PAP KiT (Feb'04)

P.P.A.P. REQUIREMENT CHECK LIST (LEVEL 3)

Doc Reference : F-CPS-13 : Rev no : 01 / 2.12.2020

Supplier : Customer : M/s GENAU EXTRUSIONSL

Part Name : Core :

Part No : PPAP Date : 19.02.2021

Sr. No. Document Title YES

1 Design Records of Saleable Product (Part Drawing)

2 Engineering Change Documents, If any

3 Customer Engineering approval

4 Design FMEA

5 Process Flow Diagram

6 Process FMEA

7 Control plan

8 Measurement System analysis studies

9 Dimensional Result

10 Material / Performance test report

11 Initial Process Studies

12 Qualified Laboratory Documents

13 Appearance Approval Report (ARR) , If Applicable

14 Sample product

15 Master Sample

16 Checking Aids

17 Records of compliance with Customer -CSR

18 Paer Submission Warrant (PSW)

 PAP KiT (Feb'04)

INITIAL SAMPLE ASSURANCE REPORT

### ###

PART NAME #REF! RELEASE NO. #REF!

PART NO. #REF! MODEL #REF! EO NO.

VENDOR NAME #REF! GRADE #REF! LIMIT SAMPLE Yes No

REASON FOR SUBMISSION

NEW DEVELOPMENT CHANGED OF COMPANY TOOLING NOT USED FOR 12 MONTHS

FACTORY SHIFTED CHANGE OF MOLD/DIE SUB VENDOR CHANGED

MATERIAL SPEC CHANGED SURFACE TREATMENT CHANGED MODIFIED PART

PRODUCTION PROCESS CHANGED DESIGN CHANGED QUALITY PROBLEM

Sr Items Judgement Annexure No.

1 Appearance inspection Report Accepted Not Applicable Others

2 Dimension inspection Report Accepted Not Applicable Others

3 Material test Report(M.S) Accepted Not Applicable Others

4 Performance test Report(E.S) Accepted Not Applicable Others

5 Spec changed Accepted Not Applicable Others

6 Limit Sample Accepted Not Applicable Others

7 Process inspection report Accepted Not Applicable Others

8 Outside lab reports Accepted Not Applicable Others

9 Others Accepted Not Applicable Others

Department Vendor's Overall Judgement Accepted Others

Date Prepared by Reviewed by Approved by

#REF!

The above part meets all the specification of HMI and it is confirmed by our inspection and testing

###
NAME
VD (GIL) TEAM SIGN
(TEL)
Sr Inspection items Judgement Annexure No
1 Fitness & Function
Accepted Rejected Not Applicable ✘ Others
Validation
Team in charge Overall Judgement S.no of Acceptance
Accepted Rejected ✘ Others

Date Prepared by Reviewed by Approved by

This assures that part is validated as per above.

 Part Drawing
First Operation
rawing
Second Operation
 PAP KiT (Feb'04)

PROCESS FLOW DIAGRAM DOC NO : XXX/PFD/2408 , Rev no ; 001 / 19.02.2021

Customer: M/s GENAU EXTRUSIONSLTD Dwg No.:

Part No.: Dwg Rev/Date.: 001

Part Desc.:
Symbols
Spl.
Process # & Incoming Source of Machine(s) / Desired Outcome /
Char. Process Characteristics
Description Variation Equipment(s) used Product characteristics
Class

Raw Material Receipt Part Mixup ,Dimensions

Required instruments Free from Part Mixup & Rust
& Inspection.(Forging) Variation,Rust

Storage Of raw
Wrong RM, Contamination RM Store Rack with Identification
material

Outer Diameter -1 Speed =

Outer Diameter -2 Feed =

Inner diameter Clamping Pressure=

Depth

Total Length
Forging defects, Rust, Part
Machining-1 CNC Machine
Miup
Distance

Concentrisity

Concentrisity
 PAP KiT (Feb'04)

PROCESS FLOW DIAGRAM DOC NO : XXX/PFD/2408 , Rev no ; 001 / 19.02.2021

Customer: M/s GENAU EXTRUSIONSLTD Dwg No.:

Forging defects, Rust, Part
Part Machining-1
No.: Dwg
CNC Rev/Date.:
Machine 001
Miup
Part Desc.:
Symbols
Spl.
Process # & Incoming Source of Machine(s) / Desired Outcome /
Char. Process Characteristics
Description Variation Equipment(s) used Product characteristics
Class

Concentrisity

Visual = Free fron Unwash, Rogh

Finishing

Outer diameter Speed =

Outer diameter Feed =

Inner diameter Clamping Pressure=

Concentrisity

Concentrisity

First Operation missing,

Machining-2 CNC Machine Concentrisity
Rejection part mixup

Distance

Distance

Distance

Distance
 PAP KiT (Feb'04)

First Operation missing, PROCESS FLOW DIAGRAM DOC NO : XXX/PFD/2408 , Rev no ; 001 / 19.02.2021
Machining-2 CNC Machine
Rejection part mixup
Customer: M/s GENAU EXTRUSIONSLTD Dwg No.:

