End Of Stage Report_2613597_tg12 C133 Front

Valeo India Pvt Ltd

End of stage PDC

Gat #: 24,744 & 745, Village Lonikand,

review report Valeo Requirements file number Project / Description

2613597

Pune.

VRF date

20.06.2010

TG12 C133 Front Housing Supplier

M/s.MAXOP ENGINEERING

General Information PA/FDP/MXP/2012-04

Index Index

A

Audit Date Date

15th Sep'12

FDP number

FDP/MXP/2012-12

Index

A

Date

15th Sep'12

Description

Objectives

Initial process audit number Follow-up process audit nbr

Full Day Production results Results

Acceptable

Production rate (pcs/h)

78 Pcs / Hr

Change-over time

45 Minutes

Y Y Y Y

2

Y

Quantity of produced parts

300

FDP time length

1 Shift

1 Shift

Comments

1397 Pcs / Day with 85% Efficiency

MTBF Rejects (ppm) Number of operators trained

Mr.Santosh KUMAR-4.5 Yrs experience.

DETAILS and ANALYSIS of NON CONFORMITIES Defect

Quantity

Root cause

Non-Filling

Comments

Setting Rejection

COMMENTS / REMARKS 1

MR.ASHOK

2

MR.BALJEET SINGH

3

MR.RAJEEV MITTAL

MAXOP 2613597

Auto: Laddle / Die Coat / Extraction / Plunger Lub Side Core: 2 & Hydraullic Cylinder. Machine #:

HPDC #13

Machine Name: ZITAI 420T Material Used: ADC 12 Shot Weight: Part Weight:

723 / 726 gms

Cavity: 1

FINAL DECISION FOR FDP PQA engineer

Accepted

Date Signature

U.KALAI SELVAN 13th Sep'12

Refused

Valeo Requirements File FDP template

Valeo confidential No copy or distribution without authorization

Group project May 10th 2006

Valeo India Pvt Ltd

End of stage TRIMMING

Gat #: 24,744 & 745, Village Lonikand,

review report Valeo Requirements file number

2613597

Pune.

VRF date

20.06.2010

TG12 C133 Front Housing Supplier

Project / Description

M/s.MAXOP ENGINEERING

General Information PA/FDP/MXP/2012-04

Index Index

A

Audit Date Date

15th Sep'12

FDP number

FDP/MXP/2012-12

Index

A

Date

15th Sep'12

Description

Objectives

Initial process audit number Follow-up process audit nbr

Full Day Production results Quantity of produced parts

300

FDP time length

1 Shift

Results

Acceptable

20

N

Comments

Trimming die breakdown.

Production rate (pcs/h) Change-over time MTBF Rejects (ppm)

0

Number of operators trained

1

DETAILS and ANALYSIS of NON CONFORMITIES Defect

Quantity

Root cause

Comments

COMMENTS / REMARKS 1

MR.ASHOK

2

MR.BALJEET SINGH

3

MR.RAJEEV MITTAL

MAXOP 2613597

Machine #:

40T Hydrullic Press

Trimming Die Location pin & Orientation pin broken while processing. Reason: Wrong Loading of part. Name Plate + Valeo Property to be added.

FINAL DECISION FOR FDP PQA engineer

Accepted

Date Signature

U.KALAI SELVAN 13th Sep'12

Refused

Valeo Requirements File FDP template

Valeo confidential No copy or distribution without authorization

Group project May 10th 2006

Valeo India Pvt Ltd

End of stage FETTLING

Gat #: 24,744 & 745, Village Lonikand,

review report Valeo Requirements file number Project / Description

2613597

Pune. 20.06.2010

VRF date

TG12 C133 Front Housing Supplier

M/s.MAXOP ENGINEERING

General Information PA/FDP/MXP/2012-04

Index Index

A

Audit Date Date

15th Sep'12

FDP number

FDP/MXP/2012-12

Index

A

Date

15th Sep'12

Description

Objectives

Initial process audit number Follow-up process audit nbr

Full Day Production results Quantity of produced parts

300

FDP time length

1 Shift

Results

Acceptable

1 Shift

Production rate (pcs/h)

