FINE CARBIDE TOOLS PTE.LTD.

PART NUMBER: 64x38 DESCRIPTION: SOT23- 6L 64x38 PROCESS: CUSTOMER: STAMPING POSSEHLS

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

REV. / DATE: TEAM: Lee YL (Stamping) NgCN (Stamping) PREPARED BY / DATE:

Page 1 of 2
REV.1 / 23/3/12

Lee YL 23-3-12 TAY K.W. 23-3-12

Risk Priority Number (RPN) = Severity x Occurrence x Detection

S=Severity 1 = Minor 2 to 3 = Low 4 to 6 = Moderate
Function Requirement Potential Failure Mode
Press machine column post overheat

7 to 8 = High 9 to 10 = Extreme

O = Occurrence 1 = <1 in 1.5KK 2 = <1 in 150 K 3 = 1 in 15K

4 = 1 in 2K 5 = 1 in 400 6 = 1 in 80
Potential Effect (s) of Failure
Machine jam

7 = 1 in 20 8 = 1 in 8 9 = 1 in 3
S E V C L A S S

10 = 1 in 2

D=Detection 1 = Certain 2 = Very High 3 = High

APPROVED BY / DATE: 4 = Moderate High 5 = Moderate 6 = Low

Current Process Control O C Control C Detection
Tonnage monitor

7 = Very Low 8 = Remote 9 = Difficult

D E T R P N Recommended Action (s)

10 = Almost Impossible

Potential Cause (s) of Failure

Overloading caused by smashed die

Control Prevention

Responsibility & Target completion Date

Item
Stamping of parts Stamping 7

Action Taken Completion Date

Action Results S O D E C E V C T

R P N

None Check die design

2 Set-up check by Toolmaker

14

None

Overloading due to die weight

35

None

7 Strip jam Punch breakage 7 Slug Pulling Dented parts 7 High burr Scratch housing 7 Slant terminal Inserting difficulty in Assy. C C C

Load off-centre Set-up check constrain to column post

Set-up check by Toolmaker

35

None To prepare feed through Divakar, Christopher. M.H. technique Tay. ECD: 31/12/2002

Operator skill

On job training 4

Tonnage monitor. Misfeed detector. Slug detector. Operator / IPQC check

84

Feed thru' SOP done 31/12/2002 Slug detection sensor installed 20/07/2003

42

Die clearance too much and punch penetration inadequate. Blunt punch or die / Excessive cutting clearance

Bazooka vacuum system

6 Operator / IPQC check 4 Operator / IPQC check 5 Operator / IPQC check 4 Operator / IPQC check 4 Operator / IPQC check

To install slug detection sensors on three plate 210 dies

Divakar, Christopher ECD : 20/07/2003

84

Die preventive maintenance

56

None To install PPT vision checking on line Divakar, Christopher ECD : 18/08/2003

Terminal rubbing guide 1. Preventive rail. 2. Presence of loose maintenance. 2. slug in die Bazooka vacuum system 1. Piercing punch wear. Die preventive 2. Incorrect pitch setting. maintenance 3. Inadequate cutting oil Sensor detection tolerance set too high Toolmaker to refer to SOP

70

Vision installed on line 18/08/2003

35

Pilot pulling

Wavy carrier 6

48

None

Detect presence of slug, Slug detection sensors die breakage and (Micron) stripper bolts loose

Fail to detect slug presence

Defective parts 7 C

84

None

Slug too small 7 Operator reset and run Defective parts machine without verifying the part condition. False stoppages Low productivity 4 Sensor faulty 4 Sensor cable faulty 4 Correcting dimension which is out of specification Cam adjustment Wrong adjustment Unable to get the desired dimension Operator untrained 6 Blower malfunction 7 None Misfeed length is smaller than the length that the None sensor can detect 1 None Die adjustment SOP & OJT 2 None 4 Human error 7 C Sensor gap set wrongly None On job training based on SOP DC-Centre #181

4 Operator / IPQC check 3 Toolmaker / Operator check 3

None

63

None

Toolmaker to refer to SOP

48

None

Toolmaker / Operator check

96

None

Toolmaker / Operator check

48

None

IPQC Verification 4 Pressure sensor 1 Misfeed pilot 2 1 14 None 7 None 3 72 None

Suck slug from die yoke Vacuum system

No vacuum

Slug pulling causing defective parts

Detect material misfeed and missing profile

Misfeed detection sensors

Fail to detect material misfeed Strip jam in die 7

PROC-01-0019 / F02-03

FINE CARBIDE TOOLS PTE.LTD.

PART NUMBER: 64x38 DESCRIPTION: SOT23- 6L 64x38 PROCESS: CUSTOMER: STAMPING POSSEHLS

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

REV. / DATE: TEAM: Lee YL (Stamping) NgCN (Stamping) PREPARED BY / DATE:

Page 2 of 2
REV.1 / 23/3/12

Lee YL 23-3-12 TAY K.W. 23-3-12

Risk Priority Number (RPN) = Severity x Occurrence x Detection

S=Severity 1 = Minor 2 to 3 = Low 4 to 6 = Moderate
Function Requirement Potential Failure Mode
Fail to detect missing profile

7 to 8 = High 9 to 10 = Extreme

O = Occurrence 1 = <1 in 1.5KK 2 = <1 in 150 K 3 = 1 in 15K

4 = 1 in 2K 5 = 1 in 400 6 = 1 in 80
Potential Effect (s) of Failure
Causing problem to subsequent processes (eg. forming, assy) False stoppages

7 = 1 in 20 8 = 1 in 8 9 = 1 in 3
S E V C L A S S

10 = 1 in 2

D=Detection 1 = Certain 2 = Very High 3 = High

APPROVED BY / DATE: 4 = Moderate High 5 = Moderate 6 = Low

Current Process Control O C Control C Detection
Operator / IPQC check 1 Operator check 6 42 None

7 = Very Low 8 = Remote 9 = Difficult

D E T R P N Recommended Action (s)

10 = Almost Impossible

Potential Cause (s) of Failure

Control Prevention

Responsibility & Target completion Date

Item
7

Action Taken Completion Date

Action Results S O D E C E V C T

R P N

Set the wrong parameter Toolmaker to verify with on the misfeed detection the process specification device. Dirt accumulate on sensor head

Fail to count as pre-set

None Calibrate the sensor during die set-up

5 Toolmaker / Operator check

40

None

Sensor amplifier not calibrated (applies to Keyence sensor)

80

None

4 Slot missing No vacuum defective parts/ 4

Sensor aperture size too Toolmaker to verify with big the process specification

Operator 1 Toolmaker / Operator check 5 20 None

Slot " die insert bell To check the tool mouth" cause slug jump condition for any wear and tear before production To monitor and install suction/bazooka

20

None

4
Not spotted by the operator during stamping

Toolmaker / Operator check

20

None

To conduct 100% visual checking on each reel

None

PROC-01-0019 / F02-03