LIST OF WORK INSTRUCTION

MASKING
1 MASKING FOR DOMESTIC SCCER WI-BR-MAS-001
2 MASKING OF CN 100 SHOCKS WI-BR-MAS-002
3 MASKING OF EXPORT SHOCKER WI-BR-MAS-003
4 MASKING FOR HANDLE SUZUKI 251& 331 WI-BR-MAS-004

PAINT SHOP
1 LOADING ON LIQUID SPRAY LINE WI-BR-PS-001
2 PARTS PER HANGER FOR HANDLE KPPR/KYJA WI-BR-PS-002
3 PARTS PER HANGER FOR PADDLE BREAK WI-BR-PS-003
4 PARTS PER HANGER FOR SOCKER(8757,8863,6137,6136,4065) WI-BR-PS-004
5 PARTS PER HANGER FOR CHAIN CASE WI-BR-PS-005
6 SUPPLY VISCOSITY CHECKING OF INCOMING PAINT WI-BR-PS-006
7 NVM TESTING OF INCOMING PAINT WI-BR-PS-007
8 THINNER INTAKE TEST INCOMING PAINT WI-BR-PS-008
9 TEMPERATURE vs VISCOSITY WI-BR-PS-009
10 LIQUID PAINT APPLICATION WI-BR-PS-010
11 FOR SETTING BAKING TEMP. WI-BR-PS-011
12 PAINT MIXING FOR SHOCER (ALL MODELS) WI-BR-PS-012
13 PREVENTIVE MAINTENANCE OF CONVEYOR WI-BR-PS-013
14 FINAL INSPECTION OF HANDLE KYJA/KPPR WI-BR-PS-014
15 FOR POLISHING WI-BR-PS-015
16 STRIPING OF REJECTED PARTS WI-BR-PS-016
17 FOR NAME OF COMPONENT vs PAINT WI-BR-PS-017
18 INSPECTION OF CHAIN CASE WI-BR-PS-018
19 INSPECTION OF HANDLE (KWSA,KSPR,KWFG,K-14,KVEA) WI-BR-PS-019
20 INSPECTION OF SASH WI-BR-PS-020
21 INSPECTION OF HANDLE (KPPR,KYJA) WI-BR-PS-021
22 INSPECTION OF SAREE GUARD WI-BR-PS-022
23 FINAL INSPECTION OF HUB WI-BR-PS-023
24 PAINTING OF HANDLE,KSPR,KVFG,KWFF,KWFA,KVEA WI-BR-PS-024
25 PAINTING OF SASH WI-BR-PS-025
26 INSPECTION OF SHOCKER WI-BR-PS-026
27 DEMASKING OF SHOCKERS WI-BR-PS-027
28 UNLOADING AFTER PAINTING WI-BR-PS-028
29 POLISHING FOR COMPONENTS OF MATT SHADE WI-BR-PS-029
30 POLISHING OF HANDLE KWSA AND OTHER GLOSSY COMPONENTS WI-BR-PS-030
31 APPLICATION OF TAG RAK WI-BR-PS-031
32 PARTS PER HANGER FOR HANDLE WI-BR-PS-032
33 PARTS PER HANGER FOR SASH WI-BR-PS-033
 INCOMING/PT
1 INCOMING PARTS INSPECTION WI-BR-IN-001
2 INSTRUCTION TO P.T LINE OPERATOR WI-BR-PT-001
3 OPERATION AIR DRIER - P.T LINE WI-BR-PT-002
4 LOADING FOR PT LINE WI-BR-PT-003
5 FOR ALL TYPES OF SHOCKS LOADING ON P.T. LINE WI-BR-PT-004
6 LOADING FOR P.T(DOMESTIC & CN100 SHOCKERS) WI-BR-PT-005
7 FOR PREPRATION OF NEW DEGREASING/KOD BATH WI-BR-PT-007
8 FOR NEW RO/DM WATER BATH PREPRATION WI-BR-PT-010
9 LOADING FOR PRE- TREATMENT WI-BR-PT-011
10 FOR PRE- TREATMENT WI-BR-PT-012
11 FOR CHECKING P.T CHEMICAL QUALITY WI-BR-PT-013

CED
1 GRINDING OF HOOKS OF C.E.D LINE BASKET WI-BR-CED-001
2 LOADING WHEEL REAR SUPPORT ON CED LINE WI-BR-CED-002
3 LOADING OF COVER RR REAR DOOR WINDOW GLASS ON CED LINE WI-BR-CED-003
4 LOADING OF SASHON CED LINE WI-BR-CED-004
5 MASKING FOR SHOCKER RTA WI-BR-CED-005
6 LOADING OF SHOCKER ON CED LINE WI-BR-CED-006
7 MASKING OF SHOCKER ALL MODELS WI-BR-CED-007

REWORK
1 FOR REWORK OF SASH WI-BR-RE-001
2 FOR REWORK ALL COMPONENTS WI-BR-RE-002

DESPATCH
1 FOR DISPATCH OF SHOCKER WI-BR-DES-001
2 FOR DISPATCH OF HUB WI-BR-DES-002
3 FOR DISPATCH OF RTA WI-BR-DES-003
4 FOR DISPATCH OF HANDLE K14 WI-BR-DES-004
5 FOR DISPATCH OF HANDLE KVEA WI-BR-DES-005
6 FOR DISPATCH OF HANDLE KYJA WI-BR-DES-006
7 FOR DISPATCH OF SAREE GUARD WI-BR-DES-007
8 FOR DISPATCH OF SHOCKER WI-BR-DES-008

LAB
1 FOR ADHESION TEST WI-BR-LAB-001
2 FOR GLOSS TESTING WI-BR-LAB-002
3 ACID RESISTANCE TEST WI-BR-LAB-003
4 PENCIL SCRATCH HARDNESS TESTING WI-BR-LAB-004
5 IMPACT TESTING WI-BR-LAB-005
6 DM WATER CONDUCTIVITY TESTING WI-BR-LAB-006
8 OIL RESISTANCE TEST WI-BR-LAB-008
9 DRY FILM THICKNESS TEST WI-BR-LAB-009
10 CALIBRATION AND PH TESTING WI-BR-LAB-010
11 GASOLINE RESISTANCE TEST WI-BR-LAB-011
12 XYLENE RESISTANCE TEST WI-BR-LAB-012
13 ALKALI RESISTANCE TEST WI-BR-LAB-013
14 SALT SPRAY TEST WI-BR-LAB-014
15 HUMIDITY RESISTANCE TEST WI-BR-LAB-015
16 WATER RESISTANCE TEST WI-BR-LAB-016
 LIST OF FORMAT
1 DAILY PRODUCT CHECK SHEET LIQUID PAINTING BR/FR/001
2 DAILY PROCESS AND PRODUCT CHECK SHEET FOR POWDER COATING BR/FR/002
3 DAILY PROCESS MONITORING SHEET (C.E.D) BR/FR/003
4 DAILY PROCESS MONITORING SHEET (P.T LINE) BR/FR/004
5 PRODUCT TEST REPORT FOR SAMPLES BR/FR/005
6 DAILY PROCESS AND PRODUCT CHECK SHEET FOR C.E.D COATING BR/FR/006
7 PRODUCT TEST REPORT BR/FR/007
8 OIL CONTENT CHECK SHEET BR/FR/008
9 SALT SPRAY CHECK SHEET BR/FR/009
10 SLUDGE CONTENT CHECK SHEET BR/FR/010
11 ON JOB TRAINING RECORD BR/FR/011
12 FOG COLLECTION CHECK SHEET BR/FR/012
13 BOOTH PROCESS MONITORING SHEET BR/FR/013
14 LUX VALUE CHECK SHEET BR/FR/014
15 INCOMING INSPECTION SHEET BR/FR/015
16 DFT MONITORING SHEET BR/FR/016
17 TRANSPORTER TIME CHECK SHEET (P.T LINE) BR/FR/017
18 HUMIDITY TEST REPORT BR/FR/018
19 WATER RESISTANCE TEST REPORT BR/FR/019
20 SALT SPRAY TEST REPORT BR/FR/020
21 HUMIDITY CHECK SHEET BR/FR/021
22 WATER RESISTANCE CHECK SHEET BR/FR/022
23 CONVEOR SPEED vs FLASH OFF BAKING TIME BR/FR/023
24 CUSTOMER COMPLAINTS RECORD BR/FR/024
25 P.T LINE CLEANING CHECK SHEET BR/FR/025
26 SUPPLIER LIST OF PAINT AND CHEMICALS BR/FR/026
27 CALIBRATION PLAN BR/FR/027
28 TESTING SCHEDULE (LAB) BR/FR/028
29 TOP TWO PROBLEMS OF THE MONTH AND THEIR ACTION PLAN BR/FR/029
30 PROCESS VALIDATION BR/FR/030
31 HANGER VALIDATION BR/FR/031
32 SST SAMPLING PLAN BR/FR/032
33 HUMIDITY SAMPLING PLAN BR/FR/033
34 WATER RESISTANCE TEST SAMPLING PLAN BR/FR/034
35 BOOTH PREVENTIVE BR/FR/035
36 VALIDATION PLAN BR/FR/036
 Doc.No. : BR/FR/001

Rev. : '00
Daily Product Check Sheet Liquid Painting.
VILL-BHORA, Page : 1 of 1
KHALAN.GURGAON
(H.R) Date :20/02/11

PRIMER /PAINT/ LACQURE PRESSURE : 2-3 Kg/cm2 BAKING TIME : 25 - 30 Min.. (EMT)

PRIMER /PAINT/ LACQURE AIR PRESSURE : 3.5--4.5 Kg/cm2 BAKING TEMP : 150°C±5 (TSA) - 220°C±5( HR)

PRIMER /PAINT/ LACQURE GUN CHARGING : 40-60 KVA GUN DISTANCE : 10-12 Inch From Article

PRIMER VISCOSITY : 16 - 20 Sec. CONVEYOR SPEED : 1.0 - 1.2 Meter/Minutes

PAINT VISCOSIT : 16 - 20 Sec. LACQUER VISCOSITY : 16 - 20 Sec.

ACTUAL STATUS

DATE : LOT SIZE :

PART NAME : CONVEYOR SPEED :

PAINT SPECIFICATION: BAKING TEMP / TIME :

PRIMER NAME : PAINT NAME :

PRIMER MAKE : PAINT MAKE :

BATCH NO : BATCH NO :

VISCOSITY : VISCOSITY :

GUN CHARGING : GUN CHARGING :

OPERATOR NAME : OPERATOR NAME :

LACQUER NAME : ADHESION TEST :

GLOSS TEST (60o)

LACQUER MAKE :

BATCH NO :

VISCOSITY :

GUN CHARGING : XYLENE TEST (8 Rubs) PENCIL HARDNESS

OPERATOR NAME :

LAYER THICKNESS-: 40µ min. 5 PIECES AT 3 LOCATIONS

ACCEPTED
ACTUAL STATUS:-
REJECTED

CHECKED BY : VERIFIED BY :
CHECKED BY : VERIFIED BY :
 Doc.No. : BR/FR/HR-004

DAILY PROCESS PARAMETER MONITORING SHEET - ALODINE PROCESS Rev. : '00

Page : 1 of 1
VILL-BHORA,KHALAN.GURGAON (H.R)
DATE : Date :27/08/14
REPORT REPORT
Sr. no. Process Parameter Specification OBESERVATION 1st ADDITION AFTER/ADDITION OBESERVATION 2nd ADDITION AFTER/ADDITION REMARKS

Temperature 40°C - 50°C

1 DEGREASING
Alkality 35-45ml

pH 8 - 10
2 R.O. WATER RINSE- I
Alkality < 5 ml

pH 8 - 10
3 R.O. WATER RINSE- II
Alkality < 2 ml

Temperature R/T
4 NITRIC ACID DIPParameter
Process
for PT Line Alkality 1 -2 ml

pH 8 - 10
5 R.O. WATER RINSE- III
Alkality < 5 ml

pH 8 - 10
6 R.O. WATER RINSE- IV
Alkality < 2 ml

Temperature R/T

7 CHROMOTISING Total acid 2.5 - 4.5 ml

Free acid 0.7 - 2.0 ml

Temperature R/T
Process Parameter
8 ALODINE
for PT Line Total acid 13 -15 ml

Free acid 7.5-9.5 ml

pH 6.5-7.5
9 Process
D.M. WATER Parameter
RINSE- I
for PT Line Conductivity MAX.45µS/cm

pH 6.5-7.5
10 D.M. WATER RINSE- II
Conductivity MAX.30µS/cm

11 AIR DRYER Temperature 70°C - 90°C

Checked by: Verified by:

Process Parameter for
Process Parameter
PT Line
for PT Line
 Doc.No. : BR/FR/007

Vill,Bhora kalan Gurgaon(H.R.)

