CONTROL PLAN

Prototype Prelaunch Production Customer Assy. Ref. : - 10000038595 Alkraft Assy. Ref. No. : 72 OC 46 0000A Customer : M/s.
M.H.Zakkir Hussain /
CONTROL PLAN NUMBER : CP/72 OC 46 0000A/01 Key contact/ Phone Date (orig.) Date (Rev.) :- 17.05.2024>>
044-2625 87 50
Part No./Latest Customer Engg. Approval / Date
72 OC 46 0000A/a Core Team MP/NP/SK/MV
change level (If Reqd.)
Part name/ Customer Quality Approval / Date
AIR COMPRESSOR
Description ( If Reqd.)
Supplier / Plant Alkraft , Chennai Supplier code: Other approval / Date (If reqd.) Customer Requirement, if specified
Characteristics Methods
Special
Process Name Operation Machine, Device, Tools Error proof Test plan General Reaction Plan &
Part/ Process No. Char. Product/ Process Specification/ Evaluation Responsibility
Description for Mfg. No Product Process Sample size Sampling Frequency Control method/ Error Proofing & Reaction plan (in Corrective Action
class Tolerance Measurement technique
case of failure)

150 to 220 Amps ( Full Welding )

Welding Current 220 to 270 Amps ( Tack & Stitch a), b) Operator - Visual, FPA
Process validation done once
Welding ) a) Every setting, shift & & IPR.
a) FPA - 1no in 6 months. Adjust in welding
Visual part no change. N/A a) Line QA/Production
b) IPR - 1no parameters setting.
b) Per every 10 nos Supervisor - FPA.
1 Argon Gas flow 12 ± 1 Lpm FPA & IPR
Maintenanace shift Incharge

Stop & Correct; If not Welder, Operator, Line

2.4mm ( Full Welding ) Every setting & shift
Filler rod dia 3.2mm ( Tack & Stitch Welding ) Vernier FPA - 1no FPA N/A possible Inform to QA/Production Supervisor -
change
Supervisor. FPA.

Extrusion Tank bottom

base to M18X2.5 - 1D
2 74.6±1.5
Round Boss
( Horizontal )

Extrusion Tank bottom

3 base to Tank side Piece 2±1.5 Check the welding Fixture.
a) 100%
( Horizontal ) a) Fixture on all Parts FPA & IPR Reset the component to ensure a), c) Operator - IPR.
b) FPA T/P - Periodic
Extrusion Tank bottom ACC Sub assembly b) Every setting & shift fitment of the components in
c) IPR with Sub calibration as per the fixture.
4 base to M8X1.25 - 1.5D 16±1 welding fixture change E/P - ACC Sub Assy b) Line QA/Production
Process name: assembly welding plan. Raise B/D slip and issue to
Helicoil CL c) Per every 10 nos Welding Fixture supervisor - FPA.
Extrusion Tank (LH & fixture - 1no Tool room.
RH ) with Tank Side Extrusion Tank M8X1.25 -
Piece - 1 & Tank Side 5 1.5D 100±1.5
Piece - 2 CTC
72 OC TIG welding Machine
000460000040 & ACC Sub assembly
Description: Extrusion Tank Top base to
S-1 welding fixture
Tack & Stitch welding 6 M18X2.5 - 1D Round Boss 13±1.5
Extrusion Tank (LH & ( Horizontal )
RH ) with Tank Side
Piece - 1 & Tank Side Weldiing Leg Height at
Piece - 2 7 3.00
Tank Side Piece Welding bridge cam Every setting & shift Adjust in welding Line QA/Production
FPA - 1no FPA N/A
Weldiing Leg Height at gauge change parameters setting. Supervisor - FPA.
8 3.00
Round Boss
Stop & Correct; If not Welder, Operator, Line
Welding Projection on Tank Every setting & shift
9 1.5mm Max Vernier FPA - 1no FPA N/A possible Inform to QA/Production Supervisor -
Side Piece - 2 change
Supervisor. FPA.

a), b), c) Setter - Visual, FPA

a) Visually on all Parts Annual Welder
Part should not have Welding a) 100% & IPR.
b) Every setting, shift & qualification is done. Adjust in welding
10 Welding Apperance Undercut,Blow Holes,porosity & Visual b) FPA - 1no
part no change.
FPA & IPR b) Line QA/Production
c) IPR - 1no parameters setting.
High Point in Welding Bead c) Per every 10 nos Supervisor - FPA.
FPA & IPR.

