Format No.

- REPL/F/QMS/15
Issue Record of Procedures Origin Date.- 02/02/2024
Rev.No. / Date.- 00

No. of
Sr. No. Procedure Name Procedure No. Origin Date Rev. No. Rev. Date Dept Copies Issue Date Sign
Issued

1 Quality Policy Deployment REPL/QAP/QPD/R5 01.01.2004 05 19.05.2020 Top Management 1

2 Change Control REPL/QAP/CC/R7 01.01.2004 07 14.03.2021 Engineering 1

3 Control of Documents REPL/QAP/QMS/01 01.01.2004 06 02.02.2024 QMS 1

4 Documented Process for Customer REPL/QAP/QA/04 01.01.2004 06 14.01.2024 Quality Assurance 1

Complaints Handling

5 Control of Quality Records REPL/QAP/CQR/R5 01.01.2004 05 26.12.2017 QMS 1

6 Customer Focus REPL/QAP/CF/R5 01.12.2003 05 27.06.2020 Quality Assurance 1

7 Quality System Review REPL/QAP/QSR/R6 01.01.2004 06 01.01.2024 QMS 1

8 New Product Development REPL/QAP/NPD/R0 22.08.2023 00 -- Engineering 1

9 Determination of Customer Satisfaction REPL/QAP/DCS/R5 01.12.2003 05 02.01.2023 QA 1

10 HRM & Training procedure REPL/QAP/HR/01 01.01.2004 08 27.11.2023 HR 1

11 External Provided Processes, Product & REPL/QAP/PP/R9 01.01.2004 09 27..01.2024 Purchase 1

Services (Purchasing Process)

12 Production & Service Provision Operations REPL/QAP/PSPO/R10 01.01.2004 10 01.03.2023 Production 1

13 Documented Process for Control of Measuring REPL/QAP/QA/03 01.02.2004 09 14.01.2024 Quality Assurance 1
& Monitoring Devices

14 Calibration & Verification of Gauges REPL/QAP/CVG/R5 01.01.2004 05 08.05.2020 Quality Assurance 1

15 Measurement, Analysis & Improvement REPL/QAP/MAI/R5 01.12.2003 05 26.12.2017 QMS 1

16 Internal Quality Audit REPL/QAP/QMS/02 01.12.2003 10 28.02.2024 QMS 1

17 Control of Nonconforming Product REPL/QAP/CNCP/R5 01.12.2003 05 26.12.2017 Quality Assurance 1

18 Corrective & Preventive Action REPL/QAP/CPA/R8 01.12.2003 08 30.03.2022 Quality Assurance 1

19 Procedure For Heat Treatment REPL/QAP/HT/R5 25.02.2007 05 17.05.2020 Production (HT) 1

20 Procedure for Maintenance Process REPL/QAP/MNT/01 16.01.2015 05 31.01.2024 Maintenance 1

21 SPC Procedure REPL/QAP/SPC/R0 20.03.2023 00 -- Quality Assurance 1

M.E.
22 Manufacturing Engineering Procedure REPL/QAP/ME/R0 15.09.2023 00 -- (Tool Management) 1

M.E.
23 Tooling Management REPL/QAP/TM/01 01.04.2018 01 27.01.2024 (Tool Management) 1

M.E.
24 Fixture Management REPL/QAP/FM/R0 01.04.2018 00 -- (Tool Management) 1

25 Product Safety REPL/QAP/PS/R0 18.01.2018 00 -- Engineering 1

26 Employee Motivation & Empowerment REFL/QAP/HR/02 10.01.2018 01 27.11.2023 HR 1

27 Sales Procedure REFL/MD/SALES/SP/R0 17.01.2020 00 -- Sales & dispatch 1

28 SAP Procedure for QM REPL/QAP/SAPQM/R0 01.06.2019 00 -- Quality Assurance 1

29 SAP Procedure for PP REPL/QAP/SAPPP/R0 01.06.2019 00 -- Production 1

30 SAP Procedure for SD REPL/QAP/SAPSD/R0 01.06.2019 00 -- Sales & Dispatch 1

31 SAP Procedure for MM REPL/QAP/SAPMM/R0 01.06.2019 00 -- Material Movement 1

 Format No.- REPL/F/QMS/15
Issue Record of Procedures Origin Date.- 02/02/2024
Rev.No. / Date.- 00

No. of
Sr. No. Procedure Name Procedure No. Origin Date Rev. No. Rev. Date Dept Copies Issue Date Sign
Issued

32 Marketing, SOP RFQ, Feasibility & PO REPL/MKT/SOP/RO 20.05.2022 00 -- Marketing 1

33 4M Change Control REPL/QAP/PRD/02 27.11.2023 00 -- Production 1

34 Procedure For Management of Computer IT REPL/QAP/IT/01 10.09.2023 00 -- IT 1

Equipment's Backup and Restoration
 Format No.- REPL/F/QMS/15
Issue Record of Procedures Origin Date.- 02/02/2024
Rev.No. / Date.- 00

No. of
Sr. No. Procedure Name Procedure No. Origin Date Rev. No. Rev. Date Dept Copies Issue Date Sign
Issued

35 Warranty Analysis Procedure REPL/QAP/QA/01 07.10.2023 00 -- Quality Assurance 1

36 Documented Process for Inspection & Testing REPL/QAP/QA/02 14.01.2024 00 -- Quality Assurance 1

37 Process failure Mode and Effects Analysis REPL/QAP/QA/06 25.05.2015 01 27.01.2024 Quality Assurance 1

38 Documented Process for Production Planning REPL/QAP/PRD/01 08.02.2024 00 -- Production 1

39 Documented Process for Suspected and Non - REPL/QAP/QA/05 14.01.2024 00 -- Quality Assurance 1
Conforming Material Handling

40 Documented Process for Advance Product REPL/QAP/ENGG/01 22.08.2023 Engineering

Quality Planning(APQP)

41 Documented Process for First Production Part REPL/QAP/ENGG/02 01.04.2024 00 -- Engineering

43 Documented Process For Initial Supply Control REPL/QAP/ENGG/03 01.04.2024 00 -- Engineering

Prepared By: Checked By: Approved By:

 Doc. No. - REPL/D/QMS/03

Master List of Procedures Origin Date - 10.09.2023

Rev. No./Date - 00
Process Owner
Sr. No. Procedure Name Procedure No. Origin Date Rev. No.
Department

1 Quality Policy Deployment REPL/QAP/QPD/R5 01.01.2004 05 Top Management

2 Change Control REPL/QAP/CC/R7 01.01.2004 07 Engineering

3 Control of Documents REPL/QAP/QMS/01 01.01.2004 06 QMS

Documented Process for Customer Complaints

4 REPL/QAP/QA/04 01.01.2004 06 Quality Assurance
Handling

5 Control of Quality Records REPL/QAP/CQR/R5 01.01.2004 05 QMS

6 Customer Focus REPL/QAP/CF/R5 01.12.2003 05 Quality Assurance

7 Quality System Review REPL/QAP/QSR/R6 01.01.2004 06 QMS

8 Determination of Customer Satisfaction REPL/QAP/DCS/R5 01.12.2003 05 Quality Assurance

9 HRM & Training procedure REPL/QAP/HR/01 01.01.2004 08 HR

External Provided Processes, Product & Services

10 REPL/QAP/PP/R9 01.01.2004 09 Purchase
(Purchasing Process)

11 Production & Service Provision Operations REPL/QAP/PSPO/R10 01.01.2004 10 Production

Documented Process for Control of Measuring &

12 REPL/QAP/QA/03 01.02.2004 09 Quality Assurance
Monitoring Devices

13 Calibration & Verification of Gauges REPL/QAP/CVG/R5 01.01.2004 05 Quality Assurance

14 Measurement, Analysis & Improvement REPL/QAP/MAI/R5 01.12.2003 05 QMS

15 Internal Quality Audit REPL/QAP/QMS/02 01.12.2003 10 QMS

16 Control of Nonconforming Product REPL/QAP/CNCP/R5 01.12.2003 05 Quality Assurance

17 Corrective & Preventive Action REPL/QAP/CPA/R8 01.12.2003 08 Quality Assurance

18 Procedure For Heat Treatment REPL/QAP/PRD/03 25.02.2007 6 Production (HT)

19 Procedure for Maintenance Process REPL/QAP/MNT/01 16.01.2015 05 Maintenance

20 SPC Procedure REPL/QAP/SPC/R0 20.03.2023 00 Quality Assurance

M.E.
21 Manufacturing Engineering Procedure REPL/QAP/ME/R0 15.09.2023 00 (Tool Management)
M.E.
22 Tooling Management REPL/QAP/TM/01 01.04.2018 01 (Tool Management)
M.E.
23 Fixture Management REPL/QAP/FM/R0 01.04.2018 00 (Tool Management)

