FMT. No.

EG/01
M/S SAHIL CONTROL PLAN FOR ALKALINE ZINC PLATING WITH TRIVALENT BLACK PASSIVATION WITH Eff. Date-01-02-2021
INDUSTRIES TOP COAT Rev. Date:-
Rev. No.00
PAGE -
PROTOTYPE PRELAUNCH PRODUCTION
1 OF 4
Control Plan No.:- Supplier Code:- Key Date:- 03/08/2023 Date(Org.) :- Rev. No. & Date: Review Date :-
Key Contect No.-9818585668,9818283202
Part No.:- 8/3/2023 0
Mr. Anil Ratra, Mr. Pankaj Ratra
Part Name :- Core Team :-Mr. Anil Ratra, Pankaj Ratra, V.P. Singh, Kishan, Lalit

Customer Name:- Supplier / Plant Approval Date :- (If Reqd.) Other Approval / Date.-(If Reqd.)

Customer Engineering Approval Date (If Reqd):- Customer Quality Approval Date (If Reqd):- Other Approval /Date.- (If Reqd.)
METHODS

CHARACTERSTICS PRODUCT/PROCESS/ SAMPLE

PROCESS PROCESS NAME OPERATION M/C DEVICE, JIGS, EVALUATION,MEASUR
SPECIFICATION/ CONTROL METHOD REACTION PLAN
SR. NO. /DESCRIPTION TOOLS, FOR MFG. MENT, TECHNIQUE
NO. PRODUCTS CLASS PROCESS TOLERANCE SIZE FREQ. RESP.

Should be free from Dent, Bend As per Material Incoming Hold the Material &
QA
I Appearance and Any other visual defects and Visually sampling Each Lot Record informed to
verify Qnty According to challan Inspector F-QA 01)
plan Customer.
Incoming Material and
10 As Per Bill /Challan
inspection
As per
Parts lever comp clutch KYJ No Heavy rust allowed QA Rust Acceptance as per Material hols and
II Appearance sampling Each Lot
Should be free from Rust specially Grooves Area Inspector SOP Inform to Customer
plan

V Ph 6.5 -7.2 Ph Paper D.M. Water inward

20 Reciept D.M. Water 100% Every Lot Lab Asst. record- Returned to supplier
VII Chloride content Chloride content-0% Visual Inspection F-QA-03

I Wiring/Kundi Wires should not loose Visual

If qty more Remove
100% Extra items & If qty less
Loading Chart load with similar items
II Lot Quantity As per part design Visual FRM-PR-18
Operator and
30 Loading Jigs / Hanger 100% Jigs Loading
III Distance of Kundi Should be at equal distance Visual Person Keep at equal distance

Daily Checked Before

No carbon deposition Every lot Emery Paper
Condition of Loading
IV FRM/MNT/06
Jigs/Kundi Remove the defected
No loose or Broken strip Visual
jig/hanger
Consol MCL -585-S
Check sheet Add. Chemical as per lab
I Concentration 40 ~ 70 gm/ltr. Lab Test/In House n =1 Start/Day Engg.
FRM/QA/26 test Result
Opt.-60 gm/Ltr.
Temp. Check sheet
II Temp. 55° C- 70° C n =1 Every 4 Hrs. Sup./Ope. Material Hold
Indicator/Thermometer FRM/QA/06
Check sheet Re-Verification
III Time 2 - 5 minutes Timer … Each Lot Sup./Ope.
FRM/QA/06 Programme
40 Soak Cleaning Check sheet
(Bath Capacity-400Ltr.) IV Density 7 - 9 Be° Hydrometer n =1 Every 4 Hrs. Sup./Ope. Bath chemical diluted
FRM/QA/06
V Oil Content < 5% Lab Test From CMF n =1 Weekly Engr./Sup. Out Source report Bath chemical diluted

During decantation removing oil Check sheet Add. Chemical as per lab
VI Decantation Manual 100% Weekly Sup./Ope.
content & sludge Impurites FRM/MNT/06 test Result

Discard Sweep, No old Chemical content to Check sheet

VII Manual 100% Monthly Sup./Ope. Make fresh new Solution
Frequency be present in tank FRM/MNT/06
 CHARACTERSTICS PRODUCT/PROCESS/ SAMPLE
PROCESS PROCESS NAME OPERATION M/C DEVICE, JIGS, EVALUATION,MEASUR
SPECIFICATION/ CONTROL METHOD REACTION PLAN
SR. NO. /DESCRIPTION TOOLS, FOR MFG. MENT, TECHNIQUE
NO. PRODUCTS CLASS PROCESS TOLERANCE SIZE FREQ. RESP.

