Vda Fmea
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GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
Process failure Mode and Effects Analysis ( Process FMEA)
PLANNING & PREPARATION ( STEP 1) Company NamePlant LocationCustomer Name- ASHOK LEYLAND Model Year/ Platform- 2013 Part Name :- Rocker Arm ( Int & E xh ) CONTINOUS IMPROVEMENT
History / change Authorization ( As applicable )
SubjectPFMEA Start Date- 01.01.21 PFMEA Revision Date- 25.01.21 Cross- Functional Team- ONT/MKG/RSM/SA/KM/US/AR/PK/SM/KS/BDM
STRUCTURE ANALYSIS (STEP2)
1. Proc Proces ess s IIte tem m
Rocker Arm Sub assembly
2. Proc Proces ess s Ste Step p
10 / Incoming Inspection of Raw Material
3.Process Work Element
FUNCTION ANALYSIS (STEP 3)
1. Function of the process Item
PFMEA ID No- PFMEA/2001-2002/01 Process Responsibility- Line Incharge Confidentiality level- 04
FAILURE ANALYSIS (STEP 4)
2. Function of the 1. Failure Effects 3.Function of the process step & (FE) to the next process work element & product heigher level process charecteristics charecteristics element
E F f o ) S ( y t i r e v e S
2. Failure Mode (FM) of the Process Step
3. Failure Cause (FC) of the Work Element
Sub Supplier
Suppleir should be approved as per DS-PUR001
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Supplier Not Approved
Chemical composition
As per material standard.
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Not meeting the specification
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Not meeting the specification
Dimensional Parameters
Metallurgy
Standard packaging
To provide acceptable i.e. Conformity to the specs i.e. To transfer motion Dimensinal, from input to output Metallurgical, Physical and visual appereance material for further operation
As per standard
As per standard
As per standard to prevent any dust, damage or
Material can be produce rejection or not meeting the specifications e.g :Dimensionaly,Hardn ess & Microstructure
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Wrong material passed on the shop floor for further processing.
Not meeting the specification
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Not meeting the specification
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Not meeting the specification
colateral damage.
Visual apperance
Free from dust, dirt, rust, pitting, black spots, dents and any other
GHAZIABAD PRECISION PRODUCTS PVT LTD
RISK ANALYSIS (STEP 5)
Current Prevention Control (PC) of FC
f o ) O ( e c n C e F r r u c c O
n C o F i t f c o e ) M t e C F D D t ( l r n o o e r t r r n u o C C
f o )
D ( M n F o / i t C c F e t e D
FR-ENG-009
OPTIMIZATION (STEP 6) P A A E M F P
s c i l t s r i a i e c e t p c S e r a h C
e l d a o o n C i r t e p t o l i ( F
n o i t c A e v i t n e v e r P
n o i t c A n o i t c e t e D
e e m l b i a s n N s o ' p n o s s e r R e P
p e m t o a d C t e g r a T
s u t a t S
e h c t i n w e d i n e v e k a o t t n r e o i t t n c i A o p
n o i t e l
n o i t e l p m o C
E F f o ) S ( y t i r e v e S
) O ( e c n e r r u c c O
e t a D
) D ( n o i t c e t e D
s c i l t s i a i r c e e t p c e S r a h c
A A E M F P
e ) d l o n a C o r i e t t l p o i ( F
s k r a m e R
P
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Material can not be procured as purchase order will not be generated without Vendor code
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Chemical composition verified for every heat.
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Incoming Inspection, IIIrd party verification, procurement from approved mills.
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Receipt inspection
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Non-approved supplier can't supply as there is no vendor code provided to them
Inspection with Variable & attribute gauges (As per inspection format)
Metallurgical Inspection of every lot
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Packaging standard defined and mentioned on Purchase Order
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Receipt inspection
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Inspection with variable instruments (As per inspection format)
verify the packaging standard material
Checked visually
GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
Process failure Mode and Effects Analysis ( Process FMEA)
PLANNING & PREPARATION ( STEP 1) Company NamePlant LocationCustomer Name- ASHOK LEYLAND Model Year/ Platform- 2013 Part Name :- Rocker Arm ( Int & Exh ) CONTINOUS IMPROVEMENT
History / change Authorization ( As applicable )
SubjectPFMEA Start Date- 01.01.21 PFMEA Revision Date- 25.01.21 Cross- Functional Team- ONT/MKG/RSM/SA/KM/US/AR/PK/SM/KS/BDM
STRUCTURE ANALYSIS (STEP2)
1. Pr Proc oces ess s Ite Item m
2. Pr Proc oces ess sS Ste tep p
3. 3.Pr Proc oces ess s Work Work E Ele leme ment nt
(Cope & Drag) Dimensional Parameters
Rocker Arm Sub assembly
20 / Pattern & Tooling Inspection
Standard packaging
Visual apperance
FUNCTION ANALYSIS (STEP 3)
1. Function of the process Item
2. Function of the process step & product charecteristics
3.Function of the process work element & process charecteristics
PFMEA ID No- PFMEA/2001-2002/01 PFMEA/2001-2002/01 Process Responsibility- Line Incharge Confidentiality level- 04
FAILURE ANALYSIS (STEP 4)
1. Failure Effects (FE) to the next heigher level element
As per standard
To provide acceptable i.e. Conformity to the As per standard to prevent specs i.e. To transfer motion any dust, damage or colateral Dimensinal, from input to output damage. Physical and visual appereance material for further operation Free from dust, dirt, rust, pitting, black spots, dents and any other
E F f o ) S ( y t i r e v e S
2. Failure Mode 3. Failure Cause (FC) (FM) of the Process Step
Not meeting the specification
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Material can be produce rejection or not meeting the specifications e.g :Dimensionaly,Hardn ess & Microstructure
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of the Work Element
Wrong material passed on the shop floor for further processing.