Part No.: Dwg Rev/Date.: 001

Part Desc.:
Symbols
Spl.
Process # & Incoming Source of Machine(s) / Desired Outcome /
Char. Process Characteristics
Description Variation Equipment(s) used Product characteristics
Class

Visual = Free fron Unwash, Rogh

Finishing

Micrometer, Bore Dial

Final Inspection Dimension variation, burr, As per AOI As per AOI
Height Gauge
 PAP KiT (Feb'04)

0
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)
Customer : M/s GENAU EXTRUSIONSLTD

Part No. 0 Rev. 00 FMEA Number

Part Name . Process Responsibility :

Prepared by:

Key Date 19.02.2021

Model Year(s)/Vehicle(s)
Rev no : 001

C Potential O Current

Process
Process Potential Potential S l Cause(s)/ c
Process
number Function/ Failure Effect(s) of e a Mechanism(s) c Controls D R

Require- Mode Failure v s of Failure u Prevention Detection e P

ments s r 'A' type 'B'/'C' typ t N

Incoming inspection
OD Over size Grinding Dificult 4 Pre Turning Problem 2 Incoming Inspection 5 40
Report

Incoming inspection
OD Under size OD Unwash 4 Pre Turning Problem 2 Incoming Inspection 5 40
Report

Incoming inspection
Thickness Over size Grinding Dificult 4 Pre Turning Problem 2 Incoming Inspection 5 40
Report

Raw Material
Receipt &
10 Incoming inspection
Inspection as Thickness Under size Face Unwash 4 Pre Turning Problem 2 Incoming Inspection 5 40
Report
per drawing.

Incoming inspection
Bore Over size Bore Unwash 4 Pre Turning Problem 2 Incoming Inspection 5 40
Report

Prepared By: Page 8 of 39 Approved By:

 PAP KiT (Feb'04)

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Customer : M/s GENAU EXTRUSIONSLTD

Part No. 0 Rev. 00 FMEA Number

Part Name . Process Responsibility :

Prepared by:

Key Date 19.02.2021

Model Year(s)/Vehicle(s)
Rev no : 001
Raw Material C Potential O Current
Receipt &
10
Inspection as Process
per drawing.
Process Potential Potential S l Cause(s)/ c
Process
number Function/ Failure Effect(s) of e a Mechanism(s) c Controls D R

Require- Mode Failure v s of Failure u Prevention Detection e P

ments s r 'A' type 'B'/'C' typ t N

Incoming inspection
Bore Under size Grinding Dificult 4 Pre Turning Problem 2 Incoming Inspection 5 40
Report

Customer/ Supplier
Wrong supply from
Dent. Damages , Part rejected 6 2 final inspection Incoming inspection 5 60
Customer /Supplier
report

Deficult in Next Improper material Providing sufficient

Mixup the rawmaterial 5 2 Identifing Tag 4 40
Operation arrangement, Identification racks / stands
Storage Of raw
20 material proper
stages
Material Tracability
FIFO Not followed 4 FIFO System not followed 2 Use the FIFO board Identifing Tag 4 32
Difficult

1.Follow the SOP 1.Setting Approval

Fitment problem at Tool wear out, Wrong
OD Over size 6 2 2.Tool life Inspection, Periodic 4 48
customer end setting
monitoring Inspection

Prepared By: Page 9 of 39 Approved By:

 PAP KiT (Feb'04)

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Customer : M/s GENAU EXTRUSIONSLTD

Part No. 0 Rev. 00 FMEA Number

Part Name . Process Responsibility :

Prepared by:

Key Date 19.02.2021

Model Year(s)/Vehicle(s)
Rev no : 001

C Potential O Current

Process
Process Potential Potential S l Cause(s)/ c
Process
number Function/ Failure Effect(s) of e a Mechanism(s) c Controls D R

Require- Mode Failure v s of Failure u Prevention Detection e P

ments s r 'A' type 'B'/'C' typ t N

1.Follow the SOP 1.Setting Approval

Fitment problem at Wrong setting, Wrong
OD Under size 6 2 2.Tool life Inspection, Periodic 4 48
customer end offset
monitoring Inspection

1.Follow the SOP 1.Setting Approval

Fitment problem at Tool wear out, Wrong
ID Under size 6 2 2.Tool life Inspection, Periodic 4 48
customer end setting
monitoring Inspection

1.Follow the SOP 1.Setting Approval

Fitment problem at Wrong setting, Wrong
ID over size 6 2 2.Tool life Inspection, Periodic 4 48
customer end offset
monitoring Inspection

Prepared By: Page 10 of 39 Approved By:

 PAP KiT (Feb'04)

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Customer : M/s GENAU EXTRUSIONSLTD

Part No. 0 Rev. 00 FMEA Number

Part Name . Process Responsibility :

Prepared by:

Key Date 19.02.2021

Model Year(s)/Vehicle(s)
Rev no : 001

C Potential O Current

Process
Process Potential Potential S l Cause(s)/ c
Process
number Function/ Failure Effect(s) of e a Mechanism(s) c Controls D R

Require- Mode Failure v s of Failure u Prevention Detection e P

ments s r 'A' type 'B'/'C' typ t N

1.Follow the SOP 1.Setting Approval

Fitment problem at Tool wear out, Wrong
Depth Under size 6 2 2.Tool life Inspection, Periodic 4 48
customer end setting
monitoring Inspection

