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6-A, PHASE-1, INDUSTRIAL AREA,

ADITYAPUR, JAMSHEDPUR-832 109


POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)
ITEM : PIPE, AIR TRANSFER - 5336251/01
PROESS RESPONSIBILITY : APP, OPS, BBS, BKR, PK
MODEL YEAR(s)/VEHICLE(s) :
KEY DATE :

FMEA NUMBER : PE/ FMEA / 6251/01


PAGE : 01OF 9
PREPARED BY : O. P. SINGH
FMEA DATE (Org.)
: 20.05.2014
DATE (REV. 01)
:

CORE TEAM : APP, OPS, KBR, BBS, PK


Process
Function /

Potential Failure Potential


Mode
Effect(s)
of Failure

Requirements

Potential
Cause (s) /
Mechanism(s)
of Failure

e
Wrong Raw
material
received from
Al. alloy- supplier .
50016 Receipt
& Storage

Failure during

(01)

- Wrong raw material


supply from supplier.

v
**
---

> Improper
Verification

To
receipt & store
the Raw
Material as per
identification &
procedure.

Improper
storage of raw
material.

Wrong raw

material issue
**
*** - - -

Current
Process
Control
Prevention

Current
Process
Control
Detection

c
l

verification
***
--*>> Casting Defect
** Failure
*** Poor
Performance

- > Not follow the Work


Instruction

s-

--

Lack of Identification
Mark(colour code &
batch no.) on raw
material.
Mixed up
different alloy.

1 Specification /
requirement
clearly
mentioned in /
c with Purchase Order
and
Indent.

Supplier Invoice.
Supplier T.C.
Raw Material
Verification.
(Batch wise)
Indent.

> Third Party


Spectro Report

2 Separate rack or
Stock Register for
for different
Al. alloy
r location
raw material with tag &
colour mark.

D R Recomm- Responsended
ibility
Action(s)
& Target
Completion
e P
Date
4 32

Action Results
Action
Taken

4 32

4 64

P
t

N
e

S O D R

s
FORMAT NO. PE-F-QS-FMEA/PROC. - 021 *
REV-01

(SIGNATURE)
* EFFECT ON NEXT OPERATION

** EFFECT ON ASSEMBLY

*** EFFECT ON FIELD

PRAVIN ENGINEERING PVT LTD


6-A, PHASE-1, INDUSTRIAL AREA,
ADITYAPUR, JAMSHEDPUR-832 109

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

PRAVIN ENGINEERING PVT LTD


POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)


ITEM : PIPE, AIR TRANSFER - 5336251

Process
Function /

Potential
Failure
Mode

Potential
Effect(s)
of Failure

CORE TEAM : APP, OPS, BBS ,BKR, PK

S C

Requirements

Potential
Cause (s) /
Mechanism(s)
of Failure

l
(02)
Shell
Core Making

> Improper
cleaning of
parting line.

To manufacture
the shell core to
enable as per given > Parting line
Mismatch
shape.

> Less baking


of core.

Current
Process
Control
Prevention

Current
Process
Control
Detection

* Unwanted Projection 5
or Groove "V" form in
parting line
** Leakage
*** ---

* Roughness or Groove 5
"V" form in parting line.
**
Leakage
*** -----

> Untrained person

2 > Training

FMEA NUMBER : PE / FMEA /6251/02


FMEA DATE (Org.) : 20.05.2014
PAGE : 02
D R Recomm- ResponsAction Results
e
ended
ibility
Action S O D R
t
Action(s)
& Target Taken
e P
Completion
c
Date

e P

> Visual
Inspection

70

t N
c

* Rough surface
& Blow hole

> Guide Pin/ Bush


of Shell Core die
worn out.

2 > Die Preventive


Maintenance

> Visual
Inspection

70

> Less Temp.

2 > Temp. Controller


>W.I #3.33
(for Shell Core)

> PCS (F-10)


>Visual
Inspection

32

> Core jamming in


the die
>
Excess temp.
> Excess
cure
time. present
>
Moisture
in coated sand

2 > Use of Parting


Paste
> Temp. controller
> W.I # 3.36

> Visual
Inspection
PCS (F-10)
> Visual

56

1 > Dry the coated


sand before use at
rainy season.

> Visual
Inspection

56

3 > Training

> Visual
Inspection

63

> Visual
Inspection

70

> Less cure

time.

** ---> Excess
baking of core

* Core Break
** --*** ----

> Solid Core

* Blow hole
** ---*** ----

> Improper
coating

* Poor surface finish


(inner)
** --*** ---

> Untrained person

* Sand inclusion
** ---*** ---

> Extra sand sticking 2 > Removal of extra


on the shell core.
sand particles from
shell core.

FORMAT NO. PE-F-QS-FMEA/PROC. - 021 *


REV-01

(SIGNATURE)
* EFFECT ON NEXT OPERATION

** EFFECT ON ASSEMBLY

*** EFFECT ON FIELD

BS ,BKR, PK

FMEA NUMBER : PE / FMEA /6251/02


PAGE : 02

FMEA NUMBER : PE / FMEA /6251/02


PAGE : 02

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)


ITEM : PIPE, AIR TRANSFER - 5336251

Process
Function /

Potential Failure
Mode

Potential
Effect(s)
of Failure

CORE TEAM : APP, OPS, BBS ,BKR, PK

S C

Requirements

Potential
Cause (s) /
Mechanism(s)
of Failure

O
c

Current
Process
Control
Prevention

FMEA NUMBER : PE / FMEA /6251/03


FMEA DATE (Org.)
: 20.05.2014
PAGE : 03
Current
Process
Control
Detection

R
P

e l
t
(03)
> Low/ High molten
Melting of Al.alloy metal temp.
To achieve
molten aluminium
metal free from
dross & within
required temp.
> Improper
Purification (dross)

*>Un controlled metal


temp.
** Casting
defect
*** ----

* > Impurity in molten


metal.
** Casting defect
*** ----

> Mix-up different Al. * > Casting defect


alloy.
> Improper
mechanical
property
**
Leakage /
failure
*** Leakage /
failure

> Improper setting of


crucible.
> Furnace
running for less /
excess time

> W.I # 3.41


( for melting furnace.)

>Temp. indicator
& Controller

> In-sufficient addition


of foundry chemicals
(Al.
Cover Flux)

> W.I # 3.41


( for melting furnace.)

> Some different


alloy left over in
crucible before start
initial melting
> Ingot
or runner /
riser of
different alloy mixed up
during melting.

> Remove all Al. chips and


> W.I. # 3.41
clean crucible before charge
in furnance
> Visual
>
Provide different colour bins
(places) for different alloy

Recomm- ResponsAction Results


ended ibility
Action S O D R
Action(s) & Target
Taken
Completion
P
Date

64

N
-

v-

> Visual
Inspection

64

-c -

64

> Training

FORMAT NO. PE-F-QS-FMEA/PROC. - 021


REV-01

(SIGNATURE)
* EFFECT ON NEXT OPERATION

** EFFECT ON ASSEMBLY

N-

*** EFFECT ON FIELD

R, PK

FMEA NUMBER : PE / FMEA /6251/03


PAGE : 03

PAGE : 03

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)


ITEM : PIPE, AIR TRANSFER - 5336251

CORE TEAM : APP, OPS, BBS ,BKR, PK

FMEA NUMBER : PE / FMEA /6251/04


FMEA DATE (Org.)
: 20.05.2014
PAGE : 04

Process
Function /

Potential
Failure
Mode

Potential
Effect(s)
of Failure

S C

Requirements

Potential
Cause (s) /
Mechanism(s)
of Failure

Current
Process Control
Prevention
c

Current
Process
Control
Detection

e l
(04)
> Low molten
Preparation of metal temp.
Al.alloy
To achieve molten
aluminium metal
free from dross &
within specified
temp.
> High molten
metal temp.

* > In-complete
>> Porous grain
>> Metal jointing
** Poor Appearance
*** ----

* >> Porosity
>> Crack
>> Blow hole
**
Leakage
*** Leakage

> Improper
degassing

* >> Porous grain


>> blow hole
**Leakage / failure
*** Leakage / failure

8 -

> Improper
Verification

*>> Casting Defect


** Failure
*** Poor Performance

> Temp. Controller


( Holding
Furnance)

> PCS (F-008)

D R
e
t
e P
c
4

N
64

Recomm- ResponsAction Results


ended ibility
Action S O D R
Action(s)
& Target Taken
Completion
Date

e P

> Improper setting of


crucible.
> Furnace running
for less time

> Improper setting of


crucible.
> Furnace running
for excess time

> Temp. Controller


( Holding
Furnance)

> PCS (F-008)

64

> In-sufficient addition


of foundry chemicals
( Degassing with
tablet, Al. Cover Flux &
Innoculent tablet)

> W.I. # 3.2.A


( for Molten metal)
> Operator
awareness

> Visual
Inspection

64

> Not follow the Work


Instruction

> Physical
Property Log
Book.

32

v c

t N

c
-

FORMAT NO. PE-F-QS-FMEA/PROC. - 021


REV-01

(SIGNATURE)
* EFFECT ON NEXT OPERATION

** EFFECT ON ASSEMBLY

*** EFFECT ON FIELD

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)


ITEM : PIPE, AIR TRANSFER - 5336251

Process
Function /

Potential
Failure
Mode

Potential
Effect(s)
of Failure

CORE TEAM : APP, OPS, BBS ,BKR, PK

S C

Requirements

Potential
Cause (s) /
Mechanism(s)
of Failure

Current
Process
Control
Prevention

FMEA NUMBER : PE / FMEA /6251/05


FMEA DATE (Org.) : 20.05.2014
PAGE : 05

Current
Process
Control
Detection

c
(05)
> Blow hole in
Gravity die
casting
casting
To achieve
casting as
desired shape.

* --** Failure /
Leakage
*** Poor
Performance

e l
8

- > High molten metal


temp.
> Improper degassing
> Mix - up
material

Action Results
D R RecommResponse
ended ibility
Action S O D R
t
Action(s)
& Target Taken
e
Completion
c P
Date

e P

2 > Holding Furnance

> PCS (F-008)

64

e-

c-

96

> Training

> Visual

c t N

Inspection
> Improper grain
structure

* --** --*** Failure

- > Low molten metal


temp.

2 > Holding Furnance > > PCS (F-008)


Provide different
colour separate bins
for different alloy.
2 > W.I # 3.2( for molten > Visual Inspection
metal.)
(every one hr.
interval)

64

96

- > Die mismatch


( guide pin / bush of
G.D.C die worn out )
> Im-proper core

24

3 > W.I. # 3.3( for die


refractory coating)

> Visual Inspection

63

> Improper air vent


cleaning

> W.I. # 3.3( for die


refractory coating)

> Visual Inspection

63

> High molten metal


temp.

> Holding Furnance

> PCS (F-008)

> Un-uniform die coat


spray.

> Work Instruction for


die refractory coating

> Visual Inspection

> Improper cleaning of


Die coat from die.

> Training

> Visual Inspection

7 63

> Improper purifying

> Dimension not


as per
requirement.

* ---** Failure
*** ----

> Poor surface


finish

* --** ---*** Poor


Appearance

- > Un-uniformed die


coat coating

> Shrinkage /
crack in casting

--** --*** Poor


Appearance

> Invisible Product * Part No.


Identification
Ingraving
** ---*** Customer Unhappy

3 -

> Die Preventive


Maintenance
>Proper core
sitting area

> FPA (F-15)

FORMAT NO. PE-F-QS-FMEA/PROC. - 021


REV-01

(SIGNATURE)
* EFFECT ON NEXT OPERATION

** EFFECT ON ASSEMBLY

*** EFFECT ON FIELD

BKR, PK

FMEA NUMBER : PE / FMEA /6251/05


PAGE : 05

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)


ITEM : PIPE, AIR TRANSFER - 5336251

Process
Function /

Potential
Failure
Mode

Potential
Effect(s) of
Failure

CORE TEAM : APP, OPS, BBS ,BKR, PK

S C

Requirements

Potential
Cause (s) /
Mechanism(s)
of Failure

e l
(06)
Cutting of
Runner/Riser
To achieve cast
component free
from runner & riser.

