FORMAT NO - NPD/R/03

PROCESS VALIDATION REPORT ISSUE NO : 01

ISSUE
DATE : 02.01.2019
REV NO. / Date: 00
CUSTOMER : Pricol Wiping system India Pvt Ltd PROCESS : Forging
PART NO : 38155-562-01 MACHINE NO : CH-02
PART NAME : Joint , Ball PROCESS PARAMETER : MACHINE SPEED DATE : 18-10-2019
PROCESS PROCESS PRODUCT PARAMETER
PARAMETER PARAMETER
Trail No sphere Sphere sphere
Sphere angle Sphere shaft
Sequence center Trail no Sequence angle center shaft length sphere height
Diameter Height length Diameter diameter
diameter

13.75 / 13.95 / 14.00 / 13.95 /

Specificaiton 13.93 / 13.940 7.35 / 7.85 7.35 / 7.85 13.75 / 14.25
14.25 14.10 13.96 14.10

1 20 RPM 13.94 14.14 7.55 13.965 2 25 RPM 14.022

13.96 13.99 7.65
13.94 14.14 7.48 13.968 14.017
13.96 13.98 7.73
13.94 14.13 7.57 13.982 14.01
13.94 13.99 7.68
13.94 14.15 7.59 13.955 14.028
13.95 14.01 7.59
13.96 14.15 7.56 13.975 14.015
13.94 13.987 7.775
13.96 14.14 7.57 13.972 14.025
13.96 13.985 7.65
13.96 14.14 7.59 13.975 14.026
13.94 13.975 7.63
13.96 14.14 7.59 13.958 14.009
13.95 14.000 7.55
13.96 14.14 7.54 13.968 14.024
13.96 13.985 7.72
13.96 14.14 7.53 13.979 14.014
13.95 14.000 7.64
MIN 13.94 14.13 7.48 13.955 MIN 13.94 13.975 7.55 14.009

