Mr. Prem Kumar, Mr. B.S Verma, Mr. M.Mishra, Adesh Kumar, Puneet, Parveen goyal Key Date :- O c c u r a n c e CURRENT PROCESS CONTROL PREVENTION CURRENT PROCESS CONTROL DETECTION Area/Person Responsible & completion date Action(s) Taken & effective date S e v e r i t y O c c u r a n c e D e t e c t i o n R P N 10 (MPI Crack Detection) MPI Machine Crack Customer Dissatisfaction, Field Failure 9 ImProper Inspection by Supplier 3 Instruction given to the supplier regarding 100% MPI 100% Visual Inspection at final Stage 3 81 Chemical Composition will not meet customer Req. Customer Dissatisfaction 6 ImProper Inspection/ Wrong material supplied by the Supplier 3 WI For Incoming Material Inspection/ Mill TC MTC/ Incoming inspection 5 90 OD O/S More Tool Wear/ Rework 4 3 3 36 OD U/S Material unclean / Reject 4 3 3 36 BEND COULD NOT LOAD AT TRAUB/Reject 5 4 3 60 PITTING MARKS Rejected/ Rework 4 3 3 36 Colour Code Mixing Of the Material/ Customer Dissatisfaction 4 Unaware of requirements 4 Instruction given to the supplier regarding color code 3 48 QTY / WT. SCHEDULE WILL NOT MEET/ Customer Dissatisfaction 4 ImProper Inspection 3 Challan/ Training given to the inspector INCOMING INSPECTION /Receipt Inspection 3 36 Criteria Symbol Rev.# Critical 1 Major Minor Part or Function ( 2 0 )
R a w
M a t e r i a l
I n s p e c t i o n Process Requireme nts R a w
M a t e r i a l POTENTIAL FAILURE MODE AND EFFECT ANALYSIS (PROCESS FMEA) PFMEA : AMT/FMEA/2300 Item :- PIN Blank Puneet Sharma FMEA Rev. No. : 01 Prep. By : Parveen goyal Core Team :- Drawing No.: 05/15/13 FMEA Rev.Date :- 12.08.2013 G-02-860 Page : 1 of 1 Potential Failure Mode Potential Effect(s) of the Failure S e v e r i t y Current Process D e t e c t i o n Opeartion :- Raw Material Inspection 06/30.06.2012 C l a s s i f i c a t i o n R P N Process Reviwed Description Parveen goyal 12.08.2013 Action Root Cause Rev. By. Date Action Results Recommended Action(s) Potential Cause(s) of the Failure Traning Given to the inspector/ Process Sheet for inspection Work Instruction given to the workers SIZE VARIATION IN RAW MATERIAL FROM Supplier STORAGE & HANDLLING PROBLEM INCOMING INSPECTION Process Responsibility :- Drg. Rev. No./Date: Key Date :- O c c u r a n c eCURRENT PROCESS CONTROL PREVENTION CURRENT PROCESS CONTROL DETECTION Area/Person Responsible & completion date Action(s) Taken & effective date S e v e r i t y O c c u r a n c e D e t e c t i o n R P N Length U/S Rejected/ Material Unclean 5 Improper Setting 4 First 5 pcs. Setup Approval Hourly inspection Report 4 80 Length O/S Tool breakage problem/ Rejected /Rework More Tool Wear out 5 Improper Setting/ Tool Wear out 4 Proper Setting of band saw First 5 pcs. Approval/ Instruct to follow tool change Freq. Hourly inspection Report/ Tool Change history card 4 80 ID U/S Rejected/Rework Tool breakage problem More Tool wear 5 * Wrong Setting *Tool wear out 4 first Piece approval Report Training to Supervisor & Operator/ Instruct to follow tool change Freq. Hourly inspection Report/ Tool Change history card 4 80 ID O/S Rejected Material Unclean 5 * Improper Setting 4 first Piece approval Report Training to Supervisor & Operator Hourly inspection Report 4 80 OD Chamfer Length O/S Tool breakage problem Problem in next operation/ Rejected 4 * Wrong Setting 3 first Piece approval Report Training to Supervisor Hourly inspection Report 4 48 OD Chamfer Length U/S Rejected/ rework/ Problem in next opeartion 4 * Wrong Setting * Tool wear out 3 first Piece approval Report Training to Supervisor