Product Test Report Rev. : '00
PART NAME :-
CUSTOMER :-
Date :20/02/11
DATE:

S.NO TEST/ PARAMETERS OBSERVATION REMARKS

Appearance (SHALL BE FREE

1 FROM PIN HOLE, DUST, SCRATCH,
EXPOSED SURFACE, BLISTER,
WRINKLES & ORANGE PEEL)

2
Color As Per Master Shade

3
Dry Film Thickness

Adhesion (SHALL PASS

4
100/100Sq.)

5 Pencil Hardness

6 Gloss Test ( 60°)

7 Xylene/MIVK Test

Gasoline Resistance
8

9 Salt Spray Test

10 Water Resistance

11 Shock Resistance

12 Spot Resistance
13 Oil Resistance

CHECKED BY: VERIFIED BY:

 SALT SPRAY TEST REPORT DOC NO. BR/FR/020

(BINOLA) (ALL PAINTED PARTS) DATE : 18.11.2010

COMPONENT : PART NO. :

PRODUCTION DATE : TESTING DATE :

SHADE : BATCH NO :

CUSTOMER NAME : LOT QTY. :

SR. NO SPECIFICATION TEST RESULT REMARKS

1 24 hrs SALT SPRAY TEST FOR 72 hrs (no

corrosive product , blister,excessive
2mm from the cut on each side.

2 48 hrs

3 72 hrs

4 96 hrs

5 120 hrs

6 144 hrs

7 168 hrs

8 192 hrs

9 216 hrs

10 240 hrs
CHECKED BY : APPROVED BY :
 Doc.No. : BR/FR/009

SALT SPRAY CHECK SHEET Rev. : '00

Page : 1 of 1
MONTH : Date :20/02/11
PARAMETER SPEC TIME 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

10:00 AM

0.8 ~ 1.5
PRESSURE
KG/CM2

6:00 PM

10:00 AM

TEMPRATURE 33 ~37OC

6:00 PM

10:00 AM

pH 6.5 ~ 7.2

6:00 PM

CHECKED BY : APPROVED BY :
 Doc.No. : BR/FR/008
Rev. : '00

VILL-BHORA,
OIL CONTENT CHECK SHEET Page : 1 of 1
KHALAN.GURGAON (H.R) Date :20/02/11

PT LINE ( max 4000 ppm ) PTCED LINE ( max 4000 ppm )

SR. NO DATE REMARKS
KOD DEGREASING KOD DEGREASING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

PREPARED BY : APPROVED BY :
 Doc.No. : BR/FR/010

SLUDGE CONTENT CHECK Rev. : '00

Page : 1 of 1
VILL-BHORA,
KHALAN.GURGAON (H.R)
SHEET
Date 20.02.2011

SR. NO DATE PT LINE CED LINE REMARKS

10

11

12

13

14

15

16

17

18

19

20

PREPARED BY : APPROVED BY :
 Doc.No. : BR/FR/011

ON JOB TRAINING Rev. : '00

Page : 1 of 1
VILL-BHORA, KHALAN.GURGAON
(H.R)
RECORD
Date :20.02.2017

TITLE OF TRAINING : NEW PRODUCT

NEW PROCESS ADDITION

VENUE : PROCESS CHANGE

NEW OPERATOR

FACULTY : PRODUCT CHANGE

ANY OTHER

TIME : FROM ………………. TO ………………… DATE :

SR. NO. NAME OF EMPLOYEE DESIGNATION DEPARTMENT
SIGNATURE
Signature of Faculty : Signature of HOD :
 Doc.No. : BR/FR/012
Rev. : '00
FOG COLLECTION CHECK SHEET Page : 1 of 1
BINOLA,GURGAON Date : 20.02.2011

Sr.No. Date Start Time Stop Time Total Fog Fog Collection per
Collected Hour (1~2 ml/hr)
1

10

11

12

13

14

15

16

17

18

19

20

Checked By : Approved By :
 Doc.No. BR/FR/013
BOOTH PROCESS MONITORING SHEET Rev. : '02
Page : 1 of 1
BINOLA Date :01/09/2013
MONTH :
INSPECTION
DATE
S.NO. CHECK POINT SPECIFICATION
FREQ.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

AIR PRESSURE OF 2
1 PAINTING GUN 3.5 - 4.5 Kg/Cm TWICE/SHIFT

AIR PRESSURE OF
2 PAINT PUMP 2-3 Kg/Cm2 TWICE/SHIFT

ELECTROSTATIC
3 CURRENT 40~60 KVA TWICE/SHIFT

AIR FILTER SHOULD BE

4 CLEANING FREE FROM TWICE/SHIFT
MOISTURE

150 ~ 200
5 PAINT DELIVERY ML/MIN TWICE/SHIFT

6 GUN EARTHING CONTINUITY ONCE/SHIFT

BOOTH AIR
7 BALANCE POSITIVE ONCE/SHIFT

8 ILLUMINATION >500 LUX ONCE/SHIFT

BOOTH
9 TEMPERATURE 30±5 ONCE/SHIFT

RH VALUE
10 BOOTH HUMIDITY 50~70 ONCE/SHIFT

OPERATOR
SIGNATURE
SUPERVISOR
 Doc.No. BR/FR/HR-013

PAINTING PROCESS CHECK SHEET FOR H.R. PAINT Rev. : '02

Page : 1 of 1

BINOLA DATE : TIME Date :07/03/2014

S.NO. CHECK POINT SPECIFICATION
MAKE MAHARANI PAINTS
BATCH NO./MFG
EXP. DATE

PAINT DELIVERY(HVLP GUN) 80-90 ML/MIN

PAINT DELIVERY ( ELECTROSTATIC GUN) 100-120 ML/MIN

VISCOSITY 16 - 20 SEC
AIR PRESSURE OF GUN 3.0 - 3.5 KG/CM2
H.R.
1 PRIMER AIR PRESSURE OF PUMP 2.0 - 3.0 KG/CM2
ELECTROSTATIC GUN CHARGING
40 - 60 KVA
KVACURRENT
BOOTH TEMP 25 - 32 oC

BOOTH HUMIDITY 55-75 RH%

LUX VALUE > 500 ON HANGER
SHOULD BE POSITIVE BY ON LINE
BOOTH BALANCING
THREAD

NO. OF OPERATORS 2 NOS. + 1 RELIVER / SHIFT

MAKE MAHARANI PAINTS
SHADE
BATCH NO./MFG
EXP. DATE
PAINT DELIVERY (HVLP GUN) 80-90 ML/MIN
PAINT DELIVERY ( ELECTROSTATIC GUN) 100-150 ML/MIN
VISCOSITY 16 - 20 SEC
AIR PRESSURE OF GUN 3.0 - 4.5 KG/CM2
2 H.R. PAINT
AIR PRESSURE OF PUMP 2.0 - 3.0 KG/CM2
ELECTROSTATIC GUN CHARGING 40 - 60 KVA
KVACURRENT
BOOTH TEMP. 25 - 32 oC

BOOTH HUMIDITY 55-75 RH%

LUX VALUE > 500 ON HANGER
SHOULD BE POSITIVE BY ON LINE
BOOTH BALANCING THREAD

NO. OF OPERATORS 2 NOS. + 1 RELIVER / SHIFT

3 BAKING TEMP ( SET TEMP) FOR HR PAINT - 200-210oC

4 CONVEYOR SPEED 1.0 METER/MIN.

CHECKED BY : VERIFIED BY :
 Doc.No. : BR/FR/014
LUX VALUE CHECK SHEET ( ONCE / WEEK )
Rev. : '01
BINOLA,GURGAON STATION : Date 05.07.2014

LUX VALUE (MIN. 500 LUX IN PAINTING BOOTHS & 750 LUX ON INSPECTION
TABLES)
SR. NO. DATE REMARKS
DAY TIME NIGHT TIME
Checked By : Verified By :
 Doc.No. : BR/FR/015

VILL-BHORA,
KHALAN.GURGAON
INCOMING INSPECTION SHEET Rev. : '00
Date 11.01.2013
(H.R)

REJECT QUANTITY
SR. COMPONENT CHALLAN CHECKED OK
NO DATE NAME NO. LOT SIZE QUANTITY QUANTITY REMARKS
DENT RUST HEAVY
OIL/GREASE

PREPARED BY : APPROVED BY :
 Doc.No. : BR/FR/016

VILL-BHORA,
KHALAN.GURGAON
DFT MONITORING SHEET Rev. : '00
Page : 1 of 1
(H.R)
PRIMER + PRIMER + BASE
PRIMER COAT BASE COAT TOP COAT BASE COAT COAT + TOP
SR. DATE COMPONENT (15-20 (10-15 (25-35 COAT (35-50 REMARKS
NO NAME (10 -15
MICRONS) MICRONS) MICRONS) MICRONS) MICRONS)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

PREPARED BY : APPROVED BY :
 Doc.No. :BR/FR/017

TRANSPORTER TIME CHECK SHEET ( PT LINE ) Rev. : '00

Page : 1 of 1
VILL-BHORA,
KHALAN.GGN. (H.R)
MONTH : Date : 11.01.2013

DATE
SR. NO. PROCESS NAME REMARKS
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

1 HOT WATER ( 1 - 2 MIN.)

2 KOD ( 2 - 3 MIN.)

3 DEGREASING (4 - 5 MIN.)

4 RO WATER RINSE 1st ( 10 - 30 SEC.)

5 RO WATER RINSE 2nd ( 1 - 2 MIN. )

6 SURFACE ACTIVATION ( 1 - 2 MIN. )

7 PHOSPHATING ( 4 - 5 MIN. )

8 CHROMATISING ( 4 - 5 MIN. )

9 DM WATER RINSE 1st ( 1 - 2 MIN. )

10 DM WATER RINSE 2nd ( 1 - 2 MIN.)

11 DRY OFF (8 MIN.)

LEGEND : OK
X - NOT OK
CHECKED BY : VERIFIED BY :
 Doc.No. : BR/FR/021

HUMIDITY CHECK SHEET Rev. : '00

Page : 1 of 1
VILL-BHORA,
KHALAN.GURGAON (H.R) Date : 11.01.2013
MONTH :

PARAMETER SPEC TIME 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

10:00 AM

TEMPRATURE 48 ~52OC

6:00 PM

10:00 AM

HUMIDITY > 95 RH

6:00 PM

CHECKED BY : APPROVED BY :
 DOC NO. BR/FR/020
HUMIDITY TEST REPORT
(BINOLA) (ALL PAINTED PARTS) DATE : 18.11.2010

COMPONENT : PART NO. :

PRODUCTION DATE : TESTING DATE :

SHADE : BATCH NO :

CUSTOMER NAME : LOT QTY. :

SR. NO SPECIFICATION TEST RESULT REMARKS

48°~52oC FOR 48 HRS. ( no

1 24 hrs blisters, flacking wrinkle, rust
excessive change in gloss etc)

2 48 hrs

3 72 hrs

4 96 hrs

5 120 hrs

6 144 hrs

7 168 hrs

8 192 hrs

9 200 hrs

CHECKED BY : APPROVED BY :
 Doc.No. :BR/FR/018
Rev. : '00
HUMIDITY TEST REPORT Page : 1 of 1
VILL-BHORA, KHALAN.GURGAON (H.R)
Date : 11.01.2013

OBSERVATION AFTER
DATE PART NAME REMARK
24 HRS. 48 HRS. 72 HRS. 96 HRS. 120 HRS.

