Customer :-M&M

BPI Process Flow Chart Date :- 4-10-2023

Part Name :- Shifter Bush Part No :-222029

SHIFTER BUSH

10 Received Raw Material Inspection

20 Shearing(inspection)

30 Die Pre Heating

40 Cut Piece Heating & Forging

50 Trimming & Inspection

60 Belt Grinding

70 Shot Blast & Inspection

100% Pre Despatch Inspection

80
( P.D.I. )

90 Dispatch

D Temporary Storage Revision No. Date Revision Description

storage

Quantity Insp.

LEGENDS Operation
FOR
CONTROL Quality Insp.

Operation Cum Insp.

Qlty Cum Qty Insp.

Transfer

Checked By :- Approved By :-
 BPI Revision 0
PROCESS FAILURE MODE AND EFFECTS ANALYSIS
Focal Point, Ludhiana Code :

(Rev.'0' )(4-10-2023) Core Team :[Link] ./ Mr,Jagjit / [Link] bhargave FMEA No. : 01
Part Name: Shifter Bush Customer :M&M Prepared By:
Assy. Name: Process Responsibility: [Link] Reviewed By: CFT
Assy. No: Key Date : 4-10-2023 Rev. Date :
Process Potential Potential Potential Action Results
O Current Process Control Responsibilit
Function Failure Effect (s) of CL Cause(s) C Action S O D R
SE D E T R Recommended y & Target
Requirement Mode Failure AS Mechanism(s) C Taken E C E P
V U E C PN Action (S) Completion
S To Prevent Occurrence
R Date
of Failure V C T N

Technical delivery
conditions ( insp. Std. ) Supplier lab report and
Improper comp. at
1. Improper chemical comp. Low/ High Hardness 7 S 1 given to supplier and same Incoming inspection at 7 49
supplier end
mentioned on Purchase our end
Order .

10. Receipt of Raw Matl. Sampling inspection at Step down and

2. Crack Premature failure 6 C Improper pouring 1 supplier end for crack upsetting test during 7 42
detection incoming inspection

100% meta scope / spectro Grade wise color

3. Matl. Mixup Low/High Hard. 7 C Poor 5S at sup. end 1 insp. At supplier end before coding & separate 7 49
dispatch. storage of material.

1. Excess weight Thickness O/Size 4 m 2 5 40

Inspection during Stopper Inprocess inspection
Wrong stopper setting
setting during cutting
2. Less weight Unfilling/ thickness less 6 m 2 5 60
20. Billet cutting
(SHEARING) Mistake while storage Separate storage of different operator training
3. Mix up with other grade Low/ High Hardness 7 C 1 7 49
after cutting the matl. grades provide

Resharpening of tool is done

4. Burr Overlapping while forging 5 m Re-sharpening not done 2 when burr observed during Display of limit samples 7 70
inprocess inspection
Preventive maintenance of
Unfilling/thick. O/Size/ furnace and automatic Monitoring through
30. Die Pre heating Low Heating 7 M Die not properly heat 3 3 63
tool worn out temperature sorter installed digital display meters.
in the furnace

Scaling not cleaned by Training to operators for

1. Pitting 6 m 2 5 60
operator from die cavities removal of scaling
Inprocess inspection &
Non-clearance while
100 % visual inspection
machining & in house rej.
Billet less weight/ die size Billet & die inspection before forging
2. Unfilling 6 m not ok / opt. fails to get 2 before production & 5 60
correct piece Training to operators

Shearing burr Resharpening of shearing 100% Inspection

3. Over lapping/ Crack Rejection of component 7 C 2 5 70
tool. through Magnaflux

M-Major, m-Minor, C - Critical, S-Safety parameter Page 2 of 9

 BPI Revision 0
PROCESS FAILURE MODE AND EFFECTS ANALYSIS
Focal Point, Ludhiana Code :

(Rev.'0' )(4-10-2023) Core Team :[Link] ./ Mr,Jagjit / [Link] bhargave FMEA No. : 01
Part Name: Shifter Bush Customer :M&M Prepared By:
Assy. Name: Process Responsibility: [Link] Reviewed By: CFT
Assy. No: Key Date : 4-10-2023 Rev. Date :
Process Potential Potential Potential Action Results
O Current Process Control Responsibilit
Function Failure Effect (s) of CL Cause(s) C Action S O D R
SE D E T R Recommended y & Target
Requirement Mode Failure AS Mechanism(s) C Taken E C E P
V U E C PN Action (S) Completion
S To Prevent Occurrence
R Date
of Failure V C T N

