Copy of Potential (FMEA) (Original)

Doc # ___QC\FM\009_________________________
Action Taken
S
E
V
O
C
R
Diametetr Up
Fitment problem in Next
Operation
2 Insert wear/Setting 1 In Process Inspection 1 2
Diametetr Down
Operation
Length Up
Operation
Length Down
Operation
OuterDiameter up Fitment not ok in vehical 5 Insert wear/Setting 4 In Process Inspection 2 40
Outer Diameter Down Fitment not ok in vehical 6 Insert wear/Setting 5 In Process Inspection 2 60
Thickness Variation Prblem in Next Operation 4 Setting 2 In Process Inspection 2 16
Height Fitment not ok in vehical 4 Insert wear/Setting 2 In Process Inspection 2 16
Boring Diameter up Fitment not ok in vehical 6 Insert wear/Setting 3 In Process Inspection 1 18
Boring Diameter Down Fitment not ok in vehical 4 Insert wear/Setting 4 In Process Inspection 4 64
Depth up & Down Fitment not ok in vehical 4 Insert wear/Setting 3 In Process Inspection 4 48
Heights Fitment not ok in vehical 4 Setting 1 In Process Inspection 2 8
Thickness Variation Fitment not ok in vehical 6 Setting 5 In Process Inspection 2 60
Run out up Vibration in vehical 4 S.C Setting 5 In Process Inspection 2 40
Concentricity up Vibration in vehical 6 Setting 4 In Process Inspection 4 96
Perpendicularity up Vibration in vehical 4 Setting 2 In Process Inspection 4 32
Hole Dia Up Vibration in vehical 6 Drill Wear 2 In Process Inspection 2 24
PCD Out & True Position Vibration in vehical 6 Setting 2 In Process Inspection 2 24
Spline damage Vibration in vehical 6 Tool Grinding 2 In Process Inspection 2 24
Major Dia up Vibration in vehical 6 Tool Grinding 2 In Process Inspection 2 24
Burr Vibration in vehical 3 Tool Grinding 3 In Process Inspection 2 18
In Process Inspection
Bolt Press Damage Fitment not ok in vehical
PCD Fitment not ok in vehical 3 Burr and Setting Problem 3 In Process Inspection 2 18
Packing Dent Fitment not ok in vehical 6 Seprator 2 In Process Inspection 1 12
Storage
Un proper stacking ,
Moisture , Rust
6 1 10 60
Delivery
Demaged parts not
accepted by OEM
5 Improper stacking on vahicle not filt, Rash driving 5
Stacjing , Instruction ,
Inspection
4 100
Prepared By: Approved By: Approved By:
Zaffar Razzaq (Asst. Manager Q.C) Majid Mehmood (Manager Q.C) Mr. Rafi (Manager Production)
S.C
C
L
A
S
Current Process Controls
Process Function /
Requirements
Potential Failure Mode
Potential Effect(s) of
Failure
S
E
V
R
P
N
Recommended Actions
Responsibility
& Target Date
D
E
T
E
Potential Cause(s) / Mechanism(s) of Failure
Action Results
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
(PROCESS FMEA)
Part Name/ Item__Hub Front Axle Corolla_____________
O
C
C
U
Ist Side Machining
FMEA Number ___03________________________
Part # __________43511-12160_____________________ Prepared By __Zaffar Razzaq________________________
Rough Turning& Pre
Drill
Date (Orig) __08-01-2008________________________
Team __Develoment, Production, QC_____________ Date (Rev) ___________________________
OEM _________ Agriauto________________________
Process Responsibility___Production and QC_______
3 Drill Wear
2nd Side Machning
Broaching
3 Counter & Chamfer Burr Prblem in Next Operation 1 1
D
E
T
R
P
N
Action Results
FMEA Number ___03________________________
Prepared By __Zaffar Razzaq________________________
Date (Orig) __08-01-2008________________________
Date (Rev) ___________________________
Doc # ___QC\FM\009_________________________
Action Taken
S
E
V
O
C
R
Diametetr Up
Operation
Diametetr Down
Operation
Length Up
Operation
Length Down
Operation
Run out up Vibration in vehical 4 Setting 5 In Process Inspection 2 40
Corbon Cleaning Appereance no Effect 1 1 1 1
Damage Fitment not ok 3 Setting 2 In Process Inspection 2 12
PCD Out & True Position Vibration in vehical 6 Pressure / Setting 1 In Process Inspection 1 6
Storage
Moisture , Rust
6 1 10 60
Delivery
Demaged parts not
accepted by OEM
5
Improper stacking on vahicle not filt, Rash
driving
5
Inspection
4 100
Counter & Chamfer Burr Prblem in Next Operation
R
P
N
Recommended Actions
Responsibility
& Target Date
C
L
A
S
2nd Side Machning
S.C
Date (Orig) __08-01-2008________________________
Team _____Develoment, Production, QC__________ Date (Rev) __________________________
O
C
C
U
Current Process
Controls
Process Function /
Requirements
Failure
S
E
V
Action Results
FMEA Number ___04________________________
Part # __________43502-87 Z 04_________________ Prepared By __Zaffar Razzaq________________________
6
3
OEM _________IMC______________________
Rough Turning&
Pre Drill
Ist Side Machining
Drill Wear 1 1 3
POTENTIAL
(PROCESS FMEA)
Part Name/ Item_ Hub S/A Front Axle Cuore Hub___
D
E
T
E
Broaching
1 12
Bolt Press
Seprator 2 In Process Inspection Packing Dent Fitment not ok in vehical
D
E
T
R
P
N
Date (Orig) __08-01-2008________________________
Date (Rev) __________________________
Action Results
FMEA Number ___04________________________
Doc # ___QC\FM\009_________________________
Action Taken
S
E
V
Diametetr Up
Operation
Diametetr Down
Operation
Length Up
Operation
Length Down
Operation
Chamfer Burr Fitment Problem 3 Tool Grinding 1 1 3
Storage