Instruct to tool change Freq. Hourly inspection Report/ Tool Change History Card 4 48 Chf. Angle O/S Material Unclean/ Rejected/ Rework 4 Wrong Setting 3 first Piece approval Report Training to Supervisor & Operator Hourly inspection Report 4 48 Chf. Angle U/S more Tool Wear/ Rejected/ Rework 4 Wrong Setting / Tool Wear Out 3 first Piece approval Report Training to Supervisor & Operator/ Instruct to follow tool change Freq. Hourly inspection Report/ Tool Change history card 4 48 ID U/S Rejected/ Rework Tool breakage problem 5 * Wrong Setting * Tool wear out 4 first Piece approval Report Training to Supervisor & Operator/ Instruct to follow tool change Freq. Hourly inspection Report/ Tool Change history card 4 80 ID O/S Rejected Deep Lining/ Material Unclean 5 Wrong Setting 3 first Piece approval Report Training to Supervisor & Operator Hourly inspection Report 4 60 Length U/S Rejected/ Material Unclean/ Customer Dissatisfaction 5 Improper Setting 3 Proper Setting of band saw First 5 pcs. Approval Hourly inspection Report 4 60 Length O/S Tool breakage problem Rework 5 Improper Setting/ Tool Wear out 4 Proper Setting of band saw First 5 pcs. Approval/ Instruction to follow tool change Freq. Hourly inspection Report/ Tool Change history card 4 80 Taper Dia. O/S Rejected/ Material unclean 5 * Wrong Setting 4 first Piece approval Report Training to Supervisor Hourly inspection Report 4 80 Taper Dia. U/S Tool breakage problem Rework 4 * Wrong Setting * Tool wear out 4 first Piece approval Report Training to Supervisor instruct to follow tool change work instruction Hourly inspection Report/ Tool Change history card 4 64 Taper Angle O/S Problem In Next Operation/ Rejected/ Material Unclean 4 Wrong Setting 3 first Piece approval Report Training to Supervisor & Operator Hourly inspection Report 4 48 Taper Angle U/S Tool Breakage Problem/ Rework 4 Wrong Setting / Tool Wear Out 3 first Piece approval Report Training to Supervisor & Operator/ Instruct to follow tool change Freq. Hourly inspection Report/ Tool Change history card 4 48 Taper Dia. O/S Rejected/ Material unclean 5 * Wrong Setting 4 first Piece approval Report Training to Supervisor Hourly inspection Report 4 80 Taper Dia. U/S Tool breakage problem Rework 4 * Wrong Setting * Tool wear out 4 first Piece approval Report Training to Supervisor instruct to follow tool change work instruction Hourly inspection Report/ Tool Change history card 4 64 Taper Angle O/S Problem In Next Operation/ Rejected/ Material Unclean 4 Wrong Setting 3 first Piece approval Report Training to Supervisor & Operator Hourly inspection Report 4 48 Taper Angle U/S Tool Breakage Problem/ Rework 4 Wrong Setting / Tool Wear Out 3 first Piece approval Report Training to Supervisor & Operator/ Instruct to follow tool change Freq. Hourly inspection Report/ Tool Change history card 4 48 Length U/S Rejected/ Material unclean 5 3 4 60 Length O/S Tool breakage problem More tool wear 5 3 4 60 ID O/S Rejected/ Rework More Tool Wear 4 4 4 64 ID U/S Rejected Tool breakage problem 5 4 4 80 OD Chamfer Length O/S Rework/ Material Unclean 4 3 4 48 OD Chamfer Length U/S Tool breakage problem More Tool wear 4 3 4 48 Chf. Angle O/S Material Unclean/ Rejected/ Rework 4 3 4 48 Chf. Angle U/S more Tool Wear/ Rejected/ Rework 4 3 4 48 Taper Dia. O/S Rejected/ Material unclean 4 3 4 48 Taper Dia. U/S Tool breakage problem Rework 4 4 4 64 Taper Angle O/S Problem In Next Operation/ Rejected/ Material Unclean 4 4 4 64 Taper Angle U/S Tool Breakage Problem/ Rework 4 3 4 48 Criteria Rev.