Item :Hinge Key Date: 15/6/2004
Page: 01 of 03
Process Responsibility: Quality / Production FMEA Date (Orignal): 12/04/2004
FMEA No.: 03 Rev. No. 00
Prepared By: D.S Wilkhoo
Core Team: D. S Wilkhoo(Systems), Raman Kr. / Raman Kr. / Rakesh Gill(Quality), Navdeep Mitalia(T/Room), Ved Prakash(Casting), Janak Dev(Machining) Occurrence Action Results Responsible Recommended / Target R.P.N Actions Completion Action Taken Date Occurrence 80 Severity
1. Raw material Inspection
Composition Of Material
In-adequate physical strength
10
Cr.
Chemical components is not as per requirement
Comparision of material test certificate with required composition Aluminium Treatment in every Two Hrs. Air cleaning of die after each shot Vent cleaning after every shot
2. Casting
Blow Holes Poursity
Less Strength
Cr.
[Link] Aluminium Treatment [Link] cleanning of Die /Tool 3. Improper Vents / Overflow or closed Vents
64
80
80
Non-Filling
Appearance
Mj.
Under Heat Molten Metal Improper Aluminium treatment
Check Temp. of the Molten Metal after every Hour & 100% Visual Inspection
48
60
Detection
Process Potential Function Failure Mode requirements
Potential Effect(s) of Failure
Potential cause(s) / Class Mechanism of failure
Current Process Control
Detection
Severity
.: 03
00
lts
R.P.N
Item :
Hinge
Page: 02 of 03 Prepared By: D.S Wilkhoo
Process Responsibility: Quality / Production FMEA Date (Orignal): 12/04/2004
FMEA No.: 03 Rev. No.00
Key Date: 15/6/04
Core Team: D.S Wilkhoo(Systems), Raman Kr. / Rakesh Gill(Quality), Navdeep Mitalia(T/Room), Ved Prakash(Casting), Janak Dev(Machining) Occurrence Action Results Responsible Recommended / Target R.P.N Actions Completion Action Taken Date Occurrence Severity 84
Detection
Process Potential Function Failure Mode requirements [Link] Non-Filling
Potential Effect(s) of Failure Appearance
Potential cause(s) / Class Mechanism of failure Mj. 2nd & 3rd Phase Pressure of machine not Adequate
Current Process Control Check the parameters after every two hours & 100% Visual Inspection Approximate Weight Manually Spraying of Die coat & Air Cleaning & 100% visual inspection Weight of component after every hour Check the parameters after every two hours Weight of component after every hour
Detection
Severity
R.P.N
7 Oil Mark 6
Mj. Mi.
Less Aluminum Improper Die Coat & Cleaning
3 5
4 3
84 90
Less / Excess Weight
Mj.
Loose Die
98
Mj.
3rd Phase or intensification Pressure of Machine is excess Improper Matching of Die / Tools
70
Mj.
70
Item : Hinge Key Date: 15/06/2004
Page: 01 of 03 Prepared By: D.S Wilkhoo
Process Responsibility: Quality / Production FMEA Date (Orignal): 12/04/2004
FMEA No.: 03 Rev. No.00
Core Team: D.S Wilkhoo(Systems), Raman Kr. /Rakesh Gill(Quality), Navdeep Mitalia(T/Room), Ved Prakash(Casting), Janak Dev(Machining) Occurrence Action Results Responsible / Recommended Target R.P.N Actions Completion Action Taken Date Occurrence Severity 72
Detection
Process Potential Function Failure Mode requirements [Link] Dimensions
Potential Effect(s) of Failure Not fit for purpose
Potential cause(s) / Class Mechanism of failure Cr. Improper Die Matching
Current Process Control Match the die at startup & Check the critical dimensions after every hour & 100% Visual Inspection 100% Visual Inspection Check the critical dimensions after every two hours 100% Visual Inspection
Detection
Severity
R.P.N
Cr.
Broken hole forming Pins Improper Movement of Slides or hole forming pins Low workmanship & Un-skilled labour Low workmanship & Un-skilled labour
81
Cr.
72
Fettling
Un-Even Filling Of component
Poor appearance
Mi.
42
Changed Dimensions
Cr.
100% Visual Inspection
80
