Potential Failure mode and effects Analysis

(Process FMEA)

System Vehicle Drawing No. Key Date : 7/10/2016 FMEA Number: JPPL/PFMEA/86403 01
Sub System Rubber Packing Protector 18293-KVT-9000 FMEA Date : 17/10/2016 Page No. OF
Component Rubber Packing Protector Rev. No. 00 FMEA Rev. No.: 0 Prepared by: D.Srininvasa babu
Vehicle: A Dt: 04/04/2000 FMEA Rev. Date: 23/11/07 Approved by: Manikandaraja
Core Team: Process Responsibility: Srinivasa Babu D
Rajesh Kannan (QA), Vinoth Kumar (Development), Vignesh (Mfg), Manivannan(QA), Sivanesan (QA), Vignesh
(Development)
Item / Process Action Results
C

Occurrence

Detection
Current Design Controls / Current Design Controls /

Occurrence
Severity
l R S Responsibility &

Detection
Severity
Potential cause(s) / Current Process controls Current Process controls - Recommended R
Process No. and Potential Failure Mode Potential Effect(s) of Failure a P O Target Completion
Requirement / Deliverable Mechanism(s) of Failure - Prevention for Causes Detection for Causes and / Action(s) Actions Taken P
Process Function s N D Date
and / or for Failure Modes or for Failure Modes N
s

Material properties on product Printed Identification on Visual Check in Receiving

6 Wrong Identification 3 4 72 634
will not meet Bags Inspection
Wrong Material
Material properties on product Mix-up in Compound Batch Code identification Visual Check in Receiving
6 3 4 72 634
will not meet Sheets provided on sheets Inspection
Weight of compound
B-10. Compound Correct compound to be received Material properties on product
6 Excess batch weight mentioned on the 2 Weighment of each batch 4 48 624
Receiving (Master without any mixup and packing will not meet
compound bag
Batch) damages Quantity variation
Weight of compound
Material properties on product
6 Less batch weight mentioned on the 2 Weighment of each batch 4 48 624
will not meet
compound bag
Material properties on product Verification of supplier test
Shelf life completed 6 Old stock Supplier test certificate 3 3 54 633
will not meet certificate
Material properties on product
Compound Mixup 6 Missing of identification tag Display of W.I. 2 Storage tag 4 48 624
will not meet
Improper storage condition Cleaning schedule of Racks
Contamination, Resulting in Bags kept stored in closed
Dust on Compound 6 (Temp., Humidity, Dust 3 and monitoring sheet for 2 36 632
variation in product performance condition
free) temp, humidity

Material properties on product Controlled through Tag with

B-20. Master Batch Storage of material in defined rack 6 Non compliance to FIFO 2 Batch FIFO monitoring chart 4 48 624
will not meet FIFO Colour code system
Inspection with identification tag Expiry of shelf life in
storage
Material properties on product Not monitoring shelf life Controlled through Tag with Expiry date mentioned in the
6 2 6 72 626
will not meet status FIFO Colour code system batch storage tag

Issue of material without FIFO monitoring through tag

Chemical property Work Instruction
Flow of compound affected 6 completing ageing 2 and colour code system on 6 72 626
variation Store personnel training
requirement bags
Material properties on product
Chemical Mixup 6 Missing of identification tag Display of W.I. 2 Storage tag 4 48 624
will not meet
Improper storage condition Cleaning schedule of Racks
Contamination, Resulting in Bags kept stored in closed
Dust on chemical bags 6 (Temp., Humidity, Dust 3 and monitoring sheet for 2 36 632
variation in product performance condition
free) temp, humidity

Material properties on product Controlled through Tag with

B-30.Storage of Master Storage of material in defined rack 6 Non compliance to FIFO 2 Batch FIFO monitoring chart 4 48 624
will not meet FIFO Colour code system
Batch with identification tag Expiry of shelf life in
storage
Material properties on product Not monitoring shelf life Controlled through Tag with Expiry date mentioned in the
6 2 6 72 626
will not meet status FIFO Colour code system batch storage tag

Issue of material without FIFO monitoring through tag

Chemical property Work Instruction
Flow of compound affected 6 completing ageing 2 and colour code system on 6 72 626
variation Store personnel training
requirement bags
Compound code
Compound should be free from Rhelogical properties will not Visual verification of tag and
Compound Mixup 6 Identification tag missed identification mentioned on 2 7 84 627
Mixing meet code on sheet
compound

Rhelogical properties will not Manual weighing system 1)Manual weighing system
8 High dosage of curatives 2 7 112 827
meet balance system available. 2) Formula Process Card

Shelf Life identified on

Rhelogical properties will not Shelf life of curatives Visual through displayed
8 each chemical bin.. 2 7 112 827
meet exceeds limit tags.
Uniform Mixing of Compound to be
Scorching
attained. Rhelogical properties will not Timers with hooters
8 Excess mixing time 2 Buzzure for time alarm 7 112 827
meet provided
Rhelogical properties will not Variation in water inlet Effective cooling system Visual through Formula
8 2 7 112 827
meet temperature through cooling tower. Process card
Rhelogical properties will not Variation in mill roll surface Effective cooling system Temp. indicator. Mixing mill
8 2 7 112 827
meet temperature through cooling tower. report.
Inadequte dosage of
Batches will be Reworked 7 accelarator and vulcanising Manual weighing system 2 Manual weighing system 2 28 722
Compound should be confirm with Rheological properties out agent
the rheological properties of spec.
B-40. Master Batch Material properties on product Improper dispersion of
6 WI displayed on machine 3 Timer and Sequence 6 108 636
Mixing (Mixing Mill) will not meet chemicals
More Fly Loss at Master All Master Batches weighed
100 % batch has to be rework 4 Regular PM of Dust Seal 2 7 56 427
Batch Stage after mixing.
Low Hardness Manual weighing system 1)Manual weighing system
Material properties on product Wt. variation in curing
6 Periodical calibration of 2 2) Formula Process Card 7 84 627
will not meet chemicals
weighing balance
Compound Hardness to be
confirmed with the specification Manual weighing system Manual weighing system
Wt. variation in curing
100 % batch has to be rework 4 Periodical calibration of 2 Formula Process Card 7 56 427
chemicals
weighing balance
High Hardness
Manual weighing system Manual weighing system
Material properties on product Wt. variation in curing
6 Periodical calibration of 2 Formula Process Card 7 84 627
will not meet chemicals
weighing balance
 Item / Process Action Results
C

Occurrence

Detection
Current Design Controls / Current Design Controls /

Occurrence
Severity
l R S Responsibility &

Detection
Severity
Potential cause(s) / Current Process controls Current Process controls - Recommended R
Process No. and Potential Failure Mode Potential Effect(s) of Failure a P O Target Completion
Requirement / Deliverable Mechanism(s) of Failure - Prevention for Causes Detection for Causes and / Action(s) Actions Taken P
Process Function s N D Date
and / or for Failure Modes or for Failure Modes N
s

Whole batch will be have to be Specific location identified

8 Selection of wrong polymer 1 Visual 7 56 817
scrapped for specific Polymer
Add Chemicals Mixup Of Polymer Performance failure 6 Kneader cleaning system in
Kneader not cleaned during
place with specific cleaning Visual through cleaning
change over to other 1 8 48 618
polymer for specifc record.
Performance failure 6 polymer
compound.
Display of W.I. for relevant
100% batch will be rejected 8 Incorrect testing method. 2 Visual control system 7 112 827
B-50. Final Batch Compound testing should be done test
Wrong Resuts
Testing as per customer requirement Material properties on product Calibration through Detection through variation
6 Faulty equipment 2 7 84 627
will not meet NABL/NPL accridited lab of test results.
100% bathces will have to be Calibration of weighing
Variation in Weight 4 Faulty balance 2 100 % slug weight checking 7 56 427
reworked in station balance
B-60. Sheet Cutting Weight of blank should be verfied
Material properties on product
Wrong Compound 6 Identification tag missed Slug weight specification 2 Visual control system 6 72 626
will not meet
Tool to be Loaded on Correct Tool loaded on wrong Specific make machines Machine-Tool matrix is
Flow of compound affected 4 2 Visual control system 7 56 427
Machine Machine are not available available
WI of mixing process 100% Rheo testing of
Over mastigation of
Timer & parts kept in Red Compound batches for
Visual defects in the part 4 rubbers (less Mooney 2 5 40 425
bins Viscosity before releasing for
viscous compound.)
production
Digital Temp. controllers
Visual defects in the part 4 Temp. drop during molding. 3 Temp indicator 5 60 435
provided
Controlled Storage
Part shall be free from surface condition & parts kept in
Air entrapment Visual defects in the part 4 Moisture in chemicals 2 Raw Material testing 6 48 426
defects like air entrapment Red bins

Insufficient venting system Mould Inspection and

Visual defects in the part 4 Ventiline provision in Mould 3 6 72 436
in mold preventive maintenance
Process chart available &
Visual defects in the part 4 Less/ improper bumping 3 PLC control system 5 60 435
parts kept in Red bins
Blanks not immerssed in Work Instruction available
Visual defects in the part 4 2 Visual control system 7 56 427
water & parts kept in Red bins
Used Templet / Barwell for
Blank Cutting ( Wherever
Visual defects in the part 4 Less Charge Weight 3 Weighing balance 6 72 436
Applicable) & parts kept in
Red bins
Part shall be free from surface WI of mixing process Rheo testing Mooney
Flow Mark Low Compound flowability
defects like Flow mark Visual defects in the part 4 Timer & parts kept in Red 3 Viscosity Testing 6 72 436
due to improper mastication
bins
Temperature controller
Visual defects in the part 4 Temp. drop during molding provided & parts kept in 3 Temperature indicator 5 60 435
Red bins
Templet / Barwell for Blank
Cutting ( Wherever
Visual defects in the part 4 Less Charge Weight Applicable) & parts kept in 3 Weighing balance 6 72 436
Red bins

Blank size defined & parts

Visual defects in the part 4 Improper blank size 3 First Piece Approval 5 60 435
kept in Red bins

Part shall be free from surface Insufficient venting system Ventiline provision in Mould Mould Inspection and
Under fill / Rubber short Visual defects in the part 4 3 6 72 436
defects like Under Fill in mold & parts kept in Red bins preventive maintenance

Bumping time defined in

respective part process
Visual defects in the part 4 Insufficient bumping time. 3 Visual control system 7 84 437
charts. & parts kept in Red
bins

W.I. for cycle time of mixing

Visual defects in the part 4 Improper flow of material 3 Rheo test 5 60 435
& parts kept in Red bins

Compound freezed during

Low Tear strength of
Visual defects in the part 4 initial development & parts 2 Rheo test 5 40 425
compound
kept in Red bins
Erratic ejection by the Trained operators & parts
Visual defects in the part 4 2 Visual control system 7 56 427
operator kept in Red bins
Preventive maintenance of
Visual defects in the part 4 Burr in mould tool. & parts kept in Red 3 Set up approval. 5 60 435
C-10 Compression bins
Molding Tear / Cracks (Tear at any Improper application of
Trained operators & parts
Part shall be free from surface portion on the product Visual defects in the part 4 releasing agent in mold 3 Visual control system 7 84 437
kept in Red bins
defects like Tear / Cracks during unloading the cavity & core
press) Temperature controller
Visual defects in the part 4 High temp. during curing provided. & parts kept in 3 Temp indicator 5 60 435
Red bins
Gate size controlled during
tool design
Pressure drop due to Vent provided along the Conttrol Panel / Pressure
Visual defects in the part 4 3 6 72 436
variation in gate joining line opposite to gauge
Injection Point & parts kept
in Red bins
Mold design & parts kept in
Visual defects in the part 4 Improper mold grooves 2 Mold preventive Maint. 4 32 424
Red bins
Part shall be free from surface
Cut Marks
defects like Cut Marks Sharp Blade used to Brass rod provided & parts
Visual defects in the part 4 2 Visual control system 7 56 427
remove flash after moluding kept in Red bins
 Item / Process Action Results
C

Occurrence

Detection
Current Design Controls / Current Design Controls /

Occurrence
Severity
l R S Responsibility &

Detection
Severity
Potential cause(s) / Current Process controls Current Process controls - Recommended R
Process No. and Potential Failure Mode Potential Effect(s) of Failure a P O Target Completion
Requirement / Deliverable Mechanism(s) of Failure - Prevention for Causes Detection for Causes and / Action(s) Actions Taken P
Process Function s N D Date
and / or for Failure Modes or for Failure Modes N
s

Low dosage of curatives

Manual weighing m/c &
Low Hardness in product 4 added during chemical 2 Rheological testing 5 40 425
parts kept in Red bins
weighing
Temperature controller
Less Tempreture. on the
Low Hardness in product 4 provided & parts kept in 3 Pyrometer 5 60 435
Part shall be free from surface mold surface
Under Cure Red bins
defects like Under Cure
Process chart specified
curing time
Low Hardness in product 4 Less Curing time PLC control /Timer 2 Alarm system 4 32 424
provided & parts kept in
Red bins
WI of mixing process
Part shall be free from surface Leading to Customer end fittment High Viscosity compound
Thickness variation 7 Timer & parts kept in Red 2 First Piece approval report 5 70 725
defects like Thickness Variation problems ( improper flow )
bins
Mould preventive
OD Oversize fittment issue 7 Guide pin worn out. mainatainance & parts kept 3 First piece approval report. 5 105 735
Part should confirm the Dimensions in Red bins
as per Drawing
Preventive Maintenance &
ID Undersize Fittment issue 7 Cavity pin wear out. 3 First piece approval report. 5 105 735
parts kept in Red bins
Tools preventive
maintainance done, proper
Part Should be free from Damages Damage Visual defect in the product 4 Mould having damage mark 3 First piece approval report. 5 60 435
intime & parts kept in Red
bins
First off Approval and
Patrol Inspection once in 3
Repeated Defects should not be Defects in previous day not Verification of Action plan of
Repeatition of defects Visual defect in the product 4 hrs. Highlighting to 2 6 48 426
produced. highlighted previous defects.
technical team and Actions
to be taken
Productivity to be achieved as per Hourly output monitoring Hourly monitoring of
Low Productivity Dispatch Failure 4 Production Qty variation 2 6 48 426
Qty defined in PSW. Master list Production
Visual checking of Cavity
Only Approved Cavities / Mould to Wrong / Un approved Excess or Un approved Cavity number Engraving
Dimensional Variation 7 1 engraving during First off 6 42 716
be taken for the Production. cavities moulds for production provided on the each cavity
Inspection

100% of Products have to be Unfinished material mixed

There should be no untrimmed flash Untrimmed Flash 7 Skilled operator 2 Visual control system 7 98 727
reworked with finished material.
7 Unfinished material mixed Skilled operator 2 Visual control system 7 98 727
100% of Products have to be with finished material.
There should be no untrimmed flash Untrimmed Flash reworked
7 Training 2 Skill Level - B 7 98 727
C-20 Deflashing and parts should not have blade cut 7 Unskilled operator Training / WI 2 Skill Level - B 7 98 727
while finishing 100% of Products have to be Training / WI/ Defective
Deep blade cut 7 Unskilled operator 2 Skill Matrix / Visual 7 98 727
scrapped Sample photographs
Correct Identified and Defined Supply of defective part to In adequate acceptance
Wrong Inspection method 7 Sampling plan defined 2 Visual control system 7 98 727
Gauges are use only customer criteria

Part No. of the fixture to be verified All fixtures are identified by

Usage of wrong fixture supply of NG parts to customer 7 No identification on fixture 2 Visual control system 7 98 727
before taking for inspection. specific part no.

It shall be ensured that only trained

Wrong measurement by 100% reinspection of parts /
operators are deployed for 4 Appraiser variation Trained Inspector 2 MSA 7 56 427
Inspector supply of NG parts to customer
inspection of parts.
100 % Inspection and
Defects in previous day not Highlighting to technical Verification of Action plan of
Rejection level within the Target Repeatition of defects Visual defect in the product 4 2 6 48 426
highlighted team and Actions to be previous defects.
D-10 Final Inspection taken
Visual defect in the product & Customer complaints not Complaints closure as per 8D and Customer top sheet
Zero Defects at Customer End Customer Complaint 4 2 6 48 426
Customer Dissatisfaction closed the agreed Lead time verification
Instrument identification
No identification of
Gauge dimensions shall be verified Selection of wrong number is ensured before
100% reinspection of parts 4 Instruments, Gauge 2 Set-up approval 7 56 427
before taking for inspection. Instruments procurement. Ensuring
calibration
gauge calibration

100% of Products have to be Unfinished material mixed

There should be no untrimmed flash Untrimmed Flash 7 Skilled Inspector 2 Visual control system 7 98 727
reworked with finished material.

i)Customer dissatisfaction Similar sizes of Parts are Proper identification to be

Visual Inspection Mixup Of Parts 7 3 Dock audit 6 126 736
ii)Customer Line Stoppage kept side by side given for each part

Operator not following the Packing slandered

Less nos. packed ODC raised by customer 1 2 Cross Check during PDI 7 14 127
WI work instruction display

Quantity to be packed as per

defined packing standard Operator not following the Packing slandered
More nos.packed Financial loss to company 1 2 Cross Check during PDI 7 14 127
D-20 Packing & WI work instruction display
Dispatch
(i) Customer dissatisfaction Similar parts kept side by Proper identification to be
Mix up 1 2 Dock audit 7 14 127
(ii) Cust line stoppage side given for each part
1) Customer dissatisfaction Packed material with wrong Verification of part number
Wrong part supply 5 2 Visual control system 7 70 527
Correct material to be send to 2) Delay in dispatch of material part number during packing
customer without damage Loading method not
Damage 1) Customer dissatisfaction 7 Trained operators 2 Visual control system 7 98 727
followed
PFMEA Action Criteria: i) If severity 9 & 10, & RPN >100- Action compulsory ii) If severity 8 & RPN >120- Action compulsory iii) If severity 1 to 7, & RPN 245 - Action compulsory