Page 1 of 16

PRIM AUTO COMPONENTS PVT LTD

PROCESS FLOW CHART
PART NO: B 0120406 DOC NO: PAC/PFC/103/406
PART NAME: CAB MOUNTING BRACKET REV NO/ ALTN.NO: # / NIL
CUS. NAME: ASHOL LEYLAND LTD DATE: 09.12.09
S.NO OPR NO: PROCESS FLOW OPERATION NAME

1 10 RAW MATERIAL RECEIVING

MOUNTING BRACKET (F7122210)

2 20 RAW MATERIAL INSPECTION

3 30 SHEARING

4 40 DEBURRING

5 50 NOTCHING

6 60 BENDING

7 70 4 HOLES PUNCHING

8 80 COUNTER SINKING

9 90 PART NO. PUNCHING

10 100 STORAGE

TOP PLATE (F8051110)

11 110 RAW MATERIAL INSPECTION

INCOMING INSPECTION OPERATION & INSPECTION

OPERATION STORAGE TRANSPORTATION

 Page 2 of 16

PREPARED BY: CHECKED BY: APPROVED BY:

PRIM AUTO COMPONENTS PVT LTD
PROCESS FLOW CHART
PART NO: B 0120406 DOC NO: PAC/PFC/103/406
PART NAME: CAB MOUNTING BRACKET REV NO/ ALTN.NO: # / NIL
CHILD PART NO: ASHOL LEYLAND LTD DATE: 09.12.09
S.NO OPR NO: PROCESS FLOW OPERATION NAME

12 120 SHEARING

13 130 DEBURRING

14 140 HOLE PUNCHING

15 150 COUNTER SINKING

16 160 STORAGE

SUPPORT BRACKET (F8037210)

17 170 RAW MATERIAL INSPECTION

18 180 SHEARING

19 190 DEBURRING

20 200 NOTCHING

21 210 2 HOLES PUNCHING

22 220 COUNTER SINKING

23 230 BENDING

INCOMING INSPECTION OPERATION & INSPECTION

 Page 3 of 16

OPERATION STORAGE TRANSPORTATION

PREPARED BY: CHECKED BY: APPROVED BY:
PRIM AUTO COMPONENTS PVT LTD
PROCESS FLOW CHART
PART NO: B 0120406 DOC NO: PAC/PFC/103/406
PART NAME: CAB MOUNTING BRACKET REV NO/ ALTN.NO: # / NIL
CHILD PART NO: ASHOL LEYLAND LTD DATE: 09.12.09
S.NO OPR NO: PROCESS FLOW OPERATION NAME

24 240 STORAGE

S/A OF CAB MOUNTING BRACKET (B0120406)

25 250 SETTING & WELDING

26 260 DEBURRING

27 270 FINAL INSPECTION

28 280 STORAGE

29 290 POWDER COATING

30 300 POWDER COATING INSPECTION

31 310 STORAGE

32 320 DESPATCH
 Page 4 of 16

INCOMING INSPECTION OPERATION & INSPECTION

OPERATION STORAGE TRANSPORTATION

PREPARED BY: CHECKED BY: APPROVED BY:
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
(PROCESS FMEA) FMEA Number
Page No.
Part No B0120406 Process Responsibility : Mr.Ramsunder Prepared By
Part Name CAB MOUNTING BRACKET Model Year(s)/Vehicle(s) FMEA Date(Orig.)
Core Team Mr.Ramsunder,Sekar,Dilip,Wilson,Guruswamy,Key Date FMEA Date(Rev.)
Process Function C O D
S l c e R. Responsibility
Potential
Potential Failure Current Process Current Process Recommended & Target
Mode
Potential Effects(s) Failure E a Cause(s)/Mechansim(s) c Control s Prevention Control s Detection t P.
Action(s) Completion
of Failure
V s u e N. Date
Requirements
s r c
Improper
Crack, Rejected and Sent Once in 5 Lot
10. Raw Material Receipts Cannot be used 7 Handling,Delivered 4 3 84
Damage,Unsize, Pit. Back to Customer Analaysation
Without Inspection

BASE PLATE QTY : 1 NO/SET ( MATERIAL:MS/IS 2062 GRADE 'A')