Not meeting the specification
Not meeting the specification
GHAZIABAD PRECISION PRODUCTS PVT LTD
RISK ANALYSIS (STEP 5) f o ) O (
Current Prevention Control (PC) of FC
c e n C e F r r u c c O
n C o F i t f c o e ) t e C D M F D t ( l r n o o r e r t r n u o C C
FR-ENG-009
OPTIMIZATION (STEP 6)
f o ) D ( M n F o / i t C c F e t e D
P A A E M F P
s c i l t s a i i c t e r e c p e S r a h C
e l d a C o i o n r t e p t o l i ( F
n o i t c A e v i t n e v e r P
n o i t c A n o i t c e t e D
e e m l b i a n s N s o ' p n s o s e r R e P
n o i t e l p t e m o a d C t e g r a T
s u t a t S
e h c t i n w e d i n e k e v a o t t n r e o i t t n c i A o p
e t a D n o i t e l p m o C
E F f o ) S ( y t i r e v e S
) O ( e
) D (
n c e r r u c c O
o n i t c e t e D
s c i l t s a i r i c t e e c p e S r a h c
P A A E M F P
e ) d l a C o n o i r t e p t l o i ( F
s k a r m e R
Receipt inspection
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Inspection with Variable & attribute gauges (As per inspection format)
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Packaging standard defined and mentioned on Purchase Order
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verify the packaging standard material
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Receipt inspection
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Checked visually
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GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
Process failure Mode and Effects Analysis ( Process FMEA)
PLANNING & PREPARATION ( STEP 1) Company NamePlant LocationCustomer Name- ASHOK LEYLAND Model Year/ Platform- 2013 Part Name :- Rocker Arm ( Int & Exh ) CONTINOUS IMPROVEMENT
SubjectPFMEA Start Date- 01.01.21 PFMEA Revision Date- 25.01.21 Cross- Functional Team- ONT/MKG/RSM/SA/KM/US/AR/PK/SM/KS/BDM
STRUCTURE ANALYSIS (STEP2)
PFMEA ID No- PFMEA/2001-2002/01 Process Responsibility- Line Incharge Confidentiality level- 04
FUNCTION ANALYSIS (STEP 3)
FAILURE ANALYSIS (STEP 4) E F f
History / change Authorization ( As applicable )
1. Pr Proc oces ess s Item Item
2. Pr Proc oces ess s Step Step 3.Pr 3.Proc oces ess s Work Work El Elem emen entt
1. Function of the process Item
2. Function of the process step & product charecteristics
3.Function of the process work element & process charecteristics
1. Failure Effects (FE) to the next heigher level element
) o S ( y t i r e v e S
2. Failure Mode (FM) of 3. Failure Cause (FC) of the Process Step the Work Element
Depression at core due to Cavity cleaning not done on depletion of carbon at regular basis resulting corebox carbon depletion
Extra metal at casting surface
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Dent at casting surface
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Tool mark on corebox pattern
Cleaning done through steel rod,brush etc
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Temperature variation showing in M/C
M/C heating controller failure
Knowledge of M/C Operation & process parameters
Skilled operator
To produce core as per specification
Core Shooter M/C
Extra metal & Sand inclusion at component
Rocker Arm Sub assembly
30 / Core Making
Air Pressure
M/C Parameters
Core Box(Cope & Drag)
Silicon Spray
To transfer motion from input to output
Shooting of sand in cavity through pressure to obtain cores
To proviide a constant presure to M/C for s hooting
Sand inclusion at casting surface
Blow holes at casting To obtain hardness within spec & good surface finish of cores Extra metal & Sand inclusion at component
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Low air shooting pressure in Air pressure not maintained M/C resulting low strength constantly cores
Low heating temperature Heating Temperature not fixed at M/C
7 High heating temperature
Lower thickness of To obtain profile & thickness casting at hollow of cores within spec surface
8
Higher thickness of core
pattern cavity worn out
Applying at pattern surface Sand inclusion at for Proper ejection of cores casting surface from M/C
7
Sand erosion from core surface during ejection
Not properly applying spray on periodicaly basis
GHAZIABAD PRECISION PRODUCTS PVT LTD
RISK ANALYSIS (STEP 5)
Current Prevention Control (PC) of FC
f o ) O ( e c C n F e r r u c c O
n C o F i t f c o t e ) C M e F D D t ( l r n o o e r r t r n u o C C
f o ) D ( M n F o / i C t c F e t e D
FR-ENG-009
OPTIMIZATION (STEP 6) P A A E M F P
s c i t s l a i r i e c t e c p e S r a h C
e l n d o a o C i r t e p t o l i ( F
n o i t c A e v i t n e v e r P
n o i t c A n o i t c e t e D
e e m l b a i s N n ' s o n p s o e s r R e P
n o i t e l
p e m t o a C d t e g r a T
s u t a t S
e h c t i n w e d v n e i k e a o t t n r e o t i t n c i A o p
e t a D n o i t e l p m o C
E F f o ) S ( y t i r e v e S
) O ( c e n e r r u c c O
) D ( n o i t c e t e D
s c i t s l a i i r c t e e p c e S r a h c
P A A E M F P
e ) l d o n a C o r i e t p t l o i ( F
s k r a m e R
Displayed Work instruction machine for reference WI-PRD-034
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Monitoring in every 4 hrs & record in core making record DOC NO- FR-PRD-036
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Displayed work instruction in machine for cleaning of corebox pattern through copper rod only
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Verification of pattern condition after returning & record maintain through pattern history card in ERP
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Preventive maintenance done as per yearly plan & autonomous maintenance on daily basis
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Preventive maintenance Plan Vs actual( FR-MNT-010) & Autonomus maintenace checksheet (FR-MNT-004)
FRL installed in line to provide constant pressure to M/C
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Monitoring in every 4 hrs & record in Set-up Approval Report ( Doc No :- FR-PRD-036)
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Heating Temp fixed according to process validation & control through PLC
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Monitoring in every 4 hrs & record in Set-up Approval Report ( Doc No :- FR-PRD-036)
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Shelf Life of pattern is fixed to 250000 shots & Pattern verification is done on every 50000 shots
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Applying of silicon spray in pattern after every 4 shots to eject core smoothly
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Monitoring through Pattern History Card in ERP
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(Doc No: FR-TLG-003)
Monitoring in every 4 hrs & record in Set-up Approval Report ( Doc No :- FR-PRD-036)
GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
Process failure Mode and Effects Analysis ( Process FMEA)
PLANNING & PREPARATION ( STEP 1) Company NamePlant LocationCustomer Name- ASHOK LEYLAND Model Year/ Platform- 2013 Part Name :- Rocker Arm ( Int & Exh ) CONTINOUS IMPROVEMENT
History / change Authorization ( As applicable )
SubjectPFMEA Start Date- 01.01.21 PFMEA Revision Date- 25.01.21 Cross- Functional Team- ONT/MKG/RSM/SA/KM/US/AR/PK/SM/KS/BDM
