CRM-PDQC-QR-018

Issue/Rev No: 1/4

Special Product/Process Characteristics
Customer:-M/S Mahindra Rev Date: 30/03/2016

Product:-HCT780X+ZF Dated: 4/30/2024

Special Product
Sl. No characteristic Specification/UOM Requirement Critical Characteristics Special Characteristics Poduct Safety Characteristics Specification

1 YS MPa Customer YES YES NO EN10346:2015

2 UTS MPa Customer YES YES NO EN10346:2015
3 El % - Customer YES NO NO EN10346:2015
4 Spot Weldability Customer YES YES NO EN10346:2015
4 Speed mpm Internal YES NO NO EN10346:2015
5 SS Temperature °C Internal YES NO NO EN10346:2015
6 Zn Coating wt gsm Customer YES NO NO EN10346:2015
7 %C % Internal YES EN10346:2015
8 %Mn % Internal YES EN10346:2015
9 %S % Internal YES EN10346:2015
10 %P % Internal YES EN10346:2015
11 %Si % Internal YES EN10346:2015
12 %Al % Internal YES EN10346:2015
13 %Cr % Internal YES
14 %Mo % Internal YES EN10346:2015
15 %V % Internal YES EN10346:2015
16 %Nb % Internal YES EN10346:2015
17 %Ti % Internal YES EN10346:2015
18 %B % Internal YES EN10346:2015
19 EN10346:2015
20 EN10346:2015
21 EN10346:2015

Prepared By: Reviwed By (GAGI In Charge) Approved By: (HOD - PDQC)

1 of 4
 PROCESS FLOW DIAGRAM - DP-GA Family Products
ITEM GI PROCESS IDENTIFICATION CRM-PDQC-QR-046
MODEL YEAR / VEHICLE RESOURCE PERSON Prashant Choudhary
PROCESS RESPONSIBILITY Head - Product
Mr. Yogender Reddy (PDQC -Technology) , Mr. Vinoth Kumar G (PDQC -Technology), Mrs. Prashant Choudary (PDQC - KEY DATE
CORE TEAM Technology), , Mr. Bubu Pradhan (Product safety Representative -Technology), Mr. Gunjan (SMS2-Technology), Mr. DATE (ORIGINAL)
Nilesh Choudary (HSM2-Technology) , Mr. Karthik Ganesh. (CGL Opr -Flat Products), Mr. Pankaj Singh (PLTCM Opr -Flat
Products), Subramanyam (CRM TE -Technology), Mr. Deepak/Respective Zonal AE (AE -CFU)
DATE(REVISED) 4/28/2024

PROCESS OPERATION # INCOMING SOURCE OF VARIATION PROCESS FLOW DIAGRAM PRODUCT CHARACTERISTICS PROCESS CHARACTERISTICS
NUMBER BRIEF DESCRIPTION
Chemistry in desired Range Operator Training
100 Ferro-alloy Addition
Steel Making Diver Surface free defects Mold Level Fluctuation
100
(SMS) t Super Heat
No Casting Speed
Yes Killing Time
Chemistry Deviations HSM FT
Slab Length and width HR Thickness and Width as per Customer HSM CT
200 HR Crown and wedge
Hot Rolling Finishing Mill Roll Diameter
200
(HSM) Diver Shape HSM Finshing stand loads
t
Scale Free Surface Slab Reheating Temperature
No Descaling Passes
Yes RMX Temperature
Improper Coiling Temperature Good Weld Strength HR YS Difference
Crown and Wedge out of Norms Free from scales High Speed
Pickling with Tandem Cold Mill 300 Thickness As per Customer % Reduction
300
(PLTCM) Thickness Difference
Weld Recipe
Shape within Norms Tension
Gauge Variations Weld Strength Welding Current
Weld Speed
Electrode Force
Sixe matrix of 2 welding Strips
Yield Stength within Desired Limit Soaking section Temperature
Continous Annealing Line UTS within Desired Limit Rapid Cooling Temperature
400 400
(CAL) Elongation Within Desired Limti Center Speed
Surface Quaity as per customer requirement H2%
Roughness as per Customer SPM Work Roll
Oiling as per Customer Oiling Qty Type
Free from Surface Defect Inspection Standard
Sampling at correct location
Weld Strength Bulge Test Pass
Gauge Variations
Yield Stength within Desired Limit Welding Current
Surface impurity UTS within Desired Limit Weld Speed
Elongation Within Desired Limit Electrode Force
Free from oxidized surface, heating buckle, Size matrix of 2 welding Strips
cooling buckle HS strip temp (°C)
500
Zn coating weight SS strip temp (°C)
RCS strip temp (°C)
Free from powdering , scratch, dross patches,
edge get up, nozzle mark, unalloyed edges, groove TDS strip temp (°C)
roll
Line Speed (Mpm)
500 Continous Galvannealing Line Proper elongation (%) H2(%)
(CGL)
Roughness as per Customer Proper Working of air knife
Oiling as per Customer Pot temperature
Sampling at correct location Bath chemistry
APH
APC
WCS
SPM Elongation
SPM Work Roll
Oiling Qty Type
Inspection Standard
Free from Surface Defect Inspection Standard
Diver
Recoiling Line 600 t
600
(RCL)
Yes No Inspector Skill Level
L2 Control
700 Packaging Line (APL) 700 Dispatch Packaging as per Order Packaging Code
Operator Skill Level