1.Follow the SOP 1.Setting Approval

Fitment problem at Wrong setting, Wrong
30 Machining-1 Depth Over size 6 2 2.Tool life Inspection, Periodic 4 48
customer end offset
monitoring Inspection

1.Follow the SOP 1.Setting Approval

Second operation Wrong Budding, Wrong
Total length under size 6 2 2.Tool life Inspection, Periodic 4 48
deficult offset
monitoring Inspection

Prepared By: Page 11 of 39 Approved By:

 PAP KiT (Feb'04)

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Customer : M/s GENAU EXTRUSIONSLTD

Part No. 0 Rev. 00 FMEA Number

Part Name . Process Responsibility :

Prepared by:

Key Date 19.02.2021

Model Year(s)/Vehicle(s)
30 Machining-1 Rev no : 001

C Potential O Current

Process
Process Potential Potential S l Cause(s)/ c
Process
number Function/ Failure Effect(s) of e a Mechanism(s) c Controls D R

Require- Mode Failure v s of Failure u Prevention Detection e P

ments s r 'A' type 'B'/'C' typ t N

1.Follow the SOP 1.Setting Approval

Second operation Tool wear out, Wrong
Total length Over size 6 2 2.Tool life Inspection, Periodic 4 48
deficult setting
monitoring Inspection

1.Follow the SOP 1.Setting Approval

Fitment problem at Wrong setting, Wrong
Distance variations 6 2 2.Tool life Inspection, Periodic 4 48
customer end offset
monitoring Inspection

1.Follow the SOP 1.Setting Approval

Fitment problem at Wrong setting, Machine
Concentrisity More 6 2 2.Machine Inspection, Periodic 4 48
customer end not accuracy
validation Inspection

Prepared By: Page 12 of 39 Approved By:

 PAP KiT (Feb'04)

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Customer : M/s GENAU EXTRUSIONSLTD

Part No. 0 Rev. 00 FMEA Number

Part Name . Process Responsibility :

Prepared by:

Key Date 19.02.2021

Model Year(s)/Vehicle(s)
Rev no : 001

C Potential O Current

Process
Process Potential Potential S l Cause(s)/ c
Process
number Function/ Failure Effect(s) of e a Mechanism(s) c Controls D R

Require- Mode Failure v s of Failure u Prevention Detection e P

ments s r 'A' type 'B'/'C' typ t N

1.Follow the SOP 1.Setting Approval

Wrong setting, Machine
Apperaence defects Performance less 8 2 2.Machine Inspection, Periodic 4 64
not accuracy
validation Inspection

1.Follow the SOP 1.Setting Approval

Fitment problem at Tool wear out, Wrong
OD Over size 6 2 2.Tool life Inspection, Periodic 4 48
customer end setting
monitoring Inspection

1.Follow the SOP 1.Setting Approval

Fitment problem at Wrong setting, Wrong
OD Under size 6 2 2.Tool life Inspection, Periodic 4 48
customer end offset
monitoring Inspection

1.Follow the SOP 1.Setting Approval

Fitment problem at Tool wear out, Wrong
ID Under size 6 2 2.Tool life Inspection, Periodic 4 48
customer end setting
monitoring Inspection

40 Maching-2
Prepared By: Page 13 of 39 Approved By:
 PAP KiT (Feb'04)

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Customer : M/s GENAU EXTRUSIONSLTD

Part No. 0 Rev. 00 FMEA Number

Part Name . Process Responsibility :

Prepared by:

Key Date 19.02.2021

Model Year(s)/Vehicle(s)
Rev no : 001

C Potential O Current

Process
Process Potential Potential S l Cause(s)/ c
Process
number Function/ Failure Effect(s) of e a Mechanism(s) c Controls D R

Require- Mode Failure v s of Failure u Prevention Detection e P

ments s r 'A' type 'B'/'C' typ t N

1.Follow the SOP 1.Setting Approval

Fitment problem at Wrong setting, Wrong
40 Maching-2 ID over size 6 2 2.Tool life Inspection, Periodic 4 48
customer end offset
monitoring Inspection

1.Follow the SOP 1.Setting Approval

Fitment problem at Wrong setting, Machine
Concentrisity More 6 2 2.Machine Inspection, Periodic 4 48
customer end not accuracy
validation Inspection

1.Follow the SOP 1.Setting Approval

Fitment problem at Wrong setting, Wrong
Distance variations 6 2 2.Tool life Inspection, Periodic 4 48
customer end offset
monitoring Inspection

1.Follow the SOP 1.Setting Approval

Wrong setting, Machine
Apperaence defects Performance less 8 2 2.Machine Inspection, Periodic 4 64
not accuracy
validation Inspection

Prepared By: Page 14 of 39 Approved By:

 PAP KiT (Feb'04)

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Customer : M/s GENAU EXTRUSIONSLTD

Part No. 0 Rev. 00 FMEA Number

Part Name . Process Responsibility :

Prepared by:

Key Date 19.02.2021

Model Year(s)/Vehicle(s)
Rev no : 001

C Potential O Current

Process
Process Potential Potential S l Cause(s)/ c
Process
number Function/ Failure Effect(s) of e a Mechanism(s) c Controls D R

Require- Mode Failure v s of Failure u Prevention Detection e P

ments s r 'A' type 'B'/'C' typ t N

Increase the
Final inspection Part not meet as per Part reject at customer Final Inspection
50 7 Improper Final Inspection 2 sampling qty, Proper 4 56
As per drawing drawing end / Fitment issue Report
final inspection

Rejections at customer
Improper Packing , Not Follow the packing
end 5 Not Follow the packing std 2 Visual inspection 4 40
done as per packing std std
Damaged in transit
Packing &
60
Despatch

Rejections at customer
DC cum Invoice Qty variation 4 2 Packing Slip Visual inspection 5 40
end

Rev No Revision Date Revision details

001 21.02.2021 Initial Release

Prepared By: Page 15 of 39 Approved By:

 PAP KiT (Feb'04)

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Customer : M/s GENAU EXTRUSIONSLTD

Part No. 0 Rev. 00 FMEA Number

Part Name . Process Responsibility :

Prepared by:

Key Date 19.02.2021

Model Year(s)/Vehicle(s)
Rev no : 001

C Potential O Current

Process
Process Potential Potential S l Cause(s)/ c
Process
number Function/ Failure Effect(s) of e a Mechanism(s) c Controls D R

Require- Mode Failure v s of Failure u Prevention Detection e P

ments s r 'A' type 'B'/'C' typ t N

Prepared by : Approved by :

Prepared By: Page 16 of 39 Approved By:

 PAP KiT (Feb'04)

FFECTS ANALYSIS (PROCESS FMEA)

FMEA Number : XXX/PFMEA/2408

Date (Orig. 20.02.2021

Date (Rev.) 20.02.2021

Recommend
ed Action Results

Actions Actions S O D R.
Responsi
bility & Taken e c e P.
Target
Date v c t N.

Prepared By: Page 17 of 39 Approved By:

 PAP KiT (Feb'04)

FFECTS ANALYSIS (PROCESS FMEA)

FMEA Number : XXX/PFMEA/2408

Date (Orig. 20.02.2021

Date (Rev.) 20.02.2021

Recommend
ed Action Results

Actions Actions S O D R.
Responsi
bility & Taken e c e P.
Target
Date v c t N.

Prepared By: Page 18 of 39 Approved By:

 PAP KiT (Feb'04)

FFECTS ANALYSIS (PROCESS FMEA)

FMEA Number : XXX/PFMEA/2408

Date (Orig. 20.02.2021

Date (Rev.) 20.02.2021

Recommend
ed Action Results

Actions Actions S O D R.
Responsi
bility & Taken e c e P.
Target
Date v c t N.

Prepared By: Page 19 of 39 Approved By:

 PAP KiT (Feb'04)

FFECTS ANALYSIS (PROCESS FMEA)

FMEA Number : XXX/PFMEA/2408

Date (Orig. 20.02.2021

Date (Rev.) 20.02.2021

Recommend
ed Action Results

Actions Actions S O D R.
Responsi
bility & Taken e c e P.
Target
Date v c t N.

Prepared By: Page 20 of 39 Approved By:

 PAP KiT (Feb'04)

FFECTS ANALYSIS (PROCESS FMEA)

FMEA Number : XXX/PFMEA/2408

Date (Orig. 20.02.2021

Date (Rev.) 20.02.2021

Recommend
ed Action Results

Actions Actions S O D R.
Responsi
bility & Taken e c e P.
Target
Date v c t N.

Prepared By: Page 21 of 39 Approved By:

 PAP KiT (Feb'04)

FFECTS ANALYSIS (PROCESS FMEA)

FMEA Number : XXX/PFMEA/2408

Date (Orig. 20.02.2021

Date (Rev.) 20.02.2021

Recommend
ed Action Results

Actions Actions S O D R.
Responsi
bility & Taken e c e P.
Target
Date v c t N.

Prepared By: Page 22 of 39 Approved By:

 PAP KiT (Feb'04)

FFECTS ANALYSIS (PROCESS FMEA)

FMEA Number : XXX/PFMEA/2408

Date (Orig. 20.02.2021

Date (Rev.) 20.02.2021

Recommend
ed Action Results

Actions Actions S O D R.
Responsi
bility & Taken e c e P.
Target
Date v c t N.

Prepared By: Page 23 of 39 Approved By:

 PAP KiT (Feb'04)

FFECTS ANALYSIS (PROCESS FMEA)

FMEA Number : XXX/PFMEA/2408

Date (Orig. 20.02.2021

Date (Rev.) 20.02.2021

Recommend
ed Action Results

Actions Actions S O D R.
Responsi
bility & Taken e c e P.
Target
Date v c t N.

Prepared By: Page 24 of 39 Approved By:

 PAP KiT (Feb'04)

FFECTS ANALYSIS (PROCESS FMEA)

FMEA Number : XXX/PFMEA/2408

Date (Orig. 20.02.2021

Date (Rev.) 20.02.2021

Recommend
ed Action Results

Actions Actions S O D R.
Responsi
bility & Taken e c e P.
Target
Date v c t N.

