Control Plan: FG 260 As Per IS 210: 2009

Control Plan
Doc. No. : PDC-EPD-F02

Rev. No. : 01 (03/04/2015)
Issue No. : 04 (03/04/2015)
Prototype Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
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Pre-launch Works / Dept / Contact Details :9829246666 CEO Mr. Vibhor V. Jain CEO
Production Drawing No. : D10447340A Revision No. (Date) : 01(26/12/2015) Mr. Pradeep Garg MR/ DGM Opr.
Control Plan Number : D10447330A CP-CAS 01-09 Organization / Plant Approval Date : N/A Date (Originated) :26/12/2015 Mr. RS Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No : FT3035 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Samdar Singh Manager - Casting
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Grade : FG 260 As Per IS 210 : 2009

Characteristics Methods
Part / Machine, Device, Special
Process Name/
Process Jig, Tools for Char. Evaluation/ Sample Reaction Plan Record
Operation Description BLN Product/ Process/
Number Mfg. No. Product Process Class Measurement Control Method
No. Specification/ Tolerance
Technique Size Freq. & Responsibility
WI - Sand
1.01 Moisture 2.0% - 4.0% Moisture Tester Remix
Preparation
Permeability - Facing Permeability WI - Sand

1.02 Minimum 60 Remix
Sand Meter Preparation
One Batch/ 90
1 Sand Preparation Sand Mixer 1 mins- Lab
Technician
Permeability - Backing Permeability WI - Sand Sand Testing
1.03 Minimum 60 Remix
Sand Meter Preparation Report
LAB-CAS-F04
Minimum 0.40 kg/ WI - Sand

1.04 GCS GCS machine Remix
Cm2 Preparation
5 Boxes / Heat- 100 % Checking &

Moulding Mould Hardness - Mould Hardness
2 Mould Making Machine 2.01
Machine Moulding
70 - 95 tester
5 Foundry Shift WI - Moulding Break Mould if not
Supervisor OK
Each Batch- 100 % Checking

Core Hardness
3 Core Making Manual 3.01 Core Hardness Min. 40 tester
5 Foundry Shift WI - Core Making & Break Core if
Supervisor not OK
Bath Sample/
Chemical Refer Grade Chart 1 Heat Readjust
4.01 ▼ Spectro Analysis Lab Testing
Composition QC-CAS-F01 1 Final Sample/ Composition
Heat
Charging
Induction Furnace
Tapping Operator Report

Digital PRD-CAS-F01
4.02 Temperature ▼ 1350 ˚ C - 1450˚ C 1 Each Heat Monitoring & Lab Reheat
Pyrometer
Technician
4
Melting and
Pouring Operator
Pouring 1300 ˚ C -1400° C Digital 1 1st Ladel/Heat
4.03 ▼ Last Ladel/ Heat
Monitoring & Lab Reheat
Temperature Pyrometer 1
Engg.
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Control Plan
Rev. No. : 01 (03/04/2015)
Issue No. : 04 (03/04/2015)
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Induction Furnace
4 /
Melting and
Part Pouring
Process Name/
Machine, Device, Special
Review Gating
Digital Wall Foundry Shift System in case No need to
4.04 Pouring Time ▼ 15-25 mins Clock
2 2 / day
Supervisor of any adverse record
observations
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Control Plan
Rev. No. : 01 (03/04/2015)
Issue No. : 04 (03/04/2015)
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Process Name/
Refer Knock out Time

Knock Out Information Foundry Shift Segregate & Charging Report
5 Knock Out Shake Out 5.01 sheet 1 Each Heat
Time ( PRD-CAS-F03 ) Table Supervisor Check PRD-CAS-F01
Blow Holes, Cold Shut,

Shrinkage, Broken
Edges, Crushes, Pin
Blasting
6 Blasting Machine
6.01 No Visual Defects Holes, Sand/ Slag Visual 100% Each Lot Visual Inspection Rework / Reject
Inclusions, Poor Finish,
Gas Holes, Burrs, Casting Analysis
Porosity, Finns. Report
Visual Inspection
7 Grinding Bench Grinder 7.01 Gating & Parting Line No extra material Visual 100% Each Lot Blasting Shop Incharge Rework / Reject
Metallurgical Test the Cut

Microscope with Microstructure 1 Per Shift- Lab
8.01 Microstructure Test 1 Lab Testing Section Reject Micro Report
Image Analyzer Test Technician
Software heat if NOT OK
Brinell Hardness
Hardness Testing Refer Grade Chart Testing Machine 3000 As Per Internal Check & Hardness Report
8 Testing 8.02 Hardness Test 1 Lab Testing
M/C ( QC-CAS-F01 ) Kg Load Ǿ 10.00 mm Sample Plan Segregate LAB-CAS-F03
Ball
In Case Of Failure
check counter Check Physical Charging Report
UTM 8.03 Tensile Strength UTM 1 1 Per Shift
sample. If this also Properties PRD-CAS-F01
fails, reject the lot.
Each Batch-
Paint Spray Coating Thicker
9.01 DFT 150-250 microns 1 Blasting Shop Re Coat
Gun Tester
Incharge
WI Painting
9 Painting N/A
(PRD-CAS-WI10)
Each Batch-
9.03 Drying Time 6-8 Hours Watch 100% Blasting Shop Adjust Time
Incharge
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Control Plan
Rev. No. : 01 (03/04/2015)
Issue No. : 04 (03/04/2015)
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Process Name/
Remarks : Reviwed on 14/05/2016.
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Format No. : QC-CAS-F01
In-House Specification (Casting) - Grade Chart Issue No. : 04 (20/05/2015)

Rev. No. : 03 (20/05/2015)
Composition Chart
Type
Grade Standards Carbon % Silicon % Manganese % Sulphur % Magnesium % Others %
(C. I / S.G.)
D 4512 3.20 - 4.10 1.80 - 3.00 0.10 - 1.00 0.035 Max 0.025 - 0.060
SG SAE J434 Revised FEB2004
D 5506 3.20 - 4.10 1.80 - 3.00 0.10 - 1.00 0.035 Max 0.025 - 0.060
FC GMI 3.30 - 3.60 1.90 - 2.30 0.60 - 0.90 0.15 Max
FG 260 3.10 - 3.40 2.30 - 1.90 0.60 - 0.90 0.1 Max.

