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Item :Hinge Key Date: 15/6/2004

Page: 01 of 03

Process Responsibility: Quality / Production FMEA Date (Orignal): 12/04/2004

FMEA No.: 03 Rev. No. 00

Prepared By: D.S Wilkhoo

Core Team: D. S Wilkhoo(Systems), Raman Kr. / Raman Kr. / Rakesh Gill(Quality), Navdeep Mitalia(T/Room), Ved Prakash(Casting), Janak Dev(Machining) Occurrence Action Results Responsible Recommended / Target R.P.N Actions Completion Action Taken Date Occurrence 80 Severity

1. Raw material Inspection

Composition Of Material

In-adequate physical strength

10

Cr.

Chemical components is not as per requirement

Comparision of material test certificate with required composition Aluminium Treatment in every Two Hrs. Air cleaning of die after each shot Vent cleaning after every shot

2. Casting

Blow Holes Poursity

Less Strength

Cr.

1.Improper Aluminium Treatment 2.Improper cleanning of Die /Tool 3. Improper Vents / Overflow or closed Vents

64

80

80

Non-Filling

Appearance

Mj.

Under Heat Molten Metal Improper Aluminium treatment

Check Temp. of the Molten Metal after every Hour & 100% Visual Inspection

48

60

Detection

Process Potential Function Failure Mode requirements

Potential Effect(s) of Failure

Potential cause(s) / Class Mechanism of failure

Current Process Control

Detection

Severity

.: 03

00

lts

R.P.N

Item :

Hinge

Page: 02 of 03 Prepared By: D.S Wilkhoo

Process Responsibility: Quality / Production FMEA Date (Orignal): 12/04/2004

FMEA No.: 03 Rev. No.00

Key Date: 15/6/04

Core Team: D.S Wilkhoo(Systems), Raman Kr. / Rakesh Gill(Quality), Navdeep Mitalia(T/Room), Ved Prakash(Casting), Janak Dev(Machining) Occurrence Action Results Responsible Recommended / Target R.P.N Actions Completion Action Taken Date Occurrence Severity 84

Detection

Process Potential Function Failure Mode requirements 2.Casting Non-Filling

Potential Effect(s) of Failure Appearance

Potential cause(s) / Class Mechanism of failure Mj. 2nd & 3rd Phase Pressure of machine not Adequate

Current Process Control Check the parameters after every two hours & 100% Visual Inspection Approximate Weight Manually Spraying of Die coat & Air Cleaning & 100% visual inspection Weight of component after every hour Check the parameters after every two hours Weight of component after every hour

Detection

Severity

R.P.N

7 Oil Mark 6

Mj. Mi.

Less Aluminum Improper Die Coat & Cleaning

3 5

4 3

84 90

Less / Excess Weight

Mj.

Loose Die

98

Mj.

3rd Phase or intensification Pressure of Machine is excess Improper Matching of Die / Tools

70

Mj.

70

Item : Hinge Key Date: 15/06/2004

Page: 01 of 03 Prepared By: D.S Wilkhoo

Process Responsibility: Quality / Production FMEA Date (Orignal): 12/04/2004

FMEA No.: 03 Rev. No.00

Core Team: D.S Wilkhoo(Systems), Raman Kr. /Rakesh Gill(Quality), Navdeep Mitalia(T/Room), Ved Prakash(Casting), Janak Dev(Machining) Occurrence Action Results Responsible / Recommended Target R.P.N Actions Completion Action Taken Date Occurrence Severity 72

Detection

Process Potential Function Failure Mode requirements 2.Casting Dimensions

Potential Effect(s) of Failure Not fit for purpose

Potential cause(s) / Class Mechanism of failure Cr. Improper Die Matching

Current Process Control Match the die at startup & Check the critical dimensions after every hour & 100% Visual Inspection 100% Visual Inspection Check the critical dimensions after every two hours 100% Visual Inspection

Detection

Severity

R.P.N

Cr.

Broken hole forming Pins Improper Movement of Slides or hole forming pins Low workmanship & Un-skilled labour Low workmanship & Un-skilled labour

81

Cr.

72

Fettling

Un-Even Filling Of component

Poor appearance

Mi.

42

Changed Dimensions

Cr.

100% Visual Inspection

80