Moisture , Rust
6 1 10 60
Delivery
Demaged parts not
accepted by OEM
Inspection
4 100
POTENTIAL
(PROCESS FMEA)
Part Name/ Item__Hub Front Wheel SF - 310_____________ FMEA Number ___06_______________________
Part # __________43421-63B00________________________ Prepared By __Zaffar Razzaq________________________
OEM _________Pak Suzuki__________________________
Date (Orig) __05-01-2008________________________
Team __Develoment, Production, QC________________ Date (Rev) __________________________
Process Function /
Requirements
Failure
S
E
V
C
L
A
S
O
C
C
U
Current Process
Controls
2nd Side Machning
S.C
Broaching
Action Results
Rough Turning&
Pre Drill
Ist Side Machining
D
E
T
E
R
P
N
Recommended Actions
Responsibility
& Target Date
O
C
R
D
E
T
R
P
N
FMEA Number ___06_______________________
Date (Orig) __05-01-2008________________________
Date (Rev) __________________________
Action Results
Doc # ___QC\FM\009____________________
Action Taken
S
E
V
O
C
R
Diametetr Up
Operation
Diametetr Down
Operation
Length Up
Operation
Length Down
Operation
Chamfer Burr Fitment Problem 3 Tool Grinding 1 1 3
Storage
Moisture , Rust
6 1 10 60
Delivery
Demaged parts not
accepted by OEM
5
Improper stacking on vahicle not filt, Rash
driving
5
Inspection
4 100
Date (Orig) __05-01-2008________________________
POTENTIAL
(PROCESS FMEA)
Part Name/ Item__Hub Front Wheel RA - 410____________
Responsibility
& Target Date
C
L
A
S
O
C
C
U
Action Results
FMEA Number ___05________________________
Part # __________43421-76G01_______________________ Prepared By __Zaffar Razzaq________________________
OEM _________Pak Suzuki_________________________
Process Responsibility___Production and QC__
Broaching
Team __Develoment, Production, QC______________
Rough Turning&
Pre Drill
Ist Side Machining
S.C
Date (Rev) ___________________________
Process Function /
Requirements
Failure
S
E
V
D
E
T
E
R
P
N
Recommended Actions
Current Process
Controls
2nd Side Machning
S.C
D
E
T
R
P
N
Date (Orig) __05-01-2008________________________
Action Results
FMEA Number ___05________________________
Date (Rev) ___________________________
Doc # ___QC\FM\009____________________
Action Taken
S
E
V
O
C
R
Diametetr Up
Operation
Diametetr Down
Operation
Length Up
Operation
Length Down
Operation
Storage
Moisture , Rust
6 1 10 60
Delivery
Demaged parts not
accepted by OEM
Inspection
4 100
POTENTIAL
(PROCESS FMEA)
Part Name/ Item__Hub Front Wheel SB______________ FMEA Number ___07_______________________
Part # __________43421-78402____________________ Prepared By __Zaffar Razzaq________________________
OEM _________ Pak Suzuki____________________
Process Responsibility___Production and QC__
Date (Orig) __01-01-2008________________________
Team __Develoment, Production, QC____________ Date (Rev) __________________________
Process Function /
Requirements
Failure
S
E
V
Action Results
Responsibility
& Target Date
D
E
T
E
R
P
N
Recommended Actions
C
L
A
S
O
C
C
U
Current Process
Controls
1 1 3 Prblem in Next Operation 3
Rough Turning&
Pre Drill
Ist Side Machining
Counter & Chamfer Burr Drill Wear
2nd Side Machning
S.C
Broaching
D
E
T
R
P
N
FMEA Number ___07_______________________
Date (Orig) __01-01-2008________________________
Date (Rev) __________________________
Action Results
Part Name/ Item__RA GSL308 _____________
Part # ___ 28100-P76G80______________
OEM ____ Pak Suzuki_______________________________
Team __ Develoment, Production, QC______________________________________________________________________________________________
S
E
Fitment Problem in Next Operation 5 Setting Problem 3 In Process Inspection 7 105
Fitment Problem in Next Operation 3 Setting Problem / Die Wear 4 In Process Inspection 7 84
Appereance Problum not accepted
By OEM.
5 Setting Problem / Die Wear 4 In Process Inspection 3 60
By OEM.
Fitment Problem in Next Operation 4 Setting Problem / Electrok Wear 3 In Process Inspection 5 60
Fitment Problem 2 Setting Problem 3 In Process Inspection 5 30
Appereance Problum 4 Setting Problem 3 In Process Inspection 5 60
Doc # ___QC\FM\019________________________ FMEA Number ___14_______________________
Process Responsibility___Production and QC__________________ Prepared By ___Zaffar Razzaq_______________________
POTENTIAL
(PROCESS FMEA)
Process Function / Requirements Potential Failure Mode Potential Effect(s) of Failure
S
E
V
Date (Orig) ___08-01-2008_________________________
Date (Rev) __________________________
D
E
T
E
R
P
N
Recommended Actions
Responsibility &
Target Date
C
L
A
S
O
C
C
U
Shearing 01 Length Up & Down
Action Results
Action Taken
Guide Plate
Blanking Distance Up& Down
Width Up&down
Bending Hight Up & Down
Hight Up & Down
Eliptical Piercing Distance Up& Down
Appereance
Rib Forming Distance Up& Down
Appereance
1st Bending Hight Up & Down
Hight Up & Down
Distance Up& Down
Pan Shape Piercing Hight Up & Down
04 Hole Piercing Distance Up& Down
2nd Bending Hight Up & Down
Bending (Legs) Hight Up & Down
Diameter Up & Down
Legs spoting Spot
Legs Bending Final Distance Up& Down
Hight Up & Down
M8 Bolt Spoting Spot
Diameter Up & Down
Rubber Extension Plate.