Prepared By Reviewed By Approved By

 CRM-PDQC-QR-045
Issue/Rev No: 2/1
PFMEA for DP GA Products Family
Product:HCT780X+ZF Rev Date: 6/7/2024
Product FMEA (POTENTIAL FAILURE MODE & EFFECTS ANALYSIS)
ITEM GA/GI Mr. Yogender Reddy (PDQC -Technology) , Mr. Vinoth Kumar G (PDQC -Technology), Mrs. Prashant Choudary (PDQC -Technology), , Mr. Bubu Pradhan (Product safety Representative -Technology), Mr. Gunjan PROCESS IDENTIFICATION CRM-PDQC-QR-045 KEY DATE 1st Sep'14
CORE TEAM (SMS2-Technology), Mr. Nilesh Choudary (HSM2-Technology) , Mr. Karthik Ganesh. (CGL Opr -Flat Products), Mr. Pankaj Singh (PLTCM Opr -Flat Products), Subramanyam (CRM TE -Technology), Mr. RESOURCE PERSON Mr Prashant Choudary ORIGINAL DATE 1st Sep'14
MODEL YEAR / VEHICLE ALL GRADES Deepak/Respective Zonal AE (AE -CFU) PROCESS RESPONSIBILITY HOD-PDQC REVISED DATE 7/21/2020
ACTION RESULT

OCCOURANC

DETECTION
SEVERITY

SEVERITY

OCCOURA
CLASS

DETECTIO
RPN
PROCESS STEP / FUNCTION REQUIREMENT POTENTIAL FAILURE MODE POTENTIAL EFFECTS OF FAILURE POTENTIAL CAUSES CURRENT PROCESS CONTROL PREVENTION CURRENT PROCESS CONTROL DETECTION RCOMMENDED ACTION RESPONSIBILITY & TARGET DATE

NCE

RPN
ACTION TAKEN

N
Heat does not go for casting (Mechanical Properties
Chemical Composition (C, Mn, Ti,Nb and V) etc. within Limit 3) Production Loss 8 CC Lillipop Sample Testing during Process (Process Checklist) 2 Automatic SPTS System Interlock 3 48
Failure out off Range)
Unskilled Operator Positional Training 2 Skill Matrix of Operator 8 128 3rd Qudrant Operator to be used for ferro Mr. Manjunath Bath 3rd Quadrant 8 1 8 64
Wrong Ferro-Alloy Addition Suggestion of ferro alloy and precalculation of chemistry after taking ferro alloy in hopper 2 Log in Level-2 5 80
Steel Making Free from Surface Crack Casting Breakout 2)Equipment Damage 8 2 Visual Check 8 128 Online Slab Inspection HOD-SMS, FY 21 8 1 8 64
100
(SMS)
Super Heat 2 Visual Check 8 128 Super Heat <30 Mr. Manjunath Bath Super Heat 20-30 8 1 8 64
Casting Speed 2 Casting Speed Alarm 5 0
Free from Inclusion SEN Nozzle Choking 2)Equipment Damage 8 1 Sulphur Printing offline 8 0
Killing Time 2 Manual Check 5 0
8 MLF 2 MLF Alarm 5 0
HR Thickness and Width within Limit Coil Cobble 2)Equipment Damage 8 Automatic Gauge L2 Gauge Control 2 Process Monitoring Report- TE HSM QR-03 5 80
HSM FT FT is controlled by Level 2 automation 2 Process Monitoring Report- TE HSM QR-03 5 80
HSM CT CT is controlled by Level 2 automation 2 Process Monitoring Report- TE HSM QR-03 5 80
Shape, HR Crown and wedge within limit Coil Cobble 2)Equipment Damage 8 2 Process Monitoring Report- TE HSM QR-03 5 80
HR Crown Automatic Gauge L2 Gauge Control 1 Process Monitoring Report- TE HSM QR-03 8 64
Hot Rolling HR Wedge Automatic Gauge L2 Gauge Control 1 Process Monitoring Report- TE HSM QR-04 8 64
200 (HSM) HSM Finshing stand loads 1 Process Monitoring Report- TE HSM QR-03 8 64
Slab Length 1 Manual Check 8 64
Finishing Mill Roll Diameter 1 Manual Check 8 64
Scale Free Surface Roll Surface Damage 2)Equipment Damage 6 Defect Online Monitoring through Parsytec 2 Process Monitoring Report- TE HSM QR-03 5 80
RMX Temperature RMX temperature is controlled by Level 2 thermal model. 2 Process Monitoring Report- TE HSM QR-03 5 80
Descaling Passes Automatic Control through L2 2 Process Monitoring Report- TE HSM QR-03 5 80