24 Product Safety REPL/QAP/PS/R0 18.01.2018 00 Engineering

25 Employee Motivation & Empowerment REFL/QAP/HR/02 10.01.2018 01 HR

 Doc. No. - REPL/D/QMS/03

Master List of Procedures Origin Date - 10.09.2023

Rev. No./Date - 00
Process Owner
Sr. No. Procedure Name Procedure No. Origin Date Rev. No.
Department

26 Sales Procedure REFL/MD/SALES/SP/R0 17.01.2020 00 Sales & dispatch

27 SAP Procedure for QM REPL/QAP/SAPQM/R0 01.06.2019 00 Quality Assurance

28 SAP Procedure for PP REPL/QAP/SAPPP/R0 01.06.2019 00 Production

29 SAP Procedure for SD REPL/QAP/SAPSD/R0 01.06.2019 00 Sales & Dispatch

30 SAP Procedure for MM REPL/QAP/SAPMM/R0 01.06.2019 00 Purchase

31 Marketing, SOP RFQ, Feasibility & PO REPL/MKT/SOP/RO 20.05.2022 00 Marketing

32 4M Change Control REPL/QAP/PRD/02 27.11.2023 00 Production

Procedure For Management of Computer IT

33 REPL/QAP/IT/01 10.09.2023 00 IT
Equipment's Backup and Restoration

34 Warranty Analysis Procedure REPL/QAP/QA/01 07.10.2023 00 Quality Assurance

35 Documented Process for Inspection & Testing REPL/QAP/QA/02 14.01.2024 00 Quality Assurance

36 Process failure Mode and Effects Analysis REPL/QAP/QA/05 25.05.2015 01 Quality Assurance

37 Documented Process for Production Planning REPL/QAP/PRD/01 08.02.2024 00 Production

Documented Process for Suspected and Non -

38 Conforming Material Handling REPL/QAP/QA/05 14.01.2024 00 Quality Assurance

Documented Process for Advance Product Quality

39 REPL/QAP/ENGG/01 22.08.2023 01 Engineering
Planning(APQP)

40 Documented Process For Control Plan REPL/QAP/ENGG/03 01.04.2024 00 Engineering

41 Documented Process For Change Management REPL/QAP/ENGG/05 01.04.2024 00 Engineering

Guideline to identify Special or Critical

42 Characteristics REPL/QAP/ENGG/06 01.04.2024 0 Engineering

Prepared By - Checked By - Approved By -

 Format. No. - REPL/F/QMS/17
Issue record of SOP Origin Date - 02.02.2024
Rev No. / Date - 00

Sr. No. Name of Standard Operating Procedure SOP No. Origin Date Rev. No. Rev. Date No. of Copies Issue Date Sign
(SOP) Issued

PRODUCTION

1 SOP - HOBBING REPL/SOP/PRD/01 13.02.2016 02 08.04.2024 08.04.2024

P
2 SOP - GUN DRILL REPL/SOP/PRD/02 15.01.2018 01 08.04.2024 08.04.2024 r
a
v
iN
3 SOP - SOFT TURNING REPL/SOP/PRD/03 13.02.2016 02 08.04.2024 08.04.2024 n
A
a
m
r
M
ae
4 SOP - SHAVING REPL/SOP/PRD/04 13.02.2016 02 08.04.2024 08.04.2024 ran
cd
Sh
r
ah
a
5 SOP - ROUNDING REPL/SOP/PRD/05 13.02.2016 01 08.04.2024 08.04.2024 ik
lG
n
ei
d
6 SOP - ROOFING REPL/SOP/PRD/06 13.02.2016 01 08.04.2024 08.04.2024 er
&
a
&
s
R
eG
7 SOP - CNC SHAPING REPL/SOP/PRD/07 13.02.2016 01 08.04.2024 08.04.2024 o
V
ih
SD
aji
et
n
8 SOP - DRILLING REPL/SOP/PRD/08 13.02.2016 01 08.04.2024 08.04.2024 P
n
d
ad
N
it
ra
p
iG
av
9 SOP - MILLING REPL/SOP/PRD/09 13.02.2016 01 08.04.2024 08.04.2024 la
G
D
n
R
a
ag
w
10 SOP - HARD TURNING REPL/SOP/PRD/10 13.02.2016 02 08.04.2024 08.04.2024 JP
atu
allh
yto
i
rid
11 SOP - PRESSING REPL/SOP/PRD/11 13.02.2016 01 08.04.2024 08.04.2024 al
m
a
12 SOP - BORE,FACE & CONE GRINDING REPL/SOP/PRD/12 13.02.2016 01 08.04.2024 08.04.2024 n

13 SOP - EXTERNAL GRINDING REPL/SOP/PRD/13 13.02.2016 02 08.04.2024 08.04.2024

14 SOP - BORE HONNING REPL/SOP/PRD/14 13.02.2016 02 08.04.2024 08.04.2024

15 SOP - VMC REPL/SOP/PRD/15 13.02.2016 01 08.04.2024 08.04.2024

16 SOP - HMC REPL/SOP/PRD/16 13.08.2018 01 08.04.2024 08.04.2024

17 SOP - WASHING REPL/SOP/PRD/17 13.02.2016 01 08.04.2024 08.04.2024

18 SOP - GEAR GRINDING REPL/SOP/PRD/18 15.01.2018 02 08.04.2024 08.04.2024

19 SOP - LASER WELDING REPL/SOP/PRD/19 13.02.2016 01 08.04.2024 08.04.2024

20 SOP - CHAMFERING REPL/SOP/PRD/20 13.02.2020 01 08.04.2024 08.04.2024

21 SOP - POWER HONNING REPL/SOP/PRD/21 20.08.2023 01 08.04.2024 08.04.2024

Quality Assurance

1 SOP -Leak Testing REPL/SOP/QA/01 13.09.2018 01 08.04.2024 1 08.04.2024

Prepared By: Checked By: Approved By:

 Doc. No. - REPL/D/QMS/05
Master List of Standard Operating Procedure Origin Date - 10.09.2023
Rev No. / Date - 00

