PFD and Pqcs of Can Rear Break

M/S SK ENTERPRISES ROHTAK PROCESS QUALITY CONTROL SHEET(1)
Part Name - CAM REAR BREAK Process Name - Alkaline Zinc Plating with yellow Document No. F02 QA 02
Trivalent Passivation Rev.No.:- 00
Part No.
Process Flow Diagram For Alkaline Zinc Plating

Raw Material Inspection
PARTS PURCHASED FROM VENDORS
S. NO. PART NAME
Loading - Bucket 1 HYDROCHLORIC ACID
Water Rinse 2 NITRIC ACID
BRIGHTENER
3 CONSOL ACF PLUS BRIGHTENER A
Soak Cleaning 4 CONSOL ACF PLUS BRIGHTENER B
5 CONSOL ACF PLUS BRIGHTENER C
Nitric Dip` 6 CONSOL ACF PLUS CONDITIONER
7 CONSOL MCL 585-S
8 CONSOL MCL 523-S
PASSIVATION
Anodic Cleaning 9 Spectramate-25 PASSTIVATION
CONSOL CC RC-303
D.M Water Rinse
10 ZINC ANODE (Australian Zinc)
Water Rinse 11 CAUSTIC SODA (NaOH)
D.M Water Rinse

Water Rinse
Acid Pickling Passivation
Water Rinse
2D.M Water Rinse
2D.M Water Rinse
Water Rinse Sealer( TOp Coat)

CUSTOMER APPROVAL
DATE AUDIT BY:- APPROVED BY:- MADE BY:-
AirRachana
Dryer
NeutralIzation
PROCESS QUALITY CONTROL SHEET(1)
Document No. F02 QA 02
Page Of
PARTS PURCHASED FROM VENDORS

SUPPLIER
C.R. GUPTA
C.R. GUPTA
BRIGHTENER
CMF
CMF
CMF
CMF
CMF
CMF
PASSIVATION
CMF
CMF
R.S Marketing
N.R. CHEMICALS
APPROVED BY:-
MR. Jogender Balhara

M/S SK ENTERPRISES, ROHTAK
Plot No. 73,74 Old IDC , Rohtak CONTROL PLAN for ALKALINE ZIN
Prototype Pre-Lauch Production Key Contact: Mr. Jogender Balhara Date (Orig)
Control Plan No. 02 Mobile no : 9034070203,7015137931
Customer Rohtash Fasteners Kay Characterstics:-Plating Thickness & Salt Sapray Specification
Part Name: Cam Rear Break SST Requirement :- 96 hrs White Rust
Supplier/ Plant: M/s S.K. ENTERPISES Rohtak. Plating Thickness :- 8-12 Micron
Characterstics
Process No. Process Name Machine For MFG Size No. Product. Process Parameter Process Specification/tolerance Evaluation Checking frequency
10 Material received 1 Counting/ Weight. Every Lot
20 Inspection 1 No pitted,no rust, no dent etc. Visual Every lot
30 Loading Bucket 1 Bucket Bucket should no be over flow Visual Every lot
1 Concentration 50-70gm/L (opt. 60 gm/L) Lab test Per Shift
2 Temp. 60~90˚C (opt. 70) Temp.Controller 2 Times / Day
40 Soak Cleaning Tank 200L 3 Consol MCL-585-S Time 2~ 5Min Timer 2 Times / Day
4 Filtration Approx. 10% Solution removed from bottom As per Check Sheet After 15 Days
5 Discard 100% Discard As per Check Sheet After 30 Days
1 Concentration 100-120gm/L (opt. 100gm/L) Lab test Per Shift
2 Temp 50-65˚C (opt. 55°C) Therma Meter 2 Times / Day
3 Time 3~10 min Timer 2 Times / Day
50 Anodic Cleaning Tank 400 L 4 Consol MCL-523-S Voltage 8- 10 v AMP. Meter 2 Times / Day
5 Current 150-300 A AMP. Meter 2 Times / Day
1 Water Running water visuallly Per Shift
60 Water Rinse Tank 50 L 2 Water ph 7~ 12 Ph meter/Ph Paper 2 Times / Day
3 Time Three Dip No No

Characterstics
70 Water Rinse Tank 50 L 2 Water ph 7.5~9.00 Ph meter/Ph Paper 2 Times / Day
1 Concentration 30~40% Lab test Per Shift
2 Time 3-5 Min Timer 2 Times / Day