Good Weld Strength Strip Breakage 2)Equipment Damage 6 CC/SC 2 Manual Check 8 96
3) Production Loss
HR YS Difference Automatic Matching in L2 system 2 System Interlock 5 60
Thickness Difference Automatic Matching in L2 system 2 System Interlock 5 60
Weld Recipe Automatic Weld Recipe Assignment 2 System Interlock 5 60
300 Pickling with Tandem Cold Mill
(PLTCM) Free from scales Damaged Roll Surface 2)Equipment Damage 8 2 Manual Check 8 12
3) Production Loss
High Speed Automatic L2 Control 2 Inspection Report 6 96
Thickness As per Customer Coil does not process at CAL (4)Downstream user -100% of the product may have to be Scrapped 8 Verification of X ray gauge 2 Alarm & Interlock in Thickness gauge HMI 5 60
% Reduction As per Level 2 2 Alarm & Interlock in Thickness gauge HMI 5 60
Shape within Norms Poor Shape (4)Downstream user -100% of the product may have to be Scrapped 8 CVC-Auto Shape Control 2 L2-monitoring 6 96
Weld Strength Strip Breakage 4)Production loss 6 CC/SC 2 Visual Check 8 128
Improper Welding current Data Flowing from Welder Preset data Table. TS-COP-WI-253 2 Welder HMI Display 5 80
Improper weld speed Data Flowing from Welder Preset data Table 2 Welder HMI Display 5 80
Improper Electrode force Data Flowing from Welder Preset data Table 2 Welder HMI Display 5 80
Improper size matrix of 2 welding strips Implementing Line specific Scheduling Ruless 2 Welder HMI Display 5 80
Yield Strength Cracking While Bending at Component Level 5) Customer Disatisfaction 8 CC/SC 2 Offline Testing in UTM Machine 8 128 Online Mechnaical Property Prediction to be planned to reduce Detection Rating Mr. L G Naidu
Low SS temp Automatic temp control by DCS 2 HMI display 8 128 Trial to be taken at SS <820 Mr. Prashant Choudhary
Low RCS Automatic temp control by DCS ( distributed control system) 2 HMI display 8 128 Trial to be taken at RCS>360 Mr. Prashant Choudhary
Hhigh Speed Automatic temp control by DCS ( distributed control system) 2 HMI display 8 128 Take Trial at <100 mpm Mr. Prashant Choudhary
TS Cracking While Bending at Component Level 5) Customer Disatisfaction 10 CC/SC 2 Offline Testing in UTM Machine 8 0 Online Mechnaical Property Prediction to be planned to reduce Detection Rating Mr. L G Naidu
Low SS temp Automatic temp control by DCS ( distributed control system) 2 HMI display 8 0 Trial to be taken at SS <820 Mr. Prashant Choudhary
Continous Annealing Line Low RCS Automatic temp control by DCS ( distributed control system) 2 HMI display 8 0 Trial to be taken at RCS>360 Mr. Prashant Choudhary
400 (CAL) Elongation Cracking While Bending at Component Level 5) Customer Disatisfaction 8 CC 2 Offline Testing in UTM Machine 8 0
Low SS temp Automatic temp control by DCS ( distributed control system) 2 HMI display 8 0 Trial to be taken at SS <820 Mr. Prashant Choudhary
Surface Quaity as per customer requirement Poor Paintability 5) Customer Disatisfaction 7 2 Inspection Report 8 0 Plan Online Inspection through Cognex, FY22 Mr. Karthik Ganesh
H2% Furnace Presure control 1 HMI display 8 0
Roughness as per Customer Poor Paintability 5) Customer Disatisfaction 7 2 Manual Check 8 0 Online Surface Roughness Monitoring to be planned to reduce Detection Rating Mr. L G Naidu
SPM Elong Process as per standard and auto elongation control 1 Property test at QA lab 8 0
WR Roughness Process as per standard and auto elongation control 2 Property test at QA lab 8 0 WR Roughness > 3 Mr. Karthik Ganesh
Oiling as per Customer Rusty strip surface 5) Customer Disatisfaction 7 Online Inspection through Cognex 2 Inspection Report 8 0 Plan Online Inspection through Cognex, FY22 Mr. Karthik Ganesh
Oiling Quantity Process as per work order 1 Mopping Test 8 0
Oiling Type Process as per work order 1 Manual Checklist 8 0
Free from Surface Defect Scratch, Dent 5) Customer Disatisfaction 7 Online Inspection through Cognex 1 Inspection Report 8 56
Inspection Without Standard Inspection As per Standard 1 Surface Inspection Report 8 56
Weld strength Strip Breakage 4)Production loss 6 2 Visual Check 8 96
Improper Welding current Data Flowing from Welder Preset data Table. TS-COP-WI-253 3 Welder HMI Display 5 90
CC/SC Improper weld speed Data Flowing from Welder Preset data Table 3 Welder HMI Display 5 90
Improper Electrode force Data Flowing from Welder Preset data Table 3 Welder HMI Display 5 90
Improper size matrix of 2 welding strips Implementing Line specific Scheduling Ruless 3 Welder HMI Display 5 90
3) Production Loss
Reflectivity Surface quality deterioration 5 Improper cleaning Reflectivity Test 2 Visual Check 5 50
6) End User
3) Production Loss
Yield Strength Cracking While Bending at Component Level 8 CC/SC 2 Offline Testing in UTM Machine 6 96
6) End User
Stabilization of furance by processing 4-5 coils in same
Improper HS and SS temp Automatic temp control by DCS 3 HMI display 8 192 Difference between HS and SS tempearture should not be more than 20 Deg C. CGL opeartion. 25th July-2020. temperature prior to actual prime coil to achieve the 8 1 8 64
desired HS and SS temperature.
Improper Line Speed Automatic temp control by DCS ( distributed control system) 1 HMI display 8 64
3) Production Loss
TS Cracking While Bending at Component Level 8 CC/SC 2 Offline Testing in UTM Machine 6 96
6) End User
Stabilization of furance by processing 4-5 coils in same
Improper HS and SS temp Automatic temp control by DCS ( distributed control system) 3 HMI display 8 192 Difference between HS and SS tempearture should not be more than 20 Deg C. CGL opeartion. 25th July-2020. temperature prior to actual prime coil to achieve the 8 1 8 64
desired HS and SS temperature.
Improper Line speed Automatic temp control by DCS ( distributed control system) 2 HMI display 6 96
3) Production Loss
Elongation % Cracking While Bending at Component Level 8 CC 2 Offline Testing in UTM Machine 6 96
6) End User
Stabilization of furance by processing 4-5 coils in same
CGL opeartion.
Improper HS and SS temp Automatic temp control by DCS ( distributed control system) 3 HMI display 8 192 Difference between HS and SS tempearture should not be more than 20 Deg C. temperature prior to actual prime coil to achieve the 8 1 8 64
25th July-2020.
desired HS and SS temperature.
Continous Galvannealing Line
500 3) Production Loss
(CGL) Free from oxidized surface, heating buckle,Dent,Black spot Poor Paintabilty and poor corrosion resistance 8 As per work instruction CRM-OP2-WI-319 1 Inspection Report 8 64
6) End User
H2% Furnace Presure control 2 HMI display 6 96
3) Production Loss
Zn coating weight Improper Bath chemistry 5 CC Automatic coating weight controller Control the Zn coating weight 1 Online Coating wt Gauge (JSW-SP-078 ) 8 40
6) End User
Gauge Variations Automatic control gauge adjustment system 1 Online Coating wt Gauge (JSW-SP-078 ) 8 40
Surface impurity Cleaning of the surface at CGL entry 1 Reflectivity Test as per CRM-OP2-WI-307 8 40
Free from powedering , scratch, dross patches, edge get up, nozzle 3) Production Loss CRM-OP2-WI-329/330 /331/341 (Control Bath Chemistry with Al and dross skimming
Poor surface quality 5 1 as per requirement 8 40
mark, unalloyed edges, groove roll 6) End User operation)
Pot temp As per work instruction CRM-OP2-WI-329 (Maintain the inductor water supply) 1 Thermocouple(Z-TE11W/12S) 8 40
Bath chemistry As per work instruction CRM-OP2-WI-329(maintain chemistry as per lab report) 1 Inductive couple plazma test 8 40
Fe% in Coating layer DCN. CRM-OP2-WI-337(Decrease GVF Power) 1 Inductive couple plazma test 8 40
GVF temp As per work instruction CRM-OP2-WI-336 1 L1 HMI display 8 40
APH As per work instruction CRM-OP2-WI-336 1 L1 HMI display 8 40
APC As per work instruction CRM-OP2-WI-337 1 L1 HMI display 8 40
WCS As per work instruction CRM-OP2-WI-336 1 L1 HMI display 8 40
Roughness as per Customer Poor Paintability 6) End User 8 1 Manual Check 8 64
SPM Elong Process as per standard and auto elongation control 1 Property test at QA lab 8 64
WR Roughness Process as per standard and auto elongation control 1 Property test at QA lab 8 64
Oiling as per Customer Rusty strip surface 6) End User 8 Online Inspection through Cognex 1 Inspection Report 7 56
Oiling Quantity Process as per work order 1 Mopping Test 8 64
Oiling Type Process as per work order 1 Manual Checklist 8 64
Free from Surface Defect (Scratch, Dent, Bare spot) Poor build, Poor Paintability and corrosion failure 6) End User 8 Online Inspection through Cognex 2 Inspection Report 6 96