Part Should be Clean,Free from

Sharp edges ,Burr,Thread & a) Visually on all Parts a), b), c) Operator - Visual, FPA
a) 100%
b) Every setting, shift & Quarantine; Inform Production & IPR.
11 Apperance Mounting Part Top Face Should Visual b) FPA - 1no
part no change.
FPA & IPR N/A
supervisor b) Line QA/Production
Not Get Damaged in Welding c) IPR - 1no
c) Per every 10 nos Supervisor - FPA.
Process
 CONTROL PLAN
Prototype Prelaunch Production Customer Assy. Ref. : - 10000038595 Alkraft Assy. Ref. No. : 72 OC 46 0000A Customer : M/s.
M.H.Zakkir Hussain /
CONTROL PLAN NUMBER : CP/72 OC 46 0000A/01 Key contact/ Phone Date (orig.) Date (Rev.) :- 17.05.2024>>
044-2625 87 50
Part No./Latest Customer Engg. Approval / Date
72 OC 46 0000A/a Core Team MP/NP/SK/MV
change level (If Reqd.)
Part name/ Customer Quality Approval / Date
AIR COMPRESSOR
Description ( If Reqd.)
Supplier / Plant Alkraft , Chennai Supplier code: Other approval / Date (If reqd.) Customer Requirement, if specified
Characteristics Methods
Special
Process Name Operation Machine, Device, Tools Error proof Test plan General Reaction Plan &
Part/ Process No. Char. Product/ Process Specification/ Evaluation Responsibility
Description for Mfg. No Product Process Sample size Sampling Frequency Control method/ Error Proofing & Reaction plan (in Corrective Action
class Tolerance Measurement technique
case of failure)

a), b) Operator - Visual, FPA &

Welding Current 220 to 270 Amps Stop & Correct; If not possible
a) Every setting, shift & part Process validation done once in IPR.
a) FPA - 1no Inform to Supervisor.
Visual no change. 6 months. N/A Adjust in welding parameters
a) Line QA/Production
b) IPR - 1no b) Per every 10 nos FPA & IPR Supervisor - FPA.
1 setting.
Maintenanace shift Incharge
Argon Gas flow 12 ± 1 Lpm

Welder, Operator, Line

Every setting & shift Stop & Correct; If not possible
Filler rod dia 3.2mm Vernier FPA - 1no FPA N/A Inform to Supervisor.
QA/Production Supervisor -
change FPA.

2 Tank Outer to Outer 1080-3.0

3 SQ Spacer CTC 806.2±3.0

Tank outer face to SQ a) 100% Check the welding Fixture.
4 125±2.0
Spacer CL ( LH ) Digital height b) FPA with height a) Fixture on all Parts FPA & IPR Reset the component to a), c) Operator - IPR.
T/P - Periodic
Tank outer face to SQ gauge/Vernier/Tank gauge/Vernier - 1no b) Every setting & shift ensure fitment of the
5 149±2.0 calibration as per
Spacer CL ( RH ) With Core assembly c) IPR with Sub change E/P - Welding fixture ( ACC , components in the fixture. b) Line QA/Production
plan.
welding fixture assembly welding c) Per every 10 nos FC & DOC ) Raise B/D slip and issue to supervisor - FPA.
6 SQ Spacer Width 40±1.0 fixture - 1no Tool room.
Process name:
Extrusion Tank With Tank Face to SQ Spacer
7 10±1.5
Core Assy TIG welding Machine Face
, Welding fixture
72 OC 8 Mounting Boss CTC 1040±3.0
Description: ( ACC , FC & DOC ) M
000460000040
Tack & Full Welding & L - BKT Welding
S-2
of Core With LH Tank Template ( LH & Check the welding Fixture.
Tank Bottom Face to L -
Assy , RH Tank RH ) 9 63±1.5 a) Visually on all Parts FPA & IPR Reset the component to ensure a), c) Operator - IPR.
BKT Top Face a) 100%
Assy,SQ Spacer & L - L - BKT Welding b) Every setting, shift & T/P - Periodic fitment of the components in
BKT b) FPA - 1no
Template part no change. E/P - L - BKT Welding calibration as per plan. the fixture. b) Line QA/Production
c) IPR - 1no
L - BKT Top Face to SQ c) Per every 10 nos Template ( LH & RH ) Raise B/D slip and issue to supervisor - FPA.
10 161±2.0 Tool room.
Spacer Face

