FMEA

FINE CARBIDE TOOLS PTE.LTD.
PART NUMBER: 64x38 DESCRIPTION: SOT23- 6L 64x38 PROCESS: CUSTOMER: STAMPING POSSEHLS
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

REV. / DATE: TEAM: Lee YL (Stamping) NgCN (Stamping) PREPARED BY / DATE:
Page 1 of 2
REV.1 / 23/3/12
Lee YL 23-3-12 TAY K.W. 23-3-12
Risk Priority Number (RPN) = Severity x Occurrence x Detection

S=Severity 1 = Minor 2 to 3 = Low 4 to 6 = Moderate
Function Requirement Potential Failure Mode
Press machine column post overheat
7 to 8 = High 9 to 10 = Extreme
O = Occurrence 1 = <1 in 1.5KK 2 = <1 in 150 K 3 = 1 in 15K
4 = 1 in 2K 5 = 1 in 400 6 = 1 in 80
Potential Effect (s) of Failure
Machine jam
7 = 1 in 20 8 = 1 in 8 9 = 1 in 3
S E V C L A S S
10 = 1 in 2
D=Detection 1 = Certain 2 = Very High 3 = High
APPROVED BY / DATE: 4 = Moderate High 5 = Moderate 6 = Low

Current Process Control O C Control C Detection
Tonnage monitor
7 = Very Low 8 = Remote 9 = Difficult

D E T R P N Recommended Action (s)
10 = Almost Impossible
Potential Cause (s) of Failure

Overloading caused by smashed die
Control Prevention
Responsibility & Target completion Date
Item
Stamping of parts Stamping 7
Action Taken Completion Date
Action Results S O D E C E V C T
R P N
None Check die design
2 Set-up check by Toolmaker
14
None
Overloading due to die weight
35
None
7 Strip jam Punch breakage 7 Slug Pulling Dented parts 7 High burr Scratch housing 7 Slant terminal Inserting difficulty in Assy. C C C
Load off-centre Set-up check constrain to column post
Set-up check by Toolmaker
35
None To prepare feed through Divakar, Christopher. M.H. technique Tay. ECD: 31/12/2002
Operator skill
On job training 4
Tonnage monitor. Misfeed detector. Slug detector. Operator / IPQC check
84
Feed thru' SOP done 31/12/2002 Slug detection sensor installed 20/07/2003
42
Die clearance too much and punch penetration inadequate. Blunt punch or die / Excessive cutting clearance
Bazooka vacuum system
6 Operator / IPQC check 4 Operator / IPQC check 5 Operator / IPQC check 4 Operator / IPQC check 4 Operator / IPQC check
To install slug detection sensors on three plate 210 dies
Divakar, Christopher ECD : 20/07/2003
84
Die preventive maintenance
56
None To install PPT vision checking on line Divakar, Christopher ECD : 18/08/2003
Terminal rubbing guide 1. Preventive rail. 2. Presence of loose maintenance. 2. slug in die Bazooka vacuum system 1. Piercing punch wear. Die preventive 2. Incorrect pitch setting. maintenance 3. Inadequate cutting oil Sensor detection tolerance set too high Toolmaker to refer to SOP
70
Vision installed on line 18/08/2003
35
Pilot pulling
Wavy carrier 6
48
None
Detect presence of slug, Slug detection sensors die breakage and (Micron) stripper bolts loose
Fail to detect slug presence
Defective parts 7 C
84
None
Slug too small 7 Operator reset and run Defective parts machine without verifying the part condition. False stoppages Low productivity 4 Sensor faulty 4 Sensor cable faulty 4 Correcting dimension which is out of specification Cam adjustment Wrong adjustment Unable to get the desired dimension Operator untrained 6 Blower malfunction 7 None Misfeed length is smaller than the length that the None sensor can detect 1 None Die adjustment SOP & OJT 2 None 4 Human error 7 C Sensor gap set wrongly None On job training based on SOP DC-Centre #181
4 Operator / IPQC check 3 Toolmaker / Operator check 3
None
63
None
Toolmaker to refer to SOP
48
None
Toolmaker / Operator check
96
None
48
None
IPQC Verification 4 Pressure sensor 1 Misfeed pilot 2 1 14 None 7 None 3 72 None
Suck slug from die yoke Vacuum system
No vacuum
Slug pulling causing defective parts
Detect material misfeed and missing profile
Misfeed detection sensors
Fail to detect material misfeed Strip jam in die 7
PROC-01-0019 / F02-03
FINE CARBIDE TOOLS PTE.LTD.

PART NUMBER: 64x38 DESCRIPTION: SOT23- 6L 64x38 PROCESS: CUSTOMER: STAMPING POSSEHLS
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

REV. / DATE: TEAM: Lee YL (Stamping) NgCN (Stamping) PREPARED BY / DATE:
Page 2 of 2
REV.1 / 23/3/12
Lee YL 23-3-12 TAY K.W. 23-3-12
Risk Priority Number (RPN) = Severity x Occurrence x Detection

S=Severity 1 = Minor 2 to 3 = Low 4 to 6 = Moderate
Function Requirement Potential Failure Mode
Fail to detect missing profile
7 to 8 = High 9 to 10 = Extreme
O = Occurrence 1 = <1 in 1.5KK 2 = <1 in 150 K 3 = 1 in 15K
4 = 1 in 2K 5 = 1 in 400 6 = 1 in 80
Potential Effect (s) of Failure
Causing problem to subsequent processes (eg. forming, assy) False stoppages
7 = 1 in 20 8 = 1 in 8 9 = 1 in 3
S E V C L A S S
10 = 1 in 2
D=Detection 1 = Certain 2 = Very High 3 = High
APPROVED BY / DATE: 4 = Moderate High 5 = Moderate 6 = Low

Current Process Control O C Control C Detection
Operator / IPQC check 1 Operator check 6 42 None
7 = Very Low 8 = Remote 9 = Difficult

D E T R P N Recommended Action (s)
10 = Almost Impossible
Potential Cause (s) of Failure
Control Prevention
Responsibility & Target completion Date
Item
7
Action Taken Completion Date
Action Results S O D E C E V C T
R P N
Set the wrong parameter Toolmaker to verify with on the misfeed detection the process specification device. Dirt accumulate on sensor head
Fail to count as pre-set
None Calibrate the sensor during die set-up
5 Toolmaker / Operator check
40
None
Sensor amplifier not calibrated (applies to Keyence sensor)
80
None
4 Slot missing No vacuum defective parts/ 4
Sensor aperture size too Toolmaker to verify with big the process specification
Operator 1 Toolmaker / Operator check 5 20 None
Slot " die insert bell To check the tool mouth" cause slug jump condition for any wear and tear before production To monitor and install suction/bazooka
20
None
4
Not spotted by the operator during stamping
20
None
To conduct 100% visual checking on each reel
None
PROC-01-0019 / F02-03

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FINE CARBIDE TOOLS PTE.LTD.

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

Lee YL 23-3-12 TAY K.W. 23-3-12

Risk Priority Number (RPN) = Severity x Occurrence x Detection

O = Occurrence 1 = <1 in 1.5KK 2 = <1 in 150 K 3 = 1 in 15K

D=Detection 1 = Certain 2 = Very High 3 = High

APPROVED BY / DATE: 4 = Moderate High 5 = Moderate 6 = Low

7 = Very Low 8 = Remote 9 = Difficult

Potential Cause (s) of Failure

Responsibility & Target completion Date

Action Taken Completion Date

None Check die design

2 Set-up check by Toolmaker

Overloading due to die weight

Load off-centre Set-up check constrain to column post

Set-up check by Toolmaker

Tonnage monitor. Misfeed detector. Slug detector. Operator / IPQC check

Bazooka vacuum system

To install slug detection sensors on three plate 210 dies

Divakar, Christopher ECD : 20/07/2003

Die preventive maintenance

Vision installed on line 18/08/2003

Fail to detect slug presence

4 Operator / IPQC check 3 Toolmaker / Operator check 3

Toolmaker to refer to SOP

Toolmaker / Operator check

Toolmaker / Operator check

IPQC Verification 4 Pressure sensor 1 Misfeed pilot 2 1 14 None 7 None 3 72 None

Suck slug from die yoke Vacuum system

Slug pulling causing defective parts

Detect material misfeed and missing profile

Misfeed detection sensors

Fail to detect material misfeed Strip jam in die 7

FINE CARBIDE TOOLS PTE.LTD.

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

Lee YL 23-3-12 TAY K.W. 23-3-12

Risk Priority Number (RPN) = Severity x Occurrence x Detection

O = Occurrence 1 = <1 in 1.5KK 2 = <1 in 150 K 3 = 1 in 15K

D=Detection 1 = Certain 2 = Very High 3 = High

APPROVED BY / DATE: 4 = Moderate High 5 = Moderate 6 = Low

7 = Very Low 8 = Remote 9 = Difficult

Potential Cause (s) of Failure

Responsibility & Target completion Date

Action Taken Completion Date

Fail to count as pre-set

None Calibrate the sensor during die set-up

5 Toolmaker / Operator check

Sensor amplifier not calibrated (applies to Keyence sensor)

4 Slot missing No vacuum defective parts/ 4

Operator 1 Toolmaker / Operator check 5 20 None

Toolmaker / Operator check

To conduct 100% visual checking on each reel

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