37 Pcs / Hr

Change-over time

30 Minutes

30 Minutes

Y Y Y Y

Comments

662 Pcs / Day with 85% Efficiency.

MTBF 0

Rejects (ppm) Number of operators trained

4

4

Y Y

4 Operators for Fettling Operation.

DETAILS and ANALYSIS of NON CONFORMITIES Defect

Quantity

Root cause

Comments

COMMENTS / REMARKS 1

MR.RAJEEV MITTAL

2

MR.ASHOK

3

MR.BALJEET SINGH

MAXOP 2613597

Outer Periphery -Parting Line Flash - (Half Round Flat File) Side Windows +Oval Hole- (Round Hole Ø5mm). Ejector Face

(Half round flat file)

All Holes & core pin faces - (Round Hole Ø5mm). Part Wt. (After Runner Breakage): 723 / 726 gms. Part Wt. (After Fettling): 719 / 719 / 716 / 723 / 719 gms

FINAL DECISION FOR FDP PQA engineer

Accepted

Date Signature

U.KALAI SELVAN 13th Sep'12

Refused

Valeo Requirements File FDP template

Valeo confidential No copy or distribution without authorization

Group project May 10th 2006

Valeo India Pvt Ltd

End of stage Shot Blasting

Gat #: 24,744 & 745, Village Lonikand,

review report Valeo Requirements file number Project / Description

2613597

Pune. 20.06.2010

VRF date

TG12 C133 Front Housing Supplier

M/s.MAXOP ENGINEERING

General Information PA/FDP/MXP/2012-04

Index Index

A

Audit Date Date

15th Sep'12

FDP number

FDP/MXP/2012-12

Index

A

Date

15th Sep'12

Description

Objectives

Initial process audit number Follow-up process audit nbr

Full Day Production results Quantity of produced parts

300

FDP time length

1 Shift

Results

Acceptable

1 Shift 563

Production rate (pcs/h) Change-over time

30 Minutes

15 Minutes

Y Y Y Y

Comments

10041 Pcs / Day with 85% Efficiency.

MTBF Rejects (ppm)

0

0

Number of operators trained

1

1

Y Y

DETAILS and ANALYSIS of NON CONFORMITIES Defect

Quantity

Root cause

Comments

COMMENTS / REMARKS 1

MR.RAJEEV MITTAL

2

MR.ASHOK

3

MR.BALJEET SINGH

MAXOP 2613597

1. Master Sample made for shade appearance. 2. Barrel Type Shot Blasting Machine. (27" x 36") 3. Cycle kept: 4' 4. Shot size followed: 0.5mm / Stainless Steel (SS) 5. Dust Collector - Yes 6. Current: 20A Part Weight (after shot blasting): 727 / 727 / 724.5 / 709.5 / 726 gms.

FINAL DECISION FOR FDP PQA engineer

Accepted

Date Signature

U.KALAI SELVAN 13th Sep'12

Refused

Valeo Requirements File FDP template

Valeo confidential No copy or distribution without authorization

Group project May 10th 2006

Valeo India Pvt Ltd

End of stage CNC Turining

Gat #: 24,744 & 745, Village Lonikand,

review report Valeo Requirements file number

2613597

Project / Description

Pune. 20.06.2010

VRF date

TG12 C133 Front Housing Supplier

M/s.MAXOP ENGINEERING

General Information PA/FDP/MXP/2012-04

Index Index

A

Audit Date Date

15th Sep'12

FDP number

FDP/MXP/2012-12

Index

A

Date

15th Sep'12

Description

Objectives

Initial process audit number Follow-up process audit nbr

Full Day Production results Quantity of produced parts

300

FDP time length

1 Shift

Results

Acceptable

1 Shift 22

Production rate (pcs/h)

3 Hrs

Change-over time

Y Y Y Y

Comments

387 Pcs / Day with 85% Efficiency.

MTBF Rejects (ppm)

0

Number of operators trained

1

100 Pcs rejected during Maxop trial. 1

Y

Operator: Mr.Sanjay Setter: Mr.Mohammed Azad Ali

DETAILS and ANALYSIS of NON CONFORMITIES Defect

Quantity

Root cause

Comments

COMMENTS / REMARKS 1

MR.RAJEEV MITTAL

2

MR.ASHOK

3

MR.SANJEEV

MAXOP

4

MR.PRADEEP SARASWAT

2613597

5

MR.SHYAM SINGH

Master Sample made for CNC Operation. Machine: LMW - SMARturn Machine #: MSCL-07 Machine Sl#: 55-00522 (Yr: 2005 Mfg) Clamping Pressure: 6 Kg/Cm²

