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No QP/THP/FMEA/01
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Procedure for Process FMEA (Heat Treatment)
1.0 PURPOSE

To establish a procedure to describe Process FMEA technique.

2.0 SCOPE:
All Process Manufactured at the Plant.

3.0 RESPONSIBILITY
1. CFT Team

Reference: AIAG Potential Failure Mode and Effects Analysis (PFMEA) Fourth
Edition

4.0 PROCEDURES
4.1.1 FMEA is to be carried out for the following cases:
 New Product Development.
 New Process Development.
 Changed Parts and Processes.
 Customer Complaints
4.1.2 New failures and cause have to be identified from the review of corrective
actions reports, concession and process capability indices and the control
charts.
4.1.3 Following records are to be available and referred during FMEA analysis:
 Trend analysis for Total Rejection Monthly.
 Pareto analysis for Defect Wise.
 Trend analysis of Customer Complaints.
 Customer returns report etc.
4.1.4 During the initial process Potential FMEA process, the responsible executive is
expected to directly and actively involve representatives from all affected
areas. These areas should include but not limited to Manufacturing, Material,
Quality Assurance and Tooling’s.
4.2 DEVELOPMENT OF PROCESS FMEA:
4.2.1 Prepare a Process Flow diagram. This flow diagram should identify the
product/process characteristics associated with each operation. Carry out risk
assessment and conduct FMEA for all high risk process steps. Copies of the
flow diagram/risk assessment should accompany the process FMEA.
4.2.2 Document the Potential failure and their consequence in FMEA Format with
Operation No.

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4.2.3 The PFMEA header should clearly identify the focus of the PFMEA as well as
information related to the document development and control process. The
header should contain the following elements.
1. FMEA Number: Enter a PFMEA Document number. The number shall be in
alphanumeric string in nature. First five digits shall indicate the type of
document (PFMEA),Next three digit shall be Plant description (THP, Next three
digits shall be the abbreviation for the department (QAD), the next digits to be
Part no or type of rings (TRB) the, and the last two digits will denote the serial
number of the document. For Example, PEMEA/THP/QAD/TRB/01
2. Item: Enter the name of the component (For Example: TRB IR & OR)
3. Process Responsibility: Enter the Section / Department responsible for
maintaining the process.
4. Model / Part No: Enter the Part No and Edition No of the component drawing
5. Key Date: Enter the initial PFMEA due date, which should not exceed the
production start date.
6. Date of Origin: Enter the date when the original FMEA was completed and the
revision number and revision date as and when the FMEA undergoes revision.
7. Core Team: Enter the name of team members responsible for developing the
FMEA with their department / designation. If space provided is not sufficient,
annex the details.
8. Prepared By: Enter the name of the team leader and affix his signature
9. Process Function and Requirements: Enter simple description end/output
requirement of the process. A process may have more than one process
requirement, list them separately
10. Potential Failure Mode: Enter the Potential failure mode for each process
requirement separately by asking how can the process/component fail to meet
the process requirement. The assumption is that the failure could occur but
may not necessarily occur (These are negative of the process requirements)
11. Potential Effect of Failure: Enter the Potential effect of failure i.e., the effect of
failure made on the customer(s). The customer may be next operation,
subsequent operation and /or vehicle owner. Each must be considered when
assigning the potential effect of a failure.
12. Severity(S): Severity is the value associated with the most serious effect for a
given failure mode to the internal or external customer. If the customer
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Procedure for Process FMEA (Heat Treatment)
affected is internal, concerned section in-charge shall be consulted for severity
estimation. The severity shall be estimated on a 1 to 10 scale as per FMEA
Manual.
13. Classification: Indicate the classification of special characteristics by the use of
symbol for process and product characteristics. The same symbol should be
specified for the identified special characteristics in control plans, drawings and
related technical documents.
14. Potential Causes/Mechanism of Failure: List to the extent possible each and
every conceivable failure causes assignable to each failure mode. Described
the cause in terms of something that can be corrected or can be controlled.
15. Occurrence: Occurrence is how frequently the specific failure cause is projected
to occur. The occurrence ranking has a meaning rather than value. Estimate
the likelihood of the occurrence of a cause on a 1 to 10 scale as per FMEA
Manual.
16. Current Process Controls: Enter the proposed or current controls that detects
the failure mode, should it occur, or prevent the failure mode from occurring.
The Types of Controls are:
Type 1: Prevent the cause or failure from occurring (Eg: Mistake Proofing,
Atomization)
Type 2: Detect the cause mechanism and lead to corrective action (Eg: SPC
Charts, Set-up Approvals)
Type 3: Detect the failure mode (Eg: 100% Inspection at stage or during the
subsequent operations)
The controls should be written against each causes listed in potential causes
column. If no controls on the causes the Write “No Controls”
17. Detection: Detection is an assessment of the probability that the proposed type
of controls listed under current control column will detect a cause or failure.
The initial detection ranking is to be based on Type 2 or 3 controls. Estimate
the detection ranking on a 1 to 10 scale as per FMEA Manual.
18. Risk Priority Number (RPN) and/or Severity, Occurrence, Detection (SOD): The
RPN or SOD Number in the product of severity (S), Occurrence (O) and
Detection (D)
RPN= (S) X (O) X (D)
The RPN value will be between 1 to 1000. For higher RPN the team must
undertake efforts to reduce the risk through corrective action. In general,