> Excess
cutting

*Scrapped
** --*** ---

Current
Process
Control
Prevention

c
> Improper blade
setting.

FMEA NUMBER : PE / FMEA /6251/06


FMEA DATE (Org.) : 20.05.2014
PAGE: 06

Current Process D R
Control
e
Detection
t
e P
c

2 >Work Instruction
> Viaual Inspection
for Bandsaw cutting

70

Recomm- ResponsAction Results


ended
ibility
Action S O D R
Action(s)
& Target Taken
Completion
P
Date
-

c e

N
c
t

(07)
Fettling
To achieve cast
component free
from burrs, sharp
edge & unwanted
material.
(Parting line)

> Improper
fettling

* Damage
Rubber hose
** Damage Subparts
*** Leakage

> Unskilled Operator 2 > Work Instruction


for Fettling

> Visual Inspection

70

(08)

> Improper
porosity
sealing.

* Leakage
**
Leakage

> Improper Temp. of


Hot water.
> Improper
Vacuum Pressure at
Auto clave.
> Improper
Cycle Time

> Temp. Controller


> Leak Proof Test.

24

Vacuum
Impregnation
To get porosity
sealed cast
component.

*** Leakage

2 > Daily Checklist


For V.I
>
W.I.# 3.13 (For V.I )

FORMAT NO. PE-F-QS-FMEA/PROC. - 021


REV-01

(SIGNATURE)
* EFFECT ON NEXT OPERATION

** EFFECT ON ASSEMBLY

*** EFFECT ON FIELD

BS ,BKR, PK

FMEA NUMBER : PE / FMEA /6251/06

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)


ITEM : PIPE, AIR TRANSFER - 5336251

Process Function /
Requirements

Potential
Failure
Mode

CORE TEAM : APP, OPS, BBS ,BKR, PK

Potential Effect(s) S
of
Failure

Potential
Cause (s) /
Mechanism(s)
of Failure
l

Current
Process
Control
Prevention
c

FMEA NUMBER : PE / FMEA /6251/07


FMEA DATE (Org.) : 20.05.2014
PAGE: 07
Current
Process
Control
Detection

e
(09)
Leak Proof Testing

> Improper Leak


Proof Test.
To

get Leak Proof cast


component.
(10)

> Machining
Machining (CNC) dimn. not as per
specification
To achieve the
Machining dimension as
per specification.
>Rough surface

(11)

Deburring > Improper


Deburring.
To achieve the facing
surface of component
free from burrs & sharp
edge.

>On job Training


> PCS (F-11)
> CNC Programme > PDS
Locking
> Cpk
> Tool Change
(major)
Frequency.

48

c-

>Tool blunt

>Tool Change
Frequency
>CNC Programme
Locking

> Visual
Inspection

56

> In- plant training

> Visual
Inspection

56

* Damage the rubber


pad
**
Fitment problem
*** Poor
Appearance

> Unskilled
Operator

24

FORMAT NO. PE-F-QS-FMEA/PROC. - 021


REV-01

(SIGNATURE)
* EFFECT ON NEXT OPERATION

>Loose clamping
>CNC
Programme error
>
Tool blunt

Appearance
*** ----

> CNC
Programme error
(RPM, FEED)

> Leak Proof Test


Record

* ---

** Poor

> Pressure Gauge


Calibration

Completio
n Date

* ---

Recomm- ResponsiAction Results


ended
bility
Action S O D R
Action(s) & Target Taken

* Leakage
** Leakage
***
Leakage

**
Fitment Problem
*** ---

> Improper air


pressure

D R
e
t
e P
c

** EFFECT ON ASSEMBLY

*** EFFECT ON FIELD

KR, PK

FMEA NUMBER : PE / FMEA /6251/07

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)


ITEM : PIPE, AIR TRANSFER - 5336251

Process Function /
Requirements

Potential Potential Effect(s) S


Failure
of
Mode
Failure

(12)
> Improper
High Pressure Cleaning
Cleaning
To achieve the
cast component free from
dust, burrs, oil particle

* Failure during
Millipore test
** ---

(13)

* Failure during P.D.I


**
Fitment problem
*** Poor
performance

Final Inspection / Pre


Dispatch Inspection
To verify the parts as per
customer requirement.

CORE TEAM : APP, OPS, BBS ,BKR, PK

> Improper
Inspection

***
Damage equipment

Potential
Cause (s) /
Mechanism(s)
of Failure

O
c

> Improper solvent


temp.
>
Less air pressure.

> Un-calibrated
Instrument
> Untrained & Un-known
Inspector

Current
Process
Control
Prevention

FMEA NUMBER : PE / FMEA /6251/08


FMEA DATE (Org) : 20.05.2014
PAGE : 08
Current
Process
Control
Detection

D
e
t

>W.I.# 3.12 ( for


H.P.C)
>Daily Checklist
(F-51)

> Temp. controller.


>
Millipore Test
20 mg max.

>Calibration of
Instrument
> Training &
Display

> PDI Report


(F-6)
> Quality Plan
(F-37)

Recomm- ResponsAction Results


ibility
ended
Action S O D R
&
Action(s)
Taken
e P
Target
P
Completion
e
e
c
Date
48

c-

t
c

48

> Log
Book for F.I

FORMAT NO. PE-F-QS-FMEA/PROC. - 021


REV-01

(SIGNATURE)
* EFFECT ON NEXT OPERATION

** EFFECT ON ASSEMBLY

*** EFFECT ON FIELD

BKR, PK

FMEA NUMBER : PE / FMEA /6251/08


PAGE : 08

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)


ITEM : PIPE, AIR TRANSFER - 5336251

Process
Function /

Potential
Failure
Mode

Potential
Effect(s)
of Failure

CORE TEAM : APP, OPS, BBS ,BKR, PK

C
e

Requirements

Potential
Cause (s) /
Mechanism(s)
of Failure

l
(14)
Packaging
To get cast
component
packed as per
packaging
standard.

(15)
Storage

> Missing of bar * --code sticker


** No
Tracking Application
***
--> Improper
* Damage / scratch
packaging
** Poor
Appearance
*** ---

> Ignorance of
packaging pattern
>Negligence of
packaging operator

> Ignorance of
packaging standard.
Such as
>Absence of partition &
Layer sheets
> improper
sealing

> Improper
Tagging

* Wrong material
storage
** Reject
*** ----

> Wrong
Quantity

* Wrong Quantity in
stock.
**
Quantity short
*** ---

> Improper
storage

* Damage
** Reject
*** ---

To
store the finish
component with
proper
> Improper
identification tag
Identification
& quantity in
proper place

* Wrong despatch
** Reject
*** ----

(16)
> Wrong
* Will pass though
Dispatch
material supply receiving inspection
The component
to be dispatch as
** ---per invoice
***
---

O Current
Process
Control
Prevention
c
2

Current
Process
Control
Detection

FMEA NUMBER : PE / FMEA /6251/09


FMEA DATE (Org) : 20.05.2014
PAGE : 09
D R
e
t
e P
c

Action Results
Recomm- Responsended
ibility
Action S O D R
Action(s)
& Target Taken
Completion
P
Date

e
e
c
N
v

> Packaging
pattern of
component
> On job
Training
2 > Packaging
Standard of
component

> Visual
Inspection

7 56

> Visual
Inspection

48

> Untrained operator


> Tagging not done
immediately after
sealing.

1 > Training
> Packaging
Standard of
component

> Visual
Inspection

42

> Untrained operator


> Ignorance of
packaging standard

1 > Training
> Packaging
Standard of
component

> Visual
Inspection

42

> Improper preservation

1 >W.I. # 3.18
> Visual
(for storage
Inspection
and preservation)
> PreDispatch
Inspection

36

> Mixed up different


component

1 > Separate
location for
different
components.

> Visual
Inspection
> PreDispatch
Inspection

36

> Improper Identification

1 > PDI Report


>
Packing Slip
> STU Tag

> Visual
Inspection

48

c
-

t
-

FORMAT NO. PE-F-QS-FMEA/PROC. - 021


REV-01

(SIGNATURE)
* EFFECT ON NEXT OPERATION

** EFFECT ON ASSEMBLY

*** EFFECT ON FIELD