FINAL DECISION FOR FDP PQA engineer

Accepted

Date Signature

U.KALAI SELVAN 18th Aug'12

Refused

Valeo Requirements File FDP template

Valeo confidential No copy or distribution without authorization

Group project May 10th 2006

Valeo India Pvt Ltd

End of stage VMC Machining

Gat #: 24,744 & 745, Village Lonikand,

review report Valeo Requirements file number Project / Description

2613597

Pune. 20.06.2010

VRF date

TG12 C133 Front Housing Supplier

M/s.MAXOP ENGINEERING

General Information PA/FDP/MXP/2012-04

Index Index

A

Audit Date Date

15th Sep'12

FDP number

FDP/MXP/2012-12

Index

A

Date

15th Sep'12

Description

Objectives

Initial process audit number Follow-up process audit nbr

Full Day Production results Quantity of produced parts

300

FDP time length

1 Shift

Results

Acceptable

30 Pcs / Hr

Production rate (pcs/h) Change-over time

Y Y Y Y

Comments

542 Pcs / Day with 85% Efficiency.

MTBF Rejects (ppm) Number of operators trained

1

1

Y Y

Setting Rejection Operator: Mr.Dharmpaul SINGH Setter: Sushant SAHOO

DETAILS and ANALYSIS of NON CONFORMITIES Defect

Quantity

Root cause

Comments

COMMENTS / REMARKS 1

MR.RAJEEV MITTAL

Machined PART WEIGHT

2

MR.ASHOK

1

3

MR.SANJEEV

2

704gms

MAXOP

4

MR.PRADEEP SARASWAT

3

706gms

2613597

4

703gms

5

703gms

700gms

1. Master Sample made for VMC Operation. 2. Machine: brother - TC - R2B (cnc tapping center) 3. Machine #: MSVM - 10 4. M/c Sl #: 111139, Yr: 2010-03 5. 2 Pcs / Cycle 6. Station # - Not identified. 7. Clamping Pressure: 5 Kg/Cm² (Line pressure)

FINAL DECISION FOR FDP PQA engineer

Accepted

Date Signature

U.KALAI SELVAN 14th Sep'12

Refused

Valeo Requirements File FDP template

Valeo confidential No copy or distribution without authorization

Group project May 10th 2006

FDPR Process: TG12 C133 Front, Part #: 2613597 PDC Casting Machine:

Material:

ZITAI - 420T Machine Cold Chamber Brick Wall Holding Furnace - 450T Capacity ADC 12

As per agreed material.

Degassing:

Nitrogen Degassing Gas Spare maintained Spindle Spare Maintained 12.5 N2 pressure level maintained.

Process parameter:

Refer Valeo process Parameter sheet

Die coat:

Water base & Centralized Frequency: Each shot Process: Manually

Extraction: Manual unloading Die surface Treatment: While start-up : First Piece Approval: Shot Wt in gms

Runner Wt

Over Flow Wt

Part Wt

719 719 716 723 719 1st Operation: CNC Turning

2nd Operation VMC Machining Fix-1

Pre-drilling of M5 Tap Holes_8 Holes_Ø4.2 Drill (Carbide) M5 Tapping_Roll Tap_Tin Coated_5 Flute Spot Facing_End Mill_Ø25 Cutter Indexable-2 Flute_Insert Type Ø10.4 Drilling_Carbide_2 Flute Through Drain Holes drilling Ø6.7 - 2 Holes - HSS- 2 Flute ( Repassing) 1 Piece / Loading Refer "Standardized Work Combination Table" of VMC sequence.

Page: 7 of 8

FDPR Process: TG12 C133 Front, Part #: 2613597 Fix-2 Spot Facing x 2 - End Mill_Ø25 Cutter Indexable-2 Flute_Insert Type Ø12.7mm Drilling_2 Holes_Carbide_2 Flute_Through till bottom boss End. Both Fix1 & Fix2 loaded in same machine in single pallet. During mass production, this will be loaded on different machine.

Page: 8 of 8