Rev. Process Owner

Sr. No. SOP Name SOP No. Origin Date
No. Department

PRODUCTION

1 SOP - HOBBING REPL/SOP/PRD/01 13.02.2016 02 Mr. P.Bhapkar

2 SOP - GUN DRILL REPL/SOP/PRD/02 15.01.2018 01 Mr. Hemant Jagdale

3 SOP - SOFT TURNING REPL/SOP/PRD/03 13.02.2016 02 Mr. Pokharkar

4 SOP - SHAVING REPL/SOP/PRD/04 13.02.2016 02 Mr. P.Bhapkar

5 SOP - ROUNDING REPL/SOP/PRD/05 13.02.2016 01 Mr. P.Bhapkar

6 SOP - ROOFING REPL/SOP/PRD/06 13.02.2016 01 Mr. P.Bhapkar

7 SOP - CNC SHAPING REPL/SOP/PRD/07 13.02.2016 01 Mr. P.Bhapkar

8 SOP - DRILLING REPL/SOP/PRD/08 13.02.2016 01 Mr. P.Bhapkar

9 SOP - MILLING REPL/SOP/PRD/09 13.02.2016 01 Mr. P.Bhapkar

10 SOP - HARD TURNING REPL/SOP/PRD/10 13.02.2016 02 Mr. Pokharkar

11 SOP - PRESSING REPL/SOP/PRD/11 13.02.2016 01 Mr. More

12 SOP - BORE,FACE & CONE GRINDING REPL/SOP/PRD/12 13.02.2016 01 Mr. P. Aiwale

13 SOP - EXTERNAL GRINDING REPL/SOP/PRD/13 13.02.2016 02 Mr. P. Aiwale

14 SOP - BORE HONNING REPL/SOP/PRD/14 13.02.2016 02 Mr. P.Bhapkar

15 SOP - VMC REPL/SOP/PRD/15 13.02.2016 01 Mr. Hemant Jagdale

16 SOP - HMC REPL/SOP/PRD/16 13.08.2018 01 Mr. Hemant Jagdale

17 SOP - WASHING REPL/SOP/PRD/17 13.02.2016 01 Mr. More

18 SOP - GEAR GRINDING REPL/SOP/PRD/18 15.01.2018 02 Mr. P.Bhapkar

19 SOP - LASER WELDING REPL/SOP/PRD/19 13.02.2016 01 Mr. More

20 SOP - CHAMFERING REPL/SOP/PRD/20 13.02.2020 01 Mr. P.Bhapkar

21 SOP - POWER HONNING REPL/SOP/PRD/21 20.08.2023 01 Mr. P.Bhapkar

Quality Assurance

1 SOP -Leak Testing REPL/SOP/QA/01 13.09.2018 01 Mr. Hemant Jagdale

Prepared By Checked By APPROVED BY

 Issue Record of Procedures Doc. No. - REPL/MD-IRQAP

Sr. No. Procedure Name Procedure No. Origin Date Rev. No. Issue Date Sign

35 Procedure For Management of Computer, IT REPL/QAP/IT/01 10.09.2023 0 10.09.2023

Equipment’s & Backup and Restoration

36 4M Change Management REPL/QAP/PRD/02 27.11.2023 0 27.11.2023

37 HRM , Education & Training Procedure REPL/QAP/HR/01 01.01.2004 8 27.11.2023

38 Documented Process For Plant Maintainence REPL/QAP/MNT/01 16.01.2015 4 12.12.2023

39 Documented Process for Inspection & Testing REPL/QAP/QA/02 14.01.2024 0 14.01.2023

Externally Provided Processes, Product and

40 Services (Purchasing Process) - Supplier Selection, REPL/QAP/PP/R9 01.01.2004 9 27.01.2024
Supplier Monitoring & Supplier Control

41

42

43

44

45

46

47

48

49

50
51

52

53

54

55

56

57

58

59

60
 Doc. No. - REPL/D/QMS/04

Master List of Work Instructions Origin Date - 10.09.2023

Rev. No./Date - 00

Rev. Process Owner

Sr. No. Name of Work instruction (WI) Work Instruction No. Origin Date
No. Department

Work Instruction - Statutory & Regulatory

1 REFL/MD/WI/SRR/R0 18.02.2018 0 HR
Requirements

Work Instruction for Criteria For Identifying

2 REFL/MD/WI/Poka/R1 01.02.2022 1 Production / QA
Pokayoke/Error Proofing/Fool Provision

Work Instruction for TPM

3 REFL/MD/WI/TPM/R0 18.02.2018 0 QMS
( Total Productive Maintenance)

(QA)Incoming
4 Work Instruction For Incoming Inspection REPL/MD/WI/II/R1 01.02.2009 1
Quality

5 Work Instruction For Insert changing REPL/MD/WI/IC/R2 01.02.2009 1 QA

Work Instruction FOR AVERAGE & RANGE PROCESS

6 REPL/MD/WI/ARPCC/R2 19.01.2010 2 ME(Tooling)
CONTROL CHART

7 WI for Special cutting Tool Resharpening / Coating REPL/MD/WI/SCTRC/R1 07.12.2019 1 ME(Tooling)

8 ◦ WI for Hob due for Resharpening & Coating REPL/MD/WI/HRC 01.12.2009 1 ME(Tooling)

◦ WI for Shaper Cutter due for Resharpening &

9 REPL/MD/WI/SCR 01.12.2009 1 ME(Tooling)
Coating

10 ◦ WI for Broach due for Resharpening & Coating REPL/MD/WI/BRC 01.12.2009 1 ME(Tooling)

11 WI for Analysis of Breakage of 'A' class toolings REPL/MD/WI/BT 01.01.2022 0 ME(Tooling)

12 WI for Scrap the A class Toolings REPL/MD/WI/ST/R1 15.01.2010 1 ME(Tooling)

13 WI for Scrap the A class Fixtures REPL/MD/WI/SF/R1 15.01.2010 1 ME(Tooling)

14 WI for Tool / Fixture Inspection REPL/MD/WI/T/FIR/R1 14.01.2023 1 ME(Tooling)

15 WI for Analysis of Damage or Rework of Fixture REPL/MD/WI/RF 01.01.2022 0 ME(Tooling)

16 WI for Vertical Storage Rack for Fixture REPL/MD/WI/VSR/R0 01.03.2023 0 ME(Tooling)

17 WI for Vertical Storage Rack of gear cutting tool REPL/MD/WI/VSR/R0 01.06.2015 0 ME(Tooling)

WORK INSTRUCTION FOR NOT IN USE “A” CLASS

18 REPL/WI/NIUT/R1 07.12.2019 1 ME(Tooling)
TOOLS

19 SOP for Logistics ( Gear / Shaft) REPL/MD/SOP/LOG/R0 18.04.2023 0 ME(Tooling)

20 SOP for Interplant Dispatch REPL/MD/SOP/IPD/R0 19.03.2016 0 ME(Tooling)

21 SOP for Purchasing Process REPL/MD/SOP/PP/R0 03.04.2016 0 QA

22 WI for Material Store REPL/MD/WI/MS/R1 19.03.2016 1 QA

23 WI for Spectral Testing REPL/MD/WI/ST/R1 06.01.2010 1 QA

REPL/HT/WI/WASH -
24 WI for Washing the Trollies 22.04.2023 0 QA
TROLLEY/R0

25 WI for Eye Checking REPL/MD/WI/EC/R0 17.01.2010 0 QA

WORK INSTRUCTION FOR VISUAL INSPECTION

26 REPL/MD/WI/VIS/R3 12.06.2016 3 QA
STUDY

WORK INSTRUCTION FOR ATTRIBUTE GAUGE

27 REPL/MD/WI/AGS/R3 12.06.2016 3 QA
STUDY

28 WORK INSTRUCTION FOR GAUGE R&R STUDY REPL/MD/WI/GRR/R1 17.10.2009 1 QA

 Doc. No. - REPL/D/QMS/04

Master List of Work Instructions Origin Date - 10.09.2023

Rev. No./Date - 00

Rev. Process Owner

Sr. No. Name of Work instruction (WI) Work Instruction No. Origin Date
No. Department

WORK INSTRUCTION FOR GAUGES OR

29 REPL/MD/WI/GIC/R1 06.08.2022 1 QA
INSTRUMENTS CALIBRATION

WORK INSTRUCTION FOR PROPER HANDLING OF

30 GAUGES & USE OF MEASURING & TEST REPL/MD/WI/PHUMTE/R2 06.08.2022 2 QA
EQUIPMENT
WORK INSTRUCTION FOR USE OF SURFACE
31 REPL/MD/WI/USRT/R0 06.08.2022 0 QA
ROUGHNESS TESTER
WORK INSTRUCTION FOR HANDLING OF NON-
32 REPL/MD/WI/HNCIG/R1 06.08.2022 1 QA
CONFORMING INSTRUMENTS & GAUGES
WORK INSTRUCTION FOR GAUGES OR
33 REPL/MD/WI/GI/R1 07.08.2022 1 QA
INSTRUMENTS ISSUE

34 WI for Linearity Study REPL/MD/WI/LS/R0 07.08.2022 0 QA

35 WI for BIAS Study REPL/MD/WI/BS/R0 07.08.2022 0 QA

REPL/MD/WI/CHARGE
36 ◦ WI for Charge Preparation 25.01.2016 1 QA
PREP/R1

REPL/HT/WI/WASH
37 ◦ WI for Washing machine Procedure 25.01.2016 0 QA
MACHINE/R0

38 ◦ WI for Pre- Heating Furnace REPL/HT/WI/PREHEAT/R0 25.01.2016 0 STORES

39 ◦ WI for SQF in AUTO MODE REPL/HT/WI/SQF AUTO/R0 25.01.2016 0 STORES

REPL/HT/WI/LOW
40 ◦ WI for Low Temp. Tempering 25.01.2016 0 STORES
TEMPERING/R0

REPL/HT/WI/ROCKWELL
41 ◦ WI for ROCKWELL HARDNESS TESTER 25.01.2016 0 STORES
HARDNESS/R0
REPL/HT/WI/MICRO
42 ◦ WI for Micro Sample Preparation 25.01.2016 1 STORES
SAMPLE/R1

◦ WI for Checking Effective case depth on REPL/HT/WI/MICRO

43 25.01.2006 0 STORES
microhardness digital tester HARDNESS/R0
REPL/HT/WI/SHOT
44 ◦ WI for Shot blasting 25.01.2006 1 STORES
BLASTING/R1
Procedure for uniformity test(furnace qualification) REPL/HT/WI/UNIFORMITY
45 25.01.2006 1 STORES
& part validation TEST/R1

46 Procedure for handeling NC parts REPL/HT/WI/NC PARTS/R1 25.01.2006 1 PURCHASE

REPL/HT/WI/FURNACE
47 Procedure for furnace Start Up 25.01.2016 0 STORES
STARTUP/R0

