PART NAME: PART NO:

Cover plate 2KN M MS 038BSN

CUSTOMER

M/s Cooper Bussmann India Pvt. Ltd., Pondicherry

SUPPLIER NAME:

M/s .ACE ELECTRICAL EQUIPMENTS (I) PVT. LTD., HOSUR .

PPAP
Production Part Approval Process
Cooper Part Number 038BSN Revision Level G

Submission Requirements Supplier Checklist

Part Description Cover plate 2KN M MS Cooper Purchasing Rep. Mr.Jagan Purchasing Rep Phone # 9442521823

Submission Level
(Please Type 1-5)

Primary Manufacturing Site

Supplier Name M/s.ACE Electrical Equipments India Pvt Ltd Submission Date 04.03.2013 PPAP Due Date Included
YES

PPAP Requirements
Element Order Level 1 Level 2 Level 3 Level 4
Important: Submit your documents in this order.

Level 5

AIAG PPAP Fourth Edition

Required Documents
Cooper PSW Required

Assigned to

Internal Due Date

Comments/Concerns/Questions

Part Submission Warrant (PSW)

AR

Design Records & Bubbled part print(s).

AR

Two Cooper Divisional Parts Prints

b b
YES

Approved Engineering Change Documentation

AR

AR

Various engineering documentation

YES

r r r

Customer Engineering Approvals

Not Required for Cooper Submissions

YES

Design FMEA,

AR

AR

AR

Can be Cooper FMEA Format or an AIAG compliant DFMEA.

YES

Process Flow Diagrams

AR

Any standard flowchart format.

YES

b b b b b b b b b b b b
r b r r r r

Process FMEA

AR

Can be Cooper PFMEA Format or an AIAH compliant PFMEA.

YES

Control Plan

AR

Can be Cooper supplied format or AIAG compliant format. Cooper GRR format or any statistical package format for gage R&R. Must be on Cooper Dimensional report format Industry Standard reports or test result formats designated by Cooper Industries. Process Capability Study using any statistical package or Cooper Capability Data Forms. Lab Scope and outside lab proof of accreditation.

YES

Measurement System Analysis Studies

AR

AR

YES

10

Dimensional Results

AR

YES

11

Material, Performance Test Results

AR

AR

YES

12

Initial Process Study (Cpk) Capability Studies

AR

AR

YES

13

Qualified Laboratory Documentation

AR

YES

14

Appearance Approval Report

AR

AR

AR

AR

AR

AIAG format AAR

YES

15

Sample Product Parts

AR

Parts tagged in accordance with Cooper PPAP reference manual

YES

16

Master Samples

Required only for level 5

YES

17

Checking aids

AR

Checking aid design prints and GRR for checking fixtures.

YES

18

Customer Specific Requirements

Documents as specified by Cooper Industries

YES

Tooling Information Form

AR

Specific document required by Cooper Industries.

Packaging Form

AR

Specific document required by Cooper Industries.

YES

Inspection Plan
(ASC Suppliers only)

YES
IA IA IA IA

Specific ASC Format

Specification Deviation Form

IA

IA

IA

IA

Specific document required by Cooper Industries.

YES

Supplier PPAP Checklist

AR

Specific document required by Cooper Industries.

YES

Required for PPAP submission

Not required

Documents on a case by case basis are marked AR for "As Requested"

AR

IF Applicable

IA

ACE Electrical Equipments India Pvt Ltd - Hosur

Part Name

Part Submission Warrant

Cooper Part Number

Yes

No

Cover plate 2KN M MS

038BSN G
Dated Dated

Safety and/or Government Regulation Additional Engineering Changes Shown on Drawing Number

Engineering Drawing Revision Level

7/18/2011 7/18/2011 51.3500g

Set in missing dimensions on holes around slot 038BSN

Purchase Order No.

Weight (kg)

SUPPLIER MANUFACTURING INFORMATION

SUBMISSION INFORMATION

ACE Electrical Equipments India Pvt Ltd

Supplier Company Name Supplier Vendor Number

609318

Cooper Bussmann
Customer Name: COOPER BUSSMAN-PONDY

Additional Manufacturing Sites

Cooper Manufacturing Locations using the part (list all)

Yes
Street Address

No No No

Mr.Jagan
Purchasing Representative

PONDICHERRY Purchasing Office

Yes

106/2A-1 BEHIND ESI HOSPITAL,OUTER RING ROAD HOSUR

City-HOSUR State

TAMIL NADUZip 635126

Yes

PPAP Due Date:

SOP Date

Does this part utilize Cooper owned tooling? Is it properly identified? Does this part contain any restricted substances or require IMDS submission?

If yes, P.O. # Substance(s)? IMDS Number

Are plastic or polymeric parts identified with appropriate ISO marking codes? REASON FOR SUBMISSION Initial submission (New Parts and Part Number Changes) Engineering Change: New/Revised drawing or other specification Tooling: transfer, replacement (new), refurbishment, modified or additional Correction of Non-conformance or discrepancy New Supplier, New material or new source for existing material Change of supplier, material or non-equivalent materials/services New process or a change in production process or method Change of manufacturing location, sub-supplier or additional location Other - please specify

YES NO Change to optional construction, material or component YES NO

REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant only submitted to the customer (Applied to non-critical parts and raw bulk material) Level 2 - Warrant with product samples amd limiting supporting data. (Applied to critical bulk product and simple changes) Level 3 - Warrant with product samples and complete supporting data. (Applied to new parts on Cooper programs) DEFAULT COOPER SUBMISSION LEVEL Level 4 - Warrant and other requirements as defined by Cooper.(Applied only with prior approval from Cooperspecial situations only!) Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. (Applied to parts requiring onsite review ) SUBMISSION RESULTS The results for dimensional measurements material and functional tests appearance criteria statistical process package

These results meet all drawing and specification requirements: Is this a multicavity tool? How many Cavities/Spindle (for molds or dies) ?

(If "NO" - Explanation Required in Explanation/comments section below ) Number of parts submitted by cavity/spindle

Interim DECLARATION
I affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable Production Part Approval Process Manual 4th Edition Approved Rejected requirements. I further warrant these samples were produced with the specified materials on regular production tooling with no operations other then the regular production process. The data and samples were produced at the production rate of are noted below in the explanation/comments section. EXPLANATION/COMMENTS:
#parts

in
# hours

on
date

Any deviations to this warrant submission

Print Name:

Vinothkumwr

Job Title

NPD

Phone No. Date

04344-274943 Email

Fax No.

274942

Supplier Authorized Signature

5/17/2013

acehosur@gmail.com

FOR COOPER INDUSTRIES USE ONLY

Quality/Supplier Quality Initial Part Warrant Disposition: Quality/Supplier Quality Management Expires: Final Part Warrant Disposition: Quality or Supplier Quality Date

SABAREESWARAN.M KALYANASUNDARAM.E

Date Date

18.05.2013 18.05.2013

Print Approver Name:

Cooper PPAP Tracking Number:

016/2013

Control Plan
Control Plan Number ACE-COOP/CP/077 Key Contact / Phone kalimuthu(prodn) Thangaraj (Qc) Vinothkumar (Designer) Date (Orig.) 4-Mar-13 Part Number/ Latest Change (Rev) Level Part Description 038BSN Cover plate 2KN M MS Core Team kalimuthu(prodn) Thangaraj (Qc) Vinothkumar (Designer) Customer Engineering Approval / Date (If Req'd) 18.07.2011 Current Release Level G Supplier Code 609318 Quality Department Approval Current Release Date July 18, 2011 Plant Location Press Shop

Supplier Name ACE Electrical Equipments India Pvt Ltd Supplier Plant Approval

Other Approval / Date (If Req'd)

CHARACTERISTICS PART / PROCESS NUMBER PROCESS NAME / OPERATION DESCRIPTION MACHINE DEVICES / JIG / TOOLS FOR MANUFACTURING SPECIAL CHAR. CLASS

METHODS SAMPLE FREQ EVALUATION/ MEASUREMENT TECHNIQUE

NO.

PRODUCT

PROCESS

SIZE

PRODUCT / PROCESS / SPECIFICATION / TOLERANCE

CONTROL METHOD

REACTION PLAN

10.1 10.2 10 Raw material out sourcing 10.3 10.4 10.5 10.6 20.1 20.2 20.3 20.4 20.5 20.6 20.7 20 Blanking & Piercing 55 ton 20.8 20.9 21 21.1 21.2 21.3 21.4 21.5 30.1 30 Piercing 40T 30.2 40.1 40 Bending 40Ton 40.2 40.3 50.1 50.2 50 Plating 50.3 50.4 50.5

material

Brass(Cu Zn37) to CW508L:BS EN 1652:1998 Temp : R350

2.0 0.10 _ _ 62 0.20
1220 2.0

test ceritifcate micro meter veriner caliper measuring tap visual

100% 100% 100% 100% 100% 100% incoming inspection done&reciving test If Not Ok Quarantine and Return to certificate by supplier Supplier

Thickness Width Length

Damage Hardness

Not allowed HV Min 120-Max 155

Hardness Will Check External Laboratory as per plan

Length Width Hole Pitch Hole Pitch 4 Holes Dia 2 Holes Dia Hole Pitch Slot width
Slot Length _ _

58 0.8 58 0.8 43.8 0.5 43.8 0.5 6.0 0.2 5.5 0.2 140.2 90.2 280.2 18.00.2 0.20 R8 0.1 2.0

Vernier Vernier Vernier Vernier Pin Gauge Pin Gauge Height Gauge Vernier Vernier Height Gauge Height Gauge Radius Gauge Height Gauge
visual

5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 As per the Sample Plan Setup Approvel and inprocess inspection as per Sample Plan If not ok , Stop the process and correct the same , segereate the ealirer produced qty

Dimension Flatness Radius Flatness Dimension Holes Dia Hole Pitch

_ _

* *
_

3.8 0.05 180.1 5.30.1 6.40.2 10.00.2 7.00.2

Tin plated 3-5 Not allowed

Pin Gauge
Vernier Pin Gauge

Hole Dia Hole Pitch

Height Dimension Plating Thickness Peel off Dull finish Plating tarish Blisters _ _

Height Gauge Height Gauge Vernier

P.T. gauge Orange peel of test visual visual visual

Not allowed Not allowed Not allowed

as per Sample plan

100% incoming inspection If Not Ok Quarantine and Return to done&reciving test Supplier certificate by supplier

Note: All part print CTQ's must be clearly identified on this control plan.

Page 4 of 14

Control Plan
Control Plan Number ACE-COOP/CP/077 Key Contact / Phone kalimuthu(prodn) Thangaraj (Qc) Vinothkumar (Designer) Date (Orig.) 4-Mar-13 Part Number/ Latest Change (Rev) Level Part Description 038BSN Cover plate 2KN M MS Core Team kalimuthu(prodn) Thangaraj (Qc) Vinothkumar (Designer) Customer Engineering Approval / Date (If Req'd) 18.07.2011 Current Release Level G Supplier Code 609318 Quality Department Approval Current Release Date July 18, 2011 Plant Location Press Shop

Supplier Name ACE Electrical Equipments India Pvt Ltd Supplier Plant Approval

Other Approval / Date (If Req'd)

CHARACTERISTICS PART / PROCESS NUMBER PROCESS NAME / OPERATION DESCRIPTION MACHINE DEVICES / JIG / TOOLS FOR MANUFACTURING SPECIAL CHAR. CLASS

METHODS SAMPLE FREQ EVALUATION/ MEASUREMENT TECHNIQUE

NO.

PRODUCT

PROCESS

SIZE

PRODUCT / PROCESS / SPECIFICATION / TOLERANCE

CONTROL METHOD

REACTION PLAN

60.1 60.2 60.3 10 60 Raw material Finel inspection out sourcing 60.4 60.5 60.6 60.7 60.8 60.9 70.1 70 packing&despacth 70.2

Thickness
Width Slot Length _ Slot width Hole to hole center _ _ _

2.0 0.10 58 0.20

micro meter veriner caliper veriner caliper veriner caliper veriner caliper 100% incoming inspection done&reciving test If Not Ok Quarantine and Return to certificate by supplier Supplier As per sampling plan If not ok Rework / Rejection

280.2 90.2 43.80.5 60.2

0.2max Not allowed Not allowed as per packing standards

4 Holes Dia
Flatness Damage Burr Part Name : Cover plate 2KN M MS Part No : 038bSN

Pin Gauge
veriner height gauge visual visual visual 100% Despatch Register

Note: All part print CTQ's must be clearly identified on this control plan.

Page 5 of 14

FLOW CHART
Control Plan Number ACE-COOP/CP/054 Key Contact / Phone
kalimuthu(prodn) Thangaraj (Qc) Vinothkumar (Designer)

Date (Orig.) 3/4/2013

Current Release Level Supplier Code 609318 Quality Department Approval

Current Release Date 18/07/2011 Plant Location

Part Number/ Latest Change (Rev) Level Part Description 038BSN Cover plate 2BK M MS Supplier Name Core Team kalimuthu(prodn)k.Thangaraj (Qc) Vinothkumar ACE Electrical Equipments India Pvt Ltd (Designer) Customer Engineering Approval / Date (If Req'd) Supplier Plant Approval

Other Approval / Date (If Req'd)

ACE ELECTRICAL EQUIPMENTS (I) PVT LTD PROCESS FLOW DIAGRAM COSTOMOR:COOPER BUSSMANN Part no : 038BSN Part Name : Cover plate 2KN M

Revision No : F Revision Date :18/7/2011

PART PROCESS NO 10

RM-SUPPLIER M/S USHA ENTER OK INCOMING INSPECTION OK

BLANKING PIERCING

NOT OK

RETURN BACK TO SUPPLIER

PART PROCESS NO 20

OK INPROCESS INSPECTION
OK

NOT OK

REWORK REJECTION

PART PROCESS NO 30

Piercing

OK INPROCESS INSPECTION OK
NOT OK

NOT OK

REWORK REJECTION

PART PROCESS NO 40

Bending

REWORK REJECTION

OK INPROCESS INSPECTION
OK

NOT OK

RETURN BACK TO SUPPLIER

PART PROCESS NO 50

PLATTING SUPPLIER CHEMTRECT OK

PART PROCESS NO 60

INCOMING/FINAL INSPECTION OK

NOT OK

RETURN BACK TO SUPPLIER

PART PROCESS NO 70

PACKING-AS PER STANDARD

NOT OK

REPLACING PROCEDURE

OK DESPATCH

Storage
Prepared By :

Inspection OK
Approved By :

ProcessK

Movement K

Page 7 of 14

Potential Failure Modes and Effects Analysis Design FMEA

Print # Item Name Rev # Core Team Design Responsibility Contact Number Key Date Customer Manufacturing Site

Please indicate EITHER: 1.) A designated RPN threshold for this process 2.) A target percentage of steps to be addressed. Check One FMEA Number Prepared By FMEA Date (Orig.) FMEA Date

Item/ Function

Requirements

C S l Potential Potential Effects E a Failure Mode of Failure V s s

Item Number

Current Product Controls Potential Cause(s)/ Failure Mechanisms O C C Responsibility D R Recommended and E P Action(s) Completion T N Date

Action Results S O D R E C E P V C T N

Prevention

Detection

Actions Taken

NOT APPLICABLE

Potential Failure Modes and Effects Analysis Process FMEA

Part No Item Name Rev # Core Team 038BSN Cover plate 2KN M MS G
kalimuthu(prodn)k.Thangaraj (Qc) Vinothkumar (Designer)

Please indicate EITHER: 1.) A designated RPN threshold for this process 2.) A target percentage of steps to be addressed. Check One FMEA Number ACE-COOP/FEMA/077 Prepared By K.Thangaraj FMEA Date (Orig.) FMEA Date 05.03.2013

Page 8 of 14

Process Responsibility Contact Number Key Date Customer Manufacturing Site

PRODUCTION Kalimuthu - 9442527496 PRESSING

Process Number

Process/Step Function

Requirements

Potential Failure Mode

Potential Effects of Failure

S E V

C l a s s

Current Process Controls Potential Cause(s)/ Failure Mechanisms O C C Responsibility D R Recommended and E P Action(s) Completion T N Date

Action Results S O D R E C E P V C T N

Prevention

Detection

Actions Taken

2.0 0.2mm

Under Size/Over Size thick

Fitment Problem

material mixup

10 Raw material

Brass to CW508L,BS EN1652 Hardness Min 120Max 155

Hardness problem

Process Rejection Will More

material mixup

visual

Peelup,Damage

unable to use production (Damaged material)

Proper handling & Storage

Each Bundlewe have to check 3 72 minium 10 Points Hardness Will Check 100%inspection External 3 72 & test certificate Laboratory as recived from per plan suppiler end Check the condition of the packing & 3 72 contents before moving it to storage area inprocess inspection 3 72 Inprocess Inspection Report

store department

As per Drawing Specification 20 Blanking & Piecring

Out of Specification Burr and share edge

Fitment Problem Fitment Problem/Safety Problem Fitment Problem

Wrong Tool Holded in the Machine Tool Allayment varition ,Punch worn out Handling Problem,proper Clean the before holding the Tool Wrong Tool Holded in the Machine Handling Problem,proper Clean the before holding the Tool Wrong Tool Holded in the Machine Handling Problem,proper Clean the before holding the Tool Timing problem,machine Problem Timing problem,machine Problem handling Problem,Process Sequence Problem handling Problem,Process Sequence Problem

With out Burr

visual As per Drawing Specification 30 Piecring visual

Damage,Dent

Periodically 3 Cuttung Edge has to Grind Periodically 3 Cuttung Face has to Clean 3 inprocess inspection

3 54

Production dept

3 54

Out of Specification
Damage,Dent

Fitment Problem

3 72

Fitment Problem

Periodically 3 Cuttung Face has to Clean 3 inprocess inspection Periodically Cuttung Face has to Clean incoming inspectin incoming inspectin finel inspection

3 54

Inprocess Inspection Report

Production dept

As per Drawing Specification 40 Bending visual

Out of Specification

Fitment Problem

3 72

Inprocess Inspection Report

Production dept

Damage,Dent

Fitment Problem Functional Problem Functional Problem Line Assy Problem Line Assy Problem

6 6 6 6 6

3 3 3 3

3 54 3 54 3 54 Supplier Inspection Report

50 Plating

Tin plated 3-5

60 Final inspection 70 Packing & Despacth

As per Drawing Specification As per Schedule Qty

Plating Thickness undersize Plating Thickness oversize Qty variation & material miss up Qty variation & material miss up

Quality dept store department store department

Final Inspection 3 54 report Final Inspection 3 54 report

finel 3 inspection

Date of Measurement:

05.01.2013

DIMENSIONAL DATA SHEET

Supplier Name: Part Name: Part Number Drawing Number: Revision Level: Revision Date:
Data Type: V=Variable A=Attribute

Page #:
Supplier Signature Title Quality incharge

ACE Electrical Equipments India Pvt Ltd Cover plate 2SK M MS 31 038BSN 038BSN G 7/18/2011

Reason for Data Submission (check all that apply):

Initial submission Correction of Non-conformance New/Revised drawing or other specification Change to optional construction or material New/revised item, material or product component New Supplier New or significantly modified process or routing Change of location, sub-supplier or material

Supplier Representative: Name K.Thangaraj

Judgement Legend Phone Number 9524735080 Email: acehosur@gmail.com

OK OKNI

Meets Requirements OK But Needs Improvement Does Not Meet Requirements Judgement Comments/Action Plan

Tooling: Transfer, replacement, refurbishment Other - please specify or additional tool.

Date:

01.04.2011

Supplier Code:

609318

NG

Required Cpk (Y/N)

REQUIREMENT: Description of Check

Measurement Method

REQUIREMENT: Target

Bonus Applied (Y/N)

ITEM #

Data for Sample Number.. Min Max 1 2 3 4 5 6 7 8 9 10 Average Range

Supplier

1 2 3 4 5 7 8 9 10 11 12 13 15 16 17 18 21 24 25 26 27 30

N N N N N N N Y Y N Y Y N N N N N N

Thickness Width Length 4 Hole Dia 2 pcs Hole Dia Hole Dia Hole pitch Bending distance Hole pitch Slot length Slot width Slot distance Hole pitch Hole pitch Leg width Radius Hole pitch Hole pitch Radius Bending Height Angle Tin Plated

Vernier Vernier Vernier Pin Gauge Pin Gauge Pin Gauge Vernier Vernier Vernier Radius Gauge Pin Gauge Height Gauge Height Gauge Height Gauge Vernier Radius Gauge Height Gauge Height Gauge Radius Gauge Vernier b.projector Plating Thickness gauge

2.00 58.00 58.00 6.0 5.3 3.8 43.80 7.00 18.00 28.00 9.00 13.20 29.00 43.80 8.00 R3 14.0 6.4 R8 10.0 90.0

1.90 57.80 57.80 5.90 5.20 3.75 43.60 6.60 17.90 27.80 8.80 13.00 28.80 43.60 7.8

2.10 58.20 58.20 6.10 5.30 3.85 44.00 7.40 18.10 28.20 9.20 13.40 29.20 44.00 8.2

1.98 58.01 58.03 6.02 5.32 3.82 43.74 7.05 18 27.99 8.98 13.18 29 43.7 7.96 3

1.99 58.02 58.01 6 5.32 3.82 43.7 6.98 18.02 28 8.97 13.2 28.95 43.9 7.99 3 14.0 6.45 8 10.02 89.3 3.8

2.01 58.04 58.06 5.98 5.32 3.82 43.75 7.05 18 28.02 8.98 13.14 28.99 43.8 7.98 3 13.9 6.45 8 10.01 90 4

1.98 58.04 58.02 5.98 5.32 3.82 43.8 6.98 18.02 28.01 8.98 13.2 28.99 43.85 7.96 3 14.0 6.42 8 10.02 89.45 3.8

1.99 58.01 58.03 5.96 5.32 3.82 43.78 6.98 17.98 28.01 8.99 13.14 28.96 43.75 7.98 3 14.0 6.41 8 10.01 90 4.2

2.01 58.04 58.06 5.98 5.32 3.82 43.75 7.05 18 28.02 8.98 13.14 28.99 43.8 7.98 3 13.9 6.45 8 10.03 90 4.6

1.98 58.04 58.02 5.98 5.32 3.82 43.8 6.98 18.02 28.01 8.98 13.2 28.99 43.85 7.96 3 14.0 6.45 8 10.01 89.45 4

1.99 58.01 58.03 5.96 5.32 3.82 43.78 6.98 17.98 28.01 8.99 13.14 28.96 43.75 7.98 3 14.0 6.42 8 10.01 90 4.2

1.98 58.01 58.03 6.02 5.32 3.82 43.74 7.05 18 27.99 8.98 13.18 29 43.7 7.96 3 13.88 6.45 8 10.02 90 4.1

1.99 58.02 58.01 6 5.32 3.82 43.7 6.98 18.02 28 8.97 13.2 28.95 43.9 7.99 3 14.0 6.42 8 10.01 89.3 4.2

1.99 58.02 58.03 5.99 5.32 3.82 43.75 7.01 18.00 28.01 8.98 13.17 28.98 43.80 7.97 3.00 13.93 6.43 8.00 10.02 89.75 4.10

0.03 0.030 0.05 0.06 0.00 0.00 0.10 0.07 0.04 0.03 0.02 0.06 0.05 0.20 0.03 0.00 0.09 0.04 0.00 0.02 0.70 0.80

OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK

13.85 6.2

14.15 6.6

13.88 6.42 8

9.8 89 3

10.2 91 5

10.01 90 4.1

NOTE: Any out of specification data will require corrective action.

Tooling Information Form

Supplier Name PPAP Submission Level Affected Feature Number(s) ACE ELECTRICAL EQUIPMENTS 3 Date PPAP Due Date Part Number Tool Location 039BSN Facility Date of Tooling Change Part Name Machine Cover plate 2BK M MS Station New Tooling Modified Tooling Required for PPAP Note: This document must be completed for all Cooper owned tool Tool Owner : M/s Cooper Bussman Tool Drawing No : APRT242,APRT244,APRT247 Tool No : APRT242 DWG,APRT244DWG,,APRT247DWG History Card No : ATHCNO 242,ATHCNO244,ATHCNO247 Schedule for Maintance : Every 10000 Stocks TOOL NO:APRT242 DWG TOOL NO : APRT244

Cooper Tooling reference number. (if applicable) Part Description

TOOL NO: APRT247

CUSTOMER NAME : Cooper Bussman Comp Name : Cover Plate Comp Part No : Cumulativ Productio e n Qty Productio n Qty 110 110 110 110 220 330

ACE ELECTRICAL EQUIPMENTS(I) PVT LTD-HOSUR

Tool No : APRT243

TOOL HISTORY CARD

Nature of Defect Press Shop Superviso r kalimuthu kalimuthu kalimuthu Action Taken

Operation : Blanking & Piercing Frequency : Tool Maker Sign/Date Chandru Chandru Chandru

Date

Remark

1 2 3

Nil Nil Nil

Nil Nil Nil

039C 038C 038D

CUSTOMER NAME : Cooper Bussman Comp Name : Cover plate Comp Part No :

ACE ELECTRICAL EQUIPMENTS(I) PVT LTD-HOSUR

Tool No : APRT252 Slot Size 28.0& 2 HOLES PIERCING Operation : Dia25.0 & 2 HOLE PIERCING TOOL TOOL PIERCING TOOL Frequency :

TOOL HISTORY CARD

Press Shop Superviso r kalimuthu kalimuthu

Date

Cumulativ Productio e n Qty Productio n Qty 110 110 110 220

Nature of Defect

Action Taken

Tool Maker Sign/Date Chandru Chandru

Remark

1 2

Nil Nil

Nil Nil

038C 038D

CUSTOMER NAME : Cooper Bussman Comp Name : Cover plate Comp Part No : Cumulativ Productio e n Qty Productio n Qty 110 110 110 110 220 330

ACE ELECTRICAL EQUIPMENTS(I) PVT LTD-HOSUR

Tool No : APRT247

TOOL HISTORY CARD

Nature of Defect Press Shop Superviso r kalimuthu kalimuthu kalimuthu Action Taken

Operation : VDia25.0 Bending &Tool 2 HOLE PIERCING TOOL Frequency : Tool Maker Sign/Date Chandru Chandru Chandru Remark

Date

1 2 3

Nil Nil Nil

Nil Nil Nil

039C 038C 038D

GR&R Study - Multiple Operators

For use with testing gage systems meant to evaluate features or processes whose output measured numerically, and for which two to three operators are expected to conduct the evaluation. Rev. 11/1/07 Dave Olson Part Number: Drawing Number: Drawing Rev.: Rev. Date: Drawing Location: Part Feature: Feature Symbol: Other Information Calibration Date: 7-Mar 038BSN 038BSN G 18/07/2011 3/8/2013 Supplier Contact Vinoth kumar - 9442527494 PCA Supplier Name: ACE Electrical Equipments India Pvt Ltd GR&R Contact Contact plate 2KN M MS PCA Address: 106/2A-1 BEHIND ESI PCA Contact HOSPITAL,OUTER RING ROAD
HOSPITAL,OUTER RING ROAD HOSUR HOSUR

Supplier Name: ACE Electrical Equipments India Pvt Ltd Supplier Address: 106/2A-1 BEHIND ESI

Date

Gage Type: Electroinc height gauge Operator 2 Name Muniraj

Gage ID: ACE/DVHG/03

Unit of Measure: 0.001mm Operator 3 Name

Operator 1 Name Ramesh 1 USL 1 18.1 LSL 1 17.9

Polash 3 Number of Operators: 3

Number of Trials:

Ramesh Muniraj Part # 1st Trial 2nd Trial 3rd Trial Range 1st Trial 2nd Trial 3rd Trial 1 18.000 18.010 18.000 0.010 18.000 18.010 18.000 2 18.000 18.010 18.000 0.010 18.000 18.010 18.000 3 17.990 18.010 18.000 0.020 18.000 18.010 18.000 4 18.000 18.010 18.000 0.010 18.000 18.010 18.000 5 18.010 18.020 18.010 0.010 18.000 18.010 18.000 6 18.000 17.980 18.000 0.020 18.000 17.980 18.000 7 17.990 18.010 18.000 0.020 18.000 18.010 18.000 8 18.020 18.010 18.020 0.010 18.000 18.010 18.000 9 18.000 18.010 18.000 0.010 18.000 18.010 18.000 10 18.000 18.010 18.000 0.010 18.000 18.010 18.000 * A minimum of six samples for each trial is required for these results to be valid

Range 0.010 0.010 0.010 0.010 0.010 0.020 0.010 0.010 0.010 0.010

Polash 1st Trial 2nd Trial 3rd Trial 18.020 18.010 18.020 18.010 18.020 17.990 18.000 18.010 18.000 18.000 18.010 18.000 18.040 18.010 18.020 18.000 18.010 18.000 18.000 18.010 18.000 17.980 18.010 18.000 18.000 18.010 18.000 18.000 18.010 18.000

Range 0.010 0.030 0.010 0.010 0.030 0.010 0.010 0.030 0.010 0.010

Gage R&R Summary

Measurement Unit Analysis Repeatability: EV= 0.041 Reproducability: AV= 0.008 R&R= 0.041 Part Variation: PV = 0.027 Total Variation: TV= 0.049 % Process Variation (TV) / % Tolerance Variation (TOL) % Equipment Variation (EVTV) 82.20% %EVTOL 20.33% % Appraiser Variation (AVTV) 15.85% %AVTOL 3.92% %GR&R (GR&RTV) 83.71% %GR&RTOL 20.71% %Part Variation (PVTV) 54.70%

Gage R&R Disposition Disposition

Marginal
Pass - Gage System is Useable Gage System is useable but marginal Fail - Gage System is Unstable

GR&RTOL% < 10 10 GR&RTOL% 30 GR&RTOL% > 30

Most part averages should be outside the control limits

Part Operator Average

3 4 5 6 7

Repeatability Range (All Operators)

8 9 10
0.040 0.035

1
18.030

18.020

0.030
0.025

Operator X Values

18.010

Bar R

0.020 0.015 0.010

18.000

17.990

0.005
17.980

0.000

1
17.970
UCLx LCLx Bar-X Op1 X Op2 X Op3 X
UCLr

10

Sample Number
Bar-R Op1 Range Op2 Range Op3 Range

Cpk for Moving Range

Use when: (a) new part, (b) part with revised specifications, (c) part in which the materials, processes, manufacturing location, or production equipment have significantly changed, or (d) part in which the material suppliers have changed AND testing is too expensive to be conducted by subgroups.

Part Number: Drawing Number: Drawing Rev.: Rev. Date: Drawing Location: Part Feature: Feature Symbol: Other Information

Cover plate 2KN M MS 038BSN G 18/07/2011

Supplier Name: ACE Electrical Equipments India Pvt Ltd Supplier Address:
106/2A-1 BEHIND ESI HOSPITAL,OUTER RING ROAD HOSUR

PCA Supplier Name: ACE ENGINEERING PCA Address:

106/2A-1 BEHIND ESI HOSPITAL,OUTER RING ROAD HOSUR

Date 20.04.2013 Supplier Contact VINOTHKUMAR - 9442527494 GR&R Contact PCA Contact

USL LSL

6.6 6.2 Process Data

PCA Summary
Potential Capability Cp= CpkL= CpkU= Cpk= %Cr= Max= Min= 1.788737864 2.200147573 1.377328155

Distribution

Subgroup Test Value 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Average 6.450 6.420 6.420 6.420 6.450 6.500 6.410 6.500 6.480 6.410 6.450 6.420 6.420 6.420 6.450 6.500 6.410 6.500 6.480 6.410 6.450 6.420 6.420 6.420 6.450 6.500 6.410 6.500 6.480 6.410 6.450 6.420 6.420 6.420 6.450 6.500 6.410 6.500 6.480 6.410 6.450 6.420 6.420 6.420 6.450 6.500 6.410 6.500 6.480 6.410 6.4460

Range

LSL= USL=

6.2 6.6 6.4460 0.037270227 6.557828571 6.334171429 0.137347347

0.03 0.00 0.00 0.03 0.05 0.09 0.09 0.02 0.07 0.04 0.03 0.00 0.00 0.03 0.05 0.09 0.09 0.02 0.07 0.04 0.03

Mean= StDev UCLX= LCLX= UCLR=

56% 6.5000 6.4100

Spec 1 2 3 4 5 6 7 8 6.2000 6.2571 6.3143 6.3714 6.4286 6.4857 6.5429 6.6000

Frequency 0 0 0 0
6.2000
6.2571 6.3143 6.3714 6.4286 6.4857 6.5429 6.6000

25 15 10 0
Averages

Frequency

1.377328155

Test Values

7 7
6

0.00 0.03 0.05 0.09 0.09 0.02 0.07 0.04 0.03 0.00 0.00 0.03 0.05 0.09 0.09 0.02 0.07 0.04 0.03 0.00 0.00 0.03 0.05 0.09 0.09 0.02 0.07 0.04

Test Value

0.00

6 6 6

6
6 1 5 9 13 17 21
X

25
X-Bar

29

33

37

41

45
Lower Control Limit

49

Sample Number
Upper Control Limit

Range Chart
0 0 0 0 Range 0 0 0 0 0

13

17

21

25

29

33

37

41

45

49

Sample
Range UCL Range Average Moving Range Average