IS 210 : 2009
FG 300 3.10 - 3.30 2.20 - 1.80 0.60 - 0.90 0.1 Max.
CI G 2500 3.40 - 3.65 2.10 - 2.50 0.60 - 0.90 0.12 Max.

SAE J431 Rev DEC 2000
G 3000 3.30 - 3.60 1.90 - 2.30 0.60 - 0.90 0.12 Max.
GJL-250* EN1561:1997 3.10-3.40 2.30-1.90 060-0.90 0.10 Max.
Metallurgical Specifications
Type Tensile Strength Yield Strength % Elongation
Grade Standards Microstructure
(C. I / S.G.) (Min.) (Min.) (Min.)
D 4512 Ferrite-Pearilite (Type1) 450 310 - 285 12%
SG SAE J434 Revised FEB2004
D 5506 Pearlitic-Ferrite (Type 1) 550 380 - 350 6%
FC GMI Type VII A&B Pearlitic-Ferrite 220
FG 260 Pearlitic-Ferrite 260

IS 210 : 2009
FG300 Pearlitic 300
CI G 2500 Type VII A&B Pearlitic-Ferrite 153 (175)

SAE J431 Rev DEC 2000
G 3000 Type VII A Pearlitic 198 (225)
GJL-250 * EN1561:1997 Pearlitic 250-350
Note : * Grade Specification in Customer Drawing doesn't stipulate Chemical composition . Composition mentioned is
based upon proprietary experience , Mechanical properties requirement & Customer Drawing.
Format No. : QC-CAS-F01
In-House Specification (Casting) - Grade Issue No. : 04 (20/05/2015)
Chart Rev. No. : 03 (20/05/2015)
Description Product Parameters Specifications Process Parameters Specifications
Moisture 2.0% - 4.0% Silica Sand 100 kg
Permeability - Facing Sand Minimum 50

Sand Preparation Bentonite 4 kg
Permeability -Backing Sand Minimum 60
GCS Minimum 0.4kg/cm2 Water 2 lit.

Mould Making -
Pneumatic M/C
Mould Hardness Min.65 No. of Jolts 4 to 8 jolts
Mould Making -
Manual
Mould Hardness Min.50 No. of Squeezes / Rammings 5 to 20 jolts
Sand & Core Fill Ratio 125/2.5 kg

Core Making (Core
Fill)
Core Hardness Min.40
Visual Inspection No cracks
Coal Dust 100 kg

Core Making
(Silicate)
Core Hardness Min. 40 Sand & Sodium Silicate Ratio 6kg
Visual Inspection No cracks
Tapping Temperature (S.G.) SG -1600˚C -1700˚C
Pouring Temperature (S.G.) SG -1350˚C -1450˚C
Tapping Temperature (C.I. ) CI -1350˚C -1450°C

Refer In House Specififcation (Casting)- Grade Chart for Chemical
Melting and Pouring
Composition
Pouring Temperature (C.I.) CI -1300˚C -1400°C
Pouring Time (S.G.) Max.6 Minutes in SG

15-25 Minutes (Dependent on Availability of
Pouring Time (C.I)
Manpower)
Weight Range
0-15 16-30 31-55 56-150
( Kgs )
Knock out Knock out time (Ref.Knock out Time sheet) Knock out Time
Time Period
30-45 45-60 60-75 75-120
( Minutes )
Control Plan Rev. No. : 01 (03/04/2015)

Issue No. : 04 (03/04/2015)
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Production Drawing No. : D10447340A-MCD-01-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-10 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. R.S. Shekhawat Engg. Drawing mail@garimacastings.com
Part Number / Model No:FT30 35 DC Other Approval / Date (if Reqd.) : N/A Customer Engineering Approval /Date (if Reqd.) : N/A Mr. Himanshu Duniwal PC
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer -CMM
Special Char. Class

Process Name/
Process Machine, Device,
Operation Product/ Process - Sample Reaction Plan Record
Numbe Jig, Tools for Mfg. BLN Evaluation/ Measurement
Description No. Product Process Specification/ Control Method
r No. Technique
Tolerance Size Freq. & Responsibility
1.Set up Approval
1.Set up Approval
1st PC Setup QC Incharge (QC-MCN-F01)
(QC-MCN-F01)
Chuck 2/Shift Operator 2.Operator log book
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER
10.01 ▼ 22 ± 2.0 kg/cm2 Dial Indicator 1 2.100% Operator Monitoring Readjust the Pressure
Pressure 2/Shift Inspector
3.In Process Inspection
(QC-MCN-F10)
1 3.In Process Inspection
report (QC-MCN-F02)
report (QC-MCN-F02)
1.Set up Approval(QC-MCN- 1.Set up Approval(QC-MCN-

