OP- 10

Incoming
OPRough Finish
100
150
200

50
0

- 20material
Incoming
Process Intent
Function

OD
Item
Rough Machining first setup
material storage (Bell Side)
& Inspection

Machining
Rough Machining first setup (Bell Side)

51010
storage
first
Finish OD Turning & Gear DEBURRING
side boring

10a
&
Op
Turning
Finish OD Turning & Gear side boring

2020
Finish OD Turning & Gear side boring

setup
30
Finish OD Turning & Gear side boring

-&2020
Gear
Finish OD Turning & Gear side boring

(Bell
Inspection
Finish
Finish OD Turning & Gear side boring

side
2020
Finish OD Turning & Gear side boring

Side)
Op
OD
boring
DEBURRING

2020a
Finish OD Turning & bellside boring

-Turning
Finish OD Turning & bellside boring

40Cross
Finish OD Turning & bellside boring
30 &hole
bellside
Finish OD Turning & bellside boring
Cross hole boring, spherical & Back face.
30boring,
boring
- 40
OPspherical

DEBURRING
45

2D Barcode Matrix Laser marking

Drilling &&Scanning
Tapping
40a
Drilling
50Revision
&50

Multi Gauging
Revision&
60
70

WASHING OILING &Inspection

PACKING
80
Back
90

FINAl
VisualINSPECTION
STORAGE/ DISPATCH
100%
100
Change
0Tapping
Number:
face. Note
: 16.12.2018

Date :16.12.2018
Siddhesh Phalke
MACHINING ALL PROCESS

SUPPLIER : KRANTI INDUSTRIES LTD.

Prashant Shetty, R.Gunjal,Sudhir Patil,
MACHINED DIFFERENTIAL, 3DU 1081746-00-B3

Doc. No. :FMEA/1081746-00-B Rev. No. : 00 Rev.

PREPARED BY FMEA DATE (ORIG) : 05/12/2018
FAILURE MODE AND EFFECTS ANALYSIS HOUSING

Siddhesh,Thakur,Karna,Aman,Ranjeet PROCESS FMEA

PROCESS RESPONSIBILITY : PRODUCTION HEAD KEY DATE

 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Incoming material storage & Inspection

Quantity Quantity verification during

verification Material shortage Shortage to inhouse production 3 counting error 3 Tagging System unloading 7 63

Material checmical Next operation - Affected Supplier report T.C.& Material - Properties
Properties properties Subsquent Process - Nil 8 Inadequate control at 2 Third party quarterly ( Mechanical & Chemical ) 4
( Mechanical & Out of Customer end - Field Failure supplier Material T.C/ 64
inspection
Chemical ) Specification User End - Nil third party inspection report

Next operation - Affected Incoming Inspection

As cast Out Of Subsquent Pocess - Nil 3 Inadequate control at 2 Inward inspection report/ Supplier PDIR 6
dimensions Specification Customer End - Dissatisfaction supplier foundry PDIR 36
User End - Nil

Next operation - Machining

operation Affected
Inadequate control at Supplier audit & process Incoming Inspection
Excess Hardness Subsquent Process - Nil 8
supplier
2
control at supplier as per IIR
5 80
Incoming Customer End - Field failure
material User End - Nil
5 storage & Hardness
Inspection
Next operation - Nil
Subsquent Process - Nil 8 Inadequate control at 2 Supplier audit & process Incoming Inspection 4
Less Hardness Customer End - Field Failure supplier control at supplier as per IIR 64
User End - Nil

Next operation - Fall out at initial

station Process control at
Die code Mark Subsquent Process - Nil 4 Inadequate control at 3 supplier & visual 7
Tracebability Missing Customer End - Identification supplier 100% visual inspection, 84
inspection
problem
User End - Nil

Poor casting
surface, Improper Next operation - Machining
fettling, Core operation Affected Inadequate control at Process control at Incoming Inspection
Apperance Mismatch, lack of Subsquent Process - Nil 4 supplier 2 supplier & visual as per IIR 6 48
material, crack, Customer End -Dissatisfaction inspection
blow holes User End - Nil
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

OP- 10 Rough Machining first setup (Bell Side)

Standard Operating 4
Improper setting 2 Procedure 40
Next operation - Will affect
Subsquent Process - Nil
Thickness oversize Customer End - Fitment problem 5 Set Up Approval , FPIR
User End - Nil Insert worn out 4 Tool Change Frequency 4 80

ROUGH FLANGE
THICKNESS 12.00 Standard Operating
± 0.2 Improper setting 2 Procedure 4 40

Next operation - Will affect

Thickness under Subsquent Process - Nil Standard Operating
size Customer End -Fitment problem 5 Part loading error 4 Procedure Set Up Approval , FPIR 4 80
User End - Nil

Insert worn out 5 Tool Change Frequency 3 75

Rough
Machining
10 first setup
Next operation - Component Standard Operating
(Bell Side) Improper setting 2 Procedure 5 50
clamping issue
Subsquent process - Nil 5 Set Up Approval , FPIR
Customer End - Fitment problem
Outer dia User End - Nil Insert worn out 2 Tool Change Frequency 5 40
Outer Dia.156.0 ±
0.3 oversize / under
size Next operation - Component Standard Operating
clamping issue Improper setting 2 Procedure 5 50
Subsquent Process - Nil
Customer End -Fitment Problem 5 Set Up Approval , FPIR
Insert worn out 2 Tool Change Frequency 5 50
User End
Next - Nil - Machining
operation
operation Affected Tool wear out Standard Operating
Improper setting 2 Procedure 5 50
Over size Subsquent Process - Nil 5 Set Up Approval , FPIR
Rough Dia.46.04 Customer End - Fitment problem Insert worn out 2 Tool Change Frequency 5 40
±0.1
(For Dia. Next operation
User End - Nil - Machining
45.015) operation Affected less margine Standard Operating
Subsquent Process - Nil Improper setting 2 Procedure 5 50
Undersize Customer End -Fitment 5 Set Up Approval , FPIR
problem User Insert worn out 2 Tool Change Frequency 5 50
End - Nil
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Process control at
Next operation - Machining supplier & visual Incoming Inspection
Excess Material 2 as per IIR 5 40
operation Affected Tool wear out inspection
Subsquent Process -
Radius oversize Nil Customer End - Fitment 4
Insert worn out 2 Tool Change Frequency 5 40
problem User Set Up Approval , FPIR
RADIUS OF DIA End - Nil Standard Operating
118,RADIUS Improper setting 2 Procedure 5 40
2.5,RADIUS Process control at
10,RADIUS 80.00 Next operation - Machining Incoming Inspection
Excess Material 2 supplier & visual as per IIR 5 40
operation Affected less allowance inspection
Subsquent Process - Nil
Radius undersize Customer End -Fitment 4 Insert worn out 2 Tool Change Frequency 5 50
problem User Set Up Approval , FPIR
End - Nil Standard Operating
Improper setting 2 Procedure 5 50

Next operation - Machining Process control at Incoming Inspection

operation Affected Tool wear out Excess Material 2 supplier & visual as per IIR 5 40
inspection
Distance oversize Subsquent Process - Nil 4 Insert worn out 2 Tool Change Frequency 5 40
Customer End - Fitment problem
Set Up Approval , FPIR
Standard Operating
Rough Rough User End - Nil Improper setting 2 Procedure 5 40
Machining Dist .65.40±0.3,7
10 first setup Process control at
5.6.+/-0.2, Next operation - Machining Incoming Inspection
(Bell Side) Excess Material 2 supplier & visual as per IIR 5 50
operation Affected less stock inspection
Subsquent Process - Nil
Distance undersize Customer End -Fitment problem 5 Insert worn out 2 Tool Change Frequency 5 50
Set Up Approval , FPIR
User End - Nil Standard Operating
Improper setting 2 Procedure 5 50

Process control at Incoming Inspection

Next operation - Less clamping area Excess Material 2 supplier & visual as per IIR 5 40
Subsquent inspection
Chamfer oversize Process - Nil Customer End 4
- Dissatisfaction Insert worn out 2 Tool Change Frequency 5 40
User End - Nil Set Up Approval , FPIR
CHAMFER OF Standard Operating
FLANGE 1.0 ±0.3 Improper setting 2 Procedure 5 40
X45°±5°
Next operation - Clamping problem
in next process
Chamfer undersize Subsquent Process - Nil 5 Improper setting 2 Program Control Set Up Approval , FPIR 5 50
Customer End -Dissatisfaction
User End - Nil
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Process control at Incoming Inspection