Galvanizing Visual
Width Up&down
Shearing Length Up & Down
Width Up&down
Blanking & Hole Piercing Length Up & Down
Distance Up& Down
Appereance Problum 4 Setting Problem 3 In Process Inspection 5 60
By OEM.
Nut Loose 2 Setting Problem / Electrok Wear 4 In Process Inspection 7 56
Hook Loose 3 Setting Problem / Electrok Wear 3 In Process Inspection 5 45
Fitment Problem in Next Operation Setting Problem 4 In Process Inspection 0
By OEM.
Fitment Problem in Next Operation 5 Setting Problem / Tool Wear 6 In Process Inspection 4 120
Fitment Problem in Next Operation 5 Setting Problem / Dia Wear 4 In Process Inspection 4 80
Diameter Up & Down
M8 Bolt Welding
M8 Bolt Spoting
Extension Rod Plate
Galvanizing Visual
Distance Up& Down
Distance Up& Down
Appereance
Hight Up & Down
Bending Distance Up& Down
Hight Up & Down
Capsule Forming Width Up&down
Diameter Up & Down
Hole Piercing Distance Up& Down
02 Hole Drilling Distance Up& Down
Starightness Straigtness
Diameter Up & Down
M6 Nut Spoting UnProper
Diameter Up & Down
RA G.S.L. Hook
Hook Spoting UnProper
Width Up&down
Hole Peiricing Diameter Up & Down
Shearing Dimension Up& Down
Hight Up & Down
Flaring Diameter Up & Down
Hight Up & Down
Bending Diameter Up & Down
Appereance
Blanking Dimension Up& Down
Pipe Cutting Length Up & Down
RA EXT. Rod Pipe 25.4
Bending Plate Side Distance Up& Down
Bending Bush Side Dimension Up& Down
Hight Up & Down
3 Setting Problem 6 In Process Inspection 4 72
Fitment Problem in Next Operation Setting Problem In Process Inspection 4 0
By OEM.
Setting Problem / Die Wear In Process Inspection 4 0
By OEM.
By OEM.
By OEM.
Punching Plate Side Hight Up & Down
Punching Bush Side Diameter Up & Down
Diameter Up & Down
Starightness ( 90 )
Distance Up& Down
RA CONT. ROD. PIPE 19.10
Bending Length Up & Down
Pipe Cutting Length Up & Down
Radius cutting (bush side) Visual
Diameter Up & Down
RA U` BKT. CONT. ROD.
Bending Radious Up & Down
Hole Piercing Fixture
Hight Up & Down
Starightness (90) Fixture
01 Hole Piercing Fixture
Appereance
Chamfer up&Down
RA LEVER ROD.
Shaft Cutting Length Up & Down
Turning Distance Up& Down
Radius Distance Up& Down
Hight Up & Down
Grinding Distance Up& Down
Hight Up & Down
Threading Distance Up& Down
Appereance
Appereance
Machining Length Up & Down
Shaft cutting Length Up & Down
Chamfering Both Side Visual
Diameter Up & Down
Machining Fixture
RA LEVER BUSH.
Shaft cutting Fixture
Appereance
Chamfering Both Side up&Down
By OEM.
3 Setting Problem / Tool Wear / Miss Handling 2 In Process Inspection 5 30
By OEM.
Appereance Problem 3 Setting Problem 5 In Process Inspection 4 60
By OEM.
By OEM.
By OEM.
Diameter Up & Down
RA EXT. ROD. BUSH. 25.4
Dimension Up& Down
Machining Diameter Up & Down
C1
Length Up & Down
Dimension Up& Down
Chamfering Both Side Radious
Diameter Up & Down
Chamfering Visual
Diameter Up & Down
RA SPACER BUSH.
Diameter Up & Down
Drilling Visual
Radious
Dimension Up& Down
Chamfering Both Side Taper Up & Down
Appereance
Appereance
Galvanizing Dimension Up& Down
Ball Welding 1st Side Distance Up& Down
RA LEVER WELDING.
Bush Welding Visual
Ball Welding 2nd Side Appereance
Hight Up & Down
Bending Length Up & Down
RA PIPE 19.1 ASSY (WELDING)
Touch Welding (U` Bkt. & Bush) Appereance
Final Welding U` Bkt. Appereance
Paint Over Flow & Pain Miss
Final Welding Bush Appereance
RA EXT. ROD. WELDING (PIPE 25.4)
By OEM.
By OEM.
By OEM.
Setting Problem / Tool Wear / Miss Handling In Process Inspection 4 0
Rust Parts , Damage Parts 6 Unproper 2 In Process Inspection 1 12
Demaged parts not accepted by
OEM
6 Unproper 1 10 60
OEM
5 Improper stacking on vahicle not filt, Rash driving 5 Stacjing , Instruction , Inspection 4 ##
Chamfering Both Side
Packing
Storage
Dimension Up& Down
Appereance
Material
Delivery
Touch Welding (Ext, Plate & Bush) Appereance
Final Welding (Ext, Plate & Bush) Appereance
RA BUSH RUBBER EXT. ROD.