Approved by :

Prepared By: Page 25 of 39 Approved By:

 PAP KiT (Feb'04)

0 CONTROL PLAN

Prototype Pre Launch Production

Control Plan Number: SRM/CP/2408 Key Contact/Phone DATE (Org) :20.02.2021 DATE (Rev) : 001 / 20.02.2021

Part No /Rev Core Team :

Part Name/Description : Supplier/Plant ApprovalDate

Other approvalDate(If Reqd)

Customer :

Supplier Code :

Charecteristics / Parameters Methods

Process Name/ Spl.
Part/ Process Machine, Device, Reaction
Operation Char.
Sample Corrective Action
Number Jigs, Tools for Mfg. Class Product/Process Evalution Plan
Description Current Process
No. Product Process Specification/ Mesurements
Size Freq Controls
Tolerance. Technoque

1 OD Micrometer

Raw Material 2 Thickness Heigh Gauge Return to

Receipt & Micrometer, Height Incoming
10 5 Nos Each lot customer/Sup
Inspection as per Gauge, Bore Dial inspection
3 Counter Bore dia Bore Dial plier
drawing.
Free from Dent &
4 Visual Defects Visual with limit sample
Scratchs

RM Storage Racks &

1 Identification must Visual Lot qty Every Lot Tag Re - arrange
Place
Storage Of raw
20
material
RM Storage Racks&
2 FIFO System Must FIFO Board and visual Lot wise Every Lot FIFO Board Re - arrange
Place

1 Speed - once Every setting setup approval Re Setting

2 Feed - once Every setting setup approval Re Setting

3 Clamping pressure - once Each wheel setup approval Re Setting

Setup / 2Hr
1 Outer Diameter -1 Digital vernier 5 Nos/ 1 Nos
Once
SIR / IPIR Re Setting

Setup / 2Hr
2 Outer Diameter -2 Digital vernier 5 Nos/ 1 Nos
Once
SIR / IPIR Re Setting

Setup / 2Hr
3 Inner diameter Digital vernier 5 Nos/ 1 Nos
Once
SIR / IPIR Re Setting

Setup / 2Hr
30 Machining-1 CNC Machine 4 Depth Digital vernier 5 Nos/ 1 Nos
Once
SIR / IPIR Re Setting

Setup / 2Hr
5 Total Length SC Digital vernier 5 Nos/ 1 Nos
Once
SIR / IPIR Re Setting

Setup / 2Hr
6 Distance Digital vernier 5 Nos/ 1 Nos
Once
SIR / IPIR Re Setting

7 Concentrisity Digital Height gauge 5 Nos Setup Once SIR Re Setting

8 Concentrisity Digital Height gauge 5 Nos Setup Once SIR Re Setting

9 Concentrisity Digital Height gauge 5 Nos Setup Once SIR Re Setting

Free from Unwash, Dent

10 Appearance Visual 100% SIR / IPIR Re Setting
, Damages

Prepared by: 26 of 39 Approved by:

 PAP KiT (Feb'04)
0 CONTROL PLAN

Prototype Pre Launch Production

Control Plan Number: SRM/CP/2408 Key Contact/Phone DATE (Org) :20.02.2021 DATE (Rev) : 001 / 20.02.2021

Part No /Rev Core Team :

Part Name/Description : Supplier/Plant ApprovalDate

Other approvalDate(If Reqd)

Customer :

Supplier Code :

1 Speed once Every setting setup approval Re Setting

Feed once Every setting setup approval Re Setting

Clamping pressure once Every setting setup approval Re Setting

1 Outer diameter 30±0.1 Micrometer 100% SIR / IPIR Re Setting

Setup / 2Hr
2 Outer diameter 28.5±0.1 Digital vernier 5 Nos/ 1 Nos SIR / IPIR Re Setting
Once

Setup / 2Hr
3 Inner diameter 8.0±0.1 Digital vernier 5 Nos/ 1 Nos SIR / IPIR Re Setting
Once

4 Concentrisity 0.1 Wrt A Digital Height gauge 5 Nos Setup Once SIR Re Setting
40 Machining-2 CNC Machine
5 Concentrisity 0.1 Wrt A Digital Height gauge 5 Nos Setup Once SIR Re Setting

6 Concentrisity 0.1 Wrt A Digital Height gauge 5 Nos Setup Once SIR Re Setting

Setup / 2Hr
7 Distance 12.5±0.1 Digital vernier 5 Nos/ 1 Nos SIR / IPIR Re Setting
Once

Setup / 2Hr
8 Distance 18.8±0.1 Digital vernier 5 Nos/ 1 Nos SIR / IPIR Re Setting
Once

Setup / 2Hr
9 Distance 44.3±0.1 Digital vernier 5 Nos/ 1 Nos SIR / IPIR Re Setting
Once

Setup / 2Hr
10 Distance 57.1±0.1 Digital vernier 5 Nos/ 1 Nos SIR / IPIR Re Setting
Once