Excess Material 2 supplier & visual as per IIR 5 40
Next operation - Nil inspection
Surface angle Subsquent Process - Nil
oversize Customer End - Dissatisfaction 4
Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
User End - Nil
ANGLE 2°, Standard Operating
ANGLE 19° Improper setting 2 Procedure 5 40

Next operation - Nil

Surface angle Subsquent Process - Nil Standard Operating
undersize Customer End -Dissatisfaction Improper setting 2 Procedure SETUP , FPIR 5 50
User End - Nil

Process control at Incoming Inspection

Excess Material 2 supplier & visual as per IIR 5 40
Next operation - Machining inspection
operation Affected
Casting Ref Subsquent Process - Nil
Oversize 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
Customer End - Fitment problem
User End - Nil
Standard Operating
Improper setting 2 Procedure SETUP , FPIR 5 40
CAST REF
Process control at
Next operation - Machining supplier & visual Incoming Inspection
Less material allowance 2 as per IIR 5 50
operation Affected less margine inspection
Casting Ref Subsquent Process - Nil
undersize Customer End -Fitment 5
Insert worn out 2 Tool Change Frequency 5 50
problem User SETUP , FPIR
End - Nil Standard Operating
Improper setting 2 Procedure 5 50

Next operation - Nil Standard Operating

Improper setting 2 Procedure 5 40
Subsquent Process - Nil Set Up Approval , FPIR, 100%
Diameter oversize Customer End - Dissatisfaction inspection
User End - Nil Insert worn out 2 Tool Change Frequency 5 40
Dia 64+/-0.3 Next operation - Machining
operation Affected less margine Insert worn out 2 Set up Approval 5 50
Diameter Subsquent Process - Nil Set Up Approval , FPIR, 100%
undersize Customer End -Fitment 5 inspection
problem User Standard Operating
Improper setting 2 Procedure 5 50
End - Nil
5 Less awareness 3 As per WI/PD/27 Visual inspection 4 60
Next Operation - Nil
PART FREE FROM Loose chips, sharp Subsquent Process - Nil
10a DEBURRING BURR, SHARP edge present on Customer End - Dissatisfaction Tool life
EDGES, CHIPS component NPD
End User - Nil 8 Deburring tool wear out 5 Tool Change Frequency Visual inspection 4 160 frequency 15.2.19
to be set
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

OP - 20 Finish OD Turning & Gear side boring

Next operation - Will be affected Insert worn out 3 Tool Change Frequency 5 40
Subsquent Process - Will
Flange thickness be affected
oversize 5 SETUP , FPIR
Customer End - Fitment problem
User End - Nil Standard Operating 5 40
FLANGE Improper setting 3 Procedure
THICKNESS
10.0±0.3
Less stock from previous Previous operation stock
Next operation - Will be affected operation 2 maintaining 5 50
Subsquent Process - will
Flange thickness be affected
undersize 5 Insert worn out 2 Set up Approval SETUP , FPIR 5 50
Customer End -Fitment problem
User End - Nil Standard Operating
Improper setting 2 Procedure 5 50

Change in Programing 2 Edit Key Lock 4 40

Machining Next operation - Will be affected
Dimensions Flage Parallalism Subsquent Process - Will Improper setting, Jaw
should OK - be affected 5 Boring 2 Setup approval SETUP , FPIR, IPIR 4 60
out of Spec.
Flange Variation Customer End - Dissatisfication
0.05 mm User End - Nil Standard Operating
Clamping Pressure 2 Procedure 4 60

Excess stock from Previous operation stock

previous operation 4 maintaining 3 96
Next operation - Nil
Subsquent Process - Nil
Bearing diameter Customer End - Dissatisfaction SETUP , FPIR, IPIR, 100%
oversize 8 checked on machine
User End - Fitment
problem Insert worn out 4 Tool Change Frequency 3 96
Finish OD BEARING DIA Standard Operating
Turning & Ø55.015+/-0.010 Improper setting 4 Procedure 3 96
20
Gear side
boring Less stock from previous Previous operation stock
operation 2 maintaining 5 80
Next operation -Nil
Subsquent Process - Nil
Bearing diameter Customer End -Dissatisfaction SETUP , FPIR, IPIR, 100%
undersize 8 Insert worn out 2 Set up Approval checked on machine 5 50
User End - Fitment
problem Standard Operating
Improper setting 3 Procedure 5 50

Standard Operating
Loading Problem 3 Procedure 4 60
Next operation - Nil
AXIAL RUNOUT Runout Out Of Subsquent Process - Nil Standard Operating
OF BEARING DIA 5 Improper setting 3 Procedure SETUP , FPIR 4 60
spec. Customer End - Fitment problem
55 User End - Nil
Standard Operating
Clamping Pressure 3 Procedure 4 60
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
Finish OD
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
Turning &
20 NO& Rev. No.
PART Gear side 1081746-00-B3 KEY DATE : 16.12.2018
COREboring
TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Less stock from previous Previous operation stock

operation 2 maintaining 5 60
Next operation - Nil
ID diameter Subsquent Process - Nil
oversize Customer End - Nil 6 Insert worn out 2 Set up Approval SETUP , FPIR 5 60
User End - Nil
Standard Operating
Improper setting 3 Procedure 5 90
INSIDE DIAMETER
47
Excess stock from Previous operation stock
previous operation 2 maintaining 5 60
Next operation - Nil
Subsquent Process - Nil
ID diameter under Customer End - Loose Fitment Standard Operating
size 6 Improper setting 2 SETUP , FPIR, IPIR 5 60
problem Procedure
User End - Nil
Insert worn out 2 Set up Approval 5 60

Excess stock from Previous operation stock

previous operation 2 maintaining 5 40
Next operation - Nil
Subsquent Process -Will affect
Depth oversize Customer End - Fitment problem 4 Insert worn out 2 Set up Approval SETUP , FPIR 5 40
User End - Nil
Standard Operating
DEPTH Improper setting 3 Procedure 5 40
7.5+/-0.1
Next operation - Machining Incoming Inspection
More Access Material 2 Report 5 40
operation Affected less
margine/unclean of surface
Depth undersize Subsquent Process - Nil 4 Insert worn out 2 Set up Approval SETUP , FPIR 5 40
Customer End -Nil
User End - Nil Wrong Offset 2 Edit Key Lock 5 40

Improper setting 2 Setting Approval 5 50

Finish OD Next operation - Nil
Turning & CHAMFER OF DIA Subsquent Process - Nil
20 55, 2±0.3 Out of Spec Customer End - Dissatisfaction 5 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 50
Gear side
boring User End - Nil
Change in Programing 3 Edit Key Lock 5 50

Next operation - Nil Improper setting 2 Setting Approval 5 50

CHAMFER ANGLE Subsquent Process - Nil
OF DIA 55, Out of Spec Customer End - Dissatisfaction 5 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 50
30°±30' User End - Fitment
issue
Change in Programing 2 Edit Key Lock 5 50

Change in Programing 2 Edit Key Lock 5 40

Next operation - Nil
SURFACE FINISH Subsquent Process - Nil Insert worn out 2 Tool Change Frequency SETUP , FPIR, Coolant 5 50
OF DIA 55 Ra 1.6 Out of Spec Customer End - Dissatisfaction 4 concentration checksheet
User End - Nil
One per day
Coolant Concentration 2 concentration checking 5 50
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Change in Programing 2 Edit Key Lock 5 40

Next operation - Nil
Subsquent Process - Nil
Radius oversize Customer End -Nil 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
User End - Fitment problem
Improper setting 2 Setting Approval 5 40
GROOVE OF DIA
55 RADIUS
Change in Programing 2 Edit Key Lock 5 40
Next operation - Nil
Subsquent Process - Nil
Radius undersize Customer End -Nil 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
Finish OD User End - Fitment problem
Turning & Improper setting 2 Setting Approval 5 40
20 Gear side
boring Less stock from previous Previous operation stock
operation 3 maintaining 3 72
Next operation - Nil
Subsquent Process - Nil
Diameter oversize Customer End - Fitment problem 8 Insert worn out 3 Tool Change Frequency FPIR, Inprocess Inspection, 3 72
User End - Nil
Dia. Should OK Change in Programing 3 Edit Key Lock 3 72
Ø35.04+/-0.01
Gear SIDE Next operation - Part loading Issue Improper setting 3 Setting Approval 3 72
Diameter Subsquent Process - Nil
undersize Customer End - Loose 8 FPIR, Inprocess Inspection
Fitment problem
User End - Nil Insert worn out 3 Tool Change Frequency 3 72

