Doc No : PFMEA/8532/00

Potential Failure Mode Effect Analysis Rev.No/Date: 00 / 10/2/2017

Process FMEA
Part Name : CASE & COVER HR -RESI 9 Part No./ECN No: S1B45313 & S1B45314 /14 &15

Model : Date(Org): 10/2/2017 Rev.No/Date: 00 / 10/2/2017

Prepared by: CFT Core Team: Kishan singh, Gopi, Chethan, Venkatesh, Manjesh, Suhas,Sunil
Supplier / Plant :PREM INDUSTRIES
MYSORE Supplier Code: 10177615 Customer Name : Schneider Electric

Process Function \ Potential Cause(s) \Mechanism of

Opr. No. Potential Failure Mode Potential effects of Failure Sev Spl Class Occ Current Process Control Prevention Current Process Control Detection Det RPN Recommended actions Res & Target Action taken S O D RPN
Requirements Failure

Next process-Cannot be processed completely 1.Improper inspection by

Main Assy-Nil supplier.
Raw material is less in quantity Cust line-Nil 4 1 Visual counting 1.Verification of invoice for quantity 7 28
2.Lack of operator skill at Supplier
Field-Nil end.

10 Receipt of raw material.

1.Material colour to be compared with invoice/test
Next process-Cannot be processed completely 1.Verification of material name, grade & colour should be cerificate.
Main Assy-Nil Material grade not mentioned in the
Wrong material recevied Cust line-Nil
7 1 check in the PO. 2.contamination(foreign particles) to be checked visualy. 4 28
PO.
Field-Nil 2.FIFO to be followed as per colour code. 3.material grade to be compare with grade mentioned in
test certificate or on the material bag.

Next process-Cannot be processed. 1.Improper inspection by

Raw material not as per the
Incoming inspection of Raw Main Assy-Nil supplier. 1.Verification of Supplier test certificate with
20 specification Cust line-Nil
7 1 Supplier test certificate 7 49
material 2.Lack of operator skill at Supplier specification. 2. Incoming inspection report
<SC> Field-Nil end.

Next process-Rejection 1. Improper identification of

Improper identification /mix up of
Main Assy-Nil raw material. 2.Raw 1.Storage layout. 2.Training to
products Cust line-Nil
4 1 Visual inspection ,Stock status board. 7 28
material not stored in operators on stacking and handling.
<SC> Field-Nil identified location
30 Storage of raw material
Next process-Cannot be processed completely 1 .Improper identification of
Main Assy-Nil 1.Identification of colour code & GRN no.
FIFO not followed Cust line-Nil
4 raw material. 1 Daily stock verification. 7 28
2.Operator training
Field-Nil 2.Unskilled operator.

Next process-Silver streaks 1.Failure of thermocouple. 1.Calibration record.

Temperature found out of spec Main Assy- Rejection
Cust line-Nil
7 2.Unskilled operator setting 1 2.Operator skill matrix. Visual , Predrying temperature monitoring check sheet. 7 49
<SC>
Field-Nil the parameters. 3.Work instruction.
Loading and predrying of raw
40
material in hopper.
Next process- Contamination
Mix up of previous raw material Main Assy- Rejection Earlier raw material not cleaned As Per Material change procedure
Cust line-Nil
7 1 First off approval report. 7 49
<SC> properly.
Field-Nil

Next process-Rejection. 1.Due to low injection

Short mould Main Assy-Nil
7 pressure, material temperature & speed. 1 Temp,pressure and speed controlled by PLC controller. First off approval / In process inspection record 7 49
<SC> Cust line-Not as per the product specification
Field-Nil 2. Shot weight less.

Next process-Rejection.
Main Assy-Nil
Flow line Cust line-Not as per the product specification 7 Low mould and material temp. 1 Mould and material temp.controlled by PLC controller. First off approval / Inprocess inspection check sheet 7 49
<SC> Field-Nil

Next process-Rejection.
Main Assy-Nil High material temperature, Low
Sink mark Cust line-Not as per the product specification 7 1 Temp & injection pressure controlled by PLC controller. First off approval / Inprocess inspection check sheet 7 49
<SC> Field-Nil injection pressure and speed.

Next process-Rejection.
Main Assy-Nil Operator training & WI display.
Silver strikes Cust line-Not as per the product specification 7 1 First off approval / Inprocess inspection check sheet 7 49
Field-Nil pre-heating time is less. Pre heating timing controller by PLC.

Next process-Rejection.
Main Assy-Nil High material temperature, high
Flash Cust line-Not as per the product specification 7 1 Temp, injection pressure & speed controlled by PLC controller. First off approval / Inprocess inspection check sheet 7 49
<SC> Field-Nil injection speed & pressure.