Free from Unwash, Dent

11 Appearance Visual 100% SIR / IPIR Re Setting
, Damages

1 Outer Diameter -1 33.5±0.1 Digital vernier

2 Outer Diameter -2 31.5±0.1 Digital vernier

3 Inner diameter 25.5±0.1 Digital vernier

4 Depth 38.5±0.1 Digital vernier

5 Total Length 56.8±0.1 Digital vernier

6 Distance 7.9±0.1 Digital vernier

HOLD & Reinspect 100%

7 Concentrisity 0.1 Wrt A Digital Height gauge

8 Concentrisity 0.1 Wrt A Digital Height gauge

9 Concentrisity 0.1 Wrt A Digital Height gauge

Report
10 Outer diameter 30±0.1 Micrometer As per Sampling
Plan

Every Lot

Final inspection
50 Final inspection Final inspection
11 Outer diameter 28.5±0.1 Digital vernier

12 Inner diameter 8.0±0.1 Digital vernier

Prepared by: 27 of 39 Approved by:

 PAP KiT (Feb'04)

HOLD & Reinspect 100%

0 CONTROL PLAN

Prototype Pre Launch Production

Report
Control Plan Number: SRM/CP/2408 Key Contact/Phone DATE (Org) :20.02.2021 DATE (Rev) : 001 / 20.02.2021
As per Sampling
Plan

Every Lot
Part No /Rev Core Team :

Final inspection
50 Final inspection Final inspection
Part Name/Description : Supplier/Plant ApprovalDate

Other approvalDate(If Reqd)

Customer :

Supplier Code :

13 Concentrisity 0.1 Wrt A Digital Height gauge

14 Concentrisity 0.1 Wrt A Digital Height gauge

15 Concentrisity 0.1 Wrt A Digital Height gauge

16 Distance 12.5±0.1 Digital vernier

17 Distance 18.8±0.1 Digital vernier

18 Distance 44.3±0.1 Digital vernier

19 Distance 57.1±0.1 Digital vernier

Free from Unwash, ,

20 Appearance Visual 100%
Dent ,Damages,

1 Packing Standard As per packing std Packing slip Each Bin E.lot Hold

Packing &
60 Packing Table
Dispatch
2 PDIR & DC As per AOI Visual As per AOI E. Lot PDIR Hold

Prepared by: 28 of 39 Approved by:

 0

Gauge Repetability and Reproducibility (MSA)

Part Name: Gauge Name: Micrometer Date: 19.02.2021
Characteristics: Outer Dia Gauge No: Performed
Specifications: 33.5±0.1 Gauge Type: Digital By:
USL: 33.4 LSL: 33.6 Part Number: Apporved By:
Appraiser/ Part
Average
Trial# 1 2 3 4 5 6 7 8 9 10
Dinesh 1 33.520 33.510 33.550 33.580 33.550 33.480 33.450 33.500 33.520 33.530 33.519
2 33.520 33.510 33.550 33.580 33.550 33.480 33.450 33.500 33.520 33.530 33.519
3 33.520 33.510 33.550 33.580 33.550 33.480 33.450 33.500 33.520 33.530 33.519
Average 33.52 33.51 33.55 33.58 33.55 33.48 33.45 33.5 33.52 33.53 33.519 X bar
Range 0 0 0 0 0 0 0 0 0 0 0 Ra bar
Arul 1 33.520 33.510 33.550 33.580 33.550 33.480 33.450 33.500 33.520 33.530 33.519
2 33.530 33.510 33.550 33.580 33.560 33.480 33.450 33.500 33.530 33.530 33.522
3 33.520 33.510 33.550 33.580 33.550 33.480 33.450 33.500 33.520 33.530 33.519
Average 33.52333 33.51 33.55 33.58 33.55333 33.48 33.45 33.5 33.52333 33.53 33.520 X bar
Range 0.01 0 0 0 0.01 0 0 0 0.01 0 0.003 Rb bar
Bala 1 33.520 33.510 33.550 33.580 33.550 33.480 33.450 33.500 33.520 33.530 33.519
2 33.520 33.510 33.550 33.580 33.550 33.480 33.450 33.500 33.520 33.540 33.52
3 33.520 33.510 33.550 33.580 33.550 33.480 33.450 33.500 33.520 33.530 33.519
Average 33.52 33.51 33.55 33.58 33.55 33.48 33.45 33.5 33.52 33.53333 33.519 X bar
Range 0 0 0 0 0 0 0 0 0 0.01 0.001 Rc bar
Part
Average 33.52111 33.51 33.55 33.58 33.55111 33.48 33.45 33.5 33.52111 33.53111 33.519
Average 0.130 Rp
R Double bar: (Ra bar+Rb bar+Rc bar)/ # of appraisers= 0.001
X bar Diff: (Max X bar-Min X bar)= 0.001
UCLR= (R Double bar X D4)= 0.003
Trials 2 3

AutolivIFB (INDIA) Pvt Ltd Q 008 REV 00 29

 D4 3.27 2.58

From Date Sheet: R Double bar= 0.001 X bar Diff= 0.001 Rp= 0.130
Tolearance= -0.2
Measurement unit Analysis %Total Variation(TV)
Repeatability - Equipment Variation (EV) %EV= 100(EV/TV)
EV= R double bar*K1 Trials K1 1.926
0.001 2 0.8862
3 0.5908

