Sakar Electricals & Electroni

CONTROL PLA
Product Description : 2x2 Base Light Product Number / Flow Chart No. SE/PFD/01
Code
Origin Date 15.03.2017
PROCESS
Process Machine / Equipment
STORE MOVE INSPECT RM
Quality Characteristics Specification / control
Process Description Work Instruction
No. Details /control item limit

10.0 Driver Assembly

10.1 Input & Output wire Temperature controlled SE/WI/2X2/DA/001, Temperature 350°C +/-10°C
soldering Soldering Station SE/WI/2X2/DA/002

Use of correct material & Wire as per BOM

Consumables Solder wire - 63/37 (Sn/Pb)

Quality of solder joint free from soldering defect

10.2 Electrical Testing VAW Meter SE/WI/2X2/DA/003 Input voltage 240V AC +/- 5V

Input current <153mA

System Power 28-33W
10.3 PCB Assembly in to NA SE/WI/2X2/DA/004 Correct fitment of PCB in to No loose fitment of PCB
case housing inside case

Top alignment and printing Free from reverse assembly

quality No smearing and illegible
printing
A
Proper interlocking of top and No Gap between top and
bottom case bottom

Sleeve coverage of wire complete coverage of sleeve

on wire

20.0 Panel Assembly

20.1 LED PCB depaneling PCB Depaneler SE/WI/2X2/PA/001 Blade A Torque setting 7
Blade B Torque setting 9
Blade C Torque setting 4

20.2 Testing of LED PCB LED Test Jig SE/WI/2X2/PA/002 Functional Test All LED on PCB shall glow

20.3 Soldering of LED PCB Temperature controlled SE/WI/2X2/PA/003 Temperature 350°C +/-10°C
Soldering Station
Use of correct material & Wire as per BOM
Consumables Solder wire - 63/37 (Sn/Pb)
 Quality of solder joint free from soldering defect

20.4 PCB Riveting with Hydraulic Riveting Machine SE/WI/2X2/PA/004 Riveting Length TBD
Housing
Force TBD

20.5 Connector soldering Temperature controlled SE/WI/2X2/PA/005 Temperature 350°C +/-10°C

Soldering Station

Use of correct material & Wire as per BOM

Consumables Solder wire - 63/37 (Sn/Pb)

Quality of solder joint free from soldering defect

20.6 Testing LED Test Jig SE/WI/2X2/PA/002 Functional Test All LED on PCB shall glow

20.7 Wire Clip Assembly Electrical Screw Driver SE/WI/2X2/PA/006 Fitment of screw No loose fitment
B

30.0
Diffuser Assembly -
Diffuser assembly with C NA SE/WI/2X2/PA/007 NA NA
frame
40 Frame Assembly with B
Electrical Screw Driver SE/WI/2X2/PA/008 Fitment of screw No loose fitment
Housing
C

50 Testing LED Test Jig SE/WI/2X2/PA/009 Defect free diffuser Diffuser free from dust ,
scratch , black spot , white
spot

60 Driver Integration with A

NA SE/WI/2X2/PA/009A Proper alignment , No loose fitment ,
panel fitment No reverse connection

70 Soaking PLC Controlled Variac SE/WI/QA/02 Voltage Voltage : 40 min @140VAC

Time 40 min@240VAC
40min @300VAC

Functionality OK No functional failure like OFF ,

Flicker etc

80 Final Testing PC Controlled Power Meter SE/WI/2X2/PA/010 Input voltage 240V AC +/- 5V

Input current <153mA

System Power 28-33W

ATHD <10%

Output - Full Load voltage 68 -74 VDC

 Output current 360mA - 400mA

Output Power 23.5W to 30.8W

90 Cleaning NA SE/WI/2X2/PA/011 Approved cleaning agent, IPA , Colin

Proper cleaning No contamination and stains

on diffuser & Panel
100 Labelling & Polybag NA SE/WI/2X2/PA/012 Label content As per approved artwork
Packing
Label position & alignment As per reference dwg
110 Master Box Packing Taping machine SE/WI/2X2/PA/013 Proper taping No loose taping

Flap alignment No misalignment , partial

opening

120 Final Quality Inspection Power Analyzer SE/WI/QA/01 Input voltage 240V AC +/- 5V

Input current <153mA

System Power 28-33W
ATHD <10%
Output - Full Load voltage 68 -74 VDC
Output current 360mA - 400mA
Output Power 23.5W to 30.8W
Lumen 3300 lm
CCT 6000-7000 K
CRI >75
Efficiency >0.88%
Visual free from visual defect like
contamination, scratches ,
bent

Labelling and packing No defect as per FQA check

sheet
130 Dispatch
Forklift SE/WI/DIS/01 Correct Qty & address as per invoice
als & Electronics Pvt.Ltd.

TROL PLAN
Issue No. 0 Prepared By Mr.Jacky Patel
Issue date NA Approved By Mr. Sandip Tambe
Sampling Frequency
Evaluation / control Start of Shift In process Abnormal
Record Responsibility
method Treatment
n Responsibility n Responsibility

Equipment calibration 05 No Line Supervisor Every 2 hour IPQC Engineer SEEPL/QC/2X2 Rework Line Supervisor
Soldering tip temperature 03 No as FPAR IPQC Engineer.
monitoring

Part Verification as per Once Line Supervisor NA NA

BOM FPAR IPQC Inspector
Visual as per assembly
dwg.

Visual Inspection 05 No Line Supervisor Every 2 hour IPQC Engineer

03 No as FPAR IPQC Inspector
Test Result Monitoring 03PFAR IPQC Engineer. 03 sample IPQC Engineer FPAR Rework Line Supervisor
100% Prod. Operator Every two hour

No audible sound after 05 No Prod. Operator Every 2 hour IPQC Engineer PFAR Rework
shaking of case by hand 03 No as FPAR IPQC Engineer.
Line Supervisor
Visual Inspection IPQC report

Visual Inspection

Visual Inspection

Manual setting 05 No Prod. Operator Every 2 hour IPQC Engineer PFAR Scrap Line Supervisor
03 No as FPAR IPQC Engineer. IPQC Report

Visual Inspection 03PFAR IPQC Engineer. 03 sample IPQC Engineer FPAR Rework Line Supervisor
100% Prod. Operator Every two hour

Equipment calibration 05 No Line Supervisor Every 2 hour IPQC Inspector SEEPL/QC/2X2 Rework Line Supervisor
Soldering tip temperature 03 No as FPAR IPQC Inspector
monitoring
Part Verification as per Once Line Supervisor NA NA
BOM FPAR IPQC Inspector
Visual as per assembly
dwg.
Visual Inspection 05 No Line Supervisor Every 2 hour IPQC Inspector
03 No as FPAR IPQC Inspector
Visual Inspection 05 No Line Supervisor Every 2 hour IPQC Inspector Rework Line Supervisor
03 No as FPAR IPQC Inspector

TBD TBD TBD TBD TBD TBD

Equipment calibration 05 No Line Supervisor Every 2 hour IPQC Inspector SEEPL/QC/2X2 Rework Line Supervisor
Soldering tip temperature 03 No as FPAR IPQC Inspector
monitoring
Part Verification as per Once Line Supervisor NA NA
BOM FPAR IPQC Inspector
Visual as per assembly
Visual Inspection
dwg. 05 No Line Supervisor Every 2 hour IPQC Inspector
03 No as FPAR IPQC Inspector

Visual Inspection 03PFAR IPQC Engineer. 03 sample IPQC Engineer FPAR Rework Line Supervisor
100% Prod. Operator Every two hour
Visual Inspection 05 No Line Supervisor Every 2 hour IPQC Inspector SEEPL/QC/2X2 Rework Line Supervisor
03 No as FPAR IPQC Inspector

NA

Visual Inspection 05 No Line Supervisor Every 2 hour IPQC Inspector SEEPL/QC/2X2 Rework Line Supervisor
03 No as FPAR IPQC Inspector

Visual Inspection 03PFAR IPQC Engineer. 03 sample IPQC Engineer FPAR Rework Line Supervisor
100% Prod. Operator Every two hour

Pokayoke NA NA NA NA NA NA NA

Pokayoke NA NA NA QA Engineer Soaking report Rework QA Engineer

Visual Inspection 100% Soaking Operator 1 hour

Data Monitoring & logging 01 No. FPAR IPQC Engineer. 01 sample every IPQC Engineer Data logging in PC Reject & Rework Line Supervisor
two hour
100% Testing Operator 100% Prod. Operator FPAR , IPQC report
Visual Inspection 01 No. FPAR IPQC Engineer. 01 sample every IPQC Engineer FPAR , IPQC report Rework Line Supervisor
two hour
100% Prod. Operator 100% Prod. Operator

Visual Inspection 01 No. FPAR IPQC Engineer. 01 sample every IPQC Engineer FPAR , IPQC report Rework Line Supervisor
two hour
100% Prod. Operator 100% Prod. Operator
Visual Inspection 100% Prod. Operator 01 sample every IPQC Engineer IPQC Report Rework Line Supervisor
two hour

Calibrated equipment As per sampling FQA Engineer NA NA FQA Report Sort QA In charge
Plan

Visual Inspection

dispatch slip / record correction FG Store In charge

Visual Inspection per shipment store executive NA NA