STRUCTURE ANALYSIS (STEP2)
1. Pr Proc oces ess s IIte tem m
2. Pr Proc oces ess s Ste Step p
3. 3.Pr Proc oces ess sW Wor ork kE Ele leme ment nt
PFMEA ID No- PFMEA/2001-2002/01 PFMEA/2001-2002/01 Process Responsibility- Line Incharge Confidentiality level- 04
FUNCTION ANALYSIS (STEP 3)
1. Function of the process Item
2. Function of the process step & product charecteristics
3.Function of the process work element & process charecteristics
FAILURE ANALYSIS (STEP 4)
1. Failure Effects (FE) to the next higher level element
E F f o ) S ( y t i r e v e S
Mold Making M/C
To produce Cope & Drag mold as per specified parameters
Pattern Plate Temp
To achieve a desired temp for pattern in which resin coated sand will start bonding & make a solid mold
Depression at casting surface
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Cavity cleaning not done on regular basis resulting carbon depletion
Cavity cleaning not done on regular basis resulting carbon depletion
Dent at casting surface
8
Tool mark on pattern surface
Cleaning done through steel rod,brush etc
Extra metal & Sand inclusion at casting
7
Temperature variation showing in M/C
M/C heating controller failure
Extra metal & Sand inclusion at casting
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High pattern plate temperature Temp thermocouple failure
Blow holes at
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casting
40 / Mold Making
Investment time
3. Failure Cause (FC) of the Work Element
Knowledge of M/C Operation & process parameters
Skilled operator
Rocker Arm Sub assembly
2. Failure Mode (FM) of the Process Step
Shooting of sand To transfer motion in cavity through from input to gravity to obtain output cope & drag molds
Low pattern plate temperature
Crack defect at casting
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Low investment time
Blow holes at casting
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High investment time
Improper setting of investment i nvestment time in PLC
To achieve a desired thickness of mold wrt time
Curing time
To cure the mold perfectly & release the excess resin from mold
Blow holes at casting
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Low curing time
Improper setting of curing time in PLC
Air Pressure
To proviide a constant presure to M/C for shooting
Sand inclusion at casting surface
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Low air shooting pressure in M/C resulting low strength cores
Air pressure not maintained maintained constantly
M/C Parameters
Cope & Drag Pattern
Silicon Spray
Blow holes at To obtain hardness within casting spec & good surface finish of Extra metal & Sand cores inclusion at component
7
Lower thickness of To obtain profile & thickness casting at hollow of mold within spec surface
8
Higher thickness of mold
pattern cavity worn out
Applying at pattern surface Sand inclusion at for Proper ejection of cores casting surface from M/C
7
Sand erosion from core surface during ejection
Not properly applying spray on periodicaly basis
Low heating temperature Heating Temperature not fixed at M/C High heating temperature
GHAZIABAD PRECISION PRODUCTS PVT LTD
RISK ANALYSIS (STEP 5) C F f o )
Current Prevention Control (PC) of FC
O ( e c n e r r u c c O
r o n o C i F t c f t e o e ) C M D t D ( F n l e o r r r t u n C o C
FR-ENG-009
OPTIMIZATION (STEP 6) f o )
D M ( n F o / i t C c F e t e D
P A A E M F P
s c i t
l s r i a i e c t e c p e S r a h C
l a n o i t p o ( e d o C r e t l i F
n o i t c A e v i t n e v e r P
n o i t c A n o i t c e t e D
e e m l b a i s N n ' s o n p o s s e r R e P
n o i t e l p e m t o a d C t e g r a T
s u t a t S
e h c t i n w e d i n e v k e a o t t n r e o t i t n c i A o p
e t a D n o i t e l p m o C
E F f o ) S ( y t i r e v e S
) O ( c e n e r r u c c O
) D ( n o i t c e t e D
s c i l t i a i s r c t e e c p e S r a h c
P
) l a n o i t
A A E M F P
o p ( e d o C r e t l i F
s k r a m e R
Displayed Work instruction machine for reference WIPRD-005
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Monitoring in every 4 hrs & record in Mold making record DOC NO- FR-PRD-0036
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Displayed work instruction in machine for cleaning of pattern through copper rod only
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Verification of pattern condition after returning & record maintain through pattern history card in ERP
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Preventive maintenance done as per yearly plan & autonomous maintenance on daily basis
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Preventive maintenance Plan Vs actual( FR-MNT-010) & Autonomus maintenace checksheet (FR-MNT-004)
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1.PLC controlled programming & Visual inspection of every mold according to color chart displayed in line 2.Setup approval before
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continous production
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Monitoring of pattern plate temp once in 4hrs through IR pyrometer
4 Monitoring of investment time in every 4 hrs through PLC & record in setup approval sheet
Process validation done & fixed the spec & monitor through PLC 4
Process validation done & fixed the spec & monitor through PLC
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FRL installed in line to provide constant pressure to M/C
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Monitoring of curing time in every 4 hrs through PLC & record in setup approval sheet Monitoring in every 4 hrs & record in Set-up Approval Report ( Doc No :FR-PRD-036)
Heating Temp fixed according to process validation & control through PLC
4
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Shelf Life of pattern is fixed to 250000 shots 7 pattern verification is done on every 50000 shots
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Displayed work instruction in machine for application of silicon spray in pattern
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Monitoring in every 4 hrs & record in Set-up Approval Report ( Doc No :FR-PRD-036)
Monitoring through Pattern History Card in ERP (Doc No: FR-TLG-003)
Monitoring in every 4 hrs & record in Set-up Approval Report ( Doc No :FR-PRD-036)
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GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
Process failure Mode and Effects Analysis ( Process FMEA)
PLANNING & PREPARATION ( STEP 1) Company NamePlant LocationCustomer Name- ASHOK LEYLAND Model Year/ Platform- 2013 Part Name :- Rocker Arm ( Int & Exh ) CONTINOUS IMPROVEMENT
History / change Authorization ( As applicable )
SubjectPFMEA Start Date- 01.01.21 PFMEA Revision Date- 25.01.21 Cross- Functional Team- ONT/MKG/RSM/SA/KM/US/AR/PK/SM/KS/BDM
STRUCTURE ANALYSIS (STEP2)
1. Pr Proc oces ess s IIte tem m
2. Proc Proces ess sS Ste tep p
3.Pr 3.Proc oces ess sW Wor ork kE Ele leme ment nt
FUNCTION ANALYSIS (STEP 3)
1. Function of the process Item
2. Function of the process step & product charecteristics
