY PLAN NUMBER :- POPQ /PARTS
OPR = OPERATOR NAME/OPERATION NO

REV. REV. DATE PREPARED BY APPROVED BY


NO.
NEW FORMATE IMPLEMENT , POPQ /F/01 , ISSSUE DATE, 01.05.2022 ,REV NO 00
VULCON COLD FORGE PVT.LTD
PART OPERATION QUALITY PLAN

DESCRIPTION :- M2.6x0.45x4.20 SCREW


PART NO. /HHM-1200-12 MATERIAL :
CUSTOMER : SANDHAR POPQ NO
MODEL OPERATION NO. :-
SKETCH :-

S INSPECTION
CHARACTERISTIC CTQ SPECIFICATION SAMPLING PLAN FREQUENCY
No. METHOD
1 LENGTH 4.00~4.20 DV 5PCS
2 HEAD DIA 5.70-0.40 DV 5PCS
3 HEAD THICK 1.50± 0.15 DV 5PCS
4 BLANK DIA 2.18~2.26 MM 5PCS
5 DIM 0.70± 0.10 DV 5PCS
6 M' SIZE 2.40± 0.10 DV 5PCS
7 U/H RADIUS R~0.30 VMM 1 PCS
CRACK,PITTED,B
8 APPERANCE URR,CHIPS VISUAL 10 PCS
LEGEANDS MM = MICRO METER , P.G = PIN GUAGE
P.I. = PATROL INSPECTION , S.I. = SET UP DMM = DIGITAL MICRO METER
INSPECTION VMM = VISION MEASURING MACHINE ,PP = PROJECTO
DVC = DIGITAL VERNIER CALIPER , VC = VERNIER CALIPER H.G = HEIGHT GAUGE , T.R.G = THREAD RING GAUGE
O.S.I. = OPERATOR SELF INSPECTION Q.C.I. = Q.C. INSPECTOR
OPR = OPERATOR PART OPERATION QUALITY PLAN NUMBER :- POPQ

REV. REV. DATE PREPARED BY


NO.
NEW FORMATE IMPLEMENT , POPQ /F/01 , ISSSUE DATE, 01.05.2022 ,REV NO 00
TD DOC. NO. : POPQ/F/01

REV. NO/DT.:

ISSUE DATE : 01.05.2022

POQP
SS (304) POQP /HHM-1200-12 / 20
POQP /HHM-1200-12 / 20

/ 20 (forging )

CONTROL
METHOD REACTION
MPLING PLAN FREQUENCY
RESPONSIBILI PLAN
TY
Every 2 hours P.I/Q.C.I REWORK & REJECT

Every 2 hours P.I/Q.C.I REWORK & REJECT

Every 2 hours P.I/Q.C.I REWORK & REJECT

Every 2 hours P.I/Q.C.I REWORK & REJECT

Every 2 hours P.I/Q.C.I REWORK & REJECT

Every 2 hours P.I/Q.C.I REWORK & REJECT

Every 4 hours P.I/Q.C.I REWORK & REJECT

Every 2 hours P.I/Q.C.I REWORK & REJECT


= PIN GUAGE
TER
G MACHINE ,PP = PROJECTOR PROFILE
.R.G = THREAD RING GAUGE
ITY PLAN NUMBER :- POPQ /PARTS NAME/OPERATION NO

APPROVED BY
VULCON COLD FORGE PVT.LTD DOC. NO. : POPQ/F/01

REV. NO/DT.:
PART OPERATION QUALITY PLAN ISSUE DATE : 01.05.2022
DESCRIPTION :- M6x1.0x20 PH.PAN SCREW
PART NO. /A-0313-00-08 MATERIAL : SAE-1010
CUSTOMER : SANDHAR POPQ NO POQP /A-0313-00-08 / 20
MODEL OPERATION NO. :- / 20 (forging )
SKETCH :-

CONTROL
S CHARACTERISTI INSPECTION REACTION
CTQ SPECIFICATION SAMPLING PLAN FREQUENCY METHOD
No. C METHOD PLAN
RESPONSIBILITY

1 LENGTH 20.00-0.50 DV 5PCS Every 2 hours P.I/Q.C.I REACTION PLAN

2 HEAD DIA 9.80~10.50 MM 5PCS Every 2 hours P.I/Q.C.I REACTION PLAN

3 HEAD THICK DV 5PCS Every 2 hours P.I/Q.C.I REACTION PLAN


3.70~4.10

4 BLANK DIA MM 5PCS Every 2 hours P.I/Q.C.I REACTION PLAN


5.25~5.30

5 Q' DEPTH QDEPTH GAUGE 5PCS Every 4 hours P.I/Q.C.I REACTION PLAN
3.00± 0.10

6 M' SIZE DV 5PCS Every 2 hours P.I/Q.C.I REACTION PLAN


6.20 REF

7 U/H RADIUS VMM ON SETTING ON SETTING TIME P.I/Q.C.I REACTION PLAN


R~0.25

CRACK,PITTED,F ONGOING 10 O.S.T./OPP.P.I./Q.C.I REACTION PLAN


8 APPERANCE VISUAL Every 2 hours
OLD,RUSTY PCS

LEGEANDS MM = MICRO METER , P.G = PIN GUAGE


P.I. = PATROL INSPECTION , S.I. = SET DMM = DIGITAL MICRO METER
UP INSPECTION
DVC = DIGITAL VERNIER CALIPER , VC = VERNIER VMM = VISION MEASURING MACHINE ,PP = PROJECTOR PROFILE
CALIPER H.G = HEIGHT GAUGE , T.R.G = THREAD RING GAUGE
O.S.I. = OPERATOR SELF INSPECTION Q.C.I. = Q.C. PART OPERATION QUALITY PLAN NUMBER :- POPQ /PARTS
INSPECTOR OPR = OPERATOR
NAME/OPERATION NO