20. Inspection

Length 350.0 ± 1.0

Stopper Unproperly History Card
30. Shearing can't be matched in Tool. 4 4 First Off Inspection 3 48
Setting Maintained
Width 232.0 ± 1.0

40.Be - burring Undressed area Rejected in Customer End 2 Lack of skill 4 100 % Visual Inspection 3 24

Length 10.0 ± 0.2

Stopper Unproperly
50. Notching Free from sharp edges 4 4 100 % Visual Inspection 3 48
Length 15.0 ± 0.2 Setting

Length 190.0 ± 0.5 Stopper Unproperly

60. 2 Bending can't be matched in Tool. 4 4 100 % Visual Inspection 3 48
Setting
Width 90.0 ± 0.2

Fails Stopper Pin Position

70. 4 Holes Punching Dia 13.0 ± 0.2 Assy. Problem Rejection 4 5 Pin Replaced Patrol Inspection 3 60 104
and Butting

Fails Stopper Pin Position

80. Counter Sinking Free from sharp holes 4 5 Pin Replaced Patrol Inspection 3 60
and Butting

TOP PLATE (F8051110)

Length 190.0 ± 0.5

Stopper Unproperly History Card
90. Shearing can't be matched in Tool. 4 4 First Off Inspection 3 48
Setting Maintained
Width 90.0 ± 1.0

100.Be - burring Undressed area Rejected in Customer End 2 Lack of skill 4 100 % Visual Inspection 3 24

Fails Stopper Pin Position

110. 1 Holes Punching Dia 15.0 ± 0.2 Assy. Problem Rejection 4 5 Pin Replaced Patrol Inspection 3 60 104
and Butting

Fails Stopper Pin Position

120. Counter Sinking Free from sharp holes 4 5 Pin Replaced Patrol Inspection 3 60
and Butting

SUPPORT BRACKET (F8037210)

Length 235.0 ± 0.5

Stopper Unproperly History Card
130. Shearing can't be matched in Tool. 4 4 First Off Inspection 3 48
Setting Maintained
 Stopper Unproperly History Card
130. Shearing can't be matched in Tool. 4 4 First Off Inspection 3 48
Setting Maintained
Width 70. ± 0.3

140.Be - burring Undressed area Rejected in Customer End 2 Lack of skill 4 100 % Visual Inspection 3 24

Length 25.0 ± 0.3

Stopper Unproperly
150. Notching Free from sharp edges 4 4 100 % Visual Inspection 3 48
Setting
Length 75.0 ± 3.0

Length 155.0 ± 0.5 Stopper Unproperly

160. 1 Bending can't be matched in Tool. 4 4 100 % Visual Inspection 3 48
Setting
Width 90.0 ± 0.3

Fails Stopper Pin Position

170. 4 Holes Punching Dia 13.0 ± 0.2 Assy. Problem Rejection 4 5 Pin Replaced Patrol Inspection 3 60 104
and Butting

Fails Stopper Pin Position

180. Counter Sinking Free from sharp holes 4 5 Pin Replaced Patrol Inspection 3 60
and Butting

S/A OF CAB MOUNTING BRACKET (B0120406)

190.Setting & Welding Fillet 5.0 ± 0.2 Crack from Customer End Lack of skill 4 100 % Visual Inspection

200.Be - burring Undressed area Rejected in Customer End 2 Lack of skill 4 100 % Visual Inspection 3 24

210. Final Inspection 100 % Visual Inspection

220.Phospating Rest Formation Rejected in Customer End 4 Inproper Handling 5 100 % Visual Inspection 3 60

230.Powder Coating Less Plating May affect Resting Quickly at Process Parameters Not Pre Qualification of Verification of Plater
7 3 3 63
(60 ± 10µm) Thickness Customer End Followed Process & Process

240.Storage

Parts Damage in
250.Packaging of Parts / Customer cannot use these Improper Packaging Work instruction for Packaging or as per
Transit & wrong size 6 3 3 54
By Despatch parts. material Customer specification (if available)
packed

Note: Corrective Action will be for above 100 RPN value

PAC/AL-01
1 of 1
P.S.Dilip
16.07.2010

Action Results
S O D R.
Actions e c e P.
Taken v c t N.