Billet insepection before acept and reject system

[Link] Rejection of component 6 c Furnace temp over heat 4 70
forging implement

40. Cut Piece Heating &

forging
Tool worn out while Inprocess inspection
Die depth more/ Billet Billet & die inspection
4. Thickness Over size machining & in house 5 M weight more
2
before production
&100% guage 4 40
salvage inspection

1) Top & bottom block 1) Lock availability in top &

allignment not ok. bottom block
5. Mismatch Rejection of component 7 M 2) 2 2) Die inspection before 5 70
Wrong die manufacturing loading
Inprocess inspection &
100 % visual inspection
before forging
Negligence of operators
Conveyor installed between
during placing of
6. Side Cut Rejection of component 7 M 2 trimming press and trolley 5 70
component in trolley after
(bin) to move the piece.
trimming.

Over heating of billet/ Automatic temperature Inprocess inspection

Non-clearance while
7. Thickness Under Size 7 M Billet weight less/ Die 2 controller & Billet and Die &100% gauge 4 56
machining In house rej.
depth less inspection before production inspection

Inprocess inspection &

50. Trimming & Material Proj./ removal of parent Trimming tool worn out/
In house salvage/ rejection 6 m 2 Training to press man 100 % visual inspection 5 60
Inspection material out trimming by operator
before machining

VISUAL AS PER REF.

BURR GRIND 1 BURR FREE 5 60
BELT GRINDER SAMPLE PER LOT
[Link] Grinding
BG.-01,02,03, 100%
BELT NO 2 36 Visual 5 54

M-Major, m-Minor, C - Critical, S-Safety parameter Page 3 of 9

 BPI Revision 0
PROCESS FAILURE MODE AND EFFECTS ANALYSIS
Focal Point, Ludhiana Code :

(Rev.'0' )(4-10-2023) Core Team :[Link] ./ Mr,Jagjit / [Link] bhargave FMEA No. : 01
Part Name: Shifter Bush Customer :M&M Prepared By:
Assy. Name: Process Responsibility: [Link] Reviewed By: CFT
Assy. No: Key Date : 4-10-2023 Rev. Date :
Process Potential Potential Potential Action Results
O Current Process Control Responsibilit
Function Failure Effect (s) of CL Cause(s) C Action S O D R
SE D E T R Recommended y & Target
Requirement Mode Failure AS Mechanism(s) C Taken E C E P
V U E C PN Action (S) Completion
S To Prevent Occurrence
R Date
of Failure V C T N

1) Readdition of fresh
shots , single shot size used
for all items.
1)Shot size not ok
2) Time duration chart
70. Shot Blasting 2) Shot blasting time Limit samples given for
Scaling not removed re-work on material 4 m 2 displayed and automatic 7 56
less, visual insp.
stoppage of machine as per
3)Leakage of shots
time duration given.
3) Preventive maintenance
of the machine.

Die setting not proper/

100% Inspection with
80*. PDI inspection Dimensional Problem Rejection at inhouse end 7 M Coining Tool sizes not 2 Training to operator 4 56
Gauge
OK

90 Packing & Dispatch Damage to material Rejection at customer 5 m Poor handling/poor 2 Packaging material 6 60

end packaging material with proper specification

To send the material to
is used.
customer in good condition
Less/Excess qnty. Customer 5 m Negligence during 2 Packing standard 6 60

dis-satisfaction packing displayed in packing area

M-Major, m-Minor, C - Critical, S-Safety parameter Page 4 of 9

 Rev. - 0
BPI
CONTROL PLAN Code:BPI/qc/16
Prototype Pre-Launch Production Key Contact Phone: Date(Orig) Date(Rev.)
Control Plan Number : 1
Part Number/latest change level :222029 Core Team:[Link] ./ [Link] / [Link] bhargave/[Link] Customer Engineering Approval

Part Name :Shifter Bush Plant approval/date Customer Quality Approval

Customer: M&M Supplier Code Other approval/date(if reqd) Other Approval

Part/ Process Machine Characteristics Methods

Process Name/ Device, Special Product/Process Evaluation/ Sample Control Reaction
No [Link]. Jig, Tools No. Product Process Char. Class 8 Measurement Size Freq. Method Plan
for BPIg. Tolerance Technique
10 Raw Mtl. EN8D

Incoming Stage As per Std (rec.)

a. Dimn./Insp. i Diameter section size 36 mm dia D.V.C. As per sampling BPI/QC/02

b Chemical ii C% IS187645C8 0.40-0.45 At Lab. Plan Rej. Material send back to

the party. And get a CP
Analysis v Mn% 0.70-0.90 BPI/QC/01 action report

vi S% 0.045max
v P% 0.045max

(d) Macro defects No Piping

Step Down Test (Macro

(i) sreak Flaw Test)
Lathe M/C No Piping/No Crack Visually IS 4075:1985

(ii) Upsetting test Hammer No Crack allowed TS-10167-1982

C : Critical; F : Fit Function ; S : Safety Parameter Page 5 of 9

 Rev. - 0
BPI
CONTROL PLAN Code:BPI/qc/16
Prototype Pre-Launch Production Key Contact Phone: Date(Orig) Date(Rev.)
Control Plan Number : 1
Part Number/latest change level :222029 Core Team:[Link] ./ [Link] / [Link] bhargave/[Link] Customer Engineering Approval

Part Name :Shifter Bush Plant approval/date Customer Quality Approval

Customer: M&M Supplier Code Other approval/date(if reqd) Other Approval

Part/ Process Machine Characteristics Methods

Process Name/ Device, Special Product/Process Evaluation/ Sample Control Reaction
No [Link]. Jig, Tools No. Product Process Char. Class 8 Measurement Size Freq. Method Plan
for BPIg. Tolerance Technique

20 Stop the machine, segregate the

I Cut Weight gms ±20 gm Wt. Balance 2 Pcs 2 Hrs BPI/QC/02 matl. & verify the stopper setting

II Dia 36mm dia D.V.C.

Shearing SHEARING
(Shearing of Raw MACHINE
Material Bar) SM01( 600T) III Length 92mm D.V.C.

Stop the machine & re-

sharpened the tool and
III Burr Not allowed Instruments 2 pc 2 Hrs Do segregate burr material for belt
grinding.

1 TEMPERATURE 250-450 degree PYROMETER

30 BLOWER/HOT EACH DIE BLOCK
DIE PRE-HEATING BILLET CUT PCS BPI/QC/02 AGAIN PRE HEATING
SET
2 SOAKING TIME 15 MINTUE CLOCK

Inform to furnace operator,

Hot Forgings I Billet Temp. 1100⁰-1200⁰ C D.T.M After 1 Hours BPI/QC/07-28 Press man, Forger or
Maintenance department

( to make the forged II No of Strokes 5 - final Visual

DROP
FORGING 1.5 Clamping of By Manual
component) TON III Should not loose
[Link] Tightening
40 & 50
By Manual
IV Clamping of Trimmming Tool Should not loose
Tightening

V Die Temp. 250-450°C

INDUCTION
Cut Piece i Temperature 1100⁰-1200⁰ C Inform to furnace opt./maint.
FURNACE O. Pyrometer /Digital During Machine
BPI/QC/25
Temperature Meter Setting
Heating deptt. to control the heat.
1 LENGTH * 42.7 Vernier Caliper
2 WIDTH * 45 Vernier Caliper
DROP 3 THIKNESS * 25 Vernier Caliper 100% CHECK
Layout
40&50 FORGING 4 DIA * 24 Vernier Caliper
5Pcs
inspection
Stop production & get the
TRIMMING &
HAMMER NO.
( 05,1.5T.) &
5 Mismatch * 0.4mm V.C AND
AND * mark in
Set up and
tool repaired from Tool
Inspection
POWER 6 CRACK * Not allowed Visual RECORD
02 hrs
inprocess
Room. If machine break
down inform to maint. deptt.
PRESS record
100T.75T
C : Critical; F : Fit Function ; S : Safety Parameter BPI/QC/02 Page 6 of 9
 Rev. - 0
BPI
CONTROL PLAN Code:BPI/qc/16
Prototype Pre-Launch Production Key Contact Phone: Date(Orig) Date(Rev.)
Control Plan Number : 1
Part Number/latest change level :222029 Core Team:[Link] ./ [Link] / [Link] bhargave/[Link] Customer Engineering Approval

Part Name :Shifter Bush Plant approval/date Customer Quality Approval

Customer: M&M Supplier Code Other approval/date(if reqd) Other Approval

100% CHECK
Part/ Process DROP
Machine Characteristics Methods Layout
40&50
Process Name/ FORGING
Device, Product/Process Evaluation/ Sample inspection
Control Reaction& get the
Special 5Pcs Stop production
HAMMER NO. Char. Class AND * mark in
No TRIMMING
[Link]. & Jig, Tools No. Product Process 8 Measurement Size AND Freq. Method Planfrom Tool
tool repaired
( 05,1.5T.) & RECORD
Set up and
Room. If machine break
Inspection for BPIg. Tolerance Technique inprocess
POWER 02 hrs down inform to maint. deptt.
PRESS 7 Burning * Not allowed Visual record
100T.75T 8 Overlap * Not allowed Visual BPI/QC/02
50 9 Pitting * Not allowed Visual
10 Unfilling * Not allowed Visual
First pcs Insp. With relavent Inspection As per Forged drawing With 1st pcs of die BPI/QC/02
Stop forging information to
instruments 100% insp. of relevant
Q.C and Production Incharge
Dimensions instruments
BELT VISUAL WITH REF.
1 BURR GRIND BURR FREE
GRINDER SAMPLE HOLD THE MATERIAL &
60 BELT GRINDING
( BG.-
100% PER LOT NIL RE- GRINDING
01,02,03, ) 2 BELT NO-36 36 Visual
460 ,550 NO
i Shot Size D.V.C. Supervision Addition of new shots
(0.8~1.2mm) During Machine
Shot blasting 30mins. For setting.
Shot Blasting ii Machine setting
70 Shot Blasting time 150~250 nos.
machine
Inform to opt. for re shot
I Scale Removal No Scales Visual 100%
blasting

C : Critical; F : Fit Function ; S : Safety Parameter Page 7 of 9

 Rev. - 0
BPI
CONTROL PLAN Code:BPI/qc/16
Prototype Pre-Launch Production Key Contact Phone: Date(Orig) Date(Rev.)
Control Plan Number : 1
Part Number/latest change level :222029 Core Team:[Link] ./ [Link] / [Link] bhargave/[Link] Customer Engineering Approval

Part Name :Shifter Bush Plant approval/date Customer Quality Approval

Customer: M&M Supplier Code Other approval/date(if reqd) Other Approval

Part/ Process Machine Characteristics Methods

Process Name/ Device, Special Product/Process Evaluation/ Sample Control Reaction
No [Link]. Jig, Tools No. Product Process Char. Class 8 Measurement Size Freq. Method Plan
for BPIg. Tolerance Technique
80 Final Inspection

As per sampling plan BPI/QC/06 Stop Packing &segregate the

(a) Dimensional 1 42.7
Vernier Caliper
LENGTH mat. & keep separate with
proper identification for
45
2 WIDTH Vernier Caliper further analysis

THIKNESS 25
3 Vernier Caliper
24
4 DIA Vernier Caliper

5 Mismatch 0.4mm V.C

6 CRACK Not allowed Visual

7 Burning Not allowed Visual

8 Overlap Not allowed Visual

Do
9 Pitting Not allowed Visual
Do
10 Unfilling Not allowed Visual
11 Mat. Proj. Not allowed Visual Do

90 Packing & Dispatch

Stop packing & & apply the
oil all around the part
a) Rust preventive Manual 100% Inspection Supervision
Dip the pcs in rust preventive oil
RP 68
Oil application

Stop packing & use the

b) Packing Manual 100% Inspection BPI/QC/06
proper packaging material.
150pc/bag

c)
Identification
Marking on jute bag
satensal
i Customer Name & Address Should be properly visible
loose
ii Component name & Part no.

III Quantity

C : Critical; F : Fit Function ; S : Safety Parameter Page 8 of 9

 Rev. - 0
BPI
CONTROL PLAN Code:BPI/qc/16
Prototype Pre-Launch Production Key Contact Phone: Date(Orig) Date(Rev.)
Control Plan Number : 1
Part Number/latest change level :222029 Core Team:[Link] ./ [Link] / [Link] bhargave/[Link] Customer Engineering Approval

Part Name :Shifter Bush Plant approval/date Customer Quality Approval

Customer: M&M Supplier Code Other approval/date(if reqd) Other Approval

Part/ Process Machine Characteristics Methods

Process Name/ Device, Special Product/Process Evaluation/ Sample Control Reaction
No [Link]. Jig, Tools No. Product Process Char. Class 8 Measurement Size Freq. Method Plan
for BPIg. Tolerance Technique

Checked By Approved By
Rev.0 Production lot
Head of Department CFT
Date of Issue Modification Detail

C : Critical; F : Fit Function ; S : Safety Parameter Page 9 of 9