REPL/HT/WI/FURNACE
48 Procedure for furnace Shut Down 25.01.2016 0 QA
SHUTDOWN/R0
REPL/HT/WI/FURNACE
49 Procedure for furnace Seasoning 25.01.2016 0 Production
SEASONING/R0

REPL/HT/WI/FURNACE
50 Procedure for furnace Desooting 03.02.2007 0 QA
DESOOTING/R0

REPL/HT/WI/METHANOL
51 ◦ WI for methanol flow meter verification 13.05.2016 0 QA
FLOW/R0

52 ◦ WI for Development of new component REPL/HT/WI/DNC/R0 11.12.2012 0 QA

REPL/HT/WI/META.
53 ◦ WI for Metallurgical Microscope 25.01.2016 0 QA
MICROSCOPE/R0

54 ◦ WI for Anti Carb Pasting REPL/HT/WI/Anticarbing/R1 25.11.2021 1 QA

REPL/HT/WI/BURN
55 ◦ WI for Burn Testing 13.01.2018 0 QA
TESTING/R0

REPL/HT/WI/PUNCHING
56 ◦ WI for Component Marking 11.02.2015 0 QA
MACHINE/R0

REPL/HT/WI/PUNCHING
57 Procedure for Safety Alarm Check 10.12.2021 1 QA
MACHINE/R1
REPL/HT/WI/GAS
58 ◦ WI for Gas Nitriding furnace 10.12.2021 0 QA
NITRIDING/R0
 Doc. No. - REPL/D/QMS/04

Master List of Work Instructions Origin Date - 10.09.2023

Rev. No./Date - 00

Rev. Process Owner

Sr. No. Name of Work instruction (WI) Work Instruction No. Origin Date
No. Department

59 ◦ WI for Checking CP by CP Coil Tester REPL/HT/WI/CPCT/R0 10.12.2021 0 QA

QUALITY ASSURANCE
1 Work Instruction For Rework REPL/WI/QA/01 07.03.2018 3 QA

2 WI for Disposal of NC parts REPL/WI/QA/02 19.08.2015 1 HR

3 WI for Inprocess Quality REPL/WI/QA/03 22.01.2024 0 PRODUCTION(HT)

WI for carrying out rework for soft/ finish turning

4 REPL/WI/QA/04 01.11.2023 0 PRODUCTION(HT)
(ID undersize) process defects

WI for carrying out rework for soft/ finish turning

5 REPL/WI/QA/05 01.11.2023 0 QA
(OD oversize) process defects

WI for carrying out rework for soft/ finish turning

6 REPL/WI/QA/06 01.11.2023 0 QA
(Boss Height oversize) process defects

WI for carrying out rework for soft/ finish turning

7 REPL/WI/QA/07 01.11.2023 0 QA
of shaft (Height oversize) process defects

WI for carrying out rework for ID/OD grinding (ID

8 REPL/WI/QA/08 01.11.2023 0 QA
undersize) process defects

WI for carrying out rework for ID/OD grinding

9 REPL/WI/QA/09 01.11.2023 0 QA
(cone oversize) process defects

WI for carrying out rework for ID/OD grinding (OD

10 REPL/WI/QA/10 01.11.2023 0 QA
oversize) process defects

WI for carrying out rework for ID/OD grinding

11 REPL/WI/QA/11 01.11.2023 0 QA
(Height oversize) process defects

WI for carrying out rework for gear cutting (Face

12 REPL/WI/QA/12 01.11.2023 0 QA
Burr) process defects

WI for carrying out rework for gear cutting

13 REPL/WI/QA/13 01.11.2023 0 QA
(Hobbing Span / DOP oversize) process defects

WI for carrying out rework for gear cutting (shaping

14 REPL/WI/QA/14 01.11.2023 0 QA
Span / DOP oversize) process defects

WI for carrying out rework for gear cutting (shaving

15 REPL/WI/QA/15 01.11.2023 0 QA
unclean) process defects

WI for carrying out rework for gear cutting (shaving

16 REPL/WI/QA/16 01.11.2023 0 QA
Span / DOP oversize) process defects

17 WI for Final inspection REPL/WI/QA/17 14.02.2024 0 QA

18 WORK INSTRUCTION FOR ROLLING REPL/WI/QA/18 14.01.2024 0 QA

WORK INSTRUCTION OF OPTICLINE CS614

19 REPL/WI/QA/19 15.02.2024 0 QA
MACHINE

20 Work Instruction Layout Inspection REPL/WI/QA/20 14.01.2024 0 QA

21 WI for Visual Inspection of forging Parts REPL/WI/QA/21 04.03.2024 0 QA

f

22 WI for Calibration of Instrument (Forging) REPL/WI/QA/22 01.01.2014 1 QA

f 18.03.2024

23 WI for Final inspection (Forging) REPL/WI/QA/23 07.03.2018 1 QA

f 18.03.2024

24 WI for Rework of Final Inspection parts REPL/WI/QA/24 07.03.2018 3 QA

f 18.03.2024

25 WI for Inprocess Inspection (Hot Forging) REPL/WI/QA/25 01.01.2014 1 QA

f 18.03.2024

26 WI for Calibration & verification process REPL/WI/QA/26 01.01.2014 1 QA

f 18.03.2024

27 WI for Sample Preparation REPL/WI/QA/27 01.04.2014 2 QA

f 18.03.2024

28 WI for Inclusion Testing REPL/WI/QA/28 01.04.2014 2 QA

f 18.03.2024

29 WI for Grain size Testing REPL/WI/QA/29 01.04.2014 2 QA

f 18.03.2024
 Doc. No. - REPL/D/QMS/04

Master List of Work Instructions Origin Date - 10.09.2023

Rev. No./Date - 00

Rev. Process Owner

Sr. No. Name of Work instruction (WI) Work Instruction No. Origin Date
No. Department

30 WI for Macro Testing REPL/WI/QA/30 01.04.2014 2 QA

f 18.03.2024

31 WI for Macro Etching Testing REPL/WI/QA/31 01.04.2014 2 QA

f 18.03.2024

32 WI for Upset Testing REPL/WI/QA/32 01.04.2014 2 QA

f 18.03.2024

33 WI for Grain Flow Testing REPL/WI/QA/33 01.04.2014 2 QA

f 18.03.2024

34 WI for Hardenability Test REPL/WI/QA/34 01.04.2014 2 QA

f 18.03.2024

35 WI for Brinell Hardness Tester REPL/WI/QA/35 01.04.2014 2 QA

f 18.03.2024

36 WI for Calibration procedure for HT furnace REPL/WI/QA/36 01.04.2014 2 QA

f 18.03.2024

37 WI for Spectrometer Handling REPL/WI/QA/37 01.04.2014 2 QA

f 18.03.2024

38 WI for Process Qualification Test REPL/WI/QA/38 01.04.2014 2 QA

f 18.03.2024

39 WI for Rockwell Hardness Tester REPL/WI/QA/39 01.04.2014 2 QA

f 18.03.2024

40 WI for Muffler Handling REPL/WI/QA/40 01.04.2014 2 QA

f 18.03.2024

41 WI for Metallurgical Microscope Handling REPL/WI/QA/41 01.04.2014 2 QA

f 18.03.2024

42 WI for Handling of Polishing Machine REPL/WI/QA/42 01.04.2014 2 QA

f 18.03.2024

43 WI for RM bar testing for material mixup REPL/WI/QA/43 01.04.2014 2 QA

f 18.03.2024

44 WI for step down Testing REPL/WI/QA/44 11.03.2023 1 QA

f 18.03.2024

45 WI for Spark Testing REPL/WI/QA/45 10.02.2019 1 QA

f 18.03.2024

46 WI for Magnetic Particle Inspection REPL/WI/QA/46 01.04.2014 2 QA

f 18.03.2024

47 WI for Spectral testing REPL/WI/QA/47 10.02.2019 1 QA

f 18.03.2024

48 WI for Optical Pyrometer Handling REPL/WI/QA/48 01.04.2014 2 QA

f 18.03.2024
WI for Using ERMA scale for Calibration of Brinell
49 REPL/WI/QA/49 01.04.2014 2 QA
microscope f 18.03.2024
WORK INSTRUCTION FOR ROCKWEL HARDNESS
50 REPL/WI/QA/50 25.01.2016 1 QA
TESTER HTM
WORK INSTRUCTION FOR
51 REPL/WI/QA/51 25.01.2016 2 QA
MICRO SAMPLE PREPARATION HTM