0
0

0
 PAGE 9 OF 7

PRIM AUTO COMPONENTS PVT LTD DOC.NO:- PAC/CP/QC/01

REV.NO:- 00 ALTN.NO: NIL

CONTROL PLAN DATE:- 15.02.1995

PART NO: B0120406 CUSTOMER: ASHOK LEYLAND.LTD Core Team:
SUPPLIER NAME:- PRIM AUTO COMPONENTS (P) LTD
PART NAME: CAB MTG BRKT
KEY CONTACT PERSON: Mr.RAMSUNDER
Process Name/ Machine,Dies Special Product Evaluation/ Sample Size & Control
Operation Operation Jigs & Fixtures char. Spec./ Measurement Frequency Method
No. Characteristics
No.
Description for mfg Tolerance Technique OPERATOR / INSP
1 THICKNESS 4.8 ± 0.2 mm MICROMETER
2 TOTAL LENGTH 2500.0 ± 2.0 mm MEASU4RING TAPE
AS PER SAMPLING
RECEIVING OF 3 TOTAL WIDTH 1250.0 ± 1.2 mm MEASURING TAPE
10 NA PLAN BY INSP. RIP
RAW MATERIAL
4 IS 2062 GR 'A' ENSURE FROM TEST CERTIFICATE REF: PAC/SIP/10
FREE FROM
5 VISUAL INSPECTION VISUAL
BEND,RUST & PIT.
BASE PLATE QTY : 1 NO/SET ( MATERIAL:MS/IS 2062 GRADE 'A')

1 THICKNESS 4.8 ± 0.2 mm MICROMETER

2 LENGTH 2500.0 ± 2 mm
RAW MATERIAL MEASURING TAPE
20 NA 3 WIDTH 1250.0 ± 1.2 mm 5 RIP
INSPECTION
FREE FROM BEND,
4 VISUAL INSPECTION VISUAL
RUST & PIT.
1 THICKNESS 4.8 ± 0.2 mm
2 TOTAL LENGTH 350.0 ± 1.0 mm MICROMETER

30 SHEARING SHEARING M/C 3 TOTAL WIDTH 232.0 ± 1.0 mm

4 IS 2062 GR 'A' ENSURE FROM TEST CERTIFICATE
FREE FROM BURR &
5 VISUAL INSPECTION VISUAL 100%
SHARP EDGES
1 NOTCHING Length 10.0 ± 0.2
VISUAL
2 NOTCHING Length 15.0 ± 0.2 100%
40 NOTCHING SHEARING M/C 3 IS 2062 GR 'A' ENSURE FROM TEST CERTIFICATE
FREE FROM BURR &
4 VISUAL INSPECTION VISUAL 100%
SHARP EDGES
1 BENDING LENGTH 190.0 ± 0.5 mm
VERNIER HEIGHT GAUGE
2 BENDING WIDTH 90.0 ± 1.0 mm
50 BENDING SHEARING M/C
3 IS 2062 GR 'A' ENSURE FROM TEST CERTIFICATE
FREE FROM BURR &
4 VISUAL INSPECTION VISUAL 100%
SHARP EDGES
1 HOLE POSITION 1 35.0 ± 0.5 VERNIER HEIGHT GAUGE
 PAGE 10 OF 7

KEY CONTACT PERSON: Mr.RAMSUNDER

Process Name/ Machine,Dies Special Product Evaluation/ Sample Size & Control
Operation Operation Jigs & Fixtures char. Spec./ Measurement Frequency Method
No. Characteristics
No.
Description for mfg Tolerance Technique OPERATOR / INSP
2 HOLE POSITION 2 11.0 ± 0.2 VERNIER HEIGHT GAUGE

3 PITCH DISTANCE 1 10.0 ± 0.3 VERNIER HEIGHT GAUGE

4 PITCH DISTANCE 2 120.0 ± 0.3 VERNIER HEIGHT GAUGE

60 4 HOLE PUNCHING POWER PRESS 12 Nos/Hr 12 Nos/Hr PCS
5 PITCH DISTANCE 3 100.0 ± 0.3 VERNIER HEIGHT GAUGE

6 PITCH DISTANCE 4 40.0 ± 0.3 VERNIER HEIGHT GAUGE

7 DIA OF 4 HOLES 13.0 ± 0.2 DIAL VERNIER

FREE FROM BURR &
8 VISUAL INSPECTION VISUAL
SHARP EDGES
FREE FROM BURR &
70 COUNTER SINKING DRILLING M/C VISUAL INSPECTION VISUAL 100%
SHARP EDGES
HAND GRINDING FREE FROM BURR &
80 DE - BURRING 1 VISUAL INSPECTION VERNIER HEIGHT GAUGE 8 Nos/Hr 8 Nos/Hr PCS
M/C SHARP EDGES