# Critical 1 Major Minor - Process Requirements C a m S h a f t S p e e d & S p i n d l e R P M ( 3 0 ) P a r t i n g , R o u g h I d , O D C h f . ( F i r s t S i d e ) C a m S h a f t S p e e d & S p i n d l e R P M ( 4 0 ) T / L & R o u g h I d ( F i n i s h ) R P M , T o o l D r i l l , T o o l D r e s s i n g F r e q . ( 5 0 ) I D T a p e r ( 1 s t S i d e ) ( 6 0 ) I D T a p e r ( 2 n d S i d e ) R P M , T o o l D r i l l , T o o l D r e s s i n g F r e q . Drawing No.: G-02-860 D e t e c t i o n Potential Failure Mode Potential Effect(s) of the Failure S e v e r i t y C l a s s i f i c a t i o Potential Cause(s) of the Failure Part or Functions R P NRecommended Action(s) Action Results Root Cause Current Process 12.08.2013 Parveen goyal Description Action Page : 1 of 1 Mr. Prem Kumar, Mr. B.S Verma, Mr. M.Mishra, Mr. Ashok Rev. By. Date Process Reviewed Shailendar, Parveen goyal FMEA Rev. No. : 01 Operation :- Parting, Rough ID Taper & ID 06/30.06.2012 Prep. By : Parveen goyal Incoming Inspection Core Team :- 05/15/13 FMEA Rev.Date :- 12.08.2013 Improper Inspection/ wrong material supplied by the suppliers Training Given to the Inspector / instruct operator to check 100% before Processing/ SPC Training Given to the Inspector / instruct operator to check 100% before Processing ( 7 0 ) R e c e i v i n g I n s p e c t i o n F r o m K u m a r POTENTIAL FAILURE MODE AND EFFECTANALYSIS (PROCESS FMEA) PFMEA : AMT/FMEA/2300 Item :- Pin Blank Mr. Ashok Tomar Process Responsibility :- Drg. Rev. No./Date: Key Date :- O c c u r a n c e CURRENT PROCESS CONTROL PREVENTION CURRENT PROCESS CONTROL DETECTION Area/Person Responsible & completion date Action(s) Taken & effective date S e v e r i t y O c c u r a n c e Wrinkle Material unclean,tolerance not provided b/w punch and die 5 Man power not awareness,die and punch defect,defect raw sheet used 4 First piece setup Approval,tranning provided to operator Hourly inspection 4 80 Compressor Pipe is provided to clean the chips and dust particles Mr alem ,mr jha Breakage Thickness variation in sheet, 5 no reason 3 Checking 10 nos while set up. Hourly inspection 4 60 Short t/l Feed length not adjusted,eror in height of die and punch 5 Error is punch and die 3 4 60 Increase t/l as tolerance Same as above 5 Same as above 3 4 60 Criteria Symbol Rev.# Critical 1 Major Minor Part or Function H y d r a u l i c
p r e s s
d r a w F e e d
l e n g t h , p r e s s u r e , d i e , p u n c h , p r e s s u r e
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s h e e t Process Requirements Page : 1 of 1 Recommended Action(s) Action Results Current Process Potential Failure Mode Potential Effect(s) of the Failure Potential Cause(s) of the Failure G-02-860 Hourly Ispection Opeartion :- DRAWN Core Team :- Drawing No.: 05.15.2013 Mr puneet sharma,mr joiginder,mr jha D e t e c t i o n Prep. By : Parveen Goyal S e v e r i t y C l a s s i f i c a t i o n R P N 06/30.06.2012 POTENTIAL FAILURE MODE AND EFFECT ANALYSIS (PROCESS FMEA) PFMEA : AMT/FMEA/2300 Item :- MIXING JAR Mr. Ashok Kumar FMEA Rev. No. : 01 FMEA Rev.Date :- 12.08.2013 Description Action Root Cause Rev. By. Process Has Been Reviewed Parveen goyal 12.09.213 Process Responsibility :- Drg. Rev. No./Date: Key Date :- Page : 1 of 1 G-02-860 Opeartion :- DRAWN Core Team :- Drawing No.: 05.15.2013 Mr puneet sharma,mr joiginder,mr jha Prep. By : Parveen Goyal 06/30.06.2012 POTENTIAL FAILURE MODE AND EFFECT ANALYSIS (PROCESS FMEA) PFMEA : AMT/FMEA/2300 Item :- MIXING JAR Mr. Ashok Kumar FMEA Rev. No. : 01 FMEA Rev.Date :- 12.08.2013 5 5 4 4 3 3 3 3 4 4 4 Criteria Symbol Rev.