80 Acid Pickling Tank 100 L HCL
90 Water Rinse Tank 50 L 2 Water ph 2~ 3 Ph meter/Ph Paper 2 Times / Day
100 Water Rinse Tank 50 L 2 Water ph 5~ 7.5 Ph meter/Ph Paper 2 Times / Day

Characterstics
1 Concentration 10 ± 2% Lab test Per Shift
2 Time Three Dip Manually Per lot
110 Caustic Dip Tank 50 L Naoh
3 Filtration Approx. 10% Solution removed from bottom As per Check Sheet After 3Days
Per Shift in-house/Weekly from

1 Concentration (Zinc Metal) 10~18gm/L (opt. 12 gm/L) Lab test
third party

2 Caustic Soda 100-150gm/L (opt. 120 gm/L) Lab test
third party
3 Time 60~90min Timer Per lot
4 Temperature 20~40*C (opt. 28) Temperature Meter Per Shift
5 Current 200-300 A AMP. Meter 2 Times / Day
6 Voltage 8~15 Volt. volt Meter 2 Times / Day

120 Alkaline Zinc BAREEL 600 L
7 Filtration Continious Manually Daily
8 Treatment Full Manually Monthly

9 Brightner-A Hull Cell 250 ~450 ml/1000 Amp. Lab test
third party

10 Brightner-B Hull Cell 200~250 ml/1000Amp. Lab test
third party

11 Brightner-C Hull Cell 30~50 ml/1000Amp. Lab test
third party

12 Conditioner Hull Cell 30~50 ml/1000Amp. Lab test
third party
Characterstics
1 TDS 10 ppm ±10 ppm TDS Meter Per Shift
130 Dragout ( DM water) Tank 50 L 2 DM Water Time Three Dip No No
3 pH 10~ 14 Ph meter/Ph Paper 2 times per day
140 DM water Tank 50 L 2 DM Water Time Three Dip No No
3 pH 6.5~ 7.5 Ph meter/Ph Paper 2 times per day
1 Conc. 10~15 ml/ltr Lab Test Per Shift
ph 1.2~ 1.5 Ph meter/Ph Paper 2 times per day

160 Nitric Acid Dip Tank 50 L HNO3
2 Time 7~10 Sec. Timer per lot
3 Discard 100% Discard. No per shift
3 pH 6.5~ 7.5 Ph meter/Ph Paper 2 times per day

Characterstics
1 Conc. 80~100 ml/L Lab Test Per Shift
2 Time 30-60 Ses Timer Per Shift
3 Ph 2.0~2.5 Ph meter/Ph Paper Per Shift
4 Temp. 21~40 °C Room Per Shift

Trivalent Yellow
190 Tank 50 L Sep-25
Passivation
5 Nitric acid 0.4~0.6 ml/L (opt. 0.4 ml/L) Per Shift
Discard Zn (1000~1500 ppm) Supplier Lab Test

After 30 Days
7 Fe (100~150 ppm) Supplier Lab Test
8 Filtration Approx. 10% Solution removed from bottom Lab test Weekly
200 D.M Water Tank 50 L 2 DM Water Time Three Dip No No
210 D.M Water Tank 50 L 2 DM Water Time Three Dip No No
3 pH 6~ 7.5 Ph meter/Ph Paper 2 times per day
Conc. 100~150ml/L Lab Test Per Shift

1
Time 15 sec.~ 1 min (opt. 40 Sec) Timer 2 times per day
2
pH 8~10.0 (opt. 8.5) Ph meter/Ph Paper 2 times per day
3
220 Sealer Tank 50L Consol TC -303 Temp. 18~35°C Temp. meter 2 times per day
4
Approx. 5% solution removed from
Filtration As per check sheet Weekly
5 bottom
220 SealerPlant:
Supplier/ Tank
M/s S.K. ENTERPISES50L
Rohtak. Consol TC -303 Plating Thickness :- 8-12 Micron
Characterstics
Discard 100% discard As per check sheet After 30 working days

6
Air Dryer
230 Centrifugal Dryer 1 Apperance No water Content Proper Drying Each lot
(Compressor)
1 Drying Time 10-15 min Timer Each lot

