Alucast Ltd

Quality Control

Process/Product Failure Modes and Effects Analysis (FMEA)

Process or Product Name: Responsible:

1234B ROTOR COVER R. Gutteridge, D. Hall, G. Woods

Prepared by: R.

Gutteridge Paul McMichael

FMEA Date (Orig) _12/12/01____________ (Rev) _01____________

Process Step/Part Number

Potential Failure Mode

Potential Failure Effects

S E V

Potential Causes

O C C

Current Controls

D E T

R P N

Actions Recommended

Resp.

Actions Taken

S E V

O C C

D E T

R P N

Goods Inward Metal Out of Spec Metal Goods Inward Metal Out of Spec Metal Die tooling procurement Die tooling procurement In-adequate material used in manufacture

Poor Finish, Insufficient strength customer complaint Poor Finish, Insufficient strength customer complaint Die Damage , Down time production loss, customer complaint Late delivery of tooling, late start to production, customer concern Misruns, Coldshuts, NCU, Customer concern Porosity after finishing operation, Loss production, Customer complaint Loss of production, short fall at finishers, customer complaint

Supplier error, Fork truck driver error Supplier error

Full spec with delivery, Every ingot colour coded QA cert with every delivery

147

Tighter controls on metal movement Tighter controls on metal quality

Fork truck operative Snr. Quality Engineer

Metal booked out of stores 10% audit on incoming ingot carried out at independant lab. Approved suppliers list drawn up

28

147

14

Poor design In-adequate preparation Poor tool maker, equipment out of calibration Operator Error

Vendor rating G.A. preparation

Only used Person 196 experienced purchasing approved tool makers tooling 14 105 Monitor casting temps Quality daily Engineer Monitor casting temps Quality daily Engineer

21

Dimensionally incorrect

7 7

1 5

Vendor Rating I.S.I.R. Process control sheet

2 3

0 Procedure drawn up 8 2 3 48

Casting Temp. Too Cold

Casting Temp. Too Hot

Operator Error

Process control sheet

126

Procedure drawn up

126

Clipping

Clipping Damage

Poor operator control, poorly designed clipping tool Viewer error unaware of acceptance standard agreed with customer

Operator experience G.A. preparation Final View Process

42 Final View sheet 112 updated, Digital Images to be used 0 Final Viewers Sheets updated using digital images to high light potential problems

Final View

Unacceptable castings to Various

24 0

Issue No. 2

Issue Date: 1st August 2001

AQC 18