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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

RM weight, cutter,shovel RPM

Bulk density

Mixing Process Not Required Not Required Not Required

Mix weight

Preforming

Leveling Process Not Required Not Required Not Required

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

Curing

Painting

Painting thickness Product Required Not Required Not Required

Grinding

Groove width Product Required Not Required PMR

Printing Grade/part number/Batch 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

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 .

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)

3.Take 100 consecutive pieces measure the roughness .

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

Process Characteristics Short term Capability study

Major study Chart / Record

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

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

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

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)

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

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:

Grinding: Parallelism 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

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