Consol MCL -523-S

Check sheet Add. Chemical as per lab
I Concentration 75 ~ 120 gm/ltr. Lab Test/In House n =1 Start/Day Engg.
FRM/QA/26 test Result
Opt.100 gm/ltr.
Temp. Check sheet
II Temp. 50 ° C- 65° C n =1 Every 4 Hrs. Sup./Ope. Material Hold
Indicator/Thermometer FRM/QA/06
Check sheet Re-Verification
III Time 2 - 4 minutes Timer … Each Lot Sup./Ope.
FRM/QA/06 Programme
Check sheet
IV Density 7 - 9 Be° Hydrometer n =1 Daily Sup./Ope. Bath chemical diluted
FRM/QA/06
50 Anodic Cleaning
(Bath Capacity-300Ltr.) Check sheet
V Voltage 6 - 8 Volt. Volt Meter n =1 Each Lot Sup./Ope. Reset Volt
FRM/QA/06
Bath chemical diluted
VI Oil Content < 3% Lab Test From CMF 1 Weekly Engr./Sup. Out Source report and Chemical as per
Spec.
During decantation removing oil Check sheet Add. Chemical as per lab
VII Decantation Manual 100% Weekly Sup./Ope.
content & sludge Impurites FRM/MNT/06 test Result
Discard Sweep, No old Chemical content to Check sheet
VII Manual 100% Monthly Sup./Ope. Make fresh new Solution
Frequency be present in tank FRM/MNT/06
Check sheet Hold the material &
I pH Value 7 -11 Ph pH Paper n =1 Every 4 Hrs. Sup./Ope.
FRM/QA/06 change of water
3 -7 Sec. Check sheet
II Dip Time Diping Manually … Each Lot Sup./Ope. Re-Water Rinse
60 Water Rinse (Bath Capacity-150Ltr.) (2-5 Dip) FRM/QA/06
Discard Sweep, No old water content to be
III Manual 100% Daily Sup./Ope. FRM/MNT/06 Change Water
Frequency present in tank

Check sheet Hold the material &

I pH Value 7 -11 Ph pH Paper n =1 Every 4 Hrs. Sup./Ope.
FRM/QA/06 change of water
3 -7 Sec. Check sheet
70 Water Rinse (Bath Capacity-150Ltr.) II Dip Time Diping Manually … Each Lot Sup./Ope. Re-Water Rinse
(2-5 Dip) FRM/QA/06
Discard Sweep, No old water content tp be
III Manual 100% Daily Sup./Ope. FRM/MNT/06 Change Water
Frequency present in tank
Check sheet Add. Chemical as per lab
I Concentration HCL-30 - 50 % Lab Test/In House n =1 Start/Day Engg.
FRM/QA/26 test Result
Check sheet
II Time 5 -10 minutes Timer … Each Lot Sup./Ope. Reset Timer
FRM/QA/06
Check sheet Add Chemical as per
IV Dencity 12- 16 Be° Hydrometer n =1 Daily Sup./Ope.
FRM/QA/06 specification
80 Acid Picking Temp. Check sheet
(Bath Capacity-150Ltr.) V Temp. 20 ° C- 40° C n =1 Every 4 Hrs. Sup./Ope. Auto Temp. Controller
Indicator/Thermometer FRM/QA/06

During decantation removing Iron Check sheet Add. Chemical as per lab
VI Decantation Manual 100% Weekly Sup./Ope.
Content Impurites FRM/MNT/06 test Result