# Critical 1 Major Minor Process Has Been Reviewed Parveen goyal Rev. By. Root Cause 12.09.213 Action Description D e t e c t i o n R P N Page : 1 of 1 Action Results Prep. By : Parveen Goyal POTENTIAL FAILURE MODE AND EFFECT ANALYSIS PFMEA : AMT/FMEA/2300 FMEA Rev. No. : 01 FMEA Rev.Date :- 12.08.2013 Date 12.09.213 Page : 1 of 1 Prep. By : Parveen Goyal POTENTIAL FAILURE MODE AND EFFECT ANALYSIS PFMEA : AMT/FMEA/2300 FMEA Rev. No. : 01 FMEA Rev.Date :- 12.08.2013 Date 12.09.213 PFMEA : AMT/FMEA/2300 Item :- Pin Blank Process Responsibility :- Mr. AmitRaj FMEA Rev. No. : 01 Opeartion :- Grinding Drg. Rev. No./Date: 06/30.06.2012 Prep. By : Parveen goyal Core Team :- Mr. Prem Kumar, Mr. B.S Verma, Mr. M.Mishra, Mr. AmitRaj Key Date :- FMEA Rev.Date :- 12.08.2013 Adesh Kumar, Sailinder, Parveen goyal Page : 1 of 1 Drawing No.: G-02-860 O c c u r a n c e CURRENT PROCESS CONTROL PREVENTION CURRENT PROCESS CONTROL DETECTION Area/Person Responsible & completion date Action(s) Taken & effective date S e v e r i t y O c c u r a n c e D e t e c t i o n R P N OD U/S REJECTED/ CREATE FITMENT PROB. AT CUSTOMER END 8 SETTING PROBLEM 5 FPA / Training Provided to the operator /SPC/ Process Sheet 4 160 OD O/S REWORK / Customer Dissatisfaction 8 SETTING PROBLEM/ Grinding wheel wear 5 FPA/ DRESSING FREQ FIXED/ SPC 4 160 GRINDING MARKS OD WILL BE UNCLEAR & Rejected AT CUSTOMER END 4 5 4 80 BURN MARKS OD WILL BE UNCLEAR & Rejected AT CUSTOMER END 4 5 4 80 SURFACE ROUGHNESS EXCESS WEAR OF GRINDING WHEEL 4 WHEEL DRESSING NOT DONE RPM CHANGE 4 DRESSING FREQ FIXED RPM FIXED 5 80 Circularity O/S OD WILL BE UNCLEAR 4 REST BLADE HIGHT NOT OK 5 REST BLADE HIGHT FIXED 4 80 Criteria Rev.# Rev. By. Dat e Critical 1 Major Minor 100% inspection by Dial Gauge on Grinding D e t e c t i o n R P N Potential Failure Mode Potential Effect(s) of the Failure S e v e r i t y C l a s s i f i c a t i o n Potential Cause(s) of the Failure Parveen goyal Current Process Recommended Action(s) Action Results Description Root Cause Action HOURLY INSPECTION WHEEL DRESSING NOT DONE DRESSING FREQ FIXED 12.08.2013 05/15/13 POTENTIAL FAILURE MODE AND EFFECT ANALYSIS (PROCESS FMEA) Part or Function ( 1 2 0 )
G r i n d i n g Process Require ments G r .
W h e e l ,
D r e s s i n g
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D r e s s e r Process Has Been Reviwed Process Responsibility :- Drg. Rev. No./Date: Key Date :- O c c u r a n c e CURRENT PROCESS CONTROL PREVENTION CURRENT PROCESS CONTROL DETECTION Area/Person Responsible & completion date Action(s) Taken & effective date S e v e r i t y O c c u r a n c e D e t e c t i o n R P N OD O/S & U/S 8 3 TRAINING Given to INSPECTORS & SPC GAUGE R&R DONE 100% Visual inspection Master sample display 4 96 CHAMFER LENGTH O/S, U/S 8 3 100% Visual inspection PDI 4 96 OD CHAMFER ANGLE O/S, U/S 8 3 100% Visual inspection PDI 4 96 ID Taper Dia O/S U/S 4 5 Final Inspection/ 100% Guaging of ID Taper 4 80 ID Taper Angle O/S U/S 4 5 Final Inspection/ 100% Guaging of ID Taper 4 80 Length O/S, U/S 8 3 TRAINING Given to INSPECTORS & SPC GAUGE R&R DONE
100% gauging of Length 4 96 Burr, Dent, Lining & Pitted, Crack 5 4 TRAINING Given to INSPECTORS & SPC Visual R&R DONE 100% Visual inspection 4 80 Criteria Sym bol Rev.# Critical 1 Major Minor Part or Function ( 1 3 0 )
F i n a l
I n s p e c t i o n
Proc ess Req. G a u g e s
&
I n s t r u m e n t s Process Has Been reviwed Parveen goyal D e t e c t i o n Recommended Action(s) Description Date TRAINING Given to INSPECTORS Frequently calibration of instrument Potential Cause(s) of the Failure S e v e r i t y 12.08.2013 C l a s s i f i c a t i o n Current Process UNTRAINED/ NEGLIGENCE OF INSPECTORS INSPECTION VARIATIONS INSTRUMENTS ERROR Rev. By. Root Cause G-02-860 Action Potential Failure Mode Potential Effect(s) of the Failure POTENTIAL FAILURE MODE AND EFFECT ANALYSIS (PROCESS FMEA) PFMEA : AMT/FMEA/2300 Item :- Pin Blank 06/30.06.2012 Adesh Kumar, Sailinder, Parveen goyal Mr. Ramesh Triphati FMEA Rev. No. : 01 FMEA Rev.Date :- 12.08.2013 Page : 1 of 1 Drawing No.: Action Results R P N CUSTOMER Dissatisfaction/ REJECTION AT CUSTOMER END Prep. By : Parveen goyal Core Team :- 05/15/13 Mr. Prem Kumar, Mr. B.S Verma, Mr. M.Mishra, Mr. Ramesh Triphati Opeartion :- Final Inspection Process Responsibility :- Drg. Rev. No./Date: Mr. Prem Kumar, Mr. B.S Verma, Mr. M.Mishra, Mr. Ramesh Triphati, Parveen goyal Key Date :- O c c u r a n c e CURRENT PROCESS CONTROL PREVENTION CURRENT PROCESS CONTROL DETECTION Area/Person Responsible & completion date Action(s) Taken & effective date S e v e r i t y O c c u r a n c e D e t e c t i o n R P N ( 1 4 0 )
C l e a n i n g
&
o i l i n g R u s t
p r e v e n t i v e
O i lProper oiling and cleaning not done. Material may be rusty/ Damage 5 Work Man miss the operation 3 Work instruction to be provided in packaging Dept. Regular inspection by packaging supervisor. DOCK audit 5 75 ( 1 5 0 )
C o l o u r
C o d i n g L e v e n d o r
C o l o r wrong Color Code Used Material Mix Up/ Customer Dissatisfaction 4 Uneducated or Untrained Worker 3 On Job training given to Worker 100% Inspection 5 60 Reject Pin Mixed With OK Pcs. Customer Complaint 4 REJECT PIN NOT IDENTIFIED 3 IDENTIFICATI ON MARK ON REJECT PINS Regular inspection by packaging supervisor. DOCK audit 5 60 Quantity not as per the customer requirement. Customer dissatisfaction 5 Defective / uncalibrated weighening machine. 3 Calibration of weighening machine. *Regular inspection by packaging supervisor. * DOCK audit 5 75 In correct labelling Wrong material may be supplied to the customer. 5 Deferent type of material kept on line without proper identification 3 Training of packaging workman Regular inspection by packaging supervisor. DOCK audit 5 75 Mix up the material Wrong material may be supplied to the customer. 5 Deferent type of material kept on line without proper identification 3 5 S implementation on packaging line. Regular inspection by packaging supervisor. DOCK audit 5 75 As per Pkg. Standard Customer dissatisfaction 4 Unadequate Handling 3
Display of packaging specification. Regular inspection by packaging supervisor. DOCK audit 6 72 Criteria Symbol Rev.# Critical 1 Major Minor Process Has Been Reveiwed 12.08.2013 R P N Action Root Cause Rev. By. Date 06/30.06.2012 Part or Function ( 1 6 0
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1 7 0 )
P a c k a g i n g
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D i s p a t c h
- Process Requirem ents Description Core Team :- 05/15/13 FMEA Rev.Date :- 12.08.2013 Drawing No.: G-02-860 Page : 1 of 1 Parveen goyal Recommended Action(s) Potential Failure Mode Potential Effect(s) of the Failure S e v e r i t y Current Process Action Results D e t e c t i o n C l a s s i f i c a t i o n Potential Cause(s) of the Failure POTENTIAL FAILURE MODE AND EFFECT ANALYSIS (PROCESS FMEA) PFMEA : AMT/FMEA/2300 Item :- Pin Blank Opeartion :- Packaging & Dispatch Prep. By : Parveen Goyal Mr. Ramesh Triphati FMEA Rev. No. : 01