Inspection Without Standard Inspection As per Standard 1 Surface Inspection Report 8 64

Trim width within specification and no strand carry over Width mis match against requirement 6) End User 5
Trimming by pass during RCL operation Inspection As per Standard 1 Inspection Report 7 35
No cutter mark Burr marks 6) End User 5
SOP violation Inspection As per Standard 1 Inspection Report 7 35
Oil quantity as Per Customer Corrosion and poor forming 6) End User 6
SOP violation Inspection As per Standard 1 Inspection Report 8 48
Oil type as per order Corrosion and poor forming 6) End User 7
SOP violation Inspection As per Standard 1 Inspection Report 8 56
Good buildup/no damage Damaged coil 6) End User 6
Recoiling Line Poor TR tension Inspection As per Standard 1 L2-monitoring 8 48
600
(RCL) Surface should be free from scratches Customer Equipment Damage 6) End User 6
Handling issue, poor rolls quality at RCL Inspection As per Standard 2 Inspection Report 6 72
Surface should be free from Dents Cracking while forming 2) Machine / Equipment 7
Handling issue, poor rolls quality at RCL Inspection As per Standard 2 Inspection Report 6 84
Wrong Despatch 6) End User 5 2 Inspection Report 6 84
Correct coil weight & identification number Catastrophic failure in Service 7) Government Regulatory 8 2 L2-monitoring for sticker matching 6 60
SOP violation Inspection As per Standard
Free from Surface Defect Poor Paintability 5) Customer Disatisfaction 8 Inspection As per Standard 1 Surface Inspection Report 8 64
Inspection Speed Positional Training 1 Manual Check 8 64
Inspector Skill Level Positional Training 1 Skill Matrix of Operator 8 64
Packaging as per Order Rusty strip surface 5) Customer Disatisfaction 7 L2 Control 1 Manual Check 8 56
700 Packaging Line (APL)
Unskilled Operator Positional Training 1 Skill Matrix of Operator 8 56

Effects Legend: (1) Operator Safety, (2) Machine / Equipment, (3) Next User, (4) Down Stream User, (5) Vehicle, (6) End User, (7) Government Regulatory

Prepared By-CFT Reviewed By GAGI incharge PDQC Approved By-HOD PDQC

 CRM-PDQC-QR-059
Issue/Rev No: 1/1
Customer:- Automobile Issue date : 09/06/2024
Control Plan Control Plan Type: PreLaunch
Product:- GAU878
HR Grade: JVHG878N0F Revision date : 5/15/2025
Doc No : CRM-PDQC-QR-059