MAX 13.96 14.15 7.59 13.982 MAX 13.96 14.01 7.775 14.028

RESULT PROCESS WITH IN SPECIFICATION RESULT PROCESS WITH IN SPECIFICATION

3 30 RPM 13.96 14.16 7.61 14.032 4 35 RPM 13.96 14.19 7.64 14.038

13.96 14.18 7.62 14.023 13.96 1419 7.61 14.029

13.94 14.17 7.6 14.035 13.95 14.22 7.6 14.041

13.95 14.15 7.61 14.024 13.95 14.18 7.63 14.02

13.95 14.16 7.63 14.029 13.95 14.2 7.61 14.034

13.97 14.16 7.64 14.008 13.95 14.2 7.6 14.032

13.95 14.14 7.61 14.029 13.95 14.18 7.62 14.012

13.96 14.16 7.6 14.014 13.96 14.13 7.63 14.019

13.95 14.16 7.64 14.034 13.95 14.19 7.62 14.016

13.95 14.15 7.61 14.02 13.95 14.19 7.61 14.028

MIN 13.94 14.14 7.6 14.008 MIN 13.95 14.13 7.6 14.012

MAX 13.97 14.18 7.64 14.035 MAX 13.96 1419 7.64 14.041

RESULT PROCESS WITH IN SPECIFICATION RESULT PROCESS WITH IN SPECIFICATION

5 40 RPM 13.95 14.19 7.59 14.019 6 45 RPM 13.95 14.21 7.66 14.02

13.95 14.19 7.59 14.021 13.94 14.22 7.57 14.025

13.95 14.19 7.58 14.02 13.94 14.21 7.62 14.024

13.94 14.19 7.56 14.041 13.95 14.21 7.6 14.049

13.94 14.2 7.58 14.036 13.95 14.21 7.64 14.048

13.95 14.19 7.56 14.03 13.95 14.22 7.62 14.028

13.94 14.18 7.59 14.024 13.94 14.22 7.61 14.027

13.95 14.15 7.73 14.029 13.94 14.22 7.54 14.034

13.95 14.18 7.58 14.024 13.94 14.21 7.6 14.034

13.94 14.19 7.57 14.015 13.94 14.22 7.58 14.033

MIN 13.94 14.15 7.56 14.015 MIN 13.94 14.21 7.54 14.02

MAX 13.95 14.2 7.73 14.041 MAX 13.95 14.22 7.66 14.049

RESULT PROCESS WITH IN SPECIFICATION RESULT PROCESS WITH IN SPECIFICATION

7 50 RPM 13.94 14.22 7.62 14.017 8 55 RPM 13.96 14.23 7.63 14.016

13.96 14.23 7.65 14.028 13.96 14.22 7.59 14.06

13.96 14.21 7.62 14.026 13.96 14.22 7.6 14.073

13.94 14.22 7.63 14.028 13.94 14.22 7.61 14.009

13.94 14.23 7.61 14.038 13.96 14.21 7.6 14.036

13.96 14.22 7.62 14.034 13.96 14.23 7.63 14.04

13.94 14.21 7.61 14.036 13.96 14.22 7.6 14.029

13.96 14.22 7.59 14.04 13.96 14.21 7.62 14.028

13.96 14.23 7.62 14.028 13.96 14.2 7.63 14.044

13.94 14.21 7.61 14.015 13.96 14.22 7.61 14.035

MIN 13.94 14.21 7.59 14.015 MIN 13.94 14.2 7.59 14.009

MAX 13.96 14.23 7.65 14.04 MAX 13.96 14.23 7.63 14.073

RESULT PROCESS WITH IN SPECIFICATION RESULT PROCESS WITH IN SPECIFICATION

RESULTS OF THE VALIDATION:

Validation Done By
1.conducted the process validation by varrying the machine production speed with 8 varriant (min to Max)

2.From the results compared the product and process parameters (critical dimension)

3. In each stage of speed is not affecting the product parameters and dimensions were with in specification
Approved By
4.Considering to avoid risk decided to run the machine in nominal speed (40 pcs/Min)
 FORMAT NO - NPD/R/03
PROCESS VALIDATION REPORT ISSUE NO : 01
ISSUE DATE :
02.01.2019
CUSTOMER : Pricol Wiping system India Pvt Ltd PROCESS : Forging DATE :02-01-2019 REV NO -
REV DATE - -
PART NO : 38155-562-01 MACHINE NO : CH-02
PART NAME : Joint , ball PROCESS PARAMETER : Feed Pressure

SEQUENCE NO WEIGHT OF LENGTH OF CUTTING SEQUENCE NO WEIGHT OF LENGTH OF CUTTING

CUTTING THE CUTTING DIAMETER CUTTING THE CUTTING DIAMETER

Feed roll Feed roll

Pressure 1 Bar 1 10.31 19.88 8.89 Pressure 2 BAR 2 10.35 19.78 8.87

10.33 19.86 8.891 10.36 20.00 8.889

10.34 19.61 8.891 10.36 20.00 8.871

10.19 19.94 8.894 10.36 19.85 8.885

10.34 19.95 8.876 10.28 19.80 8.866

10.33 19.76 8.896 10.34 19.89 8.881

10.28 19.73 8.901 10.36 19.86 8.885

10.6 19.4 8.88 10.34 19.88 8.891

10.11 19.79 8.88 10.36 19.84 8.863

10.31 19.84 8.865 10.35 19.82 8.89

MIN 10.11 19.4 8.865 MIN 10.28 19.78 8.863

MAX 10.6 19.95 8.901 MAX 10.36 19.89 8.891

RESULT 0.49 0.550 0.036 RESULTS 0.08 0.11 0.028

Feed roll Feed roll

Pressure 3 Bar 3 10.41 Pressure 4 Bar 4
19.92 8.88 10.43 19.99 8.89
10.37
19.86 8.89 10.42 20.03 8.884
10.39
19.93 8.867 10.46 20.01 8.869
10.29
19.9 8.866 10.45 20.05 8.893
10.4
19.86 8.888 10.41 20.06 8.862
10.4
19.97 8.882 10.46 20.06 8.892
10.38
19.92 8.885 10.43 20.05 8.885
10.34
19.99 8.863 10.46 20.02 8.876
10.35
19.83 8.894 10.47 20.04 8.894
10.37
19.94 8.882 10.42 20.01 8.864
10.29 19.83 8.866 10.41 19.99 8.866
MIN MIN
10.41 19.99 8.894 10.47 20.06 8.894
MAX MAX
RESULT 0.12 0.16 0.028 RESULTS 0.06 0.07 0.028