Next process-Rejection. 1.Due to high injection

Core insert broken Main Assy-Nil
7 pressure, material temperature low & high
1 Temp,pressure and speed controlled by PLC controller. First off approval / In process inspection record 7 49
<SC> Cust line-Not as per the product specification speed.
50 Injection Moulding Field-Nil 2. Shot weight high

Next process-Rejection.
Part Catch up Main Assy-Rejection 1.High material temperature,
7 1 Temp,pressure and speed controlled by PLC controller. First off approval / In process inspection record 7 49
<SC> Cust line-Fitment problem 2.material over backing.
Field-Nil

Next process-Rejection.
Ejection pin mark Main Assy-Nil Ejection pin wear and material Preventive maintenance of mould as per PPEP & mould history First off approval / Inprocess inspection check
Cust line-Not as per the product specification 7 1 7 49
<SC> Field-Nil temperature too high. card. sheet,Preventive maintenance record.

Next process-Rejection.
Main Assy-Nil Ejection pin wear and material Preventive maintenance of mould as per PPEP & mould history First off approval / In process inspection check sheet,
Colour change Cust line-Not as per the product specification 7 1 7 49
<SC> Field-Nil temperature too high. card. Preventive maintenance record.

Next process-Rejection
1.Inspection Standard /Work instruction
Part broken Main Assy-Rejection 7 MASTER BATCH DEGRADATION 4 purge out Barrel material before start up after minor stoppage 2.First off inspection /Patrol 4 112
<SC> Cust line-Fitment problem inspection report/Final Inspection report
Field-Nil
 Process Function \ Potential Cause(s) \Mechanism of
Opr. No. Potential Failure Mode Potential effects of Failure Sev Spl Class Occ Current Process Control Prevention Current Process Control Detection Det RPN Recommended actions Res & Target Action taken S O D RPN
Requirements Failure

Next process-Rejection
Main Assy-Rejection Previous raw material not cleaned
Black Dot Cust line-Fitment problem
4 properly in the hopper 4 as per Start up aprroval check sheet procedure 1.As per visual inspection standard plan 4 64
Field-Nil

Next process-Rejection. 1.Preventive maintenance

Main Assy-Nil. 1.Preventive maintenance of tool. record.
Dimensional variation Cust line-Not as per the product specification 7 Tool wear or process variation 1 7 49
<SC> Field-Nil 2.Process parameter controlled by PLC controller. 2.First off inspection /Patrol
inspection report.

Next process-Rejection 1.Incorrect inspection / problem not

60 In process Inspection Accepting the rejections Main Assy-Nil
Cust line-Fitment problem
7 defined. 1 Inspection standard Visual inspection 7 49
<SC>
Field-Nil 2.Improper lighting for inspection .

Next process- Difficult to meet customer

schedule. 1.Incorrect inspection / problem not
Rejecting the good items Main Assy-Nil 1 defined. 1 Inspection standard /Operator skill evaluation. Visual inspection 7 7
Cust line-Nil 2.Improper lighting for inspection .
Field-Nil

Next process-Rejection 1.Incorrect inspection / problem not

Accepting the rejections Main Assy-Nil
Cust line-Fitment problem
7 defined. 1 Inspection standard Visual inspection 7 49
<SC>
Field-Nil 2.Improper lighting for inspection .

70 Final Inspection
Next process- Difficult to meet customer
schedule. 1.Incorrect inspection / problem not
Visual inspection
Rejecting the good items Main Assy-Nil 4 defined. 1 Inspection standard /Operator skill evaluation. 7 28
Cust line-Nil 2.Improper lighting for inspection .
Field-Nil

Next process- Rejection

Main Assy-Nil Lack of operator knowledge on
Wrong labeling 4 1 Inspection standard /Operator skill evaluation. Visual inspection /Packing slip 7 28
Cust line-Line stoppage packing and labeling .
Field-Nil
80 Packing & Labeling
Next process- Repacking
Less quantity of products Main Assy-Nil Lack of operator knowledge on
Cust line-Difficult to meet customer schedule.
1 1 Packing standard Visual inspection /Packing slip 7 7
packed. packing and labeling .
Field-Nil

Storing at wrong location Next process-Difficult to find the product.

Main Assy-Nil Product not stored in 1.Storage layout. Visual inspection ,Stock status board.
90 Storage ( at Dispatch area ) <SC> Cust line- Rejection/Line stop
7 1 7 49
identified location 2.Training to operators on storing and handling. Dock audit
Field-Nil

Next process- Affect the delivery schedule &

Customer dissatisfaction.
Main Assy-Nil Improper
100 Dispatch Dispatch Delay Cust line-Line stoppage. 4 4 Daily dispatch schedule Visual, Delivery invoice. 4 64
planning
Field-Nil

<SC> - Special Characteristics

<CC> - Critical Characteristics

Revision History
Sl.No Reason for revision Rev.No. Date Reviewed by
1 Initial release 00 10/2/2017 GOPI N Prepared By Approved By
SUNIL G Kishan Singh