CONTROL PLAN

Process- Zinc Flake Coating

Prototype Pre-Launch Production Key Contact/Phone : Date (Origin) : 24.06.2020
Control Plan Number : CQA:SCM:QCP-QAX013 Date of review :
Part No./ Latest change Level. : 00 Core Team : Customer Engineering Approval Date (If Required) :
Part Name/Description. : Fasteners (H+B+W 8.8 & 10.9 Grd) Supplier Plant Approval Date : Customer Quality Approval Date (If Required) :
Supplier Plant : Supplier Code : Other Approval Date (If Required) : Other Approval Date (If Required) :
Characteristic Method Control Method
Part/ Process Name/ Special
Machine, Device, Jig, Evaluation
Process Operation characteri Reaction Plan
Tools for Mfg. No. Product Process Product/ Process Specification Tolerances Measurement Sample Prevention Detection
No. description stics
Techniques

1 Surface Condition Material free from rust dent, dust , damage, burr etc. Visual 100%
Stop the loading, Notify to
10 Incoming Inspection Each lot Visual
Production & QA supervisor
2 Threads -- Thread should pass through ring gauge/Plug gauges Ring gauge/Plug gauge 20%

Customer Packing/Weighing
Manual 1 -- Material Loading As per Tank Capacity 100% Every Loading Automated or Manual --
Machine

1 -- Bath Concentration 80-120gm/ Liter / Chemical supplier recommandation Titration test 10 ml Once a Day

2 -- Bath Density Max 15 beaum / Chemical supplier recommandation Hydrometer 1 Reading Max 15 beaum
Supplier Inspection Stop Bathing & Inform to
Pre Cleaning tank 3 -- Bath Time 8 to 12 minutes / Chemical supplier recommandation Stop watch / PLC 100% 100%
record Production Supervisor
4 -- Bath Temperature 80◦c ± 10◦c / Chemical supplier recommandation Temp Controller 1 Reading Hourly
Degreasing
5 -- Bath Changhing 15 Days Cleaning of Tank Whole Tank Max 15 Days

1 -- Bath Concentration 80-120gm/ Liter / Chemical supplier recommandation Titration Test 10 ml Once a Day

2 -- Bath Density Max 15 beaum / Chemical supplier recommandation Hydro Meter 1 Reading Max 15 beaum
Supplier Inspection Stop Bathing & Inform to
Ultrasonic Tank 3 -- Bath Time 3 to 5 minutes / Chemical supplier recommandation Stop watch / PLC 100% 100%
record Production Supervisor
4 -- Bath Temperature 60◦c ± 10◦c / Chemical supplier recommandation Temperature controller 1 Reading Hourly

5 -- Bath Changhing 15 Days Cleaning of Tank Whole Tank Max 15 Days

1 Component Surface Free from chemical traces, patches & foreign particles. Visual 100% Each lot
Stop Bathing & Inform to
Water Rinsing Tank 1 2 -- Bath Time 45-90 Sec / Chemical supplier recommandation Stop watch / PLC 100% 100%
Production Supervisor
3 -- Bath Changhing 7 Days Checksheet Whole Tank Max 7 Days

20 1 Component Surface Free from chemical traces, patches & foreign particles. Visual 100% Each lot
Stop Bathing & Inform to
Water Rinsing Tank 2 2 -- Bath Time 45-90 Sec / Chemical supplier recommandation Automated Timer 100% 100%
Production Supervisor
3 -- Bath Changhing 7 Days Checksheet Whole Tank Max 7 Days

1 Component Surface Free from chemical traces, patches & foreign particles. Visual 100% Each lot

2 -- pH Test 6 to 7 pH Paper 1 Reading Once a Shift

3 -- Conductivity Test MAX 1500 Micro Siemens Conductivity Meter 1 Reading Once a Shift Stop Bathing & Inform to
Water Rinsing Tank 3
Supplier In process Production Supervisor
Plain Water Rinsing 4 -- Bath Time 45-90 Sec / Chemical supplier recommandation Stop watch / PLC 100% 100% Inspection Record

If Water pH value & Conductivity is out of limit change the bath

5 -- Bath Changhing Cleaning of Tank Whole Tank Max 7 Days
other wise after 7 days

1 Component Surface Free from chemical traces, patches & foreign particles. Visual 100% Each lot

2 -- pH Test 6 to 7 pH Paper 1 Reading Once a Shift

3 -- Conductivity Test 1500 Micro Siemens Conductivity Meter 1 Reading Once a Shift Stop Bathing & Inform to
Water Rinsing Tank 4
Production Supervisor
4 -- Bath Time 30 - 45 Seconds Stop watch / PLC Control 100% 100%