Feed roll Feed roll

Pressure 5 Bar 5 10.41 19.94 8.884 Pressure 6 Bar 6 10.37 19.93 8.869

10.42 19.92 8.863 10.39 19.95 8.881

10.41 19.99 8.879 10.4 19.95 8.893

10.43 20.01 8.883 10.4 19.93 8.88

10.44 20.01 8.886 10.38 19.94 8.876

10.4 20.02 8.87 10.39 20.01 8.882

10.42 20.00 8.89 10.41 20.02 8.885

10.43 20.01 8.893 10.44 20.01 8.892

10.44 19.99 8.874 10.38 19.94 8.885

10.41 19.91 8.889 10.42 19.96 8.87

MIN 10.4 19.91 8.866 MIN 10.37 19.93 8.866

MAX 10.44 20.02 8.893 MAX 10.44 20.02 8.893

RESULT 0.04 0.11 0.027 RESULTS 0.07 0.09 0.027

RESULTS OF THE VALIDATION:

Validation Done By
1.conducted the process validation by varrying the feed roll pressure with Constant 40 pcs/min speed (1 bar min to 6 bar Max)

2.From the results compared the product and process parameters (critical dimension of the raw material)

3. First 3 trail's results shows as variation between the required dimensions were very high (1 bar to 3 bar )
Approved By
3. Last 3 trail's results shows variation between the required dimensions were very low (4 bar to 6 bar )

4. From this validation 4 bar to 6 bar pressure considered as good result and will fix the process parameter for 38155-562-01
 FORMAT NO - NPD/R/03
PROCESS VALIDATION REPORT ISSUE NO : 01
ISSUE
DATE : 02.01.2019
CUSTOMER : Pricol Wiping system India Pvt Ltd PROCESS : Forging REV NO -
REV DATE - -
PART NO : PW 58755004 MACHINE NO : CH2
PART NAME : Ball Joint PROCESS PARAMETER : MACHINE SPEED DATE : 04-05-2019
PROCESS PROCESS PRODUCT PARAMETER
PARAMETER PARAMETER
Trail No sphere Sphere sphere
Sphere angle Sphere shaft
Sequence center Trail no Sequence angle center shaft length sphere height
Diameter Height length Diameter diameter
diameter

13.75 / 14.00 / 14.00 / 14.00 /

Specificaiton 14.00 / 13.96 7.35 / 7.85 7.35 / 7.85 13.75 / 14.25
14.25 14.30 13.96 14.30

1 20 RPM 14 14.14 7.55 14.046 2 25 RPM

13.99 14.15 7.57 14.022
14 14.14 7.48 14.026
13.99 14.16 7.58 14.017
14 14.13 7.57 14.036
13.97 14.15 7.62 14.013
14 14.15 7.59 14.026
13.98 14.215 7.59 14.035
13.99 14.15 7.56 14.044
13.97 14.14 7.6 14.015
13.99 14.14 7.57 14.034
13.99 14.15 7.65 14.03
13.99 14.14 7.59 14.034
13.97 14.15 7.6 14.026
13.99 14.14 7.59 14.031
13.98 14.14 7.59 14.009
13.99 14.14 7.54 14.025
13.99 14.14 7.6 14.024
13.99 14.14 7.53 14.045
13.98 14.14 7.6 14.014
MIN 13.99 14.13 7.48 14.025 MIN 13.97 14.14 7.57 14.009

