6251 Failure Mode Effect and Analysis

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
PRAVIN ENGINEERING PVT LTD


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 FIELD
BS ,BKR, PK

PAGE : 02

PAGE : 02

Process
Function /
Potential Failure
Mode
Potential
Effect(s)
of Failure
S C
Requirements
Potential
Cause (s) /
Mechanism(s)
of Failure
O
c
Current
Process
Control
Prevention

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)
N-
*** EFFECT ON FIELD
R, PK

PAGE : 03
PAGE : 03


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

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

crucible.
> Furnace running
for less time

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
-

REV-01
(SIGNATURE)
*** EFFECT ON FIELD

Process
Function /
Potential
Failure
Mode
Potential
Effect(s)
of Failure
S C
Requirements
Potential
Cause (s) /
Mechanism(s)
of Failure
Current
Process
Control
Prevention

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)

REV-01
(SIGNATURE)
*** EFFECT ON FIELD
BKR, PK

PAGE : 05

Process
Function /
Potential
Failure
Mode
Potential
Effect(s) of
Failure
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 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

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 )

REV-01
(SIGNATURE)
*** EFFECT ON FIELD
BS ,BKR, PK

Process Function /
Requirements
Potential
Failure
Mode
Potential Effect(s) S
of
Failure
Potential
Cause (s) /
Mechanism(s)
of Failure
l
Current
Process
Control
Prevention
c

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

REV-01
(SIGNATURE)
>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 FIELD
KR, PK

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.
> 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 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)

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

REV-01
(SIGNATURE)
*** EFFECT ON FIELD
BKR, PK

PAGE : 08

Process
Function /
Potential
Failure
Mode
Potential
Effect(s)
of Failure
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 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
-

REV-01
(SIGNATURE)
*** EFFECT ON FIELD

6251 Failure Mode Effect and Analysis

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6251 Failure Mode Effect and Analysis

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6-A, PHASE-1, INDUSTRIAL AREA,

ADITYAPUR, JAMSHEDPUR-832 109

FMEA NUMBER : PE/ FMEA / 6251/01

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

Potential Failure Potential

- Wrong raw material

- > Not follow the Work

> Third Party

*** EFFECT ON FIELD

PRAVIN ENGINEERING PVT LTD

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

PRAVIN ENGINEERING PVT LTD

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

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

> Less baking

> Untrained person

FMEA NUMBER : PE / FMEA /6251/02

> Guide Pin/ Bush

2 > Die Preventive

> Less Temp.

2 > Temp. Controller

> PCS (F-10)

> Core jamming in

2 > Use of Parting

1 > Dry the coated

> Less cure

> Solid Core

* Poor surface finish

> Untrained person

> Extra sand sticking 2 > Removal of extra

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

*** EFFECT ON FIELD

FMEA NUMBER : PE / FMEA /6251/02

FMEA NUMBER : PE / FMEA /6251/02

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

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

FMEA NUMBER : PE / FMEA /6251/03

*>Un controlled metal

* > Impurity in molten

> Mix-up different Al. * > Casting defect

> Improper setting of

> W.I # 3.41

> In-sufficient addition

> W.I # 3.41

> Some different

> Remove all Al. chips and

Recomm- ResponsAction Results

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

*** EFFECT ON FIELD

FMEA NUMBER : PE / FMEA /6251/03

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

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

FMEA NUMBER : PE / FMEA /6251/04

* >> Porous grain

*>> Casting Defect

> Temp. Controller

> PCS (F-008)

Recomm- ResponsAction Results

> Improper setting of

> Improper setting of

> Temp. Controller

> PCS (F-008)

> In-sufficient addition

* -- --* Failure

* -- ---* Poor

-- --* Poor