1st PC Set up QC Incharge F01) Check Tooling & F01)
10.02 Depth 20 15.5 / 15.9 mm Depth Vernier
1 50th PC Inspector 2.In Process Inspection Report ascertain root Cause 2.In Process Inspection Report
(QC-MCN-F02) (QC-MCN-F02)
1.Set up Approval(QC-MCN-
Surface Check Tooling & Set up Approval(QC-MCN-
10.03 Surface Finish 22 ▼ 1.6μRa 1st PC Set up QC Incharge F01)
TURNING IST SETUP
Comparator 2.Program Controlled

ascertain root Cause F01)
CHUCK
Surface Set up Approval(QC-MCN- Check Tooling & Set up Approval(QC-MCN-

10.04 Surface Finish 23 3.2μRa 1st PC Set up QC Incharge
10 Comparator F01) ascertain root Cause F01)
Tool Profile Check Tooling & Set up Approval(QC-MCN-
10.05 Radius 24 R0.5 mm MAX. 1st PC Set up QC Incharge F01)
/ Visual 2.Program Controlled
10.06 Angle 25 120 ̊ Pattern Controlled
10.07 Radius 29 R5.0 mm As Cast Pattern Controlled
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Special Char. Class

Process Name/
r No. Technique
10.09 Depth 31 33.0 / 37.0 mm As Cast Pattern Controlled

CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER
Set up Approval(QC-MCN- Check Tooling & Set up Approval(QC-MCN-

10.10 Depth 32 8.8 / 11.2 mm Depth Vernier 1st PC Set up QC Incharge
F01) ascertain root Cause F01)
1.Set up Approval(QC-MCN- Check & Segregate

Set Up / Set up Approval(QC-MCN-
10.11 Perpendicularity ▼ 0.05 w.r.t.'A' CMM 1st PC 1/ Shift
F01) / CMM Report Check Tooling &
F01) / CMM Report
2.Process Controlled Ascertain root cause
TURNING IST SETUP
33
1st PC Set up QC Incharge F01) / CMM Report Check Tooling & F01) / CMM Report
10.12 Depth ▼ 8.85 / 9.15 mm Depth Vernier
1 20th PC Inspector 2.In Process Inspection ascertain root Cause 2.In Process Inspection
CHUCK
Report (QC-MCN-F02) Report (QC-MCN-F02)
10
10.13 Angle 35 45 ̊ Pattern Controlled
Check Tooling & Set up Approval(QC-MCN-
10.14 Chamfer 36 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge F01)
2. Program Controlled

Comparator F01) ascertain root Cause F01)
Surface Check Tooling & Set up Approval(QC-MCN-
10.16 Surface Finish 44 1.6μRa 1st PC Set up QC Incharge F01)
Comparator 2.Program Controlled
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Special Char. Class

Process Name/
r No. Technique
CNC TURNING CENTER WITH 3 JAW HYDRAULIC POWER CHUCK
F01)
Bore gauge with 1st PC F01)
Set up QC Incharge Check & Segregate 2. Operator Log Book (QC-
Ø 39.965 / 2.100% Operator Monitoring
10.17 Inner Diameter 45 ▼ Dial LC 0.001 100% Operator
Check tooling & MCN-F10)
39.990 mm 10th PC Inspector ascertain root cause 3.In Process Inspection
With MSR 32-1 1 Report (QC-MCN-F02)
Report (QC-MCN-F02)
4.SPC Analysis
4.SPC Chart
F01)
Bore gauge with 1st PC F01)
Set up QC Incharge Check & Segregate 2. Operator Log Book (QC-
Ø 100.000 / 2.100% Operator Monitoring
10.18 Inner Diameter 46 ▼ Dial LC 0.001 100% Operator
Check tooling & MCN-F10)
100.054 mm 10th PC Inspector ascertain root cause 3.In Process Inspection
With MSR 31-1 1 Report (QC-MCN-F02)
Report (QC-MCN-F02)
4.SPC Analysis
4.SPC Chart
Ø 128.0 /132.0 Set up Approval(QC-MCN- Check Tooling & Set up Approval(QC-MCN-

10.19 Outer Diameter 47 Vernier Caliper 1st PC Set up QC Incharge
mm F01) ascertain root Cause F01)
TURNING IST SETUP
Ø 217.5 / 222.5
10.20 Outer Diameter 48 As Cast Pattern Controlled
mm
10
Check & Segregate
Ø 277.5 / 282.5 Set up Approval(QC-MCN- Set up Approval(QC-MCN-
10.21 Inner Diameter 49 Vernier Caliper 1st PC Set up QC Incharge
F01)
Check Tooling &
F01)
mm Ascertain root cause
1st PC F01)
Set up QC Incharge F01) Check & Segregate
Ø 313.5 / 313.6 SG - 27 - 1&2 with 2. Operator Log Book (QC-
10.22 Outer Diameter 50 100% Operator 2.100% Operator Monitoring Check tooling &
mm MSP-25 20th PC Inspector 3.In Process Inspection Report ascertain root cause
MCN-F10)
1 3.In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
Check & Segregate

Ø 327.5 / 332.5 Set up Approval(QC-MCN- Set up Approval(QC-MCN-
10.23 Outer Diameter 51 Vernier Caliper 1st PC Set up QC Incharge Check Tooling &
mm F01)
Ascertain root cause
F01)

Comparator F01) ascertain root Cause F01)
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Special Char. Class