PREPARED BY : APPROVED BY :
 Doc.No. :BR/FR/019
Rev. : '00
WATER RESISTANCE TEST REPORT Page : 1 of 1
VILL-BHORA, KHALAN.GURGAON (H.R)
Date : 11.01.2013

OBSERVATION AFTER
DATE PART NAME REMARK
24 HRS. 48 HRS. 72 HRS. 96 HRS. 120 HRS.
PREPARED BY : APPROVED BY :
 Doc.No. : BR/FR/022
WATER RESISTANCE CHECK SHEET Rev. : '00
BINOLA,GURGAON Date 11.01.2013
o
TEMP. ( 38 -42 C)
SR. NO. DATE REMARK
10:00 AM 6:00 PM 2:00 AM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Checked By : Approved By :
 DOC NO. BR/FR/020
WATER RESISTANCE TEST REPORT
(BINOLA) (ALL PAINTED PARTS) DATE : 18.11.2010

COMPONENT : PART NO. :

PRODUCTION DATE : TESTING DATE :

SHADE : BATCH NO :

CUSTOMER NAME : LOT QTY. :

SR. NO SPECIFICATION TEST RESULT REMARKS

40oC FOR 48 HRS. ( no blisters,

flacking wrinkle, rust excessive
1 24 hrs change in colour or softening of
coating )

2 48 hrs

3 72 hrs

4 96 hrs

5 120 hrs
CHECKED BY : APPROVED BY :
 Doc.No. : BR/FR/023

CONVEYOR SPEED v/s FLASH OFF & BAKING Rev. : '00

TIME
VILL-BHORA, KHALAN.GURGAON
(H.R)
Date 11.01.2013

SR. NO DISPLAY UNIT CONVEYOR SPEED TIME FOR I,II & III FLASH OFF BAKING OVEN TIME
READING (METER/MIN.) ZONES (MINUTES) (MINUTES)

1 23 1.0 13 42

2 28 1.2 10.8 35

3 35 1.5 8.7 28

4 41 1.8 7.2 23

5 46 2.0 6.5 21

PREPARED BY : APPROVED BY :
 Doc.No. : BR/FR/024

VILL-BHORA, KHALAN.GURGAON
CUSTOMER COMPLAINTS RECORD Rev. : 01

(H.R)
Date 11.01.2013

SR. NAME OF COMPONEN BY

REPEATED/ ATTENDED MAIL/PHO CAPA
DATE COMPLAINT / PROBLEM ACTION MONITORING
NO. CUSTOMER T NAME NEW PERSON NE SUBMITED
PREPARED BY : APPROVED BY :
 Doc.No. : BR/FR/024

CUSTOMER COMPLAINTS RECORD Rev. : '00

VILL-BHORA,
KHALAN.GURGAON (H.R)
Date 11.01.2013

SR. NAME OF COUNTERMEASURE

NO. CUSTOMER COMPLAINT / PROBLEM DATE SUBMITED REMARKS

PREPARED BY : APPROVED BY :
 Doc.No. : BR/FR/025
Rev. : '00
P.T. LINE CLEANING CHECK SHEET Page : 1 of 1
VILL-BHORA,
KHALAN.GURGAON (H.R) Date :20/02/11

K.O.D.(if oil
Date Hot Water cont. max Deg.(if oil cont. W.R.-1 W.R.-2 S. Activation Phosphating Chromatising DI W.R.-1 DI W.R.-2
(weekly) max.4000ppm) (weekly) (weekly) (weekly) (weekly) (weekly)
4000ppm)

Prepared By : Approved By :
 Doc.No :BR/FR/026

SUPPLIER LIST OF PAINTS & Rev. : '01

Page : 1 of 2
BINOLA (GURGAON) CHEMICALS Date :05/07/14

MINIMUM
SR. NO PAINT / CHEMICAL NAME SUPPLIER NAME
STOCK QTY.

1 MONOCOAT SILVER BERGER 20 LTR

2 MATT LACQUER BERGER 20 LTR

3 AD FD BLACK BERGER 40 LTR

4 MATT AXIS GREY BERGER 20 LTR

5 GREY PRIMER BERGER 60 LTR

6 THINNER 828 BERGER 40 LTR

7 THINNER 915 BERGER 40 LTR

8 MATT BLACK POWDER BERGER 20 KG

9 GLOSSY BLACK POWDER BERGER 10 KG

10 SATIN BLACK POWDER BERGER 10 KG

11 TSA TOP COAT BLACK BERGER 20 LTR

12 LB 25 LF BLACK PIGMENT PASTE F1 KNP 50 KG

13 LB 25 LF BLACK RESIN EMULSION F2 KNP 200 KG

14 ADDTIVE -S KNP 25 KG

15 ADDTIVE -M KNP 25 KG

16 ADDTIVE -EDD KNP 25 KG

17 HR NH 108-25 BLACK PRIMER MAHARANI PAINTS 40 KG

18 HR NH 108-25 BLACK PAINT MAHARANI PAINTS 20 LTR

19 HR MATT AXIS GREY PAINT MAHARANI PAINTS 20 LTR

20 HR PRIMER THINNER MAHARANI PAINTS 40 LTR

21 HR THINNER 550 DEG. MAHARANI PAINTS 40 LTR

 PAGE : 02 OF 02

MINIMUM
SR. NO PAINT / CHEMICAL NAME SUPPLIER NAME
STOCK QTY.

22 EPOXY ZINC PHOSP.PRIMER CHEMICALS OF INDIA 24 LTR

23 PU S/G BLACK PAINT CHEMICALS OF INDIA 24 LTR

PAGAN PAINTS &
24 PAGAN CLEAN AL 124 50 KG
CHEMICALS
PAGAN PAINTS &
25 ALCHROME ELY
CHEMICALS 40 KG
PAGAN PAINTS &
26 PHOSPHATE 525
CHEMICALS 40 KG
PAGAN PAINTS &
27 PAGAN SCC
CHEMICALS 2 KG
PAGAN PAINTS &
28 PAGAN ACC
CHEMICALS 20 KG

29 NIPACEL GN 4704 NIPA CHEMICALS 25 KG

30 NIPAPHOS GN3020 M NIPA CHEMICALS 40 KG

31 NIPAPHOS GN3020 R NIPA CHEMICALS 40 KG

32 NIPAKLIN GN 4360 NIPA CHEMICALS 100 KG

33 NIPAFIN GN ZS NIPA CHEMICALS 40 KG

PREPARED BY: APPROVED BY:

 Doc.No :BR/FR/027

CALIBRATION PLAN Rev. : '00

Page : 1 of 1
Date :24/11/14

LAB
CALIBRATION CALIBRATION
SR. NO. NAME OF INSTRUMENT DATE CERTIFICATE NO. DUE DATE REMARKS

1 DFT METER 20.10.2014 NTS/G/L-8974 19.10.2015

2 BEND TESTER 20.10.2014 NTS/G/L-8980 19.10.2015

3 GLASS THERMOMETER 20.10.2014 NTS/G/L -8978 19.10.2015

4 WEIGHING BALANCE 22.10.2014 NTS/G/S-18341 21.10.2015

5 pH METER 20.10.2014 NTS/G/L-8975 19.10.2015

6 CONDUCTIVITY METER 20.10.2014 NTS/G/S-8976 19.10.2015

7 GLOSS METER 20.10.2014 NTS/G/L-8979 09.10.2015

8 FORD CUP 20.10.2014 NTS/G/L-8980 19.10.2015

9 TEMP. CONTROLLER (WATER BATH) 22.10.2014 NTS/G/S-18343 21.10.2015

10 TEMP. CONTROLLER (HUMIDITY CHAMBER) 22.10.2014 NTS/G/S-18342 21.10.2015

11 TEMP. CONTROLLER (OVEN) 22.10.2014 NTS/G/S-18344 21.10.2015

12 PENCIL HARDNER 20.10.2014 NTS/G/L -8977 19.10.2015

13 TEMP. CONTROLLER (SST) 22.10.2014 NTS/G/S-18375 21.10.2015

CED LINE
SR. NO. NAME OF INSTRUMENT CALIBRATION CERTIFICATE NO. CALIBRATION REMARKS
DATE DUE DATE
1 TEMP. CONTROLLER (HOT WATER) 22.10.2014 NTS/G/S-18348 21.10.2015

2 TEMP. CONTROLLER (KOD) 22.10.2014 NTS/G/S-18345 21.10.2015

3 TEMP. CONTROLLER (DEG.) 22.10.2014 NTS/G/S-18346 21.10.2015

4 TEMP. CONTROLLER (PHOSPHATE) 22.10.2014 NTS/G/S-18347 21.10.2015

5 TEMP. CONTROLLER (CED TANK) 22.10.2014 NTS/G/S-18356 21.10.2015

6 TEMP. CONTROLLER (OVEN) 22.10.2014 NTS/G/S-18376 21.10.2015

7 TEMP. CONTROLLER (OVEN) 22.10.2014 NTS/G/S-18377 21.10.2015

8 TEMP. CONTROLLER (OVEN) 22.10.2014 NTS/G/S-18378 21.10.2015

 PT LINE
CALIBRATION CALIBRATION
SR. NO. NAME OF INSTRUMENT DATE CERTIFICATE NO. DUE DATE REMARKS

1 TEMP. CONTROLLER (HOT WATER) 22.10.2014 NTS/G/S-18355 21.10.2015

2 TEMP. CONTROLLER (KOD) 22.10.2014 NTS/G/S-18354 21.10.2015

3 TEMP. CONTROLLER (DEG.) 22.10.2014 NTS/G/S-18353 21.10.2015

4 TEMP. CONTROLLER (PHOSPHATE) 22.10.2014 NTS/G/S-18352 21.10.2015

5 TEMP. CONTROLLER (AIR DRYER) 22.10.2014 NTS/G/S-18351 21.10.2015

HOT WATER GENERATOR

SR. NO. NAME OF INSTRUMENT CALIBRATION CERTIFICATE NO. CALIBRATION REMARKS
DATE DUE DATE
1 TEMP. CONTROLLER (HOT WATER GENERATOR) 22.10.2014 NTS/G/S-18349 21.10.2015

2 TEMP. CONTROLLER (HOT WATER GENERATOR) 22.10.2014 NTS/G/S-18350 21.10.2015

PAINT SHOP & POWDER COATING

SR. NO. NAME OF INSTRUMENT CALIBRATION CERTIFICATE NO. CALIBRATION REMARKS

DATE DUE DATE
1 TEMP. CONTROLLER (PAINT SHOP OVEN) 22.10.2014 NTS/G/S-18360 21.10.2015

2 TEMP. CONTROLLER (PAINT SHOP OVEN) 22.10.2014 NTS/G/S-18359 21.10.2015

3 TEMP. CONTROLLER (POWDER OVEN) 22.10.2014 NTS/G/S-18358 21.10.2015

4 TEMP. CONTROLLER (POWDER OVEN) 22.10.2014 NTS/G/S-18357 21.10.2015

PREPARED BY: APPROVED BY:

 Doc.No :BR/FR/028

TESTING SCHEDULE (LAB) Rev. : '00

Page : 1 of 1
BINOLA(GURGAON) Date :05/07/14

SR. NO. TEST METHOD/CHECKING AIDS RESPONSIBILITY FREQUENCY

1 DRY FILM THICKNESS DFT METER LAB SUPERVISOR 5 PCS. / LOT

2 ADHESION TEST CUTTER & ADHESION TAPE LAB SUPERVISOR 2 PCS. / LOT

3 PENCIL HARDNESS TEST PENCIL HARDNESS TESTER LAB SUPERVISOR 1 PC. / LOT

4 XYLENE TEST CLOTH & XYLENE LAB SUPERVISOR 1 PC. / LOT

AT THE TIME OF NEW BATCH OF

5 GLOSS TEST GLOSS METER LAB SUPERVISOR PAINT RECEIVED

AT THE TIME OF NEW BATCH OF

6 BEND TEST BEND TESTER LAB SUPERVISOR PAINT RECEIVED

AT THE TIME OF NEW BATCH OF

7 IMPACT TEST IMPACT TESTER LAB SUPERVISOR PAINT RECEIVED

8 GASOLINE RESISTANCE TEST GASOLINE LAB SUPERVISOR WEEKLY

9 ACID RESISTANCE TEST N/10 SULPHURIC ACID LAB SUPERVISOR WEEKLY

10 ALKALI RESISTANCE TEST N/10 SODIUM HYDROXIDE SOLUTION LAB SUPERVISOR WEEKLY

11 OIL RESISTANCE TEST 20W40 MOBIL OIL LAB SUPERVISOR WEEKLY

12 SALT SPRAY TEST SST CHAMBER LAB SUPERVISOR TWICE/MONTH

13 WATER RESISTANCE TEST HOT WATER CHAMBER LAB SUPERVISOR TWICE/MONTH

14 HUMIDITY RESISTANCE TEST HUMIDITY CHAMBER LAB SUPERVISOR TWICE/MONTH

15 HEAT AGING TEST LAB OVEN LAB SUPERVISOR TWICE/MONTH

16 RAPID WATER COOLING TEST LAB OVEN LAB SUPERVISOR TWICE/MONTH

PREPARED BY: APPROVED BY:

 Doc.No. : BR/FR/029
Rev. : '00
CRITICAL PROBLEM OF MONTH AND ITS ACTION PLAN Page : 1 of 1
BINOLA Date 10/01/13

SR. NO. MONTH PROBLEMS ACTION TAKEN REMARK

PREPARED BY: APPROVED BY:

 Doc.No. : BR/FR/030

PROCESS VALIDATION Rev. : '00

VILL-BINOLA,BHORA Page : 1 of 1
KHALLAN.GGN DATE : Date 10/01/13

SR. NO. PART NAME TANK NAME TEMP. POINTAGE RESULT REMARK

PREPARED BY: APPROVED BY:

 Doc.No. : BR/FR/031

HANGER VALIDATION Rev. : '00

VILL-BINOLA,BHORA Page : 1 of 1
KHALLAN.GGN MONTH : DATE : Date 10/11/2020

SR. NO. PART NAME PARTS PER DFT PAINT DRY RESULT REMARK
HANGER FLOW

PREPARED BY: APPROVED BY:

 No: BR/FR/032

VILL-BINOLA,BHORA
SST SAMPLEING PLAN Rev. : '02

Page : 1 of 1
KHALLAN.GGN
Date 09/08/13

SR. NO. COMPONENT NAME CUSTOMER 1ST WEEK 2nd WEEK 3rd WEEK 4th WEEK

BODY CYL. HEAD AAFB

1 BLACK ALICON

2 BODY CYL. HEAD KTRK ALICON

3 CRANK CASE KWAG SUNBEAM

4 SHOCKER MESL

5 BODY CYL HEAH AAFB SUNBEAM

SILVER

6 BODY CYL. HEAD KTRK SUNBEAM

7 CRANK CASE KTC SUNBEAM

8 MUFFLER GUARD SKH

BODY CYL. HEAD AAFB

9 ALICON
SILVER

10 BODY CYL. HEAD KZAA ALICON

PREPARED BY : APPROVED BY :
 No: BR/FR/033

HUMIDITY RESISTANCE TEST SAMPLING Rev. : '01

VILL-BINOLA,BHORA
KHALLAN.GGN
PLAN Page : 1 of 1

Date 10/11/13

SR. NO. COMPONENT NAME CUSTOMER 1ST WEEK 2nd WEEK 3rd WEEK 4th WEEK

1 HANDLE KVEA

2 BODY CYL. HEAD KSTG

3 HUB

4 PEDDAL BRAKE

5 HANDLE KWFG

6 MUFFLER GUARD

7 BODY CYL. HEAD KTRK

8 TENNECO SHOCKER

9 SHOCKER

10 CHAIN CASE

PREPARED BY : APPROVED BY :
 No: BR/FR/034

WATER RESISTANCE TEST SAMPLING Rev. : '01

VILL-BINOLA,BHORA
KHALLAN.GGN
PLAN Page : 1 of 1

Date 10/11/13

SR. NO. COMPONENT NAME CUSTOMER 1ST WEEK 2nd WEEK 3rd WEEK 4th WEEK

1 PADDLE BRAKE

2 BODY CYL. HEAD KSTG

3 MUFFLER GUARD

4 HANDLE KVEA

5 HANDLE KWFG

6 BODY CYL. HEAD KTRK

7 SHOCKER

8 CHAIN CASE

9 HUB

10 TENNECO SHOCKER

PREPARED BY : APPROVED BY :
 No: BR/FR/035

VILL-BINOLA,BHORA KHALLAN.GURGAON
BOOTH PREVENTIVE Rev. : '00
Page : 1 of 1
( HARYANA) Date 10/01/13

S NO. ACTIVITY 1ST WEEK 2ND WEEK 3RD WEEK 4TH WEEK 5TH WEEK

1 BOOTH FILTER CLINING

2 BOOTH SALAZ REMOVE
3 SCREEN CLINING & GREASING
4 BOOTH I,II,III INSIDE CLEANING
5 BUFFER PLATE CLINING
6 GRADING BURNING & CLINING
7 FLASH OF ZONE CLINING
8 TAG RAG BOOTH CLINING
9 OVEN CLEANING & MOPING
10 INDEXAL CLINING
11 BOOTH PAINTING INSIDE(WHITE
PAINT)
12 BOOTH FLASH OF ZONE,TAG RAG
BOOTH,FILTER CLINING
13 CONVEYOR OILING

LEGEND : DONE CHECKED BY :

NOT DONE
 No: BR/FR/036

VILL-BINOLA,BHORA
PROCESS VALIDATION PLAN Rev. : '00
Page : 1 of 1
KHALLAN.GGN
Date 10/02/14

SR. NO. COMPONENT NAME CUSTOMER PLANNING REMARK

MONTH

JAN
1 SHOCKER BWI

FEB
2 SHOCKER TENNECO

MAR
3 HUB SANDHAR

APR
4 BASE ASSEMBLY TENNECO

MAY
5 BODY CYL HEAD ALICON

JUNE
6 HANDLE OMAX

JUL
7 SHOCKER BWI

AUG
8 SHOCKER TENNECO

SEPT
9 HUB SANDHAR

OCT
10 BASE ASSEMBLY TENNECO

NOV
11 BODY CYL HEAD ALICON

DEC
12 HANDLE OMAX

REMARK: VALIDATION WILL DONE ON EVERY SIX MONTH.

PREPARED BY : APPROVED BY:
 Doc.No. : BR/FR/037

DAILY INSPECTION SHEET FOR PAINT ON PISTON ROD Rev. : '00

Page : 1 of 1
VILL-BINOLA,BHORA
KHALLAN.GGN
Date 14/08/13

TOTAL PARTS NO. OF PARTS WITH NAME & SIGN. OF

DATE PART NUMBER CHECKED OK PAINT ON PISTON ROD INSPECTOR REMARK

PREPARED BY: APPROVED BY:

 Doc.No. : BR/FR/038

DAILY PRODUCTION SHEET ( PT LINE ) Rev. : '00

Page : 1 of 1
VILL-BINOLA,BHORA
KHALLAN.GGN
Date 30/07/13

BALANCE QTY.
DATE SR.NO. PART NAME CUSTOMER PLAN. QTY. QTY. AFTER PT REMARK
(FOR PT)
PREPARED BY: VERIFIED BY:
 Doc.No. : BR/FR/039

PP & C - II SHEET Rev. : '00

VILL- Page : 1 of 1
BINOLA,BHORA
KHALLAN.GGN DATE : TIME : Date 25/09/13

AVAILABLE FOR AVAILABLE FOR AVAILABLE FOR REWORK CLEARANCE TARGET PRIORITY WISE
SR NO COMPONENT AVAILABLE FOR PT TOTAL REMARK
PAINTING REWORK STRIPPING
COMPONENT QTY.

PREPARED BY: APPROVED BY:

 Doc.No. BR/FR/005

Vill,Bhora kalan Gurgaon(H.R.) Rev. : '00

PART NAME :- PRODUCT TEST REPORT Rev.Date : …………

CUSTOMER :- Date:

LOT QTY :-

S.NO. PARAMETERS SPECIFICATION OBSERVATIONS REMARKS

No dry,dust, pin hole,blister,scratch,dent, orange peel

1 APPEARANCE & no any other visual defect

2 PAINT ADHESION 100/100 mm² (no paint peel off)

3 PAINT THICKNESS 50 µ min.

4 PAINT HARDNESS Min .H grade pencil

5 GLOSS @ 20° Min. 80 Unit

No excessive flaws,decresed gloss or colour gauze.

6 XYLENE RESISTANCE (rubbing by 08 times)

240 hrs min.

(no corrosive products,blisters- extending 2mm from
7 SALT SPRAY TEST the cut on each side)

120 hrs.. min

(no blisters,flaking,wrinkles,rust,excessive
8 HUMIDITY RESISTANCE TEST change in gloss or colour or softening of coating)

40°C X 120 HRS MIN.

(no
9 WATER RESISTANCE TEST blisters,flaking,cracks,wrinkles,rustexcessive changes
in colour or softening of coating)

7 HRS MIN.
10 GASOLINE RESISTANCE TEST (no blisters,cracks,wrinkles, peeling,change in colour
& gloss)

resistance to
discoloration due to
acids(colour
No excessive spot marks
difference)
SPOT RESISTANCE
11
TEST
resistance to
discoloration due to
gasoline(colour
No excessive spot marks
difference)

No crack or flaking @R.T. HEIGHT-20cm & wt. -

13 IMPACT RESISTANCE
500gm

14 BEND RESISTANCE No crack or flaking @R.T. STEM DIA -15mm.

CHECKED BY : VERIFIED BY :
 Doc.No. BR/FR/005

Vill,Bhora kalan Gurgaon(H.R.)

PRODUCT TEST REPORT Rev. : '00
PART NAME :-
(For Sample) Page : 1 of 1
CUSTOMER :- Date :20.02.2011
S.NO TEST/ PARAMETERS Sample -1 Sample -2 Sample -3 Sample -4 Sample -5 Sample -6 Sample -7 Sample -8 Sample -9 Actual status REMARKS

Appearance (SHALL BE FREE FROM PIN

1 HOLE, DUST, SCRATCH, EXPOSED
SURFACE, BLISTER, WRINKLES & ORANGE
PEEL)

2
Color As Per Master Shade (VISUAL
MATCHING)

3 Dry Film Thickness

4 Adhesion (1x1 mm SQUARE BY KNIFE &

ADHESIVE TAPE)

5 Pencil Hardness (F / H)

6 Gloss Test @ 60˚

7 Xylene Resistance test (8 RUBBINGS

WITH COTTON MOISTENED WITH XYLENE.)

Gasoline Resistance (DIPPING OF

8 HALF PORTION OF PANEL IN PETROL BATH
AT ROOM TEMP.)

9 Salt Spray Test (SALT SPRAY CHAMBER

OF TEMP.35±2˚,5%NaCl)

Water Resistance ( TO DIP HALF

10 PORTION OF A PANEL IN A WATER BATH OF
TEMP. 38-42˚C )

Humidity Resistance (HUMIDITY

11 CHAMBER TEMP.50±2˚C & HUMIDITY MORE
THAN 95 RH )

Heating Test (TO HEAT THE PAINTED

12 COMPONENT IN A CONVECTION OVEN AT
250˚C)

CHECKED BY :- VERIFIED BY :-
 Doc.No. BR/FR/041

HOURLY LOADING REPORT (PAINT SHOP) Rev. : '02

Page : 1 of 1
BINOLA DATE : SHIFT : Date :09/10/2013

SR. NO. TIME COMPONENT NAME LOADING QTY. OK REJECT NO. OF HANGERS REASON FOR LESS LOADING

10

11

12

P/SHOP DOWN TIME -

HANGER GAP -

POWER OFF -

SUPERVISOR SIGN.
 Doc.No. BR/FR/040
Rev. : '02
REWORK CLEARANCE ACTION PLAN Page : 1 of 1
BINOLA Date :07/10/2013

PLAN FOR SANDING SANDING DONE

SR. NO. DATE SHOCKER ( BWI & SHOCKER ( BWI & REMARKS
SASH QTY SASH QTY
TENNECO) QTY. TENNECO) QTY.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

PREPARED BY : APPROVED BY :
 MAN POWER REQUIREMENT
ATTENDANCE REPORT
SR. NO NAME AREA 22.10.2013 23.10.2013 24.10.2013 25.10.2013 26.10.2013
1 PAWAN PT LINE
2 MANKESHWAR PT LINE
3 JITENDER PT LINE
4 SANJEEV PT LINE

1 DHARMENDER MASKING
2 SIKENDER MASKING
3 RAMAKANT MASKING
4 RAKESH MASKING
LIQUID LINE
1 RAMU HANGER
2 MANDEEP LOADING
3 KARTAR LOADING
4 MAHESH LOADING
5 MANJAY AIR
6 RAJPAL TAG RAG
7 AJAY PASWAN PAINTER
8 RAVIENDER PAINTER
9 PYARE LAL PAINTER
10 DINESH PAINTER
11 PRAMOD PAINTER
12 VIKRAM PAINTER
13 SATISH PAINTER
14 SASHI BHUSAN UNLOADING
15 VINOD INSPECTION
16 OMBIR INSPECTION
17 AMIT POLISH
18 UPENDER PACKING
19 PUSPENDER PACKING

1 SHAKTI POWDER
2 RATAN POWDER
3 PAWAN POWDER
4 AKHILESH POWDER
5 RAJESH POWDER
6 AJIT POWDER
7 LALU POWDER
8 MUKESH POWDER
1 GANGA MANDAL PISTON ROD
2 BRIJBHAN PISTON ROD

1 MONU DISPATCH
QUIREMENT
REPORT
27.10.2013 28.10.2013 29.10.2013 30.10.2013 31.10.2013 REMARKS

1
 Doc.No. BR/FR/041
Rev. : '02
TEMP. VARIANCE CHECK SHEET (PT LINE) Page : 1 of 1
BINOLA Date :21/10/2013

TEMP. CONTROLLER THERMOMETER

SR. NO. DATE TANK NAME DISPLAY READING READING VARIANCE REMARKS

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

CHECKED BY : VERIFIED BY :
 DOC. NO. : BR/FR/043
PDI REPORT REV. NO. : 001

REV. DATE : 20.11.2013

PART NAME
PART NO.
CUSTOMER
MODEL
LOT QTY.
DATE
S.NO
PARAMETERS SPECIFICATION OBSERVATIONS REMARKS
.

no dust,dry,paint
1 APPEARANCE flow,dent,scratch,cissing,blister
& any other visual defect

100/100 mm² (no paint peel

2 PAINT ADHESION
off)

3 PAINT THICKNESS 40~60µ ( 5 pcs at 5 location )

no excessive flaws,decresed
4 XYLENE RESISTANCE gloss or colour gauze.(rubbing
by 08 times)

5 PAINT HARDNESS > HB grade pencil

REMARKS:
CHECKED BY VERIFIED BY :
 PDI REPORT
DOC. NO. : BR/FR/043

REV. NO. : 001

REV. DATE : 20.11.2013

PART NAME

PART NO.

CUSTOMER

MODEL

LOT QTY.

DATE

S.NO. PARAMETERS SPECIFICATION OBSERVATIONS REMARKS

no dust,dry,paint
flow,dent,scratch,cissing,blister,
1 APPEARANCE
orange peel,pin hole & any
other visual defect

2 PAINT ADHESION 100/100 mm² (no paint peel off)

25 - 35µ (5 pieces at 5
3 PAINT THICKNESS
locations)

no excessive flaws,decresed
XYLENE
4 RESISTANCE
gloss or colour gauze.(rubbing
by 08 times)

5 PAINT HARDNESS > HB grade pencil

REMARKS:

CHECKED BY: VERIFIED BY :

 DOC. NO. : BR/FR/043
PDI REPORT REV. NO. : 001

REV. DATE : 20.11.2013

PART NAME

PART NO.

CUSTOMER

MODEL

LOT QTY.

DATE

S.NO. PARAMETERS SPECIFICATION OBSERVATIONS REMARKS

no dust,dry,paint
1 APPEARANCE flow,dent,scratch,cissing,blister
& any other visual defect

2 PAINT ADHESION 100/100 mm² (no paint peel off)

3 PAINT THICKNESS 80µ min(5 pcs at 5 location)

no excessive flaws,decresed
XYLENE
4 RESISTANCE
gloss or colour gauze.(rubbing
by 08 times)

5 PAINT HARDNESS > HB grade pencil

REMARKS:

CHECKED BY: VERIFIED BY :

 PRODUCT TEST REPORT DOC. NO. : BR/FR/005
REV. NO. : 001
REV. DATE : 14.09.2013
DISPOSITION
PART NAME

PART NO. SHADE -

VENDOR
MODEL
LOT QTY.
DATE
STANDARD SURFACE TREATMENT AS PER HES D--2023 CLASS--2 GRADE --2
S.NO. PARAMETERS SPECIFICATION OBSERVATIONS REMARKS

1 APPEARANCE no visual defects

2 PAINT ADHESION 100/100 mm² (no paint peel off)

3 PAINT THICKNESS 50~60µ (to achieved after heat aging dft loss - 40 µ min.)

4 PAINT HARDNESS > HB grade pencil

5 SPECULAR GLOSS ON PANEL shall be equivalent to approved panel

6 PRINT RESISTANCE ON PANEL 70°CX2HRS. - no excessive tackiness or cloth marks

7 XYLENE RESISTANCE no excessive flaws,decresed gloss or colour gauze.(rubbing by 08 times)

no blisters,flaking,excessive clouding,change in gloss or colour, or softening

8 OIL RESISTANCE of coating (dip 7 hrs.)

9 WEATHER RESISTANCE ON PANEL 600 HRS. @ 0.55 watt/m2 irradation for grey scale 4 min.

10 VOLATILE RESISTANCE no blisters,cracks or flaking (DIP-0.5 hrs )

48 hrs min. (no corrosive

products,blisters- extending 2mm from the cut on each side)
11 SALT SPRAY TEST

40°C X 24 HRS MIN. (no

12 WATER RESISTANCE TEST blisters,flaking,cracks,wrinkles,rustexcessive changes in colour or softening
of coating)

resistance to discoloration due to

alkalis(colour difference)
NO EXCESSIOVE SPOT MARKS(except for roofing type silver)

SPOT resistance to discoloration due to

13 NO EXCESSIOVE SPOT MARKS(except for roofing type silver)
RESIST. acids(colour difference)

resistance to discoloration due to

gasoline(colour difference) NO EXCESSIOVE SPOT MARKS(except for roofing type silver)

48 hrs.. min (no

14 HUMIDITY RESISTANCE TEST blisters,flaking,wrinkles,rust,excessive change in gloss or colour or softening
of coating)

IMPACT RESISTANCE
15 no crack or flaking @R.T. HEIGHT-20cm & wt. - 500gm REF. S.M.PANEL
(APLICABLE ON PANEL) not in HES

BEND RESISTANCE
16 no crack or flaking @R.T. STEM DIA -15mm. REF. S.M. PANEL
(APLICABLE ON PANEL) not in HES
17 AFTER HEAT AGING @ 250°C X05 HRS OR 200 HRS TESTS
A APPEARANCE no bubbles cracks blisters flakes change in gloss decrease in gloss
B GLOSS RETENTION no execessive decrease gloss
C COATING ADHESION 100/100 mm² ( paint peel of )
IMPACT RESISTANCE (APLICABLE no cracks or flanking @ R .T \. Height 10 cm &wt. 500gm Ref. S.M. panel
ON PANEL) not in HES
D
48 hrs min. (no corrosive
products,blisters- extending 2mm from the cut on each side)
E SALT SPRAY TEST

F VOLATILE RESISTANCE no blister cracks and flanking (dip 0.5 hrs)

18 RAPID WATER COOLING TEST 03 CYCLES @250°C X03 HRS. ( EACH )
A APPEARANCE no bubbles cracks blisters flakes change in gloss decrease in gloss
B COATING ADHESION 100/100 mm² (no paint peel off )
19 DFT LOSS %age AGTER HEAT AGING @250°C X 05 HRS OR 200 HRS TESTS
A DFT LOSS %age NOT IN HES <20 %
 DOC. NO. : BR/FR/043
PDI REPORT REV. NO. : 001

REV. DATE : 20.11.2020

PART NAME
PART NO.
CUSTOMER
MODEL
LOT QTY.
DATE

S.NO. PARAMETERS SPECIFICATION OBSERVATIONS REMARKS

no dust,dry,paint
1 APPEARANCE flow,dent,scratch,cissing,blister
& any other visual defect

100/100 mm² (no paint peel

2 PAINT ADHESION
off)

40~60µ (to achieved after heat

3 PAINT THICKNESS
aging dft loss - 20 µ min.)

no excessive flaws,decresed
4 XYLENE RESISTANCE gloss or colour gauze.(rubbing
by 08 times)

5 PAINT HARDNESS > HB grade pencil

REMARKS:

CHECKED BY: VERIFIED BY :

 DOC. NO. :

ALODINE PDI REPORT BR/FR/043

REV. NO. : 001

REV. DATE :
20.11.2013

PART NAME
PART NO.
CUSTOMER
MODEL
LOT QTY:
DATE :

Sample OBSERVATIONS
no ITEM SPECIFICATIONS REMARKS

2
Shade compare
to limit
sample ,no
APPEARAN dust ,dent
3 CE scratch,
damage, & any
other visual
defect.
4

3 oxidation Surface

CHECKED BY : APPROVED BY
 Doc.No. : BR/FR/045

VILL-
INCOMING PAINT CHECK SHEET Rev. : '00
Page : 1 of 1
BINOLA,BHORA
KHALLAN.GGN Date 10/01/14

SUPPLY VISCOSITY NVM % DISPOSITION

DATE PAINT NAME / SUPPLIER BATCH NO. APPLY THINNER SHADE ADHESION XYLENE
VISCOSITY INTAKE %
SPECIFIED OBSERVED SPECIFIED OBSERVED OK \ NG
CHECKED BY : VERIFIED BY:
 Doc.No. : BR/FR/070

VILL-BINOLA,BHORA
INCOMING POWDER CHECK SHEET Rev. : '00
Page : 1 of 1
KHALLAN.GGN
Date 10/05/15

DISPOSITION
DATE POWDER NAME SUPPLIER BATCH NO. EXP. DATE SHADE ADHESION XYLENE
OK \ NG
CHECKED BY : VERIFIED BY:
 Doc.No. BR/FR/013

PAINTING PROCESS CHECK SHEET Rev. : '02

Page : 1 of 1

BINOLA DATE : TIME Date :07/03/2014

S.NO. CHECK POINT SPECIFICATION

MAKE

BATCH NO./MFG

EXP. DATE

PAINT DELIVERY

VISCOSITY @ 30 oC

AIR PRESSURE OF
GUN
AIR PRESSURE OF
PUMP
1 PRIMER
ELECTROSTATIC GUN
CHARGING
KVACURRENT
BOOTH TEMP. 25 - 32 oC

55-75 RH%
BOOTH HUMIDITY
LUX VALUE > 500 ON HANGER

SHOULD BE POSITIVE BY ON
BOOTH BALANCING LINE THREAD

NO. OF OPERATORS 2 NOS. + 1 RELIVER / SHIFT

MAKE

SHADE

BATCH NO./MFG

EXP. DATE

PAINT DELIVERY

VISCOSITY @ 30 oC

AIR PRESSURE OF
GUN
2 PAINT
AIR PRESSURE OF
PUMP
ELECTROSTATIC GUN
CHARGING
KVACURRENT
BOOTH TEMP. 25 - 32 oC

BOOTH HUMIDITY 55-75 RH%

LUX VALUE > 500 ON HANGER

SHOULD BE POSITIVE BY ON
BOOTH BALANCING LINE THREAD

NO. OF OPERATORS 2 NOS. + 1 RELIVER / SHIFT

3 BAKING TEMP.

4 CONVEYOR SPEED 1.0 METER/MIN.

CHECKED BY : VERIFIED BY :
 Doc.No. : BR/FR/047

LIST OF CRITICAL SPARE PARTS Rev. : '00

Page : 1 of 1
VILL-BINOLA,BHORA
KHALLAN.GGN
Date 14/09/13

SR. NO. PART NAME PART PART IN STOCK MIN. STOCK QTY REMARK
SPECIFICATION REQUIRED

1 Proximity sensor

2 Relay

3 contector

4 Contector

5 MCB

6 O/ L relay

7 O/ L relay

8 MCB

9 Limit swtich

10 ON push

11 OFF push botton

12 T# Hosting moter

13 T# Traversing moter

14 Traversing Guide Bearing

15 T# Traversing Wheel

16 T# Hosting Wheel

17 Power Supply

18 Temperture controler

19 Thermocople

20 Star cuppling paint shop

21 Star spider paint shop

22 Star cuppling Compressure

23 Star spider Compressure

24 Water circulation pump

25
Blower moter
26 Conveyer moter
27

28

29
PREPARED BY: APPROVED BY:
 Doc.No. : BR/FR/058

BREAK DOWN REGISTER (MAINTENANCE) Rev. : '00

Page : 1 of 1
VILL-BINOLA,BHORA
KHALLAN.GGN
Date 14/09/13

ACTUAL TOTAL
MACHINE NATURE OF SPAREPARTS ATTENDED COMPLETION
DATE & TIME DESCRIPTION COMPLAINT CAUSE PROBLEM(BREAK ACTION TAKEN USED BY DATE & TIME TIME REMARK
DOWN DESCRIPTION) TAKEN

PREPARED BY: APPROVED BY:

 Doc.No. : BR/FR/049

BREAK DOWN REPORT / ANALYSIS Rev. : '00

Page : 1 of 1
VILL-BINOLA,BHORA
KHALLAN.GGN
Date 14/09/13

TIME
MACHINE TOTAL DOWN REASON FOR REOCCURANCE OF FAULT /
SR. NO. DATE NATURE OF COMPLAINT B/DOWN SPARE USED
DESCRIPTION B/DOWN TIME OTHER REMARKS
CLOSED
PREPARED BY: APPROVED BY:
 Doc.No. BR/FR/050

LIST OF HMCL PARTS & PROCESS Rev. : '00

Page : 1 of 1
BINOLA Date :26/06/2014

PROCESS (LIQUID,POWDER OR
SR. NO. PART NAME CUSTOMER CED) SHADE REMARKS

1 BODY CYL HEAD KSTG M/S ALICON LIQUID PAINTING HR 108-25 BLACK

2 BODY CYL HEAD KTRK M/S ALICON LIQUID PAINTING HR MATT AXIS GREY

3 BODY CYL HEAD KZAA M/S ALICON LIQUID PAINTING HR NH 1 BLACK

4 BODY CYL HEAD AAFB M/S ALICON LIQUID PAINTING HR 108-25 BLACK

5 BODY CYL HEAD AAFB M/S ALICON LIQUID PAINTING HR TOUGH SILVER

6 BODY CYL HEAD KTRK M/S SUNBEAM LIQUID PAINTING HR MATT AXIS GREY

7 BODY CYL HEAD AAFB M/S SUNBEAM LIQUID PAINTING HR 108-25 BLACK

8 BODY CYL HEAD AAFB M/S SUNBEAM LIQUID PAINTING HR TOUGH SILVER

9 CRANK CASE KWAG M/S SUNBEAM LIQUID PAINTING NH 1 BLACK

10 CRANK CASE KTC M/S SUNBEAM LIQUID PAINTING TSA MAT AXIS GREY

PREPARED BY : VERIFIED BY :
 Doc.No. BR/FR/051
Rev. : '00
INTERNAL PROCESS AUDIT PLAN Page : 1 of 1
BINOLA Date :26/06/2014
ACTUAL
SR. NO. PLAN OF PROCESS AUDIT REMARKS
AUDIT DONE ( ) AUDIT NOT DONE ( X )

1 JAN. 2014

2 FEB. 2014

3 MAR. 2014

4 APR. 2014

5 MAY. 2014

6 JUN. 2014

7 JULY. 2014

8 AUG. 2014

9 SEPT. 2014

10 OCT. 2014

11 NOV. 2014

12 DEC. 2014

PREPARED BY : VERIFIED BY :
 Doc.No. BR/FR/052
HANGER CONDITION MONITORING SHEET Rev. : 03
Page : 1 of 1
BINOLA Date :26/06/2014
MONTH :
DATE
S.NO. DISCRIPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
NO. OF NG
HANGERS

1
HANGER PAINT
CLEANING
NO. OF NG
HANGERS

2 DIMENSION
NO. OF NG
HANGERS

3 BEND
NO. OF NG
HANGERS

4 DAMAGE
NO. OF NG
HANGERS

5 BROKEN HANGER

TOTAL CHECKED QTY. 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170 170

TOTAL NG QTY.