MAX 14 14.15 7.59 14.046 MAX 13.99 14.215 7.65 14.035

RESULT PROCESS WITH IN SPECIFICATION RESULT PROCESS WITH IN SPECIFICATION

3 30 RPM 13.99 14.16 7.66 14.032 4 35 RPM 13.99 14.19 7.59 14.038

13.99 14.18 7.57 14.023 13.99 1419 7.59 14.029

13.97 14.17 7.62 14.035 13.98 14.22 7.58 14.041

13.98 14.15 7.6 14.024 13.98 14.18 7.56 14.02

13.98 14.16 7.64 14.029 13.98 14.2 7.58 14.034

14 14.16 7.62 14.008 13.98 14.2 7.56 14.32

13.98 14.14 7.61 14.029 13.98 14.18 7.59 14.012

13.99 14.16 7.54 14.014 13.96 14.13 7.73 14.019

13.98 14.16 7.6 14.034 13.98 14.19 7.58 14.016

13.98 14.15 7.58 14.02 13.98 14.19 7.57 14.028

MIN 13.97 14.14 7.54 14.008 MIN 13.96 14.13 7.56 14.012

MAX 14 14.18 7.66 14.035 MAX 13.99 1419 7.73 14.32

RESULT PROCESS WITH IN SPECIFICATION RESULT PROCESS WITH IN SPECIFICATION

5 40 RPM 13.98 14.19 7.62 14.019 6 45 RPM 13.98 14.21 7.61 14.02

13.98 14.19 7.65 14.021 13.97 14.22 7.62 14.025

13.98 14.19 7.62 14.02 13.97 14.21 7.6 14.024

13.97 14.19 7.63 14.041 13.98 14.21 7.61 14.049

13.97 14.2 7.61 14.036 13.98 14.21 7.63 14.048

13.98 14.19 7.62 14.03 13.98 14.22 7.64 14.028

13.97 14.18 7.61 14.024 13.97 14.22 7.61 14.027

13.98 14.15 7.59 14.029 13.97 14.22 7.6 14.034

13.98 14.18 7.62 14.024 13.97 14.21 7.64 14.034

13.97 14.19 7.61 14.015 13.97 14.22 7.61 14.033

MIN 13.97 14.15 7.59 14.015 MIN 13.97 14.21 7.6 14.02

MAX 13.98 14.2 7.65 14.041 MAX 13.98 14.22 7.64 14.049

RESULT PROCESS WITH IN SPECIFICATION RESULT PROCESS WITH IN SPECIFICATION

7 50 RPM 13.97 14.22 7.63 14.017 8 55 RPM 13.96 14.23 7.64 14.016

13.96 14.23 7.59 14.028 13.96 14.22 7.61 14.037

13.96 14.21 7.6 14.026 13.96 14.22 7.6 14.043

13.97 14.22 7.61 14.028 13.97 14.22 7.63 14.009

13.97 14.23 7.6 14.038 13.96 14.21 7.61 14.036

13.96 14.22 7.63 14.034 13.96 14.23 7.6 14.018

13.97 14.21 7.6 14.036 13.96 14.22 7.62 14.029

13.96 14.22 7.62 14.04 13.96 14.21 7.63 14.028

13.96 14.23 7.63 14.028 13.96 14.2 7.62 14.044

13.97 14.21 7.61 14.015 13.96 14.22 7.61 14.035

MIN 13.96 14.21 7.59 14.015 MIN 13.96 14.2 7.6 14.009

MAX 13.97 14.23 7.63 14.04 MAX 13.97 14.23 7.64 14.044

RESULT PROCESS WITH IN SPECIFICATION RESULT PROCESS WITH IN SPECIFICATION

RESULTS OF THE VALIDATION:

Validation Done By
1.conducted the process validation by varrying the machine production speed with 8 varriant (min to Max)
SHRIKANTH
2.From the results compared the product and process parameters (critical dimension)

3. In each stage of speed is not affecting the product parameters and dimensions were with in specification
Approved By
4.Considering to avoid risk decided to run the machine in nominal speed (40 pcs/Min)
GOKUL RAJ
 FORMAT NO - NPD/R/03
PROCESS VALIDATION REPORT ISSUE NO :
PRD/R/04 01
ISSUE
DATE : 02.01.2019
REV NO -
CUSTOMER : Pricol Wiping system India Pvt Ltd PROCESS : Forging REV DATE - -
PART NO : PW 58755004 MACHINE NO : CH2
PART NAME : Ball Joint PROCESS PARAMETER : Feed Pressure DATE : 04-05-2019