Mr. Yogender Reddy (PDQC -Technology) , Mr. Vinoth Kumar G (PDQC -Technology),
Mrs. Prashant Choudary (PDQC -Technology), , Mr. Bubu Pradhan (Product safety Representative -
Customer Engineering Approval/Date (If
TDC/LATEST CHANGE LEVEL GAU878 Double Annealing Core Team Technology), Mr. Gunjan (SMS2-Technology), Mr. Nilesh Choudary (HSM2-Technology), Req'd.):
NA RESOURCE PERSON HOD-PDQC/42566
Mr. Karthik Ganesh. (CGL Opr -Flat Products), Mr. Pankaj Singh (PLTCM Opr -Flat Products), Subramanyam
(CRM TE -Technology), Mr. Deepak/Respective Zonal AE (AE -CFU)

EN 10346_2015 : HCT780X+ZF, Customer Quality Approval/Date (If

Reference Standard / Grades Supplier/Plant Approval/Date NA Req'd.):
NA PROCESS RESPONSIBILITY HOD-CRM
MAHINDRA G_00_0167: MM25_DP450_780
SUPPLIER/ JSW
PLANT Vijaya Nagar
SUPPLIER CODE NA Other Approval/Date (If Req'd.) NA Other Approval/Date (If Req'd.) NA Issue No / Rev No 01 / 00

PART/ PROCESS NAME/ MACHINE, DEVICE, CHARACTERISTICS SPECIAL METHODS

PROCESS OPERATION JIG, TOOLS, FOR CHAR. PRODUCT EVALUATION/ SAMPLE REACTION PLAN/Operator Instruction No. RESPONSIBILITY
PRODUCT PROCESS PRODUCT/ PROCESS SPECIFICATION/ TOLERANCE CONTROL METHOD Error Proofing
NUMBER DESCRIPTION MFG. CLASS SPECIFICATION MEASUREMENT TECHNIQUE Size Frequency
101 %C CC 0.08-0.10 Spectro 1 Each Heat CRM-PDQC-WI-001 SPTS Interlock CRM-PDQC-WI-001 SMS Opr/SMS TE
102 %Mn CC 2.00-2.10 Spectro 1 Each Heat CRM-PDQC-WI-001 SPTS Interlock CRM-PDQC-WI-001 SMS Opr/SMS TE
103 %S CC 0-0.005 Spectro 1 Each Heat CRM-PDQC-WI-001 SPTS Interlock CRM-PDQC-WI-001 SMS Opr/SMS TE
104 %P CC 0-0.015 Spectro 1 Each Heat CRM-PDQC-WI-001 SPTS Interlock CRM-PDQC-WI-001 SMS Opr/SMS TE
105 %Si CC 0-0.05 Spectro 1 Each Heat CRM-PDQC-WI-001 SPTS Interlock CRM-PDQC-WI-001 SMS Opr/SMS TE
106 %Al CC 0.03-0.05 Spectro 1 Each Heat CRM-PDQC-WI-001 SPTS Interlock CRM-PDQC-WI-001 SMS Opr/SMS TE
107 %Al CC 0.03-0.05 Spectro 1 Each Heat CRM-PDQC-WI-001 SPTS Interlock CRM-PDQC-WI-001 SMS Opr/SMS TE
108 %Mo CC 0-0.005 Spectro 1 Each Heat CRM-PDQC-WI-001 SPTS Interlock CRM-PDQC-WI-001 SMS Opr/SMS TE
109 %V CC 0-0.005 Spectro 1 Each Heat CRM-PDQC-WI-001 SPTS Interlock CRM-PDQC-WI-001 SMS Opr/SMS TE
110 %Nb CC 0.0555-0.062 Spectro 1 Each Heat CRM-PDQC-WI-001 SPTS Interlock CRM-PDQC-WI-001 SMS Opr/SMS TE
Steel Making
100 SMS 1 & SMS2 111 %Ti CC 0.008-0.015 Spectro 1 Each Heat CRM-PDQC-WI-001 SPTS Interlock CRM-PDQC-WI-001 SMS Opr/SMS TE
(SMS)
112 %B CC 0.008-0.015 Spectro 1 Each Heat CRM-PDQC-WI-001 SPTS Interlock CRM-PDQC-WI-001 SMS Opr/SMS TE
113 Skilled Operator 3rd Quadrant Skill Matrix each Once in Month Training SOP CRM-PDQC-WI-001 SMS Opr/SMS TE
Suggestion of ferro alloy and precalculation
114 Ferro-alloy Addition As per SOP
of chemistry after taking ferro alloy in hopper
1 Each Heat Log in Level-2 CRM-PDQC-WI-001 SMS Opr/SMS TE

Visual Checking. Checking result is recorded in the

115 Free from Surface Crack Zero Visual 1 Slab
inspection sheet.
CRM-PDQC-WI-001 SMS Opr/SMS TE

116 Super Heat 20-30 Level 2 1 Each Heat Monitioring through Level 2 CRM-PDQC-WI-001 SMS Opr/SMS TE
117 Casting Speed 1-2 mpm Level 2 1 Each Slab Monitioring through Level 2 CRM-PDQC-WI-001 SMS Opr/SMS TE
118 Free from Inclusion Zero Sulphur Printing offline each Each Heat Visual Checking. CRM-PDQC-WI-001 SMS Opr/SMS TE
119 Killing Time 15-25min Level 2 1 Each heat Monitioring through Level 2 CRM-PDQC-WI-001 SMS Opr/SMS TE
120 MLF <5mm Automotic MLC 1 Each Slab Monitioring through Level 2 CRM-PDQC-WI-001 SMS Opr/SMS TE

Monitoring by computer display.

Furnace temperature is controlled by DCN HSM2-OP-PR-02; DCN HSM2-OP-WI-05
201 Slab Furnace Temperature 1240±20 °C HMI display Full length per slab Preventive Maintenance of flow control valve at every
Level 2 thermal model. DCN HSM2MM-PR-01
HSM Opr/SMS TE
annual shutdown
Online monitoring by computer display.
Checking result is recorded in the inspection sheet for
FT is controlled by Level 2 DCN HSM2-OP-PR-04; DCN TEHSM-GN-10
202 HSM Finishing Temperature 895± 15 Finishing mill exit pyrometer Full length per coil every coil.
automation DCN TEHSM-PR-03; DCN PDQC-PR-10
HSM Opr/SMS TE
Mechanical Property Automation control through Level2
Online speed correction
Hot Rolling Visual checking. Checking result is recorded in inspection
200 HSM2 sheet.
DCN HSM2-OP-PR-04; DCN TEHSM-GN-10; DCN PDQC-
(HSM) CT Control by Level-2 Automation, Condition monitoring No rolling permissive in case of
203 HSM Coiling Temperature 570± 15 Pyrometer before coiler. HMI display Full length per coil
Preventive maintenance of header & header valve invalid CTC set up.
HR-010 HSM Opr/SMS TE
Preventive maint. of side sweep valve, Online monitoring of DCN HSM2-OP-WI-44; DCN HSM2MM-PR-01
coil temp.
204 HR Crown 50±10 µm Multi functional gauge meter 100% Each coil Process monitoring report- TE HSM QR03 Divert if HR Ridge is less than 30 µm CRM-PDQC-WI-001 HSM Opr/SMS TE
Profile
205 HR Wedge <=20 µm Multi functional gauge meter 100% Each coil Process monitoring report- TE HSM QR03 Divert if HR Ridge is less than 30 µm CRM-PDQC-WI-001 HSM Opr/SMS TE
DCN TEHSM-GN-10,
206 Surface Descaling Free from scale PARSYTECH online inspection Full length Each coil Process monitoring report- TE HSM QR03 None
DCN HSM2MM-PR-01
HSM Opr/SMS TE

Laser Beam welding- CRM-OP2-WI-053 / CRM-OP2-WI- Laser Beam welding- CRM-OP2-WI-053 / CRM-OP2-WI-
301 Weld Strength No Weld Breakage QAS (quality assurance system) graph 1 Each coil
054 / CRM-OP2-WI-055 / CRM-OP2-WI-056
QAS alarm for bad weld
054 / CRM-OP2-WI-055 / CRM-OP2-WI-056
PLTCM Welder Operator

302 HR YS Difference <=200 Mpa Automatic Matching in L2 system 100% Each coil Automatic Control through L2 PLTCM Opr
Pickling Section 303 Thickness Difference <= 0.60 Automatic Matching in L2 system 1 Each coil Automatic Control through L2 PLTCM Opr
304 Weld Recipe As per Level2 Automatic Weld Recipe Assignment 100% Each coil Automatic Control through L2 PLTCM Opr
Pickling with 305
Free from scales (No Under
Free from H.R scale, Acid stains Visual Inspection 1 Each coil As per WI - CRM-OP2-WI-058
Reduce the process speed / Inform to TCM/ Log the defect / Trimmer pulpit/ inspection
300 Tandem Cold Mill Pickling) Reduce set value of Fe in HMI Operator
(PLTCM) 306 Process speed Control by PPMC Model Rotational speed transducer (GD31BN) 100% Each coil As per WI - CRM-OP2-WI-058 Max/Min speed restricted by PPMC Inform L2 person to check PPMC system Trimmer pulpit Operator
Thickness measuring system database Thk. beyond +/- 20 micron, alarm TCM Operator/ TCM Electrical
307 Thickness As per Customer AS per SAP work order As per Level 2 1 Each Coil
(CRM-EM2-WI-72) generated
(CRM-EM2-WI-72)
Incharge
Tandem Mill 308 Reduction (%) AS per PQDC-CRM-003 As per Level 2 100% Each Coil PLTCM Opr
309 Shape Control by PPMC Model As per Level 2 1 Each Coil Automatic Control through L2 PLTCM Opr
310 Tension at Each Stand Control by PPMC Model As per Level 2 100% Each Coil Automatic Control through L2 PLTCM Opr
Entry 401 Weld Strength Bulge Test Pass 0.70 - 2.3 mm No Weld Breakage Temperature sensor (CAL- Welder- T1-100) 1 Each coil If temprature fault ratio is more than 5% reweld As per work instruction CRM-OP2-WI-205 ( Rewelding)

Thk(mm) L1 HMI display 100% Continuous measurement As per WI -CRM-OP2-WI-319 Mentioned in document : CRM-OP2-WI-319 CGL Opr/ CRM2 Process control
Automatic temp control by DCS ( distributed control
402 SS strip temp (°C) CC 1.2,1.4 810±10 Temp transmitter (TE3003) 1 Each coil
system)
AS Per Work Instruction CRM-OP2-WI-213

1.2 160±10 Temp transmitter (TE3003) 1 Each coil

403 Line Speed (Mpm) CC Furnace speed controlled on HMI based
1.4 140±10 Speed encoder numer 1 Continuous measurment As per work instruction CRM-OP2-WI-213
interface
AS Per Work Instruction CRM-OP2-WI-213

404 HS strip temp (°C) 1.2,1.4 810±10

Annealing Automatic temp control by DCS ( distributed control
Continous Furnace
405 SCS strip temp (°C) 1.2,1.4 660±10 Temp transmitter (TE4001) 1 Each coil
system)
AS Per Work Instruction CRM-OP2-WI-213

400 Annealing Line 406 RCS strip temp (°C) 1.2,1.4 480±20 Temp transmitter (TE5002) 1 Each coil
Automatic temp control by DCS ( distributed control
AS Per Work Instruction CRM-OP2-WI-213
system)
(CAL) Automatic temp control by DCS ( distributed control
407 OAS strip temp (°C) 1.2,1.4 340±20 Temp transmitter (TE6001) 1 Each coil
system)
AS Per Work Instruction CRM-OP2-WI-213
Automatic temp control by DCS ( distributed control
408 FCS strip temp (°C) 1.2,1.4 150±20 1 Each coil
system)
AS Per Work Instruction CRM-OP2-WI-213
Automatic temp control by DCS ( distributed control
409 WCS strip temp (°C) 0.70 - 2.3 mm 60±5 100% Each coil
system)
AS Per Work Instruction CRM-OP2-WI-213
As per work instruction CRM-OP2-WI-213 ( reduce line
410 H2(%) 3-5% HNx Composition Analyzer ( AI0051)) 100% Continuous measurment Automatic flow control of HNx through DCS system
speed & use dummy coil)
SPM rolling 411 Proper elongation (%) 1.2,1.4 Not Applicable (0.0) SPM operator

Oiling 412 Oiling 0.70 - 2.3 mm Not Applicable NA NA NA NA NA

Recoiler 412 Inner dia mm 0.70 - 2.3 mm 610 mm
CRM-OP2-WI-304 ( If bulge test will fail then reweld the
501 Weld Strength Bulge Test Pass CC/SC Bulge test (CRM-OP2-WI-304 ) Bulge Testing 100% Each coil Mentioned in DCN . CRM-OP2-WI-304
coil)
CGL Welder Operator
Alkali tank concentration, temperature & conductivity shall be 2-
5 % , 65- 85*C & 33-75mS/cm respectively . Electrolytic tank
Cleaning No oil residue after cleaning in tissue paper concentration , temperature & conductivity shall be 3-7% .65-
502 Clean strip surface Tissue paper test
test
once per shift 85*C & 45-90mS/cm respectively . Brushing current & Brush
CRM-OP2-WI-307 CGL Opr
tank temperature shall be 10-18 Amp more then 70*C
respectively
If YS is in high, decrease the line speed and if YS is low
503 YS (MPa) CC/SC JFS: (0.8-1.0mm thk):315-460, (1.0-3.2mm thk):305-450 Tensile testing machine-Z100 Length: 500 mm Each coil Lab test results report-CRM-QA-QR-34 increase the line speed within specified limits (Process CRM2 TE
validation report CRM-PV-QR04)
All thick (50mm GL) If TS is in high, decrease the line speed and if TS is low
504 TS (MPa) CC/SC T-dir JFS: ≥590 Tensile testing machine-Z100 Length: 500 mm Each coil Lab test results report-CRM-QA-QR-34 increase the line speed within specified limits (Process CRM2 TE
validation report CRM-PV-QR04)
505 Total Elongation (%) CC JFS: (0.8-1.0mm thk):17-32, (1.0-3.2mm thk):18-33 Tensile testing machine-Z100 Length: 500 mm Each coil Lab test results report-CRM-QA-QR-34 CRM2 TE
CRM-OP2-WI-319 (Maintaining SS temp. in auto, uniform &
Free from oxidized surface,
504 heating/cooling buckle
Visual check 100% Each coil As per WI -CRM-OP2-WI-319 maintaining furnace tension as per L-2 Master in auto. As per work CGL Opr
instruction)

507 HS strip temp (°C) All thick 750/770±10 Pyrometer(TICA3001) 100% Each coil As per WI -CRM-OP2-WI-319 Automatic temp control by DCS Mentioned in document : CRM-OP2-WI-319 CGL Opr/ CRM2 Process control

Annealing 508 SS Strip temp(°C) CC/SC 1.2,1.4 760/780±10 Pyrometer(TICA3002) 100% Each coil As per WI -CRM-OP2-WI-319 Automatic temp control by DCS Mentioned in document : CRM-OP2-WI-319 CGL Opr/ CRM2 Process control
furnace Furnace speed controlled on HMI based
Thk(mm) L1 HMI display 100% Continuous measurement As per WI -CRM-OP2-WI-319
interface
Mentioned in document : CRM-OP2-WI-319 CGL Opr/ CRM2 Process control
Furnace speed controlled on HMI based
509 Line Speed (Mpm) CC/SC 1.2 95±5 L1 HMI display 100% Continuous measurement As per WI -CRM-OP2-WI-319
interface
Mentioned in document : CRM-OP2-WI-319 CGL Opr/ CRM2 Process control
Furnace speed controlled on HMI based
Continous 1.4 85±5 L1 HMI display 100% Continuous measurement As per WI -CRM-OP2-WI-319
interface
Mentioned in document : CRM-OP2-WI-319 CGL Opr/ CRM2 Process control

