Potential Failure Mode and Effects Analysis

(Process FMEA) Customer :- Kaynes Technologies Customer Part No.:- 240-099-M02E Customer Part Name:- COSMETIC COVER BOTTOM Core Team : Purushothaman, Mohan, Zameer, Joshi Process Responsibility : Mohan Key Date : FMEA Number : PFMEA-240-099-M02E-GLX-R0 Prepared by : Mohan Kumar P FMEA Date (Orig.) : 24/09/2011 (Rev.) : A

Process / Function

Potential Failure Mode

Potential Effects of Failure

Potential Causes / Mechanisms of Failure

Current Design Controls Prevention

1.1.1.1. Asking for soft copy of customer drawing 1.1.2.1. Asking for correct drawing with confirming correct revision number and complete data 2.1.1.1.Counter checking the development drawing and confirm whether all the data required is mentioned before Dev. Dwg with 2.1.2.1. Checking customer dwg and make sure dimensions are properly mentioned giving visible annotations inspection is 1.1.1.1. Incoming material done & verified with material test certificate 1.1.2.1. Enough measures are taken to avoid scratches during packing 1.1.2.2. Purchasing approved material from supplier (approved supplier) 2.1.1.1. Incoming material inspection is done & verified with material test certificate 2.1.1.2. Purchasing approved material from supplier (approved supplier) 2.2.1.1. Incoming material inspection is done & verified with material test certificate 2.2.1.2. Purchasing approved material from supplier (approved supplier) 3.1.1.1. Incoming material inspection is done & verified with material test certificate 3.1.1.2. Purchasing approved material from supplier (approved supplier) 4.1.1.1. Incoming material inspection is done & verified with material test certificate 4.1.1.2. Purchasing approved material from supplier (approved supplier) 5.1.1.1. Incoming material inspection is done & verified with material test certificate 5.1.1.2. Purchasing approved material from supplier (approved supplier) 6.1.1.1. Incoming material inspection is done & verified with material test certificate 6.1.1.2. Purchasing approved material from supplier (approved supplier) 1.1.1.1. Drawings are checked before giving to the operation 1.1.2.1. Trained operators and work instructions 1 of 3

Occurrence

Current Design Controls Detection

Recommended Actions

Responsibility Action Results & Target Completion Actions Taken Date Severity Occur

Severity

Detect

R.P.N.

Class

Detection

R.P.N.

1.1.1. Customer drawing not clear 1. Errors in original drawing Part Drawings SC 2. Errors in development 2.1. Rework or rejection of the drawing product 6 2.1.2. Missing dimensions while doing development drawing 1.1.1. Handling 1.1. Rework or rejection of the product 6 SC

No action required 4 Feasibility review 4 2 48 No action required 2 48 No action required

1.1.2. Incomplete data

2.1.1. Changes in revision number

No action required

1. Scratches

1.1. Bad finish of product

3 1.1.2. Packing & transportation

45

No action required

No action required 4 2 40

2.1. Rework / Rejection 2. Bend (twist,straightness) 2.2. Dimension and angle variation

2.1.1. manufacturing process of SC supplier

No action required

No action required 4 2 40

2.2.1. manufacturing process of SC supplier

Raw Material Inspection 3. Material Hardness 3.1 Dimension and angle variation 4 3.1.1. Manufacturing process of the supplier

Supplier RMTC & chemical composition verification. Visual inspection for RM scratches / aesthetics

No action required

No action required 2 32

No action required

No action required 3 3 36

4. Chemical composition 4.1. Rejection

4.1.1. Manufacturing process of the supplier

No action required

No action required 4 2 40

5. Sheet thickness Variation

5.1. Rework or rejection of the product

5.1.1. Manufacturing process of the SC supplier

No action required

No action required 3 2 42

6. Rust

6.1. Rejection

6.1.1. Improper post-process precautions by the supplier

No action required

No action required

1.1.1. Incorrect development drawings. 1.1. Rejection / Rework . Laser Cutting 1. Program error 6 1.1.2. Programming error(human error)

First part inspection

No action required 2 48

Process / Function
Laser Cutting

Potential Failure Mode

1. Program error

Potential Effects of Failure

Potential Causes / Mechanisms of Failure

Current Design Controls Prevention

Occurrence

6 1.2. Wastage of man power and Rework hours. 1.1. machineor rejection of the product 1.1. Rejection / rework 1.2.1.1. Trained operators and work instructions 1.1.1.1. Skilled operators.

Current Design Controls First part Detection

inspection

Recommended Actions

48 No action required

Responsibility Action Results & Target Completion Actions Taken Date Severity Occur

Severity

Detect

R.P.N.

Class

Detection

R.P.N.

1.2.1. Programming error(human error) 6 SC 1.1.1. Unskilled operators

1. Errors in original drawing Part Drawings Deburring 1. Improper filing of material

4 Feasibility review First part inspection

48

No action required

1.2. dimension variation 3

1.2.1. Unskilled operators

1.2.1.1. Trained operators and work instructions

No action required 2 24 No action required

1.3. Poor appearance of the component 7 1. Reverse Bending 1.1. Rejection / Rework 4 Bending 2. Dimension variation 2.1. Rejection / Rework

1.3.1. Rough handling of the component,while deburring 1.1.1. Improper study / check of drawing

1.3.1.1.Following better processes for deburring 1.1.1.1. Studying the drawing before bending 2.1.1.1. Use proper bending tools and analyse the type of tool requirement before the process 3.1.1.1. Using Proper tools (i.e. die and punch for various thickness of sheet) 3.1.2.1. Use proper bending tools and analyse the type of tool requirement before the process 1.1.1.1. Skilled labors 3 First part inspection No action required 2 42 No action required 4 3 48 No action required

2.1.1. Improper bending tool selection

3. Taper Bending/Angle Variation

3.1. Rejection / Rework

3.1.1. Improper levelling of the sheet

48

No action required

3.1.2. Improper bending tool selection 1.1. Rework or rejection of the product 6 1.1.1. Human error 6 1.1.2. Mistakes during pre-assembly processes

ASSEMBLY

1. Wrong alignment

Verify as per drawing / sample

No action required 2 36 No action required

2. In/out in geometrical dimensions of child parts 1.2. Reject/Rework

1.1.1. Poor adhesion 1. Coating Peel off 1.1. Rework or rejection of the product 7

1.1.2.1. Make sure the parts are coming for the inspection is inspected and OK 1.1.1.1. Demoisturising the work by dry clean cloth materials or by blowing hot air 1.1.1.2. Using cleaning agents to clean the work before powder coating

3 First part check for finish / thickness / peel off test / bend test

36 No action required

No action required 2 42 No action required

1.1.2. Improper degreasing

1.1.2.1. Using proper proportions of reagents 2.1.1.1. Determining the number of passes required to attain the thickness and following it 3.1.1.1. Using proper color agents according to the customer specified color, and inspecting the first sample with the color master. 4.1.1.1. Handling carefully, and using gloves to avoid finger prints 5.1.1.1. Controling air setting parameter 3 2 42

No action required

2. Vary in thickness POWDER COATING 3. Color variation

2.1. Rejection / Rework

2.1.1. Less/excess number of passes 3.1.1. Improper combination of color agents/Improper proportions 4.1.1. Improper handling, tight holding on bare hands

No action required 3 2 24 No action required 5 2 40 No action required

3.1. Rejection / Rework

4 4. Scratches, finger prints 4.1. Rework

5. Blisters

5.1. Rework

5.1.1. Lump formation

40

No action required

5.1.1.2. Using well dried powder 1.1.1. Instrument error 1. Wrong measurement FINAL INSPECTION/VISUAL 2. Inspection not done as per customer 2.1. Customer rejection specification / sampling plan 1.1. Damage during transit / handling 1.2. Customer rejection 6 1.1. Delay in despatch 6 1.1.2. Drg not referred correctly 1.1.1.1. Calibrated instruments used for measurement 1.1.2.1. Customer drg , spec and sampling plan referred during inspection Final inspection(vis ual as per check list & dimensional inspection) No action required 2 36

No action required

2.1.1.1. Referring customer sampling 2.1.1. Customer spec/sampling plan not copy and using bubble drawings to referred inspect critical dimensions. 1.1.1. Packing not done as per part requirement 1.1.1.1. Packing done as per part requirement

No action required 3 As per customer instruction(bu bble sheet packaging) 2 36 No action required 2 42

PACKING

1. Inadquate packing

7 1.2.1. Part identification not done 1.2.1.1. Attching part identification tag on the shipment

No action required

2 of 3

Process / Function

Potential Failure Mode

Potential Effects of Failure

Potential Causes / Mechanisms of Failure

Current Design Controls Prevention

Occurrence

Current Design Controls Detection

Invoice / proper handling

Recommended Actions

Responsibility Action Results & Target Completion Actions Taken Date Severity Occur

Severity

Detect

R.P.N.

Class

Detection

R.P.N.

No action required 2 48 42

1.1.1.1. Good supervision DESPATCH 1. Errors in original 1. Transportation error drawing 1.1. Rework or rejection of the 1.1. Damage product 6 7 SC 1.1.1. Rough handling / bad transit 1.1.1.2. Provide sufficient packing for the parts Part Drawings 4 3

No action required

Feasibility review

3 of 3