3.Function of the process work element & process charecteristics
PFMEA ID No- PFMEA/2001-2002/01 Process Responsibility- Line Incharge Confidentiality level- 04
FAILURE ANALYSIS (STEP 4)
1. Failure Effects (FE) to the next heigher level element
E F f o ) S ( y t i r e v e S
High Hardness at casting
8
Wrong charging of raw material in furnace low hardness at casting
inclusion,blow w To melt the metal in required Slag inclusion,blo specification holes in casting
Induction Furnace
High & low hardness
assembly
To achieve the chemistry of part as from input to output per specification To transfer motion
60 / Melting Spectrometer
M/C Parameters
High Si % at bath
Knowledge of M/C Operation & process parameters
Skilled operator
Rocker Arm Sub
2. Failure Mode (FM) of 3. Failure Cause (FC) of the Process Step the Work Element
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High C% at bath
Hydrogen, nitrogen pickup Lining nature of furnace not in furnace during melting fixed
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To give the chemical result
Chemical composition
Internal calibration for
within specific range
showing out of specification
spectrometer not done
Mic icrr o ost strr u uct ctu ur a all defect fect
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High/low Hardness at casting
8
High Si & C% at bath
C% & Si% parameters not fixed
To provide C & Si% in order High/low Hardness to match with spectrometer at casting
6
High Si & C% at CE meter
Failure of machine showing wrong result
To achieve the chemical composition as per specification in order to achieve hardness & tensile strength of component
CE meter
GHAZIABAD PRECISION PRODUCTS PVT LTD
Process Parameters
To achieve the desired High/low Hardness microstructure & hardness of at casting component
FR-ENG-009
8
High tapping temp
Tapping temp not measured by operator while tapping
GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
RISK ANALYSIS (STEP 5)
Current Prevention Control (PC) of FC
C F f o ) O ( e c n e r r u c c O
r n o o C i t F c f t e o e ) C M D F t D n ( l e o r r r t u n C o C
5
5
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Monitoring of every lining through furnace lining life record DOC No- FR-PRD-016
3
3
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chemistry pouring & willlab notapproval done
Alternate verification of chemistry through spectrometer for assurance & Preventive maintenance done as per yearly plan
P A A E M F P
n o i t c A e v i t n e v e r P
n o i t
e e m l
A c n o i t c e t e D
a i b s N n ' s o n p o s s e r R e P
s u t a t S
e h t c i n w e d v n i e k e a o t t n r o e i t t n c i A o p
e t a D n o i t e l p m o C
E F f
) O (
) o S ( y t i r e v e S
e c n e r r u c c O
) D ( n o i t c e t e D
s c i t l a i s i r c t e e c p S e r a h c
P A A E M F P
) l a n o i t p o ( e d o C r e t l i F
k s r a m e R
6
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Monitoring on daily basis through internal CRM before start of production & record on softcopy
Daily calibration of spectrometer done as per internal CRM & weekly calibration through CRM
Displayed SOP at M/C for reference & without final bath
( D M n F o / i t C c F e t e D
s c i t l a i s i r e c t e c p e S r a h C
n o i t e l p e m t o a C d t e g r a T
Effectiveness of operator checked on every 3 months & Skill matrix for melting operation FR-HR-002
On job training providing to operator regarding machine operations & effectiveness is measured in every 3 months
Acidic nature of lining is fixed in furnace for increasing lining life & forming oxidation layer to form oxides which can remove it in the form of slag
f o )
OPTIMIZATION (STEP 6) l a n o i t p o ( e d o C r e t l i F
Monitoring on every heat basis through online display of spectrometer
4
Monitoring of every heat through spectrometer & record on softcopy & Preventive maintenance Plan Vs actual( FR-MNT-010)
GHAZIABAD PRECISION PRODUCTS PVT LTD
Displayed SOP at M/C for reference & alternate verification of pouring temp doneavoid at pouring stage to rejection
5
Monitoring on every heat basis through immersion pyrometer & record in melting recordNO- FR-PRD-005 DOC
6
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FR-ENG-009
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GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
Process failure Mode and Effects Analysis ( Process FMEA)
PLANNING & PREPARATION ( STEP 1) Company NamePlant LocationCustomer Name- ASHOK LEYLAND Model Year/ Platform- 2013 Part Name :- Rocker Arm ( Int & Exh ) CONTINOUS IMPROVEMENT
SubjectPFMEA Start Date- 01.01.21 PFMEA Revision Date- 25.01.21 Cross- Functional Team- ONT/MKG/RSM/SA/KM/US/AR/PK/SM/KS/BDM
STRUCTURE ANALYSIS (STEP2)
PFMEA ID No- PFMEA/2001-2002/01 Process Responsibility- Line Incharge Confidentiality level- 04
FUNCTION ANALYSIS (STEP 3)
FAILURE ANALYSIS (STEP 4) E F f
History / change Authorization ( As applicable )
1. Proc Proces ess s Ite Item m
2. Pr Proc oces ess sS Ste tep p
3. 3.Pr Proc oces ess sW Wor ork k Ele Eleme ment nt
1. Function of the process Item
2. Function of the process step & product charecteristics
70 / tapping
1. Failure Effects (FE) to the next heigher level element
) o S ( y t i r e v e S
2. Failure Mode (FM) of the Process Step
3. Failure Cause (FC) of the Work Element
8
Low & high amount of inoculation while tapiing
Inoculation amount of qty nt fixed
8
Low & high metal tapped in laddle
Reference for tapping at laddle not fixed
Knowledge of M/C Operation Low & High & process parameters Hardness at casting
Skilled operator
Rocker Arm Sub assembly
3.Function of the process work element & process charecteristics
To achieve the desired microstructure &
To tap the metal in laddle in specific angle
Low & High Hardness at casting
7
Homogeneity / mixing of inoculation not done properly
Ram sliding not working
Laddle
To maintain the molten metal temp within tolerated time range
Cold at castings
8
Temp drop of molten metal
Tap to pouring stage time not fixed
Process Parameters
To achieve the desired microstructure & hardness of component
8
High tapping temp
Induction Furnace
To transfer motion from input to output
hardness of component
High/low Hardness at casting
Tapping temp not measured by operator while tapping
GHAZIABAD PRECISION PRODUCTS PVT LTD
RISK ANALYSIS (STEP 5)
Current Prevention Control (PC) of FC
On job training providing to operator regarding machine operations & effectiveness is
C F f o ) O ( e c n e r r u c c O
Preventive maintenance done as per yearly plan &
D ( M n / F o i t C c F e t e D
P A A E M F P
s c i t s l a i r i e c t e c p e S r a h C
n o i t c A e v i t n e v e r P
n o i t
e e m l
A c n o i t c e t e D
b i a s N n ' s o n p o s s e r R e P
s u t a t S
e h c t i n w e d v n i e k e a o t t n r e o t i t n c i A o p
e t a D n o i t e l p m o C
E F f o ) S ( y t i r e v e S
) O ( e c n e r r u c c O
) D ( n o i t c e t e D
s c i t l a i s i r c t e e c p S e r a h c
P A A E M F P
) l a n o i t o p ( e d o C r e t l i F
k s r a
m e R
6
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5
Monitoring on once per shift basis & record in laddle lining register DOC NO - FR-PRD018