SEQUENCE NO WEIGHT OF LENGTH OF CUTTING SEQUENCE NO WEIGHT OF LENGTH OF CUTTING

CUTTING THE CUTTING DIAMETER CUTTING THE CUTTING DIAMETER

Feed roll Feed roll

Pressure 1 Bar 1 17.77 37.15 8.89 Pressure 2 BAR 2 17.8 37.24 8.85

SPEED 40 17.81 37.18 8.89 SPEED 40 17.78 37.16 8.91

17.71 37 8.9 16.4 34.32 8.9

17.75 37.07 8.9 17.83 37.25 8.9

17.78 37.14 8.9 17.77 37.19 8.9

17.83 37.26 8.9 17.86 37.29 8.9

17.79 37.28 8.92 17.76 37.15 8.9

17.71 36.98 8.9 17.78 37.16 8.92

16.32 34.11 8.95 17.18 37.23 8.9

17.84 37.29 8.92 17.82 37.26 8.9

MIN 16.32 34.11 8.89 MIN 16.4 34.32 8.85

MAX 17.84 37.29 8.95 MAX 17.86 37.29 8.92

RESULT 1.52 3.18 0.06 RESULTS 1.46 2.97 0.07

Feed roll Feed roll

Pressure 3 Bar 3 Pressure 4 Bar 4
17.84 37.45 8.9 17.83 37.24 8.94
SPEED 40 SPEED 40
16.41 34.37 8.9 17.79 37.26 8.9

15.49 32.46 8.92 17.82 37.26 8.92

17.78 37.16 8.9 17.8 37.21 8.92

17.82 37.27 8.92 17.81 37.23 8.95

17.77 37.14 8.92 17.8 37.16 8.92

17.87 37.47 8.92 17.85 37.27 8.95

17.79 37.21 8.92 17.82 37.27 8.9

17.83 37.3 8.92 17.8 37.24 8.95

17.81 37.22 8.92 17.82 37.28 8.95

MIN 15.49 32.46 8.9 MIN 17.79 37.16 8.9

MAX 17.87 37.47 8.92 MAX 17.85 37.28 8.95

RESULT 2.38 5.01 0.02 RESULTS 0.06 0.12 0.05

Feed roll Feed roll

Pressure 5 Bar 5 17.8 37.23 8.89 Pressure 6 Bar 6 17.85 37.29 8.89

SPEED 40 17.84 37.23 8.89 SPEED 40 17.82 37.27 8.89

17.86 37.24 8.89 17.77 37.24 8.89

17.79 37.23 8.89 17.84 37.3 8.89

17.85 37.26 8.89 17.88 37.34 8.89

17.89 37.28 8.89 17.82 37.28 8.89

17.78 37.24 8.89 17.78 37.25 8.89

17.8 37.26 8.89 17.83 37.26 8.89

17.83 37.23 8.89 17.77 37.3 8.89

17.86 37.29 8.89 17.88 37.28 8.89

MIN MIN
17.78 37.23 8.89 17.77 37.24 8.89
MAX MAX
17.89 37.29 8.89 17.88 37.34 8.89
RESULT 0.11 0.06 0 RESULTS 0.11 0.1 0

RESULTS OF THE VALIDATION:

Validation Done By
1.conducted the process validation by varrying the feed roll pressure with constant 40 pcs/min speed (1 bar min to 6 bar Max)

2.From the results compared the product and process parameters (critical dimension of the raw material)

3. First 3 trail's results shows as variation between the required dimensions were very high (1 bar to 3 bar )
Approved By
3. Last 3 trail's results shows variation between the required dimensions were very low (4 bar to 6 bar )

4. From this validation 4 bar to 6 bar pressure considered as good result and will fix the process parameter for PW 58755004