Discard Sweep, No old Chemical content to Check sheet

VII Manual 100% Monthly Sup./Ope. Make fresh new Solution
Frequency be present in tank FRM/MNT/06
Check sheet Hold the material &
I pH Value 2 -7 Ph pH Paper n =1 Every 4 Hrs. Sup./Ope.
FRM/QA/06 change of water
3 -7 Sec. Check sheet
90 Water Rinse (Bath Capacity-150Ltr.) II Dip Time Diping Manually … Each Lot Sup./Ope. Re-Water Rinse
(2-5 Dip) FRM/QA/06
Discard Sweep, No old water content to be
III Manual 100% Daily Sup./Ope. FRM/MNT/06 Change Water
Frequency present in tank
Check sheet Hold the material &
I pH Value 2 -7 Ph pH Paper n =1 Every 4 Hrs. Sup./Ope.
FRM/QA/06 change of water
3 -7 Sec. Check sheet
100 Water Rinse (Bath Capacity-150Ltr.) II Dip Time Diping Manually … Each Lot Sup./Ope. Re-Water Rinse
(2-5 Dip) FRM/QA/06
Discard Sweep, No old water content to be
III Manual 100% Daily Sup./Ope. FRM/MNT/06 Change Water
Frequency present in tank
 CHARACTERSTICS PRODUCT/PROCESS/ SAMPLE
PROCESS PROCESS NAME OPERATION M/C DEVICE, JIGS, EVALUATION,MEASUR
SPECIFICATION/ CONTROL METHOD REACTION PLAN
SR. NO. /DESCRIPTION TOOLS, FOR MFG. MENT, TECHNIQUE
NO. PRODUCTS CLASS PROCESS TOLERANCE SIZE FREQ. RESP.

Sodium Hydroxide Check sheet Add. Chemical as per lab

I Concentration Lab Test In House n =1 Start/Day Engr./Sup
3 - 5% /ltr. FRM/QA/26 test Result

3 -5 Sec. Check sheet

110 Neutraliser II Dip Time Diping Manually … Each Lot Sup./Ope. Re-Water Rinse
(Bath Capacity-150Ltr.) (2-5 Dip) FRM/QA/06

Discard Sweep, No old Caustic content to

III Manual 100% Every Day Sup./Ope. FRM/MNT/06 Change Water
Frequency be present in tank

Zinc Metal
I C 8 -15 gm / ltr.
(Opt. 12 gm/ltr.) Check sheet Add. Chemical as per lab
Concentration Lab Test In House n =1 Start/Day Engr./Sup
Sodium Hydroxide FRM/QA/26 test Result
II C 100 - 140 gm / ltr.
(Opt-120 gm/Ltr.)

III Add.Brightner-A 200-300 ml /1000 Amp .

IV Add. Booster-B 150-200 ml /1000 Amp .

Daily Chemical Any problem Observed
In House Hull cell test/
n =1 Start/Day Engg. Addition Check Sheet perform hull cell test
Plating Bath Solution
V Add. Purifier-C 60-80 ml /1000 Amp. FRM/QA/40 immediately

Add. Conditioner- 500ml/Day & Add As per

VI
D According NaOh
Check sheet
VII Time 20 - 30 minutes Timer n =1 Every 4 Hrs.. Engr./Sup. Re-Set Time
FRM/QA/06
Check sheet Hold the material &
VIII Temp. 20 - 40°C Temp.Indicator n =1 Every 4 Hrs.. Engr./Sup.
FRM/QA/06 Set temp
Check sheet
IX Voltage 4 - 6 Volt Volt Meter n =1 Every 4 Hrs.. Engr./Sup. Reset of voltage
FRM/QA/06
X Current 400 - 600 Amp. Amp.Meter n =1 Each Lot Engr./Sup Rectifier
Electro Plating Alkaline Zinc Solution wiil be
120 (Bath Capacity- XI Copper Impurity Max -Cu 5 ppm Lab Test From CMF n =1 15 Days Engr./Sup Out side report
(Tank Process) treatment
1800Ltr.)
Solution wiil be
XII Lead Impurity Max -Pb 5 ppm Lab Test From CMF n =1 15 Days Engr./Sup Out side report
treatment
Cadmium Solution wiil be
XIII Max. - 5 ppm Lab Test From CMF n =1 15 Days Engr./Sup Out side report
Impurity treatment
Sodium
Solution wiil be
XIV CarbonateImpuri Max 100 gm / ltr. Lab Test From CMF n =1 15 Days Engr./Sup Out side report
treatment
ty
Solution wiil be
XV Iron Impurity Max. - 100ppm Lab Test From CMF n =1 15 Days Engr./Sup Out side report
treatment

Zinc Dust -250 gm Cartridge Pack Check sheet Re-Pack Zinc Dust &
XVI Filtration By Weighing Scale n =1 Engr./Sup
Carbon- 100 gm Weekly FRM/MNT/03 Carbon

If pressure found
Check sheet
XVII Filter Pressure 0-2 PSI Pressure Meter n =1 Every Day Engr./Sup increase 0-2 PSI filter
FRM/QA/06
clean immediately.
If pressure found
Cartidge & cloth cleaning on daily Check sheet
XVIII Filter Cleaning Manually n =1 Daily Engr./Sup increase 0-2 PSI filter
basis. FRM/MNT/03
clean immediately.

Zinc Dust -2 gm/Ltr. Decant Process of Manual Check sheet

XIX Treatment n =1 Quarterly Engr./Sup Re-Treatment
Carbon-0.5 gm/Ltr. By filter FRM/MNT/06

As per master Panel Add. Chemical As per

XX Hull Cell Test To Confirm bath performance By Hull Cell Pot and Panel n =1 Every Day Engg.
and SOP (SI/WI/67) Hull cell report

PP Tank-19
130 Drag Out I No Specific measurements required in this D.M. Water solution, Discard Frequency daily Basis
(Bath Capacity-150Ltr.)
 CHARACTERSTICS PRODUCT/PROCESS/ SAMPLE
PROCESS PROCESS NAME OPERATION M/C DEVICE, JIGS, EVALUATION,MEASUR
SPECIFICATION/ CONTROL METHOD REACTION PLAN
SR. NO. /DESCRIPTION TOOLS, FOR MFG. MENT, TECHNIQUE
NO. PRODUCTS CLASS PROCESS TOLERANCE SIZE FREQ. RESP.
Check sheet Hold the material &
I pH Value 2 -7 Ph pH Paper n =1 Every 4 Hrs. Sup./Ope.
FRM/QA/06 change of water
3 -7 Sec. Check sheet
140 D.M. Water Rinse (Bath Capacity-150Ltr.) II Dip Time Diping Manually … Each Lot Sup./Ope. Re-Water Rinse
(2-5 Dip) FRM/QA/06
Discard Sweep, No old water content tp be
III Manual 100% Daily Sup./Ope. FRM/MNT/06 Change Water
Frequency present in tank
NITRIC ACID Check sheet
I Concentration Lab Test n=1 Start/Day Engr./Sup
0.5 - 1% v/v FRM/QA/26 Make Fresh every 8 Hrs.
PP Tank-21 3 -7 Sec. Check sheet Working
150 Activation Dip II Dip Time Diping Manually … Each Lot Sup./Ope.
(Bath Capacity-150Ltr.) (2-5 Dip) FRM/QA/06
Discarding Sweep, No old Nitric content to be
IV Manual Every day Daily Visual Operator Change Nitric Acid
Frequency present in tank
Check sheet Hold the material &
I pH Value 3 -7 Ph pH Paper n =1 Every 4 Hrs. Sup./Ope.
FRM/QA/06 change of water
3 -7 Sec. Check sheet
160 D.M. Water Rinse (Bath Capacity-150Ltr.) II Dip Time Diping Manually … Each Lot Sup./Ope. Re-Water Rinse
(2-5 Dip) FRM/QA/06
Discard Sweep, No old water content to be
III Manual 100% Daily Sup./Ope. FRM/MNT/06 Change Water
Frequency present in tank
Lanthane-707 A & B
Check sheet Add. Chemical as per lab
I C Concentration 100-150 ml/ltr Lab Test 1 Daily Engr./Sup
FRM/QA/26 test Result
(Opt. 125 ml/Lrt.)
Check sheet Hold the material &
II C pH Value 2.3 - 2.5 pH Paper/ pH Meter n =1 Every 4 Hrs. Sup./Ope.
FRM/QA/06 change of water
Temp. Check sheet
III Temp. 25 - 35°C n =1 Every 4 Hrs. Sup./Ope. Auto Temp. Controller
Indicator/Thermometer FRM/QA/06
45 -60 Sec. Check sheet
IV Dip Time Timer n =1 Every 4 Hrs. Sup./Ope. Reset Timer
(Opt-50 Sec.) FRM/QA/06
Add Chemical as per
V Addition 200- 300 ml/lot Manual 1 Every 2 Hrs. Operator FRM/QA/40
specification
180 Trivalent Black Passivation During decantation removing Iron Check sheet Add. Chemical as per lab
(Bath Capacity-80Ltr.) VI Decantation Continuous n =1 Every Day Engr./Sup
& Zinc Content Impurites FRM/QA/06 test Result
Solution wiil be
VII C Zinc Max. Zinc - 10 gm./ltr. Impurity Lab Test From CMF n =1 15 Days Engr./Sup Out side report
treatment
Solution wiil be
VIII C Iron Max. Iron - 100ppm Impurity Lab Test From CMF n =1 15 Days Engr./Sup Out side report
treatment