Diameter Up & Down
Radious
Drilling Visual
Taper Up & Down
O
C
D
E
R
P
FMEA Number ___14_______________________
Prepared By ___Zaffar Razzaq_______________________
POTENTIAL
(PROCESS FMEA)
Date (Orig) ___08-01-2008_________________________
Date (Rev) __________________________
Action Results
Team ______Develoment, Production, QC______________________________________________________________________________________________
S
E
V
O
C
R
Fitment In Next Operation
6 3 4 72
5 3 4 60
5 3 4 60
5 3 4 60
5 3 4 60
5 3 4 60
5 3 4 60
5 3 4 60
4 5 2 40
2 0
4 5 2 40
4 5 2 40
4 5 2 40
4 5 2 40
6 5 2 60
6 5 2 60
2 5 2 20
4 5 2 40
2 5 2 20
2 5 2 20
5 3 3 45
5 3 3 45
5 3 3 45
5 3 3 45
5 3 3 45
6 4 3 72
6 4 3 72
6 4 3 72
6 4 3 72
6 4 3 72
6 4 3 72
6 4 3 72
POTENTIAL
(PROCESS FMEA)
Date (Orig) __10-01-2008__________________
Date (Rev) _____________________________
Part Name/ Item__ROD. COMP. REAR TRAILLING L , R Doc # ___QC\FM\009_________________________ FMEA Number __11________________________
Part # __________46210-54G10 , 46210-54G20___________________ Process Responsibility___Production and QC_______ Prepared By ___Zaffar Razzaq______________
S
E
V
OEM _________Pak Suzuki__________________________________
R P N
Recommended
Actions
Responsibility &
Target Date
C
L
A
S
S
O
C
C
U
R
Action Results
Action Taken
Pipe Dia 25.4
D
E
T
E
Diameter Up &Down Setting Problem In Process inspection
Cutting LengthUp & Down
Bending Bending Marks Setting Problem In Process inspection
Setting Problem In Process inspection
Height after Bending Setting Problem In Process inspection
Length After Nib Cutting Setting Problem In Process inspection
Nib Cutting Height after Bending
Radius Cutting Radius Depth Setting Problem In Process inspection
Radius Setting Problem In Process inspection
Shearing 01 Length Up & Down Setting Problem In Process inspection
Sub Bracket
Thickness up&Down In Process inspection
Width Up&down Setting Problem In Process inspection
Bending Length Up & Down Setting Problem In Process inspection
Blanking Width Up&down
Hight Up & Down Setting Problem In Process inspection
Piericing 7 Diameter Up & Down Setting Problem In Process inspection
Nut Spot M6 Visual Setting Problem In Process inspection
Distance Up& Down
Size Up & Down Setting Problem In Process inspection
Hit Setting Problem In Process inspection
Bush 51
Nut Welding Visual
Shaft Cutting Length Up & Down Setting Problem In Process inspection
CNC Machining Length Up & Down Setting Problem In Process inspection
Chamfer Up & Down Setting Problem In Process inspection
Diameter Up & Down
Chamfering Chamfer Up & Down Setting Problem In Process inspection
U Bracket
Thickness up&Down In Process inspection
Width Up&down Setting Problem In Process inspection
Blanking Length Up & Down Setting Problem In Process inspection
Bending Dimension Up & Down Setting Problem In Process inspection
Width Up&down
Height Up & Down Setting Problem In Process inspection
6 4 3 72
2 4 3 24
2 4 3 24
2 4 3 24
6 5 3 90
2 5 2 20
6 4 3 72
2 4 3 24
6 4 3 72
2 4 3 24
2 3 3 18
By OEM.
4 3 3 36
Fitment not ok in vehical
6 3 1 18
Rust Parts , Damage Parts 6 2 1 12
OEM
6 1 10 60
OEM
5 5 4 100
Delivery Improper stacking on vahicle not filt, Rash driving Stacjing , Instruction , Inspection
Storage Unproper
12.8 Piercing Diameter Up & Down Setting Problem In Process inspection
Hit Setting Problem In Process inspection
Nut Spot M12 Visual Setting Problem In Process inspection
M 12 Nut Welding Visual Setting Problem In Process inspection
U BKT & Bush Stacking Fitment Setting Problem In Process inspection
U BKT & Bush WELDING
U BKT & Bush Final Welding Visual Setting Problem In Process inspection
Visual Setting Problem In Process inspection
U BKT & Bush Final Welding Fitment
Sub BKT Welding Fitment Setting Problem In Process inspection
Appereance Setting Problem In Process inspection
Taping Bolt Setting Problem In Process inspection
Final Inspection Dent Seprator In Process Inspection
Paint Operation Miss
Packing Material Unproper In Process Inspection
D
E
T
R
P
N
POTENTIAL
(PROCESS FMEA)
Date (Orig) __10-01-2008__________________
Date (Rev) _____________________________
FMEA Number __11________________________
Prepared By ___Zaffar Razzaq______________
Action Results
Action Taken
S
E
O
C
D
E
BASE PLATE
Shearing 01 Length Up& Down problem in Next Operation 2 Seeting Problem 2 In Process Inspection 3 12
Width up& Down problem in Next Operation 2 Seeting Problem 3 In Process Inspection 3 18
Thickness Variation problem in Next Operation In Coming Inspection 0
Shearing 02 Length Up& Down problem in Next Operation 3 Setting Problem 4 In Process Inspection 3 36
Width up& Down problem in Next Operation 3 Setting Problem 4 In Process Inspection 4 48
Thickness Variation problem in Next Operation In Process Inspection 0
Notching 01 Distance Up& Down Problem in Next Operation 5 Setting Problem 4 In Process Inspection 2 40
Notching 02 Height Up & Down Problem in Next Operation 5 Setting Problem 3 In Process Inspection 2 30