MAINTENANCE SUP.
SIGNATURE
PROD. SUP.

REMARKS

Prepared By- Mr.Mukesh Maurya Approved BY- Mr. T.N. Dubey

 Doc.No. : BR/FR/053

ANNUAL TRAINING PLAN V/s ACHIEVEMENT Rev. : '01

Page : 1 of 1
VILL-BINOLA,BHORA
KHALLAN.GGN
Date 17/12/2018

MONTH

JUNE.2019
MAR.2016

SEPT.2019
MAY.2019

NOV.2019
AUG.2019

OCT.2019
APR.2019

DEC.2019
JAN.2019

FEB.2019

JUL.2019
SR. NO. TOPIC FACULITY REMARKS

1 BASIC KNOWLEDGE OF PAINTSHOP MR.LOVELESH

KNOWLEDGE OF LOADING,
2 UNLOADING,MASKING,PAINTING MR.PRASHANT
ETC.

3 QUALITY CONTROL MR.TN.DUBEY

4 REJECTION HANDLING MR.ROHIT

5 SAFETY MR.PAWAN

6 COMPONENT DEFECTS MR.ROHIT

LEGEND: PLANNED - ACHIEVED :

PREPARED BY :ROHIT APPROVED BY : Mr.TN.Dubey

 Doc.No. : BR/FR/054

VILL-
PROCESS VALIDATION PLAN Rev. : '01
Page : 1 of 1
BINOLA,BHORA
KHALLAN.GGN Date 07/09/14

MONTH

JUNE.2015
MAR.2015

SEPT.2015
MAY.2015

NOV.2015
AUG.2015

OCT.2015
APR.2015

DEC.2015
JAN.2015

FEB.2015

JUL.2015
SR. NO. COMPONENT NAME MODEL CUSTOMER REMARKS

1 SHOCKER ALTO BWI

DOMESTIC

2 BODY CYL. HEAD KTRK ALICON

3 BODY CYL. HEAD AAFB SILVER ALICON

4 CRANK CASE KTC SUNBEAM

5 BODY CYL. HEAD AAFB BLACK ALICON

6 CRANK CASE KWAG SUNBEAM

LEGEND: PLANNED -
ACHIEVED -
PREPARED BY : APPROVED BY :
 Doc.No. : BR/FR/055

VILL-
ANNUAL INTERNAL AUDIT PLAN Rev. : '00
Page : 1 of 1
BINOLA,BHORA
KHALLAN.GGN Date 07/07/14

MONTH

JUNE.2015
MAR.2015

SEPT.2015
MAY.2015

NOV.2015
AUG.2015

OCT.2015
APR.2015

DEC.2015
JAN.2015

FEB.2015

JUL.2015
SR. NO. SECTION REMARKS

1 PAINT SHOP

2 CED LINE

3 POWDER COATING

LEGEND: PLANNED -
ACHIEVED -

PREPARED BY : APPROVED BY :
 Doc.No. : BR/FR/056

CHECK SHEET OF LIQUID PAINTED PARTS (PDI STAGE) Rev. : '01

VILL- Page : 1 of 1
BINOLA,BHORA
KHALLAN.GGN MONTH : Date 07/07/14

DATE
SR. NO. COMPONENT NAME MODEL CUSTOMER FREQ. REMARKS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

ALTO
1 SHOCKER DOMESTIC
BWI DAILY

2 BODY CYL. HEAD KTRK ALICON DAILY

AAFB
3 BODY CYL. HEAD SILVER ALICON DAILY

4 SHOCKER CLUB CAR TENNECO DAILY

5 BODY CYL. HEAD AAFB BLACK ALICON DAILY

AAFB
6 BODY CYL. HEAD SILVER
SUNBEAM DAILY

7 BODY CYL. HEAD AAFB BLACK SUNBEAM DAILY

8 CRANK CASE KTC SUNBEAM DAILY

9 CRANK CASE KWAG SUNBEAM DAILY

10 BODY CYL. HEAD KTRK SUNBEAM DAILY

LEGENDS: A - SHADE, B - DUST, C - DRY, D- OVER FLOW, E - ORANGE PEEL, F - WATER MARKS, G - BLISTERS, H - DENT & SCRATCH, I - PAINT CHIPOFF, J - PAINT INSIDE MASKING AREA, K - LESS DFT, L - HIGH DFT

M - POOR XYLENE, N - OTHER PROBLEM

NOTE : SAMPLING WILL BE DONE AS PER SAMPLING PLAN

PREPARED BY : APPROVED BY :
 Doc.No. : BR/FR/058

FRESH DM WATER CHECK SHEET Doc.No. : BR/FR/059

Page : 1 of 1
MONTH : Date :18/07/14
PARAMETER SPEC TIME 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

10:00 AM

PH 6.5 - 7.5

6:00 PM

10:00 AM

CONDUCTIVITY 0.0 - 5.0

6:00 PM

10:00 AM

CLORIDE NIL

6:00 PM

CHECKED BY

VERIFIED BY :
 Doc.No. : BR/FR/059
DM WATER CONSUMPTION Rev. : '00
RECORDING SHEET Page : 1 of 1
Date :29/07/14
DM WATER USED
DATE REMARKS
PT LINE CED LINE

NOTE : DM WATER PLANT CAPACITY - 600 LTR. PER HOUR & 300000 LTR. PER CHARGING
PREPARED BY APPROVED BY :
 Doc.No. : BR/FR/060

LIQUID LINE PRODUCTION v/s PAINT CONSUMPTION Rev. : '00

Page : 1 of 1
VILL-BINOLA,BHORA KHALLAN.GGN
Date 06/08/2014

Sr. No. Paint / Primer Name Opening Issue Qty Total Qty. Balance Paint Total Consumption Remarks
Stock Qty. Consumed Production per Piece

1 HR BLACK (ALICON/SUNBEAM) TOTAL QTY : OK : REJ :

A PRIMER

B THINNER

C PAINT

2 HR MATT AXIS GREY (ALICON/SUNBEAM) TOTAL QTY : OK : REJ :

A PRIMER

B THINNER

C PAINT

3 HR NH 1 BLACK (ALICON) TOTAL QTY : OK : REJ :

A PRIMER

B THINNER

C PAINT

4 HR SILVER (ALICON/SUNBEAM) TOTAL QTY : OK : REJ :

A PAINT

B THINNER

5 B/C SILVER (SANDHAR) TOTAL QTY : OK : REJ :

A PRIMER

B THINNER

C PAINT

6 ENAMEL BLACK (BWI/TENNECO) TOTAL QTY : OK : REJ :

A PRIMER

B THINNER

C PAINT
PREPARED BY: VERIFIED BY :
 Doc.No. : BR/FR/061

DAILY PAINT PREPARATION SHEET Rev. : '00

Page : 1 of 1
VILL-BINOLA,BHORA KHALLAN.GGN
Date 08/08/2014

VERIFIED BY
TYPE & SHADE OF QTY PAINT THINNER APPLICATION
DATE TIME PREPARED BY REMARKS
PAINT/PRIMER PREPARED USED USED VISCOSITY
PRODUCTION QUALITY

PREPARED BY: APPROVED BY :

 QUALITY DOCUMENT LIST
1 DAILY PROCESS MONITORING SHEET (P.T LINE)
2 DAILY PROCESS MONITORING SHEET (C.E.D)
3 DAILY PROCESS CHECK SHEET (LIQUID PAINTING)
4 DAILY PRODUCT CHECK SHEET FOR LIQUID PAINTING
5 DAILY PRODUCT CHECK SHEET FOR C.E.D COATING
6 DAILY PRODUCT CHECK SHEET FOR POWDER COATING
7 OIL CONTENT CHECK SHEET
8 SALT SPRAY TESTING REPORTS
9 HUMIDITY TESTING REPORTS
10 WATER RESISTANCE TESTING REPORTS
11 FOG COLLECTION CHECK SHEET
12 ON JOB TRAINING RECORD
13 LUX VALUE CHECK SHEET
14 INCOMING INSPECTION SHEET
15 ALL LAB TESTING REPORTS
16 PERAMETER SHEET FOR SST,HUMIDITY & WATER RESISTANCE
17 P.T & CED LINE CLEANING CHECK SHEET
18 BOOTH PREVENTIVE CHECK SHEET
19 CUSTOMER COMPLAINTS RECORD
20 INCOMING PARS INSPECTION SHEET
21 INCOMING PAINT TESTING RECORD
22 PROCESS VALIDATION RECORD
23 INTERNAL AUDIT RECORD
24 HANGER MAINT CHECK SHEET FOR BODY CYL HEAD
25 FRESH DM WATER CHECK SHEET
26 CALIBRATION PLAN
27 DAILY REJECTION RECORD
 Doc.No. :BR/FR/039

DAILY PLANT RUNNING HISTORY Rev. : '00

VILL-BHORA,
KHALAN.GURGAON
(P.T.LINE, C.E.D.LINE,POWDER LINE) Page : 1 of 1
Date : 30.07.2014
P.T. LINE C.E.D. LINE POWDER LINE
SL.
NO. DATE ON OFF RUNNING ON TIME OFF RUNNING ON TIME OFF RUNNING REMARKS
TIME TIME TIME TIME TIME TIME TIME

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31
 PRODUCT TEST REPORT DOC. NO. : BR/FR/005
REV. NO. : 00
DATE : 10.07.2014

DISPOSITION
PART NAME

PART NO. SHADE -

VENDOR

MODEL

LOT QTY.
DATE
STANDARD SURFACE TREATMENT AS PER HES D--2016 CLASS--2 GRADE --2
S.NO. PARAMETERS SPECIFICATION OBSERVATIONS REMARKS

1 APPEARANCE no visual defects etc.

2 PAINT ADHESION 100/100 mm² (no paint peel off)

3 PAINT THICKNESS > 50 µ MIN

4 PAINT HARDNESS > F grade pencil

no excessive flaws,decresed gloss or colour gauze.(rubbing by 08

5 XYLENE RESISTANCE times)

no blisters,cracks or flaking or excessive change in gloss etc. (DIP-

6 VOLATILE RESISTANCE 7 hrs )

48 hrs min. (no

corrosive products,blisters- extending 2mm from the cut on each
7 SALT SPRAY TEST side)

48 hrs.. min (no

8 HUMIDITY RESISTANCE TEST blisters,flaking,wrinkles,rust,excessive change in gloss or colour or
softening of coating)

40°C X 24 HRS MIN. (no

9 WATER RESISTANCE TEST blisters,flaking,cracks,wrinkles,rustexcessive changes in colour or
softening of coating)

resistance to discoloration due to

water(colour difference)
NO EXCESSIOVE SPOT MARKS

resistance to discoloration due to

alkalis(colour difference)
NO EXCESSIOVE SPOT MARKS
SPOT
10 RESIST.
ON PANEL resistance to discoloration due to
acids(colour difference) NO EXCESSIOVE SPOT MARKS

resistance to discoloration due to

gasoline(colour difference) NO EXCESSIOVE SPOT MARKS

gloss coating >72/with clear coating >80/matt coating shall be

11 SPECULAR GLOSS ON PANEL equivalent to the approved plate

colour difference due to baking cycles no colour difference,difference in specular gloss shall be within 3
COLOUR
12 RETENTION
ON PANEL colour difference due to temperature
no colour difference (slight colour difference is allowed if restored
quickly )

13 POLISHING RESISTANCE ( 8 TIMES ) no excessive change in colour,specular gloss or appearance

14 PRINT RESISTANCE ON PANEL 70°CX2HRS. - no excessive tackiness or cloth marks

IMPACT RESISTANCE NOT IN HES ON

15 no crack or flaking @R.T. HEIGHT-20cm & wt. - 500gm
PANEL REF. S.M. PANEL

BEND RESISTANCE NOT IN HES ON

16 no crack or flaking @R.T. STEM DIA -20mm.
PANEL REF. S.M. PANEL

RECOAT PERFORMANCE TEST ON

17 100/100 mm² (no paint peel off) ON PANEL
PANEL ( sanding / non-sanding )

18 WEATHER RESISTANCE ON PANEL 600 HRS. @ 0.55 watt/m2 irradation for grey scale 4 min.

REMARKS:

CHECKED BY: VERIFIED BY :

 Doc.No. BR/FR/062

POWDER COATING PROCESS CHECK SHEET Rev. : '00

Page : 1 of 1

BINOLA DATE : 20.07.2014

TIME
S.NO. CHECK POINT SPECIFICATION REMARKS
8:00AM 10:00AM 12:00PM 2:00PM 4:00PM 6:00PM 8:00PM

MAKE

BATCH NO./MFG

EXP. DATE

POWDER FLOW 100 ~ 200 GM/MIN

1 POWDER

AIR PRESSURE OF
GUN 2.5 ~ 3.5 KG/CM2

ELECTROSTATIC GUN 60 ~ 90 KV (FOR FRESH

PARTS) & 30 ~ 40KV (FOR
CHARGING
REWORK PARTS)

LUX VALUE > 500 ON HANGER

NO. OF OPERATORS 2 NOS. + 1 RELIVER / SHIFT

2 BAKING TEMP. SET TEMP. 180-190oC

3 CONVEYOR SPEED 1.0 METER/MIN.

4 CHECKED BY

5 VERIFIED BY
 Doc.No. : BR/FR/055

VILL-BINOLA,BHORA
HANGER MAINTENANCE PLAN Rev. : '01
Page : 1 of 2
KHALLAN.GGN
Date 20/12/2014

MONTH
JANUARY FEBRUARY MARCH APRIL MAY JUNE
SR. NO. PART NAME REMARKS

2nd week

2nd week

2nd week

2nd week

2nd week

2nd week
3rd week

3rd week

3rd week

3rd week

3rd week

3rd week
4th week

4th week

4th week

4th week

4th week

4th week
1st week

1st week

1st week

1st week

1st week

1st week
1 CYL HEAD

2 SHOCKER

3 CRANK CASE

LEGEND: PLANNED -
ACHIEVED -

PREPARED BY : APPROVED BY :
 Doc.No. BR/FR/064

PRODUCT SPECIFICATION (PAINT SHOP) Rev. : '00

Page : 1 of 1
BINOLA Date :26/10/2014

SR. NO. PART NAME CUSTOMER PRIMER NAME PAINT NAME LACQUER NAME BAKING TEMP. DFT (MICRONS) REMARKS

HR NH-108-25 BLACK HR NH 108-25 BLACK

1 BODY CYL HEAD KSTG BLACK M/S ALICON PRIMER PAINT …… 220 - 225oC 50 - 60 MICRONS

HR NH-108-25 BLACK
2 BODY CYL HEAD KTRK M/S ALICON HR MATT AXIS GREY …… 220 - 225oC 50 - 60 MICRONS
PRIMER

HR NH-108-25 BLACK
3 BODY CYL HEAD KZAA M/S ALICON PRIMER HR NH-1 BLACK PAINT …… 220 - 225oC 50 - 60 MICRONS

HR NH-108-25 BLACK HR NH 108-25 BLACK

4 BODY CYL HEAD AAFB BLACK M/S ALICON PRIMER PAINT …… 220 - 225oC 50 - 60 MICRONS

HR TOUGH SILVER
5 BODY CYL HEAD AAFB SILVER M/S ALICON …….. …… 220 - 225oC 25 - 35 MICRONS
PAINT

HR NH-108-25 BLACK
6 BODY CYL HEAD KTRK M/S SUNBEAM
PRIMER
HR MATT AXIS GREY …… 220 - 225oC 50 - 60 MICRONS

HR NH-108-25 BLACK HR NH 108-25 BLACK

7 BODY CYL HEAD AAFB BLACK M/S SUNBEAM
PRIMER PAINT
…… 220 - 225oC 50 - 60 MICRONS

HR TOUGH SILVER
8 BODY CYL HEAD AAFB SILVER M/S SUNBEAM ……… …… 220 - 225oC 25 - 35 MICRONS
PAINT

ANTICORROSIVE
STOVING NH-1 BLACK
9 CRANK CASE KWAG M/S SUNBEAM EPOXY PRIMER DARK
PAINT
…… 145 - 150oC 40 - 60 MICRONS
GREY

ANTICORROSIVE
10 CRANK CASE KTC M/S SUNBEAM EPOXY PRIMER DARK TSA MATT AXIS GREY TSA MATT CLEAR 145 - 150oC 40 - 60 MICRONS
GREY

PREPARED BY : VERIFIED BY :
 Doc.No. : BR/FR/065
Rev. : '00
DAILY REJECT PARTS MONITORING SHEET Page : 1 of 1
BINOLA Date 18/02/15

SR. NO. DATE PART NAME CUSTOMER REJECT QUANTITY REASON FOR REJECTION REMARK
PREPARED BY: APPROVED BY:
 Doc.No. : BR/FR/065

HOURLY MONITORING SHEET FOR PAINT STIRRER Rev. : '00

Page : 1 of 1
VILL-BHORA,
KHALAN.GURGAON (H.R) DATE : Date : 25.06.2015

10:00 AM

11:00 AM

12:00 AM
12:00 PM

10:00 PM

11:00 PM
8:00 AM

9:00 AM

1:00 AM

2:00 AM

3:00 AM

4:00 AM

5:00 AM

6:00 AM

7:00 AM
1:00 PM

2:00 PM

3:00 PM

4:00 PM

5:00 PM

6:00 PM

7:00 PM

8:00 PM

9:00 PM
PARAMETER

PRIMER

PAINT

CHECKED BY

VERIFIED BY

LEGEND : WORKING - √
NOT WORKING - X
 Doc.No .BR/FR/043
Rev :: 03 , REV DATE : 09.02.2017
DAILY DEFECT MONOTORING SHEET FOR PAINTING
Page : 1 of 1
BINOLA Date : 21/10/2013
REASON FOR REWORK
TOTAL O. K. REWORK
SR.NO. PART NAME CUSTOMER NAME QTY QTY QTY INSPECTOR'S SIGN
DRY FLOW BLISTER SCRATCH DUST CISSING PAINT INSIDE EXTRA
MASKING AREA
Preparedby: checked by:
 Doc.No. : BR/FR/043
Rev. : '02
DAILY DEFECT MONITORING SHEET FOR CRC LH AND RH Page : 1 of 1
BINOLA Date :21/10/2013

REASON FOR REWORK

DATE PART NAME TOTAL QTY OK REWORK SIGN
ORANGE INSIDE
DRY DUST RUSTY PINHOLE SCRATCH PEEL PAINT TOUCHING REJECT

PREPARED BY: APPROVED BY:

 ACTION PLAN Date :06.03.2017

Customer : M/S ALICON

Suplier : B.R SETH ASSOCIATES BINOLA

S.NO Problem Action Target date Done

PQCS not update old model KSTG cylinder head still

1 PQCS update with current model cylinder head and mentione in PQCS. 06.03.2017 Done
mentioned in PQCS

Oven tempreature observed 206°c against spec.and

2
check sheet oven temp.spec showing 190°c±5°c

3 Traceablity system not followed on final stage. Tags provide for traceability system. 06.03.2017 Done

4 Lux level standard not available on final stage. Lux lavel standard display at inspection final stage and made check sheet 06.03.2017 Done

5 FiFO system not followed properly. FIFO system following and display area 06.03.2017 Done

Prepared by : Manoj kumar checked by : Shyam Rathore Approved by : B.B Singh

BI
NO Doc.No. : BR/FR/44
LA PROCESS MATRIX WITH PART LIST
Rev: 02
Page 1 of 1
BINOLA Date-20/02/11
primer delivery primer delivery primer delivery conveyer photograph of
PART/HA Primer viscosity in ml/min GUN in ml/min GUN in ml/min GUN
SR.NO. PART NAME SHADE MODEL NGER in sec speed mt/min part
Hanger
1 2 3

HR NH10825 AAFB 10 16-20 80-90 130-140 100-120 1.0 Mt/Min

BLACK ML/MIN ML/MIN ML/MIN

HR NH10825 AANF 10 16-20 80-90 130-140 100-120 1.0 Mt/Min

BLACK ML/MIN ML/MIN ML/MIN

HR NH10825 AATA 10 16-20 80-90 130-140 100-120 1.0 Mt/Min

BLACK ML/MIN ML/MIN ML/MIN
1 BODY CYL HEAD
HR MATT AXIS 80-90 130-140 100-120
GREY KTC 10 16-20 ML/MIN ML/MIN ML/MIN 1.0 Mt/Min

HR MATT AXIS 80-90 130-140 100-120

GREY KTRK 10 16-20 ML/MIN ML/MIN ML/MIN 1.0 Mt/Min

HR TOUGH
SILVER(ADC) AAFB 10 … … … 1.0 Mt/Min

HR MATT AXIS 80-90 130-140 100-120

2 CYLINDER BLOCK GREY P-90 10 16-20 ML/MIN ML/MIN ML/MIN 1.0 Mt/Min

PREPARED BY : TANVEER ALAM VERIFIED BY : Mr. B.B SINGH

BI
NO Doc.No. : BR/FR/45
LA PROCESS MATRIX WITH PART LIST
Rev: 02
Page 1 of 1
BINOLA Date-20/02/11

Base coat vis in base coat delivery base coat delivery conveyer speed photograph of
SR.NO. PART NAME SHADE MODEL PART/HANGER
sec in ml/min GUN 1 in ml/min GUN 2 mt/min part
Hanger

HR NH10825 100-150 90-100

BLACK AAFB 10 16-20 ML/MIN ML/MIN 1.0 Mt/Min

HR NH10825 100-150 90-100

BLACK AANF 10 16-20 ML/MIN ML/MIN 1.0 Mt/Min

HR NH10825 100-150 90-100

BLACK AATA 10 16-20 ML/MIN ML/MIN 1.0 Mt/Min

1 BODY CYL HEAD

HR MATT AXIS 100-150 90-100
GREY KTC 10 16-20 ML/MIN ML/MIN 1.0 Mt/Min

HR MATT AXIS KTRK 10 16-20 100-150 90-100 1.0 Mt/Min

GREY ML/MIN ML/MIN

HR TOUGH AAFB 10 16-20 100-150 90-100 1.0 Mt/Min

SILVER(ADC) ML/MIN ML/MIN

2 CYLINDER BLOCK HR MATT AXIS P-90 10 16-20 100-150 90-100 1.0 Mt/Min
GREY ML/MIN ML/MIN

PREPARED BY : JITENDRA VERIFIED BY : Mr. B.B SINGH

 Doc.No. : BR/FR/46
Rev: 02
PRODUCT SPECIFACTION (PAINT SHOP) Page 1 of 1
BINOLA Date-20/02/11

BAKING
SR.NO. PART NAME CUSTOMER PRIMER NAME PAINT NAME LACQUER NAME DFT (MICRON)
TEMPERATURE

1 BODY CYL HEAD AAFB BLACK M/S ALICON HR NH-108-25 BLACK HR NH-108-25 BLACK ……. 185 - 205° C 40 - 60 micron
PRIMER PAINT

2 BODY CYL HEAD AAFB SILVER M/S ALICON ……. HR TOUGH SILVER PAINT ……. 185 - 205° C 25 - 35 micron

3 BODY CYL HEAD AATA BLACK M/S ALICON HR NH-108-25 BLACK HR NH-108-25 BLACK ……. 185 - 205° C 40 - 60 micron
PRIMER PAINT

4 BODY CYL HEAD AANF BLACK M/S ALICON HR NH-108-25 BLACK HR NH-108-25 BLACK ……. 185 - 205° C 40 - 60 micron
PRIMER PAINT

5 BODY CYL HEAD KTRK M/S ALICON HR NH-108-25 BLACK HR MATT AXIS GREY ……. 185 - 205° C 40 - 60 micron
PRIMER

6 BODY CYL HEAD AAFB BLACK M/S SUNBEAM HR NH-108-25 BLACK HR NH-108-25 BLACK ……. 40 - 60 micron
PRIMER PAINT 185 - 205° C

7 BODY CYL HEAD AAFB SILVER M/S SUNBEAM ……. HR TOUGH SILVER PAINT ……. 185 - 205° C 25 - 35 micron

8 BODY CYL HEAD KTRK M/S SUNBEAM HR NH-108-25 BLACK HR MATT AXIS GREY ……. 40 - 60 micron
PRIMER 185 - 205° C

HR NH-108-25 BLACK
9 CYLINDER BLOCK P-90 M/S SUNBEAM HR MATT AXIS GREY ……. 185 - 205° C 40 - 60 micron
PRIMER

PREPARED BY : TANVEER ALAM APPROVED BY : Mr. B.B SINGH

 Doc.No. : BR/FR/47
Rev: 00
SAMPLE REVALIDATION Page 1 of 1
BINOLA Date-20/02/11

SAMPLE ISSUE
SR.NO. PART NAME CUSTOMER REVALIDATE APPROVED BY PHOTO
DATE

1 BODY CYL HEAD AAFB SILVER M/S ALICON 13.06.2017 13.12.2017 MR.SACHIN SETH

2 CRANK CASE LH SS KWAG M/S SAPL 07.06.2017 07.12.2017 MR.AJAY RATHI

3 CRANK CASE RH P-17 M/S SAPL 07.06.2017 07.12.2017 MR.AJAY RATHI

4 BODY CYL HEAD AAFB BLACK M/S ALICON 13.06.2017 13.12.2017 MR.SACHIN SETH

BODY CYLINDER HEAD KTRK M/S ALICON 13.06.2017 13.12.2017 MR.SACHIN SETH

7 BODY CYL HEAD AAFB SILVER M/S ALICON 13.06.2017 13.12.2017 MR.SACHIN SETH

PREPARED BY : MR.SHYAM APPROVED BY : Mr. TANVEER ALAM

NOTE: This sample is approved by Mr.sachin Seth, we will meet Mr. shambhu and make sample approved by him.
 Doc.No. BR/FR/HR-013