Next operation - Nil Change in Programm 3 Edit Key Lock 3 72

TOTAL RUN OUT Subsquent Process - Nil
0.08 WRT A-B OF Runout Out Of Customer End - Noise in Fittment Improper setting 3 Setting Approval 3 72
spec. 8 SETUP , FPIR
DIA35 Gear SIDE User End -
Nil Process Parameter Work
Clamping Pressure 3 Instruction 3 72
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Incoming Inspection
Next operation - Nil More Access Material 2 Report 5 50
Groove dist Subsquent Process - Nil
oversize Customer End - Dissatisfaction 5 SETUP , FPIR
User End - Fitment Insert worn out 2 Tool Change Frequency 5 50
problem
GROOVE OF DIA
55 DIST 0.6 Less stock from previous Previous operation stock
operation 2 maintaining 5 50
Next operation - Nil
Groove dist Subsquent Process - Nil
undersize Customer End - Nil 5 Insert worn out 2 Set up Approval SETUP , FPIR 5 50
User End - Fitment problem
Wrong Offset 2 Edit Key Lock 5 50

Improper setting 2 Setting Approval 5 50

Next operation - Nil
GROOVE OF DIA Subsquent Process - Nil
55 ANGLE, 40° Out of Spec Customer End - nil 5 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 50
+/-3° User End - Fitment problem
Change in Programm 2 Edit Key Lock 5 50

Next operation - Nil Change in Programm 2 Edit Key Lock 5 50

GROOVE OF DIA Subsquent Process - Nil
55 SURFACE Out of Spec Customer End - Dissatisfaction 5 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 50
FINISH User End - Metting
part issue One per day
Coolant Concentration 2 concentration checking 5 50

Less stock from previous Previous operation stock

operation 3 maintaining 4 84
Next operation - Nil
Subsquent Process - Nil FPIR, Inprocess Inspection,
Diameter oversize Customer End - Dissatisfied 7 Insert worn out 3 Tool Change Frequency 100% checked on machine 4 84
Finish OD
Turning & User End - Loose Fittment
20 Gear side Change in Programing 3 Edit Key Lock 4 84
boring DiaØ112.034+/-
0.015.
Improper setting 3 Setting Approval 4 84
Next operation - Nil
Diameter Subsquent Process - Nil FPIR, Inprocess Inspection,
undersize Customer End - Dissatisfied 7 100% checked on machine
User End - Loose Fittment Insert worn out 3 Tool Change Frequency 4 84

Change in Programing 2 Edit Key Lock 5 50

Next operation - Nil
Surface FINISH Subsquent Process - Nil Insert worn out 2 Tool Change Frequency 5 50
OF DIA 112.034 Out of Spec Customer End - Dissatisfaction 5 SETUP , FPIR
Roughness Ra 1.6 User End - Nil
One per day
Coolant Concentration 2 concentration checking 5 50

Change in Programm 2 Edit Key Lock 4 40

AXIAL RUN OUT Next operation - Nil
0.03 WRT A-B OF Runout Out Of Subsquent Process - Nil Improper setting 2 Setting Approval 4 60
FLANFE FACE spec. Customer End - Noise in Fittment 5 SETUP , FPIR
GEAR SIDE User End -
Nil Process Parameter Work
Clamping Pressure 2 Instruction 4 60

Change in Programm 3 Edit Key Lock 4 84

CIRCULAR Next operation - Nil
RUNOUT OF Runout Out Of Subsquent Process - Nil
Customer End - Noise in Fittment 7 Improper setting 3 Setting Approval SETUP , FPIR 4 84
BEARING DIA spec.
112.034 User End -
Nil Process Parameter Work
Clamping Pressure 3 Instruction 4 84
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Next operation - Nil Improper setting 2 Setting Approval 5 50

SURFACE ANGLE Subsquent Process - Chamfer
10°+0/-4° Out of Spec Dimension will be affected 5 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 50
Customer End - Dissatisfaction
User End - Nil Change in Programm 2 Edit Key Lock 5 50

Change in Programing 2 Edit Key Lock 5 40

Next operation - Nil
Subsquent Process - Nil
Radius oversize Customer End -Dissatisfaction 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
User End - Nil
Improper setting 2 Setting Approval 5 40
RADIUS R5+2
Next operation - Nil Change in Programing 2 Edit Key Lock 5 40
Subsquent Process - Nil
Radius undersize Customer End -Dissatisfaction 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
User End - Nil
Improper setting 2 Setting Approval 5 40

Improper setting 2 Setting Approval 5 60

Next operation - will affect next
operation
Dist oversize Subsquent Process - Nil 6 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 60
Customer End - Fitment problem
User End - Nil
Wrong Offset 2 Edit Key Lock 5 60
DISTANCE
32.1675+/-0.05
Finish OD Improper setting 2 Setting Approval 5 60
Turning & Next operation - will affect next
20 Gear side operation Subsquent
boring Dist undersize Process - Nil Customer End 6 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 50
-Fitment problem
User End - Nil Wrong Offset 2 Edit Key Lock 5 50

Change in Programing 2 Edit Key Lock 5 50

Next operation - Nil
SURFACE FINISH Subsquent Process - Nil
OF FLANGE FACE Out of Spec Customer End - Dissatisfaction 5 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 50
Ra1.6 User End - Nil
One per day
Coolant Concentration 2 concentration checking 5 50

Change in Programing 2 Edit Key Lock 5 50

Next operation - Nil

Surface FINISH Subsquent Process - Nil Insert worn out 2 Tool Change Frequency 5 50
OF DIA 112.034 Out of Spec Customer End - Dissatisfaction 5 SETUP , FPIR
Roughness Ra 1.6 User End - Nil
One per day
Coolant Concentration 2 concentration checking 5 50
 Finish OD Doc. No. :FMEA/1081746-00-B
20
Turning &
Gear side FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
boring
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date
Process control at Incoming Inspection
Excess Material 2 supplier & visual as per IIR 5 40
Next operation - Nil inspection
Subsquent Process - Nil
Chamfer oversize Customer End - Dissatisfaction 4 Insert worn out 2 Tool Change Frequency 5 40
Set Up Approval , FPIR
User End - Nil Standard Operating
CHAMFER OF Improper setting 2 Procedure 5 40
FLANGE 1.0 ±0.3
X45°±5°
5 40
Next operation - Nil
Subsquent Process - Nil Standard Operating 5 40
Chamfer undersize Customer End -Dissatisfaction 4 Improper setting 2 Procedure SETUP , FPIR
User End - Nil
5 40
Process control at Incoming Inspection
Excess Material 2 supplier & visual as per IIR 5 40
Next operation - Nil inspection
Subsquent Process - Nil
Dist oversize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency 40
User End - Nil Set Up Approval , FPIR 5
Standard Operating
DISTANCE 7.3+/- Improper setting 2 Procedure 40
0.3
Next operation - Nil 5 50
Insert worn out 2 Set up Approval
Subsquent Process - Nil
Dist undersize Customer End -Fitment problem 5 SETUP , FPIR 5 50
User End - Nil Standard Operating
Improper setting 2 Procedure 5 50
Incoming Inspection
Finish OD More Access Material 2 Report 5 40
Turning & Next operation - Nil
20 Gear side Subsquent Process - Nil
Dist oversize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
boring
DISTANCE 18+/- User End - Nil Standard Operating
Improper setting 2 Procedure 5 40
1.5
Next operation - Nil Insert worn out 2 Set up Approval 5 50
Subsquent Process - Nil
Dist undersize Customer End - Fitment problem 5 SETUP , FPIR
Standard Operating
User End - Nil Improper setting 2 Procedure 5 50
Process control at Incoming Inspection
Excess Material 2 supplier & visual as per IIR 5 40
Next operation - Nil inspection
Subsquent Process - Nil
Dist oversize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency 5 40
User End - Nil Set Up Approval , FPIR
Standard Operating
Improper setting 2 Procedure 5 40
DISTANCE 51.5+/-
0.1 Less stock from previous Previous operation stock
operation 2 maintaining 5 40
Next operation - Nil
Subsquent Process - Nil
Dist undersize Customer End - Fitment problem 4 Insert worn out 2 Set up Approval SETUP , FPIR 5 40
User End - Nil
Wrong Offset 2 Edit Key Lock 5 40
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date
Process control at Incoming Inspection
Next operation - Nil Excess Material 2 supplier & visual as per IIR 5 40
Subsquent Process - Nil inspection
Chamfer oversize Customer End - Dissatisfaction 4 Insert worn out 2 Tool Change Frequency 5 40
Set Up Approval , FPIR
User End - Nil Standard Operating
CHAMFER Improper setting 2 Procedure 5 40
DIAMETER
37±0.3 5 40
Next operation - Nil
Subsquent Process - Nil Standard Operating
Chamfer undersize Customer End -Dissatisfaction 4 Improper setting 2 Procedure SETUP , FPIR 5 50
User End - Nil
5 50