Process Name/
r No. Technique

Set Up / Set up Approval(QC-MCN-
10.25 Cylindricity 57 ▼ 0.05 CMM 1st PC 1/ Shift
F01) / CMM Report
2.Process Controlled Ascertain root cause
CNC TURNING CENTER WITH 3 JAW
HYDRAULIC POWER CHUCK

1st PC Set up QC Incharge F01) / CMM Report Check Tooling & F01) / CMM Report
10.26 Concentricity 58A ▼ 0.05 w.r.t.'A' CMM / SPG-76
TURNING IST SETUP
1 20th PC Inspector 2.In Process Inspection ascertain root Cause 2.In Process Inspection
Report (QC-MCN-F02) Report (QC-MCN-F02)
10.27 Chamfer Angle 60 15 ̊ Bevel Protector 1st PC Set up QC Incharge F01)
10 2.Program Controlled
10.28 Chamfer Depth 61 1.4 / 1.6 mm Height Gauge 1st PC Set up QC Incharge F01)
2.Program Controlled
Set up Set up Approval(QC-MCN- Check Tooling & Set up Approval(QC-MCN-

10.29 Runout 65 ▼ 0.10 w.r.t.'A" CMM 1st PC 1 / Shift F01) / CMM Report ascertain root Cause F01) / CMM Report
Sr. No. Tool Name Tool / Insert Specifications Tool No. Ref. Ballooned No. Operation Program No.
1 E/DWLNL 25M08 WNMG080416GH UC5115 1 N/A Rough Turning

Tool Control
2 A 25EWLNL M08 WNMG080416GH UC5115 2 N/A Rough Boring
3 E/DWLNL 25M08 WNMG G080408 GHUC5115 3 N/A Finish Turning
4 A32/A25 EWNL M08 WNMG G080408 GHUC5115 4 N/A Finish Boring
Remarks: The ballooned dimension 45 , 46 & 50 to be checked by the operator 100% and has to be recorded in the log book.
Reviwed on 14/05/2016.
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Special Char. Class

Process Name/
r No. Technique
1.Set up Approval
1.Set up Approval
(QC-MCN-F01)
(QC-MCN-F01)
Chuck 2.Operator log book
11.01 ▼ 22 ± 2.0 kg/cm2 Dial Indicator 1 2/Shift 2.100% Operator Monitoring Readjust the Pressure
Pressure 3.In Process Inspection
(QC-MCN-F10)
report (QC-MCN-F02)
report (QC-MCN-F02)

1st PC Set Up QC Incharge F01) Check Tooling & F01)
11.02 Width 17 99.7 / 100.3 mm Depth Vernier
1 50th PC Inspector 2.In Process Inspection Report ascertain root cause 2.In Process Inspection Report

11.03 Depth 18 94.2 / 94.8 mm Depth Vernier
TURNING IIND SETUP

11.04 Depth 19 54.0 / 58.0 mm Depth Vernier 1st PC Set Up QC Incharge
F01) ascertain root cause F01)

11 11.05 Depth 26 5.4 / 5.6 mm Depth Vernier
ascertain root cause F01)

Set up Set up Approval(QC-MCN-
11.07 Concentricity 28 ▼ Ø 0.1 w.r.t.'A' CMM 1st PC 1 / Shift
F01) / CMM Report
2.Process Controlled ascertain root cause
Set up 1.Set up Approval(QC-MCN- Check & Segregate 1. Set up Approval(QC-

CMM / Height Gauge 1st PC
11.09 Flatness 37 ▼ 0.1 mm 1 / Shift F01) / CMM Report Check Tooling & MCN-F01) / CMM Report
with Dial LC 0.010 100% Inspector 2.Process Controlled ascertain root cause 2. On Part
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Special Char. Class

Process Name/
r No. Technique

11.10 Depth 38 4.9 / 5.1 Depth Vernier 1st PC Set Up QC Incharge

Ø 164.5 / 165.5 1st PC Set Up QC Incharge F01) Check Tooling & F01)
11.12 Inner Diameter 41 Vernier Caliper
mm 1 35th PC Inspector 2.In Process Inspection Report ascertain root cause 2.In Process Inspection Report
TURNING IInd SETUP
F01)
1st PC F01)
Set up QC Incharge 2.Operator Log Book (QC-
Ø 328.10 / MSP - 21 with SG- 2.100% Operator Monitoring Check Tooling &
11.13 Inner Diameter 42 ▼ 100% Operator MCN-F10)
328.20 mm 35-1&2 20th PC Inspector
3.In Process Inspection ascertain root cause
1 Report (QC-MCN-F02)
Report (QC-MCN-F02)
4.SPC Analysis
4.SPC Chart
11 11.14 Outer Diameter 43

Ø 365.5 / 366.5
Vernier Caliper
1st PC Set Up QC Incharge
F01) Check Tooling &
F01)
mm 1 35th PC Inspector 2.In Process Inspection Report ascertain root cause 2.In Process Inspection Report
Ø 159.5 / 160.5 Check Tooling & Set up Approval(QC-MCN-
11.15 Inner Diameter 53A Inside Caliper 1st PC Set up QC Incharge F01)
mm 2.Program Controlled
Surface Finish Set up Approval(QC-MCN- Check Tooling & Set up Approval(QC-MCN-

Comparator F01) ascertain root cause F01)
11.17 Angle 55 12 ̊ As Cast Pattern Controlled

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Special Char. Class

Process Name/
r No. Technique
JAW HYDRAULIC POWER CHUCK
CNC TURNING CENTER WITH 3

TURNING IInd SETUP
Surface Finish Set up Approval(QC-MCN- Check Tooling & Set up Approval(QC-MCN-

Tester F01) ascertain root cause F01)

11.21 Surface Finish 64 6.3μRa Visual 1st PC Set up QC Incharge

11.22 Chamfer 68 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge
D10342920
11.23 Punch 69 Visual N/A On Part
FG-260
Tool Control
1 EWLNL 2525M08 WNMG 08041G6H UC5115 1 N/A OD Turning
2 A40TEWLNLM08 WNMG 080416GH UC5115 2 N/A Bore Rough
3 A40TEWLNLM08 WNMG 080408GH UC5115 3 N/A Bore Finish
Remarks: The ballooned dimension 42 to be checked by the operator 100% and has to be recorded in the log book.
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Control Plan Rev. No.