WORK INSTRUCTION FOR CHECKING EFFECTIVE

52 REPL/WI/QA/52 25.01.2016 1 QA
CASE DEPTH ON MICROHARDNESS TESTER
htm

PROCEDURE FOR 9 POINT UNIFORMITY TEST

53 REPL/WI/QA/53 01.02.2007 1 QA
(FURNACE QUALIFICATION) & PART VALIDATION

54 WORK INSTRUCTION FOR HANDELING NC PARTS REPL/WI/QA/54 25.01.2016 1 QA

WORK INSTRUCTION FOR METALLURGICAL

55 REPL/WI/QA/55 25.01.2016 1 QA
MICROSCOPE

56 WORK INSTRUCTION FOR BURN TESTING REPL/WI/QA/56 25.01.2016 2 QA

Work Instruction for Tensile, Impact & K4 Inclusion

57 REPL/WI/QA/57 01.04.2024 0 QA
Testing for DAIPL (From Raw Material)
 Doc. No. - REPL/D/QMS/04

Master List of Work Instructions Origin Date - 10.09.2023

Rev. No./Date - 00

Rev. Process Owner

Sr. No. Name of Work instruction (WI) Work Instruction No. Origin Date
No. Department

WORK INSTRUCTION FOR CHECKING CORE

58 REPL/WI/QA/58 01.04.2024 0 QA
HARDNESS ON VICKER'S HARDNESS TESTER(HV10)

HUMAN RESOURCES
80 WI for Poison Test REPL/WI/HR/01 27.11.2023 0 HR

STORES
1 WI for Material Issue REPL/WI/ST/01 27.11.2023 0 STORES

2 WI for Material Handling REPL/WI/ST/02 19.03.2016 1 STORES

3 WI for Receiving of Material REPL/WI/ST/03 27.12.2023 0 STORES

4 WI for packaging of Finished Goods Parts REPL/WI/ST/04 27.12.2023 0 STORES

5 WI for FIRST IN FIRST OUT (FIFO) REPL/WI/ST/05 27.12.2023 0 STORES

6 WI for Using Stacker / Forklift REPL/WI/ST/06 27.12.2023 0 STORES

7 WI for Raw Material Storage REPL/WI/ST/07 01.01.2016 1 STORES

f 18.03.2024

8 WI for FIFO for raw material REPL/WI/ST/08 01.01.2016 1 STORES

f 18.03.2024

9 WI for RM Handling procedure (FIFO)-Pictorial REPL/WI/ST/09 11.04.2023 1 STORES

f 18.03.2024

10 WI for Incoming Raw Material Entry Register REPL/WI/ST/10 01.04.2023 1 STORES

f 18.03.2024

11 WI for Oiling & Packaging at Dispatch REPL/WI/ST/11 01.01.2014 1 STORES

f 18.03.2024

12 WI for FIFO Dispatch (forging) REPL/WI/ST/12 09.03.2016 1 STORES

f 18.03.2024

13 WI for Flow chart traceability procedure REPL/WI/ST/13 01.04.2014 2 STORES

f 18.03.2024

14 WI for Raw Material shifting REPL/WI/ST/14 18.03.2024 0 STORES

f

15 WI for Heatcode Issue REPL/WI/ST/15 01.04.2014 2 STORES

f 18.03.2024

16

PRODUCTION

1 4M CHANGE CONDITIONS CRITERIA REPL/WI/PRD/01 27.11.2023 0 Production

2 WI for Die Manufacturing REPL/WI/PRD/02 01.01.2016 1 Production

f 18.03.2024

3 WI for Emergency Situation in forging REPL/WI/PRD/03 02.01.2019 1 Production

f 18.03.2024

4 WI for safety work REPL/WI/PRD/04 01.04.2014 2 Production

f 18.03.2024

5 WI for General work for Hammer & Press REPL/WI/PRD/05 01.04.2014 2 Production
f 18.03.2024

6 WI for starting Forging Press REPL/WI/PRD/06 01.01.2014 1 Production

f 18.03.2024

7 WI for Die Setting REPL/WI/PRD/07 07.03.2018 1 Production

f 18.03.2024
 Doc. No. - REPL/D/QMS/04

Master List of Work Instructions Origin Date - 10.09.2023

Rev. No./Date - 00

Rev. Process Owner

Sr. No. Name of Work instruction (WI) Work Instruction No. Origin Date
No. Department

8 WI for Operating of Induction Heater REPL/WI/PRD/08 01.01.2014 1 Production

f 18.03.2024

9 WI for Identifying Pokayoke in process REPL/WI/PRD/09 07.03.2018 1 Production

f 18.03.2024

10 WI for Lock out & Tag out REPL/WI/PRD/10 07.03.2018 1 Production

f 18.03.2024

11 WI for Tagging System REPL/WI/PRD/11 07.03.2018 1 Production

f 18.03.2024

12 WI for Shift Handover REPL/WI/PRD/12 18.03.2024 0 Production

f 18.03.2024

13 WI for Shearing Machine cutting & Blade Setting REPL/WI/PRD/13 01.01.2016 1 Production
f 18.03.2024

14 WI for Band Saw and CNC cutting REPL/WI/PRD/14 01.01.2016 1 Production

f 18.03.2024

15 WI for Control Cooling REPL/WI/PRD/15 01.04.2014 2 Production

f 18.03.2024

16 WI for Acid pickling of forging parts REPL/WI/PRD/16 01.04.2014 2 Production

f 18.03.2024

17 WI for Abrassive Cutting Machine REPL/WI/PRD/17 01.04.2014 2 Production

f 18.03.2024

18 WI for Shot Blasting (Forging) REPL/WI/PRD/18 01.04.2014 1 Production

f 18.03.2024

19 WI for Rework of Heat Treatment REPL/WI/PRD/19 01.04.2014 2 Production

f 18.03.2024

20 WI for Furnace operating Procedure REPL/WI/PRD/20 01.04.2014 2 Production

f 18.03.2024

21 WI for Furnace Cleaning Trap Points REPL/WI/PRD/21 01.04.2014 2 Production

f 18.03.2024

22 WI for Maintaining Polymer Concentration REPL/WI/PRD/22 01.04.2014 2 Production

f 18.03.2024

23 WI for HT Change over Process REPL/WI/PRD/23 01.04.2014 2 Production

f 18.03.2024

24 WI for Charge Preparation REPL/WI/PRD/24 25.01.2016 2

WORK INSTRUCTION FOR WASHING OF HT

25 REPL/WI/PRD/25 25.01.2016 1
COMPONENT

26 WORK INSTRUCTION FOR CHARGE PRE-HEATING REPL/WI/PRD/26 25.01.2016 1

27 WORK INSTRUCTION FOR SQF IN AUTO MODE REPL/WI/PRD/27 25.01.2016 1

28 WORK INSTRUCTION FOR TEMPERING REPL/WI/PRD/28 25.01.2016 1

29 WORK INSTRUCTION FOR SHOT BLASTING REPL/WI/PRD/29 25.01.2016 2

WORK INSTRUCTION FOR CHARGE NUMBER

30 REPL/WI/PRD/30 25.01.2016 1
PUNCHING

WORK INSTRUCTION FOR FURNACE START UP REPL/WI/PRD/31 25.01.2016 1

WORK INSTRUCTION FOR FURNACE SHUT DOWN REPL/WI/PRD/32 25.01.2016 1

WORK INSTRUCTION FOR FURNACE SEASONING REPL/WI/PRD/33 25.01.2016 1

31 WORK INSTRUCTION FOR FURNACE DESOOTING REPL/WI/PRD/34 25.01.2016 1

Work instruction for methanol flow meter

REPL/WI/PRD/35 25.01.2016 1
verification

Work Instruction For Development Of New

REPL/WI/PRD/36 25.01.2016 1
Component

WORK INSTRUCTION FOR ANTI CARB PASTING REPL/WI/PRD/37 25.01.2016 2

WORK INSTRUCTION FOR COMPONANT MARKING REPL/WI/PRD/38 25.01.2016 1

 Doc. No. - REPL/D/QMS/04

Master List of Work Instructions Origin Date - 10.09.2023

Rev. No./Date - 00

Rev. Process Owner

Sr. No. Name of Work instruction (WI) Work Instruction No. Origin Date
No. Department

Work Instruction for Safety Alarm Check REPL/WI/PRD/39 25.01.2016 2

WORK INSTRUCTION FOR FOR GAS NITRIDING REPL/WI/PRD/40 25.01.2016 1

Work Instruction For Checking CP by CP Coil Tester REPL/WI/PRD/41 25.01.2016 1

REPL/WI/PRD/42 25.01.2016 1

Manufacturing Engg.
WI for Acceptance Criteria of Hob after
1 REPL/WI/ME/01 20.03.2024 0 ME
Resharpening