Reproducibility - Appraiser Variation (AV) Appraisers 2 3 %AV= 100(AV/TV)

AV= SQRT(X bar diff X K2) -(EV /(nr))
2 2
K2 0.7071 0.5231 1.279
0.001 n= parts r= trials

Repetability & Reproducibility (GRR) % GRR= 100(GRR/TV)

GRR= SQRT(EV2+AV2) 2.311
0.001

Part Variation(PV) Parts K3 %PV= 100(PV/TV)

PV= Rp X K3 2 0.7071 99.973
0.041 3 0.5231
4 0.4467
Total Variation (TV) 5 0.403 ndc= 1.41(PV/GRR)
TV= SQRT(GRR2+PV2) 6 0.3742 60.984
0.041 7 0.3534
8 0.3375
9 0.3249
10 0.3146

GAUGE IS ACCEPTABLE

AutolivIFB (INDIA) Pvt Ltd Q 008 REV 00 30

 GAUGE IS ACCEPTABLE

AutolivIFB (INDIA) Pvt Ltd Q 008 REV 00 31

 0 DOC NO :
LAYOUT INSPECTION REPORT
PART NAME : Customer : = GEANU SUBMITTED FOR
PART NO.: 0 REASON FOR SUBMISSION : PPAP STAGE
REV NO : 00 SAMPLE SIZE :05
A DIMENSIONAL INSPECTION :
OBSERVATIONS
S.NO CHARACTERISTICS SPECIFICATION INSTRUMENTS USED STATUS REMARKS
1 2 3 4 5

1 Outer Diameter -1 33.5±0.1 Digital vernier

2 Outer Diameter -2 31.5±0.1 Digital vernier

3 Inner diameter 25.5±0.1 Digital vernier

4 Depth 38.5±0.1 Digital vernier

5 Total Length 56.8±0.1 Digital vernier

6 Distance 7.9±0.1 Digital vernier

7 Concentrisity 0.1 Wrt A Digital Height gauge

8 Concentrisity 0.1 Wrt A Digital Height gauge

9 Concentrisity 0.1 Wrt A Digital Height gauge

10 Outer diameter 30±0.1 Micrometer

11 Outer diameter 28.5±0.1 Digital vernier

 0 DOC NO :
LAYOUT INSPECTION REPORT
PART NAME : Customer : = GEANU SUBMITTED FOR
PART NO.: 0 REASON FOR SUBMISSION : PPAP STAGE
REV NO : 00 SAMPLE SIZE :05

12 Inner diameter 8.0±0.1 Digital vernier

13 Concentrisity 0.1 Wrt A Digital Height gauge

14 Concentrisity 0.1 Wrt A Digital Height gauge

15 Concentrisity 0.1 Wrt A Digital Height gauge

16 Distance 12.5±0.1 Digital vernier

17 Distance 18.8±0.1 Digital vernier

18 Distance 44.3±0.1 Digital vernier

19 Distance 57.1±0.1 Digital vernier

Free from Unwash, , Dent

20 Appearance
,Damages,
Visual

COMMENTS: ACCEPTANCE STATUS : ACC / CA / REJ

Inspected By: Approved By:

 PAP KiT (Feb'04)

0 STATISTICAL PROCESS CONTROL STUDY

PART NAME : INSTRUMENT : Micrometer L.COUNT : 0.001 Format No:

PART NO. : SPECIFICATION 30.0±0.1 MACHINE : CNC MACHINE DATE: 19.02.201

SAMPLE SIZE : 50 Operation(Parameter) CNC Machining NO.OF DECIMALS: 3

DATA COLLECTION: -
SNO. 1 2 3 4 5 6 7 8 9 10 U.T.L. 30.1000 SAMPLE D2 A2 D4
1 30.02 30.04 30.02 30.02 30.02 30.01 30.02 30.01 30.03 30.02 1 1.123 2.560 3.270
2 30.02 30.02 30.02 30.02 30.02 30.02 30.02 30.02 30.02 30.02 2 1.128 1.880 3.270
3 30.03 30.04 30.01 30.03 30.03 30.02 30.02 30.02 30.01 30.02 L.T.L. 29.9000 3 1.693 1.020 2.570
4 30.01 30.01 30.02 30.02 30.02 29.98 30.03 30.02 30.02 30.03 4 2.059 0.730 2.230
5 30.02 30.02 30.02 30.02 30.01 30.02 30.02 30.02 30.02 30.02 5 2.326 0.590 2.110
CALCULATIONS FOR HISTOGRAM : -
XLARGE 30.0300 30.0400 30.0200 30.0300 30.0300 30.0200 30.0300 30.0200 30.0300 30.0300 Xmax. = 30.0400 NO.OF NON CONFORMING PART = 0 NOS.
XSMALL 30.0100 30.0100 30.0100 30.0200 30.0100 29.9800 30.0200 30.0100 30.0100 30.0200 Xmin. = 29.9800
RANGE 0.0200 0.0300 0.0100 0.0100 0.0200 0.0400 0.0100 0.0100 0.0200 0.0100 R - BAR = 0.01800 NO. OF PARTS ABOVE U.T.L. = 0 NOS.
AVG. 30.0200 30.0260 30.0180 30.0220 30.0200 30.0100 30.0220 30.0180 30.0200 30.0220 X - BAR = 30.0198 NO. OF PARTS BELOW L.T.L. = 0 NOS.
Process Width ( P ) = 0.0600 Specification Width(S) = 0.200000 Index (K)={2 x (D-XBAR)/S} = 0.1980 INTERVAL FREQ. CU. FREQ.