240 Oven Drying Oven
2 Temperature 80~100*C Digital Temp.Controller Each lot
1 Temperature Room Temp. No Each lot

250 Curing Curing Room
2 Time 24 Hrs. Timer Each lot
1 Visual As Per Drawing Visually Each lot
2 Thickness 10~12 microns Thickness tester 5 Pcs. Per lot

Thickness Tester
260 Inspection
SST Chamber
3 Salt Spray test Observation Lab Test Monthly
4 Travelent Chromium Test No Trivalent cromium Lab test Per Shift
As per packing
270 Packing
standard
280 Dispatch As per dispetch plan
Safety Eqiupments Eyes - Eye wear Feet - Gum boots
Hands - Hand glaves Nose - Gas masks
Front Body - Aperon
Ref No. Date
Perpared By:- Kuldeep Kumar, Rahul (CMF)

CONTROL PLAN for ALKALINE ZINC PLATING
Date (Orig) Doc. No.F02 QA 04
Rev. No.-00
Kay Characterstics:-Plating Thickness & Salt Sapray Specification
SST Requirement :- 96 hrs White Rust
Plating Thickness :- 8-12 Micron
Responsibility Record
Reaction Plan
Superviser No
Check & correct
Spperviser No
Rej. & Send Back
Helper No
Check & correct
Lab Incharge Ref.Doc. F01/QAD/02 CON. LOW - ADD- CHEMICAL & HIGH. ADD WATER
Lab Incharge/Sup. Ref.Doc. F01/QAD/02

CHECK & RESET
Lab Incharge/Sup. No
CHECK & RESET
Lab Incharge Ref.Doc. F01/QAD/02

Lab Test

Lab Test
Lab Incharge/Sup. Ref.Doc. F01/QAD/02 CON. LOW - ADD- CHEMICAL & HIGH. ADD WATER

CHECK & RESET

CHECK & RESET

CHECK & RESET

Lab Test

Lab Test
Operator/ Sup. Ref.Doc. F01/QAD/02

Change water

CHECK & RESET
Operator. No
CHECK & RESET
Rev. No.-00
Reaction Plan

Change water
Operator. No
CHECK & RESET
CON. LOW - ADD- CHEMICAL &
HIGH. ADD WATER

CHECK & RESET

Lab Test

Lab Test

Change water

CHECK & RESET
Operator. No
CHECK & RESET

Change water

CHECK & RESET
Operator. No
CHECK & RESET
Rev. No.-00
Reaction Plan
Operator/ Sup. No
CHECK & RESET

Lab Test

Lab Test
Lab Incharge Register CON. LOW - ADD- CHEMICAL & HIGH. ADD WATER
operator/sup No
CHECK & RESET

CHECK & RESET

CHECK & RESET

CHECK & RESET
Lab Incharge Ref.Doc. F03/MNT/03

CHECK & RESET

CHECK & RESET
Lab Incharge/Sup. Register

ADD WIITH EVERY LOT

ADD WIITH EVERY LOT

ADD WIITH EVERY LOT

ADD WIITH EVERY LOT
Rev. No.-00
Reaction Plan

Lab Test
Operator. No
CHECK & RESET
Lab. Incharge/Sup. Ref. Doc F01/QAD/01

CHECK & RESET

Lab Test
Operator. No
CHECK & RESET

CHECK & RESET

Lab Test
Operator. No
CHECK & RESET

CHECK & RESET

Lab Test
Operator /Sup.
CHECK & RESET

CHECK & RESET

Lab Test
Operator. No
CHECK & RESET

CHECK & RESET

Lab Test
Operator. No
CHECK & RESET

CHECK & RESET
Rev. No.-00
Reaction Plan
Lab Incharge Ref.Doc. F01/QAD/02 CON. LOW - ADD- CHEMICAL &

HIGH. ADD WATER

CHECK & RESET
Low- add NaoH & High -
HNO3

CHECK & RESET
Lab Incharge Ref.Doc. F01/QAD/02 CON. LOW - ADD- CHEMICAL &

HIGH. ADD WATER
Lab incharge Test Report

More PPM (Treatment)

Lab Test

Lab Test
Ref.Doc. F01/QAD/02
Lab Test
Operator. No
CHECK & RESET

Change water
Ref.Doc. F01/QAD/02
Lab Test
Operator. No
CHECK & RESET

Change water
Lab. Incharge Ref. Doc F01/QAD/01 Lab Test
Operator/Sup No CHECK & RESET