Tank Face to Tank Side

11 Piece - 2 Face 1.5±1.5
( LH )
Tank Face to Tank Side
12 Piece - 2 Face 1.5±1.5
( RH ) Stop & Correct; If not Welder, Operator, Line
Every setting & shift
Vernier FPA - 1no FPA N/A possible Inform to QA/Production Supervisor -
Welding Projection on Tank change
Supervisor. FPA.
13 Side Piece - 2 1.5mm Max
( LH )
Welding Projection on Tank
14 Side Piece - 2 1.5mm Max
( RH )
a) Visually on all Parts a), b), c) Operator - Visual, FPA
No welding spatter, Blow holes, a) 100%
b) Every setting, shift & Quarantine; Inform Production & IPR.
15 Appearance poor welding, incomplete welding, Visual b) FPA - 1no
part no change.
FPA & IPR N/A
supervisor b) Line QA/Production
damages allowed c) IPR - 1no
c) Per every 10 nos Supervisor - FPA.
 CONTROL PLAN
Prototype Prelaunch Production Customer Assy. Ref. : - 10000038595 Alkraft Assy. Ref. No. : 72 OC 46 0000A Customer : M/s.
M.H.Zakkir Hussain /
CONTROL PLAN NUMBER : CP/72 OC 46 0000A/01 Key contact/ Phone Date (orig.) Date (Rev.) :- 17.05.2024>>
044-2625 87 50
Part No./Latest Customer Engg. Approval / Date
72 OC 46 0000A/a Core Team MP/NP/SK/MV
change level (If Reqd.)
Part name/ Customer Quality Approval / Date
AIR COMPRESSOR
Description ( If Reqd.)
Supplier / Plant Alkraft , Chennai Supplier code: Other approval / Date (If reqd.) Customer Requirement, if specified
Characteristics Methods
Special
Process Name Operation Machine, Device, Tools Error proof Test plan General Reaction Plan &
Part/ Process No. Char. Product/ Process Specification/ Evaluation Responsibility
Description for Mfg. No Product Process Sample size Sampling Frequency Control method/ Error Proofing & Reaction plan (in Corrective Action
class Tolerance Measurement technique
case of failure)

Operator - leak test.

72 OC Process name: Wet Leak Testing No leak @ 10±0.1 bar Reject / Quarantine; Record
1 M Visual 100% 100% Leak Test Report N/A Line QA/Production
000460000042 Wet Leak Test Machine in SAP.
Supervisor - Once in a shift.

Operator - Visual.
72 OC QUARANTINE; Inform
Drying Air Gun 1 Apperance Free from water, moisture Visual Visually on all Parts. Every batch Visual N/A Line QA/Production
000460000046 Supervisor for drying
supervisor - Visual.
Packing sticker generated Quarantine and Inform Final product quality - Visual.
72 OC Parts to be packed as per through SAP for Part no
Packing Manual 1 Apperance Visual Visually on all Parts. Every Shift identification & traceability;
N/A Production Supervisor. Line QA/Production
000460000094 approved packing standard.
Visual Raise NCR supervisor - Visual.

Prepared by: Krishna Prasad . P Checked by : Approved by :Thanigainathan

All dimensions are in mm unless otherwise specified
GENERAL REACTION PLAN : If there is any deviation - STOP,REJECT THE SAMPLE, QUARANTINE THE LOT
SNO PART NAME PART NO
Revision History 1 RADIATOR CORE 72 OC 46 1000
Sl.No Rev No Rev Date Details of Changes Remarks 2 LH Tank Assembly 72 OC 46 1500
1 3 RH Tank Assembly 72 OC 46 1600
4 SQ Spacer 72 OC 46 1556
5 Mounting Boss - M8X1.5 - 1D With Helicoil 72 OC 45 1515
6 L - BKT 72 OC 46 1555
7 Tank Side Piece - 1 72 OC 46 1520
8 Tank Side Piece - 2 72 OC 46 1521
9 Extrusion Tank LH & RH 72 OC 46 1510