TOP PLATE (F8051110)

1 THICKNESS 4.8 ± 0.2 mm

2 TOTAL LENGTH 112.0 ± 1.0 mm MICROMETER

90 SHEARING SHEARING M/C 3 TOTAL WIDTH 95.0 ± 1.0 mm

4 IS 2062 GR 'A' ENSURE FROM TEST CERTIFICATE
FREE FROM BURR &
5 VISUAL INSPECTION VISUAL 100%
SHARP EDGES
1 HOLE POSITION 1 50.8 ± 0.5 VERNIER HEIGHT GAUGE

2 PITCH DISTANCE 1 60.0 ± 0.3 VERNIER HEIGHT GAUGE

110 1 HOLE PUNCHING POWER PRESS 12 Nos/Hr 12 Nos/Hr PCS
3 DIA OF 1 HOLE 15.0 ± 0.2 DIAL VERNIER
FREE FROM BURR &
4 VISUAL INSPECTION VISUAL
SHARP EDGES
FREE FROM BURR &
110 COUNTER SINKING DRILLING M/C VISUAL INSPECTION VISUAL 100%
SHARP EDGES
HAND GRINDING FREE FROM BURR &
120 DE - BURRING 1 VISUAL INSPECTION VERNIER HEIGHT GAUGE 8 Nos/Hr 8 Nos/Hr PCS
M/C SHARP EDGES

CENTER PLATE : 1 NO/SET ( MATERIAL:MS/IS 2062 GRADE 'A')

1 THICKNESS 4.8 ± 0.2 mm

2 TOTAL LENGTH 235.0 ± 0.5 mm MICROMETER

130 SHEARING SHEARING M/C 3 TOTAL WIDTH 70.0 ± 0.3 mm

4 IS 2062 GR 'A' ENSURE FROM TEST CERTIFICATE
FREE FROM BURR &
5 VISUAL INSPECTION VISUAL 100%
SHARP EDGES
 PAGE 11 OF 7

KEY CONTACT PERSON: Mr.RAMSUNDER

130 SHEARING
Process Name/ SHEARING M/C
Machine,Dies Special Product Evaluation/ Sample Size & Control
Operation Operation Jigs & Fixtures char. Spec./ Measurement Frequency Method
No. Characteristics
No.
Description for mfg FREE Tolerance
FROM BURR & Technique OPERATOR / INSP
5 VISUAL INSPECTION VISUAL 100%
SHARP EDGES
1 NOTCHING Length 25.0 ± 0.2
VISUAL
2 NOTCHING Length 75.0 ± 0.2 100%
140 NOTCHING SHEARING M/C 3 IS 2062 GR 'A' ENSURE FROM TEST CERTIFICATE
FREE FROM BURR &
4 VISUAL INSPECTION VISUAL 100%
SHARP EDGES
1 BENDING LENGTH 155.0 ± 0.5 mm
VERNIER HEIGHT GAUGE
2 BENDING WIDTH 90.0 ± 0.3 mm
150 BENDING SHEARING M/C
3 IS 2062 GR 'A' ENSURE FROM TEST CERTIFICATE
FREE FROM BURR &
4 VISUAL INSPECTION VISUAL 100%
SHARP EDGES
1 HOLE POSITION 1 45.0 ± 0.3 VERNIER HEIGHT GAUGE

2 PITCH DISTANCE 1 70.0 ± 0.3 VERNIER HEIGHT GAUGE

160 2 HOLE PUNCHING POWER PRESS 3 PITCH DISTANCE 2 25.0 ± 0.3 12 Nos/Hr 12 Nos/Hr PCS
4 DIA OF 1 HOLES 13.5 ± 0.2 DIAL VERNIER
FREE FROM BURR &
5 VISUAL INSPECTION VISUAL
SHARP EDGES
FREE FROM BURR &
170 COUNTER SINKING DRILLING M/C 1 VISUAL INSPECTION VISUAL
SHARP EDGES
HAND GRINDING FREE FROM BURR &
180 DE - BURRING 1 VISUAL INSPECTION VERNIER HEIGHT GAUGE 8 Nos/Hr 8 Nos/Hr PCS
M/C SHARP EDGES