Design Centre ( D ) = 30.0000 Interval = 0.012000 Selecting no. of classes = 5 29.9440 29.9560 0 0
Starting Point = 29.9800 No. of readings = 50 Shift Of 'X-BAR' from 'D' = 0.019800 29.9560 29.9680 0 0

HISTOGRAM 30.035 X-CHART 29.9680 29.9800 1 1

40
30.03 29.9800 29.9920 0 1
30.025
35 AV
G.
29.9920 30.0040 0 1
30.02 U.
C.
L. 30.0040 30.0160 7 8
30.015 L.
C.
30
30.01
L.
30.0160 30.0280 34 42
30.005 30.0280 30.0400 8 50
25
30
30.0400 30.0520 0 50
29.995

20 1 2 3 4 5 6 7 8 9 10 30.0520 30.0640 0 50

0.1 R- CHART 30.0640 30.0760 0 50

15 30.0760 30.0880 0 50
RA
NG
E
U.C.L.XBAR = 30.03042
10 U.C.

L.C.L.XBAR = 30.009180
L.
L.C.
L
R-
Bar

5 U.C.L.RBAR = ###
L.C.L.RBAR = 0
0 Std.Dev."s" = 0.00869
30

30

30

30

30

30

30

30

30

30

30

30

0.0
30 30 30 30 30 30 30 30 30 30 30 30
1 2 3 4 5 6 7 8 9 10
Pp=(S/6s) = 3.83710
Ppk={1-K}xPp) = 3.07740
CONCLUSION : - PROCESS IS EXCELLENT
Prepared By: Approved By:
 PAP KiT (Feb'04)
CONCLUSION : - PROCESS IS EXCELLENT

Prepared By: Approved By:

SAMPLE PRODUCT
MASTER SAMPLE
 PAP KiT (Feb'04)
0
CHECKING AIDS
Format no :

PART NUMBER : 0 Doc no :

PART NAME : Date : 15.02.2021

REVISION/DATE: 00

LEAST CALIBRATION
SR. CHARACTERISTICS RANGE NEXT DUE
COUNT DATE

1 Digital vernier 0 - 150 MM 0.001 12.12.2020 12.12.2021

2 Digital Height gauge 0-300 MM 0.01 12.12.2020 12.12.2021

3 Micrometer 25-50 0.001 12.12.2020 12.12.2021

4 Dial Gauge 1.00 mm 0.01 12.12.2020 12.12.2021

5 Plug gauge 25.5 - Internal calibration

6 Plug gauge 8.00 - Internal calibration

Reviewed by: Approved by:

 Part Submission Warrant
Part Name: Cust.Part List No:-
Safety and/or
Government Regulation ✘ Yes No Engineering Part list Change Level:- NIL Dated: Nil

Additional Engineering Changes (Miss. detail drawing ref.) nil Dated nil

Shown on Drawing No.- Purchase Order No.- Weight:

Checking Aid No. Cust. Draw. Engineering Change Level Dated

SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION

✘ Dimensional Materials / Functional Appearance

Supplier Name Supplier Code
Customer Name / Division: M/s GENAU EXTRUSIONSLTD
Hosur
Street Address Buyer / Buyer Code: Hosur

Hosur-635109 Application:
City / State / Postal Code

Note : Does this part contain any restricted or reportable substance. Yes ✘ No

Are plastic parts identified with appropriate ISO marking codes Yes ✘ No

REASON FOR SUBMISSION

✘ Initial Submission Change to Optional Construction or Material
Engineering Changes(s) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part Processing
Correction of Discrepancy Parts Produced at Additional Location
Tooling Inactive > than 1 year Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant only (and for designated apperance items, an Appearance Approval Report) submitted to customer.

Level 2 - Warrant with product samples and limited supporting data submitted to customer.

✘ Level 3 - Warrant with product samples and complete supporting data submitted to customer

Level 4 - Warrant and other requirements as defined by customer.

Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.
SUBMISSION RESULTS

The results for ✘ dimensional measurements material and functional tests and appearance criteria and✘ statistical
These results meet all drawing and specification requirements: ✘ Yes No (If "No" - Explanation Required)

DECLARATION GRINDING

I hereby affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable Production
Part Approval Process Manual 3rd Edition Requirements. I further warrant these samples were produced at the rate of 300 nos
/ 8 hours. I have noted any deviations from this declaration below:

EXPLANATION / COMMENTS: Nill

Print Name: Title: Propertor Phone No.:

Supplier Authorized Signature Date 20.02.2021

FOR CUSTOMER USE ONLY (IF APPLICABLE)

Part Warrant Approved Rejected Part Functional Approval : Approved

Disposition
Other
Waived
Print Name Customer Signature Date