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Special Char. Class

Process Name/
r No. Technique
Receiver Gauge- 1st PC Set up QC Incharge F01) Check & Segregate
F01)
12.01 Angle 1 90 ̊ ± 15 ' 100% Operator 2.100% Operator Monitoring Check tooling &
05 1 35th PC Inspector 3.In-Process Inspection Report ascertain root cause
2.In-Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
Set up Check tooling & Set up Approval(QC-MCN-F01)
12.02 Angle 2 35 ̊± 0 ̊30 ' CMM 1st PC 1 / Shift
F01) / CMM Report
ascertain root cause / CMM Report
Crank , Timing , Clutch & Side Drilling
1. Set up Approval(QC-MCN-
1st PC 1.Set up Approval(QC-MCN-
Set up QC Incharge F01)/CMM Report
Angle CMM / Receiving Check tooling & F01)/CMM Report
12.03 3 30 ̊± 0 ̊30 ' 100% Operator 2. 100% Operator Monitoring
(12 Holes) Gauge-05 1 35th PC Inspector 3. In Process Inspection Report
ascertain root cause 2.In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
VMC MACHINE
12.04 Center Distance 3A 67.2 mm CMM 1st PC 1 / Shift
F01) / CMM Report
12
12.05 Center Distance 3B 84.9 mm CMM 1st PC 1 / Shift
F01) / CMM Report
R147.8 / 148.2 1.Set up Approval(QC-MCN-

Set up Check tooling & Set up Approval(QC-MCN-
12.06 Radius 4 ▼ mm
CMM 1st PC 1 / Shift
F01) / CMM Report
ascertain root cause F01) / CMM Report
CMM / Receiving 1st PC Set up QC Incharge F01)/CMM Report
Check tooling & F01)/CMM Report
12.07 Angle 5 55 ̊ ± 0̊ 20' 100% Operator 2. 100% Operator Monitoring
Gauge - 12 1 35th PC Inspector 3. In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
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Crank , Timing , Clutch
VMC MAC
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Special Char. Class

Process Name/
r No. Technique
R135.3 / 135.5 1.Set up Approval(QC-MCN-

Set up / Check tooling & Set up Approval(QC-MCN-
12.08 Radius 5A ▼ CMM 1st PC F01) / CMM Report
mm 1 / Shift
CMM / Receiving Check tooling & F01)/CMM Report
(QC-MCN-F02)
(QC-MCN-F02)
Set up / Check tooling & Set up Approval(QC-MCN-F01)
12.10 Center Distance 7 88.9 mm CMM 1st PC
1 / Shift
F01) / CMM Report
Set up / Check tooling & Set up Approval(QC-MCN-F01)
12.11 Center Distance 8 88.9 mm CMM 1st PC
1 / Shift
F01) / CMM Report
VMC Machine

CMM / Receiving Check tooling & F01)/CMM Report
(QC-MCN-F02)
(QC-MCN-F02)
12
CMM / Receiving Set up QC Incharge F01)/CMM Report
12.13 Angle 10 60 ̊ ± 0̊ 20'
Gauge - 12
100% Operator 2. 100% Operator Monitoring
1 35th PC Inspector 3. In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
F01)
1st PC Set up QC Incharge Check tooling & F01)
12.14 2 Holes 11 Ø 6.8 / 7.2 mm Vernier Caliper 1 35th PC Inspector
Report(QC-MCN-F02)
(QC-MCN-F02)
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VMC Machine
Crank , Timing , Clutch &
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Special Char. Class

Process Name/
r No. Technique
CMM / 1st PC 1.Set up Approval(QC-MCN-
12.15 Center Distance 12 ▼ 35.7 / 36.3 mm Receiving Gauge 100% Operator 2. 100% Operator Monitoring
- 12 1 35th PC Inspector 3. In Process Inspection
(QC-MCN-F02)
Report (QC-MCN-F02)
CMM / Receiving 1st PC Set up QC Incharge F01)/CMM Report
(QC-MCN-F02)
(QC-MCN-F02)
12.17 Angle 14 35 ̊± 0 ̊30 ' CMM 1st PC 1 / Shift
F01) / CMM Report
12.18 Center Distance 14A 121.2 mm CMM 1st PC 1 / Shift
F01) / CMM Report
VMC MACHINE
12.19 Center Distance 14B 131.9 mm CMM 1st PC 1 / Shift
F01) / CMM Report
12 1. Set up Approval(QC-MCN-
1st PC Set up QC Incharge F01)
12 Holes Check tooling & F01)
12.20 M8 X 1.25 TPG - 09 100% Operator 2. 100% Operator Monitoring
Equlispaced 1 35th PC Inspector 3. In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
15 CMM / 1st PC Set up QC Incharge F01)/CMM Report
12.21 PCD ▼ Ø 312.0 mm Receiving 100% Operator 2. 100% Operator Monitoring
Gauge-05 1 35th PC Inspector 3. In Process Inspection
(QC-MCN-F02)
Report (QC-MCN-F02)
16 of 24
Crank , Timing , Clutch & Side
VMC MACHINE