Prepared By Checked By Approved by

 Format No.- REPL/F/QMS/16
Issue record of Work Instructions Origin Date.- 02/02/2024
Rev.No. / Date.- 0

Sr. Rev. No. of

Name of Work instruction (WI) Work Instruction No. Origin Date Rev. Date Dept Copies Issue Date Sign
No. No. Issued

Work Instruction - Statutory & Regulatory

1 REFL/MD/WI/SRR/R0 18.02.2018 0 -- 1 18.02.2018
Requirements

Work Instruction for Criteria For Identifying

2 REFL/MD/WI/Poka/R1 01.02.2022 1 01.03.2023 1 01.03.2023
Pokayoke/Error Proofing/Fool Provision

Work Instruction for TPM

3 REFL/MD/WI/TPM/R0 18.02.2018 0 -- 1 18.02.2018
( Total Productive Maintenance)

4 Work Instruction For Incoming Inspection REPL/MD/WI/II/R1 01.02.2009 1 12.12.2009 1 12.12.2009

5 Work Instruction For Insert changing REPL/MD/WI/IC/R2 01.02.2009 1 02.11.2009 1 02.11.2009

Work Instruction FOR AVERAGE & RANGE

6 REPL/MD/WI/ARPCC/R2 19.01.2010 2 20.03.2023 1 20.03.2023
PROCESS CONTROL CHART

WI for Special cutting Tool Resharpening /

7 REPL/MD/WI/SCTRC/R1 07.12.2019 1 22.12.2023 1 22.12.2023
Coating

8 ◦ WI for Hob due for Resharpening & Coating REPL/MD/WI/HRC/R1 01.12.2009 1 01.01.2010 1 01.01.2010

◦ WI for Shaper Cutter due for Resharpening

9 REPL/MD/WI/SCR 01.12.2009 1 04.10.2010 1 04.10.2010
& Coating

◦ WI for Broach due for Resharpening &

10 REPL/MD/WI/BRC 01.12.2009 1 15.01.2010 1 15.01.2010
Coating

WI for Analysis of Breakage of 'A' class

11 REPL/MD/WI/BT 01.01.2022 0 -- 1 01.01.2022
toolings

12 WI for Scrap the A class Toolings REPL/MD/WI/ST/R1 01.12.2009 1 15.01.2010 1 15.01.2010

13 WI for Scrap the A class Fixtures REPL/MD/WI/SF/R1 01.12.2009 1 15.01.2010 1 15.01.2010

14 WI for Tool / Fixture Inspection REPL/MD/WI/T/FIR/R1 12.12.2022 1 14.01.2023 1 14.01.2023

WI for Analysis of Damage or Rework of

15 REPL/MD/WI/RF/R0 01.01.2022 0 -- 1 01.01.2022
Fixture

16 WI for Vertical Storage Rack for Fixture REPL/MD/WI/VSR/R0 01.03.2023 0 -- 1 01.03.2023

WI for Vertical Storage Rack of gear cutting

17 REPL/MD/WI/VSR/R0 01.06.2015 0 -- 1 01.03.2023
tool

WORK INSTRUCTION FOR NOT IN USE “A”

18 REPL/WI/NIUT/R1 07.12.2019 1 27.01.2023 1 27.01.2023
CLASS TOOLS

19 SOP for Logistics ( Gear / Shaft) REPL/MD/SOP/LOG/R0 18.04.2023 0 -- 1 18.04.2023

20 SOP for Interplant Dispatch REPL/MD/SOP/IPD/R0 19.03.2016 0 -- 1 19.03.2016

21 SOP for Purchasing Process REPL/MD/SOP/PP/R0 03.04.2016 0 -- 1 03.04.2016

22 WI for Material Store REPL/MD/WI/MS/R1 19.03.2016 1 12.10.2020 1 12.10.2020

23 WI for Spectral Testing REPL/MD/WI/ST/R1 06.01.2010 1 19.03.2016 1 19.03.2016

REPL/HT/WI/WASH -
24 WI for Washing the Trollies TROLLEY/R0
22.04.2023 0 -- 1 22.04.2023

25 WI for Eye Checking REPL/MD/WI/EC/R0 17.01.2010 0 -- 1 01.03.2022

 Format No.- REPL/F/QMS/16
Issue record of Work Instructions Origin Date.- 02/02/2024
Rev.No. / Date.- 0

Sr. Rev. No. of

Name of Work instruction (WI) Work Instruction No. Origin Date Rev. Date Dept Copies Issue Date Sign
No. No. Issued

WORK INSTRUCTION FOR VISUAL INSPECTION

26 REPL/MD/WI/VIS/R3 12.06.2016 3 01.03.2022 1 01.03.2022
STUDY

WORK INSTRUCTION FOR ATTRIBUTE GAUGE

27 REPL/MD/WI/AGS/R3 12.06.2016 3 01.03.2022 1 01.03.2022
STUDY

28 WORK INSTRUCTION FOR GAUGE R&R STUDY REPL/MD/WI/GRR/R1 17.10.2009 1 24.01.2010 2 24.01.2010

WORK INSTRUCTION FOR GAUGES OR

29 REPL/MD/WI/GIC/R1 06.08.2022 1 14.01.2023 5 07.04.2023
INSTRUMENTS CALIBRATION

WORK INSTRUCTION FOR PROPER HANDLING

30 OF GAUGES & USE OF MEASURING & TEST REPL/MD/WI/PHUMTE/R2 06.08.2022 2 15.01.2023 2 15.01.2023
EQUIPMENT

WORK INSTRUCTION FOR USE OF SURFACE

31 REPL/MD/WI/USRT/R0 06.08.2022 0 -- 2 06.08.2022
ROUGHNESS TESTER

WORK INSTRUCTION FOR HANDLING OF

32 NON-CONFORMING INSTRUMENTS & REPL/MD/WI/HNCIG/R1 06.08.2022 1 15.01.2024 2 15.01.2024
GAUGES

WORK INSTRUCTION FOR GAUGES OR

33 REPL/MD/WI/GI/R1 07.08.2022 1 20.01.2023 1 07.04.2023
INSTRUMENTS ISSUE

34 WI for Linearity Study REPL/MD/WI/LS/R0 07.08.2022 0 -- 3 07.08.2022

35 WI for BIAS Study REPL/MD/WI/BS/R0 07.08.2022 0 -- 3 07.08.2022

REPL/MD/WI/CHARGE
36 ◦ WI for Charge Preparation PREP/R1
25.01.2016 1 03.07.2022 3 03.07.2022

REPL/HT/WI/WASH
37 ◦ WI for Washing machine Procedure MACHINE/R0
25.01.2016 0 -- 3 14.08.2023

38 ◦ WI for Pre- Heating Furnace REPL/HT/WI/PREHEAT/R0 25.01.2016 0 -- 3 14.08.2023

39 ◦ WI for SQF in AUTO MODE REPL/HT/WI/SQF AUTO/R0 25.01.2016 0 -- 2 14.08.2023

REPL/HT/WI/LOW
40 ◦ WI for Low Temp. Tempering TEMPERING/R0
25.01.2016 0 25.01.2016 2 14.08.2023

REPL/HT/WI/ROCKWELL
41 ◦ WI for ROCKWELL HARDNESS TESTER HARDNESS/R0
25.01.2016 0 -- 2 14.08.2023

REPL/HT/WI/MICRO
42 ◦ WI for Micro Sample Preparation SAMPLE/R1
25.01.2006 1 25.01.2016 2 19.07.2023

◦ WI for Checking Effective case depth on REPL/HT/WI/MICRO

43 25.01.2006 0 -- 1 19.07.2023
microhardness digital tester HARDNESS/R0

REPL/HT/WI/SHOT
44 ◦ WI for Shot blasting BLASTING/R1
25.01.2006 1 25.01.2016 2 14.08.2023

Procedure for uniformity test(furnace REPL/HT/WI/UNIFORMITY

45 25.01.2006 1 03.02.2007 3 22.11.2022
qualification) & part validation TEST/R1

46 Procedure for handeling NC parts REPL/HT/WI/NC PARTS/R1 25.01.2006 1 03.07.2022 3 03.07.2022

REPL/HT/WI/FURNACE
47 Procedure for furnace Start Up STARTUP/R0
25.01.2016 0 -- 3 14.08.2023

REPL/HT/WI/FURNACE
48 Procedure for furnace Shut Down SHUTDOWN/R0
25.01.2016 0 -- 3 14.08.2023

REPL/HT/WI/FURNACE
49 Procedure for furnace Seasoning SEASONING/R0
25.01.2016 0 -- 3 14.08.2023