500 Galvannealing Line 510 RCS strip temp (°C) All thick 480±20 Pyrometer(TICA4005) 100% Continuous measurement As per WI -CRM-OP2-WI-319 Automatic temp control by DCS Mentioned in document : CRM-OP2-WI-319 CGL Opr/ CRM2 Process control
(CGL)
511 GVF Temp (°C) All thick 500-520 Pyrometer(TICA5003) 100% Continuous measurement As per WI -CRM-OP2-WI-319 Automatic temp control by DCS Mentioned in document : CRM-OP2-WI-319 CGL Opr/ CRM2 Process control
CRM-OP2-WI-319(Check incomingH2 &N2 and Furnace
512 H2(%) (5-8%) Gas analyzer number (AI3053H) 100% Continuous measurement Automatic control by DCS ( distributed control system)
leakage)
CGL Opr/ CRM2 Process control
Automatic coating weight controller.
513 Zn coating weight CC As per Work order Online Coating wt Gauge (JSW-SP-078 ) 100% Continuous measurement
Controls the Zn coating weight
CRM-OP2-WI-328/325(Control air knife data) CGL Opr/ CRM2 Process control

Free from powedering , scratch,

Hot Dip CRM-OP2-WI-329/330 /331/341 (Control Bath Chemistry
514 dross patches, edge get up, nozzle CRM-PDQC-WI-006 Strapping method as per requirement as per requirement As per WI -CRM-OP2-WI-329/330 /331/341
with Al and dross skimming operation)
CGL Opr/ CRM2 Process control
Galvanising mark, unalloyed edges, groove roll
515 Pot temp All thick 460±4 deg.C Thermocouple(Z-TE11W/12S) 100% Continuous measurement As per WI -CRM-OP2-WI-329 CRM-OP2-WI-329 (Maintain the inductor water supply) CGL Opr/ CRM2 Process control
Al-0.14-0.20 (preferrably=0.14), Fe<=0.05, Pb<=0.02, Rest
516 Bath chemistry All thick
Zn
Inductive couple plazma test twice per shift As per WI -CRM-OP2-WI-329 CRM-OP2-WI-329(maintain chemistry as per lab report) CGL Opr/ CRM2 Process control
517 DD All thick 310 °C± 10 L1 HMI display 1 Each coil As per WI - CRM-OP2-WI-337 As per work instruction CRM-OP2-WI-337 CGL Opr/ CRM2 Process control
After pot cooling
518 WCS All thick 40 °C± 10 L1 HMI display 1 Each coil As per WI - CRM-OP2-WI-337 As per work instruction CRM-OP2-WI-337 CGL Opr/ CRM2 Process control
Proper elongation CRM-OP2-WI-345(Setrequired tension with continous
519
(%)
SPM Elongation (%) 1.2,1.4 0.5±0.1 L1 HMI 100% each coil As per WI -CRM-OP2-WI-345
monitioring)
CGL Opr/ CRM2 Process control
Proper elongation CRM-OP2-WI-345(Setrequired tension with continous
Cold Treatment 520
(%)
TLL Elongation (%) 1.2,1.4 NA L1 HMI 100% each coil As per WI -CRM-OP2-WI-345
monitioring)
CGL Opr/ CRM2 Process control

521 Proper Ra ` To be maintained as per SO L1 HMI 100% each coil As per WI -CRM-OP2-WI-347 CRM-OP2-WI-347(Change work roll) CGL Opr/ CRM2 Process control
CRM-PDQC-WI-004 (1. Immediate inform to centre and entry
For TDC ZAXxx- Inspection as per outer Quality Inspection Report operator to change the plan on unload the coil)
Inspection 522 Inspection speed
For TDC ZAUuu- Inspection as per inner
Micrometer, gauge, stroboscope light Once each coil
CRM-PDQC-WI-004 2. Effected coils plan in RCL and segrigate the affected
CRM2 TE
portion)
601 Free from Surface Defect l1 Visual 100% Each Coil CRM-QA-WI-25 CRM2 TE
CRM-OP2-WI-413, If Coil is defective which is not going for
602 Inspection Speed 30-60 mpm Visual 100% Each Coil Manual
intended customer, coil may be processed at higher speed
CRM2 TE
Recoiling Line 603 Inspector Skill Level Q3 Skill Test 100% Each Operator Skill Matrix CRM2 TE
600 RCL/SPCL
(RCL) 604 Free from Edge < 20 Micron Micrometer 100% Each Coil Inspection CRM2 TE
605 GAP 10-14% of Strip Thickness Manual 100% Each Thickness System Interlcok for less than 10% CRM-OP2-WI-405 CRM2 TE
606 LAP 30-80% of Strip Thickness Manual 100% Each thickness CRM2 TE
Packaging Line
700 APL 701 Packing Once each coil L2 CONTROL CRM-QA-WI-43 APL Opr
(APL)
Special Instructions: Product Audit shall take place at least every 12 months as per clause no: 8.5.1.1 of IATF 16949: Customer-Specific-Requirements (CSR‘s)of Volkswagen Group

Prepared By- Reviewed By- Reviewed By- Reviewed By Reviewed By- Reviewd By- Approved By Approved By- Approved By-
NPD PDQC NPD Incharge PDQC CGL incharge PDQC Process Ctrl I/C (CRM) HOD PDQC Section I/C - TE Line Manager - CGL Operations Head HOD CRM

S.No Issue No Revision No. Date Brief detail of amendment carried out PS- Product Safety
1 11 15.03.2025