Issue No.
: 01 (03/04/2015)
: 04 (03/04/2015)
12
L
15
Special Char. Class

Process Name/
r No. Technique
Set up Check tooling & Set up Approval(QC-MCN-
12.22 True Position ▼ Ø 0.2 CMM 1st PC 1 / Shift
F01) / CMM Report
2.Process Controlled
8°
Timing to be 10.0 mm high
12.23 15A 0.3 mm deep Visual 100% N/A On part
Punched & Green color
mark
12.24 Timing Mark Angle 15C 8 ̊ Visual 100% N/A On Part
Ø 12.8 / 13.2 Check tooling & F01)/CMM Report
12.25 6 Holes
mm
CMM / SPG - 69 100% Operator 2. 100% Operator Monitoring
(QC-MCN-F02)
(QC-MCN-F02)
16 1st PC Set up QC Incharge F01)/CMM Report
Ø 71.8 / 72.2 CMM / Receiving Check tooling & F01)/CMM Report
12.26 PCD
mm Gauge - 12
100% Operator 2. 100% Operator Monitoring
VMC MACHINE
(QC-MCN-F02)
(QC-MCN-F02)
12 12.27 True Position ▼ Ø 0.4 w.r.t.'A" CMM 1st PC
Set up
1 / Shift
F01) / CMM Report
Check tooling &
ascertain root cause
Set up Approval(QC-MCN-
F01) / CMM Report
Ø 5.80 / 6.20 Set up QC Incharge F01)/CMM Report
12.28 2 Holes CMM / SPG-66 100% Operator 2. 100% Operator Monitoring
mm 1 35th PC Inspector 3. In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
21
17 of 24
Crank , Timing , Clutch & Side Drilli
VMC MACHINE
Issue No. : 04 (03/04/2015)
L
12
Special Char. Class

Process Name/
r No. Technique
21 1. Set up Approval(QC-MCN- 1.Set up Approval(QC-MCN-

14.80 / 15.20 1st PC Set up QC Incharge F01)/CMM Report Check tooling & F01)/CMM Report
12.29 Drill Depth Vernier Caliper 1
mm 35th Pc Inspector 2.In Process Inspection Report ascertain root cause 2.In Process Inspection Report
Check tooling &
12.30 Chamfer 1.0 X 45 ̊ Visual 1st PC Set up QC Incharge F01)
Set up Approval(QC-MCN-F01)
Check tooling &
12.31 Drill Depth 62 40.0 mm Vernier Caliper 1st PC Set up QC Incharge F01)
F01)
Std Bolt with 1st PC Set up QC Incharge Check tooling & F01)
12.32
Tap Depth 63 35.0 mm 2. Program Controlled

Vernier Caliper 1 35th PC Inspector
3. In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
VMC MACHINE
Ø 0.013 Set up Check tooling & Set up Approval(QC-MCN-
12.33 True Position 70 ▼ CMM 1st PC F01) / CMM Report
w.r.t.'A" 1 / Shift
12
Ø 13.032 / Check tooling & F01)/CMM Report
12.34 Dowel Diameter 71 ▼ CMM / SPG - 70 100% Operator 2. 100% Operator Monitoring
13.059 mm 1 10th PC Inspector 3. In Process Inspection
(QC-MCN-F02)
Report (QC-MCN-F02)
18 of 24

Issue No.
: 01 (03/04/2015)
: 04 (03/04/2015)
L
VMC MACHINE
12
Special Char. Class

Process Name/
r No. Technique
Surface F01) Check tooling & Set up Approval(QC-MCN-
12.35 Surface Finish 72 ▼ 1.6 μRa 1st PC Set up QC Incharge
Comparator 2. Program & Process ascertain root cause F01)
Controlled
Check tooling &
19 of 24

Issue No.
: 01 (03/04/2015)
: 04 (03/04/2015)
L
Special Char. Class

Process Name/
r No. Technique
1 Solid Carbide Drill Ø 13.2 mm 1 N/A
3 SCLHM Ø 13.01 mm 3 N/A
4 Solid Carbide Lunge Reamer Ø 13.04 mm 4 N/A Crank Drilling & Timing
Tool Control
5 High Speed Steel Drill Ø 16.00 mm 5 N/A
7 Timing Hole Ø 8.00 mm 7 N/A
10 Solid Carbide Drill Ø 8.5 mm 10 N/A Clutch Drilling & Tapping
11 High Speed Steel machine tap M8 X 1.25 11 N/A

Remarks: Reviwed on 14/05/2016.
20 of 24

Issue No.
: 01 (03/04/2015)
: 04 (03/04/2015)
L
Special Char. Class

Process Name/
r No. Technique
Set up QC Incharge F01)
12 Holes Check tooling & F01)
13.01 M8 X 1.25 TPG - 09 100% Operator 2. 100% Operator Monitoring
Equlispaced 1 35th PC Inspector 3. In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
DRILL MACHINE
15
TAPPING
Set up QC Incharge F01)
13 13.02 True Position ▼ Ø 0.2 CMM / RG 05 100% Operator
35th PC Inspector
2. 100% Operator Monitoring
3. In Process Inspection
Check tooling &
F01)
2.In Process Inspection Report
1 (QC-MCN-F02)
Report (QC-MCN-F02)
Std Bolt with F01)
1st PC Set up QC Incharge Check tooling & F01)
13.03 Tap Depth 63 Min. 35.0 mm 1
Vernier Caliper 35th PC Inspector
3. In Process Inspection Report
(QC-MCN-F02)
(QC-MCN-F02)
Control
Tool
11 High Speed Steel machine tap M8 X 1.25 1 15 Tapping