Every 1 Month
( if Increase
Discard Sweep, No old Passivation content impurities before
IX Manual 100% Sup./Ope. FRM/MNT/06 Make new fresh Solution
Frequency to be present in tank plan will be
discarded
passivation)
 CHARACTERSTICS PRODUCT/PROCESS/ SAMPLE
PROCESS PROCESS NAME OPERATION M/C DEVICE, JIGS, EVALUATION,MEASUR
SPECIFICATION/ CONTROL METHOD REACTION PLAN
SR. NO. /DESCRIPTION TOOLS, FOR MFG. MENT, TECHNIQUE
NO. PRODUCTS CLASS PROCESS TOLERANCE SIZE FREQ. RESP.
Check sheet Hold the material &
I pH Value 3 -7 Ph Ph Paper n =1 Every 4 Hrs. Sup./Ope.
FRM/QA/06 change of water

190 D.M. Water Rinse (Bath Capacity-150Ltr.) 3 -7 Sec. Check sheet

II Dip Time Diping Manually n =1 Each Lot Sup./Ope. Re-Water Rinse
(2-5 Dip) FRM/QA/06
Discard Sweep, No old water content tp be
III Manual 100% Daily Sup./Ope. FRM/MNT/06 Change Water
Frequency present in tank
Check sheet Hold the material &
I pH Value 3 -7 Ph pH Paper n =1 Every 4 Hrs. Sup./Ope.
FRM/QA/06 change of water
3 -7 Sec. Check sheet
200 D.M. Water Rinse (Bath Capacity-150Ltr.) II Dip Time Diping Manually n =1 Each Lot Sup./Ope. Re-Water Rinse
(2-5 Dip) FRM/QA/06
Discard Sweep, No old water content tp be
III Manual 100% Daily Sup./Ope. FRM/MNT/06 Change Water
Frequency present in tank

Post Dip FT 190

(80-100 Ml/Ltr) Check sheet Add. Chemical as per lab
I Concentration Lab Test n=1 Start/Day Engr./Sup
Post Dip Surfact 10 FRM/QA/26 test Result
(5-10 Ml/Ltr)
Re-Verification
II pH Value 3.8 - 4.2 pH meter 1 Every 4Hrs Sup./Ope. FRM/QA/06
Programme
30 - 50 sec Hold the material &
III Time Timer 1 Each Lot Sup./Ope. FRM/QA/06
Opt.40 Sec change of water
210 Post Dip (Bath Capacity-80Ltr.)
Temp. Indicator/
IV Temp. 35-45 ºC 1 Every 4Hrs Sup./Ope. FRM/QA/06 Auto Temp. Controller
Thermometer
Add Chemical as per
V Addition 100-150 ml/lot Manual 1 Every 2 Hrs Operator FRM/QA/40
specification