Next operation - Nil Improper setting 2 Setting Approval 5 40

Subsquent Process - Chamfer
CHAMFER ANGLE Dimension will be affected
60°+/-5° Out of Spec 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 50
Customer End - Dissatisfaction
User End - Nil Change in Programm 2 Edit Key Lock 5 50

Change in Programing 2 Edit Key Lock 5 40

Next operation - Nil
Subsquent Process - Nil
Radius oversize Customer End -Dissatisfaction 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
User End - Nil
Improper setting 2 Setting Approval 5 40
RADIUS R2+1
Change in Programing 2 Edit Key Lock 5 40
Next operation - Nil
Subsquent Process - Nil
Radius undersize Customer End -Dissatisfaction 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40

User End - Nil Improper setting 2 Setting Approval 5 40

Next operation - will affect Change in Programm 3 Edit Key Lock 4 60

Subsquent Process - Nil
Runout Out Of Customer End - Noise in Fittment
PROFILE WRT A-B spec. 5 Improper setting 3 Setting Approval SETUP , FPIR 4 60
User End -
Nil Process Parameter Work
Clamping Pressure 3 Instruction 4 60

Finish OD
Turning &
20 Gear side
boring
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Less stock from previous Previous operation stock

operation 2 maintaining 5 40
Next operation - Nil
ID diameter Subsquent Process - Nil
oversize Customer End - Dissatisfaction 4 Insert worn out 2 Set up Approval SETUP , FPIR 5 60
User End - Nil Standard Operating
BACK BORE Improper setting 2 Procedure 5 60
DIAMETER
Ø47+/-0.3 Excess stock from Previous operation stock
previous operation 2 maintaining 5 40
Next operation - Nil
ID diameter under Subsquent Process - Nil Standard Operating
Finish OD size Customer End - fitment problem 4 Improper setting 2 Procedure SETUP , FPIR, IPIR 5 40
Turning & User End - Nil
20 Gear side Insert worn out 2 Set up Approval 5 40
boring
Next operation - Nil Incoming Inspection
More Access Material 2 Report 5 40
Subsquent Process - will affect
chamfer dimension
Diameter oversize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
CHAMFER Wrong Offset 2 Edit Key Lock 5 40
DIAMETER User End - Nil
Ø36.2+/-0.3
Next operation - Nil 5 50
Insert worn out 2 Set up Approval
Diameter Subsquent Process - Nil
undersize Customer End -Fitment problem 5 SETUP , FPIR
User End - Nil 5 50
Wrong Offset 2 Edit Key Lock

Improper setting 2 Setting Approval 5 50

DIA 35 BACK Next operation - Nil
CHAMFER ANGLE Subsquent Process - Nil
Out of Spec Customer End - Dissatisfaction 5 SETUP , FPIR
60°+/-5° Insert worn out 2 Tool Change Frequency 5 50
User End - Nil

Next operation -Nil Incoming Inspection

More Access Material 2 Report 5 40
Subsquent Process -Will affect the
chamfer dimension
Diameter oversize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
CHAMFER
DIAMETER User End - Nil Wrong Offset 2 Edit Key Lock 5 40
Ø48.76+/-0.3
Next operation - Nil Insert worn out 2 Set up Approval 5 40
Diameter Subsquent Process - Nil
undersize Customer End -Fitment problem 4 SETUP , FPIR
User End - Nil Wrong Offset 2 Edit Key Lock 5 50

Improper setting 2 Setting Approval 5 40

DIA 47 Next operation - Nil
CHAMFER ANGLE Subsquent Process - Nil
Out of Spec Customer End - Dissatisfaction 4 SETUP , FPIR 5 40
60°+/-5° Insert worn out 2 Tool Change Frequency
User End - Nil
5 40

Change in Programing 2 Edit Key Lock 5 40

Next operation - Nil
Subsquent Process - Nil
Radius oversize Customer End -Dissatisfaction 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
User End - Nil
Improper setting 2 Setting Approval 5 40
RADIUS R2-0.3
Next operation - Nil Change in Programing 2 Edit Key Lock 5 40
Subsquent Process - Nil
Radius undersize Customer End -Dissatisfaction 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
User End - Nil Improper setting 2 Setting Approval 5 40

PART FREE FROM Loose chips, sharp Next Operation - Nil 5 Less awareness 3 As per WI/PD/27 Visual inspection 4 60
20a DEBURRING BURR, SHARP edge present on Subsquent Process - Nil Tool life
EDGES, CHIPS component Customer End - Dissatisfaction NPD
End User - Nil 8 Deburring tool wear out 5 Tool Change Frequency Visual inspection 4 160 frequency 15.2.19
to be set
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Op - 30 Finish OD Turning & bellside boring

Improper setting 4 Set up Approval 3 84
Next operation - Nil
Subsquent Process - Nil FPIR, Inprocess Inspection,
Diameter oversize Customer End - Fitment problem 7 Insert worn out 3 Tool Change Frequency 100% checked on machine 3 63
Bearing Dia. User End - Nil
Should OK Programm error 3 Edit Key Lock 5 105
Dia.Ø45.015+/-
0.01
Next operation - Nil
Subsquent Process - Nil Improper setting 4 Set up Approval 3 84
Diameter Customer End - Loose Fitment FPIR, Inprocess Inspection,
undersize 7 100% checked on machine
problem
User End - Nil Specification Of Tool 4 Toolin List 3 84

Next operation - Nil Change in Programm 3 Edit Key Lock 4 84

CIRCULAR Subsquent Process - Nil
RUNOUT 0.020 Runout Out Of Customer End - Loose Noise in Standard Operating
spec. 7 Improper setting 3 Procedure CMM REPORT, FPIR 4 84
WRT A-B Fittment/ Backlash problem
User End - Nil Standard Operating
Clamping Pressure 3 Procedure 4 84

Next operation -Nil Excess stock from Maintaing previous

previous operation 2 operation stock 5 40
Subsquent Process -Will affect the
chamfer dimension
Diameter oversize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40

CHAMFER User End - Nil Improper setting 2 Setting Approval 5 40

DIAMETER
42.7±0.3 5 50
Next operation - Nil Insert worn out 2 Set up Approval
Diameter Subsquent Process - Nil
undersize Customer End -Fitment problem 5 SETUP , FPIR 5 50
User End - Nil
Wrong Offset 2 Edit Key Lock 5 50

Improper setting 2 Setting Approval 5 50

CHAMFER ANGLE Next operation - Nil
30°±5° (OF DIA Subsquent Process - Nil
Out of Spec Customer End - Dissatisfaction 5 SETUP , FPIR 5 50
45.015) Insert worn out 2 Tool Change Frequency
User End - Nil
5 50

Change in Programing 2 Edit Key Lock 5 40

Next operation - Nil
Subsquent Process - Nil
Radius oversize Customer End -Dissatisfaction 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
User End - Nil
Finish OD Improper setting 2 Setting Approval 5 40
Turning & RADIUS 1.0 - 1.5
30 bellside (OF DIA 45.01)
boring Next operation - Nil Change in Programing 2 Edit Key Lock 5 40
Subsquent Process - Nil
Radius undersize Customer End -Dissatisfaction 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
User End - Nil Improper setting 2 Setting Approval 5 40