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regardless of the resultant RPN, special attention should be given when the
severity of the potential failure effect is high.
19. Recommended Action: After completion of the steps described above, the RPNs
are to be analyzed in Pareto fashion to identify the priority areas for control.
Higher SOD ranking generally required immediate action.

The Following actions should be considered:

1 To reduce the Probability of occurrence, revisions in process controls are
required.
2 The actions recommended should be to prevent/eliminate the causes to reduce
the occurrence ranking. the prevention techniques such as Mistake Proofing
Methodology, SPC Methods and Continuous Improvements are to be
considered.
3 Only a process revision can bring about a reduction in the severity ranking.
4 Generally improving detection control is costly and ineffective for quality
improvement.
5 Increasing quality control inspection frequency is not a positive corrective
action and should only be utilized as a temporary measure.
6 Emphasis must be on preventing / reducing occurrence of a defect rather than
detecting them.
7 Recommended change to current control system such as introduction of
statistical process control and process improvements rather than random
quality checks or inspection.

If No action is recommended for a specific cause indicate by entering “NONE” in this

column.
20. Responsibility and Target Completion Date: Enter the department / individual
responsible for the recommended action and the target completion date.
21. Action Taken: After an action has been taken enter a brief description of the
action taken and effective date
22. Action Results: After the corrective action taken, the team leader is to verify
the action for implementation. Estimate and record the resulting ‘Severity’ (S),
‘Occurrence’ (O) and ‘Detection’ (D) ranking. Calculate the ‘Resulting RPN’. If
no actions are taken leave the related ranking column blank.
All resulting RPNs should be reviewed and if further action is considered necessary,
repeat step 20 to step 22

4.3 FMEA REVIEW AND UPDATING

4.3.1 This document is a living document and should always reflect the latest
revision level. This is to be reviewed once in as year or whenever there is a
change in process, modification in controls, on identification of new failures

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Procedure for Process FMEA (Heat Treatment)
and causes, during customer complaints, when the process becomes unstable
and/or incapable.
4.3.2 Whenever FMEA is reviewed the concerned process related documents like
Control Plans, Operating Instructions, Setup Instructions, and Maintenance
Work Instructions etc. are to be reviewed and updated if required

5.0 REFERENCE:
Reference Manual for Process FMEA Fourth
Edition
Master List of FMEA, CP and PFD Documents
Revision status
Sl. Rev.
Changes Issue Date Rev. Date Approval
No. No.
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 Doc. No QP/THP/FMEA/01
30.11.202
JFPL UNIT II PROCEDURE First Issue No. 00 Dated
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30.11.202
Latest Issue No 00 Dated
4
Procedure for Process FMEA (Heat Treatment)

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