If Water pH value & Conductivity is out of limit change the bath

5 -- Bath Changing Cleaning of Tank Whole Tank Max 7 Days
other wise after 7 days
 CONTROL PLAN
Process- Zinc Flake Coating
Prototype Pre-Launch Production Key Contact/Phone : Date (Origin) : 24.06.2020
Control Plan Number : CQA:SCM:QCP-QAX013 Date of review :
Part No./ Latest change Level. : 00 Core Team : Customer Engineering Approval Date (If Required) :
Part Name/Description. : Fasteners (H+B+W 8.8 & 10.9 Grd) Supplier Plant Approval Date : Customer Quality Approval Date (If Required) :
Supplier Plant : Supplier Code : Other Approval Date (If Required) : Other Approval Date (If Required) :
Characteristic Method Control Method
Part/ Process Name/ Special
Machine, Device, Jig, Evaluation
Process Operation characteri Reaction Plan
Tools for Mfg. No. Product Process Product/ Process Specification Tolerances Measurement Sample Prevention Detection
No. description stics
Techniques

6 Oil Test -- Free from Oil Visual

Stop Bathing & Inform to
Testing 1 Reading Every Lot
Production Supervisor
7 Alkaline Test -- Free from Alkaline Phenolphalein indicator

Manual Loading 1 -- Roller setting Center of Oven Fixure 100% 100%

2 -- Oven Temp. 100 °C to 150 °C Temprature Controller 1 Reading Every Lot Stop Oven & Material to flow
Supplier In process
30 Drying Drying Oven next operation & inform to
Inspection Record
3 -- Zirblast Test Clean thread (No sticking of Zirblast Powder) Visual 1 Reading Every Lot Production supervisor

Manual Unloading 4 -- -- 1 Tray in each self Manual UnLoading 100% 100%

1 -- Batch Size As per Booth size Weighing Machine 1 Reading Every lot

2 -- Blasting Time 10 to 40 min Controller 1 Reading Each Lot

Shot Blasting Machine 3 -- Tumbling 10-5 min Stop watch / PLC 1 Reading Each Lot
Supplier In process Stop Operation & Inform to
40 Shot Blasting
Inspection Record production supervisor
4 -- Shot (Ball) Size MS 0.6 mm 0.12 to 0.30 mm / Suitable Sieving 1 Reading Max 15 Days
15 sec dip in cupper
5 -- Lab Test - Hogaboom Test 15 Sec dip in Cupper sulphate solution 1 Piece Every Lot
sulphate Solution
Vibrator 1 Thread Condition -- No shots in thread 5 to 10 min 100% Every Lot

Geomet 321 (B-1) - 10.300 KGS

1 -- Weight Geomet 321( B-2) 13.700 KGS Batch Standard 100% Weighing Every Batch
Geomet 321 ( Z )80-120 gms

30 Sec to 52 Sec (at 16 to 24 °C) / Chemical Supplier

2 -- Viscosity Zahn Cup # 3 1 Reading Every Batch
recommandation

3 -- Specific Gravity 1.27 to 1.36 / Chemical Supplier recommandation Hydro Meter 1 Reading Every Batch Stop Mixing & Material to flow
Supplier In process
50 Chemical Mixing Chemical Mixing Tank next operation & inform to
Inspection Record
4 -- pH 7.5 to 8.5 / Chemical Supplier recommandation pH Meter 1 Reading Every Batch Quality supervisor

5 -- Solution Temp. 16 °C to 24 °C / Chemical Supplier recommandation Thermometer 1 Reading Every Batch

6 -- Mixing Time 06 hours / Chemical Supplier recommandation PLC Timer 1 Reading Every Batch

7 -- Room Temperature 20 °C to 30 °C Thermometer 1 Reading Every Batch

1 -- Chemical 40 to 60 kg / Chemical Supplier recommandation Batch weight -- Every Batch

2 -- Temp 16 °C to 24 °C / Chemical Supplier recommandation Thermometer 1 Reading Thrice a Shift

3 -- Viscosity 30 Sec to 52 Sec Chemical Supplier recommandation Zahn Cup # 3 1 Reading Thrice a Shift

4 -- Specific Gravity 1.27 to 1.36 / Chemical Supplier recommandation Hydro Meter 1 Reading Thrice a Shift

5 pH Test Alkaline check 7.5 to 8..5 / Chemical Supplier recommandation pH Meter 1 Reading Thrice a Shift
Supplier In process
Coating Machine 6 Part Loading -- 20 to 40 kg Automated Controller 1 Reading Every Lot Inspection Record
7 Chemical Tank Stirrer Alram Indication for stirrer running function To check alram function PLC Control Each Loading Every lot

8 -- Bath Filter Cleaning If Ph value is out of limit then change/add chemical. Visual 1 Reading Max 7 Days
Stop Coating & Material to flow
60 First Coat 9 -- Chemical Tank Cleaning If Ph value is out of limit then change/add chemical. Visual 1 Reading Max 7 Days next operation & inform to
Production supervisor
10 -- Dip Time 10-20 Sec Stop watch/PLC Automated Every setup