Next operation - Nil Improper setting 2 Setting Approval 5 40

CHAMFER Subsquent Process - will leave
FLANGE 1.0±0.2 Out of Spec sharpe edge 4 SETUP , FPIR 5 40
45°±5° Customer End - Dissatisfaction Insert worn out 2 Tool Change Frequency
User End - Nil 5 40
Excess stock from Previous operation stock
previous operation 2 maintaining 5 50
Next operation - Nil
Subsquent Process - Nil
Dist oversize Customer End - Fitment problem 5 Insert worn out 2 Tool Change Frequency SETUP , FPIR, IPIR 5 50
User End - Nil
Change in Programm 2 Edit Key Lock 5 50
DISTANCE
84.6675±0.050 Previous operation stock
More Access Material 2 maintaining 5 50
Next operation - Nil
Subsquent Process - Nil
Dist undersize Customer End -Fitment Problem 5 Insert worn out 2 Set up Approval SETUP , FPIR, IPIR 5 50
User End - Nil
Change in Programm 3 Edit Key Lock 5 50
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Change in Programm 3 Edit Key Lock 4 60

Next operation - Will affect
AXIAL RUNOUT Subsquent Process - Nil Standard Operating
0.030 WRT Runout Out Of Customer End - fitment problem Improper setting 3 4 60
spec. 5 Procedure CMM REPORT, FPIR
A-B
User End - Nil Process Parameter Work
Clamping Pressure 3 Instruction 4 60

Excess stock from Previous operation stock

previous operation 2 maintaining 5 40
Next operation - Nil
Subsquent Process - Nil
Dist oversize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
User End - Nil Standard Operating
Improper setting 3 Procedure 5 40
DISTANCE
75.4±0.3 Previous operation stock
More Access Material 2 maintaining 5 40
Next operation - Nil
Subsquent Process - Nil
Dist undersize Customer End -Fitment problem 4 Insert worn out 2 Set up Approval SETUP , FPIR 5 40
User End - Nil
Wrong Offset 2 Edit Key Lock 5 40

Change in Programm 2 Edit Key Lock 5 40

SURFACE FINISH Next operation - Nil
Ra1.6 Subsquent Process - Nil
(OF DIA Out of Spec Customer End - Dissatisfaction 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
45.015) User End - Nil One per day
Finish OD Coolant Concentration 2 concentration checking 5 40
Turning &
30 bellside Excess stock from Previous operation stock
previous operation 2 maintaining 5 40
boring Next operation -Nil
Subsquent Process - Nil
Radius oversize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
User End - Nil Standard Operating
Improper setting 2 Procedure 5 40
RADIUS R 2.0+1
(OF DIA. 64) Previous operation stock
More Access Material 2 maintaining 5 40
Next operation - Nil
Subsquent Process - Nil
Radius undersize Customer End -Fitment problem 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
User End - Nil Standard Operating
Improper setting 2 Procedure 5 40
Excess stock from Previous operation stock
previous operation 3 maintaining 5 60
Next operation - Will affect
Subsquent Process - Nil
Length oversize Customer End - Fitment problem 4 Insert worn out 3 Tool Change Frequency SETUP , FPIR 5 60
User End - Nil Standard Operating
Improper setting 3 Procedure 5 60
LENGTH
109.5±0.1 Previous operation stock
Less material allowance 3 maintaining 5 60
Next operation - Will affect
Subsquent Process - Nil Insert worn out 3 Set up Approval 5 60
Length undersize Customer End -Fitment problem 4 SETUP , FPIR
User End - Nil Standard Operating
Improper setting 3 Procedure 5 60
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Excess stock from Previous operation stock

previous operation 2 maintaining 5 40
Next operation - Will affect
Subsquent Process - Nil
Length oversize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
User End - Nil Standard Operating
Improper setting 3 Procedure 5 40
TOTAL LENGTH
161.0±0.1 Previous operation stock
Less material allowance 2 maintaining 5 50
Next operation - Nil
Subsquent Process - Nil
Length undersize Customer End -Fitment problem 5 Insert worn out 3 Set up Approval SETUP , FPIR 5 60
User End - Nil Standard Operating
Improper setting 2 Procedure 5 50

Change in Programm 3 Edit Key Lock 5 75

SURFACE FINISH Next operation - Nil
OF FLANGE FACE Subsquent Process - Nil
Out of Spec Customer End - Dissatisfaction 5 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 50
BELL SIDE Ra3.2
User End - Nil One per day
Coolant Concentration 2 concentration checking 5 50

Next operation -Nil Excess stock from Maintaing previous

previous operation 2 operation stock 5 40
Subsquent Process -Will affect the
chamfer dimension
Diameter oversize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
Standard Operating
CHAMFER User End - Nil Improper setting 3 Procedure 5 60
DIAMETER
37±0.3 5 40
Next operation - Nil Insert worn out 2 Set up Approval
Diameter Subsquent Process - Nil
undersize Customer End -Fitment problem 4 SETUP , FPIR 5 50
User End - Nil
Wrong Offset 2 Edit Key Lock 5 50
Less stock from previous Previous operation stock
operation 2 maintaining 5 80
Next operation - Nil FPIR, Inprocess
Subsquent Process - Nil Inspection,100% checked on
Diameter oversize Customer End - Fitment problem 8 Insert worn out 2 Tool Change Frequency 5 80
machine
User End - Nil
Change in Programing 2 Edit Key Lock 5 80
Dia. Ø35.046+/-
0.01 Bell side Standard Operating
Improper setting 2 Procedure 5 80
Next operation - Part loading Issue
Diameter Subsquent Process - Nil FPIR, Inprocess
Customer End - Loose 8 Inspection,100% checked on 5 80
undersize
Fitment problem Insert worn out 2 Tool Change Frequency machine
User End - Nil
5 80

Change in Programm 3 Edit Key Lock 4 60

TOTAL RUNOUT Next operation - Nil
0.080 W.R.T. A - Runout Out Of Subsquent Process - Nil Standard Operating
spec. Customer End - Noise in Fittment 5 Improper setting 3 Procedure CMM REPORT, FPIR 4 60
B (OF DIA 35.04)
User End - Nil Process Parameter Work
Clamping Pressure 3 Instruction 4 60
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Change in Programm 3 Edit Key Lock 4 60

Next operation - Nil
RUNOUT OF DIA Runout Out Of Subsquent Process - Nil
156 spec. Customer End - Noise in Fittment 5 Improper setting 3 Setting Approval CMM REPORT, FPIR 4 60
User End - Nil Process Parameter Work
Clamping Pressure 3 Instruction 4 60
Less stock from previous Previous operation stock
operation 2 maintaining 6 60
Next operation - Nil
ID diameter Subsquent Process - Nil SETUP , FPIR, 100% checked by
oversize Customer End - Nil 5 Insert worn out 2 Set up Approval PPG 6 60
User End - Nil Standard Operating
Improper setting 3 Procedure 6 90
BACK BORE
DIAMETER 47 Excess stock from Previous operation stock
Next operation - Nil previous operation 2 maintaining 6 60
Subsquent Process - Nil
ID diameter under Customer End - Loose Fitment Standard Operating SETUP , FPIR, 100% checked by
size 5 Improper setting 3 Procedure PPG 6 90
Finish OD problem
Turning & User End - Nil Insert worn out 2 Set up Approval 6 60
bellside
boring Excess stock from Previous operation stock
previous operation 2 maintaining 5 40
Next operation - Nil
Subsquent Process -Will affect
Depth oversize Customer End - Fitment problem 4 Insert worn out 2 Set up Approval SETUP , FPIR 5 40
User End - Nil Standard Operating
Improper setting 3 Procedure 5 60
DEPTH
7.5+/-0.1 Incoming Inspection
Next operation - Machining More Access Material 2 5 40
operation Affected less Report
margine/unclean of surface
Depth undersize Subsquent Process - Nil 4 Insert worn out 2 Set up Approval SETUP , FPIR 5 40
Customer End -Nil
User End - Nil Wrong Offset 2 Edit Key Lock 5 40