Notching 03 Distance Up& Down Problem in Next Operation 5 Setting Problem 4 In Process Inspection 5 100
Height Up & Down Problem in Next Operation 5 Setting Problem 5 In Process Inspection 2 50
Distance Up& Down Problem in Next Operation 6 Setting Problem 6 In Process Inspection 3 108
Vertical Bush Welding Distance Up& Down Problem in Next Operation 4 Setting Problem 2 In Process Inspection 3 24
Diameter Up & Down Fitment Problem in next Operation 6 Punch Oroblem 3 In Process Inspection 2 36
Distance Up& Down Fitment Problem in next Operation 6 Setting Problem 2 In Process Inspection 3 36
Spot Nut M8 Spot Breack Fitment Problem in next Operation 4 Setting Problem 7 In Process Inspection 3 84
Spot Bkts Distance Up& Down Fitment Problem in next Operation 6 Guage Problem/Setting Problem 6 In Process Inspection 3 108
Final Welding Bkts Boring Diameter up Fitment Problem in next Operation 6 Setting Problem 3 In Process Inspection 3 54
Visual Fitment Problem in next Operation 4 Setting Problem 3 In Process Inspection 3 36
Galanizing Visual Appereancs Problem 6 Setting Problem 3 In Process Inspection 4 72
Doc # _____QC\FM\009__________________
OEM _________ Pak Suzuki____________________ Date (Orig) ___08-01-2008_______________
Team __ Develoment, Production, QC__________ Date (Rev) ___________________________
FMEA Number ___15_______________________
Part # __________28109-79505__________________ Prepared By ___Zaffar Razzaq_______________________ Process Responsibility___Production and QC__
Part Name/ Item__STG GSL (BOLAN)_____________
O
C
C
U
Current Process
Controls
S
E
V
Action Results
Bending
4 Hole Piercing
Dia 5 Hole Piercing
D
E
T
E
R
P
N
Recommended Actions
Responsibility
& Target Date
C
L
A
S
Bkt D Welding
POTENTIAL
(PROCESS FMEA)
Dia 9 Hole Piercing
Horizantal Bush 1st Welding
Horizantal Bush 2nd Welding
Thickness Variation Problem in Next Operation 6 Setting Problem 2 In Process Inspection 4 48
Setting Problem In Process Inspection 32
Setting Problem In Process Inspection 0
Length Up& Down Problem in Next Operation 5 Setting Problem 3 In Process Inspection 6 90
Distance Up& Down Problem in Next Operation 8 Setting Problem 3 In Process Inspection 4 96
Thickness Variation Problem in Next Operation 5 Setting Problem 3 In Process Inspection 5 75
Bending Height Up & Down Problem in Next Operation 4 Setting Problem 5 In Process Inspection 3 60
Diameter Up & Down Fitment Problem in next Operation 7 Setting Problem 6 In Process Inspection 2 84
Hole Piercing Dia 9 Diameter Up & Down Fitment Problem in next Operation 5 Setting Problem 3 In Process Inspection 3 45
90 Fitment Problem in next Operation 6 Setting Problem 3 In Process Inspection 2 36
Nut Spot M8 Spot Breack Fitment Problem in next Operation 9 Setting Problem 3 In Process Inspection 4 108
Spot Breack Fitment Problem in next Operation 7 Setting Problem 3 In Process Inspection 6 126
Thickness Variation Problem In Next Operation 7 In Process Inspection 0
Problem In Next Operation 9 Setting Problem 1 In Process Inspection 4 36
Length Up& Down Problem In Next Operation 6 Setting Problem 4 In Process Inspection 2 48
Distance Up& Down Problem In Next Operation 8 Setting Problem 2 In Process Inspection 4 64
Bending Height Up & Down Fitment Problem in next Operation 4 Setting Problem 6 In Process Inspection 3 72
90 Fitment Problem in next Operation 8 Setting Problem 3 In Process Inspection 2 48
Straihtness
Spot Washer + Horizontal Bush
STG Bracket A
Shearing Width up& Down Problem in Next Operation 4 4 2
Blanking
Hole Piercing 27.2
Blanking
Hole Piercing
Straihtness
STG Bracket C
STG Bracket B
Shearing Width up& Down
Blanking
Hole Piercing
Thickness Variation Problem In Next Operation In Process Inspection 0
Hole Piercing Dia 12 Diameter Up & Down Fitment Problem in next Operation 8 Setting Problem 3 In Process Inspection 2 48
Nut Spot M8 Spot Breack Fitment Problem in next Operation 7 Setting Problem 3 In Process Inspection 2 42
Nut M8 Welding Visual Fitment Problem in next Operation 6 Setting Problem 4 In Process Inspection 2 48
Treading Pin Welding Visual Fitment Problem in next Operation 4 Setting Problem 4 In Process Inspection 3 48
Thickness Variation Problem In Next Operation 7 4 In Process Inspection 4 112
Chamfering Visual Fitment Problem in next Operation 4 Setting Problem 3 In Process Inspection 6 72
Fixture Fitment Problem in next Operation 6 Setting Problem 1 In Process Inspection 2 12
Galvanizing Visual Appereanes Problem 3 Setting Problem 2 In Process Inspection 2 12
Notching Distance Up& Down Problem In Next Operation 8 Setting Problem 5 In Process Inspection 2 80
Diameter Up & Down Problem In Next Operation 6 Setting Problem 6 In Process Inspection 3 108
Flaring
STG Bracket D
Blanking
Hole Piercing
Bush Weld
STG Control Shaft
Blanking
Hole Piercing Dia 9
STG Gear Select Arm
2 Hole Piercing + Notching
1 Hole Piercing
Height Up & Down Fitment Problem in next Operation 6 Setting Problem 2 In Process Inspection 4 48
Final Bending Distance Up& Down Fitment Problem in next Operation 8 Setting Problem 2 In Process Inspection 3 48