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5
Preventive maintenance Plan Vs actual ( FR-MNT-010) & Autonomus maintenace checksheet (FR-MNT-004)
6
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5
Monitoring of every heat through pouring time display meter & record in pouring sheet DOC NO- FR-PRD-006
6
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Monitoring on every heat
Displayed SOP at M/C for reference & alternate verification of pouring temp done at pouring stage to avoid rejection
f o )
n o i t e l p e m t o a d C t e g r a T
Effectiveness of operator checked on every 3 months & Skill matrix for melting operation FR-HR-002
autonomous maintenance on daily basis
Displayed SOP as per process validation & fixed pouring time range to avoid cold defect
OPTIMIZATION (STEP 6) l a n o i t p o ( e d o C r e t l i F
5
measured in every 3 months Marking on laddle done for reference while tapping of metal
r n o o C i t F c f o t e e ) C M D t D ( F n l e o r r r t u n C o C
FR-ENG-009
5
basis through immersion pyrometer & record in melting record DOC NO- FR-PRD-005
GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
Process failure Mode and Effects Analysis ( Process FMEA)
PLANNING & PREPARATION ( STEP 1) Company NamePlant LocationCustomer Name- ASHOK LEYLAND Model Year/ Platform- 2013 Part Name :- Rocker Arm ( Int & Exh ) CONTINOUS IMPROVEMENT
SubjectPFMEA Start Date- 01.01.21 PFMEA Revision Date- 25.01.21 Cross- Functional Team- ONT/MKG/RSM/SA/KM/US/AR/PK/SM/KS/BDM
STRUCTURE ANALYSIS (STEP2)
FUNCTION ANALYSIS (STEP 3)
PFMEA ID No- PFMEA/2001-2002/01 Process Responsibility- Line Incharge Confidentiality level- 04
FAILURE ANALYSIS (STEP 4) E F f
History / change Authorization ( As applicable )
1. Proc Proces ess s IIte tem m
2. Pr Proc oces ess sS Ste tep p
3.Pr 3.Proc oces ess s Wor Work k Ele Eleme ment nt
1. Function of the process Item
2. Function of the process step & product charecteristics
assembly
To transfer motion 80 / Pouring
Mono Rail
Laddle
Process Parameters
) o S ( y t i r e v e S
Cold at castings
8
2. Failure Mode (FM) of the Process Step
from input to output
3. Failure Cause (FC) of the Work Element
Slow pouring
Knowledge of Pouring method & time
Skilled operator
Rocker Arm Sub
3.Function of the process work element & process charecteristics
1. Failure Effects (FE) to the next heigher level element
Less knowledge about pouring to operator
Flash at castings
8
Fast pouring
To run the rail system in a specific time in order to achieve constant speed
Cold at castings
7
Slow pouring
Pneumatic cylinder failure
To maintain the molten metal temp within tolerated time range
Cold at castings
8
Temp drop of molten metal
Tap to pouring stage time not fixed
8
More pouring time
Effect of inoculation start fading at the end of pouring
To achieve the desired microstructure hardness of & component
To achieve the desired microstructure & hardness of Microstructural defect component
GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
RISK ANALYSIS (STEP 5)
Current Prevention Control (PC) of FC
C F f o ) ( O e c n e r r u c c O
r n o o C i t F c f o t e ) e C M D F t D n ( l e o r r r t u n C o C
5
f o ) D ( M n F o / i C t c F e t e D
OPTIMIZATION (STEP 6) P A A E M F P
s c i t l a i s r i e c t e c p e S r a h C
l a n o i t p o ( e d o C r e t l i F
n o i t c A e v i t n e v e r P
n o i t c A n o i t c e t e D
e e m l a i b s N n ' s o n p o s s e r R e P
n o i t e l
p e m t o a d C t e g r a T
s u t a t S
e h c t n i w e d n v e i k e a o t t n r o e i t t n c i A o p
e t a D n o i t e l p m o C
E F f o ) S ( y t i r e v e S
) O ( e c n e r r u c c O
) D ( n o i t c e t e D
s c i t l a i s i r c t e e p c S e r a h c
P A A E M F P
) l a n o i t p o ( e d o C r e t l i F
k s r a m e R
6
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Effectiveness of operator checked on every 3 months & Skill matrix for melting operation FR-HR-002
Displayed SOP for pouring time / mold for specific part & On job training providing to operator regarding machine operations & effectiveness is measured in every 3 months 5
Preventive maintenance done as per yearly plan & autonomous maintenance on daily basis
5
Preventive maintenance Plan Vs actual ( FR-MNT-010) & Autonomus maintenace maintenace checksheet (FR-MNT-004)
6
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Displayed SOP as per process validation & fixed pouring time range to avoid cold defect
3
Monitoring of every heat through pouring time display meter & record in pouring sheet DOC NO- FR-PRD-006
6
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Pouring time fixed for every part through process validation & fixed in pouring timer
4
Monitoring on every heat basis through pouring timer & record in pouring record DOC NO- FR-PRD-006
6
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GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
Process failure Mode and Effects Analysis ( Process FMEA)
PLANNING & PREPARATION ( STEP 1) Company NamePlant LocationCustomer Name- ASHOK LEYLAND Model Year/ Platform- 2013 Part Name :- Rocker Arm ( Int & Exh ) CONTINOUS IMPROVEMENT
SubjectPFMEA Start Date- 01.01.21 PFMEA Revision Date- 25.01.21 Cross- Functional Team- ONT/MKG/RSM/SA/KM/US/AR/PK/SM/KS/BDM
STRUCTURE ANALYSIS (STEP2)
FUNCTION ANALYSIS (STEP 3)
PFMEA ID No- PFMEA/2001-2002/01 PFMEA/2001-2002/01 Process Responsibility- Line Incharge Confidentiality level- 04
FAILURE ANALYSIS (STEP 4) E F f
History / change Authorization ( As applicable )
1. Proc Proces ess s Ite Item m
2. Proc Proces ess sS Ste tep p
3.Pr 3.Proc oces ess s Wor Work k Ele Eleme ment nt
1. Function of the process Item
2. Function of the process step & product charecteristics
3.Function of the process work element & process charecteristics
1. Failure Effects (FE) to the next heigher level element
) o S ( y t i r e v e S
High/Low hardness
8
Less knowledge about knockout to operator
Microstructural defect
90 / Knockout
Knockout Timer
Process Parameters
To transfer motion from input to output
3. Failure Cause (FC) of the Work Element
Fast/Late knockout
Knowledge of knockout method & time
Skilled operator
Rocker Arm Sub assembly
2. Failure Mode (FM) of the Process Step
8
Fast/Late knockout
8
Timer not showing correct time
Timer failure
More Hardness
8
Less Knockout time
Variation in knoukout time as it is not fixed
Low Hardness
8
More knockout time
Increase in knockout time shows decrease in hardness of component
To achieve the desired microstructure & hardness of component
To achieve a desired time for High/Low hardness knockout of component
To achieve the desired microstructure & hardness of component
GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
RISK ANALYSIS (STEP 5)
Current Prevention Control (PC) of FC
C F f o ) O ( e c n e r r u c c O
r n o o C i t F c f o t e ) e C M D F D t ( n l e o r r r t u n C o C
5 Displayed SOP forpart knockout time for specific & On job training providing to operator regarding machine operations & effectiveness is measured in every 3 months
f o ) D ( M n F o / i C t c F e t e D
OPTIMIZATION (STEP 6) P A A E M F P
s c i t l a i r s i e c t e c p r S e a h C