Next operation - Nil Excess stock from Maintaing previous

previous operation 2 operation stock 5 40
Subsquent Process - will affect
chamfer dimension
Diameter oversize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40

CHAMFER User End - Nil Wrong Offset 2 Edit Key Lock 5 40

DIAMETER
Ø36.2+/-0.3 5 40
Next operation - Nil Insert worn out 2 Set up Approval
Diameter Subsquent Process - Nil
undersize Customer End -Fitment problem 4 SETUP , FPIR 5 40
User End - Nil
Wrong Offset 2 Edit Key Lock 5 40

Improper setting 2 Setting Approval 5 50

DIA 35 BACK Next operation - Nil
CHAMFER ANGLE Subsquent Process - Nil
Out of Spec Customer End - Dissatisfaction 5 SETUP , FPIR 5 50
60°+/-5° Insert worn out 2 Tool Change Frequency
User End - Nil
5 50
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date
Process control at Incoming Inspection
Next operation - Nil Excess Material 2 supplier & visual as per IIR 6 48
Subsquent Process - Nil inspection
Chamfer oversize Customer End - Dissatisfaction 4 Insert worn out 2 Tool Change Frequency 5 40
Set Up Approval , FPIR
User End - Nil Standard Operating
CHAMFER Improper setting 2 Procedure 5 40
DIAMETER
Ø48.76+/-0.3 5 50
Next operation - Nil
Subsquent Process - Nil Standard Operating
Chamfer undersize Customer End -Dissatisfaction 5 Improper setting 2 Procedure SETUP , FPIR 5 50
User End - Nil
5 50

Improper setting 2 Setting Approval 5 50

DIA 47 Next operation - Nil
CHAMFER ANGLE Subsquent Process - Nil
Out of Spec Customer End - Dissatisfaction 5 SETUP , FPIR 5 50
60°+/-5° Insert worn out 2 Tool Change Frequency
User End - Nil
5 50
Excess stock from Previous operation stock
previous operation 2 maintaining 5 40
Next operation -Nil
Subsquent Process - Nil
Radius oversize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 40
User End - Nil Standard Operating
Improper setting 3 Procedure 5 60
RADIUS R 2.0+1
(OF DIA. 64) Previous operation stock
More Access Material 2 maintaining 5 50
Next operation - Nil
Subsquent Process - Nil
Radius undersize Customer End -Fitment problem 5 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 50
User End - Nil Standard Operating
Improper setting 2 Procedure 5 50

Next operation - Will affect Change in Programm 3 Edit Key Lock 4 72

AXIAL RUN OUT Subsquent Process - Nil
0.03 WRT A-B OF Runout Out Of Customer End - fitment problem Standard Operating
spec. 6 Improper setting 3 Procedure CMM REPORT, FPIR 4 72
FACE DIA 45.01
User End - Nil Process Parameter Work
Clamping Pressure 3 Instruction 4 72

Change in Programm 3 Edit Key Lock 4 60

TOTAL RUNOUT Next operation - Nil
0.080 W.R.T. A - Runout Out Of Subsquent Process - Nil
spec. Customer End - Fitment problem 5 Improper setting 3 Setting Approval CMM REPORT, FPIR 4 60
B (OF DIA 35.04)
User End - Nil Process Parameter Work
Clamping Pressure 3 Instruction 4 60

Change in Programm 3 Edit Key Lock 4 60

CIRCULAR Next operation - Nil
RUNOUT 0.080 Runout Out Of Subsquent Process - Nil
spec. Customer End - Fitment problem 5 Improper setting 3 Setting Approval CMM REPORT, FPIR 4 60
W.R.T. A-B
User End - Nil Process Parameter Work
Clamping Pressure 3 Instruction 4 60

Change in Programm 3 Edit Key Lock 4 60

CIRCULER Next operation - Nil
Finish OD RUNOUT 0.03 Subsquent Process - Nil
Turning & Runout Out Of Improper setting 3 Setting Approval 4 60
W.R.T. A-B (OF spec. Customer End - Fitment problem 5 CMM REPORT, FPIR
bellside BEARING DIA. User End -
boring 120.035) Nil Process Parameter Work
Clamping Pressure 3 Instruction 4 60

Improper setting 2 Setting Approval 5 50

CHAMFER ANGLE Next operation - Nil
60°±5° Subsquent Process - Nil
Out of Spec Customer End - Dissatisfaction 5 SETUP , FPIR 5 50
(OF DIA 35.04) Insert worn out 2 Tool Change Frequency
User End - Nil
5 50

Change in Programm 2 Edit Key Lock 5 50

Next operation - Nil
SURFACE FINISH Subsquent Process - Nil
Ra 1.6 Out of Spec 5 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 50
Customer End - Dissatisfaction
(OF DIA 35.04) User End - Nil
Improper setting 2 Setting Approval 5 50
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Op - 40Cross hole boring, spherical & Back face.

Improper setting 2 Set up Approval 5 60
Next operation - Nil
Subsquent Process - Nil FPIR, Inprocess Inspection,
Diameter oversize Customer End - Fitment problem 6 Insert worn out 2 Tool Change Frequency 100% checked on machine 5 60
User End - Nil
Hole Dia. Should Programm error 2 Edit Key Lock 5 60
OK Dia. Ø5.43+/-
0.05 UPTO P Insert worn out 2 Tool Change Frequency 5 60
Next operation - Will affect
Diameter Subsquent Process - Nil FPIR, Inprocess Inspection,
undersize Customer End - Fitment problem 6 Improper setting 3 Set up Approval 100% checked on machine 5 90
User End - Nil
Change in Programm 3 Edit Key Lock 5 90

Next operation - Nil Change in Programm 3 Edit Key Lock 4 60

POSITION OF Subsquent Process - Nil
GUNDRILL 0.1 Position Out Of Customer End - Fitment problem
spec. 5 Improper setting 3 Setting Approval CMM REPORT, FPIR 4 60
WRT A-B, C, P User End -
Nil Process Parameter Work
Clamping Pressure 3 Instruction 4 60
Excess stock from Maintaing previous
previous operation 2 operation stock 5 40
DISTANCE Next operation - Nil
34.90(CROSS Oversize / Subsquent Process - Nil CMM REPORT, FPIR, 100%
undersize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency checked on multigauging 5 40
HOLE TO FACE E)
User End - Nil
Improper setting 3 Setting Approval 5 60

Next operation - Nil Change in Programm 3 Edit Key Lock 4 60

AXIAL RUNOUT Subsquent Process - Nil
FACE E 0.05 wrt Runout Out Of Customer End - Noise in Fittment
spec. 5 Improper setting 3 Setting Approval CMM REPORT, FPIR 4 60
A-B User End -
Nil Standard Operating
Clamping Pressure 3 Procedure 4 60
Incoming Inspection
More Access Material 2 Report 5 40
DISTANCE Next operation - Nilt
34.90(CROSS Oversize / Subsquent Process - Nil CMM REPORT, FPIR, 100%
undersize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency checked on multigauging 5 40
HOLE TO FACE C)
User End - Nil
Wrong Offset 2 Edit Key Lock 5 40

Next operation - Nil Change in Programm 3 Edit Key Lock 4 48

AXIAL RUNOUT Subsquent Process - Nil
FACE E 0.05 wrt Runout Out Of Customer End - Noise in Fittment
spec. 4 Improper setting 3 Setting Approval CMM REPORT, FPIR 4 48
A-B User End -
Nil Standard Operating
Clamping Pressure 3 Procedure 4 48
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Next operation - Nil Change in Programm 2 Edit Key Lock 4 32

Subsquent Process - Nil
AXIAL RUNOUT Runout Out Of Customer End - Noise in Fittment
FACE C spec. 4 Improper setting 2 Setting Approval CMM REPORT, FPIR 4 32
User End -
Nil Standard Operating
Clamping Pressure 2 Procedure 4 32
Excess stock from Maintaing previous
previous operation 3 operation stock 5 60
Machining Next operation - Will affect
Dimensions Oversize / Subsquent Process - Nil
should OK - undersize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency CMM REPORT, FPIR 5 40
29.5+/-0.05, User End - Nil
Improper setting 2 Setting Approval 5 40