Length Up& Down Fitment Problem in next Operation 4 Setting Problem 5 In Process Inspection 2 40
Pressing Distance Up& Down Fitment Problem in next Operation 6 Setting Problem 2 In Process Inspection 5 60
Galvanizing Visual Fitment Problem in next Operation 4 Setting Problem 1 In Process Inspection 7 28
Pre Drilling Diameter Up & Down Fitment Problem in next Operation 4 Setting Problem 4 In Process Inspection 2 32
22 Boring Diameter Up & Down Fitment Problem in next Operation 5 Setting Problem 2 In Process Inspection 3 30
16 Boring Diameter Up & Down Fitment Problem in next Operation 6 Setting Problem 2 In Process Inspection 4 48
6 Drilling Diameter Up & Down Fitment Problem in next Operation 7 Setting Problem 3 In Process Inspection 5 105
8 Drilling Diameter Up & Down Fitment Problem in next Operation 2 Setting Problem 3 In Process Inspection 6 36
Shaft Cutting Length Up& Down No Problem
Inner Dia Fitment Problem in next Operation 5 Setting Problem 3 In Process Inspection 4 60
Outer Dia Fitment Problem in next Operation 6 Setting Problem 4 In Process Inspection 4 96
Shaft Cutting Length Up& Down No Problem In Process Inspection
Bending 5mm
STG Guide Shaft
Shaft Cutting
Facing
1 Hole Piercing
6 Hole Drilling
STG Yoke
STG Horizantal Bush
Machining
Grinding
STG Guide Shaft & Arm Welding
Arm Welding 1&2
5 2Hole Drilling
STG Threaded Pin
Machining
Dimension Up & Down Fitment Problem in next Operation 7 Setting Problem 5 In Process Inspection 3 105
Threading Fitment Problem in next Operation 6 Setting Problem 3 In Process Inspection 6 108
Shaft Cutting Length Up& Down No Problem
Shaft Cutting Length Up& Down Fitment Problem in next Operation 4 Setting Problem 2 In Process Inspection 2 16
Height Up & Down Fitment Problem in next Operation 3 Setting Problem 4 In Process Inspection 6 72
STG Dia 6 Pin
Drilling Diameter Up & Down Fitment Problem in next Operation 4 Setting Problem 2 In Process Inspection 2 16
Galvanizing Visual Fitment Problem in next Operation 2 Setting Problem 2 In Process Inspection 3 12
STG Dia 8 Pin
Drilling Diameter Up & Down Fitment Problem in next Operation 8 Setting Problem 3 In Process Inspection 3 72
Galvanizing Visual Appereance Problem 2 Setting Problem 3 In Process Inspection 4 24
Packing Material Rust Parts , Damage Parts 6 Unproper 2 In Process Inspection 1 12
Storage
OEM
6 Unproper 1 10 60
Delivery
OEM
Inspection
4 100
Machining
STG Vertical Bush Bush
Machining
Machining
Threading
STG Select Arm Bush
R
P
Action Results
POTENTIAL
(PROCESS FMEA)
STG Bracket A
STG Bracket C
STG Bracket B
STG Bracket D
STG Control Shaft
STG Gear Select Arm
STG Guide Shaft
STG Yoke
STG Horizantal Bush
STG Guide Shaft & Arm Welding
STG Threaded Pin
STG Vertical Bush Bush
STG Select Arm Bush
Action Taken
S
E
Problem in Next
Operation
Problem in Next
Operation
3 4 In Process Inspection 3 36
Problem in Next
Operation
Problem in Next
Operation
Problem in Next
Operation
Problem in Next
Operation
Appereance Problum
not accepted By OEM.
Appereance Problum
Appereance Problum
Piercing
6 Hole Peiricing
Shearing 02
10 Hole piericing
POTENTIAL
(PROCESS FMEA)
Shearing 01
Forming
Blanking
FMEA Number ___10_______________________ Part Name/ Item__SF GSL310___________
Process Responsibility___Production and QC__________________ Prepared By ___Zaffar Razzaq______________
Date (Orig) ___08-01-2008_________________
Doc # ____QC\FM\009_____________________________
R
P
N
Recommended
Actions
Date (Rev) __________________________
C
L
A
S
Potential Cause(s) /
Mechanism(s) of Failure
O
C
C
U
Current Process
Controls
Action Results
D
E
T
E
Responsibility & Target
Date
BASE PLATE
Length Up & Down
Process Function /
Requirements
Potential Failure Mode Potential Effect(s) of Failure
S
E
V
Thickness up&Down
Width Up&down
Length Up & Down
Thickness up&Down
Width Up&down
Width Up&down
Distance Up& Down
Diameter Up& Down
Distance Up& Down
Appearance
Length Up & Down
Width Up&down
Appearance
Diameter Up& Down
Distance Up& Down
Appearance
Distance Up& Down
Spot Nut M6 Hit
Spot Hook Spot
Part # ____28100 - 60 E 50______________
OEM ____Pak Suzuki_______________________________
Team _Develoment, Production, QC_____________________________________________________________________________________________
Appereance Problum
Appereance Problum
Problem in Next Operation 3 Setting Problem 3 In Process Inspection 3 27
Problem in Next Operation Setting Problem In Process Inspection 0
Problem in Next Operation 3 4 In Process Inspection 3 36
Appereance Problum
Appereance Problum
M6 Nut Welding Visual
Galvonizing Visual
SF BUSH
Diameter Up& Down
SF BALL
Distance Up& Down
Chamfering Visual
Diameter Up& Down
Hight Up & Down
Diameter Up& Down
Thickness up&Down
Forming Distance Up& Down
SF COVER BOOT
4 Hole Peiricing
Chamfering Visual
Width Up&down
Thickness up&Down
Blanking Length Up & Down
Width Up&down
Appearance
Strightness Straightness
SF HOOK
Galvonizing Visual
Width Up&down
Thickness up&Down
Hole Peiricing Diameter Up& Down
Shearing Dimention up& Down
Appereance Problum
Appereance Problum not
accepted By OEM.