l a n o i t p o ( e d o C r e t l i F
n o i t c A e v i t n e v e r P
n o i t c A n o i t c e t e D
e e m l b a i s N n ' s o n p o s s e r R e P
p e m t o a d C t e g r a T
s u t a t S
e h c t i n w e d n e i v k e a o t t n r e o t i t n c i A o p
n o i t e l
e t a D n o i t e l p m o C
E F f o ) S ( y t i r e v e S
) O ( e c n e r r u c c O
) D ( n o i t c e t e D
s c i t s l a i i r c t e e c p S e r a h c
P A A E M F P
) l a n o i t p o ( e d o C r e t l i F
s k r a m e R
6
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P
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Effectiveness of operator checked on every 3 months & Skill matrix for melting operation FR-HR-002 5
Monitoring on every heat Alternate verification of timing through stop watch on per heat basis & Calibration done as per yearly plan
5
basis & record basison pouring DOC NO- FR-PRD-006 Calibration Plan Vs actual ( FR-CAL-002)
5 Knockout time fixed for every
Monitoring on every heat
part through process validation & fixed in knockout timer
basis through knockout timer & record in pouring record DOC NO- FR-PRD-006 4
GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
Process failure Mode and Effects Analysis ( Process FMEA)
PLANNING & PREPARATION ( STEP 1) Company NamePlant LocationCustomer Name- ASHOK LEYLAND Model Year/ Platform- 2013 Part Name :- Rocker Arm ( Int & Exh ) CONTINOUS IMPROVEMENT
History / change Authorization ( As applicable )
SubjectPFMEA Start Date- 01.01.21 PFMEA Revision Date- 25.01.21 Cross- Functional Team- ONT/MKG/RSM/SA/KM/US/AR/PK/SM/KS/BDM
STRUCTURE ANALYSIS (STEP2)
1. Proc Proces ess s Ite Item m
2. Proc Proces ess s Ste Step p
3.Pr 3.Proc oces ess sW Wor ork kE Ele leme ment nt
FUNCTION ANALYSIS (STEP 3)
1. Function of the process Item
2. Function of the process step & product charecteristics
3.Function of the process work element & process charecteristics
PFMEA ID No- PFMEA/2001-2002/01 Process Responsibility- Line Incharge Confidentiality level- 04
FAILURE ANALYSIS (STEP 4)
1. Failure Effects (FE) to the next heigher level element
E F f ) o S ( y t i r e v e S
2. Failure Mode (FM) of the Process Step
9
More less ferrite/Pearlite judge the defect visualy in moreorcarbide at component& Not microstructure analysis
Knowledge of M/C operations Fit & function failure & checking Microstructure & at customer end hardness of component
Skilled operator
9
Rocker Arm Sub assembly
100 / Inspection( Metall urgical)
Fitment issue in engine assembly at customer end
More or less hardness at component
Not correctly measure the reading of hardness
Chemistry showing wrong result
Improper flow rate of argon gas
Chemical composition showing out of specification
Internal calibration for spectrometer not done
To check the microstructure & hardness of component 9
High & low hardness
Spectrometer
3. Failure Cause (FC) of the Work Element
8
To give the chemical result within specific range Microstruct ur ural de defect
8
GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
RISK ANALYSIS (STEP 5)
Current Prevention Control (PC) of FC
C F f o
r n o o C i t F
) O ( e c n e r r u c c O
o e c f t e ) C M D D F t ( n l e o r r r t u n C o C
Trained metallurgist are only responsible for miscrostructural inspection & their effectiveness is carried through MSA in every 3 months Also Grain morphology morphology charts are displayed in lab for reference
On job training providing to operator regarding machine operations & effectiveness is measured in every 3 months through MSA
4
4
Flow rate of argon gas fixed & displayed WI in M/C for reference
4
Effectiveness of operator checked on every 3 months & Skill matrix for Lab FR-HR-002
Effectiveness of operator checked on every 3 months & Skill matrix for Lab FR-HR-002
Monitoring on daily basis through pressure gauge & record in autonomous checksheet
4
f o ) D ( M n F o / i C t c F e t e D
OPTIMIZATION (STEP 6)
A P A E M F P
s c i t s l i a i r c e e t c p e S r a h
C
l a n o i t p o ( e d o C r e t l i F
n o i t c A e v i t n e v e r P
n o i t c A n o i t c e t e D
e e m l a b i N s n ' s o n p o s s e r R e P
n o i t e l p e m t o a d C t e g r a T
s u t a t S
e h t c i n w e i n d e v k e a o t t n r o e i t t n c i A o p
e t a D n o i t e l p m o C
E F f o ) S ( y t i r e v e S
) O ( e c n e r r u c c O
) D ( n o i t c e t e D
s c i l t s a i i r c e e t p c e S r a h c
P A A E M F P
) l a n o i t p o ( e d o C r e t l i F
s k r a m e R
6
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6
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6
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6
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-
Monitoring on daily basis through internal CRM before
Daily calibration of spectrometer done as per
start of production & record on softcopy
internal CRM & weekly calibration through CRM 4
GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
Process failure Mode and Effects Analysis ( Process FMEA)
PLANNING & PREPARATION ( STEP 1) Company NamePlant LocationCustomer Name- ASHOK LEYLAND Model Year/ Platform- 2013 Part Name :- Rocker Arm ( Int & Exh ) CONTINOUS IMPROVEMENT
SubjectPFMEA Start Date- 01.01.21 PFMEA Revision Date- 25.01.21 Cross- Functional Team- ONT/MKG/RSM/SA/KM/US/AR/PK/SM/KS/BDM
STRUCTURE ANALYSIS (STEP2)
FUNCTION ANALYSIS (STEP 3)
PFMEA ID No- PFMEA/2001-2002/01 PFMEA/2001-2002/01 Process Responsibility- Line Incharge Confidentiality level- 04
FAILURE ANALYSIS (STEP 4) E F f
History / change Authorization ( As applicable )
1. Pr Proc oces ess s Ite Item m
2. Pr Proc oces ess s Ste Step p
3.Pr 3.Proc oces ess s Wor Work k Ele Eleme ment nt
1. Function of the process Item
2. Function of the process step & product charecteristics
To remove the To transfer motion parting line, flashes & fins from from input to output component
110 / Fettling
Bench Grinder
1. Failure Effects (FE) to the next heigher level element
Knowledge of M/C operations Under dimension of & process parameters component
Skilled operator
Rocker Arm Sub assembly
3.Function of the process work element & process charecteristics
) o S ( y t i r e v e S
2. Failure Mode (FM) of the Process Step
3. Failure Cause (FC) of the Work Element
Less knowledge & awareness
7
Over grinding
to operator regarding grinding operations
suface finish not Ok in casting
7
rough surface of grinding wheel
Dressing not done by operator
Crack on chill face of casting
7
Vibr Vibrat atio ion n on on gri grind ndin ing g whe wheel el
Whee Wheell ali align gnme ment nt not not don done e
To grind the part as per specification
GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
RISK ANALYSIS (STEP 5)
Current Prevention Control (PC) of FC
Displayed WI on shop floor for grinding operatorto&operator On job training providing regarding machine operations & effectiveness is measured in every 3 months
Displayed WI for dressing procedure in M/C for
5
5
Effectiveness of operator checked on every 3 months & Skill matrix for Lab FR-HR-002
Monitoring on daily basis & record in Machine
f o ) ( D M n F o / i t C c F e t e D
OPTIMIZATION (STEP 6) P A A E M F P
s c i t l i s a i r e c t e c p e S r a h