Next operation - Nil Change in Programm 3 Edit Key Lock 4 60

Subsquent Process - Nil
Sphere 94.080+/- Oversize / Customer End - Fitment problem
0.1 undersize 5 Improper setting 3 Setting Approval CMM REPORT, FPIR 4 60
User End -
Nil Insert worn out 2 Tool Change Frequency 4 40

Next operation - Nil Change in Programm 3 Edit Key Lock 4 60

SPHERE Subsquent Process - Nil
POSITION WRT Position Out Of Customer End - Fitment problem
spec. 5 Improper setting 3 Setting Approval CMM REPORT, FPIR 4 60
( A-B) ( P-R ) User End -
Nil Standard Operating
Clamping Pressure 3 Procedure 4 60

Program error 2 Edit Key Lock 5 50

SURFACE FINISH Next operation - Nil
OF SPHERICAL Subsquent Process - Nil
Out of Spec Customer End - Dissatisfaction 5 Insert worn out 2 Tool Change Frequency FPIR, Inprocess Inspection 5 50
RADIUS
User End - Nil
Improper setting 2 Setting Approval 5 50
Excess stock from Maintaing previous
previous operation 2 operation stock 5 40
Machining Next operation - Nilt
Dimensions Oversize / Subsquent Process - Nil
should OK - undersize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency FPIR, Inprocess Inspection 5 40
51.05+/-0.1, User End - Nil
Improper setting 2 Setting Approval 5 40

Next operation - Nil Change in Programm 3 Edit Key Lock 4 60

Subsquent Process - Nil
TOTAL RUNOUT Runout Out Of Customer End - Noise in Fittment
OF DIA 35.04 spec. 5 Improper setting 3 Setting Approval CMM REPORT, FPIR 4 60
User End -
Nil Process Parameter Work
Clamping Pressure 3 Instruction 4 60

Cross hole
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Next operation - Nil Change in Program 2 Edit Key Lock 4 40

Subsquent Process - Nil
RUNOUT OF DIA Runout Out Of Customer End - Noise in Fittment
156 spec. 5 Improper setting 2 Setting Approval CMM REPORT, FPIR 4 40
User End -
Nil Process Parameter Work
Clamping Pressure 2 Instruction 4 40

Improper setting 3 Setting Approval 4 84

Next operation - Nil
Subsquent Process - Nil FPIR, Inprocess Inspection,
Diameter oversize Customer End - Fitment problem 7 Insert worn out 3 Tool Change Frequency 100% inspection on machine 4 84
User End - Nil
Hole Dia. Should Change in Program 3 Edit Key Lock 4 84
OK Dia.
Ø19.494+/-0.013 wrong offset Given 3 Edit Key Lock 4 84
Next operation - Nil
Cross hole Subsquent Process - Nil
Diameter Customer End - Loose Fitment FPIR, Inprocess Inspection,
boring, undersize 7 Improper setting 2 Set up Approval 100% inspection on machine 4 56
40 problem
spherical &
User End - Nil Insert worn out 3 Tool Change Frequency 4 84
Back face. POSITION
0.13WITHIN
SPECIFICATION
w.r.t. A-B-C, Improper setting 2 Setting Approval 5 70
Next operation - Nil
Subsquent Process - Nil FPIR, Inprocess Inspection,
Out of Spec Customer End - Fitment Problem 7 cmm report
User End - Nil
Insert worn out 2 Tool Change Frequency 5 70

Improper setting 2 Setting Approval 5 40

Next operation - Nil
POSITION 1.0 Subsquent Process - Nil FPIR, Inprocess Inspection,
WRT YZ Out of Spec Customer End - Fitment Problem 4 Insert worn out 2 Tool Change Frequency cmm report 6 48
PARELLALISM User End - Nil
WITHIN Wrong Offset 2 Edit Key Lock 5 40
SPECIFICATION
0.05 w.r.t. 'D', E, Next operation - Nil Change in Programm 3 Edit Key Lock 4 60
Subsquent Process - Nil
Parallalism Out Of Customer End - Fitment problem
spec. 5 Improper setting 2 Setting Approval FPIR, Inprocess Inspection 5 50
User End -
Nil Standard Operating
Clamping Pressure 2 Procedure 5 50
Excess stock from Maintaing previous
previous operation 2 operation stock 5 40
Machining Next operation - Nil
Dimensions Oversize / Subsquent Process - Nil
should OK - undersize Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency FPIR, Inprocess Inspection 5 40
56.5±0.3 User End - Nil
Improper setting 2 Setting Approval 5 40
 Cross hole
40
boring,
spherical &
Back face.

Doc. No. :FMEA/1081746-00-B

FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Change in Programm 3 Edit Key Lock 5 75

Next operation - Nil
SURFACE FINISH Subsquent Process - Nil
OF C/H Out of Spec Customer End - Dissatisfaction 5 Insert worn out 2 Tool Change Frequency FPIR, Inprocess Inspection 5 50
User End - Nil
Improper setting 2 Setting Approval 5 50
Excess stock from Maintaing previous
previous operation 2 operation stock 6 36
Machining Next operation - Nil
Dimensions Oversize / Subsquent Process - Nil
should OK - undersize Customer End - Fitment problem 3 Insert worn out 2 Tool Change Frequency FPIR, Inprocess Inspection 5 30
56.5±0.3 User End - Nil
Improper setting 2 Setting Approval 5 40
Excess stock from Maintaing previous
previous operation 2 operation stock 5 40
Next operation - Nil
Sharpe edge not Subsquent Process - Nil
0.8 MAX CORNER removed Customer End - Fitment problem 4 Insert worn out 2 Tool Change Frequency 100% VISUAL 5 40
User End - Nil
Wrong Offset 2 Edit Key Lock 5 40

Change in Programm 3 Edit Key Lock 5 75

Next operation - Nil
SURFACE FINISH Subsquent Process - Nil
OF C/H Out of Spec Customer End - Dissatisfaction 5 Insert worn out 2 Tool Change Frequency FPIR, Inprocess Inspection 5 50
User End - Nil
Improper setting 2 Setting Approval 5 50

Improper setting 3 Setting Approval 4 84

Next operation - Nil
Subsquent Process - Nil FPIR, Inprocess Inspection,
Diameter oversize Customer End - Fitment problem 7 Insert worn out 3 Tool Change Frequency 100% inspection on machine 4 84
User End - Nil
Hole Dia. Should Change in Program 3 Edit Key Lock 4 84
OK Dia.
Ø19.397±0.013 wrong offset Given 2 Edit Key Lock 5 70
Next operation - Nil
Subsquent Process - Nil
Diameter Customer End - Loose Fitment FPIR, Inprocess Inspection,
undersize 7 Improper setting 2 Set up Approval 100% inspection on machine 5 70
problem
User End - Nil Insert worn out 3 Tool Change Frequency 5 70

Change in Program 2 Edit Key Lock 5 70

Next operation - Nil CMM REPORT, FPIR, 100%
CONCENTRICITY Concentricity Out Subsquent Process - Nil checked by concentricity
Ø0.02 w.r.t.' P' Of spec. Customer End - Fitment problem 7 Improper setting 2 Setting Approval 5 70
mandrell
User End - Nil Standard Operating
Clamping Pressure 2 Procedure 5 70

Improper setting 2 Setting Approval 5 50

Next operation - Nil
CHAMFER ANGLE Subsquent Process - Nil
90° Out of Spec Customer End - Dissatisfaction 5 SETUP , FPIR 5 50
User End - Nil Insert worn out 2 Tool Change Frequency
5 50
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Specification Of Tool 2 Tooling List 5 30

Next operation - Nil
Subsquent Process - Nil
Diameter oversize Customer End - Fitment problem 3 Insert worn out 2 Tool Change Frequency SETUP , FPIR 5 30
User End - Nil
Chamfer Dia. Programm error 2 Edit Key Lock 5 30
Should OK Dia.
Ø48.2+/-0.2 wrong offset Given 3 Edit Key Lock 5 45
Next operation - Nil
Subsquent Process - Nil
Diameter Customer End - Loose Fitment
undersize 3 Improper setting 3 Set up Approval SETUP , FPIR 5 90
problem
User End - Nil Specification Of Tool 3 Toolin List 5 90

Improper setting 2 Setting Approval 6 60

Next operation - Nil
CHAMFER ANGLE Subsquent Process - Nil
OF DIA 47 Out of Spec Customer End - Dissatisfaction 5 SETUP , FPIR
User End - Nil Insert worn out 2 Tool Change Frequency 6 60

