ABSTRACT

With the globalization of Indian economy, India has moved from a

highly protected market to a free market economy with severe competition
from international manufacturers. Attention to the quality of product in terms
of functionality, reliability, dependability and cost has increased in several
industrial sectors. The failure rate many of mass produced products/parts has
to be confined within a few parts per million. Percentage defectives are no
longer acceptable and hence there is a need to practice tools and techniques,
which would help in Doing things right at first time. Process failure mode
and effects analysis (PFMEA) is an engineering technique used to define,
identify and eliminate known and/or potential failures, problems and errors in
the manufacturing process before they reach the customer. Therefore, PFMEA
along with other quality tools support the practice and philosophy of failure
prevention and continuous improvement, which are the key elements of any
Total Quality Management (TQM) system. This project deals with the
meaning and methodology of PFMEA with a practical study and
implementation of PFMEA system in a pump manufacturing company.

TABLEE OF CONTENTS
CHAPTER .NO

TITLE
ABSTRACT

LIST OF CONTENTS

ii

LIST OFFIGURES

2
LIST OF TABLES

PAGE.NO

INTRODUCTION TO FMEA

1.1 Failure Mode Effects Analysis

1.2 Purpose of FMEA

1.3 Define A Process

1.4 Why Do FMEAS?

1.5

History
1.6

Objectives of the FMEA

1.6.1 Design of FMEA

1.6.2PROCESS FMEA

1.6.3 System FMEA

1.7

How to FMEA

1.8

PFMEA as A Tool
1.9 Understanding the PFMEA Basics

6
7

1.10 Responsibilities of Team Leader

1.11 What Tools Are Available

To Meet Our Objective?

1.11.1 What Are Possible Outcomes?
2

10

1.12 Inputs for PFMEA

10

1.12.1 Scope

10

1.13

PFMEA Assumptions

11

1.13.1 Goals

11

1.13.2 Potential Failure Mode

11

1.14 Potential Effects

11

1.14.1 Next Operation

12

1.15 Common Failure Modes

12

1.15.1 Machining

13

1.16 Conclusion
2

13

IMPORTANCE OF FMEA IN SME

14

2.1

Introduction to SME

14

2.2

Definition of SMES

14

2.2.1 Manufacturing enterprises

14

2.2.2 Service Enterprises

14

2.3

Features of SMEs

15

2.4

Importance

of

SMEs

sector

15
In India
2.5

Conclusion

16

LITERATURE REVIEW

METHODOLOGY

17
22

4.1 The Process of the Proposed

22

4.2 PFMEA Flow Chart

23

4.3Discussion about PFMEA

4.4PFMEA Project Road Map
4.5Research Methodology
3

24
25
26

4.6Preparation for a FMEA Study

27

4.7Problem Identification

28

4.8Conclusion
5

28

PFMEA PROCESS
PFMEA Process

295.1 Steps in
29

5.2

Ranking Terms Used In PFMEA Calculations30

5.3

Sample Calculation

5.4

Best to Worst Ratings for PFMEA Calculations31

5.5

Severity Ranking

32

5.6

Occurrence Ranking

33

5.7

Detection Ranking

34

5.8

Risk Priority Number (RPN)

36

5.9

RPN as a Measure of Risk

37

30

5.10 Recommended Action andReduce

Risk of Failure Mode

37

5.10.1 Team Review

38
5.11 Conclusion
6

38

PFMEA PROCESS
6.1

Steps in PFMEA Process

6.2

Coil Forming.

6.3

Identifying the Process Failure Mode

39
39
40

In Potential Failure Mode

41

6.4

Identifying the Severity and Ranking Severity

42

6.5

Find the Potential Causes

42

6.6

Occurrence Rating For Potential

4

Causes with Team

6.7

44

Understanding the Detection of Failures If

Present or Not

45

6.8

Detection Rating and RPN Computation

46

6.9

Conclusion

47

KAIZEN FOUCS
7.1

48

Quantifying the PFMEA with Quality Rating

48

7.2

Kaizens Done Through PFMEA Project

7.3

Correlating the Present Rework with PFMEA

Project

7.4

50

Control Plan Established As an Outcome of

PFMEA Project

7.5

7.6

49

52

Revised RPN Numbers after Verifying

The Improvements Done

53

7.5.1 Average and Standard Deviation

53

7.5.2 Analysis of Variance (ANOVA) Method

53

Project Status

54

7.6.1 before Project RPN Value

55

7.6.2 After RPN Status

56

7.7

Benefits to the Organization

56

7.8

Learnings through PFMEA Project

57

7.9

Conclusion

57

CONCLUSION
REFERANCE

58
59