Demaged parts not
accepted by OEM
6 Unproper 1 10 60
Demaged parts not
accepted by OEM
5
Improper stacking on
vahicle not filt, Rash
driving
5
Inspection
4 100
Delivery
Hight Up & Down
Distance Up& Down
Flaring Diameter Up& Down
SF LEVER
WELDING
Blanking Dimenstion up& Down
Dimenstion up& Down
Hight Up & Down
Bending Diameter Up& Down
Appearance
Diameter Up& Down
Diameter Up& Down
Turning
Dimenstion up& Down
Radius
Grinding Diameter Up& Down
Radius up&Down
Threading Threading
Bush Welding Taper Up& Down
Storage
Bending Dimenstion up& Down
Dimenstion up& Down
Ball Welding 1st Side Dimenstion up& Down
Appereance
Hight Up & Down
Paint Thickness up&Down
Packing Material
Majid Mehmood (Manager Q.C)
Mr. Rafi (Manager
Production)
Zaffar Razzaq (Asst.
Manager Q.C)
O
C
D
E
R
P
POTENTIAL
(PROCESS FMEA)
FMEA Number ___10_______________________
Date (Orig) ___08-01-2008_________________
Date (Rev) __________________________
Action Results
Action Taken
S
E
Problem in Next
Operation
Problem in Next
Operation
Problem in Next
Operation
Problem in Next
Operation
Problem in Next
Operation
Problem in Next
Operation
Appereance Problum
Appereance Problum
Appereance Problum
Part # ____28100-60E50______________
OEM ____Pak Suzuki_______________________________
Team _Develoment, Production, QC_____________________________________________________________________________________________
Spot Nut M10
Spot Nut M6 Hit
Spot
Appearance
Distance Up& Down
Diameter Up& Down
Distance Up& Down
Appearance
Appearance
Length Up & Down
Distance Up& Down
Width Up&down
Thickness up&Down
Width Up&down
Width Up&down
Distance Up& Down
Length Up & Down
Diameter Up& Down
Thickness up&Down
Width Up&down
Date
BASE PLATE
Length Up & Down
Process Function /
Requirements
S
E
V
R
P
N
Recommended
Actions
Date (Rev) __________________________
C
L
A
S
Potential Cause(s) /
Mechanism(s) of Failure
O
C
C
U
Current Process
Controls
Action Results
D
E
T
E
Process Responsibility___Production and QC__________________ Prepared By ___Zaffar Razzaq______________
Date (Orig) ___10-01-2008_________________
Doc # ____QC\FM\009_____________________________
POTENTIAL
(PROCESS FMEA)
FMEA Number ___16_______________________ Part Name/ Item__SB GSL308___________
Shearing 01
Forming
Blanking
Bending
6 Hole Peiricing
Shearing 02
Piericing
Appereance Problum
Appereance Problum
Appereance Problum
Appereance Problum
Problem in Next Operation 3 Setting Problem 4 In Process Inspection 4 48 Radius Diameter Up& Down
Thickness up&Down
Turning Dimention up& Down
Width Up&down
Galvonizing Visual
Appearance
Straightness
Width Up&down
Strightness
SB LEVER
Thickness up&Down
Width Up&down
SB COVER BOOT
4 Hole Peiricing
Chamfering Visual
Diameter Up& Down
Hight Up & Down
Diameter Up& Down
Thickness up&Down
Forming Distance Up& Down
SB BALL
Distance Up& Down
Chamfering Visual
Diameter Up& Down
SB BUSH
Galvonizing Visual
M6 Nut Welding Visual
Appereance Problum
Appereance Problum
Demaged parts not
accepted by OEM
6 Unproper 1 10 60
Demaged parts not
accepted by OEM
5
driving
5
Inspection
4 100
Packing Material
Hight Up & Down
Dimenstion up& Down
Appereance
Dimenstion up& Down
Dimenstion up& Down
Ball Welding 1st Side
Bush Welding Taper Up& Down
Storage
Bending
Dimenstion up& Down
Hight Up & Down
Appearance
Hight Up & Down
Distance Up& Down
Grinding Diameter Up& Down
BUSH & BALL WELDING
Threading Diameter Up& Down
Approved By:
Mr. Rafi (Manager
Production)
Delivery
Manager Q.C)
Prepared By: Approved By:
O
C
D
E
R
P
Date (Rev) __________________________
Action Results
Date (Orig) ___10-01-2008_________________
POTENTIAL
(PROCESS FMEA)
FMEA Number ___16_______________________
Action Taken
S
E
O
C
D
E
R
P
Problem in Next
Operation
Problem in Next
Operation
Problem in Next
Operation
Problem in Next
Operation
Problem in Next
Operation
Problem in Next
Operation
Center Drilling
Deburring
Team _ Develoment, Production, QC__________________
Cutting
Width Up&down
Diameter Up& Down
Date (Orig) ___07-01-2008_________________
Doc # ___QC\FM\009____________________
POTENTIAL
(PROCESS FMEA)