REPL/HT/WI/FURNACE
50 Procedure for furnace Desooting DESOOTING/R0
03.02.2007 0 -- 2 14.08.2023
 Format No.- REPL/F/QMS/16
Issue record of Work Instructions Origin Date.- 02/02/2024
Rev.No. / Date.- 0

Sr. Rev. No. of

Name of Work instruction (WI) Work Instruction No. Origin Date Rev. Date Dept Copies Issue Date Sign
No. No. Issued

REPL/HT/WI/METHANOL
51 ◦ WI for methanol flow meter verification FLOW/R0
13.05.2016 0 -- 2 14.08.2023

52 ◦ WI for Development of new component REPL/HT/WI/DNC/R0 11.12.2012 0 01.01.2022 3 14.08.2023

REPL/HT/WI/META.
53 ◦ WI for Metallurgical Microscope MICROSCOPE/R0
25.01.2016 0 -- 2 19.07.2023

REPL/HT/WI/Anticarbing/
54 ◦ WI for Anti Carb Pasting R1
25.11.2021 1 01.01.2022 2 01.01.2022

REPL/HT/WI/BURN
55 ◦ WI for Burn Testing TESTING/R0
13.01.2018 0 -- 3 19.07.2023

REPL/HT/WI/PUNCHING
56 ◦ WI for Component Marking MACHINE/R0
11.02.2015 0 -- 2 14.08.2022

REPL/HT/WI/PUNCHING
57 Procedure for Safety Alarm Check MACHINE/R1
10.12.2021 1 01.04.2023 2 01.04.2023

REPL/HT/WI/GAS
58 ◦ WI for Gas Nitriding furnace NITRIDING/R0
10.12.2021 0 -- 1 10.12.2021

59 ◦ WI for Checking CP by CP Coil Tester REPL/HT/WI/CPCT/R0 10.12.2021 0 -- 1 10.12.2021

QUALITY ASSURANCE

1 Work Instruction For Rework REPL/WI/QA/01 07.03.2018 3 01.11.2023 QA 1 01.11.2023

2 WI for Disposal of NC parts REPL/WI/QA/02 19.08.2015 1 01.11.2023 QA 1 01.11.2023

3 WI for Inprocess Quality REPL/WI/QA/03 22.01.2024 0 -- QA 1 22.01.2024

WI for carrying out rework for soft/ finish

4 REPL/WI/QA/04 01.11.2023 0 -- QA 1 01.11.2023
turning (ID undersize) process defects

WI for carrying out rework for soft/ finish

5 REPL/WI/QA/05 01.11.2023 0 -- QA 1 01.11.2023
turning (OD oversize) process defects

WI for carrying out rework for soft/ finish

6 turning (Boss Height oversize) process REPL/WI/QA/06 01.11.2023 0 -- QA 1 01.11.2023
defects
WI for carrying out rework for soft/ finish
7 turning of shaft (Height oversize) process REPL/WI/QA/07 01.11.2023 0 -- QA 1 01.11.2023
defects

WI for carrying out rework for ID/OD grinding

8 REPL/WI/QA/08 01.11.2023 0 -- QA 1 01.11.2023
(ID undersize) process defects

WI for carrying out rework for ID/OD grinding

9 REPL/WI/QA/09 01.11.2023 0 -- QA 1 01.11.2023
(cone oversize) process defects

WI for carrying out rework for ID/OD grinding

10 REPL/WI/QA/10 01.11.2023 0 -- QA 1 01.11.2023
(OD oversize) process defects

WI for carrying out rework for ID/OD grinding

11 REPL/WI/QA/11 01.11.2023 0 -- QA 1 01.11.2023
(Height oversize) process defects

WI for carrying out rework for gear cutting

12 REPL/WI/QA/12 01.11.2023 0 -- QA 1 01.11.2023
(Face Burr) process defects

WI for carrying out rework for gear cutting

13 (Hobbing Span / DOP oversize) process REPL/WI/QA/13 01.11.2023 0 -- QA 1 01.11.2023
defects
WI for carrying out rework for gear cutting
14 (shaping Span / DOP oversize) process REPL/WI/QA/14 01.11.2023 0 -- QA 1 01.11.2023
defects

WI for carrying out rework for gear cutting

15 REPL/WI/QA/15 01.11.2023 0 -- QA 1 01.11.2023
(shaving unclean) process defects
 Format No.- REPL/F/QMS/16
Issue record of Work Instructions Origin Date.- 02/02/2024
Rev.No. / Date.- 0

Sr. Rev. No. of

Name of Work instruction (WI) Work Instruction No. Origin Date Rev. Date Dept Copies Issue Date Sign
No. No. Issued

WI for carrying out rework for gear cutting

16 (shaving Span / DOP oversize) process REPL/WI/QA/16 01.11.2023 0 -- QA 1 01.11.2023
defects

17 WI for Final inspection REPL/WI/QA/17 14.01.2024 0 -- QA 1 14.01.2024

18 WORK INSTRUCTION FOR ROLLING REPL/WI/QA/18 14.01.2024 0 -- QA 1 14.01.2024

WORK INSTRUCTION OF OPTICLINE CS614

19 MACHINE
REPL/WI/QA/19 15.02.2024 0 -- QA 1 15.02.2024

20 Work Instruction Layout Inspection REPL/WI/QA/20 15.02.2024 0 -- QA 1 15.02.2024

21 WI for Visual Inspection of forging Parts REPL/WI/QA/21 04.03.2024 0 -- QA

F

22 WI for Calibration of Instrument (Forging) REPL/WI/QA/22 01.01.2014 1 18.03.2024 QA 15.02.2024

F

23 WI for Final inspection (Forging) REPL/WI/QA/23 07.03.2018 1 18.03.2024 QA 15.02.2024

F

24 WI for Rework of Final Inspection parts REPL/WI/QA/24 07.03.2018 3 18.03.2024 QA 15.02.2024

F

25 WI for Inprocess Inspection (Hot Forging) REPL/WI/QA/25 01.01.2014 1 18.03.2024 QA 15.02.2024

F

26 WI for Calibration & verification process REPL/WI/QA/26 01.01.2014 1 18.03.2024 QA 15.02.2024

F

27 WI for Sample Preparation REPL/WI/QA/27 01.04.2014 2 18.03.2024 QA 15.02.2024

F

28 WI for Inclusion Testing REPL/WI/QA/28 01.04.2014 2 18.03.2024 QA 15.02.2024

F

29 WI for Grain size Testing REPL/WI/QA/29 01.04.2014 2 18.03.2024 QA 15.02.2024

F

30 WI for Macro Testing REPL/WI/QA/30 01.04.2014 2 18.03.2024 QA 15.02.2024

F

31 WI for Macro Etching Testing REPL/WI/QA/31 01.04.2014 2 18.03.2024 QA 15.02.2024

F

32 WI for Upset Testing REPL/WI/QA/32 01.04.2014 2 18.03.2024 QA 15.02.2024

F

33 WI for Grain Flow Testing REPL/WI/QA/33 01.04.2014 2 18.03.2024 QA 15.02.2024

F

34 WI for Hardenability Test REPL/WI/QA/34 01.04.2014 2 18.03.2024 QA 15.02.2024

F

35 WI for Brinell Hardness Tester REPL/WI/QA/35 01.04.2014 2 18.03.2024 QA 15.02.2024

F

36 WI for Calibration procedure for HT furnace REPL/WI/QA/36 01.04.2014 2 18.03.2024 QA 15.02.2024

F

37 WI for Spectrometer Handling REPL/WI/QA/37 01.04.2014 2 18.03.2024 QA 15.02.2024

F

38 WI for Process Qualification Test REPL/WI/QA/38 01.04.2014 2 18.03.2024 QA 15.02.2024

F

39 WI for Rockwell Hardness Tester REPL/WI/QA/39 01.04.2014 2 18.03.2024 QA 15.02.2024

F

40 WI for Muffler Handling REPL/WI/QA/40 01.04.2014 2 18.03.2024 QA 15.02.2024

F
 Format No.- REPL/F/QMS/16
Issue record of Work Instructions Origin Date.- 02/02/2024
Rev.No. / Date.- 0

Sr. Rev. No. of

Name of Work instruction (WI) Work Instruction No. Origin Date Rev. Date Dept Copies Issue Date Sign
No. No. Issued

