CONTROL PLAN

Program: KUBOTA - D35

Control Plan No: R / CP /EKI-029

Key Contact / Main Pal Singh Signature Issue Date Revision No & Date
Prototype Pre-Launch ✘ Production 03.12.2022 01 / 24.08.2023
Telephone: (9555928422) (Quality)
Core Team : Mr. Sanjay Sharma, [Link], [Link] Nath, [Link], Mr. Customer Engineering Approval/Date (If Required) :
Part Number (Drg Rev No) : K6C68652171 (Rev: 1) Akshay, Gaurav Singh

Part Name/Description Supplier NAME Supplier/Plant Approval/Date (If Required) : Customer Quality Approval/Date (If Required):
HANDRAIL FENDER Rikki Plastic Pvt. Ltd.

Supplier/Plant : Prithla Supplier Code : …...... Other Approval/Date (If Required) : Other Approval/Date (If Required) :

Characteristics Sample

Characteristic

Responsible
Machine

Ballooning No.
Part /

Class of

Record
Control
Process Name / Device Product / Process Evaluation Measurement Control Responsibility
Process Reaction Plan

Sr. No

Freq.
Size
Operation / Description Jig,Tools for Product Process Specifications / Tolerance Technique (Equipment) Method of Reaction Plan
Number
Mfg

Raw Material/BOP
Receiving & Receipt Verification of Metarial test
10 Manual 1 Material … … PP20% TF Each Lot Each Lot QE
Inspection certificate / Invoice / Bags
…
(Raw Material)
EXP99070ES
2 RM Grade / Make … … ,, ,, ,, ,,
Make- Machino Polymer
WI For receipt
inspection
3 … Batch Code … … As Supplier System / Standard ,, ,, ,, ,, (R/WI –QA-
05).
Return to Vendor If
Y
4 … Wt., Qty. … … As per Invoice ,, ,, ,, ,, Reject & If OK
Raw Material Incoming Quality
continue the
Inspection Control
production / If any
Standard.
5 … Colour … … Black Visual ,, ,, ,, deviation inform to QA
(R/IS-QA-03)

6 … Packing Conditions. Sealed bag Visual ,, ,, ,,

Supplier Test
As per Supplier Data sheet / Verification of Raw Metarial test Lab
… Properties … … 1 Sample Certificate - Each
Standard (R/IS-QA-03) certificate Assistant
Lot
7
Lab 3rd Party
… 3rd Party Verification 1 Sample Every 6 Months Y
Assistant Certificate

METAL INSERT
Supplier Test
1 MATERIAL GRADE …. …. MS Metarial test certificate 1 Sample Certificate - Each QE
Lot

No Burr, Dent, Bend, Twist,

2 APPEARANCE …. …. Visual 5 Nos. Each Lot QE
Scratch etc.

3 LENGTH …. …. 40 ± 0.1 DVC 5 Nos. Each Lot QE

4 Dim. …. …. 20 ± 0.1 DVC 5 Nos. Each Lot QE

5 DIA (After Plating) …. …. Ø 13 ± 0.1 DVC 5 Nos. Each Lot QE Return to Vendor If
Inword
Reject & If OK
Inspection. Incoming Quality
6 DIA …. …. Ø 9 ± 0.1 DVC 5 Nos. Each Lot QE Y continue the
Std. (R/IS-QA- Control
production / If any
170)
deviation inform to QA
7 Thread … … M10x1.25 TRG 5 Nos. Each Lot QE

EP-FE/Zn/CMS

8 Plating …. …. Color- Silver Blue appearance Review of Test Certificate / 3rd 1 Sample Each Lot QE
Party Certificate
Thickness : 8.00 to 14.00
micron

Non ferrous corrosion 96

9 Salt Spray Test (SST) …. …. hours & ferrous corrosion 360 3th Party Certificate 1 Sample Once in a Year QE
hours

WI For store
Identification & Should be Proper Identification
20 Raw Material Storage Manual 1 … Storage … Visual 100% Each Lot (R/WI/ST-01) Provide identification tag
Preservation & No Deterioration/damage
 CONTROL PLAN
Program: KUBOTA - D35
Control Plan No: R / CP /EKI-029