11 -- Spinning Speed 250 to 500 RPM Manual/PLC Automated Every setup

1 -- Part loading Spread proparly on belt Visual 100% Every lot

2 -- Oven Temp. 70°C to 80°C Thermo Couple 1 Reading Hourly

3 -- Conveyor Belt Speed 130 to 190 mm/min Oven Controller 1 Reading Hourly
Supplier In process
4 -- Drying Time 6-15 minutes Handy Logger 1 Reading Once a Month
Oven Inspection Record
5 -- Oven Temp. 300°C to 320°C Oven Controller 1 Reading Hourly

7 -- Curing Time in Oven 20 To 30 min Data Logger 1 Reading Once a month

8 -- Part Unloading Tray / Trolley - Colour coding Manually 100% 100%

 CONTROL PLAN
Process- Zinc Flake Coating
Prototype Pre-Launch Production Key Contact/Phone : Date (Origin) : 24.06.2020
Control Plan Number : CQA:SCM:QCP-QAX013 Date of review :
Part No./ Latest change Level. : 00 Core Team : Customer Engineering Approval Date (If Required) :
Part Name/Description. : Fasteners (H+B+W 8.8 & 10.9 Grd) Supplier Plant Approval Date : Customer Quality Approval Date (If Required) :
Supplier Plant : Supplier Code : Other Approval Date (If Required) : Other Approval Date (If Required) :
Characteristic Method Control Method
Part/ Process Name/ Special
Machine, Device, Jig, Evaluation
Process Operation characteri Reaction Plan
Tools for Mfg. No. Product Process Product/ Process Specification Tolerances Measurement Sample Prevention Detection
No. description stics
Techniques

1 Chemical Loading 40 to 60 kg / Chemical Supplier recommandation Batch weight -- Every Batch

2 Chemical Temp 16 °C to 24 °C / Chemical Supplier recommandation Thermometer 1 Reading Thrice a Shift

3 Viscosity Orifice Flow 30 Sec to 52 Sec Chemical Supplier recommandation Zahn Cup # 3 1 Reading Thrice a Shift

4 Specific Gravity -- 1.27 to 1.36 / Chemical Supplier recommandation Hydro Meter 1 Reading Thrice a Shift

5 pH Test Alkaline check 7.0to 8.0 / Chemical Supplier Recommandation pH Meter 1 Reading Thrice a Shift

6 Part Loading -- 20 to 40 kg Automated Controller 1 Reading Every Lot

Supplier In process
Coating Machine
Inspection Record
7 Chemical Tank Stirrer Alram Indication for stirrer running function To check alram function PLC Control Each Loading Every lot

8 -- Bath Filter Cleaning If Ph value is out of limit then change/add chemical. Visual 1 Reading Max 7 Days

9 Chemical Tank Cleaning If Ph value is out of limit then change/add chemical. Visual 1 Reading Max 7 Days
Stop Second Coat & Material to
70 Second Coat 10 -- Dip Time 10-20 Sec PLC Program Automated Every setup flow next operation & inform to
Production supervisor
11 PLC Machine PLC Programming As per Matrix PLC Program Automated Every setup

12 -- Spinning Speed 250 to 500 RPM PLC Program Automated Every setup

1 -- part loading Spread proparly on belt Visual 100% Every lot

2 Oven Temp. Preheat 70°C to 80°C ThermoCouple 1 Reading Hourly

3 Conveyor Belt Speed 130 to 190 mm/min Oven Controller 1 Reading Hourly
Supplier In process
4 Drying Time Evaporation 6-15 minutes Handy Logger 1 Reading Once a Month
Inspection Record
Oven
5 Oven Temp. Curing 300°C to 320°C Oven Controller 1 Reading Hourly

6 Oven. Curing Time 20 To 30 min Data Logger 1 Reading Once a month

7 -- Part Unloading Tray / Trolley - Colour coding Manually 100% 100%

Test 1 Coating Weight / Coating Thickness -- 240 mg/mm Sqr Minimum / 8 Microns Min Checksheet As per sampling plan Every Lot

Cellophane Tape 2 Adhession Test -- No Peeling off Checksheet 1 Part Every Lot Hold all Material to dispatch to
Supplier In process
80 Final Inspection the customer & inform to
Inspection Record
Visual 3 Appearance -- No White Spot, No Excess chemical Visual 100% Every Lot Quality supervisor

Salt Spray Machine 4 Salt Spray Test -- No red rust 720 hours Salt Spray 1 Part Every Lot

Revision history
Rev. No. Date of Rev. Clause no. Description
00 24.06.2020 -- First Issue