C
l a n o i t o p ( e d o C r e t l i F
n o i t A c e v i t n e v e r P
n o i t c A n o i t c e t e D
e e m l i b N s a n ' s o n p o s s e r R e P
n o i t e l p e m t o a C d t e g r a T
s u t a t S
e h t c i n w e n d i v e k e a o t t n r o e i t t n c i A o p
e t a D n o i t e l p m o C
E F f ) o S ( y t i r e v e S
) O ( e c n e r r u c c O
) D ( n o i t c e t e D
s c i s l i a t i r c t e e c p e S r a h c
P A A E M F P
) l a n o i t p o ( e d o C r e t l i F
s k r a m e R
6
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checksheet
reference
Displayed WI for wheel aligning procedure in M/C for reference
r o n o C i t F c o e f t e ) C M D F t D ( n l e o r r r t u n C o C
C F f o ) O ( e c n e r r u c c O
5
Monitoring on daily basis & record in Machine checksheet
GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
Process failure Mode and Effects Analysis ( Process FMEA)
PLANNING & PREPARATION ( STEP 1) Company NamePlant LocationCustomer Name- ASHOK LEYLAND Model Year/ Platform- 2013 Part Name :- Rocker Arm ( Int & Exh ) CONTINOUS IMPROVEMENT
History / change Authorization ( As applicable )
SubjectPFMEA Start Date- 01.01.21 PFMEA Revision Date- 25.01.21 Cross- Functional Team- ONT/MKG/RSM/SA/KM/US/AR/PK/SM/KS/BDM
STRUCTURE ANALYSIS (STEP2)
1. Proc Proces ess s It Item em
2. Proc Proces ess s Step Step 3.Pr 3.Proc oces ess s Work Work Elem Elemen entt
FUNCTION ANALYSIS (STEP 3)
1. Function of the process Item
2. Function of the process step & product charecteristics
3.Function of the process work element & process charecteristics
PFMEA ID No- PFMEA/2001-2002/01 PFMEA/2001-2002/01 Process Responsibility- Line Incharge Confidentiality level- 04
FAILURE ANALYSIS (STEP 4)
1. Failure Effects (FE) to the next heigher level element
E F f o ) S ( y t i r e v e S
2. Failure Mode (FM) of 3. Failure Cause (FC) of the Process Step the Work Element
Counting of components not done
Skilled operator
Rocker Arm Sub assembly
To shot the To transfer motion component in from input to order to achieve output good surface appearance
120 / Shot Blasting
Knowledge of M/C Operation & process parameters
Poor visual appearance(extrametal & Poor Surface finish on component at final inspection area Poor visual appearance(extra metal & Poor Surface finish on component at final inspection area
6
Uncleaned & surface finish not ok
Shots level not checked
To shot blast the Shot Blasting Machine
component in order to achieve good surface appearance
Impellar work not properly
GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
RISK ANALYSIS (STEP 5) C F f o ) O (
Current Prevention (PC) of FC Control
1.100% counting of component & 2.Part wise loading qty defined in process sheet
e c n e r r u c c O
Current Detection Control (DC) of FC or FM
OPTIMIZATION (STEP 6) f o ) D ( M n o / F i C t c F e t e D
P A A E M F P
s c i t l i s a r i e c e t p c e S r a h C
l a n o i t p o ( e d o C r e t l i F
n o i t c A e i v t n e v e r P
n o i t c A
e e m l a b i N s
n o i t c e t e D
o n ' s p n o s s e r R e P
n o i t e l p m e a o t d C t e g r a T
s u t a t S
e h c t i n w e d n i e v e k a t o t n r e o t i t n c i A o p
e t a D n o i t e l p m o C
E F f o ) S ( y t i r e v e S
) O ( e c n e r r u c c O
) D ( n o i t c e t e D
s c i l t s a i i r c e e c p t S e r a h c
P A A E M F P
) l a n o i t p o (
s k r
e d o C r e t l i F
a m e R
5
Monitoring in every loading basis & record in shot blasting record Doc no- FR-PRD-018
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Monitoring in every hour basis & record in shot blasting record Doc no- FR-PRD-018
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Monitoring in every hour basis & record in shot blasting record Doc no- FR-PRD-003
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for reference Doc no- FRPRD-038
1.Timer is been installed in M/C for time measurement 2.Shot blasting blasting WI for reference Doc no- FR-PRD038 3.On job training providing to operator regarding machine operations & effectiveness is measured in every 3 months
1.Amperage meter with marking is installed in M/C 2.Shot blasting blasting WI for reference Doc no- FR-PRD038 3.On job training providing to operator regarding machine operations & effectiveness is measured in every 3 months
Preventive maintenance done as per yearly plan & autonomous maintenance on daily basis
Preventive maintenance Plan 5
Vs actual( FR-MNT-010) & Autonomus maintenace checksheet (FR-MNT-004) (FR-MNT-004)
GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
Process failure Mode and Effects Analysis ( Process FMEA)
PLANNING & PREPARATION ( STEP 1) Company NamePlant LocationCustomer Name- ASHOK LEYLAND Model Year/ Platform- 2013 Part Name :- Rocker Arm ( Int & Exh ) CONTINOUS IMPROVEMENT
History / change Authorization ( As applicable )
SubjectPFMEA Start Date- 01.01.21 PFMEA Revision Date- 25.01.21 Cross- Functional Team- ONT/MKG/RSM/SA/KM/US/AR/PK/SM/KS/BDM
STRUCTURE ANALYSIS (STEP2)
1. Proc Proces ess s It Item em
2. Proc Proces ess s Step Step 3. 3.Pr Proc oces ess s Work Work Elem Elemen entt
FUNCTION ANALYSIS (STEP 3)
1. Function of the process Item
2. Function of the process step & product charecteristics
3.Function of the process work element & process charecteristics
Knowledge of M/C Operation & process parameters
Skilled operator
Rocker Arm Sub assembly
Fitment issue in engine assembly at customer end
130 / Visual Inspection Lighting conditon
Gauges
PFMEA ID No- PFMEA/2001-2002/0 PFMEA/2001-2002/01 1 Process Responsibility- Line Incharge Confidentiality level- 04
To check the visual defects in component To provide good lighting condion for observing defects
FAILURE ANALYSIS (STEP 4)
1. Failure Effects (FE) to the next heigher level element
Defective Component dispatched to customer & get break during engine running
E F f o ) S ( y t i r e v e S
2. Failure Mode (FM) of 3. Failure Cause (FC) of the Process Step the Work Element
9
Surface defects missed during visual inspection
1.Less Knowledge & awareness to operator 2. Lack of visual defect display
9
Low lux level
Lux level not defined at inspection area
9
Dimension out of specification
Gauge worn out
Defective Component dispatched to customer & get break during engine running
Fit & function To identify the OK parts & failure at customer reject the defect pieces end
GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
RISK ANALYSIS (STEP 5) C F f o ) O (
Current Prevention (PC) of FC Control
e c n e r r u c c O
Limit sample board are displayed in line for reference & On job training providing to operator regarding machine operations & effectiveness is measured in every 3 months
4
Lux level specified at visual inspection area(min 750 lux)
4
Calibration of Gauges done according to schedule
4
OPTIMIZATION (STEP 6) f o ) D ( M
Current Detection Control (DC) of FC or FM
Limit sample acceptance criteria Doc No : FR-ENG-011 & Effectiveness of operator checked on every 3 months which reflects on Skill matrix of Final inspection FR-HR-004
Monitoring on per shift basis & record in lux level register
Monitoring through Master list for calibration of gauges Doc No : FR--CAL-002
