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PROCESS FAILURE MODE AND EFFECTS ANALYSIS

Part name : ARMATURE SHAFT Rev date : FMEA Control no PT-PFMEA-P2-110 Rev no

Part number : Process Resp : Prepared by

Model Key date FMEA date (Origin)

Core team : Customer :

Action Results
Current Process Controls O Current Process Controls D R
Potential Effect(s) of Clas Potential Cause(s) / Recommended Resp. & Target
Process function/Name Requirements Potential Failure Mode S eV Prevention for cause and for c Detection for cause and failure e P
Failure s Mechanism(s) of Failure Action(s) Completion Date
failure mode c modes/effects t N Action Taken S e v O c c D e t

Inward Verification of Raw material

Wieght Out of specification Rejection 7 Wrong material supplied. Verification of supplier 2 4 56
Weight
Invoice

Breakage during
Material not conformed EN- application / Customer 3rd Party Inspection for Chemical
Material chemical composition - EN-19 7 Wrong material supplied. Material test certificate 2 4 56
19 Rejection / Functional Analysis
& colour coding
faliure.
Receipt of RM

Under size Rejection 7 Material mix up Supplier inspection 2 Inward inspection report 4 56
report
Diameter 8.3 ± 0.2
More cycle time
Over size 7 Material mix up Supplier inspection 2 Inward inspection report 4 56
during next process
report

Incorrect blade, wear of

Under size Rejection 7 blade, improper clamping of Supplier inspection 3 Inward inspection report 4 84
blade report

Unclear in Next
Bar cutting Total length 145.50 + 0.2 Taper 7 Improper Clamping of Parts Supplier inspection 3 Inward inspection report 4 84
Process
report
Incorrect blade, wear of
More cycle time
Over size 7 blade, improper clamping of Supplier inspection 2 Inward inspection report 4 56
during next process
blade report
Trained operator,
More cycle time Operation std Provided Set up verification Each set up
Over Size 7 1. Wrong Offset 2 4 56
during next process In -Process inspection

Centerless Grinding Diameter 8.05 +0.2

Trained operator,
Unclear in Next Operation std Provided Set up verification Each set up
Under size 7 1. Wrong Offset 2 4 56
Process In -Process inspection

1. Trained operator, Clean the

1.Improper loading and Butting face before loading Set up verification Each set up
7 3 4 84
Butting the part In -Process inspection
2.Operation std Provided.

Improper fitment, 1.Operation std and operator

Under size Rework & Rejection at 2.Cutting speed and feed not training Set up verification Each set up
7 3 4 84
customer end ok 2. Set cutting speed and feed In -Process inspection
and lock in program

1.Tool Changing Frequency

fixed Set up verification Each set up
7 3.Tool wear 3 4 84
2.Interlock for tool life In -Process inspection
provided.
Total length 144.0 -0.3 1. Trained operator, Clean the
1.Improper loading and Butting face before loading Set up verification Each set up
7 3 4 84
Butting the part In -Process inspection
2.Operation std Provided.

1.Operation std and operator

Improper fitment, 2.Cutting speed and feed not training Set up verification Each set up
Over size Rework & Rejection at 7 3 4 84
ok 2. Set cutting speed and feed In -Process inspection
customer end and lock in program

1.Tool Changing Frequency

fixed Set up verification Each set up
7 3.Tool wear 3 4 84
2.Interlock for tool life In -Process inspection
provided.

1.Trained operator, Clean the

1.Improper loading and Butting face before loading Set up verification Each set up
7 3 4 84
Butting the part In -Process inspection
2.Operation std Provided.

1.Operation std and operator

Improper fitment,
Finish turning 2.Cutting speed and feed not training Set up verification Each set up
Under size Rework & Rejection at 7 3 4 84
ok 2.Set cutting speed and feed In -Process inspection
customer end
and lock in program
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Action Results
Improper fitment, Current Process Controls O Current Process Controls D R
Finish turning Potential Effect(s) of Clas Potential Cause(s) / Recommended Resp. & Target
Process function/Name Requirements Under
Potential size Mode
Failure ReworkFailure
& Rejection at S eV
s Mechanism(s) of Failure
Prevention for cause and for c Detection for cause and failure e P
Action(s) Completion Date
customer end failure mode c modes/effects t N Action Taken S e v O c c D e t

1.Tool Changing Frequency

fixed Set up verification Each set up
7 3.Tool wear 3 4 84
2.:Interlock for tool life In -Process inspection
provided.
Outer diameter 8.05+0.05 & 7.98 -0.1
1.Trained operator, Clean the
Butting face before loading
1.Improper loading and the part Set up verification Each set up
7 3 4 84
Butting 2.Operation std Provided In -Process inspection

Improper fitment, 1.:Operation std and operator

Over size Rework & Rejection at 2.Cutting speed and feed not training Set up verification Each set up
7 3 4 84
customer end ok 2. Set cutting speed and feed In -Process inspection
and lock in program

1.Tool Changing Frequency

fixed Set up verification Each set up
7 3.Tool wear 3 4 84
2.Interlock for tool life In -Process inspection
provided.

1.Operation std and operator

1.Cutting speed and feed not training Set up verification Each set up
7 3 4 84
ok 2.Set cutting speed and feed In -Process inspection
and lock in program

Improper fitment & 1. Insert Changing Frequency

OD Surface finish = Ra 1.6 More Rejection at customer fixed Set up verification Each set up
7 2.Tool wear 3 4 84
end 2.Interlock for tool life In -Process inspection
provided.

1.Operation std Provided,

3.Coolant concentration less Mixing ratio work instruction Set up verification Each set up
7 3 4 84
then specification provided. In -Process inspection

1.Trained operator, Proper

Set up verification Each set up
Improper fitment, 7 1. Wrong hob use hob identification & monitor. 3 4 84
In -Process inspection
Increased
Under size backlash,Rejection at *
customer end. Trained operator, Operation Set up verification Each set up
7 2. Wrong offset 3 4 84
std Provided, In -Process inspection
Span 3.42 -0.017/-0.038
Trained operator, Proper tool
Improper fitment, Tight Set up verification Each set up
7 1. Wrong hob use identification & monitor. 3 4 84
mesh, In -Process inspection
Over size Rework ,Rejection at *
Trained operator, Operation
customer end.
std Provided, Set up verification Each set up
7 2. Wrong offset 3 4 84
In -Process inspection

1. Check the hob details

against the program Set up verification Each set up
7 Wrong input of hob details 2 4 56
2.Ist off Inspection In -Process inspection

More Customer Rejection

1.Check the drawing details
Wrong input of no. of teeth in Set up verification Each set up
7 against the program 2 4 56
Program In -Process inspection
2. Ist off Inspection
No of teeth 8
1.Check the hob details
Set up verification Each set up
7 Wrong input of hob details against the program 2 4 56
In -Process inspection
2. Ist off Inspection
Less Customer Rejection
1. Check the drawing details
Wrong input of no. of teeth in against the program Set up verification Each set up
7 2 4 56
Program 2. Ist off Inspection In -Process inspection

1.Trained operator, Proper

Gear hobbing tool identification & monitor. Set up verification Each set up
Improper fitment, 7 1. Wrong hob use 3 4 84
machine 2. Ist off Inspection In -Process inspection
Increased
Under size backlash,Rejection at
customer end. 1. Trained operator, Proper
tool identification & monitor. Set up verification Each set up
7 2. Wrong offset 3 4 84
Outer diameter (7.89 -0.2) & root 2. Ist off Inspection In -Process inspection
diameter
(4.51-0.2) 1. Trained operator, Proper
Improper fitment, Tight tool identification & monitor. Set up verification Each set up
7 1. Wrong hob use 3 4 84
mesh, In -Process inspection
Over size Rework ,Rejection at
customer end.
1.Trained operator, Operation Set up verification Each set up
7 2. Wrong offset 3 4 84
std Provided, In -Process inspection

1.Wear on butting face of Set up verification Each set up

7 1.Fixture Verification 3 4 84
fixture & component. In -Process inspection

1.Trained operator, Clean the

2.Improper loading and Butting face before loading Set up verification Each set up
7 3 4 84
Butting the part In -Process inspection
2.Operation std Provided
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Action Results
Current Process Controls O Current Process Controls D R
Potential Effect(s) of Clas Potential Cause(s) / Recommended Resp. & Target
Process function/Name Requirements Potential Failure Mode S eV Prevention for cause and for c Detection for cause and failure e P
Failure s Mechanism(s) of Failure Action(s) Completion Date
failure mode c modes/effects t N Action Taken S e v O c c D e t

1.:Operation std and operator

Noise , Rejection at 3.Cutting speed and feed not training Set up verification Each set up
PCD runout ,Lead Error , Profile Error more 7 3 4 84
customer end ok 2.Set cutting speed and feed In -Process inspection
and lock in program

1.Hob life Monitoring

Set up verification Each set up
7 4. Hob Blent 2. Set cutting speed and feed 3 4 84
In -Process inspection
and lock in program

1.Operation std and operator Set up verification Each set up

7 5.Hob & Fixture runout more 3 4 84
training In -Process inspection

1.Trained operator,
1. Wrong Programme
2.Proper heater identification Set up verification Each set up
7 2. Heat time more 2 4 56
& monitor. In -Process inspection
3. Process Validation
Results in crack &
Excess
Failure
1.Operation std and operator
2. Set feed rate, Quench flow training Set up verification Each set up
7 2 4 56
rate & dwell time not ok 2.Feed rate & dwell time and In -Process inspection
lock in program
HARDNESS (40 ~ 45 HRC ) &
INDUCTION HARDENING
Efective case depth Below Root =0.5 -
1. Trained operator,
1.50 MM @ cut off 440 hv1kg 1. Wrong heater use
2.Proper heater identification Set up verification Each set up
7 2. Wrong Setting 2 4 56
& monitor. In -Process inspection
3. Heat time less
3.Process Validation
Premature wear of
Less
teeth
1.Operation std and operator
2. Set feed rate, Quench flow training Set up verification Each set up
7 2 4 56
rate & dwell time not ok 2. Feed rate & dwell time and In -Process inspection
lock in program

Trained operator,
Set up verification Each set up
7 1. Improper loading Operation std Provided 2 4 56
In -Process inspection
Results in crack &
Excess 1.Operation std and operator
Failure
2. Set temerature & training Set up verification Each set up
7 2 4 56
tempering time not ok 2. Temerature & tempering In -Process inspection
time and lock in program
TEMPERING
HARDNESS = 40 ~ 45 Hrc
Trained operator, Set up verification Each set up
7 1. Improper loading 2 4 56
Operation std Provided. In -Process inspection

Premature wear of
Less
teeth 1.Operation std and operator
2. Set temerature & training Set up verification Each set up
7 2 4 56
tempering time not ok 2. Temerature & tempering In -Process inspection
time and lock in program

Tooth Deburring & Improper fitment & 1.Trained operator,

Free from burr & scaling Excess burr projection 7 1. Improper deburr tool use. 2 FM :100 % visual inspection 5 70
Cleaning noise 2.Operation std Provided

1.Trained operator,
1. Wrong Offset Set up verification Each set up
Over Size Improper fitment 7 2.Operation std Provided 2 4 56
2. Instrument Error In -Process inspection
3. Calibration Report
Diameter 8.009-0.009
1.Trained operator,
1. Wrong Offset Set up verification Each set up
Under size Improper fitment 7 2.Operation std Provided 2 4 56
Centerless Grinding 2. Instrument Error In -Process inspection
3. Calibration Report

1.:Operation std and operator

1.Cutting speed and feed not training
Rejection / Customer Set up verification Each set up
OD Surface finish = Ra 0.4 More 7 ok 2. Set cutting speed and feed 2 4 56
Complaint In -Process inspection
2. Dressing not ok 3. Monitor the Dressing
Frequency

Rejection / Customer Improper instrument & 1.Calibrated instrument

Final inspection As per quality plan Out of Specification 7 2 FM:Final inspection report 4 56
Complaint measurment method 2.Trained inspector.

Rejection / Customer 1.Improper selection of oil 1.Trained operator,

Anti rust oiling Free from rust & duct Rust 7 2 FM:100 % visual inspection 5 70
Complaint grade Oil grade std Provided.

Non-availability of
Not parts at customer 1. Wrong Identification, Packing instruction ,
meeting location, distruption in 2.Improper Packing & Inspection by
Packing & Dispatch As per Packing std. & Qty 7 2 FM:Invoice & Final inspection report 5 70
standards, Late delivery & production at customer Improper shipping. packing
Mismatch Qty end & Transit 3. Qty Counting Wrong. Incharge
damage
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Action Results
Current Process Controls O Current Process Controls D R
Potential Effect(s) of Clas Potential Cause(s) / Recommended Resp. & Target
Process function/Name Requirements Potential Failure Mode S eV Prevention for cause and for c Detection for cause and failure e P
Failure s Mechanism(s) of Failure Action(s) Completion Date
failure mode c modes/effects t N Action Taken S e v O c c D e t

Fit/Function Safety/Regulation

HISTORY OF DOCUMENT REVISION

Rev no Rev Date Details Sign Sl no Part No Part Description Drg Rev Customer Date
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DE AND EFFECTS ANALYSIS

Action Results

R. P.
N.
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Action Results

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N.
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Action Results

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N.
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Action Results

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N.