REV. NO. REV. DATE PREPARED BY APPROVED BY

NEW FORMATE IMPLEMENT , POPQ /F/01 , ISSSUE DATE, 01.05.2022 ,REV NO 00


VULCON COLD FORGE PVT.LTD DOC. NO. : POPQ/F/01

REV. NO/DT.:
PART OPERATION QUALITY PLAN
ISSUE DATE : 01.05.2022

DESCRIPTION :- STAY ROD AALR


PART NO. STRS23900 MATERIAL : 1018HB
CUSTOMER : SANDHAR POPQ NO POQP STRS23900 / 02
MODEL OPERATION NO. :- / 02 (Welding )
SKETCH :-

S CONTROL
No. CHARACTERISTIC CTQ SPECIFICATION INSPECTION METHOD SAMPLING PLAN FREQUENCY METHOD REACTION PLAN
RESPONSIBILITY

REWORK &
1 Ball Dia 12.70±0.07 MM 5Pcs 2hrs P.I/Q.C.I REJECT

REWORK &
2 Concentricity 0.20IA DG 1pcs 4hrs P.I/Q.C.I REJECT
REWORK &
3 Welding Visual 10pcs 2hrs P.I/Q.C.I REJECT
Projection Welding
REWORK &
4 Total length HG/DV 5Pcs 2hrs P.I/Q.C.I REJECT
220.0±0.05
REWORK &
5 Apparance Visual 10pcs 2hrs P.I/Q.C.I REJECT
no dets &pitted etc

LEGEANDS
P.I. = PATROL INSPECTION , S.I. = MM = MICRO METER , P.G = PIN GUAGE
SET UP INSPECTION DMM = DIGITAL MICRO METER
DVC = DIGITAL VERNIER CALIPER , VC = VERNIER VMM = VISION MEASURING MACHINE ,PP = PROJECTOR PROFILE
CALIPER H.G = HEIGHT GAUGE , T.R.G = THREAD RING GAUGE
O.S.I. = OPERATOR SELF INSPECTION Q.C.I. = Q.C. PART OPERATION QUALITY PLAN NUMBER :- POPQ /PARTS
INSPECTOR OPR = OPERATOR NAME/OPERATION NO

REV. NO. REV. DATE PREPARED BY APPROVED BY

NEW FORMATE IMPLEMENT , POPQ /F/01 , ISSSUE DATE, 01.05.2022 ,REV NO 00


VULCON COLD FORGE PVT.LTD DOC. NO. : POPQ/F/01

REV. NO/DT.:
PART OPERATION QUALITY PLAN
ISSUE DATE : 01.05.2022

DESCRIPTION :- STAY ROD AANF


PART NO. S-1329-000-0004 MATERIAL : SAE-1018HB
CUSTOMER : SANDHAR POPQ NO POQP S-1329-000-0004 / 02
MODEL OPERATION NO. :- / 02 (WELDING)
SKETCH :-

S CONTROL
No. CHARACTERISTIC CTQ SPECIFICATION INSPECTION METHOD SAMPLING PLAN FREQUENCY METHOD REACTION PLAN
RESPONSIBILITY

REWORK &
1 Ball Dia 17.44±0.07 MM 5pcs 2Hrs P.I/Q.C.I REJECT

REWORK &
2 Concetricity 0.20IA DG 1pcs 4Hrs P.I/Q.C.I REJECT
REWORK &
3 Welding Visual 10pcs 2Hrs P.I/Q.C.I REJECT
Projection Welding
REWORK &
4 Total Length 187.5±0.5 HG/DV 5pcs 2Hrs P.I/Q.C.I REJECT
REWORK &
5 Apperance Visual 10pcs 2Hrs P.I/Q.C.I REJECT
no dents,pitted etc

LEGEANDS
P.I. = PATROL INSPECTION , S.I. = MM = MICRO METER , P.G = PIN GUAGE
SET UP INSPECTION DMM = DIGITAL MICRO METER
DVC = DIGITAL VERNIER CALIPER , VC = VERNIER VMM = VISION MEASURING MACHINE ,PP = PROJECTOR PROFILE
CALIPER H.G = HEIGHT GAUGE , T.R.G = THREAD RING GAUGE
O.S.I. = OPERATOR SELF INSPECTION Q.C.I. = Q.C. PART OPERATION QUALITY PLAN NUMBER :- POPQ /PARTS
INSPECTOR OPR = OPERATOR NAME/OPERATION NO

REV. NO. REV. DATE PREPARED BY APPROVED BY

NEW FORMATE IMPLEMENT , POPQ /F/01 , ISSSUE DATE, 01.05.2022 ,REV NO 00

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