o n C / F i t c F e t e D
P A E A M F P
s c i t l s a i r i e e c t p c r S e a h C
l a n o i t p o ( e d o C r e t l i F
n o i t c A e i v t n e v e r P
n o i t c A
e e m l a b i N s
n o i t c e t e D
o n ' s p n s o e s r R e P
n o i t e l p m e o t a d C t e g r a T
s u t a t S
e h c t i n w e d n i e v e k a t o t n r e o t i t n c i A o p
e t a D n o i t e l p m o C
E F f o ) S ( y t i r e v e S
) O ( e c
) D ( n
s c i l t s a i i r
e n r r u c c O
i t o c e t e D
e e c t p c e S r a h c
P A A E M F P
) l a n o i t p o (
e d o C r e t l i F
s k r a m e R
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GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
Process failure Mode and Effects Analysis ( Process FMEA)
PLANNING & PREPARATION ( STEP 1) Company NamePlant LocationCustomer Name- ASHOK LEYLAND Model Year/ Platform- 2013 Part Name :- Rocker Arm ( Int & Exh ) CONTINOUS IMPROVEMENT
History / change Authorization ( As applicable )
SubjectPFMEA Start Date- 01.01.21 PFMEA Revision Date- 25.01.21 Cross- Functional Team- ONT/MKG/RSM/SA/KM/US/AR/PK/SM/KS/BDM
STRUCTURE ANALYSIS (STEP2)
1. Pro Proce cess ss Ite Item m
2. Pro Proce cess ss S Ste tep p
3. 3.Pr Proc oces ess s Work Work Elem Elemen entt
FUNCTION ANALYSIS (STEP 3)
1. Function of the process Item
2. Function of the process step & product charecteristics
3.Function of the process work element & process charecteristics
Knowledge of M/C Skilled operator
Rocker Arm Sub assembly
PFMEA ID No- PFMEA/2001-2002/01 Process Responsibility- Line Incharge Confidentiality level- 04
FAILURE ANALYSIS (STEP 4)
1. Failure Effects (FE) to the next heigher level element
E F f o ) ( S y t i r e v e S
Fit & function
2. Failure Mode (FM) 3. Failure Cause (FC) of of the Process Step the Work Element
failure at customer end
9
Dimension out of specification
Less knowledge of GD&T to operator
Fit & function To check the component failure at customer specific dimension end
9
Dimension out of specification
Uncalibrated measuring instrument used
Operation & process parameters
To check the Fitment issue in dimension of engine assembly component as per at customer end customer Dwg
140 / Final Inspection
Measuring Instruments
GHAZIABAD PRECISION PRODUCTS PVT LTD
RISK ANALYSIS (STEP 5) C F f o ) O (
Current Prevention Control (PC) of FC
e c n e r r u c c O
OPTIMIZATION (STEP 6) f o ) D ( M
Current Detection Control (DC) of FC or FM
FR-ENG-009
F o n / i C t c F e t e D
P A E A M F P
s c i l t s a i i r c e t e p c e S r a h C
l a n o i t p o (
e d o C r e t l i F
n o i t c A
n o i t c A
e e m l a b i N s
e v i t n e v e r P
n o i t c e t e D
n s o ' p n o s s e r R e P
n o i t e l p e t a o m C d t e g r a T
s u t a t S
e h c t i n w e d n i e v
e t a D n
k a e o t t n r o e i t t n c i A o p
i t o e l p m o C
E F f o ) S ( y t i r e v e S
) O ( e c
) D ( n
n e r r u c c O
i t o c e t e D
s c i l t s a i i r
c e t e p c e S r a h c
P A A E M F P
) l a n o i t p o (
e d o C r e t l i F
s k r a m e R
Monitoring of Trained personnel through Standard room
Qualified & trained personel are responsible for dimension inspection & effectiveness is measured in every 3 months
4
Calibration of equipment done as per schedule
4
capabilities matrix & Effectiveness monitored in every 3 months Doc No: DS-STD-001
Monitoring through Master list for calibration of gauges Doc No : FR--CAL-002
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GHAZIABAD PRECISION PRODUCTS PVT LTD
FR-ENG-009
Process failure Mode and Effects Analysis ( Process FMEA)
PLANNING & PREPARATION ( STEP 1) Company NamePlant LocationCustomer Name- ASHOK LEYLAND Model Year/ Platform- 2013 Part Name :- Rocker Arm ( Int & Exh ) CONTINOUS IMPROVEMENT
History / change Authorization ( As applicable )
SubjectPFMEA Start Date- 01.01.21 PFMEA Revision Date- 25.01.21 Cross- Functional Team- ONT/MKG/RSM/SA/KM/US/AR/PK/SM/KS/BDM
STRUCTURE ANALYSIS (STEP2)
1. Pr Proc oces ess s Item Item
2. Pr Proc oces ess s St Step ep 3.Pr 3.Proc oces ess s Work Work El Elem emen entt
150 / Oiling
160 / Packing
FUNCTION ANALYSIS (STEP 3)
1. Function of the process Item
Skilled Operator
To transfer motion from input to output
170 / FG Storage
Storage
2. Function of the process step & product charecteristics
3.Function of the process work element & process charecteristics
Rust prevention of
To dip the component in
final component
RP as per work instruction
Packing of component as per To pack the component as
Skilled Operator
Rocker Arm Sub assembly
PFMEA ID No- PFMEA/2001-2002 PFMEA/2001-2002/01 /01 Process Responsibility- Line Incharge Confidentiality level- 04
FAILURE ANALYSIS (STEP 4)
1. Failure Effects (FE) to the next heigher level element
Rusted component dispatch to customer
Customer
E F f o ) S ( y t i r e v e S
8
7
2. Failure Mode (FM) of 3. Failure Cause (FC) of the Process Step the Work Element
Oiling not done on
Less Knowledge &
component
awareness to operator
Improper Counting
standard/ agreement
per packing standard
dissatisfaction
Storage of component as per standard/
To store the com component ponent as per packing standard
Customer dissatisfaction
8
Rust in casting
Customer dissatisfaction
7
Proper documents not attached along with supply
Less Knowledge & awareness to operator
Components kept in floor
agreement
180 / Dispatch
Skilled Operator
Dispatch of To dispatch the component component as per as per invoice invoice
Less Knowledge & awareness to operator
GHAZIABAD PRECISION PRODUCTS PVT LTD
RISK ANALYSIS (STEP 5) C F f o ) O (
Current Prevention (PC) of FC Control
c e n e r r u c c O
100% dipping application on component & On job training providing to operator regarding machine operations
5
Dock audit as per schedule & On job training providing to operator regarding machine operations
Components are stored in pallet/bins to prevent from moisture/ rust & displayed
5
5
WI at area for reference DOC NO- WI-PRD-046
Invoice control
Current Detection Control (DC) of FC or FM
Effectiveness monitored in every 3 months which reflects through Skill matrix of Oiling operation FR-HR-004 Work instruction for oiling operation Doc No :- FR- ENG-023
Effectiveness monitored in every 3 months which reflects through Skill matrix of Packing operation FR-HR-004 Work instruction for Packing operation Doc No :- FR- ENG-023
Monitoring through Dock audit conduct once in every week
FR-ENG-009
OPTIMIZATION (STEP 6) f o ) D ( M n / F o C i t c F e t e D
P A E A M F P
s c i l t s a i r i e c t e p c e S r a h C
l a n o i t p o (
e d o C r e t l i F
n o i t c A e i v t n e v e r P
n o i t c A n o i t c e t e D
n o e i e m t l e a l b i N p s m e s n o ' o t a C d p n s o t e s e r g R e r P a T
s u t a t S
e h c t i n w e d n i e v e k a t o t n r e o t i t n i c A o p
e t a D n o i t e l p m o C
E F f o ) S ( y t i r e v e S
) O ( e c e n r r u c c O
) D ( n o i t c e t e D
s c i l t s a i i r e c t e p c S e r a h c
P A A E M F P
) l a n o i t p o (
s k r
e d o C r e t l i F
a m e R
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DOC NO - FR-IQA-014
5
Monitoring in every dispatch by store incharge
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