Key Contact / Main Pal Singh Signature Issue Date Revision No & Date
Prototype Pre-Launch ✘ Production 03.12.2022 01 / 24.08.2023
Telephone: (9555928422) (Quality)
Core Team : Mr. Sanjay Sharma, [Link], [Link] Nath, [Link], Mr. Customer Engineering Approval/Date (If Required) :
Part Number (Drg Rev No) : K6C68652171 (Rev: 1) Akshay, Gaurav Singh

Part Name/Description Supplier NAME Supplier/Plant Approval/Date (If Required) : Customer Quality Approval/Date (If Required):
HANDRAIL FENDER Rikki Plastic Pvt. Ltd.

Supplier/Plant : Prithla Supplier Code : …...... Other Approval/Date (If Required) : Other Approval/Date (If Required) :

Characteristics Sample

Characteristic

Responsible
Machine

Ballooning No.
Part /

Class of

Record
Control
Process Name / Device Product / Process Evaluation Measurement Control Responsibility
Process Reaction Plan

Sr. No

Freq.
Size
Operation / Description Jig,Tools for Product Process Specifications / Tolerance Technique (Equipment) Method of Reaction Plan
Number
Mfg

Self Life Spec. 1. Maintain other board if

Color code sticker for each material not consume in 3
FIFO / Self Life of Sheet R/F-ST-
2 … ,, … month & Expiry Date on each Visual 100% Each Lot Store year
Material 08, Fifo N [Link] in case of self life R/M Store Incharge
material bag. Incharge
Board expired.

Bags should not be in open WI For store

Conditions of Moisture Seal bags & provide
3 … ,, … Condition & in direct contact Visual 100% Each Lot (R/WI/ST-01)
Absorption wooden pallet / Racks
with Earth / Floor.

30 Raw Material Pre heating Heating Oven 1 … … Temperature … 90 ± 10 0C Digital Temp. Controller … WI For Raw 1. At starting of
At Material Trey IN Material Pre production 1st lot to be
PE Y
& OUT heating R/WI - heated in oven & then
PR-04 Production Shift In
2 … … Time … 1½ Hours Wall Clock … hopper. 2 Scrap in case
of Over Heating & Re
charge
Heating in case of less
Process Sheet Heating.
Hopper Dryer 1 … … Temperature … 90 ± 10 0C Digital Temp. Controller … … QE N

Note -- The first initial raw material lot is pre heat in oven. and is controlled through the Pre Heating Record Sheet. After that the raw material will be pre heat in m/c hopper.

40 Moulding Injection Moulding M/c- R/IM-04 (250T)

40.10 Set Up Approval (First Piece Inspection)

Machine Refer : Every Set- Up

Machine Parameter … … … … …
Parameter Process Sheet R/PS/EKI-029 (Mould Loading)
QE
Mould Refer : Every Set- Up
Mould Parameter … … … 02 … …
Temperature Process Sheet R/PS/EKI-029 (Mould Loading)

No Damage, Crack, Flash, & Every Set- Up

other Moulding defects (as per Visual / or Matching with 5 Nos./ (Mould Loading) If OK continue the
Product Parameter 1 … Appearance … … QE
visual inspection std. sheet Master Sample Cavity After Scraping First production / If NG Reset
R/WI-QA-EKI-029 5 Shots the Machine, Recheck
01 the components.
5 Nos,/ ,,
03 2 Dim.(On Machine) … … 240 ± 1.0 DVC/Gauge Cavity ,, First & Last &
Process Quality In
piece If any
charge
Inspection Y deviation in product &
03 Dim. (after 24 Hrs) … … 231 ± 1.0 DVC/Gauge 01 Report process parameter
(R/F-QA-05) inform to Head Quality
CD (On Machine) … … 204 ± 1.0 DVC/Gauge and get deviation
03 approval before run the
100% ,, m/c.
3 CD (after 24 Hrs) … C 196 ± 1 Gauge INSP. ,,
03 01
,, ,,
4 Dim. … … 72.4 ± 0.65 HG ,,

,, ,,
5 Thread … … M10x1.25 TRG ,,

Weigh (Plastic and metal ,, ,,

01 6
insert)
… C 247 ± 2gms Weight Scale ,,

40.20 Process Inspection

 CONTROL PLAN
Program: KUBOTA - D35
Control Plan No: R / CP /EKI-029

Key Contact / Main Pal Singh Signature Issue Date Revision No & Date
Prototype Pre-Launch ✘ Production 03.12.2022 01 / 24.08.2023
Telephone: (9555928422) (Quality)
Core Team : Mr. Sanjay Sharma, [Link], [Link] Nath, [Link], Mr. Customer Engineering Approval/Date (If Required) :
Part Number (Drg Rev No) : K6C68652171 (Rev: 1) Akshay, Gaurav Singh

Part Name/Description Supplier NAME Supplier/Plant Approval/Date (If Required) : Customer Quality Approval/Date (If Required):
HANDRAIL FENDER Rikki Plastic Pvt. Ltd.

Supplier/Plant : Prithla Supplier Code : …...... Other Approval/Date (If Required) : Other Approval/Date (If Required) :

Characteristics Sample

Characteristic

Responsible
Machine

Ballooning No.
Part /

Class of

Record
Control
Process Name / Device Product / Process Evaluation Measurement Control Responsibility
Process Reaction Plan

Sr. No

Freq.
Size
Operation / Description Jig,Tools for Product Process Specifications / Tolerance Technique (Equipment) Method of Reaction Plan
Number
Mfg

Refer :
Machine Machine Refer : Refer :
… …. … Process 6 Hrs. QE
Parameter Parameter Process No. 40.10 Process No. 40.10
No. 40.10

Refer : M/c stop , Hold & move

Mould Mould Refer : Refer : Process
… …. … Process 6 Hrs. QE the Non- Conforming
Parameter Temperature Process No. 40.10 Process No. 40.10 Sheet
No. 40.10 Lot to suspected area / Process Quality In
(Operation Y
Reset the Machine & charge
Std.)
Recheck the
Refer : Refer : 5 Nos./ (R/F-QA-06)
Product Parameter 1 … Appearance … … 6 Hrs. QE components.
Process No. 40.10 Process No. 40.10 Cavity

Refer : Refer : 5 Nos./

2 … Dimensional … … 6 Hrs. QE
Process No. 40.10 Process No. 40.10 Cavity

40.30 Last Piece Inspection

Refer : Refer : 5 Nos./ First & Last

Product Parameter 1 … Appearance … …
Process No. 40.10 Process No. 40.10 Cavity piece
At Mould off 1. If observation NG,
QE Inspection Y
Loading Hold the Non -
Refer : Refer : 5 Nos./ Report
2 … Dimensional … … (R/F-QA-05) Conforming Lot,
Process No. 40.10 Process No. 40.10 Cavity
Segregate and Recheck. Process Quality In
2. If OK charge
Sample
Mould sent to the
Complete Dimensional location.
3 Nos. / As per Lay out Insp. Inspection
Lay out Inspection 1 … Inspection as per … … As per markup drawing As required QE Y
Cavity Plan Report
markup drawing (R/F-QA-02)

Operator
Manual with No Flash, Excess Cut Marks, Guidance Sheet Hold the Non-
Visual Inspection & or Master 5 Nos. /
50 Deflashing Deflashing 1 … Appearance … … Excess Feed Point & 2 Hrs., QE OGS N Conforming Lot & Reset PDI QE
Sample Lot R/OGS/DF-EKI-
Tool Scratches. & Re - check
029

Visual
Hold the Non-
Inspection
No Short Filling, Flash, & other Conforming Lot , PDI QE
Appearance Standard
Moulding defects(as per visual N
60 Visual Inspection Manual 1 … … … inspection instruction sheet R/WI-
Visual & or Master Sample 100% Every Lot Operator Sheet
QA-EKI-029) Re-Check & notify to
(R/WI-QA-
QA Manager.
EKI-029)

1 … Packing Qty - 40pcs/Bin … … Refer Packing Std. (R/PS/EKI- Manual / Weighing M/C 100% Every Lot
029) WI For
Manual Notify Dispatch
Packing,
(Follow Work Packing Incharge/Production
70 Packing R/WI/PD-01 N Packing Incharge
Instruction Incharge Supervisor / QCI &
R/WI-PD-01) Any Damage & Proper No Damage & Should be Recheck
2 … … … Visual ,, ,, Packing Std.
Identification / labeling Proper Identification / labeling

80 Pre Delivery Inspection

Supplier Certificate -
Supplier TC / 3rd Party Each Lot / 3rd Party PDI Inspection
Material Inspection 1 Raw Material : … … PP20% TF Certificate
1 Sample Certificate - Once in a QE
Std.
Year

,,
Dim. 2 Dim. … … 231 ± 1.0 DVC/Gauge ,, ,,
03 Hold & move the Non-
Conforming Lot to
 CONTROL PLAN
Program: KUBOTA - D35
Control Plan No: R / CP /EKI-029

Key Contact / Main Pal Singh Signature Issue Date Revision No & Date
Prototype Pre-Launch ✘ Production 03.12.2022 01 / 24.08.2023
Telephone: (9555928422) (Quality)
Core Team : Mr. Sanjay Sharma, [Link], [Link] Nath, [Link], Mr. Customer Engineering Approval/Date (If Required) :
Part Number (Drg Rev No) : K6C68652171 (Rev: 1) Akshay, Gaurav Singh

Part Name/Description Supplier NAME Supplier/Plant Approval/Date (If Required) : Customer Quality Approval/Date (If Required):
HANDRAIL FENDER Rikki Plastic Pvt. Ltd.

Supplier/Plant : Prithla Supplier Code : …...... Other Approval/Date (If Required) : Other Approval/Date (If Required) :

Characteristics Sample

Characteristic

Responsible
Machine

Ballooning No.
Part /

Class of

Record
Control
Process Name / Device Product / Process Evaluation Measurement Control Responsibility
Process Reaction Plan

Sr. No

Freq.
Size
Operation / Description Jig,Tools for Product Process Specifications / Tolerance Technique (Equipment) Method of Reaction Plan
Number
Mfg

03 Hold & move the Non-

100% ,, Conforming Lot to
3 CD … C 196 ± 1 Gauge 01 INSP. ,, ,, suspected area /
Y
Segregate & Recheck
the components.

PDI QE
 CONTROL PLAN
Program: KUBOTA - D35
Control Plan No: R / CP /EKI-029

Key Contact / Main Pal Singh Signature Issue Date Revision No & Date
Prototype Pre-Launch ✘ Production 03.12.2022 01 / 24.08.2023
Telephone: (9555928422) (Quality)
Core Team : Mr. Sanjay Sharma, [Link], [Link] Nath, [Link], Mr. Customer Engineering Approval/Date (If Required) :
Part Number (Drg Rev No) : K6C68652171 (Rev: 1) Akshay, Gaurav Singh

Part Name/Description Supplier NAME Supplier/Plant Approval/Date (If Required) : Customer Quality Approval/Date (If Required):
HANDRAIL FENDER Rikki Plastic Pvt. Ltd.

Supplier/Plant : Prithla Supplier Code : …...... Other Approval/Date (If Required) : Other Approval/Date (If Required) :

Characteristics Sample

Characteristic

Responsible
Machine

Ballooning No.
Part /

Class of

Record
Control
Process Name / Device Product / Process Evaluation Measurement Control Responsibility
Process Reaction Plan

Sr. No

Freq.
Size
Operation / Description Jig,Tools for Product Process Specifications / Tolerance Technique (Equipment) Method of Reaction Plan
Number Hold & move the Non-
Mfg
Conforming Lot to
01 suspected area /
Y
Segregate & Recheck
,, ,, the components.
4 Dim. … … 72.4 ± 0.65 HG ,, ,,
PDI QE
,, ,,
5 Thread … … M10x1.25 TRG ,, ,,

Weight (Plastic and ,, ,,

6
metal insert)
… C 247 ± 2gms Weight Scale 01 ,, ,,

Visual Hold & move the Non-

No Short Filling, Flash, & other Inspection Conforming Lot to
defects (as per visual inspection Standard Sheet suspected area /
Appearance 1 … Appearance … … instruction sheet R/WI-QA-EKI-
Visual 100 %. Each Lot QE Y
Segregate & Recheck
029 (R/WI-QA-EKI- the components.
029)