Lab. Incharge Ref. Doc F01/QAD/01 CHECK & RESET
Lab. Incharge Ref. Doc F01/QAD/01 CHECK & RESET

Rev. No.-00
Reaction Plan
Operator/Sup. Ref.Doc. F01/QAD/02 Water content visual Report

process
Operator/Sup. Ref.Doc. F01/QAD/02

CHECK & RESET
Operator/Sup. Ref.Doc. F01/QAD/02

CHECK & RESET
Operator No
CHECK & RESET
Operator No
CHECK & RESET
Inspector Ref.Doc. F01/QAD/04

Re-work
Lab Incharge
Re-work trivalent passi.
Approved By:- Jogender Balhara

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M/S SK ENTERPRISES ROHTAK PROCESS QUALITY CONTROL SHEET(1)

Process Flow Diagram For Alkaline Zinc Plating

D.M Water Rinse

Acid Pickling Passivation

Water Rinse Sealer( TOp Coat)

PARTS PURCHASED FROM VENDORS

MR. Jogender Balhara

10 Material received 1 Counting/ Weight. Every Lot

20 Inspection 1 No pitted,no rust, no dent etc. Visual Every lot

1 Concentration 50-70gm/L (opt. 60 gm/L) Lab test Per Shift

2 Temp. 60~90˚C (opt. 70) Temp.Controller 2 Times / Day

5 Discard 100% Discard As per Check Sheet After 30 Days

1 Concentration 100-120gm/L (opt. 100gm/L) Lab test Per Shift

2 Temp 50-65˚C (opt. 55°C) Therma Meter 2 Times / Day

3 Time 3~10 min Timer 2 Times / Day

5 Current 150-300 A AMP. Meter 2 Times / Day

7 Discard 100% Discard As per Check Sheet After 30 Days

1 Water Running water visuallly Per Shift

60 Water Rinse Tank 50 L 2 Water ph 7~ 12 Ph meter/Ph Paper 2 Times / Day

3 Time Three Dip No No

1 Water Running water visuallly Per Shift

70 Water Rinse Tank 50 L 2 Water ph 7.5~9.00 Ph meter/Ph Paper 2 Times / Day

3 Time Three Dip No No

1 Concentration 30~40% Lab test Per Shift

2 Time 3-5 Min Timer 2 Times / Day

5 Discard 100% Discard As per Check Sheet After 30 Days

1 Water Running water visuallly Per Shift

90 Water Rinse Tank 50 L 2 Water ph 2~ 3 Ph meter/Ph Paper 2 Times / Day

3 Time Three Dip No No

1 Water Running water visuallly Per Shift

3 Time Three Dip No No

1 Concentration 10 ± 2% Lab test Per Shift

2 Time Three Dip Manually Per lot

110 Caustic Dip Tank 50 L Naoh

4 Discard 100% Discard As per Check Sheet After 30 Days

Per Shift in-house/Weekly from

Per Shift in-house/Weekly from

3 Time 60~90min Timer Per lot

4 Temperature 20~40*C (opt. 28) Temperature Meter Per Shift

5 Current 200-300 A AMP. Meter 2 Times / Day

6 Voltage 8~15 Volt. volt Meter 2 Times / Day

8 Treatment Full Manually Monthly

Per Shift in-house/Weekly from

Per Shift in-house/Weekly from

Per Shift in-house/Weekly from

Per Shift in-house/Weekly from

1 TDS 10 ppm ±10 ppm TDS Meter Per Shift

130 Dragout ( DM water) Tank 50 L 2 DM Water Time Three Dip No No

3 pH 10~ 14 Ph meter/Ph Paper 2 times per day

1 TDS 10 ppm ±10 ppm TDS Meter Per Shift

140 DM water Tank 50 L 2 DM Water Time Three Dip No No

3 pH 7~ 9 Ph meter/Ph Paper 2 times per day

1 TDS 10 ppm ±10 ppm TDS Meter Per Shift

150 DM water Tank 50 L 2 DM Water Time Three Dip No No

3 pH 6.5~ 7.5 Ph meter/Ph Paper 2 times per day

1 Conc. 10~15 ml/ltr Lab Test Per Shift

ph 1.2~ 1.5 Ph meter/Ph Paper 2 times per day