Starter

FAILURE MODE AND EFFECTS ANALYSIS

Item: Relay LR1-D25322IR Responsibility: C & S Noida

Model: LR1-D25322IR Prepared by: Manmohan Singh
Core Team: Mr. Pramod Wadhwa, Manmohan Singh,Rajesh Bhargava, Vineet Rawat

Current
Process Step Potential Cause(s)/
S# Potential Failure Mode Potential Effect(s) of Failure Sev. Occur Process Detection RPN Recommended Action(s)
/Function Mechanism(s) of Failure
Controls

Fix contact Fixture pressure for fixing Contacts not properly seat in
6 Less pneumatic pressure 7 0
Assembly contact with base the position

1
Relay Base broken due to Excess Pneumatic
6 6 108
excess pressure pressure

8 96

8
Thermall Element Fitment of Thermal element alignment of element
2 6 loose fitment of element 3
assembly with base disturbed
8 144

Non Allingement of thermal

Alingement of Early / delay tripping of relay
3 element with differential 6 Manual operation 5 8 240
thermal element (Partial malfunctioning)
cover

Reverse Assembly of No continuity in aux contact

contact with carrier (Partial Malfunctioning)
Mechanism
3
Assembly

Relay mixing 2 verification with rating label 6 96 _

Relay and contactor not as Operator not trained /

Relay and Contactor
4 per rating chart (mix up of Operational failure 8 untrained operator (used
wiring
multiple rating) to perform the task in 2 on job training 6 96 _
case of high
absenteeism)

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loose fitment of relay random verification by Design review of terminal screw

operational malfunctioning 8 less torque 4 7 224
terminals with contactor operator clamp of agro

NO block & Control Screw loose / Torque not

5 Loose Wiring Sparking & temp rise 8 3 Visual inspection 8 192 Verification of cutting wire insulation
wiring proper

Visual inspection not

performed as per IC Customer complaints 7 Inspector negligence 1 100% testing 7 49 _
TC/OD/QA/F1/071

no continuity of earth screw

shock hazard 8 continuity failure 2 100% testing 7 112 _
wrt mounting screw

Functional performance test regular monitoring and conseling

6 Final Testing 8 5 100% testing 5 200
(not tested) with QA inspector

Productivity loss / on time

6 _
delivery failure
Fitment failure of cover with mismatching of mounting
base screw with base
Performance test cannot be
5 10 100% testing 2 100 _
done

operator negligence 3 5 105 _

verification and stamping by 1. Printing design shall be made
wrong product supply to operator on product label non editable.
Wrong Packing label 7
customer Printing design error of (green Mark) / Sampling 2.
4 inspection 5 140
packing label printing label shall be approve by
supervisor and records shall be
maintain

CE marking on side label

require clarity from R&D _
but not on packing label

7 Packing Rust formation in stepler pin galvanized steel pins are Brass pins are to be incorporated in
aesthetic concern 6 4 Receipt inspection 8 192
of carton box used place of galvanized pins

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Paper grade standardized and

White color variation in Different grade of paper
6 5 Receipt inspection 8 240 approve limit sample given to the
packing boxes used in making carton
suppliers

verification and stamping by

Partial inconvenience to operator on product label
Wrong product side label 3 Operator negligence 3 7 63 _
customer (green Mark) / Sampling
inspection

Transportation from Dent and scratch on powder customer complaint / packed in poly bag and Packaging shall be improve to
8 7 packing 6 7 294
supplier to TC surface productivity loss news paper bubble type

Transportation of
packaging in poly bags (01 pcs in
contactors from C60 accumulation of dust and contactors are kept in the
8 Humming / Noise 8 open packaing in crate 8 7 448 one polybag), mouth shall be seal
to C58 & storage at dirt in contactor open crates
by cello tape
starter line

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FMEA number: R&D/FMEA/Starter/004

Page : 1 of 1
FMEA Date (Orig): 14/3/2017 Rev: 0

Action Results
Responsibility and Target
Completion Date Actions Taken Sev Occ Det RPN

6 3 6 108

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4/1/2017, R&D

Sudhanshu

Mr. Rajesh Bhargava

Mr. Prateek , 10/2/17

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Mr. Prateek, 100%

supplies with
standardized paper
grade from 1st March
2017

Mr. Prateek , 01/2/17

Mr. Vinod Mishra ,

28/1/17

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