Dispatch Notify Dispatch

No Damage & Should be Dispatch
90 Dispatch 1 … Appearance … … Visual Inspection Per Lot Every Lot Details Note Y Supervisor / QCI & Dispatch Incharge
Proper Identification I/C
(R/F-PD-02) Recheck

LEGEND: PE - PRODUCTION ENGINEER, QE -QUALITY ENGINEER R - RECORDING, SME = Start+ Mid+END of Shift, Y- YES, N - NO, S SIGNIFICANT CHARACTERISTIC ˜ CRITICAL TO PROCESS

ENGINEER / INSPECTOR TO RECORD DIMENSIONS CHECKED BY VERNIER AND COMPILE ALL BAKER REPORTS & CMM REPORTS C CRITICAL CHARACTERISTIC

Note - If there is any abnormality after inspection verify all previous components, inform to shift I/C & all reaction plan is to be done with the approval of shift I/C

Before Dim. was 235.7+1 (-3) revised Dim 231 ± 1.0 after deviation by EKI. And on machine dim added in process sheet for inspection at the time of
03
07.05.2024 production
Jagveer Singh

02
07.05.2024 Temperature (Core/Cavity Inserts) added in PCS Jagveer Singh

Part Weight 247 ± 2gms, Material Shot Size 130~135 mm from165 mm & cusion 5~6mm [Link] sample check change 1 sample to 5 sample at
24.08.2023 FPA/PDIR Stage. Inspection method for CD (196 ±1) change by gauge from DVC.
Gaurav Singh [Link]
01

03.12.2022 initial issue for production with production release drawing Part No. K6C68652171 was K6C6865217A Gaurav Singh [Link]
00

Rev. No. Date Revision Contents Issued By Approved By

REVISION HISTORY

R/F-AP-03, Rev.:00
 RPPL PROCESS SHEET Doc. No.: R / PS /EKI-029 Eff. Date: 07.05.2024

PROCESS / INSPECTION INSPECTION

PART NAME :- HANDRAIL FENDER MOULD NO : EKI-029 P. No.
STAGE
CHECK POINT SPECIFICATION
METHOD FREQUENCY
RESP. RECORDING

Digital temp.
PART NO. : K6C68652171 M/C NO. : R/IM- 10 (250 Ton) R/M Pre Heating
Temperature 90 ± 10 0C
Controller
At Material trey Prod.
(Draying oven) R/F-PR-08
R/ [Link] : EXP99070ES, Make - IN & OUT Engineer
RAW MATERIAL : PP20% TF Time 1½ Hours Wall Clock
Machino Polymer 30
Note - The first initial raw material lot is pre heat in oven. and is controlled through the Pre Heating Record Sheet. After that the initial raw material
PART SCHEMATIC DRAWING will be pre heat in m/c hopper.
Digital temp.
Hopper Drayer Temperature 90 ± 10 0C 2 Hrs. Q.C.I. (R/F-QA-06)
Controller
40 Moulding

40.10 Set Up Approval (First Piece Inspection)

Q.C.
Nozzle Temp. 0C N/A MPU Every Loading R/F-QA-05
Inspector
Temp. 1 (T1) 0C 215 ± 10 ,, ,, ,, ,,
Temp. 2 (T2) 0C 205 ± 10 ,, ,, ,, ,,
Temp. 3 (T3) 0C 195 ± 10 ,, ,, ,, ,,
Temp. 4 (T4) 0C 180 ± 10 ,, ,, ,, ,,
Temp. 5 (T5) 0C 165 ± 10 ,, ,, ,, ,,
Machine Injection Pressure 50 ± 10 ,, ,, ,, ,,
Parameter
Injection Speed 65 ± 10 ,, ,, ,, ,,
Injection Time 10 ± 2 Sec. ,, ,, ,, ,,
Hold Pressure 55 ± 10 ,, ,, ,, ,,
Hold Speed 65 ± 10 ,, ,, ,, ,,

आपरेटर के लिए कार्य निर्देश: 1. प्रत्येक लोडिंग / शिफ्ट के आरम्भ में आपरेटर यह सुनिश्चित कर Hold Time 2 ± 1 Sec. ,, ,, ,, ,,
ले कि सभी मोल्डिंग पैरामीटर प्रोसैस शीट के अनुसार सैट हैं / हों I Locking Pressure 120 ± 10 ,, ,, ,, ,,
2 . मोल्डिंग कॉम्पोनेन्ट को चैक करें यदि कोई मोल्डिंग दोष हो तो उस पीस को स्क्रैप कर दें एवं
लाल विन में डालें I सही पीसों के लिए नीले बिन I खराब पीसों के लिए लाल विन I फीड के लिए अलग से Cooling Time 65 ± 2 Sec. ,, ,, ,, ,,
लाल विन लें I Material shot size 130 ~135 mm ,, ,, ,, ,,
3 . किसी भी ब्रेक के बाद या मशीन बन्द होने की स्थिति में मशीन के बैरल से मैटिरियल प्रज (निकाल)
कर पीस भरें I पहले 5 पीस / शाट स्क्रैप कर रिजेक्शन बिन में डालें I Cusion 5 ~6 mm
4. पावर फेलियर या पावर ट्रिप के दौरान भरने वाला पीस / शाट स्क्रैप कर रिजेक्शन विन या अलग से Mould
Temperature
25 ~ 55 0C
Infrared
,, ,, R/F-QA -06
(Core/Cavity Inserts) 02 Thermometer
दिये गये बिन में डालें I
5. पीस को मशीन से निकलने के बाद नार्मल पानी में डालना है और पानी को हर घंटे बदलना है. the component should Visual Inspection Every Set up Q.C.
Product & or Master (Mould Loading) Inspector
6. प्रोडक्शन स्टार्ट करने से पहले इन्सपैक्टर से पीस विसुअल चैक करायें यदि पीस ठीक नहीं है तो Visual Appearance be free from flashes, sink marks and
Parameter other moulding defects. Sample 100% Pcs after
मशीन न चलायें I 01 scraping First *5
सेफ्टी पॉइंट्स : मशीन चलाते समय डाई के कोर व कैविटी में हाथ न डालें I No component damage. No mark shots.
Visual Appearance allowed on all external surfaces
during insert moulding.
First & Last Piece
Dim.(On Machine) 240 ± 1.0 DVC/Gauge * 5 NOS 01 ,, Inspection Report
1 (R/F-QA-05)
03 Dim. (after 24 Hrs)) 231 ± 1.0 DVC/Gauge
C * To be inspected
03 CD(On Machine) 204 ± 1.0 DVC/Gauge ,, 5 Nos / Cavity but
01
2 records will be
CD (Afetr 24 Hrs) C 196 ± 1 Gauge 01 ,, ,,
maintain on 1
3 Dim. 72.4 ± 0.65 HG ,, ,, sample per cavity.

Before Dim. was 235.7+1 (-3) revised Dim 231 ± 1.0 after deviation by EKI. And on
07.05.2024 4 Thread M10x1.25 TRG ,, ,,
03 machine dim added for inspection at the time of production

Weigh (Plastic and metal

07.05.2024 Mould Temp 25 ~ 55°C Was 45 ~ 55°C Gaurav Singh MPS 01 5 C 247 ± 2gms Weight Scale ,, ,,
02 insert)

Part Weight 247 ± 2gms, Material Shot Size 130~135 mm from165 mm & cusion 5~6mm
Process Same as Process No. Same as Process Q.C. R/F-QA -06
01 24.08.2023 added. the sample check change 1 sample to 5 sample at FPA/PDIR Stage. Inspection Gaurav Singh MPS 40.20 Same as Process No. 40.10 6 Hrs.
method for CD (196 ± 1) change by gauge from DVC.
Inspection 40.10 No. 40.10 Inspector (As above)

Last Piece Same as Process At Mould Off R/F-QA -05

00 03.12.2022 Initial issue Gaurav Singh MPS 40.30 Product Parameter Same as Process No. 40.10 ,,
Inspection No. 40.10 loading (As above)

Rev. No. Date Revision Content Issue By [Link] or Critical Dim, SPC to be carried out for Critical Item as per SPC Plan.
C S
R/F-AP-05, Rev.:00