POTENTIAL

FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA)

PFMEA
Part Name FMC MACHINING Drawing Rev no & Date : - Manufacturing site AHIN PFMEA No PFMEA /023-04

Rev no /
Part Number - Key Date : 18-July-23 Original PFMEA Date :18-July-23 18-July-23
Date
00

Core Team Operation - A.Vimalraj, S. Naresh,A.Ramkumar

Action Results

OCCURENCE

DETECTION
SEVERITY

OCCURANCE

DETECTION
PROCESS Current Process controls Current Process controls

RPN

SEVERITY
Process Potential Failure Mode Potential failure effects Potential causes of Failures RECOMMENDED ACTION RESPONSIBILITY TAKEN
NO PREVENTION DETECTION

RPN
ACTION

'@ Next operation -No effect

1) 1st approval given by supervisor
@ Subsequent operation - No effect
Quality and production training 2) Operator measure and record
@ Customer end -Primary function fail Excess grinding due to new
Width under size / Oversize 6 3 planned to Newly Onboarding the results every 10No's once. 4 72
@ Field -Primary function fail operator
Employees on monthly once 3)QA insepction check the
dimesions in sampling basis

01 Machining

'@ Next operation-Unable to perform next operation 1) 1st approval given by supervisor
@ Subsequent operation - Unable to perform next Fixture along with Locator pin 2) Operator measure and record
Wrong side machining operation 7 Operator careless 3 implemented to avoid wrong side the results every 10No's once. 4 84
@ Customer end -Primay function fail clamping 3)QA insepction check the
@ Field - Fitment issue/make confusion dimesions in sampling basis

'@ Next operation - No effect

1) 1st approval given by supervisor
@ Subsequent operation -No effect
Fixture along with Locator pin 2) Operator measure and record
@ Customer end -Leakage issue
Damage due to Wrong clamping 8 Operator careless 2 implemented to avoid wrong side the results every 10No's once. 3 48
@ Field -Leakage issue
clamping 3)QA insepction check the
dimesions in sampling basis

'@ Next operation - No effect

1) 1st approval given by supervisor
@ Subsequent operation -No effect
Locator pin to be implemented in the 2) Operator measure and record
@ Customer end -Fitment issue
Position interchanged 8 Operator careless 2 machining fixture to avoid wrong the results every 10No's once. 4 64
@ Field -Fitment issue
side clamping 3)QA insepction check the
dimesions in sampling basis

1)Spindle runout checking frequency

'@ Next operation - No effect
added 1) 1st approval given by supervisor
@ Subsequent operation -Leakage issue
2)Tool to be cleaned with diesel at 2) Operator measure and record
@ Customer end -Leakage issue
Bore over size 8 4 every setting the results every 10No's once. 4 128
@ Field -Leakage issue
3)Tool life to be monitored (1500 3)QA insepction check the
Nos) dimesions in sampling basis

'@ Next operation - No effect

1) 1st approval given by supervisor
@ Subsequent operation -No effect
2) Operator measure and record
@ Customer end -Fitment issue Tool grade changed from HSS to
Thread No Go answered 8 Wrong tool material selection 2 the results every 10No's once. 4 64
@ Field -Fitment issue HSSE
3)QA insepction check the
dimesions in sampling basis

'@ Next operation - No effect 1) 1st approval given by supervisor

@ Subsequent operation -No effect 2) Operator measure and record
Tool grade changed from HSS to
G1/2 Thread washout @ Customer end -Fitment issue 8 Wrong tool material selection 2 the results every 10No's once. 4 64
HSSE
@ Field -Fitment issue 3)QA insepction check the
dimesions in sampling basis

S = Severity [Significance of failure effects], O = Failure occurrence probability, D = Failure detection probability, R = Responsible, I = Date of Implementation, C = Classification, Risk Priority number [RPN] = S x O x D

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 JUSTIIFCATION DATAS FOR OCCURRENCE
Potential Failure Modes in Total Produced
Total OK Qty
AHIN Machining qty in 2022

Width under size / Oversize 27,487 27,478

Wrong side machining 27,487 27,482

Damage due to Wrong clamping 27,487 27,486

Position interchanged 27,487 27,485

M6 Tap broken 27,487 27,486

Bore over size 27,487 27,467

Threa no Go answered 27,487 27,486

Thread washout 27,487 27,486

OR OCCURRENCE STUDY
Applicable
Total NOT OK
/1000 Occurrence
qty
rating
9 0.33 3 0.000328 0.327535
5 0.18 3
1 0.04 2
2 0.07 2
1 0.04 2
20 0.73
4
1 0.04
2
1 0.04
2