Discard Frequency when the

Make Fresh new
VI Dicard frequency solution turbid,No old Post Dip Manual 1 Monthly Engr./sup FRM/MNT/06
Solution
content to be present in tank

Fom Zinthium 302 Add. Chemical as per lab

I Concentration Lab Test 1 Weekly External Lab Test Report
(200-300 Ml/Ltr) / (20-30%) test Result
Hold the material & Set
II pH Value 9.0 - 9.5 pH meter 1 Every 4 hrs Engr./Grd FRM/QA/06
pH Value
30- 60 Sec
220 Top Coat III Time Timer/Buzzer 1 Each lot Operator FRM/QA/06 Reset Time
(Bath Capacity-50Ltr.) (Opt.45 Sec)

Temp. Indicator/ Hold the material & Set

IV Temp. 20° - 25°C 1 Every 4 hrs Engr./Grd FRM/QA/06
Thermometer temp.
Add Chemical as per
V Addition 30 ml/lot Manual 1 Each lot Operator FRM/QA/40
specification
Clean dry(No water Content found
230 Air Drying Air Dryer I Part Drying
on parts Surface)
Visual 100% Every lot Operator Operator Re-Dry

80 - 100 °C material is hold and

I Temp. Temp. Controller 1 Every 4Hrs Engr./Ope. FRM/QA/06
240 Baking Oven
(Opt-90 °C) set temp.
II Time 5 - 10 Min. Timer 1 Each lot Operator FRM/QA/06 Reset Time
unloading of Part to be not dropped
250 Unloading Material Manual I Part should be unload with care visual 1 Every lot Operator Operator
parts In floor

All parts Should be free from

visual defects:- water mark, Dull Final
I Appearance Visual 100% Every lot Re- plating
Plating ,Scratch,white Inspector
Patches,blister,Uncoverd etc

5 parts Final
II Colour Tri. Black Visual Every lot Re-plating
per lot Inspector
260 Final Inspection Manual FRM/QC/35

III Plating Thickness Min.8µ Thickness tester 5 Pcs. Per Lot Each lot Inspecter Hold Material

IV Adhesion No plating peel off Tape Test 2 Pcs. Per Lot Each Lot Inspecter Verify Process
 CHARACTERSTICS PRODUCT/PROCESS/ SAMPLE
PROCESS PROCESS NAME OPERATION M/C DEVICE, JIGS, EVALUATION,MEASUR
SPECIFICATION/ CONTROL METHOD REACTION PLAN
SR. NO. /DESCRIPTION TOOLS, FOR MFG. MENT, TECHNIQUE
NO. PRODUCTS CLASS PROCESS TOLERANCE SIZE FREQ. RESP.
STD (MFZN2HK)
SST Chamber Check sheet Re- Check All
270 NSS TEST Salt Spray Chamber I N.S.S test WR-96 Hrs. 1 Every Month Inspector
Monitor After 24 hrs FRM/QA/15 Process
RR-240 Hrs.
80 Nos/Per Bin
280 Packing Manual I …. Visual Weight 10 Kg. Visual 1 Each Lot QA F/ENGG/08 Re-Packed
As per Customer packing std

Covered Vehicle No Dust and

290 Dispatch By Vehicle I ….. Vehicle Manual …… ……. …… ……
Other Particles

GOGAL HAND GLOVES

C STANDS FOR CRITICAL CHARACTERISTIC
SAFETY EQUIPMENT:- SAFETY SHOES
GAS MASK APRIN Note:- We do not use any kind of touchup in our tri-black plating.

S No Ammendent Detail Rev No. Rev Date Next Rev Date Effectiveness Remarks

PREPARED BY: CHECKED BY: APPROVED BY: