Characteristics mapping with SPC ~ Disc Pad

Critical
Process / Short term Long term Monitoring P
Process Characteristics / Major
Product capability study capability study Chart 4

Pre blending
RM weight & Time Process Not Required Not Required Not Required
Tumbler
RM weight & Time Process Not Required Not Required Not Required

Auto batching Process Not Required Not Required Not Required

RM weight, cutter,shovel RPM

Process Not Required Required X MR Chart

Bulk density
Mixing Process Not Required Not Required Not Required
Mix weight

Moisture Process Not Required Not Required Not Required

Preform weight Process Required Not Required Not Required

Compactness Process Not Required Not Required Not Required

Preforming
Leveling Process Not Required Not Required Not Required

Pressure Process Not Required Not Required Not Required

Vents Process Not Required Not Required Not Required

Auto cleaning pH Process Not Required Not Required Not Required

Back Plate Grit

Back plate roughness Process Required Not Required Not Required
blasting

Adhesive drying Time Process Not Required Not Required Not Required
Back plate
adhesive Adhesive Drying Temp Process Not Required Not Required Not Required
Coating
Adhesive coating thickness Process Required Not Required Not Required

Cured pad thickness Product Required Required Not Required

Cured pad hardness Product Required Required X bar R chart

Cured pad density Product Required Required Not Required

cured pad shear strength Product Required Required Not Required

Curing

Curing pressure Process Not Required Not Required Not Required

Curing temperature Process Required Required Not Required

Vents Process Not Required Not Required Not Required

Vent gap Process Required Not Required Not Required

Baking Temperature Process Not Required Not Required Not Required

Paint viscosity Process Not Required Not Required Not Required

Painting
Painting thickness Product Required Not Required Not Required

Thickness Product Required Required X bar R chart

Parallelism Product Required Required X bar R chart

Grinding
Groove width Product Required Not Required PMR

Depth of groove Product Not Required Not Required PMR

symmetricity Product Not Required Not Required PMR

Printing Grade/part number/Batch Product Not Required Not Required Not Required

Packing Quantity Product Not Required Not Required Not Required

Characteristics mapping with SPC ~ Disc Pad
Process / Critical / Short term Monitoring
Process Characteristics Long term capability study
Product Major Capability study Chart / Record

Control factor:
Machine type
Study:
1. Gradewise collect one sample /mix batch.
2. Measure bulkdensity for collected sample.
3.Take 48 consecutive samples and measure
bulkdensity for each sample
X MR Chart
Mixing Bulk density Process Not Required
Analysis & target: (R/d2)
1.Histogram with Individual reading
2.If stable plot X MR chart
3.If stable,meet the target do process capability
study (Cpk 1.33)- R/d2

Validity:
Until process change or 3 years
Characteristics mapping with SPC ~ Disc Pad
Long term Monitoring
Critical /
Process Characteristics Short term Capability study capability Chart /
Major
study Record

Control factor:
Machine type,part number,mould and grade

Study:
1.In preform m/c take 5 consecutive cycles and do centering. 2.
Collect 50 samples from 50 consecutive cycles and measure the
weight.
Preform cake (example: number of reading = 2 cavity x 1 cake/cavity x 50 cycles = Not
Pre forming
weight 100) Required
Not Required

Analysis & target:

1.Histogram with Individual reading (example: 100)
2.If stable,do process capability study (Ppk 1.33)

Validity:
Until process change or 3 years
Characteristics mapping with SPC ~ Disc Pad
Long term
Critical /
Process Characteristics Short term Capability study capability
Major
study

Control factor:
Machine type

Study:
1. Measure roughness in three places per back plate and calculate average of those
three readings consider multi location as per SOP and calculate average,consider as
single backplate reading (Xn)
2. Take consecutive 25 pcs and do centering.
3.Take 100 consecutive pieces measure the roughness .

Back plate Back plate Analysis & target:

Not Required
grit blasting roughness 1.Histogram with all readings without averaging per plate (not Xn)
2. If stable take 4 pieces as one sub group
3.Plot X bar-R chart
4.If stable,meet the target do process capability study (Ppk 1.33)
( use sigma n-1)

Validity:
Until process change or 3 years
 Monitoring
Chart / Record

Not Required
Characteristics mapping with SPC ~ Disc Pad
Critical / Long term Monitoring
Process Characteristics Short term Capability study
Major capabilitystudy Chart / Record
Control factor:
Machine type

Study:
1. Measure roughness in three places per back plate, and calculate average of those
three readings consider as single backplate reading (Xn)

2. Take consecutive 25 pcs and do centering.

3.Take 100 consecutive pieces measure the roughness .

Back plate Analysis & target:

adhesieve
adhesieve
thickness 1.Histogram with all readings without averaging per plate (not Xn) Not Required Not Required
coating 2. If stable take 4 pieces as one sub group
3.Plot X bar-R chart
4.If stable,meet the target do process capability study (Ppk 1.33)
( use sigma n-1)

Validity:
Until process change or 3 years
Characteristics mapping with SPC ~ Disc Pad

Critical / Long term capability Monitoring

Process Characteristics Short term Capability study
Major study Chart / Record

Control factor: Control factor:

Machine type,mould,part number(considering thickness) and grade Machine type,part number,mould and grade
Study:
1. Measure thickness in multi location as per SOP and calculate Study:
average,consider as single pad (Xn) 1.Measure thickness in multi location as per SOP and calculate
1. Cavitywise take 1load average,consider as single pad (Xn)
3.Calculate X bar for one load,If nearer to mean 2.Cavitywise take 1load and do centering if Ppk not done
4.Take min 100 consecutive pieces (minimum sub group size of 3.Collect four pieces from one load per shift. This is one sub-group . collect
4)thickness measurement in multi location as per SOP 25 subgroup(ie in 25 shift)
(example: number of reading = 16 cavity x 6 location per pad x 7 loads = (example: number of readings = 4 pieces x 6 location per pad x 25 sub
672) group = 600)
Analysis & target:
Curing: Cured pad thickness 1.Histogram with all readings (example: 672) Analysis & target: Not Required
2.If stable take average of six location reading treated as single pad 1.Histogram with all readings (example: 600)
3.Take one load as one sub group 2.If stable take average of all location reading treat as single pad
4.Plot X bar-R chart (initial) 3.Take 4 pieces per load as one sub group4.Plot X bar-R chart
5.If stable,meet the target do process capability study (Ppk 1.33) 5.If stable,meet the target do process capability study (Ppk 1.33)
(use sigma n-1)
Validity: Validity:
Until process change or 3 years Until process change or 3 years

Control factor:
Machine type,mould,part number(considering thickness) and grade Control factor:
Machine type,part number,mould and grade
Study:
1. Measure hardness in multi location as per SOP and calculate Study:
average,consider as single pad (Xn) 1. Measure hardness in multi location as per SOP and calculate
2. Cavitywise take 1load average,consider as single pad (Xn)
3.Calculate X bar for one load,If nearer to mean 2.Cavitywise take 1load and do centering if Ppk not done
4.Take min 100 consecutive pieces (minimum sub group size of 3.Collect four pieces from one load per shift. This is one sub-group . collect
4)hardness measurement in multi location as per SOP 25 subgroup(ie in 25 shift)
(example: number of reading = 16 cavity x 6 location per pad x 7 loads = (example: number of readings = 4 pieces x 6 location per pad x 25 sub
Curing: Cured pad hardness
672) group = 600)
Not Required

Analysis & target: Analysis & target:

1.Histogram with all readings (example: 672) 1.Histogram with all readings (example: 600)
2.If stable take average of six location reading treated as single pad 2.If stable take average of all location reading treat as single pad
3.Take one load as one sub group 3.Take 4 pieces per load as one sub group4.Plot X bar-R chart
4.Plot X bar-R chart (initial) 5.If stable,meet the target do process capability study (Ppk 1.33)
5.If stable,meet the target do process capability study (Ppk 1.33)
(use sigma n-1) Validity:
Validity: Until process change or 3 years
Until process change or 3 years
 Control factor:
Machine type,mould,part number and grade

Study:
1. Measure shear strength on each pad
Cured pad shear 2. Take consecutive loads to have minimum 32 pieces
Curing:
Strength

Analysis & target:
Not Required Not Required
1.Histogram with all readings
2.If stable,meet the target do process capability study (Ppk 1.33)
(use sigma n-1)
Validity:
Until process change or 3 years

Control factor:
Machine type,mould,part number and grade

Study:
1. Measure density on each pad after shear test asper SOP
2. Take consecutive loads to have minimum 32 pieces
Curing: Cured pad density
Analysis & target:
Not Required Not Required
1.Histogram with all readings
2.If stable,meet the target do process capability study (Ppk 1.33)
(use sigma n-1)
Validity:
Until process change or 3 years

Control factor:
Machine type,mould,part number and grade
Control factor:
Study: Machine type,mould,part number and grade
1. Measure temperature points as per SOP,and take reading Immediate
after cycle completing Study:
2.Take 15 consecutive load 1. Measure temperature points as per SOP,and take reading Immediate after
{example: number of reading = (16 cavity +16 top plate location/mould) x cycle completing
15 loads = 480} 2.Take three load/shift upto 32 loads(without setup change)
{example: number of reading = (16 cavity+16 top plate location/mould) x 32
Analysis & target: loads = 1024)
Curing: Curing Temperature 1.Histogram with all readings (example: 480) Not Required
2.If stable take one load (16 cavity+16 top plate = 32) as one sub group Analysis & target:
3.Plot X bar-R chart 1.Histogram with all readings (example:1024)
5.If stable,meet the target do process capability study (Ppk 1) 2.If stable take one load (16 cavity+16 top plate=24) as one sub group
(use sigma n-1) 3.Plot X bar-R chart
Validity: 5.If stable,meet the target do process capability study (Cpk 1)
Until process change or 3 years
Validity:
Until process change or 3 years
 Control factor:
Machine type,mould,part number and grade
CONDITION 1: NO DATA LOGGER
Study:
1.Take two reading per cycle(Vent gap to be taken at fixed location)
2.Take 3 consecutive cycle

3.With above six readings for centering

4.Then take consecutive 25 cycles.

Curing: Curing Vent gap Analysis & target: Not Required Not Required
1.Histogram with all 50 readings
2.If stable plot X R chart with one cycle as one sub group(25 sub group)
3.If stable,meet the target do process capability study with all readings
(Ppk 1.33)

Validity:
Until process change or 3 years

CONDITION 2: DATA LOGGER

Study:
1.Take data from one cycle- number of readings = number of vents(Vent
gap to be taken at fixed location)
2.with one cycle data , do centering
3.Take data for consecutive 25 cycles (total number of readings =
number of vents X 25 cycles)

Analysis & target:

Not Required Not Required
1.Histogram with all readings
2.If stable plot X R chart with one cycle as one sub group(25 sub group)
3.If stable,meet the target do process capability study with all readings
(Ppk 1.33)

Validity:
Until process change or 3 years
Characteristics mapping with SPC ~ Disc Pad
Monitoring
Critical / Long term capability
Process Characteristics Short term Capability study Chart /
Major study
Record

Control factor:
Paint color( black,Olive green, Red brown, Dove Grey)

Study:
1. Measure painting thickness in multi location as per SOP and
calculate average,consider as single measurement(Xn)1. In traywise
take 1load
2.Take consecutive 10 pieces and do centering
3.Take consecutive 100 pieces and its readings.
(example : number of reading = 3 point/pad x 100 = 300) Manual -PMR,
Painting: Paint thickness Not Required Auto-X bar R
Analysis & target: chart
1.Histogram with all readings (example:300)
2.If stable take average of 3 point reading treat as single pad (Xn)
3.Each four consecutive pieces as one sub group ( 25 sub group)
4.Plot X bar-R chart
5.If stable,meet the target do process capability study with all readings
(Ppk 1.00)

Validity:
Until process change or 3 years
Characteristics mapping with SPC ~ Disc Pad
Monitoring
Critical / Long term capability
Process Characteristics Short term Capability study Chart /
Major study
Record
Control factor: Control factor:
Machine type,part number and grade Machine type,part number,grade and operator skill

Study: Study:
1. Measure thickness in multi location as per SOP and calculate 1. Measure thickness in multi location as per SOP and calculate
average,consider as single pad (Xn) average,consider as single pad (Xn)
2. Cavitywise take one load and do centering 2. Cavitywise take 1load and do
3.Take 100 consecutive pices centering if Ppk not done
(ex: number of reading = 100 x 6 location per pads = 600) 3a.Take 3 pieces per load (left ,middle and right) - one sub group
3b.Take 3 loads per shift (3 sub group- shift)
Analysis & target:
1.Histogram with Individual reading (example: 600) 3c.Take 32 sub groups
Grinding: Thickness 2.If stable take average of six location reading treat as single pad (example: number of reading = 3 sub group x 6 location per pad x 32 X bar R chart
sub group = 576)
3. Plot X R chart
4.If stable,meet the target do process capability study for all readings Analysis & target:
(Ppk 1.33) 1.Histogram with all readings(example:576)
2.If stable take average of six location reading treat as single pad
Validity: 3.Take one load as one sub group
Until process change or 3 years 4.Plot X bar-R chart
5.If stable,meet the target do process capability study (Cpk 1.33)

Validity:
Until process change or 3 years

Grinding: Parallelism
Control factor:
Control factor:
Machine type,part number,mould,grade and operator skill
Machine type,part number and grade
Study:
Study:
1a. Take 3 pieces per load ( left ,middle, right)- one sub group.
1.Take 100 consecutive pieces
1b. Take 3 loads per shift (3 sub group per shift)
2.Treat each consecutive 4 pieces as one sub group
1c.Take 32 sub groups
Analysis & target:
1.Histogram with all readings
Analysis & target: X bar R chart
1.Histogram with all 96 readings .
2.Plot X bar-R chart
2.Take one load as one sub group
3.If stable,meet the target do process capability study with all readings
3.Plot X bar-R chart
(Ppk 1.33)
4.If stable,meet the target do process capability study (Cpk 1.33)
Validity:
Validity:
Until process change or 3 years
Until process change or 3 years