NUMBER FREE FROM BURR &

190 POWER PRESS 1 VISUAL INSPECTION VISUAL
PUNCHING SHARP EDGES

ASSEMBLY OF BOOSTER MTG BRKT (F8486914)

SETTING &
200 WELDING M/C 1 WELDING FILLET 5.0 ± 0.2 VISUAL 100%
WELDING

HAND GRINDING FREE FROM BURR &

210 DE - BURRING 1 VISUAL INSPECTION VERNIER HEIGHT GAUGE 8 Nos/Hr 8 Nos/Hr PCS
M/C SHARP EDGES

1 BENDING LENGTH 190.0 ± 0.5 mm

VERNIER HEIGHT GAUGE
2 BENDING WIDTH 90.0 ± 1.0 mm
3 HOLE POSITION 1 35.0 ± 0.5 VERNIER HEIGHT GAUGE
4 HOLE POSITION 2 11.0 ± 0.2 VERNIER HEIGHT GAUGE
5 PITCH DISTANCE 1 10.0 ± 0.3 VERNIER HEIGHT GAUGE
6 PITCH DISTANCE 2 120.0 ± 0.3 VERNIER HEIGHT GAUGE
 PAGE 12 OF 7

KEY CONTACT PERSON: Mr.RAMSUNDER

Process Name/ Machine,Dies Special Product Evaluation/ Sample Size & Control
Operation Operation Jigs & Fixtures char. Spec./ Measurement Frequency Method
No. Characteristics
No.
Description for mfg Tolerance Technique OPERATOR / INSP
7 PITCH DISTANCE 3 100.0 ± 0.3 VERNIER HEIGHT GAUGE
8 PITCH DISTANCE 4 40.0 ± 0.3 VERNIER HEIGHT GAUGE
9 DIA OF 4 HOLES 13.0 ± 0.2 DIAL VERNIER
10 HOLE POSITION 1 50.8 ± 0.5 VERNIER HEIGHT GAUGE
220 FINAL INSPECTION _ 11 PITCH DISTANCE 1 60.0 ± 0.3 VERNIER HEIGHT GAUGE 8 Nos/Hr 8 Nos/Hr PCS

12 DIA OF 1 HOLE 15.0 ± 0.2 DIAL VERNIER

13 BENDING LENGTH 155.0 ± 0.5 mm
VERNIER HEIGHT GAUGE
14 BENDING WIDTH 90.0 ± 0.3 mm
15 IS 2062 GR 'A' ENSURE FROM TEST CERTIFICATE
16 HOLE POSITION 1 45.0 ± 0.3 VERNIER HEIGHT GAUGE
17 PITCH DISTANCE 1 70.0 ± 0.3 VERNIER HEIGHT GAUGE
18 PITCH DISTANCE 2 25.0 ± 0.3 VERNIER HEIGHT GAUGE
19 DIA OF 1 HOLES 13.5 ± 0.2 DIAL VERNIER
FREE FROM BURR &
20 VISUAL INSPECTION VISUAL
SHARP EDGES

230 PHOSPATING

50 - 80 MICRONS
POWDER COATING AS PER SAMPLING
240 MANUAL 1 COATING THICKNESS FREE FROM COATMETER
(60 ± 10µm) PLAN
SCTACHES

250 STORAGE

PACKAGING OF
260
PARTS

PREPARED BY:- Dilip CHECKED BY: APPROVED BY:-

 PAGE 13 OF 7

ALTN.NO: NIL

Reaction
plan

RETURN TO
CUSTOMER

INFORM SUPV
 PAGE 14 OF 7

Reaction
plan

ENSURE
STOPPER
POSITION IS
AS PER SPEC.

ENSURE
STOPPER
POSITION IS
AS PER SPEC.

-
 PAGE 15 OF 7

Reaction
plan

ENSURE
STOPPER
POSITION IS
AS PER SPEC.

-
 PAGE 16 OF 7

Reaction
plan

POWDER
COATING