41 WI for Metallurgical Microscope Handling REPL/WI/QA/41 01.04.2014 2 18.03.2024 QA 15.02.2024

F

42 WI for Handling of Polishing Machine REPL/WI/QA/42 01.04.2014 2 18.03.2024 QA 15.02.2024

F

43 WI for RM bar testing for material mixup REPL/WI/QA/43 01.04.2014 2 18.03.2024 QA 15.02.2024
F

44 WI for step down Testing REPL/WI/QA/44 11.03.2023 1 18.03.2024 QA 15.02.2024

F

45 WI for Spark Testing REPL/WI/QA/45 10.02.2019 1 18.03.2024 QA 15.02.2024

F

46 WI for Magnetic Particle Inspection REPL/WI/QA/46 01.04.2014 2 18.03.2024 QA 15.02.2024

F

47 WI for Spectral testing REPL/WI/QA/47 10.02.2019 1 18.03.2024 QA 15.02.2024

F

48 WI for Optical Pyrometer Handling REPL/WI/QA/48 01.04.2014 2 18.03.2024 QA 15.02.2024

F

WI for Using ERMA scale for Calibration of Brinell

49 microscope
REPL/WI/QA/49 01.04.2014 2 18.03.2024 QA 15.02.2024
F

WORK INSTRUCTION FOR ROCKWEL HARDNESS

50 TESTER
REPL/WI/QA/50 25.01.2016 1 31.03.2024 QA

WORK INSTRUCTION FOR

51 MICRO SAMPLE PREPARATION
REPL/WI/QA/51 25.01.2016 2 31.03.2024 QA

WORK INSTRUCTION FOR CHECKING EFFECTIVE

52 CASE DEPTH ON MICROHARDNESS TESTER
REPL/WI/QA/52 25.01.2016 1 31.03.2024 QA

PROCEDURE FOR 9 POINT UNIFORMITY TEST

53 (FURNACE QUALIFICATION) & PART VALIDATION
REPL/WI/QA/53 01.02.2007 1 31.03.2024 QA

54 WORK INSTRUCTION FOR HANDELING NC PARTS REPL/WI/QA/54 25.01.2016 1 31.03.2024 QA

WORK INSTRUCTION FOR METALLURGICAL

55 MICROSCOPE
REPL/WI/QA/55 25.01.2016 1 31.03.2024 QA

56 WORK INSTRUCTION FOR BURN TESTING REPL/WI/QA/56 25.01.2016 2 31.03.2024 QA

Work Instruction for Tensile, Impact & K4 Inclusion

57 Testing for DAIPL (From Raw Material)
REPL/WI/QA/57 01.04.2024 0 -- QA

WORK INSTRUCTION FOR CHECKING CORE

58 HARDNESS ON VICKER'S HARDNESS REPL/WI/QA/58 01.04.2024 0 01.04.2024 QA
TESTER(HV10)

HUMAN RESOURCES

1 WI for Poison Test REPL/WI/HR/01 27.11.2023 0 -- HR 2 27.11.2023

STORES & DISPATCH

1 WI for Material Issue REPL/WI/ST/01 27.11.2023 0 -- ST 1 27.12.2023

2 WI for Material Handling REPL/WI/ST/02 19.03.2016 1 27.11.2023 ST 1 27.12.2023

3 WI for Receiving of Material REPL/WI/ST/03 27.12.2023 0 -- ST 2 27.12.2023

 Format No.- REPL/F/QMS/16
Issue record of Work Instructions Origin Date.- 02/02/2024
Rev.No. / Date.- 0

Sr. Rev. No. of

Name of Work instruction (WI) Work Instruction No. Origin Date Rev. Date Dept Copies Issue Date Sign
No. No. Issued

4 WI for packaging of Finished Goods Parts REPL/WI/ST/04 27.12.2023 0 -- ST 2 27.12.2023

5 WI for FIRST IN FIRST OUT (FIFO) REPL/WI/ST/05 27.12.2023 0 -- ST 1 27.12.2023

6 WI for Using Stacker / Forklift REPL/WI/ST/06 27.12.2023 0 -- ST 1 27.12.2023

7 WI for Raw Material Storage REPL/WI/ST/07 01.01.2016 1 18.03.2024 ST 18.03.2024

F

8 WI for FIFO for raw material REPL/WI/ST/08 01.01.2016 1 18.03.2024 ST 18.03.2024

F

WI for RM Handling procedure (FIFO)-

9 REPL/WI/ST/09 11.04.2023 1 18.03.2024 ST 18.03.2024
Pictorial
F

10 WI for Incoming Raw Material Entry Register REPL/WI/ST/10 01.04.2023 1 18.03.2024 ST 18.03.2024
F

11 WI for Oiling & Packaging at Dispatch REPL/WI/ST/11 01.01.2014 1 18.03.2024 ST 18.03.2024

F

12 WI for FIFO Dispatch (forging) REPL/WI/ST/12 09.03.2016 1 18.03.2024 ST 18.03.2024

F

13 WI for Flow chart traceability procedure REPL/WI/ST/13 01.04.2014 2 18.03.2024 ST 18.03.2024

F

14 WI for Raw Material shifting REPL/WI/ST/14 18.03.2024 0 -- ST 18.03.2024

F

15 WI for Heatcode Issue REPL/WI/ST/15 01.04.2014 2 18.03.2024 ST 18.03.2024

F
PRODUCTION

1 4M CHANGE CONDITIONS CRITERIA REPL/WI/PRD/01 27.11.2023 0 -- PRD 27.11.2023

2 WI for Die Manufacturing REPL/WI/PRD/02 01.01.2016 1 18.03.2024 PRD 18.03.2024

F

3 WI for Emergency Situation in forging REPL/WI/PRD/03 02.01.2019 1 18.03.2024 PRD 18.03.2024

F

4 WI for safety work REPL/WI/PRD/04 01.04.2014 2 18.03.2024 PRD 18.03.2024

F

5 WI for General work for Hammer & Press REPL/WI/PRD/05 01.04.2014 2 18.03.2024 PRD 18.03.2024
F

6 WI for starting Forging Press REPL/WI/PRD/06 01.01.2014 1 18.03.2024 PRD 18.03.2024

F

7 WI for Die Setting REPL/WI/PRD/07 07.03.2018 1 18.03.2024 PRD 18.03.2024

F

8 WI for Operating of Induction Heater REPL/WI/PRD/08 01.01.2014 1 18.03.2024 PRD 18.03.2024

F

9 WI for Identifying Pokayoke in process REPL/WI/PRD/09 07.03.2018 1 18.03.2024 PRD 18.03.2024

F

10 WI for Lock out & Tag out REPL/WI/PRD/10 07.03.2018 1 18.03.2024 PRD 18.03.2024
F

11 WI for Tagging System REPL/WI/PRD/11 07.03.2018 1 18.03.2024 PRD 18.03.2024

F

12 WI for Shift Handover REPL/WI/PRD/12 18.03.2024 0 18.03.2024 PRD 18.03.2024

F
 Format No.- REPL/F/QMS/16
Issue record of Work Instructions Origin Date.- 02/02/2024
Rev.No. / Date.- 0

Sr. Rev. No. of

Name of Work instruction (WI) Work Instruction No. Origin Date Rev. Date Dept Copies Issue Date Sign
No. No. Issued

WI for Shearing Machine cutting & Blade

13 REPL/WI/PRD/13 01.01.2016 1 18.03.2024 PRD 18.03.2024
Setting
F

14 WI for Band Saw and CNC cutting REPL/WI/PRD/14 01.01.2016 1 18.03.2024 PRD 18.03.2024
F

15 WI for Control Cooling REPL/WI/PRD/15 01.04.2014 2 18.03.2024 PRD 18.03.2024

F

16 WI for Acid pickling of forging parts REPL/WI/PRD/16 01.04.2014 2 18.03.2024 PRD 18.03.2024
F

17 WI for Abrassive Cutting Machine REPL/WI/PRD/17 01.04.2014 2 18.03.2024 PRD 18.03.2024

F

18 WI for Shot Blasting (Forging) REPL/WI/PRD/18 01.04.2014 1 18.03.2024 PRD 18.03.2024

F

19 WI for Rework of Heat Treatment REPL/WI/PRD/19 01.04.2014 2 18.03.2024 PRD 18.03.2024

F

20 WI for Furnace operating Procedure REPL/WI/PRD/20 01.04.2014 2 18.03.2024 PRD 18.03.2024

F

21 WI for Furnace Cleaning Trap Points REPL/WI/PRD/21 01.04.2014 2 18.03.2024 PRD 18.03.2024
F

22 WI for Maintaining Polymer Concentration REPL/WI/PRD/22 01.04.2014 2 18.03.2024 PRD 18.03.2024

F

23 WI for HT Change over Process REPL/WI/PRD/23 01.04.2014 2 18.03.2024 PRD 18.03.2024

F

Prepared By: Checked By: Approved By: