PROCESS F.M.E.A.

PROCESS FAILURE MODES & EFFECTS ANALYSIS FMEA No: 16

Part name: TUBULAR RING TRML M8 (SCA - 50.0) Process Resp Key Date Model Year(s) / Vehicle(s) QAD/FR/FMEA/01 Rev- 03
Pratik Patel,Vikesh Mishal NA NA FMEA Dt. (Orig.) : 04-10-2022

Part Number: 1400752502 Date (Revised) : 20-09-2024

Core Team : SURYAKANT , SHREYANSH ,PRATIK,VIKESH
Page No: 1 of 1
Process S C Potential Cause(s) / O D R Action Results
Function / Potential Failure Potential Effect(s) E L Mechanism(s) of C Current Process Control(s) E P Recommended Resp & Action(s) S O D R
Requirement
Reqmt. Mode of Failure V A Failure. C T N Action(s) Trgt dt. Taken E C E P
S S O Prevention Detection D S*O*D V C T N

(1) Approved PO to Vendor with

(1) Wrong Specification to specifications sheet attached with 1st (1) Cross Verfication at the
(1) effect on machinability
(1) Chemically & Vendor order time of Final Inspection at
(2) Part will not function as
Physically (2) no Standards available (2) Authorized Purchase order check vendor end
intended
Proper dimensionally or obsolote standards sheet system at vendor; cross verification (2) Material Test Certificate
(3) Premature Failure 8 2 7 112
Documents Incorrect, wrong available either at Ashwani by plant head at the time of 1st sample Verification at premises
(4) Material stopped as
documents supplied or Supplier end inspection and final inspection before (3) Qualified Laboratry Testing
ERP system will not
by customer (3) Wrong Process dispatch . of 1st lot then after random
accept
Validation at supplier end (3) Colour coding system at vendor for testing every 3 months
OP-10 different alloys
Raw material
inward / (1) Wrong Specification to
incoming Vendor (1) Size specification mentioned in
inspection (2) Lack of Process Control purchase order check sheet verified by (1) Final Inspection at
Dimension as (1) Dimension Not (1) Machining Problem plant head Supplier end
8 C at vendor side 2 7 112
per spec. As Per Drawing (2) Fitment Problem (3) Man handaling of two (2) In process Inspection of producton (2) Receiving Inspection at
similar materials with from 1st billet Premises
different tolerances (3) extrusion die & draw die life monitoring

(1) Man handaling

(2) Process missed or (1) Scrap & billet Quality testing (1) Final Inspection at
Material not (1) Product reduce self life
process failure at vendor (2) extrusion die & draw die periodic Supplier end
rusty, bend , (3) Visual Defects (2) Product strengt will be 7 2 7 98
end inspection & maintainence (2) Receiving Inspection at
damage weak
Premises

(1) Difficult to find out right

material (1) Material not proper
OP-20 Proper
Material storage on (2) Production person identify (1) Location identify for every material
Storage of storage of 8 2 Proper location in ERP 8 128
wrong place confuse during receiving (2) Not proper location for (2) Proper tagging on all material.
raw material raw material
of raw material material storage.
(3)Wastage of time

(1) Total Length over (1) Unskilled labour (1)Cutting size chart
size (2)Wrong cutting size input (2)Cutting work instruction
(2) Total length (2) Problem at customer in machine (3) Proper Machine Selection
OP-30
As per spec. under size end in assambly 8 (2) inappropriate machine 3 (4) Stopper pin check at regular interval (1) In Process Inspection 7 168
Tube cutting
(3) Uneven cutting (3) Customer dissatisfied selection (5) Preventive maintenance of machine. (2) Last piece inspection
4) Burr on curring (4)Sharp cutting edges (3) Stopper pin loose (6) Skilled operator
edges (4) Cutting blade were (7) First piece approval

(1) Check tool at regular interval

(1) Excess (1) Champher tool deform or (2) Preventive maintenance of tool &
OP-40 (1) Sharp edeges injured
champher damage machine
Tube As per spec. to customer 8 2 (1) In Process Inspection 8 128
(2) Less champher (2) Unskilled labour (3) First piece approval
Chamfering (2) Cable not enter easily. (2) Last piece inspection
(3)Not proper angle (3) Wrong setting (4) Work instruction
(5) Skilled operator
 (1) Wrong setting of (1) Work instruction of dropping.
(1) O.D. over size or
(1) Assembly problem at machine strock length. (2) List of die & die identification.
Under size
customer end because of (2) Wrong die use. (2) provide stopper to avoid length
OP-50 (2) Dropping length
As per spec. palm width variation 8 (3) Unskilled labour 3 variation (1) In Process Inspection 7 168
Dropping over size or Under
(2) Barrel length affected (4)Part wise list of die not (3) Dropping work instruction (2) Last piece inspection
size
(3)Part reject available. (4) Skilled operator
(5) First piece approval

(1) Palm width, (1) Wrong power press

(1) Forging & die setting work instruction
Thickness & Barrel stroke setting
During forging (2) First piece approval
under size or over (2) Problem in die setting
OP-60 Dimension as (1) Fitment problem at (2) Die set by skill person (1) In Process Inspection
size. 8 (3) Unskill operator 3 7 168
Forging per customer end (3) Ensure that all measuring instruments (2) Last piece approval
(2) Wrong setting of (4) Measuring instruments
specification are calibrated.
strock length not calibrated
(4)Preventive maintenance of machine

(1) Tool deformation of

damage (1) First piece approval
(1) Palm length & (2) Problem in die setting (2) Work instruction of holing.
total length under (3) Unskill operator (3) Skilled operator
size or over size (1) Fitment problem at (4) Measuring instruments (4) Calibrated instrument use.
During Arc not calibrated
(2) Palm bend customer end (5) Part wise list of dies available &
OP-70 cutting & Stud (5)List of die not available or
(3) Stud hole under (2) Contact area of paln marking on die should be available (1) In Process Inspection / set
Arc cutting & hole, 8 c marking on die is not 2 7 112
size or over size less (affect current (6) Monitoring tool life & changing of tool up approval
Holling dimension as available
(4) Stud hole carrying capacity) at decided time
per spec. (6)Wrong die use/setting
damage (3)Wrong product produce (7) Check holling punch before insert in
(7)Holling punch damage & holling die
were (8) Work instruction of holling
(8) Wrong selection of (9) Grinding holling plate at regular interval
Holling punch size
(9) Holling plate not sharp
Free from (1) Sharp edeges (1) Fitment Problem (1) Unskilled labour (1) Use of Skiled Labour
OP-80
sharp edegs (2) Burrr (2) Sharp edeges injured 8 (2) Deburring machine not 3 (2) Preventive maintenance of vibro (1) In Process Inspection 7 168
Deburring
& burr (3) Damage part to customer proper work machine
OP-90
All dimension (1) Customer reject the
Inspection (1) Dimension Under (1) Material not made as per (2) Before tin plating
as per material 8 2 (1)Use Latest drawing or specificatiuon 7 112
before tin size or over size specification inspection
drawing (2)Fitment problem
plating

(1) Less qty. of part

(2) Excess qty of chemical
(1) Excess Plating (1) Tinning peel off. (3) Excess dip time (1) Work instruction of plating process
6 2 (1) After plating inspection 8 96
(2) Reducing self life. (4) Water rinsing not proper (2) Skilled operators
(5) Not properly dry
Plating (6) Unskilled operators
thickness as
per spec. (1) Excess qty. of part (2)
Less qty of chemical
(3) Less dip time
OP100 (1) Blackness on part. (4) Water rinsing not proper (1) Work instruction of plating process
(2) Less Plating 6 2 (1) After plating inspection 8 96
Tin plating (2) Reducing self life. (5) Not properly dry (2) Skilled operators
(6) Unskilled operators

(1) Unskilled labour (1) Use skill labour / training given to

Part free from (1) Reducing self life (2) Work instruction not labour
(1) Blackness 7 2 (1) After plating inspection 8 112
blackness (2) Customer dis-satisfied available (2) Work instruction of plating process
(3)Part not proper dry
(1) Rectifier not proper work. (1) Preventive maintenance of rectifier
(2) Work instruction not (2) Work instruction plating process (1) After plating inspection
Part free from (1) Reduce life of product
(1) Plating peel off 7 availablr 2 (3) Skilled operator (2) 100% visual inspection 8 112
peel off (2) Customer dis-satisfied
during packing

(1) Problem at (1) Inspection standard (1) Use proper & calibrated
customer end during not available instruments used for an inspection
Dimension (1) Dimension not
fitment of part 8 (2) Untrained quality 2 (2) Training provided to quality person (1) Final inspection 8 128
as per spec. as per spec.
(2) Part jecte at person
OP-110
customer end
Final
 Final
Part free (1) Visual checksheet not (1) Visual checksheet provide
inspection
from burr, (1) Excess burr, availabe (2) Training provided to checking
(1) Product reduce self
crack, dent, dents, crack, rust 8 (2) Untrained checking 2 person for final inspection (1) Final inspection 8 128
life
rust & no & damge part person
damage
(1) missmatch quntity in
(1) Packing standard not
invoice (1) Packing standard provided &
(1) Excess or less provided & follow
and actual, Box 7 2 follow (1) DPR 7 98
qty. pack (2) Unskilled packing
Breakage (2) Training provide to packing person
packing person
Qty. should (2)Material Mix Up
be as per Wrong Material supply
Improper Identification
required/Pa to
OP-120 Material Mix Up tracing & (1) Training, & W.I. (1) DPR 7 98
cking Customer & Customer
Packing design similarity
condition Dissatisfaction
should be (1) Packing standard not (1) Packing standard provided &
proper provided & follow follow
(1) Damage (1) Materail fall down & (2) Unskilled packing (2) Training provide to packing person
7 2 (1) DPR 7 98
box/bag used may be damage packing person (3) Provide proper storage are for
(3) Not proper storage packed part
are for packed part
(1) Location not define (1) Define proper location for finish
(1) Problem at time of
Proper (1) Finish good put for FG product goods
dispatch 7 2 Dock audit 7 98
location on wrong place (2) Untrain store person (2) Training provide to store person
(2) wrong part dispatch
OP-130
(1) Plating shelf (1) Material comes (1) Plated material (1) Plating shelf life work instruction
Storage of Plating life 7 2 PDI 7 98
life expiry rusty storage for long time
FG
customer resend the Improper Identification Standardization of
Labeling tags from Identification Tag.,
material to
and (1) wrong lable 7 last station / wrong tag 2 Trained Employees, & Dock audit 7 98
supplier & Customer
tagging W.I.
Dissatisfaction
(1) Mis handling (1)Dents & Damage (1) Improper (1) logistic fixing / weight 1.Delivery as per customer
(2) Delivery not in (2) Production may be transportation fixing per box. dispatch plan.
time affected at customer (2) Packing plan not (1) Packing plan provided & followed 2. PDI batch code
OP-140 Material (3) shelf life of end. provided & followed (2) Trained & Skill person inspection.
Dispatch to shifting plating expired (3) Material become 8 (3) Untrained person 3 (3) More than 6 month stored pated 7 168
customer to customer material rusty. (4) Plating shelf life mateial should be send to replatting.
despatched to the expired due to material
customer stored more than 6
month
CRITICAL PROCESS:- C

Prepared By :- DHARMESH Approved by :- SURYAKANT

Date: 20-09-2024