Process FaiIure Mode and Effects Analysis ( Process FMEA)

Planning and Preparation (Step-1)

Company Name : ABC Subject : Rotor Assy

Plant location : Plant 3 Chakan Pune PFMEA Start Date : 18.03.2019

Customer Name : TVS Hosur PFMEA Revision No / Date: 01/ 27.08.2019

Sandip Dhanawade, Pankaj Naik, Shreedhar Patil

Model Year/Platform : Apche BS- IV / 2019 Cross Functional Team :
Paranjape

Continious
Improvement Structure Analysis (Step-2) Function Analysis (Step-3)

Process item Process Step 1. Function of the Process

Issue#

History/Change System,Sub Station item 2.Function of the Process

Process Work Element 3. Function of the Process Work element and
Authorization(As Applicable) System, Part Number, and Function of the system,Sub Step and product Chatacteristic
4 M type process Characteristics
This colum is Optional) Element or Name Name of focus System,Part element or (Quantitative value is Optional)
of Process Element Process

02 PFMEA review based on Rotor Assy Line 20 CNC Your Plant: Cup Rotating at high RPM without Man- Operator :
revised AIAG-VDA FMEA Maching on Machining of CUP & further fouling,to produce PIP radius by Product / Part knowledge,
Handbook Cup for Assembly of ROTOR , CNC turning . Cup & Boss assembly handling,
Product Print Spec: Part Loading in M/c,
Ship to Plant: 1. PIP radius- 58.1 -0.1mm, Selection of Program,
Assembly on Crank Shaft & Inspection of parts using
Man- Operator further Engine assembly, 2. Run-out w.r.t. Taper 0.05 mm M & M Resources,
max. JH & PM of M/c
End User:
Battery charging of the
vehicle

Man- Inspector:
First Piece Approval,
Man- Inspector
Set-up Approval,
Maintaining Inspection Records,
 Machine - CNC Machine M687/615 :
Turning of part,
Machine - CNC Machine M687/615
Maintain Speed
Maintain Feed

Fixture - FT 02 122 0007:

Fixture - FT 02 122 0007
Part resting & Holding w.r.t. Taper

Material (Indirect) - Coolant:

Availability of coolent,
Material - Coolant
Oil & Water mixing ratio,
ensure RUST free part

Material (Indirect)- Insert:

Material - Insert
Remove material to have Print Size/ Spec

Milieu- Lux Level:

Milieu- Lux Level
Visual Inspection at Station

Measurement- Radius Gauge:

Measurement- Radius Gauge
Inspection of Run Out & Radius

Method : Programming:
Validated Program,
Method : Programming
Program Should not tamper by anybody,
Lock the screen

Method : Orientation of part:

Method : Orientation of part
Part loading as per WI/SOP

Method: Offset -
Method: Offset Off set after Insert change
 PFMEA ID Number : PFMEA/Mag-2/02 295

Process Responsibility : SP

Confidentiality Level: Confidental

e, Pankaj Naik, Shreedhar Patil,Chandrakant Houde, Nilesh

Paranjape

Failure Analysis (Step -4)

Risk Analysis (Step -5)

Occurrence (O)

Detection of
of the FC

FC/FM
Severity (S) 3. Failure Cause (FC) Related to Current Detection Controls(DC) of
1. Failure Effects ( FE) 2. Failure Mode (FM) of the Process Step Current Prevention Control (PC) of FC
of FE work Element FC or FM

Your Plant: 1. PIP Radius Undersize and Oversize

Air Gap out of Specification,
Rejection & COPQ Increase,
OEE decrease
Ship to Plant: 1. Induction Training,
Vehicle will not start Skill level verification in Layer
2. On Job training on Product & Process,
End User: 7 Man: Operator- 3. On job Training Effectiveness Evaluation, 4 audit 5
No Spark on Trigger Start Inprocess Inspection
Not Aware about: Product, 4. L2 can be work with / Under Supervision

Your Plant:
Air Gap out of Specification,
Rejection & COPQ Increase,
OEE decrease Man: Inspector- 1. Layer Audit process maintained to verify all Skill level verification in Layer
Ship to Plant: 7 First piece approval not done, system requirements, 5 audit 5
Rubbing Issue Set-up approval not verified 2. Training to QC Inspector Inprocess Inspection
End User:
Rubbing with Pulsar Coil,
Vehicle Low Performance
Machine - CNC Machine M687/615
1. Preventive maintenance system,
: PM check sheet,
2. Critical Spares Stock maintain
Play in rotating chuck, JH check sheet
Wrong Speed
3. CBM on NVH 4 Process Parameter Checksheet 5
4. Speed Controlled by Programme
Wrong Feed Inprocess Inspection
5. Feed Controlled by Programme

Tool history card,

Fixture - FT 02 122 0007: 1. Preventive maintenance system,
PM check sheet,
Resting / Fixing pins wear out, 2. Critical Spares Stock maintain 4 JH check sheet 5
Loose part fitting on fixture, 3. CBM on NVH
Inprocess Inspection

1. Min. Coolent Level identification on Coolent

Material (Indirect) - Coolant: Tank,
Verification in JH
Coolent not available in m/c,
Oil & Water mixing ratio is not
2. Oil & Water mixing ratio verification at Set-up 5 Inprocess Inspection 5
approval
proper, 3.Coolant level verification in JH

Material (Indirect)- Insert:

Insert Blunt, Daily production report,
1. Tool life monitoring counter inbuilt in Program
Tool life monitoring not effectively 2. Min. Stock of INSERT determined in system 3 Tool change monitoring sheet 5
maintained, Inprocess Inspection
Insert not in Stock

Milieu- Lux Level: 1. Selection of required Luminous tubes / Bulbs Verification in JH

Can not verify Visual/ Aesthetic 2. Verification of Lux level in Set-up approval 4 Inprocess Inspection 5
parameters of product

Measurement- Radius Gauge:

Use of faulty Gauge
1. Calibrated instrument with sticker given on line 5 Calibration sticker 5
Inprocess Inspection

1. Interlock the program file from tampering,

2. Authority determined for Program changing to
Method : Programming:
Supervisor only, Verification in Layer process Audit
Wrong program selection,
3. Screen locked with Password 3 Inprocess Inspection 5
Program Tampered
4. Verification of Program number in Set-up
approval

Method : Orientation of part:

POKA-YOKE verification sheet
Wrong side fitment on fixture for 1. Fixture POKA-YOKE available. 2 Inprocess Inspection 5
machining

Method: Offset -
1. Off-set limit restricted for operator upto Inprocess Inspection
After Insert change, Wrong offset
Max. 0.01 mm in programme 4 POKA-YOKE verification sheet 5
given
 Inprocess Inspection
Fixture - FT 02 122 0007: Setup change as per SOP and setup/First piece
2. Run-out excess (more than 0.05 mm)
Fixture Runout Not OK Verification 4 Process Parameter Verification 5
sheet
 M
PFMEA AP

M
stics
Special
Characteri
Filter Code (Optional)

training

Operator
Preventive Action

Bio metric
Multiskilling

control, w.r.t
review-
Quarterly
Detection Action

Skill mapping
Responsible Person's
Name

Supervisor
Target Completion
Date

9/28/2019
Open
Status

Multiskilling Action Taken with

training plan Pointer to Evidence
date
Completion

Severity (S)
Optimization ( Step-6)

Occurrence (O)
3

Detection (D)

Sp Prod Char
L

PFMEA AP
Remarks
M

M
M