Remarks: Reviwed on 14/05/2016.
21 of 24

Issue No. : 04 (03/04/2015)
L
Production * Drawing No. : D10447330A Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Special Char. Class

Part / Process Name/ Machine,
Process Operation Device, Jig, Sample Reaction Plan Record
Number Description Tools for Mfg. Product/ Process/ Evaluation/ Measurement
No. Product BLN No. Process Control Method
Specification/ Tolerance Technique
Size Freq. & Responsibility
1.Set up Approval
Chamfered Side of Ring 2.Work Instructions (PRD- Set up Approval-Ring
1st PC Setup QC-Engg Check &
14.01 Gear Teeth (not To be on Top Side Visual MCN-WI11) Fittment
100% Operator Segregate
Induction Heater & Hydraulic Press
Ballooned) 3.100% Operator (QC-MCN-F17)

Monitoring
Ring Gear Heating & Fittment
Ring Gear Set up Approval-Ring

Temperature 1st PC Setup QC-Engg 1.Set up Approval Readjust the
14.02 Heating ▼ 150 °C - 170 ° C
100%
2.100% Operator Fittment
Temp. Indicator Operator Monitoring temperature
(QC-MCN-F17)
Re-Press & Set up Approval-Ring

Ring Pressing Pressure Dial 1st PC Setup QC-Engg 1.Set up Approval
13 14.03 Load
▼ 100Kgf/cm2
Indicator 100% Operator
2.100% Operator Re-adjust the Fittment
Monitoring Pressure (QC-MCN-F17)
Ring Pressing Set up Approval-Ring

Digital Wall 1st PC Setup QC-Engg 1.Set up Approval
14.04. Holding ▼ Min. 10 Sec. 2.100% Operator Re-press Fittment
Dwell Time Clock 100% Operator Monitoring (QC-MCN-F17)
Gap Between Set up Approval-Ring

Filler Gauge of 1st PC Setup QC-Engg 1.Set up Approval Check &
14.05 Shoulder & Face of ▼ 0.250 mm Max 2.100% Operator Fittment
Gear 0.100 mm 100% Operator Monitoring Segregate
(QC-MCN-F17)
Tool Control
Remarks : Reviwed on 14/05/2016.
22 of 24

Issue No. : 04 (03/04/2015)
L
Production * Drawing No. : D10447340A-MCD-04-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-15 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. RS Shekhawat Engg. Drawing mail@garimacastings.com
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Dharam Singh Engineer - CMM
Special Char. Class

Part /
Process Name/
Machine, Device,
Process Operation Sample Reaction Plan Record
Jig, Tools for Mfg. Product/ Process/ Evaluation/ Measurement
Numbe Description No. Product BLN No. Process Control Method
r Specification/ Tolerance Technique
Size Freq. & Responsibility
Ø 12.00 mm Tool Controlled Check tooling &

Set Up- DB Set Up Approval- DB
15.01 Drill Diameter Vernier Caliper 1 Supervisior
& WI ascertain root
(QC-MCN-F07)
MAX. (PRD-MCN-WI06) cause
Dynamic Balancing Machine
Measure &
Dyanamic Balancing
Set Up- DB Stopper Controlled & WI Set Up Approval- DB

15.02 Drill Depth 66 15.00 mm Max. Vernier Caliper 1 Supervisior (PRD-MCN-WI06)
Readjust the size
(QC-MCN-F07)
of stopper
14 Set Up- DB WI
Seek Clarification
Set Up Approval- DB
15.03 Center Distance 30.0 mm Vernier Caliper 1 Supervisior (PRD-MCN-WI06)
from Next higher
(QC-MCN-F07)
authority
2 {Ref. Drg No.
D10447330A}
1.Setting Approval cum In 1.Setting Approval cum In

Dynamic Set Up- DB Process Inspection Report Process Inspection Report
1 Supervisor (QC-MCN-F07) (QC-MCN-F07)
15.04 Balancing Value 20 g-cm Balancing 100%1 Operator 2.Operator log book(QC-
Check & Segregate
2. Operator Log Book(QC-
Machine 20th PC Inspector MCN-F11) MCN-F11)
3.Program Controlled 3. On Part
1 Drill Ø 12.0 mm 1 N/A Side Drilling

Tool Control
Remarks: The ballooned dimension 2 to be checked by the operator 100% and has to be recorded in the log book.
23 of 24

Issue No. : 04 (03/04/2015)
Prototype * Key Contact Person : Mr. Vibhor V. Jain Core Team Member Dept. Contact Details
L
Production * Drawing No. : D10447340A-MCD-01-04 Revision No. (Date): 01(11/05/2016) Mr. Pradeep Garg MR/GM-Operations
Control Plan Number:D10447330A CP-16,17 & 18 Organization / Plant Approval Date : N/A Date (Originated) : 26/12/2015 Mr. RS Shekhawat Engg. Drawing mail@garimacastings.com
Part Name / Description : Flywheel Assembly Organization / Supplier Code : 13434 Customer Quality Approval / Date (if Reqd.) : N/A Mr. Babulal Jangid Supervisor-Packing
Machine,
Part / Special
Process Name/ Operation Device, Jig,
Process Char. Sample Reaction Plan Record
Description Tools for BLN Product/ Process/ Evaluation/ Measurement
Number No. Product Process Class Control Method
Mfg. No. Specification/ Tolerance Technique
Size Freq.
100 % Sorting for

PDI Report
15 Pre-dispatch Inspection 16.01 AS PER PDI Report AS PER PDI Report AS PER PDI Report AS PER PDI Report In - Process Control Deviated
(QC-PDS-F01)
Parameters
Surface of the part

17.01 Cleaning of parts should be dry and free Visual 100% Each Batch Re-cleaning
from the Rust & Chips
-
Light Film of oil to be Surface shall only
17.02 applied with a soaked coated with RPO but Visual 100% Each Batch Re-Oiling
cloth no Excess Oil
Oiling Area & Packaging Area
17.03 Part Identification No Mixing Visual 100% Each Batch 100 % Sorting -
PKG-PDS-WI01,
PKG-PDS-WI02, Drg
As per Packaging No. D10447330A
16 Oiling & Packaging 17.04 Box Type Visual 100% Each Batch -
Specification Sheet PKG-01-01
& Monitoring by
Supervisor
As per Packaging Daily Packing

17.05 Quantity Per Box Visual 100% Each Batch
Specification Sheet Report
Repacking
As per Packaging
17.06 Labelling Visual 100% Each Batch -
Specification Sheet
Other Packaging As per Packaging

17.07 Visual 100% Each Batch -
Material Specification Sheet
Customer Name, Quantity, As per Dispatch DES-PDS-WI01 and Dispatch

17 Dispatch 18.01 Visual Examination 100% Each Dispatch Re-Checking
Date….. Schedule TAG & Label on Box Documents
Remarks:Reviwed on 14/05/2016.
24 of 24

Control Plan: FG 260 As Per IS 210: 2009

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Control Plan: FG 260 As Per IS 210: 2009

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Control Plan

Doc. No. : PDC-EPD-F02

Grade : FG 260 As Per IS 210 : 2009

Permeability - Facing Permeability WI - Sand

Minimum 0.40 kg/ WI - Sand

5 Boxes / Heat- 100 % Checking &

Each Batch- 100 % Checking

Tapping Operator Report

Grade : FG 260 As Per IS 210 : 2009

Refer Knock out Time

Blow Holes, Cold Shut,

Metallurgical Test the Cut

Grade : FG 260 As Per IS 210 : 2009

Remarks : Reviwed on 14/05/2016.

In-House Specification (Casting) - Grade Chart Issue No. : 04 (20/05/2015)

FC GMI 3.30 - 3.60 1.90 - 2.30 0.60 - 0.90 0.15 Max

FG 260 3.10 - 3.40 2.30 - 1.90 0.60 - 0.90 0.1 Max.

CI G 2500 3.40 - 3.65 2.10 - 2.50 0.60 - 0.90 0.12 Max.

GJL-250* EN1561:1997 3.10-3.40 2.30-1.90 060-0.90 0.10 Max.

FC GMI Type VII A&B Pearlitic-Ferrite 220

FG 260 Pearlitic-Ferrite 260

CI G 2500 Type VII A&B Pearlitic-Ferrite 153 (175)

GJL-250 * EN1561:1997 Pearlitic 250-350

Moisture 2.0% - 4.0% Silica Sand 100 kg

Permeability - Facing Sand Minimum 50

GCS Minimum 0.4kg/cm2 Water 2 lit.

Sand & Core Fill Ratio 125/2.5 kg

Coal Dust 100 kg

Visual Inspection No cracks

Tapping Temperature (S.G.) SG -1600˚C -1700˚C

Pouring Temperature (S.G.) SG -1350˚C -1450˚C

Tapping Temperature (C.I. ) CI -1350˚C -1450°C

Pouring Time (S.G.) Max.6 Minutes in SG

Control Plan Rev. No. : 01 (03/04/2015)

Special Char. Class

1.Set up Approval(QC-MCN- 1.Set up Approval(QC-MCN-

Comparator 2.Program Controlled

Surface Set up Approval(QC-MCN- Check Tooling & Set up Approval(QC-MCN-

10.06 Angle 25 120 ̊ Pattern Controlled

10.07 Radius 29 R5.0 mm As Cast Pattern Controlled

10.08 Radius 30 R5.0 mm As Cast Pattern Controlled

Control Plan Rev. No. : 01 (03/04/2015)

Special Char. Class

10.09 Depth 31 33.0 / 37.0 mm As Cast Pattern Controlled

Set up Approval(QC-MCN- Check Tooling & Set up Approval(QC-MCN-

1.Set up Approval(QC-MCN- Check & Segregate

Report (QC-MCN-F02) Report (QC-MCN-F02)

Surface Set up Approval(QC-MCN- Check Tooling & Set up Approval(QC-MCN-

Control Plan Rev. No. : 01 (03/04/2015)

Special Char. Class

Ø 128.0 /132.0 Set up Approval(QC-MCN- Check Tooling & Set up Approval(QC-MCN-

Check & Segregate

Surface Set up Approval(QC-MCN- Check Tooling & Set up Approval(QC-MCN-

Control Plan Rev. No. : 01 (03/04/2015)

Special Char. Class

1.Set up Approval(QC-MCN- Check & Segregate

1.Set up Approval(QC-MCN- 1.Set up Approval(QC-MCN-