FMEA Number ___02_______________________
Prepared By ___Zaffar Razzaq______________ Process Responsibility___Production and QC_
Part Name/ Item__SHAFT ASSEMBLY PROPELLER (STP-308)___
Part # ____ 27100-79072___________________________
OEM ____ Pak Suzuki_______________________________
Chamfering
PIPE
Date (Rev) __________________________
C
L
A
S
Potential Cause(s) / Mechanism(s)
of Failure
O
C
C
U
Current Process
Controls
Action Results
D
E
T
E
Date
Length Up & Down
Process Function /
Requirements
S
E
V
R
P
N
Recommended
Actions
Thickness up&Down
Length Up & Down
Boring
TUBE YOKE
Length Up & Down
Thickness up&Down
Width Up&down
Length Up & Down
Diameter Up& Down
Turning Length Up & Down
Length Up & Down
Diameter Up& Down
Leg Facing Length Up & Down
Boring
FLANGE YOKE
Length Up & Down
Turning Length Up & Down
Pre Drilling Visual
Diameter Up& Down
Leg Facing Visual
Width Up&down
Deburring Length Up & Down
Thickness up&Down
Appereance Problum
Rust Parts , Damage
Parts
6 Unproper 2 In Process Inspection 1 12
Demaged parts not
accepted by OEM
6 Unproper 1 10 60
Demaged parts not
accepted by OEM
5
driving
5
Inspection
4 100
Approved By:
Mr. Rafi (Manager
Production)
Delivery
Manager Q.C)
Counter Distance Up& Down
Width Up&down
Drilling Length Up & Down
Thickness up&Down
WEIGHT
Hight Up & Down
Thickness up&Down
Width Up&down
Blanking Dimention up& Down
STP SHAFT ASSEMBLY
Dimenstion up& Down
Diameter Up& Down
Diameter Up& Down
Bearing Fitting YCJF
Welding
Yoke Pressing Length Up & Down
Dimenstion up& Down
Radius up&Down
Distance Up& Down
Bending & Notching Diameter Up& Down
Calking YCS Threading
Bearing Fitting YCS Diameter Up& Down
Storage
Dimenstion up& Down
Balancing Dimenstion up& Down
Calking YCJF Taper Up& Down
Appereance
Packing Material
Action Taken
S
E
O
C
D
E
R
P
Problem in Next
Operation
Problem in Next
Operation
Problem in Next
Operation
Problem in Next
Operation
Problem in Next
Operation
Problem in Next
Operation
Appereance Problum
Appereance Problum
Appereance Problum
Appereance Problum
TUBE YOKE
FLANGE YOKE
Pre drilling
Boaring Visual
Turning Hit
Spot
Appearance
Distance Up& Down
Diameter Up& Down
Distance Up& Down
Appearance
Appearance
Length Up & Down
Width Up&down
Width Up&down
Distance Up& Down
Thickness up&Down
Width Up&down
Distance Up& Down
Length Up & Down
Diameter Up& Down
Thickness up&Down
Width Up&down
Date
PIPE ASSY.
Length Up & Down
Process Function /
Requirements
S
E
V
R
P
N
Team _ Develoment, Production, QC__________________
Recommended
Actions
Date (Rev) ____________________________
C
L
A
S
Potential Cause(s) / Mechanism(s)
of Failure
O
C
C
U
Current Process
Controls
Action Results
D
E
T
E
Date (Orig) ___02-01-2008________________
Doc # ___QC\FM\009____________________
Process Responsibility___Production and QC_
Part Name/ Item__SHAFT ASSEMBLY PROPELLER (SHP)___
Part # ____ 27100-77105___________________________
OEM ____ Dewan Farooq_______________________________
POTENTIAL
(PROCESS FMEA)
FMEA Number ___01_______________________
Prepared By ___Zaffar Razzaq_____________
Cutting
Pre drilling
Boaring
Center Drilling
Deburing
Chamfering
Turning
Appereance Problum
Appereance Problum
Appereance Problum
Appereance Problum
Appereance Problum
Rust Parts , Damage
Parts
6 Unproper 2 In Process Inspection 1 12
Demaged parts not
accepted by OEM
6 Unproper 1 10 60
Demaged parts not
accepted by OEM
5
driving
5
Inspection
4 100
Counter Visual
Drilling
Packing Material
Storage
Visual
Hight Up & Down
Width Up&down
Bearing Fitting YCS Length Up & Down
Width Up&down
Thickness up&Down
Circlip YCJF Length Up & Down
Balancing Diameter Up& Down
Appearance
Diameter Up& Down
Thickness up&Down
Circlip YCS Distance Up& Down
Bearing Fitting YCJF Visual
Yoke Pressing Length Up & Down
Welding Length Up & Down
PROPELLER SHAFT ASSY.
Distance Up& Down
Bending & Notching Visual
Diameter Up& Down
WEIGHT
Deburing Visual
Approved By:
Mr. Rafi (Manager
Production)
Delivery
Manager Q.C)

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Doc # _QC\FM\009_______________________

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