PAINTING PROCESS CHECK SHEET FOR H.R. PAINT Rev. : '02

Page : 1 of 1

BINOLA DATE : TIME Date :07/03/2014

S.NO. CHECK POINT SPECIFICATION
MAKE MAHARANI PAINTS
BATCH NO./MFG
EXP. DATE
PAINT DELIVERY(HVLP GUN) 80 - 90 ML/MIN
VISCOSITY @ 30 oC 16 - 20 SEC
AIR PRESSURE OF GUN 3.0 - 3.5 KG/CM2
H.R. PRIMER
1 BOOTH NO-1
AIR PRESSURE OF PUMP 2.0 - 3.0 KG/CM2
ELECTROSTATIC GUN CHARGING
KVACURRENT 40 - 60 KVA
BOOTH TEMP. 25 - 32 oC
BOOTH HUMIDITY 55-75 RH%
LUX VALUE > 500 ON HANGER
SHOULD BE POSITIVE BY ON
BOOTH BALANCING LINE THREAD
NO. OF OPERATORS 2 NOS. + 1 RELIVER / SHIFT
MAKE MAHARANI PAINTS
BATCH NO./MFG
EXP. DATE
PAINT DELIVERY(ELECTROSTATIC GUN-1) 130-140 ML/MIN
PAINT DELIVERY(ELECTROSTATIC GUN-2) 100-120 ML/MIN
VISCOSITY @ 30 oC 16 - 20 SEC
H.R.PRIMER AIR PRESSURE OF GUN 3.0 - 3.5 KG/CM2
2 BOOTH NO -2 AIR PRESSURE OF PUMP 2.0 - 3.0 KG/CM2
ELECTROSTATIC GUN CHARGING
40 - 60 KVA
KVACURRENT
BOOTH TEMP. 25 - 32 oC
BOOTH HUMIDITY 55-75 RH%
LUX VALUE > 500 ON HANGER
SHOULD BE POSITIVE BY ON
BOOTH BALANCING
LINE THREAD
NO. OF OPERATORS 2 NOS. + 1 RELIVER / SHIFT
MAKE MAHARANI PAINTS
SHADE
BATCH NO./MFG
EXP. DATE
PAINT DELIVERY (ELECTROSTASTIC GUN) 100 - 150 ML/MIN
PAINT DELIVERY(HVLP GUN) 90-100 ML/MIN
VISCOSITY @ 30 oC 16 - 20 SEC
2 H.R. PAINT AIR PRESSURE OF GUN 3.5 - 4.5 KG/CM2
AIR PRESSURE OF PUMP 2.0 - 3.0 KG/CM2
ELECTROSTATIC GUN CHARGING 40 - 60 KVA
KVACURRENT
BOOTH TEMP. 25 - 32 oC
BOOTH HUMIDITY 55-75 RH%
LUX VALUE > 500 ON HANGER
BOOTH BALANCING SHOULD BE POSITIVE BY ON
LINE THREAD
NO. OF OPERATORS 2 NOS. + 1 RELIVER / SHIFT

3 BAKING TEMP. FOR HR PAINT - 205-215oC

4 CONVEYOR SPEED 1.0 METER/MIN.

CHECKED BY : VERIFIED BY :
 ON JOB TRANING RECORD Doc .: BR/FR/001
Rev: 00
VILL -BHIRA KALAN,GURGAON (HR) Page :1of 1

Date ;20-02-2017
TITLE OF TRANING ;

VENUE :

FACILITY :

time : Form …… …..To……… DATE :

SR. NO. NAME OF EMPLOYEE DESIGNATION DEPARTMENT SIGNATURE

SIGNATURE OF FACULTY : Signature of HOD :

 DAILY PRODUCTION REPORT
MANPOWER = MONTH= february SHIFT= A
LOADING PRODUCTION
S. No. DATE CUSTOMER MODEL COLOUR LOADING TIME UNLOADING TIME REWORK REJECTION REMARKS
PART SIGN

04.02.2021 alicon aann black 960 11:00 3:30 6 0 Pravesh

04.02.2021 sunbeam aann black 90 12:00 5:00 0 0 Pravesh

04.02.2021 alicon aann black 1150 1:30 6:20 2 0 Pravesh

TOTAL= 2200
LOADING START LOADING STOP UNLOADING
TIME=9:10 TIME=4:30 STOP TIME=6:20
BREAKDOWN RECORD
SR. NO. TIME REASON FOR BREAKDOWN USED SPAR PARTS DETAIL
1 12:00-12:05 nozzle clean no
2
3 2:00-2:05 nozzle clean no
4
5
6
7
8
9
10
11
12
PREPARED BY : MR. JITENDRA APPROVED BY- MR. TN DUVEY
FORMAT NO.-BRSA/PD/01 REV. NO -00 ISSUE DATE- 23/11/18
 Doc. No. -BR/MNT/021

Binola ,Bhora Kalan.

LIST OF CRITICAL SPARE PARTS Rev. :02
Page:02
GGN. Date :05.05.2019
Min. stock Parts in
Sr.no. Part name Part specification quantity stock Remark

1 Proximity sensor PNF NO 24V DC 3

2 Relay OMRON 24V DC 3
3 Contector TC 24V DC 2
4 Contector LCID32 220 V AC 2
5 Mcb 4 P32 A 2
6 Mcb 4 P 63 A 2
7 Mcb 1P5A 1
8 O/Relay TC3-6A 1
9 O/Relay TC 6-12A 1
10 Limit switch 1 NO/NC 1
11 On push VAISHO-1 NO 3
12 Off push button VAISHO-1 NC 3
13 T# Hosting motor BHARAT BIJLI 3Ø415 V 5HP 1
14 T# Traversing motor BHARAT BIJLI 3Ø415 V 3HP 1
15 Traversing guide bearing 6204 1
16 T# Travesing wheel DIA 100MM 1
17 Power supply TC220AC/24 V DC 1
18 Temperature controller SELEC-0-400° 1
19 Thermocouple PT100 2
20 Water circulation pump 3Ø415 V 5HP 1
21 Blower motor 3Ø415 V 5HP 1
22 Conveyer motor 3Ø 415 V 1.5HP 1
23 Convyer chain ass. 2M
24 Paint hose pipe 3/4'' 2M (HPP) 1
25 Niddle tip STATE FIELD- CHARJET L(1694) 2
26 Electrode STATE FIELD- CHARJET L(1694) 2
27 Air hose ass. STATE FIELD- CHARJET L(1694) 1
28 Air regulator STATE FIELD- CHARJET L(1694) 1
29 Pressure gauge STATE FIELD- CHARJET L(1694) 1
30 Or ring kit STATE FIELD- CHARJET L(1694) 1 Set
31 Hv kit STATE FIELD- CHARJET L(1694) 1
32 V-Packing STATE FIELD- CHARJET L(1694) 1 Set
33 Air cap for rs Nozzle STATE FIELD- CHARJET L(1694) 1
34 Mh scrow STATE FIELD- CHARJET L(1694) 2
35 SQ controller Semence 1
36 Electrode Semence 1
37 Check valve Sent 1
38 V-belt B-44 2
39 V-belt B-120 2
40 V-belt B- 75 2
41 CFL 85 w 220v DC 2
42 Booth filters 600X600 16

Prepared by : Approved by
 DAILY CHECK SHEET Doc. No. -BR/MNT/027.1
Rev. :02

Binola ,Bhora Kalan.

GGN.
BOOTH : PAINT SHOP Page:02
Date :05.05.2019
SR. DATE CHECK
NO. POINTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
AIR PRESSURE
1 (2.5-3.5 bar)

2 Temp. meter
conveyer motor
3 belt condition
hot air blower
4 meter

5 Shower V. belt

6 Gas pressure

7 Voltage (RYB)

8 D. chain
conveyer belt
9 condition

10 ASU

11 Sturrer

12 Any leakage
Any abnormal
13 should

14 Sup. Sign.

15 Remarks

APPROBVED BY : JITENDRA
 DAILY CHECK SHEET Doc. No. -BR/FR/002
Rev. :02

Binola ,Bhora Kalan.

GGN.
MACHINE :-DIESEL GENERATOR (250kVA) Page:02
Date :10.11.20

SR.
NO. CHECK POINTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

WATER LEVEL( MEET LEVEL

OIL LEVEL(MEET LEVEL

DIESEL (MIN. 6 INCH)

IDEAL (1000)
RPM

RUN (1500)
CONDITION

NO DAMAGE
BELT

ALINGNMENT

TEMP. (80-90° C

BATTERY VOLTAGE (12 V)

CHECK GAUGE CONDITION

CONDITION
RADIATOR

NO LEAKAGE

PROPER
WORKING

REMARKS SUP. SIGN.

APPROVED BY
 DAILY CHECK SHEET Doc. No. -BR/FR/006

Rev. :02

Binola ,Bhora MACHINE EQUIPMENT :-P.T.LIN Page:02

Kalan. GGN. Date :10.11.20

SR. NO. CHECK POINTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

DAMAG
TRANSPORTER

NO

E
BELT

1 ALINGNMENT

2 Oil skimmer (proper working)

3 Air circulation
Open
close
Door

5 Any leakage

6 Any abnormal sound

7 Checked by

REMARKS

APPROVED BY SUP. SIGN.

 DAILY CHECK SHEET Doc. No. -BR/MNT/026.8
Rev. :02
Page:02
PREVENTIVE MAINTENANCE CHECK LIST AND REPORT
Binola ,Bhora Kalan. GGN. Date :10.11.20

Machine Name : Salt- Spray Year -2021

Preventive maintenance details
sr. no. Check points Acceptable condition frequency

Status Observation Status Observation Status Observation

1- Temperature

a- Temperature controler calibrated Yearly

b- Thermocouple calibrated Yearly

c- Set -Temperature 35°C Monthly

2- Air unit

a- Air pressure (0.8 -1.5) kg Monthly

b- Solution seperator Proper work Monthly

c- Pressure gauge calibrated Monthly

3 Box & cover

a- Water level ok as level indicator Monthly

b- Air flow ok Monthly

c- Water leakage No leakage Monthly

d- Air leakage No leakage Monthly

4 Heater

a- Glass No crack ,damage Monthly

b- Input voltage (215 - 220 ) V AC Monthly

Serviced by

Verified by

Legends Ok Not ok x
 DAILY CHECK SHEET Doc.No. : BR/FR/014
Rev : 01
MACHINE (EQUIPMENT ):-GAS PLANT Page : 1 of 1
BINOLA MONTH : Date :20/10/2019

SR.
NO Check points 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
High pressure pipe
1 (any leakage)

2 NRV (No leakage)

Proper work
Gate Valve

No leakage

4 Safty valve condition

5 Gas pressure (3.5 kg)

6 Temp (65-75°C )
Water level (Middle
level)
7
8 Gas regulator

Gas Pressure (set

9 value 1.5-2.0)

10 Any leakage

11 Checked by

12 Supervisor sign.

13 Remarks
Approved by
 DAILY CHECK SHEET Doc.No. : BR/mnt/27.4.1
Rev : 02
MACHINE (EQUIPMENT ):-AIR COMPRESSOR Page : 1 of 1
BINOLA MONTH : Date :20/10/2019

SR.
NO Check points 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

1 Air pressure (5-8 bar)

Pressure

Unload
2
Load

VRY
3
VYB
Voltage

VBR

IR
Phase current Line current

4 IY

IB

IR
5
IY

IB

6 Oil Level (Meet point

7 Air filter condition

8 Coupling

9 Air dryer condition

10 Any abnormal sound

11 Checked by

12 Supervisor Sign.

13 Remarks

Approved by : Jitendra
 Doc.No. : BR/MNT/025

ANNUAL PREVENTIVE MAINTENANCE PLAN Rev. : '01

Page : 1 of 1
VILL-BINOLA,BHORA KHALLAN.GGN
Date 01/01/2021

YEAR-2021
SR.

AUGUST
MACHINE NAME REMARKS

MARCH

APRIL
NO.

JUNE
MAY

NOV
JULY

OCT

DEC
JAN

FEB

SEP
Paint shop
1

2 Powder coating-I

3 Powder coating-II

4 P.T Line -I

5 P.T Line -II

6 Air compressor

7 Hot ware generator

8 Buffing Machine

9 Gas bank

10 LT Panel & Servo

11 ED Oven

12 Salt spray

13 ETP

LEGENDS :- PLAN ACTUAL OUT DOOR

PREPARED BY : SHYAM APPROVED BY : JITENDRA