Next operation - Machining Excess stock from Maintaing previous

previous operation 2 operation stock 5 40
Machining operation Affected Tool wear out
Dimensions Subsquent Process -
Out of Spec Nil Customer End - Fitment 4 Insert worn out 2 Tool Change Frequency SETUP , FPIR,CMM REPORT 5 40
should OK - 7+/-1
problem User
End - Nil Improper setting 2 Setting Approval 5 40

5 Less awareness 3 As per WI/PD/27 Visual inspection 4 60

PART FREE FROM Loose chips, sharp Next Operation - Nil
40a DEBURRING BURR, SHARP edge present on Subsquent Process - Nil Tool life
EDGES, CHIPS component Customer End - Dissatisfaction NPD
End User - Nil 5 Deburring tool wear out 8 Tool Change Frequency Visual inspection 4 160 frequency
to be set 15.2.19

2D Barcode marking &

Matrix Laser
Scanning as per Wrong Etching Part serail number not 2D marking verification 100% inspection with scan cam
45
marking & /missing Customer End - Dissatishfaction 5 traceable 4 with scanning at washing & final 3 60
Scanning SOP
 Doc. No. :FMEA/1081746-00-B
FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

OP - 50 Drilling & Tapping

Next operation - Nil Improper setting 2 Set up Approval 3 42
Subsquent Process - Nil FPIR, Inprocess Inspection,
Over size Customer End - Fitment problem 7 Insert worn out 2 Tool Change Frequency First & last tap in final 3 42
User End - Nil inspection
Programm error 2 Edit Key Lock 3 42
Insert worn out 2 Tool Change Frequency 3 42
Next operation - Nil
Subsquent Process - Nil Improper setting 3 Set up Approval FPIR, Inprocess Inspection, 3 63
M10x 1.5 @ ONE Under size Customer End - Fitment problem 7 First & last tap in final
PLACE ,TAP M10 User End - Disatisfication Standard Operating inspection
AT 15 PLACES Wrong tool use 2 Procedure 3 42

Power cut off 1 Power back up 3 24

Next operation - Nil
Subsquent Process - Nil FPIR, Inprocess Inspection,
Missing Customer End - Fitment problem 8 100% visual inspection
Programm error 1 Edit Key Lock 3 24
User End - Nil

Next operation - Nil Programm error 3 Edit Key Lock 3 36

Over size Subsquent Process - Nil FPIR, Inprocess Inspection,
M10 PCD Improper setting 3 Set up Approval 3 36
Customer End - Loose Fitment 4 100% checked on PCD at final
DIAMETER 136 problem station
Standard Operating
Under size User End - Disatisfication Wrong tool use 3 Procedure 3 36

Specification Of Tool 2 Tooling List 5 50

Next operation - Nil
Subsquent Process - Nil FPIR, Inprocess Inspection,
Diameter oversize Customer End - Fitment problem 5 Insert worn out 2 Tool Change Frequency 100% checked on final station 5 60
User End - Nil
Programm error 2 Edit Key Lock 5 60
DIA 5.1 + 0.1
wrong offset Given 3 Edit Key Lock 5 75
Next operation - Nil
Diameter Subsquent Process - Nil
undersize Customer End - Fitment problem 5 Improper setting 3 Set up Approval FPIR, Inprocess Inspection 5 75
Drilling &
50 Tapping User End - Nil
Specification Of Tool 3 Toolin List 5 75
Excess stock from Maintaing previous
Machining previous operation 2 operation stock 5 40
Dimensions Next operation - Nilt
should OK - Subsquent Process - Nil Insert worn out 2 Tool Change Frequency 5 40
51.05+/-0.1, Out of Spec Customer End - Fitment problem 4 FPIR, Inprocess Inspection
( FOR DIA 5+/- User End - Nil
0.1) Programm error 2 Edit Key Lock 5 40

Improper setting 2 Setting Approval 5 50

Angle should OK Next operation - Nil
22.5°+/- Subsquent Process - Nil
Out of Spec Customer End - Fitment Problem 5 Insert worn out 2 Tool Change Frequency CMM REPORT, FPIR 5 50
0°30
User End - Nil
Wrong Offset 2 Edit Key Lock 5 50

Improper setting 2 Setting Approval 5 50

Angle should OK Next operation - Nil
Subsquent Process - Nil
Out of Spec Customer End - Fitment Problem 5 Insert worn out 2 Tool Change Frequency CMM REPORT, FPIR 5 50
11.30°±0°30
User End - Nil
Wrong Offset 2 Edit Key Lock 5 50
 Drilling & Doc. No. :FMEA/1081746-00-B
50 Tapping FAILURE MODE AND EFFECTS ANALYSIS Rev. No. : 00
Rev. Date :16.12.2018
ITEM HOUSING MACHINED DIFFERENTIAL, 3DU PROCESS RESPONSIBILITY : PRODUCTION HEAD
PART NO& Rev. No. 1081746-00-B3 KEY DATE : 16.12.2018
CORE TEAM Prashant Shetty, R.Gunjal,Sudhir Patil, Siddhesh,Thakur,Karna,Aman,Ranjeet
PREPARED BY Siddhesh Phalke
Concept: PROCESS FMEA
Process: MACHINING FMEA DATE (ORIG) : 05/12/2018
Operation: ALL PROCESS SUPPLIER : KRANTI INDUSTRIES LTD.
Recommended
Process Intent Process Assessment Current Process Controls Action Results
Actions
S O C Respons-
Item Critical v c Current Process control D R L ibility Actio S O D
C
R
Potential Failure Current Process Controls Recommen & Target R
Function Requirement(s) Charac Mode Potential Effect(s) or Failure r Potential Causes of Failure r Prevention
Detection E P A
ded Actions Completion ns E C E
I
P
t. t n T N S Taken V C T N
S T
y c Date

Improper setting 2 Setting Approval 5 50

Next operation - Nil
Angle should OK Subsquent Process - Nil
11X90° Out of Spec Customer End - Fitment Problem 5 Insert worn out 2 Tool Change Frequency CMM REPORT, FPIR 5 50
User End - Nil
Wrong Offset 2 Edit Key Lock 5 50

Next operation - Nil Change in Programm 3 Edit Key Lock 4 60

Subsquent Process - Nil
Position Ø0.15 Position Out Of Customer End - Fitment problem
w.r.t. A-B, C, P, spec. 5 Improper setting 3 Setting Approval CMM REPORT, FPIR 4 60
User End -
Nil Process Parameter Work
Clamping Pressure 3 Instruction 4 60

All dimension Parameter not Proper gauging/ Corelation activity per 15 Defective parts highlighted
Multi Gauging
60
100% should be with in ok / skipped Customer End - Dissatishfaction 5 co-rrelation study 3 days with red colour on screen 4 60
specification

Defect sheet displayed on

Free from visual Lack of awareness, Lack work station , daily defect 100% Visual inspection, Dock
Visual
70
Inspection defects Defect Missing Customer End - Dissatishfaction 5 of knowledge on visual 3 monitoring, daily shift audit after packing. 4 60
defects, meeting

WASHING AS PER
WASHING W.I Work Instruction, daily
Washing skipped,
80 OILING & OILING & Run incomplete cycle Customer End - Dissatishfaction 4 RUSTY / UNCLEAN/ 3 check sheet Process audit 4 48
PACKING PACKING AS PER
W.I

PDI (QF/QA/26) WRONG CALIBERATION

FINAl
90
INSPECTION AS PER INSPECTION Customer End - Dissatishfaction 5 Improper Calibration 3 FREQUENCY DECIDED & 5 per lot 4 60
SPECIFICATION MINITORED

PART STORAGE WRONG AREA IDENTIFICATION/ PART STORE AS PER PACKING

STORAGE/
100
DISPATCH DESPATCH AS LOCATION Customer End - Dissatishfaction 5 INVENTORY 3 WI/ Daily inventory STANDARD 4 60
PER STANDARD DELAY 100%

Revision Change Note

Revision Number: Date of Revision : Reason Of Change Change Detail

0 05.12.2018 New Drawing Released New part

PREPARED BY : Siddhesh Phalke APPROVED BY : Prashant shetty